Testing & Adjusting

Usage:

Introduction

Reference: See 3208 Industrial Engine Attachments, SENR3692, for Specifications.

NOTE: For Specifications with illustrations, make reference to Specifications For 3208 Industrial Engine Attachments, SENR3692. If the Specifications in SENR3692 are not the same as in the Systems Operation and Testing And Adjusting, look at the printing date on the front cover of each book. Use the Specifications given in the book with the latest date.

NOTE: A "C" in the left margin is an indication of a change from the former issue.

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 of 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.

Troubleshooting Index

1. Contactor Switch For Water Temperature Fails To Activate Shutoff.

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

3. Switch For Oil Pressure Fails To Activate Shutoff.

4. Engine Protection Panel Will Not Activate Engine Shutoff.

5. Engine Protection Panel Stops Engine When Reset Button Is Released.

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

7. Clutch Shaft Has Too Much End Play.

8. Electrical Gauges Give Wrong Readings.

Problem 1: Contactor Switch For Water Temperature Fails To Activate Shutoff

Probable Cause:

1. Wrong Connections:

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

2. Low Water Level In Cooling System:

Fill the cooling system.

3. 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 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: Switch For Oil Pressure Fails To Activate Shutoff

Probable Cause:

1. Wrong Connections:

Check and make connections as shown in wiring diagrams.

2. Wrong Setting Of Switch:

Test and adjust switch. If necessary, install new switch.

Problem 4: Engine Protection Panel Will Not Activate Engine Shutoff

Probable Cause:

1. Fuse Burned Out:

Find and correct the cause for the burned out fuse. Install new fuse.

2. Grounded Or Loose Wiring:

Check and repair any worn or loose wiring.

3. Components In System Not Functioning Correctly:

Check components and install new ones as needed.

Problem 5: Engine Protection Panel Stops Engine When Reset Button is Released

Probable Cause:

1. Grounded Wiring Between "S" Terminal And Switches:

Install new wiring.

2. Broken Water Temperature Or Oil Pressure Switches:

Check the switches and install new ones as needed.

Problem 6. Clutch Will Not Engage (Slips), 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 Faces And Bores:

Check and make adjustment to alignment.

3. 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: Electrical Gauges Give Wrong Readings

Probable Cause:

1. Wrong Connections:

Check wiring connections to be sure they are tight. Check to see that the gauges are correctly connected as shown in the wiring diagrams.

2. Sending Units Fail To Operate:

Check the sending units and install a new one if necessary.

3. Wrong Sending Unit In System:

Install correct sending unit.

Electrical System

Water Temperature Switch

First Method Of Checking

1. Make a heat sink as shown. Material can be brass, steel or cast iron. Drill a 17.8 mm (.70 in) hole through the plate and use a tap to make 1/2 inch NPT threads.

2. Put marks on wire connections to water temperature switch terminals and disconnect the wire.

Heat Sink [Dimensions in mm (in)]

Test Of Water Temperature Switch
(1) 2F7112 Thermometer. (2) Fabricated heat sink.

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

4. Connect the wires to the water temperature switch to check all of the system; water temperature switch, wires, etc.

NOTE: If the wires cannot be disconnected, use the second method of testing.

5. When the water temperature switch is connected again, start the engine and run it at low idle rpm. The pressure switch will complete the circuit when the engine is running.

NOTE: When applying heat to the water in Step 6, be sure to stir (keep water moving) while heating.

6. Put the heat sink and water temperature switch in water. Use blocks to support the heat sink at surface level. Use a torch to make the water hot and read the temperature on thermometer (1) at which the water temperature switch is closed. Check the specifications for the respective temperatures at which the water temperature switch opens and closes. Let the water temperature go down. The water temperature switch will open when the temperature is 8°C (12°F) lower than the temperature at which the water temperature switch closes.

7. Install new water temperature switch if necessary.

To check other components in the system, put a jumper wire between C and NO terminals of the water temperature switch.

Second Method of Checking

1. Remove the wires from the water temperature switch.

2. Connect the 8T0500 Circuit Tester between the C and NO terminals.

3. Look at the circuit tester to see when the water temperature switch closes. The light will be activated. Check the specification for the water temperature switch closings.

4. Start the engine and get it hot. Temperature must not go more than approximately 3°C (37°F) above switch activation temperature.

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NOTICE

If the engine cannot be run safely at these high temperatures, the water temperature switch must be checked off the engine.

5. Let the engine run at a reduced speed to lower the coolant temperature before stopping the engine.

6. Install new water temperature switch if needed.

Electrical Indicators And Sending Units

Remember that the electrical indicators and sending units are to operate in electrical balance. For this reason, the voltage and resistance ratings are important to get the correct indications on the indicators.

Sending Units For Oil Pressure

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

The sending unit for engine oil pressure can be checked for resistance to find if it is operating correctly. Connect the sending unit to a pressure source that can be measured with accuracy. Connect the ohmmeter between fitting (2) and terminal (1). Take resistance readings at the pressures given in the Attachment Specifications section.

If the test performance is correct for the sending unit for the oil pressure, install a new indicator.

Sending Unit For Water Temperature

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

1. Connect a multimeter between connection (3) and nut (2). Put bulb (1) in heat sink then into a pan of water. Do not let the bulb have contact with the pan (see water temperature switch for more detail).

2. Put a 2F7112 Thermometer in the water to measure the temperature.

3. Refer to Sending Units For Water Temperature in the Specifications section. Take resistance readings at the temperature shown.

4. If a unit does not have the correct resistance readings, replace the unit.

Magnetic Pickup

(1) Distance between end of magnetic pickup and gear. (2) Nut.

(1) Distance between end of magnetic pickup and gear ... 0.30 to 0.75 mm (.012 to .030 in)

NOTE: This distance is set by turning magnetic pickup into threads until magnet is against the gear tooth while the engine is stopped. Now back magnetic pickup out 1/3 ± 1/10 turn and tighten nut as follows.

(2) Nut. Tighten nut to a torque of ... 45 ± 7 N·m (33 ± 5 lb ft)

Tachometers

Tachometers can be adjusted by the following procedure.

1. Remove the plastic plug on the rear of the tachometer.

2. Using a small screw driver, turn the adjusting screw to increase or decrease the tachometer reading.

3. Replace the plastic plug.

Electric Indicators

Wiring Diagram For Test
(1) System voltage. (2) Sender resistance. (3) Case ground.

Prior to inspection of individual pointer positions warm up indicator for minimum of five minutes. Using each sender resistance from the calibration supplied in the Specifications manual and the proper system voltage, each indicator can be checked. Check calibration indicator with ascending pointer. Position of pointer with current off is immaterial. The test must be made when the indicator is installed at the angle of 30 degrees back from vertical position.

Power Takeoff Clutches

Clutch Adjustment

2N1373

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

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 degrees. 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

4P2270 And 4W2650

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

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 Assembly Adjustments

End Play For Shaft Bearings, Clutch Assembly 2N1373

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.

Clutch Assembly 4P2270 And 4W2650

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 1 or 2 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 0.10 to 0.18 mm (.004 to .007 in).

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

Installation Of Wear Sleeve

Wear Sleeve Installation
(1) Guide assembly. (2) Wear sleeve. (3) Shaft shoulder fillets.

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

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.

Allison Transmission Mounting Group Alignment

To help prevent a failure to the flexplate, the flywheel housing spacer and the transmission adapter must be in correct alignment with the crankshaft.

NOTE: The flywheel housing and flywheel runout must be acceptable before the transmission mounting group is installed.

Face Runout (Axial Eccentricity) Of The Flywheel Housing Spacer

8T5096 Dial Indicator Group Installed

1. Install the transmission adapter and flex plate on the flywheel. Tighten the bolts to 75 ± 7 N·m (55 ± 5 lb ft). Install the flywheel housing spacer on the flywheel housing.

2. Fasten a dial indicator to the transmission adapter and position the indicator so the anvil touches the face of the flywheel housing spacer.

3. Move the crankshaft to the rear to remove all end clearance before a reading is taken at each point.

4. Set the dial indicator to 0.00 mm (.000 in) at location (A), turn the crankshaft and read the indicator at locations (B), (C) and (D).

Checking Face Runout Of The Flywheel Housing Spacer
(A) Bottom. (B) Right side. (C) Top. (D) Left side.

5. The difference between positive (+) and negative (-) measurements taken at all four points must not be more than 0.20 mm (.008 in) for AT540 Transmission and 0.51 mm (.020 in) for MT643 and MT653 Transmissions.

Bore Runout (Radial Eccentricity) Of The Flywheel Housing Spacer

8T5096 Dial Indicator Group Installed

1. Fasten a dial indicator to the transmission adapter and position the indicator so the anvil touches the large bore of the flywheel housing spacer.

2. With the dial indicator in position at (C), adjust the dial indicator to 0.00 mm (.000 in). Push the crankshaft up against the top bearing. Write the measurement for bearing clearance on Line 1 on column (C).

3. Divide the measurement from Step 1 by 2. Write this number on Line 1 in columns (B) & (D).

Checking Bore Runout Of The Flywheel Housing Spacer

4. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to 0.00 mm (.000 in).

5. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the chart.

NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation (signs). This is necessary for making the calculations in the chart correctly.

6. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the chart.

7. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the measurements in the chart.

8. Add Lines I & II by columns.

9. Subtract the smaller number from the larger number in Line III in columns (B) & (D). The result is the horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.

10. On the graph for total eccentricity find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

Graph For Total Eccentricity For AT540 Transmission

Graph For Total Eccentricity For MT643 And MT653 Transmission

11. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point of intersection is in the range marked "Not Acceptable", remove the spacer and check the bore in the flywheel housing for dirt or damage.

Bore Runout (Radial Eccentricity) Of The Transmission Adapter

8T5096 Dial Indicator Group Installed

1. Fasten the dial indicator to the flywheel housing and position the indicator so the anvil touches the bore of the transmission adapter.

2. Adjust the dial indicator to read 0.00 mm (.000 in). Turn the flywheel and read the indicator every 90 degrees.

3. The difference between positive (+) and negative (-) measurements taken at all four locations must not be more than 0.25 mm (.010 in) for AT540 Transmissions and 0.13 mm (.005 in) for MT643 and MT653 Transmissions.

Face Runout (Axial Eccentricity) Of The Transmission Adapter

8T5096 Dial Indicator Group Installed

1. Fasten the dial indicator to the flywheel housing and position the indicator so the anvil touches the face of the flex plate 76.2 mm (3.00 in) from the center of the transmission adapter bore.

2. Move the crankshaft to the rear to remove all end clearance before a reading is taken at each location.

3. Adjust the dial indicator to read 0.00 mm (.000 in). Turn the flywheel and read the indicator every 90 degrees.

4. The difference between the positive (+) and negative (-) measurements taken at all four locations must be 0.08 mm (.003 in) for AT540, MT643 and MT653 Transmissions.

Face Runout (Axial Eccentricity) Of The Flex Plate

8T5096 Dial Indicator Group Installed

1. Fasten the dial indicator to the flywheel housing and position the indicator so the anvil touches the face of the flex plate at the large diameter bolt circle.

2. Turn the crankshaft to position the indicator anvil next to one of the bolts on the large diameter of the flex plate. Move the crankshaft to the rear to remove all end clearance before a reading is taken at each location.

3. Adjust the dial indicator to read 0.00 mm (.000 in). Turn the flywheel and read the indicator at a location next to each bolt on the large diameter of the flex plate.

4. The difference between the positive (+) and negative (-) measurements taken at all locations must not be more than 0.76 mm (.030 in) for AT540, MT643 and MT653 Transmissions.

Pulley Assemblies

Procedure For Assembling Fan Mounting Pulley Assembly

Typical Pulley
(1) Pulley. (2) Seal. (3) Bearing cup. (4) Bearing cone. (5) Bearing cup.

1. Install bearing cups (3 and 5) in pulley (1).

2. Put 2S3230 Bearing Lubricant in bearing cone (4).

3. Install bearing cone (4) in bearing cup (5).

4. Install seal (2) in pulley (1). Be sure the sealing lip of seal (2) is toward bearing cone (4). Put a small amount of 2S3230 Bearing Lubricant on the lip of seal (2).

Typical Pulley Assembly With Hexagon Nut And Pinned Shaft
(1) Pulley. (2) Seal. (3) Bearing cup. (4) Bearing cone. (5) Bearing cup. (6) Sleeve. (7) Bearing cone. (8) Shaft. (9) Nut. (11) Washer. (12) 4N7950 Spacer. (15) Pin. (A) Area to put lubricant.

5. Install sleeve (6) and pulley (1) on shaft (8).

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NOTICE

Do not damage the sealing lip of seal (2) when putting the pulley on the shaft.

6. Install the 4N7950 Spacer (12) on shaft (8). The 4N7950 Spacer is 11.18 ± 0.03 mm (.440 ± .001 in) long.

7. Put 2S3230 Bearing Lubricant around spacer (12) until area (A) is one-third to one-half full of lubricant.

8. Put 2S3230 Bearing Lubricant in bearing cone (7) and install the bearing in bearing cup (3).

9. Install washer (11) and nut (9).

10. Tighten nut (9) to 149 ± 20 N·m (110 ± 15 lb ft).

11. After the nut is tightened, check the end clearance of pulley (1). The pulley must have 0.03 to 0.25 mm (.001 to .010 in) end clearance.

12. If the end clearance is less than 0.03 mm (.001 in), remove the 4N7950 Spacer (12) and install a 4N7951 Spacer, the 4N7951 Spacer is 11.43 ± 0.03 mm (.450 ± .001 in) long. Assemble the pulley and again check end clearance. If the original end clearance is more than 0.25 mm (.010 in), remove the 4N7950 Spacer and install a 4N7949 Spacer. The 7N7949 Spacer is 10.92 ± 0.03 mm (.430 ± .001 in) long.

NOTE: Be sure to put 2S3230 Bearing Lubricant around the new spacer so area (A) is one-third to one-half full of lubricant. Always put more lubricant in bearing cone (7) before installing in bearing cup (3).

13. Install the remainder of the parts and tighten nut (9) to 149 ± 20 N·m (110 ± 15 lb ft). Check the end clearance again to be sure it is correct.

14. Put 2S3230 Bearing Lubricant in area (B). Area (B) must be a minimum of one-third to one-half full of lubricant.

6N7691 Pulley Assembly
(9) Nut. (22) Hub. (23) Bolts. (24) Gasket. (B) Area to put lubricant.