0389066 JOHNSON GEARCASE AND BUSH. ASSY

Illustration 1 g02891079
Schematics of the inputs for the generator output power sensorOnly one input is used. The input that is used depends on the generator configuration.Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 2 g01076153
Terminal box (1) J1/P1 connectors for the ECM (2) 16 amp circuit breaker (3) J9/P9 connectors for the wiring to the customer connections
Set the engine control to the OFF/RESET mode. Switch 16 amp circuit breaker (2) to the OFF position.Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
Thoroughly inspect the following components:
J1/P1 connectors
J9/P9 connectors on the terminal box
Wiring and the connections between the generator output power sensor and the ECM
Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 1 N m (55 9 lb in).
Illustration 3 g02891458
Harness side of the P1 connector (P1-8) Cat Data Link + (P1-9) Cat Data Link - (P1-25) Load signal
Illustration 4 g02891476
Harness side of the P9 connector (P9-c) Cat Data Link - (P9-g) Cat Data Link + (P9-X) Load signal
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the generator output power sensor.
Check the harness and wiring for abrasion and for pinch points between the generator output power sensor and the ECM.Expected Result:All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary.STOPTest Step 2. Check for a Diagnostic Code
Connect the Cat Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Start the engine and run the engine. Attempt to apply at least a 30 percent load to the generator.
Observe the "Active Diagnostic" screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. Look for these codes:
1719-03
1719-04
1719-12
Stop the engine.Expected Result:There are no active codes for the generator output power sensor.Results:
No active codes - There are no active codes for the generator output power sensor. There may be a logged code for the generator output power sensor.Repair: If there is a logged code for the generator output power sensor, there may be a problem with the wiring and/or a connector. Refer to Troubleshooting, "Inspecting Electrical Connectors".STOP
Active 1719-03 code - There is an active 1719-03 code. If the generator is equipped with EMCP II+, proceed to Test Step 7. Otherwise, proceed to Test Step 5.
Active 1719-04 code - There is an active 1719-04 code. Proceed to Test Step 3.
Active 1719-12 code - There is an active 1719-12 code. Proceed to Test Step 9.Test Step 3. Check the "Load Signal" Wiring for a Short Circuit
Disconnect the P1 connector from the ECM.
Disconnect the "load signal" wire from the power sensor.
Check for continuity between P1-25 and all the other terminals on the P1 connector.Expected Result:Each continuity check indicates an open circuit.Results:
OK - Each continuity check indicates an open circuit. The "load signal" wiring does not have a short circuit. Proceed to Test Step 4.
Not OK - At least one continuity check indicates a short circuit.Repair: The problem may be between the P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the power sensor.Repair the harness or the connection, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 4. Check the "Load Signal" Wiring for ContinuityNote: A potentiometer may be installed in the "load signal" wiring. A high resistance reading may be caused by the potentiometer.
Check the continuity of the wire between P1-25 and the power sensor.Expected Result:The "load signal" wiring has continuity.Results:
OK - The "load signal" wiring has continuity. Reconnect the P1 connector. Reconnect the "load signal" wires to the power sensor. Be sure to observe the correct polarity. Proceed to Test Step 6.
Not OK - The "load signal" wiring has an open circuit. The open circuit may be in a wire, in a connector, or in the potentiometer.Repair: Repair the component, when possible. Replace parts, if necessary. Verify that the original problem is resolved.STOPTest Step 5. Check the "Load Signal +" Wire for a Short Circuit
Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.
Disconnect the P1 connector from the ECM.
Disconnect the "load signal +" wire from the power sensor.
Check for continuity