3V9-72019-0 Tohatsu LABEL, THROTTLE

Illustration 1 g00850421
Test Step 1. Check for Connector Damage
Turn the engine control to the OFF position.
Turn the breaker at the battery to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. 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:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Emergency Stop and the Run/Start/Stop Switch.
Verify proper operation of the Stop Switches.Expected Result:The customer supplied shutdown switch should operate normally.Results:
OK - The customer supplied shutdown switch operates correctly. Proceed to test step 3.
Not OK - The customer supplied shutdown switch does not operate correctly.Repair: Repair the switch or wiring and/or replace the switch or wiring. Stop.Test Step 3. Attempt to Start the Engine
Connect the ET to the service tool connector.
Connect the main power.
Deactivate the engine shutdowns.
Close the Normal Stop Switch. Monitor the start up mode on ET.
The crank cycle should continue for the time that is equal to the crank duration that has been programmed or the crank cycle should continue until the engine speed reaches the crank terminate speed.Expected Result:The status screen for the start up mode should display "CRANK".Results:
OK - The status screen for the start up mode displays "CRANK". The engine cranks but the engine will not start.Repair: Refer to Troubleshooting, "Engine Cranks but Will Not Start". Stop.
Not OK - The status screen for the start up mode does not display "CRANK". Proceed to test step 4.Test Step 4. Check the Start Enable Relay.
Connect main power.
Connect a voltmeter across the coil of the start enable relay.
Access the override for the start enable relay.
Activate the override for the start enable relay.
Measure the voltage across the coil of the start enable relay.
Deactivate the override for the start enable relay.Note: When the engine is not rotating, the relay will be energized for 3 seconds.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. The relay activates when the override is enabled. The engine cranks.Repair: The system is operating correctly. Stop.
Not OK - The voltage measures 24 3 VDC. The relay activates when the override is enabled. The starting motor does not run. Proceed to test step 5.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 6.Test Step 5. Check the Normally Open Contacts on the Start Enable Relay.
Connect main power.
Connect a voltmeter across the normally open contacts of the start enable relay.
Access the override for the start enable relay.
Activate the override for the start enable relay.
Measure the voltage across the normally open contacts of the start enable relay.
Deactivate the override for the start enable relay.Note: When the engine is not rotating, the relay will be energized for 3 seconds.Expected Result:The voltage should measure 24 3 VDC before the override is activated. The voltage should measure 0.0 VDC after the override is activated.Results:
OK - The voltages are correct. The start enable relay and the customer supplied starting motor activate.Repair: The system is operating correctly. Stop.
Not OK - The voltages are correct. The start enable relay activates. The starting motor did not run.Repair: The problem is in the wiring between the start enable relay and connector "G" and/or the customer supplied starting motor circuit after connector "G". Refer to the "OEM Manual". Stop.
Not OK - The voltage measurements are not correct.Repair: Check the power to the start enable relay if the voltage does not measure 24 3 VDC before activation of the start enable relay. Replace the start enable relay if the voltage does not measure 0.0 VDC after activation of the start enable relay. Stop.Test Step 6. Check the Signal to the Start Enable Relay from the ECM.
Disconnect the main power.
Disconnect ECM connector J2/P2.
Remove wire F701-BR from ECM connector P2-13. Install a wire jumper into the socket for P2-13.
Reconnect ECM connector J2/P2.
Connect the main power.
Access the override for the start enable relay.
Activate the override for the start enable relay.
Measure the voltage between the wire jumper in socket P2-13 and engine ground.
Deactivate the override for the start enable relay.Note: When the engine is not rotating, the relay will be energized for 3 seconds.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Repair the connectors or wiring and/or replace the connectors or wiring between the ECM and the crank enable relay. Stop.
Not OK - The voltage does not measure 24 3 VDC.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Stop.