13495-94J00 Suzuki CAP, RUBBER

Illustration 1 g01166639Test Step 1. Inspect the Electrical Connectors and Wiring
Turn the engine control to the OFF/RESET mode.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test 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. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Check the customer connector (allen head screw) for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Check the harness and the wiring for abrasion and for pinch points. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 2. Check the Voltage to the ECM
Remove ECM connector J1/P1.
Turn the battery disconnect switch to the ON position.
Turn the engine control to the STOP mode.
Measure the voltage between P1-63 and P1-52.
Measure the voltage between P1-65 and P1-53.
Measure the voltage between P1-67 and P1-55.
Turn the engine control to the OFF/RESET mode.
Turn the battery disconnect switch to the OFF position.
Reconnect ECM connector J1/P1. Expected Result:The voltage is 24 3 VDC from the voltage at the battery terminals.Results:
OK - The voltage is 24 3 VDC from the voltage at the battery terminals. The ECM is receiving the correct voltage. Proceed to Test Step 6.
Not OK - The voltage is not 24 3 VDC from the voltage at the battery terminals. The voltage is incorrect. The battery or the alternator may be causing the problem. Proceed to Test Step 3.
Not OK - ECM Keyswitch - The voltage is not 24 3 VDC. Proceed to Test Step 4.Test Step 3. Check the Battery Voltage
Measure no-load voltage at the battery terminals.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to the Operating Manual, SEHS9249. Refer to Special Instruction, SEHS7633. Expected Result:The no-load voltage at the batteries should be at least 24 3 VDC, and the batteries should pass the load test.Results:
OK - The no-load voltage at the batteries is 24 3 VDC, and the batteries pass the load test.Repair: There is a problem in the harness. Repair the connectors and/or wiring or replace the connectors and/or wiring between the battery and the ECM.STOP
Not OK - The battery voltage is incorrect and/or the battery fails the load test.Repair: The batteries or the alternator are causing the problem. Recharge the batteries or replace the batteries. Verify that the original condition is resolved.STOPTest Step 4. Check the Voltage from the Generator Set Control
Disconnect the generator and the engine harness connector J3/P3.
Remove wires P3-18 and P3-39 from the engine harness connector J3/P3.
Reconnect the generator and the engine harness connector J3/P3.
Turn the battery disconnect switch to the ON position.
Turn the engine control to the STOP mode.
Measure the voltage between P3-18 and P3-39 at the generator and engine harness connector J3/P3.
Turn the engine control to the OFF/RESET mode.
Turn the battery disconnect switch to the OFF position.
Replace all wires. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: The wire from the ECM to the connector J3/P3 and/or the connectors are damaged. Repair the connectors and/or wiring or replace the connectors and/or wiring.STOP
Not OK - The voltage is not 24 3 VDC. Proceed to Test Step 5.Test Step 5. Check the Voltage to the Generator Set Control
Remove wires J3-5 and J3-39 from the generator and engine harness connector J3/P3.
Turn the battery disconnect switch to the ON position.
Turn the engine control to the STOP mode.
Measure the voltage between J3-5 and J3-39 at the generator and engine harness connector J3/P3.
Turn the engine control switch to the OFF/RESET mode.
Turn the battery disconnect switch to the OFF position.
Replace all wires. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: There is a problem in the generator set control or in the harness wiring between the engine and the generator. Check the generator set control for diagnostic codes. Check the engine control for proper operation. Repair the connectors and/or wiring between the generator set control+ and the harness connector for the generator and engine J3/P3.STOP
Not OK - The voltage is not 24 3 VDC.Repair: Check the battery disconnect switch for proper operation. Ensure that the EMCPB is not tripped. Repair the connectors and/or wiring or replace the connectors and/or wiring between the battery and the engine connector J3/P3.STOPTest Step 6. Check the Voltage of the Sensor Power Supplies at the ECM Connector
Remove wires P1-18, P1-35, P1-04, and P1-05 from ECM connector P1. Install wire jumpers into the following sockets: P1-18, P1-35, P1-14 and P1-05.
Turn the battery disconnect switch to the ON position.
Turn the engine control to the STOP mode.
Measure the voltage from the analog sensor supply P1-18 to the analog sensor return P1-35 at the wire jumpers.
Measure the voltage from digital sensor supply P1-04 to the digital sensor return P1-05 at the wire jumpers.
Turn the engine control to the OFF/RESET mode.
Turn the battery disconnect switch to the OFF position.
Remove the wire jumpers and replace ECM connector J1/P1. Expected Result:The analog voltage supply is 5.0 0.2 VDC between P1-36 and P1-30. The digital voltage supply is 8.0 0.4 VDC between P1-35 and P1-29.Results:
OK - The sensor power supplies are functioning properly. The ECM is powered up. The problem is not in the electrical system. There may be a mechanical problem.Repair: Check the system for any diagnostic codes.STOP
Not OK - If the ECM is getting the correct voltage at the +Battery terminal, but the ECM does not supply the correct voltages to the sensors, replace the