3500B Engines for 5130B and 5230B Excavators Starting Aid Lamp Circuit - Test Caterpillar


Starting Aid Lamp Circuit - Test
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3500B Engines for 5130B and 5230B Excavators [RENR1305]
ELECTRICAL AND STARTING SYSTEM
STARTING AID GP
3500B Engines for 5130B and 5230B Excavators Ether Injection System
3500B Engines for 5130B and 5230B Excavators Starting Aid Lamp Circuit - Test

System Operation Description:

When the engine is in AUTO mode the engine uses an Ether 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 system uses the engine coolant temperature sensor to detect the engine temperature. The ECM determines if ether should be injected by monitoring the 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 engine rpm is at a certain level. The ether will activate for a minimum of 10 seconds at 10 °C (50 °F) up to a maximum of 130 seconds at -40 °C (-40 °F). The automatic ether injection system is disabled whenever the engine coolant temperature exceeds 10 °C (50 °F).

The ether injection system can also be operated in manual mode. The ether system is switched into manual mode whenever the start aid switch is depressed. Manual mode allows ether to be injected whenever the coolant temperature is less than 10 °C (50 °F). The manual mode will allow ether to be injected for 5 seconds when the switch is toggled. If the engine speed is 0.0 rpm and the engine coolant temperature is less than 10 °C (50 °F) the ether injection system will operate for 5 seconds.

Two driver outputs are used from the ECM. One ECM output provides the + Battery terminal to the coil of the ether start relay. The other coil terminal of the ether start relay is connected to the digital return. The other ECM output provides the current sinking for the coil of the ether hold relay. The other coil terminal of the ether hold relay is connected to the + Battery terminal. The drivers and the relays are used to provide a higher voltage signal that will actuate the ether solenoids. A lower voltage signal is then used to hold the ether solenoid valves open. The solenoids will be damaged if battery voltage is applied continuously.




Illustration 1g00813954

Typical circuit

------ WARNING! ------

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.

----------------------


NOTICE

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



NOTICE

Do not perform this procedure within 15 M (50 ft) of an open flame.


Test Step 1. Check for Connector Damage.

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

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

  1. Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect the terminals at the start aid lamp. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.

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

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

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

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

Expected Result:

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

Results:

  • OK - The connectors and wiring are okay. Proceed to test step 2.

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

    Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Verify that the system is operating correctly.

    Stop.

Test Step 2. Check the Start Aid Lamp

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

  1. Remove the ether canister from the ether solenoid.

  1. Connect the ET to the service tool connector.

  1. Set the start aid switch to the AUTO position.

  1. Turn the keyswitch to the ON position.

  1. Proceed to the diagnostic override screen on the ET and activate the ether override.

    Note: The ether override will activate one six second ether injection cycle. The ether will be on for 3 seconds and off for 3 seconds.

  1. Observe the start aid lamp.

Expected Result:

The ether start aid lamp will be off when the ether override is disabled. The ether start aid lamp will be on when the ether override is enabled.

Results:

  • OK - The ether start aid lamp is off when the ether override is disabled. The ether start aid lamp is on when the ether override is enabled.

    Repair: The start aid lamp circuit is operating correctly. Refer to Troubleshooting, "Inspecting Electrical Connectors" if you have an intermittent problem.

    Stop.

  • Not OK - Lamp Off - The ether start aid lamp will be off when the ether override is disabled. The ether start aid lamp stays off when the ether override is enabled. Proceed to test step 3.

  • Not OK - Lamp On - The ether start aid lamp is not off when the ether override is disabled. The ether start aid lamp will be on when the ether override is enabled. Proceed to test step 5.

Test Step 3. Check the Voltage to the Start Aid Lamp.

  1. Turn the keyswitch to the ON position.

  1. Measure the voltage between wire 315-GN at the connector of the start aid lamp and chassis ground.

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

Expected Result:

The voltage should measure 24 ± 3 VDC.

Results:

  • OK - The voltage measures 24 ± 3 VDC. Proceed to test step 4.

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

    Repair: Check the wiring between the start aid lamp and the + Battery terminal. Verify that the fuses and the circuit breakers are not tripped. Check the main power relay for proper operation.

    Stop.

Test Step 4. Check the Voltage at the Start Aid Lamp.

  1. Connect the ET to the service tool connector.

  1. Set the start aid switch to the AUTO position.

  1. Turn the keyswitch to the ON position.

  1. Proceed to the diagnostic override screen on the ET and activate the ether override.

    Note: The ether override will activate one six second ether injection cycle. The ether will be on for 3 seconds and off for 3 seconds.

  1. Measure the voltage between wire F707-WH at the connector of the start aid lamp and wire 315-GN at the connector of the start aid lamp.

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

Expected Result:

The voltage should measure 24 ± 3 VDC for approximately 3 seconds when the ether override is on.

Results:

  • OK - The voltage measures 24 ± 3 VDC for approximately 3 seconds when the ether override is on.

    Repair: The voltage and the ground are present at the connector for the start aid lamp. Replace the start aid lamp.

    Stop.

  • Not OK - The voltage does not measure 24 ± 3 VDC for approximately 3 seconds when the ether override is on. Proceed to test step 5.

Test Step 5. Check the Wire between the Start Aid Lamp and the ECM.

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

  1. Remove the start aid lamp from the socket.

  1. Disconnect ECM connector J1/P1.

  1. Measure the resistance between the wire F707-WH on the connector for the start aid lamp and chassis ground.

  1. Measure the resistance between the wire F707-WH on the connector for the start aid lamp and the wire 315-GN on the connector for the start aid lamp.

Expected Result:

The resistance should be greater than 20,000 Ohms.

Results:

  • OK - The resistance is greater than 20,000 Ohms. Proceed to test step 6.

  • Not OK - The resistance is less than 20,000 Ohms.

    Repair: There is a short in the wire and/or the connector. Repair the wire and/or the connector.

    Stop.

Test Step 6. Check the Input to the ECM from the Start Aid Lamp.

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

  1. Install a Breakout T at ECM connector J1/P1.

  1. Connect the ET to the service tool connector.

  1. Set the start aid switch to the AUTO position.

  1. Turn the keyswitch to the ON position.

  1. Connect a voltmeter between wire 315-GN on the connector for the start aid lamp and pin P-22 of the Breakout T.

  1. Proceed to the diagnostic override screen on the ET and activate the ether override.

    Note: The ether override will activate one six second ether injection cycle. The ether will be on for 3 seconds and off for 3 seconds.

  1. Monitor the voltage on the voltmeter.

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

Expected Result:

The voltage should measure less than 1.0 VDC when the ether override is enabled.

Results:

  • OK - The voltage measures less than 1.0 VDC when the ether override is enabled.

    Repair: The start aid lamp circuit is operating correctly. Refer to Troubleshooting, "Inspecting Electrical Connectors" if you are troubleshooting an intermittent problem.

    Stop.

  • Not OK - The voltage does not measure less than 1.0 VDC when the ether override is enabled.

    Repair: The ECM is not closing the circuit correctly. Replace the ECM.

    Stop.

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