128-02605-1 Tohatsu SPACER, 6 - 8 - 28.5

Recommended Actions
Perform the following tests in order:
Check customer specified parameters.
Verify that the complaint is not normal operation (programmed parameter).
Connect the electronic service tool.
Check the following parameters:
"Rating Number"
"Top Engine Limit"
"Vehicle Speed Limit"
"Lower Gears Engine RPM Limit"
"Intermediate Gears Engine RPM Limit"
"Gear Down Protction Engine RPM Limit"Note: If the "Rating Number" is programmed to 0, the engine is limited to 119 kW (160 hp).
Set each parameter to the maximum value one at a time and determine whether the problem is corrected.
Check cold mode operation.Note: Cold mode is normal operation if the problem occurs only after start-up in cold weather.
Connect the electronic service tool.
Monitor the electronic service tool in order to verify that the engine has progressed from cold mode.An active cold mode is indicated in the upper corner of any status screen.
Check the PTO on/off switch.
Verify that the PTO on/off switch is in the OFF position.
Connect the electronic service tool.
Verify that the status for the "PTO On/Off Switch" on the electronic service tool corresponds to the position of the switch.
Cycle the PTO on/off switch while you observe the status screen.
Check for an electronic system problem.
Connect the electronic service tool.
Monitor the "Fuel Position", the "Rated Fuel Limit" and the "FRC Fuel Limit" on the status screen.While the vehicle is operating under full load, the parameters should meet the following conditions:
The "Fuel Position" is equal to the "Rated Fuel Limit".
The "Fuel Position" is less than the "FRC Fuel Limit".If the "Fuel Position" is equal to the "Rated Fuel Limit" and the "Fuel Position" is less than the "FRC Fuel Limit", the Electronics are operating correctly. Go to Step 6.
If the "Fuel Position" is not equal to the "Rated Fuel Limit" and/or the "Fuel Position" is not less than the "FRC Fuel Limit", perform the following tests in order:
Connect the electronic service tool.
When the engine is OFF, turn the ignition key switch to the ON position. Check the status for "Boost Pressure" on the electronic service tool.When the engine is OFF, the boost pressure should be 0 kPa (0 psi).
Monitor the status of the accelerator pedal position sensor. Operate the engine at high idle with the vehicle in Neutral.If the engine cannot reach the programmed "Top Engine Limit", check the duty cycle of the accelerator pedal position sensor. Ensure that the duty cycle is within calibration Slowly operate the accelerator pedal in order to verify that the accelerator pedal position sensor is within calibration. The accelerator pedal position sensor is within calibration when both of the following conditions are met:
10 to 22 percent at low idle
75 to 90 percent at high idleAlso, ensure that the duty cycle changes as the pedal position changes. If a problem with the accelerator pedal position sensor is suspected, refer to Troubleshooting, "Accelerator Pedal (Throttle) Position Sensor Circuit - Test".Note: If the engine exceeds the "Top Engine Limit", the "Top Engine Limit with Droop" is programmed to YES.
Monitor the vehicle speed signal. Ensure the accuracy of the vehicle speed signal by comparing the vehicle speed signal to the actual vehicle speed.If the vehicle speed is greater than the "VSL", the power is limited. If a problem is discovered, refer to Troubleshooting, "Vehicle Speed Circuit - Test".
Check the "Powertrain Data Link". Ensure that the SAE J1922 or the SAE J1939 Powertrain Data Link is not limiting the power.
Connect the electronic service tool.
Monitor the "Powertrain Data Link" status screen while the vehicle is experiencing problems.If the "Powertrain Data Link" status screen indicates that the "Powertrain Data Link " is limiting the power or the rpm, verify that the limit is not normal operation. If the limit is not normal operation, refer to the vehicle OEM for repairs.
Check the fuel supply.
Monitor the exhaust for smoke while the engine is being cranked.If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the fuel supply.
Check the fuel quality. Refer to Testing and Adjusting, "Fuel Quality - Test".
Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test".
Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System - Prime".
Check for fuel supply lines that are restricted.
Check the fuel filters.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Check for air in the fuel system. Refer to Testing and Adjusting, "Air in Fuel - Test".
Check for leakage in the air-to-air aftercooler core . Refer to Testing and Adjusting, "Aftercooler - Test".
Check the air inlet system for restrictions or leakage. Check the exhaust system for restrictions or leakage. Refer to Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".
Check for an individual malfunctioning cylinder.
Ensure that the J300/P300 injector solenoid harness connector is fully connected and free of corrosion.
Ensure that the J2/P2 ECM connector is fully connected and free of corrosion.
Connect the electronic service tool. Use the "Cylinder Cutout Test". Access the "Cylinder Cutout Test" by selecting the "Diagnostic Menu" and the "Diagnostics Test Menu". Run the "Cylinder Cutout Test" in order to disable each cylinder. Disabling each cylinder allows the technician to isolate the misfiring cylinders.If the misfiring cylinder can be isolated to a specific cylinder, refer to Troubleshooting, "Injector Solenoid Circuit - Test".
Perform a PAR Test (Performance Analysis Report).
Check the torque limit switch.
Connect the electronic service tool.
Check the setting for the customer parameter for the "Torque Limit".If the "Torque Limit" is programmed below 3400 N m (2500 lb ft), check the status screen for the torque limit switch. Ensure that the status screen indicates that the torque limit switch is OFF. If the status of the torque limit switch is ON and a "Torque Limit" is programmed, the system is operating correctly. If the torque limit switch that is connected to this signal input is not switching ON and switching OFF, refer to Troubleshooting, "PTO Switch Circuit - Test".