3500B Locomotive Engines Caterpillar

Ether Injection System

Usage:

System Operation Description:

The ECM controls the ether system. The ether system has two operating modes.

Automatic mode is used to improve the cold starting capability. The engine coolant temperature is used to determine ether injection.

MANUAL mode delivers ether to the engine when the Starting Aid Switch is placed in the MANUAL position.

The ether injection is disabled when the engine rpm or the engine coolant temperature exceeds a preset limit.

The Ether Start Valve is specially designed to actuate under low voltage situations. If you operate the Ether Start at 24 VDC for more than three seconds, damage may occur.

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Illustration 1	g00851063

Test Step 1. Check for Connector Damage.

Turn the engine control to the STOP position.

Turn the breaker at the battery to the OFF position.

Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.

Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.

Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).

Check the customer connector (allen head screw) for the proper torque of 2.25 ± 0.25 N·m (20 ± 2 lb in).

Check the harness and the wiring for abrasion and pinch points.

Expected Result:

The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.

Results:

OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.

Test Step 2. Check the Manual Ether Switch Status on ET.

Remove the ether canister from the ether solenoid.

Connect the ET at the service tool connector.

Connect the main power.

Press the Ether Switch. Observe the Ether Switch status on the ET.

Expected Result:

The parameter for the Ether Switch should display "ON" while the Starting Aid Switch is toggled. The parameter for the Ether Switch should display "OFF" when the switch is released.

Results:

OK - The ECM is properly reading the position of the Starting Aid Switch. Proceed to test step 3.
Not OK - The ECM is not properly reading the position of the Starting Aid Switch. Proceed to test step 4.

Test Step 3. Check the Supply Voltage to the Ether Start Solenoid.

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NOTICE

The ether canister must be removed prior to activating this test.

Remove the ether canister(s) from the ether solenoid(s).

Connect the main power.

Select Diagnostic Tests from the Electronic Service Tool.

Select the "Override Parameters" on the Electronic Service Tool.

Activate the Ether Override.

Measure the supply voltage at the Ether Start Solenoid between terminal board 1 pin-2 and terminal board 1 pin-4.

Disconnect the wires and listen for the Ether Start Valve.

Expected Result:

The supply voltage should be slightly less than battery voltage. A click should be heard when the ether solenoid activates the valve. This indicates correct operation of the valve.

Results:

OK - The Ether Injection System is working properly.
Repair: Verify that there is ether in the ether canisters. Replace the ether canisters on the engine. Reset the system and check for any active diagnostic codes.
Stop.
Not OK - The Ether Injection System is not working properly. Proceed to test step 5.

Test Step 4. Connect the Wires at the Ether Switch.

Disconnect wires from the Ether Switch.

Observe the Ether Switch status on the ET.

Short the wires together at the Ether Switch.

Observe the Ether Switch status on the ET.

Disconnect the main power.

Expected Result:

The Electronic Service Tool should display "OFF" when the switch wires are disconnected. The Electronic Service Tool should display "ON" when the switch wires are shorted together.

Results:

OK - The wiring and connectors to the ECM are okay.
Repair: Replace the Ether Switch. Verify that the system is operating correctly.
Stop.
Not OK - There is a problem in the wiring harness between the Ether Switch and the ECM.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.

Test Step 5. Check the Resistance of the Ether Solenoid.

Disconnect the wires from terminal board 1 pin-2 and pin-4.

Measure the resistance between the disconnected wires from terminal board 1 pin-2 and pin-4.

Reconnect the wires at terminal board 1.

Expected Result:

The resistance should be less than 6 Ohms.

Results:

OK - The resistance is less than 6 Ohms. Proceed to test step 6.
Not OK - The resistance is greater than 6 Ohms. The solenoid is faulty.
Repair: Replace the Ether Solenoid. Verify that the Ether system is operating properly.
Stop.

Test Step 6. Check the Power Supply.

Measure the voltage between terminal board 1 pin-2 and terminal board 1 pin-4.

Expected Result:

The supply voltage should be 24 ± 3 VDC.

Results:

OK - The supply voltage is 24 ± 3 VDC. Proceed to test step 7.
Not OK - The supply voltage is not 24 ± 3 VDC. There is a problem in the wiring harness between the Ether relay and the power supply.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.

Test Step 7. Check the Ether Relay.

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NOTICE

The ether canister must be removed prior to activating this test.

Remove the ether canister(s) from the ether solenoid(s).

Connect the main power.

Proceed to the Interactive Diagnostic screen and reactivate the ether system.

Connect a voltage test lamp between the Ether Relay terminal 86 and terminal 85.

Expected Result:

The voltage test lamp should illuminate during the first two seconds of injection. The voltage test lamp should not illuminate after the system is activated.

Results:

OK - The voltage test lamp illuminated during the first two seconds of injection. The voltage test lamp did not illuminate after the system was activated. Proceed to test step 8.
Not OK - The voltage test lamp did not illuminate during the first two seconds of injection. The voltage test lamp did not illuminate after the system was activated. Proceed to test step 9.

Test Step 8. Check the Voltage at the Ether Relays.

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NOTICE

The ether canister must be removed prior to activating this test.

Remove the ether canister(s) from the ether solenoid(s).

Connect the main power.

Proceed to the Diagnostic Override screen and activate the ether system.

Measure the output voltage between the Ether Relay terminal 87 and engine ground.

Expected Result:

Voltage at the Ether relay should be 24 ± 3 VDC for the first two seconds of injection. Voltage should be less than 6 VDC after the system is activated.

Results:

OK - Voltage at the Ether relay is 24 ± 3 VDC for the first two seconds of injection. Voltage is less than 6 VDC after the system is activated. Proceed to test step 9.
Not OK - Voltage at the Ether relay is not 24 ± 3 VDC for the first two seconds of injection. Voltage is not less than 6 VDC after the system is activated.
Repair: Replace the Ether Relay.
Stop.

Test Step 9. Check for an Open Circuit in the Harness between the ECM and the Ether Relay.

Disconnect the main power.

Disconnect ECM connector J1/P1. Disconnect the wire (F710-GN) and the wire (998-BR) from the Ether START Relay.

Short the wire (F710-BR) and the wire (998-BR) together.

Measure the resistance between P1-22 and P1-29.

Measure the resistance between P1-40 and P1-29.

Remove jumpers and reconnect all connectors.

Expected Result:

The resistance should be less than 10 Ohms through the wires.

Results:

OK - The resistance is less than 10 Ohms through the wires.
Repair: The problem may be intermittent. If the problem is intermittent refer to Troubleshooting, "Inspecting Electrical Connectors".
Stop.
Not OK - The resistance is greater than 10 Ohms through the wires. There is an open circuit or excessive resistance in the harness.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.