2008/05/21 Sensor Signal (Analog, Passive) - Test (RENR9333-09)

SMCS - 1439 i03079180

System Operation Description:

PPS
Use this procedure to troubleshoot the electrical system if a problem is suspected with the

202 -0007
sensor or if any one of the diagnostic codes in Table 1 is active or easily repeated.

20: 3/08/0 B9FB

Table 1

Diagnostic Codes Table

1
RE 3:31- 1
Conditions which
Code and
Description N
© 2 R93 03:00
Generate this
Code
System Response

023 33
The engine's

Cat
Electronic Control
Module (ECM)

erp
110-3 Engine
detects signal voltage
Coolant

illa
that is more than 4.95 The code is logged if the engine has been running
Temperature for more than seven minutes. The ECM uses the
VDC for eight
Sensor : Voltage
Above Normal
seconds.
r In
last valid engine coolant temperature. If the
diagnostic code is active at start-up the ECM will
c.
The ECM has been
powered for at least use intake manifold temperature. If intake
two seconds. manifold air temperature is not valid, the ECM will
default to 90 °C (194 °F) for engine coolant
The ECM detects temperature. The ECM will activate the cooling
110-4 Engine signal voltage that is fan after this code has been active for more than
Coolant less than 0.2 VDC for eight seconds.
Temperature eight seconds.
Sensor : Voltage The ECM has been
Below Normal powered for at least
two seconds.
The engine's ECM
detects signal voltage
172-3 Intake
that is more than 4.95
Manifold Air
VDC for eight
Temperature
seconds.
Sensor : Voltage
The ECM has been The ECM will log the diagnostic code. The ECM
Above Normal
powered for at least will flag the intake manifold air temperature as
two seconds. invalid data and the intake manifold air
The ECM detects temperature is set to a default value of 70 °C
172-4 Intake signal voltage that is (158 °F).
Manifold Air less than 0.2 VDC for
Temperature eight seconds.
Sensor : Voltage The ECM has been
Below Normal powered for at least
two seconds.

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

Coolant temperature sensor

Intake manifold air temperature sensor

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.

Illustration 1 g01352952
Typical schematic
Illustration 2 g01352950
P2 ECM connector
(P2-13) Engine coolant temperature
(P2-30) Sensor return
(P2-56) Intake manifold air temperature

Illustration 3 g01155187
Connector for the temperature sensors
(1) Sensor signal
(2) Sensor return

Illustration 4 g01352943
C9 Sensor locations (typical left side engine view)
(1) Engine coolant temperature sensor
(2) Intake manifold air temperature sensor
Illustration 5 g01352944
C7 Sensor locations (typical left side engine view)
(3) Engine coolant temperature sensor
(4) Intake manifold air temperature sensor

Test Step 1. CHECK FOR "ACTIVE" OR "LOGGED" DIAGNOSTIC CODES

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

B. Restore electrical power to the ECM.

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 poor connection between a socket
and a pin in a connector or of a poor connection between a wire and a terminal.

E. Determine if the problem is active and related to one of the following diagnostic codes:

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, "Electrical Connectors - Inspect".

STOP

Not OK - An active 3 diagnostic code is present. Proceed to Test Step 2.

Not OK - An active 4 diagnostic code is present. Proceed to Test Step 4.

Test Step 2. CHECK FOR BATTERY VOLTAGE ON THE SIGNAL WIRE

A. Measure the voltage on the harness side of the sensor connector between pin 1 and engine
ground for the suspect 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 3.

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 3. CREATE A SHORT AT THE SENSOR CONNECTOR

A. Remove electrical power from the ECM.

B. Disconnect the suspect sensor.

C. Use a wire jumper in order to create a short between terminal 1 (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.

F. Remove power from the ECM.

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 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

Not OK - A 3 diagnostic code is still active for the suspect sensor(s). There is an open
circuit between the sensor connector and the ECM. Leave the sensor disconnected.
Proceed to Test Step 5.

Test Step 4. CREATE AN OPEN AT THE SUSPECT SENSOR CONNECTOR

A. Remove electrical power from the ECM.

B. Disconnect the sensor connector of the suspect sensor(s) with the active 4 diagnostic code.

C. Restore electrical power to the ECM. Wait at least 30 seconds for activation of the
diagnostic codes.

D. Access the "Active Diagnostic Code" screen on Cat ET. Check for an active 3 diagnostic
code.

E. Remove electrical power from the ECM.

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 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
 Not OK - 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.

Test Step 5. CHECK THE OPERATION OF THE ECM

A. Remove electrical power from the ECM.

B. Check the operation of the ECM by creating an open at the ECM.

a. Remove the signal wire for the suspect sensor from the P2 ECM connector. Refer to
Illustration 1 for terminal locations.

b. Install a jumper wire with Deutsch sockets on each end into the socket for the signal
wire of the suspect sensor. Hold the loose end of the jumper wire away from any
components in order to create an open circuit condition.

c. Reconnect the ECM connectors.

d. 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.
An open circuit diagnostic code 3 should be active for the suspect sensor.

C. Check the operation of the ECM by creating a short at the ECM.

a. Install a wire jumper between the wire jumper for the signal wire for the suspect sensor
and engine ground.

b. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds for
activation of the code.
A 4 diagnostic code should be active when the wire jumper is installed.

c. Remove the wire jumper. Reconnect all wires and connectors.

d. Remove the wire jumper. Reconnect all wires and connectors.

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 connected to engine ground.

Results:

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 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
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 installed.
Repair: Replace the ECM. Refer to Troubleshooting, "ECM - Replace". Verify that the
problem is resolved.

STOP

PPS-0007B9FB
2023/08/01
20:13:24-03:00
i02603097
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