839638 Volvo.Penta Cube

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 cannot give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs. For each problem, a list of possible causes and corrections is given. The list of probable causes and corrections should be performed in numeric sequence.1. Contactor Switch For Water Temperature Activates At Wrong Temperature.2. Contactor Switch For Oil Pressure Does Not Activate Shutoff Solenoid.Troubleshooting Problems
Problem 1: 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 2: 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.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.Magnetic Pickup
Typical Illustration(1) Clearance between magnetic pickup and flywheel ring gear ... 0.55 to 0.83 mm (.022 to .033 in) With the engine stopped, turn the pickup in until it comes in contact with the 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.(2) Tighten the locknut to a torque of ... 45 7 N m (33 5 lb ft)Oil Pressure Switch
Oil Pressure Switch
Terminal 1 is common. Terminal 2 is normally open. Terminal 3 is normally closed. For the pressure at which each circuit will be switched find the switch in specifications section of this manual.1. Connect the oil pressure switch to a pressure source that can be measured with accuracy.2. Connect a circuit tester between terminal (2) and terminal (1).3. With pressure increase, the circuit light will light.4. With pressure decrease, the circuit light will go out.5. Connect a circuit tester between terminal (3) and terminal (1).6. With pressure increase, the circuit light will go out.7. With pressure decrease, the circuit light will light.8. If the switch fails to operate at the correct pressures, replace the switch.Starting Motor Adjustments
Solenoid Position Adjustment
The solenoid position on the starting motor controls pinion clearance. If the solenoid position is correct, the pinion clearance is correct. Do the following procedure to adjust the solenoid position.
Solenoid Assembly
(1) Intermediate housing. (2) Solenoid mounting bracket. (3) Bolts. (X) 62.50 + 0.20 - 0.50 mm (2.46 + .008 - .020 in).1. Check distance (X) between intermediate housing (1) and solenoid mounting bracket (2) with calipers.2. If distance (X) is not correct, loosen bolts (3) and move the solenoid until distance (X) is correct. Bracket (2) has elongated holes.3. Tighten bolts (3) to 7 to 10 N m (5 to 7 lb ft) after the adjustment is correct.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.