3516C High Displacement Engine Caterpillar


Sensor Signal (Analog, Active) - Test

Usage:

3516C MLF

Table 1
J1939 Code and Description     CDL Code and Description     Comments    
95-2
Engine Fuel Filter Differential Pressure : Erratic, Intermittent, or Incorrect    
95-2
Fuel Filter Differential Pressure Sensor : Erratic, Intermittent, or Incorrect    
The code is logged. The value of the parameter is set to a default value.    
99-2
Engine Oil Filter Differential Pressure : Erratic, Intermittent, or Incorrect    
99-2
Engine Oil Filter Differential Pressure Sensor : Erratic, Intermittent, or Incorrect    
The code is logged. The value of the parameter is set to a default value.    
100-3
Engine Oil Pressure : Voltage Above Normal    
100-3
Engine Oil Pressure Sensor : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
100-4
Engine Oil Pressure : Voltage Below Normal    
100-4
Engine Oil Pressure Sensor : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    
101-3
Engine Crankcase Pressure : Voltage Above Normal    
101-3
Crankcase Air Pressure Sensor : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
101-4
Engine Crankcase Pressure : Voltage Below Normal    
101-4
Crankcase Air Pressure Sensor : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    
108-3
Barometric Pressure : Voltage Above Normal    
3528-3
Barometric Pressure Sensor : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
108-4
Barometric Pressure : Voltage Below Normal    
3528-4
Barometric Pressure Sensor : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    
1176-3
Engine Turbocharger #1 Compressor Inlet Pressure : Voltage Above Normal    
2738-3
Turbocharger #1 Compressor Inlet Pressure Sensor : Voltage Above Normal    
The code is logged. The ECM detects signal voltage that is not in the acceptable range.    
1176-4
Engine Turbocharger #1 Compressor Inlet Pressure : Voltage Below Normal    
2738-4
Turbocharger #1 Compressor Inlet Pressure Sensor : Voltage Below Normal    
The code is logged. The ECM detects signal voltage that is not in the acceptable range.    
1177-3
Engine Turbocharger #2 Compressor Inlet Pressure : Voltage Above Normal    
2739-3
Turbocharger #2 Compressor Inlet Pressure Sensor : Voltage Above Normal    
The code is logged. The ECM detects signal voltage that is not in the acceptable range.    
1177-4
Engine Turbocharger #2 Compressor Inlet Pressure : Voltage Below Normal    
2739-4
Turbocharger #2 Compressor Inlet Pressure Sensor : Voltage Below Normal    
The code is logged. The ECM detects signal voltage that is not in the acceptable range.    
1208-3
Engine Pre-filter Oil Pressure : Voltage Above Normal    
542-3
Engine Oil Pressure Sensor - Before Oil Filter : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
1208-4
Engine Pre-filter Oil Pressure : Voltage Below Normal    
542-4
Engine Oil Pressure Sensor - Before Oil Filter : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    
3563-3
Engine Intake Manifold #1 Absolute Pressure : Voltage Above Normal    
1785-3
Intake Manifold Pressure Sensor : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
3563-4
Engine Intake Manifold #1 Absolute Pressure : Voltage Below Normal    
1785-4
Intake Manifold Pressure Sensor : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    
5578-3
Engine Fuel Delivery Absolute Pressure : Voltage Above Normal    
289-3
Fuel Pressure Sensor - Before Fuel Filter : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
5578-4
Engine Fuel Delivery Absolute Pressure : Voltage Below Normal    
289-4
Fuel Pressure Sensor - Before Fuel Filter : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    
5580-3
Engine Filtered Fuel Delivery Absolute Pressure : Voltage Above Normal    
460-3
Fuel Pressure Sensor - After Fuel Filter : Voltage Above Normal    
The code is logged. The value of the parameter is set to a default value.    
5580-4
Engine Filtered Fuel Delivery Absolute Pressure : Voltage Below Normal    
460-4
Fuel Pressure Sensor - After Fuel Filter : Voltage Below Normal    
The code is logged. The value of the parameter is set to a default value.    

The supply voltage is routed to terminal 1 of each sensor connector. The sensor return is routed to terminal 2 of each sensor connector. The sensor signal is routed to terminal 3 of each sensor connector. The ECM provides short circuit protection for the internal power supply. A short circuit to the battery will not damage the internal power supply.

Diagnostics on the Caterpillar Electronic Technician (ET)

Wiggle Test - The Wiggle Test allows you to monitor the status of the signals from the sensors.

For additional information regarding the Wiggle Test, refer to the documentation that accompanies the Cat ET software.




Illustration 1g02722071

Schematic for the analog sensors

Table 2
Troubleshooting Test Steps     Values     Results    

1. Check for Diagnostic Codes

A. Establish communication between Caterpillar Electronic Technician (ET) and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.

B. Turn the keyswitch to the ON position.

C. Look for a -3, or -4 active or logged codes:
   

Diagnostic code
   

Result: A -3 diagnostic code is active.

Proceed to Test Step 2.

Result: A -4 diagnostic code is active.

Proceed to Test Step 3.
   

2. Create a Short at the Sensor Connector

A. Use a jumper wire in order to create a short between terminal 3 (signal) and terminal 2 (sensor return) at the sensor connector.

B. Turn the keyswitch to the ON position.

C. Monitor the diagnostic codes on Cat ET. Check for an active -4 diagnostic code for the suspect sensor.

D. Turn the keyswitch to the OFF position.
   

Short created
   

Result: A -4 diagnostic code became active after creating the short at the sensor connector.

The wiring is OK.

Repair: Replace the sensor.

Verify that the problem is resolved.

Result: A -4 diagnostic code does not become active for the suspect sensor.

Proceed to Test Step 4.
   

3. Create an Open at the Suspect Sensor Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the sensor connector of the suspect sensor with the active -4 diagnostic code.

C. Turn the keyswitch to the ON position.

D. Monitor the diagnostic codes on Cat ET. Check for an active -3 diagnostic code for the suspect sensor.

E. Turn the keyswitch to the OFF position.
   

Create an Open    

Result: A -3 diagnostic code became active after disconnecting the sensor.

The wiring is OK.

Repair: Replace the sensor.

Verify that the problem is resolved.

Result: A -3 diagnostic code did not became active after disconnecting the sensor.

Proceed to Test Step 4.
   

4. Check the 5 VDC Supply Voltage at the Sensor Connector

A. Turn the keyswitch to the ON position.

B. Measure the voltage between pin 1 and pin 2 at the suspect sensor.
   

Test passed    

Result: The supply voltage is approximately 5.0 ± 0.2 VDC

Connect the sensor and then proceed to Test Step 5

Result: The supply voltage is not approximately 5.0 ± 0.2 VDC.

There is a short in the harness to the battery.

Repair: Repair the wiring or replace the harness

Verify that the problem is resolved.
   

5. Perform the Wiggle Test

Carefully following this procedure is the best way to identify the root cause of an intermittent problem.

A. Turn the keyswitch to the ON position.

B. Use CAT ET to run the "Wiggle Test".

C. Slowly wiggle the wiring and the connectors between the P2 connector and the sensor. Pay particular attention to the wiring near each connector. Be sure to wiggle all of the wiring.
As you wiggle the wiring look for these problems.
1. Loose connectors or damaged connectors
2. Moisture on the connectors or the wiring
3. Damaged that is caused by excessive heat
4. Damage that is caused by chafing
5. Improper routing of wiring
6. Damaged insulation
   

Test passed    

Result: The wiring failed the Wiggle Test.

There is a problem with the wiring.

Repair: Repair the wiring or replace the wiring.

Verify that the problem is resolved.

STOP

Result: The wiring passed the Wiggle Test.

The problem may be intermittent. Inspect the wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".

If the wiring looks OK perform the following procedure.

1. Turn the keyswitch to the OFF position.
2. Disconnect the connectors. Carefully inspect the terminals for proper installation. Make sure that each terminal is clean and dry.
3. Insert a pin into each socket. Verify that each socket grips the pin firmly. Repair any problems.
4. Connect all connectors.
5. Verify that the problem is resolved.
6. Return the unit to service.
STOP
   

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).

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