4/25/24, 1:55 PM SIS 2.
Coolant Level Sensor (RENR5059-21)
SMCS - 1439 i02410017
System Operation Description:
PIP
Use this procedure to troubleshoot any suspect problems with the following sensors:
Engine coolant level sensor
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202 1115
06: 4 / 0 9 6 3
4 6
Coolant level sensor for the Separate Circuit Aftercooler (SCAC)
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RE 5:29+ 5
This procedure covers the following event codes:
E2143 Low Engine Coolant Level
N
© 2 R50 07:00
024 59
E552 Low Aftercooler Coolant Level
Cat
The coolant level sensor monitors the engine coolant level in order to warn the operator in the
event that the coolant level is low. The coolant level sensor is located on the side of the expansion
tank. erp
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rI nc.
Illustration 1 g01150024
Coolant level sensor
(1) Sensor
(2) Sensor probe (brass dowel)
(3) Plastic cover
Coolant level sensor (1) contains no moving parts. The sensor provides the same function as a
switch. The state of the switch is dependent on the capacitance value that is detected. The sensor
contains a probe (2) that is covered with plastic (3).
When the probe is immersed in coolant, the sensor senses a particular capacitance. The sensor's
electronics react by sinking the signal to the digital return (ground).
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When the probe is not immersed in coolant, the capacitance value changes. The change in the
capacitance value is detected by the sensor's electronic circuits. The sensor sources
approximately +5 VDC to the signal wire. The Electronic Control Module (ECM) detects the voltage
and the ECM activates the event code.
The event code is probably caused by a low coolant level. The next likely cause is a problem with a
wiring harness or with the sensor. The least likely cause is a problem with the ECM.
Illustration 2 g01150032
Typical location of the coolant level sensor
(4) Coolant level sensor
Illustration 3 g01204527
Schematic for coolant level sensor
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Pressurized System: Hot coolant can cause serious burns. To
open the cooling system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen the cooling
system pressure cap slowly in order to relieve the pressure.
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND THE WIRING
A. Remove electrical power from the ECM.
Illustration 4 g01150055
Engine view
(5) J2/P2 connectors
B. Thoroughly inspect connectors (5). Inspect the connectors for sensor (4). Refer to
Troubleshooting, "Electrical Connectors - Inspect" for details.
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Illustration 5 g01204728
P2 ECM connector
(P1-15) SCAC coolant level sensor
(P1-30) Engine coolant level sensor
(P2-57) +8 V digital supply
(P2-66) Digital sensor return
(P2-65) +8 V digital supply
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the
coolant level sensor.
D. Check the allen head screw on each ECM connector for the proper torque. Refer to
Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Expected Result:
All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and
wiring are free of corrosion, of abrasion and of pinch points.
Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and/or the wiring.
Repair: Repair the wiring and connectors or replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that the repair eliminates the problem.
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Verify that the repair eliminates the problem.
STOP
Test Step 2. CHECK THE SUPPLY VOLTAGE AT THE SENSOR CONNECTOR
A. Disconnect the coolant level sensor.
B. Restore electrical power to the ECM.
Illustration 6 g01132478
Harness connector for the coolant level sensor
(A) +8 VDC
(B) Return
C. Measure the voltage between terminals A (+8 VDC) and B (return) at the harness connector
for the coolant level sensor.
D. Remove electrical power from the ECM.
Expected Result:
The voltage measurement is 8.0 ± 0.4 VDC.
Results:
OK - The voltage measurement is 8.0 ± 0.4 VDC. The supply voltage is reaching the sensor.
Proceed to Test Step 3.
Not OK - The voltage measurement is not 8.0 ± 0.4 VDC. The digital sensor supply voltage is
not reaching the sensor.
Repair: Refer to Troubleshooting, "Digital Sensor Supply Circuit - Test".
STOP
Test Step 3. DISCONNECT THE COOLANT LEVEL SENSOR AND MONITOR THE STATUS OF
"COOLANT LEVEL"
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to
Troubleshooting, "Electronic Service Tools".
B. Disconnect the coolant level sensor connectors.
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C. Restore electrical power to the ECM.
D. Monitor the status of "Coolant Level" on Cat ET.
E. Remove electrical power from the ECM.
Expected Result:
The status changes from "OK" to "Low" when the sensor is disconnected.
Results:
OK - The status is "Low" when the sensor is disconnected. Proceed to Test Step 4.
Not OK - The status is "OK" when the sensor is disconnected. Proceed to Test Step 5.
Test Step 4. SHORT THE HARNESS AND MONITOR THE STATUS OF "COOLANT LEVEL"
A. Restore electrical power to the ECM and monitor the status of "Coolant Level" on Cat ET.
B. Install a jumper wire between terminals B (return) and C (signal) on the harness connector for
the coolant level sensor.
C. Monitor the status of "Coolant Level" on Cat ET while the jumper wire is installed.
D. Remove the jumper wire.
E. Remove electrical power from the ECM.
Expected Result:
The status changes from "Low" to "OK" when the jumper wire is installed.
Results:
OK - The status changes from "Low" to "OK" when the jumper wire is installed. The ECM and
the wiring to the coolant level sensor are OK.
Repair: Perform the following procedure:
Pressurized System: Hot coolant can cause serious burns. To
open the cooling system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen the cooling
system pressure cap slowly in order to relieve the pressure.
1. Drain the coolant below the level of the coolant level sensor.
2. Restore electrical power to the ECM and monitor the status of "Coolant Level" on Cat ET.
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3. Remove electrical power from the ECM.
If the status of the "Coolant Level" is "OK", replace the sensor. Verify that the problem is
resolved.
If the status for the coolant level is "Low", connect the sensor. Fill the cooling system
according to the procedure in the Operation and Maintenance Manual. Return the engine
to service.
STOP
Not OK - Shorting the harness does not affect the status on Cat ET. Proceed to Test Step 5.
Test Step 5. CHECK FOR OPENS IN THE WIRING
A. Remove electrical power from the ECM.
B. Disconnect the J2/P2 ECM connector and the connector for the coolant level sensor.
C. Measure the resistance between the following terminals:
P2 (digital sensor supply +8 V) to A (digital sensor supply +8 V)
P2 (digital sensor return) to B (digital sensor return)
P2 (coolant level sensor) to C (coolant level sensor)
Expected Result:
The resistance is less than five Ohms for each measurement.
Results:
OK - The resistance is less than five Ohms for each measurement. There are no opens in the
wiring. Proceed to Test Step 6.
Not OK - The resistance is greater than five Ohms for each measurement. There is an open
circuit or excessive resistance in the harness or the connectors.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP
Test Step 6. CHECK THE WIRING FOR A SHORT CIRCUIT
A. Remove electrical power from the ECM.
Note: Wiggle the harness during the following measurements in order to reveal an intermittent
condition.
B. Measure the resistance between the points that are listed in Table 1. Be sure to wiggle the
wires in the harnesses as you make each resistance measurement.
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Table 1
Resistance Measurements for the Circuit for the Coolant Level Sensors
Connector and Terminal Terminal
All of the other terminals on the P2 connector
P1-30 (engine coolant level)
OR All of the terminals on the P1 connector
P1-15 (SCAC coolant level)
Engine ground
Expected Result:
Each check of the resistance indicates an open circuit.
Results:
OK - Each check of the resistance indicates an open circuit. Proceed to Test Step 7.
Not OK - At least one check of the resistance does not indicate an open circuit. There is a
problem in the harness. There may be a problem in a connector.
Repair: Repair the wire and/or the connector, when possible. Replace parts, if necessary.
Verify that the problem is resolved.
STOP
Test Step 7. CREATE A SHORT CIRCUIT AT THE ECM
A. Remove P2-5 sensor return and P2-6 low coolant level signal.
B. Install the ends of a jumper wire into locations P2-5 and P2-6. This will create a short circuit at
the ECM connectors.
C. Restore electrical power to the ECM and monitor the status of "Coolant Level" on Cat ET.
D. Remove the jumper wire. Monitor the status of "Coolant Level" on Cat ET.
Expected Result:
The status is "Low" when the jumper wire is not connected. The status is "OK" when the jumper
wire is connected.
Results:
OK - The status is "Low" when the jumper wire is not connected. The status is "OK" when the
jumper wire is connected. The ECM is properly reading the switch input.
Repair: Perform the following procedure:
1. Remove the jumper wire from the ECM connector.
2. Install the two terminals into the correct locations on the ECM connector. Perform a pull
test on the two wires in order to verify proper installation of the terminals.
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The problem appears to be resolved. The original problem was probably caused by a
poor electrical connection. Return the engine to service.
STOP
Not OK - The status is "Low" when the jumper wire is connected. The ECM is not reading the
switch input.
Repair: Temporarily install a new ECM. Refer to Troubleshooting, "Replacing the ECM".
If the new ECM works correctly, install the original ECM and verify that the problem returns. If
the new ECM works correctly and the original ECM does not work correctly, replace the
original ECM. Verify that the problem is resolved.
STOP
PIP-11159636
2024/04/25
06:52:36+07:00
i02410017
© 2024 Caterpillar Inc.
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