5031769 JOHNSON **KEY (13)

Illustration 1 g00856337
Typical exampleTest Step 1. Check for Connector Damage.
Turn the main disconnect switch to the OFF position.
Turn the 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:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, abrasion or pinch points.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 the Status while the "Emergency Kill" Switch is Active.
Start the Caterpillar Electronic Technician (ET).
Turn the main disconnect switch to the ON position.
Turn the circuit breaker CB-8 to the ON position.
Activate the "Emergency Kill" switch. If multiple switches have been installed, ensure that any other "Emergency Kill" switch has not been activated.
Observe the status of the "Emergency Kill" switch on the Cat ET.Expected Result:The parameter for the "Emergency Kill" switch should read "ON".Results:
OK - The "Emergency Kill" switch is working correctly. Proceed to test step 3.
Not OK - The parameter for the "Emergency Kill" switch does not display "ON". Proceed to test step 4.Test Step 3. Check the Status while the "Emergency Kill" Switch is Not Active.
Deactivate the "Emergency Kill" switch.
Observe the status of the "Emergency Kill" switch on the Cat ET.Expected Result:The parameter for the "Emergency Kill" switch should read "OFF".Results:
OK - The "Emergency Kill" switch is functioning correctly.Repair: There may be an intermittent problem. Perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" if the problem is intermittent. Stop.
Not OK - The parameter for the "Emergency Kill" switch does not display "OFF". Proceed to test step 4.Test Step 4. Test the Input for the "Emergency Kill" Switch to the ECM.
Turn the circuit breaker CB-8 to the OFF position.
Disconnect ECM connector P1 from the ECM. Remove the socket pins P1-29, P1-02 and P1-20 from ECM connector P1.Note: Disconnecting the common sensor wire from the ECM will generate an open circuit diagnostic code for all sensors that are connected to the sensor common. Troubleshoot the original diagnostic code. Delete the logged diagnostic codes when you are finished.
Insert a wire jumper into the sockets for the wires in P1-29, P1-02 and P1-20, that were removed in the previous step.
Reconnect connector P1 to ECM connector J1.
Turn the circuit breaker CB-8 to the ON position.
Observe the parameters for the "Emergency Kill" switch on the Cat ET.
Turn the circuit breaker CB-8 to the OFF position.
Locate a suitable jumper wire and connect P1-02 and P1-20 to P1-29.
Turn the circuit breaker CB-8 to the ON position.
Observe the parameters for the "Emergency Kill" switch on the Cat ET.
Turn the circuit breaker CB-8 to the OFF position.
Remove the wire jumpers. Replace all wires and reconnect all connectors.Expected Result:The parameter for the "Emergency Kill" switch should display "OFF" when the jumper is installed. The parameter for the "Emergency Kill" switch should display "ON" when the jumper is removed.Results:
OK - The parameter for the "Emergency Kill" switch is displaying the proper states. The problem is not with the ECM. Proceed to test step 5.
Not OK - The parameter for the "Emergency Kill" switch is not displaying the proper states.Repair: Replace the ECM. Perform the diagnostic procedure Troubleshooting, "Replacing the ECM". Stop.Test Step 5. Check the Wiring of the "Emergency Kill" Switch Circuit.
Disconnect ECM connector J1/P1.
Install a wire jumper between terminal 2 and terminal 10 on the "Emergency Kill Relay".
Measure the resistance between P1-29 and P1-20.
Measure the resistance between P1-29 and P1-2.
Remove the wire jumper from terminal 2 and terminal 10 on the "Emergency Kill Relay".Expected Result:The resistance should measure less than 10 Ohms.Results:
OK - The resistance measures less than 10 Ohms. Proceed to test step 7.
Not OK - The resistance measures more than 10 Ohms. Proceed to test step 6.Test Step 6. Check the "Emergency Kill" Switch Circuit in the "ADEM Box".
Disconnect ECM connector J1/P1.
Install a wire jumper between terminal 2 and terminal 10 on the "Emergency Kill Relay".
Measure the resistance between terminal 101 and terminal 102 in the "ADEM Box".
Measure the resistance between terminal 101 and terminal 123 in the "ADEM Box".
Measure the resistance between terminal 101 and terminal 127 in the "ADEM Box".
Remove the wire jumper from terminal 2 and terminal 10 on the "Emergency Kill Relay". Reconnect ECM connector J1/P1.Expected Result:The resistance should measure less than 10 Ohms for each measurement.Results:
OK - The resistance measures less than 10 Ohms for each measurement.Repair: The wiring and/or the connectors between the "ADEM Box" terminals 101 and 127 and the ECM connector P1 need repair. Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.
Not OK - The resistance measures more than 10 Ohms on one of the measurements.Repair: Check the component and/or the terminal before the incorrect resistance measurement. Repair the faulty component or replace the faulty component. Refer to Illustration 1. Stop.Test Step 7. Check the Normally Closed Contacts on the "Emergency Kill Relay".
Remove the wire from terminal 2 of the normally closed contacts of the "Emergency Kill Relay".
Ensure that the main disconnect switch is in the ON position.
Turn the circuit breaker CB-8 to the ON position.
Activate the "Emergency Kill" switch.
Measure the resistance between the normally closed contacts on terminal 2 and terminal 10 of the "Emergency Kill Relay".
Deactivate the "Emergency Kill" switch. Reconnect the wire that was removed from terminal 2 of the "Emergency Kill Relay".Expected Result:The resistance should be greater than 20,000 Ohms when the "Emergency Kill" switch is activat