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Table 1
Diagnostic Codes Table    
Code and Description     Conditions which Generate this Code     System Response    
545-5 Ether Start Relay open/short to +batt     The Electronic Control Module (ECM) detects low current in the circuit.     The code is logged.
Ether injection is disabled.    
545-6 Ether Start Relay short to ground     The ECM detects excessive current flow in the circuit.    The ether injection system is used to improve the cold weather starting capability of the engine. The ECM controls the ether injection system. The ether injection system has two operating modes. The ether injection system can operate in automatic mode and in manual mode.In the automatic mode, the ECM energizes the relay for the ether in cycles of six seconds. The ether is turned ON for three seconds. The ether is then turned OFF for three seconds.In the automatic mode, the ether injection system is enabled when all of the following conditions occur:
"Ether" is programmed to "Enabled" in the configuration screen.
Engine oil temperature is less than 0 °C (32 °F).
Engine speed is below 500 rpm.Manual mode is activated by pressing the starting aid switch. In the manual mode, a single shot of ether is injected when the ether switch is actuated. The quantity of ether that is injected is controlled by the ECM. In the manual mode, the ether injection system is enabled when all of the following conditions are satisfied:
The starting aid switch is placed in the MANUAL position.
Engine speed is less than 1200 rpm.
Engine oil temperature is less than 10 °C (50 °F).
Illustration 1 g01837273
Schematic for the ether 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.
Test Step 1. Inspect Electrical Connectors and Wiring
Remove electrical power from the ECM.
Illustration 2 g01139425
ECM (1) J1/P1 connectors (2) J2/P2 connectors
Thoroughly inspect connectors (1) and (2). Thoroughly inspect the circuit that is associated with the starting aid. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01393998
P1 ECM connector (P1-25) Starting aid switch (P1-29) Return (P1-40) Ether start valve
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the ether injection system.
Check the allen head screw on each ECM connector 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 from the ether injection solenoid to the ECM. Verify that all connections and grounds are tight and free of corrosion.Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - The connectors and wiring appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Starting Aid Switch Status
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Restore electrical power to the ECM.
Press the starting aid switch to "Manual". Observe the "Starting Aid Switch Status" on Cat ET.Expected Result:When the starting aid switch is pressed, Cat ET displays the status of the starting aid switch as "On".When the starting aid switch is not pressed, Cat ET ET displays the status of the starting aid switch as "Off".Results:
OK - The starting aid switch is operating correctly. Proceed to Test Step 6.
Not OK - The ECM is not reading the input from the starting aid switch. Proceed to Test Step 3.Test Step 3. Short the Switch Wires
Remove electrical power from the ECM.
Remove the wires from the starting aid switch.
Restore electrical power to the ECM.
Create a short with the wires from the starting aid switch.
Return the wiring to the original configuration.Expected Result:When the wires are shorted, Cat ET displays the status of the starting aid switch as "On".When the wires are not shorted, Cat ET displays the status of the starting aid switch as "Off".Results:
OK - The ECM is receiving the correct switch input. There is a problem with the switch.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem.STOP
Not OK - The ECM is not receiving the correct switch input. Proceed to Test Step 4.Test Step 4. Short the Switch Inputs at the ECM
Remove electrical power from the ECM.
Disconnect the J1/P1 ECM connector.
Fabricate two jumper wires that are long enough to create a short between the two terminal of the ECM connector. Crimp connector sockets to one end of each of the jumper wires.
Remove the wire from terminal location P1-25 (starting aid switch) at the ECM connector. Install one of the jumper wires into this terminal location.
Remove the wire from terminal location P1-29 (return) at the ECM connector. Install one of the jumper wires into this terminal location.
Connect the J1/P1 ECM connector.
Short the jumper wires in terminals P1-25 (starting aid switch) and P1-29 (return).
Restore electrical power to the ECM.
Observe the results on the "Status" screen of Cat ET.
Remove electrical power from the ECM.
Remove the jumper wires.Expected Result:When the wires are shorted, Cat ET displays the status of the starting aid switch as "On".When the wires are not shorted, Cat ET displays the status of the starting aid switch as "Off".Results:
OK - The ECM is reading the switch input properly. There may be a problem in the wiring between the switch and the ECM. Proceed to Test Step 5.
Not OK - The ECM is not reading the switch input properly.Repair: Rep