3176B MARINE ENGINE Caterpillar

5.0 Vessel To Engine Control Electronic Functional Tests

Usage:

Introduction

The tests in this section are for components on the vessel connected to the engine electronic control, but not installed on the engine by Caterpillar.

These tests are designed to establish whether a component and related parts are working correctly and if not, to pinpoint the faulty component.

These tests may also be used for basic system checks, to determine if problems exist, or as a guide to check for intermittent problems.

P-501: 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 to make sure all seals are present, and properly seated. Check pins and sockets for evidence of corrosion before joining connectors.

Make sure the connector seals are in place. If any of the seals are missing, replace the seal, or if necessary, the connector. The connector seals must be present.

NOTE: If corrosion is evident on pins, sockets or the connector itself, use only denatured alcohol to clean/remove the corrosion with a cotton swab.

2. Check "DT" connector locking, and "HD" connector lock ring.

Make sure that the connector is properly locked (clicked) together and that the two halves can not be pulled apart.

3. Do not exceed 2.25 N·m (20 lb in) of torque on the ECM Connector Bolt when connecting the 40 pin "DRC" connector to the ECM.

Make sure the Connector Bolt is properly tightened, but be careful not to over-tighten and break the bolt.

4. Perform 10 pound (44.5 N) pull test on each pin/wire.

Each pin and connector should easily withstand 10 pounds (44.5 N) 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. The "DT" connectors use an orange wedge to lock the pins in place. Check to see that the orange wedge is not missing and installed properly on the "DT" connectors. Repair as needed.

NOTE: Pins should ALWAYS be crimped onto the wires using a Deutsch Crimp Too; NEVER soldered. Use the 1U5804 Deutsch Crimp Tool.

5. Inspect connectors. Verify that pins and sockets are not corroded or damaged. Verify proper alignment and location of pins in the connector.

6. Check individual pin and socket connections. 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.