5033826 JOHNSON *LEAD, HIGH TENSION

Illustration 1 g00906075
Schematic of the input for the generator output power sensorTest Step 1. Inspect the Electrical Connectors and Wiring
Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
Illustration 2 g00905932
Terminal box for the master ECM (1) J1/P1 connectors for the master ECM (2) 16 amp circuit breaker (3) J9/P9 connectors for the customer (4) J10/P10 connectors for the harness from the generator output power sensor
Thoroughly inspect the following components:
Master ECM J1/P1 connectors
J9/P9 connectors on the terminal box
J10/P10 connectors on the terminal box
Wiring and the connections between the generator output power sensor and the master 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 g00905974
Harness side of the master ECM P1 connector (P1-3) Analog return (P1-25) Input for the generator output power sensor
Illustration 4 g00905975
Harness side of the P10 connector (P10-E) Input for the generator output power sensor (P10-F) Analog return
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 pinch points between the generator output power sensor and the master 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. If you are troubleshooting a "524-03 Desired Engine Speed Sensor short to +batt" diagnostic code, proceed to Test Step 3. If you are troubleshooting a "524-04 Desired Engine Speed Sensor short to ground" diagnostic code, proceed to Test Step 5.
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 an Open Circuit
Label the two wires and remove the two wires from terminals 1 and 2 of the generator output power sensor.
Install a jumper wire between the two wires that were removed from the generator output power sensor.
Disconnect the P1 connector from the master ECM.
Illustration 5 g00905986
ECM side of the P1 connector (P1-3) Analog return (P1-25) Input for the generator output power sensor
Use an ohmmeter to measure the resistance between terminals P1-3 and P1-25 on the ECM side of the P1 connector.Expected Result:The resistance is less than 5 ohms.Results:
OK - The resistance is less than 5 ohms. The circuit is not open.Repair: Remove the jumper wire. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. Proceed to Test Step 3.
Not OK - The resistance is greater than 5 ohms. There is a problem with a connector and/or the wiring from the P1 connector.Repair: The problem may be between the P1 connector and the J10 connector. Alternatively, the problem may be between the P10 connector and the generator output power sensor.Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 3. Check for a Short Circuit to the +Battery at Terminal P1-25
Verify that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker is OFF.
Make sure that there is no electrical power to the generator output power sensor.
Illustration 6 g00905987
ECM side of the P1 connector (P1-25) Input for the generator output power sensor (P1-57) +Battery
Measure the resistance between terminals P1-25 and P1-57.Expected Result:The resistance is greater than 20,000 ohms.Results:
Yes - The resistance is greater than 20,000 ohms. The wiring from terminal P1-25 is not shorted to the +battery side. Do not reconnect any connectors. Proceed to Test Step 4.
No - The resistance is less than 20,000 ohms. There is a problem with a connection and/or the wiring from terminal P1-25.Repair: The problem may be between the P1 connector and the J10 connector. Alternatively, the problem may be between the P10 connector and the generator output power sensor.Repair the connection and/or the wire, when possible. Replace parts, if