60096 Mercury BOOT, SPARK PLUG LEAD

Illustration 1 g00934205
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Disconnect the main power.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. 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 2.25 0.25 N m (20 2 lb in).
Check the machine 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:The connectors and wiring are free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors and/or wiring or replace the connectors or wiring.STOPTest Step 2. Check the Status of the User Defined Shutdown on the Caterpillar Electronic Technician (ET).
Connect Cat ET to the cab service tool connector J31. Start Cat ET.
Ensure that the user's shutdown device is not activated.
Turn the keyswitch to the ON position. The engine should be off.
Observe the status for the user defined shutdown on Cat ET.Expected Result:The status reads "OFF".Results:
OK - The status reads "OFF". The status is correct. Proceed to Test Step 3.
Not OK - The status does not read "OFF". The status is incorrect. Proceed to Test Step 4.Test Step 3. Activate the User's Shutdown Device or Create a Short at the Connector for the User Defined Shutdown.
Turn the keyswitch to the OFF position.
Activate the user's shutdown device or use a wire with a socket terminal at both ends to short the wire E960-OR to wire 229-BK at the connector.
Turn the keyswitch to the ON position. The engine should be off.Expected Result:Cat ET indicates "User Shutdown ON" when the wire E960-OR is shorted to wire 229-BK.Results:
OK - Cat ET indicates the "User Shutdown ON" when the wire E960-OR is shorted to wire 229-BK. Cat ET indicates the correct status. The shutdown feature is working properly.Repair: There may be an intermittent problem. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - Cat ET does not indicate "User Shutdown ON" when the wire E960-OR is shorted to wire 229-BK. Cat ET does not show the correct status. Proceed to Test Step 5.Test Step 4. Check the Harness for a Short Circuit.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Measure the resistance at the ECM connector between wire E960-OR on pin P1-4 and the engine ground.Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 6.
Not OK - The resistance is less than 20,000 Ohms. There is a short circuit in the harness or a user's shutdown device is activating the shutdown feature.Repair: Repair the connectors and/or wiring or replace the connectors or wiring.STOPTest Step 5. Check the Harness for an Open Circuit.
Turn the keyswitch to the OFF position.
Use a wire with a socket terminal at one end to short the wire E960-OR to wire 229-BK at the connector for the user defined shutdown.
Disconnect the ECM connector J1/P1.
Measure the resistance at the ECM connector between the wire E960-OR on pin P1-4 and the wire 229-BK on pin P1-13.
Remove the wire short.Expected Result:The resistance is less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. The resistance is within acceptable limits. Proceed to Test Step 6.
Not OK - The resistance is greater than 5 Ohms. There is an open circuit in the harness.Repair: Repair the connectors and/or wiring or replace the connectors or wiring.STOPTest Step 6. Short the Wire at the ECM.
Remove the wire E960-OR from P1-4 at the ECM connector.
Insert a wire jumper with a socket terminal at one end into the ECM connector P1-4.
Reconnect ECM connector J1/P1.
Turn the keyswitch to the ON position. The engine should be off.
Momentarily short the wire jumper at P1-4 to the chassis ground.Expected Result:Cat ET indicates "User Shutdown ON" when the wire jumper that is in P1-4 is shorted to ground. Cat ET indicates "User Shutdown OFF" when the wire short is removed.Results:
OK - Cat ET indicates "User Shutdown ON" with the wire short in place. Cat ET indicates "User Shutdown OFF" when the short is removed. Cat ET indicates the correct status. The feature is working properly.Repair: The ECM is working properly. Recheck the wiring from the user defined shutdown input for intermittent problems. Perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - Cat ET does not indicate "User Shutdown ON" with the short in place. Cat ET does not indicate "User Shutdown OFF" when the short is removed. Cat ET does not indicate the correct status.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOP