C-10 and C-15 Petroleum Engines Caterpillar

Before testing of the ether injection system, remove the ether cylinder from the system.

Use this procedure to troubleshoot any suspect problems with the ether system.

This procedure covers the following open circuit diagnostic codes and short circuit diagnostic codes:

• 545-05 Ether Start Relay open/short to +batt

• 545-06 Ether Start Relay short to ground

The ether injection system is used to improve the cold weather starting capability of the engine. The Electronic Control Module (ECM) controls the ether injection system. The ether injection system has two operating modes. The ether injection system can operate in automatic mode and in manual mode.

In the automatic mode, the ECM energizes the relay for the ether in cycles of six seconds. The ether is turned ON for three seconds. The ether is then turned OFF for three seconds.

In the automatic mode, the ether injection system is enabled when all of the following conditions occur:

• "Ether" is programmed to the ON position in the configuration screen.

• Inlet air temperature is less than 0 °C (32 °F) or engine coolant temperature is less than 0 °C (32 °F).

• The engine has not been within 50 rpm of low idle for more than ten seconds.

• Engine speed is between 35 rpm and at least 100 rpm below the low idle speed.

• A diagnostic code for the engine coolant temperature sensor and the inlet air temperature sensor are not active.

Manual mode is activated by pressing the starting aid switch. In the manual mode, a single shot of ether is injected when the ether switch is actuated. The quantity of ether that is injected is controlled by the ECM. In the manual mode, the ether injection system is enabled when all of the following conditions are satisfied:

• The starting aid switch is placed in the MANUAL position.

• Inlet air temperature is less than 10 °C (50 °F).

• Engine speed is greater than 35 rpm and less than 1200 rpm.

• There is no active diagnostic code for both the engine coolant temperature sensor and the inlet air temperature sensor.

An override function in Caterpillar Electronic Technician (ET) allows the technician to activate the ether system. This function can be actuated when the engine speed is 0 rpm. To use the function in Cat ET, select the "Override Parameters" menu.

Illustration 1	g01060350

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The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.

Test Step 1. Inspect Electrical Connectors and Wiring

1. Turn the keyswitch to the OFF position.

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Illustration 2	g01146374
Left side engine view (typical example) (1) J1/P1 ECM connector

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Illustration 3	g01146383
Left side engine view (typical example) (2) P61 customer connector

2. Thoroughly inspect connectors (1) and (2). Inspect the harness and the wiring from the ECM to the ether control relay. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

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Illustration 4	g01146869
P1 ECM connector (P1-21) Ether start valve (P1-22) Starting aid switch

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Illustration 5	g01146887
P61/J61 customer connector (22) Ether start valve (38) Starting aid switch

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

4. Check the allen head screw on the ECM connectors and the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

5. 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 OK. Proceed to Test Step 2.

• Not OK - The connectors and/or wiring are not OK.

  Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the repair eliminates the problem.

  STOP

Test Step 2. Check for Active Diagnostic Codes

1. Connect Cat ET to the service tool connector.

2. Turn the keyswitch to the ON position.

3. Check for active diagnostic codes. Wait at least 15 seconds in order for the diagnostic codes to become active. Record any active codes.

4. Determine if the problem is related to an open circuit diagnostic code -05 or a short circuit diagnostic code -06.

Expected Result:

No active codes are present.

Results:

• OK - No active codes are present. The ether injection system does not inject ether. Proceed to Test Step 3.

• Not OK - A 545-05 diagnostic code or a 545-06 diagnostic code is active. Proceed to Test Step 4.

Test Step 3. Check the Ether Canister

1. Turn the keyswitch to the OFF position.

2. Remove the ether canister from the ether valve. Determine if the canister contains any ether.

Expected Result:

The ether canister is not empty.

Results:

• OK - The ether canister is not empty. Proceed to Test Step 4.

• Not OK - The ether canister is empty.

  Repair: Replace the empty ether canister with a full ether canister. Verify that the repair eliminates the problem.

  STOP

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

1. Turn the keyswitch to the OFF position.

2. Remove the ether canister from the ether valve.

3. Connect Cat ET to the service tool connector.

4. Remove the wire from terminal 87 of the normally open contacts of the ether start relay that goes to the ether valve.

5. Turn the keyswitch to the ON position.

6. Use the override in Cat ET to activate the ether control relay.

   Note: After activation of the ether override that is in Cat ET, the ECM powers the ether control for a ten second period.

7. Measure the voltage from terminal 87 of the start relay and ground. Record the measurement.

8. Deactivate the ether override.

9. Turn the keyswitch to the OFF position.

10. Reconnect the wire from terminal 87 of the normally open contacts of the ether start relay that goes to the ether valve.

Expected Result:

The voltage at the ether start relay is 24 ± 3 VDC.

Results:

• OK - The voltage at the ether start relay is 24 ± 3 VDC. Proceed to Test Step 5.

• Not OK - The voltage at the ether start relay is not 24 ± 3 VDC. Proceed to Test Step 6.

Test Step 5. Check the Voltage at the Ether Valve

1. Turn the keyswitch to the OFF position.

2. Disconnect the ether valve connector at the ether valve.

3. Use Cat ET to activate the ether override.

4. Measure the voltage at the ether valve connector between terminal 1 and ground.

5. Deactivate the ether override.

6. Turn the keyswitch to the OFF position.

7. Reconnect all connectors.

Expected Result:

The voltage at the ether valve is 24 ± 3 VDC.

Results:

• OK - The voltage at the ether valve is 24 ± 3 VDC.

  Repair: Verify that the ground circuit from the ether valve to the negative battery has continuity. If the wire is OK, replace the ether valve. Verify that the repair eliminates the problem.

  STOP

• Not OK - The voltage at the ether valve is not 24 ± 3 VDC.

  Repair: Inspect the wiring and connectors between the normally open contacts of the ether start relay and the connector at the ether valve. Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the repair eliminates the problem.

  STOP

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

1. Turn the keyswitch to the OFF position.

2. Disconnect the signal wire on terminal 86 of the ether start relay.

3. Turn the keyswitch to the ON position.

4. Use Cat ET to activate the ether override.

5. Measure the voltage from the signal wire at the ether start relay to engine ground.

6. Deactivate the ether override in Cat ET.

7. Turn the keyswitch to the OFF position.

8. Reconnect the signal wire to terminal 86 of the ether start relay.

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 9.

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

1. Turn the keyswitch to the ON position.

2. Measure the voltage between terminal 30 of the ether start relay and ground.

3. Turn the keyswitch to the OFF position.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

• OK - The voltage is 24 ± 3 VDC.

  Repair: Verify that the wire from terminal 85 of the ether start relay has continuity to the negative battery terminal. If the wire is OK, replace the ether start relay. Verify that the circuit is operating correctly.If the wire from terminal 85 of the ether start relay does not have continuity to the negative battery, repair the wire and retest the system. Verify that the repair eliminates the problem.

  STOP

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

Test Step 8. Check the Voltage from the Keyswitch to the Ether Start Relay

1. Turn the keyswitch to the OFF position.

2. Remove the wire from terminal R of the keyswitch.

3. Turn the keyswitch to the ON position.

4. Measure the voltage between terminal B of the keyswitch and ground.

5. Measure the voltage between terminal R of the keyswitch and ground.

6. Turn the keyswitch to the OFF position.

Expected Result:

Voltage is present on terminal B and terminal R at the keyswitch.

Results:

• OK - Voltage is present on terminal B and terminal R at the keyswitch.

  Repair: If voltage is present on terminal R, repair the wire between the keyswitch and the ether start relay. Verify that the breaker is not tripped. Return all wiring to the original configuration. Verify that the problem is eliminated.

  STOP

• Not OK - Voltage is not present on terminal B at the keyswitch.

  Repair: If voltage is not present on terminal B, repair the wire between the +Battery and the keyswitch. Verify that the breaker is not tripped. Check the battery's no-load voltage. Return all wiring to the original configuration. Verify that the problem is eliminated.

  STOP

• Not OK - Voltage is not present on terminal R at the keyswitch.

  Repair: If voltage is present on terminal B of the keyswitch but not present on terminal R, replace the keyswitch. Return all wiring to the original configuration. Verify that the problem is eliminated.

  STOP

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

1. Turn the keyswitch to the OFF position.

2. Remove terminal P1-21 from the ECM connector. Install a wire jumper into terminal P1-21.

3. Reconnect ECM connectors J1/P1.

4. Turn the keyswitch to the ON position.

5. Use Cat ET to activate the ether override.

6. Monitor the voltage between the jumper in terminal P1-21 and the −Battery.

7. Deactivate the ether override.

8. Turn the keyswitch to the OFF position.

9. Remove the wire jumper from P1-21 and return the connector to the original configuration. Reconnect the J1/P1 ECM connectors.

Expected Result:

The voltage measured 24 ± 3 VDC.

Results:

• OK - The voltage measured 24 ± 3 VDC. Proceed to Test Step 10.

• Not OK - The voltage at the ECM is not 24 ± 3 VDC.

  Repair: Temporarily connect a test ECM. Check the operation of the ether system when the test ECM is installed. If the problem is resolved with the test ECM, then reconnect the suspect ECM. If the problem returns with the suspect ECM, then replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".

  STOP

Test Step 10. Check for an Open from the ECM to the Coil of the Ether Start Relay

1. Turn the keyswitch to the OFF position.

2. Disconnect the wire on terminal 86 of the ether start relay.

3. Disconnect ECM connector J1/P1.

4. Measure the resistance in the signal wire from the P1-21 to the ether start relay. Record the measurement.

5. Restore the wiring and the connectors to the original configuration.

Expected Result:

The resistance is less than 5 Ohms.

Results:

• OK - The resistance is less than 5 Ohms. Proceed to Test Step 11.

• Not OK - The resistance is greater than 5 Ohms. There is an open in the signal wire from the ECM to the ether start relay.

  Repair: Repair the wire. Verify that the repair eliminated the original problem.

  STOP

Test Step 11. Check for a Short in the Wire between the ECM and the Ether Start Relay

1. Turn the keyswitch to the OFF position.

2. Disconnect the wire on terminal 86 of the ether start relay.

3. Disconnect the J1/P1 and J2/P2 ECM connectors.

4. Measure the resistance between terminal P1-21 and every wire in the P1 and the P2 ECM connectors. Measure the resistance between terminal P1-21 and engine ground.

5. Restore the wiring to the original configuration. Reconnect the J1/P1 ECM connectors.

Expected Result:

All measurements indicated an open circuit.

Results:

• OK - All measurements indicated an open circuit.

  Repair: The problem may be intermittent. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".

  STOP

• Not OK - At least one of the measurements did not indicate an open circuit.

  Repair: A short circuit exists in the harness or in a connector. Repair the harness and/or the connector, when possible. Replace parts, if necessary. Verify that the problem is resolved.

  STOP