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C4.4 and C6.6 Industrial Engines and Engines for SMCS - 1917,1924 i05931557
Caterpillar Built Machines (SENR9969) System Operation Description:
 Troubleshooting
Use this procedure under the following conditions:
System Overview
Use this procedure if any of the following diagnostic codes are active:
Glossary

Electronic Service Tools 0100-03 Engine Oil Pressure Sensor voltage above normal

Indicator Lamps 0100-04 Engine Oil Pressure Sensor voltage below normal
Replacing the ECM
0100-10 Engine Oil Pressure Sensor abnormal rate of change
Self-Diagnostics

Sensors and Electrical Connectors 1785-03 Intake Manifold Pressure Sensor voltage above normal

Engine Wiring Information 1785-04 Intake Manifold Pressure Sensor voltage below normal
ECM Harness Connector Terminals
1785-10 Intake Manifold Pressure Sensor abnormal rate of change
Programming Parameters

Test ECM Mode 1797-03 Fuel Rail Pressure Sensor voltage above normal

Factory Passwords 1797-04 Fuel Rail Pressure Sensor voltage below normal
Flash Programming
The following background information is related to this procedure:
Injector Trim File

Mode Switch Setup The troubleshooting procedures for the diagnostic codes of each pressure sensor are
identical. The 5 V sensor supply provides power to all 5 V sensors. The Electronic Control
Throttle Setup
Module (ECM) supplies 5.0 ± 0.2 V to terminal "1" of each sensor connector. The sensor
Multiposition Switch Setup common from the ECM connector goes to terminal "2" of each sensor connector. The sensor
Customer Specified Parameters supply is output short circuit protected. A short circuit to the battery will not damage the
Customer Specified Parameters Table circuit inside the ECM.

Customer Specified Parameters Worksheet Pull-up Voltage

System Configuration Parameters
The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The
Alternator Noise
ECM uses this pull-up voltage in order to detect an open in the signal circuit. When the ECM
Alternator Will Not Charge detects the presence of a voltage that is above a threshold on the signal circuit, the ECM will
Battery generate an open circuit diagnostic code (XXX-3) for the sensor.

Can Not Reach Top Engine RPM If the sensor is disconnected at the sensor connector, the presence of pull-up voltage at the
Coolant in Engine Oil sensor connector indicates that the wires from the sensor connector to the ECM are not
Coolant Temperature Is Too High open or shorted to ground. If the sensor is disconnected at the sensor connector, the
absence of pull-up voltage at the sensor connector indicates an open in the signal wire or a
ECM Will Not Accept Factory Passwords
short to ground. If the sensor is disconnected at the sensor connector and the voltage at the
ECM Will Not Communicate with Other Systems … sensor connector is different from pull-up voltage, the signal wire is shorted to another wire
Electronic Service Tool Will Not Communicate w… in the harness.
Engine Cranks but Will Not Start

Engine Has Early Wear

Engine Misfires, Runs Rough or Is Unstable

Engine Oil in Cooling System

Engine Speed Does Not Change

Engine Stalls at Low RPM

Engine Vibration

Engine Will Not Crank

Excessive Black Smoke

Excessive Engine Oil Consumption

Excessive Fuel Consumption

Excessive Valve Lash

Excessive White Smoke

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 Intake Air Temperature Is Too High

Intermittent Engine Shutdown

Intermittent Low Power or Power Cutout

Low Engine Oil Pressure

Low Power/Poor or No Response to Throttle

Mechanical Noise (Knock) in Engine

Noise Coming from Cylinder

Diagnostic Code Cross Reference

No Diagnostic Codes Detected

CID 0001 FMI 02

CID 0001 FMI 05

CID 0001 FMI 06

CID 0001 FMI 07

CID 0002 FMI 02

CID 0002 FMI 05

Illustration 1 g0180051
CID 0002 FMI 06 Typical example of the schematic for the sensors

CID 0002 FMI 07

CID 0003 FMI 02

CID 0003 FMI 05

CID 0003 FMI 06

CID 0003 FMI 07

CID 0004 FMI 02

CID 0004 FMI 05

CID 0004 FMI 06

CID 0004 FMI 07

CID 0005 FMI 02

CID 0005 FMI 05

CID 0005 FMI 06

CID 0005 FMI 07 Illustration 2 g0145844

Typical view of the pin locations on the P2 connector for the pressure sensors
CID 0006 FMI 02 (38) Ground (GND) Intake Manifold Pressure Sensor
(39) Ground (GND) Oil Pressure Sensor
CID 0006 FMI 05 (40) Ground (GND) Fuel Rail Pressure Sensor
(46) Voltage supply (5 V) Intake Manifold Pressure Sensor
CID 0006 FMI 06 (47) Voltage supply (5 V) Oil Pressure Sensor
(48) Voltage supply (5 V) Fuel Rail Pressure Sensor
CID 0006 FMI 07 (51) Signal (SIG) Fuel Rail Pressure Sensor
(55) Signal (SIG) Intake Manifold Pressure Sensor
CID 0041 FMI 03 (56) Signal (SIG) Oil Pressure Sensor

CID 0041 FMI 04

CID 0091 FMI 02

CID 0091 FMI 03

CID 0091 FMI 04

CID 0091 FMI 08

CID 0100 FMI 03

CID 0100 FMI 04

CID 0100 FMI 10

CID 0110 FMI 03

CID 0110 FMI 04

CID 0168 FMI 00

CID 0168 FMI 01

CID 0168 FMI 02 Illustration 3 g01170309

Fuel rail pressure sensor
CID 0171 FMI 03 (1) Voltage supply (Vs)
(2) Ground (GND)
CID 0171 FMI 04 (3) Signal (SIG)

CID 0172 FMI 03

CID 0172 FMI 04

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CID 0190 FMI 08
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 CID 0247 FMI 09

CID 0247 FMI 12

CID 0253 FMI 02

CID 0261 FMI 11

CID 0262 FMI 03

CID 0262 FMI 04

CID 0268 FMI 02

CID 0342 FMI 08

CID 0526 FMI 05

CID 0526 FMI 06

CID 0526 FMI 07

CID 0774 FMI 02 Illustration 4 g01170310

Intake manifold pressure sensor
CID 0774 FMI 03 (1) Voltage Supply (Vs)
(2) Ground (GND)
CID 0774 FMI 04 (3) Signal (SIG)

CID 0774 FMI 08

CID 1639 FMI 09

CID 1743 FMI 02

CID 1779 FMI 05

CID 1779 FMI 06

CID 1785 FMI 03

CID 1785 FMI 04

CID 1785 FMI 10

CID 1797 FMI 03

CID 1797 FMI 04

CID 1834 FMI 02

CID 2246 FMI 06

Event Codes Illustration 5 g01170311

Typical example of the oil pressure sensor
E172 High Air Filter Restriction (1) Voltage Supply (Vs)
(2) Ground (GND)
E194 High Exhaust Temperature (3) Signal (SIG)

E232 High Fuel/Water Separator Water Level

The troubleshooting procedures for the diagnostic codes of each pressure sensor are
E360 Low Engine Oil Pressure identical. The pressure sensors are active sensors. The pressure sensor has three terminals.
E361 High Engine Coolant Temperature Active sensors require supply voltage from the ECM. The P2/J2 ECM connector supplies +5
E362 Engine Overspeed V to terminal 1 of each sensor. The common line is connected to each sensor connector
terminal 2. The signal voltage from terminal 3 of each sensor is supplied to the appropriate
E396 High Fuel Rail Pressure
terminal at the P2/J2 ECM connector.
E398 Low Fuel Rail Pressure
Test Step 1. Verify All Active Diagnostic Codes
E539 High Intake Manifold Air Temperature

E2143 Low Engine Coolant Level A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the
5 Volt Sensor Supply Circuit - Test diagnostic codes.

Analog Throttle Position Sensor Circuit - Test B. Verify if any of the following diagnostic codes are active:
CAN Data Link Circuit - Test
0100-03 Engine Oil Pressure Sensor voltage above normal
Data Link Circuit - Test

Digital Throttle Position Sensor Circuit - Test 0100-04 Engine Oil Pressure Sensor voltage below normal

ECM Memory - Test 0100-10 Engine Oil Pressure Sensor abnormal rate of change
Electrical Connectors - Inspect
1785-03 Intake Manifold Pressure Sensor voltage above normal
Engine Pressure Sensor Open or Short Circuit - T…

Engine Speed/Timing Sensor Circuit - Test 1785-04 Intake Manifold Pressure Sensor voltage below normal

Engine Temperature Sensor Open or Short Circui… 1785-10 Intake Manifold Pressure Sensor abnormal rate of change
Engine Temperature Sensor Open or Short Circui…
1797-03 Fuel Rail Pressure Sensor voltage above normal
Fuel Rail Pump Solenoid - Test

Idle Validation Switch Circuit - Test 1797-04 Fuel Rail Pressure Sensor voltage below normal

Ignition Keyswitch Circuit and Battery Supply Cir…

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Expected Result: 

Indicator Lamp Circuit - Test
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 Injector Data Incorrect - Test One or more of the preceding diagnostic codes are active.

Injector Solenoid Circuit - Test

Results:
Mode Selection Circuit - Test
OK - Proceed to Test Step 2.
PTO Switch Circuit - Test

Starting Aid (Glow Plug) Relay Circuit - Test Not OK -

Repair: Do not use this procedure if 1785-10 or 0100-10 diagnostic codes are active.
Throttle Switch Circuit - Test
Refer to Troubleshooting, "5 Volt Sensor Supply Circuit - Test". When this test is
Wastegate Solenoid - Test
complete, return to the start of this test.

If the preceding codes are logged, an intermittent condition may be causing the logged
codes. Refer to Troubleshooting, "Electrical Connectors - Inspect".

Perform a "Wiggle Test" by using the electronic service tool in order to identify
intermittent connections.

STOP

Test Step 2. Inspect Electrical Connectors And Wiring

A. Thoroughly inspect the terminal connections on the P2/J2 ECM connectors.

B. Thoroughly inspect the following connectors for the engine pressure sensors:

P201 Engine Oil Pressure Sensor

P228 Fuel Rail Pressure Sensor

P200 Intake Manifold Pressure Sensor

C. Refer to Troubleshooting, "Electrical Connectors - Inspect".

D. 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.

E. Check the screw for the ECM connector for the correct torque of 5 N·m (44 lb in).

F. Check the harness for abrasions and for pinch points from the sensors back to the
ECM.

G. Use the electronic service tool to perform a "Wiggle Test". The "Wiggle Test" will
identify intermittent connections.

Expected Result:

All connectors, pins, and sockets are completely coupled and inserted. The harness should
be free of corrosion, abrasions, and pinch points.

Results:

OK - Proceed to Test Step 3.

Not OK -
Repair: Repair the connectors or the harness and/or replace the connectors or the
harness. Ensure that all of the seals are correctly in place and ensure that the
connectors are completely coupled.

Use the electronic service tool in order to clear all logged diagnostic codes and then
verify that the repair eliminates the fault.

STOP

Test Step 3. Verify that the Diagnostic Code is Still Active

A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the
diagnostic codes.

B. Use the electronic service tool to check for active diagnostic codes. Record all active
diagnostic codes.

C. Determine if the fault is related to an open circuit diagnostic code or a short circuit

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diagnostic code.  
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 Expected Result:

Either a short circuit diagnostic code is active or an open circuit diagnostic code is active.

Results:

OK - Short Circuit - A voltage below normal diagnostic code is active at this time.
Proceed to Test Step 4.

OK - Open Circuit - A voltage above normal diagnostic code is active at this time.
Proceed to Test Step 5.

Not OK - A short circuit diagnostic code is not active. An open circuit diagnostic code
is not active. An intermittent fault may exist.
Repair: Use the electronic service tool to perform a "Wiggle Test". If faults are
indicated, then go to the appropriate procedure.

STOP

Test Step 4. Disconnect The Sensor In Order To Create An Open Circuit

A. Turn the keyswitch to the OFF position.

B. Disconnect the connector for the sensor with the short circuit diagnostic code.

C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the
diagnostic codes.

D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for
an open circuit diagnostic code.

Expected Result:

An open circuit diagnostic code for the disconnected sensor is now active.

Results:

OK - A voltage above normal diagnostic code was active before disconnecting the
sensor. An open circuit diagnostic code became active after disconnecting the sensor.
Proceed to Test Step 6.

Not OK - There is a short circuit between the sensor harness connector and the ECM.
Leave the sensor disconnected. Proceed to Test Step 8.

Test Step 5. Measure the Sensor Supply Voltage

A. Turn the keyswitch to the OFF position.

B. Disconnect the sensor from the engine harness.

C. Turn the keyswitch to the ON position.

D. Measure the voltage at the plug for the sensor from the terminal 1 (pressure sensor
supply) to terminal 2 (sensor common).

Expected Result:

The voltage from terminal 1 to terminal 2 measures 4.84 to 5.16 V.

Results:

OK - The sensor supply voltage is correct. Proceed to Test Step 7.

Not OK - The sensor supply voltage is out of the nominal range. Continue testing the
sensor supply circuit.
Repair: Go to Troubleshooting, "5 Volt Sensor Supply Circuit - Test".

STOP

Test Step 6. Determine if the Short Circuit is in the Connector or in the Sensor

A. Thoroughly inspect the connector for moisture.

https://sis2.cat.com/#/detail? B. Inspect the seals and reconnect the sensor. Refer to Troubleshooting, "Electrical 

Connectors - Inspect".
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 C. If the short circuit diagnostic code reappears, the sensor or the sensor connector has a
fault.

Expected Result:
 Parts  Service The short circuit diagnostic code is still present.

2014/09/17
Results: Engine Pressure Sensor Open or Short Circuit - Test (SENR9969)  
OK - There is a fault in the sensor.
Repair: Perform the following procedure:

1. Temporarily connect a new sensor to the harness but do not install the new
sensor in the engine.

2. Use the electronic service tool to verify that the replacement sensor eliminates
the fault.

3. If the diagnostic code is eliminated, install the replacement sensor.

4. Use the electronic service tool to clear the logged diagnostic codes.

STOP

Not OK - Repair the engine harness connector. Use the electronic service tool to clear
the logged diagnostic codes.
STOP

Test Step 7. Create a Short Circuit Between the Signal and the Common Terminals at the
Engine Harness Connector

A. Turn the keyswitch to the ON position.

B. Fabricate a jumper wire that is 150 mm (6 inch) long. Crimp a terminal to both ends of
the wire.

C. Monitor the "Active Diagnostic Code" screen of the electronic service tool before
installing the jumper wire and after installing the jumper wire.

D. Install the jumper on the engine harness connector. Install one end of the jumper at the
sensor signal (terminal 3). Install the other end of the jumper at the common
connection for the pressure sensor (terminal 2). Wait at least 30 seconds for activation
of the short circuit diagnostic code.

Expected Result:

A short circuit diagnostic code is active when the jumper is installed. An open circuit
diagnostic code is active when the jumper is removed.

Results:

OK - The engine harness and the ECM are OK.

Repair: Perform the following repair:

1. Temporarily connect a new sensor to the harness but do not install the new
sensor in the engine.

2. Use the electronic service tool to verify that the replacement sensor eliminates
the fault.

3. If the diagnostic code is eliminated, install the replacement sensor.

4. Use the electronic service tool to clear the logged diagnostic codes.

STOP

Not OK - The open circuit diagnostic code remains active when the jumper is installed.
The most probable location for the open circuit is in the common wire for the sensor, or
in the sensor signal wire of the engine harness between the ECM and the sensor.
Remove the jumper. Proceed to Test Step 8.

Test Step 8. Check the Operation of the ECM by Creating Open and Short Circuits at the
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 A. Turn the keyswitch to the OFF position.

B. Disconnect the P2 connector from the ECM. Thoroughly inspect both halves of the
connector for signs of corrosion or moisture. Refer to Troubleshooting, "Electrical
Connectors - Inspect".

C. Reconnect the P2 connector.

D. Turn the keyswitch to the ON position. Use the electronic service tool in order to
monitor the "Active Diagnostic Code" screen. Wait at least 10 seconds for activation of
the code.
An open circuit diagnostic code should be active for the suspect sensor.

Note: When the P2 connector is disconnected, all of the open circuit diagnostic codes
for the pressure sensors and temperature sensors will be active. This is normal.
Disregard the diagnostic codes for the pressure sensors and the temperature sensors
that are not suspect. Address the diagnostic codes for the suspect sensors only.

E. Turn the keyswitch to the OFF position.

F. Fabricate a jumper wire that is 150 mm (6 inch) long. Crimp a terminal to both ends of
the wire.

G. Install the jumper wire on the P2 connector. Insert the jumper wire between the
terminal for the suspect sensor signal and the common connection for the engine
pressure sensor.
Use the electronic service tool to verify that there is a short circuit diagnostic code.

Expected Result:

Voltage below normal diagnostic codes and voltage above normal diagnostic codes were
active.

Results:

OK - The ECM is operating correctly. Proceed to Test Step 9.

Not OK - One of the following conditions exists: The voltage below normal diagnostic
code is not active when the harness is disconnected. The voltage above normal
diagnostic code is not active when the jumper wire is installed.
Repair: Perform the following repair:

1. Make sure that the latest flash file for the application is installed in the ECM.
Refer to Troubleshooting, "Flash Programming".

2. Contact the Technical Communicator at the Caterpillar dealer.

Note: This consultation can greatly reduce the repair time.

3. If the Technical Communicator recommends the use of a test ECM, install a test
ECM. Refer to Troubleshooting, "Replacing the ECM".

4. Remove all jumpers and replace all connectors.

5. Use the electronic service tool to recheck the system for active diagnostic codes.

. If the fault is resolved with the test ECM, reconnect the suspect ECM.

7. If the fault returns with the suspect ECM, replace the ECM.

. Use the electronic service tool in order to clear all logged diagnostic codes and
then verify that the repair eliminates the fault.

STOP

Test Step 9. Bypass the Harness Wiring Between the ECM and the Sensor Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the P2 connector and disconnect the connector from the suspect sensor.

C. Remove the sensor signal wire from the P2 connector.

https://sis2.cat.com/#/detail? D. Remove the signal wire (terminal 3) from the sensor connector on the engine harness.
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 E. Fabricate a jumper wire that is long enough to reach from the ECM to the sensor
connector or use an engine sensor harness bypass with three terminals.
Note: If an engine sensor harness bypass is being made, crimp a socket on one end in
order to connect to the ECM. Crimp either a pin or a socket on the other end, as
required.

F. Insert the one end of the engine sensor harness bypass into P2 connector on the
engine harness. Insert the other end of the engine sensor harness bypass into the
sensor connector of the engine harness.

G. Reconnect the P2 connector and the sensor connector.

H. Turn the keyswitch to the ON position.

I. Use the electronic service tool to monitor the "Active Diagnostic Code" screen for either
the open circuit diagnostic code for the sensor or the short circuit diagnostic code for
the sensor.

Expected Result:

The diagnostic code disappears when the jumper or the bypass is installed.

Results:

OK - There is a fault in the wiring harness.

Repair: Perform the following repair:

1. Repair the faulty harness or replace the faulty harness.

2. Use the electronic service tool in order to clear all logged diagnostic codes and
then verify that the repair eliminates the fault.

STOP

Not OK - The most likely cause is an intermittent fault.

Repair: Use the electronic service tool to perform a "Wiggle Test". If no fault is found,
restart this test procedure from Test Step 1.

STOP

PSP-00020CD4
2020/11/14
14:24:28-05:00
i02373634
© 2020 Caterpillar Inc.
Caterpillar:
Confidential Green

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