44357A 2 Mercury FLUSHING ATTACHMENT

Table 1
Diagnostic Trouble Codes    
CDL Code    Code Description    Comments    
3256-5     Water Pump Output: Current Low     The HV cable between the EWPC and the EWP is damaged or unconnected.
The code is logged.    
The Power Train Electric Drive System and the Accessory Power System will contain hazardous voltage levels during machine operation and for a period of time after machine shutdown.Do not remove any covers that will expose energized electrical components while the engine is operating. Do not remove any covers that will expose the energized electrical components while the components remain energized following an engine shutdown.Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the engine is operating.Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the components remain energized following an engine shutdown.Always perform the safe shutdown and de-energizing procedure before performing electrical service on the Power Train Electric Drive System or the Accessory Power System.Failure to follow these instructions could result in personal injury or death.
In order to avoid the build up of hazardous live voltages on the exposed surfaces, all grounding wires must be properly connected at all times during engine operation.Any disconnected grounding wires (including the grounding bond wires, the conductor shield wires, the power inverter grounding straps and the component housing grounding straps) must be properly reconnected before the engine is started.Failure to follow these instructions could result in personal injury or death.
Note: Always perform the procedure for shutdown and de-energizing before performing electrical service on the "Power Train Electric Drive System" or the "Accessory Power System".The procedure will verify that the voltage in the power train electrical system has been discharged to less than 50.0 VDC. Refer to the Specifications, Systems Operation, Troubleshooting, Testing and Adjusting, "Electrical Maintenance Guidelines" for the proper procedure.Note: A multimeter must be used to verify that there is little or no voltage present at the exposed conductors before any other action is taken. Manually measure the voltage in order to confirm the voltage to be at a low level (50.0 VDC or less).
Table 2
Troubleshooting Test Steps     Values     Results    
1. Check for Codes
A. Establish communication between the Caterpillar® Electric Technician (ET) and the Electronic Control Module (ECM) .
B. Determine the diagnostic codes that are active.
Note: Check for codes that pertain to the water pump circuit. Troubleshoot any codes before proceeding with this procedure.
   
Codes
   
Results: A 3256-5 code is active. - Proceed to Test Step 2.
   
Illustration 1 g02026201
EWPC at the rear of the engine compartment on the upper right side (1) EWPC (2) 320 VDC accessory power bus supply from the APC (3) Four-conductor, three-phase, AC supply conductor cable to the electric water pump (4) System power and control circuit connector
Illustration 2 g02026205
Connector for the four conductor, three-phase, AC supply cable that is connected between the EWPC and the EWP (5) Contact A - phase A (6) Contact B - phase B (7) Contact C - phase C (8) Contact D - bond grounding conductor
Illustration 3 g02029355
Electric water pump located in the engine compartment on the front right-hand side (9) EWP connector
Table 3
Troubleshooting Test Steps     Values     Results    
2. Low Pump Module Output Current At the EWP
A. While the engine is running, use the monitoring system to check the EWPC current.
   
EWPC Current
   
Results: The EWPC current is low.
Repair: Always perform the procedure for shutdown and de-energizing before performing electrical service on the "Power Train Electric Drive System" or the "Accessory Power System". Refer to the Specifications, Systems Operation, Troubleshooting, Testing and Adjusting, "Electrical Maintenance Guidelines" for the proper procedure.
Perform the following procedure.
1. Disconnect both connectors on the high voltage harness between the EWPC and the EWP.
a. Check the harness continuity for each phase of the circuit.
b. Check the harness continuity of the grounding wire for the circuit.
c. Visually check the harness for damage. If necessary, replace the connectors and/or replace the harness.
d. Connect the harness. Verify that both connectors are clean, dry, and tight.
Proceed to Test Step 3
   
3. Retest Low Pump Module Output Current At the EWP
A. While the engine is running, use the monitoring system to check the EWPC current.
   
EWPC Current
   
Results: The EWPC current is low.
Repair: If the current is still low, replace the water pump.
If the problem is not resolved, contact the Caterpillar Dealer Solution Network (DSN).
STOP