0392281 JOHNSON REMOTE CONTROL ASSY.

Table 1
Diagnostic Codes Table
Code Conditions which Generate this Code System Response
525-5 Choke Actuator : Current Below Normal The circuit driver for the electrohydraulic actuator's solenoid is energized. The Electronic Control Module (ECM) detects no current from the actuator or a current that is less than the normal level. The shutdown output is activated. The code is logged.
525-6 Choke Actuator : Current Above Normal The circuit driver for the electrohydraulic actuator's solenoid is energized. The ECM detects a current from the actuator that is greater than the normal level. The ECM controls the air choke actuator by adjusting current flow through the actuator's solenoid.The diagnostic code is probably caused by a problem in a harness or by a problem with an electrical connector. The next likely cause is a problem inside the actuator solenoid. The least likely cause is a problem with the ECM.Logged diagnostic codes provide a historical record. Before you begin this procedure, use Caterpillar Electronic Technician (ET) to print the logged codes to a file.This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 1 g01439374
Schematic of the circuit for the air choke actuator
Test Step 1. Inspect the Electrical Connectors and WiringNote: This step is important for troubleshooting a problem with instability.
Illustration 2 g01431198
Terminal Box
(1) ECM connector J2/P2
(2) ECM connector J1/P1
(3) 16 amp circuit breaker
(4) Connectors J3/P3 for the customer's connector
(5) Connectors J4/P4 for the optional control panel (if equipped) or for a customer's connector
(6) J5/P5 connectors for the harness
(7) J6/P6 connectors for the harness
Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM to the OFF position. Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01439397
P2 ECM terminals that are used by the air choke actuator's solenoid on in-line engines and vee engines
(P2-63) Air choke actuator's circuit driver
(P2-64) Return
Illustration 4 g01439394
Terminal locations on the P6 connector that are used by the air choke actuator's solenoid on in-line engines and on vee engines
(P6-12) Return (in-line engines)
(P6-22) Air choke actuator's circuit driver (in-line engines)
(P6-44) Return (vee engines)
(P6-45) Air choke actuator's circuit driver (vee engines)
Illustration 5 g01439378
Air choke actuator
(AA) Solenoid's connector
(A) Air choke actuator's circuit driver
(B) Return
(8) Engine harness connectors for the air choke actuator (in-line engines)
(9) Air choke actuator (in-line engines)
Illustration 6 g01439379
Air choke actuator
(10) Air choke actuator (vee engines)
(11) Engine harness connectors for the air choke actuator (vee engines)
Thoroughly inspect each of the following connectors:
ECM J2/P2 connectors
J6/P6 connectors on the terminal box
Connectors for the air choke actuator
Check the allen head screw on each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Perform a 45 N (10 lb) pull test on the wires that are associated with the circuit for the air choke actuator.
Thoroughly inspect the connectors for the air choke actuator for moisture and for corrosion. Check the harness and wiring for abrasion and for pinch points from the air choke actuator to 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 - All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - At least one of the connectors, pins, or sockets is not connected properly. At least one connector or wire has corrosion, abrasion, and/or pinch points. 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 Active Diagnostic Codes
Connect Cat ET to the service tool connector.
Switch the 16 amp circuit breaker for the ECM ON.
If a 525-5 and/or 525-6 diagnostic code is logged, clear the code.
Turn the engine control switch to the START position and crank the engine. Allow a minimum of 30 seconds for the generation of any codes.
Observe the "Active Diagnostic" screen on Cat ET. Check and record any active diagnostic codes.
Determine if the problem is related to an open circuit diagnostic code (-5) or a short circuit diagnostic code (-6).
Turn the engine control switch to the STOP position. Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: The problem may have been related to a faulty connection in the harness. Carefully inspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A short circuit diagnostic code (-6) is active at this time. Proceed to Test Step 3.
Not OK - An open circuit diagnostic code (-5) is active at this time. Proceed to Test Step 5.Test Step 3. Disconnect the Connector for the Air Choke Actuator's Solenoid in Order to Create an Open Circuit
Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM to the OFF position.
Disconnect the connector for the air choke actuator's solenoid.
Switch the 16 amp circuit