D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Caterpillar


Testing And Adjusting

Usage:



Problem Solving - Index

1. Water Temperature Contactor Switch Fails to Signal Shutoff.
2. Water Temperature Contactor Switch Signals Shutoff at Low Temperature.
3. Oil Pressure Contactor Fails to Signal Shutoff.
4. Overspeed Contactor Switch Fails to Signal Shutoff.
5. Overspeed Contactor Switch Signals Shutoff at Low Speed.
6. Rack Solenoid Fails to Shutoff Engine.
7. Unstable Governor (Woodward PSG).
8. Clutch Slips, Heats or Lever Disengages.
9. Clutch Shaft End Play Excessive.
10. Gas Supply Line Solenoid Valve Fails to Close.
11. Instrument Panel Gauge Switches Fail to Stop Engine.
12. Instrument Panel Gauge Switches Prevent Engine Start.
13. Oil Pressure Shutoff Prevents Engine Starting and Running.
14. Output Shaft Load Causes Engine Speed To Drop Rapidly.
15. Output Shaft Governor Surges Under A Load.
16. Output Shaft Governor Surges Under No Load.
17. Output Shaft Unloading Causes Engine Speed to Increase Excessively.

Woodward PSG Governor

Fuel System Adjustments


NOTICE

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


Fuel Rack Setting (Diesel Engines)

9S240 Rack Positioning Tool Group.8S7115 Wire.8S8159 Seals. 8S8157 Sealing Tool.1P2385 Protractor Tool.


PARTS OF 9S240 RACK POSITIONING TOOL GROUP
1. 8S4627 Circuit Tester. 2. 9S8518 Plug. 3. 9S8521 Rod. 4. 9S215 Dial Indicator. 5. 9S7350 Rack Positioning Bracket Group.

Either 9S7350 or 9S238 Rack Positioning Bracket Group makes it possible to set the rack, or measure rack position, during normal operation of the engine. The ability to observe rack position during operation, can provide most of the needed data to determine actual horsepower output and diagnose the cause for lack of power.

1. Refer to the RACK SETTING INFORMATION to obtain the correct rack setting dimension.

2. Disconnect the governor control linkage, so the governor control lever can be moved throughout its entire travel.

3. Remove the fuel rack cover and gasket from the front of the flange of the accessory drive housing.

4. Install rack positioning bracket group and dial indicator, over the opening for fuel rack cover on front flange of accessory drive housing.

5. Place spacer (6) over the rod in the bracket. Adjust the dial on the indicator to read zero when the hole attachment (7) is against the rod and the rod is against the spacer.


DIAL INDICATOR ADJUSTED TO ZERO READING (Typical Example)
6. Spacer. 7. Hole attachment.

6. Rotate the governor control lever in the fuel-on direction until the rack stop adjusting screw is contacted. Rack setting can be read at this time on the 9S215 Dial Indicator.


NOTICE

Before starting the engine be sure the rack can be moved throughout its entire length of travel.


7. To adjust the rack setting, break the seal on the rack stop adjusting screw cover, remove the cover and loosen locknut (9). With a screwdriver, adjust screw (8) clockwise to decrease rack travel. Hold the lever (10) so the rack stop screw is contacted when reading the rack travel on the 9S215 Dial Indicator.

8. After the rack stop screw is properly adjusted, tighten locknut (9), install cover and seal.


ADJUSTING RACK SETTING (D330C and D333C Engines Illustrated)
8. Rack stop adjusting screw. 9. Locknut. 10. Lever.

Governor Linkage Adjustment

Illustrated here are three basic usages of 1P2385 Protractor Tool


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.

D330C and D333C Engines

1. With engine stopped, remove the rod (2) and disconnect spring (4).

2. Assemble lever (3) on the shaft and hold the lever at an 8° angle from vertical as shown.

3. Install and adjust rod (2) so lever (1) is at an angle of 30° from vertical as shown. Install the spring.


LINKAGE ADJUSTMENT MEASUREMENTS [Dimension in inches (mm)]
1. Governor control lever. 2. Rod. 3. Lever. 4. Spring.

D334 Engine

1. With engine stopped, disconnect the linkage rod (2) from lever (1).

2. Move lever (3) counterclockwise as far as possible to shutoff position.

3. Adjust the length of rod (2) and install it so lever (1) makes a 15° angle from vertical as shown.


LINKAGE ADJUSTMENT MEASUREMENTS (Earlier) [Dimension in inches (mm)]
1. Governor lever. 2. Rod. 3. Lever.


LINKAGE ADJUSTMENT MEASUREMENTS (Later)
1. Governor lever. 2. Rod. 3. Lever.

G333C Engine

1. With engine stopped, disconnect linkage rod (2) from lever (3). Disconnect spring (4).


LINKAGE ADJUSTMENT MEASUREMENTS [Dimension in inches (mm)]
1. Throttle plate shaft lever. 2. Rod. 3. Governor lever. 4. Spring.

2. With carburetor throttle plate in the closed position, drill and pin lever (1) in position, on carburetor throttle shaft, 45° from vertical as shown.

3. Attach governor lever (3) to terminal shaft 18° from vertical as shown when shaft is in shut off position.

4. Install and adjust rod (2) so both lever angles remain as mentioned above.

5. Install the spring.

Installation Adjustments

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

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


INSTALLATION ADJUSTMENTS (D330C and D333C Engines Illustrated)
1. Knurled knob. 2. Lever.


INSTALLATION ADJUSTMENTS (G333C Engine Illustrated)
2. Lever.

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


COMPENSATING NEEDLE VALVE
3. Location of needle valve.

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

4. Test action by moving lever (2) manually to override governor control. Release the lever and engine should return promptly to original steady speed with only a small overshoot.

Low and High Idle Adjustment

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

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

1. Install an accurate tachometer.

2. Loosen the locknut and screw (2).

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

4. Tighten the locknut.


LOW AND HIGH IDLE ADJUSTMENTS (D330C and D333C Engines Illustrated)
1. Knurled knob. 2. Stop screw.

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

Speed Droop Adjustment

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


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

1. Loosen clamp screw (1).

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

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

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

Pilot Valve Plunger Central Adjustment

1P87 Adjusting Wrench.

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


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

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

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

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

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


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


HOLDING SPRING SEAT WITH 1P87 ADJUSTING WRENCH TO MAKE ADJUSTMENT

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

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

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

Output Shaft Governor

Testing And Adjusting

9S8521 Rod.9S8518 Plug.8S4627 Circuit Tester.1P2385 Protractor Tool.

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

The torque converter output shaft maximum speed is either a high speed setting or a low speed setting, which is determined by changing the position of the speed change lever (4), normally 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 ascertain the maximum permissible output shaft speed for the driven equipment.

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


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

1. Disconnect the adjustable rod (3) from the terminal lever (1) and the other adjustable linkage (15) between the servo mechanism and standard governor.

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

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

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

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

5. Retract the speed limiter with a 9S8521 Rod and 9S8518 Plug and move the governor control to full speed position.

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


GOVERNOR LINKAGE ADJUSTMENT
11. Insulated terminal. 12. Stop collar. 13. Shutoff internal lever. 14. Shutoff shaft external lever. 15. Linkage. 16. Servo boost output lever.

7. Adjust the linkage (15) to fit lever holes when shutoff external lever contacts rack stop collar (12). Then increase linkage (15) length .06 in. (1,52 mm) and install the linkage.

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

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


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.

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

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

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

12. If a surging condition is encountered, back off the nut on the rate adjusting screw one full turn. Turn the low speed adjusting screw 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.

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

Starting Systems

Air Starting

Pressure Regulating Valve Adjustments

The regulator can be adjusted by turning the adjusting screw (1) located on top of the chamber. Disconnect the regulator from the control valve. With the regulator connected to the air supply line, connect an 8M2885 Pressure Gauge to the regulator outlet (3) and check the pressure. In cold weather it may be necessary to raise the pressure delivered by the regulator. The pressure should not exceed 90 to 110 psi (6,2 to 7,7 kg/cm2). After the pressure has been set, install the regulator.


PRESSURE REGULATING VALVE
1. Adjusting screw. 2. Regulator inlet. 3. Regulator outlet.

Air Starting Motor Rotor Assembly End Clearance Adjustment


ROTOR ASSEMBLY END CLEARANCE ADJUSTMENT
1. Rotor. 2. Spacer. 3. End plate. 4. Bearing. 5. Shims.

Place shims (5) between the bearing (4) and spacer (2) so there will be .002 in. (0,05 mm) clearance between the rotor (1) and the end plate (3).

Heating the gear will aid installation. Tighten the nut and check the adjustment. Measure end play between rotor and end plate assembly by using a thickness gauge.

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


CHECKING ROTOR SHAFT END PLAY

Hydraulic Starting

Hydraulic starting system adapting hardware parts and main components are serviced. The service information and tools for main components are available from manufacturer of the components.

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

Do not attempt to disconnect lines or remove plugs in the system until the oil pressure in the system has been exhausted. Failure to heed this warning can result in the sudden release of oil under pressure as high as 1625 psi (114,2 kg/cm2).

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

Automatic Start-Stop

The system engine mounted controls can be tested and adjusted as indicated in the topic SAFETY DEVICES. To start the engine to make on engine test of engine mounted controls, place a "jumper" wire between 7A and 7B terminals in the transfer switch or use the switch located on the transfer switch panel. This actually simulates a commercial power failure and will in turn test the operation of the automatic start-stop control panel.

If the transfer switch or control panel is suspected of faulty operation, contact transfer switch manufacturer for further information on testing and adjusting.

Safety Devices

Safety shutoff controls are for the protection of the engine. To ensure they are working properly, the controls must be checked at least twice a year.

Water Temperature Contactor Switch

Fabricated heat sink.2F7112 Thermometer.3J5389 Plug.

1. Fabricate a heat sink as illustrated. Material can be brass, steel or cast iron. Drill a 23/32in. hole through the heat sink and tap for 1/2 in. NPT.


HEAT SINK FOR TESTING [Dimensions in inches (mm)]

2. Mark wiring connections to contactor terminals and disconnect wiring. C and NO terminals are normally used.


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

3. Remove the contactor and plug the opening with 3J5389 Plug. Install the contactor in the heat sink.

4. Reconnect the contactor to the wiring to check the entire system; contactor, wiring and shutoff solenoid.

NOTE: If this cannot be done, use an ohmmeter or circuit tester across the contactor terminals to check the setting.

5. If the contactor is reconnected, start the engine and run it at low idle. The fuel pressure switch will complete the circuit to the shutoff solenoid.

6. Immerse heat sink and sensing element in water. Heat the water, and, by using an accurate thermometer, note the temperature at which engine shuts down (or continuity is indicated). For the standard sea level contactor the temperature should be 209 ± 1° F (98 ± 1° C). Allow water to cool. The contactor will reset automatically when the temperature lowers approximately 12° F (8° C) from the shutdown temperature.

7. Install new contactor if necessary.

NOTE: To test the system beyond the contactor, a jumper can be touched between the C and NO contactor terminal to simulate contactor operation.

Alternate method of checking water temperature contactors.

1. Disconnect the wires from the contactor.

2. Connect ohmmeter or continuity tester across the contactors.

3. Start the engine and cause it to overheat by reducing coolant flow or air flow through radiator. Do not exceed the maximum temperature by more than 3°.


NOTICE

If the engine cannot be overheated safely, the temperature contactor will have to be checked off the engine.


4. Observe ohmmeter or continuity tester to see when the contactor shows continuity. The temperature at which this occurs should be 209° ± 1° F (98° ± 1° C) for the standard sea level contactor.

5. Allow engine to cool and then stop engine.

6. Install new contactor if required and connect wires to water temperature contactor.

Oil Pressure Contactor Switch

8M2743 Gauge,3B6483 Cap,two 3B9389 Shutoff cocks,three 3B7263 Pipe Nipples,three 1F9369 Tees,two 3B7733 Nipples,8S4627 Circuit Tester, and hoses with fittings for adapting as illustrated.

1. Disconnect oil supply line to contactor and install pressure gauge as shown.

2. With both shutoff cocks closed, start the engine and run at low idle.

3. Open supply shutoff cock (6) slowly and note pressure at which contactor switch opens. On automatic start-stop this should be at 22 psi (1,5 kg/cm2) when the starter magnetic switch is de-energized and where contactor has control knob, contacts should open at 12 psi (0,8 kg/cm2).

NOTE: Connect ohmmeter of circuit tester if desired.


TESTING OIL PRESSURE CONTACTOR SWITCH
1. 8M2743 Gauge. 2. 3B7263 Nipples. 3. 3B6483 Cap. 4. Oil supply line. 5. 3B9389 Shutoff cock (oil dump line). 6. 3B9389 Shutoff cock (supply line). 7. Oil dump line hose. 8. 1F9369 Tee. 9. 3B7733 Nipple. 10. Oil pressure contactor.

4. Close shutoff cock (6) and slowly lower pressure by use of shutoff cock (5) until contactor switch closes. Closing pressure setting should be on automatic start-stop contactors 10 psi (0,7 kg/cm2) and where contactor has control knob, contacts should open at 8 psi (0,6 kg/cm2).

5. Adjust or replace contactor if necessary. To adjust, decrease tension on main spring (12) by turning adjusting screw (11) counterclockwise. Open and close shutoff cocks until pressure on gauge indicates desired closing pressure. Turn knob to RUN position, if so equipped; turn adjusting screw (11) clockwise just to point where contacts close.


OIL PRESSURE CONTACTOR
11. Adjusting screw. 12. Main spring.

6. Repeat Step 4. Engine should shut down or alarm sound at closing pressure setting.

7. To test only the system beyond the contactor:

a. On contactors with control knob, turn the knob to the ON position.

b. On all other type oil pressure contactors, jumper between the C and NC terminals simulates contactor operation.


WIRING CONNECTIONS
A. White tab connect automatic start-stop TS1-1 (starter magnetic switch). B. Red tab connect battery or TS1-7. C. Blue tab connect rack solenoid or TS1-8.

Adjusting Micro Switch Type

1. Adjust or replace contactor if necessary. To adjust, loosen lock nut (16), increase or decrease tension on spring (15) by turning adjusting screw (14). Open and close shutoff cocks until pressure on gauge indicates desired pressure for contact action.


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

2. Adjust spring tension so switch contact button (17) acts at the desired pressure shown in the chart.

When equipped with a set-for-start button, (13) the button will be released at the rising pressure shown in the chart.


WIRING CONNECTION (Micro Switch Type)
D. Terminal B (normally closed) connect rack solenoid or TS1-8. E. Terminal W (normally open), connect automatic start-stop TS1-1 (starter magnetic switch). F. Terminal R (common), connect battery or TS1-7.

Overspeed Contactor Switch

4S6553 Instrument Group.


NOTICE

Only trained personnel should attempt to alter the high idle rpm. The low and high idle rpm for this engine is listed in the RACK SETTING INFORMATION.



NOTICE

Disconnect or immobilize all driven equipment which could be damaged by 18% overspeed. Disconnect the excitation circuit of an electric set to prevent damaging high voltage.


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

Have some type of emergency device (inlet air shutoff or CO2 fire extinguisher) readily available.

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

1. Install an accurate tachometer on the engine.


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

2. Start engine and increase speed until the overspeed contactor trips and produces shutdown. Shutdown speed setting should be no more than 18% above full load speed. (15% American Bureau of Shipping.) DO NOT exceed 18% of full load speed when making these tests.

NOTE: It will be necessary to break the standard governor seal and back out the high idle adjusting screw (3) to produce shutdown.


WOODWARD PSG GOVERNOR (D330C and D333C Engines Illustrated)
5. Control lever.


WOODWARD PSG GOVERNOR (G333C Engine Illustrated)
5. Control lever.

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

3. Place governor control in low idle position, reset the overspeed contactor by pressing reset button (6) and start engine.

4. Several overspeed shutdowns should be experienced to assure consistent readings.

5. Adjust contactor or install a new one. Adjust contactor trip speed by breaking standard seal, loosening cap lock screws (7), and turning cap clockwise to lower trip speed. Tighten cap lock screws.


OVERSPEED CONTACTOR SWITCH
6. Reset button. 7. Cap lock screws.

6. To test only the system beyond the overspeed switch, a jumper may be used between the C and NO terminals to cause shutdown.

7. Set the governor high idle setting and seal the governor and overspeed contactor.

Rack Shutoff Solenoid

Two types of solenoids are available. One for hydra-mechanical governors and one for Woodward PSG Governors.

The hydra-mechanical governor plunger shaft distance from shaft shoulder-to-plate should be initially set at .70 in. (17,8 mm). For Woodward PSG Governor the shaft shoulder-to-plate initial distance should be 1.25 in. (31,7 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 shutoff position. Current draw should be less than 2 amp.


1. Shoulder-to-plate distance .70 in. (17,8 mm) hydra-mechanical governor, 1.125 in. (31,7 mm) Woodward PSG Governor. 2. Effective travel .62 in. (15,7 mm). 3. Starting position of plunger plate from mounting flange is .44 in. (11,2 mm) to measure effective travel of plunger.

Enclosed Clutch

Clutch Adjustment

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

Clutches use two types of adjustment lock pins. The 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

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), to be sure the sleeve contours blend in with the shoulder fillets (3) on the shaft.

Tighten hub nut to remove all clearance between parts, then tighten 1/6 turn more.


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

Shaft Bearing End Clearance

Tighten adjusting nut to remove all clearance and seat bearing cups. At this point shaft should turn with dry bearing at torque of 60 lb. in. (70,0 cm.kg) in addition to seal drag. Then back off the adjusting nut the number of notches indicated in the charts and install the lock. Drive the front bearing cup to the front by striking the output end of the shaft with a soft hammer. The end clearance should now be as indicated in the chart.

Where shim adjustment is used, tighten the retainer without shims until shaft turns with dry bearings at torque of 60 lb. in. (70,0 cm.kg) in addition to seal drag. Measure the space between the retainer and carrier and add .013 in. (0,33 mm) to this measurement. Remove the retainer, then install shims and retainer and bolts with locks. Drive the front bearing cap to the front by striking the output end of the shaft with a soft hammer. The end play should now be as indicated in the chart.

Installation Adjustment

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

Solid State Ignition

Check the solid state magneto on engine in the same manner as any other magneto, by the intensity of the spark at the spark plug. When testing, remember that the magneto output is effected by the condition of the instrument panel components-magnetic switch, stop switch, oil pressure gauge and water temperature gauge. An overspeed shutoff contactor, and/or gas line solenoid valve connected with the magneto could cause an indication of magneto malfunction.

The 2P2340 Magneto Test Bench can be used to test the magneto before installation on the engine. Special Instructions GEG02059 covers the test bench operation for magneto component testing.


2P2340 MAGNETO TEST BENCH

Timing Magneto To Engine

1. Remove the timing pointer cover from the flywheel housing.

2. Rotate crankshaft in direction of engine rotation until No. 1 piston is coming up on compression stroke.

NOTE: Rotation that is stamped on the magneto name plate indicates magneto rotation.

3. Continue rotating crankshaft until desired timing mark appears directly under flywheel pointer. See Chart of Instructions for Timing Magneto for various conditions such as gas used and compression ratio.

NOTE: After top center (ATC) timing, with engine stopped, is required under some conditions. When earlier flywheels without ATC calibrations are encountered, mark the flywheel .805 in. (20,45 mm) on outside diameter of flywheel for each 5°.


FLYWHEEL TIMING MARKS (Viewed from left side of engine)
1. Flywheel pointer. 2. Calibrations after top center (ATC). 3. Calibration before top center (BTC).

4. With magneto off the engine, remove timing bolt (4) and rotate magneto drive until pulser gear yellow mark or hole appears in center of opening.

5. Position the magneto drive slots in proper position for timing. The drive coupling can be pulled to rear, then positioned and pushed forward into engagement.

6. Install the magneto. The drive tang and slot should engage.


DRIVE TANG AND DRIVE SLOT POSITIONS (Viewed from the rear of the engine)

7. Make final timing adjustment by rotating the magneto at the drive housing mounting and with the use of a timing light when the engine is running at rated speed.


SOLID STATE MAGNETO
4. Timing bolt.

Ignition Transformer

The transformer posts are indicated as positive (+) and negative (-). Transformers for all cylinders have positive (+) posts connected with a wire to the magneto pin connectors marked "G".


TRANSFORMER


NOTICE

Do not pierce the insulation on the high voltage wire to the spark plug. A hole in the insulation will cause misfiring.


Firing Order

The wiring diagrams show the connection of each transformer to the pin connector at the magneto. See the topic WIRING DIAGRAMS.

The firing order is 1, 5, 3, 6, 2, 4, which is the same as for spark gap magnetos.

Caterpillar Information System:

D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Systems Operation-Attachments
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Testing And Adjusting
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Systems Operation
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Shut Off Solenoids
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Starter Solenoids
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Starting Motors
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Alternator Regulators (8L5004 24V, 2N5882 24V, 2N5882 24V, 2N7279 24V, 2N7278 12V, 8L5413 12V And 2N5881 12V)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Alternator Regulators (6L5397 And 6L3432 32V, 2N954 And 6L3412 12V, 6L5657 24V, 6L3434 24V, 6L5658 30V, 6L3430 30V)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Alternators (8L5003 24V, 8L5006 24V, 2N6397 24V, 2N6398 24V, 2N6396 12V, 2N6395 12V, 8L5412 12V And 8L5410 12V)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Alternators (6L6024 And 7L6414 24V, 9L184112V 52A)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Alternators (5L1243 32V And 5L6468 24V)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Crankshaft
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Woodward PSG Governors
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Overspeed Contactor Switch
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Starter Magnetic Switch
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Shutoff Solenoids
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Magnetic Switch
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Oil Pressure Contactor Switches (9F7837 and 8L4537, 9F7837, 8L4537)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Oil pressure Contactor Switches (2N6955, 3N531 and 2N7124, 2N6955 and 3N531, 2N7124)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Hydraulic Starting System
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Air Starting Motor<BR> (7L8425, 8L5052, 6L4532)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Pressure Switches
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Oil Pressure Shutoff<BR> (8L4908)
D330, D333, 3304, 3306 INDUSTRIAL & MARINE ENGINES Starting Air Regulating Valve
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