5001594 JOHNSON WATER PUMP REPAIR KIT

Table 1
Diagnostic Trouble Codes for the Ground Level Shutdown Switch    
CDL Code     Description     Notes    
267-3     Remote Shutdown Input : Voltage Above Normal     The Electronic Control Module (ECM) detects the following conditions:
An open in the circuit for the ground level shutdown switch.    
267-4     Remote Shutdown Input : Voltage Below Normal     The Electronic Control Module (ECM) detects the following conditions:
A short in the circuit for the ground level shutdown switch.    The ground level shutdown switch allows the engine to be shut down from ground level. When the switch is moved to the STOP position, the engine shuts down. The ECM remains powered. The ground level shutdown switch must be in the RUN position and the power to the ECM must be cycled before the engine can restart.
Illustration 1 g03388419
Schematic for the ground level shutdown switch
Illustration 2 g02656956
Ground level shutdown switch connector (1) Ground level shutdown switch (N/C) (2) Switch ground (3) Ground level shutdown switch (N/O)
Illustration 3 g03388801
Pin locations on the P1 connector for the ground level shutdown switch. (40) Ground level shutdown switch (N/O) (41) Ground level shutdown switch (N/C)Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
Thoroughly inspect the J1/P1 ECM connectors and the connectors for the ground level shutdown switch. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires for the engine shutdown switch.
Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).
Check the harness and the wiring for abrasion and for pinch points from the switch back to the ECM.Expected Result:All of the connectors, pins, and sockets are correctly coupled and/or inserted. The harness and wiring are free of corrosion, abrasion, and pinch points.Results:
OK - The harness and the connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a fault in the connectors and/or wiring.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are correctly coupled.If necessary, use the electronic service tool to perform a "Wiggle Test".Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Restore the electrical power to the ECM.
Toggle the ground level shutdown switch and monitor the electronic service tool for the active diagnostic code. Wait at least 30 seconds so that any codes may become active.
Remove the electrical power from the ECM.Expected Result:A diagnostic code is not active.Results:
OK - The code does not become active.Repair: The switch is operating normally. There may be an intermittent fault in the wiring harness or in a connector. Check the wiring harness and the connectors for an intermittent electrical fault. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A diagnostic code is active. Proceed to Test Step 3.Test Step 3. Check the Resistance of the Switch Circuit at the ECM Connector
Disconnect the J1/P1 connector.Note: Wiggle the harnesses during the following measurements in order to detect any intermittent faults.
Measure the resistance between P1-41 (ground level shutdown switch (N/C)) and ground. The correct resistance measurement indicates a short circuit.
Measure the resistance between P1-40 (ground level shutdown switch (N/O)) and ground. The correct resistance measurement indicates an open circuit.
Toggle the ground level shutdown switch to the STOP position.
Measure the resistance between P1-41 (ground level shutdown switch (N/C)) and ground. The correct resistance measurement indicates an open circuit.
Measure the resistance between P1-40 (ground level shutdown switch (N/O)) and ground. The correct resistance measurement indicates a short circuit.
Connect the J1/P1 connectors.Expected Result:The resistance measurements are within the specifications.Results:
OK - All of the resistance measurements are within the specifications.Repair: Perform the following procedure:
Restore the electrical power to the ECM.
Use the electronic service tool to check for the active code again. Toggle the engine shutdown switch and check for the code. Also, wiggle the switch harness from the switch to the ECM in order to reveal an intermittent fault.
If the code does not recur, the fault is resolved. The original fault was probably caused by a poor electrical connection.
If the code recurs, the ECM is not detecting the switch inputs correctly. Perform the following procedure:
Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".
Contact the Technical Communicator at a Cat dealer.Note: This consultation can greatly reduce the repair time.
If the Technical Communicator recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".
Use the electronic service tool to recheck the system for active diagnostic codes.
If the fault is eliminated with the test ECM, reconnect the suspect ECM.
If the fault returns with the suspect ECM, replace the ECM.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOP
Not OK - At least one of the resistance measurements is not within specifications. There is a fault in the switch or in a harness. Proceed to Test Step 4.Test Step 4. Check the Operation of the Ground Level Shutdown Switch
Disconnect the connectors for the ground level shutdown switch.
Place the ground level shutdown switch in the RUN position.
Measure the resistance between terminals 2(return) and 3(ground level shutdown switch (N/O)). The correct resistance measurement indicates an open circuit.
Measure the resistance between terminals 1 (ground level shutdown switch (N/C)) and 2 (return). The correct resistance measurement indicates a short circuit.
Toggle the ground level shutdown switch to the STOP position.
Measure the resistance between 1 (ground level shutdown switch (N/C)) and 2 (return). The correct resistance measurement indicates an open circuit.
Measure the resistance between 2 (return) and 3 (ground level shutdown switch (N/O)). The correct resistance measurement indicates a short circuit.Expected Result:The resistance measurements are within the specifications.Results:
OK - All of the resistance measurements are within the specifications.