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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 Conditions which Generate this Code System Response
The Electronic Control Module (ECM) detects
94-3 Fuel Delivery Pressure signal voltage that is above normal for one second.
Sensor voltage above normal The code is logged.
The ECM has been powered for at least three The ECM flags fuel pressure as invalid
seconds. data.
The value of the parameter is set to a
94-4 Fuel Delivery Pressure The ECM detects signal voltage that is below default value.
Sensor voltage below normal normal for one second.
The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
100-3 Engine Oil Pressure
normal for one second. The code is logged.
Sensor voltage above normal
The ECM has been powered for at least three The ECM flags oil pressure as invalid
seconds. data.
100-4 Engine Oil Pressure The ECM detects signal voltage that is below The value of the parameter is set to a
Sensor voltage below normal normal for one second. default value.
The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
101-3 Crankcase Air Pressure
normal for one second.
Sensor voltage above normal
The ECM has been powered for at least three
seconds. The code is logged.
The value of the parameter is set to zero.
The ECM detects signal voltage that is below
101-4 Crankcase Air Pressure
normal for one second.
Sensor voltage below normal
The ECM has been powered for at least three
seconds.
The ECM detects signal voltage that is above
110-3 Engine Coolant
normal for one second.
Temperature Sensor voltage
The ECM has been powered for at least three The code is logged.
above normal
seconds. The value of the parameter is set to
110-4 Engine Coolant The ECM detects signal voltage that is below −40 °C (−40 °F).
Temperature Sensor voltage normal for one second.
below normal The ECM has been powered for three seconds.
The ECM reads turbocharger compressor outlet
273-0 Turbocharger Outlet
pressure above 200 kPa (29 psi). The engine speed
Pressure Sensor high - most
is within 50 rpm of low idle or effective fuel
severe (3)
equals 20.

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The ECM detects signal voltage that is above

273-3 Turbocharger Outlet
normal for one second.
Pressure Sensor voltage above
The ECM has been powered for at least three The code is logged.
normal
seconds. The value of the parameter is set to zero.
273-4 Turbocharger Outlet The ECM detects signal voltage that is below
Pressure Sensor voltage below normal for one second.
normal The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
274-3 Atmospheric Pressure
normal for one second.
Sensor voltage above normal
The ECM has been powered for at least three The code is logged.
seconds. The value of the parameter is set to
274-4 Atmospheric Pressure The ECM detects signal voltage that is below 45 kPa (6.5 psi).
Sensor voltage below normal normal for one second.
The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
275-3 Right Turbocharger
normal for one second.
Inlet Pressure Sensor voltage
The ECM has been powered for at least three The code is logged.
above normal
seconds. The value of the parameter is set to zero.
275-4 Right Turbocharger The ECM detects signal voltage that is below
Inlet Pressure Sensor voltage normal for one second.
below normal The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
276-3 Left Turbocharger Inlet
normal for one second.
Pressure Sensor voltage above
The ECM has been powered for at least three The code is logged.
normal
seconds. The value of the parameter is set to zero.
276-4 Left Turbocharger Inlet The ECM detects signal voltage that is below
Pressure Sensor voltage below normal for one second.
normal The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
279-3 Aftercooler Coolant
normal for one second. The code is logged.
Temperature Sensor (Front)
The ECM has been powered for at least three The ECM flags aftercooler coolant
voltage above normal
seconds. temperature as invalid data. The sensor
279-4 Aftercooler Coolant The ECM detects signal voltage that is below output is ignored by the engine monitoring
Temperature Sensor (Front) normal for one second. system.
voltage below nor The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
289-3 Fuel Pressure Sensor -
normal for one second. The code is logged.
Before Fuel Filter voltage
The ECM has been powered for at least three The ECM flags fuel pressure as invalid
above normal
seconds. data.
289-4 Fuel Pressure Sensor - The ECM detects signal voltage that is below The value of the parameter is set to a
Before Fuel Filter voltage normal for one second. default value.
below normal The ECM has been powered for three seconds.
The ECM detects signal voltage that is above
542-3 Engine Oil Pressure
normal for one second. The code is logged.
Sensor - Before Oil Filter
The ECM has been powered for at least three The ECM flags oil pressure as invalid
voltage above normal
seconds. data.
542-4 Engine Oil Pressure The ECM detects signal voltage that is below The value of the parameter is set to a
Sensor - Before Oil Filter normal for one second. default value.
voltage below normal The ECM has been powered for three seconds.

System Operation

Use this procedure to troubleshoot any suspect problems with the following sensors:

z Aftercooler temperature sensor

z Atmospheric pressure sensor

z Coolant temperature sensor

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z Crankcase pressure sensor

z Filtered engine oil pressure sensor

z Filtered fuel pressure sensor

z Left turbocharger inlet pressure sensor

z Right turbocharger inlet pressure sensor

z Turbocharger outlet pressure sensor

z Unfiltered engine oil pressure sensor

z 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.

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Illustration 1 g01441618
Typical schematic

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Illustration 2 g01383726
P1 ECM connector

(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

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Illustration 3 g01383733
P2 ECM connector

(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

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Illustration 4 g01234146
Location of ECM connectors

Illustration 5 g01094844
Typical example

(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.

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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

z 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.

z OK - The voltage is 5.0 ± 0.5 VDC. An active -4 diagnostic code is present. Proceed to Test Step 5.

z 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.

z Not OK - The signal voltage is equal to battery voltage.

Repair: There is a short in the harness to the +Battery. Repair the wiring.

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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.

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

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

z 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

A. Turn the main disconnect switch to the OFF position.

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.

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

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

z 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.

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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.

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

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.

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

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

z 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

A. Turn the main disconnect switch to the OFF position.

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.

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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

z 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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