0318989 JOHNSON SEAL,Upper mounts to exh.hsg

Illustration 1 g00728931
Typical exampleTest Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check the ON Status of the Emergency Stop Switch.
Turn the circuit breaker for the battery to the ON position.
Connect Cat ET.
Turn the ECS to the STOP position.
Activate the emergency stop switch.
Observe the status of the emergency stop switch on Cat ET.Expected Result:The parameter for the emergency stop switch reads "ON".Results:
OK - The emergency stop switch is working correctly. Proceed to Test Step 3.
Not OK - The parameter for the emergency stop switch does not display "ON". Proceed to Test Step 4.Test Step 3. Check the OFF Status of the Emergency Stop Switch.
Deactivate the emergency stop switch.Expected Result:The parameter for the emergency stop switch reads "OFF".Results:
OK - The emergency stop switch is functioning correctly.Repair: The problem may be intermittent. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The parameter for the emergency stop switch does not display "OFF". Proceed to Test Step 4.Test Step 4. Test the ECM.
Turn the ECS to the OFF/RESET position.
Disconnect ECM connector P1 from the ECM. Remove wire 998-BR from P1-29. Insert a wire jumper into P1-29.Note: The digital return will no longer be connected to the other sensors and switches. Additional diagnostic codes will be generated from the ECM. Clear the codes after you complete this test.
Remove wire F715-PU from P1-02. Insert a wire jumper into P1-02.
Remove wire F719-BR from P1-24. Insert a wire jumper into P1-29.
Reconnect connector P1 to ECM connector J1.
Use a wire jumper to connect the jumper wire in P1-29 to the jumper wires in P1-02 and P1-24.
Turn the ECS to the STOP position.
Observe the parameters for the emergency stop on Cat ET.
Remove the wire jumper that is connecting the three wires together.
Observe the parameters for the emergency stop on Cat ET.
Turn the ECS to the OFF/RESET position. Remove the wire jumpers and reinstall all wires.Expected Result:The parameter for the emergency stop switch displays "OFF" when the jumper is installed. The parameter for the emergency stop switch displays "ON" when the jumper is removed.Results:
OK - The problem is not with the ECM. Proceed to Test Step 5.
Not OK - The parameter on the ECM is incorrect.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOPTest Step 5. Check the Emergency Stop Switch and the Wiring.
Turn the ECS to the OFF/RESET position.
Disconnect connector P1 from ECM connector J1.
Activate the emergency stop switch.
Measure the resistance between P1-29 and P1-02.
Measure the resistance between P1-29 and P1-24.Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 6.
Not OK - The resistance is less than 20,000 Ohms. There is a short in the circuit.Repair: Repair the switch or wiring and/or replace the switch or wiring.STOPTest Step 6. Deactivate the Emergency Stop Switch.
Deactivate the emergency stop switch.
Measure the resistance between P1-29 and P1-02.
Measure the resistance between P1-29 and P1-24.Expected Result:The resistance is less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. The emergency stop switch is okay.Repair: The problem may be intermittent. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The resistance is greater than 5 Ohms. There is an open circuit in the emergency shutdown switch.Repair: Repair the switch or wiring and/or replace the switch or wiring.STOP