3500B Engines for Caterpillar Built Power Modules with the ADEM 2 Electronic Control Module Caterpillar

System Operation Description:

The ECM controls the ether system. The ether system has two operating modes. 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 15 seconds at 300 °C (572 °F) and a maximum of 130 seconds at 500 °C (932 °F). AUTO ether injection is disabled whenever engine rpm exceeds 400 RPM or the engine coolant temperature exceeds 300 °C (572 °F).

MANUAL mode delivers ether to the engine when the Starting Aid Switch is placed in the MANUAL position. The manual position allows the ether to be injected when the engine rpm is greater than 50 RPM and the coolant temperature is less than 300 °C (572 °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. One output provides +Battery to one terminal of the Ether Start relay. The other terminal is connected to the Digital Return. The other output connects one terminal of the Ether Hold Relay to -Battery and the other terminal to +Battery. The drivers and the relays are used to provide a voltage signal. The voltage signal is used to actuate the solenoids. A lower voltage signal is used to hold the Ether solenoid valves open. The solenoids will be damaged if battery voltage is applied continuously.

Illustration 1	g00598816

Test Step 1. Check for Connector Damage.

1. Check the circuit breakers.

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

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

4. Check connectors and wiring for the following problems: damage, corrosion, abrasion and incorrect attachment.

Expected Result:

The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.

Results:

• OK - Proceed to test step 2.

• Not OK -

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

Test Step 2. Check for Diagnostics on the ET.

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

2. Turn the ECS to the STOP position.

3. Connect the ET.

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 - No active codes or logged codes are present. The ether injection system does not inject ether. Proceed to test step 3.

• Active Code - Active Diagnostics are displayed. Proceed to test step 4.

• Logged Code - Logged Diagnostics are displayed. Check for an intermittent short or open in the wiring or connectors

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

• Not OK - The Starting Aid Switch is not functioning correctly. Proceed to test step 5.

Test Step 3. Check the Ether Canisters.

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

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

3. Remove the ether canister(s) from the ether solenoid(s). Determine if the canister contains any ether. Ether can not be injected if the canister is empty.

Expected Result:

The canister should not be empty.

Results:

• OK - Proceed to test step 4.

• Not OK -

  Repair: The ether canister is empty. Replace the ether canister. Ether can not be injected if the canister is empty.

  Stop.

Test Step 4. Check the Voltage At The Ether Solenoid.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

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

6. Turn the ECS to the STOP position.

7. Insert signal reading probes into the 2 Pin connector for the Ether Solenoid.

8. Connect a multimeter.

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

10. Select the "Override Parameters" screen on the ET.

11. Activate the Ether Override and observe the multimeter while ether injection is "ON". Disable the Ether Override. This procedure must be performed on both solenoids if two are present. Do not allow the ether to be "ON" for more than two minutes. Damage may occur.

Expected Result:

The voltage at the Ether Solenoid should be 13 to 24 VDC during the first two seconds of injection. The voltage at the solenoid should be 3 to 11 VDC after the first two seconds of injection.

Results:

• OK - The voltage is approximately 24 VDC for the first two seconds and decreases to about 3 VDC for the remainder of injection.

  Repair: If ether is not being injected, temporarily replace the Ether Solenoid. If the problem is no longer present, reinstall the old solenoid. If the problem returns replace the solenoid.

  Stop.

• Not 24 VDC - The voltage never reached 24 VDC or the voltage decreased to 3 VDC for the entire test. Proceed to test step 6.

• Not 3 VDC - The voltage reached 24 VDC for the first two seconds. The voltage did not decrease to 3 VDC for the remainder of the injection duration. Proceed to test step 7.

Test Step 5. Check the Ether Switch Wires at the Harness.

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

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

3. Disconnect J1/P1 and the Starting Aid Switch.

4. Obtain a suitable piece of wire. Connect the wires at the Starting Aid Switch together.

5. Measure the resistance between the ether switch P1-25 and the digital return 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 8.

• Not OK - There is a problem with the switch wiring in the harness.

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

Test Step 6. Check the Voltage at the Ether Hold Relay.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

5. Turn the circuit breaker for the battery to the ON position.

6. Turn the ECS to the STOP position.

7. Measure the voltage from terminal 87 and terminal 87a on the Ether Hold Relay to ground.

8. Select Diagnostic Tests from the ET.

9. Select the "Override Parameters" on the ET.

10. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. Do not allow ether to be ON more than two minutes. Damage may result.

Expected Result:

The voltage at terminal 87 should be 13 to 24 VDC during the first two seconds of injection. The voltage from terminal 87a should be 13 to 24 VDC after the first two seconds of injection.

Results:

• OK - The correct voltage appeared at both terminals. There is a problem in the wiring harness between the Resistor and the Diode Assembly and the Ether Hold Relay.

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

• Not OK - Voltage did not appear at either terminal. Proceed to test step 9.

• NO Voltage - Voltage appeared at only one of the terminals.

  Repair: There is an internal problem with the relay. Temporarily replace the relay. If the problem is no longer present, reinstall the old relay. If the problem returns replace the relay.

  Stop.

Test Step 7. Check the Voltage at the Resistor and the Diode Assembly.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

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

6. Turn the ECS to the STOP position.

7. Use signal reading probes to measure the voltage between pin 1 of the Resistor and the Diode Assembly and ground.

8. Select Diagnostic Tests on the ET.

9. Select the "Override Parameters" on the ET.

10. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. This procedure must be performed on both assemblies if two are present. Do not allow ether to be ON more than two minutes. Damage may result.

Expected Result:

The voltage should be 13 to 24 VDC after the first two seconds of injection.

Results:

• OK - The correct voltage appeared. Proceed to test step 10.

• Not OK - The correct voltage does not appear. Proceed to test step 6.

Test Step 8. Check the Ether Switch Wires in the Harness.

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

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

3. Disconnect the Starting Aid Switch.

4. Toggle the Starting Aid Switch.

5. Measure the resistance between pin 1 and pin 2 of the Starting Aid Switch.

6. Release the Starting Aid Switch and repeat the previous measurement.

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 -

  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 -

  Repair: There is a problem with the Starting Aid Switch. Temporarily replace the Starting Aid Switch with a new switch. If the problem is no longer present, reinstall the old switch. If the problem returns replace the switch.

  Stop.

Test Step 9. Check the Voltage Supply to the Ether Start Relay.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

5. Turn the circuit breaker for the battery to the ON position.

6. Turn the ECS to the STOP position.

7. Use a multimeter to measure the voltage from terminal 30 on the Ether Start Relay to ground.

8. Select Diagnostic Tests from the ET.

9. Select the "Override Parameters" on the ET.

10. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. Do not allow ether to be ON more than two minutes. Damage may occur.

Expected Result:

The voltage at terminal 30 should be 13 to 24 VDC during injection.

Results:

• OK - The correct voltage appears at the terminal. A problem may exist with the ECM or the wiring to the Ether Start Relay. Proceed to test step 11.

• Not OK - The relay is not receiving the correct voltage. Proceed to test step 12.

Test Step 10. Check the Assembly.

1. Disconnect the 2 Pin connector at 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 and observe the multimeter.

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

5. Repeat the measurements for the assemblies if two are present.

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 assembly is operating correctly. There is a problem in the harness between the assembly and the Ether Solenoid.

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

• Not OK -

  Repair: The Resistor and the Diode Assembly is causing the problem. Temporarily replace the Resistor and the Diode Assembly. If the problem is no longer present, reinstall the resistor and the diode. If the problem returns replace the resistor and the diode assembly.

  Stop.

Test Step 11. Check the Signal to the Ether Start Relay.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

5. Turn the circuit breaker for the battery to the ON position.

6. Turn the ECS to the STOP position.

7. Use a multimeter and measure the voltage from terminal 85 to terminal 86 at the Ether Start Relay. Measure the voltage from terminal 85 to +Battery.

8. Select Diagnostic Tests from the ET.

9. Select the "Override Parameters" on the ET. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. Do not allow ether to be ON more than two minutes. Damage may occur.

Expected Result:

The voltage from terminal 85 to terminal 86 should be 13 to 24 VDC during the first two seconds of injection.

The voltage from terminal 85 to +Battery should be less than 3 VDC during the first two seconds of injection.

Results:

• OK - The correct voltage appears in both measurements.

  Repair: There is an internal problem with the relay. Temporarily replace the relay. If the problem is no longer present, reinstall the old relay. If the problem returns replace the relay.

  Stop.

• Terminal 86 Not OK - The correct voltage appeared between terminal 85 and +Battery but not between terminal 85 and terminal 86.

  Repair: There is a problem in the harness between terminal 86 and +Battery.

  Stop.

• No Voltage - Proceed to test step 13.

Test Step 12. Check the Voltage at the Ether Start Relay.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

5. Turn the circuit breaker for the battery to the ON position.

6. Turn the ECS to the STOP position.

7. Use a multimeter to measure the voltage from terminal 30 and terminal 87 on the Ether Start Relay to ground.

8. Select Diagnostic Tests from the ET.

9. Select the "Override Parameters" on the ET. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. Do not allow ether to be ON more than two minutes. Damage may occur.

Expected Result:

The voltage at terminal 30 should always be 13 to 24 VDC.

The voltage at terminal 87 should be 13 to 24 VDC during the first two seconds of injection.

Results:

• OK - The correct voltage appears at both terminals.

  Repair: A problem exists in the wire that connects the Ether Start Relay and the Ether Hold Relay.

  Stop.

• Not OK - No voltage appears at terminal 30. There is a problem in the wiring between Terminal Block 4 and terminal 30.

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

• Terminal 87 Not OK - Proceed to test step 14.

Test Step 13. Check the Ether Hold Relay at the ECM.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

5. Turn the circuit breaker for the battery to the ON position.

6. Turn the ECS to the STOP position.

7. Measure the voltage from the Ether Hold P1-22 to the +Battery P1-4.

8. Select Diagnostic Tests from the ET.

9. Select the "Override Parameters" on the ET. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. Do not allow ether to be ON more than two minutes. Damage may occur.

Expected Result:

The voltage should be 13 to 24 VDC during the first two seconds of injection.

Results:

• OK - The ECM is supplying the correct voltage.

  Repair: A problem exists in the wire that connects the Ether Start Relay and the Ether Hold Relay.

  Stop.

• Not OK - The correct voltage did not appear at the ECM connector. A problem may exist in the harness. Proceed to test step 15.

Test Step 14. Check the Signal to the Ether Start Relay.

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Connect the ET.

5. Turn the circuit breaker for the battery to the ON position.

6. Turn the ECS to the STOP position.

7. Measure the voltage from terminal 85 to terminal 86 at the Ether Start Relay. Measure the voltage from terminal 86 to the Instrument Box J3A-25.

8. Select Diagnostic Tests from the ET.

9. Select the "Override Parameters" on the ET. Activate the Ether Override and observe the multimeter while ether injection is ON. Disable the Ether Override. Do not allow ether to be ON more than two minutes. Damage may occur.

Expected Result:

The voltage from terminal 85 to terminal 86 should be 13 to 24 VDC during the first two seconds of injection.

The voltage from terminal 85 to J3A-25 should be 13 to 24 VDC during the first two seconds of injection.

Results:

• OK - The correct voltage appears in both measurements. There is an internal problem with the relay.

  Repair: There is an internal problem with the relay. Temporarily replace the relay. If the problem is no longer present, reinstall the old relay. If the problem returns replace the relay.

  Stop.

• Terminal 86 Not OK - The correct voltage appeared between terminal 85 and J3A-25 but not between terminal 85 and terminal 86. There is a problem in the harness or on Terminal Block 12 between terminal 86 and J3A-25.

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.

• No Voltage - No voltage appeared at terminal 85. Proceed to test step 15.

Test Step 15. Check For Shorts in the Harness

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

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

3. Remove the ether canister(s) from the ether solenoid(s).

4. Disconnect ECM connector J1/P1, and terminal 85 at the Ether Hold Relay.

5. Measure the resistance between the Ether Hold P1-22 and the +Battery P1-4. Measure the resistance between the Ether Hold P1-22 and +Battery P1-6.

6. Reconnect ECM connector J1/P1 and terminal 85.

Expected Result:

The resistance should be greater than 20,000 Ohms.

Results:

• OK - There are no shorts in the harness. The ECM is not producing the correct signal.

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

  Stop.

• Not OK - A short exists in the harness.

  Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.

  Stop.