0432460 JOHNSON ENGINE COVER ASSY., 225

Table 1
J1939 Code CDL Code Code Description Comments
677-5 444-5 Engine Starter Motor Relay : Current Below Normal This code indicates there is a problem with the engine starter motor relay and/or the electrical circuit on the ECM.
677-6 444-6 Engine Starter Motor Relay : Current Above Normal This code indicates there is a problem with the engine starter motor relay and/or the electrical circuit on the ECM. Note: Refer to Troubleshooting, "Component Location" in this manual for the proper location of the components listed in this procedure.Electrical Checkouts on the Cat® Electronic Technician (ET)
Table 2
Component Electrical Checkout
Engine Starter Motor Relay Attempt to start the engine. Once the ECM attempts to energize the relay, the code will become active.
Refer to the machine-specific schematic for the "Engine Starter Motor Relay" wiring circuit. Reference: Use the application specific Schematic for the pin outs that are needed for testing.Recommended Actions
Table 3
Troubleshooting Test Steps Values Results
1. Determine the Diagnostic Code
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM) . Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Wait at least 30 seconds in order for the diagnostic codes to become active.
Look for an active -5 code or for a logged -6 code.
Diagnostic Trouble Codes
Result: There is an active or there is a logged -5 code.
Proceed to Test Step 2.
Result: There is an active or there is a logged -6 code.
Proceed to Test Step 3.
2. Check the Wiring for an Open Circuit
A. Verify that the harness connector is free of debris, free of corrosion and securely connected.
B. Disconnect the solenoid from the engine harness.
C. Connect a jumper wire between the terminals of the harness connector for the suspect coil. The coil is replaced with a short circuit.
D. Perform the appropriate electrical checkout. Refer to Table 2.
Open Circuit
Result: A -5 code became active during the electrical checkout.
The ECM did not detect the jumper wire. There is an open circuit in the wiring between the coil and the ECM connector. There may be a problem with a connector.
Repair: Repair the appropriate harness wiring or replace the appropriate harness.
Verify that the problem is resolved.
Result: A -6 code is activated during the electrical checkout. The ECM detected the jumper wire. There is a problem with the solenoid. Clear the -6 code by cycling the keyswitch to the OFF position.
Repair: Replace the solenoid.
Verify that the problem is resolved.
3. Check the Wiring for a Short Circuit
A. Disconnect the solenoid from the engine harness.
B. Clear the -6 code by cycling the keyswitch to the OFF position.
C. Perform the appropriate electrical checkout. Refer to Table 2.
Short Circuit
Result: A -6 code became active during the electrical checkout.
The ECM did not detect the open circuit. There is a short circuit in the wiring between the coil and the ECM connector. There may be a problem with a connector.
Repair: Repair the appropriate harness wiring or replace the appropriate harness.
Verify that the problem is resolved.
Result: A -5 code became active during the electrical checkout.
The ECM detected the open circuit. The wiring is OK. The coil has a short circuit.
Repair: Replace the solenoid. Verify that the problem is resolved.
Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).Test Step 1. Follow the procedure above.Expected Result:Procedure completedResults:
- STOP