42990A 9 Mercury DIAPHRAGM KIT

Table 1
Diagnostic Codes Table    
Code and Description     Conditions which Generate this Code     System Response    
2417-5 Ether Injection Control Solenoid current below normal     The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery in the circuit for the ether solenoid.     The code is logged.    
2417-6 Ether Injection Control Solenoid current above normal     The ECM detects a short circuit to ground in the circuit for the ether solenoid.    The ether injection system improves cold weather starting of the engine. The ECM has full control of the ether injection system. The ECM utilizes information from control maps and engine sensors in order to calculate the flow demand for the ether system during engine starting.The ether injection system is disabled if there is an active engine shutdown.A feature on Caterpillar Electronic Technician (ET) allows the technician to manually override the ether solenoid in order to diagnose problems with the system. The override feature remains functional while the engine speed is zero rpm. Access the test via the "Override Parameters" screen on Cat ET.
Illustration 1 g01419023
Schematic for the ether injection system
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01415758
Location of ECM connectors
Thoroughly inspect the J1/P1 ECM connectors. Inspect all of the other connectors that are in the circuit for the ether solenoid. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01419024
Terminal locations at the P1 ECM connector for the ether injection solenoid (P1-10) Ether injection solenoid (P1-18) Digital return
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 allen head screw on each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
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 are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring appear to be 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 completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check for Active Diagnostic Codes
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the "Active Diagnostic Code" screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Select diagnostic tests from Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override.
Monitor the "Active Diagnostic Code" screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Disable the ether override.
Determine if the problem is related to an open circuit diagnostic code -5 or a short circuit diagnostic code -6.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 inspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A short circuit diagnostic code -6 is active at this time. Proceed to Test Step 3.
Not OK - An open circuit diagnostic code -5 is active at this time. Proceed to Test Step 4.Test Step 3. Disconnect the Connector for the Ether Solenoid in Order to Create an Open Circuit
Turn the keyswitch to the OFF position.
Disconnect the connector for the ether solenoid.
Turn the keyswitch to the ON position.
Monitor the "Active Diagnostic Code" screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Select diagnostic tests from Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override.
Monitor the "Active Diagnostic Code" screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Disable the ether override.Expected Result:An open circuit diagnostic code -5 is now active for the ether solenoid.Results:
OK - A short circuit diagnostic code -6 was active before disconnecting the connector. An open circuit diagnostic code -5 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 ether solenoid. If there are no active diagnostic codes for the ether solenoid, permanently install the new ether solenoid. Clear any logged diagnostic codes.STOP
Not OK - A short circuit diagnostic code -6 remains active when the connector for the ether solenoid is disconnected. There is a short circuit between the harness connector for the ether solenoid and the ECM. Proceed to Test Step 5.Test Step 4. Create a Short at the Connector for the Ether Solenoid
Turn the keyswitch to the OFF position.
Fabricate a jumper wire that is long enough to create a short between the terminals of the connector for the ether solenoid. Crimp connector pins to each end of the jumper wire.
Disconnect the connector for th