837560 Volvo.Penta Inlet manifold

Table 1
Diagnostic Codes Table
Code 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 and/or a short to the +Battery at the output to the ether start relay. 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 has been powered for at least two seconds. 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 g01382631
Typical schematic
Illustration 2 g01382637
P1 ECM connector
(P1-20) Manual ether switch
Illustration 3 g01382639
P2 ECM connector
(P2-10) Ether solenoid +
(P2-20) Ether solenoid -
Illustration 4 g01382634
Customer connector
(Terminal 62) Manual ether switch
Illustration 5 g01234146
Location of ECM connectors
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND WIRING
Turn the main disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test 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 the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the customer connector (allen head screw) for the proper torque. Refer to the diagnostic functional test 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 completely coupled and/or inserted. The harness and wiringare free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. CHECK FOR ACTIVE DIAGNOSTIC CODES
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the main disconnect switch to the ON position.
Monitor the active diagnostic code screen on Cat ET. Check the ether system for an active diagnostic code. Note: Wait at least 30 seconds in order for any diagnostic codes to become active.
Activate the override for the ether system. Monitor the active diagnostic code screen on Cat ET. Check the ether system for an active diagnostic code. Note: Wait at least 30 seconds in order for the diagnostic code to become active.
Deactivate the override for the ether system. Expected Result:No active codes or logged codes are present.Results:
OK - No active codes or logged codes are present. The ether injection system does not inject ether.Repair: Remove the ether canister(s) from the ether solenoid(s). Determine if the ether canister(s) contains any ether. If the ether canisters are empty, replace the empty ether canister with a full ether canister. Retry the system.If the ether canisters are not empty, proceed to Test Step 3.
Active Code - Active Diagnostics are displayed. Proceed to Test Step 3.
Logged Code - Logged Diagnostics are displayed. Check for an intermittent short or for an open in the wiring or in the connectorsRepair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 3. CHECK THE VOLTAGE AT THE ETHER SOLENOIDSNote: This test step must be performed for each of the ether solenoids in the circuit.
Turn the main disconnect switch to the OFF position.
Disconnect the ether solenoid connectors at the solenoids.
Connect a voltmeter between pin 1 and pin 2 of the ether solenoid connector.
Turn the main disconnect switch to the ON position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and measure the voltage at the solenoid connector while ether injection is ON.
Deactivate the ether override.
Turn the main disconnect switch to the OFF position.
Reconnect all connectors. Expected Result:The voltage at the ether solenoid is 24 3 VDC during injection.Results:
OK - The voltage at the ether solenoid is 24 3 VDC during injection.Repair: If ether is not being injected, temporarily replace the ether solenoid. If the problem is no longer present, reinstall the old ether solenoid. If the problem returns, replace the ether solenoid.STOP
Not OK - 24 VDC - The voltage at the ether solenoid is not 24 3 VDC during injection. Proceed to Test Step 4.Test Step 4. CHECK THE VOLTAGE TO THE ETHER SOLENOIDS FROM THE ECM
Fabricate two jumper wires that can be used to replace the wires in the ECM connector for the ether solenoid. Crimp a connector socket to one end of the jumper wires.
Disconnect the J2/P2 ECM connector.
Remove the wire 382-RD(Red) from the P2-10 ECM connector.
Install the jumper wire into the terminal P2-10 of the ECM connector.
Remove the wire 383-BK(Black) from the P2-20 ECM connector.
Install the jumper wire into the terminal P2-20 of the ECM connector.
Connect the ECM connectors.
Turn the main disconnect switch to the ON position.
Select the "Diagnostic Tests" on Cat ET.
Select the "Override Parameters" screen on Cat ET.
Activate the ether override and measure the vo