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

The ECM has the ability to automatically prelube the engine. This will increase the life of certain engine parts.

The engine control will prelube the engine, when the ECS is placed in the START position or the AUTO position and the remote start/run/stop switch is closed. The engine speed must equal zero rpm before the prelube will begin.

The following conditions are possible: OFF, ON, COMPLETED and DISABLED.

The OFF status is entered when the engine control is first powered up with the ECS in the STOP position.

The "COMPLETED" status is entered when the engine prelube duration is reached or when the engine prelube pressure switch is activated.

The "DISABLED" status is entered when the engine prelube duration is programmed to 0.

The prelube function will be aborted when one of the following conditions occur:

• The engine prelube pressure switch is activated.

• The User defined engine prelube duration has been reached.

Illustration 1	g00598825

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 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 the ECS.

1. Verify that the ECS is operating correctly.

Expected Result:

Results:

• OK - Proceed to test step 3.

• Not OK - Proceed to test step 4.

Test Step 3. Check the Engine Prelube Pressure Switch.

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

2. Disconnect ECM connector J1/P1.

3. Measure the resistance between the engine prelube pressure switch P1-20 and the Digital Return P1-29.

4. Reconnect the ECM connector P1.

Expected Result:

The resistance should be greater than 20,000 Ohms.

Results:

• OK - The engine prelube pressure switch is not active. Proceed to test step 5.

• Not OK - The engine prelube pressure switch is active. Verify that the engine does not have a residual oil pressure that is high enough to activate the switch. If there is no residual oil pressure the switch is not operating correctly or there is a problem with the wiring. Proceed to test step 6.

Test Step 4. Perform the following test: Engine Control Switch (ECS)

Results:

• OK - Stop.

• REPAIRED, OK - Stop.

Test Step 5. Check the Status of the Switch.

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

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

3. Turn the ECS to the STOP position.

4. Connect the ET.

5. Observe the parameters for the engine prelube and for the ignition switch.

Expected Result:

The parameter for the engine prelube should display "OFF". The parameter for the ignition switch should display "OFF".

Results:

• OK - Proceed to test step 7.

• Prelube Disabled -

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

  Stop.

• Ignition Switch Not OFF - Proceed to test step 4.

Test Step 6. Check the Engine Prelube Pressure Switch.

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

2. Disconnect the wires from terminal 1 and terminal 2 of the engine prelube pressure switch.

3. Measure the resistance between terminal 1 and terminal 2 of the switch.

Expected Result:

The resistance should be greater than 20,000 Ohms.

Results:

• OK -

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

  Stop.

• Not OK -

  Repair: There is a problem with the engine prelube pressure switch. Install a new switch. Determine if the problem no longer exists. If the problem is no longer present, reinstall the old switch. If the problem returns, replace the switch.

  Stop.

Test Step 7. Check the Status of the Switch.

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

2. Use the ET and view the following parameters: Engine Prelube and Ignition Switch.

3. Turn the ECS to the START position.

4. View the parameters for the engine prelube pressure switch and the ignition switch. View the parameters before the engine prelube duration expires and before the switch activates.

   Note: If necessary, program the engine prelube duration to 60 seconds.

Expected Result:

When the ECS is in the OFF/RESET position both parameters should display "OFF". When the ECS is in the START position the engine prelube should display "ON" and the Ignition Switch should display "RUN".

Results:

• OK - The parameters are correct. Proceed to test step 8.

• Not OK - The status of the ignition switch does not display "RUN". Proceed to test step 4.

Test Step 8. Check the Relays.

1. Turn the ECS to the STOP position.

2. Access the override on the ET.

3. Turn the override for the prelube relays to "ON".

4. Listen for the relay to activate.

5. Turn the override "OFF".

Expected Result:

You should hear a click when the relay activates. The motor should run.

Results:

• OK - The problem is not present at this time. Stop.

• Prelube Motor Does Not Run - The relay activates but the motor does not run. Proceed to test step 9.

• Not OK - The relay did not activate. Proceed to test step 10.

Test Step 9. Check the Motor Operation.

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

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

3. Connect one side of a suitable piece of 10 AWG wire to +battery.

4. For one second, connect the other end of the wire to the + terminal of the motor.

Expected Result:

The motor should start while the wire is connected to the +terminal.

Results:

• OK - The motor starts.

  Repair: There is a problem in the wiring harness. Inspect the connectors and the wiring between the +terminal of the motor and pin 2 of the relay.

  Stop.

• Not OK - The motor did not start.

  Repair: The problem appears to be in the prelube motor. Install a new motor. If the condition is no longer present, reinstall the old motor. If the original condition returns, replace the prelube motor.

  Stop.

Test Step 10. Check the Relay Circuit.

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

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

3. Remove P-21 from the ECM connector P1.

4. Obtain a suitable piece of 18 AWG wire.

5. Connect one end to -Battery.

6. Connect the other end to P-21.

7. Place one probe of the multimeter on P-21. Connect the other probe to terminal 85 of the prelube relay.

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

Expected Result:

The relay and the motor should activate. The voltage should be 24 ± 5 VDC.

Results:

• OK - Proceed to test step 11.

• Not OK - The motor and the relay did not activate. The voltage is correct.

  Repair: The problem is with the prelube relays. Install new relays. Check that the original condition is no longer present. If the problem is no longer present reinstall the old relays. If the condition returns replace the relays.

  Stop.

• Not OK - The motor did not activate. The voltage is not correct.

  Repair: There is a problem between the ECM connector J1/P1 and the relays. Repair the connectors or wiring and/or replace the connectors or wiring.

  Stop.

Test Step 11. Check the ECM.

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

2. Ensure that the jumper wire has been removed.

3. Install signal reading probes at P1-5 and P1-4.

4. Connect the multimeter to the signal reading probes.

Expected Result:

The voltage should be 24 ± 5 VDC.

Results:

• OK - Proceed to test step 12.

• Not OK -

  Repair: There is a problem with the wiring to the battery. Repair the wiring and/or replace the wiring.

  Stop.

Test Step 12. Check the ECM.

1. Install one signal reading probe at P1-21.

2. Install one signal reading probe at P1-4.

3. Connect the multimeter to the signal reading probes.

4. Access the override on the ET.

5. Enable the override for the engine prelube pressure switch.

6. Disable the override.

Expected Result:

The voltage should be 24 ± 5 VDC when the override is enabled.

Results:

• OK - The voltage is correct.

  Repair: There is a problem between the ECM and the relay. Repair the relay or wiring and/or replace the relay or wiring.

  Stop.

• Not OK -

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

  Stop.