FK1203 Force SEAL KIT

Troubleshooting
Troubleshooting can be difficult. The Troubleshooting Index gives a list of possible problems. To make a repair to a problem, make reference to the cause and correction on the pages that follow.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 list is only a guide and can not give all possible problems and corrections. The service personnel must find the problem and its source, then make the necessary repairs.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 Indicators Give Wrong Readings.13. Automatic Start/Stop Systems. a: No Supply Of Standby Current-Lockout Light Activated (SR Relay Energized)b: No Supply Of Standby Current-No Lockout Light Activated (SR Relay Not Energized)c: Standby Current Supply Stops Before Normal Current Returnsd: Operation Of Standby System When Standby Current Is No Longer Needed14. Starting Motor Does Not Turn.15. Alternator Gives No Charge.16. Alternator Charge Rate Is Low Or Not Regular.17. Alternator Charge Is Too High.18. Alternator Has Noise.19. Rack Solenoid Does Not Stop Engine.Troubleshooting Problems
Problem 1: Contactor Switch For Water Temperature Does Not Activate Shutoff Solenoid Probable Cause:1. Wrong Connections Connect battery to Common Terminal (C) and shutoff solenoid to Normally Open (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 Activates 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 Top 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 is not functioning properly. Make reference to Testing & 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.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: 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. Malfunction 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 Indicators 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 Indicator Install correct indicator. Problem 13a: No Supply Of Standby Current-Lockout Light Activated (SR Relay Energized) Probable Cause:1. Engine Does Crank But Will Not Start-Engine Speed Correct a. Engine starting problem No fuelFuel rack not movingGovernor not operatingWrong injection timingVery low air temperatureRestriction in air inletLow compressionb. Switch problem Water temperature switch has a failureOverspeed switch setting is low or has a failureCranking panel problemOvercranking timer has a failure2. Engine Does Crank But Will Not Start-Cranking Speed Too Slowa. Starting system problem Battery does not have enough chargeFaulty cable connectionsStarting motor has a failureb. Engine problem High friction due to seizurec. Switch problem Oil pressure switch has low setting3. Engine Does Not Crank a. Starting system problem Open circuit or very high