C32 Marine Engines Switch Circuits - Test Caterpillar


Switch Circuits - Test
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System Operation Description:

Switch circuits may have problems such as faulty wiring, faulty switches, or faulty connectors. Use the following diagnostic procedures in order to diagnose problems with these switch circuits and repair these switch circuits:

  • Trolling mode switch

  • Slow vessel mode switch

  • Maintenance clear switch

  • Trip clear switch

  • Remote shutdown switch




Illustration 1g01130280

Schematic for the switch inputs

Test Step 1. Check the Electrical Connectors and the Wiring

  1. Place the keyswitch in the OFF position.



    Illustration 2g01134334

    Engine components for the switch inputs

    (1) J61/P61 customer connectors

    (2) J1/P1 ECM connectors

    (3) J69/P69 connectors for the marine engine control panel (typical location)

  1. Thoroughly inspect connectors (1), (2), and (3). Thoroughly inspect the connections for the suspect switch. Refer to Troubleshooting, "Electrical Connectors - Inspect".



    Illustration 3g01130962

    P1 terminals for the various switches

    (P1-22) Remote shutdown switch

    (P1-23) Maintenance clear switch

    (P1-40) Trip clear switch

    (P1-41) Trolling mode switch

    (P1-59) Slow vessel mode switch

    (P1-63) −Battery




    Illustration 4g01130969

    J61/P61 terminals that are associated with the switch inputs

    (3) −Battery

    (19) Trip clear switch

    (36) Remote shutdown switch

    (37) Trolling mode switch

    (38) Slow vessel mode switch

    (39) Maintenance clear switch




    Illustration 5g01130973

    J69/P69 terminals that are associated with the switch inputs

    (1) Maintenance clear switch

    (5) Remote shutdown switch

    (10) −Battery

  1. Perform a 45 N (10 lb) pull test on each of the wires in the circuit for the suspect switch.

  1. Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

  1. Check the allen head screw on the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

  1. Check the harness and wiring for abrasions and for pinch points from the battery to the ECM.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.

Results:

  • OK - The wiring and connectors are OK. Proceed to Test Step 2.

  • Not OK - There is a problem with the wiring and/or a connector.

    Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.

    STOP

Test Step 2. Test the Switch for Proper Operation

  1. Disconnect the P1 connector.

  1. Refer to Table 1. Determine the P1 terminal for the suspect switch.

    Table 1
    Terminals for the Switch Inputs    
    Name of the Switch     P1 Terminals     J61/P61 Terminals    
    Trolling mode switch     41     37    
    Slow vessel mode switch     59     38    
    Maintenance clear switch     23     39    
    Trip clear switch     40     19    
    Remote shutdown switch     22     36    

  1. Connect a meter lead to the P1 terminal for the suspect switch. Connect the other meter lead to engine ground.

    Note: Wiggle the harnesses during the following measurements in order to reveal any intermittent short condition.

  1. Measure the resistance between the P1 terminal for the suspect switch and engine ground.

  1. Activate the switch and measure the resistance again.

Expected Result:

When the switch is not activated, the resistance measurement indicates an open circuit. When the switch is activated, the resistance measurement is less than ten Ohms.

Results:

  • OK - When the switch is not activated, the resistance measurement indicates an open circuit. When the switch is activated, the resistance measurement is less than ten Ohms. The switch is operating correctly. The wiring does not have a short circuit or an open circuit.

    Repair: Operate the engine and check the switch for proper operation.If the switch does not operate correctly, there may be a short circuit between the circuit for the suspect switch and another circuit. Carefully reinspect the components. Refer to Troubleshooting, "Electrical Inspectors - Inspect". Locate the short circuit and make repairs.

    STOP

  • Not OK - Both resistance measurements indicate an open circuit or both resistance measurements are less than ten Ohms. There is a problem with the circuit for the switch.

    Repair: The problem could be in the switch, in the wiring, or in a connector.Carefully reinspect the components. Refer to Troubleshooting, "Electrical Inspectors - Inspect".If the inspection does not identify the faulty component, replace the switch and test the switch again.If the problem is not resolved, repair the wiring or the connector. Replace parts, if necessary. Verify that the problem is resolved.

    STOP

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