823042 32 Mercury BOLT (3.3 HP)

Table 1
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
444-5 Starter Motor Relay current below normal The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery in the start enable relay. The code is logged.
444-6 Starter Motor Relay current above normal The ECM detects a short circuit to ground in the start enable relay. The ECM can crank the engine when the start/run/stop switch is in the closed position. When the engine is in the start up mode, the ECM will activate the prelube system. When the prelube cycle is finished, the ECM will begin the first crank cycle.The crank cycle will continue for the time that is equal to the crank duration that has been programmed or the crank cycle will continue until the engine speed reaches the crank terminate speed. If crank terminate speed is not reached before the crank duration, the start enable relay will deactivate for a time that is equal to the cycle crank time.This process will repeat for a programmed amount of times (Total Number of Crank Cycles). If the engine does not start the starter mode on the Caterpillar Electronic Technician (ET) will display "OVERCRANK". The engine control will be in an idle state.
Illustration 1 g01934723
Typical schematic
Illustration 2 g01973262
P2 ECM connector
(P2-6) Start enable relay
Illustration 3 g01973263
P1 ECM connector
(P1-5) Digital return
(P1-21) Digital return
(P1-22) Start/run/stop switch 3
(P1-70) Start/run/stop switch 4
Illustration 4 g01258378
Connector "F"
(Terminal 2) −Battery
(Terminal 6) +Battery
Illustration 5 g01234146
Location of ECM connectors
Illustration 6 g01259406
Connector "A"
(Terminal 10) Start enable relay
(Terminal 25) Digital return
Illustration 7 g01259410
Connector "G"
(Terminal 1) Start enable relay (N/O)
(Terminal 2) Start enable relay (COM) Test Step 1. Inspect Electrical Connectors and Wiring
Turn the breaker for the ECM to the OFF position.
Thoroughly inspect the ECM connectors. Inspect all of the other connectors for the circuit. Refer to Troubleshooting, "Electrical Connectors -Inspect" 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. Refer to Troubleshooting, "Electrical Connectors -Inspect" for details.
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 - 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 for Active Diagnostic Codes for the Start Enable Relay
Connect Cat ET to the service tool connector.
Turn the breaker for the ECM to the ON position.
Monitor the active diagnostic code screen on Cat ET. Check the starting system for an active diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Turn the start/run/stop switch to the START position.
Monitor the active diagnostic code screen on Cat ET. Check the starting system for an active diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Turn the start/run/stop switch to the STOP position. Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active, but a problem is suspected in the starting system. Proceed to Test Step 6.
Not OK - A -6 diagnostic code is active at this time. Proceed to Test Step 3.
Not OK - A -5 diagnostic code is active at this time. Proceed to Test Step 4.Test Step 3. Create an Open at the Start Enable Relay
Disconnect the wire from terminal 3 on the start enable relay. Ensure that the wire is isolated from engine ground and other sources of electrical power.
Monitor the active diagnostic code screen on Cat ET. Check the starting system for an active diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Turn the start/run/stop switch to the START position.
Monitor the active diagnostic code screen on Cat ET. Check the starting system for an active diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Turn the start/run/stop switch to the STOP position. Expected Result:A -5 diagnostic code is now active for the start enable relay.Results:
OK - A -6 diagnostic code was active before disconnecting the wires. A -5 diagnostic code became active after disconnecting the wires. The harness and the ECM are OK. The problem may be in the start enable relay.Repair: Temporarily connect a new start enable relay, but do not install the new start enable relay. Verify that there are no active diagnostic codes for the start enable relay. If there