CA2554 shows in the monitor as "Exh manifold press sens in range error" When I first started working on this, the data looked fine. Sensor read 97kpa with engine off, but the failure counter would increment every time the key was turned on, whether i started the engine or not. I replaced the sensor, and cleaned the tube as those measures had fixed previous machines that I'd seen with the same problem. It didn't fix this one. Further messing around with it, I discovered that I could wiggle the harness and get the pressure reading on the monitor to fluctuate from 0 to over 200kpa, so I replaced the connector and a section of wire that had rubbed through. I now have steady 97kpa with the engine off but it still increments the failure counter at key on. All the other pressure sensors read between 95kpa and 98 kpa, so I don't know why the ECM doesn't like 97kpa from the exhaust manifold pressure sensor... Has anyone seen any similar cases?
I did not remember the exhaust pressure sensor being an absolute sensor, meaning that it does not read zero with key on/engine off - it reads atmospheric pressure. Must be wrong since the 97 kpa you are seeing is a touch over 14 psi, which if your elevation is not high seems correct. Are the readings from the exhaust pressure, charge/boost pressure, and atmospheric pressure all close to each other with key on/engine off? Is you mass air flow(MAF) sensor reading zero with key on engine off? If you are happy with sensor readings may want to perform the following fault clearing steps from the service manual. Place the machine on level ground. 1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine controller to determine drift of voltage when starting switch is turned to ON position) 2. Turn starting switch from OFF position to ON position. 3. Start engine and run it at low idle (with no load) for approximately 1 minute. 4. Warm up engine. If failure code disappears after implementing the following 1) to 4) "Brake, F3, Steering, and work equipment relieved", repair is complete. "Brake, F3, steering, and work equipment relieved" 1) Select P mode for working mode, set pedal mode to brake mode, and turn fuel dial to MAX position. 2) While depressing the deceleration/ brake pedal to stroke end position, set the parking brake lever to FREE position and PCCS lever to FORWARD position. kIf you release the deceleration/ brake pedal after setting PCCS lever to FORWARD position, machine starts moving. So be sure to keep depressing the pedal. 3) Engine speed is increased to approximately 2,280 rpm if you select gear speed F3 by using shift switch and move PCCS lever in steering direction up to stroke end. 4) While maintaining engine at high speed, raise blade to the upper end by using blade control lever and relieve its pressure intermittently. (After relieving it for approximately 1 minute, return blade control lever to neutral position. Wait for approximately 5 seconds and relieve its pressure again.) In order to finish, set PCCS lever to NEUTRAL position and set parking brake lever to LOCK position, then release the deceleration/ brake pedal. a Take care not to overheat the work equipment oil temperature. a If failure code disappears, repair is complete. 5. If failure code still remains displayed, repeat above operations 2 to 4 three times. a If failure code disappears, repair is complete. a You can clear every failure code by executing "Reset All Faults" command by using service tool "INSITE". For how to use "INSITE", see "INSITE" operation manual.