3516B Engine for Caterpillar Built Machines Caterpillar

The Electronic Control Module (ECM) controls the ether system. The ether system has two modes of operation. The ether system can operate in AUTO mode and in MANUAL mode. The engine coolant temperature and the engine rpm is used to determine ether injection. AUTO ether injection will activate for a minimum of 10 seconds at 10 °C (50 °F) and a maximum of 130 seconds at -40 °C (-40 °F). AUTO ether injection is disabled whenever engine rpm exceeds 1900 RPM or the engine coolant temperature exceeds 10 °C (50 °F).

The ether injection system can also be operated in manual mode. The ether system is switched into manual mode whenever the starting aid switch is depressed. The manual position allows the ether to be injected when the engine rpm is less than 1900 RPM and the coolant temperature is less than 10 °C (50 °F). The MANUAL mode will allow ether to be injected for a maximum of 130 seconds when the switch is toggled.

Two driver outputs are used from the ECM. The first output provides a + Battery voltage to the coil of the ether start relay. The other side of the coil is connected to the - Battery terminal. The ether start relay energizes the ether solenoids with 24 VDC. The second output connects the coil of the ether hold relay to the - Battery terminal. The other side of the coil is connected to the + Battery terminal. The ether hold relay keeps the ether solenoid energized with a reduced voltage through a dropping resistor and diode assembly. The solenoid will be damaged if battery voltage is applied continuously.

Illustration 1	g00920524

Test Step 1. Check for Connector Damage.

1. Turn the circuit breaker for the ECM to the OFF position.

2. Turn the keyswitch to the OFF position.

3. 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.

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

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

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

7. Check the harness and the wiring for abrasion and for 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 are not okay.

  Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly.

  Stop.

Test Step 2. Check the Ether Canister.

1. Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Ether can not be injected if the canister is empty.

Expected Result:

The ether canister should not be empty.

Results:

• OK - The ether canister is not empty. Proceed to test step 3.

• Not OK - The ether canister is empty.

  Repair: Replace the empty ether canister with a full ether canister.

  Stop.

Test Step 3. Check for "ACTIVE" Diagnostics on the Caterpillar Electronic Technician (ET).

1. Connect the Cat ET to the cab service tool connector J42. Start the Cat ET.

2. Turn the circuit breaker for the ECM to the ON position.

3. Turn the keyswitch to the ON position.

4. Determine if CID-FMI 545-05, 545-06, 546-05 or 546-06 is active or logged.

5. Toggle the starting aid switch. Observe the parameter for the ether switch on the Cat 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 - Active Code - The parameter for the starting aid switch displays "ON" while the starting aid switch is toggled. The parameter for the starting aid switch displays "OFF" when the starting aid switch is released. Active Diagnostics are displayed. Proceed to test step 4.

• OK - Logged Code - The parameter for the starting aid switch displays "ON" while the starting aid switch is toggled. The parameter for the starting aid switch displays "OFF" when the starting aid switch is released. 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. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

• Not OK - The parameter for the starting aid switch does not display "ON" while the starting aid switch is toggled. The parameter for the starting aid switch does not display "OFF" when the starting aid switch is released. No active codes or logged codes are present. The starting aid switch is not functioning correctly. Proceed to test step 15.

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

1. Turn the keyswitch to the OFF position.

2. Connect a voltmeter between wire 311-WH on terminal 87 of the ether start relay and ground.

3. Turn the keyswitch to the ON position.

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

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

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

6. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

Expected Result:

The voltage at the ether start relay should measure 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 measured approximately 24 ± 3 VDC for the first two seconds. The voltage then decreased to approximately 3 ± 1 VDC for the remainder of injection duration. Proceed to test step 5.

• Not OK - 24 VDC - The voltage does not measure 24 ± 3 VDC. Proceed to test step 6.

• Not OK - 3 VDC - The voltage does not decrease to 3 ± 1 VDC for the remainder of the injection duration. Proceed to test step 9.

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

1. Turn the keyswitch to the OFF position.

2. Disconnect the ether solenoid connector at the solenoid.

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

4. Turn the keyswitch to the ON position.

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

5. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

6. Reconnect all connectors.

Expected Result:

The voltage at the ether solenoid should measure 24 ± 3 VDC during the first two seconds of injection. The voltage at the ether solenoid should decrease to 3 ± 1 VDC after the first two seconds of injection.

Results:

• OK - The voltage measured approximately 24 ± 3 VDC for the first two seconds of injection. The voltage then decreases to about 3 ± 1 VDC for the remainder of injection.

  Repair: If ether is not being injected, replace the ether solenoid. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

• Not OK - 24 VDC - The voltage does not measure 24 ± 3 VDC for 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 does not decrease to 3 ± 1 VDC for the remainder of the injection duration. Proceed to test step 9.

Test Step 6. Check the ECM Voltage at the Ether Start Relay.

1. Turn the keyswitch to the OFF position.

2. Connect a voltmeter between wire F710-BR on terminal 86 of the ether start relay to ground.

3. Turn the keyswitch to the ON position.

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

4. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

Expected Result:

The voltage should measure 24 ± 3 VDC for two seconds.

Results:

• OK - The voltage measured 24 ± 3 VDC. Proceed to test step 7.

• Not OK - The voltage does not measure 24 ± 3 VDC. Proceed to test step 8.

Test Step 7. Check the Battery Voltage to the Ether Start Relay.

1. Measure the voltage between wire 150-RD on terminal 30 of the ether start relay and ground.

Expected Result:

The voltage should measure 24 ± 3 VDC.

Results:

• OK - The voltage measures 24 ± 3 VDC.

  Repair: Disconnect wire 200-BK on terminal 85 of the ether start relay. Check this wire for continuity to ground. If the wire is okay, replace the ether start relay. If the wire is not okay, repair the wire. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

• Not OK - The voltage does not measure 24 ± 3 VDC.

  Repair: Verify that the breaker for the engine is not tripped. Disconnect wire 150-RD on terminal 30 of the ether start relay. Check wire 150-RD for continuity to the + Battery terminal. If the wire is not okay, repair the wire. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

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

1. Turn the keyswitch to the OFF position.

2. Disconnect ECM connector P1.

3. Remove wire F710-BR from the ECM connector P1-40. Install a jumper wire that has a socket on one end into ECM connector P1-40. Reconnect connector P1 to the ECM.

4. Connect a voltmeter between the jumper wire in P1-40 and engine ground.

5. Turn the keyswitch to the ON position.

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

6. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

7. Remove all wire jumpers and reconnect all connectors.

Expected Result:

The voltage at the ECM should measure 24 ± 3 VDC for two seconds.

Results:

• OK - The voltage measures 24 ± 3 VDC for two seconds.

  Repair: 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. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

• Not OK - The voltage at the ECM does not measure 24 ± 3 VDC for two seconds.

  Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".

  Stop.

Test Step 9. Check the Voltage from the Ether Hold Relay.

1. Turn the keyswitch to the OFF position.

2. Connect a voltmeter between wire 377-OR on terminal 87 of the ether hold relay and engine ground.

3. Turn the keyswitch to the ON position.

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

4. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

Expected Result:

The voltage at terminal 87 should measure 24 ± 3 VDC during injection.

Results:

• OK - The voltage at terminal 87 measured 24 ± 3 VDC during injection. Proceed to test step 10.

• Not OK - The voltage at terminal 87 does not measure 24 ± 3 VDC during injection. Proceed to test step 12.

Test Step 10. Check the Voltage at the Resistor and Diode Assembly.

1. Turn the keyswitch to the OFF position.

2. Disconnect the connector at the resistor and diode assembly.

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

4. Turn the keyswitch to the ON position.

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

5. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

Expected Result:

The voltage should measure 24 ± 3 VDC.

Results:

• OK - The voltage measured 24 ± 3 VDC. Proceed to test step 11.

• Not OK - The voltage did not measure 24 ± 3 VDC.

  Repair: There is a problem in the harness between the ether hold relay and the resistor and diode assembly. Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

Test Step 11. Check the Resistor and Diode Assembly.

1. Disconnect the connector at the resistor and diode assembly.

2. Set the multimeter to the "Check Diode" setting.

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

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

Expected Result:

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

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

Results:

• OK - The resistor and 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. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

• Not OK - The resistor and diode assembly is not operating correctly.

  Repair: The resistor and diode assembly is causing the problem. Replace the resistor and diode assembly. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

Test Step 12. Check the Battery Voltage to the Ether Hold Relay.

1. Measure the voltage between terminal 86 of the ether hold relay and engine ground.

2. Measure the voltage between wire 150-RD on terminal 30 of the ether hold relay and engine ground.

Expected Result:

The voltage should measure 24 ± 3 VDC.

Results:

• OK - The voltage measured 24 ± 3 VDC. Proceed to test step 13.

• Not OK - The voltage did not measure 24 ± 3 VDC.

  Repair: Verify that the breaker for the engine is not tripped. Disconnect wire 150-RD on terminal 30 of the ether start relay. Check wire 150-RD for continuity to the + Battery terminal. If the wire is not okay, repair the wire. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

Test Step 13. Check the Coil of the Ether Hold Relay.

1. Turn the keyswitch to the OFF position.

2. Remove wire F707-WH from terminal 85 of the ether hold relay. Connect a voltmeter between terminal 85 of the ether hold relay and the - Battery terminal.

3. Turn the keyswitch to the ON position.

4. Measure the voltage between terminal 85 of the ether hold relay and the - Battery terminal.

5. Remove the voltmeter and reconnect all wires.

Expected Result:

The voltage should measure 24 ± 3 VDC.

Results:

• OK - The voltage measures 24 ± 3 VDC. Proceed to test step 14.

• Not OK - The voltage does not measure 24 ± 3 VDC. The problem is the coil of the ether hold relay.

  Repair: Replace the ether hold relay. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

Test Step 14. Check the Signal of the Ether Hold Relay to the ECM.

1. Turn the keyswitch to the OFF position.

2. Disconnect ECM connector P1.

3. Remove wire F707-WH from ECM connector P1-22. Install a jumper wire that has a socket on one end into ECM connector P1-22.

4. Reconnect ECM connector P1.

5. Connect one end of a voltmeter to the jumper wire and the other end to the + Battery terminal.

6. Turn the keyswitch to the ON position.

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NOTICE
Do not allow the Ether Injection System to be on for more than two minutes. Damage to the Ether Solenoid may occur.

7. Activate the ether override and observe the voltmeter while ether injection is activated. Disable the ether override.

8. Remove all jumpers and connect all connectors.

Expected Result:

The voltage should measure 24 ± 3 VDC.

Results:

• OK - The voltage measures 24 ± 3 VDC.

  Repair: There is a problem in the wiring between the ECM and the ether hold relay. Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

• Not OK - The voltage does not measure 24 ± 3 VDC.

  Repair: Verify that the voltmeter is operating correctly. Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".

  Stop.

Test Step 15. Check for an Open in the Harness of the Starting Aid Switch.

1. Turn the circuit breaker to the engine to the OFF position.

2. Turn the keyswitch to the OFF position.

3. Disconnect J1/P1 and wires that are going to the starting aid switch.

4. Obtain a suitable piece of wire. Connect the wires from the starting aid switch together.

5. Measure the resistance of the wires from the starting aid switch. Measure the resistance at the ECM connector P1-25 and P1-29.

6. Remove the jumper.

Expected Result:

The resistance should be less than 10 Ohms.

Results:

• OK - The resistance is less than 10 Ohms. Proceed to test step 16.

• Not OK - The resistance is greater than 10 Ohms. There is a problem with the switch wiring in the harness.

  Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

Test Step 16. Check for a Short in the Harness of the Starting Aid Switch.

1. Measure the resistance between wire F720-GN of the starting aid switch and engine ground.

2. Measure the resistance between wire 998-BR of the starting aid switch and engine ground.

3. Reconnect ECM connector J1/P1.

Expected Result:

The resistance should measure more than 20,000 Ohms.

Results:

• OK - The resistance measures more than 20,000 Ohms. Proceed to test step 17.

• Not OK - The resistance measures less than 20,000 Ohms.

  Repair: There is an open circuit or excessive resistance in the wiring between the starting aid switch and the ECM connector J1/P1. Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.

Test Step 17. Check the Starting Aid Switch.

1. Turn the circuit breaker for the engine to the OFF position.

2. Turn the keyswitch to the OFF position.

3. Disconnect the starting aid switch.

4. Measure the resistance between pin 1 and pin 2 of the starting aid switch.

5. Toggle the starting aid switch.

6. Measure the resistance between pin 1 and pin 2 of the starting aid switch.

Expected Result:

The resistance should be less than 10 Ohms with the switch toggled. The resistance should be greater than 20,000 Ohms when the switch is released.

Results:

• OK - The resistance is less than 10 Ohms with the switch toggled. The resistance is greater than 20,000 Ohms when the switch is released.

  Repair: The switch is operating correctly but the ECM is not reading the switch correctly. Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".

  Stop.

• Not OK - The resistance is greater than 10 Ohms when the switch is toggled. The resistance is less than 20,000 Ohms when the switch is released.

  Repair: There is a problem with the starting aid switch. Replace the starting aid switch with a new switch. Verify that the system is operating correctly. Replace the ether canister on the ether solenoid.

  Stop.