0386076 JOHNSON GEAR & BUSHING ASSY.,Forward

Illustration 1 g00848889
Typical schematicTest Step 1. Check for Connector Damage.
Disconnect main power.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to 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:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.Test Step 2. Check the Status while the Emergency Stop Switch is Active.
Activate the Emergency Stop Switch. If multiple Emergency Stop Switches have been installed, ensure that any other Emergency Stop Switch has not been activated.
Connect an Electronic Service Tool to the service tool connector.
Connect the main power.
Observe the status of the emergency stop switch on the Electronic Service Tool.Expected Result:The parameter for the emergency stop switch should read "ON".Results:
OK - The parameter for the emergency stop switch reads "ON". Proceed to test step 3.
Not OK - The parameter for the emergency stop switch does not read "ON". Proceed to test step 4.Test Step 3. Check the Status while the Emergency Stop Switch is Not Active.
Deactivate the emergency stop switch.
Observe the status of the emergency stop switch on the Electronic Service Tool.Expected Result:The parameter for the emergency stop switch should read "OFF".Results:
OK - The parameter for the emergency stop switch reads "OFF".Repair: The emergency stop switch is functioning correctly. There may be an intermittent problem. If the problem is intermittent refer to Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - The parameter for the emergency stop switch does not display "OFF". Proceed to test step 4.Test Step 4. Install a Jumper Wire at the Emergency Stop Inputs to the ECM.
Disconnect the main power.
Disconnect ECM connector J1/P1.
Remove wire F715-PU from the ECM connector P1-02. Install a wire jumper into the socket for P1-02.
Remove wire F719-BR from the ECM connector P1-20. Install a wire jumper into the socket for P1-20.
Connect the main power.
Observe the status of the emergency stop switch on the Electronic Service Tool.
Disconnect the main power.
Fabricate a jumper wire.Connect the wire jumpers in socket P1-02 and P1-20 to the digital return at socket P1-29.
Connect the main power.
Observe the parameters for the emergency stop on the Electronic Service Tool.
Disconnect the main power. Restore the wiring and the connectors to the original configuration.
Remove the wire jumpers and reconnect all wires.Expected Result:The parameter for the emergency stop switch should read "ON" when the jumper is not installed. The parameter for the emergency stop switch should read "OFF" when the jumper is installed.Results:
OK - The parameter for the Emergency Stop Switch is displaying the proper states. The problem is not with the ECM. Proceed to test step 5.
Not OK - The parameter for the Emergency Stop Switch is not displaying the proper states.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Stop.Test Step 5. Check the Switches and the Wiring when the Emergency Stop is Activated.
Disconnect the main power.
Disconnect the ECM connector J1/P1.
Activate the Emergency Stop Switch. If multiple Emergency Stop Switches have been installed, ensure that all other Emergency Stop Switches are not active.
Measure the resistance between the P1-29 and the P1-20.
Measure the resistance between the P1-29 and P1-2.
Deactivate the Emergency Stop Switch.
Continue this process for all the Emergency Stop Switches if multiple Emergency Stop Switches are installed.
Reconnect all connectors.Expected Result:When the switch is activated, the resistance should be greater than 20,000 ohms for all of the switches.Results:
OK - The resistance is greater than 20,000 ohms. Proceed to test step 6.
Not OK - The resistance is less than 20,000 ohms. There is a short circuit in the Emergency Stop Switch or an Emergency Stop Switch is activated.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.Test Step 6. Check the Switches and the Wiring when the Emergency Stop is NOT Activated.
Disconnect the main power.
Disconnect the ECM connector J1/P1.
Deactivate the Emergency Stop Switches. If multiple Emergency Stop Switches have been installed, ensure that all other Emergency Stop Switches are not active.
Measure the resistance between P1-29 and the P1-20.
Measure the resistance between P1-29 and the P1-2. Record this resistance.
Reconnect all connectors.Expected Result:The resistance should read less than 10 ohms.Results:
OK - The resistance is less than 10 ohms.Repair: The emergency stop switch is functioning correctly. There may be an intermittent problem. If the problem is intermittent refer to Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - The resistance is greater than 10 ohms. There is an open circuit in the Emergency Stop Switch and/or the wiring.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring. Stop.