0386430 JOHNSON STARTER MOTOR

Illustration 1 g00858628
Primary ECM
Illustration 2 g00860212
Secondary ECMTest Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF/RESET position.
Turn the ECS to the OFF position.
Check the connectors and wiring for the following problems: damage, corrosion, abrasion and incorrect attachment.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The wiring and connectors are okay. Proceed to test step 2.
Not OK - The wiring and connectors need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check for Active Diagnostic Codes.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the ECS to the STOP position. The engine should be OFF.
Wait for 15 seconds for the CID-FMI.Expected Result:Determine the failure mode identifier (FMI). Determine if diagnostic codes 262-03 or 262-04 are present. Determine if diagnostic codes 263-03 or 263-04 are present.Results:
FMI 03 - A diagnostic code with a FMI of 03 is present. Proceed to test step 3.
FMI 04 - A diagnostic code with a FMI of 04 is present. Proceed to test step 4.
FMI 00, 02 or 08 - A diagnostic code with a FMI of 00, 02 or 08 is present. Proceed to test step 8.
262-03 or 262-04 Active Code - A diagnostic code of 262-03 or 262-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Analog Sensor Supply". Stop.
263-03 or 263-04 Active Code - A diagnostic code of 263-03 or 263-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Digital Sensor Supply". Stop.Test Step 3. Check the Voltage at the Sensor Connector.
Turn the ECS to the STOP position.
Measure the voltage on the sensor side of the wiring harness. Measure the voltage between pin A and pin B for the suspect sensor.Expected Result:The supply voltage should be 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors.Results:
OK - The voltage is correct. Proceed to test step 5.
Not OK - The voltage is out of range. Proceed to test step 6.Test Step 4. Check the Voltage at the Sensor Connector.
Turn the ECS to the STOP position.
Measure the voltage on the ECM side of the wiring harness. Measure the voltage between pin A and pin B for the suspect sensor.Expected Result:The supply voltage should be 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors.Results:
OK - The voltage is correct. Proceed to test step 7.
Not OK - The voltage is out of range. Proceed to test step 6.Test Step 5. Create a Short at the Sensor Connector.
Turn the ECS to the OFF/RESET position.
Disconnect the suspect sensor.
Use a wire with socket terminals at each end. Connect pin B and pin C at the suspect sensor connector.
Turn the ECS to the ON position. The engine should be OFF.
Check if the CID-FMI has changed from 03 to 04.
Turn the ECS to the OFF/RESET position.
Remove the wire short.Expected Result:The CID-FMI should change from 03 to 04.Results:
OK - The circuit now indicates a short circuit diagnostic code.Repair: Temporarily connect a new sensor. Verify that the new sensor solves the problem before you permanently install the new sensor. Calibrate the sensor. Stop.
Not OK - The circuit indicates an open circuit diagnostic code. Proceed to test step 9.Test Step 6. Check the Voltage at the ECM.
Turn the ECS to the OFF/RESET position.
Disconnect the primary ECM connector J1/P1.
Remove the digital supply line on pin P1-35 of the ECM. Install a jumper into the socket for P1-35.Note: Disconnecting the common wire to a sensor will cause several sensor diagnostic codes to become active. Troubleshoot the original code. Reset the system. Delete the logged diagnostic codes when your are finished.
Remove the digital return line on pin P1-29 of the ECM. Install a jumper into the socket for P1-29.
Remove the analog supply line on pin P1-36 of the ECM. Install a jumper into the socket for P1-36.
Remove the analog return line on pin P1-30 of the ECM. Install a jumper into the socket for P1-30.
Reconnect the primary ECM connector J1/P1.
Turn the ECS to the STOP position. The engine should be OFF.
Measure the analog voltage between the wire jumpers in P1-36 and P1-30.
Measure the digital voltage between the wire jumpers in P1-35 and P1-29.
Turn the ECS to the OFF/RESET position.
Remove all of the test wires. Reconnect all wiring and connectors.Expected Result:The analog supply voltage should be 5.0 0.2 VDC. The digital supply voltage should be 8.0 0.4 VDC.Results:
OK - The analog supply voltage is 5.0 0.2 VDC. The digital supply voltage is 8.0 0.4 VDC.Repair: There is a problem in the wiring harness between the ECM and the sensor connector. Repair the connectors or wiring and/or replace the connectors or wiring. Stop.
Not OK - The analog supply voltage is not 5.0 0.2 VDC.Repair: Perform the diagnostic functional test Troubleshooting, "Analog Sensor Supply". Stop.
Not OK - The digital supply voltage is not 8.0 0.4 VDC.Repair: Perform the diagnostic functional test Troubleshooting, "Digital Sensor Supply". Stop.Test Step 7. Create an Open Circuit at the Sensor Connector.
Turn the ECS to the OFF/RESET position.
Disconnect the suspect sensor.
Turn the ECS to the STOP position. The engine should be OFF.
The CID-FMI should change from 04 to 03.Note: Disconnecting the Compartment Pressure Sensor will cause several sensor diagnostic codes to become active. Troubleshoot the original code. Reset the system. Delete the logged diagnostic codes when you are finished.Expected Result:The CID-FMI should change from 04 to 03 when the sensor is disconnected.Results:
OK - The CID-FMI changed from 04 to 03 when the sensor was disconnected.Repair: Replace the suspect sensor. Verify that the repair eliminates the problem. Calibrate the sensor. Stop.
Not OK - The CID-FMI did not change from 04 to 03 when the sensor was disconnected. Proceed to test step 10.Test Step 8. Compare the Pressure or Temperature to the Actual Pressure or Temperature.
Turn the ECS to the STOP position.
If you are troubleshooting a temperature sensor, install a 6V-9130 Temperature Adapter near the sensor.
Observe the temperature reading for the suspect sensor.