92323, 11:15AM sis20 Sensor Signal (Analog, Active) - Test - Sensors on the J2 connector (M0153279-02) SMCS - 1439 i09415440 This procedure covers the following diagnostic codes: Table 1 Diagnostic Codes for the Active Analog Sensors 41939 |cDL | Code Description (code descriptions Gode |Gode | may vary) Engine Oil Pressure : 100-3 | 100-3 | Voltage Above Normal Comments The Electronic Control Module (ECM) detects the following conditions: The signal voltage from the engine oil pressure sensor is greater than 4.95 VDC for more than 8 seconds. The ECM has been powered on for at least two seconds. The engine is not running or the engine coolant temperature is greater than 38 °C (100 °F). The ECM will log the diagnostic code. If equipped, the warning lamp will come on. The ECM will set data for engine oil pressure to the default value. Note: The engine oil pressure that is displayed on the electronic service tool is the default value for engine oil pressure. The default engine oil pressure is 600 kPa (87 psi). The electronic service too! will display "Voltage Above Normal on the status screens. 100-4 100-4 | Engine Oil Pressure Voltage Below Normal The ECM detects the following conditions: The signal voltage from the engine oil pressure sensor is less than 0.1 VDC for more than 8 seconds. ‘The ECM has been powered for at least 2 seconds. The engine is running The ECM will log the diagnostic code. If equipped, the warning lamp will come on. The ECM will set data for engine oil pressure to the default value. The electronic htps:ss2.cal.comit/rint previewiserviceld9de8701-0616-4aze-Bec3-tISScfOODbbE ana972323, 1115. AM sis20 service tool will display "Voltage Below Normal" on the status screens Engine Oil Pressure 100-10 | 100-10 | Abnormal Rate of Change The ECM detects the following conditions: No other codes for the oil pressure sensor are active. No 0262 diagnostic codes are active for the 5 Volt supply. The engine speed is greater than 600 rpm. The engine oil pressure signal is within the limits of 410 kPa (59 psi) to 520 kPa (75 psi) with a pressure variation of less than 1.68 kPa (0.25 psi) for more than 30 seconds. The engine oil pressure signal remains constant for 30 seconds. If equipped, the warning lamp willbe on. The ECM will log the diagnostic code. The ECM will flag the engine oil pressure as invalid data. The data for engine oil pressure is set to a default value of 500 kPa (72 psi). The electronic service tool will display "Conditions Not Met" on the status screen: Engine Intake Manifold #1 Absolute Pressure : Voltage Above Normal 102-3 | 1785-3 ‘The ECM detects the following conditions: The signal voltage from the intake manifold pressure sensor is above 4.95/VDC for at least 2 seconds. The ECM has been powered for’2 seconds. If equipped, the warning light will be on. The diagnostic code will be logged. The data for the intake manifold pressure will be set to a maximum valid pressure for two seconds. The ECM will 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 regulator 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. 102-4 | 1785-4 | Engine Intake Manifold #1 Absolute The ECM detects the following conditions: htpssss2.cal.comit/rint preview'serviceld9dc8701-2616-4a2e-Bec’-tI6ScfO0Dbb ana972323, 1115. AM Pressure : Voltage Below Normal sis20 The signal voltage from the intake manifold pressure sensor is less than 0.2 VDC for at least 2 seconds ‘The ECM has been powered for 2 seconds. The warming 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 regulator 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. Fuel Temperature The ECM detects a signal voltage from the coolant temperature sensor that is above normal Metering Rail #1 Pressure : Voltage Above Normal 174-3 | 174-3 | Sensor : Voltage The code is logged and a warning will appear on the Above Normal display on the control. panel. The ECM flags the fuel temperature as invalid data and a default value of 50 °C)(122 °F) is used ‘The ECM detects a’signal voltage from the coolant temperature sensor that is below normal Fuel Temperature 174-4 | 174-4 | Sensor : Voltage The code is logged and a warning will appear on the Below Normal display on the control panel. The ECM flags the fuel temperature as invalid data and a default value of 50 °C (12°F) is used 157-3. | 1797-3 | Engine Injector The ECM detects the following conditions: No 1079 (262) codes for the 5 Volt supply are active. Diagnostic code 0168-00 is not active. The signal voltage for the pressure in the fuel rail is more than 4.8 Volts DC for 0.6 seconds. If equipped, the warning lamp will come on. The diagnostic code will be logged. The electronic service tool will display "70000 kPa" next to “Desired Fuel Rail htpssss2.cal.comit/rint preview'serviceld9dc8701-616-4a2e-Bec’- t16ScfO006b ana972323, 1115. AM sis20 Pressure" and "Actual Fuel Rail Pressure" on the status screens The engine will be derated, The ECM detects the following conditions: No 1079 (262) codes for the 5 Volt supply are active. Diagnostic code 0168-01 is not active. Engine Injector The signal voltage for the pressure in the fuel rail is Metering Rail #1 less than 0.2 Volts DC for 0.6 seconds. 187-4 | 1797-4 | pressure : Voltage Below Normal If equipped, the warning lamp will come on. The diagnostic code will be logged. 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. Follow the troubleshooting procedure 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 3509 or 262 codes. * There are no active 168 codes. The following background information is related to this procedure: The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The 5 V sensor supply provides power to all 5 V-sensors. The Electronic Control Module (ECM) supplies 5.0 + 0.2 V to terminal "1" of each sensor connector. The sensor common from the ECM connector goes to terminal "2" 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 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 the presence of a voltage that is above a threshold on the signal circuit, the ECM will generate an open circuit diagnostic code (XXX-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 htpssss2.cal.comit/rint previewiserviceld9de8701-26164a2e-Bec3-tI6ScfO0Dbb ana93,1115 aM 51520 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. P22 ECM 201 1 PI tr 08 —}—<| 47 | OIL PRESSURE SENSOR POWER OILPRESSURE SENSOR | 2 ‘ate —|—4 ® | atv eneosuneseusoe ancwio 3 seror 56 | OlL PRESSURE SENSOR SIGNAL 228 7 R097 OR 43 | FRP SENSOR POWER SUPPLY FUEL RAIL PRESSURE SENSOR | 2 }—-—— Yoder —1— 4o | FRP SENSOR GROUND ‘yous Bu st | FRP SENSOR SIGNAL 200 7 ‘sr on 48 | IMAP SENSOR POWER SUPPLY INTAKE MANIFOLD eee 2 Toss 6 38 | IMAP SENSOR GROUND 3 x731 BU '55 | IMAP SENSOR SIGNAL 7 48 | FUEL TEMP. SENSOR SUPPLY pus. TANEATNE 2 4 | FUEL TEMP. SENSOR GROUND. 2 54 | FUEL TEMP. SENSOR SIGNAL lustration 1 907495670 ‘Schematic for the active sensors Note: Not all sensors and connectors are shown: Refer to the Electrical Schematic for the application for more information. htpssss2.cal.comit/rint previewiserviceld9de8701-26164a2e-Bec3-tI6ScfO0Dbb ena972323, 1115. AM sis20 | 27 28 29 30 31 32 ‘57 58 50 60 61 62 63 64 858856 G8S858ES 990909 OgeQgcee BORERe QQELQIee perrereren 14284648 ae Ed088S OOoodeee 4 PPPOPE Bee Sree? it oc llustration 2 go1ase4as ‘Typical view of the pin locations on the P2 connector for the pressure sensors (38) Ground (GND) Intake Manifold Pressure Sensor (89) Ground (GND) Oil Pressure Sensor (40) Ground (GND) Fuel Rail Pressure Sensor (46) Voltage supply (5 V) Intake Manifold Pressure Sensor (47) Voltage supply (5 V) Oil Pressure Sensor (48) Voltage supply (5 V) Fuel Rail Pressure Sensor (51) Signal (SIG) Fue! Rail Pressure Sensor (55) Signal (SIG) Intake Manifold Pressure Sensor (56) Signal (SIG) Oil Pressure Sensor Iiustration 3 901170309, Fuel rail pressure sensor (1) Voltage supply (Vs) (2) Ground (GND) (3) Signal (SIG) hitpssis2.cal.comih/rint previewlservceld%dc8701-206-4a2e-€ec’3-H5Scf0008bt a3972323, 1115. AM sis20 Iustration 4 901170310 Intake manifold pressure sensor (1) Voltage Supply (Vs) (2) Ground (GND) (3) Signal (SIG) ilustration 5 01170311 Typical example of the oil pressure sensor (1) Voltage Supply (Vs) (2) Ground (GND) ) Signal (SIG) The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The pressure sensors are active sensors. The pressure sensor has three terminals. Active sensors require supply voltage from the ECM. The P2/J2 ECM connector supplies +5 V to terminal 1 of each hitpssis2.cal. comih/rint previewiserviceld%dc8701-20'6-4a2e-8ec’3-H5Scf0008bt 73972323, 1115. AM sis.20 sensor, The common line is connected to each sensor connector terminal 2. The signal voltage from terminal 3 of each sensor is supplied to the appropriate terminal at the P2N2. ECM connector. Note: If 100-10 (1785-10) code is active, troubléshoot this code before proceeding with this procedure. Table 2 Troubleshooting Test Steps Values | Results 4, Diagnostic Codes Result: One or more of the diagnostic codes listed in Table 1 is logged, an A. Turn the keyswitch to the ON position. intermittent condition may be causing Wait at least 10 seconds for activation of the logged codes. the diagnostic codes. Repair: Refer to Troubleshooting, B, Download the Warranty Report and the | Diagnostic | "Electrical Connectors -Inspect". Product Status Report (PSR) with Active or Histograms before diagnosing the fault. Logged Perform a "Wiggle Test" by using the codes electronic service tool in order to Note: The downloaded information will be identify intermittent connections. required by the Dealer Solutions Network (DSN) if diagnostic assistance is needed Result: One or more of the diagnostic codes listed in Table 1 is active. C. Determine if a diagnostic code is active or recently logged. Proceed to Test Step 2. 2. Inspect Electrical Connectors and —_| Loose Result: There is a fault in a connector Wiring connection | or the wiring, or damaged A. Thoroughly inspect the terminal wire Repair: Repair any faulty connectors connections on the P2/J2 ECM connectors. B. Thoroughly inspect the following connectors for the engine pressure sensors: P201 Engine Oil Pressure Sensor 228 Fuel Rail Pressure Sensor 200 Intake Manifold Pressure Sensor Refer to Troubleshooting, "Electrical Connectors - Inspect". C. Perform a 45 N (10 Ib) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code. D. Check the screw for the ECM connector for the correct torque of 5 N-m (44 Ib in). htpssss2.cal.comit/rint previewiserviceld9de8701-2616-4a2e-Bec’-t16Scf0006b or replace the wiring hamess. Ensure that all the seals are properly in place and ensure that the connectors are correctly coupled. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points, Proceed to Test Step 3. ana92323, 11:15AM E. Check the hamess for abrasions and for pinch points from the sensors back to the ECM. F. Use the electronic service tool to perform a "Wiggle Test”. The "Wiggle Test” will identify intermittent connections. sis20 3. Check For Active 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. Wait at least 10 seconds for activation of Result: A -3 diagnostic code is active. Proceed to Test Step 4. Result: A -4 diagnostic code is active. Proceed to Test Step 5. A. Turn the keyswitch to the OFF position. hps:ss2.cal.comit/rint previewiserviceld9de8701-0616-4a2e-Bec3-tI6ScfOODbbE the diagnostic codes. Diagnostic codes Result: No diagnostic codes are D. Verify if any of the diagnostic codes that active. An intermittent fault may exist. are listed in Table 1 are active Repair: Use the electronic service tool E. Turn the keyswitch to the OFF position. to perform a "Wiggle Test’. If faults are indicated, then go to the appropriate F. Determine if the faultis related to an procedure. open circuit diagnostic code or a short circuit diagnostic code. ‘ceul Result: A voltage above normal ‘ create an Open Circuit at the Sensor diagnostic code was active before disconnecting the sensor. An open A. Turn the keyswitch to the OFF position Gireuit diagnostic code became active after disconnecting the sensor. B. Disconnect the connector for the Bispace Proceed to Test Step 6 Open Result: A voltage above normal C. Turn the keyswitch to the ON position, | Circuit Result: Wait at least 10 seconds for activation of diagnostic code is not active for the Teese ease disconnected sensor. There is a short circuit between the sensor hamess D. Use the electronic service tool to check connector and the ECM. Leave the the "Active Diagnostic Code" screen sensor disconnected. Check for an open circuit diagnostic code. proceed to Tast Step 8. 5, Measure the sensor supply voltage | 4.84V to _| Result: The voltage measurement is 5.16V not within the expected range. Repair: Continue testing the sensor gna92323, 1115. AM B. Disconnect the sensor from the engine harness, C. Tum the keyswitch to the ON position. C. Measure the voltage at the plug for the sensor from the terminal 1 (pressure sensor supply) to terminal 2 (sensor common). The voltage measurement should be 5.0 + 0.16 VDC. sis20 supply circuit. Refer to Troubleshooting, Sensor Supply - Test. Result: The voltage measurement is within the expected range. Proceed to Test Step 7. 6. Determine if the Short Circuit the Connector or in the Sensor A. Thoroughly inspect the connector for moisture. Result: The short circuit diagnostic code is still present. There is a fault in the sensor. Repair: Perform the following procedure: 1. Temporarily connect a new sensor to the harness but do not install the new sensor in the engine. 2. Use the electronic service tool to verify that the replacement sensor B. Inspect the seals and reconnect the Pisgnestic eliminates the fault, sensor. Refer to Troubleshooting, ae 3. If the diagnostic code is eliminated, “Electrical Connectors - Inspect”. install the replacement sensor. 4, Use the electronic service tool to C. If the short circuit diagnostic code clear the logged diagnostic codes. reappears, the sensor or the sensor connector has a fault. Result: The short circuit diagnostic code is no longer present. Repair: Repair the engine harness connector. Use the electronic service tool to clear the logged diagnostic codes. 7. Create a Short Circuit Between the _| Greater than | Result: A short circuit diagnostic code Signal and the Common Terminals at_ | 1k Ohm __| is active when the jumper is installed the Engine Harness Connector A. Turn the keyswitch to the ON position. B. Fabricate a jumper wire that is 150 mm (6 inch) long. Crimp a terminal to both ends of the wire. C. Monitor the "Active Diagnostic Code" screen of the electronic service tool before installing the jumper wire and after installing the jumper wire htpssss2.cal.comit/rint previewiservceld9dc8701-0616-4aze-Bec’-tI6ScfO0D6b An open circuit diagnostic code is active when the jumper is removed. The engine hamess and the ECM are OK. Repair: Perform the following procedure: 1. Temporarily connect a new sensor to the harness but do not install the new sensor in the engine. 2. Use the electronic service tool to ron92323, 1115. AM D. Install the jumper on the engine harness connector. Install one end of the jumper at the sensor signal (terminal 3) Install the other end of the jumper at the common connection for the pressure sensor (terminal 2). Wait at least 30 seconds for activation of the short circuit diagnostic code. 51520 verify that the replacement sensor eliminates the fault. 3. If the diagnostic code is eliminated, install the replacement sensor. 4. Use the electronic service tool to clear the logged diagnostic codes. Result: The open circuit diagnostic code remains active when the jumper is installed. The most probable location for the open circuit is in the common wire for the sensor, or in the sensor signal wire of the engine harness between the ECM and the sensor. Remove the jumper. Proceed to Test Step 8. 8. Check the Operation of the ECM by Creating Open and Short Circuits at the ECM Connector A. Tum the keyswitch to the OFF position. B, Disconnect the P2 connector from the ECM. Thoroughly inspect both halves of the connector for signs of corrosion of moisture. Refer to Troubleshooting, “Electrical Connectors - Inspect”. C. Reconnect the P2 connector. D. Turn the keyswitch to the ON position. Use the electronic service tool in order to monitor the "Active Diagnostic Code” screen. Wait at least 10 seconds for activation of the code. An open circuit diagnostic code should be active for the suspect sensor. Note: When the P2 connector is disconnected, all of the open circuit diagnostic codes for the pressure sensors and temperature sensors will be active. This is normal. Disregard the diagnostic codes for the pressure sensors and the temperature sensors that are not suspect. Address the diagnostic codes for the suspect sensors only. E. Tum the keyswitch to the OFF position. Diagnostic codes htpssss2.cal.comit/rint previewiserviceld9de8701-2616-4a2e-Bec’-t16Scf0006b Result: Voltage below normal diagnostic codes and voltage above normal diagnostic codes were active. The ECM is operating correctly, Proceed to Test Step 9. Result: Voltage below normal diagnostic codes and voltage above normal diagnostic codes were not active. One of the following conditions exists: The voltage below normal diagnostic code is not active when the hamess is disconnected. The voltage above normal diagnostic code is not active when the jumper wire is installed Repair: Perform the following repair: 1. Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "ECM Software - Install" 2. Contact the Technical Communicator at the Caterpillar dealer. Note: This consultation can greatly reduce the repair time. 3. If the Technical Communicator recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, "ECM - Replace" 4, Remove all jumpers and replace all connectors. nna9123723, 1115 AM F, Fabricate a jumper wire that is 150 mm. (6 inch) long. Crimp a terminal to both ends of the wire. G. Install the jumper wire on the P2 connector. Insert the jumper wire between the terminal for the suspect sensor signal and the common connection for the engine pressure sensor. Use the electronic service tool to verify that there is a short circuit diagnostic code. 515 20 5. Use the electronic service tool to recheck the system for active diagnostic codes. 6. If the fault is resolved with the test ECM, reconnect the suspect ECM. 7. If the fault returns with the suspect ECM, replace the ECM. 8. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault 9, Bypass the Harness Wiring Between the ECM and the Sensor Connector A. Tum the keyswitch to the OFF position. B. Disconnect the P2 connector and disconnect the connector from the suspect sensor. C. Remove the sensor signal wire from the P2 connector. D. Remove the signal wire (terminal 3) from the sensor connector on the engine harness. E. Fabricate a jumper wire that is long enough to reach from the ECM to the sensor connector or use an engine sensor hamess bypass with three terminals. Note: If an engine sensor harness bypass is being made, crimp a socket on one end in order to connect to the ECM. Crimp either a pin or a socket on the other end, as required. F. Insert one end of the engine sensor harness bypass into P2 connector on the engine harness. Insert the other end of the engine sensor harness bypass into the sensor connector of the engine harness. G. Reconnect the P2 connector and the sensor connector. H. Turn the keyswitch to the ON position. I. Use the electronic service tool to monitor the "Active Diagnostic Code" screen for htpssss2.cal.comit/rint preview/serviceld9dc8701-2616-4a2e-Bec’-tI6ScfO006b Less than 2 Ohms. Result: The diagnostic code disappears when the jumper or the bypass is installed. There is a fault in the wiring harness. Repair: Perform the following procedure: 1. Repair the faulty hamess or replace the faulty harness. 2. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The diagnostic code does not disappear when the jumper or the bypass is installed. The most likely cause is an intermittent fault. Repair: Use the electronic service tool to perform a "Wiggle Test. If no fault is found, restart this test procedure from Test Step 1 vane92323, 11:15AM sis20 either the open circuit diagnostic code for the sensor or the short circuit diagnostic code for the sensor. PIP-10924729 2023/09/23, 08:11:43+03:00 i09415440 © 2023 Caterpillar Inc. htps:ss2.cal.comit/rint previewiserviceld9de8701-2616-4a2e-Bec3-tI5ScfO0DbbE rain