0321963 JOHNSON BOOT,Switch

Illustration 1 g00762307
Test Step 1. Check for Connector Damage.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.
Reconnect ECM connector J2/P2.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check the Engine Prelube Pressure Switch.
Disconnect ECM connector J1/P1.
Measure the resistance between the engine prelube pressure switch P1-20 and the Digital Return P1-29.
Reconnect the ECM connector P1.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. The engine prelube pressure switch is not active. Proceed to test step 3.
Not OK - The resistance is less than 20,000 Ohms. The engine prelube pressure switch is active. Verify that the engine does not have a residual oil pressure that is high enough to activate the switch. If there is no residual oil pressure, the switch is not operating correctly or there is a problem with the wiring. Proceed to test step 4.Test Step 3. Check the Status of the Engine Prelube Pressure Switch on the Caterpillar Electronic Technician (ET).
Connect the Cat ET to the service tool connector J60/P60.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Observe the parameters for the engine prelube and for the ignition switch.Expected Result:The parameter for the engine prelube should display "OFF". The parameter for the ignition switch should display "STOP".Results:
OK - The parameter for the engine prelube displays "OFF" and the parameter for the ECS displays "STOP". Proceed to test step 5.
Prelube Disabled - The prelube function is disabled. The engine prelube duration is set to zero.Repair: The cycle time of the engine prelube must be greater than zero for the prelube function to work.STOP
Ignition Switch Not OFF - Repair: Perform the diagnostic functional test Troubleshooting, "Engine Control Switch (ECS)".STOPTest Step 4. Measure the Resistance of the Engine Prelube Pressure Switch.
Disconnect the wires from terminal 1 and terminal 2 of the engine prelube pressure switch.
Measure the resistance between terminal 1 and terminal 2 of the engine prelube pressure switch.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. There is a problem with the wiring between ECM connector J1/P1 and the switch.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The resistance is less than 20,000 Ohms. There is a problem with the engine prelube pressure switch.Repair: Temporarily replace the engine prelube pressure switch with a new switch. If the problem is no longer present, reinstall the old switch. If the problem returns, replace the switch.STOPTest Step 5. Check the Status of the ECS on the Cat ET.
Use the Cat ET and view the following parameters: Engine Prelube and Ignition Switch.
Turn the ECS to the START position.
View the parameters for the engine prelube pressure switch and the ignition switch. View the parameters before the engine prelube duration expires and before the switch activates.Note: If necessary, program the engine prelube duration to 60 seconds.Expected Result:When the ECS is in the STOP position, the engine prelube should display "OFF" and the ignition switch should display "STOP". When the ECS is in the START position, the engine prelube should display "ON" and the ignition switch should display "RUN".Results:
OK - The parameters are correct. Proceed to test step 6.
Not OK - The status of the ignition switch does not display "RUN".Repair: Perform the diagnostic functional test Troubleshooting, "Engine Control Switch (ECS)".STOPTest Step 6. Check for Output Voltage to the Prelube Motor.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Connect one end of a voltmeter to the − Battery terminal.
Connect the other end of the voltmeter to wire C465-OR on terminal 2 of the Prelube Slave Relay ("PPRS").
Turn the ECS to the START position.
Monitor the voltage at the Prelube Slave Relay.
Turn the ECS to the STOP position.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 11.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 7.Test Step 7. Check for Output Voltage to the Prelube Slave Relay.
Leave one end of the voltmeter on the − Battery terminal.
Connect the other end of the voltmeter to terminal 4 of the Prelube Master Relay ("PPRM").
Turn the ECS to the START position.
Monitor the voltage at the Prelube Master Relay.
Turn the ECS to the STOP position.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. The problem is the Prelube Slave Relay.Repair: Temporarily replace the Prelube Slave Relay with a new relay. If the problem is no longer present, reinstall the old Prelube Slave Relay. If the problem returns, replace the Prelube Slave Relay. The wire between the slave relay and the master relay could possibly be faulty.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 8.Test Step 8. Check the Coil of the Prelube Master Relay.
Leave the ECS in the S