0511530 JOHNSON ARM

Illustration 1 g01157164
Schematic for the injection actuation pressure control valveTest Step 1. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the data link connector.
Start the engine.
Check for active diagnostic codes on Cat ET.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.Expected Result:There are no active diagnostic codes.Results:
OK - There are no active diagnostic codes.Repair: The problem seems to be resolved at this time. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect"..STOP
Not OK - A 42-11 diagnostic code is active. Proceed to Test Step 2.Test Step 2. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01157054
Left side engine view (typical example) (1) J500/P500 Injection actuation pressure control valve connector (2) Injection actuation pressure sensor (3) J2/P2 ECM connector
Thoroughly inspect connectors (1) and (3) . Also, thoroughly inspect the connector for sensor (3) . Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01151730
Pin locations on ECM connector (P2-61) IAP control valve (P2-62) Sensor return
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the IAPCV.
Check the allen head screw for the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasion and for pinch points from the IAPCV back to the ECM.Expected Result:All connectors, pins, and sockets are coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and the wiring appear to be OK. Proceed to Test Step 3.
Not OK - A problem has been found with the connectors and/or the wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are coupled.Verify that the repair eliminates the problem.STOPTest Step 3. Measure the Solenoid Resistance of the Injection Actuation Pressure Control Valve
Turn the key switch to the OFF position.
Disconnect the J500/P500 IAPCV connector.Note: Ensure that the seal for the P500 connector remains in place.
Measure the resistance of the solenoid at the terminals for the IAPCV. Record the measurement.
Reverse the leads of the multimeter and measure the resistance again.Expected Result:The solenoid resistance of the injection actuation pressure control valve is 8 2 Ohms.Results:
OK - The measurement is 8 2 Ohms. The solenoid resistance is correct. Reconnect the harness connector for the injection actuation pressure control valve. Proceed to Test Step 4.
Not OK - The solenoid resistance is out of the range.Repair: Replace the unit injector hydraulic pump. Check that the diagnostic code is no longer active. Verify that the repair eliminates the original problem.STOPTest Step 4. Measure the Solenoid Resistance through the Engine Harness
Turn the key switch to the OFF position.
Disconnect the P2 connector at the ECM.
Measure the resistance from terminal P2-61 to terminal P2-62.Compare the measurement to the resistance value that was recorded in the previous step. A harness that is in good repair will add less than two percent to the total resistance of the circuit.
Measure the resistance from terminal P2-61 and terminal P2-62 to the remaining terminals that are in the P2 ECM connector.The correct measurements will indicate an open circuit.
Measure the resistance from terminal P2-61 and terminal P2-62 to the engine ground stud.The correct measurements will indicate an open circuit.Expected Result:The resistance measurements are within the specifications that are provided above.Results:
OK - The resistance measurements are within the specifications. Connect the J2/P2 ECM connectors. Proceed to Test Step 5.
No - The resistance measurements are not within the specifications.Repair: Replace the harness for the IAPCV and/or repair the circuit.Verify that the repair eliminates the original problem.STOPTest Step 5. Use the "Injection Actuation Pressure Driver Test" to Check the Harness
Connect Cat ET to the service tool connector.
Disconnect the P500/J500 IAPCV connector.
Fabricate two jumper wires. Crimp a 186-3735 Connector Pin to one end of each jumper.
Insert the connector pins of the jumper wires into the terminals of the J500 IAPCV connector.
Connect a voltage test lamp to the ends of the jumper wires.
Turn the keyswitch to the ON position.
Access the "Injection Act Press Driver Test". Start the "Injection Act Press Driver Test" on Cat ET. Observe the state of the test lamp.Note: This test procedure may cause a 42-11 to become active.Activation of the code is normal.Expected Result:The voltage test lamp illuminates when the test is active.Results:
OK - The voltage test lamp illuminates when the test is active. Proceed to Test Step 6.
Not OK - The voltage test lamp does not illuminate when the test is active. Remove the jumper wires from the J500 IAPCV connector. Connect the connector. Proceed to Test Step 7.Test Step 6. Perform the "Injection Actuation Pressure Test"
Ensure that the J500/P500 connector is disconnected.
Crank the engine for 30 seconds. Crank the engine three times at 30 second intervals in order to purge the air from the system.
Reconnect the J500/P500 connector.
Start the engine and perform the "Injection Actuation Pressure Test". Step through all of the pressure ranges that are in the test.
After performing the "Injection Actuation Pressure Test", check if a 42-11 diagnostic code is active or logged.Expected Result:The engine starts and the engine runs. The 42-11 does not become active or logged during the test.Results:
OK - The e