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Troubleshooting
C-9 Engine for Caterpillar Built Machines
Media Number - SENR9506-00 Publication Date - 09/01/2001 Date Updated - 09/27/2001

i01593141

5 Volt Engine Pressure Sensor Supply Circuit - Test

SMCS - 1408-081; 1901-081

System Operation Description:

Use this procedure to troubleshoot the system when one of the following diagnostic codes is active,
or easily repeated:

! 262-03 5 Volt Sensor Supply short to +batt

! 262-04 5 Volt Sensor Supply short to ground

Also, use this procedure to troubleshoot the system when you have been directed here by another
troubleshooting procedure.

The Electronic Control Module (ECM) supplies regulated +5 VDC to the following sensors:

! J101/P101 Engine oil temperature sensor

! J200/P200 Turbocharger outlet pressure sensor

! J201/P201 Engine oil pressure sensor

! J203/P203 Atmospheric pressure sensor

! J204/P204 Injection actuation pressure sensor

! J208/P208 Fuel pressure sensor

The +5 V short circuit diagnostic code is probably caused by a short circuit or an open circuit in the
harness. The next probable cause is a sensor and the least probable cause is the ECM.

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Illustration 17 g00
+5 VOLT SENSOR LOCATIONS

Illustration 18 g00
+5 VOLT SUPPLY CIRCUIT

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Test Step 1. Inspect Electrical Connectors And Wiring.

Illustration 19 g00
Terminal locations for ECM

A. Turn the keyswitch to the OFF/RESET position.

B. Thoroughly inspect the following connections:

" ECM engine harness connector J2/P2

" ECM machine harness connector J1/P1

" Engine oil temperature sensor J101/P101

" Turbocharger outlet pressure sensor J200/P200

" Engine oil pressure sensor J201/P201

" Atmospheric pressure sensor J203/P203

" Injection actuation pressure sensor J204/P204

" Fuel pressure sensor J208/P208

Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

C. Thoroughly inspect ECM connector J1/P1, ECM connector J2/P2, machine connector J61/P61,
and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical
Connectors - Inspect" for details.

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Refer to Illustration 19.

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

E. Check the harness and wiring for abrasion and pinch points from the sensors back to the ECM.

Expected Result:

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

Results:

! OK - Proceed to Test Step 2.

! Not OK -

Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that
all of the seals are properly in place and ensure that the connectors are completely
coupled.Verify that the repair eliminates the problem.

Stop.

Test Step 2. Connect an Electronic Service Tool and Check for Active Diagnostic Codes.

A. Connect an electronic service tool to the cab data link connector.

B. Turn the keyswitch to the ON position while the engine is OFF.

C. Monitor the active diagnostic code screen of the electronic service tool. Check and record any
active diagnostic codes.

Note: Wait at least 15 seconds in order for the diagnostic codes to become active.

Expected Result:

Select the condition of the following codes:

! 262-03 5 Volt Sensor Supply short to +batt

! 262-04 5 Volt Sensor Supply short to ground

Results:

! Active - Proceed to Test Step 3.

! Logged ONLY - Proceed to Test Step 5.

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! Not Active or Logged - The +5 V supply is operating correctly at this time. Stop.

Test Step 3. Disconnect The ECM Engine Harness Connector From The ECM.

A. Connect an electronic service tool to the cab data link connector.

B. Turn the keyswitch to the OFF position while the engine is off.

C. Disconnect ECM engine harness connector J2/P2.

D. Turn the keyswitch to the ON position while the engine is OFF.

E. Access the active diagnostic code screen on the electronic service tool. Check for one of the
following active diagnostic codes:

" 262-03 5 Volt Sensor Supply short to +batt

" 262-04 5 Volt Sensor Supply short to ground

Note: When ECM engine harness connector J2/P2 is disconnected and the keyswitch is in the
ON position, open circuit diagnostic codes will be "Active" or "Logged" for all of the engine
sensors. This is normal.

Expected Result:

The +5 V diagnostic code is active when the ECM engine harness connector is disconnected.

Results:

! Yes - The +5 V diagnostic code is active when the ECM engine harness connector is
disconnected.

Repair: Temporarily connect a test ECM to ECM machine harness connector J1/P1. Recheck
for a +5 V diagnostic code. If a +5 V diagnostic code is not active, the original ECM is faulty.
Reconnect the original ECM and check the +5 V diagnostic codes. If a +5 V diagnostic code
becomes active, replace the ECM.

Stop.

! No - The +5 V sensor diagnostic code is no longer active when the harness is disconnected.
Either the harness or a sensor that is attached to the harness is causing the problem. Reconnect
the ECM engine harness connector.Proceed to Test Step 4.

Test Step 4. Disconnect The +5 V Sensors While Active Diagnostic Codes Are Being Monitored.

A. Connect an electronic service tool to the cab data link connector.

B. Turn the keyswitch to the ON position while the engine is OFF.

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C. Access the active diagnostic code screen on the electronic service tool. Verify that one of the
following diagnostic codes is active:

" 262-03 5 Volt Sensor Supply short to +batt

" 262-04 5 Volt Sensor Supply short to ground

D. Disconnect the following sensors one at a time:

" Engine oil temperature sensor J101/P101

" Turbocharger outlet pressure sensor J200/P200

" Engine oil pressure sensor J201/P201

" Atmospheric pressure sensor J203/P203

" Injection actuation pressure sensor J204/P204

" Fuel pressure sensor J208/P208

E. Wait for 30 seconds after each pressure sensor is disconnected while the electronic service tool
is being monitored in order to verify that the disconnection of a specific sensor deactivates the
+5 V diagnostic code.

Note: When the sensors are disconnected and the keyswitch is in the ON position, open circuit
diagnostic codes will be active or logged when the +5 V diagnostic codes are no longer active.
This is normal. Clear these diagnostic codes after this test step is completed.

Expected Result:

The original +5 V diagnostic code remains active.

Results:

! Yes - The +5 V diagnostic code is still active. The harness is the cause of the problem. Leave
the sensors disconnected. Proceed to Test Step 5.

! No - The +5 V diagnostic code is not active when a specific sensor is disconnected.

Repair: Reconnect the sensor that is suspected of causing the problem. If the problem returns
after the reconnection of the sensor, disconnect the sensor. If the problem disappears after the
disconnection of the sensor, replace the sensor.Clear all diagnostic codes. Verify that the repair
eliminates the problem.

Stop.

Test Step 5. Check the Engine Harness.

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Illustration 20 g00
Terminal locations for ECM

A. Turn the keyswitch to the OFF position while the engine is OFF.

B. Disconnect ECM connector J2/P2 and ECM J1/P1. Verify that all of the +5 V engine pressure
sensors that are attached to the ECM connectors are disconnected.

" Engine oil temperature sensor J101/P101

" Turbocharger outlet pressure sensor J200/P200

" Engine oil pressure sensor J201/P201

" Atmospheric pressure sensor J203/P203

" Injection actuation pressure sensor J204/P204

" Fuel pressure sensor J208/P208

C. Set a multimeter in order to measure the resistance on the range that is close to 20 Ohms, but
not less than 20 Ohms.

a. Measure the resistance from the ECM engine harness connector P2-2 (+5 V Engine
Pressure Sensor) to each of the following terminals:

# P2-14

# P2-16

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# P2-24

# P2-27

# P2-40

# P2-3

Refer to Illustration 20.

b. Wiggle the harness during the measurement in order to reveal any intermittent short
condition.

Expected Result:

Each resistance measurement is more than 20 Ohms.

Results:

! OK - The +5 V line is not shorted in the engine harness. Ensure that the engine harness is
connected to the ECM and that all of the sensors are reconnected. There does not appear to be
a problem at this time. Clear all diagnostic codes. Continue to troubleshoot until the original
condition is resolved. Stop.

! Not OK -

Repair: Replace the engine harness. Clear all logged diagnostic codes. Verify that the repair
eliminates the problem.

Stop.

Copyright 1993, 2002 Caterpillar Inc. Fri Jan 18 14:27:12 UTC-0200 2002
All Rights Reserved.
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