5007207 JOHNSON Service Manual - English

Illustration 1 g01355799
Left side view
(1) Fuel temperature sensor
(2) Inlet air temperature sensor
(3) Inlet manifold pressure sensor
(4) Electronic control module (ECM)
(5) Secondary speed/timing sensor
(6) Primary speed/timing sensor
(7) Atmospheric sensor
(8) Engine oil pressure sensor
Illustration 2 g01355803
Top view
(9) Coolant temperature sensor
(10) Coolant level sensor
Illustration 3 g01355802
Right side view
(11) Control panel (right hand service)
(12) Fuel pressure sensor (right hand service)
Illustration 4 g01355800
Left side view
(13) Control panel (left hand service)
(14) Fuel pressure sensor (left hand service)
Illustration 5 g01355798
Rear view
(15) Connector for the exhaust temperature sensor
(16) Connector for the fuel level sensor
(17) Timing calibration connector Failure of Sensors
All Sensors
A failure of any of the sensors may be caused by one of the following malfunctions:
Sensor output is open.
Sensor output is shorted to "- battery" or "+ battery".
Measured reading of the sensor is not within the specification.Coolant Temperature Sensor
The coolant temperature sensor monitors engine coolant temperature. The coolant temperature sensor is used by the engine system diagnostics with an output from the Electronic Control Module. The output of the ECM can indicate a high coolant temperature through a relay or a lamp. In addition, the sensor activates the cold start strategy which improves the startability of the engine.The minimum coolant temperature that will activate the alarm is 106°C (223°F). The switch opens as the coolant cools. A resetting procedure is not required.Failure of the Coolant Temperature Sensor
If one of the following conditions exist, a failure of the coolant temperature sensor may have occurred:
Sensor output is open.
Sensor output is shorted to ground or supply.
Measured reading of the coolant temperature is out of the specification.The ECM will detect the failure of the coolant temperature sensor. The diagnostic lamp will warn the operator about the status of the coolant temperature sensor. Strategies that are related to the coolant temperature will be disabled if a failure occurs. The failure of the coolant temperature sensor will not cause a shutdown of the engine or any horsepower change.Coolant Level Sensor
The coolant level sensor monitors the engine coolant level. The sensor will detect coolant level. The coolant level sensor provides information to the ECM. The output from the ECM can indicate a low coolant level through a relay or a lamp. Coolant must be added to the cooling system in order to correct the condition. See the Operation and Maintenance Manual for more information.The system can be programmed with one of the following options:Enabled - The system will monitor the input from the coolant level sensor. The system is programmed with this value when the engine is shipped by Caterpillar.Disabled - The system will monitor the input from the coolant level sensor. All of the diagnostics that are associated with the coolant level sensor will be disabled.Failure of the Coolant Level Sensor
A failure of the coolant level sensor may occur under the following conditions:
The coolant level sensor is open.
The coolant level sensor is shorted to ground.
The coolant level sensor is shorted to supply.The failure of the coolant level sensor will not cause a shutdown of the engine or any horsepower change.Engine Oil Pressure Sensor
The engine oil pressure sensor can detect engine oil pressure for diagnostic purposes. The engine oil pressure sensor sends a signal to the Electronic Control Module (ECM).Low Oil Pressure Warning
The setpoint is dependent upon the engine rpm. The fault will be active and logged only if the engine has been running for more than 15 seconds. Very Low Oil Pressure Warning
The very low oil pressure setpoint is dependent upon the engine rpm. If Derate mode is selected, the ECM will derate the engine power. The engine horsepower will be limited.Failure of the Engine Oil Pressure Sensor
If one of the following conditions exist, a failure of the engine oil pressure sensor may have occurred:
The engine oil pressure sensor is open.
The engine oil pressure sensor is shorted to ground or supply.
Measured reading of the oil pressure is out of the specification.The ECM will detect the failure of the engine oil pressure sensor. The diagnostic lamp warns the user about the status of the engine oil pressure sensor. The oil pressure related strategies will be disabled. The failure of the engine oil pressure sensor will not cause a shutdown of the engine or any horsepower change.Fuel Pressure Sensor
The fuel pressure sensor monitors the fuel filter pressure. Low fuel pressure or high fuel pressure will not cause a shutdown of the engine or any horsepower change. Fuel pressure that is outside of the normal range will affect the engine performance. If the fuel filter outlet pressure is low, the fuel filter may need to be replaced.
Table 1
Fuel Pressure Sensor
Minimum allowable pressure of the fuel transfer pump at full load speed 415 kPa (60 psi)
Minimum allowable pressure in the fuel manifold at full load speed 276 kPa (40 psi)