180759 Volvo.Penta Plug

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 low current in the circuit. The ECM can only detect this condition when the output driver is not activated.     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 ECM can only detect this condition when the output driver is activated.    The ECM controls the ether system in order to improve cold starting. The ECM determines if ether should be injected by monitoring the actual engine rpm and the engine temperature. The ether system is disabled if any engine shutdown is active.In auto mode, the ether system is enabled when engine coolant temperature is less than 0 °C (32 °F) and engine speed is between 35 rpm and 525 rpm. The ECM energizes the ether relay in six second cycles. The ether cycle will be three seconds ON and three seconds OFF. The ether will continue to cycle until engine coolant temperature is greater than 0 °C (32 °F) or until engine speed is greater than 525 rpm.The ether injection system can also be operated in manual mode. The ether injection system is switched into manual mode whenever the starting aid switch is depressed. Manual mode allows ether to be injected whenever the coolant temperature is less than 10 °C (50 °F) and engine rpm is greater than 35 rpm or less than 1200 rpm. The ether system will perform one cycle when the starting aid switch is depressed. The ether cycle will be three seconds ON and three seconds OFF.
Illustration 1 g01859535
Typical schematic
Illustration 2 g01518747
P1 ECM connector (P1-29) Digital return (P1-25) Starting aid switch (P1-40) Starting aid relay
Personal injury or death can result from using ether.Failure to follow these instructions could result in an explosion and/or fire and possible personal injury.When using starting fluid, follow the manufacturer's instructions carefully. Use ether sparingly and spray it only while cranking the engine. Also, do not store starting fluid containers in the cab.
The ether canister must be removed prior to activating this test.
Do not perform this procedure within 15 M (50 ft) of an open flame.
Do not allow the ether injection system to be on for more than two minutes. Damage to the ether solenoid may occur.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect J1/P1 ECM connector, J3/P3 machine connector, and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the following components for damage, corrosion, and incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Chassis groundExpected 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 - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Starting Aid Switch Status
Remove the ether canister from the ether solenoid.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
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 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 properly reading the signal from the starting aid switch. Proceed to Test Step 3.Test Step 3. Check the Resistance of the Relay
Illustration 3 g00817854
Connector for the ether relay
Turn the keyswitch to the OFF/RESET position.
Measure the resistance across terminal 86 (Digital Return) and terminal 87 (Solenoid Power).Expected Result:The resistance is between 250 Ohms and 500 Ohms.Results:
OK - Proceed to Test Step 4.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOPTest Step 4. Short the Switch Wires
Remove wire F720-GN (Starting Aid Switch) and wire 998-BR (Digital Return) from the starting aid switch.
Short wire F720-GN (Starting Aid Switch) to wire 998-BR (Digital Return).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 starting aid switch is not operating correctly.Repair: Replace the starting aid switch.Verify that the repair eliminates the problem.STOP
Not OK - The starting aid switch is operating correctly. Proceed to Test Step 5.Test Step 5. Short the Switch Inputs at the ECM
Turn the keyswitch to the OFF position and install a 7X-1715 Adapter Cable (40 Pin Breakout T) at ECM connector J1/P1.
Turn the keyswitch to the ON position.
Use a suitable piece of wire to short P1:25 (Starting Aid Switch) and P1:29 (Digital Return) at the breakout.