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 recommendation 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 necessary repairs.

Troubleshooting Problem List

1. Contactor Switch For Water Temperature Does Not Activate Shutoff Solenoid.

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

3. Contactor Switch For Oil Pressure Does Not Activate Shutoff Solenoid.

4. Electrical Gauges Give Wrong Readings.

For information on the 2301 Electric Governor refer to 2301 Electric Governor Service Manual, SENR2928.

For information on the 2301A Electric Governor refer to 2301A Electric Governor Service Manual, SENR3585.

Troubleshooting Problems

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

Probable Cause:

1. Wrong Connections - Check connections, wiring and correct where necessary.

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 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 Does Not Activate Shutoff Solenoid.

Probable Cause:

1. Wrong Connections - Check connections, wiring and correct where necessary.

2. Wrong Setting Of Switch - Make a test of temperature setting and if necessary install new contactor switch with correct setting. See specifications.

Problem 4: Electrical Gauges Give Wrong Readings.

Probable Cause:

1. Wrong Connections - Check connections, wiring and correct where necessary.

2. Sending Units Have A Failure - Check the sending units and install new ones if necessary.

3. Wrong Sending Unit In System - Install correct sending unit.

4. Wrong Gauge - Install correct gauge.

Governor

Low Idle Adjustment Procedure

Use the 6V3121 Multitach Group or the 1U6602 photo tachometer to accurately measure the engine low idle rpm. DO NOT use the instrument panel tachometer to set engine low idle. Use this procedure any time the low idle rpm is changed, even slightly.

Governor (Typical)
(1) "Standard" Low Idle Adjustment Screw. (2) "Buffer" Spring Adjustment Screw.

1. Start the engine and allow it to warm up to operating temperature and allow the low idle reading to stabilize. Low idle readings should be taken after snapping the throttle open about 1/3 of its travel, and releasing it quickly. This will help insure the governor control is in its natural low idle position against the "standard" governor low idle screw (1).

2. Turn the "buffer" spring adjustment screw (2) out (counterclockwise) until there is no further change in low idle rpm. The rpm should drop slightly when the "buffer" spring adjustment screw (2) is turned out.

3. Actuate the governor control lever, and then quickly release the lever. Check the low idle rpm. Use the "standard" low idle adjustment screw (1) to adjust the low idle to 600 ± 10 rpm. Actuate the governor control lever, and then quickly release the lever. Check the low idle rpm. Adjust the "standard" low idle adjustment screw (1) as needed to obtain the 600 ± 10 rpm.

4. Slowly turn the "buffer" spring adjustment screw (2) in (clockwise) until the low idle rpm begins to increase. Continue to turn the "buffer" spring adjustment screw (2) until the low idle rpm is 650 ± 10 rpm. Actuate the governor control lever, and then quickly release the lever. Check the low idle rpm. Adjust the "buffer" spring adjustment screw (2) as needed to obtain the 650 ± 10 rpm.

NOTE: The "buffer" spring adjustment screw (2) MUST be turned out (counterclockwise) initially, while the low idle is set 50 rpm LESS than the final value with the "standard" low idle adjustment screw (2) is used to adjust the low idle rpm upward to the final, specified, low idle rpm. If the "buffer" spring adjustment screw (2) is used to raise the rpm too much or too little, it does not dampen the movement of the internal governor parts. Low idle instability or surge can be a result.

Governor Control Group

Governor Control Group
(1) Bracket. (2) Cylinder head. (3) Inlet manifold. (4) Control assembly.

Mount bracket (1) at the fourth and fifth bolt location from the rear of the inlet manifold (3) on six cylinder engines. Mount bracket (1) at the second and third bolt location from the rear of the inlet manifold (3) on four cylinder engines.

Instruments and Gauges

Contactor Switch For Water Temperature

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

Heat Sink
[Dimensions in mm (inches)]

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

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 multimeter 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. Stir the water while using a torch to heat it to the specified temperature given in specifications and check resistance. If the temperature contactor is not in specification a replacement must be made.

Water Temperature Sending Unit

Sending Unit for Water Temperature

1. Connect a multimeter between terminal (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 contactor switch for more detail).

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

3. Refer to Water Temperature Sending Unit 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.

Oil Pressure Sending Unit

Sending Unit for Oil Pressure
(1) Terminal connection. (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. Refer to Oil Pressure Sending Unit in the Specifications section. Take resistance readings at the pressure shown in the chart.

NOTE: Tap sender when checking calibration. Take readings on decreasing pressure.

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

Electric Gauges

1. Put the gauge in position with the letters horizontal and the face 30 degrees 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.

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

NOTE: Refer to the gauge area in the Specifications section for the Calibration Chart of each gauge.

Magnetic Pickup

Typical Illustration

(1) Clearance between magnetic pickup and flywheel ring gear ... 0.55 to 0.83 mm (.022 to .033 in)

NOTE: With the engine stopped, turn the pickup in until it comes in contact with teeth on the flywheel ring gear. Turn the pickup out 1/2 turn. This will give ... 0.55 to 0.83 mm (.022 to .033 in) clearance at (1).

(2) Tighten the locknut 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 cap.

Starting Motor Adjustments

Pinion Clearance

When the solenoid is installed, make an adjustment of the pinion clearance. The adjustment can be made with the starting motor removed.

Connection For Checking Pinion Clearance
(1) Connector from MOTOR terminal on solenoid to motor. (2) SW terminal. (3) Ground terminal.

1. Install the solenoid without connector (1) from the MOTOR connections (terminal) on solenoid to the motor.

2. Connect a battery, of the same voltage as the solenoid, to the terminal (2), marked SW.

3. Connect the other side of the battery to ground terminal (3).

4. Connect for a moment, a wire from the solenoid connection (terminal) marked MOTOR to the ground connection (terminal). The pinion will shift to crank position and will stay there until the battery is disconnected.

Pinion Clearance Adjustment
(4) Shaft nut. (5) Pinion. (6) Pinion clearance.

5. Push the pinion toward the commutator end to remove free movement.

6. Pinion clearance (6) must be as stated for the starting motor in the Specifications section of this manual.

7. To adjust pinion clearance, remove plug and turn nut (4).

8. Install plug.

Rear Power Takeoff Clutches

Single Plate Clutch (3N9097 & 4W2650)

Typical Illustration

NOTE: After clutch has been installed on engine, hit output shaft sharply on the end to relieve any preload that may result due to resistance of pilot bearing being pressed into the flywheel.

(1) Bearing Adjustment (end clearance):

3N9097

Tighten bearing retainer until there is no clearance between cup and cone. Back off retainer two or three notches and assemble the lock. Strike output end of shaft to seat the inner bearing cup against the bearing retainer. The end play must be ... 0.15 to 0.25 mm (.006 to .010 in)

4W2650

Tighten bearing retainer until there is no clearance between cup and cone. Back off retainer one or two notches and assemble the lock. Strike output end of shaft to seat the inner bearing cup against the bearing retainer. The end play must be ... 0.10 to 0.18 mm (.004 to .007 in)

Clutch Engagement Check (On Engine):

3N9097

A torque of ... 295 to 392 N·m (214 to 291 lb ft) on the splined clutch lever shaft is required to engage the clutch.

4W2650

A torque of ... 146 to 192 N·m (108 to 142 lb ft) on the splined clutch lever shaft is required to engage the clutch.

Double Plate Clutch (4P2270, 4P3073, 2W4902 & 2W4900)

Typical Illustration

NOTE: After clutch has been installed on engine, hit output shaft sharply on the end to relieve any preload that may result due to resistance of pilot bearing being pressed into the flywheel.

(1) Bearing Adjustment (end clearance):

4P2270

Tighten bearing retainer until there is no clearance between cup and cone. Back off retainer four or five notches and assemble the lock. Strike output end of shaft to seat the inner bearing cup against the bearing retainer. The end play must be ... 0.27 to 0.34 mm (.011 to .014 in)

4P3073 2W4902

2W4900

Clutch Engagement Check (On Engine):

4P2270 2W4900

A torque of ... 182 to 240 N·m (135 to 178 lb ft) on the splined clutch lever shaft is required to engage the clutch.

4P3073 2W4902

A torque of ... 295 to 392 N·m (214 to 291 lb ft) on the splined clutch lever shaft is required to engage the clutch.