0437040 JOHNSON LOCKOUT LEVER ASSY.

Illustration 1 g00675955
Connector receptacles (Deutsch) and connector plugs (Deutsch)
Illustration 2 g00665457
Harness routing and seal plugs
Test Step 1. Check the Locking of the DT Connector (Deutsch) and Check the Lock Ring of the HD Style Connector (Deutsch)
Ensure that the connector is properly locked. Also ensure that the two halves of the connector can not be pulled apart.
Verify that the latch tab of the connector is properly latched. Also verify that the latch tab of the connector returns to the locked position. Expected Result:The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connector or replace the connector, as required.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Allen Head Screw on the Connector for the Electronic Control Module (ECM)
Ensure that the allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw.
Do not exceed 2.25 N m (20 lb in) of torque on the allen head screw. Expected Result:The ECM connector is secure and the allen head screw is properly torqued.Results:
OK - Proceed to Test Step 3.
Not OK - Repair: Repair the connector or replace the connector, as required.Verify that the repair eliminates the problem.STOPTest Step 3. Perform a Pull Test on Each Wire Terminal Connection
Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
The DT connectors use a green wedge to lock the terminals in place. Ensure that the green wedge is not missing and that the green wedge is installed properly on the DT connectors. Note: Terminals should always be crimped onto the wires by using a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool.Expected Result:Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body.Results:
OK - Proceed to Test Step 4.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 4. Perform the "Wiggle Test" on the Caterpillar Electronic Technician (ET)
Select the "Wiggle Test" from the diagnostic tests on Cat ET.
Press the "OK" button after you adhere to the warning.
Choose the appropriate group of parameters to monitor.
Press the "Start" button. Wiggle the wiring harness in order to reproduce intermittent problems.
If an intermittent problem exists, the status will be highlighted and an audible beep will be heard. Expected Result:No intermittent problems were indicated during the "Wiggle Test".Results:
OK - Proceed to Test Step 5.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 5. Check Wires for Nicks or Abrasion in the Insulation
Carefully inspect each wire for signs of abrasion, nicks, or cuts. The following areas are locations that should be checked:
Exposed insulation
Points of rubbing wire against the engine
Points of rubbing wire against a sharp point
Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also check all of the hold down clamps for the harness in order to verify that the harness is not compressed by the clamp. Pull back the harness sleeves in order to check for a flattened portion of wire. The flattened portion of wire is caused by the clamp that holds the harness. Expected Result:The wires are free of abrasion, of nicks, and of cuts and the harness is properly clamped.Results:
OK - Proceed to Test Step 6.
Not OK - Repair: Repair the wires or replace the wires, as required.Verify that the repair eliminates the problem.STOPTest Step 6. Check Connectors for Moisture or Corrosion
Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.
Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture. Thoroughly inspect the J1/P1 and J2/P2 ECM connectors for evidence of moisture entry.Note: It is normal to see some minor seal abrasion on the ECM Connector seals. Minor seal abrasion will not allow the entry of moisture.
If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the problem will reoccur. Simply drying the connector will not fix the problem. Likely paths for the entrance of moisture are illustrated in the following list:
Missing seals
Improperly installed seals
Nicks in exposed insulation
Improperly mated connectorsMoisture can also travel from one connector through the inside of a wire to the ECM Connector. If moisture is found in the ECM connector, thoroughly check all connectors and wires on the harness that connect to the ECM. The ECM is not the source of the moisture. Do not replace an ECM if moisture is found in either ECM connector.Note: If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. Do not use any cleaners that contain 1,1,1 trichloro-ethylene because 1,1,1 trichloro-ethylene may damage the connector.Expected Result:All of the connectors are completely coupled and all of the seals are completely inserted. The harness and the wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - Proceed to Test Step 7.
Not OK - Repair: Repair the circuit. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem by running the engine for several minutes and by checking again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path