0584829 JOHNSON STOP SWITCH ASSY.

Table 1
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
617-5 Inlet Air Heater Relay : Current Below Normal The Electronic Control Module (ECM) has detected current below normal for at least two seconds. The code is logged.
If equipped, the warning light will come on.
The ECM is unable to activate the relay for starting aid.
The starting aid will not operate.
617-6 Inlet Air Heater Relay : Current Above Normal The ECM has detected current above normal for at least two seconds.
3257-3 Air Inlet Heater : Voltage Above Normal The monitoring for the Inlet Air Heater (IAH) is enabled.
The IAH is not enabled.
The ECM has detected voltage above normal for at least 30 seconds.
The engine is running.
OR
The ECM has detected voltage above normal for at least five seconds.
The engine is not running. The code is logged.
If equipped, the warning light will come on.
The starting aid could operate all the time.
3257-4 Inlet Air Heater : Voltage Below Normal The monitoring for the IAH is enabled.
The IAH is enabled.
The ECM has detected voltage below normal for at least five seconds. The code is logged.
If equipped, the warning light will come on.
The starting aid will not operate. The starting aid is used to improve cold engine starting. The engine ECM will monitor the coolant temperature and the intake manifold air temperature in order to determine if the starting aid is required. If the starting aid is required, then the ECM will activate the starting aid relay and electrical power is switched to the starting aid for a controlled period of time. If the optional "Wait to Start Lamp" is installed then this lamp will illuminate during this period.On a cold start, a lamp output will indicate that the operator needs to "Wait to Start". Starting aids may be used during the cranking of the engine. Starting aids may be used if the engine has previously been started. The "Wait to Start" lamp will not be active in these conditions.
Illustration 1 g02805496
Typical schematic for the starting aid
Illustration 2 g01504436
A typical view of the P1 connector (wire side) pin locations.
(1) Battery−
(2) Battery−
(3) Battery−
(9) Battery−
(10) Battery−
(26) IAH return
(29) IAH control
(49) IAH monitoring
(59) Cold start lamp
Illustration 3 g01504456
A typical view of the P1 connector (ECM side) pin locations.
Illustration 4 g01325579
Typical engine ECM
(1) P2 ECM connector
(2) P1 ECM connectorTest Step 1. Check for Active Diagnostic Codes
Verify that the ECM has the latest software.Refer to Troubleshooting, "ECM Software - Install".
Turn the keyswitch to the OFF position.
Connect Caterpillar Electronic Technician (ET) to the diagnostic connector.
Turn the keyswitch to the ON position.
Use Cat ET to select the "Air Inlet Heater Override Test".
Check for active diagnostic codes or recently logged diagnostic codes.Expected Result:One of the following diagnostic codes are active or recently logged:
617-5 Inlet Air Heater Relay : Current Below Normal
617-6 Inlet Air Heater Relay : Current Above Normal
3257-3 Air Inlet Heater : Voltage Above Normal
3257-4 Air Inlet Heater : Voltage Below NormalResults:
OK - A 617-5 diagnostic code is active or recently logged. Proceed to Test step 3.
OK - A 617-6 diagnostic code is active or recently logged. Proceed to Test step 4.
OK - A 3257-3 diagnostic code is active or recently logged. Proceed to Test step 7.
OK - A 3257-4 diagnostic code is active or recently logged. Proceed to Test step 8.
Not OK - An active diagnostic code or a recently logged diagnostic code was not displayed. Proceed to Test step 11.Test Step 2. Check for Voltage to the Heater relay
Turn the keyswitch to the OFF position.
Disconnect the connector for the heater relay.
Turn the keyswitch to the ON position.
Measure the voltage between terminal 1 and terminal 2 on the harness side of the connector for the relay.Expected Result:The voltage measures approximately 0 VDC when the power for the heater relay is not activated. The voltage measures approximately 13 3 VDC when the override for the ether system is activated.Results:
OK - The voltage measurements are correct.Repair: Check the heater relay for an open or a short circuit.STOP
Not OK - One of the voltage measurements was incorrect.Repair: There is either a short or an open in the wiring between the connector for the heater relay and the ECM. Repair the wiring and/or connectors.STOPTest Step 3. Check the Relay Circuit for an Open Circuit
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector.
Check the resistance in the wire between P1-26 and test point C at the starting aid relay.
Check the resistance in the wire between P1-29 and test point D at the starting aid relay.Expected Result:The resistance measurements are within the acceptable range. There is not an open in the harness between the ECM and the solenoid relay.Results:
OK - The resistance measurements are within the acceptable range. There is not an open in the harness between the ECM and the solenoid relay. Proceed to Test Step 5.
Not OK - The resistance measurements are not within the acceptable range. There is an open in the harness and/or the connectors.Repair: Repair the connectors and/or the harness or replace the connectors and/or the harness.Return all wiring