C4.4 and C6.6 Engines Caterpillar


Sensor Signal (Analog, Active) - Test

Usage:

C4.4 448
This procedure covers the following diagnostic codes:

Table 1
Diagnostic Codes for the Active Analog Sensors 
J1939 Code  CDL Code  Code Description
(code descriptions may vary) 
Comments 
100-3  100-3  Engine Oil Pressure Sensor : Voltage Above Normal  The Electronic Control Module (ECM) detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
100-4  100-4  Engine Oil Pressure Sensor : Voltage Below Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
108-3  3528-3  Barometric Pressure Sensor : Voltage Above Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
108-4  3528-4  Barometric Pressure Sensor : Voltage Below Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
157-3  1797-3  Fuel Rail Pressure Sensor : Voltage Above Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
157-4  1797-4  Fuel Rail Pressure Sensor : Voltage Below Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
3242-3  2452-3  Aftertreatment #1 DPF Intake Gas Temperature : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the DPF inlet temperature sensor is greater than 4.95 VDC for more than 8 seconds.

An active diagnostic code will be generated after 8 seconds. The diagnostic code will be logged if the engine has been operating for more than 7 minutes.
"Voltage Above Normal" will be displayed next to the status for "DPF Inlet Temperature" on the electronic service tool. 
3242-4  2452-4  Aftertreatment #1 DPF Intake Gas Temperature : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the DPF inlet temperature sensor is less than 0.2 VDC for more than 8 seconds.

An active diagnostic code will be generated after 8 seconds. The diagnostic code will be logged if the engine has been operating for more than 7 minutes.
"Voltage Below Normal" will be displayed next to the status for "DPF Inlet Temperature" on the electronic service tool. 
3358-3  3385-3  EGR Intake Pressure Sensor : Voltage Above Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
3358-4  3385-4  EGR Intake Pressure Sensor : Voltage Below Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
3563-3  1785-3  Intake Manifold Pressure Sensor : Voltage Above Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
3563-4  1785-4  Intake Manifold Pressure Sensor : Voltage Below Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
5019-3  3511-3  Engine Exhaust Gas Recirculation Outlet Pressure : Voltage Above Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
5019-4  3511-4  Engine Exhaust Gas Recirculation Outlet Pressure : Voltage Below Normal  The ECM detects signal voltage that is not in the acceptable range.
The code is logged.
The value of the parameter is set to a gauge pressure. 
Follow the troubleshooting procedure to identify the root cause of the fault. 

The following conditions must exist before any of the above codes will become active:

  • There are no active 3509 (262) codes.

  • There are no active 168 codes.

The following background information is related to this procedure:

The 5 VDC sensor supply provides power to all 5 VDC sensors. The ECM supplies 5 VDC to terminal "3" of the fuel rail pressure sensor connector and to terminal "1" of all other active sensor connectors. The sensor common from the ECM connector goes to terminal "1" of the connector for the fuel rail pressure sensor. The sensor common from the ECM connector goes to terminal "2" of all other active sensor connectors. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The ECM uses this pull-up voltage to detect an open in the signal circuit. When the ECM detects a voltage above a threshold on the signal circuit, an open circuit diagnostic code (XXXX-3) is generated for the sensor.

If the sensor is disconnected, pull-up voltage indicates that the wires from the sensor connector to the ECM are not open or shorted to ground. If the sensor is disconnected, the absence of pull-up voltage indicates an open in the signal wire or a short to ground. If the sensor is disconnected and the voltage is different from pull-up voltage, the signal wire is shorted to another wire in the harness.



Illustration 1g06272280
Schematic for the active sensors


Illustration 2g03374231
Fuel rail pressure sensor
(1) Ground
(2) Signal
(3) 5 VDC Supply


Illustration 3g01170310
Typical example of an engine pressure sensor
(1) 5 VDC Supply
(2) Ground
(3) Signal


Illustration 4g06272948
DPF inlet temperature sensor
(1) 5 VDC Supply
(2) Ground
(3) Signal
(4) No connection

Table 2
Troubleshooting Test Steps  Values  Results 

1. Check for Diagnostic Codes

A. Establish communication between the electronic service tool 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 to create a short between the signal terminal and the ground terminal at the sensor connector.

B. Turn the keyswitch to the ON position.

C. Monitor the diagnostic codes on the electronic service tool. 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. 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 the electronic service tool. 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. Replace the sensor.

Verify that the problem is resolved.

Result: A -3 diagnostic code did not become 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 the sensor supply pin and the sensor return pin 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 the wiring or replace the harness

Verify that the problem is resolved.
STOP
 

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 the electronic service tool 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 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 fault in the wiring. Repair the wiring or replace the wiring.

Verify that the fault is resolved.

STOP

Result: The wiring passed the Wiggle Test.

The fault 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 faults.
4. Connect all connectors.
5. Verify that the fault is resolved.
6. Return the unit to service.
STOP
 

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