3516B Marine Auxiliary Engine Caterpillar

Use this procedure to troubleshoot the electrical system if a problem is suspected with the primary engine speed/timing sensor or with the secondary engine speed/timing sensor. Use this procedure to troubleshoot the electrical system if a diagnostic code in Table 1 is active or easily repeated.

The engine uses two engine speed/timing sensors. Both sensors detect the reference for engine speed and timing from a timing reference ring with a unique pattern that is on the rear face of the fuel injection pump gear. The ECM uses the pattern of the pulses in order to determine the position of the crankshaft. The ECM measures the time between the pulses that are created by the sensors as the gears rotate in order to determine rpm.

Under normal operation, the primary speed/timing sensor determines when the piston in the number 1cylinder is at the top of the compression stroke. When the timing has been established, the sensor signal is used to determine engine speed.

When the timing has been established, the ECM triggers each injector in the correct firing order at the correct time. The actual timing and duration of each injection is based on engine rpm and on load.

The secondary speed/timing sensor provides continuous operation of the engine if the primary engine speed/timing sensor fails. If the engine is running and the signal from one sensor is lost, no change in engine performance will be noticed. If the engine is running and the signals from both sensors are lost, fuel injection will be terminated and the engine will be shut down by the ECM.

The engine will start when only one sensor signal is present. The engine will not start if the signals from both sensors are lost.

The engine speed/timing sensors receive supply voltage from the ECM that is regulated at 12.5 ± 1.0 VDC. The engine speed/timing sensors provide a pulsed DC output voltage with a frequency that is directly proportional to engine speed. A unique tooth on the timing reference ring generates a duty cycle in order to provide the ECM with information on the crankshaft position.

Illustration 1	g02350557
Schematic for the engine speed/timing sensors

Test Step 1. Inspect the Electrical Connectors and the Wiring

1. Remove electrical power from the ECM.

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Illustration 2	g01139425
ECM (1) J1/P1 connectors (2) J2/P2 connectors

2. Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit.

   Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

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Illustration 3	g01823953
P1 ECM connector (P1-29) Digital return (P1-32) Speed/timing sensor supply (P1-38) Primary speed/timing sensor signal (P1-39) Secondary speed/timing sensor signal (P1-18) TDC probe + (P1-12) TDC probe -

3. Perform a 45 N (10 lb) pull test on each of the wires in the circuit.

4. Check the allen head screw from each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque value.

5. Check the harness and the wiring for abrasion and for pinch points.

Expected Result:

All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.

Results:

• OK - The harness and connectors appear to be OK. Proceed to Test Step 2.

• Not OK - The connectors and/or wiring are not OK.

  Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.

  STOP

Test Step 2. Check for Diagnostic Codes

1. Connect the Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".

2. Restore electrical power to the ECM.

3. Check for active diagnostic codes on Cat ET.

   Look for the following codes:

   • 190-02

   • 190-03

   • 190-08

   • 342-02

   • 342-03

   • 342-08

Expected Result:

None of the above diagnostic codes are active.

Results:

• OK - None of the above codes are active, but there is a problem that has been associated with the engine speed/timing sensors. Proceed to Test Step 3.

• OK - None of the above codes are active.

  Repair: There may be an intermittent problem in the circuit. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".

  STOP

• Not OK - One or more of the above codes are active. Proceed to Test Step 3.

Test Step 3. Inspect the Condition of the Engine Speed/Timing Sensors

1. Remove electrical power from the ECM.

2. Remove the suspect engine speed/timing sensor.

3. Inspect the sensor tip for damage.

4. Inspect the plastic slip head for damage.

5. Check the tension on the slip head by gently prying the slip head out of the sensor body. Extend the slip head 3 to 4 mm (0.12 to 0.16 inch). Push the slip head back into the sensor body from the extended position. Movement of the slip head will require a small amount of force. The amount of tension that is on the slip head must not allow movement of the slip head during engine operation.

6. Again, pull the slip head from the sensor body to the fully extended position.

Expected Result:

The sensor is not damaged. An adequate amount of tension is felt on the slip head and the movement is smooth.

Results:

• OK - The engine speed/timing sensor and the slip head are undamaged. The tension on the slip head is normal.

  Repair: Reinstall the engine speed/timing sensor. Ensure that the camshaft gear is positioned correctly prior to installing the sensor.

  Proceed to Test Step 4.

• Not OK - The engine speed/timing sensor or the slip head is damaged.

  Repair: Replace the engine speed/timing sensor.

  STOP

Test Step 4. Check the Engine Speed on Cat ET

1. Restore electrical power to the ECM.

2. Observe the engine speed on Cat ET while the engine is cranking.

Expected Result:

Cat ET displays a steady engine speed between 100 and 250 rpm while the engine is cranking and the engine starts.

Results:

• OK - The engine speed/timing sensor is operating normally at this time.

  Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, "Electrical Connectors - Inspect".

  STOP

• Not OK - Cat ET displays zero engine speed and the engine does not start. Proceed to Test Step 5.

• Not OK - Cat ET displays a steady engine speed, but the engine will not start.

  Repair: Proceed to Troubleshooting, "Engine Cranks But Does Not Start".

  STOP

Test Step 5. Check the Supply Voltage at the Sensor Connector

1. Remove electrical power from the ECM.

2. Disconnect the connector for the suspect engine speed/timing sensor.

3. Restore electrical power to the ECM.

4. Measure the voltage between terminal A and terminal B at the suspect sensor connector.

5. Remove electrical power from the ECM.

Expected Result:

The supply voltage is measured at 11.5 to 13.5 VDC at the sensor connector.

Results:

• OK - The engine speed/timing sensor is receiving the correct supply voltage. Proceed to Test Step 6.

• Not OK - The supply voltage is not within the specified range. Proceed to Test Step 7.

Test Step 6. Check the Isolated Signal Voltage at the Sensor

1. Remove the wire from terminal C (speed/timing sensor signal) at the harness side of the connector for the suspect speed/timing sensor.

2. Reconnect the suspect sensor at the sensor connector.

3. Restore electrical power to the ECM.

4. Measure the voltage between the suspect sensor signal wire and terminal B of the suspect sensor connector. Also, crank the engine and measure the voltage between the suspect sensor signal wire and terminal B during engine cranking.

5. Remove electrical power from the ECM.

6. Restore the wiring to the original configuration.

Expected Result:

The voltage is less than 3 VDC or the voltage is greater than 10 VDC when the ECM is powered and the engine is not cranking. The voltage varies between 2 VDC and 4 VDC during engine cranking.

Results:

• OK - The engine speed/timing sensor is producing an output signal. Proceed to Test Step 8.

• Not OK - The engine speed/timing sensor is not producing a valid output signal.

  Repair: Replace the engine speed/timing sensor. Calibrate the sensor. Perform the calibration procedure Troubleshooting, "Timing - Calibrate".

  STOP

Test Step 7. Check the Supply Voltage at the ECM

1. Remove electrical power from the ECM.

2. Disconnect the J1/P1 ECM connector.

3. Fabricate two jumper wires that are long enough to be used as a test circuit at the ECM connector. Crimp a connector socket to one end of each of the jumper wires.

4. Remove the wire from terminal location P1-29 at the ECM connector. Install one of the jumper wires into terminal location P1-29.

5. Remove the wire from terminal location P1-32 at the ECM connector. Install one of the jumper wires into terminal location P1-32.

6. Connect the J1/P1 ECM connector.

7. Restore electrical power to the ECM.

8. Measure the supply voltage between the jumper wires in terminal locations P1-29 and P1-32.

9. Remove electrical power from the ECM.

10. Restore the wiring to the original configuration.

Expected Result:

The voltage is 12.5 ± 1.0 VDC.

Results:

• OK - The voltage is 12.5 ± 1.0 VDC.

  Repair: There is a problem in the harness wiring between the ECM and the connector for the engine speed/timing sensor. Repair the connectors and/or wiring or replace the connectors and/or wiring.

  STOP

• Not OK - The voltage is not 12.5 ± 1.0 VDC.

  Repair: Ensure that the ECM is receiving the correct supply voltage from the batteries. Refer to Troubleshooting, "Electrical Power Supply - Test".If the ECM is receiving the correct supply voltage, replace the ECM. Refer to Troubleshooting, "ECM - Replace".

  STOP

Test Step 8. Check the Signal Voltage at the ECM

1. Disconnect the J1/P1 ECM connector.

2. Remove the signal wire for the suspect sensor from ECM connector P1. Refer to Illustration 1 for the correct wire for the suspect sensor.

3. Reconnect the J1/P1 ECM connector.

4. Restore electrical power to the ECM.

5. Measure the signal voltage between the signal wire and engine ground.

6. Crank the engine and measure the signal voltage between the signal wire and engine ground.

7. Remove electrical power from the ECM.

Expected Result:

The voltage measures less than 3 VDC or more than 10 VDC when the ECM is powered and the engine is not cranking. While the engine is cranking, the voltage is between 2 VDC and 4 VDC.

Results:

• OK - The correct voltage is measured on the signal wire that was removed from the ECM connector.

  Repair: The ECM does not appear to be reading the signal. Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "ECM - Replace".

  STOP

• Not OK - The voltage is incorrect on the signal wire that was removed from the ECM connector.

  Repair: The problem is in the harness between the ECM and the engine speed/timing sensor. Repair the connectors and/or wiring or replace the connectors and/or wiring.

  STOP