Flexxaire Fan Caterpillar

Calibration

Usage:

Mark I Control System Calibration

Control Box Neutral Calibration

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Illustration 1	g00587421
(1) Actuator (2) Operator fork (3) Hitch pin (4) Position sensor lever (5) Mechanical stop (6) Position sensor (7) Screw (8) Position sensor shaft (9) Alignment plate

Unplug actuator (1). Remove the pin from actuator (1). Power should remain connected to the rest of the system.
Manually move operator fork (2) to the NEUTRAL position. Pin operator fork (2) in position with hitch pin (3).
Loosen screw (7) on position sensor lever (4) in order to allow rotation of position sensor shaft (8) with a screwdriver.
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Illustration 2 g00607902
Verify that L2 inside the control box is not on. If L2 is on, the control box is attempting to put the fan into pitch. Therefore, NEUTRAL cannot be set. The control box will attempt to put the fan into pitch if the signal of the temperature sensor is above the set point or there is an open circuit in the wiring of the temperature sensor.
If L2 is on, proceed through the following procedure:
1. Turn adjustment screw (P102) near L2, clockwise until L2 goes out. If L2 remains on, there may be a problem with the temperature sensor and/or wiring. If the temperature sensor and/or wiring are okay, the control box may need to be replaced.
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Illustration 3 g00889944
Turn position sensor shaft (8) in either direction. Turn the shaft until L5 and L6 are off. Position sensor lever (4) should not move. A clicking sound is heard in the control box when the NEUTRAL setting is passed. Check the remote display. The middle LED should be illuminated.
Tighten screw (7) on position sensor lever (4).
Rotate the actuator rod outward in order to line up the holes in the rod and the operator fork. Attach actuator (1) to operator fork (2) with hitch pin (3). Reconnect power to actuator (1).
Press the purge button on the remote display. Then release the button. The controller will set the fan at the NEUTRAL position.
Visually verify that the blades are in the NEUTRAL position and that the hole in the operator fork is in line with the center hole of alignment plate (9). In addition, the middle LED on the remote display should be on. No red LED should be on in the control box. If this is not the case, repeat Steps 1 through 8.
Proceed to "Actuator Travel Limits Calibration".

Actuator Travel Limits Calibration

Note: Perform the "Control Box Neutral Calibration" before proceeding with this calibration.

Note: If the remote display does NOT have a toggle switch, proceed to "Actuator Travel Limits Calibration for Remote Display WITHOUT a Toggle Switch".

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Illustration 4	g00889940

Note: Adjustment screws L3 for symmetry and L4 for the end of travel are located inside the control box. A LED is beside each adjustment screw. When the LED is on, the circuit is active.

Toggle the switch on the remote display so that L3 (green light) inside the control box is on.
Pull the position sensor lever away from the operator fork. The actuator should move away from the position sensor. If the actuator does not respond immediately, the problem could be a faulty position sensor. Replace the sensor and retest the sensor. If the actuator responds, but the actuator moves in the same direction as the position sensor, the red wire and the yellow wire must be reversed in order to reverse the rotation of the actuator motor.
Press and hold the purge button in order to initiate movement of the actuator rod. L4 (yellow light) inside the control box will be on. The actuator will move and one of the two following cases will occur.
1. Case 1: The actuator makes a ratcheting sound. The actuator moves too far and the actuator contacts the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position. The actuator will stop ratcheting.
  - Rotate adjustment screw (P104) that is near light (L4) in order to decrease the amount of actuator travel. Rotate the screw counterclockwise by approximately one turn.
  - Press and hold the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 4.
2. Case 2: The actuator stops short of the mechanical stop. No contact is made between the actuator and the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position.
  - Rotate adjustment screw (P104) near L4 in order to increase the amount of actuator travel. Rotate the screw clockwise by approximately one turn.
  - Press and hold the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 4.
Toggle the switch on the remote display so that L4 (yellow light) inside the control box is on.
Press and hold the purge button in order to initiate movement of the actuator rod. L3 (green light) inside the control box will be on. The actuator will move and one of the two following cases will occur.
1. Case 1: The actuator makes a ratcheting sound. The actuator moves too far and the actuator contacts the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position. The actuator will stop ratcheting.
  - Rotate adjustment screw (P103) near L3 in order to decrease the amount of actuator travel. Rotate the screw counterclockwise by approximately one turn.
  - Press and hold the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 6.
2. Case 2: The actuator stops short of the mechanical stop. No contact is made between the actuator and the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position.
  - Rotate adjustment screw (P103) near L3 in order to increase the amount of actuator travel. Rotate the screw clockwise by approximately one turn.
  - Press and hold the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 6.
Remember the number of turns that you rotated L2 in Step 4.a of the "Control Box Neutral Calibration". Turn L2 in the opposite direction by the same number of turns in order to return the temperature setpoint to the original value. The calibration of the travel limits is now complete. If you have forgotten the number of turns for L2, proceed to Step 7.
Confirm all connections. Proceed to "Single Temperature Sensor Calibration" if you have a single temperature sensor. Proceed to "Dual Temperature Sensors Calibration" if you have two temperature sensors.

Single Temperature Sensor Calibration

The temperature setpoint for all control boxes is preset at the factory. An identification tag that is attached to the control box states the set point temperature. The fan reaches maximum pitch at this temperature. The maximum pitch is set by calibrating the limits of the pitch. As the temperature rises, the fan will begin moving into pitch approximately −9.4 °C (15.0 °F) below the temperature setpoint. If the engine temperature is too high or too low, adjustments to the temperature setpoint are required. Perform the following procedure.

Allow the engine to reach operating temperature.
If the fan reaches full pitch before the engine reaches the operating temperature, adjust temperature screw (P102) near L2. Turn the screw clockwise in order to raise the temperature setpoint. Continue to turn the screw until the blades start to pitch approximately −9.4 °C (15.0 °F) below the desired operating temperature. Proceed to Step 4.
If the fan does not reach full pitch with the engine at operating temperature, adjust temperature screw (P102) that is near L2. Turn the screw counterclockwise for five turns. Allow the engine to cool to a temperature below 71.1 °C (160.0 °F). Proceed to Step 1. Once the blades begin to pitch at −9.4 °C (15.0 °F) below the desired operating temperature, proceed to Step 4.
Close the control box. Monitor the coolant temperature that is maintained. If the temperature is too high, repeat Step 3. If the temperature is too low, repeat Step 2.

Dual Temperature Sensors Calibration

If two temperature sensors are used, the second screw (P101) must be adjusted. The screw should begin in the fully clockwise position in order to prevent interference with the first temperature sensor.

For example, the second sensor is on the transmission. The transmission gets hot because the engine is not causing the fan to move enough air. Turn screw (P101) counterclockwise until L1 comes on. This indicates that the fan blades are turned farther in order to move more air.

If protection against the disconnection of the sensor is desired for the second input, connect the two pins at location J105 together with a jumper wire. This will cause the fan to go into full pitch if the sensor becomes disconnected.

Actuator Travel Limits Calibration for Remote Display WITHOUT a Toggle Switch

Note: Two Caterpillar part numbers exist for these control boxes. The first part number is the 2Q-3324 Control Box. The second part number is the 115-1945 Control Box. The 115-1945 Control Box has a jumper wire between the two pins at location J104. Follow the calibration for the control box on your machine. If you are unable to locate the part number of your control box, refer to the Parts Manual for your machine or consult your Caterpillar dealer.

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Illustration 5	g00889940

Note: Adjustment screws L3 for symmetry and L4 for the end of travel are located inside the control box. There is a LED beside each adjustment screw. The circuit is active when the LED is on.

2Q-3324 Control Box

Note: Perform a "Control Box Neutral Calibration" before attempting the following procedure.

Verify the wiring of the actuator by pulling the position sensor lever away from the operator fork. The actuator should move away from the position sensor. If the actuator does not move away, the red wire and the yellow wire connection near the actuator must be reversed in order to reverse the rotation of the actuator motor.
Note: Do NOT switch the red wire and the yellow wire in the control box.
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Illustration 6 g00606907

(1) Plug with two pins
(2) Brown wire from temperature sensor
(3) Temperature sensor
Disconnect plug (1) with two pins from the temperature sensor circuit in order to initiate the movement of the actuator.
Note: If your system is not equipped with plug (1), remove brown wire from temperature sensor (2) in the engine block or ground temperature sensor (3) to the engine block. This will initiate movement of the actuator. Put brown wire (2) back on temperature sensor (3), or stop grounding temperature sensor (3) in order to move the blades back to NEUTRAL.
L4 (yellow light) will be on. The actuator will move and one of the two following cases will occur.
1. Case 1. The actuator makes a ratcheting sound. The actuator moves too far and the actuator contacts the mechanical stop.
  - Reconnect the plug with two pins in order to move the fan blades to the NEUTRAL position. The actuator will stop ratcheting.
  - Rotate adjustment screw (P104) near L4 in order to decrease the amount of actuator travel. Rotate the screw counterclockwise by approximately one turn.
  - Disconnect the plug in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the actuator stops ratcheting due to contact with the mechanical stop.
  - Connect the plug. The fan blades will return to the NEUTRAL position.
  - Alternately connect and disconnect the plug in the temperature sensor circuit. Rotate adjustment screw (P104) near L4, clockwise until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 3.
2. Case 2. The actuator stops short of the mechanical stop. No contact is made between the actuator and the mechanical stop.
  - Reconnect the plug with two pins in order to move the fan blades to the NEUTRAL position.
  - Rotate adjustment screw (P104) near L4 in order to increase the amount of actuator travel. Rotate the screw clockwise by approximately one turn.
  - Disconnect the plug in order to move the blades to full pitch.
  - Check the actuator position.
  - Alternately connect and disconnect the plug in the temperature sensor circuit. Rotate adjustment screw (P104) near L4, clockwise until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Connect the plug in order to move the fan blades to the NEUTRAL position.
  - Proceed to Step 3.
Press the purge button in order to initiate movement of the actuator. L3 (green light) inside the control box will be on. The actuator will move and one of the two following cases will occur.
1. Case 1. The actuator makes a ratcheting sound. The actuator moves too far and the actuator contacts the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position. The actuator will stop ratcheting.
  - Rotate adjustment screw (P103) near L3 in order to decrease the amount of actuator travel. Rotate the screw counterclockwise by approximately one turn.
  - Press the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the actuator stops ratcheting due to contact with the mechanical stop.
  - Alternately press and release the purge button. Rotate adjustment screw (P103) near L3, clockwise until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 4.
2. Case 2. The actuator stops short of the mechanical stop. No contact is made between the actuator and the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position.
  - Rotate adjustment screw (P103) near L3 in order to increase the amount of actuator travel. Rotate the screw clockwise by approximately one turn.
  - Press the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 4.
Close the control box and check all connections.
Note: The plug with two pins in the temperature sensor circuit must be installed for proper operation.
Remember the number of turns that you rotated L2 in Step 4.a of the "Control Box Neutral Calibration". Turn L2 in the opposite direction by the same number of turns in order to return the temperature setpoint to the original value. The calibration of the travel limits is now complete. If you have forgotten the number of turns for L2, proceed to Step 6.
Confirm all connections. Proceed to "Single Temperature Sensor Calibration" if you have a single temperature sensor. Proceed to "Dual Temperature Sensors Calibration" if you have two temperature sensors.

115-1945 Control Box

Note: Perform a "Control Box Neutral Calibration" before attempting the following procedure.

Verify the wiring of the actuator by pulling the position sensor lever away from the operator fork. The actuator should move away from the position sensor. If the actuator does not move away, the red wire and the yellow wire connection near the actuator must be reversed in order to reverse the rotation of the actuator motor.
Note: Do NOT switch the red wire and the yellow wire in the control box.
Press the purge button in order to initiate movement of the actuator.
L4 (yellow light) inside the control box will be on. The actuator will move and one of the two following cases will occur.
1. Case 1. The actuator makes a ratcheting sound. The actuator moves too far and the actuator contacts the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position. The actuator will stop ratcheting.
  - Rotate adjustment screw (P104) near L4 in order to decrease the amount of actuator travel. Rotate the screw counterclockwise by approximately one turn.
  - Press the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the actuator stops ratcheting due to contact with the mechanical stop.
  - Alternately press and release the purge button. Rotate adjustment screw (P104) near L4, clockwise until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 3.
2. Case 2. The actuator stops short of the mechanical stop. No contact is made between the actuator and the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position.
  - Rotate adjustment screw (P104) near L4 in order to increase the amount of actuator travel. Rotate the screw clockwise by approximately one turn.
  - Press the purge button in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Release the purge button in order to move the fan blades to the NEUTRAL position.
  - Proceed to Step 3.
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Illustration 7 g00606907

(1) Plug with two pins
(2) Brown wire from temperature sensor
(3) Temperature sensor
Disconnect the plug with two pins (1) from the temperature sensor circuit.
Note: If your system is not equipped with plug (1), remove brown wire from temperature sensor (2) in the engine block or ground temperature sensor (3) to the engine block. This will initiate movement of the actuator. Put brown wire (2) back on temperature sensor (3), or stop grounding temperature sensor (3) in order to move the blades back to NEUTRAL.
L3 (green light) inside the control box will be on. The actuator will move and one of the two following cases will occur.
1. Case 1. The actuator makes a ratcheting sound. The actuator moves too far and the actuator contacts the mechanical stop.
  - Reconnect the plug with two pins in order to move the fan blades to the NEUTRAL position. The actuator will stop ratcheting.
  - Rotate adjustment screw (P103) near L3 in order to decrease the amount of actuator travel. Rotate the screw counterclockwise by approximately one turn.
  - Disconnect the plug with two pins in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the actuator stops ratcheting due to contact with the mechanical stop.
  - Connect the plug with two pins. The fan blades will return to the NEUTRAL position.
  - Alternately connect and disconnect the plug with two pins in the temperature sensor circuit. Rotate adjustment screw (P103) near L3, clockwise until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Proceed to Step 4.
2. Case 2. The actuator stops short of the mechanical stop. No contact is made between the actuator and the mechanical stop.
  - Reconnect the plug with two pins in order to move the fan blades to the NEUTRAL position.
  - Rotate adjustment screw (P103) near L3 in order to increase the amount of actuator travel. Rotate the screw clockwise by approximately one turn.
  - Disconnect the plug with two pins in order to move the blades to full pitch.
  - Check the actuator position.
  - Repeat the four previous steps until the operator fork stops approximately 3.0 mm (0.12 inch) from the mechanical stop.
  - Connect the plug with two pins in order to move the fan blades to the NEUTRAL position.
  - Proceed to Step 4.
Close the control box and check all connections.
Note: The plug with two pins in the temperature sensor circuit must be installed for proper operation.
Remember the number of turns that you rotated L2 in Step 4.a of the "Control Box Neutral Calibration". Turn L2 in the opposite direction by the same number of turns in order to return the temperature setpoint to the original value. The calibration of the travel limits is now complete. If you have forgotten the number of turns for L2, proceed to Step 6.
Confirm all connections. Proceed to "Single Temperature Sensor Calibration" if you have a single temperature sensor. Proceed to "Dual Temperature Sensors Calibration" if you have two temperature sensors.

Mark III Control System Calibration

The Mark III Control System requires calibration in the following instances:

The actuator has been replaced.
The controller has been replaced.
A controller was installed. ALL of the lights on the remote display, and ALL of the lights on the control box are flashing. This indicates that the controller has not been calibrated. The controller has not been set up with the actuator.

Refer to “Troubleshooting (Fault Codes Present)” in the “Toubleshooting” section of this service manual. The remote display will show a fault code if the controller has detected a fault with the operation of the actuator or the controller. Lights will be flashing on the remote display and inside the control box. Determine the lights that are flashing and the lights that are solid. This indicates the fault. Use this information to assist in resolving the problem.

AUTO-Calibration Sequence

The Mark III control system uses an auto-calibration sequence to determine the initial pitch of the blades. The following process constitutes one auto-calibration sequence:

Once power is applied to the controller, all of the lights on the remote display and all of the lights that are inside of the control box will come on for approximately 20 seconds.
The lights on the remote display go off.
The actuator will extend by a small amount. The actuator will then retract by a small amount.
The actuator retracts until contact with the mechanical stop is made.
The control box uses the mechanical stop as a reference position. The actuator is then moved to the NEUTRAL position.

The lights on the remote display come on when the AUTO-calibration sequence is complete.

The AUTO-calibration sequence occurs during the following situations:

starting of the machine
exiting SETUP mode
excessive movement since previous AUTO-calibration sequence
stalling of the actuator

Actuator Travel Limits Calibration

Calibration of the travel limits should be performed if the travel limits of the actuator are not correct. Calibration can be performed by connecting the remote calibrator to the control box or with the buttons within the control box.

This procedure sets the travel limits and the NEUTRAL position for the actuator. This procedure should be performed with the engine OFF or at LOW IDLE if it is not possible to shut the engine OFF.

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Illustration 8	g00929989
(1) Actuator (2) Actuator rod (3) Operator fork (4) Hitch pin (5) Mechanical stop (6) Alignment plate (7) Clevis mounting block (8) Alignment hole

Press the SETUP button. The LED will light up indicating that the control box is now in SETUP mode. Actuator rod (2) will retract until contact is made with clevis mounting block (7). The NEUTRAL LED will now blink. This indicates that the controller is waiting for information on the NEUTRAL position of actuator rod (2).
Press the Extend (EXT) button and hold the button. Actuator rod (2) will move toward the NEUTRAL position of the fan. The NEUTRAL position can be verified by aligning the hole in operator fork (3) with the middle hole in alignment plate (6). Use the Extend button or use the Retract (RET) button in order to obtain the alignment. Press the SET button after NEUTRAL alignment has been achieved. The NEUTRAL LED will remain on. This indicates that the NEUTRAL position has been set.
Note: There will be a slight delay before the actuator rod starts to move.
Press the Extend button and hold the button in order to move actuator rod (2) outward. Operator fork (3) should stop between 1.588 mm (0.0625 inch) and 3.175 mm (0.1250 inch) of mechanical stop (5) at the fully extended position. Press the SET button. The EXTEND LED will now remain on. This indicates that the extended position is now set. The RETRACT LED will continue to flash. This indicates that the controller is waiting for information on the fully retracted position of actuator rod (2).
Press the Retract button and hold the button in order to move actuator rod (2) inward. Operator fork (3) should stop between 1.588 mm (0.0625 inch) and 3.175 mm (0.1250 inch) of clevis mounting block (7) at the fully retracted position. Press the SET button. The RETRACT LED will now remain on. This indicates that the retracted position is now set.
The calibration of the travel limits for the actuator is now complete. When the RET, NTL and EXT lights are on, proceed to Step 6.
Press the SETUP button in order to exit SETUP mode. The SETUP LED will blink while the controller stores the information. The SETUP LED will then turn off and the control box will perform an auto-calibration sequence. Verify that the limits are set correctly by performing an "Actuator Travel Limits Test".

Actuator Travel Limits Test

This procedure will verify that the travel limits and the NEUTRAL position have been set correctly.

Press the TEST button. The LED will light up indicating that the control box is now in TEST mode.
Press the SET button. Actuator rod (2) will move to the NEUTRAL position and stop. The NEUTRAL LED will now be on. Verify that the fan blades are in zero pitch and that the hole in operator fork (3) is aligned with the middle hole in alignment plate (6).
Press the SET button again. Actuator rod (2) will move to the fully extended position and stop. The EXTEND LED will now be on. Verify that operator fork (3) is between 1.588 mm (0.0625 inch) and 3.175 mm (0.1250 inch) of mechanical stop (5).
Press the SET button again. Actuator rod (2) will move to the fully retracted position and stop. The RETRACT LED will now be on. Verify that operator fork (3) is between 1.588 mm (0.0625 inch) and 3.175 mm (0.1250 inch) of clevis mounting block (7).
If the position settings are NOT satisfactory, press the TEST button in order to exit TEST mode. Repeat the "Actuator Travel Limits Calibration".
If the position settings ARE satisfactory, press the TEST button in order to exit TEST mode. The TEST LED will turn off.

Temperature Setpoint Calibration

Press the temperature calibration (TEMP CAL) button. The LED will light up indicating that the control box is now in temperature calibration mode.
Press the SET button. Observe the T1 LED and the T2 LED in order to determine the set point that needs to be adjusted. Refer to Table 1.
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Table 1
Set Point "T1" LED "T2" LED

Main temperature ON OFF

Auxiliary temperature OFF ON

Purge ON ON
When the desired set point is selected, adjust the set point. Press the Extend (EXT) button in order to raise the temperature setpoint. Press the Retract (RET) button in order to lower the temperature setpoint.

Table 1
Set Point	"T1" LED	"T2" LED
Main temperature	ON	OFF
Auxiliary temperature	OFF	ON
Purge	ON	ON

To accurately set the desired temperature, hold down the Retract (RET) button. The LED will blink until the lowest setting is reached. The LED will then turn off. Release the Retract (RET) button. The set point is now set at the lowest setting (0). Increase the temperature setpoint by pressing the Extend (EXT) button. Obtain the flash count for the required setting. Refer to Table 2 for the flash count that correlates to the desired temperature setpoint. The flash count is the number of flashes from the LED that is between the Extend (EXT) button and the Retract (RET) button. Pressing either button will make the LED flash. Count the number of flashes from the light in order to get the desired temperature setpoint.

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Table 2
Flash Count	Purge setpoint ("T1" and "T2" flashing)	Main temperature setpoint ("T1" flashing)	Auxiliary temperature setpoints ("T2" flashing) Left="T2" Normal Right="T2" Low
12	----	95.0 °C (203.0 °F)	122.0 °C (251.6 °F)	87.0 °C (188.6 °F)
11	----	93.0 °C (199.4 °F)	115.0 °C (239.0 °F)	79.0 °C (174.2 °F)
10	----	90.0 °C (194.0 °F)	110.0 °C (230.0 °F)	74.0 °C (165.2 °F)
9	----	88.0 °C (190.4 °F)	106.0 °C (222.8 °F)	70.0 °C (158.0 °F)
8	100.0 °C (212.0 °F)	86.0 °C (186.8 °F)	101.0 °C (213.8 °F)	66.0 °C (150.8 °F)
7	98.0 °C (208.4 °F)	84.0 °C (183.2 °F)	97.0 °C (206.6 °F)	61.0 °C (141.8 °F)
6	95.0 °C (203.0 °F)	82.0 °C (179.6 °F)	94.0 °C (201.2 °F)	59.0 °C (138.2 °F)
5	93.0 °C (199.4 °F)	81.0 °C (177.8 °F)	91.0 °C (195.8 °F)	57.0 °C (134.6 °F)
4	90.0 °C (194.0 °F)	79.0 °C (174.2 °F)	88.0 °C (190.4 °F)	56.0 °C (132.8 °F)
3	88.0 °C (190.4 °F)	78.0 °C (172.4 °F)	87.0 °C (188.6 °F)	54.0 °C (129.2 °F)
2	86.0 °C (186.8 °F)	77.0 °C (170.6 °F)	84.0 °C (183.2 °F)	52.0 °C (125.6 °F)
1	84.0 °C (183.2 °F)	76.0 °C (168.8 °F)	82.0 °C (179.6 °F)	51.0 °C (123.8 °F)
0	82.0 °C (179.6 °F)	74.0 °C (165.2 °F)	81.0 °C (177.8 °F)	49.0 °C (120.2 °F)

If you accidentally pass the correct flash count number, press the Retract (RET) button in order to lower the set point. Each flash represents one increment.
When the set points have been set to the desired levels, press the temperature calibration (TEMP CAL) button in order to exit the TEMPERATURE CALIBRATION mode. The TEMP CAL LED will blink while the controller stores the information. The TEMP CAL LED will then turn off.

Note: Due to the fact that temperature sensors can be installed in various locations, the setpoints in the tables do not necessarily reflect actual temperatures that are on the temperature gauge of the machine. The tables reflect the temperature of the fluid at the location of the temperature sensor. Use the tables as a guide when you select initial setpoints. Base all adjustments on the temperature gauge of the machine.

Controlling the Engine Temperature at the Desired Level

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Illustration 9	g00890055

The set point temperature is a range that is 3.5 °C (7.0 °F) wide. The Mark III controller will try to maintain the fluid temperature within this range. If the temperature stays within this range, the pitch of the fan will not change. When the temperature is above this range, the pitch of the fan will slowly increase until the temperature drops back into the range or full pitch is reached. Likewise, when the temperature is below this range, the pitch of the fan will slowly decrease until the temperature rises back into the range or neutral pitch is reached. The controller reads the temperature sensors at ten second intervals. The controller adjusts the pitch of the blades at ten second intervals accordingly.

Accurate setting of the temperature setpoints depends on the following conditions:

observing the temperature gauge of the machine
noting when the fan blades begin to change the pitch

The controller will try to maintain the engine temperature just below the temperature setpoint. If the fan starts increasing pitch too soon, increase the temperature setting. If the fan starts increasing pitch too late, decrease the temperature setting.

Note: While the system is in the temperature calibration mode, the controller continues to read the temperature sensors at ten second intervals. The controller also continues to adjust the pitch of the fan according to the current settings. Settings can be raised or lowered and the controller will respond accordingly. Exiting the temperature calibration mode is not necessary in order for the controller to respond to the new settings.

Note: With two sensors, the controller will INCREASE the pitch of the fan when either of the temperature sensors read a temperature above the setting. The controller will DECREASE the pitch of the fan when both of the temperature sensors read a temperature below the corresponding setting.

Efficient Cold Weather Setup for the Main Temperature Setpoint

Set the main temperature set point above the thermostat temperature for superior fuel efficiency and operation. The fan provides the most efficient cooling of the engine with the thermostat open. Setting temperature setpoint (T1) above the thermostat temperature will keep the fan from going into pitch until the thermostat is open. Maximum fuel efficiency is achieved because the fan is using only a fraction of the engine horsepower in the NEUTRAL position. The fan is not changing pitch until the thermostat opens.

Two Temperature Sensors

The temperature setpoints become much more difficult to adjust with two temperature sensors in the system. This is due to the fact that either sensor may be controlling the pitch. The T1 LED or the T2 LED will come on. The light that comes on depends on the sensor that is controlling the pitch of the fan blades. The sensor with the highest temperature above the corresponding set point will be controlling the pitch of the fan. The appropriate LED will be on. You must not be in TEST mode, SETUP mode or TEMPERATURE CALIBRATION mode, as the T1 LED and the T2 LED are used in these modes to indicate different settings. Accurate setting of the temperature setpoints depends on the following conditions:

observing the temperature gauge of the machine
noting whether the T1 LED or the T2 LED is on when the fan blades begin to change pitch

Selecting a Purge Setpoint

The selected purge setpoint will greatly affect the performance of the Temperature Driven AUTO-Purge and the Purge Interval Override features. The temperature setting will be dependent upon the operating environment and the characteristics of the machine. Set the purge setpoint approximately 5.0 °C (10.0 °F) above the normal engine operating temperature. If this set point is reducing the plugging that was causing overheating, then the set point is correct. If this set point does not reduce the problem, then decrease the difference. If the purging is occurring too frequently, increase the difference.

If the temperature that is selected is too low, the following problems may occur:

A single Temperature Driven AUTO-Purge will occur as the engine warms up. Additional cycles will not occur because the temperature will not drop below the set point that is required to reset the Temperature Driven AUTO-Purge.
The Purge Interval Override feature will provide little benefit. The feature may be detrimental as frequent purges will occur continuously. This will cause extra wear on the mechanical components of the fan. The overall cooling capacity of the cooling system will be reduced.

If the temperature that is selected is too high, the following problems may occur:

The Temperature Driven AUTO-Purge and the Purge Interval Override features may occur too late in order to keep the engine temperature within the acceptable operating range.

Select a temperature above the normal operating temperature. Make sure that the temperature is not so high that overheating occurs.