320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0...

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Product: EXCAVATOR
Model: 320 EXCAVATOR YBP
Configuration: 320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine

Troubleshooting
C4.4 and C7.1 Engines
Media Number -UENR0629-28 Publication Date -01/09/2015 Date Updated -25/09/2018

i06198669

Sensor Signal (Analog, Active) - Test

SMCS - 1439-038

This procedure covers the following diagnostic codes:

Table 1
Diagnostic Trouble Codes
J1939 CDL
Code Description Comments
Code Code
The Electronic Control Module (ECM) detects the
following conditions:

The signal voltage from the engine oil pressure sensor is

greater than 4.8 VDC for more than 8 seconds.
Engine Oil Pressure
100-3 100-3 Sensor : Voltage
The warning lamp will come on. The ECM will log the
Above Normal
diagnostic code. The ECM will set data for engine oil
pressure to the default value. The default engine oil
pressure is 600 kPa (87 psi). The electronic service tool
will display "Voltage Above Normal" on the status
screens.
100-4 100-4 Engine Oil Pressure The ECM detects the following conditions:
Sensor : Voltage
Below Normal The signal voltage from the engine oil pressure sensor is
less than 0.2 VDC for more than 8 seconds.

The ECM has been powered for at least 2 seconds.

The warning lamp will come on. The ECM will log the

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diagnostic code. The ECM will set data for the engine oil
pressure to the default value. The default engine oil
pressure is 600 kPa (87 psi). The electronic service tool
will display "Voltage Below Normal" on the status
screens.
The ECM detects the following conditions:

The signal voltage for the fuel rail pressure sensor is

more than 4.7 VDC for 0.6 seconds.
Fuel Rail Pressure
1797-
157-3 Sensor : Voltage
3 The warning lamp will flash. The ECM will log the
Below Normal
diagnostic code. The electronic service tool will display
"70000 kPa" next to "Desired Fuel Rail Pressure" and
"Actual Fuel Rail Pressure" on the status screens.
The engine will be derated.
The ECM detects the following conditions:

The signal voltage for the fuel rail pressure sensor is less
than 0.67 VDC for 0.6 seconds.
Fuel Rail Pressure
1797-
157-4 Sensor : Current The warning lamp will flash. The ECM will log the
4
Below Normal diagnostic code.
The electronic service tool will display "70000 kPa" next
to "Desired Fuel Rail Pressure" and "Actual Fuel Rail
Pressure" on the status screens.
The engine will be derated.
The ECM detects the following conditions:

The signal voltage from the intake manifold pressure

sensor is above 4.8 VDC for at least 8 seconds.

The ECM has been powered for 2 seconds.

The warning light will come on. The ECM will log the
Intake Manifold diagnostic code.
3563- 1785- Pressure Sensor : The data for the intake manifold pressure will be set to a
3 3 Voltage Above maximum valid pressure for 2 seconds. The ECM will
Normal then flag the intake manifold pressure as being invalid. A
default value is then used for the intake manifold
pressure.
The current for the wastegate solenoid will be set to a
default value while this code is active. This condition
will cause the engine to have poor acceleration. The
default setting will prevent any overpressure in the
intake manifold which could be caused by an overspeed
of the turbocharger.

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3563- 1785- Intake Manifold The ECM detects the following conditions:
4 4 Pressure Sensor :
Voltage Below The signal voltage from the intake manifold pressure
Normal sensor is less than 0.2 VDC for at least 8 seconds.

The ECM has been powered for 2 seconds.

The warning light will come on. The ECM will log the
diagnostic code.
The data for the intake manifold pressure will be set to a
maximum valid pressure for 2 seconds. The ECM will
then flag the intake manifold pressure as being invalid. A
default value is then used for intake manifold pressure.
The current for the wastegate solenoid will be set to a
default value while this code is active. This condition
will cause the engine to have poor acceleration. The
default setting will prevent any overpressure in the
intake manifold which could be caused by an overspeed
of the turbocharger.
The Electronic Control Module (ECM) detects the
following conditions:

Fuel Pressure Sensor The signal voltage from the secondary fuel filter inlet
- Before Fuel Filter : pressure sensor is greater than 4.8 VDC for more than 8
- 289-3
Voltage Above seconds.
Normal
The warning lamp will come on. The ECM will log the
diagnostic code. The electronic service tool will display
"Voltage Above Normal" on the status screens.
The ECM detects the following conditions:

The signal voltage from the secondary fuel filter inlet

pressure sensor is less than 0.2 VDC for more than 8
Fuel Pressure Sensor
seconds.
- Before Fuel Filter :
- 289-4
Voltage Below
The ECM has been powered for at least 2 seconds.
Normal
The warning lamp will come on. The ECM will log the
diagnostic code. The electronic service tool will display
"Voltage Below Normal" on the status screens.
- 460-3 Fuel Pressure Sensor The Electronic Control Module (ECM) detects the
- After Fuel Filter : following conditions:
Voltage Above
Normal The signal voltage from the secondary fuel filter outlet
pressure sensor is greater than 4.8 VDC for more than 8
seconds.

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The warning lamp will come on. The ECM will log the
diagnostic code. The electronic service tool will display
"Voltage Above Normal" on the status screens.
The ECM detects the following conditions:

The signal voltage from the secondary fuel filter outlet

pressure sensor is less than 0.2 VDC for more than 8
Fuel Pressure Sensor
seconds.
- After Fuel Filter :
- 460-4
Voltage Below
The ECM has been powered for at least 2 seconds.
Normal
The warning lamp will come on. The ECM will log the
diagnostic code. The electronic service tool will display
"Voltage Below Normal" on the status screens.
The Electronic Control Module (ECM) detects the
following conditions:

Fuel Transfer Pump The signal voltage from the primary fuel filter outlet
2247- Intake Pressure pressure sensor is greater than 4.8 VDC for more than 8
-
3 Sensor : Voltage seconds.
Above Normal
The warning lamp will come on. The ECM will log the
diagnostic code. The electronic service tool will display
"Voltage Above Normal" on the status screens.
The ECM detects the following conditions:

The signal voltage from the primary fuel filter outlet

pressure sensor is less than 0.2 VDC for more than 8
Fuel Transfer Pump
seconds.
2247- Intake Pressure
-
4 Sensor : Voltage
The ECM has been powered for at least 2 seconds.
Below Normal
The warning lamp will come on. The ECM will log the
diagnostic code. The electronic service tool will display
"Voltage Below Normal" on the status screens.
Follow the troubleshooting procedure in order to identify the root cause of the fault.

The following conditions must exist before any of the above codes will become active:

• There are no active 262 codes.

• There are no active 168 codes.

The following background information is related to this procedure:

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The 5 VDC sensor supply provides power to all 5 VDC sensors. The ECM supplies 5 VDC to
terminal "3" of the fuel rail pressure sensor connector and to terminal "1" of all other pressure sensor
connectors. The sensor common from the ECM connector goes to terminal "1" of the connector for
the fuel rail pressure sensor. The sensor common from the ECM connector goes to terminal "2" of all
other pressure sensor connectors. The sensor supply is output short circuit protected. A short circuit to
the battery will not damage the circuit inside the ECM.

Pull-up Voltage

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 a
voltage above a threshold on the signal circuit, an open circuit diagnostic code (XXXX-3) is
generated for the sensor.

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

Illustration 1 g03506662
Schematic for the pressure sensors on the P1 connector
Not all connectors are shown. Refer to the Electrical Schematic for the application.

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Illustration 2 g03374199
Schematic for the pressure sensors on the P2 connector

Illustration 3 g03506663
Pin locations on the P1 connector for the pressure sensors
(33) Fuel pressure sensor ground
(42) Fuel pressure sensor 5 VDC supply
(54) Inlet fuel pressure sensor signal

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(55) Outlet fuel pressure sensor signal

(56) Primary fuel pressure sensor signal

Illustration 4 g03374218
Pin locations on the P2 connector for the pressure sensors
(38) Intake manifold pressure sensor ground
(39) Oil pressure sensor ground
(40) Fuel rail pressure sensor ground
(46) Intake manifold pressure sensor 5 VDC supply
(47) Oil pressure sensor 5 VDC supply
(48) Fuel rail pressure sensor 5 VDC supply
(49) Fuel rail pressure sensor signal
(55) Intake manifold pressure sensor signal
(56) Oil pressure sensor signal

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Illustration 5 g03374231
Fuel rail pressure sensor
(1) Ground
(2) Signal
(3) 5 VDC Supply

Illustration 6 g01170310
Typical example of an engine pressure sensor
(1) 5 VDC Supply
(2) Ground
(3) Signal

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Table 2
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Codes

Result: A -3 diagnostic code is
active.
A. Establish communication between the
electronic service tool and the ECM . Refer to
Proceed to Test Step 2.
Troubleshooting, "Electronic Service Tools", Diagnostic
if necessary. code
Result: A -4 diagnostic code is
active.
B. Turn the keyswitch to the ON position.
Proceed to Test Step 3.
C. Look for a -3, or -4 active or logged codes:

2. Create a Short at the Sensor Connector Result: A -4 diagnostic code

became active after creating the
A. Use a jumper wire in order to create a short short at the sensor connector.
between the signal terminal and the ground
terminal at the sensor connector. The wiring is OK. Replace the
sensor.
Short
B. Turn the keyswitch to the ON position. Verify that the problem is resolved.
created
C. Monitor the diagnostic codes on the Result: A -4 diagnostic code does
electronic service tool. Check for an active -4 not become active for the suspect
diagnostic code for the suspect sensor. sensor.

D. Turn the keyswitch to the OFF position. Proceed to Test Step 4.

3. Create an Open at the Suspect Sensor Create an Result: A -3 diagnostic code

Connector Open became active after disconnecting
the sensor.
A. Turn the keyswitch to the OFF position.
The wiring is OK. Replace the
B. Disconnect the sensor connector of the sensor.
suspect sensor with the active -4 diagnostic
code. Verify that the problem is resolved.

C. Turn the keyswitch to the ON position. Result: A -3 diagnostic code did not
became active after disconnecting
D. Monitor the diagnostic codes on the the sensor.
electronic service tool. Check for an active -3
diagnostic code for the suspect sensor. Proceed to Test Step 4.

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E. Turn the keyswitch to the OFF position.

Result: The supply voltage is

approximately 5.0 ± 0.2 VDC

Connect the sensor and then proceed

4. Check the 5 VDC Supply Voltage at the
to Test Step 5
Sensor Connector
Result: The supply voltage is not
A. Turn the keyswitch to the ON position.
Test approximately 5.0 ± 0.2 VDC.
passed
B. Measure the voltage between the sensor
There is a short in the harness to the
supply pin and the sensor return pin at the
battery. Repair the wiring or replace
suspect sensor.
the harness

Verify that the problem is resolved.

STOP

5. Perform the Wiggle Test Test Result: The wiring failed the
passed Wiggle Test.
Carefully following this procedure is the best
way to identify the root cause of an There is a problem with the wiring.
intermittent problem. Repair the wiring or replace the
wiring.
A. Turn the keyswitch to the ON position.
Verify that the problem is resolved.
B. Use the electronic service tool to run the
"Wiggle Test". STOP

C. Slowly wiggle the wiring and the Result: The wiring passed the
connectors between the P2 connector and the Wiggle Test.
sensor. Pay particular attention to the wiring
near each connector. Be sure to wiggle all of The problem may be intermittent.
the wiring. Inspect the wiring. Refer to
As you wiggle the wiring look for these Troubleshooting, "Electrical
problems. Connectors - Inspect".
1. Loose connectors or damaged connectors
2. Moisture on the connectors or the wiring If the wiring looks OK perform the
3. Damaged that is caused by excessive heat following procedure.
4. Damage that is caused by chafing
5. Improper routing of wiring 1. Turn the keyswitch to the OFF
6. Damaged insulation position.
2. Disconnect the connectors.
Carefully inspect the terminals for
proper installation. Make sure that
each terminal is clean and dry.

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3. Insert a pin into each socket.

Verify that each socket grips the pin
firmly. Repair any problems.
4. Connect all connectors.
5. Verify that the problem is
resolved.
6. Return the unit to service.
STOP

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