3801209 Volvo.Penta Aquamatic drive, exc, SX-A

Table 1
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
338-5 Engine Pre-Lube Pump Relay current below normal The engine's Electronic Control Module (ECM) detects an open circuit at the prelube pump relay.
The ECM detects a short to battery voltage at the prelube pump relay.
The ECM can only detect this condition when the prelube pump relay is not energized. The code is logged.
338-6 Engine Pre-Lube Pump Relay current above normal The ECM detects a short circuit at the prelube pump relay.
The ECM can only detect this condition when the prelube pump relay is energized. The ECM has the ability to automatically prelube the engine before cranking. This prelubrication may increase the life of certain engine parts. The ECM will prelube the engine, when the Engine Control Switch (ECS) is placed in the START position. The ECM will prelube the engine, when the ECS is placed in the AUTO position and the remote start/run/stop switch is closed. The length of time for the prelube cycle can be programmed by the customer. The prelube cycle will end when the pressure switch for the prelube system closes or if the customer programmed time ends. The engine speed must equal zero rpm before the prelube will begin.The prelube cycle has the following status codes."OFF" - The ECM is powered and the ECS is in the STOP position."ON" - The ECM is powered and the ECS is in the START position."COMPLETED" - The prelube has timed out or the prelubrication pressure switch has activated."DISABLED" - The engine prelube duration is programmed to 0.The prelube function will be aborted when one of the following conditions occur:
The pressure switch for the prelube system is activated.
The user defined engine prelube duration has been reached.
The operator activates the prelube override switch.When the ECM senses the ECS in the START position, the ECM will activate the output driver for the "PPR1" relay. When the "PPR1" relay energizes, the normally open contacts of the "PPR1" relay close. This allows current to flow to the prelube motor. The prelube motor activates the prelube pump. The prelube pump builds pressure in the engine's lubrication system. When the pressure switch for the prelube system closes as a result of the increased pressure, the ECM input for the pressure switch is taken low. The ECM then knows that the pressure in the system is adequate. The ECM will begin the starting sequence.A test on Caterpillar Electronic Technician (ET) allows the technician to activate the prelube system. The test is functional when the engine speed is 0 rpm. The test is accessed by selecting the following menus on Cat ET:
"Diagnostics"
"Diagnostic Tests"
"Override Parameters"
Illustration 1 g01241988
Typical schematic
Illustration 2 g01241989
P1 ECM connector
(P1-5) Digital return
(P1-66) Prelube override switch
Illustration 3 g01241990
P2 ECM connector
(P2-12) Driver output for Prelube
(P2-66) Digital return
Illustration 4 g01241992
Customer connector
(Terminal i) Prelube override switch
(Terminal y) PPR2 contacts
(Terminal z) PPR2 contacts
Illustration 5 g01234146
Location of ECM connectors
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the ECS to the OFF position.
Thoroughly inspect the ECM connectors. Inspect all of the other connectors for the circuit. 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. Refer to Troubleshooting, "Inspecting Electrical Connectors" 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
Connect Cat ET to the service tool connector.
Restore power to the ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the prelube override.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active, but a problem is suspected in the prelube system. Proceed to Test Step 6.
Not OK - A 06 diagnostic code is active at this time. Proceed to Test Step 3.
Not OK - A 05 diagnostic code is active at this time. Proceed to Test Step 4.Test Step 3. Create an Open Circuit at the PPR1 Relay and at the PPR2 Relay
Remove power from the ECM.
Disconnect wire F705-BK(Black) from terminal 3 of PPR1 and from terminal 86 of PPR2.
Restore power to the ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the prelube override.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Remove power from the ECM. Expected Result:A 05 diagnostic code is now active for the prelube relay.Results:
OK - A 05 diagnostic code is now active for the PPR1 relay. The wires between the ECM and the PPR1 relay are OK.Repair: Replace the PPR1 relay. Reconnect all wires to the original configuration. Recheck the prelube system with the prelube override. If a 05 diagnostic code is active, replace the PPR2