C7 and C9 Industrial Engines Troubleshooting – Ether Starting Aid – Test

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.

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.

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B. Remove the ether canister from the ether valve. Determine if the canister contains fluid.

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

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.

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.

A. Disconnect the harness connector for the ether solenoid.

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 for 10 seconds.

E. Monitor the active diagnostic code screen on Cat ET. Look for an active 05 code.

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

F. Remove electrical power from the engine ECM.

Repair: The circuit for the ether solenoid is OK. Temporarily connect a new solenoid to the harness, but do not install the new solenoid. After connecting the new solenoid to the harness, verify that there are no active codes for the ether injection system. If there are no active codes for the ether injection system, permanently install the new solenoid. Clear any logged diagnostic codes.

STOP

Results: A 06 code was active before the connector was disconnected. The 06 code remained active after the connector was disconnected. There is a problem in the circuit for the ether injection solenoid. There may be a problem with the ECM. Leave the connector for the solenoid disconnected. Proceed to Test Step 6.

A. Disconnect the harness connector for the ether solenoid.

B. Fabricate a jumper wire that is long enough to create a short circuit between terminal 1 and terminal 2 at the harness connector for the ether solenoid. Crimp connector pins to each end of the jumper wire.

C. Install the jumper wire between terminals 1 and 2 of the harness connector.

D. Restore electrical power to the engine ECM.

E. Proceed to the “Diagnostic Overrides” screen on Cat ET.

F. Activate the ether injection system. The system will activate for 10 seconds.

G. Monitor the active diagnostic code screen on Cat ET. Look for an active 06 code.

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

H. Remove electrical power from the engine ECM.

I. Remove the jumper wire from the harness connector.

Repair: The engine harness and the ECM are OK. Temporarily connect a new solenoid to the harness, but do not install the new solenoid. Verify that there are no active diagnostic codes for the solenoid. If there are no active diagnostic codes for the solenoid after the installation of the new solenoid, permanently install the new solenoid. Clear any logged diagnostic codes.

STOP

Results: A 05 code was active before the jumper wire was installed. The 05 code remained active after the jumper wire was installed. Remove the jumper wire and connect the connector. Proceed to Test Step 6.

A. Disconnect the J1/P1 ECM connectors.

B. Fabricate a jumper wire that is long enough to create a test circuit from the ECM connector to the engine ground stud. Crimp a connector socket to one end of the jumper wire.

C. Remove the wire from terminal location J1-10 (ether injection solenoid) at the ECM connector. Install the jumper wire into this terminal location.

D. Connect the J1/P1 ECM connectors.

E. Check the operation of the ECM by creating an open at the ECM:

Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

F. Check the operation of the ECM by creating a short at the ECM.

G. Remove electrical power from the engine ECM.

H. Restore the wiring to the original configuration.

Repair: The ECM is operating properly. The problem is in the circuit for the ether solenoid. The problem may be in the harness between the ECM and the ether solenoid’s harness connector or the harness between the ground connection and the ether solenoid’s harness connector. Repair the connectors or wiring and/or replace the connectors or wiring.

STOP

Results: One of the following conditions exists: A 05 code is not active when the loose end of the jumper wire is open. A 06 code is not active when the loose end of the jumper wire is grounded.

Repair: The ECM is not responding correctly. Replace the ECM. Refer to Troubleshooting, “ECM – Replace”. Verify that the problem is resolved.

STOP