0115594 JOHNSON THROTTLE LEVER

Illustration 1 g00722490
Typical example
Test Step 1. Check for Connector Damage.
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 2.25 0.25 N m (20 2 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 need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Attempt to Start the Engine.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Connect the Cat ET to the service tool connector.
Observe the "startup mode" parameter on the Cat ET status screen.
Turn the ECS to the START position. Continue monitoring engine parameters as the engine cranks.
The crank cycle will continue for the time that is equal to the cycle crank time that has been programmed or the crank cycle will continue until the engine speed reaches the crank terminate speed. Expected Result:The status screen for the "startup mode" parameter displays "CRANK". The engine cranks.Results:
OK - The "startup mode" parameter on the status screen on the Cat ET displays "CRANK". The engine cranks.Repair: The problem may be intermittent. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - Engine Doesn't Crank - The "startup mode" parameter on the status screen on the Cat ET displays "CRANK". The engine will not crank. Proceed to Test Step 3.
Not OK - Status Screen - The "startup mode" parameter on the status screen on the Cat ET does not display "CRANK".Repair: Perform the diagnostic functional test Troubleshooting, "Engine Control Switch (ECS)".STOPTest Step 3. Manually Crank the Engine.
Turn the ECS to the STOP position.
Open the electronic instrument panel.
Connect one lead of a voltmeter to the −Battery terminal. Connect the other lead of the voltmeter to wire 314-PU(Purple) on terminal 2 of the mag relay.
Activate the manual crank switch.
Monitor the voltage on the voltmeter. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 6.
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 4.Test Step 4. Check the Voltage at the Coil of the Mag Relay.
Turn the ECS to the OFF/RESET position.
Connect a voltmeter across the coil of the mag relay. Connect the voltmeter between terminal 4 and terminal 3 of the mag relay.
Turn the ECS to the STOP position.
Activate the override for the starting motor relay.
Monitor the voltage on the voltmeter.
Turn off the override for the starting motor relay.
Replace all wires. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Verify that 24 3 VDC is present on terminal 1 of the mag relay. If voltage is not present on terminal 1 of the mag relay, troubleshoot the wiring to the breaker for the mag relay. If voltage is present on terminal 1 of the mag relay, install a new mag relay. Verify that the problem is no longer present.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 5.Test Step 5. Check the ECM Signal at the ECM.
Turn the ECS to the OFF/RESET position.
Disconnect ECM connector P2 from the ECM. Remove the wire from P2-7 and P2-13 from ECM connector P2.
Obtain two suitable pieces of 18 AWG wire with socket pins on one end.
Install one wire at P2-7. Install the second wire at P2-13. Reconnect ECM connector P2.
Connect one lead of the voltmeter to the wire at P2-7. Connect the other lead of the voltmeter to the wire at P2-13.
Turn the ECS to the STOP position.
Activate the override for the starting motor relay. Note: This test will cause a 444-05 CID-FMI to be Logged. Delete this CID-FMI when you are finished with this test.
Monitor the voltage on the voltmeter.
Turn off the override for the starting motor relay.
Turn the ECS to the OFF/RESET position. Remove all jumpers and replace all wires. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The problem is not with the ECM. The problem is most likely in the wiring between ECM connector P2 and the mag relay. Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The voltage does not measure 24 3 VDC.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOPTest Step 6. Check the Solenoid.
Turn the ECS to the OFF/RESET position.
Connect one end of a suitable piece of 10 AWG wire to the +Battery terminal. Connect the other end to the S terminal of the starting solenoid for one second. Expected Result:The starting solenoid activates while the wire is connected to the S terminal.Results:
OK - The starting solenoid activated. The problem appears to be in the system wiring.Repair: Check and repair the wiring between the S terminal of the starting solenoid and terminal 2 of the mag relay. Verify repairs by checking starting solenoid operation.STOP
Not OK - The starting solenoid did not activate. The problem appears to be in the starting solenoid.Repair: Temporarily install a new starting solenoid. Verify that the problem is no longer present. Reinstall the old starting solenoid. If the problem returns, replace the starting solenoid.STOP