5005652 JOHNSON Service Manual - French

Illustration 1 g00975798Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF 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 2.25 N m (20 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. The harness and the wiring should be 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 need repair.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 2. Check for a Short to Ground Condition.
Turn the circuit breaker for the battery to the OFF position.
Disconnect the primary ECM connector P1. Disconnect the secondary ECM connector P1.
Disconnect a wire from the remote emergency stop switch.
Check the resistance of the following wires to engine ground.
wire 998-BR(Brown) on ECM connector P1-29
wire F715-PU(Purple) on ECM connector P1-02
wire F719-BR(Brown) on ECM connector P1-24
wire F715-PU(Purple) on ECM connector P2-02
wire F719-BR(Brown) on ECM connector P2-24
Reconnect the wire from the remote emergency stop switch. Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 3.
Not OK - The resistance is less than 20,000 Ohms.Repair: The wire is shorted to engine ground. Trace the wire through the harness. Locate the short to ground and repair the wire. Disconnect the wires from the left hand air shutoff switch and the right hand air shutoff switch in order to isolate the different parts of the circuit.STOPTest Step 3. Check the Resistance of the Circuit from the Primary ECM.
Ensure that the remote emergency stop switch is in the OFF position.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and wire F715-PU(Purple) in P1-02. Check the resistance at the primary ECM connector P1.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and wire F719-BR(Brown) in P1-24. Check the resistance at the primary ECM connector P1. Expected Result:The resistance should be less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. Proceed to Test Step 4.
Not OK - The resistance is greater than 5 Ohms. Proceed to Test Step 5.Test Step 4. Check the Resistance of the Circuit from the Secondary ECM.
Ensure that the remote emergency stop switch is in the OFF position.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and wire F715-PU(Purple) in P2-02. Check the resistance between the primary ECM connector P1 and the secondary ECM connector P1.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and wire F719-BR(Brown) in P2-24. Check the resistance between the primary ECM connector P1 and the secondary ECM connector P1. Expected Result:The resistance should be less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms.Repair: Activate the remote emergency stop switch. Recheck the resistance of the wires at the ECM connector. The resistance should be greater than 20,000 Ohms. Deactivate the remote emergency stop switch. Manually close the air shutoff valve. Recheck the resistance of the wires at the ECM connector. The resistance should be greater than 20,000 Ohms. Manually open the air shutoff valve. Repeat for the other air shutoff valve. If the resistance is greater than 20,000 Ohms, the circuit is operating correctly.STOP
Not OK - The resistance is greater than 5 Ohms. Proceed to Test Step 5.Test Step 5. Check the Remote Emergency Stop Switch.
Disconnect the wire 998-BR(Brown) from terminal 2 of the remote emergency stop switch.
Connect a wire jumper between 998-BR(Brown) and the wire on terminal 1 of the remote emergency stop switch.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and wire F715-PU(Purple) in P1-02. Check the resistance at the primary ECM connector P1.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and wire F719-BR(Brown) in P1-24. Check the resistance at the primary ECM connector P1.
Remove the wire jumper between 998-BR(Brown) and the wire on terminal 1 of the remote emergency stop switch. Expected Result:The resistance should be less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms.Repair: The remote emergency stop switch is open. Replace the remote emergency stop switch. Verify that the circuit is operating correctly.STOP
Not OK - The resistance is greater than 5 Ohms. There is an open in the harness wiring. Proceed to Test Step 6.Test Step 6. Check the Wiring from the Remote Emergency Stop Switch to the ECM.
Install a wire jumper between 998-BR(Brown) and engine ground at the remote emergency stop switch.
Use a voltmeter to measure the resistance between wire 998-BR(Brown) in P1-29 and engine ground. Check the resistance at the primary ECM connector P1.
Remove the wire jumper. Reconnect wire 998-BR(Brown) to the remote emergency stop switch. Expected Result:The resistance should be less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. Proceed to Test Step 7.
Not OK - The resistance is greater than 5 Ohms. There is an open in wire 998-BR(Brown).Repair: Repair the wire. Verify that the circuit is operating correctly after the repair.STOPTest Step 7. Check the Wiring from the Remote Emergency Stop Switch to the Air Shutoff Switch.
Disconnect the wires F715-PU(Purple) and wire F719-BR(Brown) from the remote emergency stop switch.
Disconnect the wire H401-PU(Purple) from the left hand air shutoff switch.
Connect a wire jumper between wire H401-PU(Purple) and the engine ground.
Use a voltmeter to measure the resistance between wires F715-PU(Purple) and the engine ground. Measure the resistance between wire F719-BR(Brown) and the engine ground. Measure the resistance at the remote emergency stop switch.
Reconnect all wires and remove