D399, G399, D398, G398, D379, G379 ENGINES Caterpillar


Engine Attachments Testing And Adjusting

Usage:



Problem Solving

1. Contactor Switch (Water Temperature) Fails to Signal Shutoff.
2. Contactor Switch (Water Temperature) Signals Shutoff at Low Temperature.
3. Oil Pressure Contactor Fails to Signal Shutoff.
4. Overspeed Contactor Switch Fails to Signal Shutoff.
5. Overspeed Contactor Switch Signals Shutoff at Low Speed.
6. Rack Solenoid Fails to Shutoff Engine.
7. Rack Solenoid Prevents Engine Start.
8. Unstable Woodward UG-8.
9. Unstable Output Shaft Governor Operation.
10. Clutch Slips, Heats or Lever Disengages.
11. Clutch Shaft End Play Excessive.
12. Air Starting Motor Cranks Slowly.
13. Hydraulic Starting System Fails to Crank or Cranks Slowly.
14. Prelubrication Pump Motor Fails to Turn or Turns Slowly.
15. Prelubrication Pump Motor Fails to Stop.

Woodward UG-8 Governor

Adjustments


NOTICE

Only competent personnel should attempt to adjust fuel rack settings and the governor. The low and high idle RPM, and rack setting dimension for these engines are listed in the RACK SETTING INFORMATION.


Adjusting Low or High Idle Speed

Check the engine LOW or HIGH IDLE speed with a hand tachometer at the tachometer drive connection. The tach drive rotates at one half engine RPM.

1. Set the load limit control knob (3) at 5 to prevent the engine from getting excessive fuel and from accelerating too rapidly.

2. Start the engine and gradually increase the amount of fuel. When the engine has reached operating temperature, turn the load limit control slowly from 5 to 10. Use the synchronizer knob to adjust the engine speed; then, check the low or high idle stop.

3. If the low or high idle stop does not permit the desired speed, adjustment is necessary. Remove the dial plate.

4. Loosen the setscrew on the synchronizer indicator knob (7), drive out the tapered pin, if so fitted and remove the knob.

5. Pull gear (6) out of mesh with gear (2).

6. When setting the high idle speed, turn synchronizer control knob (5) clockwise until the desired high idle speed is reached. Turn counterclockwise for low idle.

7. Set the high idle speed stop by turning gear (6) clockwise (counterclockwise for low idle) until the gear pin contacts idler gear (2). Mesh the gears.

8. After setting the idle speed stop, turn the synchronizer control knob to change the engine speed. Return it to the desired position and recheck the idle speed. Reset if necessary.


GOVERNOR ADJUSTMENTS (Typical Example)
1-Terminal lever. 2-Idler gear. 3-Load limit control. 4-Linkage. 5-Synchronizer control knob. 6-Gear. 7-Synchronizer indicator knob.

NOTE: The synchronizer indicator pointer disc may be reset, if necessary. With the engine running at high idle, stop the engine by turning load limit control (3) to zero. Pry off the synchronizer indicator pointer disc and reinstall at an indication such as 12 to indicate high idle.

9. Install the synchronizer indicator knob and the dial plate.

Fuel Rack Setting

9S240 Rack Positioning Tool Group.


RACK POSITIONING TOOLS
1-9S227 Bracket Group. 2-8S2283 Dial Indicator. 3- 8S3675 .125 in. (3,18 mm) Contact Point.

1. Remove eyebolt (4), cover (5), plug and O-ring.


EYEBOLT AND COVER
4-Eyebolt. 5-Cover.

2. Install bracket (1) to fuel pump housing.


BRACKET INSTALLED
1-Bracket.

3. With the governor in shut-off position, place spacer (6) of the bracket group between the shoulder on the rod in bracket (1) and the bracket. Apply pressure toward the fuel pump housing to hold the spacer snug.


DIAL INDICATOR INSTALLED
1-Bracket. 2-Dial indicator. 6-Spacer.

4. Install and zero indicator (2), then tighten the bracket screw and remove spacer (6).


COVER FOR RACK ADJUSTING SCREW
7-Lock wire. 8-Cover.

5. Set the governor load limit control knob on 10. Using the lever on the governor terminal shaft, move the fuel rack from the FUEL OFF position toward the FUEL ON position until contact is made with adjusting stop screw and read the rack setting gauge. Compare the rack travel value with that listed in the RACK SETTING INFORMATION.


NOTICE

Do not force the engine linkage toward increased fuel without first turning the load limit knob to 10.


6. If the full rack travel is not the value listed in the RACK SETTING INFORMATION, cut lock wire (7), remove cover (8), loosen the adjusting screw locknut and disengage the lock so the adjusting screw can be turned freely.

7. Turn the adjusting screw counterclockwise to increase the fuel rack travel or clockwise to decrease the rack travel. When the fuel rack is correctly adjusted, lower the lock into the nearest notch, tighten the locknut and install cover.

8. Install lock wire and seal.

Compensating Adjustment

Although the governor may appear to be operating satisfactorily at no load, high overspeeds and underspeeds after load changes and slow return to normal speed are the results of incorrect compensation adjustments.

Make compensating adjustments after the temperature of the engine and the oil in the governor have reached normal operating values and with the engine running at no load conditions.

1. Loosen nut (1) and set compensation adjusting pointer (2) at MAX.

2. Remove plug (3) and, use a screwdriver to open the compensating needle valve three or more turns.

3. Allow the engine to surge for about 1-1/2minutes to bleed trapped air from the governor oil passages, then turn compensating needle valve until surging stops. The needle valve must be approximately 1/8 turn open.


COMPENSATING ADJUSTMENT
1-Nut. 2-Compensating adjusting pointer. 3-Plug.

4. Lower the pointer to two points above MIN.

5. Move the governor terminal shaft manually to increase engine RPM, then let go and let the governor stabilize. If it takes too long to stabilize, move the pointer toward MAX two more points. Continue until the governor stabilizes, without too much over and under speed.

Governor Linkage Adjustment

Effective with D379 68B1616-Up, D398 66B2049-Up, and D399 35B1-Up.

1P2385 Protractor Tool

Illustrated here are three basic usages of 1P2385 Protractor Tool.

1) Vertical housing face-to-lever angle.
2) Horizontal or level-to-lever angle.
3) Lever-to-lever angle.


1P2385 PROTRACTOR TOOL USAGE
A-Angle setting indicator. B-Protractor plate edge aligned with lever. C-Vertical housing face and extension arm alignment. D-Level bubble. E-Angle setting indicator. F-Extension arm aligned with lever. G-Extension arm aligned with lever. H-Plate edge aligned with second lever. I-Angle setting indicator.


GOVERNOR LINKAGE ADJUSTMENT
1-Governor lever. 2-Linkage. 3-Lever.

Rotate lever (1) and lever (3) to fuel-off position. Adjust linkage (2) to obtain angles shown.

Carburetor Linkage Adjustment

Effective with G379 72B264-403, G398 73B511-795 and G399 49C1-172.


CAPTION FOR CONTROL LINKAGE ILLUSTRATIONS
1-Center lever. 2-Right end lever. 3-Governor lever. 4-Governor to center lever linkage. 5-End lever-to-right carburetor lever linkage. 6-Carburetor lever. 7-Left end lever. 8-End lever-to-left carburetor lever linkage. 9-Carburetor lever.

1. Assemble end levers (2) and (7) to cross shaft at angles shown from center lever (1).

2. With throttle plates closed, assemble carburetor levers (6) and (9) on carburetor throttle shafts at angles from horizontal as shown.

3. Position center lever at a 25° angle from vertical as shown, then adjust and assemble linkage (5) and (8) with both throttle plates in the CLOSED position.

4. Open the throttle plates to check proper positioning of levers. This will decrease angle of center lever (1) from 25°.

5. With governor at SHUTOFF position and governor lever (3) at angle shown from horizontal, adjust and assemble the linkage (4) from center lever (1) to the governor and maintain the angle of the center lever at 25°.

6. Adjust carburetor as instructed in the ENGINE SECTION of this manual.


G399 ENGINE RIGHT SIDE CONTROL LINKAGE


G399 ENGINE LEFT SIDE CONTROL LINKAGE

Carburetor Linkage Adjustment

Effective with G379 72B404-Up, G398 73B796-Up and G399 49C173-Up.


CONTROL LINKAGE
1-Governor lever. 2-Linkage. 3-Center lever. 4-End lever. 5-Linkage. 6-Carburetor levers.

1. Position center lever (3) at a 90° angle from horizontal, then assemble end levers (4) to cross shaft at angles shown.

2. With throttle plates closed, assemble carburetor levers (6) on carburetor throttle shafts at angles from horizontal as shown.

3. Adjust and assemble linkage (5) with both throttle plates in the CLOSED position.

4. Open the throttle plates to check proper positioning of levers. This will increase angle of center lever (3) from 90°.

5. With governor at SHUT-OFF position and governor lever (1) at angle shown from horizontal, adjust and assemble the linkage (2) from center lever (3) to the governor and maintain the angle of the center lever at 90°.

6. Adjust carburetor as instructed in the ENGINE SECTION of this manual.

Woodward EG-3P Governor Actuator

Adjustments

Fuel Rack Setting

9S240 Rack PositioningTool Group

NOTE: See the topic FUEL RACK SETTING for the WOODWARD UG-8 GOVERNOR.

Governor Linkage Adjustment

Effective with D379 68B1616-Up, D398 66B2049-Up, and D399 35B1-Up.

1P2385 Protractor Tool

Three uses of 1P2385 Protractor Tool.

(1) Vertical housing face to lever angle.
(2) Horizontal or level to lever angle.
(3) Lever to lever angle.


1P2385 PROTRACTOR TOOL USAGE
A-Angle setting indicator. B-Protractor plate edge aligned with lever. C-Vertical housing face and extension arm alignment. D-Level bubble. E-Angle setting indicator. F-Extension arm aligned with lever. G-Extension arm aligned with lever. H-Plate edge aligned with second lever. I-Angle setting indicator.


GOVERNOR LINKAGE ADJUSTMENT
1-Terminal shaft. 2-Linkage. 3-Lever.

Rotate shaft (1) and lever (3) to fuel-off position. Adjust linkage (2) to obtain angles shown.

Carburetor Linkage Adjustment

Effective with G379 72B404-Up, G398 73B796-Up, and G399 49C173-Up.


CONTROL LINKAGE
1-Governor lever. 2-Linkage. 3-Center lever. 4-End levers. 5-Linkage. 6-Carburetor levers.

1. Position center lever (3) at a 90° angle from horizontal, then assemble end levers (4) to cross shaft at angles shown.

2. With throttle plates closed, assemble carburetor levers (6) on carburetor throttle shafts at angles from horizontal as shown.

3. Adjust and assemble linkage (5) with both throttle plates in the CLOSED position.

4. Open the throttle plates to check proper positioning of levers. This will increase angle from center lever (3) from 90°.

5. With governor at SHUT-OFF position and governor lever (1) at angle shown from horizontal, adjust and assemble the linkage (2) from center lever (3) to the governor and maintain the angle of the center lever at 90°.

6. Adjust carburetor as instructed in the ENGINE SECTION of this manual.

Carburetor Linkage Adjustment

Effective with G379 72B264-403, G398 73B511-795.


CAPTION FOR CONTROL LINKAGE ILLUSTRATIONS
1-Center lever. 2-Right end lever. 3-Governor lever. 4-Governor to center lever linkage. 5-End lever-to-right carburetor lever linkage. 6-Carburetor lever. 7-Left end lever. 8-End lever-to-left carburetor lever linkage. 9-Carburetor lever.

1. Assemble end levers (2) and (7) to cross shaft at angles shown from center lever (1).

2. With throttle plates closed, assemble carburetor levers (6) and (9) on carburetor throttle shaft at angles from horizontal as shown.

3. Position center lever at 25° angle from vertical as shown, then adjust and assemble linkage (5) and (8) with both throttle plates in the CLOSED position.

4. Open the throttle plates to check proper positioning of levers. This will decrease angle of center lever (1) from 25°.

5. With governor at SHUTOFF position, (governor lever (3) at 15° angle), adjust and assemble the linkage (4) from center lever (1) to the governor and maintain the angle of the center lever at 25°.

6. Adjust carburetor as instructed in the ENGINE SECTION of this manual.

Pierce Output Shaft Governor

Testing And Adjusting

Four adjustments must be made: 1-linkage adjustment, 2-low speed setting, 3-high speed setting, 4-regulation, and surge. For any given output shaft governor setting, the regulation is the range or spread between the torque converter output shaft speed at no load and the output shaft speed at full load, with the diesel engine governor control, in the full open position. If the regulation is too close, surging will result.

The torque converter output shaft maximum speed is either a high speed setting or a low speed setting, which is determined by changing the position of the speed change lever (4), normally by remote control. The high speed screw (9) determines the maximum speed for the high speed setting, and the low speed screw (8) determines the maximum low speed setting. Consult the operator's manual for the equipment in which the engine is installed to ascertain the maximum permissible output shaft speed for the driven equipment.

NOTE: Perform the first nine Steps with the engine stopped.


OUTPUT SHAFT GOVERNOR ADJUSTMENT
1-Terminal lever. 2-Rate adjusting screw. 3-Adjustable rod. 4-Speed change lever. 5-Governor spring. 6-Bumper screw. 7-Lever. 8-Low speed adjusting screw. 9-High speed adjusting screw. 10-Bracket.

1. Disconnect the adjustable linkage (3) from the terminal lever (1) and the other adjustable linkage (12) between the servo mechanism (14) and standard governor.

2. Position the speed change lever (4) with low and high speed adjusting screws (8) and (9) so the rate adjusting screw (2) and the governor spring (5) are approximately parallel to lever (7).

3. Turn the rate adjusting screw until a slight tension is maintained on the governor spring. This will position the governor weights in the closed position.

4. Adjust linkage (3) between terminal lever (1) and servo boost mechanism so that it moves .08 in. (2,03 mm) before lever (13) starts to move. Install linkage (3).

5. Retract the speed limiter and move the governor control to full speed position.

6. Rotate shutoff lever (11) until shutoff lever contacts the rack stop collar. This can be determined by use of continuity tester connected to the insulated terminal of the standard governor.


GOVERNOR LINKAGE ADJUSTMENT
1-Terminal lever. 3-Linkage. 11-Shutoff lever. 12-Linkage. 13-Servo lever. 14-Servo mechanism.

7. Adjust the linkage (12) to fit lever holes when shutoff lever contacts rack stop collar, then increase linkage length .06 in. (1,52 mm) and install the linkage.

8. Back out bumper screw (6) until approximately 3/4 inch of the screw is protruding from the governor housing.

9. Fill the output shaft governor to the proper level with SAE 30 lubricating oil. The proper level can be checked by removing the small oil plug located in the drive cable end of the governor housing.

10. Start the diesel engine. After a reasonable warm-up period move the diesel engine governor control lever to the full open position.

11. Adjust the output shaft speed to the maximum desired speed with the aid of the low speed adjusting screw (8). Turn the screw clockwise to raise the speed and counterclockwise to lower the speed.

12. If a surging condition is encountered, back off the nut on the rate adjusting screw one full turn. Turn the low speed adjusting screw clockwise to return the output shaft speed to the desired RPM. Continue this procedure until all surge is removed. If it is not possible to remove all surge, set the governor at the setting which will produce the least amount of surge and remove the remaining surge by turning the bumper screw clockwise until it just makes contact with the rocker yoke.


NOTICE

Turning the bumper screw in beyond this point will raise the output shaft speed and eventually damage the internal parts of the governor. The bumper screw should not be used to remove speed surges of greater than 50 RPM.


Turning the low speed adjusting screw clockwise will increase the leverage of the governor spring (5) on the lever (7) and increase speed, with the result that minimum tension on the spring is now required. This adjustment will provide the most sensitive regulation. When the load is removed suddenly, the engine should not surge in excess of four (4) cycles. When the load is gradually removed, no surge should be evident.

13. With the output shaft running at the desired speed setting, turn the high speed adjusting screw (9) until the end of the screw contacts the stop bracket (10). Lock the high speed screw in this position.

Woodward SGT Governor

Adjustments


NOTICE

Only personnel with correct training can make adjustments to fuel rack settings and the governor. The dimensions for low and high idle speed and the rack setting for this engine can be found on the engine information plate.


Governor Linkage Adjustment

1P2385 Protractor Tool

Three uses of 1P2385 Protractor Tool.

(1) Vertical housing face to lever angle.

(2) Horizontal or level to lever angle.

(3) Lever to lever angle.


1P2385 PROTRACTOR TOOL USAGE
A-Angle setting indicator. B-Protractor plate edge aligned with lever. C-Vertical housing face and extension arm alignment. D-Level bubble. E-Angle setting indicator. F-Extension arm aligned with lever. G-Extension arm aligned with lever. H-Plate edge aligned with second lever. I-Angle setting indicator.


GOVERNOR LINKAGE
1-Governor lever. 2-Linkage. 3-Lever.

1. Move lever (1) and lever (3) clockwise to the fuel-off position.

2. Make adjustments to the governor linkage. See illustration for dimensions and angles.

Fuel Rack Setting

9S240 Rack Positioning Tool Group

NOTE: See the topic FUEL RACK SETTING for the WOODWARD UG-8 GOVERNOR.

Low and High Idle Adjustment of the Engine Governor

1. Install a tachometer and start the engine.

2. Let the engine run until it is warm.

3. Make adjustments to the low idle stop (1) on the governor control lever (2) to keep engine speed to specifications.


LOW IDLE ADJUSTMENT
1-Low idle stop. 2-Governor control lever.


HIGH IDLE ADJUSTMENT
3-Lock wire. 4-High idle screw.

4. Cut lock wire (3) and loosen the locknut on the high idle screw (4).

5. Move the governor control lever to the high idle position and make adjustments to the high idle screw to keep engine speed to specifications.

6. Tighten locknut and install lock wire and seal.

Speed Droop (Engine Governor)

1. Cut lock wire and remove the top cover of the governor.

2. Remove flexible coupling.

3. Move the droop lever of the engine governor to the center position.

4. Start the engine.

5. Move the governor linkage to cause a temporary engine speed increase. If the engine speed goes back to the original speed with only two or three oscillations, the adjustment is satisfactory. If not, move the droop lever in the direction of the rear of the engine to cause an increase in droop or move the droop lever in the direction of the front of the engine to cause a decrease in droop.

6. Install flexible coupling and the top cover of the governor.

7. Install lock wire and seal.

High Idle Adjustment of the Torque Converter Governor

NOTE: High idle, full load speed and no load speed for the torque converter can be found on the information plate in the engine compartment of the machine.

1. Start the engine and engage the clutch.

2. Move the governor control lever to the high idle position.

3. Make adjustments to the high idle screw (1) of the converter governor to keep engine speed to specifications.


HIGH IDLE ADJUSTMENT
1-High idle screw for torque converter governor.

Speed Droop (Torque Converter Governor)

9S240 Rack Positioning Tool Group

1. Install the 9S240 Tool Group.

NOTE: See the topic FUEL RACK SETTING for the WOODWARD UG-8 GOVERNOR for installation instructions of the 9S240 Tool Group.

2. Cut the lock wire and remove the top cover of the governor.

3. Put a load on the engine according to the specifications for full load speed of the torque converter. Engine speed at full rack position must be inside 10 rpm of the specifications.

4. If the rack is open at a speed higher than full load speed, move the droop lever in the direction of the rear of the engine to cause an increase in droop.

5. If the rack is not open at the full load speed given in the specifications, move the droop lever in the direction of the front of the engine to cause a decrease in droop.

6. Install lock wire and seal.

Starting Systems

Air Starting

Pressure Regulating Valve Adjustments

The regulator can be adjusted by turning the adjusting screw (1) located on top of the chamber. Disconnect the regulator from the control valve. With the regulator connected to the air supply line, connect an 8M2885 Pressure Gauge to the regulator outlet (3) and check the pressure. In cold weather it may be necessary to raise the pressure delivered by the regulator. The pressure should not exceed 90-110 PSI (6,2-7,7 kg/cm2). After the pressure has been set, install the regulator.


PRESSURE REGULATING VALVE
1-Adjusting screw. 2-Regulator inlet. 3-Regulator outlet.

Air Starting Motor Rotor Assembly End Clearance Adjustment


ROTOR ASSEMBLY END CLEARANCE ADJUSTMENT
1-Bearing. 2-End plate. 3-Shims. 4-Rotor.

Place shims (3) between the ball bearing (1) and spacer or shoulder so there will be clearance between the rotor (4) and the end plate (2). Tighten the nut and check the adjustment. Measure clearance between rotor and end plate assembly by using a thickness gauge. Rotor clearance should be .003 in. (0,08 mm) on 3H3171 and 3H3170 motors at end opposite the gear.


CHECKING ROTOR SHAFT END PLAY

If end plate to rotor clearance is not correct, the thickness gauge reading is used to determine how many shims (3) should be removed or added to obtain correct clearance.

Hydraulic Starting

Hydraulic starting system adapting hardware parts and main components are serviced. The service for main components is available from manufacturer of the components.

------ WARNING! ------

Do not attempt to disconnect lines or remove plugs in the system until the oil pressure in the system has been exhausted. Failure to heed this warning can result in the sudden release of oil under pressure as high as 1625 PSI (114,2 kg/cm2). Avoid any service work on the accumulator until information and tools are procured.

--------WARNING!------

Automatic Start-Stop System

Refer to REG00900 and REG00901 or REG00847 for testing and adjusting of the 2301 Electric Governor.

The engine mounted controls of the system can be tested and adjusted as indicated in the topic SAFETY DEVICES. To start the engine to make on engine test of engine mounted controls, place a "jumper" wire between 7A and 7B terminals in the transfer switch or use the switch located on the transfer switch panel. This actually simulates a commercial power failure and will in turn test the operation of the automatic start-stop control panel.

Governor Air Actuators

2N6006 Actuator

Air Pressure Adjustment

1. Remove linkage (1) between actuator and governor.


ACTUATOR LINKAGE
1-Linkage.

2. Start the engine. Let the engine run until it is warm.

3. Check high and low idle rpm with a tachometer. If necessary, make adjustments to the governor high and low idle screws to get correct rpm.

4. Stop the engine.

5. Install an air gauge (2) in the line between the actuator air control lever (3) and the actuator (4).


ACTUATOR AIR PRESSURE ADJUSTMENT
2-Air gauge. 3-Actuator air control lever. 4-Actuator. 5-Nut. 6-Plunger. 7-Screw.

6. Start the engine.

7. Check the air pressure to the actuator. Minimum air pressure at high idle must be 65 psi (4,6 kg/cm2). Maximum air pressure must not be more than 80 psi (5,6 kg/cm2).

8. Put the governor hand control lever in the low idle position.

9. Move the actuator air control lever (3) slowly to the high idle position. Look at the plunger (6). The plunger must start to move at 10 psi (0,7 kg/cm2) air pressure.

NOTE: If plunger (6) moves at less than 10 psi (0,7 kg/cm2) make the preload higher. If more than 10 psi (0,7 kg/cm2) air pressure is needed to move the plunger, make the preload lower.

10. Return the actuator air control lever (3) to the low idle position to change preload.

11. Turn screw (7) out until nut can be turned.

12. Turn nut (5) clockwise to make preload higher. Turn nut counterclockwise to make preload lower.

13. When plunger (6) moves at 10 psi (0,7 kg/cm2) air pressure, turn the screw in until nut can not be turned.

NOTE: If necessary, turn nut until screw is in line with next notch in nut.

14. Install linkage between actuator and governor.

Setting Low Idle Stop


ACTUATOR LINKAGE ADJUSTMENT
1-Linkage.

1. Start the engine. Let the engine run until it is warm.

2. Put the actuator air control lever in the low idle position.

3. Install a tachometer and check the low idle rpm.

4. If low idle rpm is not correct, remove linkage (1) between actuator and governor to make adjustment.

5. Make the linkage (1) shorter to decrease rpm. Make the linkage longer to increase rpm.

Setting High Idle Stop

1. Warm up engine.

2. Remove two setscrews (9) and turn the two high idle screws (8) out several turns.

3. Move the governor hand control lever to the high idle position.

4. Move the actuator air control lever (3) slowly to the high idle position.

5. Turn the high idle screws (8) in until they make contact with the plunger.

6. Install the two setscrews (9) to hold the high idle screws.

7. Return the actuator air control lever (3) to the low idle position.


HIGH IDLE ADJUSTMENT
3-Actuator air control lever. 6-Plunger. 8-High idle screws. 9-Setscrews.

8. Install a tachometer.

9. Make the governor high idle 30 rpm higher.

NOTE: Step 9 lets the actuator high idle stop control the engine rpm.

10. Return the governor hand control lever to the low idle position.

11. Move the actuator air control lever (3) to the high idle position.

12. Check the engine high idle rpm.

13. If necessary, make small adjustments to the actuator high idle screws (8) to get correct rpm.

NOTE: Turn actuator high idle screws (8) the same amount. The plunger must contact both high idle screws at the same time.

1N9318 And 7L135 Actuators

Air Pressure Adjustment


ADJUSTMENT OF ACTUATOR AIR PRESSURE
1-Air gauge. 2-Actuating air control lever. 3-Actuator. 4-Plunger. 5-Setscrew. 6-Screw. 7-Nut.

1. Start the engine. Let the engine run until it is warm.

2. Check high and low idle rpm with a tachometer. If necessary, make adjustments to the governor high and low idle screws to get correct rpm.

3. Stop the engine.

4. Install an air gauge (1) in the line between the actuator air control lever (2) and the actuator (3). See illustration.

5. Start the engine.

6. Check the air pressure to the actuator. Minimum air pressure at high idle must be 65 psi (4,6 kg/cm2). Maximum air pressure must not be more than 80 psi (5,6 kg/cm2).

7. Put the governor hand control lever in the low idle position.

8. Move the actuator air control lever (2) slowly to the high idle position. Look at the plunger (4). The plunger must start to move at 10 psi (0,7 kg/cm2) air pressure.

NOTE: If plunger (4) moves at less than 10 psi (0,7 kg/cm2), make the preload higher. If more than 10 psi (0,7 kg/cm2) air pressure is needed to move the plunger, make the preload lower.

9. Return the actuator air control lever (2) to the low idle position to change preload.

10. Remove setscrew (5) and turn screw (6) out until nut (7) can be turned.

11. Turn nut (7) clockwise to make the preload higher. Turn nut counterclockwise to make the preload lower.

Safety Devices

Safety shutoff controls are for the protection of the engine. To ensure they are working properly, the controls must be checked at least twice a year.

Contactor Switch (Water Temperature)

Fabricated heat sink,2F7112 Thermometer,3J5389 Plug.

1. Fabricate a heat sink as illustrated. Material can be brass, steel or cast iron. Drill a 23/32" hole through the heat sink and tap for 1/2" NPT.


HEAT SINK FOR TESTING [Dimensions in inches (mm)]

2. Mark wiring connections to contactor terminals and disconnect wiring. C and NO terminals are normally used.


TESTING CONTACTOR
1-2F7112 Thermometer. 2-Fabricated heat sink.

3. Remove the contactor and plug the opening with 3J5389 Plug. Install the contactor in the heat sink.

4. Reconnect the contactor to the wiring to check the entire system; contactor, wiring and shutoff solenoid.

NOTE: If this cannot be done, use an ohmmeter or continuity tester across the contactor terminals to check the setting.

5. If the contactor is reconnected, start the engine and run it at low idle. The fuel pressure switch will complete the circuit to the shutoff solenoid.

6. Immerse heat sink and sensing element in water. Heat the water, and, by using an accurate thermometer, note the temperature at which engine shuts down (or continuity is indicated). For the standard sea level contactor the temperature should be 209 ± 1° F (98 ± 1° C). Allow water to cool. The contactor will reset automatically when the temperature lowers approximately 12° F (8° C) from the shutdown temperature.

7. Install new contactor if necessary.

NOTE: To test the system beyond the contactor, a jumper can be touched between the C and NO contactor terminals to simulate contactor operation.

Alternate Method of Checking Water Temperature Contactors

1. Disconnect the wires from the contactor.

2. Connect ohmmeter or continuity tester across the contactors.

3. Start the engine and cause it to overheat by reducing coolant flow or air flow through radiator. Do not exceed the maximum temperature by more than 3°.


NOTICE

If the engine cannot be overheated safely, the temperature contactor will have to be checked off the engine.


4. Observe ohmmeter or continuity tester to see when the contactor shows continuity. The temperature at which this occurs should be 209 ± 1° F (98 ± 1° C) for the standard sea level contactor.

5. Allow engine to cool and then stop engine.

6. Install new contactor if required and connect wires to water temperature contactor.

Overspeed Contactor Switch

4S6553 Instrument Group.


NOTICE

Only competent personnel should attempt to alter the high idle RPM. The low and high idle RPM for the engine are listed in the RACK SETTING INFORMATION.



NOTICE

Disconnect or immobilize all driven equipment which could be damaged by 18% overspeed. Disconnect the excitation circuit of an electric set to prevent damaging high voltage.


------ WARNING! ------

Have some type of emergency device (inlet air shutoff or CO2 fire extinguisher) readily available.

--------WARNING!------

1. Install an accurate tachometer on the engine.

2. Start engine and increase speed until the overspeed contactor trips and produces shutdown. Shutdown speed setting should be no more than 18% above full load speed. (15% American Bureau of Shipping). DO NOT exceed 18% of full load speed when making these tests.

NOTE: Use a bar to slowly move terminal shaft lever to increase fuel and override governor action to overspeed the engine and produce shutdown.

3. Place governor control in low idle position, reset the overspeed contactor by pressing reset button (6) and start engine.

4. Several overspeed shutdowns should be made to assure consistent readings.

5. Adjust contactor or install a new one. Adjust contactor trip speed by breaking standard seal, loosening cap lock screws (7), and turning cap clockwise to lower trip speed. Tighten cap lock screws.


OVERSPEED CONTACTOR SWITCH
6-Reset button. 7-Cap lock screws.

6. To test only the system beyond the overspeed switch, a jumper may be used between the C and NO terminals to cause shutdown.

7. Set the governor high idle setting and seal the governor and overspeed contactor.

Contactor Switch (Oil Pressure)

8M2743 Gauge,3B6483 Cap,two 3B9389 Shut-off-cocks,three 3B7263 Pipe Nipples,three 1F9369 Tees,two 3B7733 Nipples,8S4627 Continuity Tester, and hoses with fittings for adapting as illustrated.


TESTING CONTACTOR SWITCH (OIL PRESSURE)
1-8M2743 Gauge. 2-3B7263 Nipples. 3-3B6483 Cap. 4-Oil supply line. 5-3B9389 Shut-off-cock (oil dump line). 6-3B9389 Shut-off-cock (supply line). 7-Oil dump line hose. 8-1F9369 Tee. 9-3B7733 Nipple. 10-Oil pressure contactor.

Testing

1. Disconnect oil supply line to contactor and install pressure gauge as shown.

2. With both shut-off cocks closed, start the engine and run at low idle.

3. Open supply shut-off cock (6) slowly and note pressure at which the switch contacts activate.

NOTE: Connect ohmmeter or continuity tester if desired. Pressures shown in the chart.

4. Close shutoff cock (6) and slowly lower pressure by use of shutoff cock (5) until the switch contacts activate.

5. To test only the system beyond the contactor:

a. On contactors with control knob or button, move the knob or button to activate the switch.

b. On all other type oil pressure contactors, use a jumper wire between the C or R and NC or B terminals. This simulates contactor operation.

Adjusting Earlier Type

1. Adjust or replace contactor if necessary. To adjust, decrease tension on main spring (12) by turning adjusting screw (11) counterclockwise. Open and close shutoff cocks until pressure on gauge indicates desired closing pressure. Turn knob to RUN position, if so equipped; then turn adjusting screw (11) clockwise just to point where contacts close.


OIL PRESSURE CONTACTOR
11-Adjusting screw. 12-Main spring.

2. Repeat Testing Step 4. Engine should shut down or alarm sound at closing pressure setting.


WIRING CONNECTIONS (Earlier Type)
A-White tab connect automatic start-stop TS1-1 (starter magnetic switch). B-Red tab connect battery or TS1-7. C-Blue tab connect rack solenoid or TS1-8.

Adjusting Micro Switch Type

1. Adjust or replace contactor if necessary. To adjust, loosen lock nut (16), increase or decrease tension on spring (15) by turning adjusting screw (14). Open and close shutoff cocks until pressure on gauge indicates desired pressure for contact action.


OIL PRESSURE CONTACTOR ADJUSTMENT
13-Set-for-start button. 14-Adjustment screw. 15-Spring. 16-Lock nut. 17-Contact button.

2. Adjust spring tension so switch contact button (17) acts at the desired pressure shown in the chart.

When equipped with a set-for-start button, (13) the button will be released at the rising pressure shown in the chart.


WIRING CONNECTIONS (Micro Switch Type)
D-Terminal B (normally closed) connect rack solenoid or TS1-8. E-Terminal W (normally open), connect automatic start-stop TS1-1 (starter magnetic switch). F-Terminal R (common), connect battery or TS1-7.

Rack Shut-Off Solenoid

The governor plunger shaft initial adjustment of distance from shaft shoulder-to-plate should be .70 in. (17,8 mm).

Effective travel can be measured with rack setting gauges to be sure rack is moved to shutoff position. Make an on engine check with a 30 amp. ammeter to be sure only the hold in windings are energized when the rack is held by the solenoid in shut off position. Current draw should be less than 2 amp.


PLUNGER SHAFT ADJUSTMENT
1-Shoulder-to-plate distance .70 in. (17,8 mm). 2-Effective travel .62 in. (15,7 mm). 3-Starting position of plunger plate from mounting flange is .44 in. (11,2 mm) to measure effective travel of plunger.

Shut-Off Valve (Water Temperature)

3J5389 Plug8B4509 Connector3B9388 Connector9M6543 Hose Assembly4D6949 Hose Assembly3B7764 Reducing Bushing Heat Sink


SHUT-OFF VALVE (WATER TEMPERATURE)

NOTE: See the topic Contactor Switch (Water Temperature) in TESTING AND ADJUSTING for instructions to make a heat sink.

1. Remove oil lines.

2. Remove shut-off valve and install the 3J5389 Plug.

3. Install the oil lines using the bushing, hoses and connectors.

4. Start the engine and let it run at low idle.

5. Put the heat sink and the shut-off valve in water. Use a torch to make the water hot and, by using a thermometer, take note of the temperature at which the engine stops.

6. Install a new valve if necessary.

NOTE: If engine does not stop, look for a defect in the contactor switch for oil pressure.

Enclosed Clutches

Clutch Adjustment

The clutch engagement lever pull adjustment establishes the clutch plate pressure. The proper clutch lever pull is indicated in the chart.

The clutches use two types of adjustment lock pins. Pin (1) should be pushed in and the adjusting ring rotated. Pin (2) should be pulled out and the ring rotated to adjust the clutch.


CLUTCH ADJUSTMENT
1-Lock pin (push in type to unlock). 2-Lock pin (pull out type to unlock).

Assembly Adjustments

Tighten hub nut to torque of 30 lb. ft. (4,1 mkg) to remove all clearance between parts, then tighten additional amount as shown in chart.

Clutch Shaft Seal Wear Sleeve Installation

Clutches which have oil lubricated shaft bearings are equipped with oil seal wear sleeves (2) on the shaft. Install wear sleeves with guide assembly (1) (part of 1P2410 Wear Sleeve Installation Tool Group). Be sure the sleeve contours blend in with the shoulder fillets (3) on the shaft.


WEAR SLEEVE INSTALLATION
1-Guide assembly. 2-Wear sleeve. 3-Shaft shoulder fillets.

Shaft Bearing End Clearance

Tighten adjusting nut to remove all clearance and seat bearing cups. At this point shaft should turn with dry bearing at torque of 60 lb. in. (70,0 cm.kg) in addition to seal drag. Then back off the adjusting nut the number of notches indicated in the charts and install the lock. Drive the front bearing cup to the front by striking the output end of the shaft with a soft hammer. The end clearance should now be as indicated in the chart.

Where shim adjustment is used, tighten the retainer without shims until shaft turns with dry bearings at torque of 60 lb. in. (70,0 cm.kg) in addition to seal drag. Measure the space between the retainer and carrier and add .013 in. (0,33 mm) to this measurement. Remove the retainer, then install shims and retainer and cap screws with locks. Drive the front bearing cup to the front by striking the output end of the shaft with a soft hammer. The end play should now be .006-.010 in.(0,15-0,25 mm).

Clutch and Mounting Adjustment Check

At time of installation, check the flywheel and flywheel housing face and bore run out.

Caterpillar Information System:

D399, G399, D398, G398, D379, G379 ENGINES Engine Attachments Systems Operation
D399, G399, D398, G398, D379, G379 ENGINES Flywheel And Flywheel Housing
D399, G399, D398, G398, D379, G379 ENGINES Balancer - (D379 Only)
D399, G399, D398, G398, D379, G379 ENGINES Basic Block Components
D399, G399, D398, G398, D379, G379 ENGINES Front Accessory Drive
D399, G399, D398, G398, D379, G379 ENGINES Timing Gears
D399, G399, D398, G398, D379, G379 ENGINES Vibration Damper
D399, G399, D398, G398, D379, G379 ENGINES Valves And Valve Mechanism
D399, G399, D398, G398, D379, G379 ENGINES Cylinder Heads (Diesel Engines)
D399, G399, D398, G398, D379, G379 ENGINES Cylinder Heads - (Natural Gas Engines)
D399, G399, D398, G398, D379, G379 ENGINES Turbocharger
D399, G399, D398, G398, D379, G379 ENGINES Turbocharger
D399, G399, D398, G398, D379, G379 ENGINES 2N6006 Governor Air Actuator
D399, G399, D398, G398, D379, G379 ENGINES 1N9318 & 7L135 Governor Air Actuators
D399, G399, D398, G398, D379, G379 ENGINES 2N6961 Clutch Assembly
D399, G399, D398, G398, D379, G379 ENGINES Flexible Coupling
D399, G399, D398, G398, D379, G379 ENGINES Air Starting Motor
D399, G399, D398, G398, D379, G379 ENGINES Governor<BR> (Woodward EG-3P) D379 68B1616-Up, D398 66B2049-Up, D399 35B1-Up
D399, G399, D398, G398, D379, G379 ENGINES Governor<BR> (Woodward UG-8) D379 68B1616-Up, D398 66B2049-Up, D399 35B1-Up
D399, G399, D398, G398, D379, G379 ENGINES Governor<BR> (Woodward UG-8) G379 72B264-403, G398 73B511-795, G399 49C1-172
D399, G399, D398, G398, D379, G379 ENGINES Governor<BR> (Woodward EG-3P) G379 72B264-403, G398 73B511-795
D399, G399, D398, G398, D379, G379 ENGINES Governor<BR> (Woodward UG-8 And EG-3P) G379 72B404-UP, G398 73B796-UP, G399 49C173-UP
D399, G399, D398, G398, D379, G379 ENGINES Governor<BR> (Woodward SGT) D379 68B1616-UP
D399, G399, D398, G398, D379, G379 ENGINES Governor Drive Upper Housing<BR> (Woodward Governor)
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