33820-95601 Suzuki STARTER SUB CABLE ASSEMBLY

Illustration 1 g00785725
Typical schematic of the ether system
Personal injury or death can result from using ether.Failure to follow these instructions could result in an explosion and/or fire and possible personal injury.When using starting fluid, follow the manufacturer's instructions carefully. Use ether sparingly and spray it only while cranking the engine. Also, do not store starting fluid containers in the cab.
The ether canister must be removed prior to activating this test.
Do not perform this procedure within 15 M (50 ft) of an open flame.
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 the diagnostic functional test 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 2.25 0.25 N m (20 2 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 for pinch points. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should not have corrosion, abrasion or 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 or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check for Diagnostics on the Caterpillar Electronic Technician (ET).
Remove the ether canister(s) from the ether solenoid(s).
Connect the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the keyswitch to the ON position.
Determine if CID-FMI 545-05, 545-06, 546-05 or 546-06 is active or logged.
Toggle the ether starting aid switch. Observe the parameter for the ether switch on the Cat ET. Expected Result:The parameter for the ether switch should display "ON" while the starting aid switch is toggled. The parameter for the ether switch should display "OFF" when the switch is released.Results:
OK - No active codes or logged codes are present. The ether injection system does not inject ether. Proceed to Test Step 3.
Active Code - Active diagnostics are displayed. Proceed to Test Step 4.
Logged Code - Logged diagnostics are displayed. Check for an intermittent short or for an open in the wiring or in the connectorsRepair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The starting aid switch is not functioning correctly. Proceed to Test Step 15.Test Step 3. Check the Ether Canisters.
Turn the circuit breaker for the battery to the OFF position.
Turn the keyswitch to the OFF position.
Remove the ether canister(s) from the ether solenoid(s). Determine if the canister contains any ether. Ether can not be injected if the canister is empty. Expected Result:The ether canister should not be empty.Results:
OK - The ether canister is not empty. Proceed to Test Step 4.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a full ether canister.STOPTest Step 4. Check the Voltage from the Ether Start Relay.
Turn the circuit breaker for the battery to the OFF position.
Turn the keyswitch to the OFF position.
Connect the Cat ET.
Turn the circuit breaker to the battery to the ON position.
Connect a voltmeter between wire 317-YL(Yellow) on terminal 87 of the ether start relay and ground.
Turn the keyswitch to the ON position.
Select the "Diagnostic Tests" on the Cat ET.
Select the "Override Parameters" screen on the Cat ET.
Activate the ether override and observe the voltmeter while ether injection is "ON". Disable the ether override. Do not allow the ether to be "ON" for more than two minutes. Damage to the solenoid may occur. Expected Result:During the first two seconds of injection, the voltage at the ether start relay should be 24 3 VDC. For the duration of injection, the voltage should decrease to 3 1 VDC.Results:
OK - During the first two seconds of injection, the voltage at the ether start relay is 24 3 VDC. For the duration of injection, the voltage decreases to 3 1 VDC. Proceed to Test Step 5.
Not OK - 24 VDC - During the first two seconds of injection, the voltage at the ether start relay is not 24 3 VDC. Proceed to Test Step 6.
Not OK - 3 VDC - For the duration of injection, the voltage did not decrease to 3 1 VDC. Proceed to Test Step 9.Test Step 5. Check the Voltage at the Ether Solenoids.
Turn the keyswitch to the OFF position.
Disconnect the ether solenoid connector at the solenoid.
Connect a voltmeter to pin 1 and to pin 2 of the ether solenoid connector.
Turn the keyswitch to the ON position.
Activate the ether override and observe the voltmeter while ether injection is on. Disable the ether override. This procedure must be performed on both solenoids if two solenoids are present. Do not allow the ether to be on for more than two minutes. Damage to the solenoid may occur.
Reconnect all connectors. Expected Result:During the first two seconds of injection, the voltage at the ether start relay should be 24 3 VDC. For the duration of injection, the voltage should decrease to 3 1 VDC.Results:
OK - During the first two seconds of injection, the voltage at the et