80606M Mariner DIAPHRAGM, FUEL PUMP

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Schematic
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Terminal locations for the ECM connector P2Test Step 1. Perform the "Air Inlet Shutoff System Control Test"
Turn the keyswitch to the OFF position.
Connect the Caterpillar Electronic Technician (ET) to the cab data link connector.
Turn the keyswitch to the ON position.
Start the engine. Increase the engine speed from low idle to 1400 rpm to 1600 rpm.
Go to the "Air Inlet Shutoff System Control Test" on ET.
Start the test.Expected Result:Fuel injection is disabled. The air inlet shutoff is activated and the engine is shutdown.Results:
OK - The engine is shutdown when the "Air Inlet Shutoff System Control Test" is activated. The air inlet shutoff is working correctly.Repair: Reset the air inlet shutoff system. Talk to the operator in order to determine the reason for the overspeed.STOP
Not OK - The engine did not shut down. Proceed to Test Step 2.Test Step 2. Check the Interlock for the Air Inlet Shutoff
Verify that J1/P1:62 (Output 12) is connected to the +Battery.Expected Result:J1/P1:62 is connected to the +Battery.Results:
OK - J1/P1:62 (Output 12) is connected to the +Battery. Proceed to Test Step 3.
Not OK - J1/P1:62 (Output 12) is not connected to the +Battery.Repair: Connect J1/P1:62 to the +Battery. Repeat Test Step 1.Test Step 3. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector and all other connectors in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on the wires that are associated with the air inlet shutoff system.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - All the wires and connections are OK. Proceed to Test Step 4.
Not OK - Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 4. Perform the "Air Inlet Shutoff Relay Output" Test
Turn the keyswitch to the OFF position.
Connect ET to the cab data link connector.
Turn the keyswitch to the ON position. Do not start the engine.
Go to the "Air Inlet Shutoff Relay Output" test on ET.
Start the test and listen for a click from the relay for the air inlet shutoff.Expected Result:The relay is active.Results:
OK - A click is heard. The relay is active. Proceed to Test Step 5.
Not OK - There is a problem with the relay circuit. Proceed to Test Step 7.Test Step 5. Check the Supply Voltage to the Air Inlet Shutoff Solenoid
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Air Inlet Shutoff Solenoid
Disconnect the air inlet shutoff solenoid.
Turn the keyswitch to the ON position.
Proceed to the "Air Inlet Shutoff Relay Output" test on ET.
Activate the relay for the air inlet shutoff solenoid.
Use signal reading probes to measure the voltage across the two terminals of the air inlet shutoff solenoid.Note: Air inlet shutoff systems that were produced after February 2002 may use a one second pulse to control the relay. The relay will only be activated for one second. A voltage test lamp may be used in place of a multimeter.Expected Result:The supply voltage should be greater than 10 VDC or the test lamp illuminates for at least one second.Results:
OK - The ECM is properly controlling the relay for the air inlet shutoff solenoid, but the air inlet shutoff solenoid is not working. Proceed to Test Step 6.
Not OK - The air inlet shutoff solenoid is not receiving the correct signal. Proceed to Test Step 10.Test Step 6. Check the Resistance of the Solenoid
Disconnect the wires for the air inlet shutoff solenoid.
Measure the resistance of the air inlet shutoff solenoid.
Reconnect the wires for the air inlet shutoff solenoid.Expected Result:Resistance should be 15 to 20 Ohms.Results:
OK - The resistance of the air inlet shutoff solenoid is OK.Repair: Check electrical connections. Refer to Troubleshooting, "Electrical Connectors - Inspect" for more information.STOP
Not OK - The resistance of the solenoid is out of specification.Repair: Replace the air inlet shutoff solenoid.Verify that the repair eliminates the problem.STOPTest Step 7. Check the Resistance of the Relay
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Relay Terminals
Turn the keyswitch to the OFF/RESET position.
Unplug the relay for the air inlet shutoff solenoid.
Measure the resistance between J520:1 (Solenoid Common) and J520:2 (Air Inlet Shutoff Output).Expected Result:The resistance should be between 5 Ohms and 10 Ohms.Results:
OK - The resistance of the relay is OK. Proceed to Test Step 8.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOPTest Step 8. Check the Signal Voltage to the Relay
Illustration 5 g00850154
Schematic for the Relay Signal
Unplug the relay for the air inlet shutoff solenoid.
Turn the keyswitch to the ON position.
Proceed to the "Air Inlet Shutoff Relay Output" test on ET.
Activate the system for the air inlet shutoff solenoid.