3406 INDUSTRIAL & MARINE ENGINES Caterpillar


Testing And Adjusting

Usage:



Introduction

The specifications given in this book are on the basis of information available at the time the book was written. These specifications give the torques, operating pressure, measurements of new parts, adjustments and other items that will affect the service of the product.

When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again.

When the word "permissible" is in the description, the specification given is the "maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

NOTE: The specifications given for "use again" and "permissible" are intended for guidance only and Caterpillar Tractor Co. hereby expressly denies and excludes any representation, warranty or implied warranty of the reuse of any component.

NOTE: This engine uses bolts (3/8 inch size only) with washer heads in some locations. The washer head bolt does not need a plain washer, lockwasher or lockplate. Where these bolts are used on aluminum covers or housings, a plain washer is needed. If you are not sure a washer is used under a bolt head, use the Parts Book to see if a washer is needed.

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 Does Not Activate Shutoff Solenoid.
2. Contactor Switch for Water Temperature Activates Shutoff Solenoid at Wrong Temperature.
3. Contactor Switch for Oil Pressure Fails to Activate Shutoff Solenoid.
4. Contactor Switch for Overspeed Fails to Activate Shutoff Solenoid.
5. Contactor Switch for Overspeed Activates Shutoff Solenoid at Wrong Speed.
6. Shutoff Solenoid Fails to Stop Engine.
7. Shutoff Solenoid Prevents Engine Start.
8. Clutch Will Not Engage (Slips), Heats or Lever Moves to Released Position.
9. Clutch Shaft Has Too Much End Play.
10. Clutch Bearings Have Short Service Life.
11. Mechanical Shutoff Fails To Stop Engine Because Of Low Oil Pressure.
12. Mechanical Shutoff Does Not Stop Engine When Coolant Temperature Is Too High.
13. Mechanical Shutoff Will Not Let Engine Start.
14. Electrical Gauges Give Wrong Readings.
15. 2301 Nonparallel Control System.
a. Engine Will Not Start.
b. Engine Overspeeds On Starts.
c. Engine Overspeeds After Operation At Rated Speed For Some Time.
d. Low Idle Speed Potentiometer Gives No Adjustment.
e. Engine Does Not Return To Low Idle When The Idle (Oil Pressure) Switch Opens.
f. Engine Speed Does Not Have Stability.
g. Speed Trim Potentiometer Gives No Adjustment.
h. Rated Speed Potentiometer Gives No Adjustment.
i. Load Sharing Is Not Correct.
j. Engine Speed Is Not Isochronous.
16. 2301 Parallel Control System.
a. Engine Will Not Start.
b. Engine Overspeeds On Starts.
c. Engine Overspeeds After Operation At Rated Speed For Some Time.
d. Low Idle Speed Potentiometer Gives No Adjustment.
e. Engine Does Not Return To Low Idle When The Idle (Oil Pressure) Switch Opens.
f. Engine Speed Does Not Have Stability.
g. Speed Trim Potentiometer Gives No Adjustment.
h. Rated Speed Potentiometer Gives No Adjustment.
i. Load Sharing Is Not Correct.
j. Engine Speed Is Not Isochronous.
k. System Does Not Have Stability When Paralleling Or In Parallel.
17. PSG Governors.
a. Engine Speed Does Not Have Stability.
b. Vibration At Governor Output Shaft.
c. Fuel Control Response When The Engine Is Started Is Not Acceptable.
d. Engine Has Slow Response To A Change In Speed Setting Or Load.
e. No Output From Governor.
f. Engine Will Not Drive Full Rated Load.
g. Load Sharing Between Paralleled Units Is Not Correct (One unit on zero droop all others on droop).
h. Load Sharing Between Paralleled Units Is Not Correct (all units on droop).
18. Automatic Start/Stop Systems.

Contactor Switch For Water Temperature Does Not Activate Shutoff Solenoid

Contactor Switch For Water Temperature Activates Shutoff Solenoid At Wrong Temperature.

Contactor Switch For Oil Pressure Fails To Activate Shutoff Solenoid.

Contactor Switch For Overspeed Fails To Activate Shutoff Solenoid.

Contactor Switch For Overspeed Activates Shutoff Solenoid At Wrong Speed.

Shutoff Solenoid Fails To Stop Engine.

Shutoff Solenoid Prevents Engine Start

Clutch Will Not Engage (Slips), Heats Or Lever Moves To Released Position.

Clutch Shaft Has Too Much End Play.

Clutch Bearings Have Short Service Life.

Mechanical Shutoff Fails To Stop Engine Because Of Low Oil Pressure.

Mechanical Shutoff Does Not Stop Engine When Coolant Temperature Is Too High.

Mechanical Shutoff Will Not Let Engine Start.

Electrical Gauges Give Wrong Readings.

Engine Will Not Start.

Engine Overspeeds On Starts.

Engine Overspeeds After Operation At Rated Speed For Some Time.

Low Idle Speed Potentiometer Gives No Adjustment.

Engine Does Not Return To Low Idle When The Idle (Oil Pressure) Switch Opens.

Engine Speed Does Not Have Stability.

Speed Trim Potentiometer Gives No Adjustment.

Rated Speed Potentiometer Gives No Adjustment.

Load Sharing Is Not Correct.

Engine Speed Is Not Isochornous.

Engine Will Not Start.

Engine Overspeeds On Starts.

Engine Overspeeds After Operation At Rated Speed For Some Time.

Low Idle Speed Potentiometer Gives No Adjustment.

Engine Does Not Return To Low Idle When The Idle (Oil Pressure) Switch Opens.

Engine Speed Does Not Have Stability.

Speed Trim Potentiometer Gives No Adjustment.

Rated Speed Potentiometer Gives No Adjustment.

Load Sharing Is Not Correct.

Engine Speed Is Not Isochronous.

System Does Not Have Stability When Paralleling Or In Parallel.

Engine Speed Does Not Have Stability.

Vibration At Governor Output Shaft.

Fuel Control Response When The Engine Is Started Is Not Acceptable.

Engine Has Slow Response To A Change In Speed Setting Or Load.

No Output From Governor.

Engine Will Not Drive Full Rated Load.

Load Sharing Between Paralleled Units Is Not Correct (one unit on zero droop all the others on droop).

Load Sharing Between Paralleled Units Is Not Correct (all units on droop).

Automatic Start/Stop System

Engine Speed Measurement

Tachometer Drive


TACHOMETER DRIVE
A. Location for tachometer drive adapter.

Most engines have a location where a tachometer drive adapter can be installed. Install an adapter. Then connect it to the tachometer in the 4S6553 Engine Test Group, the 5P2150 Engine Horsepower Meter or the 1P5500 Portable Phototach Group.

NOTE: On some engines the service meter must be removed.

4S6553 Engine Test Group


4S6553 ENGINE TEST GROUP
1. 4S6992 Differential Pressure Gauges. 2. Zero adjustment screw. 3. Lid. 4. 8M2743 Gauge. 5. Pressure tap fitting. 6. 4S6991 Tachometer. 7. 4S6997 Manifold Pressure Gauge.

Special Instruction Form SEHS7341 is with the 4S6553 Engine Test Group. It has instructions on how to use the group.

1P5500 Portable Phototach Group


1P5500 PORTABLE PHOTOTACH GROUP

The 1P5500 Portable Phototach Group can measure engine speed from the tachometer drive on the engine. It can also measure the speed of the engine parts (fan, flywheel, etc.) that have rotation. For the best accuracy the rpm of the part that is measured must be the same as the rpm of the engine. Special Instruction Form SMHS7015 has instructions on how to use the group.

5P2150 Engine Horsepower Meter


5P2150 ENGINE HORSEPOWER METER

The 5P2150 Engine Horsepower Meter can measure engine speed from the tachometer drive on the engine. Special Instruction Form SMHS7050 has instructions for this procedure. It can also measure the engine speed from the signal made by a magnetic pickup when the teeth of the flywheel go by it.

The flywheel housing has an opening for timing the engine. An adapter and magnetic pickup can be installed at this location.

With the engine stopped, turn magnetic pickup (2) clockwise until it just has contact with a tooth (5). Turn it counterclockwise 1/2 of a revolution. Tighten locknut (4). This will give .022 to .033 in. (0.56 to 0.84 mm) clearance between the flywheel teeth and the magnetic pickup.

Some flywheel housings have a location for installation of a magnetic pickup for use with a electronic speed switch. If there is a magnetic pickup for use with an electronic speed switch already installed, its signal can be used with the 5P2150 Engine Horsepower Meter. The operation of the magnetic pickup is the same for any of the installations.

The signal from the magnetic pickup is an AC voltage. Every tooth on the flywheel makes the signal have one cycle. The 5P2150 Engine Horsepower Meter has an electronic counter. It can count the number of hertz in the signal from the magnetic pickup.


NOTICE

It is necessary to install a resistor in series with one of the wires from the magnetic pickup to prevent damage to the circuits in the 5P2150 Engine Horsepower Meter. The magnetic pickup shown for testing has the correct resistance.



INSTALLATION OF MAGNETIC PICKUP
1. Clearance. 2. Magnetic pickup. 3. Wires. 4. Locknut. 5. Flywheel gear teeth. 6. Adapter.

On engines with an electronic speed switch, the signal from its magnetic pickup is strong enough to operate the electronic speed switch and the electronic counter at the same time. Connect the input wires from the 5P2150 Engine Horsepower Meter to the "SIG" and "COM" terminals on the electronic speed switch. Install the 1.5 megohm resistor in series with one of the input wires. The minimum voltage input to the electronic counter is 1.5 volts. If the voltage is too low make an adjustment to the magnetic pickup to get the minimum voltage.


MAGNETIC PICKUP FOR TESTING
2. Magnetic pickup. 7. 1.5 megohm resistor (5 or 10%) soldered in series with one of the wires. 8. Photo plug.

When the 5P2150 Engine Horsepower Meter is used with the magnetic pickup it does not show engine speed directly. This is because the signal from the magnetic pickup has more cycles per revolution of the engine than the standard tachometer generator. The signal from the standard tachometer generator has ten cycles for each revolution of the engine. The signal from the magnetic pickup has one cycle for each flywheel gear tooth. For example, if the flywheel gear has 113 teeth, there are 113 cycles for each revolution of the engine. The number that the meter shows is larger by a factor of 113 ÷ 10 or 11.3. This factor is the factor for the flywheel gear.

At lower engine speeds, the number on the meter divided by the factor for the flywheel gear gives the engine speed. At high engine speeds the number is too big (five digits) for the meter. The meter shows the last four digits. Find the first digit in the chart. Look at the chart for the approximate engine rpm. The chart has the correct meter reading for that engine rpm according to the number of flywheel gear teeth. If the number has more than four digits, put the first digit from the chart with the number which is shown on the meter. Divide this number by the factor for the flywheel gear. The result is the actual engine rpm. Remember that a change of 1 rpm in engine speed makes a change of 11.3 in the rpm shown on the meter.

Tachometer In Control Panel

Use the tachometer on the control panel, if so equipped.

Frequency Meter

If the engine is a drive for a generator with a frequency meter, use the frequency meter to measure the engine speed. If the frequency meter shows 60 hertz the engine speed is 1800 rpm. If the meter shows 50 hertz the speed is 1500 rpm.

Woodward PSG Governor

Linkage Adjustment


PSG GOVERNOR CONTROL LINKAGE
1. Lever. 2. Rod assembly. 3. Lever. 4. Governor output shaft. A. Angle. B. Angle.

1. When governor output shaft (4) is in the SHUTOFF position angle (B), between lever (3) and horizontal, must be 60°.

2. Keep lever (3) at SHUTOFF. Adjust rod assembly (2) so that when it is connected to lever (1) angle (A), between the lever and horizontal, is 40° 2'.

3. Check to make sure the linkage operates freely.

Needle Valve Adjustment

1. Start the engine and let it run at the desired speed until the coolant temperature is normal.

2. Turn compensating needle valve (2) two or three turns counterclockwise. Let the engine hunt for about 30 seconds. This lets air out of the hydraulic circuit in the governor.

3. Turn the needle valve slowly clockwise until the engine speed has stability. Put a near full load on the engine. Again turn the needle valve slowly clockwise until the engine speed has stability.

NOTE: 1/4 turn out from the seat is the approximate point of best stability.

4. To check the adjustment turn lever (1) counterclockwise to decrease engine speed. Release the lever. The engine must return rapidly to the desired speed.

5. If the engine hunts more than a small amount before it has stability turn the needle valve clockwise. If the engine is slow to return to the desired speed turn the needle valve counterclockwise. Do steps 4 and 5 until the engine returns to the desired speed and has stability in the shortest amount of time.


PSG GOVERNOR
1. Lever. 2. Compensating needle valve.

Fuel Rack Setting

8S4627 Circuit Tester9S7350 Bracket Group9S215 Dial Indicator8S4623 Dust cover

1. Remove stop (1), spacer (2) and both gaskets (3) from the drive housing for the fuel injection pump.


RACK STOP
1. Stop. 2. Spacer. 3. Gaskets.

2. Disconnect the governor control linkage to let the drive group lever move freely through its full travel.

3. Remove the standard dust cover from 9S215 Dial Indicator (6) and install 8S4623 Dust Cover (7) on the dial indicator.


MEASURE RACK TRAVEL
4. Spacer. 5. 9S7350 Bracket Group. 6. 9S215 Dial Indicator. 7. 8S4623 Dust Cover.

4. Install 9S7350 Bracket Group (5) and 9S215 Dial Indicator (6) on the drive housing for the fuel injection pump.

5. With the drive group lever in the shutoff position (fully clockwise), put spacer (4) of the bracket group over the rod that will make contact with the rack.

6. Push the hole attachment against the rod to hold the spacer in position.

7. Put the dial indicator on zero and release the hole attachment. Take the spacer away from the rod.

8. Turn the drive group lever slowly in the FUEL ON direction (counterclockwise) until it stops.

9. Read the measurement on the dial indicator. Look at the RACK SETTING INFORMATION to find the correct measurement for rack setting.

10. If the measurement is not correct do the steps that follow:

Earlier Governor Drive Groups:

a. Remove cover (11) and the washer.

b. Loosen nut (10) until lock (9) is free of pin (12).


EARLIER DRIVE GROUP
8. Screw. 9. Lock. 10. Nut. 11. Cover. 12. Pin. 13. Drive group lever.

c. Turn screw (8), as necessary, to get the correct reading on the dial indicator. Remember to push drive group lever (13) counterclockwise when reading the dial indicator.

NOTE: Turn screw (8) clockwise to decrease or counterclockwise to increase the rack setting.

NOTE: If pin (12) is not in alignment with one of the notches in lock (9), turn screw (8) to put the nearest notch in alignment with the pin.

d. Tighten nut (10). Check the adjustment by going through Steps 5 through 10 again. When the adjustment is correct, install cover (11), gaskets (3), spacer (2) and stop (1).

Later Governor Drive Groups:

a. Remove cover (17) and the washer.

b. Loosen nut (15) until lock (14) is free of the pin.


LATER DRIVE GROUP
14. Lock. 15. Nut. 16. Switch assembly. 17. Cover. 18. Terminal. 19. Drive group lever.

c. Turn switch assembly (16), as necessary, to get the correct reading on the dial indicator. Remember to push the drive group lever (19) counterclockwise when reading the dial indicator.

NOTE: Turn switch assembly (16) clockwise to decrease or counterclockwise to increase the rack setting.

NOTE: If the pin is not in alignment with one of the notches in lock (14), turn switch assembly (16) to put the nearest notch in alignment with the pin.

d. Tighten nut (15). Check the adjustment by going through Steps 5 through 10 again. When the adjustment is correct, install cover (17), gaskets (3), spacer (2) and stop (1).

NOTE: To check for full fuel with the engine running connect the 8S4627 Circuit Tester between terminal (18) of the switch assembly and a good ground. When the rack gets to full fuel the light in the tester will go on.

Adjusting The High Idle Stop

1. Start the engine and let it run until the coolant temperature is normal.

2. Loosen locknut (3). Turn stop screw (4) counterclockwise approximately two turns.


NOTICE

With the stop screw in this position the engine can overspeed. This can cause damage to engine components. Be ready to shutdown the engine if it has an overspeed condition.



PSG GOVERNOR
1. Synchronizing motor. 2. Knurled knob. 3. Locknut. 4. Stop screw.

3. Use knurled knob (2) or synchronizing motor (1) to adjust the engine to the desired speed.

NOTE: Early models use a manual adjustment screw.

4. Turn stop screw (4) clockwise until it stops. Tighten locknut (3).

5. If the engine speed is still correct, the adjustment is correct.

Check Speed Droop

The speed droop can be adjusted between zero and seven percent. The desired speed droop will be different for different applications. Percent of speed droop is the percent difference between the engine speed at no load and full load. To calculate speed droop use the formula:

1. Get the desired speed droop for the application.

2. Multiply the full load speed by the desired speed droop. Add the number from this multiplication to the full load speed to get the no load speed.

3. Start the engine and let it run until the temperature of the coolant is normal.

4. Adjust the engine speed to get the no load speed from Step 2.

5. Connect a known load to the engine. The load must be less than the full capacity of the engine. Make a record of the decrease in engine speed.

6. Make a ratio between the load on the engine and the full load capacity of the engine. This ratio must be the same as the ratio between the decrease in engine speed from Step 5 and the number from the multiplication in Step 2. For example:

7. If the ratios are not the same an adjustment of the speed droop is necessary. Remove the load and stop the engine. If the engine speed decreased too much according to the ratio decrease the amount of speed droop. If the decrease in engine speed is not enough increase the amount of speed droop. See SPEED DROOP ADJUSTMENT.

Speed Droop Adjustment (Later PSG Governors)

1. Make a mark on cover (1) to show the original position of bracket (3). This will show how much a change in bracket position changes the speed droop.

2. Loosen knob (2) that holds bracket (3) and speed droop lever (4) in position.


PSG GOVERNOR (Later)
1. Cover. 2. Knob. 3. Bracket. 4. Speed droop lever. 5. Stop screw.

3. To increase the speed droop turn lever (4) counterclockwise. To decrease the speed droop turn lever (4) clockwise.

NOTE: If the lever is turned clockwise beyond the point where the speed droop is zero the engine will hunt a large amount and will not get stability.

4. Tighten knob (2) to hold the lever and bracket in position. After an adjustment is made check the speed droop. See CHECK SPEED DROOP. Several adjustments can be necessary to get the desired speed droop.

5. When lever (4) is in the position that gives the desired speed droop, set stop screw (5) against the pin on lever (4). This will make it easy to return the speed droop lever to the desired position after disassembly and assembly of the governor.

Speed Droop Adjustment (Earlier PSG Governors)

9S215 Dial Indicator5P7285 Adjusting Bracket3P1565 Collet

1. Remove cover (1) from the governor.

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

Cover (1) is pushed away from the body of the governor by a strong spring (5). Loosen all the bolts that hold the cover in position evenly to decrease the force of compression in spring (5).

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


PSG GOVERNOR (EARLIER)
1. Cover. 2. Lever. 3. Bracket. 4. Output shaft lever. 5. Spring. 6. Pilot valve.

2. Make a mark on output shaft lever (4) to show the original position of bracket (3). This will show how much a change in bracket position changes the speed droop.

3. Loosen screw (7) that holds bracket (3) in position.

4. To increase the speed droop move bracket (3) in the direction shown by the arrow. To decrease the speed droop move the bracket in the opposite direction.

NOTE: If the bracket is moved in the direction opposite the arrow beyond the point where the speed droop is zero the engine will hunt a large amount and will not get stability.


SPEED DROOP ADJUSTMENT
3. Bracket. 7. Screw. 8. Output shaft.

NOTE: Zero droop position can be set by the use of a 5P7285 Adjusting Bracket (10), 3P1565 Collet (11) and 9S215 Dial Indicator (9). Install the bracket and collet on the governor. Install the indicator in the collet. Put the tip of the indicator on lever (2) above pilot valve (6). Turn output shaft (8) and look at the indicator. Adjust bracket (3) until rotation of the output shaft causes no movement of the indicator.


TOOLS INSTALLED
9. 9S215 Dial indicator. 10. 5P7285 Adjusting Bracket. 11. 3P1565 Collet.

Pilot Valve Adjustment


PSG GOVERNOR
1. Inspection opening.

Check the adjustment of the pilot valve when the governor is disassembled (linkage and top cover removed).

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

The top cover is pushed away from the body of the governor by a strong spring. Loosen all the bolts that hold the cover in position evenly to decrease the force of compression of the spring.

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

1. Remove the pipe plug from inspection opening (1).

2. Use a light to look for the control opening in pilot valve bushing (2) and regulating land (3) on the pilot valve.


CONTROL OPENING
1. Inspection opening. 2. Pilot valve bushing. 3. Regulating land. A. Port opening. B. Port opening.

3. Push pilot valve (6) in the direction of the drive end as far as possible. Check the length of port opening (A).

4. Pull the pilot valve in the opposite direction as far as possible. Check the length of port opening (B).

5. The length of port opening (A) must be the same, within .010 in. (0.25 mm), as port opening (B).


PSG GOVERNOR
2. Pilot valve bushing. 3. Regulating land. 4. Locknut. 5. Spring seat. 6. Pilot valve.

6. If the lengths of the port openings are not correct hold spring seat (5) with 1P87 Adjusting Wrench. Loosen locknut (4). Turn the pilot valve as necessary to get the correct adjustment.

NOTE: Turn the pilot valve clockwise to increase port opening (A) and decrease port opening (B). Turn it counterclockwise to decrease port opening (A) and increase port opening (B).


1P87 ADJUSTING WRENCH USED TO HOLD SPRING SEAT

7. Tighten locknut (4) and remove the wrench.

8. Check the adjustment according to Steps 3, 4 and 5.


NOTICE

If this adjustment is not correct the engine can have an overspeed condition. This can cause damage to engine components.


9. When the adjustment is correct, put 8H5137 Gasket Sealant on the threads of the pipe plug and install it in pipe plug opening.

2301 Control Systems

NOTE: For information on earlier 2301 control systems make reference to INDUSTRIAL DIVISION ENGINE DATA SHEET Form No. LE021991-01.

Magnetic Pickup


MAGNETIC PICKUP
1. Clearance dimension. 2. Magnetic pickup. 3. Wires. 4. Locknut. 5. Flywheel gear. 6. Adapter.

1. Crank the engine. Use a voltmeter to check the output of the magnetic pickup. Minimum cranking voltage is 1.0V. Minimum voltage at 1500 rpm is 10V. If these voltages are not correct make an adjustment as follows:

2. Loosen locknut (4).

3. Turn magnetic pickup (2) in until it just has contact with flywheel (5).

4. Turn the magnetic pickup out 1/2 a revolution. This will make clearance dimension (1) .022 to .033 in. (0.56 to 0.84 mm).

5. Tighten the locknut to 50 ± 10 lb. ft. (70 ± 14 N·m).

6. Do Step 1 again. If the voltages are still not correct make a replacement of the magnetic pickup.

Woodward EG-3P Governor Actuator

Linkage Adjustment

1. When the actuator output shaft (5) is in the SHUTOFF (fully clockwise) position, angle (4), between lever (6) and horizontal must be 30° ± 5°.


EG-3P ACTUATOR
1. Lever. 2. Angle. 3. Rod assembly. 4. Angle. 5. Output shaft. 6. Lever.

2. Keep lever (6) at SHUTOFF. Adjust rod assembly (3) so that when it is connected to lever (1) angle (2), between the lever and horizontal, is 40° 2'.

3. Check to make sure the linkage works freely.

Fuel Rack Setting

Use the procedure given on page 5-54 for PSG Governors to set the rack on engines with this governor.

Check For Actuator Coil Resistance


EG-3P ACTUATOR

1. Remove the connection plug from the EG-3P actuator.

2. There are four terminals on the actuator. They have marks "A", "B", "C" and "D". Connect the probes of an ohmmeter between terminals "A" and "B". Put a jumper wire between terminals "C" and "D".

3. If the coil resistance is not 30 to 40 ohms make a replacement of the actuator.

Potentiometer Adjustment (Parallel Or Nonparallel Control)


2301 PARALLEL CONTROL
1. Speed potentiometer. 2. Stability potentiometer. 3. Gain potentiometer. 4. Ramp time potentiometer. 5. Low speed potentiometer. 6. Load gain potentiometer. 7. Droop potentiometer. 8. De-droop potentiometer. 9. Load signal jacks.

Speed Potentiometer

Turn speed potentiometer (1) clockwise to increase or counterclockwise to decrease the full load rpm of the engine.

Stability and Gain Potentiometers

1. Connect a DC voltmeter to terminals 16 (-) and 17 (+) on the parallel control [terminals 5 (-) and 6 (+) on the nonparallel control].

2. Start the engine. Run the engine until the coolant temperature is normal.

3. Turn gain potentiometer (3) clockwise until the voltmeter does not have stability.

4. Turn stability potentiometer (2) either direction until the voltmeter has stability.

5. Do Steps 3 and 4 several times until the stability potentiometer will not give the voltmeter stability.

6. Turn the gain potentiometer a small amount counterclockwise. Adjust the stability potentiometer as necessary.

Ramp Time Potentiometer

Turn ramp time potentiometer (4) clockwise to increase or counterclockwise to decrease the amount of time it takes the engine to accelerate from low idle to full load rpm.

Low Speed Potentiometer

1. Make sure there is an open between terminals 14 and 15 (terminals 9 and 10 on the nonparallel control).

2. Turn low speed potentiometer clockwise to increase or counterclockwise to decrease the low idle rpm.

Load Gain Potentiometer

NOTE: Stability and gain potentiometers must be correctly adjusted first.

1. Put the probes of a voltmeter in the load signal jacks (9).

2. Run the engine in single unit operation until the coolant temperature is normal.

3. Put a full load on the generator. Adjust load gain potentiometers until the load signal reading on the voltmeter is 8V. If it is not possible to put a full load on the generator keep the ratio between the load and the voltage signal constant. For example: if the load on the generator is 1/2 of its rated capacity adjust the load gain potentiometer to get a load signal of 4V.

4. Do Steps 1, 2 and 3 to all the units in the system. The load signal for each unit in the system must be the same.

5. If any of the units in the system have stability problems at this load gain setting, decrease the setting for each unit a small amount. Keep the load signal for each unit in the system the same.

6. If the load signal at full load is decreased to 3V in Step 5 and the system still has a stability problem do the steps that follow.

7. Parallel all of the units in the systems at no load.

8. If the system has instability turn the stability potentiometer of each unit one mark counterclockwise. Do this until the system has stability.

9. Put a load on the system. If the system has instability turn the stability potentiometer of each unit one mark counterclockwise. Do this until the system has stability.

NOTE: The generator voltage regulator response may be too fast. Use a manual voltage regulator. If this stops the instability, slow down the response of the generator voltage regulator.

Droop Potentiometer

The amount of speed droop adjustment available will vary with the application from 0 to 13%. The desired speed droop will be different for different applications. Speed droop is the percent difference between the engine speed at no load and full load. To calculate speed droop use the formula:

1. Get the desired speed droop for the application.

2. Multiply the full load speed by the desired speed droop. Add the number from this multiplication to the full load speed to get the no load speed.

3. Run the engine until the coolant temperature is normal.

4. Adjust the engine speed to get the no load speed for Step 2.

5. Connect a known load to the engine. The load must be less than the full capacity of the engine. Make a record of the decrease in engine speed.

NOTE: Load on engine or load on generator can be used.

6. Make a ratio between the load on the engine and the full load capacity of the engine. This ratio must be the same as the ratio between the decrease in engine speed from Step 5 and the number from the multiplication in Step 2.

7. If the ratios are not the same an adjustment of the speed droop is necessary. Remove the load and stop the engine. If the engine speed decreases too much according to the ratio, decrease the amount of speed droop. If the decrease in engine speed is not enough increase the amount of speed droop.

8. Turn droop potentiometer (7) clockwise to increase or counterclockwise to decrease the amount of speed droop.

De-Droop Potentiometer

1. Set the system for isochronous operation at the desired rpm. Droop potentiometer at zero droop.

2. Put the maximum available load on the unit, up to 100% of rated capacity.

3. If there is a change in rpm use the de-droop potentiometer to return the engine to the desired rpm.

Air/Fuel Ratio Control

1. Check the fuel rack setting. Make reference to FUEL RACK SETTING The fuel rack setting must be correct before the adjustment for the hydraulic air/fuel ratio control can be checked or changed.

2. Remove the cover (3) from the hydraulic air/fuel ratio control.

3. Start the engine.

4. Push the end of valve (1) in and hold it in for two or three seconds. This action will manually move the valve into its operating position.

5. Move the governor control lever from the fuel off to the fuel on direction several times to remove the air from the control for a more accurate reading.


HYDRAULIC AIR/FUEL RATIO CONTROL
1. Valve. 2. Pin. 3. Cover.

6. Rapidly move the governor control lever in the fuel on direction and the read the measurement on the dial indicator. Read the indicator carefully because this reading will be a maximum for only a moment. Look in the RACK SETTING INFORMATION to find the correct measurement.

7. To make an adjustment to the hydraulic air/fuel ratio control, turn valve (1) in a clockwise direction to make an increase in the limited rack position and in a counterclockwise direction to make a decrease in the limited rack position.

8. After each adjustment is made, the governor control lever must be moved from the fuel off to the fuel on direction before an accurate reading can be made.

9. After the correct adjustment has been made, put cover (3) in alignment with pin (2) in the valve and turn the cover to put it in alignment with the nearest bolt holes. Install the bolts.

10. Stop the engine.

11. After the oil pressure has gone out of the hydraulic air/fuel ratio control, full rack travel must be available.

12. Now install the wire and seal on the control.

Governor Air Actuator

Air Pressure Adjustment


ACTUATOR LINKAGE
1. Linkage.

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

2. Start the engine. Let the engine run until it gets to normal operation temperature.

3. Make sure the high and low idle speeds are correct. If necessary, make adjustments to the governor high and low idle screws to get the 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.

6. Start the engine.

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. Look at plunger (6). Move actuator air control lever (3) slowly to the high idle position. The plunger must start to move at 10 psi (45 kPa) air pressure.

NOTE: If the plunger moves at less than 10 psi (45 kPa) make the preload higher. If more than 10 psi (45 kPa) is needed to move the plunger, make the preload lower.

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

11. Turn screw (7) out until nut (5) 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 screw (7) in until the nut can not be turned.

NOTE: If necessary, turn the nut a small distance until the screw is in alignment with a notch in the nut.

14. Install the linkage between actuator and governor.

Adjustment Of Low Idle Stop

1. Start the engine. Let the engine run until it gets to normal operation temperature.

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

3. Check the low idle rpm. See the topic ENGINE SPEED MEASUREMENT.

4. Stop the engine.

5. If low idle is not correct, remove linkage (1) and make an adjustment.

NOTE: Make the linkage shorter to decrease the rpm. Make the linkage longer to increase the rpm.


LOW IDLE ADJUSTMENT
1. Linkage.

Adjustment Of High Idle Stop

1. Start the engine. Let the engine run until it gets to the normal operation temperature.

2. Remove two setscrews (9) for earlier actuators or loosen locknuts (10) for later actuators, 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.


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


HIGH IDLE ADJUSTMENT (LATER ACTUATOR)
3. Actuator air control lever. 6. Plunger. 8. High idle screws. 10. Locknuts.

6. Install and tighten two setscrews (9) for earlier actuators or tighten two locknuts (10) for later actuators to hold the high idle screws.

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

8. Install a tachometer.

9. Make the governor high idle 30 rpm higher.

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

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

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

12. Check the engine high idle rpm.

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

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

Shutoff And Alarm System Components

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 Tees. 9. 5K3772 Hose Assemblies. 10. 44914 Tee.

Test Procedure

1. Remove the cover of the contactor switch and disconnect the wires 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.

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

4. Connect the 8S4627 Circuit Tester between the common terminal and the normally closed terminal. The light of the circuit tester will be activated.

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

6. Look 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.

7. 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.

8. Stop the engine.

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

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

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

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

13. Put a jumper wire between the common terminal and the normally closed terminal. This will check the system beyond the contactor switch.

14. Remove the jumper wire.

Adjustment of Earlier Type Switch


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

1. Turn adjustment screw (11) counterclockwise to make a decrease in the tension of main spring (12).

2. Disconnect the wires from the normally closed terminal of the switch.

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

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

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

6. Connect the 8S4627 Circuit Tester between the common terminal and the normally closed terminal. The light of the circuit tester must not be activated.


WIRING CONNECTIONS
A. Normally open terminal. B. Common terminal. C. Normally closed terminal.

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 wires to the normally closed 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.

Adjustment of Micro Switch Type

1. 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.

2. Disconnect the wires from the normally closed terminal of the switch.

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

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

5. Make sure the set for start button (13) is in the RUN position.

6. Connect the 8S4627 Circuit Tester between the common terminal and the normally closed terminal. The light of the circuit tester must not be activated.

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

8. Tighten the locknut.


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

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

10. Connect the wires to the normally closed terminal.

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

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

Contactor Switch For Water Temperature

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

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 1/2 in. NPT threads.

2. Put marks on the two contactor wires that connect the contactor to the circuit. Disconnect the two wires.


HEAT SINK [Dimensions in inches (mm)].

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

4. Put the heat sink and contactor in water as shown. Use blocks to support the heat sink at surface level.

5. Connect the 8S4627 Circuit Tester between the wires that connected the contactor to the circuit.


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

6. Put the 2F7112 Thermometer in the water.

7. Use a torch to heat the water to the temperature range at which the contactor must activate. If the circuit tester light does not come on within the temperature range given in the specifications make a replacement of the contactor.

8. Let the water temperature go down. If the circuit tester light does not go out within the temperature range given in the specifications make a replacement of the contactor.

Pressure Switch With Time Delay

8M2743 Gauge.8S4627 Circuit Tester.

1. Disconnect the wires from pressure switch (2). Remove the pressure switch from the junction block (1).


OIL PRESSURE SWITCH WITH TIME DELAY INSTALLED
1. Junction block. 2. Pressure switch.

2. Install an elbow, a short nipple, a shutoff valve, a short nipple and tee as shown in place of the pressure switch. Make sure that the valve is closed.

3. Install the pressure switch (2) and a 8M2743 Gauge in the open ends of the tee as shown.

4. Connect the 8S4627 Circuit Tester between the terminals of the pressure switch.


TEST TOOLS INSTALLED

5. Start the engine. Open the shutoff valve a small amount. Look at the pressure on the 8M2743 Gauge. When the pressure gets to the range given in the specifications the circuit tester light must go on.

6. Close the shutoff valve. Stop the engine. Open the shutoff valve a small amount. Look at the pressure on the 8M2743 Gauge. When the pressure gets to the range given in the specifications close the valve. After five minutes open the valve fully. The circuit tester light must stay on a minimum of 30 seconds and a maximum of 15 minutes after the valve is fully opened.

Shutoff Solenoids

1. Make sure the linkage to which the solenoid is connected does not give more than the normal amount of restriction.

2. Connect a voltmeter between the terminals of the solenoid.

3. Activate the solenoid circuit. If the voltage shown on the meter is less than the needed voltage the circuit has a failure. Check the other components of the circuit. If the voltage is the same or more than the needed voltage make a replacement of the solenoid.

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 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 meter for each rpm the input shaft is turned).


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

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 circuit, put a jumper wire between the C and NO terminals of the contactor switch.

Oil Pressure And Water Temperature Shutoff (Mechanical)

9S9102 Thermistor Thermometer Group.3J5389 Plug.Two 5K9246 Connectors.Two 4K7965 Hose Assemblies.60210 Tee.8M2743 Gauge.5P7486 Valve.

1. Make a restriction to the flow of air thru the radiator or to the flow of coolant thru the engine.

2. Install a probe from the 9S9102 Thermistor Thermometer Group as close as possible to control valve (2).

3. Start the engine. The engine must stop in less than one minute from the time that the temperature of the coolant gets to the opening temperature of the control valve. If it does not stop, do the steps that follow.


SHUTOFF SYSTEM
1. Line (oil supply). 2. Control valve (water temperature). 3. Line (oil return). 4. Oil pressure shutoff.


CONTROL VALVE

4. Stop the engine. Disconnect oil lines (1 and 3) from control valve (2).

5. Remove the control valve and install the 3J5389 plug.

6. Install a 5K9246 connector and 4K7965 hose assembly to both line (1 and 3).

7. Install the 60210 tee on the hose assembly connected to line (1).

8. Install the 8M2743 Gauge on the tee.

9. Connect the last opening of the tee to the other hose assembly with the 5P7486 valve. Make sure the valve is closed.

10. Start the engine. Run the engine at full load rpm.

11. Slowly open the 5P7486 valve. Look at the pressure gauge. Oil pressure shutoff (4) must stop the engine when the oil pressure is between 7 and 9 psi (50 and 60 kPa). If the engine does not stop there is either a restriction in the lines (1 or 3), or the oil pressure shutoff has a failure.

12. Make repairs as necessary and do Step 11 again.

13. When the oil pressure shutoff stops the engine at the correct pressure remove the tools and install control valve (2).

14. Do Steps 1, 2 and 3 again. If the control valve does not cause the engine to stop make a replacement of the control valve.

Electronic Speed Switch (Earlier)


ELECTRONIC SPEED SWITCH (EARLIER)
1. Cover.

Overspeed Adjustment

1. Remove cover (1). Make a temporary connection between terminals 1 and 2 of the speed switch.

2. Make reference to ENGINE SPEED MEASUREMENT. Use one of the methods given to measure the engine speed.

3. Start the engine. Make reference to the overspeed adjustment chart. Slowly increase the speed of the engine. The engine must stop at approximately 75% of the overspeed setting according to the rated full load speed of the engine. For example, if the rated full load speed is 1800 rpm, the engine should stop at 1593 rpm.

4. If the speed switch does not stop the engine at the correct overspeed test rpm remove screw (3). Use a small screwdriver to turn the adjustment screw behind screw (3).

NOTE: Turn the adjustment screw clockwise to increase or counterclockwise to decrease the rpm at which the engine will stop.


ADJUSTMENT LOCATIONS
2. Screw. 3. Screw.

Cranking Adjustment

NOTE: Some earlier electronic speed switches do not have a cranking adjustment.

1. If the starter motor pinion does not move away from the flywheel at 600 rpm remove screw (2). Use a small screwdriver to turn the adjustment screw behind screw (2).

NOTE: Turn the adjustment screw clockwise to increase or counterclockwise to decrease the rpm at which the starter motor pinion moves away from the flywheel.

Electronic Speed Switch (Later)

Overspeed Adjustment

1. Remove screw (4) from the switch. Use a small screwdriver to turn the adjustment screw behind screw (4) 20 revolutions clockwise.


NOTICE

Be ready to stop the engine manually if it has an overspeed condition. Overspeed can cause damage to engine components.


Electronic Overspeed Switch

Wiring Diagram


SHUTOFF SYSTEM WIRING DIAGRAM
1. Oil pressure switch. 2. Water temperature contactor. 3. Time delay switch. 4. Diode assembly. 5. 75% verify button. 6. Reset button. 7. "LED" overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank terminate). 10. Rack solenoid. 11. Magnetic pick-up. 12. Engine flywheel. 13. Voltage input. 14. Locknut. 15. Air gap.

Troubleshooting Procedure (Overspeed)

Troubleshooting Procedure (Crank Terminate)

Procedure A

Overspeed Setting Calibration


ELECTRONIC OVERSPEED SWITCH
5. Verify button. 6. Reset button. 7. "LED" overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank terminate).

1. Remove lockwire and seal from seal screws (8 & 9). Remove seal screw (8) from access hole for overspeed adjustment screw.

2. Use a small screwdriver and lightly turn O.S. (overspeed) adjustment potentiometer twenty turns in the direction of "MAX ARROW" (clockwise).

NOTE: The overspeed adjustment screw is made so that it can not cause damage to the potentiometer or be removed if the adjustment screw is turned too much.

3. Run engine at 75% of desired overspeed setting rpm. Make reference to the SPEED SPECIFICATION CAHRT.

4. With engine at 75% of overspeed setting rpm, push VERIFY pushbutton (5) and hold in. Turn O.S. (overspeed) adjustment potentiometer in the direction opposite of "MAX ARROW" (counterclockwise) slowly until "LED" overspeed light (7) comes on. Engine will shut down if speed switch is connected to the fuel shutoff solenoid and/or air inlet shutoff solenoids.

5. To reset speed switch, push in reset button (6). Air inlet shutoffs must be manually reset.

6. Slowly turn O.S. (overspeed) adjustment potentiometer approximately one turn clockwise and do Steps 3, 4 and 5 again.

NOTE: More adjustment may be needed to get the correct setting. Turn adjustment potentiometer clockwise to increase speed setting and counterclockwise to decrease speed setting. Turn adjustment potentiometer very slowly only a small amount at a time until adjustment is correct.

7. When the speed setting is correct, install seal screw (8) for overspeed adjustment hole and install lockwire and seal.

Procedure B

Magnetic Pickup Adjustment


MAGNETIC PICK-UP
12. Engine flywheel. 14. Locknut. 15. Air gap.

1. Stop engine.

2. Loosen magnetic pick-up locknut (14).

3. Turn the magnetic pick-up clockwise until contact is made with the teeth of the engine flywheel ring gear (12).

4. Turn the magnetic pick-up counterclockwise one-half turn. This will give approximately .022 to .033 in. (0.56 to 0.84 mm) clearance at location (15), between the end of the magnetic pick-up and the teeth of the flywheel ring gear.

5. After the clearance is correct, tighten the magnetic pick-up locknut to a torque of 50 ± 10 lb. ft. (70 ± 14 N·m).

NOTE: Be sure the magnetic pick-up does not turn when the locknut is tightened.

Procedure C

Crank Terminate Speed Adjustment

1. Remove lockwire and seal from seal screws (8 & 9). Remove seal screw (9) from access hole for crank terminate adjustment screw.

2. Use a small screwdriver and lightly turn C.T. (crank terminate) adjustment potentiometer twenty turns in the direction of "MAX ARROW" (clockwise).

NOTE: The crank terminate adjustment screw is made so that it can not cause damage to the potentiometer or be removed if the adjustment screw is turned too much.

3. Turn the crank terminate adjustment potentiometer twelve turns in a direction opposite of "MAX ARROW" (counterclockwise) for an approximate crank terminate setting.

4. Start engine and make a note of the speed at which the starter disengages. See the SPEED SPECIFICATION CHART for the correct crank terminate speed.

NOTE: If setting is not correct do Steps 5 and 6. If setting was correct do Step 7.

5. Stop engine and turn adjustment potentiometer (clockwise to increase and counterclockwise to decrease) crank terminate speed.

6. Start and make a note of the speed at which the starter disengages. If needed, make more small adjustments until the crank terminate speed is correct.

7. Install seal screw (9) for crank terminate adjustment hole and install lockwire and seal.


ELECTRONIC OVERSPEED SWITCH
5. Verify button. 6. Reset button. 7. "LED" overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank terminate).

Procedure D

Overspeed Verify Test

1. Run engine at rated speed, push verify button (5) in for a moment. This will cause the speed switch to activate and shut down the engine.

NOTE: Any time the engine speed is 75% or more of the overspeed setting, the engine will shut down if the verify button is pushed.

EXAMPLE: For an engine with a rated speed of 1500 rpm the overspeed setting is 1770 rpm. The overspeed verify test will shut down the engine at 75% of the overspeed setting of 1770 rpm. In this example 75% of 1770 rpm is 1328 rpm. If the verify button is pushed at an engine speed of 1328 rpm or above the engine will shut down.

The "LED" overspeed light (7) will come on and stay on until the reset button is pushed after an overspeed switch shut down. To restart the engine, push in reset button (6) for a moment. This will reset the speed switch and the rack shutoff solenoid. The "LED" overspeed light (7) will go off. The air inlet shutoff must be manually reset.

NOTE C: To verify overspeed shutdown system operation, push in for a moment the verify push button. The engine must shut down at 75% or more of overspeed setting.

NOTE D: Input Voltage: Maximum 37 VDC Minimum 8 VDC.

NOTE E: The engine overspeed setting rpm is 118% of rated engine rpm.

NOTE F: The magnetic pick-up frequency (HZ) at the overspeed or cranking termination setting is calculated with the formula that follows:

If the rated speed of the engine is other than shown in the chart, the magnetic pick-up frequency for the overspeed setting can be found according to NOTES E and F.

If a 2301 Governor is used, only one magnetic pick-up is needed. Use the magnetic pick-up from the overspeed group. Connect the wires from the magnetic pick-up to the overspeed switch and then connect wires from the speed switch to the 2301 Governor. The overspeed switch can be installed close to the 2301 Governor if needed.

To reset overspeed switch, push in reset button for a moment.

Power Takeoff Clutches

Clutch Adjustment


CLUTCH ADJUSTMENT
1. Clutch lever.

1. Fasten a spring scale to the clutch lever at the distance, from the shaft center, shown in the chart.

2. Look at the spring scale. Keep the angle between the scale and the lever at 90°. Pull the lever with the spring scale until the clutch engages. The pull needed to engage the clutch must be within the range given in the chart.

3. If the pull needed to engage the clutch is not within the range given, make an adjustment as follows:

4. Remove the inspection plate from the clutch housing.

5. Turn the clutch until lock pin (1 or 2) can be seen.

6. Release push type lock pin (1) or pull type lock pin (2). Turn the adjustment ring and check the pull needed to engage the clutch again.

NOTE: Turn the adjustment ring clockwise, as seen from the rear of the clutch, to increase the pull needed. Turn it counterclockwise to decrease the pull needed.


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

Assembly Adjustments

End Play For Shaft Bearings

1. With dry bearings installed on the shaft install the shaft in the housing.

2. Install the retainer. Tighten the retainer (nut or shim type) until 60 lb. in. (7 N·m) is needed to keep the shaft in rotation.

3. With shim type retainer measure the space between the retainer and the carrier. Add .013 in. (0.33 mm) to this measurement. Install this amount of shims between the retainer and the carrier. With nut type retainers turn it out the number of notches shown on the chart.

4. Hit the output end of the clutch shaft with a soft hammer. This will cause the front bearing cup to move against the retainer.

5. Check the shaft end play with a dial indicator. If necessary add or subtract shims; or turn nut to get the correct end play.

Hub Nut Installation

1. Tighten the hub nut to a torque of 30 lb. ft. (40 N·m)

2. Tighten the nut more according to the chart.

Flywheel And Flywheel Housing Alignment

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

Instruments And Gauges

Oil Pressure Sending Units


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

1. Connect the sending unit to a pressure source that can be measured with accuracy.

2. Connect an ohmmeter between fitting (2) and terminal (1).

3. Take resistance readings at the pressure shown in the chart.

4. If a unit does not have the correct resistance readings make a replacement of the unit.

Water Temperature Sending Unit

1. Connect an ohmmeter between terminal (1) and nut (2). Put bulb (3) in a pan of water. Do not let the bulb have contact with the pan.


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

2. Put a thermometer in the water to measure the temperature.

3. Take resistance readings at the temperatures shown in the chart.

4. If a unit does not have the correct resistance readings make a replacement of the unit.

Electric Gauges

1. Put the gauge in position with the letters horizontal and the face 30° back from vertical.


WIRING DIAGRAM FOR TEST
1. Terminal (for test voltage). 2. Test resistance.

2. Connect the gauge in series with the power source and the middle test resistance shown in the chart.

3. Let the gauge heat at the middle resistance for 5 minutes, then check the pointer position for all of the resistances given.

Mechanical Gauges For 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 oil. Do not let the bulb touch the pan. Put a thermometer in the oil 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.


DIRECT READING GAUGE


GAUGE WITH COLOR CODE

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

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