0214609 JOHNSON Operator's Manual

Illustration 1 g01208146
Schematic diagram for the electrical power supplyTest Step 1. Inspect the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
Illustration 2 g01208154
Typical left side view (1) J1/P1 ECM connectors
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P1 terminals that are associated with the electrical power supply (P1-48) +Battery (P1-52) +Battery (P1-53) +Battery (P1-61) −Battery (P1-63) −Battery (P1-65) −Battery (P1-70) Keyswitch
Thoroughly inspect connectors (1) and (2). Inspect the connections for the battery and the connections to the keyswitch. Refer to diagnostic functional tests Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply.
Check the allen head screw on each ECM connector for the proper torque. Refer to diagnostic functional tests Troubleshooting, "Electrical Connectors - Inspect".
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Also, check the harness and wiring for abrasions and for pinch points from the keyswitch to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - There is a problem with the connectors or wiring.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.STOPTest Step 2. Check the Battery Voltage at the ECM
Disconnect the J1/P1 ECM connector.
Restore the electrical power to the ECM.
Measure the voltage between P1-52 (Unswitched Positive Battery) and P1-63 (Negative Battery).
Measure the voltage between P1-48 (Unswitched Positive Battery) and P1-61 (Negative Battery).
Measure the voltage between P1-53 (Unswitched Positive Battery) and P1-65 (Negative Battery).
Measure the voltage between P1-70 (Keyswitch) and P1-63 (Negative Battery).Expected Result:The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system with no suspected intermittent problems at this time.Results:
OK - The ECM is receiving the correct voltage. Repair: If an intermittent condition is suspected, refer to diagnostic functional tests Troubleshooting, "Electrical Connectors - Inspect".STOP
Battery voltage is out of range - Proceed to Test Step 3.
Keyswitch voltage out of range - Repair: Trace the wiring for the keyswitch from the ECM through the keyswitch circuit to the batteries. Find the problem and repair the problem. Check the circuit protection for the circuit and for the wiring.Verify that the repairs eliminate the problem.STOPTest Step 3. Check the Batteries
Measure the no-load battery voltage at the battery posts.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure".Expected Result:The batteries pass the load test. The measured voltage is the minimum specification for a 12V or 24V system.Results:
OK - The batteries are OK.Repair: Check the wiring between the batteries and the ECM for shorts.Check the connectors between the batteries and the ECM for moisture and/or corrosion.Repair the wiring and/or the connectors.Verify that the repair eliminates the problem.STOP
Not OK - The battery voltage is low or the battery did not pass the load test.Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem.STOP