Testing And Adjusting

Usage:

Introduction

NOTE: For Specifications with illustrations, make reference to ATTACHMENT SPECIFICATIONS FOR 5.75" BORE, SIX CYLINDER ENGINES, Form No. REG01529. If the Specifications in Form No. REG01529 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

Troubleshooting

Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make a repair to a problem, make reference to the cause and correction.

This list of problems, causes, and corrections, will only give an indication of where a possible problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations in the list. Remember that a problem is not normally caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.

1. Contactor Switch for Water Temperature Fails to Activate a Shutoff.

2. Contactor Switch for Water Temperature Activates Shutoff at Wrong Temperature.

3. Contactor Switch for Oil Pressure Fails to Activate a Shutoff.

4. Contactor Switch for Overspeed Fails to Activate Shutoff.

5. Contactor Switch for Overspeed Activates Shutoff and Wrong Speed.

6. Rack Shutoff Solenoid Fails to Stop Engine.

7. Rack Shutoff Solenoid Prevents Engine Start.

8. No Stability in Woodward Governor Operation.

9. Clutch Will Not Engage (Slips), Heats or Lever Moves to Released Position.

10. Clutch Shaft Has Too Much End Play.

11. Hydraulic Starting Motor Fails to Turn or Turns Slowly.

12. Safety Control Shutoff Fails To Stop Engine Because Of Low Oil Pressure.

13. Safety Control Shutoff Will Not Let Engine Start.

14. Safety Control Shutoff Stops Engine at Wrong Speed.

15. Electrical Gauges Give Wrong Readings.

Woodward UG-8 Governor

Adjustments

Show/hide table

NOTICE

Fuel rack setting is done carefully at the factory. Do not change the fuel rack setting unless it is known to be wrong. A wrong setting of the fuel rack can cause a problem with the turbocharger. Make reference to the book RACK SETTING INFORMATION for the correct rack setting.

Governor Linkage Adjustment

1. Put lever (1), for the terminal shaft of the governor, on the shaft in the position shown. There must be .16 in. (4.06 mm) clearance between lever (1) and housing. The terminal shaft must be in the fuel closed position.

Three basic uses of the 1P2385 Protractor tools are shown here.

1P2385 PROTRACTOR TOOL USE
A. Indicator used for angle setting. B. Protractor plate edge in alignment with lever. C. Vertical housing face and extension arm are in alignment. D. Bubble in level. E. Indicator used for angle setting. F. Extension arm in alignment with lever. G. Extension arm in alignment with lever. H. Plate edge in alignment with second lever. I. Indicator used for angle setting. J. Angle between lever and vertical face of housing. K. Angle between level and lever. L. Angle between levers.

2. Put lever (3) on the shaft.

3. Make an adjustment to the length of rod (2) so that it can be installed when levers (1 and 3) are in the off position as shown.

WOODWARD GOVERNOR LINKAGE
1. Lever. 2. Rod. 3. Lever. A. 2.188 in. (55.58 mm) length of lever (1). B. Fuel off direction of rotation. C. 2.375 in. (60.33 mm) length of lever (3).

WOODWARD GOVERNOR LINKAGE INSTALLED
1. Lever. 2. Rod. 3. Lever.

Low Or High Idle Speed Adjustment

Check the engine LOW or HIGH IDLE rpm at the connection for tachometer drive. Make this check with a hand tachometer. The rotation of the tachometer drive is one half of engine rpm.

GOVERNOR ADJUSTMENTS (With Dial Plate Removed)
1. Lever. 2. Idler gear. 3. Load limit knob. 4. Rod. 5. Synchronizer knob. 6. Gear. 7. Synchronizer indicator knob.

1. Put the load limit knob (3) at point 5 to keep the engine from getting too much fuel and having a rapid increase in speed.

Show/hide table

NOTICE

To have a method of stopping the engine if it runs too fast, do the following:

a. Disconnect the linkage (8) for the overspeed control at lever (9).

PLACE TO DISCONNECT LINKAGE
8. Linkage. 9. Lever.

b. Have your hand on lever (9) and be ready to move the lever to the STOP position.

LEVER IN RUN POSITION
9. Lever.

c. If the engine speed goes too high, move lever (9) to the STOP position.

2. Start the engine and slowly make an increase to the amount of fuel. When the engine is at the operating temperature, slowly turn the load limit knob (3) from 5 to 10. Use the synchronizer knob (5) to make an adjustment to the engine speed; then, check the low or high idle stop.

LEVER IN STOP POSITION
9. Lever.

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

4. Loosen the set screw on synchronizer indicator knob (7) and remove the knob.

5. Pull gear (6) out so it is not engaged with gear (2).

6. When making an adjustment of the high idle speed, turn synchronizer knob (5) clockwise until the engine is at the correct high idle speed. Turn the knob counterclockwise when making the adjustment of the low idle speed.

7. To make an adjustment of the stop for the high idle speed, turn gear (6) clockwise (counterclockwise for low idle speed) until the pin in the gear is in contact with idler gear (2). Engage the gears.

8. After the adjustment to the idle speed has been made, turn the synchronizer knob to change the speed of the engine. Then turn it to the stop position and check the idle speed. If necessary, make the adjustment again.

NOTE: If necessary, make an adjustment to the synchronizer indicator pointer disc. With the engine running at high idle, stop the engine by turning load limit knob (3) to zero. Remove the synchronizer indicator pointer disc and again install it so the pointer on the disc will point to 12 on the dial plate. This will give high idle stop position.

9. Install synchronizer indicator knob (7) and the dial plate.

Fuel Rack Setting

Use the same tools and procedure to make an adjustment of the fuel rack as shown for the mechanical governor, make reference to FUEL RACK SETTING.

Compensating Adjustment

The governor can show signs of operating correctly at no load, but have high over speeds and under speeds and be slow to return to normal speed after load changes. These conditions are the result of wrong compensation adjustments.

Make the following adjustments to be sure the governor will give the desired control.

After the engine and the oil in the governor are at the normal operating temperature, make the adjustments with no load on the engine.

1. Loosen nut (1) and put compensating adjustment pointer (2) at MAX.

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

3. Permit the engine to run rough for approximately 11/2 minutes to remove the air from the oil passages in the governor. Turn the compensating needle valve in until the rough running stops. The needle valve must be approximately 1/8 of a turn open.

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

4. Lower compensating adjustment pointer (2) to two points above MIN.

5. Move the governor terminal shaft manually to make an increase in engine rpm, then let go of the lever and permit the operation of the governor to return to a stability condition. If it takes too long for the operation of the governor to return to a stability condition, move the pointer toward MAX two more points. Make this adjustment until the operation of the governor has the desired stability.

Woodward PSG Governor

Governor Adjustments

Governor Linkage Adjustments

1. Turn carburetor control shaft (3) to the fuel closed position. Put lever (1) on shaft at 20° from vertical.

2. Turn governor control shaft (5) to the low idle position and install lever 25° from horizontal.

3. Make an adjustment to rod (2) so it can be installed on lever (1) in the hole 1.0 in. (25.4 mm) from the center of shaft (3), and on lever (4) so it can be installed in the hole 5.0 in. (127.0 mm) from the center of shaft (5).

ADJUSTMENT OF LINKAGE TO THE CARBURETOR
1. Lever on carburetor control shaft. 2. Rod. 3. Carburetor control shaft. 4. Governor control lever. 5. Governor control shaft.

Installation Adjustments

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

1. Put the speed adjusting shaft at a position for the desired running speed and let the engine get to operating temperature. When there is a synchronizing motor on the governor turn the knurled knob (1) to make an adjustment to the engine speed.

2. Open the compensating needle valve (3) two or three turns and permit the engine to run for about one half minute to let air out from the governor oil passages.

INSTALLATION ADJUSTMENTS
1. Knurled knob. 2. Stop screw.

COMPENSATING NEEDLE VALVE
3. Needle valve.

NOTE: The air in the oil passages will cause the engine to run at speeds that are not regular (surge).

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

4. Test the action by moving the carburetor throttle manually to keep the governor control from causing movement of the linkage. Release the throttle and the engine should return to the original speed with only a short increase in speed.

Low and High Idle Adjustment

Before making this adjustment the installation adjustment must be made. See the subject, Installation Adjustment. If done correctly the high and low idle adjustment will not need changing unless the governor adjustment is moved.

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

1. Install a tachometer with good accuracy.

2. Loosen the locknut and screw (2).

3. With the engine running at full speed, turn the high speed stop screw until the correct rpm is read 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 installed on the governor cover. The motor needs a source of electric power. If the source of power is from the engine on which the governor is installed, the engine low idle speed must be that in the book RACK SETTING INFORMATION. When the engine speed is too slow to give a supply of electric power, the electric motor will not run. Turn the knurled knob (1) to cause an increase in engine speed so the generator will give a supply of power.

Speed Droop Adjustment

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

1. Loosen clamp screw (1).

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

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

NOTE: The setting of the zero droop position may be made by making an adjustment, checking the setting, and correcting the error (trial and error). It can also be made by using a dial indicator on the speed droop lever (3) during manual rotation of the terminal shaft (4).

NOTE: When speed droop is required, make an adjustment to the position of the bracket (2) and test by running the engine. Make an adjustment again until the desired speed droop is found.

Central Adjustment of the Pilot Valve Plunger

1P87 Adjusting Wrench.

When the governor is disassembled the central adjustment of the pilot valve plunger must be checked and an adjustment made if needed.

CENTRAL ADJUSTMENT OF THE PILOT VALVE PLUNGER
1. Pipe plug opening. 2. Control land on pilot valve (4). 3. Pilot valve bushing. 4. Pilot control valve. A. Dimension of opening above land (2). B. Dimension of opening below land (2).

1. Using a small light, look at the position of the control land (2) on the pilot valve (4) with relation to the port (3) in the pilot valve bushing. This can be seen through the 1/16 in. pipe plug hole (1) in the straight side of the base after the bushing is turned to position the opening in the bushing.

2. Push pilot valve (4) toward the drive end as far as possible. This will move the flyweights (6) to the inner position. Through the pipe plug hole, check the dimension of port opening (A) above the edge of the control land (2) for the pilot valve.

3. Holding the pilot valve against the flyweight toes, move the flyweights out as far as they will go. Check the dimension of port opening (B) below the edge of the control land (2) for the pilot valve.

CROSS SECTION OF GOVERNOR
2. Control land on pilot valve. 3. Pilot valve bushing. 4. Pilot control valve. 5. Locknut. 6. Flyweight. 7. Spring seat.

4. The difference in amounts of port openings (A and B) with the flyweights in the extreme inner and outer positions must be within .010 in. (0.25 mm).

HOLDING SPRING SEAT WITH 1P87 ADJUSTING WRENCH TO MAKE AN ADJUSTMENT

5. If the pilot valve plunger is too low, hold the spring seat (7) with 1P87 Adjusting Wrench and turn the pilot valve counterclockwise to move it up. If the pilot valve plunger is too high, hole the spring seat and turn the pilot valve clockwise to move it down.

6. When the pilot valve is in the center, tighten the locknut (5) on the spring seat and check the valve setting again.

7. Install the 1/16 in. pipe plug using 8H5137 Sealing Compound to prevent leakage of oil.

Safety Control Shutoff

Overspeed Control Adjustment

Adjustment of the overspeed control is made at the factory and must not be changed unless the carrier assembly has been disassembled or the adjustment changed in some way. The original setting of the overspeed control is to stop the engine when the engine rpm is more than 18% above full load rpm.

On Engine Adjustment

The adjustment is made by removing the plug from the bottom of the shutoff housing to get to the weight adjustment screw. If necessary, turn the flywheel until the adjustment can be made with a screwdriver as shown.

Show/hide table

NOTICE

Be sure to turn the flywheel in the direction of normal rotation. If the flywheel is turned in the wrong direction it is possible to cause damage to the worm shaft and slide follower.

ADJUSTMENT OF THE WEIGHT SPRING TENSION

One full turn of the adjustment screw will change the speed setting 45 to 50 rpm. Clockwise turning of the adjustment screw will increase the pressure on the spring and will increase the maximum speed limit. Counterclockwise turning of the screw will cause a reduction in the pressure on the spring and lower the maximum speed limit.

Off Engine Adjustment

4S6553 Engine Test Group.FT907 Drive Adapter.Reversible variable speed drill.

The FT907 Adapter (C) with a reversible variable speed drill (D) and tachometer are used for adjustment of the control.

1. Connect the 1P7443 or 4S6991 Tachometer (part of the 4S6553 Engine Test Group) to the tachometer drive on the control (A).

2. Use the FT907 Adapter and variable speed drill to drive the control as shown.

NOTE: If adjustment or check of the overspeed control is made and the oil pressure reset plunger is not pushed in, a low oil pressure shutoff action will be the result.

Show/hide table

NOTICE

All safety shutoff controls must be driven counterclockwise.

3. Read the speed on the tachometer at the moment the control is activated. The reading will give the engine speed (2 rpm on the scale for each rpm the input shaft is turned).

4. The control is to activate at a speed 18% higher than the full load rpm.

TESTING OVERSPEED CONTROL
A. Safety control. B. 4S6553 Engine Test Group. C. FT907 Adapter. D. Reversible variable speed drill.

5. If an adjustment is needed, remove plug (3). If necessary, turn the drive shaft of the safety shutoff until the screw (2) is in alignment with the hole for plug (3).

6. Use a screwdriver to make the adjustment to the overspeed carrier assembly (1). One full turn of screw (2) will change the maximum overspeed limit 45 to 50 rpm. Turn the screw counterclockwise to make the setting lower.

7. Check the setting of the overspeed control again after the adjustment is made.

ADJUSTMENT
1. Carrier assembly. 2. Weight adjustment screw. 3. Plug.

Linkage Adjustment

1. At the time of assembly, pin the collar (1) to the rod (2) so that there is 2.38 in. (60.45 mm) distance (3) from the rod end to the collar (1).

LINKAGE ADJUSTMENT AT ASSEMBLY
1. Collar. 2. Rod. 3. Distance of 2.38 in. (60.45 mm).

2. The cable length is adjustable. At the time of installation an adjustment must be made so that, with the shutoff activated, the fuel rack will be in the shutoff position. Check to be sure full rack travel can be obtained when shutoff is reset.

3. Make an adjustment by removing cotter pin from hook (4), loosen the locknut (5) and turn the hook.

LINKAGE ADJUSTMENT AT INSTALLATION
4. Hook. 5. Locknut.

Rack Shutoff Solenoid

Travel can be measured with rack gauges to make sure rack is moved to fuel OFF position. Make an on engine check with a 30A ammeter to make sure only the hold in windings are energized when the rack is held by the solenoid in the fuel OFF position. Current draw (consumption) must be less than .5A.

Adjustment of the linkage is done with pin (5) removed and the governor linkage disconnected.

1. Move the rack to the fuel OFF position with lever (6).

2. Activate solenoid (4) or push the plunger into the solenoid as far as possible.

PLUNGER SHAFT ADJUSTMENT
1. Length of linkage is correct when rack is in full closed position and .5A or less consumption (draw) results. 2. Effective travel .5 in. (12.7 mm). 3. Starting position of plunger from face of solenoid is .75 in. (19.1 mm) to measure effective travel of plunger.

3. Install the pin (5). If the pin holes are not in alignment, loosen the locknut and change the length of the solenoid linkage by turning yoke (8) so the pin can be installed.

4. Release the solenoid.

5. Connect the governor linkage.

6. Check the adjustment to be sure the amperage draw (consumption) is .5A or less when the solenoid is activated.

7. With the solenoid not activated, check to be sure the rack moves full travel freely.

ADJUSTMENT OF SHUTOFF LINKAGE
4. Solenoid. 5. Pin. 6. Lever. 7. Linkage rod. 8. Yoke.

Contactor Switch For Water Temperature

Fabricated heat sink.2F7112 Thermometer.3J5389 Plug.8S4627 Circuit Tester.

First Method of Checking

1. Make a heat sink as shown. Material can be brass, steel or cast iron. Drill a 23/32 in. hole through the plate and use a tap to make 1/2in. NPT threads.

2. Put marks on wire connections to contactor terminals and disconnect wire.

HEAT SINK [Dimensions in inches (mm)]

TEST OF CONTACTOR SWITCH
1. 2F7112 Thermometer. 2. Fabricated heat sink.

3. Remove the contactor and install a 3J5389 Plug. Install the contactor switch in the heat sink.

4. Connect the wires to the contactor switch to check all of the system; contactor switch, wires, etc.

NOTE: If the wires cannot be disconnected, use the second method of testing.

5. When the contactor switch is connected again, start the engine and run it at low idle rpm. The pressure switch will complete the circuit when the engine is running.

NOTE: When applying heat to the water in Step 6, be sure to stir (keep water moving) while heating.

6. Put the heat sink and contactor element in water. Use a torch to make the water hot and read the temperature on thermometer (1) at which the engine stops (switch is closed). For the 5L6435 Contactor the temperature should be 209 ± 1°F (98 ± 0.6°C). Let the water temperature go down. The contactor switch will open when the temperature is 12°F (8°C) lower than the temperature at which the contactor closes.

7. Install new contactor switch if necessary.

To check other components in the system, put a jumper wire between C and NO terminals of the contactor switch for water temperature.

Second Method of Checking

1. Remove the wires from the contactor switch.

2. Connect the 8S4627 Circuit Tester between the C and NO terminals.

3. Start the engine and get it hot by making a reduction in coolant flow or air flow through the radiator. Temperature must not go more than approximately 3° above the maximum.

Show/hide table

NOTICE

If the engine cannot be run safely at these high temperatures, the contactor must be checked off the engine.

4. Look at the circuit tester to see when the contactor switch closes. The light will be activated. The temperature must be 209 ± 1°F (98 ± 0.6°C) for the standard sea level contactor.

5. Let the engine run to slow cooling and then stop the engine.

6. Install new contactor switch if needed and connect wires to the contactor switch.

Contactor Switch For Overspeed

The original setting of the contactor switch for overspeed will stop the engine when the engine rpm is more than 18% above full load rpm. DO NOT check the adjustment of the contactor switch on the engine.

Off Engine Adjustment

4S6553 Engine Test Group.8S4627 Circuit Tester.5L2277 Adapter.Reversible Variable Speed Drill.

1. Connect the 1P7443 or 4S6991 Tachometer of the 4S6553 Group to the tachometer generator (2).

2. Connect the 5L2277 Adapter (3) to the contactor switch and tachometer generator (2).

3. Install variable speed drill (4) to the adapter as shown.

4. Connect the 8S4627 Circuit tester (5) between the NO and the C terminals of the contactor switch. The light must be off. If the light is on, push reset button (6).

CHECKING CONTACTOR SWITCH FOR OVERSPEED
1. 4S6553 Engine Test Group. 2. Tachometer generator. 3. 5L2277 Adapter. 4. Variable speed drill. 5. 8S4627 Circuit Tester.

5. Gradually make an increase in the rpm. Read the rpm on the tachometer at the moment the light of the circuit tester is activated. The reading will give the engine rpm (2 rpm on the scale for each rpm the input shaft is turned).

6. If needed, make an adjustment to the contactor switch by loosening lock screws (7). Turn the cap clockwise to lower the overspeed setting. Tighten the lock screws.

7. To check other components in the system, put a jumper wire between the C and NO terminals of the contactor switch.

OVERSPEED CONTACTOR SWITCH
6. Reset button. 7. Lock screws.

Contactor Switch For Oil Pressure

3P1564 Pressure Gauge (0 to 60 psi).3B7734 Pipe Nipple, 1/8 in. x 3.5 in.3B6483 Cap.Two 3B7263 Pipe Nipples, 1/8 in. x 2 in.Two 3B9389 Shutoff Cock Fittings.Two 1F9369 Tees.44914 Tee.Two 5K3772 Hose Assemblies.8S4627 Circuit Tester.

TEST EQUIPMENT
1. 3P1564 Pressure gauge (0 to 60 psi). 2. 3B7734 Pipe nipple. 3. 3B6483 Cap. 4. Oil supply line. 5. 3B7263 Pipe nipple. 6. 3B9389 Shutoff cock fitting. 7. 3B9389 Shutoff cock fitting. 8. 1F9369 Tee. 9. 5K3772 Hose assemblies. 10. 44914 Tee.

Test Procedure

1. Remove the cover of the contactor switch and disconnect the wire from the normally closed (B or Blue) terminal.

2. Disconnect the oil supply line from the contactor switch and install the test equipment as shown.

NOTE: Connect the 5K3772 Hose from tee (10) to the contactor switch. Put the end of the other hose in a pan.

3. Connect the 8S4627 Circuit Tester between the common (R or Red) terminal and the normally closed (B or Blue) terminal. The light of the circuit tester will be activated.

4. Close shutoff fitting (7) and open shutoff fitting (6)

5. While looking at the pressure gauge, start the engine and run it at low idle rpm. The light must go out, with an increase in oil pressure, at the specification of the switch.

6. Close shutoff fitting (6) and slowly open shutoff fitting (7). The light must be activated, with a decrease in oil pressure, at the specification of the switch.

7. Stop the engine.

8. Connect the wire(s) to the normally closed (B or Blue) terminal.

9. On contactor switches with a button or a control knob either push the button or turn the knob to the OFF position.

10. Close shutoff fitting (7) and open shutoff fitting (6).

11. Start the engine and run it at low idle rpm.

12. Put a jumper wire between the common (R or Red) terminal and the normally closed (B or Blue) terminal. This will check the system beyond the contactor switch.

13. Remove the jumper wire.

Adjustment of Earlier Type Switch

CONTACTOR SWITCH FOR OIL PRESSURE (Earlier Type)
11. Adjustment screw. 12. Main spring.

1. Install a new contactor switch if necessary.

2. To make adjustments to the contactor switch, turn adjustment screw (11) counterclockwise to make a decrease in the tension of main spring (12).

3. Disconnect the wire(s) from the normally closed (Blue) terminal of the switch.

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

5. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the pressure gauge shows the pressure specification at which the switch closes with a decrease in pressure.

6. Make sure the control knob is in RUN position, if so equipped.

7. Turn screw (11) clockwise until the light of the circuit tester is activated.

8. To check the adjustment, close shutoff fitting (7) and open shutoff fitting (6).

9. Connect the wire(s) to the normally closed (Blue) terminal.

10. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the engine stops or the alarm operates.

11. The pressure gauge must show the correct pressure specification of the switch as the engine stops or the alarm operates.

12. Close both shutoff fittings and remove the test equipment.

WIRING CONNECTIONS
A. Normally open (white) terminal. B. Common (red) terminal. C. Normally closed (blue) terminal.

13. Install the cover on the contactor switch.

Adjustment of Micro Switch Type

1. Install a new contactor switch if necessary.

2. To make adjustments to the contactor switch, loosen locknut (16) and turn adjustment screw (14) counterclockwise to make a decrease in the tension of spring (15).

CONTACTOR SWITCH FOR OIL PRESSURE (Micro Switch Type)
13. Set for start button. 14. Adjustment screw. 15. Spring. 16. Locknut. 17. Contact button.

3. Disconnect the wire(s) from the normally closed B terminal of the switch.

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

5. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the pressure gauge shows the pressure specification at which the switch closes with a decrease in pressure.

6. Turn screw (14) clockwise until the light of the circuit tester is activated.

7. Tighten the locknut.

8. To check the adjustment, close shutoff fitting (7) and open shutoff fitting (6).

9. Connect the wire(s) to the normally closed B terminal.

10. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the engine stops or the alarm operates.

11. The pressure gauge must show the correct pressure specification of the switch as the engine stops or the alarm operates.

12. Close both shutoff fittings and remove the test equipment.

13. Install the cover on the contactor switch.

WIRING CONNECTIONS
D. Normally closed B terminal. E. Normally open W terminal. F. Common R terminal.

Shutoff Valve For Water Temperature

3J5389 Plug.Two 3F2779 Coupler Fittings.Two 4K7965 Hose Assemblies.Heat Sink (See topic Contactor Switch forWater Temperature).

SHUTOFF VALVE FOR WATER TEMPERATURE

1. Remove oil lines.

2. Remove shutoff valve and install the 3J5389 Plug.

3. Install the shutoff valve between the oil lines using the hoses and fittings.

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

5. Install the heat sink on the shutoff valve.

6. Put the heat sink and the shutoff valve in water.

7. Use a torch to make the water hot.

8. Put a thermometer in the water and take note of the temperature at which the engine stops.

9. Install a new valve if necessary.

NOTE: If the engine does not stop, look for a defect in the safety shutoff.

Electrical Gauges And Sending Units

Source for hydraulic pressure.7S8875 Hydraulic Test Box.Ohmmeter.2F7112 Thermometer.Heat sink. See contactor switch for water temperature.

Remember that the electrical gauges and sending units are to operate in electrical balance. For this reason, the voltage and resistance ratings are important to get the correct indications on the gauges.

Sending Units for Oil Pressure

SENDING UNIT FOR OIL PRESSURE
1. Terminal. 2. Fitting.

The sending units for gear oil pressure and engine oil pressure can be checked for resistance to find if they are operating correctly. Connect the sending unit to a pressure source that can be measured with accuracy. Connect the ohmmeter between fitting (2) and terminal (1). Take resistance readings at the pressures shown.

If the test performance is correct for the sending unit for the oil pressure, install a new gauge.

Sending Unit for Water Temperature

A resistance check can be made to find if the sending unit is operating correctly. Connect an ohmmeter between nut (2) and terminal (1). Put bulb (3) in a pan of water. Use a torch to make the water hot. Put a thermometer in the water to measure the temperature. Take resistance readings at the temperature shown.

Refer to CONTACTOR SWITCH FOR WATER TEMPERATURE for heat sink and heat bath use.

SENDING UNIT FOR WATER TEMPERATURE
1. Terminal. 2. Nut. 3. Bulb.

If the test performance is correct for the sending unit for the water temperature, install a new gauge.

Electrical Gauge

To check the gauge, use the voltage shown as the test voltage. Install a resistance of the valve shown, into the supply from the voltage source and connect the ground to the frame of the gauge. The indicator of the gauge should point to the temperature or pressure value given in the chart. The test must be made when the gauge is installed at an angle of 30° back from vertical position.

DIRECT READING GAUGE FOR WATER TEMPERATURE

DIRECT READING GAUGE FOR OIL PRESSURE

Mechanical Gauges For Water Temperature

Two types of mechanical gauges are available. The first type has a direct reading face. The second type has color codes on the face to show different ranges of operation. White, green and red show the cold, normal and hot ranges respectively.

To check both types of gauges, put the bulb of the gauge in a pan of water. Use a torch to make the water hot. Put a thermometer in the water to measure the temperature. Make a comparison of temperatures on the thermometer with the temperatures on the direct reading gauge or with temperature as shown on the chart for gauges with color codes.

GAUGE WITH COLOR CODES

DIRECT READING GAUGE

Mechanical Gauges For Oil Pressure

Two types of mechanical gauges are available. The first type has a direct reading face. The second type has color codes on the face to show different ranges of operation. Red, white and green show the low pressure, pressure at low idle rpm and normal pressure ranges respectively. Some of the direct reading gauges are for gear oil pressure.

NOTE: Some gauges with color codes have only two ranges. Red for low pressure and green for normal pressure.

To check both types of gauges connect the gauge to a pressure source that can be measured with accuracy. Make a comparison of pressures on the gauge of test equipment with the pressures on the direct reading gauge or with the pressures as shown on the chart for gauges with color codes.

GAUGE WITH COLOR CODE

DIRECT READING GAUGE

Enclosed Clutches

Clutch Adjustment

The force (pull) needed to engage the clutch gives an indication of clutch adjustment. The correct lever pull is shown in the chart.

These clutches use two types of adjustment lock pins. Pin (1) must be pushed in and the adjustment ring turned. Pin (2) must be pulled out and the adjustment ring turned.

CLUTCH ADJUSTMENT
1. Lock pin (push type). 2. Lock pin (pull type).

Assembly Adjustments

Tighten hub nut to a torque of 30 lb.ft. (4.1 mkg) to remove all clearance between parts. Then tighten again to the amoung shown in the chart.

End Clearance of Shaft Bearing

Tighten adjustment nut to remove all clearance. Shaft must turn with a dry bearing at a torque of 60 lb.in. (70.0 cm.kg) in addition to seal resistance (drag). Then loosen the adjustment nut the number of notches as shown in the chart. Hit the output end of the shaft with a soft hammer and measure the end clearance. The end clearance must be as shown in the chart.

Use 8S2328 Dial Indicator for making shaft end clearance measurements. Fasten the indicator to the housing and put the universal attachment so it just touches the end of the shaft. Hold the housing and make readings after moving the shaft in and out. Install the lock.