21230092 Volvo.Penta Flange

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 of 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 can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.Troubleshooting Index
1. Contactor Switch For Water Temperature Fails To Activate Shutoff.2. Contactor Switch For Water Temperature Activates Shutoff At Wrong Temperature.3. Switch For Oil Pressure Fails To Activate Shutoff.4. Engine Protection Panel Will Not Activate Engine Shutoff.5. Engine Protection Panel Stops Engine When Reset Button Is Released.6. Clutch Will Not Engage (Slips), Heats Or Lever Moves To Released Position.7. Clutch Shaft Has Too Much End Play.8. Electrical Gauges Give Wrong Readings. Problem 1: Contactor Switch For Water Temperature Fails To Activate Shutoff Probable Cause:1. Wrong Connections: Connect battery to C and fuel shutoff solenoid to NO connections. Check connections to other components or make installation of new wiring.2. Low Water Level In Cooling System: Fill the cooling system.3. 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 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: Switch For Oil Pressure Fails To Activate Shutoff Probable Cause:1. Wrong Connections: Check and make connections as shown in wiring diagrams.2. Wrong Setting Of Switch: Test and adjust switch. If necessary, install new switch. Problem 4: Engine Protection Panel Will Not Activate Engine Shutoff Probable Cause:1. Fuse Burned Out: Find and correct the cause for the burned out fuse. Install new fuse.2. Grounded Or Loose Wiring: Check and repair any worn or loose wiring.3. Components In System Not Functioning Correctly: Check components and install new ones as needed. Problem 5: Engine Protection Panel Stops Engine When Reset Button is Released Probable Cause:1. Grounded Wiring Between "S" Terminal And Switches: Install new wiring.2. Broken Water Temperature Or Oil Pressure Switches: Check the switches and install new ones as needed. Problem 6. Clutch Will Not Engage (Slips), 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 Faces 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: Electrical Gauges Give Wrong Readings Probable Cause:1. Wrong Connections: Check wiring connections to be sure they are tight. Check to see that the gauges are correctly connected as shown in the wiring diagrams.2. Sending Units Fail To Operate: Check the sending units and install a new one if necessary.3. Wrong Sending Unit In System: Install correct sending unit.Electrical System
Water Temperature Switch
First Method Of Checking
1. Make a heat sink as shown. Material can be brass, steel or cast iron. Drill a 17.8 mm (.70 in) hole through the plate and use a tap to make 1/2 inch NPT threads.2. Put marks on wire connections to water temperature switch terminals and disconnect the wire.
Heat Sink [Dimensions in mm (in)]
Test Of Water Temperature Switch
(1) 2F7112 Thermometer. (2) Fabricated heat sink.3. Remove the water temperture switch and install a 3J5389 Plug. Install the water temperture switch in the heat sink.4. Connect the wires to the water temperature switch to check all of the system; water temperature switch, wires, etc. If the wires cannot be disconnected, use the second method of testing.5. When the water temperature switch is connected again, start the engine and run it at low idle rpm. The pressure switch will complete the circuit when the engine is running. When applying heat to the water in Step 6, be sure to stir (keep water moving) while heating.6. Put the heat sink and water temperature switch in water. Use blocks to support the heat sink at surface level. Use a torch to make the water hot and read the temperature on thermometer (1) at which the water temperature switch is closed. Check the specifications for the respective temperatures at which the water temperature switch opens and closes. Let the water temperature go down. The water temperature switch will open when the temperature is 8°C (12°F) lower than the temperature at which the water temperature switch closes.7. Install new water temperature switch if necessary.To check other components in the system, put a jumper wire between C and NO terminals of the water temperature switch.Second Method of Checking
1. Remove the wires from the water temperature switch.2. Connect the 8T0500 Circuit Tester between the C and NO terminals.3. Look at the circuit tester to see when the water temperature switch closes. The light will be activated. Check the specification for the water temperature switch closings.4. Start the engine and get it hot. Temperature must not go more than approximately 3°C (37°F) above switch activation temperature.
If the engine cannot be run safely at these high temperatures, the water temperature switch must be checked off the engine.
5. Let the engine run at a reduced speed to lower the coolant temperature before stopping the engine.6. Install new water temperature switch if needed.Electrical Indicators And Sending Units
Remember that the electrical indicators and sending units are to operate in electrical balance. For this reason, the voltage and resistance ratings are important to get the correct indications on the indicators.Sending Units For Oil Pressure
Sending Unit For Oil Pressure
(1) Terminal. (2) Fitting.The sending unit for engine oil