Troubleshooting

C4.4 Engines For Caterpillar Built Machines

Media Number -KENR6949-08 Publication Date -01/11/2012 Date Updated -11/02/2016

i05207627

Engine Speed/Timing Sensor Circuit - Test

SMCS - 1912-038

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System Operation Description:

Use this procedure to troubleshoot the system under the following conditions:

 Use this procedure if another procedure has directed you here.

 The engine will not start and the electronic service tool indicates a faulty sensor
by displaying "Not Detected" against the faulty sensor on the "No Start
Parameter" screen.
 There is an active diagnostic code or a recently logged diagnostic code that is
related to the following:

 0190-08 Engine Speed Sensor abnormal frequency, pulse width, or period

 0342-08 Secondary Engine Speed Sensor abnormal frequency, pulse width, or
period
 0261-11 Engine Timing Offset fault

The engine uses two engine speed/timing sensors. The primary speed/timing sensor is
located on the left-hand side of the cylinder block close to the flywheel housing. The
secondary speed/timing sensor is part of the fuel rail pump. The primary speed/timing
sensor generates a signal by detecting the movement of the teeth on the crankshaft
timing ring. The crankshaft timing ring is connected to the crankshaft. The signal that is
generated by the speed/timing sensor is transmitted to the Electronic Control Module
(ECM). The ECM uses the signal from the speed/timing sensor to calculate the position
of the crankshaft. The signal is also used to determine the engine speed.

The secondary speed/timing sensor is located in the fuel rail pump. The secondary
speed/timing sensor generates a signal that is related to the camshaft position. The fuel
rail pump is mechanically connected to the camshaft. The secondary speed/timing
sensor detects the movement of the teeth on the timing ring in the fuel rail pump. The
signal that is generated by the speed/timing sensor is transmitted to the ECM. The ECM
calculates the speed and the rotational position of the engine by using the signal. The
secondary speed/timing sensor is required for starting purposes.

During normal operation, the secondary speed/timing sensor is used to determine the
cycle that the engine is on. When the timing has been established, the primary
speed/timing sensor is then used to determine the engine speed and the angular position.
The loss of signal to the primary sensor and/or the secondary sensor will result in one of
the following faults:

 A loss of signal from the secondary speed/timing sensor during start-up will
prevent the engine from starting.
 A loss of signal from the secondary speed/timing sensor during operation of the
engine will result in the engine being derated.
 The engine will continue to run normally when only the signal from the
secondary speed/timing sensor is present.
 A loss of signal from both of the sensors during engine operation will cause fuel
injection to be terminated and the engine will stop.

The primary sensor and the secondary sensor are interchangeable components. If a
sensor is suspect, the sensors can be exchanged in order to eliminate a fault. If a
secondary sensor is suspect and a replacement secondary sensor is not available, then
the primary sensor and the secondary sensor can be exchanged. The exchange will allow
testing to determine if the secondary sensor is faulty.

Table 1
P2/J2 Pin Connections

Sensor Crankshaft Primary Camshaft Secondary

Function
Pin Sensor Sensor

+8 VDC
1 10 10
Supply

Signal 2 52 53

View Image
Illustration 1 g01458747
Schematic for the speed/timing sensors

View Image
Illustration 2 g01458749
Pin locations on the P2 connector for the speed/timing sensors

(10) Speed/ Timing sensor supply (8 VDC)

(52) Crankshaft speed timing sensor signal

(53) Pump/Cam speed sensor signal (Sig)

View Image
Illustration 3 g01458756
Typical view of the sensor locations on a C4.4 engine

(1) Primary speed/timing sensor

(2) Secondary speed/timing sensor

View Image
Illustration 4 g01458829
Detailed view of the sensor locations on a C4.4 engine

(1) Primary speed/timing sensor

(2) Secondary speed/timing sensor

View Image
Illustration 5 g01212995
Typical example of the speed/timing sensor

(1) Voltage Supply (8 VDC)

(2) Signal (Sig)

Test Step 1. Inspect the Electrical Connectors and the Harness

A. Turn the keyswitch to the OFF position.

B. Inspect the connectors for the speed/timing sensors. Refer to Troubleshooting,

"Electrical Connectors - Inspect".

C. Perform a 45 N (10 lb) pull test on each of the wires in the suspect sensor
connector and the sensor connections at the ECM.

D. Check that the ground connection on the ECM and the negative terminal on the
battery are correctly installed.

E. Check the ground connection on the ECM for abrasions and pinch points.

F. Check the screws for the ECM connector for the correct torque of 5 N·m (44 lb
in).

G. Check the harness for abrasion and pinch points from the suspect sensor to the
ECM.
 H. Check that the suspect sensor is installed correctly. Check that the suspect sensor
is fully seated into the engine. Check that the sensor is securely latched.

Expected Result:

The electrical connectors and the cables are correctly installed.

Results:

 The harness is OK. - Proceed to Test Step 2.

 Not OK -

Repair: Repair the faulty connectors or the harness and/or replace the faulty
connectors or the harness. Ensure that all of the seals are correctly in place and
ensure that the connectors are correctly coupled.If the primary speed/timing
sensor must be replaced or the sensor must be reinstalled, refer to Disassembly
and Assembly, "Crankshaft Position Sensor - Remove and Install". If the
secondary speed/timing sensor must be replaced or the sensor must be
reinstalled, refer to Disassembly and Assembly, "Position Sensor (Fuel Injection
Pump) - Remove and Install".Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the repair has eliminated the fault.

STOP

Test Step 2. Check for Active Diagnostic Codes and Recently Logged Diagnostic
Codes

A. Turn the keyswitch to the OFF position.

B. Connect the electronic service tool to the diagnostic connector.

C. Turn the keyswitch to the ON position. If the engine will start, then run the
engine.

D. Use the electronic service tool in order to monitor active diagnostic codes or
recently logged diagnostic codes.

Results:

 Diagnostic code 0190-08 is active or recently logged. - Proceed to Test Step 6.

 Diagnostic code 0342-08 is active or recently logged. - Proceed to Test Step 6.
 Diagnostic code 0261-11 is active or recently logged. - Proceed to Test Step 3.
 No active diagnostic codes or recently logged diagnostic codes are displayed.
-

STOP

Test Step 3. Inspect the Sensors

 A. Ensure that the speed/timing sensors are correctly seated in the cylinder block
and that the retaining bolts are tightened to a torque of 22 N·m (16 lb ft). Ensure
that the speed/timing sensors are not damaged.

Replace any damaged sensors. Refer to Disassembly and Assembly, "Crankshaft

Position Sensor - Remove and Install" or refer to Disassembly and Assembly,
"Position Sensor (Fuel Injection Pump) - Remove and Install".

B. Use the electronic service tool to check if the 0261-11 diagnostic code is still
active.

Results:

 A 0261-11 diagnostic code is still active at this time. - Proceed to Test Step 5.
 A 0261-11 diagnostic code is not active at this time. - Use the electronic
service tool to clear all logged diagnostic codes and verify that the repair
eliminates the fault.STOP

Test Step 4. Check the Timing of the Fuel Injection Pump

A. Check the timing of the fuel injection pump. Refer to Systems Operation,
Testing and Adjusting, "Fuel Injection Timing - Check".

Results:

 OK - The timing of the fuel pump is correct. Proceed to Test Step 5.

 Not OK - The timing of the fuel pump is incorrect.

Repair: Adjust the timing of the fuel pump. Refer to Systems Operation,
Testing and Adjusting, "Fuel Injection Timing - Check" for the correct
procedure.Use the electronic service tool to clear all logged diagnostic codes and
verify that the repair eliminates the fault.

STOP

Test Step 5. Check the Crankshaft Timing Ring

A. Remove the primary speed/timing sensor. Refer to Disassembly and Assembly,

"Crankshaft Position Sensor - Remove and Install".

B. Use a flashlight in order to check the crankshaft timing ring for damaged teeth
or missing teeth. Ensure that the crankshaft timing ring has not been displaced
from the crankshaft.

Results:

 Found fault with the crankshaft timing ring or the timing ring on the
camshaft -
 Repair: If necessary, replace the crankshaft timing ring. Refer to Disassembly
and Assembly, "Crankshaft Timing Ring - Remove and Install" .Use the
electronic service tool in order to clear all logged diagnostic codes and then
verify that the repair has eliminated the fault.

STOP

 No faults found - Repeat this procedure from Test Step 3.

Test Step 6. Measure the Supply Voltage at the Sensor Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the speed/timing sensor with the active diagnostic code.

C. Measure the voltage from terminal 1 on the sensor connector to engine ground.

Note: The voltage should read 7.5 to 8.5 VDC.

Expected Result:

The readings agree with the values that are listed above.

Results:

 OK - The sensor is receiving the correct supply voltage. Proceed to Test Step 7.
 Not OK - The fault is in the harness.

Repair: Repair the faulty connectors or the harness. Replace the faulty
connectors or the harness. Reconnect all sensor and ECM connectors. Ensure
that all of the seals are correctly in place. Ensure that all connectors are correctly
coupled.Use the electronic service tool in order to clear all logged diagnostic
codes and then verify that the repair has eliminated the fault.

STOP

Test Step 7. Exchange the Sensors

A. Turn the keyswitch to the OFF position.

B. Exchange the primary speed/timing sensor with the secondary speed/timing

sensor. Refer to Disassembly and Assembly, "Crankshaft Position Sensor -
Remove and Install" and refer to Disassembly and Assembly, "Position Sensor
(Fuel Injection Pump) - Remove and Install".

C. Turn the keyswitch to the ON position.

D. Start the engine.

 E. Use the electronic service tool to check for active diagnostic codes. Wait for 30
seconds in order for diagnostic codes to become active.

Expected Result:

One of the following conditions exists:

 A 0190-08 diagnostic code was previously active. A 0342-08 diagnostic code is

now active.
 A 0342-08 diagnostic code was previously active. A 0190-08 diagnostic code is
now active.

Results:

 OK - The active diagnostic code is now for the other speed/timing sensor.

Repair: Perform the following repair:

1. Turn the keyswitch to the OFF position.

2. Disconnect the suspect sensor and remove the suspect sensor from the
engine.

3. Install a replacement sensor. Refer to Disassembly and Assembly,

"Crankshaft Position Sensor - Remove and Install" or refer to
Disassembly and Assembly, "Position Sensor (Fuel Injection Pump) -
Remove and Install".

4. Turn the keyswitch to the ON position.

5. Start the engine.

6. Use the electronic service tool to clear all logged diagnostic codes and
verify that the repair eliminates the fault.

STOP

 Not OK - The diagnostic code that was previously active is still active. Proceed
to Test Step 8.

Test Step 8. Bypass the Signal Wire for the Speed/Timing Sensor

A. Turn the keyswitch to the OFF position.

B. Disconnect the P2 connector. Disconnect the connector for the suspect

speed/timing sensor.

C. For a 0190-08 diagnostic code, remove the wire from P2:52. For a 0342-08
diagnostic code, remove the wire from P2:53.
 D. Remove the wire from terminal 2 of the connector for the suspect speed/timing
sensor.

E. Fabricate a jumper wire that is long enough to reach from the connector for the
suspect speed/timing sensor to the P2 connector.

F. Insert one end of the jumper wire into terminal 2 on the connector for the
suspect speed/timing sensor. Insert the other end of the jumper wire into the
terminal for the signal of the speed/timing sensor on the P2 connector.

G. Reconnect the P2 connector and the connector for the suspect speed/timing
sensor.

H. Turn the keyswitch to the ON position.

I. Start the engine.

J. Use the electronic service tool to check for active diagnostic codes. Wait for 30
seconds in order for diagnostic codes to become active.

Expected Result:

There are no active diagnostic codes.

Results:

 OK - The fault is in the harness.

Repair: Repair the faulty connectors or replace the faulty connectors. Repair the
faulty harness or replace the faulty harness. Reconnect all sensor and ECM
connectors. Ensure that all of the seals are correctly in place. Ensure that all
connectors are correctly coupled.Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that the repair eliminates the fault.

STOP

 Not OK - The XXXX-08 diagnostic code for the speed/timing sensor is still
active. Remove all jumper wires and replace all wires to the original
configuration. Proceed to Test Step 9.

Test Step 9. Check if the Replacement of the ECM Eliminates the Fault

A. Make sure that the latest flash file for the application is installed in the ECM.
Refer to Troubleshooting, "Flash Programming".

B. Contact the Technical Communicator.

Note: This consultation can greatly reduce the repair time.

 C. If the Technical Communicator recommends the use of a test ECM, install a test
ECM. Refer to Troubleshooting, "Replacing the ECM".

D. Use the electronic service tool to recheck the system for active diagnostic codes.

Results:

 The fault is eliminated. -

Repair: Perform the following procedure:

1. Reconnect the suspect ECM.

2. If the fault returns with the suspect ECM, replace the ECM.

3. Use the electronic service tool in order to clear all logged diagnostic
codes and then verify that the repair eliminates the fault.

STOP

 The fault was not resolved with a test ECM. -

Repair: Repeat this diagnostic process from Test Step 1. If the fault persists, the
fault may be a damaged timing ring. Check the timing ring and/or replace the
timing ring. Refer to Disassembly and Assembly, "Crankshaft Timing Ring -
Remove and Install".Use the electronic service tool in order to clear all logged
diagnostic codes and then verify that the repair eliminates the fault.

STOP

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