3500B and 3500B High Displacement Generator Set Engines Caterpillar

Ether Injection System

Usage:

System Operation Description:

When the Engine Control Switch (ECS) is in the AUTO position, and the starting aid switch (SAS) is in the AUTO position, the engine uses an automatic ether system to improve starting in cold temperatures. The system automatically injects ether during the crank cycle. The duration of the ether cycle is based on the engine coolant temperature. The Electronic Control Module (ECM), which controls the ether 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 solenoid if the engine coolant temperature is below a set temperature and the engine rpm is below a certain level. The ether will activate for a minimum of 15 seconds at 30 °C (86 °F) up to a maximum of 130 seconds at -50 °C (-58 °F). The automatic ether injection system is disabled whenever engine rpm exceeds 400 rpm or the engine coolant temperature exceeds 30 °C (86 °F).

Note: Crank the engine, before you activate the ether injection system in manual mode. Damage to the engine is possible by activating the system when the engine is not turning.

The ether injection system can also be operated in manual mode when the SAS is held in the ON position (momentary contact). The ether system is switched into manual mode whenever the starting aid switch is depressed. Manual mode also allows ether to be injected whenever the coolant temperature is less than 30 °C (86 °F) and engine rpm is greater than 50 rpm. Ether is injected in manual mode if the starting aid switch is depressed and the coolant temperature is below the maximum limit. The manual mode will allow ether to be injected for a maximum of 130 seconds when the switch is toggled. The manual ether injection system is disabled whenever engine rpm exceeds 400 rpm or the engine coolant temperature exceeds 30 °C (86 °F).

The circuit uses two inputs to the ECM in order to activate the ether system. The two inputs are sinking drivers. The first sinking driver activates the ether start relay. The ether start relay energizes the ether solenoids with 24 ± 3 VDC. In order to prevent damage to the ether solenoids, a second relay is used to keep the solenoids activated by using less voltage. The second sinking driver activates the ether hold relay. The ether hold relay keeps the solenoids energized through the resistor and the diode assembly. The resistor and the diode assembly reduces the voltage to the ether solenoids. The solenoids will be damaged if battery voltage is applied continuously.

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Illustration 1	g01023645
Typical circuit with EMCP II

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Illustration 2	g01023927
Typical circuit with EMS II

Test Step 1. Check for Connector Damage.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test 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 for pinch points.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.

Results:

OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not okay.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.

Test Step 2. Check the Engine Diagnostics on the Caterpillar Electronic Technician (ET).

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Connect Cat ET to the service tool connector J60/P60.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Determine if CID-FMI 545-05 Ether Start Relay open/short to +batt, 545-06 Ether Start Relay short to ground, 546-05 Ether Hold Relay open/short to ground or 546-06 Ether Hold Relay short to +batt is active or logged.

Expected Result:

No active codes or logged codes are present.

Results:

OK - No active codes or logged codes are present. The ether injection system does not inject ether. Proceed to Test Step 3.
Active Code - Active diagnostics are displayed. Proceed to Test Step 4.
Logged Code - Logged Diagnostics are displayed. Check for an intermittent short or for an open in the wiring or in the connectors
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.

Test Step 3. Check the Ether Canisters.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Remove the ether canister(s) from the ether solenoid(s). Determine if the canister(s) contains any ether.

Expected Result:

The ether canister(s) is not empty.

Results:

OK - The ether canister(s) is not empty. Proceed to Test Step 4.
Not OK - The ether canister(s) is empty.
Repair: Replace the empty ether canister with a full ether canister. Retry the system.
Stop.

Test Step 4. Check the Voltage from the Ether Start Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

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

Connect Cat ET to the service tool connector J60/P60.

Connect a voltmeter between terminal 87 of the ether start relay and ground.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether start relay with the voltmeter.

Deactivate the ether override.

Expected Result:

The voltage at the ether start relay is 24 ± 3 VDC during the first two seconds of injection.

Results:

OK - The voltage at the ether start relay is 24 ± 3 VDC during the first two seconds of injection. Proceed to Test Step 5.
Not OK - 24 VDC - The voltage at the ether start relay is not 24 ± 3 VDC during the first two seconds of injection. Proceed to Test Step 6.

Test Step 5. Check the Voltage at the Ether Solenoids.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Disconnect the ether solenoid connector at the solenoid.

Connect a voltmeter to pin 1 and pin 2 of the ether solenoid connector.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether solenoid connector with the voltmeter.

Deactivate the ether override.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Reconnect all connectors.

Expected Result:

The voltage at the ether solenoid is 24 ± 3 VDC during the first two seconds of injection. The voltage then decreases to 3 ± 1 VDC for the remainder of the injection duration.

Results:

OK - The voltage at the ether solenoid is 24 ± 3 VDC during the first two seconds of injection. The voltage then decreases to approximately 3 ± 1 VDC for the remainder of injection duration.
Repair: If ether is not being injected, temporarily replace the ether solenoid. If the problem is no longer present, reinstall the old solenoid. If the problem returns, replace the solenoid.
Stop.
Not OK - 24 VDC - The voltage at the ether solenoid is not 24 ± 3 VDC during the first two seconds of injection.
Repair: Inspect the wiring and connectors between the ether start relay and the connectors at the ether solenoids. Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.
Not OK - 3 VDC - The voltage did not decrease to 3 ± 1 VDC for the remainder of the injection duration. Proceed to Test Step 10.

Test Step 6. Check the Voltage at the Coil of the Ether Start Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Connect a voltmeter between terminal 85 and terminal 86 of the ether start relay.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether start relay with the voltmeter.

Deactivate the ether override.

Expected Result:

The voltage measures 24 ± 3 VDC.

Results:

OK - The voltage was 24 ± 3 VDC. Proceed to Test Step 7.
Not OK - The voltage was not 24 ± 3 VDC. Proceed to Test Step 8.

Test Step 7. Check the Voltage to the Normally Open Contacts of the Ether Start Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Measure the voltage between terminal 30 of the ether start relay and the -Battery.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether start relay with the voltmeter.

Deactivate the ether override.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

OK - The voltage is 24 ± 3 VDC.
Repair: Replace the ether start relay. Verify that the circuit is operating correctly.
Stop.
Not OK - EMCP II+ - The voltage is not 24 ± 3 VDC.
Repair: Verify that 24 ± 3 VDC is present on terminal RM39 of the generator set control when the ether injection system is activated. If voltage is present on terminal RM39, repair the wire between the ether start relay and the generator set control. If voltage is not present, troubleshoot the generator set control.
Stop.
Not OK - EMS II - The voltage is not 24 ± 3 VDC.
Repair: Check for 24 ± 3 VDC at the breaker for the "EMCP II". Check for 24 ± 3 VDC at fuse F1. Verify that relay CR/3 is operating correctly. Repair any component that is not operating correctly.
Stop.

Test Step 8. Check for an Open to the ECM.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Disconnect the wire on terminal 85 of the ether start relay.

Disconnect ECM connector J1/P1.

Connect a voltmeter between the wire from terminal 85 of the ether start relay and wire F710-BR in pin P1-40.

Measure the resistance of the wire.

Reconnect all wires.

Expected Result:

The resistance is less than 5 Ohms.

Results:

OK - The resistance is less than 5 Ohms. Proceed to Test Step 9.
Not OK - The resistance is greater than 5 Ohms.
Repair: Repair the wire between terminal 85 and the ECM connector P1-40. Retest the system.
Stop.

Test Step 9. Check the Sinking Driver for the Ether Start Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Remove wire F710-BR from ECM connector P1-40. Install a wire jumper into the P1-40.

Reconnect ECM connector J1/P1.

Connect a voltmeter between the +Battery and the wire jumper in P1-40.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Monitor the voltage on the voltmeter.

Deactivate the ether override.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Remove the wire jumper and replace wire F710-BR. Reconnect ECM connector J1/P1.

Expected Result:

The voltage measured 24 ± 3 VDC for two seconds.

Results:

OK - The voltage measured 24 ± 3 VDC for two seconds.
Repair: Verify that 24 ± 3 VDC is present on terminal 86 of the ether start relay. If 24 ± 3 VDC is present on terminal 86 of the ether start relay, the wire F710-BR and/or the connectors between the ECM and the ether start relay need repair. Inspect the wiring and connectors between the ether start relay and the connector at the ECM. Repair the connectors or wiring and/or replace the connectors or wiring.If 24 ± 3 VDC is not present on terminal 86 of the ether start relay, check the components between terminal 86 of the ether start relay and the +Battery. Refer to Illustration 1 or Illustration 2.
Stop.
Not OK - The voltage at the ECM is not 24 ± 3 VDC for two seconds.
Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".
Stop.

Test Step 10. Check the Voltage from the Ether Hold Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Connect a voltmeter between terminal 87 of the ether hold relay and ground.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether hold relay.

Deactivate the ether override.

Expected Result:

The voltage at terminal 87 is 24 ± 3 VDC after two seconds of the ether injection cycle activation.

Results:

OK - The voltage at terminal 87 is 24 ± 3 VDC after two seconds of the ether injection cycle activation. Proceed to Test Step 15.
Not OK - The voltage at terminal 87 is not 24 ± 3 VDC after two seconds of the ether injection cycle activation. Proceed to Test Step 11.

Test Step 11. Check the Voltage at the Coil of the Ether Hold Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Connect a voltmeter between terminal 85 and terminal 86 of the ether hold relay.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is ON.
Note: Do not allow the ether to be ON for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether hold relay.

Deactivate the ether override.

Expected Result:

The voltage measures 24 ± 3 VDC after two seconds of the ether injection cycle activation.

Results:

OK - The voltage measures 24 ± 3 VDC after two seconds of the ether injection cycle activation. Proceed to Test Step 12.
Not OK - The voltage does not measure 24 ± 3 VDC after two seconds of the ether injection cycle activation. Proceed to Test Step 13.

Test Step 12. Check the Voltage to the Normally Open Contacts of the Ether Hold Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Connect a voltmeter between terminal 30 of the ether hold relay and the -Battery terminal.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is ON.
Note: Do not allow the ether to be ON for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the ether hold relay.

Deactivate the ether override.

Expected Result:

The voltage measures 24 ± 3 VDC.

Results:

OK - The voltage is 24 ± 3 VDC.
Repair: Replace the ether hold relay. Verify that the circuit is operating correctly.
Stop.
Not OK - EMCP II+ - The voltage is not 24 ± 3 VDC.
Repair: Verify that 24 ± 3 VDC is present on terminal RM39 of the generator set control when the ether injection system is activated. If voltage is present on terminal RM39, repair the wire between the ether hold relay and the generator set control. If voltage is not present, troubleshoot the generator set control.
Stop.
Not OK - EMS II - The voltage is not 24 ± 3 VDC.
Repair: Check for 24 ± 3 VDC at the breaker for the "EMCP II". Check for 24 ± 3 VDC at fuse F1. Verify that relay CR/3 is operating correctly. Repair any component or wiring that is not operating correctly.
Stop.

Test Step 13. Check for an Open to the ECM.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Disconnect the wire on terminal 85 of the ether hold relay.

Disconnect ECM connector J1/P1.

Connect a voltmeter between the wire from terminal 85 of the ether start relay and wire F707-WH in pin P1-22.

Measure the resistance of the wire.

Reconnect all wires.

Expected Result:

The resistance is less than 5 Ohms.

Results:

OK - The resistance is less than 5 Ohms. Proceed to Test Step 14.
Not OK - The resistance is greater than 5 Ohms.
Repair: Repair the wire between terminal 85 and the ECM connector P1-22. Retest the system.
Stop.

Test Step 14. Check the Sinking Driver for the Ether Hold Relay.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Remove wire F707-WH from ECM connector P1-22. Install a wire jumper into the P1-22.

Reconnect ECM connector J1/P1.

Connect a voltmeter between the +Battery and the wire jumper in P1-22.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is activated.
Note: Do not allow the ether to be activated for more than two minutes. Damage to the solenoid may occur.

Monitor the voltage on the voltmeter.

Deactivate the ether override.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Remove the wire jumper and replace wire F707-WH. Reconnect ECM connector J1/P1.

Expected Result:

The voltage measured 24 ± 3 VDC after two seconds of activating the ether cycle.

Results:

OK - The voltage measured 24 ± 3 VDC after two seconds of activating the ether cycle.
Repair: Verify that 24 ± 3 VDC is present on terminal 86 of the ether hold relay. If 24 ± 3 VDC is present on terminal 86 of the ether hold relay, the wire F707-WH and/or the connectors between the ECM and the ether hold relay need repair. Inspect the wiring and connectors between the ether hold relay and the connector at the ECM. Repair the connectors or wiring and/or replace the connectors or wiring.If 24 ± 3 VDC is not present on terminal 86 of the ether hold relay, check the components between terminal 86 of the ether hold relay and the +Battery. Refer to Illustration 1 or Illustration 2.
Stop.
Not OK - The voltage at the ECM is not 24 ± 3 VDC after two seconds.
Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".
Stop.

Test Step 15. Check the Voltage at the Resistor and the Diode Assembly.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Disconnect the connector at the resistor and the diode assembly.
Note: This procedure must be performed on all of the resistor and diode assemblies, if more than one resistor and diode assembly is present.

Connect a voltmeter to pin 1 of the resistor and the diode assembly and ground.

Turn the battery disconnect switch to the ON position.

Turn the ECS to the STOP position.

Select the "Diagnostic Tests" on Cat ET.

Select the "Override Parameters" screen on Cat ET.

Activate the ether override and observe the voltmeter while ether injection is ON.
Note: Do not allow the ether to be ON for more than two minutes. Damage to the solenoid may occur.

Measure the voltage at the diode assembly and ground.

Deactivate the ether override.

Turn the ECS to the OFF/RESET position.

Turn the battery disconnect switch to the OFF position.

Expected Result:

The voltage is 24 ± 3 VDC after two seconds of the ether injection cycle activation.

Results:

OK - The voltage is 24 ± 3 VDC after two seconds of the ether injection cycle activation. Proceed to Test Step 16.
Not OK - The voltage is not 24 ± 3 VDC after two seconds of the ether injection cycle activation.
Repair: There is a problem in the harness between the ether start relay and the resistor and diode assembly. Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.

Test Step 16. Check the Resistor and Diode Assembly.

Disconnect the connector at the resistor and the diode assembly.

Set the multimeter to the "Check Diode" setting.

Connect the positive lead of the multimeter to pin 2 and the negative lead to pin 1 of the resistor and the diode assembly and observe the multimeter.

Connect the positive lead of the multimeter to pin 1 and the negative lead to pin 2 of the resistor and the diode assembly and observe the multimeter.

Repeat the measurements for all of the resistor and the diode assemblies if more than one resistor and diode assembly is present.

Expected Result:

When the positive lead of the multimeter is connected to pin 2 and the negative lead to pin 1, the multimeter displays an overload "(OL)".

When the positive lead of the multimeter is connected to pin 1 and the negative lead to pin 2, the multimeter displays a number less than one.

Results:

OK - The resistor and the diode assembly is operating correctly.
Repair: There is a problem in the harness between the resistor and diode assembly and the ether solenoids. Repair the connectors or wiring and/or replace the connectors or wiring.
Stop.
Not OK - The resistor and the diode assembly is not operating correctly.
Repair: The resistor and the diode assembly is causing the problem. Temporarily replace the resistor and the diode assembly. If the problem is no longer present, reinstall the resistor and the diode assembly. If the problem returns, replace the resistor and the diode assembly.
Stop.