0341131 JOHNSON PLATE, Frame, rear, 20

Illustration 1 g00833139
Schematic for ECM battery circuit
Illustration 2 g01118220
Terminal locations for ECM (P1-48) Unswitched +Battery (P1-52) Unswitched +Battery (P1-53) Unswitched +Battery (P1-61) -Battery (P1-63) -Battery (P1-65) -Battery (P1-70) KeyswitchTest Step 1. Inspect Electrical Connectors and Wiring
Thoroughly inspect ECM machine harness connector P1, the battery connections, and the connections to the keyswitch. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires in the ECM P1 connector that are associated with the following connections:
Unswitched +Battery (terminals 48, 52, and 53)
−Battery (terminals 61, 63, and 65)
Keyswitch (terminal 70)
Check the allen head screw on each ECM connector and the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Also, check the harness and wiring from the keyswitch to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and/or of pinch points.Results:
OK - 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
Illustration 3 g01118221
ECM breakout T-connector
Disconnect machine harness connector P1 from ECM connector J1 and insert a 70-Terminal breakout T.
Measure the voltage between P1-52 (unswitched +Battery) and P1-63 (-Battery).
Measure the voltage between P1-48 (unswitched +Battery) and P1-61 (-Battery).
Measure the voltage between P1-52 (unswitched +Battery) and P1-63 (-Battery).
Measure the voltage between P1-53 (unswitched +Battery) and P1-65 (-Battery).
Turn the keyswitch to the ON position.
Measure the voltage between P1-70 (keyswitch) and P1-63 (-Battery).Expected Result:The measured voltage is a constant 23.0 to 25.5 VDC 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 Troubleshooting, "Electrical Connectors - Inspect".STOP
Battery voltage is out of range - Proceed to Test Step 3.
Intermittent or no voltage - Proceed to Test Step 4.
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 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 at least 23.0 VDC.Results:
OK - Repair: Troubleshoot the machine wiring harness and repair the machine wiring harness, as required. Verify that the repairs eliminate the problem.STOP
Not OK - Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem.STOPTest Step 4. Use the Bypass Harness for the Electronic Service Tool to Bypass the Machine Wiring
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.
Do Not connect the bypass harness to the battery until the 20 amp in-line fuse has been removed from the +Battery line. If the fuse is not removed before connection to the battery, a spark may result.
Illustration 4 g00781203
Bypass harnessNote: This bypass harness is only for test applications. This bypass harness may be left only temporarily on the vehicle. The bypass harness can be used in order to determine if the cause of the intermittent probl