C15 and C18 Industrial Engines Caterpillar

Before you test the ether injection system, remove the ether canister from the system.

The ether injection system is used to improve cold weather starting of the engine. The Electronic Control Module (ECM) controls the ether injection system during the start cycle. The ether injection system has two modes of operation:

Automatic mode - In the automatic mode, if the engine coolant temperature is below 0 °C (32 °F) and the engine speed is zero rpm, the ether injection system is actuated by the ECM. Ether is injected continuously until the engine starts (50 rpm below low idle).

Manual mode - In the manual mode, the ECM energizes the ether solenoid for a single shot of ether.

Manual mode is activated by pressing the ether starting aid switch. A short burst of ether is injected when the ether starting aid switch is pressed. In the manual mode, the ether injection system can be enabled if all of the following conditions are met:

• The ether starting aid switch is pressed.

• The intake manifold air temperature is less than 0 °C (32 °F).

• There are no active diagnostic codes for both the engine coolant temperature sensor and the intake manifold air temperature sensor.

Note: If a problem is suspected with the ether starting aid switch, refer to Troubleshooting, "Switch Circuits - Test".

Test Mode - A test mode is available in Caterpillar Electronic Technician (ET). The test mode allows the technician to activate the ether system. The test is functional when the engine speed is zero rpm. The ether injection solenoid is activated for a ten second duration when the test is activated. The test can be found in the "Override Parameters" screen in Cat ET.

Illustration 1	g01376496
Schematic of the ether injection system

Test Step 1. Check the Circuit Breakers and the Configuration Parameters

1. Check for tripped circuit breakers.

2. Use Cat ET to check the status of the configuration parameter for "Ether Control".

Expected Result:

A circuit breaker is tripped or the configuration parameter for "Ether Control" is disabled.

Results:

• Yes - A circuit breaker is tripped or the configuration parameter for "Ether Control" is disabled.

  Repair: If a circuit breaker is tripped, reset the circuit breaker. Determine the cause of the incident.If the configuration parameter for "Ether Control" is disabled, use Cat ET to enable the parameter.

  STOP

• No - No circuit breakers are tripped. The configuration parameter for "Ether Control" is enabled. Proceed to Test Step 2.

Test Step 2. Inspect the Electrical Connectors and the Wiring

1. Remove the electrical power from the ECM.

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Illustration 2	g01167488
Engine view (typical example) (1) J1/P1 ECM connectors

2. Thoroughly inspect connectors (1). Also, thoroughly inspect the connectors for the solenoid. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".

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Illustration 3	g01376504
P1 terminals for the ether injection system (P1-21) Ether injection solenoid (P1-60) Override switch

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Illustration 4	g01155187
Terminal locations at the harness connector for the ether solenoid (1) Ether injection solenoid (2) Chassis ground

3. 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.

4. 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.

5. Check the harness and the wiring for abrasion and for pinch points from the ether injection solenoid to the ECM.

Expected Result:

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

Results:

• OK - The connectors and wiring appear to be OK. Proceed to Test Step 3.

• Not OK - 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.

  STOP

Test Step 3. Check the Ether Canister for Starting Fluid

1. Remove the electrical power from the ECM.

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

Expected Result:

The ether canister is not empty.

Results:

• OK - The ether canister is not empty. Do not install the ether canister. 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 original problem is resolved.

  STOP

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

1. Remove the electrical power from the ECM.

2. Connect Cat ET to the service tool connector.

3. Remove the wire from terminal 87 of the normally open contacts of the ether relay that goes to the ether injection solenoid.

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

5. Restore the electrical power to the ECM.

6. Select the "Diagnostic Tests" on Cat ET.

7. Select the "Override Parameters" screen on Cat ET.

8. Activate the ether override. The ECM will activate the ether injection system for ten seconds.

9. Measure the voltage at the ether relay while the ether injection system is activated.

10. Deactivate the ether override.

11. Remove the electrical power from the ECM.

12. Reconnect the wire to terminal 87 of the ether relay.

Expected Result:

The measured voltage is between 9 VDC and 15 VDC for 12 volt systems. The measured voltage is between 22 VDC and 27 VDC for 24 volt systems.

Results:

• OK - The voltage is within the acceptable range. Proceed to Test Step 5.

• Not OK - The voltage is not within the acceptable range. Proceed to Test Step 6.

Test Step 5. Check the Voltage at the Ether Injection Solenoid

1. Remove the electrical power from the ECM.

2. Disconnect the electrical connector for the ether injection solenoid.

3. At the harness connector for the ether injection solenoid, connect a voltmeter between terminal 1 and engine ground.

4. Restore the electrical power to the ECM.

5. Select the "Diagnostic Tests" on Cat ET.

6. Select the "Override Parameters" screen on Cat ET.

7. Activate the ether override. The ECM will activate the override for ten seconds. Observe the voltmeter while the ether injection system is activated.

8. Deactivate the ether override.

9. Remove the electrical power from the ECM.

10. Connect all of the connectors.

Expected Result:

The measured voltage is between 9 VDC and 15 VDC for 12 volt systems. The measured voltage is between 22 VDC and 27 VDC for 24 volt systems.

Results:

• OK - The voltage is within the acceptable range.

  Repair: Verify that the wire from the ether injection solenoid to the −Battery has continuity. If the wire is OK, replace the ether injection solenoid.

  STOP

• Not OK - The voltage is not within the acceptable range.

  Repair: Inspect the wiring and connectors between the normally open contacts of the ether relay and the connector at the ether injection solenoid. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

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

1. Remove the electrical power from the ECM.

2. Disconnect the wire from terminal 86 of the ether relay.

3. Connect a voltmeter between the end of the wire and engine ground.

4. Restore the electrical power to the ECM.

5. Select the "Diagnostic Tests" on Cat ET.

6. Select the "Override Parameters" screen on Cat ET.

7. Activate the ether override. The ECM will activate the override for ten seconds. Observe the voltmeter while the ether injection system is activated.

8. Deactivate the ether override.

9. Remove the electrical power from the ECM.

10. Connect the wire to terminal 86 of the ether start relay.

Expected Result:

The measured voltage is between 9 VDC and 15 VDC for 12 volt systems. The measured voltage is between 22 VDC and 27 VDC for 24 volt systems.

Results:

• OK - The voltage is within the acceptable range. Proceed to Test Step 7.

• Not OK - The voltage is not within the acceptable range. Proceed to Test Step 9.

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

1. Restore the electrical power to the ECM.

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

3. Remove the electrical power from the ECM.

Expected Result:

The measured voltage is between 9 VDC and 15 VDC for 12 volt systems. The measured voltage is between 22 VDC and 27 VDC for 24 volt systems.

Results:

• OK - The voltage is within the acceptable range.

  Repair: Verify that the wire from terminal 85 of the ether relay has continuity to the −Battery. If the wire is OK, replace the ether relay. Verify that the original problem is resolved.If the wire from terminal 85 of the ether start relay does not have continuity to the −Battery, repair the wire. Replace the wire, if necessary. Verify that the original problem is resolved.

  STOP

• Not OK - The voltage is not within the acceptable range. Proceed to Test Step 8.

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

1. Remove the electrical power from the ECM.

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 engine ground.

5. Measure the voltage between terminal R of the keyswitch and engine 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 relay. Verify that the circuit breaker is not tripped. Return all wiring to the original configuration. Verify that the problem is resolved.

  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. Check the battery's no-load voltage. Return all wiring to the original configuration. Verify that the problem is resolved.

  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 resolved.

  STOP

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

1. Remove the electrical power from the ECM.

2. Remove wire 382-PK from terminal P1-21. Install a jumper wire into terminal P1-21.

3. Connect a voltmeter between the −Battery and the other end of the jumper wire.

4. Restore the electrical power to the ECM.

5. Select the "Diagnostic Tests" on Cat ET.

6. Select the "Override Parameters" screen on Cat ET.

7. Activate the ether override. The ECM will activate the override for ten seconds. Observe the voltmeter while the ether injection system is activated.

8. Deactivate the ether override.

9. Remove the electrical power from the ECM.

10. Remove the wire jumper and install wire 382-PK into P1-21.

Expected Result:

The measured voltage is between 9 VDC and 15 VDC for 12 volt systems. The measured voltage is between 22 VDC and 27 VDC for 24 volt systems.

Results:

• OK - The voltage is within the acceptable range. Proceed to Test Step 10.

• Not OK - The voltage is not within the acceptable range.

  Repair: Temporarily connect a test ECM. Check the operation of the ether injection system when the test ECM is installed. If the problem is resolved with the test ECM, connect the suspect ECM. If the problem returns with the suspect ECM, replace the ECM. Refer to Troubleshooting, "ECM - Replace".

  STOP

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

1. Remove the electrical power from the ECM.

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

3. Disconnect ECM connector J1/P1.

4. Measure the resistance of the wire between terminal P1-21 and wire 382-PK at the ether relay.

5. Connect all wires.

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.

  Repair: Repair the wire between terminal 86 of the ether relay and terminal P1-21. Verify that the original problem is resolved.

  STOP

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

1. Remove the electrical power from the ECM.

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

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

4. Measure the resistance between terminal P1-21 and all of the other terminal in the P1 and P2 connectors. Measure the resistance between wire P1-21 and engine ground.

5. Return the wiring to the original configuration.

Expected Result:

Each check of the resistance indicates an open circuit.

Results:

• OK - Each check of resistance indicates an open circuit.

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

  STOP

• Not OK - At least one check of the resistance does not indicate an open circuit. There is a problem with the wiring. There may be a problem with a connector.

  Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Verify that the original problem is resolved.

  STOP