0581528 JOHNSON SOLENOID ASSY.

Illustration 1 g00973881Test Step 1. Check for Connector Damage.
Verify that the circuit breakers are not tripped.
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 connectors that are associated with the circuit.
Check the ECM connectors (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the customer connectors (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 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 are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Test the Emergency Stop Circuit.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position. The engine should be off.
Activate the emergency stop switch that is located on the instrument panel.
Monitor the air shutoff solenoids. Expected Result:The air shutoff relays should activate.Results:
OK - The air shutoff solenoids activated 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 air shutoff solenoids failed to activate. Proceed to Test Step 3.Test Step 3. Test for Voltage from the Air Shutoff Relay to the Air Shutoff Solenoids.
Turn the ECS to the OFF/RESET position.
The output to the solenoids is terminal 30 on the air shutoff relays. The wires to the solenoids are 395-BR(Brown) and 394-BR(Brown). Connect a voltmeter between terminal 30 on the air shutoff relay and the engine ground.
Turn the ECS to the STOP position. The engine should be off.
Activate the emergency stop switch that is located on the instrument panel.
Monitor the voltage on the voltmeter.
If a second air shutoff relay is installed, repeat the above steps for the other air shutoff relay. Expected Result:The voltage should measure 24 3 VDC for 2.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 2.5 seconds. The relay is operating correctly. Proceed to Test Step 4.
Not OK - The voltage did not measure 24 3 VDC for 2.5 seconds. Proceed to Test Step 5.Test Step 4. Test for Voltage at the Air Shutoff Solenoids.
Turn the ECS to the OFF/RESET position.
At the solenoid, disconnect the wires that go to the air shutoff solenoid.
Use a voltmeter to monitor the voltage at the air shutoff solenoid. Connect the voltmeter between the wires that were removed from the solenoid in the previous step.
Turn the ECS to the STOP position. The engine should be off.
Activate the overspeed verify switch.
Monitor the voltage on the voltmeter.
If a second air shutoff solenoid is installed, repeat the above steps for the other air shutoff solenoid. Expected Result:The voltage should measure 24 3 VDC for 2.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 2.5 seconds. The circuit is operating correctly to this point.Repair: Temporarily install a new air shutoff solenoid. Ensure that the problem is no longer present. Reinstall the old solenoid. If the problem returns, replace the air shutoff solenoid.STOP
Not OK - The voltage did not measure 24 3 VDC for 2.5 seconds. System voltage was not available at the solenoid. There is a problem in the wiring between the air shutoff solenoids and the air shutoff relays.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 5. Check the Voltage at the Coil of the Air Shutoff Relays.
Turn the ECS to the OFF/RESET position.
Connect a voltmeter between F708-YL(Yellow) on the air shutoff relay and the engine ground.
Turn the ECS to the STOP position. The engine should be off.
Activate the emergency stop switch that is located on the instrument panel.
Monitor the voltage on the voltmeter.
If a second air shutoff solenoid is installed, repeat the above steps for the other air shutoff solenoid. Expected Result:The voltage should measure 24 3 VDC for 2.5 seconds.Results:
OK - The voltage measures 24 3 VDC for 2.5 seconds. Proceed to Test Step 6.
Not OK - The voltage did not measure 24 3 VDC for 2.5 seconds. Proceed to Test Step 7.Test Step 6. Check the Resistance at the Connector of the Air Shutoff Timer.
Turn the ECS to the OFF/RESET position.
Disconnect the connector to the air shutoff timer.
Check the resistance at the connector of the air shutoff timer. Check the resistance between wire 200-BK(Black) on P-1 and the engine ground.
Check the resistance at the connector of the air shutoff timer. Check the resistance between wire F708-YL(Yellow) on P-2 and wire 055-WH(White) on P-3. Expected Result:The resistance of the wire on P-1 should be less than 5 Ohms. The resistance between the wires on P-2 and P-3 should be approximately 260 Ohms if one relay is present. The resistance between the wires on Pin 2 and Pin 3 should be approximately 130 Ohms when two relays are present.Results:
OK - The resistance on the wires meets the above requirements. The relay coils are okay. The relay's NORMALLY OPEN contacts may be faulty.Repair: Remove the wires from the NORMALLY OPEN contacts on the air shutoff relay. Check the resistance across the contacts as the air shutoff relay is energized. If the resistance is less 5 Ohms, the relay is okay. If the resistance is more than 5 Ohms, replace the relay. Ensure that the problem is no longer present. If the air shutoff relay is okay, replace the air shutoff timer. Verify that this solves the problem.STOP
Not OK - The resistance does not meet the above requirements. Check the coil of the air shutoff relay