22262547 Volvo.Penta Shaft

Table 1
Diagnostic Codes Table    
Code and Description     Conditions which Generate this Code     System Response    
444-5 Starter Motor Relay current below normal     The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery in the start relay.     The code is logged.    
444-6 Starter Motor Relay current above normal     The ECM detects a short circuit to ground in the start relay.    The ECM receives two input signals from the start/run/stop switch. When both of the input signals are high or open, the ECM assumes that the start/run/stop switch is in the STOP position. When both of the input signals are low or shorted to the digital return terminal, the ECM assumes that the start/run/stop switch is in the START position. After the start/run/stop switch is turned to the START position, the ECM will initiate the starting sequence. The ECM will energize the prelube system if the prelube system is available and activated. After the prelube cycle is completed the ECM will energize the start relays.The ECM has the ability to crank the engine when the circuit for the start/run/stop switch is activated. The crank cycle will continue for the time that is equal to the cycle crank time that has been programmed or the crank cycle will continue until the engine speed reaches the crank terminate speed. If crank terminate speed is not reached in the time that is equal to the cycle crank time, the starting motor will deactivate for a time that is equal to the cycle crank time.This process will repeat for a programmed amount of times (Total Number of Crank Cycles). If the engine does not start the starter mode on the Caterpillar Electronic Technician (ET) will display "OVERCRANK". The engine control will be in an idle state.
Illustration 1 g01268846
Typical schematic
Illustration 2 g01268849
P1 ECM connector (P1-5) Digital return (P1-21) Start/Run/Stop input 1 (P1-22) Start/Run/Stop input 2
Illustration 3 g01269000
P2 ECM connector (P2-6) Crank relay
Illustration 4 g01268992
Machine interface connector (Terminal 03) Crank relay (Terminal 09) Digital return (Terminal 37) Start signal
Illustration 5 g01234146
Location of ECM connectorsTest Step 1. Inspect Electrical Connectors and Wiring
Turn the switch that provides power to the keyswitch input for the ECM to the OFF position.
Turn the breaker for the ECM 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 for the Start Relay
Connect Cat ET to the service tool connector.
Turn the breaker for the ECM to the ON position.
Turn the switch that provides power to the keyswitch input for the ECM to the ON position.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes for the start relays.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Turn the start/run/stop switch to the START position.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes for the start relays.Note: Wait at least 30 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 starting system. Proceed to Test Step 6.
Not OK - A -6 diagnostic code is active at this time. Proceed to Test Step 3.
Not OK - A -5 diagnostic code is active at this time. Proceed to Test Step 4.Test Step 3. Create an Open at the Start Relays
Turn the start/run/stop switch to the STOP position.
Disconnect the wires from terminal 3 on the start relays. Ensure that the wires are isolated from engine ground and other sources of electrical power.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes for the start relays.Note: Wait at least 30 seconds in order for the diagnostic codes to become active. Check for an active diagnostic code for the start relay.
Turn the start/run/stop switch to the START position.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes for the start relay.Note: Wait at least 30 seconds in order for the diagnostic codes to become active. Check for an active diagnostic code for the start relays.
Turn the start/run/stop switch to the STOP position.Expected Result:A -5 diagnostic code is now active for the start relays.Results:
OK - A -6 diagnostic code was active before disconnecting the wire. A -5 diagnostic code became active after disconnecting the wires. The harness and the ECM are OK. The problem may be in the start relays.Repair: Check for a short or an open across the coil of the start relay. The coil resistance is approximately 25 to 30 Ohms. If the resistance is incorrect, install a new start relay.STOP
Not OK - A -6 diagnostic code remains active. There is a short between the start relay and the ECM. Leave the wires for the start relays disconnected. Proceed to Test Step 5.Test Step 4. Create a Short at the Start Relays
Turn the start/run/s