38100-92J02 Suzuki MOTOR ASSY, PTT

Illustration 1 g01055154
Typical schematic
Illustration 2 g01058341
P1 ECM connector
(P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery
(P1-63) −Battery
(P1-65) −Battery
(P1-70) Keyswitch Test Step 1. Inspect Electrical Connectors and Wiring
Turn the engine control switch (ECS) to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit. 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 (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 sensors back to the ECM. 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 - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.Repair CompleteTest Step 2. Check the Voltage to the ECM
Remove ECM connector J1/P1.
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage between P1-48 and P1-61.
Measure the voltage between P1-52 and P1-63.
Measure the voltage between P1-53 and P1-65.
Measure the voltage between P1-70 and P1-65.
Turn the ECS to the OFF/RESET position.
Turn the battery disconnect switch to the OFF position.
Reconnect ECM connector J1/P1. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. The ECM is receiving the correct voltage. Proceed to Test Step 6.
Not OK - The voltage is not 24 3 VDC. The voltage is incorrect. The battery or the alternator may be causing the problem. Proceed to Test Step 3.Test Step 3. Check the Battery Voltage
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 batteries pass the load test.Results:
OK - The batteries pass the load test. Proceed to Test Step 4.
Not OK - 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. Refer to Testing and Adjusting, "Electrical System".Repair CompleteTest Step 4. Check the Voltage from the Generator Set Control (GSC)
Turn the battery disconnect switch to the ON position.
Turn the ECS to the STOP position.
Measure the voltage at RM1 of the GSC relay.
Turn the ECS to the OFF/RESET position. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC at RM1 of the GSC relay. Proceed to Test Step 5.
Not OK - The voltage is not 24 3 VDC at RM1 of the GSC relay.Repair: Verify that 24 3 VDC is present on terminal 6 of the ECS.
If 24 3 VDC is present on terminal 6 of the ECS, verify that 24 3 VDC is present on terminal 10 of the ECS.
If 24 3 VDC is present on terminal 10 of the ECS, repair the wire between terminal 10 of the ECS and RM1 of the GSC relay. Refer to Illustration 1.
If 24 3 VDC is not present on terminal 10 of the ECS, replace the ECS.
If 24 3 VDC is not present on terminal 6 of the ECS, repair the wire between terminal 6 of the ECS and the +Battery. STOPTest Step 5. Check the Voltage to the Start Relay
Turn the ECS to the STOP position.
Measure the voltage between terminal 86 of the start relay and engine ground.
Turn the ECS to the OFF/RESET position. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC on terminal 86 of the start relay.Repair: Check the remainder of the circuit that provides the +Battery inputs to the ECM.
Verify that 24 3 VDC is present on terminal 30 of the start relay.
If 24 3 VDC is not present on terminal 30 of the start relay, repair the wiring and/or the "CB3" circuit breaker between terminal 30 and the +Battery post of the battery.
If 24 3 VDC is present on terminal 30 of the start relay, measure the voltage between terminal 87 of the start relay and engine ground.
If 24 3 VDC is present on terminal 87 of the start relay, repair the wire between terminal 87 of the start relay, and the ECM connector P1.
If 24 3 VDC is present on terminal 30 and terminal 86 of the start relay but 24 3 VDC is not present on terminal 87 of the start relay, verify that the wire between terminal 85 of the start relay and the negative battery terminal has continuity.
If the wire between terminal 85 of the start relay and the negative battery has continuity, replace the start relay. Repair Complete
OK - The voltage is 24 3 VDC on terminal 86 of the start relay.Repair: Check the remainder of the circuit that provides the +Battery input to the keyswitch P1-70.
Check for 24 3 VDC on P1-70 of ECM connector P1.
If 24 3 VDC is not present on P1-70, repair the wire between socket 7 of the engine harness and P1-70. STOP
Not OK - The voltage is not 24 3 VDC on terminal 86 of the start relay.Repair: Determine the reason that voltage is not present at the start relay.
Verify that 24 3 VDC is present on terminal RM39 of the GSC relay.
If voltage is present on terminal RM39 of the GSC relay, repair the wire between terminal 86 of the start relay and terminal RM39 of the GSC relay.
If 24 3 VDC is not present on terminal RM39 of the GSC relay, verify that no voltage is present on terminal 32 of the GSC harness connector.
If no voltage is present on terminal 32 of the GSC