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Product: EXCAVATOR
Model: 336D L EXCAVATOR PRF
Configuration: 336D & 336D L Excavators PRF00001-UP (MACHINE) POWERED BY C9 Engine

Troubleshooting
C9 Engines for Caterpillar Built Machines
Media Number -RENR5089-31 Publication Date -01/11/2014 Date Updated -06/11/2014

i02886496

Engine Pressure Sensor Open or Short Circuit - Test

System Operation Description:

Use this procedure to troubleshoot any suspect problems with the following sensors:

• Injection actuation pressure sensor

• Boost pressure sensor for the intake manifold

• Atmospheric pressure sensor

• Fuel pressure sensor

• Engine oil pressure sensor

This procedure covers the following diagnostic codes:

• 094-03 Fuel Pressure open/short to +batt

• 094-04 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 voltage high

• 164-04 Injector Actuation Pressure voltage low

• 274-03 Atmospheric Pressure open/short to +batt

• 274-04 Atmospheric Pressure short to ground

• 1785-03 Intake Manifold Pressure Sensor voltage high

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• 1785-04 Intake Manifold Pressure Sensor voltage low

The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The Engine
Control Module (ECM) sends a 5 volt supply to terminal A of each sensor. The sensor common connection
is connected to terminal B of each sensor. The signal voltage from terminal C of each sensor is sent to the
appropriate terminal on an ECM connector.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect an open in the signal circuit. When the ECM detects the presence of a
voltage that is above a threshold on the signal wire, the ECM will generate a 03 diagnostic code.

If the sensor is disconnected at the sensor connector, the presence of pull-up voltage at the sensor connector
indicates that the signal wire and the return wire from the sensor connector to the ECM are good.

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, an open in the return wire, or a short to ground.

If the sensor is disconnected at the sensor connector and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal wire is shorted to another wire in the harness.

Illustration 1 g01436855

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Schematic for the engine pressure sensors

Test Step 1. Inspect the Electrical Connectors and Wiring

A. Remove the electrical power from the ECM.

Illustration 2 g01199199

A typical left side view of the C9 engine

(1) Fuel pressure sensor

(2) Injection actuation pressure sensor

(3) Boost pressure sensor for the intake manifold

(4) Atmospheric pressure sensor

(5) Engine oil pressure sensor

(6) J2/P2 connectors

(7) ECM

(8) J1/P1 connectors

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Illustration 3 g01255900

A typical left side view of the C7 engine

(9) Fuel pressure sensor

(10) Injection actuation pressure sensor

(11) Atmospheric pressure sensor

(12) Boost pressure sensor for the intake manifold

(13) Engine oil pressure sensor

(14) J2/P2 connectors

(15) ECM

(16) J1/P1 connectors

B. Thoroughly inspect connectors (6) and (8) . Thoroughly inspect the connectors for each engine
pressure sensor. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors -
Inspect".

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Illustration 4 g01209367

P2 ECM connector

(P2-15) Boost pressure sensor for the intake manifold

(P2-17) Sensor return

(P2-54) Sensor return

(P2-28) Engine oil pressure sensor

(P2-40) Fuel pressure sensor

(P2-57) Atmospheric pressure sensor

(P2-85) Injection actuation pressure sensor

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(P2-72) +5 V Supply

(P2-80) +5 V Supply

Illustration 5 g01123211

Connectors for the sensors

(A) Supply

(B) Return

(C) Signal

C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the engine pressure
sensors.

D. Check the torque of the allen head screws for the ECM connectors. Refer to the diagnostic functional
test Troubleshooting, "Electrical Connectors - Inspect".

E. Check the harness and wiring for abrasions and for pinch points from each sensor back to the ECM.

Expected Result:

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All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of
corrosion, of abrasion, and of pinch points.

Results:

• OK - The harness and wiring are OK. Proceed to Test Step 2.

• Not OK - There is a problem in the wiring and/or the connectors.

Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the connectors are completely coupled.Verify that the
problem is resolved.

STOP

Test Step 2. Check the Voltage on the +5 V Supply Wire

A. Remove the electrical power from the ECM.

B. Disconnect the harness connectors for the following sensors:

◦ Injection actuation pressure sensor

◦ Boost pressure sensor for the intake manifold

◦ Atmospheric pressure sensor

◦ Fuel pressure sensor

◦ Engine oil pressure sensor

C. Restore the electrical power to the ECM.

D. Measure the voltage between terminals A (+5 VDC) and B (Return) at each sensor connector on the
engine harness.

E. Remove the electrical power from the ECM.

F. Connect all of the sensors.

Expected Result:

Each voltage measurement is 5.0 ± 0.2 VDC.

Results:

• OK - Each voltage measurement is 5.0 ± 0.2 VDC. Proceed to Test Step 3.

• Not OK - At least one voltage measurement is not 5.0 ± 0.20 VDC.

Repair: Refer to the diagnostic functional test Troubleshooting, "5 Volt Engine Pressure Sensor
Supply Circuit - Test".

STOP

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Test Step 3. Check for Active Diagnostic Codes

A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, "Electronic Service Tools".

B. Restore the electrical power to the ECM.

C. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes may
become active. Look for an active diagnostic code for an engine pressure sensor.

D. Determine if the problem is related to a 03 diagnostic code or a 04 diagnostic code.

Expected Result:

No diagnostic codes are active.

Results:

• OK - No diagnostic codes are active for the engine pressure sensors.

Repair: If any of the above codes are logged and the engine is not running properly, refer to
troubleshooting without a diagnostic code Troubleshooting.If the engine is running properly at this
time, there may be an intermittent problem in a harness that is causing the codes to be logged. Refer
to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".

STOP

• Active 04 code - An 04 diagnostic code is active. Proceed to Test Step 4.

• Active 03 code - An 03 diagnostic code is active. Proceed to Test Step 5.

Test Step 4. Disconnect the Suspect Sensor in Order to Create an Open Circuit

A. Remove the electrical power from the ECM.

B. Disconnect the sensor connector of the sensor with the 04 diagnostic code.

C. Restore the electrical power to the ECM. Wait at least 30 seconds for activation of the diagnostic
codes.

D. Access the "Active Diagnostic Code" screen on Cat ET. Check for an active 03 diagnostic code for
the disconnected sensor.

E. Remove the electrical power from the ECM.

Expected Result:

A 03 diagnostic code is now active for the disconnected sensor.

Results:

• OK - A 04 diagnostic code was active before you disconnected the sensor. A 03 diagnostic code
became active after the sensor was disconnected. The harness and the ECM are OK. There may be a
problem with the sensor.

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Repair: Connect a new sensor to the harness, but do not install the new sensor in the engine. Verify
that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the
sensor, permanently install the new sensor. Clear any logged diagnostic codes.

STOP

• Not OK - A 04 diagnostic code was active before you disconnected the sensor. The 04 diagnostic
code remained after the sensor was disconnected. There is a problem with the harness or the ECM.
Leave the sensor disconnected. Proceed to Test Step 7.

Test Step 5. Check the Signal Wire for a Short Circuit

A. Remove the electrical power from the ECM.

B. Disconnect the J2/P2 connector and disconnect the J1/P1 connectors.

C. Disconnect the harness connector for the suspect sensor.

D. Identify the terminal for the signal wire on the ECM connector that is appropriate for the suspect
sensor. Measure the resistance between the appropriate terminal and the remaining terminals on both
ECM connectors.

E. Measure the resistance between the appropriate terminal and the engine ground.

F. Connect the J2/P2 connector and connect the J1/P1 connectors. Connect the connectors for the
suspect sensor.

Expected Result:

Each resistance measurement indicates an open circuit.

Results:

• OK - Each resistance measurement indicates an open circuit. Proceed to Test Step 6.

• Not OK - At least one resistance measurement does not indicate an open circuit. There is a problem
in the wiring for the sensor. There may be a problem with a connector.

Repair: Repair the wiring and/or the connector. Replace parts, if necessary.Verify that the problem
is resolved.

STOP

Test Step 6. Create a Short at the Suspect Sensor Connector

A. Remove the electrical power from the ECM.

B. Install a jumper wire with Deutsch sockets on each end between terminals B (Sensor return) and C
(Signal) on the harness connector for the suspect sensor.

C. Restore the electrical power to the ECM.

Note: Monitor the "Active Diagnostic Codes" screen on the electronic service tool before installing
the jumper wire and after installing the jumper wire.

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D. Observe the "Active Diagnostic Codes" screen on Cat ET. Wait at least 30 seconds so that any codes
may become active. Look for a 04 diagnostic code.

E. Remove the jumper wire.

F. Remove the electrical power from the ECM.

Expected Result:

A 04 diagnostic code was active when the jumper wire was installed. A 03 diagnostic code became active
when the jumper wire was removed.

Results:

• OK - A 04 diagnostic code was active when the jumper wire was installed. A 03 diagnostic code
became active when the jumper wire was removed. The engine harness and the ECM are OK.

Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic codes for the sensor. If there are no active
diagnostic codes for the new sensor, permanently install the new sensor. Clear any logged diagnostic
codes.Verify that the problem is resolved.

STOP

• Not OK - A 04 diagnostic code was active when the jumper wire was installed. The 04 code
remained when the jumper wire was removed. There is a problem with the harness or with the ECM.
Proceed to Test Step 7.

Test Step 7. Check the Operation of the ECM

A. Remove the electrical power from the ECM.

B. Check the operation of the ECM by creating an open at the ECM:

a. Disconnect the appropriate ECM connector.

b. Remove the signal wire for the suspect sensor from the ECM connector.

c. Remove the return wire for the suspect sensor from the ECM connector.

Note: Disconnecting the return wire from the ECM will generate an open circuit diagnostic
code for all sensors that are connected to the return wire. Ignore the additional codes.
Troubleshoot the original diagnostic code and clear the codes when you are finished.

d. Connect the ECM connector.

C. Restore the electrical power to the ECM.

D. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds so that any codes
may become active.

A 03 diagnostic code should be active for the suspect sensor.

E. Remove the electrical power from the ECM.

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F. Check the operation of the ECM by creating a short circuit at the ECM:

a. Disconnect the appropriate ECM connector.

b. Install a jumper wire between the two terminals for the sensor's signal wire and the sensor's
return wire.

c. Connect the ECM connector.

G. Restore the electrical power to the ECM.

H. Monitor the "Active Diagnostic Code" screen on Cat ET. Wait at least 30 seconds so that any codes
may become active.

A short circuit diagnostic code (04) should be active when the wire jumper is installed.

I. Remove the electrical power from the ECM.

J. Remove the jumper wire. Return the wiring to the original configuration.

Expected Result:

A 03 diagnostic code was active when the signal wire was removed from the ECM connector. A 04
diagnostic code became active when the signal wire was connected to the return wire.

Results:

• OK - The ECM is operating properly. There is a problem in the wiring between the ECM and the
sensor connector.

Repair: If the code is active for more than one sensor, the problem is most likely in the return wire
for the sensor. The problem may be in a connector. Repair the return wire and/or the connector.
Replace parts, if necessary.If the code is only active for one sensor, the problem is most likely in the
signal wire for the sensor. Repair the signal wire and/or the connector. Replace parts, if
necessary.Verify that the problem is resolved.

STOP

• Not OK - One of the following conditions exists: The 03 diagnostic code is not active when the
signal wire is disconnected. The 04 diagnostic code is not active when the wire jumper is installed.

Repair: Replace the ECM. Refer to electronic troubleshooting Troubleshooting, "Replacing the
ECM". Verify that the problem is resolved.

STOP

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