0319565 JOHNSON SHIFTER,Clutch dog

Illustration 1 g00925182
Test Step 1. Check for Connector Damage.
Verify that the circuit breakers are not tripped.BATTCB - Battery circuit breakerRCB - Relay circuit breakerMCESCB - Main crank E-stop circuit breaker
Turn the battery circuit breaker to the OFF position.
Turn the ECS to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connectors (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connectors (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 are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Test the Air Shutoff System.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the OFF/RESET position.
Connect the Caterpillar Electronic Technician (ET).
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff.
Select "Secondary ECM" from the "ECM Selector Menu". Select "Diagnostic Tests" from the "Diagnostics" menu. Select "Override Parameters" from the "Diagnostic Tests" menu.
Force the "Air Shutoff Override" to the ON position.
Disable the override for the air shutoff.Expected Result:The air shutoff relay should activate. The air shutoff relay should deactivate after 1.5 seconds. While the relay is active, the air shutoff solenoid should also be active.Results:
OK - The air shutoff solenoid activated correctly. Stop.
Not OK - The air shutoff solenoid failed to activate. Proceed to test step 3.Test Step 3. Test for Voltage from the Air Shutoff Relay.
Turn the ECS to the OFF/RESET position.
The output to the solenoids is terminal 30 on the air shutoff relays. The wires to the solenoids are 395-BR and 394-GR. Connect a voltmeter between terminal 30 on the air shutoff relay and the - Battery terminal.
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff. Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.
If a second air shutoff relay is installed, repeat the above steps for the other air shutoff relay.Expected Result:The voltage should measure 24 3 VDC for 1.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 1.5 seconds. The relay is operating correctly. Proceed to test step 4.
Not OK - The voltage did not measure 24 3 VDC for 1.5 seconds. Proceed to test step 5.Test Step 4. Test for Voltage at the Air Shutoff Solenoids.
Turn the ECS to the OFF/RESET position.
At the solenoid, disconnect the wires that go to the air shutoff solenoid.
Use a voltmeter to monitor the voltage at the air shutoff solenoid. Connect the voltmeter between the wires that were removed from the solenoid in the previous step.
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff. Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.
If a second air shutoff solenoid is installed, repeat the above steps for the other air shutoff solenoid.Expected Result:The voltage should measure 24 3 VDC for 1.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 1.5 seconds. The circuit is operating correctly to this point.Repair: Temporarily install a new air shutoff solenoid. Ensure that the problem is no longer present. Reinstall the old solenoid. If the problem returns, replace the air shutoff solenoid. Stop.
Not OK - The voltage did not measure 24 3 VDC for 1.5 seconds. System voltage was not available at the solenoid. There is a problem in the wiring between the air shutoff solenoid and the air shutoff relay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 5. Test for Voltage to the Coil of the Air Shutoff Relay.
Turn the ECS to the OFF/RESET position.
Connect a voltmeter between wire F708-YL of the air shutoff relay and the - Battery terminal.
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff.This test will cause a MID 047 - CID 0446 - FMI 05 to be logged. Be sure to delete this CID-FMI when this test is completed.
Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.
If a second air shutoff relay is installed, repeat the above steps for the other air shutoff relay.
Reconnect all wires.Expected Result:The voltage should measure 24 3 VDC for 1.5 seconds indicating that ECM voltage was present.Results:
OK - The voltage measures 24 3 VDC for 1.5 seconds. Voltage from the ECM was present. Proceed to test step 6.
Not OK - The voltage did not measure 24 3 VDC for 1.5 seconds. The voltage from the ECM was not present. Proceed to test step 7.Test Step 6. Check the Resistance at the Connector of the Air Shutoff Timer.
Turn the ECS to the OFF/RESET position.
Disconnect the connector to the air shutoff timer.
Check the resistance at the connector of the air shutoff timer. Check the resistance between wire 200-BK on Pin 1 and the - Battery terminal.
Check the resistance at the connector of the air shutoff timer. Check the resistance between wire F708-YL on Pin 2 and wire 055-WH on Pin 3.Expected Result:The resistance of the wire on Pin 1 should be less than 10 Ohms. The resistance between