3512B Petroleum Engines with the ADEM 2 Electronic Control Module Caterpillar

When the engine is in AUTO mode, the engine uses an Ether Injection 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 Injection System, uses the engine coolant temperature sensor to detect engine temperature. The ECM determines if ether should be injected by monitoring 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 the engine rpm is below a certain level. The Ether Injection System becomes enabled at 10 °C (50 °F). The Ether Injection System will run for a minimum of 10 seconds up to a maximum of 130 seconds at −40 °C (−40 °F). The automatic Ether Injection System is disabled whenever engine rpm exceeds 1900 rpm or the engine coolant temperature exceeds 10 °C (50 °F).

The Ether Injection System can also be operated in manual mode. The Ether Injection System is switched into manual mode whenever the starting aid switch is depressed. Manual mode also allows ether to be injected whenever the coolant temperature is less than 10 °C (50 °F) and engine rpm is greater than 50 rpm. Ether is injected in manual mode if the starting aid switch is depressed and the coolant temperature is below the maximum limit. The manual mode will allow ether to be injected for a maximum of 130 seconds when the switch is toggled.

The ether solenoid is specially designed to actuate under low voltage situations. If you operate the ether solenoid at 24 VDC for more than three seconds, damage may occur. Current to the solenoid will be reduced by adding a 20 Ohm resistor in series with the ether solenoid.

Note: The ether function will be disabled if the ether control parameter is disabled.

Illustration 1	g00821073

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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 the Electrical Connectors and the Wiring.

1. Turn the engine control to the OFF position.

2. Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.

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

4. Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).

5. Check the customer connector (allen head screw) for the proper torque of 2.25 ± 0.25 N·m (20 ± 2 lb in).

6. Check the harness and the wiring for abrasion and pinch points.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, abrasion or pinch points.

Results:

• OK - The wiring and connectors are okay. Proceed to Test Step 2.

• Not OK - The wiring and connectors are not okay.

  Repair: Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.

  STOP

Test Step 2. Check the Ether Canister.

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 new ether canister. Verify that the problem is no longer present.

  STOP

Test Step 3. Check for Active Diagnostic Codes.

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NOTICE
The ether canister must be removed prior to activating this test.

1. Start the Caterpillar Electronic Technician (ET).

2. Turn the engine control to the ON position.

3. Determine if a CID-FMI 545-05 or 545-06 diagnostic code is active or logged.

4. Toggle the Ether switch. Observe the parameter for the Ether switch on the Cat ET.

Expected Result:

The parameter for the Ether switch should display "ON" while the Ether switch is toggled. The parameter for the Ether switch should display "OFF" when the Ether switch is released.

Results:

• OK - Active Code - The parameter for the Ether switch displays "ON" while the Ether switch is toggled. The parameter for the Ether switch displays "OFF" when the Ether switch is released. Active Diagnostics are displayed. Proceed to test step 4.

• OK - Logged Code - The parameter for the Ether switch displays "ON" while the Ether switch is toggled. The parameter for the Ether switch displays "OFF" when the Ether 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. Replace the ether canister on the ether solenoid.

  STOP

• Not OK - The parameter for the Ether switch does not display "ON" while the Ether switch is toggled. The parameter for the Ether switch does not display "OFF" when the Ether switch is released. No active codes or logged codes are present. The Ether switch is not functioning correctly. Proceed to test step 8.

Test Step 4. Check the Output Voltage from the Ether Relay.

1. Turn the engine control to the OFF position.

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NOTICE
The ether canister must be removed prior to activating this test.

2. Remove the ether canister from the ether solenoid.

3. Remove wire 150-OR from terminal 30 on the ether relay.

4. Turn ON the power to the ECM.

5. Select Diagnostic Tests from the Cat ET.

6. Select the "Override Parameters" on the Cat ET.

7. Activate the "Ether Injection" override.

8. Measure the voltage between terminal 30 and the engine ground at the ether relay.

9. Disable the "Ether Injection" override.

10. Turn OFF the power to the ECM.

Expected Result:

The voltage should be 24 ± 3 VDC.

Results:

• OK - The voltage is 24 ± 3 VDC.

  Repair: The ether injection system is working properly. Check the wiring to the solenoid from the ether relay. Check the operation of the ether solenoid.

  STOP

• Not OK - The voltage is not 24 ± 3 VDC. The supply voltage is not present at the output of the ether relay. Proceed to test step 5.

Test Step 5. Check the Voltage to the Ether Relay.

1. Turn the engine control to the OFF position.

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NOTICE
The ether canister must be removed prior to activating this test.

2. Remove the ether canister from the ether solenoid.

3. Turn the engine control to the ON position.

4. Measure the voltage between terminal 87 of the ether relay and the − Battery terminal.

5. Measure the voltage between terminal 86 on the ether relay and the − Battery terminal.

Expected Result:

The voltage at terminals 87 and 86 of the ether relay should be 24 ± 3 VDC.

Results:

• OK - The voltage at the ether relay is 24 ± 3 VDC. Proceed to test step 6.

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

  Repair: Check that the battery voltage is 24 ± 3 VDC. Refer to Testing and Adjusting, "Electrical System". If the battery voltage is correct, there is a problem in the wiring and/or connectors between the battery and the ether relay. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

Test Step 6. Check the Coil of the Ether Relay.

1. Turn the engine control to the OFF position.

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NOTICE
The ether canister must be removed prior to activating this test.

2. Remove the ether canister from the ether solenoid.

3. Remove wire F710-GN from terminal 85 on the ether relay.

4. Connect a voltmeter between wire F710-GN and terminal 86 on the ether relay.

5. Turn ON the power to the ECM.

6. Select Diagnostic Tests from the Cat ET.

7. Select the "Override Parameters" on the Cat ET.

8. Activate the "Ether Injection" override.

9. Measure the voltage between the ether relay terminal 86 and wire F710-GN.

10. Disable the "Ether Injection" override.

11. Turn OFF the power to the ECM.

Expected Result:

The voltage should be 0.0 VDC before activating the ether override. The voltage should be 24 ± 3 VDC during ether injection.

Results:

• OK - The voltage is 0.0 VDC before activating the ether override. The voltage is 24 ± 3 VDC during ether injection.

  Repair: Replace the ether relay.

  STOP

• Not OK - The voltage is 0.0 VDC before activating the ether override. The voltage does not change after the ether injection is activated. Proceed to test step 7.

Test Step 7. Check the ECM Input.

1. Turn OFF the power to the ECM.

2. Disconnect ECM connector J1/P1.

3. Remove wire F710-GN from ECM connector P1-22.

4. Install a jumper wire with a socket terminal on one end into ECM connector P1-22.

5. Reconnect ECM connector J1/P1.

6. Connect a voltmeter between terminal 86 on the ether relay and the jumper wire at ECM connector P1-22.

7. Turn ON the power to the ECM.

8. Activate the "Ether Injection" override.

9. Measure the voltage between terminal 86 on the ether relay and the jumper wire at ECM connector P1-22.

10. Disable the "Ether Injection" override.

11. Turn OFF the power to the ECM.

12. Remove all jumpers and reconnect all connectors.

Expected Result:

The voltage should be 0.0 VDC before activating the ether override. The voltage should be 24 ± 3 VDC during ether injection.

Results:

• OK - The voltage is 0.0 VDC before activating the ether override. The voltage is 24 ± 3 VDC during ether injection.

  Repair: The wire F710-GN and/or the connectors between P1-22 and the ether relay need repair. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

• Not OK - The voltage is 0.0 VDC before activating the ether override. The voltage does not change after the ether injection is activated.

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

  STOP

Test Step 8. Connect the Wires at the Ether switch.

1. Disconnect wires 998-BR and F720-PU from the Ether switch.

2. Turn ON the power to the ECM.

3. Observe the Ether switch status on the Cat ET.

4. Short the wires together at the Ether switch.

5. Observe the Ether switch status on the Cat ET.

6. Turn OFF the power to the ECM.

Expected Result:

When the wires are disconnected from the Ether switch, the parameter on the Cat ET for the Ether switch should display "OFF". The parameter on the ET for the Ether switch should display "ON" when the switch wires are shorted together.

Results:

• OK - When the wires are disconnected from the Ether switch, the ET screen does display "OFF". The Cat ET screen does display "ON" when the switch wires are shorted together.

  Repair: Replace the Ether switch.

  STOP

• Not OK - When the wires are disconnected from the Ether switch, the Cat ET screen does not display "OFF". The Cat ET screen does not display "ON" when the switch wires are shorted together. There is a problem in the wiring harness between the Ether switch and the ECM.

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

  STOP