GEAR (29 TEETH) 2S3804 - Caterpillar

Before you test the ether injection system, remove the ether canister from the system. Use this procedure to troubleshoot any suspect problems with the ether injection system.
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Schematic of the ether injection system
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Engine view (typical example)
(1) J1/P1 ECM connectors
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Engine view (typical example)
(2) P61 customer connector
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Ether starting aid group (typical example)
(3) Ether injection solenoid
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P1 terminals for the ether injection system
(P1-10) Ether injection solenoid
(P1-22) Override switch
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P61 terminals for the ether injection system
(22) Ether injection solenoid
(38) Override switch
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Terminal locations at the harness connector for the ether solenoid
(1) Ether injection solenoid
(2) Chassis ground
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Remove electrical power from the ECM.
B. Thoroughly inspect connectors (1) and (2). Also, thoroughly inspect the connectors for solenoid (3). Refer to Troubleshooting, "Electrical Connectors - Inspect".
C. 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.
D. Check the allen head screw on each ECM connector for the proper torque. Also check the allen head screw on the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
E. Check the harness and the wiring for abrasion and for pinch points from the ether injection solenoid to the ECM.
Electrical Connectors and Wiring
Results: The connectors and wiring appear to be OK. Proceed to Test Step 2.
Results: The connectors and/or wiring are not OK.
Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. Verify that the problem is resolved.
STOP
2. Check the Ether Canister for Starting Fluid
A. Remove electrical power from the ECM.
B. Remove the ether canister from the ether valve. Determine if the canister contains fluid.
Starting Fluid
Results: The ether canister is not empty. Do not install the ether canister. Proceed to Test Step 3.
Results: The ether canister is empty.
Repair: Replace the empty ether canister with a full ether canister. Verify that the original problem is resolved.
STOP
3. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Restore electrical power to the engine ECM.
C. Proceed to the "Diagnostic Overrides" screen on Cat ET.
D. Activate the ether injection system. The system will activate for10 seconds.
E. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
F. Look for a 05 diagnostic code or a 06 diagnostic code.
G. Remove electrical power from the engine ECM.
Codes
Results: There are no active codes.
Repair: The problem seems to be resolved. The problem may have been caused by a poor electrical connection. Carefully reinspect the connectors and the wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".
STOP
Results: A 05 code is active at this time. The ECM is detecting a low current condition in the circuit. Proceed to Test Step 5.
Results: A 06 code is active at this time. The ECM is detecting excessive current in the circuit. Proceed to Test Step 4.
4. Create an Open at the Harness Connector for the Ether Injection Solenoid
A. Disconnect the harness connector for the