Caterpillar Engines Troubleshooting

Cat Engines Maintenance & Repair Guides

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M E N U

 OCTOBER 20, 2020

C13, C15, and C18 Engines Troubleshooting – Sensor Signal

(Analog, Active) – Test
System Operation Description:

Use this procedure to troubleshoot the electrical system if a problem is suspected with the
sensors. Use this procedure if any of the diagnostic codes in Table 1 are active or easily
repeated.

Table 1

Diagnostic Codes Table

CDL J1939 Code Description Comments

Code Code

100-3 100-3 Engine Oil Pressure Sensor The ECM detects signal voltage that is not in
: Voltage Above Normal 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 The ECM detects signal voltage that is not in
: Voltage Below Normal the acceptable range.

The code is logged.

The value of the parameter is set to a gauge

pressure.

101-3 101-3 Crankcase Air Pressure The ECM detects signal voltage that is not in
Sensor : Voltage Above the acceptable range.

Normal The code is logged.

 The value of the parameter is set to a gauge

pressure.

101-4 101-4 Crankcase Air Pressure The ECM detects signal voltage that is not in
Sensor : Voltage Below the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

274-3 108-3 Atmospheric Pressure The ECM detects signal voltage that is not in
Sensor : Voltage Above the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

274-4 108-4 Atmospheric Pressure The ECM detects signal voltage that is not in
Sensor : Voltage Below the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

460-3 5580- Fuel Pressure Sensor – The ECM detects signal voltage that is not in
3 After Fuel Filter : Voltage the acceptable range.

Above Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

460-4 5580- Fuel Pressure Sensor – The ECM detects signal voltage that is not in
4 After Fuel Filter : Voltage the acceptable range.

Below Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

1785- 3563- Intake Manifold Pressure The ECM detects signal voltage that is not in
3 3 Sensor : Voltage Above the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

1785- 3563- Intake Manifold Pressure The ECM detects signal voltage that is not in
4 4 Sensor : Voltage Below the acceptable range.

Normal The code is logged.

 The value of the parameter is set to a gauge

pressure.

1835- 1387- Auxiliary Pressure Sensor : The ECM detects signal voltage that is not in
3 3 Voltage Above Normal the acceptable range.

The code is logged.

The value of the parameter is set to a gauge

pressure.

1835- 1387- Auxiliary Pressure Sensor : The ECM detects signal voltage that is not in
4 4 Voltage Below Normal the acceptable range.

The code is logged.

The value of the parameter is set to a gauge

pressure.

1924- 2948- Engine Intake Valve The ECM detects signal voltage that is not in
3 3 Actuation System Oil the acceptable range. The code is logged. The
Pressure : Voltage Above value of the parameter is set to a gauge
Normal pressure.

1924- 2948- Engine Intake Valve The ECM detects signal voltage that is not in
4 4 Actuation System Oil the acceptable range. The code is logged. The
Pressure : Voltage Below value of the parameter is set to a gauge
Normal pressure.

2452- 3242- DPF #1 Intake Temperature The code is logged.

3 3 Sensor : Voltage Above The ECM detects voltage that is not in the
Normal acceptable range.

2452- 3242- DPF #1 Intake Temperature The code is logged.

4 4 Sensor : Voltage Below The ECM detects voltage that is not in the
Normal acceptable range.

2458- 3251- DPF #1 Differential The ECM detects signal voltage that is not in
2 2 Pressure Sensor : Erratic, the acceptable range.

Intermittent, or Incorrect The code is logged.

The value of the parameter is set to a gauge

pressure.

2458- 3251- DPF #1 Differential The ECM detects signal voltage that is not in
3 3 Pressure Sensor : Voltage the acceptable range.

Above Normal The code is logged.

 The value of the parameter is set to a gauge

pressure.

2458- 3251- DPF #1 Differential The ECM detects signal voltage that is not in
4 4 Pressure Sensor : Voltage the acceptable range.

Below Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

2460- 3480- ARD Fuel Pressure #1 The ECM detects signal voltage that is not in
3 3 Sensor : Voltage Above the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

2460- 3480- ARD Fuel Pressure #1 The ECM detects signal voltage that is not in
4 4 Sensor : Voltage Below the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

2497- 4077- ARD Fuel Pressure #2 The ECM detects signal voltage that is not in
3 3 Sensor : Voltage Above the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

2497- 4077- ARD Fuel Pressure #2 The ECM detects signal voltage that is not in
4 4 Sensor : Voltage Below the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

2738- 1176- Turbocharger #1 The ECM detects signal voltage that is not in
3 3 Compressor Inlet Pressure the acceptable range.

Sensor : Voltage Above The code is logged.

Normal The value of the parameter is set to a gauge

pressure.

2738- 1176- Turbocharger #1 The ECM detects signal voltage that is not in
4 4 Compressor Inlet Pressure the acceptable range.

The code is logged.

 Sensor : Voltage Below The value of the parameter is set to a gauge

Normal pressure.

3385- 3358- EGR Intake Pressure Sensor The ECM detects signal voltage that is not in
3 3 : Voltage Above Normal the acceptable range.

The code is logged.

The value of the parameter is set to a gauge

pressure.

3385- 3358- EGR Intake Pressure Sensor The ECM detects signal voltage that is not in
4 4 : Voltage Below Normal the acceptable range.

The code is logged.

The value of the parameter is set to a gauge

pressure.

3387- 411-3 Engine Exhaust Gas The ECM detects signal voltage that is not in
3 Recirculation Differential the acceptable range.

Pressure Sensor : Voltage The code is logged.

Above Normal The value of the parameter is set to a gauge

pressure.

3387- 411-4 Engine Exhaust Gas The ECM detects signal voltage that is not in
4 Recirculation Differential the acceptable range.

Pressure Sensor : Voltage The code is logged.

Below Normal The value of the parameter is set to a gauge

pressure.

3464- 3609- DPF #1 Intake Pressure The ECM detects signal voltage that is not in
3 3 Sensor : Voltage Above the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

3464- 3609- DPF #1 Intake Pressure The ECM detects signal voltage that is not in
4 4 Sensor : Voltage Below the acceptable range.

Normal The code is logged.

The value of the parameter is set to a gauge

pressure.

3485- 3241- Aftertreatment #1 Exhaust The ECM detects signal voltage that is not in
3 3 Gas Temperature #1 the acceptable range.

The code is logged.

 Sensor : Voltage Above
Normal

3485- 3241- Aftertreatment #1 Exhaust The ECM detects signal voltage that is not in
4 4 Gas Temperature #1 the acceptable range.

Sensor : Voltage Below The code is logged.

Normal

3493- 3837- Aftertreatment #1 The ECM detects signal voltage that is not in
3 3 Secondary Air Pressure the acceptable range.

Sensor : Voltage Above The code is logged.

Normal The value of the parameter is set to a gauge

pressure.

3493- 3837- Aftertreatment #1 The ECM detects signal voltage that is not in
4 4 Secondary Air Pressure the acceptable range.

Sensor : Voltage Below The code is logged.

Normal The value of the parameter is set to a gauge

pressure.

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 1 g03319752

Schematic for the active sensors

Table 2

Troubleshooting Test Steps Values Results

1. Check for Diagnostic CodesA. Establish Diagnostic Result: A -3 diagnostic

communication between Caterpillar Electronic code code is active.Proceed to
Technician (ET) and the ECM . Refer to Test Step 2.
Troubleshooting, “Electronic Service Tools”, if
necessary.
B. Turn the keyswitch to the ON position. Result: A -4 diagnostic
code is active.
C. Look for “-3″, or ” -4″ active or logged codes.
Proceed to Test Step 3.

Result: A 2458-2 or a 3251-

2 diagnostic code is active.

Proceed to Test Step 6.

2. Create a Short at the Sensor ConnectorA. Use a Short Result: A -4 diagnostic

test lamp in order to create a short between created code became active after
terminal 3 (signal) and terminal 2 (sensor return) creating the short at the
at the sensor connector. sensor connector.The
wiring is OK. Replace the
B. Turn the keyswitch to the ON position. sensor.

Verify that the problem is

C. Monitor the diagnostic codes on Cat ET. Check resolved.
for an active -4 diagnostic code for the suspect
sensor. Result: A -4 diagnostic
code does not become
D. Turn the keyswitch to the OFF position. active for the suspect
sensor.

Proceed to Test Step 4.

3. Create an Open at the Suspect Sensor Create an Result: A -3 diagnostic

ConnectorA. Turn the keyswitch to the OFF Open code became active after
position. disconnecting the
sensor.The wiring is OK.
B. Disconnect the sensor connector of the suspect Replace the sensor.

sensor with the active -4 diagnostic code. Verify that the problem is
resolved.
C. Turn the keyswitch to the ON position.
Result: A -3 diagnostic
D. Monitor the diagnostic codes on Cat ET. Check code did not became
for an active -3 diagnostic code for the suspect active after disconnecting
sensor. the sensor.

E. Turn the keyswitch to the OFF position. Proceed to Test Step 4.

4. Check the 5 VDC Supply Voltage at the Sensor Test Result: The supply voltage
ConnectorA. Turn the keyswitch to the ON passed is approximately 5.0 ± 0.2
position. VDCConnect the sensor
and then proceed to Test
B. Measure the voltage between pin 1 and pin 2 at Step 5
the suspect sensor.
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 TestCarefully following this Test Result: The wiring failed
procedure is the best way to identify the root passed the Wiggle Test.There is a
cause of an intermittent problem. problem with the wiring.
Repair the wiring or replace
A. Turn the keyswitch to the ON position. the wiring.

Verify that the problem is

B. Use CAT ET to run the “Wiggle Test”. resolved.

STOP
C. Slowly wiggle the wiring and the connectors
between the P2 connector and the sensor. Pay Result: The wiring passed
particular attention to the wiring near each the Wiggle Test.
connector. Be sure to wiggle all of the wiring.

As you wiggle the wiring look for these problems.

The problem may be
1. Loose connectors or damaged connectors
intermittent. Inspect the
2. Moisture on the connectors or the wiring
wiring. Refer to
3. Damaged that is caused by excessive heat
Troubleshooting, “Electrical
4. Damage that is caused by chafing
Connectors – Inspect”.

5. Improper routing of wiring

If the wiring looks OK
6. Damaged insulation 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

Illustration 2 g02408256

(1) Differential pressure lines

Table 3

6. Inspect the DPF Differential Pressure Lines, Lines Result: The DPF

Fittings, and Manifold inspected differential pressure lines,
fittings, and manifold are
A. Ensure that the DPF differential pressure lines connected and free from
are connected. obstructions.

Proceed to Test Step 7

 B. Ensure that the DPF differential pressure lines, Result: The DPF
fittings, and manifold are free from obstructions. differential pressure lines
Make sure that moisture has not frozen in the lines, are not connected or the
fittings, and manifold. lines, fittings, and
manifold have
Note: The 2458-2 or the 3251-2 code will not obstructions.
activate for several hours if the ambient
temperature is below 7° C (45° F) or if an active Repair or replace the DPF
regeneration has not been performed. If differential pressure line.
troubleshooting a 2458-2 or a 3251-2 code and Clear all codes. Return the
ambient temperature is below
engine to service.
7° C (45° F), perform a “Manual DPF regeneration”
after completing the repair to verify that the
problem has been resolved.

7. Inspect the Electrical Connectors for the ARD Connectors Result: A 2458-2 or a
Pilot Fuel Pressure Sensor and the DPF inspected 3251-2 diagnostic code
Differential Pressure Sensor will appear when the
connectors are switched
A. Check the connectors for the differential between sensors, be
pressure sensor and the pilot fuel pressure sensor certain the connectors are
to ensure that the connectors are connected to the connected to the correct
proper sensor. sensors.

Connect the connectors

Note: The 2458-2 or the 3251-2 code will not to the correct sensors.
activate for several hours if the ambient Verify that the problem is
temperature is below
resolved. Clear all codes.
7° C (45° F) or if an active regeneration has not Return the engine to
been performed. If troubleshooting a 2458-2 or a service.
3251-2 code and ambient temperature is below

7° C (45° F), perform a “Manual DPF regeneration”

after completing the repair to verify that the
problem has been resolved.

Test Step 1.

Complete the procedure in the order in which the steps are listed.

Results:
 

The procedure corrected the issue. – STOP 

The procedure did not correct the issue. –Repair: Contact your Cat dealer Technical
Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions
Network (DSN).
STOP

POSTED IN C18 •

Published by sam
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