KIT-SEAL 2773395 - Caterpillar

System Operation Description:Before testing of the ether injection system, remove the ether cylinder from the system.Use this procedure to troubleshoot any suspect problems with the ether system.This procedure covers the following open circuit diagnostic codes and short circuit diagnostic codes:
545-05 Ether Start Relay open/short to +batt
545-06 Ether Start Relay short to groundThe ether injection system is used to improve the cold weather starting capability of the engine. The Electronic Control Module (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 the ON position in the configuration screen.
Inlet air temperature is less than 0 °C (32 °F) or engine coolant temperature is less than 0 °C (32 °F).
The engine has not been within 50 rpm of low idle for more than ten seconds.
Engine speed is between 35 rpm and at least 100 rpm below the low idle speed.
A diagnostic code for the engine coolant temperature sensor and the inlet air temperature sensor are not active. 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.
Inlet air temperature is less than 10 °C (50 °F).
Engine speed is greater than 35 rpm and less than 1200 rpm.
There is no active diagnostic code for both the engine coolant temperature sensor and the inlet air temperature sensor.An override function in Caterpillar Electronic Technician (ET) allows the technician to activate the ether system. This function can be actuated when the engine speed is 0 rpm. To use the function in Cat ET, select the "Override Parameters" menu.
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The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
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Left side engine view (typical example) (1) J1/P1 ECM connector
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Left side engine view (typical example) (2) P61 customer connector
Thoroughly inspect connectors (1) and (2). Inspect the harness and the wiring from the ECM to the ether control relay. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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P1 ECM connector (P1-21) Ether start valve (P1-22) Starting aid switch
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P61/J61 customer connector (22) Ether start valve (38) Starting aid switch
Perform a 45 N (10 lb) pull test on