NEHS0711

May 1998

TOOL
OPERATING
MANUAL
Caterpillar PWM/Analog Sensor Adapter Kit for DataView
SMCS Code 0781
 The Caterpillar PWM/Analog Sensor Adapter Kit
Introduction contains the necessary hardware to connect
The Caterpillar 153-9630 PWM / Analog Sensor Caterpillar PWM and Analog sensors into DataView
Adapter Kit allows the 131-5050 DataView to be for testing and datalogging.
used to test, digitally monitor, graph, and Data Log
the output of most permanently installed sensors
on Caterpillar electronically controlled equipment.
This kit provides the necessary adapter box
(for PWM sensors) and cables (for PWM and
Analog sensors) to properly connect these sensors
to DataView. The sensors can be tested either
removed from the machine or installed, and testing
will not interfere with operation of the machine or
engine.

Illustration 2. 153-9630 PWM / Analog Sensor Adapter

Kit.
(1) 153-9625 Caterpillar PWM Sensor Adapter.
(2) 153-9626 Caterpillar Sensor - DT T-cable for
DataView. (3) 153-9627 Caterpillar Sensor - HD T-cable
for DataView. (4) 148-5675 PWM / Analog Sensor
Adapter Kit Case (included with the case are 153-9629
Foam Insert, 6V-6096 Lid Foam, and NEEG2813 Decal).

NOTICE
The Caterpillar PWM Sensor Adapter (1) is only for
use with PWM signal-type sensors. Plugging
Analog sensors into this adapter can permanently
damage Analog sensors.

Illustration 1. (1) PWM sensor. (2) PWM adapter box.

(3) "T" Cable. (4) Analog sensor. (5) "T" Cable.
Specifications
Chart A.
Two different types of sensors, PWM and Analog 153-9625 CAT PWM Adapter
are used on Caterpillar products. PWM sensors (1)
Description Specification
are tested with the PWM adapter box (2) installed
in a Frequency Channel of DataView. A "T" Cable Input Impedance 120 kΩ
(3) is used to connect the sensor to the adapter.
Input Voltage 5 VDC (from DataView)
Analog sensors (4) are tested by connecting them
directly to a DataView Analog Channel with a "T" Output Voltage 9.4 VDC (Sensor Power)
Cable (5). Once connected, the sensor output can Max Sensor Current 40 mA maximum at 9.4 VDC
be viewed and datalogged on DataView Software
Operating Temperature -17° to +60°C (0° to 140°F)
just like any other DataView sensor. DataView 2.0
software includes listings for setting up and Size 85 x 56 x 35 mm (3.3 x 2.2 x 1.4 in)
viewing these sensor’s output. Weight of CAT PWM 0.227 kg (.5 lb)
Sensor Adapter

2
Using the Sensor Adapter Kit High Voltage
1. First, determine if the sensor is Analog or PWM.
Information to determine sensor type is given
below in the Distinguishing Sensor Types
section of this manual.

2. Connect the sensor to DataView following the

Connecting Sensors to DataView procedure
in this manual.
Low Voltage
3. Follow the Testing Procedure provided to either
locate the specific part number in the sensor 0711-04

charts in DataView software program, or

choose CAT Analog Sensor for Analog sensors, Illustration 4. PWM Sensor Output.
or CAT PWM Sensor for PWM sensors.

4. Determine whether the sensor is operating

within specification. Refer to a service manual
or a troubleshooting manual to determine the
Caterpillar Sensor
proper output of the sensor in question. Information and
Distinguishing Sensor Types
Identification
The adapter group can test a wide variety of
The two most common types of sensors on CAT sensors used on Caterpillar electronically
equipment are Analog sensors and Pulse Width controlled equipment. A general list of sensor
Modulated (PWM) sensors. The adapter kit is types and function follows. Not all sensors are
designed to test each of these different types of listed, only the more common ones.
sensors. Analog sensors are usually mounted on
electronically controlled Caterpillar engines. In
service manuals, analog sensors are referred to as PWM Sensors
either Analog sensors, or 5V sensors. Analog
PWM sensors are used for measuring pressure,
sensors’ output signal is a voltage varying from 0
temperature, or position. The 153-9625 CAT PWM
to 5 VDC (Illustration 3). PWM sensors, such as a
Sensor Adapter connected to a Frequency channel
throttle position sensor, may be mounted
of DataView must be used to test these sensors.
elsewhere on CAT equipment. In service manuals,
All PWM sensors are either 8 VDC or 24 VDC
these sensors are referred to as either PWM
sensors, but can be tested with 9.4 VDC as
sensors or 8V or 24V sensors. These sensors’
provided by the PWM Sensor Adapter. The more
output feeds a Pulse Width Modulated square
commonly used sensors programmed into
wave (Illustration 4). Refer to the next section for
DataView’s software are listed below.
positive identification, by shape and part number.

Chart B.
PWM Sensors
5V
Rotary Sensors Output (Shaft Angle)
3E-7700 0°-72°
9X-5592 0°-72°
106-4437 0°-72°
121-0284 0°-102°

0V
0711-03

Illustration 3. Analog Sensor Output.

3
 Using a Specific Part Number to
Test Rotary Sensors
1. Observe the readout of the sensor while the
actuator is at rest.

2. It should read between 0° and 6°.

3. Fully rotate the sensor actuator, and observe

the readout.

0711-05 4. It should read between 67° and 72° or 94° and

102° depending on the type of sensor.
Illustration 5. Rotary Sensor (PWM).

Chart D.
Temperature Sensors
Chart C.
PWM Sensors Part No. Range
Pressure Sensors Range 3E-5370 -40° to 140°C (-40° to 284°F)
9X-5272 0-3155 kPa (0-458 psi) 100-3055 -40° to 135°C (-40° to 275°F)
100-4311 0-3155 kPa (0-458 psi) 131-0784 -40° to 140°C (-40° to 284°F)
107-3952 0-930 kPa (0-135 psi) 134-2252 -40° to 135°C (-40° to 275°F)
145-2362 0-840 kPa (0-122 psi)
147-7318 0-3155 kPa (0-458 psi)

0711-07

Illustration 7. Temperature Sensor (PWM).

0711-06

Illustration 6. Pressure Sensor (PWM).

4
Analog Sensors Chart F.
Temperature Sensors
Analog sensors are used for measuring pressure Part No. Range
and temperature on Caterpillar electronically
102-2240 -40° to 120°C (-40° to 248°F)
controlled engines. These sensors can be tested
with DataView by using one of the T-Cables to plug 106-0735 -40° to 125°C (-40° to 257°F)
them into any Analog channel. These sensors are 107-8618 -40° to 120°C (-40° to 248°F)
referred to as 5 Volt sensors in CAT Service
Manuals (supplied with 5 Volts from the ECM). The
more commonly used sensors programmed into
DataView’s software are listed below.
NOTE: Do not plug these sensors into the CAT
PWM Adapter or the 9.4 VDC output of the adapter
may damage the sensor.

Chart E.
Pressure Sensors
Part No. Range
103-6091 0-468 kPa (68 psi)
0711-09
103-6092 0-1136 kPa (165 psi)
103-6093 0-117 kPa (17 psi) Illustration 9. Temperature Sensor (Analog).
105-1875 0-702 kPa (102 psi)
107-7142 0-702 kPa (102 psi)
The sensors listed in the previous PWM and
111-2350 0-702 kPa (102 psi) Analog Sensor sections are included in the SETUP
111-2351 0-268 kPa (39 psi) screen sensor lists of the Caterpillar DataView
111-8125 0-117 kPa (17 psi)
software version 2.0. These are the more
commonly used sensors on Caterpillar equipment.
149-7511 0-268 kPa (39 psi)
If you are able to select the specific sensor by part
150-7673 0-117 kPa (17 psi) number from the lists, the output will be displayed
in a calibrated form relative to the type of sensor
(i.e. Temperature, Pressure, or Degrees of Rotation
for rotary sensors). If the sensor is working
properly, the value shown will be accurate within
the sensor’s rated accuracy specification.

0711-08

Illustration 8. Pressure Sensor (Analog).

5

Testing Unlisted CAT
Sensors
If a particular sensor is not found on the sensor
lists of the Setup Screen, there are generic sensors
listed to view the output signal from the sensor.
The CAT Analog Sensor can be selected from the
Sensor Table in the DataView Setup Screen for
Analog sensors. This setting will show an Analog
sensor output displayed in Volts. This setting uses
Analog inputs 1-6 on DataView.
The CAT PWM Sensor can be selected from the
Sensor Table in the DataView Setup Screen for
Pulse Width Modulated Sensors. This setting will
display the sensor output in % Duty Cycle. This
setting uses frequency inputs 7-9 on DataView. Be
sure to check both sensor lists if you are uncertain
whether a particular sensor is Analog or PWM.
Using CAT PWM Sensor on Rotary Sensors
1. Observe the readout of the sensor while the
actuator is at rest.
2. It should read between 0% and 6%.
3. Fully rotate the sensor actuator, and observe
the readout.
4. It should read between 92% and 100%.
Using CAT PWM Sensor on Temperature Sensors
1. Observe the readout of the sensor while the
sensor is at room temperature.
2. Apply heat to the sensor and the % Duty Cycle
should rise ratiometrically.
3. Remove heat from the sensor and the % Duty
Cycle should lower ratiometrically.
Using CAT Analog Sensor on Temperature Sensors
1. Observe the readout of the sensor while the
sensor is at room temperature.
2. Apply heat to the sensor and the DC Voltage
should rise ratiometrically.
3. Remove heat from the sensor and the DC
Voltage should lower ratiometrically.
Using CAT PWM Sensor on Pressure Sensors
1. Observe the readout of the sensor while the
sensor is reading ambient air pressure.
6
2. Apply pressure to the sensor and the % Duty
Cycle should rise ratiometrically.
3. Remove the pressure from the sensor and the
% Duty Cycle should lower ratiometrically.
Using CAT Analog Sensor on Pressure Sensors
1. Observe the readout of the sensor while the
sensor is reading ambient air pressure.
2. Apply pressure to the sensor and the DC
Voltage should rise ratiometrically.
3. Remove the pressure from the sensor and the
DC Voltage should lower ratiometrically.
Connecting Sensors to
DataView
Testing PWM Sensors
1. Disconnect the wire harness from the sensor,
by separating the connectors at the sensor, if
the sensor is installed on the machine or engine.
2. Select the proper T-cable which fits the sensor
plug, DT, or HD.
3. Connect the sensor and the harness to the
appropriate ends of the T-cable. If testing the
sensor off of the equipment, it is not necessary
to plug a harness into the T-cable.
4. Plug the 5 Pin connector on the T-cable into the
female end of the PWM Sensor Adapter.
5. Plug the Caterpillar PWM Sensor Adapter into
any of the three Frequency Channels (7, 8, or
9) on DataView.
6. Turn DataView ON and start the PC program.
7. Press the "Add Channel" icon on the setup screen.
8. Select the part number of the corresponding
sensor or "CAT PWM Sensor".
9. Press "OK" to choose the sensor.
10. Select channel 7, 8, or 9 by pressing the Next
Channel" button. Channel must be the same
as the channel the sensor is plugged into.
11. Press "OK" to choose the sensor.
12. View the sensor output on the Status Screen of
DataView.
 4. Plug the 5 Pin connector into any of the 6
Analog channels (1-6) on DataView.

5. Turn DataView ON and start the PC Program.

6. Press the "Add Channel" icon on the setup screen.

7. Select the part number of the corresponding

sensor or "CAT Analog Sensor".

8. Press "OK" to choose the sensor.

9. Select channel 1 through 6 by pressing the

"Next Channel" button. The channel must be
Illustration 10. PWM Sensor Connected To DataView. the same as the channel the sensor is plugged
into.

10. Press "OK" to choose the sensor.

NOTE: If the sensor being tested is installed on
the equipment, and the harness from the ECM 11. View the sensor output on the status screen of
(Electronic Control Module) is plugged into the DataView.
T-cable, the ECM is powering the sensor. If the
sensor is not on the equipment and the harness
from the ECM is not hooked up, the Caterpillar
PWM Sensor Adapter will be powering the sensor.

Testing Analog Sensors

NOTICE
Do not plug Analog sensors into the Caterpillar
PWM Sensor Adapter or the sensor may be
damaged.

Illustration 11. Analog Sensor Connected To DataView.

1. Disconnect the wire harness from the sensor,
by separating the connectors at the sensor, if
the sensor is installed on the machine or engine.
NOTE: If the sensor being tested is installed on
2. Select the proper T-cable which fits the sensor the equipment, and the harness from the ECM is
plug, DT, or HD. plugged into the T-cable, the ECM is powering the
sensor. If the sensor is not on the equipment and
3. Connect the sensor and the harness to the the harness from the ECM is not hooked up, the
appropriate ends of the T-cable. If testing a
sensor which is not installed on the equipment, Caterpillar PWM Sensor Adapter will be powering
it is not necessary to plug a harness into the the sensor.
T-cable.

7
Timing Sensors
A third type of sensor found on electronic engines
is the primary or secondary timing sensor. This
type of sensor provides position/speed information
to the ECM by generating a pulse signal as each
tooth on the reference gear pass by the sensor.
These sensors receive a regulated 12.5 ± 1 VDC
supply voltage from the ECM. Their output
provides a pulsed DC output voltage.
NOTE: Because of ECM loading, these sensors
can not be tested using DataView. To test these
sensors, follow the procedure listed in the
Troubleshooting Guide for the engine.
0711-12
Illustration 12. Timing Sensors.
Warranty and Repair
If the Caterpillar PWM/Analog Sensor Adapter Kit
does not operate properly, try it with another
DataView. If it still does not operate properly, it
can be sent to Caterpillar Service Technology
Group’s Tool Repair Service for repair. Tools that
are less than one year old will be repaired under
warranty (except for abuse). The cost of
out-of-warranty repairs will be charged to the
owner. If returning the tool to Caterpillar’s Tool
Repair Service, be sure to enclose a letter that
describes the problem and give the date of
purchase from Caterpillar. If the tool is out of
warranty, include a Proof of Purchase such as a
Purchase Order Copy and date with the shipment.
Send the tool by U.S. Mail, UPS, or EMERY to this
address:
Caterpillar Service Technology Group
Attn: Tool Repair
100 N.E. Adams St.
Peoria, IL 61629-9010
To contact CSTG, use one of the following phone
numbers:
1-800-541-8665.........................Inside Illinois
1-800-542-8665.........................Outside Illinois
1-800-523-8665........................Canada
1-309-675-6618........................Fax

For information on service tools or shop supplies

contact Caterpillar Service Technology Group on:

Caterpillar Service Technology

100 N.E. Adams Street
Peoria, Illinois 61629-9110
1-800-542-8665 (USA)
1-800-541-8665 (Illinois)
1-800-523-8665 (Canada)
404435 (Telex)
1-309-675-6618 (Fax)

or

Caterpillar Service Technology

Caterpillar Overseas S. A.
P.O. Box 6000
1211 Geneva 6
Switzerland
+41 (22) 849 40 36 (Geneva Phone)
+41 (22) 849 49 29 (Geneva Fax)
36CSTG (COSA E-Mail Address)

©1998 Caterpillar NEHS0711

All Rights Reserved Printed in U.S.A.