5030197 JOHNSON CUP, Starter

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+5 V sensor locations (typical side view)
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+5 V sensor locations (typical top view)
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Schematic for engine pressure sensorsTest Step 1. Check For Active +5 V Sensor Supply Diagnostic Codes.
Connect the Caterpillar Electronic Technician (Cat ET) to the data link connector.
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Verify if any of the following diagnostic codes are active:
262-03 5 Volt Sensor Supply short to +batt
262-04 5 Volt Sensor Supply short to groundExpected Result:One or more of the preceding diagnostic codes are active.Results:
Yes - Repair: Perform the following diagnostic procedure: Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test". Stop.
No - Proceed to Test Step 2.Test Step 2. Verify All Active Diagnostic Codes.
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Verify if any of the following diagnostic codes are active:
94-03 Fuel Pressure open/short to +batt
94-04 Fuel Pressure short to ground
100-03 Engine Oil Pressure open/short to +batt
100-04 Engine Oil Pressure short to ground
273-03 Turbocharger Outlet Pressure open/short to +batt
273-04 Turbocharger Outlet Pressure short to ground
274-03 Atmospheric Pressure open/short to +batt
274-04 Atmospheric Pressure short to groundNote: The following diagnostic codes should not be active:
262-03 5 Volt Sensor Supply short to +batt
262-04 5 Volt Sensor Supply short to groundExpected Result:One or more of the preceding diagnostic codes are active.Results:
Yes - Proceed to Test Step 4.
No - Repair: If the preceding codes are logged but not active and the engine is not running properly, refer to Troubleshooting, "Troubleshooting without a Diagnostic Code". If the engine is running properly at this time, an intermittent condition may be causing the logged codes. Refer to Troubleshooting, "Electrical Connectors - Inspect". Stop.Test Step 3. Inspect Electrical Connectors And Wiring.
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Terminal locations for pressure sensors
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Terminal locations for pressure sensors
Thoroughly inspect ECM engine harness connector J2/P2, machine harness connector J1/P1, fuel pressure sensor J208/P208, turbocharger outlet pressure sensor J200/P200, engine oil pressure sensor J201/P201, right turbocharger inlet pressure J205/P205, and atmospheric pressure sensor J203/P203. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.Refer to Illustration 4.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins, and sockets should be completely coupled and/or inserted. The harness and wiring should be free of corrosion, abrasion, and pinch points.Results:
OK - Proceed to Test Step 4.
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.Clear all logged diagnostic codes. Stop.Test Step 4. Verify That the Diagnostic Code Is Still Active.
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Monitor the "Active Diagnostic Code "screen of Cat ET. Check and record active diagnostic codes.
Determine if the problem is related to an open circuit diagnostic code or a short circuit diagnostic code.Expected Result:Either a short circuit diagnostic code is active or an open circuit diagnostic code is active.Results:
SHORT Circuit - A short circuit diagnostic code is active at this time. Proceed to Test Step 5.
OPEN Circuit - An open circuit diagnostic code is active at this time. Proceed to Test Step 6.Test Step 5. Disconnect The Sensor In Order To Create An Open Circuit.
Turn the keyswitch to the OFF position.
Disconnect the sensor connector of the sensor with the short circuit diagnostic code.
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen on Cat ET. Check for an active open circuit diagnostic code.Expected Result:An open circuit diagnostic code for the disconnected sensor is now active.Results:
OK - A short circuit diagnostic code was active before disconnecting the sensor. An open circuit diagnostic code became active after disconnecting the sensor. Proceed to Test Step 7.
Not OK - There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 9.Test Step 6. Measure the Sensor Supply