824339 Volvo.Penta Flange

Illustration 1 g01186000
Typical example
Test Step 1. Check for Connector Damage.
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 connector that are associated with the circuit.
Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for the correct torque values.
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 - The connectors and/or wiring need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check the Status of the ECS in the STOP Position.
Turn the circuit breaker for the battery to the ON position.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the ECS on the instrument panel to the STOP position.
Observe the status for the ECS on Cat ET. Expected Result:The status for the ECS is "STOP".Results:
OK - The ECS is functioning correctly. Proceed to Test Step 3.
Not OK - The status for the ECS is not "STOP". Proceed to Test Step 5.Test Step 3. Check the Status of the ECS in the START Position.
Turn the ECS on the instrument panel to the START position.
Observe the status for the ECS on Cat ET. Expected Result:The status for the ECS is "RUN".Results:
OK - The ECS is functioning correctly. Proceed to Test Step 4.
Not OK - The status of the ECS is not "RUN". Proceed to Test Step 5.Test Step 4. Check the Status of the ECS in the REMOTE Position.
Turn the ECS on the instrument panel to the REMOTE position.
Observe the status for the ECS on Cat ET. Expected Result:The status for the ECS is "AUTO".Results:
OK - The ECS is working correctly.Repair: The problem may be intermittent. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
ECS Not OK - The status for the ECS is not "AUTO". Proceed to Test Step 6.Test Step 5. Install a Wire Jumper at the ECM in order to Simulate a START/STOP Function.
Turn the ECS to the OFF/RESET position.
Disconnect the ECM connector P1.
Remove wire F716-BK(Black) from P1-21. Install a wire jumper into the socket P1-21.
Remove wire F717-BK(Black) from P1-22. Install a wire jumper into the socket P1-22.
Reconnect the ECM connector P1.
Fabricate a wire jumper.
Install the wire jumper between terminal 11 of the ECS and the wire jumpers in P1-21 and P1-22.
Turn the ECS to the STOP position.
Observe the status for the ECS on Cat ET.
Remove the wire jumper between terminal 11 of the ECS and the wire jumpers in P1-21 and P1-22.
Observe the status for the ECS on Cat ET.
Turn the ECS to the OFF/RESET position. Remove the wire jumpers and replace all wires. Reconnect the ECM connector P1. Expected Result:The status for the ECS displays "RUN" while the wire jumper is installed. The status for the ECS displays "STOP" when the wire jumper is removed.Results:
OK - The status for the ECS displays the proper states. The problem is not with the ECM. Troubleshoot the wire F716-BK(Black) and the wire F717-BK(Black). In order to troubleshoot the wire F716-BK(Black), proceed to Test Step 7. In order to troubleshoot the wire F717-BK(Black), proceed to Test Step 12.
Not OK - The status for the ECS does not display the correct state.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOPTest Step 6. Install a Wire Jumper at the ECM in order to Simulate an AUTO Condition.
Turn the ECS on the instrument panel to the OFF/RESET position.
Disconnect the ECM connector P1.
Remove wire F721-BK(Black) from P1-68. Install a wire jumper into the socket P1-68.
Reconnect the ECM connector P1.
Fabricate a wire jumper.
Install the wire jumper between terminal 11 of the ECS and the wire jumper in P1-68.
Turn the ECS to the STOP position.
Observe the status for the ECS on Cat ET.
Remove the wire jumper between terminal 11 of the ECS and the wire jumper in P1-68.
Observe the status for the ECS on Cat ET.
Turn the ECS to the OFF/RESET position. Remove the wire jumpers and replace all wires. Reconnect the ECM connector P1. Expected Result:The status for the ECS displays "AUTO" while the wire jumper is installed. The status for the ECS displays "OFF" when the wire jumper is removed.Results:
OK - The status for the ECS displays the proper states. The problem is not with the ECM. Troubleshoot the wire F716-BK(Black) and the wire F717-BK(Black). In order to troubleshoot the wire F716-BK(Black), proceed to Test Step 7. In order to troubleshoot the wire F717-BK(Black), proceed to Test Step 12.
Not OK - The status for the ECS does not display the correct state.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOPTest Step 7. Check for Voltage at the Normally Closed Contacts of the "Stop 1" Relay.
Turn the remote start switch to the OFF/RESET position.
Turn the ECS on the instrument panel to the STOP position.
Measure the voltage between wire F716-BK(Black) at the normally closed contacts of the "Stop 1" relay and engine ground. Expected Result:The voltage is 6.5 0.5 VDC.Results:
OK - The voltage is 6.5 0.5 VDC. Proceed to Test Step 13.
Not OK - The voltage is not 6.5 0.5 VDC.Repair: Repair the wire F716-BK(Black) between terminal 22 of the "Stop 1" relay and the ECM. Test for proper operation.STOPTest Step 8. Check for Voltage at the "Stop 1" Relay.
Disconnect wire LR775-BK(Black) from terminal 22 of "Remote Start Enable" relay in order to isolate the circuit for testing. Insulate the removed wire end from electrical contact.
Turn the ECS that is on the instrument panel to the STOP position.
Measure the voltage between wire DM775-BK(Black) at