Installation and Instruction Manual. Cold Weather Starting Aid Part No A. Jet-Ex 4 Diesel Generator Sets

Size: px

Start display at page:

Download "Installation and Instruction Manual. Cold Weather Starting Aid Part No A. Jet-Ex 4 Diesel Generator Sets"

Aldous Jones
5 years ago
Views:

1 TO Installation and Instruction Manual for Cold Weather Starting Aid Part No A For Use With Jet-Ex 4 Diesel Generator Sets HOBART BROTHERS COMPANY Ground Power Division Troy, Ohio U.S.A.

2 This page intentionally left blank.

3 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit DESCRIPTION/OPERATION 1. General This cold weather starting-aid kit (Figure 1) is an option available for starting the Jet-Ex 4 Diesel Engine at very cold temperatures. This cold weather starting system is a fully automatic Engine Starting Fluid System designed to spray a controlled amount of starting fluid into the air intake system of an engine during and immediately after cranking. The System s engine temperature sensor (ETS) Switch determines when the System should function. When needed, the solenoid valve is activated automatically during engine cranking; then, starting fluid is released from the pressurized cylinder, flows through the valve, through a flow metering orifice fitting at the bottom of the valve through the nylon tubing, and out of an injector nozzle located in the engine s air intake system. A reservoir in the valve maintains a flow of starting fluid after cranking to prevent the just started engine from faltering or dying. Note: Whenever the engine does not start within a normal period of cranking, the starting fluid cylinder may be empty. Refer to Servicing and Troubleshooting. 2. Field Installation WARNING Fires, fumes, and flying parts can kill or injure! Starting fluid is extremely flammable. Do not smoke when installing, maintaining, testing or troubleshooting. It is under pressure. Use caution when handling. Avoid contact with skin and avoid breathing vapor. store in a cool dry area. Refer to Figure 2 in this manual. For Series 7003A generator sets, refer to Schematic Diagram and Connection Diagram in back of this manual. For Series 7003B generator sets, refer to Schematic Diagram and Connection Diagram in back of this manual. Assemble cold weather starting kit as follows: a. Assemble elbow fitting and filter assembly (10, Fig. 2) to bottom of Dieselmatic valve assembly (7, Fig. 2). b. Connect one end of the 1/8 inch nylon tubing (11, Fig. 2) to the elbow fitting (10, Fig. 2). c. Mount cold weather starting kit (4, Fig. 2) to its mounting bracket (1, Fig.2). d. Mount bracket with starting kit to the left side of the mounting frame of the generator set, in front of the lifting yoke. e. Remove 1/8 inch pipe plug from intake manifold (approximately 2 inches from inlet), and mount the nozzle (7 Fig. 2) here with its orifice directed straight up (against the air flow). Note that the small red dot on the hex fitting of the nozzle indicated the direction of the orifice. f. Connect the other end of the 1/8 inch nylon tubing (11, Fig. 2) to the nozzle, and secure it with the wire ties provided. g. Insert the 15 amp fuse (3, Fig. 2) in the fuseholder (2, Fig. 2). Cut the fuseholder wire in half and attach the small ring tongue terminal to one wire. Connect this wire to the starter solenoid terminal which is connected directly to the starter. December 18/90 Page 1

4 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit h. Cut one wire of engine temperature sensor (8, Fig. 2) to a 6 inch length and attach the large ring tongue terminal to it. Then bend mounting tab of sensor opposite the original position, so that tab is approximately 1/8 inch above bottom of sensor. i. Mount the sensor to the lower left screw of the cylinder head cover plate on the rear of the engine, in which the water temperature switch and sender are mounted. Make sure that the bottom of the sensor is firmly seated against the cover plate. Attach the sensor s shortened wire to this screw also using the IET lock washer and flat washer supplied. j. Using the two wires provided, wire the fuseholder (2, Fig. 2) and the engine temperature sensor (8, Fig. 2) to the valve assembly according to Connection Diagram (for Series 7003A units) or Connection Diagram (for Series 7003B units). Insert the wires in the loom of the engine wire harness. 3. Tips On Cold Weather Starting a. Battery and Cables To start in cold weather, a diesel engine must crank at a fairly high speed. Worn out batteries, partially discharged batteries, and poor or loose cable connections will reduce cranking speed. Batteries, cables, and connections should be cleaned and tightened regularly. b. Fuel For an engine to start and keep running, fuel must flow through the injection system. Unblended #2 diesel fuel, clouds, forming filter-clogging was at temperatures around F (-10 0 C) making starting and running impossible. Most engine manufactures recommend that fuel have a cloud point at least 10 0 F (5 0 C) below the coldest anticipated temperature. c. Lube Oil Engine lubricating oil get thicker at lower temperatures. Many oils that flow freely at 70 0 F (21 0 C) are extremely thick at 0 0 F (-18 0 C). Follow your engine manufacturer s recommendations regarding oil viscosity for the coldest temperatures you expect your engine to encounter. 4. Servicing and Troubleshooting CAUTION When servicing or troubleshooting the cold weather starting kit, make certain that this work is done in a well ventilated area. Goggles should be worn to protect eyes when servicing this kit. Many vehicle components can affect cold weather starting. The following guide is limited to troubleshooting of the dieselmatic System. The most common problems are (1) an empty fluid cylinder, and (2) a clogging metering orifice. a. Check Fluid Cylinder Contents And Valve Gasket. (1) Clean all dirt from neck of cylinder and top of valve before removing the fluid cylinder. Protect top of valve from dirt when cylinder is removed. (2) An empty net weight 21 oz. fluid cylinder weighs 16 oz. (454 gr.), and a full fluid cylinder weighs 37 oz. (1049 gr.). (3) An empty net weight 18 oz. fluid cylinder weighs 15 oz. (425 gr.), and a full fluid cylinder weighs 33 oz. (935 gr.). (4) An empty net weight 8 oz. fluid cylinder weighs 10 oz. (283 gr.), and a full fluid cylinder weighs 18 oz. (510 gr.). (5) Check that fluid cylinder has pressure. Page 2 December 18/90

5 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit 1. Mounting bracket 4. Dieselmatic valve 2. Starting fluid cylinder 5. Block fitting and filter assembly 3. Cylinder clamp Cold Weather Starting Aid Location Figure 1 December 18/90 Page 3

6 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit (6) Check valve gasket. If gasket inside valve is damaged or worn, replace with a new gasket, KBI Part Number Make sure only one gasket is used, as two gaskets would prevent valve from operating. (7) Cylinder, or its replacement, should be reinstalled hand tight. Coupling Dirt Eliminator may be transferred from old cylinder to new cylinder or replaced with a new one, KBI Part Number b. Check of electrical system. WARNING Electrical shock can kill. Do not touch live electrical parts. (1) Check to see if fuse is blown. Check all wiring for loose connections, shorts, and broken wires. (2) Check that the Dieselmatic System is wired correctly. For Series 7003A units, it should be wired in accordance with Connection Diagram and Schematic Diagram For Series 7003B units, it should be wired in accordance with Connection Diagram and Schematic Diagram NOTE: To check system for proper operation, the Engine Temperature Sensor (ETS) must be below 40 0 F(4 0 C) or be bypassed by connecting the valve s black lead directly to a good ground. After checking be sure to reconnect the black lead in accordance with Connection Diagram (3) Test valve by removing fluid cylinder and momentarily engaging cranking motor. Valve plunger should move up and remain up while cranking motor is engaged. If valve operates, proceed to step (5). (4) If valve plunger did not function, check valve by disconnecting leads from cranking motor and ground. Momentarily touch leads directly across battery terminals. The valve plunger should move up and remain up until the leads are disconnected. If the valve does not activate when connected across the battery it is faulty and should be replaced. (5) Check Engine Temperature Sensors (ETS) Switch by chilling to sub-freezing temperatures. At cold temperatures, the ETS Switch should close (i.e. show continuity). Check with a DC powered test light or ohmmeter. At warm temperatures, the ETS Switch should open (i.e. not show continuity). The closing and opening temperature should be about 40 0 F (4 0 C). If either continuity test fails, ETS Switch should be replaced. c. Check for clogging of flow Metering Orifice Fitting CAUTION When servicing or troubleshooting the cold weather starting kit, make certain that this work is done in a well ventilated area. Goggles should be worn to protect eyes when servicing this kit. The Dieselmatic s fluid flow rate is controlled by serviceable filtered metering orifice inside the fitting at the bottom of the valve assembly. See Figure 2. The following procedure is recommended when checking for clogging: (1) Remove system s nozzle from engine. (2) If starting fluid does not spray from nozzle when the system is activated, disconnect tubing from valve fitting. If starting fluid sprays from the fitting when the system is activated, check tubing for kinks, burns, cuts, clogs, or for a clogged nozzle. When performing these two operations, be sure to spray fluid into an appropriate container. (3) If starting fluid does not spray from valve fitting, it should be removed from valve and cleaned. NOTE: Fitting end installed in valve has left hand threads. Page 4 December 18/90

7 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit The filter may be removed from the fitting. It can be washed in clean solvent and blown with compressed air. For best results, replace filter with a new one, KBI Part Number Reassemble filter with O ring into fitting. (4) It is suggested before clean filtered assembly is reinserted into valve, that valve be flushed by activating the system. When performing this operation, be sure to spray fluid into an appropriate container. (5) Reinsert clean filtered fitting assembly into valve. Remember: left hand threads. Reinstall system s nozzle into engine. Reconnect tubing to valve fitting and nozzle. (6) Check all fitting and tubing connections for leaks. 5. Replacement parts Write: Telephone: (512) Kbi Kold-Band International Ltd. 900 Pingree Road Algonquin, Illinois, Service Information If you have any questions concerning the Cold Weather Start kit, you are invited to contact our Service Department by mail, telephone or facsimile: Write: Hobart Brothers Company Airport Systems Group Ground Power Division Service Department Troy, Ohio U.S.A. Telephone: (513) Facsimile: (513) December 18/90 Page 5

8 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit Kit, Cold Weather Starting Aid Figure 2 Page 6 December 18/90

9 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit UNITS FIGURE HOBART KBI PER ITEM NO. PART NO. PART NO. NOMENCLATURE ASSY A KIT, COLD WEATHER START ASSY. REF BRACKET, MTG., VALVE FUSEHOLDER, IN-LINE 1 3 W FUSE, AGC, 15A KIT, COLD WEATHER START, KIT NO CYLINDER, STARTING FLUID CLAMP, RETAINING, CYLINDER VALVE ASSY., DIESELMATIC SENSOR, ENGINE TEMPERATURE NOZZLE, STRAIGHT WITH SIDE ORIFICE BLOCKOR FITTING & FILTER ASSY TUBING, 1/8 NYLON, 60" LONG COLLAR, DIRT ELIMINATOR 1 * LABEL, AIR FILTER HOUSING 1 * LABEL, DASH 1 * INSTRUCTIONS, INSTALLATION 1 * Not illustrated December 18/90 Page 7

10 TO-211 / Installation and Instruction Manual Part No A / Cold Weather Starting Kit This page intentionally left blank. Page 8 December 18/90

INSTALLATION - OPERATION MANUAL

AND AUTOMATIC TURN-KEY STARTING FLUID SYSTEMS INSTALLATION - OPERATION MANUAL KBi/KOLD-BAN INTERNATIONAL, LTD. 8390 PINGREE ROAD, LAKE IN THE HILLS, IL 60156-9637 U.S.A. (800) 527-8278, (847) 658-8561,