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CATERPILLAR® FORM NO.

SENR2364

FOR USE IN SERVICE MANUAL:


3500 GENERA TOR SET ENGINES,
SENR2359

~w@~®mm@ @~®[féID~D@üíJ
U®@~DüíJ® ~ ~cQ]Dll1J@~DüíJ®
3500 Generator Set
Engine Attachments

23Z1-UP 67Z1-UP
24Z1-UP 7QZ1-UP
25Z1-UP 73Z1-UP
,&WARNING

IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This
Service Manual outlines basic recommended procedures, some of which require
special tools, devices or work methods. Although not necessarily all inclusive, a
list of additional skills, precautions and knowledge required to safely perforrn
repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

REAO ANO UNOERSTANO ALl SAFETV PRECAUTIONS


ANO WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are Iisted in the SAFETY section
of this Manual and in the descriptions of operations where hazards exist. Warning
labels have also been pur on to provide instructions and identify specific hazards
which if not heeded could cause bodily injury or death to you or other persons.
These labels identify hazards which rnay not be apparent to a trained mechanic.
There are many potential hazards during repair for a untrained mechanic and there
is no way to label the product against all such hazards. These warnings in the
Service Manual and on the product are identified by this syrnbol:

A WARNING

Operations that rnay result only in mechanical damage are identified by labels on
the product and in the Service Manual by the word NOTICE.

Caterpillar can not anticipate every possible circumstance that might involve a
potential hazard. The wamings in this Manual are therefore not all inclusive. If a
procedure, tool device or work method not specificalIy recommended by Caterpil-
lar is used, you must saftisfy yourself that it is safe for you and others. You should
also ensure that the product will not be damaged or made unsafe by the procedures
you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of
information available at the time it was written. The specifications, torque, pres-
sures of operation, measurements, adjustments, illustrations and other items can
change at any time. These changes can affect the service given to the product. Get
the complete and most current information befare you start any jobo Caterpillar
Dealers have the most current information available. For a list of the most current
modules and form numbers available for each Service Manual, see the SERVICE
MANUAL CONTENTS MICROFICHE REGl139F.
A83264X2

2
".,UU \:U:Nt:.HA rOR
SET ENGINE ATTACHMENTS INDEX

SYSTEMS OPERATION
Cooling System " 9, 10
Power Take-Off Clutches " 19
Electrical System 11, 12
Air Shutoff Solenoid 12 Wiring Diagrams . 13-18
Electrical Gauges and Sending Units. . . . . . . . . . . . . . . . . .. 11 Air Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
Electric Hour Meter '.' " 11 Charging System 14
Sending Unit tor Oil Pressure. . . . . . . . . . . . . . . . . . . . . . .. 11 Converter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Sending Unit tor Water Temperature . . . . . . . . . . . . . . . .. 11 Instrument Panel................................. ..... 13
Pyrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
Fuel System '" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tachometer 18
Duplex Fuel Filter System 4
Woodward UG8 Governor 5-7
Lubrication System 8 Woodward UG8 Dial Governor. . . . . . . . . . . . . . . . . . . . . . . . . 5
Duplex Oil Filter System 8

TESTING ANO AOJUSTING


Fuel System " 26-29
Engine Speed Measurement " . . . . . . . . . . . . . . . . . . . . . . . .. 29 Lubrication System 32
Fuel Setting 27 Duplex Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32
Fuel Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 Linkage Adjustment " 32
Fuel Setting Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Selector Valve Adjustment . . . . . . . . . . .. . . . . . . . . . . . . . .. 32
Injector Synchronization 26
Power Take-Off Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36
Instruments and Gauges 33-35 Assembly Adjustment " 36
Contactor Switch for Water Temperature " 35 End Play tor Tapered Roller Bearings . . . . . . . . . . . . . . .. 36
Electric Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33 Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36
Mechanical Gauges tor Oil Pressure 34 Flywheel and Flywheel Housing Aligriment " 36
Mechanical Gauges tor Temperature " . . . . . . . . . . . . .. 34 Hub Nut Installation " . . . . . . . . . . . . . . . . . . . . . . . .. 36
Oil PressureSending Units . . . . . .. . . . . . . . . . . . . . . . . . . . .. 33
Troubleshooting .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-25
Water Temperature Sending Unit 33
Woodward UG8 Dial Governor 30, 31
Compensating Adjustment 30
High Idle Speed Adjustment .. 31

SPECIFICATIONS
NOTE: For Specifications with illustrations, make reference to SPECIFI-
CATIONS for 3500 GENERATOR SET ENGINE ATTACHMENTS,
Form No. SENR2363. lf the Specifications in Form SENR2363 are not the
same as in the Systems Operation and the Testing and Adjusting, look at the
printing date on the back cover of each book. Use the Specifications given
in the book with the latest date.

3
FUEL SYSTEM
SYSTEMS OPERATION

FUEL SVSTEM
DUPLEX FUEL FIL TER SYSTEM
When the control valve is moved to the "AUXI-
The duplex fuel filter system makes it possible to LIAR Y RUN" position, the fuel will be cleaned by
change filter elements while the engine is running at the filter elements in the auxiliary filter housing. The
a ny speed. main filter elements can be changed, at this time,
B55638Xl
after the main filter housing is drained and the fuel
_ UNFILTERED
FUEL
pressure is released.
líWhtDFILTEREDFUEL
After the filter elements in either housing have
been changed, the housing must be filIed with fuel to
keep the engine speed and fuel pressure constant
when the fuel is directed from one filter housing to
another. To filI either filter housing with fuel, move
fiJl vulve (2) to the open position for a minimum of 5
minutes. This will direct a small flow of fuel to the
empty filter housing. Some air will remain in the
filter housing until the control valve directs fuel flow
through the housing. The remainder of air in the
system is then directed back to the fuel tank by the
pressure regulating valve on front of the right fuel
manifold.
TO ENGINE

MAIN RUN OPERATION


1. Control valve handle. 2. FiII valve.

During normal operation, the control valve should


be in the "MAIN RUN" position. The fuel then will
be cleaned by the filter elements in the main filter
housing. The auxiliary filter elements can be B55639Xl
_UNFILTERED
changed, at this time, after the auxiliary housing is FUEL
drained and the fuel pressure is released. .1FILTERED FUEL

B55640Xl
_UNFILTERED
¡:UEL
&X%lP]FILTERED
FUEL

TO ENGINE

80TH RUN OPERATION


1. Control valve handle.
TO ENGINE
When the control valve is in the "80TH RUN"
posit ion, the fuel is cleaned by both the main and
AUXILl~RY RUN OPERATION
auxiliary filter elements. This position should only be
1. Control valve handle. 2. Fill valve. used when necessary.

4
... VVLlYV,","U UüU liUVERNOR
SYSTEMS OPERATION

WOODWARD UG8 GOVERNOR

SPEED . A90203X1
SETTING
o MOTOR ~ HIGH PRESS OIL
SPEED
DROOP
r'_I-~ 1111111111111 COMPENSATION OIL

ADJ. :T"r~1 í SPEED


DROOP
~ TRAPPEDOIL
~~FR~ LEVER 1:::::::::::::::::::;:1 SUMP 01 L
I CLUTCH

o
SPEEDER SLIDING
SYN. TURNS
PLUG ~1[SI.1ITTJD FULCRUM INDICATOR
.-q:::============~ r., C:::=::=BJ
SYNCHRONIZER
(SPEED)
ADJ.
FLYWEIGHT

PISTON
(SMALU
CHECK VALVE CHECK VALVE
(CLOSEO) (OPEN)

WOODWARD UG8 DIAL GOVERNOR


The power piston is connected by a lever to the
The U G8 Dial Governor is a mechanical- output terminal shaft. There is oil pressure on both
hydraulic governor. A hydraulic activated power the top and bottom of the power piston. The bottom
piston is used to turn the output terminal shaft of of the pisto n has a larger area than the topo
t he governor. A lever on the terminal shaft is con-
Less oil pressure is required on the bottom than
nectcd to the fuel rack by a linkage rod. The gover-
on the top to keep the piston stationary. When the
nor has a separate oil supply and oil pump. The
oil pressure is the same on the top and bottom of the
governor oil pump and ballhead are driven from a
pisten, the piston will move up and cause the output
shalt in the governor drive housing. The shaft is
terminal shaft to turn in the increase fuel direction.
drivcn by the fuel pump drive shaft.
When oil pressure on the bottom of the piston is
The oil purnp gives pressure oil to operate the directed to the surnp. the piston will move down and
p o wer piston. The drive gear of the oil pump has a cause the output terminal shaft to turn in the de-
bushíng in which the pilot valve plunger moves up crease fuel direction. Oil to or from the bottom of
and d own. The driven gear of the oil pump is also the power piston is controlled by the pilot valve
the drive for the ballhead.
An accumulator is used to keep a constan! oil
pressure of approximately 830 kPa (120 psi) to the
10r of the power piston and to the pilot valve.

s
WOODWARD UG8 GOVERNOR
SYSTEMS OPERATION

The pilot valve has a pilot valve plunger and a


bushing. The bushing is turned by the governor When the actuating piston moves down, the
drive shaft. The rotation of the bushing helps re- piston forces the oil under the receiving piston and
duce friction between the bushing and the plunger. moves it up. When the receiving piston moves up, it
The pilot valve plunger has a land that controls oil raises the pilot valve plunger to stop the flow of oil
to the bottorn of the power piston.
flow through the ports in the bushing. When the
pilot valve plunger is moved down, high pressure When the engine is in operation at a steady speed,
oil goes to the bottom of the power pisto n and the the land on the pilot control valve is in the center
power piston will move up. When the pilot valve of the control port of the bushing. A decrease in
plunger is moved up, the oil on the bottom of the load will cause an increase in engine speed. With an
power piston is relea sed to the sump and the power increase in engine speed, the flyweights move out
piston moves down. When the pilot valve plunger is and raise the speeder rod and floating lever. This
in the center (balance) position, the oil port to the raises the pilot valve plunger and releases oil from
bottom of the power piston is closed and the power the bottom of the power piston. As the power piston
piston will not move. The pilot valve plunger is moves down, the output terminal shaft moves in the
moved by the ballhead assembly. decrease fuel direction. When the output terminal
shaft moves, the actuating compensation piston
The ballhead assembly has a ballhead, flyweights,
moves up. This causes a suction on the receiving
speeder spring, thrust bearing, speeder plug, and
piston, which now moves down. The floating lever
speeder rod. The ballhead assernbly is driven by a
is alsd pulled down by the receiving piston, and this
gear and shaft from the driven gear of the oil pump.
lever now moves the pilot control valve down to
The speeder rod is fastened to the thrust bearing
close the control port. With the control port closed,
which is on the toes of the flyweights. The speeder
the output terminal shaft and power pisto n move-
rod is connected to the pilot valve plunger with a
ment is stopped. As the engine speed returns to
lever. The speeder spring is held in position on the
normal, the flyweights move in and the speeder rod
thrust bearing by the speeder plug.
moves down. When the pressure of the compensa-
As the ballhead turns, the flyweights move out tion system oil and the sump oil beco me the same
due to centrifugal force. This will make theflyweight through the needle valve, the receiving compensa-
toes move up and cause compression of the speeder tion piston moves up at the same rate as the speeder
spring. When the force of the speeder spring and the rod moves down. This action keeps the pilot valve
force of the flyweights are equal, the engine speed plunger in position to close the port.
is constant. The speeder plug can be moved up or
An increase in load will cause a decrease in engine
down manually (change the compression of the
speed. When engine speed decreases, the flyweights
speeder spring) to change the speed of the engine.
move in and lower the speeder rod and floating
The compensation system gives stability to engine lever. This lowers the pilot valve plunger and lets
speed changes. The compensation system has a pressure oil go under the power piston. The power
needle valve and two pistons - an actuating piston pistón moves up and turns the output terminal shaft
and a receiving piston. The actuating piston is con- in the increase fuel direction. When the output ter-
nected to the output terminal shaft by the compen- minal shaft moves, the actuating compensation
sation adjusting lever. A fulcrum that is adjustable piston moves down. This causes a pressure on the
is on the lever. When the position of the fulcrum is receiving piston, which now moves up. The floating
changed, the amount of movement possible of the lever is also pushed up by the receiving pisten, and
actuating piston is changed. the lever now moves the pilot valve plunger up to
close the control port. With the control port closed,
The receiving piston is connected to the pilot
the output terminal shaft and power piston move-
valve plunger and the speeder rod by a lever. ment is stopped.
The needle valve makes a restriction to oil flow
A change to the speed setting of the governor will
between the oil sump and the two pistons.
give the same governor movements as an increase
or decrease in load.

6
VYUUDWARD UG8 GOVERNOR
SYSTEMS OPERATION

The synchronizer is used to change engine speed.


The speed setting motor on the top of the governor TYPE UG-8
can also be used to change engine speed. Either con-
trol turns the speeder plug (which moves up or
down) and changes the force of the speeder spring.
The synchronizer indicator gives an indication of
the number of turns the synchronizer has moved.
The load limit control is used to control the
amount of travel of the output terminal shaft. The
control can be used to stop the engine if the knob
is turned to zero.

NOTICE
Do not move Ihe governor linkage in Ihe in-
crease fuel direction until the load limU control
is moved to the maximum position.

The speed droop control is used to adjust the


amount of speed droop from zero to one hundred
percent. Speed droop is the difference between no
load (high idle) rpm and full load rpm. This dif- UG8 DIAL GOVERNOR

ference in rpm divided by the full load rpm and 1. Speed droop knob. 2. Synchronizer knob. 3. Load lirnlt
knob. 4. Synchronizer indicator.
multiplied by 100 is the percent of speed droop.
Zero speed droop is used on 'a single system en-
No Load Speed - FuI! Load Speed % of gine, such as a standby generator set. Speed droop
Full Load Speed x 100 = Speed Droop higher than zero permits a load to be divided be-
tween two or more engines connected to the same
load.

'.,

7
LUBRICA nON SYSTEM
SYSTEMS OPERATION

LUBRICATION SYSTEM
DUPLEX OIL FILTER SVSTEM

/
.>.'/
r".'/ ~-,-_/

1\ -, 5

\ /
885191X1 /
/-~

\
1
- _j

6
DUPLEX OIL FILTER
(Control Valve Shown in Main Run Position)
1. Main filter housing. 2. Bypass valve. 3. Auxiliary filter housing. 4. Handle. 5. Fill valve. 6. Linkage. 7. Control valve shafts.

The duplex oil filter system makes it possible to


change the filter elements while the engine is running
at any speed.

During normal operation, the control valve


should be in the "MAIN RUN" position. The oil
then will be cleaned by the main filter elements (H)
in the main filter housing (1) and the filtered oil wiJl
move check valve ( 10) to the right to close passage
in auxiliary housing (position shown in Section
A-A). In this posit ion , the auxiliary filter elernent
can be changed after the oil pressure is released SECTION A-A
and the auxiliary housing is drained. 8. Main filter elements. 9. Control valve assembly. 10.
Check valve. 11. Auxiliary filter element.
When ha ndle (4) is pullcd out to the "Auxilia ry
Run " position, t he oil will be cleaned by the a ux il- After the filter elements in either housing ha ve
ia ry filter elerncnt The Iiltcrcd oil will now rnovc been changed, the housing must be filled again to
check valve (10) to t hc left to close passage in main maintain constant oil pressurc when oil is directed
filter housing. In this position, the main filter ele- frorn one fi!ter housing to the other.
ments (X) can be changed after the oil pressure IS
To fiJl either filter housing with oil, move fiJl valve
releascd a nd the main filter housing is drained.
(5) to the open position for a minimum of5 minutes.
This will dircct oil through a small line to fill the
em pty fi!ter housing.
COOLlNG SYSTEM
SYSTEMS OPERATION

COOLING SYSTEM
b 7

13

IZIIA 10

TOP VIEW
B38951Xl
SCHEMATICOF COOLlNGSYSTEM
(3512SHOWN)
1.Waterpump. 2. Tube (to aftercooler). 3. Oil cooler. 4. Cylinder block. 5. Cylinder head. 6. Watercooled exhaustmanifold.
7. Aftercooler. 8. Regulatorhousing. 9. Tubes (to expansiontank). 10.Tube (to water pump). 11.lnlerfrom heat exchanger.
12.Outlet to heat exchanger. 13.Expansiontank. 14.Tube (to water cooled turbocharger and exhaust elbów).

Coolant from expansion tank (13) goes through a


tube and elbow to the inlet of water pump (1). The NOTE: There is one opening on the pump outlet so
coolant flow is divided at the outlet of the water that a remote pump can be eonneeted to the system.
pump. Part of the coolant flow is sent to the after- The remote pump ean be used if there is a failure of
cooler, while most of the eoolant is sent through the the pump on the engine.
oil cooler.

ELECTRICAL SYSTEM
SYSTEMS OPERATlON

ELECTRICAL SYSTEM
ELECTRICAL GAUGES ANO
SENOING UNITS or beca use the level is too low before starting the
engine, the sending unit will not work correctly.
The electrical gauges and sending units operate
in electrical balance. Because of t his, the voltage Sendíng Unít for Oil Pressure
and resistance ratings are important to get the
corree: indications on the gauges. The chart shows
components that operate together.
COOLlNG SYSTEM
SYSTEMS OPERATION

RIGHTSIDE OF ENGINE TOP OF ENGINE


1. Water pump. 3. Oil cooler. 10. Tube (to water pump). 6. Water cooled exhaust manifolds. 7. Aftercooler.
8. Regulator housing. 9. Bypass tubes. 13. Expansion
tank.

Coolant sent to the aftercooler goes through the


aftercooler core, and then is sent through an elbow
Regulator housing (8) has an upper and lower flow
into a passage in the block near the center of the vee section, and uses four temperature regulators. The
at the rear of the block. The cooIant sent to the oil sensing bulbs of the four temperature regulators are
cooler goes through the oil cooler and flows into the
in the coolant in the lower section of the housing.
water jacket of the block at the right rear cylinder. Before the regulators open, cold coolant is sent
The cooler coolant mixes with the hotter coolant and through the lower section of the housing, through the
goes to both sides of the block through distribution by pass tubes to the expansion tank, and then back to
manifolds connected to the water jacket of al! the
the inlet of the water pump. As the temperature of
cylinders. The main distribution manifold is located
the coolant increases enough to make the regulators
just aboye the main bearing oil gallery.
start to open, cooIant flow to the bypass tubes is
The cooIant flows up through the water jackets stopped, and coolant is now sent through the outlets
and around the cylinder Iiners from the bottom to the to the heat exchanger. After the regulators are fully
topo Near the top of the cylinder liners, where the open, most of the cooIant from the water cooled
temperature is the hottest, the water jacket is made manifolds goes through the heat exchanger and back
smalIer. This shelf (smaller area) causes the coolant to the expansion tank.
to flow faster fOLbetter liner cooling. Coolant from Total.system cooIant capacity will depend on the
the top of the liners goes into the cylinder head which size of the heat exchanger. Use a coolant mixture of
sends the coolant around the parts where the te m- 50 percent pure water and 50 percent permanent
perature is the hottest. CooIant then goes to the top of antifreeze, then add a concentration of 3 to 6 percent
the cylinder head and out through an elbow, one at corrosion inhibitor.
each cylinder head, into water cooled exhaust mani-
folds (6) at each bank of cylinders. CooIant then goes
through the manifolds to the temperature regulator
(thermostat) housing.

lO

ELECTRICAL SYSTEM
SYSTEMS OPERATION

AIR SHUTOFF SOLENOID


A solenoid changes a n electrical input into a
mechanical output. The air shutoff solenoids are
used to release a plate assembly in the air inlet pipe
to a closed position. This stops the engine.
The air shutoff solenoid can only be automatically
activated by an engine overspeed condition, or
manualIy activated by pushing an emergency shut-
down button. These solenoids have single coil wind-
ings and are eneruized tA shutofLLF5J1L __
WIRING DIAGRAMS
SYSTEMS OPERATION

WIRING DIAGRAMS
INSTRUMENT PANEL

-GY- -...../ '- __ -:- ..J

r----,tt:- \&~-Kl :-<


.\.
IVI
I
5--

.\. 1
:y
,\,
1
1
} 1 1 I
I I
( I
r--------J I I

r- -r--- -=---------------- -- ~:= ~ - ~


1

R I R W¡B I W/B
8 ? ~ I W/B 1
I I I
1 I I

TSl
--.-+-02_,__ -? O ? b b ~ ~
~ q 99 Q ?~~
I I I \ I I I 1...
1 1 1 l ..... ,

) L_~~~~~-~~~---~:~~ .,:f-~:;:::!J..----
AI7333Xl
9 10 ~11 12
13
WIRING DIAGRAM FOR INSTRUMENTPANEL
1.Light switch. 2. Panellights. 3. Instrument panel. 4. Ammeter. 5. Oil pressuregauge. 6. Watertemperaturegauge. 7. Gear
oil pressuregauge. 8. Terminal strip. 9. Wire to battery. 10.Oil pressureswitch with time delay. 11.Sending unit for oll pres-
sure. 12. Sending unit for water temperature. 13. Sending unit for gear oil pressure.

1~ 2 3 4 5 6

/~\rr---j_-{;¿J~
,~~.~ ,/ I~ I
TS2-4 :-.( I :,' I ~, 1
I I I
II I I
I I I
I I
TS~5
OR
TS2-5

A17555Xl

GAUGESWITH RESISTORSFOR 32 VOLT SYSTEM


1. Resistor. 2. O lo 80 psi 011 pressuregauge. 3. Resistor.
4. 100° lo 240°F water temperature gauge. 5. Resistor.
6. O to 300 psi gear 011 pressure gauge.

IJ
WIRING DIAGRAMS
SYSTEMS OPERATION

CHARGING SYSTEM

TSj-l : TS:1-3
I TSl-21
I I
I
I
I
/2 . TABLE OF CALlBRATEO LEAOS
LENGTH OF EACH LEAO WIRE SIZE
I I I~--o l·' (AMMETER TO SHUNT) (AWG NO.)

: \IStt~1 2.3
3.7
5.9
m
m
m
( 7.7
( 12.2
( 19.4
ft)
ft)
tt)
18
16
14
j 9.5
14.9
m
m
( 31.0
( 49.0
tt)
ft)
12
10
23.8 m ( 78.0 ft)
8
37.8 m (124.0 ft)
6
IF LENGTHS OTHER THAN THOSE GIVEN ON THIS
TABLE ARE REQUIRED THE TOTAL RESISTANCE OF
A 17554XI 3 4 BOTH LEADS TO BE .100 OHM.
CHARGING SYSTEM
1. Shunt. 2. Regulator. 3. Battery. 4. Alternator.

PYROMETERS

RED
NEGATIVE

PYROMETER

NO. 18 GAGE COPPER


WIRE

THERMOCOUPLES
IN EACH EXHAUST
STACK
ENGINE CENTER LlNE

EXHAUST MANIFOLD
A99258X 1

DUAL PYROMETER ANO THERMOCOUPLES

14
SYSTEMS OPERATION

SELECTORSWITCH

----
ENGINE CENTER UNE

A99257Xl

PYROMETER, SE.LECTORSWITCH ANO


THERMOCOUPLES TO MEASURE INDIVIDUAL
EXHAUST PORT TEMPERATURES

SELECTORSWITCH

NO. 18 GAGE COPPER


WIRE

A99256Xl

PYROMETER, SELECTOR SWITCH ANO


THERMOCOUPLES TO MEASURE INDIVIDUAL
EXHAUST PORT ANO STACK TEMPERATURES

15
WIRING DIAGRAMS
SYSTEMS OPERATION

AIR START

1
r----~- __ - --- UNE
I
I
I r-------- -.- NEUTRAL
,I ,I 120 VAC

I I

2
885193X1
AC AIR STARTERWIRING DIAGRAM
1. Start pushbutton. 2. Air solenoid valve.

1 ,-------------. --- -----LlNE

\1 ,--------.-. ---. -E--NEUTRAL

'----1'-
L_
... -____ __J
I 240VAC

,-- _ _J

4 5 885194X1
AC AIR STARTERWITH AC PRELUBEPUMPWIRING DIAGRAMS
1. Prelube pump. 2. Relay. 3. Start pushbutton. 4. Air solenoid valve. 5. Pressureswitch.

16
WIRING DIAGRAMS
SYSTEMS OPERATION

CONVERTER ASSEMBL y
(AC Source lo DC Output)

2 B85195Xl

SPEED
RAISES ..... -----l~ LOWERS

5
WIRING DIAGRAM FOR 115 VOLT SOURCE
1. Voltage source. 2. Converter assembly. 3. Jumpers. 4. Toggle switch (momentary). 5. Synchronizing motor.

2 B85196Xl

SPEED

RAISES LOWERS

r-----l


_ _1

OFF RED
POSITION

3 4 5
WIRING DIAGRAM FOR 230 VOLT SOURCE
1. Voltage source. 2. Converter assembly. 3. Jumper. 4. Toggle switch (momentary). 5. Synchronizing motor.

17
WIRING DIAGRAMS
SYSTEMS OPERATION

TACHOMETER

885197X1
WIRING DIAGRAM FOR TACHOMETERCIRCUIT ONLY
1. Magnetic pickup. 2. Tachometer. 3. Second tachometer (jf used). 4. Ground connection (ground to engine). 5. Wiring
connections tor second tachometer, If used (all wires must be 22 AWG shielded cable or larger).

IX
POWER T AKE-OFF. CLUTCHES
SYSTEMS OPERATION

POWER TAKE-OFF CLUTCHES


5

~.. _-------------------

10
B25057~2

POWER TAKE-OFF CLUTCH


1. Ring. 2. Plate assemblies. 3. Levers. 4. Lever. 5. Collar
assembly. 6. Key. 7. Fork. 8. Nut. 9. Output shaft. 10.
Hub. 11. Plate assemblies.

Power take-off clutches (PTO's) are used to send


hold the faces of pIate assemblies (2), plate assem-
power Irorn the engine to accessory components. For
bIies (11) and hub (10) tight together. Friction
exarnple, a PTO can be used to drive an air compres-
sor or a water pump. between these faces permits the flow of torque from
ring (1), through plate assemblies (2), to plate as-
The PTO is driven by ring ( 1) that has spline teeth semblies (11) and hub (10). Spline teeth on the inside
around the inside diameter. The ring can be connect- diameter of the plate assembIies drive the hubo The
ed to the front or rear of the engine crankshaft by an hub is heId in position on output shaft (9) by a taper
adapter. nut (8) and key (6).

The spline teeth on the ring engage with the spline When lever (4) is moved to the NOT ENGAGED
teeth on the outside diameter of driven plate assem- position, fork (7) moves collar assembly '(5) away
blies (2). When lever (4) is moved to the ENGAG ED from the engine. The movement of the collar assern-
position, fork (7) moves collar assembly (5) in the bly will reIease levers (3). With the levers released
direction of the engine. The collar assembly is con- there will not be enough friction between the faces of
nected to four levers (3). The action of the Ievers will the clutch assembly to permit a flow of torque.

19
TROUBLESHOOTING
TESTING ANO AOJUSTING

TROUBLESHOOTING

Troubleshooting can be difficult. On the following pages there is a Iist of


possible problems. To make a repair to a problem, make reference to the cause
and correction.

This list of problems, causes, and corrections, wilI only give an indication of
where a possible problem can be, and what repairs are needed. NormalIy,
more or other repair work is needed beyond the recommendations in the list.
Remember that a problem is no! normally caused only by one part. bu! 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.

Item Problem
l. Shutoff Solenoid Prevents Engine Start.
2. Shutoff Solenoid Fails to Stop Engine.
3. Contactor Switch For Water Temperture Ooes
Not Activate Shutoff Solenoid.
4. Contactor Switch For Water Ternperature
Activates Shutoff Solenoid at Wrong Tern-
perature.
5. Contactor Switch for Oil Pressure Fails to
Activate Shutoff Solenoid.
6. Electrical Gauges Give Wrong Readings.
7. Clutch Will Not Engage (Slips), Heats or Lever
M oves to Released Position.
8. Clutch Shaft Has Too Much End Play.
9. Clutch Bearings Have Short Service Life.
10. Woodward UG-8 Governor.
a. No Output From Governor.
b. Engine Has Slow Response To A Change
In Speed Setting or Load.
c. Engine Ooes Not Have Stability.
d. Engine WilI N ot Orive Full Rated Load.
e. Load S haring Between Paralleled Units
Is Not Correct (One unir on zero Droop, all
others on Droop).
f. Load Sharing Between Paralleled Units
Is Not Correct (AII units on Oroop).
For information on the 230 I Electric Governors
(see module 2301 ELECTRIC GOVERNORS,
Form No. SENR2928).
For information on the 3161 Governor (See
module CATERPILLAR 3161 GOVERNOR,
Form No. SENR3028).

For information on the Electric Protective Sys-


tem (See module ELECTRIC PROTECTIVE
SYSTEM, Form No. SENR2985).

20
I HUUBLESHOOTlNG

TESTING ANO ADJUSTING

1. SHUTOFF SOLENOIO PREVENTS ENGINE START


Cause
Correction
Shutoff Solenoid Does Not Oper-
ate 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. lf the
engine starts, the shutoff solenoid is either not installed correctly
or it is bad. Make reference to TESTING ANO AOJUSTING.

2. SHUTOFF SOLENOIO FAILS TO STOP ENGINE


Cause
Correction
Wrong Connections
Check connections and wiring.
Plunger Shaft Adjustment Wrong
Make adjustment to plunger shaft.
Wrong Plunger in Shutoff Sole-
noid 1nstall the correct plunger shaft.

Not Enough Plunger Travel


Make adjustment to plunger shaft or replace solenoid if necessary.

J. SOLENOIO
CONTACTOR SWITCH FOR WATER TEMPERATURE DOES NOT ACTlVATE SHUTOFF

Cause
Correction
Wrong Connections
Connect battery to C and shutoff solenoid to NO connections.
Check connections to other components or make installation of new
WIfIng .:
Failure of Shutoff Solenoid
Check the shutoff solenoid.
Low Water Level in Cooling
System Fill the cooling system.

Wrong Setting of Switch


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

4. AT
CONTACTOR SWITCH FOR WATER
WRONG TEMPERATURE TEMPERATURE ACTlVATES SHUTOF¡'.· SOLENOID

Cause
Correction
Wrong Setting of Switch
Make a test 01' temperature setting a nd if necessary install new
contactor switch with correct setting. See specifications.

21
TROUBLESHOOTI~G
TESTING ANO AOJUSTING

5. CONTACTOR SWITCH FOR OIL PRESSURE FAILS TO ACTIVATE SHUTOFF SOLENOID


Cause
Correction
Wrong Connections
Check connections, wiring and correct where necessary.
Wrong Setting of Switch
Test contactor switch. If necessary, install new contactor switch.

6. ELECTRICAL GAUGES GIVE WRONG READINGS


Cause
Correctlon
Wrong Connections
Check wiring connections to be sure they are correct.
Sending Units Have a Failure
Check the sending units and install new ones if necessary.
Resistor in 32 Volt Systems Has a
Install a new resistor.
Failure
Wrong Sending Unit in System
Install correct sending unit.
Wrong Gauge
Install correct gauge.

7. CLUTCH WILL NOT ENGAGE (SLIPS). HEATS OR LEVER MOVES TO RELEASED POSITION.
Cause
Correction
Wrong Adjustment
Make adjustment to clutch engagement lever pullo
Alignment of Flywheel and
Check and make adjustment to alignment.
Flywheel H ousing M ounting
Face and Bores
Overload on Clutch
Reduce load or reduce engine speed when engaging clutch.

8. CLUTCH SHAFT HAS TOO MUCH END PLAY.


Cause
Correction
Bearing Worn or Adjustment
Wrong Replace andj or make adjustment to shaft bearing.

9. CLUTCH BEARINGS HAV~ SHORT SERVICE LIFE


Cause
Correction
Too M uch Bearing Clearance
Replace andj or make adjustment to shaft bearing.
Side Load Too High
Make reduction of side load.

22
I HUUBLESHOOTlNG
TESTING ANO AOJUSTING

lOa. NO OUTPUT FROM GOVERNOR


Cause
Correction
Engine Cranking Speed Too Low
Make reference to TROUBLESHOOTING in ENGINE TESTING
ANO ADJUSTING.
Bad Lubrication Oil
Remove, drain and clean the governor. Fill governor with clean oil
of the correct grade, and make sure to bleed any trapped air in gov-
ernor oil passages.
N o Governor Oil Pressure
Inspect the governor oil pressure relief valve. Make replacement if
necessary.

Inspect pump check valves and their seats. Make replacements if


necessary.

Inspect governor oil pump. Make repairs as necessary.


Governor Orive Has a Failure
Repair the governor drive.
Fuel Control Linkage Has a
Failure Inspect and adjust linkage. Make repairs as necessary.

lOb. ENGINE HAS SLOW RESPONSE TO A CHANGE IN SPEED SETTlNG OR LOAD


Cause
Correction
Compensation Adjustments
Incorrect Adjust needle valve and compensation pointer.

Load Limit Knob Set to Restrict


Increase load limit setting.
Fuel (UG8 OialGovernor Only)
Engine Has an Overload
Decrease the load.
Low Governor Oil Pressure
Remove, drain and clean the governor.
Inspect the governor oil pressure relief valve. Make a replacement
if necessary.

Inspect pump check valves and their seats. Make replacement if


necessary.

Inspect governor oil pump. Make repairs as necessary.


Fill the governor with clean oil of the correct grade, and bleed any
trapped air from the governor oil passages.
Problem With Engine Fuel
System Make reference to FUEL SYSTEMS in ENGINE TESTlNG ANO
ADJUSTlNG.
TROUBLESHOOTING
TESTING ANO AOJUSTING

roe. ENGINE SPEED DOES NOT HAVE STABILITY.


Cause
Correction
Compensation Adjustments
lncorrect Adjust needle valve and compensation adjustment pointer.
Dirty Oil in Governor
Drain oil. Clean governor and refill with the correct grade of new oil.
Low Oil Leve1
Add oil to correct level. Check for leaks, especially at drive shafr.
Air In Oil (Foarn) in Governor
Drain oil. Refill with correct grade of oil.
Too Much Play in Governor
to Engine Linkage Repair or replace linkage.

Governor to Engine Linkage


Does Not Move Freely Make reference to GOVERNOR ALIGNMENT PROCEDURE
in specifications.
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.
Low Governor Oil Pressure
Remove, drain and clean "lhe governor.

Inspect the governor oil pressure relief valve. Make a replacement


if necessary.

Inspect pump check valves and their seats. Make replacements as


necessary.

lnspect governor oil pump. Make repairs as necessary.


Fill the governor with clean oil of the correct grade, and bleed any
trapped air from the governor oil passages.
Power Piston Sticking
Check alignment of piston, power link and power lever. Check for
end play of terminal shaft.
Voltage Regulator Does
Not Operate Correctly Adjust or repair the generator voltage regulator.

Engine Misfiring
Make reference to FUEL SYSTEMS in ENGINE TESTING AND
ADJUSTlNG.

24
I HUUBLESHOOTlNG

TESTING ANO AOJUSTING

lOd. ENGINE WILL NOT DRIVE FULL RATED LOAD


Cause
Correction
Fuel Control Linkage Does Not
Move Freely Make reference to GOVERNOR ALIGNMENT PROCEDURE
in Specifications.
Engíne Fuel System Has a
Problem Use the FUEL SYSTEM section ofTESTING ANO ADJ USTlNG
as a reference. Make repairs as necessary.
Low Governor Oil Pressure
Remove, drain and clean the governor. Make sure air is not he Id 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 and their seats. Make replacernents as


necessary.

Inspect governor oil pump. Make repairs as necessary.


Fill the governor with clean oil of the correct grade, and bleed any
trapped air from the governor oil passages.
Voltage Regulator Does Not
W ork Correctly Adjust or repair generator voltage regulator.

lOe. LOAD SHARING BETWEEN PARALLELED UNITS IS NOT CORRECT (one unit on zero droop
and all the others on droop)

Cause
Correction
Droop Setting is Too Low on
Sorne Units Increase droop setting on these units until the load is constant on
each droop unit.
Different Speed Settings on the
Units Adjust speed settings on droop units. No load speed on all droop
units should be the same.

IOr. LOAD SHARING BETWEEN PARALLELED UNITS IS NOT CORRECT (all units on droop)
Cause
Correction
Speed Droop Setting on One or
M ore Units is N ot Correct Adjust droop on each unit to get the desired division of load.

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


Different Speed Settings on the
Units Adjust the speed settings. No load speed on all units should be the
same.

25
FUEL SYSTEM
TESTING ANO AOJUSTING

FUEL SYSTEM
INJECTOR SYNCHRONIZAT~ON
l. The top bolt that holds cover (3) in position is
i
Tools Needed: synchronizing pin (2). Remove synchronizing
6V3119 Rack Synchronizing Gauge. pin (2) and plug (1) from the front drive hous-
ing. DO NOT destroy seal or remove cover (3).
Injector synchronization is the setting of all in- 2. Remove the washer from synchronizing pin (2)
jector racks to a reference position so each injector and install it into the threaded hole where plug
gives the same amount of fuel to each cylinder. This (1) was removed. Tighten synchronizing pin (2).
is done by setting each injector rack to the same
position while the control linkage is in a fixed posi- NOTICE
tion (called the synchronizing position). The pro-
cedure for adjustment of injector synchronization Do not force the governor linkage toward in-
is as follows: creased fuel unless the load limit knob is
turned to TEN. The result will be damage to
the governor.

3. Turn the governor or actuator terminal shaft


to the fuel "ON" position until the fIat face of
fuel stop lever (4) contacts synchronizing pin
(2). This is the synchronizing position or zero
reference point. Hold the controllinkage in this
position when the injectors are adjusted.

LOCATION OF FUEL SETTING COVER


ANO SYNCHRONIZINGPIN
(Typical Example)
1. Plug. 2. Synchronizing pino 3. Cover.

LOCATION FOR GAUGE ANO CONTROLROOAOJUSTMENT


(Rocker Shaft Removedtor IlIustration)
5. 6V3119Rack Synchronizing Gauge [12.7 mm (.50 in.)].
6. Control rod.

4. Remove the valve covers.


5. With the fuel stop lever against the synchroniz-
ing pin, put 6V3119 Rack Synchronizing Gauge
(5) on the round part of the fuel injector rack
(7) between the injector body and the end of
the rack. Use a screwdriver and make an adjust-
ment of control rod (6). Turn the screw on
control rod (6) one "click " at a time until rack
synchronizing gauge (5) just fits bet ween the
injector body and the shoulder at the end of
SYNCHRONIZINGPOSITION
(Governor FastenerCover RemovedOnly For lIIustration) . the rack. Remove the screwdriver frorn control
2. Synchronizing pino 4. Fuel stop lever.
rod (6) so no presssure is on the linkage while
the setting is checked with rack synchronizing

26
I-UEL SYSTEM
TESTING ANO ADJUSTING

gauge (5). Any pressure on the linkage with the


screwdriver will not give a correct indication
when the setting is checked with the rack syn-
chronizing gauge. To make sure the linkage is
free and giving the correct setting, move (flip)
the linkage and check the setting again. Put the
box end of a 9/ ]6" to 5/8" combination wrench
over the nut and bolt that holds control rod (6)
and the bellcrank together. Pull up on the con-
trol rod two or three times; then check the set-
ting again.
A98724Xl

SYNCHRONIZATIONANO FUEl SETTINGTOOlS


1. 6V3119Rack Synchronizing Gauge. 2. 6V3075Dial In-
dicator (metric). 3. 5P4814Collet. 4. 5P7263Contact
Point, 76.2mm (3.00in.) long.

Before the fuel setting is checked, the injectors


must be correctly synchronized. See the subject IN-
JECTOR SYNCHRONIZATION. After the in-
jectors are synchronized correctly, leave the syn-
chronizing pin in place for the proced ure tha t
follows.

GAUGEIN POSITIONON INJECTORRACK


(Rocker Shaft Removedfor lIIustration)
5. 6V3119Rack Synchronizing Gauge[12.7 mm (.50 in.)].
7. Fuel injector rack.

6. Use rack synchronizing gauge (5) and, if neces-


sary, make the adjustment to the other injec-
torso When all adjustments have been made,
release the actuator terminal shaft.
7. 1nstall the val ve covers.
8. Make a check of the fuel setting and make
adjustments if necessary. See subject FUEL
SETTING for this procedure. INSTAllolAllNolCATOR
(Typical Example)
2. 6V3075Dial Indicator with 5P7263Contact Point at-
FUEL SETTING tached. 3. 5P4814Collet.

Tools Needed:
6V3139 Timing and Fuel Setting Tool Group.
5P4814 Collet. l. Put 6V3075 ~ial Indicator (2) with 5P7263
6V3075 Dial Indicator (metric). Contact Point (4) in 5P4814 Collet (3). Remove
5P7263 Contact Poínt, 76.2 mm (3.00 in.) long. the plug from the right side of fuel setting cover
6V3119 Rack Synchronizing Gauge 12.7 mm (.50 in.). (8).

Fuel Setting Check


NOTICE
Fuel setting is the adjustment of the fuel setting
screw to a specified position. The fuel setting screw Do not force the governor linkage toward in-
limits the power output of the engine by setting the creased fuel unless the load limit knob is
maximum travel of all the injector racks. turned to TEN. The result will be damage to
the governor.
FUEL SYSTEM
TESTING ANO AOJUSTING

NOTE: See FUEL SETTING AND RELATED


INFORMA TION FICHE for the correct fuel
setting.

5. If fuel setting is correct, remove the dial indica-


tor and synchronizing pin (5). Install the two
plugs, and install pin (5) back into cover (8).
6. If fuel setting needs adjustment, go on to Fuel
Setting Adjustment.

Fuel Setting Adjustment

DIAL INDICATOR IN POSITION


NOTICE
(Covers Removed Only for Photo lIIustration)
A mechanic with governor and fuel setting
2. 6V3075 Dial Indicator. 4. 5P7263Contact Point, 76.2 training is the ONLy one to make adjustments
mm (3.00 in.) long. 5. SynchrOnizing pino 6. Fuel stop
lever. to the engine fuel setting.

2. Move the governor or actuator terminal shaft l. Cut the seal wire and remove fuel setting cover
in the fuel HON" direction until the flat face of (8) and the gasket. Loosen locknut (7) and (with
fuel stop lever (6) contacts synchronizing pin fuel stop lever still held against end of the fuel
(5). Hold the linkage in this position. setting screw) turn the fuel setting screw in or
out until the correct reading is on the dial
3. Install the dial indicator and collet (3) in the indicator.
threaded hole as shown. When the contact point
seats against fuel stop lever (6), slide the dial
indicator in or out until the indicator reads zero.
Now tighten collet (3) just enough to hold in-
dicator at this position.
4. Turn synchronizing pin (5) back out a mínimum
of 25 mm (1 in.) (or remove it cornpletely), and
then slowly move the governor or actuator ter-
minal shaft in the fuel HON" direction until the
flat face of the fuel stop lever is against the end
of the fuel setting screw. With the linkage held
in this position, the dial indicator reading will
be the present fuel setting.
ADJUSTMENT OF THE FUEL SETTING SCREW

2. Now tighten locknut (7). Be sure that the fuel


setting screw does not turn when the locknut (7)
is tightened. Release the fuellinkage and again
move linkage all the way in the fuelHON" direc-
tion. Check the dial indicator reading again to
be sure that fuel setting is still correct.
3. Remove the dial indicator and synchronizing
pin (5), then install the two plugs.

4. Put fuel setting cover (8) and gasket in position


CHECKING FUEL SETTING over the fuel settíng screw and install bolt and
2. 6V3075Dial Indicator (metric). 5. Synchronizing pino synchronizing pin (5) in cover. Install a new seal
8. Fuel setting cover. wire.

2X
r-UEL SYSTEM
TESTING ANO AOJUSTING

INSTALL COVER
7. Locknut. 8. Fuel setting cover.

ENGINE SPEED MEASUREMENT

·0· o·. - .:.ijtl~:


.
..¡;'~ .

~-
B19988X2
CJ -JI
,

6V3121 MULTITACH GROUP

The 6V3121 M uItitach Group can measure engine


speed frorn a tachometer drive on the engine. It also
has the ability to measure the engine speed [rom
visual engine parts in rotation.
Special Instruction, Form No. SEHS7807 is with
the 6V3121 M ultitach Group and gives instructions
for the test proced ure.
WOODWARD UG8 DIAL GOVERNOR
TESTING ANO ADJUSTING

WOODWARD UG8 DIAL GOVERNOR


COMPENSATING ADJUSTMENT
7. Check the number of tums the needle valve is
Although thc governor may appear ro be operaring open. To find the number of tums the needle valve
sati",factorily at no load. high ovcrspeeds and under- is open, cIose the valve completely and make a
speeds alter load changcs and slow return lo normal note of the number of turns needed to close the
speed are the results 01' incorrect compensatíon valve.
adjustments.
8. Open the needle valve to the sarne posi tion at
Make compcnsaring adjustments after the tempera- which the engine did not surge.
ture of the engine ami the oil in the governor have
reached normal operating values and with the engine 9 .. Move the governor linkage to change the engine
running at no load conditions. speed. If the engine does not surge, and the needJe
valveis 1/2 to 3/4 of a turn open, the governor
adjustment is correct. Install the plug in the base.
TYPE UG-8 If the needle valve is more than 3/4 of a turn open,
do the steps that follow.
l· ==_"?~~,)_~~~~'
1 ~ : 10. Loosen the nut that holds the compensation point-

.:~r'"
!U1 "¡
er and move the pointer up two rnarks on the
.,
'"
SPEEO OIiOQp
I •
SYNCHRCNllfR pointer scale.

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


L040-lf"'lT ~R
counterclockwise direction.

12. Let the engine surge for approximately 30 seconds


to help rernove air frorn the governor.

13. Slowly turn the needle valve in a cIockwise direc-


tion until the engine does not surge.
14. Check the number of turns the needle valve is
open. To find the number of turns the needle valve
is open, close the valve completely and make a
A90207X1 note of the number of turns needed to el ose the
valve.
UG8 DIAL GOVERNOR
1. Nut. 2. Compensationpointer. 3.Plug. 15. Open the needle valve to the sarne posi tion at
which the engine did not surge.
l. Loosen the nut that holds the compensation point-
er and move the pointer up as far as it will go. 16.. Move the governor linkage to change the engine
Tighten the nut . speed.

2. Remove the plug fmm rhe base of the governor. If the engine does not surge, and the needle valve is
1/2 to 3/4 of a tum open, the govemor adjustment is
J. U se a wide blade screwdriver and engage lhe wide correcto Install the plug in the base. If the needle valve
screwdriver slot in the needle valve. Turn the is more than 3/4 of a turn open do Steps 10 thru 16
needle val ve three or more tums in a counterclock- again.
wise direction.
A needle valve that is opened less than 1/2 tllrn will
4-. Let the engi ne surge for approxímarely 30 seconds cause the engine to be slow to retum to normal speed
to help remove air from the govemor. after a load change.
5. Loasen rhe nur rhat holds the compensation point- If the compensation pointer is too far toward the
er and move the pointer down as far as it will go. maximum position, the engine speed change wiIl be too
Tighren rhe .nut.
great when the load changes.
6. Slowly turn rhe needle valve in a clockwise direc-
tion until the engine does nor surge.

~o
VVUUUWARO UG8 DIAL GOVERNOR
TESTING ANO AOJUSTING

HIGH IOLE SPEEO AOJUSTMENT


7. Turn the synchronizer control knob counter-
Connect a tachometer with good accuracy to the clockwise to change the engine speed. N ow turn
engine. Make reference to subject MEASURING the knob to the high idle stop and check the high
ENGINE SPEED. idle adjustment.
1. Start the engine and run to get the engine to the 8. lnstall the synchronizer indicator knob and the
normal temperature of operation. dial plate.
2. Use synchronizer control knob (5) to adjust the NOTE: Low idle speed is not adjustable, but wiII
engine speed and check the high idle speed stop change as high idle adjustment is made. If Iow idIe
adjustment. is not correct, an increase in high idIe speed will
increase low idle speed, and a decrease in high idIe
speed will decrease Iow idIe speed.

GOVERNORADJUSTMENTS
(Example Only)
1. Terminal lever. 2. Idler gear. 3. Load limit con-
trol. 4. Linkage. 5. Synchronizer control knob. 6. Gear.
7. Synchronizer indicator knob.

3. 1f the high idIe speed is not correct, remove the


dial plateo

NOTE: Make reference to the FUEL SETTING


AND RELATED INFORMATION FICHE for
the correct high idle speed.

4. Loosen the setscrew on synchronizer indicator


knob (7), remove tapered pin if equipped and
remove the knob.

5. Pull gear (6) out of mesh with idler gear (2).


Turn synchronizer control knob (5) until the
correct high idle speed is reached.
6. To set the high idIe speed stop, turn gear (6)
cIockwise untiI the stop pin on the gear makes
contact with idler gear (2). Push gear (6) into
mesh with idIer gear (2).

JI
LUBRICATION SYSTEM
TESTING ANO AOJUSTING

LUBRICATION SYSTEM
DUPLEX OIL FIL TER

DUPLEXOIL FILTER
1. Selector valve shaft. 2. Handle. 3. Plunger assembly. 4. Linkage. 5. Lever.

Linkage Adjustment
corners of nut) until the selector valve shaft (1)
l. Disconnect linkage (4) from lever (5) andj or
handle (2). has an axial movement of 0.22 ± 0.08 mm (.OOX
± .003 in.).
2. Rotate lever (5) to move selector valve to Main
3. Hold adjustment nut (6) with a wrench. and
Run position (countercIockwise direction) until tighten ja m nut (7) to a torque of 45 ± 7 N-n:
valve is against stop pin inside cover assembly (35 ±. 5 lb. ft.).
(8 ).
4. Now rotate selector va lvc. Va lve should m ove
3. Push handle (2) to Main Run position untiI ball
freely with no binding. Ir valvc does not m ovo
of plunger assembIy (3) seats into hole of freely, more adjustment is necessary.
mounting bracket.
4. Now adjust Iinkage to fit between Iever (5) and
handle (2). Install linkage back to Iever (5)
and o r handle (2).

Selector Valve Adjustment


NOTE: The adjustment procedure that follows must
be done with the temperatureat 20° e (68 ° F) and
the complete surface of selector valve must be lu-
brica ted wit h engine oil.
l. Loosen ja m nut (7). Tighten adjustment nut (6)
to a torque of 3 Nvm (2 lb. ft.). Scribe a mark
on face of cover assembly (8) to locate one of
the corners of the adjustment nut (6).
2. No w back off (Ioosen) adjustment nut (6) ap- SECTlON A-A
proximately 30° (VS the distance between two 1. Selector valve shaft. 6. Adjustment nut. 7. Jam nut.
8. Cover assembly.

32
In., I HUMENTS ANO GAUGES
TESTING ANO AOJUSTING

INSTRUMENTS ANO GAUGES


OIL PRESSURE SENDING UNITS

SENDING UNIT FOR WATER TEMPERATURE


1.Terminal. 2. Nut. 3. Bulb.

3. Take resistance readings at the temperatures shown


32979Xl in the chart.
SENOING UNIT FOR OIL PRESSURE
PART NO. TEMPERATURE RESISTANCE (OHMS)
1. Terminal. 2. Fitting.
5L7442 800 to 900

l. Conneet the sending unit to a pressure souree that


ean be measured with aeeuraey.
2. Conneet an ohmmeter between fitting (2) and ter-
minal (1). 4. If a unit does not have the correet resistance
readings, make a replaeement of the unit.
3. Take resistanee readings at the pressure shown in
the ehart.

ELECTRIC GAUGES

1. Put the gauge in position with the letters horizontal


and the Iace 30° baek from vertical.
5L7450 SENDING UNIT
PRESSURE RESISTAN CE (OHMS)
O kPa (O psi) O
415 kPa (20 psi) 13.5
550 kPa (80 psi) 30

4. lf a unit does not have the eorreet resistanee read-


ings, make a replaeement of the unit.

WIRING DIAGRAM FOR TEST


WATER TEMPERA TURE SENDING UNIT 1.Terminal (for test voltage). 2. Test resistance.

l. Conneet an ohmmeter between terminal (1) and nut


(2). Put bulb (3) in a pan of water. Do not let the 2. Conneet the gauge in series with the power source
bulb have eontaet with the pan. and the middle test resistunce shown in the chart.

2. Put a thermometer in the water to measure the 3. Let the gauge heat at the middle resistance for 5
temperature. minutes, then check the pointer position for all 01'
the resistanees given.

33
INSTRUMENTS ANO GAUGES
TESTING ANO AOJUSTING

CHART FOR TESTING TEMPERATURE GAUGE


GAUGE TEST
PART NUMBER TEST
VOLTAGE RESISTANCE TEMPERATURE SENOER
28.5 *RESISTOR
5L7444 33880hms 38°C (100°F)
28.5 10500hms 5L7442 5L7441
28.5 77°C (170°F) 5L7442
4600hms 5L7441
116°C (240°F) 5L7442
'In 32 volt systems the resistor IS needed. 5L7441

CHART FOR TESTING OIL PRESSURE GAUGE


GAUGE TEST
PART NUMBER TEST
VOLTAGE RESISTANCE PRESSURE SENOER *RESISTOR
28.5 O Ohms
5L7456 O kPa (O psi) 5L7450
28.5 13.50hms 5L7441
140 kPa (20 psi) 5L7450 5L7441
28.5 300hms 550 kPa (80 psi) 5L7450 5L7441
·In 32 valt systems the resistar is needed.

MECHANICAL GAUGES FOR


TEMPERATURE MECHANICAL GAUGES FOR
OIL PRESSURE

To check these gauges, put the bulb of the gauge in a


pan of" oil. Do not let the bulb touch the pan. Put a To check these gauges connect the gauge to a pressure
thermometer in the oil to measure the temperature. source that can be measured with accuracy. Make a
Muke a comparison of temperatures on the thermom- comparison of pressure on the gauge of test equipment
der with the temperatures on the direct reading guage. with the pressures on the direct reading gauge.

48735X 1
95584Xl

OIRECT REAOING GAUGE


OIRECT REAOING GAUGE

34
INSTRUMENTS ANO GAUGES
TESTING ANO ADJUSTING

CONTACTOR SWITCH FOR WATER


TEMPERATURE 5. Connect the 8S4627 Circuit Tester between the
wires that connected the contactor to the circuit.
Tools Needed:
Fabricated heat sink.
2F7112 Thermometer.
3J5389 Plug.
8S4627 Circuit Tester.

1. Make a heat sink as shown. Material can be brass,


steel orcast iron. Drill a 23/32 in. hole through the
pIate 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.

X3974

TEST OF CONTACTOR SWITCH


1. 2F7112Thermometer. 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 test light does not come on within the
temperature range given in the specifications
make a replacement of the contactor.
HEAT SINK
[Dimensions in inches (mm)) 8. Let the water temperature go down. Ir the circuit
tester light does not go out within the temperature
range given in the specifications make a replace-
3. Remove the contactor and install a 3J5389 Plug. ment 01' the contactor.
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
leveI.

35
C.ATERPILLAR®

SENR2364
Printed In U.S.A. (7/84)