GEAR-SUN 4568268 - Caterpillar

Illustration 2 g01981196
View of the pin locations on the P1 connector for the isolator switch and battery supply circuit (48) Battery+ (52) Battery+ (53) Battery+ (55) Battery+ (57) Battery+ (61) Battery ground (63) Battery ground (65) Battery ground (67) Battery ground (69) Battery ground (70) Ignition key switch
Table 2
Troubleshooting Test Steps    Values    Results    
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect the battery connections and the connections to the isolator switch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
B. Perform a
45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with electrical power supply circuit.
C. Check the ECM connector for the correct torque of
5 N m (44 lb in)
D. Check the harness for abrasion and for pinch points from the battery through the isolator switch to the ECM.
    Damaged wire or connector     Result: A damaged wire or damaged connector was found.
Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 2.
   
2. Check for Active Diagnostic Codes or Logged Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the isolator switch to the ON position and start the engine.
C. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes or logged diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
   
Diagnostic codes    
Result: There are no active 168 diagnostic codes at this time.
If the fault is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".
If the ECM is receiving no battery voltage, proceed to Test Step 3.
Result: There is an active 168 diagnostic code.
Proceed to Test Step 3.
   
3. Check the Batteries
A. Load-test the batteries. Use a suitable battery load tester. Refer to Systems Operation, Testing and Adjusting, "Battery - Test" for the correct procedure.
   
Battery load test passed    
Result: The batteries do not pass the load test. For 12 V systems, the measured voltage is less than 11.0 VDC. For 24 V systems, the measured voltage is less than 22.0 VDC.
Recharge or replace the faulty batteries.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The batteries pass the load test. For 12 V systems, the measured voltage is at least 11.0 VDC. For 24 V systems, the measured voltage is at least 22.0 VDC.
Proceed to Test Step 4.
   
4. Check the Battery Voltage at the ECM Connector
A. Disconnect the P1 connector from the ECM.
B. Turn the isolator switch to the ON position.
C. Measure the voltage between the following points:
P1:48 and P1:61
P1:52 and P1:63
P1:53 and P1:65
P1:55 and P1:67
P1:57 and P1:69
P1:70 and P1:69    
At least 11 VDC for a 12 V system. At