PULLEY (Alternator) 5S9080 - Caterpillar

Use this procedure in order to troubleshoot the ether system or use this procedure if any one of the diagnostic codes in Table 1 is active or easily repeated.
Table 1
Diagnostic Codes Table    
Code and Description     Conditions which Generate this Code     System Response    
546-5 Ether Hold Relay open/short to ground     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.    
546-6 Ether Hold Relay short to +batt     The ECM detects excessive current flow in the circuit. The ECM can only detect this condition when the output driver is activated.    This starting aid output is used to connect to a relay and/or a solenoid in order to control a starting aid system. Typical starting aid systems will inject ether into the intake manifold in order to aid starting of the engine during cold-weather operation. The output is automatically controlled by the ECM.The reading of the coolant temperature sensor is used to determine if conditions require the use of the starting aid. If a fault condition exists with the circuit for the coolant temperature sensor, the reading for the intake manifold air temperature sensor will be used. The starting aid output will be enabled for a maximum of 30 seconds while the engine is cranking and the temperature reading is below 0 °C (32 °F). The starting aid output will be disabled if the engine starts. The starting aid output will also be disabled if a condition that prevents fuel injection occurs.An override parameter on Caterpillar Electronic Technician (ET) allows the technician to activate the ether system. The test is only functional when the engine speed is zero rpm. Access the test via the "Override Parameters" screen on Cat ET.
Illustration 1 g03364134
Typical schematic
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.
Illustration 2 g01155187
Connector for the Ether start valve (Terminal 1) Digital return (Terminal 2) Ether injection solenoid
Table 2
Troubleshooting Test Steps    Values    Results    
1. Inspect Electrical Connectors and Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect the connectors associated with the either starting aid. 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 circuit.
D. Check the ECM connector (allen head screw) for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors