0394605 JOHNSON REWIND STARTER ASSY.

Illustration 1 g01955230
Schematic for the engine's lamp circuitsNote: There may be configuration parameters that are associated with some indicator lamps. Ensure that these parameters are configured correctly prior to troubleshooting the lamp circuits. Refer to Troubleshooting, "Configuration Parameters" for information that is related to the configuration of the lamp circuits.Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove electrical power from the ECM.
Thoroughly inspect any of the connectors that are associated with the lamp circuits. Refer to the Schematic of the engine for connector locations. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 2 g01955227
Terminal locations at the P1 connector on the ECM that are for the lamp circuits (P1-12) Engine overspeed lamp (P1-19) Diagnostic lamp (P1-20) Warning lamp (P1-28) Low oil pressure lamp (P1-29) High coolant temperature lamp (P1-30) ECM active lamp (P1-31) Fuel injection malfunction lamp
Perform a 45 N (10 lb) pull test on each of the wires for the lamp circuits.
Check the torque of the allen head screw on the ECM connectors and the engine interface connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the dash display back to the ECM.Expected Result:All of the 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 harness and connectors appear to be in good repair. Proceed to Test Step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. 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.STOPTest Step 2. Check for Proper Operation of the Lamp Circuits
Connect Cat ET to the service tool connector.
Restore electrical power to the ECM.
Select the "Override Parameters" option from the "Diagnostic Tests" on Cat ET.
Use the correct override parameter to power the circuit for the suspect lamp.
Remove electrical power from the ECM.Expected Result:The suspect lamp illuminates when the override is turned on.Results:
OK - The suspect lamp illuminates when the override is on.Repair: There does not appear to be a problem with the lamp circuit at this time. The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The suspect lamp does not illuminate when the override is on. Inspect the lamp and the lamp socket for the suspect circuit. If either of the components are questionable, replace the component. Retest the circuit. If the problem persists or if the components of the lamp assembly appear to be in good repair, proceed to Test Step 3.Test Step 3. Use the Override to Check the Wiring Harness
Remove the lamp for the suspect circuit from the lamp socket.
Connect a test lamp between the terminal that is for the driver circuit from the ECM and the −Battery terminal.
Restore electrical power to the ECM.
Use the override parameter in Cat ET to power the circuit for the suspect lamp.
Remove electrical power from the ECM.Expected Result:The test lamp illuminates when the override is turned on.Results:
OK - The test lamp illuminates when the override is turned on.Repair: Check for continuity between the negative terminal of the lamp socket and −Battery.If the circuit is continuous then the lamp or the lamp socket is the cause of the problem. Replace the faulty lamp or the faulty lamp socket. Verify that the repair eliminates the original problem.If the circuit is not continuous then there is a problem in the ground circuit for the lamp. Repair the ground circuit. Verify that the repair eliminates the original problem.STOP
Not OK - The test lamp does not illuminate when the override is turned on. There is a problem in the harness or in a connector. There may be a problem with the ECM. Proceed to Test Step 4.Test Step 4. Check for Proper Operation of the ECM
Ensure that electrical power has been removed from the ECM.
Disconnect the appropriate ECM connectors for the suspect lamp circuit.
Remove the signal wire for the suspect lamp from the ECM connector. Refer to Illustration 1 for the correct terminal locations.
Fabricate a jumper wire that is long enough to create a test circuit between the ECM connector and the negative battery connection. Crimp a connector socket to one end of the jumper wire.
Install the socket end of the jumper wire into the terminal location that is for the signal wire of the suspect lamp.
Reconnect the ECM connectors.
Connect a test lamp between the loose end of the jumper wire and −Battery.
Restore electrical power to the ECM.
Use the override parameter in Cat ET to power the circuit for the suspect lamp.
Remove electrical power from the ECM. Restore all wiring to the original configuration.Expected Result:The test lamp illuminates when the override is turned on.Results:
OK - The test lamp illuminates when the override is on.Repair: The ECM is operating correctly. There is a problem in the harness or in a connector. Repair the harness and/or the connector or replace the harness and/or the connector. If necessary, replace parts. Verify that the repair eliminates the problem.STOP
Not OK - The test lamp does not illuminate when the override is on.Repair: The harness that is for the lamp circuit is OK. The ECM is not powering the lamp circuit correctly. Replace the ECM. Refer to Troubleshooting, "ECM - Replace" for details.STOP