5033361 JOHNSON GUIDE, ROD

Illustration 1 g00820834
Test Step 1. Check for Connector Damage.
Turn the main disconnect to the OFF position.
Turn the engine control to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check for "ACTIVE" Diagnostic Codes.
Start the Caterpillar Electronic Technician (ET).
Turn the main disconnect to the ON position.
Turn the engine control to the ON position. The engine should be off.
Wait for 15 seconds for the CID-FMI.Expected Result:Determine the failure mode identifier (FMI). Determine if the diagnostic codes 262-03 5 Volt Sensor DC Power Supply short to +batt and/or 262-04 5 Volt Sensor DC Power Supply short to ground are present. Determine if the diagnostic codes 263-03 Digital Sensor Supply short to +batt and/or 263-04 Digital Sensor Supply short to ground are present.Results:
262-03 or 262-04 Active Code - A diagnostic code of 263-03 or 263-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Analog Sensor Supply".STOP
263-03 or 263-04 Active Code - A diagnostic code of 263-03 or 263-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Digital Sensor Supply".STOP
FMI 03 - A diagnostic code with a FMI of 03 is present. Proceed to test step 3.
FMI 04 - A diagnostic code with a FMI of 04 is present. Proceed to test step 4.
FMI 08 - A diagnostic code with a FMI of 08 is present. Proceed to test step 11.Test Step 3. Check the Sensor Supply Voltage at the Sensor Connector if the Diagnostic Code FMI-03 is Present.
Turn the engine control to the OFF position.
Disconnect the sensor.Note: Disconnecting the sensor wire from the ECM will generate an open circuit diagnostic code for the sensor. Troubleshoot the original diagnostic code. Delete the logged diagnostic codes when you are finished.
Turn the engine control to the ON position. The engine should be off.
Measure the voltage between pin A and pin B for the sensor.Expected Result:The supply voltage should reach 5.0 0.2 VDC for all analog sensors and 8.0 0.4 for all digital sensors.Results:
OK - The supply voltage is 5.0 0.2 VDC for all analog sensors and 8.0 0.4 for all digital sensors. The voltage is correct. Proceed to test step 5.
Not OK - The supply voltage is not 5.0 0.2 VDC for all analog sensors and 8.0 0.4 for all digital sensors. The voltage is out of range. Proceed to test step 7.Test Step 4. Check the Sensor Supply Voltage at the Sensor Connector if the Diagnostic Code FMI-04 is present.
Turn the engine control to the OFF position.
Disconnect the sensor.Note: Disconnecting the sensor wire from the ECM will generate an open circuit diagnostic code for the sensor. Troubleshoot the original diagnostic code. Delete the logged diagnostic codes when you are finished.
Turn the engine control to the ON position. The engine should be off.
Measure the voltage between pin A and pin B for the sensor.Expected Result:The supply voltage should reach 5.0 0.2 VDC for all analog sensors and 8.0 0.4 for all digital sensors.Results:
OK - The supply voltage is 5.0 0.2 VDC for all analog sensors and 8.0 0.4 for all digital sensors. The voltage is correct. Proceed to test step 8.
Not OK - The supply voltage is not 5.0 0.2 VDC for all analog sensors and 8.0 0.4 for all digital sensors. The voltage is out of range. Proceed to test step 7.Test Step 5. Check for a Short to the + Battery.
Turn the engine control to the OFF position.
Disconnect the suspect sensor.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the engine control to the STOP position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin B and the engine ground.
Measure the voltage on the ECM side of the sensor connector between pin C and the engine ground.
Turn the engine control to the OFF position.Expected Result:The voltage will measure 24 3 VDC when a short to the + Battery is present.Results:
OK - The voltage measures 24 3 VDC. A short to the + Battery is present.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The voltage on pin B should measure 0 VDC. The voltage on pin C may measure approximately 6.5 VDC. The voltage on pin C is a pull up voltage. The ECM provides the pull up voltage to the signal input when the ECM senses an open circuit in the incoming input signal. Frequency sensors do not receive a pull up voltage. The sensor common and signal wire are not shorted to the + Battery. 6.Test Step 6. Create a Short at the Sensor Connector.
Turn the engine control to the OFF position.
Use a wire with socket terminals at each end. Connect pin B and pin C together on the ECM side of the sensor connector.
Turn the engine control to the ON position. The engine should be off.
Check if the diagnostic code has changed from