5032960 JOHNSON WASHER (17X23X1.7mm)

Illustration 1 g01080837
Schematic for the warning lampThe ECM provides a path to ground for the lamp. When the ECM connects the lamp to ground the lamp will turn on.
Illustration 2 g00741073
Terminal locations for customer connectorTest Step 1. Check for Normal Operation of the Warning Lamp
Monitor the warning lamp.
Place the engine control in the ON mode and observe the lamp. The lamp should turn on for five seconds. Then, the lamp should turn off.Note: The lamp will turn off only if a "Warning", "Derate", or a "Shutdown" condition does not exist.Expected Result:The warning lamp turns on and the warning lamp turns off.Results:
Yes - The warning lamp appears to be operating correctly at this time.STOP
No - The warning lamp did not work properly. Proceed to Test Step 2.Test Step 2. Inspect Electrical Connectors and Wiring
Place the engine control in the OFF/RESET mode and thoroughly inspect the J61/P61 customer connector, and J1/P1 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the connector wires in the circuit that are associated with the maintenance overdue lamp.Refer to Illustration 1.
Check the J61/P61 customer connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the ECM connector J1/P1 for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 3.
Not OK - There is a problem in the connectors and/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.Verify that the repair eliminates the problem.STOPTest Step 3. Test the Lamp Circuit
Illustration 3 g00741089
Terminal locations for the warning lamp
Disconnect ECM engine harness connector J1/P1.
Remove wire F420-GN from ECM connector P1-29.
Connect a wire jumper between wire F420-GN and engine ground.
Place the engine control in the ON mode and observe the lamp.Expected Result:The warning lamp turns on while the jumper is connected to wire F420-GN. Also, the warning lamp turns off when the jumper is removed from wire F420-GN.Results:
OK - The circuit for the warning lamp is functioning properly. Proceed to Test Step 6.
Not OK - The warning lamp did not turn on. The warning lamp circuit is not functioning properly. Proceed to Test Step 4.Test Step 4. Test the Lamp Circuit at the Warning Lamp
Place the engine control in the OFF/RESET mode.
Remove wire F420-GN from the lamp.
Connect a wire jumper between the warning lamp and engine ground.
Place the engine control in the ON mode and observe the warning lamp.Expected Result:The warning lamp turns on while the jumper is connected. Also, the warning lamp turns off when the jumper is removed.Results:
OK - The circuit for the warning lamp is functioning properly.Repair: Repair the wire F420-GN between the warning lamp and the ECM connector P1-29.STOP
Not OK - The warning lamp did not turn on. The warning lamp circuit is not functioning properly. If voltage is present on the battery side of the warning lamp, replace the lamp. If voltage is not present on the battery side of the warning lamp, proceed to Test Step 4.Test Step 5. Check the Voltage from the Keyswitch to the Warning Lamp
Place the engine control in the OFF/RESET mode.
Remove the wire from the terminal R of the keyswitch.
Place the engine control in the ON mode.
Measure the voltage on terminal B of the keyswitch to engine ground.
Measure the voltage on terminal R of the keyswitch to engine ground.
Place the engine control in the OFF/RESET mode.Expected Result:Voltage is present on terminal B and terminal R at the keyswitch.Results:
OK - Voltage is present on terminal B and terminal R at the keyswitch.Repair: If voltage is present on terminal R, repair the wire between the keyswitch and the warning lamp. Verify that the breaker is not tripped. Return all wiring to the original configuration. Verify that the problem is eliminated.STOP
Not OK - Voltage is not present on terminal B at the keyswitch.Repair: If voltage is not present on terminal B, repair the wire between the +Battery and the keyswitch. Verify that the breaker is not tripped. Check the battery's no-load voltage. Return all wiring to the original configuration. Verify that the problem is eliminated.STOP
Not OK - Voltage is not present on terminal R at the keyswitch.Repair: If voltage is present on terminal B of the keyswitch but not present on terminal R, replace the keyswitch. Return all wiring to the original configuration. Verify that the problem is eliminated.STOPTest Step 6. Check ECM Operation of the Warning Lamp
Fabricate a jumper wire 100 mm (4 inch) long. Crimp a Deutsch pin to both ends of the wire.
Insert the jumper into P1-29 Warning Lamp.
Reconnect ECM Connector J1/P1.
Connect one probe of a voltage test lamp to the wire jumper in P1-29.
Connect the other probe of the voltage test lamp to +Battery.
Place the engine control in the ON mode.
The test lamp should turn ON.Expected Result:The test lamp turns ON for five seconds. Then, the test lamp turns OFF.Results:
OK - The ECM is operating correctly. The circuit appears to be operating correctly.Repair: The problem may be intermittent. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Temporarily connect a test ECM. Check the operation of the warning lamp when the test ECM is installed. If the problem is resolved with the test ECM, then reconnect the suspect ECM. If the problem returns with the suspect ECM, then replace the ECM.STOP