99011-92D52-03A Suzuki OWNERS MANUAL

Illustration 1 g01250264
Schematic for the ether injection system
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 the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 2 g01144470
Left side engine view (typical example)
(1) J1/P1 ECM connectors
Illustration 3 g01250265
Engine compartment (left side)
(2) Ether injection solenoid
Thoroughly inspect ECM connectors (1) and the connectors for solenoid (2). Also inspect the circuit from the ECM connector to the ether injection solenoid. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 4 g01250273
Terminal locations at the P1 ECM connector for the ether injection solenoid
(P1-10) Ether injection solenoid
(P1-18) Digital return
Illustration 5 g01218763
Terminal locations at the harness connector for the ether injection solenoid
(Terminal 1) Ether injection solenoid
(Terminal 2) Solenoid return
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 torque of the allen head screws for the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the ether injection solenoid to the ECM. 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 the wiring appear to be OK. Proceed to Test Step 2.
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 2. Check for Active Diagnostic CodesNote: The ether canister must be removed prior to activating this test.
Turn the battery disconnect switch to the ON position.
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The diagnostic override will activate for ten seconds.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to a low current diagnostic code 05 or a high current diagnostic code 06. Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. If an intermittent electrical problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A high current diagnostic code (06) is active at this time. Proceed to Test Step 3.
Not OK - A low current diagnostic code (05) is active at this time. Proceed to Test Step 4.Test Step 3. Create an Open Circuit at the Connector for the Ether Solenoid and Check for Active Codes
Turn the keyswitch to the OFF position.
Disconnect the connector for the ether solenoid.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The diagnostic override will activate for ten seconds. Note: Monitor the "Active Diagnostic Codes" screen on Cat ET.
Check for an active low current diagnostic code (05) for the ether solenoid. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Turn the keyswitch to the OFF position. Expected Result:A low current diagnostic code 05 is now active for the ether solenoid.Results:
OK - A high current diagnostic code (06) was active before disconnecting the connector. A low current diagnostic code (05) became active after disconnecting the connector.Repair: Temporarily connect a new ether solenoid to the harness, but do not install the new ether solenoid. Verify that there are no active diagnostic codes for the solenoid. If there are no active diagnostic codes for the solenoid, permanently install the new solenoid. Clear any logged diagnostic codes.STOP
Not OK - There is a high current between the solenoid harness connector and the ECM. Leave the solenoid connector disconnected. Proceed to Test Step 5.Test Step 4. Create a Short Circuit at the Connector for the Ether Solenoid and Check for Active Codes
Turn the keyswitch to the OFF position.
Install a jumper wire between terminal 1 (ether solenoid) and terminal 2 (digital return) of the solenoid connector. Connect the jumper on the harness side of the co