334-04005-0 Tohatsu DIAPHRAGM

Illustration 1 g00749647
Note: The following process must be followed if one or more emergency stop switches are present in the circuit.Test Step 1. Check the Electrical Connectors and the Wiring.
Turn the Battery switch for the ECM to the OFF position.
Turn the breaker at the battery to the OFF position.
Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - The wiring and connectors are okay. Proceed to Test Step 2.
Not OK - Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status while the Emergency Stop Switch is Activated.
Connect an Electronic Service Tool to the service tool connector.
Turn the breaker at the battery to the ON position.
Turn the Battery switch for the ECM to the ON position.
Activate the emergency stop switch.
Observe the status of the emergency stop switch on the Electronic Service Tool.Expected Result:The parameter for the emergency stop switch should read "ON".Results:
OK - The parameter for the emergency stop switch reads "ON". Proceed to test step 3.
Not OK - The parameter for the emergency stop switch does not read "ON". Proceed to test step 4.Test Step 3. Check the Status while the Emergency Stop Switch is Not Activated.
Deactivate the emergency stop switch.
Observe the status of the emergency stop switch on the Electronic Service Tool.Expected Result:The parameter for the emergency stop switch should read "OFF".Results:
OK - The parameter for the emergency stop switch reads "OFF". The emergency stop switch is functioning correctly.STOP
Not OK - The parameter for the emergency stop switch does not display "OFF". Proceed to test step 4.Test Step 4. Check the Emergency Stop Input to the ECM.
Turn the Battery switch for the ECM to the OFF position.
Disconnect ECM connector J1/P1.
Install a 40-pin Breakout T between the ECM connectors, P1, and J1.
Remove the wire F717-YL from pin 14 of the Breakout T that is connected to P1.
Remove the wire 998-BR from pin 29 of the Breakout T that is connected to P1.
Turn the Battery switch for the ECM to the ON position.
Observe the status of the emergency stop switch on the Electronic Service Tool when the wires are separated.
Short the wires that were removed from the Breakout T together.
Observe the status of the emergency stop switch on the Electronic Service Tool.
Turn the Battery switch for the ECM to the OFF position. Restore the wiring and the connectors to the original configuration.Expected Result:The parameter for the emergency stop switch should read "ON" when the wires are separated. The parameter for the emergency stop switch should read "OFF" when the wires are shorted together.Results:
OK - The parameter for the emergency stop switch is displaying the proper states. The problem is not with the ECM. Proceed to test step 5.
Not OK - The parameter for the emergency stop switch is not displaying the proper states.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOPTest Step 5. Check for an Open Circuit in the Emergency Stop Circuit.
Turn the Battery switch for the ECM to the OFF position.
Disconnect the ECM connector J1/P1.
Ensure that all emergency stop switches are not actuated.
Measure the resistance between the wire F717-YL at the ECM connector P1-14 and the wire 998-BR at the ECM connector P1-29.Expected Result:The resistance should measure less than 10 Ohms.Results:
OK - The resistance measures less than 10 Ohms. Proceed to test step 6.
Not OK - The resistance measures more than 10 Ohms.Repair: Install a jumper between terminal 1 and terminal 2 at the emergency stop switch. If the resistance measures less than 10 Ohms replace the emergency stop switch. If the resistance measures more than 10 Ohms repair the connectors and/or wiring or replace the connectors and/or wiring between the emergency stop switch and the ECM. Verify that the problem is no longer present.STOPTest Step 6. Check for a Short Circuit in the Emergency Stop Circuit.
Turn the Battery switch for the ECM to the OFF position.
Disconnect the ECM connector J1/P1.
Actuate the emergency stop switch.
Measure the resistance between the wire F717-YL at the ECM connector P1-14 and the wire 998-BR at the ECM connector P1-29.
Reconnect all connectors.Expected Result:The resistance should be greater than 20,000 Ohms after the switch is actuated.Results:
OK - The resistance is greater than 20,000 Ohms after the switch is actuated. Verify that the problem is no longer present.STOP
Not OK - The resistance is less than 20,000 Ohms after the switch is actuated. There is a short circuit in the emergency stop switch or in the wiring. Proceed to test step 7.Test Step 7. Check the Operation of the Emergency Stop Switch.
Disconnect the ECM connector J1/P1.
Disconnect the wire from terminal 1 of the emergency stop switch.
Actuate the emergency stop switch.
Measure the resistance between terminal 1 and terminal 2 on the emergency stop switch.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. The emergency stop switch is okay. There is a short in the wiring and/or connectors between the emergency stop switch and the ECM.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring. Verify that the problem is no longer present.STOP
Not OK - The resistance is less than 20,000 Ohms.Repair: Replace the emergency stop switch. Verify that the problem is no longer present.STOP