CAT D399 Workshop Manual
CAT D399 Workshop Manual
CAT D399 Workshop Manual
D 379-68B 02540-U P
D 379-69B 01227-U P
D 398-66B 03561 -UP
D 39 8-6 7B 01 391 -UP
D 399-35B 00688-U P
D 399-91B 00378-U P
SPECIFICATIONS (Section 1)
ATTACHMENTS (Section 5)
IN T R O D U C T IO N
T h e sp e c i fi c a t i o n s given in this b o o k ar e o n th e W h e n t h e w o r d “ p e r m i s s ib l e ” is in th e d e s c r i p t i o n ,
basis o f i n f o r m a t i o n available a t t h e t i m e t h e b o o k t h e s p e c i fi c a t i o n given is t h e “ m a x i m u m o r m i n i
was w r i t te n . T h e s e sp e c i fi c a t i o n s give t h e t o r q u e s , m u m ” tolerance p e r m itte d before adju stm en t,
o p e r a t i n g p ress u re, m e a s u r e m e n t s o f n e w p a r ts, re p a i r a n d / o r n e w p a r t s ar e n e e d e d .
a d j u s t m e n t s a n d o t h e r i t e m s t h a t will a f f e c t th e A c o m p a r i s o n can be m a d e b e t w e e n th e m e a s u r e
service o f th e p r o d u c t . m e n t s o f a w o r n p a r t , a n d th e s p e c i fi c a t i o n s o f a
W hen th e w o r d s “ use a g a i n ” are in t h e d e s c r i p t i o n , n e w p a r t t o f i n d t h e a m o u n t o f wear. A p a r t t h a t is
th e s p e c i fi c a t i o n given ca n be u se d t o d e t e r m i n e if w o r n can b e safe t o use if a n e s t i m a t e o f th e r e
a p a r t can be u se d again. I f t h e p a r t is e q u a l t o or m a i n d e r o f its service life is g o o d . I f a s h o r t service
w i t h i n t h e s p e c i fi c a t i o n given, use t h e p a r t again. life is e x p e c t e d , re p la c e t h e p a r t.
NO TE: The specifications given for "use again" and "permissible" are in
tended for guidance only and Caterpillar Tractor Co. hereby expressly denies
and excludes any representation, warranty or implied w arranty of the reuse
of any component.
SPECIFICATIONS (Section 1)
Aftercooler .............................................................................................. 1-10 G eneral Tightening Torques ................................................................... 6
Air-Fuel Ratio Control .......................................................................... 1-7 G enerator Regulator ........................................................................... 1-39
Air Starting M otor ................................................................................ 1-42 G overnor ................................................................................................... 1-6
Alternator Regulators .......................................................................... 1-39
Hand Pump for Hydraulic S ta r te r..................................................... 1-43
Alternators and Regulators ................................................................ 1-38
Hydraulic Starting Motor ..................................................................... 1-43
Bearing Surface (Journal) for Connecting R o d s ............ 1-28
Intake Manifold ..................................................................................... 1-10
Bearing Surface (Journal) for Main Bearings ................. 1-29
Magnetic Switch ................................................................................... 1-39
Camshaft and Tim ing Gears ................................................................ 1-8 Main Bearings ...................................................................................... 1-27
Charging Pump for Hydraulic S ta r te r .............................................. 1-43
Connecting Rod ................................................................................... 1-25 Oil F ilt e r ................................................................................................... 1-18
Connecting Rod Bearings.................................................................... 1-26 Oil Pump ................................................................................................ 1-16
Cooling System Pressure Cap ........................................................ 1-19 Oil Pump Relief V a lv e ......................................................................... 1-1 7
Crankshaft .............................................................................................. 1-24
Cylinder Block ...................................................................................... 1-21 Pistons and Rings ............................................................................... 1-23
Cylinder Head ......................................................................................... 1-9 Prelube Pump ....................................................................................... 1-18
Pressure Accum ulator for Hydraulic Starter .................................. 1-43
Cylinder Liner ........................................................................................ 1-22
Cylinder Liner Projection .................................................................... 1-22 Pressure Regulating Valve for A ir Starting Motor ....................... 1-42
2
INDEX
D379, D398, D399, INDUSTRIAL AND MARINE ENGINES
Air Inlet and Exhaust System ........................................................... 3-35 Fuel System ........................................................................................... 3-15
Compression ................................................................................... 3-36 Air-Fuel Ratio Control Adjustm ent ............................................. 3-30
Crankcase (Crankshaft Compartment) Pressure ................... 3-36 Cam shaft Cluster G ear Installation ........................................... 3-33
Cylinder Head ................................................................................. 3-37 Checking Engine Cylinders Separately .................................... 3-15
M easurem ent of Pressure in Inlet Manifold ............................ 3-35 Checking Fuel Injection Pump Timing
Precom bustion Chamber ............................................................. 3-36 with Tim ing Pin .......................................................................... 3-22
Restriction of Air Inlet and Exhaust ........................................... 3-35 Checking Tim ing by the Fuel Flow Method ........................... 3-24
Valves ............................................................................................... 3-37 Checking Timing by M easuring Timing Dimension
Valve Guides .................................................................................. 3-37 (Depth M icrom eter) ..................................................................... 3-22
Valve Lash Adjustm ent and Check ........................................... 3-38 Checking Tim ing by Measuring Tim ing Dimension
Valve Seat Inserts ......................................................................... 3-37 (Dial In d ic a to r).............................................................................. 3-23
W ater Directors ............................................................................... 3-36 Finding Top Center Compression Position
For No. 1 P is to n .......................................................................... 3-21
Fuel Injection Service ................................................................... 3-19
Basic B lo c k ............................................................................................. 3-46 Fuel N ozzle Test Sequence ........................................................ 3-17
Checking Crankshaft Deflection (Bend) ................................... 3-50 Fuel Rack Adjustm ent ................................................................. 3-29
Connecting Rod and Main Bearings ......................................... 3-46 Fuel System Inspection ................................................................ 3-15
Connecting Rods and Pistons .................................................... 3-46 G overnor Adjustm ents .................................................................. 3-31
C ylinder Block ................................................................................ 3-46 M easuring Engine Speed ............................................................ 3-32
Cylinder Liner Projection ............................................................ 3-47 Setting Fuel Injection Pump Timing Dimension:
Flywheel and Flywheel Housing ................................................. 3-47 Off Engine ..................................................................................... 3-27
Piston Ring Groove Gauge ......................................................... 3-46 Start Up Procedure ....................................................................... 3-20
Vibration Damper .......................................................................... 3-51 Testing C apsule-Type Fuel Injection Nozzles
for PC E n g in e s ............................................................................. 3-15
Tim ing Balancer G ear in Accessory Drive
Cooling System .................................................................................... 3-43 (V -8 Only) ...................................................................................... 3-33
Testing the Cooling System ........................................................ 3-43 Timing C am shaft for Fuel Injection Pumps ............................ 3-26
Visual Inspection of the Cooling S y s te m .................................. 3-43
3
D379, D398, D399, INDUSTRIAL AND MARINE ENGINES INDEX
Autom atic Start/Stop System ............................................................. 5-34 Pierce Output Shaft Governor
Attachments For Cranking Panel ................................................ 5-40
Autom atic Transfer Switch ............................................................. 5-34 Power Take-off C lu tc h e s .................................................................... 5-10
2301 Control System Application ................................................ 5-38
Cranking Panel ................................................................................ 5-35 S hutoff And Alarm System Com ponents ....................................... 5-11
Electric S e t ......................................................................................... 5-36 Circuit Breaker ................................................................................ 5-12
Hydraulic G overnor Application .................................................. 5-36 Contactor Switch ............................................................................. 5-13
Oil Pressure Switch ....................................................................... 5-11
Governor Air Actuators ......................................................................... 5-9 Pressure Switch .............................................................................. 5-11
Shutoff Solenoid ............................................................................. 5-12
Hydra-M echanical Shutoff ................................................................... 5-14 Shutoff Valve For W ater Tem perature ..................................... 5-13
Hydra-M echanical Shutoff (5N5993 and 5N5994) .................. 5-14 W ater Tem perature C ontactor Switch ...................................... 5-12
Hydra-M echanical Shutoff (3N5760 and 5N1978) .................. 5-22
W oodw ard SG T G overnor ................................................................... 5-8
2301 Nonparallel Control System ...................................................... 5-32
W oodward UG 8 G o v e rn o rs .................................................................. 5-2
2301 Parallel Control System ............................................................. 5-30 W oodward UG 8 Dial and Lever G overnors ............................. 5-2
4
D379 D398 D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G I N E S IN D E X
GENERAL INSTRUCTIONS
DISASSEMBLY AND ASSEMBLY (Section 6)
Batteries ................................................................................................... 6-8 Lines and W ires ..................................................................................... 6-6
Bearings ................................................................................................... 6-7
Locks ......................................................................................................... 6-6
Anti-Friction ........................................................................................ 6-7 Lubrication ................................................................................................ ° '
Double Row, Tapered Roller ......................................................... 6-7 Lubrication For a Rebuilt Engine ...................................................... 6-2
Procedure For Pressure Lubrication ........................................... 6-3
Heating Bearings ............................................................................. 6-7
Installation .......................................................................................... 6-7
Preload ............................................................................................... 6-7 Pressing Parts 6-5
Sleeve B e a rin g s ................................................................................ 6-7
Bolts and Bolt Torque ........................................................................... 6-5 Removal and In s ta lla tio n ....................................................................... 6-2
Torque W rench Extension ............................................................ 6-6 Rules for Use of Tools .......................................................................... 6-5
T-T-T Procedure ............................................................................... 6-5
Rust Preventive Com pounds .............................................................. 6-7
5
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES SPECIFICATIONS
G E N E R A L T IG H T E N IN G TO R Q U E FOR
BOLTS, NUTS A N D TA PER LO C K STUDS Y
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.
Standard thread
, • ------ Trmrmmnnh, Use these torques for bolts and nuts with stan
dard threads (conversions are approximate).
lin O
•
1/4 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 7 0 ± 15
1/2 12.70 75 ± 10 100 ± 15
9 /16 14.29 110 ± 15 150 ± 20
5/8 15.88 150 ± 20 20 0 ± 25
3 /4 19.05 265 ± 35 360 ± 50
7/8 22.23 4 2 0 ± 60 5 7 0 ± 80
1 25.40 64 0 ± 80 875 ± 100
1 1/8 28.58 80 0 ± 100 1100 ± 150
1 1/4 31.75 1000 + 120 1350 ± 175
1 3/8 34 .9 3 1200 ± 150 1600 ± 200
1 1/2 38.10 1500 ± 200 2 0 0 0 ± 275
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
Taperlock stud
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 /1 6 14.29 60 ± 10 8 0 + 15
5/8 15.88 75 + 10 100 + 15
3/4 19.05 110 ± 15 150 + 20
7/8 22 .2 3 170 ± 2 0 2 3 0 + 30
1 25.40 260 + 30 35 0 + 40
1 1/8 2 8.58 320 + 30 4 0 0 + 40
1 1/4 31.75 4 0 0 + 40 5 5 0 + 50
1 3/8 3 4.93 4 8 0 ± 40 6 5 0 ± 50
1 1/2 3 8 .1 0 5 5 0 ± 50 7 5 0 + 70
6
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L & M A R IN E ENG IN ES SPEC IFIC ATIO N S
Ill
Pro per repair is im portant to the safe and reliable oper ation o f this product. This
Service Manual outlines basic rec o m m e n d e d p r o cedu res, some o f w hich require
special tools, dev ices or work m ethods. A lthough not necessarily all inclusive, a
list o f additional skills, precautions and kno w ledg e required to safely perform
repairs is provided in the S A F E T Y section o f this Manual.
Im pro per repair procedures can be d ang ero u s and could result in injury or d e a t h .
Basic safety precautions, skills and k n ow led ge are listed in the S A F E T Y section
o f this M anual and in the de scriptions o f operations where hazards exist. W arning
labels have also been put on to pro vid e instructions and identify specific hazards
which if not heeded could cau se bodily injury or death to you or other persons.
These labels identify hazards which m ay not be apparent to a trained m ec hanic.
There are m any potential hazards du ring repair for a untrained m ech an ic and there
is no way to label the pr oduct agains t all such hazards. These w arnings in the
Service Manual and on the product are identified by this symbol:
A WARNING
Ca terpillar can not anticipate ev ery poss ible circum stan ce that might involve a
potential hazard. The warnings in this Manual are therefore not all inclusive. If a
procedure, tool device o r work m eth o d not specifically r eco m m en d ed by C a te rp il
lar is used, you must saftisfy y ou rself that it is safe for you and others. You should
also ensure that the product will not be d am ag ed or m ade unsa fe by the procedures
you choose.
IMPORTANT
SAFETY
1. Read and understand all W a r n in g plates and d e 8. D isc o nn ect battery and disc harg e any capac itors
cals bef ore oper ating, lubr icating or repairing this b ef ore starting any repair w ork. H an g ” Do Not
product. O p e r a t e ’ ’ tag in the O p e r a t o r ’s c o m p artm en t or on
the controls.
2. M ake sure the work area around the prod uct is
m ad e safe and be awar e o f haz ard ou s co nditions 9. D o not work on an y th ing that is supported only by
that m ay exist. lift j a c k s or a hoist. A lw ay s use blocks or p ro p er
stands to support the pro du ct before perform ing
3. A lw ay s w ear protective glasses and protective any se rvice work.
shoes w h en working. In particular, w e a r p rotec
tive glas ses w hen a h a m m e r o r sledge is used for 10. R eliev e all pr ess ure in air, oil o r water systems
p ou n d in g to m ak e repairs. Use welders gl oves , bef ore any lines, fittings or related item s are dis
h o o d /g o g g le s, apron and other protective c lothing co n nected o r rem oved. Be alert for possible p r e s
appr opriate to the w elding jo b being perfo rm ed. sure w hen discon necting any device from a system
D o not w ear loose-fitting o r torn clothing. R e that utilizes pressure. D o not check for pressure
m ove all rings fro m fingers when w orkin g on leaks with y o u r hand. High p ressure oil or fuel can
m achinery. pierce the skin.
A83265X1
A WARMING
11. N e v e r b en d a fuel injection line, o r install a line 18. A lw ay s use tools that are in g o o d condition and be
w h ich has b een bent. K eep the fuel injection lines sure you und erstand h o w to use th em b efore p e r
and co n nectio n s clean. Be sure to install ca ps and f o rm in g any service w ork. U se onl y Cate rp illar
cover s any tim e a l i n e is re m o v e d or disconnected. rep lacem en t parts.
12. D uring service w ork, do not hit the fuel injection 19. Reinstall all fasteners with sam e part num ber. Do
lines with w renches o r o th er tools. W h e n lines are not use a les ser quality fasten er if rep lacem ents are
installed, use the corre ct torque to tighten c o n n e c necessa ry .
tions and be sure all clam p s a n d d am p ers are
corre ctly installed. 20. R epairs which require w eld in g should be p er
fo rm e d onl y with the benefit o f the appropriate
13. M a k e sure all fuel injection lines and press ure oil refe re nce inform ation and by per so nnel ad e q u a te
lines h ave en o u gh clearance to prevent co ntact ly trained and k n o w led g eab le in w elding p r o c e
with any ot her co m p on en t. D o not put any fuel o r dures. M a k e reference to “ T ech n iq u es o f S tru c
oil lines close to a h ot c o m p on en t. tural R e p air C o u r s e ” form n u m b e r J E G 0 3 7 1 9 .
D eterm in e type o f metal being w eld ed and select
14. T o av oid back injury use a hoist or get help w h en
corre ct w eldin g pro ced u re and electrodes, rods or
lifting co m p o n en ts which w eigh 50 lb. (23 kg) or wire to pro vid e a w eld m etal strength eq uiv alen t at
more. M a ke sure all chains, hoo ks, slings, etc .,
least to that o f paren t metal.
are in g o o d condition and are o f the correct c a p a c
ity. Be sure hooks are positioned correctly. L ift 21. B efo re do ing electrical w ork , d isconnect battery.
ing ey es are not to be side load ed during a lifting D o not d a m a g e wiring d uring rem ov al ope rations.
oper ation. Reinstall the w iring so it is not da m a g e d n o r will it
be d a m a g e d in operation by contacting sharp c o r
15. T o avoid b u m s , be alert for hot parts on prod ucts
n er s, o r by ru bbing against so m e object o r hot
which h ave ju s t been stopped and hot fluids in
surface. D o not co nnect wiring to a line containing
lines, tubes and com partm ents.
fluid.
16. Be careful w h en rem o vin g co v er plates. G r a d u a l
22. Be sure all protective d ev ices including guar ds
ly back o f f the last two bolts o r nuts located at
and shields are pr operly installed and functionin g
o pp osite en ds o f the c ov er o r d ev ice and pr y c ov er
corre ctly b efore starting a repair. If a gu ard or
loose to relieve any spring o r ot her pressu re, b e
shield m u st be r em o ved to p erfo rm the repair
fore rem o v in g th em com pletely.
w o r k , use extra caution. A fter the repair is c o m
17. Be careful w hen rem o v in g filler ca ps, breathers pleted, reinstall any g u ard o r shield that w as re
and pl ugs on the product. H o ld a rag o v er th e cap m ov ed .
o r plu g to prevent being sp ray ed or splashed by
liquids u n d er pressure. T h e d a n g e r is even g reater
if the pro d uct has recently been stopped becau se
fluids can be hot.
A83 266X2
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENG IN ES IN D E X
SPECIFICATIONS (Section 1)
E N G IN E D E S IG N
» 1 6 5 4 3 2 1
oooo oooo
D 3 7 9 Engine ........................................................................................................ V8
B o re 6 .2 5 in. (1 5 8 .8 m m )
S tro k e
S AE S ta n da rd R o t a t io n ...............................................
8 .0 0 in. (2 0 3 .2 m m )
C o u n te rc lo c k w is e
S AE S ta n da rd R o t a t io n .................................................... 1-8-5-4-7-2-3-6
©© © © ® ©
12 11 10 9 8 7 6 5 4 3 2 1
D 3 9 8 E ngine ...................................................................................................... V 12
OOOO ooo o o o o o
B o re 6 .2 5 in. (1 5 8 .8 m m }
S tro k e 8 .0 0 in. (2 0 3 .2 m m )
S AE S ta n da rd R o t a t io n ............................................... C o u n te rc lo c k w is e
S AE S ta n da rd R o t a t io n .............................................. C o u n te rc lo c k w is e
( j p © ( n ) © © © © ( ©
S AE O p p o site R o t a t io n .............................................................. C lo ckw ise
SAE S ta n da rd R o ta tio n . . 1 -2 -5 -6 -3 -4 -9 -1 0 -1 5 -1 6 -1 1 -1 2 -1 3 -1 4 -7 -8
1-2
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
FUE L IN JE CTIO N E Q U IP M E N T
(2) L en gth o f p u m p
p lu n g e r ........................ 2 .9 8 3 4 +.0 0 1 5 in. (7 5 .7 7 8 + 0 .0 3 8 m m )
O n Engine (p is to n at to p ce n te r):
D 3 9 9 Engine .................. 2 .0 7 6 to 2 .0 8 0 in. (5 2 .7 3 to 5 2 .8 3 m m )
D 3 9 8 and D 3 7 9 Engines 2 .0 8 8 to 2 .0 9 2 in. (5 3 .0 4 to 5 3 .1 4 m m )
(5) 3 S 1 2 52 S pring:
O u tsid e d ia m e t e r ....................................................... 1 .1 4 in . (2 9 .0 m m )
(7) T o rq u e fo r g lo w p l u g s .......................... 10 ± 2 lb . ft . (1 4 ± 3 N -m )
(8 ) T o rq u e fo r n u $ th a t holds
fu e l lines ....................................... 30 ± 5 lb . ft . (4 0 ± 7 N -m )
(9) T o rq u e fo r n u ts th a t h o ld
n o z z le s .................................................... 105 5 lb . f t . (142 ± 7 N -m )
(10) B o d y.
(1 2) T o rq u e f o r p re c o m b u s tio n ch am be r
(P ut 9 M 3 7 1 0 A nti-S e ize C o m p o u n d
on threads) ..................................... 225 15 lb. f t . (305 ± 2 0 N -m )
1-3
D379, D398, D399 INDU STR IA L & MARINE ENGINES SPECIFICATIONS
F UE L T R A N S F E R PUMP
T o rq u e f o r hex plugs in
cover (la te r) .......................................................... 30 ± 5 lb. f t . (4 0 ± 7 N-m )
S h a ft d ia m e t e r ......................... 5 3 0 0 ± .0 0 0 2 in. (1 3 .4 6 2 ± 0 .0 0 5 m m )
S h a ft d ia m e t e r .........................4 9 3 8 ± .0 0 0 2 in. (1 2 .5 2 7 + 0 .0 0 5 m m )
S h a ft d ia m e t e r .........................4 9 6 3 ± .0 0 0 3 in. (1 2 .6 0 3 ± 0 .0 0 8 m m )
FUEL C O N T R O L V A L V E
O u tsid e d ia m e t e r 81 in . (2 0 .6 m m )
O u tsid e d ia m e t e r 81 in. (2 0 .6 m m )
O u tsid e d ia m e t e r 6 5 6 in. (1 6 .6 6 m m )
O utsid e d ia m e t e r 5 9 4 in. (1 5 .0 9 m m )
1-4
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
F UE L PUMP A N D G O V E R N O R D R I V E
1-5
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
GOVERNOR
O utsid e d ia m e t e r 4 2 5 in. (1 0 .8 0 m m )
(2) T o rq u e fo r n u t 9 ± 3 lb . f t . (1 2 ± 4 l\l-m )
(3) T o rq u e fo r p l u g 27 ± 5 lb . f t . (3 8 ± 7 N-m )
T h e n add m o re fo rc e to m ake
sp rin g s h o rte r b y 9 0 0 in. (2 2 .8 6 m m )
O u tsid e d ia m e t e r 1.371 in . (3 4 .8 2 m m )
(5) 9 M 6 3 0 3 S pring:
O u tsid e d ia m e t e r 4 8 0 in. (1 2 .1 9 m m ) (8 ) D is t a n c e t h e b e a r in g
e xte n d s ........................ ... .47 0 ± .005 in. (1 1 .9 4 ± 0 .1 3 m m )
(6) T o rq u e fo r b o lt .......................................... 9 ± 3 lb. f t . (12 ± 4 N -m )
(9) O u tsid e d ia m e te r o f
(7) B y p a s s va lve : b e a r in g ....................... .8 1 1 0 + .0 0 0 3 in. (2 0 .5 9 9 ± 0 .0 0 8 m m )
T o r q u e f o r b y p a s s v a lv e a n d p lu g o n Inside d ia m e te r
o p p o s ite s i d e ......................................... 27 ± 5 lb. ft. (3 8 ± 7 N -m ) o f g e a r ............................. .8 1 3 0 ± .0 0 0 5 in. (2 0 .6 5 0 ± 0 .0 1 3 m m )
O utsid e d ia m e t e r ............................................................2 9 0 in . (7 .37 m m ) (13) S h a ft end p l a y ................ ....................02 to .06 in . (0.5 to 1.5 m m )
1-6
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
A I R - F U E L R A T IO C O N T R O L
(1) 3S 4 8 18 S pring:
(2) 6 N 3 0 1 7 S pring :
(3) 6 N 9 6 8 S pring :
1-7
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
C A M S H A F T AN D T I M I N G G E A R S
B ore in bearing fo r
ca m sh aft . 2 .9 7 0 ± .001 in. (7 5 .4 4 + 0 .0 3 m m )
V A L V E R O C K E R A R M S A N D L IF T E R S
(3) T o rq u e f o r n u t 4 0 ± 5 lb . ft . (5 5 ± 7 N-m)
(4) D ia m e te r o f ro c k e r arm
sh aft .................................. 1 .2 2 3 5 ± .00 0 5 in. (3 1 .0 7 7 0 .0 1 3 m m )
1-8
V
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
C Y L IN D E R HEAD
C Y LIN D E R HE AD T IG H T E N IN G SEQUENCE
1. T ig h te n all n u ts in n u m b e r
sequence to .......................................... 150 ± 10 Ib. ft . (2 0 5 ± 14 N-m )
1-9
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
EXHAUST M AN IFO LD
IN T A K E M A N I F O L D
(1) T o rq u e fo r b o lts th a t h o ld
in s tru m e n t panel ....................................... 5 0 ± 5 lb. f t . (7 0 ± 7 N -m )
AFTERCOOLER
1-10
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
TURBOCHARGER
(S ch w itzer F 3 0 2 and F 6 5 4 )
(4) T o rq u e fo r cla m p b o lts (co m p re ssor hou sin g, tu rb in e (9) T o rq u e f o r fo u r n u ts (p u t 9 M 3 7 1 0 A nti-S e ize
hou sin g and e xha ust p i p e ) 10 ± 2 Ib. f t . (1 4 ± 3 N-m ) C o m p o u n d on threads) .......................... 4 0 + 4 Ib. ft . (55 ± 5 N -m )
1-11
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
TURBOCHARGER
(S c h w itz e r 4 H D and 4 H F )
1-12
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
TURBOCHARGER
(S c h w itz e r 4 M D 4 5 5 and 4 M E 4 5 5 )
A84488X1 9'
T o rq u e fo r n uts h o ld in g
t u r b o e h a r g e r ................................................. 3 6 to 4 4 lb. ft . (4 6 to 6 0 N-m)
(7) D ia m e te r o f b ore in
(1) End p la y o f s h a f t ............................ 0 0 4 to .0 0 6 in. (0 .1 0 to 0 .1 5 m m ) h ou sin g 1 .0 6 2 8 to 1 .0 6 3 3 in. (2 6 .9 9 5 to 2 7 .0 0 8 m m )
M a x im u m p erm issib le end p la y o f s h a f t ............... 0 0 8 in. (0 .2 0 m m ) O u tsid e d ia m e te r o f the
(2) T o rq u e fo r b o lts fo r th r u s t b earing ........................ 60 lb . in. (7 N -m ) bearing ..................... 1 .0 5 8 5 to 1 .0 5 9 0 in. (2 6 .8 8 6 to 2 6 .8 9 9 m m )
(4) D ia m e te r o f bearing surface (jo u rn a l) f o r Side clearance betw e en tw o o f the ring seals
sh a ft b e a r in g 6 8 6 2 to .6 8 6 5 in. (1 7 .4 2 9 to 1 7.4 37 m m ) and sleeve g r o o v e 0 0 2 to .0 0 6 in. (0 .05 to 0 .1 5 m m )
Bore in b e a r in g ................6 8 8 0 to .6 8 8 3 in. (1 7 .4 7 5 to 1 7.4 83 m m ) (9) Clearance b etw een hou sin g and
i m p e lle r 0 1 8 to .02 2 in. (0 .4 6 to 0 .5 5 m m )
(5) M a x im u m p e rm issib le gap o f ring
seal ( w o r n ) 0 0 9 in. (0 .2 3 m m ) (10) T o rq u e f o r n u t fo r band
c la m p 120 ± 2 4 lb . in. (1 3 .6 ± 2 .8 N-m )
M a x im u m p e rm issib le groove in ring
(11) T h ickn ess o f th ru s t
seal ( w o r n ) 068 in. (1 .7 3 m m )
b e a rin g 225 t o .22 6 in. (5 .7 2 to 5 .7 4 m m )
M in im u m perm issib le w id th o f ring
(12) T o rq u e fo r n u t fo r band
seal ( w o r n ) 0 6 2 in . (1 ,57 m m )
c la m p 120 ± 2 4 lb. in. (1 3 .6 ± 2 .8 N -m )
(6) T o rq u e fo r n u t h o ld in g im p e lle r ... 32 ± 2 lb . f t . (43 ± 3 N-m )
T o rq u e fo r nuts fo r exha ust
N O T E : Do n o t bend o r add stress to the shaft w h en n u t is tig h te n e d . e lb o w c la m p ............................................ 10 ± 2 lb. f t . (14 ± 3 N-m)
1-13
D379, D398, D399 IN D U S T R IA L & M A R IN E E N G IN ES SPECIFICATIONS
VALVES
N O T E : G U ID E L IN E S FO R R E U S A B L E P A R T S ; V A L V E S A N D
V A L V E S P R IN G S , F o rm S E B F 8 0 0 2 , has the p ro ce d u re necessary fo r
ch e ckin g used valves and valve springs.
In ta k e v a lv e ....................................................................... 0 1 5 in. (0 .3 8 m m )
(1) 9 M 5 3 5 0 S pring (o u te r ) :
Use again m in im u m lo ad at le ng th u nd er
te s t f o r c e ................................................................................... 13.5 Ib. (6 0 N)
1-14
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
Valves (Cont.)
T h ic k n e s s of valve seat
in s e rt............................... 6 2 5 0 ± .00 2 5 in. (1 5 .8 7 5 ± 0 .0 6 4 m m )
D ia m e te r o f in ta k e valve
seat insert ..................... 2 .5 9 0 0 .0 0 0 5 in. (6 5 .7 8 6 ± 0.01 3 m m )
In ta k e v a lv e ...................................................................... 0 7 5 in . (1.91 m m )
M a x im u m p e rm issib le d im e n sio n f o r
e xha ust v a lv e ....................................................................1 70 in. (4 .32 m m )
M in im u m p erm issib le d im e n s io n fo r
in ta k e v a lv e .......................................................................120 in. (3 .0 5 m m )
E xh a u st seat 2 .3 0 2 in. (5 8 .4 7 m m )
M a x im u m p e rm issib le , in ta k e s e a t 2 .5 1 0 in. (6 3 .7 5 m m )
1-15
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
1-16
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
OIL PUMP R E L IE F V A L V E
(3) D ia m e te r o f v a lv e 1 .6 2 2 0 ± .0 0 0 5 in. (4 1 .1 9 9 ± 0 .0 1 3 m m )
Bore in housing fo r
valve .................................... 1 .6 2 5 0 + .00 0 5 in. (4 1 .2 7 5 ± 0 .0 1 3 m m )
E N G IN E OIL P R E S S U R E
1-17
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
OIL F IL T E R
L en gth u n d e r te st f o r c e 2 .7 8 in. (7 0 .6 m m )
O utsid e d ia m e t e r 1 .1 3 5 in. (2 8 .8 3 m m )
T U R B O C H A R G E R LUBRICATION V A L V E
P R E L U B E PUMP
V ik in g P um p C o., M o d el H J 7 5 M , In te rn a l gear p u m p :
1-18
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
6 L 5 8 5 1 and 9 N 2 8 9 4 Regulator:
M in im u m o p e n in g d is ta n c e 3 7 5 in . (9 .53 m m )
C O O L IN G S Y S T E M P R E S S U R E CAP
6 L 9 8 5 0 Cap
W A T E R L E V E L SWITCH
(2N9768 and 6L7037)
(2) C o n d u it o p e n in g 1 /2 in.
1-19
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
F RES H AN D A U X I L I A R Y W A T E R PUMPS
1 c
(5) D ia m e te r o f p u m p
sh aft .................................. 1 .2 4 5 3 ± .0 0 0 5 in. (31.631 + 0 .0 1 3 m m )
S E A W A T E R PUMP
D ia m e te r o f p u m p
sh aft .................................. 1 .2 4 53 ± .0 0 0 5 in. (31.631 ± 0 .0 1 3 m m )
1-20
D379, D398, D399 IN DUSTRIAL 8< MARINE ENGINES SPECIFICATIONS
C Y L I N D E R BL O CK
(6 ) D e pth o f lin e r c o u n te rb o re
in b l o c k .............................................4 9 9 .001 in. (1 2 .6 7 ± 0 .0 3 m m )
(8 ) B ore in b lo c k f o r m ain
b e a rin g .......................... 6 .3 7 2 5 .0 0 0 5 in. (1 6 1 .8 6 2 ± 0 .0 1 3 m m )
A lig n m e n t fo r th e b ore in th e b lo c k
f o r the m a in b e a rin g s ...................... 0 0 0 to .003 in. (0 .0 to 0 .0 8 m m )
1-21
SPECIFICATIONS
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
CYLINDER LINER
"U s e a g a in " m a x im u m b o re (w h e n m e a s u re d
n e a r u p p e r e n d o f th e w e a r s u rfa c e o f th e
c y lin d e r l i n e r ) ..................................................... 6 .2 5 6 in . (1 5 8 .9 0 m m )
(2) T h ic k n e s s o f fla n g e o n
l i n e r ............................................ 5 05 0 ± .0008 in. (1 2 .8 2 7 ± 0 .0 2 0 m m )
(3) F ille r B a n d .
I n s ta lla tio n p ro c e d u r e .
N O T E : M a k e re fe r e n c e to G U ID E L IN E F O R R E U S A B L E P A R T S ;
P IS T O N S A N D C Y L IN D E R L IN E R S , F O R M N O . S E B F 8 0 0 1 .
C Y L I N D E R L IN E R PROJE CTI ON
4 th s t e p 5 0 Ib. ft . (7 0 N -m )
M a x im u m p e rm is s ib le d iffe re n c e b e tw e e n all
fo u r m e a s u re m e n ts ....................................................... 0 0 2 in. (0 .05 m m )
M a x im u m p e rm is s ib le d iffe re n c e b e tw e e n
a v e ra g e p ro je c tio n of a n y tw o c y lin d e r lin e rs
n e x t to e a ch o th e r u n d e r a n y o n e h ea d .............. 0 0 2 in. (0 .0 5 m m )
3. D e p th o f b ore in b lo c k
f o r l i n e r ............................. 4 9 8 to .5 0 0 in . (1 2 .6 5 to 1 2 .7 0 m m )
M a x im u m p e rm issib le d e p th to m a ch ine c o u n te rb o re to
a d ju st c y lin d e r lin e r p ro je c tio n ...............................5 4 5 in. (13 mm)
1-22
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
PI S TO N S A N D R I N G S
Make reference to G U ID E L IN E FO R R E U S A B L E P A R T S ; P IS T O N S A N D C Y L IN D E R
L IN E R S , F o rm N o. S E B F 8 0 0 1 .
P IS T O N S A N D P IS T O N R IN G S
(1) TO P R IN G (2 ) IN T E R M E D IA T E R IN G (3 ) O IL C O N T R O L R IN G
*9 S 7 5 0 7 ♦3 S 4 0 5 9 **5 M 5 4 8 7
Increase in clearance
betw e en ends o f p isto n
rin g fo r each .001 in. .00 3 in.
(0 .0 3 m m ) increase in (0 .0 8 m m )
c y lin d e r lin e r bore size.
N O T E : Use 5 P 3 5 1 9 P IS T O N R IN G G R O O V E G A U G E to ch eck to p and ce n te r rin g grooves w ith s tra ig h t sides. F o r in s tru c tio n s
on the use o f th e gauge, see th e G U ID E L IN E FO R R E U S A B L E P A R T S ; P IS T O N S A N D C Y L IN D E R L IN E R S F o rm No.
SEBF8001.
(4) Bore in p is to n fo r
p in 2 .4 5 0 6 ± .0 0 0 3 in. (6 2 .2 4 5 ± 0 .0 0 8 m m )
I -2 3
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
CRANKSHAFT
(1) End p la y f o r th e
c ra n k s h a ft 0 0 5 to .021 in . (0.1 3 to 0 .5 3 m m )
(2) T o rq u e f o r c o u n te rw e ig h t
b o lts .......................................... . 160 ± 10 lb. f t . (2 1 9 ± 14 N -m )
N O T E : Heat the th ro w e r to a m a x im u m o f 4 50 ° F (2 3 2 ° C) b e fo re
in s ta lla tio n on c ra n k s h a ft. Insta ll seal rin g w ith the w o rd " o u t " a w ay
fro m cra n k s h a ft and the end gap UP.
(5) C r a n k s h a ft d e f le c tio n (D 3 9 9 a n d D 3 9 8
E n g in e s ) ................... - .0 0 0 5 to + .0 0 1 0 in. ( - 0 .0 1 3 to + 0 .0 2 5 m m )
R e a r ........................................................................................177 in. (4 .4 9 m m )
N O T E : Som e cra n ksh a fts have o n ly a rro w s on the ends. SEAL IN S T A LLA TIO N
1-24
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
C O N N E C T IN G ROD
Pin d ia m e te r 2 .4 4 9 8 ± .0 0 0 2 in. (6 2 .2 2 5 ± 0 .0 0 5 m m )
a. P ut crankcase o il on threads.
1-25
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
C O N N E C T IN G RO D B E A R I N G S
C O N N E C T IN G R O D B E A R IN G S
D ia m e te r o f cra n k s h a ft
jo u rn a l (bearing surface) 4 .9 9 9 2 + .0 0 1 0 in. 4 .9 7 4 2 + .0 0 1 0 in. 4 .9 4 9 2 ± .0 0 1 0 in.
fo r c o n n e c tin g rod. (1 2 6 .9 8 0 ± 0 .0 2 5 m m ) (1 2 6 .3 4 5 ± 0 .0 2 5 m m ) (1 2 5 .7 1 0 + 0 .0 2 5 m m )
1-26
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
M AIN BE A RIN G S
M A IN B E A R IN G S
.0 5 0 in . (1 .2 7 m m )
O R IG IN A L U N D E R S IZ E
S IZ E (S M A L L E R )
JO U R N A L JOURNAL
M a x im u m p e rm issib le
clearance b etw een .01 5 in.
bearing and jo u rn a l (0 .3 8 m m )
1-27
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
B E A R I N G S U R F A C E (JOUR N AL )
FOR C O N N E C T IN G R O D S
B E A R IN G S U R F A C E ( J O U R N A L ) F O R C O N N E C T IN G R O D S
(A ) D ia m e te r o f cra n ksh a ft
jo u rn a l (bearing surface) 4 .9 9 9 2 ± .0 0 1 0 in. 4 .9 7 4 2 ± .0 0 1 0 in. 4 .9 4 9 2 ± .0 0 1 0 in.
f o r co n n e c tin g rod. (1 2 6 .9 8 0 ± 0 .0 2 5 m m ) (1 2 6 .3 4 5 ± 0 .0 2 5 m m ) (1 2 5 .7 1 0 ' 0 .0 2 5 m m )
(C) W id th o f jo u rn a l 4 .6 2 2 5 + .0 07 - . 0 0 3 in.
(1 1 7 .4 1 2 + 0 .1 8 - 0 . 0 8 m m )
1-28
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
B E A R I N G S U R F A C E (JO UR N AL)
FOR M AIN BE A R IN G S
B E A R IN G S U R F A C E ( J O U R N A L ) F O R M A IN B E A R IN G S
.0 5 0 in. (1 .27 mm )
O R IG IN A L U N D E R S IZ E
S IZ E (S M A L L E R )
JOURNAL JO U R N A L
S urface
fin ish 10 m ic ro inches o r sm o o th e r
on d ia m e te r (0 .2 5 m ic ro m e tre )
o f jo u rn a l
(F) W id th o f jo u rn a ls 3 .0 8 3 in. m a x im u m
e xcep t rear jo u rn a l (78.31 m m )
W id th o f 3 .0 0 0 +.0 07 - . 0 0 3 in.
rear jo u rn a l (7 6 .2 0 + 0 .18 —0 .0 8 m m )
S urface fin is h
o n th ru s t faces 16 m ic ro in ches o r s m o o th e r
o f rear jo u rn a l (0 .4 0 m ic ro m e tre )
1-29
D379, D398, D399 IN D U S T R IA L & M A R IN E EN G IN ES SP EC IF IC A T IO N S
V IBR A T IO N DAMPER
(1) T o rq u e fo r b o lts th a t h o ld d am pe r
D 399EA R LY
to a da pte r .................................................... 32 ± 5 Ib. f t . (4 3 ± 7 N-m )
1-30
S P E C IF IC A T IO N S
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L & M A R IN E E N G IN E S
F RO NT A C C E S S O R Y D R I V E
Bore in bearing
in re ta in e r ..................... 1 .2 4 7 5 + .0 0 2 0 in. (3 1 .6 8 7 ± 0.051 m m )
M a x im u m p e rm issib le end p la y fo r
th e g e a r 0 1 8 in. (0 .4 6 m m )
End clearance fo r id le r
gears .................................................. 0 0 3 to .01 4 in. (0 .0 8 to 0 .3 6 m m )
(6) O il p u m p d rive :
1-32
S P E C IF IC A T IO N S
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
FLYWHEEL
D 3 9 9 Engines 6 7 0 ± 5 0 lb . ft . (9 0 5 ± 7 0 N -m )
D 3 7 9 and D 3 9 8 Engines 4 5 0 ± 30 lb . f t . (6 1 0 ± 4 0 N -m )
F L Y W H E E L HOUSIN G
l -3 3
D379, D398, D399 IN D U S T R IA L & M A R IN E EN G IN ES SPECIFICATIONS
2. Set th e d ia l in d ic a to r t o read .0 0 0 in . (0 .0 m m ).
1-34
S P E C IF IC A T IO N S
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES
F L Y W H E E L H O U S IN G R U N O U T
C (T O P )
1-35
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
C (T O P )
F L Y W H E E L H O U S IN G BO RE
4. T u rn the c ra n k s h a ft c o u n te rc lo c k w is e to p u t th e d ia l in d ic a to r at
(B ). W rite the m ea sure m e n t in th e ch a rt.
5. T u rn the c ra n k s h a ft c o u n te rc lo c k w is e to p u t th e d ia l in d ic a to r at
(C). W rite the m ea sure m e n t in th e ch a rt.
6. T u rn the c ra n k s h a ft c o u n te rc lo c k w is e to p u t the d ia l in d ic a to r at
(D ). W rite the m easurem ent in the ch art.
7. A d d lines I & (I b y co lu m n s.
C H A R T FOR D IA L IN D IC A T O R M E A S U R E M E N TS
Position of
dial indicator
Line
No. A B C D
D ial In d ic a to r Reading II 0
1-36
SP EC IF IC A T IO N S
D379, D398, D399 IN D U S T R IA L & M A R IN E EN G IN ES
1-37
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
(1) N u t.
(2) O u tp u t te rm in a l.
P o la rity is negative g ro un d.
G ENERATO R ALTERNATORS
Supplier Delco-Rem y
1117226
S u p p lie r Part No. 1105148 1117734 1117236 1117733 1117074
C irc u it A B B B B
Speed f o r te stin g
(rp m ) 1 95 0 5000 5000 5000 1800 2500
20A * 51 A *
O u tp u t (co ld ) 35 A 58 A * * 54 A * * 56 A * * at at
3 7 .5 V 3 7 .5 V
Rated o u tp u t (h o t) - 60 A 50 A 60 A 60 A
F ie ld c u rre n t at
ra ted vo ltag e and 1.5 4 to 1.67 A 2 .5 to 2 .9 A 2 .5 to 2 .9 A 1.5 to 1.6 A 2 to 2 .7 A
8 0 ° F (2 7 °C )
T o rq u e fo r o u tp u t 36 ± 6 Ib. in. 6 6 ± 6 Ib. in. 10 ± 1 Ib. ft. 6 6 ± 6 Ib. in. 3 6 ± 6 Ib. in.
te rm in a l (2) (4.1 ± 0.7 N-m ) (7 .5 ± 0.7 N-m) (1 4 + 1 N-m ) (7 .5 + 0 .7 N-m ) (4.1 ± 0 .7 N-m)
REGULATORS
V o lta g e se ttin g
range (See 26 to 3 0 V 2 6 to 3 0 V 3 3 .7 to 3 7 .7 V
GENERATOR (See A L T E R N A T O R
A d ju s t vo ltag e to : REG ULATO R R E G U L A T O R fo r
fo r « *» a d ju s tm e n t range)
28V 28V
th e n increase a d ju s tm e n t
speed to get m ax. range) 60 A 50 A 60 A
o u tp u t o f:
ALTERNATOR REGULATORS
6 L 5 3 9 7 3 2 V (D e lco -R e m y N u m b e r 9 0 0 0 5 9 3 )
C irc u it ........................................................................................................................ B
6 L 5 6 5 8 3 0 V (D e lc o -R e m y N u m b e r 9 0 0 0 5 9 2 )
C irc u it ........................................................................................................................ B
GENERATOR REGULATOR
5 L 4 5 9 9 1 2 V (D elco-R em y N um ber 1 1 1 9 1 6 8 )
P o la rity is negative g ro un d.
C irc u it ........................................................................................................................ A
(1) C u to u t re la y :
(2) C u rre n t re g u la to r:
(3) V o lta g e re g u la to r:
M A G N E T I C SWITCH
9 F 3 0 9 9 2 4 V (D e lc o -R e m y N u m b e r 0 0 0 1 4 8 1 )
C u rre n t d ra w b o th w in d in g s at 2 4 V 8 3 to .8 9 A
I -3 9
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
STARTER MOTOR
8 L 5 9 3 7 3 2 V (D e lc o -R e m y N u m b e r 1 1 0 9 6 2 7 )
8 L 5 9 3 9 3 2 V (D e lco -R e m y N u m b e r 1 1 0 9 6 2 5 )
8 L 6 2 0 5 3 2 V (D e lco -R e m y N u m b e r 1 1 0 9 6 2 6 )
4 N 3 3 4 9 2 4 V (D e lc o -R e m y N u m b e r 1 1 0 9 6 4 2 )
4 N 3 3 5 0 2 4 V (D e lc o -R e m y N u m b e r 1 1 0 9 6 4 3 }
M a x im u m w ith so le n o id at 20 V 170 A
6 N 4 2 4 (D e lc o -R e m y N u m b e r 1 1 0 9 9 6 2 )
M in im u m w ith so le n o id at 2 0 V 95 A
C le a ra nc e b e tw e e n p in io n a n d h o u s in g
(p in io n c le a r a n c e ) 3 6 in. (9.1 m m )
1-40
S P E C IF IC A T IO N S
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
S P R IN G C H A R T
(1) (2)
9 ± .5 Ib. 14 ± .5 Ib.
Test force (4 0 ± 2 N) (6 0 ± 2 N)
C U R R E N T C O N S U M P T IO N (D R A W )
C urrent
U. 1 . uo. Delco-Rem y
Part No. Part N o .* V oltage Settings P ull-in windings Hold-in windings
9 V 7 .4 to 8 .3 A
32V 5L8595 1119836 27 to 32 V 2 2 .2 to 2 9.5 A 4 .6 to 6.1 A
28 V 4 .8 to 5 .3 A
1-41
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
A I R S T A R T IN G M O T O R
6 N 6 0 0 2 o r 6 N 6 0 0 3 ( In g e rso ll-R a n d N u m b e r 1 5 0 B M P -E 7 8 R H -5 4 )
3 H 3 1 7 1 (S c h w itz e r N u m b e r L -1 2 5 3 5 4 M o d e l 3 0 R )
O u tp u t to rq u e ................................................................... 8 2 Ib. f t . (1 1 3 N -m )
w it h m o to r at ................................................................................. 3 6 0 0 rp m
H o rse po w e r ........................................................................................................... 6 .7
1-42
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
H Y D R A U L I C S T A R T IN G M O T O R
N o rm a l pressure fo r
o p e r a t io n 1 5 0 0 to 3 0 0 0 psi (1 0 3 0 0 to 2 0 7 0 0 kPa)
O u tp u t to rq u e w ith p in io n speed o f 2 5 0 0 rp m :
O u tp u t to rq u e w ith p in io n at stall:
C H A R G I N G PUMP FOR H Y D R A U L I C S T A R T IN G
N o rm a l pressure to sto p th e p u m p
a u to m a tic a lly (c u t-o u t) ............................................... 3 0 0 0 psi (2 0 7 0 0 kPa)
O u tp u t at 3 0 0 0 rp m o f p u m p and pressure o f
3 0 0 0 psi (2 0 7 0 0 kPa) ............................................5 U.S. gpm (2 .0 litr e /m in )
H AN D PUMP FOR H Y D R A U L I C S T A R T E R
O u tp u t per s t r o k e 1 .22 in . 3 (2 0 .0 c m 3)
P R E S S U R E A C C U M U L A T O R FOR
H YDR A U LIC STARTER
l -43
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES INDEX
I
F u el I n je c tio n V a lv e .......................................................................... 2 -4
C o o lin g System ............................................................................... 2-12 F u e l R a tio C o n t r o l ............................................................................ 2 -6
C o o la n t Level S w itch ................................................................ 2-14 H y d r a - m e c h a n ic a l G o v e r n o r ....................................................... 2 -5
Engine Jacket W ater C o o lin g S y s te m ................................. 2-12
Sea W ater and Separate C irc u it A fte rc o o le r H y d r a u lic S ta rtin g S y s te m ................................................................. 2-21
W ater System s ......................................................................... 2-15 H y d r a u lic S ta r tin g M o t o r .............................................................. 2 -2 2
L u b r ic a tio n S y s t e m ............................................................................... 2 -9
D u p le x O il F ilte r S y s te m .............................................................. 2 -1 0
P r e lu b r ic a tio n S y s te m ..................................................................... 2 -1 0
2-1
r
FUEL SYSTEM SYSTEMS OPERATION
FUEL SYSTEM
2 3 4 5
SC H E M A T IC OF FUEL SY STEM
1. Fuel transfer pump inlet line. 2. Fuel priming pump. 3. Fuel passage. 4. Fuel return line. 5. Fuel tank. 6. Fuel transfer
pump outlet line. 7. Fuel transfer pump. 8. Fuel filter housing. 9. Fuel injection pum p housing.
2 -2
SYSTEMS OPERATION
FUEL SYSTEM
F uel p r i m i n g p u m p (2) is l o c a t e d o n t h e t o p o f t h e
fuel filter h o u sin g . T h e fuel p r i m i n g p u m p is u se d to DUPLEX FUEL FILTER SYSTEM
ven t air f r o m th e fuel sys tem a n d t o fill t h e fuel filter
h o u s i n g w ith fuel a f te r th e filters h a v e b e e n c h a n g e d . T h e d u p l e x fuel filter sy s tem m a k e s it p o ss ib le to
c h a n g e el e m e n t s f o r th e fuel filters w h ile th e e n g i n e
is r u n n i n g a t a n y spe ed.
D u r i n g n o r m a l o p e r a t i o n , th e s e l e c t o r lever ( l )
s h o u l d be in t h e “ M a i n F ilte r R u n - A u x . O f f ' p o s i
tion. T h e fuel t h e n will be c le a n e d by th e e l e m e n t s o f
th e m a i n filter w h ic h are lo c a t e d in th e right side of
t h e filter h o u sin g . T h e t w o e l e m e n t s o f th e a u x i l i a r y
filter a r e l o c a t e d in th e left side o f t h e h o u s i n g .
S U C T IO N STRO KE OF P R IM IN G PU M P
1. Fuel transfer pump Inlet line. 2. Fuel priming pump.
3. Fuel passage. 6. Fuel transfer pump outlet line. 8. Fuel
filter housing. 10. Fuel passage. 11. Fuel control valve.
12. Spring. 13. Fuel passage.
W h e n t h e h a n d l e f o r th e p r i m i n g p u m p is p u lle d
o u t (su c t i o n str o k e ) , fuel c o n t r o l va lve ( l l ) m o v e s
t o w a r d fuel p r i m i n g p u m p (2). T h is p e r m i t s fuel
f r o m line ( l ) to flow in t o fuel p r i m i n g p u m p (2).
DU PLEX FUEL FILTER
1. Selector lever. 2. Priming pump.
W h e n th e h a n d l e f o r the fuel p r i m i n g p u m p is
p u s h e d in ( p r e s s u r e s t r o k e ) , t h e f o r c e o f f u e l
p r e s s u re a n d s p r i n g (12) ca u s e s fuel c o n t r o l v alve
( I 1) to m o v e a w a y f r o m fuel p r i m i n g p u m p (2). W i t h
fuel c o n t r o l valve (11) in this p o s i t i o n , fuel p a s s a g e W h e n th e g a u g e fo r fuel p re ss u re sh o w s
(3) f r o m line (1) is closed a n d fuel f r o m t h e p r i m i n g i n d i c a t i o n o f m i n i m u m p r e s s u re o f 20 psi (140 k P a )
p u m p goes t h r o u g h fuel p a s s a g e (13) t o fuel filter t h e m a i n e l e m e n t s m u s t be c h a n g e d . W h ile th e m a i n
h o u s i n g (8). A ir in th e fuel s y s te m goes t h r o u g h fu el e le m e n ts a r e b eing c h a n g e d , th e fuel m u s t be c le a n e d
p a s s a g e (10) a n d b a c k t o th e fuel t a n k . by th e t w o e le m e n ts o f th e a u x i l i a r y filter.
2 -3
FUEL SYSTEM SYSTEMS OPERATION
E x p l a n a t i o n o f (low. with th e e n g in e r u n n i n g , f o r
the se lecto r lever p o s i t i o n s is as follows:
AUX. V E N T -M A IN RUN
B O T H FILTERS RUN
2 -4
SYSTEMS OPERATION
FUEL SYSTEM
HYDRA-MECHANICAL GOVERNOR
T h e gov e r n o r c o n t r o l s th e a m o u n t o f fuel n e e d e d
to keep th e eng ine at th e d es ired r p m .
T h e su p p ly o f e n g in e oil t o th e g o v e r n o r is se n t
t h r o u g h the oil m a n i f o l d (A) o f th e fuel p u m p a n d
g o v e r n o r d rive h o u sin g . Drilled p a s s a g e s (B) se n d
oil to the u p p e r h o u s i n g a n d r e s e r v o i r o f t h e g o v e r
nor. T h e oil re s e r v o i r in th e g o v e r n o r d riv e h o u s i n g
gives a s u p p l y o f oil f o r t h e g e a r - tv p e oil p u m p (C).
T h e p r e s s u re oil f r o m oil p u m p (C) gives a s s i s t a n c e
to the g o v e r n i n g ac tio n .
G O VERN O R
1. Shutoff shaft. 2. Collar. 3. Adjusting screw. 4. Stop
bar. 5. Lever assembly. 6. Seat assembly. 7. G overnor
spring. 8. Valve. 9. W eight assembly. 10. Seat. 11.011
passage. 12. Cylinder. 13. Piston. 14. Sleeve. 15. Oil
pum p gear. 16. Governor drive housing. 17. Oil pump
cover. 18. Pin assembly. 19. Shaft assembly. 20. Lever.
21. Fuel rack. 22. Drive pinion.
G O VERN O R O IL PU M P SUPPLY
A. Oil manifold. B. Drilled passages. C. Oil pump.
2-5
FUEL SYSTEM SYSTEMS OPERATION
W h e n th e en g ine is st a r t e d , th e p l u n g e r f o r th e
speed lim ite r p u ts a res t r i c t i o n o n th e m o v e m e n t o f
the g o v e r n o r c o n t r o l . W h e n oil p r e s s u re in crease s to
th e o p e r a t i n g level, t h e g o v e r n o r c o n t r o l c a n be
m o v e d to the H I G H I D L E p o s itio n .
W h e n en g in e r p m is at L O W I D L E , a s p r i n g -
lo a d e d p l u n g e r in lever a s s e m b l y (5) c o m e s in
c o n t a c t with a s h o u l d e r o n th e a d j u s t m e n t sc rew f o r
low idle. T o s t o p the e n g in e pull b a c k o n th e
g o v e r n o r c o n t r o l . T h is will let th e s p r i n g - l o a d e d
p lu n g e r m o v e o v er th e s h o u l d e r o n t h e lo w idle
1. Lever. 2. Housing. 3. Spring. 4. Spring. 5.Diaphragm.
a d j u s ti n g sc rew a n d m o v e th e fuel r a c k t o th e fuel
6. Collar. 7, Bolt.
clos ed p o sition . W i t h n o fuel to t h e e n g in e c ylin d ers,
the en g ine will stop .
W h e n th e o p e r a t o r m o v e s th e g o v e r n o r c o n t r o l to
Oil fro m th e g o v e r n o r p u m p gives l u b r i c a t i o n t o i n c r e a s e e n g in e r p m , the g o v e r n o r s p r i n g m o v e s
th e b e a r i n g s o f the g o v e r n o r weights. T h e o t h e r c o l l a r (6). T h is cau s es the c o l l a r t o c o n t a c t th e h e a d
p a r t s o f th e g o v e r n o r get l u b r i c a t i o n f r o m “ sp l a s h - o f b o l t (7). T h e b o lt cau s es a r e s t r i c t i o n t o th e
l u b r i c a t i o n ” (oil t h r o w n by o t h e r p arts). Oil f r o m m o v e m e n t o f th e c o l l a r u n til inlet m a n i f o l d air
th e g o v e r n o r ru n s back in to th e d riv e h o u s i n g f o r p r e s s u r e in th e c h a m b e r a b o v e th e d i a p h r a g m is
th e fuel in jectio n p u m p s . h i g h e n o u g h t o m o v e d i a p h r a g m (5), s p r i n g (4), a n d
b o l t (7). T h is will let th e r a c k m o v e t o in c r e a se th e
fuel t o th e e n g in e at a r a t e e q u a l t o (the s a m e as) th e
a i r a v a ila b le fo r g o o d c o m b u s t i o n .
FUEL RATIO CONTROL
T h e fuel r a t i o c o n t r o l a u t o m a t i c a l l y cau s es a
r e str ic tio n to th e a m o u n t o f tr a v e l o f t h e r a c k in t h e
“ fuel o n ” d i r e c t i o n , u ntil t h e air p r e s s u re in th e inlet
m a n i f o l d is h i g h e n o u g h t o g i v e g o o d f u e l
c o m b u s t i o n . T h e fuel r a tio c o n t r o l k e e p s en g i n e
p e r f o r m a n c e hig h so t h a t t h e a m o u n t o f b la c k
e x h a u s t gases are at a m i n i m u m .
A n o v e r ri d e lever ( l ) is used t o p e r m i t r a c k m o v e
m e n t w h e n th e e n g in e is s t a r t e d at co o l t e m p e r a
tures. A f te r th e e n g in e sta rts , th e o v e r r i d e a u t o
m a tically m o ves to th e R U N p o sitio n .
2 -6
SYSTEMS OPERATION
AIR INLET AND EXHAUST SYSTEM
AIR IN LE T A N D EX H A U ST SYSTEM
1. Exhaust manifolds. 2. Right cylinders. 3. Diffuser plate. 4. Right turboeharger impeller. 5. Exhaust elbow. 6. Left
cylinders. 7. Turboeharger turbine wheels. 8. Left turboeharger impeller. 9. Aftercooler.
AFTERCOOLER
T h e air inlet a n d e x h a u s t s y s te m h a s t w o t u r b o -
ch a r g e r s a n d a n a f t e r c o o le r (9). T h e r ig ht t u r b o T h e a f t e r c o o l e r is installed o n th e t o p o f th e
c h a r g e r uses e x h a u s t gas f r o m th e right side to d r iv e flywheel h o u sin g . T h e a f t e r c o o le r h as t w o s e p a r a t e
the t u r b i n e (7). b u t gives air t o t h e left cy lin d e r s (6). cores, o n e f o r each inlet m a n i f o ld . A ir is p u s h e d by
T h e left t u r b o e h a r g e r uses e x h a u s t gas f r o m t h e left th e t u r b o e h a r g e r i n to th e a f t e r c o o l e r a n d t h e air
side t o d rive t u r b i n e (7) a n d gives a i r t o th e r ig h t goes a r o u n d th e fins o f th e a f t e r c o o l e r core. C o o l a n t
cy lin d ers (2). c o n s t a n t l y flows t h r o u g h t h e t u b e s in t h e a f t e r c o o l e r
c o r e to r e m o v e th e h e a t f r o m th e air. T h e c o o l e r air,
W h e n th e en g in e lo ad in creases, t h e v o l u m e o f w h ic h is h eav ier ( m o r e dense), will p e r m i t m o r e fuel
e x h a u s t gases in c r e a se a n d ca u s e th e t u r b i n e in t h e to b u r n a n d give a n in c r e a se in p o w e r .
t u r b o e h a r g e r t o t u r n faster . T h is will c a u s e t h e
i m p eller (4 & 8) to t u r n f a s t e r a n d in c r e a se t h e in let
VALVES AND VALVE MECHANISM
m a n i f o ld a i r p ress u re. As th e p r e s s u r e o f t h e air
i n creases, the t e m p e r a t u r e o f t h e air a ls o in creases. T h e valves a n d valve m e c h a n i s m c o n t r o l th e flow
A n a f t e r c o o l e r is i n s t a l l e d b e t w e e n t h e t u r b o o f inlet air a n d e x h a u s t gases i n to a n d o u t o f th e
c h a r g e r s a n d th e inlet m a n i f o l d t o h elp co o l t h e inlet cylinder .
air.
T h e i n t a k e a n d e x h a u s t valves a r e o p e n e d a n d
A d iffu s er p la te (3) in th e c e n t e r o f e x h a u s t e l b o w closed by m o v e m e n t o f th es e c o m p o n e n t s ; c r a n k
(5) k eep s th e e x h a u s t gases f r o m th e t u r b o e h a r g e r sh a ft, c a m s h a f t , lifters, p u s h r o d s, r o c k e r a r m s , a n d
o u tle ts a p a r t t o re d u c e e x h a u s t b a c k p ress u re. valve sp rin gs.
2-7
AIR INLET AND EXHAUST SYSTEM SYSTEMS OPERATION
T h e g e a r on the c r a n k s h a f t is t i m e d to a n d drives
the c a m s h a f t g ear a t t a c h e d to th e c a m s h a f t . W h e n
the c a m s h a f t t u r n s , th e lobes o n th e c a m s h a f t ca u s e
the valve lifters to m o v e u p a n d d o w n . T h e valve
lifters m o v e the p u sh r o d s, w h ic h m o v e th e r o c k e r
arm s. M o v e m e n t o f th e r o c k e r a r m s ca u s e s th e
in t a k e a n d e x h a u s t valves to o p e n a n d close in th e
firing o r d e r ( in je ctio n s e q u e n c e ) o f th e engine. V alve
sp ring s for each v alv e close th e valve a n d h o l d s t h e m
in the closed p o sitio n.
CR O SS S E C T IO N OF TU R B O C H A R G E R
1. Compressor wheel. 2. Compressor housing. 3. Thrust
bearing. 4. Lubrication inlet port. 5. Turbine housing.
6. Turbine wheel. 7. Air inlet. 8. Exhaust outlet. 9. Sleeve.
10. Shaft journal bearings. 11. Sleeve. 12. Exhaust inlet.
W h e n th e en g in e lo ad in creases, m o r e fuel is
injected in to th e e n g in e cylinders. T h e v o l u m e o f
e x h a u s t gas increases w h ic h ca u s e s t h e t u r b o c h a r g e r
t u r b i n e wheel a n d c o m p r e s s o r i m p eller t o t u r n
faster . T h e i n crease d r p m o f th e i m p eller in crease s
th e q u a n t i t y of inlet air. As th e t u r b o c h a r g e r
p r o v i d e s a d d i t i o n a l inlet air. m o r e fuel ca n be
b u r n e d . T h is re sults in m o r e h o r s e p o w e r f r o m th e
VALVE AND VALVE M E C H A N IS M en gine.
(Cross Section, Single Spring Type)
1. Rocker arm. 2. Locks. 3. Spring. 4. Retainer 5. Guide. M a x i m u m r p m o f th e t u r b o c h a r g e r is c o n t r o l l e d
6. Valve rotator. 7. Push rod. 8. Valve. 9. Bracket
assembly. 10. Connector. 11. Valve lifter.
by the r ack setting, th e high idle spe ed se t ti n g a n d
the height a b o v e sea level at w h ic h th e e n g in e is
E a c h va lve has a valve r o t a t o r u n d e r th e v alv e operated.
sp rin g . T h e valve r o t a t o r cau s es th e valve t o t u r n
a p p r o x i m a t e l y t h r e e d egrees e a c h t im e t h e v alv e
o p e n s an d closes. T h is a c t i o n o f th e valve k e e p s CAUTION
c a r b o n d e p o s i ts off o f the v alv e face a n d valve seat. If the high idle rpm or the rack setting is higher
than given in the RACK SETTING INFORMA
TION (for the height above sea level at which
TURBOCHARGER
the engine is operated), there can be damage to
engine or turbocharger parts.
T h e t u r b o c h a r g e r s are in stalled at th e r e a r o f t h e
e x h a u s t m a n if o ld s . All o f th e e x h a u s t gases f r o m t h e T h e b e a r i n g s f o r the t u r b o c h a r g e r use en g in e oil f o r
en g ine go t h r o u g h th e t u r b o c h a r g e r s . l u b r ic a t io n . T h e oil c o m e s in t h r o u g h l u b r i c a t i o n
inlet p a s s a g e (4) a n d goes t h r o u g h p a s s a g e s in the
T h e e x h a u s t gases e n t e r t u r b i n e h o u s i n g (5) a n d c e n t e r se ctio n f o r l u b r i c a t i o n o f t h e b e a r in g s. Oil
go t h r o u g h th e blad es o f t u r b i n e w heel (6), c a u s i n g f r o m th e t u r b o c h a r g e r goes o u t t h r o u g h th e l u b r i
the t u r b i n e wheel a n d c o m p r e s s o r w heel ( l) t o t u r n . c a t i o n o u t l e t p a s sa g e in th e b o t t o m o f th e c e n te r
s e ctio n a n d g o es b a c k t o the e n g in e l u b r i c a t i o n
system .
W h e n th e c o m p r e s s o r w heel t u r n s , it p ulls filtered
air f r o m the air clean ers t h r o u g h t h e c o m p r e s s o r
h o u s i n g air inlet. T h e air is p u t in c o m p r e s s i o n by
a c t i o n o f the c o m p r e s s o r w heel a n d is p u s h e d t o th e
inlet m a n i f o ld o f th e engine.
2-8
SYSTEMS OPERATION
LUBRICATION SYSTEM
LUBRICATION SYSTEM
S C H E M A T IC FLOW D IA G R A M O F TH E L U B R IC A T IO N SYSTEM
(Pressure oil flow is shown in light grey, suction oil, return oil or splash-lubricated points are shown in dark grey)
1. Oil return line for turbocharger. 2. Oil supply line for turbocharger. 3. Oil manifold. 4. Booster oil pump for governor.
5. Valve mechanism. 6. Oil manifold. 7. Oil cooler. 8. Filter housing. 9. Camshaft bearings. 10. Main bearings of
crankshaft. 11. Connecting rod bearings. 12. Piston cooling jets. 13. Pump of prelube system. 14. Pressure regulating
valve. 15. Suction bell. 16. Single section oil pump. 17. Oil pan base.
2-9
LUBRICATION SYSTEM SYSTEMS OPERATION
T h e r e a r t i mi n g g e a r b e a r i n gs get p r e s s u r e oil
t h r o u g h pas sages f r o m t he r ear c a m s h a f t a n d c r a n k
shaft bear i ngs. T h e gear s get l u b r i c a t i o n f r o m t he
r e t u r n oil f r o m t he t u r b o c h a r g e r s .
DU PLEX LUBE FILTER SYSTEM
1. Selector (diverter) valve. 2. Filter vent valve. 3. Main
filter. 4. Filter pressure gauges. 5. A u xilia ry filter.
6. Adapting oil lines.
S C H E M A T IC FLOW DIAG RA M
OF TH E FR O N T A C CE SSO RY DRIVE
6. Oil manifold. 18. Water pum p gear. 19. Oil pum p gear.
20. Main idler gear. 21. Balancer gear. 22. Crankshaft
gear. 23. Idler gear. 24. Idler gear.
T h e f r o nt a c c e s s o r y dr i ve gets p r e s s u r e oil f r o m
oil m a n i f o l d (6) t h r o u g h a p a s s a g e f r o m t h e f r o n t
c r a n k s h a f t m a i n bear i ng. St eel t u b e s in t h e f r o n t
acce s s or y dr i ve ho u s i n g give oil t o all o f t he b e a r i ngs
for t he gears.
S C H E M A T IC FLOW D IA G R A M O F DU PLEX
L U B R IC A T IO N FILTER SYSTEM
1. Selector (diverter) valve. 2. Filter vent valve. 3. Main
filter. 4. Filter pressure gauges. 5. A u xilia ry filter.
7. Check valves. 8. Vent lines to engine crankcase from
filters. 9. Pump for engine oil. 10. Oil cooler.
DUPLEX OIL FILTER SYSTEM
2- 10
LUBRICATION SYSTEM SYSTEMS OPERATION
C O M P O N E N T LO C A TIO N
1. Oil pump. 2. Tee. 3. Electric motor. 4. Check valve.
W h e n y o u st ar t t he engi ne, t h e p r e l u b r i c a t i o n
p u m p will give l ub r i c a t i o n t o t he engi ne b e f o r e t h e
st a r t i ng m o t o r s t ur n . W h e n oil pr e s s u r e at t h e oil
lines t o t he t u r b o c h a r g e r s is l t o 3 psi (7 t o 20 k P a ) , a
pr e s s u r e swit ch will close a n d a ct i vat e t h e s t a r t i n g
mo t o r s . W h e n t he engi ne st a r t s a n d t h e s t a r t swi t c h
or air val ve is r el eased t he p r e l u b r i c a t i o n p u m p
stops.
COOLING SYSTEM SYSTEMS OPERATION
COOLING SYSTEM
FLOW OF C O O L A N T IN R A D IA T O R C O O L IN G SYSTEM
1. Aftercooler. 2. Exhaust manifold. 3. Tubes. 4. W ater m anifold. 5. Regulator housing. 6. Radiator. 7. Bypass line.
8 .W ate rp u m p . 9. Cylinder head. 10. Engine oil cooler. 11. Junction housing. 12. Bottom passage. 13. Flywheel housing.
14. Top passage.
o f t h e engi ne o n t he r e a r of t he a c c e s s o r y dr i ve
ENGINE JACKET WATER COOLING SYSTEM h o u s i ng.
T h e t w o m o s t used m e t h o d s t o r e m o v e heat f r o m
T h e f low o f c o o l a n t t h r o u g h t he en g i n e is as
t he en g i n e j a c k e t w a t e r a r e t he r a d i a t o r a n d t h e heat
f ollows: C o o l a n t f r o m r a d i a t o r (6) o r e x p a n s i o n
e x c h a n g e r . T h e heat e x c h a n g e r m e t h o d m u s t have
t a n k (16) is pul l ed t h r o u g h t he inlet line by w a t e r
an e x p a n s i o n t a n k t o give r o o m for t he e x p a n s i o n o f
p u m p (8). T h e w a t e r p u m p t h e n p u s h e s t h e c o o l a n t
t he c o o l a n t . T h e r a d i a t o r has a t o p t a n k t o give
t o engi n e oil c oo l e r (10). F r o m t he oil c o o l e r t he
r o o m f or t he e x p a n s i o n o f t he c ool a nt . c o o l a n t goes to t o p p a s s a ge (14) in fl ywheel h o u s i n g
(13).
A g ear dr i v e n cent r i f u g a l - t y p e w a t e r p u m p is used
t o m o v e t he c o o l a n t t h r o u g h t he en g i n e j acket w a t e r C o o l a n t goes t h r o u g h t h e t o p p a s s a g e in t he fly
c ool i n g syst em. T h e w a t e r p u m p is o n t he r i ght si de wheel h o u s i n g t o j u n c t i o n h o u s i n g (1 1) o n t he left
2- 1 2
SYSTEMS OPERATION
COOLING SYSTEM
FLOW OF C O O L A N T IN H E A T EX C H A N G ER C O O L IN G SYSTEM
1. Aftercooler. 2. Exhaust manifold. 3. Tubes. 4. W ater manifold. 5. Regulator housing. 8. W ater pump. 9. Cylinder
head. 10. Engine oil cooler. 11. Junction housing. 12. Bottom passage. 13. Flywheel housing. 14. Top passage.
15. W ater cooled turbocharger shield. 16. Expansion tank. 17. Engine jacket water heat exchanger.
2- 1 3
COOLING SYSTEM SYSTEMS OPERATION
C o o l a n t f r o m t he c yl i nder h e a d s goes t h r o u g h
t ube s (3) t o t he e x h a u s t ma n i f o l d shi el ds o r t he
w a t e r co o l e d e x h a u s t m a n i f o l d s a n d t h e n t o t he
f r ont of t he engi ne t o w a t e r ma n i f o l d (4).
C o o l a n t go e s f r o m t h e w a t e r m a n i f o l d t o
r e g u l a t o r h o u s i n g (5). T h e r e g u l a t o r s in t he ho u s i n g
c o n t r o l t he f l ow of c o o l a n t t o t he r a d i a t o r or heat
e x c h a n g e r t o co n t r o l t he t e m p e r a t u r e in t he coo l i n g
syst em.
W h e n t he s ys t e m ha s a r a d i a t o r , t he r e is a b yp a s s
line (7) f r o m t he inlet side of t he r e g u l a t o r h o u s i n g t o
t he inlet pi pe f or t he w a t e r p u m p . W h e n t he s y s t e m
h a s a heat e x c h a n g e r a n d e x p a n s i o n t a n k , t h e r e is a
b yp as s p a s s a g e f r o m t h e inlet side of t he r e g u l a t o r
h o u s i n g t o t he e x p a n s i o n t a n k . In e i t he r s ys t em C O O LA N T LEVEL SW ITC H
wh e n t he t e m p e r a t u r e of t he c o o l a n t is n o t hi g h (Earlier Type)
e n o u g h t o o p e n t he r e gu l a t or s , c o o l a n t will b y p a s s 1. Float. 2. Switch.
t he r a d i a t o r o r heat e x c h a n g e r t o p e r m i t q u i c k
w a r m - u p of t he engine.
S o m e sys tems wi th e x p a n s i o n t a n k s h av e a
c o o l a n t level swi t c h for t he p u r p o s e of c h e c k i n g
c o o l a n t level in the sys t em. T h e c o o l a n t level ca n be
seen t h r o u g h t he glass o n e ar l i er t yp e switches. T h e
float ( l ) wh i c h o p e r a t e s t he swi t c h (2) al so c a n be
seen. T h e float pos i t i o n o n t he l at er t y p e s wi t c h is
s h o w n by t he o p e r a t i n g a r m (3).
2 - 14
SYSTEMS OPERATION
COOLING SYSTEM
‘V
1 1
L —1 1---- >
2- 15
COOLING SYSTEM S Y S T E M S O P E R A T IO N
2- 1 6
COOLING SYSTEM SYSTEMS OPERATION
C o o l a n t f r o m t h e w at e r out l et c o n n e c t i o n goes t o
keel c o o l e r (26) o r a f resh w a t e r heat e x c h a n g e r
wh i c h will r e m o v e t he heat f r o m t he c o o l a n t . T h e
c o o l a n t t h e n r e t u r n s t o t he w a t e r p u m p inlet pipe.
A n e x p a n s i o n t a n k (27) is i nst all ed in t h e inlet pi pe
t o give r o o m for e x p a n s i o n o f t he c o o l a n t .
2- 17
BASIC BLOCK SYSTEMS OPERATION
BASIC BLOCK
CYLINDER BLOCK, HEADS AND LINERS CRANKSHAFT
A steel heat p l u g in t he t o p o f t he p i s t o n p r e v e n t s
e r o s i on ( we a r i n g a wa y ) of t he t o p o f t he p i s t o n at t he
po i n t of hi ghest heat .
149971
P i s t on co o l i n g jets, l oc a t e d o n t he b o t t o m of t he T IM IN G GEARS
val ve lifter br a c ke t s , t h r o w oil t o cool a n d give (8 Cylinder Engine Illustrated)
l u b r i c a t i o n t o t he pi s t on c o m p o n e n t s a n d cy l i nder 1. Fuel pump and governor drive gear. 2. Camshaft cluster
gear. 3. B alancer gear (8 cylin der engines o nly).
walls.
4. Crankshaft gear.
2- 18
BASIC BLOCK SYSTEMS OPERATION
T h e v i b r a t i o n d a m p e r is i nst al l ed o n t he f r o n t o f T h e d i r e c t i o n of r o t a t i o n of t h e a c c e s s or y dr i ve is
t he c r a n k s h a f t . T h e d a m p e r ha s a wei ght in a me t a l t h e s a m e f or s t a n d a r d o r op p o s i t e r o t a t i o n engi nes.
h ou s i ng. T h e space b e t we e n t he we i ght a n d t he
h o u s i n g is filled wi t h a t hi ck fluid. T h e we i ght m o v e s
in t he h o u s i n g t o limit t h e t o r s i o n a l vi b r a t i o n .
2- 1 9
AIR S T A R T IN G SYSTEM SYSTEMS O PER A TIO N
A IR S T A R T IN G SYSTEM
A IR S T A R T IN G S Y S T E M (T Y P IC A L E X A M P L E ) A IR S T A R T IN G M O T O R
Ongersoll-Rand M o to r Shown)
1. Starter control valve. 2. O iler. 3. Relay valve. 4. A ir
starting m otor. 5 , Vanes. 6. R otor. 7 . A ir inlet. 8. Pinion. 9. Gears, 10.
Piston. 11. Piston spring.
T h e air st a r t i ng m o t o r can be m o u n t e d on ei t her T h e air f r o m the suppl y goes to relay valve (3).
side o f the engi ne. Air is n o r m a l l y c o n t a i n e d in a T h e s t a r t e r c o n t r o l valve ( 1 ) is c o n n e c t e d to the
st or age t a n k and t he v o l u m e o f t he t a n k will line b e f o r e t he relay valve (3). T h e flow o f air is
d e t er m i n e t u r n i n g t i me of engi ne. T h e st or age t a n k s t o p p e d by t h e rel ay valve (3) until t he s t a r t e r
m u s t hol d this v o l u m e o f air at 2 5 0 psi ( l 7 2 0 k P a ) c o n t r o l valve ( 1) is act i vat ed. T h e n air f r o m the
wh e n filled.
s t a r t e r c o n t r o l valve ( 1) goes to t he pi s t on ( 10)
F o r engi nes wh i c h d o n o t have heavy loads wh e n b e h i n d t he pi ni on (8) f or the start er . T h e air
start ing, t he r e g u l a t o r set ti ng is a p p r o x i m a t e l y 10 0 pr ess ur e on t he pi st on ( 1 0 ) p u t s the spr i ng ( 1 1 ) in
psi ((MO kPa). Thi s s et t i ng gives a g o o d r el at i onshi p c o mp r e s s i o n a nd p u t s t he pi ni o n (8) in e n g a g e me n t
b e t we e n c r a n k i n g s pe eds fast e n o u g h for easy wi t h t he f l ywheel gear. Wh e n the pi ni on is in
s t a r t i ng a nd t he l engt h o f t i me the air st a r t i ng e n g a g e m e n t , air can go o u t t h r o u g h a n o t h e r line t o
m o t o r can t ur n t he engi ne b e f o r e t he air s up p l y is t he relay valve (3). T h e air act i vat es t he relay valve
gone. ( 3 ) wh i c h o p e n s t he s u p p l y line t o t he air st art i ng
motor.
If t he engi ne has a heavy l oad wh i c h can n o t be
T h e flow o f air goes t h r o u g h t he oiler (2) whe r e
d i s c o n n e c t e d dur i n g s t art i ng, t he set t i ng o f t he air
it picks up l ubr i c a t i o n oil for the air s t art i ng
pr essure r egul at i ng valve needs t o be hi g h e r in
motor.
or d e r t o get hi gh e n o u g h s pe ed for easy starti ng.
The air wi t h l ubr i c a t i on oil goes i nt o the air
The air c o n s u m p t i o n is di r ect l y r el at ed to speed. m o t o r . T h e pr ess ur e o f t he air pu s he s agai nst t he
T h e air pr ess ur e is r el at ed t o t he ef f or t neces sary t o vanes ( 5) in t he r o t o r (6). Thi s t ur ns t he r o t o r
t ur n t he engi ne f l ywheel . T h e s e t t i ng o f t he air wh i c h is c o n n e c t e d by gears (A) t o t he s t a r t er
pr ess ure r e gul a t or can be up to l 50 psi ( 1 0 3 0 kPa) pi ni o n ( 8) wh i c h t u r n s t he engi ne fl ywheel .
i f neces sar y to get t he cor r e c t c r a n k i n g s peed f o r a When t he engi ne st art s r u n n i n g the fl ywheel will
heavily l o a d e d engi ne. Wi t h t he cor r e ct set t i ng, the start t o t ur n f ast er t ha n t he s t a r t e r pi n i on (8). The
air s t a r t i ng m o t o r can t ur n t he heavi ly l oa d e d pi ni on ( 8) r et r ac t s u n d e r this c o n d i t i o n . This
engi ne as fast as it can t ur n a lightly l oaded engi ne. pr e v e n t s d a ma g e t o t he m o t o r , pi ni on (8) or
fl ywheel gear.
O t h e r air s uppl i es can be used if t he y have t he
co r r e c t pr ess ur e a nd v ol ume . F o r g o o d life o f the Whe n t he s t a r t e r c o n t r o l valve i 1 ) is released, t he
air st a r t i ng m o t o r , t he suppl y s h o u l d be free o f di rt air pr ess ur e a n d fl ow t o t he p i st on ( 10) b e h i n d the
and wat er . The m a x i m u m pr essure for use in t he s t a r t e r p i ni on ( 8) is s t o p p e d . T h e pi s t on spri ng ( 11)
air st a r t i ng m o t o r is 150 psi ( 1030 kPa). Hi gher pul ls ba c k t he pi n i on (8). The relay valve (3) st ops
pr essures can cause safet y p r o b l e ms . t he f l ow o f air t o the air st a r t i ng m o t o r .
2-20
^ S Y S T E M S O P E R A T IO N
H Y D R A U L IC S T A R T IN G S Y S T E M
H Y D R A U L IC S T A R T IN G SYSTEM
H Y D R A U L IC S T A R T IN G S Y S T E M D IA G R A M
1. Reservoir. 2. Hand pum p. 3. Pressure gauge. 4. H ydrau lic starting m otor 5 . Starter control valve. 6. H ydrau lic pum p (driven by
engine tim ing gears). 7. Unloading valve. 8. Filte r. 9 . Accu m u lator.
2 - 2!
H Y D R A U L IC S T A R T IN G S Y S T E M SYSTEMS O P E R A TIO N
2- 22
ELECTRICAL SYSTEM SYSTEMS OPERATION
ELECTRICAL SYSTEM
The electrical system can have three se par ate a m o u n t of a l t e r n a t i n g c u r r e n t ( AC) is p r o d u c e d in
circuits: t he c h a r g i n g circuit, t he st a r t i n g ci rcui t a n d t he s t a t o r wi n d i n g s f r o m t he sma l l ma g n e t i c lines of
t he l ow a m p e r a g e circuit. S o m e o f t h e elect r i cal force m a d e by t h e r esi dual m a g n e t i s m ot t he poles.
s ys t em c o m p o n e n t s a r e used in m o r e t h a n o n e cir Th i s A C c u r r e n t is c h a n g e d t o dir ect c u r r e n t ( D C )
cuit. T h e b a t t e r y (bat t eri es), circui t b r e a k e r , a m w h e n it passes t h r o u g h t he d i o d e s of t he rectifier
met er . cabl es a n d wires f r o m t h e b a t t e r y a r e all br idge. M o s t o f t he c u r r e n t goes t o c h a r g e t he
c o m m o n in e ach of t he circuits. ba t t e r y a n d t o s u p p l y t he low a m p e r a g e ci rcui t, a n d
t he r e m a i n d e r is sent o n t o t he tield wi ndi ngs . T h e
T h e c h a r g i n g circuit is in o p e r a t i o n w h e n t h e D C c u r r e n t (l ow t h r o u g h t he field wi n d i n g s (wi res
engi ne is r u n ni ng. A n a l t e r n a t o r m a k e s el ect rici ty a r o u n d a n i r on cor e) now i ncr ease s t h e s t r e n g t h of
f or t he c h a r g i n g circuit. A vo l t a g e r e g u l a t o r in t h e t he m a g n e t i c lines of force. T h e s e s t r o n g e r lines of
circuit c o n t r o l s t he el ect rical o u t p u t t o ke e p t he f or ce now' i ncr ease t he a m o u n t of A C c u r r e n t
ba t t e r y at full char ge. p r o d u c e d in t he s t a t o r wi ndi ngs . T h e i ncr eas e d
speed of t he r o t o r a s s e m b l y al so i ncr ease s t h e
T h e s t a r t i n g circuit is in o p e r a t i o n onl y w h e n t h e c u r r e n t a n d v o l t a g e o u t p u t of t he a l t e r n a t o r .
st ar t swi t ch is act i vat ed.
T h e vol t age r e g u l a t o r is a soli d st ate ( t r a n s i s t o r
T h e s t a r t i ng circuit ca n ha ve a g l ow p l u g f o r e a c h s t a t i o n a r y par t s) el ect r oni c swi tch. It feels t he
cyl i nder of t he diesel engi ne. G l o w p l ugs a r e sma l l vol t a ge in t he s ys t e m a n d swi t ches on a n d of f m a n y
he a t i n g uni t s in t h e p r e c o m b u s t i o n c h a m b e r s . Gl ow' t i mes a s e c o n d t o c o n t r o l t he field c u r r e n t ( D C
pl ugs m a k e i gni t i on o f t he fuel easi er w h e n t h e c u r r e n t t o t he field wi nd i ngs ) f o r t he a l t e r n a t o r t o
en g i n e is st a r t ed in col d t e m p e r a t u r e . m a k e t he n e e d e d vol t a ge o u t p u t .
T h e l ow a m p e r a g e circuit a n d t he c h a r g i n g ci rcuit
ar e b o t h c o n n e c t e d t o t h e s a m e si de of t he a m m e t e r .
T h e s t a r t i n g circuit c o n n e c t s t o t he o p p o s i t e side o f
t he a m m e t e r .
T h e a l t e r n a t o r is dr i v e n by V- t ype belts f r o m a
pull ey o n t he a cce s s or y dri ve. Th i s a l t e r n a t o r is a
t h r e e phas e, self-rectifyi ng c h a r g i n g uni t , a n d t h e
5S9088 D E LC O -R EM Y A LTER NA TO R
r e g u l a t o r is pa r t of t he a l t e r n a t o r .
1. Regulator. 2. Roller bearing. 3. Stator winding. 4. Ball
bearing. 5. Rectifier bridge. 6. Field winding. 7. Rotor
Thi s a l t e r n a t o r des i gn has n o need f or slip r i ngs or assembly. 8. Fan.
br us hes , a n d t he onl y par t t h a t ha s m o v e m e n t is t he
r o t o r as s embl y. All c o n d u c t o r s t h a t c a r r y c u r r e n t
a r e s t a t i o n a r y . T h e c o n d u c t o r s ar e : t h e fi el d
wi ndi n g, s t a t o r wi ndi ng s , six r ect i fyi ng di od e s , a n d STARTING SYSTEM COMPONENTS
the r e g u l a t o r circuit c o m p o n e n t s .
Starting Motor
T h e r o t o r a s s e m b l y h a s m a n y m a g n e t i c pol es like
fingers wi t h ai r s pa c e be t we e n e a c h o p p o s i t e pol e. T h e s t a r t i n g m o t o r is used t o t u r n t h e en gi ne
T h e poles h ave r esi dual m a g n e t i s m (like p e r m a n e n t fl ywheel fast e n o u g h t o get t he en gi ne r u n n i n g .
m a g n e t s ) t h a t p r o d u c e a smal l a m o u n t o f m a g n e t
like lines o f f orce ( ma g n e t i c field) b e t we e n t h e poles. T h e s t a r t i n g m o t o r has a s ol e noi d. W h e n t h e st ar t
As t he r o t o r a s s e m b l y begi ns t o t u r n b e t we e n t h e swi t ch is a c t i vat ed, el ectricity f r o m t he el ect rical
field wi n d i n g a n d t he s t a t o r wi n d i n g s , a sma l l sys t e m will c a u s e t he s ol e n o i d t o m o v e t h e s t a r t e r
2- 23
E L E C T R IC A L S Y S T E M S Y S T E M S O P E R A T IO N
OTHER COMPONENTS
Circuit Breaker
STA R TIN G M O TO R
T h e circuit b r e a k e r is a safet y swi t c h t ha t o p e n s
t he b a t t e r y ci rcui t if t he c u r r e n t in t h e electri cal
1. Field. 2. Solenoid. 3. Clutch. 4. Pinion. 5. C o m
mutator. 6. Brush assembly. 7. Armature. s y s t e m goes hi gher t h a n t he r a t i n g of t he circuit
b r eaker .
2
m
V, 77/7777/L77
v>J
7/y//tV/'A xA
/A y
A /// %
S C H E M A TIC OF A SO LE N O ID
1. Coll. 2. Switch terminal. 3. Battery terminal. 4. Con T89119X1 5
tacts. 5. Spring. 6. Core. 7. Com ponent terminal.
C IR C U IT BREAKER S C H E M A TIC
1. Reset button. 2. Disc in open position. 3. Contacts.
T h e r e ar e c o n t a c t s (4) o n t h e e n d o f cor e (6). T h e
4. Disc. S. Battery circuit terminals.
c o n t a c t s a r e held in t he o p e n p o s i t i o n by s p r i n g (5)
t ha t pus h e s c or e (6) f r o m t he m a g n e t i c c ent er of coil
( l ). T o w c u r r e n t will ener gi ze coil ( l ) a n d m a k e a
ma g n e t i c field. T h e m a g n e t i c field pul l s c o r e (6) to
t he c ent er of coil ( I ) a n d t h e c o n t a c t s close.
2- 2 4
WIRING DIAGRAMS SYSTEMS OPERATION
W IRING DIAGRAMS
N O T E : A u t o m a t i c S t a r t - S t o p s ys t e ms use di f f er ent
Gl o w pl ugs a r e p r ov i d e d f or l ow t e m p e r a t u r e w i r i ng d i a g r a m s . M a k e r e f e r en ce t o t h e Ser vi ce
s t a r t i ng c o nd i t i ons . S y s t e ms w i t h o u t gl o w pl ugs a r e M a n u a l f or t he g e n e r a t o r or t o t h e A t t a c h m e n t
usua l l y used w h e r e i deal s t a r t i n g c o n d i t i o n s exi st o r S e c t i o n s o f thi s m a n u a l , f o r t hi s i n f o r m a t i o n .
w'here a n A u t o m a t i c S t a r t - S t o p s y s t e m is used.
T h e c h a r t gives t he cor r e c t wi r e sizes a n d c o l o r
A fuel or oil pr es s ur e swit ch is used in all s y s t e ms codes. M a k e r ef e r ence t o t he de s c r i p t i o n in S y s t e ms
wi t h a n e x t e r n a l r egul at or . T h e swi t ch p r e v e n t s c u r O p e r a t i o n f or t he f u n c t i o n of e a c h of t he c o m
rent d i s c h a r g e (field e x c i t a t i o n ) t o a l t e r n a t o r f r o m p o ne nt s .
t he b a t t e r y w h e n t he engi n e is n o t in o p e r a t i o n . In
M A X IM U M RECOMMENDED
COLOR CODE TOTAL BATTERY CABLE LENGTH WIRES MARKED # X
2- 2 5
W IR IN G D IA G R A M S SYSTEMS O PER A TIO N
C H A R G IN G S Y S T E M C H A R G IN G S Y S T E M
1. Heat-S tart switch. 2. Magnetic switch. 3. G low plugs. 4. 1. Heat-S tart switch. 2. Magnetic switch. 3. G low plugs. 4.
A m m eter. 5. Regulator. 6. B attery. 7. Pressure switch. 8. A m m eter. 5. Regulator. 6. Battery. 7. Pressure switch. 8.
A lternator. A lte rna tor.
SYSTEMS O P E R A TIO N
W IR IN G D IA G R A M S
G R O U N D E D E L E C T R I C A L S Y S T E M S (Cont.) I N S U L A T E D E L E C T R I C A L S Y S T E M S (Cont.)
C H A R G IN G S Y S T E M W IT H C H A R G IN G S Y S T E M W IT H
E L E C T R IC S T A R T IN G M O T O R E L E C T R IC S T A R T IN G M O T O R
1. Start switch. 2. A m m eter. 3. Regulator. 4. Starting 1. Start switch. 2. A m m eter. 3. Regulator. 4. Starting
m otor. 5. Battery. 6. Pressure switch. 7. A lternator. m otor. 5. Battery. 6. Pressure switch. 7. A lternator.
C H A R G IN G S Y S T E M W IT H E L E C T R IC C H A R G IN G S Y S T E M W IT H E L E C T R IC
S T A R T IN G M O T O R A N D G L O W P L U G S S T A R T IN G M O T O R A N D G LO W P L U G S
1. H eat-S tart switch. 2. Magnetic switch. 3. G low plugs. 1. Magnetic switch. 2. H eat-S tart switch. 3. A m m eter. 4.
4. Am m eter. 5. Regulator. 6. Battery. 7. Starting m otor. G low plugs. 5. Regulator. 6. B attery. 7. Starting m otor.
8. Pressure switch. 9. A lternator. 8. Pressure switch. 9. A lternator.
2- 2 7
W IR IN G D IA G R A M S S Y S T E M S O PE R A T IO N
G R O U N D E D E L E C T R I C A L S Y S T E M S (Cont. ) I N S U L A T E D E L E C T R I C A L S Y S T E M S (Cont.)
C H A R G IN G S Y S T E M W IT H TW O C H A R G IN G S Y S T E M W IT H TW O
E L E C T R IC S T A R T IN G M O T O R S E L E C T R IC S T A R T IN G M O T O R S
C H A R G IN G S Y S T E M W IT H T W O E L E C T R IC C H A R G IN G S Y S T E M W IT H TW O E L E C T R IC
S T A R T IN G M O T O R S A N D G LO W P L U G S S T A R T IN G M O T O R S A N D G L O W P LU G S
1. H eat-S tart switch. 2. M agnetic switch. 3. G low plugs. 1. H eat-S tart switch. 2. Magnetic switch. 3. G low plugs. 4.
4. Am m eter. 5. Regulator. 6. Battery. 7. Starting m otor. A m m e te r. 5. Regulator. 6. Battery. 7. Starting m otor. 8.
8. Pressure switch. 9. A lternator. Pressure switch. 9. A lte rn a to r.
2- 2 8
W IR IN G D IA G R A M S SYSTEMS O P E R A TIO N
G R O U N D E D E L E C T R I C A L S Y S T E M S (Cont.) I N S U L A T E D E L E C T R I C A L S Y S T E M S (Cont.)
(R egulator Inside A lterna tor) (Reg ula tor Inside Alte rna tor )
C H A R G IN G S Y S T E M C H A R G IN G S Y S T E M
1. Heat-S tart switch. 2. Magnetic switch. 3. G low plugs. 4. 1. H eat-S tart switch. 2. Magnetic switch. 3. G low plugs. 4.
A m m eter. 5. Battery. 6. A lte rna tor. A m m eter. 5. Battery. 6. A lte rn a to r.
2-29
W IR IN G D IA G R A M S SYSTEMS O P E R A TIO N
G R O U N D E D E L E C T R I C A L S Y S T E M S (Cont.) I N S U L A T E D E L E C T R I C A L S Y S T E M S (Cont.
C H A R G IN G S Y S T E M W IT H E L E C T R IC C H A R G IN G S Y S T E M W IT H E L E C T R IC
S T A R T IN G M O T O R S T A R T IN G M O T O R
1. Start switch. 2. Am m eter. 3. A lte rn a to r. 4. Battery. 5. 1. Start switch. 2. A m m eter. 3. A lte rna tor. 4. Battery. 5.
Starting m otor. Starting m otor.
C H A R G IN G S Y S T E M W IT H E L E C T R IC C H A R G IN G S Y S T E M W IT H E L E C T R IC
S T A R T IN G M O T O R A N D G L O W P LU G S S T A R T IN G M O T O R A N D G LO W P L U G S
1. H eat-S tart switch. 2. M agnetic switch. 3. G low plugs. 4. 1. H eat-S tart switch. 2. M agnetic switch. 3. G low plugs. 4.
A m m eter. 5. Battery. 6. Starting m otor. 7. A lte rna tor. A m m eter. 5. Battery. 6. Starting m otor. 7. A lternator.
2- 3 0
SYSTEMS O P E R A TIO N
W IR IN G D IA G R A M S
G R O U N D E D E L E C T R I C A L S Y S T E M S (Cont.) I N S U L A T E D E L E C T R I C A L S Y S T E M S (Cont.)
C H A R G IN G S Y S T E M W IT H TW O C H A R G IN G S Y S T E M W IT H TW O
E L E C T R IC S T A R T IN G M O T O R S E L E C T R IC S T A R T IN G M O T O R S
1. Magnetic switch. 2. Start switch. 3. A m m eter. 4. 1. Magnetic switch. 2. Start switch. 3. A m m eter. 4.
Battery. 5. Starting motors. 6. A lte rna tor. Battery. 5. Starting m otors. 6. A lte rna tor.
C H A R G IN G S Y S T E M W IT H TW O E L E C T R IC C H A R G IN G S Y S T E M W IT H TW O E L E C T R IC
S T A R T IN G M O T O R S A N D G L O W P LU G S S T A R T IN G M O T O R S A N D G LO W PLU G S
1. H eat-Start switch. 2. Magnetic switch. 3. G low plugs. 4. 1. Heat-S tart switch. 2. Magnetic switch. 3. G low plugs. 4.
Am m eter. 5. Battery. 6. Starting motors. 7. A lte rna tor. Am m eter. 5. B attery. 6. Starting m otors. 7. A lte rna tor.
2-31
WIRING DIAGRAMS SYSTEMS OPERATION
2-32
PROTECTION DEVICES SYSTEMS OPERATION
S H U TO FF C O N T R O L
1. Shutoff control. 2. Plug (pressure oil connection to
water tem perature shutoff). 3. Fuel rack shutoff reset
cable assembly. 4. Pressure oil line to shutoff control.
5. Reset button. 6. Emergency manual shutoff button.
T h e o v e r s pe e d s h u t o f f p a r t of t he c o n t r o l s t o p s
t he en g i n e me c h a n i c a l l y in t he e ve nt o f e n g i n e
over s pee di ng. S H U TO FF C O N T R O L
(Cross Sectional Side View; Normal Operation)
C o n t r o l s e q u i p p e d wi t h r ever sal p r o t e c t i o n a r e 1. W orm shaft. 2. S lid e follow er. 3. Slide follow er
a c t i v a t e d by l ow oil pr e s s u r e o nl y w h e n t he en g i n e shaft. 4. Cover. 5. G uide. 6. Piston. 7. Spring.
8. Release rod.
r uns in reverse.
T h e e m e r g e n c y m a n u a l s h u t o f f b u t t o n (6) w o r k s U n d e r n o r m a l engi ne o p e r a t i o n , en g i n e l u b r i c a t
wi t h t he o v e r s p e e d s h u t o f f a n d pr o v i d e s t he o p e r a i ng oil goes t h r o u g h line (4). ( See i l l u s t r a t i o n of
t o r wi th a n e m e r g e n c y s h u t o f f cont r ol . S h u t o f f C o n t r o l . ) Th i s oil goes t o c o v e r (4) a n d
2- 33
PROTECTION DEVICES SYSTEMS OPERATION
W o r m shaft (1) is t u r n e d by t he s h u t o f f dr i ve
whi ch is t u r n e d by t he fuel p u m p a n d g o v e r n o r dr i ve
shaft. A n y t i me t he engi ne is r u n n i n g t he c o n t r o l is
in op e r a t i o n .
W h e n t he pr es s ur e of t he eng i ne oil is n o r m a l ,
pi st on (6) is held agai ns t g ui d e (5) p u t t i n g s p r i n g (7)
in c o m p r e s s i o n a n d keeps slide f ol l ower (2) o u t of
c o n t a c t wi t h w o r m shaft (1).
S H U TO FF C O N T R O L
(Side View; Shutoff O peration Position)
1. Worm shaft. 2. Slide follower. 3. Slide follower shaft.
5. Guide. 6. Piston. 7. Spring. 8. Release rod.
1 2
S H U TO FF C O N T R O L
(Top View; Normal O peration Position)
I . Worm shaft. 2. Slide follower. 3. Slide follow er shaft.
5. Guide. 8. Release rod. 9. Pin. 10. Release latch.
I I . Spring.
W h e n t he pr es s ur e of t he l u b r i c a t i o n oil d r o p s
bel ow n o r m a l o p e r a t i n g r ange, t he oil p r es s ur e o n
pi s t on (6) will al so d r o p a n d s p r i n g (7) will f or ce
g ui de (5) a n d pi st on (6) t o t he s t o p p o s i t i o n a n d
c aus e slide f ol l ower (2) t o t u r n on sha f t (3) a n d
c o n t a c t w o r m shaft (l).
S H U TO FF C O N T R O L
T h e slide f ol l ower (2) will m o v e t h e l engt h of (Top View, Shutoff Operation Position)
w' orm p o r t i o n o f shaft ( l ) w h e n slide f o l l o we r (2) is
1. Worm shaft. 2. Slide follower. 8. Release rod. 9. Pin.
en g a g e d wi t h w o r m shaft ( l ). As t he f o l l o we r c o me s 10. Release latch. 11. Spring.
close t o t he end of its m o v e m e n t , pi n (9) o n t he
f ol l ower m a k e s c o n t a c t w'ith release l at ch (10).
2- 3 4
PROTECTION DEVICES SYSTEMS OPERATION
O v e r s p e e d c a r r i e r a s s e m b l y ( l ) is d r i v e n by gear s
a n d t he s h u t o f f dr i ve w h i c h is d r i ve n by t he fuel
p u m p a n d g o v e r n o r dr i ve shaft . W h e n t h e en gi ne is
r u n n i n g t h e o v e r s p e e d c a r r i e r will t u r n . A r o t a t i n g
wei ght (2) in t he c a r r i e r f l ange is hel d t o w a r d t he
c e n t e r of t he c a r r i e r sha f t by a n a d j u s t m e n t screw,
s p r i ng a n d nut.
Overspeed Shutoff
E M ER G E NC Y SH U TO FF
1. Spring loaded w eight. 2. C a rrie r assem bly. 3. Pin
4. Plunger. 5. Button.
M a n u a l s h u t o f f b u t t o n (5) is used o n l y t o s t o p t he
e n g i n e in a n e me r g e n c y . D O N O T use t h e s h u t o f f
b u t t o n t o s t o p t h e engi ne in n o r m a l o p e r a t i o n . In
O VERSPEED C O N T R O L n o r m a l o p e r a t i o n , r e m o v e all of t h e l o a d f r o m t h e
1. Carrier assembly. 2. Rotating weight. 3. Release latch. e n g i n e a n d m a k e a r e d u c t i o n in en g i n e r p m t o l ow
4. Release rod. idle b e f o r e t he eng i ne is s t o p p e d .
2- 35
PROTECTION DEVICES SYSTEMS OPERATION
W h e n b u t t o n (5) is pu s h e d , it will m o v e p l u n g e r
(4) a ga i ns t pin (?) whi ch will f orce wei ght (1) o u t of
car r i e r a s s e mb l y (2). Th i s m a k e s t he s h u t o f f c o n t r o l
o p e r a t e t he s a m e as a n o v e r s p e e d ( engi ne r u n n i n g
t o o fast) c o n d i t i on.
T5027I U 5
S H U TO FF S E TTIN G C O N T R O L
1. Slide fo llow er guide. 2. Slide follow er. 3. C o ntrol
piston. 4. Reset button. 5. Release rod.
N O T E : In cold w e a t h e r o p e r a t i o n , it m a y be n e c e s
s a r y t o p u s h t he reset b u t t o n (4) whi l e c r a n k i n g t he
diesel en gi ne t o p r e v e n t ac t i v a t i n g t he s h u t o f f
c on t r ol . Th i s is neces s a r y as t h e oil pr e s s u r e will not
i ncr eas e t o t he o p e r a t i n g r a n g e fast e n o u g h b e c a u s e
o f t h e l o nge r c r a n k i n g p e r i o d n e e d e d u n d e r t hese
co n d i t i o n s .
P u s h reset b u t t o n (4) o n t he t o p of t h e s h u t o f f
c o n t r o l hous i ng. Th i s m o v e s c o n t r o l p i s t on (3) a n d
pin aga i ns t slide f ol l ower g ui d e ( l ). T h e m o v e m e n t
of t he gui de t u r n s slide f ol l ower (2) a w a y f r o m t he
e nd of t he w o r m shaft. Th i s p e r mi t s t he s p r i n g t o
m o v e t h e slide f ol l ower t o t he st ar t o f t he w o r m shaft
t hr eads .
2- 3 6
D379, 0398, D399 INDUSTRIAL AND MARINE ENGINES INDEX
TROUBLESHOOTING
T r o u b l e s h o o t i n g c a n be difficult. O n t h e f o l l o wi ng p a ge s t he r e is a list of
possi bl e p r o b l e m s . T o m a k e a r e p a i r t o a p r o b l e m , m a k e r ef er ence to t he c a us e
a n d c or r e c t i on.
R e m e m b e r t h a t a p r o b l e m is n o t n o r m a l l y c a u s e d onl y by o n e par t , bu t by t he
r el at i on of o n e p a r t w ith o t h e r par t s. Th i s list ca n n o t give all pos s i bl e p r o b l e m s
a n d cor r e c t i ons . The s e r v i c e ma n m u s t f i nd t he p r o b l e m a n d its sour ce, t he n
m a k e t he necessary repai rs.
TROUBLESHOOTING INDEX
3-2
TROUBLESHOOTING TESTING AND ADJUSTING
1. E N G I N E C R A N K S H A F T W I L L N O T T U R N W H E N S T A R T S W I T C H IS O N
Cause Correction
Ba t t e r y H a s L o w O u t p u t M a k e Re f e r e n c e t o I t e m 25.
Wi r i n g or S wi t c he s Ha v e M a k e R e f e r e n c e t o I t e m 25.
Def ect
S t ar t i n g M o t o r H a s A M a k e Re f e r e n c e t o I t e m 25.
Def ect
P r e l u b r i c a t i o n Oil P u m p R e p a i r o r r e pl a c e p u m p c o m p o n e n t s as n eeded .
H a s A Def ect
2. E N G I N E W I L L N O T S T A R T
Cause Correction
Sl o w C r a n k i n g S p e e d M a k e Re f e r e n c e t o I t e m 26.
F u e l P r e s s u r e is L o w At s t a r t i n g r p m , t he m i n i m u m fuel pr e s s u r e f r o m fuel t r a n s f e r p u m p
m u s t be 3 psi (20 k P a ) . If fuel pr e s s u r e is less t h a n 3 psi (20 k P a ) ,
c h a n g e t h e fuel filter e l ement . L o o k f o r ai r in t he fuel sys t em. If fuel
p r e s s u r e is still l ow, c h e c k t h e fuel c o n t r o l val ve a n d t he fuel t r a n s f e r
pump fo r correct operation.
W r o n g F u e l I nj ect i on M a k e a d j u s t m e n t t o t i mi ng.
Timi ng
TROUBLESHOOTING TESTING AND ADJUSTING
Cause Correction
W r o n g Val ve C l e a r a n c e M a k e a d j u s t m e n t a c c o r d i n g t o T e s t i n g a n d Ad j u s t i n g .
4. STALL AT L O W RPM
Cause Correction
( Co n t . nex t page)
3-4
TROUBLESHOOTING TESTING AND ADJUSTING
4. S T A L L A T L O W R P M ( Co n t . )
Cause Correction
5. S U D D E N C H A N G E S IN E N G I N E S P E E D (rpm)
Cause Correction
Cause Correction
( C o n t . n ex t pa ge)
3-5
TROUBLESHOOTING TESTING AND ADJUSTING
6. N O T E N O U G H P O W E R ( Co n t . )
Cause Correction
Ra c k S e t t i ng T o o L o w M a k e r e f e r ence t o t h e R A C K S E T T I N G I N F O R M A T I O N .
Fuel R a t i o C o n t r o l Ha s W r o n g M a k e a d j u s t m e n t t o co n t r o l . C h e c k f or b a d d i a p h r a g m a n d we a k
A d j u s t m e n t or Def ect or b r o k e n spr i ngs. R e p l a c e p a r t s if needed.
7. T O O M U C H V I B R A T I O N
Cause Correction
Vi b r a t i o n D a m p e r or C h e c k v i b r a t i o n d a m p e r a n d pul l ey f or d a m a g e . T i g h t e n bol t s
Pull ey is L o o s e o r nut s. If v i b r a t i o n d a m p e r o r pul l ey b ol t hol es h a v e d a m a g e or
wear , r e pl a c e wi t h n e w par t s.
Vi b r a t i o n D a m p e r H a s A Instal l a n e w v i b r a t i o n d a m p e r .
Defect
D r i v e n E q u i p m e n t is no t in C h e c k a l i g n m e n t a n d ba l a n c e , c o r r e c t if needed.
Al i gn m e n t or is O u t of Ba l a nc e
Mi s f i r i ng o r R u n n i n g R o u g h M a k e Re f e r e n c e t o I t e m 3.
3-6
TROUBLESHOOTING TESTING AND ADJUSTING
8. L O U D C O M B U S T I O N N O I S E ( S O U N D )
Cause Correction
W r o n g F u e l I nj ect i on M a k e a d j u s t m e n t t o t i mi ng.
Timi ng
9. V A L V E T R A I N N O I S E ( C L I C K I N G )
Cause Correction
No t E n o u g h L u b r i c a t i o n C h e c k l u b r i c a t i o n in val ve c o m p a r t m e n t . T h e r e m u s t be a s t r o n g
f l ow o f oil a t e n g i n e h i gh r p m . b u t on l y a s ma l l f l ow o f oil at l ow
r p m. Oil pa s s a g e s m u s t be cl ean, especi al l y t h o s e s e n d i n g oil t o t he
c y l i nde r head.
T o o M u c h Val ve C l e a r a n c e M a k e a d j u s t m e n t a c c o r d i n g t o T e s t i n g a n d Ad j u s t i n g .
10. O I L I N C O O L I N G S Y S T E M
Cause Correction
Def ect In C o r e of Oil I nst al l a n e w c o r e in t h e oil cool er .
Cooler
F a i l u r e of C y l i n d e r H e a d C h e c k c y l i n d e r li ner p r o j e c t i o n . R e p l a c e h e a d gasket .
Gasket
11. M E C H A N I C A L N O I S E ( K N O C K ) IN E N G I N E
Cause Correction
( C o n t . n e x t pag e)
3-7
TROUBLESHOOTING TESTING AND ADJUSTING
11. M E C H A N I C A L N O I S E ( K N O C K ) IN E N G I N E ( Co n t . )
Cause Correction
12. F U E L C O N S U M P T I O N T O O H I G H
Cause Correction
Fuel a n d C o m b u s t i o n Noi se M a k e Re f e r e n c e t o I t e m 3 a n d I t em 6.
( Kn o c k )
13. L O U D V A L V E T R A I N N O I S E
Cause Correction
14. T O O M U C H V A L V E L A S H
Cause Correction
No t E n o u g h L u b r i c a t i o n C h e c k l u b r i c a t i o n in val ve c o m p a r t m e n t . T h e r e m u s t be a s t r o n g
fl ow o f oil at e n g i n e hi gh r p m , but o n l y a s mal l f l ow at l ow r pm.
Oil pa s s a g e s m u s t be clean, especi al l y t h o s e s e n d i n g oil to t he
c yl i nd er head.
W o r n P u s h Ro d s If t h e r e is t o o m u c h we a r , inst al l n e w p u s h r ods. M a k e a d j u s t m e n t
o f val v e c l e a r a n c e a c c o r d i n g t o T e s t i n g a n d Ad j u s t i n g .
( C o n t . n e x t page)
3-8
TROUBLESHOOTING TESTING AND ADJUSTING
14. L O O M U C H V A L V E L A S H ( Co n t . )
Cause Correction
15. V A L V E R O T O C O I L O R S P R I N G L O C K IS F R E E
Cause Correction
16. O I L A T T H E E X H A U S T
Cause Correction
17. L I T T L E O R N O V A I . V E C L E A R A N C E
Cause Correction
18. E N G I N E H A S E A R L Y W E A R
Cause Correction
( C o n t . next page)
3-9
TROUBLESHOOTING TESTING AND ADJUSTING
18. E N G I N E H A S E A R L Y W E A R ( C o n t . )
Cause Correction
19. C O O L A N T I N L U B R I C A T I O N O I L
Cause Correction
F a i l u r e of Li ne r Seal s R e p l a c e seals.
20. T O O M U C H B L A C K O R G R A Y S M O K E
Cause Correction
N o t E n o u g h Ai r F o r C h e c k ai r c l e a n e r f o r rest r i ct i ons.
Combustion
21 . T O O M U C H W H I T E O R B L U E S M O K E
Cause Correction
( C o n t . nex t page)
3-10
TROUBLESHOOTING TESTING AND ADJUSTING
21. M U C H W H I T E O R B L U E S M O K E (Cont.)
TOO
Cause Correction
Mi s f i r i ng or R u n n i n g R o u g h M a k e R e f e r e n c e t o I t e m 3.
W r o n g F u e l I nj ect i on M a k e a d j u s t m e n t t o t i mi ng.
T imi ng
Cause Correction
Oil P u m p S u c t i o n P i p e Ha s R e p l a c e m e n t o f pi pe is needed.
A Def ect
T o o M u c h Cl e a r a n c e I nst al l n e w c a m s h a f t a n d c a m s h a f t b e a r i n g s if necessary.
Be t we e n C a m s h a f t a n d
C a m s h a f t Be ar i ngs
23. E N G I N E U S E S T O O M U C H L U B R I C A T I O N O i l .
Cause Correction
24. E N G I N E C O O L A N T IS T O O H O T
Cause Correction
Re s t r i c t i o n T o F l o w of C l e a n a n d f lush r a d i a t o r .
Coolant Through Radiator
Core Tubes
Re s t r i c t i on T o Ai r F l o w R e m o v e all r e s t r i c t i o ns o f flow.
Through Radiator
L o w F a n S pe e d C h e c k f o r w o r n o r l oose f an belts.
3-12
TROUBLESHOOTING TESTING AND ADJUSTING
25. S T A R T I N G M O T O R D O E S N O T T E R N
Cause Correction
Ba t t e r y Ha s Low O u t p u t C h e c k c o n d i t i o n of bat t er y. C h a r g e b a t t e r y or m a k e r e p l a c e m e n t
as neces sary.
S t a r t i n g M o t o r Ha s A M a k e r e p a i r or r e p l a c e m e n t of s t a r t i n g mo t o r .
Defect
26. A L T E R N A T O R GIVES NO C H A R G F
Cause Correction
27. A L T E R N A T O R C H A R G E R A T E IS L O W O R N O T R E G L E A R
Cause Correction
A l t e r n a t o r R e g u l a t o r Ha s A M a k e a n a d j u s t m e n t o r r e p l a c e m e n t o f a l t e r n a t o r r egul at or.
Def ect
3-13
TROUBLESHOOTING TESTING AND ADJUSTING
Cause Correction
A l t e r n a t o r or A l t e r n a t o r T i g h t e n all c o n n e c t i o n s t o a l t e r n a t o r or a l t e r n a t o r r egul at or .
R e g u l a t o r Ha s Loos e
Con ne ct io ns
A l t e r n a t o r R e g u l a t o r Ha s A M a k e a n a d j u s t m e n t or r e p l a c e m e n t of a l t e r n a t o r r egul at or .
Del ect
Cause Correction
W o r n A l t e r n a t o r Beari mi s Inst al l n e w b e a r i n g s in t he a l t e r n a t o r .
30. E X H A U S T T E M P E R A T U R E IS T O O H I G H
Cause Correction
3-14
TESTING AND ADJUSTING
FUEL SYSTEM
FUEL SYSTEM
E i t h e r t o o m u c h fuel or n o t e n o u g h fuel f or t h a t r u n s r o u g h ( misfires) a n d ca us e s bl ack s m o k e to
c o m b u s t i o n c a n be t he caus e o f a p r o b l e m in t h e c o m e o u t o f t he e x h a u s t pipe.
fuel syst em.
R u n t he eng i ne at t h e spe ed t h a t is t he r oughes t .
M a n y t i mes w o r k is d o n e o n t h e fuel s ys t e m L o o s e n t he fuel line nut at a t uel i nj ect i on p u m p .
w h e n t he p r o b l e m is reall y wi t h s o m e o t h e r p a r t T h i s will s t o p t he flow o f fuel to t h a t cyl i nder . D o
o f t h e e n g i n e . T h e s o u r c e o f t h e p r o b l e m is t hi s f or e a c h c yl i n der unt i l a l o o s e n e d luel line is
difficult t o find, especi al l y w h e n s m o k e c o m e s f o u n d t h a t m a k e s n o d i f f er ence in engi ne p e r f o r m
f r o m t he e x h a u s t . S m o k e t h a t c o m e s f r o m t h e a nce. Be s ur e t o t i g h t e n e a c h fuel line n u t a f t er t he
e x h a u s t c a n be ca u s e d by a b a d fuel i nj ect i on test bef or e t he n e xt fuel line nut is l oo s e n e d . C h e c k
valve, b u t it c a n al so be c a u s e d by o n e o r m o r e o f e a c h c y l i nde r bv t his m e t h o d . W h e n a c yl i nder is
t he r e a s o n s t h a t follow: f o u n d wh e r e t he l o o s e n e d luel line nut d o e s not
m a k e a di f f er ence in engi ne p e r f o r m a n c e , test t h e
a. N o t e n o u g h ai r f or g o o d c o m b u s t i o n . i nj ect i on p u m p a n d i nj ect i on valve f or t ha t cyl inder .
T e m p e r a t u r e o f a n e x h a u s t m a n i f o l d po r t , w h e n
b. A n o v e r l o a d at hi gh al t i t ude.
t he engi ne r u n s at l ow idle spe ed, c a n al s o be a n
i n d i c a t i o n o f t he c o n d i t i o n of a fuel i nj ect i on nozzl e.
c. Oil l e a ka ge i nt o c o m b u s t i o n c h a m b e r . L o w t e m p e r a t u r e at a n e x h a u s t m a n i f o l d p o r t is a n
i nd i c a t i o n o f n o fuel t o t he cyl i nder . Thi s c a n
d. No t e n o u g h c o m p r e s s i o n . p os s i bl y be a n i n d i c a t i o n of a n ozzl e wi t h a defect.
E x t r a h i gh t e m p e r a t u r e at a n e x h a u s t m a n i f o l d p o r t
FUEL SYSTEM INSPECTION c a n be a n i n d i c a t i o n of t o o m u c h fuel t o t h e cyl i nder ,
al so c a u s e d by a nozzl e wi t h a defect.
A p r o b l e m wi t h t he c o m p o n e n t s t h a t s e n d fuel to
t he engi ne c a n c a us e l ow fuel pr ess ur e. T h i s c a n T h e m o s t c o m m o n def ect s f o u n d wi t h t h e fuel
decr e a s e e ngi ne p e r f o r m a n c e . i nj ect i on val ves are:
3 - 15
FUEL SYSTEM TESTING AND ADJUSTING
I l l u s t r a t i o n I s h o w s t h e latest 5 P 8 7 4 4 A d a p t e r .
I l l us t r a t i on II s h o w s t he f o r m e r 5 P 4 7 1 7 A d a p t e r .
Unl es s s o m e i n d i c a t i o n is m a d e , t h e p r o c e d u r e is t h e
s a m e for use of ei t her a d a p t e r .
3 - 16
TESTING AND ADJUSTING
FUEL SYSTEM
c. T h e r e is a n i n d i c a t i o n of a p r o b l e m wi t h t he
nozzl e tester.
I. No zzl e I ns t al l at i on
II. P r e s s ur e F o s s Lest
ILLU S TR A TIO N II
1. Test nozzle (welded orifice). 2. Bottom part of 5P4717 III. Val ve O p e n i n g P r e s s u r e Tes t ( Y O P )
Adapter (J). J. 5P4717 Adapter.
CAUTION
3. Cl os e o n - o f f val ve (F). O p e n p u m p i s o l a t o r DO NOT use a drill or a reamer on the orifice of
valve (G). O p e n g a u g e p r o t e c t o r val ve (E). a nozzle. DO NOT use a steel brush or a wire
wheel to clean the tip of the nozzle. The orifice
4. O p e r a t e t h e t est er p u m p unt i l a p r e s s u r e o f 3500 and the valve can be damaged easily.
psi (24 000 k P a ) is r ead o n 2 P 2 3 2 4 G a u g e (C).
N o w . close p u m p i s ol a t or val ve (G).
I. Nozzle Installation
A WARNING
T h e p r o c e d u r e f or N O Z Z L E T E S T E R P R E 3. Bl eed ( r e m o v e ) ai r f r o m t he t es t er as follows:
P A R A T I O N m u s t be d o n e e a c h t i m e a n y of t h e
c o n d i t i o n s t h a t f ol l ow exist: a. L o o s e n b o t t o m pa r t (2) of a d a p t e r (J) one-
h a l f tur n.
a. T h e c o m p l e t e 5 P 8 7 4 4 or 5 P 4 7 1 7 A d a p t e r is
r e m o v e d a n d inst al l ed agai n. b. O p e r a t e t he p u m p unt il cl ear oil (free of air
b u b b l e s ) l eaks p a s t t he t h r e a d s at t o p of
b. Befor e a n d af t er a series o f tests. a d a p t e r (J).
3 - 17
FUEL SYSTEM TESTING AND ADJUSTING
NOT I': Wi t h s o m e 5 P 8 7 4 4 A d a p t e r s , p r e s s u r e m a y
s t art t o i ncr ease b ef or e t her e is a n i nd i c a t i o n of cl ear
test oil. T o cor r e c t this c o n d i t i o n , d o S t e p C.
1. O p e n p u m p i s o l a t o r val ve (G) o n e - h a l f t ur n .
2. O p e r a t e t he p u m p t o i ncr eas e t h e pr e s s u r e
slowly unt i l test oil c o m e s f r o m t he nozzl e tip.
TESTER N O M EN C LA TU R E
B. 5P4146 Gauge. 0 to 1000 psi (0 to 6900 kPa). D. Gauge
protector valve. F. O n-off valve. G. Pump isolator valve.
3. Af t er 30 s e c onds , t a k e a p r e s s u r e r e a d i n g f r o m
t he gauge. T h e pr e s s u r e at t his t i m e m u s t n o t be
be l o w 100 psi ( 690 k P a ) r e a d i n g o n t he di al face.
3- 18
TESTING AND ADJUSTING
FUEL SYSTEM
3. T h e pr es s ur e r e a d i n g o n t h e g a u g e at t hi s t i me
mu s t be in t h e pr es s u r e r a n g e of 400 t o 750 psi
(2750 t o 5200 k P a ) as s ho wn .
4. 11' t he val ve o p e n i n g pr e s s u r e ( V O P ) is n o t in t h e
400 t o 750 psi ( 2750 t o 5200 k P a ) r a n g e as
s h o w n , do not use the fuel nozzle again.
A n i nj ect i on p u m p c a n h a v e a g o o d fuel f l ow o u t
p u t but n o t be a g o o d p u m p b e c ua s e o f slow t i mi n g
t h a t is c a u s e d by w e a r o n t he b o t t o m e n d of t he
W h e n i nj ect i on p u m p bar r e l s a n d p l u n g e r s a r e p l un ge r . W h e n a test is m a d e o n a p u m p t h a t has
r e m o v e d f r o m t h e i nj ect i on p u m p h o u s i n g , ke e p t h e be e n us e d f or a l o n g t i me, use a m i c r o m e t e r a n d
pa r t s o f e a c h p u m p t o g e t h e r so t h e y c a n be i nst al l ed m e a s u r e t he l engt h of t h e p l ung e r . If t he l engt h of
b a c k in t hei r or i gi nal l ocat i on. t he p l u n g e r is s h o r t e r t h a n t he m i n i m u m l engt h
( wo r n ) d i m e n s i o n gi ven in t he c ha r t , i nstall a new
Be car ef ul w h e n r e m o v i n g i nj ect i on p u m p s . D o pump.
n ot d a m a g e t he sur f a c e on t he pl ung e r . T h e p l u n g e r
a n d bar r e l for e a c h p u m p ar e m a d e as a set. D o n o t
p u t t he p l u n g e r of o n e p u m p in t h e ba r r e l o f a n o t h e r
p u m p . If o ne p a r t is w o r n , i nst all a c o m p l e t e n e w
FUEL PU M P PLUNG ER
p u m p a s s e m b l y . Be c a r e f u l w h e n p u t t i n g t h e
p l u n g e r in t h e b o r e of t he bar rel . L en gth (new) 2.9834 + .0015 in. (75.778 ± 0.038 m m)
3 - 19
FUEL SYSTEM TESTING AND ADJUSTING
W h e n t her e is t o o m u c h w e a r on t he p u m p 6. L o w e r t h e p u m p o n t o t he d o w e l pi ns a n d l as t e n
p l unger , t he lifter y o k e m a y al so be w o r n a n d t he r e in place. L i ght e n bol ts (8) first a n d t h e n t i ght en
will not be g o o d c o n t a c t b e t we e n t he t w o part s. T o bol t s (7). T o r q u e for bol t s is 32 ± 5 lb. It. (43 ± 7
s t o p fast w e a r o n t he end of a new p l un ge r , install N-m). T o r q u e for t h e fuel line nut s is 30 r 5 lb.
new lifter yokes in t he pl ace of t h o s e wi t h wear . ft. (40 ± 7 N- m).
1. R e m o v e t he ai r c l e a n e r c over s a n d ai r c l e a n e r
2. W a s h t he p u m p p l u n g e r a n d bar r e l wi t h cl ean el e me n t s f r o m t h e ai r inlets of b o t h t u r b o
diesel fuel bef or e installing. char ger s.
3- 20
TESTING AND ADJUSTING
FUEL SYSTEM
Tools Needed:
5P7307 Engine Turning Tool Group or
2P8300 Engine Turning Tool Group
5P7307 E N G IN E T U R N IN G TO O L 4. T u r n t he c r a n k s h a f t in a d i r e c t i o n o p p o s i t e of
2. 5P7306 Housing. 3. 5P7305 Gear. n o r m a l r o t a t i o n a p p r o x i m a t e l y 30 degrees. T h e
r e a s o n f or m a k i n g t his st ep is t o be s ur e t h e play
No. I p i s t on at t o p c e n t e r o n t h e c o m p r e s s i o n is r e m o v e d f r o m t he t i mi n g gear s w h e n t he
s t r o k e is t h e s t a r t i ng p o i n t f or all t i m i n g p r o c e d u r e s . engi ne is p u t o n t o p cent er.
3-21
FUEL SYSTEM TESTING AND ADJUSTING
6. T h e i n t a k e a n d e x h a u s t \ a h es f or No. 1 c y l i nd e r 3. T u r n t he t i mi n g pi n i nt o t h e t i mi n g hol e in t he
will be closed if No. 1 pi s t on is o n t h e c o m fuel i nj ect i on p u m p h o u s i ng. If t he t i mi n g pin
p r ess i on st r oke. Yo u c a n m o v e t he r o c k e r a r m s goes int o t he t i m i n g slot (3) of t he fuel p u m p
u p a n d d o w n wi t h y o u r h a n d . If t he No. 1 pi s t o n c a ms h a f t , t h e t h r e a d s o n t h e t i m i n g pi n c a n not
is n o t o n t he c o m p r e s s i o n s t r ok e , t u r n t he be seen.
c r a n k s h a f t in t he d i r e c t i o n of n o r m a l r o t a t i o n
360 degr ees a n d m a k e a l i g n m e n t o f t he t i mi n g 4. If t he t i m i n g pi n goes i nt o t h e t i m i n g slot o f t he
m a r k a n d t he poi nt er . fuel p u m p c a m s h a f t , t h e fuel p u m p c a m s h a f t is
cor r e ct l y in t i me wi t h t he c r a n k s h a f t . If t he
t i m i n g pi n d oes n ot go i nt o t he t i m i ng slot of t he
CHECKING FUEL INJECTION P U M PTIM IN G
fuel p u m p c a m s h a f t , m a k e r e f e r e n c e to
WITH TIM ING PIN
TIM IN G THE C A M S H A F T FOR THE
FUEL INJECTION PUMPS.
1. P u t No. 1 pi s t on at t o p c e n t e r in t h e c o m p r e s
si on posi t i on. M a k e r ef e r ence t o L O C A T I N G
TOP CENTER C O M PR E SSIO N POSITION CHECKING TIM ING BY MEASURING TIM IN G
F O R NO. 1 P I S T O N . DIMENSION (Depth Micrometer)
1. P u t No. I p i s t o n at t o p ce n t e r ( T C ) in t he c o m
pr e s s i on p os i t i on. M a k e r ef e r ence t o L O C A T
ING T O P C E N T E R C O M P R E S S I O N P O S I
T I O N F O R NO. I P I S T O N .
2. R e m o v e No . I fuel i nj ect i on p u m p a n d p l u n g e r
f r o m t h e h o u s i ng. C l e a n all di rt a n d p a i n t f r o m
t he s ur f ace of t he fuel i nj ect i on h o u s i ng.
T IM IN G PIN
1. Fuel inlet flange. 2. Tim ing pin.
A84448X1
M EA S U R IN G LIFTER D IM E N S IO N
(Typical Illustration)
A. Distance to be measured.
O N E N G IN E LIFTER SE TTIN G
E N G IN E D IM E N S IO N (A)
3- 22
TESTING AND ADJUSTING
FUEL SYSTEM
N O T E : If t h e t i m i n g d i m e n s i o n is n o t cor r e c t ,
check to see if t he t i mi n g pi n will g o in t he sl ot
of t he fuel p u m p c a ms h a f t . If t h e t i mi n g pi n will
n o t fit. m a k e r ef er ence t o T I M I N G TEI E C A M
SHAFT FOR THE FUEL INJECTION PUMPS.
If t h e t i m i n g p i n d o e s fit, m a k e r e f e r e n c e t o
SETTING FUEL INJECTION P U M P TIM ING
DIMENSION: O F F ENGINE.
To ols N eeded:
5P 4165 D ial In d ic a to r G rou p
8S 3158 In d ica to r
3P 1565 C ollet C lam p
5P 4156 Base M E A S U R IN G T IM IN G D IM E N S IO N
5P4161 C on tac t Point, 2.75 in. (6 9.9 m m ) long. A. Tim ing dimension.
5P 4158 G au g e 2.00 in. (5 0.8 m m )
5P 4159 G au g e stand
1. P u t No. I p i s t o n at t o p c e n t e r ( T C ) in t h e
com p re ss io n position. M a k e reference to 5. P u t t he i n d i c a t o r a s s e m b l y o n t h e fuel i nj ect i on
LOCATING TOP CENTER C O M P R E S h o u s i n g as s h o w n a n d m e a s u r e d i m e n s i o n (A).
S I O N P O S I T I O N F O R N O. I P I S T O N . See t h e c h a r t f or t he c o r r e c t O N E N G I N E l ifter
se t t i ng d i me n s i o n s .
2. R e m o v e No. I fuel i nj ect i on p u m p a n d p l u n g e r
f r o m t h e hous i ng. C l e a n all dir t a n d p a i n t f r o m
t he s ur f ace of t he fuel i nj ect i on h o u s i ng.
ON E N G IN E LIFTER S E TTIN G
3. Inst al l 3 P 1 5 6 5 Col l et C l a m p in 5 P 4 1 5 6 Base.
P u t 8S 3158 I n d i c a t o r in collet. Be s ur e t he EN G IN E D IM E N S IO N A
i n d i c a t o r is a g a i n s t t he s h o u l d e r in t he col let D379 2.090 ± .002 in.
a n d t i ght e n t h e n u t t o p r e v e n t t h e i n d i c a t o r D398 (53.09 ± 0.05 mm)
f r o m m o v i n g in t h e collet. P u t 5 P4161 C o n t a c t
D399 2.078 ± .002 in.
P o i n t 2.75 in. (69.9 m m ) l o n g o n t h e i n d i c a t o r . (52.78 ± 0.05 mm)
4. T h e i n d i c a t o r mu s t be a d j u s t e d t o zer o bef or e
any mea s ur em en ts are taken. P ut 5P4158
G a u g e 2.00 in. (50.8 m m ) o n t h e 5 P 4 1 5 9 G a u g e
S t a n d a n d p u t i n d i c a t o r wi t h c o n t a c t p o i n t o n
t he g a u g e unt i l t he i n d i c a t o r bas e is even wi t h N O T E : If t h e t i mi n g d i m e n s i o n is n o t cor r e ct ,
t he gauge. L o o s e n t he s cr ew o n t he di al c l a m p ch e c k t o see if t i mi n g pi n will go in t h e slot o f t h e
a n d t u r n di al face until t h e zer o is in a l i g n m e n t fuel p u m p c a ms h a f t . If t he t i mi n g pi n will n o t fit,
wi t h t he l ar ger poi nt er . T i g h t e n t he c l a m p f or m a k e r ef er ence t o T I M I N G T H E C A M S H A F T
t he dial. M a k e a n o t e o f t he pos i t i o n o f t he r e v F O R T H E F U E L I N J E C T I O N P U M P S . If t h e
o l u t i o n c o u n t e r ( smal l poi nt er ) . JTie i n d i c a t i m i n g pi n d o e s fit, m a k e r e f e r ence t o S E T T I N G
t o r n o w r e a ds zer o f or a m e a s u r e m e n t o f 2. 00 FUEL INJECTION P U M P TIM IN G D IM E N
in. (50.8 mm) . SION: O F F E NG IN E .
3- 23
FUEL SYSTEM TESTING AND ADJUSTING
5P6524 E N G IN E T IM IN G IN D IC A T O R G RO UP
INSTALLE D
5. T u r n t he c r a n k s h a f t a m i n i m u m o f 45 degr ees in
a di r e c t i on o p p o s i t e of n o r m a l r o t a t i o n . Sl o wl y
t u r n t h e c r a n k s h a f t in t he di r e c t i o n o f n o r m a l
r o t a t i o n unti l a m a x i m u m r e a d i n g is seen o n t he
dial indi cat or . A d j u s t t h e i n d i c a t o r u p or d o w n
in t he collet unt i l t h e r e v o l u t i o n c o u n t e r is at
+ . 3 0 0 in. ( Bl ack N u m b e r s ) . T i g h t e n t he collet t o
h o l d t he i n d i c a t o r in t his posi t i on. L o o s e n t he
bezel l ock a n d t u r n t he bezel unt i l t he z e r o on
t he f ace of t he di al is in a l i g n m e n t wi t h t he h a n d .
T i g h t e n t he bezel lock.
6. Sl o wl y t u r n t he c r a n k s h a f t in t he di r e c t i o n of
n o r m a l r o t a t i o n unti l t he di al i n d i c a t o r mo v e s
b e y o n d .020 in. N o w t u r n t he c r a n k s h a f t in t he
o p p o s i t e d i r e c t i o n unt i l t he dial i n d i c a t o r is at
. 020 in.
M EA S U R IN G PISTO N TRAVEL
1. 3P1565 Collet. 2. 9S215 Dial Indicator with 3S3270
Contact Point. 3. 5P7265 A dapter. 4. Precom bustion 7. M a k e a t e m p o r a r y m a r k o n a r o t a t i n g c o m
chamber. 5. 3S3264 Rod. 6. Inlet port. 7. Piston. p o n e n t ( fl ywheel, v i b r a t i o n d a m p e r , or c r a n k
sha f t pul l ey) in r e l a t i on t o a s t a t i o n a r y p o i n t e r
o r ma r k .
3- 2 4
TESTING AND ADJUSTING
FUEL SYSTEM
8. T u r n t he cr a n k s h a f t in t h e d i r e c t i o n o p p o s i t e o f
n o r m a l r o t a t i o n b e y o n d t he m a x i m u m i n d i c a
t o r r e a d i n g a n d b e y o n d . 020 in. N o w t u r n t h e
c r a n k s h a f t in t h e di r e c t i o n o f n o r m a l r o t a t i o n
until t h e dial i nd i c a t o r is at . 020 in.
9. M a k e a s e c o n d t e m p o r a r y m a r k o n t he r o t a t i n g
c o m p o n e n t in r el at i on t o t he s t a t i o n a r y p o i n t e r
o r m a r k . N o w m a k e a m a r k o n t he r o t a t i n g
c o m p o n e n t t h a t is o n e - h a l f t h e d i s t a n c e b e
t we e n t he t wo t e m p o r a r y ma r k s . T his m a r k is
t he po i nt of m o s t a c c u r a c y for t o p c e n t e r No. 1
pist on. 5J4634 HO SE ASSEM BLY IN STA LLE D
8. 5J4634 Hose assembly. 11. Fuel return line.
10. T u r n t he cr a n k s h a f t in t he di r e c t i on o p p o s i t e of
n o r m a l r o t a t i o n a p p r o x i m a t e l y 45 degr ees a n d
t h e n t u r n t he c r a n k s h a f t in t he o p p o s i t e d i r 13. Fill t he fuel t a n k wi t h 1 gal l on (3.8 litres) ot
ect i on to t h e t o p cent er m a r k t h a t wa s m a d e in c l ean diesel fuel. Ke e p t he p r e s s u r e in t he t a n k at
S t e p 9. If ne e d e d a d j us t t he dial i n d i c a t o r as in 15 psi (105 k P a ) by t he use o f t h e h a n d p u m p or
St ep 5. s h o p ai r pr ess ure.
11. T u r n t he c r a n k s h a f t in t he d i r e c t i o n o p p o s i t e o f CAUTION
n o r m a l r o t a t i o n a p p r o x i m a t e l y 45 d e g r e e s . If shop air is used, make an adjustment to the
M o v e t he fuel r ack t o t h e full l oa d posi t i on. If regulator so the air pressure in the tank is a
t he engi ne has a h y d r a m e c h a n i c a l g o v e r n o r maximum of 15 psi (105 kPa).
install a 9 S 8519 p l u g a n d 9S8521 R o d , a n d p u s h
14. W i t h fuel p r e s s u r e t o t h e fuel i nj ect i on h o us i ng,
in t he speed l i mi ter pl unger . T i g h t e n t h e pl ug t o
sl owl y t u r n t he c r a n k s h a f t in t h e d i r e c t i o n ot
ho l d t he r o d in this posi t i on. N o w t he g o v e r n o r
n o r m a l r o t a t i o n . W h e n t he fuel flow f r o m t he
can be m o v e d t o t he full l oad posi t i on.
t u b e is 6 to 12 d r o p s per m i n u t e , s t o p t u r n i n g
t he cr a n k s h a f t . T h i s is t he p oi nt of inlet por t (6)
12. C o n n e c t h o s e (8) f r o m t h e fuel pr e s s u r e t a n k closing.
(10) t o t he fuel pr e s s u r e g a u g e c o n n e c t i o n o n t h e
left side o f t he fuel filter hou s i n g . Di s c o n n e c t 15. Use t he c h a r t t o c h a n g e t he i n d i c a t o r r e a d i n g t o
tuel r e t u r n line f I I ) at t he fuel c o n t r o l val ve a n d t i mi n g angl e. T h e t i m i n g mu s t be wi t h i n ±1
install a plug. Di s c o n n e c t t h e fuel line f r o m No . degr ee of t he speci fied t i m i n g angl e.
1 fuel i nj ect i on p u m p a n d install 7 M 1 9 9 9 t u b e
A s s e m b l y (9). The o p e n e n d of t h e t u b e a s s e m
bly m u s t be at a n u p w a r d sl ope.
A35549X1
3-25
FUEL SYSTEM TESTING AND ADJUSTING
Tools Needed:
9S6054 Socket
N O T E : T h e fuel p u m p c a m s h a f t t i m i n g g e a r (1) ha s
a pul l er a t t a c h e d . T h e pul l er is us e d t o l o o s e n or
t i ght e n t he g e a r o n t he dr i ve shaft . T h e pul l e r has
pul l er bol t (3). col l ar (6), a n d pl at e (2). T h e pul l er
T76039X2
bol t is hel d in t he pl at e by t h e col l ar wh i c h is
wel ded t o t he bolt. T h e pl at e is f a s t e n e d t o t he T IM IN G PIN IN T IM IN G SLO T OF C A M SH A FT
gear wi t h bolt s. W h e n t he pul l er bol t is t u r n e d
7. Tim ing pin. 10. Tim ing slot.
c o u n t e r c l o c k wi s e , t he col l ar p u s h e s a g a i n s t t h e
plat e a n d pulls t he g e a r f r o m sha f t (4). W h e n t he
4. Inst al l t he t i m i n g pi n f i nger tight.
pul l er bol t is t u r n e d cl ockwi se, t he b ol t h e a d p us h e s
o n t he pl at e a n d pus h e s t he ge a r on t he shaft .
5. R e m o v e t he b r e a t h e r f r o m t he f r ont of t he fuel
i nj ect i on hous i ng.
6. Use a 9 S 6 0 5 4 S o c k e t a n d r a t c h e t w r e n c h (8) t o
t u r n t h e fuel p u m p c a m s h a f t . P u t t he s o c k e t a n d
wr e n c h o n t he e nd of t he fuel p u m p c a m s h a f t
a n d t u r n t he c a m s h a f t unt i l t i m i ng slot (10) is at
t he t op. T i g h t e n t h e t i m i n g pin i n t o t h e t i m i n g
slot.
1. P u t No. I pi s t o n at t o p c e nt e r ( T C ) in t h e
compression position. M ake reference to
LOCATING TOP CENTER C O M P R E S 7. T i g h t e n t he c a m s h a f t pul l er b ol t (3) t o p u s h the
S IO N P O S I T I O N F O R NO. I P I S T O N . g e a r on t h e shaft . T i g h t e n bol t (3) t o a t o r q u e of
265 ± 35 lb.ft. (360 ± 45 N- m). Be nd t he l ock t o
2. R e m o v e t h e pi pe p l u g b e t w e e n t h e a f t e r c o o l e r t he bolt.
s u p p o r t s o n t he fl ywheel h o u s i ng . Be n d l ock (5)
f r o m pul l er bol t (3) a n d t u r n p ul l e r bol t t o 8. R e m o v e t he t i m i n g pi n a n d t u r n t h e c r a n k s h a f t
l oos e n ge a r ( l ) f r o m sha f t (4). t w o r e v o l u t i o n s in t h e d i r e c t i o n of n o r m a l r o
t a t i o n unt i l t he engi ne is a g a i n at t o p c e nt e r
3. R e m o v e t i mi n g pi n (7) a n d t h e fuel inlet fl ange. ( T C ) c o m p r e s s i o n p o s i t i o n f or No. I pi st on.
3- 2 6
TESTING AND ADJUSTING
FUEL SYSTEM
T h e l uel i n j e c t i o n p u m p h o u s i n g m u s t be
r e m o v e d I r o m t he en g i n e f or t h e p r o c e d u r e t h a t
follows:
TO O LS IN STALLED
l. R e m o v e the fuel i nj ect i on p u m p s f r o m fuel in- 1- 1P7410 Plate. 3. 1P7415 Pointer. 9. Edge of pointer.
j e c t i o n p u m p h o u s i n g . M a k e r ef e r ence t o A. Tim ing dimension to be measured.
F U E L I N J E C T I O N S E R V IC E ; Removal of
I nj ect i on P u m p . C l e a n t he t o p su r f a c e o f t h e
h o u s i n g of all pa i n t a n d dirt.
3-27
FUEL SYSTEM TESTING AND ADJUSTING
1 0° 12 ° 0° 12 ° 179° 193°
2 210 ° 222 ° 210 ° 222 ° 209° 223°
3 270° 102 ° 240° 132° 269° 103°
4 120 ° 312° 90° 342° 299° 133°
5 90° 282° 120 ° 252° 224° 148°
6 300° 132° 330° 102 ° 254° 178°
7 180° 192° 300° 72° 134° 238°
8 30° 42» 150° 282° 164° 268°
9 — — 60° 312° 314° 58°
10 — — 270° 162° 344° 88°
11 — — 180° 192° 44 » 328°
12 _ — 30° 42° 74° 358°
13 — — — 89° 283°
14 — — — — 119° 313°
15 — — — — 359° 13°
16 - — — — 29° 43°
3- 28
TESTING AND ADJUSTING
FUEL SYSTEM
5. P u t s pa c e r (9) be t we e n t he f l ange o n t he r od a n d
t he br a c k e t . P u s h t he f l ange t o w a r d t he fuel
p u m p h o u s i n g t o hol d t he s p a c e r t i ght a nd
a dj u s t t he dial i n d i c a t o r so t h a t t he r e v o l u t i o n
c o u n t e r is at zero. T i g h t e n t h e c l a m p f or t he
i ndi cat or . T u r n t he dial o f t he i n d i c a t o r until t he
zer o is in a l i g n m e n t wi t h t h e h a n d . R e m o v e t he
spacer .
9S240 RACK P O S IT IO N TO O L G RO UP
1. 8S4627 Circuit Tester. 2. 9S227 Bracket Group. 3.
8S2283 Dial Indicator. 4. 8S3675 Contact Point, .125 in.
(3.18 mm) long. 5. 9S8519 Plug. 6. 9S8521 Rod.
R e m o v e t he air-fuel r at i o c on t r ol . D i s c o n n e c t
BRACKET G RO UP AND IN D IC A T O R INSTALLE D
t he g o v e r n o r c o n t r o l l i n kage f r o m t he g o v e r n o r
9. Spacer. 10. Dust cover.
lever.
N O T F : T h e h y d r a u l i c se r vo - val vc t h a t mo v e s t he
r ack w h e n t he engi ne is r u n n i n g , d o e s not h a v e a
di rect c o n n e c t i o n wi t h t he r ack w h e n t h e en g i n e is
not r u n n i n g . T h e r ack ca n go b e y o n d t h e set
p o s i t i on a p p r o x i m a t e l y . 100 in. ( 2.54 mm) . Be caus e
o f this, t he r ack set t i ng m u s t be c h e c k e d wi t h an
a p p l i c a t i o n of f orce aga i ns t t he r ack in t he F U E I -
C O M P O N E N T LO C A TIO N
O F F d i r e c t i on t o r e m o v e t he free m o v e m e n t b e
7. Tim ing pin. 8. Clamp.
t we e n t he r ack a n d t he s t o p col l ar in t h e g o v e r n o r .
3- 29
FUEL SYSTEM TESTING AND ADJUSTING
N O T E : T h e s a m e t ool s ar e n e e d e d f or t he ai r-fuel
r at i o c o n t r o l a d j u s t m e n t t h a t wer e used f or t he
fuel r ack setting. M a k e r ef e r ence t o t he F U E L
R A C K A D J U S T M E N T for t h e t ool s n e e d e d a n d
i n s t r u c t i o n s to install t he tools.
3-30
TESTING AND ADJUSTING
FUEL SYSTEM
5. M a k e r e f e r e n c e t o t h e R A C K S E T T I N G
I N F O R M A T I O N f o r t he c o r r e c t ai r-fuel r at i o
c o n t r o l set ting, a n d t u r n t he c ov e r c o u n t e r
cl ockwi s e t he n u m b e r of t u r n s pl us a n y p a r t oi a
t u r n for bet t er hol e a l i g n m e n t t o get t h e c o r r e c t
d i me n s i o n .
T h e ov e r r i d e c o n t r o l l ever a d j u s t m e n t is m a d e
wi t h t h e air -f uel r a t i o c o n t r o l of f t he engi ne.
D IA P H R A G M TE ST
2. Bolt. 6. Port. 7. Diaphragm .
3-31
TESTING AND ADJUSTING
FUEL SYSTEM
a. M o v e t he g o v e r n o r c o n t r o l t o H I G H I D L E
pos i t i o n a n d t u r n s c r ew (1) t o ad j u s t H I G H Spe c i a l I n s t r u c t i o n F o r m No. S E H S 7 3 4 1 is wi t h
I D L E r p m. W h e n t he specific r p m se t t i ng is t he 4 S 6553 E n g i n e Test G r o u p a n d gives i n s t r u c
m a d e , m o v e t he g o v e r n o r c o n t r o l t o r e d u c e t i o n s f or t he test p r o c e d u r e .
engi ne s peed, t he n m o v e t he l i nkage t o
3-32
TESTING AND ADJUSTING
FUEL SYSTEM
4S6553 IN S T R U M E N T G R O U P
1. D ifferen tial pressure gauges. 2. Zero adjustm ent
screw. 3. Lid. 4. Pressure gauge. 5. Pressure tap IN ST A LLIN G CLUSTER GEAR
fitting. 6. Tachom eter. 7. Manifold pressure gauge.
1. L a rg e c lu s te r g e a r. 2. S m all c lu s te r g e ar. 3. R e ta in e r.
4. A-marks. 5. Dowel. 6. Alignm ent mark for flywheel
installation. 7. Hole in crankshaft flange.
N O T E : M a k e sur e t he No. I pi s t o n is at t o p ce n t e r
o n t he c o m p r e s s i o n st r oke. TIM ING BALANCER GEAR IN ACCESSORY
DRIVE (D379 ONLY)
2. M a r k t he cl us t e r g e a r C - m a r k a n d t he c r a n k
shaft g e a r p u n c h m a r k e d t o o t h wi t h chal k. T h e
b ack of t he gear s c a n be m a r k e d f or c h e c k i n g N O T E : T h e gear s of t he a c c e s s or y dr i ve f or 12 a n d
wi t h a m i r r o r af t er i nst al l at i on. 16 cyl i nder engi nes d o not need t o be t i med.
3-33
FUEL SYSTEM TESTING AND ADJUSTING
V-8 Engines With Standard Rotation V-8 Engines With Opposite Rotation
3- 34
TESTING AND ADJUSTING
AIR INLET AND EXHAUST SYSTEM
A ir flow t h r o u g h th e air c le a n e r m u s t n o t h a v e a
Use th e 4 S 65 5 3 I n s t r u m e n t G r o u p to ch eck
r e str ic tio n ( n eg ativ e p r e ss u re diffe r e n c e m e a s u r e
m e n t b e tw e e n a t m o s p h e r i c air a n d air t h a t h a s g o n e e n g in e r p m a n d t h e p r e ss u re in th e inlet m a n i f o ld .
t h r o u g h air cleaner) o f m o r e t h a n 30 in. (762 m m ) o f
water.
Back p re ss u re fro m the e x h a u s t ( p re s s u r e
d ifference m e a s u r e m e n t b e t w e e n e x h a u s t at o u t l e t
elbow a n d a t m o s p h e r i c air) m u s t n o t be m o r e t h a n
27 in. (685 m m ) o f w ater.
T h e efficiency o f a n e n g in e c a n be c h e c k e d by
m a k i n g a c o m p a r i s o n o f the p r e s s u re in t h e in let
m a n i f o ld w ith th e i n f o r m a t i o n given in t h e R A C K
45C89X!
S E T T I N G I N F O R M A T I O N . T h is test is u se d
w h e n th e r e is a d e c r e a s e o f h o r s e p o w e r f r o m t h e 4S6553 IN S T R U M E N T G RO UP
en g in e, yet t h e r e is no real sign o f a p r o b l e m w ith t h e
1. Differential pressure gauges. 2. Zero adjustm ent screw.
engine. 3. Lid. 4. Pressure gauge. 5. Pressure tap fitting.
6. Tachom eter. 7. M anifold pressure gauge.
T h e c o r re c t pr e ss u re f o r th e inlet m a n i f o l d is
given in th e R A C K S E T T I N G I N F O R M A T I O N . T h is i n s t r u m e n t g r o u p h as a t a c h o m e t e r to read
D e v e l o p m e n t o f this i n f o r m a t i o n is d o n e w ith th e s e e n g in e r p m . It also has a g a u g e t o r ead p r e s s u r e in
conditions. th e inlet m a n i f o ld . S p ecial I n s t r u c t i o n F o r m No.
S E H S 7 3 4 1 is w i t h t h e t o o l g r o u p a n d g ives
a. 29.4 in. (747 m m ) o f m e r c u r y b a r o m e t r i c p r e s i n s t r u c t i o n s for th e test p r o c e d u r e .
sure.
b. 8 5° E ( 2 9° C) o u t s i d e air t e m p e r a t u r e .
c. 35 A P I r a t e d fuel.
A n y c h a n g e f r o m th es e c o n d i t i o n s c a n c h a n g e t h e
p r e s s u re in th e inlet m a n i f o ld . O u t s i d e air t h a t h a s
h igh er t e m p e r a t u r e a n d lo w er b a r o m e t r i c p r e s s u r e
t h a n given a b o v e will caus e a l o w e r h o r s e p o w e r a n d
a low er inlet m a n i f o ld p r e s s u re m e a s u r e m e n t t h a n
given in th e R A C K S E T T I N G I N F O R M A T I O N .
O u t s i d e air t h a t h a s a lo w er t e m p e r a t u r e a n d a
h i g h e r b a r o m e t r i c p r e s s u r e will c a u s e h i g h e r
h o r s e p o w e r a n d a h i g h e r inlet m a n i f o l d p r e s s u r e
m easurem ent.
1P3060 PY RO M E TER G R O U P
A d i f f e r e n c e in fu el r a t i n g will a l s o c h a n g e
h o r s e p o w e r a n d th e p r e s s u re in th e inlet m a n i f o ld . If
the fuel is ra te d a b o v e 35 A P I , p r e s s u r e in t h e inlet U se t h e 1 P 3 0 6 0 P y r o m e t e r G r o u p t o c h e c k
m a n i f o ld c a n be less t h a n given in t h e R A C K e x h a u s t t e m p e r a t u r e . S p ecial I n s t r u c t i o n F o r m No.
S E T T I N G I N F O R M A T I O N . If t h e fuel is r a t e d S M H S 7 1 7 9 is w i t h t h e t o o l g r o u p a n d g ives
below' 35 A P I . th e p r e s s u re in th e inlet m a n i f o l d c a n i n s t r u c t i o n s f o r th e test p r o c e d u r e .
3-35
AIR INLET AND EXHAUST SYSTEM TESTING AND ADJUSTING
P R E C O M B U S TIO N C H AM BER
P O S IT IO N IN G D IA G R A M
A. Parallel to centerline of crankshaft. B. No go range.
C. Go (grey) range.
W ATER D IR E C TO R S
1. Water director. 2. Ferrule. 3. Seal.
In stall IP 8 0 0 5 g a sk et m a r k e d “ 3 J ” . In stall
p r e c o m b u s t i o n c h a m b e r a n d t i g h t e n to t o r q u e o f
225 ± 15 lb.ft. (305 ± 20 N-m ). I f th e glo w p lug
o p e n i n g is n o t p o s i t i o n e d in t h e g rey r a n g e (C)
W a t e r d i r e c t o r s a r e p ressed i n to p lace in t h e h e a d s r e m o v e t h e c h a m b e r a n d r e p l a c e g a s k e t w ith t h e
a f te r a l i g n in g th e n o t c h o n t h e d i r e c t o r w i t h t h e V- 1 P 8004 G a s k e t m a r k e d “ 3 D ” .
m a r k o n th e he ad.
C RANKCASE(CRANKSHAFT
R e p l a c e m e n t ty p e seals (3) a n d f e rr u l e (2) go COMPARTMENT)PRESSURE
b e t w e e n th e h e a d a n d t o p o f t h e blo ck . P u t s o a p o n
the in n e r su r f a c e o f th e seal a n d p la c e t h e g r o o v e in
P i s t o n s o r rings t h a t h a v e d a m a g e ca n be th e
t h e se al o v e r t h e r i d g e o n t h e f e r r u l e b e f o r e
c a u s e o f t o o m u c h p r e s s u r e in th e c r a n k c a s e . T h is
in s ta llin g . Use th e F T 1 1 7 S eal a n d F e r r u le
c o n d i t i o n will cau s e th e e n g in e t o r u n r o u g h . T h e r e
A s s e m b l y T o o l to in stall th e seal o n t h e ferrule.
will also be m o r e t h a n th e n o r m a l a m o u n t o f f u m e s
c o m i n g f r o m th e c r a n k c a s e b r e a t h e r . T h is c r a n k c a s e
p r e s s u re can also c a u s e th e e le m e n t f o r the
c r a n k c a s e b r e a t h e r to h av e a r e s t r i c t i o n in a ver y
s h o r t tim e. It c a n also be th e ca u s e o f oil le a k a g e at
g a s k e ts a n d seals t h a t w o u l d n o t n o r m a l l y h av e
leakage.
COMPRESSION
A n e n g in e t h a t r u n s r o u g h c a n h a v e a leak at th e
valves, o r have valves t h a t need a d j u s t m e n t . Use th e
tes t t h a t f o llo w s f o r a fast a n d eas y m e t h o d t o fin d a
FT117 SEAL A N D FERRULE ASSEM BLY TO O L c y lin d e r t h a t has lo w c o m p r e s s i o n , o r d o e s n o t h a v e
4. 5H3182 Pin.
g o o d fuel c o m b u s t i o n . F i n d th e sp e ed t h a t th e
10. Bracket.
5. 2A3672 Spring. 11. Connecting Joint. e n g i n e r u n s th e r o u g h e s t , a n d keep t h e e n g in e at this
6. Flat Washer. 12. Lower Rod. r p m u n til t h e test is finis h ed . L o o s e n a fuel line n u t
7. Chain. 13. Base.
8. Upper Rod A. Rubber Seals.
at fuel injectio n p u m p t o s t o p th e flow o f fuel t o t h a t
9. Connecting Pin. B. Ferrule. cy lin der. D o this fo r e a c h c y l i n d e r u ntil a lo o s e n e d
TESTING AND ADJUSTING
AIR INLET AND EXHAUST SYSTEM
Valves
T h e ill u s t r a t i o n s h o w s th e 5S 1 3 3 0 Valve S p r i n g
C o m p r e s s o r A s s e m b l y w ith th e 5S 1 3 2 9 J a w (1) t o
put th e va lve s p r in g u n d e r c o m p r e s s i o n . W h e n
in stalling the valve k eepers, use th e 5 S 13 2 2 V alve
K eep e r In staller (2) with the c o m p r e s s o r as s e m b l y .
C O M PR E SS IN G VALVE SP RING S
1. 5S 1329 Jaw. 2. 5S 1322 Valve K eeper Installer.
3 -3 7
AIR INLET AND EXHAUST SYSTEM TESTING AND ADJUSTING
N O T E : W h e n th e valve lash ( c le a r a n c e ) is c h e c k e d ,
a d j u s t m e n t is N O T N E C E S S A R Y if th e m e a s u r e
m e n t is in the r a n g e given in th e c h a r t f o r V A L V E
CLEARANCE CHECK: E N G IN E S T O P P E D .
If th e m e a s u r e m e n t is o u t s i d e this r a n g e , a d j u s t m e n t
is necessa rv . See th e c h a r t for V A L V E C L E A R
A N C E S E T T IN G : E N G IN E S T O P P E D , and
m a k e th e s e ttin g to th e n o m i n a l ( d e s ir e d )
sp e cificatio n s in this ch art.
3 -3 8
TESTING AND ADJUSTING
AIR INLET AND EXHAUST SYSTEM
Intake 1-3-6-8 1-3-4-6-7-12 1-2-6-7-8-11-13-14 Intake 2-4-5-7 2-5-8-9-10-11 3-4-5-9 -10 -12 -15 -16
3 -3 9
L U B R IC A T IO N S Y S T E M TESTING AND ADJUSTING
LUBRICATION SYSTEM
O n e o f t h e p r o b l e m s in th e list t h a t fo llo w s will MEASURING ENGINE OIL PRESSURE
g en erally be a n i n d i c a t i o n o f a p r o b l e m in th e
l u b r ic a t io n sy s tem fo r th e engine. Tools Needed:
5P6225 Hydraulic Test Box.
T O O M U C H O IL C O N S U M P T IO N 9S9102 Thermlster Thermometer Group.
O I L P R E S S U R E IS L O W
O I L P R E S S U R E IS H I G H A n oil p r e s s u r e g a u g e t h a t h a s a defect ca n give a n
T O O M U CH B E A R IN G W EA R i n d i c a t i o n o f low oil p ressu re.
O IL PRESSURE
p r e s s u re in th e c r a n k c a s e , a n d this will c a u s e g a s k e t
a n d seal leakage.
T h is p r o c e d u r e m u s t be follow'ed e x a c t l y f o r the
p r e s s u re r e a d i n g s t o h a v e a n y valu e f o r c o m p a r i s o n
Oil Leakage Into Combustion w ith E n g in e Oil P r e s s u r e C h a r t .
Area of Cylinders
I. Be su r e t h a t th e e n g in e is filled to the c o r re c t
level w i t h S A E 30 oil. If any o t h e r viscosity o f
Oil l e a k a g e in t o th e c o m b u s t i o n a r e a o f th e
oil is u sed , th e i n f o r m a t i o n in th e E n g in e Oil
cy lin d ers can be th e c a u s e o f b lue s m o k e . T h e r e are
P r e s s u r e C h a r t d o e s n o t apply .
f o u r p o s s i b l e w a y s f o r oil l e a k a g e i n t o t h e
c o m b u s t i o n a r e a o f t h e cylinders:
1. Oil l e a k a g e b e tw e e n w o r n valve gu id es a n d
valve stem s.
2. C o n n e c t th e 8 M 2 7 4 4 G a u g e f r o m th e 5P 6 2 2 5
T o o m u c h oil c o n s u m p t i o n c a n a ls o be t h e result H y d r a u l i c T est B o x t o o n e o f th e p o r t s in the
if oil w ith th e w r o n g visco sity is u sed . Oil w ith a th i n b a c k side o f th e g o v e r n o r o r g o v e r n o r driv e
viscosity c a n be c a u s e d by fuel l e a k a g e in t o t h e h o u s i n g . R e m o v e th e p ipe p lu g o n the oil ou tle t
c r a n k c a s e , o r by in c r e a se d en g i n e t e m p e r a t u r e . e l b o w o n t h e oil c o o l e r a n d in stall a p r o b e f ro m
the 9S9102 T h e rm is to r T h e rm o m e te r G roup.
3 -4 0
t-S f l N O A N D ADJUSTING
LUBRICATION SYSTEM
3-41
LUBRICATION SYSTEM TESTING AND ADJUSTING
W h e n s o m e c o m p o n e n t s of th e en g i n e s h o w
b e a r i n g w e a r in a s h o r t tim e, the cau s e ca n be a
r estr ictio n in an oil passage. A b r o k e n oil p a s s a g e
c a n also be th e cause.
45941X1
TU R B O C H A R G E R L U B R IC A T IO N VALVE
AT R IG H T REAR OF E N G IN E
3 -4 2
TESTING AND ADJUSTING
COOLING SYSTEM
COOLING SYSTEM
C OOL I MG S Y S T E M P R E S S U R E
T h e e n g in e has a p r e s s u re t y p e c o o l i n g s ystem . A
p r e ss u re ty p e c o o l i n g s y s te m gives t w o a d v a n t a g e s . A LTITU D E
T h e first a d v a n t a g e is t h a t t h e c o o l i n g s y s te m c a n
o p e r a t e at a t e m p e r a t u r e t h a t is h i g h e r t h a n t h e
n o r m a l p o in t w h e r e w a t e r c h a n g e s t o s te a m . T h e
se c o n d a d v a n t a g e is t h a t this ty p e s y s t e m p r e v e n t s
ca v i t a t i o n (air in inlet o f p u m p ) in t h e w a t e r p u m p .
W i t h this ty p e sy s tem it is m o r e d ifficu lt t o h a v e a n
air o r s te a m p o c k e t in th e c o o l i n g sy stem .
T h e cau s e fo r a n en g in e g e t t i n g t o o h o t is
g en erally becau s e r e g u l a r in s p e c t io n s o f th e c o o l i n g
sy stem were n o t d o n e . M a k e a visual i n s p e c t io n o f
the c o o l i n g sy stem b e f o re a test is m a d e w ith test
equipm ent. Test Tools for Cooling System
5. C h e c k f o r d a m a g e t o th e f a n b lades.
T h e 9 S 9 1 0 2 T h e r m i s t o r T h e r m o m e t e r G r o u p is
TESTING THE COOLING SYSTEM u sed in th e d i a g n o s is o f h e a t i n g p r o b l e m s . T h e
te s ti n g p r o c e d u r e is in S p ecial I n s t r u c t i o n F o r m N o.
SMHS7140.
R em em b er th at tem p eratu re and pressure w ork
to g e t h e r . W h e n m a k i n g a d i a g n o s is o f a c o o l i n g
sy s tem p r o b l e m , t e m p e r a t u r e a n d p r e s s u r e m u s t T h e 9 S 73 73 A i r M e t e r G r o u p is used t o c h eck the
b o t h be ch eck e d . C o o l i n g s y s te m p r e s s u r e will h a v e a ir flow t h r o u g h th e r a d i a t o r core. I he t e s tin g p r o
a n effect o n c o o l i n g sy s te m t e m p e r a t u r e s . F o r a n c e d u r e is in S pecial I n s t r u c t i o n f o r m No.
e x a m p l e , lo o k a t t h e c h a r t t o see th e effect o f SMHS7063.
p r e ss u re a n d th e heig h t a b o v e sea level o n t h e
b oilin g p o i n t ( ste a m ) o f w ater.
3-4?
C O O L I N G SYSTEM TESTING AND ADJUSTING
T he 9S 8 1 4 0 C o o l i n g S y ste m P re s s u ri z i n g P u m p
G r o u p is used to test p r e ss u re cap s a n d p r e s s u re
relief valves, a n d to p r e s s u re check th e c o o l i n g
sy s tem fo r leaks.
1. R e m o v e th e r e g u l a t o r f r o m th e engine.
2. H e a t w a t e r in a p a n u ntil t h e t e m p e r a t u r e is c o r
SS7373 AIR METER G RO UP rect l o r o p e n i n g t h e r e g u l a t o r a c c o r d i n g t o th e
chart.. M o v e th e w a t e r a r o u n d in th e p a n to
m a k e it all he th e s a m e t e m p e r a t u r e .
3. H a n g t h e r e g u l a t o r in t h e p a n o f w a te r . T h e r e g
u l a t o r m u s t be below th e su r f a c e o f th e w a t e r
a n d it m u st be a w a y f r o m th e sides a n d b o t t o m
o f th e p an .
4. K eep th e w a t e r at the c o r re c t t e m p e r a t u r e f o r 10
m in u tes.
5. R e m o v e th e r e g u l a t o r f r o m th e w ater. I m m e d
iat ely m a k e a m e a s u r e m e n t o f th e d i s t a n c e th e
r e g u l a t o r is o pen.
1P5500 PORTABLE P H O T O TA C H G RO UP
6. If th e r e g u l a t o r is o p e n to a d i s t a n c e less t h a n
T h e I P5500 P o r t a b l e P h o t o t a c h G r o u p is used to given in th e c h a r t, in stall a new r e g u l a t o r .
check the Ian spe ed. T h e te s tin g p r o c e d u r e is in
S pecial I n s t r u c t i o n F o r m No. S M H S 7 0 I 5 .
Minim um
Open Distance Tem perature
9N2894
.375 9.53 197° 92°
6L5851
Tools Needed:
9S9102 Thermistor Thermometer Group
T o ch e c k the a c c u r a c y o f t h e w a t e r t e m p e r a t u r e
9S8140 C O O LIN G SYSTEM P R ES SU R IZ IN G
PUM P G RO UP g a u g e , u se t h e 9 S 9 1 0 2 T h e r m i s t o r T h e r m o m e t e r
G r o u p . S p ecial I n s t r u c t i o n F o r m N o. S M H S 7 1 4 0
h as in s tr u c tio n s fo r th e use o f th e 9 S 9 1 0 2
T h erm isto r T h e rm o m e te r G roup.
3-44
TESTING AND ADJUSTING
C O O L IN G SYSTEM
R e m o v e th e plu g n ex t to th e s e n s o r un it f o r t h e
w a t e r t e m p e r a t u r e g a u g e in t h e w a t e r o u t l e t
m a n i f o ld . Install r e d u c i n g b u s h i n g a n d p r o b e in th is
hole.
S t a r t th e en g in e a n d get th e c o o l a n t w a r m . M a k e
a c o m p a r i s o n o f th e t e m p e r a t u r e at p o s i t i o n s 1 a n d 2
o n the w a t e r t e m p e r a t u r e g a u g e a n d t h e t e m p e r a
t u r e on th e t h e r m i s t o r t h e r m o m e t e r . Use t h e c h a r t
to find th e t e m p e r a t u r e at p o s i t i o n s 1 a n d 2.
TE ST R E AD IN G TE M P ER A TU R E
P O IN TER
P O SITIO N F° C°
1 160 + 10 71 ± 6
C O O L A N T LEVEL S W ITC H
(Earlier Type)
2 210 + 8 - 0 9 9 + 4 - 0
1. Float. 2. Vent line connection. 3. Term inal screw.
C O O L A N T LEVEL SW ITC H
(Later Type)
2. Vent line con nection . 4. Sw itch o p erating arm.
T e s tin g
L o w e r th e c o o l a n t level in t h e s y s te m t o c a u s e t h e
float (1) to lo w er a n d c a u s e t h e sw itc h p o i n t s t o
m a k e c o n t a c t . T h is c a n be d o n e by r e m o v i n g s o m e
o f th e c o o l a n t o r w ith a p p l i c a t i o n o f 10 t o 20 psi (70
t o 140 k P a ) o f a i r p r e s s u r e t o t h e v e n t li n e
c o n n e c t i o n (2) o n t o p of th e sw itch. L o o k a t t h e f l o a t
a n d sw it c h as th e c o o l a n t level lowers. T h e f l o a t
p o s i t i o n o n th e l ater ty p e sw it c h is s h o w n b y t h e
sw itch o p e r a t i n g a r m (4). T h e d ev ice c o n n e c t e d will
be a c tiv a te d as th e p o i n t s m a k e c o n t a c t .
Adjustment
T h e t e r m i n a l scre w (3) o n t h e b o t t o m o f t h e
earlier sw'itch can be t u r n e d in t o raise a n d o u t t o
low'er th e level at w h ic h th e p o i n t s will m a k e
c o n ta c t.
3-45
BASIC BLOCK TESTING AND ADJUSTING
BASIC BLOCK
CONNECTING RODS AND PISTONS CONNECTING ROD AND MAIN BEARINGS
CYLINDER BLOCK
4. T ig h t e n e a c h n u t 120° f r o m th e m a r k .
B o r e in b lo c k f o r m a i n b e a r i n g s c a n be c h e c k e d
T h e c o n n e c t i n g r o d b e a r i n g s s h o u l d fit tig h t l y in w ith m a i n b e a r i n g c a p s i n sta lle d w i t h o u t b e a r in g s.
t h e b o r e in th e rod . If b e a r i n g j o i n t s o r b a c k s are T i g h t e n t h e s t u d n u t s t o t o r q u e s h o w n in th e
w o r n (fretted), c h eck f o r b o r e size as this is a n S P E C I F I C A T I O N S . A l i g n m e n t e r r o r in th e b o res
i n d i c a t i o n o f w e a r b e c a u s e o f loo se n ess. m u s t n o t be m o r e t h a n .003 in. (0.08 m m ).
A 5 P 3 5 1 9 P i s t o n R i n g G r o o v e G a u g e is a v a i l a b l e
f o r c h e c k i n g rin g g r o o v e s w i t h s t r a i g h t sides. F o r
i n s t r u c t i o n s o n t h e u s e o f t h e g a u g e , see t h e
G U ID E L IN E F O R R E U SA B L E PA R T S; P IS T
O N S A N D C Y L IN D E R L IN E R S . F o rm No.
SEBF8001.
S p ecial I n s t r u c t i o n F o r m N o. G M G 0 0 5 0 3 gives th e
use o f 1P4000 L in e B o r i n g T o o l G r o u p t o m a c h i n e
m a i n b e a r i n g b ores. 1P 3537 D i a l B o re G a u g e
G r o u p c a n be u sed to ch eck bores. S p ecial
5P3519 PISTO N RING G RO OVE G AUG E I n s t r u c t i o n F o r m N o . G M G 0 0 9 8 1 is w ith t h e g r o u p .
3 -4 6
TESTING AND ADJUSTING
b a s ic b l o c k
CYLINDER LINER PROJECTION 4. M easu re the cylin der liner projection as close as
po ssible to the fo ur corners o f the a dapter plate on
Tools Needed: the liner. The liner projection m ust be .004 to .008
1P2398 Puller Plate
8B7548 Push Puller Crossbar and three 3H465 Plates. in. (0 .1 0 to 0 . 2 0 m m ). The d ifferen ce betw een the
8S3140 Cylinder Block Counterboring Tool four m easurem ents m ust not be m ore than .002 in.
Arrangement. (0 .05 m m ). T he m a x i m u m difference in height of
1P5510 Liner Projection Tool Group. liners next to each other under the sam e cylinder
head is .002 in. (0 .0 5 m m ).
T h e c o r re c t cy lin d e r liner p r o j e c t i o n is i m p o r t a n t
N O T E : If t h e liner p r o j e c t i o n c h a n g e s f r o m p o i n t
t o p r e v e n t a leak b e t w e e n t h e liner , c y lin d e r h e a d
t o p o i n t a r o u n d t h e liner , t u r n th e lin er to a n ew
a n d blo ck . Use the p r o c e d u r e t h a t f o llo w s t o c h e c k
p o s i t i o n in t h e bo re. I f t h e liner p r o j e c t i o n is still n o t
c y l i n d e r liner p r o j e c t i o n .
t o s p e cificatio n s , m o v e t h e lin er t o a d i f fe r e n t b o re.
I . M a k e sure t h a t th e b o r e a n d c o u n t e r b o r e in t h e
5. W h e n t h e c y lin d e r liner p r o j e c t i o n is c o r re c t ,
b lock a n d th e liner f lang e a r e clean. I n sta ll t h e
p u t a t e m p o r a r y m a r k o n t h e liner a n d t h e cyl
c y lin d e r liner w i t h o u t seals in t h e c y l i n d e r b l o c k
i n d e r b l o c k so at final i n s t a l l a t i o n t h e liner ca n
b e in stalled in t h e c o r r e c t p o s i t i o n .
C y l i n d e r liner p r o j e c t i o n c a n be a d j u s t e d b y th e
rem oval of m aterial fro m (m achining) the co n tact
face o f t h e c y lin d e r b l o c k w i t h t h e use o f t h e 8 S 3 140
C y l i n d e r B lo ck C o u n t e r b o r i n g T o o l A r r a n g e m e n t .
T h e i n s t r u c t i o n s f o r th e use o f t h e t o o l g r o u p are in
S p ecial I n s t r u c t i o n F o r m N o. F M 0 5 5 2 2 8 .
S h i m s ar e a v a i l a b l e f o r a d j u s t m e n t o f t h e lin er
p r o je c tio n .
A D JU S TM E N T SH IM S FOR LINER P R O JE C T IO N
3 -4 7
BASIC BLOCK TESTING AND ADJUSTING
C (T O P j
M a k e t o o l s e tu p f r o m p a r t s o f th e 8S 2 32 8 D i a l T est
Indicator G roup.
1. F a s t e n a dial i n d i c a t o r to th e c r a n k s h a f t f la n g e
so th e i n d i c a t o r anvil will t o u c h t h e flywheel
h o u s i n g face.
2. P u s h th e c r a n k s h a f t to th e r e a r t o r e m o v e all
e nd p lay be f o re r e a d i n g th e i n d i c a t o r a t e a c h
po int.
TOP
A (B O T T O M )
C H E C K IN G BORE R U N O U T OF TH E
FYW HEEL HO U S IN G
C H E C K IN G FLYW HEEL H O U S IN G
FACE R U N O U T
A. B o tto m . B. R ig h t side. C. Top. D. Le ft side. 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.
3 -4 8
TESTING AND ADJUSTING
BASIC BLOCK
5. T u r n th e c r a n k s h a f t c o u n t e r c l o c k w i s e t o p u t
th e dial i n d i c a t o r at (C). W r i t e t h e m e a s u r e m e n t
in the chart.
6. T u r n the c r a n k s h a f t c o u n t e r c l o c k w i s e t o p u t
the dial i n d i c a t o r at (D). W r i t e t h e m e a s u r e Face Runout (axial eccentricity)
m e n t in th e ch art. of the Flywheel
7. A d d lines I & II by c o l u m n s .
1. I n sta ll th e dial i n d i c a t o r as s h o w n . M o v e th e
8. S u b t r a c t th e sm a ll n u m b e r f r o m t h e la r g e r n u m fly wheel to th e f r o n t o r r e a r to r e m o v e all e n d
b e r in line III in c o l u m n s (B) & ( D ). T h e r e su lt is play.
th e h o r i z o n t a l “ e c c e n tr i c i t y ” ( o u t o f r o u n d ) .
Lin e III, c o l u m n (C) is th e v er tical e cce n tricity .
C H A R T FOR D IA L IN D IC A T O R M E A S U R E M E N TS
Position of
dial indicator
Line
No. A B c D
9. O n th e g r a p h f o r t o t a l e c c e n tr ic ity find t h e p o i n t
2. Set t h e d ial i n d i c a t o r to r e a d .000 in. (0.0 m m ).
o f in t e r s e c t i o n o f th e lines f o r v er tical e c c e n tr i -
4. T h e d ifferen ce b e t w e e n t h e lo w e r a n d h i g h e r
m e a s u r e m e n t s t a k e n at all f o u r p o i n t s m u s t n o t
be m o r e t h a n .006 in. (0.15 m m ), w h ic h is the
m axim um p e r m i s s ib l e face r u n o u t (a x ia l e c c e n
tricity) o f th e flywheel.
3-49
BASIC BLOCK TESTING AND ADJUSTING
T h e c r a n k s h a f t d e f l e c t i o n m u s t be c h e c k e d a f te r
th e final in s t a l l a t i o n o f th e engine. T h e check m u s t
be m a d e w ith th e e n g in e cold a n d also w i t h th e
e n g i n e at t h e t e m p e r a t u r e o f n o r m a l o p e r a t i o n . T h e
p r o c e d u r e t h a t fo llo w 's c a n be u s e d t o c h e c k
c r a n k s h a f t d ef lectio n w ith th e e n g in e e i t h e r co ld or
warm.
1. R e m o v e a n in s p e c t io n c o v e r f r o m th e c y lin d e r
b lo c k t h a t will give ac cess to th e c o n n e c t i n g r o d
j o u r n a l o f th e c r a n k s h a f t n e a r e s t t o th e c e n t e r o f
th e engine.
CAUTION
Read the notice on the cylinder block covers
CH E C K IN G BORE R U N O U T OF TH E FLYW HEEL before removal of the covers on a warm engine.
1. 7 H 1 9 4 5 H o ld in g Rod. 2. 7 H 1 6 4 5 H o ld in g Rod.
3. 7H1942 Indicator. 4. 7H1940 Universal Attachm ent
2. T u r n th e c r a n k s h a f t in t h e d i r e c t i o n o f n o r m a l
r o t a t i o n un til t h e c e n t e r o f th e c o u n t e r w e i g h t s
j u s t g o b e y o n d th e c o n n e c t i n g r o d .
C H E C K IN G FLYW HEEL C LU TC H
PILO T BEARING BORE M EAS UR IN G D E FLE C TIO N OF TH E CR A N K S H A FT
1. Dial gauge. 2. Mounting face.
3-50
TESTING AND ADJUSTING
BASIC BLOCK
3. I n stall a S t a r r e t t C r a n k s h a f t D i s t o r t i o n D ial-
G a u g e No. 696 w ith S t a r r e t t No. 696B B a la n c e r
A t t a c h m e n t b e t w e e n th e c o u n t e r w e i g h t s as
s h o w n . P u t D ial G a u g e (1) w i t h i n .25 in. (6.4
m m ) o f c o u n t e r w e i g h t m o u n t i n g stiriace (2).
I u r n th e dial o f th e i n d i c a t o r to get a l i g n m e n t
o f t h e zero a n d th e p o i n t e r . T u r n t h e i n d i c a t o r
o n its e n d p o i n t s until th e p o i n t e r o f t h e i n d i c a
t o r will n o t m o v e f r o m zero.
4. T u r n the c r a n k s h a f t in t h e d i r e c t i o n o f n o r m a l
r o t a t i o n until t h e i n d i c a t o r a l m o s t m a k e s c o n
tact w ith t h e c o n n e c t i n g r o d o n t h e o t h e r side o f
the c r a n k s h a f t .
N O T E : D o n o t let th e i n d i c a t o r m a k e c o n t a c t w i t h
t h e c o n n e c t i n g rod.
5. T h e dial i n d i c a t o r r e a d i n g m u s t n o t c h a n g e
m o r e t h a n .001 in. (0.03 m m ) f o r t h e a p p r o x i
m a te ly 300 d eg rees o f c r a n k s h a f t r o t a t i o n . N o w
t u r n th e c r a n k s h a f t in t h e o p p o s i t e d i r e c t i o n to
th e s t a r t i n g p o sitio n . T h e dial i n d i c a t o r m u s t
n o w r ead zero. If th e dial i n d i c a t o r d o e s n o t
r ead zero , d o th e p r o c e d u r e again.
VIBRATION DAMPER
D a m a g e t o o r failu re o f th e d a m p e r will in c r e a s e
v i b r a t i o n s a n d resu lt in d a m a g e t o t h e c r a n k s h a f t .
If th e d a m p e r is b e n t o r d a m a g e d , o r if t h e b o l t h o les
in th e d a m p e r are lo o se f ittin g, r e p l a c e t h e d a m p e r .
R e p l a c e m e n t o f th e d a m p e r is a ls o n e e d e d a t t h e
t im e of c r a n k s h a f t f a ilu re (if a t o r s i o n a l ty pe) .
3-51
ELECTRICAL SYSTEM TESTING AND ADJUSTING
ELECTRICAL SYSTEM
M o s t o f the tes tin g o f th e electrical s y s te m c a n be a m p e r e / h o u r ratin g . L et t h e r e s i s t a n c e r e m o v e th e
d o n e o n th e engine. T h e w irin g i n s u l a t i o n m u s t be in c h a r g e ( d i s c h a r g e t h e b a t t e r y ) f o r 15 s e c o n d s .
g o o d c o n d i t i o n , th e wire a n d c ab le c o n n e c t i o n s I m m e d i a t e l y tes t th e b a t t e r y v o ltag e. A 6 volt
clean a n d tight a n d th e b a t t e r y fully c h a r g e d . If on b a t t e r y in g o o d c o n d i t i o n will test 4.5 volts; a 12 vo lt
th e en gin e test s h o w s a defect in a c o m p o n e n t , b a t t e r y in g o o d c o n d i t i o n will tes t 9 volts.
r e m o v e th e c o m p o n e n t f o r m o r e testing. T h e wire
size, c o l o r a n d r e c o m m e n d a t i o n s o f l e n g th a r e gi ven T h e S p e c ia l I n s t r u c t i o n F o r m No. S E H S 6 8 9 1
in t h e W I R I N G D I A G R A M S in S Y S T E M S w ith th e 9 S 1 9 9 0 C h a r g e r T e s t e r gives th e b a t t e r y
O P E R A T IO N . te s ti n g p r o c e d u r e .
T h e c o n d i t i o n o f c h a r g e in th e b a t t e r y a t e a c h
T h e b a t t e r y circuit is a n electrical lo a d o n th e r e g u l a r i n s p e c t io n will s h o w if t h e c h a r g i n g s y s te m is
c h a r g i n g un it. T h e lo ad is v a r i a b l e b e c a u s e o f t h e o p e r a t i n g co r re ctly . A n a d j u s t m e n t is n e c e s sa ry
c o n d i t i o n of the c h a r g e in th e b a t t e r y . D a m a g e t o w h e n th e b a t t e r y is a lw a y s in a low c o n d i t i o n o f
the c h a r g i n g u nit will result, if t h e c o n n e c t i o n s , c h a r g e o r a larg e a m o u n t o f w a t e r is n e e d e d (o n e
(either po sitive o r neg ative) b e t w e e n t h e b a t t e r y a n d o u n c e p e r cell p er w eek o r ev ery 50 serv ice h o u r s) .
c h a r g i n g u n it are b r o k e n while th e c h a r g i n g u n i t is
ch arg in g . T h is is be c a u s e th e b a t t e r y l o a d is lost a n d
T e s t th e c h a r g i n g u n its a n d v o l t a g e r e g u l a t o r s on
t h e r e is a n increase in c h a r g i n g v oltage. High
th e en g in e, w h e n p ossible, u s i n g w ir in g a n d c o m
v o lta g e will d a m a g e , n ot o nly the c h a r g i n g un it b ut
p o n e n t s t h a t a r e a p e r m a n e n t p a r t o f th e sy stem . O f f
also th e r e g u l a t o r a n d o t h e r electrical c o m p o n e n t s .
th e en g i n e ( b e n c h ) te s ti n g will give a n o p e r a t i o n a l
tes t o f t h e c h a r g i n g u n it a n d v o l t a g e r e g u l a t o r . T h is
te s ti n g will give a n i n d i c a t i o n of n e e d e d r e p a i r. F i n a l
te s ti n g will give p r o o f t h a t t h e u n its are r e p a i r e d to
t h e i r o r ig in a l o p e r a t i n g c o n d i t i o n .
B e fo re s t a r t i n g o n t h e en g in e tes tin g , t h e c h a r g i n g
s y s t e m a n d b a t t e r y m u s t be c h e c k e d . See th e
f o l lo w in g S teps.
2. C a b le s b e t w e e n th e b a t t e r y , s t a r t e r a n d en g in e
CAUTION
g r o u n d m u s t be t h e c o r r e c t size. W ires a n d
Never disconnect any charging unit circuit cab les m u s t be free o f c o r r o s i o n a n d h a v e cab le
or battery circuit cable from battery when s u p p o r t c l a m p s to p r e v e n t stress o n b a t t e r y c o n
the charging unit is charging. n e c t i o n s (te rm in a ls ).
3. L e a d s , j u n c t i o n s , sw itc h es a n d p a n e l i n s t r u
L o a d test a b a t t e r y t h a t d o e s n o t h o l d a c h a r g e m e n t s t h a t h a v e direct r e l a t i o n t o t h e c h a r g i n g
w h e n in use. T o d o this, p u t a r esis tan ce, a c r o s s t h e circuit m u s t give p r o p e r circu it c o n t r o l .
b a t t e r y m a i n c o n n e c t i o n s (te rm in a ls ). F o r a 6 volt
b a tte r y , pu t a re s is ta n c e o f tw o tim es th e 4. I n s p e c t th e d riv e c o m p o n e n t s f o r th e c h a r g i n g
a m p e r e h o u r r a t i n g o f t h e b a tte r y . F o r a 12 volt u n it t o be s u r e t h e y ar e free o f g rease a n d oil a n d
b a tte ry , put a re sis ta n c e of th re e tim es the ar e a b le t o d riv e t h e lo a d o f t h e c h a r g i n g un it.
3-52
TESTING AND ADJUSTING
ELECTRICAL SYSTEM
F u r t h e r test by f a s t e n i n g o ne v o l t m e t e r lead t o th e
c o n n e c t o r ( t e rm i n a l ) f o r th e sm a ll w ire at th e
s o l e n o id a n d th e o t h e r lead to th e g r o u n d . L o o k at
th e v o l t m e t e r a n d a c tiv a te th e s t a r t e r s o l e n o id . A
v o l t m e t e r r e a d i n g sh o w s t h a t th e p r o b l e m is in th e
s o le n o id . N o v o l t m e t e r r e a d i n g s h o w s t h a t th e
p r o b l e m is in th e s t a r t e r sw it c h o r wiring. F a s t e n o ne
lead o f t h e v o l t m e t e r to t h e b a t t e r y wire c o n n e c t i o n
o f th e s t a r t e r sw itc h a n d g r o u n d t h e o t h e r lead. A
v o l t m e t e r r e a d i n g in d i c a t e s a fa ilu re in th e sw itch.
M o v e th e s t a r t i n g c o n t r o l sw itc h to a c t i v a t e th e
s t a r t e r so le n o id . S t a r t e r so l e n o id o p e r a t i o n c a n be
h e a r d as th e p i n i o n ot th e s t a r t e r m o t o r is e n g a g e d
w ith th e rin g g e a r o n th e e n g in e flywheel. T h e s o l e
n oid o p e r a t i o n also closes th e electric circuit t o t h e
m o t o r . C o n n e c t o n e lead o f th e v o l t m e t e r t o th e
s o l e n o id c o n n e c t i o n ( t e r m i n a l ) t h a t is f asten ed t o
the m o t o r . G r o u n d the o t h e r lead. A c t i v a t e t h e
s t a r t e r s o l e n o id a n d lo o k at the v o l t m e t e r. A r e a d i n g
o f b a t t e r y v o lta g e s h o w s th e p r o b l e m is in th e C O N N E C T IO N FOR C H E C K IN G P IN IO N C L EAR AN CE
m o t o r . I he m o t o r m u s t be r e m o v e d f o r f u r t h e r t e s t 1. Connector from M O TO R terminal on solenoid to motor.
ing. N o r e a d i n g on th e v o l t m e t e r s h o w s t h a t th e 2. SW terminal. 3. Ground terminal.
3-53
ELECTRICAL SYSTEM TESTING AND ADJUSTING
2. C o n n e c t a b a t t e r y , o f th e s a m e v o l t a g e as th e R e m o v e th e wire f r o m a r o u n d th e oil p r e s s u re
so l e n o id , to the t e r m i n a l (2). m a r k e d S W . switch.
3. C o n n e c t th e o t h e r side o f b a t t e r y t o g r o u n d
te r m i n a l (3).
4. C o n n e c t f o r a m o m e n t , a w ire f r o m th e so l e n o id
c o n n e c t i o n ( t e rm i n a l ) m a r k e d M O T O R t o th e
g r o u n d c o n n e c t i o n ( te rm in a l) . T h e p i n i o n will
shift to c r a n k p o s i t i o n a n d will sta y t h e r e u n til
the b a t t e r v is d isc o n n e c t e d .
W i t h a w ire in stalled b e t w e e n b o t h t e r m i n a l s ( l )
o f th e oil p r e s s u r e sw itc h , e n g a g e th e s t a r t e r sw itc h a
m o m e n t . If th e s t a r t e r a n d s o l e n o id s e n g a g e , t h e n
t h e oil p r e s s u re sw itc h h a s failed a n d m u s t be
r e p l a c e d w ith a n ew sw itch. L e a v e th e w ire in place if
P IN IO N CLEAR AN CE A D JU S TM E N T
t h e sw it c h h a s n o t failed a n d c h e c k th e s t a r t e r
4. Shaft nuf. 5. Pinion. 6. Pinion clearance. sw itch.
5. P u s h th e p i n i o n t o w a r d c o m m u t a t o r e n d t o r e
m o v e free m o v e m e n t .
7. P i n i o n c l e a r a n c e a d j u s t m e n t is m a d e by r e m o v
ing p lug a n d t u r n i n g n u t (4).
PRELUBE SYSTEM
Relay
3-54
ELECTRICAL SYSTEM TESTING AND ADJUSTING
C H E C K IN G STARTER SW ITC H
1. Starter relay terminal. 2. Starter battery terminal.
3-55
ENGINE SHUTOFF CONTROL TESTING AND ADJUSTING
1. R e m o v e th e en gin e s h u t o f f c o n t r o l a n d reset Start, Stop Arrangem ent 8L5967 needs overspeed to activate at
cable f r o m th e engine. 1500 + 25 rpm.
2. C o n n e c t th e I P 7 4 4 3 o r 4S6991 T a c h o m e t e r
(p a rt o f th e 4 S 6 5 5 3 E n g in e T est G r o u p ) t o
6E221 l T a c h o m e t e r D r iv e (E) o n c o n t r o l (A).
N O T E : W h e n a d j u s t m e n t o r c h e c k o f t h e o v ersp ee d
c o n t r o l is m a d e a n d th e oil p r e ss u re reset p l u n g e r is
n o t p u s h e d in. a lo w oil p r e s s u re s h u t o f f a c t i o n will
be th e result.
A D JU S TM E N T
1. Carrier assembly. 2. W eight adjustment screw. 3. Plug.
6. I f a n a d j u s t m e n t is n e e d e d , r e m o v e p lu g (3). If
n eces sa ry , t u r n t h e driv e sh a ft o f t h e s h u t o f f u n
TE ST OF O VERSPEED C O N T R O L
til t h e scre w (2) is in a l i g n m e n t w ith t h e h o l e f o r
A. Shutoff control. B. 4S6553 Engine Test Group. C.
p lu g (3).
FT907 A dapter. D. R eversible variable speed drill. E.
6L2211 Tachom eter Drive Group.
7. Use a sc r e w d r i v e r t o m a k e t h e a d j u s t m e n t t o th e
CAUTION o v e r s p e e d c a r r ie r a s s e m b l y (1). O n e full t u r n o f
All shutoff controls must be turned counter sc rew (2) will c h a n g e th e m a x i m u m o v e r s p e e d
clockwise. limit 45 to 50 r p m . T u r n the screw c o u n t e r
c lo ck w is e to m a k e th e s e ttin g lower.
4. R e a d the r p m on t h e t a c h o m e t e r at th e m o m e n t
th e c o n t r o l is ac t i v a t e d . T h e r e a d i n g will give
th e e n g in e r p m (2 r p m o n t h e sc ale f o r e a c h r p m 8. C h e c k th e se ttin g o f t h e o v e r s p e e d c o n t r o l a g a i n
th e in p u t sha ft is tu r n e d ) . a f t e r th e a d j u s t m e n t is m a d e .
3-56
IN D E X
D379, D398 & D399 I & M
ENGINE ATTACHMENTS
CABLE A D J U S T M E N T
(Air Inlet Shut-off)
1. P ut th e m e c h a n ic a l s h u t - o f f in th e re s e t p o s itio n .
4-1
D379,- D398 & D399 I & M
ENGINE ATTACHMENTS SPECIFICATIONS
GO VE RNOR
(W O O D W A R D U G -8 Dial & Lever)
D 379 :68 B 1 61 6 -UP
D 3 9 8 :6 6 B 2 0 4 9 -U P
D 399 :35 B 1 -UP
(4) L e n g th o f le v e r fo r d riv e h o u s in g 4 .3 7 5 in . (1 1 1 .1 3 m m )
GO VE RNOR
(W O O D W A R D EG-3P)
(1) A n g le o f g o v e rn o r le v e r to h o riz o n ta l
(w ith g o v e rn o r at m in im u m fu e l p o s itio n ) 35 =
GOVE RNOR
(W O O D W A R D SGT)
D 3 7 9 68B1 61 6-UP
(1) L e n g th o f g o v e rn o r l e v e r 5 .0 0 in. (1 2 7 .0 m m )
(3) L e n g th o f le v e r fo r d riv e h o u s in g 4 .3 7 5 in . (1 1 1 .1 3 m m )
4-2
D379, D398 & D399 I & M
SPECIFICATIONS
ENGINE ATTACHMENTS
GO VER N OR DRIVE
UPP ER H O U S IN G
(W O O D W A R D GOVERNO R)
D 3 7 9 6 8 B 2 5 4 0 thru 6 8 B 2 8 4 5
D 3 9 8 :6 6 B 3 5 6 1 thru 6 6 B 3 9 2 8
D 3 9 9 :3 5 B 6 8 8 thru 3 5 B 9 8 8
(1) O u ts id e d ia m e te r o f d riv e
s le e v e ................................... 7 2 9 0 r .0 0 0 5 in. (1 8 .5 1 7 ± 0 .0 1 3 m m )
In s id e d ia m e te r o f d riv e sle e v e
b e a r in g .................................7 3 4 5 o. 0 0 0 5 in. (1 8 .6 5 6 ± 0 .0 1 3 m m )
(3) O u ts id e d ia m e te r o f d riv e s h a ft
jo u r n a l...................................9 0 3 8 r .0 0 0 2 in. (2 2 .9 5 7 + 0 .0 0 5 m m )
In s id e d ia m e te r o f d riv e s h a ft
b e a r in g .................................9 0 6 5 r .0 0 1 0 in. (2 3 .0 2 5 _i 0 .0 2 5 m m )
GO VER N OR DRIVE
U PP ER H O U S IN G
(W O O D W A R D GOVERNO R)
D 3 7 9 :6 8 B 2 8 4 6 -U P
D 3 9 8 :6 6 B 3 9 2 9 -U P
D 3 9 9 :3 5 B 9 8 9 -U P
(1) O u ts id e d ia m e te r of d riv e
s le e v e ......................................7 3 0 0 r .0 0 0 5 in. (1 8 .5 4 2 ± 0 .0 1 3 m m )
In s id e d ia m e te r o f d riv e sle e v e
b e a r in g ....................................7 3 2 5 u .0 0 1 5 in. (1 8 .6 0 9 1 0 .0 3 8 m m )
(3) O u ts id e d ia m e te r of d riv e s h a ft
j o u r n a l ....................................9 0 4 5 : .0 0 0 5 in. (2 2 .9 7 4 i. 0 .0 1 3 m m )
In s id e d ia m e te r o f d riv e s h a ft
b e a r in g ....................................9 0 6 5 - .0 0 1 0 in. (2 3 .0 2 5 r 0 .0 2 5 m m )
4 -3
D379, D 398 & D 399 I & M
E N G IN E A T T A C H M E N T S SPECIFICATIONS
R a ng e o f o p e r a t io n 10 to 8 0 p si (7 0 to 5 5 0 kPa)
A ir p re s s u re at h ig h i d l e 6 5 p si (4 5 0 kPa)
M a x im u m a ir p re s s u re 8 0 psi (5 5 0 kPa)
2 N 6 0 0 6 A IR A C T U A T O R
(1) 7 J 9 9 5 8 S p rin g
L e n g th u n d e r te s t f o r c e 5 .7 5 in. (1 4 6 .1 m m )
T e st fo rc e 1 0 0 lb. (4 4 5 N)
O u ts id e d ia m e t e r 3 .8 8 in. (9 8 .6 m m )
(2) 2 N 6 0 0 5 S p rin g
L e n g th u n d e r te s t f o r c e 3 .8 0 in. (9 6 .5 m m )
T e st fo rc e ....................................................................................... 2 0 .8 lb. (9 3 N)
O u ts id e d ia m e t e r 8 6 in . (2 1 .8 m m )
1 N 9 3 1 8 A N D 7 L 1 3 5 A IR A C T U A T O R S
L e n g th u n d e r te s t f o r c e 3 .6 2 in. (9 1 .9 m m )
T e st fo rc e ..................................................................................... 1 5 .7 1b. (7 0 N)
O u ts id e d ia m e t e r 1 .8 2 in. (4 6 .2 m m )
L e n g th u n d e r te s t f o r c e 5 .3 3 in. (1 3 5 .4 m m )
T e st fo rc e .......................................................................................... 2 0 lb. (9 0 N)
O u ts id e d ia m e t e r 6 4 in . (1 6 .3 m m )
4-4
D379, D398 & D399 I & M
SPECIFICATIONS
ENGINE ATTACHMENTS
(1) L e n g th of ro d e n d a n d e y e b o l t 2 -8 8 in. (7 3 .2 m m )
(2) L e n g th of a c tu a to r le v e r 4 .0 0 in. (1 0 1 .6 m m )
M A G N E T IC PIC KUP
(2) C le a ra n c e b e tw e e n m a g n e tic p ic k u p a n d
fly w h e e l rin g g e a r 0 2 2 to .0 3 3 in. (0 .5 6 to 0 .8 4 m m )
4 -5
D379, D398 & D399 I & M
ENGINE ATTACHM ENTS SPECIFICATIONS
SHU T-OFF S O L E N O ID S
2 N 2 3 8 5 2 4 V or 3 2 V (D e lc o -R e m y N u m b e r 1 1 1 5 5 2 4 )
C u rre n t p u ll in w in d in g s at 9 V 5 .5 to 6 .3 A
C u rre n t p u ll in w in d in g s at 2 0 to 2 4 V ............................1 2 .2 to 1 6 .8 A
C u rre n t h o ld in w in d in g s at 2 0 to 2 4 V ................................................ 4 5 A
(2) 5 L 8 9 8 3 S p rin g fo r p lu n g e r
L e n g th u n d e r te s t f o r c e 1 .2 5 in. (3 1 .8 m m )
T e st f o r c e .............................................................................. 2 .0 0 lb. (8 .9 N)
O u ts id e d ia m e t e r ..................................................... 1 .7 5 in. (4 4 .5 m m )
(3) D is ta n c e b e tw e e n s h a ft a n d p la te *
3 N 5 4 8 S h a f t ....................................................................... 7 0 in. (1 7 .8 m m )
(4) D is ta n c e o f p lu n g e r tra v e l [s ta rt w it h d im e n s io n
o f .4 4 in. (1 1 .2 m m ) at ( 5 ) j 6 2 in. (1 5 .7 m m )
* 0 n e n g in e a te s t ca n s h o w n e e d fo r m o re a d ju s tm e n t H o ld in te s t o n
e n g in e m u s t ta k e le ss th a n 2 A.
3 L 2 8 7 1 2 4 V or 3 2 V (D e lc o -R e m y N u m b e r 1 1 1 9 8 1 7 )
C u rre n t p u ll in w in d in g s at 2 0 V 3 .9 to 4 .2 A
C u rre n t h o ld in w in d in g s at 2 0 to 2 4 V ...................................................5 A
(2) D is ta n c e fro m fa c e o f s o le n o id to c e n te r o f
h o le in lin k w h e n p lu n g e r is 7 5 in. (19.1 m m )
fro m fa c e o f s o le n o id .......................................... 6 .1 2 in. (1 5 5 .4 m m )
(4) D is ta n c e fro m fa c e o f p lu n g e r to fa c e
o f s o le n o id ........................................................................... 7 5 in . (19.1 m m )
T e m p e ra tu re at w h ic h v a lv e o p e n s 2 1 0 ° F (9 9 °C )
4 -6
D379, D398 & D399 I & M SPECIFICATIONS
ENGINE ATTACHMENTS
T e st f o r c e .............................................................................. 1 .5 0 lb. (6 .7 N)
O u ts id e d ia m e t e r ......................................................... 7 6 0 in. (1 9 .3 0 m m )
L e n g th u n d e r te s t f o r c e 1 .9 9 0 in . (5 0 .5 5 m m )
T e st f o r c e 1 5 .5 0 lb. (6 8 .9 N)
O u ts id e d ia m e t e r .........................................................6 6 0 in. (1 6 .7 6 m m )
(1) D ia m e te r of s h a f t . .7 4 9 .001 in . (1 9 .0 2 ± 0 .0 3 m m )
B o re in h o u s in g
fo r s h a f t ............................... 7 5 1 5 ± .0 0 0 5 in . (19 ± 0 .0 1 3 m m )
D im e n s io n b e tw e e n p la te a n d h o u s in g b ore
w h e n at s h u to ff m u s t be le ss th a n ................... 0 0 3 in. (0 .0 8 m m )
4 -7
D379, D398 & D399 I & M
ENGINE ATTACHM ENTS SPECIFICATIONS
H Y D R A M E C H A N IC A L SHUT-OFF
3N 5760, 5N 1978, 5N 5993 & 5N 5994
(1) O ve rsp e e d a d ju s tm e n t bolt
(2 j 3 N 5 7 4 7 S p rin g , O v e rs p e e d (1 001 th ru 1 3 0 0 rp m ) fo r 3 N 5 7 6 0 a n d
5 N 5 9 9 4 U n its
L e n g th u n d e r te s t f o r c e ........................................... 6 6 3 in . (1 6 8 4 m m )
O u ts id e d ia m e t e r ......................................................... 4 2 6 in. (1 0 .8 2 m m )
(2) 3 N 8 4 0 2 S p rin g ; O v e rs p e e d ( 9 0 0 th r u 1 0 0 0 r p m ) f o r 5 N 1 9 7 8 a n d
5 N 5 9 9 3 U n its
L e n g th u n d e r te s t f o r c e ........................................... 6 6 3 in. (1 6 .8 4 m m )
T e st f o r c e .......................................................................... 1 .5 9 Ib. (7 .0 5 N)
O u ts id e d ia m e t e r .........................................................4 1 5 in. (1 0 .5 4 m m )
(3 ) 3 N 5 75 1 S p rin g ; S p e e d e r (1 001 th ru 1 3 0 0 rp m ) fo r 3 N 5 7 6 0 a n d
5 N 5 9 9 4 U n its
T e st f o r c e ....................................................................... 3 .1 9 Ib. (1 4 .2 5 N)
O u ts id e d ia m e t e r ................................................ 1 .3 7 8 in. (3 5 .0 0 m m )
(3 ) 3 N 8 4 0 3 S p rin g ; S p e e d e r (9 0 0 th r u 1 0 0 0 rp m ) fo r 5 N 1 9 7 8 a n d
5 N 5 9 9 3 U n its
L e n g th u n d e r te s t f o r c e .................................. 1 .5 0 4 in (3 8 .2 0 m m )
T e st f o r c e ......................................................................... 1 .4 0 Ib (6 .2 5 N)
O u ts id e d ia m e t e r ................................................ 1 ,3 7 8 in. (3 5 .0 0 m m )
(5) T h ic k n e s s of o il p u m p
ro to r s 3745 jl .0 0 0 5 in. (9.51 2 - 0 .0 1 3 m m )
D e p th o f c o u n te rb o re
................ 3 7 6 0 - . 0 0 0 5 - 0 0 0 0 in (9 5 5 0 —0 .0 1 3 0 .0 0 0 m m )
(6) D ia m e te r o f s h a f t . .6 2 3 5 - 0 0 0 5 in (1 5 .8 3 7 = 0 .0 1 3 m m )
D ia m e te r of b o re in
h o u s in g 6 2 5 5 T 0 0 0 5 in. (1 5 .8 8 8 ± 0 .0 1 3 m m )
L e n g th u n d e r te s t f o r c e .................................. 1 .6 2 4 in. (4 1 .2 5 m m )
T e st f o r c e ............................................................................ 2 9 .2 Ib. (1 3 0 N)
O u ts id e d ia m e t e r 4 1 5 in. (1 0 .5 4 m m )
T e st f o r c e ................................................................................ 51 Ib. (2 2 5 N)
F re e le n g th a fte r te s t 2 .1 0 1 in. (5 3 .3 7 m m )
O u ts id e d ia m e t e r 4 1 7 in. (1 0 .5 9 m m )
(8) S p e e d e r s p rin g a d ju s tm e n t b o lt
(9 ) In s ta ll s h a ft so e n d is even w it h side o f h o u s in g .
4-8
D379, D398 & D399 I & M SPECIFICATIONS
ENGINE ATTACHMENTS
L e n g th u n d e r te s t f o r c e ................................ 1 0 0 5 in. (2 5 .5 3 m m )
T e st f o r c e ....................................................................... 9 .6 7 lb. (4 3 .0 N)
O u ts id e d ia m e t e r 3 5 0 in. (8 .8 9 m m )
(11) 3 N 5 7 5 7 S p rin g fo r s e le c to r v a lv e
L e n g th u n d e r te s t f o r c e ................................ 1 .0 0 4 in . (2 5 .5 0 m m )
T e st f o r c e ............................................................................. 2 .2 0 lb. (9 .8 N)
O u ts id e d ia m e t e r 3 4 7 in. (8.81 m m )
(1 2 ) 3 N 5 7 3 8 S p rin g fo r lo w ra n g e o il p re s s u re va lve :
L e n g th u n d e r te s t f o r c e ................................ 1 .1 8 8 in . (3 0 .1 8 m m )
O u ts id e d ia m e t e r ......................................................4 9 7 in. (1 2 .6 2 m m )
(1 3 ) 5 N 2 7 2 3 S p rin g fo r h ig h ra n g e o il p re s s u re va lve :
L e n g th u n d e r te s t f o r c e ................................ 1 .7 5 0 in. (4 4 .4 5 m m )
T e st f o r c e .............................................................................. 1 5 .5 lb. (6 9 N)
O u ts id e d ia m e t e r 4 7 2 in. (1 1 .9 9 m m )
L e n g th u n d e r te s t f o r c e ................................ 1 .0 0 4 in. (2 5 .5 0 m m )
T e st f o r c e ............................................................................. 4 .4 lb. (1 9 .6 N)
O u ts id e d ia m e t e r ......................................................5 4 4 in. (1 3 .8 2 m m )
(1 51 5 N 4 7 4 8 R ack C ir c u it S e q u e n c e V a lv e fo r 3 N 5 7 6 0 a n d 5 N 1 9 7 8
U n its :
S et v a lv e to b yp a ss at 65 ± 2 p si (4 5 0 ± 14 kPa)
(1 5) 5 N 5 7 5 5 R ack C ir c u it S e q u e n c e V a lv e fo r 5 N 5 9 9 3 a n d 5 N 5 9 9 4
U n its :
L e n g th u n d e r te s t f o r c e 7 0 3 in. (1 7 .8 6 m m )
T e st f o r c e ................................................................................... 9 5 lb. (4 .3 N)
F re e le n g th a fte r t e s t 8 7 5 in. (2 2 .2 3 m m )
O u ts id e d ia m e t e r 2 3 4 in. (5 .9 4 m m )
(1 7 ) 5 N 4 7 4 9 A ir In le t C ir c u it S e q u e n c e V a lve :
T ig h te n v a lv e to a to rq u e o f 43 ± 3 lb. ft. (5 9 ± 4 N -m )
S et v a lv e to b yp a ss at 15 ± 2 psi (1 0 5 ± 1 4 kPa)
4-9
D379, D398 & D399 I & M
ENGINE ATTACHM ENTS SPECIFICATIONS
M E C H A N IC A L O V ER SPEE D SH UTOFF
R o ta tio n is c o u n te r c lo c k w is e at h a lf e n g in e s p e e d w h e n se e n fro m
d riv e e nd .
L e n g th u n d e r te s t f o r c e 9 6 9 in. (2 4 .6 1 m m )
Te st f o r c e 1 1 2 to 1 .2 4 lb (4 9 8 to 5 .5 0 N)
Free le n g th a fte r t e s t 1 .1 7 2 in . (2 9 .7 7 m m )
O u ts id e d ia m e t e r 406 in. (1 0 .3 1 m m )
L e n g th u n d e r te s t f o r c e 9 6 9 in. (2 4 .6 1 mm)
T e st f o r c e ..................................... 1 .9 0 to 2 .3 2 lb. (8 .4 5 to 1 0 .3 0 N)
O u ts id e d ia m e t e r 4 0 6 in. (1 0 .3 1 m m )
L e n g th u n d e r te s t f o r c e ....................................... 4 .0 3 in. (1 0 2 .4 m m )
T e s t f o r c e ................................................................................. 4 5 lb. (2 0 0 N)
O u ts id e d ia m e t e r 5 7 9 to 5 9 9 in. (1 4 .7 1 to 1 5 .2 2 m m )
D is ta n c e fro m fa c e o f a d a p te r to
c e n te r o f yo k e on lin k a g e 2 .2 5 in. (5 7 .2 m m )
NOTE: O n e t u r n o f w e ig h t a d ju s tm e n t s c re w c h a n g e s s e ttin g 4 5 to 5 0
rpm .
O VE R S P EE D A D J U S T M E N T
E N G IN E rp m
FU LL LO A D O V E R S P E E D SETTIN G SPR IN G
rp m c. 2 5 rp m NUM BER
4 -1 0
D379, D398 & D399 I & M SPECIFICATIONS
ENGINE ATTACHMENTS
(1) A d ju s tm e n t of c lu tc h le v e r p u ll:
(2) E nd c le a ra n c e
2N 6961 0 0 6 to 0 1 0 in. (0 .1 5 to 0 .2 5 m m )
2 N 7 0 8 0 .............................................................................. N o n -a d ju s ta b le
7L7490 0 1 0 to .0 1 2 in. (0 .2 5 to 0 .3 0 m m )
T h e n tig h te n a d d itio n a l:
2 N 6 9 6 1 ..................................................................................... 150 to 1 8 0
2 N 7 0 8 0 ..................................................................................... 2 1 0 ° to 2 4 0 °
7 L 7 4 9 0 ..................................................................................... 2 7 0 ° to 3 0 0 °
FLEXIBLE COUPLING
(5L3395)
M a x im u m o u t o f s q u a re d im e n s io n b e tw e e n fa c e
o f o u te r c o u p lin g a n d s h a ft .0 0 8 in. (0 .2 0 m m )
(1) M a x im u m o u t o f ro u n d d im e n s io n b e tw e e n o u ts id e d ia m e te r
of o u te r c o u p lin g a n d s h a ft 0 0 8 in. (0 .2 0 m m )
(2) C le a ra n c e b e tw e e n re a r p la te a n d c e n te r
c o u p lin g 0 0 9 in . (0 .2 3 m m )
(3) C le a ra n c e b e tw e e n f r o n t p la te a n d c e n te r
c o u p lin g 0 0 9 in. (0 .2 3 m m )
4-11
D379, D398 & D399 I & M
ENGINE ATTACHM ENTS SPECIFICATIONS
M E C H A N IC A L GA UGE S
E N G IN E O IL PR ES SU R E W ATE R T E M P E R A T U R E
Engine
Type O il Pressure Fuel Pressure W a te r T e m p e ra tu re
4 -1 2
D379, D398 & D399 I & M SPECIFICATIONS
ENGINE ATTACHMENTS
R a t in g ..................................................................................................................... 12V
P re s s u re ra n g e 0 to 8 0 p si (0 to 5 5 0 kPa)
0 p s i (0 k P a ) ..................................................................................... 0 O hm s
2 0 psi (1 4 0 k P a )..................................................................... 1 3 .5 O h m s
8 0 psi (5 5 0 k P a ).......................................................................... 30 O hm s
5 L 7 4 5 6 G a u g e ; U se w ith 5 L 7 4 5 0 S e n d in g U n it.
R a t in g ..................................................................................................................... 24V
P re s s u re ra n g e 0 to 8 0 p si (0 to 5 5 0 kPa)
0 psi (0 k P a ) ..................................................................................... 0 O hm s
2 0 psi (1 4 0 k P a )...................................................................... 1 3 .5 O h m s
8 0 psi (5 5 0 k P a ).......................................................................... 30 O hm s
5 L 7 4 5 4 G a u g e ; U se w ith 5 L 7 4 4 9 S e n d in g U n it.
R a t in g ..................................................................................................................... 12V
P re s s u re ra n g e ............................................ 0 to 3 0 0 p si (0 to 2 0 5 0 kPa)
0 psi (0 k P a ) ..................................................................................... 0 O hm s
1 5 0 psi (1 0 3 0 k P a ) ..................................................................... 15 O hm s
3 0 0 psi (2 0 5 0 k P a ) ..................................................................... 3 0 O hm s
5 L 7 4 5 1 G a u g e ; U se w ith 5 L 7 4 4 9 S e n d in g U n it.
R a t in g ...................................................................................................................... 24V
1 5 0 psi (1 0 3 0 k P a ) ....................................................................... 15 O h m s
3 0 0 psi (2 0 5 0 k P a ) ....................................................................... 30 O hm s
5 L 7 4 4 4 G a u g e ; U se w ith 5 L 7 4 4 2 S e n d in g U n it.
R a t in g ...................................................................................................................... 24V
T e m p e ra tu re r a n g e 1 0 0 to 2 4 0 F (3 8 to 1 1 5 C)
100 F (3 8 C ) ............................................................. 3 3 8 8 O hm s
240 F (1 1 5 C ) ................................................................. 4 6 0 O hm s
4 -1 3
D379, D398 & D399 I & M
ENGINE ATTACHMENTS SPECIFICATIONS
5 L 7 4 4 2 S e n d in g U n it; U se w ith 5 L 7 4 4 4 G a u g e .
R a t in g ...................................................................................................................... 24V
T e m p e ra tu re r a n g e 1 0 0 to 2 4 0 F (3 8 to 1 1 5 C)
48 7 3 6 X 1
R e s is ta n c e at:
200 F (9 3 C ) 8 0 0 to 9 0 0 O h m s
S E N D IN G UN IT S FOR OIL P R E S S U R E
R e s is ta n c e at
0 psi (0 k P a ) ............................................................................ 0 to 1 O h m s
6 0 psi (4 1 5 k P a ) 4 .5 to 6 .5 O h m s
3 0 0 psi (2 0 5 0 k P a ) ....................................................... 2 8 to 31 O h m s
R a t in g ...................................................................................................................... 24V
P re s s u re ra n g e 0 to 8 0 p si (0 to 5 5 0 kPa)
R e s is ta n c e at:
0 p si (0 k P a ) 0 O hm s
8 0 p si (5 5 0 k P a ).............................................................................. 3 0 O hm s
PRESSURE SW ITCHES
2 L 3 4 0 2 S w itc h
W ith an in c re a s e in p re s s u re ,
5 L 5 5 0 0 S w itc h
W ith an in c re a s e in p re s s u re ,
s w itc h c lo s e s a t .............................................................. 12 p si (8 5 kPa)
W ith a d e c re a s e in p re s s u re ,
s w itc h o p e n s a t .............................................................. 1 0 p si (7 0 kPa)
2 N 7 7 4 4 S w itc h
W ith an in c re a s e in p re s s u re ,
s w itc h c lo s e s ....a t .............................................................. 12 p si (8 5 kPa)
W ith a d e c re a s e in p re s s u re ,
s w itc h o p e n s ....a t ................................................................. 5 p si (3 5 kPa)
3 N 1 4 0 0 S w itc h
W ith an in c re a s e in p re s s u re ,
s w itc h c lo s e s a t ..................................... 5 to 1.5 psi. (3 .5 to 1 0 .5 kPa)
3 L 6 3 0 6 O il P res su re S w it c h
W ith a d e c re a s e in p re s s u re s w itc h
c lo s e s a t 6 to 1 0 psi (4 0 to 7 0 kPa)
1 N 5 8 3 3 O il P res su re S w itc h
W ith an in c re a s e in p re s s u re s w itc h
o p e n s a t ............................................................ 5 to 7 psi (3 5 to 5 0 kPa)
4-14
D379, D398 & D399 I & M SPECIFICATIONS
ENGINE ATTACHMENTS
ELECTRIC TACH O M ET ER
S e n d in g u n it tu r n s at 1 2 e n g in e sp ee d
R ange 0 to 2 5 0 0 rp m
C h e ck at n o rm a l e n g in e o p e ra tin g sp ee d
M in im u m a m o u n t o f a d ju s tm e n t (sca le r e a d in g ) ......................... ± 5%
M a x im u m e x te rn a l c ir c u it re s is ta n c e 20 ohm s
M a x im u m te m p e ra tu r e r a t i n g .............................................. 1 8 0 F (8 2 C)
(1) A d ju s tm e n t s c re w
(2) S e a le d cap.
(1) A d ju s tm e n t s c re w .
M a x im u m p e rc e n t a b o ve f u ll lo a d rp m
th a t c o n ta c ts c l o s e ........................................................................................ 1 8%
2 N 4 5 3 7 , 3 N 4 9 1 3 and 3 N 4 0 2 8 S w itc h e s .
OVERSPEED A D JU S T M E N T
E N G IN E rp m
FU LL L O A D rp m O V E R S P E E D SETTIN G
1 0 0 0 J 10 1180 ± 20
1 1 0 0 r 10 1298 ± 20
1 2 0 0 ± 10 1416 + 20
1 3 0 0 c. 10 1534 ± 20
4- J5
D379, D398 & D399 I & M
ENGINE ATTACHMENTS SPECIFICATIONS
CONTACT OR SW IT C H FOR
T EM P ERAT U RE
S W IT C H O P E R A T IN G T E M P E R A T U R E
w it h in c re a s e w it h d e c re a s e
in t e m p e r a t u r e in t e m p e r a t u r e
5L6435 2 0 9 : 1 F (9 8 c 0 6 C) 197 i 1 F ( 9 2 1 0 .6 C)
5L6434 1 9 7 c 1 F (9 2 : 0 6 C) 1 8 5 r 1 F (8 5 1 0 . 6 ° C )
5L6901 2 0 2 • 1 F (9 4 • 0 6 C) '9 0 ' 1 1 :8 8 • 0 6 Ci
2N 2920 2 1 5 c 1 F (1 0 3 i 0 6 C) 2 0 3 • 1 i •:95 • 0 6 C j
3N 7429 1 3 5 * 3 F (5 6 8 ! 1.7 C) 1 2 7 + 3 : F (5 3 ± 1 ,7°C )
3N 4690 1 5 0 - 3 F (6 6 i 1 .7 C) 1 4 2 i 3 i (6 2 ± 1 .7 C)
3R 1380 220 3 F (1 0 4 r 1 .7 C) 2 0 8 l 3 F (9 8 + 1 .7 C)
M ic r o S w it c h T y p e
2 N 6 9 5 5 a nd 3 N 5 3 1
W ith an in c re a s e o f p re s s u re ,
c o n ta c ts o p e ra te a t 12 psi (8 5 kPa)
2N 7124
E a rlie r T y p e
9F7837
8L4537
4 - lf i
INDEX
D379, D398, D399 I & M
ENGINE ATTACHMENTS
I
Governor Air Actuators ................ 5-80
W oodward UG8 Dial Governor ......................................................... 5-66
2N6006 Actuator ...................... 5-80
Com pensating A d ju s tm e n t........................................................... 5-66
1N9318 and 7L135 Actuators 5-81
Fuel Rack Adjustm ent ................................................................. 5-67
3N9125 Actuator ...................... 5-82
G overnor Linkage Adjustm ent .................................................... 5-69
High Idle Speed Adjustm ent ........................................................ 5-67
Instruments and G a u g e s ............................ 5-87
Electric Gauges ..................................... 5-87
5-89 W oodward UG8 Lever Governor ..................................................... 5-70
Mechanical Gauges for Oil Pressure
5-89 Com pensating A d ju s tm e n t........................................................... 5-70
Mechanical Gauges for Temperature
5-87 Fuel Rack Adjustm ent ................................................................ 5-71
Oil Pressure Sending Units ................
W a te r T e m p era tu re Sending Unit .... 5-87 G overnor Linkage Adjustm ent .................................................... 5-73
Low and High Idle Speed Adjustm ent ...................................... 5-71
Speed Droop Adjustm ent ........................................................... 5-72
Measuring Engine S p e e d ................................................................... 5-59
5-1
WOODWARD UG8 GOVERNORS SYSTEMS OPERATION
WOODWARD UG8 DIAL AND LEVER L ess oil pr ess ure is required on the bottom than on
GOVERNOR the top to keep the piston stationary. W hen the oil
p ressure is the sam e on the top and bo ttom o f the piston,
the piston will m ov e up and cau se the output terminal
The UG 8 Dial G o v ern o r is a m ech anical-hydraulic
shaft to turn in the increase fuel direction. W h e n oil
governor. A hy draulic a ctivated p o w e r piston is use d to
press ure on the bottom o f the piston is directed to the
turn the output terminal shaft o f the go vernor. A lever
su m p , the piston will m ove d o w n and cause the output
on the ter minal shaft is con nected to the fuel rack by a
terminal shaft to turn in the d ecrease fuel direction. Oil
linkage rod. The gov ern o r has a separate oil supply and
to o r fro m the bottom o f the p o w e r piston is controlled
oil pum p. The go vernor oil p u m p and b allhead are
by the pilot valve.
driven from a shaft in the g o v ern or drive h ousing. The
shaft is driven by the fuel p u m p drive shaft. T h e pilot valve has a pilot valve plu ng er and a
bushing. T h e bushin g is turned by the g o verno r drive
The oil p u m p gives pr ess ure oil to op erate the p o w e r
shaft. T he rotation o f the bu shing helps re duce friction
piston. The drive gear o f the oil p u m p has a bu sh in g in
b etw een the b ushing and the plunger. T h e pilot valve
which the pilot valve plu n ger m o ves up and dow n . The
p lu n g er has a land that controls oil flow th rough the
driven gear o f the oil p u m p is also the drive for the
ports in th e bu shin g. W h e n the pilot valve p lu n g er is
ballhead.
m o ved d o w n , high pressure oil go es to the bo ttom o f
An accu m u lato r is used to k eep a con stant oil p r es the p o w e r piston and the p o w e r piston will m o v e up.
sure of approxim ately 120 psi (830 kPa) to the top o f W h en the pilot valve plu ng er is m o v ed up, the oil on the
the p o w er piston and to the pilot valve. b ottom o f the p o w e r piston is release d to the su m p and
the p o w e r piston m oves d ow n. W h en the pilot valve
The p o w e r piston is c o n nected by a lever to the p lu n g e r is in the center (balance) p o s i t i o n , the oil po rt to
output ter minal shaft. T here is oil press ure on both the the b otto m o f the p o w e r piston is closed and the p o w e r
top and bo ttom o f the p o w er piston. The bo ttom o f the piston will not m ove. The pilot valve p lun ger is m o ved
piston has a larger area than the top. by the ballhead as sembly.
5 -2
SYSTEMS OPERATION
WOODWARD UG8 GOVERNORS
(S M A L L ) (C LO SED )
The b allhead as se m bly has a ballhead, fly w eig hts, valve and tw o pistons — an actuating piston and a
sp eed er spring, thrust b earing, sp eeder plug, a n d re ceiving piston. T he actuating piston is con nected to
sp eeder rod. The ballhead assem b ly is driven by a g ear the ou tput term in al shaft by the c om pensatio n adjus ting
and shaft from the driven g ear o f the oil p u m p. T h e lever. A fulcru m that is adjustable is on the lever. W h en
speeder rod is fastened to the thrust bearing w hich is on the position o f the fulcrum is ch an g ed , the am o u n t of
the toes o f the flyweights. T h e speeder rod is con nected m o v em en t poss ible o f the actuating piston is ch an ged.
to the pilot valve p lun ger with a lever. T he s p e ed er
spring is held in position on the thrust bearing by the The receiving piston is conn ected to the pilot valve
sp eeder plug. plu ng er and the speeder rod by a lever.
As the ballhead turns, the f ly w eig hts m o v e out d ue to T h e ne edle valve m akes a restriction to oil flow
centrifugal force. This will m ake the flyweight toes b etw een the oil sum p and the tw o pistons.
m ove up and cau se co m pression o f the sp eeder spring. W h e n the actuating piston m ov es d ow n , the piston
W hen the force o f the sp eeder spring and the force o f forces the oil un der the re ceiving piston and m o ves it
the f ly w eig hts are equal the en gin e speed is constan t. up. W h e n the receiving piston m ov es up it raises the
The sp eeder plug can be m o v ed up or d o w n m anually to pilot valve p lu n g er to stop the flow o f oil to the bo tto m
change the co m p ression o f the spe ed er spring and will o f the p o w e r piston.
change the sp eed o f the engine.
The c om pens atio n sy stem gives stability to en gin e W h en the engine is in ope ration at a steady sp eed the
speed chang es. T h e com pensation sy stem has a n eed le land on the pilot control valve is in the center of the
5-3
WOODWARD UG8 GOVERNORS SYSTEMS OPERATION
5 -4
WOODWARD UG8 GOVERNORS SYSTEMS OPERATION
5-5
PIERCE OUTPUT SHAFT GOVERNOR SYSTEMS OPERATION
5-6
PIERCE OUTPUT SHAFT GOVERNOR SYSTEMS OPERATION
Oil, deliver ed from the en g ine oil p u m p , flows into T h e piston m ov em en t is transm itted to c am (25),
the se rv o m echanism and norm ally flows th rough the shaft (23) and the gov ern or linkage, and in turn d e
piston, valve and back to the crankcase. W h e n the creases the a m o u nt o f fuel b eing delivered to the
output shaft go v ern or takes effe ct, due to an increase in engine.
the tor que co nv erter output shaft sp eed, the go verno r
linkage m o ves the control valve in the piston. T h e flow W h e n the load on the output shaft is in creased, the
o f oil th rough the piston is block ed and results in an oil output shaft spe ed is re duced and the lorce exerted by
pressure build-u p. This pressure m oves the piston to the ou tp ut shaft go v ern or w eights decreases. The force
follow the m o v e m e n t o f the valve. This m o v e m e n t ex er ted by the output shaft g o v ern o r spring then o v e r
continues until the piston ports are u ncovered and oil c om es the forc e exerted by the weights and the actuat
flows through the piston o nce again. ing linkage m o ves the se rvo m ech an is m valve into the
piston. T h e m o v em en t o f the valve into the piston
uncovers d u m p ports and allows oil to flow unrestricted
thr ough the se rv o m echan ism . T h e valve and piston are
inactive and then the diesel eng ine g o verno r takes ov er
full control o f the en gine and the fuel rack m o ves in the
direction o f increase d fuel, increasing en gine spe ed to
its full g o v ern ed speed.
5-7
WOODWARD SGT GOVERNOR SYSTEMS OPERATION
P ow er tak e-o ff clutches ( P T O 's ) are used to send faces o f drive discs (2), dr ive plates ( 10) and hub (9)
p ow er from the engine to accessory co m p on en ts. F o r tight together. Friction b etw een these faces perm its the
e xam p le, a P T O can be used to drive an air co m p ressor flow o f torque from ring ( l ) , th rough driven discs (2),
or a water pu m p . to plates (10) and hub (9). Spline teeth on the inside
d iam eter o f the driven discs dr ive the hub. The hub is
The P T O is driven by a ring ( l ) that has spline teeth held in position on the output shaft ( 11) by a taper, nut
arou nd the inside di am eter . T h e ring can be con nected (7) and key (5).
to the front or rear o f the en gine cran ksh aft by an
adapter.
N O T E : A P T O can h ave from one to three driven discs
NOT E: On so m e P T O 's located at the rear o f the (2) with a respec tive n u m b e r o f plates.
engine, ring ( l) is a part o f the flyw heel.
The spline teeth on the ring en gage wuth the spline W h e n lever (4) is m o v ed to the N O T E N G A G E D
teeth on the outside d iam eter o f driven discs (2). W h e n p osition, y ok e assem bly (8) m o v e s collar assem bly (6)
lever (4) is m o v ed to the E N G A G E D position, yoke to the left. T h e m o v em en t o f the collar assem bly will
as se m bly (8) m oves collar assem bly (6) to the right. release link as sem blies (3). With the link as sem blies
The collar as se m bly is co nn ected to four link a s s e m release d there will not be e n ou gh friction b etw een the
blies (3). The action o f the link assem blies will hold the faces o f the clutch as se m bly to p erm it a flow o f t o r q u e .
5 -1 0
SYSTEMS OPERATION
SHUTOFF AND ALARM SYSTEM COMPONENTS
Micro Switch Type Early type sw itches for oil pr essure have a control
knob ( l ) . T h e kn o b must be turned (reset) every time
The oil press ure switch is used to give protection to the en gine is stopped. Turn the kn o b counterclockw ise
the engine fro m dam age be cause of low oil pressure. to the O F F position before the en gine is started. The
W h en oil press ure lowers to the pr ess ure specifications knob will m o ve to the RU N position when the oil
of the sw itch, the switch closes and activates the rack pressure is nor mal.
shutoff solenoid.
PRESSURE SWITCH
These type pr essure sw itches are used for several
pu rp oses and are available with different specifica
tions. T h ey are used in the oil sy stem and in the fuel
system. O ne use of the switch is to open the circuit
b etween the battery and the rack sh uto ff solenoid after
the oil press ure is below the press ure specifications o f
the sw itc h. It also closes when the engine starts.
OIL PRESSURE SW ITCH
(Micro Switch Type)
A n oth er use o f the switch is to clos e and activate the
battery' ch arg ing circuit when the pressure is ab o v e the
1. Locknut. 2. Adjustm ent screw. 3. Spring. 4. Arm. 5.
Spring. 6. Bellows. 7. Latch plate. 8. Button for m icro pressure specification o f the switch. It also disc onnects
switch. 9. Arm. 10. Projection of arm. the circuit when the engine is stopped.
5-11
SHUTOFF AND ALARM SYSTEM COMPONENTS SYSTEMS OPERATION
CAUTION
Find and correct the problem that caused the
circuit breaker to open. This will help prevent
damage to the circuit components from too
much current.
SHUTOFF SOLENOID
A sh utoff solenoid changes electrical input into m e
chanical output. T hey are use d to m ov e the fuel rack to
a no fuel position or to m ove a valve assem bly in the air
inlet pipe to a closed position. This stops the engine.
5 -1 2
SHUTOFF AND ALARM SYSTEM COMPONENTS SYSTEMS OPERATION
X3970 tX ? f
5 -1 3
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
I here ar e l o u r h y d r a - m e c h a n i c a l s h u t o f f s used on
Y-8. Y - 1 2 a n d \ -16 e n gin es . T h e 3 N 5 7 6 0 S h u to lT is
used on V-N a n d \ -12 en g in es w ith r a t e d en g in e
sp e ed s oi 1001 t h r u 1300 rpm . T h e 5 M 9 7 8 S h u t o f i
is used on V-8 a n d \ -12 e n g ines w ith a r a t e d en g in e
sp e ed ot 900 t h r u 1000 r p m . T h e 5 N 5 9 9 3 S h u t o f f is
used on V-8. V-12 a n d V-16 e n g in e s w ith a r a t e d
speed o f 900 t h r u 1000 r p m . T h e 5M5994 S h u t o f f
is used on V-8. V-12 a n d V-16 e n g in es w ith ra te d
sp e ed s ot 1001 t h r u 1300 rp m . T h e r e is a p a r t
n u m b e r id e n t i fi c a t io n p l a t e a t t a c h e d to e a c h un it.
5 -1 4
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
OIL PRESSURE PROTECTION psi (205 kP a) . S elector valve (15) is nor m ally open and
is oper ated by pilot oil press ure from valve (1).
Make reference to schematic No. 1 Low Speed Range (Normal Operation)
At app ro xim ately 1Q% o f en gine full load speed, the Make reference to schematic No. 1
oil pressure protection ch ang es fro m low ran ge to high
range. This change is made with the use o f valves (1 3), Oil go es fro m oil p u m p (4) to rack sequence valve
(14), (15) and (1). Engine oil pressure goes to valves (6). Valve (6) keeps oil pressure at the start o f the rack
(13) and (14). Valves (13) and (14) are norm ally circuit at 110 psi (760 kPa). The rem ain d er o f the oil is
closed. T he valves will open on ly if the eng ine oil sent to air inlet se quence valve (7), air inlet sh u to ff
pressure is m ore than the force o f the spring b ehind the actuators (8), and pilot operated two way valve (9), and
valves. V alve (13) is for low sp eed range protection then to the su m p. The rack circuit oil goes through fuel
and will o pen if en gine oil press ure is more than 20 psi rack orifice (12), and through valves (13) and (15) and
(140 kPa). Valve (14) is for high spe ed ran ge p r o t e c then back to the sum p through pilot op er ated tw o way
tion and will open if engine oil pr essure is m ore than 30 valve (9).
5 -1 5
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
cKUjhA
5 -1 6
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
SC HE M A TIC NO. 3
1. Speed sensing spool valve. 9. Pilot operated, tw o way valve. 13. Low range oil pressure sensing valve. 14. High range oil
pressure sensing valve. 15. Selector valve.
5 -1 7
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
5-18
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
SC HE M A TIC NO. 1
1. Speed sensing spool valve. 4. Oil pum p. 5. Oil pum p relief valve. 6. Rack sequence valve. 7. Air inlet sequence valve. 8.
Air inlet shutoff actuator. 9. Pilot operated, tw o w ay valve. 10.Diverter valve. 11. Fuel rack actuator. 12. Fuelrack
orifice. 13. Low range oil pressure sensing valve. 14. High range oil pressure sensing valve. 15. Selector valve. 16.
Therm ostatic pilot valve. 17. Engine oil pressure orifice. 18. Manual shutoff valve.
5 -1 9
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
Oil pr ess ure to valve (9) will also not let rack circuit
oil return to the sump. With the increase in oil press ure
in the rack circuit, fuel rack actuator (11) is m o v ed in
the sa m e w ay as for a low oil pressure condition.
5 -2 0
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
MANUAL SHUTOFF
Make reference to schematic No. 6.
T h e m anual ope ration o f m anual sh uto ff valve (18)
will shut o f f the fuel and air to the engine.
5-21
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
The fuel rack shutoff will m ove the rack to the fuel
off position with either low oil pr essure or high coolan t
tem per ature. Both the fuel rack and inlet air shutoffs
will activate when the engine oversp eeds or if the
manual control is used. The fuel rack shutoff will reset
automatically but the inlet air shu toff must be man ually
reset.
outside the heavy das hed lines are lines, valves, and 1. Speed sensing spool valve. 2. Flyweights. 3. Drive shaft.
actuators located on the engine aw ay from the shu toff
unit.
5 -2 2
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
OIL PRESSURE PROTECTION kPa). S elector valve (16) is norm ally open and is o p e r
ated by pilot oil press ure fro m valve (1).
Make reference to schematic No. 1
At ap p roxim ately 70% o f en gine full load speed, the Low Speed Range (Normal Operation)
oil pr ess ure protection ch an ges fro m low ra nge to high Make reference to schematic No. 1.
range. This change is m ade with the use o f valves (1 4),
(15), (16) and (1). Engin e oil press ure goes to valves Oil goes fro m oil p u m p (4) to rack se q uence valve
(14 and 15). Valves (14 and 15) are nor m ally closed . (6). V alv e (6) keeps oil press ure at the start o f the rack
The valves will open only if the en gine oil press ure is circuit at 65 psi (450 kPa). The r em ain d er o f the oil is
m ore than the force of the spring b ehind the valves . sent to air inlet sequence valve (7), air inlet sh utoff
Valve (14) is for low speed ran ge protection and will actuators (8), and pilot oper ated two way valve (9), and
op en if en gine oil pr essure is m ore than 2 0 psi (140- then to the su m p. The rack circuit oil goes th rough fuel
k P a ) . V alve (15) is for high spe ed ran ge p rotection and rack orifice (1 2), interface valve (13) and through
will open if en gine oil pressure is more than 30 psi (205 valves (14 and 16) and then back to the sum p.
5 -2 3
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
o fr g iN A
5 -2 4
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
r
1
fll
T :X -
1 /
“y 1 ^15
L --------------------
tk
n
j t v
m
I____
I________ _i
SC HE M A TIC NO. 3
1. Speed sensing spool valve. 14. Low range oil pressure sensing valve. 15. High range oil pressure sensing valve. 16.
Selector valve.
5 -2 5
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
5 -2 6
SYSTEMS OPERATION
HYDRA-MECHANICAL SHUTOFF
HIGH COOLANT TEMPERATURE shutoff m ust be m anually reset bef ore the en gine is
PROTECTION started again.
If the en g in e o versp eeds to a spe ed 18% abo ve full N O T E: L o w oil pr essure or high coolant tem perature
load sp eed the shutoff control will activate and sh ut o f f conditions do not change the oil flow in the air inlet
both the fuel and air supply to the engine. T he air inlet circuit.
5 -2 7
HYDRA-MECHANICAL SHUTOFF SYSTEMS OPERATION
5 -2 8
SYSTEMS O PER A TIO N
HYDRA-MECHANICAL SHUTOFF
SC HE M A TIC NO. 6
1. Speed sensing spool valve. 7. A ir inlet sequence valve. 8. Air inlet shutoff actuator. 9. Pilot operated, tw o way valve. 11.
Fuel rack actuator. 13. Interface valve. 19. Manual shutoff valve.
MANUAL SHUTOFF
5 -2 9
2301 PARALLEL CONTROL SYSTEM SYSTEMS OPERATION
O o
W w w
2301 LOAD SHARING & SPEED CONTROL
LOAD GAIN
©
©© © ©I) ©
£L J L _@ L
o © O
The 2 3 0 1 Parallel Control has two functions: ex act d riven generato r sets is m ad e p ossible by electric cir
engine spe ed and kilowatt load sharing. The sy stem cuits in the control box. The load on each g enerator in
m easures en gin e speed constantly and m akes n eces sa ry the sy stem is m easure d co nstantly by its control box.
corre ctio ns to the engine fuel setting through an a ctu L o ad s are c o m p ared betw een control boxes thr ough
ator co n n ected to the fuel sys tem . paralleling wires between all the units on the sam e bus.
F ro m the inp ut o f the par alleling wires the load sharing
The engine spe ed is felt by a mag netic pickup. As the
circuits m ake constant corre ctio ns to the control v ol
teeth o f the flyw heel go thr ou gh the m agn etic lines of
tages sent to the actuators. T h is gives kilowatt load
force around the pi ckup an A C voltage is m ade. The
sharing.
ratio betw een the fre quency of this vo ltage and the
speed o f the en gin e is directly proportional. An electric T h e rated and low idle en gine sp eeds are set with
circuit inside the control box feels this A C voltage. In speed setting potentiom eters. An optional rem ote
response it sends a DC control voltage, inversely p r o speed trim p o ten tiom eter will give ± 49 c spe ed setting
po rtional to en gine speed, to the actuator. a djustm ent. T h e ram p time p otentio m eter con trols the
a m o un t o f time it takes the en gine to go from low idle to
T he ac tuator is co nnected to the fuel system by
rated spe ed. A n oil pr essure switch is co nn ected b e
linkage. It ch an ges the electrical input from the control
tw een term in als 14 and 15. This switch is norm ally
box to m ec hanical outpu t that ch an g es the en g ine fuel
o pen . W h e n the engine oil pr ess ure increases to 6 .4 ±
setting. For ex am ple, if the en gin e speed was m ore than
2 .7 psi (44 ± 19 kPa) the sw itch closes. This perm its
the spe ed setting, the control box will d ecrease fuel to
the control to accelerate the engine to rated speed. If the
the engine.
oil p ressure decreases to 3 .9 ± 3.3 psi (27 ± 23 kPa)
Kilowatt load sharing b etw een a g rou p o f en g ine the control will return the en gine to low idle.
5 -3 0
2301 PARALLEL CONTROL SYSTEM SYSTEMS OPERATION
The load gain p oten tiom eter is set so that the ratio
between the actual kilowatt outpu t and the rated kilo
watt output o f each unit in the sy stem is the same.
ACTUATOR
5-31
2301 NONPARALLEL CONTROL SYSTEM SYSTEMS OPERATION
O O
The 2 3 0 1 Nonparallel Control gives exact en gine setting. F o r ex a m p le , if the engine spe ed was m ore than
speed control. The system m easu res en gine spe ed c o n the spe ed setting, the control box will de crease its
stantly and m ak es necessa ry co rre ctio ns to the en gin e output and the actuator will de crease fuel to the engine.
fuel setting through an actuator co nn ected to the fuel
T he rated and low idle en gine speeds are set with
system.
speed setting po tentiom eters. An optional rem ote
The engine spe ed is felt by a mag netic p ickup. As the speed trim p o ten tiom eter will give ± 6 9c spe ed setting
teeth of the fly wheel go through the magnetic lines o f ad justm ent. A ca pacitor can be used b etw een term in als
force around the pi ck up an A C voltage is m ade. T h e 15 and 16 to control the a m o un t of time it takes the
ratio b etw een the fre quency o f this voltage and the engine to go fro m low idle to rated speed. An oil
speed o f the en gine is directly proportional. An electric pressure switch is co nnected b etw een term in als 9 and
circuit inside the control box feels the A C voltage. In 10. This switc h is nor m ally open. W h e n the en gine oil
response it sends a DC control voltage, inversely p r o pressure increase s to 6 .4 ± 2 .7 psi (44 ± 19 kPa) the
portional to en gine speed, to the actuator. sw itch closes. T h is per m its the control to acce lerate the
en gin e to rated speed. If the oil pr ess ure decreases to
The actuator is co n n ected to the fuel sy stem by 3 . 9 ± 3.3 psi (27 ± 23 kPa) the control will return the
linkage. It chang es the electrical input fro m the control en gin e to low idle.
box to m echanical output that chang es the eng ine fuel
5 -3 2
SYSTEMS OPERATION
2301 NONPARALLEL CONTROL SYSTEM
5 -3 3
AUTOMATIC START/STOP SYSTEMS SYSTEMS OPERATION
An au tom atic start/stop sy stem is used when a set. W h en the normal p o w e r returns to the rated voltage
standby electric set has to give p o w e r to a system if the and freq ue ncy and the tim e delay (if so eq uip ped) is
normal (c om m erc ial) p ow er supply has a failure. There o ver, the transfer switch will return the load to the
are three main sections in the system . T hey are: the norm al p o w e r supply.
automatic tran sfer sw itc h, the cranking panel and the
electric set.
5 -3 4
AUTOMATIC START/STOP SYSTEMS SYSTEMS OPERATION
TRANSFFR
SWITCH
COMMERCIAL
POWE R □
- m -
IN IT IA T IN G
CONTACTOR
ft
5 -3 5
AUTOMATIC START/STOP SYSTEMS SYSTEMS OPERATION
ELECTRIC SET
T he c o m p o n e n ts o f the electric set are: the eng ine,
the generator, the starting m oto r, the battery, the shut-
o ff solenoid and signal sw itches on the engine. The
electric set gives em ergency p o w e r to drive the load.
CO NTRO L PANEL
Components of the automatic start/stop CO NTRO LS IN AUTO M ATIC POSITION:
ENGINE STARTING
system:
AR A uxiliary relay
CB Circuit breaker
CR C ran k ing relay
CT C ran kin g term inate relay (part o f OS)
D Diode
1R Initiating relay
MS Magnetic switch
OCT Overcran k timer
OPS Oil pressure shut of f switch
FPS Fuel pr essure switch
OS O v ersp ee d shut of f switch
PS Pinion solenoid
RR Ru n relay
RS R ack shut o ff switch
SM S tar ting M otor
SR S hu td o w n relay
SW1 A u to m atic/M an u a l switch CO NTRO L PANEL
CO NTRO LS IN AU TO M A TIC POSITION:
SW 2 O n / O f f/ S t o p switch
ENGINE STARTS
WT W ater tem per ature shut off switch
5 -3 6
SYSTEMS OPERATION
AUTOMATIC START/STOP SYSTEMS
CO NTRO L PANEL
C O NTRO LS IN AUTO MATIC POSITION:
EM ERGENCY POW ER NOT NEEDED
Automatic Stopping Operations
CONTROL PANEL
CO NTRO LS IN AU TO M A TIC POSITION:
SHUTDOW N BY PROTECTION CO M PO NENT
CONTROL PANEL
W h e n the contacts for any o f the shutdown sw itches
C O NTRO LS IN M ANUAL POSITION:
clos e, the sh utd ow n relay and the alarm light are e n e r ENGINE STARTING
gized. This de-energizes the initiating relay, run relay
and auxiliary relay. T h e rack solenoid is energized to
m ove the fuel rack to the fuel O F F position. A parallel Sw itch ( S W 1 ), in the M A N U A L position, rem o ves
circuit th rough the fuel press ure switch and the n o r m a l the initiating con tactor from the circuit. In the M A N
ly closed contact o f the run relay is also com pleted to U A L position the initiating relay and the run relay are
the rack solenoid. The sh utd ow n relay is en erg ized en er gized. This en ergizes the m agnetic switch and the
until switch (SW 2) is m anually turned to the O F F pinion solenoid . T h e starting m o to r is now con nected
position. to the battery. T he starting o peration starts. T he o ver
cr an k tim er is not in the circuit, so if the engine do es not
W h e n com m ercial p o w e r is started again, the initiat start, either switc h (SW 1) or ( S W 2 ) must be turned to
ing co ntactor op ens. This de-energizes the initiating an oth er position to stop the starting oper ation. W h en
relay, the run relay and the auxiliary relay. Current th en the en g ine starts, the mag netic switc h and the pinion
go es th rough the nor m ally closed co ntact o f the run solenoid are de-energized in the sam e way they are d e
relay to the rack solenoid. T h e rack solenoid is e n e r energized w hen the engine starts in the A U T O M A T I C
gized to m ove the fuel rack to the F U E L O F F position. position.
5 -3 7
AUTOMATIC START/STOP SYSTEMS SYSTEMS OPERATION
CONTROL PANEL
CO NTRO LS IN AUTO MATIC POSITION:
MANUAL SHUTDOW N
5 -3 8
SYSTEMS OPERATION
AUTOMATIC START/STOP SYSTEMS
5 -3 9
AUTOMATIC START/STOP SYSTEMS SYSTEMS OPERATION
this circuit, so if the en gine does not start, either switch ATTACHMENTS FOR CRANKING PANEL
(SW 1) or (SW 2) must be m oved to an oth er position to
stop the starting operation. W hen the engine starts, the Separate Alarm Lights
magnetic switch and the pinion solenoid are de-ener-
gized in the sam e way as they are de- energized when
the engine starts in the A utom atic Starting Operation.
5 -4 0
SYSTEMS OPERATION
AUTOMATIC START/STOP SYSTEMS
It' the (com m erc ial) norm al p o w e r stops before the If the initiating co ntactor (I) closes just as the engine
engine stops turning, the engine can start ru nning again stops turnin g the starting m oto r can activate almost
im m ediately. This is because the initiating co ntactor (I) im m ediately. This is because the oil pressure switch
closes again. This closes the circuit to run relay (RR) (OPS) is activated bv engine oil pressure. W h en the
and initiating relay (IR). T he run relay (RR) activates en gine stops running, the oil pressure de creases taste r
and o pens its norm ally closed contacts in the circuit than the en gine stops its m otion. It the engine does not
with the time delay relay (TD). T he time delay relay start running again because of the force of rotation of
(TD) is now di sc onnectd so it o pens its norm ally op en the flyw heel, the engine oil pr essure does not increase
contacts in the circuit with the sh uto ff solenoid (RS). to activate the oil pressure switch (OPS). It the oil
T he shutoff solenoid (RS) releases the fuel in the fuel pressure switch (OPS) does not activate, the starting
injection p um p. The g overnor controls the fuel su pply m o tor (SM ) activates when the initating relay (1R)
to the engine. The gov ern or gives the en gine m ore fuel closes its contacts.
to m ak e the spe ed increase to the correct spe ed for the
engine.
A175 52-1X1
5-41
TROUBLESHOOTING TESTING AND ADJUSTING
TROUBLESHOOTING
5 -4 2
TESTING AND ADJUSTING
TROUBLESHOOTING
5A3
TROUBLESHOOTING TESTING AND ADJUSTING
Cause Correction
W ron g Conn ectio ns C o nn e ct Battery to C and sh u to ff solenoid to N O connections.
C h eck co n nectio n s to ot her co m p o n en ts or m ake installation o f new
wiring.
W ro n g Setting of Switch M ake a test o f tem p eratu re setting and if n eces sa ry install new
co n tacto r switch with corre ct setting. See S P E C IF I C A T IO N S .
Cause Correction
W ro n g Setting o f Switch M ake a test o f tem p eratu re setting and if necessary install new
co n tacto r switch with correct setting. See S P E C IF I C A T IO N S .
3. C O N T A C T O R S W I T C H F O R O IL P R E S S U R E F A IL S T O A C T I V A T E S H U T O F F S O L E N O I D .
Cause Correction
W ron g C o nn e ction s Check co n nectio ns, wiring and corre ct where neces sa ry.
4. C O N T A C T O R S W I T C H F O R O V E R S P E E D F A IL S T O A C T I V A T E S H U T O F F S O L E N O I D .
Cause Correction
W ron g C o nn e ction s Check co n nectio ns, wiring and corre ct w h ere neces sa ry.
W ron g Setting o f Switch M ake a dju stm en t to setting o r install new c o ntacto r switch it
neces sa ry . M a k e re fe re nce to T E S T I N G A N D A D J U S T I N G .
Cause Correction
5 -4 4
TROUBLESHOOTING TESTING AND ADJUSTING
6. S H U T O F F S O L E N O I D F A IL S T O S T O P E N G IN E .
Cause Correction
P lunger Shaft A djustm ent W ron g M ake ad ju s tm ent to plu n ger shaft.
Not E n ou gh P lu n ger Travel Make a dju stm ent to p lun ger shaft or replace solenoid it necessary.
7. S H U T O F F S O L E N O I D P R E V E N T S E N G I N E S T A R T .
Cause Correction
S hutoff Solenoid Does Not O perate the control for the shutoff solenoid. Listen to r a noise. A
Oper ate Correctly s h utoff solenoid m akes noise w hen it works. It it m akes noise but
the eng ine still do es not start, rem o ve the shutoff solenoid. Try to
start the engine. If the eng ine starts, the shu toff solenoid is either
not installed correctly or it is bad. M ake re fe re nce to T E S T I N G
A N D ADJUSTING.
8. C L U T C H W I L L N O T E N G A G E ( SL IPS ), H E A T S O R L E V E R M O V E S T O R E L E A S E D P O S IT IO N .
Cause Correction
W ron g A djustm ent M ake a d justm en t to clutch en g a g e m e n t lever pull.
Alignm ent o f Fly wheel and Che ck and m ake ad justm ent to alignm ent.
Flywheel Housin g Mounting
Face and Bores
Ove rload on Clutch Re d u ce load or red uce en g in e sp eed when eng ag ing clutch.
9. C L U T C H S H A F T H A S T O O M U C H E N D P L A Y .
Cause Correction
Bearing W o rn or A dju stm ent W ron g Re p la ce a n d / o r m ake a dju stm ent to shaft bearing.
10. C L U T C H B E A R I N G S H A V E S H O R T S E R V I C E LIF E.
Cause Correction
Too M uch Bearing Clea rance R e pla ce a n d / o r make adju s tm en t to shaft bear ing.
11. H Y D R A - M E C H A N I C A L S H U T O F F W I L L N O T L E T E N G IN E S T A R T .
Cause Correction
Air Inlet Shutoffs Closed R eset air inlet shutoff plates.
L o w Oil Press ure At C h e ck en gin e oil press ure at cr ank ing spe ed. Oil pressure must be a
Cran kin g Speed m in im u m o f 20 psi (140 kPa).
5 -4 5
TROUBLESHOOTING TESTING AND ADJUSTING
C ause C orrectio n
L ow Engine Oil Pressure Check en g ine oil press ure. Oil pressure must be a m in im u m o f 30
psi (205 kPa).
13. H Y D R A - M E C H A N I C A L S H U T O F F A C T I V A T E S W I T H E N G I N E O IL P R E S S U R E A N D W A T E R
TEM PERATURE NORMAL.
C au se C orrectio n
Orifices Have A C h e ck and clean, if need ed, the orifice in the di verter valve and the
Restriction orifice in the en g ine oil pr ess ure sensing line.
14. E L E C T R I C A L G A U G E S G I V E W R O N G R E A D I N G S .
Sending Units Have A Failure C h e ck the se n din g units and install new ones if necessary.
15a. E N G I N E W I L L N O T S T A R T .
C au se C o rre ctio n
Engine Fuel System Has A Failure If the ac tuator m ov es the fuel control linkage to the start position ch eck
the fuel system . Use the F U E L S Y S T E M section in T E S T I N G A N D
A D J U S T I N G as a refe re nce. M ake repairs as necessa ry.
Control Output Polarity Revers ed Revers e the actuator co n nectio n s to T5 and T6.
Short or O pen Betw een the Control C h e ck all wiring and co nnections. Make repairs as neces sa ry. Clean
and the Actuator and tighten all co nnections.
Actuator Has A Failure Check the actuato r coil resistan ce. If it is not ap proxim ately 35 o hm s
m ake a replacem en t o f the actuator.
Fuel Control Lin kage Has Check linkag e fo r correct installation and operation. Make repairs as
Failure neces sa ry .
No S upply V oltage to the Control C h e ck T 2 ( + ) and T1 (-) for voltage. If the vo ltag e at these terminals
is not the sam e as the su pply voltage ± 10% ch eck the wiring betw een
the control and the sour ce o f su pply v o l t a g e . M ake repairs as n e c e s s a ry .
(Cont. next p a g e . )
5 -4 6
TROUBLESHOOTING TESTING AND ADJUSTING
15a. E N G I N E W I L L N O T S T A R T .( C o r n .)
Cause Correction
No Output Vol tage from the C h e ck T 6 ( + ) and T 15 (-) for voltage. If the voltage is not 9 ± 1 V DC
Control m ake a rep lacem ent o f the control.
R A T E D S P E E D Potentiom eter Increase the setting by clockw ise rotation of the p otentiom eter until
Settine is L o w e r than C ranking the actu ato r m o ves the fuel control linkage to the start position.
Speed
CAUTION
If clockwise adjustment of the RATED SPEED potentiometer
does not cause the linkage to move to start position, return
the potentiometer to normal start position (less than two
turns from full counterclockwise).
L O W ID L E S P E E D P oten tiom eter Increase the setting by clockw ise rotation o f the po ten tiom eter .
Setting is T o o Low
Short or O p en Betw een the C h eck all wiring and connections. M ake repairs as necessa ry. Clean
Magnetic P ickup and the Control and tighten all connections.
Magnetic P ickup Not Installed A djust the distance b etw een the m agnetic p ick up and the ring gear.
Correctly
M agnetic P ickup Has A Failure C h eck T7 and T8 for voltage while cranking. If it is less than 1V AC
m ake a replacem en t o f the m agnetic pickup.
Failsafe Circuit o f the Control R e m o v e the j u m p e r b etw een T3 and T4. If the fuel control linkage
Has A Failure m o v es to the start position m ak e a replacem en t o f the control.
CAUTION
Be ready to control the engine speed manually. With the fail
safe jumper removed the engine can overspeed. This can
cause damage to engine components.
R A T E D S P E E D Potentiom eter If optional S P E E D T R I M p otentio m eter is not used m ak e sure T1 1 and
Has a Failure T12 are ju m p e r e d .
15b. E N G I N E O V E R S P E E D S O N S T A R T S .
Cause Correction
Accele ra tion fro m L ow Idle to A d d capac itanc e b etw een T 1 5 and T 16. T w o se conds increase in
Rated S peed is T o o Fast acce le ra tion tim e per 50 uf; 20 0 u f m a xim um .
R A T E D S P E E D P oten tiom eter Decrease the setting by c ou nterclo ck w ise rotation o f the potentiom eter.
Setting T o o High
5-47
TROUBLESHOOTING TESTING AND ADJUSTING
15b. E N G I N E O V E R S P E E D S O N S T A R T S . (Cont.)
Cause Correction
Short in the System C h e ck for correct shielding and system gro u n d. Make repairs as
neces sa ry.
Control Has A Failure C h e ck T5 (-) and T 6 ( + ) for voltage. If the control does not decr ease
the v oltage to the actuator as the R A T E D S P E E D p oten tiom eter is
turned co un terclockw ise m ake a r eplacem ent o f the control.
15c. E N G IN E O V E R S P E E D S A F T E R O P E R A T I O N A T R A T E D S P E E D F O R S O M E T IM E .
Cause Correction
Engine Fuel System Has A Use the F U E L S Y S T E M section in T E S T I N G A N D A D J U S T I N G as
Failure a reference. M a k e repairs as necessary.
M agnetic P ickup Signal and Find and corre ct the signal failure and replace the control.
Failsafe Circuit o f the Control
Have A Failure
Control Has A Failure Control the en gine m anually b etw een low idle and rated speed. T urn the
R A T E D S P E E D p otentio m eter fully cou n terclo ckw ise. If the output
voltage at T5 (-) and T 6 ( + ) is not zero m ake a replacem ent o f the
co n t r o l .
15d. L O W ID L E S P E E D P O T E N T I O M E T E R G I V E S N O A D J U S T M E N T .
Cause Correction
L O W ID L E S P E E D P o tentio m eter T urn the p o ten tiom eter clockw ise to increase the setting.
Setting is T o o L ow
Control Has A Failure If a d justm en t o f the L O W I D L E S P E E D p o tentio m eter, with the low
idle speed switch open, do es not ch ang e the outp ut voltage at T5 (-)
and T 6 ( + ) m a k e a replacem en t o f the control.
Cause Correction
Control Has A Failure R e m o v e the wiring fro m T 9 and T 10 . If the en gine does not return to
low idle m ake a replacem ent o f the control.
5 -4 8
TESTING AND ADJUSTING
TROUBLESHOOTING
15f. E N G I N E S P E E D D O E S N O T H A V E S T A B IL I T Y .
Cause Correction
Wiring is Not Correctly Shielded Ad d sh ield ing or m ove the wiring aw ay fro m wires or c o m p on en ts that
from Electrical Noise carry high current.
Fuel Control L in kage W o rn or Inspect a nd adjust fuel control linkage. M ake repairs as necessary.
not Cor rectly Adjuste d
S upply Voltage to the Control C h eck T2 ( + ) and T1 (-) for voltage. If the voltage at these terminals
is Low is not the sa m e as the supply voltage ± lOCr check the wiring b etw een
the control and the source o f supply voltage. M ake repairs as necessary.
M agnetic P ickup Wiring Has M ake rep lacem ent o f the wiring.
A Failure
15g. S P E E D T R I M P O T E N T I O M E T E R G I V E S N O A D J U S T M E N T .
Cause Correction
S P E E D T R I M P otentiom eter M ake rep lacem en t o f the potentiom eter.
Has A Failure
15h. R A T E D S P E E D P O T E N T I O M E T E R G I V E S N O A D J U S T M E N T .
Cause Correction
R A T E D S P E E D P oten tiom eter M a k e rep lacem ent o f the control.
Has A Failure
15i. L O A D S H A R I N G IS N O T C O R R E C T .
Cause Correction
Engine Fuel S y stem Has A Failure Use the F U E L S Y S T E M section in T E S T I N G A N D A D J U S T I N G as
a refe re nce. M ake repairs as necessary.
Fuel Control Lin kage W orn In sp ect and adjust fuel control linkage. M ake repairs as necessary.
or Not Correctly Adjusted
5 -4 9
TROUBLESHOOTING TESTING AND ADJUSTING
15j . E N G IN E S P E E D IS N O T I S O C H R O N O U S .
Cause Correction
16a. E N G I N E W I L L N O T S T A R T .
Cause Correction
Engine Fuel System Has A Failure If the actuator m o ves the fuel control linkage to the start position
check the fuel system . Use the F U E L S Y S T E M section in T E S T I N G
A N D A D J U S T I N G as a reference . Make repairs as necessary.
Control O utp ut Polarity Reversed R everse the actuator co nn ectio ns to T16 and T17.
Short or O pen Betw een the Control C h e ck all wiring and co nnections. M ake repairs as necessary.
and the A ctu ator C lean and tighten all co nnections.
A ctu ato r Has A Failure C h e ck the actuator coil resistance. If it is not approxim ately 35
o h m s m ak e a rep lacem ent o f the actuator.
Fuel Control L in kage Has A Failure C h e ck linkage fo r correct installation and oper ation. Make repairs
as n eces sa ry .
No S upply Voltage to the Control O n 32 V sy stem s check T 2 5 ( + ) and T13 (-) for voltage. On 24V sy s
tem s check T12 ( + ) and T13 (-) for voltage. If the vo ltage at these
t er m inals is not the sa m e as supply voltage ± 10 9c check the wiring
b etw een the control and the so urce o f supply voltage. Make repairs
as neces sa ry .
No O utput Voltage from the C h e ck T28 ( + ) and T13 (-). If the voltage is not approxim ately 21V
Control D C m a k e a replacem en t o f the control.
R A T E D S P E E D P otentiom eter Increase the setting by clockw ise rotation o f the p otentiom eter until
Setting is L o w er than Crank ing the actuator m ov es the fuel control linkage to the start position.
Speed
CAUTION
If clockwise adjustment of the RATED SPEED potentiometer
does not cause the linkage to move to start position, return
the potentiometer to normal start position (less than two
turns from full counterclockwise).
L O W ID L E S P E E D P o ten tio m eter Increase the setting by clo ck w ise rotation o f the p otentiom eter
Setting Is T o o Low
R A M P T I M E Potentiom eter Increase the setting by clockw ise rotation ot the potentiom eter .
Setting is T o o Low
Short or O p en Betw een the C h e c k all wiring and co nn ectio ns. M a k e repairs as necessary. Clean
M agnetic P ick up and the Control and tighten all co nnections.
5-50
TROUBLESHOOTING TESTING AND ADJUSTING
16a. E N G I N E W I L L N O T S T A R T (C ont.)
Cause Correction
Magnetic P ickup Not Installed Adjust the distance b etw een the magnetic pick u p and the ring gear.
Correctly
Magnetic Pick up Has A Failure Check T 1 8 and T 1 9 for voltag e while cranking. If it is less than IV AC
m ake a rep lacem en t of the mag netic pickup.
Failsafe Circuit of the Control R e m o v e the j u m p e r b etw een T 2 9 and T 30. It the fuel control linkage
Has A Failure m o v es to th e start position m ak e a replacem ent ot the control.
CAUTION
Be ready to control the engine speed manually. With the
failsafe jumper removed the engine can overspeed. This can
cause damage to engine components.
R A T E D S P E E D P o tentio m eter If optional S P E E D T R I M p otentio m eter is not used m ake sure
Has A Failure T 2 0 and T21 are j u m p ered .
16 b. E N G I N E O V E R S P E E D S O N S T A R T S .
Cause Correction
Acce leration F ro m L ow Idle to Turn R A M P T IM E p o ten tio m eter clockwise. T h is will decr ease the
Rated Speed is T o o Fast acce le ra tion rate.
R A T E D S P E E D Potentiom eter Decrease the setting by co u nterclo ck w ise rotation o f the potentiometer .
Setting T o o High
Control Has A Failure C h eck T 1 6 (-) and T 17 ( + ) for voltage. If the control does not decr ease
the v oltage to the actuator as the R A T E D S P E E D p oten tiom eter is
tur ned co un terclockw ise m ake a r ep lacem ent o f the control.
5-51
TROUBLESHOOTING TESTING AND ADJUSTING
16c. E N G IN E O V E R S P E E D S A F T E R O P E R A T I O N A T R A T E D S P E E D F O R S O M E T IM E.
Cause Correction
Engine Fuel System Has A Failure Use the F U E L S Y S T E M section in T E S T I N G A N D A D J U S T I N G as
a refe re nce. M ake repairs as necessary.
Magnetic Pick up Signal and Find and correct the signal failure and replace the control.
Failsafe Circuit of the Control
Have a Failure
Control Has A Failure Control the engine m an ually b etw een low idle and rated speed. T urn the
R A T E D S P E E D po ten tiom eter fully co u nterclock w ise. If the output
voltage at T 16 (-) and T17 ( + ) is not zero m ak e a replacem ent o f the
control.
16d. L O W ID L E S P E E D P O T E N T I O M E T E R G I V E S N O A D J U S T M E N T .
Cause Correction
L O W ID L E S P E E D P otentiom eter Turn the p o ten tiom eter clo ck w ise to increase the setting.
Setting Is T o o Low
Control Has A Failure If a d ju stm ent o f the L O W ID L E S P E E D po ten tiom eter, with the low
idle speed sw itc h op en , do es not change the output voltage at T 1 6 (-)
and T 1 7 ( + ) m ak e a replacem en t o f the control.
Cause Correction
Control Has A Failure R e m o v e the wiring f ro m T 14 and T 15. If the en gine does not return to
low idle m ak e a rep lacem en t o f the control.
16f. E N G IN E S P E E D D O E S N O T H A V E S T A B IL I T Y .
Cause Correction
G A I N and S T A B IL I T Y Adjust thes e po tentiom eters.
P otentiom eters are not Cor rectly
Adjusted
W iring is not Correctly Shielded Ad d sh ield ing or m ov e the wiring aw ay fro m wires or c o m po n en ts that
fro m Electrical Noise carry high current.
Fuel Control L in kage W o rn or not Insp ect and adjust fuel control linkage. M ake repairs as necessary.
Correctly Adjusted
5 -5 2
TROUBLESHOOTING TESTING AND ADJUSTING
16f. E N G I N E S P E E D D O E S N O T H A V E S T A B I L I T Y . ( C o n t . )
Cause Correction
Supply Voltage to the Control O n 32V system s check T 25 ( + ) and T 13 ( - ) for voltage. On 24V
is L ow sy stem c h e c k T 12 ( + ) and T 13 ( —) for voltage. It the voltage at these
ter m in als is not th e sam e as supply voltage ± 10% check the wiring
b etw een the control and the source ot supply voltage. M a k e repair as
neces sa ry .
16g. S P E E D T R I M P O T E N T I O M E T E R G I V E S N O A D J U S T M E N T .
Cause Correction
S P E E D T R I M P oten tiom eter M ake a rep lacem en t o f the pot en tiom eter .
Has A Failure
16h. R A T E D S P E E D P O T E N T I O M E T E R G I V E S N O A D J U S T M E N T .
Cause Correction
R A T E D S P E E D P otentiom eter M a k e replacem en t o f the control.
Has A Failure
16i. L O A D S H A R I N G IS N O T C O R R E C T .
Cause Correction
Engine Fuel S ystem Has A Failure U se the F U E L S Y S T E M section in T E S T I N G A N D A D J U S T I N G as
a refe re nce. M ake repairs as necessa ry.
Fuel Control L in kage W o rn or not Insp ect a n d adjust fuel control linkage. M ake repairs as necessary.
Cor rectly Adjusted
Rated S peed Settings o f All R e m o v e all load from the system . Adjust the R A T E D S P E E D
Units in Parallel are not the Sam e p otentiom eters so that the speed o f each unit is the same.
Load G ain V oltag es o f All Units Ad ju st the L O A D G A I N p otentiom eters so that the load gain voltage
in Parallel are not the Sam e o f each unit is the same.
Paralleling Contacts Are Dirty or Clean an d inspect the contacts. M ake repairs as n eces sa ry . Clean and
H av e A Failure tighten all connections.
5-53
TROUBLESHOOTING TESTING AND ADJUSTING
16j . E N G I N E S P E E D IS N O T I S O C H R O N O U S .
Cause Correction
E ngine is O verloaded If the en gin e gives rated h o rsep o w er at the m a x i m u m fuel position,
de crease the load on the engine.
Load Sensing Phasing is not Check voltage, current and tran sfo rm er wiring. M ake repairs as
Correct necessa ry.
16k. S Y S T E M D O E S N O T H A V E S T A B I L I T Y W H E N P A R A L L E L I N G O R IN P A R A L L E L .
Cause Correction
L O A D G A I N Potentiom eters Adjust these potentiom eters.
not Correctly Adjusted
Load Has A Cycle D ecrease the gain and increase the stability po ten tiom eter settings.
Voltage R e g u la to r Response is in Adjust the voltag e re gulator to a slow er resp onse rate.
Phase With the Control R esponse.
17a. E N G IN E S P E E D D O E S N O T H A V E S T A B IL I T Y .
Cause Correction
C o m p en s ation A djustm ents Incorrect A djust ne edle valve and c o m p en sation a dju stm ent pointer.
Dirty Oil in G o v ern o r Drain oil. Clea n g o v er n o r and refill with oil.
Low Oil Level A d d oil to correct level. C he ck for leaks, espe cially at drive shaft.
Air In Oil (Fo am ) in G o v ern o r Drain oil. Refill with correct grade o f oil.
L ow G o v e r n o r Oil Pressure C h e ck corre ct oil level. Oil p u m p check valves do not seat. Replace
valves. Oil p u m p worn. R e pla ce parts.
5 -5 4
TROUBLESHOOTING TESTING AND ADJUSTING
17b. F U E L C O N T R O L R E S P O N S E W H E N E N G I N E IS S T A R T E D IS N O T A C C E P T A B L E .
Cause Correction
Low Oil Pressure in G o v e r n o r oil p u m p worn. R e pla ce parts. C h e ck valves do not seat.
G o vern or Re p la ce parts.
17c. E N G I N E IS S L O W T O R E S P O N D T O A S P E E D O R L O A D C H A N G E .
Cause Correction
C o m p en s atio n Adjustm ents Adjust ne edle valve and com p en s atio n pointer.
Incorrect
Low Oil Press ure in G o v e r n o r oil p u m p w orn. Repla ce parts. C h e ck valves do not seat.
Go v ern o r Repla ce parts.
Cause Correction
Speed D roo p A djustm ent Adjust d ro o p on each unit to g et the desired division o f load.
Is Not Cor rect N O T E: Incre ase droop to decrease load sharing by the unit.
Different S peed Settings Adjust sp eed settings. No load high idle spe ed on all units m ust be the
On Units same.
Cause Correction
S peed Droop Setting on Adjust d ro o p on each unit to get the desired division o f load.
One or More Units is Not N O T E: Incre ase droop to d ecrease load sharing by the unit.
Correct
Different Speed Settings Ad ju st the sp eed settings. N o load spe ed on all units should be the
5 -5 5
TROUBLESHOOTING TESTING AND ADJUSTING
The charts that follow give som e o f the p roblem s and pro bable causes for trouble
with au tom atic start/stop systems.
— No fuel — Battery does not have enough — Open circuit or very high resistance
— Fuel rack not moving charge in circuit to the magnetic switch
— Governor not operating
— W rong injection timing — Bad cable connections — Magnetic switch has a failure
— Very low air temperature
— Restriction in air inlet — Starting motor has a failure — Circuit breaker has a failure
— Low com pression
5 -5 6
TESTING AND ADJUSTING
TROUBLESHOOTING
— No load
— O verload
— Mechanical failure
5 -5 7
TROUBLESHOOTING TESTING AND ADJUSTING
— 1V, 2V or 3V relay contacts not clos — IR relay has a failure — TS main contacts welded
ing or bad contact
— RR relay has a failure (not always — TS auxiliary contacts bad
— SE relay has a failure fitted)
— SE relay contacts bad
— TS switch a nd /or contacts not — TD relay has a failure (not always
operating fitted)
— SE contacts welded
5-58
MEASURING ENGINE SPEED TESTING AND ADJUSTING
5 -5 9
PIERCE OUTPUT SHAFT GOVERNOR TESTING AND ADJUSTING
A gT
Di sc onnect the adjusta ble linkage (3) fro m the 10. Start the diesel engine. After a re aso nable w a r m
terminal lever ( l ) and the other adjustable linkage up p er iod m ove the diesel en gin e go verno r control
(12) b etw een the servo m ech an is m (14) and stan lever to the full open position.
dar d gov ernor.
11. A d just the ou tput shaft sp eed to the m a x i m u m
Position the speed chang e lever (4), with low and d es ired sp eed with the aid o f the low spe ed ad ju st
high sp eed adjusting sc re ws (8 and 9) so the rate ing scre w (8). Turn the scre w clockwise to raise
adjusting screw (2) and the go v ern o r spring (5) are the speed and cou n terclockw ise to low er the
ap proxim ately parallel to lever (7). sDeed.
5 -6 0
PIERCE OUTPUT SHAFT GOVERNOR TESTING AND ADJUSTING
12. If a surging condition is en co u ntered , back off the Turn ing the low spe ed adjusting screw clockwise
nut on the rate adjusting sc rew one full turn. Turn will increase the leverage o f the gov erno r spring (5) on
the low spe ed adjusting sc rew clockwise to return the lever (7) and increase sp eed, with the result that
the output shaft spe ed to the des ired R P M . C o n m in im u m tensio n on the spring is now required. This
tinue this procedure until all surge is r em ov ed . If it adjustm ent will prov ide the m ost sensitive regulation.
is not possible to rem o v e all su rge, set the g o v er W h en the load is rem o ved su dd e n ly , the engine should
nor at the setting which will produce the least not surge in excess o f four (4) cycles . W hen the load is
am o u n t o f surge and r em o v e the re m aining su rge gradually r e m o ved, no surge sh ould be evident.
by turnin g the b u m p e r sc rew clockwise until it j u s t
13. With the output shaft running at the desired speed
m akes contact with the rocker yoke.
setting, turn the high spe ed adjusting sc rew (9)
until the end o f the screw co ntacts the stop bracket
CAUTION
(10). Lock the high speed screw in this position.
Turning the bumper screw in beyond this point
will raise the output shaft speed and eventually
damage the internal parts of the governor. The
bumper screw should not be used to remove
speed surges of greater than 50 RPM.
5-61
WOODWARD SGT GOVERNOR TESTING AND ADJUSTING
. ^5
5 -6 2
TESTING AND ADJUSTING
WOODWARD SGT GOVERNOR
BRACKET INSTALLED
8. T u rn the adjustm ent scre w co un terclo ck w ise to
1. Bracket.
increase the fuel rack travel or clock wise to d e
3. Disc onnect the linkage from the gov erno r te r m i crease rack travel. W h e n the fuel rack is adjusted
nal shaft and move the fuel rack to the F U E L - corre ctly , m ove the lock to engage the nearest
O F F position. Install dial indicator (2) with c o n notch with the pin. T ighten the locknut and install
tact point (3) on bracket ( l ) . the c ov er and lockwire and seal.
4. Put sp acer (6) betw een the flange on the rod and
the bracket. Push the flange towards the fuel p u m p
h ousing to hold the sp acer tight. Adjust the dial
ind icator so that the revo lution cou n ter is at zero. ENGINE GOVERNOR SPEED DROOP
T ig hten the clam p for the indicator. Turn the dial
1. Cut lockwire and rem o ve the top co v er o f the
go vernor.
2. R e m o v e flexible coupling.
5 -6 3
WOODWARD SGT GOVERNOR TESTING AND ADJUSTING
6. Install flexible coupling and the top co ver o f the 2. Cut the lockwire and rem o v e the top co ver o f the
governor. governor.
7. Install lock wire and seal. 3. Put a load on the engine according to the s p ecifica
tions for full load spe ed o f the tor que conver ter.
TORQUE CONVERTER GOVERNOR HIGH E n gin e sp eed at full ra ck position m ust be within
IDLE SPEED ADJUSTMENT 10 rp m o f the specifications.
NOTE: High idle, full load spe ed and no load spe ed for 4. If the rack is open at a speed h ig her than full load
the torque co nv erter can be found on the information speed, m o v e the d ro op lever in the direction o f the
plate in the en gine co m p artm en t o f the m achine. rear o f the en gine to cause an increase in droop.
1. Start the engine and en g ag e the clutch. 5. If the rack is not open at full load spe ed, m ov e the
d roop lever in the direction of the front o f the
2. M ove the gov ern or control lever to the high idle engine to cau se a d ecrease in droop.
position.
6. Install lockwire and seal.
3. Make adjustm ents to the high idle screw (1) o f the
co nv erter go verno r to keep en gine sp eed to
specifications. GOVENROR LINKAGE ADJUSTMENT
Tools Needed:
1P2385 Protractor Tool
l. Install the 9 S 24 0 Tool G rou p. 1. M o v e lever (1) and lever (3) clo ck w ise to the
angles show n.
NOTE: M ake reference to F U E L R A C K A D J U S T
M E N T for W O O D W A R D S G T G O V E R N O R S for 2. Adju st the length o f linkag e (2) to fasten to the
installation instructions of the 9 S 2 4 0 Tool G roup. outside holes o f levers (1) and (3).
5 -6 4
WOODWARD SGT GOVERNOR TESTING AND ADJUSTING
G OVERNOR LINKAGE
1. Governor lever. 2. Linkage. 3. Lever.
5 -6 5
WOODWARD UG8 DIAL GOVERNOR TESTING AND ADJUSTING
5. Loosen the nut that holds the co m p en satio n p oin t If the com pensation poi nter is too far toward the
er and m ove the po inter d o w n as far as it will go. m a x im u m position, the engine spe ed change will be too
T ighten the nut. great when the load changes.
5 -6 6
WOODWARD UG8 DIAL GOVERNOR TESTING AND ADJUSTING
5 -6 7
WOODWARD UG8 DIAL GOVERNOR TESTING AND ADJUSTING
BRACKET INSTALLED
1. Bracket.
3. I u rn th e g o v e r n o r lo ad limit k n o b to ten a n d
in stall dial i n d i c a t o r (2) with c o n t a c t p o i n t (3)
o n b r a c k e t ( I ).
CAUTION
Do not force the governor linkage toward in
creased fuel unless the load limit knob is
turned to TEN. The result will be damage to the
C O VER FOR RACK A D JUSTING SCREW
governor.
7. Lockwire. 8. Cover.
4. Put sp acer (6) b etw een the flange on the rod and
the bracket. Push the flan ge to w ard the fuel p u m p
h ousing to hold the spacer tight. Adjust the dial
ind icator so that the revolutio n co un ter is at zero.
T ig hten the clam p for the indicator. T urn the dial
o f the indicator until the zero is in alignm en t with
the hand . R e m o v e the spacer.
5 -6 8
WOODWARD UG8 DIAL GOVERNOR TESTING AND ADJUSTING
LFVER -TO-LEVtK
J -V
3 Isrt
a ¥r ,-2
5 -6 9
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
5-70
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
LOW AND HIGH IDLE SPEED ADJUSTMENT 3. After the high idle spe ed has been adjus ted, tight
en the locknut and ch eck high idle speed again.
C o nn ect a tach om eter with g oo d accuracy to the
engine. Vlake reference to M E A S U R I N G E N G I N E NOTE: M a k e reference to the R A C K S E T T I N G I N
SPEED. F O R M A T I O N for the correct low and high idle speed.
1. Start the engine and run to get the en gine to the 4. M o v e the g o verno r speed adju sting lever (5) to run
norm al tem per ature of oper ation. the en gin e at low idle spe ed. L o o sen locknut (2)
and turn low idle adju stm en t sc rew ( l ) . T urn a d
j u stm e n t screw (1) clo ck w ise to increase low idle
speed and cou n terclo ck w ise to d ecr ease low idle
speed.
-“4^1
t 5 ! 55X t
2. M ove the gov ernor speed adjusting lever (5) to run
the en gine at high idle speed. L oose n locknut (4)
RACK PO SITIONING TO OLS
and turn high idle adju stm en t sc rew (3). T u rn
1. 9S 227 Bracket Group. 2. 8S2283 Dial Indicator. 3.
ad justm ent screw (3) clo ck w ise to decr ease eng ine 8S3675 Contact Point .125 in. (3.18 m m ) long.
spe ed and co un terclo ck w ise to increase en g ine
speed. 1. R e m o v e timing pin (4), c la m p (5), and the plug
and seal behind the clam p.
LOW AND HIGH IDLE STOP LEVERS TIMING PIN AND CLAM P
6. Low idle stop lever. 7. High idle stop lever. 4. Tim ing pin. 5. Clam p.
5-71
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
r
CO VER FOR RACK AD JUSTING SCREW
7. Lockwire. 8. Cover.
BRMCrveT INSTALLED
1. Bracket. 8. T urn the adjustm ent sc rew co un terclockw ise to
increase the fuel rack travel or clockwise to d e
3. Disc onnect the linkage fro m the gov ern o r term i crease rack travel. W h e n the fuel rack is adjusted
nal shaft and move the fuel rack to the F U E L - corre ctly , m ov e the lock to eng ag e the nearest
O F F position. Install dial indicator (2) with c o n notch with the pin. Tig hten the locknut and install
tact point (3) on bracket ( l ) . the co v e r and lockwire and seal.
4. Put sp acer (6) betw een the flang e on the rod and
the bracket. Push the flan ge to w ard s the fuel pu m p
housing to hold the spacer tight. Adjust the dial SPEED DROOP ADJUSTMENT
indicator so that the revolutio n cou n ter is at zero.
T ig hten the clam p for the indicator. T urn the dial Adjustment for Zero Droop
o f the indicator until the zero is in alignm ent with Tools Needed:
the ha nd. R e m o v e the spacer. 8S2328 Dial Indicator Group.
5P7264 Indicator Contact Point Group.
7. T o adjust the rack travel, cut lockwire (7) and DIAL INDICATOR INSTALLED
rem o ve co v er (8). Loo sen the adjustm en t scre w 1. Speeder plug. 2. Bracket. 3. Droop cam . 4. G overnor
locknut and m ove lock free of pin. term inal lever. 5. Screw.
5 -7 2
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
5. If the d roo p adjustm ent is not correct, loosen 6. R e m o v e all load from the en gine and make a note
screw (5) and m ove droop c am (3). Tig hten sc rew o f the no load high idle rpm.
(5). M ove dro op cam (3) to w ard speeder plug (1)
7. Find the differen ce of the no load high idle rpm
to increase dro op , and aw ay fro m the sp eeder plug
and the full load rpm. Div ide the dif ference by the
to decrease droop.
full load rp m and multiply tim es 100. The result is
6. C h e ck the speed d roop ad justm ent again with the the per cent o f speed droop.
dial indicator. No load high idle speed - full load rpm v in n % of
■ Full load rpm speed droop
with the eng ine running. A. A ngle setting indicator. B. Protractor plate edge
aligned with lever. C. Vertical housing face and extension
arm alignm ent. D. Level bubble. E. Extension arm aligned
4. Start the engine and get to the norm al t e m
with lever. G. Extension arm aligned with lever. H. Plate
per ature o f operation. edge aligned with second lever. I. A ngle setting indicator.
5 -7 3
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
5 -7 4
WOODWARD EG-3P ACTUATOR TESTING AND ADJUSTING
BRACKET INSTALLED
1. Bracket.
4. Put spacer (6) betw een the flan ge on the rod and
the bracket. Push the flan ge t ow ards the fuel p u m p
h ou sing to hold the spacer tight. Adjust the dial
indicator so that the revolutio n co un ter is at zero.
T ighten the clam p for the indicator. Turn the dial
RACK POSITIONING TO OLS of the indicator until the zero is in alignment with
1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. the han d. R e m ov e the spacer
8S3675 Contact Point .125 in. (3.18 mm) long.
2. Fasten bracket (1) to the fuel p u m p hou sing. 6. Read the rack travel m eas u rem en t on the dial
indicator and com pare with the m easu rem ent g iv
en in the R A C K S E T T I N G I N F O R M A T I O N .
3. Disc onnect the linkage from the actuator term in al
shaft and m ove the fuel rack to the F U E L - O F F 7. T o adjust the rack travel, cut lockwire (7) and
position. Install dial indicator (2) with contact rem ov e c ov er (8). L oose n the adjustm en t screw
point (3) on bracket (1). locknut and m ove lock free o f pin.
5 -7 5
WOODWARD EG-3P ACTUATOR TESTING AND ADJUSTING
5 -7 6
2301 CONTROL SYSTEMS TESTING AND ADJUSTING
MAGNETIC PICKUP
MAGNETIC PICKUP
1. Clearance dim ension. 2. Magnetic pickup. 3. W ires. 4. EG-3P ACTUATO R
Locknut. 5. Flywheel gear. 6. Adapter.
3. If th e coil resis ta n c e is n o t 30 t o 40 o h m s m a k e
1. C ran k the engine. Use a voltm eter to check the a r e p l a c e m e n t ot the a c t u a t o r .
output o f the m agnetic p ickup. M inim um c r a n k
ing voltage is l.OV. M in im u m voltage at 1500
rp m is 10V. If these vo ltages are not correct m ake
an ad justm ent as follows:
Stability and Gain Potentiometers 5. If any o f the units in the system have stability
prob lem s at this load gain setting, decrease the
1. C o n n e c t a DC' v o l t m e t e r to t e r m in a ls 16 ( —) setting for each unit a small am ou nt. K eep the load
a n d 17 ( J ) o n the p arallel c o n t r o l [ t e rm i n a l s signal for each unit in the sy stem the same.
5 (--) a n d b ( + ) on th e n o n p a r a l l e l c o n tr o l],
6. If the load signal at full load is decreased to 3 V in
2. Start the engine. Run the en gine until the coolant Step 5 and the system still has a stability p ro blem
tem perature is normal. do the steps that follow.
3. Turn gain potentiom eter (3) clockwise until the 7. Parallel all o f the units in the sy stem at no load.
v oltm eter does not have stability.
8. If the system has instability turn the stability p o
4. Turn stability po tentiom eter (2) either direction tentiom eter o f each unit one mark co u n te r c lo c k
until the voltm eter has stability. wise. Do this until the system has stability.
5 Do Steps 3 and 4 several tim es until the stability 9. Put a load on the system. If the sy stem has insta
po ten tio m eter will not give the voltm eter st a b il ity. bility turn the stability po ten tiom eter o f each unit
6. Turn the gain p otentiom eter a small am ou n t c o u n one mark co u nterclockw ise. Do this until the sy s
tem has stability .
terclockwise . Adjust the stability p o ten tio m eter as
neces sa ry. NO TE: T h e g enerator voltage re gulator respons e may
be too fast. Use a manual voltage regulator. If this stops
Ramp Time Potentiometer the instability, slow dow n the resp on se of the generator
voltage regulator.
Turn ram p time p oten tiom eter (4) clockwise to in
crease or co u nterclockw ise to d ecrease the am o un t o f
time it takes the engine to accelerate from low idle to Droop Potentiometer
full load rpm.
T h e am o un t o f speed d roop adju stm en t available will
Low Speed Potentiometer vary with the application from 0 to 1397. The desired
speed d roo p will be different for different applications.
1. M a k e su re t h e r e is a n o p e n b e tw e e n te r m in a ls Speed d roo p is the percent diffe rence betw een the e n
14 a n d 15 ( t e r m i n a l s 9 a n d 10 o n the n o n p a r a l l e l gine speed at no load and full load. To calculate speed
co n tr o l). droo p use the formula:
2. Turn low speed po ten tio m eter clock wise to in
crease or co unterclockw ise to decr ease the low No load high idle speed - full load rpm x iq q = % of
Full load rpm speed droop
idle rpm.
1. Get the des ired spe ed d roop for the application.
Load Gain Potentiometer
2. Multiply the full load spe ed by the des ired speed
NO TE: Stability and gain p otentiom eters must be c o r
droop. A d d the n u m b er fro m this multiplicatio n to
rectly adjus ted first.
the full load spe ed to get the no load speed.
1. Put the pr obes o f a voltm eter in the load signal
3. Run the en gine until the coolant tem perature is
jacks (9).
norm al.
2. Run the engine in single unit operation until the
4. Adjust the engine speed to get the no load speed
coolant tem per ature is normal.
for Step 2.
3. Put a full load on the gen er ator. Adjust load gain 5. C o n n e ct a k now n load to the engine. The load
po tentiom eters until the load signal readi ng on the must be less than the full capacity of the engine.
voltm eter is 8V. If it is not poss ible to put a full M ake a recor d o f the de crease in en gine speed.
load on the gen er ator keep the ratio b etw een the
load and the voltage signal cons tant. F or exam ple: N O T E: L oad on eng ine or load on generator can be
if the load on the g en erato r is 1/2 o f its rated used.
capac ity adjust the load gain p o tentio m eter to get a
6. M a ke a ratio betw een the load on the en gine and
load signal of 4 V .
the full load capac ity o f the engine. This ratio
4. Do Steps 1. 2 and 3 to all the units in the system . must be the same as the ratio b etw een the de crease
The load signal for each unit in the system must be in en gin e spe ed from Step 5 and the n u m b e r from
the same. the multiplication in Step 2. F o r exam ple:
5 -7 8
2301 CONTROL SYSTEMS TESTING AND ADJUSTING
De-Droop Potentiometer
1. Set the sv stem for isochro nous operation at the
desired rpm. Droop p otentiom eter at zero dr oop.
5 -7 9
GOVERNOR AIR ACTUATORS TESTING AND ADJUSTING
10. Retu rn the actuator air control lever (3) to the low
idle position to change preload.
2. Start the engine. Let the engine run until it is 13. W h en plu n ger (6) m oves at 10 psi (70 kPa) air
warm . pressu re, turn the screw in until nut can not be
turned.
3. Ch eck high and low idle rp m with a tachom eter. If
necessa ry , make adjustm ents to the g o verno r high N O T E: If necessa ry , turn nut until sc rew is in line with
and low idle sc rews to get correct rpm. n ext no tch in nut.
4. Stop the engine. 14. Install link age b etw een actuator and governor.
5 -8 0
GOVERNOR AIR ACTUATORS TESTING AND ADJUSTING
H IG H IDLE A D JU S TM E N T
(EARLIER A C TU A TO R ) N O T E: Turn actuator high idle screws (8) the sam e
3. Actuator air control lever. 6. Plunger. 8. High idle am ount. The plu ng er must co ntact both high idle
screws. 9. Setscrews. screws at the sam e time.
5-81
GOVERNOR AIR ACTUATORS TESTING AND ADJUSTING
1N9318 and 7L135 ACTUATORS NOTFi: If plu ng er (4) mor es at less than 10 psi (70
k P al. m ak e the preload higher. It more than 10 psi (70
Air Pressure Adjustment
kPa) air press ure is needed to mov e the plunger , make
the preload lower.
3N9125 ACTUATOR
ADJUSTM ENT OF ACTUATOR AIR PRESSURE Linkage Adjustment
1. Air gauge. 2. Actuator air control lever. 3. Actuator. 4.
Plunger. 5. Setscrew. 6. Screw. 7. Nut. 1. Adjust rod end (4) to get dim ension (A).
5 -8 2
TESTING AND ADJUSTING
SHUTOFF AND ALARM SYSTEMS
Test Procedure
1. R e m o v e the co ver of the contactor switch and
di sc onnect the wires from the nor m ally closed (B
or Blue) terminal.
2. Disc onnect the oil supply line fro m the con tacto r
switch and install the test equ ipm en t as sh ow n . CO NTACTOR SW ITCH FOR OIL PRESSURE
(Earlier Type)
3. C o nn ect the 5 K 3772 Hose from tee (10) to the 11. Adjustm ent screw. 12. Main spring.
co ntactor switch. Put the end o f the other 5 K 3 7 7 2
H o se in a pan. 1. Turn ad justm en t sc rew ( l l ) co u nterclock w ise to
m ake a de crease in the tension o f main spring (12).
4. C on ne ct the 8S 4627 Circuit T ester b etw een the
c o m m o n terminal and the norm ally closed te r m i 2. Disconnect the wires from the normally closed
nal. T h e light o f the circuit tester will be activated. terminal of the swtich.
5. Close sh utoff fitting (7) and op en shutoff fitting 3. Start the en gine and run it at low idle rpm.
( 6 ).
4. Close sh u to ff fitting (6) and slowly open shutoff
6. Loo k at the pressure g au g e, start the en g ine and fitting (7) until the pressure gauge show s the p r es
run it at low idle rpm . The light m ust go out, with sure specification at whi ch the su'itch must close
an increase in oil pressure , at the specification o f with a d ecrease in pressure. Close shutoff fitting
the switch. (7).
5 -8 3
SHUTOFF AND ALARM SYSTEMS TESTING AND ADJUSTING
5. Make sure the control knob is in R U N position. If 2. D isconnect the wires from the no rm ally closed
so equipped. terminal o f the spring.
6. C o nn ect the 8S 4627 Circuit Tester betw een the 3. Start the en gine and run it at low idle rpm.
co m m o n terminal and the norm ally closed term i
nal. The light of the circuit tester must not be 4. Close sh u to ff fitting (6) and slowly open shutoff
activated. fitting (7) until the press ure gau ge shows the p r es
sure spe cification at which the switch must close
with a decrease in pressure. Close shutoff fitting
(7).
W IRING CO NNECTIO NS
7. T urn sc rew (14) clockw ise until the light o f the
circuit tester is activated.
A. Norm ally open terminal. B. Comm on terminal. C. Nor
m ally closed terminal.
8. T ig hten the locknut.
5 -8 4
SHUTOFF AND ALARM SYSTEMS TESTING AND ADJUSTING
2. Put m arks on the two con tacto r wires that co nn ect RACK SHUT-OFF SOLENOID
the co n tacto r to the circuit. Disc onnect the tw o
wires. T h e g o v er n o r plu n ger shaft initial adjustm ent of dis
tance fro m shaft shoulder-to-pl ate should be .70 in.
(1 7.8 mm).
HEAT SINK
[Dimension in inches (mm)]
1. R e m o v e oil lines.
5 -8 5
SHUTOFF AND ALARM SYSTEMS TESTING AND ADJUSTING
16262X 1
SHUT-O FF VALVE (WATER TEM PERATURE) C H ECKING CO NTACTOR SW ITCH FOR OVERSPEED
1. 4S6553 Engine Test Group. 2. Tachom eter gener
5. Put the heat sink and the sh ut-off valve in water. ator. 3 . 5L2277A dapter. 4 . V a riablespeeddrill. 5.8S 4627
Use a torch to m ak e the w ater hot an d, by using a Circuit Tester.
2. C on nect an oh m m e te r b etw een fitting (2) and ter PART NO. TEM PERATURE RESISTANCE (OHMS)
minal ( l ). 5L7442 200° F (93” C) 800 to 900
0 psi (0 kPa) 0 to 1
5 -8 7
INSTRUMENTS AND GAUGES TESTING AND ADJUSTING
5 -8 8
INSTRUMENTS AND GAUGES TESTING AND ADJUSTING
MECHANICAL GAUGES FOR TEMPERATURE N O T E : S o m e g au ges with co lor co des have only two
ranges. R ed for low press ure and green to r normal
T w o types of m echanical g au g es are available. T h e p r e s s u re .
first type has a direct reading face. T h e se co nd type has
co lor codes on the face to sh ow different ranges o f T o ch eck both types o f gau g es connect the ga uge to a
oper ation. W hite, green and r ed sho w the cold, nor m al pr essure source that can be m easu red w'ith accuracy.
and hot rang es respec tively. M ake a com p ariso n of press ure on the gauge of test
eq uip m ent with the pressures on the direct readi ng
T o check bot h types o f g aug es, put the bu lb o f the
g auge or with the press ures as show n on the chart lo r
g auge in a pan o f oil. Do not let the bulb touch the pan.
g auges with color codes.
Put a th e r m o m e te r in the oil to m easure the t e m p e r a
ture. M ake a com pariso n of tem perature s on the th e r
m o m eter with the tem perature s on the direct reading
g auge or with tem perature as sho w n on the chart fo r
g aug es with color codes.
TEST THERMOMETER T
POWER TEMPERATORE READING
POSITION F. C.
5 -8 9
POWER TAKE-OFF CLUTCHES TESTING AND ADJUSTING
5 -9 0
ELECTRONIC OVERSPEED SWITCH TESTING AND ADJUSTING
5 -9 1
TRO UBLESHOOTING PROCEDURE (O VERSPEED)
A 9 3749X1
5-92
TROUBLESHOOTING PROCEDURE (CRANK TERMINATE)
1. C o n n e c t s p e e d s w itc h te r m in a l 10 to te r m in a l I I to d is e n g a g e th e s ta r te r
m o to r.
3. C o n n e c t a s ta r te r te s te r th a t h a s a m a n u a l d i s c o n n e c t c o n tro l.
N O T E B: M a k e r e f e r e n c e to th e S P E E D S P E C I F I C A T I O N C H A R T fo r th e
c o r r e c t o v e r s p e e d o r c ra n k te r m in a te s p e e d s e ttin g .
A93750X1
5-93
ELECTRONIC OVERSPEED SWITCH TESTING AND ADJUSTING
PROCEDURE A
OVERSPEED SETTING CALIBRATION
1. R e m o v e lockwire and seal from seal sc rews (8 & N O T E : M o r e ad justm ent m ay be needed to get the
9). R e m o v e seal screw (8) from acce ss hole for corre ct setting. T urn ad justm en t p otentiom eter c lo c k
o verspeed adjustm ent screw. w ise to increase spe ed setting and co u nterclockw ise to
d ecrease speed setting. T urn ad justm en t p otentiom eter
2. Use a small sc re wdriver and lightly turn O .S .
very slowly onl y a small am o u n t at a time until adjust
(o verspeed) adjustm ent po tentio m eter tw enty
m e n t is correct.
turns in the direction of " M A X A R R O W ”
(clockwise). 7. W h en the speed setting is corre ct, install seal
scre w (8) for oversp ee d adju stm ent hole and in
stall lock wire and seal.
N O T E: The ov ersp eed adju stm ent screw is m a d e so
that it can not cause dam ag e to the p oten tiom eter or be
r em oved if the adjustm ent sc rew is turned too m uch.
PROCEDURE B
3. Run en g ine at 759f o f des ired oversp eed setting
rpm. M ake reference to the S P E E D S P E C I F I MAGNETIC PICKUP ADJUSTMENT
CATION CAHRT.
5-94
ELECTRONIC OVERSPEED SWITCH TESTING AND ADJUSTING
CRANK TERMINATE SPEED ADJUSTMENT 6. Start and m ak e a note o f the sp eed at whi ch the
starter dise ngag es. If n eeded, m ake m o re small
1. R e m o v e lo ck wire and seal from seal sc re ws (8 & adjustm ents until the crank ter m inate spe ed is
9). R e m o v e seal screw (9) fro m acce ss ho le for correct.
cran k term in ate adjustm ent screw.
7. Install seal screw (9) for cr an k ter m inate adjust
2. Use a small sc re wdriver and lightly turn C .T . m ent hole and install lock wire and seal.
5 -9 5
ELECTRONIC OVERSPEED SWITCH TESTING AND ADJUSTING
PROCEDURE D
OVERSPEED VERIFY TEST verify test will shut d o w n the en gine at 1 5 % o f the
o verspee d setting o f 1416 rpm . In this ex am ple 1 5 % of
1416 r p m is 1062 rpm. If the verify button is p u sh e d at
an en gin e speed o f 1062 rpm o r above the en gine will
I . Run en g ine at rated speed, push verify button (5)
in for a m o m en t. This will cau se the sp eed switch sh ut do w n .
to activate and shut d o w n the engine. T h e “ L E D ” ov ersp eed light (7) will com e on and
NOTE: A ny time the en gine speed is 75% or m o re o f stay on until the reset button is push e d after an o v e r
the oversp ee d setting, the en gin e will shut d o w n if the speed sw itc h shut d ow n . T o restart the engine, push in
verify button is pushed. reset button (6) for a m o m e n t. This will reset the spe ed
switc h and the rack shutoff solenoid . The “ L E D ”
E X A M P L E : F or an engine with a rated spe ed o f 1200 o versp ee d light (7) will go off. T he air inlet shutoff
rpm the o versp eed setting is 1416 rpm. T h e overspee d m u st be m anu ally reset.
ENGINE NO. OF TEETH TYPIC AL ENGINE M AGNETIC ENGINE M AGNETIC ENGINE MAGNETIC
MODEL ON RING GEAR RATED SPEED PICKUP SPEED PICKUP SPEED PICKUP
ENGINE (RPM) FREQ UENCY (RPM) FREQUENCY (RPM) FREQUENCY
SPEED NOTE E (HZ) NOTE F NOTE C & E (HZ) (HZ) NOTE F
(RPM) NOTE C & F
MAGNETIC P IC K -U P OVERSPEED
^C L E A R — O 4 S IG
MAGNETIC OR CRANKING
O 5 NEG
PICKUP NO. OF TEETH TERM INATION
O 6 POS
FREQ UENCY = ON RING GEAR X RPM SETTING
O 7 NO ] 60
OVERSPEED
O 8 COM>
R E LA Y
O 9 NC J
N O T E E: T he engine oversp ee d setting rpm is T o reset o versp ee d sw itch, p ush in reset button
118% o f rated engine rpm. for a m o m en t.
5 -9 6
IN D E X
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
GENERAL INSTRUCTIONS
DISASSEMBLY AND ASSEMBLY (Section 6)
GENERAL INSTRUCTIONS
T h e f o llo w in g i n s t r u c t i o n s will p r o v e h elp fu l to If a p a r t resists r e m o v a l . cheek to be c e r ta in all
d i s a s s e m b le a n d a s s e m b l e en g in e c o m p o n e n t s . T h e n u t s a n d bolts have been r e m o v e d a n d t h a t an
i n f o r m a t i o n s h o u l d be read a n d t h e n refe rr ed to as a d j a c e n t p art is not in terferin g .
necessarv.
EYEBOLT LOAD R E C O M M EN D A TIO N
CLEANLINESS
M A XIM U M LOAD
W h e n e v e r h y d r a u l i c . fuel, l u b r ic a t in g oil o r air S IZ E PART NO.
lbs. kg
lines a r e d i s c o n n e c t e d , clean the p o in t o f d i s c o n
n e c tio n a n d th e a d j a c e n t area. As s o o n as th e 20 1P7403 600 2 7 2 .3
CORRECT
DISASSEMBLY AND ASSEMBLY
1 T 6 0 8 8 4_______________
6-2
DISASSEMBLY AND ASSEMBLY
GENERAL INSTRUCTIONS
6-3
GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY
Push Pullers
P u s h P ullers cun he use d to r e m o v e pulleys, gears,
sh afts, etc.. a n d c a n he used in a v a r ie ty o f pu llin g
com binations.
TY P IC A L EXAMPLE
1. Push Puller. 2. Ratchet Box W rench. 3. Step Plate. 4.
Bearing Pulling Attachm ent.
TY PIC A L EXAMPLE
*1. Adapters. 2. Ratchet Box W rench. 3. Push Puller. 4.
Step Plate. 5. Legs.
*Use as required.
T Y P IC A L EXAMPLE
1. Push Puller. 2. Bearing Cup Pulling Attachm ent. 3.
Reducing Adapter.
TY P IC A L EXAMPLE
1. Push Puller. 2. Adapter. 3. Step Plate. TY P IC A L EXAMPLE
1. Bearing Pulling Attachm ent. 2. Push Puller. 3. Re
ducing Adapter.
6 -4
DISASSEMBLY AND ASSEMBLY
GENERAL INSTRUCTIONS
T-T -T Procedure
A t o r q u e - t u r n - t i g h t e n ( T - T - T ) p r o c e d u r e is used
in m a n y s p e c ific a tio n s a n d in s t r u c t i o n s .
1. C l e a n th e bo lt a n d n u t th r e a d s .
2. P u t l u b r i c a n t o n th e t h r e a d s a n d the se at face
o f th e b olt a n d t h e nut.
3. T u r n th e b olt o r th e n u t tig ht a c c o r d i n g to th e
t o r q u e sp e cificatio n .
4. P u t a l o c a t i o n m a r k o n th e p a r t a n d o n th e bo lt
o r th e nut.
TY P IC A L EXAMPLE 5. T u r n t h e bolt o r t h e n u t t i g h t e r th e a m o u n t o f
1. Screw. 2. B e a r in g Cup Pulling Attachm ent. 3. Step d eg r ees a c c o r d i n g to th e s p e cificatio n s .
Plate.
TU R N T IG H T E R CH AR T
TU R N TU R N
(B O LT OR N U T) DEGREES
1 360
RULES FOR USE OF TOOLS 1/2 180
1/3 120
RULE 1: Always use safe tools. 1/4 90
RULE 2: Keep tools in safe working condition. 1/6 60
RULE 3: Use the correct tool for the job. 1/12 30
RULE 4: Common sense with tools pays off.
6-5
GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY
LOCKS
F l a t m e t a l lo c k s m u s t be in stalled p r o p e r l y to be
effectiv e. Bend o n e e n d o f th e lo ck a r o u n d th e edge
Torque Wrench Extension
o f th e p a r t. B end th e o t h e r e n d a g a i n s t o n e flat
W h e n a t o r q u e w r e n c h e x t e n s i o n is use d w ith a s u r f a c e o f th e n u t o r bo lt h ead .
t o r q u e w r e n c h , the t o r q u e i n d i c a t i o n o n th e t o r q u e
A l w a y s install new locks in c o m p a r t m e n t s w h ic h
w r e n c h will be less t h a n th e real to r q u e .
h o u s e m o v i n g parts.
If lo c k w a s h e r s are in stalled o n h o u s i n g s m a d e o f
a l u m i n u m , use a flat w a s h e r b e tw e e n th e lockv vasher
a n d the housing.
I NCORRECT
T O R Q U E W R E N C H W IT H T O R Q U E W RE NC H
E X TEN SIO N
E: Torque wrench drive axis-to-torque wrench extension
drive axis. W: Mark on handle-to-torque wrench drive
axis.
INCORRECT
P u t a m a r k on th e h a n d l e . M e a s u r e th e h a n d l e
f r o m th e m a r k to th e ax is o f th e t o r q u e w r e n c h
d riv e (W ).
M e a s u r e th e t o r q u e w r e n c h e x t e n s i o n f r o m th e
t o r q u e w r e n c h d riv e to th e axis o f th e t o r q u e T 6 3 4 8 8
w r e n c h e x t e n s i o n d r iv e (E).
T o get c o r re c t t o r q u e i n d i c a t i o n ('I I) w h e n th e
real t o r q u e ( R T ) is k n o w n :
6-6
DISASSEMBLY AND ASSEMBLY
GENERAL INSTRUCTIONS
BEARINGS
Anti-Friction Bearings
W h e n a n a n t i - f r i c t i o n b e a r i n g is r e m o v e d , c o v e r
it to keep o u t dirt a n d abr a siv e s . W a s h b e a r i n g s in
n o n f l a m m a b l e c l e a n i n g s o l u t i o n a n d allow t h e m to
d r a i n drv. T he b e a r i n g m a v be d r ie d w ith c o m
p ress ed air. but D O N O T S P I N T H E B E A R I N G .
6-7
GENERAL IN S T R U C T IO N S D ISA SS EM B LY A N D A S SEM B LY
T 9 3 9 6 7 -A
6-8
IN D E X
D 379, D 398, D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S
C a m s h a f t........................................................................................................................................................................ 7 1«7
C a m s h a ft B e a r in g s ...................................................................................................................................................
C o n n e c tin g Rod B e a r in g s ........................................................................................................................................ "Z °
C r a n k s h a f t ......................................................................................................................................................................
C ra n k s h a ft F ro n t S e a l (L ip T ype) a n d W e a r S le e v e ................................................................................... '2 0
C ra n k s h a ft F ro n t S e a l R in g a n d T h r o w e r ........................................................................................................ 7 -1 8
C ra n k s h a ft M a in B e a rin g s ................................................................................................................................... 7 -1 0 5
C ra n k s h a ft R e ar S ea l R in g a n d T h ro w e r ..................................................................................................... 7 154
C y lin d e r L in e r s ............................................................................................................................................................. 7 -1 1 9
C y lin d e r H e a d s ............................................................................................................................................................. 7 -1 1 0
F ly w h e e l ........................................................................................................................................................................ 7 -1 5 2
F ly w h e e l H o u s i n g ...................................................................................................................................................... 7 -1 5 6
F re sh W a te r P u m p ...................................................................................................................................................... 7 -4 0
Fre sh W a te r P u m p , A s s e m b le ............................................................................................................................... 7 -4 4
F re sh W a te r P um p, D is a s s e m b le ........................................................................................................................ 7 4 2
Fuel F ilte r H o u s in g ...................................................................................................................................................... 7 -1 1
Fuel In je c tio n P u m p s ................................................................................................................................................. 7 -7 0
F uel In je c tio n L in e s ................................................................................................................................................... 7 -7 1
Fuel In je c tio n V a l v e s ................................................................................................................................................. 7 -9 7
F uel In je c tio n P u m p H o u s in g ................................................................................................................................. 7 -7 9
F uel In je c tio n P u m p H o u s in g , S h u to ff C o n tro l, G o v e rn o r a n d G o v e rn o r D riv e ........................... 7 -7 7
F u el P rim in g P u m p ........................................................................................................................................................ 7 -7
Fuel P rim in g P um p, D is a s s e m b le & A s s e m b le ................................................................................................ 7 -8
Fuel R a tio C o n tro l W ith O v e r r id e ........................................................................................................................ 7 -5 1
F u el R a tio C o n tro l W ith O v e rrid e , D is a s s e m b le & A s s e m b le .............................................................. 7 -5 2
F u el T ra n s fe r P u m p ...................................................................................................................................................... 7 -3
F uel T ra n s fe r P um p, A s s e m b le ............................................................................................................................... 7 6
F uel T ra n s fe r P um p, D is a s s e m b le ........................................................................................................................ 7 -5
G e n e ra to r S ee S p e c ia l In s tru c tio n F o rm S M H S 7 2 5 9
G o v e rn o r D riv e H o u s i n g .......................................................................................................................................... 7 -8 8
G o v e r n o r .......................................................................................................................................................................... 7 53
G o v e rn o r, A s s e m b le ................................................................................................................................................... 7 5 9
G o v e rn o r, D is a s s e m b le ............................................................................................................................................. 7 55
In ta k e M a n if o ld s ........................................................................................................................................................ 7 -1 0 4
7-1
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S IN D E X
P is to n s ........................................................................................................................................................... 7-116
Pistons, Disassem ble & A s s e m b le ........................................................................................................ 7-118
Piston Cooling T u b e s ................................................................................................................................. 7-108
Precom bustion C h a m b e rs .......................................................................................................................... 7-98
P relubrication Oil Pump (D399) ................................................................................................. 7-46
P relubrication Oil Pump (D399), D isassem ble &A ssem ble ............................................................ 7-47
V a lv e s .............................................................................................................................................................. 7-112
Valve C o ve rs................................................................................................................................................. 7-1 09
V ibration Damper ID 398 and D399) ...................................................................................................... 7-17
Valve Guides ............................................................................................................................................... 7-114
Valve L if t e r s ................................................................................................................................................. 7-1 02
Valve Seat In s e rts ....................................................................................................................................... 7-115
DISCONNECT BATTERIES
\ BEFORE PERFORMANCE
OF ANY SERVICE WORK
7-2
i
D379, D398, D399 IND U STR IA L AND MARINE ENGINES DISASSEMBLY AND ASSEM BLY
I. T u r n th e fuel va lve t o th e “ O F F ” p o s i t i o n .
*
2. R e m o v e th e b o lt ( l ) f r o m th e c l a m p t h a t
h o l d s fuel line t o ac c e s s o ry d riv e h o u s i n g .
\
4. I n s p e c t a n d m a k e a r e p l a c e m e n t o f O - r i n g
seal (5) if n ecessary .
5. In stall n ew g a s k e t (6) o n t h e a c c e s s o ry d r iv e
h o u sin g .
6. P u t th e fuel t r a n s f e r p u m p (4) o n t h e e n g in e .
In stall th e t w o b olts t h a t h o l d p u m p to h o u s
ing. C o n n e c t fuel lines (2) t o t h e p u m p . I n
stall b o l t ( l ) t h a t h o l d s c l a m p t o h o u s i n g .
I A 82056X1
T u r n th e fuel v alv e t o t h e “ O N ” p o s i t i o n .
7-3
D 379 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E EN GIN ES D ISA SS E M B LY A N D ASSEM BLY
7-4
D 3 7 9 , D 3 9 8 . D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES DISA SSEM B LY A N D ASSEMBLY
T o o ls N e e d e d
9S8100 T o ol G ro u p
s t a r t by:
a) r e m o v e fuel t r a n s f e r p u m p
l . R e m o v e six b o l t s ( l ) f r o m t h e p u m p a s s e m
bly.
CAUTION
Do not cause damage to machined surface of
the cover or body.
2. R e m o v e t h e co v e r (2) f r o m b o d y (3).
3. R e m o v e r e t a i n e r r in g (4) f r o m sh a ft (7). R e
m o v e sh a ft (7), id ler g e a r (6) a n d cag e (5)
f r o m th e b o d y . R e m o v e t w o O - r i n g se als (8)
f r o m th e cage.
6. R e m o v e th e b e a r i n g f r o m b o d y (3) w i t h t o o l A 82052XI
ing (A).
7-5
D 3 7 9 , D 3 9 8 D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES DIS A SS E M B LY A N D ASSEMBLY
Tools Needoc A B
CAUTION
Do not let Liquid Gasket material get in the
pump.
5. P m a sm a ll a m o u n t o f 7 M 7260 L iq uid
Ua.skct M a teria] on th e m a c h i n e d s u r f a c e o f
i he b o d \ . Install c o \ e r (7) w ith six holts.
N O 1 12 T h e s h a ll m u s t t u r n freely a f te r th e c o v e r
bolts are ti g h t e n e d .
end by: A 82045X1
a) in stall fuel t r a n s f e r p u m p
7-6
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S SE M B LY
2. D i s c o n n e c t inlet lines (3 ) f r o m t h e p u m p .
3. R e m o v e o u t l e t line ( l ) fro m th e p u m p .
5. R e m o v e the fuel p r im in g p u m p .
7-7
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S S E M B LY
3. R e m o v e k n o b , n u t , p la te , g u ide a n d spring.
R e m o v e p i s t o n a n d r o d f r o m th e t u b e .
A SS EM BLE FUEL P R I M I N G PU M P 1 2 5 8 — 16
T o o ls Needed A
9S289 C om pressor 1
2. P u t a sm all a m o u n t o f 4 L 7 4 6 4 S ilicone
G rease o n th e rings an d seals.
4. Install the p i s t o n in th e t u b e w i t h t o o l (A ).
Install th e sp ring, g uid e, p late, n u t a n d k n o b
o n th e rod (4). In stall th e b r a c k e t a n d r e
tainer.
5. P u t th e t u b e ( 5 ) o n th e valve b o d y ,
en d by:
a) install fuel p r im in g p u m p
7-8
D ISA SS E M B LY A N D ASSEMBLY
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E EN GIN ES
1. R e m o v e c o o l a n t f r o m en g in e t o a level b e
low t h e r e g u l a t o r ho usin g.
2. R e m o v e th e f o u r b o l t s ( l ) t h a t h o l d e l b o w
o f th e e x p a n s i o n t a n k t o th e cover. R e m o v e
line (3) on M arine engines .
3. O n I n d u s tr ia l en gin es o n l y , d i s c o n n e c t t h e
w a t e r b y p a s s line f r o m th e cover. R e m o v e
t h e co v e r f r o m th e b o t t o m . R e m o v e t h e r e g
u la to r s f r o m th e cover.
4. R e m o v e th e co v e r (2 ).
5. R e m o v e th e r e g u l a t o r s ( 4 ) f r o m t h e h o u s
ing.
6. R e m o v e th e seals f r o m t h e h o u sin g .
INS TALL W A TE R T E M P E R A T U R E
REGULATORS 1 3 5 5 — 12
T o o ls Needed A
1P529 H andle 1
1. P u t n e w seals (1 ) in t h e h o u s i n g w i t h t o o l
ing (A ). Install seals w i t h lip o f seal a w a y
f r o m r e g u la to r.
2. C lea n th e m a c h i n e d su r f a c e s a n d install n e w
g as k et f o r cover.
3. I n stall t h e r e g u l a t o r s ( 2 ) in t h e h o u s i n g o n
t h e M arine engines. Install t h e cover.
4. O n I n d u s t r i a l engines, install t h e r e g u l a t o r s
in th e c o v e r a n d install cover. C o n n e c t th e
b y p a s s line for t h e w a te r .
5. I n stall t h e b o l t s t h a t h o l d e l b o w o f t h e e x
p a n s i o n t a n k t o cover.
7-9
D 379 , D 398 . D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SSEM B LY A N D ASSEMBLY
I. R e m o v e c o o l a n t f r o m engine. D i s c o n n e c t
lines for sw itc h f ro m e x p a n s i o n t a n k . R e
m ove tw o bo lts t h a t h old sw itc h to e x
p an s io n tank . R e m o v e the sw itc h .
2. R e m o v e th e ho se ( I ) a n d c l a m p s f r o m e x
p an s io n tank . R e m o v e v e n t i l a t i o n line (3 ).
R e m o v e b olts (2) th a t ho ld h o u sin g to e x
pansion tank .
F a s t e n a h oist to e x p a n s i o n t a n k . R e m o v e
b o lts fro m the t w o b races t h a t h o l d e x p a n
sion t a n k in p ositio n .
4. L o o se n c l a m p ( 5 ) t h a t h o ld s th e t u b e s t o
g eth er. R e m o v e the b o lts (4 ) t h a t h o l d t u b e
(7 ) to e x p a n s i o n tan k . R e m o v e b o l t s t h a t
h old b r a c k e t s ( 6 ) to oil filter ho u sin g . R e
m ove e x p a n s i o n t a n k . W eight is 2 2 0 lb.
( l O O k u ) .
IN S T A L L E X P A N S I O N T A N K
(M A R IN E EN G IN ES ) 1 3 5 4 — 12
Use a hoist a n d p u t e x p a n s i o n t a n k in p o s i
tion o n engine. Install b o lts t h a t h o ld th e
b r a c k e t s t o oil filter h o usin g. Install b olts
t h a t h old o u t l e t t u b e ( l ) t o e x p a n s i o n t a n k .
T ig h t e n c l a m p t h a t h o ld s o u t l e t t u b e s t o
gether.
7 - 10
D IS A S S E M B L Y A N D A S S E M B L Y
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES
st a rt by:
a) re m o v e e x p a n s i o n t a n k (M a r in e e n
gines o n ly )
b) r e m o v e fuel p r im in g p u m p
3. D i s c o n n e c t in let line ( 1 ) fo r th e in j e c t i o n
p u m p h o u sing .
4. D i s c o n n e c t fuel line (3 ) f o r t h e tr a n s f e r
pump.
5. R e m o v e th e f o u r b o lts ( 4 ) t h a t h o ld th e
h o u s i n g o n t h e oil filter hou sing .
I N S T A L L FU E L FILTE R H O U S I N G 1 2 6 2 — 12
l . P u t t h e fuel filter h o u s i n g in p o s i t i o n o n t h e
en gin e. Install t h e b o l t s t h a t h o ld h o u s i n g t o
oil filter housing.
2. C o n n e c t th e fuel line f o r t h e t r a n s f e r p u m p .
3. C o n n e c t in let line f o r th e i n j e c t i o n p u m p
ho u sing .
7 - 11
D ISA SSEM B LY A N D ASSEMBLY
D 3 7 9 . D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES
s ta rt by:
a) r e m o v e fuel filter h o u s i n g
1. R e m o v e oil f r o m t h e filter h o usin g.
2. R e m o v e b o lt t h a t h o l d s c l a m p ( 2 ) t o m a n i
fold.
3. R e m o v e the c l a m p ( 1 ) t h a t h o ld s o u t l e t
lines to g e t h e r . Install t w o 3 / 8 ” —16 NC
fo rg ed e y e b o l t s . w as h ers a n d n u t s in b r a c k
et.
4. F a s t e n a h o i s t . R e m o v e th e f o u r b o lts (3 )
t h a t ho ld h o u s i n g to b lo c k .
IN S T A L L O IL FILTER H O U S I N G 1 3 0 6 — 12
3. P u t th e h o u s i n g in p o s i t i o n o n en gin e. I n
stall b o lts t h a t h o l d h o u s i n g o n engine.
4. Install c la m p t h a t h o l d s o u t l e t lines t o
g eth er . Install b o l t t h a t h o l d s c l a m p t o th e
m a n i f o ld .
7 - 12
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES DISA SSEM B LY A N D ASSEMBLY
1. R e m o v e plug f ro m b o t t o m o f p u m p a n d r e
move sea w a t e r f ro m p u m p .
3. R e m o v e e l b o w ( l ) a n d t o p t a n k ( 2 ) f ro m
the p u m p .
4. R e m o v e th e r e t a i n e r as sem b ly (4 ).
b. R e m o v e th e six bo lts t h a t h o ld p u m p t o
acce ss o ry drive housing.
7. R e m o v e th e sea w a t e r p u m p .
IN S T A L L S E A W A T E R P U M P 1 3 7 1 — 12
2. Install th e r e t a i n e r a s se m b ly (4 ).
3. Install th e co v e r ( 2 ) w i t h e n o u g h g a s k e ts ( 5 )
to have a c l earan ce o f .005 t o . 0 2 0 in. ( 0 . 1 3
to 0.51 m m ) b e t w e e n c o ver ( 2 ) a n d face o f
im p eller (3).
4. In stall th e t o p t a n k a n d e lb o w .
7- 13
D 3 7 9 , D 3 9 8 , D 3 9 9 I N D U S T R I A L A N D M A R I N E ENGINES D IS ASS EMBLY A N D ASSEMBLY
T97915X2
7- 14
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES DISA SSEM BLY
T o o ls Needed
FT884 Leg
8B7560 S te p Plate
st a rt by:
a) r em o v e sea w a t e r p u m p
1. R e m o v e the c o t t e r p in . n u t an d w a s h e r t h a t
h o ld i m p eller t o sh aft.
3. R e m o v e to o l i n g (A ). R e m o v e n u t , im p eller,
p late an d gas k et (1).
5. R e m o v e th e plate (3 ) a n d bellow s (5 ) f r o m
t h e ho usin g .
7. R e m o v e th e gear ( 6 ) f r o m sh a ft.
8. R e m o v e f o u r b o l t s (9) a n d lo c k s t h a t h o l d
bearing o n re ta in e r. R e m o v e b earin g ( 1 0 ) .
9. R e m o v e t w o b o l t s (8) a n d lo ck s t h a t h o l d
r e t a i n e r t o h o u sing . R e m o v e r e t a i n e r a s se m
bly (7).
11. R e m o v e th e seal ( 1 2 ) f r o m re ta in e r.
D IS A S S E M B LY A N D A S SE M B LY
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S
T o o ls Needed A B
H andle 1 1
1P529
D rive Plate 1
1P475
D rive Plate 1
1P466
D rive Plate 1
1P483
e nd by:
a) install sea w a t e r p u m p
7 - 16
D IS A S S E M B L Y A N D A S S E M B LY
D 379, D 398, D 399 IN D U S T R IA L A N D M A R IN E E N G IN E S
1. O n D 3 9 8 . r e m o v e the b o lts ( 1 ). P u t an
i d e n t i f i c a t io n m a r k on b o l t s (3 ) a n d ( 4 ) a n d
h ousing. R e m o v e th e co v e r (2 ).
2. O n D 3 9 9 . r e m o v e b o l t s t h a t h o ld t h e co ver .
R e m o v e th e cover.
3. O n D 3 9 8 . r e m o v e th e b o l t s t h a t h o l d v i b r a
tio n d a m p e r . Install t w o 1 P 7 4 0 7 E y e b o l t s
in the t a p p e d h o l e s o f th e v i b r a t io n d a m p e r .
F a ste n a ho ist.
4. O n D 3 9 9 . re m o v e th e b o lts t h a t h o ld v ib r a
ti o n d a m p e r . In stall t w o b o l t s (6 ) as a g uid e.
Move th e v i b r a t io n d a m p e r o u t o n t h e g u id e
b o lts w ith forcing screw s (5 ). F a s t e n a h o i s t
a n d r e m o v e v i b r a t io n d a m p e r . W eig ht o f
D 3 9 9 d a m p e r is 2 7 0 lb. ( 1 2 2 kg) a n d th e
D 3 9 8 is 130 lb. ( 5 9 kg).
CAUTION
Do not hit the vibration damper.
INSTALL V IB R A T IO N D A M P E R
(D398 & D399) 1 2 0 5 — 12
1. I n stall t w o b o l t s as g u id e. F a s t e n a h o i s t to
th e v i b r a t io n d a m p e r . P ut th e d a m p e r in
p o s i t i o n o n th e a d a p t e r .
2. P u t 9 S 3 2 6 3 T h r e a d L o c k o n th e t h r e a d s o f
b o lts f o r v i b r a t io n d a m p e r . P u t t h r e a d lock
on th e t w o b o lts w i t h a m a r k f o r c o ver o n
th e D 3 9 8 .
3. Install th e bolts a n d r e m o v e g u id e bolts,
l i g hten th e I in. b olts ( l ) t o 670 ± 50 lb. ft.
(905 ± 70 N - m ) o n D399. T i g h t e n th e b o lts
( l ) o n D 3 9 8 to 280 ± 20 lb. ft. (377 ± 25 N-m ).
7 - 17
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D IS A SS E M B LY A N D ASSEM BLY
T o o ls Needed A B
8B 7550 Leg 2
5 F73 4 1 A d a p te r 2
FT884 Leg 3
st a rt by:
a) re m o v e v i b r a t io n d a m p e r ( D 3 9 8 a n d
D 3 9 9 only)
l. O n D 3 7 9 only, rem ove the cover (1). P u t a
m a r k o n t w o b o l t s (2 ) fo r i n s ta lla tio n .
2. R e m o v e th e b o lts t h a t h o l d a d a p t e r ( 3 ) to
th e c r a n k s h a f t .
3. Use to o l i n g (A) to r e m o v e t h e a d a p t e r (3 ).
6. Install to o l i n g (B) o n th e t h r o w e r . P u t h e a t
o n t h e o u t e r d i a m e t e r o f t h r o w e r w i t h an
o p e n f lam e a t a m a x i m u m t e m p e r a t u r e o f
400° F (2 0 4 °C ). R em ove the th ro w e r im
m e d i a t e l y w i t h t o o lin g (B).
7 -1 8
D IS A S S E M B LY A N D A S SE M B LY
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENG IN ES
T603 B o lt 2
9 H 10 3 1 Washer 2
1. P u t 8 M 8 0 6 0 Q u i c k C u r e P r i m e r a n d 9 S 3 2 6 5
R e ta in i n g C o m p o u n d o n ring. Install ring in
acce ss o ry drive ho usin g.
2. H e a t th e t h r o w e r ( l ) in oil t o a m a x i m u m
t e m p e r a t u r e o f 4 0 0 ° F ( 2 0 5 ° C ) . Install
t h r o w e r o n c r a n k s h a f t . Use t o o l i n g ( A ) t o
install t h r o w e r in c o r r e c t l o c a t i o n o n c r a n k
sh a ft.
CAUTION
Do not install a used oil thrower, seal ring or
spring.
6. Install th e a d a p t e r ( 4 ) o n D 3 7 9 o n l y . P u t
7 M 7 4 5 6 L o c t it e S e a l a n t o n t w o o f b o lts
f o r cover.
7 - 19
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B LY
T o o ls N e ed e d A
1P3075 P u lle r A s s e m b ly 1
s t a r t by: %
a) r e m o v e v i b r a t i o n d a m p e r ( D 3 9 8 a n d
D 3 9 9 only)
✓
l. O n 0 3 7 9 only, r e m o v e c o v e r ( l ) ; p u t a m a r k
o n t w o b o lts (2) f o r in s t a l l a t i o n .
3. M a k e t w o holes ( 180° a p a r t ) in t h e m e t a l s u r
face o f c r a n k s h a f t f r o n t seal (6). R e m o v e the
seal w i t h t o o l i n g (A).
4. R e m o v e w e a r sleeve (7) f r o m th e c r a n k s h a f t .
7-20
D ISA SSEM B LY A N D ASSEMBLY
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES
T o o ls N e ed e d
5P3022 In s ta lle r
1. C l e a n th e c o n t a c t su r f a c e s o f t h e w e a r sleeve
a n d c r a n k s h a f t w ith 8 M 8 0 6 0 Q u i c k C u r e P r i
m er . P u t 9S 3 26 5 R e t a i n e r C o m p o u n d o n t h e
c o n t a c t surfaces. I n s t a l l t h e w e a r sleeve o n
the c r a n k s h a f t w ith t o o l i n g (A). T h e t a p e r e d
ed g e o n th e o u t s i d e o f th e w e a r sleeve go es
t o w a r d th e e n d o f t h e c r a n k s h a f t .
3. P u t 5 P 3 4 1 3 S e a l a n t o n t h e t h r e a d s o f t h e
bolts w hich fasten the a d a p te r to the c r a n k
shaft. In stall a d a p t e r (9) o n t h e c r a n k s h a f t .
I n sta ll th e c o v e r o n D 3 7 9 only. P u t 5 P 3 4 1 3
S e a l a n t o n t h e t h r e a d s o f t h e b o l t s in t h e l o
c a t i o n s w ith th e X m a r k .
e n d by:
install v i b r a t i o n d a m p e r ( D 3 9 8 a n d
D 3 9 9 on ly)
► 73727X2
7-21
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S SE M B LY
Tools Needed
2. R e m o v e t w o b o lts (3). l o c k w a s h e r s , c l a m p s
a n d t a c h o m e t e r d riv e a s s e m b l y (4).
A 82789X 1
3. R e m o v e f o u r bo lts (5). l o c k w a s h e r s a n d
h o u s i n g (6).
A 82788X 1
7- 22
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENG IN ES D ISA SS E M B LY A N D ASSEM BLY
B e nd th e locks.
7-23
D 3 7 9 . D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
T o o ls Needed
8B7550 Leg
5F 73 4 1 A d a p te r
start by:
a) r em o v e v ib r a tio n dam per (D398 &
D399)
h) r e m o v e f uel t r a n s f e r p u m p
e) r e m o v e oi l p r e s s u r e r e g u l a t i n g v a l v e
1. O n D 3 7 9 o n l y , r em o v e th e a d a p t e r cover.
R e m o v e b o lts for th e a d a p t e r . R e m o v e the
a d a p t e r ( 1 ) w ith to o l i n g (A).
5. R e m o v e f o u r b o l t s t h a t h o ld p la te (4 ) fo r
oil p u m p t o oil p an base.
6. R e m o v e th e f o u r b o l t s ( 6 ) t h a t h o ld w a t e r
p u m p t o h o u sin g. R e m o v e th e f o u r b o lts (8 )
t h a t h old oil p u m p t o h ou sing .
7. R e m o v e o r d i s c o n n e c t all c o n n e c t i o n s f ro m
c y l i n d e r b l o c k t o oil p an base.
9. F a s t e n a ho ist to f r o n t o f en g in e. L o o se n
t h e bo lts t h a t h o ld c y l i n d e r b l o c k t o oil p an
base. Lift th e en gine e n o u g h to install
s pacers (7 ) b e tw e e n c y lin d e r b lock an d oil
pan base.
7-24
D IS A S S E M B L Y A N D A S S E M B L Y
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S
ACCESSORY D R IV E HOUSING
IN S T A L L A C C E S S O R Y D R I V E
H O U S IN G 1 2 0 7 -1 2
5. In stall b o l t s t h a t h o l d th e w a t e r p u m p a n d
oil p u m p to drive ho usin g .
7. Install th e f o u r b o l t s t h a t h o ld plate ( 4 ) f o r
oil p u m p to oil p a n base. Install o r c o n n e c t
all o f the lines for en g ine b e t w e e n c y l i n d e r
b l o c k a n d oil pan base.
7-25
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
SAE S T A N D A R D R O T A T I O N I L L U S T R A T I O N D 3 7 9
7-26
D 3 7 9 . D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E EN GIN ES DISA SSEM B LY AN D ASSEMBLY
ACCESSORY DR IV E GEARS
R E M O V E A C C E S S O R Y D R IV E
GEARS 1206—11
T o o ls Needed A
FT884 Leg 3
st a rt by:
a) r e m o v e acce ss o ry drive h o u s i n g
1. R e m o v e b o lts a nd locks f r o m w a t e r p u m p
drive gear (2 ). R e m o v e g ear f r o m sh a ft.
2. R e m o v e oil p u m p drive gear ( 4 ) f r o m its
shaft.
3. R e m o v e th e m a i n id ler g ear ( 1 ) a n d its
sh aft. T u r n t h e c r a n k s h a f t t o ge t b o l t s t h a t
h o ld sh a ft to c y l i n d e r b l o c k a n d p la te ( 3 ).
4. R e m o v e bearing s f ro m gears ( 1 ), ( 2 ), a nd
(4 ).
5. O n D 3 7 9 o n l y , install to o l i n g ( A ) o n t h e
throw er. Put heat on the o u te r d iam eter o f
t h r o w e r w ith an o p e n f lam e at a m a x i m u m
tem p e ra tu re o f 4 0 0 ° F (2 0 5 °C ). R em ove th e
t h r o w e r i m m e d i a t e l y w ith to o l i n g (A ).
6. R e m o v e th e b a l a n c e r g ear (6 ).
7. R e m o v e th e b earin g f r o m b a l a n c e r gear.
8. R e m o v e oil t u b e ( 5 ) f r o m p late. If p la te is
t o be r e m o v e d , r e m o v e oil p u m p a n d fresh
w a t e r p u m p . R e m o v e p l a t e ( 3 ) f r o m c y l
i n d e r blo ck .
N O T E : C h e c k th e m a r k o n p la te f o r c o r r e c t in stal
latio n. T h e f r o n t o f p l a t e f o r S A E s t a n d a r d r o t a
tio n en gin e ( c o u n t e r c l o c k w i s e as view ed f r o m
fly w h eel e n d ) is m a r k e d “ F R O N T S T D . R O T . ”
T h e f r o n t o f p la te f o r S A E o p p o s i t e r o t a t i o n e n
gine (c l o c k w i s e as v iew ed f r o m th e fl y w h e e l e n d ) is
m arked “ F R O N T REV. R O T .”
7-27
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
1P529 Handle 1
T603 B o lt 1
9 H 10 3 1 Washer 1
1. I n s t a l l t h e p l a t e (3) o n c y l i n d e r b l o c k ,
l igh ten fi\ e 1 2" bolts to 90 ± 5 lb. ft. (120 ±
7 V m ).
N O T E : T h e g e a r tr a i n o f ac c e s s o ry d rive are th e
sa m e o n th e 8. 12. a n d 16 cy lind er eng ines, e x c e p t
fo r b a l a n c e r g e a r used on 8 cy lin d er engine. O n S A E
s t a n d a r d r o t a t i o n ( c o u n t e r c lo c k w i s e ) eng ines, th e
b a l a n c e r g ear t i m i n g m a r k “ B " m u s t be in a l i g n m e n t
w ith the t o o t h on c r a n k s h a f t g e a r w ith p u n c h m a r k s
( fo u r , five o r six p u n c h m a r k s) . T h e b a l a n c e r g e a r T87A32-A I ______________
t i m i n g m a r k " B " m u s t be in a l i g n m e n t w ith th e " B ”
S A E S t a n d a r d R o t a t i o n 8 C y l i n d e r E n gin e
m a r k on th e m a i n idler gear.
7 -2 8
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SSEM B LY A N D ASSEMBLY
SAE O P P O S I T E R O T A T I O N
8 C Y L IN D E R E N GINE
6. O n D 3 7 9 , h e a t th e t h r o w e r ( 4 ) in oil t o a
m a x im u m te m p e ra tu re o f 300° F (149°C ).
In stall th e t h r o w e r ( 4 ) o n c r a n k s h a f t . Use
t o o l i n g (B) t o install t h r o w e r in c o r r e c t lo
c a t i o n on c r a n k s h a f t .
CAUTION
Do not use an old oil thrower, seal ring or
spring.
e n d by:
a) install ac c e ss o ry drive h o u s i n g
7-29
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S SE M B LY
D IS A S S E M B L E OIL PRESSURE
RELIEF VALVE 1 3 1 5 — 15
s t a rt by:
a) r e m o v e oil p r e s s u r e relief valve
1. R e m o v e th e b olts (2) t h a t h o l d t u b e t o h o u s
ing. R e m o v e th e t u b e ( l ).
2. R e m o v e th e p is t o n , s p r i n g a n d g u i d e f r o m
the h o u sin g .
en d by:
a) in stall oil p r e s s u r e relief va lve
7-30
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E EN GIN ES D ISA SSEM B LY A N D ASSEMBLY
OIL PUMP
R E M O V E O IL P U M P 1 3 0 4 — 11
s t a r t by.
a) r e m o v e fuel t r a n s f e r p u m p
3. R e m o v e t w o b o l t s a n d c l a m p (8). R e m o v e
b o lts (4), (5) a n d (10). R e m o v e tee (7), t u b e
(6) a n d oil p r e s s u r e r e g u l a t o r (9).
4. F a s t e n a h o ist t o t h e oil p u m p . R e m o v e b o l t
(12). R e m o v e six b o l t s (11) t h a t f a s t e n t h e oil
p u m p to th e a c c e s s o r y d r iv e h o u s i n g . R e
m o v e t h e oil p u m p . T h e w e i g h t o f t h e oil Si
p u m p is 110 lb. (49.5 kg). * *
5. R e m o v e b e a r i n g (13) f r o m a d a p t e r (2).
^ A82849X1
A 82829X1
7-31
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D AS SE M B LY
OIL PUMP
IN S T A L L OIL P U M P 1 3 0 4 — 12
Tools Needed A
1 P ol 0 Driver G roup 1
7-32
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S SE M B LY
OIL PUMP
7-33
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES DISA SS E M B LY A N D ASSEMBLY
OIL PUMP
DISASSEMBLE OIL PUMP 1 3 0 4 —15
Tools Needed A B
1J629 8 Bolt 1
4B 4279 W asher . 1
4B4281 W asher 1
4B 4285 W asher 1
s t a rt by:
a) r e m o v e oil p u m p
3. R e m o t e ni ne b o lts (5).
4. M a k e a s e p a r a t i o n o f h o u s i n g (6), m a n i f o l d
(7) a n d m a n i f o l d (8).
A82842X1
A82844X1
7-34
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SSEM B LY A N D ASSEMBLY
OIL PUMP
7. R e m o v e t w o sh a fts (14) f r o m t h e m a n i f o l d
w ith t o o l i n g (A) as s h o w n . R e m o v e b e a r i n g
(15) f r o m th e m a n i f o ld .
7 -35
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SSEM B LY A N D ASSEMBLY
OIL PUMP
A S S E M B L E O IL P U M P 1 3 0 4 — 16
Tools Needed
3. L o w e r th e t e m p e r a t u r e o f s h a ft (4). I n sta ll
the key in th e sh a ft a n d in stall t h e s h a ft in
g e a r (5) w ith a press u n til t h e g e a r m a k e s c o n
tact w ith th e s h o u l d e r o n th e sh aft.
4. L o w e r th e t e m p e r a t u r e o f t w o sh a fts (6) a n d
install in m a n i f o l d (7). I n sta ll th e b e a r i n g in
the m a n i f o l d w ith t o o l i n g (A). T h e i n stalled
b e a r i n g m u s t be .030 in. (0 .76 m m ) b e l o w t h e
m a c h i n e d s u r f a c e o f th e m a n i f o ld .
7-36
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S S E M B LY
OIL PUMP
6. I nstall th e b e a r i n g in h o u s i n g ( 8 ) w ith t o o l i n g
(A) un til th e b e a r i n g is e v en w ith t h e m a V
ch i n e d su r f a c e o f th e h o u sin g . ■H
e n d by:
a) in stall oil p u m p .
« * -
7-37
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
1. R e m o v e th e c o o l a n t f ro m th e engine.
3. R e m o v e t w o h o lts (4) a n d c l a m p (2 ). R e
m ov e the e l b o w (1).
4. R e m o v e t w o b o lts f ro m p ipe (3 ).
7. R e m o v e th e b o lts (7 ) t h a t h o ld plate a nd
s u p p o r t to the b lo ck .
4. R e m o v e the f o u r b o lts t h a t h o ld e l b o w t o
th e w a t e r p u m p .
1 2. R e m o v e th e e l b o w a n d t u b e as sem b ly .
7 -3 8
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SSEM B LY A N D ASSEMBLY
2. In stall t u b e a ssem b ly ( 2 ) a n d e l b o w ( 3 ).
5. Install b o lts ( 5 ) t h a t h o ld p la te a nd s u p p o r t
to b lo ck .
6. In stall t w o b o lts t h a t h o l d t u b e a s se m b ly
(6 ) t o th e tee.
I 0. A d d oil t o en gin e as n e e d e d .
7 -3 9
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SSEM B LY A N D ASSEMBLY
1. R e m o v e th e c o o l a n t f r o m engine.
3. R e m o v e t w o b o lts ( 2 ) a n d c l a m p t h a t h old
oil line ( l ) t o oil co o ler . Move oil line aw ay
f r o m oil co o ler . R e m o v e w a t e r line (3 ).
7. R e m o v e th e six b o l t s (6) t h a t h o ld w a t e r
p u m p to acce sso ry drive h o u sing .
8. R e m o v e th e fresh w a t e r p u m p . W eig h t is 86
lb. ( 3 9 kg).
IN S T A L L F R E S H W A T E R P U M P 1 3 6 1 — 12
1. F a s t e n a ho ist to w a t e r p u m p . P u t th e p u m p
on engine. In stall th e six b o lts t h a t h o ld
p u m p to acce ss o ry drive housing.
6. A d d oil to en gine as n e e d e d .
7-40
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D ISA SS E M B LY A N D ASSEMBLY
7-41
D 3 7 9 , D 398 , D 3 9 9 IN D U STR IA L A N D M A R IN E ENGINES D IS A SS E M B LY A N D ASSEMBLY
T o o ls N e ed e d A
1 P 2321 P u lle r A s s e m b ly 1
F T 8 84 Leg 2
8B7560 S te p P la te 1
2B2694 B o lt 2
st a rt by:
a) r e m o v e fresh w a t e r p u m p
7-42
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U STR IA L A N D M A R IN E EN GIN ES D ISA SSEM B LY A N D ASSEMBLY
© — /
6. R e m o v e r e t a i n e r (16) f r o m h o u s i n g (15).
7-43
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
1P510 D riv e r S et
CAUTION
Clean water only is permitted for use as a
lubricant for assistance at installation. 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.
4. P u t sh a ft (4) in p o s i t i o n in t h e h o u s i n g . I n
stall b e a r i n g (5) o n th e h o u s i n g w i t h f o u r
b o lts a n d locks. B e n d t h e locks.
5. P u t th e c e r a m i c r in g (6) in p o s i t i o n in th e
r u b b e r seal. Use h a n d p r e s s u r e a n d t o o l (7)
( w h ic h is w i t h th e r e p l a c e m e n t rin g ) t o i n
stall c e r a m i c rin g (6). U se h a n d p r e s s u r e a n d
th e t o o l ( w h ic h is w i t h t h e r e p l a c e m e n t ring)
t o install th e seal a s se m b ly . P u s h se al a s
se m b ly o n sh a ft u n til seal faces m a k e ligh t
contact.
V s-1
7 -4 4
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBL Y
7-45
D379 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
2. D i s c o n n e c t oil o u t l e t line ( l ).
3. R e mo v e t he bol t s ( 2) t h a t hol d p u m p to
p u m p m o t o r . R e mo v e t he p r e l u b r i c a t i o n oil
pump.
IN S T A L L P R E L U B R I C A T I O N OIL
PUMP (D 399) 1 3 1 9 — 12
3. C o n n e c t oil o u t l e t line.
TYPICAL RXAMPLE
7-46
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
st ar t by:
a) r e mo v e p r e l u b r i c a t i o n oil p u m p
1. R e mo v e inlet oil line ( 1) f r o m p u m p . Jr'
2. R e mo v e bol t s (2) t h a t ho l d h e a d a s s e mbl y .
R e m o v e idl er a s s e mbl y f r o m h e a d a s s e mb l y.
3. R e mo v e r o t o r f r o m p u m p housi ng.
4. R e mo v e seals f r o m hous i ng. R e m o v e s c r ew
( s o c k e t he a d) f r o m housi ng.
A S S E M B L E P R E L U B R I C A T I O N OIL
PUMP (D 399) 1 3 1 9 — 16
T o o ls Needed A
1P529 Handle 1
3. C h e c k e n d c l e a r a n c e o f r o t o r wi t h t h i c k n e s s
g a u g e (2). T h e e n d c l e a r a n c e m u s t be . 003 t o
.005 in. (0.08 t o 0.13 mm) .
45473Xi
e n d by:
a) install p r e l u b r i c a t i o n oil p u m p
7-47
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S DISASS EMB LY A N D ASSEMBLY
5 B 1 161 W ire
st ar t by:
a) r e m o v e engi ne oil c o o l e r
b) r e m o v e f resh w a t e r p u m p
c) r e m o v e st a r t er s
d) r e m o v e engi n e oil p u m p
e) r e m o v e oil pr e s s u r e relief val ve
1. F a s t e n a hoi st a n d r e m o v e t h e p r e l u b r i c a t i o n
oil p u m p a n d m o t o r as a un i t , (if so e q u i p
ped). We i g h t is 105 lb. (47. 3 kg).
2. R e m o v e t he wi r i ng h a r n e s s a n d pl at e for the
p r e l u b r i c a t i o n oil p u m p a n d mo t o r .
3. R e m o v e t he b ol t s (1) t h a t h o l d i n s p e c t i o n c o
vers t o bl ock. R e m o v e t he i n s p e c t i o n c o ver s
(2) f r o m e a c h si de o f bl ock.
4. T u r n c r a n k s h a f t (in t h e d i r e c t i o n o f n o r m a l
r o t a t i o n ) unt i l t he r o d c a p s (4) c a n be r e
m o v e d t h r o u g h t he o pe ni ng.
6. R e m o v e t he b e a r i n g (5) f r o m t h e r o d cap.
7-48
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBLY
7. P u s h t he c o n n e c t i n g r o d s (6) a w a y f r o m
crankshaft.
8. R e m o v e t h e u p p e r h a l f o f b e a r i n g s f r o m t he
c o n n e c t i n g r ods.
N O T E : Be sur e t he t a b on ba c k of b e a r i n g fits in t a b
g r o o v e (slot) of cap.
12. R e m o v e t h e cap. M e a s u r e t h i c k n e s s o f t h e
wire. T h e c l e a r a n c e b e t we e n a n e w r o d b e a r
ing a n d c r a n k s h a f t J o u r n a l m u s t be .0031 t o
.0073 in. (0. 079 t o 0. 185 m m) . T h e m a x i m u m
per mi s s i b l e c l e a r a n c e is .012 in. (0. 30 m m ) .
T Y P I C A E EX A M PI 1
13. P u t t h e c a p s in p o s i t i o n o n t h e c o n n e c t i n g
r o d s a n d instal l t h e nut s. T i g h t e n t h e n u t s t o a 15. Inst al l t he pl at e a n d wi r i ng h a r n e s s f o r p r e
t o r q u e o f 40 ± 4 lb. ft. (55 ± 5 N. m) . P u t a l u b r i c a t i o n oil p u m p a n d m o t o r (if so e q u i p
m a r k o n t h e b ol t h e a d s a n d b e a r i n g c a p s t h e n ped) . I nst al l t h e p r e l u b r i c a t i o n oil p u m p a n d
t i g h t e n t he bol t s 120° mo r e . m o t o r wi t h a hoi st . We i g h t is 105 lb. (47.3 kg)
N O T E : L o c k s a n d c o t t e r pi ns a r e n o t n eces s a r y e n d by:
wi t h t his m e t h o d t o t i g h t e n t he bolt s, even t h o u g h a) i nst all f resh w a t e r p u m p
t he bol t has a hole. b) instal l en g i n e oil p u m p
c) inst al l engi ne oil cool er
14. I nst al l t h e i n s p e c t i o n c over s w i t h n e w g a s d) i nst all st a r t er s
kets. e) inst al l oil pr e s s u r e relief val ve
7-49
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
6. R e m o v e bol t s ( 2) t ha t h o l d c y l i n d e r b l oc k
t o t he base.
IN S T A L L O IL P A N B A S E 1 3 0 2 — 12
3. Install t he f o u r b ol t s t h a t ho l d pl at e f o r oil
p u m p to t he base.
5. C o n n e c t fuel s u p p l y a n d r e t u r n lines t o e n
gine.
7-50
D379 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
I. R e m o v e t he t hr ee b ol t s ( 2) t h a t h o l d o v e r
ride as s e mb l y ( l) t o fuel r at i o co n t r o l .
2. R e mo v e t he over r i de a s s e mbl y ( l ).
4. R e mo v e t he t w o b ol t s t h a t h o l d t he fuel
r at i o c o n t r o l t o gover n or . Move t he fuel
r at i o c o n t r o l ( 4) t o w a r d f r o n t o f engi ne a n d
r e m o v e it f r o m srovernor.
I N S T A L L FU E L R A T I O C O N T R O L
W ITH O V E R R ID E 1 2 7 8 — 12
l . Install t he fuel r at i o c o n t r o l o n t h e g o v e r
nor . Ma ke sure t he b o l t ( l ) engages t he
gr oove ( sl ot ) in r ack s t o p col lar ( 2). Install
t he t w o bo l t s t h a t h o l d fuel r at i o c o n t r o l in
place.
4. Ma ke an a d j u s t m e n t t o t he fuel r at i o c o n
t r o l. See F U E L RA T IO CONTROL
S E T T I N G IN T E S T I N G A N D A D J U S T I N G .
7 -5 I
D 3 7 9 , D 398 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBL Y
st ar t by:
a) r e m o v e fuel r at i o c o n t r o l wi t h o v e r
ride
1. R e m o v e t he c over ( 1) , spr i ng ( 2 ) , a nd
pl unge r ( 3) f r o m over r i de ho u s i n g ( 4).
2. R e m o v e t he n u t a n d s c r ew t h a t ho l d lever
as s e mbl y t o t he over r i de h o u s i n g ( 4) . R e
m o v e t he lever as s e mb l y a n d spri ng. R e
mo v e t he seal f r o m t he housi ng.
if
r e m o v e t he was her , d i a p h r a g m , r e t a i n e r an d
bol t .
A S S E M B L E FUEL R A T I O C O N T R O L
W IT H O V E R R I D E 1 2 7 8 — 16
7-52
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
GOVERNOR
REMOVE GOVERNOR 1 2 6 4 — 11
1. Di s c o n n e c t c o n t r o l linkage ( l ) f r o m g o v e r
nor.
4. Di s c o n n e c t oil lines ( 6) a n d ( 5) f r o m t he
gover no r .
5. R e mo v e six bo l t s ( 4) t h a t h o l d g o v e r n o r t o
g o v e r n o r drive housi ng.
IN S T A L L G O V E R N O R 1 2 6 4 -1 2
2. Install t he bo l t s t h a t h o l d g o v e r n o r t o gov
e r n o r drive housi ng.
6. C o n n e c t c o n t r o l l i nkage t o t h e g over no r .
7 -5 3
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEMBL Y
GOVERNOR
A83698X1
7 -5 4
D 3 7 9 , D 398 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
GOVERNOR
D IS A S S E M B L E G O V E R N O R 1 2 6 4 — 15
start by:
a) r e mo v e g o v e r n o r
b) r e mo v e fuel r at i o c o n t r o l wi t h o v e r
ride
l. R e mo v e cover s ( l ) a n d (2) f r o m t he g o v e r
nor.
3. R e mo v e t h e bol t s ( 6) t h a t ho l d levers t o
shaft .
4. R e mo v e t he levers (7). R e mo v e t h e s h a f t
(4).
5. R e m o v e b ol t ( 5) t h a t h o l ds h o u s i n g to g o v
e r nor . R e mo v e h o u s i n g (8).
6. R e m o v e t he seals f r o m ho u s i n g (8).
7. R e m o v e t he s t o p g r o u p ( 9).
8. R e mo v e t he s c r ew t h a t h o l d s t he stop
collar. R e m o v e t he s t o p col l ar ( 1 0 ) .
9. R e mo v e t he s pr i ng a n d seat.
10. R e m o v e t he f o u r b ol t s ( 1 1 ) t h a t ho l d g o v e r
n o r hous i ng. R e m o v e t h e g o v e r n o r h o u s i n g
( 12).
1 2. R e m o v e t he lever (1 7) f r o m t he shaft .
7-55
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S SE M B LY
GOVERNOR
13. R e m o v e t he g o v e r n o r spri ng, seat , spring
a nd washer.
i 5. R e m o v e t he sha f t ( 20) f r o m g o v e r n o r h o u s
ing. R e m o v e t he bear i ngs a n d seal f r o m g ov
e r n o r housi na.
21) (22
18. R e m o v e t he spr i ng ( 2 2 ) a n d p l u n g e r ( 2 3 ) .
7-56
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
GOVERNOR
22. R e mo v e t he seat ( 3 1 ) . bol t ( 3 2 ) , was her s
( 3 3 ) a n d spr i ng ( 3 4 ) .
< ? o
23. R e mo v e t he sleeve a n d b e a r i ng as s e mb l y
f r o m t he wei ght as s embl y.
27. R e m o v e t he ring ( 3 9 ) t h a t h o l d s c y l i n d e r t o
we i g h t a s s e mbl y. R e m o v e t h e wei ght a s s e m
bly.
28. R e m o v e p i s t on ( 4 1 ) a n d sleeve ( 4 0 ) f r o m
t he c y l i n d e r (43) .
7-57
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S DISASS EMB LY A N D ASSEMBL Y
GOVERNOR
32. R e m o v e t he b ol t ( 4 7 ) and wa s h e r f r o m
shaft as s embl y.
37. R e m o v e t he pl ug as s e mb l y ( 5 3 ) a n d gasket .
7-58
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
GOVERNOR
ASSEMBLE GOVERNO R 1 2 6 4 —16
T o o ls Needed A
© ©
1P529 H andle 1
2. Inst al l t he pl ug a s s e mb l y ( 2).
& *
N O T E : F o r s t a n d a r d eng i ne r o t a t i o n , t h e l oc a t i o n
o f val ve (1) is o n t he ri ght si de o f g o v e r n o r dr i ve
ho u s i ng. F o r r ever se engi n e r o t a t i o n , c h a n g e t h e
pl ug a s s e m b l y (2) wi t h t he val ve (1).
4. Instal l t he bu s h i n g in drive h o u s i n g wi t h
t oo l i n g ( A).
N O T E : Inst al l t h e b u s h i n g so it is n o t e x t e n d e d
m o r e t h a n .465 t o .475 in. (11.81 t o 12.07 m m ) a b o v e
t he b o t t o m o f p u m p bor e.
5. Install t he pi n a s s e mb l y ( 7).
7. H e a t t h e drive gear ( 9) t o 2 5 0 ° F t o 3 0 0 ° F
(1 2 1 ° C t o 149 ° C) , a n d install it o n t he s h a f t
a n d c over a s s e mb l y (8).
7 3859X 1
8. Inst all t h e v/ asher a n d b o l t ( 1 0 ) .
7-59
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS ASS EMB LY A N D ASSEM BLY
GOVERNOR
9. Install O- r i ne seal ( 1 3 ) on t he sleeve ( 14).
7-60
D 3 7 9 , D 39H. 0 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B I Y A N D A S S E M B L Y
GOVERNOR
i Install gear ( 2 5 1 o n t he pin a s s e m b l y .
7-61
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
GOVERNOR
26. Install t he seat ( 3 5 ) . spr i ng ( 3 4 ) a n d wa s h e r
( 36) in g o v e r n o r h o u s i n g (30) .
e nd by:
a) install g o v e r n o r
b) m a k e a d j u s t m e n t t o g o v e r n o r ( See
G O V E R N O R A D J U S T M E N T S in
TESTING AND ADJUSTING)
c) install fuel r at i o c o n t r o l wi t h over r i de
7-62
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBL Y
SHUTOFF CONTROL
R EM OVE SHUTOFF CON TR O L 7 4 1 8 — 11
3. R e m o v e five bol t s t h a t ho l d s h u t o f f c o n t r o l
t o fuel i nj ect i on p u m p h ous i ng.
4. R e m o v e s h u t o f f c o n t r o l a n d c a b l e as a uni t.
IN S T A L L S H U T O F F C O N T R O L 7 4 1 8 — 12
1. P u t s h u t o f f c o n t r o l in p o s i t i o n o n fuel i nj ec
t i on p u m p hou s i n g . Inst al l t he bol t s t h a t
hold sh ut of f co nt ro l to injection p u m p
hous i ng.
7-63
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
SHUTOFF CONTROL
D IS A SS E M B LE SHUTOFF
CONTROL 741 9 — 15
i•
start b \ :
a) r e m o v e s h u t o f f c o n t r o l
I. Di sass embl e reset b u t t o n a n d pi s t on as fol
l ows:
d) R e m o v e b e a r i n g ( 4 ) f r o m c o v e r ( 1 ).
- 64
D 3 7 9 . 0 3 9 8 , D 3 9 9 ( Nl - US TR i At AND M A R I N f E N G I N E S D IS A S S E M B L Y A N D A S S E M B L Y
SHUTOFF CONTROL
c) R e m o v e ihe Piii i I ' i ) fita! ho l d s gem ( I 3 1
t o s h a f t ( i f 1 R e mo v e t he gear.
d) Slide sl i al t l I 2) o u t o f ad a p ter (9) Re- ,
m o v e t h e t w o d o w e l s ! 14) t h a t h o l d g e a r
a s s e t n h l y ! I Oi t o g e t h e r .
m s
il5)
1
2. Di s a s s embl e e a r n e r and w e i g h t a s f o l l o w s :
a ! I i n i ai iaer i 1 fi f r om tie- housing.
hi R e m o v e screw ( de l f r om carrier ( 74) .
N o i l,: R e m e m b e r t he n u m b e r o f t u r n s n e e d e d !o
r e move the screw ( l t d a nd use this s a me n u m b e r
for i nst al l at i on.
d) R e mo v e gear ( 1 ° ) f r o m s hal l ( 7 0 ) wi t h
pul l er ( A i .
4. R e m o v e e me r g e n c e s h u t o f f b u t t o n as f ol
lows:
a) R e mo v e b u t t o n ( 77) a nd s pr i ng by l o o s
eni ng s cr ew ( 7b) .
h) Push p l u n g e r ! \S) d o w n t h r o u g h h o u s i ng
(21) .
7-b2
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D ISA SSEM B LY A N D A SSEM B LY
SHUTOFF CONTROL
7. R e mo v e t w o pins f r o m col l ar ( 3 5 ) . R e m o v e
t he col lar ( 3 5 ) a n d spr i ng ( 3 3) .
8. R e mo v e pin ( 3 2 ) a n d m a k e a s e p a r a t i o n o f
nut ( 34) f r o m cable.
9. R e m o v e t w o c o t t e r pi ns ( 3 7 ) , wa s h e r s ( 3 9 )
an d springs.
1 1. R e m o v e pl ug ( 45 ) f r o m e n d o f hous i ng .
5. T h e f o l l o we r s h a f t ( 4 0 ) is p u s h e d ( pr es sed)
i nt o t he h o u s i n g ( 31) . T o r e m o v e t he s pr i ng
( 4 6 ) , gui de ( 4 4 ) a nd spacer , it is neces sar y
t o cause d a m a g e t o t h e s ha f t ( 4 0) .
Wv
A.
7. R e mo v e t he s pr i ng a n d l at ch ( release lever).
7-66
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBL Y
SHUTOFF CONTROL
ASSEMBLE SHUTOFF CONTROL 7 4 1 8 — 16
T o o ls Needed A
1P529 H andle 1
2. It is neces s a r y t o install n e w f o l l o we r s h a f t
( 5).
5. As s e mb l e w o r m sha f t as f ol lows:
a) Install bear i ng i nt o h o u s i n g ( I ).
b) Install gear ( 7) on s ha f t ( 8) wi t h pin.
c) Slide a s s e mb l e d gear a nd s h a f t ( 8) i nt o
h o u s i ng ( l ) a nd ho l d wi t h ring.
d) Install pl ug ( 9) in e n d o f h o u s i ng ( l ).
6. Pus h l at ch o u t o f t he wa y a n d install t h e
gui de ( l l ) .
7-67
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L AND M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B LY
SHUTOFF CONTROL
8. \ s s c m b ! e t h e c a b l e as f o l l o w s :
al C o n n e c t n u t ( I 8 ) 10 c a b l e a s s e m b l y ( 1 7 ) % 07
u itii pin i i (i).
b) Install s p r i n g ( I 1)) a n d collar I 70) with
t w o pins ( 73).
9. I n s t a l l e m e r g e n c e s h u t o f f b u t t o n as f o l l o w s :
ai P u s h p l u n g e i ( 3 4 ) u p t h r o u g h h o u s i n g ( 1).
in 1i wt a l ! t h e s p r i n g ( 7 5 ) a n d b u t t o n ( 3 b )
o n I In' p l u n g e i I m b u m the screw (27).
I 0. A s s e m b l e c a r r i e r a n d w e i g h t as f o l l o w s :
a) Install gear ( 3 1 ) o n s h af t ( 3 3 ).
b) Install n u t ( 3 3 ) . pin ( 3 4 ) . w e i g h t ( 3 0 ) a n d
spr ing ( 39).
1 1 . Instal l t h e c a r r i e r a s s e m b l y ( 3 b ) in t h e h o u s
! 1704 >. I
i ng.
7-68
7 if I'Sm h I -.' .i ' -i f iS' .n ‘ M S Mi >>C, n !M:i3iWFS
« s n u r o r r C O N i r i m
ia m .-n ;in,i a . a a M r
fs
(m
It'. I n s t a l l c o v e r ( 4 8 ) w i t h t w o s c r e w s a m ! on*
h o l t t h a t h o l d c o v e r t 1( 4 t o h o u s i n g ( I ).
end b \ :
a I in stall s h tito fl c o n t r o l
D3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
D i s c o n n e c t t h e fuel line ( l ) f or t h e p u m p t o
be r e m o v e d by r e m o v i n g n u t (2) . P u t a p r o
t ect i ve c over over t he o p e n e n d o f fuel line.
Move t h e fuel lines ( l) o u t o f t h e way.
3. R e m o v e t he bol t s (3).
4. Lift t h e p u m p b o d y ( 5) s t r ai ght u p a n d r e
mo v e b o d y .
IN S T A L L FUEL I N J E C T I O N
PUMPS 1 2 5 1 — 12
1. T u r n t he p u m p pl u n g e r unt i l t o o t h ( 2) o f
p l un ge r is in a l i g n m e n t wi t h m a r k ( l ) o n
r ack. Install t he pl u n g e r ( 3) b y sliding e nd
i nt o y o k e o f lifter.
CAUTION
Be careful when installing pump barrels and
plungers. Do not put plunger of one pump in
barrel of another pump.
7-70
D 3 7 9 , D 398 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBLY
1. R e m o v e t he d a m p e r s ( l ) f r o m t h e fuel lines
at fuel i nj ect i on p u m p s . D i s c o n n e c t t he fuel
line f r o m t he p u m p s . D i s c o n n e c t linkage
f rom governor and remove governor control
channel .
2. R e m o v e t he clips a n d r emai nder o f t he
d a m p e r s f r om fuel lines.
3. Di s c o n n e c t fuel lines f r o m fuel i nj ect i on
valves. R e mo v e t he fuel i nj e c t i on lines. P u t
covers and plugs over o p e n i n g s t o k e e p di r t
a nd cl List out .
I N S T A L L FUEL I N J E C T I O N
L IN E S 1 2 5 2 — 12
4. Install g o v e r n o r c o n t r o l c h a n n e l . C o n n e c t
l inkage t o gover nor .
7 -7 1
D 3 7«. ' • > ! ' ; i - * h-i< ' o : so < , d o F r-N M IN F S HSR A.^RFIylHI f / ’«NM /' S S F M RI Y
R E f w n V h r s s ! / \ U ; > ! ! Vi A d o r ■> r « .
i fi ! ' - i . F ^ R i ^ f S ; 1 t 'b Q 1 1
mt-d.! e ; \ e !n h l \
sh ie ld i ! > So
! : Me ” !
i i ms i aH .i M i o'" id 3 • 'ro e l e\ c h o l t in
h e m o v e t h e oi l l i n e f M M o m e n g i n e .
S ! iio1.111 a : N" i d Nh l o m e d e y e b o U in
s h i e l d . I :i .ion .1 i e i ' i >i1•I r e m o v e wat er
• J 11 e 1d Vv i ' i 1’ h i e. U d ' H, > ;H ; ,n 11 I /0 ;
|) ; *e
° I M - i m u e tlii- l « „ l i . I S ) t h e ! Iiold t i i a n i l o l d t o
0 i t 1' « ' i h e t e--t l o - m o \ c e,;it«e line Iroi n hack
«I sh ie ld .
Kk i i n n e O k !i O, ( i i i i a i bold shield to
ox'iaiisl i i la n ! I '
.0 K e m o \ e till- al l i c i d i i I b o m M a n i f o l d .
I N b l A I L tXHAUSI M A N i K H O b
( I NDU S T RI AL EiSKiiiMEh) K)b9 12
tn j*
k ■j k .
■
1 ii! a iI i
0) ib H
ia- M i i e k i ( ! h I igi
(II N*iio
( he b o ha ( I « in
V r ah
isildk
t h r e a d s o i al l b o l t s t h a t h o l d e x h a u s i m a n i
fold to c y l in d e r b e a d s a m i tu r h o c l u i i g e r .
4. b a s t e d a h o is t t o t he e x h a u s t m a n i f o l d . Put
t he ex h a u s t ma n i f o l d i n p o s i t i o n o n e ngi ne.
end by:
a) install valve covers
b) install fuel i nj ect i on lines
7-74
D 3 7 9 . D 398 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMB LY AN D ASSEMBL Y
st art by:
a) r e mo v e t u r b o e h a r g e r h e a t shield
b) r e m o v e fuel lines
c) r e m o v e valve covers
1. R e m o v e t he w a t e r line ( 3) f r o m m a n i f o l d .
3. R e m o v e t he shield ( l ).
4. R e mo v e bol t s t h a t hol d e l b o ws ( 4) to e x
haus t ma n i f o l d .
5. Hi t t he e l b o w s w i t h a sof t h a m m e r t o di s
c onnect t he m from manifold.
6. R e mo v e f o u r bol t s t h a t ho l d w a t e r c o n
n e c t o r s ( 6) t o t he e x h a u s t ma n i f o l d .
7. R e m o v e t he b ol t t h a t h ol ds br ace ( 5 ) t o
ma n i f o l d .
8. R e mo v e b ol t s ( 7) t h a t h o l d e x h a u s t m a n i
fold t o t he c y l i n d e r heads.
9. R e mo v e bol t s a n d n u t s t h a t hol d e x h a u s t
m a n i f o l d to t he t u r b o e h a r g e r .
7 -7 5
0 3 79 d . o l e i . . v •■■■) Wh j . i m o d ,L E N G I N E S oi.sAbbhMHl AND A S S E M B L Y
M A N IF O L D S (M A R IN E ENGINES)
INS [ A t i E X H A U b l NAt-iltw M Ora
( M A R IN E EN G INES) 1 0 b 9 -12
! . i ; I, u ; i i .] m b 1- 1 ■ huged I hid! and a
: ; i (■ \ t ! • s- d . ebnlt in manifold .
Ihi t M ’.ioo! ui i i, e i o m p o u n d on
i l i i cads ot bents Install tlu: bolt s (3) t hat
i o d d o s h j i f - t n'uo'u.lohl t o t i n b o e h a r u e r .
I u d ile il ili,. i; i,, 40 - 4 !|-, |{ . (5 S a; 5
'a aii L
| in: ■
' ■ ■■ h:,i a... i h e a t
i ha su r b ' v h a r u e r
n: line l ea turbo-
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D AS SE MB LY
st art by:
a) r e m o v e fuel i nj e c t i on lines
b) r e mo v e e x h a u s t m a n i f o l d ( o n e side
onl y)
1. R e mo v e t he b ol t s ( 2) that hold ex hau st
e l b o w t o s u p p o r t (3).
2. R e mo v e bol t s ( 4) t h a t ho l d s u p p o r t ( 3) a n d
l ifting eye (1) t o c y l i n d e r bl ock. R e m o v e
t he s u p p o r t a nd lifting eye f r o m engi ne.
3. Di s c o n n e c t w a t e r line c o n n e c t i o n f r o m
water t em pe r at u re regulator housing and
t he m a n i f o l d . F a s t e n a hoi st t o r e g u l a t o r
housi ng. R e m o v e t h e bol t s t h a t h o l d f r o n t
lifting eye a n d s u p p o r t t o c y l i n d e r bl ock.
R e mo v e t he w a t e r r e g u l a t o r h ou s i n g , m a n i
f old. a n d li ft i ng eye as a uni t . We i g h t is I SO
lb. ( 6 8 kg).
4. R e mo v e t h e line ( 5) f or air t o f uel r at i o
c o n t r o l . R e m o v e t he oil l ine f r o m b a c k o f
gover no r .
6. R e mo v e t he b ol t s ( 6) t h a t h o l d h o u s i n g t o
c y l i nde r bl ock.
CAUTION
Do not cause damage to the oil tube for fuel
pump and governor drive when unit is removed.
7-77
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEMBLY
1. P u t 7 M 7 2 6 0 Li qui d G a s k e t Ma t e r i a l o n b o t
t o m o f h o u s i n g s a n d sur f a c e o f c o n t a c t wi t h
c yl i nd er bl ock.
2. P u t f o u r 3 / 8 ” - 1 6 NC bol t s ( 1) f or a gui de
in t he c yl i nder bl ock.
5. F a s t e n a hoi st t o w a t e r t e m p e r a t u r e r e g u
l at or housi ng, m a n i f o l d , li ft i ng ey e a n d s u p
p o r t (2). Inst all as a uni t . Inst al l t he b ol t s
a n d c o n n e c t t h e w a t e r lines.
10. Ma ke a d j u s t m e n t o f t i mi n g ; See T I M I N G
T H E F U E L INJECTION PUMP CAM
S H A F T in T E S T I N G A N D A D J U S T I N G .
e nd by:
a) install e x h a u s t m a n i f o l d
b) install fuel i n j e c t i o n l ines
7 -7 8
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBL Y
T o o ls Needed A B C
9M 4568 W rench 1
In s ta lla tio n T o o l G ro u p
1P529 H andle 1
s t art by:
a) r e mo v e fuel i nj ect i on p u m p h o u s i n g
a n d g o v e r n o r as a uni t
b) r e m o v e g o v e r n o r
c) r e m o v e s h u t o f f c o n t r o l (if so e q u i p p e d )
R e m o v e g o v e r n o r drive h o u s i n g ( l ) from
fuel i nj ect i on p u m p housi ng.
7 -7 9
D 3 7 9 , D 3 9 8 , D 3 9 9 I N D U S T R I A L A N D M A R IN E ENGINES D ISA SSEM B LY AND A SSEM B LY
CAUTION
Be very careful when removing fuel injection
pumps to prevent damage to plunger surfaces.
The body and plunger of each are put together
at the factory and cannot be used with the
bodies or plungers of other pumps.
8. R e m o v e t he t h r e e bol t s ( 1 0 ) a n d l ocks t h a t
hol d t h r u s t plat e. R e m o v e t he t h r u s t pl at e
(9).
7 -8 0
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIA L A N D M A R IN E ENGINES DISA SS EMB LY A N D ASSEMBLY
10. R e m o v e y o k e s cr ews ( 1 1 ) . P u t i d e n t i f i c a
t i on o n e ach y o k e s cr ew by its l o c a t i on in
i nj ect i on p u m p housi ng.
gHj yy
: 2. T i g h t e n t he bol t s ( 1 3 ) e n o u g h t o ho l d lifters
a w a v f r o m t he c a ms h a f t .
CAUTION
Be careful when removing the camshaft. Do not
cause damage to camshaft or bearings.
7-81
D379, D398, D399 IND USTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY
7-1 OH 7 x 1
7 -8 2
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY
7- 83
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
A B C
9M 4568 W rench 1
1P529 Handle 1
CAUTION
Be sure the tool group (B) is in center position
on bearing while installing bearings, so no
damage will be caused to them.
6. T i g h t e n t he bol t s ( 3) e n o u g h t o ho l d lifters
74105X 1
up t o install c a ms h a f t .
7 -8 4
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS A S S E M B L Y A N D A S S E M B L Y
N O T E : If t h e engi ne lias a c o u n t e r c l o c k w i s e r o t a
t i on. t he c a m s h a f t is i nst al l ed wi t h t he a r r o w a n d
t he F - m a r k ( 5) at t he f r o n t o f p u m p h o u s i n g as
s h o w n . F o r cl ockwi s e r o t a t i o n o f engi ne, t h e c a m
shaft is i nst al l ed wi t h t he F - m a r k a n d a r r o w at t h e
r ear o f p u m p housi ng.
9. R e m o v e t he bol t s a n d wa s h e r s t h a t we r e
us e d t o ho l d lifters up.
10. Install t he t h r u s t pl at e ( 6) . l oc ks a n d b o l t s
t h a t hol d c a m s h a f t in housi ng.
7-85
DIS ASS EMB LY A N D ASSEMBL Y
D379 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES
a) R e m o v e t he pl unger ( 9) f r o m t h e p u m p
(1 0) t o be installed.
©
b) Put clean diesel fuel o n t he p l u n g e r a nd
barrel of t he p u m p .
d) Slide t he e n d o f p l unge r i nt o t h e y o k e
s cr ew o f t he lifter.
7-86
D 3 7 9 , D398 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
e nd by:
7-87
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEM BLY
T o o ls Needed A
1P529 H andle 1
s t ar t by:
a) r e mo v e fuel i nj e c t i on p u m p hous i ng,
go v e r n o r , a nd g o v e r n o r dri ve as a uni t
b) r e m o v e g o v e r n o r
e) r e m o v e s h u t o f f c o n t r o l
1. R e m o v e t he g o v e r n o r drive ho u s i n g f r o m
t he fuel i nj ect i on p u m p h o u s i ng wi t h a
hoi st . Wei ght o f g o v e r n o r drive f or D 3 7 9 is
8 0 lb. ( 3 6 kg): l o r D 3 9 8 a n d D 3 9 9 is l 25
lb. ( 5 7 kg). R e m o v e c oupl i ng.
3. R e m o v e pin t h a t h ol d s s ha f t a s s e mbl y. R e
mo v e lever ( 2) . spr ing ( 4) . k e y a n d sha f t
as s e mb l y (5). R e mo v e t he seal f r o m h o u s
ing.
4. R e mo v e g o v e r n o r drive pi n i o n (3).
8. T u r n pul l er bol t ( 1 2 ) c o u n t e r c l oc k w i s e a nd
r e mo v e drive gear ( 11) .
7 -88
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
1P529 Handle 1
1P472 D rive Plate 1
1P475 D rive Plate 1
8 S 2 3 28 D ial Test In d ic a to r G ro u p
1
1. Install t he bear i ngs ( 1) in h o u s i n g wi t h
t o o l i n g ( A). P u t cl ean engi ne oil o n
bearings.
2. Install t he dri ve sha f t ( 2) a n d l o c k n u t , k e y
a n d g e a r ( 3).
4. He a t t h e t h r u s t wa s h e r t o a t e m p e r a t u r e o f
2 5 0 ° F ( 1 2 0 ° C ) . Install bear i ng a n d gear (4)
in housi ng. Push t h r u s t wa s h e r ov e r gear
unt i l wa s h e r is even wi t h t o p o f gear. T h e r e
m u s t be . 015 t o . 045 in. ( 0 . 3 8 t o 1. 14 m m )
e n d clear ance.
5. Install seal ( 6) in h o u s i n g w i t h lip o f seal t o
inside. Inst al l lever a n d s ha f t a s s e mbl y
(5). Install spring, k e y a n d pin.
N O T E : Be sure t h e pi n is e n gaged wi t h gr oo ve in
sha f t a n d sha f t t u r n s f reely. T h e spr i ng m u s t h o o k
over t he pin a n d a r o u n d s ha f t lever.
7 -8 9
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEM BLY
2. Di s c o n n e c t t he d r a i n t u b e f r o m t h e b o t t o m
o n t he s h u t o f f c on t r ol .
3. R e m o v e ni ne bo l t s (2) a n d l o c k w a s h e r . R e
m o v e s h u t o f f c o n t r o l (3) f r o m t h e oil p u m p .
CAUTION
Be sure the splines on the shutoff control drive
shaft are in alignment with the splines in the oil
pump drive coupling.
5. I nst al l t he s h u t o f f c o n t r o l o n t h e oil p u m p
wi t h ni ne bol t s (2) a n d l o c k wa s h e r s .
6. C o n n e c t t he t u b e t o t h e b o t t o m o f t h e s h u t
of f cont r ol .
7 -9 0
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
1P 1855 S n a p R in g P lie rs
start by:
a) r e m o t e s h u t o f f c o n t r o l g r o u p
1. R e m o v e t u b e s (1) a n d (2) f r o m t h e s h u t o f f
c o n t r o l gr o u p .
A WARMING
There is spring pressure on cover (6). Use
caution when the cover is removed.
4. P u t i d e nt i f i c a t i on o n f o u r s p r i n g s (9) a n d
l o u r val ves (8) f o r as s e mb l y . R e m o v e t h e
s pr i ngs a n d val ves f r o m t h e val ve b o d y .
5. P u t i d e nt i f i c a t i o n o n t w o val v e a s s e mb l i e s
(14) f o r a s s e mbl y . R e m o v e t w o v al ve a s s e m
blies (14) f r o m p r e s s u r e c o n t r o l val ve b o d y .
R e m o v e pl u g (13), val ve (12) a n d s p r i n g (11)
f r o m t he b o d y . R e m o v e v al ve a s s e m b l y (10)
f r o m t he bodv.
7-91
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D AS SE MB LY
A 82774X1
8. R e m o v e t e n b o l t s (18) a n d washers.
R e m o v e p u m p a s s e m b l y ( 19) f r o m the
body .
9. R e m o v e r e t a i n e r r i ng (20) wi t h t oo l (A).
R e m o v e t h e w a s h e r , oil p u m p h o u s i n g
(19) a n d g e r o t o r a s s e m b l y f r o m c o v e r
(21 ).
10. R e m o v e g e r o t o r a s s e m b l y (22) f r o m p u m p
h o u s i n g (19). R e m o v e r e t a i n e r r i ng (23) wi t h
t ool (A). R e m o v e t he seat, s p r i n g a n d p l u n
ger f r o m t he h ous i ng.
Lit
7-92
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
R e m o v e k e y (25), c a r r i e r a s s e m b l y ( 24)
a n d w a s h e r f r o m c o v e r (21).
A WARNING
Spring pressure is on cover (32). Use caution
when the cover is removed.
14. R e m o v e f o u r b ol ts (33), w a s h e r s a n d
cove r (32) f r o m t he h o u s i n g . R e m o v e t h e
s p r i n g a n d seat f r o m t he cover .
7-93
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEM BLY
T o o ls N e ed e d
1P510 D riv e r G ro u p
I n s t a l l a n e w g a s k e t (4) b e t w e e n c o v e r
(1) a n d t h e b o d y . I n s t a l l a s e a t (3) in
c o v e r (1) a n d o n t h e b o d y as s h o w n .
I nst all s p r i ng (2) in seat a n d i nst all t he
c ove r wi t h f o u r bol t s a n d was her s .
3. I n s t a l l s e a t (10), s p r i n g ( 11) a n d s p e e d
s e n s i n g v a l v e a s s e m b l y (5) in t h e b o d y
as s ho wn .
7 -9 4
D 3 7 9 , D 398 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS ASS EMBLY A N D
7. I n s t a l l a n e w g a s k e t b e t w e e n t h e b o d y
a n d p u m p as s em bl y. I nst al l t h e p u m p
a s s e m b l y o n t he b o d y wi t h t e n bol t s a n d
was her s .
in t he bodv.
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S DIS ASS EMB LY A N D A SSEMB LY
end by:
a) inst al l s h u t o f f c o n t r o l g r o u p
A 82759X1
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
2. R e m o v e n u t (3) t h a t h ol ds valve in t h e p r e
comb us ti on chamber.
x R e mo v e t he nozzl e f r o m b o d y .
I N S T A L L FU E L I N J E C T I O N
VALVES 1 2 5 4 — 12
I. T u r n t he nozzl e ( 1 ) o n t he t h r e a d s o f b o d y
( 2) finger tight.
5. Install a n e w seal o n t o p o f n u t b e t we e n
valve b o d y a n d t h e nut .
7-97
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
PRECOMBUSTION CHAMBERS
R EM O VE P R E C O M B U S TIO N
CHAMBERS 1 1 0 6 — 11
T o o ls Needed A
5F8353 W rench 1
s t a r t by:
a) r e mo v e fuel i nj ect i on valves
1. R e m o v e c o o l a n t f r o m engi ne.
2. R e mo v e p r e c o m b u s t i o n c h a m b e r ( 1) wi t h
w r e n c h (A).
INSTA LL P R E C O M B U S T IO N
CHAMBERS 1 1 0 6 — 12
T o o ls Needed
5F8353 W rench
4. l ighten p r e c o m b u s t i o n c h a m b e r with
w r e n c h ( A) t o a t o r q u e of 225 ± 15 lb. ft. (300
± 20 N- m) .
7 -9 8
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEM BLY
st art by:
a) r e mo v e valve covers
l. L o o s e n t he a d j u s t m e n t s cr ews ( l ) t o get
m a x i m u m valve cl ear ance. Di s c o n n e c t oil
line ( 4) f r o m shaft .
2. R e m o v e nu t s (3) a n d s t u d s ( 2) t h a t hol d
sha f t o n head.
N O I E : It s t u d s (2) a r e r e m o v e d w h e n nu t s a r c
l oos e ne d, i nstall t he s t uds in t he head. T i g h t e n t he
s t uds t o a t o r q u e of 40 ± 5 lb. ft. (55 ± 7 N*m).
3. Re mo v e r o c k e r shaft . R e m o v e t h e pu s h r o d s
( 5) f r o m t h e c y l i nde r h ead.
INS TALL R O C K ER S H A F T S A N D
PUSH R O D S 11 0 2 & 1 2 0 8 — 12
l. Install pu s h r o d s ( l ) i nt o po s i t i o n o n t he
lifters.
2. Install r o c k e r s h a f t ( 2) o n c y l i n d e r head.
3. Install t he n u t s a n d s t u d s t h a t h o l d r o c k e r
sha f t to c yl i nde r head. C o n n e c t oil line t o
t he shaft .
N O T E : Be sur e t he s t uds a n d nu t s ar c t i g h t e n e d t o
a t o r q u e o f 40 ± 5 lb. ft. (55 ± 7 N*m).
7-99
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S
ROCKER SHAFTS
D IS A SS E M B LE ROCKER SHAFTS 1 1 0 2 — 15
T o o ls Needed A
1P529 Handle 1
st art by:
a) r e mo v e r o c k e r s haf t s a nd pu s h r o d s
l. Remove cotter pins (l), was her s a nd
springs.
2. R e mo v e the i nt a ke r o c k e r a r ms ( 5) f r o m t he
r o c k e r shaft .
3. R e m o v e t he b r a c k e t s ( 4) a n d e x h a u s t r o c k e r
a r ms (3) f r o m shaft . R e m o v e t h e f i t t i ng ( 6)
a nd spr ing (2).
4. R e mo v e t he bear i ngs f r o m t h e r o c k e r a r ms
wi t h t ool i ng ( A) . R e m o v e t he n u t a n d s cr ew
for t he a d j u s t m e n t f r o m t he ar ms. R e m o v e
t he rings a nd b u t t o n s f r o m t he ar ms.
T o ols Needed A
1P529 Handle 1
2. Install t he s pr i ng a n d f i t t i ng o n t he shaft .
3. Inst all t he r o c k e r ar ms, br a c k e t s , wa s h e r s
( l ) , spri ngs ( 2) a n d c o t t e r pi ns o n e ach end
o f shaft .
N O T E : Be sur e e x h a u s t r o c k e r a r ms a n d i n t a k e
r o c k e r a r m s are inst all ed in c o r r e c t l o c a t i o n o n
shaft .
end by:
a) install r o c k e r s ha f t s a n d p u s h r od s
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBL Y
7-101
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D UST RIA L A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
VA LVE LIFTERS
REMOVE VALVE LIFTERS 1209—11
start by:
a) r e m o t e pi s t on c oo l i ng t ube s
b) r e m o t e fuel i nj ect i on p u m p h o u s i ng,
shut of f control, g over no r and gover
n o r d r i \ e as a unit
e) r e m o t e t a l t e v o t e r s
1. L o o s e n t he a d j u s t m e n t s cr ews f or valves to
get m a x i m u m cl ear ance.
N O T E : F l y w h e e l h o u s i ng r e m o v e d f or i l l ust r at i on
onl y.
2. R e m o v e t he pu s h r ods ( 2).
3. R e m o v e t he oil t u b e s ( 1) a w a y f r o m t h e
br acket s.
4. P u t a wi re or large r u b b e r b a n d a r o u n d t h e
lifters (3) t o hol d t h e m in pl ace in br a c ke t .
5. R e m o v e t h e bol t s a n d l ocks t h a t ho l d b r a c k '
et a s s e mb l y t o c yl i n de r bl ock. R e m o v e t he
b r a c k e t s a n d l ifters (3).
N O T E : If d a m a g e has b e e n ca u s e d t o lifters, inspect
t h e l o b e s o f c a m s h a f t . If n e c e s s a r y m a k e a
r e p l a c e m e n t o f t h e c a m s h a f t . Se e R E M O V E
C A M S H A F T . C l e a r a n c e be t we e n lifter a n d b r a c k e t
m u s t be no m o r e t h a n .010 in. (0.25 m m )
7 -1 0 2
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D A SSEMB LY
VA LVE LIFTERS
I N S T A L L V A L V E LIF T E R S 1 2 0 9 — 12
T o o ls Needed A
3P 2 2 43 1n sta lle r 1
2. Put wi r e or large r u b b e r b a n d s ( 1) a r o u n d
lifters t o ho l d t h e m in br a c ke t .
3. P u t t he b r a c k e t a n d lifters in p o s i t i o n o n
dowel s . Install t he l ocks a n d bol t s t h a t ho l d
b r a c k e t s t o c y l i n d e r bl ock. R e m o v e t he wi r e
o r r u b b e r b a n d f r o m lifters.
4. P u t t he oil t u b e s (2) on t h e b r a c k e t s a n d
install l ocks a nd bolts.
5. P u t t he seals b e t we e n t h e b r a c k e t a s s e m
blies.
7. Inst al l t he p us h rods.
end b y :
a) inst al l pi s t on c o o l i n g t u b e s
b) install fuel i nj ect i on p u m p h o u s i n g ,
s h u t o f f c o n t r o l , gov e r n o r , a n d g o v e r
n o r drive, as a uni t
c) install val ve cover s
7 -1 0 3
D379 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEM BLY
INTAKE M ANIFOLDS
R E M O V E IN TA K E M A N IF O L D S 1 0 5 8 — 11
N O T E : O n t he D 3 9 9 Engines, t he i n t a k e ma n i f o l d
can be r e m o v e d as o n e s e ct i on f or e ach t w o cy l i n
ders. R e mo v e s pa cer t h a t c o n n e c t s t he ma n i f o l d s .
R e mo v e t he c l a m p ( 4) t h a t ho l d s t h e oil line
for t he oil c o o l e r t o t he ma n i f o l d .
3. R e m o v e bol t s ( 3) t h a t h o l d ma n i f o l d t o t he
c y l i n d e r heads . R e mo v e t he i nt ake m a n i f o l d .
1. Install ne w ma n i f o l d gaskets.
N O T E : O n t he D 3 9 9 Engi nes, t he m a n i f o l d s c an be
installed as o n e se ct i on for e ach t w o cyl inder s.
7 - 104
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
C RANKSHAFT M A IN BEARINGS
R E M O V E C R A N K S H A F T M A IN
B E A R IN G S 1 2 0 3 — 11
T o o ls N e ed e d A B
8M 9379 W re n c h 1
start by:
a) remove engine oil cooler
L .J
b) remove fresh water pump
c) engine oil pump
d) remove oil pressure regulator valve
e) remove starters
N O T E : O n t he b e a r i n g j o u r n a l t h a t h a s n o dri ll ed
hol e, p u t a t hi n pi ece o f fi ber, h a r d w o o d o r pl asti c
a ga i ns t e n d o f b e a r i n g op p o s i t e t ab. Hit t he b e a r i n g
l ightly wi t h t he a b o v e unt i l t a b o f b e a r i n g is free
f r o m c y l i nde r bl ock. R e m o v e t he u p p e r h a l f o f
bear i nus.
7-105
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBLY
C RANKSHAFT M A IN BEARINGS
INS TALL C R A N K S H A F T M A IN
B E A R IN G S 1 2 0 3 -1 2
T o o ls N e ed e d A B C D
8M 9379 W re n c h 1
5 B 1 161 W ire
8S2328 D ia l T e st In d ic a to r G ro u p 1
2. C l e a n m a i n b e a r i n g c a p s a n d i nstal l l o w e r
hal ves of b e a r i n g s in caps.
\ C ) I L: W hen t he b e a r i n g c l e a r a n c e is c he c k e d a n d
t he engi ne is in a \ e r t i e a l p os i t i on , su c h as in t he
vehicle, t he c r a n k s h a f t will have t o be lifted u p a n d
hel d a ga i ns t t he u p p e r h a h e s of t he m a i n be a r i ngs to
get a cor r e c t m e a s u r e m e n t wi t h wire (C). T h e wi re
will not hol d t he wei ght ot t he c r a n k s h a f t a n d give a
cor r e ct i ndi cat i on. If t he engi ne is in a h o r i z o n t a l
posi t i on, such as o n a n e ngi ne s t a n d , it is not n e c e s
sary t o hol d t he c r a n k s h a f t up. D o not t u r n c r a n k
shaft w h e n lead wire is in pos i t i on to ch e c k c l e a r
ance. If lead wi re is not avai l abl e. P E A S T I G A G E
ca n be used to check b e a r i n a cl ear ance.
3. Use wir e ( C) t o c h e c k b e a r i n g cl e a r a nc e . I n
stall cap s a n d t i g h t e n b o t h n u t s wi t h t o o l (B)
t o 200 ± 10 lb. ft. (270 ± 14 N . m) . P u t a m a r k
o n n u t s a n d e n d of st uds. T i g h t e n n u t s 120°
f r om t h e mar k. R e m o v e caps a n d check
t hi c k n e s s of wir e (C) t o f i nd b e a r i n g c l e a r
ance. Be a r i n g c l e a r a n c e m u s t be .0048 t o
. 0090 in. (0. 122 t o 0. 229 m m ) f o r n e w par t s. TYPICAL EXAMPLL
M a x i m u m pe r mi s s i bl e c l e a r a n c e f o r u s e d
p a r t s is .015 (0.38 mm) .
4. P u t cl e a n en g i n e oil o n t h r e a d s of st u d s a n d
se at f o r nut . Inst al l m a i n b e a r i n g c a p s a n d
nut s. I nst al l t h r u s t pl at es o n d o w e l s o n r e a r
cap. T h e d o we l s m u s t n o t b e e x t e n d e d m o r e
N O T E : M a i n b e a r i n g caps have n u m b e r s as t o t hei r t h a n . 160 in. (4. 06 m m ) f r o m c o u n t e r b o r e
l oc a t i on in c yl i nder bl ock. Inst al l b e a r i n g c a p s so f ace o f b e a r i n g cap. T i g h t e n n u t s wi t h w r e n c h
t he n u m b e r o n c a p is s a m e as n u m b e r o n c yl i nder (B) t o 200 ± 10 lb. ft. (270 ± 14 N. m) . P u t
bl ock. Bo t h n u m b e r s m u s t be on s a m e si de of a m a r k o n n u t s a n d e n d s o f s t uds . T i g h t e n
c yl i n der bl ock. n u t s a n e x t r a 120° f r o m m a r k .
7-106
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS A SS E MB LY A N D ASSEM BLY
CR ANKSHAFT M A IN BEARINGS
5. Use i n d i c a t o r g r o u p ( D ) t o c h e c k e n d p la y o f
c r a n k s h a f t as c o n t r o l le d b y t h r u s t p lates.
E n d p lay w i t h n ew p a r t s m u s t b e .005 t o .021
in. (0.13 t o 0.53 m m ). M a x i m u m p e r m i s s ib l e
e n d p lay w ith u se d p a r t s is .035 in. (0.8 9 m m ).
e n d by:
a) install oil p u m p
b) install fresh w a t e r p u m p
c) in stall en g in e oil c o o l e r
d) install oil p r e s s u r e r e g u l a t o r va lve
7-107
D3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBL Y
s t a r t by:
a) r e m o v e e n g in e oil c o o l e r
b) r e m o v e fresh w a t e r p u m p
c) r e m o v e s t a rt e r s
d) r e m o v e e n g in e oil p u m p
e) r e m o v e oil p r e s s u r e re lief valve
1. F a s t e n a h o ist a n d r e m o v e t h e p r e l u b r i c a t i o n
oil p u m p a n d m o t o r as a u n i t (if so e q u i p p e d ) . IS 7 2 3 6 b x T m
W e ig h t is 105 lb. (47.3 kg).
2. R e m o v e th e wire h a r n e s s a n d p la te f o r p r e
l u b r i c a t i o n oil p u m p a n d m o t o r .
3. R e m o v e th e b o lts (1) t h a t h o l d i n s p e c t io n
c ov ers t o c y lin d e r b lo ck . R e m o v e i n s p e c t io n
c ov ers (2) f r o m each side o f b lock.
4. R e m o v e t h e b o lt (3) a n d lo ck t h a t h o l d t u b e
to b o t t o m side o f lifter b r a c k e t . R e m o v e t h e
p i s t o n c o o l i n g t u b e s (4).
5P8709 P is to n C o o lin g T u be
T o ol G ro u p 1
1. check th e a l i g n m e n t o f th e p i s t o n c o o l i n g
t u b e s w ith t o o l i n g (A). See U S E O F 5 P 8 7 0 9
T O O L G R O U P FO R A L IG N M E N T O F
P IS T O N C O O L IN G JE T S , F o rm No.
S M H S 7 2 6 7 , f o r th e c o r r e c t a l i g n m e n t p r o
c edu re.
2. In stall th e p i s t o n c o o l i n g t u b e s (1) in p o s i
ti o n o n th e lifter b r a c k e t . I n s t a l l t h e lo ck s
a n d bolts.
3. In stall th e i n s p e c t io n co v e r s o n engine.
4. I n sta ll wire h a r n e s s a n d p la te f o r p r e l u b r i c a
t i o n oil p u m p a n d m o t o r . F a s t e n a h o i s t a n d
in stall p r e l u b r i c a t i o n oil p u m p a n d m o t o r as
a u n it (if so e q u i p p e d ) .
en d by:
a) install e n g in e oil p u m p
b) install f res h w a t e r p u m p
c) install e n g in e oil c o o l e r
d) install oil p r e s s u re r elief valve
e) install s t a rt e r s
7-108
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBLY
VALVE COVERS
R E M O V E VALVE C O VE R S 1 1 0 7 — 11
2. R e n u n e \ a l v e e o \ e r (2).
7-109
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMBLY A N D ASSEM BLY
CYLINDER HEADS
RE M O V E CY L IN D E R HEA DS 1 1 0 0 —11
sta rt by:
a) re m o v e r o c k e r s h a ft s a n d p u s h ro d s
b) r em o v e in ta k e m a n i f o ld s
1 . R e m o v e t h e i n s t r u m e n t p a n e l f r o m c y lin d e r
h ead t o be r e m o v e d ( i f so e q u i p p e d ) .
2. R e m o v e tire c o o l a n t f r o m engine.
4. R e m o v e th e b o lts t h a t h o ld t h e p la te ( 2 ) o n
b o t t o m o f e x h a u s t shield. L e t t h e p la te lay
in th e " V ” o f engine.
5. R e m o v e th e plugs ( l ) f ro m th e shield.
6. R e m o v e th e eig ht b o l t s t h a t h o l d t h e e x
h a u s t m a n i f o ld to each c y l i n d e r h e a d .
7. R e m o v e t h e fuel lines ( 5 ) f o r t h e h e a d t o be
r e m o v e d . P u t covers o n fu el valves, lines,
a n d p u m p s . R e m o v e t w o e l b o w s ( 4 ) for
each c y l i n d e r head . R e m o v e t h e g o v e r n o r
c o n t r o l c h a n n e l f o r c y l i n d e r h e a d s o n left
h a n d side o n ly .
10. Install t w o 1 / 2 ” - 1 3 NC f o rg e d e y e b o l t s in
head.
7-1 10
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEMBL Y
CYLINDER HEADS
INSTALL C Y L IN D E R H EA DS 1 1 0 0 —12
1. C lea n th e b l o c k a n d c y l i n d e r h e a d . I n stall
n e w h e a d g askets, n e w w a t e r seals, a n d f e r
rules.
2. Install t w o 1 / 2 ” - 1 3 NC f o rg e d e y e b o l t s in
h ead . F a s t e n a h o i s t a n d slo w ly l o w e r t h e
h e a d o v er th e s t u d s u n t i l it is in c o r r e c t
p o s i t i o n over h e a d g as k ets a n d seals. W eigh t
is 190 lb. ( 8 6 kg).
3. P u t 5 P 3 9 3 1 A n t i - S e i z e C o m p o u n d o n
t h r e a d s o f h e a d st u d s , a n d o n t h e b o lts f o r
e x h a u s t m a n i f o ld . In stall n u t s a n d w a s h e r s
o n s tu d s . T i g h t e n n u t s in f o l lo w in g ste p se
q uence:
S t e p 1 T i g h t e n n u t s bv n u m b e r to a t o r q u e
o f 150 ± 10 l b .'f t. (205 ± 14 N u n ) .
S te p 2 T i g h t e n n u t s by n u m b e r t o a t o r q u e
o f 250 ± 10 l b .'f t. (340 ± 14 N-m).
S te p 3 T i g h t e n n u t s a g a i n by n u m b e r ( h a n d
t o r q u e o nly) t o a t o r q u e o f 250 ± 10
lb. ft. ( 3 4 0 ' ± 14 N-m ).
4. I nstall new g a s k e t s fo r t h e e x h a u s t m a n i f o ld .
I n stall th e b o lts (1) t h a t h o ld e x h a u s t m a n i
fold to h ead . T i g h t e n b o lts (1) to a t o r q u e o f
1 10 ± 10 lb. ft. (149 ± 14 N*m) o n M a r i n e
Eng in es. T i g h t e n bo lts (1) o n I n d u s t r i a l
E n gin e s to 75 ± 10 lb. ft. (100 ± 14 N-m).
7-111
D379 . D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
VALVES
R EM O VE VALVES 1 1 0 5 — 11
T o o ls N e ed e d A B
5S1330 V a lv e S p rin g C o m p re s s o r 1
s t a r t by:
a) r e m o v e c y lin d e r h e a d
2. P u t id e n t i f i c a t io n on th e valves a n d h e a d f o r
c o r re c t a s sem b ly . Use t o o l i n g (B) as s h o w n to
pu t valve s p r i n g (4) u n d e r c o m p r e s s i o n . R e
m o v e t h r e e locks (3). S lo w ly r elease c o m p r e s
si o n f r o m th e va lve s p r i n g a n d r e m o v e t o o l
ing (B). R e m o v e r e t a i n e r (2), t w o sp r i n g s (4),
r o t a t o r , sp a c e r a n d valve f r o m t h e h ead .
3. D o S t e p s l a n d 2 a g a i n f o r th e r e m a i n d e r o f
valves.
7-112
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
VALVES
INSTALL VALVE S 110 5-1 2
T o o ls N e e d e d A B C
FT8 06 C y lin d e r H e ad R e p a ir B e n c h 1
8S2263 V a lv e S p rin g T e s te r 1
5S1330 V a lv e S p rin g C o m p re s s o r 1
2. In s p e c t a n d m a k e a r e p l a c e m e n t , if n e c e s
sary , o f th e O - r i n g seals in th e in let v a lv e
reta in e rs . P u t th e valves , s p a c e r , r o t a t o r ,
sp rin g s a n d r e t a i n e r in p o s i t i o n o n t h e h e a d .
P u t th e sp r i n g s u n d e r c o m p r e s s i o n w ith t o o l
(C). I nstall t h r e e lo ck s (1). T h e t h i c k en d o f
th e lo ck goes t o w a r d t h e c y l i n d e r h e a d .
A WARMING
Locks can be thrown from the valve when tool
(C) is released if they are not in their correct
position on the valve stem.
4. D o S te p s 1 t h r o u g h 3 a g a i n f o r t h e r e m a i n d e r
o f t h e valves.
e n d by:
a) install c y lin d e r h e a d
7-1 13
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMBLY A N D ASSEM BLY
VALVE GUIDES
R E M O V E A N D INSTALL VALVE
G U ID ES 1 1 0 4 — 10
T o o ls N e ed e d A B C D
4H 446 D riv e r 1
5P1726 B u s h in g 1
1P7430 D riv e r 1
2P2313 B u s h in g 1
s t a r t by:
A 82803X1
a) r e m o v e valves
e n d by:
a) in stall va lve
7-114
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D MA R IN E ENGINES DISASS EMB LY A N D ASSEMBL Y
T o o ls N e ed e d
9S3080 V a lv e S e a t In s e rt G ro u p
s t a r t by:
a) r e m o v e valves
1. R e m o v e valve se at i n se rts ( l ) w i t h t o o l g r o u p
(A).
2. C l e a n a n d r e m o v e b u r r s f r o m t h e valv e se at
b ore.
3. I n sta ll t h e n ew v alv e se at i n se rt w i t h t o o l
g r o u p (A). D o n o t in c r e a se d i a m e t e r o f e x
t r a c t o r in valve se a t i n se rt w h e n i n se rt is i n
sta lled in c y lin d e r h ead .
4. G r i n d valve se at i n se rts ( l ) a c c o r d i n g to
s p e c ific a tio n s giv en in S P E C I F I C A T I O N S
SECTIO N .
end by:
a) install valves I
R E M O V E A N D INSTALL
WATER DIR E C TO R S 1 1 1 5 — 10
T o o ls N e ed e d A
1 P 510 D riv e r G ro u p 1
s t a r t by:
a) remove cylinder head
2. In stall n ew w a t e r d i r e c t o r w i t h t o o l i n g (A).
CAUTION
Hole (2) in water director must be in alignment
with “V” mark on cylinder head.
e n d by:
a) in stall c y lin d e r h e a d 4 f b o
V i
7-115
D379 , D 398 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
PISTONS
R EM O VE PISTO NS 1 2 1 4 — 11
sta rt by:
a) rem ove c y lin d e r h e a d s ■
b) rem ove e n g in e oil c o o l e r
c) rem ove jacket w ater p u m p
d) rem ove e n g in e oil p u m p
e) rem ove oil p u m p p r e s s u r e r e g u l a t o r
valve
1. F a s t e n a h o ist a n d r e m o v e t h e p r e l u b r i c a t i o n
oil p u m p a n d m o t o r as a u n it (if so e q u i p
ped). W eigh t is 105 lb. (47.3 kg).
2. R e m o v e t h e wire h a r n e s s a n d p la te f o r th e
p r e l u b r i c a t i o n oil p u m p a n d m o t o r .
3. R e m o v e th e b o lts ( l ) t h a t h o l d i n s p e c t i o n c o
vers t o b lo c k . R e m o v e th e c o v e r s (2).
4. T u r n th e c r a n k s h a f t (in t h e d i r e c t i o n o f n o r
m al r o t a t i o n ) un til th e r o d c a p s (4) c a n be r e
m o v e d t h r o u g h th e o p e n in g s . R e m o v e t h e
b olts (3) a n d r o d cap s (4).
5. R e m o v e th e c a r b o n rid ge (5) f r o m t h e t o p o f
the cy lin d e r liner.
6. P u s h th e c o n n e c t i n g r o d a n d p i s t o n u p u n til
rings a r e o u t o f th e c y l i n d e r liner.
7. R e m o v e t h e p i s t o n a n d c o n n e c t i n g r o d f r o m
t h e cy lin d e r liner. W e i g h t is 45 lb. (20 kg).
7 - 1 16
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMBLY A N D ASSEM BLY
PISTONS
INSTALL PISTO NS 1 2 1 4 — 12
T o o ls N e ed e d A
5P3528 P is to n R in g C o m p re s s o r 1
1. P u t clean S A E 30 en g in e oil o n t h e p i s t o n ,
rings, c o n n e c t i n g r o d b e a r i n g s a n d walls o f
c y lin d e r liner. In stall u p p e r b e a r i n g in c o n
n e c tin g rod.
CAUTION
Be careful not to cause damage to connecting
rod bearing or journal on crankshaft when
piston is installed.
5. P u t 5 P 3 9 3 1 A n t i - S e i z e C o m p o u n d o n
th r e a d s of ro d bolts. In s ta ll r o d bo lts.
T i g h t e n t h e r o d b o lts t o a first t o r q u e o f 40 ±
4 lb. ft. (55 ± 5 N .m ) . P u t a m a r k o n b o l t
h e a d s a n d b e a r i n g ca ps. T i g h t e n t h e b o l t s
a g a i n 120° f r o m th e m a r k .
6. P u t i n s p e c t io n co v ers in p o s i t i o n o n en g in e .
In stall th e b o lts t h a t h o l d co v e r s t o c y l i n d e r
block.
7. I n sta ll t h e w ire h a r n e s s a n d p l a t e f o r t h e p r e
l u b r i c a t i o n oil p u m p a n d m o t o r (if so e q u i p
ped).
8. P u t t h e p r e l u b r i c a t i o n oil p u m p a n d m o t o r
o n en g i n e w i t h a hoist.
TYP1CAT E X A M P L E
en d by:
a) in stall oil p u m p p r e s s u r e r e g u l a t o r
valve
b) in stall en g in e oil p u m p
c) in stall jack et w ater p u m p
d) install en g in e oil c o o l e r
e) in stall cylinder head
7-1 17
D 3 7 9 , D 398 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEM BLY
PISTONS
DIS A S S E M B L E A N D A SSEM BLE
PISTO NS 1 2 1 4 — 17
T o o ls N e ed e d A B
5H9621 P is to n R in g E x p a n d e r 1
5P8639 P re ss G ro u p 1
5P8655 T o o l G ro u p 1
s t a r t by:
a) r e m o v e p i s t o n
1. R e m o v e r e t a i n e r s (5) a n d p i n (3) f r o m th e
p isto n . R e m o v e c o n n e c t i n g r o d (2) f r o m t h e
pisto n.
CAUTION
Do not use a broken ring or carbon scraper to
clean carbon. They will cut the ring grooves or
cause damage to piston.
3. R e m o v e th e c a r b o n f r o m r in g g r o o v e s o n pis
ton .
6. In stall s p r i n g f o r oil c o n t r o l r i n g ( b o t t o m
ring) in t h e b o t t o m r in g g r o o v e o f p i s t o n . I n
stall oil c o n t r o l ring.
7. In stall c e n t e r rin g in c e n t e r g r o o v e o f p i s t o n
so th e m a r k “ U P - 2 ” o n r i n g is t o w a r d t o p o f
p isto n . In stall t o p rin g in t o p g r o o v e o f p i s
t o n so th e m a r k “ U P - 1 ” o n r i n g is t o w a r d t o p
o f p isto n.
8. T u r n th e p i s t o n rings in th e g r o o v e s so t h e
ring g a p s a r e 120° a p a r t .
9. P u t the c o n n e c t i n g r o d (2) so t h e b e a r i n g c a p
(1) is t u r n e d up. P u t t h e p i s t o n w i t h r elief (4)
f o r valves is t u r n e d u p a n d “ V ” m a r k (6) is
d o w n . In stall p in (3) a n d t w o r e t a i n e r s (5).
E a c h r e t a i n e r (5) m u s t fit in a g r o o v e in p is
t o n o n e a c h e nd o f p in (3).
en d by:
a) in stall p i s t o n s
7 -118
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIA L A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
CYLINDER LINERS
RE M O V E C YL IN D ER LINERS 1 2 1 6 — 11
T o o ls N e e d e d A
s t a r t by:
a) r e m o v e p i s t o n s
1. P u t a piece o f g a s k e t m a t e r i a l o r a c o v e r o v e r
c r a n k s h a f t j o u r n a l s as a p r o t e c t i o n b e f o r e
liner is r e m o v e d .
CAUTION
Do not cause damage to piston cooling tube (1)
when tooling (A) is installed.
7-1 19
D 3 7 9 , D 3 9 8 , D 3 9 9 IND UST RIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEM BLY
CYLINDER LINERS
INSTALL CY L IN D E R LINERS 1 2 1 6 — 12
T o o ls N e e d e d A B C
1P2398 P u lle r P la te 1
8B7548 P u lle r A s s e m b ly 1
1P5510 L in e r P ro je c tio n T o ol G ro u p 1
1. C l e a n th e c y lin d e r liners a n d b lo c k . I n s t a l l
th e liners in th e b l o c k w i t h o u t t h e O - r i n g
seals.
N O T E : T h e liner p r o j e c t i o n ca n c h a n g e if th e liner
is t u r n e d in the bore.
e nd by:
a) in stall p i s t o n s
7-120
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
I . D i s c o n n e c t oil lines ( l) a n d (2 ) f r o m t o p o f
t u r b o c h a r g e r l u b r ic a t io n valve.
2. L o o se n o t h e r en d s a n d clips o f u p p e r oil
lines e n o u g h t o m ov e u p p e r lines f ro m
valve.
4. R e m o v e f o u r n u t s (3 ) t h a t h o ld valve (4 ) to
ch a n n e l. R e m o v e th e t u r b o c h a r g e r l u b r ic a
t io n valve.
l. Install t u r b o c h a r g e r , l u b r ic a t io n valve ( l ) t o
c h a n n e l w ith f o u r b o l t s ( 2 ) a n d n u t s .
3. T i g h t e n all c o n n e c t o r s a n d clips.
7-121
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B LY
s t a rt by:
a) r e m o v e tu rb o ch arg e r l u b r ic a t io n
©
valve
l . R e m o v e th e b o l t s a n d c o v er (3 ).
R e m o v e th e b o d y (2 ) a n d a d a p t e r ( 1 ). R e
m o ve t h e p lu n g e r a n d sp rin g f r o m b o d y .
ASSEMBLE TURBOCHARGER
LU B R IC A TIO N VALVE 1 3 0 9 — 16
7-122
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
SUMP PUMP
REMOVE SUMP PUMP 1 3 1 9 — 11
1. R e m o v e six b o l t s ( l ) t h a t h o l d co v e r ( 2 ) to
h o u sin g.
2. R e m o v e co v e r f r o m h o u sin g .
3. R e m o v e r o t o r ( 6 ). v an es ( 5 ) a n d springs
f r o m h o using .
4. R e m o v e n u t (3 ) f r o m t h e sh a ft.
5. R e m o v e h a n d l e (4) f r o m sh a ft.
7. R e m o v e s h a ft f ro m cover.
IN S T A L L S U M P P U M P 1 3 1 9 — 12
1. Install sh a ft (7 ) in cov er (2 ).
2. Install p a c k i n g ( 6 ) a n d n u t in cover.
3. Install h a n d l e ( l ) o n sh a ft.
4. Install n u t o n sh a ft.
5. I n stall t h r e e c a r b o n v an es ( 5 ) , springs ( 3 )
a nd r o t o r (4 ) in th e h o u sing .
6. In stall c o v er (2 ) w i t h pin in s h a ft ( 7 ) e n
gaged in r o t o r . Install six b o lts.
7 - 123
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
AIR CLEANER
R EM O VE A N D INSTALL AIR
CLEANER 1 0 5 1 — 10
I. L o o s e n c l a m p (2) t h a t f a ste n s th e t u r b o -
c h a r g e r air inlet ho se t o th e a i r c l e a n e r
h o u s i n g (3).
2. R e m o v e b olt ( l ) t h a t f a ste n s t h e b r a c e t o th e
air c l e a n e r h o u s i n g .
3. R e m o v e t w o b o l t s (4) f r o m e a c h side o f t h e
air cleaner housing. R em ove the air cleaner
h o u sin g . T h e w eight o f th e air c le a n e r
h o u s i n g a s s e m b l y is 43 lb. (20 kg).
4. P u t t h e air c l e a n e r h o u s i n g a s s e m b l y in
p o s i t i o n o n th e eng ine. I n sta ll t h e t w o b o l t s
(4) o n e a c h side o f th e air c l e a n e r h o u s i n g .
5. I n stall b olt ( l ) t h a t fa s t e n s th e b r a c e t o th e
air c l e a n e r h o u sin g .
V *
6. I n stall th e t u r b o c h a r g e r a i r in let h o s e o n t h e
air c l e a n e r h o u s i n g a n d t i g h t e n th e c l a m p
t h a t fa ste n s th e h o se t o th e a i r c l e a n e r
h o u sin g .
\
7 - 124
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B L Y A N D A S S E M B L Y
I. R e m o v e c o o l a n t f r o m th e engine.
4. R e m o v e t h r e e b o l t s (6) t h a t f a s t e n t h e
t u r b o c h a r g e r shield t o th e a f t e r c o o le r .
6. R e m o v e f o u r b o l t s (8) f r o m th e shield.
7. F a s t e n a h o ist to th e shield as s h o w n a n d
r e m o v e f r o m t h e m a c h i n e . T h e w e ig h t o f th e
shield is 43 lb. (20 kg).
11. Fill th e en g i n e w i t h c o o l a n t t o t h e c o r r e c t
level.
7-125
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D U S T R IA L A N D M A R IN E E N G IN E S D IS A S S E M B LY A N D A S S E M B LY
TURBO CHARG ER
R E M O V E A N D IN STALL
TURBOCHARGERS 1 0 5 2 -1 0
s t a r t by:
a) r e m o v e t u r b o c h a r g e r h e a t s h i e l d
( M a r i n e E n g in e s only )
b) r e m o v e air c l e a n e r h o u s i n g s
1. I o o s e n c l a m p ( l ) t h a t h o l d s t h e c o u p l i n g t o
the exhaust elbow and remove shield ( 3)
( M a r i n e E n g i n e s only).
4. L o o s e n c l a m p (6) t h a t f a ste n s th e e l b o w t o
t h e a f t e rc o o le r.
5. R e m o v e th e t u r b o c h a r g e r f r o m th e eng ine.
T h e t u r b o c h a r g e r w eig h s 42 lb. (19 kg).
6. P u t th e t u r b o c h a r g e r in p o s i t i o n o n th e
e n g in e a n d install a n d t i g h t e n c l a m p (6).
7. P u t 5P3931 A n t i - S e iz e C o m p o u n d o n t h e
t h r e a d s o f f o u r b o lts (4). I n sta ll th e b o l t s a n d
t i g h t e n to a t o r q u e o f 40 ± 4 lb.ft. (55 ±
5 N .m ). I n sta ll new g a s k e t a n d t u r b o c h a r g e r
oil r e t u r n line (5).
8. I n s t a l l n e w g a s k e t a n d t u r b o c h a r g e r oil
s u p p l y line (2).
e n d bv:
a) i n s t a l l t u r b o c h a r g e r h e a t s h i e l d
( M a r i n e E n g in e s only )
b) in stall air c l e a n e r h o u s i n g s
7-126
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
TURBOCHARGER
DIS A S S E M B L E
TURBOCHARGER 1052—15
Tools Needed A B C
9S 6363 Turbocharger Fixture G roup 1
9S 6343 Fixture Assem bly 1
FT745 M odified Pliers 1
s t a r t by:
a) r e m o v e t u r b o c h a r g e r
1. P u t th e t u r b o c h a r g e r in p o s i t i o n o n t o o l (A).
3. R e m o v e “ V” c i a m p (2) a n d r e m o v e c o m p r e s
s o r c o v e r (1).
4. R e m o v e “ V ” c l a m p (3) a n d r e m o v e sh a ft
h o u s i n g f r o m t u r b i n e h o u s i n g (4).
CAUTION
When the nut is loosened do not put a side force
on the shaft.
5. P u t sh a ft h o u s i n g in t o o l (B). R e m o v e n u t
a n d c o m p r e s s o r w h eel (5) f r o m t h e sh aft.
6. R e m o v e sh a ft h o u s i n g f r o m t o o l (B) a n d
r e m o v e t u r b i n e w heel (7) a n d s h a ft f r o m
h o u sin g .
7-127
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D MA R IN E ENGINES D IS A SS EMB LY A N D ASSEMBL Y
TURBOCHARGER
(S. R e m o v e sn a p ring a nd insert (8 ) f ro m the
h ou sine .
7 - 128
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBLY
TURBOCHARGER
7 -1 2 9
D 3 7 9 , D 3 9 8 , D 3 9 9 IN D UST RIAL A N D M A R IN E ENGINES DIS ASS EMBLY A N D ASSEMBL Y
TURBO CHARG ER
ASS EM BLE T U R B O C H A R G E R 1 0 5 2 -1 6
Tools Needed A B C
FT745 M odified Pliers 1
3. In stall s h r o u d (5) o n t h e h o u s i n g . T u r n t h e
s h r o u d t o m a k e su r e it is d o w n o n t h e h o u s i n g
even. T h e hig h p a r t (w eb ) (6) o n s h r o u d , will
k eep t h e s h r o u d f r o m t u r n i n g o n t h e h o u s i n g
a f te r assem b lv .
4. I n stall s n a p r in g t h a t h o l d s th e s h r o u d in
place.
5. I n sta ll t h e b e a r i n g a n d t w o s n a p rin gs in t h e
a .e a * •
c o m p r e s s o r e nd o f t h e h o u s i n g . I n sta ll t h e
s n a p rings w i t h t o o l (A).
7. P u t h o u s i n g in p o s i t i o n o n t o o l (B).
CAUTION o
The oil hole in bearing (11) must be open and
clean.
8. In stall rin g (13), b e a r i n g (11), sleeve (12),
r in g (10) a n d d e f l e c t o r (9) in t h e h o u s i n g .
7-130
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DISA SS EMB LY A N D ASSEMBLY
TURBO CHARG ER
! I :
10. In stall in sert in t h e h o u s i n g a n d in sta ll s n a p W W t.i'W W S J t
r in g (17).
CAUTION
When nut is tightened do not put a side force on
the shaft.
13. I n sta ll sh a ft h o u s i n g in t o t h e t u r b i n e h o u s i n g .
P u t 5P3931 A n ti-S eize C o m p o u n d on the
t h r e a d s o f t h e b o lts t h a t h o l d “ V” c l a m p (21) in
p o s i t i o n . In stall th e “ V ” c l a m p a n d t i g h t e n t h e
c l a m p t o a t o r q u e o f 10 ± 2 lb.ft. (14 ± 3 N .m ).
14. I n s t a l l c o m p r e s s o r c o v e r (19) a n d “ V ” c l a m p
(20). T i g h t e n “ V” c l a m p t o a t o r q u e o f 10 ± 2
lb.ft. (14 ± 3 N .m ).
e n d by:
a) install t u r b o c h a r g e r
7-131
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEMBL Y
AFTERCOOLER HOUSING
R EM O VE AFTE RCOOLER
H O U S IN G 1 0 6 3 — 11
sta rt by:
a) r em o v e air cle a n e r h ou sin g s
b) r e m o v e t u r b o c h a r g e r h e a t shield ( M a
rine E ng in e s o n lv )
I. R e m o v e th e c o o l a n t f r o m engine. L o o se n
the c la m p s ( l ) t h a t h old air e l b o w s t o a f t e r
co o le r ho usin g. Move th e c la m p s a w a y f ro m
a f t e r c o o l e r hou sing.
■jp-awf
2. R e m o v e th e b o lts t h a t h o ld t u b e s ( 4 ) to
a f t e r c o o l e r ho u sing . R e m o v e b o l t s ( 3 ) t h a t
h o ld t u b e s ( 4 ) to f ly w h e e l h o usin g . R e m o v e
the tubes.
R e m o v e b olts (2) t h a t ho ld a f t e r c o o le r
h o u sin g to f ly w h e e l housing.
4. R e m o v e th e b o lts (5 ) f ro m t o p o f a fter-
c o o le r housing.
5. F a s te n a hoist to th e a f t e r c o o l e r ho usin g .
6. R e m o v e a f t e r c o o l e r h o u s i n g f ro m engine.
W eight o f a f t e r c o o le r h o u s i n g is 2 6 0 lb.
( 1 1 8 kg).
7-132
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMBLY A N D ASSEM BLY
AFTERCOOLER H O U S IN G
INSTALL AFTE RCOOLER
H O U S IN G 1 0 6 3 — 12
1. F a s t e n a h o i s t a n d p u t t h e a f t e r c o o l e r
h o u s i n g in p o s i t i o n on engine.
2. In stall th e b olts t h a t h o l d a f t e r c o o l e r h o u s i n g
t o flywheel h o u s i n g .
4. P u t th e c l a m p s (2) t h a t h o l d a i r e l b o w s t o
a f t e r c o o l e r in t o p o s i t i o n . T i g h t e n t h e c l a m p s .
5. Fill t h e e n g in e w i t h c o o l a n t t o c o r r e c t level,
e n d by:
a) install a i r c l e a n e r h o u s i n g s
b) i n s ta ll t u r b o c h a r g e r h e a t s h ie ld
( M a r i n e E n g in e s on ly )
7-133
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEM BLY
AFTERCOOLER CORES
RE M O V E AFTE RCOOLER
CO RES 1 0 6 4 — 11
s t a r t by:
l. R e m o v e c h a n n e l (2) f r o m a f t e r c o o l e r h o u s
ing. R e m o v e b o lts t h a t h o l d p ip e ( l ) t o
a fte rc o o le r h o u sin g . R e m o v e th e pipe.
R e m o v e b o lts (3) t h a t h o ld h o u s i n g s t o
63030X1
gether.
2. R e m o v e th e t o p h o u s i n g .
4. F a s t e n a h o ist t o t h e co res a n d r e m o v e t h e
co res f r o m b o t t o m h o u s i n g . W e i g h t o f e a c h
c o r e is 75 lb. (34 kg).
INSTALL AF TERCOOLER
CO RES 1 0 6 4 — 12
1. F a s t e n a h o ist a n d p u t th e c o r e s ( l ) in
p o s i t i o n in b o t t o m h o u sin g .
2. In stall th e t o p h o u s i n g .
a) T i g h t e n t h r e e b o l t s in t h e c e n t e r o f
the h o u sin g .
b) T i g h t e n th e flan g e b o l t s a t t h e f r o n t
a n d rear.
c) T i g h t e n th e f lan ge b o l t s at t h e sides.
5. In stall c h a n n e l o n a f t e r c o o l e r h o u s i n g ,
en d by:
a) install a f t e r c o o l e r h o u s i n g
7 - 134
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS A S S E M B L Y A N D A S S E M B L Y
1. D i s c o n n e c t w ires f r o m t h e s t a r t i n g m o t o r
an d th e so le n o id .
2. P u t i d e n t i f i c a t io n on wires a n d te r m in a ls f o r
in stallatio n .
3. F a s t e n a h o ist to s ta rte r . R e m o v e th e t h r e e
b o lts (1 ) t h a t h o l d s t a r t e r t o t h e fl y w h e e l
h o u sin g . R e m o v e th e ele c tr ic s t a r t e r . W eigh t
is 8 0 lb. ( 3 6 kg).
INSTALL ELECTRIC S T A R T IN G
MOTORS 1 4 5 3 — 12
I . F a s te n a h o ist a n d p u t th e s t a rt i n g m o t o r o n
engine. Install th e t h r e e bolts.
2. C o n n e c t th e wires to s ta rtin g m o t o r a n d to
so le n o id .
T Y PICA L EXAM PLE
7 - 135
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMBLY AN D ASSEMBLY
AIR STARTER
RE M O V E A N D INSTALL
AIR STARTER 1451—10
A WARNING
Be sure the air supply to the air starter is turned
off.
1. R e m o v e t u b e s ( I ) f r o m th e s t a r t e r d r iv e a s
se m b ly h o u sin g .
3. F a s t e n a h o ist ( n o t s h o w n ) t o t h e a i r s t a r t
m o t o r . R e m o v e t h r e e b o l t s (3) a n d r e m o v e
the air s t a rt e r . T h e w e ig h t o f t h e a i r s t a r t e r is
A80975X1
85 lb. (39 kg).
T Y PIC A L E X A M PL E
4. In stall a new g a s k e t b e t w e e n t h e a i r s t a r t e r
a n d th e flywheel h o u s i n g . In stall t h e air
s t a r t e r w ith t h r e e b o lts (3) a n d lo c k w a s h e r s .
6. C o n n e c t t u b e s ( l ) t o t h e s t a r t e r driv e a s
s e m b ly h o u sin g .
T Y PIC A L E X A M P L E
7 - 136
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBLY
7-137
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEM BLY
AIR STARTER
DISASSEMBLE AIR STARTER 1451-15
Tools Needed A B C
1 P I 861 Retaining Ring Pliers 1
8H663 Bearing Puller Attachment 1
8B7548 Puller Assembly 1
8B7550 Leg 1
T774 Spacer 1
1P2851 Spanner W rench 1
start by:
a) re m ove air starter
N O T E : M a k e su re t h e r e is a c o m p l e t e set o f new
g as k ets, van es, seals a n d O - ri n g seals b e f o re th e air
s t a r t e r is d i sa sse m b le d .
|§R
7 -1 3 8
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
AIR STARTER
5. Disa ss em ble the drive assem bly as follows:
7-139
D 3 7 9 , D 3 9 8 , D 3 9 9 IND UST RIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBL Y
AIR STARTER
7. R em ov e the eo v er with shaft assem bly (16) and
w as her (17) from case as se m bly (15).
10. Rem ove gear (21) from shaft (20) with a press.
7-140
D 3 7 9 , D 398 , D 3 9 9 INDUST RIA L A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBLY
AIR STARTER
R e m ov e key (22) and rem ove hearing (23) from
the shaft with a press.
7- 141
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBL Y
AIR STARTER
16. Install gear retainer (26) in an up side d ow n
position on the rotor and install the bolts that hold
it in plaee. Do not tighten the bolts com pletely.
17. Install tooling (B) under gear (27) and rem ove
the gear from the rotor.
A4 2341 X I
7-142
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
AIR STARTER
22. R e m ov e lock (32). plate (35). cy linder (34),
dowel (38) and spacer (37) fro m rotor (36).
7-144
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS A S S E M B LY A N D A S SE M B LY
AIR STARTER
3. Install five va nes (5) in the rotor.
7-145
D3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEM BLY
AIR STARTER
10. Make a record o f the four holes (20) and dowel
hole (18) in h ousing (19). Dow el hole (1 7) is not
used on this m odel o f air starter.
13. Install gas ket (24) on the plate and install co ver
as se m bly (22) on the housing. Install the bolts
that hold the co v er assem bly in position. T urn the
rotor as the bolts are tightened to m ake sure the
rotor will turn freely.
7-146
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R I N t ENG INES D IS ASS EMB LY A N D ASSEMBLY
AIR STARTER
15. Install retainer (28) and the two bolts that hold it
in position.
7-147
D 379 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS A SS EMB LY A N D ASSEMBL Y
AIR STARTER
19. Install bearing (.->2) on shatt (31) with a press. I
7-148
D 3 7 9 , D 3 9 8 . D 3 9 9 IND USTRIAL A N D MA R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
AIR STARTER
24. Use tool (D) and install seal (39) in co v er (38)
with the large metal surface in an up position.
The large metal surface must not he above c o u n
terbore (37) in the cover. Put a thin l a y e r o f oil on
the lip o f seal (39).
7 -149
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEM BLY
AIR STARTER
d) Lift the piston and install retainer (45) in the
groove o f the piston with tool (E).
y
28. Install drive a s se m b le (46) as show n on the shaft.
d b
'55
7-150
1
AIR STARTER
32. Install oiler (51) in the housing and install the
plug that holds the oiler in place. Do not tighten
the plug at this time.
34. Install the bolts that hold the h o u sing assem bly in
position. T ighten the bolts evenly a small a m ou nt
at a time to a torque o f 100 lb.in. (1 1.3 N-m).
7-151
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D A SSEMB LY
FLYWHEEL
R EM O VE FLYWHEEL 1 1 5 6 — 11
T o o ls Needed A
4. R e m o v e th e f lyw h eel. F o r D 3 7 9 a n d D 3 9 8 .
w eig h t o f th e fl y w h e e l is 4 5 0 lb. ( 2 0 4 kg).
F o r D 3 9 9 o n l v . w eigh t o f fly w h eel is 5 5 0
lb. ( 2 4 9 kg).
7-152
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
FLYWHEEL
INSTALL FLYWHEEL 1 1 5 6-1 2
T o o ls Needed A
1. F o r D 3 7 9 an d D 3 9 8 , install t w o 7 / 8 ” - 1 4
N F x 8 in. lo ng b o l t s ( 1 ) as a g u id e , in t h e
c r a n k s h a f t . O n D 3 9 9 o n l y , install t w o
1” - 14 N F x 10 in. long b o l t s as a guide.
5. Install p o i n t e r (2 ) in f ly w h e e l h o u sin g . I n
stall co ver on fly w h eel ho usin g.
7 -1 5 3
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTR IAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEM BLY
T o o ls Needed A
FT884 Leg 3
sta rt by:
a) r em o v e fly w h eel
2. R e m o v e th e baffle ( 2 ) f r o m h o u sing .
4. Install to o l i n g (A ) o n t h e t h r o w e r . P u t h e a t
o n th e o u t e r d i a m e t e r o f t h r o w e r w i t h an
o p e n flam e at a m a x i m u m t e m p e r a t u r e o f
4 0 0 ° F ( 2 0 4 ° C ) . R e m o v e th e t h r o w e r i m
m e d i a t e l y w ith to o l i n g (A ).
5. R e m o v e th e ring f ro m f ly w h e e l ho usin g.
7-154
D 3 7 9 . D 3 9 8 , D 3 9 9 IND UST RIAL A N D M A R IN E ENGINES D IS A S S E M B LY A N D A S SE M B LY
T o o ls Needed A
T603 B o lt 2
9 H 10 3 1 W asher 2
2. H e a t th e t h r o w e r in oil t o a m axim um te m
perature o f 3 0 0 ° F (1 4 9 °C ). Install t h r o w e r
on c r a n k s h a f t . Use to o l i n g ( A ) t o install
t h r o w e r in c o r r e c t l o c a t i o n on crankshaft.
CAUTION
Do not use an old oil thrower, seal ring or
spring.
N O T E : T h e w o r k “ O U T ” o n ring m u s t be installed
aw ay f r o m c r a n k s h a f t . P u t th e gap o f t h e ring t o
the t o p o f c r a n k s h a f t w h e n in stalled.
7-155
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEM BLY
FLYWHEEL HOUSING
RE M O V E FLYWHEEL H O U S IN G 1 1 5 7 — 11
s ta rt by:
a) r em o v e a f t e r c o o l e r h o u s i n g
b) r em o v e fly w h eel
e) r em o v e s ta rte r s
1. L o osen bo lts (4 ) that ho ld c y l i n d e r b lock to
oil p an base. R e m o v e oil pressu re r eg u latin g
valve ( 5) .
2. R e m o v e th e f o u r b o lts t h a t h o ld flange fo r
oil p u m p to oil pan base.
5. R e m o v e t w o b o l t s (1 ) fro m fl y w h e e l h o u s
ing. R e m o v e t h r e e b olts ( 3 ) f r o m e lb o w .
R e m o v e the rem ainder o f bolts (3) that
h old fly w h eel h o u sin g to c y l i n d e r blo ck .
8. R e m o v e b o lts t h a t h o ld g o v e r n o r drive
h o u sin g to f ly w h e e l ho usin g.
7-156
D 3 7 9 , D 3 9 8 , D 3 9 9 INDUST RIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBLY
FLYWHEEL HOUSING
INSTALL FLYWHEEL H O U S IN G 1 1 5 7 — 12
1. P u t 7 M 7 2 6 0 L iq u id G a s k e t M a terial o n t o p
su rface o f h o u s i n g t h a t m a k e s c o n t a c t w ith
g o v e r n o r drive housing.
2. In stall t w o 5 / 8 ” - 1 l NC b o l t s 6 ” lo n g as a
g uid e in th e c y l i n d e r blo ck . Install t w o
3 / 8 ” —I 6 NC f org ed e y e b o l t s a n d f a s t e n a
ho ist. P u t th e f ly w h e e l h o u s i n g o n t h e c y l i n
d er blo ck . Install th e b o lts t h a t h o ld f l y
wheel housing.
N O T E : T h e w o r d “ O U T ” o n ring m u s t be in stalled
a w ay f ro m c r a n k s h a f t . P u t gap o f rin g t o t o p o f
c r a n k s h a f t w h e n in stalled. Install b o l t s t h a t h o ld
baffle to f ly w h e e l ho usin g.
6. F a s t e n a h o i s t t o engine. L if t t h e e n gin e
e n o u g h t o r e m o v e t h e sp acers (1 ).
8. In stall th e f o u r b o l t s ( 3 ) t h a t h o ld flange f o r
oil p u m p to oil p a n base.
9. T ig h t e n b o lts ( 4 ) t h a t h o ld c y l i n d e r b l o c k
t o oil p an base.
e n d by:
a) install f ly w h e e l
b) install a f t e r c o o l e r h o u sin g
c) install sta rte r s
7-157
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D ASSEMBLY
T o o ls Needed A B
FT884 Leg 3
8B7550 Leg 2
8H684 R a tc h e t W rench 1
4B4280 Washer 2
L1329 B o lt 2
st a rt by:
a) re m o v e fly w h eel h o u sin g
1. Be sure the No. I p isto n is at t o p c e n t e r o n
the c o m p r e s s i o n s t r o k e . See T I M I N G T H E
A A
C A M S H A F T F O R I III F U E L I N J E C T I O N Jf
PU M P S in T E S T I N G A N D A D J U S T I N G .
CAUTION
Do not turn the crankshaft with large camshaft
gear removed and the camshaft installed.
3. R e m o v e b o lts a nd locks t h a t h o ld t h r u s t
w a s h e r to th e c y l i n d e r blo ck . R e m o v e
th r u s t w ash er. R e m o v e b o lts a n d r e t a i n e r.
O n D 3 7 9 o n l y , r em o v e th e t h r o w e r ( 5 ) w i t h
t o o lin g (A ). R e m o v e bo lts, lock a n d r e t a i n e r
t h a t h o ld b a l a n c e r gear o n its s h a ft. R e m o v e
re ar b a la n c e r g ear ( 4 ). R e m o v e b earing f ro m
b a la n c e r gear.
7-15S
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
REAR T IM IN G GEARS
INSTALL REAR T IM I N G
GEARS 1 2 0 6 —D — 12
T o o ls Needed A B
1P529 Handle 1
T603 B o lt 2
9 H 10 3 1 Washer 2
1. O n D 3 7 9 o n l y , use to o l i n g (A ) t o install t h e
b earing in b a l a n c e r gear.
N O T E : Be sure No. 1 p i s t o n is at t o p c e n t e r o n th e
co m p r e s s i o n s t r o k e . See T I M I N G T H E C A M
S H A F T F O R T H E F U E L I N J E C T I O N PU M P S in
T E S T IN G AND A D U ST IN G .
2. I n stall sm a ll c a m s h a f t g e a r ( 2 ) , t h r u s t w a s h e r
(3). l o c k a n d b o l t s . I n s t a l l r e t a i n e r (6).
l i g h t e n b olts (1) to a t o r q u e o f 60 to 70 lb.
ft. (80 t o 95 N-m ).
6. O n D 3 7 9 . h e a t th e t h r o w e r in oil t o a m a x i
m u m t e m p e r a t u r e o f 3 0 0 ° F ( 1 4 9 °C ). Install
t h r o w e r o n c r a n k s h a f t . Use t o o l i n g (B) to
install t h r o w e r in c o r r e c t l o c a t i o n o n c r a n k
sh aft.
CAUTION
Do not use an old oil thrower, seal ring or
spring.
7-159
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D MA R IN E ENGINES DISASS EMB LY A N D A SSEMB LY
CAMSHAFT
RE M O V E C A M S H A F T 1210— 11
T o o ls N e e d e d A B
FT751 C a m s h a ft A lig n m e n t T o ol 1
8B7548 P u lle r A s s e m b ly 1
8B7550 Leg 2
8F3672 P u lle r P la te 1
4B4280 W asher 2
L1329 B olt 2
s t u n by:
a i i e m o \ c tuel in jectio n p u m p h o u sin g ,
shutoil control. g o \e r n o r. and g over
n o r d riv e as a unit
b) r e m o v e flywheel h o u s i n g
c) r e m o v e v i b r a t io n d a m p e r (D 3 9 9
only)
1. L o o se n th e a d j u s t m e n t sc rew s f o r valves t o
get m a x i m u m clearance.
2. R e m o v e th e p u sh rods.
5. R e m o v e h o u sin g f o r v ib r a t io n d a m p e r , if so
e q u i p p e d . R e m o v e p o w e r t a k e o f f , if so
equipped.
6. R e m o v e th e service m e t e r an d t a c h o m e t e r
drive fro m f r o n t o f engine. Install th e align
m e n t tool ( A).
R em ov e th e large c a m s h a f t g e a r (4). R e m o v e
the bol ts a n d locks t h a t h o ld t h r u s t w a s h e r
(5).
If sm all c a m s h a f t g e a r (6) is to be r e m o v e d ,
b e n d th e lock a n d r e m o v e the t w o bolts a n d
plate f r o m th e en d of t h e c a m s h a f t .
7 -1 6 0
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D MA R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
CAMSHAFT
9. E sc t o o ls (B) to r e m o v e the sm a ll c a m s h a f t
g ear (6) f r o m th e c a m s h a f t .
10. R e m o v e th e c a m s h a f t . W e ig h t o f the c a m
shaft is a p p r o x i m a t e l y :
1)379 E n g i n e ........................ 60 lb. (27 kg)
1)398 E n g i n e 85 lb. (39 kg)
1)399 E n g i n e ........................... 100 lb. (45 kg)
F O O T S (B) F O R R ! 'M O V I N C ,
S M A l 1 C W I S H \1 I ( i i A R
INSTALL C A M S H A F T 1 2 1 0 — 12
T o o ls Needed A
N O T E : O n S A E s t a n d a r d r o t a t i o n en g in es,
( c o u n t e r c l o c k w i s e as v iew ed f ro m f ly w h e e l en d ) in
stall th e small c a m s h a f t gear o n the e n d o p p o s i t e
t h e F -nta rk on c a m s h a f t . F o r SAE o p p o s i t e r o t a
tio n eng ines ( c lo c k w ise as v iew ed f r o m fly w h e e l
e n d ) install this gear on e n d w ith the F -m a rk .
2. Install th e p late, lock, a n d b o lts t h a t h old
s m all g e a r o n c a m s h a f t . T ig h t e n bo lts t o 60
to 70 lb. ft. (80 to 95 \ '* m ) . Install a l i g n m e n t
to o l (A) on e n d o f c a m s h a f t . I n stall c a m s h a f t
in engine.
7- 161
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBL Y
CAMSHAFT
5. R e m o v e th e a l i g n m e n t to o l ( A ) f r o m f r o n t
o f c a m s h a f t . Install the service m e t e r a nd
t a c h o m e t e r drive. Install h o u s i n g f o r v ib r a
t i o n d a m p e r or p o w e r t a k e o f f if so
equipped.
6. R e m o v e r u b b e r b a n d s o r wires f r o m lifters.
Install th e p u sh r o d s ( 4 ). C o n n e c t th e oil
lines (3 ) f o r r o c k e r s h a ft as semblies .
7. M a k e a d j u s t m e n t o f valve c le a r a n c e . T h e
co ld c l e a r a n c e m u s t be: i n t a k e .015 in. (0.38
m m ) a n d e x h a u s t .035 in. (0.89 m m ). See
V A L V E C L E A R A N C E A D J U S T M E N T in
T ESTIN G A N D A D JU ST IN G .
end b \ :
a) install flywheel h o u s i n g
b) install fuel injectio n p u m p h o u sin g ,
s h u to ff control. g o \e r n o r. and g over
n o r d r i \ e as a unit
c) install v i b r a t i o n d a m p e r ( D 3 9 9 only)
7 -1 6 2
D 3 7 9 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBL Y
CAMSHAFT BEARINGS
R E M O V E C A M S H A F T B E A R IN G S 1 2 3 0 — 11
T o o ls Needed A
5P 1 6 66 P uller Plate 1
5P 1667 Spacer 1
8 S 8 2 92 E xte n sio n 1
s ta rt by:
a) re m o v e c a m s h a f t
b) re m o v e valve lifter s
INSTALL C A M S H A F T B EA RING S 1 2 3 0 — 12
T o o ls Needed A
8H684 R a tc h e t W rench 1
5 P 1 6 66 P u lle r Plate 1
5P 1667 Spacer 1
8S 8 2 92 E xte n sio n 1
1. P u t th e bearing s in th e c y l i n d e r b lo c k w ith
t o o l i n g (A ). P u t clean en g in e oil o n
bearings.
e nd by:
a) install c a m s h a f t
b) install valve lifters
7-163
D 379 , D 398 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DISASS EMB LY A N D ASSEMBL Y
CRANKSHAFT
REMOVE CRANKSHAFT 1202-11
!
i
T o ols Needed A
start by:
a rem o v e fly w h eel h o u sing
b r em o ve a c ce ss o rs- drive h o u sin g
c ) r em o v e i n ta k e m a n i f o ld s
d rem o ve c r a n k s h a f t f r o n t seal ring a n d
throw er
e) rem o ve c r a n k s h a f t rear seal ring a nd
throw er
f) rem o ve en gin e oil c o o ler
I A WARNING
Never use the engine tilting group unless the
base of engine is fastened safely to its founda
tion.
5. Install 8 F 4 2 2 5 B olts ( 1 1 ) . (six f o r D 3 9 8
a n d D 3 9 9 E ng in e s a n d f o u r fo r D 3 7 9 E n
1. R e m o v e the i n s p e c t io n cover s f ro m b o t h gines) in place o f b o l t s use d to h old c y l i n d e r
sides o f engine. In stall 5B l 181 T u r n b u c k l e s b l o c k t o oil p a n base.
(5 ) w ith le f t-h a n d t h r e a d s to to p o f engine.
6. In stall steel plates o r steel pip es as a s u p p o r t
Rut F T 7 3 1 L eft a nd F T 7 3 5 R igh t S u p p o r t
u n d e r th e s u p p o r t b e a m s (9).
Be am s (9) a nd F T 7 3 4 S u p p o r t s ( 1 0 ) on
th eir respective sides o f engine. D 3 9 8 and
D 3 7 9 E ngin es use F T l 13A a n d F T l 13 S u p
p o r t Beam s.
2. Install 8 F 4 2 3 9 B lo ck s (1 ) a n d 8 F 4 2 2 6
Y o k e s (7 ) o n s u p p o r t b e a m s (9). T ig h t e n
th e 8 F 4 2 3 0 S t u d s (6 ) 14.5 in. ( 3 6 8 . 3 m m )
long in t o the 8 F 4 2 2 6 y o k e s (7 ). Use the
n u t s o n st u d s as sh o w n .
3. T u r n the 5B1 181 T u r n b u c k l e s (5 ) o n st u d s
(6 ). T u r n 8 F 4 2 3 1 S t u d s (4 ) 9 in. ( 2 2 9 m m )
long in t o the t u r n b u c k l e s .
CAUTION
The turnbuckles and studs must carry the
engine evenly and must be turned evenly or
restriction will be caused. If either turnbuckle is
extra hard to turn, correct the restriction before
proceeding. Turning with a force will cause
damage to threads.
4. T u r n the t o p o f 8 F 4 2 3 1 S t u d s in 8 F 4 2 2 6
Y o k e s (3 ) a n d install 8 F 4 2 3 9 Y o k e , b lo c k
( 1). a n d F T 7 3 6 B r a c k e t (2 ) to th e c y l i n d e r
heads.
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D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
CRANKSHAFT
7. Lit't the en gin e f o u r i n c h e s ( 1 0 2 m m ) w ith
the t u r n b u c k l e s a n d install 8 F 4 2 2 8 H inge
Y o k e s (1 2) a n d 8 F 4 2 3 3 Hinge Blocks.
A WARNING
The engine must be kept level while it is lifted
from the base. If an extra amount of effort is
needed to turn one turnbuckle, or hinge block
and holes do not have alignment, check the
opening around the base with a scale. Make
adjustments to keep the distance the same
between cylinder block and base.
8. Install 8 F 4 2 2 8 Hinge Y o k e s a n d 8 F 4 2 3 3
Hinge Block s b e t w e e n blo ck a n d oil p an
base. Use LI 178 B olts b e t w e e n y o k e s a n d
base. Use b o lts r e m o v e d t o h o ld hinge
b lo ck s to th e blo ck .
9. R e m o v e th e 8 F 4 2 2 5 B o lts use d as a guid e in
S t e p 5.
10. T o tilt th e e n g in e t u r n th e t u r n b u c k l e s o n
b o t h sides o f th e en gin e. W h e n th e en d s o f
s t u d s a r e even w ith in side base o f t u r n
b uckles. m a k e a r e p l a c e m e n t o f the 8 F 4 2 3 0
S t u d s w ith F T 1 1 1-A stu d s 20.5 in. (521 m m )
lon g. C h a n g e st u d s o n e at a tim e.
A WARNING
If the ends of studs are extended farther than
even with inside base of turnbuckles it can
cause damage to threads of studs and in
turnbuckles. If damage is caused to threads the 12. l ilt th e en g in e m o r e until s t u d s ar e a g a in
engine can fail. e x t e n d e d th e pe r m iss ib le d istan c e. R e m o v e
F 1733-5 S t u d s a n d m a k e a r e p l a c e m e n t with
F T 7 3 3 - 7 S t u d s 18.5 in. (470 m m ) long.
1 I. li l t th e e n g in e until st u d s a r e e x t e n d e d th e
p e r m iss ib le d ista n c e . R e m o v e 8F4231 S t u d s 13. Tilt en g i n e a g a i n until st u d s are e x t e n d e d
a n d m a k e a r e p l a c e m e n t w ith F T 7 3 3 - 5 S t u d s th e p e r m iss ib le d ista n c e . R e m o v e the b I 7 3 3 -
1 1.5 in. (292 m m ) long. R e m o v e th e F I 1 1 1- 7 S t u d s a n d m a k e a r e p l a c e m e n t w ith b 1 7 3 3 -
A S tu d s a n d m ak e a re p la ce m en t w ith 9 S t u d s ( 16) 2 1 . 5 in. ( 5 4 6 m m ) long. M o v e to
F T 7 3 3 - 1 0 S t u d s (18) 23.5 in. (597 m m ) long. side o f e n g in e w ith hin ges a n d r e m o v e the
T h e s e r e p l a c e m e n t s a r e o n th e side t h a t is to FT1 1 1 S t u d s a n d m a k e a r e p l a c e m e n t with
be o p e n e d . B e fo re th e en g i n e is tilted f a r t h e r , FT 7 3 3 - 2 S t u d s ( 1 4 ) 8 in. ( 2 0 3 m m ) long.
r e m o v e 8 F 4 2 3 0 S t u d s f r o m side o f e n g in e R e m o v e th e 8 1 4 2 3 1 S t u d s a n d m a k e a re
w ith hinges . M a k e a r e p l a c e m e n t w ith FT1 1 I p l a c e m e n t w ith b I 7 3 3 - 1 S t u d s ( 13 ) 6 i n . ( 1 5 2
S t u d s 10 in. (254 m m ) long. m m ) long.
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D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES D IS ASS EMBLY A N D A SSEMB LY
CRANKSHAFT
14. Tilt th e e n g in e un til t h e r e is 17 in. (432 m)
c le a r a n c e . I nstall lifting c h a n n e l s (15) o n
c y lin d e r heads.
1 5. P u t a clean c o ver ( 2 0 ) o n th e oil p a n b ase t o
lo w e r c r a n k s h a f t o n.
16. Install pins o r b o l t s as a gu ide ( 1 9 ) o n each
e nd o f c r a n k s h a f t . F a s t e n a r a t c h e t h o i s t to
each guide.
17. R e m o v e the b earing cap s f r o m c o n n e c t i n g
r o d s a n d p u sh t h e p i s t o n s a n d r o d s t o t o p o f
th e i r s t r o k e .Use wire o r r o p e t o h o l d r o d s o n
side o f en gin e t h a t has been lifted so ro d s
will n o t d r o p .
CAUTION
Do not cause damage to piston cooling tubes.
18. R e m o v e m a i n b e a r i n g ca p s a n d b earin gs.
Put- t a p e on t h r e a d s o f st u d s t o p r e v e n t
d a m a g e to t h e m d u r i n g r e m o v a l . L o w e r the
c r a n k s h a f t w ith t w o h o ists (17) o n c o v e r
(20) a n d re m o v e . W e i g h t o f c r a n k s h a f t fo r
D 3 7 9 is 650 lb. (293 kg); D 3 9 8 is 890 lb.
(406 kg); D 3 9 9 is 1100 lb. (495 kg).
7-166
D 3 7 9 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D M A R IN E ENGINES DIS ASS EMB LY A N D ASSEMBLY
CRA NKSHA FT
INSTALL CRANKSHAFT 1 2 0 2 -1 2
Tools Needed A B C
8F 2 550 Engine T iltin g G roup 1
1. F a s t e n h oists a n d p u t t h e c r a n k s h a f t in
p o s i t i o n u n d e r th e c y lin d e r b lo ck .
3. Lift th e c r a n k s h a f t in t o p o s i t i o n in t h e c y l i n
d e r b lo ck . R e m o v e t h e t a p e f r o m t h r e a d s o f
stud s.
N O T E : Be su re th e t i m i n g m a r k s a r e in a l i g n m e n t .
See C A M S H A F T A N D T I M I N G G E A R S A N D
F R O N T A C C E S S O R Y D R I V E in T E S T I N G
A N D A D JU ST IN G .
N O T E : W h e n the b e a r i n g c l e a r a n c e is c h e c k e d a n d
the en g in e is in a v ertical p o s i t i o n , s u c h as in th e
vehicle, th e c r a n k s h a f t will h a v e to be lifted u p a n d
held a g a i n s t th e u p p e r halves o f th e m a i n b e a r in g s to
get a c o r r e c t m e a s u r e m e n t w ith w ire (C). T h e wire
will n o t h o ld the w eig ht o f th e c r a n k s h a f t a n d give a
c o r re c t in d ic a tio n . If th e e n g in e is in a h o r i z o n t a l
p o s i t i o n , such as o n a n e n g in e s t a n d , it is n o t n e c e s
sa ry to h o ld th e c r a n k s h a f t up . D o n o t t u r n c r a n k
sh aft w h e n lead wire is in p o s i t i o n to c h eek c l e a r
an ce. If lead wire is n o t av a i l a b l e . P E A S T 1 G A G E N O T E : M a i n b e a r i n g ca p s h av e n u m b e r s as to th e ir
c a n be use d to ch e c k b e a r i n g clearan ce. l o c a t i o n in c y lin d e r blo ck . Install b e a r i n g cap s so
th e n u m b e r on c a p is the s a m e as n u m b e r o n
c y l i n d e r blo ck . B o th n u m b e r s m u s t be o n s a m e side
4. P u t new b e a r i n g s in m a i n b e a r i n g caps. U se o f c y lin d e r block.
wire (C) to ch e c k b e a r in g c le a r a n c e . I n
stall c a p s a n d t i g h t e n b o t h n u t s t o 200 ± 10 5. P u t c le a n e n g in e oil o n t h r e a d s o f s t u d s a n d
lb. ft. (270 ± 14 Nvm). P u t a m a r k o n n u t s a n d se at f o r n ut. I nstall m a i n b e a r i n g c a p s a n d
en d o f stu d s . T i g h t e n n u t s 120° f r o m t h e nu ts. I n sta ll th e t h r u s t p la te s o n d o w e l s o n
m a r k . R e m o v e cap s a n d c h e c k t h i c k n e s s o f r e a r cap . T h e d o w e l s m u s t n o t be e x t e n d e d
wire (C) to find b e a r i n g c le a r a n c e . B e a r i n g m o r e t h a n .160 in. (4.06 m m ) f r o m c o u n t e r
c l e a r a n c e m u s t be .0048 t o .0090 in. (0 .1 22 t o b o r e fa ce o f b e a r i n g ca p. T i g h t e n t h e n u t s to
0.229 m m ) f o r n ew p a r ts. M a x i m u m p e r m i s 200 ± 10 lb. ft. (270 ± 14 N .m ). P u t a m a r k o n
s ib le c l e a r a n c e f o r u s e d p a r t s is .015 in. n uts an d ends of studs an d tighten nuts an
(0.38 m m ). e x t r a 120° f r o m m a r k .
7-167
D 3 7 9 , D 3 9 8 , D 3 9 9 IND UST RIAL A N D M A R IN E ENGINES D IS ASS EMB LY A N D ASSEMBLY
CRANKSHAFT
6. P u t th e c o n n e c t i n g r o d s on th e c r a n k s h a f t .
Install lo w e r h a l f o f n ew r o d b earin g s in
caps. P u t clean en gin e oil o n bearings.
N O T E : Be su re th e t a b s o n b a c k o f b e a r i n g fits in
t a b g r o o v e s o f cap a n d on c o n n e c t i n g r o d . Install th e
b e a r i n g c a p s a n d bolts. T i g h t e n t h e b o lts first to 40 ±
4 lb. ft. (55 ± 5 \ * m ) . P u t a m a r k o n b olt h e a d s a n d
b e a r i n g caps. T ig h t e n bo lts a g a i n 120° f r o m m a r k .
CAUTION
The turnbuckles and studs must carry the
engine evenly and must be turned evenly or
restriction will be caused. If either turnbuckle is
extra hard to turn, correct the restriction before
more of the procedure is done. If it is turned
with a force it will cause damage to threads.
9. W hen en gin e is l o w e r e d t o 4 in. ( 1 0 2 m m )
w ith tiu 'n b u c k le s a n d stu d s , r e m o v e t h e
8 F 4 2 2 8 Hinge Y o k e s (2 ) a n d 8 F 4 2 3 3 Hinge
Blocks.
10. Install 8 F 4 2 2 5 B o lts ( 1) as a guide. Install a
n ew g as ket o n th e oil p an base.
1 1. L o w e r the en g ine o n th e base w ith th e t u r n
b u c k le s an d n ecessa ry studs. Install the
b o lts t h a t h old c y l i n d e r b lo c k to oil pan
base.
12. Install th e i n s p e c t io n cov ers o n each side o f
engine.
13. R e m o v e th e b e a m s , s u p p o r t s , t u r n b u c k l e s ,
y o k e s , b lo c k , b r a c k e t s , a nd s t u d s o f t o o l
g r o u p (A).
en d by:
a) install c r a n k s h a f t t r o n t seal ring and
throw er
b) install ac c e ss o ry drive h o u sin g
c) install en g in e oil c o o l e r
d) install in ta k e m a n i f o ld s
e) install fly w h eel h o u sin g
f) install c r a n k s h a f t rear seal ring a n d
throw er
7-168