5.4" BORE INDUSTRIAL & MARINE ENGINE ATTACHMENTS Caterpillar


Testing And Adjusting

Usage:



Problem Solving

1. Water Temperature Contacor Switch Fails to Signal Shutoff.
2. Water Temperature Contactor Switch 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 and PSG Governor.
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. Output Shaft Load Causes Engine Speed To Drop Rapidly.
15. Output Shaft Governor Surges Under a Load.
16. Output Shaft Governor Surges Under No Load.
17. Output Shaft Unloading Causes Engine Speed To Increase Excessively.

Woodward PSG Governor - (D343 and G343 Engines)

Adjustments

D343 Engines


NOTICE

Only competent personnel should attempt to adjust fuel rack settings and the governor. The low and high idle rpm, and rack setting dimensions are listed in the RACK SETTING INFORMATION.


Fuel Rack Setting

Follow the procedure given in the standard engine information to check fuel rack setting, however, since this arrangement with PSG governor requires no torque spring, the continuity tester operation should be disregarded. The rack travel is limited by a stop bolt in the governor adapter housing.

High Idle Stop Adjustment

Remove the rack shut off solenoid, slide the bolt (4) out of the slot in the collar (5) and lift out the solenoid plunger. Remove the rod which connects the terminal shaft lever with the rack control shaft external lever (7) to relieve tension on spring (8).

Push control pin collar (5) to contact high idle stop bolt (3). This rack setting measurement is given in the RACK SETTING INFORMATION.


PSG GOVERNOR ADJUSTMENTS
1. Fuel rack. 2. Rack shut-off solenoid plunger stop bolt. 3. High idle stop bolt. 4. Rack shut-off solenoid adjusting bolt. 5. Rack control pin collar. 6. Rack control lever. 7. Rack control shaft external lever. 8. Governor spring. 9. Terminal shaft lever.

Before installing the rack shut off solenoid, check adjustment of the shut off plunger stop bolt (2). There should be 1.75 in. (44,45 mm) from the head of the bolt to the adapter housing mounting face for the solenoid.

Be sure to fit the adjusting bolt (4) in the slot in the collar (5) and seal the shut off solenoid in place.

Governor Linkage Adjustment

1P2385 Protractor Tool.

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

First: Vertical housing face-to-lever angle.

Second: Horizontal or level-to-lever angle.

Third: 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.

D343 Engines

Assemble rod (4) between rack control shaft lever (1) and terminal lever (3) so that both levers maintain the angles shown [lever (3) 18° from vertical and lever (1) 14° from vertical] when engine is stopped and governor set at extreme shut off position.


PSG GOVERNOR LINKAGE ADJUSTMENT (Dimensions in inches (mm)]
1. Rack control shaft external lever. 2. Governor spring. 3. Terminal shaft lever. 4. Rod.

G343 Engines

1. With engine stopped, disconnect linkage rods (5) from levers (2 and 4). Disconnect spring (6).

2. With carburetor throttle plate in closed position and carburetor lever (3) at 15° from vertical, adjust the linkage rod from carburetor to cross shaft lever (2) so lever (2) is at 30° from horizontal.

3. Install cross shaft lever (1) at 90° from vertical.

4. Adjust the linkage rod from governor to cross shaft so governor lever (4) is at 50° from horizontal when governor terminal shaft is in off position and throttle closed.

5. Install spring.


LINKAGE ADJUSTMENT MEASUREMENTS [Dimensions in inches (mm)]
1. Cross shaft right lever. 2. Cross shaft left lever. 3. Carburetor lever. 4. Governor lever. 5. Linkage rods. 6. Spring.

Installation Adjustments

When the governor linkage adjustments are correct, the following adjustments should be made.

1. Position the speed adjusting shaft for desired running speed and allow the engine to warm up. Where the governor is equipped with a synchronizing motor, knurled knob (1) can be turned to adjust engine speed.

2. Open the compensating needle valve (3) two or three turns and allow the engine to hunt or surge for about one-half minute to bleed trapped air from the governor oil passages.


INSTALLATION ADJUSTMENTS
1. Knurled knob. 2. Lever.

3. Gradually close the needle valve until hunting just stops. Closing the needle valve farther than necessary will make the governor slow to return to normal speed after a load change.

4. Test action by manually reducing engine speed by turning lever (2) clockwise. Release the lever and engine should return promptly to original steady speed with only a small overshoot.


COMPENSATING NEEDLE VALVE
3. Location of needle valve.

Low and High Idle Adjustment

Before making this adjustment the installation adjustments should be made, and if done correctly, it will never require changing unless the governor is disturbed.

High idle (maximum speed) settings are made by adjustment of stop screw (2) in the governor body.

1. Install an accurate tachometer.

2. Loosen the locknut and screw (2).

3. With the engine running at full speed, turn high speed stop screw until the correct rpm is indicated on the tachometer.

4. Tighten the locknut.


LOW AND HIGH IDLE ADJUSTMENTS
1. Knurled knob. 2. Stop screw.

Low idle (minimum speed) is controlled by the synchronizing motor mounted on the governor cover.

The motor requires a source of electric power. If the source of power is from the engine on which the governor is mounted, the engine low idle speed should be that indicated in the RACK SETTING INFORMATION. When the engine speed is too low to supply electric power, the electric motor will not run. Turn knurled knob (1) to increase engine speed so the generator will supply power.

Speed Droop Adjustment

Adjustment is made on the inside of the governor after removing the cover on which the synchronizing motor is mounted.

NOTE: Zero droop position may be set by trial and error on the engine or by use of a dial indicator on the speed droop lever (3) during manual rotation of the terminal shaft (4).


SPEED DROOP ADJUSTMENT
1. Clamp screw. 2. Adjusting bracket. 3. Speed droop lever. 4. Terminal shaft.

1. Loosen clamp screw (1).

2. Move speed droop adjusting bracket (2) toward terminal shaft (4) for minimum droop.

NOTE: When speed droop is required, adjust position of bracket (2) and test by running engine. Readjust until the desired speed droop is obtained.

Pilot Valve Plunger Central Adjustment

1P87 Adjusting Wrench

Whenever the governor is disassembled the pilot valve plunger central position adjustment should be checked and adjusted if necessary.


PILOT VALVE PLUNGER CENTRAL ADJUSTMENT
1. Pipe plug opening. 2. Pilot valve control land. 3. Pilot valve bushing. A. Port opening above land. B. Port opening below land.

1. Using a small flashlight, observe the position of the pilot valve control land (2) with respect to the port in the pilot valve bushing (3), through the 1/16" pipe plug hole (1) in the straight side of the base.

2. Push pilot valve toward drive end as far as possible-this will move the flyweights (5) to inner position. Through the pipe plug hole, check the amount of port opening (A) above the edge of the pilot valve control land.

3. Holding the pilot valve against the flyweight toes, move the flyweights outward as far as they will go, and check the amount of port opening (B) now appearing below the edge of the pilot valve control land.

4. The amount of port opening with the flyweights at extreme inner and outer positions-should be equal within .010 in. (0,25 mm).


GOVERNOR CROSS SECTION
3. Pilot valve bushing. 4. Locknut. 5. Flyweight. 6. Spring seat.

5. If the pilot valve plunger is too low, hold the spring seat (6) with 1P87 Adjusting Wrench and turn the pilot valve counterclockwise to raise it. If the pilot valve plunger is too high, hold the spring seat and turn the pilot valve clockwise to lower it.


HOLDING SPRING SEAT WITH 1P87 ADJUSTING WRENCH TO MAKE ADJUSTMENT

6. When the pilot valve appears to be centered, tighten the locknut (4) on the spring seat, re-check the valve setting.

7. The 1/16" pipe plug can now be installed, using a 8H5137 Sealing Compound to prevent leakage of oil.

Woodward UG-8 Governor - (D346 and D348 Engines)

Adjustments


NOTICE

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


Governor Linkage Adjustment - D346 Engines 39J413-Up, D348 Engines 36J363-Up and D349 Engines 61P1-Up


GOVERNOR LINKAGE ADJUSTMENT D346 (39J413-Up), D348 (36J363-Up) and D349 (61P1-Up) Engines
1. Terminal lever is 2.25 in. (57,15 mm) long. 2. Terminal lever to horizontal is 30°. 3. Lower lever is 3.5 in. (88,9 mm) long. 4. Rod. 5. Lower lever to horizontal angle is 30°. Arrow indicates off direction.

1. With rack at shut off position and key in shaft put lower lever (3) on shaft. This should result in angle of 30° as shown at (5).

2. Put terminal shaft in shut off position.

3. Put terminal shaft lever (1) on terminal shaft at angle of 30° from horizontal as shown at (2).

4. Make rod (4) correct length so angles of levers are not changed.

Governor Linkage Adjustment-D346 Engines 39J1-39J412 and D348 Engines 36J1-36J362.

1P2385 Protractor Tool

With governor shaft at shutoff position, assemble terminal shaft lever (1) to the shaft at angle from vertical as shown. Adjust link (2) so the rack indicator reading from center position (zero position) is minus .077 ± .005 in. (2,0 ± 0,1 mm). Tool arrangement for establishing center position (zero position) is the same as for standard hydra-mechanical governor. See the topic Rack Setting in the BASIC ENGINE portion of this manual.

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

First: Vertical housing face-to-lever angle.

Second: Horizontal or level-to-lever angle.

Third: 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.

Install shims (4) under stop plate to obtain .020 in. (0,51 mm) clearance between the rack lever stop bolt (5) and stop plate with the governor lever in stop position.


GOVERNOR LINKAGE ADJUSTMENT D346 (39J1-39J412), D348 (36J1-36J362) Engines [Dimensions in inches (mm)]
1. Terminal shaft lever. 2. Adjustable link. 2. Roll pin. 4. Shims. 5. Rack lever stop bolt.

Pin the adjustable link (2) to the rod end with pin (3).

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.

3. 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.

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

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

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


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.

7. 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.

8. 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.

9. 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.

NOTE: The synchronizer indicator pointer disc may be rest, 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.

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

Setting Fuel Rack Limit Stop

9S240 Rack Positioning Tool Group2P2977 Tool Group (Later Type)

1. Install a dial indicator and use the rack centering timing pin to zero the indicator as described for the standard engine Hydra-mechanical governor. See the FUEL SYSTEM (Rack Adjustment) information covered in the BASIC ENGINE portion of this manual.


FUEL RACK TRAVEL ADJUSTMENT (Later Type)
1. Stop screw. 2. Screw locknut.


FUEL RACK TRAVEL ADJUSTMENT (Earlier Type)
1. Stop screw. 2. Locknut. 3. Lock.

2. 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 (1), 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.


3. If the full rack travel is not the value listed in the RACK SETTING INFORMATION loosen the adjusting screw locknut (2). Earlier type governors require that the lock (3) be raised so the adjusting screw can be turned freely.

4. 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 and tighten the locknut.

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 11/2minutes 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.

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.


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

Woodward EG-3P Governor Actuator

Adjustments

Setting Fuel Rack Limit Stop

9S240 Rack Positioning Tool Group2P2977 Tool Group (Later Type)

1. Install a dial indicator and use the rack centering timing pin to zero the indicator as described for the standard engine Hydra-mechanical governor. See the FUEL SYSTEM (RACK ADJUSTMENT) information covered in the BASIC ENGINE portion of this manual.


FUEL RACK TRAVEL ADJUSTMENT (Later Type)
1. Stop screw. 2. Locknut


FUEL RACK TRAVEL ADJUSTMENT (Earlier Type)
1. Stop screw. 2. Locknut. 3. Lock.

2. Using the lever on the governor terminal shaft, move the fuel rack from the FUEL OFF position towrad the FUEL ON position until contact is made with adjusting stop screw (1), and read the rack setting gauge. Compare the rack travel value with that listed in the RACK SETTING INFORMATION.

3. If the fuel rack travel is not the value listed in the RACK SETTING INFORMATION, loosen the adjusting screw locknut (2). Earlier type governor requires the lock (3) be raised so the adjusting screw can be turned freely.

4. 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 and tighten the locknut.

Linkage Adjustments (D346 and D348 Engines)

1P2385 Protractor Tool

1. Place governor terminal shaft at shut off position.

2. Install terminal shaft lever (1) at angle shown from horizontal.

3. Adjust link (2) so rack lever assembly (3) makes the angle shown from horizontal.

NOTE: The angle will position the fuel rack in the shut off (zero) position. Tool arrangement for checking second tooth centerline position (zero position) is the same as for standard hydra-mechanical governor.

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

First: Vertical housing face-to-lever angle.

Second: Horizontal or level-to-lever angle.

Third: 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.


EG-3P ACTUATOR LINKAGE ADJUSTMENT [Dimensions in inches (mm)]
1. Terminal shaft lever. 2. Adjustment link. 3. Rack lever assembly.

Linkage Adjustment (G343 Engine)

1P2385 Protractor Tool

1. Rotate terminal shaft to shut off position and attach lever (4) at angles shown from horizontal.


EG-3P GOVERNOR ACTUATOR LINKAGE ADJUSTMENT [Dimensions in inches (mm)]
1. Cross shaft right lever. 2. Carburetor throttle shaft lever. 3. Linkage rods. 4. Terminal shaft lever.

NOTE: 1P2385 Protractor Tool usage is illustrated earlier in this topic.

2. Turn carburetor throttle plate shaft to shut off position and attach lever (2) at the angle shown from vertical.

3. Check the angle between cross shaft left lever and right (1). When the left lever is horizontal, the right lever should be at the angle shown.

4. Adjust length of linkage rods (3) so the angles are maintained with terminal shaft and throttle plate in shut off positions.

Linkage Adjustment (G348 Engine)

1P2385 Protractor Tool

1. Turn terminal shaft to shut off position and install lever (2) at angle of 45° as shown.

NOTE: 1P2385 Protractor Tool usage is illustrated earlier in this topic.

2. Turn carburetor throttle plate to shut off position and install lever (1) at the angle of 15° from vertical as shown.

3. Make rods (3) correct length so the angles are not changed with terminal shaft and throttle plates in shut off positions.


EG-3P ACTUATOR LINKAGE ADJUSTMENT G348 ENGINE
1. Carburetor lever is 1.75 in. (44,45 mm) long. 2. Terminal lever is 3.25 in. (82,55 mm) long. 3. Rods. Arrows indicate off direction.

Linkage Adjustment (D349 Engine)

1P2385 Protractor Tool

1. Turn terminal shaft to shut off position and install terminal shaft lever (1) at an angle of 30° from horizontal.

NOTE: 1P2385 Protractor Tool usage is illustrated earlier in this topic.

2. Move the rack to shut off position. Install the key in shaft and the lower lever (3). This should result in lever angle of 30° from horizontal.


EP-3P ACTUATOR LINKAGE ADJUSTMENT (D349 Engine)
1. Terminal shaft lever is 2.25 in. (57,15 mm) long. 2. Rod. 3. Lower lever is 3.5 in. (88,9 mm) long. Arrows indicate off direction.

3. Make the rod (2) the correct length so the angles are not changed when terminal shaft lower levers are in shut off position.

Output Shaft Governor - (D343 Engines)

Testing And Adjusting

9S8521 Rod9S8518 Plug8S4627 Circuit Tester

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.

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 be 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. Rocker shaft lever. 8. Low speed adjusting screw. 9. High speed adjusting screw. 10. Bracket.

1. Disconnect the adjustable rod (3) from the terminal lever (1) and the other adjustable linkage (15) between the servo mechanism 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 paralled to rocker shaft lever (7).

NOTE: A remote control may be attached to the lower portion of speed change lever (4). If so connect it.

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 rod (3) between terminal lever (1) and servo boost mechanism so that it moves .08 in. (2,03 mm) before lever (16) starts to move. Install rod (3).

5. Retract the speed limiter with a 9S8521 Rod End and 9S8518 Plug. Move the governor control to full speed position. See the topic FUEL SYSTEM in the Basic Engine part of this manual.

6. Rotate shutoff shaft (14) until shutoff lever (13) contacts the rack stop collar (12). This can be determined by use of circuit tester connected to the insulated terminal (11).


GOVERNOR LINKAGE ADJUSTMENT
11. Insulated terminal. 12. Stop collar. 13. Shutoff lever. 14. Shutoff shaft. 15. Linkage. 16. Lever.

7. Adjust the linkage (15) 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 low speed with the aid of the 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 (8) 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.


GOVERNOR LINKAGE ADJUSTMENT
1. Terminal lever is installed on rocker shaft at angle of 90° from horizontal. 3. Adjustable rod. 15. Adjustable linkage. 16. Servo actuator output shaft lever is installed at 30° from vertical. 17. Servo actuating lever is installed at 30° from vertical as shown.


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 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.

14. Adjustment of the low speed adjustment screw (8) should be made to return the setting to the desired low speed adjustment.

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

First: Vertical housing face-to-lever angle.

Second: Horizontal or lever-to-lever angle.

Third: 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 Air Actuator

Adjustment of 2N6006 Actuator Air Pressure

1. Remove linkage (1) from governor control cross shaft lever.

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).

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 moe 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.


ACTUATOR LINKAGE
1. Linkage.


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

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/cm) 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 (1) to governor control cross shaft lever.

Setting Low Idle Stop

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

2. Put the actuator air control lever (2) 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 between actuator and governor to make adjustment.

5. Make the linkage (1) approximately 4.8 in. (121,92 mm) long, shorter to decrease rpm. Make the linkage longer to increase rpm.

Setting High Idle Stop

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

2. Remove two setscrews (5) and turn the two high idle screws (4) out several turns.

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

4. Move the actuator air control lever (2) slowly to the high idle position.


ACTUATOR LINKAGE ADJUSTMENT
1. Linkage.

5. Turn the high idle screws (4) in until they make contact with the plunger (3).

6. Install the two setscrews (5) to hold the high idle screws.

7. Return the actuator air control lever (2) to the low idle position.


HIGH IDLE ADJUSTMENT
2. Actuator air control lever. 3. Plunger. 4. High idle screws. 5. 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.


GOVERNOR LINKAGE
6. Rod should be 16.58 in. (421,13 mm). 7. Angle of governor lever to horizontal should be 15 ± 5°.

11. Move the actuator air control lever (2) to the high idle position.

12. Check the engine high idle rpm.

13. If necessary, make small adjustments to the actuator high idle screws (4) to get correct rpm.

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

14. Check linkage between governor and cross shaft. The length of rod (6) and angle (7) of governor lever should be as shown.

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.

Water Temperature Contactor Switch

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.

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.


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

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 whould 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 this 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: It will be necessary to break the standard governor seal and back out the high idle adjusting screw (2) to produce shutdown.


STANDARD GOVERNOR ADJUSTING SCREWS
1. Low idle adjusting screw. 2. High idle adjusting screw. 3. Cover. 4. Retaining holes.

On engines with Woodward PSG Governors, use a bar to slowly move terminal shaft lever (5) to increase fuel and override governor action to overspeed the engine and produce shutdown.


WOODWARD PSG GOVERNOR (D343 Engine Illustrated)
5. Terminal shaft lever.

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.

Rack Shut-Off Solenoid

Two types of solenoids are covered. There is no adjustment for the earlier solenoid used with Woodward PSG Governors.


1. Shoulder-to-plate distance .70 in. (17,8 mm) hydra-mechanical governor, 1.10 in. (27,9 mm) Woodward PSG Governor. 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.

The hydra-mechanical governor plunger shaft initial adjustment of distance from shaft shoulder-to-plate should be .70 in. (17,8 mm). For Woodward PSG Governor the shaft shoulder-to-plate initial adjustment distance should be 1.10 in. (27,9 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.

Oil Pressure Contactor Switch

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

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.


TESTING OIL PRESSURE CONTACTOR SWITCH
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.

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 locknut (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.

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.


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


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.

Shut-Off Valve (Water Temperature)

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

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.


SHUT-OFF VALVE (WATER TEMPERATURE)

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.

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

6. Install a new valve if necessary.

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 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 and Mounting Adjustment Check

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

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 to .010 in. (0,15 to 0,25 mm).

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 to 110 psi (6,2 to 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

Place shims (5) between the ball bearing (4) and spacer or shoulder (2) so there will be clearance between the rotor (1) and the end plate (3). On 7L8424 Motor clearance should be .002 in. (0,05 mm) and on 3H3171 or 7L8174 Motor .003 in. (0,08 mm) at end opposite the gear.

Heating the gear will aid installation of 7L8424 Motor. Tighten the nut and check the adjustment. Measure clearance between rotor and end plate assembly by using a thickness gauge.


ROTOR ASSEMBLY END CLEARANCE ADJUSTMENT (7L8424 Illustrated)
1. Rotor. 2. Spacer. 3. End Plate. 4. Bearing. 5. Shims.


CHECKING ROTOR SHAFT-TO-PLATE CLEARANCE

If end plate to rotor clearance is not correct, the thickness gauge reading is used to determine how many shims (5) should be removed or added to obtain correct clearance. Upon assembly fill gear compartment with lubricant.

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

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.

If the transfer switch, control panel, 2301 Electric Governor or the EG-3P Actuator are suspected of faulty operation, see the topic 2301 ELECTRIC GOVERNING SYSTEM APPLICATION and Instruction Form REG00847 for further information on testing and adjusting.

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