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 cannot give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.

Troubleshooting Problem List

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. Shutoff Solenoid Fails To Stop Engine.

5. Shutoff Solenoid Prevents Engine Start.

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

7. Clutch Shaft Has Too Much End Play.

8. Clutch Bearings Have Short Service Life.

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

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

11. Mechanical Shutoff Will Not Let Engine Start.

12. Electrical Gauges Give Wrong Readings.

13. Contactor Switch For Overspeed Fails To Activate Shutoff Solenoid.

14. Contactor Switch For Overspeed Activates Shutoff Solenoid At Wrong Speed.

15. PSG Governors.

a. Engine Speed Does Not Have Stability.

b. Vibration At Governor Output Shaft.

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

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

e. No Output From Governor.

f. Engine Will Not Drive Full Rated Load.

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

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

16. Automatic Start/Stop Systems.

Problem 1: Contactor Switch For Water Temperature Does Not Activate Shutoff Solenoid

Probable Cause:

1. Wrong Connections:

Connect battery to C and shutoff solenoid to NO connections. Check connections to other components or make installation of new wiring.

2. Failure Of Shutoff Solenoid:

Check the shutoff solenoid.

3. Low Water Level In Cooling System:

Fill the cooling system.

4. Wrong Setting Of Switch:

Make a test of temperature setting and if necessary install new contactor switch with correct setting. See specifications.

Problem 2: Contactor Switch For Water Temperature Activates Shutoff Solenoid At Wrong Temperature

Probable Cause:

1. Wrong Setting Of Switch:

Make a test of temperature setting and if necessary install new contactor switch with correct setting. See specifications.

Problem 3: Contactor Switch For Oil Pressure Fails To Activate Shutoff Solenoid

Probable Cause:

1. Wrong Connections:

Check connections, wiring and correct where necessary.

2. Wrong Setting Of Switch:

Test contactor switch. If necessary, install new contactor switch.

Problem 4: Shutoff Solenoid Fails To Stop Engine

Probable Cause:

1. Wrong Connections:

Check connections and wiring.

2. Plunger Shaft Adjustment Wrong:

Make adjustment to plunger shaft.

3. Wrong Plunger In Shutoff Solenoid:

Install the correct plunger shaft.

4. Not Enough Plunger Travel:

Make adjustment to plunger shaft or replace solenoid if necessary.

Problem 5: Shutoff Solenoid Prevents Engine Start

Probable Cause:

1. Shutoff Solenoid Does Not Operate Correctly:

Activate to shutoff or activate to run type: Operate the control for the shutoff solenoid. Listen for a noise. A shutoff solenoid makes noise when it works. If it makes noise but the engine still does not start, remove the shutoff solenoid. Try to start the engine. If the engine starts, the shutoff solenoid is either not installed correctly or it is bad. Make reference to Testing And Adjusting.

Problem 6: Clutch Will Not Engage (Slips), Heats Or Lever Moves To Released Position

Probable Cause:

1. Wrong Adjustment:

Make adjustment to clutch engagement lever pull.

2. Alignment Of Flywheel And Flywheel Housing Mounting Face And Bores:

Check and make adjustment to alignment.

Overload On Clutch:

Reduce load or reduce engine speed when engaging clutch.

Problem 7: Clutch Shaft Has Too Much End Play

Probable Cause:

1. Bearing Worn Or Adjustment Wrong:

Replace and/or make adjustment to shaft bearing.

Problem 8: Clutch Bearings Have Short Service Life

Probable Cause:

1. Too Much Bearing Clearance:

Replace and/or make adjustment to shaft bearing.

2. Side Load Too High:

Make a reduction of side load.

Problem 9: Mechanical Shutoff Fails To Stop Engine Because Of Low Oil Pressure

Probable Cause:

1. Plunger Is Held In Normal Run Position Or A Spring Is Broken:

Disassemble and clean parts. Install new parts if needed.

Problem 10: Mechanical Shutoff Does Not Stop Engine When Coolant Temperature Is Too High

Probable Cause:

1. Oil Lines Have A Restriction:

Clean oil lines, make replacements as necessary.

2. Control Valve Does Not Work Correctly:

Clean control valve, make replacement if necessary.

3. Defect In Oil Pressure Shutoff:

Clean oil pressure shutoff. Install new parts if necessary.

Problem 11: Mechanical Shutoff Will Not Let Engine Start

Probable Cause:

1. Control Has Not Been Set For Start:

Set the control for start.

2. Spring Is Broken:

Install new spring.

3. High Water Temperature:

Let engine cool.

Problem 12. Electrical Gauges Give Wrong Readings

Probable Cause:

1. Wrong Connections:

Check wiring connections to be sure they are correct.

2. Sending Units Have A Failure:

Check the sending units and install new ones if necessary.

3. Resistor In 32 Volt Systems Has A Failure:

Install a new resistor.

4. Wrong Sending Unit In System:

Install correct sending unit.

5. Wrong Gauge:

Install correct gauge.

Problem 13: Contactor Switch For Overspeed Fails To Activate Shutoff Solenoid

Probable Cause:

1. Wrong Connection:

Check connections and wiring. Correct where necessary.

2. Wrong Setting Of Switch

Make adjustment to setting or install new contactor switch if necessary. Make reference to Testing And Adjusting.

Problem 14: Contactor Switch For Overspeed Activates Shutoff Solenoid At Wrong Speed

Probable Cause:

1. Wrong Setting:

Make adjustment to setting or install new contactor switch if necessary.

Problem 15a: Engine Speed Does Not Have Stability

Probable Cause:

1. Compensation Needle Valve Opened Too Far:

Adjust the needle valve.

2. Bad Lubrication Oil:

Remove, drain and clean the governor. Make sure air is not held in the oil supply. Change the oil and make a replacement of the filter.

3. Fuel Control Linkage Worn Or Not Correctly Adjusted:

Inspect and adjust the fuel control linkage. Make repairs as necessary.

4. Engine Fuel System Has A Failure:

Use the Fuel System section in Testing And Adjusting as a reference. Make repairs as necessary.

5. Negative Droop Set Into Governor:

Adjust droop setting.

6. Oil Does Not Drain Correctly From The Governor:

Make sure governor drain passages have no restrictions.

7. Buffer Springs Have A Failure:

Make a replacement of the buffer springs.

8. Governor Parts Worn:

Disassemble and inspect pilot valve, power piston, flyweight pins, pin bearings, flyweight toes, flyweight head thrust bearing and centering bearing. Operation of all parts should be smooth and free. Make repairs as necessary.

9. Pilot Valve Not Correctly Adjusted:

Adjust the pilot valve.

Problem 15b: Vibration At Governor Output Shaft

Probable Cause:

1. Rough Governor Drive:

Inspect the gear drive. Make repairs as necessary.

2. Spring Driven Flyweight Head Has A Failure:

Clean and inspect flyweight head. Make repairs as necessary.

3. Gear Drive Not In Correct Alignment:

Make sure governor is installed correctly.

Problem 15c: Fuel Control Response When The Engine Is Started Is Not Acceptable

Probable Cause:

1. Low Governor Oil Pressure:

Remove, drain and clean the governor. Make sure air is not held in the oil supply. Change the oil and make a replacement of the filter.

Inspect the governor oil pressure relief valve. Make replacement if necessary.

Inspect pump check valves (if so equipped). Make replacements if necessary.

Inspect governor oil pump. Make repairs as necessary.

Problem 15d: Engine Has Slow Response In A Change In Speed Setting Or Load

Probable Cause:

1. Compensation Needle Valve Closed Too Far:

Adjust the needle valve.

2. Engine Has An Overload:

Decrease the load.

3. Operation Of Buffer Piston Is Not Smooth:

Remove, drain and clean the governor. Make sure air is not held in the oil supply. Change the oil and make a replacement of the filter.

4. Oil Does Not Drain Correctly From The Governor:

Make sure governor drain passages have no restrictions.

5. Low Governor Oil Pressure:

Remove, drain and clean the governor. Make sure air is not held in the oil supply. Change the oil and make a replacement of the filter.

Inspect the governor oil pressure relief valve. Make a replacement if necessary.

Inspect pump check valves (if so equipped). Make replacement if necessary.

Inspect governor oil pump. Make repairs as necessary.

6. Wrong Buffer Springs In Governor:

Install correct buffer springs.

7. Engine Fuel System Has A Failure:

Use the Fuel System section of Testing And Adjusting as a reference. Make repairs as necessary.

Problem 15e: No Output From Governor

Probable Cause:

1. Bad Lubrication Oil:

Remove, drain and clean the governor. Make sure air is not held in the oil supply. Change the oil and make a replacement of the filter.

2. No Governor Oil Pressure:

Inspect the governor oil pressure relief valve. Make replacement if necessary.

Inspect pump check valves (if so equipped). Make replacements if necessary.

Inspect governor oil pump. Make repairs as necessary.

3. Governor Drive Has A Failure:

Repair the governor drive.

4. Fuel Control Linkage Has A Failure:

Inspect and adjust linkage. Make repairs as necessary.

Problem 15f: Engine Will Not Drive Full Rated Load

Probable Cause:

1. Fuel Control Linkage Not Correctly Adjusted:

Adjust the linkage.

2. Engine Fuel System Has A Failure:

Use the Fuel System section of Testing And Adjusting as a reference. Make repairs as necessary.

3. Low Governor Oil Pressure:

Remove, drain and clean the governor. Make sure air is not held in the oil supply. Change the oil and make a replacement of the filter.

Inspect the governor oil pressure relief valve. Make a replacement if necessary.

Inspect pump check valves (if so equipped). Make replacements as necessary.

Inspect governor oil pump. Make repairs as necessary.

4. Voltage Regulator Does Not Work Correctly:

Adjust or repair the voltage regulator.

Problem 15g: Load Sharing Between Paralleled Units Is Not Correct (one unit on zero droop all the others on droop)

Probable Cause:

1. Droop Setting Is Too Low On Some Units:

Increase droop setting on these units until the load is constant on each droop unit.

2. Different Speed Settings On The Units:

Adjust speed settings on droop units. No load speed on all droop units should be the same.

Problem 15h: Load Sharing Between Paralleled Units Is Not Correct (all units on droop):

Probable Cause:

1. Speed Droop Setting On One Or More Units Is Not Correct:

Adjust droop on each unit to get the desired division of load.

NOTE: Increase droop to decrease load sharing by the unit.

2. Different Speed Settings On The Units:

Adjust the speed settings. No load speed on all units should be the same.

16. AUTOMATIC START/STOP SYSTEM

The charts that follow give some of the problems and probable causes for trouble with automatic start/stop systems.

Governor Air Actuator

Air Pressure Adjustment

Actuator Linkage
(1) Linkage

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

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

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

4. Stop the engine.

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

Adjustment Of Actuator Air Pressure
(2) Air gauge (3) Actuator air control lever (4) Actuator (5) Nut (6) Plunger (7) Screw

6. Start the engine.

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

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

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

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

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

11. Turn screw (7) out until nut (5) can be turned.

12. Turn nut (5) clockwise to make preload higher. Turn nut counterclockwise to make preload lower.

13. When plunger (6) moves at 45 kPa (10 psi) air pressure, turn screw (7) in until the nut cannot be turned.

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

14. Install the linkage between actuator and governor.

Adjustment Of Low Idle Stop

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

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

3. Check the low idle rpm. See the topic Engine Speed Measurement.

4. Stop the engine.

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

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

Low Idle Adjustment
(1) Linkage

Adjustment Of High Idle Stop

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

2. Remove two screws (9). Turn two high idle screws (8) out several turns.

3. Move the governor hand control lever to the high idle position.

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

5. Turn high idle screws (8) in until they just have contact with plunger (6).

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

7. Make the governor high idle 30 rpm higher.

NOTE: Steo 7 lets the actuator control the high idle rpm.

High Idle Adjustment
(3) Actuator air control lever (6) Plunger (8) High idle screws (9) Screw

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

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

10. Check the high idle rpm. If necessary, make adjustments to high idle screws (8) to get the correct rpm.

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

11. When the high idle rpm is correct, install screws (9) to hold the high idle screws in place.

Linkage Adjustment

Actuator Linkage
(1) Angle (2) Rod assembly (3) Lever

1. Install governor control lever (3) so angle (1) between vertical and the centerline of the lever at low idle is 12° ± 5°.

2. Set the air pressure on the actuator at zero. With the governor control lever at low idle adjust rod assembly (2) to fit between the lever and the actuator.

Woodward PSG Governor

Linkage Adjustment

PSG Governor Control Linkage
(1) Rod assembly (2) Lever (3) Lever

1. Make sure levers (2 and 3) are at the SHUTOFF position (fully counterclockwise).

2. With both levers at the SHUTOFF position, adjust rod assembly (1) to fit between them.

3. Check to make sure the linkage operates freely.

Needle Valve Adjustment

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

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

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

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

4. To check the adjustment push lever (1) in the direction of the arrow. This will cause the engine speed to decrease. Release the lever. The engine must return rapidly to the desired speed.

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

PSG Governor
(1) Lever (2) Compensating needle valve

Fuel Rack Setting

6V9128 Rack Position Tool Group.6V3075 Dial Indicator.9S8883 Contact Point; 12.7 mm (.50 in.) long.3P1565 Collet Clamp.6V6019 Timing Pin.

1. Disconnect linkage (1) from governor drive lever (2). This will permit the lever to move freely through its full travel.

2. Remove shutoff solenoid (4), if so equipped.

3. Remove rack setting plug (3) from the injection pump housing.

Governor Linkage (Typical Illustration)
(1) Linkage (2) Governor drive lever

Injection Pump Housing
(3) Rack setting plug (4) Shutoff solenoid

4. Install 6V6019 Timing Pin (5), tapered end out, in the timing plug hole.

5. Remove plug from the injection pump housing.

6. Install a 9S8883 Contact Point on the 6V3075 Dial Indicator. Install 3P1565 Collet Clamp (7) and 6V3075 Dial Indicator (9) as shown.

Rack Setting Pin Installed
(5) 6V6019 Timing Pin (6) Plug

Dial Indicator Installed
(7) 3P1565 Collet Clamp (8) Cover (9) 6V3075 Dial Indicator

7. Move governor drive lever (2) in the FUEL ON direction (clockwise) until the timing pin is engaged in the notch (groove) in the rack.

8. Put the dial indicator on zero. Remove the timing pin.

9. Move governor drive lever (2) in the FUEL ON direction (clockwise) until it stops.

10. Read the measurement on the dial indicator. Look in the Fuel Setting And Related Information Fiche to find the correct measurement for the rack setting.

11. If the measurement on the dial indicator is not correct, do the steps that follow:

a. Remove cover (8) and the washer.

b. Loosen nut (12) until lock (11) is free of pin (10).

c. Turn switch assembly (13), as necessary, to get the correct rack setting. Remember drive lever (2) must be pushed fully clockwise when the dial indicator is read.

NOTE: Turn switch assembly (13) clockwise to decrease rack setting dimension.

NOTE: If pin (10) is not in alignment with one of the notches in lock (11), turn switch assembly (13) to put the nearest notch in alignment with the pin.

d. Tighten nut (12) to a torque of 12 ± 4 N·m (9 ± 3 lb.ft.). Check the adjustment by going through Steps 9 through 11 again.

NOTE: To check for full fuel when the engine is in operation, connect the 8T500 Circuit Tester between the terminal of switch assembly (13) and a good ground. When the rack gets to full fuel the light in the tester will go on.

Fuel Rack Setting
(10) Pin (11) Lock (12) Nut (13) Switch assembly

Adjusting The High Idle Stop

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

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

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NOTICE

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

PSG Governor
(1) Synchronizing motor (2) Knurled knob (3) Locknut (4) Stop screw

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

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

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

Check Speed Droop

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

1. Get the desired speed droop for the application.

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

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

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

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

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

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

Speed Droop Adjustment (Later PSG Governors)

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

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

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

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

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

4. Tighten knob (2) to hold the lever and bracket in position. After an adjustment is made check the speed droop. See Check Speed Droop. Several adjustments may be necessary to get the desired speed droop.

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

Speed Droop Adjustment (Earlier PSG Governors)

6V3075 Dial Indicator5P7285 Adjusting Bracket3P1565 Collet

1. Remove cover (1) from the governor.

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

PSG Governor (Earlier)
(1) Cover (2) Lever (3) Bracket (4) Output shaft lever (5) Spring (6) Pilot valve

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

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

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

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

Speed Droop Adjustment
(3) Bracket (7) Screw (8) Output shaft

NOTE: Zero droop position can be set by the use of a 5P7285 Adjusting Bracket (10), 3P1565 Collet (11) and 6V3075 Dial Indicator (9). Install the bracket and collet on the governor. Install the indicator in the collet. Put the tip of the indicator on lever (2) above pilot valve (6). Turn output shaft (8) and look at the indicator. Adjust bracket (3) until rotation of the output shaft causes no movement of the indicator.

Tools Installed
(9) 6V3075 Dial Indicator (10) 5P7285 Adjusting Bracket (11) 3P1565 Collet

Pilot Valve Adjustment

PSG Governor
(1) Inspection opening

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

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

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

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

Control Opening
(1) Inspection opening (2) Pilot valve bushing (3) Regulating land (A) Port opening (B) Port opening

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

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

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

PSG Governor
(2) Pilot valve bushing (3) Regulating land (4) Locknut (5) Spring seat (6) Pilot valve

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

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

1P87 Adjusting Wrench Used To Hold Spring Seat

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

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

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NOTICE

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

9. When the adjustment is correct, put 5P3413 Pipe Sealant on the threads of the pipe plug and install it in pipe plug opening.

Shutoff And Alarm System Components

Contactor Switch For Oil Pressure

3P1584 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.8T500 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 8T500 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 8T500 Circuit Tester between the common terminal and the normally closed terminal. The light of the circuit tester must not be activated.

Wiring Connections
(A) Normally open terminal (B) Common terminal (C) Normally closed terminal

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

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

9. Connect the wires to the normally closed terminal.

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

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

Adjustment Of Micro Switch Type

1. Loosen locknut (16) and turn adjustment screw (14) counterclockwise to make a decrease in the tension of spring (15).

Contactor Switch For Oil Pressure (Micro Switch Type)
(13) Set for start button (14) Adjustment screw (15) Spring (16) Locknut (17) Contact button

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

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

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

6. Connect the 8T500 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.8T500 Circuit Tester.

Method Of Checking

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

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

Heat Sink [Dimensions in mm (inches)]

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 8T500 Circuit Tester between the wires that connected the contactor to the circuit.

Test of Contactor Switch
(1) 2F7112 Thermometer (2) Fabricated heat sink

6. Put the 2F7112 Thermometer in the water.

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

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

Pressure Switch With Time Delay

6V6166 Gauge.8T500 Circuit Tester.

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

Oil Pressure Switch With Time Delay Installed
(1) Junction block (2) Pressure switch

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

3. Install the pressure switch (2) and a 6V6166 Gauge in the open ends of the tee as shown.

4. Connect the 8T500 Circuit Tester between the terminals of the pressure switch.

Test Tools Installed

5. Start the engine. Open the shutoff valve a small amount. Look at the pressure on the 6V6166 Gauge. When the pressure gets to the range given in the specifications the circuit tester light must go on.

6. Close the shutoff valve. Stop the engine. Open the shutoff valve a small amount. Look at the pressure on the 6V6166 Gauge. When the pressure gets to the range given in the specifications, close the valve. After five minutes, open the valve fully. The circuit tester light must stay on a minimum of 30 seconds and a maximum of 15 minutes after the valve is fully opened.

Shutoff Solenoids

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

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

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

Electronic Speed Switch (Earlier)

Electronic Speed Switch (Earlier)
(1) Cover

Overspeed Adjustment

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

2. Make reference to Engine Speed Measurement. Use one of the methods given to measure the engine speed.

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

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

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

Adjustment Locations
(2) Screw (3) Screw

Cranking Adjustment

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

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

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

Electronic 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 the engine at 75% of desired overspeed setting rpm. Make reference to the Speed Specification Chart.

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 0.56 to 0.84 mm (.022 to .033 in.) 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 70 ± 14 N·m (50 ± 10 lb.ft.).

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 cannot cause damage to the potentiometer or be removed if the adjustment screw is turned too much.

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

4. Start engine and make a note of the speed at which the starter disengages. See the Speed Specification Chart for the correct crank terminate speed.

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

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

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

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

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

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

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

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

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

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

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

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

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

Power Takeoff Clutches

Clutch Adjustment (Earlier)

Clutch Adjustment

1. Disconnect linkage (if so equipped) from the clutch lever. Fasten a spring scale to the clutch lever at the distance, from the lever shaft center, shown in the chart.

2. Look at the spring scale. Keep the angle between the scale and the lever at 90°. Pull the lever with the spring scale until the clutch engages. Make reference to the chart to find the correct amount of pull for the clutch assembly.

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

4. Remove the inspection plate from the clutch housing.

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

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

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

Clutch Adjustment
(1) Lock pin (push type) (2) Lock pin (pull type)

Assembly Adjustments

End Play For Shaft Bearings (Pilot-Type Clutch Only)

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

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

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

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

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

Clutch Adjustment (Later)

1. Disconnect linkage (if so equipped) from the clutch lever.

2. Use a torque wrench and apply torque to the splined clutch lever shaft until the clutch engages. Make reference to the chart to find the correct amount of torque needed for the clutch assembly.

3. If the torque needed to engage the clutch is not correct, make an adjustment as follows:

4. Remove the inspection plate from the clutch housing.

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

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

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

Clutch Adjustment
(1) Lock pin (push type) (2) Lock pin (pull type)

Assembly Adjustments

End Play For Shaft Bearings

5N7329 & 5N7330 Clutch Groups

1. Install the output shaft, bearings and spacers in the clutch housing.

2. Install the nut and lock on the shaft and tighten the nut to a torque of 750 ± 70 N·m (550 ± 50 lb.ft.).

3. Check the shaft end play with a dial indicator. Shaft end play is 0.08 to 0.25 mm (.003 to .010 in.).

4. If the shaft end play is not within the range given, check the bearing and spacers for wear or damage and make a replacement as needed.

3N8614 Clutch Groups

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

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

3. Measure the space between the retainer and the carrier. Add 0.33 mm (.013 in.) to this measurement. Install this amount of shims between the retainer and the carrier.

4. Check the shaft end play with a dial indicator. If necessary, add or subtract shims. Correct shaft end play is 0.15 to 0.25 mm (.006 to .010 in.).

3N8615 Clutch Groups

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

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

3. Now, loosen the retainer 5 to 6 notches and install the bolt and lock to hold the retainer.

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

5. Check the shaft end play with a dial indicator. Shaft end play is 0.25 to 0.30 mm (.010 to .012 in.).

6. If necessary, remove the bolt and lock and turn the retainer to get the correct end play.

Hub Nut Installation (Both Clutch Types)

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

2. Tighten the nut more according to the chart.

Flywheel And Flywheel Housing Alignment

At the time of installation of rear mounted PTO's, check the flywheel and flywheel housing face and bore run out.

Instruments And Gauges

Oil Pressure Sending Units

Sending Unit For Oil Pressure
(1) Terminal (2) Fitting

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

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

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

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

Water Temperature Sending Unit

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

Sending Unit For Water Temperature
(1) Terminal (2) Nut (3) Bulb

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

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

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

Electric Gauges

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

Wiring Diagram For Test
(1) Terminal (for test voltage) (2) Test resistance

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

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

Mechanical Gauges For Temperature

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

Direct Reading Gauge

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.

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

Gauge With Color Code