0321942 JOHNSON SCREW,Socket head

Illustration 1 g00861631
Typical exampleTest Step 1. Check for Connector Damage.
Turn the main 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 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.STOPTest Step 2. Check for "ACTIVE" Diagnostic Codes
Start the Caterpillar Electronic Technician (ET).
Turn the main disconnect switch 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.
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. Verify that the original condition is resolved. Refer to Testing and Adjusting, "Electrical System".STOPTest Step 4. Check for Supply Voltage to the ECM.
Turn the main disconnect switch to the OFF position.
Disconnect ECM connector J1/P1.
Turn the main disconnect switch to the ON position.
Measure the voltage at the ECM connector P1 between pins P1-04 and P1-11.
Measure the voltage at the ECM connector 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. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 5. Check the Voltage to the ECM from the Battery.
Measure the voltage at the ECM connector P1 between pins P1-23 and P1-11.
Turn the main disconnect switch to the OFF position.
Reconnect ECM connector J1/P1.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 6.
Not OK - The voltage does not measure 24 3 VDC.Repair: Check for voltage at the Battery. There may be a problem with the wiring and/or connectors between the Battery and the ECM. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 6. Check the Voltage at the Emergency Stop Input to the ECM.
Turn the main disconnect switch to the ON position.
Connect a voltage test lamp at the ECM connector P1 between pins P1-20 and P1-29.
Connect a voltage test lamp at the ECM connector P1 between pins P1-02 and P1-29.Expected Result:The voltage test lamp should not illuminate.Results:
OK - The voltage test lamp did not illuminate. Proceed to test step 7.
Not OK - The voltage test lamp illuminated.Repair: The Emergency Stop circuit has been activated or the emergency stop circuit has an open circuit. Verify that the Emergency Stop switches are not activated. Check the Emergency Stop switches for proper operation. There may be a problem in the wiring and/or connectors. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 7. Check the Voltage at the ECM from the Start/Run/Stop Switch.
Connect a voltage test lamp at the ECM connector P1 between pins P1-14 and P1-29.
Connect a voltage test lamp at the ECM connector P1 between pins P1-08 and P1-29.
Turn the Start/Run/Stop switch to the RUN position.
Monitor the voltage test lamp at the ECM connector P1 between pins P1-14 and P1-29.
Monitor the voltage test lamp at the ECM connector P1 between pins P1-08 and P1-29.
Turn the Start/Run/Stop switch to the STOP position.Expected Result:The voltage test lamp should be illuminated before the Start/Run/Stop switch is activated. The voltage should not be illuminated after the Start/Run/Stop switch is activated.Results:
OK - The Start/Run/Stop switch and the wiring to the ECM are okay.Repair: There may be an intermittent problem. If the problem is intermittent perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - No Voltage Present - The voltage test lamp does not illuminate before the Start/Run/Stop switch is activated. Proceed to test step 8.
Not OK - No 0.0 VDC - The voltage test lamp illuminates after the Start/Run/Stop switch is activated.Repair: Check the voltage at the Start/Run/Stop switch. Voltage should not be present after the Start/Run/Stop switch is activated. The Sta