0397001 JOHNSON STEERING HANDLE ASSY., Inner

Illustration 1 g00809763
Note: The Engine Control Switch (ECS) is mounted within an instrument panel that is located on the right side of the engine. The ECS is locked into the AUTO position with a pin. The pin must be removed in order to perform this test. After performing this test, ensure that the ECS is placed in the AUTO position and that the locking pin has been reinstalled.Test Step 1. Check for Connector Damage.
Turn the ECS to the OFF/RESET position.
Disconnect the main power.
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 pinch points.Expected Result:All connectors, pins, and sockets are 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 need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check the Active Lamp and the Ready Lamp for the Secondary ECM.
Observe the Active lamp and the Ready lamp on the instrument panel when the ECS is turned to the STOP position.Expected Result:Both lamps should illuminate for five seconds. The Ready Lamp should remain illuminated. The Active lamp should illuminate for five seconds. The Active lamp should then turn off.Results:
OK - Both lamps illuminated for five seconds. The Ready Lamp remained illuminated. The Active Lamp is off. The problem is no longer present.Repair: The secondary ECM reads the primary ECM heartbeat signal. Active injector codes are not present. If the problem is intermittent perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - READY LAMP - The ready lamp is not illuminated. Proceed to test step 4.
ACTIVE LAMP ON - Both lamps illuminated for five seconds. The Active lamp remained illuminated. The Secondary ECM has assumed control of the engine. Proceed to test step 3.Test Step 3. Check for "LOGGED" Diagnostic Codes.
Turn the ECS to the OFF/RESET position.
Connect the Caterpillar Electronic Technician (ET).
Turn the ECS to the STOP position.
Observe the diagnostic codes on the Cat ET.Note: The Secondary ECM will assume control of a 12 cylinder engine if two or more diagnostic codes for the injectors are present.Expected Result:No "LOGGED" diagnostic codes should be present.Results:
OK - No "LOGGED" diagnostic codes are present. Proceed to test step 4.
Not OK - A diagnostic code of CID 0579 - FMI 05 or a diagnostic code of CID 0579 - FMI 06 is present. Proceed to test step 8.
Not OK - A diagnostic code for the fuel injector is present.Repair: Perform the following diagnostic procedure Troubleshooting, "Injector Solenoids".STOPTest Step 4. Check the Primary ECM Heartbeat Signal at the Primary ECM.
Turn the ECS to the OFF/RESET position.
Disconnect the primary ECM connector J1/P1.
Remove wire C401-BU from the primary ECM connector P1-22. Install a wire jumper with sockets on both ends into ECM connector P1-22.
Connect a multimeter that is capable of reading frequency between the wire jumper in P1-22 and the engine ground.
Reconnect the primary ECM connector J1/P1.
Turn the ECS to the STOP position.
Observe the frequency (Primary ECM Heartbeat Signal) on the multimeter display. If a number does not appear on the multimeter display, verify the connections. Measure the frequency from another digital sensor. Verify that the multimeter is operating correctly.
Turn the ECS to the OFF/RESET position.
Remove the wire jumper. Reconnect all wires and connectors.Expected Result:The frequency should be between 15.67 and 17.67 Hz.Results:
OK - The frequency is between 15.67 and 17.67 Hz. Proceed to test step 5.
Not OK - The frequency is not between 15.67 and 17.67 Hz. The Primary ECM Heartbeat Signal is not within the frequency range.Repair: Verify that the proper software has been installed. Verify that the Primary ECM is receiving the correct voltage. Perform the diagnostic functional test Troubleshooting, "Electrical Power Supply".STOPTest Step 5. Check the Primary ECM Heartbeat Signal at the Secondary ECM.
Verify that ALL of the connectors are reconnected.
Turn the ECS to the OFF/RESET position.
Disconnect the secondary ECM connector J1/P1.
Remove the wire C401-BU from the Secondary ECM connector P1-12.
Connect a multimeter that is capable of reading frequency between wire C401-BU and engine ground.
Reconnect the secondary ECM connector J1/P1.
Turn the ECS to the STOP position.
Observe the frequency (Primary ECM Heartbeat Signal) on the multimeter display. If a number does not appear on the multimeter display, verify the connections. Measure the frequency from another digital sensor. Verify that the multimeter is operating correctly.
Remove the wire C401-BU from the Secondary ECM connector P1-20.
Repeat the above measurement by using the wire C401-BU from the Secondary ECM connector P1-20.
Turn the ECS to the OFF/RESET position.
Reconnect all wires and connectors.Expected Result:The frequency should be between 15.67 and 17.67 Hz.Results:
OK - The frequency is between 15.67 and 17.67 Hz. Proceed to test step 6.
Not OK - The frequency is not between 15.67 and 17.67 Hz. The signal is not within the frequency range. There is a problem in the wiring harness between the Primary ECM and the Secondary ECM.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 6. Test the Ready Lamp.
Turn the ECS to the OFF/RESET position.
Disconnect the Secondary ECM connector J1/P1.
Remove the wire 675-BR from the secondary ECM connector J1-22.
Connect a wire jumper between wire 675-BR and the engine ground.
Reconnect the secondary ECM connector J1/P1.
Turn the ECS to the STOP position.
Observe the Ready Lamp.
Turn the ECS to the OFF/RESET position.
Remove the wire jumper. Reconnect all wires and connectors.Expected Result:The lamp should illuminate while the wire jumper is connected. The lamp should not illuminate when the jumper is removed.Results:
OK - The lamp illuminates