48862-90J10 Suzuki BOLT

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SchematicTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J2/P2 ECM connector, the J3/P3 machine connector, and the connection to the user defined shutdown device (switch). 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 and the sensor connectors that are associated with the active diagnostic code.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and for pinch points from the user defined shutdown device to the ECM.Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem with the harness and/or wiring.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 2. Check the Status on the Electronic Service Tool
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status of "User Shutdown" on Cat ET.Expected Result:The status is "Off".Results:
OK - The status is "OFF". Proceed to Test Step 3.
Not OK - The status is not "OFF". Proceed to Test Step 4.Test Step 3. Short the Input at the Machine Connector
Turn the keyswitch to the OFF/RESET position.
Use a suitable piece of wire to short J3:12 (User Defined Shutdown) to chassis ground.
Turn the keyswitch to the ON position.
Observe the status of "User Shutdown" on Cat ET.Expected Result:The status is"On" when the terminal is grounded.Results:
OK - The status shows "On". The circuit from machine connector J3 to the ECM is functioning properly. A problem may exist in either the user defined shutdown device (switch) or the circuit between the switch and machine connector P3.Repair: Troubleshoot the circuit between machine connector P3 and the switch. Repair the circuit and/or replace the switch, as needed. Stop.
Not OK - The status does not show "On". Proceed to Test Step 4.Test Step 4. Check the Harness for Shorts
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P2 ECM connector (ECM side)
Turn the keyswitch to the OFF/RESET position.
Disconnect the J2/P2 ECM connector.
Measure the resistance between P2:24 (User Defined Shutdown) and engine ground.Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is acceptable. Proceed to Test Step 5.
Not OK - The resistance is not acceptable. There is a short circuit in the harness or a user defined shutdown device is activating the shutdown feature.Repair: Ensure that a user defined shutdown device is not activating the shutdown feature.Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 5. Check the Resistance through the Harness
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P2 ECM connector (ECM side)
Disconnect the J2/P2 ECM connector.
Use a suitable piece of wire to short J3:12 User Defined Shutdown to chassis ground.
Measure the resistance between P2:24 (User Defined Shutdown) and engine ground.
Remove the wire short.Expected Result:The resistance is less than 10 Ohms when the terminal is grounded.Results:
OK - The resistance is within acceptable limits. Proceed to Test Step 6.
Not OK - There is an open circuit or excessive resistance in the harness.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 6. Short the Input at the ECM
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J2/P2 breakout
Verify that the keyswitch is in the OFF/RESET position and install a 7X-1715 Adapter Cable (40 Pin Breakout T) at the J2/P2 ECM connector.
Turn the keyswitch to the ON position.
Observe the status of "User Shutdown" on Cat ET.
Use a suitable piece of wire to short P2:24 (User Defined Shutdown) to engine ground.
Observe the status of "User Shutdown" on Cat ET.Expected Result:The status is "On" when the wire short is in place. The status is "Off" when the wire short is removed.Results:
OK - The status is the expected result. The shutdown feature is working properly. Stop.
Not OK - The status is not the expected result. The correct switch input appears at the ECM, but the ECM is not reading the switch input properly.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM. Stop.