5032703 JOHNSON CLAMP

Illustration 1 g00854421
Typical exampleTest Step 1. Check for Connector Damage.
Turn the main disconnect switch to the OFF position.
Turn circuit breaker "CB-8" 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 pinch points.Expected Result:The connectors and wiring are free of the following problems: damage, abrasion, corrosion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.Test Step 2. Check for "ACTIVE" Diagnostic Codes
Start the Caterpillar Electronic Technician (ET).
Turn the main disconnect switch to the ON position.
Turn circuit breaker "CB-8" to the ON position.
Determine if you have either of the following active diagnostic codes:
CID-FMI 168-00 System Voltage High
CID-FMI 168-01 System Voltage LowExpected Result:One of the diagnostic codes is present.Results:
OK - One of the diagnostic codes is present. Proceed to test step 3.
Not OK - One of the diagnostic codes is not present. Proceed to test step 4.Test Step 3. Check the Battery Voltage.
Turn the main disconnect switch to the OFF position.
Turn circuit breaker "CB-8" to the OFF position.
Measure no-load voltage at the battery posts. Refer to Testing and Adjusting, "Test Tools for the Electrical System" for the proper procedures to check the batteries.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to the Operating Manual, SEHS9249. Refer to Special Instruction, SEHS7633.Expected Result:The no-load voltage at the batteries should be at least 23.5 VDC, and the batteries should pass the load test.Results:
OK - The no-load voltage at the batteries is at least 23.5 VDC, and the batteries pass the load test. Proceed to test step 4.
Not OK - The no-load voltage at the batteries is less than 23.5 VDC, and/or the batteries fail the load test.Repair: The batteries or the alternator are causing the problem. Recharge the batteries or replace the batteries. Refer to Testing and Adjusting, "Initial Troubleshooting Procedure". Verify that the original condition is resolved. Stop.Test Step 4. Check for Battery Voltage to the ECM.
Turn the main disconnect switch to the OFF position.
Turn circuit breaker "CB-8" to the OFF position.
Remove ECM connector J1/P1.
Turn circuit breaker "CB-8" to the ON position.
Measure the voltage at ECM connector J1/P1 between pins P1-04 and P1-11.
Measure the voltage at ECM connector J1/P1 between pins P1-06 and P1-05.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 5.
Not OK - The voltage does not measure 24 3 VDC.Repair: There is a problem with the wiring and/or connectors between the battery and the ECM. Verify that circuit breaker "CB-8" is not tripped. Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.Test Step 5. Check the Voltage to the Input for the Keyswitch on the ECM.
Turn circuit breaker "CB-8" to the ON position.
Turn the main disconnect switch to the ON position.
Measure the voltage at the ECM connector J1/P1 between pins P1-23 and P1-11.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 8.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 6.Test Step 6. Check the Voltage from the Contacts of the "Main Disconnect Relay".
Use a voltmeter to check the voltage between terminal 5 on the "main disconnect relay" and engine ground.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: There is a problem in the harness and/or connectors between terminal 5 of the "main disconnect relay" and the ECM. Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 7.Test Step 7. Check the Voltage to the Coil of the "Main Disconnect Relay".
Use a voltmeter to check the voltage between terminal 13 of the "main disconnect relay" and engine ground.
Use a voltmeter to check the voltage between terminal 9 on the "main disconnect relay" and engine ground.Expected Result:The voltage should measure 12 1 VDC on terminal 13 of the "main disconnect relay". The voltage should measure 24 3 VDC on terminal 9 of the "main disconnect relay".Results:
OK - The voltage measures 12 1 VDC.Repair: Verify that the wire on terminal 14 of the "main disconnect relay" has continuity to the - Battery terminal. Replace the "main disconnect relay". Verify that the problem is no longer present. Stop.
Not OK - Terminal 9 - The voltage does not measure 24 3 VDC.Repair: There is a problem with the wiring and/or connectors between the battery and terminal 9 of the "main disconnect relay". Verify that circuit breaker "CB-8" is not tripped. Repair the connectors and/or wiring or replace t