3500B Engines for Caterpillar Built Power Modules with the ADEM 3 Electronic Control Module Caterpillar

Use this procedure in order to troubleshoot the ether system or use this procedure if any one of the diagnostic codes in Table 1 is active or easily repeated.

The ether injection system will improve cold weather starting of the engine. The ECM controls the ether injection system. The ECM energizes the ether solenoid in a continuous flow for a predetermined amount of time that is based on the coolant temperature. The ether injection system is disabled if there is an active engine shutdown.

The ether injection system can also be operated in manual mode. The ether system is switched into manual mode whenever the starting aid switch is depressed.

An test on Caterpillar Electronic Technician (ET) allows the technician to activate the ether system for a ten second period. The test is functional when the engine speed is 0 rpm. The test is accessed by selecting the following menus on Cat ET:

• "Diagnostics"

• "Diagnostic Tests"

• "Override Parameters"

Illustration 1	g01448106
Typical schematic

Illustration 2	g01444508
Location of the ECM connectors (1) J2/P2 ECM connectors (2) J1/P1 ECM connectors

Illustration 3	g01443872
P1 ECM connector (P1-20) Ether aid switch

Illustration 4	g01443875
P2 ECM connector (P2-10) Ether hold in +Battery (P2-20) Ether hold in −Battery (P2-66) Digital return

Illustration 5	g01443550
Generator connector (Terminal 9) Starting aid switch (Terminal 15) Digital return

Test Step 1. Inspect Electrical Connectors and Wiring

1. Turn the Engine Control Switch (ECS) to the OFF position. Turn the main disconnect switch to the OFF position.

2. Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit.

   Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

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

4. Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

5. Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM.

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 harness and connectors appear to be OK. Proceed to Test Step 2.

• Not OK - There is a problem with the 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.

  Verify that the repair eliminates the problem.

  STOP

Test Step 2. Check for Diagnostic Codes on Cat ET

1. Connect Cat ET.

2. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

3. Activate the ether override. Monitor the active diagnostic code screen on Cat ET. Check the ether system for an active -5 diagnostic code.

   Note: Wait at least 30 seconds in order for the diagnostic code to become active.

4. Activate the ether override. Monitor the active diagnostic code screen on Cat ET. Check the ether system for an active -6 diagnostic code.

   Note: Wait at least 30 seconds in order for the diagnostic code to become active.

Expected Result:

The status for the ether switch displays "ON" while the starting aid switch is toggled. The status for the ether switch displays "OFF" when the switch is released. No active codes are present for the ether system.

Results:

• OK - No active codes are present. If the ether system was not injecting ether proceed to Test Step 3.

• Not OK - Active codes are present for the ether system. Proceed to Test Step 4.

Test Step 3. 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 is not empty.

Results:

• OK - The ether canister is not empty. Proceed to Test Step 14.

• 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 4. Check the Voltage from the Ether Start Relay

1. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

2. Remove the ether canister(s).

3. Connect a voltmeter between terminal 30 of the ether start relay and ground.

4. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

5. Activate the ether override and observe the voltmeter while the ether override is activated.

6. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

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 during the first two seconds of injection. Proceed to Test Step 5.

• Not OK - 24 VDC - The voltage at the ether start relay is not 24 ± 3 VDC during the first two seconds of injection. Proceed to Test Step 6.

• Not OK - 3VDC - The voltage did not decrease to 3 ± 1 VDC for the remainder of the injection duration. Proceed to Test Step 9.

Test Step 5. Check the Voltage at the Ether Solenoids

1. Disconnect the ether solenoid connector at the solenoid.

2. Connect a voltmeter between pin 1 and pin 2 of the ether solenoid connector.

3. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

4. Activate the ether override and observe the voltmeter while the ether override is activated.

   Note: This procedure must be performed on both solenoids if two solenoids are present.

5. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

6. Reconnect all connectors.

Expected Result:

The voltage at the ether solenoid is 24 ± 3 VDC during the first two seconds of injection. The voltage then decreases to 3 ± 1 VDC for the remainder of the injection duration.

Results:

• OK - The voltage at the ether solenoid is 24 ± 3 VDC during the first two seconds of injection. The voltage then decreases to approximately 3 ± 1 VDC for the remainder of injection duration.

  Repair: Temporarily replace the ether solenoid. If the problem is resolved, reinstall the old solenoid. If the problem returns, replace the solenoid.

  STOP

• Not OK - 24 VDC - The voltage at the ether solenoid is not 24 ± 3 VDC during the first two seconds of injection.

  Repair: Inspect the wiring and connectors between the ether start relay and the connectors at the ether solenoids. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

• Not OK - 3 VDC - The voltage did not decrease to 3 ± 1 VDC for the remainder of the injection duration. Proceed to Test Step 9.

Test Step 6. Check the ECM Voltage to the Ether Start Relay

1. Turn the engine control to the OFF/RESET mode. Turn the main disconnect switch to the OFF position.

2. Connect a voltmeter between terminal 85 of the ether start relay and ground.

3. Turn the main disconnect switch to the ON position. Turn the engine control to the STOP mode.

4. Activate the ether override and observe the voltmeter while ether injection is ON.

   Note: Do not allow the ether to be ON for more than two minutes. Damage to the solenoid may occur.

5. Measure the voltage at the ether start relay with the voltmeter.

6. Turn the engine control to the OFF/RESET mode. Turn the main disconnect switch to the OFF position.

Expected Result:

The voltage is 24 ± 3 VDC for two seconds.

Results:

• OK - The voltage was 24 ± 3 VDC. Proceed to Test Step 7.

• Not OK - The voltage was not 24 ± 3 VDC. Proceed to Test Step 8.

Test Step 7. Check the Battery Voltage to the Ether Start Relay

1. Turn the main disconnect switch to the ON position. Turn the engine control to the STOP mode.

2. Measure the voltage between the +Battery terminal of the ether start relay and ground.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

• OK - The voltage is 24 ± 3 VDC.

  Repair: Disconnect the +Battery wire from the +Battery terminal of the ether start relay. Check this wire for continuity to ground. If the wire is OK, replace the ether start relay. If the wire is not OK, repair the wire. Verify that the system is operating correctly.

  STOP

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

  Repair: Verify that the circuit breaker for the engine control is not tripped. Ensure that the main disconnect switch is operating properly. Disconnect the +Battery wire from the +Battery terminal of the ether start relay. Check the wire from the +Battery terminal for continuity to the +Battery terminal. If the wire is not OK, repair the wire. Verify that the system is operating correctly.

  STOP

Test Step 8. Check the Voltage to the Ether Start Relay at the ECM

1. Turn the engine control to the OFF/RESET mode. Turn the main disconnect switch to the OFF position.

2. Disconnect connector P2 from the ECM.

3. Remove wire 382-RD(Red) from connector P2-10. Install a jumper wire that has a socket on one end into P2-10. Reconnect connector P2 to the ECM.

4. Connect a voltmeter between wire 382-RD(Red) and ground.

5. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

6. Activate the ether override and observe the voltmeter while the ether override is activated.

7. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

8. Remove all wire jumpers and reconnect all connectors.

Expected Result:

The voltage at the ECM is 24 ± 3 VDC for two seconds.

Results:

• OK - The voltage at the ECM is 24 ± 3 VDC for two seconds.

  Repair: The wire 382-RD(Red) and/or the connectors between the ECM and the ether start relay need repair. Inspect the wiring and connectors between the ether start relay and the connector at the ECM. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

• Not OK - The voltage at the ECM is not 24 ± 3 VDC for two seconds.

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

  STOP

Test Step 9. Check the Voltage from the Ether Hold Relay

1. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

2. Connect a voltmeter between the +Battery terminal of the ether hold relay and ground.

3. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

4. Activate the ether override and observe the voltmeter while the ether override is activated.

5. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

6. Reconnect all of the wires.

Expected Result:

The voltage at terminal 30 is 24 ± 3 VDC during injection.

Results:

• OK - The voltage at terminal 30 is 24 ± 3 VDC during injection. Proceed to Test Step 10.

• Not OK - The voltage at terminal 30 is not 24 ± 3 VDC during injection. Proceed to Test Step 12.

Test Step 10. Check the Voltage at the Resistor and Diode Assembly

1. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

2. Connect a voltmeter between the +Battery pin of the resistor and diode assembly and ground.

3. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

4. Activate the ether override and observe the voltmeter while the ether override is activated. This procedure must be performed on all of the resistor and diode assemblies, if more than one resistor and diode assembly is present.

5. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

• OK - The voltage is 24 ± 3 VDC. Proceed to Test Step 11.

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

  Repair: There is a problem in the harness between the ether hold relay and the resistor and diode assembly. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

Test Step 11. Check the Resistor and Diode Assembly

1. Disconnect the connector at the resistor and 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 of the resistor and diode assembly and observe the multimeter.

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

5. Repeat the measurements for all of the resistor and diode assemblies if more than one resistor and diode assembly is present.

Expected Result:

When the positive lead of the multimeter is connected to pin 2 and the negative lead to pin 1, the multimeter displays an overload "(OL)".

When the positive lead of the multimeter is connected to pin 1 and the negative lead to pin 2, the multimeter displays a number less than one.

Results:

• OK - The resistor and diode assembly is operating correctly.

  Repair: There is a problem in the harness between the resistor and diode assembly and the ether solenoids. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

• Not OK - The resistor and diode assembly is not operating correctly.

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

  STOP

Test Step 12. Check the Battery Voltage to the Ether Hold Relay

1. Turn the ECS to the STOP position. Turn the main disconnect switch to the ON position.

2. Measure the voltage between the +Battery terminal of the ether hold relay and ground.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

• OK - The voltage is 24 ± 3 VDC. Proceed to Test Step 13.

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

  Repair: Verify that the breakers for the battery and/or the relay are not tripped. Repair the connectors or wiring and/or replace the connectors or wiring.

  STOP

Test Step 13. Check the Coil of the Ether Hold Relay

1. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

2. Remove the +Battery wire from the ether hold relay. Connect a voltmeter between the +Battery wire and the +Battery terminal.

3. Turn the main disconnect switch to the ON position. Turn the ECS to the STOP position.

4. Activate the ether override and observe the voltmeter while the ether override is activated.

5. Turn the ECS to the OFF position. Turn the main disconnect switch to the OFF position.

6. Reconnect the wires.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

• OK - The voltage is 24 ± 3 VDC.

  Repair: Temporarily replace the ether hold relay. If the problem is resolved, reinstall the ether hold relay. If the problem returns, replace the ether hold relay.

  STOP

• Not OK - The voltage is not 24 ± 3 VDC. Proceed to Test Step 14.

Test Step 14. Check the Wires of the Starting Aid Switch at the Harness

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

2. Disconnect ECM connector J1/P1.

3. Obtain a suitable piece of wire and create a short between the wires at the starting aid switch.

4. Measure the resistance between the starting aid switch P1-20 and digital return P1-23 at the ECM connector.

Expected Result:

The resistance measurement indicated a short circuit.

Results:

• OK - The resistance measurement indicated a short circuit. The wires to the starting aid switch are not the problem. Proceed to Test Step 15.

• Not OK - The resistance measurement indicated an open circuit. There is a problem with the wiring to the starting aid switch.

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

  STOP

Test Step 15. Check the Starting Aid Switch

1. Disconnect the wires to the starting aid switch.

2. Measure the resistance between pin 1 and pin 2 of the starting aid switch.

3. Toggle the starting aid switch.

4. Release the starting aid switch and repeat the previous measurement.

Expected Result:

The resistance measurement indicated a short circuit when the switch was toggled. The resistance measurement indicated an open circuit when the switch was released.

Results:

• OK - The starting aid switch is operating correctly.

  Repair: The starting aid switch is operating correctly but the ECM is not reading the starting aid switch correctly. Replace the ECM. Refer to Troubleshooting, "ECM - Replace".

  STOP

• Not OK - The resistance measurement did not indicate a short circuit when the switch was toggled. The resistance measurement did not indicate an open circuit when the switch was released.

  Repair: There is a problem with the starting aid switch. Replace the starting aid switch with a new switch.

  STOP