Testing & Adjusting

Usage:

Component Testing

Valve Assembly

To test the valve assembly, remove the ether bottle and jumper around the temperature switch. With the toggle switch in the Auto position, crank the engine. Observe the valve to see if it is functioning (valve will actuate). It is important to make sure that the resistor is still in place to protect the solenoid.

Control Group

Test the control group using the test diagram shown. Perform the tests in sequence at both 18.0 ± 0.5 VDC and 32.0 ± 0.5 VDC. Start the test with SW1 and SW2 open.

Test Circuit Diagram

Normal Operation

With SW1 open, close SW2. The solenoid should pull in.

Short Circuit

Turn power on by closing SW2. Close SW1. Maximum current reading on ammeter should be 500 mA.

Reverse Polarity

1. With the power off, reverse leads. Connect Lead No. 1 to -Battery and Lead No.2 to +Battery.

2. Turn power on by closing SW2. The solenoid should not pull in.

3. Turn power off by opening SW2. Reconnect leads for normal operation.

Resistor Check

The resistance of the Resistor Assembly should be 20 ± 1 Ohm. Be certain to check the resistor itself, not just the leads from the resistor. There is a diode in the lead line. Testing here will not give the desired results.

Resistor Assembly Check

Temperature Switch Assembly

Remove the Temperature Switch Assembly from the system. Immerse the Temperature Switch Assembly in an ice bath. Using an ohmmeter check the resistance between the pins in the receptacle. At a temperature of 13°C (55°F) the resistance should be less than 1 Ohm. Warm the sensor and measure the resistance. At a temperature of 18 to 24°C (61 to 82°F) the resistance should be greater than 20k Ohms.

Ether Cylinder Removal

Non-Empty Cylinders

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Ether is poisonous and flammable. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Use ether only in well ventilated areas. Use ether with care to avoid fires. Do not smoke while changing ether cylinders. Do not store ether cylinders in direct sunlight or at temperatures above 48°C (120°F). Discard ether cylinders properly. Do not puncture or burn ether cylinders. Keep ether cylinders out of reach of unauthorized personnel.

1. Turn the disconnect switch to the OFF position.

2. Remove ether cylinder(s).

3. Perform the desired service operations.

4. Install the ether cylinder(s). Hand tighten the ether cylinder to the solenoid valve.

Warm Climate Applications

In warm climates, [(temperatures never below 10°C (50°F)], it may be desirable to remove the ether cylinders but keep the system intact for future use. It may also be desirable to remove the ether cylinders during summer months.

Ether Cylinder Replacement

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Always check the following before installing the ether cylinder(s):

* Cylinder Type: Use only Caterpillar supplied ether cylinders. Incorrect ether cylinders will adversely effect the ether injection control.

* Non-Empty Cylinders: Always replace an old ether cylinder with a new (FULL) ether cylinder. Do not reinstall the used ether cylinder. Unless special measures are taken prior to removal, installing used ether cylinders will result in improper function of the system.

* Cross Threading: Properly align the threads when installing ether cylinders.

* Bent Cylinder Necks: Do not use ether cylinders with necks that have been bent. This can result in binding of the solenoid valve plunger.

* Cylinder Filter/Gasket Assembly: Failure to install the gasket will result in leaks. Do not over tighten the ether cylinder after engaging the gasket. This can distort the gasket and disrupt ether injection.

* Contamination: The gasket filters can be easily clogged by contamination in the system. Remove all dirt and debris around the solenoid valve and ether cylinder before removing the cylinder.