0583786 JOHNSON POWER PACK

Illustration 1 g00904082
SchematicTest Step 1. Check for Active +5 V Sensor Supply Diagnostic Codes
Connect the Caterpillar Electronic Technician (Cat ET) to the service tool connector.
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Verify that neither 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:Neither of the preceding diagnostic codes are active.Results:
OK - The diagnostic codes are not active. Proceed to Test Step 2.
Not OK - At least one of the diagnostic codes is active.Repair: Perform the following diagnostic procedure: Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test". Stop.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
164-03 Injector Actuation Pressure open/short to +batt
164-04 Injector Actuation 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 ground
290-03 Engine Fan Pump Pressure open/short to +batt
290-04 Engine Fan Pump Pressure short to groundExpected Result:One or more of the preceding diagnostic codes are active.Note: 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 groundResults:
OK - Proceed to Test Step 3.
Not OK - 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
Illustration 2 g00904083
ECM connectors (wire side)
Thoroughly inspect the J1/P1 ECM connector, the J2/P2 ECM connector, and the connectors for each pressure sensor. 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 2.
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 on Cat ET. Record any 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 Voltage
Illustration 3 g00810608
Terminals for pressure sensors
Turn the keyswitch to the OFF position.
Disconnect the sensor from the engine harness.
Turn the keyswitch to the ON position.
Measure the voltage from terminal A (Engine Pressure Sensor +5V) to terminal B (Engine Pressure Sensor Common) on the engine harness side of the connector.Refer to Illustration 3.Expected Result:The DC voltage from terminal A to terminal B measures 4.5 to 5.5 VDC.Results:
OK - The sensor supply voltage is correct. Proceed to Test Step 8.
Not OK - The sensor supply voltage is out of range.Repair: Proceed to the following procedure: Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test" Stop.Test Step 7. Determine if the Short Circuit is in the Connector or in the Sensor
Thoroughly inspect the connector for moisture.
Inspect the seals and reconnect the sensor.
If the short circuit diagnostic code reappears, the sensor or the pigtail harness connector is the problem.
Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine.
Check for a short circuit diagnostic code while the new sensor is connected to the harness.Expected Result:The short circuit diagnostic code is not present when a new sensor is connected.Results:
OK - Verify that the repair eliminates the problem. Permanently install the new sensor. Clear the logged diagnostic codes. Stop.
Not OK - Repair the engine harness connector. Stop.Test Step 8. Create a Short Circuit Between the Signal and the Common Terminals at the Engine Harness Connector
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