SHAFT 1772481 - Caterpillar

System Operation Description: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    
545-5 Ether Start Relay open/short to +batt     The Electronic Control Module (ECM) detects an open circuit and/or a short to the +Battery at the output to the ether start relay.     The code is logged.
Ether injection is disabled.    
545-6 Ether Start Relay short to ground     The ECM detects a short circuit to ground at the output to the ether start relay.
The ECM has been powered for at least two seconds.    When the engine is in auto mode, the engine uses an ether injection system to improve starting in cold temperatures. The duration of the ether cycle is based on the engine coolant temperature. The ECM, which controls the ether injection system, uses the engine coolant temperature sensor to detect engine temperature. The ECM determines if ether should be injected by monitoring actual engine rpm and the engine temperature. The ECM will activate the ether start relay if the engine coolant temperature is below a set temperature and the engine rpm is below a certain level. The ether injection system becomes enabled at 10 °C (50 °F). The ether injection system will run for a minimum of 10 seconds up to a maximum of 130 seconds at −40 °C (−40 °F). The automatic ether injection system is disabled whenever engine rpm exceeds 1900 rpm or the engine coolant temperature exceeds 10 °C (50 °F).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 50 rpm.Note: The ether function will be disabled if the ether control parameter is disabled.
Illustration 1 g01266052
Typical schematic
Illustration 2 g01213344
P1 ECM connector (P1-5) Digital return (P1-20) Starting aid switch
Illustration 3 g01213347
P2 ECM connector (P2-10) Ether start relay
Illustration 4 g01266054
Machine interface connector (Terminal 09) Digital return (Terminal 22) Ether start relay (Terminal 38) Starting aid switch
Illustration 5 g01234146
Location of ECM connectors
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 switch that provides power to the keyswitch input for the ECM to