F510841 Force WIRE, STARTER INTERLOCK SWITCH

Illustration 1 g01056924
Typical schematic
Illustration 2 g01091896
P1 connector for the Electronic Control Module (ECM)
(P1-21) Ether starting aid
(P1-22) Auto/manual switch Test Step 1. Inspect Electrical Connectors and Wiring
Turn the Engine Control Switch (ECS) to the OFF/RESET position.
Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors. 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 circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 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, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem with the electrical 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.Repair CompleteTest Step 2. Check for Active Diagnostic Codes
Turn the ECS to the OFF/RESET position.
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the ECS to the COOLDOWN/STOP position.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to an open circuit diagnostic code 05 or a short circuit diagnostic code 06.
Determine if 545-05 or 545-06 diagnostic code is active. Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active. The ether injection system does not inject ether. Proceed to Test Step 3.
Not OK - Active diagnostics are displayed. Proceed to Test Step 4.Test Step 3. Check the Ether Canisters
Turn the ECS to the OFF/RESET position.
Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Expected Result:The ether canister is not empty.Results:
OK - The ether canister is not empty. Remove the ether canister for the ether solenoid for the remainder of this test. Proceed to Test Step 4.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a full ether canister. Retry the system.Repair CompleteTest Step 4. Check the Voltage from the Ether Start Relay
Turn the ECS to the OFF/RESET position.
Remove the ether canister from the ether solenoid.
Connect Cat ET to the service tool connector.
Disconnect the wire to the ether solenoid from terminal 87 of the ether relay.
Connect a voltmeter between terminal 87 of the ether start relay and ground.
Turn the ECS to the COOLDOWN/STOP position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and observe the voltmeter while ether injection is activated. Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.
Measure the voltage at the ether start relay with the voltmeter.
Deactivate the ether override.
Reconnect the wire to terminal 87 of the ether relay. 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. Proceed to Test Step 5.
Not OK - 24 VDC - The voltage at the ether start relay is not 24 3 VDC. Proceed to Test Step 6.Test Step 5. Check the Voltage at the Ether Solenoids
Turn the ECS to the OFF/RESET position.
Disconnect the ether solenoid connector at the solenoid.
Connect a voltmeter to terminal 1 and terminal 2 of the ether solenoid connector.
Turn the ECS to the COOLDOWN/STOP position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and observe the voltmeter while ether injection is activated. Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.
Measure the voltage at the ether solenoid connector with the voltmeter.
Deactivate the ether override.
Turn the ECS to the OFF/RESET position.
Reconnect all connectors. Expected Result:The voltage at the ether solenoid is 24 3 VDC.Results:
OK - The voltage at the ether solenoid is 24 3 VDC during the first two seconds of injection.Repair: If ether is not being injected, replace the ether solenoid. Verify that the problem is no longer present.Repair Complete
Not OK - The voltage at the ether solenoid is not 24 3 VDC.Repair: Inspect the wiring and connectors between the ether start relay and the connectors at the ether solenoids. Repair the connectors or wiring and/or replace the connectors or wiring.Repair CompleteTest Step 6. Check the Voltage at the Coil of the Ether Start Relay
Turn the ECS to the OFF/RESET position.
Disconnect the wire to terminal 86 of the ether relay.
Connect a voltmeter between the wire that was removed from terminal 86 of the ether relay and engine ground.
Turn the ECS to the COOLDOWN/STOP position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and observe the voltmeter while ether injection is activated. Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.
Deactivate the ether override.
Reconnect the wire to terminal 86 of the ether relay. Expected Result:The voltage measures 24 3 VDC.Results:
OK - The voltage was 24 3 VDC. Proceed to Test Step 7.
Not OK - The voltage was not 24 3 VDC. Proceed to Test Step 8.Test Step 7. Check the Voltage to the Normally Open Contacts of the Ether Start Relay
Turn the ECS to the COOLDOWN/STOP position.
Measure the voltage between terminal 30 of the ether start relay and the −Battery. Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: Verify that the wire from terminal 85 of the ether start relay has continuity to the −Battery. If the wire is okay, replace the ether start relay. Verify that