61458-99E60 Suzuki LABEL, ENGINE COVER

Troubleshooting
Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make a repair to a problem, make reference to the cause and correction.This list of problems, causes, and corrections, will only give an indication of where a possible problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations in this 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.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. Mechanical Shutoff Fails to Stop Engine Because of Low Oil Pressure7. Mechanical Shutoff Does Not Stop Engine When Coolant Temperature Is Too High.8. Mechanical Shutoff Will Not Let Engine Start.9. Electrical Gauges Give Wrong Readings.10. PSG Governors. a. Engine Speed Does Not Have Stability.b. Vibration at Governor Output Shaft.c. Fuel Control Response When The Engine Is Started Is Not Acceptable.d. Engine Has Slow Response To A Change In Speed Setting Or Load.e. No Output From Governor.f. Engine Will Not Drive Full Rated Load.g. Load Sharing Between Paralleled Units Is Not Correct (One unit on zero droop all others on droop).h. Load Sharing Between Paralleled Units Is Not Correct (all units on droop).11. Automatic Start/Stop Systems.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. MECHANICAL SHUTOFF FAILS TO STOP ENGINE BECAUSE OF LOW OIL PRESSURE 7. MECHANICAL SHUTOFF DOES NOT STOP ENGINE WHEN COOLANT TEMPERATURE IS TOO HIGH 8. MECHANICAL SHUTOFF WILL NOT LET ENGINE START 9. ELECTRICAL GAUGES GIVE WRONG READINGS 10a. ENGINE SPEED DOES NOT HAVE STABILITY 10b. VIBRATION AT GOVERNOR OUTPUT SHAFT 10c. FUEL CONTROL RESPONSE WHEN THE ENGINE IS STARTED IS NOT ACCEPTABLE 10d. ENGINE HAS SLOW RESPONSE TO A CHANGE IN SPEED SETTING OR LOAD 10e. NO OUTPUT FROM GOVERNOR 10f. ENGINE WILL NOT DRIVE FULL RATED LOAD 10g. LOAD SHARING BETWEEN PARALLELED UNITS IS NOT CORRECT (one unit on zero droop all the others on droop) 10h. LOAD SHARING BETWEEN PARALLELED UNITS IS NOT CORRECT (all units on droop) 11. AUTOMATIC START/STOP SYSTEMThe charts that follow give some of the problems and probable causes for trouble with automatic start/stop systems. Fuel System
Governor Adjustment For Fuel Ratio Control Linkage
6V4186 Timing Pin.6V2106 Rack Adjustment Tool Group.6V2017 Governor Adjusting Tool Assembly.S1614 Bolt [1/4-20 NC x 12.7 mm (.5 in.) long.]6V2031 Rack Position Indicator. 9S229 Contact Point, 9.7 mm (.38 in.) long.5P4814 Collet.6V3075 Dial Indicator.6V7941 Compressor, Overfueling Spring.The governor adjustment for the fuel ratio control linkage can be done with the fuel injection pump and governor on or off the engine.1. Remove cover (1) from the side of the fuel injection pump housing.
FUEL INJECTION PUMP AND GOVERNOR
1. Cover.2. Install 5P4814 Collet (2) on 6V2014 Bracket Assembly (3).3. Install the bracket assembly on the fuel pump housing. Lever (5) on the bracket assembly must be in slot (4) on the fuel rack. Push up on the bracket assembly while the bolts are tightened.After the bracket assembly is tightened to the pump housing, shaft (6) must have axial (in and out) movement. If there is no axial movement of shaft (6), check to be sure lever (5) is in the slot on the fuel rack and that the bracket assembly is installed correctly. Check to make sure that lever (5) is not bent. Lever (5) must be perpendicular (at right angle) to the mounting face of the bracket assembly.
BRACKET ASSEMBLY INSTALLED
2. 5P4814 Collet. 3. Bracket assembly.
COVER REMOVED
4. Slot on fuel rack.
BRACKET ASSEMBLY
5. Lever. 6. Shaft.4. Put 9S229 Contact Point, 9.7 mm (.38 in.) long on 6V3075 Dial Indicator (7) and install dial indicator in collet (2).5. Remove fuel ratio control (8) from the rear of the governor housing.6. Remove plug (9) from the rear of the governor housing.
DIAL INDICATOR INSTALLED
7. 6V3075 Dial Indicator.
GOVERNOR
8. Fuel ratio control.
REAR OF GOVERNOR HOUSING
9. Plug.7. Move the governor control lever to the FUEL OFF Position (rotate governor shaft clockwise).8. Install 6V4186 Timing Pin (10) in the hole in the bracket assembly. Push timing pin in until contact is made with the fuel rack. Hold the timing pin gently against the fuel rack for Steps 9 and 10. If too much force is used to hold the timing pin the fuel rack can stick and cause an incorrect zero reading.
TIMING PIN INSTALLED
10. 6V4186 Timing Pin.9. Hold the governor control lever in the HIGH IDLE position (rotate governor shaft counterclockwise).10. Insert 6V7942 Hook (11) into the hole that plug (9) was removed from. Engage the end of hook (11) with collar (12) and pull toward the rear of the governor housing until the collar stops moving. This will make sure the fuel rack stops against the timing pin. This is the zero rack position.
6V7942 HOOK IN USE
11. 6V7942 Hook.
CUTAWAY VIEW OF GOVERNOR
11. Hook. 12. Collar.11. With the hook still pulled toward the rear of the governor, loosen collet (2) and adjust the revolution counter on the dial indicator to zero. Tighten the collet just enough to hold the indicator in this position. Move the dial of the indicator to get alignment of the pointer and zero.12. Remove timing pin (10).13. Turn rod (13) out of 6V7941 Compressor Assembly (15) until knob (14) is 25.4 mm (1.0 in.) from the compressor body. Install 6V7941 Compressor Assembly (15) in the hole plug (9) was removed from. The 6V7941 Compressor Assembly is used to compress the overfueling spring. The overfueling spring must be compressed to