Manual Tecnico Motor CAT 3508

TM 5-2815-232-14
TECHNICAL MANUAL
OPERATOR’ S, UNIT, INTERMEDIATE

(DS) AND INTERMEDIATE (GS)
MAINTENANCE MANUAL
FOR
ENGINE, DIESEL,
CATERPILLAR, MODEL 3508
NSN 2815-01-216-0938
HEADQUARTERS, DEPARTMENT OF THE ARMY
25 JULY 1986
FORM NO. SENR2995
IMPORTANT SAFETY NOTICE
Proper repair-is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work
methods. Although not necessarily all inclusive, a list of additional skills, precautions and knowledge
required to safely perform repairs is provided in the SAFETY section of this Manual.
Improper repair procedures can be dangerous and could result in injury or death.
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS
Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in
the descriptions of operations where hazards exist. Warning labels have also been put on to provide
instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained mechanic. There
are many potential hazards during repair for a untrained mechanic and there is no way to label the product
against all such hazards. These warnings in the Service Manual and on the product are identified by this
symbol:
Operations that may result only in mechanical damage are identified by labels on the product and in
the Service Manual by the word CAUTION or NOTICE.
Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The
warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the procedures
you choose.
IMPORTANT
The information, specifications and illustrations in this book are on the basis of information available
at the time it was written. The specifications, torque, pressures of operation, measurements, adjustments,
illustrations and other items can change at any time. These changes can affect the service given to the
product. Get the complete and most current information before you start any job. Caterpillar Dealers
have the most current information available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F.
a
SAFETY
4. If an engine must be started to make pressure or

speed checks, be sure all guards and shields are
installed. To help prevent an accident caused by
Improper performance of lubrication or maintenance parts in rotation, work carefully around
machinery that has been put into operation.
procedures is dangerous and could result in injury
or death. Read and understand the lubrication and
5. If an engine has been running and the coolant is
maintenance procedures, recommended by
hot, loosen the filler cap slowly and let the
Caterpillar, that are outlined in the OPERATION pressure out of the cooling system, before any
GUIDE and/or OWNER’S MANUAL for this product caps, plugs or lines are removed or
before performing disconnected.
any lubrication or maintenance.
6. Corrosion inhibitor contains alkali. Avoid contact
Do not operate this product unless you have read with eyes. Avoid prolonged or repeated contact
and understood the instructions. Improper with skin. Do not take internally. In case of
operation is dangerous and could result in injury or contact, immediately wash skin with soap and
death. water. For eyes, flush with large amounts of
water for at least 15 minutes. CALL
The servicemen or mechanic may be unfamiliar with PHYSICIAN. KEEP OUT OF REACH OF
many of the components and systems of this product. CHILDREN.
This makes it important to use caution when performing
service work. A knowledge of the system and/or 7. Do not smoke when an inspection of the battery
components is important before the removal or electrolyte level is made. Never disconnect any
disassembly of any component. charging unit circuit or battery circuit cable from
the battery when the charging unit is operating.
Because of the size of some components, the A spark can cause an explosion from the
serviceman or mechanic should check the weights noted flammable vapor mixture of hydrogen and
in this Manual. Use proper lifting procedures when oxygen that is released from the electrolyte
removing any components. through the battery outlets. Do not let electrolyte
solution make contact with skin or eyes.
Following is a list of basic precautions that should Electrolyte solution is an acid. In case of
always be observed. contact, immediately wash skin with soap and
water. For eyes, flush with large amounts of
1. Read and understand all Warning plates and water for at least 15 minutes. CALL
decals before operating, lubricating or repairing PHYSICIAN. KEEP OUT OF REACH OF
this product. CHILDREN.
2. Make sure the work area around the product is 8. Disconnect battery and discharge any capacitors
made safe and be aware of hazardous before starting any repair work. Hang “Do Not
conditions that may exist. Operate” tag in the Operator’s compartment or
on the controls.
3. Always wear protective glasses and protective
shoes when working. In particular, wear 9. Do not work on anything that is supported only
protective glasses when a hammer or sledge is by lift jacks or a hoist. Always use blocks or
used for pounding to make repairs. Use welders proper stands to support the product before
gloves, hood/goggles, apron and other protective performing any service work.
clothing appropriate to the welding job being
performed. Do not wear loose-fitting or torn 10. Relieve all pressure in air, oil or water systems
clothing. Remove all rings from fingers when before any lines, fittings or related items are
working on machinery. disconnected or removed. Be alert for possible
pressure when disconnecting any device from a
system that utilizes pressure. Do not check for
pressure leaks with your hand. High pressure oil
or fuel can pierce the skin.
b
11. Never bend a fuel injection line, or install a line 18. Always use tools that are in good condition and
which has been bent. Keep the fuel injection be sure you understand how to use them before
lines and connections clean. Be sure to install performing any service work. Use only
caps and covers anytime a line is removed or Caterpillar replacement parts.
disconnected.
19. Reinstall all fasteners with same part number.
12. During service work, do not hit the fuel injection Do not use a lesser quality fastener if
lines with wrenches or other tools. When lines replacements are necessary.
are installed, use the correct torque to tighten
connections and be sure all clamps and 20. Repairs which require welding should be
dampers are correctly installed. performed only with the benefit of the
appropriate reference information and by
13. Make sure all fuel injection lines and pressure oil personnel adequately trained and
lines have enough clearance to prevent contact knowledgeable in welding procedures. Make
with any other component. Do not put any fuel reference to “Techniques of Structural Repair
or oil lines close to a hot component. Course” form number JEG03719. Determine
type of metal being welded and select correct
14. To avoid back injury use a hoist or get help when welding procedure and electrodes, rods or wire
lifting components which weigh 50 lb. (23 kg) or to provide a weld metal strength equivalent at
more. Make sure all chains, hooks, slings, etc., least to that of parent metal.
are in good condition and are of the correct
capacity. Be sure hooks are positioned 21. Before doing electrical work, disconnect battery.
correctly. Lifting eyes are not to be side loaded Do not damage wiring during removal
during a lifting operation. operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
15. To avoid burns, be alert for hot parts on products contacting sharp corners, or by rubbing against
which have just been stopped and hot fluids in some object or hot surface. Do not connect
lines, tubes and compartments. wiring to a line containing fluid.
16. Be careful when removing cover plates. 22. Be sure all protective devices including guards
Gradually back off the last two bolts or nuts and shields are properly installed and functioning
located at opposite ends of the cover or device correctly before starting a repair. If a guard or
and pry cover loose to relieve any spring or other shield must be removed to perform the repair
pressure, before removing them completely. work, use extra caution. After the repair is
completed, reinstall any guard or shield that was
17. Be careful when removing filler caps, breathers removed.
and plugs on the product. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the product has recently been stopped
because fluids can be hot.
A83266X2
c
Proper repair is important to the safe and reliable operation of this product. This Service Manual
outlines basic recommended procedures, some of which require special tools, devices or work
methods. Although not necessarily all inclusive, a list of additional skills, precautions and knowledge
required to safely perform repairs is provided in the SAFETY section of this Manual.

symbol:
the Service Manual by the word NOTICE.
Caterpillar can not anticipate every possible circumstance that might involve a potential hazard.
The warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not
you choose.
IMPORTANT
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGI 139F.
A83264X2
d
outlines basic recommended procedures, some of which require special tools, devices or work methods.
Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to
safely perform repairs is provided in the SAFETY section of this Manual.

symbol:
you choose.
IMPORTANT
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1 139F.
A83264 X2
e

other persons. These labels identify hazards which may not be apparent to a trained mechanic. There are
many potential hazards during repair for a untrained mechanic and there is no way to label the product
symbol:
you choose.
IMPORTANT
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGI 139F.
A83264 X2
f
3500 ENGINES DISASSEMBLY AND ASSEMBLY
Proper repair is important to the safe and reliable operation of a machine. This Service Manual
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE
the descriptions of operations where hazards exist. Warning labels have also been put on the machine to
provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to
you or other persons. These labels identify hazards which may not be apparent to a trained mechanic.
There are many potential hazards during repair for an untrained mechanic and there is no way to label. the
machine against all such hazards. These warnings in the Service Manual and on the machine are
identified by this symbol:
Operations that may result only in machine damage are identified by labels on the machine and in
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings, in this Manual are therefore not all inclusive. If a procedure, tool, device or work method not
others. You should also ensure that the machine will not be damaged or made unsafe by the procedures
you choose.
IMPORTANT
at the time it was written. The specifications, torques, pressures of operation, measurements,
adjustments, illustrations and other items can change at any time. These changes can effect the service
given to the product. Get the complete and most current information before you start any job. Caterpillar
Dealers have the most current information which is available. For a list of the most current modules and
form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE
REG1 139F.
67200-1 X1
g
Proper repair is important to the safe and reliable operation of a machine. This Service Manual
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE
the descriptions of operations where hazards exist. Warning labels have also been put on the machine to
provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to
you or other persons. These labels identify hazards which may not be apparent to a trained mechanic.
There are many potential hazards during repair for an untrained mechanic and there is no way to label ,the
machine against all such hazards. These warnings in the Service Manual and on the machine are
identified by this symbol:
Operations that may result only in machine damage are identified by labels on the machine and in
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings, in this Manual are therefore not all inclusive. If a procedure, tool, device or work method not
others. You should also ensure that the machine will not be damaged or made unsafe by the procedures
you choose.
IMPORTANT
at the time it was written. The specifications, torques, pressures of operation, measurements,
adjustments, illustrations and other items can change at any time. These changes can effect the service
given to the product. Get the complete and most current information before you start any job. Caterpillar
Dealers have the most current information which is available. For a list of the most current modules and
form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE
REG1139F.
67200-1 X1
h
3500 ENGINES DIASSEMBLY AND ASSEMBLY
SAFETY
machinery that has been put into operation.
Improper performance of lubrication or maintenance 5. If an engine has been running and the coolant is
hot, loosen the filler cap slowly and let the
procedures is dangerous and could result in injury
pressure out of the cooling system, before any
or death. Read and understand the lubrication and
caps, plugs or lines are removed or
maintenance procedures, recommended by
disconnected.
Caterpillar, that are outlined in the OPERATION
GUIDE and/or OWNER’S MANUAL for this product 6. Corrosion inhibitor contains alkali. Avoid contact
before performing any lubrication or maintenance. with eyes. Avoid prolonged or repeated contact
with skin. Do not take internally. In case of
Do not operate this product unless you have read contact, immediately wash skin with soap and
and understood the instructions. Improper water. For eyes, flush with large amounts of
operation is dangerous and could result in injury or water for at least 15 minutes. CALL
death. PHYSICIAN. KEEP OUT OF REACH OF
CHILDREN.
The servicemen or mechanic may be unfamiliar with
many of the components and systems of this product. 7. Do not smoke when an inspection of the battery
This makes it important to use caution when performing electrolyte level is made. Never disconnect any
service work. A knowledge of the system and/or charging unit circuit or battery circuit cable from
components is important before the removal or the battery when the charging unit is operating.
disassembly of any component. A spark can cause an explosion from the
flammable vapor mixture of hydrogen and
Because of the size of some components, the oxygen that is released from the electrolyte
serviceman or mechanic should check the weights noted through the battery outlets. Do not let electrolyte
in this Manual. Use proper lifting procedures when solution make contact with skin or eyes.
removing any components. Electrolyte solution is an acid. In case of
contact, immediately wash skin with soap and
Following is a list of basic precautions that should water. For eyes, flush with large amounts of
always be observed. water for at least 15 minutes. CALL
PHYSICIAN. KEEP OUT OF REACH OF
1. Read and understand all Warning plates and CHILDREN.
decals before operating, lubricating or repairing
this product. 8. Disconnect battery and discharge any capacitors
before starting any repair work. Hang "Do Not
2. Make sure the work area around the product is Operate" tag in the Operator’s compartment or
made safe and be aware of hazardous on the controls.
conditions that may exist.
9. Do not work on anything that is supported only
3. Always wear protective glasses and protective shoes by lift jacks or a hoist. Always use blocks or
when working. In particular, wear protective glasses proper stands to support the product before
when a hammer or sledge is used for pounding to performing any service work.
make repairs. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to the 10. Relieve all pressure in air, oil or water systems
welding job being performed. Do not wear loose- before any lines, fittings or related items are
fitting or torn clothing. Remove all rings from fingers disconnected or removed. Be alert for possible
when working on machinery. pressure when disconnecting any device from a
4. system that utilizes pressure. Do not check for
4. If an engine must be started to make pressure or pressure leaks with your hand. High pressure oil
speed checks, be sure all guards and shields are or fuel can pierce the skin.
installed. To help prevent an accident caused by
parts in rotation, work carefully around
i
11. Never bend a fuel injection line, or install a line 18. Always use tools that are in good condition and
which has been bent. Keep the fuel injection be sure you understand how to use them before
lines and connections clean. Be sure to install performing any service work. Use only
caps and covers anytime a line is removed or Caterpilla, replacement parts.
disconnected.
19. Reinstall all fasteners with same part number.
12. During service work, do not hit the fuel injection Do not use a lesser quality fastener if
lines with wrenches or other tools. When lines replacements are necessary.
are installed, use the correct torque to tighten
connections and be sure all clamps and 20. Repairs which require welding should be
dampers are correctly installed. performed only with the benefit of the
appropriate reference information and by
13. Make sure all fuel injection lines and pressure oil personnel adequately trained and
lines have enough clearance to prevent contact knowledgeable in welding procedures. Make
with any other component. Do not put any fuel reference to "Techniques of Structural Repair
or oil lines close to a hot component. Course" form number JEG03719. Determine
type of metal being welded and select correct
14. To avoid back injury use a hoist or get help when welding procedure and electrodes, rods or wire
lifting components which weigh 50 lb. (23 kg) or to provide a weld metal strength equivalent at
more. Make sure all chains, hooks, slings, etc., least to that of parent metal.
are in good condition and are of the correct
capacity. Be sure hooks are positioned 21. Before doing electrical work, disconnect battery.
correctly. Lifting eyes are not to be side loaded Do not damage wiring during removal
during a lifting operation. operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
15. To avoid burns, be alert for hot parts on products contacting sharp corners, or by rubbing against
which have just been stopped and hot fluids in some object or hot surface. Do not connect
lines, tubes and compartments. wiring to a line containing, fluid.
16. Be careful when removing cover plates. 22. Be sure all protective devices including guards
Gradually back off the last two bolts or nuts and shields are properly installed and functioning
located at opposite ends of the cover or device correctly before starting a repair. If a guard or
and pry cover loose to relieve any spring or other shield must be removed to perform the repair
pressure, before removing them completely. work, use extra caution. After the repair is
completed, reinstall any guard or shield that was
17. Be careful when removing filler caps, breathers removed.
and plugs on the product. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the product has recently been stopped
because fluids can be hot.
A83266X2
j

symbol:
you choose.
IMPORTANT
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1 139F.
A83264 X2
k

symbol:
you choose.
IMPORTANT
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG 139F.
A83264 X2
l
IMPORTANT SAFETY INFORMATION
Most accidents involving engine operation and maintenance are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident
occurs.
Read and understand all safety precautions and warnings before operating or performing
lubrication and maintenance on this engine.
Basic safety precautions are outlined in the "Safety" section of this guide and in the description of
operations where hazards exist. WARNING labels have also been put on the engine to provide
instructions and to identify specific hazards which if not heeded could cause bodily injury or
death to you or other persons. These warnings in the guide and on the engine labels are identified
by the symbol
Operations that may cause only engine damage are identified by NOTICE labels on the engine and
in the guide.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this guide and on the engine are therefore not all inclusive. If a procedure, tool or
work method or operating technique not specifically recommended by Caterpillar is used, you
must satisfy yourself that it is safe for you and others. You should also ensure that the engine will
not be damaged or made unsafe by the method of operation or maintenance procedures you
choose.
Improper operation, lubrication or maintenance of this engine can be dangerous and could result
in injury or death.
Do not operate this engine until you read and understand the instructions in the "Operation"
section of the Operation and Maintenance Guide or the Owner’s Manual.
Do not perform any lubrication and maintenance on this engine until you read and understand the
instructions in the "Maintenance" section of the Operation and Maintenance Guide or the Owner’s
Manual.
m/(n Blank)
TM 5-2815-232-14
Table of Contents
WHERE TITLE SHOWS DELETED TEXT DOES NOT PERTAIN TO THE 3508 ENGINE.
Page Page
Specifications for Engine Attachments, Cooling System
3500 Industrial ............................................. 1
Water Pump .............................................. 31
General Tightening Torque for Bolts, Nuts, Aftercooler .............................................. 32
and Taperlock Studs .............................. 3
Water Connection Group - Outlet ............. 32
Torque for Flared and O-Ring Fittings 4
Engine Design ........................................ 5 Water Temperature Regulators ................ 33
Fuel System V-Belt Tension Chart................................. 33

Fuel Injection ....................................... 8
Fuel Pressure Regulator (Earlier)........ 8 Basic Engine Components
Fuel Pressure Regulator (Later).......... 9 Cylinder Block ........................................... 34

Manual Shutoff Group ......................... 9 Cylinder Liners .......................................... 35
Fuel Injection Control Group ............... 10 Cylinder Liner Projection........................... 35
Governor Fastener Group ................... 11 Pistons and Rings ..................................... 36
Governor Drive .................................... 11 Connecting Rods ...................................... 37
Connecting Rod and Main Bearing Journals 38
Air Induction and Exhaust System
Crankshaft .............................................. 39
Camshafts ........................................... 12
Crankshaft Wear Sleeves and Seals ........ 40
Valves ............................................. 14
Front Balancer Group (3508) .................... 41
Valve Covers ....................................... 15
Lower Front Gear Group .......................... 42
Valve Rocker Arms, Lifters and Bridges 15
Upper Front Gear Group (7N4871)........... 44
Cylinder Heads.................................... 16
Rear Gear Group ...................................... 45
Turbocharger Impeller Installation....... 17
Flywheel .............................................. 47
Turbochargers ..................................... 18
Flywheel Runout ....................................... 48
Exhaust Manifolds ............................... 22
Flywheel Housing...................................... 50
Air Intake Shutoff................................. 23
Flywheel Housing Bore ............................. 52
Lubrication System Flywheel Housing Runout ......................... 53

Alternators and Regulators ....................... Deleted
Oil Pump ............................................. 26
Oil Filter Bypass Valve (Earlier)........... 28
Electrical System
Oil Filter Bypass Valve (Later)............. 29
Electric Starter Motors ............................. Deleted
Oil Cooler Bypass and Cooling Jet Starter Solenoids ..................................... Deleted
Sequence Valves................................. 30
i
Table of Contents (Continued)
Page Page
Air Starter Motors ................................ Deleted Troubleshooting.............................................. 91
Pressure Regulating Valve for Fuel System .............................................. 107
Air Starter Motor ............................................. Deleted
Fuel System Inspection............................. 107
Systems Operation, 3500 Industrial Engines 61
Checking Engine Cylinders Separately..... 107
Engine Design ........................................ 63 Fuel Injector Testing ................................. 107
Fuel System ............................................ 65 Injector Tester Preparation ....................... 108
Fuel Injection Control Linkage............. 67 Operation of the Tester ............................. 108
Fuel Injector......................................... 68 Leak Test for Injector Tester ..................... 109
Woodward UG8 Lever Governors ....... 71 Injector Test Sequence ............................. 110
Air Fuel Ratio Control .......................... 73 Fuel Pressure ........................................... 116
Engine Rotation ........................................ 117
Air Inlet and Exhaust System................ 75 Finding Top Center Position for No. 1
Aftercooler ........................................... 77 Piston .............................................. 117
Turbochargers ..................................... 78 Camshaft Timing....................................... 118
Valve System Components ................. 78 Startup Procedure..................................... 120
Lubrication System ................................ 80 Crankshaft Positions for Fuel Timing ........ 121
Cooling System ........................................ 82 Fuel Timing .............................................. 122
Basic Block ............................................. 84 Injector Synchronization............................ 123
Cylinder Block, Liners and Heads ....... 84 Fuel Setting .............................................. 125
Pistons, Rings and Connecting Rods.. 84 Fuel Setting Adjustment............................ 126
Crankshaft ........................................... 84 Engine Speed Measurement .................... 127
Camshafts ........................................... 85 Woodward UG8 Lever Governor ................... 128
Air Starting System ................................ 86 Compensating Adjustment........................ 128
Electrical System...................................... 88 Low and High Idle Speed Adjustment....... 129
Alternator............................................. 88 Speed Droop Adjustment.......................... 129
Starter Motor ....................................... 88 Air Fuel Ratio Control ..................................... 132
Starter Solenoid................................... 89 Air Inlet and Exhaust System.................... 133
Circuit Breaker..................................... 89 Restriction of Air Inlet and Exhaust........... 133
Contactor Switch (Water Temperature) 90 Measurement of Pressure in Inlet Manifold 133
Testing and Adjusting ........................... 91
ii
Page Page
Exhaust Temperature............................... 134 Projection of Cylinder Liners ..................... 145
Crankcase (Crankshaft Compartment) Flywheel and Flywheel Housing................ 146
Pressure ............................................. 134 Checking Crankshaft Deflection (Bend).... 148
Compression ............................................ 134 Vibration Damper ...................................... 149
Cylinder Heads......................................... 134 Electrical System ............................................ 150
Valves ............................................. 134 Test Tools for Electrical System ............... 150
Bridge Adjustment .................................... 135 Battery .............................................. 151
Crankshaft Positions for Valve Charging System ...................................... 151
Clearance Setting .................................... 136 Starting System......................................... 152
Valve Clearance ....................................... 137 Air Starting System ................................... Deleted
Lubrication System ........................................ 139 Caterpillar, 3161 Governor........................ 155
Too Much Oil Consumption...................... 139 Governor Types ........................................ 157
Measuring Engine Oil Pressure................ 139 Basic Governor ......................................... 159
Oil Pressure is Low ................................. 140 Governor Components ............................. 159
Oil Pressure is High.................................. 140 Operation of the 3161 Governor ............... 161
Too Much Bearing Wear .......................... 140 Auxiliary Controls ........................................... 164
Increased Oil Temperature ...................... 140 Manual Shutdown ..................................... 164
Cooling System ............................................. 141 Pressure Shutdown................................... 164
Visual Inspection of the Cooling System.. 141 Electric Shutdown .................................... 164
Testing the Cooling System ..................... 141 Manual Mechanical Speed Control ........... 164
Test Tools for Cooling System ................. 141 Pneumatic Speed Control ......................... 165
Pressure Cap Test ................................... 142 Air Fuel Ratio Control................................ 167
Radiator and Cooling System Leak Tests 143 Speed Adjusting Motor Governor Head.... 169
Water Temperature Gauge Test .............. 143 Manual Speed Setting Control .................. 169
Water Temperature Regulator Test ......... 144 Pneumatic Mid Speed Control .................. 170
Basic Block ............................................. 145 Troubleshooting.............................................. 172
Connecting Rod Bearings ........................ 145 Governor Troubleshooting ........................ 172
Main Bearings .......................................... 145 Air Fuel Ratio Control Troubleshooting..... 176
Cylinder Block .......................................... 145
iii
Page Page
Pneumatic Speed Setting System Checks ......................................... 243
Control Troubleshooting ........................... 178 System Tests ............................................ 245
Testing and Adjusting ................................... 180 Shutoff Speed Setting Adjustment ............ 245
Governor Oil Pump ................................. 180 Wiring Diagrams ....................................... 247
Governor Preparation............................... 181
Governor Installation ................................ 182 3500 Industrial Engines .................................. 253
Governor Adjustments ............................. 187 Disassembly and Assembly
Auxiliary Controls ..................................... 192 Manual Shutoff ......................................... 257
Hydramechanical Protective System, Gauge Panel ............................................. 259
3500 Series Engines....................................... 197
Air Intake Shutoff ...................................... 262
Specifications Tachometer Drive ..................................... 269
Shutoff Control Group .............................. 199 Crankcase Breather .................................. 270
Thermostatic Pilot Valve .......................... 202 Water Temperature Regulators ................ 272
Accessory (Shutoff) Drive Group ............. 202 Water Pump .............................................. 275
Air Intake Shutoff...................................... 206 Fuel Filter Housing.................................... 279
Tachometer and Service Meter Drive ...... 209 Fuel Priming Pump, Fuel Transfer Pump . 283
Remote Shutoff Valve Group ................... 209 Oil Pump .............................................. 288
Electrical Switches ................................... 210 Oil Filter Housing ...................................... 293
Systems Operation Oil Pan .............................................. 300
Overspeed ............................................. 211 Oil Sequence Valves................................. 304
Low Engine Oil Pressure ......................... 211 Oil Cooler .............................................. 305
High Coolant Temperature....................... 211 Turbochargers .......................................... 312
System Components ................................ 211 Exhaust Manifolds..................................... 321
System Hydraulics.................................... 214 Aftercooler .............................................. 322
Hydraulic Circuits (Earlier)........................ 214 Governor .............................................. 326
Hydraulic Circuits (Later).......................... 228 Governor Drive.......................................... 328
Hydraulic Circuits, Later with an Hydramechanical Shutoff Control ............. 332
Alarm System ........................................... 232
Hydramechanical Shutoff Drive ................ 345
Testing and Adjusting
Accessory Drive (Front) ............................ 347
Troubleshooting........................................ 239
iv
Page Page
Oil and Water Pump Drive ....................... 350 Oil Pans .............................................. 421
Crankshaft Vibration Damper................... 353 Oil Filter Bypass Valve ........................... 422
Crankshaft Front Seal and Wear Sleeve . 354 Duplex Oil Filter ..................................... 423
Crankshaft Rear Seal and Wear Sleeve .. 356 Oil Scavenge Pump ................................ 424
Front Drive Housing ................................. 358 Exhaust Manifolds .................................. 426
Flywheel ............................................. 362 Turbochargers......................................... 427
Flywheel Housing ..................................... 363 Air Intake Shutoff .................................... 436
Valve Covers ............................................ 365
Front Gear Groups.................................. 437
Rocker Shafts and Push Rods ................. 366
Auxiliary Drive ........................................ 440
Fuel Injectors............................................ 369
Tachometer Drive ................................... 441
Fuel Injection Control Linkage ................. 371
Trunnion (Front)...................................... 443
Cylinder Heads......................................... 377
Engine Front Support Group (Wide) ..... 443
Valves ............................................. 381
Vibration Damper Group ........................ 444
Bridge Dowels .......................................... 382
Front Mounting Group............................ 447
Connecting Rod Bearings ........................ 384
Stub Shafts .............................................. 447
Front Balancer Group............................... 385
Time Delay Relay .................................... 449
Rear Gear Group ..................................... 387
Heaters, Jacket Water ............................ 449
Spacer Plates ........................................... 391
Crankshaft Main Bearings........................ 393 Magnetic Pickup ..................................... 449
Pistons ............................................. 396 Tachometer, Digital ............................... 450
Cylinder Liners ......................................... 398 Contactors .............................................. 451
Camshafts ............................................. 400 Pressure Switches ................................. 452

Crankshaft ............................................. 407 Temperature Switches .......................... 453
Specifications for Engine Attachments Sending Units, Oil Pressure .................. 454
49Y1-UP, 95Y1-UP, 27Z1-UP, 65Z1-UP, Tachometer, Electric .............................. 454
68Z1-UP, 71Z1-UP................................... 411
Gauges, Ammeter/Oil Pressure/
Ether Starting Aid................................... 416 Water Temperature ................................ 455
Primary Fuel Filter.................................. 416 Air Shutoff Solenoids ............................. 456
Fuel Filter Change Indicator Group...... 416 Air Compressor Group .......................... 457
Governor ............................................. 417 Air Control Valve Group ........................ 458
v
Page Page
Electric Protective System for Engines Step Oil Pressure, Chart C ....................... 492
Equipped with Reversal Protection .............. 459 Reversal Detection, Chart D .................... 494
Components ........................................... 460 Troubleshooting Procedures ........................ 496
Individual Circuit Description .............. 462 Overspeed Setting Calibration,
Engine Stopped ...................................... 462 Procedure A .............................................. 496
Starting Engine....................................... Deleted Crank Terminate, Speed Adjustment,
Engine Starts to Run: No Faults ........... Deleted Procedure B .............................................. 497
Engine Runs at Rated Speed: Oil Step Calibration, Procedure C............. 498
No Faults ............................................. Deleted Overspeed Verify Test, Procedure D ........ 499
Pressure (At Engine Speeds above Oil Step Reversal Detection, Procedure E.............. 500
Speed Setting) ........................................ Deleted
Sensor Assembly Verify, Procedure F ...... 501
Engine Shutdown Due to Fault:
On/Off Time Delay (Relay), Procedure G . 503
Loss of Engine Oil.................................. Deleted
Wiring Diagrams.............................................. 504
Engine Running Below Oil Step
Speed Setting: No Faults (or Just Electric Protective System Schematic ..... 505
Accelerating through Step Speed) ....... Deleted Engine Wiring Diagram ............................. 506
Engine Shutdown Due to Fault: Low Oil Typical Junction Box Wiring Diagram ....... 507
Pressure (At Engine Speeds Below Oil
Step Speed Setting) ............................... Deleted Customer Wiring with Electric
Protective System .................................... 510
Coolant Overheating .............................. Deleted Electrical Protective System for Generator Set,
Industrial and Marine Engines............... 513
Engine Overspeed.................................. Deleted Components ............................................ 514
Engine Shutdown Due to Fault: Individual Circuit Description ................ 516

Engine Reversal .................................... Deleted Engine Stopped....................................... 516
Shutdown System with 2301 Electric Starting Engine ...................................... 518
Governor Control: No Faults................. Deleted
Engine Starts to Run: No Faults ........... 520
Troubleshooting ..................................... 484
Engine Runs at Rated Speed: No Faults 522
Functional Test ....................................... 485
System Problem Index........................... 486 Loss of Engine Oil Pressure (At Engine
System Troubleshooting Charts, Speeds Above Oil Step Speed Setting) 524
Preliminary Checks ................................ 487 Engine Shutdown Due to Fault: Low Oil
Overspeed, Chart A........................... 488 Pressure (At Engine Speeds Below Oil
Step Speed Setting) ................................ 528
Crank Terminate, Chart B ................. 490
vi
Page Page
Engine Shutdown Due to Fault: Operation and Maintenance, 3508 Industrial Engine
Coolant Overheating ...................................... 530
Safety .............................................. 565
Operation Section ................................... 568
Engine Overspeed.......................................... 532
Model Views.............................................. 569
Shutdown System with 2301 Electric
Governor Control: No Faults......................... 534 Gauges .............................................. 571
Electric Protective System Shutoff and Alarm System Components... 573
Functional Tests ............................................. 536 Engine Controls ........................................ 575
Speed Specification Chart ............................ 537 Before Starting the Engine ....................... 578
Troubleshooting ............................................ 538 Starting the Engine ................................... 579
Problem Identification Index ......................... 539 After Starting the Engine........................... 582
System Troubleshooting Charts, Stopping the Engine.................................. 583
Preliminary Checks ........................................ 540
After Stopping the Engine ......................... 584
System Arming, Chart A........................... 541
Lifting Engine and Attachment .................. 584
Overspeed, Chart B.................................. 542
Engine Storage ........................................ 585
Crank Terminate, Chart C ........................ 544
Maintenance Section ...................................... 586
Step Oil Pressure, Chart D....................... 546
Serial Number Location ............................ 587
Troubleshooting Procedures
Maintenance Recommendations .............. 587
Overspeed Setting Calibration,
Fuel, Coolant and Lubricant
Procedure A ............................................. 548
Specifications ......................................... 590
Crank Terminate Speed Adjustment,
Procedure B ............................................ 549 Refill Capacities ........................................ 592
Oil Step Calibration, Procedure C ............ 550 Engine Specifications................................ 592
Overspeed Verify Test, Procedure D ....... 551 Recommended Lubricant Viscosities........ 593
Magnetic Pickup Verify, Procedure E....... 552 Lubrication and Maintenance Chart ......... 594
On/Off Delay (Relay), Procedure F .......... 553 When Required ......................................... 596
Wiring Diagrams ............................................. 554 Every 10 Service Hours or Daily ............... 597
Every 50 Service Hours or Weekly .......... 609
Electric Protective System Schematic...... 555
Every 100 Service Hours or 2 Weeks ....... 611
Engine Wiring Diagram ............................ 556
Every 250 Service Hours or Monthly......... 612
Typical Junction Box Wiring Diagram ...... 557
Every 500 Service Hours or 3 Months ...... 617
Customer Wiring with Electric
Protective System ................................... 560 Every 1000 Service Hours or 6 Months .... 618
Every 2000 Service Hours or 1 Year......... 624
Troubleshooting Section ....................... 628
vii/(viii Blank)
FORM NO. SENR235341
FOR USE IN SERVICE MANUALS:
3500 INDUSTRIAL ENGINES,
SENR2573
VOLUME I SPECIFICATIONS,
REGO1312
SPECIFICATIONS
FOR
3500 INDUSTRIAL
ENGINE ATTACHMENTS
49Y1-UP 65Z1-UP
95Y1-UP 68Z1-UP
27Z1-UP 71Z1-UP
1/(2 Blank)
3500 ENGINE SPECIFICATIONS
3
TORQUE FOR FLARED AND O-RING FITTINGS

The torques shown in the chart that follows are to be used on the part of 37° Flared, 45° Flared and Inverted Flared
fittings (when used with steel tubing), O-ring plugs and O-ring fittings.
ASSEMBLY OF FITTINGS WITH

STRAIGHT THREADS AND O-RING SEALS
1. Put locknut (3), backup washer (4) and O-ring

seal (5) as far back on fitting body (2) as
possible. Hold these components in this
position. Turn the fitting into the part it is used
on, until backup washer (4) just makes contact
with the face of the part it is used on.
NOTE: If the fitting is a connector (straight fitting) or plug,

the hex on the body takes the place of the locknut. To
install this type fitting tighten the hex against the face of
ELBOW BODY ASSEMBLY
the part it goes into.
1. End of fitting body (connects to tube). 2.
2. To put the fitting assembly in its correct position
turn the fitting body (2) out (counterclockwise) a Fitting body. 3. Locknut. 4. Backup washer. 5. O-
.
maximum of 359° Tighten locknut (3) to the ring seal. 6. End of fitting that goes into other part.
torque shown in the chart.y
A71009X3
4
ENGINE DESIGN
CYLINDER AND VALVE LOCATION
5
ENGINE DESIGN
ENGINE
SPECIFICATIONS 3508 3512 3516
NUMBER AND ARRANGEMENT 60° V-8 60° V-12 60° V-16

OF CYLINDERS
VALVES PER CYLINDER 4 4 4
DISPLACEMENT 34.5 LITER 51.8 LITER 69.1 LITER
(2105 cu. in.) (3158 cu. in.) (4210 cu. in.)
BORE 170mm (6.7 in.)
STROKE 190mm (7.5 in.)
COMPRESSION RATIO 13:1
TYPE OF COMBUSTION Direct Injection
VALVE Intake 0.38mm (.015 in.)
SETTING Exhaust 0.76mm (.030 in.)
FIRING ORDER (INJECTION SEQUENCE)
ENGINE SAE STANDARD ROTATION* SAE OPPOSITE ROTATION*
3508 1-2-7-3-4-5-6-8 1-8-7-2-6-5-4-3
3512 1-12-9-4-5-8-11-2-3-10-7-6 14-9-8-5-2-11 -10-3-6-7-12
3516 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8 1-6-5-4-3-10-9-16-15-12-11-14-13-8-7-2
* Direction of Rotation (as viewed from flywheel end):

SAE Standard Rotation ----------Counterclockwise
SAE Opposite Rotation -----------Clockwise
NOTE: Front end of engine is opposite the flywheel end.

Left side and right side of engine are as seen from flywheel end.
No. 1 cylinder is the front cylinder on the right side.
No. 2 cylinder is the front cylinder on the left side. B62375X1
6
INTRODUCTION
The specifications given in this book are on the basis can be used again. If the part is equal to or within the
of information available at the time it was written. The specification given, use the part again.
specifications torques, pressures of operation,
measurements, adjustments and other items can change When the word "permissible" is in the description,
at any time. These changes can effect the service given the specification given is the "maximum or minimum"
to the product. Get the complete and most current tolerance permitted before adjustment, repair and/or new
information before you start any job. Caterpillar Dealers parts are needed.
have the most current information which is available. For
a list of the most current modules and form numbers A comparison can be made between the
available for each Service Manual, see the SERVICE measurements of a worn part, and the specifications of a
MANUAL CONTENTS MICROFICHE REG 1139F. new part to find the amount of wear. A part that is worn
can be safe to use if an estimate of the remainder of its
When the words "use again" are in the description, service life is good. If a short service life is expected,
the specification given can be used to determine if a part replace the part.
77200X2
NOTE: For Systems Operation and Testing and Adjusting, make reference to
3500 INDUSTRIAL ENGINES, Form No. SENR2352.
7
FUEL INJECTION
(1) Torque for locknut for rocker arm

adjustment screw .... 70 + 15 N•m (50 + 11 lb. ft.)
(2) Diameter of rocker arm
shaft...... 37.084 + 0.013 mm (1.4600 + .0005 in.)
Bore in bearing for rocker arm shaft
.............. 37.140 ± 0.015 mm (1.4622 + .0006 in.)
(3) Injector installation:
a. Put multipurpose type grease in bore of cylinder

head for lubrication of the O-ring seals.
b. Put injector in bore. Use bolt and clamp to

push injector into the correct position.
NOTE:Do not tap (hit) surface "Y" to install injector.
c. Tighten bolt that holds fuel injector

clamp to.............. 65 + 7 N-m (48 + 5 lb. ft.)
d. After clamp is tightened, injector rack "X"
must move freely.
(4) Fuel timing dimension set by gauge.

See FUEL SETTING AND RELATED
INFORMATION FICHE for the correct dimension
to use.
(5) Guide springs must not be used again. Always

install new guide springs.
(6) Diameter of valve lifter

(new)..... 29.937 + 0.010 mm (1.1786 + .0004 in.)
Bore in head for valve

lifter....... 30.000 + 0.025 mm (1.1811 + .0010 in.)
FUEL PRESSURE REGULATOR

(Earlier)
(1) Fuel manifold adapter on right hand front fuel

manifold
(2) 9N4053 Spring for fuel pressure regulator valve

plunger
Length under test force .......... 28 5 mm (1.12 in.)
Test force ...................40 8 + 2 1 N (9 17 + 46 lb)

Free length after test .............. 57 2 mm (2 25 In )
Outside diameter .................. 15 24 mm ( 600 in )
(3) Regulator valve plunger. Regulator valve to hold fuel
manifold pressure at
............................... 415 to 620 kPa (60 to 90 psi)
8
FUEL PRESSURE REGULATOR

(Later)
(1) Fuel manifold adapter on right hand front fuel

manifold.
(2) 9N4053 Spring for fuel pressure regulator valve

plunger
Length under test force .......... 28.5 mm (1.12 in.)
Test force .................40.8 + 2 1 N (9.17 + .46 lb.)
Free length after test .............. 57.2 mm (2.25 in )
Outside diameter .................. 15.24 mm ( 600 in.)
(3) Regulator valve plunger. Regulator valve to hold fuel

manifold pressure at
............................... 415 to 450 kPa (60 to 65 psi)
MANUAL SHUTOFF GROUP
NOTE: The shutoff group must be installed on the same

side of the engine that the governor is installed.
(1) When right hand mounted, "RH FRONT" should

be visible from front of engine. When left hand
mounted, "LH FRONT" should be visible from
front of engine.
(2) Put clean engine oil on the O-ring seal and lip-
type seal at assembly.
(3) Pull shutoff lever until governor linkage stops

against internal stop. Turn adjustment screw
until it makes contact with lever. Turn
adjustment screw one complete turn more and
tighten locknut.
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
9
FUEL INJECTION CONTROL GROUP
(1) Bore of the bearings in the bracket assemblies (after (4) Clearance between the lever assemblies on the
assembly) front cross shaft and the side shafts
................ 21.925 + 0.015 mm (.8632 + .0006 in.) ..........................0 80 ± 0.10 mm (.031 + .004 in.)
(2) Diameter of the surfaces for the bearings and rod (5) Tighten locknuts at each end of bellcrank to a
assemblies on the shafts torque of ..........................8 + 2 N-m (6 + 1 lb. ft.)
................ 21.850 + 0.015 mm (.8602 + .0006 In )
(3) Bore of the bearings in the two support

assemblies (after
assembly}21.925 + 0.015 mm (.8632 + .0006 in.)
10
GOVERNOR FASTENER GROUP

(UG8L & 3161 Governors)
(1) Torque for:
Bolts (3161) ................ 45 + 7 N-m (32 + 5 lb. ft.)
Studs (UG8) ............... 30 + 5 N-m (22 + 4 lb. ft.)
(2) Torque for plugs ..... 70 + 15 N-m (50 + 11 lb. ft.)
GOVERNOR DRIVE
7N1889 & 8N9662 Drive Groups Used With UG8-L Woodward

Governors
1W2135 Drive Group Used With Caterpillar 3161 Governors
(1) Diameter of bore in adapter

.............. 34.072 + 0.025 mm (1.3414 + .0010 in.)
Diameter of shaft on governor drive pinion (3)

.............. 34.000 + 0.013 mm (1.3386 + .0005 in.)
(2) Adapter.
(3) Governor drive pinion.
(4) Bevel gear.
(5) Diameter of shaft on bevel gear
.............. 34.000 + 0.013 mm (1.3386 + .0005 in.)
Diameter of bore in bearing after assembly in

drive housing
.............. 34.072 + 0.039 mm (1.3414 ± .0015 in.)
(6) Shims. Use as required to get a gear clearance

(backlash) between pinion (3) and gear (4) of .....
0.00 + 0.050 or -0.025 mm (.0039 +.0020 or -.0010 in.)
(7) Diameter of bore in drive

housing
.............. 40.432 + 0.025 mm (1.5918 + .0010 in.)
Diameter of bearing
.............. 40.545 + 0.013 mm (1.5963 + .0005 in.)

11
CAMSHAFTS
(1) Thickness of washer

(new).................. 8.50 + 0 05 mm (335 + .002 in.)
Thickness of groove In camshaft

(new).................. 8.75 + 0 05 mm( 344 ± .002 in.)
End play for the camshafts

(new)............... 0.15 to 0.35 mm (.006 to .014 in.)
(2) L. H. camshaft.
(3) R. H. camshaft.
(4) Diameter of the surfaces (journals) for the

camshaft bearings (new)
...................... 85.88 + 0.02 mm (3.381 + .001 in.)
Bore in the bearings for the camshafts (after

assembly) ..... 86.00 + 0.06 mm (3.386 + .002 in.)
(5) Height of camshaft lobes. To find lobe height,

use the procedure that follows:
A Measure camshaft lobe height (5).
B Measure base circle (7).
C. Subtract base circle (STEP B) from lobe

height (STEP A) The difference is actual lobe
lift.
D. Specified camshaft lobe lift (6) is:
a. Exhaust lobe.................. 9.078 mm ( 3574 in.)

b. Intake lobe ..................... 9.314 mm (.3667 in.)
c. Injector lobe ................. 13.678 mm ( 5385 in.)
12
CAMSHAFTS
(3512 and 3516)

(new).................. 8.50 + 0.05 mm (.335 + 002 In.)
Thickness of groove in camshaft

(new)............... 8.75 + 0005 mm (3441 + 002 in.)
End play for the camshafts (5) Height of camshaft lobes

(new)................. 015 to 0.35 mm (.006 to 014 In )
To find lobe height, use the procedure that
(2) Diameter of the surfaces (journals) for the follows:
camshaft earings
(new).............. 85 88 + 002 mm (3 381 + .001 in.) A Measure camshaft lobe height (5).
Bore in the bearings for the camshafts (after B Measure base circle (7)
assembly) ...... 86.00 + 0 06 mm (3.386 + 002 in )
C. Subtract base circle (STEP B) from lobe
(3) Distance dowel is extended from end of R H rear height (STEP A). The difference is actual
and L H front camshafts lobe lift.
................................ 22.0 + 0 5 mm ( 87 + .02 In )
D. Specified camshaft lobe lift (6) is:
(4) Clean the threads of the bolts and the contact a. Exhaust lobe ................ 9 078 mm (.3574 in.)
surfaces of the parts thoroughly Put 9S3263
Thread Lock on the bolt threads and hand tighten b. Intake lobe ................... 9.314 mm (.3667 in.)
only to a torque of ......... 45 + 7 N•m (33 + 5 lb ft) c. Injector lobe ............... 13 678 mm (.5385 in.)

13
(1) Height to top of valve guides (4) Diameter of valve stems

...................... 26.00 + 2.00 mm (1.024 + .079 in.) (new) .........9.441 + 0.008 mm (.3717 + .0003 in.)
(2) 7N1904 Spring (outer) for valve:
Length under test force ...... 56.36 mm (2.219 in.)

Test force ...................254 + 25 N (56.9 + 5.6 lb.)
Use again minimum load at length under test
force ............................................ 229 N (51.5 lb.)
Length of spring at valve open position
............................................ 40.36 mm (1.589 in.)
Use again minimum load at valve open position
...................................................... 800 N (180 lb.)
Bore in valve guides with guides installed in the head
Free length after test .......... 62.50 mm (2.461 in.)
(new) .........9.487 + 0.025 mm (.3735 + .0010 in.)
Outside diameter ................ 43.96 mm (1.731 in.)
Use again maximum bore in valve guides with
Spring must not be bent more than guides installed in the head
................................................ 2.18 mm (.086 in.) ............................................9.540 mm (.3755 in.)
(5) Diameter of valve
(3) 7N1903 Spring (inner) for valve:
heads ............56.00 + 0.15 mm (2.205 + .006 in.)
(6) Angle of valve faces..........................291/4 + 1/4°
Test force ..................... 125 ± 12 N (28 + 2.7 lb.)
(7) Depth of bore in head for valve
Use again minimum load at length seat inserts........14.00 + 0.15 .lm (.551 +.006 in.)
under test force ........................... 113 N (25.4 lb.)
(8) Diameter of valve seat
Length of spring at valve inserts....60.119 + 0.015 mm (2.3669 + .0006 in.)
open position ...................... 29.49 mm (1.161 in.)
Bore in head for valve seat
Use again minimum load at valve inserts....60.000 + 0.025 mm (2.3622 + .0010 in.)
open position ............................... 397 N (89.3 lb.)
(9) Angle of face of valve seat
Free length after test .......... 51.54 mm (2.029 in.) inserts.................................................3014 + 1/2°
Outside diameter ................ 29.24 mm (1.151 in.) (10) Outside diameter of the face of valve seat
Spring must not be bent inserts............55.14 + 1.48 mm (2.171 + .058 in.)
more than ............................... 1.83 mm (.072 in.)
14
VALVE COVERS
(1) Torque for bolts that hold valve cover in

position ......................... 20 + 3 N•m (15 + 2 lb. ft)
(2) Cut seal to fit at assembly
VALVE ROCKER ARMS, LIFTERS,

AND BRIDGES
(1) Torque for valve adjustment screw

locknut .................... 70 + 15 N•m (50 + 11 lb. ft.)
(2) Clearance for valves:
Intake valves .......................... 0.38 mm (.015 in.)
Exhaust valves ....................... 0.76 mm (.030 in.)
(3) Torque for bridge adjustment screw
locknut ........................ 30 + 4 N•m (22 + 3 lb. ft.)
(4) Diameter of dowel
(new)....... 11.008 + 0.003 mm (.4334 + .0001 in.)
Bore In bridge for dowel
(new)............... 12.00 + 0.25 mm (.472 + .010 in.)
Bore in head for
dowel ...... 10.968 + 0.020 mm (.4318 + .0008 in.)
(5) Diameter of rocker arm
shaft...... 37.084 + 0.013 mm (1.4600 + .0005 in.)
Bore In bearings for rocker arm shaft
.............. 37.140 + 0.015 mm (1.4622 + .0006 in.)
(6) Height to top of
dowel .................... 66.5 + 0.5 mm (2.62 + .02 in.)
(7) Guide springs must not be used again. Always
install new guide springs.
(8) Diameter of valve lifter
(new)..... 29.937 + 0.010 mm (1.1786 + .0004 in.)
Bore In head for valve
lifter....... 30.000 + 0.025 mm (1 1811 + .0010 in.)

15
CYLINDER HEADS
NOTICE
Before installation of this cylinder head on an engine
that has water cooled manifolds, the plug at location
(A) MUST be removed. If the engine has dry
manifolds the plug at location (A) MUST NOT be
removed.
(1) Put 5P3931 Anti-Seize Compound on the

threads of the bolts and tighten them as follows:
a. Tighten all the bolts to

30 + 5 N•m (22 + 4 lb. ft.)
b. Tighten bolts 1 through 8

in number sequence
to ................... 270 + 35 N•m (200 ± 26 lb. ft.)
c. Tighten bolts 1 through 8 In number sequence

to ................... 450 ± 20 N•m (330 + 15 lb. ft.)
(2) Depth that two plugs are installed

in top of cylinder head
.................................. 9.0 + 0.5 mm (.35 + .02 in )
Use 6V1541 Quick Cure Primer and 9S3265

Retaining Compound in the plug bores at
assembly.
(3) Height of cylinder head

(new)........... 142.00 + 0.15 mm (5.591 + .006 in.)
(4) Depth below bottom of chamfer that the seven

plugs are installed In cylinder
head.......................... 1.0 + 0.5 mm (.04 + .02 In.)
Use 6V1541 Quick Cure Primer and 9S3265

Retaining Compound in the plug bores at
assembly.
16
TURBOCHARGER IMPELLER INSTALLATION
INSTALLATION PROCEDURE CHART

TURBOCHARGER MODELS
T04, T04B, TM51 T12, TV61, T18, TV81, TV91, TW91,
Step by Step Procedure T04C, TM54 TW61, TL61 TW81, TL81, TL91, TV92,
TW4B, TW4C TV72, TW72, TW92, TL92
TL4B, TL4C TL72, TV78,
TW78, TL78
A. Put impeller on the shaft.
B. Put a small amount of clean oil
on the threads and impeller face
area that contacts the nut.
C. Install and tighten the nut to: 2.25 N•m 5 N•m 17 N•m 17 N•m 31 N•m
(20 lb. in.) (50 lb. in.) (13 lb. ft.) (13 lb. ft.) (23 lb. ft.)
NOTICE
Do not bend or add stress to
the shaft when the nut is
loosened or tightened.
D. Loosen the nut on the shaft. • •
E. Now tighten the nut to: • • 3.5 N•m 3.5 N•m 5 N•m
(30 lb. in.) (30 lb. in.) (50 lb. in.)
F. Tighten the nut more: 110° 120° 120° 120° 135°
G. Remove the nut from the shaft.
H. Use 6V1541 Quick Cure Primer
on the threads of the shaft and
nut.
J. Put 9S3265 Retaining
Compound on the threads of the
shaft and nut.
K. Install and tighten the nut to: 2.25 N•m 5 N•m 3.5 N•m 3.5 N•m 5 N•m
(20 lb. in.) (50 lb. in.) (30 lb. in.) (30 lb. in.) (50 lb. in.)
L. Tighten the nut more: 110° 120° 120° 1200 135°
• Does not apply to these turbochargers.

17
TURBOCHARGER TV61
(1) Nut for impeller (See TURBOCHARGER Diameter for the surfaces (journals) on the shaft for the
IMPELLER INSTALLATION). bearings ........ 15.E875 to 15.885 mm (.6250 to .6254 in.)
NOTICE (5) Bore in the housing

Do not bend or add stress to the shaft when the nut ............24.961 to 24.973 mm (.9827 to .9832 in.)
is loosened or tightened.
Outside diameter of the
(2) Torque for the bolts that hold bearings ...........24.846 to 24.859 mm (.9782 to .9787 in.)
the backplate .............10 + 1 N•m (90 + 10 lb. in.)
(6) Clearance between the ends of the oil seal ring
(3) Torque for the clamp (when installed
bolts ...................14.0 + 1.5 N•m (120 + 13 lb. in.) in its bore) .......0.20 to 0.38 mm (.008 to .015 in.)
Lightly hit all around clamp with a soft faced
hammer and again (7) End play for the
tighten to............14 0 + 1.5 N•m (120 + 13 lb. in.) shaft .............. 0.08 to 0.25 mm (.003 to .010 in.)
(4) Bore in the bearings (8) Torque for bolts and nuts that hold the
............ 15.921 to 15.931 mm (.6268 to .6272 in.) turbocharger to the exhaust manifold (put
5P3931 Anti-Seize Compound on the threads)
54 + 5 N•m (40 • 4 lb. ft.)
18
TURBOCHARGER TV81
(1) Nut for impeller (See TURBOCHARGER Diameter for the surfaces (journals) on the shaft
IMPELLER INSTALLATION). for the bearings
............15.875 to 15.885 mm (.6250 to .6254 in.)
NOTICE
Do not bend or add stress to the shaft when the nut (5) Bore in the housing
is loosened or tightened. .............. 24.961 to 24.973 mm (.9827 to .9832 in
(2) Torque for the bolts that hold the backplate Outside diameter of the bearings
...................................10 + 1 N•m (90 ± 10 lb. in.) ............24.846 to 24.859 mm (.9782 to .9787 in.)
(3) Torque for the clamp (6) Clearance between the ends of the oil seal ring
bolts ...................14.0 + 1.5 N•m (120 + 13 lb. in.) (when installed in its bore)
Lightly hit all around clamp with a soft faced hammer and again ........................0.20 to 0.38 mm (.008 to .015 in.)
tighten to.............14.0 + 1.5 N•m (120 + 13 lb. in)
(7) End play for the shaft
(4) Bore in the bearings ........................0.08 to 0.25 mm (.003 to .010 in.)
............ 15.921 to 15.931 mm (.6268 to .6272 in.)
(8) Torque for bolts and nuts that hold the
turbocharger to the exhaust manifold (put
5P3931 Anti-Seize Compound on the threads)
......................................54 + 5 N•m (40 + 4 lb ft.)

19
TURBOCHARGER TV91
(1) Nut for impeller (See TURBOCHARGER (5) Clearance between the ends of oil seal ring (when
IMPELLER INSTALLATION). installed in its bore
........................0.20 to 0.38 mm (.008 to .015 in.)
NOTICE
Do not bend or add stress to the shaft when the nut (6) End play for the shaft
is loosened or tightened. ..................0.165 + 0.063 mm (.0065 + .0025 in.)
(2) Torque for the clamp (7) Torque for the bolts that hold the backplate
bolt......................... 14.0 + 1.5 N•m (10 + 1 lb. ft.) .....................................40 + 2 N•m (30 + 1 lb. ft.)
Hit lightly all around clamp with a soft faced
hammer and again tighten to (8) Torque for the bolts that hold the turbine housing
............................... 14.0 + 1.5 N•m (10 + 1 lb. ft.) to the cartridge housing (put 5P3931 Anti-Seize
Cornpound on the threads
(3) Bore in the bearings .....................................40 + 2 N•m (30 + 1 lb. ft.)
............ 21.585 to 21.595 mm (.8498 to .8502 in.)
Torque for the bolts and nuts that hold the
Diameter of the surfaces (journals) on the shaft turbocharger to the exhaust manifold (put 5P3931
............ 21.539 to 21.549 mm (.8480 to .8484 in.) Anti-Seize Compound on the threads
.....................................54 ± 5 N•m (40 + 4 lb. ft.)
(4) Bore in the housing
........ 30.594 to 30.607 mm (1.2045 to 1.2050 in.)
Outside diameter of bearings

........ 30.467 to 30.480 mm (1.1995 to 1.2000 in.)
20
TURBOCHARGER C153
(1) Torque for the bolts and nuts that hold the (6) Width of oil seal ring at
turbocharger to the exhaust manifold (put turbine end ......2.500 ± 0.010 mm (.0984 ±.0004
5P3931 Anti-Seize in.)
Compound on threads)................. 270 ± 25 N-m
(200 ± 18 lb. ft.) Width of oil seal ring groove at
turbine end ......2.550 + 0.030 - 0.010 mm
(2) Torque for the bolts that hold the turbine housing (.1004 + .0012 - .0004 in.)
to the cartridge housing........................... 48
± 3 N•m (35 ± 2 lb. ft.) (7) End play for the shaft ...... 0.090 to 0.130 mm
(.0035 to .0051 mm)
(3) Torque for the bolts that hold the compressor
housing to the cartridge housing (put 5P3931 (8) Bore in the bearings...... 24.020 +0.010-0.0mm
Anti-Seize Compound on the threads) ......... 25 (.9457 + .0004 - .00 in.)
± 5 N-m (18 ±4 lb. ft.)
Diameter of the surfaces (journals)
(4) Width of oil seal ring at on the shaft ......24.000 + 0.0 - 0.009 mm
(.9449 + .00 - .0004 in.)
compressor end........2.500 ± 0.010 mm (.0984 ±
.0004 in.)
(9) Bore in the
housing ........32.000 + 0.016 - 0.0 mm
Width of oil seal ring groove at
(1.2598 + .0006 - .00 in.)
compressor end............................ 2.635
±0.035 mm (.1037 ± .0014 in.) Outside diameter of
the bearings ....31.890 + 0.0 - 0.010 mm
(5) Turbocharger impeller installation: (1.2555 + .00 - .0004 in.)
a. Put impeller on the shaft. (10) Torque for the three bolts that hold the
thrust bearing ......... 10 ± 2 N•m (7 ±1 lb. ft.)
b. Put a small amount of 2P2506 Thread
Lubricant on the threads and impeller face
that will be under the nut.
c. Tighten the nut to.................. 95 ±5 N-m (70

±4 lb. ft.)
NOTICE
Do not bend or add stress to the
shaft when the nut Is loosened or
tightened.
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL
TIGHTENING TORQUES
21
EXHAUST MANIFOLDS
(3512 EXHAUST MANIFOLDS ILLUSTRATED)
(1) Left exhaust manifolds.
(2) Put 5P3931 Anti-Seize Compound on the threads of all exhaust manifold bolts, nuts and plugs (3).
Torque for all exhaust manifold

bolts and nuts ........... 45 ±7 N-m (32 ±5 lb. ft.)
(3) 5B7890 Plugs.
Torque for exhaust manifold

plugs ......................... 35 N•m (25 lb. ft.)
(4) Right exhaust manifolds
22
AIR INTAKE SHUTOFF
(1) Install shaft assembly in housing as follows (8) Torque for nut that holds cylinder
to flange ........45 ±7 N•m (33 ± 5 lb ft
a. Install spacer (3) and spring (2) on shaft
assembly (1). (9) Diameter of pin6.299 ±0.008 mm (2480 ±.0003
b. Install the assembly in the housing Turn In )
spring (2) until It engages correctly with pin
(4) Bore in spacer bushing for pin
(after assembly) ................... 6.314 ±0.011 mm
c Install handle (10) on the shaft assembly (1)
( 2486 ±.0004 n )
Turn shaft assembly (1) upward and install
pin (13) so handle (10) can rest on pin (13).
Bore in spacer for
d. With the shaft assembly and handle (10) In bushing. ........7.938 ±0.013 mm (.3125 +.0005
contact with pin (13), Install plate In.)
assemblies (5) and (6) on the shaft
assembly. (10) Handle
e. Remove pin (13) to release the handle and
let plate assemblies (5) and (6) move to the (11) Diameter of pin (13) ...................... .6.299
"shutoff" position. A 0.076 mm (.003 in) ±.0.008 mm (2480 ±.0003 in )
feeler gauge should not pass between each
plate assembly and the housing. Bore in housing for
pin .............................. 6.408 ±0.051 mm
f. Remove handle (10) and Install spacer (.2523 ±.0020 in)
assembly (12), pin, (13), the gasket, cover
assembly and handle (10). Bore in spacer bushing for pin
(2) Spring (after assembly) ................... 6.314 ±0.011 mm
(3) Spacer for spring (2). (.2486 ±.0004 in.)
Bore In spacer for shaft .. 20 80 ±0 25 mm (819 Bore in spacer for

+.010 in) bushing ........7.938 ± 0.013 mm (.3125±.0005
Diameter of shaft .............. 18.94 ±0.02 mm in)
(.746 + .001 In ) (12) Spacer.
(4) Pin
(13) Pin.
(5) Plate assembly
(14) Diameter of shaft ...................... 18.94 ±0.02
(6) Plate assembly mm (.746 ±.001 In)
(7) Hydraulic cylinder must be Installed before the
Inside diameter of
air shutoff can be installed on the engine. Put the air
bushings for shaft ...................... 19.050
shutoff group in the "open" position and install the
gasket, flange and cylinder with cylinder shaft (15) ±0.044 mm (.7500 ±.0017 In)
between the spacer assembly in the shaft lever and (15) Hydraulic cylinder shaft
spacer assembly (16). The bolts that hold the unit to the
aftercooler housing can now be installed. (16) Spacer assembly
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR
GENERAL TIGHTENING TORQUES
23
AIR INTAKE SHUTOFF
(1) Hydraulic shutoff cylinder. Make an alignment of cylinder port and vent hole (9) in a vertical downward position at
assembly.
(2) Torque for nut that holds cylinder

(1) to the flange ............................ 45 ±7 N•m (33 ±5 lb. ft.)
(3) Diameter of cylinder

rod ..................................... 7.920 ± 0.013 mm (.3118 ± .0005 in.)
Bore in bushing after

assembly ..................................... 7.996 ± 0.044 mm (.3148 ± .0017 in.)
Bore in housing for

bushing ..................................... 9.525 ± 0.013 mm (.3750 ±.0005 in.)
Install bushing with split along centerline (8) toward front or rear.
(4) 2V244 Spring for shutoff actuator pin:
Length under test force ................ 29.2 mm (1.15 in.)

Test force ....... 8.9 ± 0.7 N (2.00 ±.16 lb.)
Free length after test .................... 54.6 mm (2.15 in.)
Outside diameter ..................... 9.04 mm (.356 in.)
(5) Torque for carrier (put 2P2506 Thread Lubricant

on the threads) ............................. 70 ± 10 N•m (50 ± 7 lb. ft.)
(6) Bore in spring bushing.................. 19.30 ± 0.25 mm (.760 ±.010 in.)
Diameter of shaft ..................... 18.97 ±0.02 mm (.747± .001 in.)
(7) Diameter of shaft ..................... 18.97 ±0.02 mm (.747 ± .001 in.)
Bore in two shaft bushings

(after assembly) ..................... 19.050 ±0.044 mm (.7500 + .0017 in.)
Bore in housing for

bushings ....... .22.205 ±0.013 mm (.8742 0005 in.)
24
AIR INTAKE SHUTOFF
(1) Latch.
(8) Shaft assembly.
(2) Shutoff cylinder rod. (9) Plate assembly.
(3) Install shutoff cylinder as follows: NOTE: With plate assembly (9) in closed (shutoff)
position, a 0.8 mm (.03 in.) feeler gauge must not pass
a. Assemble shutoff cylinder on the flange at between the plate assembly and the housing bore at any
the angle shown. position.
b. Tighten the nut that holds the shutoff (10) Lever return spring.
cylinder to the flange to a torque of.... 45
± 7 N•m (33 ±5 lb. ft.) (11) Lever.
c. Install the flange on the air shutoff housing. (12) Sleeve.

Make sure cylinder rod (2) is engaged in the
notch of lever (11). (13) Diameter of
sleeve.................. 4.945 ± 0.009 mm (.5995
NOTE: The cylinder vent hole, between the ±0004 in.)
ports, must be in the downward position.
Bore in bushing (after
(4) Knob. assembly)........5.024 ±0.034 mm (.6026 ±.0014
in.)
(5) Diameter of shaft assembly
at seal ....... 15.88 ±0.05 mm (.625 ±.002 in.) Bore in lever for
(6) Air shutoff spring. bushing.............7.009 ±0.009 mm (.6823 ±.0004

in.)
(7) Diameter of shaft
assembly ....... 24.88 ±0.02 mm (.980 ±.001 in.) NOTE : Install both bushings to a dimension of 0.8 ±0.3
mm (.03 ±.01 in.) below the surface of lever ends.
Bore in bushings for shaft assembly
(after assembly)........ 25.017 ±0.040 mm (14) Dimension to install end of two bushings from
(1.0035 ±0016 in.) machined
Bores in housing for housing bore ...0.35 ±0.15 mm (.014 ±.006 in.)
bearings ....... 27.997 ±0.010 mm
(1.1230 ±.0004 in.)
25
OIL PUMP
(2W5474)
Rotation of drive gear (as seen from drive

end) ................................ Clockwise
(1) Length of gears

(new) ....... 54.000 ±0.015 mm (2.1260
±.0006 in.)
Depth of bores for gears

(new) ....... 54.150 ±0.020 mm (2.1319
±.0008 in.)
(2) Diameter of gear

shafts (new).... 31.742 ±0.008 mm (1.2497
±.0003 in.)
Bore in bearings for gear shafts (after

assembly) ....... 31.811 ±0.013 mm (1.2524
±.0005 in.)
(3) Distance dowels extend

from cover. ..... 6.0 ±0.5 mm (.24 ±.02 in.)
(4) Distance from the end of the idler shafts

to gear faces........... 34.0 ±0.5 mm (1.34 ±.02
in.)
(5) Distance from the end of the drive shaft

to gear face. ... 47.0 ±0.5 mm (1.85 ±.02 in.)
(6) Depth that bearings are installed

in cover ....... 1.5 ±0.5 mm (.06 ±.02 in.)

in housing ....... 1.5 ±0.5 mm (.06 ±.02 in.)
(8) The location of each bearing junction must be as

shown. Position bearing junctions from the
centerline through the bearing bores to an angle
of ............................... .45 + 15°
(9) 2S2760 Spring (oil pressure relief):
Length under test force........117.9 mm (4.64 in.)

Test force ....... 490 ±27 N (110 ±6 lb.)
Free length after test ...... 52.9 mm (6.02 in.)
Outside diameter .... 27.00 mm (1.063 in.)
26
OIL PUMP
(2W5477)
Rotation of drive gear (as seen from drive

end) ........................ Clockwise
(1) Length of gears

(new)............... 84.000 ±0.015 mm (3.3071
±.0006 in.)

(new) ....... 84.150 ±0.020 mm (3.3130
±.0008 in.)
(2) Diameter of gear

shafts (new).... 31.742 ±0.008 mm (1.2497
±.0003 in.)
Bore in bearings for gear shafts (after
assembly) ....... 31.811 ±0.013 mm (1.2524
±.0005 in.)
(3) Distance dowels extend
from cover ...... 6.0 ±0.5 mm (.24 ±.02 in.)
(4) Distance from the end of the idler shafts
to gear faces.......... 34.0 ±0.5 mm (1.34 ±.02
in.)
(5) Distance from the end of the drive shaft
to gear face .... 47.0 ±0.5 mm (1.85 ±.02 in.)
in cover ....... 1.5 ±0.5 mm (.06 ±.02 in.)
in housing. ...... 1.5 ± 0.5 mm (.06 ±.02 in.)
(8) The location of each bearing junction must be as

shown. Position bearing junctions from the centerline
through the bearing bores to an angle of .. 45 ±15°
(9) 2S2760 Spring (oil pressure relief):
Length under test force. ..... 117.9 mm (4.64

in.)
Test force ....... .490 ±27 N (110 ±6 lb.)
Free length after test .................... 52.9 mm
(6.02 in.)
Outside diameter. ........... 27.00 mm (1.063
in.)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST 27 PAGE OF SPECIFICATIONS FOR
27
OIL FILTER BYPASS VALVE
(1) Oil filter housing.
(2) Oil filter bypass valve must start to

open at ....... 110 ±20 kPa (16 ±3 psi)
and fully open at ........................... 325 ±20 kPa (47 ±3 psi)
(3) 3N4316 Spring for the filter bypass valve:
Length under test force. ............... 70.6 mm (2.78 in.)
Test force. ...... 155 ±7.5 N (35.0 ±1.7 lb.)
Outside diameter. ..................... 28.83 mm (1.135 in.)
28
(2) Torque for three bolts that hold bypass housing to filter housing............................. 55 ±7 N•m (41 ±5 lb. ft.)
(3) 2W1635 Spring for the filter bypass valve:
Length under test force ................ 102 mm (4.02 in.)

Test force ....... 518 N (115 lb.)
Outside diameter ..................... 37.25 mm (1.470 in.)

open at ....... 287 ± 7 kPa (42 ±1 psi)
and fully open at. ..................... 480 ±7 kPa (70 + 1 psi)
29
OIL COOLER BYPASS AND

COOLING JET SEQUENCE VALVES
(1) Tighten plug in elbow to a and must be fully open at .............. 200 ±30 kPa
torque of. ....... 100 ± 15 N-m (75 ± 11 lb. ft.) (29 ± 4.5 psi)
(2) 6B9202 Spring for cooling jet sequence valve (3) 8M3182 Spring for oil cooler bypass valve:
(one at each end of block):
Length under test force ................. 63.5 mm
Length under test force ......... 68.3 mm (2.69 (2.5 in.)
in.)
Test force ........40 N (9 lb.)
Test force ....... 85 to 102 N (19 to 23 lb.)
Free length after test..................... 1.7 mm
Free length after test ........... 112.7 mm (4.44 (3.61 in.)
in.)
Outside diameter ...................... 20.60 mm
Outside diameter ..................... 24.60 mm (.810 in.)
(.969 in.)
Oil cooler bypass valve must open with a
Both cooling jet sequence valves must start to pressure difference of ................... 180 ± 20
open at a pressure difference of .. 130 ± 30 kPa (26 ± 3 psi)
kPa (19 ±4.5 psi)
30
WATER PUMP
EARLIER WATER PUMP ILLUSTRATED
(1) Oil seal. Put glycerin or clean engine oil on the the bore for the seal.
lip of the seal. Assemble with the lip toward the
splined end of the pump shaft as shown. (5) Earlier water pumps:
(2) Ceramic ring and rubber water seal. Torque for bolt that holds
impeller ........90 ± 15 N•m (65 ± 11 lb. ft.)
a. Put clean water on the seal and ring.
Hit bolt with hammer and again
b. Use the seal installation tool (part of the tighten bolt to................. 90 ± 15 N•m (65 ± 11
replacement seal assembly) and hand lb. ft.)
pressure to install the rubber seal and
ceramic ring as a unit in the housing bore. *Later water pumps:
Make sure the identification groove of the
ceramic ring is installed inside the rubber Torque for nut that holds
seal. impeller ........200 ± 25 N•m (150 ± 18 lb. ft.)
(3) Seal Assembly: (6) Torque for the three studs in pump
housing ........27 ± 4 N•m (20 ± 3 lb. ft.)
a. Remove the spring from the seal assembly.
(7) Clearance between impeller and cover:
b. Put clean water inside the seal assembly.
Earlier water pumps ...................... 0.12 to 0.89
c. Use the seal installation tool (part of the
mm (.005 to .035 in.)
replacement seal assembly) and hand
pressure to install the seal assembly on the
*Later water pumps ...................... 0.62 to 1.39
shaft until the carbon face makes light
mm (.024 to .055 in.)
contact with the shiny face of the ceramic
seal.
*NOTE: Later water pumps have a nut that
holds the impeller on the pump shaft.
d. Install the spring.
(4) Seal. Put a light amount of clean engine oil in
31
AFTERCOOLER
(3512 AFTERCOOLER ILLUSTRATED)
(1) Put clean engine oil or glycerin on all O-ring seals and in their bores at assembly.
(2) Cut the ends of the gaskets even with the bottom of the housings for assembly.
(3) Torque for all the bolts that hold the aftercooler housings to the cylinder block........55 ±7 N•m (41 ±5 lb. ft.)
WATER CONNECTION GROUP - OUTLET
(1) Tighten bolts to a torque of...135 ±15 N•m (100 ± 11 lb. ft.)
32
WATER TEMPERATURE REGULATORS
Temperature when completely open ......... 2° C (197° F)
Minimum opening distance at

92° C (197° F) ....... 9 53 mm (.375 in.)
V-BELT TENSION CHART

BELT BELT BORROUGHS GAGUE NUMBERS
TENSION TENSION
“INITIAL”* “USED”**
BELT WIDTH BELT WIDTH TOP GAUGE GAUGE
SIZE TOP OF PULLEY READING READING
GROOVE
mm in. mm. in. N lb. N lb. OLD GUAGE NEW GAUFE NO
NO.
3/8 10.7 .422 9.65 .380 445±2 100± 400±2 90±5 BT-33-73F BT-33-95
2 2 5 2
½ 13.8 .547 12.70 .500 534±2 120± 400±4 90±1 BT-33-96-4-16 BT-33-95
9 2 5 4 0
5V 15.8 .625 15.24 .600 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
8 2 5 4 0
11/16 17.4 .688 15.88 .625 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
8 2 5 4 0
¾ 19.0 .750 17.53 .690 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
5 2 5 4 0
15/16 23.8 .938 22.30 .878 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
3 2 5 4 0
MEASURE TENSION OF BELT FARTHEST FROM THE ENGINE
"'INITIAL" BELT TENSION is for a new belt.
**""USED" BELT TENSION is for a belt which has more than 30 minutes of operation at rated speed of engine. A10232-1
X1
33
CYLINDER BLOCK
(1) Thickness of spacer plates....................2.313 ±0.025 Install main bearing caps with "FRONT" and cast part
mm (.4848 ± .0010 in.) number toward front of the block. Each cap has a
number and must be installed in the same position as
(2) Thickness of gasket between the cylinder block the correct number on the side of the cylinder block
and spacer plates ................ 0.208 ± 0.025 mm (.0082 pan rail.
± .0010 in.)
a. Before assembly, put Fel-Pro C100 Lubricant (if
(3) Distance all dowels extend above block not available, use 2P2506 Thread Lubricant) on
face.........20.0 ± 0.5 mm (.79 ±.02 in.) the bolt threads and all surfaces that make
contact between the bolt and the cap.
(4) Torque for plugs....100 ± 15 N-m (75 ± 11 lb. ft.)
b. Tighten the bolts in letter sequence
to............. 136 ± 14 N•m (100 ± 10 lb. ft.)
(5) Make reference to CYLINDER LINER PROJECTION,
for the height of the liner.
c. Tighten the bolts in
(6) Bore in the block for the camshaft letter sequence more 180±50
bearings ........92.000 ± 0.020 mm (3.6220 ± .0008
(14) Distance dowel extends from rear face
in.)
of block.............. 6.0 ± 0.5 mm (.24 ±.02 in.)
(7) Camshaft bearing junction.
(15) Torque for adapter ................... 100 ± 15 N-m (75 ±
(8) Centerline through oil holes in camshaft 11 lb. ft.)
bearings. Oil holes must be positioned from
horizontal at angle "X" 20 ± 5° (16) Distance dowels extend from front face
of block.............. 6.0 ± 0.5 mm (.24 ± .02 in.)
NOTE: All bearing oil hole centerlines (8) and bearing
junctions (7) must be in position shown for each side of
cylinder block.
(9) Dimension (new) from centerline of crankshaft

bearing bore to top of block
(top deck) ........ 586.00 mm (23.071 in.)
(10) Width of main bearing

cap.....................340.000 ± 0.015 mm (13.3858 ±.
0006 in.)
Width of cylinder block for main

bearing cap........340.000 ± 0.015 mm (13.3858 ±
.0006 in.) FRONT VIEW OF CYLINDER BLOCK
Clearance between the sides of the main bearing cap
and the cylinder
block ..................0.030 mm (.0012 in.) tight to 0.030
mm (.0012 In.) loose
(11) Bore in the block for the main bearings:
Standard, original size

(new)..................69.742 ± 0.020 mm (6.6828 ±.0008
in.)
0.63 mm (.025 in.) larger than original

size. ...................170.372 ± 0.020 mm (6.7076 ±.
0008 in.) (17) Distance dowels extend from rear face of block...19.0
± 0.5 mm (.75 ± .02 in.)
(12) Dimension (new) from centerline of crankshaft
bearing bore to bottom (18) Distance dowels extend from front face of
of block (pan rails) .............................. 230.00 mm
block.......40.0 ± 0.5 mm (1.58 ±.02 in.)
(9.055 in.)
(13) Tighten the bolts that hold the caps for the main
bearings as follows:
34
CYLINDER LINERS
For Installation
a. Put liquid soap on cylinder block liner bore
surfaces and rubber seals on the lower part
of the liner.
b. Put the filler band completely in clean

engine oil for a moment.
c. Install filler band (3) in the groove under the

liner flange, without delay.
d. Install the liner in the bore immediately,

before expansion of the filler band.
(1) Bore in liner

(new)....................... 170.025±0.025 mm (6
6939 ± 0010 in.)
(2) Thickness of flange

on liner............ 12.65 ± 0.02 mm (.498 ± 001 in )
(3) Filler Band.
CYLINDER LINER PROJECTION

liner must be.......................... 0.059 to 0
Make reference to CYLINDER LINER PROJECTION in 199 mm (.0023 to .0078 in.)
Testing and Adjusting for the complete procedure.
Maximum permissible difference between
1. Install the gasket and spacer plate (5). all four measurements .......... 0.05 mm
Install copper washers and bolts (4) to hold (.002 in.)
the spacer plate Tighten bolts (4) evenly in
four steps. (1) 3H465 Plate
1st step .................. 14 N•m (10 lb. ft.)
(6) 8B7548 Push-Puller Crossbar.
2nd step................. 35 N•m (25 lb. ft )
3rd step................... 70 N•m (50 lb. ft )
4th step................... 95 N•m (70 lb. ft )
2. Install tooling as shown. Tighten bolts for

crossbar evenly in four steps.
1st step ..................... 7 N•m (5 lb ft.)
2nd step....................... 20 N•m (15 lb ft )
3rd step.......................... 35 N•m (25 lb ft.)

4th step........................ 70 N•m (50 lb ft.)
3. Measure cylinder liner projection with dial
indicator (2) in 1P2402 Gauge Body (3) as
shown Measure at four places around each
cylinder liner near the clamped area
Average of four projection measurements
from any cylinder
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST35 PAGE OF SPECIFICATIONS FOR
35
PISTONS AND RINGS
PISTONS AND PISTON RINGS

(1) TOP RING* (2) INTERMEDIATE (3) OIL CONTROL (3) OIL CONTROL
RING* RING**(with 17 oil RING**(with 12 oil
slots) slots)
Width of groove in __ __ 5.050 ± 0.013 mm 5 050 ± 0.013 mm

piston for piston ring
(new)
(.1988 ± .0005 in ) (.1988 ± .0005 in.)
Thickness of piston __ __ 4.968 ±0.013 mm 4.954 ± 0 019 mm
ring (new).
(.1956 ± 0005 in.) (.1950 ±0007 In )
Clearance between __ __ 0.082 ±0 013 mm 0 064 to 0 128 mm
groove and piston ring
(new).
(0032 ±.0005 In.) ( 0025 to .0050 in.)
Clearance between 0.80 ± 0.20 mm 0 80 ± 0.20 mm 0 56 ±12 mm 0 70 ± 0.19 mm
ends of piston ring (.031 ± .008 In, ) (.031 ± 008 in.) (.022 ±005 In.) (.028 ± 007 in )
when installed in a
cylinder liner with a
bore size of 170 mm
(6.694 in )
Increase in clearance (.0010 08 mm ( 003 in )

between ends of
piston ring for each 0
03 mm in ) increase in
cylinder liner bore size
*Install piston ring with "UP" side toward top of piston.
NOTE: Top Ring (1) has the mark "UP-1." Intermediate Ring (2) has the mark "UP-2."
**Install Oil Control Ring (3) with the gap in the spring 180° away from the gap in the ring.
White portion of spring must be visible at the ring end gap.
(4) Bore in piston

for pin ............................... 69.983 + .008 mm (2.7552 + .0003 in.)
Clearance between pin and bore

in piston ............................ 0.008 to 0.034 mm (.0003 to .0013 in.)
Pin diameter ........................ 69.962 ±.005 mm (2.7544 ±.0002 in.)
36
CONNECTING RODS Diameter of piston

(1) Distance between center of pin (new) ........69.962 ± 0.005 mm (2.7544 ±.
bearings.................. 380.00 mm (14.961 in.) 0002 in.)
NOTE: Connecting rod must be heated for installation of
(2) Distance that locating pin extends piston pin bearing. Do not use a torch. Heat connecting
from rod cap ..... 4.0 ± 0.5 mm (.16 ±.02 in.) rod to a temperature of 177 to 204° C (350 to 400°
F)
(3) Bore in connecting rod for bearing
with bolts tightened to specifications Side clearance between two connecting rods on
(6) ........... 143.028 ± 0.015 mm (5.6310 ± .0006 same crankshaft pin (new):
in.) 3508 ............ 0.900 ± 0.282 mm (.0354 ±
.0111 in.)
(4) Take the connecting rod bearing measurements 3512 .......... 0.850 ± 0.232 mm (.0335 ±
on the centerline of the connecting rod bores. .0091 in.)
3516 .......... 0.850 ± 0.332 mm (.0335 ±
Bore in bearing for .0131 in.)
crankshaft....... ............................. 135.133 to
135.194 mm (5.3202 to 5.3226 in.)
Clearance between bearing and crankshaft

(new)............ 0.107 to 0.218 mm (.0042 to
.0086 in.)
(5) Side of connecting rod with chamfer.
(6) Tighten connecting rod bolts as follows:
NOTE: Bolts A and B are on the same end of

the rod cap that has bearing tabs and location
pin (7).
a. Before assembly, put Fel-Pro C100

Lubricant (if not available, use 2P2506
Thread Lubricant) on the bolt threads and
all surfaces that make contact between the
bolt and the cap.
b. Tighten bolts A and B

to .................... 90 ± 5 N•m (65 ± 4 lb. ft.)
c. Tighten bolts C and D

to ....... 90 ± 5 N•m (65 ±4 lb. ft.)
d. Tighten bolts A and B

again to...... 90 ±5 N•m (65 ± 4 lb. ft.)
e. Tighten bolts C and D

again to........... 90 ± 5 N•m (65 ± 4 lb. ft.)
f. Tighten each bolt more......... 90 ± 5°

(7) Location pin for correct installation of connecting
rod caps.
(8) Bore in bearing for piston pin

(new)....... 70.000 ± 0.008 mm (2.7559 ±.0003
in.)
37
CONNECTING ROD AND MAIN

BEARING JOURNALS
CONNECTING ROD BEARING JOURNALS

0.63 mm (.025 in.) 1.27 mm (.050 in.)
UNDERSIZE UNDERSIZE
ORIGINAL SIZE (SMALLER) (SMALLER)
JOURNAL JOURNAL JOURNAL
Diameter of
crankshaft
journal (bearing 135 000 ± 0.025 mm 134.370 ± 0.025 mm 133.730 ± 0 025 mm
surface)
for connecting rod (5.3150 ± 0010 in.) (5.2902 ± .0010 in.) (5.2650 ±.0010 in.)
Clearance between 0.107 to 0.218 mm

bearing
and journal (new). (.0042 to 0086 in.)
MAIN BEARING JOURNALS

0.63 mm (.025 in.) 1.27 mm (.050 in.)
UNDERSIZE UNERSIZE
ORIGINAL SIZE (SMALLER) (SMALLER)
JOURNAL JOURNAL JOURNAL
Diameter of crankshaft
journal
(bearing surface) for main 160.000 ± 0.025 mm 159.370 ± 0 025 mm 158 730 ± 0 025 mm
bearings. (6.2992 ± 0010 in.) (6.2744 ± .0010 in.) (6.2492 ± .0010 In.)
Clearance between 0.122 to 0.241 mm

bearing and
journal (new) (.0048 to .0095 in.)
38
CRANKSHAFT
(3508)
(3512 & 3516)
(1) Thrust plates for center bearing only.

(5) Make reference to Main Bearing Journals.
(2) End play for the crankshaft
(new) ...... 0.170 to 0.630 mm (.0067 to (6) Procedure to tighten counterweight bolts:
.0248 in.)
a. Before assembly, put Fel-Pro C100
(3) Plugs. Lubricant (if not available, use 2P2506
Thread Lubricant) on the bolt threads,
Earlier: shank, and underside of bolt head.
Torque for 1/4 pipe thread b. Tighten the bolts evenly to ......... 50 ±5
plugs ....... 25 N•m (20 lb. ft.) min N•m (37 ± 4 lb. ft.)
"Stake" (make a mark with a punch) the c. Tighten each bolt more ......... 120 ± 5°
crankshaft to hold the pipe plugs tight.
NOTICE
Later:
Each counterweight has a number and must be
installed in the same position as the correct number
Torque for straight thread
on the crankshaft mounting pad to prevent damage
plugs ....... 50 ± 7 N•m (37 ± 5 lb. ft.)
to the crankshaft when the engine is run.
(4) Make reference to Connecting Rod Bearing
Journals.
39
CRANKSHAFT WEAR SLEEVES

AND SEALS
(1) Adapter.
NOTE: For complete procedure with illustrations, make
(2) Crankshaft seals: reference to Disassembly and Assembly section of this
Service Manual.
Crankshaft seals must be installed with the lip of
the seal toward the inside of the engine as b. Install sleeve and seal assembly into
shown. Make sure the correct seal is installed adapter (1) with correct tools.
on each end of the crankshaft. For SAE
Standard Rotation engines use 1W6974 Seal c. Clean the outer surface of the crankshaft
Group on the front and 1W6977 Seal Group on and the inner surface of wear sleeve (4)
the rear. For SAE Opposite Rotation engines with 6V1541 Quick Cure Primer.
use 1W6977 Seal Group on the front and
1W6974 Seal Group on the rear. d. Carefully put a thin coat of 9S3265
Retaining Compound on the inner surface
(3) Put clean engine oil on the O-ring seals at of wear sleeve (4) and on crankshaft
assembly. surface.
(4) Wear sleeve. e. Install adapter (1), seal (2) and wear sleeve
(4) as a unit on the end of the crankshaft
Removal: with the correct tools.
a. Remove the seal adapters from each end of Tools Needed

the engine and remove the seals from the
adapters. 6V4002 Forcing Bracket (2)
6V4001 Forcing Ring (1)
NOTE: Seals and wear sleeves can not be used again, 1B4330 Nut (5/16"-18 NC) (4)
after the seals and wear sleeves are separated.
6V4003 Locator (1)
b. Remove wear sleeves with 5P7409 2N5006 Bolt (1"-14 NF x (2)
Distorter and 6V3143 Distorter Adapter. 2 5 in. long)
Guide Bolts (5/16"- (2)
Installation: 18 NC x 4 in. long)
6V4977 Installer (1)
a. Do not separate wear sleeves (4) from 9S8858 Nut (1)
crankshaft seals (2). Once they are
separated, they can not be used again.
40
FRONT BALANCER GROUP
(1) Balancer gear.

(2) Diameter of shaft
(new) ..................................74 900 + 0 015 mm (2 9488 + .0006 in )
Bore in bearing (after
assembly)...........................75 000 + 0.053 mm (2 9528 + .0021 in )
Bearing joint must be in center of heavy section in gear at
assembly.
(3) Balancer gear marks must be in alignment with crankshaft gear marks as shown for SAE
standard rotation engines
(4) Balancer gear marks must be in alignment with crankshaft gear marks as shown for SAE
opposite rotation engines
(5) Crankshaft gear.

41
LOWER FRONT GEAR GROUP
(1) Drive gear for water and oil pumps.

(2) Idler gear.
(4) Bore in bearing (after
assembly) ..........................90.000 + 0.065 mm (3.5430 + .0026 in.)
Diameter of shaft
(new) .................................89.880 + 0.020 mm (3.5386 + .0008 in.)
(5) Bore in bearings (after
assembly) ..........................75.000 + 0.055 mm (2.9528 + .0022 in.)
Diameter of shaft
(new) .................................74.900 + 0.015 mm (2.9488 _ .0006 in.)
(6) Thickness of thrust
washer (new) .....................8.50 _ 0.05 mm (.335 _ .002 in.)
Width of groove in
shaft (new) ........................8.750 + 0.025 mm (.3445 + .0010 in.)
End play for
shaft ..................................0.175 to 0.325 mm (.0069 to .0128 in.)
42
LOWER FRONT GEAR GROUP

(2) Idler gear.
assembly) ..........................106.000 _ 0.065 mm (4.1732 _ .0026 in.)
Diameter of shaft
(new) .................................105.880 ± 0.020 mm (4.1685 + .0008 in.)
assembly) ..........................75.000 _ 0.055 mm (2.9528 _ .0022 in.)
Diameter of shaft
(new) .................................74.900 + 0.015 mm (2.9488 + .0006 in.)
(6) Thickness of thrust
washer (new) .....................8.50 + 0.05 mm (.335 _ .002 in.)
Width of groove in
shaft (new) ........................8.750 _ 0.025 mm (.3445 + .0010 in.)
End play for
shaft ..................................0.175 to 0.325 mm (.0069 to .0128 in.)

43
UPPER FRONT GEAR GROUP

(7N4871)
(1) Bore in the bearings (after

assembly) ..................................75.000 + 0.055
mm (2.9528 _ .0022 in.)
Diameter of
shaft ...........................................74.900 _ 0.015
mm (2.9488 + .0006 in.)
(2) Drive gear on shaft for governor drive.
(new) ..........................................8.50 ± 0.05 mm
(.335 _ .002 in.)
Width of groove in shaft
(new) ..........................................8.750 _ 0.025
mm (.3445 + .0010 in.)
End play for the
shaft ...........................................0.175 to 0.325
mm (.0069 to .0128 in.)
(4) Gear fastened to water and oil pump drive.
44
2REAR GEAR GROUP
(1) Camshaft drive gears. e. Hit the face of plate (2) or drive gear (6),
(2) Plate. then tighten the bolts to a torque
(3) Camshaft idler gears of 100 + 15 N-m (75 + 11 lb. ft.)
(4) Diameter of shafts f. Again hit the face of plate (2) or drive gear
(new) 74.900 + 0 015 mm (2.9488 + .0006 in.) (6) and again tighten the bolts to a
+
Bore in bearings (after torque of ............................ 100 15 N-m
+
assembly) ..................................75.000+0.055 (75 11 lb. ft.)
mm (2.9528 + .0022 in.) NOTE: If necessary, repeat Step 7f until the bolts hold
(5) Cluster idler gear (balancer gear). torque (can not be moved) to make sure the drive gears
(6) Gear for hydramechanical protective system are in full contact with the taper on the camshafts.
drive.
(7) Bolts. tighten the bolts as follows: (8) Diameter of shaft
a. Put camshaft drive gears (1) in position on (new) 74.900 + 0 015 mm (2.9488 + .0006
the camshafts. in.)
b. Use hand pressure to turn and hold Bore in bearing (after
camshaft drive gears assembly) .................................. 75.000 + 0 053
(1) in their normal direction of rotation. mm (2.9528 + .0021 in.)
This removes all gear clearance Bearing joint must be in center of heavy section
(backlash) between camshaft drive in gear at assembly.
gears (1) and camshaft idler gears (3). (9) Balancer gear marks must be in alignment with
c. Install plate (2) (on left side of engine) crankshaft gear marks as shown for SAE
and/or drive gear (6) (on right side of standard rotation engines
engine) to hold camshaft drive gears (1) to (10) Crankshaft gear.
each camshaft. (11) Balancer gear marks must be in alignment with
d. Tighten bolts (7) in steps to a torque crankshaft gear marks as shown for SAE
of 100 + 15 N-m (75 + 11 lb. ft.) opposite rotation engines
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST45

45
REAR GEAR GROUP
(1) Camshaft drive gears. d. Tighten bolts (7) in steps to a torque of

(2) Plate. of 100 ±15 N-m (75 + 11 lb. ft.)
(3) Camshaft idler gears. e. Hit the face of plate (2) or drive gear (6),
(4) Diameter of shafts then tighten the bolts to a torque
(new) 74.900 + 0.015 mm (2.9488 + .0006 in ) of 100 f 15 N-m (75 ± 11 lb. ft.)
Bore in bearings (after f. Again hit the face of plate (2) or drive gear
assembly) ..................................75.000 0.055 (6) and again tighten the bolts to a
mm (2.9528 + 0022 in.) torque of ............................ 100 15 N-m
(5) Cluster idler gear. (75 + 11 lb. ft.)
(6) Gear for hydramechanical protective system NOTE: If necessary, repeat Step 7f until the bolts hold
drive. torque (can not be moved) to make sure the drive gears
(7) Bolts. Tighten the bolts as follows: are in full contact with the taper on the camshafts.
a. Put camshaft drive gears (1) in position on
the camshafts. (8) Diameter of shaft
b. Use hand pressure to turn and hold (new) 74.900 + 0.015 mm (2.9488 + 0006
camshaft drive gears (1) in their normal in )
direction of rotation. This removes all gear Bore in bearing (after
clearance (backlash) between camshaft assembly) .................................. 75 000 + 0 053
drive gears (1) and camshaft idler gears mm (2 9528 t .0021 in )
(3). (9) Crankshaft gear.
c. Install plate (2) (on left side of engine)
and/or drive gear (6) (on right side of
engine) to hold camshaft drive gears (1) to
each camshaft.
46
FLYWHEEL
(1N3770 & 7N7732)
Make reference to FLYWHEEL RUNOUT for the correct

method of
flywheel inspection.
(1) Put 2P2506 Thread Lubricant on all the bolt threads that hold the flywheel to the crankshaft and tighten to a
torque of ....................................1150 + 60 N-m
(840 + 44 lb. ft.)
NOTE: When flywheel is installed, put dash mark on flywheel (near pilot bore) in alignment with dash mark on crankshaft

47
FLYWHEEL
(1N3565 & 7N5014)
Make reference to FLYWHEEL RUNOUT for the correct

method of flywheel inspection.
(1) Crankshaft.
(2) Flywheel.
(3) Put 2P2506 Thread Lubricant on all the bolt
threads that hold the flywheel to the crankshaft
and tighten
to a torque of .............................1150 + 60 N-m
(840 + 44 lb. ft.)
NOTE: When flywheel is installed, put dash mark on

flywheel (near pilot bore) in alignment with dash mark on
crankshaft.
FLYWHEEL RUNOUT
Face Runout (axial eccentricity) of the Flywheel:
1 Install the dial indicator as shown Put a force on the flywheel toward the rear
2 Set the dial indicator to read 0 0 mm ( 000 in )
3 Turn the flywheel and read the indicator every 90 Put a force on the flywheel to the rear before each reading
4 The difference between the lower and
higher measurements taken at all four
points must not be more than 0 15 mm (
006 in ) which is the maximum permissible
face runout (axial eccentricity of the
flywheel)
CHECKING FACE RUNOUT OF THE FLYWHEEL

(TYPICAL EXAMPLE)
48
Flywheel Runout (Cont.)
Bore Runout (radial eccentricity) of the Flywheel:
1 Install the dial indicator (3) and make an

adjustment of the universal attachment (4) so
it makes contact as shown.
2. Set the dial indicator to read 0.0 mm (.00 in.)
3. Turn the flywheel and read the indicator every
90°
4. The difference between the lower and higher
measurements taken at all four points must not
be more than 0 15 mm (.006 in ), which is the
maximum permissible bore runout (radial
eccentricity) of the flywheel.
5. Runout (eccentricity) of the bore for the pilot
bearing for the flywheel clutch, must not exceed
0.13 mm ( 005 in )
CHECKING FLYWHEEL BORE
CHECKING FLYWHEEL CLUTCH

PILOT BEARING BORE

49
FLYWHEEL HOUSING
Make reference to FLYWHEEL HOUSING RUNOUT and

FLY-WHEEL HOUSING BORE for the correct methods
of flywheel housing inspection.
(1) Torque for plugs ........................70 + 15 N-m
(50 + 11 lb. ft.)
(2) Tighten the bolts that hold the flywheel housing
to the engine
block evenly See FLYWHEEL HOUSING BOLT
INSTALLA-
TION CHART for correct position
Torque for 1/2"-13 NC
bolts ...........................................100 ++ 14 N-m
(75 + 10 lb ft )
+
bolts ...........................................200 25 N-m
(150 ± 20 lb ft )
50
FLYWHEEL HOUSING
Make reference to FLYWHEEL HOUSING RUNOUT and

FLY-WHEEL HOUSING BORE for the correct methods
of flywheel housing inspection
(1) Torque for plugs ........................70 + 15 N-m

(50 + 11 lb. ft.)
(2) Install three dowels to a
height of .....................................6.0 + 0 5 mm (
24 + .02 In.)
(3) Tighten the bolts that hold the flywheel housing
to the engine
block evenly See FLYWHEEL HOUSING BOLT
INSTALLA-
TION CHART for correct position
bolts ...........................................100 + 14 N-m
(75 + 10 lb ft.)
bolts ...........................................200 + 25 N-m
(150 + 20 lb ft.)

51
FLYWHEEL HOUSING BORE
NOTE: Write the dial indicator measurements with

their positive (+ and negative (-) notation (signs).
This notation is necessary for making the
calculations in the chart correctly.
1. Fasten the dial indicator to the flywheel so the

anvil of the indi cator will touch the flywheel
housing bore With the dial indi cator In position
at (C), adjust the dial Indicator to "O" (zero)
Push the crankshaft up against the top bearing.
Write the, measurement for bearing clearance
on line 1 In column (C)
2. Divide the measurement from Step 1 by 2. Write
this number on line 1 in columns (B) & (D).
3. Turn the crankshaft to put the dial Indicator at
(A) Adjust the, dial indicator to "O" (zero).
4. Turn the crankshaft counterclockwise to put the
dial Indicator at (B) Write the measurement in
the chart.
dial Indicator at (C) Write the measurement In
the chart.
6 Turn the crankshaft counterclockwise to put the
dial indicator at (D). Write the measurement
in the chart.
7 Add fines I and II by columns.
8 Subtract the smaller number from the larger
number in line II In columns (B) & (D) The
result is the horizontal "eccentricity (out of
round). Line Ill, column (C) is the vertical
eccentricity
CHART FOR DIAL INDICATOR MEASUREMENTS
Position of
dial indicator
Line
No. A B C D
Correction for bearing clearance I 0

Dial Indicator Reading II 0
Total of Line 1 & 2 III 0 ** * **
* Total Vertical eccentricity (out of round).
** Subtract the smaller No. from the larger No. The
difference is
the total horizontal eccentricity.
A10234X1
9 On the graph for total eccentricity find the point
of intersection of the lines for vertical eccentricity and
horizontal eccentricity
10 If the point of intersection Is In the range marked
"Acceptable" the bore is In alignment If the point of
intersection is In the range marked "Not Acceptable" the
flywheel housing must be changed.
52
FLYWHEEL HOUSING RUNOUT
Face Runout (axial eccentricity) of the Flywheel

Housing:
1. Fasten a dial indicator to the crankshaft flange 8S2328 DIAL INDICATOR GROUP INSTALLED
so the anvil of the Indicator will touch the face (TYPICAL EXAMPLE)
of the flywheel housing.
2. Put a force on the crankshaft toward the rear
before reading the indicator at each point
3 With dial indicator set at 0 0 mm (.000 in.) at
location (A), turn the crankshaft and read the
indicator at locations (B), (C) and (D)
4. The difference between lower and higher
be more than 0.30 mm (.012 in.), which is the
maximum permissible face runout (axial
eccentricity) of the flywheel housing.

53
ALTERNATORS AND REGULATORS Deleted
54
Alternators and Regulators (Cont.) Deleted

55
ELECTRIC STARTER MOTORS Deleted
56
STARTER SOLENOIDS Deleted

57/(58 Blank)
AIR STARTER MOTORS Deleted
PRESSURE REGULATING VALVE

FOR AIR STARTER MOTOR Deleted
59/(60 Blank)
FORM NO. SENR2352-01
FOR USE IN SERVICE MANUAL’

SENR2573
SYSTEMS OPERATION
TESTING AND ADJUSTING
3500 INDUSTRIAL ENGINES
49Y1-UP 65Z1-UP
95Y1-UP 68Z1-UP
27Z1-UP 71Z1-UP
61/(62 Blank)
3500 ENGINE SYSTEMS OPERATION
ENGINE DESIGN

63
3500 ENGINE SYSTEMS OPERATION
ENGINE DESIGN
ENGINE
SPECIFICATIONS
3508 3512 3516
NUMBER AND ARRANGEMENT 60° V-8 60° V-12 60° V-16

OF CYLINDERS
VALVES PER CYLINDER 4 4 4
DISPLACEMENT 34.5 LITER 51.8 LITER 69.1 LITER
(2105 cu. in.) (3158 cu. in.) (4210 cu. in.)
BORE 170mm (6.7 in.)
STROKE 190mm (7.5 in.)
COMPRESSION RATIO 13:1
TYPE OF COMBUSTION Direct Injection
VALVE Intake 0.38mm (.015 in.)
SETTING Exhaust 0.76mm (.030 in.)
FIRING ORDER (INJECTION SEQUENCE)

ENGINE SAE STANDARD ROTATION* SAE OPPOSITE ROTATION*
3508 1-2-7-3-4-5-6-8 1-8-7-2-6-5-4-3
3512 1-12-9-4-5-8-11-2-3-10-7-6 1-4-9-8-5-2-11-10-3-6-7-12
3516 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8 1-6-5-4-3-10-9-16-15-12-11-14-13-8-7-2
* Direction of Rotation (as viewed from flywheel end):

SAE Standard Rotation----------Counterclockwise
SAE Opposite Rotation--------Clockwise
NOTE: Front end of engine is opposite the flywheel end. Left side
and right side of engine are as seen from flywheel end,
No. 1 cylinder is the front cylinder on the right side. 64No.
2 cylinder is the front cylinder on the left side.
64
FUEL SYSTEM SYSTEMS OPERATION
FUEL SYSTEM
GENERAL
FUEL FLOW SCHEMATIC

(3512 Illustrated)
1. Fuel manifolds. 2. Fuel priming pump. 3. Fuel filter housing. 4. Fuel injectors. 5. Pressure regulating valve.
6. Fuel return to supply. 7. Fuel transfer pump. 8. Fuel from supply.
Fuel transfer pump (7) is located on the right The transfer pump pushes fuel through fuel filter
side of the engine. The lower shaft of engine oil pump housing (3) to fuel manifolds ( ). The fuel manifolds have
(12) drives the gear type transfer pump. Fuel from the two sections. The fuel flows through the top section of
supply tank is pulled through a primary fuel filter by the the manifold to inlet fuel line ( 14) connect-
transfer pump and sent to the fuel filter housing.
The transfer pump has a check valve and a

bypass valve. The check valve is located in the pump
head assembly located behind where line (9) is
connected. The check valve prevents fuel flow back
through the transfer pump when priming pump (2) is
used. The bypass valve is located behind a cap (plug) in
the drive end of the pump. The bypass valve limits the
maximum pressure of the fuel. It will open the outlet side
of the pump to the pump inlet if the fuel pressure goes
up to 860 kPa (125 psi). This helps prevent damage to
fuel system components caused by too much pressure. RIGHT SIDE OF ENGINE
7. Fuel transfer pump. 9. Fuel line to filter housing.
10. Fuel line to priming pump. 11. Elbow (fuel
supply).
12. Engine oil pump.
65
FUEL FLOW THRU INJECTOR
4. Injector. 13. Outlet fuel line. 14. Inlet fuel line.

15. Drilled passage. 16. Cylinder head. 17. Cylinder.
Check each engine installation for an excess fuel

flow based on fuel consumed (used for combustion).
Minimum flow is three times the amount of fuel
consumed. Excess fuel is then returned to the fuel tank,
not back to the pump inlet. This will make sure that any
air in the system will be removed before the fuel is sent
RIGHT SIDE OF ENGINE back to the injectors.
1. Fuel manifold (right hand). 2. Priming pump. 3.
Pressure regulating valve (2) has a spring and
Fuel filter housing. 5. Pressure regulating valve. 9.
plunger arrangement between the bottom section of the
Fuel line to filter housing (from transfer pump). 10.
fuel manifolds and the line that returns fuel to the tank.
Fuel line to priming pump (from transfer pump).
This valve keeps the pressure of the fuel at 415 to 450
kPa (60 to 65 psi) in the cylinder heads and fuel
ed to the right side of each cylinder head. On earlier manifolds. The valve also has resistance to fuel flow but
engines, filter screens are located in the fittings where little resistance to air. This helps remove (bleed) air
fuel goes into each cylinder head. On later engines, the from the fuel injection system when the engine is in
filter screens are located in the ports of the unit injector. operation. The air is returned to the fuel tank and vented
A drilled passage (15) in cylinder head (16) takes fuel to to the atmosphere.
a circular (shape of a circle) chamber around the
injector. The chamber is made by O-rings on the outside A small orifice connects the inlet and outlet
diameter of injector (4) and the injector bore in the passages in the adapter (housing) of pressure regulating
cylinder head. valve (2). The orifice is used as a syphon break when
the fuel filters are changed. This keeps the fuel lines and
manifolds from being drained and the use of fuel priming
pump (4) is not normally needed. The fuel priming pump
must be used when the lines are dry. For example: after
an overhaul or other major fuel system work.
CYLINDER HEADS
3. Fuel injector. 13. Outlet fuel line. 14. Inlet fuel

line.
Only part of the fuel in the chamber is used for injection.

Approximately 4½/2 times as much fuel as needed for
normal combustion flows through the chamber to a
drilled passage in the left side of the cylinder head. This
passage is connected by outlet fuel line (13) to the
bottom section of the fuel manifold. This constant flow of
fuel around the injectors helps to cool them.
The fuel flows back through the bottom section

of each fuel manifold to pressure regulating valve (2), on
the front of the right fuel manifold. The fuel flows
through this valve and then back to the tank.
66
FUEL INJECTION CONTROL LINKAGE
FUEL INJECTOR CONTROL LINKAGE

1. Injector. 2. Control shaft (left side). 3. Bellcrank. 4. Control rod. 5. Rack. 6. Lever. 7. Governor shaft. 8.
Control shaft (right side}. 9. Cross shaft.
A fuel injector ( 1 ) is located in each cylinder When the rotation of governor shaft (7) is clock-
head. The position of rack (5) controls the amount of fuel wise, as seen from in front of the engine, the action of
injected into-the cylinder. Pull the rack out of the injector the governor linkage moves control shaft (8) coun-
for more fuel, push it in for less fuel. terclockwise. That is, in the fuel "ON" direction.
Rack position is changed by bellcrank (3). The Right control shaft (8) and left control shaft (2)
bellcrank is moved by control rod (4). The control rods are connected by cross shaft (9). The linkage between
have an adjustment screw on the top. The adjustment the injectors on the left side of the engine and control
screw is used to synchronize the injectors. The control shaft (2) is similar to the linkage on the right side.
rods are spring loaded. If the rack of one injector sticks
(will not move), it will still be possible for the governor to Should the linkage become disconnected from
control the other racks so the engine can be shutdown. the governor, the weight of the control linkage will move
Each control rod on the right side of the engine is the fuel injector racks to the fuel "SHUTOFF" position,
connected by a lever (6) to control shaft (8). and the engine will stop.
67
Fuel then goes through the center passage of

plunger (6) and the lower port during the remainder of
the downstroke. This sudden release of pressure as the
lower port is opened causes the fuel to hit the spill
deflector with a high force. The spill deflector gives
protection to the injector housing (nut) from erosion
(wear) because of the force of the released fuel. On the
return (UP) stroke, the chamber inside the injector barrel
is filled with fuel again.
The plunger can be turned by rack (5) at the

same time it is moved up and down by rocker arm (2).
The upper section of the plunger has a flat side that fits
in the gear, which is engaged with the rack. The plunger
slides up and down in the gear, which also has a flat side
CYLINDER HEAD on its inside diameter. The flat sides let the parts turn
(Rocker Shaft Removed for Photo Illustration) together. The rack is engaged with the gear.
1. Injector. 3. Bellcrank. 5. Rack.
When the rack moves, it turns the plunger
through the gear. The rotation of plunger (6) controls
FUEL INJECTOR
injection timing and the fuel output of the injector.
Rotation of the plunger changes the relation of the
The injector is held in position by clamp (3).
plunger scrolls to the ports in the barrel, and this
Fuel is injected when rocker arm (2) pushes the top of
increases or decreases the length of the effective stroke
the injector down. The movement of the rocker arm is
and the point at which injection takes place.
controlled by the camshaft through lifter assembly (7)
and push rod (4). The amount of fuel injected is
When rack (5) is moved all the way in against
controlled by rack (5). Movement of the rack causes
the injector body, no injection takes place during the
rotation of a gear fastened to plunger (6). Rotation of the
downstroke of the plunger. This is the fuel "SHUT-OFF"
plunger changes the effective stroke (that part of the
position. A small amount of rack movement "OUT" from
stroke during which fuel is actually injected) of the
the injection body is used as a "NO FUEL" movement or
plunger.
"SHUTOFF" position for governing purposes. This "NO
FUEL" distance starts at the "ALL-THE-WAY-IN" position
Injection timing is a product of two factors; the
of the rack, and ends when the lower scroll opens the
angular location of camshaft (8) and the location of
lower port and the upper scroll closes the upper port.
plunger (6). The angular location of the camshaft is
Movement of the rack "OUT" from this point in the fuel
controlled by the camshaft drive gears at the rear of the
"ON" direction, gives an interval in the plunger stroke
engine. The location of the plunger can be adjusted with
when both ports are closed by the plunger and injection
screw (1).
takes place. As the rack is moved farther "OUT" in the
fuel "ON" direction, the quantity of fuel during the
Injection Cycle injection stroke increases until a maximum is available at
full rack movement.
When the plunger is at the top of its stroke, fuel
flows from the fuel supply chamber, around the injector The scrolls on plunger (6) are used to time the
and through both the lower and upper ports of the barrel. start of injection and set the amount of fuel per injection
As plunger (6) is moved down by rocker arm (2), fuel is stroke. The scrolls can change the start of injection in
pushed back into the supply chamber through the lower relation to the engine piston position and the length of
port. The fuel can now go up through a passage in the the effective stroke in relation to the different engine
center of the plunger and out through the upper port of loads. The start of injection can be retarded (made later)
the barrel. As the lower port is closed by the end of with a decrease or increase in injector output according
plunger (6), fuel can still flow through the upper port until to the engine needs.
it is closed by the upper scroll on plunger (6). At this
point, injection starts and the effective stroke begins. During the fuel injection stroke, fuel passes from
During the effective stroke, fuel is injected into the the barrel chamber through a valve assembly. The valve
cylinder until the downward movement of plunger (6) assembly has a spring-loaded needle valve with a cone
causes the lower scroll to open the lower port and shaped end which operates against a seat. The angle of
release the fuel pressure. the valve is slightly larger than that of the
68
FUEL INJECTOR OPERATION

1. Screw. 2. Rocker arm. 3. Clamp. 4. Control rod. 5. Rack. 6. Plunger. 7. Litter assembly. 8. Camshaft.
seat to give line contact. The valve opens at A flat check valve is used above the needle
approximately 20 000 to 23 300 kPa (2800 to 3400 psi) valve to keep the high pressure combustion gases out of
and closes at approximately 10 300 kPa ( 1500 psi). The the injector. If the needle valve is held open by small
fuel flows from the chamber inside the barrel through foreign particles for a moment between injection cycles,
drilled passages and grooves in the spring cage, and combustion gases can come into the injector and cause
then through passages around the guide section of the damage. The injector operates with the flat check valve
valve to the valve chamber. Here the fuel pressure lifts until the foreign particle has washed on through and
the needle valve off its seat, and the fuel now flows normal operation takes place.
through the spray tip and out the orifices into the
combustion chamber.
69
The spray tip of the injector extends a short

distance below the cylinder head into the combustion
chamber. The spray tip has several small orifices
spaced evenly around the outside diameter. The tip
sprays fuel into the combustion chamber. The top
surface of the piston has a shaped (mexican hat-type)
crater. The design of the piston causes rotation of the air
as it comes through the valves into the combustion
chamber, which improves the mixture of the fuel and air.
70
WOODWARD UG8 LEVER GOIVERNORS
SCHEMATIC OF UG8 LEVER GOVERNOR

The Woodward UG8L is the standard governor An accumulator is used to keep a constant oil
used on Industrial Engines. Standard location for the pressure of approximately 830 kPa (120 psi) to the top of
governor is on the right side of the front housing; with an the power piston and to the pilot valve.
attachment gear group it can be located on the left side.
The power piston is connected by a linkage
The UG8 Lever Governor is a mechanical- system to one side of the output terminal shaft. There is
hydraulic governor. A hydraulic activated power piston is oil pressure on both the top and bottom of the power
used to turn the output terminal shaft of the governor. piston. The bottom of the piston has a larger area than
The terminal shaft is connected by linkage to the fuel the top.
control torsion shafts. The rotation of the fuel control
torsion shafts controls rack movement at each fuel Less oil pressure is required on the bottom than
injector. Make reference to FUEL INJECTOR on the top to keep the piston stationary. When the oil
CONTROL LINKAGE. The governor oil pump and pressure is the same on the top and bottom of the
ballhead are driven by a bevel gear set in the governor piston, the piston will move up and cause the output
drive housing. The bevel gear set is driven by the front terminal shaft to turn in the increase fuel direction. When
gear group. oil pressure on the bottom of the piston is directed to the
sump (drain), the piston will move down and cause the
The oil pump gives pressure oil to operate the output terminal shaft to turn in the decrease fuel
power piston. The drive gear of the oil pump has a direction. Oil to or from the bottom of the power piston is
bushing in which the pilot valve plunger moves up and controlled by the pilot valve.
down. The driven gear of the oil pump is also the drive
for the ballhead. The pilot valve has a plunger and bushing. The bushing
is turned by the governor drive shaft. The rotation of the
bushing helps reduce friction between
71
the bushing and plunger. The pilot valve plunger has a When the engine is in operation at a steady
land that controls the oil flow through the ports in the speed the land on the pilot control valve is in the center
bushing. When the pilot valve plunger is moved down, of the control port of the bushing. A decrease in load will
high pressure oil goes to the bottom of the power piston cause an increase in engine speed. With an increase
and the power piston will move up. When the pilot valve in engine speed the flyweights move out and raise the
plunger is moved up, the oil on the bottom of the power speeder rod and floating lever. This raises the pilot valve
piston is released to the sump and the power piston plunger and releases oil from the bottom of the power
moves down. When the pilot valve plunger is in the piston. As the power piston moves down, the output
center (balance) position, the oil port to the bottom of the terminal shaft moves in the decrease fuel direction.
power piston is closed and the power piston will not When the output terminal shaft moves, the actuating
move. The pilot valve plunger is moved by the ballhead compensation piston moves up and causes a suction on
assembly. the oil under the receiving piston which moves down.
The floating lever is pulled down by the receiving piston
The ballhead assembly has a ballhead, flyweights, and the lever moves the pilot control valve down to close
speeder spring, thrust bearing, speeder plug and the control port. The output terminal shaft and power
speeder rod. The ballhead assembly is driven by a gear piston movement is stopped. As the engine speed
and shaft from the driven gear of the oil pump. The returns to normal, the flyweights move in and the
speeder rod is fastened to the thrust bearing which is in speeder rod moves down. When the oil pressure in the
contact with the flyweights. The speeder rod is compensation system and the sump oil become the
connected to the pilot valve plunger by a lever. The same through the needle valve, the receiving
speeder spring is held in position on the thrust compensation piston moves up at the same rate as the
bearing by the speeder plug. speeder rod moves down. This action keeps the pilot
valve plunger in position to close the port.
As the ballhead turns, the flyweights move out
due to centrifugal force. This will make the flyweight toes An increase in load will cause a decrease in engine
move up and cause compression of the speeder spring. speed. When engine speed decreases, the flyweights
When the force of the speeder spring and the force of move in and lower the speeder rod and floating lever.
the flyweights are equal the engine speed is constant. This lowers the pilot valve plunger and lets pressure oil
The speeder plug can be moved up or down manually to go under the power piston. The power piston moves up
change the compression of the speeder spring which will and turns the output terminal shaft in the increase fuel
change the speed of the engine. direction. When the output terminal shaft moves, the
actuating compensation piston moves down and causes
The compensation system gives stability to a pressure on the receiving piston which moves up. The
engine speed changes. The compensation system has a floating lever is pushed up by the receiving piston and
needle valve and two pistons-an actuating piston and a the lever moves the pilot valve plunger up to close the
receiving piston. The actuating piston is also con-nected control port. The output terminal shaft and power piston
to the output terminal shaft by the compensation movement is stopped.
adjusting lever and linkage system. A fulcrum that is
adjustable is on the lever. When the position of the A change to the speed setting of the governor will give
fulcrum is changed, the amount of movement possible of the same governor movements as an increase or
the actuating piston is changed. decrease in load.
The receiving piston is connected to the pilot A lever on the speed adjustment shaft is used to change
valve plunger and the speeder rod by a lever. the engine speed. The speed adjustment shaft moves
the speeder plug up and down to change the force of the
The needle valve makes a restriction to oil flow speeder spring.
between the oil sump and the two pistons.
This governor is also equipped with speed droop,
When the actuating piston moves down, the however, it must be adjusted inside the governor.
piston puts a force on the oil under the receiving piston
and moves it up. When the receiving piston moves up it
raises the pilot valve plunger to stop the flow of oil to the
bottom of the power piston.
72
Governor accumulator oil pressure is changed to

a restricted variable (pulsating) oil flow as small holes
(ports) in the pilot valve bushing move past a passage in
the controlet housing. In a constant speed operation,
the ball valve is not tight against its seat and lets oil flow
back to the sump. The ball valve is held in position by
the sensing bellows, which is connected to inlet manifold
air pressure. The force used to hold the ball valve is
proportional to the inlet manifold air pressure.
As inlet manifold air pressure increases, the ball

valve makes contact with its seat and oil pressure
increases to move the limiter piston to the right against
the force of the restoring spring. This movement
increases the tension on the restoring spring until the
spring force is in balance with the sensing bellows force.
The oil pressure now can push the ball valve off its seat
and let a small amount of oil flow to the sump. This
reduces the pressure behind the limiter piston and the
UG8 LEVER GOVERNOR piston stops movement. The piston position is
1. Air-Fuel ratio control. 2. Governor. 3. Governor proportional to inlet manifold air pressure.
drive.
AIR FUEL RATIO CONTROL The cam fastened to the limiter piston operates
through linkage to limit the travel of the governor terminal
The air fuel ratio control is installed on top of the basic shaft. The governor terminal shaft limits the fuel to the
UG8L Governor. The unit is made up of an inlet engine through the fuel control linkage. The terminal
manifold pressure sensor, a hydraulic circuit and shaft can turn in the increase fuel direction until the pivot
mechanical linkage that connects the unit to the lever lifts the pilot valve above center. Oil pressure on
governor. Pressure oil from the governor hydraulic the bottom of the power piston is now directed to the
system is used to operate the unit. sump. The power piston moves down and causes the
terminal shaft to turn in the decrease fuel direction.
When engine speed or load is increased rapidly, it is
possible for a standard (unlimited) governor to supply When the engine is stopped, the limiter piston is
more fuel than can be burned with the amount of held to the left by the restoring spring. The fuel limit
available air. Too much smoke and poor acceleration valve at this position is set high enough by the cam to
are the result. The fuel ratio control works to limit the give enough fuel for start up. At cranking speed, oil
movement of the governor terminal shaft in the increase pressure behind the limiter piston goes by the diaphram
fuel direction as a direct result of inlet manifold pressure. to the sump. After the engine has started, engine
Thus, fuel which can be burned is limited to the air lubrication oil pressure pushes the diaphram against its
available for combustion as the engine speed is seat and closes the governor oil drain. Oil pressure now
increased. This gives more complete combustion and increases behind the limiter piston. The limiter piston
keeps smoke to a minimum while acceleration is moves out until the roller follower is on the operating
improved. slope of the cam. At this point the ball valve is moved off
its seat, the oil can now flow to sump and the piston
The air fuel ratio is also used for protection to limit the movement is stopped.
fuel as the result of any large, sudden restriction of air
supply to the engine.
73
SCHEMATIC OF AIR FUEL RATIO CONTROL SYSTEM

74
AIR INLET AND EXHAUST SYSTEM
The components of the air inlet and exhaust The intake valves close and the piston starts to move up
system control the quality and amount of air available on the compression stroke. When the piston is near the
for combustion. There is a separate turbocharger and top of the compression stroke, fuel is injected into the
exhaust manifold on each side of the engine. A common cylinder. The fuel mixes with the air and combustion
aftercooler is located between the cylinder heads in the starts. The force of combustion pushes the piston down
center of the engine. The inlet manifold is a series of on the power stroke. When the piston moves up again it
elbows that connect the aftercooler chamber to the inlet is on the exhaust stroke. The exhaust valves open and
ports (passages) of the cylinder heads. Two camshafts, the exhaust gases are pushed through the exhaust port
one in each side of the block, control the movement of into exhaust manifold (I). After the piston makes the
the valve system components. exhaust stroke, the exhaust valves close and the cycle
(inlet, compression, power, exhaust) starts again.
Exhaust gases from the exhaust manifold go into the

turbine side of the turbocharger (8) and cause turbine
wheel (6) to turn. The turbine wheel is connected to the
shaft that drives compressor wheel (5). The exhaust
gases then go out the exhaust outlet (7) through exhaust
elbow (9).

1. Exhaust manifold. 2. Aftercooler. 3. Engine
cylinder. 4. Air inlet. 5. Turbocharger compressor
wheel. 6. Turbocharger turbine wheel. 7. Exhaust
outlet.
Air flow is the same on both sides of the engine. AIR SYSTEM COMPONENTS
Clean inlet air from the air cleaners is pulled through air (3512 Engine Shown)
inlet (4) by compressor wheel (5). The rotation of the 1. Exhaust manifolds. 2. Aftercooler. 8.
compressor wheel causes compression of the air and Turbochargers. 9. Exhaust elbow. 10. Cylinder
forces it through a tube to aftercooler (2). The head.
aftercooler lowers the temperature of the compressed
air before it goes into the inlet chambers in each cylinder
head. This cooled, compressed air fills the inlet
chambers in the cylinder heads. Air flow from the inlet
chamber into the cylinder is controlled by the intake
valves.
There are two intake and two exhaust valves for

each cylinder. Make reference to Valve System
Components. The intake valves open when the piston
moves down on the inlet stroke. Cooled, compressed air
from the inlet chamber is pulled into the cylinder.
75
AIR FLOW SCHEMATIC

1. Exhaust manifold. 2. Aftercooler. 3. Cylinder. 8. Turbocharger.
76
AIR INLET AND EXHAUST SYSTEM SYSTEMS OPERATION
AFTERCOOLER
The aftercooler is located at the center of the

vee, and has a coolant charged core assembly. The
3516 can have two core assemblies. Coolant from water
pump (3) flows through pipe (2) into the aftercooler. It
then flows through the core assembly (assemblies) and
back out of the aftercooler through a different pipe into
the rear of the cylinder block.
There is a connector (tube) that connects the

bottom rear of each core assembly to the cylinder block.
This is used to drain the core assembly (assemblies)
when the coolant is drained from the engine.
Inlet air from the compressor side of the turbo-

chargers flows into the aftercooler through pipes. This
air then passes through the fins of the core assembly
(assemblies) which lowers the temperature. The cooler
air goes out the bottom of the after-cooler into the air
chamber, and then up through the elbows to the inlet RIGHT FRONT OF ENGINE
ports (passages) in the cylinder heads. 2. Pipe. 3. Water pump.
AFTERCOOLER AIR CHAMBER DRAIN

4. Drain plug.
One drain plug is located between the No. 1 and

No. 3 cylinder heads, and another plug is located
between the last two cylinder heads on the left side of the
TOP OF ENGINE engine. These plugs can be removed to check for water
1. Aftercooler housing. or coolant in the aftercooler air chamber.
77
TURBOCHARGERS (3512 Shown)

4. Compressor wheel. 5. Bearing. 6. Oil Inlet. 7.
There are two turbochargers, on the rear of the Bearing. 8. Turbine housing. 9. Turbine wheel. 10. Air
engine. The turbine side of the turbochargers is fastened in-let. 11. Oil outlet.
to the exhaust manifolds. The compressor side of the
turbocharger is connected to the aftercooler. Clean air from the air cleaners is pulled through
the compressor housing air inlet (10) by rotation of
compressor wheel (4). The action of the compressor
wheel blades causes a compression of the inlet air. This
compression gives the engine more power because it
makes it possible for the engine to burn additional fuel
with greater efficiency.
Maximum rpm of the turbocharger is controlled

by the fuel setting, the high idle rpm setting and the
height above sea level at which the engine is operated.
NOTICE
If the high idle rpm or the fuel setting is higher than

given in the Fuel Setting And Related Information
TURBOCHARGERS Fiche (for the height above sea level at which the
1. Turbocharger. 2. Oil drain line. 3. Oil supply line. engine is operated), there can be damage to engine
or turbocharger parts. Damage will result when
The exhaust gases go into turbine housing (8) increased heat and/or friction due to the higher
and push the blades of turbine wheel (9). This causes engine output goes beyond the engine cooling and
the turbine wheel and compressor wheel to turn at up to lubrication systems abilities. A mechanic that has
70,000 rpm. the proper training is the only one to make the
adjustment of fuel setting and high idle rpm setting.
The bearings (5 and 7) in the turbocharger use

engine oil under pressure for lubrication. The oil comes
in through oil inlet port (6) and goes through passages in
the center section for lubrication of the bearings. Then
the oil goes out oil outlet port (11) and back to the oil pan.
VALVE SYSTEM COMPONENTS
The valve system components control the flow of

inlet air and exhaust gases into and out of the cylinders
during engine operation.
The crankshaft gear drives the camshaft gears

through idlers. Both camshafts must be timed to the
crankshaft to get the correct relation between piston and
valve movement.
TURBOCHARGER
78
VALVE SYSTEM COMPONENTS

1. Rocker arm. 2. Bridge. 3. Rotocoil. 4. Valve
spring. 5. Push rod. 6. Lifter.
The camshafts have three cam lobes for each

cylinder. Two lobes operate the valves and one operates
the fuel injector.
As each camshaft turns the lobes on the

camshaft cause lifters (6) to go up and down. This
movement makes push rods (5) move the rocker arms
(1). Movement of the rocker arms makes the bridges (2)
move up and down on dowels in the cylinder head. The
bridges let one rocker arm open and close two valves
(intake or exhaust). There are two intake and two
exhaust valves for each cylinder.
Rotocoils (3) cause the valves to turn while the

engine is running. The rotation of the valves keeps the
deposit of carbon on the valves to a minimum and gives
the valves longer service life.
Valve springs (4) cause the valves to close when

the lifters move down.
79
LUBRICATION SYSTEM SYSTEMS OPERATION
LUBRICATION SYSTEM
B39100-1X1
LUBRICATION SYSTEM SCHEMATIC

1. Main oil gallery. 2. Left camshaft oil gallery. 3. Piston cooling jet oil gallery. 4. Piston cooling jet oil gallery. 5. Right
camshaft oil gallery. 6. Turbocharger oil supply. 7. Sequence valve. 8. Sequence valve. 9. Elbow. 10. Oil filter bypass
valve. 11. Oil cooler. 12. Oil cooler bypass valve. 13. Oil pump relief valve. 14. Engine oil pump. 15. Elbow. 16.
Suction bell. 17. Oil filter housing.
This system uses an oil pump (14) with three Cartridge type filters are located in oil filter
pump gears that are driven by the front gear train. Oil is housing (17) at the front of the engine. A single bypass
pulled from the pan through suction bell (16) and elbow valve is located in the oil filter housing.
(15) by the oil pump. The suction bell has a screen to
clean the oil. Clean oil from the filters goes into the block
through elbow (9). Part of the oil goes to left camshaft oil
The oil pump pushes oil through oil cooler (11) gallery (2), and the remainder goes to main oil gallery ( ).
and the oil filters to oil galleries (I and 2) in the block.
The fin and tube type oil cooler lowers the temperature of The camshaft oil galleries are connected to each
the oil before the oil is sent on to the filters. camshaft bearing by a drilled hole. The oil goes around
each camshaft journal, through the cylinder head and
Bypass valve (12) lets oil flow directly to the rocker arm housing, to the rocker arm shaft. A drilled
filters if the oil cooler becomes plugged or if the oil hole connects the bores for the valve lifters to the oil hole
becomes thick enough (cold start) to increase the oil for the rocker arm shaft. The valve lifters get lubrication
pressure differential (cooler inlet to outlet) by an amount each time they go to the top of their stroke.
of 180 ± 20 kPa (26 ± 3 psi).
80
LUBRICATION SYSTEM SYSTEMS OPERATION
Main oil gallery (1) is connected to the main turbocharger drain lines (21 and 22) are connected to the
bearings by drilled holes. Drilled holes in the crankshaft flywheel housing on each side of the engine.
connect the main bearing oil supply to the rod bearings.
Oil from the rear of the main oil gallery goes to the rear of Oil is sent to the front and rear gear groups
right camshaft gallery (5). through drilled passages in the front and rear housings
and cylinder block faces. These passages are
Sequence valves (7 and 8) let oil from main oil connected to camshaft oil galleries (2 and 5).
gallery ( 1 ) go to piston cooling jet oil galleries (3 and 4).
The sequence valves open at 140 kPa (20 psi). The After the oil for lubrication has done its work, it
sequence valves will not let oil into the piston cooling jet goes back to the engine oil pan.
oil galleries until there is pressure in the main oil gallery.
This decreases the amount of time necessary for
pressure build-up when the engine is started. It also
helps hold pressure at idle speed.
PISTON COOLING AND LUBRICATION

18. Cooling jet. RIGHT FRONT SIDE OF ENGINE
10. Oil filter bypass valve. 17. Oil filter housing. 19. Oil
There is a piston cooling jet (18) below each line to filter housing.
piston. Each cooling jet has two openings. One opening
is directed at a passage in the bottom of the piston. This
passage takes oil to a manifold behind the ring band of
the piston. A slot (groove) is in the side of both piston pin
bores and connects them with the manifold behind the
ring band. The other opening is directed at the center of
the piston. This helps cool the piston and gives
lubrication to the piston pin.
LEFT FRONT OF ENGINE

9. Elbow. 10. Oil filter bypass valve. 17. Oil filter
TURBOCHARGERS housing. 20. Oil outlet line from oil filter housing. 23.
(3516 Shown) Filter oil supply from oil pump.
6. Oil supply lines. 21. Oil drain for left turbocharger.
22. Oil drain for right turbocharger.
Oil lines (6) send oil to the turbochargers. The
81
COOLING SYSTEM SYSTEMS OPERATION
COOLING SYSTEM
SCHEMATIC OF COOLING SYSTEM

(3516 SHOWN)
1. Water pump. 2. Tube (to aftercooler). 3. Oil cooler. 4. Block. 5. Cylinder head. 6. Water manifold. 7. Aftercooler.
8. Regulator housing. 9. Tube (to radiator or heat exchanger). 10. Bypass tube.
Coolant goes in water pump (I) through an elbow The coolant flows up through the water jackets
that connects to the radiator or heat exchanger. The and around the cylinder liners from the bottom to the top.
coolant flow is divided at the outlet of the water pump. Near the top of the cylinder liners, where the temperature
Part of the coolant flow is sent to the aftercooler, while is the hottest, the water jacket is made smaller. This
most of the coolant is sent through the oil cooler. shelf (smaller area) causes the coolant to flow faster for
better liner cooling. Coolant from the top of the liners
NOTE: There is one opening on the pump outlet so that goes into the cylinder head which sends the coolant
a remote pump can be connected to the system. The around the parts where the temperature is the hottest.
remote pump can be used if there is a failure of the pump Coolant then goes to the top of the cylinder head and out
on the engine. through an elbow, one at each cylinder head, into water
manifolds (6) at each bank of cylinders. Coolant goes
Coolant sent to the aftercooler goes through the through the manifolds to the temperature regulator
aftercooler core, and then is sent through an elbow into a (thermostat) housing.
passage in the block near the center of the vee at the
rear of the block. The coolant sent to the oil cooler goes Regulator housing (8) has an upper and lower
through the oil cooler and flows into the water jacket of flow section, and uses four temperature regulators. The
the block at the right rear cylinder. The cooler coolant sensing bulbs of the four temperature regulators are in
mixes with the hotter coolant and goes to both sides of the coolant in the lower section of the housing. Before
the block through distribution manifolds connected to the the regulators open, cold coolant is sent through the
water jacket of all the cylinders. The main distribution lower section of the housing and through the bypass line
manifold is located just above the main bearing oil back to the inlet of the water pump. As the temperature
gallery. of the coolant increases
82
COOLING SYSTEM SYSTEMS OPERATION
enough to make the regulators start to open, coolant flow

in the bypass line is stopped and coolant is sent through
the outlets to the radiator or heat exchanger.
Total system coolant capacity will depend on the

size of the heat exchanger. Use a coolant mixture of 50
percent pure water and 50 percent permanent antifreeze,
then add a concentration of 3 to 6 percent corrosion
inhibitor.
TOP OF ENGINE
6. Water manifolds. 7. Aftercooler. 11. Exhaust
manifolds.
RIGHT SIDE OF ENGINE

1. Water pump. 3. Oil cooler. 10. Bypass tube.
WATER TEMPERATURE REGULATOR HOUSINGS

6. Water manifolds. 8. Regulator housing. 10. Bypass
tube. 12. Regulator housing. 13. Housing.
FRONT OF ENGINE
1. Water pump. 3. Oil cooler. 10. Bypass tube.
83
BASIC BLOCK SYSTEMS OPERATION
BASIC BLOCK
CYLINDER BLOCK, LINERS AND HEADS Covers (1) allow access to the camshafts, valve
lifters and fuel control shaft.
The cylinders in the left side of the block make
an angle of 600 with the cylinders in the right side of the Covers (2) allow access to the crankshaft
block. The main bearing caps are fastened to the block connecting rods, main bearings and piston cooling jets.
with four bolts per cap. With covers removed, all the openings can be used for
inspection and service.
The cylinder liners can be removed for
replacement. The top surface of the block is the seat for PISTONS, RINGS AND CONNECTING RODS
the cylinder liner flange. Engine coolant flows around the
liners to keep them cool. Three O-ring seals around the The aluminum pistons have an iron band for the
bottom of the liner make a seal between the liner and the top two rings. This helps reduce wear on the
cylinder block. A filler band goes under the liner flange compression ring grooves. A chamber is cast into the
and makes a seal between the top of the liner and the piston just behind the top ring grooves. Oil from the
cylinder block. piston cooling jets flows through this chamber to cool the
piston and improve ring life. The pistons have three
The engine has a separate cylinder head for rings; two compression rings and one oil ring. All the
each cylinder. Four valves (two intake and two exhaust), rings are located above the piston pin bore. The oil ring
controlled by a push rod valve system, are used for each is a standard (conventional) type. Oil returns to the
cylinder. Valve guides without shoulders are pressed crankcase through holes in the oil ring groove. The top
into the cylinder heads. The opening for the fuel injector two rings are the KEYSTONE type, which are tapered.
is located between the four valves. A third lobe on the The action of the ring in the piston groove, which is also
camshaft moves the push rod system that operates the tapered, helps prevent seizure of the rings caused by too
fuel injector. Fuel is injected directly into the cylinder. much carbon deposit.
There is an aluminum spacer plate between The connecting rod has a taper on the pin bore
each cylinder head and the block. Coolant goes out of end. This gives the rod and piston more strength in the
the block through the spacer plate and into the head areas with the most load. Four bolts set at a small angle
through eight openings in each cylinder head face. hold the rod cap to the rod. This design keeps the rod
Water seals are used in each opening to prevent coolant width to a minimum, so that a larger rod bearing can be
leakage. Gaskets seal the oil drain passages between used and the rod can still be removed through the liner.
the head, spacer plate and block.
CRANKSHAFT
The crankshaft changes the combustion forces

in the cylinder into usable rotating torque which powers
the machine. A vibration damper of the fluid type is used
at the front of the crankshaft to reduce torsional
vibrations (twist on the crankshaft) that can cause
damage to the engine.
The crankshaft is symmetrical. This makes it

possible to turn the crankshaft end for end when opposite
engine rotation is desired.
The crankshaft drives a group of gears on the

front and rear of the engine. The gear group on the front
LEFT SIDE OF 3512 ENGINE of the engine drives the oil pump, water pump, fuel
1. Covers for camshafts and fuel control linkage transfer pump, governor and two accessory drives. The
Inspection. 2. Covers for crankshaft main and rod gear group on the rear of the engine drives the
bearing inspection. camshafts.
84
BASIC BLOCK SYSTEMS OPERATION
Lip seals and wear sleeves are used at both

ends of the crankshaft for easy replacement and a
reduction of maintenance cost. Pressure oil is supplied
to all main bearings through drilled holes in the webs of
the cylinder block. The oil then flows through drilled
holes in the crankshaft to provide oil to the connecting
rod bearings. The crankshaft is held in place by five
main bearings on the 3508, seven main bearings on the
3512, and nine main bearings on the 3516. A thrust plate
at either side of the center main bearing controls the end
play of the crankshaft.
CAMSHAFTS
The engine has a camshaft or camshaft group

for each side of engine, driven at the rear of the engine.
Five bearings for the 3508, seven bearings for the 3512,
and nine bearings on the 3516 support each camshaft or
camshaft group. The 3512 and 3516 each use two
camshafts per side that are doweled and bolted together
to make a camshaft group. As the camshaft turns, each
lobe moves a lifter assembly. There are three lifter
assemblies for each cylinder. Each outside lifter
assembly moves a push rod and two valves (either intake
or exhaust). The center lifter assembly moves a push
rod that operates the fuel injector. The camshafts must
be in time with the crankshaft. The relation of the cam
lobes to the crankshaft position cause the valves and fuel
injectors in each cylinder to operate at the correct time.
85
4AIR STARTING SYSTEM SYSTEMS OPERATION
AIR STARTING SYSTEM
The air starting motor is used to turn the engine temperatures below 0°C (32àF)] should be used with the
flywheel fast enough to get the engine running. starting system. The maximum pressure for use in the
air starting motor is 1030 kPa (150 psi). Higher
pressures can cause safety problems.
TYPICAL AIR STARTING SYSTEM

1. Air starting motor. 2. Relay valve. 3. Oiler.
TYPICAL AIR START INSTALLATION
The air starting motor can be mounted on either 4. Air start control valve.
side of the engine. Air is normally contained in a storage
tank and the volume of the tank will determine the length The air from the supply goes to relay valve (2).
of time the engine flywheel can be turned. The storage The starter control valve (4) is connected to the line
tank must hold this volume of air at 1720 kPa (250 psi) before the relay valve (2). The flow of air is stopped by
when filled. the relay valve (2) until starter control valve (4) is
activated. The air from starter control valve (4) goes to
For engines which do not have heavy loads when piston (10) behind pinion (8) for the starter. The air
starting, the regulator setting is approximately 690 kPa pressure on piston (10) puts spring (11) in compression
(100 psi). This setting gives a good relationship between and puts pinion (8) in engagement with the flywheel gear.
cranking speeds fast enough for easy starting and the When the pinion is in engagement, air can go out through
length of time the air starting motor can turn the engine another line to relay valve (2). The air activates relay
flywheel before the air supply is gone. valve (2) which opens the supply line to the air starting
motor.
If the engine has a heavy load which can not be
disconnected during starting, the setting of the air
pressure regulating valve needs to be higher in order to
get high enough speed for easy starting.
The air consumption is directly related to speed;

the air pressure is related to the effort necessary to turn
the engine flywheel. The setting of the air pressure
regulator can be up to 1030 kPa (150 psi), if necessary,
to get the correct cranking speed for a heavily loaded
engine. With the correct setting, the air starting motor
can turn the heavily loaded engine as fast and as long as
it can turn a lightly loaded engine.
Other air supplies can be used if they have the AIR STARTING MOTOR
correct pressure and volume. For good life of the air 5. Air inlet. 6. Vanes. 7. Rotor. 8. Pinion. 9. Gears.
starting motor, the supply should be free of dirt and 10 Piston. 11. Piston spring.
water. A lubricator with SAE 10 nondetergent oil [for
temperatures above 0°C (32àF)], or diesel fuel [for
86
AIR STARTING SYSTEM SYSTEMS OPERATION
The flow of air goes through the oiler (3) where it

picks up lubrication oil for the air starting motor.
The air with lubrication oil goes into the air motor
through air inlet (5). The pressure of the air pushes
against vanes (6) in rotor (7), and then exhausts through
the outlet at bottom of air motor. This turns the rotor
which is connected by gears (9) and a drive shaft to
starter pinion (8) which turns the engine flywheel.
When the engine starts running the flywheel will

start to turn faster than starter pinion (8). Pinion (8)
retracts under this condition. This prevents damage to
the motor, pinion (8) or flywheel gear.
When starter control valve (4) is released, the air

pressure and flow to piston (10) behind starter pinion (8)
is stopped, piston spring (11) retracts pinion (8). Relay
valve (2) stops the flow of air to the air starting motor.
87
ELECTRICAL SYSTEM SYSTEMS OPERATION
ELECTRICAL SYSTEM
The electrical system has three separate circuits: iron core) now increases the strength of the magnetic
the charging circuit, the starting circuit and the low lines of force. These stronger lines of force now increase
amperage circuit. Some of the electrical system the amount of AC current produced in the stator
components are used in more than one circuit. The windings. The increased speed of the rotor assembly
battery (batteries), circuit breaker, ammeter, cables and also increases the current and voltage output of the
wires from the battery are all common in each of the alternator.
circuits.
The charging circuit is in operation when the

engine is running. An alternator makes electricity for the
charging circuit. A voltage regulator in the circuit controls
the electrical output to keep the battery at full charge.
The starting circuit is in operation only when the

start switch is activated.
The low amperage circuit and the charging circuit

are both connected to the same side of the ammeter.
The starting circuit connects to the opposite side of the
ammeter.
CHARGING SYSTEM COMPONENTS
Alternator ALTERNATOR
The alternator is driven by V-type belts from the The voltage regulator is a solid state (transistor,
crankshaft pulley. This alternator is a three phase, self- stationary parts) electronic switch. It feels the voltage in
rectifying charging unit, and the regulator is part of the the system, and switches on and off many times a
alternator. second to control the field current (DC current to the field
windings) to the alternator. The output voltage from the
This alternator design has no need for slip rings alternator will now supply the needs of the battery and
or brushes, and the only part that has movement is the the other components in the electrical system.
rotor assembly. All conductors that carry current are
stationary. The conductors are: the field winding, stator NOTICE
windings, six rectifying diodes, and the regulator circuit
components. Never operate the alternator without the battery in
the circuit. Making or breaking an alternator
The rotor assembly has many magnetic poles connection with heavy load on the circuit can cause
like fingers with air space between each opposite pole. damage to the regulator.
The poles have residual magnetism (like permanent
magnets) that produce a small amount of magnetlike STARTER SYSTEM COMPONENTS
lines of force (magnetic field) between the poles. As the
rotor assembly begins to turn between the field winding Starter Motor
and the stator windings, a small amount of alternating
current (AC) is produced in the stator windings from the The starter motor is used to turn the engine
small magnetic lines of force made by the residual flywheel fast enough to gel the engine running.
magnetism of the poles. This AC current is changed to
direct current (DC) when it passes through the diodes of The starter motor has a solenoid. When the
the recitifer bridge. Most of this current goes to charge start switch is activated, electricity will flow through the
the battery and to supply the low amperage circuit, and windings of the solenoid. The solenoid core will now
the remainder is sent on to the field windings. The DC move to push the starter pinion, by a mechanical
current flow through the field windings (wires around an
88
linkage to engage with the ring gear on the flywheel of

the engine. The starter pinion will engage with the ring There are contacts (4) on the end of core (6).
gear before the electric contacts in the solenoid close the The contacts are held in the open position by spring (5)
circuit between the battery and the starter motor. When that pushes core (6) from the magnetic center of coil (1).
the circuit between the battery and the starter motor is Low current will energize coil (I) and make a magnetic
complete, the pinion will turn the engine flywheel. A field. The magnetic field pulls core (6) to the center of
clutch gives protection for the starter motor so that the coil (I) and the contacts close.
engine, when it starts to run, can not turn the starter
motor too fast. When the start switch is releasd, the
starter pinion will move away from the flywheel ring gear. OTHER COMPONENTS
Circuit Breaker
The circuit breaker is a switch that opens the

battery circuit if the current in the electrical system goes
higher than the rating of the circuit breaker.
A heat activated metal disc with a contact point

completes the electric circuit through the circuit breaker.
If the current in the electrical system gets too high, it
causes the metal disc to get hot. This heat causes a
distortion of metal disc which opens the contacts and
breaks the circuit. A circuit breaker that is open can be
STARTER MOTOR reset after it cools. Push the reset button to close the
1. Field. 2. Solenoid. 3. Clutch. 4. Pinion. 5. contacts and reset the circuit breaker.
Commutator. 6. Brush assembly. 7. Armature.
NOTICE
Starter Solenoid
Find and correct the problem that causes the circuit
A solenoid is a magnetic switch that causes low breaker to open. This will help prevent damage to
current to close a high current circuit. The solenoid has the circuit components from too much current.
an electromagnet with a core (6) which moves.
CIRCUIT BREAKER SCHEMATIC

1. Reset button. 2. Disc in open position. 3. Contacts.
SCHEMATIC OF A SOLENOID 4. Disc. 5. Battery circuit terminals.
1. Coil. 2. Switch terminal. 3. Battery terminal. 4.
Contacts. 5. Spring. 6. Core. 7. Component terminal.
89
Water Temperature Contactor Switch
The contactor switch for water temperature is

installed in the regulator housing. No adjustment to the
temperature range of the contactor can be made. The
element feels the temperature of the coolant and then
operates the micro switch in the contactor when the
coolant temperature is too high. The element must be in
contact with the coolant to operate correctly. If the
reason for the engine being too hot is caused by low
coolant level or no coolant, the contactor switch will not
operate.
The contactor switch is normally connected to an

alarm system in the marine application. When the
temperature of the coolant lowers again to the operating
range, the contactor switch opens automatically.
WATER TEMPERATURE CONTACTOR SWITCH
90
TROUBLESHOOTING TESTING AND ADJUSTING
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.
TROUBLESHOOTING INDEX
Item Problem Item Problem
1. Engine Crankshaft Will Not Turn When Start 27. Engine Coolant Is Too Hot.
Switch Is On. 28. Starter Motor Does Not Turn.
2a. Engine Will Not Start. Governor Terminal 29. Alternator Gives No Charge.
Shaft Does Not Move. 30. Alternator Charge Rate Is Low or Not Regular.
2b. Engine Will Not Start. Governor Terminal 31. Alternator Charge Too High.
Shaft Moves. 32. Alternator Has Noise.
3. Engine Overspeeds On Start. 33. Exhaust Temperature Too High.
4. Engine Speed Does Not Have Stability. 34. Air Starting Motor Turns Slowly or Has A Loss
5a. Engine High Idle Speed Too Low. of Power.
5b. Engine Loses High Idle After Start Up. 35. Air Starting Motor Pinion Does Not Engage
6. Engine Can Not Be Shut Down Through With The Flywheel.
Governor. 36. Air Starting Motor Runs, Pinion Engages But
7. Engine Misfiring or Running Rough. Does Not Turn The Flywheel.
8. Engine Stall at Low rpm. 37. Air Starting Motor Pinion Does Not Engage
9. Not Enough Power. Correctly With The Flywheel.
10. Too Much Vibration. 38. Protective Systems (See Troubleshooting sec-
11. Loud Combustion Noise. tion of);
12. Valve Train Noise (Clicking). SENR3078 - Hydramechanical
13. Oil In Cooling System. SENR2985 - Electrical
14. Mechanical Noise (Knock) In Engine. SENR2984 - Electrical With Reversal Protection
15. Fuel Consumption Too High
16. Loud Valve Train Noise.
17. Too Much Valve Lash.
18. Valve Rotocoil or Spring Lock is Free.
19. Oil at the Exhaust.
20. Little or No Valve Clearance.
21. Engine Has Early Wear.
22. Coolant in Lubrication Oil.
23. Too Much Black or Gray Smoke.
24. Too Much White or Blue Smoke.
25. Engine Has Low Oil Pressure.
26. Engine Uses Too Much Lubrication Oil.
91
1. ENGINE CRANKSHAFT WILL NOT TURN WHEN START SWITCH IS ON
Cause: Correction:
Battery has Low Output Check condition of battery. Charge battery or make replacement
as necessary.
Wiring or Switches Have Defect Make repairs or replacements as necessary.
Problem with Engine Protective Make reference to ELECTRIC PROTECTIVE SYSTEM, in Form
System SENR2984 or Form SENR2985.
Starter Motor Solenoid Has A Install a new solenoid.

Defect
Starter Motor Has a Defect Make repair or replacement of starter motor.
Oil Pressure Switch For Prelubri- Make a replacement of defective switch.

cation Pump Has A Defect
Prelubrication Oil Pump Has A Repair or replace pump components as needed.

Defect
Inside Problem Prevents Engine If the crankshaft can not be turned after disconnecting the driven
Crankshaft From Turning equipment, remove the fuel injectors and check for fluid in the
cylinders while turning the crankshaft. If fluid in the cylinders is
not the problem, the engine must be disassembled to check for
other inside problems. Some of these inside problems are
bearing seizure, piston seizure, or valves making contact with the
pistons.
2a. ENGINE WILL NOT START - GOVERNOR TERMINAL SHAFT
DOES NOT MOVE FUEL CONTROL LINKAGE
Cause: Correction:
Low Oil Level In Governor Check gauge and add correct amount of clean oil to
WOODWARD UG-8 GOVERNORS. Check for plugged oil
supply passages to CATERPILLAR 3161 GOVERNORS.
Too Much Binding In Control Engine can start cold, but with hot oil governor does not develop
Linkage enough pump pressure to move linkage. Check linkage effort
and correct.
Speed Control Shaft Setting Too Move control shaft toward high idle while cranking engine.
Low (Low Idle Not set Correctly) Terminal shaft on properly operating governor will move fuel
control linkage to the "FUEL ON" position.
Solenoid Stuck In Shut Off On UG8L remove top cover assembly and make sure shut down
Position strap is up. Crank engine to start. Repair or make a replacement
of faulty solenoid.
Problem with Engine Protective Make reference to ELECTRIC PROTECTIVE SYSTEM, in Form
System SENR2984 or Form SENR2985.
Solenoid Energized in Shutoff Disconnect wiring harness to stop signal. Correct by

Position During Cranking troubleshooting wiring to solenoid.
Low Oil Pressure In Governor The governor oil pump relief valve may be stuck open or leaking.
Correct by governor disassembly and cleaning.
92
2b. ENGINE WILL NOT START - GOVERNOR TERMINAL SHAFT OPENS AT LEAST HALF WAY OR MORE AT
CRANKING AS OBSERVED BY OUTBOARD SHAFT ROTATION
Cause: Correction:
Slow Cranking Speed Battery has low output, make reference to Item 29.
No Fuel To Injectors Check fuel tank and fill. "Prime" (remove the air and/or low
quality fuel from the fuel system).
Install new fuel filters if necessary.

Blocked or broken fuel lines should be cleaned or replaced.
Check the fuel transfer pump for damage or wear and make
replacements as needed.
Control lever, on governor terminal shaft, not connected to the

fuel control linkage such as improper assembly during overhaul.
Make sure governor linkage is correctly engaged.
During cranking, the air-fuel ratio control will restrict injector rack
to approximately 7 to 9 mm (.28 to .35 in.) which is below the fuel
setting as set by the engine fuel setting screw. Once the lube oil
pressure signal reaches the air-fuel ratio control from the engine,
the rack will be further restricted to approximately 0 mm (0 in.).
The engine must be running and generating boost pressure
before the air-fuel ratio control allows more injector rack travel.
A worn or damaged start-up override valve in the

hydramechanical protective system can also hold the governor in
the shutoff position. On later engines, after a fault condition, the
start-up override valve must be used to release the hydraulic
pressure on the fuel shutoff actuator before the engine can be
started again. Make a replacement and make sure the governor
and control linkage move.
Bad Quality Fuel Remove fuel from the tank. Install new fuel filters and put a good
grade of clean fuel in the fuel tank.
Fuel Pressure is Low. At starting rpm, the minimum fuel pressure from fuel transfer
pump must be 20 kPa (3 psi). If fuel pressure is less than 20 kPa
(3 psi) change the fuel filters. Look for air in the fuel system. If
fuel pressure is still low, check the fuel bypass valve and the fuel
transfer pump for correct operation.
Wrong Fuel Injection Timing Make adjustment to timing.
93
3. ENGINE OVERSPEEDS ON START
Cause: Correction:
Fuel Control Linkage Improper assembly after overhaul, linkage not free, bound up in
"FUEL ON" position, governor control lever not connected with
stop lever of fuel control linkage. Make repairs or replacements
as needed.
High Idle Setting Incorrect Start engine in mid speed position and make an adjustment of the
high idle setting.
Compensation Needle Valve Adjustment Make an adjustment of the compensation needle valve to get
stable governor operation.
Incorrect Governor Oil Used Oil viscosity is too high for ambient temperature starting
conditions. Change oil to correct weight as recommended for the
engine. In extreme low ambient temperatures DEXRON ATF can
be used in UG-8 Governors only.
Dirty Governor Oil (Woodward UG-8) Oil is sludged slowing governor response. Oil should be changed
before it gets too thick. Drain and flush with diesel fuel and add
new oil.
Governor Not Engaged In Drive Coupling Make sure governor is driven by the engine. If necessary,
remove and install governor to make sure it is engaged correctly
with the governor drive. Also, check for worn or damaged drive
components in the governor and engine.
4. ENGINE SPEED DOES NOT HAVE STABILITY.
Cause: Correction:
Air In Oil (Foam) in Governor Especially on Initial Open compensation needle valve and let governor
Start With New Oil. oscillate for several minutes until air is vented from governor.
Reset needle valve to approximately ½ to 3/4 open. Also make
sure the correct grade of oil is used as recommended for the
engine.
Low Oil Level Add oil to correct level in WOODWARD UG-8 GOVERNORS.
Check for leaks, especially at drive shaft. Check for plugged oil
supply passages for CATERPILLAR 3161 GOVERNORS.
Compensation Adjustments Incorrect Needle valve should be approximately 1/2 to ¾ open.
Negative Speed Regulation (Engine Speeds Up On governors with Isochronous droop setting, correct droop
With Load Addition) setting on governor.
Linkage Is Binding, Or Worn With Flat Spots and Inspect and repair or replace linkage as needed.
High Clearances.
(Cont. next page)
94
4. ENGINE SPEED DOES NOT HAVE STABILITY. (Cont.)
Cause: Correction:
Rough Governor Drive Worn splines and/ or high gear clearances can cause rough
governor drive. Inspect and replace parts as needed.
Governor can also be out of alignment with drive. Loosen

governor and adjust as needed for correct alignment with drive.
Engine Misfiring Make reference to Item 7.
Dirty Oil in Governor (Woodward UG-8) Oil is decomposed and sludged slowing governor response.
Replace with new oil after flushing with diesel fuel. High
operating temperatures may require heavier viscosity oils.
Pneumatic (Air) Speed Setting Adjustment Wrong If engine is equipped with pneumatic speed setting, improper
adjustment or excessive play in the governor linkage can be a
problem. Inspect and correct.
Power Piston Sticking Governors on engines that have not been run for long periods
may develop rust in areas of the compensation pistons, etc.
causing instability. Oil varnish also causes parts to stick. Correct
by governor disassembly and cleaning.
Governor Worn Repair or replace governor.
Low Governor Oil Pressure Check correct oil level. Oil pump relief valve does not seat.
Replace valve. Oil pump worn. Replace parts.
5a. ENGINE HIGH IDLE SPEED TOO LOW
Cause: Correction:
Speed Setting Shaft Not Against High Idle Stop Check speed control linkage and/or pneumatic controls for
restrictions. Make repairs or replacement as needed.
Incorrect Adjustment of High Idle Governor speed setting shaft is against high idle stop and high
idle is too low. Make adjustment to correct high idle. Also, check
to make sure engine fuel setting is correct.
Speed Droop Adjustment Incorrect Internal adjustable speed droop is set at the factory. Make
adjustment if necessary.
95
5b. ENGINE LOSES HIGH IDLE AFTER START UP
Cause: Correction:
Normal RPM Loss Loss of approximately 20 rpm can be expected from average cold
start to operating temperature.
A shift of 6 to 8 rpm can be expected on the UG8D. A continuous

steady speed loss suggests a slipping motor clutch. Adjust motor
clutch to 0.51 to 0.62 Nâm (4.5 to 5.5 lb. in.).
High Idle Adjustment Incorrect Make sure governor and engine fuel settings are correct. Make
an adjustment of the high idle as needed.
6. ENGINE CANNOT BE SHUT DOWN THROUGH GOVERNOR.
Cause: Correction:
Bad Shut Down Solenoid Solenoid with a fault, shorted or broken wires, or stuck in open
position. Inspect and replace as needed.
Wires Not Connected Correctly Shut down signal not connected with correct polarity to solenoid A
positive (+), B negative (-) to 2 pin connector.
Hydraulic/ Pneumatic Shutoff Signal Too Low The signal must be 172 to 276 kPa (25 to 40 psi). The bellows
may also be damaged. Measure signal pressures, inspect parts
and make repairs or replacements as needed.
Governor Not Correctly Installed Make sure control lever on governor terminal shaft is engaged
correctly with the stop lever of the engine fuel control linkage.
Governor Needs Repair Disassemble, clean and inspect governor for worn and damaged
parts. Make a replacement of parts as needed.
6
7. ENGINE MISFIRING OR RUNNING ROUGH
Cause: Correction:
Fuel Pressure is Low Make sure there is fuel in the fuel tank. Look for leaks or bad
bends in the fuel line between fuel tank and fuel transfer pump.
Look for air in the fuel system, sticking, binding or defective fuel
bypass valve. Check fuel pressure. The outlet pressure of the
fuel transfer pump must be a minimum of 415 kPa (60 psi) at full
load speed. The pressure in both fuel manifolds must be 415 to
450 kPa (60 to 65 psi). If fuel pressure is lower than the above
pressure, install new filters. If fuel pressure is still low, check the
fuel transfer pump and fuel pressure regulator valve in the fuel
manifold.
Air in Fuel System Find the air leak in the fuel system and correct it. If air is in the
fuel system it will generally get in on the suction side of the fuel
transfer pump.
Leak or Break in Fuel Line Between Fuel Manifold Install a new fuel line.
and Cylinder Head Defect in Fuel Injector(s) Temperature of an exhaust manifold port, when the engine runs
at low idle speed, can be an indication of the condition of a fuel
injector. Low temperature at an exhaust manifold port is an
indication of no fuel to the cylinder. This can possibly be an
indication of an injector with a defect. Extra high temperature at
an exhaust manifold port can be an indication of too much fuel to
the cylinder, also caused by an injector with a defect.
Wrong Valve Clearance Make adjustment according to Subject, VALVE CLEARANCE.
Bent or Broken Push Rod Replacement of push rod is necessary.
Fuel Has "Cloud Point" Higher Than Atmospheric Drain the fuel tank, lines and fuel manifolds. Change
Temperature ("Cloud Point" = Temperature the fuel filter. Fill the tank with fuel which has the
Which Makes Wax Form In Fuel). correct "cloud point" and remove the air from the system with the
priming pump.
In some installations it can be necessary to use fuel heaters to

insure proper fuel flow and to prevent filter blockage from fuel
wax. The fuel temperature at which flow is reduced and filter
blockage occurs is usually dependent upon the amount of wax in
the fuel or its cloud point.
97
8. ENGINE STALL AT LOW RPM
Cause: Correction:
manifold.
Idle rpm Too Low Make adjustment to governor so idle rpm is the same as given in
the FUEL SETTING AND RELATED INFORMATION FICHE.
Engine Accessories Check engine accessories for damage and correct adjustment. If
necessary, disconnect the accessories and test the engine.
Defect in Fuel Injector(s) Make Reference to Item 7.
9. NOT ENOUGH POWER
Cause: Correction:
Dirty Fuel Filters Install new fuel filters.
Bad Quality Fuel or Water in Fuel Remove the fuel from the fuel tank. Install new fuel filters. Put a
good grade of clean fuel in the fuel tank.
Fuel Temperature is High Excess fuel flow temperature should be 65.6 to 82.2àC (160 to
180àF). If excess fuel flow temperature exceeds 82.2àC (
180àF), the use of a fuel cooler is recommended to prevent
excessive engine power loss and to maintain an acceptable
injector life.
manifold. (Cont. next page)
98
9. NOT ENOUGH POWER (Cont.)
Cause: Correction:
Defect in Fuel Injector Make Reference to Item 7.
Leaks in Air Inlet System Check the pressure in the air intake manifold. Look for
restrictions in the air cleaner.
Governor And Fuel Control Linkage Make sure governor is moving fuel control linkage against fuel
setting screw. Make adjustment to get full travel of linkage.
Install new parts for those that have damage or defects. If control
linkage is not against stop and engine runs below rated speed
under load:
(a) Check high idle and adjust if necessary.
(b) Air-fuel ratio control may be restricting control linkage travel

and should be adjusted if necessary.
Wrong Valve Clearance Make adjustment according to Subject, VALVE CLEARANCE.
Wrong Fuel Injection Timing Make adjustment to timing. See Subject, FUEL TIMING.
Fuel Setting Incorrect Make an adjustment of the fuel setting. See FUEL SETTING
AND RELATED INFORMATION FICHE for the correct fuel
setting. Also see Subject, FUEL SETTING for the correct
procedure.
Defect in Aftercooler Check temperature of inlet and outlet water supply. Remove any
external or internal restrictions.
Turbocharger Has Carbon Deposits or Other Make inspection and repair of turbocharger as necessary.
Causes of Friction.
10. TOO MUCH VIBRATION
Cause: Correction:
Vibration Damper Loose Check vibration damper for damage. Tighten bolts. If vibration
damper bolt holes have damage or wear, replace with new parts.
Vibration Damper Has A Defect Install a new vibration damper
Engine Supports Are Loose, Wrong or Have A Tighten all mounting bolts. Install new components if necessary.
Defect
Driven Equipment Is Not In Alignment Or Is Out of Check alignment and balance, correct if needed.
Balance
Misfiring or Running Rough Make Reference to Item 7.
99
11. LOUD COMBUSTION NOISE (SOUND)
Cause: Correction:
Bad Quality Fuel Remove the fuel from the fuel tank. Install new fuel filters. Put a
good grade of clean fuel in the fuel tank.
12. VALVE TRAIN NOISE (CLICKING)
Cause: Correction:
Damage to Valve Spring(s), Locks, or Broken or Install new parts where necessary. Broken locks can
Worn Valve Lifter cause the valve to get into the cylinder. This will cause much
damage.
Not Enough Lubrication Check lubrication in valve compartment. There must be a strong
flow of oil at engine high rpm, but only a small flow of oil at low
rpm. Oil passages must be clean, especially those that send oil
to the cylinder head.
Too Much Valve Clearance Make adjustment according to the Subject, VALVE CLEARANCE.
Damage to Valve(s) Make a replacement of the valve(s) and make an adjustment as

necessary.
13. OIL IN COOLING SYSTEM
Cause: Correction:
Defect In Core of Engine Oil Cooler Install a new engine oil cooler.
Failure of Cylinder Head Gasket or Water Seals Check cylinder liner projection. Install a new cylinder head gasket
and new water seals in the spacer plate. Tighten the bolts that
hold the cylinder head according to the Specifications.
14. MECHANICAL NOISE (KNOCK) IN ENGINE
Cause: Correction:
Failure of Bearing For Connecting Rod Inspect the bearings for the connecting rods and the bearing
surfaces (journals) on the crankshaft. Install new parts where
necessary.
Damaged Gears Install new parts where necessary.
Damaged Crankshaft Make replacement of the crankshaft.
Defect in Attachment Repair or install new components.
100
15. FUEL CONSUMPTION TOO HIGH
Cause: Correction:
Fuel System Leaks Tighten or make replacement of parts at points of

leakage.
Fuel and Combustion Noise (Knock) Make Reference to Item 7 and Item 9.
16. LOUD VALVE TRAIN NOISE
Cause: Correction:
Damage to Valve Spring(s) Make replacement of parts with damage.

Damage to Camshaft Make replacement of parts with damage. Clean engine
thoroughly. If replacement of camshaft is made, new
valve lifters are also necessary.
Damage to Valve Lifter Clean engine thoroughly. Make a replacement of the
damaged valve lifters. Inspect camshaft lobes for
damage. Look for valves that do not move freely. Make
an adjustment to valve clearance according to the
Subject, VALVE CLEARANCE.
17. TOO MUCH VALVE LASH
Cause: Correction:
Not Enough Lubrication Check lubrication in valve compartment. There must be

a strong flow of oil at engine high rpm, but only a small
flow at low rpm. Oil passages must be clean, especially
those sending oil to the cylinder head.
Rocker Arm Worn at Face That Makes Contact If there is too much wear, install new parts or rocker
With Bridge arms. Make adjustment of valve clearance according to
Subject, VALVE CLEARANCE.
Bridges for Valves Worn Make an adjustment or replacement as necessary.
End of Valve Stem Worn If there is too much wear, install new valves. Make
adjustment to valve clearance according to Subject,
VALVE CLEARANCE.
Worn Push Rods If there is too much wear, install new push rods. Make
adjustment of valve clearance according to Subject,
VALVE CLEARANCE.
Broken or Worn Valve Lifters Install new valve lifters. Check camshaft for wear.
Check for free movement of valves or bent valve stem.
Clean engine thoroughly. Make adjustment of valve
clearance according to Subject, VALVE CLEARANCE
(Cont. next page)
101
17. TOO MUCH VALVE LASH (Cont.)
Cause: Correction:
Worn Cams on Camshaft Check valve clearance. Check for free movement of
valves or bent valve stems. Install a new camshaft.
Install new valve lifters. Make adjustment of valve
clearance according to Subject, VALVE CLEARANCE.
18. VALVE ROTOCOIL OR SPRING LOCK IS FREE
Cause: Correction:
Broken Locks Broken locks can cause the valve to slide into the
cylinder. This will cause much damage.
Broken Valve Spring(s) Install new valve spring(s)
Broken Valve Replace valve and other damaged parts.
19. OIL AT THE EXHAUST
Cause: Correction:
Too Much Oil in the Valve Compartment Be sure that the dowel is installed in the left bolt hole of
the rocker shaft.
Worn Valve Guides Reconditioning of the cylinder head is needed.
Worn Piston Rings Inspect and install new parts as needed.
20. LITTLE OR NO VALVE CLEARANCE
Cause: Correction:
Worn Valve Seat or Face of Valve Reconditioning of cylinder head is needed. Make
adjustment of valve clearance according to the Subject,
VALVE CLEARANCE.
21. ENGINE HAS EARLY WEAR
Cause: Correction:
Dirt in Lubrication Oil Remove dirty lubrication oil. Install new oil filters. Put
clean oil in the engine. Check oil filter bypass valve for a
weak or broken spring.
Air Inlet Leaks Inspect all gaskets and connections. Make repairs if
leaks are found.
Fuel Leakage Into Lubrication Oil This will cause high fuel consumption and low engine oil
pressure. Make repairs if leaks are found. Install new
parts where needed.
102
22. COOLANT IN LUBRICATION OIL
Cause: Correction:
Failure of Oil Cooler Core Install a new core for the oil cooler. Drain crankcase and
refill with clean lubricant. Install new oil filter element.
Failure of Cylinder Head Gasket or Water Seals Check cylinder liner projection. Install a new cylinder
head gasket and new water seals in the spacer plate.
Tighten the bolts that hold the cylinder head according to
the Specifications.
Crack or Defect in Cylinder Head Install a new cylinder head.
Crack or Defect in Cylinder Block Install a new cylinder block.
Failure of Liner Seals Replace seals.
23. TOO MUCH BLACK OR GRAY SMOKE
Cause: Correction:
Not Enough Air For Combustion Check air cleaner for restrictions.
Bad Fuel Injectors Install new fuel injectors.
24. TOO MUCH WHITE OR BLUE SMOKE
Cause: Correction:
Too Much Lubrication Oil in Engine Remove extra oil. Find where extra oil comes from. Put
correct amount of oil in engine.
Engine Misfires or Runs Rough Make Reference to Item 7.
Worn Valve Guides Reconditioning of cylinder head is needed.
Worn Piston Rings Install new piston rings.
Failure of Turbocharger Oil Seal Check inlet manifold for oil and repair turbocharger if
necessary.
103
25. ENGINE HAS LOW OIL PRESSURE
Cause: Correction:
Dirty Oil Filters or Oil Cooler Check the operation of bypass valve for the filter. Install
new oil filters if needed. Clean or install new oil cooler
core. Remove dirty oil from engine. Put clean oil in
engine.
Diesel Fuel in Lubrication Oil Find the place where diesel fuel gets into the lubrication
oil. Make repairs as needed. Remove the lubrication oil
that has diesel fuel in it. Install new oil filters. Put clean
oil in the engine.
Too Much Clearance Between Rocker Arm Shaft Check lubrication in valve compartments. Install
and Rocker Arms new parts as necessary.
Oil Pump Suction Pipe Has A Defect Replacement of pipe is needed.
Oil Pressure Relief Does Not Close Clean valve and housing. Install new parts as
necessary.
Oil Pump Has A Defect Repair or replace oil pump.
Too Much Clearance Between Crankshaft and Inspect the bearings and make replacement as
Crankshaft Bearings necessary.
Too Much Clearance Between Camshaft and Cam- Install new camshaft and camshaft bearings if
shaft Bearings necessary.
Defect in Oil Pressure Gauge Install new gauge.
26. ENGINE USES TOO MUCH LUBRICATION OIL
Cause: Correction:
Too Much Lubrication Oil In Engine Remove extra oil. Find where extra oil comes from. Put
correct amount of oil in engine. Do not put too much oil
in engine.
Oil Leaks Find all oil leaks. Make repairs as needed. Check for
dirty crankcase breather.
Oil Temperature is Too High Check operation of oil cooler. Install new parts if
necessary. Clean the core of the oil cooler.
Too Much Oil in the Valve Compartment Be sure that the dowel is installed in the left bolt hole of
the rocker shaft. The dowel is located between the
rocker shaft and valve cover base.
Worn Valve Guides Reconditioning of the cylinder head is needed.
Worn Piston Rings Inspect and install new parts as needed.
Failure of Seal Rings in Turbocharger Check inlet manifold for oil and make repairs to the
turbocharger if necessary.
104
27. ENGINE COOLANT IS TOO HOT
Cause: Correction:
Restriction To Flow of Coolant Through Radiator Clean and flush radiator or heat exchanger.
Core Tubes or Heat Exchanger
Restriction To Air Flow Through Radiator Remove all restrictions of flow.
Low Fan Speed Check for worn or loose fan belts.
Not Enough Coolant in System Add coolant to cooling system. Check for leaks.
Pressure Cap Has A Defect Check operation of pressure cap. Install a new pressure
cap if necessary.
Combustion Gases in Coolant Find out where gases get into the cooling system. Make
repairs as needed.
Water Temperature Regulators (Thermostats) or Check water temperature regulators for correct
Temperature Gauge Has A Defect operation. Check temperature gauge operation. Install
new parts as necessary.
Water Pump Has A Defect Make repairs to the water pump as necessary.
Too Much Load On The System Make a reduction to the load.
28. STARTER MOTOR DOES NOT TURN Deleted.
29. ALTERNATOR GIVES NO CHARGE Deleted.
105
33. EXHAUST TEMPERATURE IS TOO HIGH
Cause: Correction:
Air Inlet System Has A Leak Check pressure in the air intake manifold. Look for
restrictions at the air cleaner. Correct any leaks.
Exhaust System Has A Leak Find cause of exhaust leak. Make repairs as
necessary.
Air Inlet or Exhaust System Has A Restriction Remove restriction.
Wrong Fuel Injection Timing Make an adjustment to the timing. See Subject, FUEL
TIMING.
34. AIR STARTING MOTOR TURNS SLOWLY OR HAS A LOSS OF POWER
Cause: Correction:
Low Supply Air Pressure Make an increase to the air supply pressure.
Pressure Regulator Adjustment Not Correct Make an adjustment to the air pressure regulator.
Oiler Not Working Correctly Check the oiler, inlet hose, fitting and oil supply hose to
make sure they are vacuum tight and free of leaks.
Clean, make adjustment, tighten all fittings, fill oiler or
make a replacement, if necessary.
Worn Motor Parts Disassemble the motor and make an inspection of the
parts. A guide for determining worn parts that cannot be
used again is as follows:
a. Install a set of new vanes if any vane is cracked,

damaged or worn to the extent that its width is 32
mm (1.25 in.) at either end.
b. Replace rotor bearings if any roughness or

looseness is apparent in the bearings.
c. Replace rotor if the body has deep scoring that

cannot be removed with the use of emery cloth.
d. Replace cylinder if there are any cracks or deep

scoring.
e. Clean up end plate scoring with emery cloth

placed on a flat surface.
Air Leakage Check the motor for worn seals. Plug the exhaust.
Apply 205 kPa (30 psi) air to the inlet and put the unit in
nonflammable fluid for 30 seconds. If bubbles appear,
make a replacement of the motor seals.
106
FUEL SYSTEM TESTING AND ADJUSTING
FUEL SYSTEM
Either too much fuel or not enough fuel for com- FUEL INJECTOR TESTING
bustion can be the cause of a problem in the fuel system.
Tools Needed:
Many times work is done on the fuel system when the 6V4022 Injector Tester.
problem is really with some other part of the engine. The 6V4172 Injector Sleeve.
source of the problem is difficult to find, especially when 6V6068 Calibration Fluid 19 liters (5 U.S. gal.)
smoke comes from the exhaust. Smoke that comes -or-
from the exhaust can be caused by a bad fuel injector, 6V6067 Calibration Fluid 208 liters (55 U.S.
but it can also be caused by one or more of the reasons gal.)
that follow:
NOTICE
a. Not enough air for good combustion. Be sure to use clean SAE J967 Calibration Fluid
b. An overload at high altitude.
when tests are made. Dirty test fluid will damage
c. Oil leakage into combustion chamber.
components of the fuel injectors. The temperature
d. Not enough compression. O O
of the test fluid must be 18 to 24 C (65 to 75 F) for
good test results.
FUEL SYSTEM INSPECTION
A problem with the components that send fuel to

the engine can cause low fuel pressure. This can
decrease engine performance.
1. Check the fuel level in the fuel tank. Look at the cap
for the fuel tank to make sure the vent is not filled with
dirt.
2. Check the fuel lines for fuel leakage. Be sure the fuel
supply line does not have a restriction or a bad bend.
3. Install new fuel filters. Clean the primary fuel filter.
4. Inspect the fuel pressure relief valve in the fuel

transfer pump to see that there is no restriction to good
operation.
6V4022 INJECTOR TESTER
CHECKING ENGINE CYLINDERS 1. Sight tube. 2 Test pressure gauge. 3. Load cell
SEPARATELY pressure gauge. 4. Handle (to pump test fluid). 5.
Temperature of an exhaust manifold port, when Injector holding block. 6. Spray shield. 7. Drain
the engine runs at low idle speed, can be an indication of panel. 8. Base (reservoir).
the condition of a fuel injector. Low temperature at an
exhaust manifold port is an indication of no fuel to the
cylinder. This can possibly be an indication of an injector
with a defect. Extra high temperature at an exhaust When fuel injectors are tested, be sure to wear eye
manifold port can be an indication of too much fuel to the protection. Test fluid comes from the orifices in the
cylinder, also caused by an injector with a defect. injector tip with high pressure. The test fluid can
pierce (go thru) the skin and cause serious injury to
the operator. Also, the 6V4022 Injector Tester must
be used in an area that is well ventilated (good
movement of air).
107
Install test plug (17) and check the adjustment of

rocker arm (10). The roller on the rocker arm must just
clear (be just above) the top of test plug (17) when the
rocker arm is moved to either the extended or retracted
position. If an adjustment is needed, see
MAINTENANCE AND ADJUSTMENT PROCEDURES in
Special Instruction, Form No. SEHS7788. While test
plug (17) is still in position, check the tester for leaks.
See LEAK TEST FOR INJECTOR TESTER in this
section.
Operation Of The Tester
6V4022 INJECTOR TESTER

9. Test pressure valve. 10. Rocker arm. 11. Light
switch. 12. Rocker arm control lever. 13. Clamp
plate. 14. Light panel. 15. Drain cover. 16. Fluid
level indicator.
The test procedures that follow will give an

indication of injector condition. Do not use an injector in
an engine unless all test results are within the test
specifications.
Injector Tester Preparation TESTER NOMENCLATURE

1. Sight tube. 2. Test pressure gauge. 4. Handle.
Before a new 6V4022 Injector Tester is put to 5. Injector holding block. 9. Test pressure valve.
use, some specific procedures must be followed to make 10. Rocker arm.
sure the tester will operate correctly. Remove drain
panel (7) to make sure that the test fluid reservoir is
clean, and also that there is a clean filter element in its Operation of handle (4) backward and forward
correct location. Use clean SAE J-967 Calibration Fluid pumps (sends) test fluid from the reservoir in the base of
to fill the supply reservoir to its correct level. This is the the tester, through the filter element (in the base), to an
same type and quality of test fluid as that used in a inlet check valve and an outlet check valve to test
Caterpillar Fuel Injection Test Bench. Be sure to put pressure gauge (2), then down to injector holding block
drain panel (7) back in position after the reservoir is (5). When an injector is in position in injector holding
filled. block (5), the test fluid fills the injector and the chamber
around it, and is then sent to test pressure valve (9),
through sight tube (1). It then returns to the reservoir in
the base of the tester.
When test pressure valve (9) is in the "CLOSED"

position, test fluid cannot go back to the reservoir c when
handle (4) is operated. This causes high pressure in
injector holding block (5), and in the injector. This high
pressure is used to test the injector for external (outer)
leakage and leakdown rate (amount of time for pressure
drop between the specific pressure limits).
TESTER PREPARATION
7. Drain panel. 10. Rocker arm. 17. Test plug.
108
2. Install test plug (17) and then pump (operate)

handle (4) to remove air from the system.
3. Turn test pressure valve (9) to the "CLOSED"

position and use handle (4) to increase the
pressure above 13 000 kPa on test pressure
gauge (2). PRESSURE MUST NOT GO ABOVE
15 000 kPa.
4. When handle (4) is released, the pressure will

always drop some amount. If the pressure has
now dropped below the 13 000 kPa, move the
handle just enough to maintain 13 000 kPa (or
TESTER NOMENCLATURE more) when handle is released.
1. Sight tube. 2. Test pressure gauge. 4. Handle.
5. Injector holding block. 9. Test pressure valve. 5. If necessary, slightly open test pressure valve (9)
10. Rocker arm. 12. Rocker arm control lever. to lower the pressure to the desired 13 000 kPa
and close valve (9).
When test pressure valve (9) is in the "OPEN"
position, the operation of handle (4) causes test fluid to 6. Pressure must not drop to 12 500 kPa in less
be sent to the injector. Use control lever (12) to extend than 7 minutes.
or retract rocker arm (10). The External Leakage Test,
Tip Leakage Test and the Leakdown Rate Test must LEAK TEST SPECIFICATION FOR INJECTOR TESTER
each be done with the rocker arm in the retracted Maximum Pressure Drop Minimum Time Interval
position. The Valve Opening Pressure Test and the 500 kPa 7 Minutes
Orifice Inspection Test are each done with the rocker
arm in the extended position.
Leak Test For Injector Tester
1. The 6V4022 Injector Tester must be checked

with a leak test to make sure that there are no
leaks within the tester. Do this test at regular
intervals to be sure of good operation of the
tester. This test can be done at any time, either
before or after a test of an injector or a group of
injectors.
TESTER LEAK TEST PRESSURE RANGE

(7 MINUTES)
7. If the test shows too much leakage, find the

leakage source and make the necessary repair.
LEAK TEST Check the seals on test plug (17). Test pressure
1. Sight tube. 4. Handle. 9. Test pressure valve. valve (9) is also a possible leak source. This
leakage can possibly be seen at sight tube (1).
17. Test plug.
109
INJECTOR CLEANING
22. Injector sleeve.
2. Remove sleeve (22) and drain all fuel from in-

side the injector.
CHECK BACK OF TESTER FOR LEAKS NOTE: If each injector is cleaned before it is put on the
18. Fittings. 19. Fluid line and fittings at both ends. tester, the test fluid in the tester will be kept clean, and
20. Fluid line and fittings at both ends. 21. Fittings. can be used for a longer period of time. See
MAINTENANCE AND ADJUSTMENT PROCEDURES in
8. Other possible locations or areas to check for a Special Instruction, Form No. SEHS7788 for more
leak are shown in illustration. Check all fittings information on the test fluid.
and fluid lines similar to those shown.
TEST SEQUENCE
To test fuel injectors, use the sequence that

follows:
I. Injector Cleaning and Installation

II. Orifice Inspection
III. Valve Opening Pressure
IV. External Leakage
V. Tip Leakage
VI. Leakdown Rate
I. Injector Cleaning and Installation

CLAMP PLATE OPEN
1. Clean the outer surface of the injector before it is A. Bore for injector. 6. Spray shield. 23. Clamp
tested. Install 6V4172 Injector Sleeve (22) on
plate. 24. Clamp lever.
the injector, to cover the injector fuel ports. This
will keep dirt and other foreign material out of the
3. Lift clamp lever (24) just enough so it is above
injector. Use clean solvent and a brush to clean
clamp plate (23). Move clamp plate (23) all the
the outside of the injector. After the outside of
way out as shown. Make sure that bore (A), in
the injector is clean, let it become completely
the injector block, is clean. Put spray shield (6)
dry.
on the drain panel.
110
INJECTOR INSTALLED
25. Injector.
INJECTOR IN TEST POSITION
4. Inspect the seals on the injector and install 9. Test pressure valve, 10. Rocker arm. 12. Rocker
replacement seals as necessary. To get a good arm control lever. 24. Clamp lever. 25. Injector.
test, the injector must have good seals. Put
clean test fluid on the seals for lubrication, then 7. Open test pressure valve (9). Use control lever
install injector (25) in bore (A) of the injector (12) to retract rocker arm (10).
block, with the dowels engaged as shown.
8. Pull rack (27) all the way out. Move handle (4)
NOTE: Use only clean test fluid as a lubricant for the backward and forward to pump (push) the test
seals. Use of any other lubricant can make a mixture fluid into and through the injector, until no air
that will give test information that is not correct. bubbles can be seen in sight tube (1).
5. Turn clamp plate (23) so the slot is completely

engaged with bolt (26).
AIR REMOVAL FROM TESTER

1. Sight tube. 4. Handle. 27. Injector rack.
CLAMP PLATE CLOSED 9. When no more air bubbles can be seen in sight
23. Clamp plate. 26. Bolt. tube (l), release handle (4) to its original upright
(released) position. Use control lever (12) to
6. Push down fully on clamp lever (24) to pull extend rocker arm (10) as shown.
injector (25) into the test position.
10. With rocker arm (10) in the fully extended
NOTE: Make sure clamp lever (24) is all the way down. position, operate handle (4) for 10 to 12 strokes.
High pressure caused by the test will put an upward This will activate injector (25) and remove any air
force on injector (25). that is inside the injector.
111
1. Handle (4) must be in an upright position as

shown. Use control lever (12) to extend rocker
arm (10), then pull injector rack (27) all the way
out. Use switch (11 ) to turn on the panel light.
Open test pressure valve (9) a minimum of one
complete turn.
AIR REMOVAL FROM INJECTOR

1. Sight tube. 4. Handle. 10. Rocker arm. 12.
Rocker arm control lever. 25. Injector. 27. Injector
rack.
11. Release handle (4) and let it come back to the INJECTOR UNDER TEST
upright position. Move control lever (12) to 4. Handle.
retract rocker arm (10). Again use handle (4) to
pump test fluid through the tester, for 10 or 12
strokes, and look for air bubbles at sight gauge 2. The injector tip shown has nine orifices.
(1). When no air bubbles can be seen at sight Numbers on the tip of the injector will show:
gauge ( I ), the injector is ready for the test number of orifices, size of the orifices, and spray
procedure. If air bubbles are seen at sight angle of orifices. An explanation of the 9-0.254-
gauge (1), do Steps 8 through 11 again until all 160 as shown in illustration is as follows: nine
air is removed from the tester system. 0.254 mm orifices that have a 1600 spray angle.
According to engine model and/or application,
NOTE: Injector rack (27) must be pulled out all the way these numbers or specifications can be different
for all tests. from engine to engine.
II. Orifice Inspection
INJECTOR TIP
3. Use handle (4) to pump the tester just fast

enough to make sure orifices are not plugged.
INJECTOR IN POSITION FOR TEST
4. Handle. 9. Test pressure valve. 10. Rocker arm.
11. Light switch. 12. Rocker arm control lever. 27.
Injector rack.
112
CORRECT SPRAY ANGLE
4. If none of the orifices are plugged, rapidly pump

handle (4) to make sure there is good flow of the
test fluid at each orifice, and to make sure spray
angle is correct.
INJECTOR UNDER TEST
NOTE: If any orifices are plugged (closed), or if injector 4. Handle. 9. Test pressure valve. 10. Rocker arm.
does not have a satisfactory spray angle, do not use the 25. Injector. 27. Injector rack.
injector again.
3. Look at load cell gauge (3). Slowly operate
III. Valve Opening Pressure (VOP) handle (4) to pump the tester and activate
injector (25). During each stroke, the dial needle
The load cell and load cell gauge of the 6V4022 of load cell gauge (3) will go to a maximum
Tester are used to determine (find) the valve opening pressure reading and then decrease.
pressure of an injector. Valve opening pressure cannot
be measured unless the injector is disassembled, but NOTE: The highest gauge readings are made with a
when the load cell and the load cell gauge of this tester slow, steady movement of handle (4). Some extra
are used, a measurement can be made of the force practice (extra use of tester to learn better operating
needed to depress (move down) the injector plunger. procedure) will show that a slow, steady movement of
This force is in direct relation to the valve opening handle (4) will give the highest gauge readings.
pressure. A conversion of these load cell gauge
readings will give the valve opening pressure of an 4. Operate handle (4)just fast enough to cause test
injector. All specifications for the valve opening pressure fluid to flow through the injector tip until the
of an assembled injector will be given as load cell maximum reading on load cell gauge (3) is
pressure readings. It will not be necessary to make any constant.
conversions or to have a special gauge. It must be
remembered that the load cell gauge reading is a direct
measurement of load cell pressure, and is not a direct
measurement of valve opening pressure.
1. Make sure that all air has been removed from

the tester and injector, and that test pressure
valve (9) is OPEN a minimum of one complete
turn. Pull injector rack (27) OUT all the way.
2. With rocker arm (10) extended, use handle (4) to

pump the tester just fast enough to unseat
(move off its seat) the needle valve inside
injector (25). Test fluid will now move through
the injector tip.
LOAD CELL PRESSURE INDICATION
3. Load cell pressure gauge. 9. Test pressure valve.
10. Rocker arm. 25. Injector.
113
Look at test pressure gauge (2) during the procedure

in Step 3. High pressure can come rapidly, so be
careful. PRESSURE MUST NOT GO ABOVE 14 000
kPa.
3. Pump the tester just fast enough to maintain a

pressure between 10 000 and 14 000 kPa on
gauge (2). With this amount of pressure on the
injector, make a thorough visual inspection of the
injector for any leakage.
4. There must be no leakage at the seals. If there

is leakage, new seals must be installed. Make
this repair before any other tests are started.
LOAD CELL PRESSURE RANGE
5. The Load Cell Pressure for a new or used

injector must be 3100 to 4100 kPa. If pressure
is not within this pressure range, do not use the
injector again.
IV. External Leakage

INJECTOR UNDER TEST
2. Test pressure gauge. 4. Handle. 9. Test pressure
valve.
5. If there is leakage at any part of the injector

(except at the rack hole or from the injector tip),
do not use the injector again. A repair or
replacement of the injector must be made.
If there is leakage at the rack hole or from the

injector tip, do the LEAKDOWN RATE TEST and the TIP
LEAKAGE TEST (after EXTERNAL LEAKAGE TEST is
complete) to see if the leakage is excessive.
NOTE: If there is to be a repair to the injector, see

INJECTOR INSTALLED FOR TEST REPAIR OF UNIT INJECTORS in Special Instruction,
2. Test pressure gauge. 4. Handle. 9. Test pressure Form No. SEHS8190.
valve. 25. Injector.
V. Tip Leakage
1. Remove all fluid from the injector holding block, 1. Remove all fluid from the injector holding block,
injector body and injector tip with a clean cloth. injector body and injector tip with a clean cloth.
2. Close test pressure valve (9). Be sure the 2. Close test pressure valve (9). Be sure the
injector tip is completely dry. injector tip is completely dry.
NOTICE
114
INJECTOR UNDER TEST

2. Test pressure gauge. 4. Handle. 9. Test pressure INJECTOR UNDER TEST
valve.
4. Handle. 9. Test pressure valve. 28. Stopwatch.
NOTICE
Look at test pressure gauge (2) during the procedure 1. Test pressure valve (9) must be in the CLOSED
in Step 3. High pressure can come rapidly, so be position. Use handle (4) to slowly pump the
tester and get a pressure of approximately 10
careful. PRESSURE MUST NOT GO ABOVE 14 000
000 kPa. PRESSURE MUST NOT GO ABOVE
kPa.
14 000 kPa.
3. Pump the tester just fast enough to maintain a
2. Put handle (4) in the up (released) position.
pressure between 10 000 and 14 000 kPa on
When pressure falls to 7000 kPa, activate stop-
gauge (2). Use a stopwatch and make a visual
watch (28) and check the amount of time it takes
inspection of the injector tip for 30 seconds.
for the pressure to drop to 3500 kPa.
TIP LEAKAGE SPECIFICATION
LEAKDOWN RATE SPECIFICATION
No more than 15 drops can fall from the injector tip within
Injector Pressure Acceptable
30 seconds.
Condition Drop Time Interval
New or Rebuilt 3500 kPa 30 Seconds Minimum
NOTE: The test fluid must come from inside the injector
through the tip orifice, not from any leakage above. Used 3500 kPa 20 Seconds Minimum
4. If more than 15 drops fall from the injector tip in

30 seconds, do not use the injector again. A
repair or replacement of the injector must be
made.
If there is to be a repair of the injector, see

REPAIR OF UNIT INJECTORS in Special Instruction,
Form No. SEHS8190.
VI. Leakdown Rate
LEAKDOWN RATE PRESSURE RANGE
115
3. If leakdown time for the first test is one minute or

more, the leakdown time is acceptable and no
additional leakdown tests are necessary.
4. If leakdown time for the first test is less than one

minute, it will be necessary to make three
additional leakdown tests. Get an average of the
results of the three additional tests.
5. If the average leakdown time of an injector is

less than the time given in the specifications
shown, do not use the injector. A repair or
replacement of the injector must be made.
If there is to be a repair of the injector, see

REPAIR OF UNIT INJECTORS in Special Instruction,
Form No. SEHS8190.
FUEL PRESSURE
The 6V3150 Engine Pressure Group can be

used to check engine fuel pressures.
FUEL MANIFOLD AND LINES
6. Fuel supply line to cylinder head. 7, Fuel manifold.
The fuel pressure regulating valve keeps the

pressure in fuel manifolds (7) between 415 and 450 kPa
(60 to 65 psi). To check the fuel manifold pressure,
disconnect one of the fuel lines (6) and install a tee
between the line and manifold. Connect the 6V3150
Engine Pressure Group to the tee and operate the
engine.
6V3150 ENGINE PRESSURE GROUP

1. Differential pressure gauges. 2. Zero adjustment
screw. 3. Pressure gauge 0 to 1100 kPa (0 to 160 psi).
4. Pressure tap. 5. Pressure gauge 0 to 415 kPa (0 to
60 psi).
This tool group has a gauge to read pressure in

the fuel manifolds. Special Instruction Form No.
SEHS7851 is with the tool group and gives information
for its use.
FUEL TRANSFER AND FILTER DIFFERENTIAL
PRESSURES
8. Fuel filter housing. Plug. 10. Plug.
The outlet pressure of the fuel transfer pump can

be checked at the location of plug (10) in filter housing
(8).
Also the fuel filter differential can be checked at

plugs (9) and (10) in filter housing (8).
116
ENGINE ROTATION
SAE standard engine crankshaft rotation is

counterclockwise as seen from the flywheel end of the
engine.
FINDING TOP CENTER POSITION FOR NO. 1

PISTON
Tools Needed:
9S9082 Engine Turning Tool.
TIMING BOLT INSTALLATION

2. Timing bolt. 4. 9S9082 Engine Turning Tool.
4. The intake and exhaust valves for the No. 1

cylinder are fully closed if No. 1 piston is on the
compression stroke and the rocker arms can be
moved by hand. If the rocker arms can not be
moved and the valves are slightly open, the No.
1 piston is on the exhaust stroke. Make
reference to charts for CRANKSHAFT
POSITIONS FOR INJECTOR TIMING AND
VALVE CLEARANCE SETTING to find the
TIMING BOLT LOCATION correct cylinder(s) to be checked/adjusted for the
1. Cover. 2. Timing bolt. 3. Timing bolt hole In stroke position of the crankshaft when the timing
flywheel housing. bolt has been installed in the flywheel.
1. Remove cover (1) and the timing hole plug from NOTE: When the actual stroke position is identified, and
the right front side of the flywheel housing. On the other stroke position is needed, it is necessary to
some engines there is a cover and timing bolt remove the timing bolt from the flywheel and turn the
hole located on the left side, also. flywheel 3600 in the direction of normal engine rotation.
2. Put timing bolt (2) [long bolt that holds cover (1)
on the flywheel housing] through the timing hole
in the flywheel housing. Use the 9S9082 Engine
Turning Tool (4) and 1/2" drive ratchet wrench to
turn the engine flywheel in the direction of
normal engine rotation until the timing bolt
engages with the threaded hole in the flywheel.
NOTE: If the flywheel is turned beyond the point that the

timing bolt engages in the threaded hole, the flywheel
must be turned opposite normal engine rotation
approximately 30 degrees. Then turn the flywheel in the
direction of normal engine rotation until the timing bolt
engages with the threaded hole. The reason for this
procedure is to make sure the play is removed from the
gears when the No. 1 piston is put on top center.
3. Remove the valve cover for the No. I cylinder (3512 SHOWN)
head.
117
CAMSHAFT TIMING timing pins (2) from their storage positions.

Timing Check 5. Install timing pins (2) through holes (1) in the
Tools Needed: engine block and into the groove (slot) in
9S9082 Engine Turning Tool. camshaft (4) on each side of the engine. For the
engine to be timed correctly, the timing pins
1. Remove rear camshaft cover (3) from both sides must fit into the groove of each camshaft.
of the engine.
6. If timing pins (2) do not engage in the grooves of
both camshafts, the engine is not in time, and
one or both camshafts must be adjusted.
7. Both camshafts are adjusted the same way.

See TIMING ADJUSTMENT for the procedure to
put the camshafts in time with the crankshaft.
NOTICE
If a camshaft is out of time more than 18 degrees

(approximately 1/2 the diameter of timing pin out of
groove), the valves can make contact with the
pistons. This will cause damage that will make
1. Timing hole. 2. Timing pin. 3. Cover.
engine repair necessary.
2. Make reference to FINDING TOP CENTER
Timing Adjustment
POSITION FOR NO. I PISTON.
Tools Needed:
NOTE: Since both rear camshaft covers have to be
removed to check the timing, it is not necessary to 9S9082 Engine Turning Tool.
remove No. 1 valve cover to find the compression stroke 6V3010 Puller Group.
when timing bolt is installed in flywheel. 9S9089 Two 1/2 - 13 NC Bolts 114.3 mm (4.50
in.) long.
3. With timing bolt installed in flywheel, look at rear 5P1076 Two Washers (Hardened).
of camshaft to see if timing groove (slot) is
visible on the camshaft. If it is visible, No. 1 NOTE: Before any timing adjustments are made, the
piston is on the compression stroke. If it is not timing must be checked first to see if adjustment is
visible, feel the backside of the camshaft for the necessary. See subject TIMING CHECK for this
groove. If the groove is at the back of the procedure.
camshaft, the flywheel will have to be turned
3600 to put No. 1 piston on the compression After TIMING CHECK procedure is complete,
stroke. timing bolt will be engaged in flywheel with No. 1 piston
at top center (TC) position.
INSTALLATION OF TIMING PINS LOOSEN ROCKER SHAFTS

2. Timing pin. 4. Camshaft (L.H.). 1. Bolt. 2. Rocker shaft.
4. With timing bolt installed in flywheel with No. 1
piston now on compression stroke, remove
118
1. Remove all valve covers on the same side of the camshaft drive gear (7). Remove the bolts and
engine that camshaft needs adjustment. Now plate from the left camshaft drive gear.
loosen bolts (1) [that hold all rocker shafts (2) to
valve cover bases] until all rocker arms are free
from the injectors and the valves.
NOTE: The above procedure must be done before

camshaft drive gear (7) is pulled off the camshaft taper.
REMOVE CAMSHAFT DRIVE GEARS (RH SIDE)

6. Bolt. 7. Drive gear. 8. Accessory drive gear for
hydramechanical protective system.
4. Install the 6V3010 Puller Group, two 9S9089

Bolts and two 5P1076 Washers. Loosen drive
REMOVE COVER (LH SIDE) gears (7) from the taper on the camshafts.
3. Cover. Remove the tooling and the gears.
2. Remove camshaft drive gear cover (3) from the 5. Remove timing pin(s) (10) from the storage
left side of the flywheel housing. Remove position (under the rear camshaft covers) on
hydramechanical shutoff control group (5) and each side of the engine.
the shutoff drive (4) from the right side of the
flywheel housing.
NOTE: See DISASSEMBLY AND ASSEMBLY install the

hydramechanical protective system.
CAMSHAFT TIMING
9. Timing hole. 10, Timing pin.
REMOVE HYDRAMECHANICAL PROTECTIVE 6. Turn the camshafts until timing pins (10) can be
SYSTEM (RH SIDE) installed through timing holes (9) and into the
4. Hydramechanical shutoff drive. 5. Hydramechanical grooves (slots) in the camshafts.
shutoff control group.
3. Remove bolts (6) and gear (8) from the right
119
and timing pins.
INSTALL CAMSHAFT DRIVE GEARS

7. Drive Gear.
STORAGE POSITION FOR TIMING PINS
7. Install camshaft drive gears (7) as follows: 10. Timing pin. 11. Cover.
a. Put camshaft drive gears (7) in position on 11. Install the 5M6213 Plug in the flywheel housing
the camshafts. timing hole. Remove the engine turning pinion
and install the cover and gasket.
b. Use hand pressure to turn and hold
camshaft drive gears (7) in the direction of 12. Make sure the rocker arms are engaged
normal engine rotation. This removes all correctly with the push rods and tighten the bolts
gear clearance (backlash) between to hold all of the rocker shafts in position.
camshaft drive gears (7) and the idler gear.
13. Make adjustments to the valves and injector
c. Install the plate (on left side of engine) and timing. See VALVE CLEARANCE SETTING
drive gear (8) for the hydramechanical and FUEL TIMING for the correct procedures.
protective system (on right side of engine)
to hold camshaft drive gears (7) to the START UP PROCEDURE
camshaft.
Use this procedure when an engine is started for
d. Tighten the bolts in steps to a torque of 100 the first time after work is done on the fuel system or
± 15 Nâm (75 ± 11 lb. ft.). governor.
e. Hit the face of the plate and drive gear and 1. Disconnect the air inlet system from the
tighten the bolts to a torque of 100 ± 15 turbochargers.
Nâm (75 ± 11 lb. ft.).
2. Have a person in position near each
f. Again hit the face of the plate and drive turbocharger air inlet with a piece of steel plate
gear and again tighten the bolts to a torque large enough to completely cover the
of 100 ± 15 Nâm (75 ± 11 lb. ft.). turbocharger air inlet.
NOTE: If necessary, do Step 7f until the bolts hold

torque (can not be moved) to make sure the drive gears
are in full contact with the taper on the camshafts. Be careful when plate is put against air inlet opening.
Due to excessive suction, the plate can be pulled quickly
8. Install the gasket and cover on the left side of against air inlet openings. To avoid crushed fingers, do
the flywheel housing. not put fingers between plate and air inlet opening.
9. Install the hydramechanical protective system on

the right side of the flywheel housing. 3. Start the engine. If the engine starts to run too
fast or runs out of control, immediately put the
10. Remove timing pins (10) from the camshafts. steel plates against the turbocharger air inlets.
Remove the timing bolt from the flywheel This will stop the air supply to the engine, and
housing. Install timing pins (10) in their storage the engine will stop.
positions. Install covers (11) over the camshafts
120
CRANKSHAFT POSITIONS FOR FUEL TIMING AND VALVE CLEARANCE SETTING

STANDARD ROTATION (COUNTERCLOCKWISE)
- as Viewed From Flywheel End
ENGINE CORRECT STROKE CYLINDERS TO CHECK/ADJUST
FOR NO.1 PISTON VALVES INJECTORS
AT TOP CENTER
POSITION* INTAKE EXHAUST
3508 COMPRESSION 1-2-6-8 1-2-3-7 3-4-5-7
EXHAUST 3-5-4-7 4-5-6-8 1-2-6-8
3512 COMPRESSION 1-3-6-7-10-12 1-4-5-6-9-12 2-4-5-8-9-11
EXHAUST 2-4-5-8-9-11 2-3-7-8-10-11 1-3-6-7-10-12
3516 COMPRESSION 1-2-5-7-8-12-13-14 1-2-3-4-5-6-8-9 3-4-6-9-10-11-15-16
EXHAUST 3-4-6-9-10-11-15-16 7-10-11-12-13-14-15-16 1-2-5-7-8-12-13-14
REVERSE ROTATION (CLOCKWISE)

FOR NO.1 PISTON
AT TOP CENTER VALVES INJECTORS
POSITION*
INTAKE EXHAUST
3508 COMPRESSION 1-3-4-8 1-2-7-8 2-5-6-7
EXHAUST 2-5-6-7 3-4-5-6 1-3-4-8
3512 COMPRESSION 1-3-4-6-7-12 1-4-5-8-9-12 2-5-8-9-10-11
EXHAUST 2-5-8-9-10-11 2-3-6-7-10-11 1-3-4-6-7-12
3516 COMPRESSION 1-2-5-6-7-8-13-14 1-2-3-4-5-6-9-10 3-4-9-10-11-12-15-16
EXHAUST 3-4-9-10-11-12-15-16 7-8-11-12-13-14-15-16 1-2-5-6-7-8-13-14
*Put No. 1 piston at top center (TC) position and make identification for the correct stroke. Make reference to FINDING
TOP CENTER POSITION FOR NO. 1 PISTON. After top center position for a particular stroke is found and adjustments
are made for the correct cylinders, remove the timing bolt and turn the flywheel 3600 in the direction of normal engine
rotation. This will put No. 1 piston at top center (TC) position on the other stroke. Install the timing bolt in the flywheel and
complete the adjustments for the cylinders that remain.

(3512 SHOWN)121
121
FUEL TIMING 2.Install the 8S3675 Contact Point on the dial indicator
stem.
Tools Needed:
6V3139 Timing and Fuel Setting Tool Group. 3. Install 6V3075 Dial Indicator (2) in the collet of
8S3675 Contact Point, 3.0 mm (.12 in.) long. 6V3118 Timing Fixture (4).
6V3075 Dial Indicator (Metric).
6V3117 Set Gauge.
6V3118 Timing Fixture.
9S9082 Engine Turning Tool.
NOTICE
The camshafts must be correctly timed with the
crankshaft before an adjustment of fuel timing is
made. The timing pins must be removed from the
camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.
ADJUSTMENT OF FUEL TIMING TOOLS
1. See chart CRANKSHAFT POSITIONS FOR 4. Put the dial indicator and timing fixture on
FUEL TIMING AND VALVE CLEARANCE 6V3117 Set Gauge (1) with the angle of the
SETTING and put the engine in time. With the timing fixture on the top surface and the
two crankshaft positions given in the chart, all of extension rod on the bottom step.
the injectors can be checked or adjusted. This
will make sure the pushrod lifters are off the 5. Move the dial indicator in the collet until the
lobes and on the base circles of the camshafts. pointers indicate zero. Now move the dial
indicator in the collet until the large pointer
NOTE: See the Fuel Setting And Related Information indicates setting shown in the DIAL INDICATOR
Fiche for the correct fuel timing dimension to use. SETTING CHART (if other than zero setting) and
tighten the collet.
Before a check or an adjustment of the fuel
timing can be made, the tooling must be set to the *DIAL INDICATOR SETTING CHART
correct dimension as follows:
Fuel Timing Dial Indicator
Dimension mm Setting mm
88.28 +1.28
88.07 +1.07
87.85 +0.85
87.64 +0.64
87.43 +0.43
87.21 +0.21
87.00 0.00
86.79 --0.21
86.57 --0.43
86.36 --0.64
86.15 -0.84
85.93 -1.07
FUEL TIMING TOOLS
85.72 -1.28
1. 6V3117 Set Gauge. 2. 6V3075 Dial Indicator
*See Fuel Setting Information for the correct fuel timing
(metric). 3. 8S3675 Contact Point, 3.0 mm (.12 in.)
dimension to use.
long. 4. 6V3118 Timing Fixture.
122
6. Make sure the top surfaces of injector follower

(5) and shoulder (6) are clean and dry.
7. Put 6V3075 Dial Indicator (2) and 6V3118

Timing Fixture (4) in position on the injector to be
checked. Make sure the angle of the timing
fixture is on the top surface of follower (5) and
the extension rod is on the top surface of injector
shoulder (6) as shown in illustration.
FUEL TIMING TOOLS IN POSITION
13. Turn the adjustment screw until zero is read on

the dial indicator. Tighten the adjustment screw
locknut to a torque of 70 ± 15 N-m (50 ±11 lb. ft.)
and check adjustment again. If necessary, do
this procedure again until the adjustment is
correct.
FUEL TIMING TOOLS IN POSITION

2. 6V3075 Dial Indicator (metric). 4.6V3118 Timing
Fixture. 5. Injector follower. 6. Shoulder on injector
body. ADJUSTMENT OF FUEL TIMING
8. The dial indicator pointers must indicate 0.00 ± 14. Remove the timing bolt from the flywheel when
0.20 mm. the fuel timing check is completed.
9. If the dial indicator pointers indicate zero, or are

within the tolerance given in Step 8, no
adjustment is necessary. Proceed to Step 14.
10. If the dial indicator pointers do not indicate 0.00 INJECTOR SYNCHRONIZATION
± 0.20 mm, do Steps 11 through 14.
Tools Needed:
11. Loosen the push rod adjustment screw locknut 6V3119 Rack Synchronizing Gauge.
for the injector to be adjusted.
Injector synchronization is the setting of all
12. Put 6V3075 Dial Indicator (2) and 6V3118 injector racks to a reference position so each injector
Timing Fixture (4) in position on the injector to be gives the same amount of fuel to each cylinder. This is
adjusted. Make sure that both edges of the done by setting each injector rack to the same position
angle of the timing fixture sets flat on the top while the control linkage is in a fixed position (called the
surface of follower (5), and the extension rod is synchronizing position). The procedure for adjustment of
on the top surface of injector shoulder (6). injector synchronization is as follows:
123
LOCATION OF FUEL SETTING COVER LOCATION FOR GAUGE AND CONTROL ROD
AND SYNCHRONIZING PIN ADJUSTMENT
1. Plug. 2. Synchronizing pin. 3. Cover. (Rocker Shaft Removed for Illustration)
1. The top bolt that holds cover (3) in position is 5. 6V3119 Rack Synchronizing Gauge [12.7 mm (.50
synchronizing pin (2). Remove synchronizing pin in.)]. 6. Control rod.
(2) and plug (1) from the front drive housing. DO
NOT destroy seal or remove cover (3). 3. Turn the governor or actuator terminal shaft to
the fuel "ON" position until the flat face of fuel
2. Remove the washer from synchronizing pin (2) stop lever (4) contacts synchronizing pin (2).
and install it into the threaded hole where plug This is the synchronizing position or zero
(1) was removed. Tighten synchronizing pin (2). reference point. Hold the control linkage in this
position when the injectors are adjusted.
4. Remove the valve covers.
5. With the fuel stop lever against the

synchronizing pin, put 6V3119 Rack
Synchronizing Gauge (5) on the round part of the
injector rack between the injector body and the
end of the rack. Use a screwdriver and make an
adjustment of control rod (6). Turn the screw on
control rod (6) one "click" at a time until rack
synchronizing gauge (5) just Fits between the
injector body and the shoulder at the end of the
rack. Remove the screwdriver from control rod
(6) so no pressure is on the linkage while the
setting is checked with rack synchronizing
gauge(5). Any pressure on the linkage with the
screwdriver will not give a correct indication
when the setting is checked with the rack
synchronizing gauge. To make sure the linkage
is free and giving the correct setting, move (flip)
SYNCHRONIZING POSITION the linkage and check the setting again. Put the
(Governor Fastener Cover Removed Only For box end of a 9/16" or 5/8" combination wrench
Illustration) over the nut and bolt that holds control rod (6)
and the bellcrank together. Pull up on the control
rod two or three times; then check the setting
2. Synchronizing pin. 4. Fuel stop lever.
again.
124
Fuel Setting Check
Fuel setting is the adjustment of the fuel setting

screw to a specified position. The fuel setting screw
limits the power output of the engine by setting the
maximum travel of all the injector racks.
GAUGE IN POSITION ON INJECTOR RACK

(Rocker Shaft Removed for Illustration)
5. 6V3119 Rack Synchronizing Gauge [12.7 mm (.50
in.)]. 7. Fuel injector rack.
SYNCHRONIZATION AND FUEL SETTING TOOLS

1. 6V3119 Rack Synchronizing Gauge. 2. 6V3075
Dial Indicator (metric). 3. 5P4814 Collet. 4. 5P7263
Contact Point, 76.2 mm (3.00 in.) long.
Before the fuel setting is checked, the injectors must be

correctly synchronized. See the subject INJECTOR
SYNCHRONIZATION. After the injectors are
synchronized correctly, leave the synchronizing pin in
place for the procedure that follows.
1. Put 6V3075 Dial Indicator (2) with 5P7263

ADJUSTMENT OF FUEL CONTROL ROD Contact Point (4) in 5P4814 Collet (3). Remove
5. 6V3119 Rack Synchronizing Gauge. the plug from the right side of fuel setting cover
(8).
6. Use rack synchronizing gauge (5) and, if
necessary, make the adjustment to the other
injectors, When all adjustments have been
made, release the actuator terminal shaft.
7. Install the valve covers.
8. Make a check of the fuel setting and make

adjustments if necessary. See FUEL SETTING
AND RELATED INFORMATION FICHE for this
procedure.
FUEL SETTING
Tools Needed:
6V3139 Timing and Fuel Setting Tool Group.
5P4814 Collet.
6V3075 Dial Indicator (metric). INSTALL DIAL INDICATOR
5P7263 Contact Point, 76.2 mm (3.00 in.) long.
6V3119 Rack Synchronizing Gauge 12.7 mm (.50 2. 6V3075 Dial Indicator with 5P7263 Contact Point
in.). attached. 3. 5P4814 Collet.
125
2. Move the governor or actuator terminal shaft in NOTE: See FUEL SETTING AND RELATED
the fuel "ON" direction until the flat face of fuel INFORMATION for the correct fuel setting.
stop lever (6) contacts synchronizing pin (5).
Hold the linkage in this position. 5. If fuel setting is correct, remove the dial indicator
and synchronizing pin (5). Install the two plugs,
and install pin (5) back into cover (8).
6. If fuel setting needs adjustment, go on to Fuel

Setting Adjustment.
Fuel Setting Adjustment
NOTICE
A mechanic with governor and fuel setting training is
the ONLY one to make adjustments to the engine
DIAL INDICATOR IN POSITION fuel setting.
(Cover Removed Only for Photo Illustration)
2. 6V3075 Dial Indicator. 4. 5P7263 Contact Point, 1. Cut the seal wire and remove fuel setting cover
76.2 mm (3.00 in.) long. 5. Synchronizing pin. 6. (8) and the gasket. Loosen locknut (7) and (with
Fuel stop lever. fuel stop lever still held against end of the fuel
setting screw) turn the fuel setting screw in or
3. Install the dial indicator and collet (3) in the out until the correct reading is on the dial
threaded hole as shown. When the contact point indicator.
seats against fuel stop lever (6), slide the dial
indicator in or out until the indicator reads zero.
Now tighten collet (3) just enough to hold
indicator at this position.
ADJUSTMENT OF THE FUEL SETTING SCREW

CHECKING FUEL SETTING
2. 6V3075 Dial Indicator (metric). 5. Synchronizing
pin. 8. Fuel setting cover. 2. Now tighten locknut (7). Be sure that the fuel
setting screw does not turn when the locknut (7)
4. Turn synchronizing pin (5) back out a minimum is tightened. Release the fuel linkage and again
of 25 mm (1 in.) (or remove it completely), and move linkage all the way in the fuel "ON"
then slowly move the governor or actuator direction. Check the dial indicator reading again
terminal shaft in the fuel "ON" direction until the to be sure that fuel setting is still correct.
flat face of the fuel stop lever is against the end
of the fuel setting screw. With the linkage held 3. Remove the dial indicator and synchronizing pin
in this position, the dial indicator reading will be (5), then install the two plugs. (5), then install the
the present fuel setting. two plugs.
126
ENGINE SPEED MEASUREMENT
6V3121 MULTITACH GROUP

INSTALL COVER
7. Locknut. 8. Fuel setting cover. The 6V3 121 Multitach Group can measure
engine speed from a tachometer drive on the engine. It
4. Put fuel setting cover (8) and gasket in position also has the ability to measure engine speed from visual
over the fuel setting screw and install bolt and engine parts in rotation.
synchronizing pin (5) in cover. Install a new seal
wire. Special Instruction, Form No. SEHS7807 is with
the 6V3121 Multitach Group and gives instructions for
the test procedure.
127
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
WOODWARD UG8 LEVER GOVERNOR
COMPENSATING ADJUSTMENT 6. Slowly turn the needle valve in a clockwise

direction until the engine surge just stops.
Although the governor may appear to be
operating satisfactorily at no load, high overspeeds and 7. Now check the number of turns the needle valve
underspeeds after load changes and slow return to is open. To find the number of turns the needle
normal speed are the results of incorrect compensation valve is open, close the valve completely and
adjustments. make a note of the number of turns needed to
close the valve.
After the temperature of the engine and the oil in
the governor have reached normal operating values, 8. Open the needle valve to the same position at
make compensation adjustments with the engine running which the engine did not surge (Step 6).
at no load conditions.
9. Move the governor linkage to change the engine
speed. If the engine does not surge, and the
needle valve is 1/2 to 3/4 of a turn open, the
governor adjustment is correct. Install plug (3) in
the base. If the needle valve is more than 3/4 of
a turn open, do the steps that follow.
10. Loosen nut (2) and move compensation pointer

(1) up two marks on the pointer scale.
11. Turn the needle valve three to five turns in a

counterclockwise direction.
12. Let the engine surge for approximately 30

seconds to help remove air from the governor oil
passages.
13. Slowly turn the needle valve in a clockwise

direction until the engine surge just stops.
UG8 LEVER GOVERNOR 14. Now check the number of turns the needle valve
1. Compensation pointer. 2. Nut. 3. Plug. is open. To find the number of turns the needle
valve is open, close the valve completely and
1. Loosen nut (2) that holds compensation pointer make a note of the number of turns needed to
(1) and move the pointer up as far as it will go. close the valve.
Tighten the nut.
15. Open the needle valve to the same position at
2. Remove plug (3) from the base of the governor which the engine did not surge (Step 13).
to get access to the needle valve.
16. Move the governor linkage to change the engine
3. Use a screwdriver and turn the needle valve speed. If the engine does not surge, and the
three to five turns in a counterclockwise (open) needle valve is 1/2 to 3/4 of a turn open, the
direction. Make sure the screwdriver engages governor adjustment is correct. Install plug (3) in
with the shallow slot of the compensating needle the base. If the needle valve is more than 3/4 of
valve and not in the deep slot that is at right a turn open, do Steps 10 thru 16 again.
angles to the shallow screwdriver slot.
A needle valve that is opened less than 1/2 turn
4. Let the engine surge for approximately 30 will cause a slow return of the engine to normal speed
seconds to help remove air from the governor oil after a load change.
passages.
If the compensation pointer is too far toward the
5. Loosen nut (2) that holds compensation pointer maximum position, the engine speed change will be too
(1) and move the pointer down as far as it will great when the load changes.
go. Tighten the nut.
128
LOW AND HIGH IDLE SPEED ADJUSTMENT
Connect a tachometer with good accuracy to the

engine. Make reference to MEASURING ENGINE
SPEED.
1. Start the engine and run to get the engine to the

normal temperature of operation.
LOW AND HIGH IDLE STOP LEVER

6. Low and high idle stop lever.
SPEED DROOP ADJUSTMENT
Adjustment for Zero Droop
Tools Needed:
8S2328 Dial Indicator Group.
LOW AND HIGH IDLE ADJUSTMENT 5P7264 Indicator Contact Point Group.
1. Low idle adjustment screw. 2. Locknut. 3. Locknut.
4. High idle adjustment screw. 5. Governor speed 1. Disconnect the engine oil pressure and air inlet
adjustment shaft. pressure lines for the air fuel ratio control
housing.
2. Move the governor speed adjusting shaft (5) to
run the engine at high idle speed. Loosen
locknut (3) and turn high idle adjustment screw
(4). Turn adjustment screw (4) clockwise to
decrease engine speed and counterclockwise to
increase engine speed.
3. After the high idle speed has been adjusted,

tighten the locknut and check high idle speed
again.
NOTE: Make reference to the Fuel Setting Information

Fiche for the correct low and high idle speed.
4. Move the governor speed adjusting shaft (5) to

run the engine at low idle speed. Loosen locknut
(2) and turn low idle adjustment screw ( I ). Turn
adjustment screw ( I ) clockwise to increase low
idle speed and counterclockwise to decrease low
idle speed.
COVER AND SHUT-OFF SOLENOID
1. Cover assembly.
2. Remove the oil level gauge from cover assembly

(1).
129
3. Remove the screws that hold cover assembly ( )

in position. Remove cover assembly (I ) and the
shut-off actuator as a unit from the governor.
OIL PRESSURE LINE TO AIR FUEL RATIO CONTROL

2. Junction block. 3. Oil pressure line (from rotating
bushing).
GOVERNOR SHUT-OFF STRAP
4. Remove the screw and pull junction block (2) 6. Shut-off strap.
from oil pressure line (3).
6. Move shut-off strap (6) off the pins in the governor
housing and remove it.
REMOVAL OF AIR FUEL RATIO CONTROL

3. Oil pressure line. 4. Air fuel ratio control housing. 5.
Lever. 6. Shut-off strap.
5. Remove the eight bolts that hold air fuel ratio DROOP ADJUSTMENT
control housing (4) to the governor housing. Lift 7. Speeder plug. 8. Droop cam. 9. Screw. 10.
the unit until lever (5) is disconnected from the Bracket. 11. Terminal shaft.
compensation lever. Turn and lift the unit to
move the air fuel ratio control around and off 7. Install the 3S3269 Contact Point, 25.4 mm( 1.00
shut-off strap (6). Be careful not to damage in.) long on the dial indicator. Put the dial
pressure line (3) when the air fuel ratio control is indicator in position on the governor with the
removed. contact point on bracket (10) of speeder plug (7).
Adjust the dial of the indicator to zero.
130
DROOP ADJUSTMENT
10. Bracket. AIR FUEL RATIO CONTROL OIL LINE
13. Junction block.
8. Move governor terminal shaft (11) from the
maximum position to the minimum position. The
dial indicator must read 0.00 to 0.05 mm (.000 to
.002 in.) for zero droop.
9. If the droop adjustment is not correct, loosen

screw (9) and move droop cam (8). Tighten
screw (9). Move droop cam (8) toward speeder
plug (7) to increase droop, and away from the
speeder plug to decrease droop.
10. Check the speed droop adjustment again with

the dial indicator.
11. Install the shut-off strap in the governor.

GOVERNOR COVER ASSEMBLY
14. Oil level gauge. 15. Cover assembly.
12. Install the air fuel ratio control over the shut-off
strap. Make sure lever (5) is engaged correctly
14. Install the shut-off actuator and cover assembly (
with compensation lever (12) and install the
15) on the air fuel ratio control housing. Install
screws to hold the unit to the governor.
oil level gauge (14) in the cover assembly.
15. Connect the engine oil pressure and air inlet

pressure lines to the air fuel ratio control
housing.
Adjustment for Positive Droop
1. Remove the air fuel ratio control from the

governor. See Steps I thru 6 in Adjustment for
Zero Droop.
2. Connect a tachometer with good accuracy to the

engine. Make reference to MEASURING
ENGINE SPEED.
GOVERNOR ASSEMBLY
12. Compensation lever. 3. Loosen screw (9) and move droop cam (8) on
droop lever ( 16) to get distance (A) for the droop
13. Make sure the O-ring seals are installed on the percentage needed. See SPEED DROOP
oil pressure line and into the air fuel ratio control. CHART to get the dimension needed.
Install junction block (13).
131
Error! Not a valid filename. 9. Do Steps I thru 8 to check the speed droop and
adjust again if needed.
SPEED DROOP ASSEMBLY
8. Droop cam. 9. Screw. 16. Droop lever. A. Speed AIR FUEL RATIO CONTROL
droop setting.
The UG8 Lever governors are equipped with an
SPEED DROOP CHART air fuel ratio control. Most adjustments are made at the
Droop Percentage Distance A factory or when the unit is rebuilt and there is a test
3 8.33 mm (.328 In.) bench available to make the adjustments. The following
5 6.76 mm (.266 in.) adjustment can be used to control acceleration smoke
10 3 58 mm (.141 in) and engine response.
Adjustment
NOTE: Dimension (A) is an approximate dimension.
The final adjustments must be determined with the
NOTE: Engine must be shutdown before making this
engine running.
adjustment to keep dirt and foreign material out of the
governor.
4. Install the air fuel ratio control on the governor.
See Steps 12 thru 16 in the Adjustment for Zero
1. Remove the cover assembly and shut-off
Droop. Start the engine and run to get the
actuator as a unit from the top of the governor.
engine to the normal temperature of operation.
2. Turn adjusting screw (I) clockwise to reduce
5. Put a load on the engine to get maximum full
smoke or counterclockwise to increase engine
load. Make a note of the full load rpm.
response.
6. Remove all load from the engine and make a
3. Turn the adjusting screw 1/2 turn or less in the
note of the no load high idle rpm.
desired direction.
7. Find the difference of the no load high idle rpm
4. Replace the top cover assembly and shut-off
and the full load rpm. Divide the difference by
actuator on the governor.
the full load rpm and multiply times 100. The
result is the percent of speed droop.
5. Start the engine and check the acceleration
smoke and engine response to see if further
No load high idle speed full load rpm X 100 = % of
adjustment is necessary. If necessary repeat
Full load rpm speed droop
Steps I, 2 and 3.
8. If the speed droop is not correct, stop the engine
and move droop cam (8) toward speeder plug Error! Not a valid filename.
(7) to increase speed droop, or move away from
the speeder plug to decrease speed droop. LOCATION OF ADJUSTMENT SCREW
1. Adjusting screw.
132
RESTRICTION OF AIR INLET AND EXHAUST
There will be a reduction of horsepower and

efficiency of the engine if there is a restriction in the air
inlet or exhaust system.
Air flow through the air cleaner must not have a

restriction (negative pressure difference measurement
between atmospheric air and air that has gone through
air cleaner) of more than 762 mm (30 in.) of water.
Back pressure from the exhaust (pressure

difference measurement between exhaust at outlet
elbow and atmospheric air) must not be more than 686
mm (27 in.) of water. PRESSURE TEST LOCATION
1. Inlet water elbow to aftercooler. 2. Elbow or plug for
MEASUREMENT OF PRESSURE IN INLET MANIFOLD aftercooler air chamber pressure.
The efficiency of an engine can be checked by Use the 6V3150 Engine Pressure Group to
making a comparison of the pressure in the inlet check the pressure in the inlet manifold.
manifold with the information given in the FUEL
SETTING AND RELATED INFORMATION FICHE. This
test is used when there is a decrease of horsepower
from the engine, yet there is no real sign of a problem
with the engine.
The correct pressure for the inlet manifold is

given in the FUEL SETTING AND RELATED
INFORMATION FICHE. Development of this information
is done with these conditions:
a. 737 mm (29 in.) of mercury barometric

pressure (dry).
b. 29à C (850 F) outside air temperature.

6V3150 ENGINE PRESSURE GROUP
c. 35 API rated fuel. 1. Differential pressure gauges. 2. Zero adjustment
screw. 3. Pressure gauge 0 to 100 kPa (0 to 160 psi).
On a turbocharged aftercooled engine, a change 4. Pressure tap. 5. Pressure gauge 0 to 415 kPa (O to
in fuel rating will also change horsepower and the 60 psi).
pressure in the inlet manifold. If the fuel is rated above
35 API, pressure in the inlet manifold can be less than This tool group has a gauge to read pressure in
given in the FUEL SETTING AND RELATED the inlet manifold. Special Instruction, Form No.
INFORMATION FICHE. If the fuel is rated below 35 API, SEHS7851 is with the tool group and gives instructions
the pressure in the inlet manifold can be more than given for its use.
in the FUEL SETTING AND RELATED INFORMATION
FICHE. BE SURE THAT THE AIR INLET AND
EXHAUST DO NOT HAVE A RESTRICTION WHEN
MAKING A CHECK OF PRESSURE IN THE INLET
MANIFOLD.
133
AIR INLET AND EXHAUST SYSTEM TESTING AND ADJUSTING
EXHAUST TEMPERATURE Valves
Valve removal and installation is easier with use

of the IP3527 Valve Spring Compressor Assembly.
Valve Seat Inserts
To remove and install valve seat inserts, use the

6V4805 Valve Seat Extractor Group. For installation,
lower the temperature of the insert before it is installed in
the head.
Valve Guides
Tools needed to remove and install valve guides

are the 5P1729 Bushing and 7M3975 Driver. The
counterbore in the driver bushing installs the guide to the
1P3060 PYROMETER GROUP correct height. Use a I P7451 Valve Guide Honing
Group to make a finished bore in the valve guide after
Use the IP3060 Pyrometer Group to check installation of the guide in the head. Special Instruction,
exhaust temperature. Special Instruction, Form No. Form No. SMHS7526 gives an explanation for this
SMHS7179 is with the tool group and gives instructions procedure. Grind the valves after the new valve guides
for the test procedure. are installed.
CRANKCASE (CRANKSHAFT Checking Valve Guide Bores

COMPARTMENT) PRESSURE
Use the 5P3536 Valve Guide Gauge Group to
Pistons or rings that have damage can be the check the bore of the valve guides. Special Instruction,
cause of too much pressure in the crankcase. This Form No. GMG02562 gives complete and detailed
condition will cause the engine to run rough. There will instructions for use of the 5P3536 Valve Guide Gauge
also be more than the normal amount of fumes coming Group.
from the crankcase breather. This crankcase pressure
can also cause the element for the crankcase breather to
have a restriction in a very short time. It can also be the
cause of oil leakage at gaskets and seals that would not
normally have leakage.
COMPRESSION
An engine that runs rough can have a leak at the
valves, or have valves that need adjustment. Removal
of the head and inspection of the valves and valve seats
is necessary to find those small defects that do not
normally cause a problem. Repair of these problems is
normally done when reconditioning the engine.
CYLINDER HEADS
The cylinder heads have valve seat inserts,

valve guides and bridge dowels that can be removed
when they are worn or have damage. Replacement of
these components can be made with the tools that
follow.
SP3536 VALVE GUIDE GAUGE GROUP
134
Bridge Dowels
5. Turn adjustment screw (5) clockwise until it just
Use a 5P944 Dowel Puller Group with a 5P942 makes contact with valve stem (3). Then turn
Extractor to remove the bridge dowels. Install a new the adjustment screw 20 to 300 more in a
bridge dowel with a 6V4009 Dowel Driver. This dowel clockwise direction to make the bridge straight
driver installs the bridge dowel to the correct height. on the dowel, and to make compensation for the
clearance in the threads of the adjustment
BRIDGE ADJUSTMENT screw.
When the cylinder head is disassembled, keep

the bridges with their respective valves. To make an
adjustment to the bridges, use the procedure that
follows:
NOTE: The only time bridge adjustment is necessary is

when a valve has been replaced, ground, or cylinder
head has been reconditioned. Valves must be fully
closed when adjustment is made. To find when valves
are fully closed, see subject FINDING TOP CENTER
POSITION FOR NO. 1 PISTON and chart
CRANKSHAFT POSITIONS FOR INJECTOR TIMING
AND VALVE CLEARANCE SETTING.
1. Put engine oil on bridge dowel (4) in the cylinder BRIDGE ADJUSTMENT
head and in the bore in bridge (2). 5. Adjustment screw.
2. Install bridge (2) with adjustment screw (5) 6. Hold adjustment screw (5) in this position and
toward the exhaust manifold. tighten the locknut to 30 ± 4 Nâm (22 ± 3 lb. ft.).
BRIDGE INSTALLATION
1. Top contact surface. 2. Bridge. 3. Valve stem. 4.
Bridge dowel.
TIGHTEN LOCKNUT
3. Loosen the locknut for adjustment screw (5) and
loosen the adjustment screw several turns. 7. Put engine oil on top contact surface (I) where
the rocker arm makes contact with the bridge.
4. Put a force of 5 to 45 N (I to 10 lb.) by hand
straight down on top contact surface (I ) of
bridge (2).
135
CRANKSHAFT POSITIONS FOR FUEL TIMING AND VALVE CLEARANCE SETTING
STANDARD ROTATION (COUNTERCLOCKWISE)

as Viewed From Flywheel End
FOR NO. PISTON
POSITION*
INTAKE EXHAUST
3508 COMPRESSION 1-2-6-8 1-2-3-7 3-4-5-7
EXHAUST 3-5-4-7 4-5-6-8 1-2-6-8
3512 COMPRESSION 1-3-6-7-10-12 1-4-5-6-9-12 2-4-5-8-9-11
EXHAUST 2-4-5-8-9-11 2-3-7-8-10-11 1-3-6-7-10-12
3516 COMPRESSION 1-2-5-7-8-12-13-14 1-2-3-4-5-6-8-9 3-4-6-9-10-11-15-16
EXHAUST 3-4-6-9-10-11-15-16 7-10-11-12-13-14-15-16 1-2-5-7-8-12-13-14
REVERSE ROTATION (CLOCKWISE)

FOR NO.1 PISTON
POSITION*
INTAKE EXHAUST
3508 COMPRESSION 1-3-4-8 1-2-7-8 2-5-6-7
EXHAUST 2-5-6-7 3-4-5-6 1-3-4-8
3512 COMPRESSION 1-3-4-6-7-12 1-4-5-8-9-12 2-5-8-9-10-11
EXHAUST 2-5-8-9-10-11 2-3-6-7-10-11 1-3-4-6-7-12
3516 COMPRESSION 1-2-5-6-7-8-13-14 1-2-3-4-5-6-9-10 3-4-9-10-11-12-15-16
EXHAUST 3-4-9-10-11-12-15-16 7-8-11-12-13-14-15-16 1-2-5-6-7-8-13-14
*Put No. 1 piston at top center (TC) position and make identification for the correct stroke. Make reference to FINDING
TOP CENTER POSITION FOR NO. 1 PISTON. After top center position for a particular stroke is found and adjustments
are made for the correct cylinders, remove the timing bolt and turn the flywheel 360° in the direction of normal engine
rotation. This will put No. 1 piston at top center (TC) position on the other stroke. Install the timing bolt in the flywheel and
complete the adjustments of the cylinders that remain.

(3512 SHOWN)
136
VALVE CLEARANCE 3. Loosen the locknut for the push rod adjustment
screw. If there is not enough clearance for feeler
Valve clearance (lash) is measured between the gauge between rocker arm and bridge contact
rocker arm and the bridge for the valves. All clearance surface, turn the adjustment screw
measurements and adjustments must be made with the counterclockwise to increase the valve
engine stopped, and with the valves FULLY CLOSED. clearance.
Valve Clearance Check VALVE CLEARANCE SETTING: ENGINE STOPPED

VALVES GUAGE DIMENSION
When the valve clearance is checked, Intake 0.28 mm (.015 in.)
adjustment is NOT NECESSARY if the measurement is Exhaust 0.76 mm (.030 in.)
in the range given in the chart for VALVE CLEARANCE
CHECK: ENGINE STOPPED. However, it is the 4. Put a feeler gauge of the correct dimension
recommendation of Caterpillar that the valve clearance between the rocker arm and bridge contact
setting is to be made at the initial (first) 1000 service surface. Turn the adjustment screw clockwise
hours of operation, and every 3000 service hours until the valve clearance is set to the
thereafter. specifications in the chart VALVE CLEARANCE
SETTING: ENGINE STOPPED.
VALVE CLEARANCE: ENGINE STOPPED
VALVES ACCEPTABLE CLEARANCE RANGE
Intake 0.30 to 0.46 mm (.012 to .018 in.)
Exhaust 0.68 to 0.84 mm (.027 to .033 in.)
If the measurement is not within this range, or if

the service meter indication is at the specified interval,
adjustment is necessary. See the subject VALVE
CLEARANCE ADJUSTMENT.
Valve Clearance Adjustment
NOTICE
Due to normal changes (break-in effects) of new or VALVE CLEARANCE ADJUSTMENT
rebuilt engines, the recommended first interval for
valve clearance setting is at 1000 service hours of 5. After each adjustment, tighten the nut for the
engine operation. adjustment screw to a torque of 70 + 15 N-m (50
+ 11 lb. ft.) and check the adjustment again.
Use the procedure that follows for adjustment of
the valves:
1. Put No. 1 piston at top center (TC) position.

Make reference to FINDING TOP CENTER
POSITION FOR NO. 1 PISTON.
2. With No. 1 piston at top center position of the

correct stroke, adjustment can be made to the
valves as shown in the chart CRANKSHAFT
POSITIONS FOR FUEL TIMING AND VALVE
CLEARANCE SETTING.
NOTE: Before any actual adjustments are made, tap (hit TIGHTEN ADJUSTMENT SCREW LOCKNUT
lightly) each rocker arm (at top of adjustment screw) with
a soft hammer to be sure that the lifter roller is seated
against the camshaft base circle.
137
6. Remove the timing bolt and turn the flywheel

3600 in the direction of engine rotation. This will
put No. 1 piston at top center (TC) position on
the opposite stroke. Install the timing bolt in the
flywheel.
7. With No. I piston at top center position of the

opposite stroke, adjustment can be made to the
remainder of the valves as shown in the chart
CRANKSHAFT POSITIONS FOR FUEL TIMING
AND VALVE CLEARANCE SETTING.
8. Repeat Steps 3, 4 and 5 for these valve

adjustments.
9. Remove the timing bolt from the flywheel when

all valve clearances have been adjusted.
138
LUBRICATION SYSTEM TESTING AND ADJUSTING
LUBRICATION SYSTEM
One of the problems in the list that follows will MEASURING ENGINE OIL PRESSURE
generally be an indication of a problem in the lubrication
system for the engine. Tools Needed:
6V3150 Engine Pressure Group or
TOO MUCH OIL CONSUMPTION 5P6225 Hydraulic Test Box.
OIL PRESSURE IS LOW
OIL PRESSURE IS HIGH
TOO MUCH BEARING WEAR
INCREASED OIL TEMPERATURE
TOO MUCH OIL CONSUMPTION
Oil Leakage on Outside of Engine
Check for leakage at the seals at each end of

the crankshaft. Look for leakage at the oil pan gasket INSTRUMENT PANEL
and all lubrication system connections. Check to see if
oil comes out of the crankcase breather. This can be
An oil pressure gauge that has a defect can give an
caused by combustion gas leakage around the pistons.
indication of low or high oil pressure.
A dirty crankcase breather will cause high pressure in the
crankcase, and this will cause gasket and seal leakage.
Oil Leakage Into Combustion Area of Cylinders
Oil leakage into the combustion area of the

cylinders can be the cause of blue smoke. There are
four possible ways for oil leakage into the combustion
area of the cylinders:
1. Oil leakage between worn valve guides and

valve stems.
2. Worn or damaged piston rings, or dirty oil return

holes in the piston.
3. Compression ring and/or intermediate ring not 6V3150 ENGINE PRESSURE GROUP
installed correctly.
1. Differential pressure gauges. 2. Zero
4. Oil leakage past the seal rings in the impeller adjustment screw. 3. Pressure gauge 0 to
end of the turbocharger shaft. 1100 kPa (0 to 160 psi). 4. Pressure tap. 5.
Pressure gauge 0 to 415 kPa (0 to 60 psi).
Too much oil consumption can also be the result
if oil with the wrong viscosity is used. Oil with a thin The 6V3150 Engine Pressure Group can be
viscosity can be caused by fuel leakage into the used to measure the pressure in the system. This tool
crankcase, or by increased engine temperature. group has a gauge to read pressure in the oil manifold.
Special Instruction Form No. SEHS7851 is with the tool
group and gives instruction for its use.
139
LUBRICATION SYSTEM TESTING AND ADJUSTING
Oil Filter Bypass Valve
If the bypass valve for the oil filters is held in the

open position (unseated) because the oil filters have a
restriction, a reduction in oil pressure can result. To
correct this problem, remove and clean the bypass valve
and bypass valve bore. Install new Caterpillar oil filters
to be sure that no more debris makes the bypass valve
stay open.
Too Much Clearance at Engine Bearings or Open

Lubrication System (Broken or Disconnected Oil
Line or Passage)
OIL GALLERY PLUG
6. Plug. Components that are worn and have too much
bearing clearance can cause oil pressure to be low. Low
oil pressure can also be caused by an oil line or oil
passage that is open, broken or disconnected.
Work carefully around an engine that is running. Piston Cooling Jets

Engine parts that are hot, or parts that are moving,
can cause personal injury. When engine is operated, cooling jets direct oil
toward the bottom of the piston to lower piston and ring
Oil pressure to the camshaft and main bearings temperatures. If a jet is broken, plugged or installed
should be checked on each side of the cylinder block at wrong, seizure of the piston will be caused in a very short
oil gallery plug (6). With the engine at operating time.
temperature, minimum oil pressure at full load rpm
should be approximately 280 kPa (40 psi), and minimum OIL PRESSURE IS HIGH
oil pressure at low idle rpm should be approximately 140
kPa (20 psi). Oil pressure will be high if the bypass valve for
the oil pump can not move from the closed position.
OIL PRESSURE IS LOW
TOO MUCH BEARING WEAR
Crankcase Oil Level
When some components of the engine show
Check the level of the oil in the crankcase. Add bearing wear in a short time, the cause can be a
oil if needed. It is possible for the oil level to be too far restriction in an oil passage.
below the oil pump supply tube. This will cause the oil
pump not to have the ability to supply enough lubrication If the gauge for oil pressure shows enough oil
to the engine components. pressure, but a component is worn because it can not
get enough lubrication, look at the passage for oil supply
Oil Pump Does Not Work Correctly to the component. A restriction in a supply passage will
not let enough lubrication get to a component, and this
The inlet screen of the supply tube for the oil will cause early wear.
pump can have a restriction. This will cause cavitation
(low pressure bubbles suddenly made in liquids by INCREASED OIL TEMPERATURE
mechanical forces) and a loss of oil pressure. Air
leakage in the supply side of the oil pump will also cause Look for a restriction in the oil passages of the oil
cavitation and loss of oil pressure. If the bypass valve for cooler. If the oil cooler has a restriction, the oil
the oil pump is held in the open (unseated) position, the temperature will be higher than normal when the engine
lubrication system can not get to maximum pressure. Oil is operated. The oil pressure of the engine will not get
pump gears that have too much wear will cause a low just because the oil cooler has a restriction.
reduction in oil pressure.
Also check the oil cooler bypass valve to see if it
is held in the open position (unseated). This condition
will let the oil through the valve instead of the oil cooler,
and oil temperature will increase.
140
COOLING SYSTEM TESTING AND ADJUSTING
COOLING SYSTEM
This engine has a pressure type cooling system. system problem, temperature and pressure must both be
A pressure type cooling system gives two advantages. checked. Cooling system pressure will have an effect on
The first advantage is that the cooling system can have cooling system temperatures. For an example, look at
safe operation at a temperature that is higher than the the chart to see the effect of pressure and height above
normal boiling (steam) point of water. The second sea level on the boiling (steam) point of water.
advantage is that this type system prevents cavitation
(low pressure bubbles suddenly made in liquids by
mechanical forces) in the water pump. With this type
system, it is more difficult for an air or steam pocket to
be made in the cooling system.
VISUAL INSPECTION OF THE COOLING SYSTEM
The cause for increased engine temperature is

generally because regular inspections of the cooling
system were not made. Make a visual inspection of the
cooling system before a test is made with test
equipment.
Tests Tools for Cooling System
DO NOT loosen the filler cap or pressure cap on a Tools Needed:

hot engine. Steam or hot coolant can cause severe 8T470 Thermistor Thermometer Group.
burns. 9S7373 Air Meter Group.
6V3121 Multitach Group.
1. After the engine is cool, loosen the pressure cap 9S8140 Cooling System Pressurizing Pump
and turn it to the first stop to let pressure out of Group.
the cooling system. Then remove the pressure
cap.
2. Check coolant level in the cooling system.

Work carefully around an engine that is running.
3. Look for leaks in the system. Engine parts that are hot, or parts that are moving,
can cause personal injury.
4. Look for bent radiator fins. Be sure that air flow
through the radiator does not have a restriction.
5. Inspect the drive belts for the fan.
6. Check for damage to the fan blades.
7. Look for air or combustion gas in the cooling

system.
8. Inspect the filler cap and the surface that seals

the cap. This surface must be clean and the
seal must not be damaged.
TESTING THE COOLING SYSTEM 8T470 THERMISTOR THERMOMETER GROUP
Remember that temperature and pressure work

together. When a diagnosis is made of a cooling
141
The 8T470 Thermistor Thermometer Group is

used in the diagnosis of overheating (engine hotter than
normal) or overcooling (engine cooler than normal)
problems. This group can be used to check
temperatures in several different parts of the cooling DO NOT loosen the filler cap or pressure cap on a
system. The testing procedure is in Special Instruction hot engine. Steam or hot coolant can cause severe
Form No. SEHS8446. burns.
The 9S7373 Air Meter Group is used to check

the air flow through the radiator core. The test procedure
is in Special Instruction Form No. SMHS7063.
TYPICAL SCHEMATIC OF PRESSURE CAP A.

A. Sealing surface of cap and radiator.
1. After the engine is cool, loosen the pressure cap

9S7373 AIR METER GROUP to the first stop and let the pressure out of the cooling
system. Then remove the pressure cap.
The 6V3121 Multitach Group can be used to
check the fan speed. Special Instruction Form No. One cause for a pressure loss in the cooling
SEHS7807 is with this group and gives instructions for system can be a bad seal on the pressure cap of the
the procedure. system. Inspect the pressure cap carefully. Look for
damage to the seal or to the surface that seals. Any
foreign material or deposits on the cap, valve, seal, or
surface that seals must be removed.
2. Put the pressure cap on the 9S8140 Cooling

System Pressurizing Pump Group.
6V3121 MULTITACH GROUP
1. Carrying case. 2. Power cable. 3.

Tachometer generator. 4. Tachometer drive
group. 5. Multitach.
Pressure Cap Test

9S8140 COOLING SYSTEM PRESSURIZING PUMP
GROUP
Tools Needed:
9S8140 Cooling System Pressurizing Pump
Group
142
3. Look at the gauge for the exact pressure that 4. Get the pressure reading on the gauge to 20 kPa
makes the pressure cap open. (3 psi) more than the pressure on the pressure
cap.
4. Make a comparison of the reading on the gauge
with the correct pressure at which the pressure 5. Check the radiator for outside leakage.
cap must open.
6. Check all connections and hoses of the cooling
NOTE: The correct pressure that makes the pressure system for outside leakage.
cap open is on the pressure cap and is also in the
SPECIFICATIONS. 7. If you do not see any outside leakage and the
pressure reading on the gauge is still the same
5. If the pressure cap is bad, install a new pressure after 5 minutes, the radiator and cooling system
cap. does not have leakage. If the reading on the
gauge goes down and you do not see any
Radiator and Cooling System Leak Tests (Systems outside leakage, there is leakage on the inside of
That Use Pressure Cap) the cooling system. Make repairs as necessary.
Tools Needed: Water Temperature Gauge Test

9S8140 Cooling System Pressurizing Pump
Group. Tools Needed:
8T470 Thermistor Thermometer Group or
To test the radiator and cooling system for leaks, 2F7112 Thermometer and 6B5072 Bushing
use the procedure that follows:
DO NOT loosen the filler cap or pressure cap on a

hot engine. Steam or hot coolant can cause severe
burns.
1. After the engine is cool, loosen the pressure cap

to the first stop and let the pressure out of the
cooling system. Then remove the pressure cap.
2. Make sure the coolant is over the top of the TEST LOCATION
radiator core. 1. Plug (one on each side of engine).
3. Put the 9S8140 Cooling System Pressurizing Check the accuracy of the water temperature
Pump Group on the radiator. gauge if either of the conditions that follow are found: 1.
The gauge reads normal, but the engine is too hot and a
loss of coolant is found.
2. The gauge shows that the engine is hot, but no

loss of coolant can be found.
Remove plug (1) [1/2 Std. Pipe Thread] and

install the 8T470 Thermistor Thermometer Group or the
2F7112 Thermometer and 6B5072 Bushing. A
temperature gauge of known accuracy can also be used
to make this check.
9S8140 PRESSURIZING PUMP GROUP INSTALLED

ON RADIATOR THAT USES PRESSURE CAP
(TYPICAL EXAMPLE)
143
2. Heat water in a pan until the temperature is 920C

(1970F). Move the water around in the pan to
make it all the same temperature.
Work carefully around an engine that is running.
Engine parts that are hot, or parts that are 3. Hang the regulator in the pan of water. The
moving, can cause personal injury. regulator must be below the surface of the water
and it must be away from the sides and bottom of
Start the engine and run it until the temperature the pan.
reaches the desired range according to the test
thermometer. If necessary, put a cover over part of the 4. Keep the water at the correct temperature for 10
radiator or cause a restriction of the coolant flow. The minutes.
reading on the gauge for water temperature should
agree with test thermometer within the tolerance range of 5. After ten minutes, remove the regulator and
the gauge. Make reference to SPECIFICATIONS or immediately measure the distance the regulator
ATTACHMENT SPECIFICATIONS in this manual to find has opened. The distance must be a minimum of
correct range for a specific gauge. 9.53 mm (.375 in.).
Water Temperature Regulator Test. 6. If the distance is less than 9.53 mm (.375 in.),
make a replacement of the regulator.
1. Remove the regulator from the engine.
V-BELT TENSION CHART

WIDTH TOP BELT TENSION BELT TENSION
BELT WIDTH OF PULLEY “INITIAL” “USED”**
SIZE BELT TOP GROOVE BORROUGHS GAUGE
GAUGE READING GAUGE READING NUMBERS
mm in. mm in. N lb. N lb. OLD GAUGE NO. NEW GAUGE
NO.
3/8 10.72 .422 9.65 .380 445 + 22 100 + 5 400 + 22 90 + 5 BT-33-73F BT-33-95
1/2 13.89 .547 12.70 .500 534 + 22 120 + 5 400 + 44 90 + 10 BT-33-96-4-16 BT-33-95
5V 15.88 .625 15.24 .600 534 + 22 120 + 5 400 + 44 90 + 10 BT-33-72-4-15 BT-33-72C
11/16 17.48 .688 15.88 .625 534 + 22 120 + 5 400 + 44 90 + 10 BT-33-72-4-15 BT-33-72C
3/4 19.05 .750 17.53 .690 534 + 22 120 + 5 400 + 44 90 ± 10 BT-33-72-4-15 BT-33-72C
15/16 23.83 .938 22.30 .878 534 + 22 120 + 5 400 + 44 90 + 10 BT-33-72-4-15 BT-33-72C
MEASURE TENSION OF BELT FARTHEST FROM THE ENGINE
*"INITIAL" BELT TENSION is for a new belt.
**"USED" BELT TENSION is for a belt which has more than 30 minutes of operation at rated speed of engine. A10232-1X1
144
BASIC BLOCK TESTING AND ADJUSTING
BASIC BLOCK
CONNECTING ROD BEARINGS Two 8F6123 3/4"-16NF Bolts, 140 mm (5.5 In.)
long.
The connecting rod bearings fit tightly in the bore Four Washers (3/4"-Copper).
in the rod. If bearing joints or backs are worn (fretted), Four S1575 3/4"-16NF Bolts, 76 mm (3.0 in.)
check bore size. This can be an indication of wear long.
because of a loose fit. 8T455 Liner Projection Tool Group.
Connecting rod bearings are available with 0.63 Check liner projection above the spacer plate as
mm (.025 in.) and 1.27 mm (.050 in.) smaller inside follows:
diameter than the original size bearings. These bearings
are for crankshafts that have been ground (made smaller 1. Make sure the top surface of the cylinder block,
than original size). the liner bores, spacer plates and liner flanges
are clean and dry.
MAIN BEARINGS
2. Install a new gasket and spacer plate (5) on the
Main bearings are available with a larger outside cylinder block.
diameter than the original size bearings. These bearings
are for cylinder blocks that have had the bore for the 3. Install the cylinder liners in the cylinder block
main bearings "bored" (made larger than the original without seals or bands.
size). The size available is 0.63 mm (.025 in.) larger
outside diameter than the original size bearings.
CYLINDER BLOCK
The bore in the block for main bearings can be

checked with the main bearing caps installed without
bearings. Tighten the nuts that hold the caps to the
torque shown in the SPECIFICATIONS section.
Alignment error in the bores must not be more than 0.08
mm (.003 in.). Special Instruction, Form No.
SMHS7606 gives instructions for the use of 1P4000 Line
Boring Tool Group for alignment of the main bearing
bores. The 1P3537 Dial Bore Gauge Group can be used
to check the size of the bores. Special Instruction, Form
No. GMG00981 is with the group.
MEASURING LINER HEIGHT PROJECTION
1. 3H465 Plate. 2. Dial indicator. 3. 1P2402

Gauge Body. 4. S1575 Bolt. 5. Spacer plate.
6. 8B7548 Puller Assembly (Crossbar).
4. Hold the spacer plate and liner in position as

follows:
a. Install four bolts (4) and washers around
each cylinder liner as shown. Tighten the
bolts evenly to a torque of 95 N-m (70 lb.
ft.).
1P3537 DIAL BORE GAUGE GROUP
b. Install crossbar (6), plates (1) and the two
PROJECTION OF CYLINDER LINERS 8F6123 Bolts. Be sure the crossbar is in
position at the center of the liner and the
liner surface is clean. Tighten the bolts
Tools Needed:
evenly to a torque of 70 N-m (50 lb. ft.).
8B7548 Puller Assembly (Crossbar).
Two 2H465 Plates.
145
c. Check the distance from the bottom edge of 1. Fasten a dial indicator to the crankshaft flange
crossbar (6) to the top edge of the spacer so the anvil of the indicator will touch the face of the
plate. The distance on each end of the flywheel housing.
crossbar must be the same.
2. Put a force on the crankshaft toward the rear
5. Use 8T455 Liner Projection Tool Group to before the indicator is read at each point.
measure liner projection.
6. To zero dial indicator (2), use the back of 1

P5507 Gauge with dial indicator (2) mounted in
1P2402 Gauge Body (3).
7. Liner projection must be 0.059 to 0.199 mm

(.0023 to .0078 in.). Make the measurement to
the outer flange of the liner, not the inner ring.
The maximum difference between high and low
measurements made at four places around each
liner is 0.05 mm (.002 in.).
NOTE: If liner projection changes from point to point

around the liner, turn the liner to a new position within the
bore. If still not within specifications, move liner to a
different bore.
NOTE: When liner projection is correct, put a temporary

mark on the liner and spacer plate so when the seals CHECKING FACE RUNOUT OF THE FLYWHEEL
and band are installed, the liner can be installed in the HOUSING
correct position. A. Bottom. B. Right side. C. Top. D. Left side.
3. With dial indicator set at "O" (zero) at location

FLYWHEEL AND FLYWHEEL HOUSING (A), turn the crankshaft and read the indicator at
locations (B), (C) and (D).
Tools Needed:
4. The difference between lower and higher
8S2328 Dial Indicator Group.
Face Run Out (axial eccentricity) of the Flywheel
maximum permissible face run out (axial
Housing eccentricity) of the flywheel housing.
Bore Runout (radial eccentricity) of the Flywheel

Housing
1. Fasten the dial indicator as shown so the anvil of

the indicator will touch the bore of the flywheel
housing.
2. With the dial indicator in position at (C), adjust

the dial indicator to "O" (zero). Push the
crankshaft up against the top of the bearing.
Write the measurement for bearing clearance on
line 1 in column (C) in the CHART FOR DIAL
INDICATOR MEASUREMENTS.
8S2328 DIAL INDICATOR GROUP INSTALLED
146

dial indicator at (C). Write the measurement in
the chart.

dial indicator at (D). Write the measurement in
the chart.
CHART FOR DIAL INDICATOR MEASUREMENTS

Position of dial indicator
Line
No. A B C D
Correction for bearing clearance I 0
Dial Indicator Reading II 0
Total of Line 1 & 2 III 0 •• • ••
8S2328 DIAL INDICATOR GROUP INSTALLED *Total Vertical eccentricity (out of round).
NOTE: Write the dial indicator measurements with **Subtract the smaller No. from the larger No. The
their positive (+) and negative (-) notation (signs). difference is the total horizontal eccentricity.
This notation is necessary for making the
calculations in the chart correctly. A10234X5
3. Divide the measurement from Step 2 by 2. Write 8. Add lines I & II by columns.
this number on line 1 in columns (B) & (D).
9. Subtract the smaller number from the larger
4. Turn the crankshaft to put the dial indicator at number in line III in columns (B) & (D). The
(A). Adjust the dial indicator to "O" (zero). result is the horizontal eccentricity (out of round).
Line III, column (C) is the vertical eccentricity.
dial indicator at (B). Write the measurements in 10. On the graph for total eccentricity, find the point
the chart. of intersection of the lines for vertical eccentricity
and horizontal eccentricity.
11. If the point of intersection is in the range marked

"Acceptable", the bore is in alignment. If the
point of intersection is in the range marked "Not
Acceptable", the flywheel housing must be
changed.
CHECKING BORE RUNOUT OF THE FLYWHEEL

HOUSING
GRAPH FOR TOTAL ECCENTRICITY
147
Face Runout (axial eccentricity) of the Flywheel
1. Install the dial indicator as shown. Always put a

force on the crankshaft in the same direction
before the indicator is read so the crankshaft
end clearance (movement) is always removed.
CHECKING BORE RUNOUT OF THE FLYWHEEL

1. 7H1945 Holding Rod. 2. 7H1645 Holding Rod. 3.
7H1942 Indicator. 4. 7H1940 Universal Attachment.
CHECKING FACE RUNOUT OF THE FLYWHEEL
2. Set the dial indicator to read "0" (zero).

90à.

maximum permissible face runout (axial
Bore Runout (radial eccentricity) of the Flywheel
1. Install the dial indicator (3) and make an

adjustment of the universal attachment (4) so it
makes contact as shown.
2. Set the dial indicator to read "0" (zero).

CHECKING FLYWHEEL CLUTCH PILOT BEARING
BORE
90à.
CHECKING CRANKSHAFT DEFLECTION (BEND)
The crankshaft can be deflected (bent) because
the installation of the engine was not correct. If the
engine mounting rails are not fastened correctly to the
maximum permissible bore runout (radial
foundation mounting rails, the cylinder block can twist or
bend and cause the crankshaft to deflect. This
deflection can cause crankshaft and bearing failure.
5. Runout (eccentricity) of the bore for the pilot
bearing for the flywheel clutch, must not exceed
0.13 mm (.005 in.).
148
The crankshaft deflection must be checked after 4. 4. Turn the crankshaft in the direction of normal
the final installation of the engine. The check must be rotation until the indicator almost makes contact with
made with the engine cold and also with the engine at the connecting rod on the other side of the
the temperature of normal operation. The procedure that crankshaft.
follows can be used to check crankshaft deflection with
the engine either cold or warm. NOTE: Do not let the indicator make contact with the
connecting rod.
1. Remove an inspection cover from the cylinder
block that will give access to the connecting rod 5. The dial indicator reading must not change more
journal of the crankshaft nearest to the center of than 0.03 mm (.001 in.) for the approximately
the engine. 300 degrees of crankshaft rotation. Now turn the
crankshaft in the opposite direction to the
2. Turn the crankshaft in the direction of normal starting position. The dial indicator must now
rotation until the center of the counterweights read zero. If the dial indicator does not read
just go beyond the connecting rod. zero, do the procedure again.
If the dial indicator reads more than 0.03 mm

(.001 in.), the cylinder block is bent. Loosen the bolts
that hold the engine mounting rails to the foundation
mounting rails and adjust the shims to make the engine
straight again. Also check to see if the engine mounting
bolts have enough clearance to let the engine have
expansion as it gets hot.
VIBRATION DAMPER
Damage to or failure of the damper will increase

vibrations and result in damage of the crankshaft.
If the damper is bent or damaged, or if the bolt

MEASURING DEFLECTION OF THE CRANKSHAFT holes in the damper are loose fitting, replace the damper.
(TYPICAL EXAMPLE) Replacement of the damper is also needed at the time of
1. Dial gauge. 2. Mounting face. crankshaft failure (if a torsional type).
3. Install a Starrett Crankshaft Distortion Dial Gauge

No. 696 with Starrett No. 696B Balancer
Attachment between the counterweights as shown.
Put dial gauge (1) within 6.4 mm (.25 in.) of
counterweight mounting surface (2). Turn the dial of
the indicator to get alignment of the zero and the
pointer. Turn the indicator on its end points until the
pointer of the indicator will not move from zero.
149
ELECTRICAL SYSTEM TESTING AND ADJUSTING
ELECTRICAL SYSTEM
TEST TOOLS FOR ELECTRICAL SYSTEM

NOTE: Make reference to Special Instruction Form No.
Tools Needed: SEHS8268 for more complete information for use of the
6V4930 Battery Load Tester. 6V4930 Battery Load Tester.
8T900 AC/DC Clamp-On Ammeter.
6V7070 Heavy-Duty Digital Multimeter or
6V7800 Regular-Duty Digital Multimeter.
Most of the tests of the electrical system can be

done on the engine. The wiring insulation must be in
good condition, the wire and cable connections must be
clean and tight, and the battery must be fully charged. If
the on-engine test shows a defect in a component,
remove the component for more testing.
The service manual TESTING AND

ADJUSTING ELECTRICAL COMPONENTS, Form No.
REG00636 has complete specifications and procedures
for the components of the starting circuit and the
charging circuit. 8T900 AC/DC CLAMP-ON AMMETER
The 8T900 AC/DC Clamp-On Ammeter is a

completely portable, self-contained instrument that
allows electrical current measurements to be made
without breaking the circuit or disturbing the insulation on
conductors. A digital display is located on the ammeter
for reading current directly in a range from 1 to 1200
amperes. If an optional 6V6014 Cable is connected
between this ammeter and one of the digital multimeters,
current readings of less than 1 ammeter can then be
read directly from the display of the multimeter.
A lever is used to open the jaws over the

conductor [up to a diameter of 19 mm (.75 in.)], and the
spring loaded jaws are then closed around the conductor
for current measurement. A trigger switch that can be
locked in the ON or OFF position is used to turn on the
ammeter. When the turn-on trigger is released, the last
6V4930 BATTERY LOAD TESTER current reading is held on the display for 5 seconds.
This allows accurate measurements to be taken in
The 6V4930 Battery Load Tester is a portable limited access areas where the digital display is not
unit in a metal case for use under field conditions and visible to the operator. A zero control is provided for DC
high temperatures. It can be used to load test all 6, 8 an operation, and power for the ammeter is supplied by
12V batteries. This tester has two heavy-duty load batteries located inside the handle.
cables that can easily be fastened to the battery
terminals, and a load adjustment knob on the front panel
permits a current range up to a maximum of 700 NOTE: Make reference to Special Instruction Form No.
amperes. The tester also has a thermometer to show SEHS8420 for more complete information for use of the
when the safe operating temperature limit of the unit has 8T900 Clamp-On Ammeter.
been reached.
150
condition of the charge in the battery. Damage to the

charging unit will result if the connections (either positive
or negative) between the battery and charging unit are
broken while the charging unit is in operation. This is
because the battery load is lost and there is an increase
in charging voltage. High voltage will damage, not only
the charging unit, but also the regulator and other
electrical components.
Load test a battery that does not hold a charge

when in use. To do this, put a resistance across the
main connections (terminals) of the battery. For a 6, 8 or
12V battery, use a test load of three times the
ampere/hour rating (the maximum test load on any
battery is 500 amperes). Let the test load remove the
charge (discharge) of the battery for 15 seconds and with
6V7070 HEAVY-DUTY DIGITAL MULTIMETER the test load still applied, test the battery voltage. A 6V
battery in good condition will show 4.5V; and 8V battery
The 6V7070 Heavy-Duty Digital Multimeter is a will show 6V; a 12V battery will show 9V. Each cell of a
completely portable, hand held instrument with a digital battery in good condition must show 1.6V on either a 6, 8
display. This multimeter is built with extra protection or 12V battery.
against damage in field applications, and is equipped
with seven functions and 29 ranges. The 6V7070
CHARGING SYSTEM
Multimeter has an instant ohms indicator that permits
continuity checks for fast circuit inspection. It also can
The condition of charge in the battery at each
be used for troubleshooting small value capacitors.
regular inspection will show if the charging system
operates correctly. An adjustment is necessary when the
The 6V7800 Regular-Duty Digital Multimeter (a
battery is constantly in a low condition of charge or a
low cost option to the Heavy-Duty Multimeter) is also
large amount of water is needed (more than one ounce
available; however, the 6V7800 Multimeter does not
of water per cell per week or per every 50 service hours).
have the O1A range or the instant ohms feature of the
6V7070 Multimeter.
When it is possible, make a test of the charging
unit and voltage regulator on the engine, and use wiring
NOTE: Make reference to Special Instruction Form No.
and components that are a permanent part of the
SEHS7734 for more complete information for use of the
system. Off-engine (bench) testing will give a test of the
6V7070 and 6V7800 Multimeters.
charging unit and voltage regulator operation. This
testing will give an indication of needed repair. After
BATTERY
repairs are made, again make a test to give proof that
the units are repaired to their original condition of
operation.
Never disconnect any charging unit circuit or battery Before the start of on-engine testing, the
circuit cable from battery when the charging unit is charging system and battery must be checked as shown
operated. A spark can cause an explosion from the in the Steps that follow:
flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the 1. Battery must be at least 75% (1.240 Sp. Gr.)
fully charged and held tightly in place. The
battery outlets. Injury to personnel can be the result.
Battery holder must not put too much stress on
the battery.
The battery circuit is an electrical load on the
charging unit. The load is variable because of the
151
2. Cables between the battery, starter and engine 1. Voltage adjustment cap.
ground must be the correct size. Wires and
cables must be free of corrosion and have cable No adjustment can be made to change the rate
support clamps to prevent stress on battery of charge on these alternator regulators. If the rate of
connections (terminals). charge (ampere output) is within 10 amperes of rated
output (marked on the alternator frame) the regulator is
3. Leads, junctions, switches and panel good. An over or under charged battery condition can be
instruments that have direct relation to the corrected sometimes by an adjustment to the voltage. If
charging circuit must give correct circuit control. rate of charge is not correct, a replacement of the
regulator is necessary.
4. Inspect the drive components for the charging
unit to be sure they are free of grease and oil Alternator Pulley Nut Tightening
and have the ability to operate the charging unit. (Delco-Remy)
Alternator Regulator Adjustment Tighten nut that holds the pulley to a torque of 100 ± 10
(Delco-Remy) Nâm (75 Z± 5 lb. ft.) with the tools shown.
When an alternator is charging the battery too
much or not enough, an adjustment can be made to the
output voltage of some alternators. Make reference to
the SPECIFICATIONS section to find all testing
specifications for the alternators and regulators.
Delco-Remy 24V 60A (4N3986 Alternator)
No adjustment of voltage output can be made on

this alternator. If the voltage and ampere output is not
correct, the alternator must be repaired or replaced.
Delco-Remy 32V 60A (4N3987 Alternator)
To make an adjustment to the voltage output,

pull out voltage adjustment cap (1). Turn the cap 90°
and install it again into the alternator. The voltage TOOLS TO TIGHTEN ALTERNATOR PULLEY NUT
adjustment cap has four positions: HI, LO, and two 1. 5P7425 Torque Wrench. 2. 8S1588 Adapter (1/2"
positions between the high and the low setting. female to 3/8" male). 3. FT1697 Socket. 4. 8H8517
Combination Wrench (1 1/8"). 5. FT1696 Wrench.
The 4N3987 Alternator can be adjusted for either
30 or 32 volts. A replacement alternator shipped from
the factory will be adjusted for 32V (16 battery cells) STARTING SYSTEM
systems. Where the alternator is to be used in a 30V (15
battery cells) system, pull out voltage adjustment cap (1) Use the multimeter in the DCV range to find
and change from the HI position to position 3. starting system components which do not function.
Move the start control switch to activate the

starter solenoid. Starter solenoid operation can be heard
as the pinion of the starter motor is engaged with the ring
gear on the engine flywheel.
If the solenoid for the starter motor will not

operate, it is possible that the current from the battery did
not get to the solenoid. Fasten one lead of the
multimeter to the connection (terminal) for the battery
cable on the solenoid. Put the other lead to a good
ground. A zero reading is an indication that there is a
broken circuit from the battery. More testing is
necessary when there is a voltage reading on the
multimeter.
CAP TYPE REGULATOR ADJUSTMENT
152
The solenoid operation also closes the electric

circuit to the motor. Connect one lead of the multimeter
to the solenoid connection (terminal) that is fastened to
the motor. Put the other lead to a good ground. Activate
the starter solenoid and look at the multimeter. A
reading of battery voltage shows the problem is in the
motor. The motor must be removed for further testing.
A zero reading on the multimeter shows that the solenoid
contacts do not close. This is an indication of the need
for repair to the solenoid or an adjustment to be made to
the starter pinion clearance.
Make a test with one multimeter lead fastened to

the connection (terminal) for the small wire at the
solenoid and the other lead to the ground. Look at the
multimeter and activate the starter solenoid. A voltage CONNECTION FOR CHECKING PINION CLEARANCE
reading shows that the problem is in the solenoid. A zero 1. Connector from MOTOR terminal on solenoid to
reading is an indication that the problem is in the start motor. 2. SW terminal. 3. Ground terminal.
switch or the wires for the start switch.
4. Connect for a moment, a wire from the solenoid
Fasten one multimeter lead to the start switch at connection (terminal) marked MOTOR to the
the connection (terminal) for the wire from the battery. ground connection (terminal). The pinion will
Fasten the other lead to a good ground. A zero reading shift to crank position and will stay there until the
indicates a broken circuit from the battery. Make a check battery is disconnected.
of the circuit breaker and wiring. If there is a voltage
reading, the problem is in the start switch or in the wires
for the start switch.
A starter motor that operates too slow can have

an overload because of too much friction in the engine
being started. Slow operation of the starter motor can
also be caused by a short circuit, loose connections
and/or dirt in the motor.
Pinion Clearance Adjustment
When -the solenoid is installed, make an

adjustment of the pinion clearance. The adjustment can
be made with the starter motor removed. PINION CLEARANCE ADJUSTMENT
4. Shaft nut. 5. Pinion. 6. Pinion clearance.
1. Install the solenoid without connector (1) from
the MOTOR connections (terminal) on solenoid 5. Push the pinion toward the commutator end to
to the motor. remove free movement.
2. Connect a battery, of the same voltage as the 6. Pinion clearance (6) must be 8.4 to 9.9 mm (.33
solenoid, to the terminal (2), marked SW. to .39 in.).
3. Connect the other side of the battery to ground 7. To adjust pinion clearance, remove plug and turn
terminal (3). nut (4).
153/(154 Blank)
FORM NO. SENR3028
SERVICE MANUAL
CATERPILLAR
3161 GOVERNOR
155/(156 Blank)
3161 GOVERNOR SYSTEMS OPERATION
GOVERNOR TYPES
The 3161 Standard Governor is the base

governor.
The 3161 Standard Governor is equipped with:
A pneumatic speed setting control (I) or

manual mechanical speed control.
An air fuel ratio control (2).
The optional controls for this governor are:

3161 GOVERNORS
1. 3161 Standard Governor. 2. 3161 Governor with 1. Manual mechanical speed control (or pneumatic
Torque Rise. 3. 3161 Generator Set Governor. speed setting control).
The 3161 Standard Governor (1), the 3161 2. Manual shutdown.

Governor with Torque Rise (2) and the 3161 Generator
Set Governor (3) are the three arrangements of this 3. Pressure (pneumatic or hydraulic) shutdown.
governor that are available.
4. Electric "energize to shutdown" solenoid.
A mechanical head cover, a pneumatic head
cover and a speed adjusting motor head cover are the 5. Electric "energize to run" solenoid.
three top covers available for use with any of the 3161
governors. These top covers make each governor 6. Pneumatic mid-speed control.
adaptable for use with optional controls. The optional
controls can be factory installed or added to a governor The shutdown controls (manual, pneumatic and
already in service without any electric) can be used separately or together as needed.
3161 STANDARD GOVERNOR 3161 GOVERNOR WITH TORQUE RISE
3161 STANDARD GOVERNOR 3161 GOVERNOR WITH TORQUE RISE

1. Pneumatic speed setting control. 2. Air fuel ratio 1. Pneumatic speed setting control. 2. Air fuel ratio
control. control.
The 3161 Governor with Torque Rise is a

standard base governor with the torque rise components
installed.
157
This governor is used with engine arrangements The 3161 Generator Set Governor is a special
that require a specific torque rise application. The torque arrangement of the base governor and is primarily for
rise control can be adjusted and gives similar engine use on electric set engine arrangements.
output to that given by the torque spring and spacer
arrangement used in other Caterpillar governors. An electric set engine equipped with a 3161
Generator Set-Governor can be paralleled with other
The 3161 Governor with Torque Rise comes generator set engines governed by a 3161, 2301, a
with: hydramechanical governor, or with an infinite bus.
A pneumatic speed setting control (1) or a The 3161 Generator Set Governor comes with:
manual mechanical speed control;
A manual speed setting control (1).
An air fuel ratio control (2); and
A speed adjusting motor head [24-32 volts
A torque rise control (internal not shown). DC] (2).
The optional controls for this governor are: An external droop adjustment (3).
1. Pneumatic speed setting control (not to be used The optional controls for this governor are:
with a manual mechanical speed control).
1 Manual shutdown.
2 Manual shutdown.
2. Pressure (pneumatic or hydraulic) shutdown.
3. Pressure (pneumatic or hydraulic) shutdown.
3 Electric "energize to shutdown" solenoid.
4. Electric "energize to shutdown" solenoid.
4. Electric "energize to run" solenoid.
5. Electric "energize to run" solenoid.
5. Utility power converter (115-230 volts AC) for
The shutdown controls (manual, pneumatic and speed adjusting motor (24-32 volts DC).
electric) can be used separately or together as needed.
The shutdown controls (manual, pneumatic and
3161 GENERATOR SET GOVERNOR electric) can be used separately or together’ as needed.
3161 GENERATOR SET GOVERNOR

1. Manual speed setting control. 2. Speed adjusting
motor
head. 3. External droop adjustment.
158
BASIC GOVERNOR
engine oil before engine startup. The oil fill plug on all
3161 Governors is located on the top cover.
GOVERNOR COMPONENTS
Gerotor Oil Pump
The gerotor oil pump is located in the base of the

governor. The inner rotor of the pump is driven by a pin
in the drive shaft, and carries the outer rotor around in
mesh, this pushes oil to the accumulator piston.
3161 STANDARD GOVERNOR

Accumulator
The 3161 Governor is a mechanical-hydraulic
A single accumulator, that consists of a piston
governor that senses (feels) engine speed and is
and spring, acts as a relief valve for the oil pump and
connected to the engine fuel system by mechanical
supplies a reservoir of high pressure oil for rapid power
linkage. The governor controls the rate of fuel injected
piston movement. Oil is sent to the accumulator by the
into each of the engine cylinders as needed to adjust for
governor pump, with an increase in pressure as the
engine loads.
accumulator spring is put under compression. When the
pressure gets to a set point, oil is returned to sump
Droop and compensation can be adjusted on the
through relief ports in the piston wall.
governor as needed for stability of engines with different
rates of engine speed changes.
The 3161 Governor has a maximum of 8 N•m (6 Power Piston

lb. ft.) of torque output over the full 42 degrees of
terminal (output) shaft rotation in both the fuel ON and The power piston is fastened to the output shaft
OFF directions. Because the governor terminal shafts by a link and lever assembly. The power piston has a
are moved in both directions by hydraulic pressure, no large area on the bottom and a small area on top
return spring is used on the outside of the governor. A (differential piston). A small pressure increase on the
1.4 N•m (1 lb. ft.) spring inside the governor moves the large area of the piston will move the piston up, this
terminal shafts to the full shutoff position when the causes the output shaft to turn in the "increase" direction.
governor is not in operation. The piston can move down only when oil under the
piston is released to sump. Oil to or from the bottom of
The recommended travel (rotation) of the the power piston is controlled by the ballhead pilot valve
terminal shafts is approximately 30 degrees from low idle and ballhead pilot valve bushing.
to full load. This gives extra travel at each end for the
governor to make a complete shutdown and gives
maximum fuel when needed. Pilot Valve System
The 3161 Governor is connected to the engine The pilot valve system is made of two
lubrication oil system. The oil supply (under pressure) is components, the ballhead pilot valve (rotating) bushing,
sent to the governor through an orifice and internal and the ballhead pilot valve plunger. The bushing is
passages. The governor keeps the correct oil level and turned relative to the pilot valve plunger to reduce friction
drains excess oil back into the engine, this gives a between the two parts. The control land of the pilot valve
constant flow of oil through the governor. plunger controls the flow of oil through the control ports
of the ballhead bushing.
After removal or overhaul, the governor must be
filled with approximately 1.8 liters (2. U.S. qt.) of clean
159
When the pilot valve plunger is lowered, oil The 3161 Standard and Torque Rise Governors
under high pressure moves through the control port of are designed to operate with a 2 to 8 percent droop and
the bushing, to the bottom side of the power piston, and have an internal droop pivot pin adjustment.
the piston moves up. When the pilot valve plunger is
raised, the oil from the bottom of the power piston is The 3161 Generator Set Governor is designed to
released to sump, and the higher oil pressure on top of operate with a 0 to 4 percent droop. It has an external
the piston moves the piston down. When the engine is adjustment lever connected to the internal droop pivot
running at a steady state, the control land of the pilot pin. This permits droop adjustments to be on the outside
valve plunger covers the ports in the ballhead bushing of the governor housing.
and the power piston does not move. The movement of
the pilot valve plunger is controlled by the ballhead Torque Rise Control
assembly.
Ballhead Assembly
The ballhead system has a ballhead, flyweights,

speeder spring, thrust bearing, and speeder plug. The
ballhead, as part of the pilot valve bushing, is turned by
the drive coupling and drive shaft.
As the ballhead turns, the centrifugal force

causes the flyweights to pivot outward. At the same
time, the force of the speeder spring pushes the thrust
bearing down on the flyweight toes against the
centrifugal force of the flyweights. When the speeder
plug is pushed down this increases the downward
pressure on the speeder spring, and the governor speed
setting is increased. The engine then runs at a higher
speed and puts a higher centrifugal force on the
flyweights to equal the speeder spring force and put the
system back in balance. TORQUE RISE COMPONENTS
1. Torque control lever. 2. Cam.
Speeder spring force or speed setting is
controlled through the speed setting shaft. The torque rise control consists of a cam that
Compensation System makes the governor give more fuel to the engine under
The compensation system has a needle valve lug conditions.
and a buffer piston with two springs. This system can be Different percentages of torque rise can be
adjusted to give the desired rate of governor control and selected by changing the cam to a programmed rate of
engine speed stability. Since the governor makes an rise. This change can be made on or off the engine.
adjustment rapidly to a change in engine load or speed Cam selection and high idle settings must be based on
setting, the engine can go into a "hunt" condition factory recommendations.
(temporary increase and decrease in engine speed) if The torque rise control is factory installed. It is
too much adjustment is made. The purpose of the not practical to install it in the field.
compensation system is to prevent overcorrection to the The torque rise cam has three distinct profiles:
engine load or speed setting change. The system uses the base circle area (3); the approach ramp area (4); and
a pressure differential that is applied across the the cam lift area (5).
compensation land of the pilot valve plunger to give a The "base circle area" is a radius that does not
stable governor control. lift the cam follower. The cam follower must be
Speed Droop positioned on the base circle area when the dial indicator
The 3161 Governor is an isochronous governor is zeroed, for a check or adjustment of the torque rise
with the ability to operate with droop by the adjustment of setting.
an internal droop pivot pin. The governor may be used The "approach ramp area" is the "transition
with droop to allow for load division between two or more area" from the base circle to the cam lift area.
engines connected to a single shaft, or for operating in The "cam lift area" is the area on the cam that
parallel. lifts the cam follower and torque rise pilot valve lever,
The speed droop of a governor is the percent which allows additional fuel for torque rise greater than
that the engine speed drops between high idle and full the natural torque rise of the engine.
load.
160
control the pump pressure.

The pump pressure, as set by the accumulator,
controls the work output of the governor. Pump pressure
is also used for the auxiliary controls installed on the
governor top cover.
Increase In Speed Setting
When the speed setting shaft is turned

clockwise, the speed setting of the governor is
increased. The high idle screw limits the high speed
setting of the governor. As the speed setting shaft turns,
the speed setting lever pushes down on the floating lever
which is fastened to the speeder plug. The downward
pressure on the speeder plug puts the speeder spring
under compression. The speeder spring force then
TORQUE RISE CAM becomes greater than the centrifugal force of the
3. Base circle area. 4. Approach ramp area. 5. Cam ballhead flyweights, and the ballhead pilot valve plunger
lift area. is moved down. This increases the governor speed
setting.
During the torque rise cam adjustment the set
point of the terminal shaft is positioned by the As the pilot valve plunger is moved down,
synchronizing pin at the full load fuel setting. The cam is pressure oil moves under the power piston and pushes
moved to position the cam follower on the start of the the piston up. This moves the terminal lever up and the
cam lift area at a specified point that will lift the cam output shafts are turned in the "increase" fuel direction to
follower 1.00 ± 0.05 mm above the base circle. This increase the engine speed.
removes the free travel (clearances) from the governor
and fuel control linkages so the torque rise will occur at Before the engine gets to the new set speed, the
the correct engine speed. compensation system starts to move the pilot valve
plunger back to its center position and put the governor
Limit/Shutdown Pilot Valve under stable control as follows.
Shutdown of the engine is done with the limit/ The oil above the power piston is connected to
shutdown pilot valve. With the engine running on speed, the upper side of the buffer piston and lower side of the
the ballhead pilot valve is in the centered position. When pilot valve compensation land. As the power piston
the limit/shutdown pilot valve is lowered, pressure oil moves up the oil pressure moves the buffer piston down
above the control land of the ballhead pilot valve is and increases the compression of the lower buffer piston
drained back to the pump area. As engine speed begins spring. The force of the spring works against the buffer
to slow, ballhead flyweights move in, lowering the piston movement and this results in a small increase in
ballhead pilot valve plunger. Oil under the power piston oil pressure on the upper side of the buffer piston. This
is then drained to the pump area. As the power piston higher pressure is directed to the lower side of the pilot
moves down, the output shaft is turned in the decrease valve compensation land and makes a force to push the
direction, and the engine is shut down. pilot valve plunger up toward its center position. This
OPERATION OF THE 3161 GOVERNOR stops the flow of pressure oil to the lower side of the
Make reference to the 3161 Governor Schematic power piston and movement of the piston is stopped.
for use with the systems operations that follow. The As the pilot valve plunger is returned to its center
schematic shows the governor pilot valve in the increase position and the power piston movement is stopped,
fuel position. there is oil leakage through the needle valve orifice.
The 3161 Governor uses engine lubrication oil This lets the oil pressure above and below the
for its hydraulic system. The oil supply (under pressure) pilot valve compensation land become equal and the
is sent to the governor through an orifice and internal pilot valve plunger movement is stopped and the engine
passages. The oil goes from the suction side to the speed is returned to a stable condition. As the pressure
pressure side of the gerotor pump as the drive shaft is above and below the compensation land become equal,
turned by the engine. An accumulator spring and piston the buffer springs return the buffer piston to its center
keeps the pump pressure at approximately 690 kPa (100 position.
psi). The accumulator piston moves up in its cylinder
until the pump pressure is 690 kPa
(100 psi). At this time, ports in the piston are opened to
161
SCHEMATIC OF THE 3161 GOVERNOR

16 2(Increased Fuel Position)
162
Decrease In Speed Setting movement of the power piston, and the output shaft, is
now stopped.
When the speed setting shaft is turned
counterclockwise, the speed setting of the governor is The continued decrease of engine speed to its
decreased. The low idle screw limits the low speed steady-state setting, results in a continued increase in
setting of the governor. As the speed setting shaft is downward force of the speeder spring on the pilot valve
turned counterclockwise, the force of the speed setting plunger as the ballhead flyweights move in. At the same
lever on the floating lever is removed. This lowers the time, the pressure difference on each side of the buffer
compression of the speeder spring. Centrifugal force piston (and at top and bottom of the compensation land)
from the ballhead flyweights lifts the pilot valve plunger to is being released by the flow of oil through the needle
open the control port in the rotating bushing. Control oil valve orifice. This controlled discharge allows the buffer
under the power piston now drains to the sump and lets piston to return slowly to its normal, "centered" position.
the power piston move down. The output shafts are The speeder spring continues to push down on the pilot
turned in the "decrease" fuel direction and the engine valve plunger until the spring force and ballhead flyweight
speed is decreased. force become equal. At the same time the controlled
reduction of the pressure difference on the two sides of
Before the engine gets to the new set speed, the the compensation land occur exactly at the same rate
compensation system starts to move the pilot valve (while the pilot valve plunger remains centered) until the
plunger back to its center position and put the governor engine is again at the on-engine speed condition at the
under stable control as follows. new speed setting.
When the pilot valve plunger is lifted the oil NOTE: An increase or decrease in engine load will give
under the power piston is released to drain back to the the similar governor movement as an increase or
governor sump. Pump pressure oil on the bottom of the decrease in governor speed setting.
buffer piston now forces the buffer piston up. The oil
above the buffer piston then puts a force on the top of Shutdown
the power piston to move the power piston down.
The limit/shutdown pilot valve is located in the
The movement of the buffer piston up increases pump oil pressure supply line to the ballhead pilot valve.
the compression of the upper buffer piston spring. The When the engine shutdown system is activated, the
force of the upper spring works against the buffer piston limit/shutdown rod pushes the limit/ shutdown pilot valve
movement and this results in a small increase to the plunger below the supply passage. This drains oil from
pump oil pressure on the lower side of the buffer piston the supply to the ballhead pilot valve plunger. Control oil
and on the top surface of the pilot valve plunger from under the power piston now drains past the control
compensation land. This small increase is greater than land of the pilot valve plunger. The power piston then
the pressure sent to the bottom surface of the moves down and the output shaft is turned in the
compensation land. This pressure difference on the two "decrease fuel" direction. As the engine speed
sides of the compensation land makes a force (greater at decreases, the ballhead flyweights move in and this
the top) to push the pilot valve plunger back down to the lowers the ballhead pilot valve. Oil from under the power
center position. piston is now drained to the governor sump at a faster
rate. As the power piston continues to move down, the
When the output shaft has turned far enough to output shaft is turned to the shutdown position until the
satisfy the new fuel setting, the force of the pressure engine is stopped.
difference on the compensation land puts the pilot valve
plunger in its center position (even though the engine
speed is not yet completely back to normal). The
163
AUXILIARY CONTROLS
This section describes the Auxiliary Controls and let control oil drain and cause engine shutdown.
attachments that are available for the 3161 Governor. The manual shutdown can be used in addition to
These controls are installed and calibrated at the factory the pressure or electric shutdown controls.
before shipment to the user. The shutdown controls can
be added to a governor already in service without any PRESSURE SHUTDOWN
further modification to the governor.
The controls that can be fastened to the

governor top cover are:
1. Manual Shutdown
2. Mechanical Shutdown
3. Electric Shutdown
PRESSURE SHUTDOWN
4. Pneumatic Speed Setting Control
1. Shutdown plunger. 2. Shutdown piston. 3.
Shutdown control pressure passage.
5. Air Fuel Ratio Control
Other controls added to the governor include: The pressure shutdown assembly is installed on
the right front cover of the governor top cover.
1. Speed Adjusting Motor Head
This shutdown uses either pneumatic or
2. Manual Speed Setting Control hydraulic pressure at a minimum of 276 kPa (40 psi) to
shutdown the engine. When the pressure (air or oil) is
3. Manual Mechanical Speed Control applied to the shutdown piston, the piston is moved down
and makes contact with the shutdowns plunger. The
4. Pneumatic Mid Speed Control plunger then pushes down on the shutdown rod and the
shutdown/limit pilot valve. The pilot valve then lets
MANUAL SHUTDOWN control oil drain from under the power piston and causes
engine shutdown. The shutdown will reset when
pressure goes below 138 kPa (20 psi) and lower.
The pressure shutdown can be used in addition

to the manual or electric shutdown controls. If this
shutdown is added after the governor has been shipped
from the factory, and is not used with any other
shutdown, a small cover and gasket must be installed on
top of the shutdown assembly.
ELECTRIC SHUTDOWN
MANUAL SHUTDOWN
The electric shutdown assembly (1) is installed
1. Threaded shutdown handle. 2. Boot. 3. Shutdown on the right front corner of the governor top cover. This
plunger. shutdown uses a 24 volt DC (energized-to-shutdown)
solenoid that positions the shutdown lever and
The manual shutdown assembly is installed on shutdown/limit pilot valve. When the solenoid is
the right front corner of the governor top cover. energized the plunger moves down. It lowers the
shutdown rod and shutdown/limit pilot valve to let control
To shutdown the engine, the threaded shutdown oil drain from under the power piston and cause engine
handle can be either pushed down or tilted in any one of shutdown.
the 360 degrees to make contact with the shutdown rod.
As the shutdown handle is tilted, the flat disc of the
shutdown handle lowers the shutdown/limit pilot valve, to
164
As control air pressure enters the speed setting

bellows through the inlet port, expansion of the bellows
takes place. The bellows pushes down on the speed
setting lever to the left of the pivot. This lifts the right end
of the speed setting lever against the feedback spring
force to close the nozzle to drain.
Supply oil flows through an orifice to the lower

side of the speed setting pilot valve plunger and then to
drain through the nozzle. When oil flow from the nozzle
is stopped by the speed setting lever, oil pressure
increases and the speed setting pilot valve plunger
moves up. This lets control oil go to the top of the speed
setting piston. As the control oil pressure increases, the
speed setting piston moves down to increase the
ELECTRIC SHUTDOWN governor speed setting through a rod and lever
1. Electric shutdown assembly. connected to the governor speed setting shaft.
There is a diode used in the circuit for the As the speed setting piston moves down, the
electric solenoid because it is polarity sensitive. If the feedback spring is put under compression and pushes
wires are connected the wrong way the solenoid will not the speed setting lever away from the nozzle. Control oil
operate. can now go to drain and the pilot valve loading spring
pushes the pilot valve plunger down to stop oil flow to the
The electric shutdown can be used by itself, or in top of the speed setting piston. This results in the speed
addition to the manual and pressure shutdown controls. setting piston stopped in a new position that is
If this shutdown is added after the governor has been proportional to the air pressure supplied to the speed
shipped from the factory, an adjustment must be made. setting bellows.
See TESTING AND ADJUSTING section for the correct
adjustment. Decrease Engine Speed
When the electric shutoff is used by itself, a When the control air pressure is lowered, the
small cover and gasket must be installed on top of the speed setting bellows moves back toward its original
shutdown assembly. position. The feedback spring now pushes the speed
setting lever away from the nozzle and control oil goes to
drain through the nozzle.
PNEUMATIC SPEED SETTING CONTROL
As control oil pressure goes to drain, the oil
The pneumatic speed setting control is installed pressure below the speed setting pilot valve plunger is
on the left front corner of the governor top cover. decreased and the pilot valve loading spring moves the
Because of its design, it is not practical to add the plunger down. This lets control oil above the speed
pneumatic speed control on the 3161 Governor in the setting piston go to drain and the feedback spring
field. pushes the piston up. When the piston moves up, the
force on the governor speed setting lever is lowered and
System air pressure from a remote throttle and the governor speed setting is reduced.
internal pressure oil from the governor operate the
control to increase or decrease the speed at which the The speed setting piston moves up until the
engine runs. This control has the ability to repeat force of the feedback spring and the speed setting
constant speed settings over a large range of conditions. bellows moves the speed setting lever to close control oil
to drain at the nozzle. At this time, the speed setting pilot
The pneumatic speed setting control has a valve plunger moves up to stop control oil movement
standard air pressure range of 70 to 415 k Pa ( 10 to 60 above the speed setting piston. This results in the speed
psi). Special applications of this control can use a setting piston stopped in a new position that is
pressure range of 35 to 380 kPa (5 to 55 psi) or 35 to proportional to the air pressure applied to the speed
620 kPa (5 to 90 psi). setting bellows.
Increase Engine Speed
165
PNEUMATIC SPEED SETTING CONTROL SCHEMATIC
1. Speed setting bellows. 2. Speed setting piston. 3. Orifice. 4. Spring seat. 5. Pilot valve loading
spring. 6. Speed setting pilot valve plunger. 7. Base speed adjusting screw. 8. Upper speed setting
bias spring. 9. Speed setting lever. 10. Lower speed setting bias spring. 11. Pivot. 12. Nozzle.
13. Feed-back spring.
166
AIR FUEL RATIO CONTROL limiter piston and the pressure of the oil starts to
increase. When the oil pressure is high enough, the
limiter piston is pushed down against the limiter servo
spring force. The lower edge of the fuel limiter plunger
opens the port in the limiter piston when the piston has
moved down far enough. This lets supply oil go to drain.
The air fuel ratio control is now activated and can
operate as needed.
Engine Load Increases
As more load is put on the engine, the air

pressure in the inlet manifold is increased. The
increased air pressure pushes the rolling diaphragm
assembly up and lifts the fuel limiter plunger more. Oil
pressure on the limiter piston decreases as the limiter
3161 GOVERNOR WITH AN AIR FUEL piston drain port is opened and the limiter piston moves
RATIO CONTROL up until the port is closed again. At this time the limiter
1. Air fuel ratio control. piston is stopped in a new position that is proportional to
the air pressure in the inlet manifold.
The air fuel ratio control assembly (1) is installed
on the right rear corner of the top cover. The control is Now, with the engine in operation at a steady
factory calibrated and installed. This control is not for speed, load added decreases engine speed. The
field installation. governor moves to increase fuel as the power piston
moves up to turn the output shafts in the "increase"
The air fuel ratio control is similar to hydraulic air direction. As the output shafts turn, the right end of the
fuel ratio controls used on current Caterpillar engines. limit floating lever is lifted. Because the limit floating
This control automatically controls the governor output lever is fastened to a pivot (pivot position is set by the air
shaft movement in the "fuel increase" direction, until air fuel ratio control), the left end of the lever pushes the
pressure in the engine inlet manifold is high enough to limit/shutdown rod down. The limit/shutdown pilot valve
give complete fuel combustion. plunger closes off governor control oil to the power
piston and limits the power piston movement.
The air fuel ratio control limits the fuel to the
engine in proportion to the amount of turbocharger boost As the engine picks up load, air pressure to the
pressure (pressure above atmospheric) in the inlet air fuel ratio control increases. The rolling diaphragm
manifold. The control is not activated during engine start assembly moves up and lifts the fuel limiter plunger
up and is cocked (activated) by a combination of oil which opens the port in the limiter piston. Oil pressure
pressure and the initial surge of boost when the engine is on the limiter piston is lowered, and lets the limit servo
first loaded. spring push the piston and output rod up. This lets the
limit/shutdown pilot valve move up. Fuel limit level is
Engine Start Up then increased.
As the engine is started and the speed or load is NOTE: The air fuel ratio control fuel limit range is set by
increased, air pressure from the inlet manifold increases the position of the limit cam on the limit lever. When the
and pushes up on the rolling diaphragm assembly to put cam is moved away from the shutdown rod, the limit
the limiter spring under compression. As the rolling range is longer. When the cam is moved closer to the
diaphragm assembly moves up, the fuel limiter plunger shutdown rod, the limit range is shorter.
also moves up and closes off the port in the limiter
piston. Now the supply oil can not drain through the
167
SCHEMATIC OF AIR FUEL RATIO CONTROL ON THE 3161 GOVERNOR
168
SPEED ADJUSTING MOTOR GOVERNOR HEAD NOTE: If the speed adjusting motor has been allowed to
run after the low speed setting has been reached, it may
take a period of time for the speed adjusting screw to
turn in and make contact with the speed adjusting lever
(when an increase in speed setting is required).
All wiring and power to the remote speed setting

motor on the governor must be low voltage DC. A
converter drop box which will convert 115 or 230 volt AC
(50 to 60 Hertz) to 24 volt DC is available (2W4523).
This box should be remote mounted from the engine to
isolate the engine wiring harness from high voltage AC
currents.
An internal one-half inch thread conduit

connection (1) is on top of the governor cover. It is used
3161 GENERATOR SET GOVERNOR for installations which require conduit protection for the
1. Conduit connection. 2. Speed adjusting meter. wiring.
3. Electric shutdown assembly.
The top governor cover is made for installation of
The speed adjusting motor governor head any of the three shutdown assemblies.
includes a 24/32 Volt DC remote control speed adjusting
motor (2) for changing engine speeds from remote MANUAL SPEED SETTING CONTROL
locations. The speed adjusting motor is installed on the
governor top cover and is connected to the governor
speed setting mechanism through a friction clutch. The
motor drives through the friction clutch and rotates the
speed adjusting screw to position the governor’s speed
adjusting lever. The governor set speed may be
increased or decreased at the rate of 13 rpm/ second.
One revolution of the manual adjusting screw will
increase engine speed 63 rpm (approximately).
To increase the speed setting, the motor shaft

rotates clockwise. As the motor shaft rotates, it turns the
speed adjusting screw to make contact with the speed
adjusting lever and lowers it to increase the governor’s
speed setting. The motor shaft turns the speed adjusting
screw until the speed adjusting lever contacts the high
speed stop. If the motor continues to run, the clutch will
slip to prevent damage to the motor.
3161 GENERATOR SET GOVERNOR
NOTICE
The motor should not be left running with the clutch The manual speed setting control is located on
slipping, or clutch wear will occur. To decrease the front of the speed adjusting motor governor head.
speed setting, the motor shaft turns Engine speed is set manually as the speed setting screw
counterclockwise and the speed adjusting screw is turned. The high and low idle stops limit the speed
backs out, allowing the speed adjusting lever to range.
move to the "decrease speed" setting.
If the motor shaft is permitted to rotate

counterclockwise after the speed adjusting lever has
reached the low speed stop screw, the speed
adjusting screw will turn out to the maximum
position. The clutch will then slip until the motor is
stopped.
169
.70 SYSTEMS OPERATION The manual mechanical

speed control with remote and positive lock is available
for torque rise and non-torque rise equipped governors.
The control is used for manually setting different ~,_
engine speeds, or it can be used as a remote speed
control.
The shaft (1) goes through the handle assembly (2) and
is threaded into the hub (4) on the spline of the speed
setting shaft. The guide (3) rotates on the speed setting
shaft and supports the handle assembly. The ratchet
mounting plate (6) is bolted to the front of the governor
and has notches to hold the handle for different engine
TOP COVER OF THE 3161 GENERATOR SET speeds. The quadrant (5) can be engaged with the
GOVERNOR handle assembly and used as a mechanical linkage to
1. Speed adjusting screw. the speed setting shaft.
An indicator lever is attached to the governor A cable or rod can be connected to the quadrant and
speed setting shaft with a bolt. The bolt can be loosened used for remote speed control.
and the indicator lever can be set to the reference points
on the identification and information plate to correspond To increase or decrease engine speed, push on the shaft
with the number on the dial. The indicator lever will show and lift on the handle assembly. This disengages the
the speed setting before the engine is started. handle assembly from the ratchet mounting plate. The
control can then move the speed setting shaft.
The manual speed setting control and the speed Movement of the handle in the clockwise direction
adjusting motor use a common speed adjusting screw increases the engine speed.
which contacts the governor speed adjusting lever.
To disengage the handle assembly from the ratchet and
The speed adjusting motor clutch is above the connect the quadrant, push on the shaft and lift on the
gear and connects the motor to the speed adjusting handle assembly. With the handle assembly raised, turn
screw. This clutch keeps force off of the speed adjusting it 180 degrees and connect it to the quadrant. The
motor as the speed setting is adjusted manually. control can now be used for remote operation.
MANUAL MECHANICAL SPEED CONTROL NOTE

: The manual mechanical speed control with remote and
3161 GOVERNOR 1. Shaft. 2. Handle assembly. 3. positive lock should not be used with a pneumatic speed
Guide. 4. Hub. 5. control. Vibration can cause the manual mechanical
speed control to engage and stop pneumatic speed
Quadrant. 6. Ratchet mounting plate. control operation.
PNEUMATIC MID SPEED CONTROL A pneumatic

speed control is normally used on 3161 Governors on
vehicular engine arrangements to control the engine
speed. A pneumatic mid speed control is also used to
make the engine go from low idle to mid speed for
dynamic braking with the direct current generator and
drive motors.
This control is installed on the front of the governor.

With a lever fastened to the speed setting " control shaft,
the control cylinder sets the engine speed from low idle
to mid speed. The mid speed setting of the governor is
set by the position the control lever is fastened to the
speed setting control shaft.
170
PNEUMATIC MID SPEED CONTROL
The control cylinder rod is spring activated

(extended) and air retracted. When the cylinder rod is
extended the lever moves the speed setting shaft in the
"fuel increase" direction. As air pressure is supplied to
the control cylinder, the cylinder rod moves away from
the speed setting shaft lever. The governor turns the
output shafts in the "fuel decrease" direction to lower the
engine speed. When there is a loss or reduction of air
pressure, the control moves the speed setting shaft and
the engine runs at a speed set by the governor
proportional to speed setting shaft position.
171
3161 GOVERNOR TROUBLESHOOTING
GOVERNOR TROUBLESHOOTING
172
173
174
175
AIR FUEL RATIO CONTROL TROUBLESHOOTING
AIR FUEL RATIO CONTROL

TROUBLESHOOTING
176
AIR FUEL RATIO CONTROL TROUBLESHOOTING
177
PNEUMATIC SPEED SETTING CONTROL TROUBLESHOOTING

TROUBLESHOOTING
178
PNEUMATIC SPEED SETTING CONTROL TROUBLESHOOTING
179
3161 GOVERNOR TESTING AND ADJUSTING
GOVERNORS FOR 3500 SERIES ENGINES
GOVERNOR OIL PUMP
GOVERNOR OIL SUPPLY GOVERNOR OIL PUMP ROTATION
1. Oil passages. 2. Passage for oil supply. 3. Check the direction of the oil pump rotation
Passage for oil drain. before the governor is installed on the engine.
The governor drive adapter has four passages Two arrows are cast into the oil pump housing.
with seals. Passages (2 and 3) on the right side are One arrow indicates counterclockwise, and the other
used when the governor is installed -on the right side of clockwise. A reference ROTATION V is -cast in the
the engine. Passage (2) is the oil supply to the governor. bottom of the governor housing.
Passage (3) is the oil drain port for the governor.
In the above illustration, the counterclockwise
Passages (I1) with the seals are used when the arrow is in alignment with the ROTATION V. This is the
governor is installed on the left side of the engine. correct direction of rotation for the 3161 Governor when
it is installed on the right hand side of standard rotation
3500 Series Engines.
OIL PASSAGES IN GOVERNOR HOUSING
4. Passage (oil drain). 5. Groove in PUMP ROTATION DECAL

governor pump housing for O-ring seal. 6.
Passage (oil supply). A decal on the outside of the governor housing
indicates the direction of governor rotation. This oil
Passage (4) is for oil drain and passage (6) is for pump is set for counterclockwise direction as shown by
-the -oil supply in the 316l Governors. the decal.
No gasket is used between the governor and the If the direction of rotation of the governor and oil
drive adapter housing. A seal in groove (5) on the pump is changed, a new decal must be installed with the
outside of the oil pump housing seals between the decal arrow in the correct direction.
governor and the large bore in the adapter housing.
Replace the large seal and the four counterbore seals
each time the governor is removed and installed.
180
7. Use a soft faced hammer and hit the outer pump

drive shaft so the pump snaps (moves suddenly)
in place.
8. Install the four bolts and tighten them to a torque

of 10 N-m (90 lb. in.).
9. Make sure the drive shaft turns freely after the

bolts have been tightened.
GOVERNOR PREPARATION
OIL PUMP INSTALLATION
7. Roll pin. 8. Reference hole for roll pin. 9. Plug.
10. Location hole for roll pin to change pump
rotation. 11. Strap to hold plug in position when
pump housing is removed.
To change the direction of pump rotation do the

following steps:
The pump housing holds plug (9) in position. There

is spring force on the plug. To prevent injury,
mechanically hold plug (9) in the governor housing
when the pump housing is removed.
1. Remove the four bolts that hold the pump in

place.
INSTALL COVER ON GOVERNOR
2. Use two screwdrivers to lift the pump housing 1. Location for bolt. 2. Cover.
and O-ring seal from the governor.
Because of the close clearance between the fuel
3. Pull roll pin (7) from the pump housing flange control linkage cover and governor, the upper left hand
and install it in location hole (10) in the opposite bolt must be installed at location (1) before cover (2) is
side of the flange. put on the terminal shaft and the governor is bolted to
the drive adapter housing. The other bolts can be put in
4. Turn the pump housing and make an alignment place after the governor is in position on the engine.
of roll pin (7) and reference hole (8) in the
governor base. Put clean engine oil on the lip of the seal and
install cover over the governor terminal shaft.
5. Put a new seal on the oil pump housing. Put
clean engine oil on the seal and install the
assembly part way into the bore in the base of
the governor.
6. Make sure the external pump drive spline is in

correct alignment with the internal coupling
spline. If the splines are not in alignment,
damage to the governor will be the result when
the pump housing bolts are installed and
tightened.
CONTROL LEVERS
3. Lever. 4. Lever.
181
There are two control levers for the 3161

Governor used on 3500 Series Engines. Lever (3) has a After fuel control linkage cover (2) is in position,
fixed pin and lever (4) has an adjustable pin. The fixed install lever (3) on the governor terminal shaft and tighten
pin lever (3) is used on the 3161 Standard and Generator the bolt to a torque of 25 ± 7 N-m (18 ± 5 lb. ft.). Control
Set Governors. levers will go on only the correct way because of the flat
and groove of the terminal shaft and the lever pin. This
The adjustable pin lever (4) is used on 3161 control lever is for right-hand mounted governors. On
Governors with torque rise. Lever (4) is used to control levers for left-hand mounted governors, the pin is
synchronize governor torque rise set point (balance reversed.
point) position to engine fuel setting position.
The adjustable pin lever (4) can be used on a

right hand or left hand mounted governor. To convert
the lever from right hand governor use to left hand
governor use, remove the lock bolt and lock from the
adjustable pin. Remove the adjustable pin from the
lever, turn it around and install it into the lever the
opposite way. Install the lock and bolt into the adjustable
pin and tighten just enough to hold it in place. The lever
can now be used on the other end of the terminal shaft
for left hand mounted governors. INSTALL LEVER
4. Lever. 6. Bolt.
For 3161 Governors with torque rise, the

adjustable pin control lever is installed on the terminal_
shaft. Bolt (6) is then tightened to a torque of 25 ± 7 N m
o
(18 ± 5 lb. ft.).
Before the governor is installed on the engine,

tighten the pin lock bolt enough to hold the pin in position
when the governor is installed on an engine.
ALIGNMENT OF CONTROL LEVER After the governor is installed on an engine, the

5. Notch in fuel control linkage stop lever. adjustable pin is turned to synchronize the governor
travel to the fuel control linkage. See Governor
The lever and pin (fixed or adjustable) connect Installation for the correct adjustment and setting of
the governor terminal shaft to the fuel control linkage these governors.
stop lever. The lever pin moves in notch (5) of the stop
lever, this causes the two to move together. NOTICE
Before the governor is installed on an engine, make

sure the pin of adjustable control lever (4) is at the
bottom of the lever as shown. if the pin is not in this
position, the control lever can bind or become
disconnected from the engine fuel control linkage.
Engine overspeed can be the result.
GOVERNOR INSTALLATION
INSTALL LEVER
NOTICE
2. Cover. 3. Lever.
To prevent damage to the governor, do not drop the
The 3161 Standard and Generator Set
Governors with fixed pin levers do not require any governor or set it on the drive shaft, terminal shaft or
special adjustments or setting when installed on the speed adjusting shaft.
engine.
182
3161 Standard and Generator Set Governors maximum runout of the governor drive shaft and
coupling must be less than 0.15 mm (.006 in.). Parts
that do not fit correctly or are not in alignment can cause
early wear, shaft seizure, or governor drive shaft failure.
INSTALL SEALS
1. O-ring seals. 2. O-ring seals.
1. Make sure the four O-ring seals (1) and (2) are
in position on the governor drive housing. Install
the seal on the governor oil pump housing and FASTEN GOVERNOR TO DRIVE HOUSING
put clean engine oil on all seals. 6. Cover. 7. Bolts.
3. Move the governor to put cover (6) in correct

alignment (square) with the front housing of the
engine. With the governor in alignment, install
and tighten bolts (7) to hold the governor to the
drive housing.
INSTALL GOVERNOR
2. Put the governor and cover gasket in position.
Make sure the governor drive shaft and the
spline drive are in correct alignment. Also,
make sure the pin on the governor lever is
engaged in the slot in the fuel control linkage
stop lever. INSTALL COVER AND BRACKET
6. Cover. 8. Bracket.
4. Put cover (6) against the front drive housing and

make sure the gasket is in alignment. Install and
tighten the bolts. Check the governor terminal
shaft for free movement, see Step 6.
5. Install bracket (8) as follows:
a. Install two bolts in the side of the governor.
b. Slide bracket (8) in place on the bolts.

Tighten the bolts enough to hold bracket (8)
ALIGNMENT OF GOVERNOR AND DRIVE in position. The bracket must be free
(Cover removed for photo illustration only) enough to move.
NOTE: Be sure there is no binding, side load on the c. Install and tighten the two bolts that hold
drive shaft, or looseness in the drive coupling. The bracket (8) to the top of cover (6). This puts
the bracket in correct alignment.
183
d. Tighten the two bolts that hold bracket (8) to the governor before the first engine start up.
governor. Replace the plug in the top cover and tighten.
e. Check the governor terminal shaft for free 3161 Governor With Torque Rise
movement, see Step 6.
Tools Needed:
5P4814 Collet.
6V3075 Dial Indicator (metric).
5P7263 Contact Point, 76.2 mm (3.00 in.) long.
FT1819g Governor Torque Arm Tool.
1. Put the governor in position on the engine as in

Steps I through 3 for 3161 Standard and
Generator Set Governors.
CHECK TERMINAL SHAFT MOVEMENT
6. Use a 7/16" wrench and move the governor

terminal shaft several times in the ’FUEL ON"
direction and release it. The terminal shaft must
return completely to the "FUEL OFF" position
each time. If the terminal shaft does not return,
binding can be the result of parts not in correct
alignment.
If the terminal shaft is binding, loosen the cover FUEL SETTING COVER
bolts, make an alignment of the cover again, then tighten 1. Synchronizing pin. 2. Plug. 3. Plug.
the bolts again. Check for binding again with the above
procedure. If this does not correct the binding, loosen 2. Remove plugs (2) and (3) from each side of the
the governor base to drive housing bolts. Move the fuel setting cover.
governor and tighten the bolts again. Check for binding
again with the above procedure. 3. Remove synchronizing pin (1) from the fuel
setting cover and remove the washer from it.
NOTE: If the governor terminal shaft is binding after the Install synchronizing pin (I) in the threaded hole
above procedure, loosen the bolts for the fuel control for plug (2). Tighten the synchronizing pin (1) in
linkage cover. Then loosen the bolts that hold the position.
governor drive housing in position and move the housing
to make an alignment of the cover bolt holes. Tighten all
of the bolts again and check for terminal shaft binding.
MOVE FUEL CONTROL LINKAGE

CORRECT GOVERNOR OIL LEVEL AGAINST SYNCHRONIZING PIN
4. FT1819 Governor Torque Arm Tool.
7. It is necessary to prime the governor. Remove
the oil fill plug from the governor top cover. Add
1.8 liter (2 U.S. quarts) of clean engine oil to the
184
4. Use FT1819 Governor Torque Arm Tool (4) to

move and hold the governor terminal shaft in the
"FUEL ON" direction. This puts the fuel control
linkage stop lever against the end of
synchronizing pin (1). The FT1819 Governor
Torque Arm Tool is to be attached only with the
engine shut down.
NOTE: A torque wrench and a 7/16 in. crowfoot wrench

can be used to move the terminal shaft in the "FUEL ON"
direction. Hold the governor terminal shaft and fuel
control linkage against the synchronizing pin with 10 N-m
(90 lb. in.) force to give an accurate dial indicator setting.
ENGAGE GOVERNOR ZEROING PIN
9. The zeroing pin is engaged to hold the governor

at a fixed position for setting the adjustable pin
lever to synchronize the governor travel with the
engine fuel control linkage travel. This pin is to
be engaged only with the engine shut down.
Put a 5/32 inch hex wrench in the governor

zeroing pin, push in and turn it counterclockwise
until the roll pin locks squarely behind the
bracket.
10. Install FT1819 Governor Torque Arm Tool (4)

again to turn and hold the governor terminal
shaft and linkage against the zeroing pin.
INSTALL DIAL INDICATOR

5. Manual fuel shutoff lever. 6. 6V3075 Dial
Indicator with the 5P7263 Contact Point in the
5P4814 Collet. 7. Bolt.
5. Put 6V3075 Dial Indicator (6) with the 5P7263

Contact Point in the 5P4814 Collet. Install the
dial indicator and collet in the threaded hole as
shown. When the contact point seats against
the fuel stop lever, slide the dial indicator in or ADJ USTABLE PIN SETTING
out until the indicator reads zero. Now tighten
the collet just enough to hold indicator at this 11. With a 1/2 in. by 3/8 in. drive socket on a 12 in.
position. extension and ratchet put the socket and
extension between the cover and housing. Put
6. Remove tool (4) from the governor terminal the socket on the bolt that holds the adjustable
shaft. Make sure the terminal shaft returns to pin lock and loosen the bolt.
the "FUEL OFF" position.
7. Remove bolt (7) and manual fuel shutoff lever NOTE: Later pins use a hex socket head bolt for
(5). use with 3/ 8in. drive sockets with a 12/4 in. hex
bit.
8. Turn synchronizing pin (l) back out a minimum of
25 mm (I in.) or remove it completely. Move the ratchet and extension up or down until
the dial indicator reads zero Put 0.13 mm while
the terminal shaft is held in the "FUEL ON"
direction against the governor zeroing pin.
185
Tighten the bolt on the lock to a torque of 25 ± 7 15. Remove 6V3075 Dial Indicator (6) and the collet.
Nom (18 ± 5 lb. ft.). Remove synchronizing pin (3) and install it with
the washer to hold the fuel setting cover in
Move tool (4) in the "FUEL OFF" position and position.
release. The dial indicator must return to zero
each time. If it does not, do the above 16. Install the two plugs on each side of the fuel
procedure again. setting cover.
17. Follow Steps 4 through 7 for 3161 Standard and

Generator Set Governors to install the cover,
bracket and check for free movement of the fuel
control linkage and governor.
RELEASE GOVERNOR ZEROING PIN
12. Remove tool (4) from the governor terminal

shaft.
13. Release the governor zeroing pin. Push on the

hex wrench and turn it clockwise until the roll pin
unlocks from the bracket. Release the hex
wrench and the spring will return the pin to the
disengaged position. Remove the hex wrench.
14. Turn synchronizing pin (1) in all of the way and

tighten it (install the pin as in Step 4 if it was
removed). Use tool (4) to hold the fuel control
linkage against synchronizing pin 1) as in Step 5.
Without change to the dial indicator position,
make sure the reading is zero to indicate correct
fuel control linkage setting.
REMOVE SYNCHRONIZING PIN AND

DIAL INDICATOR
1. Synchronizing pin. 6. 6V3075 Dial Indicator.
186
GOVERNOR ADJUSTMENTS
DROOP SETTING - INTERNAL

ADJUSTMENT
INTERNAL DROOP ADJUSTMENT

1. Locknut.
When the position of the droop pivot pin (internal

or external) is changed on the terminal lever, the percent EXTERNAL DROOP ADJUSTMENT
of governor droop changes. 1. Bolt.
To change the droop pivot pin setting on To change the droop setting, loosen the
governors not equipped with an external adjustment adjustment lever bolt (1) and move the lever down to
lever, the governor top cover must be removed. decrease droop, and up to increase droop.
The droop pivot pin is fastened to the terminal DROOP SETTING CHECK
lever with locknut (1). With the nut loosened, the pivot After an adjustment has been made to the droop
pin can be moved from minimum droop to maximum pivot pin (internal or external), the setting can be
droop. It is shown here in the minimum droop position. checked by alternately loading and checking the high idle
speed.
The terminal shafts are clamped in the ends of
the terminal lever by two bolts. A line can be drawn As this procedure is performed, the high idle
through the center of the two bolt heads and used for screw will probably have to be adjusted. The full load
reference in adjusting the droop pivot pin position. speed of the engine will also adjust upward or downward.
When the pivot pin and nut is moved near the As droop is decreased, full load speed is
reference line as shown, the governor is set for minimum increased, high idle speed is decreased. The greater
droop. As the pivot pin and nut are moved farther away the percent droop, expect the full load speed to
from the reference line, the droop is increased. When decrease, and the high idle speed to increase.
the pivot pin and nut are moved to the farthest point Therefore high idle speed should be adjusted to set the
away from the reference line the governor is set for full load speed at the correct rpm.
maximum droop.
COMPENSATION NEEDLE VALVE

DROOP SETTING - EXTERNAL ADJUSTMENT
ADJUSTMENT
After the engine has started and is under
On the 3161 Generator Set Governor, the governor control, open the needle valve (turn it
internal droop pivot pin locknut must be kept loose counterclockwise) until governor operation just becomes
enough to be moved by the external droop adjustment unstable (starts to hunt), then turn the needle valve in
lever. The external droop adjustment lever is held in until engine speed has stability. Let the governor and
place with a bolt which retains the droop setting. engine get to operating temperature by operating a
minimum of one-half hour. After the engine and
governor are at the operating tempera-
187
ture, again check for stable operation. Adjust as engine TESTING AND ADJUSTING Service Manual for
necessary. DO NOT fully close the needle valve. This the fuel setting procedure.
can cause excessive overshoot on startup, or load
rejection.
LOW IDLE ADJUSTMENT

1. Low idle stop screw. 2. Plate.
NEEDLE VALVE ADJUSTMENT
Low and high idle speed stop screws are on the
With the engine at normal operating temperature left side of the governor case, and are adjusted from the
and no load, operate the engine at low idle speed. Open outside of the governor.
the governor compensation needle valve and let the
governor increase and decrease engine speed (hunt) for The low idle speed stop screw is not covered,
a minimum of 30 seconds to remove air from the system. and can be adjusted without breaking the wire seal (wire
If the governor does not hunt, rapidly move the speed and seal not shown).
control shaft to change governor stability.
The high idle speed stop screw is covered by
After 30 seconds and the air is removed from the plate (2). The plate is held to the governor case with two
system, turn the needle valve in (clockwise) until the wire lock bolts. Install a wire and seal on the high idle
engine runs smoothly. speed adjustment cover bolts to prevent tampering.
With the engine running at medium (mid) speed, A 1/8 inch hex wrench is used for turning both
load the engine (at least one-quarter load) to find the low and high idle speed stop screws.
stability of the setting. Quickly remove the load. A slight
overshoot of speed is ideal, as it reduces response time.
The engine speed should return to smooth steady
operation. If it does not have a slight overshoot and The engine may overspeed due to improper
return to a smooth steady operation, adjust the needle reassembly or adjustment, which could result in
valve and repeat the above procedure. personal injury, loss of life, and/or property damage.
Governor terminal shaft "jiggle" or surge is an Be prepared to stop the engine by activating the
indication of: emergency air shut off or closing the air inlets.
1. Too little compensation (needle valve out

too far);
2. Torsional vibration (pulsing);
3. Improperly aligned governor drive spline;
4. A binding or loose fuel control mechanism.
LOW AND HIGH IDLE ADJUSTMENTS
NOTE: Make sure the engine fuel setting is correct

before low and high idle adjustments are made. See the
HIGH IDLE ADJUSTMENT
3. High idle stop screw.
188
To increase the engine low idle speed, turn On 3500 Series Engines equipped with 3161
screw (1) clockwise. Governors with torque rise there are two static fuel
settings. One is torque rise, which is maximum travel,
Turn high idle speed stop screw (3) clockwise to and is set with the fuel setting screw.
decrease high idle speed.
The second setting is full load, which is a
"reference position" where the fuel control linkage is held
while the torque rise cam is adjusted. This is a
temporary setting set with the synchronizing pin. This
setting is shown in the Fuel Setting and Related
Information Fiche as "full load."
Torque rise fuel setting is greater than full load

fuel setting, thus making the torque rise setting the
"maximum travel" setting of the fuel control linkage.
INSTALL COVER
2. Plate.
When the high and low idle speeds are adjusted

to the specifications given in the Fuel Setting and
Related Information Fiche, install the plate and the two
bolts. Put a seal wire through the holes in the bolt heads
and install the seal as required on other Caterpillar fuel
systems.
TORQUE RISE SETTING (ON 3500 SERIES ENGINES)

INSTALL SYNCHRONIZING PIN
Tools Needed:
1. Synchronizing pin. 2. Plug. 3. Plug.
5P4814 Collet.
2. Remove plugs (2) and (3) from each side of the
6V3075 Dial Indicator (two required). fuel setting cover.
5P7263 Contact Point, 76.2 mm (3.00 in.)
long. 3. Remove synchronizing pin (1) from the cover
FT1819 Governor Torque Arm Tool. and remove the washer from it. Install
9S228 Rack Position Tool Group. synchronizing pin (1) in the threaded hole for
9S225 Bracket Assembly. plug (2) and tighten it.
3S3269 Contact Point, 25.4 mm (1.00 in.)
long.
1. Look in the Fuel Setting and Related Information

Fiche to find the correct engine fuel setting,
torque rise and full load.
In the past only "static fuel setting" was listed in

the Fuel Setting and Related Information Fiche for the
3500 Series Engines. This fuel setting was "maximum
travel" and listed as "static fuel setting."
MOVE FUEL CONTROL LINKAGE AGAINST THE
On 3500 Series Engines equipped with a 3161
SYNCHRONIZING PIN
Standard or Generator Set Governor, the fuel setting
4. FT1819 Governor Torque Arm Tool.
procedure has not changed. The fuel setting screw is
used to set the "maximum travel" but the specification in
4. Use tool (4) to move and hold the fuel control
the Fuel Setting and Related Information Fiche has
linkage in the "FUEL ON" direction against the
changed and is shown as "full load."
synchronizing pin.
189
housing with bracket assembly (10) as follows:
Use a top cover bolt with three washers (as

spacers under the bolt head) on it and put the
bolt through the fixed diameter hole in the
bracket. Fasten the bracket to the left side of
the housing in the second threaded hole from
the front. Put the dial indicator in the adjustable
hole in the bracket assembly and position it so
the indicator contact point (11) rests on the bolt
head (12) of the torque control lever.
INSTALL DIAL INDICATOR
8. Check to make sure the cam follower is on the
1. Synchronizing pin. 5. 6V3075 Dial Indicator. 6. base circle of the governor torque rise cam. See
Systems Operation section for a description of
Fuel setting cover.
the base circle.
5. Put dial indicator (5) with the 5P7263 Contact
9. Move dial indicator (9) until it reads zero and
Point in the 5P4814 Collet. Install dial indicator
fasten it in place.
(5) and the collet in the threaded hole for plug
(3). When the contact point seats against the
10. Turn the synchronizing pin out of the engine front
fuel stop lever, slide the dial indicator in or out
drive housing a minimum of half-way. As the
until it reads zero. Now tighten the collet just
synchronizing pin is backed out, dial indicator (5)
enough to hold dial indicator (5) at this position.
will follow the fuel control linkage movement until
the fuel control linkage stop lever contacts the
fuel setting screw. Dial indicator (5) now shows
the torque rise fuel setting. Make sure the
torque rise fuel setting is correct. If not, an
adjustment is necessary.
11. Look in the Fuel Setting and Related Information

Fiche for the full load setting for the engine you
are adjusting.
12. Turn the synchronizing pin in until dial indicator

(5) reads the full load fuel setting. The full load
setting is a reference position and is a temporary
REMOVE GOVERNOR TOP COVER setting used to adjust the torque rise cam
7. Cover. 8. Gasket. position.
6. Remove the bolts that hold cover (7) in position. The purpose of this procedure is to hold the fuel
Lift cover (7) off the governor and remove gasket control linkage at the full load setting while the
(8). torque rise cam is adjusted.
13. Dial indicator (9) must read 1.00 + 0.05 mm, if it

does not, an adjustment is needed. Loosen the
bolt that holds the cam enough so the cam can
be moved, but keep the bolt tight enough to
provide a small drag on the cam.
14. Slide the cam to cause the torque control lever

and dial indicator contact to lift 1.00 + 0.05 mm.
INSTALL DIAL INDICATOR 15. Tighten the bolt while the cam is held in place.
9. 6V3075 Dial Indicator. 10. 9S228 Bracket This adjustment of 1.00 + 0.05 mm positions the
torque control lever so the torque rise (additional
Assembly. 11. 3S3269 Contact Point. 12. Bo8t.
fuel) begins to occur at the correct engine speed.
7. Install dial indicator (9) on the top of the governor
190
TORQUE RISE CAM ADJUSTMENT
16. Check the cam position by lifting and lowering

governor torque arm tool (4) on the terminal
shaft. The dial indicator (9) should return to the
1.00 + 0.05 mm setting. If it does not, repeat
the adjustment procedure and check again.
The following is an example of this torque rise cam

setting. If the engine were running at a rated 1800 r/min
with a load, the fuel control linkage would be at full load
position and the torque rise cam follower would have
lifted 1.00 mm. Torque rise would not have occurred, but
would be at the starting point. Should more load be
added, the engine speed would decrease. As the speed
drops, the terminal shaft and torque rise cam will move
and lift the torque rise pilot valve lever beyond the 1.00 +
0.05 mm set point. This will lift the pilot valve and
provide additional fuel to the engine and give torque rise
greater than the natural torque rise of the engine.
As more load is applied, engine speed will decrease.

The fuel control linkage will continue to move in the
"FUEL ON" direction, increasing the fuel rate until the
fuel control linkage stop lever contacts the fuel setting
screw. This is the torque rise fuel setting, and is
maximum travel.
17. With the torque rise cam setting made, remove

the dial indicator and bracket assembly and
install the gasket and top cover on the governor.
NOTE: Make sure the air fuel ratio control limit lever is
engaged correctly in the notch of the governor housing
before the top cover is installed.
18. Remove dial indicator (5) and the collet.

Remove synchronizing pin (1) and install it with
the washer to hold the fuel setting cover.
19. Install the two plugs on each side of the fuel

setting cover.
191
AUXILIARY CONTROLS
ELECTRIC SHUTDOWN
PNEUMATIC SPEED SETTING CONTROL 1. Bellows.

2. Plug over low idle adjustment screw.
The other is the pneumatic speed level ratio

(bias spring) adjustment, made by removing plug (2) and
turning the adjustment screw with a 1/8 inch hex wrench.
Pneumatic Speed Level Ratio Adjustment
The shutdown lever in the electric shutdown

assembly is adjusted up or down to keep the shutdown/
limit rod in the correct position until the shutoff solenoid
is activated.
1. Install the gasket and electric shutdown on top of

the governor. Tighten the bolts to 10 Nom (90 lb. in.).
2. Remove the cover, manual shutdown or

pressure shutdown, if so equipped, from the top of the
electric shutdown assembly.
ADJUSTMENT OF LOW IDLE
3. Turn the adjustment screw until the shutdown
When the speed level adjusting screw is turned
plunger is even with the top of the gasket for the cover or
the low speed setting of the pneumatic control is
other shutdowns.
changed.
4. Install the cover, manual shutdown or pressure
With the plug removed, put a 1/8 in. hex wrench
shutdown, if so equipped.
in the hole until it engages with the adjustment screw.
Turn the screw clockwise to decrease the low idle
setting. Turn the screw counterclockwise to increase the
ADJUSTMENTS low speed setting.
The pneumatic speed setting control has two
Feedback Spring
adjustments. One is the speed range bellows
adjustment made by turning the bellows (1) inside the
To use the pneumatic speed setting control with
bellows housing to increase or decrease the speed
different air pressure ranges and engine speed settings
range.
the feedback spring must be changed.
192
is not in good condition.
8. Push plug (3) down in the bore and remove the

bolt.
9. Put plate (2) in position, and install the three

bolts and tighten them to 10 N-m (90 lb. in.).
10. Install tube assembly (1) on the governor.
NOTICE
Be careful not to get paint or other foreign material

REMOVE OIL LINE down in the bore, as this will affect the control
1. Tube assembly. 2. Plate. operation.
1. Remove tube assembly (I) and plate (2) from the 3500 ENGINE PNEUMATIC SPEED CONTROL
governor. SPRING CHART
RATED LOW HIGH FEEDBA SPRING
SPEED IDLE IDLE CK IDENTIFIC
RPM RPM RPM SPRING ATIN
* * PART **
NO.
900 897 to 4W6628 79
1016
1000 967 to 4W6632 65
450 1165
1100
1200 1108 to 4W6627 50 (std.)
1300 1397
REMOVE PLUG 1400
3. Plug. 1500 1375 to 4W6632 64
1670
2. Install one of the bolts for plate (2) into plug (3) 600
as shown and pull plug (3) out of its bore. 1600 1585 to 4W6627 50 (std.)
1700 2018
FEEDBACK SPRING AND SPEED SETTING PISTON 1800
POSITION
3. Plug. 4. Piston. 5. Spring. *The speed settings shown are for the standard
governor setting air pressure of:
3. With plug (3) out of the bore, speed setting Low Idle 35 kPa (5 psi) or 70 kPa (10 psi)
piston (4) and feedback spring (5) can be lifted High Idle 380 kPa (55 psi) or 415 kPa (60 psi)
out of the bore with a magnet. **The spring identification number is on the flat
ground surface on one end of each spring.
4. Find the correct feedback spring to use for the
air pressure range and engine speed rating from Speed Range Bellows Adjustment
the pneumatic speed control spring chart.
The bellows is made off-center (eccentric) to the
5. Install spring (5) in the bore over the speed top flange area. The bottom of the bellows has a swivel
setting rod. pin that engages the hole in the end of the speed setting
lever. The swivel pin is set off-center (eccentric) to the
6. Place piston (4) over spring (5) and push it down bottom of the bellows but is in line with the center of the
into the counterbore. air inlet port in the top of the flange.
7. Install a new seal on plug (3), if the original seal
193
LOWER SPEED SETTING

SPEED SETTING BELLOWS AND LEVER
There is an index mark (notch) 0.76 mm (.030

in.) deep on the outer face of the bellows flange. The
index mark is approximately mid range position when it is
turned to the front of the governor (when facing the
governor name plate).
HIGHER SPEED SETTING
With the index mark to the left side of the

governor (as seen from governor nameplate), the
bellows is farther away from the pivot pin. The lever arm
is now longer and engine speed is increased for a given
amount of air pressure.
SPEED SETTING CONTROL
1. Air inlet port. 2. Feedback spring. 3. Pivot.
Control air pressure enters the bellows through

air inlet port (1) at the top of the flange. Control air
pressure expands the speed setting bellows, which
pushes down on the lever at the left of pivot (3), raising
the right end of the lever against feedback spring (2).
The force of the feedback spring is marked on the end of
the spring.
When the bellows is turned, the eccentric

changes the position of the bellows on the speed setting
lever. This changes the length of the lever arm. The
lever arm is the distance from pivot (3) to the outer edge
of the bellows.
When the bellows is turned with the index mark

to the right side of the governor (counterclockwise as
seen from governor nameplate), the bellows moves CONNECT PRESSURE REGULATOR AND GAUGE
closer to the pivot pin. This makes the lever arm shorter ASSEMBLY
and lowers engine speed for a given amount of air
pressure. Before the control adjustment can be made,
install n pressure regulator and gauge assembly in the
control air supply line. Also, connect a tachometer with
good accuracy to the engine.
194
Increase the control air to the high idle air

pressure [for example 407 kPa (59 psi)] for the engine
high idle speed setting (for example, 1980 rpm).
If the speed is too high, lower the air to the low

idle air pressure setting [76 kPa (11 psi)].
ADJUST AIR PRESSURE
Start the engine and let it run at the low idle

ADJUST BELLOWS
speed setting as given in the Fuel Setting and Related
Information Fiche (for example, 600 rpm).
Loosen the two bolts that hold the bellows clamp
down. With a 3/4 inch wrench, rotate the bellows in a
Turn the air pressure regulator and slowly
counterclockwise direction (as seen from governor
increase and then decrease control air pressure. Engine
nameplate). Again adjust the low idle speed setting back
speed must increase and decrease smoothly and return
to 600 rpm at low air pressure [76 kPa (I psi)], turn the
to the original speed setting (600 rpm).
speed level adjusting screw clockwise.
Return the control air pressure with the regulator
If the speed is too low, lower the air to the low
and gauge assembly to 0 kPa (O psi).
idle air pressure [76 kPa (11 psi)].
NOTE: The governor is shown off engine for
Loosen the two bolts that hold the bellows clamp
photographic purposes. The pneumatic speed setting
down. With the 3/4 inch wrench, turn the bellows in a
control adjustments must be made with the governor on
clockwise direction (as seen from governor nameplate)
the engine, and with the engine running.
and again adjust the low idle speed setting back to the
600 rpm at low air pressure [76 kPa ( 11 psi)].
Adjust the pressure regulator and apply the
required low idle air pressure to the speed setting
Again, increase the control air to the pressure
bellows [for example 76 kPa (11 psi)].
required for the high idle speed. If the speed range is
still incorrect, repeat the above steps until the correct low
idle speed and high idle speed setting is reached for
each required air pressure. Make sure to tighten the
bellows clamp bolts after the speed setting is correctly
adjusted.
Check the pneumatic speed setting control for

external leaks. Remove the air pressure regulator and
pressure gauge assembly from the control air supply
line.
ADJUST LOW IDLE SPEED
Turn the speed level adjusting screw with a 1/8

inch hex wrench and bring the engine speed to the
desired low idle speed setting (for example, 600 rpm).
195
AIR FUEL RATIO CONTROL ADJUSTMENTS (ON PNEUMATIC MID-SPEED CONTROL (ON 3500
3500 SERIES ENGINES) SERIES ENGINES)
ADJUSTMENT OF FUEL LIMIT LEVEL
There are three adjustments for the air fuel ratio PNEUMATIC MID-SPEED CONTROL ADJUSTMENT
control. One is the fuel limit level adjustment screw, the
second is gain rate cam slide adjustment. The third is The control cylinder mounts on the front of the
the cocking level setting. These last two are factory set governor. An adjustable lever is fastened on the speed
and do not require adjustment. Any change to their setting control shaft. The cylinder rod is spring-actuated
settings will require the governor to be put on a test (extended) and air-retracted. With the cylinder retracted,
bench and correct settings made to test bench and the speed setting shaft in the fuel shutoff position,
procedures. set the lever at 60 degrees below the horizontal
centerline. When the cylinder rod is extended the lever
To adjust the fuel limit level, remove the plug will move the speed setting shaft in the "FUEI ON"
from the right front corner of the top cover. Put a 3/16 direction to 45 degrees below the horizontal centerline. If
inch hex wrench through the hole in the top cover until it necessary, adjust the lever to achieve a 1400 rpm engine
engages the fuel limit level adjustment screw. Install and speed.
zero the dial indicator on the side of the engine front
drive housing for checking fuel setting.
For an initial setting, turn the limit level screw in

until it stops, then back it out 10 turns (about mid-travel).
Start the engine and load it enough to generate boost of
10 inches of mercury to cock the control. Disconnect the
air pressure line from the control to the manifold.
Rapidly move the speed control shaft in the

speed increase direction. The dial indicator will go up to
the fuel limit position, pause momentarily, then drop
back. Do this several times and read the dial indicator
during each pause. Or, load the engine until the dial
indicator stops. Where the dial indicator pauses or
stops, is the limit travel setting of the control. Turn the
limit level screw until the dial indicator agrees with the
specifications given in the Fuel Setting and Related
Information Fiche.
When the adjustment is correct, connect the air

pressure line from the control to the manifold. Remove
the hex wrench and install the plug in the top cover.
Remove the dial indicator from the front drive housing.
196
SPECIFICATIONS
SYSTEMS OPERATION
TESTING AND ADJUSTING
HYDRAMECHANICAL
PROTECTIVE SYSTEM
FOR
3500 SERIES ENGINES
197/(198 Blank)
HYDRAMECHANICAL PROTECTIVE SYSTEM
SHUTOFF CONTROL GROUP IDENTIFICATION

Engine Model 3508, 3512, 3516
Rated Engine
RPM 900-1100 1101-1300 1301-1650 1651-1800
OS* 5N6050 5N6051 5N5338 5N5608
Shutoff LOP,*
Control HWT, 5N5328 5N5329 5N5330 5N1960
Group OS
*OS - Overspeed
LOP - Low Oil Pressure
HWT - High Water Temperature
199
HYDRAMECHANICAL PROTECTIVE SYSTEM SPECIFICATIONS
GENERAL TIGHTENING TORQUE FOR

BOLTS, NUTS AND TAPERLOCK STUDS
The following charts give the standard torque values for bolts, nuts and
taperlock studs of SAE Grade 5 or better quality. Exceptions are given in
other sections of the Service Manual where needed.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb. ft. Nâm*
Use these torques for bolts and nuts with standard

threads (conversions are approximate).
114 6.35 9±3 12 ± 4

5/16 7.94 18 ± 5 25 ± 7
3/8 9.53 32 ± 5 45 ± 7
7/16 11.11 50 ± 10 70 ± 15
1/2 12.70 75 ± 10 100 ± 15
9/16 14.29 110 ± 15 150 ± 20
5/8 15.88 150 ± 20 200 ± 25
3/4 19.05 265 ± 35 360 ± 50
7/8 22.23 420 ± 60 570 ± 80
1 25.40 640 ± 80 875 ± 100
1 1/8 28.58 800 ± 100 1100 ± 150
1 1/4 31.75 1000 ± 120 1350 ± 175
1 3/8 34.93 1200 ± 150 1600 ± 200
1 1/2 38.10 1500 ± 200 2000 ± 275
Use these torques for bolts and nuts on hydraulic valve
bodies.
5/16 7.94 13 ± 2 20 ± 3
3/8 9.53 24±2 35 3
7/16 11.11 39 ±2 50 ± 3
1/2 12.70 60 ±3 80 ± 4
5/8 15.88 118 ±4 160 ± 6
Use these torques for studs with Taperlock threads.
1/4 6.35 5±2 7±3

5/16 7.94 10 ± 3 15 ± 5
3/8 9.53 20 ± 3 30 ± 5
7/16 11.11 30 ± 5 40 ± 10
1/2 12.70 40 ± 5 55 ± 10
9/16 14.29 60 ± 10 80 ± 15
5/8 15.88 75 ± 10 100 ± 15
3/4 19.05 110 ± 15 150 ± 20
7/8 22.23 170 ± 20 230 ± 30
1 25.40 260 ± 30 350 ± 40
1 1/8 28.58 320 ± 30 400 ± 40
1 1/4 31.75 400 ± 40 550 ± 50
1 3/8 34.93 480 ± 40 650 ± 50
1 1/2 38.10 550 ± 50 750 ± 70
*1 newton meter (Nâm) is approximately the same as 0.1 mkg. T95416-7
200
The torques shown in the chart that follows are to be used on the part of 37° Flared, 45° Flared and Inverted Flared fittings
(when used with steel tubing), O-ring plugs and O-ring fittings.


possible. Hold these components in this position.
Turn the fitting into the part it is used on, until
backup washer (4) just makes contact with the
face of the part it is used on.
NOTE: If the fitting is a connector (straight fitting) or

plug, the hex on the body takes the place of the locknut.
To install this type fitting tighten the hex against the face
of the part it goes into.

turn the fitting body (2) out (counterclockwise) a
maximum of 359°. Tighten locknut (3) to the ELBOW BODY ASSEMBLY
torque shown in the chart. 1. End of fitting body (connects to tube). 2. Fitting
body. 3. Locknut. 4. Backup washer. 5. O-ring
A71009X3 seal. 6. End of fitting that goes Into other part.
201
THERMOSTATIC PILOT VALVE

(4L7108)
Temperature at which valve

opens................................................99 ± 2°C (210 ± 3°F)
ACCESSORY (SHUTOFF) DRIVE GROUP
(1) Distance dowels extend from (8) Drive gear. Tighten the bolts that hold drive gear
housing ................. 6.0 + 0.5 mm (.236 + .020 in.) (8) and the camshaft drive gear as follows:
(2) Diameter of gear shaft a. Use hand pressure to turn and hold
- (new) .... 15.890 ± 0.013 mm (.6256 + .0005 in.) camshaft drive gear in its of normal
Bore in bearings for gear direction of rotation. This removes all gear
shaft........ 16.027 + 0.013 mm (.6310 + .0005 in.) clearance (backlash) between camshaft
(3) Diameter of drive gear and the idler gear.
bearings.... 20.70 + 0.013 mm (.8150 + .0005 in.) b. Install drive gear (8) to hold camshaft drive
Bore in housing for the gear to the camshaft.
bearings.......... 20.66 + 0.03 mm (.813 + .001 in.) c. Tighten the bolts in steps to a torque of 100
Distance bearings are installed from ends ± 15 Nâm (75 ± 11 lb. ft.)
of bore .................. 1.5 + 0.5 mm (.059 + .020 in.) d. Hit the face of drive gear (8) and tighten the
(4) Install the seal with the lip toward the engine as bolts to a torque of 100 ± 15 Nâm (75 ± 11
shown. Put clean engine oil on the lip of the lb. ft.).
seal. e. Again hit the face of drive gear (8) and
(5) Distance bearing is again tighten the bolts to a torque of 100 4
installed ...................... 26 + 1 mm (1.02 + .04 in.) 15 N-m (75 + 11 lb. ft.).
(6) Distance dowels extend from NOTE: If necessary, repeat the steps above until the
gear .................... 9.5 +- .0.5 mm (.374 + .020 in.) bolts hold torque (cannot be moved) to make sure the
(7) Distance two dowels extend from camshaft drive gear is in full contact with the taper of the
housing ................. 6.0 + 0.5 mm (.236 + .020 in.) camshaft.

202
SHUTOFF CONTROL GROUP
(1) Torque for 6K9194 Elbow...11 ± 3 Nâm (8 ± 2 lb. ft.)

(2) Torque for 321267
Connectors .................................11 ± 3 Nâm (8 ± 2 lb. ft.)
(3) Torque for 5M6213 Plugs...11 ± 3 Nâm (8 ± 2 lb. ft.)
(4) Torque for 321268 Elbows ...11±3 Nâm (8 ± 2 lb. ft.)
(5) Spring for overspeed adjustment: See
OVERSPEED SPRING CHART.
OVERSPEED SPRING CHART

Part No. 7B7714 2N7029 5N5297
Length under 18.3 mm 31.0 mm 20.3 mm
test force (.72 in.) (1.22 in.) (.80 in.)
Test force 34.7 to 40.9 N 18 N 16 ± .05 N
(7.8 to 9.2 lb.) (4 lb.) (3.6 ± .1 lb.)
Free length 33.7 mm 50.0 mm 37.3 mm
after test (1.33 in.) (1.97 in.) (1.47 in.)
Outside 11.94 mm 9.53 mm 9.22 mm
diameter (.470 in.) (.375 in.) (.363 in.)
Used with 5N5328
Shutoff 5N 1960 5N5329 5N5330
Control 5N5608 5N6051 5N5338
Group 5N6050
(6) Dimension from end of speed sensing valve to the

seat ................ 117.21 ± 0.25 mm (4.615 ± .010 in.)
(7) Torque for eight cover
bolts...........................3.4 ± 0.5 N-m (31 ± 4 lb. in.)
(8) Speeder Spring: See SPEEDER SPRING
CHART.
(9) Thickness of geroter
assembly .. 25.000 ± 0.006 mm (.9843 ± .0002 in.)
Depth of
counterbore25.033 ± 0.006 mm (.9856 ± .0002 in.)
(10) Diameter of
shaft ......... 14.750 ± 0.013 mm (.5807 ± .0005 in.)
Diameter of bore
in cover..... 14.801 + 0.013 mm (.5827 ± .0005 in.)
(11) Diameter of
shaft ......... 12.000 + 0.013 mm (.4724 ± .0005 in.)
Diameter of bore
in housing.........12.051 4 0.013 (.4744 ± .0005 in.)
203
Shutoff Control Group (Cont.)
SPEEDER SPRING CHART

Spring Part No. 8M 1682 3N5751 3N8403 5N5296 6N2129
Put a force on spring of - - - - 8.9 N
(2.00 lb.)
Then add more force to - - - - 17.8 mm
make spring shorter by (.70 in.)
Total test force - - - - 36.92 ± 0.89 N
(8.307 ± .200 lb.)
Length under test force 15.8 mm 38.2 mm 38.2 mm 38.2 mm
(.62 in.) (1.50 in.) (1.50 in.) (1.50 in.)
Test force 44.5 ± 3.6 N 14.2 N 6.23 N 8.01 N
(10 ± .8 lb.) (3.2 lb.) (1.4 lb.) (1.8 lb.)
41.2 mm 45.0 mm 41.2 mm 45.72 mm 44.2 ± 0.5 mm
Free length after test (1.62 in.) (1.77 in.) 1.62 in.) (1.80 in.) (1.74 ± .02 in.)
Outside diameter 35.33 mm 35.00 mm 35.00 mm 34.60 mm 37.84 mm
(1.391 in.) (1.378 in.) (1.378 in.) (1.362 in.) (1.490 in.)
Used with Shutoff 5N1960 5N5330 5N5328
Control Group 5N6051 5N5608 5N5338 5N5060 5N5329
(12) 5N6449 Spring for oil pump relief valve:

Test force .................................... 226.9,N (51 lb.)
Free length after test .......... 53.37 mm (2.101 in.)
Outside diameter .................. 10.59 mm (.417 in.)
(13) Speeder spring adjustment bolt used with two
step oil pressure protection function.
(14) Install shaft so end is even with side of
housing within...................... 0.25 mm (± .010 in.)

204
Shutoff Control Group (Cont.)
(15) 3N5757 Spring for selector valve:

Length under test force .....25.50 mm (1.004 in.)
Test force ................................... 9.8 N (2.20 lb.)
Free length after test .........37.69 mm (1.484 in.)
Outside diameter ...................8.81 mm (.347 in.)
(16) 3N5738 Spring for low range oil pressure valve:
Test force ................................. 39.1 N (8.79 lb.)
Free length after test .........66.62 mm (2.623 in.)
Outside diameter .................12.62 mm (.497 in.)
(17) 3N5739 Spring for high range oil pressure valve:
Test force ................................. 68.9 N (15.5 lb.) ACTUATOR VALVE
Free length after test .......111.56 mm (4.392 in.)
Outside diameter .................11.99 mm (.472 in.)
(18) 5N5755 Fuel (Rack) Shutoff Circuit Sequence
Valve:
Tighten valve to a torque of 58±4 Nâm (43±3 lb. ft.)
Set valve to bypass at...... 806 ± 28 kPa (117 - 4 psi)
at7.57 liter/min (2 U.S. gpm)
(19) 5N6096 Spring for manual shutoff valve:
Length under test force.........25.50 mm (1.004 in.)
Test force....................................... 19.6 N (4.4 lb.)
Free length after test ............48.77 mm (1.920 in.)
Outside diameter ....................13.82 mm (.544 in.)
(20) 8H8731 Spring for pilot valve:
Length under test force...........17.86 mm (.703 in.)
Test force......................................... 4.3 N (.95 lb.)
Free length after test ..............22.23 mm (.875 in.)
Outside diameter ......................5.94 mm (.234 in.)
(21) 5N4749 Air Inlet Shutoff Circuit Sequence Valve:
Tighten valve to a torque of 58 ± 4 Nâm (43 ± 3 lb. ft.)
Set valve to bypass at....103 + 14 kPa (15 + 2 psi)
PRESSURE CONTROL VALVE
205
AIR INTAKE SHUTOFF

(5N9060)
(1) Install shaft assembly in housing as follows: shutoff group in the "open" position and install the
a. Install spacer (3) and spring (2) on shaft gasket, flange and cylinder with cylinder shaft (15)
assembly (1). between the spacer assembly in the shaft lever and
b. Install the assembly in the housing. Turn spacer assembly (16). The bolts that hold the unit to
spring (2) until it engages correctly with pin the aftercooler housing can now be installed.
(4).
c. Install handle (10) on the shaft assembly (8) Torque for nut that holds cylinder to
(1). Turn shaft assembly (1) upward and flange .............................. 45±7 Nâm (33±5 lb. ft.)
install pin (13) so handle (10) can rest on (9) Diameter of
pin (13). pin ...............6.299 + 0.008 mm (.2480±.0003 in.)
d. With the shaft assembly and handle (10) in Bore in spacer bushing for pin (after
contact with pin (13), install plate assembly)......6.314±0.011 mm (.2486±.0004 in.)
assemblies (5) and (6) on the shaft Bore in spacer for
assembly.
bushing..........7.938±0.013 mm (.3125±.0005 in.)
e. Remove pin (13) to release the handle and
(10) Handle.
let plate assemblies (5) and (6) move to the
(11) Diameter of
"shutoff" position. A 0.08 mm (.003 in.)
feeler gauge should not pass between each pin (13) ..........6.299±0.008 mm (.2480±.0003 in.)
plate assembly and the housing. Bore in housing for
f. Remove handle (10) and install spacer pin .................6.408±0.051 mm (.2523±.0020 in.)
assembly (12), pin (13), the gasket, cover Bore in spacer bushing for pin (after
assembly and handle(10). assembly)......6.314±0.011 mm (.2486±.0004 in.)
(2) Spring. Bore in spacer for
(3) Spacer for spring (2): bushing..........7.938±0.013 mm (.3125±.0005 in.)
Bore in spacer for (12) Spacer.
shaft......................... 20.80±0.25 mm (.819±.010 in.) (13) Pin.
Diameter of shaft .. 18.94 4±0.02 mm (.746±.001 in.) (14) Diameter of shaft.18.94±0.02 mm (.746±.001 in.)
(4) Pin. Inside diameter of bushings for
(5) Plate assembly. shaft ............19.050±0.044 mm (.7500±.0017 in.)
(6) Plate assembly. (15) Hydraulic cylinder shaft
(7) Hydraulic cylinder must be installed before the air (16) Spacer assembly.
shutoff can be installed on the engine. Put the air

206
AIR INTAKE SHUTOFF

(2W7163)
(1) Hydraulic shutoff cylinder. Make an alignment of Free length after test...............54.6 mm (2.15 in.)
cylinder port and vent hole (9) in a vertical Outside diameter.....................9.04 mm (.356 in.)
downward position at assembly. (5) Torque for carrier (put 2P2506 Thread Lubricant
(2) Torque for nut that holds cylinder (1) to the on the
flange...............................45±7 Nâm (33±5 lb. ft.) threads) ......................... 70±10 Nâm (50±7 lb. ft.)
(3) Diameter of cylinder (6) Bore in spring
rod ........................7.920±0.013 (.3118±.0005 in.) bushing................19.30±0.25 mm (.760±.010 in.)
Bore in bushing after Diameter of
assembly ...... 7.996±0.044 mm (.3148±.0017 in.) shaft ....................18.97±0.02 mm (.747±.001 in.)
Bore in housing for (7) Diameter of
bushing ......... 9.525±0.013 mm (.3750±.0005 in.) shaft ....................18.97±0.02 mm (.747±.001 in.)
Install bushing with split along centerline (8) Bore in two shaft bushings (after
toward front or rear. assembly)....19.050±0.044 mm (.7500±.0017 in.)
(4) 2V244 Spring for shutoff actuator pin: Bore in housing for
Length under test force .......... 29.2 mm (1.15 in.) bushings......22.205±0.013 mm (.8742±.0005 in.)
Test force ....................... 8.9±0.7 N (2.00±.16 lb.)
207
AIR INTAKE SHUTOFF

(2W5216)
(1) Latch. bearings ....27.997±0.010 mm (1.1230±.0004 in.)

(2) Shutoff cylinder rod. (8) Shaft assembly.
(3) Install shutoff cylinder as follows: (9) Plate assembly.
a. Assemble shutoff cylinder on the flange at NOTE: With plate assembly (9) in the closed (shutoff)
the angle shown. position, a 0.8 mm (.03 in.) feeler gauge must not pass
b. Tighten the nut that holds the shutoff between the plate assembly and the housing bore at any
cylinder to the flange to a position.
torque of ..................45±7 Nâm (33±5 lb. ft.) (10) Lever return spring.
c. Install the flange on the air shutoff housing. (11) Lever.
Make sure cylinder rod (2) is engaged in (12) Sleeve.
the notch of lever (11). (13) Diameter of
NOTE: The cylinder vent hole, between the ports, must sleeve..........14.945±0.009 mm (.5995±.0004 in.)
be in the downward position. Bore in bushing (after
(4) Knob. assembly)....15.024±0.034 mm (.6026±.0014 in.)
(5) Diameter of shaft assembly at Bore in lever for
seal ..................... 15.88±0.05 mm (.625±.002 in.) bushing........17.009±0.009 mm (.6823±.0004 in.)
(6) Air shutoff spring. NOTE: Install both bushings to a dimension of 0.8 + 0.3
(7) Diameter of shaft mm (.03 + .01 in.) below the surface of lever ends.
assembly ............ 24.88±0.02 mm (.980±.001 in.) (14) Dimension to install end of two bushings from
Bore in bushings for shaft assembly (after machined
assembly) . 25.017±0.040 mm (1.0035±.0016 in.) housing bore .........0.35±0.15 mm (.014±.006 in.)
Bores in housing for

208
TACHOMETER AND SERVICE camshaft drive gear is in full contact with the taper on the
METER DRIVE camshaft.
(5) Tachometer drive adapter.
(1) Put clean engine oil or glycerin on the O-ring (6) Camshaft drive gear.
seal at assembly. (7) Cover.
(2) Bearing.
(3) Install seal in cover (7) with the lip of the seal
toward bearing (2). Put clean engine oil on the
lip of the seal after it is installed.
(4) Bolts. Tighten the bolts as follows:
a. Use hand pressure to turn and hold
camshaft drive gear (6) in its normal
direction of rotation. This removes all gear
clearance (backlash) between camshaft
drive gear (6) and the idler gear.
b. Install tachometer drive adapter (5) to hold
the camshaft drive gear to the camshaft.
c. Tighten the bolts in steps to a torque of
100±15 Nâm (75 = 11 lb. ft.)
d. Hit the face of tachometer drive adapter (5)
and tighten bolts to a torque of 100±15
Nâm (75±11 lb. ft.).
e. Again hit the face of tachometer drive
adapter (5) and again tighten the bolts to a
torque of 100 + 15 Nâm (75 + 11 lb. ft.).
NOTE: If necessary, repeat steps above until the bolts
hold torque (cannot be moved) to make sure the
REMOTE SHUTOFF VALVE GROUP
(1) Locknut.
(2) Cylinder threads.
Clean threads of cylinder and locknut (1) thoroughly. Put
9S3265
Retaining Compound on threads of cylinder and locknut
at
assembly.
209
ELECTRICAL SWITCHES
5N8597 Contactor (Coolant)

Switch operates when temperature increases
to........................................98.3±0.6°C (208±1°F)
7N5946 Pressure Switch

Circuit 1: normally closed
Circuit 2: normally open
With an increase in pressure, circuit 1 opens and
circuit 2 closes at ...........................145 kPa (21 psi) max.
With a decrease in pressure, circuit 2 opens and
circuit 1 closes at ........................... 75±20 kPa (11±3 psi)
9D7032 Pressure Switch,

With an increase In pressure; switch closes
at .................................................. 517±35 kPa (75±5 psi)
With a decrease in pressure, switch opens
at................................................ 415±35 kPa (60 4±5 psi)

210
HYDRAMECHANICAL PROTECTIVE SYSTEM SYSTEMS OPERATION
The hydramechanical protective system is de- From Figure 1, it can be seen that if only the low
signed as a self contained system separate from the range oil pressure protection level was used for the full
engine governor. This system is used to activate an speed range, the engine could operate at rated speed
alarm or shutdown an engine for low oil-pressure, high with oil pressure below the required level. Also, if only
coolant temperature or engine overspeed conditions. the high range oil pressure protection level was used for
the full speed range, the system would shutdown the
OVERSPEED engine at low idle, since the engine oil pump develops
lower pressure at that speed. Therefore, the protective
In general, an overspeed condition is the result system must operate between the required oil pressure
of a fuel system that fails to operate correctly. This in curve and the engine oil pressure curve. This is done
turn allows the combustion system to get more fuel than with a step action of pressure versus speed.
the engine load needs. The excess fuel can accelerate
the engine to a point that engine failure can be the result. The hydramechanical protective system
operates within the two ranges of engine oil pressure.
The rate of engine acceleration is controlled by As engine speed increases, the minimum oil pressure
several factors. Friction horsepower, attached inertial needed at the main bearings also increases. At low
loads and operating loads make up the main affects on engine speed, an alarm or fuel shutoff actuator will
acceleration. In most all cases, the protective system activate when oil pressure is reduced to within 140 ± 35
must have a response time of less than one second. kPa (20 ± 5 psi). At high engine speeds, an alarm or fuel
Response time is the time interval between the shutoff actuator will activate when oil pressure is reduced
overspeed and the actuation of the protective system. to within 205 ± 35 kPa (30 ± 5 psi).
The protective system must provide this response under
different conditions such as engine start up at extreme For a low oil pressure condition, the protective
ambient temperatures and under full load operation. system activates an alarm or moves the fuel control
linkage, through the governor, to the "SHUTOFF"
For an overspeed condition the fuel control linkage is position. The combustion air supply is not shutoff for this
moved to the "SHUTOFF" position and the engine condition.
combustion air supply is stopped.
HIGH COOLANT TEMPERATURE
LOW ENGINE OIL PRESSURE
If the coolant temperature of an engine goes
As engine speed increases, the required oil pressure for above a set limit, the protective system activates an
main bearing protection increases. The engine oil pump alarm or moves the fuel control linkage to the
is a positive displacement type pump, therefore, engine "SHUTOFF" position to shutdown the engine. The
oil pressure varies in direct proportion to speed until the combustion air supply is not stopped under this
pump goes on controlled bypass. condition.
SYSTEM COMPONENTS
The system consists of an emergency manual
shutoff, a shutoff control group, a diverter valve, a
thermostatic pilot valve, an air inlet shutoff and a fuel
shutoff actuator for the governor.
The air and fuel shutoff systems are separate

from each other to give complete engine shutdown for an
overspeed condition. If the engine fuel is held in the
"ON" position, the air inlet shutoff must work to shutdown
the engine.
FIGURE 1. TWO-STEP OIL
PRESSURE PROTECTION
211
Emergency Manual Shutoff flyweights move out and push the speed sensing valve
spool out to open and close passages to put oil pressure
This shutoff is used under emergency conditions into the correct system circuits. This gives correct
to shutdown the engine manually. When operated, this protective system operation under the two engine oil
shutoff simulates an engine overspeed condition in the pressure ranges.
protective system. Thus, the air and fuel to the
combustion chambers is stopped. The shutoff is also Diverter Valve
used to check the protective system for correct operation
at regular engine maintenance periods. If there is a low oil pressure, high coolant
temperature or engine overspeed condition, the diverter
The emergency manual shutoff can be operated valve moves to put system oil pressure in the fuel shutoff
at the engine or from a remote location. For remote circuit. This moves the governor and fuel control linkage
operation, either air or electric power can be used. to the "SHUTOFF" position to shutdown the engine.
Shutoff Control Group Thermostatic Pilot Valve
This valve is used to feel engine coolant

temperature. If the coolant temperature goes above the
limit of the thermostatic pilot valve, the valve opens and
causes engine shutdown through the fuel shutoff circuit
of the protective system.
Water Temperature Contactor
The contactor switch for water temperature is

installed in the water manifold housing (below the
regulator housing). This is normally where the
thermostatic pilot valve is installed. No adjustment to the
temperature range of the contactor can be made. The
element feels the temperature of the coolant and then
operates a micro switch (in the contactor) when the
coolant temperature is too high. The element must be in
contact with the coolant to operate correctly. If the cause
for the engine being too hot is because of low coolant
level or no coolant, the contactor switch will not operate.
The switch is connected to an alarm system and

SHUTOFF CONTROL GROUP activates an alarm under high coolant temperature
1. Spring for overspeed adjustment. 2. Emergency conditions. When the temperature of the coolant lowers
manual shutoff valve. 3. Valve spool (not used). 4. to the operating range, the contactor switch opens
Selector valve. 5. Speed sensing valve spool. 6. automatically.
Speeder spring. 7. Flyweights. 8. Low speed oil
protection valve. 9. High speed oil protection valve.
10. Oil pump. 11. Oil pressure relief valve. 12.
Pressure control valve group which consists of: the
fuel and air inlet sequence valves, the two-way pilot
operated valve and emergency manual shutoff valve
(2).
A flyweight controlled, speed sensing valve spool is used

to feel engine speed. The speed sensing valve spool is
moved by flyweights which are turned by a drive shaft.
The drive shaft is driven by the engine camshaft through
an accessory drive group that has an oil reservoir for the WATER TEMPERATURE CONTACTOR SWITCH
shutoff system. When engine speed increases, the
212
Air Inlet Shutoff
The air inlet shutoff consists of a shutoff valve in

the engine air inlet housing and a hydraulic actuator that
holds the shutoff valve in the "OPEN" position.
If an engine is operated in a combustible atmo-

sphere, such as an oil or gas blow out on an oil rig, the
air supply must be stopped to give a positive method of
engine shutdown. If only the fuel control linkage was
moved to the "SHUTOFF" position, the engine may
continue to run on the air-oil-gas mixture pulled into the
engine air intake.
The hydramechanical protective system closes SHUTOFF CONTROL GROUP

the air inlet shutoff valve to stop combustion air supply to 3. Shutoff control group. 4. Engine oil pressure
the engine in an overspeed condition, to give a more line. 7. Diverter valve. 9. Oil line to thermostatic
positive shutdown. The air inlet shutoff valve is also pilot valve. 10. Oil line to fuel shutoff actuator.
closed when the emergency manual shutoff is operated.
Since overspeed is a serious occurrence, the air inlet

shutoff must be manually reset. This action requires a
person t6 physically go to the engine and see if any
damage has occurred.
Fuel Shutoff Actuator
This actuator is located on top of the Woodward

UG-8 or the Caterpillar 3161 Governor. The actuator
can be either an electric or hydraulic actuator that is
operated any time the hydramechanical protective
system causes engine shutdown. When operated by the
diverter valve, the actuator moves the governor shutoff
strap which causes the governor to move the engine fuel
AIR INLET SHUTOFF
control linkage to the "SHUTOFF" position.
11. Air inlet shutoff housing. 12. Air inlet shutoff
actuator. 13. Aftercooler housing.
COMPONENT LOCATIONS ON ENGINE

1. Oil lines to air inlet shutoff actuator. 2. Rack
sequence valve. 3. Shutoff control group. 4.
Engine oil pressure line. 5. Emergency manual AIR INLET SHUTOFF
shutoff valve. 6. Cover (oil reservoir). 7. Diverter 11. Air inlet shutoff housing. 13. Aftercooler
valve. 8. Air inlet sequence valve. housing. 14. Reset knob.
213
SYSTEM HYDRAULICS
Engine lubrication oil (under pressure) is sent to

the oil reservoir for the shutoff control. The reservoir
keeps the correct level of oil for the system and drains
the excess oil back into the engine. This gives a
constant oil supply to the system.
An oil pump and pressure relief valve (located in

the shutoff control group) supplies oil flow and pressure
for the protective system hydraulic circuits.
There are two main hydraulic circuits in the protective

COOLANT TEMPERATURE PROTECTION system. One circuit is for the fuel shutoff and the other is
13. Aftercooler housing (coolant inlet). 15. for air inlet shutoff. A constant flow of oil through the air
Thermostatic pilot valve. 16. Housing (below inlet shutoff circuit removes (bleeds) air and keeps the
regulator housing). lines full of oil to give a minimum time for system
response. If a fault condition occurs, the oil pressure in
one or both hydraulic circuits is increased to operate an
actuator to shutdown an engine or activate an alarm.
HYDRAULIC CIRCUITS (EARLIER)
(Without Check Valves In Diverter Valve)
The schematics that follow, show only hydraulic

actuators that are filled to cause engine shutdown. The
fuel shutoff actuator can be replaced with an electric
solenoid that is operated by the system hydraulics with
the use of a pressure switch.
NOTE: Some of the schematics show only the

GOVERNOR SHUTOFF ACTUATOR
components needed for explanation and do not show the
(Woodward UG-8 Governor Shown)
complete hydramechanical protective system circuits.
9. Oil line to thermostatic pilot valve. 10. Oil line to
fuel shutoff actuator. 17. Fuel shutoff actuator.
214
SCHEMATIC NO. 1 (COMPLETE HYDRAMECHANICAL PROTECTIVE SYSTEM)

1. Selector valve. 2. Low speed oil protection valve. 3. Start-up override valve. 4. Diverter valve orifice. 5.
Engine oil pressure orifice. 6. Speed sensing valve spool. 7. Diverter valve. 8. Fuel shutoff actuator. 9.
Thermostatic pilot valve. 10. High speed oil protection valve. 11. Emergency manual shutoff valve. 12. Air inlet
shutoff actuator. 13. Air inlet sequence valve. 14. Pilot operated two-way valve. 15. Fuel shutoff sequence
valve. 16. Air inlet shutoff valve. 17. Oil pump. 18. Oil pressure relief valve.
215
SCHEMATIC NO. 2 (LOW ENGINE OIL PRESSURE CIRCUIT)

(Low Speed Range)
1. Selector valve. 2. Low speed oil protection valve. 4. Diverter valve orifice. 6. Speed sensing valve spool. 7.
Diverter valve. 8. Fuel shutoff actuator. 10. High speed oil protection valve. 15. Fuel shutoff sequence valve.
17. Oil pump.
LOW SPEED RANGE (NORMAL ENGINE OIL

PRESSURE)
Make Reference to Schematic No. 2 At diverter valve (7), the oil flows through orifice
(4) which causes a pressure difference across both ends
When an engine is started and speed increases, of the valve spool. The valve spool is then moved by
engine oil pressure moves low speed oil protection valve system oil pressure, against a spring force, to keep the
(2) open. At the same time, oil in the protective system fuel shutoff actuator from being operated. The oil then
flows from oil pump (17) to fuel shutoff sequence valve ( flows from diverter valve (7) to drain through low speed
15) and diverter valve (7). Fuel shutoff sequence valve oil protection valve (2) and selector valve ( I ).
(15) keeps the inlet pressure to diverter valve (7) at 760
kPa (110 psi) and then directs the remainder of oil flow NOTE: Engine oil pressure is not high enough at this
through the air inlet shutoff circuit. Most of the air inlet point to move valve (10) against the force of the spring.
shutoff circuit has been left out since it is not directly in
use at this point.
216
SCHEMATIC NO. 3 (LOW ENGINE OIL PRESSURE FAULT)

(Low Speed Range)
17. Oil pump.
LOW SPEED RANGE (LOW ENGINE OIL

PRESSURE FAULT)
Make Reference to Schematic No. 3
If the engine oil pressure goes below 140 kPa

(20 psi), the spring force on low speed oil protection
valve (2) will close the valve. The oil flow in the
circuit is then stopped and can not flow to drain.
The pressure of the oil will become equal to both
sides of diverter valve orifice (4). Spring force will
move the valve spool of diverter valve (7) down so
that there is alignment with the passage that leads
to fuel shutoff actuator (8). Oil pressure will now
activate the fuel shutoff actuator, which will cause
the governor to move the fuel control linkage to the
"SHUTOFF" position and shutdown the engine.
217
SCHEMATIC NO. 4 (LOW ENGINE OIL PRESSURE CIRCUIT)

(High Speed Range)
Diverter valve. 8. Fuel shutoff actuator. 10. High speed oil protection valve. 12. Air inlet shutoff actuator. 13.
Air inlet sequence valve. 14. Pilot operated two-way valve. 15. Fuel shutoff sequence valve. 16. Air inlet shutoff
valve. 17. Oil pump. 18. Oil pressure relief valve.
HIGH SPEED RANGE (NORMAL ENGINE

OIL PRESSURE)
At approximately 70% of engine full load speed,
the oil pressure protection changes from the low
speed range to the high speed range. At this
point engine oil pressure is high enough to open
high speed oil protection valve (10).
System oil flow to diverter valve (7) is the same

as it is for the low speed range except speed
sensing valve spool (6) has been shifted. When
the engine speed increases to the high speed
range, speed sensing valve spool (6) will be
moved up by the flyweights. This directs system
oil pressure at 760 kPa (110 psi) to selector valve
(1). The valve closes toL/ remove low range oil
pressure protection valve (2) from the circuit. The
oil now flows from diverter valve (7) to drain
through high speed oil protection valve (10) and
pilot operated two-way valve (14).
218
SCHEMATIC NO. 5 (LOW ENGINE OIL PRESSURE FAULT)

(High Speed Range)
17. Oil pump.
HIGH SPEED RANGE (LOW ENGINE OIL

PRESSURE FAULT)
When engine oil pressure decreases to 205 kPa (30

psi), the spring force on high speed oil protection
valve (10) will move the valve to stop oil flow to the
drain. The difference in oil pressure across diverter
valve orifice (4) will now go to zero. The valve spool
of diverter valve (7) will move down by spring force,
which will cause alignment of the ports to fuel shut-
off actuator (8). The actuator now causes the
governor to move the fuel control linkage to the
"SHUT- OFF" position and shutdown the engine.
219
SCHEMATIC NO. 6 (ENGINE COOLANT TEMPERATURE CIRCUIT)

(Low Speed Range Shown)
1. Selector valve. 2. Low speed oil protection valve. 4. Diverter valve orifice. 7. Diverter valve. 8. Fuel shutoff
actuator. 9. Thermostatic pilot valve. 10. High speed oil protection valve. 15. Fuel shutoff sequence valve.
HIGH, ENGINE COOLANT TEMPERATURE

CIRCUIT (NORMAL CONDITIONS)
Under high coolant temperature conditions, the low

engine oil pressure circuits are used to shutdown an
engine. The schematic shows the low speed range
engine oil pressure circuit in use and the coolant
temperature circuit added to the engine oil pressure
line. Engine temperature is normal and
thermostatic pilot valve (9) is closed.
Oil flow through the system is the same as in the low

and high speed range of the LOW ENGINE OIL
PRESSURE CIRCUIT.
NOTE: The sensor of the thermostatic pilot valve (9)

must be below the water level in the coolant manifold
to operate.
220
SCHEMATIC NO. 7 (HIGH ENGINE COOLANT TEMPERATURE FAULT)

1. Selector valve. 2. Low speed oil protection valve. 4. Diverter valve orifice. 7. Diverter valve. 8. Fuel shutoff
actuator. 9. Thermostatic pilot valve. 10. High speed oil protection valve. 15. Fuel shutoff sequence valve.
HIGH ENGINE COOLANT TEMPERATURE

CIRCUIT (FAULT CONDITION)
When engine coolant temperature increases to

99°C (2100F), thermostatic pilot valve (9) will
open. This will let engine oil in the circuit drain
and cause a decrease in oil pressure on low
speed oil protection valve (2) and high speed oil
protection valve (10). Valves (2) and (10) will
close and stop oil flow from diverter valve (7).
The difference in oil pressure across diverter
valve orifice (4) will now go to zero. The valve
spool of diverter valve (7) will move down by
spring force, which will cause alignment of the
ports to fuel shutoff actuator (8). The actuator
now causes the governor to move the fuel
control linkage to the "SHUTOFF" position and
shutdown the engine.
221
OVERSPEED CIRCUIT (NORMAL

CONDITIONS)
When an engine is started and speed

increases, engine oil pressure opens low speed
oil protection valve (2) and high speed oil
protection valve (10). At the same time, oil in the
protective system flows from oil pump (17) to
fuel shutoff sequence valve (15), speed sensing
valve spool (6) and diverter valve (7). Fuel
shutoff sequence valve (15) keeps the oil
pressure to diverter valve (7) and speed sensing
valve spool (6) at 760 kPa (110 psi) and then
directs the remainder of oil flow through the air
inlet shutoff circuit. At higher engine speeds,
speed sensing valve spool (6) directs oil
pressure to close selector valve (1).
Oil in the air inlet shutoff circuit is directed to

air inlet sequence valve (13) and air inlet shutoff
actuator (12). Air inlet sequence valve (13)
keeps the oil pressure in air inlet shutoff actuator
(12) at 105 kPa ( 15 psi) and then directs the
remainder of oil flow to drain through pilot
operated two-way valve (14), which is normally
open. Pilot operated two-way valve (14) is held
open by spring force and the pilot oil pressure is
connected to the drain through speed sensing
valve spool (6).
At diverter valve (7), the oil flows through

orifice (4) which causes a pressure difference
across both ends of the valve spool. The valve
spool is then moved by system oil pressure,
against a spring force, to keep the fuel shutoff
actuator from being operated. The oil then flows
from diverter valve (7) to drain through high
speed oil protection valve (10) and pilot operated
two-way valve (14).
NOTE: Low engine oil pressure or high coolant

temperature conditions do not change the oil
flow in the air inlet shutoff circuit.
222
SCHEMATIC NO.8 (OVERSPEED CIRCUIT)

Engine oil pressure orifice. 6. Speed sensing valve spool. 7. Diverter valve. 8. Fuel shutoff actuator. 9.
Thermostatic pilot valve. 10. High speed oil protection valve. 11. Emergency manual shutoff valve. 12. Air inlet
shutoff actuator. 13. Air inlet sequence valve. 14. Pilot operated two-way valve. 15. Fuel shutoff sequence
valve. 16. Air inlet shutoff valve. 17. Oil pump. 18. Oil pressure relief valve.
223
SCHEMATIC NO. 9 (OVERSPEED FAULT)

Diverter valve. 8. Fuel shutoff actuator 12. Air inlet shutoff actuator 13. Air inlet sequence valve. 14. Pilot
operated two-way valve. 15. Fuel shutoff sequence valve. 18. Oil pressure relief valve.
OVERSPEED CIRCUIT (OVERSPEED FAULT) supply to the engine. Fuel shutoff circuit oil also can not
go to drain. The difference in oil pressure across diverter
Make Reference to Schematic No. 9. valve orifice (4) will now go to zero. The valve spool of
diverter valve (7) will move down by spring force, which
When the engine speed is 18% above full load will cause alignment of the ports to fuel shutoff actuator
speed, speed sensing valve spool (6) will be moved up (8). Now, oil pressure in the fuel shutoff circuit will
by the flyweights. This will send oil to pilot operated two- activate fuel shutoff actuator (8), which will cause the
way valve (14) and to the spring side of air inlet governor to move the fuel control linkage to the
sequence valve (13). The oil pressure will close both “SHUTOFF” position.
valves and oil in the air inlet shutoff system can not go to
drain. The oil pressure in the system will i crease until oil NOTE: Because the air inlet shutoff is the most positive
pressure relief valve (18) opens at 1720kPa (250psi). way to shutdown an engine, air inlet shutoff actuator (12)
The increase pressure will move air inlet shutoff actuator is activated by the protective system before fuel shutoff
(12), which will release the air inlet shutoff valve. This actuator (8) is activated.
stops the combustion air
224
SCHEMATIC NO. 10 (EMERGENCY MANUAL SHUTOFF)

4. Diverter valve orifice. 6. Speed sensing valve spool. 7. Diverter valve. 8. Fuel shutoff actuator. 11.
Emergency manual shutoff valve. 13. Air inlet sequence valve. 14. Pilot operated two-way valve. 15. Fuel
shutoff sequence valve. 18. Oil pressure relief valve.
EMERGENCY MANUAL SHUTOFF
When the knob on emergency manual shutoff (

11 ) is pulled, system oil flow is directed to pilot
operated two-way valve (14) to close the valve.
This stops oil flow to drain in both the fuel and air
inlet shutoff circuits. The protective system then,
shuts down the engine in the same sequence as
for an overspeed fault condition. The
combustion air supply is stopped and the fuel
control linkage is moved to the "SHUT- OFF"
position to shutdown the engine.
225
SCHEMATIC NO. 11 (START-UP OVERRIDE)

2. Low speed oil protection valve. 3. Start-up override valve. 4. Diverter valve orifice. 7. Diverter valve. 8.
Fuel shutoff actuator. 15. Fuel shutoff sequence valve.
START-UP OVERRIDE OF LOW ENGINE OIL

PRESSURE
On a hot restart, after severe operating

conditions, the engine oil pressure can increase
slowly. If the rate of pressure increase is too
slow, the protective system activates fuel shutoff
actuator (8) to move the fuel control linkage to
the "SHUTOFF" position because of a low
engine oil pressure fault condition. Therefore, an
override of the engine oil pressure circuit is
needed in the protective system.
An electric solenoid or air operated start-up over-

ride valve (3) is installed in the diverter valve
return line. The valve is normally closed. When
start-up override valve (3) is operated, the outlet
of the diverter valve is connected to drain. This
maintains a pressure drop across diverter valve
orifice (4) and does not let the diverter valve shift
to the shutdown position.
When start-up override valve (3) is not in use,

the engine oil circuit is put back into normal
operation as in Schematics No. 2 and No. 4.
226
SCHEMATIC NO. 12 (REMOTE NORMAL SHUTOFF)

4. Diverter valve orifice. 7. Diverter valve. 8. Fuel shutoff actuator. 19. Remote normal shutoff valve.
REMOTE NORMAL SHUTOFF
Make Reference to Schematic No. 12.
The remote normal shutoff is an option that can

be used with the hydramechanical protective
system. An air or electric operated remote
normal shutoff valve ( 19) is installed in the
diverter valve return line. When remote normal
shutoff valve (19) is operated, the outlet of the
diverter valve is stopped. The oil pressure
becomes equal on both sides of diverter valve
orifice (4). Spring force will move the valve
spool of diverter valve (7) to make an alignment
of the oil passage with the oil line to fuel shutoff
actuator (8). Oil pressure can now activate fuel
shutoff actuator (8) which causes the governor to
move the fuel control linkage to the "SHUTOFF"
position and shutdown the engine.227
227
HYDRAULIC CIRCUITS (LATER)
(With Check Valves in Diverter Valve)
Later hydramechanical protective systems

have hydraulic circuits that use check valves to
hold hydraulic pressure on (lock) the fuel shutoff
actuator in the "SHUTOFF" position, after the
engine has been shutdown. In this system, the
start-up override valve must be operated to
release the hydraulic pressure from the fuel
shutoff actuator before the engine can be
started. Also, make sure the air inlet shutoff is in
the open position before the engine is started.
The operation of these hydraulic circuits is -

the same as that of the earlier hydraulic circuits
except for the check valves in the diverter valve
for the fuel shutoff circuit.
START-UP OVERRIDE
When operated, the start-up override valve

connects the fuel shutoff actuator circuit to drain.
This removes any hydraulic pressure on the
actuator so the governor can move the fuel
control linkage and the engine can be started.
Also, on hot restart, after severe operating

conditions, the engine oil pressure can increase
slowly. If the rate of pressure increase is too
slow, the protective system activates actuator (8)
to move the fuel control linkage to the
"SHUTOFF" position because of a low engine
oil pressure fault. Therefore, an override of the
low engine oil pressure circuit is needed in the
protective system.
An electric solenoid or air operated start-up over-

ride valve (3) is installed in the diverter valve
return line. The valve is normally closed. When
start-up override valve (3) is operated, the outlet
of the diverter valve is connected to drain. This
maintains a pressure drop across orifice (4) and
does not let the diverter valve shift to the
shutdown position. The fuel shutoff actuator line
is also connected to drain to make sure fuel
shutoff actuator (8) does not hold the governor
shutoff strap in the off position.
When start-up override valve (3) is not in use,

the engine oil circuit is put back into normal
operation as in Schematics No. 2 and No. 4.
228
SCHEMATIC NO. 13 (START-UP OVERRIDE)

17. Oil pump. 19. Remote normal shutoff valve.
229
SCHEMATIC NO. 14 (LOW ENGINE OIL PRESSURE FAULT)’

(Low Speed Range)
Speed sensing valve spool. 7. Diverter valve. 8. Fuel shutoff actuator. 10. High speed oil protection valve. 15.
Fuel shutoff sequence valve. 17. Oil pump. 19. Remote normal shutoff valve.
LOW SPEED RANGE (LOW ENGINE OIL As the crankshaft rpm becomes slower, the
PRESSURE FAULT) governor feels the speed reduction and moves the
terminal shaft and linkage in the fuel "ON" direction,
Make Reference to Schematic No. 14 against fuel shutoff actuator (8). This moves the
protective system oil back toward the system oil pump.
If the engine oil pressure goes below 140 kPa The check valves in diverter valve (7) move to stop this
(20 psi), the spring force on low speed oil protection oil flow and keep the engine from surging.
valve (2) will close the valve. The oil flow in the circuit is
then stopped and can not flow to drain. The pressure of NOTE: The start-up override valve (3) must be operated
the oil will become equal on both sides of diverter valve to release the fuel shutoff actuator hydraulic pressure
orifice (4). Spring force will move the valve spool of before the engine can be started.
diverter valve (7) down so that there is alignment with the
passage that leads to fuel shutoff actuator (8). Oil
pressure will now move the fuel shutoff actuator which
will cause the governor to move the fuel control linkage
to the "SHUTOFF" position and shutdown the engine.
230

3. Start-up override. 4. Diverter valve orifice. 7. Diverter valve. 8. Fuel shutoff actuator. 19. Remote normal
shutoff valve.
REMOTE NORMAL SHUTOFF As the crankshaft rpm becomes slower, the

governor feels the speed reduction and moves the
Make Reference to Schematic No. 15 terminal shaft and linkage in the fuel "ON" direction,
against fuel shutoff actuator (8). This moves the
The remote normal shutoff is an option that can protective system oil back toward the system oil pump.
be used with the hydramecahnical protective system. An The check valves in diverter valve (7) move to stop this
air or electric operated remote normal shutoff valve ( 19) oil flow and keep the engine from surging.
is installed in the diverter valve return line. When remote
normal shutoff valve (19) is operated, the outlet of the NOTE: The start-up override valve (3) must be operated
diverter valve is stopped. The oil pressure becomes to release the fuel shutoff actuator hydraulic pressure
equal on both sides of diverter valve orifice (4). Spring before the engine can be started.
force will move the valve spool of diverter valve (7) to .
make an alignment of the oil passage with the oil line to
fuel shutoff actuator (8). Oil pressure can now activate
the fuel shutoff actuator, which causes the governor to
move the fuel control linkage to the "SHUTOFF" position
and shutdown the engine.
231
LATER HYDRAULIC CIRCUITS WITH AN 10. Oil pump. 11. Oil pressure relief valve. 12.
ALARM SYSTEM Pressure control valve group which consists of: the
fuel and air inlet sequence valves, the two-way pilot
This hydramechanical protective system is de- operated valve and emergency manual shutoff valve
signed to give automatic engine shutdown from an (2).
overspeed condition only. An alarm is activated for low
engine oil pressure and high coolant temperature OVERSPEED CIRCUIT (NORMAL CONDITIONS)
conditions.
The main difference between this system and
systems shown in the EARLIER and LATER When an engine is started and speed increases,
HYDRAULIC CIRCUITS, is that the fuel shutoff circuit oil engine oil pressure opens low speed oil protection valve
return from the diverter valve is connected with the air (8) and high speed oil pressure protection valve (9). At
inlet shutoff circuit return, and not to the normal fuel the same time, oil in the protective system flows from oil
shutoff return port on the shutoff control group. A pump (10) to fuel shutoff sequence valve (24) and is
normally open pressure switch (13) is installed in the divided between the fuel shutoff and air inlet shutoff
shutoff control group at the location the diverter valve oil circuits. Fuel shutoff sequence valve (24) keeps the oil
return line is normally connected. Also, there is an orifice pressure at the start of the fuel shutoff circuit at 760 kPa
plug [orifice (14)] installed in the shutoff control group. (110 psi).
The orifice plug is located in the valve body that holds
valves (4), (8) and (9). In the hydraulic circuit, this orifice Oil in the air inlet shutoff circuit is directed to air
is between the oil pressure supply and the low and high inlet sequence valve (22) and air inlet shutoff actuator
oil pressure protection valves (8) and (9). (26). Air inlet sequence valve (22) keeps the oil pressure
in air inlet shutoff actuator (26) at 105 kPa ( 15 psi) and
then directs the remainder of oil flow to drain through
pilot operated two-way valve (23) which is normally open.
Pilot operated two-way valve (23) is held open by spring
force and the pilot oil pressure is connected to drain
through speed sensing valve spool (5).
Oil flow in the fuel shutoff circuit is divided into

different directions as follows:
1. Oil from fuel shutoff sequence valve (24) goes to
speed sensing valve spool (5) and is stopped at
low engine speeds. When engine speed is high
enough, speed sensing valve spool (5) moves to
direct the oil pressure and close selector valve
(3). This changes the oil flow in the alarm circuit
from the low speed range to the high speed
range and connects system oil pressure to drain
through high speed oil protection valve (9) and
pilot operated two-way valve (23).
2. Oil flow from fuel shutoff sequence valve (24)

goes through orifice (14), low speed oil protec-
tion valve (8) or high speed oil protection valve
(9) and to drain through pilot operated two-way
valve (23). This circuit has an oil pressure
switch (13), that is normally open. Switch (13) is
connected to the alarm circuit oil pressure after
orifice (14) and senses the lower system oil
SHUTOFF CONTROL GROUP pressure. The switch activates an alarm, without
1. Spring for overspeed adjustment. 2. Emergency engine shutdown, if there is a low engine oil
manual shutoff valve. 3. Selector valve. 4. Valve pressure or high coolant temperature condition.
spool (not used). 5. Speed sensing valve spool. 6. (Make reference to Schematic No. 18).
Speeder spring. 7. Flyweights. 8. Low speed oil
protection valve. 9. High speed oil protection valve.
232
SCHEMATIC NO. 16 (OVERSPEED CIRCUIT)

2. Emergency manual shutoff valve. 3. Selector valve. 5. Speed sensing valve spool. 8. Low speed oil
protection valve. 9. High speed oil protection valve. 10. Oil pump. 11. Oil pressure relief valve. 13. Oil
pressure switch. 14. Orifice. 15. Diverter valve orifice. 16. Remote normal shutoff valve. 17. Fuel shutoff
actuator. 18. Diverter valve. 19. Engine oil pressure orifice. 20. Start-up override valve. 21. Thermostatic pilot
valve. 22. Air inlet sequence valve. 23. Pilot operated two-way valve. 24. Fuel shutoff sequence valve. 25. Air
inlet shutoff. 26. Air inlet shutoff actuator.
3. Oil from fuel shutoff sequence valve (24) goes to

the inlet of diverter valve (18) then to orifice (15)
in the valve spool. The oil goes through orifice
(15) and goes to the system drain through two-
way pilot operated valve (23). The pressure of
the oil is lowered after the oil goes through orifice
(15), this causes the oil pressure to move the
diverter valve spool against a spring force and
connect the fuel shutoff actuator oil circuit to the
system drain. Thus, the actuator will not
shutdown the engine. Engines with electric shut-
off solenoids on the governors have a pressure
switch installed in the diverter valve outlet for the
shutoff actuator. The pressure switch will not
shutdown the engine until system oil pressure is
directed to it.
233
OVERSPEED CIRCUIT (OVERSPEED FAULT)
When the engine speed is 18% above full

load speed, speed sensing valve spool (5) will be
moved up by the flyweights. This will send oil to
pilot operated two-way valve (23) and to the
spring side of air inlet sequence valve (22). The
oil pressure will close both valves and oil in the
air inlet shutoff system can not go to drain. The
oil pressure in the system will increase until oil
pressure relief valve (11) opens at 1720 kPa
(250 psi). The increased pressure will move air
inlet shutoff actuator (26), which will release air
inlet shutoff valve (25). This stops the
combustion air supply to the engine. Fuel
shutoff circuit oil also can not go to drain. The
difference in oil pressure across orifices (14) and
( 15) will now go to zero. The valve spool of
diverter valve (18) will move down by spring
force, which will cause alignment of the ports to
the fuel shutoff actuator (17). The blocked oil
pressure in the fuel shutoff circuit will activate
fuel shutoff actuator ( 17), which will cause the
governor to move the fuel control linkage to the
"SHUTOFF" position. Also, oil pressure switch
(13) will be closed by the higher pressure oil and
will activate an alarm.
When the emergency manual shutoff knob is

pulled, system oil flow is directed to pilot
operated two-way valve (23) and the spring side
of air inlet sequence valve (22). Valve (23) stops
oil flow to drain in both the fuel and air inlet
shutoff circuits. The protective system then,
shuts down the engine in the same sequence as
for an overspeed fault condition. The
combustion air supply is stopped and the fuel
control linkage is moved to the "SHUTOFF"
position to shutdown the engine.
234
SCHEMATIC NO. 17 (OVERSPEED FAULT)

2. Emergency manual shutoff valve. 3. Selector valve. 5. Speed sensing valve spool. 8. Low speed oil
protection valve. 9. High speed oil protection valve. 10. Oil pump. 11. Oil pressure relief valve. 13. Oil
pressure switch. 14. Orifice. 15. Diverter valve orifice. 16. Remote normal shutoff valve. 17. Fuel shutoff
actuator. 18. Diverter valve. 19. Engine oil pressure orifice. 20. Start-up override valve. 21. Thermostatic pilot
valve. 22. Air inlet sequence valve. 23. Pilot operated two-way valve. 24. Fuel shutoff sequence valve. 25. Air
inlet shutoff. 26. Air inlet shutoff actuator.
235
LOW OIL PRESSURE OR HIGH COOLANT If the engine oil pressure decreases to 205 kPa
TEMPERATURE FAULT (30 psi), the spring force on high speed oil protection
valve (9) will move the valve and stop the oil flow to
Make Reference to Schematic No. 18 drain. The pressure of the oil will become equal onj both
sides of orifice (14) and oil pressure switch (13) senses
Under normal operation at low engine speeds, 760 kPa (110 psi). The normally open switch closes and
the engine oil pressure must be 140 kPa (20 psi) to activates an alarm.
move low speed oil protection valve (8). The fuel shutoff
circuit oil can then flow from pump (10) at 760 kPa (110 For the engine coolant temperature circuit, a
psi) through orifice (14), oil pressure switch ( 1 3), low thermostatic pilot valve (21) is connected to the engine
speed oil protection valve (8), selector valve (3) and pilot oil pressure supply. Thermostatic pilot control valve (21)
operated two-way valve (23) to drain. is normally closed.
If the engine oil pressure goes below 140 kPa NOTE: The sensor of thermostatic pilot valve (21) must
(20 psi), the spring force on low speed oil protection be below the water level in the coolant manifold to
valve (8) will close the valve. The oil flow in the circuit is operate correctly.
then stopped and can not flow to drain. The pressure of
the oil will become equal on both sides of orifice (14) and When coolant temperature increases to 99°C
oil pressure switch (13) senses 760 kPa (I 10 psi). The (210°F), thermostatic pilot valve (21) will open. This will
normally open switch closes and activates an alarm. let oil in the circuit go to drain and cause a decrease in
engine oil pressure at low speed oil protection valve (8)
At approximately 70% of engine full load speed, and high speed oil protection valve (9). The valves close
the oil pressure protection changes from the low speed and stop oil flow through orifice (14). The pressure of
range to the high speed range. the oil will become equal on both sides of orifice ( 14)
and oil pressure switch ( 13) senses 760 kPa ( I10 psi).
When the engine speed increases to the high The normally open switch closes and activates an alarm.
speed range, speed sensing valve spool (5) will be
moved up by the flyweights. This will send pilot oil to NOTE: When the engine is started, the low oil pressure -
selector valve (3). This will close selector valve (3) and high coolant temperature alarm will be activated for a
remove low speed oil protection valve (8) from the short time until the engine has enough oil pressure to
circuit. The oil must now flow to drain through high open low speed oil protection valve (8) or’ high speed oil
speed oil protection valve (9) and pilot operated two- way protection valve (9).
valve (23).
236
SCHEMATIC NO. 18 (LOW OIL PRESSURE OR HIGH COOLANT TEMPERAFAULT)

(High Speed Range)
3. Selector valve. 5. Speed sensing valve spool. 8. Low speed oil protection valve. 9. High speed oil protection
valve. 10. Oil pump. 13. Oil pressure switch. 14. Orifice. 21. Thermostatic pilot valve. 23. Pilot operated two-
way valve.
237

15. Diverter valve orifice. 16. Remote normal shutoff valve. 17. Fuel shutoff actuator. 18. Diverter valve. 20.
Start-up override valve.
REMOTE NORMAL SHUTOFF
The remote normal shutoff is an option that can

be used with the hydramechanical protective
system. An air or electric operated remote
normal shutoff valve ( 16) is installed in the
diverter valve return line. When remote normal
shutoff valve (16) is operated, the outlet of the
diverter valve is stopped. The oil pressure
becomes equal on both sides of diverter valve
orifice (15). Spring force will move the valve
spool of diverter valve (18) to make an alignment
of the oil passage with the oil line to fuel shutoff
actuator (17). Oil pressure can now activate fuel
shutoff actuator (17), which causes the governor
to move the fuel control linkage to the
"SHUTOFF" position and shutdown the engine.
238
HYDRAMECHANICAL PROTECTIVE SYSTEM TROUBLESHOOTING
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.
TROUBLESHOOTING INDEX
Item Problem
1. Engine Will Not Start.

2. Engine Will Start, But Shuts Down When Oil
Pressure Override is Released.
3. Engine Will Only Run Below 70% of Rated Speed.
4. Air Inlet Shutoff Activates on Load Rejection.
5. Air Inlet Does Not Close.
6. Engine Will Not Restart After Operation of
Emergency Manual Shutoff.
7. Engine Will Not Shutdown When Checking Low
Engine Oil Pressure Protection Circuit.
8. Shutoff Control Unit Does Not Operate.
FIGURE 1.PROTECTIVE SYSTEM OIL LINES
1. Plug. 2. Oil line to thermostatic pilot valve. 3. Oil FIGURE 2. PROTECTIVE SYSTEM OIL LINES
return line from diverter valve. 4. Oil supply line to
diverter valve. 5. Oil drain line from diverter valve. 2. Oil line to thermostatic pilot valve. 3. Oil return line
from diverter valve. 4. Oil supply line to diverter valve.
5. Oil drain line from diverter valve. 6. Cover on
actuator valve body.
239
1. ENGINE WILL NOT START
Cause Correction
Engine Start-Up Override Not By- Disconnect drain line (5), See Figure 1. Operate the override (push button
Passing Oil Pressure By Shut- off switch for electric, push button valve for air) and crank the engine. Oil should
Control Group To Drain flow from drain line. If not, inspect the solenoid or air operated two-way valve
and the push button switch or push button air valve and lines.
Fuel Shutoff Actuator Stuck In The Make sure that the start-up override system is operating correctly. Operate the
Shutoff Position start-up override and crank the engine. Check the governor linkage and fuel
control linkage to see if they are in the run position. If not, check the shutoff
actuator for binding.
2. ENGINE WILL START, BUT SHUTS DOWN WHEN START-UP OVERRIDE IS RELEASED
Cause Correction
Engine Oil Pressure Is Too Low Install a pressure gauge in oil line (2) or in port ( I ) behind oil supply line (4),
see Figure 1. Operate the start-up override and start the engine. Engine oil
pressure must be 175 kPa (25 psi) minimum at low idle and 240 kPa (35 psi)
minimum at rated speed.
Engine Oil Pressure Sensing Remove the control group from the engine to disassemble and clean
Orifice Plugged orifice if necessary.
The Oil Return Line Between Disconnect oil return line (3) at the shutoff control group, see Figure
Diverter Valve And Shutoff Control 1. Crank the engine without using the start-up override valve. Oil should flow
Group Is Plugged out of the oil return line. Check the oil line for damage and clean or replace as
needed.
Remote Normal Shutoff Still Disconnect oil return line (3) at the shutoff control group, see Figure
Activated 1. Crank the engine without using the start-up override valve. Oil should flow
out of the oil return line. If there is no oil flow and the line is not plugged or
damaged, check the remote normal shutoff system. Make a repair or
replacement of worn or damaged parts and clean the valve if necessary.
Engine Oil Pressure Is Drained
Through Thermostatic Pilot Valve Check drain side of valve. Replace valve, if flow is present at cranking and
engine coolant temperature is normal.
Engine Oil Pressure Sensing
Portion Of The Control Group Has Remove cover (6), see Figure 2. Inspect the valve spools in the actuator valve
Malfunctioned body to make sure valves are not stuck. Replace cover (6) after inspection.
Check the engine oil pressure. Install a pressure gauge in oil line (2) or in port
(1) behind oil supply line (4), see Figure 1. Operate start-up override and start
the engine. If the engine oil pressure is equal to or greater than 175 kPa (25
psi) at low idle and 240 kPa (35 psi) at rated speed, replace-the oil pressure
sensing group (part of the shutoff control group).
actuator valve body to make sure valves are not stuck. Replace cover (6) after
inspection.
240
3. ENGINE WILL ONLY RUN BELOW 70% OF RATED SPEED
Cause Correction
Engine Oil Pressure Is Not High Check engine oil pressure in oil line (2), see Figure 1. A minimum of 240 kPa
Enough In The High Speed (35 psi) is required in high speed range. Clean the engine oil pressure line to
Range the shutoff control group, if needed. Also, engine repair may be needed.
4. AIR INLET SHUTOFF ACTIVATES ON LOAD REJECTION
Cause Correction
Governor Overshoot Lets Engine Correct governor overshoot. If this can not be done, increase overspeed
Speed Exceed Overspeed Setting setting to a maximum of 25% of rated speed.
5. AIR INLET DOES NOT CLOSE

Cause Correction
Tube Fittings At Hydraulic Actuator Turn fittings out until cylinder rod is free to move.
Are Installed Too Far. The End Of
The Fitting Is Binding The Cylinder
Rod
Air Inlet Valve Shaft Sticking Or Check for corrosion on shaft bearing surfaces or improper alignment.
Binding
6. ENGINE WILL NOT RESTART AFTER OPERATION OF EMERGENCY MANUAL SHUTOFF
Cause Correction
The 5N5880 Remote Emergency Check for binding of 5N5878 valve in the valve bore.
Manual Shutoff Did Not Fully
Return To The Run Position When
Switch Or Valve Was Released
Fuel Shutoff Actuator Stuck In The Remove the actuator. Check surface finish of bore and polish, if necessary.
Shutoff Position Put a small amount of clean oil in the bore and on the seal. Move the rod and
piston in the actuator cylinder to check for free movement. Replace actuator, if
necessary.
Air Inlet Valve Shaft Sticking Or Check for corrosion on shaft bearing surfaces or improper alignment.
Binding
241
7. ENGINE WILL NOT SHUTDOWN WHEN CHECKING LOW ENGINE OIL PRESSURE
PROTECTION CIRCUIT
Cause Correction
Fuel Shutoff Actuator Stuck In The Remove the actuator. Check surface finish of bore and polish, if necessary.
Run Position Remove Put a small amount of clean oil in the bore and on the seal. Move the rod and
piston in the actuator cylinder to check for free movement. Replace actuator, if
necessary.
Orifice Plugged In Diverter Valve Disconnect oil return line (3) at the diverter valve. Crank the engine without
using the start-up over-ride valve. Oil should flow from the diverter valve outlet
port.
Orifice Not Installed In Control Remove control group from engine and disassemble. Install or replace orifice
Group if needed.
Oil Flow To Drain Is Not Enough Install a manual operated ball or gate valve in the engine oil pressure sensing
To Create A Fault Condition line. Slowly close the valve to add more restriction to flow. If engine shutdown
does not occur, the shutoff control group needs repair.
8. SHUTOFF CONTROL UNIT DOES NOT OPERATE
Cause Correction
Drive Coupling Failure Start the engine and run supply line at low idle. Loosen the nut that holds oil
supply line (4) at the shutoff control group, see Figure 1. Oil under pressure
present should be present. If not, remove shutoff control group and inspect
the drive coupling. Make a replacement of parts as needed. A pressure gauge
installed in oil supply line (4) [see Figure 1] can also be used to make this
check. A minimum pressure of 590 kPa (85 psi) at high idle should be the
reading.
Not enough System Oil Pressure Make sure there is oil in the reservoir for the system. Low oil pressure can be
caused by a faulty oil pump relief valve (18) or fuel shutoff sequence valve
(15), see Schematic No. I in the System Operation section for part locations.
Make a replacement or repair as needed.
242
PROTECTIVE SYSTEM WITH ENGINE SHUTDOWN FOR ALL FUNCTIONS (LOP, HWT, OS)
1. Oil line to air inlet shutoff actuator. 2. Return line from air inlet shutoff actuator. 3. Oil line to thermostatic
pilot valve. 4. Return line from diverter valve. 5. Oil line to diverter valve. 6. From two-way valve at the diverter
valve to drain. 7. From diverter valve to governor (fuel) shutoff actuator.
Many engines run thousands of hours in If no engine shutdown occurs, further inspection
continuous-duty applications without any operation of the of the system is needed. The drive coupling and the two-
protective system shutoff actuators, valves and alarms (if way, 5N641 1 Valve (palm valve) can be tested while the
so equipped). engine is operating under full load. However, tests of the
air inlet shutoff and the (fuel) shutoff are done with the
Every 500 Service Meter Units, the emergency engine at low idle. Use the following procedures to
manual shutoff should be operated. This will check the check the system more completely.
protective system for correct operation.
DRIVE COUPLING CHECK
NOTICE
Put a rag around the fitting to prevent oil spray
After the emergency manual shutoff has been on oil supply line (5) at the diverter valve.
operated, the air inlet shutoff valve must be opened.
Also, the start-up override must be operated to Operate the engine at low idle and loosen the
release hydraulic pressure from the fuel shutoff nut on the fitting at the diverter valve one-half to three-
actuator before the engine can be started again. quarters of a turn. Shake the line to break the paint. If
any oil comes out under pressure, the shutoff is being
driven through the coupling. Tighten the nut.
243
PROTECTIVE SYSTEM WITH ENGINE SHUTDOWN FOR OVERSPEED ONLY, ALARMS FOR OTHER FUNCTIONS
(LOP, HWT)
1. Oil line to air inlet shutoff actuator. 2. Return line from air inlet shutoff actuator. 3. Oil line to thermostatic
pilot valve. 4. Return line from diverter valve. 5. Oil line to diverter valve. 6. From two-way valve at the diverter
valve to drain. 7. From diverter valve to governor (fuel) shutoff actuator. 8. Oil pressure switch for alarms.
AIR INLET SHUTOFF CHECK
Operate the engine at low idle and pull the red,

emergency knob. The air inlet shutoff valve must close
and stop the engine. Low oil pressure and high coolant
temperature alarms should also be activated, if so
equipped.
The fuel shutoff actuator must also move the

governor and fuel control linkage to the "SHUTOFF"
position.
PROTECTIVE SYSTEM OIL LINES
NOTICE
3. Oil line to thermostatic pilot valve. 5. Oil line to
diverter valve. 6. From two-way valve (at the After this test has been performed, the air inlet
diverter valve) to drain. shutoff valve must be opened. Also, the startup
override valve must be operated to release hydraulic
START-UP OVERRIDE VALVE CHECK pressure from the governor shutoff actuator before
the engine can be started again.
On an engine with an air start system, start and
operate the engine at low idle. Loosen the drain line
from the two-way (palm) valve. There should be no oil
present. If there is any oil flow, the valve has failed and
replacement is necessary.
244
HYDRAMECHANICAL PROTECTIVE SYSTEM TESTING AND ADJUSTING
FUEL SHUTOFF TEST

Remove the hose assembly, connector and
Hold open the air inlet shutoff valve with a length shutoff valve from the engine. Connect the oil supply to
of wire. (If another person is present, the valve can be the thermostatic pilot valve.
held open by hand.) Pull the red, emergency. knob.
Since the air inlet shutoff valve has been held open, the All of the above tests are performed at low idle.
fuel shutoff actuator should stop the engine. The low oil Successful shutdowns and alarms at low idle indicate
pressure, high coolant temperature alarms should also correct operation. Therefore, it is not necessary to
be activated, if so equipped. perform the tests at high idle.
NOTICE SHUTOFF SPEED SETTING ADJUSTMENT
Before starting the engine, make sure the air inlet NOTE: When major disassembly or adjustment of the
shutoff is reset so the protective system can shutoff control group is needed, see CATERPILLAR
operate, if needed, and to prevent damage to the FUEL INJECTION TEST BENCH BOOK, FORM NO.
engine at start up. SEHS7466 for the complete specifications and test
bench procedures to use.
LOW OIL PRESSURE TEST
NOTICE
Disconnect the oil supply line that is installed
between the thermostatic pilot valve and the shutoff A mechanic with training in governor adjustments is
control group, at the control group. Attach a 3N4847 the ONLY one that should perform the following
Hose Assembly to the control. Use a 7D5363 Connector procedure. Severe engine damage could occur if
to adapt a 3R3837 Shutoff Valve to the end of the hose. this procedure is not followed. Also, check the
capabilities of driven equipment to make sure
NOTE: If the engine is not equipped with a thermostatic damage will not occur if run at overspeed.
pilot valve, remove the plug from where line (4) would
connect to the shutoff control group. 1. Check and make sure the engine fuel settings
are correct. See FUEL SETTING CHECK in the
Close the valve and start the engine and operate Engine TESTING AND ADJUSTING section of
it at low idle. The engine will run normally. this Service Manual.
Place the end of the hose in a bucket or other 2. Start the engine and operate it at low idle.
container and open the valve to drain approximately one-
half liter (one U.S. pint) of oil to lower the oil pressure.
This will actuate the low oil pressure protection

circuit and cause engine shutdown through the fuel
shutoff actuator or activate the low oil pressure, high
coolant temperature alarms, if so equipped. The air inlet
shutoff should not be activated by this test.
NOTE: The fuel shutoff actuator will not be activated in a

protective system that gives overspeed protection only,
when a low oil pressure fault is simulated.
If the fuel shutoff actuator is not activated by this
test, check the actuator, oil lines or electrical
1. Emergency manual shutoff. 2. Overspeed setting
connections, and the shutoff control group for defects.
adjustment bolt.
If the alarms fail to activate, make sure the
pressure switch on the control valve group, the wiring 3. Before any adjustment to the shutoff control
and alarms work correctly to locate and repair parts as overspeed setting is made, check for correct
needed. operation of the hydramechanical protective
245
HYDRAMECHANICAL PROTECTIVE SYSTEM TESTING AND ADJUSTMENT
system. Pull emergency manual shutoff

knob ( I). Successful shutdown of intake
air and fuel indicate correct operation.
NOTICE
After the emergency manual shutoff has been
operated, the air inlet shutoff valve must be opened.
Also, the start-up override must be operated to
release hydraulic pressure from the fuel shutoff
actuator before the engine can be started again.
4. Remove seal and wire from the bolts and

remove the cover from over the high idle
adjustment screw on the Caterpillar 3161 UG-8L GOVERNOR
Governor, or the seal wire from high idle screw
lock nut on Woodward UG-8L Governor. 3. High idle adjustment screw.
5. Connect a tachometer of known accuracy to the clockwise. Again, slowly increase the
engine. engine rpm to check for engine
shutdown at 18% + 25 rpm above full
NOTE: Some types of engine driven equipment, such as load rpm.
generators, pumps or compressors, can be damaged if
operated at 18% above full load speed. If so, the driven
equipment must be disconnected from the engine during
this test. If this cannot be done, adjustment of the
shutoff control group can be made on the
CATERPILLAR FUEL INJECTION TEST BENCH. See
Form No. SEHS7466 for the complete test bench
procedures.
6. Start the engine again and operate it at high idle

with no load.
7. Turn the governor high idle adjustment screw

slowly to increase engine rpm. The air inlet ADJUSTMENT OF HIGH IDLE ON 3161 GOVERNOR
shutoff must close and the fuel must be shut off
through the governor and fuel control linkage at NOTE: If engine shutdown occurs before 18% + 25 rpm
18% + 25 rpm above full load rpm. For example, of full load rpm, turn overspeed adjusting bolt (2)
this is 2124 + 25 rpm for an engine rated at 1800 clockwise to increase the shutoff control group
rpm. overspeed setting.
NOTICE 9. Repeat the above procedure until engine

shutdown occurs at the correct rpm.
After the hydramechanical protective system has
been activated, the air inlet shutoff valve must be
10. Adjust engine high idle to the specifications
opened. Also, the start-up override must be
shown on the Engine Information Plate which is
operated to release hydraulic pressure from the fuel attached to one of the right side camshaft
shutoff actuator before the engine can be started inspection covers. If the Engine Information
again. Plate is missing, see the FUEL SETTING AND
RELATED INFORMATION FICHE for the correct
8. If engine shutdown does not occur at 18% + 25 specifications to use.
rpm above full load rpm, slowly increase engine
rpm 50 rpm more. For example, this is 2174 11. Install the seals and lockwires for the shutoff
rpm for an engine rated at 1800 rpm. If engine control group and the governor high idle
shutdown still does not occur, decrease the adjustment screw.
engine rpm and remove the seal and lockwire
and turn overspeed adjusting bolt (2) one turn
counter
246

WIRING DIAGRAMS
COMPONENT ABBREVIATIONS
ALT ALTERNATOR MGOPSU MARINE GEAR OIL PRESSURE

SENDING UNIT
AMM AMMETER MGOTAS MARINE GEAR OIL TEMPERATURE
ALARM
ASOS AIR SHUTOFF SOLENOID SWITCH
ASSV AIR START SOLENOID VALVE MPU MAGNETIC PICK-UP
B- BATTERY NEGATIVE OPG OIL PRESSURE GAGE
B+ BATTERY POSITIVE OPS OIL PRESSURE SWITCH
BATT BATTERY OPSU OIL PRESSURE SENDING UNIT
CB CIRCUIT BREAKER PB PUSH BUTTON
EGA ELECTRIC GOVERNOR ACTUATOR PP PRELUBE PUMP
EGC ELECTRIC GOVERNOR CONTROL PPMS PRELUBE PUMP MAGNETIC SWITCH
ENCL ENCLOSER PPPS PRELUBE PUMP PRESSURE SWITCH
FSOS FUEL SHUTOFF SOLENOID RNS REMOTE NORMAL SHUTOFF SWITCH
HM HOUR METER SM STARTER MOTOR
HMMPU HOUR METER MAGNETIC PICK-UP SMMS STARTER MOTOR MAGNETIC SWITCH
HMOBSV HYDRAMECHANICAL OIL BYPASS TM TACHOMETER
SOLENOID
VALVE TMMPU TACHOMETER MAGNETIC PICK-UP
HMOPS HYDRAMECHANICAL OIL PRESSURE TS TERMINAL STRIP
SWITCH
HMRSSV HYDRAMECHANICAL REMOTE WTG WATER TEMPERATURE GAGE
SHUTOFF WTS
SOLENOID VALVE WTSU WATER TEMPERATURE SWITCH
HWTAS HIGH WATER TEMPERATURE ALARM WATER TEMPERATURE SENDING UNIT
SWITCH
LOPAS LOW OIL PRESSURE ALARM SWITCH
LWTAS LOW WATER TEMPERATURE ALARM
SWITCH
MGOPG MARINE GEAR OIL PRESSURE GAGE
WIRE COLOR CODE

ABBREVIATIONS
B BLACK
BR BROWN
B/W BLACK WITH WHITE STRIPE
CU COPPER (BARE WIRE)
DK BL DARK BLUE
DK GR DARK GREEN
GR GREEN
LT BL LIGHT BLUE
O ORANGE
O/B ORANGE WITH BLACK STRIPE
P/B PINK WITH BLACK STRIPE
PUIW PURPLE WITH WHITE STRIPE
R RED
W WHITE
W/O WHITE WITH ORANGE STRIPE
W/R WHITE WITH RED STRIPE
Y YELLOW
Y/BR YELLOW WITH BROWN STRIPE
247
HYDRAMECHANICAL PROTECTIVE SYSTEM WIRING DIAGRAMS
3500 ENGINE WIRING DIAGRAM (REF. 5N8944)

(Earlier Systems With 5N9310 Pressure Switch Assembly)
248
3500 ENGINE WIRING DIAGRAM (REF. 5N8944)

(Later Systems With 4W2188 Pressure Switch Assembly)
249
SEE NOTES ON PAGE THAT FOLLOWS
250
NOTE A: Magnetic pick-up and oil pressure switch to be

wired to electric governor control (Woodward 2301 ) with
a two conducter shielded cable (Belden Corp. type 8780
or equivalent). Shields are to be grounded at electric
governor control grounding stud. Each shield should not
have more than one ground connection.
NOTE B: Woodward 2301 Electric Governor Control

terminal identification chart:
STAND-BY
SYMBOL FUNCTION TS NO.
P Batt + 2
R Batt- 1
S EGA + 6
T EGA - 5
U Mag Pick-up 7
V Mag Pick-up 8
Y Oil Pressure Speed Limiter 9
Z Oil Pressure Speed Limiter 10
NOTE C: Caterpillar alarm and prealarm contacts are

rated for a maximum of 3 amps inductive at the charging
system voltage.
251/(252 Blank)
FOR USE IN SERVICE MANUAL:
FORM NO. SENR2573
DISASSEMBLY AND ASSEMBLY
SERIAL NUMBERS:
68Z1-UP, 65Z1-UP
253/(254 Blank)
255
ALTERNATOR (AN ATTACHMENT)
REMOVE ALTERNATOR 1405-11

Deleted.
INSTALL ALTERNATOR 1405-12

Deleted.
256
MANUAL SHUTOFF
REMOVE MANUAL SHUTOFF 7418-11
Tools Needed A
1P1856 Pliers 1
1. Remove bolt (1) and the washer. Pull lever (2),

the adapter and lever from the front drive
housing. There is an O-ring seal that holds the
adapter in the front drive housing.
2. Remove bolt (3) and the washer to remove lever

(2) from adapter (4).
3. Use tool (A) and remove the ring that holds lever
(5) in adapter (4). Remove lever (5) from
adapter (4).
4. Remove 0-ring seal (6) from adapter (4).
5. Remove seal (7) from adapter (4).
257
MANUAL SHUTOFF
INSTALL MANUAL SHUTOFF 7418-12
Tools Needed A B
1P510 Driver Group 1
1P1856 Pliers 1
1. Use tool group (A) and install the seal in adapter

(1) with the lip of the seal toward the inside as
shown. Put clean engine oil on the lip of the
seal.
2. Install O-ring seal (2) on adapter (1) and put

clean engine oil on it.
3. Put lever (4) in adapter (1) and use tool (B) to

install ring (3) to hold the unit together.
4 Put lever (5) in position and install the washer

and bolt to hold it to lever (4).
5. Install the levers and adapter in the front drive

housing. Make sure lever (4) is under and in
contact with the governor stop lever. Install the
bolt and washer to hold the unit in position.
6. To make an adjustment of the shutoff levers,

loosen the locknut and screw on the adapter.
Pull lever (5) until the governor linkage makes
contact with its stop and hold lever (5) in this
position. Turn the adjustment screw until it
makes contact with lever (5) and then turn it one
more complete turn. Tighten the locknut.
258
GAUGE PANEL
REMOVE GAUGE PANEL 7450-11
1. Remove water jacket temperature sending unit

(1) from the regulator housing adapter.
2. Disconnect hoses (2) and (4) from the engine

and disconnect hose (3) from the gauge panel.
Remove clamp (5) from the gauge panel
bracket.
3. Disconnect hose (6) from the oil cooler.
4. Disconnect wiring harness (11) from engine

shutdown switch (9).
5. Remove four bolts (10) from supports (12) and

remove gauge panel (8), brackets (7), supports
(12) and switch (9) as a unit from the engine.
6. Remove the nuts and remove brackets (7),

supports (12) and shutdown switch (9) from the
gauge panel.
259
GAUGE PANEL
7. Put identification marks on hoses (2), (4) and (6)

for correct installation, and remove the hoses
from the gauges.
8. Remove the nuts and brackets (14) to remove

the four gauges (13) from the front of panel (8).
INSTALL GAUGE PANEL 7450-12
1. Put the four gauges (1) in position in panel (2)

and install brackets (3) and the nuts to hold the
gauges in position.
2 Install hoses (4), (5) and (6) on the gauges.
260
GAUGE PANEL
3. Put brackets (7), supports (9) and engine

shutdown switch (8) in position on the gauge
panel and install the nuts to hold these in
position.
4. Put gauge panel (2), brackets (7), supports (9)

and the shutdown switch as a unit in position on
the engine. Install the bolts to hold the unit in
position.
5. Connect hose (5) to the oil cooler.
6. Install clamp (I 1) on the gauge panel bracket.

Connect hose (10) to the gauge panel and
connect hoses (4) and (6) to the engine.
NOTE: Make sure the capillary tube from sending unit

(12) does not make direct contact with the engine.
7. Install water jacket temperature sending unit (12)

in the regulator housing adapter.
261
AIR INTAKE SHUTOFF (3508)
REMOVE AIR INTAKE SHUTOFF 1078-11
1. Disconnect the harness assembly to the shutoff

solenoid.
2. Remove the bolts to remove shield ( ) and pipes

(2) from the engine.
3. Remove the bolts and remove air intake cover

(3) from the air shutoff group.
4. Remove bolts (5) and remove air shutoff group

(4) from the aftercooler housings.
INSTALL AIR INTAKE SHUTOFF 1078-12
1. Put the gaskets and air shutoff group (1) in

position on the aftercooler housings. Install the
bolts to hold the group in position.
262
2. Put the gasket and air intake cover (2) in position

on the air shutoff group. Install the bolts to hold
cover (2) in position.
3. Put clean engine oil on the O-ring seals on pipes

(4). Put pipes (4) and shield (3) in position on
the engine and install the bolts to hold these in
position.
DISASSEMBLE AIR INTAKE SHUTOFF 1078-15
start by:
a) remove air intake shutoff
1. Remove the bolts from solenoid (1). Hold

handle (2) in the position as shown by hand or
with a wrench and remove solenoid (1) from the
air shutoff group. Slowly release handle (2) to
the shutoff position.
2. Bend the locks away from bolts (3) and loosen

all of bolts (3) that hold the plate assemblies to
the shaft assembly.
263
3. Move handle (2) back to the position as shown

by hand or with a wrench and put solenoid (1) in
position in the shutoff housing assembly. Install
the bolts and release the handle.
4. Remove the bolts, the locks, the plates and

bushings from plate assemblies (4). Remove
plate assemblies (4) from the shaft assembly.
5. Do Step I again to remove solenoid (1).
6. Remove the bolt and remove handle (2) from the

shaft assembly.
7. Remove the bolts and remove cover assembly

(5) from the housing assembly.
8. Remove seal (6) from cover assembly (5).
9. Remove pin (8) to remove spacer assembly (7)

from the housing assembly.
264
10. Remove shaft assembly (9), the spacer and

spring from the housing assembly. Remove the
spring and spacer from the shaft assembly.
11. If necessary, remove the dowel and remove

lever (10), spacer assembly (12) and pin ( 11 )
as a unit from shaft assembly (9). Remove pin
(11 ) from lever (10) to remove spacer assembly
(12) from lever (10) if necessary.
ASSEMBLE AIR INTAKE SHUTOFF 1078-16
Tools Needed A
1. If necessary, make a replacement of dowel (1)

and make sure the end of the dowel as shown is
83.0 ± 0.5 mm (3.268 ± .020 in.) below surface
(X).
2. If shaft assembly (2) was disassembled, put

spacer assembly (5) in position on lever (3) and
use a press to install pin (4) until it is even (flush)
with the surface of lever (3) as shown. Put lever
(3), spacer assembly (5) and pin (4) as a unit in
position on shaft assembly (2). Install the dowel
to hold the unit on shaft assembly (2) and put
marks (stake) the end of the dowel.
265
3. Install spacer (8) and spring (6) on shaft

assembly (2). Install shaft assembly (2) in
housing assembly (7). Make sure spring (6) is
correctly engaged with dowel (I) as shown.
4. Install handle (10) on the shaft assembly. Turn

handle (10) up (upward) and install pin ( 11 ) so
handle (10) can be put in contact with pin ( 1).
With handle (10) in contact with pin (11), install
plate assemblies (9) on the shaft assembly.
5. Release handle (10) from the pin and remove

the pin so plate assemblies (9) can move to the
"SHUTOFF" position. A 0.076 mm (.003 in.)
feeler gauge must not pass between plate
assemblies (9) and the housing assembly as
shown. Remove handle (10) from the shaft
assembly.
6. Put spacer assembly (12) in position and install

pin (11) in the housing assembly through the
spacer assembly.
266
7. Use tool group (A) to install the seal until it is

even (flush) with the inside surface of cover
assembly (13). Make sure the lip of the seal is
toward the outside surface of the cover as
shown.
8. Install cover assembly (13) on the housing

assembly and the bolts to hold it.
9. Install handle (10) on the shaft assembly and the

bolts to hold it.
NOTE: To make the installation of the bolts in the air

shutoff group easier, the electric solenoid must be
installed before the air shutoff group is installed on the
engine.
10. Turn handle (10) to the open position as shown

and put the gasket and solenoid (14) in position on the
housing assembly. Release the handle and install the
bolts to hold the solenoid in position.
end by:
a) install air intake shutoff
267
REMOVE AIR INTAKE SHUTOFF 1078-11

1. Remove shield (3) from the shutoff housing.
2. Turn off the air supply to the engine.
3. Disconnect tube assemblies (1) and remove

bolts (2). Remove air shutoff cylinder (4) and the
flange from the shutoff housing.
4. Remove pipes (5) from the turbochargers and

shutoff housing.
5. Remove the bolts and remove air intake shutoff

INSTALL AIR INTAKE SHUTOFF 1078-1

1. Put the gasket and air intake shutoff (I) in
position and install the bolts that hold it in
position.
268
TACHOMETER DRIVE
REMOVE TACHOMETER DRIVE 7487-11
start by:
a) remove service meter
1. Disconnect the harness assemblies from the

adapter assembly.
2. Remove bolts (1) and the clamps to remove

adapter assembly (2) from the shutoff drive
housing assembly.
3. Remove shaft (3) from the gear assembly on the

end of the camshaft and the shutoff drive
housing assembly.
INSTALL TACHOMETER DRIVE 7487-12

1. Install shaft ( 1 ) through the shutoff drive hous-
ing assembly and into the gear assembly on the
end of the camshaft.
2. Put clean engine oil on O-ring seal (2) and install

adapter assembly (3) in the shutoff drive
assembly. Make sure the shaft of the adapter
assembly engages in the groove (slot) on the
end of shaft ( 1 ). Install the bolts and the
clamps to hold the adapter assembly.
3. Connect the harness assemblies to the adapter

assembly.
end by:
a) install service meter
269
CRANKCASE BREATHER
REMOVE CRANKCASE BREATHER 1317-11

1. Remove the bolts from clips (2). Loosen the
clamps that hold the hose assembly to the
crankcase breather assemblies. Remove fumes
disposal group (1) and the hose assembly as a
unit from the breather assemblies.
2. Remove four nuts (4) and remove breather as-

semblies (3) from the elbow.
3. Remove cover assembly (5) from each breather

assembly (3).
4. Remove filter element (6) from each breather

assembly (3).
5. Remove O-ring seals (8) from elbow (7).
6. Remove elbow (7) and the gasket from the front

drive housing.
270
CRANKCASE BREATHER
INSTALL CRANKCASE BREATHER 1317-12
1. Install the gasket and elbow (2) on the front drive

housing.
2. Install O-ring seals (1) on the elbow and put

clean oil on the seals.
3. Install element (4) in each breather assembly

(3).
4. Install cover assembly (5) on each breather

assembly (3).
5. Put breather assemblies (3) in position on elbow

(2) and install the four nuts to hold the breathers
in position.
6. Put fumes disposal group (6) and the hose as-

sembly in position on the breather assemblies.
Tighten the clamps for the hose assembly and
install the bolts to hold clips (7) to the front drive
housing.
271
REMOVE WATER TEMPERATURE

REGULATORS 1355-11
start by:
a) remove fuel filter housing
1. Remove the clamps to remove the fuel lines

from the water temperature regulator housings
and remove the plate on top of the oil filter
housing.
2. Disconnect tube (I) from the regulator housings

and the aftercooler adapter. Remove the tube
from the engine.
3. Fasten a hoist to water temperature regulator

housings (2) as shown. Remove the bolts that
hold housings (2) to water manifolds (3) and
brackets (4). Remove the housings from the
engine. The weight of housings (2) is 49 kg (108
lb.).
4. Remove the bolts and remove housing (5) from

the water temperature regulators.
5. Remove regulators (6) from the housing.
6. If necessary, remove seals (8) from the housing.
7. Remove ferrule (7) and the ball from the hous-

ing necessary.
272
INSTALL WATER TEMPERATURE

REGULATORS 1355-12
Tools Needed A
1. If the ball and ferrule were removed, install the

ball and use tooling (A) to install the ferrule until
it makes contact with the bottom of the bore.
Make sure the open end of the ferrule is toward
the outside of the housing.’
2. If the seals were removed, use tooling (A) to

install the seals in the housing. Make sure the
lip of the seal is toward the inside of the housing
as shown.
NOTICE
If the water temperature regulators are installed
wrong, it will cause the engine to overheat.
3. Install water temperature regulators (1) in the,

housing with the spring up as shown.
4. Put housing (2) and the gasket in position on the
regulators. Install the bolts to hold the housing in
position.
5. Fasten a hoist to water temperature regulator
housings (3) and put the housings and gaskets
in position on the engine. Install the bolts to hold
the housings to water manifolds (5) and brackets
(4).
6. Install the tube between the aftercooler adapter
and the regulator housings.
7. Put the plate on top of the oil lifter housing and
install the bolts. Install the fuel lines and the
clamps on the water temperature regulator
housings.
end by:
a) install fuel filter housing
273
WATER PUMP
REMOVE WATER PUMP 1361-11

1. Drain the coolant from the cooling system.
2. Disconnect the water supply line from the water

pump inlet.
3. Remove the bolts and retainers from both ends,

of tube (1) and remove tube (1) from the engine.
4. Remove the bolts and remove damper guard (2)

from the engine.
5. Remove bolts (3) that hold the pump to the water

line adapter.
6. Fasten a hoist to water pump (4) and remove the

four bolts that hold the pump to the oil and water
pump drive adapter. Remove pump (4) from the
engine. The weight of the pump is 39 kg (85 lb.).
274
WATER PUMP
INSTALL WATER PUMP 1361-12
1. Make sure the gasket for the water line adapter

and the O-ring seal on the pump are in position.
Put clean engine oil on the O-ring seal. Fasten a
hoist to water pump (1) and put water pump (1)
in position on the engine. Make sure the splines
on the pump shaft are correctly engaged and
install the bolts to hold the pump to the oil and
water pump drive adapter.
2. Install bolts (2) to hold the pump to the water line

adapter.
3. Install damper guard (3) on the engine.
4. Make sure the O-ring seals on both ends of tube

(4) are in position and put clean engine oil on the
seals. Put tube (4) in position and install
retainers and bolts to hold the tube in position.
5. Connect the water supply line to the water pump

inlet.
6. Fill the cooling system with coolant to the cor-

rect level.
275
WATER PUMP
DISASSEMBLE WATER PUMP 1361-15
Tools Needed A
5F7465 Puller Assembly 1
4B3903 Bolt (5/16"-18 NC x 4 in. long) 2
4B5270 Washer (5/16") 2
4B5271 Washer (3/8") 2
4B5273 Washer (1/2") 2
1P458 Drive Plate 1
start by:
a) remove water pump
1. Remove elbow (1) from housing assembly (2).

Remove the 0-ring seal from elbow (1).
2. Remove O-ring seal (5) from the back of hous-

ing assembly (2).
3. Remove washer (4) that holds shaft assembly

(3) in housing assembly (2).
4. Remove cover (6) from housing assembly (2).

Remove the O-ring seal from cover (6).
5. Loosen bolt (8) and the washer that hold im-

peller (7) to the pump shaft. Use tooling (A) to
loosen impeller (7) from the end of the pump
shaft. Remove tooling (A), bolt (8), the washer
and impeller (7) from the pump shaft and hous-
ing assembly (2).
6. Remove spring (10) from seal assembly (9) and

shaft assembly (3).
7. Use a soft faced hammer and push shaft

assembly (3) out of seal assembly (9) and
housing assembly (2). Remove seal assembly
(9) from housing assembly (2).
276
WATER PUMP
8. Remove ceramic seal (11) from the rubber ring.

Remove the rubber ring from housing assembly
(2).
9. Remove seal (12) from the back of housing

assembly (2).
ASSEMBLE WATER PUMP 1361-16
Tools Needed A
1. If necessary, make a replacement of the two

filters in the pump housing at location (1).
2. If necessary, make a replacement of plug (2)

and the seal.
3. Use tool group (A) to install the seal in the

housing assembly. Make sure the lip of the seal
is toward the outside as shown. Put clean
engine oil on the lip of the seal.
4. Install shaft assembly (3) in housing assembly

(4). Install washer (5) and the bolts to hold shaft
assembly (3) in position.
NOTICE
Clean water only is permitted for use as a lubricant
for assembly. Do not damage or put hands on the
wear surface of the carbon ring or the ceramic ring.
Install the ceramic ring with the smoothest face of
the ring toward the carbon seal assembly.
5. Put ceramic seal (6) in position in the rubber

ring. Use hand pressure and the tool (which is
with the replacement seal) to install the ceramic
seal.
277
WATER PUMP
6. Remove spring from seal assembly (7). Use

hand pressure and the tool (which is with the
replacement seal) to install the seal assembly.
Push seal assembly on shaft until seal faces
make light contact.
7. Install spring (8) on the carbon seal assembly.
8. Put impeller (9) in position on the pump shaft as

shown.
9. Install washer (11) and bolt (10). Tighten bolt

(10) to a torque of 90 ± 15 N•m (66 ± 11 lb.ft.).
Hit the bolt with a hammer and tighten it again to
a torque of 90 ± 15 N.m (66 ± 11 lb.ft.).
NOTE: Make sure the studs for cover (12) are tightened
to a torque of 27 ± 4 N.m (20 ± 3 lb.ft. in the pump
housing.
10. Put clean engine oil on O-ring seal (13) and

install it on cover (12). Put cover (12) in position
and install the nuts to hold it to the pump
housing.
11. Put clean engine oil on the O-ring seal and install
it in elbow (14). Put elbow (14) in position on
housing assembly (4) and install the bolts to hold
the unit together.
it on the back of housing assembly (4).
end by:
a) install water pump
278
FUEL FILTER HOUSING
REMOVE FUEL FILTER HOUSING 1262-11
1. Close the fuel supply to the engine.
3. Remove tube (1) from the engine.
4. Disconnect fuel lines (2) and (3) from the fuel

filter housing.
5. Remove eight bolts (5) and fasten a hoist or use

two men to remove fuel filter housing (4) from
the engine. The weight of the housing is 25 kg
(55 lb.).
INSTALL FUEL FILTER HOUSING 1262-12
1. Fasten a hoist to fuel filter housing (1) and put it

in position on the oil filter housing. Install the
bolts to hold housing (1) in position.
7
279
FUEL FILTER HOUSING
2. Connect fuel lines (2) and (3) to the fuel filter

housing.
3. Install tube (4) on the engine.
4. Fill the cooling system to the correct level.
5. Open the fuel supply to the engine.
DISASSEMBLE FUEL FILTER

HOUSING 1262-15
Tools Needed A
1P1855 Pliers 1
start by:
a) remove fuel filter housingB43366X1
1. Remove cover (I) from the end of the filter

housing.
2. Use tool (A) to remove ring (2) from the cover.
280
FUEL FILTER HOUSING
3. Remove retainer (3), O-ring seal (4), spring (5)

and O-ring seal (6) from cover (1).
4. Remove the five filter elements (7) from the filter

housing.
5. Disconnect fuel line (9) from cover (8). Remove

cover (8) from the filter housing and remove the
O-ring seal from the cover.
ASSEMBLE FUEL FILTER HOUSING 1262-16
Tools Needed A
1P1855 Pliers 1
1. Install O-ring seal (2) on cover (1) and put clean

engine oil on the seal.
2. Install cover (1) on the end of the filter housing.

Connect fuel line (3) to the cover.
281
FUEL FILTER HOUSING
3. Install the five filter elements (4) in the filter

housing.
4. Put O-ring seal (6), spring (7) and retainer (5) in

position on cover (9).
5. Use tool (A) to install ring (10) on the cover.
6. Install O-ring seal (8) on cover (9) and put clean

engine oil on it. Install cover (9) on the end of
the filter housing.
end by:
282
FUEL PRIMING PUMP, FUEL TRANSFER PUMP
REMOVE FUEL PRIMING PUMP 1258-11
1. Close the fuel supply line to the engine.
2. Remove the bolts and clamp (1) from the pump.
3. Remove bolts (2) and remove fuel priming pump

(3) and the gasket from the fuel filter housing.
INSTALL FUEL PRIMING PUMP 1258-12
1. Put priming pump (1) and the gasket in position

and install the clamp and bolts to hold it.
2. Open the fuel supply line to the engine.
REMOVE FUEL TRANSFER PUMP 1256-11
1. Close the fuel supply line to the engine.
2. Disconnect fuel lines (2) from fuel transfer pump

(1).
3. Remove the four bolts to remove fuel transfer

pump (1) from the engine.
INSTALL FUEL TRANSFER PUMP 1256-

12
1. Make a replacement of the O-ring seal on the

fuel transfer pump if necessary. Put clean
engine oil on the seal.
2. Put fuel transfer pump (1) in position on the

engine oil pump. Make sure the drive coupling
for the fuel transfer pump is engaged correctly
with the engine oil pump shaft.
3. Install the bolts that hold the fuel transfer pump.
4. Connect fuel lines (2) to fuel transfer pump (1).
5. Open the fuel supply line to the engine and use

the fuel priming pump to remove (bleed) the air
from the system.
283
FUEL TRANSFER PUMP
DISASSEMBLE FUEL TRANSFER.

PUMP 1256-15
start by:
a) remove fuel transfer pump
1. Pull drive coupling (2) from the pump shaft.
2. Remove O-ring seal (1) from the pump.3x1
3. Remove cap (6), seal washer (5), spring (4) and

relief valve poppet (3) from the pump bracket
assembly.
4. Remove bolts (7) and remove pump head (8)

from plate (9).
5. If necessary, remove check valve (10) from head

(8).
6. Remove plate (9) from the pump casing.
7. Remove gasket (11) and the O-ring seal from’

the opposite side of plate (9).
8. If necessary, remove the bearings from plate (9).
284
FUEL TRANSFER PUMP
9. Remove gear assembly (12) and shaft assembly

(13) from the pump bracket and casing (14).
10. Remove casing (14) and sleeves (15) from

pump bracket (16).
11. Remove the O-ring seal from casing (14).
12. Remove outer seal (17) and inner seal (18) from
bracket (16).
13. If necessary, remove the two bearings from

bracket (16).
l
ASSEMBLE FUEL TRANSFER PUMP 1256-16
Tools Needed A
1. Use tool group (A) to install the inner and outer

lip type seals in bracket (1). Make sure the lips
of the seals are in the position shown at
assembly. Put clean engine oil on the lips of the
seals.
285
FUEL TRANSFER PUMP
2. Use tool group (A) to install bearings (2) 1.5 mm

(.06 in.) below the surface of bracket (1).
3. Install sleeves (4) in bracket (1).
4. Install O-ring seal (5) in casing (3) and put

casing (3) over sleeves (4) on bracket (1).
5 Install gear assembly (6) and shaft assembly (7)

in the bracket and casing.
6. Use tool group (A) to install bearings (8) 1.5 mm

(.06 in.) below the surface of plate (9).
7. Install O-ring seal (10) in plate (9) and put plate

(9) in position on the pump casing.
286
FUEL TRANSFER PUMP
8. Use tool group (A) to install the check valve in

head (11) until it makes contact with the
shoulder in its bore. Make sure the spring on the
check valve is toward the inside before it is
installed.
9. Put gasket (12) and head (11) in position on the

plate and install the two bolts that hold the pump
together.
10. Install the relief valve poppet (13), spring (14),

the seal washer and cap (15) in the pump.
11. Install O-ring seal (16) around the pump and put
12. Install drive coupling (17) on the pump shaft.

end by:
a) install fuel transfer pump
287
OIL PUMP
REMOVE OIL PUMP 1304-11

start by:
a) remove fuel transfer pump
2. Drain the oil from the oil pan.
3. Remove all bolts (1) and (2) to remove adapter

4. Remove all the bolts and remove oil pump (4)

from the engine. The weight of the pump is 39
kg (85 lb.).
INSTALL OIL PUMP 1304-12

NOTE: The oil pump shaft must turn by hand and the
pump must have oil for lubrication before it is
installed.
1. Put clean engine oil on the O-ring seals and put

oil pump (1) in position. Make sure the splines
on the pump shaft are correctly engaged with the
splines of the oil pump drive. Install the bolts to
hold the oil pump in position.
2. Put the gaskets and adapter (2) in position.

Install the bolts to hold the adapter and gaskets
in position.
3. Fill the engine with oil to the correct level.’
4. Fill the cooling system with coolant to the correct

level.
end by:
a)install fuel transfer pump
288
OIL PUMP
DISASSEMBLE OIL PUMP 1304-15
Tools Needed A
start by:
a) remove oil pump
1. Remove adapter assembly (1) from the pump.
Cover (2) has spring tension on it. Loosen the bolts

that hold it slowly and the same amount to remove
the tension on the cover.
2. Remove the bolts, cover (2), gasket (3), spring

(4) and valve spool (5) from the pump.
3. Remove cover assembly (6) and the gasket from

the pump.
4. Remove cover assembly (7) from the pump.
289
OIL PUMP
5. Use tooling (A) to remove bearings (8) from

cover assembly (7).
6. Remove shaft assemblies (10) from body as-

sembly (9).
7. Use a press to remove gears (11) from the shaft

assemblies.
8. Use tooling (A) to remove bearings (12) from

body assembly (9).
290
OIL PUMP
ASSEMBLE OIL PUMP 1304-16
Tools Needed A
1. Make an alignment of bearings (1) so the joints

are 45 ± 15 from a line through the center of the
O
bearing bores as shown.
2. Use tooling (A) to install bearings (1) in the body

assembly until they are 1.5 ± 0.5 mm (.059 ±.020
in.) below the gear bore in the body assembly.
Check the inside diameter of the bearings after
installation. The diameter must be 31.837 ±
0.070 mm (1.2534 ± .0028 in.).
3. Heat gears (2) to a maximum temperature of

O O
316 C (600 F).
4. Install the gears on shaft assemblies (3) until

they are 34.0 ± 0.5 mm (1.34 ± .020 in.) from the
cover end of the shaft assemblies to the face of
the gears and 47.0 ± 0.5 mm (1.85 ± .020 in.)
from the fuel pump drive end of shaft assembly
(4).
5. Install shaft assemblies (3) and (4) in the body

assembly.
291
OIL PUMP
6. Make sure dowels (5) and (8) are installed in

cover assembly (6) so they extend 6 ± 0.5 mm
(.236 ± .02 in.) above the surface of the cover
assembly.
7. Use tooling (A) and install bearings (7) in cover

assembly (6) with the joints of the bearings in the
positions as shown.
8. Put cover assembly (6) in position and tighten

the bolts to hold it to the body assembly.
9. Make sure the two pins in cover assembly (9)

are installed so they extend 6 ± 1 mm (.236 ±
.039 in.) above the surface of the cover assem-
bly. Install the gasket and cover assembly (9) on
the pump.
10. Put clean engine oil on valve spool (13). Install

valve spool (13), spring (12), gasket (11), cover
(10) and the bolts on the pump body.
11. Install the gasket and adapter assembly (14) on

the pump body.
end by:
a) install oil pump
292
OIL FILTER HOUSING
REMOVE OIL FILTER HOUSING 1306-11
Tools Needed A
6V2156 Link Bracket 2
start by:
a) remove fuel filter housing
1. Remove the bolts to remove the clamps and

spacers from plate (1). Remove the bolts and
remove plate (1) from the engine.
2. Remove the bolts from adapter (2) to disconnect

it from the filter housing.
3. Use tooling (A) to fasten a hoist to oil filter

housing (3). Remove the bolts that hold the
housing to the support and remove housing (3)
from the engine. The weight of the oil filter
housing is 75 kg (165 lb.).
Install Oil Filter Housing 1306-12
Tools Needed A
1. Use tooling (A) to fasten a hoist to oil filter

housing (1). Put the housing in position on the
support and install the bolts to hold it in position.
293
OIL FILTER HOUSING
2. Install the bolts to connect adapter (2) to the oil

filter housing.
3. Put plate (3) the spacers and clamps in position

and install the bolts.
end by:
DISASSEMBLE OIL FILTER HOUSING 1306-15

start by:
a) remove oil filter housing
1. Remove the bolts and remove cover (1) from the

housing assembly.
2. Remove O-ring seal (2) from cover (1).
3. Remove ring (3) to remove retainer (4), the

spring and the O-ring seal from cover (1).
294
OIL FILTER HOUSING
4. Remove three element assemblies (5) from the

housing assembly.
5. Remove O-ring seals (7) from housing (6) and

remove the bolts to remove housing (6) from the
housing assembly. The weight of housing (6) is
25 kg (55 lb.).
6. Remove O-ring seal (8) from the housing.
Cover (10) has spring tension behind it. Slowly

remove bolts (9) to release the tension and prevent
possible personal injury.
7. Slowly remove bolts (9) to release the spring

tension behind cover (10) and remove cover (10)
from the housing.
8. Remove 0-ring seals (11), spring (12) and the

valve from the housing.
9. Remove the bolts and nuts to remove cover

assembly (13) from the housing.
295
OIL FILTER HOUSING
10. If necessary, remove pins (14) from cover as-

sembly (13).
11. Remove O-ring seal (15) from the housing.
12. Remove plug (17) to remove valve (16) from the

housing.
13. Remove adapter (18) from housing assembly

(19).
14. Remove O-ring seal (20) from adapter (18).
296
OIL FILTER HOUSING
ASSEMBLE OIL FILTER HOUSING 1306-16

clean engine oil on it. Install adapter (1) in the
housing assembly.
2. Install valve (3) in housing (4) as shown.
NOTE: If valve (3) has been installed wrong, plug (5)

can be installed correctly.

plug (5) in housing (4).
4. If pins (6) were removed, install the new pins in

cover (7). Make sure they are 7 ± 0.5 mm (.275
±.020 in.) above the surface of the cover.
297
OIL FILTER HOUSING
5. Install O-ring seal (8) on the housing and put

6 Put cover (7) in position on housing (4) and

make sure pins (6) are in alignment with the hole
in housing (4) and the groove (slot) in valve (3).
Install the bolts and nuts to hold the cover in
position.
7. Install valve (9) in housing (4). Install O-ring

seals (10) in housing (4) and put clean engine oil
on the seals.
8. Put spring (12) in position and install cover (11)

on housing (4).
9. Install O-ring seal (14) on housing (4) and put

clean engine oil on it. Install housing (4) on
housing assembly (13).
298
OIL FILTER HOUSING
10. Install O-ring seals (15) on housing (4) and put

clean engine oil on the seals.
11. Put the O-ring seal, spring (17) and retainer (16)
in position on cover (18).
12. Install ring (19) to hold the retainer and spring in

position. Install O-ring seal (20) on cover (18)
and put clean engine oil on it.
13. Install three element assemblies (21) in housing

assembly (13). Install cover (18) on housing
assembly (13).
end by:
a) install oil filter housing
299
OIL PAN
REMOVE OIL PAN 1302-11 5. Fill the engine with oil to the correct level.
1. Drain the oil from the engine.
2. Remove bolts (1) that hold the oil pump adapter

to the oil pan.
3. Remove the bolts that hold oil pan (2) to the

engine and lift the engine off of the oil pan or
lower the oil pan away from the engine. The
weight of the 3512 oil pan is 295 kg (650 lb.) and
the weight of the 3508 oil pan is 240 kg (530 lb.).
The weight of the 3512 engine is approximately
5443 kg (12, 000 lb.) and the weight of the 3508
engine is approximately 4445 kg (9800 lb.).
INSTALL OIL PAN 1302-12
1. Make sure the O-ring seal is installed on the oil

pump adapter and put clean engine oil on it.
2. Install four 3/8"-16 NC guide bolts in the pan and

put the oil pan gasket in position on the pan.
3. Put the engine in position on the oil pan or put oil

pan (1) in position under the engine. Install the
bolts that hold the oil pan to the engine.
4. Install bolts (2) that hold the oil pump adapter to

the oil pan.
300
OIL PAN
DISASSEMBLE OIL PAN 1302-15
start by:
a) remove oil pan
1. Remove covers (1), (2) and the O-ring seals.
2. Remove screen assembly (3) from the oil pan.

Remove O-ring seals from the screen assembly.
3. Remove the bolts and remove oil level gauge (4)

from the oil pan.
4. Remove the bolts that hold bell (5) to the oil pan.
Pull bell (5) off the O-ring seals on the end of the
tube assembly and remove bell (5) from the oil
pan.
301
OIL PAN
5. Pull tube assembly (7) from housing (6).

Remove the bolts that hold housing (6) in
position and remove it from the oil pan. Remove
the 0ring seals from the oil pan.
6. Remove tube assembly (7) from the oil pan.

Remove the O-ring seals from tube assembly
(7).
Assemble Oil Pan 1302-16
1. Install the O-ring seals on the ends of tube

assembly (1) and put clean engine oil on the
seals. Install tube assembly (1) in the oil pan.
2. Install the O-ring seal in the top of housing (2)

and put clean engine oil on it. Put housing (2) in
position and install the bolts to hold it in position.
302
OIL PAN
3. Push tube assembly (1) into housing (2).
4. Put bell (3) in position over the end of tube

assembly (1) and install the bolts to hold it to the
oil pan.
5. Install oil level gauge (4) and the gasket in the oil
pan. Install the bolts to hold the gauge in
position.
6. Install the O-ring seals on screen assembly (7)

and put clean engine oil on the seals. Install
screen assembly (7) in the oil pan.
7. Install the O-ring seals on covers (5), (6) and put

clean engine oil on the seals. Install covers (5)
and (6) on the front of the oil pan.
end by:
a) install oil pan
303
OIL SEQUENCE VALVES
REMOVE AND INSTALL OIL SEQUENCE

VALVES
start by:
a) remove front drive housing
b) remove flywheel housing
1. Remove cover (1) from the front of the cylinder

block.
2. Remove plunger assembly (2) and spring (3)

from the front of the cylinder block.
3. Remove the gear assembly, idler gear and shaft

from over cover (4) on the rear of the cylinder
block.
4. Remove cover (4) from the rear of the cylinder

block.
5. Remove plunger assembly (5) and spring (6)

from the rear of the cylinder block.
6. Put clean engine oil on spring (6) and plunger

assembly (5) and install them as shown in the
rear of the cylinder block.
7. Install cover (4). Install the idler gear, shaft and

gear assembly over cover (4) on the rear of the
cylinder block.
8. Put clean engine oil on spring (3) and plunger

assembly (2) and install them in the front of the
cylinder block as shown.
9. Install cover (I) to hold the plunger assembly and

spring in position.
end by:
a) install flywheel housing
b) install front drive housing
304
OIL COOLER
REMOVE OIL COOLER 1378-11
2. Drain the oil from the oil cooler.
3. Remove the bolt and remove clips (1) from oil

tube (2).
4. Disconnect oil hose (3) from elbow (4).
5. Remove the bolts and retainers that hold oil tube

(2) to elbow (4) and pull tube (2) out of elbow (4).
Remove the bolts and remove elbow (4) from
the oil cooler.
6. Remove the bolts to disconnect flange (5) and

tube (6) from the water line adapter.
NOTE: Step 7 is for the 3512 Engines.
7. Remove the bolts from elbow (7) and remove

elbow (7) and tube (8) as a unit from the oil
cooler bonnet.
8. Fasten a hoist to the oil cooler and remove the

bolts from bracket (9).
3512 ENGINES
305
OIL COOLER
NOTE: Step 9 is for the 3512 Engine.
9. Deleted.
10. Remove the four bolts from bonnet (16) and pull
oil cooler (15) from oil tube (14). Remove the
cooler from the engine. The weight of cooler
(15) is 50 kg (110 lb.). 3512 ENGINES
INSTALL OIL COOLER 1378-12
NOTE: Step I is for the 3508 Engine.
1. Put clean engine oil on the O-ring seal on oil

tube (2). Fasten a hoist to oil cooler (3) and put
cooler (3) in position on oil tube (2). Make sure
the gasket is in place and install the four bolts in
bonnet (1) to hold the cooler in position.
3512 ENGINES
2. Put clean engine oil on the O-ring seal on oil

tube (4). Fasten a hoist to oil cooler (6) and put
cooler (6) in position on oil tube (4). Install the
two bolts in bonnet (5) to hold the cooler in
position.
3508 ENGINES
3508 ENGINES
306
OIL COOLER
3. Install the bolts that hold the oil cooler to bracket

(7) and remove the hoist from the oil cooler.
4. Deleted.
5. Make sure the gasket is in place and install the

bolts to hold flange (I I ) and tube (10) to the
water line adapter.
6. Put clean engine oil on the O-ring seal on elbow

(14). Put elbow (14) in position on the oil cooler
and install the bolts to hold it.
7. Put clean engine oil on the O-ring seal on the

end of tube (13). Put tube (13) in position in
elbow (14) and install the retainers and bolts to
hold the tube.
8. Connect oil hose (12) to elbow (14).
9. Put clips (15) in position on tube (13) and install

the bolt to hold the clips in position.
307
OIL COOLER
DISASSEMBLE OIL COOLER 1378-15
start by:
a) remove oil cooler
1. Remove the bolts from elbow (1) and remove

elbow (1) and tube (2) as a unit from the oil
cooler.
2. Remove tube (2) from elbow (1) and remove the

O-ring seals from tube (2) and elbow (1).
3. Put marks on bonnet (3) and core assembly (4)

for correct alignment at assembly. Remove
bonnet (3) from core assembly (4).
4. Remove flange (7) and tube (6) as a unit from

bonnet (5). Remove the O-ring seals from tube
(6).
5. Remove the bolts and remove elbow (8) from

core assembly (4).
308
OIL COOLER
6. Remove the bolts and remove cover (9) from

elbow (8). Remove the O-ring seal from cover
(9).
7. Remove spring (10) and plunger (11) from elbow

(8).
8. Remove the bolts to remove cover (13) and

remove O-ring seals (12) from elbow (8).
9 Put marks on bonnet (5) and core assembly (4)

for correct alignment at assembly. Remove
bonnet (5) from core assembly (4).
309
OIL COOLER
ASSEMBLE OIL COOLER 1378-16
1. Make sure the tubes in core assembly (I) are

clean and free of dirt and foreign material.
2. Put the gasket and bonnet (2) in position on core

assembly (1) and install the bolts.
3. Install O-ring seals (4) on elbow (3) and put

clean engine oil on the seals. Install cover (5) on
elbow (3).
4. Put plunger (7) and spring (8) in position in

elbow (3). Install the O-ring seal in cover (6) and
put clean engine oil on it. Install cover (6) on
elbow (3).
5. Put elbow (3) in position on the core assembly

310
OIL COOLER
6. Install the O-ring seals on tube (9) and put clean

engine oil on the seals. Install tube (9) and
flange (10) as a unit in bonnet (2).
7. Put the gasket and bonnet (11) in position on

core assembly (1) and install the bolts.
8. Install the O-ring seals on tube (13) and put

clean engine oil on the seals. Install tube (13) in
elbow (12).
9. Install the O-ring seal on elbow (12) and put

clean engine oil on it. Put elbow (12) and tube
(13) as a unit in position and install the bolts in
elbow (12) to hold the elbow and the tube in
position.
end by:
a) install oil cooler
311
TURBOCHARGERS
REMOVE TURBOCHARGERS 1052-11
1. Remove the bolts to remove support assembly

(2) from the air cleaner housing and the engine.
2. Loosen the clamp that holds the air cleaner

housing to the turbocharger. Fasten a hoist to
air cleaner housing (I) or use two men to remove
the housing from the turbocharger. The weight
of housing (1) is 29 kg (65 lb.).
3. Remove turbocharger oil drain tube (3), elbow

(4) and the gaskets from the engine. Remove
elbow (4) and the O-ring seal from oil drain tube
(3).
4. Disconnect oil supply line (5) from the turbo-

charger.
5. Remove turbocharger outlet pipe (6) from the

engine. Remove the flange and the O-ring seals
from each end of the pipe.
312
TURBOCHARGERS
6. Fasten a hoist to turbocharger (7) and remove

the bolts that hold it to exhaust manifold (8). Pull
turbocharger (7) and the coupling from the
exhaust elbow and remove these as a unit from
the engine. The weight of the 3508 Turbo-
charger is 45 kg (100 lb.) and the 3512 Turbo-
charger is 20 kg (45 lb.).
7. Remove coupling (9) from the turbocharger

turbine housing.
8. Do Steps 1 through 7 for the other turbocharger.
Install Turbochargers 1052-12
1. Install coupling (I) in the turbocharger turbine

housing.
2. Fasten a hoist to turbocharger (2) and put it and

the gasket in position. Put 5P3931 Anti- seize
Compound on the threads of the nuts and bolts
that hold the turbocharger to the exhaust
manifold. Install the bolts and nuts and tighten
the nuts to a torque of 54 + 5 N.m (40 + 4 lb. ft.).
313
TURBOCHARGERS
3. Install the O-ring seals on both ends of pipe (3)

and put clean engine oil on the seals. Install
flange (4) on the pipe and install pipe (3) on the
engine.
4. Make sure the gasket is in position and connect

oil supply line (5) to the turbocharger.
5. Install the O-ring seal on drain tube (6) and put

clean engine oil on it. Install elbow (7) on the
drain tube.
6. Install the gaskets, elbow (7) and turbocharger

oil drain tube (6) on the engine.
7. Fasten a hoist to air cleaner housing (8) and put

it in position on the turbocharger compressor
housing. Install the bolts that hold housing (8) to
bracket (10) and tighten clamp (9).
8. Install the support assembly between the air

cleaner housings.
9. Do Steps I through 8 for the other turbocharger.
314
TURBOCHARGERS (3508)
DISASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61)
Tools Needed A B C D E F
9S6363 Turbocharger Fixture 1
Group
9S6343 Fixture Assembly 1
8S9946 Holder 1
5S9566 T-Wrench 1
5P6518 Fixture Group 1
FT745 Modified Pliers 1
start by:
a) remove turbochargers
1. Install the turbocharger on tool (A) as

shown. Put marks on the three housings of
the turbocharger for correct installation
and alignment at assembly.
2. Loosen clamp (1) and remove compressor

housing (2) and the clamp from the
cartridge assembly.
3. Loosen clamp (3) and remove cartridge

assembly (4) from turbine housing (5).
NOTICE
To prevent a bent shaft, do not put a side force on
the turbine shaft when the compressor wheel nut is
loosened.
4. Install tool (C) in tool (B) and put the

cartridge assembly in tool (C) as shown.
Use tool (D) to remove the nut that holds
compressor wheel (6).
5. Use a press to push the turbine shaft out of

compressor wheel (6) and the cartridge
housing. Remove compressor wheel (6)
from the cartridge housing.
315
6. Put the turbine shaft in tool (C). Remove seal

ring (8) and shroud (7) from the shaft.
7. Use tool (E) to make sure the turbocharger shaft

is straight. See SPECIAL INSTRUCTION Form
No. SMHS6998.
8. Bend the tabs of the locks from bolts (10) and

remove the bolts and locks.
9. Remove backplate assembly (I1 ) from the

cartridge housing. Remove spacer (9) from
backplate assembly (11).
10. Remove seal rings (12) from spacer (9).
11. Remove thrust collar (13) from the cartridge

housing.
316
12. Remove seal ring (14) and thrust bearing (15)

NOTE: If the bearings are to be used again, put

identification on them as to their location for
correct assembly.
13. Remove bearing (16) and the washer below the

bearing from the cartridge housing.
14. Use tool (F) to remove snap rings (17) and (18)
15. Remove bearing (19) and washer (20) from the

cartridge housing.
16. Use tool (F) to remove snap ring (21) from the
cartridge housing if necessary.
17. Check all the parts of the turbocharger for

damage. If the parts have damage, use new
parts for replacement. See SPECIAL
INSTRUCTION Form No. SMHS6854 for
TURBOCHARGER RECONDITIONING. Also
see GUIDELINE FOR REUSABLE PARTS Form
No. SEBF8018.
317
ASSEMBLE TURBOCHARGERS
(AIRESEARCH TV61 AND TW61) 1052-16
Tools Needed A B C D E
FT745 Modified Pliers 1
9S6343 Fixture Assembly 1
8S9946 Holder 1
8S2328 Dial Test Indicator 1
Group
9S6363 Turbocharger Fixture 1
Group
1. Make sure all of oil passages in the turbocharger

cartridge housing, backplate assembly and
bearings are clean and free of dirt and foreign
material.
2. Put clean engine oil on all parts of the cartridge

at assembly.
NOTE: Make sure the round edge of the snap rings are
toward the bearings when the snap rings are
installed.
3. If necessary, use tool (A) to install snap ring ( 1 )

in the turbine end of the cartridge housing.
4. Install washer (2) and bearing (3). Use tool (A)

to install snap ring (4) to hold the washer and
bearing in the cartridge housing.
5. Use tool (A) to install snap ring (5) in the

cartridge housing.
6. Install the washer and bearing (6) until the

washer makes contact with snap ring (5).
7. Install thrust bearing (8) over the dowels in the

cartridge housing. Make sure the grooves in
bearing (8) are toward the outside as shown.
8. Install seal ring (9) in the groove of the cartridge

housing.
9. Put thrust collar (7) in position on the thrust

bearing with the counterbore for the spacer up.
318
10. Install seal rings (10) on spacer ( 11 ) so the

gaps in the rings are 180° apart.
11. Install spacer ( 11) in backplate assembly (12)

with the chamfer end of the spacer toward the
cartridge housing.
12. Make sure the oil passage in the cartridge

housing and the backplate assembly are in
alignment. Put the backplate assembly (12) in
position on the cartridge housing.
13. Install the locks and bolts to hold backplate

assembly (12) to the cartridge housing. Tighten
the bolts to a torque of 10 + 1.1 N•m (90 + 10 lb.
in.) and bend the tabs of the locks on the bolts.
14. Install tool (C) in tool (B). Put the turbine shaft in
position in tooling (C). Put 6V2055 High Vacuum
Grease in the groove for seal ring ( 14). Make
sure the grease fills the groove approximately
one half or more of the groove depth for the
complete circumference of the groove to help
make a carbon dam under the seal ring. Install
seal ring (14) and shroud (15) on turbine shaft
(13).
15. Install the cartridge housing on the turbine shaft

while spacer (11) is held in position. Make sure
the seal ring on the turbine is fitted correctly in
the cartridge housing.
16. Put compressor wheel (16) in position on the

turbine shaft.
319
NOTICE
Do not put a side force on the turbine
shaft when the nut is tightened or a
bent shaft will be the result.
17. Put a small amount of oil on the turbine shaft

threads and the compressor wheel face that will
be under the nut. Install the nut and tighten it to
a torque of 13.6 N•m (120 lb. in.) to push the
compressor wheel (16) on the shaft. Loosen the
nut and tighten it again to 3.4 N•m (30 Ib. in.).
Tighten the nut 1200 of a turn more.
18. Put the cartridge housing in a vise as shown.

Check the shaft end play with tool group (D).
The shaft end play must be 0.08 mm to 0.25 mm
(.003 to .010 in.).
19. Install turbine housing (17) on tool group (E) as

shown. Put the cartridge and clamp (18) in
position in turbine housing (17). Make sure the
marks on the housing and cartridge are in
alignment and tighten clamp (18) to a torque of
13.6 + 1.1 N•m (120 + 10 lb. in.). Lightly hit all
around the clamp with a soft faced hammer and
again tighten clamp nut to same torque.
20. Install clamp and compressor housing (19) on

the cartridge in the correct position. Move clamp
into position and tighten the nut to a torque of
13.6 + 1.1 N•m (120 + 10 lb. in.). Lightly hit all
around the clamp with a soft faced hammer and
again tighten clamp nut to the same torque.
end by:
a) install turbochargers
320
EXHAUST MANIFOLDS
REMOVE EXHAUST MANIFOLDS 1059-11
start by:
a) remove turbochargers
b) remove air intake shutoff (3508)
1. Remove bracket (1) that holds the rear of the

exhaust manifold in position.
2. Fasten a hoist to exhaust manifold (2) and

remove the bolts that hold it to each cylinder head.
Remove the exhaust manifold from the engine. The
weight of the 3512 exhaust manifold is 56 kg (125 lb.).
The weight of the 3508 exhaust manifold is 49 kg (110
lb.).
INSTALL EXHAUST MANIFOLDS 1059-12
1. If the exhaust manifold was disassembled, put

5P3931 Anti-Seize Compound on the threads of the bolts
and nuts at assembly.
2. Fasten a hoist and put exhaust manifold (1) and

the gaskets in position on the engine.
NOTE: The gaskets can be fastened to the exhaust

manifold ports with tag wire or short 3/8"-16 NC studs
can be used as guide bolts for alignment at assembly.
3. Put 5P3931 Anti-Seize Compound on the

threads of the bolts and install them to hold the exhaust
manifolds to the cylinder heads. Tighten the bolts to a
torque of 45 + 7 N-m (32 + 5 lb. ft.).
4. Install bracket (2) to hold the rear of the exhaust

manifold in position. start by:
a) install turbochargers
b) install air intake shutoff (3508)
321
AFTERCOOLER
REMOVE AFTERCOOLER 1063-11
Tools Needed A
start by:
a) remove air intake shutoff
2. Remove the two bolts to remove elbow (1) and a

sleeve from the rear of the aftercooler housings.
3. Remove adapter (2) from the rear of aftercooler

housings.
4. Disconnect tube assembly (3) from adapter (5)

and the water temperature regulator housing.
Remove the tube assembly from the engine.
5. Remove all the bolts that hold elbow (4) in

position and disconnect elbow (4) from adapter
(5).
6. Remove the two bolts and remove adapter (5)

from the front of the aftercooler housings.
322
AFTERCOOLER
7. Remove sleeve (7) from adapter (6) and remove

adapter (6) from the front of the aftercooler
housings.
8. Fasten a hoist to aftercooler housings (8) with

tooling (A). Remove the bolts to remove
aftercooler housings (8) from the engine. The
weight of the 3508 Aftercooler Housings is 28 kg
(62 lb.) and the 3512 Aftercooler Housings is 66
kg (145 lb.).
NOTICE
Be careful when the aftercooler core
is removed because the lower rear
part of the core is held in position by
a connector and O-ring seals.
9. Fasten a hoist to strap (11) and remove the bolts

and two plates that hold aftercooler core (10) in
position. Remove aftercooler core (10) from the
engine. The weight of the 3512 Aftercooler Core
is 39 kg (85 lb.). The weight of the 3508
Aftercooler Core is 29 kg (65 lb.).
NOTE: The 3512 and 3508 Engines use the same

aftercooler core but the 3508 Engines do not
have pipes (9) at the ends of the core or the two
plates to hold the core in position.
10. Remove pipes (9) from the ends of the

aftercooler core and remove the O-ring seals
from the tubes.
11. Remove O-ring seals (12) from each end of the

aftercooler core. Remove ring (13) to remove
connector (14) from the aftercooler core.
Remove the O-ring seals from the connector.
323
AFTERCOOLER
INSTALL AFTERCOOLER 1063-12

Tools Needed A
NOTE: Clean and inspect all of the O-ring seals and

gaskets. Make a replacement of any worn or damaged
seals and gaskets.
1. Install the O-ring seals on connector (1) and put

clean engine oil on the seals. Put connector (I)
in position and install ring (2) to hold the
connector in position.
2. Install the O-ring seals on the ends of the

aftercooler core and put clean engine oil on the
seals.
3. Install the O-ring seals on pipes (3) and put

clean engine oil on the seals. Install pipes (3) on
the ends of the 3512 Aftercooler Core only.
4. Fasten a hoist to aftercooler core (4) as shown

and put it in position on the engine. Make sure
connector (I) is correctly engaged with adapter
(5) in the cylinder block. Install the bolts and
plates to hold the core in position. The 3508
Engines do not use the plates.
5. If the aftercooler housings were taken apart and

new gaskets installed, cut the gaskets even with
the bottom of the housings.
6. Fasten a hoist to aftercooler housings (6) with

tooling (A). Put housings (6) and the gasket in
position and install the bolts to hold the housings
in position. Tighten the bolts to a torque of 55 +
7 N•m (40 + 5 lb. ft.).
7. Put clean engine oil on the O-ring seal on

adjuster (7). Install adapter (7) and sleeve (8) in
the front of the aftercooler housings and over the
end of the pipe.
324
AFTERCOOLER
8. Put clean water on the O-ring seal and put

adapter (10) and the gasket in position in the
front of the aftercooler housings. Install the bolts
to the adapter.
9. Put clean water on the O-ring seal and push

elbow (9) into adapter (10). Put the gasket in
position between elbow (9) and the tube. Install
the bolts to hold elbow (9) in position.
10. Install tube assembly (11) on the regulator

housing and adapter (10).
adapter (12) in the rear of the aftercooler
housings and over the end of the pipe.
12. Put clean water on the O-ring seal on elbow (14).

Install sleeve (13) and elbow (14) in the rear of
the aftercooler housings. Make sure sleeve ( 13)
is over the end of the pipe and install the bolts to
hold elbow (14).
end by:
a) install air intake shutoff
325
GOVERNOR
REMOVE GOVERNOR 1264-11
2. Remove the bolts and retainers to remove tube

3. Disconnect hose assemblies (3) and (4) from the

governor. Disconnect hose assembly (2) from
the engine and remove it from the governor.
4. Remove bolts (5) that hold the governor fastener

group to the engine.
5. Remove bolts (7) to remove governor (6) and the

fastener group as a unit from the engine. The
weight of the unit is 23 kg (50 lb.).
6. Remove the bolt and remove lever assembly

(10) from the governor output shaft. If
necessary, remove pin (11) from the lever
assembly.
7. Remove bolts (8) and remove cover (9) from the

governor.
8. Remove seal (12) and the washer from cover

(9).
326
GOVERNOR
INSTALL GOVERNOR 1264-12
Tools Needed A
1. Install the washer in cover (1) and use tool group

(A) to install the seal in cover (1). Make sure the
lip of the seal is toward the engine as shown and
put clean engine oil on the seal.
2. Make sure two bolts (3) are in position and put

cover (1) in position on the governor.
Install.48013X1 bolts (2) to hold the cover in
position.
3. If pin (5) was removed, use a press to install the

new pin until it is 18 ± 1 mm (.71 ± .04 in.)
above the surface of the lever assembly as
shown. Put lever assembly (4) in position on the
governor output shaft and install the bolt to hold
it.
4. Put the gaskets for the governor and the

fastener group in position on the engine. Fasten
a hoist or use two men to put governor (6) and
the fastener group as a unit in position on the
engine. Make sure the pin on lever assembly (4)
engages in the groove (slot) of the lever for the
fuel control. Make sure the splines on the
governor input shaft are engaged correctly in the
governor drive and install the bolts to hold the
governor and fastener group in position.
5. Install hose assembly (7) on the governor and

connect it to the engine. Connect hose
assemblies (8) and (9) to the governor.
6. Put clean engine oil on the O-ring seals and’

install tube (10) on the engine. Install the bolts
and retainers to hold the tube in place.

level.
327
GOVERNOR DRIVE
REMOVE AND INSTALL GOVERNOR

DRIVE 1288-10
start by:
a) remove governor
1. Remove bolts (2) and pull governor drive (1)

from the front drive housing.
2. Make sure the O-ring seals are in position on the

front of governor drive (1) and put clean engine
oil on the seals.
3. Put governor drive (1) in position and install

bolts (2) to hold it to the front drive housing.
end by:
a) install governor401X
DISASSEMBLE GOVERNOR DRIVE 1288-15
start by:
a) remove governor drive
1. Remove O-ring seals (1), (2) and (3) from the

front of the governor drive housing.
2. Remove the bolts that hold adapter (4) in

position and pull adapter (4) from the housing.
3. Remove pinion (5), shims (6), seals (7) and (8)

from adapter (4). Make a measurement of
the.4-0 thickness of shims (6) and put
identification on them for assembly purposes.
328
GOVERNOR DRIVE
4. Remove hose assembly (9), cover (11) and the

gasket from governor drive housing (10).
5. Remove gear (13) and coupling (12) from

housing (10) as a unit.
6. Remove ring (14) to remove coupling (12) from

gear (13).
7. If necessary, remove bearing (1 5 ) from

housing (10).
329
GOVERNOR DRIVE
ASSEMBLE GOVERNOR DRIVE 1288-16
Tools Needed A B
8S2328 Dial Test Indicator Group 1
1. Make an alignment of the oil hole in the bearing

with the drilled oil passage in governor drive
housing (1). Use tool group (A) and install the
bearing in housing (1) until it is 1.0 ± 0.5 mm
(.039 ± .020 in.) below the inside surface of the
housing.
2. Put coupling (3) in position in gear (2) and install

ring (4) to hold the gear and coupling as a unit.
3. Install coupling (3) and gear (2) as a unit in

housing (1).
4. Install pinion (5) in adapter (6).
330
GOVERNOR DRIVE
5. Put adapter (6) and shims (7) of the original

thickness in position and install the bolts to hold
the unit together.
6. Make an adjustment of the gear clearance

(backlash) between gear (2) and the pinion as
follows:
a) Install tool group (B) on gear (2) as shown

to check the gear clearance (backlash) at
four locations around gear (2) 90° apart.
b) Hold the pinion in position and push down"

while gear (2) is moved back and forth.
Make a record of the indications on tool
group (B) and use the lowest indication as
the correct gear clearance (backlash)
value. The correct gear clearance
(backlash) is 0.100 + 0.050 or 0.025 mm
(.0039 + .0020 or .0010 in.).
c) Add or subtract shims (7) as necessary until

the gear clearance (backlash) is correct.
7 Remove tool group (B), the adapter and pinion

from the housing.
8. Connect hose assembly (8) to housing (1). Put

the gasket and cover (9) in position and install
the bolts and washers to hold them to housing
(1).
9. Install seals (10) and (11) on adapter (6) and put

clean engine oil on them.
10. Install the correct amount of shims (7) and

adapter (6) with the pinion in housing (1) and
tighten the bolts.
11. If necessary, make a replacement of pins (14).(

Make sure the pins are 14 ±1 mm (.55 ±.04 in.)
above the surface of the housing.
12. Install O-ring seal (12) and seals (13) on the

front of the housing. Put clean engine oil on the
seals.
end by:
a) install governor
331
HYDRAMECHANICAL SHUTOFF CONTROL
REMOVE HYDRAMECHANICAL SHUTOFF

CONTROL
1. Disconnect tube assemblies (2) from diverter

valve (3) and disconnect tube assemblies (1)
from the shutoff control.
2. Remove the bolts to remove cover (5), tube (4)

and the diverter valve as a unit from the shutoff
drive housing assembly and the shutoff control.
3. Disconnect tube assemblies (6), (7) and (9) from

the shutoff control. Remove the bolts and
hydramechanical shutoff control (8) from the
shutoff drive housing assembly.
4. Remove coupling (10) from the end of the shut

off drive gear.
332
INSTALL HYDRAMECHANICAL SHUTOFF CONTROL
1. Install coupling (2) on the end of the shutoff drive

gear.
2. Put hydramechanical shutoff control (1) and the

gasket in position on the shutoff drive housing
assembly. Make sure the shaft of the shutoff
control is correctly engaged with the coupling
and install the bolts to hold the shutoff control in
position.
3. Connect tube assemblies (3), (4) and (5) to the

shutoff control.
4. Put clean engine oil on the O-ring seals and

install tube (6) in the bottom of the shutoff
control. Put cover (7) and the diverter valve as a
unit in position on tube (6) and the shutoff drive
housing assembly. Install the bolts to hold these
in position.
5. Connect tube assemblies (8) to the shutoff

control and connect tube assemblies (9) to the
diverter valve.
333
DISASSEMBLE HYDRAMECHANICAL SHUTOFF

CONTROL
Tools Needed A B C
1P1855 Pliers 1
1P1853 Pliers 1
start by:
a) remove hydramechanical shutoff control
1. Remove the bolts and remove actuator valve (1)

from the pressure control valve.
There is spring pressure on cover (2). To prevent

possible personal injury slowly release the bolts that
hold cover (2) until all the pressure is removed.
2. Remove the bolts and remove cover (2) from the

actuator valve body.
3. Remove springs (4), spacer (5) and valve
assemblies (3) from the valve body.
4. Remove tube assembly (7) from the shutoff
control.
5. Remove pressure control valve (6) from the
shutoff control.
6. Put identification marks on valve assemblies
(12) and (13) for assembly purposes. Remove
rack shutoff valve (12) and air inlet shutoff valve
(13) from the pressure control body assembly.
Remove three O-ring seals from each valve.
7. Remove plug (11) to remove pilot valve (10),
and spring (9) from the pressure control body
assembly.
8. Remove manual shutoff valve (8) as a unit from
the pressure control body assembly.
334
9. Loosen nut (16) to remove knob (17) and nut

(16) from valve (14). Remove adapter (18) and
spring (19) from valve (14). Remove O-ring seal
(15) from adapter (18).
10. Remove seal (20) from adapter (18).
11. Remove eight bolts (22) to remove gerotor pump

group (21) from the shutoff control housing
assembly.
12. Use tool (A) to remove ring (24) and the washer
from the carrier assembly shaft.
NOTE: Do not remove bolts (23) at this time.
13. Remove carrier assembly (25) from the gerotor

pump group.
335
14. Remove dowels (27) to remove weights (26)

from carrier (25). Remove pin (28) and use a
press to remove shaft (29) from carrier (25).
15. Remove washer (30) from the pump group.
16. Remove the two bolts (23) to remove cover

assembly (31) from the plate.
17. Remove gasket (32) from the plate.
18. Remove plate (33) from the housing assembly.
336
19. Remove seal (34) from plate (33).
NOTE: Carefully remove driven gear (36) from sleeve

(35) so brush (39) and spring (38) do not become lost.
20. To remove the gerotor assembly, remove drive

gear (37), driven gear (36) and sleeve (35) from
the housing assembly.
21. Remove brush (39) and spring (38) from driven

gear (36).
22. Use tool (B) to remove snap ring (43) and

remove seat (42), spring (41) and plunger
assembly (40) from the housing assembly.
23. Remove O-ring seal (44) from the housing

assembly.
337
24. Remove speed sensing valve (46), spring (45)

and the seat from the housing assembly guide.
25. Remove ring (50) to remove race (49), bearing

(51 ) and race (48) from seat (52). Loosen nut
(47) to remove seat (52) and nut (47) from
speed sensing valve (46).
26. Remove shaft (53) to remove lever (54) from the

housing assembly.
27. Remove the wire seal and bolts (55) to remove

cover (56), the two seats and the spring from the
housing assembly.
28. Use tool group (C) to remove the guide from the
housing assembly.
338
339
ASSEMBLE HYDRAMECHANICAL SHUTOFF

CONTROL
Tools Needed A B C
1P1853 Pliers 1
1 1P1855 Pliers 1
1. If necessary, make a replacement of dowels (2)

and make sure they are 3.0 + 0.5 mm (.118. +
.020 in.) above the surface of the housing
assembly.
2. Put guide (I) in position in the housing assembly

and make sure the dash mark on the end of, the
guide is in alignment with hole (3). Use tool
group (A) to install guide (I) in the housing
assembly.
3. Put lever (5) in position in the housing assembly

as shown and install shaft (4) to hold lever (5) in
position. Make sure the end of the shaft is, a
even (flush) + 0.25 (.010 in.) with the housing
assembly.
4. Put the seat, spring (7) and seat (6) in position in

cover (8) and put cover (8) and the gasket in
position on the housing assembly. Install the
bolts to hold the cover in position.
5. Install nut (15) and seat (10) on speed sensing

valve (9). Make sure the dimension between the
end of the valve and the nut face of the seat is
117.21 + 0.25 mm (4.614 + .010 in.) and tighten
the nut. Put race (14), bearing (11) and race
(13) in position on seat (10) and install ring (12)
to hold these in position.
340
6. Install seat (16), spring (17) and speed sensing

valve (9) on the housing assembly guide.
7. Put clean engine oil on O-ring seal (18) and put

0-ring seal (18), plunger assembly (19), spring
(20) and seat (21) in position in the housing
assembly. Use tool (B) to install snap ring (22)
to hold the plunger assembly, the spring and
seat in position.
8. If necessary, make a replacement of pin (24)

and make sure pin (24) is 3.96 + 0.50 mm (.156
+ .020 in.) above the bottom surface of the bore.
9. Install the gerotor assembly as follows:

10.
a) Install sleeve (23) and make sure the groove
(slot) on sleeve (23) is in alignment with pin
(24).
b) Put the spring and brush (26) in position in
the driven gear (25). Install driven gear (25)
in the sleeve.
c) Install drive gear (27) in the driven gear.
341
10. Install seal (29) on plate (28) and put clean

engine oil on it.
11. Install plate (28) on the housing assembly.
12. If necessary, make a replacement of dowels

(31) and make sure they are 6.5 + 0.5 mm (.256
+ .020 in.) above the surface of the cover
assembly.
13. Put gasket (32) in position and install-cover

assembly (30) on the plate.
14. Use a press to install shaft (37) in carrier (35)

until dimension (X) is 84.08 + 0.25 mm (3.310 +
.010 in.).
NOTE: If either or both the shaft and the carrier are new,
a hole 3.175 + 0.051 0.000 mm (.125 + .002 .000 in.) in
diameter must be drilled through either or both the shaft
and the carrier at location (Z) and dimension (Y) must be
5.0 + 0.5 (.197 + .020 in.). This must be done before
Step 15 can be done.
15. Install pin (36) to hold the shaft and carrier in

position.
16. Put weights (33) in position on carrier (35) and

install dowels (34) to hold the weights. Each
weight must move freely on its dowel and must
have 0.02 to 0. 18 mm (.001 to .007 in.) end play
after assembly. Put marks (counter punch) four
places around both ends of the dowels.
17. Install washer (38) on the cover assembly and

put carrier assembly (35) in position in the
gerotor pump group.
342
18. Put the washer in position and use tool (C) to

install snap ring (39) on the carrier assembly
shaft.
19. Install two bolts (40) to hold the gerotor pump

group together as a unit.
20. Put gerotor pump group (41) in position on the

housing assembly. Make sure the speed
sensing valve is correctly engaged with the
carrier assembly and install the eight bolts to
hold the pump in position.
21. If necessary, make a replacement of dowels (45)

and make sure they are 3.0 + 0.5 mm (.1 18 +
.020 in.) above the surface of the valve body.
22. Put spring (44) and pilot valve (43) in position in

the valve body. Put clean engine oil on the
0ring seal and install plug (42) to hold the spring
and pilot valve in position.
23. Install three O-ring seals on air inlet shutoff valve

(46) and put clean engine oil on the seals. Install
valve (46) in the valve body and tighten it to a
torque of 58 + 4 N•m (43 + 3 lb. ft.).
24. Install three O-ring seals on rack shutoff valve

(47) and put clean engine oil on the seals.
Install valve (47) in the valve body and tighten it
to a torque of 58 + 4 N•m (43 ± 3 lb. ft.).
25. Install the seal in adapter (48) with tool group

(A). Make sure the lip of the seal is toward the
valve body as shown.
343

clean engine oil on it. Install spring (53), adapter
(48), nut (51) and knob (52) on manual shutoff
valve (49). Tighten the nut to hold the knob on
the valve.
27. Install manual shutoff valve (49) as a unit in the

valve body.
28. Put pressure control valve (55) and the gasket in

position on the shutoff control.
29. Install tube assembly (54) on the shutoff control.
30. Put four valve assemblies (56), three springs

(57) and spacer (60) in position in the actuator
valve body. Install gasket (58), cover (59) and
the bolts to hold the valves, the springs and
spacer in position.
31. Put the gasket, actuator valve (61) and the bolts
in position on the pressure control valve.
Tighten the bolts to hold the actuator valve and
the pressure control to the shutoff control.
32. See CATERPILLAR FUEL INJECTION TEST

BENCH, Form No. SEHS7465 Section IV, X for
the correct procedure to adjust the
hydramechanical shutoff control after assembly.
end by:
a) install hydramechanical shutoff control.
344
HYDRAMECHANICAL SHUTOFF DRIVE
REMOVE HYDRAMECHANICAL SHUTOFF DRIVE
Tools Needed A
1P 1855 Pliers 1
start by:
a) remove hydramechanical shutoff control
b) remove tachometer drive
1. Remove tube assemblies (1) and (2) from the

shutoff drive housing assembly and the engine.
2. Remove the bolts and remove shutoff drive

housing assembly (3) from the flywheel housing.
3. Use tool (A) to remove snap ring (5) and the

washer from the end of drive gear (4). Remove
drive gear (4) from the housing assembly.
4. If necessary, remove dowels (6) from the

housing assembly.
5. Remove bearing (9) and seal (7) from the

housing assembly. The bearing can be used to
push the seal out of the bore.
6. Remove two bearings (8) from the drive gear

bore.
7. If necessary, remove dowels (10) from the

housing assembly.
8. Remove gear assembly ( 11 ) from the end of

the crankshaft.
345
HYDRAMECHANICAL SHUTOFF DRIIVE
INSTALL HYDRAMECHANICAL SHUTOFF DRIVE
Tools Needed A B
1P 1855 Pliers 1
1. If necessary, make a replacement of dowels ( 1)

in gear assembly (2). The dowels must extend
9.5 + 0.5 mm (.374 + .020 in.) from the gear.
Put gear assembly (2) in position on the end of
the camshaft and install the bolts to hold it.
Tighten the bolts evenly to a torque of 100 + 15
N•m (75 + 10 lb. ft.). Hit the gear assembly with
a hammer and tighten the bolts again to the
same torque. Do this until the torque does not
change.
2. If dowels (5) were removed, install the new

dowels until they extend 6.0 + 0.5 mm (.236 +
.020 in.) from the housing assembly.
3. Use tool group (A) to install two bearings (4) in

the drive gear bore until they are 1.5 + 0.5 mm
(.059 + .020 in.) from the ends of the bore.
4. Put drive gear (3) in position in the housing

assembly.
5. Put washer (8) in position and use tool (B) to

install snap ring (7) to hold the washer and drive
gear in position.
6. Use tool group (A) to install bearing (6) in the

housing assembly until it is 26 ± 1 mm (1.02 +
.04 in.) below surface (X). Use tool group (A)
and install seal (10) to the bottom of the bore.
Make sure the lip of the seal is toward the
engine as shown and put clean engine oil on the
lip.
7. If dowels (9) were removed, install the new

dowels until they extend 6.0 + 0.5 mm (.236 +
.020 in.) from the housing.
8. Install shutoff drive housing assembly (13) and

the bolts to hold it on the flywheel housing.
Make sure the teeth of drive gear (3) are
correctly engaged with the teeth of gear
assembly (2).
9. Install tube assemblies (11) and (12) on the X

housing assembly and the engine.
end by:
a) install hydramechanical shutoff control
b) install tachometer drive
346
ACCESSORY DRIVE (FRONT)
REMOVE ACCESSORY DRIVE

(FRONT) 1207-11
start by:
a) remove governor drive
b) remove alternator (if so equipped)
1. Remove the bolts and remove cover (1) from

adapter assembly (2).
2. Use two 1/2"-13 NC forcing screws to remove

adapter assembly (2) from the front drive hous-
ing.
3. Remove the bolts and remove adapter assembly

(3), the drive gear and shaft as a unit from the
front drive housing.
INSTALL ACCESSORY DRIVE

(FRONT) 1207-12
1. Make sure the two O-ring seals are in position

on adapter assembly (1) and put clean engine oil
on them.
2. Install the drive shaft, gear and adapter assem-

bly (1) in the front drive housing. Make sure the
teeth of the accessory drive gear are correctly
engaged with the teeth of the oil and water pump
drive gear and install the bolts to hold adapter
assembly (1) in position.
3. Make sure the two O-ring seals are installed on

adapter assembly (2) and put clean engine oil on
the seals. Put clean oil on the lip of the seal and
bearing in adapter assembly (2) and install the
adapter assembly. Tighten the bolts to hold
adapter assembly (2) in position.
4. Install the cover on adapter assembly (2).

end by:
a) install governor drive
b) install alternator (if equipped)
347
DISASSEMBLE ACCESSORY DRIVE

(FRONT) 1207-15
Tools Needed A
start by:
a) remove accessory drive (front)
1. Remove O-ring seals (2) and (3) from the

adapter.
2. Remove seal (4) from adapter (1). Use a press

and tool group (A) to remove bearing (5) from
adapter (1).
3. Remove bolts (7) to remove gear (8) from shaft

(6).
4. Remove bolts (9) and the retainer washer to

remove shaft (6) from adapter (10).
5. Remove O-ring seals (12) and (13) from adapter

(10).
6. Use a press and tool group (A) to remove bear-

ing (11) from adapter (10)
348
ASSEMBLE ACCESSORY DRIVE

(FRONT) 1207-16
Tools Needed A

and the oil hole in adapter (1). Use a press and
tool group (A) and install the bearing in adapter
(1). Check the bore in the bearing after
assembly. The bore in the bearing must be
75.000 ± 0.055 mm (2.9528 ± .0022 in.).
2. Install the two O-ring seals in adapter (1).
3. Put clean engine oil on the bearing and install

shaft (3) in adapter (1). Install retainer washer
(2) to hold the shaft and adapter together.
4. Put gear (4) in position on shaft (3) and install

the bolts to hold them together.

and the oil hole in adapter (5). Use a press and
tool group (A) and install the bearing in adapter
(5). Check the bore in the bearing after
assembly. The bore in the bearing must be
75.000 ± 0.055 mm (2.9528 ±.0022 in.).
6. Use tool group (A) to install the seal in adapter

(5). Make sure the lip of the seal is toward the
bearing as shown.
7. Install 0-ring seals (6) and (7) on adapter (5) and

put clean engine oil on them.
end by:
a) install accessory drive (front)
349
OIL AND WATER PUMP DRIVE
REMOVE OIL AND WATER

PUMP DRIVE 1313-11
start by:
a) remove oil pump
b) Remove water pump
1. Remove bolts (1) and pull adapter assembly (2)

and the gears from the front drive housing as a
unit. The weight of the unit is 23 kg (50 lb.).
2. Remove bolts(4) and pull adapter assembly(3)

from the front drive housing.
INSTALL OIL AND WATER

PUMP DRIVE 1313-12
1. Make sure the O-ring seal is installed in the

groove of adapter assembly (1) and put clean
engine oil on it.
2. Put adapter assembly (1) in position and install

the bolts to hold it to the front drive housing.
3. Make sure the 0-ring seals are installed on the

grooves of adapter assembly (2) and have clean
engine oil on them.
4. Put the gears and adapter assembly (2) in posi-

tion as a unit. Make sure the drive gear is
engaged correctly with the idler gear and tighten
the bolts to hold adapter assembly (2) in
position.
end by:
a) install oil pump.
b) install water pump
350
DISASSEMBLE OIL AND WATER

PUMP DRIVE 1313-15
Tools Needed A
start by:
a) remove oil and water pump drive
1. Remove oil pump O-ring seal (4) from adapter

(3).
2. Remove washers (2). Remove adapter (3) from

shaft assembly (1).
3. Remove O-ring seals (6) and (7) from adapter

(3).
4. Use a press and tool group (A) to remove

bearing (5) from adapter (3).
5. Remove bolts (9) to remove gears (8) and (10)

from shaft assembly (1).
6. Remove O-ring seal (13) from the water pump

adapter assembly (12).
7. Use a press and tool group (A) to remove

bearing ( 11) from adapter assembly (12).
351
ASSEMBLE OIL AND WATER

PUMP DRIVE 1313-16
Tools Needed A
1. Lower the temperature of the bearing for water

pump adapter (1). Use tool group (A) and install
the bearing in adapter (1). Check the bore in the
bearing after assembly. The bore in the bearing
must be 75.00 ± 0.06 mm (2.953 ± .002 in.).
Install O-ring seal (2) on adapter (1).
2. Put gears (3) and (4) in position on the shaft

assembly as shown and install the bolts to hold
the unit together.
3. Lower the temperature of the bearing for adapter

(5). Make an alignment of the oil hole in the
bearing with the oil hole in adapter (5) and use
tool group (A) to install the bearing. Make sure
the bearing does not extend beyond the surface
shown and the inside diameter is 75.00 ± 0.06
mm (2.953 ± .002 in.) after installation.
4. Install O-ring seals (6) and (7) on adapter (5).
5. Put adapter (5) in position on shaft assembly (8)

and install washers (9) to hold the unit together.
6. Install the oil pump O-ring seal (10) on adapter

(5).
end by:
a) install oil and water pump drive
352
CRANKSHAFT VIBRATION DAMPER
REMOVE CRANKSHAFT VIBRATION

DAMPER 1205-11
Tools Needed A
5P9736 Link Bracket 2
1. Remove the bolts and remove damper guard (1)

from the engine.
2. Remove two bolts (3) and install two 1"-14 NF

guide bolts 11 in. long. Fasten a hoist to vibra-
tion damper (2) with tooling (A) and remove the
remainder of bolts (3). Remove vibration
damper (2) from the engine. The weight of the
damper is 81 kg (180 lb.).
3. If necessary, remove the bolts and remove the

damper from the adapter. The weight of the
damper is 52 kg (115 lb.) and the weight of the,
adapter is 29 kg (65 lb.).
INSTALL CRANKSHAFT VIBRATION

DAMPER 1205-12
Tools Needed A
1. If the damper was removed from the adapter,

put the damper on the adapter and install the
bolts to hold the unit together.
2. Install two 1"-14 NF guide bolts 11 in. long in the

end of the crankshaft. Fasten a hoist to vibration
damper (1) with tooling (A). Put the damper in
position on the guide bolts and make sure the
mark on the damper is in alignment with the
mark on the end of the crankshaft a Install four
of the bolts to hold the damper in position and
remove tooling (A). Remove the guide bolts and
install the remainder of the bolts.
3. Put damper guard (2) in position and install the

bolts to hold it in position on the engine.
353
CRANKSHAFT FRONT SEAL AND WEAR SLEEVE
REMOVE CRANKSHAFT FRONT SEAL AND

WEAR SLEEVE 1160-11
Tools Needed A B
5P7409 Distorter 1
6V3143 Distorter Adapter 1
start by:
a) remove crankshaft vibration damper
NOTE: Any time the crankshaft seal is removed from
the wear sleeve, a new sleeve and seal must be installed
as a unit. If the seal is put back on the sleeve, the seal
will leak.
1. Remove the bolts from adapter (1) and install

two 5/16"- 13 NC forcing screws in the adapter
to remove it from the drive housing.
2. Remove O-ring seal (3) and crankshaft seal (2)
from adapter (1).
3. Install tool (B) in adapter bore as shown.
4. Install tool (A) between tool (B) and wear sleeve
(4). Turn tool (A) until the edge of the tool
makes a flat plate (crease) in the wear sleeve.
Do this several places around the wear sleeve
until the sleeve can be removed from the end of
the crankshaft by hand.
INSTALL CRANKSHAFT FRONT SEAL AND

WEAR SLEEVE 1160-12
Tools Needed A B C D E F G
6V4002 Forcing Bracket 2
6V4001 Forcing Ring 1
1B4330 Nut (5/ 16"-18 NC) 4
6V4003 Locator 1
2N5006 Bolt (1"-14 NF x 2.5
in. long) 2
Guide Bolts (5/ 16"-
18 NC x 4 in. long) 2
6V4977 Installer 1
9S8858 Nut 1
will leak.
1. Install adapter (3) on tooling (A) as shown.

NOTICE
If the crankshaft seal and wear sleeve come apart
during installation, the seal and sleeve become
scrap and a new seal and sleeve must be used as a
replacement.
NOTE: The front seal and wear sleeve can not be exchange of front and rear seals would pump the oil out
exchanged with the rear seal and wear sleeve. There of the crankcase.
are grooves in the sealing lip of the seals that direct the 2. Put crankshaft seal ( 1) and wear sleeve (2) as a
oil back into the crankcase as the crankshaft turns. An unit in position on adapter (3). Make sure the lip
of the seal is up as shown.
354
CRANKSHAFT FRONT SEAL AND WEAR SLEEVE
3. Install tool (B) over the studs of tooling (A).

Install nuts (C) and tighten the nuts evenly until
the seal is against the bottom of the adapter
bore.
4. Remove nuts (C), tool (B) and tooling (A) from

the adapter.
NOTE: Do not put engine oil on the lip of the seal during
installation. Lubrication of the seal at installation can be
a wrong indication for linkage at a later time.
5. Put clean engine oil on the O-ring seal and,

install the seal on the adapter.
6. Install tooling (D) on the end of the crankshaft.
7. Install guide bolts (E) in the drive housing. Put

adapter (3) in position on guide bolts (E) and
over tooling (D). Make sure the wear sleeve
makes contact with the end of the crankshaft.
8. Install tool (B) over the small outside diameter of

tool (F) until tool (B) is against the shoulder on
tool (F).
9. Install tooling(B) and(F) as a unit on the guide

bolts and over the locator.
10. Put clean engine oil on the face of nut (G) and,
install nut (G) on the locator. Tighten nut (G)
until the wear sleeve and adapter are in posi-
tion.
11. Remove the tooling from the engine.
12. Install bolts (4) to hold adapter (3) in position.

end by:
a) install crankshaft vibration damper
355
CRANKSHAFT REAR SEAL AND WEAR SLEEVE
REMOVE CRANKSHAFT REAR SEAL AND

WEAR SLEEVE 1161-11
Tools Needed A B
5P7409 Distorter 1
6V3143 Distorter Adapter 1
start by:
a) remove flywheel
will be damaged.
1. Remove the bolts from adapter (1) and install

two 5/16"- 18 NC forcing screws in the adapter
to remove it from the drive housing.
2. Remove O-ring seal (3) and crankshaft seal (2)
from adapter (1).
3. Install tool (B) in adapter bore as shown.
4. Install tool (A) between tool (B) and wear sleeve
(4). Turn tool (A) until the edge of the tool
makes a flat place (crease) in the wear sleeve.
Do this several places around the wear sleeve
until the sleeve can be removed from the end of
the crankshaft by hand.
INSTALL CRANKSHAFT REAR SEAL AND

WEAR SLEEVE 1161-12
Tools Needed A B C D E F G
6V4002 Forcing Bracket 2
6V4001 Forcing Ring 1
1B4330 Nut (5/16"-18 NC) 4
6V4003 Locator 1
2N5006 Bolt (1"-14 NF x 2.5
in.
long) 2
Guide Bolts (5/16"-18
NC x 4 in. long) 2
6V4977 Installer 1
9S8858 Nut 1

will be damaged.
1. Install adapter (3) on tooling (A) as shown.

NOTICE
If the crankshaft seal and wear sleeve come apart
during installation, the seal and sleeve become
scrap and a new seal and sleeve as a unit must be
used as a replacement. An exchange of front and rear seals can cause the oil to
NOTE: The rear seal and wear sleeve can not be come out of the crankcase.
exchanged with the front seal and wear sleeve. There 2. Put crankshaft seal (1) and wear sleeve (2) as a
are grooves in the sealing lip of the seals that direct the unit in position on adapter (3). Make sure the
oil back into the crankcase as the crankshaft turns. lip of the seal is up as shown.
356
CRANKSHAFT REAR SEAL AND WEAR SLEEVE
3. Install tool (B) over the studs of tooling (A).

Install nuts (C) and tighten the nuts evenly
until the seal is against the bottom of the
adapter bore.
4. Remove nuts (C), tool (B) and tooling (A)

from the adapter.
NOTE: Do not put engine oil on the lip of the seal during
installation. Lubrication of the seal at installation can be
a wrong indication for linkage at a later time.
5. Put clean engine oil on the O-ring seal and,

install the seal on the adapter.
6. Install tooling (D) on the end of the

crankshaft.
7. Install guide bolts (E) in the drive housing.

Put adapter (3) in position on guide bolts
(E) and over tooling (D). Make sure the
wear sleeve makes contact with the end of
the crankshaft.
8. Install tool (B) over the small outside

diameter. of tool (F) until tool (B) is against
the shoulder on tool (F).
9. Install tooling (B) and (F) as a unit on the

guide bolts and over locator.a8’" "A
10. Put clean engine oil on the face of nut (G)

and install nut (G) on the locator. Tighten
nut (G) until the wear sleeve and adapter
are in position.
11. Remove the tooling from the engine.
12. Install bolts (4) to hold adapter (3) in

position.
end by:
a) install flywheel
357
FRONT DRIVE HOUSING
REMOVE FRONT DRIVE HOUSING 1151-

11zit
Tools Needed A B C
1P74 Slide Hammer and Puller 1
8B7557 Threaded Adapter 1
1P520 Drive Group 1
start by:
a) remove oil filter housing
b) remove crankcase breather
c) remove front crankshaft seal and wear sleeve
d) remove accessory drive (front)
e) remove governor drive.
NOTE: Make sure there is a new front crankshaft seal

and wear sleeve before the front drive housing is
removed. Anytime the front seal is removed from the
wear sleeve, a new seal and sleeve must be installed.
1. Remove oil tube (I) from the engine.
2. Fasten a hoist to support (2) with tooling (A)

and remove support (2) from the drive
housing. The weight of the support is 102
kg (225 lb.).
3. Remove elbow (3) and tube (4) as a unit

from the engine.
4. Remove the bolts and use tooling (B) to

remove shaft (6) and idler gear (5) from the
drive housing.
5. If necessary, use tooling (C) to remove the

bearing from idler gear (5).
358
FRONT DRIVE HOUSING
6. Remove washer (7) from the inside of the

drive housing.
7. Remove bolt (9) and washer to remove clip

(8) from the drive housing.
8. Remove cover (11) from the drive housing
9. Remove all of the bolts that hold the oil pan

to the engine. Install 3/8"-16 NC guide
bolts in each side of the oil pan. Fasten a
hoist to the engine and lift the engine
approximately 12E mm (0.5 in.) off of the
oil pan. Put two 50 mm.-66 wide x 100 mm
long x 6 mm thick (2 in. wide x 4 in. long x
l/4 in. thick) plates in position between the
cylinder block and the oil pan on each side
of the engine. Lower the engine on the
plates and remove the hoist. The weight of
the 3512 2 Engine is approximately 5443 kg
(12, 000 lb.). The weight of the 3508 Engine
is 4445 kg (9800 lb.).
NOTICE.
Fuel control linkage (10) must be
moved for clearance to pull the front
drive housing from the engine or
damage to parts can be the result.
10. Fasten a hoist to front drive housing (12)

with tooling (A). Remove bolts (13) and the
remainder of the bolts that hold housing
(12) in_ 1 position. Remove front drive
housing (1 2) from the engine. The weight
of the housing is 209 kg (460 lb.).:
359
FRONT DRIVE HOUSING
INSTALL FRONT DRIVE HOUSING 1157-12
Tools Needed A B
1P520 Drive Group 1
1. Put the housing gasket in position on the

front of the cylinder block. Install two 5/8"-
11 NC guide bolts (1) in the cylinder block.
2. Fasten a hoist to front drive housing (2) with

tooling (A). Put housing (2) in position on
the guide bolts and install the bolts to hold it
in position. Remove the guide bolts and
install the remainder of the bolts. Tighten
all of the bolts evenly and cut the housing
gasket even with the bottom of the
cylinder block.
3. Fasten a hoist to the engine and lift the

engine enough to remove the plates
between the cylinder block and the oil pan.
If the oil pan gasket damaged, the engine
will have to be removed from the oil pan to
make a replacement of the gasket. Lower
the engine on the oil pan and remove the
guide bolts of the oil pan. Install all of the
bolts that hold the oil pan to the engine.
4. Put clean engine oil on the O-ring seals and

install cover (3) on the drive housing.
5. Put washer (4) in position inside the drive

housing.
360
FRONT DRIVE HOUSING
6. Use tooling (B) and a press to install the bearing

in idler gear (5). Check the bore in the bearing
after assembly. The bore in the bearing must be
90.00 + 0.06 mm (3.543 + .002 in.).
7. Put clean engine oil on the O-ring seal on shaft

(6). Install idler gear (5) and shaft (6) in the front
drive housing.
8. Make sure the gasket and seals are in position

and install aftercooler water line (7) on the
engine. Install clip (8) on the drive housing.
9. Install oil tube (9) on the engine.-4.
10. Fasten a hoist to support (10) with tooling (A)’

and put it in position on the front drive housing.
Install the bolts to hold the support in position.
NOTE: Anytime the front crankshaft seal and wear

sleeve are removed a new seal and wear sleeve must be
installed.
end by:
a) install oil filter housing
b) install crankcase breather
c) install front crankshaft seal and wear sleeve
d) install accessory drive (front)
e) install governor drive
361
FLYWHEEL
REMOVE FLYWHEEL1156-11
Tools Needed A
6V2157 Link Bracket 2’
1. Fasten a hoist to the flywheel with tooling (A).
2. Remove flywheel (2) from the engine. The NF

guide bolts 11 in. long in their place. Remove
the remainder of bolts (I).
3. If necessary, install a 5/8"- 1 NC forged eye-bolts

in each side of the flywheel and use a pry bar to
remove the flywheel from the pilot on theW5
crankshaft.
4. Remove flywheel (2) from the engine. The

weight of the 3512 Flywheel is 167 kg (370 lb.).
The weight of the 3508 Flywheel is 126 kg (280
lb.).
INSTALL FLYWHEEL 1156-12
Tools Needed A
1. If the flywheel ring gear has damage, a

replacement can be made as follows:
a) Heat the ring gear to a maximum
temperature of 316° C (6000 F) and install
it on the., flywheel so the chamfer of the
gear teeth will be toward the starter pinion
when the flywheel is installed.
2. Install two 1"-14 NF guide bolts 11 in. long in the

end of the crankshaft.
3. Fasten a hoist to flywheel (1) with tooling (A) and

put it in position on the guide bolts. Make sure
the mark on the flywheel is in alignment with the
mark on the crankshaft.
4. Put clean engine oil on the threads of bolts (2)

and install them to hold the flywheel in place.
Tighten bolts (2) to a torque of 1 150 + 30 N-m
(848 + 22 lb. ft.).
362
FLYWHEEL HOUSING
REMOVE FLYWHEEL HOUSING 1157-11
Tools Needed A B
8B7548 Puller Assembly 1
8B7559 Threader Adapter 2
8B7561 Step Plate 1
8H684 Ratchet Box Wrench 1
start by
a) remove exhaust elbow’
b) remove tachometer drive
c) remove crankshaft rear seal and wear
sleeve
NOTE: Make sure there is a new rear crankshaft seal

and wear sleeve before the housing is removed. Anytime
the seal is removed from the wear sleeve a new sleeve
and seal must be installed.
1. Remove brackets (1) and (2) from the engine.
2. Use tooling (A) to remove the camshaft drive

gears from the camshafts.
4. Remove all of the bolts that hold the oil pan to.,
the engine. Install two 3/8"-16 NC guide bolts in
each side of the oil pan. Fasten a hoist to the
engine and lift the engine approximately 12 mm
(0.5 in.) off of the oil pan. Put two 50 mm wide x
100 mm long x 6 mm thick(2 in. wide x 4 in.
long x l/4 in. thick) plates in position between the
cylinder block and the oil pan on each side of the
engine. Lower the engine. Lower the engine on
the plates and remove the hoist. The weight of
the 3512 Engine is approximately 5443 kg (12,
000 lb.). The weight of the 3508, Engine is 4445
kg (9800 lb.).
5. Use tooling (B) to fasten a hoist to the flywheel

housing. Remove the bolts and remove flywheel
housing (3) from the engine. The weight of the
housing is 245 kg (540 lb.).
6. Remove O-ring seal (4) from the engine block.
363
FLYWHEEL HOUSING
INSTALL FLYWHEEL HOUSING1157-12
Tools Needed A
1. Install O-ring seal (1) on the engine block and

put clean engine oil on it.
2. Put the flywheel housing gasket in position on
the rear of the engine block.
3. Install two 5/8"-11 NC guide bolts (2) in the,
engine block.
4. Fasten a hoist to flywheel housing (3)
with_43056 tooling (A) and put the housing in
position on the guide bolts. Install the bolts to
hold the housing in position and tighten the bolts
evenly. Remove the guide bolts and install the
remainder of the bolts.
5. Cut the flywheel housing gasket even with the
bottom of the cylinder block.-!_w
6. Fasten a hoist to the engine and lift the engine
enough to remove the plates between the
cylinder block and the oil pan. If the oil pan
gasket is damaged, the engine will have to be
removed from the oil pan to make a replacement
of the gasket. Lower the engine on the oil pan
and 430 remove the guide bolts from the oil pan.
Install all of the bolts that hold the oil pan to the
engine.
7. Put camshaft drive gears (4) in position on the
ends of the camshafts. Install the plate and
tachometer drive adapter assembly to hold the
gears in position. Tighten the bolts evenly
to a torque of 100 + 15 N-m (75 + 11 lb. ft.). Hit
the plate and adapter assembly with a hammer3
and tighten the bolts again to the same torque.
Do this until the torque does not change.
8. Install brackets (5) and (6) on the engine.
NOTE: Any time the rear crankshaft seal and wear
sleeve are removed, a new seal and sleeve must be
installed.
end by:
b) install tachometer drive
a) install exhaust elbow
c) install crankshaft rear seal and wear sleeve’
364
VALVE COVERS, ROCKER SHAFTS AND PUSH RODS
REMOVE VALVE COVERS1107-11
1. Remove bolts (1) and remove valve cover (2)

from the valve cover base.
2. If necessary, remove the seal from valve cover,

(2).
INSTALL VALVE COVERS 1107-12
1. Make sure seal (I) is installed in the groove of

valve cover (3). Cut new seals to fit at assembly.
2. Put valve cover (3) in position on valve cover

base (2) and install the four bolts to hold it.
Tighten the bolts to a torque of 14 + 3 N•m (10 +
2 lb. ft.).
REMOVE ROCKER SHAFTS AND

PUSH RODS 1102 & 1208-11
start by:
a) remove valve covers
1. Remove bolts (1) and lift shaft (2) and the rocker
arms off the valve cover base and the push rods.
2. Remove push rods (3) from the valve lifters and

valve cover base.
365
ROCKER SHAFTS AND PUSH RODS
3. Remove bridge assemblies (4) from the dowels.
INSTALL ROCKER SHAFTS AND

PUSH RODS 1102 & 1208-12
1. Loosen the adjustment nuts and screws (1) on

valve bridges (2)
2. Put clean engine oil on the bridge dowels, the

inside diameter of valve bridges (2) and on the
top pad of the valve bridge. Install valve bridges
(2) on the bridge dowels as shown.’
3. While bridges (2) are pushed straight down with

a force of 25 + 20 N (5.6 + 4.5 lb.) on the top
contact surface, turn adjustment screw (1) : until
it makes contact with the valve stem. Turn :
screw (1) another 200 to 300. This will
straighten the dowel in the guide and make
compensation for clearance (slack) in the
threads.
4. Hold adjustment screw (1) in position and,

tighten the nut around screw (I) to a torque of.
30 _ 4 N•m (22 ± 3 lb. ft.).B3797
5. Put push rods (3) in position in the valve lifters

and valve cover base.
NOTICE
Make sure the crankshaft and
camshafts are in time with each
other and that adjustment screws (5)
are turned all the way out before the
rocker shaft bolts are tightened or
damaged to, the valves or pistons
can be the result. See INSTALL
CAMSHAFTS for the procedure to
time the engine.
6. Put the rocker arms and shaft (4) in position on

the valve cover. Make sure the rocker shafts
and push rods are in alignment and install the
bolts to hold shaft (4).
7. Make an adjustment of the valves to have a

clearance of 0.40 mm (.016 in.) for intake and
0.76 mm (.030 in.) for exhaust. See VALVE
CLEARANCE SETTING in TESTING" AND
ADJUSTING section for the complete procedure.
a) install valve covers.
366
ROCKER SHAFT ASSEMBLIES
DISASSEMBLE ROCKER SHAFT

ASSEMBLIES 1102-15
Tools Needed A
start by:
a) remove rocker shafts and push rods
1. Slide shaft assembly (1) out of rocker arms (2).

If necessary, remove the dowel from shaft
assembly (1).
2. Remove adjustment screw (4) and the nut from

rocker arm (2).
3. Use a hammer and punch to push socket (3)

out( of rocker arm (2).
4 Remove the ring that holds button (5) in socket

(3) and remove the button from the socket.
5. Use tool group (A) to remove bearing (6) from

rocker arm (2).
6. Do Steps 2 through 5 for the other two rocker

arms.
367
ROCKER SHAFT ASSEMBLIES
ASSEMBLE ROCKER SHAFT

ASSEMBLIES 1102-16-
Tools Needed A
1. Make an alignment of the oil hole (slot) in the

bearing with the oil passage in rocker arm (1).
Use tool group (A) to install the bearing in rocker
arm (1) with the joint in the bearing toward the
top of the rocker arm. The bore in the bearing
must be 37.140 ± 0.015 mm (1.4622 ± .0006 in.)
after assembly.
2. Make an alignment of the scribe mark on socket

(2) with the mark on rocker arm (1) and install
the socket in the rocker arm.
3. Put button (3) in socket (2) and install ring (4) to

hold the unit together.
4. Install adjustment screw (5) and nut (6) on

rocker arm (1).
5. Do Steps I through 4 for the other two rocker

arms.
6. If the dowel was removed from shaft assembly

(7), install the new dowel in the shaft until it is 7.7
± 0.5 mm (.303 ± .020 in.) above the-surface of
the shaft.
7. Put clean engine oil on the rocker arm bearings

and shaft assembly (7). Install rocker arms (1)
on shaft assembly (7).
end by:
a) install rocker shafts and push rods
368
FUEL INJECTORS
REMOVE FUEL INJECTORS 1251-11
start by:
1. Close the fuel supply to the engine.
2. Remove inlet fuel tube (1) and outlet fuel tube

(2) from the cylinder head. Put caps on the fuel
openings.
NOTE: Step 2 must be done to prevent fuel leakage into

the combustion chambers and the crankcase.
3. Remove locknut (4) and the washer. Disconnect

lever assembly (3) from the control rod.
4. Remove bolts and remove lever assembly (3)

from the cylinder head.
5. Remove bolt (6) and clamp (5) that hold the fuel
injector in position.
NOTICE
Do not put a force on the fuel
injection rack or cause damage to it
when the injectors are removed from
the cylinder head.
6. Use a pry bar and loosen injector (7) from the

cylinder head. Pull injector (7) out of the cylinder
head and remove it from the engine.
7. Remove O-ring seals (8) from the injector.
8. If necessary, remove the plug for clamp (5) from

the cylinder head.
369
FUEL INJECTORS
INSTALL FUEL INJECTORS 1251-12 the correct adjustment of the fuel injection of the
fuel injection control group. Make sure the
Tools Needed A control group can move to the fuel off position
6V4062 Injector Spring Compressor 1 with the governor linkage disconnected.
end by:
1. Use tool (A) as shown to make sure the fuel a) install rocker shafts and push rods
injection rack will move freely by its own weight
when injector (1) is turned a total of. 180° in
both directions. Check the rack movement with
the injector spring under compression. in several
positions.
NOTE: To prevent a carbon deposit between the injector

and the injector bore, make sure the injector body
(especially the tapered area) and the injector bore are
clean and free of foreign material.
2. Make sure the three O-ring seals (2) are

installed on injector (1) and put clean engine oil
on the seals and in the bore for the injector.
3. Make sure the plug that the anvil of clamp (5)

sets on is installed in the top of the cylinder
head.
NOTICE
Do not tap or hit on the injector
follower to install the injector.
Damage and failure of the injector
can be the result.
4. Put injector (1) in position in the cylinder head.

Install clamp (5) and tighten the bolt and washer
to push injector (1) all the way into its bore.
Tighten the bolt to a torque of 65 ± 7 N•m (48 ±
5 lb.ft.).
5. Check to make sure the fuel injection rack

moves freely by hand in the injector after the
injector is installed.
6. Put lever assembly (6) in position. Connect the

lever assembly to control rod (7) and make sure
lever assembly (6) is engaged correctly with the
fuel injection rack. Install the two bolts to
holdB7. the lever assembly in place.
7. Remove the caps from the fuel openings and

install inlet fuel tube (3) and outlet fuel tube (4)
on the cylinder head. Open the fuel supply to the
engine.
8. See TESTING AND ADJUSTING section for
370
REMOVE FUEL INJECTION CONTROL

LINKAGE 1269
Tools Needed A B
9S9082 Engine Turning Pinion 1
start by:
b) remove front drive housing
1. Remove the bolts that hold the brackets for shaft

(2) to the front of the cylinder block. Disconnect
the levers on shaft (2) from the levers on shafts
(1) and remove shaft (2) from( the engine.
2. Remove levers (4) and (5) and brackets (3) from

shaft (2).
3. Remove bearings (6) from brackets (3) with tool

group (A).
4. Remove access covers (7) from over the

camshafts.
371
5. Remove bolts (9) and the caps that hold the

levers of rod assemblies (8) to the fuel control
rod.
6. If necessary, remove the cover from the front

right side of the flywheel housing and use tool
(B) to turn the engine flywheel until the camshaft
is moved in a position so the levers of rod
assemblies (8) can be removed between the
cylinder block and camshaft.
7. Remove bolts (11) and remove lever assemblies

(10) and fuel control rod assemblies (8) as a unit
from the cylinder heads. See Step 6 if the levers
on the lower ends of rod assemblies (8) do not
have enough clearance to be removed from the
engine.
8. Remove locknut (12) and the washer to remove

rod assembly (8) from lever assembly (10).
9. Remove levers (14) from control shafts (1).
10. Remove the bolts and supports(13) from each

side of the engine.
372
11. If necessary, remove bearings (15) from

supports (13) with tool group (A).
12. Pull control shaft (1) out of each side of the

engine block.
13. Remove the bolts and remove two bracket

assemblies ( 16) on each side of the 3512
Engine. The 3508 Engine has only one bracket
assembly (16) on each side.
14. If necessary, use tool group (A) to remove

bearings (17) from bracket assemblies (16).
373
INSTALL FUEL INJECTION CONTROL

LINKAGE 1269-12
Tools Needed A B
1 Use tool group (A) to install the bearings in

bracket assemblies (1) until they are in the
center of their bores. Check the bore in the
bearings after assembly. The bearing bores
must be 21.925 ± 0.015 mm (.8632 ± .0006 in.).
2. Install two bracket assemblies (1) on each side

of the 3512 Engines. Install one bracket
assembly (1) on the 3508 Engines.
3. Install control shaft (2) on each side of the

engine block.
4. Use tool group (A) and install the bearings in the

center of the bores in supports (3). Check the
bore in the bearings after assembly. The
bearing bores must be 21.925 ± 0.015 mm
(.8632 ± .0006 in.).
374
5. Install supports (3) to hold the front of the control

shafts. Install levers (4) on each of the control
shafts.
6. Connect lever assembly (6) to rod assembly (5).
7. Install lever assembly (6) and rod assembly (5)

as a unit in each cylinder head. If necessary,
use tool (B) to turn the engine flywheel until the
camshaft moves enough to permit the lever of
the rod assembly to move into position.
8. Make sure lever assembly (6) is engaged

correctly with the fuel injection pump rack and
install the two bolts to hold it in place.
9. Make sure the lever for the fuel control and

assembly is in position on the control shaft and
install the bolt and cap (7).
375
10. Install access covers (8) and seal over the

camshafts and control rods.
11. Use tool group (A) and install the bearings in

the center of the bores in front control shaft
brackets (9). Check the bore in the bearings
after assembly. The bearing bores must be
21.925 + 0.015 mm (.8632 ± .0006 in.). If
necessary, make a replacement of the pins in
brackets (12). The pins must extend 8.0 + 0.5
mm (.315 ± .020 in.) above the surface of
brackets (9).
12. Install brackets (9) and levers (10) on the ends

of front control shaft (11).
13. Put shaft (11) in position on the front of the

engine. Make sure levers (10) and (4) are
engaged correctly and install the bolts to hold the
brackets and shaft (11 ) to the engine.
NOTE: After assembly the control shafts must turn

freely by hand and the linkage must return to the
"SHUTOFF" position when it is turned and released.
See TESTING AND ADJUSTING section for the correct
adjustment of the fuel injection control group.
end by:
a) rocker shafts and push rods
b) front drive housing
376
CYLINDER HEADS
REMOVE CYLINDER HEADS 1101-11
Tools Needed A B
start by:
2. Shut off the fuel supply to the engine.
3. Remove fuel lines (2) from the cylinder head and

fuel line manifold (1). Remove the bolts and
remove fuel line manifold (1) and the bracket
from the cylinder head.
4. Remove the access cover from over the camshaft

and remove bolt (4) and cap (5) that hold fuel rod
assembly (3) to the fuel control shaft.
5. Remove bolts (7) and remove lever assembly "

(6) and fuel rod assembly (3) as a unit. If
necessary remove the cover from the front right
side of the flywheel housing and use tool (A) to
turn the engine flywheel until the camshaft is
moved in a position so the lever of rod assembly
(3) can be removed between the engine block
and camshaft.
6. Remove the bolts and remove valve cover base

(10) and the gasket from the cylinder head.
7. Remove bolt (8) and clamp (11) from the fuel

injector.
NOTICE
Do not put a force on the fuel injection rack or cause
damage to it when the injectors are removed.
8. Use a pry bar to loosen fuel injector (9) and

remove the injector from the cylinder head.
377
CYLINDER HEADS
9. Remove a section of water manifold (12) and

elbows (13) from the cylinder head
10. Remove the bolts that hold air inlet elbow (15)
and exhaust manifold (14) to the cylinder head.
11. Fasten a hoist to cylinder head (16) with tooling.

Remove bolts (17) and (18) to remove cylinder
head (16) from the engine. The weight of the
head is 45 kg (100 lb.).
12. Remove head gasket (19) and the seals from

the spacer plate. Remove spacer plate (20) and
the gasket from the cylinder block.
378
CYLINDER HEADS
INSTALL CYLINDER HEADS 1101-12
Tools Needed A B
NOTE: A new spacer plate gasket must be installed

when the cylinder head is removed. See REMOVE AND
INSTALL SPACER PLATE.
1. Thoroughly clean the spacer plate and bottom

surface of the cylinder head. Install a new spacer
plate gasket and the spacer plate on the cylinder
block. Install a new head gasket and seals on the
spacer plate. Do not use any adhesives.
2. Put the gaskets for the exhaust manifold and air

inlet elbow in position. Use heavy grease or
5N5561 Silicone Lubricant to hold the gaskets in
position.
3. Fasten a hoist to the cylinder head with tooling

(A). Put the cylinder head into position on the
spacer plate.
4. Put clean engine oil on the threads of the cylinder

head bolts. Install the cylinder head bolts and
washers. Tighten the bolts in the following
sequence:
a) Tighten all of the bolts in the following
sequence: a) Tighten all of the bolts to a
torque of 30 + 5 N•m (22 + 4 lb. ft.).
b) Tighten bolts 1 through 8 in number sequence
to a torque of 270 + 35 N•m (200 + 25 lb. ft.).
c) Tighten bolts 1 through 8 in number sequence
to a torque of 450 + 20 N•m (330 + 15 lb.
ft.).
5. Install bolts (I) and the washers to hold the

cylinder head to the engine.
6. Put 5P3931 Anti-Seize Compound on the

threads of the bolts for exhaust manifold (2) and
install the bolts and washers to hold manifold (2)
to the cylinder head.
7. Install the bolts and washers to hold air inlet

elbow (3) to the cylinder head.
8. Put the gaskets, water manifold (4) and elbows

(5) in position as a unit and install the bolts.
379
CYLINDER HEADS
9. Make sure the three O-ring seals are installed on

injector (6) and put clean engine oil on them and
in the bore for the injector.
NOTICE
Do not tap or hit on the injector follower to install the
injector. Damage and failure to the injector can be
the result.
10. Put injector (6) in position. Install the clamp,

washer and bolt. Tighten the bolt to push
injector (6) all the way in its bore. Tighten the
bolt to a torque of 65 + 7 N•m (48 + 5 lb. ft.).
11. Check to make sure the fuel injection rack

moves freely by hand in the injector after the
injector is installed.
12. Make sure the O-ring seals are installed around

the three dowels in the bottom of valve cover
base (7). Put the gasket and base (7) in position
and install the bolts to hold them to the cylinder
head.
13. Put fuel control rod assembly (9) and lever

assembly (8) in position in the cylinder head. If
necessary, use tool (B) to turn the engine fly
44219Xl wheel until the camshaft moves
enough to permit the lever of rod assembly (9) to
move into position.

correctly with the fuel injection rack and install
the two bolts and washers to hold it in place.
15. See TESTING AND ADJUSTING section for

the correct adjustment of the fuel injection
control group.
16. Make sure the lever for the fuel control and
assembly is in position on control shaft (10) and
install the bolt and cap (11).
17. Install the access cover and seal over the

camshaft and control shaft (10).
18. Make sure the 0-ring seals for the fuel manifold
and lines are installed and have clean engine oil
on the seals. Install fuel manifold (12) and fuel
lines (13) on the engine.
19. Turn the fuel supply to the engine.

level.
end by:
380
VALVES
REMOVE VALVES 1105-11

Tools Needed A B
5S1330 Compressor Assembly 1
8S2263 Valve Spring Tester 1
start by:
a) remove cylinder heads
1. Use tool (A) to put valve springs (1) under

compression.
2. Remove locks (2) from the valve stem.
3. Release the tension on springs ( 1 ) with tool (A)

and remove tool (A), the rotor coil assembly,
springs ( 1 ) and washer from the valve stem
and guide.
4. Remove the valves from the cylinder head.

NOTE: If the valves can be used again, put identification
on them as to their location for installation purposes.
5. Check the valve spring force with tool (B). See

SPECIFICATIONS for the correct spring force
values.
6. Do Steps I through 5 again for the remainder of

the valves.
INSTALL VALVES 1105-12
Tools Needed A
5S1330 Compressor Assembly 1
1. Put clean engine oil on the valve stem and install
valve (4) in the cylinder head.
2. Put washer (2), the inner spring, outer spring (I)

and rotocoil assembly (3) over the valve stem
and valve guide.
3. Put the valve springs under compression with

tool (A) and install locks (5).
The locks can be thrown from the valve when the

spring compressor is released if they are not in their
correct position on the valve stem. To prevent
possible personal injury be sure to stay away from in
front of the valve retainer and springs.
4. Remove tool (A) and hit the top of the valve with
a plastic hammer to be sure the locks are in their
correct position on the valve stem.
5. Do Steps 1 through 4 again for the remainder of

valves.
end by:
a) install cylinder heads
381
VALVE LIFTERS, BRIDGE DOWELS
REMOVE AND INSTALL VALVE LIFTERS 1209-10
start by:
NOTICE
The lifter guide springs can be assembled on the
lifter assembly or installed in the cylinder head lifter
bore only once. If a lifter assembly is removed from
the cylinder head or a lifter guide spring is removed
from a lifter assembly, a new lifter guide spring must
be installed at assembly.
1. Pull lifter assemblies (1) out of the cylinder head

lifter bore.
2. Remove the guide springs from the lifter

assemblies.
3. Install guide spring (2) on each of the lifter

assemblies (i1).
4. Put lifter assemblies (I) in a container of clean

engine oil before they are installed. Install lifter
assemblies (1) in the lifter bore of the cylinder
head.
end by:
REMOVE AND INSTALL BRIDGE DOWELS
Tools Needed A B
5P944 Dowel Puller Group 1
5P942 Extractor 1
6V4009 Dowel Driver 1
start by:
a) remove valves
1. If necessary, use tooling (A) to remove bridge
dowels (1) from the cylinder head.
2. Use tool (B) and a hammer to install dowels (1)

in the cylinder head. The dowels must extend
66.5 + 0.5 mm (2.62 + .02 in. above the head
surface.
end by:
a) install valves
382
VALVE SEAT INSERTS, VALVE GUIDES
REMOVE VALVE SEAT INSERTS 1103-11

Tools Needed A
9S3095 Handle Assembly 1
6V4008 Extractor 1
start by:
a) remove valves
1. Remove the valve seat inserts from the cylinder
head with tooling (A).
2. Clean and remove any burrs from the valve seat

bores.
INSTALL VALVE SEAT INSERTS 1103-12

Tools Needed A
9S3095 Handle Assembly 1
6V4008 Extractor 1
1. Lower the temperature of valve seat inserts (1)

and install them with tooling (A).
NOTICE
Do not make the diameter of the extractor larger
when the insert is installed or damage to the insert
and cylinder head can be the result.
2. Grind valve seat inserts (1) as to the values

given in SPECIFICATIONS.
end by:
a) install valves
REMOVE VALVES GUIDES 1104-11
Tools Needed A
7M3975 Driver 1
start by:
a) remove valves
1. Use tool (A) and a hammer to push the valve

guides out of the cylinder head as shown.
INSTALL VALVE GUIDES 1104-12

Tools Needed A
7M3975 Driver 1
5P1729 Bushing 1
1. Put clean engine oil on the outside diameter of

the valve guides.
2. Use tooling (A) and install the valve guides until

they extend 26 mm (1.024 in.) from the surface of
the cylinder head. See SPECIFICATIONS for the
correct values for the inside diameters of new
and used valve guides.
end by:
a) install valves
383
CONNECTING ROD BEARINGS
REMOVE AND INSTALL CONNECTING ROD

BEARINGS 1219-10
Tools Needed A
start by:
a) remove piston cooling jets
1. Use tool (A) and turn the engine flywheel to
move the connecting rod cap bolts into a position
for removal.
2. Remove bolts (I) to remove bearing caps (2) from

the crankshaft and connecting rod. Remove the
lower half of the bearings from caps (2).
3. Push the connecting rods away from the

crankshaft and remove the upper halves of the
bearings from the rods.
NOTE: Install rod bearings dry when the clearance
checks are made. Put clean engine oil on the rod
bearings for final assembly.
4. Clean the surfaces where the bearing halves fit.
Install bearing halves (3) in the rods and caps
(2). Put 5P960 Multipurpose Type Grease on
the bolt threads and contact surfaces of the bolts
and caps.
5. Make a check of the bearing clearance with

Plastigage. Put caps (2) in position on the
connecting rods and make sure the number on
the side of the cap is next to and respective with
the number on the side of the connecting rod.
Tighten the bolts in the number sequence shown
as follows:
NOTICE
Do not use an impact wrench to tighten the bolts the
additional 90 ± 50 of a turn more.
NOTE: Bolts (6) and (7) are on the end of the rod cap
opposite the end that has the location pin for correct
installation.
a) Tighten bolts No. 4 and 5 to a torque of 90
+ 5 N•m (65 + 4 lb. ft.).
b) Tighten bolts No. 6 and 7 to a torque of 90
+ 5 N•m (65 + 4 lb. ft.).
c) Tighten bolts No. 6 and 7 again to a torque
of 90 + 5 N•m (65 + 4 lb. ft.).
d) Tighten each bolt 90 + 50 of a turn more.
6. Remove the cap and measure the Plastigage.
The rod bearing clearance must be 0.107 to
0.218 mm (.0042 to .0086 in.).
7. Put clean engine oil on both halves of the rod

bearings. Put caps (2) in position and tighten the
bolts as in Step 5.
end by:
a) install piston cooling jets
384
FRONT BALANCER GROUP (3508)
REMOVE FRONT BALANCER GROUP 1220-11

Tools Needed A B
start by:
a) remove front drive housing
1. Remove the bolts that hold the brackets for shaft

(2) to the front of the cylinder block. Disconnect
the levers on shaft (2) from the levers on shafts
(I) and (3) and remove shaft (2) from the engine.
2. Use tool (A) to make an alignment of the marks

on balancer gear (4) and crank gear (6)
according to the rotation of the engine as shown.
3. Remove the bolts and remove plate (5) from

balancer gear (4). Remove balancer gear (4)
from the shaft.
4. Use tool group (A) and a press to remove

bearing (7) from balancer gear (4).
5. Remove shaft (8) from the end of the cylinder

block.
6. Remove crank gear (6) from the end of the

crankshaft.
385
FRONT BALANCER GROUP (3508)
INSTALL FRONT BALANCER GROUP
Tools Needed A
1. Put crank gear (2) in position on the end of the

crankshaft and install the bolts.
2. Install shaft (1) on the end of the cylinder block.
3. Use tool group (A) and a press to install the

bearing in balancer gear (3). Make sure the
bearing joint is in the center of the heavy section
in gear (3). The bore in the bearing must be
75.00 + 0.053 mm (2.9528 + .0021 in.) after
assembly.
4. Put balancer gear (3) in position on the shaft.

Make sure the marks on the balancer gear and
the crank gear are in alignment according to the
rotation of the engine as shown.
5. Install plate (4) and the bolts to hold it on the

balancer gear.
6. Put shaft (7) in position on the cylinder block.

Make sure the levers on shaft (7) are correctly
engaged with the levers on shafts (5) and (6) and
install the bolts to hold the brackets and shaft (7)
to the cylinder block.
end by:
a) install front drive housing
386
REAR GEAR GROUP
REMOVE REAR GEAR GROUP 1212-11
Tools Needed A
start by:
a) remove flywheel housing
NOTE: Before the flywheel housing is removed, the

3508 engine must be put in time to make sure the rear
gear group is in alignment according to the rotation of the
engine as shown.
1. Remove plate (1) to remove gear assembly (2)

from the shaft.
2. Use tool group (A) and a press to remove

bearing (3) from gear assembly (2).
3. Use tool group (A) and a press to make a

separation of the gears for gear assembly (2).
4. Remove the bolts to remove the shafts, gears

(4) and the washers from the cylinder block.
387
REAR GEAR GROUP
5. Remove washers (6) and shafts (5) from gears

(4).
6. Use tool group (A) and a press to remove the

bearings from gears (4). Remove shaft (7) from
engine.
7. Remove the bolts and remove gear (8) from the

end of the crankshaft.
INSTALL REAR GEAR GROUP 1212-12
Tools Needed A
1. Put gear (1) in position on the end of the

crankshaft and install the bolts.
388
REAR GEAR GROUP
2. Install shaft (2) on the cylinder block.
3. Use tool group (A) and a press to install the

bearings in both gears (3) until the bearings are
in the center of their bores. The bore in the
bearing must be 75.00 ± 0.053 mm (2.9528 ±
.0021 in.) after assembly.
4. Put clean engine oil on the bearings and install

shafts (5) in gears (3). Install washers (4) on the
shafts.
5. Put gears (3) in position on the cylinder block

and install the bolts to hold the gears in position.
389
REAR GEAR GROUP
6. Use tool group (A) and a press to install bearing

(6) in gear assembly (7). The bore in bearing (6)
must be 75.00 ± 0.053 mm (2.9528 ± .0021 in.)
after assembly.
7. Heat the larger gear of gear assembly (7) to a

maximum temperature of 400° C (752° F) and
install it on the smaller gear as shown.

gear assembly (7) on the shaft.

the gear assembly on the shaft. Make sure the
marks on the gear assembly and the crankshaft
gear are in alignment according to the rotation of
the engine as shown.
10. Put plate (8) in position on gear assembly (7)

end by:
a) install flywheel housing
390
SPACER PLATES
REMOVE SPACER PLATES 1221-11
start by:
1. Remove gasket (4), seals (1), seals (2) and O-

ring seal (3) from the spacer plate.
2. Remove spacer plate (5) from the dowels in the

cylinder block.
3. Remove gasket (6) from the dowels.
4. Remove the O-ring seal from around dowel (7).
391
SPACER PLATES
INSTALL SPACER PLATES 1221-12
1. Make sure the spacer plate and the machined

surface of the cylinder block are clean and free
of dirt and foreign material.
2. Install the O-ring seal around dowel (2).
NOTICE
Both surfaces of the spacer plate gasket and the top
of the cylinder block must be clean. Do not use a
gasket adhesive on these surfaces.
3. Install new spacer plate gasket (1) over the

dowels in the cylinder block.
4. Install spacer plate (3) on the dowels.
5. Install the O-ring seal around dowel (5).
6. Install new water seals (4) and (6) in spacer

plate (3).
7. Install new cylinder head gasket (7) on the

spacer plate.
8. Check the cylinder liner projection. See

INSTALL CYLINDER LINERS.
end by:
392
CRANKSHAFT MAIN BEARINGS
REMOVE CRANKSHAFT MAIN 8. Remove thrust plates (4) from each side of the
BEARINGS 1203-11 center main bearing.
Tools Needed A B
C
9S9082 Engine Turning Tool 1
6V3147 Main Bearing Wrench 1
2P5517 Bearing Removal and
Installation Tool
1
start by:
a) remove piston cooling jets
2. Use tool (A) to turn the engine flywheel to move

counterweights (1) in position for removal.
Remove counterweights (1) from the crankshaft
through the side of the cylinder block.
3. Use tool (A) and turn the engine flywheel to

move the connecting rod bearing surface
(journal) to the top center position.
4. Use tool (B) and loosen the four bolts that hold
the main bearing cap in position.
5. Hold the main bearing cap in position with a pry

bar and remove the bolts and lower the bearing
cap from the cylinder block.
6. Remove the bearing caps from the side of the

engine. The weight of the bearing cap is 16 kg
(35 lb.).
7. Remove the lower bearing half (2) from bearing

cap (3).
393
NOTICE follows:
If the crankshaft is turned in the wrong direction, the
tab of the bearing will be pushed between the
crankshaft and cylinder block. This can cause
damage to either or both.
NOTE: On the center main journal that has no oil hole,
put a thin piece of soft material that will not damage the
crankshaft journal against the end of the bearing,
opposite the tab. Hit the bearing with the soft material
until the tab of the bearing is free from the cylinder block.
Remove the upper half of the main bearing.
9. Install tool (C) in the oil hole in the crankshaft

journal and remove upper main bearing halves
(5) as the crankshaft is turned and the bearing is
moved out of the cylinder block.
INSTALL CRANKSHAFT MAIN

BEARINGS 1203-12
Tools Needed A B C D
2P5517 Bearing Removal and
Installation Tool 1
8S2328Dial Test
Indicator Group 1
6V3147 Main Bearing Wrench 1
NOTICE
Make sure the upper and lower halves of bearings
are installed so the bearing tabs fit into the notch in
cylinder block and bearing caps.
NOTE: Install the main bearings dry when the clearance
checks are made. Put clean engine oil on the main
bearings for final assembly. a) Put a piece of the Plastigage on the surface
of the lower bearing half.
1. Install tool (B) in the oil hole of the crankshaft. b) Install the main bearing caps with the word
Put the upper bearing half (half with oil hole) in "FRONT" and the cast part number toward
position on the crankshaft. Use tool (A) to turn the front of the cylinder block. Each cap
the engine flywheel and push the bearing half in has a number on the bottom surface and
position with tool (B). must be installed in the same position as
2. Make sure the bearing caps are clean and install the correct number on the right side of the
the lower bearing halves in the caps. block pan rail.
NOTICE c) Put clean engine oil on the main bearing
Do not use an impact wrench to tighten the cap bolts and tighten them in the number
sequence shown with tool (D) to a torque of
bolts the additional 180 ± 5° of a turn more.
NOTE: When the bearing clearance is checked and the 136 ± 14 N.m (100 ± 10 Ib.ft.). Then
engine is in a vertical position, such as in the vehicle, the tighten the bolts in the number sequence
crankshaft will have to be lifted up and held against the shown 180 ± 5° of a turn more.
upper halves of the main bearings to get a correct d) Remove the caps and measure the
measurement with the Plastigage. The Plastigage will Plastigage. The main bearing clearance
not hold the weight of the crankshaft and give a correct must be 0.122 to 0.241 mm (.0048 to .0095
indication. If the engine is in a horizontal position, it is in.).
not necessary to hold the crankshaft up. Do not turn the
crankshaft when the Plastigage is in position to check
clearances.
3. Check the bearing clearances with Plastigage as
394
4. Put clean engine oil on thrust plates (5) and

install them on each side of the center main
bearing with the grooves in the plates against the
crankshaft.
5. Put clean engine oil on bearings (7) and put

bearing caps (6) in position and tighten the bolts
as in Step 3.
NOTICE
to the crankshaft when the engine is run. Also do
not use an impact wrench to tighten the bolts the
additional 120 ± 5° of a turn more.
6. Make sure the dowels are in position and install

counterweights (8) on the crankshaft. Put
2P2506 Thread Lubricant on the bolts and
tighten them evenly to a torque of 50 ± 5 N•m
(37 + 4 lb.ft.). Then tighten the bolts 120 ± 5° of
a turn more.
7. Check the crankshaft end play with tooling (C).

The end play is controlled by the thrust plates on
the center main bearing. End play with new
bearings must be 0.15 to 0.50 mm (.006 to .020
in.).
8. Fill the engine with oil to the correct level.

end by:
a) install piston cooling jets
395
PISTONS
REMOVE PISTONS 1214-11
Tools Needed A B
C
Pliers 1
6V4020 Piston Ring Expander
1
start by:
a) remove spacer plates
b) remove piston cooling jets
1. If necessary, remove the cover from the front

right side of the flywheel housing and use tool
(A) to turn the engine flywheel until all four of
bolts (1) can be removed.
2. Remove bolts (1) and bearing cap (2) from the

connecting rod.
3. Push the piston up until the piston rings are clear

of the cylinder liner. Remove pistons (3) and the
connecting rods.
NOTE: Put identification on each piston as to its location

for correct installation and alignment. Keep each bearing
cap with its connecting rod.
4. Use tool (B) and remove the rings that hold

piston pin (4) in position. Remove pin (4) and
remove piston (3) from connecting rod (5).
5. Remove the bearings from the bearing cap and

connecting rod (5).
6. Use tool (C) to remove piston rings (6) from

piston (3).
396
PISTONS
INSTALL PISTONS 1214-12

Tools Needed A B C D
6V4020 Piston Ring Expander 1
Pliers 1
6V4021 Piston Ring Compressor 1
1. Clean the ring grooves in the piston.
2. Use tool (A) to install the oil ring on piston ( 1).
Make sure the oil ring spring ends are 1800
apart from the ring end gap.
3. Use tool (A) to install the two compression rings
on piston (I ). Make sure the sides with the "UP"
marks are toward the top of the piston and all
three ring end gaps are 120° apart after
installation.
4. Put clean engine oil on pin (3), the pin bearing in
rod (2) and the pin bore in piston ( 1). Put rod
(2) in position in piston (1) and install pin (3).
Use tool (B) to install rings (4) on each side of
pin (3).
5. Install the upper half of the connecting rod
bearing in the connecting rod and put clean
engine oil on it. Make sure the tab on the back
of the bearing fits in the groove of the rod.
6. Put clean engine oil on the piston rings and
cylinder liner bore. Use tool (D) to put the piston
rings under compression and install the pistons
and connecting rods in the cylinder liners.
NOTICE
Make sure the piston is installed with the side of the
connecting rod that has the chamfer in the rod
bearing bore next to the crankshaft thrust surface.
The side with the square shoulder for the connecting
rod bearing bore must be next to the other
connecting rod on the same crankshaft journal.
7. Install the lower half of the connecting rod
bearing in cap (5) and put clean engine oil on it.
Make sure the tab on the back of the bearing fits
in the groove of the cap.
8. See INSTALL CONNECTING ROD BEARINGS
for the procedure to install the connecting rod
caps and to check the bearing clearance.
9. Check the side clearance between two

connecting rods on the same crankshaft journal.
The clearance must be 0.85 + 0.23 mm (.0335
+end by: .0091 in.) for the 12 cylinder and 0.900
+ .282 a) install cooling jets mm (.0354 +
.0111 in) for the 8 cylinder. b) install spacer
plates
397
CYLINDER LINERS
REMOVE CYLINDER LINERS 1216-11
Tools Needed A
5P8665 Cylinder Liner Puller 1
6V4133 Wedge Bracket 1
start by:
a) remove pistons
1. Drain the coolant from the cooling system and

cylinder block.
2. Put covers on the crankshaft journals for

protection from dirt and coolant.
3. Remove the cylinder liner with tool (A).
4. Remove seals (I) and filler band (2) from the

cylinder liner.
INSTALL CYLINDER LINERS 1216-12

Tools Needed A B C
8B7548 Puller Assembly (Crossbar) 1
3H465 Plate 2
8F6123 Bolt (Y4"-16 NF x 5 /2 in. long) 2
3B1925 Washer (3/4"-Copper) 4
S1575 Bolt (3/4"-16 NF x 3 in. long) 4
1P5510 Liner Projection Tool Group 1
2P8260 Liner Installation Group 1
7N1961 Bolt (from Cylinder head) 1
FT1543 Plate 1
1. Install the gasket and spacer plate.
2. Clean the cylinder liners and liner bores in the

cylinder block.
3. Install the cylinder liners in the cylinder block

without seals or bands.
4. Check the cylinder liner projection as follows:

a) Install four bolts (4) and washers from d) Check the liner projection with tool (B) at
tooling (A) around each cylinder liner as four locations around the liner. Liner
shown. Tighten the bolts evenly to a torque projection must be 0.059 to 0.199 mm
of 95 N-m (70 lb. ft.). (.0023 to .0078 in.). The difference between
b) Install crossbar (2), plates (3) and bolts (I ) the four measurements on the same liner
from tooling (A). Be sure the crossbar is in must not be more than 0.05 mm (.002 in.).
position at the center of the liner and the NOTE: If the liner is turned in the cylinder block, it can
liner surface is clean. Tighten bolts (1) make a difference in liner projection.
evenly to a torque of 70 N-m (50 lb. ft.).
c) Check the distance from the bottom edge of
crossbar (2) to the top edge of the spacer
plate. The distance on each end of the
crossbar must be the same.
398
CYLINDER LINERS
5. If the liner projection is not 0.059 to 0.199 mm (.0023

to .0078 in.), check the thickness of the following
parts:
a) Spacer plate (X): 10.313 + 0.025 mm
(.4060 + .0010 in.).
b) Spacer plate gasket (Y): 0.208 + 0.025 mm
(.0082 + .0010 in.). [All surfaces must be
clean and dry when gaskets are installed].
c) Cylinder liner flange (Z): 10.65 + 0.02 mm
(.419 + .001 in.).
6. Put a mark on the cylinder liners and block so

the liners can be installed in same position.
7. Remove tooling (A) and tool (B). Remove the

liner.
8. Put liquid soap on seals (5), grooves of the liner

and the bore of the block. Install the seals on the
cylinder liner.
9. Put the filler band completely in clean engine oil

for a moment. Install filler band (6) in the groove under
the liner flange without delay.
10. Install the liner immediately after the filler band is

installed before expansion of the band. Make sure the
mark on liner is in alignment with the mark on the block.
Use tooling (C) to push the liner into position.
11. Use Steps 7 through 10 for the remainder of the

liners.
end by:
a) install pistons
399
CAMSHAFTS
REMOVE CAMSHAFTS 1210-11

Tools Needed A B C
8B7548 Push-Puller Assembly 1
8B7559 Threaded Adapter 2
8B7561 Step Plate 1
8H684 Ratchet Wrench 1
6V4019 Camshaft Pilot Group 1
start by:
b) remove crankcase breathers (left side only)
c) remove hydramechanical shutoff drive
(right side only)
d) remove governor (right side only)
1. Remove access covers (1) from the sides of the

engine.
2. Remove bolt (3) and cap (4) that hold fuel rod
assembly (2) to the fuel control shaft.
3. Remove bolts (5) to remove lever assembly (6)

and fuel rod assembly (2) as a unit from the
cylinder heads. If necessary, use tool (A) to turn
the flywheel until the camshaft is moved in a
position so that the fuel rod assembly can be
removed between the engine block and
camshaft.
4. Remove cover (7) from the left side of the

flywheel housing.
400
CAMSHAFTS
5. Remove the bolts and remove plate (8) from the

end of the camshaft on the left side of the engine.
6. Use tooling (B) to remove drive gear (9) from the

end of the camshaft on each side of the engine.
Remove the drive gears from the flywheel housing.
7. Remove the bolts and remove washer (10) from

the end of the camshaft on each side of the engine.
8. Push valve lifters ( 11) up away from the

camshaft into the cylinder heads and hold the lifters in
this position. An O-ring seal can be used to hold the
valve lifters up.
401
CAMSHAFTS
9. Install the pilot assembly part of tool group (C)

on one end of the camshaft.
10. Install the handle part of tool group (C) on the

other end of the camshaft.
11. Pull camshaft (12) out of the engine block until a

hoist can be fastened to it.
12. Put identification on the camshafts as to their

location in the engine so they can be installed correctly.
13. Remove camshaft (12) and tool group (C) from

the engine. The weight of the 3512 camshaft is 63 kg
(140 lb.). The 3508 Camshaft weight is 43 kg (95 lb.).
14. If necessary, remove bolts (13) to make a

separation of the 3512 Camshaft only.
402
CAMSHAFTS
INSTALL CAMSHAFTS 1210-11
Tools Needed A B
6V4019 Camshaft Pilot Group 1
1. If the 3512 Camshafts were taken apart, make

sure spacer (2) is in position between the
camshaft and camshaft assembly. Put 9S3263
Thread Lock on the threads of bolts (1) and
tighten the bolts by hand only to a torque of 45 +
7 N•m (33 + 5 lb. ft.).
NOTE: Make sure the camshafts are installed

respective to the marks (Rear L.H., Rear R.H.) on the
ends of the camshafts.
2. Install the pilot assembly part of tool group (A) to

one end of the camshaft and the handle part of
tool group (A) to the other end.
3. Fasten a hoist to camshaft (3) and put the

camshaft in position and push it into the engine
block. Remove the hoist and tool group (A).
4. Install washers (4) on each side of the engine to

hold the camshafts in position.
5. Remove timing pins(5) from their storage

positions on each side of the engine.
403
CAMSHAFTS
6. Turn the camshafts until timing pins (5) can be

installed through the engine block and into the
grooves (slots) in the camshafts.
7. Remove cover (6) and plug (7) from the right

front side of the flywheel housing.
8. Put timing bolt (8) in position in the flywheel

housing. Use tool (B) and a ratchet wrench to
turn the flywheel until the timing pin engages with
the hole in the flywheel. The No. 1 cylinder is
now at top center.
9. Put drive gears (9) in position on the end of the

camshaft on each side.
10. Install plate (11) and the bolts to hold the drive
gear to the camshaft. Tighten the bolts evenly to
a torque of 100 + 15 N•m (75 + 10 lb. ft.). Hit
the plate with a hammer and tighten the bolts
again to the same torque. Do this until the
torque does not change.
11. Install the gasket and cover (10) over the

camshaft.
404
CAMSHAFTS
12. Install the tachometer drive adapter on the other

camshaft to hold the drive gear in position. See
INSTALL TACHOMETER DRIVE.
13. Remove the timing pins for the camshaft and

install the pins in their storage positions.
14. Remove the timing bolt from the flywheel and

install the plug in the timing hole in the housing.
Remove tool (B) and install the cover on the
housing.
15. Remove the O-ring seals from valve lifters (12)

and push the lifters down against the camshaft.
16. Install fuel rod assembly (14) and lever assembly

(13) as a unit in the cylinder heads. If necessary
use tool (B) to turn the flywheel until camshafts
move enough to permit the fuel rod assembly to
move into position.

correctly with the fuel injection pump rack and
install the bolts.
18. Install the bolt and cap (15) to hold the fuel rod
assembly to the fuel control shaft.
19. Install access covers (16) on each side of the

engine.
20. See TESTING AND ADJUSTING section for the

correct adjustment of the fuel injection control
group.
end by:
b) install crankcase breather
c) install hydramechanical shutoff drive
d) install governor
405
CAMSHAFT BEARINGS
REMOVE AND INSTALL CAMSHAFT

BEARINGS 1211-10
Tools Needed A B C D E F
S1621 Bolt (1/2"-13 NC x
1 in. long) 1
6V4012 Backup Plate 1
6V4014 Cam Bearing Pilot 1
6V4015 Pulling Bar 1
6V4005 Spacer 2
6V4011 Spacer 1
6V4010 Pulling Plate 1
8S8292 Short Extension 4
(part of 8S2241)
8S8293 Long Extension 2
(part of 8S2241) 1
6V4013 Screw 1
5P3100 Pump Group (or 1
electric)
5P5247 Hydraulic Puller 1
5H1504 Washer (3/4"- 1
Hardened)
2J3506 Nut (3/4"- 1
Hardened)
start by:
a) remove camshafts
1. Install tooling (A) as follows:

a) Install the cam bearing pilot in the camshaft
bearing.
b) Put the backup plate in position so the
bearing is between the parts.
c) Install the bolt to hold the tooling together.
NOTE: Tooling (D) is used in place of tooling (B) and (C)

to remove and install the camshaft bearings when the
flywheel and front drive housings have been removed
from the cylinder block. NOTE: When the bearings are installed in the bore of
the block, the bearing joint must be on the horizontal
2. Install tool (B) on the flywheel housing as shown centerline of the bore and the upper oil hole of the
or install tooling (B) and (C) on the front drive bearing toward the vee of the block. The upper bearing
housing. Tooling (C) must be used behind the oil hole must be put 20 + 50 above the horizontal
bolt holes for clearance to install tool (B) on the centerline of the bore in the block and the location of the
front drive housing. lower (outside or outboard) bearing oil hole will be (and
5°
must be) 20 ± below the horizontal centerline of the
3. Use tooling (E) as needed to get the correct bearing bore as shown. Also, the bearing joint of the
length. Connect the extensions to the stud on right side bearings must be toward the vee of the block
tooling (A). and the left side bearings must be toward the outside of
NOTE: The threaded shaft, thrust bearing assembly and the block.
nut (all part of 8S2241 Tool Group) can be used
with an 8H684 Ratchet Box Wrench in place of 5. Install the camshaft bearings as follows:
tooling (F) if a hydraulic puller is not available. a) Install camshaft bearing (1) on tooling
4. Connect tooling (F) to extensions of tool group (A) as shown and put unit (2) in position
(E) and pull the bearing from its bore in the in the bearing bore.
cylinder block.
406
CAMSHAFT BEARINGS, CRANKSHAFT
b) Follow Steps 2, 3 and 4 to install the

tooling and pull the bearing into the
center of its bore.
c) Check the bore in bearing (1) after it is
installed. The bore must be 86.00 +
0.06 mm (3.386 + .002 in.).
end by:
a) install camshafts
REMOVE CRANKSHAFT 1202-11
start by:
b) remove front drive housing
c) remove front balancer group (3508)
d) remove rear gear group (Step 1 only)
e) remove piston cooling jets
NOTICE
The rocker shafts and push rods do not have to be
removed to remove the crankshaft but bent push
rods can be the result if they are not removed.
1. Put the engine in the position as shown.
The weight of the 3512 Engine is
approximately 5443 kg (12, 000 lb.). The
weight of the 3508 Engine is approximately
4445 kg (9800 lb.).
2. Remove counterweights (1) from the
crankshaft.
3. Remove bearing caps (2) from the
connecting rod and push the connecting
rods away from the crankshaft. Use wire to
hold the upper half of the connecting rods
away from the crankshaft.
4. Remove the center main bearing cap and
remove two thrust plates (3) from each side
of the main bearing.
5. Use two of the bolts that hold the flywheel
to the crankshaft and install a bolt in each
end of the crankshaft. Fasten a hoist to the
crankshaft as shown.
407
CRANKSHAFT
6. Remove the remainder of main bearing caps (5)

and remove crankshaft (4) from the engine
block. The weight of the 3512 Crankshaft is 454
kg (1000 lb.). The weight of the 3508
Crankshaft is 299 kg (660 lb.).
7. If necessary, remove bolts (7) to remove gears
(6) from each end of the crankshaft.
INSTALL CRANKSHAFT1202-12
1. If gears (I) were removed, install gears (1) on
each end of the crankshaft and install the bolts
to hold the gears.
2. Make sure the upper halves of main bearings (2)
(bearings with oil holes) are in position in the
cylinder block. Put clean engine oil on the
bearings.
3. Fasten a hoist to crankshaft (3) with two fly-
wheel bolts and put it in position. Make sure the
word "FRONT" on the end of the crankshaft is
toward the front of the cylinder block.
4. Make sure the lower halves of the main bearings
are in position in the main bearing caps. Put
clean engine oil on the bearings and install all
but the center main bearing cap on the cylinder
block. The caps must be installed with the word
"FRONT" and the cast part number toward the
front of the cylinder block. Each cap has a
number on the bottom surface and must be
installed in the same position as the correct
number on the right side of the block pan rail.
NOTICE
Do not use an impact wrench to tighten the bolts
1800 + 50 of a turn more.
5. Put clean engine oil on the main bearing cap
bolts and tighten the bolts in the number
sequence as shown to a torque of 136 + 14 Nm (
100 + 10 lb.ft.). Then tighten each bolt in the
number sequence as shown 1800 + 50 of a turn
more.
408
CRANKSHAFT
6. Put clean engine oil on the thrust plates and
install thrust plates (8) on each side of the
center main bearing. Install the center
main bearing cap and the bolts to hold it.
Use the same procedure in Step 5 to
tighten the bolts.
NOTE: See INSTALL CRANKSHAFT MAIN BEARINGS
for the correct bearing clearance check and crankshaft
end play.
7. Remove the wire that holds the upper half
of the connecting rods in position. Make
sure the upper and lower halves of the
bearings are in position on the connecting
rods and the rod caps. Put clean engine oil
on the bearings.
NOTICE
Do not use an impact wrench to tighten the bolts 900
+ 50 of a turn more.
8. Put the connecting rods in position on the
crankshaft. Install caps (9) in the same
location as they were removed from with
the number on the side of the cap next to
the number on’ the side of the connecting
rod. Put 5P960 Multi- purpose Type
Grease on the bolt threads and contact
surfaces of the bolts and caps and tighten
the bolts in number sequence as follows:
NOTE: Bolts (12) and ( 13) are on the end of the rod cap
opposite the end that has the location pin for correct
installation.
a) Tighten bolts No. 10 and 11 to a torque of
90 + 5 N-m (65 + 4 lb.ft.).
b) Tighten bolts No. 12 and 13 to a torque of
90 + 5 N-m (65 + 4 lb.ft.).
c) Tighten bolts No. 12 and 13 again to 90 + 5
N-m (65 + 4 lb.ft.).
d) Tighten each bolt 90 + 50 of a turn more.
NOTE: See INSTALL CONNECTING ROD BEARINGS
for the correct bearing clearance check.
NOTICE
to the crankshaft when the engine is run.
9. Make sure the dowels are in position and
install counterweight (14) on the crankshaft.
NOTICE
Do not use an impact wrench to tighten the bolts end by:
1200 + 5 of a turn more. a) install rocker shafts and push rods
10. Put 2P2506 Thread Lubricant on the b) install front drive housing
counter-weight bolts and tighten the bolts to c) install front balancer (3508)
a torque of 50 + 5 N-m (37.5 + 4.0 lb.ft.). d) install rear gear group
5°
Then tighten the bolts 120° + of a turn e) install piston cooling jets
more.
11. Put engine in a vertical position.
409/(410 Blank)
FORM NO. SENR2353-01
FOR USE IN SERVICE MANUALS
SENR2573
VOLUME I SPECIFICATIONS
REG01312
SPECIFICATIONS
FOR
3500 INDUSTRIAL
ENGINE ATTACHMENTS
49Y1-UP 65Z1-UP
95Y1-UP 68Z1-UP
27Z1-UP 71Z1-UP
411/(412 Blank)
3500 ENGINE ATTACHMENTS SPECIFICATIONS
413

The torques shown in the chart that follows are to be used on the part of 37° Flared 45° Flared and
Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.


possible. Hold these components in this position.
Turn the fitting into the part it is used on, until
backup washer (4) just makes contact with the
face of the part it is used on.
NOTE: If the fitting is a connector (straight fitting) or plug,

the hex on the body takes the place of the locknut. To
install this type fitting tighten the hex against the face of
the part it goes into.

turn the fitting body (2) out (counterclockwise) a
.
maximum of 359° Tighten locknut (3) to the
torque shown in the chart. ELBOW BODY ASSEMBLY
A71009X3
1. End of fitting body (connects to tube). 2. Fitting
body. 3. Locknut. 4. Backup washer. 5. O-ring
seal. 6.
End of fitting that goes into other part.
414
INTRODUCTION
The specifications given in this book are on the basis of can be used again. If the part is equal to or within the
information available at the time it was written. The specification given, use the part again.
specifications torques, pressures of operation,
measurements, adjustments and other items can change When the word "permissible" is in the description, the
at any time. These changes can effect the service given specification given is the "maximum or minimum"
to the product. Get the complete and most current tolerance permitted before adjustment, repair and/or new
information before you start any job. Caterpillar Dealers parts are needed.
have the most current information which is available. For
a list of the most current modules and form numbers A comparison can be made between the measurements
available for each Service Manual, see the SERVICE of a worn part, and the specifications of a new part to
MANUAL CONTENTS MICROFICHE REGI 139F. find the amount of wear. A part that is worn can be safe
to use if an estimate of the remainder of its service life is
When the words "use again" are in the description, the good. If a short service life is expected, replace the
specification given can be used to determine if a part part.
77200X2
415
ETHER STARTING AID
(1) Location of atomizer on air inlet manifold.

(2) Location of temperature switch on regulator
housing.
NOTE: Ether will not inject when water
temperature is above 38°C (100° F).
(3) Atomizer identification mark.
(4) Direction of spray (toward front of engine).
PRIMARY FUEL FILTER
(1) Torque for nut............................. 25 ± 5 N-m (18

+ 4 lb. ft.)
(2) 7S9323 Spring:
Length under test force .............. 27.9 mm (1.10
in.)
Test force ................................... 125 to 145 N
(28 to 33 lb.)
Free length after test .................. 42.7 mm (1.68
in.)
Outside diameter ........................ 17.3 mm (.68
in.)
FUEL FILTER CHANGE INDICATOR GROUP
(1) Indicator assembly.

Tighten to a torque of ................. 55 + 10 N-m
(40 + 7 lb. ft.)
When indicator can be seen at a position
1/2 of the distance from the top, the fuel
pressure
differential is ............................... 85 to 105 kPa
(12 to 15 psi)
416

(2301 Governor with EG3P Actuators)
8N116 Fastener Group
(1) Diameter of shaft on lever (6) Tighten nut to a torque

assembly .......................... 19.050 + 0.013 mm of ............................................... 3.4 + 0.5 N-m
(.7500 + .0005 in.) (2.3 + .4 lb. ft.)
Bore in bearings after assembly (7) Rod assembly.
in bracket.......................... 19.126 + 0.038 mm (8) Tighten the plug to a torque
(.7530 ± .0015 in.) of ................................................ 70 ± 15 N-m
(2) Distance bearing is installed from (50 + 11 lb. ft.)
end of bracket................... 4.0 + 0.5 mm (.16 + (9) Tighten the studs in the bearing adapter to
.02 in.) a torque of ............................................... 15 + 5 N-m (11
(3) Rod end. Adjust rod end (3) on rod assembly (7) + 4 lb. ft.)
to put the levers in the shut off position as (10) Tighten nut to a torque
shown. of ................................................ 68 + 13 N-m
(4) Distance bearing is installed from end of bracket (50 + 10 lb. ft.)
.......................................... 0.5 + 0.5 mm (.02 ± (11) Distance between end of magnetic pick-up
.02 in.) and gear ..................................... 0.50 to .075
(5) Distance pin is installed from lever mm (.020 to
.......................................... 18 + 1 mm (.71 + .04 .030 in.)
in.)

417

(2301 Governors With EG10P Actuators)
4W5030 Fastener Group

(1) Diameter of shaft on lever (8) Rod assembly.
assembly .................................... 19.050 + 0.013 (9) Lever.
mm (.7500 +
.0005 in.) Linkage Adjustment:
Bore in bearings after assembly 1. With control linkage in the SHUTOFF position
in bracket ................................... 19.126 _ 0.038 against its stop, install lever (3) as shown.
mm (.7530 + 2. With actuator shaft in the SHUTOFF position
.0015 in.) against its stop, lever (9) must be installed at
(2) Distance bearing is installed from the angle shown.
end of bracket 4.0 _+ 0.5 mm (.16 + .02 in.) 3. With levers (3) and (9) in the SHUTOFF position,
(3) Lever. adjust rod end(4) and rod assembly (8) to the
(4) Rod end. needed length. Tighten nuts (7) to hold rod ends
(5) Distance bearing is installed from in position.
end of bracket 0.5 + 0.5 mm (.02 + .02 in.) NOTE: Threads of rod ends (4) must be visible through
(6) Distance pin is installed from holes in rod to make sure there is minimum thread
lever ........................................... 181 mm (.71 + engagement. Fill holes in rod with 9S3263 Thread Lock
.04 in.) after adjustment is correct.
(7) Nut: Tighten on each end of
rod assembly to a torque 4. Connect levers (3) and (9) together with rod
of ............................................... 12 + 4 N-m (9 + assembly (8).
3 lb. ft.)
418

(1) Torque for:

Bolts (3161) ......................... 45+ 7N•m (32+5 lb.
ft.)
Studs (UG8) ........................ 30+5N•m(22+4 lb.
ft.)
(2) Torque for plugs .................. 70+15N•m (50+11
lb. ft.)
GOVERNOR DRIVE
7N1889 & 8N9662 Drive Groups Used With UG8-L

Woodward Governors
1W2135 Drive Group Used With Caterpillar 3161
Governors
(1) Diameter of bore in

adapter (2)........................... 34.072+0.025mm
(1.3414+0.010 in.)
Diameter of shaft on governor drive
pinion (3) ............................
34.000+0.013mm(1
.3386+.0005 in.)
(2) Adapter.
(3) Governor drive pinion.
(4) Bevel gear.
(5) Diameter of shaft on bevel
gear (4) ............................ 34.000+0.013mm
(1.3386+.0005)
(6) Shims. Use as required to get
a gear clearance (backlash)
between pinion (3) and gear (4)
of ............................ 0.100+0.050 or-
0.025mm(.0039+.00
20or -.0010 in.)
(7) Diameter of bore in drive
housing 40.032+0.025mm(1.5918+0.010 in.)
Diameter of bearing............. 40.545+0.013mm
(1.5963+.0005 in.)

419
GOVERNOR ALIGNMENT PROCEDRE

NOTE: Make sure governor output lever is connected NOTE: Spring pressure in the Caterpillar 3161 Governor
correctly to rack fork lever (1). should cause the output terminal shaft to go back to the
fuel-off position when released from the full-fuel position.
1. Position base of governor (8) so side (A) of base Spring pressure in the Woodward UG8 Governor should
is parallel with surface (B) of governor drive cause the output terminal shaft to move when released
housing (12). Tighten governor mounting bolts from the full-fuel position, but it will not go all the way to
(10). the fuel-off position.
2. Now loosen adapter bolts (13).
3. Move the governor and drive housing as needed 7 If output terminal shaft does not turn freely, do
until holes in cover (5) are in alignment with Steps 2 thru 6 again.
holes in accessory drive housing (11). Install, 8. Put bracket (6) in position with open slots over
but do not tighten, the seven cover bolts (9). bolts (3). Install washers and bolts (2) that hold
4. Tighten the six adapter bolts (13). bracket (6) to cover (5), but do not tighten these
5. Now tighten the seven cover bolts (9). bolts.
6. After all bolts are tightened, check to be sure 9. Tighten bolts (3) that hold bracket to governor
governor terminal shaft (4.) has free rotation. first, then tighten bolts (2) that hold bracket to
cover.
420
3500 ENGINE ATTACHMENT SPECIFICATIONS
OIL PANS
(1) Tighten all 4B2363 Plugs in the oil pans to a

torque
of ......................................... 145 + 15 N-m (105
+11 lb. ft.)
(2) At assembly, put 7M7260 Liquid Gasket or
PERMATEX NO. 2 on all gasket joints and where
gaskets contact each other.

PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES421
421

(L.H.)

(2) Torque for three bolts that
hold bypass housing to
filter housing ................................55+7 N-m (41 + 5 lb. ft.)
(3) 2W1635 Spring for the filter bypass valve:
Length under test force ...........................................102 mm (4.02 in.)
Test force5 ............................................... 518 N (115 lb.)
Free length after test ........................................143.4 mm (5.65 in.)
Outside diameter ......................................37.25 mm (1.470 in.)
open at ...................................287 + 7 kPa (42 1 psi)
and fully open at .............................. 480 + 7 kPa (70 + 1 psi)
422
DUPLEX OIL FILTER
(1) Handle. (8) Jam nut.

(2) Lever. (9) 2W1635 Spring for oil filter bypass valve: Length
(3) Linkage.(9) 2W1635 Spring for oil filter bypass under test force ....................... 102 mm (4.02 in)
valve: Test force ..............................518 N (116.55 lb.)
(4) Valve assembly cover. Free length after test .......... 143.4 mm (5.65 in.)
(5) Bolt (three at each end of valve body housing.) Outside diameter ............. 37.25 mm (1.470 in.)
Tighten to a torque of 55 + 7 N’m (40 + 5 lb. ft.) Bypass valve must start to open at 287 + 7 kPa
(6) Valve assembly shaft. (42 + 1 psi) and
(7) Adjustment nut be fully opened at 480 + 7 kPa (70 + (10) Bypass Valve
1 psi).
See Testing and Adjusting for adjustment procedure..

423
Rotation of drive gear (as seen from

drive end) ............................................Counterclockwise
(1) Length of gears
(new)...........84.000± 0.015 mm (3.3071+0006 in.)
(new) ............. 84.15 + 0.02 mm (3.313 + .001 In.)
(2) Diameter of gear shafts
(new) ... 31.742 + 0.008 mm (1.2497 + .0003 In.)
Bore In bearings for gear shafts after assembly
(new) ... 31.837 ± 0.070 mm (1.2534 + .0028 in.)
(3) Distance from the end of the shafts to the
gear faces ...............34.0 ± 0.5 mm (1.34 ± .02 in.)
(4) Depth that bearings are installed in pump
body ........................ 1 5 ± 0.5 mm (.06 + .02 in.)
(5) Depth that bearings are installed In
cover ........................ 1.5 ± 0.5 mm (.06 + .02 in.)
(6) Position of bearing joints from the centerline
°
through the bearing bores ........................ 45 + 15
(7) Distance dowels extend from
cover ....................... 6.4 + 0.5 mm (.25 ± .02 In.)
424
OIL SCAVENGE
PUMP
(1W8505)
Rotation of drive gear (as seen from
drive end) ............................................Counterclockwise
(1) Length of gears
(new).........110.000± 0.015 mm (4.3307+0006 in.)
(new) ........... 110.15 + 0.02 mm (4.337 + .001 In.)
(2) Diameter of gear shafts
(new) ... 31.742 + 0.008 mm (1.2497 + .0003 In.)
Bore In bearings for gear shafts after assembly
(new) ... 31.837 ± 0.070 mm (1.2534 + .0028 in.)
(3) Distance from the end of the shafts to the
gear faces ...............34.0 ± 0.5 mm (1.34 ± .02 in.)
(4) Depth that bearings are installed in pump
body ........................ 1 5 ± 0.5 mm (.06 + .02 in.)
(5) Depth that bearings are installed In
cover ........................ 1.5 ± 0.5 mm (.06 + .02 in.)
(6) Position of bearing joints from the centerline
°
through the bearing bores ........................ 45 + 15
(7) Distance dowels extend from
cover ....................... 6.4 + 0.5 mm (.25 ± .02 In.)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL
TIGHTENING TORQUES
425
EXHAUST MANIFOLDS
(WATER COOLED)
(1) Right exhaust manifold. (5) Studs. Tighten the studs in the exhaust manifolds
(2) Plugs. Tighten plugs to a to a torque of .............. 30 + 5 N-m (22 + 4 Ib.ft.)
torque of ...................................... 90 Nm (65 Ib.ft.) (6) Plugs. Tighten the plugs to a
NOTE: Put 5P3931 Anti-Seize Compound on the threads torque of .................................... 25 N-m (20 Ib.ft.)
of bolts (3), studs (5) and plugs (6) at assembly.
(3) Bolts. Tighten the bolts that hold exhaust NOTICE
manifolds (1) and (4) to Before installation of this cylinder head on an engine
a torque of .................... 45 + 7 N-m (32 + 5 Ib.ft.) that has water cooled manifolds, the plug at location
(4) Left exhaust manifold. (A) MUST be removed. If the engine has dry
manifolds, the plug at location (A) MUST NOT be
removed.

426
TURBOCHARGER IMPELLER INSTALLATION
INSTALLATION PROCEDURE CHART

TURBOCHARGER MODELS
T04, T04B, TM51 T12, TV61, T18, TV81, TV91, TW91,
T04C, TM54 TW61, TL61 TW81, TL81, TL91, TV92,
Step by Step Procedure TW4B, TW4C TV72, TW72, TW92, TL92
TL4B, TL4C TL72, TV78,
TW78, TL78
A. Put impeller on the shaft.
B. Put a small amount of clean oil
on the threads and impeller
face area that contacts the nut.
2.25 N•m 5 N•m 17 N•m 17 N•m 31 N•m
C. Install and tighten the nut to:
(20 lb. in.) (50 lb. in.) (13 lb. ft.) (13 lb. ft.) (23 lb. ft.)
NOTICE
Do not bend or add stress to
the shaft when the nut is
loosened or tightened.
D. Loosen the nut on the shaft. * *
* * 3.5 N•m 3.5 N•m 5 N•m
E. Now tighten the nut to:
(30 lb. in.) (30 lb. in.) (50 lb. in.)
F. Tighten the nut more: 110° 120° 120° 120° 135°
G. Remove the nut from the shaft.
H. Use 6V1541 Quick Cure
Primer on the threads of the
shaft and nut.
J. Put 9S3265 Retaining
Compound on the threads of
the shaft and nut.
2.25 N•m 5 N•m 3.5 N•m 3.5 N•m 5 N•m
K. Install and tighten the nut to:
(20 lb. in.) (50 lb. in.) (30 lb. in.) (30 lb. in.) (50 lb. in.)
L. Tighten the nut more: 110° 120° 120° 120° 135°
*Does not apply to these turbochargers.
427
TURBOCHARGER TW61
(1) Nut for impeller (See TURBOCHARGER Diameter for the surfaces (journals)
IMPELLER INSTALLATION). on the shaft for the bear-
ings.... 15.875 to 15.885 mm (.6250 to .6254 in.)
NOTICE
Do not bend or add stress to the shaft when the nut (5) Bore in the hous-
is loosened or tightened. ing ...... 24.961 to 24.973 mm (.9827 to .9832 in.)
(2) Torque for the bolts that hold the Outside diameter of the bear-
backplate .................. 10 ± 1 N•m (90 ±10 lb. in.) ings..... 24.846 to 24.859 mm (.9782 to .9787 in.)
(3) Torque for the clamp (6) Clearance between the ends of the
bolts ................. 14.0 ± 1.5 N•m (120 ± 13 lb. in.) oil seal ring (when installed in
its bore) ......... 0.20 to 0.38 mm (.008 to .015 in.)
Lightly hit all around clamp with a
soft faced hammer and again (7) End play for the
shaft. ............. 0.08 to 0.25 mm (.003 to .010 in.)
tighten to......... 14.0 ± 1.5 N•m (120 ± 13 lb. in.)
Torque for bolts and nuts that hold the turbocharger to
the exhaust manifold (put 5P3931 Anti-Seize Compound
(4) Bore in the bear-
on the threads) ........................ 54 ± 5 N•m (40 + 4 lb. ft.)
ings .... 15.921 to 15.931 mm (.6268 to .6272 in.)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE
OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
428
TURBOCHARGER TW81
(1) Nut for impeller (See TURBOCHARGER Diameter for the surfaces (journals) on the shaft
IMPELLER INSTALLATION). for the bear-
ings.... 15.875 to 15.885 mm (.6250 to .6254 in.)
NOTICE
Do not bend or add stress to the shaft when the nut (5) Bore in the hous-
is loosened or tightened. ing ..... 24.961 to 24.973 mm (.9827 to .9832 in.)
(2) Torque for the bolts that hold the Outside diameter of the bear-
backplate ..................... 101 N•m (90 ± 10 lb. in.) ings.... 24.846 to 24.859 mm (.9782 to .9787 in.)
(3) Torque for the clamp (6) Clearance between the ends of the oil seal ring
bolts ................. 14.0 ± 1.5 N•m (120 ± 13 lb. in.) (when installed in its
bore).............. 0.20 to 0.38 mm (.008 to .015 in.)
Lightly hit all around clamp with a
soft faced hammer and again (7) End play for the
tighten to.......... 14.0 ± 1.5 N•m (120 ± 13 lb. in.) shaft .............. 0.08 to 0.25 mm (.003 to .010 in.)
(4) Bore in the bear- Torque for bolts and nuts that hold the turbocharger to
ings .... 15.921 to 15.931 mm (.6268 to .6272 in.) the exhaust manifold (put 5P3931 Anti-Seize Compound
on threads) .............................. 54 ± 5 N•m (40 ± 4 lb. ft.)
429
TURBOCHARGER TW91
(1) Nut for impeller. (See TURBOCHARGER Outside diameter of bear

IMPELLER INSTALLATION.) ings..30.467 to 30.480 mm (1.1995 to 1.2000 in.)
NOTICE (5) Clearance between the ends of oil seal ring

Do not bend or add stress to the shaft when the nut (when installed in its
is loosened or tightened. bore).............. 0.20 to 0.38 mm (.008 to .015 in.)
(2) Torque for the clamp (6) End play for the
bolt.................... 14.0 ±1.5 N•m (120 + 13 lb. in.) shaft ......... 0.165 ± 0.063 mm (.0065 ± .0025 in.)
Hit lightly all around clamp with a soft faced (7) Torque for the bolts that hold the
hammer and again tighten backplate.................... 40 ± 2 N•m (30 ± 1 lb. ft.)
to...................... 14.0 + 1.5 N-m (120 + 13 lb. in.)
(8) Torque for the bolts that hold the turbine housing
(3) Bore in the bear- to the cartridge housing (put 5P3931 Anti-Seize
ings .... 21.585 to 21.595 mm (.8498 to .8502 in.) Compound on the
threads) ...................... 40 ± 2 N•m (30 ± 1 lb. ft.)
Diameter of the surfaces (journals) on the Torque for bolts and nuts that hold the turbocharger to
shaft... 21.539 to 21.549 mm (.8480 to .8484 in.) the exhaust manifold (put 5P3931 Anti-Seize Compound
on threads) .............................. 54 ± 5 N•m (40 ± 4 lb. ft.)
(4) Bore in the hous-
ing... 30.594 to 30.607 mm (1.2045 to 1.2050 in.)
430
TURBOCHARGER W153
NOTICE Width of oil seal ring groove at turbine

Do not bend or add stress to the shaft when the nut end ............................ 2.550 + 0.030 - 0.010 mm
is loosened or tightened. (.1004 + .0012 - .0004 in.)
(6) End play for the

(1) Turbocharger impeller installation: shaft ....... 0.090 to 0.130 mm (.0035 to .0051 in.)
a. Put impeller on the shaft.
b. Put a small amount of 2P2506 Thread (7) Torque for the three bolts that hold the thrust
Lubricant on the threads and impeller face bearing ......................... 12 ± 4 N-m (9 ± 3 lb. ft.)
that will be under the nut.
c. Tighten the nut (8) Bore in the
to......................... 95 ± 5 N•m (70 ± 4 lb. ft.) bearings ...................... 24.020 + 0.010 - 0.0 mm
(.9457 + .0004 - .00 in.)
(2) Torque for the bolts that hold the compressor
housing to the cartridge hous- Diameter of the surfaces (journals) on the
ing............................... 25 ± 5 N•m (18 ± 4 lb. ft.) shaft ............................ 24.000 + 0.0 - 0.009 mm
(.9449 + .00 - .0004 in.)
(3) Width of oil seal ring at compressor
end.......... 2.500 ± 0.010 mm (.0984 + .0004 in.) (9) Bore in the
housing........................ 32.000 + 0.016 - 0.0 mm
Width of oil seal ring bore at compressor (1.2598 + .0006 - .00 in.)
end.......... 2.635 ± 0.035 mm (.1037 ± .0014 in.)
Outside diameter of the
bearings ...................... 31.890 + 0.0 - 0.010 mm
(4) Torque for the bolts that hold the turbine housing
(1.2555 + .00 - .0004 in.)
to the cartridge housing (put 5P3931 Anti-Seize
Compound on the
Torque for bolts that hold the turbocharger to the
threads) ...................... 48 ± 3 N•m (35 ± 2 lb. ft.) exhaust manifold (put 5P3931 Anti-Seize Compound
on threads) ...................... 135 ± 15 N•m (100 ± 11 lb. ft.)
(5) Width of oil seal ring at turbine
end.......... 2.500 ± 0.010 mm (.0984 ± .0004 in.)
431
TURBOCHARGER INSTALLATION
(Watercooled Exhaust Elbow)
(3508 - 95Y & 68Z)
(1) Turbine housing.
(2) Exhaust elbow.
(3) Clamp.
(4) Adapter.
(5) Seal.
(6) Collar.
(7) Bracket mounting bolts.
(8) Exhaust elbow mounting bolts.
Seal installation procedure:
A. Loosen exhaust elbow and bracket mounting bolts (8) and (7).
B. Slide adapter (4) out of bore of turbine housing (1) until it

contacts pilot of exhaust elbow (2).
C. Install seal (5) and collar (6). Make sure collar joint and
clamp tightening mechanism are offset. Tighten clamps
to a torque of.................................... 6.0 ± 0.5 N•m (55 ± 4 lb. in.)
D. After both clamps are tightened, tighten exhaust elbow mounting

bolts (8) and bracket mounting bolts (7).
432
(Watercooled Exhaust Elbow)
(3512 - 49Y & 65Z, 3516 - 71Z)
(1) Turbine housing.
(2) Exhaust elbow.
(3) Clamp.
(4) Adapter.
(5) Seal.
(6) Collar.
(7) Bracket mounting bolts.
(8) Exhaust elbow mounting bolts.
Seal installation procedure:
A. Loosen exhaust elbow and bracket mounting bolts (8) and (7).
B. Slide adapter (4) out of bore of turbine housing (1) until it

contacts pilot of exhaust elbow (2).
C. Install seal (5) and collar (6). Make sure collar joint and clamp
tightening mechanism are offset. Tighten clamps to a torque
of........................................................6 0 ± 0 5 N•m (55 ± 4 lb. in.)
D. After both clamps are tightened, tighten exhaust elbow mounting

bolts (8) and bracket mounting bolts (7)
433
(Watercooled Turbochargers)
(3516 - 27Z)
(1) Exhaust elbow (not water cooled). D. Install gasket between adapter (5) and
(2) Coupling. turbocharger. Now install bolts (9) that hold
(3) Metal seal rings. the adapter to the turbocharger, but do not
(4) Ring expander. tighten the bolts.
(5) Adapter. E. Use the same procedure for the other
(6) Exhaust elbow support bracket. coupling, adapter and turbocharger.
(7) Exhaust elbow mounting bolts. F. Loosen bolts (7) and (8). Loosen or remove
(8) Support bracket mounting bolts. bolts that hold exhaust pipe to exhaust
(9) Adapter bolts. elbow (1).
G. Shake the exhaust elbow to be sure that the
Installation Procedure: couplings and metal seals are not binding.
Now position exhaust elbow in alignment
A. Install correct ring expander (4) in each with the turbochargers.
groove of coupling (2). Now install the H. Tighten the bolts snugly (not tight) in the
correct four metal seal rings (3) in each sequence that follows:
groove over ring expander (4). a. Support bracket to exhaust elbow bolts
NOTE: Seal rings (3) must be installed with the gaps of (7).
each ring spaced approximately 90° apart from each b. Support bracket to flywheel housing
other. bolts (8).
B. Install coupling (2) in elbow (1), and then c. Adapter to turbocharger bolts (9).
install adapter (5) over coupling (2). J. Hit adapters (5) lightly with a soft hammer,
NOTE: Position coupling (2) in elbow so that largest lug and check alignment of parts again.
is at top as marked on coupling. K. Now tighten all bolts again in same
C. Install turbocharger to exhaust manifold, sequence.
and make sure face of turbocharger is in L. Install and tighten bolts that hold exhaust
vertical alignment with adapter (5). elbow to exhaust pipe.
434
(Watercooled Turbochargers)
(3508 - 95Y & 68Z, 3512 - 49Y & 65Z, 3516 - 71Z)
(1) Exhaust elbow (not water cooled). D. Install gasket between adapter (2) and
(2) Adapter. turbocharger. Now install bolts (9) that hold
(3) Ring expander. the adapter to the turbocharger, but do not
(4) Metal seal rings. tighten the bolts.
(5) Coupling. E. Use the same procedure for the other
(6) Exhaust elbow support bracket. coupling, adapter and turbocharger.
(7) Exhaust elbow mounting bolts. F. Loosen bolts (7) and (8). Loosen or remove
(8) Support bracket mounting bolts. bolts that hold exhaust pipe to exhaust
(9) Adapter bolts. elbow (1).
G. Shake the exhaust elbow to be sure that the
Installation Procedure: couplings and metal seals are not binding.
Now position exhaust elbow in alignment
A. Install ring expander (3) in each groove of with the turbochargers.
coupling (5). Now install the four metal seal H. Tighten the bolts snugly (not tight) in the
rings (4) in each groove over ring expander sequence that follows:
(3). a. Support bracket to exhaust elbow bolts
NOTE: Seal rings (4) must be installed with the gaps of (7).
each ring spaced approximately 90° apart from each b. Support bracket to flywheel housing
other. bolts (8).
B. Install coupling (5) in elbow (1), and then c. Adapter to turbocharger bolts (9).
install adapter (2) over coupling (5). J. Hit adapters (2) lightly with a soft hammer,
C. Install turbocharger to exhaust manifold, and check alignment of parts again.
and make sure face of turbocharger is in K. Now tighten all bolts again in same
vertical alignment with adapter (2). sequence.
L. Install and tighten bolts that hold exhaust
elbow to exhaust pipe.
435
AIR INTAKE SHUTOFF

(5N9060)
(1) Shaft assembly. Install in housing as follows: (b) Turn air shutoff handle (11) to the "open"
a. Install spacer (3) and spring (2) on shaft position and put plunger in position so the
assembly (1). stop is between spacer assemble (12) and
b. Install the assembly in the housing. Turn shaft assembly (1). Now release handle
spring (2) until it engages correctly with pin (11) to allow shaft assembly to rest against
(4). stop (16).
c. Temporarily install handle (11) on the shaft (c) Install the lower gasket, spacer plate (9)
assembly (1). Turn shaft assembly (1) and the upper gasket.
upward and install pin (13) a small distance (d) Install spring (8) over plunger and install the
in bore (14) so handle (11) can rest on pin solenoid assembly.
(13). (8) Spring.
d. With the shaft assembly and handle (11) in (9) Spacer plate.
contact with pin (13), install plate (10)Diameter of
assemblies (5) and (6) on the shaft pin ........... 6.299 ± 0.008 mm (.2480 ± .0003 in.)
assembly. Bore in spacer bushing for pin (after as-
e. Remove pin (13) to release the handle and sembly)..... 6.314 ± 0.011 mm (.2486 ± .0004 in.)
let plate assemblies (5) and (6) move to the Bore in spacer for bush-
"shutoff" position. A 0.08 mm (.003 in.) ing ........... 7.938 ± 0.013 mm (.3125 ± .0005 in.)
feeler gauge should not pass between each (11)Handle.
plate assembly and the housing. (12)Spacer assembly.
f. Remove handle (11) and install pin (13), (13)Pin.
spacer assembly (12), the gasket, cover (14)Diameter of
assembly and handle (11). pin (13) ..... 6.299 ± 0.008 mm (.2480 ± .0003 in.)
(2) Spring. Bore in housing for
(3) Spacer for spring (2): pin ........... 6.408 ± 0.051 mm (.2523 ± .0020 in.)
Bore in spacer for Bore in spacer assembly bushing for pin (after
shaft.............. 20.80 ± 0.25 mm (.819 + .010 in.) assembly)... 6.314 ± 0.011 mm (.2486 ± .0004 in.)
Diameter of Bore in spacer for
shaft................ 18.94 ± 0.02 mm (.746 ± .001 in.) bushing..... 7.938 ± 0.013 mm (.3125 ± .0005 in.)
(4) Pin. (15)Diameter of
(5) Plate assembly.
shaft .............. 18.94 ± 0.02 mm (.746 ± .001 in.)
(6) Plate assembly.
Inside diameter of bushings for
(7) Electric solenoid assembly. Install solenoid
assembly to housing as follows: shaft ...... 19.050 ± 0.044 mm (.7500 ± .0017 in.)
(a) Remove the plunger from solenoid (16)Stop.
assembly (7) and install stop (16) to the
plunger.
436
(UPPER) FRONT GEAR GROUPS
7N4871 (Right Hand) (Standard Rotation) 8N9166

(Left Hand) (Standard Rotation)
8N5768 (Right Hand) (Reverse Rotation) 8N5745 (Left

Hand) (Reverse Rotation)
8N5769 (Right Hand) (Reverse Rotation) 8N5743 (Left

Hand) (Reverse Rotation)
(1) Bore in the bearings (after assemb-

ly).......... 75.000 ± 0.055 mm (2.9528 ± .0022 in.)
Diameter of
shaft.... 74.900 ± 0.015 mm (2.9488 ± .0006 in.)
(2) Drive gear on shaft for governor drive.

(new)............... 8.50 ± 0.05 mm (.335 ± .002 in.)

(new)....... 8.750 ± 0.025 mm (.3445 ± .0010 in.)
End play for the

shaft....... 0.175 to 0.325 mm (.0069 to .0128 in.)
(4) Gear fastened to water and oil pump drive.
437
LOWER FRONT GEAR GROUPS
8N7174 (Right Hand) (Standard Rotation) 8N9167 (Left Hand)

(Standard Rotation)
8N5768 (Right Hand) (Reverse Rotation) 8N5767 (Left Hand)

(Reverse Rotation)
(2) Idler gear.

assembly....................... 90.000 ± 0.065 mm (3.5430 ± .0026 in.)
Diameter of shaft
(new)............................. 89.880 ± 0 020 mm (3.5386 ± .0008 in.)

assembly) .................... 75.000 ± 0.055 mm (2.9528 ± .0022 in.)
Diameter of shaft
(new)............................. 74.900 ± 0.015 mm (2.9488 ± .0006 in.)
(6) Thickness of thrust washer

(new)......................................... 8.50 ± 0.05 mm (.335 ± .002 in.)

(new)................................. 8.750 ± 0.025 mm (.3445 ± .0010 in.)
End play for

shaft ............................... 0.175 to 0.325 mm (.0069 to .0128 in.)
438
LOWER FRONT GEAR GROUPS
8N5620 (Right Hand) (Standard Rotation) 8N5678 (Left Hand)

(Standard Rotation)
8N5769 (Right Hand) (Reverse Rotation) 8N5767 (Left Hand)

(Reverse Rotation)
(2) Idler gear.

assembly) ................... 106.000 ± 0.065 mm (4.1732 ± .0026 in.)
Diameter of shaft
(new) ............................ 105.880 ±0.020 mm (4.1685 ± .0008 in.)

assembly) ..................... 75.000 ± 0.055 mm (2.9528 ± .0022 in.)
Diameter of shaft
(new) ............................. 74.900 ± 0.015 mm (2.9488 ± .0006 in.)
(6) Thickness of thrust washer

(new) ......................................... 8.50 ± 0.05 mm (.335 ± .002 in.)

(new) ................................. 8.750 ± 0.025 mm (.3445 ± .0010 in.)
End play for

shaft ................................ 0.175 to 0.325 mm (.0069 to .0128 in.)
439
AUXILIARY DRIVE PULLEY GROUPS
7N8041 Pulley Group:
(1) Seal. Install seal as shown and put clean engine

oil on the lip of the seal at assembly.
(2) Tighten bolts to............ 55 ± 7 N•m (41 ± 5 lb. ft.)
8N8467 Pulley Group:
(1) Bore in bearing (after assemb-

ly)........... 75.000 ± 0.055 mm (2.9528 ±.0022 in.)
Diameter of drive shaft

(new).... 74.900 ± 0.015 mm (2.9488 ± .0006 in.)
(2) O-ring seal.
(3) Seal. Install seal with the lip toward the bearing
as shown.
NOTE: Put clean engine oil on O-ring seal (2) and the lip
of seal (3) at assembly.
(4) Adapter assembly.
440
AUXILIARY DRIVE SHAFT GROUP
(1) Tighten bolts to a torque

of ................................ 45 ± 7 N-m (32 ± 5 lb. ft.)
Install seal as shown and put clean engine oil on

the lip of the seal at assembly.
TACHOMETER DRIVE
(1) Put clean engine oil or glycerin on the O-ring

seal at assembly.
(2) Bearing.
(3) Install seal in cover (7) with the lip of the seal
toward bearing (2).
Put clean engine oil on the lip of the seal after it

is installed.
(4) Tighten bolts in steps to a torque

of .......................... 100 ± 15 N•m (75 ± 11 lb. ft.)
Hit face of adapter (5) and tighten bolts in steps

to a torque
of .......................... 100 ± 15 N•m (75 ± 11 lb. ft.)
Again hit face of adapter (5) and again tighten

bolts in steps to a torque
of ......................... 100 ± 15 N•m (75 ± 11 lb. ft.)
(5) Tachometer drive adapter.
(6) Camshaft drive gear.
(7) Cover (RH rear of engine).
441
TRUNNION
(1) Tighten the bolts that hold the mount

assembly to the support to a
torque of....................................... 200 ± 20 N•m (150 ± 15 lb. ft.)
(2) Tighten the bolts that hold trunnion to

front drive housing to a
torque of....................................... 135 ± 15 N-m (100 ± 11 lb. ft.)
442
FRONT TRUNNION SUPPORT
(1) Bolt. (3) Top half of support.
Put 2P2506 Thread Lubricant on the threads and (4) Distance ferrule extends from surface of
face of bolt head. Tighten bolt to a bottom support ............................. 8 mm (.31 in.)
torque of ............... 100 ± 15 N•m (75 ± 10 lb. ft.)
(5) Ferrule.
Now turn bolt an additional................... 120 ± 5
O
(6) Distance ferrule extends from surface of

(2) Bottom half of support. top support ................................... 8 mm (.31 in.)
ENGINE FRONT SUPPORT GROUP (WIDE)
(1) Leveling screw.
(2) Tighten locknut to a

torque of ...................................... 150 ± 20 N•m (110 ± 15 lb. ft.)
(3) Trunnion support bolts. Tighten

to a torque of................................ 750 ± 80 N•m (550 ± 60 lb. ft.)
(4) Use shims as required between rails and support.
443
VIBRATION DAMPER GROUP

(FOR HIGH INERTIA DRIVEN EQUIPMENT)
(1) Crankshaft (front end).
(2) Damper mounting bolts. Tighten to a

torque of......................................... 100 ± 15 N•m (75 ± 10 lb. ft.)
(3) Adapter mounting bolts. Put 2P2506 Thread

Lubricant on threads and tighten to a torque
of................................................ 875 ± 100 N•m (640 ± 80 lb. ft.)
(4) Alignment marks. Put mark on adapter in alignment with mark

on crankshaft.
(5) Adapter.
(6) Damper (two).
444
VIBRATION DAMPER GROUP

(3508 & 3512)
8N7182 Damper Group:
(1) Crankshaft.
(2) Adapter.
(3) Damper.
(4) Put mark on adapter (2) in alignment with mark on end of crank-
shaft (1) before installation of bolts (5).
(5) Bolts.
445
VIBRATION DAMPER GROUPS

(3516)
4W278 Damper Group: (4) Damper (rubber).

(5) Put mark of adapter (2) in alignment with mark
(1) Crankshaft. on end of crank-shaft (1) before installation of
(2) Adapter. bolts (6).
(3) Damper (fluid). (6) Bolts.
8N339 Damper Group: (4) Put all marks of crankshaft (1), adapter (2) and
damper (3) in alignment before installation of
(1) Crankshaft. bolts (5).
(2) Adapter. (5) Bolts.
(3) Damper. (6) Bolts. Tighten to a torque
of ................................ 55 ± 7 N•m (41 ± 5 lb. ft.)
446
FRONT MOUNTING GROUP

(For Hydraulic Pump or PTO Clutch)
(1) Damper.
(2) Adapter.
(3) Damper adapter.
At assembly, put 2P2506 Thread Lubricant on the
threads of the bolts that hold damper adapter (3)
to the crankshaft. Tighten the bolts to a torque of
875 + 100 N•m (640 + 80 lb. ft.)
(4) Coupling.
Put dash mark on coupling in alignment with

marks on damper adapter and crankshaft.
REAR STUB SHAFT
(1) Crankshaft.
(2) Flywheel.
(3) Put 2P2506 Thread Lubricant on threads and tighten

bolts that hold stub shaft and flywheel to crankshaft
to a torque of
...........................1150 + 30 N-m (840 _ 22 lb. ft.)
447
FRONT STUB SHAFT
FOR LOW KW (HP) APPLICATIONS
FOR FULL ENGINE KW (HP) APPLICATIONS
(1)Crankshaft.
(2) Adapter.
(3) Put 2P2506 Thread Lubricant on the threads and tighten bolts
to a torque
of...................................................... 875 + 100 N-m (640 + 80 lb. ft.)
(4) Put dash mark on shaft in alignment with dash mark on

adapter.

448
TIME DELAY RELAY
5N2124 (Dynalco Corp. Number DSC-9)

Operating voltage range...............................8 to 40 VDC
On Delay.
Control 1..........No delay on setting (O seconds)
Control 2........... 8 to 10 second delay on setting
Off Delay.
60 to 80 second delay on resetting
JACKET WATER HEATERS
5N5739 120 VAC, 3000 Watts

5N5740 240 VAC, 3000 Watts
(1) Thermostat adjustment

range ........... 16 to 82° C (60 to 180° F)
(2) Coolant inlet
(3) Coolant outlet
MAGNETIC PICKUP
(1) Distance between end of magnetic

pickup and gear
...............0.56 to .085 mm (.022 to .033 in.)
(2) Nut. Tighten nut to a

torque of ...................45 + 7 N-m (33 + 5 lb. ft.)

449
DIGITAL TACHOMETER
3T2159 Digital Tachometer (3) Magnetic Pickup terminals.

General Specifications:
(1) Program terminals (Ratio 1:1).
(2) Program boards (5 available). (a) Operating temperature
range ...................-20 to + 85° C (-4 to + 185° F)
3T2159 TACHOMETER PROGRAM RANGE (b) Tachometer must be accurate within + .5%
Number of Correct Jumper Locations
Flywheel Teeth For Program Boards (c) Input frequency range ........ 750 to 9000 Hz
183 Terminal A to Terminal 1
(d) Time required for display update
151 Terminal A to Terminal 3 Maximum ..........................................1.0 second
113 Terminal A to Terminal 5 Minimum ............................................25 second
450
TEMPERATURE CONTACTOR
4W2637 Contactor
With an increase in temperature, contacts

close at ...............................92 + 2° C (198 + 36° F)
With a decrease in temperature, contacts

open at ............................. 82 + 2° C (180 + 37° F)
4W2640 Contactor
With an increase in temperature, contacts

close at ..............................98 + 2° C (208 + 36° F)
With a decrease in temperature, contacts

open at ..............................88 + 3° C (190 + 37° F)
PRESSURE CONTACTOR
4W2641 Contactor
NOTE: Test contactor at 25° C (77° F).
With an increase in pressure, contacts

close at ...........................160 + 20 kPa (23 + 3 psi)
With a decrease in pressure, contacts

open at ........................120 ± 10 kPa (17 + 1.5 psi)
4W2642 Contactor
NOTE: Test contactor at 25° C (77° F).
With an increase in pressure, contacts

close at ..........................310 + 20 kPa (45 + 3 psi)
With a decrease in pressure, contacts

open at ..........................260 + 20 kPa (38 + 3 psi)

PAGE OF SPECIFICATIONS FOR-GENERAL TIGHTENING TORQUES
451
PRESSURE SWITCHES
67750 Switch
With an increase in pressure, switch

opens at ...........................275 + 28 kPa (40 ± 4 psi)
2L3402 Switch

closes at ........................20.7 to 27.6 kPa (3 to 4 psi)
3N1400 Switch

closes at .....................6.9 to 10.35 kPa (1 to 1.5 psi)
7N5946 Switch
Circuit 1 normally closed
Circuit 2 normally open
With an increase in pressure, circuit 1 opens

and circuit 2 closes at................... 145 kPa (21 psi) max.
With a decrease in pressure, circuit 2 opens

and circuit 1 closes at................75 + 20 kPa (11 ± 3 psi)
907032 Switch

closes at ............................517 + 35 kPa (75 + 5 psi)
With a decrease in pressure, switch
opens at ............................415 ± 35 kPa (60 + 5 psi)
9G8010 Switch
NOTE: Test switch at 25° C (77° F)
With an increase in pressure, switch closes

at ............................110 + 20 kPa (16 ± 3 psi)
With a decrease in pressure, switch opens
at ................................62 ± 20 kPa (9 + 3 psi)
8N407 Switch
NOTE: Test switch at 25° C (77° F).
With an increase in pressure,
switch opens at........................152 + 20 kPa (22 + 3 psi)
With a decrease in pressure,
switch closes at ......................110 + 20 kPa (16 + 3 psi)
452
TEMPERATURE SWITCHES
7W705 Contactor (Coolant)
Switch operates when temperature

increases to ........................104.5 + 0.6° C (220 + 1° F)

Switch operates when the temperature
increases to ..............................91.7 + 1° C (197 + 1° F)

Switch operates when temperature
increases to ........................... 98.3 + 0.6° C (208 + 1° F)
5L6435 Contactor (Coolant)

increases to ............................... 98° + 1° C (209° + 1°F)
6L4207 Contactor (Inlet Air)

increases to ................................110 + 1° C (230 + 1° F)
8N1693 Switch (Ether Aid)
Switch must open

between .................. 35 and 40.5° C (95 and 105° F)
Switch must close

at a minimum of ....................................... 26.7° C (80° F)
3N7442 Switch (Low Coolant Temperature)
Switch must open

between .................... 24 and 29.5° C (75 and 85° F)
Switch must close
at a minimum of ....................................... 18.3° C (65° F)

453
SENDING UNITS
5L7450 Sending Unit (Oil Pressure)

for 24V or 32V systems
Resistance at’
0 kPa (0 psi) ........................................... 0 ohms
140 kPa (20 psi) ................................ 13.5 ohms
550 kPa (80 psi) ................................... 30 ohms
5L7442 Sending Unit (Coolant Temperature)

for 24V or 32V systems
Resistance at:
93°C (200° F) .......................... 800 to 900 ohms
ELECTRIC TACHOMETER
3N7288 (Faria No. B-1594-2); Use with 5N8176

Sender Assembly.
Output to input ratio................................................ 2 to 1

Range ..............................................0 to 2500 rpm
Check at normal engine operating speed
Amount of adjustment available (dial reading .........+ 5%
Maximum external circuit resistance ................. 20 ohms
Maximum temperature rating .................... 82°C (180° F)
(1) Adjustment screw
(2) Sealed cap.
(3) Rubber washer.
NOTE A maximum of two tachometers can be operated
with one sender assembly.
454
AMMETER
3N5992 Gauge (Stewart-Warner Number 690-C)
CALIBRATION CHART
POINTER POSITION A + 60 A
TOLERANCE + 0.8 mm (.03 in.) + 12 A
OIL PRESSURE GAUGE

(ELECTRIC)
5L7456 Gauge 24V**; Use with 5L7450 Sending Unit

Range ............................0 to 550 kPa (0 to 80 psi)
Test voltage 285 V
TEST
RESISTANCE (ohms) 0 13 5 30
POINTER POSITION 0 20 80
TOLERANCE* + 0.8 mm (.03 in.)
*Measure tolerance from the end of the pointer to the

center-line of the mark on the face of the gauge.
*For 32V systems the 5L7441 Resistor (65 ohms) Is

used with this gauge.
WATER TEMPERATURE GAUGE

(ELECTRIC)
5L7444 Gauge 24V**; Use with 5L7442 Sending Unit
Range ....................... 38 to 116° C (100 to 240° F)

Test voltage ..........................................................28 5 V
TEST
RESISTANCE ohms) 3388 1050 460
POINTER POSITION 100 170 240
TOLERANCE* + 0.8 mm (.03 In.)
'Measure tolerance from the end of the pointer to the

center-line of the mark on the face of the gauge
**For 32V systems the 5L7441 Resistor (65 ohms) is
used with this gauge

455
AIR SHUTOFF SOLENOIDS
6T4751 Solenoid (G. W. Lisk, W-1080-2)

Voltage rating ...................................................24 to 32V
Coil resistance at 25° C (77° F).............. 3.3 to 4.1 ohms
Activate to ......................................................... shutoff
NOTICE
This solenoid must not be used in constant
operation for more than 2.5 minutes or damage may
result.
Distance of plunger travel

.....................................15.75 mm (.620 in.)
(2) Torque for terminal nuts
.............. 1.23 to 1.92 N-m (11 to 17 lb. in.)
9G8180 Solenoid (G. W. Lisk, W-1121-2)

Voltage rating ...................................................24 or 32V
Coil resistance at 25° C (77° F).............. 3.3 to 4.1 ohms
Activate to ......................................................... shutoff
NOTICE
This solenoid must not be used in constant
operation for more than 2.5 minutes or damage may
result.
(1) Distance of plunger travel....15.75 mm (.620 in.)

(2) Tighten shaft nut to a
torque of ....................24 + 7 N•m (18 + 5 lb. ft.)
(3) Torque for terminal
nuts .............. 1.23 to 1.92 N-m (11 to 17 lb. in.)
456
AIR COMPRESSOR GROUP

(8N8360)
(1) Air compressor. (6) Nut. Tightened the nut to a

torque of ............................ 135 N•m (100 lb. Ft.)
(2) Bore in bearing (after If the cotter pin can not be installed, tighten the
assembly) nut more to make an alignment of the nearest
.............75.000 + 0.055 mm (2.9528 + .0022 in.) slot in the nut with the hole in the shaft.
(3) O-ring seal. (7) Seal. Install the seal in adapter assembly (4)
Diameter of drive shaft (new) with the bearing as shown.
.....74.900 + 0.015 mm (2.9488 + .0006 in.) (8) V-Belt. Tighten the V-Belt to the specifications
given in the V-BELT TENSION CHART.
(4) Adapter assembly.
NOTE: Put clean engine oil on O-ring seal (3) and the lip
(5) Governor. The governor air pressure range is of seal (7) at assembly.
....................620 to 795 kPa (90 to 115 psi)

457
AIR CONTROL VALVE GROUPS
For Air Start And Oil Pressure Override
(1) Tighten locknut to a torque of

...........................32 + 7 N•m (24 + 5 lb. ft.)
458
FORM NO. SENR2984
SYSTEMS OPERATION
TROUBLESHOOTING
INDIVIDUAL CIRCUIT DESCRIPTION
ELECTRIC PROTECTIVE SYSTEM
FOR
ENGINES EQUIPPED WITH REVERSAL PROTECTION
459
INTRODUCTION
The electric protective system is designed to The electric protective system consists of the
activate an alarm or shut the engine off if there is a basic components that follow: tachometer speed sensor,
problem or a failure in any of five different engine electronic speed switch, water temperature contactor
systems. The engine systems monitored are: engine switch, two time delay relays and two slave relays. This
overspeed, starter motor crank terminate, engine system monitors the engine from starting through rated
reversal, engine oil pressure and engine coolant speed.
temperature.
COMPONENT DESCRIPTION
Tachometer Speed Sensor (TSS) The sensor switches are used [280 kPa (40 psi), 140 kPa (20 psi)].
generates a signal that measures engine speed, but also Once the step oil pressure speed setting is made, an
has a special characteristic that sends the signal in a engine that runs above this speed setting must maintain
certain sequence. If the direction of rotation is changed, an oil pressure that is more than 280 kPa (40 psi). An
the signal sequence is changed. engine that runs at a speed below this speed setting
must maintain an oil pressure that is more than 140 kPa
Electronic Speed Switch (ESS) The speed switch has (20 psi). If either condition is not correct, a switch will
controls (in a single unit) to monitor four of the basic close and cause the fuel to be shut off to the engine.
functions. These four functions are:
Water Temperature Contactor Switch This contactor
Engine Overspeed An adjustable engine speed setting switch is a separate unit (mounted in the regulator
(normally 118% of rated speed) that gives protection to housing) that is wired into the shutdown circuit. It has an
the engine from damage if the engine runs too fast. This element that feels the temperature of the coolant (it must
condition will cause a switch to close that shuts off both be in contact with the coolant). When the engine coolant
the inlet air and the fuel to the engine. temperature becomes too high, the switch closes to
cause the fuel to be shut off to the engine.
Crank Terminate (Starter Motors) An adjustable engine
speed setting that gives protection to the starter motor Time Delay Relays These relays are special ON/OFF
from damage by overspeed. This condition will cause a switches with two controls that will either make the relay
switch to open that stops current flow to starter motor activate immediately, or after a 9 second delay. One of
circuit, and the starter motor pinion gear will then the time delay relays is used to arm the shutdown
disengage from engine flywheel ring gear. system, and the other time delay relay controls the oil
pressure circuits for the two oil pressure switches. Both
Engine Reversal A condition where the engine starts to time delay relays have a 70 second OFF delay to be sure
run backwards. This will cause a change in the signal of complete engine shutdown.
from the TSS, which will close a switch to cause the fuel
to be shut off to the engine. Slave Relays These are standard type relays that, when
energized, have contacts that open across one circuit
Engine Step Oil Pressure An adjustable engine speed and close across another circuit. When activated, one of
setting that gives protection to the engine from a failure the relays causes the fuel to be shut off, and the other
caused by not enough oil pressure. To maintain desired relay causes the inlet air to be shut off.
protection through the complete speed range of engine
operation, two different oil pressure
460
ELECTRIC PROTECTIVE SYSTEM SYSTEMS OPERATION
AIR SHUTOFF SOLENOID

1. Air shutoff housing. 2. Air shutoff solenoid. 3.
WATER TEMPERATURE CONTACTOR SWITCH After-cooler housing.
1. Regulator housing. 2. Contactor switch.
TACHOMETER SPEED SENSOR (TSS) JUNCTION BOX CLOSED

1. Tachometer speed sensor. 2. Service meter. 3. 1. Junction box. 2. Fuel shutoff switch. 3. Circuit
Tachometer drive housing. breakers. 4. Magnetic pickup. 5. Electric governor
actuator (EGA).
LEFT SIDE OF ENGINE

1. Enclosure group.
JUNCTION BOX OPENED
1. Terminal strips. 2. Electronic speed switch
(ESS). 3. Slave relays. 4. Time delay relays. 5. Oil
pressure switches. 6. Circuit breakers.
461
The information that follows show the current flow through the wiring schematic. As switches are
opened or closed, either automatically or manually, the current flow of the individual circuit affected is
shown schematically.
Also included (on each facing page) is a story that explains all the components involved for this
particular condition, and why the current will take the path shown.
ENGINE STOPPED (Fig. 1)
With the engine stopped, power is always available across terminals 3 and 4 of time delay relays
(TD1 and TD2) and across terminals 5 and 6 of electronic speed switch (ESS). At this time all switches
are in their normally open or normally closed positions.
462
ENGINE STOPPED
Fig. 1
463
MANUAL START Deleted.
Air Starter Motor

(Current Flow Not Shown in Fig. 2) Deleted.
464
STARTING ENGINE WITH ELECTRIC STARTER MOTORS Deleted
465
ENGINE STARTS TO RUN: NO FAULTS Deleted
466
ENGINE STARTS TO RUN: NO FAULTS Deleted
467
ENGINE RUNS AT RATED SPEED: NO FAULTS Deleted
468
ENGINE RUNS AT RATED SPEED: NO FAULTS Deleted
469
ENGINE SHUTDOWN DUE TO FAULT:

LOSS OF ENGINE OIL PRESSURE
(AT ENGINE SPEEDS ABOVE OIL STEP
SPEED SETTING)Deleted
470
ENGINE SHUTDOWN DUE TO FAULT: LOSS OF ENGINE OIL PRESSURE

(AT ENGINE SPEEDS ABOVE OIL STEP SPEED SETTING) Deleted
471
ENGINE RUNNING BELOW OIL STEP SPEED

SETTING: NO FAULTS
(OR JUST ACCELERATING THROUGH STEP
SPEED) Deleted
472
ENGINE RUNNING BELOW OIL STEP SPEED SETTING: NO FAULTS

(OR JUST ACCELERATING THROUGH STEP SPEED) Deleted
473

LOW OIL PRESSURE
(AT ENGINE SPEEDS BELOW OIL STEP SPEED
SETTING)Deleted
474
ENGINE SHUTDOWN DUE TO FAULT: LOW OIL PRESSURE

(AT ENGINE SPEEDS BELOW OIL STEP SPEED SETTING) Deleted
475

COOLANT OVERHEATING Deleted
476
ENGINE SHUTDOWN DUE TO FAULT: COOLANT OVERHEATING Deleted
477

ENGINE OVERSPEED Deleted
478
ENGINE SHUTDOWN DUE TO FAULT: ENGINE OVERSPEED Deleted
479

ENGINE REVERSAL Deleted
480
ENGINE SHUTDOWN DUE TO FAULT: ENGINE REVERSAL Deleted
481
SHUTDOWN SYSTEM WITH 2301 ELECTRIC

GOVERNOR CONTROL: NO FAULTS Deleted
482
SHUTDOWN SYSTEM WITH 2301 ELECTRIC GOVERNOR CONTROL: NO FAULTS Deleted
483
INTRODUCTION TO THE TROUBLESHOOTING GUIDE
The troubleshooting guide, when followed exactly as shown, can be an aid for the serviceman to find
if a problem exists, and to find the cause of the existing problem.

FUNCTIONAL TESTS
These tests are to be performed on an engine that is started for the first time and at recommended
check intervals. They consist of quick and easy procedures for each system that can immediately identify
if there is a problem in that system with a minimum amount of test time. If a problem is found, go to the
correct chart of the more specific troubleshooting procedures.

TROUBLESHOOTING PROCEDURES
The troubleshooting charts that follow show a definite sequence to be followed for a logical, one by
one elimination of many variables. There are specific procedures written to check out different
components of the system, and they can be found at the end of the troubleshooting charts. When the
chart makes reference to a specific procedure, do this procedure before proceeding any farther in the
chart.
When a problem is found and corrected, always check the system again by use of verify procedure
as shown at bottom of charts.
Some areas of the charts say to go to an alphabetical letter. When told to go to this specific letter,
find this letter with a circle around it in the chart. Follow the test procedures from this point to the bottom
of the chart.
484
ELECTRIC PROTECTIVE SYSTEM FUNCTIONAL TEST
Check each system of the engine as shown to verify if all components of the protective system works
properly. To find the correct engine speed, make reference to SPEED SPECIFICATION CHART in
troubleshooting procedures for overspeed verify test (Procedure D).
TEST I. OVERSPEED (AIR AND FUEL SHUT-OFF)
STEP RUN ENGINE AT: ACTION CORRECT RESULT

A. 25 ± 5 rpm Less Than Verify rpm Press 75% Verify Button No Engine Shutdown
(75% Overspeed)
B. 25 ± 5 rpm More Than Verify Press 75% Verify Button Air and Fuel Shut-off
rpm (75% Overspeed)
C. Manually Reset Air Shut-off Lever At Top Of Air Inlet Housing and Press ESS Reset Button.
TEST II. REVERSAL AND CRANK

TERMINATION (FUEL SHUT-OFF ONLY)
STEP RUN ENGIN AT: ACTION CORRECT RESULT

A. Any Speed Above Crank Put Jumper Across Terminals Fuel Shut-off
Terminate rpm ESS-16 & ESS-17
B. Remove Jumper From Terminals ESS-16 and ESS-17
TEST III. NORMAL SHUT-OFF SWITCH (FUEL SHUT-OFF ONLY)

A. Any Speed Above Crank Push Shut-off Switch to OFF Fuel Shut-off
Terminate rpm Position
TEST IV. OIL PRESSURE (FUEL SHUT-OFF ONLY)

A. 25 ± 5 rpm Less Than Oil Step Put Jumper Across Terminal 1 No Engine Shutdown
Speed & Terminal 2 of Oil Pressure
Switch OPS2
B. - Remove OPS2 -
C. Same Speed as Step A Put Jumper Across Terminal 1 Fuel Shut-off After 9 ± 1
& Terminal 3 of Oil Pressure Seconds
Switch OPS1
D. - Remove Jumper From OPS1 -
E. 25 ± 5 rpm More Than Oil Step After 9 Seconds, Put Jumper Fuel Shut-off
Speed Across Terminals 1 and
Terminal 2 (OPS2)
F. Remove Jumper From OPS2 Terminals 1 and 2
TEST V. WATER TEMPERATURE (FUEL SHUT-OFF ONLY)

A. Any Speed Above Crank Put Jumper Across Terminals Fuel Shut-off
Terminal rpm TS11 & TS 22
B. Remove Jumper From Terminals TS11 and TS 22
485
SYSTEM PROBLEM INDEX
Engine Will Not Start Chart Page
Overspeed Switch Closed (Battery Voltage at Speed Switch Terminal ESS-7).................... A 33

Overspeed Trips (Light ON) When Power is First Applied With Engine
Stopped ......................................................................................................................... A 33
Reversal Indication (System Voltage Across Strip Terminals TS-21 & TS-27)..................... D 38
Speed Switch Will Not Reset After Reversal Shutdown Indication ....................................... D 39
Starter Motor Cranks Intermittently ....................................................................................... B 34
Starter Motor Cranking Stops Too Soon ............................................................................... B 34
Starter Motor Will Not Crank ................................................................................................. B 35
Engine Runs, But There is Still a Problem:
Overspeed Trips (Light ON) at Wrong Speed ....................................................................... A 32

Overspeed Trips Intermittently (Light ON and OFF) With Engine Running .......................... A 32
Overspeed Will Not Trip (Light OFF) During 75% Overspeed Verify Test ........................... A 32
Reversal Trips Intermittently (Light ON and OFF) ............................................................... D 39
Starter Motor Cranking Stops at Wrong Speed..................................................................... B 34
Starter Motor Will Not Disengage ......................................................................................... B 35
Engine Will Not Shut Down:
Engine RPM is Above Oil Step RPM and Engine Oil Pressure is Lower
Than Preset Value (35 psi), But No Engine Shutdown.................................................. C 36
Engine RPM is Below Oil Step RPM and Engine Oil Pressure is Lower
Than Preset Value (15 psi), But No Engine Shutdown.................................................. C 36
Overspeed Trips (Light ON), But No Engine Shutdown ........................................................ A 33
Reversal Conditions Exist (Actual or Simulated), But No Engine Shutdown......................... D 38
486
SYSTEM TROUBLESHOOTING CHARTS
toggle switch to control the electric starter motor

NOTE B: Do Not Leave Starter Motor Engaged With magnetic switch (install the switch in series with
Engine Running. Engines that have electric the magnetic switch coil lead).
starter motor(s), or a DC actuated air
starter motor, automatically disengage 3. Manually disengage by installing a toggle
when crank termination rpm is reached. switch to control the air starter solenoid
Positive (+) battery voltage is removed from valve (install the switch in series with either
the engine mounted or remote mounted of the solenoid valve leads).
starter controls when the normally closed
crank termination contacts open. To
perform test measurements, one of the
methods that follow may be necessary to
disengage the starter motor: NOTE: For wiring diagrams and schematics, make
reference to Wiring Diagrams Section.
1. Disconnect wire at speed switch
terminal ESS-12.
2. Manually disengage by installing a
487
TROUBLESHOOTING (OVERSPEED)
CHART A.
488
CHART A (Continued)
489
TROUBLESHOOTING (CRANK TERMINATE)
CHART B.
490
CHART B (Continued)
491
TROUBLESHOOTING (STEP OIL PRESSURE)
CHART C.
492
CHART C (Continued)
493
TROUBLESHOOTING (REVERSAL DETECTION)
CHART D.
494
CHART D (Continued)
495
ELECTRIC PROTECTIVE SYSTEM TROUBLESHOOTING
PROCEDURE A
5N1955 ELECTRONIC SPEED SWITCH
1. Verify button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed). 5. Seal
screw plug (crank terminate). 6. Seal screw plug (oil step).
OVERSPEED SETTING CALIBRATION (counterclockwise) slowly until "LED" overspeed

light (3) comes on. Engine will shutdown if
1. Remove lockwire and seal from seal screw plugs speed switch is connected to the fuel shutoff
(4), (5) and (6). Remove seal screw plug (4) solenoid and/or air inlet shutoff solenoid.
from access hole for overspeed adjustment
screw. 5. To reset speed switch, push in reset button (2).
Air inlet shutoff must be manually reset.
2. Use a small screwdriver and lightly turn
overspeed adjustment potentiometer twenty 6. Slowly turn overspeed adjustment potentiometer
turns in the direction of "MAX ARROW" approximately one turn clockwise and do Steps
(clockwise). 3, 4 and 5 again.
NOTE: The overspeed adjustment screw is made so NOTE: More adjustment may be needed to get the
that it can not cause damage to the potentiometer, or be correct setting. Turn adjustment potentiometer
removed, if the adjustment screw is turned too many clockwise to increase speed setting, and
turns in either direction. counterclockwise to decrease speed setting. Turn
adjustment potentiometer very slowly only a small
3. Run engine at 75% of desired overspeed setting amount at a time until adjustment is correct.
rpm. Make reference to the SPEED
SPECIFICATION CHART (Part of PROCEDURE 7. When the speed setting is correct, install seal
D). screw plug (4) in overspeed adjustment access
hole. Tighten screw to a torque of 0.20 ± 0.03
4. With engine at 75% of overspeed setting rpm, N•m (2 ± .3 lb. in.). Install the lockwire and seal
push VERIFY button (1) and hold in. Turn (if crank termination and oil step adjustments are
overspeed adjustment potentiometer in the complete).
direction opposite of "MAX ARROW"
496
PROCEDURE B
1. Verify button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed). 5. Seal screw plug (crank
terminate). 6. Seal screw plug (oil step).
CRANK TERMINATE SPEED ADJUSTMENT disengages). See the SPEED SPECIFICATION

CHART (Part of PROCEDURE D) for the correct
1. Remove lockwire and seal from seal screw plug crank terminate speed.
(4), (5) and (6). Remove seal screw plug (5)
from the access hole for crank terminate NOTE: If setting is not correct, do Steps 5, 6 and 7. If
adjustment screw. setting was correct, go to Step 7.
2. Use a small screwdriver and lightly turn the 5. Stop the engine and turn the crank terminate
crank terminate adjustment potentiometer twenty adjustment potentiometer one full turn in the
turns in the direction of "MAX ARROW" correct direction (clockwise to increase and
(clockwise). counterclockwise to decrease).
NOTE: The crank terminate adjustment screw is made 6. With the voltmeter still connected as in Step 4,
so that it can not cause damage to the potentiometer, or start the engine and make a note of the speed at
be removed, if the adjustment screw is turned too many which the system voltage is canceled (this is the
turns in either direction. speed at which the DC starter system
disengages). If needed, make more small
3. Turn the crank terminate adjustment adjustments until the crank terminate speed is
potentiometer twelve turns in a direction opposite correct.
of "MAX ARROW" (counterclockwise) for an
approximate crank terminate setting. 7. Install seal screw plug (5) in crank terminate
adjustment access hole. Tighten to a torque of
4. Connect a voltmeter (6V3030 Multimeter or a 0.20 ± 0.03 N.m (2 ± .3 lb. in.). Install the
voltmeter of same accuracy) with the positive lockwire and seal (if overspeed and oil step
lead at ESS-12 and the negative lead at ESS-5. adjustments are complete).
Start the engine and make a note of the speed at
which the system voltage is canceled (this is the
speed at which the DC starter system
497
PROCEDURE C
1. Verify button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed). 5. Seal screw plug
(crank terminate). 6. Seal screw plug (oil step).
OIL STEP CALIBRATION column for Oil Step Speed Setting. Run the
engine at this specified rpm.
1. Remove the lockwire and seal from seal screw
plugs (4), (5) and (6). Remove seal screw plug 5. With the engine running, look into the oil step
(6) from access hole for the oil step adjustment adjustment access hole. A red "LED" (light
screw. emitting diode) light will be on. After an 8 to 10
second delay, positive (+) voltage will be seen at
2. Use a small screwdriver and lightly turn oil step terminal ESS-13. Now turn the oil step
adjustment potentiometer 20 turns in the adjustment potentiometer clockwise until the red
direction opposite of "MAX ARROW" light in the oil step access hole goes out. When
(counterclockwise). This will lower the oil step the light goes out, this indicates that the oil step
speed setting to its lowest value. rpm setting is above the present running rpm of
the engine. Slowly turn the adjustment
NOTE: The oil step adjustment screw is made so it can potentiometer counterclockwise until the light
not cause damage to the potentiometer, or be removed, comes back on. After an 8 to 10 second delay,
if the adjustment screw is turned too many turns in either positive (+) voltage will be seen at terminal ESS-
direction. 13.
3. Use a 6V3030 Multimeter (or a voltmeter of 6. When the oil step setting is correct, install seal
same accuracy) to check for positive (+) voltage screw plug (6) into the adjustment access hole
at terminal ESS-13 [negative (-) voltage is at for the oil step function. Tighten plug to a torque
terminal ESS-5]. of 0.20 ± 0.03 N•m (2 ± .3 lb. in.). If all other
adjustments are complete (overspeed and crank
4. Make reference to SPEED SPECIFICATION terminate), install lockwire and seal.
CHART (Part of PROCEDURE D). For a
particular engine rating, find the specified rpm in
498
PROCEDURE D
1. Verify button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed). 5. Seal screw plug
OVERSPEED VERIFY TEST stay on until the reset button is pushed after an
overspeed switch shutdown. To restart the engine,
1. Run the engine at rated speed and push verify push in reset button (2) for a moment. This will reset the
button (1) in for a moment. This will cause the speed switch, and the "LED" overspeed light (3) will go
speed switch to activate and shutdown the off. The air inlet shutoff lever must now be manually
engine. reset before the engine can be started.
NOTE: Any time the engine speed is 75% or more of the NOTE C: To verify overspeed shutdown system
overspeed setting, the engine will shutdown if the verify operation, push in the VERIFY button for a moment. The
button is pushed. engine must shutdown at 75% or more of overspeed
setting.
EXAMPLE: For an engine with a rated speed of 1800
rpm, the overspeed setting is 2125 rpm (see SPEED NOTE D: Input Voltage: Maximum 40 VDC; Minimum 8
SPECIFICATION CHART and Note E). The overspeed VDC.
verify test will shutdown the engine at 75% (± 25 rpm) of
the overspeed setting of 2125 rpm. In this example, 75% NOTE E: The engine overspeed setting rpm is 118% of
of 2125 rpm is approximately 1600 rpm. If the verify rated engine rpm.
button is pushed at an engine speed of approximately
1600 rpm or above, the engine will shutdown.
The "LED" overspeed light (3) will come on and
SPEED SPECIFICATION CHART (RPM)

TYPICAL RATED OVERSPEED 75% OVERSPEED OIL STEP SPEED CRANK TERMINATE
ENGINE SPEED SETTING (±25) NOTE VERIFY (±25) NOTE SETTING
E C
1800 2125 1600 1125 600
1600 1890 1415 1125 600
1500 1775 1325 1125 600
1300 1535 1150 750 400
1200 1415 1060 750 400
1000 1180 885 750 400
900 1065 800 750 400
499
PROCEDURE E
1. Verily button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed). 5. Seal screw plug
REVERSAL DETECTION Assembly according to Procedure F.
1. Stop the engine and reverse the wires from NOTE: Different wiring connections must be used for
PICKUP terminals SW1 (ESS-1) and SW2 engines with different rotation. For a specific engine
(ESS-2) [this will simulate an engine reversal rotation, use the correct connections that follow:
when the engine is cranked at least two full
revolutions]. Connect the 6V3030 Multimeter or
a voltmeter between terminals ESS-16 and ESS- *STANDARD ROTATION (Counterclockwise)
5. Crank the engine at least two full revolutions Connect -
and check for positive (+) voltage at ESS16. If White wire from sensor assembly to
voltage is indicated, the reversal detection is PICKUP terminal SW1 (ESS-1).
functioning properly.
Dark green wire from sensor assembly to
2. To reset the reversal function, connect again PICKUP terminal SW2 (ESS-2).
SW1 wire (white) back on terminal ESS-1 and
SW2 wire (dark green) back on terminal ESS-2. *REVERSE ROTATION (Clockwise)
Crank the engine at least two full revolutions and Connect -
check for positive (+) voltage at ESS-16. No Dark green wire from sensor assembly to
voltage should be indicated. PICKUP terminal SW1 (ESS-1)
3. If no voltage is indicated, then reversal function White wire from sensor assembly to
has reset correctly. PICKUP terminal SW2 (ESS-2).
4. If voltage is still indicated, crank the engine again *Rotation as viewed from flywheel end of engine.
and check PICKUP wires for proper connection.
If voltage is still indicated, check 7N7412 Sensor
500
PROCEDURE F
7N7412 SENSOR ASSEMBLY VERIFY

A. Slowly turn the shaft of 7N7412 Sensor
NOTE : For bench testing, connect a voltage source with Assembly (2) one full turn in a
a range from 8-40 VDC (24 VDC preferred) across the counterclockwise direction [as viewed from
electronic speed switch (ESS) terminals ESS-5 and drive end (4)]. and watch the voltage indication.
ESS-6. Terminal ESS-5 is the battery negative terminal, A 4 to 6 VDC reading should be seen for all but
and ESS-6 is the battery positive terminal. one small area of the shaft rotation. Mark the
position of the shaft where the voltage reading
was zero volts. This point is called SW1 00
reference point.
NOTE : If no voltage is indicated between terminal SW1

(ESS-1) and terminal ESS-5 through one full turn of the
sensor shaft rotation, check speed switch for proper
voltages. A voltage of 4 to 6 VDC should be seen across
terminals ESS-4 and ESS-5. If speed switch voltage is
correct, then either the sensor is defective or the wiring
from the sensor to the speed switch is defective.
INSTALLED SENSOR ASSEMBLY After finding SW1 0° reference point (the position
(Position shown is for RH rear of engine) where zero voltage was measured on the sensor), an
1. Tachometer drive housing. 2. 7N7412 Sensor additional zero volts indication will be measured once for
Assembly. 3. Sensor harness connector. 4. Sensor every 900 of shaft rotation from the 0° reference point by
drive end. using the sequence that follows:
1. Disconnect 7N7412 Sensor Assembly (2) from B. Connect the positive (+) voltmeter lead to SW2
engine tachometer drive housing (1). Set the (ESS-2) and leave the negative (-) voltmeter lead
voltmeter (6V3030 Multimeter or a voltmeter of connected to ESS-5. Now slowly turn the
same accuracy) voltage scale to a scale higher sensor shaft counterclockwise. A 4 to 6 VDC
than 6 VDC. Connect the voltmeter to the 5N reading should be seen for all but one small area
1955 Electronic Speed Switch with the positive of shaft rotation at an interval 900 from the SW1
0°
(+) voltmeter lead connected to SW1 (ESS-1) reference point. Zero volts will be indicated at
and the negative (-) voltmeter lead connected to this area.
terminal ESS-5 (-).
SW2 CHECK
SW1 CHECK
501
C With the negative (-) voltmeter lead still

connected to ESS-5, connect the positive ( + )
voltmeter lead to SW3 (ESS-3). Again, slowly
turn the sensor shaft counterclockwise. A 4 to 6
VDC reading should be seen for all but two small
areas of shaft rotation; one at the 1800 interval
and one at the 2700 interval (both measured
from the SWI 0° reference point). Zero volts will
be indicated at both of these areas.
SW3 CHECK
2. If all four zero volt levels are recorded in the

proper sequence and at the proper degree of
rotational position (900 apart from each other),
then the 7N7412 Sensor Assembly operates
properly.
3. Before installing 7N7412 Sensor Assembly (2)

back on the engine, start the engine and check
to be sure that the drive shaft in tachometer
drive housing (1) is turning properly.
4. If tachometer drive shaft is in rotation, stop

engine and install sensor assembly.
NOTE: The tachometer drive housing has two output

drives (one marked A and the other marked B).
Be sure that sensor assembly is always
connected to output drive marked A.
502
PROCEDURE G
ON/OFF TIME DELAY (RELAY)

2. (a) Apply positive (+) source voltage to terminal
1 (either relay) and immediately verify the
chart that follows (do not leave voltage on
terminal 1 for more than 60 seconds):
Terminals Relay Position

5 Open
7 Closed
(b) Remove positive (+) source voltage from

terminal 1. Use a stop watch and check the
time from the moment of removal to verify
chart that follows:
Terminals Delay Time to Function

0 to 60 Secs. After 80 Secs.
5 Open Closed
7 Closed Open
ON/OFF DELAY (RELAY)
2.
NOTE: If bench testing, Step 3 can be used with either
relay. When installed on engine, Step 3 can only be
checked with TD2. Do not apply positive (+) voltage
to terminal 2 of TD1, or a direct short will result.
Performance Check (either TD1 or TD2 relays can be
checked with methods that follow)
Check the time from the moment voltage is
applied to verify chart that follows (do not leave
A. Items Required For Check:
voltage on terminal 2 for more than 60 seconds):
1. Battery or any D. C. source of 8 to 40 volts.
2. Voltmeter (6V3030 Multimeter or one of Terminals Delay Time to Function

same accuracy). 0 to 8 Secs. After 10 Secs.
5 Closed Open
3. Stop watch. 7 Open Closed
B. Bench Or Installed Test (b) Remove positive (+) source voltage from
terminal 2. Check the time from the moment
Connect or verify source voltage to relay of removal to verify chart that follows:
terminals 3 (-) and 4 (+) [if bench testing, also connect
positive (+ ) voltage to relay terminal 6]. All connections Terminals Delay Time to Function
must be maintained until tests are complete. 0 to 60 Secs. After 80 Secs.
5 Open Closed
NOTE: There will be voltage when the relay is closed. 7 Closed Open
When relay is open, there will be no voltage [voltage may
be positive (+) or negative (-) when relay is tested on 4. Remove wire from terminal 4 and verify chart that
engine; when bench testing, voltage will always be follows:
positive (+)].
1. Use the voltmeter to verify chart that follows:
5 Closed
2.
7 Open
5 Closed
7 Open
503
ELECTRIC PROTECTIVE SYSTEM WIRING DIAGRAMS
(REF 5N360)
ALT ALTERNATOR OPS OIL PRESSURE SWITCH

AMM AMMETER OPSS OIL PRESSURE STEP SWITCH
ASOS AIR SHUT-OFF SOLENOID OPSU OIL PRESSURE SENDING UNIT
ASSV AIR START SOLENOID VALVE OSI OVERSPEED INDICATOR
B- BATTERY NEGATIVE OSS OVERSPEED SWITCH
B+ BATTERY POSITIVE PB PUSH BUTTON
BATT BATTERY PP PRELUBE PUMP
CB CIRCUIT BREAKER PPMS PRELUBE PUMP MAGNETIC SWITCH
CT CRANK TERMINATE PPPS PRELUBE PUMP PRESSURE SWITCH
D DIODE PS PINION SOLENOID
EGA ELECTRIC GOVERNOR ACTUATOR RES RESISTOR
EGC ELECTRIC GOVERNOR CONTROL RESS REMOTE EMERGENCY SHUT-OFF
SWITCH
ERI ENGINE REVERSAL INDICATOR RNS REMOTE NORMAL SHUT-OFF SWITCH
ERS ENGINE REVERSAL SWITCH RSS REMOTE START SWITCH
ESS ELECTRIC SPEED SWITCH SM STARTER MOTOR
FSOS FUEL SHUT-OFF SOLENOID SMMS STARTER MOTOR MAGNETIC SWITCH
HWTAS HIGH WATER TEMPERATURE ALARM SWITCH SR SLAVE (SHUTDOWN) RELAY
LOPAS LOW OIL PRESSURE ALARM SWITCH TD TIME DELAY
LWTAS LOW WATER TEMPERATURE ALARM SWITCH TM TACHOMETER
MGOPG MARINE GEAR OIL PRESSURE GAGE TS TERMINAL STRIP
MGOPSU MARINE GEAR OIL PRESSURE SENDING UNIT TSS TACHOMETER SPEED SENSOR
MGOTAS MARINE GEAR OIL TEMPERATURE ALARM SWITCH WTG WATER TEMPERATURE GAGE
MPU MAGNETIC PICK-UP WTI WATER TEMPERATURE INDICATOR
NSS NORMAL SHUT-OFF SWITCH WTS WATER TEMPERATURE SWITCH
OPG OIL PRESSURE GAGE WTSU WATER TEMPERATURE SENDING
UNIT
OPI OIL PRESSURE INDICATOR Z ZENER DIODE
WIRE COLOR CODE

ABBREVIATIONS
B BLACK
BR BROWN
DK BL DARK BLUE
DK GR DARK GREEN
GR GREEN
LT BL LIGHT BLUE
O ORANGE
0/B ORANGE WITH BLACK STRIPE
PU/W PURPLE WITH WHITE STRIPE
R RED
W WHITE
Y YELLOW
504
ELECTRIC PROTECTIVE SYSTEM SCHEMATIC

NOTE A: Terminal strip jumpers between terminals TS17 & TS18 and TS19 & TS20 are not required for low oil
pressure and high water temperature alarms.
NOTE B: The wire at terminal strip between terminals TS26 & TS27 is in the wiring harness when a UG8D or UG8L
is installed. No wire is required when an EGA is used.
NOTE C: This wire is provided by customer if electric starter motor(s) are not used.
505
3500 ENGINE WIRING DIAGRAM (REF 5N8944)

(All Possible Combinations)
NOTE A: Reverse wires at SW1 and SW2 for reverse rotation engines.
NOTE B: Jumper required only with UG8D and UG8L governors.
506
TYPICAL JUNCTION BOX WIRING DIAGRAM (REF 5N8944)
NOTE A: Terminal strip jumpers between terminals T817 & TS818 and TS819 T820 are not required on Marine
Engines which have alarms only for low oil pressure and high water temperature.
NOTE B: Earlier circuit breakers were as follows: CB3 and CB5, 15 amp; CB4, 4 amp.
507
JUNCTION BOX (REF 5N8513)

*Nomenclature in ( ) indicates former identification
508
JUNCTION BOX WIRING HARNESS (REF 5N8511)
509
CUSTOMER WIRING WITH ELECTRIC PROTECTIVE SYSTEM (NOTE A)
510
NOTE A: Wire, cable and components shown with dotted lines are to be added by customer. See
wire and cable gage charts for size selection.
NOTE B: Do not use remote emergency switch for normal engine shutdown. The use of emergency
switch requires manual reset of air shut-off at top of air inlet housing.
NOTE C: Caterpillar alarm and prealarm contacts are rated for a maximum of 3 amps inductive at the
charging system voltage.
NOTE D: Switch to be a single pole, normally open switch (may be latching if desired) with a minimum
contact rating of .5 amp inductive at the charging system voltage.
NOTE E: Switch to be a single pole, normally open switch (may be latching if desired) with a minimum
contact rating of 1 amp inductive at the charging system voltage.
NOTE F: Magnetic pick-up and oil pressure switch to be wired to electric governor control (Woodward
2301) with a two conductor shielded cable (Belden Corp. type 8780 or equivalent). Shields
are to be grounded at electric governor control grounding stud. Each shield should not have
more than one ground connection.
NOTE G: Woodward 2301 Electric Governor Control terminal identification chart:
SYMBOL FUNCTION STAND-BY LOAD SHARING

TS NO. TS NO.
P Batt + 2 12
R Batt - 1 13
S EGA + 6 17
T EGA - 5 16
U Mag Pick-up 7 18
V Mag Pick-up 8 19
Y Oil Pressure Speed Limiter 9 14
Z Oil Pressure Speed Limiter 10 15
511/(512 Blank)
FORM NO. SENR2985
SYSTEMS OPERATION
TROUBLESHOOTING
FOR
GENERATOR SET, INDUSTRIAL AND

MARINE ENGINES
513
INTRODUCTION
The electric protective system is designed to activate an The electric protective system consists of the basic
alarm or shut the engine off if there is a problem or a components that follow: magnetic pickup, electronic
failure in any of four different engine systems. The speed switch, water temperature contactor switch, two
engine systems monitored are: engine overspeed, time delay relays and two slave relays. This system
starter motor crank terminate, engine oil pressure and monitors the engine from starting through rated speed.
engine coolant temperature.
COMPONENT DESCRIPTION
Magnetic Pickup (MPU) The magnetic pickup is a operation, two different oil pressure switches are used
single pole, permanent magnet generator made of wire [280 kPa (40 psi), 140 kPa (20 psi)]. Once the step oil
coils around a permanent magnet pole piece. pressure speed setting is made, an engine that runs
above this speed setting must maintain an oil pressure
As the teeth of the flywheel ring gear go through the that is more than 280 kPa (40 psi). An engine that runs
magnetic lines of force around the pickup, an AC voltage at a speed below this speed setting must maintain an oil
is made. A positive voltage is made when each tooth pressure that is more than 140 kPa (20 psi). If either
goes by the pole piece. Each time the space between condition is not correct, a switch will close to activate an
the teeth goes by the pole piece, a negative voltage is alarm or cause the fuel to be shut off to the engine.
made. Engine speed is then determined by the
frequency of these signals. Water Temperature Contactor Switch This contactor
switch is a separate unit (mounted in the regulator
Electronic Speed Switch (ESS) The 4W2218 Electronic housing) that is wired into the shutdown circuit. It has an
Speed Switch can easily be identified by its black color element that feels the temperature of the coolant (it must
(the earlier speed switch was yellow). This speed switch be in contact with the coolant). When the engine coolant
has controls (in a single unit) to monitor three of the temperature becomes too high, the switch closes to
basic functions. These three functions are: activate an alarm or cause the fuel to be shut off to the
engine.
Engine Overspeed An adjustable engine speed setting
(normally 118% of rated speed) that gives protection to Time Delay Relays These relays are special ON/OFF
the engine from damage if the engine runs too fast. This switches with two controls that will either make the relay
condition will cause a switch to close that shuts off both activate immediately, or after a 9 second delay. One of
the inlet air and the fuel to the engine. the time delay relays is used to arm the shutdown
system, and the other time delay relay controls the oil
Crank Terminate (Starter Motors) An adjustable engine pressure circuits for the two oil pressure switches. Both
speed setting that gives protection to the starter motor time delay relays have a 70 second OFF delay to be sure
from damage by overspeed. This condition will cause a of complete engine shutdown.
switch to open that stops current flow to starter motor
circuit, and the starter motor pinion gear will then Slave Relays These are standard type relays that, when
disengage from engine flywheel ring gear. energized, have contacts that open across one circuit
and close across another circuit. When activated, one of
Engine Step Oil Pressure An adjustable engine speed the relays will activate an alarm or cause the fuel to be
setting that gives protection to the engine from a failure shut off, and the other relay will cause the inlet air to be
caused by not enough oil pressure. To maintain desired shut off.
protection through the complete speed range of engine
514
WATER TEMPERATURE CONTACTOR SWITCH

AIR SHUTOFF SOLENOID
1. Regulator housing. 2. Contactor switch.
1. Air shutoff housing. 2. Air shutoff solenoid. 3.
After-cooler housing.
LOCATION FOR MAGNETIC PICKUP

(Later Engines)
1. Plug (one of three available locations on top of
flywheel housing).
JUNCTION BOX CLOSED

1. Junction box. 2. Fuel shutoff switch. 3. Circuit
breakers. 4. Magnetic pickup. 5. Electric governor
actuator (EGA).
JUNCTION BOX OPENED

1. Terminal strips. 2. Electronic speed switch
(ESS). 3. Slave relays. 4. Time delay relays. 5. Oil LEFT SIDE OF ENGINE
pressure switches. 6. Circuit breakers. 1. Enclosure group.
515
The information that follows show the current flow through the wiring schematic. As switches are
opened or closed, either automatically or manually, the current flow of the individual circuit affected is
shown schematically.
Also included (on each facing page) is a story that explains all the components involved for this
particular condition, and why the current will take the path shown.
ENGINE STOPPED (Fig. 1)
With the engine stopped, power is always available across terminals 3 and 4 of time delay relays
(TD1 and TD2) and across terminals 5 and 6 of electronic speed switch (ESS). At this time all switches
are in their normally open or normally closed positions.
516
ENGINE STOPPED
Fig. 1.
517
MANUAL START
Electric Starter Motors (Fig. 2)
When the start pushbutton (PB) or remote start switch (RSS) is

pushed, current will flow through starter motor magnetic switches (SMMSI
and SMMS2). With magnetic switches energized, contacts (SMMSI and
SMMS2) close and pinion solenoids (PS I and PS2) are energized. This
causes contacts (PS 1I and PS2) to close, and starter motors (SMI and
SM2) will now crank the engine. When engine starts to run and the rpm
increases to the speed of the crank terminate (CT) speed setting, the
ESS(CT) switch will automatically open across terminals ESS-l I and ESS-
12 to stop current flow to the start pushbutton.
Air Starter Motor

(Current Flow Not Shown in Fig. 2)
If engine has an air starter motor, current will flow through DC operated
air start solenoid valve (ASSV) when start pushbutton (PB or RSS) is
pushed. The ASSV will open the air supply to the air starter motor, which
will now crank the engine. When the engine starts to run and the rpm
increases to the speed of the crank terminate (CT) speed setting, ESS(CT)
switch will automatically open across terminals ESS-11 and ESS-12 to stop
current flow to ASSV pushbutton. This will move the valve to shut off the
air supply to the air starter motor.
518
STARTING ENGINE WITH ELECTRIC STARTER MOTORS
Fig. 2.
519
ENGINE STARTS TO RUN: NO FAULTS
When the engine starts to run, the speed will increase to the
speed setting of the ESS crank terminate function, and the ESS(CT)
switch across terminals ESS- I and ESS-12 will open. The current
flow is now stopped to the start pushbutton for the starter motor(s) as
shown in Fig. 3.
When the ESS(CT) switch (line 10) opens across terminals ESS-
11 and ESS-12, ESS(CT) switch (line 32) will close across terminals
ESS-11 and ESS-10. This closed switch will give current flow to
Control 1 (terminal 1) of time delay relay (TDI), and will immediately
close switch (TDI) across terminals TD1-6 and TDI-7 (line 25). The
complete protection system is now armed to activate an alarm or
cause engine shutdown if there is a fault in any of the three engine
systems now being monitored.
520
ENGINE STARTS TO RUN: NO FAULTS
Fig. 3.
521
ENGINE RUNS AT RATED SPEED: NO FAULTS
With no existing problems and engine running at

rated speed, or at some speed above the oil step
speed setting, the circuit will look like Fig. 4. The oil
pressure step switch (OPSS) at line 36 is now
closed, but oil pressure switch (OPS2) is now open,
so there is still no current flow to TD2. The engine will
continue to run with these conditions.
OPS2 will not open until there is at least 280 kPa

(40 psi) oil pressure available, and after opening, will
not close again until the oil pressure has dropped
below 240 kPa (35 psi). The ESS(OPSS) switch is
not activated to open until engine speed is the same
as, or above, the step oil pressure speed setting.
After it is activated, the ESS(OPSS) switch has a 9
second delay before it closes. This makes sure that
oil pressure has time to increase enough to open
OPS2, or system would constantly activate engine
shutdown.
522
ENGINE RUNS AT RATED SPEED: NO FAULTS
Fig. 4.
523

LOSS OF ENGINE OIL PRESSURE
(AT ENGINE SPEEDS ABOVE OIL STEP
SPEED SETTING)
The circuit of Fig. 5 shows the current flow if there is a fault in

the high pressure side of the oil pressure circuit. When engine
oil pressure drops below 240 kPa (35 psi), oil pressure switch
(OPS2) will close. Since the engine is running at a speed above
the step oil pressure setting, ESS(OPSS) switch is already
closed and the circuit is now completed to Control 1 (terminal 1)
of time delay relay (TD2). There is no time delay at Control 1,
so TD2 relay contacts (line 20) will close immediately across
terminals TD2-6 and TD2-7. This makes a complete circuit
from the battery through TDI contacts (line 25) to activate oil
pressure indicator (OPI) and to energize slave relay (SR1).
When SR1 is energized, contacts across terminals SR 1 - 1

and SR 1-2 open and contacts across terminals SR 1-1 and SR
1-3 close. The circuit is now completed to energize fuel shut-off
solenoid (FSOS), and the fuel is shut off to the engine.
524
ENGINE SHUTDOWN DUE TO FAULT: LOSS OF ENGINE OIL PRESSURE

(AT ENGINE SPEEDS ABOVE OIL STEP SPEED SETTING)
Fig. 5.
525
ENGINE RUNNING BELOW OIL STEP SPEED

SETTING: NO FAULTS
(OR JUST ACCELERATING THROUGH STEP
SPEED)
If engine continues to run below the step oil pressure

speed setting, oil pressure step switch (OPSS) will
remain open and will not complete the circuit to
shutdown as shown in Fig. 6. Since oil pressure has
increased enough to run at this speed (OPS I switch is
open), the engine can safely run at this speed and will
not be shut down.
If the engine is accelerating through oil step speed

setting, the circuit could still look as shown in Fig. 6.
When engine speed is the same as (or goes above) the
oil step speed setting engine oil pressure must increase
to 280 kPa (40 psi) to open oil pressure switch (OPS2)
within the 9 second time delay of the oil pressure step
switch ESS(OPSS). The OPSS switch will close after 9
seconds and, if OPS2 is still closed, engine will shut
down as shown in Fig. 5. If OPS2 has opened before
OPSS has closed, engine will continue to run as shown
in Fig. 4.
526
ENGINE RUNNING BELOW OIL STEP SPEED SETTING: NO FAULTS

(OR JUST ACCELERATING THROUGH STEP SPEED)
Fig. 6.
527

LOW OIL PRESSURE
(AT ENGINE SPEEDS BELOW OIL STEP SPEED
SETTING)
As engine is started and begins to run, crank terminate switch ESS(CT)

opens across terminals ESS-11 and ESS-12 and closes across terminals
ESS-11 and ESS-10. This immediately arms the system when current is
sent to Control I (terminal 1) of time delay relay (TD1), which closes TD1
relay contacts (line 25) across terminals TD1-6 and TDI-7.
At the same time that TD1 is armed, there is current flow to Control 2
(terminal 2) of time delay relay (TD2) if oil pressure switch (OPS I ) has not
yet opened. The engine oil pressure has 9 seconds (from the time that
TD1 is armed) to increase to the 140 kPa (20 psi) necessary to open
OPS1. If OPSI does not open, TD2 contacts will close across terminals
TD2-6 and TD2-7 and slave relay (SRI) will be energized. SR1 relay
contacts (line 42) will now open across terminals SRI-I and SRI-2, and SRI
relay contacts (line 40) will close across terminals SR1-1 and SR 1-3. The
fuel shut-off solenoid (FSOS) is now energized, and will shut the fuel off to
the engine.
If the engine had been running (with no faults) at a speed less than the
oil step setting, and then lost engine oil pressure, the protection system
would cause engine shutdown in the same way as shown in Fig. 7. OPS1
would close when oil pressure decreased to 105 kPa (15 psi), and 9
seconds later the engine would shut down.
528
ENGINE SHUTDOWN DUE TO FAULT: LOW OIL PRESSURE

(AT ENGINE SPEEDS BELOW OIL STEP SPEED SETTING)
Fig. 7.
529

COOLANT OVERHEATING
The current flow of the circuit shown in Fig. 8 is for an engine running at
a speed above the oil step setting with coolant temperature hot enough
[980C (2080F)] to close water temperature contactor switch (WTS).
When WTS closes, this completes the circuit through slave relay (SR1)
and through water temperature indicator (WTI). When slave relay (SR 1
) is energized, the contacts across terminals SR1-1 and SR1-3 will
close. Now the fuel shut-off solenoid (FSOS) is energized to shut the
fuel off to the engine.
After 70 seconds (when TDI contacts open), the engine can be started
again, but it will immediately be shutdown. The engine will not continue
to run until coolant temperature cools down enough to open switch
WTS.
NOTE: Engine shutdown caused by coolant overheating will also be the

same if the engine is running at a speed below the oil step setting.
530
ENGINE SHUTDOWN DUE TO FAULT: COOLANT OVERHEATING
Fig. 8.
531

ENGINE OVERSPEED
When engine speed increases above the overspeed setting ( 118% of

rated speed) of the electronic speed switch (ESS), the overspeed switch
ESS(OSS) will close across terminals ESS-7 and ESS-8 (line 23). This
completes the circuit from the battery through overspeed indicator (OSI)
and also through both slave relays (SRI and SR2) as shown in Fig. 9.
Both slave relays (SR1 and SR2) are now energized at the same time.
SR2 contacts will close across terminals SR2-1 and SR2-3 to activate air
shut-off solenoid (ASOS). ASOS will now shut the inlet air off to the
engine. At the same time, SRI contacts open across terminals SRI-I and
SRI-2 (Line 42) and close across terminals SRI-I and SR1-3 (line 40).
The fuel shut-off solenoid (FSOS) is now activated, and will shut the fuel
off to the engine.
A reset button on the ESS must be pushed to open the overspeed

switch ESS(OSS), and the air shut-off lever (at top of air inlet housing)
must be manually reset before the engine will run.
532
ENGINE SHUTDOWN DUE TO FAULT: ENGINE OVERSPEED
Fig. 9.
533
SHUTDOWN SYSTEM WITH 2301 ELECTRIC GOVERNOR CONTROL:

NO FAULTS
When the 2301 Electric Governor Control (EGC) is used, all systems of
the electronic speed switch (ESS) are activated the same way as shown
with a 3161, UG8D or a UG8L governor. The only difference in the circuit
is that the fuel shut-off solenoid (FSOS) at line 40 is not used, and a jumper
between terminal 26 and 27 is not used.
With the circuit shown in Fig. 10, current normally flows through electric
governor actuator (EGA). When a fault in the system causes current to
energize slave relay (SRI), the contacts open across terminals SR1-1 and
SR1-2 (line 42) and close across terminals SRI-I and SR1-3 (line 40).
When SR1 contacts open across terminals SR1-1 and SR1-2, the current
can no longer flow through the EGA. The mechanical spring load in the
EGA system will now move the fuel control rod to shut the fuel off to the
engine.
NOTE: Except for the differences shown above, all fault circuits for the ESS
system are the same for the EGC as those shown in Fig. 5 through Fig. 9
for the 3161 and UG8 governors.
534
SHUTDOWN SYSTEM WITH 2301 ELECTRIC GOVERNOR CONTROL: NO FAULTS

(CIRCUIT SHOWN AT RATED SPEED)
Fig. 10.
535
ELECTRIC PROTECTIVE SYSTEM FUNCTIONAL TEST
These tests are to be performed on an engine that is started for the first time
and at recommended check intervals. They consist of quick and easy procedures
for each system that can immediately identify if there is a problem in that system
with a minimum amount of test time. If a problem is found, go to the correct chart
of the more specific troubleshooting procedures.
Check each system of the engine as shown to verify if all components of the
shut-off system works properly. To find the correct engine speed, make reference
to SPEED SPECIFICATION CHART.
TEST I. OVERSPEED (AIR AND FUEL SHUTOFF)

A. 25 + 5 rpm Less Than Press 75% Verify No Engine
Verify rpm (75% Overspeed) Button Shutdown
B. 25 + 5 rpm More Than Press 75% Verify Air and Fuel
Verify rpm (75% Overspeed) Button Shut-off
C. Manually Reset Air Shut-off Lever At Top Of Air Inlet Housing and Press ESS Reset Button.
TEST II. NORMAL SHUTOFF SWITCH (FUEL SHUTOFF ONLY)

A. Any Speed Above Push Shut-off Switch Fuel Shut-off
Crank Terminate rpm To OFF Position
TEST III. OIL PRESSURE (FUEL SHUTOFF ONLY)
STEP RUN ENGINE AT: ACTION CORRECT

RESULT
A. 25 + 5 rpm Less Than Oil Put Jumper Across No Engine
Step Speed Terminal 1 & Terminal Shutdown
2 of Oil Pressure
Switch OPS2
B. Remove OPS2
--- Jumper -----
C. Same Speed as Step A Put Jumper Across Fuel Shut-off
After 9
Terminal 1 & Terminal + 1 Seconds
3 of Oil Pressure
sure Switch OPS1
D. ---- Remove Jumper -----
From OPSI
E. 25 + 5 rpm More Than Oil After 9 Seconds, Fuel Shut-off
Step Speed Put Jumper Across
Terminal 1 and Terminal
2 (OPS2)
F. Remove Jumper From OPS2 Terminals 1 and 2
TEST IV. WATER TEMPERATURE (FUEL SHUTOFF ONLY)

STEP RUN ENGINE AT: ACTION CORRECT
RESULT
A. Any Speed Above Put Jumper Across Fuel Shut-off
Crank Terminate rpm Terminals TS11 &
TS 22
B. Remove Jumper From Terminals TS11 and TS 22
536
SPEED SPECIFICATION CHART

OVERSPEED 75% OVERSPEED
TYPICAL RATED SETTING (+25) VERIFY ( +25) OIL STEP CRANK
ENGINE SPEED NOTE E NOTE C SPEED SETTING TERMINATE
1800 2125 1600 1125 600
1600 1890 1415 1125 600
1500 1775 1325 1125 600
1300 1535 1150 750 400
1200 1415 1060 750 400
1000 1180 885 750 400
900 1065 800 750 400
537
INTRODUCTION TO THE TROUBLESHOOTING GUIDE
The troubleshooting guide, when followed exactly as shown, can be an

aid for the serviceman to find if a problem exists, and to find the cause of
the existing problem.

AND PROCEDURES
The troubleshooting charts that follow show a definite sequence to be

followed for a logical, one by one elimination of many variables. There are
specific procedures written to check out different components of the
system, and they can be found at the end of the troubleshooting charts.
When the chart makes reference to a specific procedure, do this
procedure before proceeding any farther in the chart.
When a problem is found and corrected, always check the system

again by use of verify procedure as shown at bottom of charts.
Some areas of the charts say to go to an alphabetical letter. When

told to go to this specific letter, find this letter with a circle around it in the
chart. Follow the test procedures from this point to the bottom of the
chart.
538
PROBLEM IDENTIFICATION INDEX
Engine Will Not Start: Chart Page
Overspeed Switch Closed (Battery Voltage at Speed Switch Terminal ESS-7)......... B 33

Overspeed Trips (Light ON) When Power is First Applied With Engine
Stopped .................................................................................................................... B 33
Starter Motor Cranks Intermittently ........................................................................... C 34
Starter Motor Cranking Stops Too Soon ................................................................... C 34
Starter Motor Will Not Crank ..................................................................................... C 35
Engine Runs, But There is Still a Problem:
Overspeed Trips (Light ON) at Wrong Speed ............................................................ B 32

Overspeed Trips Intermittently (Light ON and OFF) With Engine Running ............... B 32
Overspeed Will Not Trip (Light OFF) During 75% Overspeed Verify Test................. B 32
Starter Motor Cranking Stops at Wrong Speed.......................................................... C 34
Starter Motor Will Not Disengage............................................................................... C 35
Engine Will Not Shut Down:
Engine RPM is Above Oil Step RPM Setting and Engine Oil Pressure is
Lower Than Preset Value (35 psi), But No Engine Shutdown ............................. D 36
Engine RPM is Below Oil Step RPM Setting and Engine Oil Pressure is
Lower Than Preset Value (15 psi), But No Engine Shutdown ............................. D 36
Normal Shutoff Switch in OFF Position (While Operating at Any Speed
Greater than Crank Terminate), But No Engine Shutdown ................................ A 31
Overspeed Trips (Light ON), But No Engine Shutdown ............................................ B 33
539

AND PROCEDURES
NOTE B. Do Not Leave Starter Motor Engaged With 2. Manually disengage by installing a
Engine Running. Engines that have electric toggle switch to control the electric
starter motor(s), or a DC actuated air starter starter motor magnetic switch (install
motor, automatically disengage when crank the switch in series with the magnetic
termination rpm is reached. Positive (+) switch coil lead).
battery voltage is removed from the engine
mounted or remote mounted starter controls 3. Manually disengage by installing a
when the normally closed crank termination toggle switch to control the air starter
contacts open. To perform test solenoid valve (install the switch in
measurements, one of the methods that series with either of the solenoid valve
follow may be necessary to disengage the leads).
starter motor:
NOTE: For wiring diagrams and schematics, make
1. Disconnect wire at speed switch reference to Wiring Diagrams Section.
terminal ESS-2.
540
TROUBLESHOOTING (SYSTEM ARMING)
CHART A.
541
TROUBLESHOOTING (OVERSPEED)
CHART B.
542
CHART B (Continued)
543
TROUBLESHOOTING (CRANK TERMINATE)
CHART C.
544
CHART C (Continued)
545
CHART D.
546
CHART D (Continued)
547
PROCEDURE A
4W2218 ELECTRONIC SPEED SWITCH (ESS)

1. Verify button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed).
5. Seal screw plug (crank terminate). 6. Seal screw plug (oil step).
OVERSPEED SETTING CALIBRATION 5. To reset speed switch, push in reset button (2).
Air inlet shutoff must be manually reset.
1. Remove lockwire and seal from seal screw plugs
(4), (5) and (6). Remove seal screw plug (4) 6. Slowly turn overspeed adjustment potentiometer
from access hole for overspeed adjustment approximately one turn clockwise and do Steps
screw. 3, 4 and 5 again.
2. Use a small screwdriver and lightly turn NOTE: More adjustment may be needed to get the
overspeed adjustment potentiometer twenty correct setting. Turn adjustment potentiometer
turns in the direction of "MAX ARROW" clockwise to increase, speed setting, and
(clockwise). counterclockwise to decrease speed setting. Turn
adjustment potentiometer very slowly only a small
NOTE: The overspeed adjustment screw is made so amount at a time until adjustment is correct.
that it can not cause damage to the potentiometer, or be
removed, if the adjustment screw is turned too many 7. When the speed setting is correct, install seal
turns in either direction. screw plug (4) in overspeed adjustment access
hole. Tighten screw to a torque of 0.20 + 0.03
3. Run engine at 75% of desired overspeed setting N-m (2 +.3 lb. in.). Install the lockwire and seal
rpm. Make reference to the SPEED (if crank termination and oil step adjustments are
SPECIFICATION CHART (Part of PROCEDURE complete).
D).
4. With engine at 75% of overspeed setting rpm,

push VERIFY button (I) and hold in. Turn
overspeed adjustment potentiometer in the
direction opposite of "MAX ARROW"
counterclockwise) slowly until "LED" overspeed
light (3) comes on. Engine will shutdown if
speed switch is connected to the fuel shutoff
solenoid and/or air inlet shutoff solenoid.
548
PROCEDURE B

1. Verify button. 2. Reset button. 3. "LED" overspeed light. 4. Seal screw plug (overspeed). 5. Seal screw
plug (crank terminate). 6. Seal screw plug (oil step).
CRANK TERMINATE SPEED ADJUSTMENT which the system voltage is canceled (this
1. Remove lockwire and seal from seal screw is the speed at which the DC starter system
plug (4), (5) and (6). Remove seal screw disengages). See the SPEED
plug (5) from the access hole for crank SPECIFICATION CHART (Part of
terminate adjustment screw. PROCEDURE D) for the correct crank
terminate speed.
2. Use a small screwdriver and lightly turn the NOTE: If setting is not correct, do Steps 5, 6 and 7.
crank terminate adjustment potentiometer If setting was correct, go to Step 7.
twenty turns in the direction of "MAX AR-
ROW" (clockwise). 5. Stop the engine and turn the crank
NOTE: The crank terminate adjustment screw is made terminate adjustment potentiometer one full
so that it can not cause damage to the potentiometer, or turn in the correct direction (clockwise to
be removed, if the adjustment screw is turned too many increase and counterclockwise to
turns in either direction. decrease).
3. Turn the crank terminate adjustment 6. With the voltmeter still connected as in Step
potentiometer twelve turns in a direction 4, start the engine and make a note of the
opposite of "MAX ARROW" speed at which the system voltage is
(counterclockwise) for an approximate canceled (this is the speed at which the DC
crank terminate setting. starter system disengages). If needed,
4. Connect a voltmeter (6V7070 Multimeter or make more small adjustments until the
a voltmeter of same accuracy) with the crank terminate speed is correct.
positive lead at ESS-12 and the negative 7. Install seal screw plug (5) in crank
lead at ESS-5. Start the engine and make a terminate adjustment access hole. Tighten
note of the speed at to a torque of 0.20 ± 0.03 N-m (2 ± .3 lb.
in.). Install the lockwire and seal (if
overspeed and oil step adjustments are
complete).
549
PROCEDURE C

OIL STEP CALIBRATION particular engine rating, find the specified rpm in column
1. Remove the lockwire and seal from seal for Oil Step Speed Setting. Run the engine at this
screw plugs (4), (5) and (6). Remove seal screw plug (6) specified rpm.
from access hole for the oil step adjustment screw.
5. With the engine running, look into the oil
2. Use a small screwdriver and lightly turn oil step adjustment access hole. A red "LED" (light emitting
step adjustment potentiometer 20 turns in the direction diode) light will be on. After an 8 to 10 second delay,
opposite of "MAX ARROW" (counterclockwise). This positive (+) voltage will be seen at terminal ESS-13.
will lower the oil step speed setting to its lowest value. Now turn the oil step adjustment potentiometer clockwise
until the red light in the oil step access hole goes out.
NOTE: The oil step adjustment screw is made so it can When the light goes out, this indicates that the oil step
not cause damage to the potentiometer, or be removed, rpm setting is above the present running rpm of the
if the adjustment screw is turned too many turns in either engine. Slowly turn the adjustment potentiometer
direction. counterclockwise until the light comes back on. After an
8 to 10 second delay, positive (+) voltage will be seen at
3. Use a 6V7070 Multimeter (or a voltmeter of terminal ESS-13.
same accuracy) to check for positive (+) voltage at
terminal ESS-13 [negative (-) voltage is at terminal ESS- 6. When the oil step setting is correct, install
5]. seal screw plug (6) into the adjustment access hole for
the oil step function. Tighten plug to a torque of 0.20 ±
4. Make reference to SPEED 0.03 N-m (2 + .3 lb. in.). If all other adjustments are
SPECIFICATION CHART (Part of PROCEDURE D). complete (overspeed and crank terminate), install
For a lockwire and seal.
550
PROCEDURE D

OVERSPEED VERIFY TEST The "LED" overspeed light (3) will come on and
1. Run the engine at rated speed and push stay on until the reset button is pushed after an
verify button (l) in for a moment. This will overspeed switch shutdown. To restart the engine,
cause the speed switch to activate and push in reset button (2) for a moment. This will reset the
shutdown the engine. speed switch, and the "LED" overspeed light (3) will go
off. The air inlet shutoff lever must now be manually
NOTE: Any time the engine speed is 75% or more of the reset before the engine can be started.
overspeed setting, the engine will shutdown if the verify
button is pushed. NOTE C: To verify overspeed shutdown system
operation, push in the VERIFY button for a moment. The
EXAMPLE: For an engine with a rated speed of 1800 engine must shutdown at 75% or more of overspeed
rpm, the overspeed setting is 2125 rpm (see SPEED setting.
SPECIFICATION CHART and Note E). The overspeed NOTE D: Input Voltage: Maximum 40 VDC; Minimum 8
verify test will shutdown the engine at 75% (+ 25 rpm) of VDC.
the overspeed setting of 2125 rpm. In this example, 75% NOTE E: The engine overspeed setting rpm is 118% of
of 2125 rpm is approximately 1600 rpm. If the verify rated engine rpm.
button is pushed at an engine speed of approximately
1600 rpm or above, the engine will shutdown.
OVERSPEED 75% OVERSPEED
TYPICAL RATED SETTING (±25) VERIFY ( + 25) OIL STEP CRANK
ENGINE SPEED NOTE E NOTE C SPEED SETTING TERMINATE
1800 2125 1600 1125 600
1600 1890 1415 1125 600
1500 1775 1325 1125 600
1300 1535 1150 750 400
1200 1415 1060 750 400
1000 1180 885 750 400
900 1065 800 750 400
551
PROCEDURE E
MAGNETIC PICKUP VERIFY 3. Remove magnetic pickup (2) from the engine
flywheel housing (earlier location, front drive
1. Connect a 6V7070 Multimeter (or a voltmeter of housing) and turn the flywheel until a gear tooth
same accuracy) to electronic speed switch (5) is directly in the center of the threaded
common terminal (ESS-3) and signal terminal opening for the magnetic pickup. Install the
(ESS4). Set the meter voltage scale to a scale magnetic pickup again in the threads of housing
greater than 1.5 VAC. Start the engine and run (6).
at idle rpm or 600 rpm (whichever is greater).
By hand, turn in a clockwise direction until the end
If the measured voltage is 1.5 VAC or more, the of the magnetic pickup just makes contact with the gear
operation of the magnetic pickup is correct. If measured tooth (5). Now turn the magnetic pickup back out 1/2
voltage is less than 1.5 VAC, go to Step 2. turn (180° in the counterclockwise direction) to get the
correct air gap [clearance dimension (1)]. Now tighten
2. Disconnect the wiring from the magnetic pickup locknut (4) to a torque of 68 ± 13 N•m (50 + 10 lb. ft.).
and connect the voltmeter to magnetic pickup
connector terminals I and 2. Set the voltmeter NOTE: Do not let the magnetic pickup turn while
voltage scale to a scale greater than 1.5 VAC. locknut is tightened.
Start the engine and run at idle rpm or 600 rpm
(whichever is greater). Do Step 2 again. If voltage is still less than 1.5
VAC, replace the magnetic pickup.
If the measured voltage is 1.5 VAC or more,
repair or replace the wiring between the magnetic pickup
and the electronic speed switch. If the measured voltage
is less than 1.5 VAC, go to Step 3.
MAGNETIC PICKUP
1. Clearance dimension. 2. Magnetic pickup. 3.
Wires. 4. Locknut. 5. Gear tooth. 6. Housing.
552
PROCEDURE F
ON/OFF TIME DELAY (RELAY) tage on terminal 1 for more than 60 seconds):

5 Open
7 Closed

terminal 1. Use a stop watch and check the
time from the moment of removal to verify
chart that follows:
Terminals Delay Time to Function

0 to 60 Secs. After 80 Secs.
5 Open Closed
7 Closed Open

2.
NOTE: If bench testing, Step 3 can be used with
ON/OFF TIME DELAY (RELAY) either relay. When installed on engine, Step 3
Performance Check (either TD1 or TD2 relays can only be checked with TD2. Do not apply
can be checked with methods that follow) positive (+) voltage to terminal 2 of TD1, or a
A. Items Required For Check: direct short will result.
Check the time from the moment voltage is
1. Battery or any D.C. source of 8 to 40 volts. applied to verify chart that follows (do not
2. Voltmeter (6V7070 Multimeter or one of same leave voltage on terminal 2 for more than
accuracy). 60 seconds):
3. Stop watch.
B. Bench Or Installed Test Terminals Delay Time to Function
Connect or verify source voltage to relay ter- 0 to 8 Secs. After 10 Secs.
minals 3 (-) and 4 (+) [if bench testing, also connect 5 Closed Open
positive (+) voltage to relay terminal 6]. All connections 7 Open Closed
must be maintained until tests are complete.
NOTE: There will be voltage when the relay is closed. terminal 2. Check the time from the
When relay is open, there will be no voltage [voltage may moment of removal to verify chart that
be positive (+) or negative (-) when relay is tested on follows:
engine; when bench testing, voltage will always be
positive (+)]. Terminals Delay Time to Function
1. Use the voltmeter to verify chart that 0 to 60 Secs. After 80 Secs.

follows: 5 Open Closed
7 Closed Open
5 Closed
4. Remove wire from terminal 4 and verify chart
7 Open
that follows:
2. (a) Apply positive (+) source voltage to terminal I
(either relay) and immediately verify the chart Terminals Relay Position
that follows (do not leave vol- 5 Closed
7 Open
553
ELECTRIC PROTECTIVE SYSTEMS TROUBLESHOOTING
ELECTRIC SHUT-OFF WIRING DIAGRAMS
(REF 5N360)
ALT ALTERNATOR OPS OIL PRESSURE SWITCH

AMM AMMETER OPSS OIL PRESSURE STEP SWITCH
ASOS AIR SHUT-OFF SOLENOID OPSU OIL PRESSURE SENDING UNIT
ASSV AIR START SOLENOID VALVE OSI OVERSPEED INDICATOR
B- BATTERY NEGATIVE OSS OVERSPEED SWITCH
B+ BATTERY POSITIVE PB PUSH BUTTON
BATT BATTERY PP PRELUBE PUMP
CB CIRCUIT BREAKER PPMS PRELUBE PUMP MAGNETIC SWITCH
CT CRANK TERMINATE PPPS PRELUBE PUMP PRESSURE SWITCH
D DIODE PS PINION SOLENOID
EGA ELECTRIC GOVERNOR ACTUATOR RES RESISTOR
EGC ELECTRIC GOVERNOR CONTROL RESS REMOTE EMERGENCY SHUT-OFF
SWITCH
ESS ELECTRIC SPEED SWITCH RNS REMOTE NORMAL SHUT-OFF SWITCH
FSOS FUEL SHUT-OFF SOLENOID RSS REMOTE START SWITCH
HWTAS HIGH WATER TEMPERATURE ALARMSWITCH SM STARTER MOTOR
LOPAS LOW OIL PRESSURE ALARM SWITCH SMMS STARTER MOTOR MAGNETIC SWITCH
LWTAS LOW WATER TEMPERATURE ALARMSWITCH SR SLAVE (SHUTDOWN) RELAY
MGOPG MARINE GEAR OIL PRESSURE GAGE TD TIME DELAY
MGOPSU MARINE GEAR OIL PRESSURE SENDING UNIT TM TACHOMETER
MGOTAS MARINE GEAR OIL TEMPERATURE ALARM TS TERMINAL STRIP
SWITCH
MPU MAGNETIC PICK-UP WTG WATER TEMPERATURE GAGE
NSS NORMAL SHUT-OFF SWITCH WTI WATER TEMPERATURE INDICATOR
OPG OIL PRESSURE GAGE WTS WATER TEMPERATURE SWITCH
OPI OIL PRESSURE INDICATOR WTSU WATER TEMPERATURE SENDING UNIT
Z ZENER DIODE
WIRE COLOR CODE

ABBREVIATIONS
B BLACK
BR BROWN
DK BL DARK BLUE
DK GR DARK GREEN
GR GREEN
LT BL LIGHT BLUE
O ORANGE
O/B ORANGE WITH BLACK STRIPE
PU/W PURPLE WITH WHITE STRIPE
R RED
W WHITE
Y YELLOW
554
ELECTRIC PROTECTIVE SYSTEMS WIRING DIAGRAMS
ELECTRIC PROTECTIVE SYSTEM SCHEMATIC

NOTE A: Terminal strip jumpers between terminals TS17 & TS18 and TS19 & TS20 are not required when alarms
are used for low oil pressure and high water temperature.
NOTE B: The terminal strip wire between terminals TS26 & TS27 is in the wiring harness when a 3161, UGSD or
UG8L governor is installed. When a 2301 governor is used, no wire is required; also, no fuel shutoff solenoid is
used between TS6 & TS12.
NOTE C: This wire is provided by customer if electric starter motor(s) are not used.
555
3500 ENGINE WIRING DIAGRAM (REF 5N8944)

(All Possible Combinations)
NOTE A: Jumper required only with 3161, UG8D and UG8L governors.
556
TYPICAL JUNCTION BOX WIRING DIAGRAM (REF 5N8944)
NOTE A: Terminal strip jumpers between terminals TS17 & TS18 and TS19 & TS20 are not required on Marine
Engines which have alarms only for low oil pressure and high water temperature.
557
JUNCTION BOX (REF 4W2635)
558
JUNCTION BOX WIRING HARNESS (REF 4W2636)
559
CUSTOMER WIRING WITH ELECTRIC PROTECTIVE SYSTEM (NOTE A)
560
NOTE A: Wire, cable and components shown

with dotted lines are to be added by
customer. See wire and cable gage charts
for size selection.
NOTE B: Do not use remote emergency switch

for normal engine shutdown. The use of
emergency switch requires manual reset of
air shut-off at top of air inlet housing.
NOTE C: Caterpillar alarm and prealarm

contacts are rated for a maximum of 3 amps
inductive at the charging system voltage.
NOTE D: Switch to be a single pole, normally

open switch (may be latching if desired) with
a minimum contact rating of .5 amp
inductive at the charging system voltage.
NOTE E: Switch to be a single pole, normally

open switch (may be latching if desired) with
a minimum contact rating of 1 amp inductive
at the charging system voltage.
NOTE F: Magnetic pick-up and oil pressure

switch to be wired to electric governor
control (Woodward 2301) with a two
conductor shielded cable (Belden Corp.
type 8780 or equivalent). Shields are to be
grounded at electric governor control
grounding stud. Each shield should not have
more than one ground connection.
NOTE G: Woodward 2301 Electric Governor

Control terminal identification chart:
STAND-BY LOAD SHARING

SYMBOL FUNCTION TS NO. TS NO.
P Batt + 2 12
R Batt - 1 13
S EGA + 6 17
T EGA - 5 16
U Mag Pick-up 7 18
V Mag Pick-up 8 19
Y Oil Pressure Speed Limiter 9 14
Z Oil Pressure Speed Limiter 10 15
561/(562 Blank)
SEBU5853
563
Foreword
This guide contains operation instructions and lubrication Continuing improvement and advancement of product
and maintenance information. design may have caused changes to your engine which
may not be covered in this publication. Each publication
The operation section is a reference for the new operator is reviewed and revised, as required, to update and
and a refresher for the experienced one. Read — study include these changes in later editions.
— and keep it handy.
Whenever a question arises regarding your engine or
Illustrations guide the operator through the correct this publication, please consult your Caterpillar dealer for
procedures of checking, starting, operating and stopping the latest available information.
the engine.
Engine Identification
The maintenance section is a guide to equipment care.
The illustrated, step-by-step instructions are grouped by Caterpillar engines are identified with SERIAL
servicing intervals. Topics without specific intervals are NUMBERS and ARRANGEMENT NUMBERS. In some
listed under "When Required." Topics in the "Lubrication cases MODIFICATION NUMBERS are also used.
and Maintenance Chart" are referenced to detailed These numbers are shown on the serial number plate
instructions that follow. mounted on the engine. The Specification Section at the
back of the Parts Book indicates the location of the serial
Use the service meter to determine servicing intervals. number plate.
Calendar intervals shown (daily, weekly, monthly, etc.)
may be used instead of service meter intervals if they Caterpillar dealers need all of these numbers to
provide more convenient servicing schedules and determine which components were included on the
approximate the indicated service meter reading. engine when it was assembled at the factory. This
permits accurate identification of replacement part
Under extremely severe, dusty or wet operating numbers.
conditions, more frequent lubrication than is specified in
the "Lubrication and Maintenance Chart" may be Ordering Parts
necessary.
Quality Caterpillar replacement parts are available from
Perform service on topics at multiples of the original Caterpillar dealers throughout the world. Their parts
requirement. For example, at Every 500 Service Hours stocks are up to date and include all parts normally
or 3 Months, also service those topics listed under Every required to protect your investment in Caterpillar
250 Service Hours or Monthly, Every 50 Service Hours or engines. When ordering parts, your order should specify
Weekly and Every 10 Service Hours or Daily. the quantity, part number, part name and serial number,
arrangement number and modification number of the
Some photographs in this publication may show details engine for which the parts are needed. If in doubt about
or attachments that may be different from your engine. the part number, please provide your dealer with a
complete description of the needed item.
564
Safety
Warning Plates and Decals When using pressure air, wear protective glasses and
protective clothing.
Read and understand all Warning plates and decals
before operating, lubricating or repairing this equipment. Wear ear protective devices to prevent hearing damage,
Do not attempt any repairs you do not understand. if working inside an enclosed engine room with engine
running.
General
Fire or Explosion
Do not allow unauthorized personnel on or near the
engine while it is being serviced Do not wear loose
clothing and jewelry whenever working around engines
or machinery.
Stop engine before making adjustments or repairs to the

engine or driven equipment unless specified otherwise.
Attach a "DO NOT OPERATE" tag on the start switch,

start button or air start knob, before servicing the engine.
These tags, Form SEHS7332, are available from your
Caterpillar dealer.
Be sure the remote starting and the automatic start-stop

systems are inoperative on engines being serviced.
Remove the starter key. A flash fire may result in personal injury if crankcase
covers are removed within 15 minutes after an
Disconnect and tape the battery ground lead before emergency shutdown.
working on an engine to prevent accidental starting.
Fire may result from lubricating oil or fuel sprayed on hot
To prevent injury, install guards over all exposed drive surfaces causing personal injury and property damage.
shafts, pulleys, any application with exposed rotating Inspect all lines and tubes for wear or deterioration.
parts.
They must be routed, supported or clamped securely.
Always use tools that are in good condition and be sure Tighten all connections to the recommended torque.
you understand how to use them before performing any
service work. Remove all tools, electrical cords and any Keep all exhaust manifold and turbocharger shields in
other loose items from the engine before starting. place to reduce fire hazard.
Engine speeds, temperatures and load are the best Collect drained liquids and wipe up all oil, fuel or coolant
indications of performance. spills.
Rely on your instruments, record and compare readings Store oily rags in proper containers. Do not leave rags
to detect developing abnormalities. on engine.
Wear a hard hat, face shield, clothing, shoes, respirator Never store flammable liquids near the engine.
or other protective items when necessary.
Keep all lubricants stored in properly marked containers.
Never put maintenance fluids into glass containers.
565
Safety
Provide adequate and safe waste oil disposal. When starting from an external power source attach the
ground cable last, and remove it first, to prevent sparks
Oil and fuel filters must be properly installed and from occurring near the battery. Attach the ground cable
tightened when being changed. from the booster source to the starter ground terminal.
Diesel fuel and all lubricants are flammable. Do not weld Always have a fire extinguisher on hand and know how
on pipes or tubes that contain oil. Clean them thoroughly to use it. Inspect and have it serviced as recommended
with nonflammable solvent before welding. on its instruction plate or decal.
Do not smoke while refueling. Burns
Loose or damaged lines, or tubes that allow oil, fuel or To prevent personal injury, do not step up on engine to
coolant to leak can cause overheating and/or fire. remove the radiator filler cap. Use an adequate ladder.
Do not bend or strike high pressure lines. Do not install Always inspect the cooling system with the engine
bent or damaged lines and tubes. Do not replace steel stopped and cool.
tubes with copper tubes.
Extreme caution should be used whenever draining a
Do not allow debris, dirt and foreign material to lubricant. The lubricant may be hot and could cause
accumulate around or on the engine. Overheating or fire personal injury.
could result.
Relieve all pressure in air, oil, fuel or water systems
Wiring must be kept in good condition, properly routed before any lines, fittings or related items are
and firmly attached. Routinely inspect wiring for wear or disconnected or removed. Be alert for possible pressure
deterioration. Loose, unattached, or unnecessary wiring when disconnecting any device from a system that
must be eliminated. All wires and cables must be of the utilizes pressure. Do not check for pressure leaks with
recommended gauge and fused if necessary. Do not your hand.
use smaller gauge wire or bypass fuses. Tight
connections, recommended wiring and cables properly Do not touch any part of an operating engine. Allow the
cared for will help prevent arcing or sparking which could engine to cool before any repairs are performed on the
cause a fire. engine.
Batteries must be kept clean, covers on all cells, Use caution when removing cover plates. Gradually
recommended cables and connections used and battery loosen (do not remove) the last two bolts or nuts located
box covers in place when operating. at opposite ends of the cover or device. Pry cover loose
to relieve any spring or other pressure, before removing
Do not smoke when observing battery electrolyte level. the last bolts or nuts.
Batteries give off flammable fumes.
Use caution when removing radiator filler cap, grease
Never disconnect any charging unit circuit or battery fittings, pressure taps, breathers or drain plugs. Hold a
circuit cable from the battery when charging unit is rag over the cap or plug to prevent being sprayed or ½
operating. A spark can cause the flammable vapor splashed by liquids under pressure.
mixture of hydrogen and oxygen to explode.
566
Stop any fuel or oil leak as soon as it is discovered.
Cooling system conditioner contains alkali; do not drink,

or let conditioner contact skin or get in eyes.
Battery electrolyte contains acid. Avoid contact with skin

or eyes.
Preparing to Start
Be sure all protective guards and covers are installed if

an engine must be started to make adjustments or
checks. To help prevent an accident caused by parts in
rotation, work carefully around them.
Do not disable or bypass automatic shutoff circuits.

They are provided to prevent personal injury and
equipment damage.
Never start an engine with the governor linkage

disconnected.
Make provisions for shutting off air supply to stop the

engine if there is an overspeed on start-up after servicing
the engine.
Inspect engine for potential hazards.
See the "Lubrication and Maintenance" section of this

guide for adjustment, or the Service Manual for repairs.
Starting
Do not start the engine or move any of the controls if

there is a warning tag attached to the controls.
Make sure no one is working on, or close to the engine

or engine driven components before starting it.
Start and operate engine in well ventilated area. If it is

necessary to operate in a closed area, vent exhaust to
the outside.
567
Operation Section
568
Model Views
3508 INDUSTRIAL ENGINE
569
Model Views
3508 INDUSTRIAL ENGINE
570
Gauges
3. Inlet Air Temperature – Indicates inlet air

temperature. As the inlet air temperature increases, the
air expands, less fuel is burned in the cylinders, and less
horsepower is developed. As a result, at full load
governor position with a full load, the engine may be
overloaded. Maximum inlet air temperature is 1150°C
(235àF).
4. Exhaust Temperature – Indicates exhaust

gas temperature. The temperature readings are taken
from both the left and right banks. The two readings will
vary slightly from each other. Maximum exhaust
temperature is approximately 480°C (900àF).
1. Tachometer - Indicates engine
RPM. When the governor control 5. Engine Oil Pressure – Indicates
lever is moved to the full speed engine oil pressure. The oil pressure
position without load, the engine is reading will be greatest after starting a
running at high idle. cold engine. Oil pressure will decrease
as the engine warms while idling. As the
When the governor control lever is moved to the full engine speed is increased to full load
speed position and load is applied, the engine will slow speed, oil pressure will increase and stabilize. Minimum
slightly to full load speed. engine oil pressure is 345 kPa (50 psi), at rated speed.
The engine can be operated between these two speed 6. Engine Oil Temperature - Indicates
limits for long periods of time without shortening engine engine oil temperature. The purpose of
life. The high idle RPM, 1980, and the full load RPM, the oil is to lubricate all moving parts
1800, are stamped on the engine’s Altitude Information inside the engine, and to cool the pistons
Plate. and bearings. The oil cooler transfers
the heat in the oil to the engine jacket water.
2. Engine Jacket Water Temperature -
Indicates engine water temperature.
The water temperature reading may
vary according to load, but should
never exceed the boiling temperature
for the pressurized system being used.
Engine jacket water temperature range is 800 to 100°C
(175à to 210àF).
571
Gauges
If the cooling system cannot remove the necessary heat 9. Air Cleaner Differential Pressure –
from the water, the engine oil cannot be properly cooled. Indicates the difference of air pressure
Above normal oil temperature indicates a heat problem between the inlet side (dirty side) and
has occurred in the lubrication and/or cooling system. A the engine side (clean side) of the air
problem can occur with cylinder heads, liners, pistons or filter element. As the element becomes plugged, the
bearings. Maximum oil temperature is 110°C (2300F). difference in pressure between the two sides of the
element will increase. Maximum air cleaner pressure
differential is 762 mm (30 in.) H20.
10. Fuel Filter Differential Pressure - Indicates

the difference of fuel pressure between the inlet side and
the outlet side of the fuel filter elements. As the element
becomes plugged, the difference in pressure between
the two sides of the element will increase. Maximum fuel
filter differential pressure is 105 kPa (15 psi).
7. Oil Filter Differential Pressure - Indicates the

difference of oil pressure between the inlet side (dirty
side) and the outlet side (clean side) of the oil filter. As
the element becomes plugged, the difference in pressure
between the two sides of the element will increase. Oil
filter maximum pressure differential is 105 kPa (15 psi).
8. Fuel Pressure – Indicates pressure of

the filtered fuel. The fuel pressure range
is 345 to 520 kPa (50 to 75 psi).
572
Shutoff and Alarm
System Components
Emergency Shutoff Controls

To silence the bell or horn while repairs are being made,
Emergency shutoff controls may be electrically, a two-way switch and a red indicator light may be
mechanically or hydraulically operated. Familiarize installed. The red indicator light will come on when the
yourself with the types and locations of the shutoff alarm is turned off.
controls, the conditions which cause each control to
function, and the resetting procedure required to start The red light will stay on, to indicate that the engine is not
your engine. protected, if the switch is left in the OFF position after the
repairs have been made.
The operation of all electrical shutoff controls is similar.
A critical operating condition actuates a switch to stop Testing Alarms
the engine. The shutoff control may require resetting
before the engine can start. All alarms on the engine should be tested twice a year
for proper operation by referring to the Service Manual or
The shutoff controls should be tested every 1000 hours authorized Caterpillar dealer personnel.
by authorized Caterpillar dealer personnel. Every 500
hours, the Hydra-Mechanical Shutoff can be tested NOTICE
remotely by engine personnel.
During testing abnormal operating conditions must be
Do not use an emergency shutoff control for a normal simulated. Perform the tests correctly to prevent
stopping procedure. possible damage to the engine.
Always determine the cause of the shutdown, and have
the necessary repairs made before restarting the engine.
Pressure Switch
See the "Troubleshooting" section of this guide.
Alarm Switches
Alarm switches are set at a less critical temperature,

pressure, or level limit than the shutoff controls. The
purpose of the alarm switch is to warn the operator that
an unsafe operating condition is starting to occur.
Corrective measures must be taken to avoid possible
damage to the engine.
When an alarm is activated, corrective measures must

be taken before the situation becomes an emergency.
This low oil pressure switch is used in the oil system to
Each alarm switch is electrically connected to an shut the engines down when oil pressure drops below
indicator light, bell or horn. The alarm will continue until system pressure.
the condition is corrected. Then the light will turn off and
the bell or horn will be silenced.
573
Shutoff and Alarm
System Components
Electrical High Water Temperature Electrical Overspeed Shutoff

Shutoff
This shutoff has an overspeed switch which works

The shutoff switch is located in the water temperature through the governor shutoff solenoid and the air inlet
regulator housing. Excessive water temperature closes shutoff solenoids. If the engine should overspeed, fuel
the switch. No resetting procedure is required. The and air will be cut off to stop the engine.
switch opens as the coolant cools.
Manual Fuel Shutoff Lever
NOTICE
The sensing element must be submerged in the coolant

to operate. The shutoff cannot actuate if the coolant
level is low.
Coolant Level Alarm
A manual shutdown lever is provided to override the

governor control of the engine. This shutdown will only
move the fuel control linkage to the fuel-off position. It
does not shut off the air inlet.
The expansion tank has a low coolant level gauge, which

is used to determine when the coolant is low. When the
coolant is near the LOW mark, coolant must be added to
the expansion tank to avoid engine overheating or
possible engine damage.
574
Engine Controls
Hydra-Mechanical Shutoff (HMSO)
The HMSO will automatically stop the engine if there is 1. Pull out the red emergency knob while
an overspeed, low oil pressure or high coolant observing the air inlet shutoff valve.
temperature. The fuel rack and the air inlet shutoff will
activate when the engine overspeeds.
2. The air inlet shutoff knob must move to the

The fuel rack will reset automatically, but the air inlet STOP position and shut off the air supply to the engine.
shutoff must be reset to the RUN position manually. The engine must stop.
The HMSO uses lubrication oil from the engine. It has 3. Push in the red emergency knob to reset the
an oil pump that supplies pressure to the shutoff system. HMSO.
There is a sump in the valve which must be refilled, if it
was drained, before starting the engine. 4. Move the air shutoff knob to the RUN position
to open the air inlet valve.
The HMSO can also be used as an emergency manual
shutoff.
Test the operation of the HMSO every 500 hours. Use

the following procedure.
575
Engine Controls
Consult your Caterpillar dealer if the HMSO or the air The air actuated governor control is attached directly to
inlet shutoff did not operate correctly. the UG8L Governor. This is connected to the governor
speed control lever, used to control engine speed.
Mechanical Governor Control
3161 Lever-Type Governor (3516
Industrial Engines)
The 3161 lever-type governor has an air-fuel ratio control

to limit smoke and provides pneumatic speed setting.
The 3161 uses engine oil for lubrication and actuation.
3161 Dial-Type Governor (3516 Gen.

Set Engines)
The 3161 dial-type governor has speed setting control

and external droop adjustment but will not have a load
limit control. It will have a 24-32 volt DC permanent
magnet, synchronizing motor for remote control of
engine speed. This governor will allow paralleling with
The mechanical governor control is used to control other hydra-mechanical governors or electronic
engine speed remotely. It will manually move the governors.
governor speed control lever.
EG3P and EG1OP Actuator
Air Actuated and Hydra-Mechanical
Governor Controls The EG3P and EG1OP Actuator controls the fuel rack
linkage with hydraulic power using the engine oil supply.
The dipstick gauge shows the amount of oil in the

governor. This governor is equipped with speed droop,
however, it must be adjusted inside the governor. See
the Service Manual for adjusting speed droop
576
UG8D Governor (3508/3512 Gen. Set Woodward 2301 Electronic Governors
Engines) (Gen. Set Engines Only)
The 2301 Nonparallel Control gives exact engine speed

control. The system measures engine speed constantly
and makes necessary corrections to the engine fuel
setting through an actuator connected to the fuel system.
The 2301 Parallel Control has two functions: Exact

engine speed and kilowatt load sharing. The system
measures engine speed constantly and makes
necessary corrections to the engine fuel setting through
an actuator connected to the fuel system.
The actuator is connected to the fuel system by linkage.

It changes the electrical input from the control box to
mechanical output that changes the engine fuel setting.
The UG8D Governor will have, as standard equipment, For example, if the engine speed was more than the
either the 24V to 32V shutdown solenoid to be used with speed setting, the control box will decrease fuel to the
electric shutoffs or the hydra-mechanical shutoff system. engine.
The UG8D Governor has no smoke limiter but does have
the usual adjustments for droop, load limit and speed
override.
UG8L Governor (3508/3512 Industrial

Engines)
The UG8L Governors have 10% regulation and a boost-

acutated smoke limiter. The UG8L Governor also has
either a hydraulic/pneumatic shutoff cylinder or an
electric shutoff solenoid that moves the fuel control
linkage to the fuel-off position. The hydraulic/pneumatic
cylinder is normally for use with the hydra-mechanical
protection device. This governor is equipped with speed
droop, however, it must be adjusted inside the governor.
See Service Manual for adjusting speed droop.
577
Before Starting the
Engine
Perform required periodic maintenance before starting

the engine. Make a walk-around inspection of the
installation. It only takes a few minutes to make minor
corrections. This can prevent major repairs at a later
date.
NOTICE
All valves in fuel return line must be open before and

during engine operation to prevent high fuel
pressure. High fuel pressure may cause filter
housing failure or other damage.
2. Measure the crankcase oil level. Check dipstick for

correct level. The oil level must be between the FULL
and the ADD marks on the ENGINE STOPPED side of
the dipstick. Add oil if necessary.
3. Disconnect any battery chargers that are not

protected against the starter current drain.
1. Inspect the coolant level. The level should be to the

bottom of the filler neck. Operate the engine until it is at
operating temperature. Add coolant if necessary. Install
filler cap.
4. All guards must be in place. Repair or replace all

guards that are damaged or missing.
578
Starting the Engine
Direct Electric Starting
NOTICE
Do not engage starter when flywheel is turning.
Do not start engine under load.
Above 0àC (32àF)
1. Place the transmission in NEUTRAL. Open the main

electrical circuit breaker on generator sets.
5. Make sure air inlet shutoff valve is in the RUN 2. Move the throttle to low idle engine speed.
position.
6. Make sure fuel lines are properly clamped and tight.

Check for loose fittings or leaks.
3. Turn the starter switch to START or move toggle

switch to the ON position, press button ô to START.
If the engine does not start after 10 seconds, move the
fuel shutoff lever to shut off the fuel; then continue to
crank for 10 seconds. This will clear the cylinders of fuel.
4. As soon as the engine starts, allow the engine to idle

for three to five minutes, or until the water temperature
gauge has begun to rise.
5. Do not apply load to the engine or increase engine

speed until the oil pressure gauge indicates normal.
579
Starting the Engine
NOTICE
NOTICE
If starting fluid is necessary, spray starting fluid into
If oil pressure does not raise within 15 seconds after the air cleaner inlet. Spray starting fluid only while
the engine starts, stop the engine and make cranking the engine. Otherwise, damage to engine
necessary corrections. can result.
If the engine fails to start within 30 seconds, release

6. Operate the engine at low load until all systems reach the starter switch or button and wait two minutes to
operating temperatures. Check all gauges during the allow the starting motor to cool before using it again.
warmup period.
Below 0àC (32àF) Heating of jacket water and crankcase oil, use of starting
aid fluid and/or use of extra battery capacity may be
required to assist starting in cold temperatures.
Ether is poisonous and flammable. Air Starting

Do not store replacement cylinders in living areas. 1. Open and close the bleed valve on the bottom of the
Do not smoke while changing cylinders. air tank to drain condensation and oil carryover.
Use only in well ventilated areas. 2. Check the air supply pressure. The air starter must
Use with care to avoid fires. have 690 kPa (100 psi) to operate properly.
Avoid breathing of vapors or repeated contact with

skin.
Do not puncture or burn cylinders.
Discard cylinders in a safe place.
Keep ether container away from heat, sparks, open
flame, or open sunlight. It may explode.
If an aerosol container is used, follow instructions
on the container.
Do not store or use at temperatures above 93° C
(200°F). 3. Check the oil level in the air lubricator. Keep jar at
least half full. Add oil if necessary. See the Lubrication
Use ether sparingly while cranking the engine.
and Maintenance Chart for the proper oil to use.
580
Starting From External Electrical
Source
Always wear protective glasses when working with

batteries.
Prevent sparks near the batteries. They could cause

vapors to explode. Do not allow cable ends to
contact each other or the engine.
Batteries give off flammable fumes that can explode.
4. Move toggle switch to the ON position and push Electrolyte is an acid and can cause personal injury
the air control valve ô in to crank the engine. As soon if it contacts skin or eyes.
as the engine starts, release the valve; or
NOTICE
Before attaching the booster cables, move toggle

switch at the engine to the OFF position.
When using booster cables, be sure to connect in

parallel: NEGATIVE (-) to NEGATIVE (-) and
POSITIVE (+) to POSITIVE (+).
Do not allow the free end of booster cables to touch

the engine. This helps avoid sparks.
This engine has a 24 or 32 Volt starting system. Use

push in the oil pressure lockout knob í and hold. Push only equal voltage for boost starting. The use of a
air control valve knob ÷ in to crank the engine. As soon welder or higher voltage will damage the electrical
as the engine starts, release the air control valve knob ÷ system.
and the oil pressure lockout knob í.
581
Starting the Engine After Starting the Engine
Connect one end of cable to the POSITIVE (+) NOTICE

(ungrounded) terminal of the battery of the engine.
Connect the other end to the POSITIVE (+) terminal of If oil pressure does not raise within 15 seconds after
the power source. the engine starts, stop the engine and make
necessary corrections.
Connect one end of the second cable to the NEGATIVE
(-) terminal of the power source. Connect the other end
to the starter ground terminal of the engine.
Start the engine. 1. Do not apply a load to the engine, or increase the
speed, until oil pressure gauge indicates normal. Oil
Disconnect the cable from the starter ground terminal pressure should raise to normal within 15 seconds after
first. Disconnect the other end from the NEGATIVE (-) the engine starts.
terminal of the power source. Disconnect the cable from
the POSITIVE (+) terminal of the battery. Disconnect the
other end from the POSITIVE (+) terminal of the power
source.
2. Operate the engine at low load until all systems reach

operating temperatures. Check all gauges during the
warmup period.
582
Stopping the Engine
Toggle Switch
NOTICE
Stopping the engine immediately after it has been

working under load, can result in overheating and
accelerated wear of the engine components. Follow
the stopping procedure, outlined below, to allow the
engine to cool. Excessive temperatures in the
turbocharger centerhousing will cause oil coking
problems.
1. Reduce engine speed to low idle.
2. Shift into NEUTRAL. On generators, open the main Move toggle switch to the OFF position.
electrical circuit breaker.
Manual Fuel Shutoff Lever
3. Increase engine speed to no more than half engine
speed. Idle for at least five minutes to cool the engine.
4. Reduce engine speed to low idle.
5. Check the crankcase oil level while the engine is

idling. Maintain the oil level between the ADD and FULL
marks on the CHECK WITH ENGINE RUNNING side of
the dipstick.
6. The engine may be stopped by using one of the

following engine mounted controls:
Pull the red handle lever out to shut off the fuel supply to
the engine.
583
After Stopping the Engine Lifting Engine and
Attachment
1. Fill the fuel tank. NOTICE
2. If below freezing temperatures are expected, allow When it is necessary to remove a component on an
the engine jacket water expansion tank to cool; then angle, remember that the capacity of an eyebolt is
check the coolant for proper antifreeze protection. Add less as the angle between the supporting members
permanent-type antifreeze if required. See the Operation and the object becomes less than 900. Eyebolts and
and Maintenance Procedures.
brackets should never be bent and should only have
stress in tension.
3. Repair any leaks, perform minor adjustments, tighten
loose bolts, etc.
Use a hoist to remove heavy components. Lift the
engine by using an adjustable lifting beam. All
supporting members (chains and cables) should be
parallel to each other, and as near perpendicular as
possible to the top of the object being lifted.
Some removals require the use of lifting fixtures to obtain

proper balance and to provide safe handling.
Lifting eyes are designed for the arrangement as sold.

Alterations to lifting eyes and/or arrangement weight
make the lifting devices obsolete.
If you make alterations, you are responsible for providing

4. Observe the service meter reading. Perform periodic adequate lifting devices.
maintenance as instructed in the Lubrication &
Maintenance Chart. Engine With or Without Generator
5. Perform the required periodic maintenance on all

other equipment as outlined in the equipment
manufacturer’s instructions.
To remove the engine only or the engine and generator

together, use the two lifting eyes on the engine.
584
Engine Storage
If the engine is not started for several weeks, the

lubricating oil drains from the cylinder walls and piston
rings. This lack of oil permits the piston rings to rust.
This causes metal-to-metal contact between the piston
rings, the pistons and the cylinder liners when the engine
is started. This metal-to-metal contact will result in
shorter engine life. To prevent excessive engine wear:
1. Be sure all lubrication points mentioned in the

Lubrication and Maintenance Chart are serviced.
2. If freezing temperatures can be expected, check the

cooling system for adequate protection against freezing.
A 50-50 solution of permanent-type antifreeze and
approved water treated with the proper amount of
coolant conditioner, will give protection below -29°C (-
20°F).
If it will be impossible to start the engine every week,

consult your Caterpillar dealer for instructions to prepare
your engine for longer storage periods.
585
Maintenance Section
586
Serial Number Locations Maintenance
Recommendations
Cooling System
Check coolant only when engine is stopped and filler cap

is cool enough to touch. Remove filler cap slowly to
avoid steam. Allow coolant and components to cool
before draining.
NOTICE
Engine Never add coolant to an overheated engine. Allow

the engine to cool first.
Check the specific gravity of the antifreeze solution

frequently in cold weather to ensure adequate
protection.
If the engine is to be stored in, or shipped to, an area

with below freezing temperatures, the cooling
system must be protected against freezing to the
lowest expected ambient temperature.
All water is corrosive at engine operating

temperature. The cooling system should be
Generator protected with a 3% to 6% concentration of cooling
system conditioner at all times regard- less of the
concentration of antifreeze, or by using Caterpillar
Coolant Conditioner Elements.
Do not use Caterpillar Cooling System Conditioner

or Coolant Conditioner Elements with Dowtherm 209
Full-Fill coolant. Follow the instructions provided
with the Dowtherm 209 Full-Fill coolant.
Coolant should be drained and replaced "Every 2000

Service Hours or 1 Year." However, when cooling system
conditioner additions are made every 250 service hours
as recommended, the drain period can be extended to
"4000 Service Hours or 2 Years."
587
Maintenance
Recommendations
A 3% to 6% concentration of Caterpillar Cooling System Never use both the liquid cooling system conditioner and
Conditioner can be maintained by adding .50 liter (1 pint) coolant conditioner elements at the same time.
for each 15 liters (4 gallons) of coolant used.
Operate with a thermostat in the cooling system all year-
Premix antifreeze solution to provide protection to the round. Cooling system problems can arise without a
lowest expected ambient temperature. Pure undiluted thermostat.
antifreeze will freeze at -23°C (-10°F).
Fuel System
Acceptable water for use in the ethylene glycol-type
antifreeze and water mixture is shown on the chart NOTICE
below.
Fill the fuel tank at the end of each day of operation
Acceptable Water to drive out moist air and to prevent condensation.
50% or More Less Than Do not fill the tank to the top. The fuel expands as it
Water Content Antifreeze 50% Antifreeze gets warm and may overflow.
Chlorides 100 ppm 50 ppm
or less or less Do not fill fuel filters with fuel before installing them.
Sulfates 100 ppm 50 ppm Contaminated fuel will cause accelerated wear to
or less or less fuel system parts.
Hardness as 200 ppm 100 ppm
CaCo3 or less or less
Dissolved Solids 500 ppm 250 ppm After changing fuel filters, open fuel supply and return
or less or less valves that were closed. The fuel system will bleed air
back through the return.
pH 6.5 or higher 6.5 or higher
ppm = parts per million Drain water and sediment from any fuel storage tank
weekly, and before the tank is refilled. This will help
Use clean water that is low in scale forming mineral. Do prevent water or sediment from being pumped from the
not use softened water. Add Caterpillar Cooling System storage tank into the engine fuel tank.
Conditioner, Caterpillar Coolant Conditioner Elements, or
equivalent, to the water to provide corrosion protection. Use only fuel as recommended in the "Fuel, Coolant and
Lubricant Specifications" section of this guide.
Filling at over 20 liters (5 U.S. gallons) per minute can
cause air pockets in the cooling system. Air Intake System
After draining and refilling the cooling system, run the As the air cleaner elements become plugged, the
engine with the filler cap off until the coolant reaches difference of air pressure between the inlet side (dirty
normal operating temperature and the coolant level side) and the engine side (clean side) will increase.
stabilizes. Add coolant as necessary to fill the system to Service the air cleaners when the air cleaner restriction
the proper level. gauge registers 762 mm (30 inches) H 20.
588
The primary element can be cleaned up to six times NOTICE
before replacement. The element, when cleaned, should
be thoroughly checked for rips or tears in the filter When boost starting an engine, follow the
material. Replace the primary element every year even instructions in "Starting the Engine" in the
though it has not been cleaned six times. "Operation Section" of flywheel to properly start the
engine.
Scheduled Oil Sampling
This engine has a 24 or 32 volt starting system. Use
Use scheduled oil sampling to monitor engine and
only equal voltage for boost starting. The use of a
maintenance requirements. Each oil sample should be
taken when the oil is hot and well mixed, to ensure the welder or higher voltage will damage the electrical
sample is representative of the oil in the compartment. system.
S.O.S. Interval Chart

General
Compartment Interval
Engine Crankcase At Oil Change
NOTICE
Consult your Caterpillar dealer for complete information
Accumulated grease and oil on an engine or deck is
and assistance in establishing a scheduled oil sampling
a fire hazard. Remove this debris with steam
program for your engine.
cleaning or high pressure water, at least every 1000
Electrical System hours or each time any significant quantity of oil is
spilled on an engine.
Wipe all fittings, caps and plugs before servicing.

Prevent sparks near the batteries. They could cause
Keep a close watch for leaks. If leaking is observed,
vapors to explode. Do not allow cable ends to
find and correct the source of the leak.
contact each other or the engine.
Check the fluid levels more frequently than the
recommended periods if leaking is suspected or
observed.
589
Fuel, Coolant and
Lubricant Specifications
Fuel Specifications Engine Coolant Specifications
Types of Fuel Use a mixture of approved fill water and antifreeze, and
Cooling System Conditioner.
Caterpillar Diesel Engines have the ability to burn a wide
variety of fuels. These fuels are divided into two general "Know Your Cooling System" Form SEBD0518, can
groups, preferred and permissible. provide more detailed specifications.
The preferred fuels provide maximum engine service life Fill Water
and performance. They are distillate fuels. They are
commonly called fuel oil, furnace oil, diesel fuel, gas oil, Always add conditioner to water. Never use plain water
or kerosene. only.
Acceptable water for use in the ethylene glycol-type
The permissible fuels are crude oils or blended fuels. antifreeze and water mixture is shown on the chart
Use of these fuels can result in higher maintenance below:
costs and reduced engine service life.
Acceptable Water
See "Fuels for Caterpillar Diesel Engines," Form 50% or More Less Than
SEHS7067, for a detailed summary of preferred and Water Content Antifreeze 50% Antifreeze
permissible fuels and their specifications.
chlorides 100 ppm 50 ppm
Cetane Requirement or less or less
Sulfates 100 ppm 50 ppm
The minimum fuel cetane number recommended for the or less or less
engine is 40. Hardness as 200 ppm 100 ppm
CaCo3 or less or less
Fuel Cloud Point Dissolved Solids 500 ppm 250 ppm
or less or less
Fuel waxing can plug the fuel filters in cold weather. The pH 6.5 or higher 6.5 or higher
fuel cloud point must be below the temperature of the ppm = parts per million
surrounding air to prevent filter waxing and power loss.
Fuel heating attachments are available from your Antifreeze
Caterpillar dealer to minimize fuel filter waxing.
Use ethylene glycol-type antifreeze. Use the correct
Fuel Sulfur Content amount to provide freeze protection to the lowest
expected operating environment.
The percent of sulfur in the fuel will affect the engine oil
recommendations. If the fuel has over 0.5% sulfur Conditioner
content, the CD engine oil must have a TBN of 20 times
the percentage of fuel sulfur. Your oil supplier should be Use Caterpillar Cooling System Conditioner or
able to furnish the correct oils. equivalent. Follow the instructions on the container.
On a new or reconditioned engine add 1 liter (1 quart) of

Caterpillar Cooling System Conditioner, or equivalent, for
each 30 liters (8 U.S. gallons) so that the cooling system
will have a 3%/o to 6% concentration of conditioner.
590
If the engine is not equipped with spin-on Coolant Air Lubricator Oil (CD)
Conditioner Elements, add .50 liter (1 pint) of Caterpillar
Cooling System Conditioner for each 15 liters (4 U.S Use SAE10 or 10W nondetergent oil for temperatures
gallons) of coolant used to maintain the 3% to 6%. above 0°C (32°F). Use diesel fuel for temperatures
below 0°C (32°F). NOTE: Change oil and filter element
Lubricant Specifications after first 50 hours of operation for new or reconditioned
engines.
The abbreviations listed below, follow S.A.E. J754
nomenclature. The classifications follow S.A.E. J183 Lubricating Grease (MPG)
classifications. The MIL specifications are U.S.A.
Military Specifications. These definitions will be of Use Multipurpose-type Grease (MPG). Multipurpose-type
assistance in purchasing lubricants. The specific grease which contains 3% to 5% molybdenum disulfide
classifications for this engine are found on the is preferred. NLGI No. 2 Grade is suitable for most
"Recommended Lubricants" Chart. temperatures. Use NLGI No. 1 or No. 0 Grade for
extremely low temperatures.
Engine Oils (CD)
Use oils that meet Engine Service Classification CD or

MIL-L-2104C.
Consult the "EMA Lubricating Oils Data Book," Form

SEBU5939, for a listing of CD oil brands.
NOTICE
The percentage of sulfur in the fuel will affect the

engine oil recommendations. If the fuel has over
0.5% sulfur content, the CD engine oil must have a
TBN of 20 times the percentage of fuel sulfur. Your
oil supplier should be able to furnish the correct oils.
591
Refill Capacities- Engine Specifications
Approximate
3508 Engines
Compartment U.S. Imperial Engine Specifications

or System Liters Gallons Gallons Operating Range (rpm)
ENGINE 68Z1-UP, 70Z1-UP 900-1300
CRANKCASE Operating Range (rpm)
3508 Industrial 104 27 22 95Y1-UP, 23Z1-UP 1500-1800
227 59 42 Number of Cylinders 8
3512 Industrial 152 40 33 Stroke 190 mm (7.5 in.)
312 81 68 Firing Order 1-2-7-3-4-5-6-8
613 162 134
Rotation
3516 Industrial 204 53 44 (viewed from flywheel) Counterclockwise
401 106 88
842 219 182
3512 Engines
COOLING SYSTEM
3508 Engine Only 114 30 25 Engine Specifications
3512 Engine Only 148 39 33
Operating Range (rpm)
3516 Engine Only 205 54 45
65Z1-UP, 67Z1-UP 900-1300
49Y1-UP, 24Z1-UP 1500-1800
Number of Cylinders 12
Stroke 190 mm (7.5 in.)
Firing Order 1-12-9-4-5-8-
11-2-3-10-7-6
Rotation
(viewed from flywheel) Counterclockwise
3516 Engines
Engine Specifications
71Z1-UP, 73Z1-UP 900-1300
25Z1-UP, 27Z1-UP 1500-1800
Number of Cylinders 16
Stroke 190 mm (7.5 in.)
Firing Order 1-2-5-6-3-4-9-10-
15-16-11-12-13-14-7-8
Rotation
(viewed from flywheel) Counterclockwise
592
Recommended Lubricant
Viscosities
593
Lubrication and Maintenance Chart
Item Service Lube. Page

When Required
Air Starter Fill motor air lubricator and adjust oiler CD 38
feed.
Every 10 Service Hours or Daily
Walk-Around Inspection Inspect engine. 39
Clutch Throwout Collar and Engagement Shaft Bear- Check clutch adjustment and lubricate fit- MPG 47
ings tings.
Cooling System Check coolant level. 48
Woodward UG8L Governor Measure oil level. 49
Engine Crankcase Measure oil level. CD 49
Fuel Tank Drain water and sediment. 50
Every 50 Service Hours or Weekly
Zinc Rods Inspect and replace rods if necessary. 51
Batteries Check electrolyte level. 52
Every 100 Service Hours or 2 Weeks
Clutch Bearing Lubricate fitting. MPG 53
Every 250 Service Hours or Monthly
Alternator Belts Inspect - replace and/or adjust. 54
Fan Pulley Bearing Lubricate fitting. MPG 55
Cooling System Coolant conditioner. 55
Engine Crankcase Change oil and filters.
3508 Engines -104 liter (27 gal.) The percent of sulfur in the fuel will affect CD 56
3512 Engines -152 liter (40 gal.) the engine oil recommendations. If the fuel CD 56
3516 Engines -204 liter (53 gal.) has over 0.5% sulfur content, the CD en-
gine oil must have a TBN of 20 times the CD 56
percentage of fuel sulfur. Your oil supplier
should be able to furnish the correct oils.
594
Lubrication and Maintenance Chart
Item Service Lube. Page

Every 500 Service Hours or 3 Months
Emergency Shutoff Controls Test for proper operation. 59
3508 Engines - 227 liter (59 gal.) See fuel sulfur note under Every 250 Ser- CD 59
3512 Engines - 312 liter (81 gal.) vice Hours or Monthly. CD 59
3516 Engines - 401 liter (106 gal.) CD 59
Shutoff Controls Check for proper operation. 60
Woodward UG8L Governor Change oil. 60
Governor Air Actuator Lubricate fittings. MPG 64
Engine Crankcase Breathers Clean. 64
3512 Engines - 613 liter (162 gal.) See fuel sulfur note under Every 250 Ser- CD 65
3516 Engines - 842 liter (219 gal.) vice Hours or Monthly. CD 65
Every 2000 Service Hours or 1 Year
Engine Valve Lash Adjust if necessary. Inspect valve rota- 66
tors.
Cooling System Change coolant. 66
595
When Required
Air Starter
Filling Air Lubricator
a. Turn the valve needle (the uppermost knob is

the oiler) counterclockwise to increase the number of
NOTICE drops per minute.
b. Turn the valve needle clockwise to decrease the

Never allow the air lubricator jar to become empty. The
number of drops per minute.
starting motor will be damaged by lack of proper
lubrication.
The vanes of the starting motor are lubricated with a fine

oil mist from the motor oiler while the motor is operating.
When the air lubricator jar becomes half empty, remove

the oil filler plug and fill the jar with clean oil.
Adjusting Oiler Feed Adjust the oiler to release four

drops of oil per minute into the starting motor air stream.
1. Be sure the fuel supply line valve to the engine is

closed.
2. Crank the engine.
3. Count the drops of oil released per minute into

the air stream.
596
Walk-Around Inspection
Inspect Engine
1. Make sure lines are properly clamped and tight.

Check for loose fittings or leaks.
2. All guards must be in place. Repair or replace

missing or damaged guards.
3. Disconnect any battery chargers that are not

protected against the starter current drain. Check
condition of batteries and the level of electrolyte.
4. Check for coolant, fuel or oil leaks on or below

engine.
For changing engine oil filter elements see topic entitled
"Engine Crankcase." NOTE
5. Check condition of all belts. Replace if
: Follow the Lubrication and Maintenance Chart under
necessary.
normal operation.
6. Check condition of gauges. Replace if cracked or
Fuel System
not calibrated to "O."
7. While operating, frequently observe the engine

oil pressure gauge, the fuel pressure gauge, the fuel filter
differential pressure gauges, the oil filter differential
pressure gauges, and the air cleaner differential Fuel leaked or spilled onto hot surfaces or electrical
pressure gauges. components can cause a fire.
Engine Oil Filter Disconnect the battery when changing fuel filters.
NOTICE
Do not fill fuel filter housings with fuel before installing

elements. Contaminated fuel will cause accelerated
wear to fuel system components.
The engine oil filter elements should be changed when

the oil filter differential pressure gauge registers 105 kPa
(15 psi) when engine is at rated speed, and is at
operating temperature.
597
5. Inspect and install the two cover gaskets. Install

new gaskets if necessary.
6. Install the cleaned filter element and case.
7. Open fuel supply line valve.
8. Prime the fuel system. See "Priming the Fuel

System."
Changing Final Fuel Filters
1. Close the fuel supply line valve.

The final fuel filter elements should be replaced when the
fuel filter differential pressure gauge registers 105 kPa
(15 psi), when engine is at rated speed and operating
temperature. The primary fuel filter should be cleaned
each time the elements are changed.
Cleaning the Primary Fuel Filter
1. Stop the engine.
2. Close the fuel supply line valve.
2. Attach one end of the drain hose to drain valve

1. Put the other end of the hose in a container to catch
the fuel. Open drain valve 1. Remove vent plug 2 and
drain the fuel filter housing.
3. Loosen nut 1 on the cover and remove case 3.
4. Remove filter element 2. Clean the element and

case in clean nonflammable solvent.
598
3. Remove cover 3 from each end of the filter 7. Inspect the cover O-ring seal. Install new seal if
housing. necessary.
4. Remove the five used filter elements from inside 8. Install the cover.
the filter housing.
9. Install vent plug 2, close drain valve 1 and
remove the drain hose.
10. Open the fuel supply line valve.
11. Prime the fuel system. See "Priming the Fuel

System."
Priming the Fuel System
1. Open the fuel supply line valve.
5. Wipe all sediment from inside the filter housing.
2. Move the ON/OFF switch at the engine, to the

OFF position.
6. Install new filter elements.
599
3. Turn the pump handle knob counterclockwise. When the fuel filter differential gauge registers 105 kPa
Release the lock plate from the retainer on the fuel (’15 psi), the main fuel filter elements should be
priming pump. replaced.
4. Operate the fuel priming pump until the air in the Changing the Main Final Fuel Filters
fuel system has been pumped through the fuel return line
to the fuel tank.
Duplex Fuel Filters
The duplex fuel filter system will allow continuous Fuel leaked or spilled onto hot surfaces or electrical
operation while the fuel filters are being changed. components can cause a fire.
NOTE: Under normal operation, the main fuel filters are

to be used, until they need to be replaced. The auxiliary 1. Open fill valve 1 for five minutes minimum.
filters can be transferred to during continuous engine
operation while the main filters are being changed. 2. Close fill valve 1 and rotate control valve 2 to the
Auxiliary Run position.
600
3. Attach one end of the drain hose to drain valve 11. Open fill valve 1 for minimum of five minutes.
3. Put the other end of hose in a container to catch the
fuel. Open drain valve stem 4. Remove vent plug 5 and 12. Close fill valve 1 and rotate control valve 2 to
drain the fuel filter housing. the Main Run position.
4. Remove cover () from the end of the filter Changing Auxiliary Final Fuel Filters
housing.
5. Remove the five used filter elements from inside

the filter housing.
7. Install five new filter elements.
8. Inspect the cover O-ring seal. Install new seal if

necessary.
9. Install cover 6.
10. Make sure vent plug 5 is installed, and drain

valve stem 4 is closed. If the main final fuel filters have been used and there are
no replacement filters, the auxiliary filters may be used
for a maximum of 100 hours engine operation.
601
The auxiliary filters must be replaced when the fuel filter 3. Attach one end of drain hose to drain valve 3.
differential gauge registers 105 kPa (15 psi). NOTE: Put the other end of the hose in a container to catch the
Engine must be shut down to change the auxiliary filters, fuel. Open drain valve stem 4. Remove vent plug 5 and
if the main fuel filters are empty. drain the fuel filter housing.
4. Remove cover 6 from the end of the filter

housing.
5. Remove the two used filter elements from inside

the filter housing.
7. Install two new filter elements.

necessary.
9. Install cover 6.
1. To change the auxiliary filters when the control
valve is in the Auxiliary Run position, open fill valve 1 for 10. Make sure that vent plug 5 is installed, and drain
minimum of five minutes. valve stem 4 is closed.
2. Close fill valve 1 and rotate control valve 2 to the 11. Open fill valve 1 for minimum of five minutes.
Main Run position.
12. Close fill valve 1 and leave control valve 2 in the
To change the auxiliary filters when the control valve is in
Main Run position, for normal operation.
the Main Run position, proceed to step 3.
602
Air Cleaners
Observe gauges for both left and right air cleaners. 2. Remove the cover.
If air cleaner restriction gauge registers 762 mm (30

inches) H20, clean or replace air cleaner elements.
NOTICE
Service the air cleaners with engine stopped.
Keep spare filter elements on hand for replacement.
Changing Air Cleaner Elements

3. Remove the element.
1. Release the cover fasteners from around the

filter housing. 4. Clean the inside of the housing.
603
Cleaning Air Cleaner Elements
When using pressure air, wear protective face shield

and clothing. Use 205 kPa (30 psi) maximum air
pressure for cleaning purposes.
NOTICE
5. Install the new or cleaned element.
Do not clean elements by bumping or tapping them.
The primary element can be cleaned up to six times
before replacement. The element, when cleaned, should Inspect element after cleaning. Do not use an
be thoroughly checked for rips or tears in the filter element with damaged pleats, gaskets or seals.
material. Replace the primary element every year even
though it has not been cleaned six times.
Element can be cleaned with pressure air.
Pressure Air 205 kPa (30 psi) Maximum
6. Install the cover and fasten it.
7. Repeat steps 1 thru 6 for the air cleaner on the

other side of the engine. 1. Direct air along pleats inside of element, outside
of element and then inside of element.
2. Inspect element after cleaning.
604
Inspecting Elements
Clutch Throwout Collar
and Engagement Shaft
Bearings
Check Clutch Adjustment
1. Insert a light inside a dry and cleaned element.

Discard an element with rips or tears.
If the clutch is damaged to the point of a burst

failure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to prevent accidents.
Do not operate engine with cover plate removed

2. Wrap and store elements in a clean, dry place.
as personal injury may result.
When clutch is disengaged, the hand lever must fall

behind the vertical position. If the clutch slips, overheats
or operating lever disengages, adjustment is necessary.
To adjust: Remove cover plate .
605
Cooling System
Check Coolant Level
At operating temperature, engine coolant is hot and

under pressure.
Check coolant level only when engine is stopped

and filler cap is cool enough to touch with your
Rotate clutch until lock pin ô can be reached. hand.
Disengage lock pin and turn adjusting ring clockwise to
increase engagement torque and counterclockwise to Remove filler cap slowly to relieve pressure.
decrease engagement torque. Turn adjusting ring so
that 345 ± 50 N.m (254 ± 35 lb ft) torque or 636 ± 90 N Steam can cause personal injury.
(143 ± 20 lb) force at 540 mm (21.3 in) length on lever, is
required to engage the clutch.
Lubricate Fittings
1. Remove filler cap O slowly to relieve pressure.

Inspect condition of cap gasket. Replace cap if
necessary.
1. Lubricate clutch throwout collar .
2. Maintain coolant level to the bottom of the filler
2. Lubricate engagement shaft bearing ô. tube. Install the filler cap.
3. Inspect for leaks or damaged hoses. Make

repairs if necessary.
606
Woodward UG8L Engine Crankcase
Governor
Measure Oil Level

Measure Oil Level
Maintain oil level at the FULL mark on

dipstick gauge . 1. Measure engine oil level.
2. Maintain oil level to FULL mark on the ENGINE

STOPPED side of dipstick. Add oil if necessary.
607
Fuel Tank
Drain Water and Sediment
Open drain valve. Allow water and sediment to drain into

a container. Close drain valve. Wipe up spills.
608
Zinc Rods
Inspect
All zinc rod locations, heat exchanger, water pump

piping, etc.
3. Tap the zinc rods lightly with a hammer. If the

rod has deteriorated, or if it flakes when tapped, install a
new zinc rod.
Installing New Zinc Rods
1. Move the ON/OFF switch at the engine to the

OFF position.
1. Unscrew or drill the existing rod from the plug

base.
2. Install a new rod in the plug base.
3. Install the plug.

2. Remove all the plugs. They are painted red for
easy identification.
609
Batteries
Cleaning Batteries
Check Electrolyte Level
Batteries give off flammable fumes that can explode.
Electrolyte is an acid and can cause personal injury

if it contacts skin or eyes.
Do not smoke when observing battery electrolyte

level.
1. Loosen and remove cable clamps from all
Always wear protective glasses when working with battery terminals.
batteries.
2. Clean all battery terminals.
3. Clean all cable clamps.
4. Install and tighten cable clamps to battery

terminals.
5. Coat cable clamps and terminals with grease.
1. Remove fill caps. Maintain electrolyte to bottom

on fill plug openings.
If addition of water is necessary, use distilled water. If

distilled water is not available use clean water that is low
in minerals. Do not use artificially softened water.
At proper charging rate, batteries should not require

more than 30 cc (1 ounce) water per cell per week.
Keep batteries clean.
610
Every 100 Service Hours or 2 Weeks
Clutch Bearing
Lubricate Fitting
1. Lubricate clutch bearing .
611
Alternator Belts
To Adjust
Inspect Belt
1. Remove belt guard.

1. Apply a 110 N (25 pound) force perpendicular to
the belt, midway between the driving and driven pulley.
Measure the belt deflection.
Proper belt deflection is 15 to 20 mm (.6 to .8 inch).

Adjust the belt tension as required.
2. Loosen locknut on the belt tightener rod.
3. Turn adjustment nut ô until correct belt

deflection is obtained.
2. Inspect the belts for wear. Replace belts if worn, 4. Tighten locknut .
cracked or frayed.
5. Check the belt adjustment.
When belt replacement is necessary, belts must be
replaced in complete matched sets. Never replace only 6. Install the belt guard.
one belt. The new belt will carry all of the load and
consequently, fail rapidly.
3. If belts do not require replacement or

adjustment, install the belt guard. If belts require
adjustment or replacement, do not install the belt guard.
See "To Adjust” below when belt adjustment and/or
replacement is necessary.
612
Fan Pulley Bearing
Lubricate Fitting
Cooling System
Add Coolant Conditioner
At operating temperature, the engine coolant is hot

and under pressure.
Check the coolant level only when the engine is

stopped and the filler cap is cool enough to touch
with your hand.
Remove the filler cap slowly to relieve pressure.

Lubricate fan pulley bearing .
Steam can cause personal injury.
Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes to prevent personal
injury.
NOTICE
All water is corrosive at engine operating temperature.

Use either Caterpillar Cooling System Conditioner, or
Coolant Conditioner Element to treat either plain water or
ethylene glycol antifreeze solution. Never use both the
cooling system conditioner and the coolant conditioner
element at the same time.
Do not use Caterpillar Cooling System Conditioner or

Coolant Conditioner Elements with Dowtherm 209 Full-
Fill coolant. Follow recommendations provided with
Dowtherm 209 Full-Fill coolant.
Add .5 liter (1 pint) of Caterpillar Cooling System

Conditioner for each 15 liters (4 U.S. gallons) of coolant
used. This will maintain the required 3% to 6%
concentration of conditioner.
613
Engine Crankcase
3508 Engines With 104 Liter (27 Gal.) Capacity Oil

Sump

Sump

Sump
1. Remove filler cap slowly to relieve pressure.
It may be necessary to drain enough coolant to allow for Use caution when draining oil or changing filters.
the addition of cooling system conditioner. Hot oil or components can cause burns if they
contact skin.
2. Add Caterpillar Cooling System Conditioner.
3. Inspect filler cap gasket. Replace cap if

damaged. Change Oil and Filters - Clean Suction Screen
With the oil warm and the engine stopped, drain the
4. Install filler cap. crankcase.
1. Remove the oil pan drain plug. Allow the oil to

drain.
2. Clean and install the drain plug.
614
3. Attach one end of hose ô) to drain valve . Put 6. Remove cover ÷
the other end of hose ôin a container to catch the oil.
7. Remove the three oil filter elements.
4. Open oil filter housing drain valve
8. Wipe out the oil filter housing with a clean rag.

5. Remove vent plug ífrom the side of the filter
housing.
9. Install three new filter elements.
57
615

necessary.
11. Install cover ÷
12. Close the filter housing drain valve
13. Remove the drain hose.
19. If prelube pump is not available, then proceed

with filling the crankcase. See "Refill Capacities" and
"Fuel, Coolant and Lubricant Specifications."
20. Clean and install vent plug íinto the filter

housing.
21. Crank the engine with the fuel supply line closed
until 70 kPa (10 psi) oil pressure shows on the gauge.
Open the fuel supply line valve. Then start and run the
NOTE: The suction screen cover is on left hand side of engine. Inspect for leaks. Reduce engine speed to low
small capacity oil pans (250 hour service only). idle.
14. Remove four bolts and cover û) from the right

front side of oil pan.
15. Remove suction screen and clean.
16. Inspect O-ring seals. Install new seals if

necessary.
17. Install the suction screen and coverû
18. If a prelube pump is available, fill the oil filter

housing and the oil cooler with oil.
22. Maintain oil level to the FULL mark on ENGINE

RUNNING side of dipstick. Stop the engine.
616
Emergency Shutoff Engine Crankcase

Controls
Test for Proper Function 3508 Engines 227 Liter (59 Gal.)
Capacity Oil Sump
3512 Engines 312 Liter (81 gal.)

Capacity Oil Sump
3516 Engines 401 Liter (106 Gal.)

Capacity Oil Sump
Refer to "Engine Crankcase" at the Every 250 Service

Hours or Monthly interval for procedure to change oil and
filters.
The Hydra-Mechanical Shutoff should be tested to

ensure proper operation and protection to the engine.
Refer to "Engine Controls - Standard and/or Attachment"
in the Operation Section.
Check air inlet valve to make sure it closes during

testing.
617
Shutoff Controls Woodward UG8L

Governor
Change Oil
Check for Proper Operation
To prevent personal injury be sure the engine cannot

be started. Disconnect the ground cable from the
battery terminal.
The engine protective shutoff controls must be checked

for proper operation. They are the coolant level alarm,
low oil pressure switch, electrical high water temperature
shutoff, electrical overspeed shutoff and the manual fuel
shutoff lever. Refer to "Shutoff and Alarm System
Components" in the "Operation Section" for information
on these controls. This will ensure that if a malfunction
should occur, the engine will stop without being
damaged. 1. Move the ON/OFF switch to the OFF position.
Have the checks made by a qualified mechanic. Consult 2. Close the fuel tank fuel supply valve.
your authorized Caterpillar engine dealer, or refer to the
Service Manual for your engine. 3. Disconnect the ground cable from the battery
terminal.
618
Bleed Air From the Governor
4. Remove the drain plug. Allow oil to drain. 1. Start the engine and allow the engine to reach
normal operating temperature.
5. Clean and install the drain plug.
2. Loosen nut on the side of the governor which

6. Fill the governor, with clean oil, to the FULL holds compensation adjusting pointerô
mark on the dipstick. Refer to the Lubrication and
Maintenance Chart for proper oil. 3. Manually move pointer ôto the extreme upper
position. Tighten nut This will allow the governor to be
7. Connect the ground cable to the battery. purged of air.
8. Open the fuel tank supply valve.
9. Use the procedure that follows to bleed the

governor.
619
4. Remove the plug from the base of the governor. 7. Loosen the nut and move the compensation
adjusting pointer to the extreme downward position.
Tighten the nut.
8. Slowly turn the needle valve clockwise until the

surging stops.
9. It should now take less than one turn from this

point to close the valve completely.
5. Use a wide blade screwdriver to turn the needle

valve three or more turns counterclockwise.
6. Allow the engine to surge for approximately 30

seconds.
10. Open the valve to the same position

where the surging had stopped.
620
19. A valve opened less than 1/2 of a turn produces
a slow response to load changes. A valve opened more
than 3/4 of a turn produces excessive speed response to
load change. If the engine does not stabilize between
1/2 to 3/4 turn open, raise the pointer two divisions and
repeat steps 12 through 19.
20. When the engine speed stabilizes, install the

base plug.
11. Manually move the governor linkage to disturb

the engine speed.
If the engine speed stabilizes, and the needle

valve is only 1/2 to 3/4 turn open, the governor is
properly adjusted. Install the base plug.
If more than a 3/4 turn is required to stop engine

surging, proceed with the following steps.
12. Raise the pointer two divisions on the pointer

scale.
13. Turn the needle valve counterclockwise three or

more turns.
14. Allow the engine to surge approximately 30

seconds.
15. Gradually turn the needle valve clockwise until

surging just stops.
16. Note the portion of a turn required to close the

needle valve.
17. Open the valve exactly to the same position

surging stopped.
18. Manually move the governor linkage to disturb

the engine speed. The engine speed should stabilize
with the needle valve opened 1/2 to 3/4 turn.
621
Governor Air Actuator Engine Crankcase

Breathers
Lubricate Fittings Clean
1. Lubricate governor air actuator. 1. Remove cover assembly from each breather.
2. Remove mesh ôfrom each breather.
3. Clean mesh elements in clean nonflammable

solvent.
4. Install mesh elements ôin the breathers.
5. Install cover assembly onto each breather.
622
Engine Crankcase
3512 Engines With 613 Liter (162 Gal.)

Capacity Oil Sump
3516 Engines With 842 Liter (219 Gal.)

Capacity Oil Sump
Refer to "Engine Crankcase" at the Every 250 Service

Hours or Monthly interval for procedure to change oil and
filters.
623
Engine Valve Lash Cooling System
Measure Valve Lash (Clearance) Change Coolant
To prevent possible injury when rotating the At operating temperature, engine coolant is hot and
flywheel, do not use the starter motor to turn the under pressure.
flywheel.
Check coolant level only when engine is stopped
and filler cap is cool enough to touch with your
hand.
Remove filler cap slowly to relieve pressure.
NOTICE
Steam can cause personal injury.
With the engine stopped and cold, measure the valve
clearance. Always turn the flywheel in the direction of Cooling System Conditioner contains alkali. Avoid
normal rotation. contact with skin and eyes to prevent personal
injury.
Use all cleaning solutions with care.

Valve Clearance Check
When the valve clearance is checked, adjustment is not

necessary if the measurement is in the range given in
the Valve Clearance Check chart. NOTICE
Valve Clearance Check All water is corrosive at engine operating temperature.

Intake .................... 0.32 to 0.48 mm (.013 to .019 in.) Use Caterpillar Cooling System Conditioner to treat
Exhaust ................. 0.68 to 0.84 mm (.027 to .033 in.) either approved plain water or ethylene glycol solution.
Valve Clearance Setting Do not use Caterpillar Cooling System Conditioner or

Coolant Conditioner Elements with Dowtherm 209 Full-
If the measurement is outside of the range given for Fill coolant. Follow recommendations provided with
valve clearance check, adjustment is necessary. Set Dowtherm 209 Full-Fill coolant.
the clearance to the nominal clearance given in the
"Valve Clearance Setting" chart. Refer to the Service If the engine is to be shipped to, or stored in, an area
O O
Manual or your Caterpillar dealer for the valve with temperatures below 0 C (32 F), the cooling system
adjustment procedures. must be protected to the lowest expected ambient
temperature.
Valve Clearance Setting
Intake ............... 0.40 mm (.016 in.) Clean the cooling system if there is a scale buildup, oil in
Exhaust ............ 0.76 mm (.030 in.) the coolant, if the coolant is muddy, if engine
overheating or foaming is observed. Refer to "Clean
the Cooling System."
624
NOTE: If cooling system conditioner has been added at
Every 250 Service Hours as recommended, the coolant
change period can be extended to 4000 Service Hours.
3. Remove the block drain plugs. Allow coolant to

drain.
4. Clean and install all drain plugs.

1. Remove the filler cap slowly to relieve pressure. 5. Fill the system with a solution of approved water,
antifreeze and 1 liter (1 quart) of Caterpillar Cooling
System Conditioner for each 30 liters (8 U.S. gallons) of
coolant added. See "Refill Capacities" for amount of
solution needed.
NOTE: The addition of .5 liter (1 pint) of conditioner per

15 liters (4 U.S. gal.) of water will give the system a 3%
to 6% concentration of conditioner.
Add solution slowly at 20 liters (5 U.S. gal.) or less per

minute to avoid air locks.
6. Start the engine with the filler cap off. Operate

the engine until the thermostat opens and coolant level
stabilizes. Fill the cooling system to the bottom of fill
2. Remove the drain plug on bottom of water pump tube. Install the filler cap.
housing.
625
Clean the Cooling System 6. Install the drain plug. Fill the system with a
neutralizer. Use a commercially available neutralizer or
250 grams (1/2 lb.) sodium carbonate crystals per 38
liters (10 gal.) of water.
7. Operate engine for ten minutes. Stop the engine

and drain the neutralizer.
8. With the engine stopped, flush the system with

water until drain water is clear. Install the drain plug.
9. Fill the system with clean water and operate the

engine for five minutes. Remove the drain plug, drain
the cooling system and install the drain plug.
10. Repeat Step 9 until water drained is clear.

1. Remove the filler cap slowly to relieve pressure.
11. Mix a solution of water, antifreeze and cooling
system conditioner. See "Refill Capacities" for amount of
coolant needed.
12. Add solution slowly at 20 liters (5 U.S. gal) or

less per minute to avoid air locks.
13. Start and operate the engine with the filler cap
removed until the thermostat opens and the coolant level
stabilizes. Fill the system to the bottom of fill tube.
14. Stop the engine.
15. Install the filler cap.
2. Remove the drain plug. Allow coolant to drain.

Install the drain plug when all of solution is drained.
3. Fill the cooling system with a cleaning solution.

Use a commercially available cleaner or 1 Kg (2 lb.)
sodium bisulfate per 38 liters (10 gal.) of water.
4. Start and operate engine for ½ hour. Stop

engine and drain the cleaning solution.
5. With the engine stopped, flush the system with

water until draining water is clear.
626
Troubleshooting Section
627
Troubleshooting
Troubleshooting
Troubleshooting Index
1. Engine will not turn when start switch is on
2. Engine will not start
On the following pages there is a list of possible 3. Starting motor does not turn
problems. To correct a problem, make reference to the 4. Air starting motor turns slowly
CAUSE and CORRECTION. 5. Alternator gives no charge
6. Alternator charge rate is not regular
If problems are encountered, they should be corrected 7. Alternator has noise
promptly to maintain engine operation. 8. Misfiring or running rough
9. Not enough power
This list of problems, causes, and corrections, will only
10. Stall at low rpm
give an indication of where a possible problem can be,
11. Sudden changes in rpm
and what repairs may be needed. Remember that a
12. Loud combustion noise
problem is not normally caused only by one part, but by
the relation of one part with other parts. 13. Valve train noise
14. Loud valve train noise
This list can not give all possible problems and 15. Too much valve lash
corrections. The serviceman must find the problem and 16. Little or no valve clearance
its source, then make the necessary repairs. 17. Valve rotocoil or spring lock is free
18. Noise in engine
19. Too much vibration
20. Too much white or blue smoke
21. Oil at the exhaust
22. Too much lubrication oil used
23. Too much black or gray smoke
24. Fuel consumption too high
25. Low oil pressure
26. Coolant in oil
27. Oil in cooling system
28. Coolant is too hot
29. Engine has early wear
30. Exhaust temperature too high
628
Troubleshooting
1. Engine will not turn when start switch is on
Cause Correction
Battery has low output. Make reference to Item 3.
Wiring or switches have defect. Make reference to Item 3.
Starting motor solenoid has a defect. Make reference to Item 3.
Starting motor has a defect. Make reference to Item 3.
Oil pressure switch for prelubrication pump Make a replacement of defective switch.
has a defect.
Prelubrication oil pump has a defect. Repair or replace pump components as needed.
Inside problem prevents engine crankshaft If the crankshaft can not be turned after
from turning. disconnecting the driven equipment, remove the
fuel injectors and check for fluid in the cylinders
while turning the crankshaft. If fluid in the
cylinders is not the problem, the engine must be
disassembled to check for other inside
problems. Some of these inside problems are
bearing seizure, piston seizure or wrong pistons
installed in the engine.
2. Engine will not start
Cause Correction
Slow cranking speed. Make reference to Items 3, 4 and 5.
Dirty fuel filter. Install new fuel filter.
Dirty or broken fuel lines. Clean or install new fuel lines as necessary.
Fuel pressure is low. At starting rpm, the minimum fuel pressure from
fuel transfer pump must be 20 kPa (3 psi). If
fuel pressure is less than 20 kPa (3 psi) change
the fuel filter element.
Look for air in the fuel system. If fuel pressure is

still low, check the fuel control valve and the fuel
transfer pump for correct operation.
No fuel to cylinders. Put fuel in tank. "Prime" (remove the air and/or
low quality fuel from the fuel system).
629
Troubleshooting
2. Engine will not start (cont’d)
Cause Correction
Bad quality fuel. Remove the fuel from the fuel tank. Install a
new fuel filter element. Put a good grade of
clean fuel in the fuel tank.
Wrong fuel injection timing. Make adjustment to timing.
3. Starting motor does not turn Deleted.
4. Air starting motor turns slowly Deleted.
5. Alternator gives no charge Deleted.
630
6. Alternator charge rate is not regular Deleted.
7. Alternator has noise Deleted.
8. Misfiring or running rough
Cause Correction
Fuel pressure is low. Make sure there is fuel in the fuel tank. Look for
leaks or bad bends in the fuel line between fuel
tank and fuel transfer pump.
Look for air in the fuel system, sticking, binding

or defective fuel control valve.
Check fuel pressure. The outlet pressure of the

fuel transfer pump must be a minimum of 140
kPa (20 psi) at full load speed.
If fuel pressure is lower than the above pressure,

install a new fuel filter element. If fuel pressure
is still low, check the fuel transfer pump.
Air in fuel system. Find the air leak in the fuel system and correct it.
If air is in the fuel system it will generally get in
on the suction side of the fuel transfer pump.
631
Troubleshooting
8. Misfiring or running rough (cont’d)
Cause Correction
Leak or break in fuel line between fuel Install a new fuel line.
manifold and cylinder head.
Wrong valve clearance. Make adjustment.
9. Not enough power
Cause Correction
tank and fuel transfer pump. Look for air in the
fuel system, sticking, binding or defective fuel
control valve. Check fuel pressure. The outlet
pressure of the fuel transfer pump must be a
minimum of 140 kPa (20 psi) at full load speed.
Leaks in air inlet system. Check the pressure in the air intake manifold.
Look for restrictions in the air cleaner.
Governor linkage. Make adjustment to get full travel of linkage.

Install new parts for those that have damage or
defects.
Wrong valve clearance. Make adjustment.
Power setting too low. Make an adjustment of the power setting to

specifications shown on the engine information
plate.
Turbocharger has carbon deposit. Inspect and repair turbocharger as necessary.
632
10. Stall at low rpm
Cause Correction
tank and fuel transfer pump. Look for air in the
fuel system, sticking, binding or defective fuel
control valve.
Check fuel pressure. The outlet pressure of the

fuel transfer pump must be a minimum of 140
kPa (20 psi) at full load speed.

Idle rpm too low. Make adjustment to governor so idle rpm is the
same as given on the engine information plate.
Engine accessories. Check engine accessories for damage and

correct adjustment. If necessary, disconnect the
accessories and test the engine.
11. Sudden changes in rpm
Cause Correction
Failure of governor or fuel injection pump. Look for damaged or broken springs, linkage or
other parts. Remove the governor.
Check for free travel of the control linkages.

Install new parts for those that have damage or
defects.
12. Loud combustion noise
Cause Correction
633
Troubleshooting
13. Valve train noise
Cause Correction
Broken valve spring(s) or locks. Install new parts where necessary. Broken locks
can cause the valve to slide into the cylinder.
This will cause much damage.
Not enough lubrication. Check lubrication in valve compartment. There

must be a strong flow of oil at engine high rpm,
but only a small flow of oil at low rpm.
Oil passages must be clean, especially those

sending oil to the cylinder head.
Damage in bridge for valves. Make a replacement of the bridge and make an
adjustment as necessary.
Too much valve clearance. Make correct adjustment.
14. Loud valve train noise
Cause Correction
Broken valve spring(s). Make replacement of damaged parts.
Broken camshaft. Make replacement of damaged parts. Clean

engine thoroughly.
15. Too much valve lash
Cause Correction
Not enough lubrication. Check lubrication in valve compartment. There
must be a strong flow of oil at engine high rpm,
but only a small flow at low rpm.
Oil passages must be clean, especially those

sending oil to the cylinder head.
Rocker arm worn at face that makes If there is too much wear, install new parts
contact with bridge. or rocker arms. Make adjustment of valve
clearance.
End of valve stem worn. If there is too much wear, install new valves.
Make adjustment of valve clearance.
Worn push rods. If there is too much wear, install new push rods.
Make adjustment of valve clearance.
634
15. Too much valve lash (cont’d)
Cause Correction
Valve lifter worn. If there is too much wear, install new valve
lifters. Make adjustment of valve clearance.
Bridges for valves worn. Make an adjustment or replacement as

necessary.
Broken or worn valve lifters. Clean engine thoroughly. Install new valve
lifters.
Check camshaft for wear. Check for. Free movement of valves or bent
valve stem. Make adjustment of valve
clearance.
Worn cams on camshaft. Check valve clearance. Check for free

movement of valves or bent valve stems. Install
a new camshaft. Install new valve lifters. Make
adjustment of valve clearance.
16. Little or no valve clearance
Cause Correction
Worn valve seat or face of valve. Reconditioning of cylinder head is needed. Make
adjustment of valve clearance.
17. Valve rotocoil or spring lock is free
Cause Correction
Broken locks. Broken locks can cause the valve to slide into
the cylinder. This will cause much damage.
Broken valve spring(s). Install new valve spring(s).
Broken valve. Replace valve and other damaged parts.
635
Troubleshooting
18. Noise in engine
Cause Correction
Failure of bearing for connecting rod. Inspect the bearing for the connecting rod and
the bearing surface (journal) on the crankshaft.
Install new parts where necessary.
Damaged gears. Install new parts where necessary.
Defect in attachment. Repair or install new components.
19. Too much vibration
Cause Correction
Vibration damper or pulley is loose Check vibration damper and pulley for damage.
Tighten bolts or nuts. If vibration damper or
pulley bolt holes have damage or wear, replace
with new parts.
Vibration damper has a defect. Install a new vibration damper.
Engine supports are loose, wrong, or have Tighten all mounting bolts. Install new
a defect. components if necessary.
Driven equipment is not in alignment or is Check alignment and balance. Correct if

out of balance. needed.
Misfiring or running rough. Make reference to Item 8.
20. Too much white or blue smoke
Cause Correction
Too much lubrication oil in engine. Remove extra oil. Find where extra oil comes
from. Put correct amount of oil in engine.
Misfiring or running rough. Make reference to Item 8.
Worn valve guides. Recondition cylinder head.
Worn piston rings. Install new piston rings.
Failure of turbocharger oil seal. Check inlet manifold for oil and repair
turbocharger if necessary.
636
21. Oil at the exhaust
Cause Correction
Too much oil in the valve compartment. Be sure that there is plug in the end of the rocker
shaft.
Worn valve guides. Reconditioning of the cylinder head is needed.
Worn piston rings. Inspect and install new parts as needed.
22. Too much lubrication oil used
Cause Correction
Too much lubrication oil in engine. Remove extra oil. Find where extra oil comes
from.
Fill engine with oil to the FULL mark on the

dipstick. Then, check oil level while engine is
running. Do not put too much oil in engine.
Oil leaks. Find all oil leaks. Make repairs as needed.

Check for dirty oil breather.
Oil temperature is too high. Check operation of oil cooler. Install new parts if
necessary. Clean the core of the oil cooler.
Too much oil in the valve compartment. Be sure that there is a plug in the end of the
rocker shaft.
Worn valve guides. Recondition the cylinder head.
Worn piston rings. Inspect and install new parts as needed.
23. Too much black or gray smoke
Cause Correction
Not enough air for combustion. Check air cleaner for restrictions.
Bad fuel injectors. Install new fuel injectors.
Wrong fuel injection timing. Make adjustments of timing.
637
Troubleshooting
24. Fuel consumption too high
Cause Correction
Fuel system leaks. Replacement of parts is needed at points of
leakage.
Fuel and combustion noise (knock). Make reference to Item 8 and Item 9.
25. Low oil pressure
Cause Correction
Dirty oil filter or oil cooler. Check the operation of bypass valve for the filter.
Install new oil filter element if needed.
Clean or install new oil cooler core. Remove

dirty oil from engine. Put clean oil in engine.
Diesel fuel in lubrication oil. Find the place where diesel fuel gets into the
lubrication oil. Make repairs as needed.
Drain the lubrication oil that has diesel fuel in it.

Install a new oil filter element. Fill the engine
with clean oil.
Too much clearance between rocker arm Check lubrication in valve compartments.
shaft and rocker arms. Install new parts as necessary.
Oil pump suction pipe has a defect. Replace pipe.
Pressure regulating valve does not close. Clean valve and housing. Install new parts as
necessary.
Oil pump has a defect. Repair or replace oil pump.
Too much clearance between crankshaft Inspect the bearings and make replacement
and crankshaft bearings. if necessary.
Too much clearance between camshaft and Install new camshaft and camshaft bearings
camshaft bearings. if necessary.
Defect in oil pressure gauge. Install new gauge.
638
26. Coolant in oil
Cause Correction
Failure of oil cooler core. Install a new core for the oil cooler. Drain
crankcase and refill with clean lubricant. Install
new oil filter element.
Failure of cylinder head gasket. Check cylinder liner projection. Install a new
cylinder head gasket. Tighten the bolts holding
the cylinder head.
Crack or defect in cylinder head. Install a new cylinder head.
Crack or defect in cylinder block. Install a new cylinder block.
Failure of, liner seals. Replace seals.
27. Oil in cooling system
Cause Correction
Defect in core of oil cooler. Install a new core in the oil cooler.
Failure of cylinder head gasket. Check cylinder liner projection. Replace head
gasket.
28. Coolant is too hot

Cause Correction
Not enough coolant in system. Add coolant to cooling system. Check for
leaks.
Pressure relief valve has a defect. Check operation of pressure relief valve. Install
a new pressure relief valve if necessary.
Combustion gases in coolant. Find out where gases get into the cooling
system. Make repairs as needed.
Water temperature regulators (thermostats) or Check water temperature regulators for correct
temperature gauge has defects. operation. Check temperature gauge operation.
Install new parts as necessary.
Water pump has a defect. Make repairs to the water pump as necessary.
Too much load on the system. Reduce the load.
639
Troubleshooting
29. Engine has early wear
Cause Correction
Dirt in lubrication oil. Remove dirty lubrication oil. Install a new oil
filter element. Put clean oil in the engine.
Check oil filter bypass valve for a weak or

broken spring.
Air inlet leaks. Inspect all gaskets and connections. Make

repairs if leaks are found.
Fuel leakage into lubrication oil. This will cause high fuel consumption and low
engine oil pressure. Make repairs if leaks are
found. Install new parts where needed. Make
reference to Items 24 and 25.
30. Exhaust temperature is too high
Cause Correction
Air inlet system has a leak. Check pressure in the air intake manifold. Look
for restrictions at the air cleaner. Correct any
leaks.
Exhaust system has a leak. Find cause of exhaust leak. Make repairs as
necessary.
Air inlet or exhaust system has a restriction. Remove restriction.
Wrong fuel injection timing. Make an adjustment to the timing.
640
641
3508 DIESEL ENGINE CATERPILLAR
SECTION II.MAINTENANCE ALLOCATION CHART
(1) (2) (3) (4) (5) (6)
GROUP MAINTENANCE MAINTENANCE CATEGORY TOOLS AND

NUMBER COMPONENT ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
01 Exhaust System
Manifold, Exhaust Inspect 0.5
Replace 6.0
Repair 8.0
02 Cooling, System
Hoses & Clamps Inspect 0.2
Replace 2.0
Thermostat Engine Inspect 0.5

Test 0.5
Replace 2.0
Heater, External Inspect 0.5

Engine Block Replace 4.0
Repair 6.0
Water Manifold Assy Inspect 0.5

Replace 6.0
Repair 12.0
Pump Water Inspect 0.2

Replace 4.0
Repair 8.0
Overhaul 10.C
03 Fuel System Inspect 0.5

Turbocharger Replace 10.C
Repair 12.0
Overhaul 24.0
Lines & Fittings Inspect 0.2

Replace 2.0
Repair 4.0
Filter, Fuel Inspect 0.1

Replace 0.3
Pump, Fuel Reciprocating - Inspect 0.3

Test 1.5
Pumps Fuel Injection Replace 3.0
Repair 6.0
Overhaul 8.0
642
SECTION II. MAINTENANCE ALLOCATION CHART
(1) (2) (3) (4) (5) (6)

Injectors, Fuel Inspect 0.5

Test 1.0
Adjust 1.0
Replace 2.0
Repair 3.0
04 Engine
Engine Assembly Inspect 1.5

Test 8.0
Service 1.5
Replace 40.0
Repair 24.0
Overhaul 120.0
Filter, Oil Inspect 0.2

Replace 0.5
Lube Oil Cooler Inspect 0.2

Replace 4.0
Repair 8.0
Drive Mechanism Inspect 1.0

Fuel Pump Replace 8.0
Repair 16.0
Pump, Oil Inspect 2.0

Replace 5.0
Repair 10.0
Overhaul 12.0
Compression Release Inspect 2.0

Mechanism Replace 4.0
Repair 8.0
Governor Inspect 0.3

Test 2.0
Replace 2.0
Repair 10.0
Overhaul 16.0
Governor Drive Inspect 2.0

Replace 4.0
Repair 8.0
Manifold, Intake Inspect 0.5

Replace 4.0
Repair 6.0
643
(1) (2) (3) (4) (5) (6)

After Cooler Inspect 0.5

Replace 8.0
Repair 12.0
Fly Wheel & Damper Inspect 1.0

Replace 2.0
Rocker Arms Inspect 0.3

Replace 1.5
Repair 3.0
Cylinder Head Assy Inspect 0.5

Replace 4.0
Repair 10.0
Overhaul 16.0
Rods, Push Inspect 1.0

Replace 1.0
Valves, Intake & Inspect 1.0

Exhaust Adjust 1.5
Replace 8.0
Repair 12.0
Lifters, Valve Inspect 1.0

Replace 1.0
Oil Pan Inspect 1.0

Replace 16.0
Repair 24.0
Pistons & Connecting Inspect 2.0

Rods Replace 12.0
Repair 20.0
Liners, Cylinder Inspect 2.0

Replace 12.0
Repair 20.(
Camshaft & Bearings Inspect 4.0

Replace 16.(
Crankshaft & Inspect 2.5

Bearings Replace 40.0
Repair 60.0
644
(1) (2) (3) (4) (5) (6)

Engine Block Inspect 1.0

Test 8.0
Replace 40.0
Repair 24.0
Overhaul 80.0
645
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS
REF. MAINT. NATIONAL/NATO TOOL*

CODE CAT. NOMENCLATURE STOCK NUMBER NUMBER
646
TM 5-2815-232-14
By Order of the Secretary of the Army:
JOHN A. WICKHAM, JR.

General, United States Army
Official: Chief of Staff
R. L. DILWORTH
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Operator, Organizational Direct and General Support
Maintenance Requirements for Locomotive, Diesel-Elec, 0-4-4-0 Wheel, 60-T, 500 HP, Model RS-4-TC.
U.S. GOVERNMENT PRINTING OFFICE: 1990 - 261-88/22713

PIN: 059984-000

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TM 5-2815-232-14

OPERATOR’ S, UNIT, INTERMEDIATE

HEADQUARTERS, DEPARTMENT OF THE ARMY

IMPORTANT SAFETY NOTICE

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

4. If an engine must be started to make pressure or

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

IMPORTANT SAFETY NOTICE

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

IMPORTANT SAFETY NOTICE

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

machinery that has been put into operation.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

Fuel System V-Belt Tension Chart................................. 33

Fuel Pressure Regulator (Later).......... 9 Cylinder Block ........................................... 34

Lubrication System Flywheel Housing Runout ......................... 53

Pistons ............................................. 396 Tachometer, Digital ............................... 450

Cylinder Liners ......................................... 398 Contactors .............................................. 451

Camshafts ............................................. 400 Pressure Switches ................................. 452

Engine Shutdown Due to Fault: Individual Circuit Description ................ 516

Oil Step Calibration, Procedure C ............ 550 Engine Specifications................................ 592

TORQUE FOR FLARED AND O-RING FITTINGS

ASSEMBLY OF FITTINGS WITH

1. Put locknut (3), backup washer (4) and O-ring

NOTE: If the fitting is a connector (straight fitting) or plug,

CYLINDER AND VALVE LOCATION

SPECIFICATIONS 3508 3512 3516

NUMBER AND ARRANGEMENT 60° V-8 60° V-12 60° V-16

FIRING ORDER (INJECTION SEQUENCE)

ENGINE SAE STANDARD ROTATION* SAE OPPOSITE ROTATION*

3508 1-2-7-3-4-5-6-8 1-8-7-2-6-5-4-3

3512 1-12-9-4-5-8-11-2-3-10-7-6 14-9-8-5-2-11 -10-3-6-7-12

3516 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8 1-6-5-4-3-10-9-16-15-12-11-14-13-8-7-2

* Direction of Rotation (as viewed from flywheel end):

NOTE: Front end of engine is opposite the flywheel end.

(1) Torque for locknut for rocker arm

a. Put multipurpose type grease in bore of cylinder

b. Put injector in bore. Use bolt and clamp to

NOTE:Do not tap (hit) surface "Y" to install injector.

c. Tighten bolt that holds fuel injector

(4) Fuel timing dimension set by gauge.

(5) Guide springs must not be used again. Always

(6) Diameter of valve lifter

Bore in head for valve

FUEL PRESSURE REGULATOR

(1) Fuel manifold adapter on right hand front fuel

(2) 9N4053 Spring for fuel pressure regulator valve

Length under test force .......... 28 5 mm (1.12 in.)

Test force ...................40 8 + 2 1 N (9 17 + 46 lb)

FUEL PRESSURE REGULATOR

(1) Fuel manifold adapter on right hand front fuel

(2) 9N4053 Spring for fuel pressure regulator valve

Length under test force .......... 28.5 mm (1.12 in.)

Test force .................40.8 + 2 1 N (9.17 + .46 lb.)

Free length after test .............. 57.2 mm (2.25 in )

Outside diameter .................. 15.24 mm ( 600 in.)

(3) Regulator valve plunger. Regulator valve to hold fuel