801763309 Mercruiser SUPPORT

Illustration 1 g00838782
Typical schematic
Illustration 2 g01090782
P1 ECM connector (P1-22) Ether hold relay (P1-25) Ether request (P1-29) Digital return (P1-40) Ether start relayTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1. Inspect all of the other connectors. Refer to 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 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 harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.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 2. Check the Ether Canisters
Turn the keyswitch to the OFF position.
Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Ether can not be injected if the canister is empty.Expected Result:The ether canister is not empty.Results:
OK - The ether canister is not empty. Proceed to Test Step 3.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a full ether canister. Verify that the system is operating correctly.STOPTest Step 3. Check for Active Diagnostic Codes
Remove the ether canister from the ether solenoid.
Connect Caterpillar Electronic Technician (ET) to the cab service tool connector J42. Start Cat ET.
Turn the keyswitch to the ON position.
Toggle the starting aid switch. Observe the parameter for the starting aid switch on Cat ET.
Determine if CID-FMI 545-05, 545-06, 546-05 or 546-06 is active or logged.Expected Result:The parameter for the starting aid switch displays "ON" while the starting aid switch is toggled. The parameter for the starting aid switch displays "OFF" when the starting aid switch is released. An active diagnostic code is present or a logged diagnostic code is present.Results:
OK - Active Code - The parameter for the starting aid switch displays "ON" while the starting aid switch is toggled. The parameter for the starting aid switch displays "OFF" when the starting aid switch is released. Active diagnostics are displayed. Proceed to Test Step 4.
OK - Logged Code - The parameter for the starting aid switch displays "ON" while the starting aid switch is toggled. The parameter for the starting aid switch displays "OFF" when the starting aid switch is released. Logged diagnostics are displayed. Repair: Check for an intermittent short or for an open in the wiring or in the connectors. Refer to Troubleshooting, "Inspecting Electrical Connectors". Repair any suspect connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.STOP
Not OK - The parameter for the starting aid switch does not display "ON" while the starting aid switch is toggled. The parameter for the starting aid switch does not display "OFF" when the starting aid switch is released. The starting aid switch is not functioning correctly. Proceed to Test Step 15.Test Step 4. Check the Voltage from the Ether Start Relay
Turn the keyswitch to the OFF position.
Connect a voltmeter between wire 317-YL on terminal 87 of the ether start relay and ground.
Turn the keyswitch to the ON position.
Select the "Diagnostic Tests" on Cat ET.
Do not allow the ether injection system to be on for more than two minutes. Damage to the ether solenoid may occur.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and observe the voltmeter while the ether injection is activated.
Disable the ether override.Expected Result:The voltage at the ether start relay is 24 3 VDC during the first two seconds of injection. The voltage then decreases to 3 1 VDC for the remainder of the injection duration.Results:
OK - The voltage is approximately 24 3 VDC for the first two seconds. The voltage then decreases to approximately 3 1 VDC for the remainder of injection duration. Proceed to Test Step 5.
Not OK - 24 VDC - The voltage did not measure 24 3 VDC. Proceed to Test Step 6.
Not OK - 3 VDC - The voltage did not decrease to 3 1 VDC for the remainder of the injection duration. Proceed to Test Step 9.Test Step 5. Check the Voltage at the Ether Solenoid
Turn the keyswitch to the OFF position.
Disconnect the ether solenoid connector at the solenoid.
Connect a voltmeter to terminal 1 and terminal 2 of the ether solenoid connector.
Turn the keyswitch to the ON position.