09800-81840 Suzuki TOOL SET

Illustration 1 g01007618
Schematic for Lamp
Illustration 2 g01007619
P1 ECM connectorTest Step 1. Inspect Electrical Connectors and Wiring
Thoroughly inspect J1/P1 ECM connector, the J3/P3 machine connector, and the check engine lamp. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the check engine lamp:
Check the ECM connector (allen head screw) for the proper torque of 2.25 N m (20.0 lb in).
Check the harness and wiring for abrasion and for pinch points from the battery 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 or of pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - 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. Stop.Test Step 2. Check for Normal Operation of the Lamp
Monitor the check engine lamp.
Turn the keyswitch to the ON position.Note: The lamp will stay on if there is an active diagnostic code. If there is an active diagnostic code, connect the Caterpillar Electronic Technician (Cat ET) in order to read the active diagnostic code. Troubleshoot the problem.Expected Result:The lamp turns on for five seconds. Then, the lamp turns off.Results:
OK - The check engine lamp appears to operating correctly at this time. Stop.
Not OK - Proceed to Test Step 3.Test Step 3. Test the Lamp Circuit
Disconnect J1/P1 ECM connector.
Fabricate a jumper wire 100 mm (4 inch) long. Crimp a Deutsch pin to both ends of the wire.
Insert the jumper into P1:40 (Check Engine Lamp).
Connect the other side of the jumper wire to P1:4 (+Battery).
Turn the keyswitch to the ON position.
While the lamp is monitored, remove the jumper wire and insert the jumper wire. Expected Result:The check engine lamp turns on while the jumper wire is installed. The check engine lamp turns off when the jumper wire is removed.Results:
OK - The check engine lamp circuit is functioning properly. Proceed to Test Step 4.
Did not turn on - The lamp did not turn on. The lamp is probably burned out or there is a problem in the wiring from the cab to either the ECM or the -Battery connection. Repair the lamp circuit or send the vehicle to the OEM dealer for repairs.Repair: Check the lamp. Replace the lamp if the lamp is burned out.If the lamp is OK, check the wiring for open circuits.Repair the wiring or replace the wiring.Verify that the repair eliminates the problem. Stop.
On continuously - The circuit between the ECM and the lamp is shorted to a voltage source.Repair: Inspect the electrical wiring.Repair the wiring or replace the wiring.Verify that the repair eliminates the problem. Stop.Test Step 4. Check the ECM for Proper Operation of the Check Engine Lamp
Disconnect the J1/P1 ECM connector.
Insert a 7X-1715 Adapter Cable (Forty-Pin Breakout) and a 134-5195 Adapter Cable between the J1 and P1 ECM connectors.
Connect a voltage test lamp between terminal 40 (Check Engine Lamp) and terminal 5 (- Battery) of the breakout T.
While the voltage test lamp is monitored, turn the keyswitch to the ON position.Expected Result:The lamp turns on for five seconds. Then, the lamp turns off. The lamp will stay on if there is an active diagnostic code.Results:
OK - The ECM is operating correctly.Repair: If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect". Stop.
Not OK - There may be a problem with the ECM.Repair: Temporarily connect a test ECM.If the test ECM fixes the problem, reconnect the suspect ECM.If the problem returns, permanently replace the suspect ECM.Verify that the repair eliminates the problem. Stop.