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P-201: Inspecting Electrical Connectors
Many of the Operational Procedures and Diagnostic Code Procedures in this troubleshooting guide will direct you to check a specific electrical connector. Use the following steps to help determine if the connector is the cause of the problem. If a problem is found in the electrical connector, repair the connector and continue the test procedure.1. Check connector lock ring. Make sure that connector was properly locked and that the lock ring is capable of locking connector together.2. Perform 10 pound pull test on each pin/wire. Each pin and connector should easily withstand 10 pounds of pull, and remain in the connector body. This test checks whether the wire was properly crimped in the pin, and whether the pin was properly inserted into the connector. Repair as needed. Any time a wire is removed from a connector for testing purposes, do a 10 pound pull test after reinserting the wire. Pins should ALWAYS be crimped onto the wires; NEVER soldered. Use 1U5804 Crimping Tool (part of 4C3406 Connector Repair Kit).3. Visually inspect wiring. Look for worn or abraded wires. Check for pinched or damaged harnesses.4. Visually inspect connectors. Verify that pins and sockets are not corroded or damaged. Verify proper alignment and location of pins in the connector.5. Check individual pins and sockets. This is especially important for intermittent problems. Using a new pin, insert the pin into each socket one at a time to check for a good grip on the pin by the socket. Repeat for each pin on the mating side of the connector, using a new socket for the test.P-210: Electrical Power Supply To PEEC Test
The PEEC ECM receives + 12 volt DC power from the 24/12 volt DC power converter (Pin 1), through the Electronic Speed Switch (ESS) (Pin 8 in, Pin 9 out), to J2/P2 pin A (+ battery).Throughout these test procedures, when "battery voltage" is mentioned, it refers to the 12 volts DC (+ Battery) that is supplied to PEEC from the 24/12 volt converter. Ground (- Battery) comes from the terminal board (Pin 32) to the System Connector (J2/P2) Pin B.In typical applications, PEEC receives power whenever the Master Power Switch is turned ON.Keep in mind that these devices may be the cause of no (or intermittent) power to the ECM.This procedure tests whether proper voltage is being supplied to the ECM.Note that the ECAP is supplied with electrical power through direct connections inside the ECM. Therefore, if the ECAP has power, so does the ECM.For intermittent problems that could be caused by system wiring (such as intermittent shutdowns), temporarily bypassing the system wiring may be an effective means of determining the root cause. If symptoms vanish with the wiring bypassed, system wiring was the cause. A means of bypassing system wiring is explained below. Step 1. Check Electrical Connectors And WiringCheck system connector (J2/P2) and + 12 volt power and grounds to J2/P2, being sure to:* Check Connector lock rings.* Perform 10 pound pull test on each pin or wire.* Inspect wiring for damage or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details. Repair any damage, then continue with the next step.* Visually and physically check grounds for looseness or corrosion. If a problem is found, disconnect, clean, and reconnect the connector Step 2. Check Battery Voltage Coming To ECMA. Connect a 9-pin "T" at the ECM system connector (J2/P2).B. Turn power switch(es) ON, engine OFF.C. Measure the voltage between + Battery (Pin A) and ground (Pin B). The voltage at Pin A should be between 11.5 and 13.5 VDC. OK: The ECM is currently receiving the correct voltage. If intermittent problems with battery voltage may be occurring, consider temporarily bypassing system wiring as shown in Step 4. Otherwise, Stop. NOT OK: The ECM is NOT receiving the correct voltages. Continue with the next step. Step 3. Check BatteriesA. Measure battery voltage at the battery posts.B. Load test the batteries using the 4C4911 Battery Load Tester. Make reference to Operation Manual, Form No. SEHS9249 for more complete information for use of the 4C4911 Battery Load Tester. The voltage at the batteries should be at least 11.5 VDC, and the batteries should pass the load test. OK: The batteries are not the problem. Wiring or components between the batteries and PEEC are preventing voltage from reaching PEEC. NOT OK: The batteries are defective. Replace the defective batteries. Stop. Step 4. Bypass System Wiring For Testing This bypass is for TEST PURPOSES ONLY. It may be left on the system temporarily to test whether intermittent problems are due to interruptions in battery power to the ECM. The bypass switch is installed in parallel with the power switch. Either one will turn power ON, and both must be OFF to turn power OFF and shutdown the engine.Use a spare 12 volt battery for test purposes, or a 120 volt AC to 12 volt DC power converter capable of supplying at least 7.5 amps at 12 volts, filtered.A. Build a bypass circuit as shown in the illustration below, using #14 AWG wire.
System Power Bypass Circuit - for TEST PURPOSES ONLYB. Connect the battery end of the bypass DIRECTLY to the battery posts (or power converter).C. Remove Pins A (+ Battery) and B (-Battery) from J2 (System connector - system side).D. Insert the other end of the bypass into J2 Pins A and B (as shown below).E. Connect the wire that was formerly in J2 Pin B into the socket spliced into the bypass.F. Connect the wire that was formerly in J2 Pin A into the socket that is spliced into the bypass. (This supplies power to the throttle sensor and through the bypass rather than the system wiring). Tape this connection to keep it clean, prevent shorting, and prevent loosening during operation. Then turn the master power switch OFF. This will isolate the PEEC system from the original system power circuit.G. Install the temporary switch on the front panel.H. After tests are complete, restore