C9 Engine for the 816F Series 2 Landfill Compactor, the 815F Series 2 Soil Compactor, and the 814F Series 2 Wheel Dozer Caterpillar

Sensor Supply - Test

Usage:

System Operation Description:

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

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Table 1
Diagnostic Codes Table
Code and Description	Conditions which Generate this Code	System Response
41-3 8 Volt DC Supply voltage above normal	The digital sensor supply voltage is above normal for one second. The Electronic Control Module (ECM) has been powered for three seconds.	The code is logged. All sensors are set to default values.
41-4 8 Volt DC Supply voltage below normal	The digital sensor supply voltage is below normal for one second. The ECM has been powered for three seconds.	The code is logged. All sensors are set to default values.
262-3 5 Volt Sensor DC Power Supply voltage above normal	The analog sensor supply voltage is above normal for one second. The ECM has been powered for three seconds.	The code is logged. All sensors are set to default values.
262-4 5 Volt Sensor DC Power Supply voltage below normal	The analog sensor supply voltage is below normal for one second. The ECM has been powered for three seconds.	The code is logged. All sensors are set to default values.
269-3 Sensor Power Supply voltage above normal	The analog sensor supply voltage is above normal for one second. The ECM has been powered for three seconds.	The code is logged. All sensors are set to default values.
269-4 Sensor Power Supply voltage below normal	The analog sensor supply voltage is below normal for one second. The ECM has been powered for three seconds.	The code is logged. All sensors are set to default values.
1785-10 Intake Manifold Pressure Sensor abnormal rate of change	The ECM detects a value for the intake manifold pressure that is between 191 kPa (28 psi) and 252 kPa (37 psi). The pressure changes less than 0.55 kPa (0.08 psi) in 30 seconds. The engine speed must be greater than 1000 rpm in order for this code to be set.	The code is logged. The value of the parameter will be set to 100 kPa (15 psi).

Note: The 262 diagnostic codes indicate a problem with the 5 V power supply on the J2 ECM connector. The 269 diagnostic codes indicate a problem with the 5 V power supply on the J1 ECM connector.

System Operation

The ECM supplies a regulated voltage of 5.0 ± 0.2 VDC to the following sensors:

Fuel pressure sensor
Engine oil pressure sensor
Injection actuation pressure sensor
Atmospheric pressure sensor
Turbocharger inlet pressure sensor
Intake manifold pressure sensor

The ECM supplies a regulated voltage of 8.0 ± 0.4 VDC to the throttle position sensor.

The supply voltage for the sensors is routed from the ECM to terminal A of each sensor connector. The sensor return for the sensors is routed from the ECM to terminal B of each sensor connector. The ECM provides short circuit protection for the internal power supply. A short circuit to the battery will not damage the internal power supply.

If a -10 code is logged, this indicates that the 5 volt supply is not available at the sensor connector. During normal engine operation, each of the signals from the pressure sensors fluctuate slightly. When the 5 volt supply becomes unavailable at the pressure sensor connector, the signal from that sensor floats to a midrange value. The signal will not fluctuate. If the signal from the sensor remains abnormally steady for more than 30 seconds, the ECM will activate this code.

Note: The sensors are not protected from overvoltage. A short from the supply line to the +Battery may damage the sensors. If any of the 3 diagnostic codes are active, it is possible that a sensor has been damaged. Repair the sensor supply and check for any active sensor diagnostic codes in order to determine if a sensor has failed.

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Illustration 1	g01339831
Schematic for the sensor supply circuit

Test Step 1. Inspect the Electrical Connectors and the Wiring

Remove electrical power from the ECM.

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Illustration 2	g01339949
Locations of the components that are associated with the sensor supply circuits Component locations for the analog sensors (typical left side engine view) (1) Intake manifold pressure sensor (2) Atmospheric pressure sensor (3) Turbocharger inlet pressure sensor (4) Fuel pressure sensor (5) Injection actuation pressure sensor (6) Engine oil pressure sensor (7) J2/P2 ECM connector (8) J1/P1 ECM connector (9) Machine interface connector (20-Pin)

Thoroughly inspect the connectors for sensors (1 through 6). Also, thoroughly inspect connectors (7), (8), and (9) .
Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

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Illustration 3	g01340124
Terminal locations at the P1 ECM connector for the sensor supply (P1-2) 5 V Sensor supply (P1-3) Sensor return (P1-4) 8 V Sensor supply (P1-5) Sensor return

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Illustration 4	g01340136
Terminal locations at the P2 ECM connector for the sensor supply (P2-17) Sensor return (P2-54) Sensor return (P2-72) 5 V Sensor supply (P2-80) 5 V Sensor supply

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Illustration 5	g01339654
Terminal locations at the machine interface connector for the sensor supply (Terminal 9) 8 V sensor supply (Terminal 12) Sensor return

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Illustration 6	g01159881
Terminal locations at the sensor connector for the sensor supply (Terminal A) 5 V or 8 V sensor supply (Terminal B) Sensor return (Terminal C) Sensor signal

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

Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

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 2.
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

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

Restore electrical power to the ECM.

Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Look for the following diagnostic codes:
- 41-3
- 41-4
- 262-3
- 262-4
- 269-3
- 269-4
- 1785-10
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

Expected Result:

No diagnostic codes are active.

Results:

OK - No diagnostic code is active.
Repair: The problem is no longer present. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".
STOP
Not OK - The 1785-10 diagnostic code is logged at this time. The analog supply is not reaching the sensor. Proceed to Test Step 3.
Not OK - A 262-3, 262-4, 269-3 or 269-4 diagnostic code is active at this time. There is a problem with the sensor supply for the analog sensors. Proceed to Test Step 4.
Not OK - A 41-3 or 41-4 diagnostic code is active at this time. There is a problem with the sensor supply for the digital sensors. Proceed to Test Step 6.

Test Step 3. Check the Supply Voltage at the Sensor Connector

Disconnect the harness connectors for the intake manifold pressure sensor.

Restore the electrical power to the ECM.

Note: Be sure to wiggle the harness during the following measurements in order to reveal an intermittent condition.

Measure the voltage between terminals A and B at the connector.

Remove the electrical power from the ECM.

Connect all of the sensors.

Expected Result:

The voltage measurement is 5.0 ± 0.2 VDC.

Results:

OK - The voltage measurement is 5.0 ± 0.2 VDC.
Repair: The analog supply is reaching the sensor connector. There may be a problem with the sensor. Perform the following procedure:
1. Clear all diagnostic codes.
1. Run the engine. Allow the engine to warm-up. Check if the code has been logged again.
If the code becomes active or logged, the sensor is faulty. Replace the sensor. Verify that the repair eliminates the original problem.If the code does not become active or logged, there may be an intermittent problem in the harness or in a connector. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct troubleshooting procedure.
STOP
Not OK - The voltage measurement is not 5.0 ± 0.2 VDC. There is a problem with the harness wiring or with the ECM. Proceed to Test Step 5.

Test Step 4. Disconnect the 5 Volt Sensor(s) while you Monitor the Active Diagnostic Codes

Use this procedure for any 262 diagnostic codes.
1. Monitor the active diagnostic code screen on Cat ET while you disconnect each 5 Volt sensor at the sensor connector. Check for an active 262-3 code or an active 262-4 code.
  Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
1. Disconnect the following sensors one at a time:
  - Atmospheric pressure sensor
  - Engine oil pressure sensor
  - Fuel pressure sensor
  - Injection actuation pressure sensor
  - Intake manifold pressure sensor

Use this procedure for any 269 diagnostic codes.
1. Monitor the active diagnostic code screen on Cat ET while you disconnect each 5 Volt sensor at the sensor connector. Check for an active 269-3 code or an active 269-4 code.
  Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
1. Disconnect the turbocharger inlet pressure sensor.

Remove electrical power from the ECM.

Expected Result:

The diagnostic code deactivates when a particular sensor is disconnected.

Results:

OK - The diagnostic code deactivates when a particular sensor is disconnected.
Repair: Connect the suspect sensor. If the code returns, replace the sensor. Connect the connector(s). Verify that the problem is resolved.
STOP
Not OK - The diagnostic code remains active after the sensor(s) is disconnected. Leave the sensor(s) disconnected. The sensor(s) is not the cause of the diagnostic code. Proceed to Test Step 5.

Test Step 5. Check the 5 Volt Supply Voltages at the ECM

Use this procedure for any 262 diagnostic codes:
1. Disconnect the J2/P2 ECM connector.
1. Fabricate four jumper wires that are long enough to be used to create a test circuit at the ECM connector. Crimp connector sockets to one end of each of the jumper wires.
1. Remove the wires from terminal locations P2-72 (5 V sensor supply) and P2-17 (sensor return). Install a jumper wire into each of these terminal locations.
1. Remove the wires from terminal locations P2-80 (5 V sensor supply) and P2-54 (sensor return). Install a jumper wire into each of these terminal locations.
1. Connect the J2/P2 ECM connector.
1. Restore electrical power to the engine ECM.
1. Measure the voltage between the jumper wire in P2-72 (5 V sensor supply) and the jumper wire in P1-17 (sensor return).
1. Measure the voltage between the jumper wire in P2-80 (5 V sensor supply) and the jumper wire in P1-54 (sensor return).
1. Remove electrical power from the ECM.

Use this procedure for any 269 diagnostic codes.
1. Disconnect the J1/P1 ECM connector.
1. Fabricate two jumper wires that are long enough to create a test circuit across the ECM connector. Crimp connector sockets to one end of each of the jumper wires.
1. Remove the wires from terminal locations P1-2 (5 V sensor supply) and P1-3 (sensor return). Install a jumper wire into each of these terminal locations.
1. Connect the J1/P1 ECM connector.
1. Restore electrical power to the engine ECM.
1. Measure the voltage between the jumper wire in P1-2 (5 V sensor supply) and the jumper wire in P1-3 (sensor return).
1. Remove electrical power from the ECM.

Expected Result:

Each voltage measurement is 5.0 ± 0.2 VDC.

Results:

OK - The voltage measurement is 5.0 ± 0.2 VDC. The ECM is operating correctly.
Repair: The supply wire is shorted to another wire in the harness or the supply wire is shorted to engine ground. There may be an open circuit in the supply wire that is in the harness. Repair the supply wire.
STOP
Not OK - The voltage measurement is not 5.0 ± 0.2 VDC.
Repair: There is a problem with the ECM. Perform the following procedure:
1. Temporarily connect a test ECM.
  Refer to Troubleshooting, "ECM - Replace".
1. Recheck the circuit in order to ensure that the original problem has been resolved.
  If the problem is resolved with the test ECM, install the suspect ECM. If the problem returns with the suspect ECM, replace the ECM. Verify that the problem is resolved.
  If the problem is not resolved with the test ECM, install the original ECM. There is a problem in the wiring.
STOP

Test Step 6. Disconnect the 8 Volt Sensor while you Monitor the Active Diagnostic Codes

Monitor the active diagnostic code screen on Cat ET while you disconnect the throttle position sensor at the sensor connector. Check for an active 41-3 code or an active 41-4 code.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

Remove electrical power from the ECM.

Expected Result:

The diagnostic code deactivates when the throttle position sensor is disconnected.

Results:

OK - The 41-3 or 41-4 diagnostic code deactivates when the throttle position sensor is disconnected.
Repair: Connect the suspect sensor. If the code returns, replace the sensor. Connect all of the connectors. Verify that the problem is resolved.
STOP
Not OK - The 41-3 or 41-4 diagnostic code remains active after the throttle position sensor is disconnected. The sensor is not the cause of the diagnostic code. Leave the sensor disconnected. Proceed to Test Step 7.

Test Step 7. Check the 8 Volt Supply Voltage at the ECM

Disconnect the J1/P1 ECM connector.

Fabricate two jumper wires that are long enough to be used to create a test circuit at the ECM connectors. Crimp connector sockets to one end of each of the jumper wires.

Remove the wires from terminal locations P1-4 (8 V sensor supply) and P1-5 (sensor return). Install a jumper wire into each of these terminal locations.

Connect the J1/P1 ECM connector.

Restore electrical power to the engine ECM.

Measure the voltage between the jumper wire in P1-4 (8 V sensor supply) and P1-5 (sensor return).

Remove electrical power from the ECM. Restore all wires and connectors to the original configuration.

Expected Result:

The voltage measurement is 8.0 ± 0.4 VDC.

Results:

OK - The voltage measurement is 8.0 ± 0.4 VDC. The ECM is operating correctly.
Repair: The supply wire is shorted to another wire in the harness or the supply wire is shorted to engine ground. There may be an open circuit in the supply wire that is in the harness. Repair the supply wire.
STOP
Not OK - The voltage measurement is not 8.0 ± 0.4 VDC.
Repair: There is a problem with the ECM. Perform the following procedure:
1. Temporarily connect a test ECM.
  Refer to Troubleshooting, "ECM - Replace".
1. Recheck the circuit in order to ensure that the original problem has been resolved.
  If the problem is resolved with the test ECM, install the suspect ECM. If the problem returns with the suspect ECM, replace the ECM. Verify that the problem is resolved.
  If the problem is not resolved with the test ECM, install the original ECM. There is a problem in the wiring.
STOP