16789 78 Force LINE-FUEL (9') CUT AS REQ'D

Table 1
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
545-5 Ether Start Relay open/short to +batt The Electronic Control Module (ECM) detects an open circuit or a short to the +Battery. The ECM can only detect this condition when the ether start relay is not energized. The code is logged.
Ether injection is disabled.
545-6 Ether Start Relay short to ground The ECM detects a short circuit to ground at the output to the ether start relay. The ECM can only detect this condition when the ether start relay is energized.
546-5 Ether Hold Relay open/short to ground The ECM detects a short circuit to ground at the output to the ether hold relay. The ECM can only detect this condition when the ether hold relay is not energized. The code is logged.
Ether injection is disabled.
546-6 Ether Hold Relay short to +batt The ECM detects an open circuit and/or a short to the +Battery at the output to the ether hold relay. The ECM can only detect this condition when the ether hold relay is energized. The ether injection system will improve cold weather starting of the engine. The ECM controls the ether injection system. The ECM energizes the ether solenoid in a continuous flow for a predetermined amount of time that is based on the coolant temperature. The ether injection system is disabled if there is an active engine shutdown.The ether injection system can also be operated in manual mode. The ether system is switched into manual mode whenever the starting aid switch is depressed.An test on Caterpillar Electronic Technician (ET) allows the technician to activate the ether system for a ten second period. The test is functional when the engine speed is 0 rpm. The test is accessed by selecting the following menus on Cat ET:
"Diagnostics"
"Diagnostic Tests"
"Override Parameters"
Illustration 1 g01448106
Typical schematic
Illustration 2 g01444508
Location of the ECM connectors
(1) J2/P2 ECM connectors
(2) J1/P1 ECM connectors
Illustration 3 g01443872
P1 ECM connector
(P1-20) Ether aid switch
Illustration 4 g01443875
P2 ECM connector
(P2-10) Ether hold in +Battery
(P2-20) Ether hold in −Battery
(P2-66) Digital return
Illustration 5 g01443550
Generator connector
(Terminal 9) Starting aid switch
(Terminal 15) Digital return Test Step 1. Inspect Electrical Connectors and Wiring
Turn the Engine Control Switch (ECS) to the OFF position. Turn the main 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. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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 harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with 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 Diagnostic Codes on Cat ET
Connect Cat ET.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Activate the ether override. Monitor the active diagnostic code screen on Cat ET. Check the ether system for an active -5 diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic code to become active.
Activate the ether override. Monitor the active diagnostic code screen on Cat ET. Check the ether system for an active -6 diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic code to become active.Expected Result:The status for the ether switch displays "ON" while the starting aid switch is toggled. The status for the ether switch displays "OFF" when the switch is released. No active codes are present for the ether system.Results:
OK - No active codes are present. If the ether system was not injecting ether proceed to Test Step 3.
Not OK - Active codes are present for the ether system. Proceed to Test Step 4.Test Step 3. Check the Ether Canister
Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Ether can not be injected if the canister is empty. Expected Result:The ether canister is not empty.Results:
OK - The ether canister is not empty. Proceed to Test Step 14.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a new ether canister. Verify that the problem is no longer present.STOPTest Step 4. Check the Voltage from the Ether Start Relay
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.
Remove the ether canister(s).
Connect a voltmeter between terminal 30 of the ether start relay and ground.
Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.
Activate the ether override and observe the voltmeter while the ether override is activated.
Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position. Expected Result:The voltage at the ether start relay is 24 3 VDC.Results:
OK - The voltage at the ether start relay is 24 3 VDC during the first two seconds of injection. Proceed to Test Step 5.
Not OK - 24 VDC - The voltage at the ether start relay is not 24 3 VDC during the first two seconds of injection. Proceed to Test Step 6.
Not OK - 3VDC - The voltage did not decrease to 3 1 VDC for the remainder of the injection duration. Proceed to Test Step 9.Test Step 5. Check the Voltage at the Ether