0208165 JOHNSON SEAL, Motor cover, 140

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
This procedure covers the following diagnostic trouble codes.
Table 1
Diagnostic Trouble Codes
Code Description Conditions Present Response
651-3 Open circuit of harness/coil in first cylinder injector Engine is running.
Battery voltage is normal.
Occurs during injection
CPU is normal Open circuit occurs eight times or more.
Engine derate
EGR stops.
Intake throttle is open 100 percent
Warning Level 3
Other injectors continue to operate, which will cause increase vibration.
652-3 Open circuit of harness/coil in second cylinder injector
653-3 Open circuit of harness/coil in third cylinder injector
654-3 Open circuit of harness/coil in fourth cylinder injector
523523-3 No.1 & 4 cylinder injector short to +B or GND Engine is operating
Battery voltage is normal
Wiring harness short to +B or Wiring harness short to ground 3 times or more. Injectors that have DTC will stop injection
Engine is derated
EGR stop
Intake throttle fully open
Warning Level 3
523524-3 No. 2 & 3 cylinder injector short to +B or GND
523535-0 Injector Charge Voltage: High Battery voltage is normal
CPU is normal Engine derated
EGR stop
Intake throttle fully open
Engine stopped 60 seconds later.
523605-6 Internal Injector Drive Circuit Short Battery voltage is normal. Injectors which have error stop injection.
Engine derates 25%
EGR stops
Intake throttle full open
Engine Vibration increases.
Engine stops in some case.
Illustration 1 g06110895For 523535-0 Injector Charge Voltage: High, skip to the next troubleshooting table.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check that the wires going to the connector are not pulled.
B. Check that the connector pins and sockets are not damaged and aligned correctly.
C. Check the harness for corrosion, abrasion, and pinch points from the injector to the engine ECM connector. Check that the engine ECM pins are not bent and connector is fully seated.
Loose connections, poor routing, damaged wires
Result: There is a fault in a connector or wiring.
Replace the engine harness.
Result: No fault is found.
Proceed to Test Step 2.
2. Check the Resistance Between the Injector Terminals
1.5 Ohms or lower
Result: The resistance is 1.5 ohms or lower.
Proceed to Test Step 3.
Result: The resistance is greater than 1.5 ohms.
Replace the injector.
3. Disconnect the Engine Harness from the ECM
A. With the key switch in the OFF position, measure the resistance at the engine ECM connector between the common ground and injector drivers.
This checks the resistance of the harness and the injector. The resistance should be 1.5 ohms or lower.
1.5 ohms or lower
Result: The resistance is NOT OK.
Replace the engine harness.
Result: The resistance is OK.
Contact your dealer Technical Communicator (TC).
For 523535-0 Injector Charge Voltage: High, refer to following troubleshooting steps.
Table 3
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring.
A. Check that the wires going to the connector are not pulled
B. Check that the connector pins and sockets are not damaged and aligned correctly.
C. Check the harness for corrosion, abrasion, and pinch points from the injector to the engine ECM connector. Check that the engine ECM pins are not bent and connector is fully seated.
Loose connections, poor routing, damaged wires
Results: There is a fault in a connector or wiring.
Replace the engine harness.
Results: No fault is found.
Proceed to Test Step 2.
2. Key Off and Back On
A. Check to see if the diagnostic code is active.
Diagnostic Code
Result: The diagnostic code is not active.
A temporary malfunction could have happened by radio waves. No action is required.
Result: The diagnostic code is active.
Proceed to Test Step 3.
3. With Code Active, Swap the Engine ECM's with another Machines
ECM
Result: The code is NOT active with the suspect ECM.
Replace the injector.
Result: The code remains active with the suspect ECM.
Replace the ECM.
If the procedure did not correct the issue, Contact your Caterpillar dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).