30500-ZW1-004 Honda COIL ASSY., IGNITION (1) (Honda Code 4899100).

Table 1
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
444-5 Start Relay open circuit The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery in the start relay. The ECM can only detect this condition when the start relay is not energized. The code is logged.
444-6 Start Relay short to ground The ECM detects a short circuit to ground in the start relay. The ECM can only detect this condition when the start relay is energized. The ECM can crank the engine when the Engine Control Switch (ECS) is placed in the START position. After the ECS is placed in the START position, the ECM will begin the prelube cycle. When the prelubrication pressure switch opens, the ECM will start the first crank cycle. The crank cycle will continue for the time that is equal to the cycle crank time that has been programmed . Or the crank cycle will continue until the engine speed reaches the crank terminate speed. If crank terminate speed is not reached before the crank cycle time, the starting motor will deactivate at the end of the crank cycle time.This process will repeat for a programmed amount of times (Total Number of Crank Cycles). If the engine does not start, Caterpillar Electronic Technician (ET) will display "OVERCRANK". The engine control will be in an idle state. The process can be restarted by turning the ECS to the OFF position. Next turn the ECS to the STOP position. Then turn the ECS to the START position. The ECM will send a signal to the starting motor relays after the prelube cycle is complete. The starting motor relays will energize closing the normally open contacts of the relays. Current will flow to the starting motors from the "mag relay breaker". The starting motors will begin to crank the engine.The engine can be manually started by using the manual crank switch.
Illustration 1 g03323826There are also configuration parameters that are used to configure the ECM for the type and the location of the starting motors. The following types of starting motors can be used on this engine:
Air starting motor
Electric starting motorThe wiring for each of these types of engine starting circuits is similar. Follow this procedure in order to troubleshoot the circuit diagnostics for any of these types of engine starting system.The ECM can control a secondary starting system that is installed on the engine opposite the primary starting system. Refer to Troubleshooting, "Configuration Parameters" for information that is related to the configuration parameters that are for the secondary starting system.ECM Activation of the Starting MotorsThe ECM utilizes two output drivers in order to crank the engine. Each output driver is provided with 24 VDC during engine cranking. The circuits for the output drivers utilize a return line to the ECM. This circuit includes crank relays that can be powered by an external power supply in order to override the ECM activation of the starting motors.Manual Overrides for the Engine Starting SystemThe engine can be manually cranked by using a manual crank switch that can be wired into the engine interface connector. The engine starting circuit incorporates four crank relays. When the relay coils are powered by 24 VDC, the starting motor magnetic switches are fused at the low current power distribution panel. The switch and the wiring for the circuit must be supplied by the customer.Caterpillar Electronic Technician (ET) can be used in order to override the output command that is provided by the engine state control. This override can be used to diagnose the circuit that is for the starting motor magnetic switches. View the "Starting System Relay Status" that is available in Cat ET in order to determine the status of the ECM outputs.
Illustration 2 g03323854
Table 2
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Turn the main disconnect switch to the OFF position.
B. Thoroughly inspect the connectors that are associated with the starting system. Ensure that a circuit breaker has not tripped. Refer to Troubleshooting, "Electrical Connectors - Inspect " for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
D. Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect " for the correct torque values.
E. Check the harness and the wiring for abrasion and for pinch points.
Connectors
Results: The connectors and wiring are OK.
Proceed to Test Step 2
Results: The connectors and/or wiring need repair.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Verify that the repair eliminates the problem.
2. Check for Active Diagnostic Codes
A. Connect Cat ET to the service tool connector.
B. Restore the electrical power to the ECM.
C. Select diagnostic tests from Cat ET.
D. Select the "Override Parameters" screen on Cat ET.
E. Activate the override for the appropriate starting system for your application.
F. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes for the starting system.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
G. Deactivate the override for the starting system.
H. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
I. Turn the main disconnect switch to the OFF position.
Active Diagnostic Codes
Results: No diagnostic codes are active, but a problem is suspected in the circuit for the starting system.
Repair: The circuit for the starting system appears to be operating correctly between the ECM and the starting motor magnetic switch. Isolate the starting motor magnetic switch from the primary circuit and the secondary circuit. Test the operation of the switch.
If a problem with the switch is discovered, replace the switch.
If the switch is OK, there is a problem in the circuit to the starting motors. There may be a problem in the power cables from the batteries to the starting motors. Check each of the circuits