3FW-76010-0 Tohatsu STARTER MOTOR ASSEMBLY

Illustration 1 g01190695
Typical schematic
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM. Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and 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. Attempt to Start the Engine
Connect Cat ET to the service tool connector J60/P60.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Observe the "startup mode" parameters on the Cat ET status screen.
Turn the engine control to the RUN or to the AUTO mode. Continue monitoring engine parameters as the engine cranks.
The crank cycle will continue for the time that is equal to the cycle crank time that has been programmed or the crank cycle will continue until the engine speed reaches the crank terminate speed.
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position. Expected Result:The status screen for the "startup mode" parameter displays "CRANK". The engine cranks.Results:
OK - The "startup mode" parameter on the status screen on the Cat ET displays "CRANK".Repair: The engine cranks. The starting system is working properly.STOP
Not OK - Engine Doesn't Crank - The "startup mode" parameter on the status screen on the Cat ET displays "CRANK". The engine will not crank. Proceed to Test Step 3.
Not OK - Status Screen - The "startup mode" parameter on the status screen on the Cat ET does not display "CRANK".Repair: The problem is in the engine control (generator) and/or the associated wiring. Repair the engine control and/or the wiring.STOPTest Step 3. Check Voltage to the Starting Motor
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.
Open the power distribution box that is located on the left side of the engine, close to the starter motors.
Connect one probe of a digital voltmeter to the −Battery terminal. Connect the other probe of the digital voltmeter to wire 314-PU(Purple) on terminal 2 of the magnetic switch.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Monitor the voltage on the digital voltmeter. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to Test Step 7.
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 4.Test Step 4. Check the Coil on the SMMS
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.
Connect one probe of the digital voltmeter to terminal 3 of the SMMS. Connect the other probe of the digital voltmeter to wire 102-BK on terminal 4 of the SMMS.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.
Remove the digital voltmeter and replace all wires. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The problem appears to be with the SMMS. Temporarily install a new SMMS. Verify that the problem is no longer present. Reinstall the old SMMS. If the problem returns, replace the SMMS.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 5.Test Step 5. Check the Voltage to the SMMS
Connect one probe of a digital voltmeter to −Battery terminal. Connect the other probe of the digital voltmeter to wire F701-BR on terminal 3 of the SMMS.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The coil of the SMMS is open. Temporarily install a new SMMS. Verify that the problem is no longer present. Reinstall the old SMMS. If the problem returns, replace the SMMS.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to Test Step 6.Test Step 6. Check the Voltage from the Engine Control to the Connector of the Generator and Engine
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.
Disconnect the harness connector for the generator.
Remove the wires from terminal 24 and 39 from the connector for the generator. Remove the wires from the side of the connector that is going to the generator.
Reconnect the connector for the generator .
Connect one probe of a digital voltmeter to the wire from terminal 24. Connect the other probe of the digital voltmeter to the wire from terminal 39.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Monitor the voltage on the digital voltmeter.
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: The problem is most likely in the wiring between the harness connector for