Systems Operation

Usage:

Introduction

An ether aid starting system is designed to help the engine start at low ambient temperatures. Ether is injected into the intake manifold to aid combustion. White smoke in the exhaust stream is one indication of incomplete combustion. Using an ether system will help prevent engine damage during cold start due to rough combustion.

The system can be operated in auto or manual mode. A toggle switch is located on the EMCP panel, the junction box, or remote mounted on the customer control panel. This switch has three positions: Manual (momentary switch), Off (middle position), and Auto (continuous).

Sequence of Operation

Auto Mode

When the switch is in the auto position it will operate in the auto mode. The auto mode receives power only during cranking. Ether is injected until the cranking signal is lost, or the jacket water temperature requirement is met.

1. Power is supplied when the jacket water temperature is less than 13°C (55°F) and the engine is cranking.

2. The solenoid is supplied with full battery voltage to open the valve.

3. The control group cuts the voltage by energizing the resistor assembly to protect the solenoid.

4. Ether is injected until the cranking signal is terminated, or the jacket water temperature is 21°C (70°F).

Manual Mode

When the switch is in the manual position the system will operate in the manual mode. This mode is enabled after the loss of the cranking signal. The use of this mode is to help the engine run smoothly when cold, and to reduce or eliminate white smoke.

1. Power is supplied when jacket water temperature is less than 13°C (55°F) and crank terminate has been reached.

2. The solenoid is supplied with full battery voltage to open the valve.

3. The control group cuts the voltage by energizing the resistor assembly to protect the solenoid.

4. Ether is injected until jacket water temperature is 21°C (70°F) or the operator releases the switch.

Show/hide table

NOTICE

To protect the engine from damage due to cold starts below 13°C (55°F), the toggle switch must be pressed and held in the manual position until the engine can operate smoothly without ether. Failure to do this will result in piston and ring damage.

Locomotive Engines

The locomotive engines use a slightly different arrangement. Locomotives operate on a 64 volt system. This requires a different valve assembly that does not need the controller/resistor combination.

Operation

Auto Mode

1. Power is supplied when the jacket water temperature is less than 13°C (55°F) and the engine is cranking.

2. The solenoid is supplied with full battery voltage to open the valve.

3. Ether is injected until the cranking signal is terminated, or the jacket water temperature is 21°C (70°F).

Manual Mode

The difference between the manual mode operation above, and the locomotive manual mode, is how the power is supplied. The power comes from the non-essential locomotive power. The output power from the battery charger is available only when the engine is turning.

Starting Procedure

Operator In Sight Of The Exhaust

1. Initiate start sequence with the system in the auto mode. This will inject a metered amount of ether for the duration of the cranking cycle.

2. Switch to manual mode after engine starts, and inject ether to clear up visual white smoke.

Remote Operation (Cannot See Exhaust)

Install a timer on the manual side of the switch to inject ether. It will be necessary to bypass the switch due to the momentary nature of the manual side.

1. Remove the wire to the manual side of the switch and use it as input to the timer. Install the output from the timer to the manual side of the switch.

NOTE: Timer is customer supplied.

NOTE: Timer is normally closed for time indicated on chart.

2. Set the timer by performing tests to see how much ether is needed to clear the white smoke. Since this will be a function of ambient temperature, inlet and exhaust restriction, tests at different conditions would be ideal. If testing cannot be performed, use the following chart as an approximation.

Plumbing Components

Ether Cylinder Components
(1) Ether cylinder. (2) Dust collar. (3) Gasket filter.

The ether cylinder contains ethyl ether and uses carbon dioxide as the propellant. The dust collar (2) and gasket filter (3) come with the ether cylinder (1).

NOTE: Use only Caterpillar supplied ether cylinders. Incorrect ether cylinders will adversely effect the ether injection control.

NOTE: The 3508 and 3512 engines use one ether bottle. The 3516 engine uses two ether bottles.

(4) Orifice fitting. (5) Filter.

Orifice fitting (4) screws into the bottom of the solenoid valve. Orifice fitting (4) is left hand thread. The function of the orifice fitting is to control the amount of ether that flows through the lines to the engine. Replaceable filter (5) fits inside the orifice fitting.

Nozzle
(6) External mark. (7) Spray orifice.

A nozzle is mounted between the aftercooler and the turbocharger. The nozzle controls the ether spray pattern into the inlet system. The nozzle is oriented with the spray directed upward (towards the turbocharger). External mark (6) aligns with spray orifice (7) and is oriented towards the turbocharger.

Show/hide table

Ether is poisonous and flammable. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Use ether only in well ventilated areas. Use ether with care to avoid fires. Do not smoke while changing ether cylinders. Do not store ether cylinders in direct sunlight or at temperatures above 48°C (120°F). Discard ether cylinders properly. Do not puncture or burn ether cylinders. Keep ether cylinders out of reach of unauthorized personnel.

Component Description

9X-3207 Control Group

The control group is a timer that will alter the circuit after a timed interval has expired. This will protect the solenoid. 24 VDC ("Pull-In Voltage") is needed to open the valve. The control group provides full voltage to the valve assembly in order to open the valve. The control group then reduces the voltage to 12 VDC ("Hold-In Voltage").

3E-7298 Temperature Switch Assembly

The temperature switch limits when ether can be injected. It provides the ether starting system information on jacket water temperature. The switch is open at temperatures greater than 21°C (70°F). It is closed at temperatures lower than 13°C (55°F). The switch control is the same for manual and auto modes.

9X-9584 Resistor Assembly

The resistor assembly is used in conjunction with the control group to step down the voltage to protect the solenoid while the valve is held open. Its value is 20 Ohms.