TRAVEL GEAR ASSY. 1R5394 - Caterpillar

The Electronic Control Module (ECM) creates a regulated voltage of 5.0 0.2 VDC that is supplied to terminal A of the harness connectors for these sensors:
Injection actuation pressure sensor
Boost pressure sensor for the Intake manifold
Atmospheric pressure sensor
Fuel pressure sensor
Engine oil pressure sensorThis procedure covers the following diagnostic codes:
262-03 5 Volt Sensor DC Power Supply short to +batt
262-04 5 Volt Sensor DC Power Supply short to ground
1785-10 Intake Manifold Pressure Signal abnormal rate of changeA +5 V diagnostic code is probably caused by a short circuit to ground or a short circuit to another voltage source in the harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with the ECM.
Illustration 1 g01436855
Schematic for the 5 volt supply
Test Step 1. Inspect the Electrical Connectors and the Wiring
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
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
Thoroughly inspect the ECM connectors. Thoroughly inspect the connectors for each pressure sensor. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
Illustration 4 g01223554
P2 terminals that are associated with the 5 volt supply for the pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
Illustration 5 g01123211
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the pressure sensor supply.
Check the torque of the allen head screws for the ECM connectors. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
Check the harness and the wiring for abrasion and for pinch points from each sensor back to the ECM. Expected Result:All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.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 repair eliminates the problem.STOPTest Step 2. Check for Active Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Restore electrical power to the ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Look for the following diagnostic codes:
03
04
10Note: Wait at least 30 seconds in order for the diagnostic codes to become active.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic code is active.Repair: The problem is no longer present. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - One