Professional Documents
Culture Documents
Lämppäri Renr6136!00!01 All
Lämppäri Renr6136!00!01 All
July 2002
Systems Operation
Testing and Adjusting
Machine Preheaters for Forwarders
1AM1-Up (Machine)
1FM1-Up (Machine)
i01658146
Table of Contents
Systems Operation Section
Introduction
General Information ................................................ 4
General Safety Notes .............................................. 6
Heater Operation
Before Starting the Heater ...................................... 6
Heater Start-up ....................................................... 6
Heater Operation .................................................... 7
Operating Switches ................................................. 7
Heater Function Monitor ......................................... 9
Operational Flow Chart ......................................... 10
Heater System Electrical Schematic ..................... 11
Index Section
Index ..................................................................... 20
4
Machine Preheaters for Forwarders
Systems Operation Section
• flame sensor
• temperature sensor
• overheat sensor
5
Machine Preheaters for Forwarders
Systems Operation Section
g00901878
Illustration 1
(1) Combustion air blower wheel (11) Flame sensor
(2) Main fuse (12) Combustion air tube
(3) Glow pin (13) Fuel-metering pump
(4) Temperature sensor (14) Exhaust tube
(5) Combustion chamber (A) Water outlet
(6) Coolant pump (B) Water inlet
(7) Electric motor (C) Water outlet
(8) Overheat sensor (D) Water inlet
(9) Control unit (E) Combustion air inlet
(10) Heat exchanger (F) Exhaust outlet
6
Machine Preheaters for Forwarders
Systems Operation Section
Cooling system conditioner contains alkali. Avoid • Refill the engine coolant.
contact with the skin and eyes to prevent personal
injury. • Purge the air from the coolant system by
loosening the purge screw of top of the heater.
i01765152 i01764052
The following operations will take place after a The control panel for the preheat system is capable
successful ignition: of setting one start time within seven days. The
control panel will also display the time of day and
• The machine preheater will operate in high heat any fault codes for the machine preheater. The
mode. The temperature is monitored at the heat display is automatically illuminated while the heater
exchanger. is operating.
• The machine preheater will automatically switch The operator presets the time for the activation
to low heat mode if the coolant temperature of the preheat system. The system will operate
exceeds 85 C (185 F). automatically at the selected start time until the start
time is changed by the operator.
• If the coolant temperature falls below 75 C
(167 F) the machine preheater will automatically The default operating duration is set at 30 minutes.
switch back to high heat mode. The operating duration can be regulated by the
operator. Due to drainage of the battery, the
• If the coolant temperature rises to 86 C (187 F) maximum operating duration is between 1 hour and
the machine preheater will automatically switch 1 1/2 hours.
off.
Note: The system will operate if the secondary
• The coolant pump will continue to circulate disconnect switch is in the ON position or in the
coolant in order to allow the machine preheater OFF position. If the battery disconnect switch is
to monitor engine temperature. turned off, the preheat system will not operate and
the settings for the preheat system will be erased.
• The machine preheater will automatically restart
The settings must be programmed again.
once the coolant temperature reaches 75 C
(167 F). Reference: For additional information about the
usage of the battery disconnect switches, refer to
• The machine preheater continues to operate Operation and Maintenance Manual, SEBU7197.
until switched off manually, by a timer, or by a
malfunction shutdown.
To set the time of day, hold down select key (6) for Start Heating within 24 Hours
three seconds. Then, press arrow keys (9) and (10)
until the correct time of day is shown on display (1). The preselected day is automatically obtained.
The time is stored when the display stops flashing.
The day of the week will then flash. Press arrow key To set a preselected time press select key (7) until
(9) or (10) in order to set the day of the week. The the required memory display (1, 2, or 3) flashes
day of the week is stored when the display stops on the display. Briefly press arrow key (9) or (10)
flashing. The display is retained with the ignition in and release. The preset time will now flash on the
the ON position. The display is turned off after ten display. Use arrow keys (9) or (10) in order to set
seconds with the ignition in the OFF position. the preselected time for heating. The setting can
only be changed when the preselected time flashes
Manually Starting the Preheat System on the display. When the settings are complete
press select key (7).
with the Engine Start Switch in the OFF
Position Start Heating Later than 24 Hours
Press on/off key (8) in order to start the preheat To set a preselected time and day press select key
system at any time. The remaining preheat time and (7) until the required memory display (1, 2 , or 3)
the symbol are shown on display (1). The preheat flashes on the display. Briefly press arrow key (9)
time can be changed by pressing arrow keys (9) or (10) and release. The preset time flashes on the
or (10). display. Use arrow keys (9) and (10) in order to set
the preselected time for heating.
9
Machine Preheaters for Forwarders
Systems Operation Section
The preselected day will start to flash approximately The control unit ensures that the electrical circuits
five seconds after the preselected time has been are complete prior to starting the machine preheater.
set. Use arrow keys (9) and (10) in order to set the If the machine preheater fails to ignite within 90
preselected day for heating. seconds of the fuel-metering pump activation, the
starting procedure will be repeated. If the machine
The preselected time and the preselected day are preheater again fails to ignite after 90 seconds of
stored in memory when the time display disappears fuel delivery, a no-start safety shutdown follows.
or when the display is changed over to indicate the
time. The memory display indicates the activated If the machine preheater flames out during
memory. A on/off key (8) additionally indicates an operation, the machine preheater automatically
activated memory. attempts to restart. If the machine preheater fails to
ignite within 10 seconds of fuel delivery, or ignites
Checking the Activated Memory but flames out again within 3 minutes, a flame-out
shutdown follows. After troubleshooting the problem
The preselected time on memory display (2) is the machine preheater can be started again by
shown for approximately five seconds. This is then switching the machine preheater off and then back
either turned off or the current time is displayed. on again.
The display of the preselected time and day can be
viewed by pressing select key (7) once. Overheating due to lack of coolant, a restriction,
or a poorly purged coolant system results in the
overheat shutdown. Fuel delivery will cease and
i01765247 an overheat shutdown follows. If the machine
preheater overheats 3 consecutive times, a lockout
Heater Function Monitor on the control unit will occur. Use the proper
troubleshooting procedures In order to unlock the
SMCS Code: 1383; 7304 control unit.
i01765269
i01765303
g00903134
Illustration 4
(1) Flame Sensor (A) Circuit for the Backlight
(2) Water Pump (B) Battery Power
(3) Temperature Sensor (C) Blower Fan Motor
(4) Overheat Sensor (D) Disconnect Switch
(5) Glow Pin (E) Disconnect Switch
(6) Blower Motor
12
Machine Preheaters for Forwarders
Testing and Adjusting Section
g00492735
Personal injury can result from hot coolant, steam Illustration 5
and alkali. TROUBLESHOOTING Position
At operating temperature, engine coolant is hot 2. Park the machine on a smooth, level surface.
and under pressure. The radiator and all lines Move away from other operating machines and
to heaters or the engine contain hot coolant or away from personnel.
steam. Any contact can cause severe burns.
g00658192
Illustration 9
Parking Brake Switch
g00908825
Illustration 10
Steering Frame Lock (LOCKED Position)
At operating temperature, engine coolant is hot • Check for interference in the combustion air
and under pressure. The radiator and all lines passage and in the exhaust passage.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. • Check for fuel in the tank. Ensure that the fuel is
suitable for the climate.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool • Check the battery voltage.
enough to touch with your bare hand.
• Check for coolant around the machine preheater
Cooling System Conditioner contains alkali. Avoid and on the ground under the machine.
contact with skin and eyes.
• Check all lines, all hoses, and all connections for
damage and for leaks.
• Ensure that the machine preheater has been 5. Check for contacts that are dirty or corroded.
properly purged after service.
• Clean the contacts with a cotton swab or with
• Check all fuel lines for leaks. a soft brush.
• Check the fuel filter. If necessary, replace the fuel 6. Check each connector pin and each connector
filter. receptacle.
• Check the glow plug for damage. If necessary, • Use a new connector pin and a new connector
replace the glow plug. receptacle to check each connector contact
for a snug fit. The new contact should stay
connected if the connector is held with the
Electrical System contacts facing downward.
Intermittent electrical problems are often caused by
poor connections. Use the following checks as a i01766266
guideline for inspecting connectors:
Fault Code Retrieval Device
1. Check the mating fit of the connectors.
SMCS Code: 1383; 7304
• Ensure that the locking rings lock in place.
• Ensure that locking clips are used on Sure-Seal
connectors.
• Ensure that each connector contact is properly The machine preheater is equipped with a
locked into the connector body. When the
connector contact is locked properly, the diagnostic tool. Diagnostic fault codes will be
contact or the wire cannot be pulled out of the displayed on the control panel. Use arrow keys (5)
connector body without excessive force. and (6) to scroll through the fault codes. In order to
remove a fault code, repair the machine preheater
3. Check each wire for nicks and for signs of and restart the machine preheater. This process
abrasion in the insulation. must be followed in order to remove each fault
code.
4. Check for moisture at the connector. The
following conditions are possible causes of Reference: For additional information about
moisture: troubleshooting fault codes, refer to Systems
Operation/Testing and Adjusting, “Troubleshooting
Diagnostic Codes”.
• Connector seals are damaged or missing.
• Plugs for the wire holes are loose or missing.
• Wires do not enter the back of the connector
straight. If the wires enter the connector at an
angle, there may not be a good seal between
the connector and the wire insulation.
i01766366
Troubleshooting Diagnostic
Codes
SMCS Code: 1383-038; 7304-038
Table 3
Fault Code Fault Description Causes/ Repair
000 Normal Operation None
Check voltage between pins 1 and 2 at connector B1. This must
be less than 16 volts.
010 Overvoltage
Check battery, all electrical leads, and machine charging
system.
Check voltage between pins 1 and 2 at connector B1. This must
be greater than 10.2 volts.
011 Under voltage shut down
Check battery, all electrical leads, and machine charging
system.
Check for possible causes of overheat.
Check overheat switch resistance values. Temperature at the
012 Overheating
temperature sensor or the overheat sensor is greater than
125 C (260 F).
Difference of measured values at temperature sensor <15 C
(60 F) (minimum 70 C (160 F) coolant temperature and
014 Possible overheating detected metering pump in operation).
Check temperature sensor and overheating sensor, replace
if necessary.
015 Excess overheats Remove cause of overheat.
Temperature at temperature sensor or overheat sensor ≥130 C
(265 F), emergency OFF if fault code 012 or 014 are not
017 Overheating detected applicable.
Check the coolant circuit, the temperature sensor, and the
overheat sensor; replace if necessary.
Check the glow plug and electrical leads for continuity, replace
020 Open circuit - glow plug
if necessary.
Check the glow plug and electrical leads for continuity, replace
021 Short circuit - glow plug
if necessary.
Blower impeller or electric motor may be obstructed. Fix the jam
030 Combustion air blower motor
and replace the electric motor if necessary.
Check the lead to the combustion air motor for continuity.
031 Combustion air blower motor
Replace the motor if necessary.
Check the combustion air blower motor (electric motor), replace
Combustion air blower motor
032 if necessary.
short-circuit
Check electrical connections.
Check the electrical lead to the relay, repair or replace if
038 Machine fan relay control break
necessary.
Check the electrical lead to the relay, repair or replace if
039 Machine fan relay control short circuit
necessary.
Check the supply lead to coolant pump for continuity, repair
041 Coolant pump break
or replace if necessary.
Check the supply lead to coolant pump for short circuit.
042 Coolant pump short-circuit
Check the condition of the coolant pump, replace if necessary.
(continued)
17
Machine Preheaters for Forwarders
Testing and Adjusting Section
(Table 3, contd)
Check all wires for short circuits to the fuel metering pump. Test
047 Short circuit - fuel metering pump
the fuel-metering pump. Replace if necessary.
Check the supply lead to the fuel metering pump for continuity,
048 Open circuit - fuel metering pump
repair and replace if necessary.
i01766814
g00908358
Illustration 12
Unexpected machine movement can cause injury 1. Pull the fuel line off the combustion chamber.
or death. Activate the parking brake if an adjust-
ment must be made with the engine running. 2. Insert the fuel line into a graduated measuring
glass.
Allow only approved personnel on the machine.
Keep other personnel off the machine and in clear 3. Start the machine preheater and run the machine
view of the service personnel. preheater for 40 seconds. Turn off the machine
preheater.
Perform the fuel quality test if the machine preheater
has difficulty starting or maintaining a flame. 4. Empty the graduated measuring glass.
Note: Measure the fuel quality when the battery 5. Insert the fuel line in the graduated measuring
is sufficiently charged. When performing the fuel glass.
quality test, the applied voltage at the control unit
must be at least 11 volts and at most 13 volts. Measurement
1. Start the machine preheater. Fuel delivery will
automatically begin approximately 40 seconds
after switching on the machine preheater.
Evaluation
Table 4
Nominal Value
8.6 cm3/90 seconds
7.5 cm3/90 seconds
General Information................................................. 4
General Safety Notes .............................................. 6
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 18
Testing and Adjusting Section ............................... 12
Troubleshooting ..................................................... 12
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.