12221-93101 Suzuki Crankshaft, Upper

Illustration 1 g01643973
Illustration 2 g01643993
(10) + 8 VDC (22) Solenoid ground (23) Rack solenoid (30) + 5 VDC (35) Analog return (40) Rack position
Table 1
Diagnostic Codes Table    
Code and Description    Flash Code    Conditions which Generate this Code    System Response    
23-02 Engine Power Excessive
    48
    The actual rack position is greater than the desired rack position. Excessive power is being generated by the engine.
    The code is logged.    
Factory passwords are required to clear this code.
23-05 Rack BTM current low
    43
    The actual rack position is not proportional to the desired rack position. There are no sensor supply voltage faults. The arm of the rack solenoid is not in the desired position.
    The code is logged.    
The ECM uses the engine speed to govern the engine. The rack sensor signal is ignored. The rack limit is set to
13.5 mm (0.53 inch).
23-06 Rack BTM current high
    43
    The actual rack position is not proportional to the desired rack position. There are no sensor supply voltage faults. The arm of the rack solenoid is not in the desired position.
    The code is logged.    
The ECM uses the engine speed to govern the engine. The rack sensor signal is ignored. The rack limit is set to
13.5 mm (0.53 inch). Test Step 1. Inspect the Electrical Connectors and the Wiring Harness
Remove electrical power from the ECM.
Thoroughly inspect the J6/P6 connector for the rack solenoid (BTM) and the J11/P11 connector for the rack position sensor. Inspect the ECM connector J14/P14. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.
Check the allen head screw on the ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points. Proceed to Test Step 2.
NOT OK - There is a problem with the connectors and/or the wiring.Repair: Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.Verify that the repair eliminates the problem.STOPTest Step 2. Remove the Rack Solenoid and Inspect the Rack Solenoid
Turn the engine control switch to the OFF position.
Remove the rack solenoid.
Make sure that the rack and the rack servo have free movement.
Inspect the arm of the rack solenoid for damage and signs of binding in the sleeve of the servo.Expected Result:The arm of the rack solenoid is not damaged or the arm of the rack solenoid does not show signs of binding.Results:
OK - The arm of the rack solenoid is not damaged or the arm of the rack solenoid does not show signs of binding. Proceed to Test Step 3.
NOT OK - The arm of the rack solenoid is damaged or the arm of the rack solenoid shows signs of binding.Repair: Repair the arm of the rack solenoid or replace the arm of the rack solenoid.STOPTest Step 3. Sweep Test for the Rack Solenoid
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the engine control switch to the ON position.
Activate the sweep test for the rack solenoid and observe the arm of the rack solenoid.Note: Some applications may have an auxiliary system that can interrupt power to the ECM. These systems may need to be temporarily bypassed in order to perform the sweep test.
Deactivate the sweep test.Expected Result:The arm of the rack solenoid moves smoothly in a clockwise direction. Once the arm moves slightly past the dot on the face plate, the arm moves back to the OFF position.Results:
OK - The arm of the rack solenoid moves smoothly in a clockwise direction. Once the arm moves slightly past the dot on the face plate, the arm moves back to the OFF position. The rack is functioning properly.STOP
NOT OK - The arm of the rack solenoid does not move smoothly in a clockwise direction. Once the arm moves slightly past the dot on the face plate, the arm does not move back to the OFF position. Proceed to Test Step 4.Test Step 4. Check the Resistance of the Rack Solenoid
Turn the engine control switch to the OFF position.
Disconnect the rack solenoid connector J6/P6.
Measure the resistance between pin (A) and pin (B) of the rack solenoid connector.Expected Result:The resistance is between 0.5 Ohms and 1.5 Ohms.Results:
OK - The resistance is between 0.5 Ohms and 1.5 Ohms. Proceed To Test Step 5.
NOT OK - The resistance is not between 0.5 Ohms and 1.5 Ohms.Repair: Replace the rack solenoid.STOPTest Step 5. Check the Harness for Shorts
Disconnect the ECM connector J14/P14.
Disconnect the rack solenoid connector J6/P6.
Measure the resistance between pin (A) and pin (B) of the J6 connector.
Measure the resistance between pin (A) and engine ground.
Measure the resistance between pin (B) and engine ground.Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 6.
NOT OK - The resistance is less than 20,000 Ohms.Repair: Repair the harness or replace the harness.STOPTest Step 6. Check Resistance through the Harness
Connect Deutsch socket terminals at each end to a 152 mm (6 inch) wire.
Connect the wire to pin (A) and pin (B) of connector J6.
Measure the resistance between pin (23) and