D379, D398, D399 INDUSTRIAL & MARINE ENGINES Caterpillar


D379, D398I on Engine Attachments Testing And Adjusting

Usage:



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. Hydra-mechanical Shutoff Will Not Let Engine Start.
12. Hydra-mechanical Shutoff Will Not Let Engine Run Above 70% of Rated Engine Speed.
13. Hydra-mechanical Shutoff Activates With Engine Oil Pressure and Water Temperature Normal.
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. Woodward UG-8 Governors
a. Engine Speed Does Not Have Stability.
b. Fuel Control Response When the Engine Is Started Is Not Acceptable.
c. Engine Is Slow To Respond To A Change In Speed Setting or Load.
d. Load Sharing Between Paralleled Units Is Not Correct (One unit on zero droop all others on droop).
e. Load Sharing Between Paralleled Units Is Not Correct (all units on droop).
18. Automatic Start/Stop Systems.

Measuring Engine Speed

Measuring Engine Speed

5P2150 Engine Horsepower Meter or4S6553 Instrument Group or1P5500 Portable Phototach Group


5P2150 ENGINE HORSEPOWER METER

The 5P2150 Engine Horsepower Meter can measure engine speed from the tachometer drive on the engine. Special Instruction Form No. SMHS7050 has instructions for its use.

Special Instruction Form No. SEHS7341 is with the 4S6553 Engine Test Group and gives instructions for the test procedure.


4S6553 INSTRUMENT GROUP
1. Differential pressure gauges. 2. Zero adjustment screw. 3. Lid. 4. Pressure gauge. 5. Pressure tap fitting. 6. Tachometer. 7. Manifold pressure gauge.


1P5500 PORTABLE PHOTOTACH GROUP

The 1P5500 Portable Phototach Group can measure engine speed from the tachometer drive on the engine. It also has the ability to measure engine speed from visual engine parts in rotation. Special Instruction Form No. SMHS7015 has instructions for its use.

Pierce Output Shaft Governor

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

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

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


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

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

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

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

4. Adjust linkage (3) between terminal lever (1) and servo boost mechanism so that it moves .08 in. (2.0 mm) before lever (13) starts to move. Install linkage (3).

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

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


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

7. Adjust the linkage (12) to fit lever holes when shutoff lever contacts rack stop collar, then increase linkage length .06 in. (1.5 mm) and install the linkage.

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

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

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

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

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


NOTICE

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


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

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

Woodward SGT Governor

Engine Governor Low And High Idle Adjustment

Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE SPEED.

1. Start the engine and run to get the engine to the normal temperature of operation.

2. Move governor control lever (2) against low idle stop (1) and check low idle speed.

NOTE: Make reference to the RACK SETTING INFORMATION for the correct low and high idle speed.

3. If the low idle speed is not correct, loosen locknut and turn low idle stop (1) as needed. Tighten the locknut.


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

4. Move the governor control lever to run the engine at high idle speed, and check the high idle rpm.

5. If the high idle speed is not correct, remove lockwire (3) and loosen the locknut on high idle screw (4). Turn the high idle screw as needed to get the correct high idle speed. Tighten the locknut.

6. Move the governor control lever to change the engine speed and then return to high idle speed and check the high idle speed again.

7. When the high idle speed is correct, install the lockwire and seal.


HIGH IDLE ADJUSTMENT
3. Lockwire. 4. High idle screw.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.


RACK POSITIONING TOOLS
1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.

2. Fasten bracket (1) to the fuel pump housing.


TIMING PIN AND CLAMP
4. Timing pin. 5. Clamp.


BRACKET INSTALLED
1. Bracket.

3. Disconnect the linkage from the governor terminal shaft and move the fuel rack to the FUEL-OFF position. Install dial indicator (2) with contact point (3) on bracket (1).

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange towards the fuel pump housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero. Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the hand. Remove the spacer.


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

5. Move the fuel rack to the FUEL-ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut and move lock free of pin.


COVER FOR RACK ADJUSTING SCREW
7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the pin. Tighten the locknut and install the cover and lockwire and seal.

Engine Governor Speed Droop

1. Cut lockwire and remove the top cover of the governor.

2. Remove flexible coupling.

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

4. Start the engine.

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

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

7. Install lockwire and seal.

Torque Converter Governor High Idle Speed Adjustment

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

1. Start the engine and engage the clutch.

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

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


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

Torque Converter Governor Speed Droop Adjustment

9S240 Rack Positioning Tool Group

1. Install the 9S240 Tool Group.

NOTE: Make reference to FUEL RACK ADJUSTMENT for WOODWARD SGT GOVERNORS for installation instructions of the 9S240 Tool Group.

2. Cut the lockwire and remove the top cover of the governor.

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

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

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

6. Install lockwire and seal.

Govenror Linkage Adjustment

1P2385 Protractor Tool

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.
II. Horizontal or level to lever angle.
III. 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.

1. Move lever (1) and lever (3) clockwise to the angles shown.

2. Adjust the length of linkage (2) to fasten to the outside holes of levers (1) and (3).


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

Woodward UG8 Dial Governor

Compensating Adjustment

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

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


UG8 DIAL GOVERNOR
1. Nut. 2. Compensation pointer. 3. Plug.

1. Loosen the nut that holds the compensation pointer and move the pointer up as far as it will go. Tighten the nut.

2. Remove the plug from the base of the governor.

3. Use a wide blade screwdriver and engage the wide screwdriver slot in the needle valve. Turn the needle valve three or more turns in a counterclockwise direction.

4. Let the engine surge for approximately 30 seconds to help remove air from the governor.

5. Loosen the nut that holds the compensation pointer and move the pointer down as far as it will go. Tighten the nut.

6. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

7. Check the number of turns the needle valve is open. To find the number of turns the needle valve is open, close the valve completely and make a note of the number of turns needed to close the valve.

8. Open the needle valve to the same position at which the engine did not surge.

9. Move the governor linkage to change the engine speed. If the engine does not surge, and the needle valve is 1/2 to 3/4 of a turn open, the governor adjustment is correct. Install the plug in the base. If the needle valve is more than 3/4 of a turn open, do the steps that follow.

10. Loosen the nut that holds the compensation pointer and move the pointer up two marks on the pointer scale.

11. Turn the needle valve three or more turns in a counterclockwise direction.

12. Let the engine surge for approximately 30 seconds to help remove air from the governor.

13. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

14. Check the number of turns the needle valve is open. To find the number of turns the needle valve is open, close the valve completely and make a note of the number of turns needed to close the valve.

15. Open the needle valve to the same position at which the engine did not surge.

16. Move the governor linkage to change the engine speed.

If the engine does not surge, and the needle valve is 1/2 to 3/4 of a turn open, the governor adjustment is correct. Install the plug in the base. If the needle valve is more than 3/4 of a turn open do Steps 10 thru 16 again.

A needle valve that is opened less than 1/2 turn will cause the engine to be slow to return to normal speed after a load change.

If the compensation pointer is too far toward the maximum position, the engine speed change will be too great when the load changes.

High Idle Speed Adjustment

Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE SPEED.

1. Start the engine and run to get the engine to the normal temperature of operation.

2. Use synchronizer control knob (5) to adjust the engine speed and check the high idle speed stop adjustment.


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

3. If the high idle speed is not correct, remove the dial plate.

NOTE: Make reference to the RACK SETTING INFORMATION for the correct high idle speed.

4. Loosen the setscrew on synchronizer indicator knob (7), remove tapered pin if equipped and remove the knob.

5. Pull gear (6) out of mesh with idler gear (2). Turn synchronizer control knob (5) until the correct high idle speed is reached.

6. To set the high idle speed stop, turn gear (6) clockwise until the stop pin on the gear makes contact with idler gear (2). Push gear (6) into mesh with idler gear (2).

7. Turn the synchronizer control knob counterclockwise to change the engine speed. Now turn the knob to the high idle stop and check the high idle adjustment.

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

NOTE: Low idle speed is not adjustable, but will change as high idle adjustment is made. If low idle is not correct, an increase in high idle speed will increase low idle speed, and a decrease in high idle speed will decrease low idle speed.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.


RACK POSITIONING TOOLS
1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.


TIMING PIN AND CLAMP
4. Timing pin. 5. Clamp.

2. Fasten bracket (1) to the fuel pump housing.


BRACKET INSTALLED
1. Bracket.

3. Turn the governor load limit knob to ten and install dial indicator (2) with contact point (3) on bracket (1).


NOTICE

Do not force the governor linkage toward increased fuel unless the load limit knob is turned to TEN. The result will be damage to the governor.



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

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange toward the fuel pump housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero. Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the hand. Remove the spacer.

5. Use the lever on the governor terminal shaft to move the fuel rack to the FUEL ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut and move lock free of pin.


COVER FOR RACK ADJUSTING SCREW
7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the pin. Tighten the locknut and install the cover and lockwire and seal.

Governor Linkage Adjustment

1P2385 Protractor Tool.

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.
II. Horizontal or level or lever angle.
III. 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.

1. Turn governor terminal shaft to the FUEL-OFF position and install lever (1) on the shaft at the angle shown.

2. Install lever (3) with the rack in the FUEL-OFF position at the angle shown.

3. With both levers at the FUEL-OFF position, adjust linkage (2) and install on the levers.


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

Woodward UG8 Lever Governor

Compensating Adjustment

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

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


UG8 LEVER GOVERNOR
1. Nut. 2. Compensation pointer. 3. Plug.

1. Loosen the nut that holds the compensation pointer and move the pointer up as far as it will go. Tighten the nut.

2. Remove the plug from the base of the governor.

3. Use a wide blade screwdriver and engage the wide screwdriver slot in the needle valve. Turn the needle valve three or more turns in a counterclockwise direction.

4. Let the engine surge for approximately 30 seconds to help remove air from the governor.

5. Loosen the nut that holds the compensation pointer and move the pointer down as far as it will go. Tighten the nut.

6. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

7. Check the number of turns the needle valve is open. To find the number of turns the needle valve is open, close the valve completely and make a note of the number of turns needed to close the valve.

8. Open the needle valve to the same position at which the engine did not surge.

9. Move the governor linkage to change the engine speed. If the engine does not surge, and the needle valve is 1/2 to 3/4 of a turn open, the governor adjustment is correct. Install the plug in the base. If the needle valve is more than 3/4 of a turn open, do the steps that follow.

10. Loosen the nut that holds the compensation pointer and move the pointer up two marks on the pointer scale.

11. Turn the needle valve three or more turns in a counterclockwise direction.

12. Let the engine surge for approximately 30 seconds to help remove air from the governor.

13. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

14. Check the number of turns the needle valve is open. To find the number of turns the needle valve is open, close the valve completely and make a note of the number of turns needed to close the valve.

15. Open the needle valve to the same position at which the engine did not surge.

16. Move the governor linkage to change the engine speed.

If the engine does not surge, and the needle valve is 1/2 to 3/4 of a turn open, the governor adjustment is correct. Install the plug in the base. If the needle valve is more than 3/4 of a turn open do Steps 10 thru 16 again.

A needle valve that is opened less than 1/2 turn will cause the engine to be slow to return to normal speed after a load change.

If the compensation pointer is too far toward the maximum position, the engine speed change will be too great when the load changes.

Low And High Idle Speed Adjustment

Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE SPEED.

1. Start the engine and run to get the engine to the normal temperature of operation.


LOW AND HIGH IDLE ADJUSTMENT
1. Low idle adjustment screw. 2. Locknut. 3. High idle adjustment screw. 4. Locknut. 5. Governor speed adjusting lever.

2. Move the governor speed adjusting lever (5) to run the engine at high idle speed. Loosen locknut (4) and turn high idle adjustment screw (3). Turn adjustment screw (3) clockwise to decrease engine speed and counterclockwise to increase engine speed.


LOW AND HIGH IDLE STOP LEVERS
6. Low idle stop lever. 7. High idle stop lever.

3. After the high idle speed has been adjusted, tighten the locknut and check high idle speed again.

NOTE: Make reference to the RACK SETTING INFORMATION for the correct low and high idle speed.

4. Move the governor speed adjusting lever (5) to run the engine at low idle speed. Loosen locknut (2) and turn low idle adjustment screw (1). Turn adjustment screw (1) clockwise to increase low idle speed and counterclockwise to decrease low idle speed.

NOTE: If the high idle stop lever (7) or the low idle stop lever (6) are removed, mark the levers and the shaft so that the levers can be installed in the correct location.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.


RACK POSITIONING TOOLS
1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.


TIMING PIN AND CLAMP
4. Timing pin. 5. Clamp.

2. Fasten bracket (1) to the fuel pump housing.


BRACKET INSTALLED
1. Bracket.

3. Disconnect the linkage from the governor terminal shaft and move the fuel rack to the FUEL-OFF position. Install dial indicator (2) with contact point (3) on bracket (1).

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange towards the fuel pump housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero. Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the hand. Remove the spacer.


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

5. Move the fuel rack to the FUEL-ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut and move lock free of pin.


COVER FOR RACK ADJUSTING SCREW
7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the pin. Tighten the locknut and install the cover and lockwire and seal.

Speed Droop Adjustment

Adjustment for Zero Droop

8S2328 Dial Indicator Group.5P7264 Indicator Contact Point Group.

1. Disconnect linkage from governor terminal lever (4).

2. Remove cover from the top of governor.


DIAL INDICATOR INSTALLED
1. Speeder plug. 2. Bracket. 3. Droop cam. 4. Governor terminal lever. 5. Screw.

3. Install 3S3269 Contact Point 1.00 in. (25.4 mm) long on the dial indicator and install as shown with the contact point on bracket (2) of speeder plug (1). Adjust the dial of the indicator to zero.

4. Move the governor terminal lever from the maximum position to the minimum position. The dial indicator must read .000 to .002 in. (0.00 to 0.05 mm) for zero droop.

5. If the droop adjustment is not correct, loosen screw (5) and move droop cam (3). Tighten screw (5). Move droop cam (3) toward speeder plug (1) to increase droop, and away from the speeder plug to decrease droop.

6. Check the speed droop adjustment again with the dial indicator.

Adjustment for Positive Droop

1. Remove the cover from the top of the governor.

2. Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE SPEED.

3. Loosen screw (5) and move droop cam (3) on droop lever (6) to get distance (A) for the droop percentage needed. See the chart for Speed Droop to get the dimension needed.


SPEED DROOP ASSEMBLY
3. Droop cam. 5. Screw. 6. Droop lever. A. Speed droop setting.

NOTE: Dimension (A) is an approximate dimension. The final adjustments must be determined with the engine running.

4. Start the engine and get to the normal temperature of operation.

5. Put a load on the engine to get maximum full load. Make a note of the full load rpm.

6. Remove all load from the engine and make a note of the no load high idle rpm.

7. Find the difference of the no load high idle rpm and the full load rpm. Divide the difference by the full load rpm and multiply times 100. The result is the percent of speed droop.

8. If the speed droop is not correct, stop the engine and move droop cam (3) toward speeder plug (1) to increase speed droop, or move away from the speeder plug to decrease speed droop.

9. Do Steps 4 thru 8 to check the speed droop and adjust again if needed.

Governor Linkage Adjustment

1P2385 Protractor Tool

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.
II. Horizontal or level to lever angle.
III. 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. Extension arm aligned with lever. G. Extension arm aligned with lever. H. Plate edge aligned with second lever. I. Angle setting indicator.

1. Turn governor terminal shaft to the FUEL-OFF position and install lever (1) on the shaft at the angle shown.

2. Install lever (3) with the rack in the FUEL-OFF position at the angle shown.

3. With both levers at the FUEL-OFF position, adjust linkage (2) and install on the levers.


GOVERNOR LINKAGE ADJUSTMENT (TYPICAL ILLUSTRATION)
1. Governor lever. 2. Linkage. 3. Lever.

Woodward EG-3P Actuator

There are no inside adjustments on the EG-3P Actuator. The low and high idle adjustments are made on the control panel.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.


RACK POSITIONING TOOLS
1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.


TIMING PIN AND CLAMP
4. Timing pin. 5. Clamp.

2. Fasten bracket (1) to the fuel pump housing.

3. Disconnect the linkage from the actuator terminal shaft and move the fuel rack to the FUEL-OFF position. Install dial indicator (2) with contact point (3) on bracket (1).


BRACKET INSTALLED
1. Bracket.

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange towards the fuel pump housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero. Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the hand. Remove the spacer.


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

5. Move the fuel rack to the FUEL-ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut and move lock free of pin.


COVER FOR RACK ADJUSTING SCREW
7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the pin. Tighten the locknut and install the cover and lockwire and seal.

Actuator Linkage Adjustment

1P2385 Protractor Tool.

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.
II. Horizontal or level to lever angle.
III. 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. Extension arm aligned with lever. G. Extension arm aligned with lever. H. Plate edge aligned with second lever. I. Angle setting indicator.

1. Turn actuator terminal shaft to the FUEL-OFF position and install lever (1) on the shaft at the angle shown.

2. Install lever (3) with the rack in the FUEL-OFF position at the angle shown.

3. With both levers at the FUEL-OFF position, adjust linkage (2) and install on the levers.


ACTUATOR LINKAGE ADJUSTMENT
1. Actuator lever. 2. Linkage. 3. Lever.

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 revolution. This will make clearance dimension (1) .022 to .030 in. (0.56 to 0.76 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 replacement of the magnetic pickup.

Woodward EG-3P Governor Actuator

Check for Actuator Coil Resistance

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".


EG-3P ACTUATOR

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 system 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. 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 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.

Governor Air Actuators

2N6006 Actuator

Air Pressure Adjustment

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


ACTUATOR LINKAGE
1. Linkage.

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

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

4. Stop the engine.

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


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

6. Start the engine.

7. Check the air pressure to the actuator. Minimum air pressure at high idle must be 65 psi (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 (70 kPa).

NOTE: If plunger (6) moves at less than 10 psi (70 kPa) make the preload higher. If more than 10 psi (70 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 (70 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.

Setting Low Idle Stop


ACTUATOR LINKAGE ADJUSTMENT
1. Linkage.

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

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

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

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

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

Setting High Idle Stop

1. Warm up engine.

2. Remove two setscrews (9) 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.

1N9318 and 7L135 Actuators

Air Pressure Adjustment


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

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

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

3. Stop the engine.

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

5. Start the engine.

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

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

8. Move the actuator air control lever (2) slowly to the high idle position. Look at the plunger (4). The plunger must start to move at 10 psi (70 kPa) air pressure.

NOTE: If plunger (4) moves at less than 10 psi (70 kPa), make the preload higher. If more than 10 psi (70 kPa) air pressure is needed to move the plunger, make the preload lower.

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

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

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

3N9125 Actuator

Linkage Adjustment

1. Adjust rod end (4) to get dimension (A).

2. Move governor lever (2) counterclockwise until contact is made with the low idle stop.

3. Adjust linkage (1) to fit between rod end (4) and governor lever (2).

4. Put air pressure to the actuator until governor lever (2) makes contact with the high idle stop. Loosen the locknut and turn stroke stop (3) until contact is made with actuator piston. Tighten locknut.


3N9125 ACTUATOR
1. Linkage. 2. Governor lever. 3. Stroke stop. 4. Rod end. A. 4.00 in. (101.6 mm)

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 spring.

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 [Dimension 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.

Rack Shut-Off Solenoid

The governor plunger shaft initial adjustment of distance from shaft shoulder-to-plate should be .70 in. (17.8 mm).

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


PLUNGER SHAFT ADJUSTMENT
1. Shoulder-to-plate distance .70 in. (17.8 mm). 2. Effective travel .62 in. (15.7 mm). 3. Starting position of plunger plate from mounting flange is .44 in. (11.2 mm) to measure effective travel of plunger.

Shut-Off Valve (Water Temperature)

3J5389 Plug.8B4509 Connector.3B9388 Connector.9M6543 Hose Assembly.4D6949 Hose Assembly.3B7764 Reducing Bushing.Heat Sink.

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

1. Remove oil lines.

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

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

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


SHUT-OFF VALVE (WATER TEMPERATURE)

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

6. Install a new valve if necessary.

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

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).

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).


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

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.


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

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 pressure 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

Power Take-Off Clutches

Clutch Adjustment

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

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


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

Assembly Adjustments

Tighten hub nut to torque of 30 lb. ft. (40 N·m) to remove all clearance between parts, then tighten additional amount as shown in chart.

Clutch Shaft Seal Wear Sleeve Installation

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


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

Shaft Bearing End Clearance

Tighten adjusting nut to remove all clearance and seat bearing cups. At this point shaft should turn with dry bearing at torque of 60 lb. in. (6.8 N·m) in addition to seal drag. Then back off the adjusting nut the number of notches indicated in the chart and install the lock. Drive the front bearing cup to the front by striking the output end of the shaft with a soft hammer. The end clearance should now be as indicated in the chart.

Where shim adjustment is used, tighten the retainer without shims until shaft turns with dry bearings at torque of 60 lb. in. (6.8 N·m) in addition to seal drag. Measure the space between the retainer and carrier and add .013 in. (0.33 mm) to this measurement. Remove the retainer, then install shims and retainer and cap screws with locks. Drive the front bearing cup to the front by striking the output end of the shaft with a soft hammer. The end play should now be .006 to 010 in. (0.15 to 0.25 mm).

Clutch and Mounting Adjustment Check

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

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 for D379, D398 and D399 Engines.

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 1200 rpm the overspeed setting is 1416 rpm. The overspeed verify test will shut down the engine at 75% of the overspeed setting of 1416 rpm. In this example 75% of 1416 rpm is 1062 rpm. If the verify button is pushed at an engine speed of 1062 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.

Caterpillar Information System:

D379, D398, D399 INDUSTRIAL & MARINE ENGINES Systems Operations D379, D398, D399 I & M Engine Attachments
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Contactor Switch For Oil Pressure
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Contactor Switch For Temperature
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Contactor Switch For Overspeed
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Electric Tachometer
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Pressure Switches
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Sending Units For Oil Pressure
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Sending Unit For Water Temperature
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Gauges For Water Temperature
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Gauges For Gear Oil Pressure
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Gauges For Engine Oil Pressure
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Mechanical Gauges
D379, D398, D399 INDUSTRIAL & MARINE ENGINES General Instructions
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Fuel Transfer Pump
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Fuel Priming Pump
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Water Temperature Regulators
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Expansion Tank (Marine Engines)
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Fuel Filter Housing
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Oil Filter Housing
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Sea Water Pump
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Vibration Damper (D398 and D399)
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Crankshaft Front Seal Ring And Thrower
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Crankshaft Front Seal (Lip Type) And Wear Sleeve
D379, D398, D399 INDUSTRIAL & MARINE ENGINES Service Meter And Tachometer Drive
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