3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines Caterpillar


Engine Speed/Timing Sensor - Calibrate

Information for equipment:


ELECTRICAL AND STARTING SYSTEM
SENSOR GP

On-Highway Heavy Duty 1999 Model Year Truck Electronic System{1900} 1999/01/01
Optional 4-Pin Coolant Level Sensor {1395} 1999/03/01
Atmospheric Pressure Sensor Design Improvements {1901,1923} 1999/03/01
New Crankshaft And Camshaft Speed Sensor Groups Available For 1999 And 2000 Model Year Heavy Duty On-Highway Truck Engines {1907} 2000/05/01
Repair Kits For Engine Speed Sensors Are Now Available {1907, 1912} 2000/07/01
New Engine Pressure Sensors are Available {1917, 1923, 1925} 2001/01/01

Sensors and Electrical Components 3406E, C-10, C-12, C-15 and C-16 Truck Engines

Installation of 185-7733 Sensor Kit {1928} Installation of 185-7733 Sensor Kit {1928}
Installation Of The 194-5338 Speed Sensor Gp and 194-5341 Speed Sensor Gp Service Repair Kits{1000} Installation Of The 194-5338 Speed Sensor Gp and 194-5341 Speed Sensor Gp Service Repair Kits{1000}
Installation Of The 194-5339 Speed Sensor Gp and The 194-5340 Speed Sensor Gp Kits{1900, 1907} Installation Of The 194-5339 Speed Sensor Gp and The 194-5340 Speed Sensor Gp Kits{1900, 1907}

ADEM2000 Heavy Duty Truck Engine Speed Sensor Service ADEM2000 Heavy Duty Truck Engine Speed Sensor Service

Inlet Air Temperature Sensor 3406E Truck Engines
Engine Oil Pressure Sensor 3406E Truck Engines
Atmospheric Pressure Sensor 3406E Truck Engines
Coolant Temperature Sensor 3406E Truck Engines
Accelerator Pedal Position Sensor 3406E Truck Engines
Boost Pressure Sensor 3406E Truck Engines
Engine Oil Temperature Sensor 3406E Truck Engines
Fuel Temperature Sensor 3406E Truck Engines

Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439} Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439}

Sensors and Electrical Connectors 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Engine Speed/Timing Sensor Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Engine Speed/Timing Sensor - Calibrate 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
5 Volt Engine Pressure Sensor Supply Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Engine Pressure Sensor Open or Short Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Engine Temperature Sensor Open or Short Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0030-08 Invalid PTO Throttle Signal (29) C-10, C-12, 3406E, C-15, C-16 and C-18 Engines - Electronic PTO Installation and Application
0030-13 PTO Throttle Sensor Calibration (29) C-10, C-12, 3406E, C-15, C-16 and C-18 Engines - Electronic PTO Installation and Application
0171-11 Ambient Air Temperature Data Lost 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0064-12 Secondary Engine Speed loss of signal (34) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0190-12 Primary Engine Speed loss of signal (34) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0102-00 Excessive Boost Pressure 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0100-01 Low Oil Pressure Warning (46) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0100-11 Very Low Oil Pressure (46) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0105-00 High Intake Manifold Air Temperature Warning (64) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0105-11 Very High Intake Manifold Air Temperature (64) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0110-00 High Coolant Temperature Warning (61) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0110-11 Very High Coolant Temperature (61) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Remote PTO Accelerator Position Sensor Circuit - Test C-10, C-12, 3406E, C-15, C-16 and C-18 Engines - Electronic PTO Installation and Application
Remote PTO Accelerator Position Sensor Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0174-03 Fuel Temperature voltage high (13) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0174-04 Fuel Temperature voltage low (13) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0110-04 Coolant Temperature voltage low (27) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0110-03 Coolant Temperature voltage high (27) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0105-04 Intake Manifold Air Temperature voltage low (38) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0105-03 Intake Manifold Air Temperature voltage high (38) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0100-03 Oil Pressure voltage high (24) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0100-04 Oil Pressure voltage low (24) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0102-03 Boost Pressure voltage high (25) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0102-04 Boost Pressure voltage low (25) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0232-03 5 Volt Supply voltage high (21) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0232-04 5 Volt Supply voltage low (21) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0022-11 Primary to Secondary Engine Speed Signal Calibration (42) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0022-13 Engine Speed Signal Calibration Not Performed (42) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0108-03 Barometric Pressure voltage high (26) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0108-04 Barometric Pressure voltage low (26) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0041-03 8 Volt Supply voltage high (21) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0041-04 8 Volt Supply voltage low (21) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0190-00 Engine Overspeed Warning (35) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0030-08 PTO Throttle signal invalid (29) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0030-13 PTO Throttle out of calibration (29) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0171-03 Ambient Air Temperature voltage high 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0171-04 Ambient Air Temperature voltage low 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0111-03 Coolant Level voltage high (12) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0111-04 Coolant Level voltage low (12) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0091-08 Throttle Position Invalid (32) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0091-13 Throttle Position out of calibration (28) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
0174-00 High Fuel Temperature Warning (65) 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Accelerator Pedal (Throttle) Position Sensor Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Coolant Level Sensor Circuit - Test 3406E, C-10, C-12, C-15, C-16 and C-18 On-highway Engines
Remote PTO Accelerator Position Sensor Circuit - Test On-Highway Engines Electronic PTO Installation and Application Guide
0030-13 PTO Throttle out of calibration (29) On-Highway Engines Electronic PTO Installation and Application Guide
0030-08 PTO Throttle signal invalid (29) On-Highway Engines Electronic PTO Installation and Application Guide

Coolant Temperature Sensor - Remove and Install 3406E On-Highway Engine
Engine Oil Pressure Sensor - Remove and Install 3406E On-Highway Engine
Camshaft Position Sensor - Remove and Install 3406E On-Highway Engine
Crankshaft Position Sensor - Remove and Install 3406E On-Highway Engine
Fuel Temperature Sensor - Remove and Install 3406E On-Highway Engine
Atmospheric Pressure Sensor - Remove and Install 3406E On-Highway Engine
Inlet Air Temperature Sensor - Remove and Install 3406E On-Highway Engine
Boost Pressure Sensor - Remove and Install 3406E On-Highway Engine


System Operation Description:

Use this procedure under the following situation:

Use this procedure if any of the following conditions exist:

  • The ECM has been replaced and the old ECM will not communicate with the Caterpillar Electronic Technician (Cat ET).

  • 22-13 Check Timing Sensor Calibration is active.

  • Work has been done to the front gear group.

The primary engine speed/timing sensor provides an engine speed signal (rpm) to the ECM. The signal is created as the crankshaft gear rotates past the pickup of the primary engine speed/timing sensor. The secondary engine speed/timing sensor provides the timing signal to the ECM. The signal is created as the camshaft gear rotates past the pickup of the secondary engine speed/timing sensor. A unique pattern on the gear allows the ECM to determine the crankshaft position. This unique pattern on the gear allows the ECM to determine the top center position of the piston in the No. 1 cylinder. If the signal is lost from one of the sensors, a diagnostic code is generated. If the signal is lost from one of the sensors, the ECM will use a special type of logic that will allow the engine to start on only one sensor and this special type of logic will allow the engine to run on only one sensor.

Timing calibration is accomplished by installing a special magnetic transducer into the side of the engine block. The magnetic transducer senses a special slot on the crankshaft counterweight. The magnetic transducer is connected to the ECM through the P400 Speed/Timing Calibration Connector that is on the engine wiring harness.

When the engine rpm is from 1000 to 1200 rpm, the ECM is placed in timing calibration mode with Cat ET.




Illustration 1g00660979

Note: The Timing Calibration will not increase the available engine power or the Timing Calibration will not decrease the available engine power. Do not expect an increase in power due to the performance of the timing calibration.

Replacement ECM

If a replacement ECM is required, the ECM parameters and the timing calibration can be transferred from the suspect ECM to the replacement ECM. Timing calibration will NOT be necessary. This feature requires Cat ET and this feature is only possible if the existing ECM can communicate with Cat ET.

Table 1
Required Special Tools    
Part Number     Description    
6V-2197     Magnetic Transducer    
7X-1695     Cable    
7X-1171     Transducer Adapter    
9S-9082     Engine Turning Tool    

Test Step 1. Install the 7X-1171 Transducer Adapter

  1. Turn the key switch to the OFF position.

  1. Use the 9S-9082 Engine Turning Tool to put either the No. 1 piston or the No. 6 piston at top center. Rotate the engine in the opposite direction of the correct engine rotation by the following amount:

    • 60 Degrees

  1. Use the following procedure for a C-10 or C-12 engine:

    1. Remove the timing calibration plug from the right side of the cylinder block as the engine is viewed from the flywheel. The timing calibration plug is located on the No. 4 cylinder rod pocket.

    1. Install the 7X-1171 Transducer Adapter into the hole for the plug.

  1. Use the following procedure for a 3406E, C-15, C-16 or C-18 Engine:

    1. Remove the timing calibration plug from the left side of the cylinder block as the engine is viewed from the flywheel.

    1. Install the 7X-1171 Transducer Adapter into the hole for the plug.

Results:

  • OK - Proceed to Test Step 2.

Test Step 2. Install the 6V-2197 Magnetic Transducer on the Engine


    NOTICE

    If the crankshaft is not in the correct position when the 6V-2197 Magnetic Transducer is installed, the Magnetic Transducer will be damaged when the engine is started.


  1. Put a 2D-6392 O-Ring Seal on the end of the magnetic transducer.

    Note: A small amount of clean engine oil will allow the seal to slide onto the transducer more easily.

  1. Push the magnetic transducer through the adapter until the magnetic transducer comes in contact with the outermost portion of the crankshaft counterweight. Move the O-ring seal downward against the adapter.

  1. Withdraw the magnetic transducer 1.0 mm (0.04 inch) and hand tighten the nut on the adapter sleeve in order to secure the magnetic transducer in place.

  1. Connect the 6V-2197 Magnetic Transducer to the 7X-1695 Cable .

Results:

  • OK - Proceed to Test Step 3.

Test Step 3. Start the Engine and Allow the Coolant to Reach Operating Temperature

  1. Start the engine and run at low idle until the engine has warmed up enough to exit cold mode operation. The status screen on Cat ET will display "COLD MODE" in the upper corner when cold mode operation exists. The engine will adjust idle rpm from cold mode idle to the programmed low idle rpm when cold mode operation is complete.

  1. Check for active diagnostic codes. Use the procedures in this manual to troubleshoot and repair any active diagnostic codes before attempting a calibration check. The engine must not have any diagnostic fault conditions that are present during the timing calibration except the following condition:

    • 22-13 Engine Speed Signal Calibration Not Performed

  1. After the engine has warmed up, set the engine speed to 1100 rpm by the use of the cruise control switches or the accelerator pedal.

    Note: The engine rpm must be steady within the 1000 to 1200 rpm range in order to perform a timing calibration.

Results:

  • OK - Proceed to Test Step 4.

Test Step 4. Connect Cat ET

  1. Connect Cat ET to the data link connector.

  1. After the engine has exited cold mode operation, access the "Timing Calibration Screen" on Cat ET. Access the following display screens in order:

    • "Service"

    • "Calibrations"

    • "Timing Calibration"

    Note: To perform a timing calibration, the engine rpm must remain as steady as possible at approximately 1100 rpm. This can be performed by the use of the cruise control switches or a steady foot on the accelerator pedal. Any changes to engine rpm that are more than 100 rpm will slow down the procedure. These changes will also reduce the accuracy of the procedure.

  1. Connect the 7X-1695 Cable for the 6V-2197 Magnetic Transducer to the P400 Speed/Timing Calibration Connector.

  1. Ensure that all of the connections are made correctly.

Results:

  • OK - Proceed to Test Step 5.

Test Step 5. Calibrate the Speed/Timing Sensor

  1. To calibrate the timing to the correct setting, select "Continue" on Cat ET. Wait until Cat ET indicates that the timing is "CALIBRATED".

    Note: If Cat ET displays "CALIBRATION UNSUCCESSFUL", the electronic injection timing has not been set. Recheck the tool installation and tool operation and try again to calibrate electronic injection timing. If the crankshaft and camshaft gears have been reassembled incorrectly, the engine will not calibrate.

    If the timing calibration has been successfully completed, do not exit the timing calibration screen on Cat ET until you have disconnected the 7X-1695 Cable for the 6V-2197 Magnetic Transducer from the P400 Speed/Timing Calibration Connector.

Expected Result:

The timing calibration procedure was completed successfully.

Results:

  • OK - The timing calibration procedure was completed successfully. Proceed to Test Step 6.

  • Not OK -

    Repair: Perform the following procedure:

    1. Verify that the engine rpm was stable during the testing (± 50 rpm). If the engine rpm was unstable or the engine rpm could not be controlled within ± 50 rpm because of mechanical factors or electrical factors, refer to Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".

    1. If all of the problems have been corrected but the timing can not be calibrated, check the cable of the 6V-2197 Magnetic Transducer and check the 6V-2197 Magnetic Transducer in order to verify that the Magnetic Transducer is not bent. If the 6V-2197 Magnetic Transducer is not bent, restart this procedure.

    STOP

Test Step 6. Disconnect the 6V-2197 Magnetic Transducer Before Exiting the "Monitor/Calibrate Timing" Screen

  1. Disconnect the 6V-2197 Magnetic Transducer from the P400 Speed/Timing Calibration Connector.

  1. Exit the timing calibration screen on Cat ET.

    Note: Exiting the timing calibration screen on Cat ET will drop the engine rpm to the programmed low idle if the cruise control switches were used to maintain engine rpm during calibration. This is normal.

Expected Result:

The magnetic transducer was disconnected before exiting the timing calibration screen on Cat ET.

Results:

  • OK - STOP

  • Not OK - If the magnetic transducer is still installed after exiting the timing calibration screen on Cat ET, vehicle speed diagnostic codes may be generated.

    Repair: If vehicle speed diagnostic codes are generated, the vehicle speed diagnostic codes should be cleared.

    STOP

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