3500B Engines for 5130B and 5230B Excavators Ether Injection System Caterpillar

System Operation Description:

When the engine is in AUTO mode the engine uses an Ether System to improve starting in cold temperatures. 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 the engine temperature. The ECM determines if ether should be injected by monitoring the 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 engine rpm is at a certain level. The ether will activate for a minimum of 10 seconds at 10 °C (50 °F) up to a maximum of 130 seconds at -40 °C (-40 °F). The automatic ether injection system is disabled whenever 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. Manual mode allows ether to be injected whenever the coolant temperature is less than 10 °C (50 °F). The manual mode will allow ether to be injected for 5 seconds when the switch is toggled. If the engine speed is 0.0 rpm and the engine coolant temperature is less than 10 °C (50 °F) the ether injection system will operate for 5 seconds.

Two driver outputs are used from the ECM. One ECM output provides the + Battery terminal to the coil of the ether start relay. The other coil terminal of the ether start relay is connected to the digital return. The other ECM output provides the current sinking for the coil of the ether hold relay. The other coil terminal of the ether hold relay is connected to the + Battery terminal. The drivers and the relays are used to provide a higher voltage signal that will actuate the ether solenoids. A lower voltage signal is then used to hold the ether solenoid valves open. The solenoids will be damaged if battery voltage is applied continuously.

Illustration 1	g00813954

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Personal injury or death can result from using ether. Failure to follow these instructions could result in an explosion and/or fire and possible personal injury. When using starting fluid, follow the manufacturer's instructions carefully. Use ether sparingly and spray it only while cranking the engine. Also, do not store starting fluid containers in the cab.

Test Step 1. Check for Connector Damage.

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

2. Turn the ECS to the OFF/RESET position.

3. Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to 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 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 Canisters.

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 Diagnostics on the ET.

1. Connect the ET.

2. Turn the circuit breaker for the battery 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 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. Reinstall 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 circuit breaker for the battery to the OFF position.

2. Turn the keyswitch to the OFF position.

3. Connect the ET.

4. Turn the circuit breaker to the battery to the ON position.

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

6. Turn the keyswitch to the ON position.

7. Select the "Diagnostic Tests" on the ET.

8. Select the "Override Parameters" screen on the 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.

9. 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 4 ± 2 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 decreases to approximately 4 ± 2 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 - 4 VDC - The voltage does not decrease to 4 ± 2 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 4 ± 2 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 4 ± 2 VDC for the remainder of injection.

  Repair: If ether is not being injected, replace the ether solenoid. Verify that the system is operating correctly. Reinstall 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 - 4 VDC - The voltage does not decrease to 4 ± 2 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. Connect a voltmeter between wire F710-BR on terminal 85 of the ether start relay to ground.

2. 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.

3. 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 315-GN 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 998-BR on terminal 86 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 breakers for the battery and/or the relay are not tripped. Disconnect wire 315-GN on terminal 30 of the ether start relay. Check wire 315-GN 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 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. Reinstall 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 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 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 30 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 the Diode Assembly.

1. Turn the keyswitch to the OFF position.

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

3. Connect a voltmeter to pin 1 of the resistor and the 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. Reinstall the ether canister on the ether solenoid.

  Stop.

Test Step 11. Check the Resistor and the Diode Assembly.

1. Disconnect the 2 Pin connector at the resistor and the 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 the 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 the 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)".

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 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. Verify that the system is operating correctly. Reinstall the ether canister on the ether solenoid.

  Stop.

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

  Repair: The resistor and the diode assembly is causing the problem. Replace the resistor and the diode assembly. Verify that the system is operating correctly. Reinstall 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 wire 315-GN on terminal 30 and terminal 86 of the ether hold relay and 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 breakers for the battery and/or the relay are not tripped. Disconnect wire 315-GN on terminal 30 of the ether hold relay. Check wire 315-GN for continuity to the + Battery terminal. If the wire is not okay repair the wire. Verify that the system is operating correctly. Reinstall 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 F706-PU from terminal 85 of the ether hold relay. Connect a voltmeter between terminal 85 of the ether hold relay and - Battery terminal.

3. Turn the keyswitch to the ON position.

4. Monitor the voltage on the voltmeter.

5. Remove the voltmeter and reconnect all wires.

Expected Result:

The voltmeter should measure 24 ± 3 VDC.

Results:

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

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

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

  Stop.

Test Step 14. Check the Input from the Ether Hold Relay to the ECM.

1. Turn the keyswitch to the OFF position.

2. Disconnect ECM connector P1.

3. Remove wire F706-PU from ECM connector P1-27. Install a jumper wire that has a socket on one end into ECM connector P1-27.

4. Reconnect ECM connector P1.

5. Connect a voltmeter between the jumper wire and 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 wire F706-PU 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. Reinstall 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 Troubleshooting, "Replacing the ECM".

  Stop.

Test Step 15. Check the Wires of the Starting Aid Switch at the Harness.

1. Turn the keyswitch to the OFF position.

2. Disconnect J1/P1 and the starting aid switch.

3. Obtain a suitable piece of wire. Jumper the wires from the starting aid switch together.

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

Expected Result:

The resistance should be less than 10 Ohms.

Results:

• OK - The resistance is less than 10 Ohms. The switch wiring is not the problem. 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. Reinstall the ether canister on the ether solenoid.

  Stop.

Test Step 16. Check the Starting Aid Switch.

1. Turn the keyswitch to the OFF position.

2. Disconnect the starting aid switch.

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

4. Toggle the starting aid switch.

5. Measure the resistance between pin 2 and pin 3 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 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. Reinstall the ether canister on the ether solenoid.

  Stop.