Speed/Timing - Test...

3512B and 3512C

Petroleum Generator Set Engines
#i05178570 Caterpillar

Usage:
3512B LDE 3512B LDF 3512C LDJ

Use this procedure to troubleshoot the electrical system if a problem is suspected with
one or more of the engine speed/timing sensors. Also, use this procedure if any of the
diagnostic codes in Table 1 is active.

Table 1

Diagnostic Codes Table

CDL Code and Conditions which

System Response
Description Generate the Code

The engine speed from this

190-8 Engine Speed The Electronic Control sensor is ignored.
Sensor : Abnormal Module (ECM) detects The code is active.
Frequency, Pulse Width, an abnormal signal The code is logged if the
or Period frequency. pattern from the timing ring
returns for 5 seconds.

The code is latched in the

active state until the power to
the ECM is cycled.
The offset for the timing
723-8 Engine Speed
The ECM detects an calibration is set to zero while
Sensor #2 : Abnormal
abnormal signal the diagnostic code is active.
Frequency, Pulse Width,
frequency. The sensor is ignored. The
or Period
engine speed is calculated by
using only the signal from the
primary speed/timing
sensor.

The ECM provides the engine speed/timing sensors with a regulated voltage of 8.0 ±
0.5 VDC. The engine speed/timing sensors provide a pulse signal to the ECM. The
signal is created as the timing reference gear rotates past the pickup of the engine
speed/timing sensors. The timing reference gear is mounted on the rear of the left
camshaft. A unique tooth pattern on the timing reference gear allows the ECM to
determine the crankshaft position, rotation, and rpm.

The engine speed/timing sensors generate a pulse signal to the ECM as each tooth
passes the sensors. The ECM counts the pulses in order to determine the engine rpm.
The ECM memorizes the pattern of the pulses. The ECM compares that pattern to a
standard pattern in order to determine the crankshaft position. The ECM uses this
information to determine the position of the No. 1 cylinder. The ECM then triggers
each unit injector to fire in the correct firing order and at the correct time. The actual
timing and duration of each injection is determined by the ECM. The ECM uses
engine rpm and engine load to determine the timing and duration of injection. The
loss of a signal from an engine speed/timing sensor generates a diagnostic on
Caterpillar Electronic Technician (ET). If the signals from both the primary engine
speed/timing sensor and the secondary engine speed/timing sensor are lost, the ECM
will terminate fuel injection.

Under normal operation, the ECM utilizes the signal from the primary speed/timing
sensor to determine the crankshaft position for an accurate fuel delivery and timing.
This feature eliminates the need for a separate procedure for timing calibration. A
timing offset is determined during each engine start-up. The value of the timing offset
is stored in the non-volatile memory of the ECM until the successful completion of
the next engine start-up. If a failure mode for the primary engine speed/timing sensor
is detected during engine start-up, timing calibration is aborted. The value of the
timing offset stored in ECM memory will be used. This value will continue to be used
for the engine timing calibration until the diagnostic is resolved. A timing calibration
cannot be performed manually on this engine.
Illustration 1 g03321450
Schematic for the engine speed/timing sensor and timing calibration probe
Illustration 2 g03321493
Terminal locations at the P1 ECM connector
Illustration 3
Left side view
(1) Engine speed/timing sensor
Troubleshooting Test Steps
1. Check for Diagnostic Codes
A. Connect Cat ET to the service
tool connector. Refer to
Troubleshooting, "Electronic
Service Tools", if necessary.
B. Restore electrical power to the
ECM.
C. Start the engine and run the
engine until the engine is at
normal operating temperature.
Note: If the engine will not start,
g01218411
Table 2
Values Results
Results: None of the diagnostic
codes that are listed above are active
or logged.
Repair: If the diagnostic codes that
are listed above are not active or
logged, and the engine is not
Codes running properly, refer to the
appropriate engine symptom in this
Troubleshooting manual.
Results: A 190-08 or a 723-08 code
is active or logged.
Proceed to Test Step 2.
monitor the engine rpm on Cat
ET while the engine is being
cranked. If necessary, power Cat
ET from another battery while
the engine is being cranked.
Results: No engine rpm. - Cat ET is
not reporting engine rpm for at least
one engine speed/timing sensor
while the engine is cranked.

E. Look for these codes on Cat Proceed to Test Step 3.

ET:

- 190-08
- 723-08

Results: The O-ring seals are

properly installed. The bracket and
the seals are free of damage.
2. Check the Installation of the
Sensor Assembly
Repair: Perform the following
procedure in order to install a sensor
A. Turn the main disconnect
assembly:
switch to the OFF position.
1. Lubricate the O-ring seals with
B. Visually inspect the sensors
oil.
without removing the sensor
assembly from the engine.
2. Fully seat the sensor into the
Verify that the bracket securely
housing.
holds the flange of the sensor
flush against the mounting
Note: If the sensor assembly will
surface.
not fully seat into the engine,
Verify that the bracket is not
replace the sensor assembly.
bent. If the bracket is bent or if an
Sensor
obstruction is preventing the
3. Tighten the bolts.
sensor assembly from being
installed correctly, the engine
4. Connect the connector.
will not start.
5. Ensure that the harness is
Note: The bracket cannot be
properly secured, and that the tie-
replaced separately.
wraps are placed in the correct
location.
C. Remove the suspect engine
speed/timing sensor from the
Proceed to Test Step 3.
engine.
Results: At least one of the sensor
D. Ensure that the O-ring seals
assembly components is not OK.
are installed and free of damage.
Repair: Install a new sensor
assembly.
Verify that the repair eliminated the
 problem.

3. Inspect the Electrical

Connectors and the Wiring

A. Turn the main disconnect

switch to the OFF position.

B. Thoroughly inspect the Results: The harness and the wiring

connectors. Refer to appear to be OK.
Troubleshooting, "Electrical
Connectors - Inspect" for details. Proceed to Test Step 4.

C. Perform a Results: There is a problem in the

45 N (10 lb) pull test on each of
the wires that are associated with
Circuit
the circuit for the engine
speed/timing sensors
D. Check the allen head screw for
each ECM connectors and the rail
connectors for the proper torque.
Refer to Troubleshooting,
"Electrical Connectors - Inspect"
for the correct torque values.
connectors and/or wiring.
Repair: Repair the connectors or
wiring and/or replace the connectors
or wiring. Ensure that all of the seals
for the connectors are properly in
place and ensure that the connectors
are coupled.
Verify that the repair eliminated the
problem.

E. Check the harness and wiring

for abrasion and for pinch points
from the engine speed/timing
sensors to the ECM.

4. Check the Supply Voltage to

the Sensors
Results: The battery voltage is OK.
A. Turn the main disconnect
switch to the OFF position.
Proceed to Test Step 5.
Supply
B. Disconnect the connectors for
voltage Results: The battery voltage is not
the speed/timing sensors.
OK.
C. Restore electrical power to the
Proceed to Test Step 7.
ECM. Measure the voltage
between terminal A and terminal
B at the sensor connectors.

5. Check the Signal Voltage at
the Sensor
A. Crank the engine and measure
the voltage between the sensor
signal wire and terminal B.
6. Check the Signal Voltage at
the ECM
A. Turn the main disconnect
switch to the OFF position.
B. Remove the signal wire from
the ECM connector P-53.
C. Restore electrical power to the
ECM.
D. Crank the engine and measure
the voltage between the sensor
signal wire and the sensor return.
E. Turn the main disconnect
switch to the OFF position.
F. Remove the signal wire from
the ECM connector P2-46.
G. Restore electrical power to the
ECM.
Results: The signal voltage is OK.
The voltage measures less than 3
VDC or more than 9 VDC when the
ECM is powered and the engine is
not cranking. While the engine is
cranking, the voltage is between 2
VDC and 7 VDC.
Proceed to Test Step 6.
Signal
voltage Results: The signal voltage is not
OK.
Repair: Replace the engine
speed/timing sensor. A timing
calibration is not required when the
sensors are replaced.
Verify that the repair eliminated the
problem.
Results: The signal voltage is OK.
The voltage measures less than 3
VDC or more than 9 VDC when the
ECM is powered and the engine is
not cranking. While the engine is
cranking, the voltage is between 2
VDC and 7 VDC.
Proceed to Test Step 7.
ECM
Results: The signal voltage is not
signal
OK. There is a problem in the
voltage
engine speed/timing circuit.
Repair: The problem is between the
ECM and the engine speed/timing
sensor. Repair the connectors and/or
wiring or replace the connectors
and/or wiring.
Verify that the repair eliminated the
problem.
 Results: The supply voltage is OK.
There is an open circuit or a short
circuit between the ECM and the
7. Check the Supply Voltage for
connectors for the engine
the Engine Speed/Timing
speed/timing sensors.
Sensor at the ECM
Repair: Repair the connectors
A. Turn the main disconnect
and/or wiring or replace the
switch to the OFF position.
connectors and/or wiring.
B. Remove the supply wire from
Verify that the repair eliminated the
ECM connector P1-51. Install a
problem.
wire jumper into the socket P1-
ECM
51.
supply Results: The supply voltage is not
voltage OK. There appears to be a problem
C. Reconnect ECM connector
with the ECM.
J1/P1.
Repair: Replace the ECM. Refer to
D. Restore electrical power to the
Troubleshooting, "Test ECM
ECM.
Mode".
Note: Before you consider replacing
E. Measure the supply voltage
the ECM, consult with the Dealer
between the wire in ECM
Solutions Network (DSN) for
connector P1-43 and the wire
assistance.
jumper in P1-51.
Verify that the repair eliminated the
problem.

If the procedure did not correct the issue, contact your Cat Dealer Technical
Communicator (TC). For further assistance, your TC can confer with the Dealer
Solutions Network (DSN).