830163A00 Mercury DECAL SET

Illustration 1 g00903323
Typical air shutoff circuitNote: The Engine Control Switch (ECS) is mounted within an instrument panel that is located on the right side of the engine. The ECS is locked into the AUTO position with a pin. The pin must be removed in order to perform this test. After performing this test, ensure that the ECS is placed in the AUTO position and that the locking pin has been reinstalled.Test Step 1. Check for Connector Damage.
Verify that the circuit breakers are not tripped.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET 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 connectors that are associated with the circuit.
Check the ECM connectors (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connectors (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 pinch points.Expected Result:All connectors, pins, and sockets are coupled and/or inserted, and the harness and wiring should be free of corrosion, abrasion, or pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Test the Air Shutoff System.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the OFF/RESET position.
Connect the Caterpillar Electronic Technician (ET).
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff.
Disable the override for the air shutoff.Expected Result:The air shutoff relay should activate. The air shutoff relay should deactivate after 1.5 seconds. While the relay is active, the air shutoff solenoid should also be active.Results:
OK - The air shutoff solenoid activated correctly.Repair: The problem may be intermittent. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The air shutoff solenoid failed to activate. Proceed to test step 3.Test Step 3. Test for Voltage from the Air Shutoff Relay.
Turn the ECS to the OFF/RESET position.
The output to the solenoids is terminal 30 on the air shutoff relays. The wires to the solenoids are 395-BR and 394-GN. Connect a voltmeter between terminal 30 on the air shutoff relay and the − Battery terminal.
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff. Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.
If a second air shutoff relay is installed, repeat the above steps for the other air shutoff relay.Expected Result:The voltage should measure 24 3 VDC for 1.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 1.5 seconds. The relay is operating correctly. Proceed to test step 4.
Not OK - The voltage did not measure 24 3 VDC for 1.5 seconds. Proceed to test step 5.Test Step 4. Test for Voltage at the Air Shutoff Solenoids.
Turn the ECS to the OFF/RESET position.
At the solenoid, disconnect the wires that go to the air shutoff solenoid.
Use a voltmeter to monitor the voltage at the air shutoff solenoid. Connect the voltmeter between the wires that were removed from the solenoid in the previous step.
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff. Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.
If a second air shutoff solenoid is installed, repeat the above steps for the other air shutoff solenoid.Expected Result:The voltage should measure 24 3 VDC for 1.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 1.5 seconds. The circuit is operating correctly to this point.Repair: Temporarily install a new air shutoff solenoid. Ensure that the problem is no longer present. Reinstall the old solenoid. If the problem returns, replace the air shutoff solenoid.STOP
Not OK - The voltage did not measure 24 3 VDC for 1.5 seconds. System voltage was not available at the solenoid. There is a problem in the wiring between the air shutoff solenoid and the air shutoff relay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 5. Test for Voltage to the Coil of the Air Shutoff Relay.
Turn the ECS to the OFF/RESET position.
Connect a voltmeter between wire F708-YL of the air shutoff relay and the − Battery terminal.
Turn the ECS to the STOP position. The engine should be off.
Access the override on the Cat ET. Activate the override for the air shutoff.
Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.
If a second air shutoff relay is installed, repeat the above steps for the other air shutoff relay.
Reconnect all wires.Expected Result:The voltage should measure 24 3 VDC for 1.5 seconds indicating that ECM voltage was present.Results:
OK - The voltage measures 24 3 VDC for 1.5 seconds. Voltage from the ECM was present. Proceed to test step 6.
Not OK - The voltage did not measure 24 3 VDC for 1.5 seconds. The voltage from the ECM was not present. Proceed to test step 7.Test Step 6. Check the Resistance of the Coils of the Air Shutoff Relays.
Turn the ECS to the OFF/RESET position.
Disconnect the connector to the air shutoff timer.
Check the resistance at the connector of the air shutoff timer. Check the resistance between wire 200-BK on Pin 1 and the − Battery terminal.
Check the resistance at the connector of the air shutoff timer. Check the resistance between wire F708-YL on Pin 2 and wire 055-WH on Pin 3.Expected Result:The resistance of the wire on Pin 1 should be less than 10 Ohms. The resistance between the wires on Pin