0439368 JOHNSON FLOAT CHAMBER ASSY.

Illustration 1 g00830070
Schematic
Illustration 2 g01007992
P1 ECM connector
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector and all other connectors in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and the wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status of the Ether Switch
Remove the ether canister from the ether solenoid.
Connect the Caterpillar Electronic Technician (Cat ET) to the service tool connector.
Turn the keyswitch to the ON position.
Press the starting aid switch to "MANUAL". Observe the status of "Ether Switch" on Cat ET.Expected Result:When the starting aid switch is pressed, Cat ET displays the status of the switch as "On".When the starting aid switch is not pressed, Cat ET displays the status of the switch as "Off".Results:
OK - The starting aid switch is operating correctly. Proceed to Test Step 6.
Not OK - The ECM is not seeing the signal from the starting aid switch. Proceed to Test Step 8.Test Step 3. Short the Switch Wires
Turn the keyswitch to the ON position.
Disconnect the starting aid switch.
Observe the status of "Ether Switch" on Cat ET.Note: The status should be "Off".
Install a jumper wire between terminal 2 and terminal 3 in the plug for the starting aid switch.
Observe the status of "Ether Switch" on Cat ET.Note: The status should be "On".Expected Result:When the terminals are shorted, Cat ET displays the status of the starting aid switch as "On".When the terminals are not shorted, Cat ET displays the status of the starting aid switch as "Off".Results:
OK - The ECM and the harness are OK, but the starting aid switch is not operating correctly.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem.STOP
Not OK - There may be a problem with the harness. Proceed to Test Step 4.Test Step 4. Short the Switch Inputs at the ECM
Turn the keyswitch to the OFF/RESET position.
Remove the wires from P1:22 (Starting Aid Switch) and P1:5 (Digital Return).
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on Cat ET.Note: The status should be "Off".
Install a jumper wire with Deutsch sockets on each end between P1:22 (Starting Aid Switch) and P1:5 (Digital Return).
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on Cat ET.Note: The status should be "On".
Remove the jumper wire and reinstall the wires in the P1 connector.Expected Result:When the jumper wire is installed, Cat ET displays the status of the switch as "On".When the jumper wire is not installed, Cat ET displays the status of the starting aid switch as "Off".Results:
OK - The ECM is operating correctly. There is a problem in the wiring between the switch and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOP
Not OK - The ECM is not reading the switch input properly.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.Verify that the repair eliminates the problem.STOPTest Step 5. Check for Correct Operation of the SolenoidNote: The ether canister must be removed prior to activating this test.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system.Note: The diagnostic override will only activate the relay for three seconds.
Listen for an audible click as the ether solenoid is activated. Listen for an audible click as the ether solenoid is deactivated.Expected Result:A click is heard when the solenoid is activated.Results:
OK - The ether injection system is operating correctly.STOP
Not OK - The solenoid is not being energized or there is a problem with the solenoid. Proceed to Test Step 6.Test Step 6. Check the Resistance of the Solenoid
Disconnect the J504/P504 start aid solenoid connector.
Measure the resistance of the solenoid between J504:1 (Solenoid Power) and J504:2 (Solenoid Return).
Reconnect J504/P504 Start Aid Solenoid connector.Expected Result:The resistance is less than 10 Ohms.Results:
OK - The resistance of the solenoid is OK. Proceed to Test Step 7.
Not OK - The resistance of the solenoid is not within the specification.Repair: Replace the solenoid.Verify that the repair eliminates the problem.STOPTest Step 7. Check the Supply Voltage to the SolenoidNote: The ether canister must be removed prior to activating this test.
Disconnect the J504/P504 start aid solenoid connector.
Turn the keyswitch to the ON position.