65700-95516 Suzuki CLIP

Illustration 1 g00687459
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector, J3/P3 machine connector, and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the following components for damage, corrosion, and incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Chassis groundExpected Result:All connectors, pins, and sockets should be completely inserted and coupled. The harness and wiring should be free of corrosion, abrasion, and pinch points. All connections and grounds should be tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Starting Aid Switch Status
Remove the ether canister from the ether solenoid.
Connect the Caterpillar Electronic Technician (Cat ET) to the service tool connector.
Turn the keyswitch to the ON position.
Press the starting aid switch to "MANUAL". Observe the "Starting Aid Switch Status" on Cat ET.Expected Result:When the starting aid switch is pressed, Cat ET should display the status of the starting aid switch as "ON".When the starting aid switch is not pressed, Cat ET should display the status of the starting aid switch as "OFF".Results:
OK - The starting aid switch is operating correctly. Proceed to Test Step 6.
Not OK - The ECM is not properly reading the signal from the starting aid switch. Proceed to Test Step 3.Test Step 3. Check the Resistance of the Relay
Illustration 2 g00673774
Connector for the ether relay
Turn the keyswitch to the OFF/RESET position.
Disconnect the wires from terminal 85 (Solenoid Return) and terminal 86 (Ether ON) of the ether relay.
Measure the resistance across terminal 85 (Solenoid Return) and terminal 86 (Ether ON) of the ether relay.
Reconnect the wires to the ether relay.Expected Result:The resistance should be between 250 Ohms and 500 Ohms.Results:
OK - Proceed to Test Step 4.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOPTest Step 4. Short the Switch Wires
Remove wire F721-GY (Starting Aid Switch) and wire 998-BR (Digital Return) from the starting aid switch.
Short wire F721-GY (Starting Aid Switch) to wire 998-BR (Digital Return).Expected Result:When the wires are shorted, Cat ET should display the status of the starting aid switch as "ON".When the wires are not shorted, Cat ET should display the status of the starting aid switch as "OFF".Results:
OK - The starting aid switch is not operating correctly.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem.STOP
Not OK - The starting aid switch is operating correctly. Proceed to Test Step 5.Test Step 5. Short the Switch Inputs at the ECM
Illustration 3 g00687965
J1/P1 breakout
Turn the keyswitch to the OFF position and install a 7X-1715 Adapter Cable (40 Pin Breakout T) at ECM connector J1/P1.
Turn the keyswitch to the ON position.
Use a suitable piece of wire to short P1:19 (Starting Aid Switch) and P1:29 (Digital Return) at the breakout.
Observe the results on the "Status" screen of Cat ET.Expected Result:When the wires are shorted, Cat ET should display the status of the starting aid switch as "ON".When the wires are not shorted, Cat ET should display the status of the starting aid switch as "OFF".Results:
OK - There is a problem in the wiring between the switch and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOP
Not OK - 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.Verify that the repair eliminates the problem.STOPTest Step 6. Check the Resistance of the Ether Solenoid
Disconnect the J37/P37 Ether Solenoid connector .
Measure the resistance between J37:1 (Solenoid Power) and J37:2 (Solenoid Return).Expected Result:Resistance should be less than 8 Ohms.Results: