12100-986A0-025 Suzuki PISTON/RING SET (OS:0.25)

Illustration 1 g00815521
Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the keyswitch to the OFF position.
Disconnect the main power.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
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 ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors and/or wiring or replace the connectors or wiring.STOPTest Step 2. Check the Status of the User Defined Shutdown on Caterpillar Electronic Technician (ET).
Connect Cat ET to the cab service tool connector J42. Start the Cat ET.
Turn the keyswitch to the ON position. The engine should be off.
Observe the status for the user defined shutdown on Cat ET.Expected Result:The status should read "OFF".Results:
OK - The status reads "OFF". The status is correct. Proceed to test step 3.
Not OK - The status does not read "OFF". The status is incorrect. Proceed to test step 4.Test Step 3. Create a Short at the Connector for the User Defined Shutdown.
Turn the keyswitch to the OFF position.
Use a wire with a socket terminal at one end to short the wire F722-OR at the connector for the user defined shutdown to the chassis ground.
Turn the keyswitch to the ON position. The engine should be off.Expected Result:Cat ET should indicate "User Shutdown ON" when the wire F722-OR is shorted to chassis ground.Results:
OK - The Cat ET screen indicates the "User Shutdown ON" when the wire F722-OR is shorted to chassis ground. The Cat ET screen indicates the correct status. The shutdown feature is working properly.Repair: There may be an intermittent problem. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The Cat ET screen does not indicate "User Shutdown ON" when the wire F722-OR is shorted to chassis ground. The Cat ET screen does not show the correct status. Proceed to test step 5.Test Step 4. Check the Harness for a Short Circuit.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Measure the resistance at the ECM connector between J1-13 and the chassis ground.Expected Result:The resistance should be 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. There is a short circuit in the harness or a User Defined Device is activating the shutdown feature.Repair: Repair the connectors and/or wiring or replace the connectors or wiring.STOPTest Step 5. Check the Harness for an Open Circuit.
Turn the keyswitch to the OFF/RESET position.
Use a wire with a socket terminal at one end to short the wire F722-OR at the connector for the user defined shutdown to the chassis ground.
Disconnect the ECM connector J1/P1.
Measure the resistance at the ECM connector between P1-13 and chassis ground.
Remove the wire short.Expected Result:The resistance should be less than 10 Ohms.Results:
OK - The resistance is less than 10 Ohms. The resistance is within acceptable limits. Proceed to test step 6.
Not OK - The resistance is greater than 10 Ohms. There is an open circuit in the harness.Repair: Repair the connectors and/or wiring or replace the connectors or wiring.STOPTest Step 6. Short the Wire at the ECM.
Remove the wire from the ECM connector at P1-13.
Insert a wire with a socket terminal at one end into the ECM connector atP1-13.
Reconnect ECM connector J1/P1.
Turn the keyswitch to the ON position. The engine should be off.
Momentarily short the wire at P1-13 to the chassis ground.Expected Result:Cat ET should indicate "User Shutdown ON" with the wire short in place. Cat ET should indicate "User Shutdown OFF" when the wire short is removed.Results:
OK - The Cat ET screen indicates "User Shutdown ON" with the wire short in place. The Cat ET screen indicates "User Shutdown OFF" when the wire short is removed. The Cat ET screen indicates the correct status. The feature is working properly.STOP
Not OK - The Cat ET screen does not indicate "User Shutdown ON" with the wire short in place. The Cat ET screen does not indicate "User Shutdown OFF" when the wire short is removed. The Cat ET screen does not indicate the correct status.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOP