47704400_100 Volvo.Penta cables and terminals

Illustration 1 g00894813
Typical exampleTest Step 1. Check for Connector Damage.
Turn the main breaker to the OFF 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 connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer 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 pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
Not OK - The wiring and connectors are okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
OK - The wiring and/or connectors need repair. Proceed to test step 2.Test Step 2. Check the Engine Prelube Pressure Switch.
Turn the engine control to the OFF position.
Ensure that the Prelube Override Switch is OPEN.
Disconnect ECM connector J1/P1.
Measure the resistance between the engine prelube pressure switch P1-19 and the Digital Return P1-29.
Reconnect the ECM connector P1.Expected Result:The resistance should be greater than 20,000 ohms.Results:
OK - The resistance is greater than 20,000 ohms. The engine prelube pressure switch is not active. Proceed to test step 3.
Not OK - The resistance is less than 20,000 ohms. The engine prelube pressure switch is active. Verify that the engine does not have a residual oil pressure that is high enough to activate the switch. If there is no residual oil pressure the switch is not operating correctly or there is a problem with the wiring. Proceed to test step 4.Test Step 3. Check the Status of the Prelube Switch on the Caterpillar Electronic Technician (ET).
Start the Cat ET.
Turn the engine control to the ON position.
The engine should not be running.
Observe the parameters for the engine prelube pressure switch and the parameter for the start/run/stop switch.Expected Result:The parameter for the engine prelube should display "OFF". The parameter for the start/run/stop switch should display "OFF".Results:
OK - The status parameters are correct. Proceed to test step 5.
Prelube Disabled - Repair: Set the engine prelube duration to a value that is greater than zero. Restart this test.STOP
Start/Run/Stop Switch NOT OFF - Repair: There is a problem in the wiring to the start/run/stop switch. Perform the diagnostic functional test Troubleshooting, ""Start/Run/Stop Switch"".STOPTest Step 4. Check the Engine Prelube Pressure Switch.
Turn the engine control to the OFF position.
Disconnect the wires from terminal 1 and terminal 2 of the engine prelube pressure switch.
Measure the resistance between terminal 1 and terminal 2 of the engine prelube pressure switch.Expected Result:The resistance should be greater than 20,000 ohms.Results:
OK - The resistance is greater than 20,000 Ohms.Repair: The problem is in the wires and/or connectors between the ECM connector J1/P1 and the engine prelube pressure switch. Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The resistance is less than 20,000 ohms. There is a problem with the engine prelube pressure switch.Repair: Install a new switch. Verify that the problem is no longer present.STOPTest Step 5. Check the Status of the Engine Prelube Pressure Switch on Cat ET.
Turn the engine control to the ON position.
Turn the "Start/Run/Stop Switch" to the START position.
View the parameters for the engine prelube pressure switch and the parameters for the start/run/stop switch. View the parameters before the engine prelube duration expires. View the parameters before the engine prelube pressure switch activates.Note: If necessary, program the engine prelube duration to 60 seconds.
If the engine prelube displays "COMPLETED", the engine prelube duration is reached. Reset the system and troubleshoot any active diagnostic code.
Turn the "Start/Run/Stop Switch" to the "STOP" position.Expected Result:The parameter for the engine prelube pressure switch should display "ON". The parameter for the start/run/stop switch should display "ON".Results:
OK - The parameter for the engine prelube pressure switch does display "ON". The parameter for the start/run/stop switch does display "ON". Proceed to test step 6.
Not OK - The parameter for the engine prelube pressure switch does not display "ON". The parameter for the start/run/stop switch does not display "ON".Repair: There is a problem in the wiring from the "Start/Run/Stop Switch". Perform the diagnostic functional test Troubleshooting, ""Start/Run/Stop Switch"".STOPTest Step 6. Check the Voltage to the Secondary Prelube Relay.
Connect a voltmeter between terminal 4 of the secondary prelube relay and engine ground.
Access the override on the Cat ET.
Turn the override for the engine prelube to "ON".
Monitor the voltage on the voltmeter.
Deactivate the override for the engine prelube.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 7.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 9.Test Step 7. Check the Voltage from the Secondary Prelube Relay.
Connect a voltmeter between terminal 2 of the secondary prelube relay and engine ground.
Access the override on the Cat ET.
Turn the override for the engine prelube to "ON".
Monitor the voltage on the voltmeter.
Deactivate the override for the engine prelube.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 8.
Not OK - The voltage does not measure 24 3 VDC.Repair: Disconnect the wire on terminal 3 of the secondary prelube relay. Check this wire for continuity to engine ground. If the wire is okay, replace the secondary prelube relay. Verify that the problem is no longer present.STOPTest Step 8. Check the Voltage to the Prelubrication Motor.
Connect a voltmeter between the wire from the secondary prelube relay at the prelubrication motor and engine ground.
Access the override on the Cat ET.
Turn the override for the engine prelube to "ON".
Monitor the voltage on the voltmeter.
Deactivate the override for the engine prelube.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. The prelubrication motor does not start.Repair: Check the connections at the prelubrication