8/16/2021 SIS 2.

2005/09/16 Analog Sensor Supply (RENR5059)

SMCS - 1439 i02417903

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 DC Power Supply short to +batt

262-04 5 Volt Sensor DC Power Supply short to ground

The Electronic Control Module (ECM) supplies a regulated voltage of 5.0 ± 0.2 VDC to the following sensors:

Coolant temperature sensor

Aftercooler temperature sensor

Unfiltered engine oil pressure sensor

Filtered engine oil pressure sensor

Left turbocharger inlet pressure sensor

Right turbocharger inlet pressure sensor

Atmospheric pressure sensor

Crankcase pressure sensor

Turbocharger outlet pressure sensor

Unfiltered fuel pressure sensor

Filtered fuel pressure sensor

The supply for the +5 V engine pressure sensor is routed from the ECM to terminal A of each pressure sensor connector. The sensor common 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.

Note: The sensors are not protected from overvoltage. A short from the supply line to the +Battery may damage the sensors. If the CID-FMI 262-03
is logged, it is possible that all of the sensors have been damaged. Repair the sensor supply and check for any "ACTIVE" sensor diagnostic codes
in order to determine if a sensor has failed.

The +5 V diagnostic code is probably caused by a short circuit to ground or a short circuit to another voltage source in the harness.

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Illustration 1 g01161442
Schematic

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Illustration 2 g01161474
P1 ECM connector
(P1-2) Analog sensor power
(P1-3) Analog sensor common
(P1-6) Aftercooler temperature
(P1-7) Coolant temperature
(P1-16) Filtered oil pressure
(P1-17) Unfiltered oil pressure
(P1-18) Analog sensor power
(P1-35) Analog sensor common
(P1-24) Filtered fuel pressure
(P1-25) Unfiltered fuel pressure

Illustration 3 g01161487
P2 ECM connector
(P2-3) Atmospheric pressure
(P2-36) Turbocharger outlet pressure
(P2-38) Left turbocharger inlet pressure
(P2-39) Right turbocharger inlet pressure
(P2-46) Crankcase pressure

Illustration 4 g01094844
Sensor connector

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Illustration 5 g01142488
Typical sensor locations
(1) Engine oil pressure sensor

Illustration 6 g01161501
Typical sensor locations
(2) Turbocharger inlet pressure sensor
(3) Boost pressure sensor
(4) Filtered fuel pressure sensor
(5) Inlet manifold pressure sensor
(6) Atmospheric pressure sensor
(7) Unfiltered fuel pressure sensor

Test Step 1. INSPECT ELECTRICAL CONNECTORS AND WIRING

A. Turn the battery disconnect switch to the OFF position.

B. Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit.
Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.

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C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.

D. Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.

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

Expected Result:

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

Results:

OK - The harness and connectors appear to be OK. Proceed to Test Step 3.

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

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. CHECK FOR ACTIVE DIAGNOSTIC CODES

A. Connect Caterpillar Electronic Technician (ET) to the service tool connector.

B. Turn the battery disconnect switch to the ON position.

C. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
Note: Wait at least 15 seconds in order for the diagnostic codes to become active.

Expected Result:

One of the following diagnostic codes is active:

262-03

262-04

Results:

OK - A 262-03 diagnostic code is active. Proceed to Test Step 3.

OK - A 262-04 diagnostic code is active. Proceed to Test Step 4.

Not OK - No diagnostic code is active.

Repair: The problem is no longer present. If the problem is intermittent, refer to Troubleshooting, "Inspecting Electrical Connectors".

STOP

Test Step 3. CHECK THE SUPPLY VOLTAGE AT THE SENSOR CONNECTOR

A. Turn the battery disconnect switch to the OFF position.

B. Disconnect all of the following analog sensors at the sensor connector:

Coolant temperature sensor

Aftercooler temperature sensor

Unfiltered engine oil pressure sensor

Filtered engine oil pressure sensor

Left turbocharger inlet pressure sensor

Right turbocharger inlet pressure sensor

Atmospheric pressure sensor

Crankcase pressure sensor

Turbocharger outlet pressure sensor

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Unfiltered fuel pressure sensor

Filtered fuel pressure sensor

C. Turn the battery disconnect switch to the ON position.

D. Measure the voltage between terminal A (5 V analog supply) and terminal B (sensor common) at the sensor connectors.

E. Turn the battery disconnect switch to the OFF position.

F. Reconnect all of the sensors.

Expected Result:

The voltage is 5.0 ± 0.2 VDC.

Results:

OK - The voltage is correct.

Repair: Replace all wires to the original configuration. Clear all diagnostic codes. Check for active diagnostic codes. If the problem is
intermittent, refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".

STOP

Not OK - The voltage is not 5.0 ± 0.2 VDC. The voltage is incorrect. Proceed to Test Step 5.

Test Step 4. DISCONNECT THE +5 V SENSORS WHILE YOU MONITOR THE ACTIVE DIAGNOSTIC CODES

A. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
Note: Wait at least 15 seconds in order for the diagnostic codes to become active.

B. Disconnect the following sensors one at a time at the sensor connector as you monitor Cat ET:

Coolant temperature sensor

Aftercooler temperature sensor

Unfiltered engine oil pressure sensor

Filtered engine oil pressure sensor

Left turbocharger inlet pressure sensor

Right turbocharger inlet pressure sensor

Atmospheric pressure sensor

Crankcase pressure sensor

Turbocharger outlet pressure sensor

Unfiltered fuel pressure sensor

Filtered fuel pressure sensor

Expected Result:

The 262-04 diagnostic code deactivates when a particular sensor is disconnected.

Results:

OK - The 262-04 diagnostic code deactivates. The diagnostic code is not active after 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. Reconnect all wires to the original
configuration. Clear all diagnostic codes. Verify that the repair eliminates the problem.

STOP

Not OK - The 262-04 diagnostic code stays active. Leave the sensors disconnected. Proceed to Test Step 5.

Test Step 5. CHECK THE +5 V SUPPLY WIRE FOR A SHORT TO ENGINE GROUND OR A SHORT TO ANOTHER WIRE IN THE HARNESS

A. Turn the battery disconnect switch to the OFF position.

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B. Disconnect the J2/P2 ECM connector. Disconnect the J1/P1 ECM connector.

C. Leave the analog sensors disconnected at the sensor connectors.

Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.

D. Measure the resistance between P1-2 (+5 V Supply) and all of the remaining pins on the P1 and P2 ECM connectors.

a. Measure the resistance from the ECM connector P1-2 to the ECM ground strap.

Expected Result:

Each resistance measurement is more than 20,000 Ohms.

Results:

OK - The resistance check does not indicate a short in the engine harness or a short to engine ground. Proceed to Test Step 6.

Not OK - A resistance measurement is less than 20,000 Ohms. The +5 V supply wire is shorted in the engine harness or the +5 V supply
wire is shorted to engine ground.
Repair: Repair the wire or replace the wire. Clear all logged diagnostic codes. Replace all wires to the original configuration. Verify that the
repair eliminates the problem.

STOP

Test Step 6. CHECK THE +5 V SUPPLY AND THE SENSOR COMMON FOR AN OPEN CIRCUIT

A. Install a wire jumper between P1-2 (+5 V Supply) and P1-3 (sensor common).
Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.

B. Record the resistance at each analog sensor connector between terminal A and terminal B.

C. Remove the wire jumpers.

Expected Result:

The resistance is less than 5 Ohms for each measurement.

Results:

OK - The resistance check does not indicate an open circuit in the engine harness. Proceed to Test Step 7.

Not OK - A resistance measurement is greater than 5 Ohms. The +5 V supply wire or the sensor common has excessive resistance.
Repair: Repair the wires or replace the wires. Clear all logged diagnostic codes. Reconnect all wires to the original configuration. Verify that
the repair eliminates the problem.

STOP

Test Step 7. CHECK THE +5 V SUPPLY AT THE ECM

A. Remove the wire 997-RD(Red) from ECM connector P1-2 (+5 V Supply). Install a wire jumper with socket terminals on both ends into P1-2.

a. Remove the wire 993-BK(Black) from ECM connector P1-3 (sensor common). Install a wire jumper with socket terminals on both ends
into P1-3.
Note: Disconnecting the common sensor wire from the ECM will generate an open circuit diagnostic code for all sensors that are
connected to the sensor common. Troubleshoot the original diagnostic code. Delete the logged diagnostic codes when you are finished.

B. Reconnect ECM connectors J1/P1 and J2/P2.

C. Turn the battery disconnect switch to the ON position.

D. Measure the voltage between the wire jumper in P1-2 and the wire jumper in P1-3.

E. Turn the battery disconnect switch to the OFF position.

F. Reconnect all wires to the original configuration.

Expected Result:

The voltage is 5.0 ± 0.2 VDC.

Results:

OK - The voltage is 5.0 ± 0.2 VDC. The voltage is correct.

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Repair: Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to Troubleshooting, "Inspecting
Electrical Connectors".

STOP

Not OK - The voltage is not 5.0 ± 0.2 VDC. The voltage is incorrect.
Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".

STOP

BGX120-UP, BLF166-UP, BMB132-UP, BPJ472-UP, BRK287-UP, CMC1107-UP, CNB1100-UP, CPA182-UP, FDN1515-UP, GAR1-UP, GBZ1-UP,
GD31-UP, GZS1-UP, GZT1-UP, GZY1-UP, JCG1-UP, JCH1-UP, JCN1-UP, JCY1-UP, JDE1-UP, JDH1-UP, JDJ1-UP, JM21-UP, JM31-UP, JM41-UP,
LD41-UP, LD91-UP, LY51-UP, LY71-UP, LY81-UP, LY91-UP, LYH1-UP, LYM1-UP, LYP1-UP, PBR1-UP, PDR1-UP, PXY1-UP, RRM1-UP, SBG1-UP,
SBJ1-UP, SBK1-UP, SEK1-UP, SFJ1-UP, SNE1-UP, TLN1-UP, TLT1-UP, YAH1-UP, YAL1-UP, YAM1-UP, YAN1-UP, YAP1-UP, YAR1-UP, YAT1-UP,
YAW1-UP, YAY1-UP, YAZ1-UP, YBB1-UP, YBC1-UP, YBD1-UP, YBR1-UP, YBT1-UP, YBW1-UP, ZAD1-UP, ZAH1-UP, ZAJ1-UP, ZAP1-UP, ZAR1-
UP, ZBP1-UP, ZBR1-UP, ZNT1-UP

PIP-10331007
2021/08/16
02:46:22+04:00
i02325316
© 2021 Caterpillar Inc.
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