0438515 JOHNSON THROTTLE BODY, Upper

Illustration 1 g00890024
Schematic for user defined shutdownTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect ECM connector J1/P1, machine connector J3/P3, and user defined shutdown connector J116. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and for pinch points from user defined shutdown connector J116 to the ECM.Expected Result:All connectors, pins, and sockets should be completely inserted and coupled. The harness and wiring should be free of corrosion, abrasion, and pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 2. Check the Status on Caterpillar Electronic Technician (Cat ET)
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status of "User Shutdown" on Cat ET.Expected Result:The status should be "Off".Results:
OK - Proceed to Test Step 3.
Not OK - Proceed to Test Step 4.Test Step 3. Short the Input at the Connector
Use a suitable piece of wire to short the terminals of J116 (user defined shutdown connector).
Observe the status of "User Shutdown" on Cat ET.Expected Result:The status should be "On" when the terminals of user defined shutdown connector J116 are shorted.Results:
OK - The shutdown feature is working properly.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent. Stop.
Not OK - Proceed to Test Step 5.Test Step 4. Check the Harness for Shorts
Illustration 2 g00890028
ECM connector P1 (ECM side)
Disconnect ECM connector J1/P1.
Measure the resistance between P1:45 (User Defined Shutdown) and P1:5 (Digital Return).Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - Proceed to Test Step 6.
Not OK - There is a short circuit in the harness or a user defined shutdown device is activating the shutdown feature.Repair: Ensure that a user defined shutdown device is not activating the shutdown feature.Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 5. Check the Resistance through the Harness
Turn the keyswitch to the OFF/RESET position.
Disconnect ECM connector J1/P1.
Use a suitable piece of wire to short the terminals of J116 (user defined shutdown connector).
Measure the resistance between P1:45 (User Defined Shutdown) and P1:5 (Digital Return). Refer to Illustration 2.
Remove the wire short.Expected Result:The resistance should be less than 10 Ohms when the terminals of J116 (user defined shutdown connector) are shorted.Results:
OK - The resistance is within acceptable limits. Proceed to Test Step 6.
Not OK - There is an open circuit or excessive resistance in the harness.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 6. Short the Input at the ECM
Illustration 3 g00890029
ECM connector P1 (wire side)
Turn the keyswitch to the OFF/RESET position.
Remove the wire from terminal P1:45 (User Defined Shutdown) and remove the wire from terminal P1:5 (Digital Return).
Turn the keyswitch to the ON position.
Observe the status of "User Shutdown" on Cat ET.
Turn the keyswitch to the OFF/RESET position.
Make a jumper wire with a Deutsch pin on each end of the wire.
Insert one end of the jumper wire into terminal P1:45 (User Defined Shutdown). Insert the other end of the jumper wire into terminal P1:5 (Digital Return).
Turn the keyswitch to the ON position.
Observe the status of "User Shutdown" on Cat ET.
Remove the jumper and reinstall the wires to the P1 connector.Expected Result:The status should be "On" when the wire short is in place. The status should be "Off" when the wire short is removed.Results:
OK - The shutdown feature is working properly. Stop.
Not OK - The correct switch input appears at the ECM, but the ECM is not reading the switch input properly.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM. Stop.