0390605 EVINRUDE MOTOR COVER ASSY., 115

Illustration 1 g01383764
Schematic for the normally open switch and the normally closed switch
Typical switch inputs
The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Check the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
Illustration 2 g01388291
Left side view
(1) J1/P1Electronic Control Module (ECM) connectors
Thoroughly inspect the J1/P1 connectors. Thoroughly inspect the connections for the suspect switch. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01383775
P1 terminals for the various switches
(P1-6) Maintenance clear switch
(P1-7) Torque limit switch
(P1-22) Ether starting aid switch
(P1-41) PTO interrupt switch
(P1-44) Remote shutdown switch
(P1-45) Intermediate engine speed switch
(P1-54) Overspeed verify switch
(P1-56) PTO enable switch
(P1-58) PTO ramp up switch or set switch
(P1-60) PTO ramp down switch or resume switch
Perform a 45 N (10 lb) pull test on each of the wires in the circuit for the suspect switch.
Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the allen head screw on the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque value.
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.STOPTest Step 2. Test the Switch for Proper Operation
Disconnect the J1/P1 connector.
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
Maintenance clear switch 6 12
Torque limit switch 7 2
Ether starting aid switch 22 38
PTO interrupt switch 41 19
Remote shutdown switch 44 27
Intermediate engine speed switch 45 28
Overspeed verify switch 54 40
PTO enable switch 56 29
PTO ramp up switch or set switch 58 30
PTO ramp down switch or resume switch 60 39
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.
Measure the resistance between the P1 terminal for the suspect switch and engine ground.
Activate the switch and measure the resistance again. Expected Result:When the switch is open, the resistance measurement indicates an open circuit. When the switch is closed, the resistance measurement is less than ten Ohms.Results:
OK - One resistance measurement indicates an open circuit. The other 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