32120-96J00 Suzuki COIL, BATTERY CHARGING

Table 1
Diagnostic Codes Table    
Code and Description     Conditions which Generate this Code     System Response    
E540(1) Low Engine Oil Refill Tank Level     The switch closes when no fluid is present.     The code is active.    The Electronic Control Module (ECM) may modify the operation of the engine in the event of a low oil level in the makeup oil tank for the oil renewal system. The ECM cannot determine if the oil level switch or associated components have failed.The low oil level switch signals the ECM if the oil level falls below a predetermined level in the makeup oil tank. The switch closes when the oil level is below a predetermined level. The ECM warns the operator to take action in order to prevent engine damage.The ECM adds a controlled amount of engine oil to the fuel by energizing the engine oil renewal solenoid. The engine oil is added to the fuel and burned during combustion. The need to drain the engine oil at a typical oil change interval is avoided.For further information, refer to Service Manual, RENR2223, "Oil Renewal System".
Illustration 1 g01417197
Schematic for the makeup oil level switch
Illustration 2 g01417199
P2 ECM connector (P2-33) 12 V supply (P2-54) Analog return
Illustration 3 g01417201
P1 ECM connector (P1-16) Makeup oil level
Illustration 4 g01159881
Sensor connector (A) 12 V sensor supply (B) Sensor return (C) Signal
Illustration 5 g01415758
Location of ECM connectorsTest Step 1. Check the Level of the Oil in the Makeup Oil Tank
Check the oil level in the makeup oil tank.Expected Result:The oil is at the correct level.Results:
OK - The oil level is correct. Proceed to Test Step 2.
Not OK - The oil level is low.Repair: Add oil to the makeup oil tank.STOPTest Step 2. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connector J1/P1 and the ECM connector J2/P2. Inspect the connector for the makeup tank's low oil level 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 connectors that are associated with the circuit.
Check the ECM connector's (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" 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 harness and wiring are OK. Proceed to Test Step 3.
Not OK - There is a problem in 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 3. Check the Status of the "Engine Oil Refill Tank Level" on Caterpillar Electronic Technician (ET)
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status of the "Engine Oil Refill Tank Level" on Cat ET.Expected Result:The status of the "Engine Oil Refill Tank Level" reads "OK".Results:
OK - The status of the "Engine Oil Refill Tank Level" reads "OK".Repair: The switch signal is correct. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect" for information on inspecting electrical connections.STOP
Not OK - The status of the "Engine Oil Refill Tank Level" reads "Low". The switch signal to the ECM is not correct. Proceed to Test Step 4.Test Step 4. Check the 12 Volt Supply Voltage at the Connector for the Makeup Tank's Low Oil Level Switch
Do not disconnect the connector for the makeup tank's low oil level switch.
Connect a multimeter between pin A and pin B on the switch side of the connector for the makeup tank's low oil level switch.
Measure the voltage between pin A and pin B of the connector.
Wiggle the harness while you monitor the voltage on the voltmeter. Perform the 45 N (10 lb) pull test on each wire in the circuit. Each terminal and each connector should easily withstand 45 N (10 lb) of tension and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.Expected Result:The supply voltage is approximately 12.0 0.5 VDC.Results:
OK - The supply voltage is approximately 12.0 0.5 VDC. Proceed to Test Step 5.
Not OK - The supply voltage is not approximately 12.0 0.5 VDC.Repair: There is an open or a short in the wiring or connectors between the switch and the ECM. Repair the wiring and connectors. Retest the circuit after the repair.STOPTest Step 5. Short the Wires at the Connector for the Makeup Tank's Low Oil Level Switch
Turn the keyswitch to the OFF position.
Disconnect the connector for the makeup tank's low oil level switch.
Fabricate a wire jumper that is long enough to create a test circuit at the connector for the makeup tank's low oil level switch. Use the jumper wire to create a short between terminal C (switch signal) and terminal B (return) at the connector.
Turn the keyswitch to the ON position.
Observe the status of the "Engine Oil Refill Tank Level" on Cat ET.
Remove the wire short.
Observe the status of the "Engine Oil Refill Tank Level" on Cat ET.
Turn the keyswitch to the OFF position.Expected Result:Cat ET indicates "LOW" when the wire short is installed. Cat ET indicates "OK" when the wire short is removed.Results:
OK - Cat ET indicates "LOW", when the wire short is in place. Cat ET indicates "OK", when the wire short is removed. Cat ET recognized the input from the switch.Repair: Temporarily replace the switch. Ve