C9.3 Engines for Caterpillar Built Machines Sensor Signal (Analog, Passive)

Sensor Signal (Analog, Passive) - Test

C9.3 Engines for Caterpillar Built Machines [KENR5393]

C9.3 Engines for Caterpillar Built Machines Sensor Signal (Analog, Active) - Test

C9.3 Engines for Caterpillar Built Machines Intake Manifold Air Temperature Is High

ELECTRICAL AND STARTING SYSTEM

SENSOR GP

C9.3 Engines for Caterpillar Built Machines Coolant Level - Test

C9.3 Engines for Caterpillar Built Machines Sensor Signal (Analog, Active) - Test

C9.3 Engines for Caterpillar Built Machines Sensor Signal (Analog, Passive) - Test

C9.3 Engines for Caterpillar Built Machines Sensor Supply - Test

C9.3 Engines for Caterpillar Built Machines Sensor Calibration Required - Test

C9.3 Engines for Caterpillar Built Machines Timing - Calibrate

C9.3 Engines for Caterpillar Built Machines Cooling Fan Speed - Test

System Operation Description:

Use this procedure to troubleshoot the electrical system if a problem is suspected with a sensor. Also, use this procedure if any one of the diagnostic codes in Table 1 is active or easily repeated.

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Table 1
Diagnostic Codes Table
Code and Description	Conditions which Generate this Code	System Response
110-3 Engine Coolant Temperature Sensor voltage above normal	The engine Electronic Control Module (ECM) detects signal voltage that is more than 4.95 VDC for 8 seconds. The ECM has been powered for at least 2 seconds.	The code is logged if the engine has been running for more than 7 minutes. The ECM uses the last valid engine coolant temperature. If the diagnostic code is active at start-up, the ECM will use intake manifold temperature. If intake manifold air temperature is not valid, the ECM will default to 90 °C (194 °F) for engine coolant temperature. The ECM will activate the cooling fan after this code has been active for more than 8 seconds.
110-4 Engine Coolant Temperature Sensor voltage below normal	The ECM detects signal voltage that is less than 0.2 VDC for 8 seconds. The ECM has been powered for at least 2seconds.
172-3 Intake Manifold Air Temperature Sensor voltage above normal	The engine ECM detects signal voltage that is more than 4.95 VDC for 8 seconds. The ECM has been powered for at least 2 seconds.	The ECM will log the diagnostic code. The ECM will flag the intake manifold air temperature as invalid data and the intake manifold air temperature is set to a default value of 40 °C (104 °F).
172-4 Intake Manifold Air Temperature Sensor voltage below normal	The ECM detects signal voltage that is less than 0.2 VDC for 8 seconds. The ECM has been powered for at least 2seconds.
174-3 Fuel Temperature Sensor voltage above normal	The engine Electronic Control Module (ECM) detects signal voltage that is more than 4.95 VDC for 8 seconds. The ECM has been powered for at least 2 seconds.	The code is logged. The ECM will flag the fuel temperature as invalid data and the fuel temperature is set to a default value of 40 °C (104 °F).
174-4 Fuel Temperature Sensor voltage below normal	The ECM detects signal voltage that is less than 0.2 VDC for 2 seconds. The ECM has been powered for at least 2 seconds.
2526-3 Air Inlet Temperature Sensor : Voltage Above Normal	The engine Electronic Control Module (ECM) detects signal voltage that is more than 4.95 VDC for 8 seconds. The ECM has been powered for at least 2 seconds.	The code is logged. The ECM detects voltage that is not in the acceptable range.
2526-4 Air Inlet Temperature Sensor : Voltage Below Normal	The ECM detects signal voltage that is less than 0.2 VDC for 2 seconds. The ECM has been powered for at least 2 seconds.	The code is logged. The ECM detects voltage that is not in the acceptable range.

System Operation

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

Coolant temperature sensor
Intake manifold air temperature sensor
Fuel temperature sensor
Air inlet temperature

The sensor signal for the passive sensor is routed from the ECM to terminal 1 of each sensor connector. The sensor return for the passive sensors is routed from the ECM to terminal 2 of each sensor connector.

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Illustration 1	g02165060
Schematic for the passive analog sensors

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Illustration 2	g02165062
Terminal locations at the P2 ECM connector for the engine temperature sensors (P2-17) Analog sensor return (P2-83) Analog sensor return (P2-84) Engine coolant temperature (P2-95) Intake manifold air temperature (P2-96) Fuel temperature

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Illustration 3	g01423043
Terminal locations at the connector for the passive analog sensors (Terminal 1) Sensor signal (Terminal 2) Analog sensor return

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Table 2
Troubleshooting Test Steps	Values	Results
1. Check for Codes A. Remove electrical power from the ECM. B. Connect AVSpare Electronic Technician (ET) to the service tool connector. C. Restore electrical power to the ECM. D. 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. E. 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 poor connection between a socket and a pin in a connector or of a poor connection between a wire and a terminal. F. Determine if the problem is active and related to one of the following diagnostic codes: • -3 • -4 G. Remove electrical power from the ECM.	Codes	Result: A diagnostic code is not active. Repair: The problem may be intermittent. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect". STOP Result: An active -3 diagnostic code is present. Proceed to Test Step 2. Result: An active -4 diagnostic code is present. Proceed to Test Step 4.
2. Check for Battery Voltage on the Signal Wire A. Restore electrical power to the ECM. B. Measure the voltage on the harness side of the sensor connector between pin 1 and engine ground for the suspect sensor. C. Remove electrical power from the ECM.	Battery Voltage	Result: The signal voltage is less than battery voltage. Proceed to Test Step 3. Result: The signal voltage is equal to battery voltage. Repair: There is a short circuit to battery voltage in the harness. Repair the wiring harness or replace the wiring harness. STOP
3. Create a Short Circuit at the Connector for the Suspect Sensor A. Disconnect the suspect sensor. B. Fabricate a jumper wire that is long enough to create a test circuit across the harness side of the sensor connector. Crimp connector pins to each end of the jumper wire. C. Install the jumper wire between terminal 1 (sensor signal) and terminal 2 (sensor return) at the sensor connector. D. Restore electrical power to the ECM. E. Access the "Active Diagnostic Code" screen 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. Remove electrical power from the ECM. .	Short Circuit	Result: 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 wiring between the ECM and the sensor connector is OK. 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 Result: A -3 diagnostic code is still active for the suspect sensor. There is an open circuit between the sensor connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 5.
4. Create an Open Circuit at the Connector for the Suspect Sensor	Open Circuit	Result: A -4 diagnostic code was active before disconnecting the sensor. A -3 diagnostic code became active after disconnecting the sensor. The wiring between the ECM and the sensor connector is OK. 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 Result: A -4 diagnostic code is still active for the suspect sensor. There is a short circuit between the sensor connector and the ECM. Proceed to Test Step 5.
5. Check for Proper Operation of the ECM A. Ensure that electrical power has been removed from the ECM. B. Disconnect the appropriate ECM connectors for the sensor circuit. C. Check the operation of the ECM by creating an open at the ECM. a. Remove the signal wire for the suspect sensor from the appropriate ECM connector. b. Fabricate a jumper wire that is long enough to create a test circuit between the ECM connector and the negative battery connection. Crimp a connector socket to one end of the jumper wire. c. Install the socket end of the jumper wire into the J2 terminal location that is for the signal wire of the suspect sensor. Hold the loose end of the jumper wire away from any ground source in order to create an open circuit condition. d. Reconnect the ECM connectors. e. Restore electrical power to the ECM. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds for activation of the code. 4. Check the operation of the ECM by creating a short at the ECM. a. Install the loose end of the jumper wire that is for the signal wire for the suspect sensor to negative battery. b. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds for activation of the code. c. Remove the jumper wire. Restore the wiring to the original configuration.	ECM	Result: 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 sensors. Repair the return wire for the sensor 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 Result: One of the following conditions exists: The -3 diagnostic code is not active when the open circuit condition is present on the signal wire of the suspect sensor. The -4 diagnostic code is not active when the signal wire for the suspect sensor is connected to the negative battery connection. Repair: The ECM is not operating properly. Replace the ECM. Refer to Troubleshooting, "ECM - Replace". Verify that the problem is resolved. STOP

Test Step 1.

The procedure corrected the issue. Return to service.

Results:

The procedure did not correct the issue. -
Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).

STOP