Elect Sect04 Span

Components Needed To Start
PEEC has 8 #5 Speed sensor

#1 POWER
#2 ECM #6 Shut-off solenoid
+ Battery
#3 P.M.
- Battery #7 BTM
#4 Parameters
#8 Rack position sensor
CATERPILLAR
Miami Skills Acquisition Center
EUI has 6 #5 Speed/Timing sensor

#1 POWER
#2 ECM #6 Good Injectors
+ Battery
#3 P.M.
- Battery
#4 Parameters
CATERPILLAR
HEUI has 7 #5 Speed/Timing sensor

#1 POWER
#2 ECM #6 Good Injectors
+ Battery
#3 P.M.
- Battery #7 IAPCV
#4 Parameters
CATERPILLAR
The Diagnostic Process
 Gather information
– Driver Questionnaire
– Questionnaire response
– Performance effect of active diagnostic codes
– Check the repair history
– What happened, in what order
CATERPILLAR
 Verify operational problems

– Is the complaint due to misunderstanding of
parameters
– Is the complaint due to a change of parameters
– Is the engine performing as expected
– Is the problem repeatable
CATERPILLAR
 Determine probable causes

– Repair “ACTIVE” diagnostic codes first
– What subsystem could cause the problem
– What subsystem does the troubleshooting guide
suggest
CATERPILLAR
 Narrow the list of causes

– Use driver information
– Check “LOGGED” diagnostic codes
– Check “STATUS SCREENS”
– If more than one symptom, look for common
causes
– Avoid “PRE-CONCEIVED IDEAS”
CATERPILLAR
 Test subsystems
– Use procedure in manual
– Connector checks are extremely important
– Check every pin, socket, and wire
CATERPILLAR
Troubleshooting Manual
 Electronic system overview

 Programming parameters
 Troubleshooting without a diagnostic code
 Troubleshooting with a diagnostic code
(functional tests)
 Diagnostic code listing
CATERPILLAR
 Electronic system overview

– Brief explanation of component operation
– Component diagrams
– Sensor and connector locations
– Engine and vehicle wiring harness diagrams
– Service tools
CATERPILLAR
 Programming parameters
– Overview of parameters
– Customer and factory passwords
– Programming a new ECM
– Programming or changing a personality module
– How to use ECM information
CATERPILLAR
 Troubleshooting without a diagnostic code

– Section designation
– General description of symptom
– Page number to begin troubleshooting procedure
 Example:
– PA-19: Engine cranks, but will not start …. Page 65
CATERPILLAR
 Troubleshooting with a diagnostic code

(functional tests)
– Section designation
– General description of subsystems and circuits
 Example:
– PC-31: Engine speed/timing circuit test …. Page 233
CATERPILLAR

– Diagnostic code
– Code description
– Flash code
 Example:
– 232-04: 5 volt supply below normal (21) …. Page 265
CATERPILLAR
 Troubleshooting Without a diagnostic code

– Step by step elimination of all systems that could
cause symptom
 Troubleshooting with a diagnostic code or
functional tests
– Beginning of section on a specific subsystem
– Begins with System operation overview
– Step 1 for that item
CATERPILLAR
Engine Cranks, But Will
3406E
Not Start
 Troubleshooting Without a diagnostic code
 A-19 page 65
 Probable root causes
– Connect an electronic service tool
– Will the ECM communicate
– Electrical connection to injectors
– Engine speed/timing signal
– Incorrect engine software
– Theft deterrent active
CATERPILLAR
Not Start
Example 1
EUI has 6
#1 POWER #2 ECM #5 Speed/Timing sensor
+ Battery
#3 P.M.
#4 Parameters #6 Good Injectors
- Battery
Not an electronic problem
CATERPILLAR
Not Start
Example 2
EUI has 6
#1 POWER #2 ECM #5 Speed/Timing sensor
+ Battery
#3 P.M.
#4 Parameters #6 Good Injectors
- Battery
No speed
CATERPILLAR
Not Start
 Find no speed or ……
 Have code 190-02 loss of engine RPM signal
– Referred to page 233 or 234 (PC-31)
– Page 233 is systems operation
 Read several steps to see where you are going
Step 1 - Check all connectors, pins, and sockets
Step 2 - Check for active code
Step 3 - Connect service tool
CATERPILLAR
Not Start
 Step 4 – Install a 3 - pin breakout T at the harness side
of the sensor connector, J9 only
P9 J9
A A A
Speed timing sensor B B B
C C C
ECM
A
B
C
CATERPILLAR
Not Start
 Step 4 – Measure voltage at J9 pin A, with reference to
J9 pin B
P9 J9
A A A
C C C
ECM
A
B
C
+V
Com
CATERPILLAR
Not Start
 Step 4 – Is voltage between 11.5 and 13.5 volts DC
YES
P9 J9
A A A
C C C
ECM
Sensor is
A
receiving the B + 13.32 v
correct voltage C
+V
Com
CATERPILLAR
Not Start
 Step 5 – Connect sensor to the breakout T
P9 J9
A A A A
Speed timing sensor B B B B
C C C C
ECM
CATERPILLAR
Not Start
 Step 5 – Measure the voltage at pin A with reference to
pin B
P9 J9
A A A A
C C C C
ECM
+V
Com
CATERPILLAR
Not Start
 Step 5 – Is the voltage still between 11.5 and 13.5 volts
YES
P9 J9
A A A A
C C C C
ECM
The sensor is receiving the + 12.75 v

correct voltage +V
Com
CATERPILLAR
Not Start
 Step 6 – Remove the signal wire (pin C) from the engine
harness connector J9 to isolate the sensor signal wire
P9 J9
A A A A
C C C C
ECM
CATERPILLAR
Not Start
 Step 6 – Measure the voltage from breakout pin-C to
breakout pin-B, before and while cranking
P9 J9
A A A A
C C C C
ECM
+V
Com
CATERPILLAR
Not Start
 Step 6 – Is the voltage less than 2.0 volts DC or more
than 10.0 volts with key on, before cranking
P9 J9
A A A A
C C C C
ECM
+ .162v
+V
Com
CATERPILLAR
Not Start
 Step 6 – During cranking is the voltage between 2.0
volts DC and 9.0 volts DC
P9 NO J9
A A A A
C C C C
ECM
There is no output signal + .162 v

or it is out of limits +V
Com
CATERPILLAR
Speed Timing Sensor
Step 7
 Remove the existing
speed/timing sensor
 Pull the slip head out
 Reinstall the
speed/timing sensor
Position the timing wheel in a place not

allowing the slip head to fill a slot
CATERPILLAR
Component Diagram
CATERPILLAR
5 volt Active Sensors
3176B, C-10,
+ 5V
(36) +5v C-12, & 3406E
Oil Pressure Ground (30) Sensor common
(8) Oil pressure
Data link Diagnostic
Tool
Fuel Temp
(3) Fuel Temp
ECM
Boost Pressure
(23) Boost pressure
Coolant Temp
(14) Coolant Temp
Signal
CATERPILLAR
Diagnostic Codes
CATERPILLAR
Diagnostic Codes
A + 5V
100 Oil Pressure B Ground
C
Tool
Fuel Temp
174
ECM
Boost Pressure
102
Coolant Temp
110
Signal
03 = Open 04 = Short
CATERPILLAR
Diagnostic Codes
A + 5V
C
Tool
Fuel Temp
174 102 – 03
ECM
Boost Pressure
102
Coolant Temp
110
Signal
CATERPILLAR
Diagnostic Codes
A + 5V
“A” shorted to “B”
C
Tool
Fuel Temp
174 232 – 04
ECM
Boost Pressure
102
Coolant Temp
110
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Tool
Fuel Temp
174 232 – 04
ECM
Boost Pressure
102
Coolant Temp
110 Unplug
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Tool
Fuel Temp
174 232 – 04
ECM
Boost Pressure
102 Unplug
Coolant Temp
110 Unplug
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Tool
Fuel Temp
174 Unplug 232 – 04
ECM
Boost Pressure
102 Unplug
Coolant Temp
110 Unplug
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Unplug

Tool
Fuel Temp
174 Unplug 100-03
174-03
ECM
Boost Pressure 102-03
102 Unplug
110-03
Coolant Temp
110 Unplug
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Tool
Fuel Temp
174 102 – 03
ECM
Boost Pressure
102
Coolant Temp
110
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Tool
Fuel Temp
174 232 – 04
ECM
Boost Pressure
102
Coolant Temp
110
Signal
CATERPILLAR
Troubleshooting
A + 5V
C
Unplug

Tool
Fuel Temp
174 Unplug 232 – 04
ECM
Boost Pressure
102 Unplug
110
Coolant Temp
Unplug
?
Signal
CATERPILLAR
ECM - Battery
ECM
ECM + Battery
5 V + 0.25 V
A +5 volt
Any 3 wire,
5 volt
Common
B Pressure
Ground
or temp.
Sensor Signal C Signal
sensor
CATERPILLAR
“C” Wire Signal Output Voltage
“- 04” Short
120
100
80
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
0
“- 04”
Short
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
CATERPILLAR
ECM - Battery
ECM
ECM + Battery
5 V + 0.25 V
A +5 volt
Any
3 wire
Common
B 5 volt
Ground
Pressure
or temp.
sensor
“B” to “C” short
CATERPILLAR
“- 04” Short
120
100
80
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
“B” to “C” short
0
“- 04” Code 100-04
Short
X
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
CATERPILLAR
ECM - Battery
ECM
ECM + Battery
5 V + 0.25 V
A +5 volt
Any
3 wire
Common
B 5 volt
Ground
Pressure
or temp.
sensor
“C” to “A” short
CATERPILLAR
“- 04” Short
120
100
80
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
0 “C” to “A” short
“- 04” 100-04
Short
X
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
CATERPILLAR
ECM - Battery
ECM
ECM + Battery
5 V + 0.25 V
A +5 volt
Any
3 wire
Common
B 5 volt
Ground
Pressure
or temp.
sensor
“C” Open What code? 100-03
CATERPILLAR
“- 04” Short
120
100 What’s the voltage on the “C” wire?

80 6v+
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
0
“- 04”
Short
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
CATERPILLAR
Battery +
100 volt DC EUI
Battery -
13.2 v speed timing sensor
8 v throttle position sensor
6.4 v pull up
A 5 v sensor supply
B
C Micro-processor
CATERPILLAR
ECM - Battery “B” to “C” swap
ECM
ECM + Battery
5 V + 0.25 V
A +5 volt
Any
3 wire
B 5 volt
Ground
Pressure
C Signal
or temp.
sensor
What code? No code
CATERPILLAR
“- 04” Short
120
100
80
2.5 volts = 60 PSI
PSI 60
Look at status “- 04”
40
screen – low oil Short
20 pressure or
0 “B” to “C” swap temp – etc.
“- 04”
Short
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
CATERPILLAR
ECM - Battery “A” to “C” swap
ECM
ECM + Battery
5 V + 0.25 V
A +5 volt
Any
A 3 wire
B 5 volt
Ground
B Pressure
C Signal
or temp.
C sensor
What code? No code
CATERPILLAR
“- 04” Short
120
100
80
2.5 volts = 60 PSI
PSI 60
Look at status “- 04”
40
screen – High oil Short
20 pressure or
0 temp – etc.
“- 04”
Short “A” to “C” swap
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
CATERPILLAR
Electronics Class
Questions so
far?
CATERPILLAR

Elect Sect04 Span

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Elect Sect04 Span

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Components Needed To Start

PEEC has 8 #5 Speed sensor

EUI has 6 #5 Speed/Timing sensor

HEUI has 7 #5 Speed/Timing sensor

 Verify operational problems

 Determine probable causes

 Narrow the list of causes

 Electronic system overview

 Electronic system overview

 Troubleshooting without a diagnostic code

 Troubleshooting with a diagnostic code

 Diagnostic code listing

 Troubleshooting Without a diagnostic code

Not an electronic problem

The sensor is receiving the + 12.75 v

There is no output signal + .162 v

Position the timing wheel in a place not

Data link Diagnostic

Data link Diagnostic

“B” to “C” short

“C” to “A” short

“C” Open What code? 100-03

100 What’s the voltage on the “C” wire?

13.2 v speed timing sensor

8 v throttle position sensor

What code? No code

What code? No code

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