0582138 JOHNSON POWER PACK

Illustration 1 g00996218
Status indicator for the fuel metering valve
The fuel metering valve contains a status indicator. The indicator flashes in different colors during operation in order to indicate the status of the valve:Green - Normal operationOrange - The valve has detected a problem and the valve continues to operate.Red - The valve has detected a serious problem. The valve has shut down.The flash code indicates the particular error that has been detected by the valve. Before performing maintenance on the valve, observe the status indicator. Refer to Installation and Operation Manual, SEBU7630, "Woodward Raptor Gas Regulation and Metering Valve/Actuator System" for additional information.Note: If an open circuit is suspected in the circuit between the power supply and the powered component also inspect the power distribution box for the following conditions:
Abrasion of the insulation on the wiring within the box
Damage to the posts for the wiring to the circuit breakers
Damage to the internal parts of the circuit breakersThose conditions can contribute to the following difficulties with operation:
Unstable engine performance
Interruption of communication between the ECM, the fuel metering valve, the actuator for the compressor bypass, and the throttle actuator
Intermittent loss of power to the ECM
Intermittent diagnostic codes for conditions such as engine overspeed and lack of communication between electronic components
Unexpected engine shutdown
Illustration 2 g01114299
Schematic for the circuit of the fuel metering valve
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND WIRING
Remove the electrical power from the engine. Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Thoroughly inspect each of the following connectors:
J1/P1 connectors
J6/P6, J7/P7, and J9/P9 connectors
Connectors on the fuel metering valve
Check the torque of the allen head screw for the ECM connectors.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel metering valve.
Check the wiring for abrasion and for pinch points from the fuel metering valve to the master ECM. Expected Result:All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem.STOPTest Step 2. CHECK FOR DIAGNOSTIC CODES
Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box.
Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
Use Cat ET to determine if any of the following diagnostic codes are active:
1446-5 Fuel Metering Module : Current Below Normal
1446-9 Fuel Metering Module : Abnormal Update Rate
1446-12 Fuel Metering Module : Failure
1446-13 Fuel Metering Module : Calibration Required
1447-12 Fuel Metering Sensor Module : FailureExpected Result:There are no active diagnostic codes.Results:
OK - There are no active diagnostic codes. The signal and the communication between the master ECM and the fuel metering valve appear to be OK at this time. However, diagnostic codes may be logged.Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK (Active 1446-5) - The master ECM has detected an open circuit or a short circuit for the circuit of the fuel flow signal between the ECM and the fuel metering valve. Proceed to Test Step 5.
Not OK (Active 1446-9) - The master ECM has detected an open circuit or a short circuit for the circuit of the CAN data link between the master ECM and the fuel metering valve. Proceed to Test Step 3.
Not OK (Active 1446-12) - The fuel metering valve has detected an internal malfunction.Repair: Refer to Installation and Operation Manual, SEBU7630, "Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar".STOP
Not OK (Active 1446-13) - The fuel metering valve requires calibration.Repair: Refer to Installation and Operation Manual, SEBU7630, "Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar".STOP
Not OK (Active 1447-12) - There is a malfunction of the sensor module in the fuel metering valve.Repair: Refer to Installation and Operation Manual, SEBU7630, "Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar".STOPTest Step 3. CHECK FOR ELECTRICAL POWER TO THE FUEL METERING VALVE
Disconnect the J24/P24 connectors.
Illustration 3 g00952242
P24 harness connector for the fuel metering valve
(P24-K) Unswitched +Battery
(P24-L) −Battery
(P24-M) Switched +Battery
Use a multimeter to measure the voltage between the following terminals of the harness connector for the fuel metering valve:
P24-M and P24-L
P24-K and P24-LExpected Result:The voltage between terminals P24-M and P24-L is between 22.0 VDC and 24.0 VDC.The voltage between terminals P24-K and P24-L terminals is 22.0 VDC and 24.0 VDC.Results:
OK - The voltage is correct at the P24 plug for the fuel metering valve. Proceed to Test Step 4.
Not OK - The voltage is not correct at the P24 plug for the fuel metering v