COMMON RAIL ENGINE DIAGNOSTIC/REPAIR KIT

(New Engine Family NEF) Part No. 380040185

TIER II COMPLIANT

Part No. 380040185 TIER II COMPLIANT COMMON RAIL ENGINE (NEF)

Harness Diagnostic and Repair Kit STRUCTURAL AND NON-STRUCTURAL APPLICATIONS
The 380040185 Harness Diagnostic Kit allows you to quickly, accurately and safely diagnose harness, sensor and actuator faults by connecting in-line to run system checks with the engine running or in static, key-on condition. The interface harnesses give you the ability to connect your DVOM in-line without damaging connectors or harness terminals. Other adapters in this kit allow you to check harness integrity at the Engine Control Unit without damaging the delicate pins in the ECU connectors. Also included are replacement connectors and pigtails for repair of damaged harnesses.

1. Fuel pressure sensor 2. Coolant temperature sensor 3. Engine oil pressure and temperature sensor 4. Crankshaft sensor 5. Electro-injector 6. Air pressure temperature sensor 7. Camshaft sensor 8. Fuel heater and fuel temperature sensor 9. Pressure regulator 10. EDC 7 control unit

CAM/CRANKSHAFT SENSOR DIAGNOSTICS

Interface Harness Part # 380002411

Crankshaft Sensor Engine Harness Connector Face/Latch Up 1 2 3 1. Yellow boot, ground 2. Red boot, positive

Camshaft Sensor

1 2 3 3. Black boot, ground shield

Camshaft and Crankshaft Sensor Check

Perform test on both sensors. 1. Attach interface harness (380002411) to sensor but not to engine harness. 2. Sensor Resistance Test: Connect ohmmeter to yellow and red clips. Reading should be 900 ohms 75 ohms at 20 degrees C. If not, replace the sensor. 3. Connect engine harness to interface harness. 4. Circuit Ground Test: Connect ohmmeter to black and yellow clips. Reading should be less than 5 ohms. If reading is not less than 5 ohms, go to line 6. 5. Sensor Output Test: Connect an AC voltmeter to the yellow and red clips. Reading should be a minimum of .50 volts AC while cranking engine. Voltage will be higher with engine running. If not, replace the sensor. 6. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing/Probe Adapter (380002416) in the appropriate processor terminal and the Male Pigtail Spade (380002415) to the appropriate terminal of the sensor. Connect the ohmmeter lead to each end of the suspected wire and check for continuity. 7. The reading should be less than 5 ohms. If the reading is more than 5 ohms, check for a light drag on the pin sizing tool moving the tool in and out of the terminal. If the pin sizing tool is loose in the terminal, repair as necessary. 8. If drag is felt on the pin sizing tool check for a damaged wire or terminal in the sensor connector. Repair as necessary.

COMMON RAIL PRESSURE SENSOR DIAGNOSTICS

Interface Harness Part # 380002412

Common Rail Pressure Sensor

Engine Harness Connector Face/Latch up Attach interface harness to sensor

1. Black boot, Ground

1 2 3 2. Yellow boot, Signal

3. Red boot, Reference Voltage

Common Rail Pressure Sensor Check

1. Attach interface harness to sensor and to the engine harness 2. Reference Voltage Check: Connect Voltmeter + to the red clip and the to the black clip. Turn the key switch to the ON position. Reading should be 5 volts 0.5v. If not, connect the voltmeter lead to a good ground. If the voltmeter reading now is 5 volts 0.5v, repair the ground return circuit to the processor. 3. Sensor Voltage Check: Connect the voltmeter + to the yellow clip and the voltmeter to the black clip. 4. Start engine , the voltage should be 1.15 volts at 800 RPM (300 bar) and 2.30 volts at 2120 RPM. (790 bar) 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade Pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 6. The reading should be less than 5 ohms. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK, use the wiring schematic and check the voltage and ground supply at the processor. If voltage is OK, processor replacement may be necessary. 7. If drag is felt on the Pin Sizing tool check for a damaged wire or terminal in the sensor connector. Repair as necessary

Other observations: EST defaults to 710 bar at OL, pump solenoid energizes
when reconnecting the rail pressure, monitoring of pressure relief code on EST, OL error at key ON.

COOLANT/FUEL TEMPERATURE SENSOR DIAGNOSTICS

Interface Harness Part # 380002409.
Coolant Temperature Sensor Fuel Temperature Sensor

2 1. Black boot, ground

1 2. Red boot, reference volts

Coolant and Fuel Temperature Sensor Check Perform test on both sensors

1. Attach interface harness to sensor and to engine harness. 2. Sensor Function Check: Connect voltmeter to red and black clips. Readings should be Coolant 1.5 volts 0.2 at 65 degrees C. Fuel 2.5 volts 0.2 at 41 degrees C. 3. Reference Voltage Check: Connect the + voltmeter lead to the red clip and the voltmeter lead to ground. Voltage reading should be 4.75 volts. If not, go to step 5. 4. Sensor Resistance Check: Disconnect engine harness and connect ohmmeter lead to black and red clip. Sensor readings should be 0.55K ohms at 65C, and 1.1K at 41 degrees C. If not, replace the sensor. 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal,

and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 6. The reading should be less than 5 ohms. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK, using the wiring diagram, check voltage and ground supply at the processor. If OK, processor replacement may be necessary. 7. If drag is felt on the Pin Sizing tool check for a damaged wire or terminal in the sensor connector. Repair as necessary Other observations: Both Ols default to 60 degrees C on the EST. OL errors at key ON.

OIL PRESSURE/TEMPERATURE SENSOR DIAGNOSTICS

Interface Harness Part # 380002413 Oil Temperature/Pressure Sensor
Engine Harness Connector Face/Latch up 1 Temperature 1. Green boot, signal 2. Black boot, ground 2 3 4

Pressure 3. Red boot, voltage reference 4. Yellow boot, signal Oil Pressure Note: If diagnostic tests have indicated an oil pressure problem, perform a mechanical oil pressure test before proceeding with the electrical diagnosis. 1. Sensor Output Test: Attach interface harness to sensor and to engine harness and start the engine. Connect the + voltmeter lead to the yellow clip and the lead to the black clip. Yellow to black .82 volts at 1 bar, 3.5 volts at 4.65 bar (idle), 4.7 volts at 6 bar. (high idle) 2. Reference Voltage Check: Connect the + voltmeter lead to the red clip and the lead to the black clip, reading should be 5.0 volts. If the voltage reading is 0 volts check the voltage from the red clip to ground, it should be 5 volts. 3. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 4. The reading should be less than 5 ohms. 5. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK, check voltage supply and ground at the processor. If voltage is OK, processor replacement may be necessary. 6. If drag is felt on the Pin Sizing tool check for a damaged wire or terminal in the sensor connector. Repair as necessary. 6

Oil Temperature 1. Attach interface harness to sensor and to engine harness, Key ON 2. Sensor Output Test: Connect voltmeter to green and black clips, Reading should be 3.18 volts 0.2 volts at 20 degrees C or 1.8 volts 0.2 at 63 degrees C. 3. Reference Voltage Test: connect the + voltmeter lead to the red clip and the voltmeter lead to the black clip. Voltage reading should be 4.75 volts. If not, connect the voltmeter to ground, voltage should be 4.75 volts If voltage is not present, go to step 5. 4. Sensor Resistance Test: Disconnect engine harness and connect ohmmeter leads to the black and red clips. Readings should be 5.9 K at 63 degrees C and 2.5 K at 20 degrees C. 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity.

AIR PRESSURE/TEMPERATURE SENSOR DIAGNOSTICS

Sensor Interface Harness Part # 380002414 Air Pressure Sensor Air Temperature Sensor

Engine Harness Connector Face/Latch up 1 Temperature 1. Green boot, signal 2. Black boot, ground AIR TEMPERATURE 1. Attach interface harness (380002414) to sensor and to engine harness. Turn the key switch ON. 2. Sensor Output Test: Connect voltmeter to green and black clips. Reading should be 1 volt at 49 degrees C, or 3.22 volts at 20 degrees C. 0.2volts. 3. Reference Voltage Test: Connect the + voltmeter lead to the red clip and the voltmeter lead to the black clip. Voltage reading should be 5.00 volts 0.2 v. If not, connect the voltmeter lead to ground. If voltage is not 5 volts, go to step 5. 4. Sensor Resistance Test: Disconnect engine harness and connect ohmmeter leads to black and green clips. Reading should be 2.5K ohms at 20 degrees C or 3.6 K at 50 degrees C. If not, replace the sensor. 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. Repair as necessary. 2 3 4

Pressure 3. Red boot, voltage reference 4. Yellow boot, sensor signal AIR PRESSURE 1. Sensor Output Test: Attach interface harness (380002414) to sensor and to engine harness and start the engine. Connect the + voltmeter lead to the yellow clip and the lead to the black clip. Voltage should be 1.0 volt at idle and 1.7 volts at high idle. 2. Reference Voltage Test: Connect the + lead of the voltmeter to the red clip and the lead to the black clip. The voltage reading should be 5 volts. If not, ground the negative voltmeter lead. If the voltage is 0, go to step 3. 3 If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 4. The reading should be less than 5 ohms. 5. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK check voltage supply and ground at the processor. If voltage is OK, processor replacement may be necessary. 6. If drag is felt on the Pin Sizing tool, check for a damaged wire or terminal in the sensor connector. Repair as necessary. 7

FUEL INJECTOR INTERFACE HARNESS

Fuel Injector Interface Harness Part # 380002408
The Fuel Injector Interface Harness allows access to the processor controlled fuel injector system. The processor controls voltage and the ground circuit for the injector ON time resulting in precise fuel control to the engine.

1 2

4 3

4 3

1 2 Male Connector

Female Connector Interface boot colors: 1 = Red 2 = Black 3 = Black 4 = Red 1. Attach the Interface harnesses to each of the plugs at the cylinder head spacer plate. (See illustration at bottom of page.) The black connector boots are the ground circuit and the red connector boots are positive. Note: Voltage is not at the injector unless the engine is running. 2. Connect the + lead of the voltmeter to the red clip and the lead to the black clip. 3. Start the engine, when the engine is first started the voltage should be about 30 volts. At normal operating temperature, the voltage at idle is about 29 volts and at WOT, no load, about 31 volts. Each injector should read the same voltage. 4. If the injector readings are not the same, do an ohmmeter check on the injectors. 5. Disconnect the engine harness, do an ohm-

meter test from terminal 1 to 2 and 3 and 4 on each harness. The reading should be .56 ohms. If not replace the injector. 6. A "click test" can be done on each injector with the Solenoid/Injector Pulse Tool (380002417) included in this kit. Connect the tool to a voltage supply (either 12 or 24 volts), Red lead to positive and Black lead to ground. 7. With the engine harness still disconnected, connect the injector tester harness connector to the black and red leads. Push button on Pulse Tool to activate injector. A distinct click should be heard at the injector. This test must be done without the engine running. This test indicates, if the click is heard, that electrically, the injector is O.K.

FUEL HIGH PRESSURE SOLENOID INTERFACE HARNESS

Part #380002410
The Fuel High Pressure Solenoid Interface Harness allows access to the processor controlled Fuel High Pressure Solenoid. This solenoid allows fuel to the injectors when a cranking signal or an engine running signal is present at the processor. Fuel High Pressure Solenoid Connector Face/Latch up

Interface harness boot colors: 1 = Red

2 = Black

1. Attach the Interface Harness to the Fuel Solenoid (see A on the illustration below) and to the Engine Harness. 2. Connect the + voltmeter lead to the red clip and the voltmeter lead to the black clip. 3. Start the engine and the voltmeter should read system voltage. If not, attach the voltmeter lead to a good ground and retest. 4. If the voltmeter still reads 0 volts unplug the solenoid and connect the Solenoid/Injector Pulse Tool (380002417) to the solenoid and push button to activate.

5. If the solenoid clicks the problem is most likely in the processor. If the solenoid does not click, replace the solenoid. 6. If any readings are open, carefully remove the connector from the processor, install the Sizing Pin tool in the appropriate processor terminal and connect the ohmmeter lead to each end of the suspected wire and check for continuity. A pigtail with a male spade terminal is supplied allowing access to the sensor side of the harness.

ENGINE QUICK REFERENCE CHART

(NOTE: Voltage readings based on actual test of 721 D loader info needs validation) Sensor Readings Taken at 20 degreees C (68F.)

TEMP SENSORS VOLTAGE V-Ref 4.75V Coolant Temp Air Temp Oil Temp Fuel Temp 3.36 3.22V 3.34V 3.34V OHMS 2.5K +/- 75 2.5K +/- 75 2.5K +/- 75 2.5K +/- 75 CONNECTOR C - 18 C - 36 C - 21 C - 29 C - 19 C - 33 C - 17

PRESSURE SENSORS STATIC - KEY ON V-Ref 5.00V Air 3.91V Common Rail Pressure 4.49V

IDLE 3.91V 3.43V

FAST IDLE 3.18V 2.46V

CONNECTOR C - 10 C - 28 C - 12 C - 20 C - 27 C-9 C - 35

Oil Pressure

4.10V

.678V

.278V

MAGNETIC SENSORS @ ENGINE CRANKING SPEED VOLTAGE (1.5V MIN) OHMS Camshaft Sensor 1.76V AC 900 +/- 75 Crankshaft Sensor 1.856V AC 900 +/- 75

CONNECTOR C-5 PIN 1 C - 25 PIN 1

SENSORS CONNECTOR (C) TERMINAL LOCATIONS

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REPAIR PROCEDURES

TERMINAL TOOLS Tool Number 380002418, For All Sensor Connectors

Push wire towards the front of the connector, install the terminal tool into the two slots on the face of the connector to release terminal locking tabs and pull the wire out of the back of the connector.

Tool Number 380002419, For All Injector Harness Connectors

Remove the orange locking plug from the inside of the connector with a needle nose or small pliers. Push the wire towards the front of the connector, place the terminal tool on the locking tab inside of the connector and release the terminal. Pull the wire out of the back of the connector.

89 Pin Processor Connector Latch Release Tools Part No. 380002429

Use this Release Tool to release the latches on the cover to access the terminals. There are four different size tools for these connectors.

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Butt Splice Connector Procedure Part No. 380002490

Use the appropriate wire crimper as shown in the illustration. After crimping the connector, apply heat to the splice connector until a small amount of glue is seen coming out of the connection. This will waterproof the splice.

Jumper Wires and Pin Size/Probe Adapter Part No. 380002416

Place the Pin Size/Probe Adapter into the 89 pin processor adapter and the Male Spade Adapter into the sensor connector. Connect the meter leads to the Male Spade Adapter wire and Pin Size adapter and read the resistance on the ohmmeter. The reading should be less than 5 ohms.

Pin Size Adapter

Male Spade Adapter

Solenoid/Injector Pulse Tool Part No. 380002417

Connect the Red (Bat+) and Black (Bat ) leads to the battery. The small clips are connected to the injector harness (part no. 380002408) red and black clips. Push the button on the Pulse Tool and listen for a "click" at the injector. If the injector doesn't click, test the resistance of the injector, the reading should be .57 ohms. If not, bench check or replace the injector. The same test should be performed on the high pressure fuel solenoid. Use the adapter harness 380002410 to access the solenoid. Connect the tester to the battery and to the solenoid adapter leads the same as described on the 380002408 harness. A distinct click should be heard when activating the tester. 12

TIER II COMPLIANT COMMON RAIL ENGINE DIAGNOSTIC/REPAIR KIT (New Engine Family NEF)
Part No. 380040185 Contents:
3 each 380002408 Fuel Injector Interface Harness 1 each 380002409 Coolant/Fuel Temperature Sensor 1 each 380002410 Fuel High Pressure Solenoid 1 each 380002411 Cam/Crank Sensor 1 each 380002412 Common Rail Pressure Sensor 1 each 380002413 Oil Pressure/ Temperature Sensor 1 each 380002414 Air Pressure/ Temperature 6 each 380002415 Male Spade to Clip Jumper Adapters 1 each 380002416 Pin Size/Probe Adapters 1 each 380002417 Solenoid/Injector Pulse Tool 1 each 380002418 Terminal Release Tool (AMP) 1 each 380002419 Terminal Release Tool (Deutsch) 4 each Connector Cap Removal Clips 1 each Instruction Booklet 1 each Carry/Storage Case (includes drawer assembly, dividers and frame) 1 each 380002427 Connector Pack 1 each 380002428 Pigtail Pack 1 each 380002429 Terminal Tool Pack 1 each 380002490 Crimper Tool Extra Drawer Assembly Order part number 380002424

REPLACEMENT PARTS ARE AVAILABLE FROM CNH PARTS

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