BOLT 8T9396 - Caterpillar

System Operation Description:This procedure covers the following event codes:
E264-3 Emergency Stop ActivatedThis application is equipped with two emergency stop switches. One switch is located on the control panel. The other switch is located on the generator enclosure. The Electronic Control Module (ECM) is configured to record an event when either of the switches is activated.When an emergency stop switch is activated, the ECM input for the emergency stop switch at J1-23 will go high. This will cause the ECM to disable injection to the cylinders. The engine shuts down. The ground circuit to the control solenoid of the start relay also becomes open. This removes supply voltage (+Battery) to the engine ECM. The engine shuts down.
Illustration 1 g01215513
Schematic for the emergency stop switches
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the battery isolator switch to the OFF position.
Illustration 2 g01186024
Location of the J1/P1 ECM connectors (typical left side engine view)
Thoroughly inspect the J1/P1 ECM connector. Inspect all of the connectors that are associated with the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01241230
Terminal locations at the P1 ECM connector for the emergency stop switch
(P1-23) Emergency stop
(P1-61) +Battery
(P1-63) +Battery
(P1-65) +Battery
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors and the connector for the EMCP that are associated with the circuit.
Check the torque of the allen head screws for each of the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the batteries 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 and of pinch points.Results:
OK - The connectors and wiring appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary.STOPTest Step 2. Check the Circuit for the Emergency Stop Switches
Turn the battery isolator switch to the OFF position.
Place both of the emergency stop switches in the RUN position.
Disconnect the wire in terminal location 85 from the start relay.
Disconnect the J1/P1 ECM connectors.
Check continuity between terminal P1-23 at the ECM connector and the following test points. If an open circuit condition exists at a test point, the problem is in the device, in the wire or in the connector that precedes the test point in the circuit. Refer to Illustration 1 as a reference.
Table 1
Device Terminal
70 way general connector Terminal 17
Emergency stop switch (control panel) Terminals on either side
70 way general connector Terminal 50
Enclosure connector Terminal 5
Emergency stop switch (enclosure) Terminals on either side
Enclosure connector Terminal 6
P1 ECM connector P1-61, P1-63, and P1-65
Restore the wiring to the original configuration. Expected Result:All measurements indicate that continuity exists at the test point.Results:
OK - All measurements indicate that continuity exists. All measurements are correct. The harness is OK. Proceed to Test Step 3.
Not OK - At least one of the measurements