3508B Generator Set CNB00001-UP(SEBP3301 - 12) - Product Structure Page 1 of 8

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Product: GENERATOR SET

Model: 3508B GENERATOR SET CNB
Configuration: 3508B Generator Set CNB00001-UP

Troubleshooting
3500B and 3500B High Displacement Engines For Caterpillar Built Generator Sets
Media Number -RENR4954-04 Publication Date -01/03/2003 Date Updated -18/03/2003

i01726751

Analog Sensor Supply

SMCS - 1901-038

System Operation Description:

The Analog Sensor Supply provides power to all analog sensors. The Electronic Control Module (ECM)
supplies 5.0 ± 0.2 VDC from the ECM connector J1/P1 to each analog sensor connector. The sensor
return line connects to the ECM connector J1/P1. The analog sensor supply is output short circuit
protected. A short circuit to the battery will not damage the circuit inside the ECM.

Note: The Analog Sensors are not protected from overvoltage. A short from the analog supply line to
the + Battery supply may damage the sensors. If CID-FMI 262-03 is logged, it is possible that all of the
analog sensors have been damaged. Repair the Analog Sensor Supply and check for any "ACTIVE"
sensor diagnostic codes in order to determine if a sensor has failed.

Note: The Engine Monitoring System can be programmed by dealers and/or customers. Dealers and/or
customers can monitor customized warnings, derates, shutdown override setpoints, and delay times
using the Caterpillar Electronic Technician (ET). Customized parameters may affect the behavior of the
ECM. The behavior of the ECM may vary from the description that is given in this system operation
section. You may refer to Troubleshooting, "Engine Monitoring System" in order to determine if there
are any parameters that are affecting engine operation.

The following list contains a description of the analog sensors that are found on the engine.

Aftercooler Temperature Sensor - The ECM uses the signal from the sensor to monitor changes in
system temperature. The ECM makes adjustments to the system's operating parameters as the
temperature changes. This allows the engine to operate at optimal performance through a wide range of
operating temperatures. The operating range of the sensor is -40 °C to 120 °C (-40 °F to 248 °F).

Coolant Temperature Sensor - Cold Mode operation improves the engine starting ability. Cold Mode
operation helps to control white smoke during cold starts. Cold Mode operation helps to improve warm
up time of the engine. In Normal Mode, injection timing is varied as a function of engine speed and of
load. The process of combustion is improved by controlling the injection timing in Cold Mode.
Transient engine response is slower in Cold Mode operation. Cold Mode operation is activated when the

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engine water temperature is below 60 °C (140 °F). Cold Mode operation will remain active until water
temperature rises above 63 °C (145 °F). The engine will alternate between Cold Mode and Normal
Mode during operation, as engine temperature fluctuates. The operating range of the sensor is -40 °C to
120 °C (-40 °F to 248 °F).

Filtered Fuel Pressure Sensor - The sensor is used in conjunction with the Unfiltered Fuel Pressure
sensor to determine the restriction across the fuel filters. The sensor output is a DC voltage that varies
with filtered fuel pressure between 0.2 VDC and 4.8 VDC. The sensor is located on the end cap of the
fuel filter housing. The operating range of the sensor is 0.0 kPa to 1090 kPa (0.0 psi to 158 psi). The
ECM calibrates the sensor within the first five seconds after power is applied to the ECM. The ECM
checks the sensor value against an acceptable pressure range. If the pressure value is not in this range,
the previous calibration will be used. A manual calibration of the sensor should be done if the sensor or
the ECM has been replaced. Refer to Troubleshooting, "Anolog Sensor - Calibrate".

Unfiltered Fuel Pressure Sensor - The sensor is used in conjunction with the Filtered Fuel Pressure
sensor to determine the restriction across the fuel filters. The sensor output is a DC voltage that varies
with unfiltered fuel pressure between 0.2 VDC and 4.8 VDC. The sensor is located on the end cap of the
fuel filter housing. The operating range of the sensor is 0.0 kPa to 1090 kPa (0.0 psi to 158 psi). The
ECM calibrates the sensor within the first five seconds after power is applied to the ECM. The ECM
checks the sensor value against an acceptable pressure range. If the pressure value is not in this range,
the previous calibration will be used. A manual calibration of the sensor should be done if the sensor or
the ECM has been replaced. Refer to Troubleshooting, "Anolog Sensor - Calibrate".

Filtered Engine Oil Pressure Sensor - The sensor is used in conjunction with the Unfiltered Engine
Oil Pressure sensor in order to determine the restriction across the engine oil filters. The ECM uses this
sensor to detect low engine oil pressure. The signal is compared with a map of engine oil pressure versus
engine rpm which is stored in the ECM. The sensor output is a DC voltage that varies with engine oil
pressure between 0.2 VDC and 4.8 VDC. The sensor is located downstream of the engine oil filter. The
operating range of the sensor is 0.0 kPa to 1090 kPa (0.0 psi to 158 psi). The ECM calibrates the sensor
within the first five seconds after power is applied to the ECM. The ECM checks the sensor value
against an acceptable pressure range. If the pressure value is not in this range, the previous calibration
will be used. A manual calibration of the sensor should be done if the sensor or the ECM has been
replaced. Refer to Troubleshooting, "Anolog Sensor - Calibrate".

Unfiltered Engine Oil Pressure Sensor - The sensor is used in conjunction with the Filtered Engine
Oil Pressure sensor to determine the restriction across the engine oil filters. The sensor output is a DC
voltage that varies with unfiltered engine oil pressure between 0.2 VDC and 4.8 VDC. The sensor is
located before the engine oil filters in the oil passage of the engine oil filter housing. The operating
range of the sensor is 0.0 kPa to 1090 kPa (0.0 psi to 158 psi). The ECM calibrates the sensor within the
first five seconds after power is applied to the ECM. The ECM checks the sensor value against an
acceptable pressure range. If the pressure value is not in this range, the previous calibration will be used.
A manual calibration of the sensor should be done if the sensor or the ECM has been replaced. Refer to
Troubleshooting, "Anolog Sensor - Calibrate".

Left Turbocharger Compressor Inlet Pressure Sensor - The sensor is used in conjunction with the
Atmospheric Pressure Sensor to determine if the engine air filter is plugged. The sensor indicates if the
left turbocharger compressor inlet has a restriction. The sensor output is a DC voltage between 0.2 VDC
and 4.8 VDC that varies with left turbocharger compressor inlet pressure. The operating range of the
sensor is 0.0 kPa to 111 kPa (0.0 psi to 16 psi). The ECM calibrates the sensor within the first five
seconds after power is applied to the ECM. The ECM checks the sensor value against an acceptable
pressure range. If the pressure value is not in this range, the previous calibration will be used. A manual

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calibration of the sensor should be done if the sensor or the ECM has been replaced. Refer to
Troubleshooting, "Anolog Sensor - Calibrate".

Right Turbocharger Compressor Inlet Pressure Sensor - The sensor is used in conjunction with the
Atmospheric Pressure Sensor to determine if the engine air filter is plugged. The sensor indicates if the
right turbocharger compressor inlet has a restriction. The sensor output is a DC voltage between 0.2
VDC and 4.8 VDC that varies with right turbocharger compressor inlet pressure. The operating range of
the sensor is 0.0 kPa to 111 kPa (0.0 psi to 16 psi). The ECM calibrates the sensor within the first five
seconds after power is applied to the ECM. The ECM checks the sensor value against an acceptable
pressure range. If the pressure value is not in this range, the previous calibration will be used. A manual
calibration of the sensor should be done if the sensor or the ECM has been replaced. Refer to
Troubleshooting, "Anolog Sensor - Calibrate".

Turbocharger Compressor Outlet Pressure Sensor - The sensor is used to obtain boost pressure.
Boost pressure is used to control the ratio of fuel to air during acceleration. The ECM limits the amount
of fuel that is injected, based upon inlet manifold pressure. Information in the ECM defines the
relationship between the manifold pressure and the fuel ratio control limit (FRC). The operation is
similar to the fuel ratio control on an engine with a mechanical governor. The sensor output is a DC
voltage between 0.2 VDC and 4.8 VDC that varies with turbocharger outlet pressure. The operating
range of the sensor is 0.0 kPa to 452 kPa (0.0 psi to 65 psi). The ECM calibrates the sensor within the
first five seconds after power is applied to the ECM. The ECM checks the sensor value against an
acceptable pressure range. If the pressure value is not in this range, the previous calibration will be used.
A manual calibration of the sensor should be done if the sensor or the ECM has been replaced. Refer to
Troubleshooting, "Anolog Sensor - Calibrate".

Atmospheric Pressure Sensor - The sensor is used to provide an atmospheric pressure signal to the
ECM. If the Atmospheric Pressure Sensor should fail, the Right Turbocharger Compressor Inlet
Pressure Sensor is used as a substitute. If the Right Turbocharger Compressor Inlet Pressure Sensor
should fail, the Left Turbocharger Compressor Inlet Pressure Sensor is used as a substitute. The sensor
output is a DC voltage between 0.2 VDC and 4.8 VDC that varies with atmospheric pressure. The
operating range of the sensor is 0.0 kPa to 111 kPa (0.0 psi to 16 psi). The sensor is used to calibrate the
other pressure sensors within the first five seconds after power is applied to the ECM. The ECM checks
the sensor value against an acceptable pressure range. If the pressure value is not in this range, a
diagnostic message will be generated and the engine may be derated. A manual calibration of the sensor
should be done if the sensor or the ECM has been replaced. Refer to Troubleshooting, "Anolog Sensor -
Calibrate".

Crankcase Pressure Sensor - The sensor is used in conjunction with the Atmospheric Pressure Sensor
to determine if the engine crankcase pressure is too high. The Atmospheric pressure is subtracted from
the Absolute crankcase pressure. The difference between the Atmospheric pressure and the Absolute
crankcase pressure is the Differential Crankcase Pressure. The sensor output is a DC voltage between
0.2 VDC and 4.8 VDC that varies with crankcase pressure. The operating range of the sensor is 0.0 kPa
to 111 kPa (0.0 psi to 16 psi). The ECM calibrates the sensor within the first five seconds after power is
applied to the ECM. The ECM checks the sensor value against an acceptable pressure range. If the
pressure value is not in this range, the previous calibration will be used. A manual calibration of the
sensor should be done if the sensor or the ECM has been replaced. Refer to Troubleshooting, "Anolog
Sensor - Calibrate".

Note: The Generator Set has a jumper wire between terminals 6 and 9 on the Engine Control Switch
(ECS). This jumper wire provides power to the Generator Set Control (GSC+) when the battery
disconnect switch is closed and the ECS is in the OFF/RESET position. Unless a timer is installed in the

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circuit, this jumper wire also provides power to the key switch input of the engine ECM when the
battery disconnect switch is closed and the ECS is in the OFF/RESET position. The timer interrupts
power to the key switch input of the engine ECM when the battery disconnect switch is closed and the
ECS is in the OFF/RESET position. Cycling power to the key switch input of the ECM will reset the
ECM and all active diagnostic codes. The bottom dial on the timer should be set to 0.7. The middle dial
on the timer should be set to 3 seconds. The top dial on the timer should be set to E.

Illustration 1 g00599048
Schematic

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Test Step 1. Check for Connector Damage.

A. Turn the Engine Control Switch (ECS) to the OFF/RESET position.

B. Turn the battery disconnect switch to the OFF position.

C. Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors.
Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for
details.

D. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated
with the circuit.

E. Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).

F. Check the customer connector (allen head screw) for the proper torque of 2.25 ± 0.25 N·m (20 ± 2
lb in).

G. Check the harness and the wiring for abrasion and for pinch points.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should
be free of corrosion, of abrasion or of pinch points.

Results:

z OK - The connectors and wiring are okay. Proceed to test step 2.

z Not OK - The connectors and/or wiring are not okay.

Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

Stop.

Test Step 2. Check for a Short Circuit in the Harness.

A. Disconnect ECM connector J1/P1. Disconnect all of the analog sensors.

B. Measure the resistance between the analog supply P1-36 and the analog return P1-30.

C. Measure the resistance between the analog supply P1-36 and the engine ground.

D. Measure the resistance between the analog return P1-30 and the engine ground.

Expected Result:

The resistance should be more than 20,000 Ohms for each measurement.

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Results:

z OK - The resistance is greater than 20,000 Ohms. Proceed to test step 3.

z Not OK - The resistance is less than 20,000 Ohms.

Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

Stop.

Test Step 3. Check the Analog Sensor Supply Voltage at the ECM.

A. Remove the wire P1-36 from the ECM connector P1. Install a jumper wire into the socket for P1-
36.

B. Remove the wire P1-30 from the ECM connector P1. Install a jumper wire into the socket for P1-
30.

Note: If you remove the sensor common from the ECM, an open circuit diagnostic code will be
generated for all sensors that use the sensor common. Troubleshoot the original code. Delete the
logged diagnostic codes when you are finished.

C. Turn the battery disconnect switch to the ON position.

D. Turn the ECS to the STOP position. The engine should be off.

E. Measure the voltage between the analog sensor supply P1-36 and the analog sensor return P1-30
at the wire jumpers.

F. Turn the ECS to the OFF/RESET position.

G. Turn the battery disconnect switch to the OFF position.

H. Remove the wire jumpers and reconnect J1/P1. Reconnect all wires.

Expected Result:

The analog supply voltage should be 5.0 ± 0.2 VDC.

Results:

z OK - The supply voltage is 5.0 ± 0.2 VDC. Proceed to test step 4.

z Not OK - The supply voltage is not 5.0 ± 0.2 VDC.

Repair: The analog supply voltage is not correct at the ECM. Perform the diagnostic functional
test Troubleshooting, "Electrical Power Supply".

Stop.

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Test Step 4. Check the Analog Sensor Supply Voltage at the Sensor Connector.

A. Turn the battery disconnect switch to the ON position.

B. Turn the ECS to the STOP position. The engine should be off.

C. Measure the voltage between socket A and socket B on the harness side of all analog sensor
connectors. Ensure that you are measuring on the harness side of the connector since the sensors
are disconnected.

Note: If the sensor is disconnected from the harness, an open circuit diagnostic code will be
generated for that sensor. Troubleshoot the original code. Delete the logged diagnostic codes
when you are finished.

D. Turn the ECS to the OFF/RESET position.

Expected Result:

The supply voltage should be 5.0 ± 0.2 VDC.

Results:

z OK - The supply voltage is 5.0 ± 0.2 VDC. Proceed to test step 5.

z Not OK - The supply voltage is not 5.0 ± 0.2 VDC. There is an open circuit in the harness or
connectors.

Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

Stop.

Test Step 5. Check the Analog Sensors for Short Circuits.

A. Turn the battery disconnect switch to the ON position.

B. Turn the ECS to the STOP position. The engine should be off.

C. Connect one analog sensor at a time.

Note: If the sensor is disconnected from the harness, an open circuit diagnostic code will be
generated for that sensor. Troubleshoot the original code. Delete the logged diagnostic codes
when you are finished.

D. Measure the analog sensor supply voltage between the analog supply P1-36 and the analog return
P1-30 at the ECM connector J1/P1. Repeat this step with all of the analog sensors.

E. Turn the ECS to the OFF/RESET position.

F. Turn the battery disconnect switch to the OFF position.

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Expected Result:

The supply voltage should be 5.0 ± 0.2 VDC after each analog sensor is connected.

Results:

z OK - The analog supply voltage is 5.0 ± 0.2 VDC when all of the sensors are connected. The
analog sensor supply and the harness are okay.

Repair: Reset the system and check for any diagnostic codes.

Stop.

z Not OK - The supply voltage is not 5.0 ± 0.2 VDC after a sensor is connected. The sensor may be
internally shorted.

Repair: Temporarily install a new sensor. Ensure that the problem is no longer present. Reinstall
the old sensor. If the problem returns, replace the sensor.

Stop.

z Intermittent - The problem is intermittent.

Repair: If the problem is intermittent, perform the diagnostic functional test Troubleshooting,
"Inspecting Electrical Connectors".

Stop.

Copyright 1993 - 2006 Caterpillar Inc. Thu Mar 2 15:35:03 CST 2006
All Rights Reserved.
Private Network For SIS Licensees.

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