244584 Volvo.Penta Lever

Illustration 1 g01153132
Switch circuits
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND THE WIRING
Remove the electrical power from the ECM.
Illustration 2 g01146374
Left side engine view (typical example)
(1) J1/P1 ECM connector
Illustration 3 g01146383
Left side engine view (typical example)
(2) J61 Customer connector
Thoroughly inspect connectors (1) and (2). Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 4 g01153174
P1 terminals for the various switches
(22) Remote shutdown switch
(23) Maintenance clear switch
(40) Trip clear switch
(41) Trolling mode switch
(59) Slow vessel mode switch
Illustration 5 g01153178
J61/P61 terminals for the various switches
(Terminal 19) Trip clear switch
(Terminal 36) Remote shutdown switch
(Terminal 37) Trolling mode switch
(Terminal 38) Slow vessel mode switch
(Terminal 39) Maintenance clear switch
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the diagnostic lamp.
Check the allen head screw on the customer connector and on the ECM connectors for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Expected Result:There are no problems with the connector or the wiring.Results:
OK - There are no problems with the connector or the wiring. Proceed to Test Step 2.
Not OK - 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. VERIFY THE CONNECTIONS TO THE NEGATIVE BATTERY BUS BAR
Locate the −Battery bus bars and verify that the connections for the switches are properly installed. Refer to the information that is provided by the OEM of the vessel.Expected Result:The −Battery connections are properly installed.Results:
OK - The connections for the −Battery bus bar are properly installed. Proceed to Test Step 3.
Not OK - There is a problem with the connections for the −Battery bus bar.Repair: Repair the connections in order to ensure proper installation.Proceed to Test Step 3.Test Step 3. CHECK THE STATUS OF THE SUSPECT SWITCH
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Restore the electrical power to the ECM.
Cycle the suspect switch. Use Cat ET to monitor the status of the switch. Expected Result:The status of the suspect switch is displayed as "ON" and "OFF" when the switch is cycled.Results:
OK - Cat ET recognized the correct status of the suspect switch.Repair: The switch is operating correctly at this time. There may be an intermittent problem with the harness and/or the connector. If an intermittent problem is suspected, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Cat ET did not recognize the correct status of the switch. There is a problem with the wiring or the switch. Proceed to Test Step 4.Test Step 4. INSTALL A JUMPER AT THE CUSTOMER CONNECTOR AND CHECK THE STATUS OF THE SWITCH
Remove the electrical power from the ECM.
Fabricate a jumper wire that can be installed from the −Battery bus bar to the J61 customer connector.
Crimp a socket terminal to one end of the jumper wire and a connector that will connect to the −Battery bus bar on the opposite end.
Connect the jumper wire from the −Battery bus bar to the pin for the suspect switch on the J61 customer connector.
Restore the electrical power to the ECM.
Monitor the status screen on Cat ET as the jumper wire is connected and disconnected from the customer connector. Expected Result:The status screen indicates a change in status for the suspect switch.Results:
OK - The status of the switch indicated a change in switch status on Cat ET. There is a problem in the circuit between the customer connector and the −Battery bus bar. Proceed to Test Step 5.
Not OK - The switch status on the status screen did not change. The problem may be between the ECM and the customer connector. Proceed to Test Step 8.Test Step 5. BYPASS THE SWITCH
Fabricate a jumper wire that can be used to bypass the suspect switch.
Remove the electrical power from the ECM.
Use the jumper wire to bypass the suspect switch.
Restore the electrical power to the ECM.
Monitor the status screen for the suspect switch on Cat ET. Expected Result:The switch status changes for the suspect switch as the switch is bypassed.Results:
OK - The switch status for the suspect switch changes.Repair: The problem is with the switch. Replace the switch.Verify that the repair solved the problem.STOP
Not OK - The switch status did not change. Proceed to Test Step 6.Test Step 6. CHECK THE −BATTERY WIRING FOR THE SUSPECT SWITCH
Remove the electrical power from the ECM.
Measure the resistance between the −Battery terminal on the suspect switch and the engine ground stud. Expected Result:The resistance measurement is less than five Ohms.Results:
OK - The resistance is less than five Ohms. The wiring for the ground circuit is OK. Proceed to Test Step 7.
Not OK - The resistance is greater than five Ohms. There is a problem with the ground circuit between the −Battery terminal on the suspect switch and the engine ground stud.Repair: Repair the ground wire and/or connections between the engine ground stud and the −Battery bus bar or repair the ground wire and/or connections between the −Battery terminal on the suspect switch and the −Battery bus bar. Verify that the repair eliminates the problem.STOPTest Step 7. MEASURE THE VOLTAGE FOR THE SUSPECT SWITCH AT THE CUSTOMER CONNECTOR
Restore the electrical power to the ECM.
Close the suspect switch.
Measure the voltage for the input of the suspect switch on the J61 customer connector. Connect the negative probe of the voltmeter to the −Battery bus bar. Expected Result:The voltage is less than 0.9 VDC.Results:
OK - The voltage is less than 0.9 VDC. The input voltage to the swit