G3600 A4 Engines Sensor Signal (Analog, Passive) - Test Caterpillar


Sensor Signal (Analog, Passive) - Test
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Use this procedure to troubleshoot the electrical system if a problem is suspected with the passive sensors. Also, use this procedure if any one of the diagnostic codes is active or easily repeated.

Table 1
J1939 Code and Description  Comments 
105-3
Engine Intake Manifold #1 Temperature : Voltage Above Normal 
The Electronic Control Module (ECM) detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
105-4
Engine Intake Manifold #1 Temperature : Voltage Below Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
110-3
Engine Coolant Temperature : Voltage Above Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
110-4
Engine Coolant Temperature : Voltage Below Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
174-3
Engine Fuel Temperature 1 : Voltage Above Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
174-4
Engine Fuel Temperature 1 : Voltage Below Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
174-12
Engine Fuel Temperature 1 : Failure 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
175-3
Engine Oil Temperature 1 : Voltage Above Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
175-4
Engine Oil Temperature 1 : Voltage Below Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
1172-3
Engine Turbocharger #1 Compressor Inlet Temperature : Voltage Above Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 
1172-4
Engine Turbocharger #1 Compressor Inlet Temperature : Voltage Below Normal 
The ECM detects signal voltage that is not in the acceptable range.
The value of the parameter is set to a default value.
The code is logged. 


Illustration 1g03788765

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

The ECM continuously creates a pull-up voltage on the signal wire for each sensor. The ECM uses this pull-up voltage in order to detect a problem in the signal circuit. When the ECM detects voltage that is above a threshold on the signal wire, the ECM activates a high voltage -3 diagnostic code. When the ECM detects voltage that is below a threshold on the signal wire, the ECM activates a low voltage -4 diagnostic code.

Note: There may be a delay of 30 seconds or more in order for Cat® Electronic Technician (ET) to display an active diagnostic code. When you check for a diagnostic code, be sure to wait at least 30 seconds.



Illustration 2g01218763
Terminal locations at the sensor connector for the analog sensors
(Terminal 1) Sensor signal
(Terminal 2) Analog return

Table 2
Troubleshooting Test Steps  Values  Results 

1. Check for Codes

A. Connect Cat® Electronic Technician (ET) to the service tool connector.

B. Determine if a code is active or logged.
 

Codes
 

Result: A -3 code is active.

Proceed to Test Step 2.

Result: A -4 code is active.

Proceed to Test Step 3.

Result: For a code that is logged, but not currently active.

Proceed to Test Step 4.
 

2. Create a Short at the Sensor Connector

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

B. Disconnect the sensor with the active -3 code.

C. Install the jumper wire between the following terminals at the sensor connector:

- Terminal 1 (sensor signal) and Terminal 2 (sensor return)

D. Connect Cat ET.

E. Use Cat ET to monitor the following:

- -4 code

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

Create a Short
 

Result: The -3 code remains active.

Repair: There is an open in the wiring harness. Repair or replace the wiring harness.

Verify that the repair eliminated the problem.

Result: A -4 code became active.

Repair: The wiring harness is OK. Replace the sensor.

Verify that the repair eliminated the problem.
 

3. Create an Open at the Sensor Connector

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

B. Disconnect the sensor with the active -4 code.

C. Connect Cat ET.

D. Use Cat ET to monitor the following:

- -3 code

Note: For a 110-3 code, start the engine and let the engine idle for 7 minutes. The engine must be running for at least 7 minutes in order for the diagnostic to run.

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

Create an Open
 

Result: The -4 code remains active.

Repair: There is an open in the wiring harness. Repair or replace the wiring harness.

Verify that the repair eliminated the problem.

Result: A -3 code became active.

Repair: The wiring harness is OK. Replace the sensor.

Verify that the repair eliminated the problem.
 

4. Perform the Wiggle Test

Carefully following this procedure is the best way to identify the root cause of an intermittent problem.

A. Connect Cat ET.

B. Use AVS ET to perform the following test:

- "Wiggle Test"

C. Slowly wiggle the wiring and the connectors between the P2 connector and the sensor. Slowly wiggle the wiring and the connectors between the P1 connector and the sensor. Pay particular attention to the wiring near each connector. Be sure to wiggle all of the wiring.

D. As you wiggle the wiring look for the following problems:

- Loose connectors or damaged connectors
- Moisture on the connectors or the wiring
- Damage that is caused by excessive heat
- Damage that is caused by chafing
- Improper routing of wiring
- Damaged insulation
 

Test
 

Result: The wiring failed the Wiggle Test.

Repair: There is a problem with the wiring harness. Repair or replace the wiring harness.

Verify that the repair eliminated the problem.

Result: The wiring passed the Wiggle Test.

Repair: The problem may be intermittent. Inspect the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for additional information.

If the wiring looks OK perform the following procedure.

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

2. Disconnect the connectors. Carefully inspect the terminals for proper installation. Make sure that each terminal is clean and dry.

3. Insert a pin into each socket. Verify that each socket grips the pin firmly. Repair any problems.

4. Connect all connectors.

5. Verify that the repair eliminated the problem.
 

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).

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