F5H079 Force SYNCHRO-DRIVE CONTROL BOX

Illustration 1 g01338727
Schematic of the ether injection system
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in HOLD or NEUTRAL when starting the engine.
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND THE WIRING
Turn the keyswitch to the OFF position.
Illustration 2 g01338736
Left side engine view (typical example)
(1) J1/P1 ECM connectors
(2) Ether injection solenoid
(3) Machine connector (20-Pin)
Thoroughly inspect connectors (1) and (3). Also, thoroughly inspect the connector for the ether solenoid (3). Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01338801
P1 terminals for the ether injection system
(P1-18) Solenoid return
(P1-20) Ether injection solenoid
Illustration 4 g01338812
Terminal locations at the machine connector 20-pin for the ether injection system
(Terminal 2) Ether injection solenoid
(Terminal 3) Solenoid return
Illustration 5 g01155187
Terminal locations at the connector for the ether injection system
(Terminal 1) Ether injection solenoid
(Terminal 2) Solenoid return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the ether injection system.
Check the torque of the allen head screws for the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the ether injection solenoid 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 connectors and the wiring appear to be OK.
Not OK - The connectors and/or the wiring are not OK.Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 2. CHECK FOR VOLTAGE TO THE ETHER SOLENOIDNote: Remove the ether canister before you perform this procedure.
Turn the keyswitch to the OFF position.
Connect Cat ET to the service tool connector.
Disconnect the connector for the ether solenoid.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The system will activate for ten seconds.
Measure the voltage between terminal 1 and terminal 2 on the harness side of the connector for the ether solenoid.
Turn the keyswitch to the OFF position. Expected Result:The voltage measures approximately 0 VDC when the override for the ether system is not activated. The voltage measures approximately 24 3 VDC when the override for the ether system is activated.Results:
OK - The voltage measurements are correct.Repair: Measure the resistance of the ether solenoid. The resistance of the coil in the ether solenoid is approximately 20 Ohms. If the measurement indicates that there is an open or a short in the solenoid, replace the solenoid. Verify that the original condition has been resolved.STOP
Not OK - One of the voltage measurements was incorrect. There is either a short or an open in the wiring between the connector for the ether solenoid and the ECM. There may be a problem with the ECM. Proceed to Test Step 3.Test Step 3. CHECK FOR THE PROPER OPERATION OF THE ECM
Disconnect the J1/P1 ECM connectors.
Fabricate two jumper wires that are long enough to create a test circuit at the ECM connector. Crimp connector sockets to one end of each of the jumper wires.
Remove the wires from terminal locations P1-18 and P1-20 at the connector. Install a jumper wire into each of these terminal locations.
Connect the J1/P1 ECM connectors.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The system will activate for ten seconds.
Measure the voltage between the two jumper wires.
Turn the keyswitch to the OFF position. Expected Result:The voltage measures approximately 0 VDC when the override for the ether system is not activated. The voltage measures approximately 24 3 VDC when the override for the ether system is activated.Results:
OK - The voltage measurements are correct.Repair: The ECM is operating properly. There is either a short or an open in the wiring between the connector for the ether solenoid and the ECM. Repair the harness and/or the connectors. Replace parts, if necessary. Verify that the original problem has been resolved.STOP
OK - The voltage measurements are not correct.Repair: There is a problem with the ECM. Perform the following procedure:
Temporarily connect a test ECM. Refer to Troubleshooting, "ECM - Replace".
Recheck the circuit in order to ensure that the original problem has been resolved. If the problem is resolved with the test ECM, install the suspect ECM. If the problem returns with the suspect ECM, replace the ECM. Verify that the problem is resolved.If the problem is not resolved with the test ECM, install the original ECM. There is a problem in the wiring.STOP