Refer to Electronic Troubleshooting, RENR1328 for 3176B and 3406E. This manual will provide an explanation of each diagnostic code.
Diagnostic codes are used by the 3406E System to warn the vehicle operator of a problem. Diagnostic codes are used by the service technician to determine the nature of the problem. Some codes are used only to record an event. These codes do not indicate problems that need repair.
An active diagnostic code represents a problem that should be corrected as soon as possible. Repairing the cause of an ACTIVE code will cause the code to be cleared.
If an ACTIVE code is generated, the diagnostic lamp will turn ON and the lamp will remain ON. The lamp will blink at five second intervals. If the condition that generated the fault occurs only for a brief moment, the lamp will go OFF after five seconds. The code will be LOGGED.
There are a few codes that are not a response to a performance problem. The codes merely record an event. These codes are 01, 35, 41 and 55. Troubleshooting is not required in these cases.
Some Diagnostic Codes will cause the 3406E System to make major changes. The changes that were made are in the engine operation or the engine limits. This is a result of the code that is being generated.
LOGGED Diagnostic Codes And Events
When the ECM generates a diagnostic code, the ECM usually logs the code in permanent memory within the ECM. The ECM has an internal diagnostic clock. When a code is logged, the ECM will record the hour for EACH time. Knowing the condition and the time that the code was generated can be a valuable indicator. This will help to troubleshoot intermittent problems. The logged codes can be retrieved or the logged codes can be erased. This is accomplished by using an ECAP Service Tool. The codes are valuable indicators. The codes help to troubleshoot the intermittent problems.
The 3406E System must be out of Cold Mode at least ten seconds before codes will be logged. When the logging begins, any active code is permanently logged.
Diagnostic Codes that are logged repeatedly may indicate a problem that needs special investigation. Codes that are logged may not need attention. These codes only need attention if the codes result in complaints by the driver. These codes can be investigated during the next scheduled maintenance interval.
Refer to Electronic Troubleshooting, RENR 1328, "Troubleshooting with a Diagnostic Code" for the procedure to troubleshoot a Logged Diagnostic Code. Refer to Electronic Troubleshooting, RENR 1328, "Troubleshooting Without A Diagnostic Code" if the symptoms continue.
Note: The most likely cause of an intermittent problem is a faulty connection or damaged wiring. The next most likely cause is a component failure (sensor or switch for example). The least likely cause is the ECM.
3406E Electronic Service Tools
The Caterpillar electronic service tools for the 3406E Electronic Control System are designed to help the service technician in analyzing the faults and locating the problems within the system. The electronic service tools are required to perform sensor calibrations. The electronic service tools will read the programmable engine parameter. The electronic service tools will also change the programmable engine parameter.
The tools have small plug-in modules. These modules are called Service Program Modules (SPM). These modules adapt the basic tools to a particular engine or a particular application.
The 3406E Diesel Truck Engine requires an electronic service tool to communicate with the 3406E Electronic Control Module and read certain Diagnostic Codes. This service tool is capable of performing the following functions:reading the various sensor output signals, reading status inputs, switching status inputs and electronically calibrating the Boost Sensor. The ECAP can calibrate the Speed/Timing Sensor. The ECAP measures Pulse Width Modulation(PWM) signals. such as those produced by the throttle position sensor.
Installation OR Removal Of The Speed/Timing Sensor
| Tools Needed | ||
| 9S-9082 | Engine Turning Tool | 1 |
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| Illustration 1 | g00305643 |
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Engine Front (Right Side) (1) Speed/timing sensor. (2) "P9/J9" Connector. | |
- Disconnect the speed/timing connector "P9/J9" (2). Inspect the connector for the following conditions.
- Corrosion
- Bent pins
- Missing pins
- Damaged sockets
- Mismating
- Broken wires
- Remove the Speed/timing sensor (1) from the front gear cover.
- Examine the plastic end of the sensor for signs of wear or contaminants such as metal filings. The plastic end of the speed/timing sensor should have no contaminants and should show no wear (greater than
0.051 mm (0.0020 inch) from the face). - Use a screwdriver to carefully pry the plastic sensor end to the fully extended position (approximately
4.775 mm (0.1880 inch) beyond the metal housing of the sensor). - Gently push in on the plastic end of the sensor. The plastic end should be firm. The plastic end should resist movement in the retract direction. If there is no resistance replace the sensor.
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Illustration 2 g01414003 Locating Top Center (Left Side Of Engine)
(3) Bolt. (4) Timing bolt location. (5) Cover. - Remove the two bolts (3) and remove the cover (5) from the flywheel housing. This hole is used for engine turning.
- Put one bolt (3) in the timing bolt location (4). The timing bolt location is approximately
127 mm to 152 mm (5 inch to 6 inch) above the hole in the flywheel housing for engine turning.Show/hide table
Illustration 3 g01414038 Using 9S-9082 Engine Turning Tool
(3) Bolt. (6) 9S-9082 Engine Turning Tool. - Use 9S-9082 Engine Turning Tool (6) and a 1/2 inch drive ratchet wrench to turn the engine flywheel in the direction of normal engine rotation. The normal engine rotation is in a counterclockwise direction when viewed from the flywheel end. Turn the engine flywheel until the timing bolt engages with the threaded hole in the flywheel.
Note: Visually check the location of the tooth on the wheel on which the speed/timing sensor is to be positioned. The end of the sensor must be in alignment with a tooth on the wheel and not in alignment with the valley of the wheel.
Note: The No. 1 piston must be at either top center of the compression stroke or at top center of the exhaust stroke.
- Inspect the speed/timing sensor before installation. Use steps 3 through step 6 to inspect the sensor.
- If the sensor end is not fully extended, use a screwdriver to carefully pry the plastic sensor end to the fully EXTENDED position approximately
4.775 mm (0.1880 inch) beyond the metal housing of the sensor. - Examine the O-ring seal at the base of the sensor threads. If the seal is missing or damaged, install a new O-ring seal.
- Install the speed/timing sensor into the front gear cover.
Tighten the sensor to the following torque. ...
45 ± 5 N·m (33 ± 4 lb ft) - Connect the "P9/J9" connector for the speed/timing sensor near the coolant inlet pipe on the top of the engine.
Note: Be sure that the "P9/J9" lock is properly connected.
- Remove bolt (3).
Note: The electronic injection timing must be recalibrated after the reinstallation of the speed/timing sensor. Refer to Electronic Troubleshooting, RENR 1328, "Engine Timing Calibration" for 3176B and 3406E.
Throttle Position Sensor Adjustment
The throttle position sensor (TPS) is used to provide a throttle signal to the Electronic Control Module (ECM). The sensor output is a constant frequency signal. The signal pulse width varies with the throttle position. This output signal is referred to as either “Duty Cycle” or a “Pulse Width Modulated (PWM)” signal and is expressed as a percentage. When correctly adjusted, the TPS will produce a “Duty Cycle” signal of 15 percent to 20 percent at the low idle throttle position and 80 percent to 85 percent at the maximum throttle position. This signal is translated by the ECM into a “Throttle Position” signal of three percent at low idle and 100 percent at maximum throttle.
The “Pedal-Mounted” throttle position sensor is mounted directly to a specific style of throttle pedal. There is no adjustment possible on the “Pedal-Mounted”TPS.
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| Illustration 4 | g00305968 |
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Pedal-Mounted Throttle Sensor | |
The Pedal-Mounted Throttle Sensor is mounted on the back of the OEM-supplied pedal. No adjustments are required for the Pedal-Mounted Throttle Sensor. The calibration of the Pedal-Mounted Throttle Sensor is done automatically by the ECM. The correct calibration can be displayed with the ECAP. The correct percent throttle (governor control movement) is displayed as three percent with the throttle completely released, and 100 percent with the throttle completely depressed.