11. 10. 2021. 09:26 SIS 2.

2006/01/31 Ether Injection System - Test (RENR5096)

SMCS - 1456 i02486497

System Operation Description:

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

The ether injection system can be operated in manual mode when the ether start switch is held in the ON position (momentary contact). The ether
system is switched into manual mode whenever the ether start switch is depressed. Manual mode also allows ether to be injected whenever the
coolant temperature is less than 18 °C (64 °F) and engine rpm is greater than 50 rpm. The manual ether injection system is disabled whenever
engine rpm exceeds 400 rpm or the engine coolant temperature exceeds 18 °C (64 °F).

Illustration 1 g01201894
Schematic for the ether injection system (typical configuration)

Test Step 1. Inspect the Electrical Connectors and the Wiring

A. Remove electrical power from the Electronic Control Module (ECM). Turn the battery isolator switch to the OFF position.

Illustration 2 g01186024
Location of the J1/P1 ECM connector (typical left side engine view)

B. Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors that are in the circuit. Refer to Troubleshooting, "Electrical
Connectors - Inspect" for details.

Illustration 3 g01241629
Terminal locations at the P1 ECM connector for the ether injection system
(P1-21) Ether starting aid
(P1-22) Auto/manual switch

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

D. Check the allen head screw for each of the ECM connectors for the proper torque. Refer to the diagnostic functional Troubleshooting,
"Electrical Connectors - Inspect" for correct torque values.

E. 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 and of pinch
points.

Results:

OK - The connectors and wiring appear to be OK. Proceed to Test Step 2.

Not OK - There is a problem with the electrical connectors and/or wiring.

Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure
that the connectors are completely coupled.

STOP

Test Step 2. Check the Ether Canisters for Fluid

A. Turn the battery isolator switch to the OFF position.

B. Remove the ether canister from the ether solenoid. Determine if the canister contains any ether.

Expected Result:

The ether canister is not empty.

Results:

OK - The ether canister is not empty. Remove the ether canister from the ether solenoid for the remainder of this test. Proceed to Test Step 3.

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11. 10. 2021. 09:26 SIS 2.0

Not OK - The ether canister is empty.

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

STOP

Test Step 3. Check the Voltage from the Ether Start Relay

A. Turn the battery isolator switch to the OFF position.

B. Connect Caterpillar Electronic Technician (ET) to the service tool connector.

C. Disconnect the wire from terminal 87 of the ether relay.

D. Fabricate a jumper wire that is long enough to provide a test circuit from the engine ground stud to the ether relay. Connect one end of the
wire to the engine ground stud. The other end of the jumper wire will be used to provide a ground circuit for the voltmeter.

E. Turn the battery isolator switch to the ON position.

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

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

H. Activate the ether override and observe the voltmeter while ether injection is activated.
Note: The ether override will activate the solenoid for ten seconds. The measurement must be taken within this time period.

I. Measure the voltage between terminal 87 of the ether relay and the loose end of the jumper wire.

J. Turn the battery isolator switch to the OFF position.

K. Restore the original wire to terminal 87 of the ether relay.

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. The start relay is OK. Proceed to Test Step 4.

Not OK - 24 VDC - The voltage at the ether start relay is not 24 ± 3 VDC. Proceed to Test Step 5.

Test Step 4. Check the Voltage at the Starting Aid Solenoid Valve

A. Disconnect the connector from the starting aid solenoid valve.

B. Connect a voltmeter between terminal 1 and terminal 2 on the harness side of the connector.

C. Turn the battery isolator switch to the ON position.

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

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

F. Activate the ether override and observe the voltmeter while ether injection is activated.
Note: The ether override will activate the solenoid for ten seconds. The measurement must be taken within this time period.

G. Measure the voltage at the connector for the starting aid solenoid valve.

H. Turn the battery isolator switch to the OFF position.

I. Reconnect all connectors.

Expected Result:

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

Results:

OK - The voltage at the connector for the ether solenoid is 24 ± 3 VDC.

Repair: Control input voltage is present at the connector for the starting aid solenoid valve. There is a problem with the valve. Replace the
starting aid solenoid valve.

STOP

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

Repair: There is a problem in the harness between the ether relay and the starting aid solenoid valve. The problem may be in the ground
circuit for the starting aid solenoid valve. Check the wiring harness and the connectors for problems. Repair the harness and/or the
connectors. Replace parts, if necessary.

STOP

Test Step 5. Check the Control Input Voltage at the Ether Start Relay

A. Turn the battery isolator switch to the OFF position.

B. Disconnect the wires from terminals 85 and 86 of the ether relay.

C. Turn the battery isolator switch to the ON position.

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

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

F. Activate the ether override and observe the voltmeter while ether injection is activated.
Note: The ether override will activate the solenoid for ten seconds. The measurement must be taken within this time period.

G. Measure the voltage between terminals 85 and 86 of the ether relay.

H. Turn the battery isolator switch to the OFF position.

I. Restore the original wires into terminals 85 and 86 of the ether relay.

Expected Result:

The voltage measures 24 ± 3 VDC.

Results:

OK - The voltage measured 24 ± 3 VDC. Control input voltage is reaching the ether relay. Proceed to Test Step 6.

Not OK - The voltage was not 24 ± 3 VDC. Control input voltage is not reaching the control relay. Proceed to Test Step 7.

Test Step 6. Check the Secondary Voltage to the Ether Relay

A. Fabricate a jumper wire that is long enough to provide a test circuit from the battery to the ether relay. Connect one end of the wire to the
battery terminal for −Battery.

B. Turn the battery isolator switch to the ON position. Start the engine.

C. Measure the voltage between terminal 30 of the ether relay and the −Battery.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

OK - The voltage is 24 ± 3 VDC.

Repair: The wiring and the connectors to the ether relay are OK. There is a problem with the ether relay. Replace the ether relay. Verify that
the ether starting aid is operating correctly.

STOP

Not OK - The voltage is not 24 ± 3 VDC.

Repair: If the engine started in the Test Step above and voltage is not present at terminal 30 of the ether relay, the voltage is correct at the
control relay. The problem is in the harness between the control relay and the ether relay. There may be a problem with a connector. Repair
the harness and/or the connectors. Replace parts, if necessary.

STOP

Test Step 7. Check the Operation of the ECM

A. Turn the battery isolator switch to the OFF position.

B. Fabricate a jumper wire that is long enough to measure voltage from a terminal at the ECM connector. Crimp a connector socket to one end
of the jumper wire.

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11. 10. 2021. 09:26 SIS 2.0

C. Disconnect the J1/P1 ECM connectors.

D. Remove the wire from terminal location P1-21 at the ECM connector. Install the wire jumper into this terminal location.

E. Connect the J1/P1 ECM connector.

F. Connect a voltmeter between the −Battery and the wire jumper in terminal P1-21.

G. Turn the battery isolator switch to the ON position.

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

I. Activate the ether override and observe the voltmeter while ether injection is activated.
Note: The ether override will activate the solenoid for ten seconds. The measurement must be taken within this time period.

J. Monitor the voltage on the voltmeter.

K. Turn the battery isolator switch to the OFF position.

L. Restore the wiring to the original configuration.

Expected Result:

The voltage measured 24 ± 3 VDC.

Results:

OK - The voltage measured 24 ± 3 VDC. The output driver for the ether relay at the ECM is OK. the problem is in the harness from the ECM
to the ether relay. The problem may be in a connector. Repair the harness and/or the connector. Replace parts, if necessary.

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

Repair: Replace the ECM. Refer to electronic troubleshooting Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.

STOP

AR21-UP, C5E1-UP, C5H1-UP, C5L1-UP, C9E1-UP, CYY1-UP, EKW1-UP, FST1-UP, FTE1-UP, L8B1-UP, LN91-UP, LT91-UP, LX91-UP, NBP1-UP,
NGP1-UP, NKL1-UP, NTX1-UP, RZ91-UP, S9L1-UP, S9P1-UP, X3R1-UP, X4R1-UP, X6X1-UP, XP71-UP, XPL1-UP

PPI-0001A599
2021/10/11
07:26:39+02:00
i02406190
© 2021 Caterpillar Inc.
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