Use this procedure under the following situation:
Use this procedure to troubleshoot the system when one of the following diagnostic codes is active or easily repeated:
- 232-03 5 Volt Supply voltage high
- 232-04 5 Volt Supply voltage low
Also, use this procedure to troubleshoot the system when you have been directed here by another troubleshooting procedure.
The following background information is related to this procedure:
The Engine Control Module (ECM) supplies the following sensors with regulated 5 VDC:
- Atmospheric pressure sensor
- Boost pressure sensor
- Engine oil 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 supply voltage is 5.0 ± 0.16 VDC.
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 | g00692909 |
Sensor locations for C-10 and C-12 engines | |
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| Illustration 2 | g00662230 |
Sensor locations for 3406E engines | |
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| Illustration 3 | g00693763 |
Sensor locations for C-15, C-16 and C-18 engines | |
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| Illustration 4 | g00662235 |
Schematic | |
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| Illustration 5 | g00662237 |
P2 ECM connector | |
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| Illustration 6 | g00810608 |
Sensor connector | |
Test Step 1. Disconnect the ECM Connector and Check for Active Diagnostic Codes
- Turn the key switch to the OFF position.
- Connect the Caterpillar Electronic Technician (Cat ET) to the data link connector.
- Disconnect the P2 ECM connector from the ECM.
- Check the ECM connector for corrosion and moisture.
- Turn the key switch to the ON position.
- Check for active diagnostic codes on Cat ET.
Note: A "voltage high" diagnostic code (open circuit) should be active for all of the engine pressure sensors.
Expected Result:
The 5 volt diagnostic codes are not active. A "voltage high" diagnostic code (open circuit) should be active for all of the engine pressure sensors.
Results:
- OK - The 5 volt diagnostic codes are not active.
Repair: Reconnect the P2 ECM connector.
Proceed to Test Step 2.
- Not OK - The 5 volt diagnostic codes are still active.
Repair: Connect a test ECM.If the test ECM fixes the problem, reconnect the suspect ECM.If the problem returns, permanently install the new ECM.Verify that the repair eliminates the problem.
STOP
Test Step 2. Disconnect the Sensors
- Turn the key switch to the ON position.
- Monitor the active diagnostic code screen on Cat ET.
- Disconnect the pressure sensors one at a time. Wait for 30 seconds after each pressure sensor is disconnected.
Note: The 5 volt diagnostic code will become inactive if a pressure sensor is the cause of the 5 volt diagnostic code.
- Ensure that all of the pressure sensors are disconnected.
Expected Result:
The 5 volt diagnostic code is still active when all of the pressure sensors are disconnected.
Results:
- OK - The 5 volt diagnostic code is still active.
Repair: Leave all of the pressure sensors disconnected.
Proceed to Test Step 4.
- Not OK - The 5 volt diagnostic code disappears when the pressure sensors are disconnected.
Repair: Reconnect all of the pressure sensors except the suspect sensor.
Proceed to Test Step 3.
Test Step 3. Check the Signal Wire
- Turn the key switch to the ON position.
Note: The suspect sensor should be disconnected.
- Measure the voltage between terminal C (Signal) and terminal B (Pressure Sensor Common) of the connector for the suspect sensor on the engine harness.
Expected Result:
The voltage should be less than 7.0 VDC.
Results:
- OK - The voltage is within the range.
Repair: Temporarily connect a new sensor.If the problem is resolved with the new sensor, reconnect the suspect sensor.If the problem returns, replace the suspect sensor.Verify that the repair eliminates the problem.
STOP
- Not OK - The voltage is greater than 7.0 VDC.
Repair: Inspect the signal wire for a short circuit to a voltage source.Repair the signal wire or replace the signal wire.Verify that the repair eliminates the problem.
STOP
Test Step 4. Determine the Condition that is Present
- Turn the key switch to the ON position.
- Access the active diagnostic code screen on Cat ET.
Expected Result:
232-03 or 232-04 is active.
Results:
- 232-03 - Proceed to Test Step 5.
- 232-04 - Proceed to Test Step 7.
Test Step 5. Measure the 5 Volt Supply to the Sensor
- Turn the key switch to the ON position.
Note: All of the pressure sensors should be disconnected.
- Measure the voltage between terminal A (Pressure Sensor +5V) and chassis ground for each pressure sensor.
Expected Result:
The voltage should be 5.0 ± 0.16 VDC.
Results:
- OK - The 5 volt supply is within the range. Proceed to Test Step 6.
- Not OK - The voltage is greater than 5.16 volts.
Repair: Check the 5 volt supply wire for a short to a higher voltage source.Repair the 5 volt supply wire or replace the 5 volt supply wire.Verify that the repair eliminates the problem.
STOP
Test Step 6. Check the Common Wire
- Turn the key switch to the ON position.
- Measure the voltage between terminal A (Pressure Sensor +5V) and terminal B (Pressure Sensor Common) on all of the pressure sensors.
- While the voltage is monitored, perform a 45 N (10 lb) pull test on the common wires for the 5 volt supply.
- P2:3 (Pressure Sensor Common)
- P2:42 (Pressure Sensor Common (Actuator))
- P2:3 (Pressure Sensor Common)
Expected Result:
The voltage should be 5.0 ± 0.16 VDC.
Results:
- OK - The voltage is within the range.
Repair: If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".
STOP
- Not OK - The voltage is not within the range.
Repair: Inspect the common wire for an open circuit.Repair the common wire or replace the common wire.Verify that the repair eliminates the problem.
STOP
Test Step 7. Check the Resistance of the Harness
- Turn the key switch to the OFF position.
- Verify that all of the sensors are disconnected.
- Measure the resistance between terminal A (Pressure Sensor +5V) and terminal B (Pressure Sensor Common) of each connector for the pressure sensor on the engine harness.
Expected Result:
The resistance should be greater than 20,000 Ohms, or "OL" is displayed on the multimeter.
Results:
- OK - The 5 volt supply and the pressure sensor common are not shorted.
Repair: Check the 5 volt supply for a short to ground.Repair the 5 volt supply wire or replace the 5 volt supply wire.Verify that the repair eliminates the problem.
STOP
- Not OK - There is a short between the 5 volt supply and the pressure sensor common.
Repair: Locate the short between the 5 volt supply and the pressure sensor common.Repair the faulty wiring or replace the faulty wiring.Verify that the repair eliminates the problem.
STOP