0387660 JOHNSON PISTON,Standard

Illustration 1 g00835362
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 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.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 connector and/or wiring or replace the connector and/or wiring.STOPTest Step 2. Check the Cat Data Link.
Connect the Cat ET to the service tool connector J60/P60. Start the Cat ET.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Check for any LOGGED diagnostic codes.
Start the engine and read the status information on the Cat ET.
Observe the engine oil pressure and the coolant temperature on the Cat ET.Note: If some of the parameters, but not all of the parameters were displayed, the Cat Data Link is okay. Check the component that is associated with any missing parameter.Expected Result:The Cat ET should display the Status Information. The Cat ET should display engine parameters.Results:
OK - The Cat Data Link is operating correctly at this time.Repair: Check the system for any diagnostic codes.STOP
No Parameter Displayed. - There is a problem with the Cat Data Link. Proceed to test step 3.
Service Tool Did Not Power Up. - The Cat ET or the Communication Adapter did not power up. Proceed to test step 4.Test Step 3. Check Communication with the Cat ET and the Communication Adapter.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Connect the Cat ET to the service tool connector. Start the Cat ET.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Read LOGGED Diagnostics and Status Information on the Cat ET.Expected Result:Status Information appears on the Cat ET.Results:
OK - The Status Information appears on the Cat ET. Proceed to test step 5.
Not OK - Status Information does not appear on the Cat ET. Proceed to test step 6.Test Step 4. Check for the Battery Voltage.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Ensure that all connectors are connected.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage between pin A and pin B at J60.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Reconnect connector J60.Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: Repair the connector and/or wiring or replace the connector and/or wiring.STOP
Not OK - The voltage is not 24 3 VDC. There is a problem in the harness or electrical power supply.Repair: Perform the diagnostic functional test Troubleshooting, "Electrical Power Supply".STOPTest Step 5. Check for Shorts in the Harness
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Disconnect the ECM connectors J1/P1. Disconnect the service tool connector J60/P60. Disconnect any other devices that are attached to the Data Link circuit.
Measure resistance from P1-3 to P1-9.
Check the resistance at the following points on ECM connector P1:
P1-3 to P1-4
P1-3 to P1-5
P1-3 to P1-6
P1-3 to P1-11
P1-9 to P1-4
P1-9 to P1-5
P1-9 to P1-6
P1-9 to P1-11Expected Result:Resistance should read more than 20,000 Ohms for each measurement.Results:
OK - The resistance is greater than 20,000 Ohms. The harness is free of shorts. Proceed to test step 7.
Not OK - The resistance is less than 20,000 Ohms.Repair: Repair the connector and/or wiring or replace the connector and/or wiring.STOPTest Step 6. Check the Operation of the Cat ET.Verify proper operation of the Cat ET on another engine.Expected Result:The Cat ET and the Communications Adapter should work on another engine.Results:
OK - The Cat ET and the Communications Adapter did work on another engine. Proceed to test step 5.
Not OK - The Cat ET and the Communications Adapter did not work on another engine. There is a problem with the Cat ET, with the cables, or with the Communication Adapter.Repair: Repair the connector and/or wiring or replace the connector and/or wiring.STOPTest Step 7. Check the Resistance through the Harness.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Disconnect the ECM connectors J1/P1. Disconnect any other devices that are attached to the Data Link circuit.
Ensure that the customer connector J3/P3 is connected.
Use a suitable piece of wire to short P1-9 to P1-3.
Measure the resistance between pin D and pin E of the Service Tool Connector J60.Expected Result:Resistance should read less than 10 Ohms through the wires.Results:
OK - Resistance is less than 10 Ohms through the harness and connectors. Proceed to test step 8.
Not OK - Resistance is greater than 10 Ohms. There is an open circuit in the harness or connectors.Repair: Repair the connector and/or wiring or replace the connector and/or wiring.STOPTest Step 8. Check Isolated Communication.
Reconnect the ECM connectors.
Connect the Cat ET to the service tool connector J60. Start the Cat ET.
Disconnect the Customer Communication Module from the circuit.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Read LOGGED diagnostics.
Turn the ECS to the START position.
Read the status information.Expected Result:The Cat ET should display any diagnostics and statu