Sensor Signal (PWM) - Test
The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the PWM Sensors of the machine.
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| Machine ECM (MID 39) | ||
| DTC | Code Description | System Response |
| 96–3 | Fuel Level Sensor: Voltage Above Normal | Fuel level indicator will not display accurately. |
| 96–4 | Fuel Level Sensor: Voltage Below | Fuel level indicator will not display accurately. |
| 127-3 | Transmission Oil Pressure Sensor: Voltage Above Normal | Machine will not travel. |
| 127-4 | Transmission Oil Pressure Sensor: Voltage Below Normal | Machine will not travel. |
| 127-8 | Transmission Oil Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Machine will not travel. |
| 1130-3 | Left Side Attachment Pedal Sensor: Voltage Above Normal | The pedal will be inoperable. |
| 1130-4 | Left Side Attachment Pedal Sensor: Voltage Below Normal | The pedal will be inoperable. |
| 1657–3 | Left Joystick Thumbwheel: Voltage Above Normal | It will not be possible to operate the feature assigned to the Left joystick thumbwheel. |
| 1657–4 | Left Joystick Thumbwheel: Voltage Below Normal | It will not be possible to operate the feature assigned to the Left joystick thumbwheel. |
| 1658–3 | Right Joystick Thumbwheel: Voltage Above Normal | It will not be possible to operate the feature assigned to the Right joystick thumbwheel. |
| 1658–4 | Right Joystick Thumbwheel: Voltage Below Normal | It will not be possible to operate the feature assigned to the Right joystick thumbwheel. |
| 1968-3 | Boom Cylinder Rod End Pressure Sensor: Voltage Above Normal | Ride control and smart boom functions will be disabled if installed. |
| 1968-4 | Boom Cylinder Rod End Pressure Sensor: Voltage Below Normal | Ride control and smart boom functions will be disabled if installed. |
| 1969-3 | Boom Cylinder Head End Pressure Sensor: Voltage Above Normal | Ride control, smart boom, and overload warning functions will be disabled if installed. |
| 1969-4 | Boom Cylinder Head End Pressure Sensor: Voltage Below Normal | Ride control, smart boom , and overload warning functions will be disabled if installed. |
| 1971–3 | Bucket Cylinder Head End Pressure Sensor : Voltage Above Normal | The bucket cylinder cannot be raised when requested. |
| 1971–4 | Bucket Cylinder Head End Pressure Sensor : Voltage Below Normal | The bucket cylinder cannot be raised when requested. |
| 1971–8 | Bucket Cylinder Head End Pressure Sensor : Abnormal Frequency, Pulse Width, or Period | The bucket cylinder cannot be raised when requested. |
| 2429-3 | Boom Cylinder Extend Pilot Pressure Sensor: Voltage Above Normal | Boom cylinder extend function will still be operable, performance will be reduced. |
| 2429-4 | Boom Cylinder Extend Pilot Pressure Sensor: Voltage Below Normal | Boom cylinder extend function will still be operable, performance will be reduced. |
| 2429-8 | Boom Cylinder Extend Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Boom cylinder extend function will still be operable, performance will be reduced. |
| 2828-3 | Main Hydraulic Pump Pressure Sensor #1: Voltage Above Normal | Implement performance will be reduced. |
| 2828-4 | Main Hydraulic Pump Pressure Sensor #1: Voltage Below Normal | Implement performance will be reduced. |
| 2828-8 | Main Hydraulic Pump Pressure Sensor #1: Abnormal Frequency, Pulse Width, or Period | Implement performance will be reduced. |
| 2830-3 | Main Hydraulic Pump Load Sense Pressure Sensor #1: Voltage Above Normal | Implement performance will be reduced. |
| 2830-4 | Main Hydraulic Pump Load Sense Pressure Sensor #1: Voltage Below Normal | Implement performance will be reduced. |
| 2830-8 | Main Hydraulic Pump Load Sense Pressure Sensor #1: Abnormal Frequency, Pulse Width, or Period | Implement performance will be reduced. |
| 2974-3 | Brake Charge Pressure Sensor: Voltage Above Normal | Travel lock will be disabled, heavy lift function cannot be enabled. |
| 2974-4 | Brake Charge Pressure Sensor: Voltage Below Normal | Travel lock will be disabled, heavy lift function cannot be enabled. |
| 3012-3 | Boom Cylinder Retract Pilot Pressure Sensor: Voltage Above Normal | Boom cylinder retract function will still be operable, performance will be reduced. |
| 3012-4 | Boom Cylinder Retract Pilot Pressure Sensor: Voltage Below Normal | Boom cylinder retract function will still be operable, performance will be reduced. |
| 3012-8 | Boom Cylinder Retract Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Boom cylinder retract function will still be operable, performance will be reduced. |
| 3036-3 | Ride Control Accumulator #1 Pressure Sensor: Voltage Above Normal | Ride control will be disabled. |
| 3036-4 | Ride Control Accumulator #1 Pressure Sensor: Voltage Below Normal | Ride control will be disabled. |
| 3037-3 | Ride Control Accumulator #2 Pressure Sensor: Voltage Above Normal | Ride control will be disabled. |
| 3037-4 | Ride Control Accumulator #2 Pressure Sensor: Voltage Below Normal | Ride control will be disabled. |
| 3545-3 | Stick Cylinder Extend Pilot Pressure Sensor: Voltage Above Normal | Stick Extend function will still be operable, performance will be reduced. |
| 3545-4 | Stick Cylinder Extend Pilot Pressure Sensor: Voltage Below Normal | Stick Extend function will still be operable, performance will be reduced. |
| 3545-8 | Stick Cylinder Extend Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Stick Extend function will still be operable, performance will be reduced. |
| 3546-3 | Stick Cylinder Retract Pilot Pressure Sensor: Voltage Above Normal | Stick retract function will still be operable, performance will be reduced. |
| 3546-4 | Stick Cylinder Retract Pilot Pressure Sensor: Voltage Below Normal | Stick retract function will still be operable, performance will be reduced. |
| 3546-8 | Stick Cylinder Retract Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Stick retract function will still be operable, performance will be reduced. |
| 4482-3 | Bucket Cylinder Extend Pilot Pressure Sensor: Voltage Above Normal | Bucket cylinder extend function will still be operable, performance will be reduced. |
| 4482-4 | Bucket Cylinder Extend Pilot Pressure Sensor: Voltage Below Normal | Bucket cylinder extend function will still be operable, performance will be reduced. |
| 4482-8 | Bucket Cylinder Extend Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Bucket cylinder extend function will still be operable, performance will be reduced. |
| 4483-3 | Bucket Cylinder Retract Pilot Pressure Sensor: Voltage Above Normal | Bucket cylinder retract function will still be operable, performance will be reduced. |
| 4483-4 | Bucket Cylinder Retract Pilot Pressure Sensor: Voltage Below Normal | Bucket cylinder retract function will still be operable, performance will be reduced. |
| 4483-8 | Bucket Cylinder Retract Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Bucket cylinder retract function will still be operable, performance will be reduced. |
| 4484-3 | Variable Adjustable Boom Cylinder Extend Pilot Pressure Sensor: Voltage Above Normal | Variable adjustable boom cylinder extend function will still be operable, performance will be reduced. |
| 4484-4 | Variable Adjustable Boom Cylinder Extend Pilot Pressure Sensor: Voltage Below Normal | Variable adjustable boom cylinder extend function will still be operable, performance will be reduced. |
| 4484-8 | Variable Adjustable Boom Cylinder Extend Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Variable adjustable boom cylinder extend function will still be operable, performance will be reduced. |
| 4485-3 | Variable Adjustable Boom Cylinder Retract Pilot Pressure Sensor: Voltage Above Normal | Variable adjustable boom cylinder retract function will still be operable, performance will be reduced. |
| 4485-4 | Variable Adjustable Boom Cylinder Retract Pilot Pressure Sensor: Voltage Below Normal | Variable adjustable boom cylinder retract function will still be operable, performance will be reduced. |
| 4485-8 | Variable Adjustable Boom Cylinder Retract Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Variable adjustable boom cylinder retract function will still be operable, performance will be reduced. |
| 4486-3 | Blade Lift Pilot Pressure Sensor: Voltage Above Normal | Blade will still be operable, performance will be reduced. |
| 4486-4 | Blade Lift Pilot Pressure Sensor: Voltage Below Normal | Blade will still be operable, performance will be reduced. |
| 4486-8 | Blade Lift Pilot Pressure Sensor: Abnormal Frequency, Pulse Width, or Period | Blade will still be operable, performance will be reduced. |
| 5235–3 | Right Joystick Thumbwheel #1 Position Sensor : Voltage Above Normal | It will not be possible to operate the feature assigned to the Right joystick thumbwheel #1 |
| 5235–4 | Right Joystick Thumbwheel #1 Position Sensor : Voltage Below Normal | It will not be possible to operate the feature assigned to the Right joystick thumbwheel #1 |
| 5236–3 | Right Joystick Thumbwheel #2 Position Sensor : Voltage Above Normal | It will not be possible to operate the feature assigned to the Right joystick thumbwheel #2 |
| 5236–4 | Right Joystick Thumbwheel #2 Position Sensor : Voltage Below Normal | It will not be possible to operate the feature assigned to the Right joystick thumbwheel #2 |
| 5237–3 | Left Joystick Thumbwheel #1 Position Sensor : Voltage Above Normal | It will not be possible to operate the feature assigned to the Left joystick thumbwheel #1. |
| 5237–4 | Left Joystick Thumbwheel #1 Position Sensor : Voltage Below Normal | It will not be possible to operate the feature assigned to the Left joystick thumbwheel #1. |
| 5238–3 | Left Joystick Thumbwheel #2 Position Sensor : Voltage Above Normal | It will not be possible to operate the feature assigned to the Left joystick thumbwheel #2. |
| 5238–4 | Left Joystick Thumbwheel #2 Position Sensor : Voltage Below Normal | It will not be possible to operate the feature assigned to the Left joystick thumbwheel #2. |
Possible Causes for an FMI 3 Diagnostic code are:
- The sensor has failed.
- The sensor supply or the ground circuit in the machine harness is open.
- The signal circuit in the machine harness is shorted to the +battery.
- The signal circuit in the machine harness is open or the sensor is disconnected.
- The ECM has failed. A failure of the ECM is unlikely.
Possible Causes for an FMI 4 Diagnostic code are:
- The sensor has failed.
- The signal circuit in the machine harness is shorted to ground.
- The ECM has failed. A failure of the ECM is unlikely.
Possible Causes for an FMI 8 Diagnostic code are:
- The sensor has failed.
- Intermittent connections or poor connections.
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| Illustration 1 | g06134241 |
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Schematic of the PWM sensors | |
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| Illustration 2 | g06136935 |
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Schematic of the Joystick PWM sensors | |
Note: The diagram above is a simplified schematic of the connections for the PWM sensors. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of the electrical schematic for the specific machine being serviced for the complete schematic.
Diagnostic Trouble Code Procedure
Note: Prior to beginning this procedure, inspect the harness connectors that are involved in this circuit. Poor connections can often be the cause of a problem in an electrical circuit. Verify that all connections in the circuit are clean, secure, and in good condition. Check the wiring for pinch points or abrasions. Look for and repair areas that indicate wires are exposed. If a problem with a connection is found, correct the problem and verify that this diagnostic code is active before performing a troubleshooting procedure.
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| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 1. Identify The Active FMI Code Associated With The Sensor Circuit | Code present. |
FMI 3 diagnostic code, proceed to Test Step 2. FMI 4 diagnostic code, proceed to Test Step 6. FMI 8 diagnostic code, proceed to Test Step 9. |
| Begin Process For FMI 3 Troubleshooting HERE | ||
| 2. Check The Control And The Harness A. Turn key start switch and disconnect switch ON. B. Disconnect the machine harness from sensor. C. Refer to the schematic to determine the voltage source for the suspected faulty sensor. D. Measure voltage between signal and ground contacts at the machine harness connector for the sensor. |
Voltage is 5.0 ± 0.2 VDC, 8.0 ± 0.4 VDC, or 10.0 VDC ± 0.95. |
OK - The voltage reading is correct for the suspected faulty sensor. Proceed to Test Step 3. NOT OK - The voltage is NOT correct for the circuit. Repair: There may be an open or short in the machine harness. The open or short will be on the power or ground circuit wires. Repair or replace the machine harness. Proceed to Test Step 16. |
| 3. Check For An Open In The Sensor Circuit A. The sensor remains disconnected from the machine harness. B. Turn the key start switch and the disconnect switch OFF. C. At the harness connector for the sensor, place a jumper wire between the ground contact and the signal contact. D. Disconnect J1 and J2 harness connectors from the ECM. E. At machine harness connector for sensor, measure the resistance from the signal contact to return contact. F. At the ECM Connector, gently pull on the wires and move the wires in a circular motion. Observe the resistance readings. Repeat the process for the sensor connector. |
The resistance is less than 5 Ω at all times during the manipulation of the harness. |
OK - The resistance is less than 5 Ω. The signal circuit and the ground circuits of the sensor are not open in the machine harness. Proceed to Test Step 4. NOT OK - Resistance reading for the signal circuit or the return circuit is greater than 5 Ω. Repair: Check the signal circuit or the ground circuit for opens or bad connections. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| 4. Check Signal Circuit For A Short To +Battery A. The Sensor and the ECM are disconnected from the harness. B. Turn the disconnect switch and the key start switch OFF. C. Measure the resistance between the signal and +battery contacts of the harness connector for the sensor. D. At machine harness connector J1 and J2 measure the resistance from signal contact to all possible sources of +battery. |
Resistance greater than 5K Ω for all readings. |
OK - The resistance is greater than 5K Ω. The harness circuit is correct. Proceed to Test Step 5. NOT OK - The resistance less than 5 Ω. Repair: A short exists in the harness between the +battery and signal circuit. Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| 5. Check The Harness For A Short A. The disconnect switch and key start switch are OFF. B. The sensor and ECM disconnected from harness. C. Measure the resistance from the signal wire to all other J1 and J2 contacts. |
Resistance greater than 5K Ω for all readings. |
OK - The resistance is greater than 5K Ω. The harness circuit is correct. Repair: A short exists in the harness between the signal circuit and the circuit with the lower resistance measurement. Repair or replace the machine harness. Proceed to Test Step 16. NOT OK - The resistance less than 5 Ω. Repair: A short exists in the harness between the signal circuit and the circuit with the lower resistance measurement. Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| Begin Process For FMI 4 Troubleshooting HERE | ||
| 6. Check The Control And The Harness A. Turn key start switch and disconnect switch ON. B. Disconnect the machine harness from sensor. C. Refer to the schematic to determine the voltage source for the suspected faulty sensor. D. Measure voltage between signal and ground contacts at the machine harness connector for the sensor. |
Voltage is 5.0 ± 0.2 VDC, 8.0 ± 0.4 VDC, or 10.0 VDC ± 0.95. |
OK - The voltage reading is correct for the suspected faulty sensor. Proceed to Test Step 7. NOT OK - The voltage is NOT correct for the circuit. Repair: There may be an open or short in the machine harness. The open or short will be on the power or ground circuit wires. Repair or replace the machine harness. Proceed to Test Step 16. |
| 7. Check The Sensor A. With FMI 4 active, disconnect the sensor from the machine harness. B. Observe Cat ET or the operator monitor for code change as the sensor is disconnected and connected to harness. |
Code changes from FMI 4 to FMI 3. |
OK - The diagnostic changed to FMI 3 when the sensor was disconnected. Repair: Replace the sensor. Proceed to Test Step 16. NOT OK - The FMI 4 diagnostic code remains active when sensor is disconnected. The sensor not the cause of the problem. Proceed to Test Step 8. |
| 8. Check The Signal Circuit For A Short To Ground A. Turn the key start switch and the disconnect switch OFF. B. Disconnect the J1 harness connector from the ECM. C. Measure the resistance between the signal contact for sensor and frame ground. |
The resistance is greater than 5K Ω. |
OK - The resistance is greater than 5K Ω. The harness circuit is correct. Proceed to Test Step 16. NOT OK - The resistance is less than 5 Ω. A short circuit exists between frame ground and the signal circuit. Repair: Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| Begin Process For FMI 8 Troubleshooting HERE | ||
| 9. Check The Control And The Harness A. Turn key start switch and disconnect switch ON. B. Disconnect the machine harness from sensor. C. Refer to the schematic to determine the voltage source for the suspected faulty sensor. D. Measure voltage between signal and ground contacts at the machine harness connector for the sensor. |
Voltage is 5.0 ± 0.2 VDC, 8.0 ± 0.4 VDC, or 10.0 VDC ± 0.95. |
OK - The voltage reading is correct for the suspected faulty sensor. Proceed to Test Step 10. NOT OK - The voltage is NOT correct for the circuit. Repair: There may be an open or short in the machine harness. The open or short will be on the power or ground circuit wires. Repair or replace the machine harness. Proceed to Test Step 16. |
| 10. Check Harness For An Open A. Turn the disconnect switch and the key start switch OFF. B. The sensor and ECM are disconnected from the harness. C. Connect a jumper wire from the end of signal wire at the ECM to a known ground. D. Measure the resistance of the signal wire at ECM. |
The reading is less than 5 Ω. |
OK - The measurement is less than 5 Ω. Proceed to Test Step 11. NOT OK - The measurement is greater than 5K Ω. The signal circuit in the harness is open. Repair: Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| 11. Check The Signal Circuit For A Short To Ground A. Turn key start switch and disconnect switch OFF. B. Disconnect J1 harness connector from ECM. C. Measure resistance between signal contact for sensor and frame ground. |
Reading is greater than 5K Ω. |
OK - Measurement is greater than 5K Ω. Proceed to Test Step 12. NOT OK - Measurement is less than 5 Ω. The signal circuit in the harness is shorted to ground. Repair: Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| 12. Check The Sensor For A Short To Case A. Turn the key start switch and the disconnect switch OFF. B. At the machine harness connector for the sensor, measure the resistance between each pin of sensor and an unpainted location on case of sensor. |
The reading is greater than 5K Ω. |
OK - All measurements are greater than 5K Ω. Proceed to Test Step 13. NOT OK - A measurement is less than 5 Ω. The sensor has failed. Repair: Replace the sensor. Confirm that the new sensor corrects the problem. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 16. |
| 13. Check The Sensor For A Short To +Battery A. Disconnect the machine harness at the sensor. B. Turn the key start switch and the disconnect switch ON. C. At machine harness connector for J1 connector, measure the voltage between the signal pin of sensor and frame ground. |
The voltage is 0 VDC. |
OK - Voltage is 0 VDC. Proceed to Test Step 14. NOT OK - Significant voltage is present in circuit. Repair: Repair or replace the machine harness. Proceed to Test Step 16. |
| 14. Check The Harness For A Short To +Battery A. Turn the key start switch and the disconnect switch ON. B. At machine harness connector for sensor, measure the voltage between each pin of sensor and frame ground (contacts 1, 2, and 3). |
The voltage is 0 VDC. |
OK - Voltage is 0 VDC. Proceed to Test Step 15. NOT OK: Significant voltage is present in circuit. Circuit shorted to +battery. Repair: Replace the sensor. Verify that the new sensor corrected the diagnostic code. Proceed to Test Step 16. |
| 15. Check The Sensor A. Turn the key start switch and the disconnect switch ON. B. Use Cat ET or the operator monitor to confirm the existence of the diagnostic code. C. Disconnect the sensor from machine harness. |
The diagnostic code is no longer present. |
OK - Diagnostic code is NO longer active. The sensor has failed. Repair: Replace the sensor. Verify new sensor corrected the diagnostic code. Proceed to Test Step 16. NOT OK - The diagnostic code remains active. Proceed to Test Step 16. |
| 16. Check If The Diagnostic Code Remains A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn key switch and disconnect switch ON. D. Operate the machine. E. Check if diagnostic code is active. |
Diagnostic code is no longer present. |
OK - Diagnostic code does not exist at this time. Initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections. Resume machine operation. STOP NOT OK - Diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement. Prior to replacing this component, always contact the Technical Communication at your dealership for possible consultation with Caterpillar. This consultation may greatly effect repair time. Follow the steps in Troubleshooting, "Electronic Control Module (ECM) - Replace" if the ECM needs to be replaced. STOP |
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