0318922 JOHNSON LEAF

Table 1
Diagnostic Codes Table    
Description     Conditions which Generate this Code     System Response    
546-5 Ether Hold Relay open/short to ground     The Electronic Control Module (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.A 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 g02568842
Typical schematic
Illustration 2 g01444508
Location of the ECM connectors (1) J2/P2 ECM connectors (2) J1/P1 ECM connectors
Illustration 3 g01147914
P1 ECM connector (P1-5) Digital return (P1-20) Ether start aid switch
Illustration 4 g01147915
(P2-10) Ether current level relayTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors for 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 connector 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 the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in 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 coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Ether Canisters
Turn the keyswitch to the OFF position.
Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Ether cannot 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 3.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a full ether canister. Verify that the system is operating correctly.STOPTest Step 3. Check for Active Diagnostic CodesNote: The ether canister must be removed prior to activating this test.
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The diagnostic override will activate for 10 seconds.
Monitor the active diagnostic code screen on Cat ET. 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 a 05 or 06 diagnostic code.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A 06 diagnostic code is active at this time. Proceed to Test Step 4.
Not OK - A 05 diagnostic code is active at this time. Proceed to Test Step 5.Test Step 4. Create an Open at the Connector for the Ether Solenoid
Turn the keyswitch to the OFF position.
Disconnect the connectors for the ether solenoids.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The diagnostic override will activate for 10 seconds.Note: Monitor the "Active Diagnostic Codes" screen on Cat ET.
Check for a 05 diagnostic code for the ether solenoid.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Turn the keyswitch to the OFF position.Expected Result:A 05 diagnostic code is now active for the ether solenoid.Results:
OK - A 06 diagnostic code was active before disconnecting the connector. A 05 diagnostic code became active after disconnecting the connector.Repair: Temporarily connect a new ether solenoid to the harness, but do not install the new ether solenoid. Verify that there are no active diagnostic codes for the solenoid. If there are no active diagnostic codes for the solenoid, permanently install the new solenoid. Clear any logged diagnostic codes.STOP
Not OK - A 06 diagnostic code is active. There is a short between the solenoid harness connector and the ECM. Leave the solenoid connector disconnected. Proceed to Test Step 6.Test Step 5. Create a Short at the Connector for the Ether Solenoid
Turn the keyswitch to the OFF position.
Install a jumper wire between terminal 1 (ether solenoid) and terminal 2 (engine ground) of the solenoid connector. Connect the jumper on the harness side of the connector.
Turn the keyswitch to the ON position.Note: Monitor the "Active Diagnostic Codes" screen on Cat ET after installing the jumper wire.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The diagnostic override will activate for 10 seconds.Note: Monitor the "Active Diagnostic Codes