0582976 JOHNSON CABLE ASSY.

Illustration 1 g00807932
Typical schematicNote: The Engine Control Switch (ECS) is mounted within an instrument panel that is located on the right side of the engine. The ECS is locked into the AUTO position with a pin. The pin must be removed in order to perform this test. After performing this test, ensure that the ECS is placed in the AUTO position and that the locking pin has been reinstalled.Test Step 1. Check for Connector Damage.
Verify that the circuit breakers are not tripped.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET 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 pinch points.Expected Result:All connectors, pins, and sockets are coupled and/or inserted, and 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. Check the Voltage to the ECM.
Disconnect the Primary ECM connector J1/P1 and the Secondary ECM connector J1/P1.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.Note: If a remote START/STOP switch is installed, the remote START/STOP switch must be in the COOL/STOP position.
Measure the voltage at the Primary ECM and the Secondary ECM. Measure the voltage between P1-6 and P1-5. Measure the voltage between P1-4 and P1-11. Measure the voltage between P1-23 and P1-11.Expected Result:The voltage should be 24 3 VDC.The difference between the three voltage measurements should be less than 0.5 VDC.Results:
OK - The ECM is receiving the correct voltage. Proceed to test step 8.
Not OK - The voltage is incorrect. The wiring or components between the battery and the ECM may be preventing the voltage from reaching the ECM. Proceed to test step 3.Test Step 3. Check the Battery Voltage.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Measure no-load battery voltage at the battery terminals.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to the Operating Manual, SEHS9249. Refer to Special Instruction, SEHS7633.Expected Result:The no-load voltage at the batteries should be at least 23.5 VDC and the batteries should pass the load test.Results:
OK - The battery voltage is okay and the battery passes the load test. Proceed to test step 4.
Not OK - The battery voltage is incorrect and/or the battery fails the load test.Repair: The batteries or the alternator are causing the problem. Recharge the batteries or replace the batteries. Check the operation of the alternator. Verify that the original condition is resolved.STOPTest Step 4. Check the Voltage at the Emergency Stop Relay.
Reconnect the Primary ECM connector and the Secondary ECM connector J1/P1.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.Note: If a remote START/STOP switch is installed the remote START/STOP switch must be in the COOL/STOP position.
Measure the voltage from wire 103-RD on terminal 30 of the emergency stop relay to the − Battery terminal.Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to test step 5.
Not OK - The voltage is not 24 3 VDC. Proceed to test step 7.Test Step 5. Check the Voltage at the ECM Relay.
Measure the voltage from wire 103-RD on terminal 86 of the ECM relay to the − Battery terminal.Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to test step 6.
Not OK - The voltage is not 24 3 VDC.Repair: Check the voltage on terminal 87A on the Emergency Stop relay. If the voltage is correct, the wire from the Emergency Stop relay to the ECM relay may be the problem. If the voltage is incorrect, replace the Emergency Stop relay.STOPTest Step 6. Check the Voltage at the Output of the ECM Relay.
Measure the voltage from wire 102-RD on terminal 87 of the Primary ECM relay to the − Battery terminal.
Measure the voltage from wire 150-OR on terminal 30 of the Primary ECM relay to the − Battery terminal.
Measure the voltage from wire 102-RD on terminal 87 of the Secondary ECM relay to the − Battery terminal.
Measure the voltage from wire 106-WH on terminal 30 of the Secondary ECM relay to the − Battery terminal.Expected Result:The voltage should be 24 3 VDC on all terminals.Results:
OK - The voltage is 24 3 VDC on all terminals.Repair: The wire from the ECM relay to the ECM is bad. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOP
Not OK - Terminal 87 - The voltage is incorrect on terminal 87.Repair: Verify that the circuit breakers for the battery and for the ECM are not tripped. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOP
Not OK - Terminal 30 - The voltage is incorrect on terminal 30.Repair: Verify that wire 200-BK on terminal 85 of the ECM relay is not damaged or open. If wire 200-BK is okay, replace the ECM relay. Verify that the original condition is resolved.STOPTest Step 7. Check the Voltage at the Engine Control Switch.
Measure the voltage at the ECS when the switch is in the positions that are listed in Table 1.
Table 1
Engine Control Switch    
Switch Position     Terminal     Voltage    
STOP