TROUBLESHOOTING PULSE WIDTH MODULATED (PWM)

SENSOR PROBLEMS
The Computerized Monitoring System (CMS), and automatic Ether Injection System (AEIS), are
just two systems developed by Caterpillar, Inc., that use pulse width modulated (PWM) sensors to
help assure maximum system reliability.

The PWM signal allows minor harness and connector deterioration compared to conventional
analog signals before an incorrect reading occurs. It also provides a monitoring system that is
extremely reliable. This means the CMS or AEIS control will notify the operator of an abnormal
system condition resulting from either a system fault or a true machine system event. At the same
time, a service code will be stored for later reference so the problem does not go undetected.

Failure to understand how this system functions can cause wasted troubleshooting time and
incorrect parts replacement.

A problem or fault means a malfunction in the electrical circuits of the CMS, and NOT a condition
where the CMS correctly indicates system conditions like low fuel or high system operating
temperatures.

The CMS indicates an input signal problem related to a PWM sensor in two ways, and at the same
time.

1. The gauge will show in the warning zone for that gauge function and flash. This means
fuel and air pressure gauges would show red at the LOW end, and temperature gauges
would show red at the High end.
2. The SERV CODE indicator will turn on to indicate service codes have been stored. This
code(s) will indicate the root cause of the problem or condition for the service
technician.

Several probable causes of these conditions include, but are not limited to the following. The
causes are shown in the most likely order to occur.

1. For the wiring harness: an open, a short to the positive side of the battery, or a short to
ground.
2. For sensor failure: dead (no pulsing output), a short to the positive side of the battery,
or a short to ground.
3. The CMS control has failed (see the Note below).

Note: A failed CMS control is relatively unlikely to occur If the self-test mode operates correctly
when the start key is turned on at machine startup.

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 PROCEDURE FOR TROUBLESHOOTING PWM SENSOR PROBLEMS
1. Verify the sensor is working AT THE SENSOR by checking between the sensor and
the sensor’s connector (see the References). This step should be performed with the
CMS control connected just as it would be when arriving on the job location.
2. Probe through the sensor wire insulation or use the 7X1710 Probe Cable Group to
probe into the connector through the connector grommet beside the lead wires.

Note: If the signal wire from the sensor to the CMS control is open, the signal voltage measured at
the sensor will be the same as the reference chart for Sensor Dynamic Test (CMS disconnected) in
the third Reference on Page 64.

3. Verify the condition of the wiring harness by checking between the sensor’s connector
and the sensor:

A. If there is no sensor signal detected in Step 2, check for both power and ground
with the sensor connected.
B. Check the signal circuit

1. If the sensor is working according to the test performed in Step 1, check for
sensor signal voltage on the CMS or AEIS side of the sensor connector. If
the signal voltage is the same on both sides of this connector, the problem is
not in the connector. Proceed to the next step.

2. To check the signal harness wire from the CMS or AEIS to the sensor,
disconnect the sensor at the sensor connector. Measure the voltage from the
machine harness connector signal contact to the ground contact. Voltage
should equal +5± .5 volts. A value less than this indicates an open in this
wire. A value greater than this indicates a short to the positive side of the
battery.

Note: It is VERY IMPORTANT to make sure the previous steps are completed before
performing the next step.

4. If both the sensor and wiring harness test correctly, the CMS control is most likely the
cause.

IN SUMMARY

Intermittent problems are the most difficult to locate and verify. The service technician must
remember that with PWM sensors: an open wiring harness, a short on the positive side of the
battery, a short to ground, or very poor connections, can sometimes be very difficult to find. Any
one or more of the previous conditions will cause the CMS or AEIS control to store a service code
for incorrect temperature, low oil pressure, or a similar fault condition.

ALSO, WITH CMS, THE OPERATOR SEES A WARNING THAT AGREES WITH THAT GAUGE.
This means the gauge will flash and show in the red (high or low). If required, the action light will
flash and the action alarm will sound. At this stage, the operator does not know if the machine
system Is causing the warning or a CMS fault exists, but the Warning must be treated as
appropriate for the warning indicated. CMS is the most reliable monitoring system available
because any problems within the monitoring system never go undetected. The same features with
similar warning indications for the operator, relate to AEIS.

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 Understanding “Shorts,” “Opens” and “Intermittents
1400

REFERENCE ARTICLES: Understanding Causes Of Blown Fuses And Tripped Circuit Breakers
and How To Troubleshoot A Short-To-Ground In Power Wiring In this issue.

SIMS and claims comments are very helpful in diagnosing failure modes of electrical components.
“Shorted, open and intermittent” can often be used to quickly and easily identify the condition of a
component that is not performing correctly. These terms are often misunderstood. Correct
understanding of these terms aids correct reporting of component problems and speeds the
problem cause/resolution process.

OPEN

An “open” Is an electrical circuit that will not conduct current, a broken path for electron flow. It is
sometimes described as “Infinite” or many ohms.

Examples: Blown fuse or tripped circuit breaker, headlamp switch in “off” position, engine that will
not crank because of corroded battery connection, dead wiper motor because of poor ground to
cab, EMS oil pressure switch with dead engine, or dead hour meter because engine oil pressure
switch did not close during operation.

SHORT

A “short” Is a direct electrical connection between two points, usually very low resistance or
opposition to current flow. It most often describes an unwanted or Incorrect connection and may
draw higher than expected current.

Examples: Dead forward warning horn causing blown fuses/breakers, head lamp switch that will not
turn lights off, engine oil pressure switch that will not turn off hour meter, pinched harness causing
blown fuses (or tripped circuit breakers), or a start switch that keeps the starter engaged.

INTERMITTENT

An “intermittent” is an unwanted and erratic event that occurs in a normal or correctly operating
circuit. It most often causes a closed circuit (one that is “on”) to open up or turn “off.” It can also
take place in a powered circuit (+12 or +24V, etc.) where it might be connected to ground and
blows a fuse or trips a circuit breaker.

Examples of an “intermittent open”: Vehicle tall lights that sometimes blink “off,” EMS oil pressure
LED that sometimes blinks “on” during normal operation when pressure has been confirmed to be
within specifications, when one or both gear indicator LED’s blink “off” on transmission controls, or
a loose screw on a head light housing causes the light to blink.

Examples of an “Intermittent short”: A turn signal switch in the “off” position that continues to flash
the lights, or start-aid. push button that will not release (open) and causes ether solenoid to burn
out (often “shorts” and blows the fuse/breaker), or wire-to-wire harness connection (short) where
application of brake lights also turns “on” taillights.

Examples of an intermittent short-to-ground” Where a third LED turns “on” In a given gear on the
transmission control, when a fan or wiper motor burns out (shorts) and blows a fuse or trips a circuit
breaker, when a powered wire is pinched to ground and blows a fuse/breaker, when a screw driver
Is used to ground a circuit to see if it Is “hot”. These conditions in power wiring often cause
permanent damage to other components like switches, fuses, and circuit breakers.

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