61575A 1 Mercury STARTER CABLE ASSEMBLY

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Schematic for Cat Data LinkTest Step 1. Inspect Electrical Connectors and Wiring
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Terminal locations for ECM
Thoroughly inspect the following electrical connectors:
ECM connector J1/P1
Cab Data Link connector
Firewall Bulkhead connector
Electronic service tool connectors
Cat Data Link (terminal 8 and terminal 9) in the connectorsRefer 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 Cat Data Link.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and pinch points from the connector to the ECM.Refer to Illustration 2.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following 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. Determine the Type of Problem with the Data Link
Connect an electronic service tool to the cab data link connector.
Start the engine.Expected Result:Result 1 The engine starts. The ET powers up and the Electronic Service Tool communicates without error.Result 2 The engine starts. The ET powers up but an error is displayed.Result 3 The engine cranks but the engine will not start regardless of the condition of the ET.Result 4 The engine will not crank regardless of the condition of the ET.Result 5 The engine starts but the ET does not power up.Note: Check the display screen or check the Communication Adapter display in order to determine if the ET has powered up. The ET will display information that shows if the tool is getting power. If the ET powers up, the cab data link connector is receiving power.Results:
Result 1 - There is not a problem with the Cat Data Link at this time. If an intermittent condition exists, thoroughly inspect all wiring and connectors. Repair: Perform the following diagnostic procedure:Troubleshooting, "Electrical Connectors - Inspect"STOP
Result 2 - The ET displays an error message. The ECM is receiving battery power. Proceed to Test Step 3.
Result 3 - Repair: Perform the following diagnostic procedure:Troubleshooting, "Engine Will Not Crank"STOP
Result 4 - Repair: Perform the following diagnostic procedure:Troubleshooting, "Engine Cranks But Will Not Start"STOP
Result 5 - The ET does not power up or the communications adapter does not power up. Ensure that the ECM is receiving the correct battery power. Proceed to Test Step 4.Test Step 3. Check the Battery Voltage at the ECM
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Breakout T
Ensure that the ET is connected to the cab data link connector.
Disconnect machine harness connector P1 from ECM connector J1 and insert a 70-Terminal Breakout T.
Turn the keyswitch to the ON position.
Measure the voltage between machine harness connector P1 terminal 48 (UNSWITCHED +BATTERY) and terminal 61 (− BATTERY). Also measure the voltage between terminal 52 (UNSWITCHED +BATTERY) and terminal 63 (− BATTERY).
Measure the voltage between machine harness connector P1 terminal 70 (keyswitch) and terminal 63 (− BATTERY).Refer to Illustration 3.Expected Result:The voltage is between 22.0 VDC and 27 VDC when the keyswitch is in the ON position.Results:
Yes - The ECM is currently receiving the correct voltage. Proceed to Test Step 5.
No - The ECM is not receiving the correct voltage. Repair: Perform the following diagnostic procedure:Troubleshooting, "Electrical Power Supply Circuit - Test"STOPTest Step 4. Check the Battery Voltage that Is Coming to the Cab Data Link Connector.
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Data Link connector
Turn the keyswitch to the ON position.
Use a multimeter in order to measure the voltage from the + BATTERY terminal of the cab data link connector to the − BATTERY terminal of the cab data link connector.Refer to Illustration 4.Expected Result:The voltage is between 22.0 VDC and 27.0 VDC.Results:
Yes - The cab data link connector is currently receiving the correct voltage. Proceed to Test Step 6.
No - The cab data link connector is not receiving the correct voltage.Repair: Inspect the wiring and fuses to the connector. Repair the wiring or batteries and/or replace the wiring or batteries, as required. Send the machine to the OEM dealer for repair, if necessary. Verify that the repair eliminates the problem.STOPTest Step 5. Connect the Electronic Service Tool Directly to the ECM.
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Bypass harness
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.