Sensor Signal (Analog, Active) - Test: Troubleshooting

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Troubleshooting
3500B Engines for Caterpillar Built Power Modules with the ADEM 3 Electronic Control Module
Media Number -RENR5006-00
Publication Date -2008/02/01
Date Updated -2008/02/19

i02896712
Sensor Signal (Analog, Active) - Test

SMCS - 1439-038
System Operation Description:
Use this procedure to troubleshoot the electrical system if a problem is suspected with the sensors or if any one of the diagnostic
codes in Table 1 is active or easily repeated.
Table 1
Diagnostic Codes Table
Code and Description
94-3 Fuel Delivery Pressure
Sensor voltage above normal
94-4 Fuel Delivery Pressure

Sensor voltage below normal
100-3 Engine Oil Pressure


101-3 Crankcase Air Pressure

101-4 Crankcase Air Pressure

Conditions which Generate this Code

The Electronic Control Module (ECM) detects
signal voltage that is above normal for one second.
The ECM has been powered for at least three
seconds.
The ECM detects signal voltage that is below
normal for one second.
The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
seconds.
seconds.
seconds.
110-3 Engine Coolant

Temperature Sensor voltage
above normal

seconds.
110-4 Engine Coolant

Temperature Sensor voltage
below normal

273-0 Turbocharger Outlet

Pressure Sensor high - most
severe (3)
The ECM reads turbocharger compressor outlet

pressure above 200 kPa (29 psi). The engine speed
is within 50 rpm of low idle or effective fuel
equals 20.
System Response
The code is logged.

The ECM flags fuel pressure as invalid
data.
The value of the parameter is set to a
default value.
The code is logged.

The ECM flags oil pressure as invalid
data.
default value.
The code is logged.

The value of the parameter is set to zero.
The code is logged.

The value of the parameter is set to
40 C (40 F).
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Pressure Sensor voltage above
normal

seconds.

Pressure Sensor voltage below
normal

274-3 Atmospheric Pressure

274-4 Atmospheric Pressure


seconds.
275-3 Right Turbocharger

Inlet Pressure Sensor voltage
above normal

seconds.
275-4 Right Turbocharger

Inlet Pressure Sensor voltage
below normal

276-3 Left Turbocharger Inlet

Pressure Sensor voltage above
normal

seconds.
276-4 Left Turbocharger Inlet

Pressure Sensor voltage below
normal

279-3 Aftercooler Coolant

Temperature Sensor (Front)
voltage above normal

seconds.
279-4 Aftercooler Coolant

Temperature Sensor (Front)
voltage below nor

289-3 Fuel Pressure Sensor Before Fuel Filter voltage

above normal

seconds.
289-4 Fuel Pressure Sensor Before Fuel Filter voltage

below normal


Sensor - Before Oil Filter
voltage above normal

seconds.

Sensor - Before Oil Filter
voltage below normal

The code is logged.

The code is logged.

The value of the parameter is set to
45 kPa (6.5 psi).
The code is logged.

The code is logged.

The code is logged.

The ECM flags aftercooler coolant
temperature as invalid data. The sensor
output is ignored by the engine monitoring
system.
The code is logged.

The ECM flags fuel pressure as invalid
data.
default value.
The code is logged.

The ECM flags oil pressure as invalid
data.
default value.
System Operation
Use this procedure to troubleshoot any suspect problems with the following sensors:
z
Aftercooler temperature sensor
Atmospheric pressure sensor
Coolant temperature sensor
Crankcase pressure sensor
Filtered engine oil pressure sensor
Filtered fuel pressure sensor
Left turbocharger inlet pressure sensor
Right turbocharger inlet pressure sensor
Turbocharger outlet pressure sensor
Unfiltered engine oil pressure sensor
Unfiltered fuel pressure sensor
The analog sensor supply voltage is routed to terminal A of each sensor connector. The sensor return is routed to terminal B of each
sensor connector. The sensor signal is routed to terminal C of each sensor connector. The ECM provides short circuit protection for
the internal power supply. A short circuit to the battery will not damage the internal power supply.
The ECM performs an automatic calibration of these sensors whenever the ECM is powered and the engine is off for at least five
seconds. During an automatic calibration, the ECM calibrates pressure sensors to the value of the atmospheric pressure sensor and
against an acceptable offset pressure range.
The ECM continuously outputs a pull-up voltage on the input terminal from an analog sensor. The ECM uses this pull-up voltage in
order to detect an open or a short in the signal circuit. When the ECM detects the presence of a voltage that is above the normal
range of the sensor on the signal circuit, the ECM will generate an open circuit diagnostic code -3 for that sensor. When the ECM
detects the absence of the pull-up voltage on the signal circuit, the ECM will generate a short circuit diagnostic code -4 for that
sensor. The presence of pull-up voltage at the sensor connector indicates that the wires from the sensor connector to the ECM are
not open or shorted to ground.
Illustration 1
Typical schematic
g01441618
Illustration 2
P1 ECM connector
g01383726
(P1-2) Analog sensor supply

(P1-3) Analog sensor return
(P1-6) Coolant level sensor for the separate circuit aftercooler (SCAC)
(P1-7) Coolant temperature sensor
(P1-16) Filtered engine oil pressure sensor
(P1-17) Unfiltered engine oil pressure sensor
(P1-18) Analog sensor supply
(P1-24) Filtered fuel pressure sensor
(P1-25) Unfiltered fuel pressure sensor
(P1-35) Analog sensor return
Illustration 3
P2 ECM connector
g01383733
(P2-36) Turbocharger outlet pressure sensor

(P2-37) Atmospheric pressure sensor
(P2-38) Left turbocharger inlet pressure sensor
(P2-39) Right turbocharger inlet pressure sensor
(P2-46) Crankcase pressure sensor
Illustration 4
Location of ECM connectors
g01234146
Illustration 5
Typical example
g01094844
(Pin A) Sensor supply

(Pin B) Sensor return
(Pin C) Signal
Test Step 1. Check for "Active" or "Logged" Diagnostic Codes

A. Connect Caterpillar Electronic Technician (ET) to the service tool connector.
B. Turn the main disconnect switch to the ON position.
C. Monitor the diagnostic codes on Cat ET. Check and record any diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
D. Determine if a diagnostic code has occurred several times.

Note: A diagnostic code that is logged several times is an indication of an intermittent problem. Most intermittent problems
are the result of a bad connection between a socket and a pin in a connector or a bad connection between a wire and a
terminal. The problem may be caused by moisture, corrosion, or wear.
E. Determine if the problem is active and related to one of the following diagnostic codes:
{
-3
-4
Expected Result:
A diagnostic code is not active.
Results:
z
OK - A diagnostic code is not active.

Repair: The problem may be intermittent. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors Inspect".
STOP
Not OK - A diagnostic code is active. Proceed to Test Step 2.
Test Step 2. Check the Analog Sensor Supply Voltage at the Sensor Connector
A. Do not disconnect the suspect connector.
B. Connect a voltmeter between pin A and pin B on the sensor side of the connector for the suspect sensor.
C. Measure the voltage between pin A and pin B for the suspect sensor(s).
D. Wiggle the harness while you monitor the voltage on the voltmeter. Perform the 45 N (10 lb) pull test on each wire in the
circuit. Each terminal and each connector should easily withstand 45 N (10 lb) of tension and each wire should remain in the
connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was
properly inserted into the connector.
Expected Result:
The analog sensor supply voltage is 5.0 0.5 VDC.
Results:
z
OK - The voltage is 5.0 0.5 VDC. An active -3 diagnostic code is present. Proceed to Test Step 3.
OK - The voltage is 5.0 0.5 VDC. An active -4 diagnostic code is present. Proceed to Test Step 5.
Not OK - The voltage is not 5.0 0.5 VDC. Proceed to Test Step 7.
Test Step 3. Check for a Short to the +Battery at the Sensor Connector
A. Measure the voltage on the harness side of the sensor connector between pin B and pin C for the suspect sensor(s).
Expected Result:
The signal voltage is less than battery voltage.
Results:
z
OK - The signal voltage is less than battery voltage. Proceed to Test Step 4.
Not OK - The signal voltage is equal to battery voltage.

Repair: There is a short in the harness to the +Battery. Repair the wiring.
STOP
Test Step 4. Create a Short at the Sensor Connector
A. Turn the main disconnect switch to the OFF position.
B. Disconnect the suspect sensor.
C. Use a wire jumper in order to create a short between terminal C (signal) and terminal B (sensor return) at the sensor
connector.
D. Turn the main disconnect switch to the ON position.
E. Monitor the diagnostic codes on Cat ET. Check for an active -4 diagnostic code for the suspect sensor.
F. Turn the main disconnect switch to the OFF position.
Expected Result:
A -4 diagnostic code is now active for the suspect sensor(s).
Results:
z
OK - A -3 diagnostic code was active before creating the short at the sensor connector. A -4 diagnostic code became active
after creating the short at the sensor connector. The harness and the ECM are OK. There may be a problem with the sensor.
Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are
no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new
sensor. Clear any logged diagnostic codes.
STOP
Not OK - A -3 diagnostic code is still active for the suspect sensor(s). The problem may be in the harness or with the ECM.
Proceed to Test Step 6.
Test Step 5. Create an Open at the Suspect Sensor Connector

B. Disconnect the sensor connector of the suspect sensor(s) with the active -4 diagnostic code.
C. Turn the main disconnect switch to the ON position.
D. Monitor the diagnostic codes on Cat ET. Check for an active -3 diagnostic code for the suspect sensor.
E. Turn the main disconnect switch to the OFF position.
Expected Result:
A -3 diagnostic code is now active for the suspect sensor(s).
Results:
z
OK - A -4 diagnostic code was active before disconnecting the sensor. A -3 diagnostic code became active after
disconnecting the sensor. The harness and the ECM are OK. There may be a problem with the sensor.
Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are
no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new
sensor. Clear any logged diagnostic codes.
STOP
Not OK - A -4 diagnostic code is still active for the suspect sensor. Leave the sensor disconnected. The problem may be in
the harness or with the ECM. Proceed to Test Step 6.
Media Search - RENR5006 - 3500B Engines for Caterpillar Built Power Modules with the ADEM 3 Electronic Co... Page 10 of 11
Test Step 6. Test the Operation of the ECM

A. Fabricate jumper wires that can be used to replace the signal wire in the ECM connector for the suspect sensor. Crimp a
connector socket to one end of the jumper wire.
B. Disconnect the appropriate ECM connector for the suspect sensor.
C. Remove the signal wire for the suspect sensor from the ECM connector.
D. Install the jumper wire into the terminal location for the suspect sensor at the ECM connector.
E. Connect the ECM connector.
F. Check the operation of the ECM by creating an open at the ECM:
a. Hold the loose end of the jumper wire away from any components in order to create an open circuit condition.
b. Monitor the active diagnostic code screen on Cat ET. Check for a -3 diagnostic code for the suspect sensor.
G. Check the operation of the ECM by creating a short circuit at the ECM:
a. Short the jumper wire for the suspect sensor to the analog sensor return in order to create a short circuit condition.
b. Monitor the active diagnostic code screen on Cat ET. Check for a -4 diagnostic code for the suspect sensor.
H. Remove all jumper wires. Return the wiring to the original configuration.
Expected Result:
A -3 diagnostic code is active when the sensor signal wire is removed from the ECM connector. A -4 diagnostic code is active when
the signal wire is shorted to the analog sensor return.
Results:
z
OK - The ECM is operating properly. The problem is in the wiring between the ECM and the connector for the sensor.
Repair: If the code is active for more than one sensor, the problem is most likely in the return wire for the sensor. Repair the
wire for the analog sensor return or replace the harness.If the code is only active for one sensor, the problem is most likely in
the signal wire for the sensor. Repair the signal wire for the sensor.
STOP
Not OK - One of the following conditions exists: The -3 diagnostic code is not active when the sensor signal wire is
disconnected. The -4 diagnostic code is not active when the wire jumper is shorted to the analog sensor return.
Repair: Replace the ECM. Refer to Troubleshooting, "ECM - Replace". Verify that the problem is resolved.
STOP
Test Step 7. Check the Analog Sensor Supply Voltage at the ECM
B. Remove the analog sensor supply wire(s) from the appropriate ECM connector. Install a wire jumper(s) into the socket(s) for
the analog sensor supply.
C. Turn the main disconnect switch to the ON position.
D. Measure the voltage between the wire jumper(s) and the analog sensor return.
E. Turn the main disconnect switch to the OFF position.
F. Remove the wire jumpers and replace all wires.
Media Search - RENR5006 - 3500B Engines for Caterpillar Built Power Modules with the ADEM 3 Electronic Co... Page 11 of 11
Expected Result:
The analog sensor supply voltage is 5.0 0.5 VDC.
Results:
z
OK - The analog sensor supply voltage is 5.0 0.5 VDC. The supply voltage at the ECM is correct. There is a problem in the
wiring between the ECM and the sensor connector. Check for an open circuit condition in the wires for the analog sensor
return and the analog sensor supply.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
STOP
Not OK - The analog sensor supply voltage is not 5.0 0.2 VDC. The voltage at the ECM is not correct.
Repair: Replace the ECM. Refer to Troubleshooting, "ECM - Replace". Verify that the problem is resolved.
STOP
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Mon Jun 9 00:43:17 EST 2008

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Media Search - RENR5006 - 3500B Engines for Caterpillar Built Power Modules with the ADEM 3 Electronic Contr...

Publication Date -2008/02/01

Date Updated -2008/02/19

Sensor Signal (Analog, Active) - Test

94-4 Fuel Delivery Pressure

100-3 Engine Oil Pressure

100-4 Engine Oil Pressure

101-3 Crankcase Air Pressure

101-4 Crankcase Air Pressure

Conditions which Generate this Code

110-3 Engine Coolant

The ECM detects signal voltage that is above

110-4 Engine Coolant

The ECM detects signal voltage that is below

273-0 Turbocharger Outlet

The ECM reads turbocharger compressor outlet

The code is logged.

The code is logged.

The code is logged.

The code is logged.

273-3 Turbocharger Outlet

The ECM detects signal voltage that is above

273-4 Turbocharger Outlet

The ECM detects signal voltage that is below

274-3 Atmospheric Pressure

274-4 Atmospheric Pressure

The ECM detects signal voltage that is above

275-3 Right Turbocharger

The ECM detects signal voltage that is above

275-4 Right Turbocharger

The ECM detects signal voltage that is below

276-3 Left Turbocharger Inlet

The ECM detects signal voltage that is above

276-4 Left Turbocharger Inlet

The ECM detects signal voltage that is below

279-3 Aftercooler Coolant

The ECM detects signal voltage that is above

279-4 Aftercooler Coolant

The ECM detects signal voltage that is below

289-3 Fuel Pressure Sensor Before Fuel Filter voltage

The ECM detects signal voltage that is above

289-4 Fuel Pressure Sensor Before Fuel Filter voltage

The ECM detects signal voltage that is below

542-3 Engine Oil Pressure

The ECM detects signal voltage that is above

542-4 Engine Oil Pressure

The ECM detects signal voltage that is below

The code is logged.

The code is logged.

The code is logged.

The code is logged.

The code is logged.

The code is logged.

The code is logged.

Aftercooler temperature sensor

Atmospheric pressure sensor

Coolant temperature sensor

Crankcase pressure sensor

Filtered engine oil pressure sensor