0321668 EVINRUDE SEAL

Illustration 1 g00836130
Typical schematicTest Step 1. Check for Connector Damage.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Attempt to Start the Engine
Connect Cat ET to the service tool connector J60/P60.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Observe the "startup mode" parameters on the Cat ET status screen.
Turn the ECS to the START position. Continue monitoring engine parameters as the engine cranks.
The crank cycle will continue for the time that is equal to the cycle crank time that has been programmed or the crank cycle will continue until the engine speed reaches the crank terminate speed.
Turn the ECS to the OFF/RESET position.Expected Result:The status screen for the "startup mode" parameter should display "CRANK". The engine cranks.Results:
OK - The "startup mode" parameter on the status screen on the Cat ET displays "CRANK".Repair: The engine cranks. The starting system is working properly.STOP
Not OK - Engine Doesn't Crank - The "startup mode" parameter on the status screen on the Cat ET displays "CRANK". The engine will not crank. Proceed to test step 3.
Not OK - Status Screen - The "startup mode" parameter on the status screen on the Cat ET does not display "CRANK".Repair: Perform the diagnostic functional test Troubleshooting, "Engine Control Switch (ECS)".STOPTest Step 3. Manually Crank the Engine.
Turn the battery disconnect switch to the OFF position.
Open the power distribution box that is located on the left side of the engine, close to the starter motors.
Connect one probe of a digital voltmeter to the − Battery terminal. Connect the other probe of the digital voltmeter to wire 314-PU on terminal 2 of the magnetic switch.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the START position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF/RESET position.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 7.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 4.Test Step 4. Check the Coil on the Magnetic Switch.
Turn the battery disconnect switch to the OFF position.
Connect one probe of the digital voltmeter to terminal 3 of the magnetic switch. Connect the other probe of the digital voltmeter to wire 102-GN/YL on terminal 4 of the magnetic switch.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the START position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Remove the digital voltmeter and replace all wires.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The problem appears to be with the magnetic switch. Temporarily install a new magnetic switch. Verify that the problem is no longer present. Reinstall the old magnetic switch. If the problem returns, replace the magnetic switch.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 5.Test Step 5. Check the Voltage to the Magnetic Switch.
Connect one probe of a digital voltmeter to − Battery terminal. Connect the other probe of the digital voltmeter to wire F701-BR on terminal 3 of the magnetic switch.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the START position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF/RESET position.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The coil of the magnetic switch is open. Temporarily install a new magnetic switch. Verify that the problem is no longer present. Reinstall the old magnetic switch. If the problem returns, replace the magnetic switch.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 6.Test Step 6. Check the Voltage from the Generator Set Control to the Connector of the Generator and Engine.
Turn the battery disconnect switch to the OFF position.
Disconnect the generator and the engine harness connector J3/P3.
Remove the wires J3-24 and J3-39 from the generator and engine connector J3/P3. Remove the wires from the side of the connector that is going to the generator.
Reconnect the generator and engine connector J3/P3.
Connect one probe of a digital voltmeter to the wire from J3-24. Connect the other probe of the digital voltmeter to the wire from J3-39.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the START position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The problem is most likely in the wiring between the generator and engine