860256A 4 Mercruiser HOUSING ASSEMBLY, Thermostat, Thermostat

Illustration 1 g01030195
Typical example
Test Step 1. Check for Connector Damage
Turn the Engine Control Switch (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 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 allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for the correct torque values.
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 are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check the Current Input to the Signal Converter
Measure the current to the signal converter. Note: Some external governors may only be able to output approximately 150 mA. This should not be seen as a problem with the external governor.Expected Result:The current range is between 0 and 200 mA.Results:
OK - The current is within the correct range. Proceed to Test Step 3.
Not OK - The current is not within the correct range.Repair: Replace the external governor that is supplying the controlling current.STOPTest Step 3. Check the Voltage at the Battery
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Measure no-load battery voltage at the battery terminals. 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 voltage is 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 4.
Not OK - The voltage is not 24 3 VDC.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 the Voltage at the Signal Converter
Connect one probe of the voltmeter to the +Battery terminal at the signal converter.
Connect one probe of the voltmeter to the −Battery terminal at the signal converter. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to Test Step 5.
Not OK - The voltage is not 24 3 VDC.Repair: Check the wiring and/or the connectors that are between the battery and the signal converter. Repair the wiring and/or connectors.STOPTest Step 5. Check the Fuel Position
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Start Cat ET.
Turn the ECS to the STOP position.
Observe the throttle position reading on Cat ET.
Vary the current to the signal converter. Expected Result:The throttle position on Cat ET varies from 5 percent to 85 percent as the current input is adjusted from 0 mA to 200 mA.Results:
OK - The throttle position on Cat ET corresponds with the current input.Repair: Check the system for any diagnostic codes.STOP
Not OK - The throttle position does not correspond to the current input. Proceed to Test Step 6.Test Step 6. Check the Signal from the Signal Converter
Remove the signal wire from the signal converter.
Set the multimeter to "VDC".
Press the "Hz" button twice so that the "%" symbol is displayed.
Place one probe on the signal wire of the signal converter.
Place the other probe on the −Battery terminal of the signal converter.
Monitor the output of the percent duty cycle from the signal converter.
Adjust the current input from a low current setting to a high current setting. Note: The throttle position on Cat ET will not match the percent duty cycle on the multimeter.Expected Result:The duty cycle is between 3 and 5 percent at the low setting and above 85 percent at the high setting.Results:
OK - The correct signal is being supplied. Proceed to Test Step 7.
Not OK - The duty cycle is not correct on the multimeter.Repair: Temporarily install another signal converter. Verify that the problem is no longer present. Reinstall the old signal converter. If the problem returns, replace the signal converter.STOPTest Step 7. Check the Signal at the ECM
Turn the ECS to the STOP position.
Replace the signal wire on the signal converter.
Set the multimeter to "VDC".
Press the "Hz" button twice so that the "%" symbol is displayed.
Measure the voltage between the signal wire at ECM connector P1-10 and the digital reference at ECM connector P1-05.
Monitor the output of the percent duty cycle on the multimeter.
Monitor the percent throttle position on Cat ET.
Vary the input current to the signal converter. Expected Result:The duty cycle is between 3 and 5 percent at the low setting and above 85 percent at the high setting. The percent throttle position is between 5 and 85 percent.Results:
OK - The duty cycle and the throttle position are correct.Repair: Check the system for any diagnostic codes.STOP
Not OK-Duty Cycle - The duty cycle is not correct.Repair: There is a problem in the wiring between the signal wire at ECM connector P1-10 and the signal converter.STOP
Not OK-Throttle Position - The duty cycle is OK. The throttle position is incorrect.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOP