9101E3-5652 Tohatsu BOLT

Illustration 1 g01114245
Schematic for the status indicators
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND WIRING
Remove the electrical power from the engine.
Thoroughly inspect each of the following connectors:
J2/P2 connectors
J6/P6 connectors
Check the torque of the allen head screw for the ECM connectors.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the status indicators. Note: These outputs do not provide enough current for illumination of standard incandescent lights. If a lamp is burned out, replace the lamp with the lamp that is specified in the engine's Parts Manual.
Inspect the wiring and the receptacles for the status indicators.
Check the harness and wiring for abrasion and for pinch points from the customer's equipment to the master ECM. Expected Result:All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary.STOPTest Step 2. CHECK FOR DIAGNOSTIC CODES
Connect Cat ET to the service tool connector on the terminal box. Refer to Troubleshooting, "Electronic Service Tools".
Restore the electrical power to the engine.
Attempt to start the engine and observe the status indicators. Allow a minimum of 30 seconds for any diagnostic codes to activate. Use the "Active Diagnostic" screen on Cat ET to look for the codes that are listed in Table 1:
Table 1
Diagnostic Codes and Descriptions with Corresponding ECM Outputs
Code Description ECM Output
323-3 Engine Shutdown Lamp : Voltage Above Normal "Fault Relay"
324-3 Warning Lamp (Action) : Voltage Above Normal "Engine Control Alarm Status"
443-3 Crank Terminate Relay : Voltage Above Normal "Crank Terminate Relay"
445-3 Run Relay : Voltage Above Normal "Run Relay" Expected Result:There are no active diagnostic codes. The "Engine On" indicator and the "Crank Terminate" indicator (if equipped) illuminated normally. The "Active Alarm" indicator and the "Engine Failure" indicator did not illuminate.Results:
Yes (Original 443-3 or 445-3 Diagnostic Code) - The original diagnostic code was 443-3 or 445-3. When the engine was started, the "Run Relay" indicator and the "Crank Terminate Relay" indicator (if equipped) illuminated normally. The "Engine Control Alarm Status" indicator and the "Fault Relay" indicator did not illuminate. There are no active diagnostic codes.Repair: The outputs for the status indicators seem to be operating correctly at this time. The original diagnostic code was probably caused by a poor electrical connection.If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Yes (Original 323-3 or 324-3 Diagnostic Code) - The original diagnostic code was 323-3 or 324-3. When the engine was started, the "Run Relay" indicator and the "Crank Terminate Relay" indicator (if equipped) illuminated normally. The "Engine Control Alarm Status" indicator and the "Fault Relay" indicator did not illuminate. There are no active diagnostic codes.Repair: The 323-3 and 324-3 diagnostic codes can only be activated when the corresponding indicator is activated. There may still be a problem with the output for the alarm indicator or the shutdown indicator. The alarm and/or the shutdown must be activated.Allow the engine operation to continue. Proceed to Test Step 3.
Not OK (Active 323-3 or 324-3 Diagnostic Code) - There is an active 323-3 or 324-3 diagnostic code. There must be a shutdown condition before a 323-3 diagnostic code can be generated. There must be an alarm condition before a 324-3 diagnostic code can be generated. Both of these conditions are serious.Repair: Use Cat ET to determine the event code or the diagnostic code that corresponds to the 323-3 or 324-3 diagnostic code. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-3 or 324-3 diagnostic code. Refer to Troubleshooting, "Symptom Troubleshooting" or Troubleshooting, "Diagnostic Trouble Code List".Exit this procedure. After you have resolved the condition, return to this procedure in order to troubleshoot the 323-3 and/or 324-3 diagnostic code, if necessary.STOP
Not OK (Active 443-3 or 445-3 Diagnostic Code) - When the engine was started, the "Run Relay" indicator and/or the "