3A3-76086-1 Tohatsu NEUTRAL SWITCH

Table 1
Diagnostic Trouble Codes for the Starting Aid System
J1939 Code Code Description Information
626-5 Engine Start Enable Device 1 : Current Below Normal This code indicates that the current flow through the circuit for the starting aid is low. This condition is usually caused by an open wire. The problem may be in a connector.
626-6 Engine Start Enable Device 1 : Current Above Normal This code indicates that the current flow through the circuit for the starting aid is high. This condition is usually caused by moisture or debris in a connector.
Follow the troubleshooting procedure in order to identify the root cause of the problem. Programmable Parameters"Starting Aid Output" - This "Output Selection" parameter indicates the P1 terminal that is controlling the starting aid system. This parameter must be programmed to match the vehicle's wiring in order for the starting aid system to work correctly. The ECM does not attempt to control a starting aid system if this parameter is programmed to "None"."Starting Aid On/Off Switch" - This "Input Selection" parameter indicates the P1 terminal that is connected to the optional starting aid switch. This parameter must be programmed correctly in order for the ECM to receive the input from the switch. The ECM does not look for a starting aid switch if this parameter is programmed to "None".The ECM provides nine output terminals that can be used to control the starting aid output. The Caterpillar Electronic Technician (ET) is used to program the starting aid output to a P1 terminal. Each of the output terminals is a high side driver or a low side driver.High Side Driver - The ECM provides an output voltage that is approximately equal to the battery voltage in order to control the starting aid.Low Side Driver - The ECM provides a connection to ground in order to control the starting aid.
Illustration 1 g01437214
Examples of circuits for a high side driver and a low side driver
A switch can be added to the system. The switch allows the operator to disable the system, if the operator desires. The switch can be programmed to one of 14 different terminals on the P1 connector.
Illustration 2 g01437215
Typical circuit for the starting aid switch
The switch is shown in the ON position.
The signal from the coolant temperature sensor is used to determine if conditions require the use of the starting aid. If a fault condition exists with the circuit for the coolant temperature sensor, the signal from the intake manifold air temperature sensor is used. The starting aid output will be enabled for a maximum of 30 seconds while the engine is cranking and the temperature reading is below 0 °C (32 °F). The starting aid output is disabled when the engine starts. The starting aid output is disabled if a condition that prevents fuel injection occurs.Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the J1/P1 ECM connector and the firewall bulkhead connectors. 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 circuit.
Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the solenoid to the ECM. Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and the wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with 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 2. Determine the Configuration of the Starting Aid Output
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Use Cat ET to check the configuration parameter for "Starting Aid Output". Record the parameter setting.
Verify that the "Starting Aid Output" parameter is programmed to reflect the current wiring for the circuit.
Turn the keyswitch to the OFF position. Expected Result:The parameter is programmed to reflect the current wiring for the circuit.Results:
OK - The parameter is programmed to reflect the current wiring for the circuit. The relay for the engine shutdown output is wired correctly. Proceed to Test Step 3.
Not OK - The parameter is not programmed to reflect the current wiring for the circuit.Repair: The parameter is not programmed correctly. Update the customer specified parameter in order to match the correct wiring for the circuit.STOPTest Step 3. Check the Starting Aid Circuit
Personal injury or death can result from not following the proper procedures.To avoid the possibility of injury or death, follow the established procedure.
Turn the keyswitch to the ON position.
Access the "Starting Aid Output Special Test" on Cat ET. The "Starting Aid Output Special Test" will enable the starting aid output when the test is active. Disconnect the ether starting aid cylinder in order to prevent accidental discharge.
Begin the "Starting Aid Output Special Test" and listen for the solenoid or the relay for an audible click. You will need to be near the solenoid or the relay in order to hear the audible click.
Turn the keyswitch to the OFF position. Expected Result:The solenoid or the relay activates when the special test is enabled.Results:
OK - The solenoid or the relay activates when the special test is enabled.Repair: The circuit for the starting aid output appears to be operating correctly at this time. The ECM and vehicle components are operating correctly. Check that the ether starting aid cylinder is not empty. There may be an intermittent electrical problem in the harness or in a connector. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect" for information that is related to troubleshooting