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

The engine has Electronic Unit Injectors that are mechanically actuated and electronically energized. The Electronic Control Module sends a 105 volt pulse to each injector solenoid. The pulse is sent at the proper time and at the correct duration for a given engine load and speed. The solenoid is mounted on top of the fuel injector body. The 105 volt pulse can be individually cut out to aid in troubleshooting misfire problems.

If an open is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a short is detected, a diagnostic code is generated. The ECM will disable the solenoid circuit. The ECM will then enable the solenoid. If the short circuit remains this sequence of events will be repeated until the problem is corrected.

Illustration 1	g00599630
8 Cylinder Engine

Illustration 2	g00599635
12 or 16 Cylinder Engine

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. Check the 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 LOGGED Diagnostic Codes

1. Connect the ET.

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

3. Turn the ECS to the STOP position.

4. Observe the diagnostic codes on the ET.

Expected Result:

A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 should not be logged.

Results:

• OK - Proceed to test step 3.

• Not OK - Proceed to test step 4.

Test Step 3. Perform the Cylinder Cutout Test.

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NOTICE
Engine power is reduced when a properly functioning cylinder is cut out. Make sure that you will not damage auxiliary or driven equipment if the engine power is suddenly reduced.

Note: The test verifies that the ECM can fire the solenoids. Do not try to crank the engine during this test. The engine will start and the ECM will terminate the Injector Solenoid Test.

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

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

3. Verify that the ECM connector J2/P2 and the injector connectors J4/P4 through J19/P19 are properly connected.

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

5. Install the ET.

6. Start the engine.

7. Apply a load to the engine.

8. Use the diagnostic tests on the ET to initiate the injector solenoid test.

9. Check for a difference in the sound, feel, or power of the engine as each cylinder is cut out. The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or a bad cylinder.

10. Disable the override. Repeat above steps for each cylinder (solenoid).

Expected Result:

The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or a bad cylinder.

Results:

• OK - Stop.

• Not OK - Proceed to test step 5.

Test Step 4. Check the Harness Resistance.

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This engine uses high voltage to control the fuel injectors. Disconnect electronic fuel injector enable circuit connector to prevent personal injury. Do not come in contact with the fuel injector terminals while the engine is running.

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

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

3. Disconnect J2/P2 and J4/P4 through J19/P19.

4. Measure the resistance at the J2 connector between the power output for the individual solenoid and the solenoid return. For the eight cylinder engine, refer to illustration 1. For the twelve or the sixteen cylinder engine, refer to illustration 2.

Expected Result:

The resistance should be greater than 20,000 Ohms.

Results:

• OK - Proceed to test step 6.

• Not OK -

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

  Stop.

Test Step 5. Check the Spring and the Valve Lash.

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

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

3. Check the Injector and the engine Valve Lash Setting. Refer to the Systems Operation.

Expected Result:

Results:

• OK - The injector is OK. Stop.

• Not OK - A problem is found with the injector.

  Repair: Repair the injector. If the problem is still present, replace the injector. If the new injector has a 4 Digit code that is different from the old injector, change the code in the ECM.

  Stop.

Test Step 6. Check the Harness Resistance.

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This engine uses high voltage to control the fuel injectors. Disconnect electronic fuel injector enable circuit connector to prevent personal injury. Do not come in contact with the fuel injector terminals while the engine is running.

1. For the 3508B, measure the resistance between the following points and engine ground: J2-5, J2-16, J2-17, J2-26, J2-27, J2-30, J2-31, J2-32, J2-36, J2-37, J2-38 and J2-39.

2. For the 3512B and 3516B, measure the resistance between the following points and engine ground: J2-4, J2-5, J2-6, J2-10, J2-11, J2-12, J2-16, J2-17, J2-18, J2-21, J2-22, J2-26, J2-27, J2-28, J2-30, J2-31, J2-32, J2-33, J2-34, J2-36, J2-37, J2-38, J2-39 and J2-40.

Expected Result:

The resistance should be greater than 20,000 Ohms.

Results:

• OK - Proceed to test step 7.

• Not OK -

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

  Stop.

Test Step 7. Check the Harness Resistance.

1. Use a suitable piece of wire to short socket 1 to socket 2 at each injector connectors.

2. Measure the resistance at the J2 connector between the power output for the individual solenoid and the solenoid return. For the eight cylinder engine, refer to illustration 1. For the twelve or the sixteen cylinder engine, refer to illustration 2.

Expected Result:

The resistance should be less than 10 Ohms.

Results:

• OK - Proceed to test step 8.

• Not OK -

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

  Stop.

Test Step 8. Measure the Resistance at the Valve Cover Base.

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Personal injury can result from high voltage. The Electronic Control Module produces high voltage. Make sure the Electronic Control Module is not powered and the fuel injector solenoids are disconnected before proceeding.

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

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

3. Ensure that the ECM connector J2/P2 is disconnected. Ensure that the injector connectors J4/P4 through J19/P19 are disconnected.

4. Measure the solenoid resistance between pin 1 and pin 2 at J4 through J19.

5. Record the measured resistance for each solenoid.

Expected Result:

Resistance should be between 0.5 and 1.5 Ohms.

Results:

• OK - Proceed to test step 9.

• Not OK - Proceed to test step 10.

Test Step 9. Perform the Injector Solenoid Test.

Note: This test will help the service technician verify that the ECM can fire the solenoids. DO NOT try to manually crank the engine during this test. The ECM will terminate the Injector Solenoid Test.

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

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

3. Ensure that the ECM connector J2/P2 is connected. Ensure that the injector connectors J4/P4 through J19/P19 are connected.

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 Diagnostic Tests on the ET to initiate the Injector Solenoid Test.

8. As each solenoid is energized by the ECM an audible click can be heard at the valve cover. Listen for a click at each valve cover. A black square will appear over the cylinder number when the cylinder is being fired.

Expected Result:

As each solenoid is energized by the ECM, an audible click of the solenoid should be heard. The solenoids will be energized one at a time in the following numerical order: 1-16. There will be momentary delay between each one.

Results:

• OK - Proceed to test step 3.

• Not OK - Proceed to test step 11.

Test Step 10. Check the Resistance.

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This engine uses high voltage to control the fuel injectors. Disconnect the fuel enable circuit connector to prevent personal injury. Do not come in contact with the fuel injector terminals while the engine is running.

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

2. Remove the valve cover of the suspected cylinder.

3. Remove the harness yoke from the solenoid terminals.

4. Measure the resistance between the two solenoid terminals on top of the injector. Record the resistance.

5. Measure the resistance from either solenoid terminal to the fuel injector body (metal).

6. Record the resistance.

7. Reconnect the harness yoke and install the valve cover.

Expected Result:

Resistance between the two solenoid terminals should be between 0.5 and 1.5 Ohms. Resistance from either solenoid terminal to the fuel injector body (metal) should be greater than 20,000 Ohms.

Results:

• OK - All resistance readings are within limits. There is a problem in the valve cover base harness.

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

  Stop.

• Not OK - The injector has failed.

  Repair: Repair the injector. If the problem is still present, replace the injector. If the new injector has a 4 Digit code that is different from the old injector, change the code in the ECM.

  Stop.

Test Step 11. Perform the following test: Electrical Power Supply

Results:

• REPAIRED, OK - Stop.

• OK - Stop.