CELECT Electronic Control System Troubleshooting and Repair Manual

View Related Topic


ECM – No Communication Troubleshooting Tree

Symptoms

    • No communication and engine will
      not start
    • No communication and engine will start
    • No communication related INSITE™ electronic service tool errors
    • Communication with some ECMs but
      not all ECMs on a multi-module engine.

How To Use This Tree

This troubleshooting procedure can be used to troubleshoot J1939 and J1587 data link communication issues between the electronic service tool and the ECM. There are four procedures that can be used to support this troubleshooting tree:

  • Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, in the appropriate electronic control system troubleshooting and repair manual.
  • Procedure 019-165 (Data Link Circuit, SAE J1939) in Section 19 in the appropriate electronic control system troubleshooting and repair manual.
  • Procedure 019-166 (Data Link Circuit, SAE J1587) in Section 19 in the appropriate electronic control system troubleshooting and repair manual.

The troubleshooting steps in this procedure build upon information obtained in previous steps. The troubleshooting steps
must be performed in the sequence specified in the troubleshooting procedure.

This troubleshooting procedure supports several engine families, therefore some instructions are stated in a general manner. Apply the requested procedures and actions to the specific engine family with the support of engine specific documentation that can be found in the Troubleshooting and Repair manuals for the specific engine family.

Shop Talk

Three basic principles were used to define and sequence the troubleshooting steps that are listed in this tree.

  • Verify high level system operation prior to troubleshooting individual components of the system. The purpose for this is to learn from the behavior of the system in order to direct the next steps for troubleshooting.
  • Use the Bench Top Harness to separate the ECM from the vehicle so the ECM can be isolated from vehicle issues that could be causing no communication.
  • Use a second vehicle or a second ECM to isolate high level system issues before troubleshooting individual components of the system.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. INSITE™ electronic service tool error code check  
  STEP 1A. Check for INSITE™ electronic service tool error code 5023. Is INSITE™ electronic service tool error code 5023 present?
  STEP 1B. INSITE™ electronic service tool error code 5080 or 5081 check. Is INSITE™ electronic service tool error code 5080 or 5081 present?
  STEP 1C. INSITE™ electronic service tool other error code checks. Are any INSITE™ electronic service tool error codes present other than 5023, 5080, or 5081?
  STEP 1D. ECM password check Does INSITE™ electronic service tool indicate the ECM is password protected?
STEP 2. Initial data link adapter and INSITE™ electronic service tool check  
  STEP 2A. Initial data link adapter check Are the communication lights on the data link adapter flashing?
  STEP 2B. data link adapter reset check Does the ECM communicate?
  STEP 2C. Initial INSITE™ electronic service tool check Does the ECM communicate?
  STEP 2D. data link adapter verification check Is an Inline or Inline I being use to communicate with the ECM?
  STEP 2E. data link adapter firmware check Is firmware version compatible with ECM?
STEP 3. Bench communication setup checks  
  STEP 3A. Bench setup availability check Is a bench setup available?
  STEP 3A-1. Engine start check
  STEP 3B. Initial bench setup communication check Does the ECM communicated using bench setup?
  STEP 3B-1. Engine start check
  STEP 3C. Second vehicle or second ECM availability check for bench setup Is second vehicle or second ECM available to connect to the bench setup?
  STEP 3D. Initial bench setup functionality check Does the second ECM communicate using bench setup?
  STEP 3E. Troubleshoot bench setup Does bench setup check OK?
  STEP 3F. data link adapter replacement check Does bench setup communicate with the second ECM using a replacement data link adapter?
STEP 4. ECM power up circuit check  
  STEP 4A. Engine configuration check Is the engine equipped with a fuel shutoff valve?
  STEP 4A-1. Check fuel shutoff valve voltage
  STEP 4A-2. Coolant temperature sensor signal voltage check
  STEP 4B. ECM keyswitch voltage check Is the keyswitch voltage within 1-VDC or vehicle system voltage?
  STEP 4C. Check the ECM power and ground Is the ECM battery supply voltage equal to the battery voltage?
STEP 5. Initial electronic tool check  
  STEP 5A. Bench setup previously used for troubleshooting check In Step 3 checks, was bench setup used to successfully communicate with the ECM?
  STEP 5B. Second vehicle availability check for electronic tool Is a second vehicle available to connect to the electronic tool?
  STEP 5C. Initial electronic tool functionality check Does the second ECM communicate using electronic tool?
STEP 6. data link adapter power check  
  STEP 6A. data link adapter determination check Is an Inline I data link adapter being used to communicate with INSITE™ electronic service tool?
  STEP 6B. Check data link adapter power Is the data link adapter power light on?
  STEP 6C. Determination if communication is being attempted at OEM dash connector Is the communication being attempted at the OEM data link dash connector?
  STEP 6D. OEM data link dash connector voltage check Is the voltage equal to or greater than 9-VDC?
  STEP 6E. Check voltage at data link adapter auxiliary power supply Is the voltage equal to or greater than 9-VDC?
  STEP 6F. Check voltage at vehicle battery Is the voltage equal or greater than 11-VDC?
  STEP 6G. Computer serial port voltage check Is a minimum of 5 VDC available?
STEP 7. data link circuit check  
  STEP 7A. Check J1939 or J1587 circuits Does the circuit check OK?
STEP 8. Initial electronic tool check  
  STEP 8A. Second vehicle availability check for electronic tool Is a second vehicle available to connect to the electronic tool?
  STEP 8B. Initial electronic tool functionality check Does the second ECM communicate using the electronic tool?
STEP 9. Detailed electronic tool check  
  STEP 9A. Troubleshoot electronic tool hardware Does the electronic tool hardware check OK?
STEP 10. Serial cable and computer check  
  STEP 10A. Troubleshoot serial cable and computer Do the serial cable and computer check OK?
STEP 11. ROM boot ECM  
  STEP 11A. ROM boot tool availability check Is the ROM boot tool available?
  STEP 11B. ROM boot ECM Does the ECM communicate?


Guided Step 1 – INSITE™ electronic service tool error code check

Guided Step 1A – INSITE™ electronic service tool error code 5023 check

Conditions

  • Connect INSITE™ electronic service tool.
  • Turn keyswitch ON.

Action

Check for INSITE™ electronic service tool error code 5023.

  • Use INSITE™ electronic service tool to read the error codes.

Is INSITE™ electronic service tool error code 5023 present?

YES NO
No Repair No Repair

Guided Step 1B – INSITE™ electronic service tool error code 5080 or 5081 check

Conditions

  • Connect INSITE™ electronic service tool.
  • Turn keyswitch ON.

Action

Check for INSITE™ error code 5080 or 5081.

  • Use INSITE™ electronic service tool to read the error codes.

Is INSITE™ electronic service tool error code 5080 or 5081 present?

YES NO

Perform the ECM calibration download

No Repair
Repair complete

Guided Step 1C – INSITE™ electronic service tool other error code checks.

Conditions

  • Connect Is INSITE™ electronic service tool.
  • Turn keyswitch ON.

Action

Are any INSITE™ electronic service tool error codes present other than 5023, 5080, or 5081?

  • Use INSITE™ electronic service tool to read the error codes.

Are any INSITE™ electronic service tool error codes present other than 5023, 5080, or 5081?

YES NO

See the INSITE™ Electronic Service Tool manual for troubleshooting guidelines.

No Repair
Repair Complete

Guided Step 1D – ECM password check

Conditions

  • Connect INSITE™ electronic service tool.
  • Turn keyswitch ON.

Action

Does INSITE™ electronic service tool indicate the ECM is password protected?

  • Use INSITE™ electronic service tool.

Does INSITE™ electronic service tool indicate the ECM is password protected?

YES NO

Enter correct password

If password is unavailable, contact customer to request password information. If customer can
not supply password information, see the INSITE™ electronic service tool manual for password removal information. Normal warranty guidelines will apply if ECM password removal is required.

No Repair
Repair complete


Guided Step 2 – Initial data link adapter and INSITE™ electronic service tool check

Guided Step 2A – Initial data link adapter check

Conditions

  • data link adapter connected to OEM data link connector in vehicle.
  • INSITE™ electronic service tool computer
    must not be connected.
  • Note: If connected to the 3 pin engine data link connector the communication lights will
    not blink, continue to Step 2B.

Action

Turn keyswitch on.

Are the communication lights on the data link adapter flashing?

  • J1708 light for Inline
  • J1708 or J1939 for Inline II, Inline 4, and Inline 5.
YES NO

No Repair

No Repair

Guided Step 2B – data link adapter reset check

Conditions

INSITE™ electronic service tool connected to vehicle.

Action

Data link adapter reset check

  • Disconnect power from the data link adapter.
  • Leave disconnected for 30 seconds
  • Connect power again to the Inline adapter
  • Turn keyswitch ON.

Does the ECM communicate?

YES NO
No Repair No Repair
Repair complete

Guided Step 2C – Initial INSITE™ electronic service tool check

Conditions

  • INSITE™ electronic service tool connected to vehicle
  • Turn keyswitch ON.

Action

Reboot INSITE™ electronic service tool PC.

  • Launch INSITE™ electronic service tool
  • Check for communication.

Does the ECM communicate?

YES NO
No Repair No Repair
Repair complete

Guided Step 2D – data link adapter verification check

Conditions

None

Action

Verify if an Inline or Inline I data link adapter is being used to communicate with ECM.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for General Information – data link Adapters, in the appropriate electronic control system troubleshooting and repair manual for data link adapter identification information.

Is an Inline or Inline I being used to communicate with the ECM?

YES NO
No Repair No Repair

Guided Step 2E – data link adapter firmware check

Conditions

None

Action

Verify data link adapter firmware version is compatible with ECM.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for General Information – data link Adapters, in the appropriate Electronic Control System Troubleshooting and Repair manual for data link adapter identification information.

Is firmware version compatible with the ECM?

YES NO
No Repair

Load correct firmware version


Guided Step 3 – Bench communication setup checks

Guided Step 3A – Bench setup availability check

Conditions

  • Bench setup available.

Action

Verify bench setup is available.

Is a bench setup available?

YES NO
No Repair No Repair

Guided Step 3A-1 – Engine start check

Conditions

  • None

Action

Verify if engine will start.

Will engine start?

YES NO
No Repair No Repair

Guided Step 3B – Initial bench setup communication check.

Conditions

  • Use the same INSITE™ electronic service tool PC as was used for the previous checks
  • Bench setup connected to ECM
  • Bench top calibration harness keyswitch ON.

Action

Attempt to comunicate with the ECM using bench setup.

Does the ECM communicate with bench setup?

YES NO
No Repair No Repair

Guided Step 3B-1 – Engine start check

Conditions

  • None

Action

Disconnect the bench top calibration cable from the ECM. Reconnect the ECM to the original engine or OEM wiring harness connector. Verify if the engine will start.

Will the engine start?

YES NO
No Repair No Repair

Guided Step 3C – Second vehicle or second ECM availability check for bench setup

Conditions

  • Second vehicle or second ECM available for testing.

Action

Verify if a second vehicle or second ECM is available to connect to the bench setup.

Is a second vehicle or second ECM available to connect to the bench setup?

YES NO
No Repair No Repair

Guided Step 3D – Initial bench setup functionality check

Conditions

  • Use the same INSITE™ electronic service tool PC and bench setup tools that were originally used on the problem vehicle.
  • Bench setup connected to second vehicle or second ECM
  • Bench top calibration harness keyswitch ON.

Action

Attempt to communicate with the ECM on the second vehicle or a spare ECM using bench setup.

Does the second ECM communicate using bench setup?

YES NO
No Repair No Repair

Guided Step 3E – Troubleshoot bench setup hardware

Conditions

  • None

Action

Troubleshoot bench calibration cable, bench calibration harness, and serial cable.

  • Perform troubleshooting procedures for evaluating the bench calibration cable, bench calibration harness, and serial cable. Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for Resistance Check – Serial Cable, Benchtop Calibration Harness, Benchtop Calibration Cable, in the appropriate Electronic Control System Troubleshooting and Repair manual.

Does bench setup check OK?

YES NO
No Repair

Repair or replace bench calibration cable, bench calibration harness, or serial cable.

Guided Step 3F – data link adapter replacement check

Conditions

  • None

Action

Try to communicate with the bench setup using a replacement datalink.

Does bench setup communicate with the second ECM using a replacement data link adapter?

YES NO

Use replacement data link adapter.

Issue with bench setup should have been found. Troubleshoot the bench setup again.


Guided Step 4 – ECM power up circuit check

Guided Step 4A – Engine configuration check

Conditions

  • None

Action

Determine if the engine is equipped with a fuel shutoff valve

Is the engine equipped with a fuel shutoff valve?

YES NO
No Repair No Repair

Guided Step 4A-1 – Check fuel shutoff valve voltage

Conditions

  • Turn keyswitch ON.

Action

Measure the voltage from the fuel shutoff valve post to engine block ground.

There are 12 and 24 volt systems, the fuel shutoff valve voltage needs to be within 1-VDC of the vehicle system voltage.

Is the fuel shutoff valve voltage within 1-VDC of vehicle system voltage?

YES NO
No Repair No Repair

Guided Step 4A-2 – Coolant temperature sensor signal voltage check

Conditions

  • Turn keyswitch ON.
  • Disconnect the coolant temperature sensor connector.

Action

Measure the voltage across the two pins of the coolant temperature sensor on the wiring harness connector.

Reference the wiring diagram or circuit diagram for connector pin identification.

Is the coolant temperature signal voltage greater than 4.5-VDC?

YES NO
No Repair No Repair

Guided Step 4B – ECM keyswitch voltage check

Conditions

  • Turn keyswitch OFF.
  • Disconnect the wiring harness connector that contains the keyswitch signal from the ECM.
  • Turn the keyswitch ON.

Action

Measure the voltage from the keyswitch input SIGNAL wire of the wiring harness to engine block ground.

Reference the wiring diagram or circuit diagram for connector pin identification.

Is the keyswitch voltage within 1-VDC of vehicle system voltage?

YES NO
No Repair

Repair or replace the wiring harness that contains the keyswitch signal, or repair or replace the keyswitch, or check the battery connection. Reference Procedure 019-064 (Key Switch Battery Supply Circuit) in Section 19 in the appropriate troubleshooting and repair manual.

See the Engine Performance Troubleshooting Tree in the appropriate troubleshooting and repair manual, if the no start condition is still present.

Repair complete

Guided Step 4C – Check the ECM power and ground

Conditions

  • Turn keyswitch OFF
  • Disconnect from the ECM the wiring harness connector that contains the ECM battery SUPPLY (-) and SUPPLY (+) wiring.

Action

Measure the voltage from each ECM battery SUPPLY (+) pin to all battery SUPPLY (-) pins in the wiring harness connector.

Reference the wiring diagram or circuit diagram for connector pin identification.

Is the ECM battery supply voltage equal to the battery voltage?

YES NO

Call for authorization.

Replace the ECM. Reference Procedure 019-031 (Electronic Control Module (ECM)) in Section 19 in the appropriate troubleshooting and repair manual.

Repair or replace the wiring harness that contains the ECM battery SUPPLY (+) and battery SUPPLY (-) wiring.

See the Engine Performance Troubleshooting Tree if no start condition is still present.

Repair complete

Repair complete


Guided Step 5 – Initial electronic tool check

Guided Step 5A – Bench setup previously used for troubleshooting check

Conditions

  • None

Action

In Step 3 checks, was bench setup used to successfully communicate with the ECM?

In Step 3 checks, was bench setup used to successfully communicate with the ECM?

YES NO

ECM is OK, repair complete if communication is
not required through OEM data link connector or harness.

If communication is required through the OEM data link connector or harness continue to Step 6A.

No Repair

Guided Step 5B – Second vehicle availability check for electronic tool

Conditions

  • Second vehicle available for testing

Action

Verify a second vehicle is available to connect to the electronic tool.

Is a second vehicle available to connect to the electronic tool?

YES NO
No Repair No Repair

Guided Step 5C – Initial electronic tool functionality check

Conditions

  • Electronic tool connected to a second vehicle.
  • Keyswitch ON.

Action

Attempt to communicate with the ECM on the second vehicle using the same electronic tool hardware used on the problem vehicle.

Does the second ECM communicate using electronic tool?

YES NO
No Repair No Repair


Guided Step 6 – data link adapter power check

Guided Step 6A – data link adapter determination check

Conditions

  • None

Action

Determine if an Inline I datalink adapter is being used to communicate with INSITE™ electronic service tool.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for General Information – data link adapter, in the appropriate electronic control system troubleshooting and repair manual.

Is an Inline I data link adapter being used to communicate with INSITE™ electronic service tool?

YES NO
No Repair No Repair

Guided Step 6B – Check data link adapter power

Conditions

  • Do
    not use an Inline I
  • Electronic tool hardware connected to the vehicle.
  • INSITE™ electronic service tool launched
  • Keyswitch ON.

Action

Note: For all datalink adapters except Inline I.

Attempt to communicate with INSITE™ electronic service tool and check to see if the data link adapter power light is on.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for General Information – data link Adapter, in the appropriate electronic control system troubleshooting and repair manual.

Is the data link adapter power light on?

YES NO
No Repair No Repair

Guided Step 6C – Determination if communication is being attempted at the OEM data link dash connector

Conditions

  • None

Action

Check to see if communication is being attempted at the OEM datalink dash connector.

Is communication being attempted at the OEM data link dash connector?

YES NO
No Repair No Repair

Guided Step 6D – OEM data link dash connector voltage check

Conditions

  • Turn keyswitch ON.

Action

Measure voltage across the SUPPLY and ground pins of the OEM datalink connector.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for In Cab data link Connector or 6-pin In Cab data link connector, in the appropriate Electronic Control System Troubleshooting and Repair manual for pin locations.

Is the voltage equal to or greater than 9 VDC?

YES NO

Replace data link adapter

No Repair
Repair complete

Guided Step 6E – Check voltage at data link adapter auxiliary power supply

Conditions

  • Turn keyswitch ON.

Action

Measure the data link adapter supply voltage at the datalink adapter harness connector.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for 3-pin data link Cable, in the appropriate Electronic Control System Troubleshooting and Repair manual for pin locations.

Is the voltage equal to or greater than 9-VDC?

YES NO

Replace data link adapter.

No Repair
Repair complete

Guided Step 6F – Check voltage at vehicle battery

Conditions

  • None

Action

Measure vehicle battery voltage in all cases except if using an Inline I.

If using an Inline I measure data link adapter voltage supply from computer.

Is the voltage equal to or greater than 11-VDC?

YES NO

Repair or replace damaged wiring.

Clean the battery connections or replace the batteries.

Repair complete

Repair complete

Guided Step 6G – Computer serial port voltage check

Conditions

  • None

Action

Note: For Inline I only.

Measure voltage across the SIGNAL ground pin and the data terminal ready pin and the SIGNAL ground pin and the request to send pin on the computer serial port.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, for Serial Cable, in the appropriate Electronic and Control System Troubleshooting and Repair manual for pin locations.

Is a minimum of 5 VDC available?

YES NO

Replace data link adapter

Contact PC administration support.

Repair complete

Repair complete


Guided Step 7 – data link circuit check

Guided Step 7A – Check J1939 or J1587 circuits

Conditions

  • None

Action

Use the following procedures to perform J1939 or J1587 circuit checks depending on the datalink circuit being used.

Reference Procedure 019-165 (Data Link Circuit, SAE J1939) in Section 19 in the appropriate troubleshooting and repair manual.

This procedure gives information for a complete resistance check, check for short circuit to ground, and check for short circuit from pin-to-pin.

Reference Procedure 019-166 (Data Link Circuit, SAE J1587) in Section 19 in the appropriate troubleshooting and repair manual.

This procedure gives information for a complete resistance check, check for short circuit to ground, check for short circuit from pin-to-pin, and voltage check.

Reference Procedure 019-428 (Engine data links) in Section 19 in the appropriate troubleshooting and repair manual. Complete resistance check, check for short circuit to ground, and check for short circuit from pin-to-pin.

Does the circuit check OK?

YES NO
No Repair

Repair or replace the harness with the data link problem, either the engine or OEM harness.

Repair complete


Guided Step 8 – Initial electronic tool check

Guided Step 8A – Second vehicle availability check for electronic tool

Conditions

  • Second vehicle available for testing

Action

Verify if a second vehicle is available to connect to electronic tool?

Is a second vehicle available to connect to the electronic tool?

YES NO
No Repair No Repair

Guided Step 8B – Initial electronic tool functionality check

Conditions

  • Electronic tool connected to second vehicle

Action

Attempt to communicate with the ECM on the second vehicle using the electronic tool.

Does the second ECM communicate using the electronic tool?

YES NO
No Repair No Repair


Guided Step 9 – Detailed electronic tool check

Guided Step 9A – Troubleshoot electronic tool hardware

Conditions

  • None

Action

Perform troubleshooting procedures for evaluating electronic tool hardware:

  • data link adapter cable
  • data link adapter power supply cable
  • data link adapter
  • Serial cable
  • Computer.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, in the appropriate troubleshooting and repair manual.

Complete the following checks:

  • Initial Check – INSITE™ electronic service tool
  • Initial Check – data link Adapters
  • Resistance Check – Serial Cable
  • Resistance Check for data link adapter cable and data link adapter power supply cable.

Does the electronic tool hardware check OK?

YES NO

Communication issue found.

Repair or replace damaged hardware.

Repair complete


Guided Step 10 – Serial cable and computer check

Guided Step 10A – Troubleshoot serial cable and computer

Conditions

  • None

Action

Perform troubleshooting procedures for evaluating the serial cable and computer.

Reference Procedure 022-999 (Service Tools and Hardware – Overview) in Section F, in the appropriate troubleshooting and repair manual.

Complete the following checks:

  • Initial Check – INSITE™ electronic service tool
  • Resistance Check – Serial Cable.

Do the serial cable and computer check OK?

YES NO

Communication issue found

Repair or replace damaged hardware.

Repair complete


Guided Step 11 – ROM boot ECM

Guided Step 11A – ROM boot tool availability check

Conditions

  • None

Action

Verify if ROM boot tool is available for specific ECM.

Is the ROM boot tool available?

YES NO
No Repair

Call for pre-authorization

Replace the ECM.

Reference Procedure 019-031 (Electronic Control Module (ECM)) in Section 19 in the appropriate troubleshooting and repair manual.

Repair complete

Guided Step 11B – ROM boot the ECM

Conditions

  • None

Action

ROM boot the ECM.

Reference Procedure 019-427 (ECM ROM Boot) in Section 19 in the appropriate troubleshooting and repair manual.

Does the ECM communicate?

YES NO

Calibrate the ECM again.

Call for pre-authorization

Replace the ECM.

Reference Procedure 019-031 (Electronic Control Module (ECM)) in Section 19 in the appropriate troubleshooting and repair manual.

Repair complete

Repair complete

Last Modified:  07-Dec-2007

Leave a Reply

Your email address will not be published. Required fields are marked *