0439552 JOHNSON ENGINE COVER ASSY., 200

Illustration 1 g00956594
SchematicTest Step 1. Inspect Electrical Connectors and Wiring.
Illustration 2 g00782831
Terminal locations for ECM J1 connector
Thoroughly inspect the following electrical connectors:
ECM connector J1/P1
Cab data link connector
Firewall bulkhead connector
Connectors for Cat ET
Cat Data Link (P1:8 and P1:9) in the connectorsRefer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the Cat Data Link.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and for pinch points from the connector to the ECM.Refer to Illustration 2.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasions, and of pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Determine the Type of Problem with the Data Link.
Connect Cat ET to the Cat Data Link connector.
Start the engine.Expected Result:The engine starts. Cat ET powers up and Cat ET communicates without error.Note: Check the display screen or check the communication Adapter display in order to determine if Cat ET has powered up. Cat ET will display information that shows if Cat ET is getting power. If Cat ET powers up, the Cat Data Link connector is receiving power.Results:
OK - There is not a problem with the Cat Data Link at this time. If an intermittent condition exists, thoroughly inspect all wiring and connectors.Repair: Perform the following diagnostic procedure:Troubleshooting, "Electrical Connectors - Inspect"STOP
Not OK - The engine starts. Cat ET displays an error message. The ECM is receiving battery power. Proceed to Test Step 3.
Not OK - The engine will not crank regardless of the condition of Cat ET.Repair: Perform the following diagnostic procedure:Troubleshooting, "Engine Will Not Crank"STOP
Not OK - The engine cranks but the engine will not start regardless of the condition of Cat ET.Repair: Perform the following diagnostic procedure:Troubleshooting, "Engine Cranks But Will Not Start"STOP
Not OK - The engine starts but Cat ET does not power up or the communications adapter does not power up. Ensure that the ECM is receiving the correct battery power. Proceed to Test Step 4.Test Step 3. Check the Battery Voltage at the ECM.
Illustration 3 g00781870
Breakout T
Ensure that Cat ET is connected to the Cat Data Link connector.
Disconnect machine harness connector P1 from ECM connector J1 and insert a 70-Terminal Breakout T.
Turn the keyswitch to the ON position.
Measure the voltage between P1:48 (unswitched +Battery) and P1:61 (− Battery). Measure the voltage between P1:52 (unswitched +Battery) and P1:63 (−Battery). Measure the voltage between P1:53 (unswitched +Battery) and P1:65 (−Battery).
Measure the voltage between P1:70 (keyswitch) and P1:63 (−Battery).Refer to Illustration 3.Expected Result:The voltage is between 22.0 VDC and 27 VDC when the keyswitch is in the ON position.Results:
Yes - The ECM is currently receiving the correct voltage. Proceed to Test Step 5.
No - The ECM is not receiving the correct voltage.Repair: Perform the following diagnostic procedure:Troubleshooting, "Electrical Power Supply Circuit - Test"STOPTest Step 4. Check the Battery Voltage that is Coming to the Cat Data Link Connector.
Illustration 4 g00979567
Data link connector
Turn the keyswitch to the ON position.
Use a multimeter to measure the voltage from the +Battery terminal to the -battery terminal.Refer to Illustration 4.Expected Result:The voltage is between 22.0 VDC and 27.0 VDC.Results:
Yes - The Cat Data Link connector is currently receiving the correct voltage. Proceed to Test Step 6.
No - The Cat Data Link connector is not receiving the correct voltage.Repair: Inspect the wiring and fuses to the connector. Repair the wiring or batteries and/or replace the wiring or batteries, as required. Send the machine to the dealer for repair, if necessary. Verify that the repair eliminates the problem.STOPTest Step 5. Connect Cat ET Directly to the ECM.
Illustration 5 g01053306
Bypass harness
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.
Do Not connect the Bypass Harness to the battery until all of the 20 Amp in-line fusesn have been removed from the +Battery line. If th