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Product:  EXCAVATOR 
Model:  320D L EXCAVATOR KGF 
Configuration: 320D & 320D L Excavators KGF00001-UP (MACHINE) POWERED BY C6.4 Engine 

Troubleshooting
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR5342-21 Publication Date -01/11/2012 Date Updated -07/11/2012

i03706166

Sensor Signal (Analog, Active) - Test

SMCS - 1439-038

System Operation Description:

Use this procedure to troubleshoot the electrical system if a problem is suspected with the 5 volt
sensors or if any one of the diagnostic codes in Table 1 is active or easily repeated.

Table 1
Diagnostic Codes Table
Conditions which
Description System Response
Generate this Code
The code is logged.
94-3 Fuel Delivery The Electronic Control
If equipped, the warning light will
Pressure Sensor : Module (ECM) detects
illuminate.
Voltage Above Normal signal voltage above
The ECM will set the delivery pressure for
normal.
fuel to a default value.
The code is logged.
94-4 Fuel Delivery
The ECM detects signal If equipped, the warning light will
Pressure Sensor :
voltage that is below illuminate.
Voltage Below Normal
normal. The ECM will set the delivery pressure for
fuel to a default value.
95-3 Fuel Filter
The ECM detects signal The code is logged.
Differential Pressure
voltage that is above If equipped, the warning light will
Sensor : Voltage Above
normal. illuminate.
Normal
95-4 Fuel Filter
Differential Pressure

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Sensor : Voltage Below The ECM detects signal The code is logged.
Normal voltage that is below If equipped, the warning light will
normal. illuminate.
The ECM detects signal
voltage above normal for The code is logged.
100-3 Engine Oil
eight seconds. If equipped, the warning light will
Pressure Sensor :
The engine is not running illuminate.
Voltage Above Normal
or coolant temperature is The ECM will set engine oil pressure to a
greater than default value.
38 °C (100 °F).
The code is logged.
100-4 Engine Oil The ECM detects signal
If equipped, the warning light will
Pressure Sensor : voltage below normal for
illuminate.
Voltage Below Normal eight seconds.
The ECM will set engine oil pressure to a
The engine is running.
default value.
The code is logged.
460-3 Fuel Pressure
The ECM detects signal If equipped, the warning light will
Sensor - After Fuel
voltage that is above illuminate.
Filter : Voltage Above
normal. The ECM flags the fuel pressure as invalid
Normal
data.
The code is logged.
460-4 Fuel Pressure
The ECM detects signal If equipped, the warning light will
Sensor - After Fuel
voltage that is below illuminate.
Filter : Voltage Below
normal. The ECM flags the fuel pressure as invalid
Normal
data.
The code is logged.
If equipped, the warning light will
1785-3 Intake Manifold illuminate.
The ECM detects signal
Pressure Sensor : The ECM will set intake manifold (boost)
voltage above normal for
Voltage Above Normal pressure to a maximum valid pressure for
two seconds.
two seconds. The ECM will then set intake
manifold (boost) pressure to a default value.

The code is logged.

If equipped, the warning light will
1785-4 Intake Manifold illuminate.
The ECM detects signal
Pressure Sensor : The ECM will set intake manifold (boost)
voltage below normal for
Voltage Below Normal pressure to a maximum valid pressure for
two seconds.
two seconds. The ECM will then set intake
manifold (boost) pressure to a default value.

1797-3 Fuel Rail The ECM detects signal The code is logged.
Pressure Sensor : voltage above normal for If equipped, the warning light will
two seconds.

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Voltage Above Normal illuminate.

The engine will be derated.
1797-4 Fuel Rail The code is logged.
The ECM detects signal
Pressure Sensor : If equipped, the warning light will
voltage below normal for
Voltage Below Normal illuminate.
two seconds.
The engine will be derated.

The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The
ECM supplies 5.0 ± 0.2 VDC to terminal "A" of each sensor connector. The sensor return from the
ECM connector goes to terminal "B" of each sensor connector. The sensor supply is output short
circuit protected. A short circuit to the battery will not damage the circuit inside the ECM.

The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The ECM
uses this pull-up voltage in order to detect an open in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the signal circuit, the ECM will generate an open
circuit diagnostic code -3 for the sensor.

If the sensor is disconnected at the sensor connector, the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor connector to the ECM are not open or shorted to
ground. If the sensor is disconnected at the sensor connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire or a short to ground. If the sensor is
disconnected at the sensor connector and the voltage at the sensor connector is different from pull-up
voltage, the signal wire is shorted to another wire in the harness.

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Illustration 1 g01323297

Typical example of the schematic for the sensors

Illustration 2 g01170309

Typical pressure sensor

(1) Voltage supply

(2) Sensor return

(3) Signal

Illustration 3 g01325134

A typical view of the P2 connector (harness side) pin locations.

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(38) Intake manifold (boost) pressure sensor return

(39) Oil pressure sensor return

(40) Fuel rail pressure sensor return

(46) Intake manifold (boost) pressure sensor + 5V supply

(47) Oil pressure sensor + 5V supply

(48) Fuel rail pressure sensor +5V supply

(51) Fuel rail pressure sensor signal

(55) Intake manifold (boost) pressure sensor signal

(56) Oil pressure sensor signal

(54) Fuel filter differential pressure sensor signal

(50) Fuel pressure sensor signal

(39) Fuel filter differential pressure sensor return

(38) Fuel pressure sensor return

(47) Fuel filter differential pressure sensor + 5V supply

(46) Fuel pressure sensor + 5V supply

Illustration 4 g01345581

A typical view of the P2 connector (ECM side) pin locations.

Test Step 1. Inspect Electrical Connectors And Wiring.

A. Turn the keyswitch to the OFF position.

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Illustration 5 g01325579

Typical engine ECM

(1) J2 ECM connector

(2) J1 ECM connector

B. Thoroughly inspect the terminal connections on the P2/J2 ECM connectors. Thoroughly inspect
the connectors for each engine pressure sensor.

C. Refer to service Troubleshooting, "Electrical Connectors - Inspect".

D. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the engine pressure
sensors.

E. Check the torque of the allen head screws for the ECM connectors. Refer to service
Troubleshooting, "Electrical Connectors - Inspect".

F. Check the harness for abrasions and for pinch points from the sensors back to the ECM.

Expected Result:

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

Results:

• OK - The harness and wiring are OK. Proceed to Test Step 2.

• Not OK - There is a problem in the wiring and/or the connectors.

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Repair: Repair the connectors or the harness and/or replace the connectors or the harness.
Ensure that all of the seals are correctly in place and ensure that the connectors are completely
coupled.Verify that the problem is resolved.If applicable, use Caterpillar Electronic Technician
(ET) to perform a wiggle test.

STOP

Test Step 2. Check the Voltage on the +5 V Supply Wire

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connectors for the pressure sensors.

C. Turn the keyswitch to the ON position.

D. Measure the voltage between terminals 1 (+5 VDC) and 2 (Return) at each sensor connector on
the engine harness.

E. Turn the keyswitch to the OFF position.

F. Connect all of the sensors.

Expected Result:

Each voltage measurement is 5.0 ± 0.2 VDC.

Results:

• OK - Each voltage measurement is 5.0 ± 0.2 VDC. Proceed to Test Step 3.

• Not OK - At least one voltage measurement is not 5.0 ± 0.2 VDC.

Repair: Refer to the circuit test Troubleshooting, "Sensor Supply - Test".

STOP

Test Step 3. Check for Diagnostic Codes

A. Connect Cat ET to the service tool connector. Refer to the introduction Troubleshooting,
"Electronic Service Tools".

B. Turn the keyswitch to the ON position.

C. Check for active and/or for logged diagnostic codes on Cat ET. Wait at least 30 seconds so that
any codes may become active. Look for an active diagnostic code for an engine pressure sensor.

D. Determine if the problem is related to a -3 diagnostic code or a -4 diagnostic code.

Expected Result:

No diagnostic codes are active.

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Results:

• OK - No diagnostic codes are active for the engine pressure sensors.

Repair: If any of the above codes are logged and the engine is not running properly, refer to
troubleshooting without a diagnostic code Troubleshooting.If the engine is running properly at
this time, there may be an intermittent problem in a harness that is causing the codes to be
logged. Refer to service Troubleshooting, "Electrical Connectors - Inspect".

STOP

• Not OK - An -4 diagnostic code is active. Proceed to Test Step 4.

• Not OK - An -3 diagnostic code is active. Proceed to Test Step 5.

Test Step 4. Disconnect the Suspect Sensor in Order to Create an Open Circuit

A. Turn the keyswitch to the OFF position.

B. Disconnect the sensor connector of the sensor with the -4 diagnostic code.

C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic
codes.

D. Access the "Active Diagnostic Code" screen on Cat ET. Check for an active -3 diagnostic code
for the disconnected sensor.

E. Turn the keyswitch to the OFF position.

Expected Result:

A -3 diagnostic code is now active for the disconnected sensor.

Results:

• OK - A -4 diagnostic code was active before you disconnected the sensor. A -3 diagnostic code
became active after the sensor was disconnected. The harness and the ECM are OK. There may
be a problem with the sensor.

Repair: Connect a new sensor to the harness, but do not install the new sensor in the engine.
Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic
codes for the sensor, permanently install the new sensor. Clear any logged diagnostic
codes.Verify that the problem is resolved.

STOP

• Not OK - A -4 diagnostic code was active before you disconnected the sensor. The -4
diagnostic code remained after the sensor was disconnected. There is a problem with the
harness or the ECM. Leave the sensor disconnected. Proceed to Test Step 7.

Test Step 5. Check the Signal Wire for a Short Circuit

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A. Turn the keyswitch to the OFF position.

B. Disconnect the J2/P2 connector.

C. Disconnect the harness connector for the suspect sensor.

D. Identify the terminal for the suspect sensor signal wire on the ECM connector. Measure the
resistance between the terminal for the suspect sensor signal wire and the remaining terminals
on both ECM connectors.

E. Measure the resistance between the terminal for the suspect sensor signal wire and the engine
ground.

F. Connect the J2/P2 connector. Connect the connectors for the suspect sensor.

Expected Result:

Each resistance measurement indicates an open circuit.

Results:

• OK - Each resistance measurement indicates an open circuit. Proceed to Test Step 6.

• Not OK - At least one resistance measurement does not indicate an open circuit.

Repair: Repair the wiring and/or the connector. Replace parts, if necessary.Verify that the
problem is resolved.If applicable, use Cat ET to perform a wiggle test.

STOP

Test Step 6. Create a Short at the Suspect Sensor Connector

A. Turn the keyswitch to the OFF position.

B. Install a jumper wire with Deutsch sockets on each end between terminals 2 (Sensor return) and
3 (Signal) on the harness connector for the suspect sensor.

C. Turn the keyswitch to the ON position.

Note: Monitor the "Active Diagnostic Codes" screen on Cat ET before installing the jumper
wire and after installing the jumper wire.

D. Observe the "Active Diagnostic Codes" screen on Cat ET. Wait at least 30 seconds so that any
codes may become active. Look for a -4 diagnostic code.

E. Remove the jumper wire.

F. Turn the keyswitch to the OFF position.

Expected Result:

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A -4 diagnostic code was active when the jumper wire was installed. A -3 diagnostic code became
active when the jumper wire was removed.

Results:

• OK - A -4 diagnostic code was active when the jumper wire was installed. A -3 diagnostic code
became active when the jumper wire was removed. The engine harness and the ECM are OK.

Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in
the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active
diagnostic codes for the new sensor, permanently install the new sensor. Clear any logged
diagnostic codes.Verify that the problem is resolved.

STOP

• Not OK - A -4 diagnostic code was active when the jumper wire was installed. The -4 code
remained when the jumper wire was removed. There is a problem with the harness or with the
ECM. Proceed to Test Step 7.

Test Step 7. Check the Operation of the ECM

A. Turn the keyswitch to the OFF position.

B. Check the operation of the ECM by creating an open at the ECM:

a. Disconnect the appropriate ECM connector.

b. Remove the signal wire for the suspect sensor from the ECM connector.

c. Remove the return wire for the suspect sensor from the ECM connector.

Note: Disconnecting the return wire from the ECM will generate an open circuit
diagnostic code for all sensors that are connected to the return wire. Ignore the additional
codes. Troubleshoot the original diagnostic code and clear the codes when you are
finished.

d. Connect the ECM connector.

C. Turn the keyswitch to the ON position.

D. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds so that any
codes may become active.

A -3 diagnostic code should be active for the suspect sensor.

E. Turn the keyswitch to the OFF position.

F. Check the operation of the ECM by creating a short circuit at the ECM:

a. Disconnect the appropriate ECM connector.

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b. Install a jumper wire between the two terminals for the sensor's signal wire and the
sensor's return wire.

c. Connect the ECM connector.

G. Turn the keyswitch to the ON position.

H. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds so that any
codes may become active.

A short circuit diagnostic code -4 should be active when the wire jumper is installed.

I. Turn the keyswitch to the OFF position.

J. Remove the jumper wire. Return the wiring to the original configuration.

Expected Result:

A -3 diagnostic code was active when the signal wire was removed from the ECM connector. A -4
diagnostic code became active when the signal wire was connected to the return wire.

Results:

• OK - The ECM is operating properly. There is a problem in the wiring between the ECM and
the sensor connector.

Repair: If the code is only active for one sensor, the problem is most likely in the signal wire
for the sensor. Repair the signal wire and/or the connector. Replace parts, if necessary.Verify
that the problem is resolved.If applicable, use Cat ET to perform a wiggle test.

STOP

• Not OK - One of the following conditions exists: The -3 diagnostic code is not active when the
signal wire is disconnected. The -4 diagnostic code is not active when the wire jumper is
installed.

Repair: Replace the ECM. Refer to service Troubleshooting, "ECM - Replace". Verify that the
problem is resolved.

STOP

Copyright 1993 - 2021 Caterpillar Inc. Tue Oct 5 21:33:17 EST 2021 
All Rights Reserved.
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