20540340 Volvo.Penta Intermediate housing

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 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.1. Contactor Switch for Water Temperature Fails to Activate a Shutoff.2. Contactor Switch for Water Temperature Activates Shutoff at Wrong Temperature.3. Contactor Switch for Oil Pressure Fails to Activate a Shutoff.4. Contactor Switch for Overspeed Fails to Activate Shutoff.5. Contactor Switch for Overspeed Activates Shutoff and Wrong Speed.6. Rack Shutoff Solenoid Fails to Stop Engine.7. Rack Shutoff Solenoid Prevents Engine Start.8. No Stability in Woodward Governor Operation.9. Clutch Will Not Engage (Slips), Heats or Lever Moves to Released Position.10. Clutch Shaft Has Too Much End Play.11. Hydraulic Starting Motor Fails to Turn or Turns Slowly.12. Safety Control Shutoff Fails To Stop Engine Because Of Low Oil Pressure.13. Safety Control Shutoff Will Not Let Engine Start.14. Safety Control Shutoff Stops Engine at Wrong Speed.15. Electrical Gauges Give Wrong Readings. Woodward UG-8 Governor
Adjustments
Fuel rack setting is done carefully at the factory. Do not change the fuel rack setting unless it is known to be wrong. A wrong setting of the fuel rack can cause a problem with the turbocharger. Make reference to the book RACK SETTING INFORMATION for the correct rack setting.
Governor Linkage Adjustment
1. Put lever (1), for the terminal shaft of the governor, on the shaft in the position shown. There must be .16 in. (4.06 mm) clearance between lever (1) and housing. The terminal shaft must be in the fuel closed position.Three basic uses of the 1P2385 Protractor tools are shown here.
1P2385 PROTRACTOR TOOL USE
A. Indicator used for angle setting. B. Protractor plate edge in alignment with lever. C. Vertical housing face and extension arm are in alignment. D. Bubble in level. E. Indicator used for angle setting. F. Extension arm in alignment with lever. G. Extension arm in alignment with lever. H. Plate edge in alignment with second lever. I. Indicator used for angle setting. J. Angle between lever and vertical face of housing. K. Angle between level and lever. L. Angle between levers.2. Put lever (3) on the shaft.3. Make an adjustment to the length of rod (2) so that it can be installed when levers (1 and 3) are in the off position as shown.
WOODWARD GOVERNOR LINKAGE
1. Lever. 2. Rod. 3. Lever. A. 2.188 in. (55.58 mm) length of lever (1). B. Fuel off direction of rotation. C. 2.375 in. (60.33 mm) length of lever (3).
WOODWARD GOVERNOR LINKAGE INSTALLED
1. Lever. 2. Rod. 3. Lever.Low Or High Idle Speed Adjustment
Check the engine LOW or HIGH IDLE rpm at the connection for tachometer drive. Make this check with a hand tachometer. The rotation of the tachometer drive is one half of engine rpm.
GOVERNOR ADJUSTMENTS (With Dial Plate Removed)
1. Lever. 2. Idler gear. 3. Load limit knob. 4. Rod. 5. Synchronizer knob. 6. Gear. 7. Synchronizer indicator knob.1. Put the load limit knob (3) at point 5 to keep the engine from getting too much fuel and having a rapid increase in speed.
To have a method of stopping the engine if it runs too fast, do the following:
a. Disconnect the linkage (8) for the overspeed control at lever (9).
PLACE TO DISCONNECT LINKAGE
8. Linkage. 9. Lever.b. Have your hand on lever (9) and be ready to move the lever to the STOP position.
LEVER IN RUN POSITION
9. Lever.c. If the engine speed goes too high, move lever (9) to the STOP position.2. Start the engine and slowly make an increase to the amount of fuel. When the engine is at the operating temperature, slowly turn the load limit knob (3) from 5 to 10. Use the synchronizer knob (5) to make an adjustment to the engine speed; then, check the low or high idle stop.
LEVER IN STOP POSITION
9. Lever.3. If the low or high idle stop does not permit the correct speed, an adjustment is necessary. Remove the dial plate.4. Loosen the set screw on synchronizer indicator knob (7) and remove the knob.5. Pull gear (6) out so it is not engaged with gear (2).6. When making an adjustment of the high idle speed, turn synchronizer knob (5) clockwise until the engine is at the correct high idle speed. Turn the knob counterclockwise when making the adjustment of the low idle speed.7. To make an adjustment of the stop for the high idle speed, turn gear (6) clockwise (counterclockwise for low idle speed) until the pin in the gear is in contact with idler gear (2). Engage the gears.8. After the adjustment to the idle speed has been made, turn the synchronizer knob to change the speed of the engine. Then turn it to the stop position and check the idle speed. If necessary, make the adjustment again. If necessary, make an adjustment to the synchronizer indicator pointer disc. With the engine running at high idle, stop the engine by turning load limit knob (3) to zero. Remove the synchronizer indicator pointer disc and again install it so the pointer on the disc will point to 12 on the dial plate. This will give high idle stop position.9. Install synchronizer indicator knob (7) and the dial plate.Fuel Rack Setting
Use the same tools and procedure to make an adjustment of the fuel rack as shown for the mechanical governor, make reference to FUEL RACK SETTING.Compensating Adjustment
The governor can show signs of operating correctly at no load, but have high over speeds and under speeds and be slow to return to normal speed after load changes. These conditions are the