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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

 

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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

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.

94-4 Fuel Delivery Pressure Sensor voltage below normal

100-3 Engine Oil Pressure Sensor voltage above normal

100-4 Engine Oil Pressure Sensor voltage below normal

101-3 Crankcase Air Pressure Sensor voltage above normal

101-4 Crankcase Air Pressure Sensor voltage below normal

System Response

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 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 normal for one second. The ECM has been powered for at least three seconds.

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. The value of the parameter is set to a default value.

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

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for at least three seconds.

110-3 Engine Coolant Temperature Sensor voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

110-4 Engine Coolant Temperature Sensor voltage  below normal

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

273-0 Turbocharger Outlet Pressure Sensor high - most severe (3)

The ECM reads turbocharger compressor outlet  pressure above above 200 kPa (29 psi). The The engine speed speed is within 50 rpm of low idle or effective fuel equals 20.

The code is logged. The value of the parameter is set to −40 °C (−40 °F).

 

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273-3 Turbocharger Outlet Pressure Sensor voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

273-4 Turbocharger Outlet Pressure Sensor voltage below normal

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

274-3 Atmospheric Pressure Sensor voltage above normal

274-4 Atmospheric Pressure Sensor voltage below normal

The 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.

275-3 Right Turbocharger Inlet Pressure Sensor voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

275-4 Right Turbocharger Inlet Pressure Sensor voltage  below normal

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

276-3 Left Turbocharger Inlet Pressure Sensor voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

276-4 Left Turbocharger Inlet Pressure Sensor voltage below normal

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

279-3 Aftercooler Coolant Temperature Sensor (Front) voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

279-4 Aftercooler Coolant Temperature Sensor (Front) voltage below nor

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

289-3 Fuel Pressure Sensor Before Fuel Filter voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

289-4 Fuel Pressure Sensor Before Fuel Filter voltage  below normal

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

542-3 Engine Oil Pressure Sensor - Before Oil Filter voltage above normal

The ECM detects signal voltage that is above normal for one second. The ECM has been powered for at least three seconds.

542-4 Engine Oil Pressure Sensor - Before Oil Filter voltage below normal

The ECM detects signal voltage that is below normal for one second. The ECM has been powered for three seconds.

System Operation 

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

Aftercooler temperature sensor



Atmospheric pressure sensor



Coolant temperature sensor

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

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

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 zero.

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. The value of the parameter is set to a default value.

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

 

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

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 conne connector. ctor. 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 f or 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 t he 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 Typical schematic 

g01441618

 

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  Illustration 2 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

g01383726

 

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  Illustration 3 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

g01383733

 

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  Illustration 4

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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 E Electronic lectronic T Technician echnician (ET) to the serv service ice tool connector. B. Turn th thee main disco disconnec nnectt switch switch to the O ON N posi position. tion. C. Monitor the diagnostic codes o on n Cat E ET. T. Check and record record any diagnostic diagnostic codes. codes. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

 

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D. Determine Determine if a diagnos diagnostic tic code code has occurred occurred sever several al times. 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 followin following g diagnostic diagnostic codes: 

-3



-4

Expected Result: 

A diagnostic code is not active. Results:  

OK - A diagnostic code is not active. Repair: The problem may be intermittent. If the problem is intermittent, refer to Troubleshooting 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 not disc disconne onnect ct the susp suspect ect conne connector. ctor. B. Connect a voltmeter betwee between n pin A an and d pin B on the sensor side of the connector for the suspec suspectt sensor. C. Meas Measure ure the vol voltage tage be betwee tween n pin A and pin B for the suspect suspect sen sensor(s sor(s). ). D. Wiggle the ha harness rness while y you ou monitor the voltage on the voltmeter. Perform Perform the 45 N (10 lb) pull test o on n 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 the connector. Expected Result: 

The analog sensor supply voltage is 5.0 ± 0.5 VDC. Results:  

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 volta voltage ge on the harnes harnesss side of the sensor sensor connector betwe between en pin B and pin C for the suspect sensor(s). sensor(s). Expected Result: 

The signal voltage is less than battery voltage. Results:  

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.

 

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STOP  Test Step 4. Create a Short at the Sensor Connector 

A. Turn the the main disco disconnec nnectt switch switch to the OF OFF F position. position. B. Disc Disconne onnect ct the suspect suspect sensor. sensor. C. Use a wire jumper in order to create a short short between terminal terminal C (signal) aand nd terminal B (sensor return) aatt the senso sensorr connector. D. Turn the the main disco disconnec nnectt switch switch to the O ON N posi position. tion. E. Monitor the diagnostic diagnostic codes codes on Cat ET. ET. Check for an active -4 diagnostic diagnostic code code for the sus suspect pect senso sensor. r. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

F. Turn th thee main disco disconnec nnectt switch switch to the OF OFF F position. position. Expected Result: 

A -4 diagnostic code is now active for the suspect sensor(s). Results:  

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 an and d 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. sensor. Clear any logged diagnostic codes.If there are no active diagnostic codes for the sensor, permanently install the new 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 

A. Turn the the main disco disconnec nnectt switch switch to the OF OFF F position. position. B. Disconnect the sens sensor or conne connector ctor of the suspect sensor(s) with the active -4 diagnos diagnostic tic code. C. Turn th thee main disco disconnec nnectt switch switch to the O ON N posi position. tion. D. Monitor the diag diagnostic nostic codes codes on Cat ET. ET. Check for an active -3 diagnostic diagnostic code code for the sus suspect pect senso sensor. r. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

E. Turn the the main disco disconnec nnectt switch switch to the OF OFF F position. position. Expected Result: 

A -3 diagnostic code is now active for the suspect sensor(s). Results:  

OK - A -4 diagnostic code was active before disconnecting the sensor. A -3 diagnostic code became active after disconnecting the sensor. The harness 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 disconnecte disconnected. d. 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 jumpe jumperr wires that ca can n be used to replace the signal wire in the ECM conn connector ector for the ssuspect uspect sens sensor. or. Crimp a connector socket to one end of the jumper wire. B. Disc Disconne onnect ct the app appropria ropriate te ECM connector connector for the suspec suspectt sensor. sensor. C. Remo Remove ve the signal signal wire for the sus suspect pect sensor sensor from th thee ECM connector connector.. D. Install the jumper wire into the terminal location for the ssuspect uspect sensor sensor at the ECM connector. E. Connec Connectt the E ECM CM co conne nnecto ctor. r. F. Check the operation of the ECM by creating an open at the ECM:  a. Hold the loose loose end of the jumper wire away from an any y components components in order to create an op open en circuit con condition. dition.  b. Monitor the active diag diagnostic nostic code screen screen on Cat ET. Check Check for a -3 diagnostic ccode ode for the suspec suspectt 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 jumper wire for the suspect suspect sen sensor sor to the analog analog sensor sensor return in order to create a sshort hort circuit cond condition. ition.  b. Monitor the active diag diagnostic nostic code screen screen on Cat ET. Check Check for a -4 diagnostic ccode ode for the suspec suspectt sensor. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

H. Remove Remove all jumper jumper wires. Re Return turn the wir wiring ing to the original original configura configuration. tion. 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 t he analog sensor return. Results:  

OK - The ECM is operating properly. The problem is in the t he 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 iiss most likely in the signal wire for the sensor. Repair the signal wire for the sensor. STOP 



Not OK - One of the following conditions -3the diagnostic codeisisshorted not active when the sensor disconnecte disconnected. d. The -4 diagnostic code is notexists: active The when wire jumper to tthe he analog sensorsignal return.wire is 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 the main disco disconnec nnectt switch switch to the OF OFF F position. position. B. Remove the analog se sensor nsor supply wire(s) from the ap appropriate propriate ECM cconnector. onnector. Insta Install ll a wire jumper(s) into the sock socket(s) et(s) for the analog sensor supply. C. Turn th thee main disco disconnec nnectt switch switch to the O ON N posi position. tion. D. Measure th thee voltage between th thee wire jumper(s) jumper(s) and the analog analog sensor return. E. Turn the the main disco disconnec nnectt switch switch to the OF OFF F position. position. F. Remo Remove ve the the wire jumpe jumpers rs and and replace replace aall ll wires. wires.

 

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Expected Result: 

The analog sensor supply voltage is 5.0 ± 0.5 VDC. Results:  

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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