5031105 JOHNSON VALVE, Needle

Illustration 1 g00879567
Schematic for ECM battery circuitTest Step 1. Inspect Electrical Connectors And Wiring.
Illustration 2 g00762055
Terminal locations for ECM
Thoroughly inspect the harness connector J1/P1. Also inspect the connections for the battery and the connections to the keyswitch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the following connections:
P1:48, P1:52, and P1:53 (Unswitched positive battery)
P1:61, P1:63, and P1:65 (Negative Battery)
P1:70 (Keyswitch)
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Also, check the harness and wiring for abrasions and for pinch points from the keyswitch to the ECM.Expected Result:All connectors, pins, and sockets should be completely coupled and/or inserted. The harness and wiring should be free of corrosion, abrasion, and/or pinch points.Results:
OK, Troubleshooting a 168-02 - Proceed to Test Step 2.
Not OK - There is a problem with the connectors or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Stop.Test Step 2. Check the Battery Voltage at the ECM.
Illustration 3 g00762060
ECM Breakout T-Connector
Disconnect engine harness connector P1 from ECM connector J1 and insert a 70 Pin Breakout T.
Reconnect the harness.
Turn the keyswitch ON.
Measure the voltage between P1:52 (unswitched positive battery) and P1:63 (negative battery).
Measure the voltage between P1:48 (unswitched positive battery) and P1:61 (negative battery).
Measure the voltage between P1:53 (unswitched positive battery) and P1:65 (negative battery).
Measure the voltage between P1:70 (keyswitch) and P1:63 (negative battery).Refer to Illustration 3 for the ECM breakout T-connector.Expected Result:The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system with no suspected intermittent problems at this time.Results:
OK - The ECM is receiving the correct voltage. Repair: If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect". Stop.
Battery Voltage is out of range - Proceed to Test Step 3.
Intermittent Or No Voltage - Proceed to Test Step 4.
Keyswitch Voltage Out Of Range - Repair: Trace the wiring for the keyswitch from the ECM through the keyswitch circuit to the batteries. Find the problem and repair the problem. Check the circuit protection for the circuit and for the wiring.Verify that the repairs eliminate the problem. Stop.Test Step 3. Check The Batteries.
Measure no-load battery voltage at the battery posts.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure".Expected Result:The batteries pass the load test. The measured voltage is the minimum specification for a 12V system.Results:
OK - Repair: Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Stop.
Not OK - Repair: Recharge or replace the faulty batteries. Verify that the repair eliminates the problem. Stop.Test Step 4. Use the Bypass Harness for the Electronic Service Tool to Bypass the Machine Wiring.
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.
Do Not connect the bypass harness to the battery until the 20 Amp in-line fuse has been removed from the +Battery line. If the fuse is not removed before connection to the battery, a spark may result.
Illustration 4 g00700001
Bypass harnessNote: This bypass harness is only for test applications. This bypass harness may be left only temporarily on the engine. The bypass harness can be used in order to determine if the cause of the intermittent problem is interruptions in battery power to the ECM or the keyswitch circuit.
Turn the keyswitch to the OFF position.
Disconnect harness connector J1/P1 from the ECM.
Connect a bypass harness to ECM connector J1.
Remove the in-line fuse from the + battery wire of the bypass harness. Connect the unswitched + battery wire and the - battery wire