D353 INDUSTRIAL & MARINE ENGINES Caterpillar


Attachments Testing And Adjusting

Usage:



Woodward UG-8 Governor

Adjustments


NOTICE

Fuel rack setting is done carefully at the factory. Do not change the fuel rack setting unless it is known to be wrong. See the RACK SETTING INFORMATION for the correct rack setting dimension, high idle and low idle rpm.


Low or High Idle rpm Adjustment

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

1. Put the load limit knob (3) at point 5 to prevent the engine from getting too much fuel.

2. If the engine rpm goes too high, the linkage can be easily moved and the fuel rack controlled manually with linkage (4) to keep engine rpm low.

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

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

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

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

7. When making adjustment of the high idle rpm, turn synchronizer knob (5) clockwise until the engine is running at the correct high idle rpm. Turn knob (5) counterclockwise for low idle rpm.

8. Make an adjustment to the stop for high idle rpm by turning gear (6) clockwise (counterclockwise for low idle) until the gear pin makes contact with idler gear (2). Engage the gears.

9. After making adjustment to the idle rpm stop, turn the synchronizer knob to change the engine rpm. Turn it to the stop position and check the idle rpm. Make adjustment if necessary.

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


GOVERNOR ADJUSTMENT
1. Terminal lever. 2. Idler gear. 3. Load limit knob. 4. Linkage. 5. Synchronizer knob. 6. Gear. 7. Synchronizer indicator knob.

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

Fuel Rack Setting

Use the same tools and procedure for adjustment of the rack as shown for a mechanical governor. Make reference to Fuel Rack Setting.

Compensating Adjustment

Slow return to normal rpm, after load changes, is the result of wrong compensation adjustments.

Make compensating adjustments after the engine and the oil in the governor are at normal operating temperature and with the engine running at no load condition.

1. Loose nut (1) and move compensation adjustment pointer (2) to MAX.

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

3. Let the engine run rough for about 1 1/2 minutes to remove air from the governor oil passages, then turn compensating needle valve until the engine runs smoothly. The needle valve must be approximately 1/8 turn open.

4. Lower the pointer to two points above MIN.


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

5. Move the governor terminal shaft manually to make an increase in engine rpm. then let go and let the governor operation return to a stability condition. If it takes too long to return to a stability condition, move the pointer toward MAX. two more points. Continue making adjustments until the governor operates with the desired stability.

Governor Linkage Adjustment

1P2385 Protractor Tool.

Shown here are three basic ways to use the 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. Fuel OFF direction. 3. Linkage. 4. Fuel OFF direction. 5. Lower lever. A. Angle of 30° from horizontal. B. Angle of 4° from horizontal.

1. Install lever (1) at the angle shown with the governor terminal shaft turned to the fuel OFF position.

2. Install lever (5) at the angle shown with the rack moved to the fuel OFF position.

3. With the levers in the fuel OFF position, install linkage (3).

Woodward EG-3P Governor Actuator

Adjustments

Fuel Rack Setting

Use the same tools and procedure for adjustment of the rack as shown for a mechanical governor. Make reference to Fuel Rack Setting.

Actuator Linkage Adjustment

1P2385 Protractor Tool.

See topic WOODWARD UG-8 GOVERNOR for an illustration of the 1P2385 Protractor Tool.


GOVERNOR ACTUATOR LINKAGE
1. Fuel OFF direction. 2. Actuator lever. 3. Linkage. 4. Lower lever. A. Angle of 12° 30' from vertical. B. 7.31 in. (185.7 mm) reference dimension.

1. Install lever (2) at the angle shown with the actuator shaft turned to the fuel OFF position.

2. Assemble linkage (3) to the 7.31 in. (185.7 mm) reference dimension.

3. Connect one end of linkage (3) to lever (2) on the actuator.

4. With the rack moved to the fuel OFF position, install lower lever (4) so that linkage (3) can be connected without changing the length of the linkage.

Governor Air 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).


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

7. Check the air pressure to the actuator. Minimum air pressure at high idle must be 65 psi (450 kPa). Maximum air pressure must not be more than 80 psi (550 kPa).

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 (45 kPa) air pressure.

NOTE: If plunger (6) moves at less than 10 psi (45 kPa) make the preload higher. If more than 10 psi (45 kPa) 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 (45 kPa) 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.

Adjustment Of 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 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.

Adjustment Of 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.

8. Install a tachometer.


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

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.

Safety Controls

Safety controls are for the protection of the engine. To make sure they are working correctly, the controls must be checked every six months.

Mechanical Safety Shutoff

Overspeed Control Adjustment

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

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.


NOTICE

All safety shutoff controls must be turned counterclockwise.


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

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


TEST OF 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


ADJUSTMENT
4. Shutoff lever. 5. Linkage. A. 2.25 in. (57.2 mm) dimension. 6. Adapter.

8. With shutoff lever (4) for the fuel rack in the RUN position, make an adjustment to linkage (5) to get the 2.25 in. (57.2 mm) dimension (A) from the face of adapter (6) to the center of the yoke on the linkage.

Rack Shutoff Solenoid With Hydraulic Boost

The first adjustment of the linkage from the face of solenoid to the linkage hole center must be 3.875 in. (98.43 mm).

Travel can be measured with rack gauges to make sure rack is moved to fuel OFF position. Make an on engine check with a 30 amp. 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 2 amp.

The next adjustment of the linkage is done with pin (4) removed and the governor linkage disconnected.

1. Move the rack to the fuel OFF position.

2. Activate solenoid (5) or push the plunger into the solenoid as far as possible.

3. Install the pin (4). If the pin holes are not in alignment, loosen the locknut (6) and change the length of the solenoid linkage so the pin can be installed.


PLUNGER SHAFT ADJUSTMENT
1. 3.875 in. (98.43 mm) dimension from face of solenoid to link hole center when plunger face is .75 in. (19.1 mm) from face of solenoid. 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.

4. Release the solenoid.

5. Connect the governor linkage.

6. Check the adjustment to be sure the amperage draw (consumption) is correct when the solenoid is activated.

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


RACK SHUTOFF SOLENOID
4. Pin. 5. Solenoid. 6. Locknut.

Rack Shutoff Solenoid

Travel can be measured with rack gauges to be sure rack is moved to the fuel OFF position. Make an on engine check with a 30 amp. 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 2 amp.


RACK SHUTOFF SOLENOID
1. Governor linkage. 2. Solenoid linkage. 3. Pin. 4. Solenoid. 5. Lower lever of governor linkage. 6. Locknut.

The adjustment of the linkage is done with pin (3) removed and the governor linkage (1) disconnected.

1. Move the rack to the fuel OFF position.

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

3. Install the pin (3). If the pin holes are not in alignment, loosen the locknut (6) and change the length of solenoid linkage (2) so the pin can be installed.

4. Release the solenoid.

5. Connect the governor linkage (1).

6. Check the adjustment to be sure the amperage draw (consumption) is correct when the solenoid is activated.

7. With the solenoid not activated, check to make sure the rack moves freely.

Contractor 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.


HEAT SINK [Dimensions in inches (mm)]

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


TEST OF CONTACTOR SWITCH
1. 2F7112 Termometer. 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.

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.


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.

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 an ohmmeter between fitting (2) and terminal (1). Take resistance readings at the pressures shown.

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.


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

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


GAUGE WITH COLOR CODE


DIRECT READING GAUGE

Starting Systems

Air Starting System Pressure Regulating Valve


PRESSURE REGULATING VALVE (TYPICAL ILLUSTRATION)
1. Adjustment screw. 2. Regulator inlet. 3. Regulator outlet.

Use the following procedure to check and adjust the pressure regulating valve.

1. Drain the line to the pressure regulating valve or drain the air storage tank.

2. Disconnect the regulator from the starter control valve.

3. Connect an 8M2885 Pressure Gauge to the regulator outlet.

4. Put air pressure in the line or tank.

5. Check the pressure.

6. Adjust the pressure regulating valve according to Chart For Air Pressure Setting.

7. Remove the air pressure from the line or tank.

8. Remove the 8M2885 Pressure Gauge and connect the air pressure regulator to the line to the air starting motor.

Each engine application will have to be inspected to get the most acceptable starting results. Some of the factors that affect regulating valve pressure setting are: attachment loads pulled by engine during starting, ambient temperature conditions, oil viscosity, capacity of air reservoir, and condition of engine (new or worn).

The advantages of setting the valve at the higher pressures are increased torque for starting motor and faster rotation of engine. The advantage of setting the valve at the lower pressures is longer time of engine rotation for a given reservoir capacity of supply air.

Lubrication

Always use an air line lubricator with these Starters.

For temperatures above 32° F (0° C), use a good quality SAE 10 motor oil.

For temperatures below 32° F (0° C), use diesel fuel.

To maintain the efficiency of the starting motor, flush it at regular intervals. Pour approximately 1 pt. (0.5 litre) of diesel fuel into the air inlet of the starting motor and operate the motor. This will remove the dirt, water and oil mixture (gummy coating) from the vanes of the motor.

Air Starting Motor (Schwitzer)

End Clearance Adjustment of Air Starting Motor

Put shims (3) between bearing (1) and spacer or shoulder of end plate (2). Tighten the nut. Measure the clearance between the rotor and the end plate with a thickness gauge. Clearance must be .003 in. (0.08 mm) at end opposite the gear.


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

If clearance is not correct, the reading on the thickness gauge is used to find the number of shims (3) that must be installed or removed to get the correct clearance.


CHECKING END CLEARANCE ADJUSTMENT

Air Starting Motor (Ingersoll-Rand)

The cylinder (12) must be assembled over the rotor (15) and on the front end plate (16) so the dowel hole (12A) and the inlet passages (12B) for the air are as shown in the rear view illustration of the cylinder and rotor. If the installation is not correct, the starter drive (42) will turn in the wrong direction.

Tighten the bolts (6) of the rear cover in small increases of torque for all bolts until all bolts are tightened to 20 to 25 lb. ft. (25 to 35 N·m).

Put a thin layer of lubricant on the lip of the seal (29) and on the outside of the collar (35), for installation of drive shaft (34). After installation of the shaft through the cover (28), check the lip of the grease seal (29). It must be turned correctly toward the drive gear (25). If the shaft turned the seal lip in the wrong direction, remove the shaft and install again. Use a tool with a thin point to turn the seal lip in the correct direction.


REAR VIEW OF THE CYLINDER AND ROTOR FOR CLOCKWISE ROTATION
12. Cylinder. 12A. Air inlet passages. 12B. Dowel hole. 15. Rotor.

Tighten the bolts (32) of the drive housing in small increases of torque for all bolts until all bolts are tightened to 100 lb. in. (11.3 N·m).


AIR STARTER (INGERSOLL-RAND)
6. Bolt. 12. Cylinder. 15. Rotor. 16. Front end plate. 22. Gear case. 25. Drive gear. 28. Gear case cover. 29. Grease seal. 32. Bolt. 34. Drive shaft. 35. Drive shaft collar. 42. Starter drive (pinion). 45. Drive housing. 49. Air inlet. 50. Deflector (air outlet). 51. Mounting flange on the drive housing.

Check the motor for correct operation. Connect an air hose to the motor inlet (49) and make the motor turn slowly. Look at the drive pinion (42) from the front of the drive housing (45). The pinion must turn clockwise.

Connect an air hose to the small hole with threads in the drive housing (45), nearer the gear case (22). When a little air pressure goes to the drive housing, the drive pinion (42) must move forward to the engaged position. Also, the air must get out through the other hole with threads nearer the mounting flange (51).


COMPONENTS OF THE AIR STARTER (INGERSOLL-RAND, SIZE 150 BMP, MODEL C OR E)
1. Motor housing cover. 2. Plug. 3. Plug. 3A. Plug. 6. Bolt (cap screw). 7. Lockwasher. 8. Gasket. 9. Rotor rear bearing. 10. Bearing retainer. 11. Rear end plate. 12. Cylinder. 13. Dowel. 14. Rotor vane. 15. Rotor. 16. Front end plate. 17. Rotor front bearing. 18. Motor housing. 19. Gear case gasket. 20. Rotor pinion. 21. Rotor pinion retainer. 22. Gear case. 23. Bearing ejecting washer. 24. Rear bearing for the drive shaft. 25. Drive gear. 25A. Thrust washer. 26. Key for the drive gear. 27. Front bearing for the drive shaft. 28. Gear case cover. 29. Grease seal for the drive shaft. 30. Cover seal. 31. Piston seal. 32. Bolt. 33. Lockwasher. 34. Drive shaft. 35. Drive shaft collar. 36. Piston. 36A. Piston ring. 37. Shift ring. 38. Shift ring retainer. 39. Shift ring spacer. 40. Piston return spring. 41. Return spring seat. 42. Starter drive (pinion). 43. Lockwasher. 44. Bushing for the bolts. 45. Drive housing. 46. Drive housing bushing. 47. Oiler felt for the bushing. 48. Oiler plug.

Hydraulic Starting System

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

Do not disconnect lines or remove plugs from the system until the oil pressure has been released. The system can have 3000 psi (20 700 kPa) pressure. After all the system pressure is released, the accumulator still can have 1625 psi (11 200 kPa) pressure.

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

Do not work on the accumulator, unless you have the correct service tools and service information. Service or service information is available from the manufacturer.

Automatic Start/Stop System

See the correct topic in SAFETY CONTROLS for information on the engine controls of the automatic start/stop systems. To make on engine tests of the safety controls use a jumper wire between the 7A and 7B terminals in the transfer switch or use the switch on the control panel. This will check the operation of the automatic start/stop system.

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. (40 N·m) to remove all clearance between parts. Then tighten again to the amount shown in the chart.

Installation of Wear Sleeve

Clutch shaft bearings that have oil lubrication are equipped with wear sleeves (2). Install wear sleeves with guide assembly (1) (part of 1P2410 Wear Sleeve Installation Tool Group). Make sure the sleeve fits the shoulder fillets (3) on the shaft.


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

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. (6.8 N·m) in addition to seal resistance (drag). Then loosen the adjustment nut the number of notches as shown in the chart. Install the lock. Hit the output end of the shaft with a soft hammer. The end clearance must be as shown in the chart.

Installation Check

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

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