CAT D399 Workshop Manual

Service Manual
D379, D398, D399

INDUSTRIAL and MARINE ENGINE
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
From the library of Barrington Diesel Club

D379, D398 & D399
INDUSTRIAL AND
MARINE ENGINES
SERIAL NUMBERS
D379: 68B2540-UP AND 69B1227-UP
D398: 66B3561-UP AND 67B1391-UP
D399: 35B688-UP AND 91B387-UP
SPECIFICATIONS (Section 1)
SYSTEMS OPERATION (Section 2)
TESTING AND ADJUSTING (Section 3)
ATTACHMENT SPECIFICATIONS (Section 4)
ATTACHMENTS (Section 5)
GENERAL INSTRUCTIONS (D & A) (Section 6)
DISASSEMBLY AND ASSEMBLY (Section 7)
Individual Service Manuals are available

for the following MARINE TRANS
MISSIONS:
7241 Marine Transmission, REG00953
7271 Marine Transmission, SENR7476
See your Caterpillar Dealer.
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES INDEX
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.
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
Sea W ater P u m p .................................................................................. 1-20

Engine Design ......................................................................................... 1-2
Service Meter and Tachom eter D r iv e ................................................ 1-7
Engine Oil Pressure ........................................................................... 1-17
Starter Motor ......................................................................................... 1-40
Exhaust M a n ifo ld .................................................................................. 1-10
Starter S o le n o id s .................................................................................. 1-41
Flywheel 1-33 Torque for Flared and O -Ring F ittin g s .................................................. 7
Flywheel Runout .................................................................................. 1-34 T u rb o c h a rg e r......................................................................................... 1-11
Flywheel Housing ................................................................................ 1-33 Turbocharger Lubrication V a lv e ........................................................ 1-18
Flywheel Housing Bore ..................................................................... 1-36
Flywheel Housing Runout ................................................................. 1-35 V-Belt Tension C h a r t........................................................................... 1-37
Fresh and Auxiliary W ater Pumps ................................................... 1-20 Valves .................................................................................................... 1-1 4
Front Accessory D r iv e ......................................................................... 1-32 Valve Rocker Arm s and Lifters ........................................................... 1-8
Fuel Control Valve ................................................................................ 1-4 Vibration Damper ................................................................................ 1-30
Fuel Injection Equipm ent ...................................................................... 1-3
Fuel Pump and Governor Drive .......................................................... 1-5 W ater Level Switch .............................................................................. 1-19
Fuel Transfer Pump ............................................................................... 1-4 W ater Tem perature Regulators ....................................................... 1-19

Air Inlet and Exhaust System ............................................................. 2-7 Cooling System ..................................................................................... 2-12
Aftercooler ......................................................................................... 2-7 Coolant Level Switch .................................................................... 2-14
Turbocharger .................................................................................... 2-8 Engine Jacket W ater Cooling System ...................................... 2-12
Valves and Valve Mechanism ....................................................... 2-7 Sea W ater and Separate C ircuit Aftercooler
Air Starting System .............................................................................. 2-20 W ater System s ........................................................................... 2-15
Basic B lo c k ............................................................................................. 2-18

Crankshaft ...................................................................................... 2-18 Electrical S y s te m .................................................................................. 2-23
Cylinder Block, Heads and Liners ............................................... 2-18 Charging System C o m p o n e n ts ................................................... 2-23
Front Accessory Drive .................................................................. 2-19 O ther C om ponents ........................................................................ 2-24
Pistons, Rings and Connecting R o d s ......................................... 2-18 Starting C om ponents ..................................................................... 2-23
Timing G ears ................................................................................. 2-18 Wiring Diagram s ........................................................................... 2-25
Vibration Damper .......................................................................... 2-19
2
INDEX
D379, D398, D399, INDUSTRIAL AND MARINE ENGINES
SYSTEMS OPERATION Cont. (Section 2)
Engine Protection Devices ................................................................. 2-33 Fuel Ratio C o n tr o l............................................................................. 2-6

Setting the Shutoff Control .......................................................... 2-36 Plydra-mechanical G o v e rn o r.......................................................... 2-5
Shutoff Control ................................................................................ 2-33
Shutoff Control Operation ............................................................ 2-33
Hydraulic Starting S y s te m .................................................................. 2-21
Hydraulic Starting Motor ............................................................... 2-22
Fuel System ........................................................................................... 2-2
Duplex Fuel Filter System ............................................................. 2-3
Lubrication S y s te m ................................................................................. 2-9
Fuel Injection Pumps ..................................................................... 2-4
Duplex Oil Filter System ............................................................... 2-10
Fuel Injection Valve ......................................................................... 2-4
Prelubrication System ................................................................... 2-10
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
Lubrication S y s te m ............................................................................... 3-40

Electrical S y s te m .................................................................................. 3-52 M easuring Engine Oil Pressure ................................................ 3-40
Battery .............................................................................................. 3-52 Oil Pressure is High .................................................................... 3-42
Charging System ........................................................................... 3-52 Oil Pressure is Low ....................................................................... 3-41
Prelube System ............................................................................. 3-54 Too Much Bearing W e a r ............................................................ 3-42
Starting System .............................................................................. 3-53 Too Much Oil Consum ption ......................................................... 3-40
Turbocharger Lubrication Valve ................................................. 3-42
Engine Shutoff Control ....................................................................... 3-56

O verspeed Control Adjustment ................................................. 3-56 Troubleshooting ..................................................................................... 3-2

A ir A c tu a to r G ro u p (U G 8-L G overnor) ..................................... 4-5 M a g n e tic P ic k u p ................................................................................. 4-5
Cable A d ju s tm e n t (A ir Inlet S h u to ff) ......................................... 4-1 Pressure S w itc h e s ........................................................................ 4-14

C o n ta c to r S w itch fo r O il Pressure ......................................... 4-16
C o n ta c to r S w itch fo r O v e rs p e e d .............................................. 4-15 S e ndin g U n its fo r E le c tric a l G auges ..................................... 4-14
C o n ta c to r S w itch fo r T e m p e r a tu r e ......................................... 4-16 S h u t-o ff, A ir Inlet ............................................................................... 4-7
S h u t-o ff, H y d ra -m e c h a n ic a l .......................................................... 4-8
Enclosed C lu t c h e s ........................................................................ 4-11 S h u t-o ff, M e chanical O v e rs p e e d .............................................. 4-10
S h u t-o ff, Rack C y lin d e r .................................................................. 4-7
F lexible C o u p lin g .......................................................................... 4- n S h u t-o ff S o le n o id s ............................................................................. 4-6
S h u t-o ff Valve fo r W ater T e m p e ra tu re ....................................... 4-6
Gauges, E lectrical ........................................................................ 4-13
G auges, M echanical .................................................................... 4-12 T ach om e ter, E le c t r ic .................................................................... 4-15
G eneral T ig h te n in g T o r q u e s ............................................................ 6 T o rq u e fo r Flared and O -rin g F it t in g s ......................................... 7
G o v e r n o r s ............................................................................................. 4-2
G o v e rn o r A ir A c tu a to rs .................................................................... 4-4
G o ve rn o r U p per D r iv e ...................................................................... 4-3
3
D379, D398, D399, INDUSTRIAL AND MARINE ENGINES INDEX
ATTACHMENT SYSTEMS OPERATION (Section 5)
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
ATTACHMENT TESTING AND ADJUSTING (Section 5)
2301 Control S y s te m s ......................................................................... 5-77 Power Take-off C lu tc h e s ..................................................................... 5-90

M agnetic Pickup ............................................................................ 5-77 Assem bly Adjustm ents ................................................................. 5-90
Potentiometer Adjustment Clutch A d ju s tm e n t........................................................................... 5-90
(Parallel or Nonparallel Control) ............................................. 5-77
W oodward EG-3P Governor Actuator ...................................... 5-77 Shutoff and Alarm System C om ponents ........................................ 5-83
Contactor Switch for Oil Pressure .............................................. 5-83
E le c tr o n ic O v e rs p e e d S w itc h ............................................................ 5-91 C ontactor Switch for O verspeed ................................................ 5-86
P ro c e d u r e A ............................................................................................ 5 -9 4 Contactor Switch for W ater T e m p e ra tu re ................................. 5-84
O v e rs p e e d S e ttin g C a lib r a tio n ................................................... 5 -9 4 Rack Shutoff Solenoid ................................................................. 5-85
P ro c e d u r e B ............................................................................................ 5 -9 4
Shutoff Valve (W ater Temperature) .......................................... 5-85
M a g n e tic P ic k u p A d ju s t m e n t ........................................................ 5 -9 4
P ro c e d u r e C ............................................................................................. 5 -9 5 Troubleshooting .................................................................................... 5-42
C r a n k T e rm in a te S p e e d A d j u s t m e n t ........................................ 5 -9 5
P ro c e d u r e D ............................................................................................. 5 -9 6 W oodw ard EG-3P A c tu a to r................................................................ 5-75
O v e rs p e e d V e r ify T e s t ...................................................................... 5 -9 6 Actuator Linkage A d ju s tm e n t....................................................... 5-76
S p e e d S p e c ific a tio n C h a r t ............................................................... 5 -9 6 Fuel Rack Adjustm ent ................................................................. 5-75
T r o u b le s h o o t in g P ro c e d u r e (C ra n k T e rm in a te ) ................. 5 -9 3
T r o u b le s h o o tin g P ro c e d u r e (O v e rs p e e d ) .............................. 5 -9 2
W oodward SGT Governor ................................................................ 5-62
Engine Governor Low and High Idle Adjustm ent ................... 5-62
W irin g D ia g r a m ...................................................................................... 5-91
Engine G overnor Speed Droop .................................................. 5-63
Fuel Rack Adjustm ent ................................................................. 5-62
G overnor Linkage Adjustm ent .................................................... 5-64
Governor Air Actuators ...................................................................... 5-80 Torque Converter G overnor High Idle
2N6006 Actuator ............................................................................ 5-80 Speed A d ju s tm e n t....................................................................... 5-64
1N9318 and 7L135 Actuators .................................................... 5-81 Torque Converter G overnor Speed
3N 9125 Actuator ............................................................................ 5-82
Droop Adjustment ...................................................................... 5-64
W oodward UG 8 Dial G overnor ......................................................... 5-66
Instruments and G a u g e s .................................................................... 5-87 Compensating A d ju s tm e n t........................................................... 5-66
Electric Gauges .............................................................................. 5-87 Fuel Rack Adjustm ent ................................................................. 5-67
Mechanical Gauges for Oil Pressure ........................................ 5-89 Governor Linkage Adjustm ent .................................................... 5-69
Mechanical Gauges for Tem p e ra tu re........................................ 5-89 High Idle Speed A d ju s tm e n t........................................................ 5-67
Oil Pressure Sending Units ......................................................... 5-87
W oodward UG 8 Lever G overnor ..................................................... 5-70
Water Temperature Sending Unit ............................................ 5-87
Compensating A d ju s tm e n t........................................................... 5-70
Fuel Rack Adjustm ent .....................................................................5-71
Measuring Engine S p e e d ................................................................... 5-59 Governor Linkage Adjustm ent .................................................... 5-73
Low and High Idle Speed A d ju s tm e n t...................................... 5-71
Pierce Output Shaft Governor .......................................................... 5-60 Speed Droop Adjustm ent ........................................................... 5-72
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
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
Cleanliness ....................................... 6-2

Conversion Chart (Inches to mm) 6-8 Seals (Lip-Type) ..................................................................................... 6-8
Service Tools .......................................................................................... 6-3
Disassem bly and Assembly 6-2 Bearing Cup Pulling Attachm ent .................................................. 6-5
Bearing Pulling Attachm ent ........................................................... 6-5
G askets 6-7 Puller Assembly (2 or 3 arm) ...................................................... 6-3
Push P u lle rs ....................................................................................... 6-4
Initial Operation After Engine Reconditioning 6-3 Shims ........................................................................................................ 6-7

Accessory Drive Gears ....................................................................... 7-26 Intake Manifolds ................................................................................. 7-104
Accessory Drive Housing ................................................................... 7-24
Marine Gear ...................... See Special Instruction Form GEG00969
A ftercooler Cores ............................................................................... 7-134
Aftercooler Housing ........................................................................... 7-132
Air Cleaner .......................................................................................... 7-124 Oil Filter Housing 7 ,2
Oil Pan Base ......................................................................................... 7_50
Air Starter ............................................................................................ 7-136
Air Starter, Assemble ....................................................................... 7-144 Oil Pressure Relief Valve ................................................................... 7_30
Oil Pressure Relief Valve, Disassem ble & Assemble ................ 7-30
Air Starter, Disassem bly ................................................................. 7-138
Oil Pump ................................................................................................ 7 3'
Oil Pump, Assemble .......................................................................... 7-36
Cam shaft .............................................................................................. 7-160 Oil Pump, D is a s s e m b le ....................................................................... 7-36
Cam shaft Bearings ............................................................................ 7-163
Connecting Rod Bearings ................................................................. 7-48 Pistons ................................................................................................ 7-116
Crankshaft ........................................................................................... 7-164 Pistons, Disassem ble & Assem ble ............................................... 7-118
Crankshaft Front Seal (Lip Type) and W ear Sleeve ................. 7-20 Piston Cooling Tubes ....................................................................... 7-108
C rankshaft Front Seal Ring and T h ro w e r...................................... 7-18 Precom bustion C h a m b e rs .................................................................. 7-98
Crankshaft Main B e a rin g s ................................................................ 7-105 Prelubircation Oil Pump (D399) ...................................................... 7-46
Crankshaft Rear Seal Ring and Thrower .................................... 7-154 Prelubrication Oil Pump (D399), Disassemble
Cylinder Liners ................................................................................... 7-119 & A s s e m b le ...................................................................................... 7-47
Cylinder H e a d s ................................................................................... 7-110
Rear Timing Gears ............................................................................. 7-158
Electric Starting Motors .................................................................... 7-135 Rocker Shafts and Push Rods ......................................................... 7-99
Engine Oil Cooler ................................................................................. 7-38 Rocker Shafts and Push Rods, Disassem ble
Exhaust Manifold (Industrial Engines) ............................................ 7-72 & A s s e m b le ................................................................................... 7-100
Exhaust Manifolds (Marine Engines) .............................................. 7-75
Expansion Tank (Marine Engines) ................................................. 7-10 Torque for Flared and O-Ring F ittin g s .................................................. 7
T u rb o c h a rg e r....................................................................................... 7-126
Flywheel ............................................................................................... 7-152 Turbocharger, Assem ble ................................................................. 7-130
Flywheel Housing ............................................................................... 7-156 Turbocharger, Disassem ble ............................................................ 7-126
Fresh W ater Pump................ ................................................................ 7-40 Turbocharger Lubrication Valve ..................................................... 7-121
Fresh W ater Pump, A s s e m b le ...................................................... 7-44 Turbocharger Lubrication Valve, Disassem ble
Fresh W ater Pump, Disassem ble ................................................... 7-42 & A s s e m b le ................................................................................... 7-122
Fuel Filter Housing ............................................................................... 7-11 Turbocharger Heat Shield ................................................................ 7-125
Fuel Injection Pumps .......................................................................... 7-70
Sea W ater P u m p .................................................................................. 7-13
Fuel Injection L in e r ............................................................................... 7-71
Sea W ater Pump, Assem ble ........................................................... 7-16
Fuel Injection Valves ........................................................................... 7-97
Sea W ater Pump, Disassem ble ........................................................ 7-15
Fuel Injection Pump Housing ............................................................ 7-79
Fuel Injection Pump Housing, Shutoff Control, Service Meter and Tachom eter Drive ............................................ 7-22
Shutoff Control ...................................................................................... 7-63
Governor and Governor Drive .................................................... 7-77
Fuel Prim ing Pump ................................................................... 7-7 Shutoff Control, Assem ble ................................................................. 7-67
Shutoff Control, D isassem ble ........................................................... 7-64
Fuel Priming Pump,Disassem ble & Assemble ............................... 7-8
Fuel Ratio Control With O v e rrid e ..................................................... 7-51 Shutoff Control Group ......................................................................... 7-90
Fuel Ratio Control With Override, Shutoff Control Group, Assem ble .................................................... 7-94
Disassem ble & Assem ble ............................................................ 7-52 Shutoff Control Group, Disassem ble .............................................. 7-91
Fuel Transfer Pump ............................................................................... 7-3 Sump Pump ........................................................................................ 7-123
Fuel Transfer Pump, Assem ble .......................................................... 7-6
Valves .................................................... .................................. 7-112
Fuel Transfer Pump, Disassem ble .................................................... 7-5
Valve Covers ....................................... .................................. 7-109
Vibration Damper (D398 and D399) .................................... 7-17
General Tightening Torques ................................................................... 6 Valve Guides ....................................... .................................. 7-114
Generator .......................... See Special Instruction Form SM HS7259 Valve Lifters ........................................................................................ 7-102
Governor Drive Housing .................................................................... 7-88 Valve Seat In s e r ts .............................................................................. 7-115
Governor ................................................................................................ 7-53
Governor, Assemble ........................................................................... 7-59 W ater Directors ................................................................................. 7-115
Governor, D is a s s e m b le ....................................................................... 7-55 W ater Tem perature Regulators .......................................................... 7-9
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.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb. ft. N-m *
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
Use these torques for bolts and nuts on

hydraulic valve bodies.
5/16 7.94 13 ± 2 20 + 3
3 /8 9.53 24 ± 2 35 ± 3
7/16 11.11 39+2 50+3
1/2 12.70 60 ± 3 80 ± 4
5/8 15.88 118+4 160 ± 6
Taperlock stud
Use these torques for studs with Taperlock threads.
1/4 6.35 5 ±2 7 ± 3
5/16 7.94 10 ± 3 15 ± 5
3 /8 9.53 20 ± 3 30 ± 5
7/16 11.11 30 ± 5 40 ± 10
1/2 12.70 40 ± 5 55 + 10
9 /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
newton meter (N-m) is approximately the same as 0.1 mkg.
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
TORQUE FOR FLARED AND O-RING FITTINGS

T h e torques sh o w n in the chart that follo w s are to be use d on the pa rt o f 37° F lared, 45° Flared and
Inv erted F lared fittings (w h en u se d with steel t u b ing ), O-rin g p lug s and O-ring fittings.
Ill
' E f e " It-' BD

IN VE R TE D O-RING
45° FLA R E D 37° FLA R E D 45° FLA R E D F ITTIN G - PLUG SW IVEL NUTS
TUBE 3.18 4.78 6.35 9.52 TUBE 22.22 38.10 50.80

SIZE SIZE
(O.D) .125 .250 .312 .375 (O.D.) .500 .625 .750 .875 1.000 1.500 2.000
TH R EA D 9/16 TH R E A D 1 3/16
5/16 3/8 7/16 1 /2 3/4 7/8 1 1/16 1 5/16 1 5/8 1 7/8 2 1/2
SIZE (in.) 5/8 SIZE (in.) 1 1/4
TO RQ UE TO RQ UE 110 135 160 310

N-m N-m ±7 +15 ±15 +30
TORQUE 45 80 145 155 190 TORQUE

30 ±5 40 ±5 55 ±5 65 ±5 80 ±5 100 ±10 120 ± 1 0 230 ±20
lb .in . ±10 ±10 ±20 ±20 ±20 Ib.ft.
ASSEMBLY OF FITTINGS WITH

STRAIGHT THREADS AND O-RING SEALS
1. Put lo ck nu t (3), b a cku p w as h er (4) and O-ring

seal (5) as far back on fitting bo d y (2) as po ssible.
Flold these c o m p on en ts in this position. T urn th e
fitting into the part it is use d on , until b a c k u p
w as h er (4) ju st m ak es co ntact with the face o f the
part it is use d on.
N O T E : If the fitting is a c o n n ecto r (straight fitting) or

pl ug, the h ex on the bo dy takes th e place o f the lo cknut.
T o install this type fitting tighten the hex against the
face o f the part it goes into.
2. T o pu t the fitting assem b ly in its corre ct po sition

turn the fitting bo dy (2) o ut (counterc lo ckw ise) a
m a x i m u m o f 359°. Tig hten lo ck nu t (3) to the ELBOW BODY ASSEM B LY
torque sh o w n in the chart. 1. End of fitting body (connects to tube). 2. Fitting
body. 3. Locknut. 4. Backup w asher. 5. O-ring seal. 6.
A 7 1009X1 End of fitting that goes into other part.
A WARNING
IMPORTANT SAFETY NOTICE
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 .
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS
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
Operation s that may result only in m echanical d am ag e are identified by labels on

the product and in the Service Manual by the wo rd C A U T I O N .
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
T he inform ation, specifications and illustrations in this bo ok are on the basis o f

inform ation available at the time it was written. T h e spe cifications, torque, p res
sures of operation, m easu rem en ts, adjustm ents, illustrations and other items can
change at any time. These chang es can affect the service given to the product. Get
the com plete and most current inform ation bef ore you start any job. Caterpillar
Dealers have the most curre nt in form ation available. F or a list o f the most current
m o du les and form num bers availab le for each Ser vi ce M an ual, see the S E R V IC E
M A N U A L C O N T E N T S M I C R O F I C H E R E G I 139F.
A83264X1
A WARMING
SAFETY
4. If an en gin e m ust be started to m ake pr ess ure or

A WARNING speed check s , be sure all guards and shields are
installed. T o help prevent an accident caused by
Improper performance of lubrication or main parts in rotation, work caref ully around m ach inery
tenance procedures is dangerous and could that has been put into op er ation.
result in injury or death. Read and understand
the lubrication and maintenance procedures, 5. If an en gin e has been ru nn in g and the coolant is
recommended by Caterpillar, that are outlined hot, loosen the filler cap slowly and let the p res
in the OPERATION GUIDE and/or OWNER’S sure o u t o f the cooling system , before any ca ps,
MANUAL for this product before performing pl ugs or lines are re m o v e d or di sconnected.
any lubrication or maintenance.
6. C o rro sion inhibitor co ntains alkali. Avoid co ntact
Do not operate this product unless you have with eyes . Avoid p r o lon ged or repeated contact
read and understood the instructions. Improp with skin. Do not take internally. In case o f c o n
er operation is dangerous and could result in tact, im m ediately w ash skin with soap and water.
injury or death. F o r eyes, flush with large am o u n ts o f w ater for at
least 15 m inutes. C A L L P F IY SICIAN. K E E P
O U T O F REACH OF CHILDREN.
7. D o not sm o k e when an inspection of the battery

T h e se rv icem en or m echanic m ay be u nfam iliar with electrolyte level is m ade. N ever d isconnect any
m any o f the c o m p on en ts and system s o f this product. c h arg in g unit circuit or battery circuit cable from
This m akes it important to use caution w hen p e r fo r m the battery w h en the ch arg ing unit is oper ating. A
ing service work. A k n ow ledg e o f the system a n d / o r spark can cau se an explosio n from the flam m a b le
c o m po n en ts is im portant bef ore the rem oval or d isa s v ap or m ixture o f hydro g en and ox yg en that is
sem bly o f any co m po nent. release d from the electrolyte through the battery
outlets. D o not let electrolyte solution m ake c o n
Because o f the size of som e co m p o n en ts , the se rvice
tact with skin or eyes. E le ctrolyte solution is an
m an or m echanic should check the w eights noted in this acid. In case o f co ntact, im m ediately was h skin
Manual. Use prop er lifting pro cedu res when rem o vin g with soap and water. F or ey es, flush with large
any c o m p on en ts .
a m o un ts o f water for at least 15 minutes. C A L L
F ollo w ing is a list o f basic precautions that should PH Y SICIA N . KEEP O U T O F REACH OF
always be ob se rv ed. CHILDREN.
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
A ftercooler .............................................................................................. 1-10 G eneral Tightening Torques ................................................................... 6

Air-Fuel Ratio Control .......................................................................... 1-7 G enerator Regulator ............................................................................ 1-39
Air Starting Motor ................................................................................ 1-42 G overnor ................................................................................................... 1-6
Alternator Regulators .......................................................................... 1-39
Alternators and Regulators ................................................................ 1-38 Hand Pump for Hydraulic S ta r te r ..................................................... 1-43
Hydraulic Starting Motor ..................................................................... 1-43
Bearing Surface (Journal) for Connecting R o d s .......... 1-28
Intake M anifold ..................................................................................... 1-10
Bearing Surface (Journal) for Main Bearings ................. 1-29
Magnetic Switch .................................................................................... 1-39
Cam shaft and Timing Gears ................................................................ 1-8 Main Bearings ...................................................................................... 1-27
Charging Pump for Hydraulic S ta rte r .............................................. 1-43
Connecting Rod ................................................................................... 1-25 Oil F ilt e r .................................................................................................. 1-18
Connecting Rod Bearings................................................................. 1-26 O il Pump ................................................................................................ 1-16
Cooling System Pressure Cap ...................................................... 1-19 Oil Pump Relief Valve ......................................................................... 1-17
Crankshaft .............................................................................................. 1-24
Cylinder Block ...................................................................................... 1-21 Pistons and Rings ............................................................................... 1-23
Cylinder Head ......................................................................................... 1-9 Prelube Pump ....................................................................................... 1-18
Cylinder Liner ........................................................................................ 1-22 Pressure Accum ulator for Hydraulic Starter .................................. 1-43
Cylinder Liner Projection .................................................................... 1-22 Pressure Regulating Valve for Air Starting Motor ....................... 1-42
Engine Design ......................................................................................... 1-2 Sea W ater P u m p .................................................................................. 1-20

Engine Oil Pressure ........................................................................... 1-17 Service Meter and Tachom eter D r iv e ................................................ 1-7
Exhaust M a n ifo ld .................................................................................. 1-10 Starter Motor ......................................................................................... 1-40
Starter S o le n o id s .................................................................................. 1-41
Flywheel ................................................................................................. 1-33
Torque for Flared and O-Ring F ittin g s .................................................. 7
Flywheel Runout .................................................................................. 1-34
T u rb o c h a rg e r......................................................................................... 1-11
Flywheel Housing ................................................................................ 1-33
Turbocharger Lubrication Valve ........................................................ 1-18
Flywheel Housing Bore ..................................................................... 1-36
Flywheel Housing Runout ................................................................. 1-35 V-Belt Tension C h a r t........................................................................... 1-37
Fresh and Auxiliary W ater Pumps ................................................... 1-20 Valves .................................................................................................... 1-14
Front Accessory D r iv e ......................................................................... 1-32 Valve Rocker Arm s and Lifters ........................................................... 1-8
Fuel Control Valve ................................................................................ 1-4 Vibration Damper ................................................................................ 1-30
Fuel Injection Equipment ..................................................................... 1-3
Fuel Pump and Governor Drive .......................................................... 1-5 W ater Level Switch .............................................................................. 1-19
Fuel Transfer Pump ............................................................................... 1-4 W ater Tem perature Regulators ...................................................... 1-19
D379, D398, D399 INDU STR IA L & MARINE ENGINES SPECIFICATIONS
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
D ire c tio n o f R o ta tio n (w hen seen fro m fly w h e e l end).
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
SAE O p p o site R o t a t io n ............................................................... C lo ckw ise

A 7 1003X1
©©©©
F irin g O rd e r (In je c tio n S equence).
S AE S ta n da rd R o t a t io n .................................................... 1-8-5-4-7-2-3-6
S AE O p p o site R o t a t io n .................................................... 1-4-5-2-7-6-3-8
©© © © ® ©
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 )
D ire c tio n o f R o ta tio n (w hen seen fro m fly w h e e l end ).
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 A E O p p o s ite R o t a t io n ............................................................... C lo ckw ise
F irin g O rd e r (In je c tio n Sequence).
S AE S ta n da rd R o t a t io n ............................. 1 -1 2-9 -4 -5 -8 -1 1-2-3-1 0 -7 -6
S AE O p p o site R o t a t io n ............................. 1 -4 -9-8-5-2-1 1 -1 0-3-6 -7 -1 2
D399 Engine ........................................................................................... V16

© ® @ ® © © © ©
B o re 6 .2 5 in. (1 5 8 .8 m m )
16 1 5 1 4 1 3 12 11 10 9 8 7 8 5 4 3 2 1
S tro k e 8 .0 0 in . (2 0 3 .2 m m )
|o o o o oooo oooo o oo ol
D ire c tio n o f R o ta tio n (w he n seen fro m fly w h e e l end).
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
F irin g O rd e r (In je c tio n Sequence).
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
S AE O p p o site R o ta tio n . . 1 -6 -5 -4-3-10 -9 -1 6-15 -1 2-11 -1 4-13 -8 -7 -2
1-2
D379, D398, D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS
FUE L IN JE CTIO N E Q U IP M E N T
Pump lim in g before TC (top center):
D 399 E n g in e ........................................................................... 14±1°
D 398 and D379 E n g in e s .................................................... 12 ± 1 °
(1) Torque for b o l t s ................................. 32 ± 5 lb. ft. (43 ± 7 N-m)
N O T E : T o rq u e b o lt on the side w ith th e rack firs 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 )
M in im u m p e rm issib le length 2.9781 in. (7 5 .6 4 4 m m )
(3) T im in g d im e n s io n f o r th e fu e l in je c tio n p um ps:
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 )
O ff E ngine (A ll E ngines) 2 .1 5 6 to 2 .1 5 7 in. (5 4 .7 6 to 5 4 .7 9 m m )
(4) D ia m e te r o f the fue l

r a c k ............................... .6 0 9 5 ± .0 0 0 5 in. (15 .4 8 1 ± 0 .0 1 3 m m )
Bore in bearing fo r the

r a c k .......................................... 6 1 2 5 0 0 1 5 in. (1 5 .5 5 8 ± 0 .0 3 8 m m )
M a x im u m p erm issib le clearance betw e en b ore

in the bearings and th e r a c k .......................................0 0 6 in. (0 .15 m m )
(5) 3 S 1 2 52 S pring:
L en gth u n d e r test f o r c e 1.73 in. (4 3 .9 m m )
T e st fo rc e ...................................... ^ ............. 19 to 21 lb . (85 to 9 5 N)
Free le ng th a fte r t e s t 1.98 in . (5 0 .3 m m )
O u tsid e d ia m e t e r ....................................................... 1 .1 4 in . (2 9 .0 m m )
(6 ) B ore in bearings f o r the

ca m sh aft ....................... 2 .4 4 5 5 ± .0 0 0 5 in. (6 2 .1 1 6 ± 0 .0 1 3 m m )
D ia m e te r o f bearing surface (jo u rn a l) o f the

ca m sh a ft ........................ 2 .4 4 2 5 ± .00 0 5 in. (6 2 .0 4 0 ± 0 .0 1 3 m m )
M a x im u m p e rm issib le clearance b etw e en bearing

and bea rin g surface (jo u rn a l) o f ca m sh a ft . . . .0 0 6 in. (0 .1 5 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.
(11) T ig h te n nozzle fin g e r tig h t in 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
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 )
(1) C learance b etw een gear

and c o v e r ................................... 001 3 to .0 0 2 5 in. (0 .0 3 3 to 0 .0 6 4 m m )
(2) Bore in bearing 5 3 1 5 ± .0 0 0 3 in. (1 3 .5 0 0 ± 0 .0 0 8 m 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 )
(3) B ore in bearing 4 9 5 3 ± .0 0 0 3 in. (1 2.581 ± 0 .0 0 8 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 )
(4) B ore in g e a r 4 9 7 4 ± .0 0 0 3 in. (1 2 .6 2 9 ± 0 .0 0 8 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 )
N O T E : P ut a th in la yer o f 8 S 6 7 47 Sealer on face o f p u m p b o d y b e fo re

in sta llin g p u m p cover. D o n o t le t any o f 8 S 6 7 4 7 Sealer get in to the
p um p.
FUEL C O N T R O L V A L V E
(1) 4 M 5 9 2 3 S pring (E a rlie r):
Len gth u n d e r test f o r c e 3 .1 9 in. (8 1 .0 m m )
T est force ............................................... 4 1 .8 ± 3 .3 lb. (1 8 6 ± 14.5 N)
Free le ng th a fte r t e s t 4 .3 8 in. (1 1 1 .3 m m )
O u tsid e d ia m e t e r 81 in . (2 0 .6 m m )
(1) 3 N 6 6 9 0 S pring (L a te r):
Len gth u n d e r te st f o r c e 3 .3 3 in. (8 4 .7 m m )
Test fo rc e ....................................................... 29.7 ± 2 .5 lb. (1 32 ± 1 1 N)
Free le ng th a fte r t e s t 4 .4 3 in. (1 1 2.5 m m )
O u tsid e d ia m e t e r 81 in. (2 0 .6 m m )
(2) 7 B 4 9 7 0 S pring (E a rlie r):
L en gth u n d e r test f o r c e 1.03 in. (2 6 .2 m m )
Test fo rce ...................................................... 2 .6 ± . 1 lb. (11.5 ± 0 .4 N)
Free le ng th a fte r t e s t ................................................. 2 .1 9 in. (5 5 .6 m m )
O u tsid e d ia m e t e r 6 5 6 in. (1 6 .6 6 m m )
(2) 8 M 8 5 9 7 S pring (L a te r):
L en gth u n d e r te st f o r c e 1.38 in. (35.1 m m )
T e s tfo rc e ......................................................... 3 .6 ± .3 lb . (1 6 ± 1.3 N)
Free le ng th a fte r t e s t 2 .5 5 in. (6 4 .8 m m )
O utsid e d ia m e t e r 5 9 4 in. (1 5 .0 9 m m )
(3) T o rq u e fo r p l u g ....................................... 50 ± 10 lb. f t . (7 0 ± 14 N-m )
1-4
F UE L PUMP A N D G O V E R N O R D R I V E
(1) T o rq u e fo r b o l t .................................. 265 ± 35 Ib. ft. (3 6 0 ± 4 5 N -m ) (4) E nd p la y o f s h u to ff

d r i v e ...........................
......................................015 to .045 in. (0.38 to 1.14 m m )
(2) D 3 9 9 Eng ine; d ia m e te r o f m id d le and
rear bearing surfaces (jo u rn a ls) o f the D ia m e te r o f b earing surface (jo u rn a l)
shaft 1 .6 2 3 0 ± .0 0 0 3 in. (4 1 .2 3 2 ± 0 .0 0 8 m m ) fo r gear 7 47 5 ± .0 0 0 5 in. (1 8 .9 8 7 ± 0 .0 1 3 m m )
D 3 7 9 and D 3 9 8 Engines; d ia m e te r o f Bore in bearing fo r

rear bearing surface (jo u rn a l) o f th e g e a r ............................................. 7523 ± .0005 in. (19.114 ± 0.013 m m )
sh aft 1 .6 2 3 0 ± .00 0 5 in . (4 1 .2 3 2 ± 0 .0 1 3 m m )
(5) D ia m e te r o f f r o n t bearing surface
Bore in ce n te r and rear (jo u rn a l) o f the sh aft . . 1.9250 ± .0005 in. (48.895 ± 0.013 m m )
b e a rin g s ............................. 1 .6 2 5 5 + .0 0 0 5 in. (4 1 .2 8 8 ± 0 .0 1 3 m m )
B ore in fr o n t bearing . . 1.9275 ± .0005 in. (48.959 ± 0.013 m m )
M a x im u m perm issib le clearance b etw een
M a x im u m p erm issib le clearance betw e en
bearings and bearing surfaces ( jo u r n a ls ) 0 0 9 in. (0 .2 3 m m )
b ea rin g and bearing surface ( j o u r n a l) ....................... 009 in. (0.23 m m )
(3) End p la y o f bevel p i n i o n ................ 0 0 4 ± .00 2 in. (0 .1 0 ± 0 .0 5 m m )
(6 ) End p la y o f d riv e s h a f t .................005 to .009 in. (0.1 3 to 0.23 m m )
D ia m e te r o f p in io n bearing surface
M a x im u m p erm issib le end p la y o f
(jo u rn a l) 9 3 5 8 ± .0 0 0 2 in. (2 3 .7 6 9 ± 0 .0 0 5 m m )
d riv e s h a f t ........................................................................... 015 in . (0.38 m m )
Bore in bearing f o r
(7) A m o u n t o f free m o v e m e n t (backlash) b etw een
p in io n 9 3 7 5 ± .00 0 5 in. (2 3 .8 1 3 ± 0 .0 1 3 m m )
bevel gear and p i n i o n ......................002 to .006 in. (0.05 to 0.15 m m )
M a x im u m p erm issib le clearance betw e en
p in io n and b e a r in g 0 0 8 in . (0 .2 0 m m )
1-5
D379, D398, D399 IN DUSTRIAL & MARINE ENGINES SPECIFICATIONS
GOVERNOR
(1) 2 S 7235 S pring fo r c o lla r guide:
L en gth u n d e r test f o r c e .............................................. 375 in. (9 .5 3 m m )
Test fo rc e ......................................................... 3 9 ± .03 lb. (1 .8 ± 0.1 N)
Free le ng th a fte r t e s t ..................................................... 68 in. (1 7 .3 m m )
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 )
7 M 7 2 4 4 S pring f o r speed lim ite r:
Len gth u n d e r te st f o r c e .................................................4 9 in. (1 2 .4 m m )
T est fo rce 1.48 + .14 lb. (6 .6 ±0 .6 2 N)
Free le ng th a fte r t e s t ............................................... 2 .0 0 in. (5 0 .8 m m )
O u tsid e d ia m e t e r 507 in. (1 2 .8 8 m m )
(4) 8 M 9 14 1 S pring fo r g o ve rn o r (E a rlie r):
C o lo r code is ................................................................. one p u rp le strip e
P ut fo rce on spring o f .................................................... 4 .0 0 lb. (1 8 N)
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 )
T e st fo rce ................................................... 14.8 ±.5 lb. (6 6 .0 ± 2 .2 N)
Free le ng th a fte r t e s t ....................... 2 .3 4 ± .03 in . (5 9 .4 ± 0 .8 m m )
O u tsid e d ia m e t e r 1.371 in. (3 4 .8 2 m m )
(4) 4 N 66 8 1 S pring fo r g o ve rn o r ( L a te r):
C o lo r code is .................................................................... tw o p u rp le stripes
Put fo rce on spring o f .................................................... 4 .0 0 lb . (18 N)
T h en add m o re force to make

sprin g sh o rte r b y 9 0 0 in . (2 2 .8 6 m m )
Test fo rc e ................................................... 14.8 ± .5 lb . (6 6 .0 ± 2 .2 N)
Free le ng th a fte r t e s t ....................... 2 .2 4 ± .03 in. (5 6 .9 ± 0 .8 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:
L en gth u n d e r te st f o r c e ...............................................180 in. (4 .57 m m )
Test fo rce .................................................... 10.0 ± .5 lb . (45 ± 2 .2 N)
Free le ng th a fte r t e s t ....................................................3 4 4 in . (8 .7 4 m m )
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 )
N O T E : F o r engines th a t have standard r o ta tio n , th e bypass valve is (10) H e ig h t o f g e a rs ............. .2 5 0 0 + .0 0 0 3 in. (6 .3 5 0 ± 0 .0 0 8 m m )

in stalled on the side w ith the g o ve rn o r c o n tro l lever. F o r engines th a t
have o p p o s ite ro ta tio n , th e bypass valve is in stalled on th e side o p p o site D e p th o f c o u n te rb o re .2 5 1 5 ± .0 0 0 3 in. (6 .3 8 8 ± 0 .0 0 8 m m )
the g o ve rn o r c o n tro l lever.
(11) O u tsid e d ia m e te r o f
7 L 8 6 9 6 S p rin g fo r bypass valve: sh a ft ............................... 6 8 6 0 ± .00 0 5 in. (1 7 .4 2 4 ± 0 .0 1 3 m m )
L en gth u n d e r test f o r c e .......................................... 1.13 in. (2 8 .7 m m ) D ia m e te r o f b o r e .......... 6 8 8 0 ± .0 0 0 5 in. (1 7 .4 7 5 ± 0 .0 1 3 m m )
T e st fo rc e .................................................. 7 .2 2 ± .4 lb . (32.1 ± 1.8 N) (1 2 ) O u tsid e d ia m e te r o f p in 6 2 3 5 ± .0 0 0 5 in. (1 5 .8 3 7 ± 0 .0 1 3 m m )
Free le ng th a fte r t e s t 1 .3 7 0 ± .0 1 0 in. (3 4 .8 0 ± 0 .2 5 m m ) D ia m e te r o f b o r e .......... 6 2 5 5 ± .0 0 0 5 in. (1 5 .8 8 8 ± 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
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:
Len gth u nd er te st f o r c e 8 8 in. (2 2 .4 m m )
Test fo rce .................................................... 1.03 ± .08 Ib. (4 .6 ± 0 .4 N)
Free le ng th a fte r t e s t 1.23 in. (3 1 .2 m m )
O u tsid e d ia m e t e r 592 in. (1 5 .0 4 m m )
(2) 6 N 3 0 1 7 S pring :
C o lo r c o d e ................................................................................. one red strip e
L en gth u n d e r test f o r c e 6 6 0 in. (1 6 .7 6 m m )
Test fo rc e ............................................................ 6 .0 ± 1.0 Ib. (27 ± 4 N)
Free le ng th a fte r t e s t 1.30 in. (3 3 .0 m m )
O u tsid e d ia m e t e r ......................................................... 1.28 in. (3 2 .5 m m )
(3) 6 N 9 6 8 S pring :
C o lo r c o d e ............................................................................ one green strip e
L en gth u n d e r test f o r c e ....................................... 1.3 7 5 in. (3 4 .9 3 m m )
Test fo rce ................................................................. 15 ± 1 Ib. (67 + 4 N)
Free le ng th a fte r t e s t 1.50 in . (38.1 m m )
SER V ICE M ETER AND TACHO M ETER D RIV E
(1) D ia m e te r o f s h a f t ............. 4313 .0 0 0 2 in . (1 0 .9 5 2 ± 0 .0 0 5 m m )
Bore in bearing ............... 4333 .0 0 0 5 in . (1 1.011 ± 0 .0 1 3 m m )
(2) T o rq u e fo r housing .......... . . . 5 0 ± 3 Ib. f t . (7 0 ± 4 N -m )
(3) D ia m e te r o f s h a f t ............. .00 0 2 in. (1 0 .9 5 2 ± 0 .0 0 5 m m )
M in im u m b ore in bearing . ......................... 4 3 3 in . (11.01 m m )
(4) T o rq u e fo r b o lts ................ . . . . 8 ± 2 Ib. f t . (11 ± 3 N-m )
(5) Push sh aft (3) to w a rd s service m e te r and

add o r rem ove shim s to get end p la y o f
p in io n t o ..............................................001 to .00 8 in. (0 .0 3 to 0 .2 0 m m )
1-7
C A M S H A F T AN D T I M I N G G E A R S
(1) T o rq u e fo r b o lts .................................... 6 0 to 70 lb . f t . (80 to 95 N-m}
(2) End p la y fo r the ca m sh aft . . . .0 0 6 to .01 0 in. (0 .15 to 0 .2 5 m m )
M a x im u m perm issib le p la y 0 2 0 in. (0.51 m m )
(3) D ia m e te r o f bearing surface (jo u rn a l) o f

the ca m sh aft ..................... 2 .9 6 6 to 2 .9 6 7 in. (7 5 .3 4 to 7 5 .3 6 m m )
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 )
M a x im u m p e rm issib le cle arance b etw een bearing

and ca m sh aft bearing surfaces ( j o u r n a ls ) 0 0 9 in. (0 .23 m m )
(4) T im in g m arks f o r ca m sh aft and bala n cer (D 3 7 9 Engines o n ly ).
(5) T im in g m a rks f o r c ra n k s h a ft and ca m sh a ft gears ( A ll engines).
(6) S AE O p p o site R o ta tio n (clo ckw ise engine), p u t c lu s te r gear on

end o f ca m sh aft w ith " F " m ark.
(7) SAE S ta n da rd R o ta tio n (c o u n te rc lo c k w is e engine), p u t c lu s te r

gear on end o f ca m sh aft w ith o u t " F ” m ark.
N O T E : S p e c ific a tio n s (8) and (9) f o r D 3 7 9 Engines o n ly .
(8) Bore in bearing fo r

balance g e a r ..................... 1 .6 0 3 6 ± .0 0 1 9 in. (4 0.731 ± 0 .0 4 8 m m )
D ia m e te r o f b earing surface (jo u rn a l) o f

balance gear shaft . . . . 1 .5 9 9 8 ± .0 0 0 2 in. (4 0 .6 3 5 ± 0 .0 0 5 m m )
M a x im u m p e rm issib le clearance betw e en bearing

and bea rin g surface ( j o u r n a l ) 0 0 6 in. (0 .1 5 m m )
(9) End p la y o f balancer

g e a r ........................................................0 0 4 to .012 in. (0 .1 0 to 0 .3 0 m m )
M a x im u m p e rm issib le end p la y 0 1 9 in. (0 .4 8 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
(1 ) T u rn n u t u n til c o n ta c t is made w ith w asher,

th e n to rq u e t o 10 ± 3 lb . f t . (1 4 ± 4 N-m )
(2) T o rq u e fo r studs 4 0 ± 5 lb. f t . (55 ± 7 N-m )
(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 )
Bore in ro cke r arm

b e a r in g .......................................... 1 .2 2 6 ± .001 in. (3 1 .1 4 + 0 .0 3 m m )
M a x im u m p e rm issib le clearance b etw een

sh aft and b e a r in g 0 0 9 in. (0 .2 3 m m )
(5) D ia m e te r o f l i f t e r .................. 9 9 6 5 + .0 0 0 5 in. (25.311 ± 0 .0 1 3 m m )
Bore in lifte r b ra cke t . . . .9 9 9 5 ± .0 0 0 5 in. (2 5 .3 8 7 ± 0 .0 1 3 m m )
M a x im u m p e rm issib le clearance betw e en

lif t e r and bore 0 1 0 in. (0 .25 m m )
1-8
V
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
T o rq u e fo r nuts f o r c y lin d e r head:
P ut 9 M 3 7 1 0 A nti-S e ize C o m p o u n d on threads:
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 )
2. A ga in tig h te n all nuts in n u m b e r

sequence to .......................................... 250 ± 10 Ib. f t . (3 4 0 ± 14 N -m )
3. A gain tig h te n all n u ts in n u m b e r sequence

(hand to rq u e o n ly ) to .................... 2 5 0 + 10 Ib. f t . (3 4 0 + 14 N -m )
(A ) T h ickn ess o f c y lin d e r head

( n e w ) .......................................... 7 .0 6 5 + .0 0 4 in. (1 7 9 .4 5 + 0 .1 0 m m )
1-9
EXHAUST M AN IFO LD
(1) T o rq u e fo r b o lts f o r exha ust

b ellow s c l a m p ................................................. 57 ± 5 lb. f t . (78 ± 7 N-m )
(2) T o rq u e fo r b o lts h o ld in g w ater cooled exhaust

m a n ifo ld to c y lin d e r h e a d 110 ± 10 lb . f t . (149 t: 14 N-m )
T o rq u e fo r b o lts w ith fla ng ed hex heads on w a ter

shielded m a n ifo ld ............................. 75 ± 10 lb. ft. (1 0 0 ± 14 N -m )
N O T E : Put 9 M 3 7 1 0 A n ti-S e ize C o m p o u n d on threads o f b o lts.
(3) T o rq u e fo r b o lts h o ld in g exha ust

m a n ifo ld to shield 10 lb. f t . (14 N -m )
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 )
(2) T o rq u e fo r b o lts th a t h o ld in ta k e m a n ifo ld to

c y lin d e r h e a d ................................... 75 ± 10 lb. ft . (1 0 0 ± 14 N -m )
N O T E : P ut 9 M 3 7 1 0 A n ti-S e ize C o m p o u n d on threads o f b o lts.
AFTERCOOLER
(1) T o rq u e b o lts and nuts in

n u m b e r sequence t o 32 ± 5 lb. f t . (43 ± 7 N-m )
A gain to rq u e b o lts and n u ts in

n u m b e r sequence t o 32 ± 5 lb. f t . (4 3 ± 7 N-m)
1-10
TURBOCHARGER
(S ch w itzer F 3 0 2 and F 6 5 4 )
(5) M a x im u m p erm issib le gap o f o il seal rin g , measured

(1) End p la y fo r shaft in b o re o f housing ........................................................... 0 0 9 in. (0 .23 m m )
( n e w ) .............................................0 0 4 5 ± .0 0 1 5 in. (0 .1 1 4 ± 0 .0 3 8 m m ) (6) T o rq u e fo r n u t ............................................ 22 ± 2 Ib. ft . (28 ± 3 N-m)
M a x im u m p e rm issib le end p la y (w o rn ) 0 0 8 in. (0 .2 0 m m ) N O T E : D o n o t bend o r add stress to the sh aft w h en n u t is tig h te n e d .
(2) Thickness of th ru s t (7) B ore in housing
b e a rin g .......................................... 211 ± .001 in. (5.36 ± 0.03 mm) (n e w ) 8 7 6 2 to .8 7 6 7 in. (2 2 .2 5 5 to 2 2 .2 6 8 m m )
(3) D ia m e te r o f shaft O u tsid e d ia m e te r o f the
( n e w ) ......................................5 6 1 2 to .5 6 1 5 in. (1 4 .2 5 4 to 1 4 .2 6 2 m m ) bearing ( n e w ) ...................... 8 7 1 8 to .8 7 2 2 in. (2 2 .1 4 4 to 2 2 .1 5 4 m m )
Bore in th e bearing M a x im u m p erm issib le clearance betw e en bearing
( n e w ) ......................................5 62 7 to .5 6 3 0 in. (1 4 .2 9 3 to 1 4 .3 0 0 m m ) and b ore in housing (w o rn )............................................. 0 0 6 in. (0 .15 m m )
M a x im u m p e rm issib le cle arance betw e en bearing (8) T h ickn ess o f each

and sh aft (w o rn ) 0 0 3 in. (0 .0 8 m m ) th r u s t r i n g 1 005 ± .00 0 5 in . (2 .5 5 3 t 0 .0 1 3 m m )
(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
TURBOCHARGER
(S c h w itz e r 4 H D and 4 H F )
(1) End p la y o f s h a f t ...........................0 0 4 to .00 6 in. (0 .1 0 to 0 .1 5 m m )

(7) D ia m e te r o f b o re in
M a x im u m p e rm issib le end p la y o f s h a f t ...............0 0 8 in. (0 .2 0 m m )
hou 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 )
(2) T o rq u e fo r b o lts f o r th ru s t bearing ........................ 60 lb. in. (7 N-m )
O u tsid e d ia m e te r o f the
(3) T h ickn ess o f each th r u s t b e a r in g ..................... 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 )
rin g .......................... ..........................0 9 9 to .1 0 0 in. (2.51 to 2 .5 4 m m )
(8) W id th o f gro ove in sleeve fo r
(4) D ia m e te r o f bearing surface (jo u rn a l) fo r ring s e a l s 128 to . 1 30 in. (3 .2 5 to 3 .3 0 m m )
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 )
Side cle arance betw e en tw o o f the ring
M in im u m p e rm issib le jo u rn a l d ia m e te r . . .6861 in. (1 7 .4 2 7 m m ) seals and sleeve g r o o v e 0 0 2 to .00 6 in. (0 .05 to 0 .1 5 m m )
B ore in th e bearing .6 8 8 0 to .6 8 8 3 in. (1 7 .4 7 5 to 1 7 .4 8 3 m m ) (9) Clearance betw e en housing

and im p e lle r 0 1 8 to .022 in. (0 .4 6 to 0 .5 6 m m )
(5) M a x im u m p erm issib le gap o f rin g seal
( w o r n ) ..................................................................................0 0 9 in. (0 .2 3 m m ) (1 0 ) T o rq u e f o r n u t f o r b and cla m p
(com pressor h ou sin g and e xha ust p ip e ) . . 120 lb. in. (13.6 N-m )
M a x im u m p e rm issib le gro ove in rin g seal
( w o r n ) ..................................................................................0 6 8 in . (1 .73 m m ) (11) T h ickn ess o f th ru s t
b e a r in g 2 2 5 to .2 2 6 in. (5 .7 2 to 5 .7 4 m m )
M in im u m p e rm issib le w id th o f rin g seal
( w o r n ) ..................................................................................0 6 2 in . (1 .57 m m ) M in im u m p e rm issib le bearing th ic k n e s s ...............2 2 4 in. (5 .69 m m )
(6) T o rq u e f o r n u t h o ld in g im p e lle r: (12) P ut 9 M 3 7 1 0 A nti-S e ize C o m p o u n d on

b o lts h o ld in g tu rb in e h ou sin g and
4 H F 4 5 5 and 4 H D 7 5 5 32 ± 2 lb. ft . (43 ± 3 N -m )
tig h te n t o ...................................................................... 17 lb. ft . (23 N-m )
4H D 857, 4H F854, 4H F864,
(1 3 ) P ut 9 M 3 7 1 0 A n ti-S e iz e C o m p o u n d on b o lts
4 H F 8 5 7 .................................................. 4 5 to 5 0 lb. ft . (60 to 7 0 N-m )
h o ld in g tu rb o c h a rg e r to m a n ifo ld and
N O T E : Do n o t b end o r add stress to th e sh a ft w h en n u t is tig h te n e d . tig h te n t o ............................................... 36 to 4 4 lb. ft. (4 6 to 6 0 N -m )
1-12
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 )
(3) T h ickn ess o f each th r u s t (8) W id th o f gro ove in sleeve fo r

tin g ..................................................... 09 9 to .1 0 0 in. (2.51 to 2 .5 4 m m ) ring s e a ls ........................................... 1 28 to .1 3 0 in. (3 .2 5 to 3 .3 0 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.
V alve cle arance s e ttin g ; engine stop p ed :
In ta k e v a lv e ....................................................................... 0 1 5 in. (0 .3 8 m m )
E xha u st v a lv e ..................................................................... 035 in . (0 .8 9 m m )
(1) 9 M 5 3 5 0 S pring (o u te r ) :
L e n g th u n d e r test f o r c e ....................................... 2 .2 1 9 in. (5 6 .3 6 m m )
Test fo rc e ............................................................ 65 ± 3 Ib. (2 9 0 ± 13 N )
Use again m in im u m load at le ng th u nd er

te st f o r c e ......................................................................... 4 3 .5 Ib. (1 9 3 .5 N)
L en gth o f spring at valve open p o s itio n 1 .6 1 4 in. (4 1 .0 0 m m )
Use again m in im u m load at valve

o pen p o s it io n .................................................................... 148 .8 Ib. (6 6 2 N)
Free le ng th a fte r t e s t .............................................. 2 .5 7 4 in . (6 5 .3 8 m m )
O utsid e d ia m e t e r .................................................... 1.7 1 3 in. (43.51 m m )
S pring m u st n o t be b e n t m o re t h a n ..........................0 9 0 in. (2 .2 9 m m )
(1) 9 M 5 3 4 9 S pring (in n e r):
L en gth u n d e r test f o r c e ....................................... 1.791 in. (4 5 .4 9 m m )
Test fo rce ................................................................. 2 0 ± 1 Ib. (90 + 4 N)
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)
L en gth o f sprin g at valve o pen p o s itio n . . . . 1.187 in. (3 0 .1 5 m m )
Use again m in im u m lo ad at valve o pen p o s itio n . . 43.1 Ib. (1 9 2 N)
Free le ng th a fte r t e s t .............................................. 2 .1 7 9 in. (5 5 .3 5 m m )
O utsid e d ia m e t e r .................................................... 1.1 2 5 in . (2 8 .5 8 m m )
S pring m u st n o t be b e n t m o re t h a n ..........................0 7 6 in. (1 .9 3 m m )
(2) D istance betw e en to p o f valve guide

and to p o f h e a d 1 .7 5 0 ± .0 2 0 in. (4 4 .4 5 ± 0.51 m m )
(3) L en gth o f guide:
In ta ke valve g uide 5 .0 6 ± .04 in. (1 2 8 .5 ± 1 .0 m m )
E xha u st valve g u i d e 5 .4 4 ± .0 4 in. (1 3 8 .2 ± 1 .0 m m )
(4) D ia m e te r o f valve stem :
In ta k e V alve (new ) ..............4 9 5 5 i .0 0 0 5 in. (1 2 .5 8 6 ± 0 .0 1 3 m m )

(5) T h ickn ess o f valve lip :
Use again m i n im u m ...................................................... 4 9 4 in. (1 2 .5 5 m m )
In ta k e valve, use again m i n im u m ........... .147 in. (3 .7 3 m m )
E xha u st Valve (new ) . . . .4 9 5 5 ± .0 0 0 5 in . (1 2 .5 8 6 ± 0 .0 1 3 m m )
E xha u st valve, use again m in im u m . . . . .1 4 0 in. (3 .5 6 m m )
Use again m i n im u m ......................................................4 9 4 in . (1 2 .5 5 m m )
(6 ) D ia m e te r o f valve h e a d :
B ore in valve guid e a fte r in s ta lla tio n :
In ta k e v a lv e 2 .5 0 5 ± 0 0 5 in. (6 3 .6 3 : 0 .1 3 m m )
V alve guides ( n e w ) ........................................................ 4 9 9 in. (1 2 .6 7 m m )
E xha u st v a lv e 2 .3 5 0 ± .00 5 in. (5 9 .6 9 : 0 .1 3 m m )
M a x im u m p erm issib le bore in
valve guid e : (w o rn ) ...................................................... 5 0 3 in. (1 2 .7 8 m m ) (7) A n g le o f valve f a c e ....................................... . . 29° 1 5 '
1-14
Valves (Cont.)
( 8) D epth of bore in iiead fo r valve

seat in s e r t ........................ 6365 ± .0050 in. (16.167 ± 0.127 m m)
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 )
(9) B ore in head f o r in ta k e valve

seat insert ..................... 2 .5 8 6 5 .0 0 0 5 in. (6 5 .6 9 7 ± 0 .0 1 3 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 )
Bore in head f o r e xha ust valve

seat in sert ..................... 2 .4 3 1 5 t .0 0 0 5 in. (6 1 .7 6 0 + 0 .0 1 3 m m )
D ia m e te r o f exha ust valve

seat insert ..................... 2 .4 3 5 0 ± .0 0 0 5 in. (6 1 .8 4 9 t 0 .0 1 3 m m )
(10) A n g le o f the face o f the valve seat insert........................ 30°
(11) M a x im u m p e rm issib le w id th o f valve seat: T Y P IC A L ILLU S TR A TIO N

E xha u st v a lv e ....................................................................07 5 in. (1.91 m m )
In ta k e v a lv e ...................................................................... 0 7 5 in . (1.91 m m )
(1 2) D im en sio n fro m to p o f closed valve to face o f head:
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 perm issib le d im e n sio n fo r

e xha ust v a lv e ....................................................................120 in. (3 .0 5 m m )
M a x im u m perm issib le d im e n sio n fo r

in ta k e v a l v e ...................................................................... 170 in. (4 .3 2 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 )
(13) O utsid e d ia m e te r o f the face o f the valve seat in sert:
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 , e xha ust s e a t 2 .3 5 0 in. (5 9 .6 9 m m )
In ta ke s e a t ............................................................... 2 .4 5 7 in. (62.41 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 )
(14) A n g le to g rin d seat face o f th e insert

to get a re d u c tio n o f m a x im u m seat d ia m e t e r ............................. 15°
1-15
(1) D ia m e te r o f rear bearing surface (jo u rn a l)

(4) D ia m e te r o f bearing surface (jo u rn a l)
o f d riv e s h a f t .................. 1 .2 4 8 9 ± .0 0 0 3 in. (3 1 .7 2 2 ± 0 .0 0 8 m m )
o f id le r sh a ft .................. 1 .3 7 4 5 ± .0 0 0 3 in. (3 4 .9 0 7 * 0 .0 0 8 m m )
B ore in rear bea rin g fo r
B ore in bearing in
sh aft 1.2521 * .0 0 0 5 in. (3 1 .8 0 3 + 0 .0 1 3 m m )
id le r g e a r .......................... 1.3761 r .0 0 0 5 in. (3 4 .9 5 3 ± 0 .0 1 3 m m )
M a x im u m p e rm issib le clearance b etw een bearing
M a x im u m p e rm issib le clearance betw e en bearing
and rear bearing surface (jo u rn a l) 008 in. (0 .2 0 m m )
and b earing surface ( j o u r n a l) 0 0 6 in. (0 .15 m m )
(2) D ia m e te r o f fr o n t bearing surface (jo u rn a l)
(5) T h ickn ess o f o il p u m p h ousing:
fo r d riv e sh aft ................ 1 .6 1 5 0 ± .0 0 0 3 in. (4 1.021 ± 0 .0 0 8 m m )
D 3 7 9 .................................. 2 .1 0 0 5 ± .0 0 0 8 in. (5 3 .3 6 0 t 0 .0 2 0 m m )
B ore in f r o n t bearing
fo r s h a f t ............................. 1 .6 1 82 ± .0 0 0 5 in. (4 1 .1 0 2 ± 0 .0 1 3 m m ) D 3 9 8 .................................. 2 .7 5 0 5 ± .0 0 0 8 in. (6 9 .8 6 3 ± 0 .0 2 0 m m )
M a x im u m p e rm issib le cle arance betw e en bearing D 3 9 9 .................................. 3 .5 0 6 2 + .0 0 0 8 in. (8 9 .0 5 7 * 0 .0 2 0 m m )

and bearing surface (jo u rn a l) 008 in. (0 .2 0 m m )
T h ickn ess o f o il p u m p gear:
(3) Bore in bearing in
D 3 7 9 .................................. 2 .0 9 4 3 + .0 0 0 5 in. (5 3 .2 0 0 ± 0 .0 1 3 m m )
re ta in e r ............................. 2 .1 2 4 5 + .0 0 2 0 in. (5 3 .9 6 2 ± 0.051 m m )
D 3 9 8 .................................. 2 .7 4 4 3 ± .0 0 0 5 in. (6 9 .7 0 5 ± 0 .0 1 3 m m )
D ia m e te r o f bearing surface
(jo u rn a l) .......................... 2.1 205 ± .0 0 0 5 in. (53.861 ± 0 .0 1 3 m m ) D 3 9 9 .................................. 3 .5 0 0 0 ± .0 0 0 5 in. (8 8 .9 0 0 ± 0 .0 1 3 m m )
M a x im u m p e rm issib le clearance betw e en bearing Clearance b etw e en gears and covers

and bearing surface ( j o u r n a l) 0 0 8 in. (0 .2 0 m m ) fo r all engines 0 0 4 9 to .0 0 7 5 in. (0.1 24 to 0.191 m m )
1-16
OIL PUMP R E L IE F V A L V E
(1) T o rq u e fo r p l u g .................................. 2 8 0 ± 10 lb . f t . (377 ± 14 N -m )
N O T E : D o n o t use sealant o n plug.
(2) 3 N 4 8 7 5 S pring fo r re lie f valve:
L en gth u nd er te st f o r c e .............................................. 2.91 in. (1 3 .9 m m )
Test fo rc e ......................................................... 190 ± 9 lb. (8 4 5 + 4 0 N)
Free le ng th a fte r t e s t ................................................. 3 .9 8 in. (101.1 m m )
(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
A ll steps o f th is p ro ce d u re m u st be fo llo w e d fo r the pressure fin d in g s to

be usable. E N G IN E O IL P R E S S U R E
Step 1. Be sure th a t th e engine is fille d to th e c o rre c t level w ith SAE

Engine Oil Pressure
30 o il. If any o th e r visco sity o f o il is used, the in fo r m a tio n in
Engine Rating
the C H A R T FO R E N G IN E O IL P R E S S U R E does n o t a p p ly.
M odel rpm psi kPa
Step 2. F in d a lo c a tio n o n the m a n ifo ld to in sta ll a tee. Insta ll a p ro be
fro m th e 9 S 9 1 0 2 T h e rm is to r T h e rm o m e te r G ro u p in one side D 379 1 200 5 9 to 6 6 4 0 5 to 4 6 0
o f th e tee. C o nn e ct a 8 M 2 7 4 4 Gauge fro m the 5P 6 2 25
H y d ra u lic Test B ox to th e o th e r side o f the tee. D 398 1200 5 6 to 63 3 8 5 to 4 3 0
Step 3. R un the e ngine to get the o il te m p e ra tu re at 2 0 0 ± 10° F (93

D 399 1200 56 to 63 3 8 5 to 4 3 0
± 6° C).
Step 4. M a in ta in th e c o n s ta n t o il te m p e ra tu re w ith the engine at 1200

rp m and read th e pressure gauge.
If th e results d o n o t fall w ith in the pressure range given in the c h a rt,

fin d th e cause and c o rre c t it. C o n tin u e d o p e ra tio n o f engine w ith o il
m a n ifo ld pressure o u tsid e th is range m ay re su lt in engine fa ilu re o r
re d u c tio n in engine life .
1-17
OIL F IL T E R
(1) T o rq u e fo r ve nt p l u g 3 0 ± 5 Ib. f t . (4 0 ± 7 N-m )
(2) 3 N 4 3 1 6 S pring fo r bypass valve fo r the filt 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 )
Test fo rc e 35 ± 1.75 Ib. (1 5 5 ± 7 .8 N)
Free le ng th a fte r t e s t 4.97 in. (1 2 6 .2 m m )
O utsid e d ia m e t e r 1 .1 3 5 in. (2 8 .8 3 m m )
(3) T o rq u e fo r p l u g 2 0 ± 5 Ib. f t . (25 ± 7 N-m )
T U R B O C H A R G E R LUBRICATION V A L V E
(1) 7M61 24 S pring f o r valve:
Len gth u n d e r test f o r c e 1.5 9 in . (4 0 .4 m m )
Test fo rc e 1 9 .4 0 + .97 Ib. (8 6 .3 ± 4 .3 N)
Free le ng th a fte r t e s t .................................................. 2 .2 4 in. (5 6 .9 m m )
O u tsid e d ia m e t e r .................................................... 1 .4 5 3 in. (36.91 m m )
(2) Bore in b o d y ................. 1 .5 0 0 5 ± .0 0 0 5 in . (3 8 .1 1 3 + 0 .0 1 3 mm)
(3) D ia m e te r o f p lu n g e r . . . 1 .4 9 8 0 ± .00 0 7 in. (3 8 .0 4 9 ± 0 .0 1 8 mm)
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 :
O u tp u t w ith p u m p at 1 1 5 0 r p m ..................... 15 U.S. gpm (5 7 litr e /m in )
Pressure using 7 5 0 SUS o i l .................................................... 25 psi (1 7 0 kPa)
(1) D e p th o f b ore in h o u s in g 2 .2 0 7 in. (5 0 .9 8 m m )
(2) End clearance o f ro to r (a d ju st w ith

2 N 7 5 2 2 G asket K it) ...................... 0 0 3 to .00 5 in. (0 .0 8 to 0 .1 3 m m )
1-18
WATER TEM PERATURE REG ULATO RS
6 L 5 8 5 1 and 9 N 2 8 9 4 Regulator:
T e m p e ra tu re w h en c o m p le te ly o pen .................................. 197° F (92° C)
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
Pressure th a t m akes re lie f valve

open ................................................. 3 .5 to 4 .0 psi (24 to 28 kPa)
W A T E R L E V E L SWITCH
(2N9768 and 6L7037)
(1) Th re ad size o f v e n t p i p e ......................................................... 1 /4 —18 NPT
Th re ad size o f s u p p ly p i p e .................................................... 1 /2 —14 N P T
(2) C o n d u it o p e n in g 1 /2 in.
(3) S w itch ra tin g 1 2 5 -2 5 0 V A C ................................................................ 1 0A
1-19
F RES H AN D A U X I L I A R Y W A T E R PUMPS
1 c
(1) T o rq u e fo r im p e lle r n u t ............................................... 55 lb. f t . (75 N-m )
T ig h te n fa rth e r, if needed, to in sta ll c o tte r pin.
(2) Clearance betw e en im p e lle r

and c o v e r 0 0 5 to .0 2 0 in. (0 .13 to 0 .5 0 m m )
(3) T o rq u e fo r p u lle y n u t (fresh w a te r

p u m p o n ly ) ................................................................. 100 lb . f t . (135 N-m )
T ig h te n fa rth e r, if needed, to in sta ll c o tte r p in .
(4) Bore in bearing ............. 1 .2 4 8 5 ± .00 0 5 in. (3 1 .7 1 2 ± 0 .0 1 3 m m )
M a x im u m perm issib le bearing cle arance 0 0 8 in. (0 .2 0 m m )
(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 )
(6) S ha ft end c le a r a n c e .........................0 0 2 to .006 in . (0 .0 5 to 0 .1 5 m m )
M a x im u m p e rm issib le end cle arance

of s h a f t 0 0 9 in. (0 .2 3 m m )
S E A W A T E R PUMP
(1) T o rq u e fo r zinc r o d ....................................... 5 ± 2 lb. ft . (7 ± 3 N-m)
N O T E : Put 9 S 3 2 6 3 S ealant on s h o u ld e r o f zin c ro d . D o n o t p u t sealant

on threads.
(2) T o rq u e fo r im p e lle r n u t ............................................ 55 lb. ft . (75 N -m )
(3) Clearance b etw een im p e lle r

and c o v e r ..............................................0 0 5 to .0 2 0 in . (0 .1 3 to 0 .5 0 m m )
(4) Bore in bearing ............. 1 .2 4 8 5 ± .00 0 5 in. (3 1 .7 1 2 ± 0 .0 1 3 m m )
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 )
M a x im u m p e rm issib le bearing clearance ...............0 0 8 in. (0 .2 0 m m )
(5) S h a ft end c l e a r a n c e ........................ 0 0 2 to .0 0 6 in. (0 .0 5 to 0 .1 5 m m )
M a x im u m p erm issib le end clearance

o f s h a f t ................................................................................ 0 0 9 in. (0 .23 m m )
1-20
D379, D398, D399 IN DUSTRIAL 8< MARINE ENGINES SPECIFICATIONS
C Y L I N D E R BL O CK
(1) T o rq u e fo r ta p e rlo c k studs fo r

c y lin d e r h e a d 120 ± 10 lb . f t . (1 6 0 ± 14 N-m )
(2) D e p th to in sta ll fr o n t ca m sh aft b e a r in g .................... 31 in . (7 .9 m m )
(3) D e p th to in sta ll rear ca m sh aft b e a r in g .................... 6 6 in . (1 6 .8 m m )
N O T E : In sta ll ca m sh a ft bearings so o il holes in bearings are in

a lig n m e n t w ith o il passages in c y lin d e r b lo c k .
(4) Bore in c y lin d e r b lo c k fo r ca m sh aft

b e a rin g s .......................... 3 .2 5 0 5 ± .0 0 0 5 in. (8 2 .5 6 3 0 .0 1 3 m m )
(5) B alancer gear shafts (V -8 Engines o n ly ).
D im e n sio n fro m boss on c y lin d e r b lo c k to end

o f sh aft .................................... 2 .6 8 6 ± .0 0 2 in. (6 8 .2 2 0.05 mm)
N O T E : Install shafts so ce n te rlin e o f tw o holes w ith threa d s is p a ra lle l
w ith b o tto m face o f c y lin d e r b lo c k .
(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 )
M a x im u m p erm issib le bore d e p th a fte r

r e c o n d it io n in g .............................................................. 5 4 5 in. (1 3 .8 4 m m )
H e ig h t o f lin e r over b lo c k (u n de r in s ta lla tio n

pressure) ...........................................0 0 4 to .0 0 8 in. (0 .1 0 to 0 .2 0 m m )
(7) D im e n sio n (new ) fro m ce n te rlin e o f

c ra n k s h a ft b earing b ore to to p o f b lo c k
(to p deck) ................ 2 7 .1 8 7 5 ± .0 0 2 5 in. (6 9 0 .5 6 3 0 .0 6 4 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 )
(9) D im e n sio n (new ) fro m c e n te rlin e o f

c ra n k s h a ft bea rin g bore to b o tto m o f
b lo c k (pan rails) . . . . 7 .9 9 8 5 ± .0 0 1 5 in. (2 0 3 .1 6 2 0 .0 3 8 m m )
(10) T o rq u e fo r ta p e rlo c k studs fo r m ain

bearing cap .......................... 5 0 0 +5 0 —0 lb. f t . ( 6 8 0 + 7 0 0 N-m)
(11) T o rq u e fo r n u t h o ld in g cap f o r m ain bearings (lu b ric a te stud

th re a d s):
a. T ig h te n all n uts t o 2 0 0 ± 10 lb. f t . (2 7 0 ± 14 N -m )
b. P ut m a rk on each n u t and end o f stud.
c. T ig h te n each n u t fro m m a r k ........................................ 120 ± 5°
(12) Clearance b etw een m a in bearing caps and

c y lin d e r b l o c k ................................................. 0 0 1 0 (0 .0 2 5 m m ) t ig h t to
.0 0 1 2 (0 .0 3 0 m m ) loose
1-21
SPECIFICATIONS
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
CYLINDER LINER
(1) B o re in lin e r ( n e w ) 6.251 ± .001 in . (1 5 8 .7 8 ± 0 .0 3 m m )
"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 .
P u t liq u id s o a p o n se a ls, lin e r g ro o v e s a n d b o re in c y lin d e r

b lo c k . In s ta ll s e a ls o n b o tto m o f lin e r. P u t f ille r b a n d in S A E
30 o il f o r a m o m e n t, th e n in s ta ll it o n th e lin e r. In s ta ll th e lin e r
in th e c y lin d e r b lo c k im m e d ia te ly a fte r th e b a n d is in s ta lle d
o n th e lin e r (b e fo re e x p a n s io n o f th e b a n d ).
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
M ake reference to C Y L IN D E R L IN E R P R O J E C T IO N in T e sting and

A d ju s tin g fo r the co m p le te p ro ced ure.
1. Insta ll to o lin g as show n. T ig h te n b o lts fo r crossbar evenly in fo u r

steps:
1st step ................................................................................. 5 Ib. f t . (7 N-m )
2 nd s t e p ........................................................................... 15 Ib. ft. (2 0 N-m )
3 rd s t e p 2 5 Ib. f t . (35 N-m )
4 th s t e p 5 0 Ib. ft . (7 0 N -m )
2. M easure c y lin d e r lin e r p ro je c tio n w ith d ia l in d ic a to r (2) in 1P 2402

B lo c k (3) as sh ow n . Measure at fo u r places a ro u n d each c y lin d e r
lin e r near the cla m p ed area.
Average o f fo u r p ro je c tio n m easurem ents fro m a n y c y lin d e r
lin e r m u st b e ..................................... 0 0 4 to .00 8 in. (0 .1 0 to 0 .2 0 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 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)
Insta ll a .0 3 0 in. (0 .7 6 m m ) shim plus any added shim s necessary to

g et the c o rre c t c y lin d e r lin e r p ro je c tio n .
A D J U S T M E N T S H IM S F O R L IN E R P R O J E C T IO N
N O T E : Be sure th a t the .0 3 0 in. (0 .7 6 m m ) shim is d ire c tly u nd er
the c y lin d e r lin e r flange. S H IM T H IC K N E S S , C O L O R C O D E , A N D P A R T N U M B E R
P u t 7 M 7 2 6 0 L iq u id G asket on the to p o f th e to p sh im and on the

.00 7 in. .0 0 8 in. .0 0 9 in. .01 5 in. .0 3 0 in.
b o tto m o f the b o tto m shim b e fo re in sta llin g . (0 .7 6 m m )
(0 .1 8 m m ) (0 .2 0 m m ) (0 .2 3 m m ) (0 .3 8 m m )
(1) 3 H 4 6 5 Plate.
B LAC K RED GREEN B RO W N B LU E
(4) 8 B 7 5 4 8 P ush -p ulle r Crossbar. 5 S 8 1 48 5S8149 5S 8 1 50 5S8151 5S 8 1 5 2
(5) 1P 2398 A d a p te r Plate.
1-22
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
W id th o f groove .1 2 9 3 ± .0 0 0 5 in. .0 9 7 0 + .0 0 0 5 in. .2 5 1 0 ± .0 0 0 5 in.

in p is to n fo r p is to n (3 .2 8 4 + 0 .0 1 3 m m ) (2 .4 6 4 + 0 .0 1 3 m m ) (6 .3 7 5 ± 0 .0 1 3 m m )
rin g (n e w ).
T h ickn ess o f p isto n .1 2 4 0 + .0 0 0 0 t o - . 0 0 0 8 in. .0 9 3 5 + .0 0 0 0 to - . 0 0 0 8 in. .2 4 8 5 ± .0 0 0 5 in.

ring (n e w ). (3 .1 5 0 + 0 .0 0 0 to - 0 . 0 2 0 m m ) ( 2 .3 7 5 + 0 .0 0 0 to - 0 . 0 2 0 m m ) (6 .3 1 2 ± 0 .0 1 3 m m )
Clearance b etw een .0 0 4 8 to .0 0 6 6 in. .0 0 3 0 to .0 0 4 8 in. .0 0 1 5 to .0 0 3 5 in.

groove and p is to n (0 .1 2 2 t o 0 .1 6 8 m m ) (0 .0 7 6 to 0 .1 2 2 m m ) (0 .0 3 8 to 0 .0 8 9 m m )
rin g (n e w ).
Clearance b etw een

ends o f p is to n rin g w hen
in sta lle d in a c y lin d e r .0 3 2 5 ± .0 0 7 5 in. .0 3 0 5 + .0 0 7 5 in. .0 2 5 5 ± .0 0 7 5 in.
lin e r w ith a b ore size (0 .8 2 6 ± 0.191 m m ) (0 .7 7 5 ± 0.191 m m ) (0 .6 4 8 i 0.191 m m )
o f 6 .2 5 0 in . (1 5 8 .7 5 m m )
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.
'I n s t a ll p is to n ring w ith ''U P '' side to w a rd to p o f p is to n .
N O T E : 9 S 7507 T o p R in g (1) has th e m a rk " U P - 1 ."

3 S 4 0 59 In te rm e d ia te R in g (2) has th e m a rk " U P - 2 ."
* * I n sta ll 5 M 5 4 8 7 O il C o n tro l R in g (3) w ith th e gap in th e sprin g 1 80 ° a w ay fro m th e gap in th e ring.
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 )
C learance betw e en p in and

b o re in p is to n (n e w ) . . . .0 0 0 3 to .001 2 in . (0 .0 0 8 to 0 .0 3 0 m m )
M a x im u m perm issib le cle arance b etw een p isto n

p in and bore in p is to n (w o rn ) ....................................0 0 2 in. (0 .0 5 m m )
T o rq u e fo r n u t o n heat plug ................ 30 ± 5 lb . f t . (4 0 ± 7 N -m )
N O T E : W hen in s ta lle d in the engine, th e " V " m a rk on to p o f th e p is to n

m u st be in a lig n m e n t w ith th e " V " m a rk on th e c y lin d e r b lo c k .
I -2 3
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 )
M a x im u m perm issib le end play

fo r th e c ra n k s h a ft 035 in. (0 .8 9 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 )
(3) W id th o f ring groove

in t h r o w e r .................. .255 to .2 5 6 in . (6 .48 to 6 .5 0 m m )
M in im u m cle arance betw e en rin g seal and

groove ...................................................................................0 0 2 in. (0 .0 5 m m )
Clearance betw e en ends o f ring sea!

(end g a p ) ............................................. 0 2 4 to .05 6 in. (0.61 to 1 .42 m m )
R ing seal groove " r u n o u t " (a xia l e c c e n tric ity )

o f rin g groove face o f t h r o w e r ...................................0 0 6 in. (0 .1 5 m 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.
(4 ) T o rq u e f o r b o l t .......................................... 35 ^ 5 lb. f t . (45 ± 7 N -m )
(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 )
M easure b etw een faces o f c o n n e c tin g rod th ro w s o f th e cra n ksh a ft

n e x t to th e ce n te r m ain bearings w it h in .25 0 in. (6 .3 5 m m ) o f
c o u n te rw e ig h t.
(6) D e p th to d riv e 3 N 3 2 3 4 R ing in to fly w h e e l housing or fro n t

accessory d rive housing.
F r o n t ..................................................................................... 3 4 4 in. (8.71 m m )
R e a r ........................................................................................177 in. (4 .4 9 m m )
N O T E : P ut 9 S 3 2 6 5 R e ta in in g C o m p o u n d on o u tsid e o f ring b efo re

in s ta lla tio n . Insta ll rin g w ith holes at b o tto m and ch a m fe r to w a rd in side
o f housing.
(7) L ip ty p e seal fo r c ra n k s h a ft. P u t 9 S 3 2 6 5 R e ta in in g C o m p o u n d on

c ra n k s h a ft and I.D . o f w e ar sleeve b e fo re in s ta lla tio n .
Insta ll lip seal w ith b o lts and spacers in th e sequence sh ow n . D o

n o t tig h te n b o lts m o re th a n 3 tu rn s each tim e .
(8) Insta ll cra n k s h a ft in c y lin d e r b lo c k so d ire c tio n o f ro ta tio n m arks

on end o f cra n k s h a ft show c o rre c t ro ta tio n at the fr o n t o f engine.
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
C O N N E C T IN G ROD
(1) B ore in bearing

fo r p i n 2 .4 5 1 3 ± .0 0 0 3 in. (6 2 .2 6 3 ± 0 .0 0 8 m m )
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 )
M a x im u m p e rm issib le cle arance o f

used p in and bearing 0 0 3 in . (0 .0 8 m m )
(2) D ista nce betw e en p in ce n te r to

bea rin g ce nte r ..................... 1 8 .0 0 0 + .001 in. (4 5 7 .2 0 + 0 .0 3 m m )
(3) Bore in co n n e c tin g rod fo r

b e a rin g 5 .3 8 4 5 + .0 0 0 5 in. (1 3 6 .7 6 6 i 0 .0 1 3 m m )
C learance betw e en b earing and bearing

surface (jo u rn a l) ................... 0031 to .0 0 7 3 in. (0 .0 7 9 to 0 .1 8 5 m m )
M a x im u m p e rm issib le clearance o f used bearing

and w o rn bearing surface (jo u rn a l) 0 1 2 in. (0 .3 0 m m )
(4) T o rq u e fo r b o th b o lts f o r c o n n e c tin g ro d :
a. P ut crankcase o il on threads.
b. T ig h te n all b o lts to .......................... 4 0 + 4 Ib. ft . (55 i 5 N -m )
c. Put a m a rk on each b o lt and cap.
d. T ig h te n each b o lt fro m m a rk .................................................... 120°
A fte r tig h te n in g c o n n e c tin g rod b o lts ; end cle arance

betw een bearing cap f o r c o n n e c tin g ro d and
c ra n k s h a ft ........................................ 0 0 9 5 to .0 3 5 5 in. (0.241 to 0 .9 0 2 m m )
Install p is to n on rod so " V " m a rk on to p o f p is to n is o p p o s ite the ro d

cap b o lts.
N O T E : P iston p in bearing ju n c tio n and lo c a tin g n o tc h m u st be

assem bled as sh ow n . Bearing ju n c tio n can be lo ca te d at e ith e r p o s tio n
"A ".
1-25
C O N N E C T IN G RO D B E A R I N G S
M ake reference to G U ID E L IN E FO R REUSABLE PAR TS: M A IN AND C O N N E C T IN G ROD

B E A R IN G S , F o rm N o. S E B F 8 0 0 9 .
C O N N E C T IN G R O D B E A R IN G S
.0 2 5 in. (0 .6 4 m m ) .0 5 0 in. (1 .27 m m )

O R IG IN A L U N D E R S IZ E U N D E R S IZ E
S IZ E (S M A L L E R ) (S M A L L E R )
JOU RNAL JOURNAL JOU RNAL
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 )
Clearance b etw een .0031 to .0 0 7 3 in.

bea rin g and jo u rn a l (new) (0 .0 7 9 to 0 .1 8 5 m m )
M a x im u m perm issib le .0 1 2 in.

clearance betw een (0 .3 0 m m )
bearing and jo u rn a l.
O rig in a l size b ore in co n n e c tin g ro d fo r b e a r in g ......................................................................................... 5 .3 8 4 5 + .0 0 0 5 in. (1 3 6 .7 6 6 * 0 .0 1 3 m m )
.010 in. (0.25 m m) Oversize (Larger than orig in a l) bore in connecting

rod fo r b e a rin g 5 .3945 ± 0 0 0 5 in (1 3 7 .0 2 0 r 0 0 1 3 mm)
1-26
M AIN BE A RIN G S
Make reference to G U ID E L IN E FO R REUSABLE PARTS: M A IN AND C O N N E C T IN G ROD

B E A R IN G S , F o rm N o. S E B F 8 0 0 9 .
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
D ia m e te r o f cra n ksh a ft 5 .7 4 9 2 ± .0 0 1 0 in. 5 .6 9 9 2 *: .0 0 1 0 in.

jo u rn a l (bearing surface) (1 4 6 .0 3 0 ± 0 .0 2 5 m m ) (1 4 4 .7 6 0 .t 0 .0 2 5 m m )
fo r m ain bearings.
Clearance b etw een

bearing and jo u rn a l .0 0 4 8 to .0 0 9 0 in.
(new ) (0 .1 2 2 to 0 .2 2 9 m m )
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 )
O rig in a l size bore in b lo c k f o r m a in b e a rin g ................................................................................................. 6 .3 7 2 5 ± .0 0 0 5 in. (1 6 1 .8 6 2 t 0 .0 1 3 m m )
1-27
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
.0 2 5 in. (0 .6 4 m m ) .0 5 0 in. (1 .27 m m )

O R IG IN A L U N D E R S IZ E U N D E R S IZ E
S IZ E (S M A L L E R ) (S M A L L E R )
JOU RNAL JOU RNAL
(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 )
S urface fin is h on 10 m ic ro inches o r sm o o th e r

d ia m e te r o f jo u rn a l (0 .2 5 m ic ro m e tre )
* ( B ) Radius .4 0 6 ± .007 in.

(10.31 ± 0 .1 8 m m )
S urface fin is h 6 3 m ic ro in ches o r sm o o th e r

in radius (1 .6 m icro m e tre s)
(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 )
*R a d iu s (B) m u st b len d s m o o th ly (have no sharp edges) w ith th e m a ch ine d surfaces o f the jo u rn a ls .
1-28
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
(D) D ia m e te r o f 5 .7 4 9 2 t .0 0 1 0 in. 5 .6 9 9 2 ± .0 0 1 0 in.

Jo u rn a l (1 4 6 .0 3 0 i 0 .0 2 5 m m ) (1 4 4 .7 6 0 + 0 .0 2 5 m m !
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
* ( E) Radius .4 0 6 ± .007 in.

(10.31 ± 0 .1 8 m m )
S urface fin is h 6 3 m ic ro in ches o r sm o o th e r

in radius (1 .6 m icro m e tre s)
(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 )
* R adius m u st b len d s m o o th ly (have no sharp edges) w ith th e m a ch in e d surfaces o f the jo u rn a ls.
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
D 3 9 9 Engine w ith one dam per:
(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 )
(2) T o rq u e f o r b o lts th a t h o ld a da pte r and d am pe r

to c r a n k s h a f t 6 7 0 ± 5 0 Ib. f t . (9 0 5 ± 7 0 N-m )
N O T E : P ut 8 H 5 1 3 7 S ealant on threads o f b o lts th a t h o ld a da pte r and

d a m p e r to c ra n k s h a ft.
D 3 9 9 Engine w ith tw o dampers:
(3) T o rq u e fo r nuts th a t h o ld dam pers

to a d a p te r .................................................... 32 ± 5 Ib. f t . (43 ± 7 N -m )
N O T E : Spacers (A ) m u st be in sta lle d betw e en the d am pe rs as show n. D 399LA TER
(4) T o rq u e fo r b o lts th a t h o ld a dapter

to c r a n k s h a f t 6 7 0 ± 5 0 Ib. f t . (9 0 5 ± 7 0 N -m )
N O T E : P ut 8 H 5 1 3 7 S ealant on threads o f b o lts th a t h o ld a da pte r to

c ra n k s h a ft.
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
Vibration Damper (Cont.|
D 3 9 8 Engines; effective in production w ith Serial Num bers 66B 1 thru

6 6 B 4 4 0 5 and 67B 1 thru 6 7 B 1 7 0 9 :
(5) T o rq u e f o r b o lts th a t h o ld a da pte r to

c ra n ksh a ft ........................................ 4 2 0 ± 6 0 lb. ft. (565 ± 8 0 N-m )
N O T E : P ut 8 H 5 1 3 7 S ealant on threads o f b o lts th a t h o ld a da pte r to D 398EA R LY

cra n k s h a ft.
(6) T o rq u e f o r b o lts ( 3 /4 —10 NC) th a t h o ld dam pe r

to a da pte r ............................................ 2 8 0 ± 2 0 lb . f t . (377 ± 25 N -m )
D 3 98 Engines; effective in production w ith Serial Num bers 6 6 B 4 4 0 6

up and 6 7 B 1 7 1 0 Up:
(7) T o rq u e f o r b o lts th a t h o ld a da pte r to

c ra n k s h a ft 4 6 0 ± 2 0 lb . f t . (6 2 4 ± 25 N-m )
N O T E : P ut 8 H 5 1 3 7 Sealant on threads o f b o lts th a t h o ld a da pte r to

cra n k s h a ft.
(8) T o rq u e fo r b o lts (1 /2 —13 NC) th a t h o ld d a m p e r

to a da pte r 75 + 10 lb. ft . (1 0 0 + 14 N -m )
F RO NT A C C E S S O R Y D R I V E
A u x ilia ry D rive at u pp er le ft tu rn s c o u n te rc lo c k w is e (vie w fro m fr o n t)

a t 1 .92 tim e s engine speed.
(1) W a ter p u m p d rive :
T u rn s clo c k w is e (view fro m fr o n t) at 1.92 tim e s engine speed.
D ia m e te r o f sh a ft bea rin g surface

(jo u rn a l) 1 .2 4 5 5 + .0 0 0 5 in. (3 1 .6 3 6 ± 0 .0 1 3 m m )
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 clearance betw e en shaft

bea rin g surface (jo u rn a l) and b e a r in g .....................0 0 8 in. (0 .2 0 m m )
(2) Bore in bearing in m ain id le r

gear 2 .9 9 9 0 t .00 1 5 in . (7 6 .1 7 5 + 0 .0 3 8 m m )
D ia m e te r o f bearing surface (jo u rn a l)

o f sh aft 2 .9 9 6 5 ± .0 0 0 5 in. (7 6 .1 1 1 ± 0 .0 1 3 m m )
M a x im u m p e rm issib le clearance b e tw e en bearing and

b ea rin g surface (jo u rn a l) o f the s h a f t ....................0 1 0 in . (0 .2 5 m m )
E nd clearance ................................ 0 0 5 to .0 1 4 in. (0 .1 3 to 0 .3 6 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 )
(3) T o rq u e f o r 5 /1 6 " b o lts h o ld in g

o il lin e f la n g e ............................................ 3 2 ± 3 lb. ft . (4 3 ± 4 N -m )
(4) Bore in bearings fo r small

id le r gears 2 .0 0 0 0 ± .0 0 1 5 in. (5 0 .8 0 0 ± 0 .0 3 8 m m )
D ia m e ter o f bearing surface (jo u rn a l)
o f s h a f t ........................ 1 .9 9 8 0 ± .0 0 0 5 in. (5 0 .7 4 9 ± 0 .0 1 3 m m )
M a x im u m p e rm issib le clearance b etw een bearing

and bearing surface (jo u rn a l) o f sh aft 0 0 8 in. (0 .2 0 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 )
M a x im u m p e rm issib le end p la y o f SAE O P P O S IT E R O T A T IO N T IM IN G M A R K S FO R D 3 7 9 E N G IN E

id le r g e a r 0 1 8 in . (0 .4 6 m m )
(5) T o rq u e fo r b o lt .......................................... 3 5 ± 5 lb. ft. (4 5 ± 7 N-m)
(6) O il p u m p d rive :
T u rn s clo ckw ise (view fro m fr o n t) at 1.5 tim e s engine speed.
B ore in bearing f o r gear o f

o il p u m p 2 .1 2 4 5 ± .0 0 2 0 in. (5 3 .9 6 2 ± 0.051 m m )
D ia m e te r o f bearing surface (jo u rn a l) (10) T o rq u e f o r 1 /2 " b o lts h o ld in g small

on gear h u b .................. 2 .1 2 0 5 ± .0 0 0 5 in. (53.861 ± 0 .0 1 3 m m ) id le r s h a f t s 9 0 + 5 lb. f t . (1 2 0 ± 7 N-m)
(7) T o rq u e fo r 1 /2 " b o lts h o ld in g m ain T o rq u e fo r 3 / 8 " b o lts h o ld in g small

id le r sh a ft 9 0 ± 5 lb . f t . (1 2 0 ± 7 N-m ) id le r s h a f t s 4 0 ± 4 lb. f t . (5 5 -f 5 N -m )
(8) C ra n ksh a ft gear. (11) T o rq u e f o r fiv e 112" b o lts h o ld in g

p la te to b lo c k 9 0 1 5 lb . f t . (1 2 0 ± 7 N -m )
(9) Bore in bearing f o r
balance g e a r 1 .6 0 22 + .0 0 0 3 in, (4 0 .6 9 6 ± 0 .0 0 8 m m ) (1 2 ) L e ft side lo w e r o r a u x ilia r y w a te r p u m p d rive :
D ia m e te r o f bearing surface (jo u rn a l) T u rn s c o u n te rc lo c k w is e (v ie w fro m fr o n t) at 1.55 tim e s engine
o f sh a ft .......................... 1 .5 9 9 8 ± .0 0 0 2 in. (4 0 .6 3 5 ± 0 .0 0 5 m m ) speed.
M a x im u m p e rm issib le clearance betw e en bearing and Bore in b earing f o r a u x ilia r y w a te r p u m p
bea rin g surface (jo u rn a l) o f s h a f t 0 0 6 in. (0 .1 5 m m ) sh a ft ............................... 1 .2 4 7 5 ± .0 0 2 0 in. (3 1 .6 8 7 +0.051 m m )
E nd p la y o f balance D ia m e te r o f b e a rin g surface (jo u rn a l)
g e a r ........................................... 0 0 6 0 to .0 1 3 5 in. (0.1 52 to 0 .3 4 3 m m ) o f sh aft .......................... 1 .2 4 5 5 ± .0 0 0 5 in. (3 1 .6 3 6 ±0 .0 1 3 m m )
M a x im u m p erm issib le end p la y o f M a x im u m p erm issib le clearance b etw een bearing
balance g e a r 0 1 9 in. (0 .4 8 m m ) and bearing surface (jo u rn a l) o f sh a ft 0 0 8 in. (0 .2 0 m m )
1-32
FLYWHEEL
(1) M a x im u m p e rm issib le " r u n o u t " (radial

e c c e n tric ity ) o ff c e n te r o f b o re (to ta l
in d ic a to r reading) ............................................................0 0 6 in . (0 .15 m m )
(2) T o rq u e fo r b o lts h o ld in g fly w h e e l to c ra n k s h a ft:
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 )
(3) M a x im u m p e rm issib le " r u n o u t "

(radial e c c e n tric ity ) o f f c e n te r o f
bore (to ta l in d ic a to r re a d in g ) .......................................0 0 5 in. (0 .1 3 m m )
(4) M a x im u m perm issib le " r u n o u t " (axial

e c c e n tric ity ) o f face (to ta l
in d ic a to r reading) ............................................................0 0 6 in . (0 .1 5 m m )
F L Y W H E E L HOUSIN G
(1) M a x im u m p e rm issib le " r u n o u t " (radial

e c c e n tric ity ) o f f c e n te r o f b ore in housing
(to ta l in d ic a to r re a d in g ).................................................0 1 2 in. (0 .3 0 m m )
(2) T o rq u e fo r fo u rte e n b o lts (inside

h o u s in g ) ............................................... 150 ± 2 0 lb. f t . (2 0 5 ± 25 N -m )
(3) T o rq u e fo r ten b o lts (o u tside

h o u s in g ) .................................................... 75 ± 10 lb . f t . (1 0 0 ± 14 N -m )
(4) M a x im u m p erm issib le " r u n o u t " (axial

e c c e n tric ity ) o f face (to ta l
in d ic a to r reading) ........................................................... 01 2 in. (0 .3 0 m m )
l -3 3
D379, D398, D399 IN D U S T R IA L & M A R IN E EN G IN ES SPECIFICATIONS
FLYW HEEL RUNOUT
Face R u n o u t (a xia l e c c e n tric ity ) o f th e F ly w h e e l:
1. Insta ll the d ia l in d ic a to r as show n. Put a fo rc e on th e fly w h e e l

to w a rd the rear.
2. Set th e d ial in d ic a to r to read .000 in. (0 .0 m m ).
3. T u rn th e fly w h e e l and read the in d ic a to r every 9 0 °. P ut a fo rc e on

th e fly w h e e l to the rear b e fo re each reading.
4. T h e d iffe re n c e betw e en th e lo w e r and h igh e r m easurem ents take n

at all fo u r p o in ts m u st n o t be m o re th a n .0 0 6 in. (0 .15 m m ), w h ic h
is th e m a x im u m p erm issib le face ru n o u t (axial e c c e n tric ity ) o f the
fly w h e e l.
Bore R unou t (radial eccentricity) of the Flyw heel:
1. Insta ll th e d ial in d ic a to r (3) and m ake an a d ju s tm e n t o f the

universal a tta c h m e n t (4) so it makes c o n ta c t as show n.
2. Set th e d ia l in d ic a to r t o read .0 0 0 in . (0 .0 m m ).
3. T u rn the fly w h e e l and read the in d ic a to r every 9 0 °.
4. The d iffe re n c e betw e en the lo w e r and h ig h e r m easurem ents take n

at all fo u r p o in ts m u s t n o t be m o re th a n .0 0 6 in. (0 .1 5 m m ), w h ic h
is the m a x im u m p e rm issib le b ore ru n o u t (rad ia l e c c e n tric ity ) o f the
fly w h e e l.
5. R u n o u t (e c c e n tric ity ) o f th e bore f o r the p ilo t bearing fo r th e P IL O T B E A R IN G B O R E

fly w h e e l c lu tc h , m u st n o t exceed .00 5 in. (0 .1 3 m m ).
1-34
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 )
Face Runout (axial eccentricity) of the Flywheel Housing:
1. Fasten a d ia l in d ic a to r to th e c ra n k s h a ft flange so the anvil o f the

in d ic a to r w ill to u c h th e face o f the fly w h e e l housing.
2. Put a fo rc e on th e c ra n k s h a ft to w a rd th e rear b e fo re reading th e

in d ic a to r at each p o in t.
3. W ith dial in d ic a to r set at .00 0 in. (0 .0 m m ) at lo c a tio n (A ), tu rn
th e c ra n k s h a ft and read the in d ic a to r at lo c a tio n s (B ), (C) and (D ).
4. The d iffe re n c e b etw een lo w e r and h igh e r m easurem ents take n at

all fo u r p o in ts m u st n o t be m o re tha n .01 2 in (0 .3 0 m m ), w h ic h is
the m a x im u m p e rm issib le face ru n o u t (axial e c c e n tric ity ) o f the
fly w h e e l housing.
1-35
C (T O P )
F L Y W H E E L H O U S IN G BO RE
N O T E : W rite the dial indicator measurements w ith their positive (+)

and negative {—) notation (signs). This notation is necessary for making
the calculations in the chart correctly.
1. W ith th e d ial in d ic a to r in p o s itio n at (C ), a d ju st the dial in d ic a to r

to " 0 ” (ze ro ). Push the c ra n k s h a ft up against the to p b earing. W rite
the m ea sure m e n t fo r bearing clearance o n line 1 in c o lu m n (C).
2. D ivid e th e m ea sure m e n t fro m S tep 1 b y 2. W rite th is n u m b e r on

lin e 1 in c o lu m n s (B) & (D ).
3. T u rn th e cra n k s h a ft to p u t th e d ial in d ic a to r at (A ). A d ju s t th e dial

in d ic a to r to " 0 " (zero).
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.
8 . S u b tra c t the sm a lle r n u m b e r fro m the larger n u m b e r in lin e III in

c o lu m n s (B) & (D ). The re s u lt is th e h o riz o n ta l " e c c e n tr ic ity ” (o u t
o f ro u n d ). Line I I I, c o lu m n (C) is the v e rtic a l e c c e n tric ity .
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
C orrection fo r bearing clearance I 0
D ial In d ic a to r Reading II 0
T o ta l o f Line 1 & 2 III 0 " * **
'T o ta l V ertical e c c e n tricity (o u t o f round).

" 'S u b tr a c t the smaller No. fro m the larger No. The difference is
the to ta l h o rizo n ta l eccentricity.
A t 0234X1
9. O n th e g ra p h fo r to ta l e c c e n tric ity fin d th e p o in t o f in te r s e c tio n o f

th e lin e s fo r v e rtic a l e c c e n tric ity a n d h o r iz o n ta l e c c e n tric ity .
10. If th e p o in t o f in te r s e c tio n is in th e ra n g e m a rk e d " A c c e p ta b le "

th e b o re is in a lig n m e n t. If th e p o in t of in te r s e c tio n is in th e ra n g e
m a rk e d " N o t A c c e p ta b le ", th e f ly w h e e l h o u s in g m u s t be
changed.
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
V-BELT TE NSIO N CHART

BELT TENSION BELT TENSION
W IDTH TOP
“ INITIAL”* “ USED” **
BELT SIZE W IDTH OF PULLEY RnnRni r a iir e n u m r f r r
BELT TOP GROOVE G AUG E READING GAUGE READING
in. mm in. mm Ib. N Ib. N O LD GAUGE NO. NEW G AUG E NO.

3 /8 .422 10.72 .380 9.65 100 ± 5 445 ± 22 90 ± 5 400 ± 22 BT-33-73F BT-33-95
1 /2 .547 13.89 .500 12.70 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-96-4-16 BT-33-95
5V .625 15.88 .600 15.24 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C
11/16 .688 17.48 .625 15.88 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C
3 /4 .750 19.05 .690 17.53 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C
15/16 .938 23.83 .878 22.30 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C
M EASURE TENSION O F BELT FA RTH EST FROM THE ENGINE

' “ INITIAL" BELT TENSION is for a new belt.
■'"U SED" BELT TENSION is for a belt which has m ore than 30 m inutes of operation at rated speed of engine. A 1 0232X 5
1-37
ALT ERN AT O R S AND REGULATORS
(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
V o lta g e R a ting 12V 24V 30 or 32V 32 V
Part No. 5L5750 4N 3986 5S 9 0 88 4N 3987 5L1243
1117226
S u p p lie r Part No. 1105148 1117734 1117236 1117733 1117074
Service B u lle tin o r

F o rm No. 1 G -150 1G -28 0 1G -275 1 G -2 80 1G-251
C irc u it A B B B B
R o ta tio n (as seen

fro m d rive end) C lo ckw ise E ith e r E ith e r E ith e r C lo ckw ise
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 )
55 ± 5 Ib. ft. 75 ± 5 Ib. ft . 7 5 ± 5 Ib. f t . 75 ± 5 Ib. ft . 55 ± 5 Ib. ft.

T o rq u e fo r n u t (1) (7 5 ± 7 N-m) (1 0 0 ± 7 N-m ) (1 0 0 ± 7 N -m ) (1 0 0 ± 7 N -m ) (75 ± 7 N-m )
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)
T ension o f brush 28 oz. 10 oz.

springs (7 .8 N) brushless brushless brushless (2 .8 N)
REGULATORS
Part No. 5L4599 in side a lte rn a to r inside a lte rn a to r 6 L 5 3 9 7 -6 L 5 6 5 8
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:
* 6 .5 to 9.3% high e r w ith no re g u la to r.

** F a s te n ca rb o n p ile to b a tte ry to get m a x im u m o u tp u t.
* * * F o r 3 2 V a lte rn a to rs , a d ju st to ......................................................... 3 6 .7 V
* * * F o r 3 0 V a lte rn a to rs , a d ju st to .......................................................... 3 4 .7 V
l -3 8
SPECIFICATIONS
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 )
P o la rity is negative g ro u n d o r insulate d.
C irc u it ........................................................................................................................ B
V o lta g e re g u la to r s e ttin g r a n g e ............................................... 3 6 .7 to 3 8 .3 V
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 )
P o la rity is negative g ro u n d o r in sulate d.
C irc u it ........................................................................................................................ B
V o lta g e re g u la to r s e ttin g r a n g e ............................................... 3 4 .4 to 3 5 .6 V
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 :
A ir gap betw e en a rm a tu re and

c o r e ........................................................0 1 8 to .02 2 in. (0 .4 6 to 0 .5 6 m m )
P o in t g a p ..............................................................................0 2 0 in. (0.51 m m )
V o lta g e clo sin g r a n g e 11.8 to 13.5 V
(2) C u rre n t re g u la to r:
A ir gap betw e en a rm a tu re and

c o r e ........................................................ 0 6 8 to .08 2 in. (1 .7 3 to 2 .0 8 m m )
C u rre n t s e ttin g range at 8 5 ° F (29° C ) 3 4 to 3 8 .5 A )
(3) V o lta g e re g u la to r:
V o lta g e s e ttin g range at 8 5 ° F (29° C ) 1 4 .2 to 1 5.2 V )
(4) T o rq u e f o r b o l t 3 6 ± 6 lb . in. (4.1 ± 0 .7 N-m )
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
(1) T o rq u e f o r large te rm in a l nuts . . . . 35 ± 5 lb . in . (4 .0 ± 0 .6 N-m )
I -3 9
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 )
R o ta tio n is clo c k w is e w h en seen fro m d rive end e xcep t 8 L 6 2 0 5 w h ic h

is c o u n te rc lo c k w is e .
M in im u m speed w ith no lo a d ...................................................... 7 5 0 0 rp m
M a x im u m speed w ith no load 10 5 0 0 rpm
C u rre n t c o n s u m p tio n (draw ) at no lo ad :
M in im u m w ith so le n o id at 28 V .................................................... 100 A
M a x im u m w ith so len o id at 2 8 V .................................................... 125 A
Clearance b etw een p in io n and housing

(p in io n c le a ra n c e )........................................................................... 36 in. (9.1 m m )
(1) T e nsion o f brush s p r in g ......................................................... 80 oz. (22 N)
(2) T o rq u e fo r screws h o ld in g nose housing

to lever h o u s in g 13 to 17 lb. ft. (18 to 2 3 N -m )
(3) T o rq u e fo r te rm in a l n u t s 2 0 to 25 lb . f t . (25 to 35 N-m )
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 }
R o ta tio n is clo ckw ise w h en seen fro m d rive end.
M in im u m speed w ith no l o a d ...................................................... 5 5 0 0 rpm
M a x im u m speed w ith no lo ad ................................................... 7 5 0 0 rp m
C u rre n t c o n s u m p tio n (d ra w ) at no load:
M in im u m w ith so len o id at 2 0 V 140 A
M a x im u m w ith so le n o id at 20 V 170 A
Clearance betw e en p in io n and housing

(p in io n c le a ra n c e )........................................................................... 36 in. (9.1 m m )
(1) Te nsion o f brush s p r in g ......................................................... 8 0 oz. (22 N)
(2) T o rq u e fo r screws h o ld in g nose housing

to lever h o u s in g 13 to 17 lb. f t . (18 to 23 N-m )
(3) T o rq u e fo r te rm in a l n u t s 2 0 to 25 lb. ft. (25 t o 35 N-m )
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 )
R o ta tio n is clo ckw ise w h en seen fro m d rive end.
M in im u m speed w ith no l o a d .............................................................. 5 5 0 0 rp m
M a x im u m speed w ith no lo a d .............................................................. 7 5 0 0 rp m
C u rre n t c o n s u m p tio n (d ra w ) at no load:
M in im u m w ith so le n o id at 2 0 V 95 A
M a x im u m w ith so len o id at 2 0 V .............................................................. 120 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) T e nsion o f brush s p r in g ......................................................... 8 0 oz. (2 2 N)
(2) T o rq u e fo r screws th a t h o ld nose

house to lever h o u s in g ............................. 18 ± 5 lb. ft . (25 ± 7 N-m )
(3) T o rq u e f o r te rm in a l n u t s 20 to 25 lb . f t . (25 to 3 5 N-m )
1-40
STARTER SO LENO IDS
(1) 4 M 1 8 1 5 S pring (c o n ta c t release):
(2) 9 M 7 6 0 9 S pring (to re tu rn th e c lu tc h lever):
(3) T o rq u e f o r te rm in a l screws 16 to 3 0 Ib. in. (2 to 3 N-m )
S P R IN G C H A R T
(1) (2)
Part No. 4M 1815 9M 7609
Len gth u n d e r test .42 in. 1 .5 6 in.

force (1 0 .7 m m ) (3 9 .6 m m )
9 ± .5 Ib. 14 ± .5 Ib.
Test force (4 0 ± 2 N) (6 0 ± 2 N)
Free le ng th a fte r .83 ± .02 in. 2 .7 9 in.

test (21.1 ± 0 .5 m m ) (7 0 .9 m m )
.37 5 — .01 0 in. 1.3 9 3 ± .01 5 in.

O utsid e d ia m e te r (9 .5 3 ± 0 .2 5 m m ) (3 5 .3 8 + 0 .3 5 m m )
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
4M 181 2 1119832 5 V 10 to 11.5 A

1119848 2 0 to 2 4 V 4 0 to 5 5 .2 A 8 .2 A max.
24V
6N 5123 1115544 20 V 4 0 to 4 5 .5
2 0 to 2 4 V (n o p u ll-in w in d in g s) 4 0 to 5 4 .6
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
’ B u lle tin No. 1S-120
1-41
PRESSURE REG ULATING VALV E

FOR A I R S T A R T IN G M O T O R
(1) A d ju s tin g screw.
(2) M a x im u m perm issib le in le t pressure 2 5 0 psi (1 7 2 0 kPa)
(3) M a x im u m perm issib le o u tle t pressure 150 psi (1 0 3 0 kPa)
M in im u m o u tle t p re s s u re .................................................. 9 0 psi (6 2 0 kPa)
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 )
O u tp u t to rq u e ........................................................................ 5 0 Ib. ft . (70 N -m )
w ith p in io n speed o f .................................................................... 2 2 4 0 rp m
at a ir pressure to m o to r o f .......................................... 120 psi (8 3 0 kPa)
R o ta tio n is clo c k w is e w h en seen fro m d rive end.
(1) T o rq u e fo r b o lts o f rear co ver (tig h te n

b o lts e ven ly) 2 0 to 25 Ib. ft . (25 to 35 N-m )
(2) T o rq u e f o r b o lts o f p in io n hou sin g (tig h te n

b o lts e ven ly) ......................................................... 100 Ib. in. (1 1 .3 N -m )
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
at a pressure o f ............................................................... 100 psi (6 9 0 kPa)
H o rse po w e r ........................................................................................................... 6 .7
(1) Clearance b etw een ro to r and end p l a t e 0 0 3 in. (0 .0 8 m m )
1-42
H Y D R A U L I C S T A R T IN G M O T O R
7 L 8 6 5 6 (Am erican Bosch M odel C M D 2 A 111)
M a x im u m perm issib le pressure

f o r o p e ra tio n 3 0 0 0 psi (2 0 700 kPa)
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 :
W ith o il pressure at 3 0 0 0 psi

(2 0 7 0 0 kPa) 7 0 lb. ft . (95 N-m )
W ith o il pressure at 1 50 0 psi (10 3 0 0 kPa) ... 32 lb. f t . (43 N -m )
O u tp u t to rq u e w ith p in io n at stall:
W ith o il pressure at 3 0 0 0 psi (2 0 7 0 0 kPa) ... 7 2 lb . f t . (98 N-m )
W ith o il pressure at 1 5 0 0 psi (1 0 3 0 0 kPa) ... 35 lb. ft . (4 5 N-m )
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
6 L 8 7 2 1 (A m erican Bosch Num ber R P A 3 0 0 3 7 4 )
Pressure a d ju s tm e n t range . 1 500 to 3 0 0 0 psi (1 0 3 0 0 to 2 0 7 0 0 kPa)
N o rm a l pressure to sta rt the p u m p

a u to m a tic a lly ( c u t - in ) .................................................... 2 5 0 0 psi (17 0 0 0 kPa)
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 )
M a x im u m su ctio n h e ig h t (head) .................................................3 ft . (0.91 m )
N O T E : The o il R E T U R N passage near the m o u n tin g fla ng e m u st be

above the h o riz o n ta l c e n te r lin e . T h is p o s itio n m akes c o rre c t lu b ric a
tio n o f p u m p parts.
H AN D PUMP FOR H Y D R A U L I C S T A R T E R
2 L 8 3 4 2 (Am erican Bosch N um ber H P A 3 0 0 1 1 8 )
W o rk in g pressure 3 0 0 0 psi (2 0 7 0 0 kPa)
F orce to m ove h a n d le 4 8 .5 lb. (2 1 6 N)
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
3 N 9 5 0 3 (A m erican Bosch N um ber A C C 3 0 A 2 3 1 )
N itro g e n p re lo a d pressure . . 1 50 0 to 1 625 psi (1 0 3 0 0 to 11 2 2 0 kPa)
l -43
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES INDEX
A ir Inlet and E xhaust S y s te m .................................................... 2-7 E le c tr ic a l S y s t e m ................................................................................... 2 -2 3

A fte r c o o le r ................................................................................... 2-7 C h a r g in g S y s te m C o m p o n e n t s ................................................. 2 -2 3
T u rb o e h a rg e r............................................................................... 2-8 O th e r C o m p o n e n ts .......................................................................... 2 -2 4
Valves and Valve M e c h a n is m ................................................ 2-7 S ta rtin g S y s te m C o m p o n e n t s ..................................................... 2 -2 3
W irin g D ia g r a m s ................................................................................. 2 -2 5
A ir S tarting S y s te m ......................................................................... 2-20
E n g in e P r o te c tio n D e v ic e s .............................................................. 2 -3 3
Basic B lock ....................................................................................... 2-18 S e ttin g T h e S h u to ff C o n t r o l ....................................................... 2 -3 6
C r a n k s h a ft..................................................................................... 2-18 S h u t o f f C o n t r o l................................................................................... 2 -3 3
C y lin d e r B lock, Heads and Liners ........................................ 2-18 S h u to ff C o n tr o l O p e r a t io n ............................................................ 2 -3 3
F ront A cce ssory Drive .............................................................. 2-19
P istons, Rings and C o n n e c tin g Rods .................................... 2-18 Fuel S y s te m ..................................................................................... 2-2
T im ing G e a rs ................................................................................. 2-18 D u p le x F u e l F ilte r S y s t e m ............................................................ 2 -3
V ib ra tio n D a m p e r......................................................................... 2-19 F u e l I n je c tio n P u m p s ........................... 2-4
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.
T h e r e is o n e fuel in jectio n p u m p a n d o n e fuel

injectio n valve f o r each cylin der. T h e fuel in j e c t i o n
p u m p s ar e lo c a t e d in th e fuel i n je c tio n p u m p
h o u s i n g in th e Vee o f th e engine. T h e fuel in jec
t i o n v a l v e s a r e l o c a t e d 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 in th e cy lin d e r h eads .
W h e n th e en g ine is r u n n i n g , fuel is p u lle d f r o m

fuel t a n k (5) t h r o u g h fuel t r a n s f e r p u m p inlet line ( l )
by fuel t r a n s f e r p u m p f7). T h e fuel is t h e n p u s h e d t o
fuel filter h o u s i n g (8). O n l y th e fuel n e e d e d goes FUEL FLOW T H R O U G H FUEL C O N T R O L VALVE
t h r o u g h th e fuel filters. T h e e x t r a fuel goes to fuel (E N G IN E R U N N IN G )
c o n t r o l valve ( l l ) . T h e fuel f r o m th e fuel filter s go es
to th e fuel in jectio n p u m p h o u s i n g (9). A p a s s a g e in
1. Fuel transfer pump inlet line. 2. Fuel priming pump.
th e h o u s i n g gives fuel to e a c h fuel in j e c t i o n p u m p . 3. Fuel passage. 6. Fuel transfer pum p outlet line. 8. Fuel
I n d i v i d u a l fuel lin es c a r r y f u e l f r o m t h e f u e l filter housing. 10. Fuel passage. 11. Fuel control valve.
in jectio n p u m p s t o e a c h cylinder. 13. Fuel passage.
2 -2
SYSTEMS OPERATION
FUEL SYSTEM
F uel c o n t r o l valve (11) c o n t r o l s th e p r e s s u re o f

t h e fuel in th e fuel system . W h e n t h e fuel s y s te m is a t
m a x i m u m pr e ss u re , fuel c o n t r o l valve (11) m o v e s
a n d th e e x t r a fuel n o t n e e d e d by t h e e n g in e is
b y p a s se d . A p a r t o f th e b y p a s s e d fuel goes b a c k t o
the inlet o f t h e fuel t r a n s f e r p u m p a n d t h e rest go es
t h r o u g h fuel p as sag e (10) a n d r e t u r n s t o t h e fuel
t a n k . A n y air in t h e fuel filter h o u s i n g go es a r o u n d
the g r o o v e s in fuel c o n t r o l v alv e (11) t o fuel p a s s a g e
(10) a n d to th e fuel t a n k .
PRESSURE STRO KE OF P R IM IN G PU M P
F uel t r a n s f e r p u m p (7) is l o c a t e d on t h e f r o n t , 1. Fuel transfer pum p Inlet line. 2. Fuel priming pump.
r ight h a n d side of th e acc e ss o ry d riv e h o u s i n g . T h e 3. Fuel passage. 6. Fuel transfer pump outlet line. 8. Fuel
p u m p is d r i v e n f r o m th e f r o n t o f t h e oil p u m p d r iv e filter housing. 10. Fuel passage. 11. Fuel control valve.
12. Spring. 13. Fuel passage.
gear.
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
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
A n y air in th e a u x i l i a r y filter will go b a c k t o th e

fuel t a n k while th e m a i n filters will filter t h e diesel
fuel.
AUX. FILTER R U N -M A IN OFF
T h e a u x i l i a r y el e m e n t s n o w filter th e diesel fuel

in stea d o f th e m a i n elem en ts.
M AIN VEN T -A U X . RUN
W hile the a u x i l i a r y e l e m e n t s filter t h e fuel, th e

m a i n filter h o u s i n g will fill w ith fuel.
M AIN FILTER RU N -AU X. OFF FUEL IN JE C T IO N PU M P

1. Pump. 2. Inlet port. 3. Pump plunger. 4. G ear seg
m ent. 5. Fuel rack. 6. Fuel pas sag e. 7. L ifte r.
T h e m a i n filters will n o w be filterin g th e fuel. 8. Camshaft.
B O T H FILTERS RUN
T h is will p e r m it m o r e r u n n i n g ti m e w h e n b o t h FUEL INJECTION VALVE

filter sy s tem s are a l m o s t to a c o n d i t i o n o f re s t r i c t i o n
as s h o w n by th e fuel p r e s s u r e gauge.
FUEL INJECTION PUMPS
F uel en te r s th e fuel in jectio n p u m p h o u s i n g

t h r o u g h fuel p a s sa g e (6) a n d e n te r s th e fuel in jectio n
p u m p b o d y t h r o u g h inlet p o r t (2). P u m p p l u n g e r (3)
a n d lifter (7) are lifted by lob es o n c a m s h a f t (8) a n d
alw ay s m a k e a full str o k e . E a c h p u m p m e a s u r e s th e
a m o u n t o f fuel to be in jected i n to its resp ec tiv e
cy lin d e r a n d forces the fuel o u t th e fuel in jectio n
valve.
T h e q u a n t i t y o f fuel sent t o t h e fuel in j e c t i o n valve

is c h a n g e d by the r o t a t i o n o f th e p u m p p l u n g e r in
th e b arre l. T h e p u m p p l u n g e r is t u r n e d by th e
T 49079
g o v e r n o r a c t i o n t h r o u g h fuel rack (5). T h e fuel rack
tu r n s g ear s e g m e n t (4) o n th e b o t t o m o f t h e p u m p FUEL IN J E C T IO N VALVE CR O S S S E C T IO N
p l un ger. 1. Fuel Injection line. 2. Nut. 3. Body. 4.Nozzle assembly.
2 -4
SYSTEMS OPERATION
FUEL SYSTEM
H ig h p r ess u re fuel f r o m th e fuel i n je c tio n p u m p s

is m o v e d t h r o u g h th e fuel i n je c tio n lines to th e fuel
in jectio n valves. As hig h p r e s s u re fuel e n te r s t h e
n ozzle a s sem b ly , th e check valve in t h e n o zzle o p e n s
a n d p e r m i ts the fuel t o e n t e r th e p r e c o m b u s t i o n
c h a m b e r . T h e fuel in jectio n valve gives th e c o r r e c t
c h a r a c t e r i s t i c s ( sp r a y p a t t e r n ) f o r g o o d fuel c o m
b ustio n .
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.
will get slow er. ( T h e g o v e r n o r w e ig h ts will m o v e

t o w a r d e a c h o th er). G o v e r n o r s p r i n g (7) m o v e s seat
(10), a n d valve (8) d o w n . T h is lets oil flow a r o u n d
T h e g o v e r n o r h as a g o v e r n o r w eig ht a s s e m b l y (9), valve (8) a n d t h r o u g h oil p a s s a g e ( l l ) t o fill th e
w h ich is d r iv e n by th e en g i n e t h r o u g h t h e d riv e c h a m b e r b e h i n d p i s t o n (13). T h i s p r e s s u r e oil
p i n i o n (22). T h e se at (10). valve (8). a n d p i s t o n (13) p u s h e s p i s t o n (13) a n d p in a s s e m b l y (18) d o w n to
ar e c o n n e c t e d to fuel r a c k (21) t h r o u g h p in a s s e m b l y give m o r e fuel to th e engine. (T h e u p p e r e nd o f valve
(18) a n d lever (20). P r e s s u r e oil f o r t h e g o v e r n o r (8) s t o p s th e flow o f oil t h r o u g h the t o p o f th e p is t o n ,
co m e s f r o m th e oil p u m p in th e g o v e r n o r . P r e s s u r e a r o u n d the valve.) E n g in e r p m i n crease s u n til th e
oil goes t h r o u g h a p a s s a g e a n d a r o u n d sleeve (14). r o t a t i o n o f w eig h t a s s e m b l y (9) is fast e n o u g h t o be
The g o v e rn o r co n tro l, c o n tro ls only the c o m in b a l a n c e w ith th e f o rce o f g o v e r n o r s p r i n g (7).
p r e ss io n o f g o v e r n o r s p r i n g (7). C o m p r e s s i o n o f t h e W h e n th es e t w o forc es a r e in b a l a n c e , th e en g in e will
sp r in g alw ay s p u sh e s d o w n t o give m o r e fuel t o t h e r u n at t h e d es ired r p m ( g o v e r n e d r p m ).
engine. T h e c e n tr ifu g a l fo rc e ( r o t a t i o n ) o f w e ig h t
as s e m b l y (9) a lw ay s pulls to get a r e d u c t i o n o f fuel t o W h e n th e e n g in e lo ad d e creas es, e n g in e r p m in
th e engine. W h e n th es e t w o forc es a r e in b a l a n c e , t h e cr eases a n d w eigh t a s s e m b l y (9) t u r n s faster. T h is
en g in e r u n s at th e d esired r p m ( g o v e rn e d rp m ). will m o v e se at (10) a n d valve (8) up. T h is s t o p s oil
f low f r o m g o in g a r o u n d th e b o t t o m o f valve (8).
W h e n th e eng in e lo a d in creases, t h e e n g in e r p m P r e s s u r e oil a b o v e p i s t o n (13) go es o u t a r o u n d th e
d ecreas es a n d th e r o t a t i o n o f w eigh t a s s e m b l y (9) t o p o f va lve (8). N o w . t h e p r e s s u r e oil b e t w e e n sleeve
2-5
(14) a n d p i sto n (13) p u sh e s t h e p i s t o n a n d pin

as s e m b l y (18) u p to give less fuel t o t h e engine.
E n g in e r p m d e creas es un til t h e c e n t r i f u g a l force
( ro t a t i o n ) o f w eight a s s e m b l y (9) is in b a l a n c e w ith
the fo rce o f g o v e r n o r s p r i n g (7). W h e n th e s e t w o
forces a r e in b a la n c e , th e e n g in e will r u n at th e
d es ired r p m (g o v e rn e d rpm ).
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 .
C o l l a r (6) m e c h a n i c a l l y f asten s to t h e fuel r a c k

t h r o u g h th e g o v e r n o r. T h e h e a d o f b o lt (7) e n g a g e s
in co lla r (6). A n air line c o n n e c t s th e c h a m b e r a b o v e
d i a p h r a g m (5) w ith th e inlet m a n i f o ld .
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.
T h e l ub r i c a t i o n s ys t e m uses a single s e ct i on oil A service i n d i c a t o r f or t h e oil filters is o n t o p of

p u m p t o send l ub r i c a t i o n oil t o t he en g i n e c o m t he oil filter h ous i ng. W h e n t he red i n d i c a t o r b u t t o n
p o n e n t s . T h e 16 cyl i nder e n gi n e s h a v e a p r e l u b r i goes u p a p p r o x i m a t e l y t o t he c e n t e r o f t h e cl ear
c a t i o n p u m p in a d d i t i o n t o t he m a i n oil p u m p . T h e i n d i c a t o r wi t h t he oil w a r m t he oil filter e l e me n t s
p r e l u b r i c a t i o n p u m p is used t o give l u b r i c a t i o n t o m u s t be c h a n g e d .
t he engi ne c o m p o n e n t s b e f o r e t h e en g i n e is s t a r t ed.
Oil f r o m t he oil m a n i f o l d f l ows t h r o u g h oil
p a s s a g e s a n d l i nes t o t h e i n s i d e a n d o u t s i d e
Oil f r o m t he oil p a n bas e (17) is pul l ed t h r o u g h
c o m p o n e n t s of t h e engi ne.
su c t i o n bell (15) a n d pi pe t o oil p u m p (16). T h e oil
p u m p t h e n p u s h e s t he oil t o oil co o l e r (7). T h e p r e s
sur e r e g u l a t i n g val ve (14) be t we e n t h e oil p u m p a n d T h e oil in oil m a n i f o l d (6) goes t o c a m s h a f t
t he oil c o o l e r c o n t r o l s t h e m a x i m u m p r e s s u r e o f t h e b e a r i n g s ( 9), c r a n k s h a f t m a i n b e a r i n g s ( 1 0 ) ,
oil to t he engi ne. Oi l f r o m t he oil c o o l e r goes t o oil c o n n e c t i n g r od be a r i n g s (11), val ve m e c h a n i s m (5),
filter h o u s i n g (8). A n oil filter relief val ve in t he oil pi s t on co o l i n g jet s (12), a n d t o oil ma n i f o l d (3).
filter h o u s i n g c o n t r o l s t he f l ow o f oil in t he h o u s i n g .
W h e n t he oil is col d or t he oil filters h a v e a r es t r i c T h e oi l i n oi l m a n i f o l d (3) g o e s t o t h e
t i on, t he relief val ve o p e n s a n d oil f l ows a r o u n d t h e t u r b o c h a r g e r , g o v e r n o r , a n d fuel i nj ect i on p u m p
oil filter e l e me n t s t o oil m a n i f o l d (6). W h e n t he oil hous i n g. W h e n t h e e ngi ne is e q u i p p e d wi t h a n oil
gets w a r m , a n d t he r e is n o r e s t r i ct i on t o t h e oil pr e s s u r e s h u t o f f o r r ever sal p r o t e c t i o n c o n t r o l , t h e y
filters, t he relief val ve is cl os ed a n d oil f l ows t h r o u g h al so get oil f r o m oil m a n i f o l d (3). O n 8 a n d 12
t he oil filters t o t he oil ma n i f o l d . c yl i n der engi nes t he r e is a t u r b o c h a r g e r q u i c k
2-9
LUBRICATION SYSTEM SYSTEMS OPERATION
l u b r i c a t i o n valve t h a t gives i m m e d i a t e p r e s s u r e oil

t o t he t u r b o c h a r g e r s at en g i n e st ar t up. Unf i l t e r ed
oil f r o m t h e oil cool er goes t h r o u g h a n oil line t o t h e
t u r b o e h a r g e r q ui c k l u b r i c a t i o n val ve at e ngi ne st ar t
up. W h e n t he oil in oil m a n i f o l d (3) gets pr ess ur e,
t he l ub r i c a t i o n valve s h u t s of f t he u n f i l t er ed oil a n d
t he t u r b o c h a r g e r s n o w get filtered oil f r o m oil
ma n i f o l d (3).
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.
W h e n t he sel ect or val ve h a n d l e is par al l el wi t h t he

en g i n e c r a n k s h a f t , t he flow' of oil is t o t he m a i n oil
filters. W h e n t h e h a n d l e is t u r n e d 90° a w a y f r o m t he
engi ne, t he oil f l ow is t o t h e a u x i l i a r y oil filters.
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
T h e du p l e x oil filters p e r mi t t he m a i n oil filters t o

be c h a n g e d whi l e t he engi ne is in o p e r a t i o n .
PRELUBRICATION SYSTEM
(16 Cylinder Engines Only)
T h e d u p l e x oil filter s y s t e m ha s t w o a u x i l i a r y oil
filters (5), a filter vent val ve (2) a n d s e l ect or val ve
(I). T h e p r e l u b r i c a t i o n s y s t e m ha s a n oil p u m p ( l )
t h a t is t u r n e d by a m o t o r (3). T h e m o t o r s used are: a
T h e s el ect or val ve ( l ) is us e d t o c h a n g e t h e f l ow of 1 1 5/ 2 3 0 V A C , 24 V D C , 32 V D C . a n d a n ai r m o t o r .
engi ne oil f r o m t he m a i n oil filters (3) t o t he T h e m o t o r a n d p u m p ar e m o u n t e d o n t h e r ight side
auxi l i a r y oil filters (5). T h e filter v e n t val ve (2) o f t he engi ne. T h e p u m p pul ls oil f r o m t he oil p a n
p e r mi t s air t o be v e n t e d f r o m t h e oil filters be f o r e t he b a s e a n d t h e n pus h e s t he oil t h r o u g h a t u b e t h a t
s el ect or val ve is mo v e d . c o n n e c t s t o t h e engi ne oil line at tee (2). C h e c k valve
2- 10
LUBRICATION SYSTEM SYSTEMS OPERATION
(4) is used to pr e v e nt t he f l ow of e n g i n e oil

b a c k w a r d s t h r o u g h t h e p r e l u b r i c a t i o n p u m p t o t he
oil p a n base.
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.
side. T h e c o o l a n t t u r n s 180 degr ees in t he j u n c t i o n t h r o u g h t he af t er c ool e r .

h o u s i n g c over a n d goes i nt o b o t t o m p a s s a g e ( 12) in
t he f l ywheel hous i ng. In t he b o t t o m p a s s a ge of t he fl ywheel h o u s i n g
N O T E : O n engi nes e q u i p p e d wi t h a j a c k e t w a t e r pa r t of t he c o o l a n t goes t o t he left side of t he
af t er c ool e r , pa r t of t he c o o l a n t goes t o t he a f t e r cyl i nder bl ock. T h e r e m a i n d e r of t he c o o l a n t goes
cool er t h r o u g h a pi pe f r o m t he t o p p a s s a ge of t h e ac r o s s t he fl ywheel h o u s i n g i nt o t he right si de o f t he
j u n c t i o n h o us i ng. T h e c o o l a n t goes t h r o u g h t h e cyl i nder bl ock. T h e c o o l a n t t h e n f l ows t h r o u g h t he
f r o n t cor e o f t he af t e r c ool e r , a n d t h r o u g h a pi pe t o cyl i nder bl ock , a r o u n d t h e c yl i nder l iners a n d i nt o
t he r e a r core. F r o m t h e r e a r a f t e r c o o l e r c or e t h e cyl i nder he a d s (9). Lines f r o m t he r ear of t he
c o o l a n t goes t h r o u g h a pi pe t o t he b o t t o m p a s s a g e cyl i nder b l oc k let c o o l a n t go t o w a t e r cool e d
of t he j u n c t i o n h o u s i ng. A pl at e wi t h a n orifice is t u r b o c h a r g e r shi eld (15). C o o l a n t goes f r o m t he
i nst all ed b e t we e n t he j u n c t i o n h o u s i n g a n d t h e shi eld t h r o u g h lines t o ei t her w a t e r c o o l e d or w'ater
j u n c t i o n h o u s i n g cover , t o ca us e t h e c o o l a n t t o f l ow shi elded e x h a u s t m a n i f o l d s (2).
2- 1 3
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.
COOLANT LEVEL SWITCH
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).
W h e n t he c o o l a n t level get s t o o l ow, t he swi t c h

c a n be used t o s o u n d a n a l a r m , light a w a r n i n g light
C O O L A N T LEVEL S W ITC H
or o p e r a t e a devi ce t o s t o p t h e engi ne. (Later Type)
2. Switch. 3. Operating arm.
2 - 14
SYSTEMS OPERATION
COOLING SYSTEM
‘V
1 1
L —1 1---- >
FLOW OF C O O L A N T IN SEA W ATER C O O L IN G SYSTEM

17. Engine jacket water heat exchanger. 18. Sea w ater pump. 19. Aftercooler inlet elbow. 20. Outlet elbow. 21. Marine
gear oil cooler. 22. Flange. 23. W ater outlet connection. 24. Flange.
SEA WATER AND SEPA RA TE C IR C U IT

AFTERCOOLER WATER SYSTEMS
Se a wa t e r p u m p ( 18) pulls w a t e r t h r o u g h t h e inlet

Sea Water System pi pe a n d t h e n p u s h e s it t h r o u g h a pi pe t o a f t e r
c ool e r inlet e l b o w (19). A p a r t o f t h e w a t e r at t he
e l b o w goes t o t h e f r o n t a f t e r c o o l e r c o r e a n d t h r o u g h
T h e sea w a t e r a f t e r c o o l e r s ys t e m uses sea w a t e r a pi pe t o t he r e a r a f t e r c o o l e r cor e, a n d t h e r e m a i n
( wa t e r t h a t is n o t t r e a t e d) t o r e m o v e h e a t f r o m t h e de r o f t h e w a t e r goes t h r o u g h a pi pe t o out l et e l b o w
a f t e r c ool e r cor es a n d o t h e r c o o l i n g s ys t e m c o m (20). T h e r es t r i ct i on of t h e pi pe t o t h e out l et e l b o w
ponents. A gear driven, centrifugal-type wa te r will ca us e m o s t o f t he w a t e r t o go t h r o u g h t he a f t e r
p u m p is used t o m o v e t he sea w a t e r t h r o u g h t h e cool er . W a t e r f r o m t he r ear a f t e r c o o l e r c o r e goes t o
s ys t em. T h e p u m p is on t he left side of t h e en g i n e o n t he out l et e l b o w a n d mi x e s wi t h t he w a t e r f r o m t he
t he acce s s or y dr i ve h ou s i ng. Zi n c r o d s a r e inst al l ed inlet el bow.
in t he sea w a t e r s ys t em t o h el p pr e v e n t c o r r o s i o n of
t h e s y s t e m c o m p o n e n t s . T h e s e r o d s m u s t be N O T E : T h e r e is a pl at e wi t h a n ori fi ce i nst al l ed
r epl aced f r o m t i me t o t i me to k e e p t h e r e s i s t ance of b e t we e n t he r e a r a f t e r c o o l e r c or e a n d t h e out l et
c o r r o s i o n high. T h e pl ugs f or t h e zi nc r o d s h a v e r ed e l b o w t o hel p ke e p t he a f t e r c o o l e r cor es full of
pa i nt f or easy i dent i fi cat i on. wat er .
2- 15
COOLING SYSTEM S Y S T E M S O P E R A T IO N
FLOW OF C O O LA N T IN SEPARATE C IR C U IT C O O L IN G SYSTEM

19. Aftercooler inlet elbow. 20. Outlet elbow. 21. M arine gear oil cooler. 22. Flange. 23. Water outlet connection.
24. Flange. 25. Fresh water pump. 26. Keel cooler. 27. Expansion tank.
P a r t o f t he w a t e r at t he out l et e l b o w goes to Separate Circuit System

m a r i n e gear oil c ool e r (21). a n d t he r e m a i n d e r goes
t h r o u g h f l ange (22) t o w'ater out l et c o n n e c t i o n (23). T h e s e p a r a t e circuit a f t e r c o o l e r sy s t e m uses f resh
W a t e r f r o m t he m a r i n e g e a r oil c o o l e r goes t o f l ange w a t e r ( wa t e r t h a t is t r e a t e d ) t o r e m o v e heat f r o m t he
(24). T h e r e is a pl at e wi t h a n ori fi ce i nst al l ed af t er cooler - cor es a n d o t h e r c o o l i n g s y s t e m c o m
b e t we e n t h e a f t e r c o o l e r o ut l e t el b o w a n d f l ange (22) ponents. A gear-driven centrifugal-type wat er p u m p
t o m a k e t he w a t e r go t h r o u g h t he m a r i n e g e a r oil is used t o m o v e t he f resh w a t e r t h r o u g h t h e sys t em.
cool er . T h e p u m p is on t he left side o f t he engi ne on t h e
a c c e s s or y dr i ve hous i ng .
W a t e r f r o m t he w a t e r out l et c o n n e c t i o n goes t o
t he t u b e si de o f t he engi ne j acket w a t e r h e a t F r e s h w a t e r p u m p (25) pul l s c o o l a n t t h r o u g h t he
e x c h a n g e r (17). T h e w a t e r goes t h r o u g h t h e heat inlet pi pe a n d t h e n p u s h e s it t h r o u g h a pi pe to t he
e x c h a n g e r a n d t h e n t o t h e sea w a t e r o u t l e t f r o n t a f t e r c o o l e r core. T h e c o o l a n t fl ows t h r o u g h
( o v e r b o a r d di scharge) . t he f r o n t af t e r c o o l e r c o r e a n d t h e n t h r o u g h t he re a r
a f t e r c o o l e r cor e t o out l et e l b o w (20). P a r t of t he
2- 1 6
c o o l a n t at t he out l et e l b o w goes t o m a r i n e g e a r oil

c o o l e r (21) a n d t he r e m a i n d e r goes t h r o u g h f l an ge
(22) to w a t e r out l et c o n n e c t i o n (23). C o o l a n t f r o m
t he m a r i n e g e a r oil c o o l e r goes to f l ange (24). T h e r e
is a pl at e wi t h a n orifice i nst all ed b e t we e n t h e
af t e r c o o l e r o ut l et el bow a n d f l ang e (22) t o m a k e t h e
c o o l a n t g o t h r o u g h t he m a r i n e g e a r oil cool er .
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
T h e cyl i nder b l oc k is a 60° vee. T h e r e is a c o u n t e r C o m b u s t i o n f orces in t he c y l i nde r a r e c h a n g e d

b o r e in t he t o p o f t he bl ock f or e ach c yl i n de r liner. i n t o us a b l e r o t a t i n g p o w e r by t he c r a n k s h a f t . T h e
T h e b o t t o m of t h e c o u n t e r b o r e is t he s u p p o r t for c r a n k s h a f t has a gear o n e ach end. T h e ge a r at t h e
each liner. C o v e r s on t he side o f t he c y l i nd e r b l oc k f r o n t dr i ves t he gear s in t he a c c e s s or y drive. T h e
per mi t i ns pe ct i on o r r e p l a c e m e n t of t he c o n n e c t i n g ge a r at t he b a c k dr i ves t he engi ne c a m s h a f t a n d t he
r od a n d m a i n be a r i n g s w i t h o u t r e m o v a l of t he oil fuel i nj ect i on p u m p c a m s h a f t . T h e c r a n k s h a f t e nd
p a n base. pl a y is c o n t r o l l e d by t h r u s t b e a r i ngs on t h e r ear
m a i n b e a r i n g cap. F o r a n o p p o s i t e r o t a t i o n eng i ne
T h e engi ne has one cyl i nder h e a d f or e a c h t w o t he c r a n k s h a f t is t u r n e d e nd f or end.
cyl i nders. The b l oc k has s t uds t o f ast en t he cyl i nder
heads. TIM IN G GEARS
C o o l a n t in t he engi ne fl ows a r o u n d t h e liners t o T h e t i mi n g gear s ar e in a c o m p a r t m e n t at t he r ear

r e m o v e heat f r o m t h e m. T h r e e o - r i ng seals at t he o f t he cyl i nder bl ock. T h e i r c o v e r is t he f r o n t face of
b o t t o m a n d a filler b a n d at t he t o p of e ach c yl i nd e r t he fl ywheel hous i ng. T h e t i mi n g gear s k e e p t he
liner m a k e a seal be t we e n t he c yl i nder l iner a n d t he r o t a t i o n of t he c r a n k s h a f t , c a m s h a f t , b a l a n c e r s (8
cyl i nder bl ock. c y l i n de r engi ne) , fuel p u m p a n d g o v e r n o r dr i ve in
t he cor r e c t r el at i on t o each ot her . T h e t i mi ng gear s
a r e dr i ven by a ge a r in f r on t of t he r ear f l ange o f t he
crankshaft.
PISTONS, RINGS AND CONNECTING RODS
T h e pi s t on has t hr e e rings: t w o c o m p r e s s i o n r i ngs

a n d one oil ring. All ri ngs ar e l o c a t e d a b o v e t h e
pi s t on pin bor e. T h e t w o c o m p r e s s i o n r ings seat in
a n i r on b a n d wh i c h is cast in t he pi st on. T h e oil ri ng
is s p r i n g l oa de d. Ho l e s in t he oil r i ng g r o o v e r e t u r n
oil t o t he cr a nk c a s e .
T h e ful l- f l oat ing pi s t on pi n is held in pl ace by t w o

s n a p rings wh i c h fit in g r o o v e s in t he pi n bor e.
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.
T h e c o n n e c t i n g r ods a n d cap s a r e cut at a n angl e

wh i c h let t he pi st on a n d c o n n e c t i n g r o d a s s e m b l y be T h e c r a n k s h a f t g e a r (4) t u r n s t he c a m s h a f t cl us t e r
r e m o v e d u p t h r o u g h t h e c y l i n d e r l i ner . T h e g e a r (2). Th i s ge a r t u r n s t he b a l a n c e r g e a r (3) (8
c o n n e c t i n g r od be a r i ngs a r e hel d in l o c a t i o n wi t h a c yl i n der engi ne) a n d g e a r ( l ) o f t he fuel p u m p a n d
t a b t h a t fits in a g r o o v e in t he c o n n e c t i n g r o d a n d g o v e r n o r drive.
cap. T h e c o n n e c t i n g r ods m u s t be inst al l ed wi t h t he
pa r t n u m b e r t ow' ar d t he r a d i u s in t he c r a n k s h a f t T h e sma l l cl ust er ge a r o f t he c a m s h a f t is held t o
j our nal . t he c a m s h a f t wi t h a key. pl at e a n d bolts.
2- 18
BASIC BLOCK SYSTEMS OPERATION
VIBRATION DAMPER FRONT ACCESSORY DRIVE
T h e f or ce f r o m c o m b u s t i o n in t h e cyl i nder s will T h e f r o n t a cce s s o r y dr i ve gives a l o c a t i o n t o

caus e the c r a n k s h a f t t o twist. Th i s is cal led t o r s i o n a l o p e r a t e access ori es suc h as a sea w a t e r p u m p , t r es h
v i b r a t i o n . I f t h e v i b r a t i o n is t o o g r e a t , t h e w a t e r p u m p , ai r c o m p r e s s o r , h y d r a u l i c p u m p , a n d
c r a n k s h a f t will be d a m a g e d . T h e v i b r a t i o n d a m p e r a l t e r n a t o r . T h e en g i n e oil p u m p , fuel t r a n s f e r p u m p ,
l imits t o r s i o n a l v i b r a t i o n s t o a n ac c e p t a b l e a m o u n t a n d j a c k e t w a t e r p u m p ar e al so d r i v e n by t he f r o n t
t o pr event d a m a g e t o t he c r a n k s h a f t . a cce s s o r y drive.
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 .
C ROSS S E C TIO N OF A TY PIC A L

VIB R A TIO N DAMPER
1. Solid cast iron weight. 2. Space between weight and
case. 3. Case.
T h e 8 cyl i nder eng i ne has a s hor t , rigid c r a n k s h a f t

a n d d o e s n o t need a v i b r a t i o n d a m p e r e x c e p t f o r
s o m e speci al ap p l i c a t i o n s . T h e 12 c yl i n der e n g i n e
ha s o n e v i b r a t i o n d a m p e r . 16 C y l i n d e r E n g i n e s
Seri al No. 35B1 t h r u 35B1275, 9 1 B 1 t h r u 9 1 B63 3
and 91B732 thr u 91B755 have one v ib r at io n
d a m p e r . 16 C y l i n d e r E n gi ne s Ser i al No. 35B1276 -
Up, 91B634 t h r u 91 B7 3 I a n d 9 I B 7 5 6 - U p h a v e t w o
vi b r a t i o n d a m p e r s .
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
The air st a r t i ng m o t o r is used to t ur n t he engi ne The 1 L 5 011 Re gul a t i ng and Pressure Re d u c i n g

f l ywheel fast e n o u g h to get t he engi ne r unni ng. Valve Clroup has the c o r r e c t char act er i s t i cs t or use
wi t h t he air st a r t i ng m o t o r . Most o t h e r t y p e s ot
r egul at or s d o n o t have t he cor r e ct char act er i st i cs .
Do n o t use a di f f e r e nt styl e ot valve in its place.
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.
The hyd r a u l i c st a r t i ng m o t o r ( 4) is used t o t ur n ( 2 0 7 0 0 kPa) t he u n l o a d i ng valve ( 7) sends t he

the engi ne f l ywheel fast e n o u g h t o get t he engi ne hy d r a u l i c p u m p ( 6) o u t p u t b a c k t o t he reservoi r
st a r t ed. When t he engi ne is r u n n i n g , the h y d r a u l i c ( l ). At t he s a m e t i me it s t ops t he How o f oil f r om
p u m p (6) pus he s oil t h r o u g h t he filter ( 8) i nt o t he t he a c c u m u l a t o r (9) ba c k t o h y d r a u l i c p u m p (6).
a c c u m u l a t o r (4). T h e a c c u m u l a t o r ( 9) is a t hi ck At thi s t i me t h e r e is 3 0 0 0 psi ( 2 0 7 00 kPa)
wall cyl i nder . It has a pi s t on w h i c h is free t o mo v e pr essure on t he oil in t h e a c c u m u l a t o r (9), in t he
axi al l y in the cyl i nder . A char ge o f n i t r o g e n gas line t o t he u n l o a d i n g valve ( 7). in t he lines t o t he
( N 2 ) is sealed in on e e n d o f t he c y l i n d e r by t h e h a n d p u m p ( 2 ) a n d to t he h v d r a u l i c s t a r t i ng m o t o r
pi st on. T h e o t h e r e n d o f t he c y l i n d e r is c o n n e c t e d (4).
to t he h y d r a u l i c p u m p (6) a nd t he h y d r a u l i c
st a r t i ng m o t o r (4). T h e oil f r om t he h y d r a u l i c
p u m p ( 6) pus h e s on t he pi s t o n wh i c h p u t s m o r e
c o mp r e s s i o n on the n i t r o g e n gas ( N 2 ) in t h e Be f or e s t a r t i ng t h e engi ne, t h e pr ess ur e on t h e
cyl i nder . Wh e n t he oil pr ess ure gets t o 3 0 0 0 psi pr ess ure gauge ( 3) s ho u l d be 3 0 0 0 psi ( 2 0 7 0 0
( 2 0 7 0 0 kPa) . t he a c c u m u l a t o r (9) has a full kPa) . Wh e n t he s t a r t e r c o n t r o l valve (5) is a c t i
charge. At thi s p o i n t t he p i s t on is a p p r o x i m a t e l y in vat ed, t he oil is p u s h e d f r o m t he a c c u m u l a t o r (9)
t he m i d d l e o f the cyl i nder . by t he n i t r o g e n gas ( N ; ). T h e oil How is t h r o u g h
t he h y d r a u l i c st a r t i ng m o t o r (4), wh e r e t he ener gy
The u n l o a d i n g valve ( 7 ) feels t he pr es s u r e in t h e f r o m t he c o m p r e s s i o n o f t h e fluid is c h a n g e d to
a c c u m u l a t o r ( 9). Wh e n t he pr ess ure is 3 0 0 0 psi me c h a n i c a l e ner gy f or t ur n i n g the engi ne f l ywheel .
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
HYDRAULIC STARTING MOTOR valve pu s h e s t he s t a r t e r p i n i o n ( 4) i nt o e n g a g e m e n t

wi t h t he engi ne f l ywheel at the s a me t i me it o p e n s
t he wa y f or high pr ess ure oil t o get i n t o t he
h y d r a u l i c s t a r t i ng m o t o r .
When t he high pr ess ur e oil goes i nt o the h y d r a u

lic s t a r t i ng m o t o r , it goes b e h i n d a series o f pi s t ons
( 2) in a r o t o r (l ). T h e r o t o r ( l ) is a c y l i n d e r wh i c h
is c o n n e c t e d by spl ines t o t he drive shaft for t he
s t a r t e r p i n i o n (4). Wh e n t h e p i st o n s ( 2) feel t he
f orce o f t he oil t h e y mo v e unt i l t h e y are agai nst
t he t h r u s t bear i ng (3). The t h r u s t bear i ng ( 3) is at
v ......... ii —t xmm2 an angle t o t he axis o f the r o t o r (1). Thi s m a k e s
t h e p i s t on s ( 2) slide a r o u n d t he t h r u s t bear i ng (3).
H Y D R A U L IC S T A R T IN G M O T O R
As t h e y slide, t h e y t u r n t he r o t o r (1) whi ch
1. R otor. 2. Piston. 3. Thrust bearing. 4. Starter pinion.
c o n n e c t s t h r o u g h t he dri ve sha f t a nd s t a r t e r pi ni on
A . Oil inlet. B. Oil outlet.
( 4 ) t o the engi ne f l ywheel . T h e pr ess ure o f t he oil
The h y d r a u l i c st ar t i ng m o t o r is an axial pi st on m a k e s t he r o t o r ( 1) t u r n very fast. Thi s t u r n s the
h yd r a u l i c m o t o r . The lever for t he s t a r t e r c o n t r o l engi ne f l ywhe e l fast e n o u g h f or q u i c k starti ng.
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 .
CHARGING SYSTEM COMPONENTS

Alternator (Delco-Remy)
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
p i ni on to e n g a g e wi th t he r i ng g e a r on t he f l ywheel Magnetic Switch

o f t he engi ne. T h e s t a r t e r p i ni on w ill e n g a g e wi t h t he
r i ng g e a r bef or e t he elect ri c c o n t a c t s in t h e sol e n o i d
close t he circuit b e t we e n t he b a t t e r y a n d t he s t a r t i n g
A ma g n e t i c swi t c h (relay) is used s o m e t i m e s f or
m o t o r . W h e n t he st art swit ch is r el eased, t h e s t a r t e r
t h e s t a r t e r s o l e n o i d o r gl ow p l u g c i r c u i t . Its
pi ni on will m o v e a w a y f r o m t he r i ng ge a r of t h e
o p e r a t i o n electrically, is t he s a m e as t he sol e n oi d. Its
flv wheel.
f u n c t i o n is t o r e d u c e t he low c u r r e n t l oad o n t he
st ar t swi t ch a n d c o n t r o l l ow c u r r e n t t o t he s t a r t e r
s ol e n o i d or hi gh c u r r e n t t o t he glow plugs.
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 .
Solenoid A heat act i vat ed me t a l disc wi t h a c o n t a c t poi nt

c o m p l e t e s t he el ect ri c ci rcui t t h r o u g h t he circuit
b r e a k e r . If t he c u r r e n t in t h e elect ri cal sys t em gets
A s ol e noi d is a ma g n e t i c sw'itch t h a t uses low
t o o high, it caus es t h e me t a l disc t o get hot. T h i s heat
c u r r e n t to close a hi gh c u r r e n t circuit. T h e so l e noi d
c aus es a di s t o r t i o n of t he me t a l disc w hi ch o p e n s t he
has an e l e c t r o m a g n e t wi t h a cor e (6) wh i c h moves .
c o n t a c t s a n d b r e a k s t he circuit. A ci rcui t b r e a k e r
t h a t is o p e n can be r eset af t er it cool s. P u s h t he reset
b u t t o n t o close t he c o n t a c t s a n d reset t h e circuit
br e a ke r .
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
M a n y t ypes of electri cal s ys t ems ar e a va i l a b l e f o r s ys t ems wh e r e t he r e g u l a t o r is pa r t of t h e a l t e r n a t o r ,

t h e s e e n g i n e s . S o m e c h a r g i n g s y s t e m s us e a n t he t r a n s i s t o r ci rcui t p r e v e n t s c u r r e n t d i s c h a r g e t o
a l t e r n a t o r a n d a r e g u l a t o r in t h e wi r i ng circuit. t he a l t e r n a t o r a n d t h e fuel o r oil pr e s s u r e swi t c h is
O t h e r s have t he r e g u l a t o r i nside t h e a l t e r n a t o r . n o t r equi r ed.
S o m e s t a r t i ng s ys t ems ha ve o n e s t a r t i n g m o t o r .
Engi ne s whi c h m u s t o p e r a t e in b a d s t a r t i n g c o n d i All wi r i ng s c h e ma t i c s a r e u s a b l e wi t h 12, 24, 30 or
t i ons can have t w o s t a r t i n g m o t o r s . O t h e r s t a r t i n g 32 vol ts unl ess t h e title gives a specifi c d e s c r i pt i on.
s ys t ems use air or h y d r a u l i c m o t o r s .
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
B - Black CABLE ELECTRIC CHARGING U N IT WIRE

W - White SIZE STARTING OUTPUT SIZE
R - Red
0 - Orange 12 V O LT 24-32 V O LT 0-18 amps. #14
BR - Brown 19-30 amps. #10
0 4.0 FEET 15.0 FEET
LT GN - Light Green 31-45 amps. # 8
00 5.0 FEET 18.0 FEET
PU - Purple 46-65 amps. # 6
000 6.0 FEET 21.0 FEET
W/B White with 0000 7.5 FEET 27.0 FEET NUMBER FOLLOWING COLOR
W/S Black Stripe CODE IS
X 35 6 0 -1 X 1 RECOMMENDED WIRE SIZE
2- 2 5
W IR IN G D IA G R A M S SYSTEMS O PER A TIO N
GROUNDED ELECTRICAL SYSTEMS INSULATED ELECTRICAL SYSTEMS
(Regulator Separate From Alternator) (Regulator Separate From Alternator)
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. Am m eter. 2. Regulator. 3. Battery. 4. Pressure 1. A m m eter. 2. Regulator. 3. Battery. 4. Pressure

switch. 5. A lternator. switch. 5. A lternator.
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.)
(Regulator Separate Fr om Alternator) (Regulator Separate From Alternator)
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.)
(Regulator Separate From Alternator) (Regulator Separate From Alternator)
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 e te r. 4. 1. Magnetic switch. 2. S tart switch. 3. A m m eter. 4.

Regulator. 5. Battery. 6. Starting m otor. 7. Pressure Regulator. 5. Battery. 6. Starting m otor. 7. Pressure
switch. 8. A lternator. switch. 8. A lte rna tor.
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
(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. A m m eter. 2. A lte rn a to r. 3. Battery. 1. A m m eter. 2. A lternator. 3. Battery.
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.
(Regulator Inside A lterna tor) (Re gul at or Inside Al ternator)
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.
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
(R egulator Inside Al ternator) ( R e g u l a t o r Inside A l t e r n a t o r )
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
GROUNDED ELECTRICAL SYSTEMS (Cont.) INSULATED ELECTRICAL SYSTEMS (Cont.)

(Prelubrication Pump) (Prelubrication Pump)
230V-AC PR E LU B R IC A TIO N PU M P 230V-A C P R E LU B R IC A TIO N PU M P

1. Oil pressure switch. 2. Start switch. 3. M agnetic switch. 1. Oil pressure switch. 2. Start switch. 3. Magneticswltch.
4. 230V-AC Prelubrication pump. 5. Battery. 6. Starting 4. 230V-AC Prelubrication pump. 5. Battery. 6. Starting
motor. 7. Relay. motor. 7. Relay.
24-30-32 V -D C PR E LU B R IC A TIO N PUM P 24-30-32 V -D C P R E LU B R IC A TIO N PU M P

1. Oil pressure switch. 2. Start switch. 3. M agnetic switch. 1. Oil pressure switch. 2. Start switch. 3. M agneticswltch.
4. 24-3 0 -3 2 V -D C P relubrication pum p. S. B attery. 4. 24-3 0 -3 2 V -D C P relu b ricatio n pum p. 5. B attery.
6. Starting motor. 6. Starting motor.
2-32
PROTECTION DEVICES SYSTEMS OPERATION
ENGINE PROTECTION DEVICES

SHUTOFF CONTROL N O T E : D O N O T use t h e e m e r g e n c y m a n u a l s h u t
of f b u t t o n t o s h u t d o w n t he en g i n e in n o r m a l
A s h u t o f f c o n t r o l f or o v e r s p e e d ( engi ne r u n n i n g o p e r a t i o n . Thi s will caus e m o r e t h a n n o r m a l w e a r
t o o fast) a n d l ow oil pr es s ur e is p r o v i d e d f or i n d u s o n t h e o v e r s p e e d s h u t o f f part s.
trial engi nes. A n a t t a c h m e n t is al so av a i l a b l e t o
p r o v i d e p r o t e c t i o n f or hi gh c o o l a n t t e m p e r a t u r e
Reset b u t t o n (5) is used t o set t he c o n t r o l af t er t he
an d is used wit h t he s h u t o f f cont r ol .
e ngi ne has been s t o p p e d by t he c o n t r o l b e c a u s e of
V12 a n d V16 M a r i n e E n g i n e s ar e e q u i p p e d wi t h l ow oil pr ess ure. It is al so used af t er t he engi n e has
r ever sal p r o t e c t i o n in a d d i t i o n t o ov e r s p e e d . T h e been s t o p p e d b e c a us e o f hi gh w a t e r t e m p e r a t u r e .
s h u t o f f for reversal p r o t e c t i o n is a va i l a bl e as a n
a t t a c h m e n t for V8 M a r i n e Engi nes. T h e s e r ever sal N O T E : It is not neces s a r y t o set t he co n t r o l af t er a
p r o t e c t i o n c o n t r o l s d o not h a v e p r o t e c t i o n f o r l ow n o r m a l engi ne stop.
oil pr essure.
T h e s h u t o f f c o n t r o l p ar t s get l ub r i c a t i o n f r o m
T h e s h u t o f f c o n t r o l (1) is i nstal led in t h e V o f t h e l e a ka ge past t h e oil p r e s s u r e s h u t o f f pi st on. R e t u r n
engi ne at t he r e a r of t he g o v e r n o r . T h e c o n t r o l is
oil goes t h r o u g h t wo dri ll ed hol es in t he b o t t o m ot
dr i ven f r o m t he fuel p u m p a n d g o v e r n o r dr i ve shaft .
t he hous i ng.
En g i n e oil pr es s u r e is used t o a ct i vat e t h e l ow oil
SHUTOFF CONTROL OPERATION
pr es s u r e s h u t o f f cont r ol . T h e l oc a t i o n of pl ug (2) is
for t he c o n n e c t i o n of a s h u t o f f c o n t r o l val ve f or Low Oil Pressure Shutoff and
wa t e r t e m p e r a t u r e . T h e line (4) s uppl i es en g i n e oil Water Temperature Shutoff
p r e s s u r e t o t he s h u t o f f cont r o l .
T h e oil pr e s s u r e c o n t r o l will s t o p t h e en g i n e w h e n
t he l ub r i c a t i o n oil pr e s s u r e d r o p s b e l o w 12 ± 3 psi
(85 ± 20 k P a ) . It will al so s t o p t he e ngi ne w h e n hi gh
w a t e r t e m p e r a t u r e o p e n s a s h u t o f f c o n t r o l valve
w h i c h causes l ow oil pr es s u r e t o t he co nt r ol .
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
agai ns t c o n t r o l p i s t on (6). ( See i l l us t r at i on S h u t o f f T h e release l at ch is t h e n m o v e d out of e n g a g e d

C o n t r o l . C r o s s S e c t i o n a l S i d e Vi ew; N o r m a l po s i t i o n a n d releases r o d (8) w h i c h m o v e s out w-ard
Operation.) by f orce o f s p r i n g ( l l ) .
O n e end o f slide f ol l ower (2) is e n g a g e d wi t h gui de
(5). T h e f ol l ower is free t o pi vot a b o u t slide f ol l ower
shaft (3) in t he h o u s i n g a n d is ac t i v a t e d by t he
m o v e m e n t of gui de (5).
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).
(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
(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).
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
Release r od (8) mo v e s t o c o n t a c t p l u n g e r (12) in W h e n a n o v e r s p e e d ( engi ne r u n n i n g t o o fast)

t he r ear of t he g o v e r n o r dr i ve h o u s i ng. T h e p l u n g e r c o n d i t i o n has h a p p e n e d , t h e o v e r s p e e d s h u t o f f
t h e n m o v e s f o r w a r d t o c o n t a c t t h e lever a s s e m b l y in c o n t r o l , l oc a t e d in t he s h u t o f f c o n t r o l h o u s i n g , will
t he g o v e r n o r dr i ve h o u s i n g t o m o v e t he fuel r ac k t o act i vat e t he rel ease r od. T h e rel ease r od m o v e s t he
t he fuel of f pos i t i on a n d s t o p t he engi ne. fuel r a c k t o t he of f pos i t i o n t o s t o p t he engine.
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.
W h e n t h e en gi ne r p m i ncr eases, t he c ent r i f ugal

f or ce a c t i ng o n t he wei ght i ncr eases, a n d t he wei ght
m o v e s o u t o f t he car r i e r flange. T h i s m o v e m e n t of
the weight co n tin u es until the spring force
( r es t r i ct i on o f wei ght m o v e m e n t o u t w a r d ) is e q u a l
t o t he f or ce m o v i n g t he wei ght out.
W h e n t he engi n e o ve r s p e e ds , t h e wei ght will mo v e

o u t o f t he c a r r i e r f l ange a n d m a k e c o n t a c t wi th
RACK S H U TO FF rel ease l at ch (3). Re l e as e l at ch (3) will m o v e a n d
12. Plunger. p e r m i t rel ease r o d (4) t o m o v e d o w n w'hich m o v e s
t he s h u t o f f l ever a n d t he fuel r ack to t he fuel O F F
Engine Reversal Protection Control p osi t i on.
T h e s h u t of f c o n t r o l f or engi ne r ever sal p r o t e c t i o n Emergency Manual Shutoff Button

is t he s a m e as t he c o n t r o l f o r l ow oil p r e s s u r e e x c e p t
t he t h r e a d s o n w o r m shaft ( l ) go in t he o p p o s i t e
di r ect i on. L o w oil p r e s s u r e will s h u t of f t he en g i n e
o nl y if t he engi ne r u n s in reverse. T h e oil p r e s s u r e
will be low b e c a u s e t he engi ne oil p u m p will n o t give
oil pr es s ur e in reverse.
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
In a n e m e r g e n c y w h e r e t he eng i ne m u s t be s h u t L a t c h t h e r el ease r o d (5) by pul l i ng on t he s h u t o f f

d o w n i mme d i a t e l y , p u s h t he e m e r g e n c y s h u t o f f set ti ng c o n t r o l lever.
b u t t o n a n d hol d it in unt i l t he rel ease r od ha s b e e n
released. T h e engi ne c a n n o w be st a r t ed.
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.
SETTING THE SHUTOFF CONTROL

W h e n t he engi ne ha s been s h u t - d o w n by t h e
s h u t o f f c ont r ol , t h e r e a s o n f or t h e s h u t - d o w n m u s t
be c o r r e c t e d a n d t he c o n t r o l set a g a i n b e f o r e t he
engi ne can be st ar t ed.
Setting After Overspeed and Emergency

Manual Shut-down
T h e r el ease r od is set by m o v i n g t he lever (1). T h e

engi ne n o w ca n be st a r t ed.
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 .
S H U TO FF S E TTIN G C O N T R O L Under conditions of no rm al oper at ion, pressure

1. Lever. o f t he l u b r i c a t i o n oil will i ncr eas e t o t he o p e r a t i n g
r a n g e bef or e t he f ol l ower h'as m o v e d t o t he limit of
t r avel a n d act i vat es t h e release l at ch a n d r od.
Setting After Low Oil Pressure or High Water

Temperature Shut-down
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
A ir Inlet and Exhaust S y s te m .................................................... 3-35 Fuel S y s te m ..................................................................................... 3-15

C o m p re s s io n ............................................................................... 3-36 A ir-F u e l Ratio C o n tro l A d ju s tm e n t..................................... 3-30
C rankcase (C rankshaft C o m p a rtm e n t) P re s s u re 3-36 C a m sha ft C lu s te r G ear In s ta lla tio n ................................... 3-33
C y lin d e r H e a d ............................................................................. 3-37 C h e c k in g E n gine C y lin d e rs S e p a ra te ly ............................. 3-15
M easurem ent of Pressure in Inlet M a n ifo ld ..................... 3-35 C h e c k in g Fuel In je c tio n Pum p T im in g
P rec o m b u s tio n C h a m b e r........................................................ 3-36 w ith T im in g P in ....................................................................... 3-22
R e striction of A ir Inlet and E x h a u s t................................... 3-35 C h e c k in g T im in g by The Fuel Flow M e th o d ................... 3-24
V a lves............................................................................................. 3-37 C h e c k in g T im in g by M easuring T im in g D im ension
Valve G u id e s ............................................................................... 3-37 (D epth M ic ro m e te r).............................................................. 3-22
Valve Lash A d ju s tm e n t and C h e c k ..................................... 3-38 C h e c k in g T im in g by M easuring T im in g D im ension
Valve Seat In s e rts ...................................................................... 3-37 (Dial In d ic a to r ) ....................................................................... 3-23
W ater D ir e c to r s .......................................................................... 3-36 L o c a tin g T o p C e nte r C o m p re s s io n P osition
For No. 1 P is to n ..................................................................... 3-21
Basic B lock ..................................................................................... 3-46 Fuel In je c tio n S e rv ic e .............................................................. 3-19
C h e c k in g C ra n ksh a ft D e fle c tio n ( B e n d )........................... 3-50 Fuel Nozzle Test S e q u e n c e .................................................... 3-17
C o n n e c tin g Rod and M ain B earings ................................. 3-46 Fuel Rack A d ju s tm e n t.............................................................. 3-29
C o n n e c tin g Rods and P is to n s ............................................. 3-46 Fuel System Insp e ctio n .......................................................... 3-15
C y lin d e r B lo ck .......................................................................... 3-46 G o v e rn o r A d ju s tm e n ts ............................................................ 3-31
C y lin d e r Liner P ro je c tio n ........................................................ 3-47 M easuring Engine S p e e d ........................................................ 3-32
Flyw heel and Flyw heel H o u s in g ......................................... 3-47 S e tting Fuel In je c tio n Pum p T im in g D im ension :
Piston R ing G roove G a u g e .................................................... 3-46 O ff Engine ............................................................................... 3-27
V ibra tio n D a m p e r...................................................................... 3-51 S tart Up P r o c e d u re .................................................................. 3-20
Testin g C a psule -T yp e Fuel In je c tio n Nozzles
C o o lin g System ............................................................................. 3-43 For PC E n g in e s ....................................................................... 3-15
T esting The C o o lin g System ................................................ 3-43 T im in g B a lance r G ear in A c c e s s o ry Drive
Visual Insp e ctio n of the C o o lin g S y s te m ......................... 3-43 (V -8 O n ly ) ................................................................................. 3-33
T im in g C a m sha ft fo r Fuel In je c tio n P u m p s ..................... 3-26
E lectrical S y s te m .......................................................................... 3-52
B a tte ry ........................................................................................... 3-52 L u b ric a tio n S y s te m ....................................................................... 3-40
C h a r g i n g S y s te m ...................................................................... 3-52 M easuring Engine O il P re s s u re ............................................ 3-40
Prelube S y s te m ........................................................................... 3-54 O il Pressure is H igh ................................................................ 3-42
S ta rtin g System ........................................................................ 3-53 O il Pressure is L o w .................................................................. 3-41
T o o M uch B earing W e a r ........................................................ 3-42
Engine S h u to ff C o n tro l .............................................................. 3-56
T o o M uch O il C o n s u m p tio n .................................................. 3-40
O verspeed C o n tro l A d ju s tm e n t............................................ 3-56
T u rb o c h a rg e r L u b ric a tio n V a lv e ......................................... 3-42
T ro u b le s h o o tin g ............................................................................. 3-2

TROUBLESHOOTING TESTING AND ADJUSTING
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.
Th i s list of p r o b l e m s , caus es , a n d c o r r e c t i o n s , will on l y give a n i n d i c a t i o n of

wh e r e a poss i bl e p r o b l e m c a n be, a n d w h a t r e p a i r s a r e ne e de d . N o r m a l l y , m o r e
or o t h e r r e pa i r w o r k is ne e d e d b e y o n d t h e r e c o m m e n d a t i o n s in t he list.
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
Item Problem Item Problem
1. E n g i n e Will N o t T u r n W h e n S t a r t S wi t c h Is 16. Oil at t h e E x h a u s t .

On. 17. Tit tl e o r N o Val ve C l e a r a n c e .
2. En g i n e Will No t St ar t. 18. E n g i n e H a s Ea r l y We a r .
3. Mi s f i r i ng or R u n n i n g R o u g h . 19. C o o l a n t In L u b r i c a t i o n Oil.
4. Stall at l o w r p m. 20. T o o M u c h Bl ack o r G r a y S m o k e .
5. S u d d e n C h a n g e s In E n g i n e r pm. 21. T o o M u c h Wh i t e or Bl ue S m o k e .
6. No t E n o u g h Powe r . 22. E n g i n e Ha s L o w Oil Pr e ss ur e.
7. T o o M u c h Vi b r at i on. 23. E n g i n e Uses T o o M u c h L u b r i c a t i o n Oil.
8. l . o u d C o m b u s t i o n Noise. 24. E n g i n e C o o l a n t Is T o o Hot .
9. Valve T r a i n Noi s e ( Cl i cki ng). 25. Starting M o t o r Does No t Turn.
10. Oil In C o o l i n g Syst em. 26. A l t e r n a t o r Gi ves N o Ch a r g e .
11. Me c h a n i c a l Noi s e ( K n o c k ) In Engi ne. 27. A l t e r n a t o r C h a r g e R a t e Is Low' or N o t R e g u
12. Fuel C o n s u m p t i o n T o o Hi gh. lar.
13. I . ou d Val ve T r a i n Noi se. 28. A l t e r n a t o r C h a r g e T o o Hi gh.
14. T o o M u c h Val ve Lash. 29. A l t e r n a t o r H a s Noi se.
15. Val ve Ro t o c o i l or S p r i n g L o c k is Free. 30. E x h a u s t T e m p e r a t u r e T o o Hi gh.
3-2
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
Starting M o to r Solenoid M a k e Re f e r e n c e t o I t e m 25.

H a s A 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
Oil P r e s s u r e S wi t c h F o r M a k e a r e p l a c e m e n t of def ect i ve swit ch.

P r e l u b r i c a t i o n P u m p H a s A Def e c t
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
I nsi de P r o b l e m Pr e v e n t s If t he c r a n k s h a f t c a n not be t u r n e d a f t er d i s c o n n e c t i n g t he dr i ven

Eng i n e C r a n k s h a f t F r o m e q u i p m e n t , r e m o v e t he fuel nozzl es a n d check f or fl uid in t he
Turning cyl i nder s whi l e t u r n i n g t h e c r a n k s h a f t . If fl uid in t h e cyl i nder s is
n o t t h e p r o b l e m , t h e en g i n e m u s t be d i s a s s e m b l e d t o ch e c k f or
o t h e r i nsi de p r o b l e m s . S o m e o f t hes e i nsi de p r o b l e m s ar e b e a r i n g
seizure, p i s t o n sei zure, w r o n g pi s t o n s i nst al l ed in t he engi ne.
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.
Di r t v F u e l Fi lt er Inst al l n e w fuel filter.
Di r t v or B r o k e n F u e l Lines Cl e a n o r i nst al l n e w fuel lines as neces sary.
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.
N o F u e l T o Cyl i nder s P u t fuel in fuel t a n k . “ P r i m e ” ( r e m o v e t he ai r a n d or l ow qual i t y

fuel f r o m t he fuel syst em) .
Ba d Qu a l i t y Fuel R e m o v e t h e fuel f r o m t he fuel t a n k . Inst all a new' fuel filter

el e me nt . P u t a g o o d g r a d e o f cl ean fuel in t h e fuel t ank.
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
3 M ISFIRING OR RUNNING ROUGH
Cause Correction
F uel P r e s s ur e is Lo w Make sur e t h e r e is fuel in t he fuel t a n k . L.ook l o r l eaks or b a d b e n d s

in t he fuel line b e t we e n fuel t a n k a n d fuel t r a n s f e r p u m p . L o o k for
ai r in t he fuel s y s t e m, st i cki ng, b i n d i n g or def ect i ve fuel c o n t r o l
valve. C h e c k fuel pr ess ur e. T h e out l et p r e s s u r e o f t h e fuel t r a n s f e r
pump mu s t be a m i n i m u m of 20 psi ( 140 k P a ) at full l oad speed.
If fuel p r e s s u r e is l owe r t h a n t h e a b o v e p r es s u r e, install a n e w filter

el e me nt . If fuel p r e s s u r e is still low. ch e c k t he fuel t r a n s f e r p u m p .
Ai r in Fuel S y s t e m F i n d t h e ai r l eak in t h e fuel s y s t e m a n d cor r e c t it. If ai r is in t he

fuel s y s t e m it will gen er al l y get in o n t he s u c t i o n side of t he fuel
transfer pump.
L e a k or Br e a k in Fuel Lane I nstal l a n e w fuel line.

Be t ween I nj ect i on P u m p
a n d I nj ect i on Val ve
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 .
Def ect in Fuel I nj ect i on R u n en g i n e at r p m t h a t gives m a x i m u m mi sf i r i ng or r o u g h

Val ve(s) or I nj ect i on r u n n i n g . T h e n l o o s e n a fuel line n u t o n t h e i nj ect i on val ve f or each
Pump(s) cyl i nder , o n e at a t ime. F i n d t he c yl i nder w h e r e l oo s e n i n g t he fuel
line n u t d o e s n o t c h a n g e t h e wa y t h e engi ne runs. Test t he
i nj ect i on p u m p a n d i nj ect i on val ve for t h a t cyl i nder . Instal l new'
p a r t s w h e r e n eeded.
W r o n g Fuel Inj ect i on M a k e a d j u s t m e n t t o t i ming.

Timi ng
4. STALL AT L O W RPM
Cause Correction
Fuel P r e s s ur e is Low Make s u r e t h e r e is fuel in t h e fuel t a n k . L o o k f or l eaks o r b a d b e n d s

in t h e fuel line b e t we e n fuel t a n k a n d fuel t r a n s f e r p u m p . L o o k f or
ai r in t h e fuel s ys t e m, st i cki ng, b i n d i n g or def ect i ve fuel c o n t r o l
valve. C h e c k fuel pr es s ur e. T h e o ut l e t p r e s s u r e o f t h e fuel t r a n s f e r
pum p m u s t be a m i n i m u m o f 20 psi (140 k P a ) at full l oad speed.
If fuel p r e s s u r e is l o w e r t h a n t h e a b o v e p r es s ur e, i nstall a new' fuel

f i l t er e l e m e n t . If f ue l p r e s s u r e is still low', c h e c k t h e fuel
transfer pump.
Idle r p m T o o L o w M a k e a d j u s t m e n t t o g o v e r n o r so idle r p m is t he s a m e as gi ven in

t he R A C K S E T T I N G I N F O R M A T I O N .
( Co n t . nex t page)
3-4
4. S T A L L A T L O W R P M ( Co n t . )
Cause Correction
Def ect in Fuel I nj ect i on R u n e n g i n e at r p m t h a t gives m a x i m u m mi st i r i ng or r o u g h

Val ve(s) or Fu el I nj ect i on r u n n i n g . T h e n l o os e n a fuel line nut on t he i nj ect i on p u m p l or
Pump(s) e a c h cyl i nder , o n e at a t ime. F i n d t he c y l i nder w h e r e l oo s e n i n g the
fuel line n u t do e s n o t c h a n g e t he wa y t h e engi ne runs. l es t t he
i nj ect i on p u m p a n d i nj ect i on val ve for t h a t cyl i nder . Inst al l new
pa r t s w h e r e needed.
E n gi ne Accessor i es C h e c k e n g i n e acce ss or i es f or d a m a g e a n d cor r e c t a d j u s t m e n t . II

neces s a r y, d i s c o n n e c t t he acce ss or i es a n d test t he engi ne.
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
F a i l u r e o f G o v e r n o r o r Fuel L o o k f o r d a m a g e d o r b r o k e n spr i ngs, l i n ka ge or o t h e r parts.

I nj ect i on P u m p R e m o v e t h e g o v e r n o r . C h e c k for free t ravel of t he fuel rack. Be
s ur e fuel i nj ect i on p u m p s a r e i nst al l ed cor rect l y. C h e c k f or cor r ect
g o v e r n o r spr i ng. Inst al l new pa r t s f or t h o s e t h a t h ave d a m a g e or
defects.
6. NOT ENOUGH POWER
Cause Correction
Ba d Qu a l i t y Fuel R e m o v e t he fuel f r o m t h e fuel t a n k . Inst al l a new fuel filter

el e me nt . P u t a g o o d g r a d e of c l ean fuel in t he fuel t ank.
Fuel P r e s s u r e is L o w Make s u r e t h e r e is fuel in t he fuel t a n k . L o o k f or l eaks o r b a d b ends

in t he f uel line b e t we e n fuel t a n k a n d fuel t r a n s f e r p u m p . L o o k f or
ai r in t h e fuel sys t em, st i cki ng, b i n d i n g or def ect i ve fuel c o n t r o l
valve. C h e c k fuel pr ess ur e. T h e o ut l e t p r e s s u r e o f t h e fuel t r a n s f e r
pump m u s t be a m i n i m u m o f 20 psi ( 140 k P a ) at full l oad speed.
If fuel p r e s s u r e is l o w e r t h a n t h e a b o v e p r es s ur e, install a new fuel

filter e l ement . If fuel p r e s s u r e is still l ow. check t he fuel t r ans f er
pump.
L e a ks in Ai r Inlet S y s t e m C h e c k t h e pr e s s u r e in t he ai r i n t a k e m a n i f o l d , . ook for restric-

t i ons in t h e ai r cl eaner .
G o v e r n o r Linkage M a k e a d j u s t m e n t t o get full t r avel of l i nkage. Instal l new p ar t s o

t h o s e t h a t h a v e d a m a g e o r defect s.
W r o n g Val ve Cl 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 Speci f i cat i ons.
( C o n t . n ex t pa ge)
3-5
6. N O T E N O U G H P O W E R ( Co n t . )
Cause Correction
Def ect in Fuel I nj ect i on R u n e n g i n e at r p m t h a t gives m a x i m u m mi sf i r i ng or r o u g h

Valve(s) o r Fuel I nj ect i on r u n n i n g . T h e n l o o s e n a fuel line n u t o n t he i nj ect i on p u m p for
P u mp ( s ) e ach cyl i nder , o n e at a t i me. F i n d t h e cyl i nder w h e r e l o o s e n i n g t he
fuel line n u t d o e s n o t c h a n g e t he w a y t h e engi ne runs. Test t he
i nj ect i on p u m p a n d i nj ect i on val ve f or t h a t cyl i nder . Inst all new
p a r t s w h e r e ne e d e d .
W r o n g Fuel 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
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.
T u r b o c h a r g e r has C a r b o n Ins pect a n d r e p a i r t u r b o c h a r g e r as necessary.

De p os i t
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
En g i n e S u p p o r t s Ar e Loose. T i g h t e n all m o u n t i n g bolt s. I nst al l ne w c o m p o n e n t s if necessary.

W o r n , or H a v e A Def ect
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
Fl exi bl e C o u p l i n g Be t we e n Re p ai r or replace coupl ing c om po ne nt s .

E n g i n e a n d Dr i v e n E q u i p m e n t
H a s A Def ect
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
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
Ba d Qu a l i t y Fuel R e m o v e t h e fuel f r o m t he fuel t a n k . I nst al l a n e w fuel filter

e l e me nt . P u t a g o o d g r a d e of cl ean fuel in t he fuel t a nk.
Def ect in Fuel I nj ect i on R u n e n g i n e at r p m t h a t gives m a x i m u m mi sf i r i ng o r r o u g h

Val ve(s) o r Fuel I nj ect i on r u n n i n g . T h e n l o o s e n a fuel line n u t o n t he i nj ect i on p u m p f or
Pump(s) e a c h cyl i nd er , o n e at a t i me. F i n d t h e c yl i nder w h e r e l oo s e n i n g t he
fuel line n u t do e s n o t c h a n g e t h e w a y t h e en g i n e r uns. Test t he
i nj ect i on p u m p a n d i nj ect i on val ve f or t h a t cyl i nder . Inst al l new
p a r t s w h e r e n eeded.
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
B r o k e n Val ve Spr i ng( s ) or I nst al l n e w p a r t s w h e r e neces sa r y. B r o k e n l ocks c a n caus e t he

Locks val ve t o slide i nt o t h e cyl i nder . T h i s will ca us e m u c h d a m a g e .
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
Failure of Bearing F o r I ns pe c t t h e b e a r i n g f o r t he c o n n e c t i n g r o d a n d t he b e a r i n g sur f ace

Connecting Rod ( j o u r n a l ) o n t h e c r a n k s h a f t . I nst al l ne w p a r t s w h e r e necessary.
( C o n t . n e x t pag e)
3-7
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
D a m a g e d T i m i n g Ge a r s Inst al l new p a r t s w h e r e necessary.
Def ect in A t t a c h m e n t R e p a i r or i nstall n e w c o m p o n e n t s .
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 S y s t e m Leak s R e p l a c e m e n t o f p a r t s is n e e d e d at p o i n t s of leakage.
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 )

T i mi n g
13. L O U D V A L V E T R A I N N O I S E
Cause Correction
B r o k e n Val ve Spr i ng( s) M a k e r e p l a c e m e n t of p ar t s wi t h d a m a g e .
Broken Ca ms haf t M a k e r e p l a c e m e n t of pa r t s wi t h d a m a g e . C l e a n e ngi ne t h o r o u g h l y
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.
R o c k e r A r m W o r n at Lace If t he r e is t o o m u c h we a r , inst all ne w p a r t s o r r o c k e r a r ms . M a k e

T h a t C o n t a c t s E n d of Valve a d j u s t m e n t o f val ve 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 us t i ng .
E nd of Val ve S t e m W o r n If t h e r e is t o o m u c h wear , inst al l ne w valves. M a k e a d j u s t m e n t to

val ve 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 .
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 .
Valve Lifters W o r n If t h e r e is t o o m u c h we a r , i nstall n e w val ve lifters. M a k e a d j u s t m e n t

o f val ve 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
14. L O O M U C H V A L V E L A S H ( Co n t . )
Cause Correction
B r o k e n or W o r n Val ve Instal l n e w val ve lifters. C h e c k c a m s h a f t f or wear . C h e c k f or free

Lifters m o v e m e n t o f val ves or b e nt val ve s t em. C l e a n engi ne t h o r o u g h l y .
M a k e a d j u s t m e n t o f val ve c l e a r a n c e a c c o r d i n g t o Te s t i n g a n d
Ad j u s t i n g .
W o r n C a m s on C a m s h a f t C h e c k va l v e c l ear ance. C h e c k f o r free m o v e m e n t of val ves or bent

val ve st e ms . Inst al l a new c a m s h a i t . M a k e a d j u s t m e n t ol val ve
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 .
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
B r o k e n L ocks B r o k e n l ocks c a n c a u s e t he val ve t o slide i nt o t he cyl i nder. Thi s

will c a u s e m u c h d a m a g e .
B r o k e n Val ve Spr i ng( s) Inst all n e w val ve spring(s).
B r o k e n Val ve R e p l a c e val ve a n d o t h e r d a m a g e d parts.
16. O I L A T T H E E X H A U S T
Cause Correction
T o o M u c h Oil in t he Val ve L o o k a t b o t h e n d s o f t he r o c k e r a r m shaft . Be sur e t h a t t he r e is a

C ompartment pl u g in e a c h end.
W o r n Val ve Gu i d e s R e c o n d i t i o n i n g o f t he c yl i n der h e a d is needed.
W o r n P i s t o n Ri ngs I ns pe c t a n d i nst al l n e w pa r t s as need ed.
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
W o r n Val ve S e a t o r F a c e of R e c o n d i t i o n i n g o f cyl i nder h e a d is n e e de d. M a k e a d j u s t m e n t of

Valve val ve 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 .
18. E N G I N E H A S E A R L Y W E A R
Cause Correction
Di r t in L u b r i c a t i n g Oil R e m o v e di r t y l u b r i c a t i o n oil. Instal l a new oil filter el ement . Put

cl ean oil in t he engi ne. C h e c k oil filter b yp a s s val ve f or a w'eak or
b r o k e n spr i ng.
( C o n t . next page)
3-9
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
Ai r Inlet Leaks I ns pe c t all g a s k e t s a n d c o n n e c t i o n s . M a k e r epai r s if l eaks are

found.
Fu e l L e a k a g e I n t o T h i s will ca us e hi g h fuel c o n s u m p t i o n a n d l ow en g i n e oil pr ess ure.

L u b r i c a t i o n Oil M a k e r e pa i r s if l e a ks a r e f o u n d . Inst al l ne w p a r t s w h e r e needed.
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
Fa i l u r e o f Oil C o o l e r C o r e I nst al l a n e w c o r e f or t h e oil cool er . D r a i n c r a n k c a s e a n d refill

wi t h c l e a n l ub r i c a n t . Inst al l n e w oil filter el ement .
F a i l u r e o f Cy l i n d e r H e a d C h e c k c y l i nde r l i ner pr o j e c t i o n . I nst al l a n e w c yl i nd er h ead gasket .

Ga s k e t T i g h t e n t h e bol t s h o l d i n g t he c y l i n d e r h e a d , a c c o r d i n g t o the
Speci f i cat i ons.
C r a c k or Def ect in Cy l i n d e r Inst al l a n e w c y l i nd e r head.

Head
Cr a c k or Def ect in Cy l i n d e r Inst al l a ne w c y l i n d e r bl ock.

Block
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
Bad Fuel I nj ect i on Valve(s) Test fuel i nj e c t i on val ves. R e p l a c e b a d valves.
W r o n g Fuel I nj ect i on M a k e a d j u s t m e n t s t o t i mi ng.

Timi ng
Def ect in F u e l R a t i o M a k e a n a d j u s t m e n t t o c o n t r o l . C h e c k f or b r o k e n springs.

Control R e p l a c e if n e e de d.
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
T o o M u c h L u b r i c a t i o n Oil R e m o v e e x t r a oil. F i n d w h e r e e x t r a oil c o m e s f r o m. Put cor r e ct

in En g i n e a m o u n t o f oil in engi ne. D o n o t p u t t o o m u c h oil in engi ne.
( C o n t . nex t page)
3-10
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.
T imi ng
W o r n Val ve Gu i d e s R e c o n d i t i o n i n g of c y l i nder h e a d is n eeded.
W o r n P i s t on Ri ngs Inst al l n e w p i s t o n rings.
F a i l u r e of T u r b o c h a r g e r Oil C h e c k inl et m a n i f o l d f or oil a n d r e p a i r t u r b o c h a r g e r if necessary.

Seal
22. E NGIN E HAS LOW OIL P R E S S U R E
Cause Correction
Di r t v Oil Fi l t er or Oil C h e c k t h e o p e r a t i o n of b y p a s s val ve f o r t he filter. Inst al l new' oil

Cooler filter e l e m e n t s if n e e d e d . C l e a n o r inst al l n e w oil c o o l e r core.
R e m o v e di r t y oil f r o m engi ne. P u t cl ean oil in engi ne.
Di esel Fuel in L u b r i c a t i o n F i n d t h e pl ace w h e r e diesel fuel gets i nt o t he l ub r i c a t i o n oil. M a k e

Oil r e pa i r s as ne e de d. R e m o v e t h e l u b r i c a t i o n oil t h a t has diesel fuel in
it. I nst al l a n e w oil filter el ement . P u t cl ean oil in t he engi ne.
Too Much Clearance 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 . Inst all n e w par t s as

Be t ween R o c k e r A r m S h a f t neces sary.
and Roc ker Ar ms
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
Pr e s s u r e Re g u l a t i n g Val ve C l e a n val ve a n d h o u s i ng. Inst al l new p a r t s as necessary.

D o e s N o t Cl os e
Oil P u m p Ha s A Def ect R e p a i r o r r e pl a c e oil p u m p .
T o o M u c h Cl e a r a n c e C h e c k t h e oil filter f or c o r r e c t o p e r a t i o n . Inst al l n e w par t s if

Be t we e n C r a n k s h a f t a n d neces sary.
C r a n k s h a f t Bear i ngs
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
Def ect in Oil Pr e s s u r e Inst al l n e w gauge.

Gauge
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
T o o M u c h L u b r i c a t i n g Oil R e m o v e e x t r a oil. F i n d w h e r e e x t r a oil c o m e s f r om. Put cor r ect

in E ng i n e a m o u n t o f oil in engi ne. D o n o t pu t t o o m u c h oil in engi ne.
Oil Leaks F i n d all oil l eaks. M a k e r e pa i r s as n e e de d. C h e c k t o r di r t y oil

breather.
Oil T e m p e r a t u r e is T o o C h e c k o p e r a t i o n o f oil c ool er . I nst al l ne w p a r t s if necessary. Cl e a n

Hi gh t he c o r e of t he oil cool er .
T o o M u c h Oil in t he Val ve L o o k at b o t h e n d s o f t he r o c k e r a r m shaft. Be sur e t ha t t h er e is a

C ompartment pl ug in e a c h end.
W o r n Val ve Gui de s R e c o n d i t i o n i n g o f t h e c y l i nder h e a d is needed.
W o r n P i s t on Ri ngs I ns pect a n d instal l n e w p a r t s as needed.
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.
No t E n o u g h C o o l a n t in A d d c o o l a n t t o c o o l i n g sys t em. C h e c k f or leaks.

System
Pr e s s u r e Reli ef Valve Ha s A C h e c k o p e r a t i o n o f p r e s s u r e relief valve. Inst al l a new pr es s ur e

Defect r elief v al ve if neces sar y.
C o m b u s t i o n Ga s e s in F i n d o u t w h e r e gas es get i nt o t he c o o l i n g sys t em. M a k e r epai r s as

Coolant needed.
W' ater T e m p e r a t u r e C h e c k w a t e r t e m p e r a t u r e r e g u l a t o r s f o r cor r e c t o p e r a t i o n . C h e c k

R e g u l a t o r s ( Th e r m o s t a t s ) or t e m p e r a t u r e g a u g e o p e r a t i o n . Inst all n e w p a r t s as necessary.
T e m p e r a t u r e G a u g e Ha s A
Defect
W a t e r P u m p H a s A Def ect M a k e r e pa i r s t o t h e w a t e r p u m p as neces sary.
T o o M u c h Toad On The M a k e a r e d u c t i o n t o t he l oad.

System

Timi ng
3-12
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.
Wi r i n g or S wi t c h Ha s Det ect M a k e r e p a i r s o r r e p l a c e m e n t as necessary.
S tarting M o t o r Solenoid Inst al l a n e w sol e noi d.

H a s A Defect
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
L o os e Dr i ve Belt F o r M a k e a n a d j u s t m e n t to put t he cor r e ct t e ns i on on t he dr i ve belt.

Al ter nat or
C h a r g i n g or G r o u n d R e t u r n I n s p e c t all c a b l e s a n d c o n n e c t i o n s . C l e a n a n d tighten till

Ci r cui t o r Bat t er y c o n n e c t i o n s . M a k e r e p l a c e m e n t of p ar t s wi t h detect.
C o n n e c t i o n s Ha v e A Defect
Br us he s H a v e A Def ect Inst all ne w br ushes .
R o t o r ( Fi eld Coi l ) Ha s A Instal l a ne w r ot or .

Defect
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
L o os e Dr i ve Belt F o r M a k e a n a d j u s t m e n t t o put t he cor r e c t t e n s i o n on t he dr ive belt.

Al ter nat or
C h a r g i n g or G r o u n d R e t u r n I ns pe c t all cabl es a n d c o n n e c t i o n s . C l e a n a n d t i g h t e n all c o n n e c

Ci r cui t or Bat t er s t i ons. M a k e r e p l a c e m e n t of p a r t s wi t h defects.
C o n n e c t i o n s H a v e A Def ect
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
A l t e r n a t o r Br ushe s H a v e A I nst al l new br us hes .

Def ect
Recti f i er D i o d e s H a v e A M a k e r e p l a c e m e n t of rect ifi er d i o d e t h a t ha s a delect.

Def ect
R o t o r ( Fi el d Coi l) Ha s A I nst all a n e w r ot or .

Def ect
3-13
28. A L TE R N A T O R C H A R G E TOO HIGH
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
29. A L T E R N A T O R HAS NOISE
Cause Correction
Dr i v e Belt L o r A l t e r n a t o r is Inst all a n e w dr i v e belt f or t h e a l t e r n a t o r .

W o r n or H a s A Def ect
Lo o s e A l t e r n a t o r Dr i ve C h e c k g r o o v e in pul l ey f o r key t h a t h ol ds pul l ey in place. If

Pul l ev g r o o v e is w'orn, inst al l a new' pulley. T i g h t e n pul ley n u t a c c o r d i n g
t o Speci f i cat i on s .
Dr i ve Belt a n d Dr i ve Pull ey M a k e a n a d j u s t m e n t t o p u t dr i ve belt a n d dr i ve pul l ey in cor r ect

F o r A l t e r n a t o r Ar e No t in a l i g n me n t .
Al i g n me n t
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
Ai r Inlet S y s t e m Ha s A C h e c k p r e s s u r e in t h e ai r i n t a k e m a n i f o l d . L o o k f o r r est r i ct i ons at

leak t he ai r cl eaner . C o r r e c t a n y leaks.
E x h a u s t S y s t e m Ha s A Leak F i n d c a u s e of e x h a u s t l eak. M a k e r e p a i r s as necessary.
Ai r Inlet or E x h a u s t S y s t e m R e m o v e r est r i ct i on.

H a s A Re s t r i c t i on
W r o n g Fuel I nj ect i on M a k e a n a d j u s t m e n t t o t h e t i mi ng.

T imi nu
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:
1. C h e c k t he fuel level in t h e fuel t a n k . L o o k a t t he 1. C a r b o n o n tip o f t he nozzl e or in t he nozzl e

ca p for t h e fuel t a n k t o m a k e s ur e t h e v e n t is n o t orifice.
filled wi t h dirt.
2. Or i fi ce wear .
2. C h e c k t he fuel lines f or fuel l eakage. Be s ur e t h e
fuel s u p p l y line does not h a v e a r est r i ct i on or a 3. Di r t y nozzl e screen.
b a d bend.
3. I nst al l a ne w fuel filter. C l e a n t h e p r i m a r y fuel TESTING CAPSULE-TYPE FUEL INJECTION

filter if so e q u i p p e d . NOZZLES FOR PC ENGINES
Tools Needed:
4. R e m o v e a n y a i r t h a t m a y be in t h e fuel sys t em. 5P4150 Nozzle Testing Group
If t he r e is ai r in t he fuel sys t em, use t h e p r i m i n g 5P4720 Fitting
p u m p a n d l o os e n t h e nut s h o l d i n g t h e fuel l ines 5P8744 Adapter or
5P4717 Adapter
t o t h e ou t s i d e o f t he c yl i nder h e a d , o n e at a t i me.
8S2270 Fuel Collector
D o this unt i l fuel, w i t h o u t air. c o m e s f r o m t h e FT1384 Extension
fuel line c o n n e c t i o n .
5. I ns pect t h e fuel c o n t r o l val ve to see t h a t t h e r e is

n o r est r i ct i on t o g o o d o p e r a t i o n .
CAUTION
Be sure to use clean SAE J967 Calibration Oil
CHECKING ENGINE CYLINDERS when testing. Dirty test oil will damage compo
SEPARATELY nents of the fuel injection nozzle. The tempera
ture of the test oil must be 65° to 75° F (18° to
A n eas y ch e c k c a n be m a d e t o f i nd t he c yl i nder 24° C) for good test results.
3 - 15
FUEL SYSTEM TESTING AND ADJUSTING
O r d e r ca l i b r a t i o n oil by pa r t n u m b e r , in t he T h e test p r o c e d u r e s t h a t f ol l ow will give a n

q u a nt i t i e s needed, a c c o r d i n g t o t he i n f o r m a t i o n t h a t i n d i c a t i o n o f nozzl e c o n d i t i o n . A nozzl e t h a t ha s a
follows: def ect is n o t a l w a y s t he onl y caus e f o r a specific
en g i n e p r o b l e m.
Kent-Moore Corp.
1501 South Jackson St.
Jackson. Ml 49203
Order:
J-26400-5 [5 gal. (18.9 litre)]
J-26400-15 [15 gal. (56.7 litre)]
A WARNING
J-26400-30 [30 gal. (113.5 litre)]
J-26400-55 [55 gal. (208.2 litre)] When fuel injection nozzles are tested, be sure
to wear eye protection. Fuel comes from the
Viscosity Oil Company
orifices in the nozzle tip with high pressure.
3200 South Western Ave. The fuel can pierce (go thru) the skin and cause
Chicago. IL 60608 serious injury to the operator. Keep the tip of
Order:
Viscor Calibration Fluid
the nozzle pointed away from the operator and
1487C-SAE J-967C into the 8S2270 Fuel Collector and FT1384
Available in 30 gal. (113.5 litre) or Extension.
55 gal. (208.2 litre) drums.
Nozzle Tester Preparation
5P4150 NO ZZLE T E S TIN G G RO UP

A. 5P4721 Tube. B. 5P4146 Gauge, 0 to 1000 psi (0 to
ILLU S TR A TIO N I
6900 kPa) used to test PC capsule valves. C. 2P2324
Gauge. 0 to 5000 psi (0 to 34 500 kPa) used to test Dl 1. Test nozzle (welded orifice). 2. Bottom part of 5P8744
capsule valves and pencil-type nozzles. D, G auge pro Adapter (J). J. 5P8744 Adapter. M. FT1384 Extension.
tector valve for 5P4146 Gauge (B). E. G auge protector N. 8S2270 Fuel Collector.
valve for 2P2324 Gauge (C). F. On-off valve. G. Pump
isolator valve. H. 5P4720 Fitting. J. 5P8744 Adapter for
capsule nozzles. K. 5P4244 A dapter for pen cil-typ e
F i n d a n old c a p s u l e t ype fuel n ozzl e a n d wel d t he
nozzles. ori fice closed. Ke e p t hi s fuel nozzl e wit h t he t ester
g r o u p f or use in t he f ut ur e.
NOTE: D o n o t wel d t h e fuel nozzl es t h a t ar e t o be

tested.
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 .
1. Instal l t h e t o p p a r t o f a d a p t e r (J) t ha t hol ds the

c a p s u l e valve.
EXTRA VALVE 2. P u t test nozzl e ( l ) ( wi t h we l d e d orifice) in t he

L. Gauge protector valve (must be In open position at all b o t t o m p a r t (2) o f a d a p t e r (J) t h a t h ol ds t he
times). c a p s u l e valve. Inst all a n d t i g h t e n b o t t o m p a r t
(2) t o t o p p a r t of a d a p t e r (J).
3 - 16
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.
FUEL NOZZLE TEST SEQUENCE
T o test P C c a p s u l e - t y p e fuel nozzl es, use t he

s e q u e n c e t ha t t o l l o w s :
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
5. C h e c k all c o n n e c t i o n s f o r l e a ks . T i g h t e n 1. P u t one o f t he nozzl es t o be test ed in t h e b o t t o m

c o n n e c t i o n s t o s t o p a n y l eaks t h a t a r e f o u n d . par t (2) of a d a p t e r (J). Inst al l a n d t i g h t e n
b o t t o m p a r t (2) t o t o p pa r t o f a d a p t e r (J).
6. O p e n o n - o f f val ve ( F) a n d r e m o v e test ( we l de d)
fuel nozzle. 2. Cl os e o n - o f f val ve (F). O p e n g a u g e p r o t e c t o r
val ve ( D) o n e - h a l f t u r n . O p e n p u m p i s ol a t or
valve ( G) o n e - h a l f t ur n.
A WARNING
Do not loosen the bottom half of the adapter

to remove fuel nozzle until on-off valve is
opened and no pressure is read on the gauge.
Unless the high pressure is released in the
pump, the fuel discharge from the adapter can
cause injury to the operator.
N O T E : T o pr e ve nt fuel l eakage, t h e t o p sur f a c e o f

t he test ( wel ded) nozzl e, a n d all o t h e r nozzl es t h a t
ar e t o be tested, m u s t be free of s c r a t c h e s o r b u r r s AIR REMO VAL FROM TESTER
( s h a r p edges). 2. Bottom part of adapter (J). J. 5P8744 Adapter.
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
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.
c. Tighten b o t t o m pa r t (2) o f a d a p t e r (J).
\ O I I : The 5 P 8 7 4 4 A d a p t e r m a k e s its o w n seal,

a n d n o r ma l l y needs ver y little f orce w h e n t u r n e d on
b o t t o m pa r t (2) of t he a d a p t e r .
II. Pressure Loss Test 0 1000

PSI A 75076X1
1. O p e n g a u g e p r o t e c t o r v a l v e ( D ) a n e x t r a
PRESSURE LOSS RANG E FOR G O O D N O ZZL E
a m o u n t of o n e - h a l f t u r n ( t he t ot al a m o u n t is
now one t u r n open) .
III. Valve Opening Pressure Test (VOP)
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.
2. O p e r a t e p u m p t o incr ease p r e s s u r e slowly t o

TESTER N O M E N C LA TU R E
300 psi ( 2050 k P a ) . a n d cl ose p u m p i s ol a t or
val ve (G). N o w t u r n g a u g e p r o t e c t o r val ve ( D) B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). D. Gauge
protector valve. F. O n-off valve. G. Pump Isolator valve.
t o adj us t pr es s ur e a g a i n t o 300 psi (2050 k P a ) .
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.
4. T h e val ve m u s t n ot lose m o r e t h a n 200 psi ( 1380

kPa) .
5. If t he pr es s ur e loss is not in t he 200 psi (1380

k P a ) r a n g e as s h o w n , s t o p t he test s e quence. Do
not use the fuel nozzle again. 0 1000
PSI A75074X1
6. If nozzl e is in spe ci f i cat i on r ange, see V A L V E VALVE O PEN IN G PRESSURE (V O P ) RANGE

O P E N I N G P R E S S U R E T E S T (VOP).
3- 18
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.
FUEL INJECTION SERVICE
Injection Valve (Capsule-Type Nozzle)
If a fuel i nj ect i on nozzl e has b e e n r e m o v e d f r o m

t he p r e c o m b u s t i o n c h a m b e r , test t h e nozzl e bef or e it
is a g a i n i nstal l ed in t he p r e c o m b u s t i o n c h a m b e r .
R E M O V IN G FUEL IN JE C T IO N PU M P
S ee T E S T I N G C A P S U L E - T Y P E F U E L I N J E C
TION NOZZLES FOR PC ENGINES. 1. Cover. 2. Plug. 3. Plug. 4. Seal.
Bef or e i nst al l at i on o f a fuel i nj ect i on valve,

i nspect t he val ve a n d p r e c o m b u s t i o n c h a m b e r f o r 3. Sli de t he end o f t he p l u n g e r out o f t he y o k e in
di r t or d a m a g e o n t he s ur f aces t h a t go t oge t h e r . t he lifter a n d lift out t he pl unger . Be s ur e t he
p l u n g e r is i nst all ed in t he bar r el f r o m wh i c h it
It is i m p o r t a n t t o keep t he c or r e ct t o r q u e o n t h e wa s r e mo v e d .
n u t t h a t h o l d s t he fuel nozzl e in t h e p r e c o m b u s t i o n
c h a m b e r . T i g h t e n t h e fuel i nj ect i on val ve o n t h e
Be car ef ul w h e n i nj ect i on p u m p s a r e d i s a s s e m
b o d y f i nger tight. T i g h t e n t h e n u t t o 105 ± 5 lb.ft.
bled. D o n o t d a m a g e t he sur f a c e o n t he pl unger . T h e
( 142 ± 7 N-m). T h e r e will be d a m a g e t o t h e n ozzl e if
p l u n g e r a n d bar r el f o r e a c h p u m p ar e m a d e as a set.
t he n ut is t o o tight. If t he nut is not t i ght e n o u g h , t h e
D o n o t put t h e p l u n g e r of o n e p u m p in t he bar r e l of
nozzl e can leak.
a n o t h e r p u m p . If o n e p a r t is w o r n, inst all a c o m p l e t e
n e w p u m p a s s e mb l y. Be car ef ul w h e n t he p l u n g e r is
Removal of Injection Pump p u t in t he b o r e of t he barrel.
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)
M inim um length (w orn) 2.9781 in. (75.644 mm)

1. R e m o v e t he fuel i nj ect i on line f r o m t h e p u m p
a n d inst all c o v e r (1) a n d pl u g (3).
2. Lift the p u m p s t r a i ght u p t o cl ear t h e d o w e l pi ns L o o k f o r w e a r at t he t o p p a r t o f t h e pl unger .

a n d t he p u m p pl unger . Inst all seals (4) a n d pl u g C h e c k t he o p e r a t i o n o f t he pl u n g e r a c c o r d i n g t o t he
(2) f or p r o t e c t i o n f r o m dirt. i ns t r u c t i o n s f or t he F u e l I n j e c t i o n Tes t Be nch.
3 - 19
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).
WEAR BETW EEN LIFTER YOKE A N D PLUNG ER

Fig. A illustrates the contact surfaces of a new pump
plunger and a new lifter yoke. In Fig. B the pump plunger
and lifter yoke have worn considerably. Fig. C shows how
the flat end of a new plunger does not make a good contact
with a worn lifter yoke. The result is rapid wear to both
parts.
63572X3
Installation of Injection Pump SEQ U EN C E TO T IG H T E N BO LTS

7. Bolts, tighten second. 8. Bolts, tighten first.
T h e seal u n d e r t he m a c h i n e d sur f ace, a r o u n d t he
large d i a m e t e r of t he p u m p mu s t be in cor r e ct
posi t i on wh e n t he p u m p is i nst al l ed. Al so, t h e r e START UP PROCEDURE
mu s t be a seal a r o u n d t he fuel out l et f er r ul e on t h e
fuel p u m p hous i n g. If ei t her seal is d a m a g e d install Use this p r o c e d u r e w h e n an eng i ne is s t a r t e d for
a new one. t h e first t i me af t er w o r k is d o n e o n t he fuel i nj ect i on
1. R e m o v e t he p u m p p l u n g e r f r o m t h e barrel. p u m p s or g o v e r n o r .
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. T u r n t he p u m p pl unger , until t o o t h (6) wi t h a 2. H a v e a p e r s o n in p o s i t i o n n e a r e ach t u r b o

m a r k is in a l i g n me n t wi t h r ack m a r k (5). c h a r g e r ai r inlet wi t h a pi ece o f steel pl at e lar ge
4. Sl i de the end of t he p l u n g e r i nt o t he y o k e in t he e n o u g h t o c o mp l e t e l y c o v e r t he t u r b o c h a r g e r
lifter. ai r inlet.
5. L o w e r t he p u m p bar r el o n t o t he p l u nge r , t a k i n g 3. If t he en g i n e st ar t s t o r u n t o o fast o r r u n s o u t of
car e t hat t he p u m p p l u n g e r is st r ai ght in t he co n t r o l , i mm e d i a t e l y p ut t he steel pl at es a g a i n s t
barrel. t he t u r b o c h a r g e r a i r inlet. Thi s will s t o p t h e air
s u p p l y to t he en g i n e a n d t h e en g i n e will st op.
IN STA LLIN G FUEL IN JE C T IO N PUM P

5. Mark on rack. 6. Tooth mark. STO P P IN G TH E E N G IN E
3- 20
FUEL SYSTEM
Fuel In je c tio n Lines
Fuel f r o m t he fuel i nj ect i on p u m p s is sent t h r o u g h

t he fuel i nj ect i on lines t o t he fuel i nj ect i on valves.
E a c h fuel i nj ect i on line o f a n e ngi ne h a s a speci al

desi gn a n d m u s t he i nst al l ed in a ce r t a i n l o c a t i o n .
W h e n fuel inj ect i on lines ar e r e m o v e d f r o m a n
engi ne, put i d ent i f i ca t i on m a r k s or t ags o n t h e fuel
lines as t hey ar e r e m o v e d , so t h e y c a n be put in t he
cor r e ct l o c a t i o n w h e n t hey a r e i nst al l ed. T IM IN G MARKS ON FLYW HEEL
(16 Cylinder Engine Illustrated)
T h e nut s t h a t hol d a fuel i nj ect i on line t o a n 1. Pointer.
i nj ect i on val ve a n d i nj ect i on p u m p m u s t be kept
3. R e m o v e t h e s t a r t e r f r o m t he ri ght si de of t he
t ight. Use a t o r q u e w r e n c h a n d a 5 P 1 4 4 S o c k e t t o
engine. Install 5 P7 30 7 or 2 P 8 3 0 0 E n g in e
t i ght en t he fuel line n u t s t o 30 ± 5 lb.ft. (40 ± 7 N- m) .
T u r n i n g T ool .
LOCATING TOP CENTER COMPRESSION N O T E : P u t 5 P 9 0 6 Gr e a s e in b o r e of 5 P 7 3 0 6 o r

POSITION FOR NO. 1 PISTON 2 P 8 2 9 4 h o u s i n g bef or e t he p i n i o n is i nstal led.
Tools Needed:
5P7307 Engine Turning Tool Group or
2P8300 Engine Turning Tool Group
T IM IN G M ARKS ON FLYW HEEL

(8 and 12 Cylinder Engines Illustrated)
1. Pointer.
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.
N O T E : T h e engi ne is seen f r o m t h e fl ywheel e n d 5. 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 o f n o r m a l

w h e n t he d i r e c t i o n of c r a n k s h a f t r o t a t i o n is given. r o t a t i o n unt i l t he t i mi n g m a r k s o n t he f l ywheel
a r e in a l i g n m e n t wi t h t he p o i n t e r in t he f l ywheel
N o r m a l d i r e c t i o n of c r a n k s h a f t r o t a t i o n f o r s t a n
hous i ng.
d a r d engi nes is c o u n t e r c l o c k wi s e , a n d f o r o p p o s i t e
r o t a t i o n engi nes is cl ockwi se.
1. R e m o v e t he val ve c o v e r f o r No . 1 cyl i nder . T h e

t wo val ves at t he f r o n t of t he ri ght b a n k a r e t h e N O T E : If t he c r a n k s h a f t is t u r n e d b e y o n d t he
i n t a k e a n d e x h a u s t val ves f o r No. 1 cyl i nder . t i m i n g m a r k , 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
o p p o s i t e o f n o r m a l r o t a t i o n a m i n i m u m of 30
2. R e m o v e t he t i m i n g m a r k c o v e r f r o m t h e r i ght degr ees bef or e t h e c r a n k s h a f t is t u r n e d t o t he
side of t he fl ywheel h ous i ng. t i mi n g m a r k agai n.
3-21
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)
2. R e m o v e t i m i n g pi n (2) f r o m fuel inlet f l an ge (1)

Tools Needed:
a n d r e m o v e fuel inlet flange.
6F6922 Micrometer Depth Gauge
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)
D379 2.090 ± .002 in.

D398 (53 09 r 0.05 mm)
D399 2.078 ± .002 in.

T IM IN G PIN LO CA TED IN T IM IN G SLOT (52.78 i 0.05 m m)
(Pum p housing removed for better illustration)
2. Tim ing pin. 3. Tim ing slot.
3- 22
FUEL SYSTEM
3. Instal l t he 2 t o 3 in. shaft in t he d e p t h m i c r o

met er . P u t t he d e p t h m i c r o m e t e r o n t h e fuel
i n j e c t i o n 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). See t he c h a r t f or t h e c o r r e c t O N
E N G I N E lifter set t i ng d i me n s i o n s .
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.
CHECKING TIM ING BY MEASURING TIM IN G

DIMENSION (Dial Indicator)
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
CHECKING TIM ING BY THE FUEL FLOW 3. Inst al l 5 P 7 2 6 5 A d a p t e r (3) in p r e c o m b u s t i o n

METHOD c h a m b e r (4). T i g h t e n t he a d a p t e r f i nger t ight
onl y t o pr e ve nt d a m a g e t o t he fuel i nj ect i on
val ve seat. P u t a s mall a m o u n t of oil on 3 S 32 64
Tools Needed:
1P540 Flow Checking Tool Group R o d (5) a n d p u t t he r od in t he a d a p t e r wi t h t he
3S2954 Engine Timing Indicator Group or s ma l l e nd d o wn .
5P6524 Engine Timing Indicator Group
9S215 Dial Indicator
3P1565 Collet
4. Instal l 3 P 1 565 Col l et ( l ) o n t he a d a p t e r . P u t t he
3 S 3270 C o n t a c t P o i n t o n 9 S 2 I 5 I n d i c a t o r (2)
3S3270 Contact Point 1.75 in. (44.5 mm) long
3S3264 Rod 7.12 in. (180.9 mm) long a n d p u t t h e i n d i c a t o r in t he collet.
5P7265 Adapter
7M1999 Tube Assembly
i. Put No. I pi st on at t o p c ent er ( T C ) in t he c o m

pression position. M a k e reference to L O
CATING TOP CENTER C O M PRE SSIO N
P O S I T I O N F O R NO. I P I S T O N .
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 .
2. Di s c o n n e c t t he fuel l ine f r o m No. I c yl i nde r fuel

i nj ect i on valve body. R e m o v e t h e val ve b o d y CAUTION
a n d t he fuel val ve f r o m t h e p r e c o m b u s t i o n Do not use a hammer and punch to mark a
chamber. vibration damper.
3- 2 4
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.
V. PISTO N TRAVEL TO T O P CENTER
Tim ing Angie Indicator Reading
10° 076 in. (1 93 mm)

11° 092 in (2.34 mm)
'1 2 ° 110 in (2 79 mm)
13° 1 29 in (3 28 mm)
"1 4 ° .149 in (3.78 mm)
15° .171 in. (4.34 mm)
16° ,194 in. (4.93 mm)
'S p e c ifie d tim in g fo r D379 and D398 Engines

" S p e c ifie d tim in g fo r D399 Engine
✓
A35549X1
N O T E : If t he t i mi n g of t he fuel s y s t e m is di f fer ent

1P540 FLOW C H E C K IN G T O O L G RO UP t h a t t he cor r e c t t i mi n g d i m e n s i o n given in t he char t ,
8. 5J4634 Hose assembly. 9. 7M 1999 Tube Assembly. m a k e r ef e r ence t o T I M I N G T H E C A M S H A F T
10. Tank assembly.
FO R TH E FUEI. IN JECTION PU M P.
3-25
TIM ING THE CAMSHAFT FOR THE

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.
C A M SH A FT GEAR ASSEMBLY T IM IN G TH E FUEL IN JE C T IO N PU M P C A M SH A FT

1. Camshaft gear. 2. Plate. 3. Puller bolt. 4. Shaft. 5. 7. Tim ing pin. 8. Ratchet wrench handle (3/4 in. drive).
Lock. 6. Collar.
9. Breather opening.
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
FUEL SYSTEM
9. Inst all t he t i m i n g pin. If t he t i m i ng pi n e n g a g e s 2. C h e c k t he di r e c t i o n of r o t a t i o n of t h e fuel p u m p

wi th t he t i mi n g slot in t h e c a m s h a f t , t h e t i m i n g c a ms h a f t . F o r a n en gi ne w ith s t a n d a r d r o t a t i o n ,
is cor rect . If t he t i m i ng pi n do e s n ot e n g a g e wi t h t he “ F ” m a r k a n d a r r o w o n t he e nd of t h e fuel
t he t i mi n g slot, t he t i m i n g is n ot c o r r e c t a n d p u m p c a m s h a f t will be at t he f r o n t e nd of t he
S t e p s 1 t h r u 8 m u s t be d o n e agai n. p u m p h o u s i ng. F o r a n en g i n e wi t h o p p o s i t e
r o t a t i o n t he “ F ” m a r k a n d a r r o w on t h e e nd of
10. R e m o v e t he t i mi n g pin. Inst al l t h e b r e a t h e r , t he fuel p u m p c a m s h a f t w ill be at t h e r e a r e nd of
pi pe pl u g in flywheel h o u s i n g , fuel inlet f l ange, t he p u m p hous i ng .
a n d t he t i mi n g pin. 3. Inst al l t i m i n g pl at e ( l ) o n s ha f t (2) wi t h bol t (6)
a n d W'asher (5). P u t t he t i m i n g p l at e a n d shaft
SETTING FUEL INJECTION PUMP TIM ING on t h e fuel p u m p c a m s h a l t at t h e r e a r o f t he
DIMENSION: OFF ENGINE p u m p h o us i ng. T h e key in sha f t (2) mu s t be in
a l i gn m e n t a n d e n g a g e in t he slot in t he c a m
shaft.
Tools Needed:
5P6600 or
1P5600 Off Engine Lifter Setting Tool Group 4. Inst al l p o i n t e r (3) o v e r t he d o we l in t he t o p of
5P4165 Dial Indicator Group or t he p u m p h o u s i n a at t he r ear. Inst al l t he bol t
6F6922 Depth Micrometer (4).
A334I6 1X6
5. I n t he c ha r t , f ind t he t i m i n g pl at e s e t t i ng f o r t h e
lifter t ha t is to be set. T u r n t he t i m i n g pl a t e t o
t his s et t i ng in t he d i r e c t i o n of c a m s h a f t r o t a
tion. T h e di r e c t i on of c a m s h a f t r o t a t i o n as seen
f r o m t h e r e a r of t he p u m p h o u s i n g is c o u n t e r
cl ockwi s e f or s t a n d a r d r o t a t i o n engi nes a n d is
cl ockwi s e f or o p p o s i t e r o t a t i o n engi nes. T h e
degr ee m a r k i n g on t he t i mi n g pl at e m u s t be in
a l i g n m e n t wi t h t he i nsi de edge (9) of p o i n t e r (3).
5P6600 OFF E N G IN E LIFTER S E T T IN G T O O L G R O U P

SH O W N
1. 1P7410 Plate. 2. 5P 6564 Shaft. 3. 1P7415 Pointer.
4. S1594 Bolt. 5. 2S6160 Washer. 6. S509 Bolt. 7. 9M 4568
Wrench. 8. 9M 4567 Wrench.
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
6. Use t he 6 F 6 9 2 2 D e p t h M i c r o m e t e r or t he 7. Set e a c h lifter in t he f i ring o r d e r ( i nj e ct i on

5 P 4 I 6 5 Di al I n d i c a t o r G r o u p a n d m e a s u r e s e q u e n c e ) of t he engi ne. M a k e r ef e r ence t o t he
t i mi n g d i me n s i o n (A). T i m i n g d i m e n s i o n ( A) is C H A R T F O R F I R I N G O R D E R . C h e c k t he
t he d i s t a nc e f r o m t h e t o p sur f a c e o f t h e fuel t i m i n g d i m e n s i o n f or e ach lifter a g a i n af t er an
p u m p h o u s i n g t o t he fuel p u m p p l u n g e r c o n t a c t a d j u s t m e n t has been m a d e a n d t h e l o c k n u t
sur f ace in t he y o k e of t he lifter. T h e m e a s u r e t i ght ened.
m e n t for t i mi n g d i m e n s i o n ( A) is 2. 1565 ± . 0005
in. (54.775 ± 0.013 m m ) f or all engi nes. Use
wr e n c h e s (7) a n d (8) t o a d j u s t t he y o k e o f t he
lifter to t he cor r e ct t i m i n g d i me n s i o n .
T h e fuel i nj ect ion p u m p s a r e n u m b e r e d in o r d e r

f r o m f r ont t o r ear on all engi nes
CH AR T FOR FIR IN G ORDER (Injection Sequence)

SAE Standard Rotation (Counterclockwise)
D379 Engine 1-8-5-4 -7-2-3-6
D398 Engine 1-12-9-4-5 -8-11-2-3-10-7-6
D399 Engine 1-2-5-6 -3-4-9-10-15-16-11-12-13-14-7-8
SAE Opposite Rotation (Clockwise)
D379 Engine 1-4-5-2 -7-6-3-8
D398 Engine 1-4-9-8 -5-2-11-10-3-6-7 -12
D399 Engine 1-6-5-4 -3-10-9-16-15-12-11-14-13-8-7-2
5P4165 DIA L IN D IC A T O R G R O U P IN STA LLE D

A. Tim ing Dimension.
LIFTER SE TTIN G IN DEGR EES (O FF E N G IN E )

Tim ing Plate Tim ing Plate Tim ing Plate
Lifter No. Degrees D379 Degrees D398 Degrees D399
(num bered SAE SAE SAE SAE SAE SAE
in order from Standard Opposite Standard Opposite Standard Opposite
front to rear) Rotation Rotation Rotation Rotation Rotation Rotation
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
FUEL SYSTEM
FUEL RACK ADJUSTMENT 4. F a s t e n b r a c k e t (2) t o t h e fuel p u m p h ou s i ng.

M o v e t h e g o v e r n o r lever t o t he fuel on po s i t i on
a n d install dial i n d i c a t o r (3) wi t h c o n t a c t poi nt
Tools Needed:
9S240 Rack Position Tool Group (4) on b r a c k e t (2).
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.
2. R e m o v e t he s peed l i mi t er access plug. Inst all

pl ug (5). T h r o u g h t he o p e n i n g in t he pl ug, 6. P u t t he clip end o f t es ter ( l ) on t he br ass t e r
install r o d (6) a n d p u s h in t he s pe ed l i mi t e r mi nal o n t he si de o f t he gov e r nor . P u t t h e o t h e r
pl unger . T i g h t e n t he pl ug t o c a us e a c l a m p end of t h e t es t er t o a g o o d el ect ri cal g r o u n d .
a c t i o n on t he r od. Thi s will let t he g o v e r n o r
c o n t r o l lever m o v e t h r o u g h its c o m p l e t e l engt h 7. R e m o v e d u s t cov er (10) f r o m t h e dial i ndi c a t o r .
of travel. M o v e t h e g o v e r n o r c o n t r o l lever in t he fuel on
di r e c t i o n unt i l t he t est er light b e c o m e s b r i ght
3. R e m o v e t i mi n g pin (7). c l a m p (8). a n d t he p l u g a n d f ast en lever in this posi t i on.
a n d seal be h i n d the cl amp.
8. P u s h on t he s t e m of t he dial i n d i c a t o r t h a t was
u n d e r t he dus t c o ve r t o keep a sma l l a m o u n t of
pr es s u r e on t he fuel rack. Use a I l 4 in. o p e n
e nd w r e n c h on r ack s h u t o f f lever ( l l ) a n d mo v e
t he l ever in t he fuel off di r e c t i o n until t h e test er
light b e c o m e s a di m light.
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
AIR-FUEL RATIO CONTROL ADJUSTMENT
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.
Air-Fuel Ratio Control Setting
T h e fuel r ack set ti ng m u s t be c or r e ct b e f o r e t he

air-fuel r at i o c o n t r o l c a n be ad j u s t e d . M a k e r ef e r
RACK SH U TO FF LEVER ence t o F U E L R A C K S E T T I N G . T h e ai r-fuel r at i o
11. Rack shutoff lever. c o n t r o l set t i ng is d o n e wi t h t he c o n t r o l on t he
engi ne.
9. R e a d t he r a c k set t i ng m e a s u r e m e n t o n t h e dial 1. R e m o v e t he o v e r r i d e c o n t r o l a n d co ve r (1).

indicator. M a k e reference to the R A C K
S E T T I N G I N F O R M A T I O N f or t h e cor r e c t
2. T u r n bol t (2) wi t h cov e r (1) c l oc kwi s e unt i l t he
r ack set ti ng d i me n s i o n .
circuit t es t er light c o m e s on.
10. T o adj us t t he fuel r ack set ting, l oos e n t he

l o c k n u t on a d j u s t m e n t s cr ew (12) a n d t u r n as
needed. T i g h t e n t he l o c k n u t a n d check t he r a c k
set ti ng agai n.
SE TTIN G AIR FUEL R A TIO C O N T R O L

1. Cover. 2. Bolt.
FUEL RACK A D JU S TM E N T 3. Use t he l l ' 4 in. w r e n c h a n d t u r n s h u t o f f lever

12. Adjustment screw. unt i l light j us t goes off. C h e c k t he di al i n d i c a t o r
r e a d i n g t o be s ur e t he fuel r a c k se t t i ng is at t he
specifi ed setting.
4. M o v e t h e fuel r a c k unt i l t he t es t er l ight j us t

comes on (dim light). T u r n c ov e r ( l ) c o u n t e r
cl ockwi s e unt i l t h e t es t er light goes out . M a r k
t he cove r and t he ai r -f uel r at i o c o n t r o l f or
reference.
11. Af t e r t he a d j u s t m e n t p r o c e d u r e is d o n e , t i g h t e n
t he a d j u s t m e n t s cr ew l o c k n u t t o a t o r q u e o f 9 ±
3 lb.ft. (12 ± 4 N-m). N O T E : W h e n co ve r ( l ) is us e d t o t u r n bol t (2). one
r e v o l u t i o n of t he c o v e r c o u n t e r c l o c k w i s e will ca us e
N O T E : T h e s a m e t ool s t h a t a r e used in t hi s p r o .090 in. ( 2.29 m m ) r est r i ct i on of t h e r ack. R o t a t i o n
c e d u r e ar e al so used f or t he ai r-fuel r a t i o c o n t r o l o f t he c ove r t h e d i s t a n c e o f o n e ho l e will give .015
a d j u s t me n t . in. (0.38 m m ) a d j u s t m e n t .
3-30
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 .
6. Inst al l t he cover , ov e r r i d e c o n t r o l , a n d l ock ware

a n d seal. R e m o v e t he r a c k set t i ng t ool s.
Override Control Lever Adjustment
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 .
2. A d j u s t t he pr e s s u r e r e g u l a t o r t o 5 psi (35 k Pa) .

O VER RIDE C O N T R O L LEVER A D JU S T M E N T Bol t (2) mu s t st ar t t o move.
3. Override control lever. 4. Screw. 5. Nut.
3. A d j u s t t h e pr e s s u r e r e g u l a t o r t o 16.5 t o 20. 5 psi
1. P u t t he ov e r r i d e c o n t r o l lever (3) in t he s t a r t (114 t o 142 k P a ) . T h e bol t m u s t n o w be fully
posi t i on. extended.
2. P u t bol t (2) in a vise a n d pul l o n t h e co n t r o l . At 4. A d j u s t t he p r e s s u r e r e g u l a t o r t o 35 psi (240

first m o v e m e n t of t he bol t, t he c o n t r o l l ever k P a ) a n d t u r n of f t h e ai r p r e s s u r e t o t he air-fuel
mu s t m o v e fast t o t h e r u n posi t i on. r a t i o co n t r o l . T h e ai r p r e s s u r e m u s t n o t d r o p
m o r e t h a n 2 psi (14 k P a ) in 10 seconds.
3. If t he c o n t r o l lever d o e s n o t m o v e c or r e ct l y p u t
a s c r e wd r i v e r in t he slot of a d j u s t m e n t s c r ew (4) GOVERNOR ADJUSTMENTS
a n d l o os e n l o c k n u t (5). T u r n t h e a d j u s t m e n t Tools Needed:
s cr ew 1 4 o f a t u r n c o u n t e r c l o c k w i s e a n d 4S6553 Instrument Group.
t i g h t e n t he l oc knut . D o thi s p r o c e d u r e unt i l t h e 1P7448 Mechanical Tachometer Cable.
control lever moves correctly.
CAUTION
Diaphragm Test A mechanic with training in governor adjust
ments is the only one to make the adjustment
T h e d i a p h r a g m tes-t is m a d e wi t h t h e ai r-fuel r a t i o
to the low idle and high idle rpm. The correct
low idle and high idle rpm, and the measure
c o n t r o l of f t he engine. A n ai r s u p p l y a n d a p r e s s u r e
ment for the adjustment of the fuel rack are in
r e g u l a t o r ar e n e e d e d t o d o thi s test.
the RACK SETTING INFORMATION and on
1. C o n n e c t a line f r o m t h e ai r pr e s s u r e r e g u l a t o r the ENGINE INFORMATION PLATE installed
t o p o r t (6) of t h e air -f uel r at i o c ont r ol . on the engine.
3-31
FUEL SYSTEM
En g i n e r p m mu s t be c h e c k e d wi t h a n a e e u r a t e H I G H I DL.E a n d c h e c k t he set t i ng agai n.

t a c h o m e t e r . T h e I P7 4 4 3 T a c h o m e t e r a n d t he Re p e a t t his p r o c e d u r e unt i l r p m set t i ng is
1P7448 Me c h a n i c a l T a c h o m e t e r C a b l e ( f r o m t he cor rect .
4S 6 553 I n s t r u m e n t G r o u p ) ca n be used.
b. T o a d j us t t he L O W I D L E r p m . m o v e t he
1. C o n n e c t one end o f t he I P 7448 Me c h a n i c a l g o v e r n o r l i nkage t o L O W IDI.F. po s i t i on
T a c h o m e t e r C a b l e t o t he t a c h o m e t e r dr i ve on a n d t u r n screw (3). I ncr e as e t he engi ne
t he t r o nt of t he engi ne. speed a n d t h e n r e t u r n l i nkage b a c k t o LOW'
I D E E p o s i t i o n t o ch e c k t h e set t i ng agai n.
N O T E : O n engi nes t h a t have o p p o s i t e r o t a t i o n ,
c o nne c t t he end o f t he t a c h o m e t e r cabl e to t he side c. W h e n g o v e r n o r a d j u s t m e n t is c or r e ct , i n
of t he t a c h o m e t e r dr i ve t ha t has t h e a d a p t e r . stall t he cove r o n t he r e a r of t h e g o v e r n o r .
W h e n t he c over is inst al l ed on t he g o v e r n o r ,
2. C o n n e c t t he o t h e r e nd o f t he t a c h o m e t e r cabl e t he idle a d j u s t m e n t screws fit i nt o r et ai ner
to t he i n s t r u m e n t used to m e a s u r e engi ne speed. holes (2) in t he cover . T h e s h a p e of t he hol es
will n o t let t he idle a d j u s t m e n t screw t u r n
af t er t he idle a d j u s t m e n t is d o n e a n d t he c o
N O T E : T h e I F’7448 Me c h a n i c a l T a c h o m e t e r C a b l e
c a n be c o n n e c t e d to a n v o f t he i n s t r u m e n t s s h o w n ver is i nst al l ed.
in article M E A S U R I N G E N G I N E S P E E D .
d. N o w install a new w'ire a n d seal t o t he c ove r
bolt.
A WARNING
To help prevent an accident caused by parts in
rotation, work carefully around an engine that MEASURING ENGINE SPEED
has been started. Tools Needed:
5P2150 Engine Horsepower Meter or
4S6553 Instrument Group or
3. St ar t the en gi ne a n d c heck t h e l ow idle a n d hi gh
1P5500 Portable Phototach Group.
idle r p m. See t he R A C K S E T T I N G I N F O R
M A T I O N . or l ook at t h e E N G I N E I N F O R
M A T I O N P E A T F i nst al l ed on t he engi ne, f or
t he cor r ect l ow idle a n d hi g h idle r pm.
5P2150 E N G IN E HO RSEPO W ER METER
G O VE R N O R A D JU S TM E N T S T h e 5P2150 Engine H or s e p o w e r Me ter can m ea s

1. High Idle screw. 2. Retainer holes. 3. Low Idle screw. ur e en g i n e s pe ed f r o m t h e t a c h o m e t e r dr i ve on t he
4. C o v e r. e ngi ne. Speci al I n s t r u c t i o n F o r m No. S M H S 7 0 5 0
h a s i n s t r u c t i o n s for its use.
4. If an a d j u s t m e n t is neces sar y, r e m o v e c o v e r (4)
a n d use t he p r o c e d u r e t h a t follows:
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
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.
3. Inst all a large cl us t er g e a r ( l ) >o t he C - m a r k on

t he cl us t er ge a r is in a l i gn m e n t wi t h t he p u n c h
m a r k s on t he t o o t h ol t he c r a n k s h a l t gear. D o
t his by l o o k i n g t h r o u g h t he hol e (7) in t he
c r a n k s h a l t flange.
4. O n 8 cvl i nder engi nes, tilt t he large cl us t er gear

a n d t u r n t h e b a l a n c e r g e a r until t he A- m a r k s (4)
ar e in a l i gnme n t .
1P5500 PORTABLE P H O T O T A C H G R O U P 5. Wi t h t he t i mi n g m a r k s in a l i g n m e n t , slide t he

l arge cl uster gear over t he do we l (5) in t he smal l
cl ust er g e a r a n d install t he m o u n t i n g bolts.
T h e I P 5500 P o r t a b l e P h o t o t a c h G r o u p c a n
m e a s u r e engi ne s peed f r o m the t a c h o m e t e r dr i ve o n
t he engi ne. It al so has t he abi l it y t o m e a s u r e e n g i n e
speed f r o m visual en gi ne p a r t s in r o t a t i o n . Speci al
I n s t r u c t i o n F o r m No. S M H S 7 0 1 5 h a s i n s t r u c t i o n s
f or its use.
CAMSHAFT CLUSTER GEAR INSTALLATION
1. Inst al l t he s mal l cl us t er g e a r (2), t he t h r u s t

w a s h e r a n d t he r e t a i n e r a n d t i g h t e n t o t o r q u e o f
C H E C K IN G A L IG N M E N T
60 to 70 lb.ft. (80 t o 95 N-m). W IT H M IR RO R AN D CHALK ON BACK OF GEARS
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
V-8 Engines With Standard Rotation V-8 Engines With Opposite Rotation
Inst al l t he m a i n idler g e a r wi t h t h e “ C ” m a r k in I nst al l t h e idler ge a r wi t h one o f t he “ R ” m a r k s in

a l i g n me n t wi t h t he t o o t h o f t he c r a n k s h a f t g e a r t h a t a l i gn m e n t b e t we e n t w o t eet h o n t h e c r a n k s h a f t gear
h a s f our, five o r six p u n c h m a r k s . Al so, t h e “ B” t h a t have t w o p u n c h m a r k s on e a c h t o o t h .
m a r k o n t he m a i n idler g e a r m u s t be in a l i g n m e n t
wi th t he “ B” m a r k on t he b a l a n c e r gear. T h e o t h e r “ R ” m a r k o n t h e idler g e a r m u s t be in
a l i g n m e n t wi t h t he “ R ” m a r k o n t h e b a l a n c e r gear.
SAE ST AND AR D R O TA TIO N 8 CYLIN D E R E N G IN E SAE O P PO SITE R O T A T IO N 8 C Y LIN D E R E N G IN E
3- 34

RESTRICTION OF AIR INLET AND EXHAUST be m o r e 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 . BE S U R E T H A T T H E A I R
T h e r e will be a r e d u c t i o n o f h o r s e p o w e r a n d IN L E T A N D E X H A U S T DO N O T H A V E A
efficiency o f th e e ng ine if t h e r e is a r e s t r i c t i o n in th e R E S T R IC T IO N W H EN M A K IN G A C H E C K O F
air inlet o r e x h a u s t sys tem . P R E S S U R E IN T H E I N L E T M A N I F O L D .
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.
MEASUREMENT OF PRESSURE IN INLET

MANIFOLD
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
WATER DIRECTORS PRECOMBUSTION CHAMBER
T h e r e a r e eigh t w a t e r d i r e c t o r s ( I ) p ress ed in t o Use th e 5 F 9 2 1 7 f o o l G r o u p t o r e m o v e a n d in stall

e a c h c ylin der h e a d to direct th e flow o f c o o l a n t . O n c h a m b e r . C o a t t h r e a d s w ith 5P3931 A n t i - S e iz e
th e e x h a u s t side, c o o l a n t is d i r e c t e d t o w a r d t h e C o m p o u n d a n d use e i t h e r I P800 5 o r l P 8 0 04 g a s k e t
p r e c o m b u s t i o n c h a m b e r s a n d t h e e x h a u s t valv e to p o s i t i o n p r e c o m b u s t i o n c h a m b e r .
p orts; a n d on th e inlet side, t o w a r d t h e o t h e r side o f
th e valve p o r t s , as i n d i c a t e d by th e V - m a rk s .
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
fuel line is f o u n d t h a t m a k e s no diffe r e n c e in en g i n e Valve Seat Inserts

p e r f o r m a n c e . Be sure to ti g h t e n e a c h fuel line n u t
after the test before th e n ex t fuel line n u t is l o o s e n e d . T o o l s n eed ed to r e m o v e a n d install seat inse rts are
T h is test can also be an i n d i c a t i o n t h a t th e fuel in the 9 S 3 0 8 0 Valve Insert P u ller G r o u p . S p ecial
in jectio n is w r o n g , so th e cy lin d e r will h a v e t o be I n s t r u c t i o n F o r m N o. G M G 0 2 1 1 4 gives an
c h e c k e d t h o r o u g h ly . e x p la n a tio n for th is p ro c e d u re . F o r easier
in s t a l l a t i o n , lo w er th e t e m p e r a t u r e o f th e inse rt
A cy lin d e r l e ak ag e test t h a t uses air p r e ss u re in th e b e f o re it is installed in th e head .
c y lin d e r c a n be used t o in d ic a te th e c o n d i t i o n o f t h e
p isto n rings, valves, a n d valve seats. M a k e refe re n c e Valve Guides
to S P E C I A L I N S T R U C T I O N F O R M N O .
G M G 0 0 6 9 4 for a list o f t o o l s need ed a n d th e test
p r o c e d u r e . R e m o v a l o f th e h e a d a n d in s p e c t io n o f T h e i n t a k e a n d e x h a u s t v a l v e s o p e r a t e in
th e valves a n d valve se ats is n ec e s sa ry t o find t h o s e r e p l a c e m e n t ty p e valve gu ides . A f te r th e valves h ave
sm all de fects t h a t d o n o t n o r m a l l y c a u s e a p r o b l e m . b een r e m o v e d , clean th e valve ste m s a n d valve
R e p a i r of th ese p r o b l e m s is n o r m a l l y d o n e w h e n gu ides . Use th e 5 P 3 5 3 6 Valve G u i d e M e a s u r i n g
r e c o n d i t i o n in g th e engine. G r o u p to c h ec k the v alve g u id e s fo r w e ar.
I n s t r u c t i o n s a r e in S p e c i a l I n s t r u c t i o n ( G M G
02562).
CYLINDER HEAD
T h e 4 H 4 4 6 D r iv e r a n d 5 P 1 726 B u s h i n g is used for
T h e cy lin d e r h e a d has valves, va lve se at inserts,
i n s t a l l a t i o n o f new valve guides .
a n d v alv e guides t h a t ca n be r e m o v e d w h e n t h e y a r e
w o rn or have d am ag e. R e p la c e m e n t of these
c o m p o n e n t s can be m a d e w ith t h e t o o l s t h a t follo w .
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
VALVE LASH ADJUSTMENT AND CHECK 2. P u t N o . 1 pisto n at t o p c e n t e r ( T C ) on th e c o m

p r ess io n str o k e . M a k e refe re n c e t o L O C A T
Valve lash is c h eck e d a n d a d j u s te d w ith th e en g in e IN G T O P C E N T E R C O M P R E S S I O N P O S I
stopped. T IO N F O R NO. 1 P IS T O N .
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.
VALVE CLEARANCE CHECK: E N G IN E S T OPPED

E x h a u s t..............................032 to .038 in. (0.81 to 0.97 m m)
In ta k e 012 to 018 in (0 30 to 0.46 m m)
VALVE CLEAR AN CE SE TTING : E N G IN E STOPPED

A D JU S T IN G VALVE LASH
Exhaust 035 in. (0.89 m m)
In ta k e 015 in (0.38 m m)
3. W i t h No. 1 p i s t o n at t o p c e n t e r ot the c o m p r e s
sio n s t r o k e , a d j u s t th e c l e a r a n c e for the valves
s h o w n in th e c h a r t N O . 1 P I S I O N O N
T o m a k e an a d j u s t m e n t to th e v alve c le a r a n c e , C O M PR E SSIO N STROKE.
lo o se n the l o c k n u t on th e a d j u s t m e n t screw. T u r n
the a d j u s t m e n t screw to get th e c o r re c t c l e a r a n c e
s h o w n in t h e c h a r t V A L V E C L E A R A N C E 4. T u r n th e c r a n k s h a f t o n e r e v o l u t i o n in the d i r e c
S E T T IN G : E N G IN E S T O P P E D . H old the ad ju s t ti o n o f n o r m a l r o t a t i o n a n d align t h e p o i n t e r
m en t sc rew a n d tig h te n the l o c k n u t to 40 ± 5 lb.ft. a n d th e T C I m a r k o n t h e flyw heel. T h e en g in e
n o w is at t o p c e n t e r e x h a u s t s t r o k e No. 1 p iston .
(55 ± 7 N-m). R e c h e c k the valve clea r a n c e . Valve
c le a r a n c e a d j u s t m e n t c a n be m a d e by u sin g th e
p r o c e d u r e t h a t follows: 5. W i t h N o. 1 p i s t o n at t o p c e n t e r o n th e e x h a u s t
s t r o k e , a d j u s t th e c l e a r a n c e f o r th e valves
1. D e t e r m i n e the n o r m a l d i r e c t i o n o f c r a n k s h a f t s h o w n in th e c h a r t N O . 1 P I S T O N O N E X
r o t a t io n . Sec th e decal on th e fly w h eel h o u s i n g . HAUST STROKE.
3 -3 8
NO. 1 PIS TO N ON C O M P R E S S IO N STROKE NO. 1 P ISTO N ON EX HA UST STRO KE

C O U N TE R C L O C K W IS E R O T A T IO N - C O U N TE R C L O C K W IS E R O T A T IO N -
Viewed from Flywheel Viewed from Flywheel
D379 D398 D399 D379 D398 D399

VALVES C Y LINDERS CY LINDE RS C Y LIN D E R S VALVES CYLIN D E R S C Y LIN D E R S C Y LIN D E R S
Exhaust 1-4-5-8 1-4-5-6-9-12 1-2-3-4 -5-6-8-9 Exhaust 2-3-6-7 2-3-7-8-10-11 7-10-11-12-13-14-15-16
Intake 1-2-3-6 1-3-6-7-10-12 1 -2-7-8-11-12-13-14 Intake 4-5-7-8 2-4-5-8-9-11 3-4-5-6 -9-10-15-16
CLO C KW ISE R O TA TIO N - CL O C K W IS E R O T A T IO N -

Viewed from Flywheel Viewed from Flywheel
D379 D398 D399 D379 D398 D399

VALVES C YLINDERS CYLIN D E R S C Y LIN D E R S VALVES CYLIN D E R S CYLIN D E R S C Y LIN D E R S
Exhaust 1-4-5-8 1-4-5-8-9-12 1-2-3-4-5-6-9-10 Exhaust 2-3-6-7 2-3-6-7-10-11 7-8-11-12-13-14-15-16
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
CYLIN D E R A N D VALVE LO C A TIO N
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.
TOO MUCH OIL CONSUMPTION A n 8 M 2 7 4 4 Oil P r e s s u r e G a u g e w h ich is p a r t o f

t h e 5 P 6 2 2 5 H y d r a u l i c T est B o x ca n be use d t o check
oil p r e s s u re in th e system .
Oil Leakage on Outside of Engine
O IL PRESSURE
C h e c k f o r le a k a g e at th e seals at e a c h end o f t h e EN G INE psi kPa

c r a n k s h a f t . L o o k f o r l e a k a g e a t th e oil p a n g a s k e t
a n d all l u b r i c a t i o n sy s tem c o n n e c t i o n s . C h e c k to see D379 59 to 66 405 to 460
if oil c o m e s o u t o f t h e c r a n k c a s e b r e a t h e r . T h is can 56 to 63 385 to 430

D398
be c a u s e d by c o m b u s t i o n g as le a k a g e a r o u n d th e
p iston s. A d ir ty c r a n k c a s e b r e a t h e r will ca u s e h igh D399 56 to 63 385 to 430
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. W o r n o r d a m a g e d p isto n rings, o r d i r ty oil

r e t u r n holes.
3. C o m p r e s s i o n rin g n o t in stalled corre ctly .
4. Oil le a k a g e p as t th e seal rings in th e i m p eller

e nd o f th e t u r b o e h a r g e r shaft.
5P6225 H Y D R A U LIC T E S T BOX
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. S ta r t th e eng ine a n d rim to get the oil t e m p e r a

tu r e to 200 10 1 (03 e 0 C ).
4. Keep the oil t e m p e r a t u r e c o n s t a n t with th e

e ng ine sp eed at 1200 rpm . M a k e a c o m p a r i s o n
oi th e g a u g e r e a d i n g an d th e ch art.
If the results d o n ot fall w i t h i n th e p r e s s u re range-

given in the c h a r t , find the cause a n d c o r r e c t it.
F n g in e failure o r a r e d u c t i o n in e n g in e life can he th e
result if en gin e o p e r a t i o n is c o n t i n u e d w ith oil
m a n i f o ld p r ess u re o u t s i d e th is range.
O IL FILTER BYPASS VALVE

1- Valve.
OIL PRESSURE IS LOW
Crankcase Oil Level
C h e c k the level of th e oil in th e c r a n k c a s e . A d d oi!

if n eeded . It is p ossible for the oi! level t o be t o o f a r
b elo w th e oil p u m p s u p p l y tu b e . T h is will ca u s e t h e
oil p u m p to no t h a v e the ability t o s u p p l y e n o u g h
l u b r ic a t io n to th e en gin e c o m p o n e n t s .
Oil Pump Does Not Work Correctly
T h e inlet sc re en o f the s u p p l y t u b e fo r th e oil

p u m p c a n h a v e a r e s t r i c t i o n . T h i s will c a u s e FILTER C O N D IT IO N IN D IC A T O R
c a v i t a t i o n (low p r e s s u re b u b b l e s s u d d e n l y m a d e in 2. Later Ind ica to r. 3. E a riler Indica tor.
liqu ids by m e c h a n i c a l fo rc es) a n d a loss o f oil
p ressure. A ir l e a k a g e in th e s u p p l y side o f t h e oil
p u m p will also cau s e c a v i t a t i o n a n d loss o f oil Too Much Clearance at Engine Bearings or
p ressure. If th e b y p ass va lve f o r th e oil p u m p is held Open, Broken or Disconnected Oil Line or
in th e o p e n ( u n s e a t e d ) p o s i t i o n , th e l u b r i c a t i o n Passage in Lubrication System
sy s tem c a n not get to m a x i m u m p r e ss u re . Oil p u m p
gears t h a t h av e t o o m u c h w e a r w ill c a u s e a r e d u c t i o n
in oil pressu re.
C o m p o n e n t s t h a t are w o r n a n d h a v e t o o m u c h
b e a r i n g c l e a r a n c e c a n cau s e oil p r e s s u re to be low.
L o w oil p r e s s u re c a n also be ca u s e d by a n oil line or
Oil Filter and Bypass Valve oil p a s sa g e t h a t is o p e n , b r o k e n o r d isc o n n e c t e d .
As th e oil filters b e c o m e filled w ith d ir t, a

r e d u c t i o n o f e n g in e oil p r e ss u re will be seen u n til oil
Oil Cooler
filter b y p a s s valve ( I ) op en s. W h e n th e b y p a s s valve
o p e n s , u n f ilte r e d oil will go t h r o u g h t h e engine.
L o o k fo r a r e str ic tio n in t h e 'o il p as sag es ot the oil
W h e n th e oil p r e s s u re o n th e clean side (inside) o f co oler.
the ele m e n ts b e c o m e s 12 to 15 psi (85 t o 105 k P a )
less t h a n th e oil p r e s s u re t o th e u n f i lt e r e d side If t h e oil c o o l e r lias a r e s t r i c t i o n th e oil
(o u tsid e ) o f th e elem en ts , filter c o n d i t i o n i n d i c a t o r t e m p e r a t u r e will be h ig her t h a n n o r m a l w h e n the
(2) or (3) will m o v e u p a p p r o x i m a t e l y h a l f w ay. T h is e n g in e is r u n n i n g . 1 he oil p r e s s u i e ol the en g ine will
s h o w s t h a t th e oil filter e l e m e n t s m u s t be c h a n g e d . b e c o m e low it th e oil c o o l e r has a restriction .
3-41
LUBRICATION SYSTEM TESTING AND ADJUSTING
OIL PRESSURE IS HIGH
Oil p r e ss u re will be high if th e p r e ss u re r e g u l a t i n g

valve f o r th e oil p u m p ca n n o t m o v e f r o m t h e closed
p ositio n .
TOO MUCH BEARING WEAR
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.
If the g au g e for oil p r e ss u re s h o w s th e c o r re c t oil

p ress u re, b u t a c o m p o n e n t is w o r n b e c a u s e it is n o t
g ettin g e n o u g h l u b r ic a t io n , lo o k at t h e p a s s a g e for
oil s u p p l y to t h a t c o m p o n e n t . A r e s t r i c t i o n in a
su p p l y p as sag e will n o t let e n o u g h l u b r i c a t i o n get to
a c o m p o n e n t a n d this will cau se early w'ear.
TURBOCHARGER LUBRICATION VALVE
(D379 and D398 Engines)
W h e n the g au g e for oil p r e s s u re s h o w s th e c o r re c t

oil p r e s s u re a n d b e a r i n g f ailu re o r w'ear is p r e s e n t in
b o t h t u r b o c h a r g e r s , check th e o p e r a t i o n o f t h e
t u r b o c h a r g e r l u b r ic a t io n valve. T h e valve c a n be
o p e n a n d allo w u n f ilte r e d oil to c o n s t a n t l y l u b r ic a t e
the t u r b o c h a r g e r .
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
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
VISUAL INSPECTION OF THE

COOLING SYSTEM Tools Needed:
9S9102 Thermistor Thermometer Group.
9S7373 Air Meter Group.
1. C h e c k c o o l a n t level in th e c o o l i n g sy stem . 1P5500 Portable Phototach Group.
9S8140 Cooling System Pressurizing Pump Group.
2. T o o k for leaks in th e system .
3. L o o k for b en t r a d i a t o r fins. Be su r e t h a t a i r flow

t h r o u g h th e r a d i a t o r d o es n o t h a v e a r e str ic tio n .
4. In sp ect the d rive fo r th e fan.
5. C h e c k f o r d a m a g e t o th e f a n b lades.
6. L o o k for air o r c o m b u s t i o n gas in t h e c o o l i n g

system .
7. I nspect th e p r e s s u re relief valve a n d th e se alin g

su r f a c e o f the filler ca p. T h e se alin g su r f a c e
m u s t be clean.
9S9102 TH E R M IS T O R T H E R M O M E TE R G R O U P
8. L o o k f o r large a m o u n t s o f d irt in t h e r a d i a t o r
co re a n d o n th e engine.
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.
Water Temperature Regulators
Use the p r o c e d u r e t h a t fo llo w s to ch e c k th e

o p e r a t i o n o f th e w a t e r t e m p e r a t u r e r e g u l a t o r :
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 .
W ATER TEM P ERA TUR E R E G U LA TO R S
Minim um
Open Distance Tem perature
Part No. In. mm °F °C
9N2894
.375 9.53 197° 92°
6L5851
Gauge for Water Temperature
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
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
Use th e 5H9 621 P i s t o n R i n g E x p a n d e r t o r e m o v e

o r in stall p i s t o n rings. M a i n b e a r i n g s a r e a v a i l a b l e w i t h .050 in. (1.27
m m ) s m a ll e r inside d i a m e t e r t h a n o r i g in a l size
Use th e 5 P 3 5 2 8 P i s t o n R i n g C o m p r e s s o r t o in stall b e a r in g s. T h e s e b e a r i n g s are f o r c r a n k s h a f t s t h a t
p i s t o n s i n to c y lin d e r b lo ck . h a v e b e e n “g r o u n d ” ( m a d e s m a ll e r t h a n o r i g in a l
size).
T igh ten the co n n ectin g rod b o l t s in t h e s t e p
s e q u e n c e t h a t follows: C o n n e c t i n g r o d b e a r in g s a r e a v a i l a b l e w ith .025
in. (0.64 m m ) a n d .050 in. (1.27 m m ) s m a ll e r in sid e
1. P u t c r a n k c a s e oil o n t h r e a d s . d i a m e t e r t h a n o rig in a l size b e a r in g s. T h e s e b e a r i n g s
ar e also a v a ila b le w ith .010 in. (0.25 m m ) l a r g e r
o u t s i d e d i a m e t e r t h a n o r ig in a l size b e a r in g s. T h e s e
2. T ig h t e n all n u t s t o 40 ± 4 lb.ft. (55 ± 5 N-m).
b e a r i n g s a r e f o r c o n n e c t i n g r o d s t h a t h a v e b een
“b o r e d ” ( m a d e l a r g e r t h a n o r ig in a l size).
3. P u t a m a r k o n e a c h n u t a n d cap.
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 ).
PISTON RING GROOVE GAUGE
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.
1P3537 DIA L BORE G AUG E G RO UP
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
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
SH IM TH IC K N E S S , C O LO R CO DE, A N D PART NU M BER

M EA S U R IN G LINER P R O JEC TIO N
1. 3H465 Plate. 2. Dial indicator. 3. 1P2402 Block. .007 in. .008 in. .009 in. .015 in. .030 in.
4. Crossbar. 5. 1P2398 Puller Plate. (0.18 mm) (0.20 mm) (0.23 mm) (0.38 mm) (0.76 mm)
BLA C K RED GREEN BROW N BLUE

5S8148 5S8149 5S8150 5S8151 5S8152
2. P u t p u ller p la te (5) o n t h e c y l i n d e r liner a n d p u t

p la te ( l ) in th e c e n t e r o f t h e a d a p t e r p l a t e as
s h o w n . Install c r o s s b a r (4) w ith n u ts, w a s h e rs ,
a n d 3 H 4 6 5 P la te s as s h o w n . T i g h t e n th e n u t s
ev en lv in f o u r ste ps: 5 lb. ft. (7 V m ) , 15 lb. ft.
(20 V m ) . 25 lb. ft. (35 N*m). a n d 50 lb. ft. (70 FLYWHEEL AND FLYWHEEL HOUSING
V m ) . T h e m e a s u r e m e n t f r o m th e b o t t o m o f
c r o s s b a r (4) t o th e t o p o f c y l i n d e r b lo c k , m u s t Tools Needed:
be t h e s a m e o n b o t h sides o f th e c y l i n d e r liners. 9S2328 Dial Indicator Group
3. I n stall th e 1P5512 C o n t a c t P o i n t o n d ia l i n d i Flywheel Ring Gear

c a t o r (2). P u t th e d ial i n d i c a t o r in th e 1 P 2 4 02
G a u g e Body. T o a d j u s t th e dial i n d i c a t o r to z e
ro. p u t dial i n d i c a t o r a n d g a u g e b o d y on t h e
b a c k o f t h e 1P5507 G a u g e . M o v e th e dial i n d i
c a t o r un til th e h a n d m o v e s 1 4 t u r n . T i g h t e n H e a t th e r in g g e a r t o a m a x i m u m o f 600° F (316°
bo lt o n b o d y to h o l d th e dial i n d i c a t o r in th is C) t o install. In stall t h e rin g g e a r so th e c h a m f e r o n
p o sitio n . T u r n th e dial face u ntil t h e z ero is in th e g e a r t e e t h is n e x t t o t h e s t a r t e r p i n i o n w h e n t h e
a l i g n m e n t w ith th e h a n d . flyw heel is installed.
3 -4 7
Face Runout (axial eccentricity) of the Bore Runout (radial eccentricity)

Flywheel Housing of the Flywheel Housing
C (T O P j
If an y m e t h o d o t h e r t h a n given h ere is use d ,

a l w a y s r e m e m b e r b e a r i n g c l e a r a n c e s m u s t be
r e m o v e d to get c o r re c t m e a s u r e m e n t s .
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
8S2328 DIAL IN D IC A T O R G R O U P INSTALLE D
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. W i t h dial i n d i c a t o r set at .000 in. (0.0 m m ) at 1. W i t h t h e dial i n d i c a t o r in p o s i t i o n at (C), a d j u s t

p o i n t (A), r o t a t e c r a n k s h a f t a n d t a k e r e a d i n g s th e dial i n d i c a t o r t o “0 ” (zero). P u s h t h e c r a n k
at p o i n t s (B), (C) a n d (D). sh a ft up a g a i n s t th e t o p b e a r in g . W r i t e t h e m e a
s u r e m e n t f o r b e a r i n g c l e a r a n c e o n line 1 in c o l
4. T h e d ifferen ce b e tw e e n the lo w est a n d h ig hest u m n (C).
r e a d i n g s t a k e n at all f o u r p o i n t s s h o u l d n o t e x
ceed .012 in. (0.30 m m ), w h ic h is th e m a x i m u m 2. D i v i d e t h e m e a s u r e m e n t f r o m S t e p 1 b y 2. Write
p e r m iss ib le flywheel h o u s i n g face r u n o u t . this n u m b e r o n line 1 in c o l u m n s (B) & (D).
3 -4 8
BASIC BLOCK
3. T u r n th e c r a n k s h a f t t o p u t th e dial i n d i c a t o r a t 10. If th e p o i n t ol in t e r s e c t i o n is in th e r ang e

(A). A d j u s t th e dial i n d i c a t o r t o “ 0” (zero). m a r k e d " A c c e p t a b l e " the b o r e is in a l i g n m e n t .
If the p o i n t ot in t e r s e c t i o n is in the r ang e
m a r k e d " N o t A c c e p t a b l e " , th e flywheel h o u s
4. 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
ing m u s t be c h a n g e d .
th e dial i n d i c a t o r at (B). W r i t e t h e m e a s u r e m e n t
in th e chart.
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
C orrection fo r bearing clearance I 0
Dial In d ica to r Reading II 0
T o ta l o f Line 1 & 2 III 0 ** * **
•T o ta l V ertical e c c e n tricity (o u t o f rou n d ).

• ’ S ubtract the sm aller No. fro m the larger No. The difference is
th e to ta l ho rizo n ta l ecce n tricity.
A t0 2 3 4 X I
C H E C K IN G FACE R U N O U T OF TH E FLYW HEEL
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 -
3. T u r n t h e flywheel a n d r ead th e i n d i c a t o r every

9 0°. Be su r e to r e m o t e e n d play th e s a m e way
e a c h tim e.
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.
Bore Runout (radial eccentricity)

of the Flywheel
1. In stall th e dial i n d i c a t o r (3) a n d m a k e a n a d j u s t

m e n t o f th e u n iv e r sa l a t t a c h m e n t (4) so it m a k e s
G RAPH FOR TO TA L E C C E N TR IC ITY c o n t a c t as sh o w n .
3-49
2. Set th e dial i n d i c a t o r to r e a d .000 in. (0.0 m m ). 5. R u n o u t (eccen tricity ) o f t h e b o r e f o r th e p ilot

b e a r i n g f o r th e flyw h eel c lu tc h , m u s t n o t excee d
3. T u r n th e flywheel a n d r e a d t h e i n d i c a t o r ev ery .005 in. (0.13 m m ).
90°.
CHECKING CRANKSHAFT DEFLECTION
(BEND)
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 ig 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 i c h is t h e T h e c r a n k s h a f t c a n be d eflected ( b en t) b e c a u s e
m a x i m u m p e r m iss ib le b o r e r u n o u t ( r a d i a l e c th e in s t a l l a t i o n o f the e n g in e w as n o t c o r re ct. If th e
centricity ) o f t h e flyw heel. en g in e m o u n t i n g rails are n o t f a s t e n e d c o r re c t ly to
th e f o u n d a t i o n m o u n t i n g rails, t h e c y lin d e r b lo c k
c a n tw ist o r b e n d a n d c a u s e t h e c r a n k s h a f t to
def lect. T h is d ef lectio n c a n c a u s e c r a n k s h a f t a n d
b e a r i n g failure.
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
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.
If th e dial i n d i c a t o r r e a d s m o r e t h a n .001 in. (0.03

m m ), th e c y lin d e r b l o c k is bent. L o o s e n t h e b o lts
t h a t h o ld th e e n g in e m o u n t i n g rails t o th e f o u n d a
t io n m o u n t i n g rails a n d a d j u s t th e sh i m s to m a k e th e
e n g in e s t r a i g h t ag ain . A lso c h e c k to see if th e e n g i n e
m o u n t i n g b o lts h a v e e n o u g h c l e a r a n c e t o let t h e e n
gine have e x p a n s i o n as it gets h ot. T h e o n ly b olts
t h a t c a n h a v e a tigh t fit a r e b o l t s a t t h e rig h t h a n d
r e a r o f th e en g in e a n d th e right h a n d r e a r b olt t h a t
h o ld s the en gin e to th e oil p a n base.
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 .
BATTERY CHARGING SYSTEM

Tools Needed: Battery
9S1990 Battery Charger Tester.
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.
1. B a tt e r y m u s t be a t least 1 5 % (1 .240 S p . G r . ) full

c h a r g e d a n d held t ig h tly in p lace. T h e b a t t e r y
h o l d e r m u s t n o t p u t t o o m u c h str es s o n t h e b a t
9S1990 BATTERY CH AR GER TESTER tery.
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
ELECTRICAL SYSTEM
A lte rn a to r R e g u la to r so l e n o id c o n t a c t s d o n o t close. I his is an in d i c a t i o n

o f th e need fo r r e p a i r t o the s o l e n o id o r an a d j u s t
m e n t to be m a d e to s t a r t e r p in i o n clea r a n c e . P in io n
W h e n a n a l t e r n a t o r is c h a r g i n g th e b a t t e r y t o o
c l e a r a n c e is .36 in. ( 9 . 1 m m ).
m u c h o r n o t e n o u g h , a n a d j u s t m e n t c a n be m a d e t o
th e c h a r g i n g r a t e o f th e a l t e r n a t o r . R e m o v e t h e
If th e so l e n o id f o r th e s t a r t i n g m o t o r will n o t
h o l l o w h ead screw' (1) f r o m t h e c o v e r o f t h e a l t e r
o p e r a t e , c u r r e n t f r o m th e b a t t e r y m a y n o t be g e t
n a t o r r e g u l a t o r a n d use a sc r e w d r i v e r t o t u r n t h e
t in g to th e so le n o id . F a s t e n o ne lead o f th e v o l t
a d j u s t m e n t screw. T u r n th e a d j u s t m e n t sc rew o n e o r
m e t e r t o th e c o n n e c t i o n ( t e r m i n a l ) f o r th e b a t t e r y
tw o n o t c h e s t o in c r e a se o r d e c r e a s e t h e c h a r g i n g r a t e
cab le o n t h e so le n o id . G r o u n d th e o t h e r lead. N o
o f the a l t e r n a t o r .
v o l t m e t e r r e a d i n g s h o w s t h e r e is a b r o k e n circuit
f r o m t h e b a t t e r y . F u r t h e r t e s tin g is n e c e s sa ry w h e n
t h e r e is a r e a d i n g o n the v o l t m e t e r .
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.
LO C A TIO N OF A D JU S TM E N T SCREW FOR TH E A s t a r t i n g m o t o r t h a t o p e r a t e s t o o slow can h a v e

6L5397 and 6L3432 ALTER NA TO R RE G U LA TO R S a n o v e r l o a d b e c a u s e o f t o o m u c h fri c t i o n in th e
1. Hollow head screw. 2. Connector. e n g in e b e in g st a r t e d . S lo w o p e r a t i o n o f th e s t a r t i n g
m o t o r c a n a ls o be c a u s e d by s h o r t s , lo o se
c o n n e c t i o n s a n d o r d irt in th e m o t o r .
STARTING SYSTEM Pinion Clearance Adjustment

(Delco-Remy)
W h e n th e en g ine h as a p r e l u b e s y s te m , c h eck it
first to be su re all c o m p o n e n t s f u n c t i o n co r re ctly . W h e n e v e r th e s o l e n o id is in stalled , m a k e a n a d
S ee P R E L U B E S Y S T E M . A f t e r c h e c k i n g t h e j u s t m e n t o f th e p in i o n c le a r a n c e . I he a d j u s t m e n t
p r e l u b e sy stem , p u t a w ire t e m p o r a r i l y b e t w e e n t h e can be m a d e w ith the s t a r t i n g m o t o r r e m o v e d .
c o n n e c t i o n s o f th e oil p r e s s u re sw itc h . T h is will let
the fo llo w in g c h eck s be m a d e w h i c h is t h e s a m e as I. I n stall th e so l e n o id w i t h o u t c o n n e c t o r ( l ) f r o m
c h e c k i n g e ng ines t h a t d o n o t h a v e a p r e l u b e sy s tem . th e M O T O R c o n n e c t i o n ( t e r m i n a l ) o n so l e n o id
t o th e m o t o r .
Use a D. C. V o l t m e t e r to find s t a r t i n g s y s t e m
c o m p o n e n ts which do not function.
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
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 .
C H E C K IN G PRELUBE SYSTEM RELAY

1. Relay terminal.
Oil Pressure Switch
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 .
6. P i n i o n c l e a r a n c e (6) m u s t be .36 in. (9.1 m m ).
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
T h e electrical c o m p o n e n t s in this circu it a r e th e

p u m p m o t o r , relay, oil p r e s s u r e sw itc h a n d s t a r t e r PRELUBE SYSTEM O IL PRESSURE SW ITC H
switc h. I n stall a w ire a r o u n d t h e oil p r e s s u r e sw itc h 1. Terminals.
t o tes t th e c o m p o n e n t s . T h is m u s t be d o n e w i t h
CA U TIO N .
Relay
F i n d t h e d a m a g e d c o m p o n e n t by first c h e c k i n g t o Starter Switch

see if t h e r e is A C c u r r e n t t o th e p u m p m o t o r . F a s t e n
a wire f r o m th e positive ( + ) side o f t h e b a t t e r y t o th e
relay t e r m i n a l ( l) to c o m p l e t e t h e circuit t h r o u g h th e U se a wire i n stalled b e t w e e n th e s t a r t e r b a t t e r y
relay coil. T h e relay m u s t a c t i v a t e a n d c o m p l e t e th e t e r m i n a l (2) a n d s t a r t e r relay t e r m i n a l ( l ) . If th e
A C circuit a n d ca u s e th e p u m p m o t o r to r u n . W h e n s t a r t e r a n d s o l e n o id s e n g a g e , th e failu re is in th e
this is d o n e , r u n th e p u m p lo n g e n o u g h t o m a k e s t a r t e r sw itch. If th e s t a r t e r sw it c h has n o t failed,
p r e s s u re s h o w o n t h e p r e s s u r e g au ge. D u r i n g ch e c k s r e m o v e all wires t h a t w ere i n stalled f o r testin g . See.
t h a t will follo w , en g ine p a r t s will receive l u b r i c a S T A R T I N G S Y S T E M for further checks of the
tion. c ir c u it c o m p o n e n t s o f t h e s t a r t i n g system .
3-54
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
ENGINE SHUTOFF CONTROL

OVERSPEED CONTROL ADJUSTMENT 5. T h e c o n t r o l is t o a c t i v a t e at a r p m 1897 h i g h e r
t h a n t h e full l o a d r p m .
Tools Needed:
4S6553 Engine Test Group
OVERSPEED A D JU S T M E N T
6L2211 Tachometer Drive Group
FT907 Drive Adapter E N G IN E SPEED
Reversible Variable Speed Drill
FULL LOAD A C T IV A T E D S P E E D S P R IN G
RPM i 25 R P M NUM BER
A d j u s t m e n t o f the o v e r s p e e d c o n t r o l is m a d e at 9 00 1062 4L1648
th e f a c t o r y a n d m u s t n o t be c h a n g e d u nles s th e
1000 1180 4L1648
c a r r ie r a s s e m b l y has b e e n d i s a s s e m b le d o r th e
a d j u s t m e n t c h a n g e d in s o m e way. T h e o r i g in a l 1100 1298 4L1648
settin g o f th e o v e r s p e e d c o n t r o l will s t o p th e en g in e 1200 1416 2L8705

w h e n th e eng ine r p m is m o r e t h a n I89f a b o v e full 1534 2L8705
1300
l o a d r p m . D O N O T c h eck t h e a d j u s t m e n t o f th e
1400 1652 2L8705
o v e r sp e e d c o n t r o l o n the engine.
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).
3. Use F T 9 0 7 A d a p t e r (C) a n d rev ersible v a r i a b l e

speed drill (D ) to driv e th e c o n t r o l as s h o w n .
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
A ir A c tu a to r G ro u p (U G 8 -L G o v e rn o r) ......................................... 4-5 M a g n e tic P ic k u p .
C a b le A d ju s t m e n t ( A ir In le t S h u to ff) .............................................. 4-1 P re s s u re S w itc h e s

C o n t a c t o r S w itc h f o r O il P re s s u re .............................................. 4 -1 6
C o n t a c t o r S w itc h f o r O v e r s p e e d ................................................... 4 -1 5 S e n d in g U n its f o r E le c tr ic a l G a u g e s ........................................... 4 -1 4
C o n t a c t o r S w itc h f o r T e m p e r a t u r e .............................................. 4 -1 6 S h u t-o ff, A ir In le t ....................................................................................... 4-7
S h u t-o ff, H y d r a - m e c h a n ic a l ................................................................ 4 -8
E n c lo s e d C l u t c h e s ................................................................................ 4-11 S h u t-o ff, M e c h a n ic a l O v e r s p e e d ................................................... 4 -1 0
S h u t-o ff, R a c k C y lin d e r .......................................................................... 4 -7
F le x ib le C o u p l i n g ................................................................................... 4-11 S h u t - o ff S o l e n o i d s ..................................................................................... 4 -6
S h u t - o ff V a lv e f o r W a te r T e m p e r a t u r e ............................................. 4 -6
G a u g e s , E le c tr ic a l ................................................................................. 4 -1 3
G a u g e s . M e c h a n ic a l ............................................................................ 4 -1 2 T a c h o m e te r , E l e c t r i c ............................................................................ 4 -1 5
G e n e ra l T ig h te n in g T o r q u e s ................................................................... 6 T o r q u e f o r F la re d a n d O - r in g F i t t i n g s .............................................. 7
G o v e r n o r s ....................................................................................................... 4 -2
G o v e rn o r A ir A c t u a t o r s ............................................................................ 4 -4
G o v e rn o r U p p e r D r iv e .............................................................................. 4-3
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 .
2. A d ju s t c a b le (1) at e n d (5) u n til d a s h m a rk (4) is p a ra lle l to th e

c e n te rlin e o f th e in le t m a n ifo ld .
3. A fte r ca b le (1) is a d ju s te d , a d ju s t c a b le (2) at rod e n d (3) so th a t

d a sh m a rk (6) is p a ra lle l to th e c e n te rlin e o f th e in le t m a n ifo ld .
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
(1) L e n g th o f g o v e rn o r l e v e r ................................... 4 .0 0 In. (1 0 1 .6 m m )
(2) A n g le o f g o v e rn o r le v e r to v e r t i c a l ................................................. 44°
(3) A n g le to h o riz o n ta l o f le v e r fo r d riv e h o u s in g ............................ 9'
(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 =
(2) A n g le of le v e r to h o riz o n ta l fo r d riv e h o u s in g

(w ith fu e l ra ck at m in im u m fu e l p o s it io n ) ..................................... 9°
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 )
(2) A n g le of g o v e rn o r le v e r to h o r iz o n t a l............................................ 15°
(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) A n g le to h o r iz o n ta l o f le v e r fo r d riv e h o u s in g ............................ 9°
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 )
(2) End p la y of s h a f t .........................0 1 0 to .0 5 4 in. (0 .2 5 to 1 .3 7 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 )
(2) End p la y of s h a f t 01 1 to 0 7 3 in. (0 .2 8 to 1 .8 5 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
GO VE RNOR AIR ACTU AT ORS

(2 N 6 0 0 6 , 1 N 9 3 1 8 , 7L135)
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)
Fre e le n g th a fte r t e s t 6 .1 9 in. (1 5 7 .2 m m )
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)
Free le n g th a fte r t e s t 4 .9 1 in. (1 2 4 .7 m m )
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
(1) 7L1 2 8 S p rin g :
T e st fo rc e ..................................................................................... 1 5 .7 1b. (7 0 N)
Free le n g th a fte r t e s t 3 .7 3 in. (9 4 .7 m m )
O u ts id e d ia m e t e r 1 .8 2 in. (4 6 .2 m m )
(2) 7L1 2 9 S p rin g ;
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)
Free le n g th a fte r t e s t 8 .5 1 in. (2 1 6 .2 m m )
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
3N9125 AIR ACTUATOR GROU P

(UG8-L Governor)
(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 )
(3) T ig h te n b o lts to a to rq u e o f 22 i 5 Ib. ft. (2 8 ± 7 N-m )
M A G N E T IC PIC KUP
(1) T o rq u e fo r lo c k n u t .............................. 5 0 r 1 0 Ib. ft. (7 0 ± 1 4 N -m )
(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
(1) T o rq u e fo r te r m in a l n u t s .............. 1 4 : 3 lb. in. (1 .6 iL 0 .3 N -m )
(2) 5 L 8 9 8 3 S p rin g fo r p lu n g e r
T e st f o r c e .............................................................................. 2 .0 0 lb. (8 .9 N)
Free le n g th a fte r t e s t 2 .2 5 in. (5 7 .2 m m )
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 p u ll in w in d in g s at 2 0 to 2 4 V ................................ 3 .9 to 5.1 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
(1) T o rq u e fo r t e r m in a l n u t s ................ 1 4 x 3 lb. in. (1 .6 T 0 .3 N-m )
(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 )
(3) T ra v e l of p lu n g e r [s ta rtin g fro m a p o in t

.7 5 in (1 9 1 m m ) fro m fa c e o f s o le n o id ) . . . .5 0 in. (1 2 .7 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 )
SH UTOFF VALVE FOR

W AT ER T EM P ERAT U RE
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
R ACK SH U T OFF CYLINDER

1 N 5 0 7 3 and 5 N 5 7 6 2
(1) 8 L 8 9 5 1 S p rin g , (1 N 5 0 7 3 C y lin d e r):
L e n g th u n d e r te s t f o r c e ....................................... 1.91 in. (4 8 .5 m m )
T e st f o r c e .............................................................................. 1 .5 0 lb. (6 .7 N)
Free le n g th a fte r te s t ............................................ 2 .1 6 in. (5 4 .9 m m )
O u ts id e d ia m e t e r ......................................................... 7 6 0 in. (1 9 .3 0 m m )
(1) 5 N 5 7 5 8 S p rin g ; (5 N 5 7 6 2 C y lin d e r):
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)
Free le n g th a fte r te s t ................................... 4 .2 0 0 in . (1 0 6 .6 8 m m )
O u ts id e d ia m e t e r .........................................................6 6 0 in. (1 6 .7 6 m m )
AIR INLET S H U T OFF
(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
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 )
Test f o r c e ....................................................................... 3 .5 0 Ib. (1 5 .6 0 N)
Free le n g th a fte r te s t ...............................................9 5 5 in. (2 4 .2 6 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)
F re e le n g th a fte r te s t ....................................... 1 .4 5 7 in. (3 7 .0 1 m m )
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
L e n g th u n d e r te s t f o r c e .................................. 1 .5 0 4 in. (38 2 0 m m )
T e st f o r c e ....................................................................... 3 .1 9 Ib. (1 4 .2 5 N)
Fre e le n g th a fte r te s t ....................................... 1.7 7 1 in. (4 4 .9 8 m m )
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)
F re e le n g th a fte r te s t ....................................... 1.621 in. (4 1 .1 7 m m )
O u ts id e d ia m e t e r ................................................ 1 ,3 7 8 in. (3 5 .0 0 m m )
(4) D im e n s io n fro m end o f s p e e d s e n s in g va lve

to th e s e a t ............................ 4 61 5 c .01 0 in . (1 1 7 .2 2 t 0 .2 5 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 )
(7) 4 L 9 9 7 1 S p rin g fo r o il p u m p re lie f v a lv e (3 N 5 7 6 0 a n d 5 N 1 9 7 8

U n its);
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)
Fre e le n g th a fte r te s t ............................................ 2 .0 8 in. (5 1 .0 m m )
O u ts id e d ia m e t e r 4 1 5 in. (1 0 .5 4 m m )
(7) 5 N 6 4 4 9 S p rin g fo r o il p u m p re lie f v a lv e (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 .................................... 16 2 4 in. (41 2 5 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 )
(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
ENGINE ATTACHMENTS
Hydramechanical Shut-Off (Cont.]
(1 0) 5 N 5 2 0 4 S p rin g fo r in te r fa c e va lve (3 N 5 7 6 0 a n d 5 N I 9 7 8 U n its ):
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)
Fre e le n g th a fte r t e s t ......................................... 1 .7 5 in. (4 4 .5 m m )
O u ts id e d ia m e t e r 3 5 0 in. (8 .8 9 m m )
NO TE: 5 N 5 9 9 3 a n d 5 N 5 9 9 4 U n its do n o t h ave an in te r fa c e va lve .
(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)
Free le n g th a fte r t e s t ....................................... 1 .4 8 in. (3 7 .5 9 m m )
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 )
T e st f o r c e ....................................................................... 8 .7 9 lb. (39 .1 N)
Free le n g th a fte r t e s t ....................................... 2 .6 2 in . (6 6 .5 5 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)
Fre e le n g th a fte r te s t 4 .3 9 in . (11 1 .5 m m )
(14) 5 N 6 0 9 6 S p rin g fo r m a n u a l va lve :
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)
Fre e le n g th a fte r t e s t ..................................... 1 .9 2 0 in . (4 8 .7 7 m m )
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 :
T ig h te n v a lv e to a to r q 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 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 :
T ig h te n v a lv e to a to r q 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 ..................... 110 ± 3 psi (7 6 0 ± 2 0 kPa)
(1 6 ) 8 H 8 7 3 1 S p rin g fo r p ilo t va lve :
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
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 .
(1) 4L1 6 4 8 S p rin g fo r o v e r sp ee d tr ip (9 0 0 to 1 1 0 0 rp m e n g in e s ):
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 )
(1) 2 L 8 7 0 5 S p rin g fo r o v e rs p e e d trip (1 2 0 0 to 1 4 0 0 rp m e n g in e s ):
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)
Free le n g th a fte r t e s t 1 .2 5 in. (3 1 .7 5 m m )
(2) 7L21 1 6 S p rin g fo r re le a s e rod
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)
Fre e le n g th a fte r t e s t ........................................... 7 .0 3 in. (1 7 8 .6 m m )
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
900 1062 4L1648

1000 1 180 4L1648
1 100 1298 4L1648
1200 1416 2L8705
1300 1534 2L8705
1400 1652 2L8705
4 -1 0
ENGINE ATTACHMENTS
EN CLO SE D CLU TCHE S
(1) A d ju s tm e n t of c lu tc h le v e r p u ll:
F orce at 21 4 in (541 m m ) fro m c e n te r of s h a ft

(2 N 6 9 6 1 ) C lu tc h 1 2 3 to 1 6 3 lb. (5 4 5 to 7 2 5 N)
F o rce at 3 9 7 in. (1 0 0 8 m m ) fro m c e n te r o f s h a ft

(2 N 7 0 8 0 & 7 L 7 4 9 0 ) C lu tc h e s . . 1 5 5 to 2 0 4 lb (6 9 0 to 9 0 8 N)
(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 )
(3) T o rq u e of s h a ft to h u b n u t .......................................3 0 lb. ft. (4 0 N-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
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
P art No. 4N 5025 4S6574 2N 2413

0 to 1 0 0 psi 0 to 2 8 psi 1 0 0 to 2 4 0 F
R ange
(0 to 6 9 0 kPa) (0 to 1 9 5 kPa) (3 8 to 11 5 =C)
5 0 ± 2 psi 1 7 ± 1 p si 1 6 0 r 10 F
1
(3 4 5 + 1 4 kPa) (1 1 5 ± 7 kPa) (71 ± 6 C)
C h e ck P o in ts
210 - 8 - O F
2 — — (9 9 • 4 0 C)
4 -1 2
ENGINE ATTACHMENTS
GA U G ES FOR ENGINE OIL P R E S S U R E
5 L 7 4 5 5 G a u g e ; use w ith 5 L 7 4 5 0 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 8 0 p si (0 to 5 5 0 kPa)
C a lib ra tio n te s t at 1 4V (3 0 m o u n tin g )
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
C a lib ra tio n te s t at 2 8 .5 V (3 0 m o u n tin g )
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
GA U G E S FOR GEAR OIL P R E S S U R E
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)
C a lib ra tio n te s t at 1 4 V (3 0 m o u n tin g )
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
R a t in g ...................................................................................................................... 24V
P re s s u re ra n g e ............................................ 0 to 3 0 0 psi (0 to 2 0 5 0 kPa)
C a lib ra tio n te s t at 2 8 5V (3 0 m o u n tin g ):

0 p s i (0 k P a ) ....................................................................................... 0 O hm s
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
G A U G E S FOR W ATER TEM P ERAT URE
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)
C a lib ra tio n te s t at 2 8 .5 V (3 0 m o u n tin g ):
100 F (3 8 C ) ............................................................. 3 3 8 8 O hm s
170 F (7 7 C ) ............................................................... 105 0 O hm s
240 F (1 1 5 C ) ................................................................. 4 6 0 O hm s
4 -1 3
D379, D398 & D399 I & M
S E N D IN G UNIT FOR W AT ER T EM P ERAT U RE
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 .
T o rq u e fo r c o n n e c t io n ................................................... 2 0 lb. in. (2 .3 N-m )
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
5 L 7 4 4 9 S e n d in g U n it; U se w ith 5 L 7 4 5 4 and 5 L 7 4 5 1 G a u g e s .
R a t in g ................................................................................................. 1 2V and 24V
P re s s u re ra n g e ............................................ 0 to 3 0 0 psi (0 to 2 0 5 0 kPa)
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
5 L 7 4 5 0 S e n d in g U n it; U se w ith 5 L 7 4 5 5 and 5 L 7 4 5 6 G a u g e s .
R a t in g ...................................................................................................................... 24V
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 ,
s w itc h c lo s e s a t ............................................ 3 to 4 psi (2 0 to 2 5 kPa)
5 L 5 5 0 0 S w itc h
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
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
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
ENGINE ATTACHMENTS
ELECTRIC TACH O M ET ER
3 N 7 2 8 8 (F a ria N o . B-1 5 9 4 - 2 ) ; U se w ith 3 N 4 4 3 0 S e n d in g U n it.
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.
(3) Rubber washer.
CONTACTOR SW IT C H FOR OV E R SP EED
(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
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)
CONTACTOR SW ITC H FOR OIL P R E S S U R E
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)
W ith a decrease of pressure,

c o n ta c ts o p e ra te a t 8 psi (5 5 kPa)
2N 7124
W ith an increase of pressure,

c o n ta c ts o p e ra te a t 2 2 p si (1 5 0 kPa)

c o n ta c ts o p e ra te a t 10 p si (7 0 kPa)
E a rlie r T y p e
9F7837
W ith an in crease of pressure,


8L4537
W ith an increase of pressure,

c o n ta c ts o p e ra te a t 2 2 psi (1 5 0 kPa)

c o n ta c ts o p e ra te a t 1 0 psi (7 0 kPa)
4 - lf i
INDEX
D379, D398, D399 I & M
ENGINE ATTACHMENTS

Pierce Output Shaft Governor ............................................................ 5-6
Automatic Start/Stop System ........................................................... 5-34
Attachments For Cranking Panel ............................................... 5-40
Automatic Transfer S w itch........................................................... 5-34 Power Take-off C lutches.................................................................... 5-10
2301 Control System Application .............................................. 5-38
Cranking Panel ............................................................................... 5-35
Shutoff And Alarm System Components ....................................... 5-11
Electric S e t ....................................................................................... 5-36 Circuit Breaker ................................................................................ 5-12
Hydraulic Governor Application ................................................. 5-36
Contactor S w itc h ............................................................................. 5-13
Oil Pressure Switch ....................................................................... 5-11
Governor Air Actuators ......................................................................... 5-9 Pressure Switch .............................................................................. 5-11
Shutoff Solenoid ............................................................................. 5-12
Shutoff Valve For Water Temperature ..................................... 5-13
Hydra-Mechanical Shutoff ................................................................. 5-14
Water Temperature Contactor Switch ...................................... 5-12
Hydra-Mechanical Shutoff (5N5993 and 5N5994) ................ 5-14
Hydra-Mechanical Shutoff (3N5760 and 5N1978) ................ 5-22
Woodward SG T Governor ................................................................... 5-8
2301 Nonparallel Control System .................................................... 5-32
Woodward UG8 G overnors.................................................................. 5-2
2301 Parallel Control System ........................................................... 5-30 Woodward UG8 Dial and Lever Governors ............................. 5-2

2301 Control S y stem s......................................................................... 5-77 Rack Shutoff Solenoid ................................................................. 5-85
Magnetic Pickup ............................................................................ 5-77 Shutoff Valve (W ater Temperature) .......................................... 5-85
Potentiometer Adjustment (Parallel or Nonparallel Control) 5-77
Woodward EG-3P Governor Actuator ...................................... 5-77 Troubleshooting .................................................................................... 5-42
E le c tro n ic O verspeed S w itch ...................................................... 5-91
Proced ure A ................................................................................. 5 -9 4 W oodward EG-3P A c tu a to r................................................................ 5-75
O verspeed S e tting C a lib ra tio n ........................................... 5 -9 4 Actuator Linkage A d ju s tm e n t....................................................... 5-76
P ro c e d u r e B .......................................................................................... 5 -9 4 Fuel Rack Adjustm ent ................................................................. 5-75
M agnetic P ickup A d ju s tm e n t................................................ 5 -9 4
P roced ure C ................................................................................. 5 -9 5
C ra n k T e rm in a te S p e e d A d j u s t m e n t ..................................... 5 -9 5 W oodward SG T G overnor ................................................................ 5-62
5 -9 6 Engine G overnor Low and High Idle A d ju s tm e n t................... 5-62
P ro c e d u r e D ..........................................................................................
O verspeed V e rify T e s t ............................................................ 5 -9 6 Engine G overnor Speed Droop .................................................. 5-63
S p e e d S p e c if ic a t io n C h a r t ............................................................ 5 -9 6 Fuel Rack Adjustm ent ................................................................. 5-62
T ro u b le s h o o tin g P roced ure (C rank T erm in a te ) ............ 5 -9 3 Governor Linkage Adjustm ent .................................................... 5-64
T ro u b le s h o o tin g P roced ure (O verspeed) ......................... 5 -9 2 Torque C onverter Governor High Idle Speed Adjustment ... 5-64
W irin g D ia g ra m ................................................................................... 5-91 Torque C onverter G overnor Speed Droop A d ju s tm e n t 5-64
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
Pierce Output Shaft Governor .......................................................... 5-60
Power Take-off C lutches.................................................................... 5-90

Assembly Adjustments ................................................................. 5-90
Clutch Adjustm ent.......................................................................... 5-90
Shutoff and Alarm System Components ........................................ 5-83

Contactor Switch for Oil Pressure ............................................. 5-83
Contactor Switch for Overspeed ................................................ 5-86
Contactor Switch for Water Tem perature................................. 5-84
5-1
WOODWARD UG8 GOVERNORS SYSTEMS OPERATION
WOODWARD UG8 GOVERNORS
SCHEMATIC OF UG8 LEVER G OVERNOR
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 )
SCHEMATIC OF UG8 DIAL G OVERNOR
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
control port o f the bushing. A decr ease in load will

cause an increase in engine speed. With an increase in
engine spe ed the flyweights m ove out and raise the
speeder rod and floating lever. This raises the pilot
valve plu ng er and releases oil from the bottom of the
p ow er piston. As the p o w er piston m oves d ow n the
output terminal shaft m oves in the d ecr ease fuel d ir e c
tion. W hen the output terminal shaft m ov es , the actuat
ing com pensation piston m oves up and c auses a suction
on the receiving piston which m o v es down. T h e float
ing lever is pulled d own by the receiving piston and the
lever m oves the pilot control valve dow n to close the
control port. The output terminal shaft and p o w e r pis
ton m o v em en t is stopped. As the engine speed returns
to normal the fl\ weights move in and the sp eeder rod
mov es d o w n. W hen the oil pressure in the c o m p e n s a
tion system and the su m p oil b eco m e the same through
the needle valve, the receiving co m p ensation piston
m oves up at the sa m e rate as the speeder rod m oves
do wn. This action keeps the pilot valve p lun ger in
position to close the port.
UG8 LEVER G OVERNOR
An increase in load will ca use a decrease in en gine
speed. W hen en gine spe ed d ecreases, the flyweights UG8 Dial Governor
move in and lower the speeder rod and floating lever.
This lower s the pilot valve plu ng er and lets pr essure oil T h e sy n c h ron izer is use d to ch an g e en gine spe ed.
go under the p o w e r piston. The p o w e r piston m o ves up T h e speed setting m o to r on the top o f the g o vern or can
and turns the output terminal shaft in the increase fuel also be used to change en gine spe ed. E ither control
direction. W h en the output term in al shaft m o v es , the tur ns the sp e eder plug which m o v es up or d o w n and
actuating co m p en sation piston m ov es d ow n and ca uses ch an g es the force o f the sp eed er spring. T h e sy n c h ro
a pressure on the receiving piston which m oves up. The nizer indicator gives an indication o f the n u m b e r of
floating lever is pushed up by the receiving piston and tur ns the sy nc h ron izer has m oved.
the lever m o ves the pilot valve plu ng er up to close the
T h e load limit control is used to control the am ou n t
control port. The output terminal shaft and p o w e r pis
o f travel o f the output terminal shaft. The control can be
ton m o vem en t is stopped.
used to stop the en gine if the k n ob is tur ned to zero.
A change to the speed setting o f the g o v ern or will
give the sam e gov ern o r m o v em en ts as an increase or CAUTION
decreas e in load.
Do not move the governor linkage in the in
crease fuel direction until the load limit control
UG8 Lever Governor is moved to the maximum position.
A lever on the speed ad justm en t shaft is use d to
T h e spe ed d roop control is used to adjust the am o un t
chan ge the en gine speed. The speed adjustm ent shaft
o f speed d ro op from zero to one hundred percent.
m oves the sp eed er plug up and d ow n to ch an ge the
Speed d roo p is the differen ce b etw een no load high idle
force o f the sp eed er spring.
rpm and full load rpm. T h is d iffe rence in rpm divided
This g ov ern o r is eq u ipp ed with spe ed droo p , h o w by the full load rpm and m ul tiplied by 100 is the percent
ever, it m ust be adjusted inside the governor. o f speed droop.
5 -4
UG8 DIAL G OVERNOR

1. Speed droop knob. 2. Synchronizer knob. 3. Load lim it
knob. 4. Synchronizer indicator.
No load high idle speed - full load rpm ^ ^ qo = % °*

Full load rpm speed droop
Z e ro spe ed d roo p is used on a single sy stem eng in e,

such as a standby generator set. Speed droo p h ig h e r
than zero per m its a load to be divided b etw een tw o or
more en gin es connected to the sam e load.
5-5
PIERCE OUTPUT SHAFT GOVERNOR SYSTEMS OPERATION
PIERCE OUTPUT SHAFT GOVERNOR

Output shaft gover nor (2) is driven by a flexible W h e n the output shaft spe ed ap proaches the p r e d e
cable assembly ( I ) which co n nects to the g o vern or term in ed go verned spe ed setting, weights (15) are
drive m ech an ism on the torque conver ter. Output shaft fo rc ed out m ov in g thrust sleeve (17) and b earin g as
go v ernor (2) and hydraulic se rvo m ech an ism are co n se m bly (18) against the ro ck er yoke (19). As the output
nected by m eans o f an adjustable link (9). shaft speed reach es the p redeterm in ed g o verno r spe ed
setting, the force o f the weights o v erco m es the force of
the go v er n o r spring and the ro ck er yoke is m o v ed ,
rotating the ro ck er shaft (4). L in kage attached to the
ro cker shaft ov er rides the diesel engine g ov ern o r and
r edu ces e n gin e spe ed which in turn red uces converter
o utp ut shaft speed. As the ro ck er yoke m oves o utw ard,
it contacts small b u m p e r spr ing (16) in the end o f the
go v er n o r b o d y , whi ch d a m p e n s oscillation o f the yoke
preventin g erratic g o vern or control. A b u m p e r sc rew
positions the b u m p e r spring.
As to rq ue converter ou tput shaft spe ed drops below

the m a x i m u m g overned spe ed limit, the force exerted
by the ou tput shaft g overnor w'eights is red uced. Since
O UTPUT SHAFT G OVERNOR AND
th e g o v e r n o r is then no lo ng er effective, the diesel
HYDRAULIC SERVO MECHANISM
en gin e g o verno r takes o v er full en gine control and
1. Flexible drive cable. 2. O utput shaft governor. 3.Term i-
nal lever. 4. Rocker shaft. 5. Rate adjusting screw. 6. increase s en gin e speed toward its full g overned spe ed.
Speed change lever. 7. G overnor spring. 8. Bumper
screw. 9. Link. 10. Lever. 11. Lever. 12. Low speed ad T h e ter minal lever (3) m ounted on the ro cker shaft is
justing screw. 13. High speed adjusting screw. 14. co nn ected to the hydr aulic se rvo m ech an ism by the
Bracket.
adjusta ble link (9) and actuating lever (10). Any m o v e
m ent o f the rocker shaft is thus transm itted to the
The output shaft g overnor acts as an “ assistant o p e r
h yd rau lic se rv o m ec hanism .
a t o r . " automatically reducing eng ine speed, which in
turn reduces conv erter output shaft speed w heneve r the
load on the converter output shaft decr eases. T h u s , it
acts as a speed limiting device by preventing the output
shaft and drive equipm ent from suddenly overspeed-
ing. This also relieves the operator of m ak ing speed
adjustm en ts through the en gine gover nor.
The torque converter output shaft m ax im u m spe ed is

either a high spe ed setting or a low spe ed setting, which
is d eterm in ed by changing the position o f spe ed change
lever (6), normally by remote control. High spe ed
screw (13) de term ines the m a x im u m speed for the high
speed setting, and low spe ed sc rew (12) determ ines the
m a x im u m low speed setting. In other w ords, for either
setting there is a p redeterm ined m ax im u m spe ed which
the output shaft cannot exceed.
OUTPUT SHAFT G OVERNOR OPERATION
The operation of the g o v er n o r is the sam e as most
15. W eight. 16. Bumper spring. 17. Thrust sleeve. 18.
rotating weight-type gover nors. The go verno r operates Bearing assembly. 19. Rocker yoke.
only when the torque co nverter output shaft attem pts to
exceed a p redeterm ined m a x im u m speed. This sp eed is
determ ined by the am ount of tension placed on g o v er T h e hy draulic se rvo m e ch an is m consists essentially
nor spring (7). On a variable speed g overnor, the spring o f a se rvo piston (24), control valve and the neces sa ry
tension is controlled by rate adju sting sc rew (5) and the co nn ecting linkage. The piston is co nnected to the
position of the speed ch an ge lever. Increasing the actuating lever by link (2 1), lever (22) and shaft (20),
spring tension increases the m a x im u m speeds. and fits into the cylinder bore.
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.
T h e w ho le oper ation se q uence o f the to rque c o n v ert

er g o v er n o r overriding the diesel en gine g o v erno r and
then relin qu is hin g control again to the engine g o vern or
occurs each tim e the load variations are severe e n o u gh
to perm it the ou tput shaft spe ed to increase or d ecrease
and activate the output shaft g overnor.
G OVERNOR SERVO M ECHANISM

20. Shaft. 21. Link. 22. Lever. 23. Shaft. 24. Piston. 25.
Cam.
5-7
WOODWARD SGT GOVERNOR SYSTEMS OPERATION
WOODWARD SGT GOVERNOR

The S G T G o v e r n o r for the torque co nverter has two T h e tw o go vern ors use a single servo piston to m ove
speed droop g overnors assem bled in a single hou sin g so the fuel system linkage. The actions of the sp eeder
that either go verno r can control fuel to the engine. O ne springs in the go vernor, which are oper ated by the
g ox ernor is operated by the engine. The ot her go v ern or se rvo piston, are separate so that ad justm ent of either
is operated by a flexible cable from the tor que spe ed d roo p can be m ade for control o f en gine and
converter. tor que co n verter speed. Oil fro m the pilot valve o f the
en gin e g o v er n o r is m oved to and from the g o v ern or
se rv o piston by g oing through the piston valve o f the
co nv erter go vernor.
W h e n the torque converter sp eed is less than the

value given in the spe cifications, the pilot valve for the
co n verter g o v erno r gives a straight through oil passa ge
fro m the en g ine gov ern or to the se rv o piston b ecause
the force f ro m the flyweights o f the converter g o v ern or
is not e n o u g h to lift the pilot valve. U n der this c o n d i
tion the fuel is under control o f the en gin e gov ern o r
only. At an increase in the en gin e spe ed setting or a
d ecrease in the load, the sp eed o f the torque con verter
will go to the m ax im u m sp eed adjustm ent for the c o n
ver ter go vernor. At this point, the pilot valve to r the
c on verter g o v er n o r will be lifted to close the passa ge
b etw een the en gine gov ern or and the servo piston and
th e con v erter go vernor will take control. A decrease in
load o r increase in en gine spe ed setting will now cause
no increase in torque co nv erter spe ed bec ause the pilot
valve for the co nv erter g ov ern o r will be lifted to release
W OODW ARD SGT GOVERNOR
oil fro m the se rv o piston and the converter gov ern o r
1. Fuel control lever. 2. High idle screw for the torque will control fuel flow to the engine.
converter governor. 3. Speed adjusting lever. 4. High idle
screw for the engine governor.
GOVERNOR AIR ACTUATORS SYSTEMS OPERATION
GOVERNOR AIR ACTUATORS

3 N 91 24 Air Actuator lor L G 8 Lexer G o v e r n o r is
The go v ern o r air actuator gives rem ote control ot
variable spe ed for the engine. The actuator op erates on attached directly to the gov ernor. One linkage rod
air pressure. Air pressure on the cup in the actuator co nnects the actuator to the gov ernor speed control
m oves the p lunger, spring and rod. This motion c o n lever.
trols the g o v ern or through the linkage.
2N6006 AIR ACTUATO R

1. Linkage.
T hre e types o f actuators are available. T he 2 N 600 6

Actu ator connects directly to the g o v ern or control shaft 3N9124 AIR ACTUATO R
through linkage ( I) . Inspection or r eplacem ent o f the
diaph rag m without changing the adjustm ent o f the high
or low idle speeds or the spring preload is possible. See
R E M O V E A N D IN S T A L L D I A P H R A G M in D IS
A S S E M B L Y A N D A S S E M B L Y . T H E 1N9318 and
7L 135 Actuators control the g o v er n o r through the hand
control lever (2) and cross shaft linkage. These a ctu
ators have an adjustm ent for spring preload only.
1N9318 and 7L135 AIR ACTUATO RS

2. Hand control lever for the governor.
POWER TAKE-OFF CLUTCHES SYSTEMS OPERATION
POWER TAKE-OFF CLUTCHES
POW ER TA KE-O FF CLUTCH

(Typical Illustration)
1. Ring. 2. Driven discs. 3. Link assem blies. 4. Lever. 5. Key. 6. Collar assem bly. 7.
Nut. 8. Yoke assem bly. 9. Hub. 10. Plates. 11. Output shaft.
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

OIL PRESSURE SWITCH Earlier Type Switch
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.
On autom atic start/stop installations, this sw itch

closes to rem ov e the starting sy stem from the circuit
when the en gine is running with norm al oil pressure.
This switch for oil pressure can be connected in a

warning sy stem for indication o f low oil pressure with a
light or horn.
As pressure o f the oil in bellows (6) beco m es higher ,

arm (4) is m o v ed against the force o f spring (3). W h en
projection (10) o f ar m (4) m akes contact with ar m (9),
pressure in the bellow s m o ves both arms. This also
m oves button (8) of the micro switch to activate the
micro switch. OIL PRESSURE SWITCH
(Earlier Type)
1. Control knob.
k 2 J A
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.
S om e o f these sw itches h ave a “ Set F or S t a r t "

button. W h en the button is p u shed in, the m icro switch
is in the S T A R T position. This is done b ecause latch
plate (7) holds arm (9) against button (8) o f the m icro
switch and the switch o perates as if the oil press ure was
norm al. W h en the engine is started, pr ess ure oil flows
into bellows (6). The bellows m ov e arm (4) into co ntact
with latch plate (7). The latch plate releases the “ Set
F or S t a r t " button and spring (5) m oves it to the R U N
position. This puts the switch in a ready to operate
condition. PRESSURE SW ITCH
5-11
SHUTOFF AND ALARM SYSTEM COMPONENTS SYSTEMS OPERATION
S om e sw itches o f this type h ave three terminal c o n

nections. T hey are used to do tw o oper ations with one
switch. They open one circuit and close another with
the single switch.
WATER TEMPERATURE CONTACTOR

SWITCH
The co ntactor switch for w ater tem perature is in

stalled in the water m anifold. No adjustm ent to the
tem per ature range o f the co ntacto r can be m ade. The
elem ent feels the temperature o f the coolant and then
oper ates the micro switch in the contact when the co o l
ant tem perature is too high, the elem ent m ust be in RACK SHUTOFF SO LENOID
contact with the coolant to operate correctly. If the (Typical Illustration)
cause for the engine being too hot is b ecause o f low

coolant level or no coolant, the co ntactor switch will CIRCUIT BREAKER
not operate.
T h e circuit b reak er gives protection to an electrical
T he co ntactor switch is con n ected to the rack sh u to ff circuit. Circuit breakers are rated as to how much
solenoid to stop the engine. T he sw itc h can also be curre nt they will permit to flow . If the current in a
connected to an alarm system . W h en the tem perature o f circuit gets too high it will ca use heat in disc (3). Heat
the cool ant lower s to the operating ran ge, the c o ntactor will cau se distortion of the disc and contacts (2) will
switch opens automatically. op en . No curre nt will flow in the circuit.
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.
An open circuit breaker will close (reset) a u to m a ti

cally w h en it beco m es cooler.
W ATER TEM PERA TUR E CONTACTOR SW ITCH
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.
T he sh u to ff solenoid can be activated by any one o f

the man y sour ces. The most usual are: water t e m p e r a CIRCUIT BREAKER SC HEM A TIC
ture contactor, oil pressure sw itch, o v erspeed sw itc h 1. Disc in open position. 2. Contacts. 3. Disc. 4. Circuit
and rem ote man ual control switch. terminals.
5 -1 2
SHUTOFF AND ALARM SYSTEM COMPONENTS SYSTEMS OPERATION
SHUTOFF VALVE FOR WATER CONTACTOR SWITCH FOR OVERSPEED

TEMPERATURE
T he c o ntactor switch for o v erspee d is installed on the
The shutoff valve for w ater tem perature is co nn ected tach o m eter drive on the front ot the engine. It gives
in an oil line from the m echanical shutoff. T h erm o s tat protection to the engine fro m ru nning too fast.
asse m bly (4) is in contact with the en gine coolant.
T he sw itc h is co nnected to the rack shutott solenoid
W hen the w ater tem perature is no rm al, spring (1) holds
to stop the engine. After the en gin e is stopped b ecause
ball (5) on its seat which stops the flow o f oil. T his lets
o f an o versp ee d co ndition, push the button ( l ) to open
the oil pressure beco m e norm al in the shutoff. High
the switch and permit the starting ot the engine.
water tem perature above the setting o f the valve will
cause the th erm ostat as se m bly to m ove stem (3). This
will m o v e ball (5) off its seat to let the oil pressure in the
sh utoff go back to the engine oil sum p through outlet
port (6). T he low oil pressure causes the shutoff to stop
the engine.
X3970 tX ? f
CO NTAC TOR SW ITCH FOR O VERSPEED

1. Button.
SHUTO FF VALVE FOR W ATER TEM PERATURE

1. Spring. 2. Inlet port. 3. Stem. 4. Therm ostat assem
bly. 5. Ball. 6. O utlet port.
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.
N O T E: V-8 and V-12 eng ines h av e a m an ually o p e r a t

ed valve located at the starter control to prevent en g ine
sh u tdo w n w hen a w arm eng ine is started. W h e n the
valve is activated at start-up, a valve in the rack circuit
op ens, and prev en ts rack actu ato r fro m m o vin g. W h e n
the en gine starts and the eng ine oil pr ess ure is n o rm al,
the valve is release d and the rack circuit is return ed to
norm al oper ation.
HYDRA-MECHANICAL SHUTOFF (5N5993 and

5N5994)
The hy dra-m ech an ical shutoff gives protection for

low oil pressure , high coolant tem perature, and en gine
oversp eed. T h e shutoff also has a manual control to
stop the engine. The shutoff uses lubrication oil from
the en gine and has an oil p u m p to gi ve pressure to the
shutoff sys tem .
The fuel rack shutoff will m o v e the rack to the fuel

off po sition with either low oil press ure or high coolan t
tem perature . Both the fuel rack and inlet air shutoffs
will activate when the engine o verspeeds o r if the
man ual control is used. The fuel rack shutoff will reset
auto m atically but the inlet air shutoff m ust be man ually
reset. HYDR A-M ECH AN IC AL SHUTOFF
1. Speed sensing spool valve. 2. Flyweights. 3. Drive shaft.
The h yd ra-m echanical sh uto ff gives two ranges of
engine oil pr essure protection. As eng ine sp eed in
creases. the m inim um oil pr essure n eeded also in
creases. At low engine spe ed, the shutoff will activate
at a m in im u m oil pressure o f 20 psi (140 kPa). At high
engine sp eeds, the shutoff will activate at a m in im u m
oil pr essure of 30 psi (205 kPa).
A flyweight con trolle d, speed sensing spool valve

(1) is used to feel engine speed. This provides the two M ake refe re nce to the sch em atics for the explanation
ranges of oil pressure protection and oversp eed p ro tec that fol lows o f the hyd ra-m ec hanical shutoff hydraulic
tion. T h e speed sensing spool valve (1) is m o v ed by circuits. T h e hydraulic circuits inside the heavy dashed
flyweights (2) which are turned by drive shaft (3). The lines are in the basic shutoff group. T he co m p o n e n ts
drive shaft is co nnected to the en gin e oil p u m p drive o utside the heavy dashed lines are lines, valves , and
shaft. W h en engine speed increase s, the flyw eights actuators located on the en gine aw ay fro m the shutoff
m ove out and push the spe ed sensing spool valve. unit.
5 -1 4
SYSTEMS OPERATION
SC HEM A TIC NO. 1

1. Speed sensing spool valve. 4 .0 ilp u m 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 way valve. 10. Diverter valve. 11. Fuel rack actuator. 12. Fuel rack
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.
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
cKUjhA
SC HEM A TIC NO. 2

10. Diverter valve. 11. Fuel rack actuator. 12. Fuel rack orifice 13. Low range oil pressure sensing valve.
Low Speed Range (Low Oil Pressure)

Make reference to schematic No. 2.
If the en gine oil pressure go es below 20 psi (140
kpa), valve (13) will close a n d keep rack circuit oil
from the su m p. The pressure drop across fuel rack
orifice (12) go es to zero and pilot oil pressure goes to
diverter va lve (10). V alve (10) m ov es and oil pressure
goes to fuel rack actuator (11) which m o v es the fuel
rack to the sh uto ff position.
5 -1 6
SYSTEMS OPERATION
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.
High Speed Range (Normal Operation)

W hen en gin e spe ed increases to ap p rox im ately 70%
o f full load sp eed, sp eed sensing spool valve ( l ) will
m ove to give pilot oil press ure to selector valve (15).
This will close valve (15) and r em o v e the effect o f
valve (13) fro m the circuit. T h e oil flow in the rack
circuit is the s am e as for the low s peed rang e except that
oil m u st go th rough valve (14) to return to sum p
thr ough valve (9) because va lve (15) is closed.
5 -1 7
SC HEM A TIC NO. 4

10. Diverter valve. 11. Fuel rack actuator. 12. Fuel rack orifice. 14. High range oil pressure sensing valve.
High Speed Range (Low Oil Pressure)

If the en g in e oil pr essure goes b elo w 3 0 psi (205 kPa)
valve (14) will close and keep rack circuit oil from the
sump. T h e press ure drop across fuel rack orifice (12)
goes to ze ro and pilot oil p ressure goes to diver ter valve
(10). V alve (10) m oves and oil pressure goes to fuel
rack actuator (11) which m o v es the fuel rack to the
shutoff position.
5-18
SYSTEMS OPERATION
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.
HIGH COOLANT TEMPERATURE Overspeed Circuit (Normal Operation)

PROTECTION
Make reference to schematic No. 1
Oil goes from oil pu m p (4) to rack sequence valve
Therfnsotatic pilot valve (16) is norm ally closed and (6). Valve (6) ke eps oil pressure at the start o f the rack
is installed in the jacket w ater sys tem . W h en the en g ine circuit at 110 psi (760 kPa). T he rem aind er of the oil
coolant tem perature gets to 210° F (99° C) valve (16) g oes to air inlet sequence valve (7) and to air inlet
will open. Engin e oil pressure from eng ine oil p ressure s hutoff actuators (8). Valve (7) keep s the oil pressure at
orifice (17) will go to the sum p. With no oil p ressu re, the start o f the air inlet circuit at 15 psi (105 k P a ) . The
valves (13 and 14) will close and the engine will shut r e m ain d er o f the oil goes th rough valve (9), which is
d ow n the sam e as with low oil pressure. n orm ally o p en , to the sump.
OVERSPEED PROTECTION N O T E: L o w oil pr essure or high coolant tem perature

co nditions do not ch an ge the oil flow in the air inlet
If the en gine over sp ee ds to a spe ed 18% ab o ve full
circuit.
load speed the shutoff control will activate and shut o f f
both the fuel and air supply to the engine. T he air inlet
shutoff m ust be m anually reset bef ore the en gine is
started again.
5 -1 9
SC HEM A TIC NO. 5

1. Speed sensing spool valve. 7. Air inlet sequence valve. 8. A ir inlet shutoff actuator. 9. Pilot operated, tw o w ay valve. 11.
Fuel rack actuator.
Overspeed Circuit (Overspeed condition)

W h e n the engine gets to an oversp eed condition,
spe ed sensing spool valve ( l ) m o v e s and sends pressure
oil to valve (9), and to the spr ing side o f air inlet
sequence va lve (7). T h e oil pressure will cau se valves
(7 and 9) to clos e and will not let the oil in the air inlet
circuit return to the su m p. Oil pressu re in the air inlet
circuit increases. A ir inlet sh u to ff actuators (8) will
m ove and release the valve plates in the inlet m anifold
to shut o ff the air supply to the engine.
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
SC HEM A TIC NO. 6

1. Speed sensing spool valve. 7. Air inlet sequence valve. 8. Air inlet shutoff actuator. 9. Pilot operated, two way valve. 11.
Fuel rack actuator. 18. Manual shutoff valve.
MANUAL SHUTOFF
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.
N OT E: T h e m anual shutoff valve is to be used only for

an e m erg en cy and not fo r norm al en gine shutdow n.
M a n u al sh u to ff va lve (18) is co n n ected in series with

speed sensing spool valve (1). W h e n valve (18) is
m o v e d to the sh u to ff position, press ure oil is sent
through v alve (1) to air inlet s e q u en ce valve (7), and
pilot valve (9). Fuel ra ck actuator (11) and air inlet
actuators (8) are n o w activated the sa m e as for an
o verspee d condition.
5-21
HYDRA-MECHANICAL SHUTOFF (3N5760 and

5N1978)
The hydra-m ec han ical sh uto ff gives protection for

low oil press ure , high coolant tem perature , and en gine
over spee d. The shutoff also has a manual control to
stop the engine. The shutoff uses lubrication oil from
the en gine and has an oil pu m p to give pressure to the
shutoff system .
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.
The h ydra-m echanical sh utoff gives two rang es of

engine oil pressure protection. As engine spe ed in
creases, the m inim um oil pr essure needed also in
creases. At low engine speed, the shutoff will activate
at a m in im u m oil pressure of 20 psi (140 kPa). At high
engine speeds, the shutoff will activate at a m inim um
oil pr essure o f 30 psi (205 kPa).
A fly weight controlle d, spe ed sensing spool valve

( l ) is used to feel engine speed. This provides the tw o
ranges of oil pressure protection and oversp eed p ro tec
tion. T he spe ed sensing spool valve ( l ) is m ov ed by
fly weights (2) which are turned by drive shaft (3). T h e
drive shaft is connected to the en gine oil p u m p drive
shaft. W h en engine speed increase s, the flyweights
move out and push the spe ed sensing spool valve.
Make reference to the sc hem atics for the explan ation

that follows of the h y d ra-m ech an ical shutoff hydraulic
circuits. The hydraulic circuits inside the heavy d ashed
lines are in the basic shutoff group. The c o m p o nents HYDRA-M ECH AN IC AL SHUTOFF
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
SC HEM A TIC NO. 1

1. Speed sensing spool valve. 4 .0 ilp u m 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 way valve. 10. Diverter valve. 11. Fuel rack actuator. 12. Fuel rack
orifice. 13. Interface valve. 14. Low range oil pressure sensing valve. 15. High range oil pressure sensing valve. 16.
Selector valve. 17. Therm ostatic pilot valve. 18. Engine oil pressure orifice. 19. Manual shutoff valve.
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
o fr g iN A
SC HEM A TIC NO. 2

10. Diverier valve. 11. Fuel rack actuator. 12. Fuel rack orifice. 14. Low range oil pressure sensing valve.
Low Speed Range (Low Oil Pressure)

If the en gine oil pressure g o e s below 20 psi (140
kPa) , valve (14) will close and k eep rack circuit oil
fro m the su m p . The press ure d ro p across fuel rack
orifice (12) go es to zero and pilot oil press ure goes to
diver ter valve (10). V alv e (10) m o v e s and oil press ure
goes to fuel ra ck actuator (11) which m ov es the fuel
rack to the sh u to ff position.
5 -2 4
SYSTEMS OPERATION
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.
High Speed Range (Normal Operation)
W h e n en g ine sp eed increases to ap proxim ately 70%

o f full load sp eed, spe ed sensing spool valve (1) will
m ov e to gi ve pilot oil press ure to selector valve (16).
This will clos e valve (16) and rem ov e the effect of
valve (14) from the circuit. T h e oil flow in the rack
circuit is the s am e as for the low sp eed range ex cept that
oil m ust go through valve (15) to return to sum p b e
cause valve (16) is closed.
5 -2 5
SC HEM A TIC NO. 4

10. Diverter valve. 11. Fuel rack actuator. 12. Fuel rack orifice. 15. High range oil pressure sensing valve.
High Speed Range (Low Oil Pressure)

If the en gine oil press ure goes b elo w 30 psi (205 kPa)
valve (15) will close and k eep rack circuit oil fro m the
sump. T h e press ure drop across fuel rack orifice (12)
goes to zero and pilot oil pressu re go es to diverter valve
(10). Valve (10) m oves and oil pr ess ure goes to fuel
rack ac tuator (11) which m o v e s the fuel rack to the
sh uto ff position.
5 -2 6
SYSTEMS OPERATION
SC HEM 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, two way valve. 10. Diverter valve. 11. Fuel rack actuator. 12. Fuel rack
orifice. 13. Interface valve. 14. Low range oil pressure sensing valve. 15. High range oil pressure sensing valve. 16.
Selector valve. 17. Therm ostatic pilot valve. 18. Engine oil pressure orifice. 19. M anual'shutoff valve.
HIGH COOLANT TEMPERATURE shutoff m ust be m anually reset bef ore the en gine is
PROTECTION started again.
Make reference to schematic No. 1. Overspeed Circuit (Normal Operation)

T h erm o static pilot valve (17) is norm ally closed and Make reference to schematic No. 1.
is installed in the j ack et w ater system . W h en the en g in e
coolant tem perature gets to 210° F (99° C) valve (17) Oil goes from oil pu m p (4) to rack sequence valve
will op en . Engin e oil pressure fro m en gine oil press ure (6). V alv e (6) keeps oil pressure at the start o f the rack
orifice (18) will go to the sum p. W ith no oil p ressure, circuit at 65 psi (450 kPa). The rem ain d er o f the oil
valves (14 and 15) will close and the en gine will shut goes to air inlet se quence valve (7) and to air inlet
d ow n the sam e as with low oil pressure. sh uto ff actuators (8). Valve (7) keeps the oil pressure at
the start o f the air inlet circuit at 15 psi (105 kPa). The
rem ain der o f the oil goes th rough valve (9), which is
OVERSPEED PROTECTION norm ally o p e n , to the sum p.
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
SC HEM A TIC NO. 5

1. Speed sensing spool valve. 7. Air inlet sequence valve. 8. Air inlet shutoff actuator. 9. Pilot operated, tw o way valve. 11.
Fuel rack actuator. 13. Interface valve.
Overspeed Circuit (Overspeed condition)

W h e n the en gine gets to an ov ersp eed co n ditio n,
spe ed sensing spool valve ( l ) m o v e s and sends press ure
oil to interface valve (13), va lve (9), and to the spring
side o f air inlet sequence valve (7). T h e oil press ure
will cau se valves (7 and 9) to close and will not let the
oil in the air inlet circuit return to the su m p. Oil p r e s
sure in the air inlet circuit increase s and air inlet shutoff
actuators (8) will m o ve and re lease the valve plates in
the inlet m anifold to shut o f f the air sup ply to the
engine.
Oil p ressure to interface valv e (13) will cause the

valve to clos e and will not let rack circuit oil return to
the su m p. With the increase in oil press ure in the rack
circuit, fuel rack actuator (11) is m o v ed in the sam e
way as for a low oil press ure condition.
5 -2 8
SYSTEMS O PER A TIO N
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

The m anual operation o f m anual shutoff valve (19)
will shut o f f the fuel and air to the engine.
NOT E: T h e man ual shu toff valve is to be used onl y for

an em e r g e n c y and not for no rm al en gine shutdow n.
Manual sh u to ff valve (19) is conn ected in series with

speed sensing spool valve (1). W h en valve (19) is
moved to the sh uto ff position, press ure oil is sent
throug h valve (1) to interface valve (13), air inlet se
q uence valve (7), and pilot valve (9). Fuel rack actuator
(11) and air inlet actuators (8) are now activated the
sam e as for an oversp eed condition.
5 -2 9
2301 PARALLEL CONTROL SYSTEM SYSTEMS OPERATION
2301 PARALLEL CONTROL SYSTEM
O o
W w w
2301 LOAD SHARING & SPEED CONTROL
LOAD GAIN
R OPEN DROOP REMOVE

CLOSE ISOCH JUMPER
90 990 MAGNETIC 11 TO DEPEAT
ACTUATOR PICKUP SPEED r« S SYNC 32 r 11-» FAIL SAFE
INPUT TRIM IN VDC
A B C A
1 2 3 4 5 10 11 12 13 14 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 30
©
©© © ©I) ©
£L J L _@ L
o © O
2301 PA RALLEL CO NTRO L BOX
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
A m in im u m fuel switch can be co nnected between

ter m inals 22 and 23. This gives an optional m etho d tor
sh utd ow n . W h e n this switch is closed the voltage o u t
put to the actuator is zero.
T he gain and stability p oten tiom eters control the

resp onse o f the engine to a ch an ge in load. The gain
p otentiom eter is used to d ecrease resp onse time to a
m in im u m . T he stability po ten tiom eter is used to get the
best spe ed stability for the gain setting that is used.
The spe ed d roop p oten tiom eter controls the am o un t

o f spe ed droop. It can be set between 0 and 13 9 c . Droop
is neces sa ry when paralleling with a utility bus or a unit
with a hy dra-m echanical gov ernor.
The de-d ro o p po ten tio m eter gives co m p en satio n

during isochro nous oper ation for dro op caus ed by c o m
ponent toler an ces and outside electrical noise.
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
The spe ed failsafe circuit will return the voltage

output o f the control to zero if the m agnetic pickup
signal has a failure. This will cau se the actuator to
m o ve to the F U E L O F F position. Also the en gine will
not start if the m agnetic p ickup signal has a failure.
NOTE: Earlier arrangem ents will go to the m a x im u m

fuel position with loss of voltage to the actuator.
5-31
2301 NONPARALLEL CONTROL SYSTEM SYSTEMS OPERATION
2301 NONPARALLEL CONTROL SYSTEM
O O
NO NPARALLEL CO NTRO L BOX
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
The gain and stability p otentiom eters control the

resp onse o f the engine to a ch an ge in load. T h e gain
p oten tiom eter is used to de crease res po nse time to a
m in im u m . T h e stability p o ten tio m ter is used to ge t the
best spe ed stability for the gain setting that is used.
A d roop p o ten tiom eter can be connected b etw een

terminals 13, 14 and 15 to control the am o un t o f speed
d roop. Dro op is necessa ry w hen par alleling with a
utility bus or a unit with a hydra-m ec h an ical go verno r.
The sp eed failsafe circuit will return the vol tage

output of the control to zero if the mag netic picku p
signal has a failure. This will cause the actuator to
m o v e to the F U E L O F F position. Also the en g ine will
not start if the m agnetic p ick u p signal has a failure.
NOT E: Earlier arrangem ents will go to the m a x i m u m

fuel position with loss o f vol tage to the actuator.
5 -3 3
AUTOMATIC START/STOP SYSTEMS SYSTEMS OPERATION
AUTOMATIC START/STOP SYSTEM

(Non-Package Generator Sets)
AU TO M A TIC S T A R T /S TO P SYSTEM SC HEM A TIC

(Hydraulic Governor)
1. Starter m otor and solenoid. 2. Shutoff solenoid. 3. Fuel pressure switch. 4. W ater tem perature switch. 5. Oil pressure
switch. 6. O verspeed contactor. 7. Battery. 8. Initiating relay (IR). 9. Shutdown relay (SR). 10. Auxiliary relay (AR). 11.
O vercrank tim er (OCT). 12. O N /O F F /S T O P switch (SW2). 13. A U TO M A TIC /M A N U A L switch (SW1). 14. Term inal board
(TS1).
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.
AUTOMATIC TRANSFER SWITCH

The au tom atic transfer switch nor m ally connects the
3-phase norm al (com m erc ial) p o w e r supply to the load.
W hen the com m ercial p o w e r supply has a failure the
switch will transfer the load to the standby electric set.
The tran sfer switch will not tran sfer the load fro m
com m ercial to em erg en cy p o w e r until the e m erg en cy
p ow er gets to the rated voltage and frequency. T h e
reason for this is, the solenoid that causes the transfer o f
p ow er operates on the voltage from the standby electric AUTO MATIC TR AN SFER SW ITCH
5 -3 4
TRANSFFR
SWITCH
COMMERCIAL
POWE R □
- m -
IN IT IA T IN G
CONTACTOR
ft
AUTO M ATIC S T A R T /S TO P SYSTEM SCHEMATIC

(2301 Control System)
1. Magnetic pickup. 2. Starter m otor and solenoid. 4. Oil pressure switch 1 (OPS1). 5. W ater tem perature switch. 7.
O verspeed switch. 8. Battery. 9. Initiating relay (IR). 10. Shutdow n relay (SR1). 11. A uxiliary relay (AR). 12. Overcrank
tim er (OCT). 13. O N /O F F /S T O P switch (SW2). 14. A U TO M A TIC /M A N U A L switch (SW1). 15. Term inal board (TS1). 16. EG-
3P Actuator. 17. Oil pressure switch 2 (OPS2). 18. 2301 Control box.
CRANKING PANEL L O C K O U T indicator light ( l ) will activate if, the

en gine do es not start, or if a protection d evice gives the
T h e main function o f the cranking panel is to control signal to shu toff during oper ation.
the start and shu toff o f the electric set.
Switch (2) gives either A U T O M A T I C or M A N
U A L starting. In the diag ram s show n later this switch
is called S W l . Switch (3) has three positions “ O N ” ,
“ O F F ” and “ S T O P ” . This sw itch is called S W 2 in
the d iagram s. M ove S W 2 (3) to O N and S W l (2) to
M A N to start the engine im m ediately. M ove S W 2 (3)
to O F F on an electric set in o peration to start the shutoff
sequence. If the system is eq uip ped with a time delay
the eng ine will not stop im m ed iately . W hen S W 2 (3) is
m o ved to the S T O P position the en gine stops im m e-
diatley. The switch must be held in the S T O P position
until the en g in e stops. W h en the switch is released a
spring returns it to the O F F position. With S W 2 (3) in
the O N position and S W l (2) in the A U T O position the
control is re ady for standby operation.
There are several attachm ents that can be ordere d for

BASIC CRANKING PANEL this p a n e l . A description o f h o w each one w or ks and the
1. Indicator light. 2. M anual-Autom atic switch. 3. ON- effect it has on the oper ation o f the standard sy stem is
O FF-STO P switch. given after the expl anations o f the standard system.
5 -3 5
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.
An ex planation of each of the signal co m p o n en ts is

given in separate topics.
HYDRAULIC GOVERNOR APPLICATION

The circuit illustrations that follo w are basic sc h e
matics. D O N O T use them as com plete wiring
diagram s.
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
Automatic Starting Operations

W hen e m erg en cy p o w e r is n eeded the initiating c o n
tactor d o s e s . This ener gi zes the initiating relay and the
run relay. T h e current flow th rough the initiating relay
contacts then en er gizes the mag netic sw itch, which
ener gi zes the pinion solenoid. T h e starting m o to r is
no w co nn ected to the battery. The starting oper ation
starts. At the sam e time the overcran k tim er is en er
gized and starts to run.
At 600 rp m the cranking term in ate relay closes. Oil

pressure cau ses oil pressure sh utd ow n switch (OPS) to
activate. T h e nor m ally closed contacts o pen and the
no rm ally o pen contacts close. W h e n oil press ure sh ut
d ow n switch (OPS) activates , the auxiliary relay is
energized and current flow to the mag netic sw itc h and CO NTRO L PANEL
pinion solenoid is stopped. T he starting operation then C O NTRO LS IN AU TO M A TIC POSITION:
stops. ENGINE DOES NOT START
5 -3 6
SYSTEMS OPERATION
AUTOMATIC START/STOP SYSTEMS
It the en gine does not start in 30 seconds, the ov er

crank tim er contact closes. This en ergizes the shu t
d ow n relay and the alarm light. T h e sh u tdo w n relay
stops curre nt flow to the initiating relay and th e run
relay. D e-energizing the run relay also stops current
flow to the auxiliary relay. W h e n the shutdown relay is
en erg ized , the magnetic switch and the pinion solenoid
are de- energized. T h e starting operation then stops.
The shutdown relay also energizes the rack solenoid to
m ove the fuel rack to the fuel O F F position. T he
shutdown relay is ener gized until sw itc h ( SW 2) is m a n
ually tur ned to the O F F position.
CO NTRO L PANEL
C O NTRO LS IN AUTO MATIC POSITION:
EM ERGENCY POW ER NOT NEEDED
Automatic Stopping Operations
Manual Starting Operation
CONTROL PANEL
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
Manual Stopping Operation Components of the 2301 control system:

2 301 GOV. 2301 C O N T R O L
E G -3 P A C T . ACTUATOR
MP M agnetic p ickup
OPS2 R a m p switch for 2301 C O N T R O L
Automatic Starting Operations

W h e n e m erg en cy p o w e r is n eed ed , the initiating
co ntacto r closes. This energizes the intiating relay, the
cr ank ing relay , and connects the 2301 Control to the
battery. The cran king relay en ergizes the magnetic
switch and the pinion solenoid. The starting m o to r is
n o w con n ected to the battery. T h e starting ope ration
starts. At the sam e time the o vercrank tim er is e n e r
g ized and starts to run.
CONTROL PANEL
CO NTRO LS IN AUTO MATIC POSITION:
MANUAL SHUTDOW N
W h en switch (SW 2) is m o v ed to the S T O P po sition,

current flow is directly to the rack solenoid. T he rack
solenoid m ov es the fuel rack to the fuel O F F position.
The initiating relay, run relay and auxiliary relay are
de-e nergized. Switch (SW 2) m ust be held in the S T O P
position until the engine stops.
2301 CONTROL SYSTEM APPLICATION

The circuit illustrations that follo w are basic sc h e
CO NTRO L PANEL
matics. D O N O T use them as com plete wiring
C O NTRO LS IN AUTO M ATIC POSITION:
diagram s. ENGINE STARTING
A t 6 0 0 r p m the cr anking term in ate relay closes. Oil

p ressure switch (OPS2) closes at ap proxim ately 6 .4 psi
Components of the automatic start/stop (44 kPa). T h is lets the 2301 Control signal the actuator
system: to m ov e fro m low idle to the des ired rpm. Oil press ure
also causes oil press ure sh utd ow n switch (O P S1 ) to
AR Auxiliary relay activate. T h e nor m ally clos ed co ntacts op en and the
CB Circuit breaker n oram lly open contacts close. W h e n oil pr ess ure sh ut
CR Cran kin g relay d o w n sw itch (O P S1 ) activates , the auxiliary relay is
CT C ran k in g terminate relay (part o f OS) e nergized and curre nt flow to the cranking relay stops.
D Diode T his d e-energizes the m ag n etic sw itch and the pinion
1R Initiating relay solenoid . T h e starting operation stops.
MS M ag netic switch
OCT O v ercran k timer If the en gin e does not start in 30 seconds, the o v e r
OPS1 Oil pressure shut off switch cr an k tim er co ntact closes. T his energizes the shu t
OPS 2 Oil pressure switch d o w n relay and the alar m light. The sh u tdo w n relay
OS Ov ersp ee d shut o ff switch stops curre nt flow to the initiating relay. T h e current
PS Pinion solenoid flow is then stopped to the 2301 Con trol. The E G -3 P
SM Starting M otor A c tu a to r m o v e s the fuel rack to the F U E L O F F p o si
SRI S h u td o w n relay tion. T h is also de-energizes the magnetic switch and
SW1 Au to m atic/M an u a l switch the pinion solenoid . T he starting operation stops. The
SW 2 O n / O f f/ S t o p switch sh utd ow n relay is energized until switch (SW 2) is m a n
WT W a te r tem per ature shut off switch ually turned to the O F F position.
5 -3 8
SYSTEMS OPERATION
CONTROL PANEL CONTROL PANEL

CO NTRO LS IN AU TO M A TIC POSITION: CO NTRO LS IN AUTO M ATIC POSITION:
ENGINE STARTS SH UTD OW N BY PROTECTION CO M PO NENT
CO NTRO L PANEL CONTROL PANEL

CO NTRO LS IN AUTO M ATIC POSITION: CO NTRO LS IN AUTO M ATIC POSITION:
ENGINE DOES NOT START EM ER G ENC Y POW ER NOT NEEDED
Automatic Stopping Operations

W hen the contacts for any o f the shutdown sw itches
close, the sh utd ow n relay and the alarm light are e n e r
gized. This de-energizes the initiating relay and the
auxiliary relay. Current flow to the 2301 Control is
Manual Starting Operation
stopped. The E G -3 P A ctuato r will then m ov e the fuel
rack to the F U E L O F F position. T h e sh u td o w n relay is S w itch ( S W l ) , in the M A N U A L position, r em o ves
ener gized until switch (SW 2) is man ually turned to the the initating co ntactor fro m the circuit. In the M A N
O F F position. U A L position the intiating relay is ener gized and c u r
rent goes to the 2301 Control. T h e curre nt flow thr ou gh
W hen com m ercial p o w e r is started again, the initiat the initiating relay contacts also energizes the cranking
ing contactor opens. This de-energizes the initiating relay. T he cranking relay en erg izes the mag netic
relay and the auxiliary relay. Curren t flow to the 2301 switch which in turn en ergizes the pinion solenoid. The
Control is stopped. T h e E G -3 P A ctuato r will then starting m o to r is no w con n ected to the battery . The
m ove the fuel rack to the F U E L O F F position. starting op eration starts. T h e ov ercrank tim er is not in
5 -3 9
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.
SEPARATE ALARM LIGHTS
T his attach m en t show s the reaso n for sh u td o w n.
Cycle Cranking Timer

The cycle crank ing tim er has a cycle cr an k m o du le
CONTROL PANEL
CO NTRO LS IN M ANUAL POSITION:
(CC). It perm its adjustm ent o f the am o un t o f tim e that
ENGINE STARTING the starting m o to r operates. It can be set for 30 se conds
o f constan t oper ation to 5 cy cles o f 10 se conds of
o peration with a 10 se co nd delay betw een each cycle ot
oper ation. W h en the cranking cy cles set in the tim er are
c o m p leted , cy cle crank m od u le (CC) close the circuit
to the overcrank relay (OCT ).
Manual Stopping Operation
Time Delay Relay
W hen switch (SW 2) is m o ved to the S T O P position,
current flow' to the 2301 Control is stoppe d. T h e EG- This attach m ent caus es a 2 m inute delay in the acti
3P A ctuato r will then m ove the fuel rack to the F U E L vation o f the shutoff solenoid (RS) w hen the en gin e is
O F F position. The initiating relay and auxiliary relay au tom atically being stopped becau se o f the return of
are also de-energized. Switch (SW 2) must be held in (com m erc ial) norm al power .
the S T O P position until the en g in e stops.
T he pu rpo se o f this tim e delay is to let the en gine
cool m o re slowly after running.
W h e n the ( co m m erc ial) nor m al p o w e r starts ag ain,

the initiating co ntactor (I) op ens. T his op en s the circuit
to the run relay (R R) and initiating relay (IR). T h e run
relay (RR) h as norm ally closed co ntacts which co nnect
the oil press ure time delay sw itch (O P T D ) with the
tim e delay relay (TD). T h e oil pr ess ure tim e de lay
switch (O P T D ) is closed at this time. T he time delay
relay (TD ) starts to m easu re time. A fter 2 m ore m i n
utes o f en g in e oper ation, the tim e delay relay (TD )
activates. It closes its norm ally o p en contacts in the
circuit b etw een the oil press ure time delay switch
(O P T D ) and the sh uto ff solenoid (RS). Because the oil
p ressure tim e delay switch (O P T D ) is closed , the cir
cuit is n o w closed to the sh u to ff solenoid (RS). T h e
shutoff solenoid (RS) activates. It m oves the fuel rack
to the F U E L O F F position. T his m ak es the en gine stop
M ANUAL SHUTDOW N running.
5 -4 0
SYSTEMS OPERATION
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
SCHEMATIC OF CONTROL PANEL

(SHOWS ALL STANDARD ATTACHMENTS)
(ALL COMPONENTS ARE SHOWN IN NORMAL CONDITIONS)
The components are:
RR Run relay
AR Auxiliary relay RS Rack shutoff solenoid
BATT Battery SM Starting m otor
CC C ycle cr an k in g timer S R - 1,2,3 S hu tdo w n relays
D1 and D2 Diodes SWl A u to m atic/M an u a l switch
I Initiating co ntactor SW2 O n /O f f/S to p switch
IR Initiating relay TD T im e delay relay
MS M ag netic switch WT W ater tem perature sh u to ff switch
OCT O vercrank tim er © T erm inals in cr ank ing panel
O PS Oil pressure sh utd ow n switch
OPTD Oil pr ess ure tim e delay switch
N O T E: D otted lines show co m p o n en ts outside the
cr anking panel.
5-41
TROUBLESHOOTING
Troubleshooting can be difficult. On the following pages there is a list of

possible problems. To make a repair to a problem, make reference to the
cause and correction.
This list of problems, causes, and corrections, will only give an indication
of where a possible problem can be, and what repairs are needed. Normally,
more or other repair work is needed beyond the recommendations in the list.
Remember that a problem is not normally caused only by one part, but by the
relation of one part with other parts. This list can not give all possible
problems and corrections. The serviceman must find the problem and its
source, then make the necessary repairs.
5 -4 2
TROUBLESHOOTING
Item Problem Item Problem
1. C o ntac to r Switch F or W a te r T em p erature Does 16. 2301 Parallel Control System .

Not Activate S hutoff S olenoid. a. Engin e Will Not Start.
2. Co ntacto r Switch for W ater T em peratu re A cti b. E ngin e O verspee d s On Starts.
vates S h u to ff Solenoid at W r o n g T em pera ture. c. E ngin e O versp ee ds A fter Operation At Rated
3. C on tac tor Switch for Oil Pre ss ure Fails to A ctivate S peed F or S o m e T im e.
S h u to ff Solenoid. d. L o w Idle S peed P otentiom eter G ives No
4. C o ntac to r Switch for O v ersp ee d Fails to A ctivate A d justm en t.
S hu to ff Solenoid. e. Engin e Does Not R e tu rn T o L ow Idle W h en
5. C o n tac to r Switch for O v erspeed Activates S h u to ff T h e Idle (Oil Press ure) Switch Opens.
Sol enoid at W ro n g Speed. f. E n gin e Speed Does Not H av e Stability .
6. Sh uto ff Solenoid Fails to Stop Engine. g. S p e e d T rim P o te n tio m e te r G iv e s No
7. Sh uto ff Solenoid Pre ven ts E ngin e Start. Adju stm en t.
8. Clutch Will Not Engage (Slips), Heats or L e v e r h. 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 No
Moves to Released Position. Adju stm en t.
9. Clutch Shaft Has T oo M uch End Play. i. L o ad Sharing Is Not Correct.
10. Clutch Bearings Have Short Service Life. j. E ngin e Speed Is Not Iso chronous.
11. H y d ra-m e chan ical Shu toff Will Not Let E ng in e k. S y stem Does Not Have Stability W hen Par allel
Start. ing O r In Parallel.
12. H ydra-m e ch an ical S hu to ff Will Not Let E ngin e 17. W o o d w a r d UG-8 G o v ern ors
Run A b o v e 70% of R ate d Engin e Speed. a. E n g in e S peed Does Not Have Stability .
13. H ydra-m e chanical S hu toff Activates With E ng in e b. Fuel Control R e sp o nse W h en the Engin e Is
Oil Pre ss ure and W ater T em peratu re Norm al. Starte d Is Not Accepta ble .
14. Electrical G au ges Give W ro n g Read ings. c. E ngin e Is Slow To R e sp o n d T o A C h a n g e In
15. 2301 Nonparallel Control System . Speed Setting o r Load .
a. Engin e Will Not Start. d. L o ad S haring B etw een P ar alleled Units IsNot
b. Engin e O v ersp eed s O n Starts. Correct (One unit on zero d ro op all others on
c. Eng ine Ov ersp eeds After Operation At R ate d droop).
S peed For S o m e Tim e. e. L oad Shar ing Be tw een Par alleled Units Is Not
d. L o w Idle Speed P otentio m eter G ives N o C o rrect (all units on droop).
A djustm ent. 18. A utom atic Start/Stop System s.
e. E ngin e Does Not Return To L o w Idle W h e n
T h e Idle (Oil Pre ss ure) Switch Open s.
f. E ngin e Speed Does Not H av e Stability.
g. 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
Adjustm ent.
h. 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
Adjustm ent.
i. L o ad Sharing Is Not Correct.
j. Engin e Speed Is Not Iso ch ronous.
5A3
C O N TA C TO R SW ITC H FOR W A T E R T E M PE R A T U R E DOES NOT A C T IV A TE

S HU TO FF SO LEN O ID
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.
Failure o f S h u to ff Solenoid C h eck the shu toff solenoid.
Low W ater Level in Coo ling Fill the cooling system .

System
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 .
2. C O N T A C T O R SW ITCH FOR WATER TEM PERATURE A CTIVATES SHUTOFF SOLENOID AT

WRONG TEM PERATURE.
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.
W ro n g Setting o f Switch Test contactor sw itc h. If necessa ry install n ew contactor switch.
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 .
5. CONTACTOR SW ITCH FOR OVERSPEED A CTIVA TES SHUTOFF SO LEN O ID AT WRONG

SPEED.
Cause Correction
W ro ng Setting Make ad justm ent to setting o r install new co n tacto r switch if

n eces sa ry .
5 -4 4
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
W r o n g C on nectio ns C h e ck con n ectio n s and wiring.
P lunger Shaft A djustm ent W ron g M ake ad ju s tm ent to plu n ger shaft.
W ro n g P lu n g er in Shu toff S olenoi d Install the corre ct p lun 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.
Side L o ad T oo High M a k e reduction o f side load.
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
12. H Y D R A -M EC H A N IC A L SHUTOFF W ILL NOT L E T EN GINE RUN ABOVE 70% OF RATED

EN G IN E SPEED.
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
Defect In T herm ostatic Clea n or replace valve.

Pilot Valve
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 .
C ause C o rre ctio n
W ron g C on ne ctio n s C h e ck wiring co nn ectio ns to be sure they are correct.
Sending Units Have A Failure C h e ck the se n din g units and install new ones if necessary.
Re sistor in 32 Volt System s Install a n ew resistor.

Has a Failure
W ron g S en din g Unit in Install corre ct se nding unit.

System
W ron g G au g e Install corre ct gauge.
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
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 .
M ake replacem en t o f the control.
S P E E D T R I M Potentiom eter M ake replacem en t o f the pot entiom eter.

Has A Failure
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
G A I N and S T A B IL I T Y A djust th ese po ten tiom eter s.

are Not Correctly Adjusted
5-47
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
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 ake repairs as necessary.
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.
Actuator Has A Failure M a k e replacem en t o f the actuator.
Fuel Control L in kage Is Not A djust the linkage.

Correctly Adjusted
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.
15e. E N G I N E D O E S N O T R E T U R N T O L O W ID L E W H E N T H E I D L E (Oil Pre ss ure ) S W I T C H O P E N S .
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
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
G A IN and S T A B IL I T Y A d just po tentiom eters.

are Not Correctly Adjusted
R A T E D S P E E D or S P E E D T R I M M ake rep lacem en t o f the control or S P E E D T R I M poten tiom eter .

P otentio m eter Has A Failure
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
A ctu ato r Has a Failure M a k e rep lacem ent o f the actuator.
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. Make repairs as necessary.
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
Actuator W iring Has A Failure M a k e replacem en t o f the wiring.
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
R A T E D S P E E D or D R O O P Adju st th ese poten tiom eter s.

P otentio m eter is Not
A djusted Correctly
5 -4 9
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
Engine is O v erloaded If the en gin e gives rated h o r se p o w e r at the m a x im u m fuel position,

decrease the load on the engine.
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.
C h e ck T28 ( + ) and T 3 0 (-). If the voltage is not approxim ately 9.5 V

DC m ake a replacem ent 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
M inim um Fuel Switch Clos ed O p en m in im u m fuel switch.
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.
(Cont. next page)
5-50
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 .
M a k e rep lacem ent of the control.
S P E E D T R I M P o tentio m eter M a k e rep lacem en t o f the poten tiom eter .

Has A Failure
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
G A I N and S T A B IL I T Y A djust th ese po ten tiom eter s.

P o tentiom eters are not Correctly
Adjusted
Engin e Fuel System 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. Make repairs as necessary .
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.
A ctu ato r Has A Failure M a k e r ep lacem en t o f the actuator.
Fuel Control Lin kage is Not Ad ju st th e linkage.

C or rectly Adjusted
5-51
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
Engine M in im u m Fuel Position Adjust the en gine m in im u m fuel position. See F U E L S Y S T E M in

is T o o High TESTIN G A N D AD JU STING .
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.
16e. E N G I N E D OE S N O T R E T U R N T O L O W ID L E W H E N T H E I D L E (Oil Pre ss ure) S W I T C H O P E N S .
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
R A T E D S P E E D or S P E E D T R I M M ake r ep lacem en t o f the control o r S P E E D T R I M pot en tiom eter .

P otentiom eter Has A Failure
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
Actu ator Has A Failure M a k e rep lacem ent o f the actuator.
Engine Fuel S ystem Has A Failure Use the F U E L S Y S T E M se ction 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 a ke repairs as neces sa ry.
(Cont. next page.)
5 -5 2
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 .
Magnetic P ickup W iring M a ke rep lacem en t o f the wiring.

Has A Failure
Actuator W iring Has A Failure M ake rep lacem en t o f the wiring.
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
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
R A T E D S P E E D or D R O O P Adjust thes e po tentiom eters.

P otentiom eter is not Adjusted
Correctly
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.
A Large A m o u n t of Current Adjust the generator vol tage controls.

Return to Gen erato rs in the System
D E - D R O O P P oten tiom eter is not Adjust the pot en tiom eter .

Adjusted Correctly N O T E: If this p otentio m eter do es not have en o ug h ran ge to give the
en gine stability see I T E M 16f.
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.
Lost M o v e m en t in G o vern or R e p air o r replace linkage.

to Engin e Lin kage
G o v e r n o r to Engin e Linkage R e pair o r replace linkage.

Does Not M ov e Freely
G o v e r n o r W orn R e pair o r replace gov ernor.
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.
P o w e r P iston Sticking C h e c k alig nm en t o f piston, p o w e r link and p o w e r lever. Check to r end

play o f terminal shaft.
Voltage R e gu la to r Does Adjust o r repair voltag e regulator.

Not O perate Correctly
Engine Misfiring M ake r efe re n ce to F U E L S Y S T E M S in E N G I N E T E S T I N G A N D

ADJUSTING.
5 -5 4
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.
Engine C ran k in g Speed Make r efe re nce to T R O U B L E S H O O T I N G in E N G I N E T E S T I N G

T o o Low AND ADJUSTING.
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.
Ove rload On Engine R e d uce load.
Load Lim it K n o b Set to Incre ase load limit setting.

Restrict Fuel (UG8 Dial
G o v e r n o r Only)
17d. L O A D S H A R I N G B E T W E E N P A R A L L E L E D U N IT S IS N O T C O R R E C T (All units on dr oop).
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.
17e. L O A D S H A R I N G B E T W E E N P A R A L L E L E D U N I T S IS N O T C O R R E C T (all units on droop).
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
18. A U TO M A TIC STA R T/ST O P SYSTEM.
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 SUPPLY OF STANDBY CURRENT
Engine Starting Problem Starting System Problem Starting System Problem
— 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
Switch Problem Engine Problem
— W ater tem perature switch has a — High friction due to seizure

failure
— O verspeed switch setting is low or Switch Problem

has a failure
— Oil pressure switch has low setting
Cranking Panel Problem
— Overcranking tim er has a failure
5 -5 6
TROUBLESHOOTING
NO SUPPLY OF STANDBY CURRENT
circuit G enerator Problem Transfer Switch Problem
— 1V, 2V and 3V contactor shorted — S e e to p ic “ No A C V o lta g e ” in — SE relay contacts bad

Troubleshooting section of the Gen
erator Service Manual. — TS relay contacts bad
Cranking Panel Problem
— Lo relay or related circuit has a
— Toggle switches SW-1 and SW-2 failure
are in the wrong posihon or have a
failure — Diodes in rectifier bridge for TS so
lenoid have a failure
— NC contact of SE relay has a failure
— IR relay open circuit Wiring Problem
— Phase EA or EC not connected

(open) to transfer switch
STANDBY CURRENT SUPPLY

STOPS BEFORE NORMAL CURRENT RETURNS
— High w ater temperature -M alfunction developed during oper

ation— see topic “ No AC Voltage” in
— Low oil pressure Troubleshooting section of G ener
ator Service Manual.
— O verspeed
— No load
— O verload
— Mechanical failure
5 -5 7
OPERATION OF STANDBY SYSTEM

WHEN STANDBY CURRENT IS NO LONGER NEEDED
Transfer Switch Problem Cranking Panel Problem Transfer Switch Problem
— 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)
— Tim e delay relay (if fitted) has a

failure Problem on Engine
— Fuel pressure switch has a failure
— Rack stop solenoid has a failure or

open in its circuit
— Fuel rack seizure in the open posi

tion (overspeed possible)
Transfer Switch Problem
— SE contacts welded
5-58
MEASURING ENGINE SPEED TESTING AND ADJUSTING
MEASURING ENGINE SPEED

MEASURING ENGINE SPEED
Tools Needed:
5P2150 Engine Horsepower Meter or
4S6553 Instrument Group or
1P5500 Portable Phototach Group
1P5500 PO RTABLE PHOTOTACH GROUP
The 1P5500 Portable Phototach G ro up can m easure

engine sp eed from the ta ch om eter drive on the engine.
It also has the ability to m easu re engine sp eed from
visual en gine par ts in rotation. Special Instruction
F orm No. S M H S 7 0 1 5 has instructions for its use.
5P2150 ENGINE HORSEPOW ER METER
T he 5 P 2 1 5 0 Engin e H o rsep o w e r Meter can m eas u re

engine spe ed from the ta cho m eter drive on the engine.
Special Instruction F orm No. S M H S 7 0 5 0 has instruc
tions for its use.
Special Instruction F orm No. S E H S 7 3 4 I is with the

4 S 6 55 3 E ngin e Test G rou p and gives instructions for
the test procedure.
4S6553 INSTRUM ENT GROUP

1. Differential pressure gauges. 2. Zero adjustm ent
screw. 3. Lid. 4. Pressure gauge. 5. Pressure tap fit
ting. 6. Tachom eter. 7. Manifold pressure gauge.
5 -5 9
PIERCE OUTPUT SHAFT GOVERNOR TESTING AND ADJUSTING
PIERCE OUTPUT SHAFT GOVERNOR

Four adjustm ents must be made: 1. linkage adjust 3. T urn the rate adjusting sc rew until a slight tension
ment, 2. low spe ed setting, 3. high spe ed setting, 4. is maintained on the g o verno r spring. T his will
regulation , and surge. F or any given output shaft g o v position the go v ern or w eig hts in the clos ed
er nor setting, the regulation is the range or spread position.
between the torque converter output shaft spe ed at no
load and the output shaft speed at full load, with the 4. Adjust link age (3) b etw een terminal lever (1) and
diesel en gine g o vernor control, in the full open p o si servo b oo st m ech an ism so that it m oves .08 in.
tion. It the regulation is too close, surging will result. ( 2 .0 m m ) before lever (13) starts to m ove. Install
linkage (3).
The torque converter output shaft m a x im u m sp eed is
either a high spe ed setting or a low spe ed setting, which 5. Retract the spe ed limiter and m ove the g o verno r
is determ ined by ch anging the position of the sp eed control to full spe ed position.
change lever (4), nor m ally by r em ote control. T he high
speed sc rew (9) determ ines the m a x im u m spe ed for the 6. R o tate sh u to ff lever (11) until shutoff lever c o n
high spe ed setting, and the low sp eed sc rew (8) deter tacts the ra ck stop collar. This can be d eterm in ed
mines the m a x im u m low sp eed setting. Consult the by use o f continuity tester co nn ected to the insu lat
o perato r's m anual for the e q u ip m en t in which the e n ed ter minal o f the standard gov er nor.
gine is installed to be sure o f the m a x im u m perm iss ib le
output shaft spe ed for the driven eq uipm ent.
NOT E: P erfo rm the first nine Steps with the engine

stopped.
A gT
G OVERNOR LINKAGE ADJUSTM ENT

1. Term inal lever. 3. Linkage. 11. Shutoff lever. 12. Link
age. 13. Servo lever. 14. Servo m echanism .
7. Adju st the linkage (12) to fit lever holes when

sh uto ff lever contacts rack stop collar, then in
crease linkag e length .06 in. (1.5 m m ) and install
the linkage.
8. B ack out b u m p e r sc rew (6) until approxim ately

3 /4 inch o f the screw is pro tru ding fro m the g o v e r
OUTPUT SHAFT GOVERNOR ADJUSTM ENT n or housing.
1. Term inal lever. 2. Rate adjusting screw. 3. Adjustable
linkage. 4. Speed change lever. 5. G overnor spring. 6. 9. Fill the output shaft go v er n o r to the prop er level
B u m p er s c re w . 7. L ev er. 8. Low s p e e d a d ju s tin g with S A E 30 lubric ating oil. T h e p rop er level can
screw. 9. High speed adjusting screw. 10. Bracket. be c heck e d by r em o vin g the small oil plug located
in the drive cable end o f the gov ern or hou sing.
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

ENGINE GOVERNOR LOW AND
HIGH IDLE ADJUSTMENT
Connect a tacho m eter with good accuracy to the
engine. Make reference to M E A S U R I N G E N G I N E
S P EE D .
1. Start the engine and run to get the engine to the

normal tem per ature o f operation.
2. M ove go v ern o r control lever (2) against low idle

stop (1) and check low idle speed.
NOTE: Make reference to the R A C K S E T T I N G IN

F O R M A T I O N for the correct low and high idle speed.
3. If the low idle speed is not corre ct, loosen locknut

and turn low idle stop (1) as needed. Tig hten the
locknut.
HIGH IDLE ADJUSTM ENT

3. Lockwire. 4. High idle screw.
FUEL RACK ADJUSTMENT

Tools Needed:
9S240 Rack Positioning Tool Group.
. ^5
LOW IDLE ADJUSTM ENT ■ t

1. Low idle stop. 2. G overnor control lever.
4. M ove the go verno r control lever to run the en gine

at high idle spe ed, and check the high idle rpm .
5. It the high idle speed is not corre ct, rem ov e lock-

wire (3) and loosen the locknut on high idle screw RACK POSITIONING TO OLS
(4). Turn the high idle sc rew as needed to get the 1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3.
correct high idle speed. Tig hten the locknut. 8S3675 Contact Point .125 in. (3.18 mm) long.
6. M ove the go vernor control lever to change the

engine spe ed and then return to high idle spe ed and 1. R e m o v e tim ing pin (4). clam p (5), and the plug
check the high idle sp eed again. and seal behind the clam p.
7. W hen the high idle spe ed is correct, install the

lock wire and seal. 2. Fasten bracket ( l ) to the fuel p u m p housing .
5 -6 2
o f the indicator until the zero is in alignm en t with

the hand . R e m o ve the spacer.
5. M ove the fuel rack to the F U E L - O N position

until contact is made with the adjustm ent stop
screw.
6. Re ad the rack travel m easu rem ent on the dial

ind icator and co m pare with the m easu rem ent g iv
en in the R A C K S E T T IN G I N F O R M A T I O N .
7. T o adjust the rack travel, cut lockwire O ) and

r em o ve cov er (8). L oose n the adjustm ent screw
locknut and move lock free ot pin.
TIMING PIN AND CLAMP
4. Timing pin. 5. Clamp.
COVER FOR RACK ADJUSTING SCREW

7. Lockwire. 8. Cover.
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.
3. M o v e the d roop lever of the engine gov er nor to the

center position.
4. Start the engine.
5. M o ve the go vern or linkage to cau se a tem porary

en gin e sp eed increase. If the en gine spe ed goes
back to the original spe ed with only tw'o or three
o scillations , the adjustm ent is satisfactory . If not,
m ove the droop lever in the direction of the rear of
the en gine to cause an increase in droop or move
DIAL INDICATOR INSTALLED the droop lever in the direction of the front o f the
1. Bracket. 2. Dial indicator. 6. Spacer. engine to cause a decrease in droop.
5 -6 3
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
T h e three basic ways to use the 1P2385 P ro tractor

T ool are show n:
I. Vertical h o usin g face to lever angle.

II. H orizontal or level to lever angle.
III. L ev er to lever angle.
HIGH IDLE ADJUSTM ENT

1. High idle screw for torque converter governor
1P2385 PROTRACTO R TO O L USAGE
A. A ngle setting indicator. B. Protractor plate edge
TORQUE CONVERTER GOVERNOR SPEED
aligned with lever. C. Vertical housing face and extension
DROOP ADJUSTMENT arm alignm ent. D. Level bubble. E. A ngle setting indica
tor. F. Extension arm aligned with lever. G. Extension
Tools Needed: arm aligned with lever. H. Plate edge aligned with second
9S240 Rack Positioning Tool Group lever. I. A ngle setting indicator.
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
G OVERNOR LINKAGE
1. Governor lever. 2. Linkage. 3. Lever.
5 -6 5
WOODWARD UG8 DIAL GOVERNOR TESTING AND ADJUSTING
WOODWARD UG8 DIAL GOVERNOR

COMPENSATING ADJUSTMENT 7. Check the nu m b er of turns the needle valve is
op en . T o find the n u m b er o f turns the needle valve
A lthough the go vernor may ap p ear to he oper ating is op en , close the valve co m pletely and m ake a
satisfactoriK at no load, high oversp eeds and u n d er note o f the nu m b er o f turns needed to close the
speeds after load ch anges and slow return to normal val v e .
speed are the results o f incorrect com pensation
adjus tm ents. 8. O pen the needle valve to the same position at
which the engine did not surge.
Make com p en satin g adjustm ents after the tem p e r a
ture o f the engine and the oil in the go verno r have 9. M ove the go v ern or linkage to ch an ge the engine
reached normal operating values and with the engine speed. If the engine d oes not surge, and the needle
runnimz at no load conditions. valve is 1/2 to 3/4 o f a turn op en , the g o vern or
ad justm ent is correct. Install the plug in the base.
If the needle valve is more than 3/4 o f a turn op en ,
do the steps that follow.
10. L oosen the nut that holds the co m p en satio n p o in t

er and m ove the po inter up two mar ks on the
p ointer scale.
11. T urn the needle valve three or more turns in a

co un terclockw ise direction.
12. Let the en gine surge for ap p rox im ately 30 seconds

to help rem o ve air from the go vernor.
13. Slowly turn the needle valve in a clockwise dir e c

tion until the engine does not surge.
14. C he ck the nu m b er o f turns the needle valve is

op en . T o find the n u m b er o f turns the needle valve
is open, close the valve co m pletely and m ake a
note o f the nu m b er o f turns needed to close the
valve.
UG8 DIAL G OVERNOR
15. O p en the needle valve to the same po sition at
1. Nut. 2. Com pensation pointer. 3.Plug.
w hich the engine did not surge.
1. L oosen the nut that holds the co m p en sation p oin t
16. M ove the go v ern or link age to change the en gine
er and move the po inter up as far as it will go.
speed.
Tighten the nut.
If the en g ine does not surge, and the needle valve is
2. Remov e the plug from the base of the gov ernor.
1/2 to 3/4 o f a turn open , the g o verno r adjustm ent is
3. Use a wide blade sc re wdriver and engage the wide correct. Install the plug in the base. If the needle valve
screw d river slot in the needle valve. T urn the is m ore than 3 /4 o f a turn open do Steps 10 thru 16
needle valve three or more turns in a counterclock- again.
w'ise direction.
A needle va lve that is o p en ed less than 1/2 turn will
4. Let the engine surge for ap proxim ately 30 se conds cause the en g ine to be slow to return to norm al speed
to help rem o ve air from the go vernor. after a load change.
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.
6. Slowly turn the needle valve in a clockwise d irec

tion until the engine does not surge.
5 -6 6
HIGH IDLE SPEED ADJUSTMENT 7. T u rn the sy n ch ro nizer control kn ob c o u n terclo ck

wise to ch an g e the engine speed. N ow turn the knob
C o nn ect a ta cho m eter with good accuracy to the to the high idle stop and check the high idle
engine. M ake reference to M E A S U R I N G E N G IN E ad justm ent.
SP E E D .
8. Install the synchro nizer indicator knob and the dial
1. Start the engine and run to get the engine to the plate.
norm al tem perature o f operation.
NOT E: L o w idle speed is not adjustable, but will
2. Use syn ch ron izer control knob (5) to adjust the ch an g e as high idle ad justm ent is m ade. If low idle is
en gine spe ed and check the high idle sp eed stop not co rre ct, an increase in high idle speed will increase
adjustment. low idle sp eed, and a d ecrease in high idle sp eed will
decrease low idle speed.

Tools Needed:
RACK POSITIONING TOOLS

1. 9S 227 Bracket Group. 2. 8S2283 Dial Indicator. 3.
8S3675 Contact Point .125 in. (3.18 mm) long.
G OVERNOR ADJUSTM ENTS
(Typical Exam ple)
1. Term inal lever. 2. Idler gear. 3. Load limit con I. R e m o v e timing pin (4), clam p (5), and the plug
trol. 4. Linkage. 5. Synchronizer control knob. 6. and seal b ehind the clam p.
Gear. 7. Synchronizer indicator knob.
3. It the high idle spe ed is not corre ct, rem o v e the

dial plate.
i'
NOTE: M ake reference to the R A C K S E T T I N G IN
F O R M A T I O N for the correct high idle speed.
4. Loosen the setscr ew on sy nc h ron izer indicator

k nob (7). rem o v e tapered pin if eq uip ped and
r em ov e the knob. 5 ^ ~ £ _•••
5. Pull g ear (6) out o f mesh with idler g ear (2). T u rn

sy nc h ron izer control kn o b (5) until the corre ct
high idle speed is reached.
6. T o set the high idle spe ed stop, turn g ear (6)

TIM ING PIN AND CLAMP
clo ck w ise until the stop pin on the g ear m ak es
4. Tim ing pin. 5. Clamp.
co ntact with idler g e a r ( 2 ) . P ush g ear (6) into m es h
with idler g ear (2).
5 -6 7
2. Fasten bracket ( I ) to the fuel p um p housing. 5. Use th e lever o n th e g o v e r n o r t e r m i n a l sh a ft to

m o v e th e fuel r ack to the F U E L O N p o s i t i o n
u ntil c o n t a c t is m a d e w ith th e a d j u s t m e n t s t o p
screw .
6. R e ad the rack travel m e a s u rem en t on the dial

ind icator and com pare with the m easu rem en t 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 .
7. T o adjust the rack travel, cut lockwire (7) and

r em o v e co ver (8). L oose n the adjustm en t sc rew
locknut and move lock free o f pin.
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.
8. T u rn the adjustm ent sc rew co u nterclo ck w ise to

increase the fuel rack travel or clockwise to d e
cr ease rack travel. W h en the fuel rack is adjusted
corre ctly , m ove the lock to eng ag e the nearest
notch with the pin. T ig h ten the locknut and install
the co v e r and lockwire and seal.
DIAL INDICATOR INSTALLED

1. Bracket. 2. Dial indicator. 6. Spacer.
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
GOVERNOR LINKAGE ADJUSTMENT 1. T u rn g o v ern or terminal shaft to the F U E L - O F F

p osition and install lever (1) on the shatt at the
Tools Needed:
angle sh ow n.
1P2385 Protractor Tool.
2. Install lever (3) with the rack in the F U E L - O F F
T he three basic ways to use the 1P2385 P ro tractor
position at the angle show n.
Tool are show n:
3. W ith both levers at the F U E L - O F F position, a d
I. Vertical housing face to lever angle.
just linkage (2) and install on the levers.
II. Horizontal or level or lever angle.
III. L ev er to lever angle.
LFVER -TO-LEVtK
J -V
3 Isrt
a ¥r ,-2
1P2385 PROTRACTOR TO O L USAGE

A. Angle setting indicator. B. Protractor plate edge
aligned with lever. C. Vertical housing face and extension G O VERN O R LINKAGE AD JUSTM ENT
arm alignm ent. D. Level bubble. E. A ngle setting indica
1. G overnor lever. 2. Linkage. 3. Lever.
tor. F. Extension arm aligned with lever. G. Extension
arm aligned with lever. H. Plate edge aligned with second
lever. I. Angie setting indicator.
5 -6 9
WOODWARD UG8 LEVER GOVERNOR TESTING AND ADJUSTING
WOODWARD UG8 LEVER GOVERNOR

COMPENSATING ADJUSTMENT 7. C h e ck the nu m b er o f turns the needle valve is
open. T o find the n u m b er o f turns the needle valve
Although the go vernor may ap pear to be oper ating is o pen, close the valve com pletely and m ake a
satisfactorily at no load, high oversp eeds and u n d er
note o f the nu m b er of turns needed to close the
speeds alter load ch anges and slow return to norm al
valve.
speed are the results o f incorrect co m p en satio n
adjus tments. K. O p en the needle valve to the same position at
Make co m p en sating adjustm ents after the t e m p e r a
ture o f the engine and the oil in the go verno r have 9. M ov e the gov erno r link age to change the en gine
reached norm al operating \ allies and with the en gine speed. If the engine do es not surge, and the needle
runnine at no load conditions. valve is l /2 to 3/4 o f a turn op en , the g o v ern or
ad justm ent is correct. Install the plug in the base.
If the needle valve is more than 3/4 o f a turn o p en ,
d o the steps that follow.
10. L o osen the nut that holds the co m pensation p o in t

er and m o ve the p ointer up two m ar ks on the
p oin ter scale.
11. T urn the needle valve three or more turns in a

co un terclockw ise direction.
12. Let the engine surge for ap proxim ately 30 seconds

to help rem ov e air from the governor.
13. Slowly turn the needle valve in a clo ck w ise d irec

tion until the en gine does not surge.
14. Ch eck the n u m b er o f turns the needle valve is

U G 8 LEVER G O V E R N O R open . T o find the n u m b e r o f turns the n eedle valve
1. N u t. 2. C o m p e n s a tio n p o in te r . 3. P lu g . is o p en , close the valve completely and m ake a
note o f the n u m b er o f turns nee ded to close the
valve.
1. L oose n the nut that holds the com pen satio n p oin t
15. O pen the needle valve to the sam e position at
er and m ove the po inter up as far as it will go.
Tig hten the nut.
16. M o v e the gov ern or linkage to change the engine
2. R e m o v e the plug from the base o f the governor.
speed.
3. Use a wide blade screwdriv er and en gage the wide
If the en gin e does not surge, and the needle valve is
sc rew driv er slot in the needle valve. T u rn the
1/2 to 3/4 o f a turn op en, the gov ern or adjustm ent is
needle valve three or more turns in a c o un terclock
correct. Install the plug in the base. If the needle valve
wise direction.
is m ore than 3 /4 o f a turn open do Steps 10 thru 16
4. Let the engine surge for approxim ately 30 seconds again.
to help remov e air from the gover nor.
A needle valve that is op en ed less than 1/2 turn will
5. Loosen the nut that holds the co m p ensation p o in t cause the eng ine to be slow to return to norm al spe ed
er and m ove the pointer d o w n as far as it will go. af ter a load ch an ge.
T ighten the nut.
If the c o m p en s atio n p o inter is too far towrnrd the
6. Slowly turn the needle valve in a clockwise direc m a x im u m position, the en gine spe ed change will be too
tion until the engine does not surge. great w hen the load ch an ges .
5-70
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.
N O T E: If the high idle stop lever (7) or the low idle

stop lever (6) are rem o v ed , m ar k the levers and the
shaft so that the levers can be installed in the correct
location.

Tools Needed:
-“4^1
LOW AND HIGH IDLE AD JUSTM ENT

1. Low idle adjustm ent screw. 2. Locknut. 3. High idle
adjustm ent screw. 4. Locknut. 5. G overnor speed adjust
ing lever.
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
2. Fasten bracket (1) to the fuel p um p housing.
r
CO VER FOR RACK AD JUSTING SCREW
BRMCrveT INSTALLED
1. Bracket. 8. T urn the adjustm ent sc rew co un terclockw ise to
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.
1. D isc on nect linkage fro m go verno r terminal lever

(4).
2. R e m o v e c o v er fro m the top o f governor.


until co ntact is m ade with the adjustm ent stop
screw.
6. R ead the rack travel m e as u rem en t on the dial

indicator and co m p are with the m eas u rem en t g iv
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
3. Install 3S 3 2 6 9 Contact Point 1.00 in. (2 5.4 m m ) SPEED DR OO P CHART

long on the dial indicator and install as show n with Droop Percentage Distance A
the contact point on bracket (2) o f sp eed er plug .328 in. (8.33 mm)
3
(1). Adjust the dial o f the indicator to zero.
5 .266 in. (6.95 mm)
10 .144 in. (3.65 mm)

4. M ove the gov ern o r term in al lever fro m the m a x i
m u m position to the m in im u m position. T h e dial
indicator m ust read .000 to .002 in. ( 0.00 to 0 .0 5 5. Put a load on the engine to get m a x im u m lull load.
m m ) for zero droop. M ake a note o f the full load rpm.
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
Adjustment for Positive Droop

8. If the spe ed d roop is not co rre ct, stop the engine
1. R e m o v e the co v er from the top of the g overnor. and m o ve droop cam (3) to w ard sp eed er plug ( l )
to incr ease spe ed dro op , or move aw ay from the
2. Co nn ect a tachom eter with good accuracy to the sp e eder plug to decrease speed droop.
engine. M ake reference to M E A S U R I N G E N
G IN E SPEED. 9. Do Steps 4 thru 8 to check the speed dro op and
adjust again if needed.
3. L oosen screw' (5) and inove d roop cam (3) on
droop lever (6) to get distance (A) for the dro o p
p ercentag e needed. See the chart for S peed Droop GOVERNOR LINKAGE ADJUSTMENT
to get the di m ension needed.
Tools Needed:
1P2385 Protractor Tool
A87926X1 3
The three basic ways to use the 1P2385 Protractor

T ool are show n:
I. Vertical h ousing face to lever angle.
II. Horizontal or level to lever angle.
III. L e v e r to lever angle.
3. Droop cam. 5. Screw. 6. Droop lever. A. Speed

droop setting.
N O T E: Dim en sio n (A) is an ap prox im ate d i m e n

sion. T he final adjustm ents must be d eterm in ed 1P2385 PROTRACTOR TO O L USAGE
with the eng ine running. A. A ngle setting indicator. B. Protractor plate edge
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
1. Turn g o verno r terminal shaft to the F U E L - O F F

po sition and install lever (1) on the shaft at the
angle show n.

position at the angle shown.
3. With both levers at the F U E L - O F F position, a d

just linkage (2) and install on the levers.
G OVERNOR LINKAGE ADJUSTM ENT

(TYPICAL ILLUSTRATION)
1. Governor lever. 2. Linkage. 3. Lever.
5 -7 4
WOODWARD EG-3P ACTUATOR TESTING AND ADJUSTING
WOODWARD EG-3P ACTUATOR

There are no inside adjustm ents on the E G -3 P A c tu
ator. The low and high idle adjustm ents are m ade on the
control panel.

Tools Needed:
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.
I. R e m o v e timing pin (4). c la m p (5), and the plug

and seal behind the clam p.


TIM ING PIN AND CLAM P
until contact is made with the adjustm ent stop
4. Tim ing pin. 5. Clam p.
screw .
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
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
1. T urn actuator terminal shaft to the F U E L - O F F

position and install lever (1) on the shaft at the
an gle show n.

position at the angle show n.
3. W ith both levers at the F U E L - O F F position, a d

just link age (2) and install on the levers.
COVER FOR RACK ADJUSTING SCREW

8. T urn the adjustm ent sc rew co un terclo ck w ise to

cr ease rack travel. W h en the fuel rack is adjusted
corre ctly , m ove the lock to eng ag e the nearest
notch with the pin. T ighten the locknut and install
the c o v e r and lockwire and seal.
ACTUATOR LINKAGE ADJUSTMENT

Tools Needed:
1P2385 Protractor Tool.
The three basic ways to use the 1P2385 P ro tractor

Tool are shown:
I. Vertical hou sing face to lever angle.
II. Horizo ntal or level to lever angle.

AC TU ATO R LINKAGE AD JUSTM ENT
III. L ever to lever angle.
1. A ctuator lever. 2. Linkage. 3. Lever.
1P2385 PROTRACTOR TO OL USAGE

A. Angle setting indicator. B. Protractor plate edge
arm alignm ent. D. Level bubble. E. Extension arm aligned
with lever. G. Extension arm aligned with lever. H. Plate
edge aligned with second lever. I. Angle setting indicator.
5 -7 6
2301 CONTROL SYSTEMS TESTING AND ADJUSTING
2301 CONTROL SYSTEMS

N O T E: For information on ear lier 2301 control sy s
tem s m ake reference to I N D U S T R I A L D I V IS IO N
E N G IN E D A T A S H E E T F o rm No. L E 0 2 1 99 1 -01 .
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:
2. L o osen locknu t (4). POTENTIOMETER ADJUSTMENT

(PARALLEL OR NONPARALLEL CONTROL)
3. T urn m agnetic pick up (2) in until it just has c o n
tact with flywheel (5).
4. T urn the magnetic p ickup out l /2 revolution. This

will m ak e clearance d im ension (1) .022 to .030 in.
(0 .56 to 0 .7 6 mm).
5. T ig hten the locknut to 50 ± 10 lb. ft. (70 ± 14

N-m).
6. Do Step 1 again. If the voltages are still not correct

m ake rep lacem en t of the magnetic pickup.
WOODWARD EG-3P GOVERNOR ACTUATOR 2301 PARALLEL CO NTRO L

1. Speed potentiom eter. 2. Stability potentiom eter. 3.
Check for Actuator Coil Resistance Gain potentiom eter. 4. Ramp tim e potentiom eter. 5. Low
speed potentiom eter. 6. Load gain potentiom eter. 7.
Droop potentiom eter. 8. De-droop potentiom eter. 9. Load
1. R e m o v e the connection plug fro m the E G -3 P signal jacks.
actuator.
Speed Potentiometer
2. 4 here a r e f o u r t e r m in a ls o n th e a c t u a t o r . T h ey
h av e m a r k s “ A ”. "B ". “ C ” a n d “ D ”. C o n n e c t Turn sp eed p otentiom eter ( I ) clock w ise to increase
the p r o b e s o f a n o h m m e t e r b e t w e e n t e r m i n a l s or co u nterclockw ise to decr ease the full load rpm of the
" A " a n d “ B ” . P u t a j u m p e r wire b e t w e e n t e r m i engine.
nals " C " a n d “ D".
5 -7 7
2301 CONTRO L S Y S T E M S TESTING AND ADJUSTING
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
7. If the ratios are not the same an adjustm ent of the

spe ed droop is necessary. R e m o ve the load and
stop the engine. It the engine speed decreases too
much acco rding to the ratio, decrease the am ount
o f speed droop. If the decrease in eng ine speed is
not enough increase the am o un t o f speed droop.
8. Turn d roop po tentiom eter (7) clockwise to in

crease or co unterclockw ise to decr ease the am ou n t
of speed droop.
De-Droop Potentiometer
1. Set the sv stem for isochro nous operation at the
desired rpm. Droop p otentiom eter at zero dr oop.
2. Put the m axim um available load on the unit, up to

HKK'f o f rated capacity.
3. If there is a change in rpm use the d e-dro op p o te n

tio m eter to return the en gine to the desired rpm.
5 -7 9
GOVERNOR AIR ACTUATORS TESTING AND ADJUSTING
GOVERNOR AIR ACTUATORS

2N6006 ACTUATOR 6. Start the engine.
Air Pressure Adjustment 7. C h e ck the air pressure to the actuator. M in im u m

air press ure at high idle m ust be 65 psi (450 kPa).
I. R e m o v e linkage (1) b etw een actuator and
M a x im u m air pressure m ust not be m ore than 80
governor. psi (550 kPa).
8. Put the g o v er n o r hand control lever in the low idle

position.
9. M ov e the actuator air control lever (3) slowly to

the high idle position. L ook at the p lu ng er (6).
The p lu n g er must start to m o ve at lOpsi ( 7 0 k P a ) .
N O T E: If p lu n g er (6) m o ves at less than 10 psi (70

kPa) m ake the preload higher. If more than 10 psi (70
kP a) air pressu re is needed to m o v e the p lunger, m ake
the preload lower.
10. Retu rn the actuator air control lever (3) to the low
idle position to change preload.
11. T urn scre w (7) out until nut can be turned.
12. T urn nut (5) clockw ise to m ake preload higher.

ACTUATOR LINKAGE Turn nut cou nterclo ck w ise to make preload
1. Linkage. lower.
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. Install an air g auge (2) in the line betw een the

ac tuator air control lever (3) and the actuator (4).
Setting Low Idle Stop
AC TU ATO R AIR PRESSURE ADJUSTM ENT

AC TU ATO R LINKAGE AD JUSTM ENT
2. Air gauge. 3. Actuator air control lever. 4. Actuator. 5.
Nut. 6. Plunger. 7. Screw. 1. Linkage.
5 -8 0
1. Start the engine. Let the engine run until it is

warm .
2. Put the actuator air control lever in the low idle

position.
3. Install a tach om eter and ch eck the low idle rpm .
4. If low idle rpm is not corre ct, rem o ve linkage (1)

b e t w e e n a c t u a t o r a n d g o v e r n o r to m a k e
adjustm en t.
5. M ake linkage (1) shorter to decr ease rpm . M a k e

the linkage longer to increase rpm.
Setting High Idle Stop

H IG H IDLE A D JU S TM E N T
1. W a r m u p engine.
(LATER A C TU A TO R )
2. R e m o v e tw o se tscrew s (9) l o r e a r l i e r a c t u a 3. Actuator air control lever. 6. Plunger. 8. High idle
t o r s o r lo o s e n l o c k n u t s (10) fo r l ater a c t u a t o r s , screws. 10. Locknuts.
a n d t u r n th e t w o hig h idle sc re ws (8) o u t sev
eral t u r n s. 6. Install a n d t i g h t e n t w o se tscrew s (9) t o r earlier
a c t u a t o r s o r t i g h t e n t w o l o c k n u t s (10) t o r later
3. M o v e the g o v e r n o r h a n d c o n t r o l lever to the a c t u a t o r s t o h o ld th e high idle screws.
h igh idle p ositio n .
7. R e t u r n the a c t u a t o r air c o n t r o l lever (3) to th e
4. M o v e th e a c t u a t o r a i r c o n t r o l lever (3) slowly low idle p o s i t i o n .
t o the hig h idle p o sitio n .
8. Install a tachometer .
5. T u r n th e hig h idle sc re ws (8) in u ntil th ey m a k e
c o n t a c t w ith th e p l u ng er. 9. M ake the gov ern o r high idle 30 rpm higher.
NOT E: Step 9 lets the actuator high idle stop control

the en g ine rpm .
10. Return the g ov ernor hand control lever to the low

idle position.
11. M ov e the actuator air control lever (3) to the high

idle position.
12. C h e ck the eng ine high idle rpm.
13. If necessary , m ak e small adjustm ents to the actu

ator high idle screws (8) to get correct rpm.
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
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.
9. Return the actuator air control lever (2) to the low

idle position to change preload.
I(). R e m o v e setscrew (5) and turn screw (6) out until

nut (7) can be turned.
I I . Turn nut (7) clock wise to m ak e the preload h ig h

er. T urn nut cou nterclockw ise to 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).
2. M ove g o verno r lever (2) co un terclo ck w ise until

1. Start the engine. Let the engine run until it is contact is m ad e with the low idle stop.
w arm .
3. Adjust linkage ( l ) to fit b etw een rod end (4) and
2. Check high and low idle rpm w ith a tachom eter. It' g ov ern o r lever (2).
n e c e s s a rv . make adjustm ents to the gov ern or high
and low idle sc rews to get correct rpm. 4. Put air pressure to the ac tuator until gov er nor lever
(2) m ak es contact with the high idle stop. L oosen
3. Stnp the engine. the lo cknut and airn stroke stop (3) until co ntact is
m ade with actuator piston. T ighten locknut.
4. Install an air gauge ( l ) in the line between the
actuator air control lever (2 ) and the actuator (3).
See illustration.
5. Start the engine.
6. Ch eck the air pressure to the actuator. M in im u m

air pr essure at high idle must be 65 psi (450 kPa).
M a x im u m air pressure must not be more than 80
psi (550 kPa).
7. Put the go v ernor hand control lever in the low idle

position.
8. M ove the actuator air control lever (2) slowly to

the high idle position. L ook at the plu n ger (4).
The plunger must start to m ove at 10 psi (70 kPa)
air pressure. 3N9125 ACTUATO R
1. Linkage. 2. G overnor lever. 3. Stroke stop. 4. Rod
end. A. 4.00 in. (101.6 mm)
5 -8 2
SHUTOFF AND ALARM SYSTEMS

CONTACTOR SWITCH FOR OIL PRESSURE 7. Close shutoff fitting (b) and slowly open shutoti
fitting (7). The light must he activated, with a
Tools Needed: decrease in oil pressure, at the specification ot the
3P1564 Pressure Gauge (0 to 60 psi).
3B7734 Pipe Nipple, 1/8 in. X 3.5 in. switch.
3B6483 Cap.
Two 3B7263 Pipe Nipples, 1/8 in. X 2 in. 8. Stop the engine.
Two 3B9389 Shutoff Cock Fittings.
9. C o n n e ct the wire(s) to the normally closed
Two 1F9369 Tees.
44914 Tee. ter minal.
Two 5K3772 Hose Assemblies.
8S4627 Circuit Tester. 10. O n co ntactor sw itches with a button or a control
kn o b either push the button or turn the knob to the
O F F position.
11. Close sh u to ff fitting (7) and open shutott fitting

( 6 ).
12. Start the en gine and run it at low idle rpm
13. Put a jum per wire betw een the c o m m o n terminal

and the normally closed terminal. This will check
the system b e y o nd the con tacto r switch.
14. R e m o v e the ju m p e r wire.
Adjustment of Earlier Type Switch
TEST EQ UIPM ENT

1. 3P1564 Pressure gauge (0 to 60 psi). 2. 3B7734 Pipe
nipple. 3. 3B 6483 Cap. 4. Oil supply line. 5. 3B7263 Pipe
nipple. 6. 3B9389 Shutoff cock fitting. 7. 3B9389 Shutoff
cock fitting. 8. 1F9369 Tees. 9. 5K 3772 Hose assem
blies. 10. 44914 Tee.
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).
5. Make sure the set for start button (13) is in the

R U N position.
6. C o n n e ct the 8S 4627 Circuit T ester betw een the

c o m m o n terminal and the no rm ally closed t e r m i
nal. T h e light o f the circuit tester must not be
activated.
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.
7. Turn screw ( I I ) clockwise until the light o f the

circuit tester is activated.
8. To check the ad justm ent, close shutoff fitting (7)

and open shutoff fitting (6).
9. C on n e ct the wires to the norm ally closed terminal.
10. Close shutoff fitting (6) and slowly open sh utoff

fitting (7) until the en gine stops o r the alar m
operates.
11. The pressure gau ge must sh ow the correct p r es D E F

sure specification o f the switch as the engine stops 37211X 2
or the alar m operates.
W IRING CO NNECTIO NS
Adjustment of Micro Switch Type D. Norm ally closed B terminal. E. Norm ally open W ter
minal. F. Com m on R terminal.
1. L o o sen locknut (16) and turn adjustm ent scre w
(14) cou nterclockw ise to m ake a de crease in the 9. T o check the adjustm ent, close shutoff fitting (7)
tension of spring (15). and open shutoff fitting (6).
10. C o n n e ct the wires to the norm ally closed t erminal.
11. C lose sh u to ff fitting (6) and slowly open s'hutoff

fitting (7) until the eng ine stops or the alarm
operates.
12. T h e pressure g auge must sho w the correct p r es

sure specification o f the sw itch as the en gine stops
o r the alar m operates.
CONTACTOR SWITCH FOR WATER

TEMPERATURE
CO NTACTOR SW ITCH FOR OIL PRESSURE Tools Needed:

(Micro Switch Type) Fabricated heat sink.
13. Set for start button. 14. Adjustm ent screw. 15.
2F7112 Thermometer.
Spring. 16. Locknut. 17. Contact button. 3J5389 Plug.
8S4627 Circuit Tester.
5 -8 4
Method of Checking 7. U se a torch to heat the w ater to the tem perature

ran ge at which the con tacto r must activate. If the
1. M ake a heat sink as show n. Material can be brass, circuit tester light does not com e on within the
steel or cast iron. Drill a 23 /3 2 in. hole through the tem peratu re range given in the specifications
plate and use a tap to m ak e 1/2 in. N P T threads. m ak e a replacem ent o f the contactor.
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).
Effective travel can be m easu red with rack setting

gauges to be sure rack is m o ved to shutoff position.
Make an on en gine check with a 30 am p am m e te r to be
sure only the hol d in win d ing s are energized w hen the
rack is held by the solenoid in sh ut-off position. C u r
rent d raw shuld be less than 2 am p.
HEAT SINK
[Dimension in inches (mm)]
3. R e m o v e the co ntactor and install a 3J53 89 Plug.

Install the contactor sw itc h in the heat sink.
4. Put the heat sink and co ntactor in w ater as sh ow n.
Use blocks to support the heat sink at surface
level. PLUNG ER SHAFT ADJUSTM ENT
1. Shoulder-to-plate distance .70 in. (17.8 mm). 2. Effec
5. C on ne ct the 8 S 4627 Circuit T ester b etw een the
tive travel .62 in. (15.7 mm). 3. Starting position of plunger
wires that co nn ected the c o n tacto r to the circuit. plate from m ounting flange is .44 in. (11.2 mm) to m easure
effective travel of plunger.
SHUT-OFF VALVE (WATER TEMPERATURE)

Tools Needed:
3J5389 Plug.
8B4509 Connector.
3B9388 Connector.
9M6543 Hose Assembly.
4D6949 Hose Assembly.
3B7764 Reducing Bushing.
Heat Sink.
NO T E: See the topic C o ntac to r Switch for W ater T em -

perature in T E S T I N G A N D A D J U S T I N G for
instructions to make a heat sink.
1. R e m o v e oil lines.
TE ST OF CO NTACTOR SW ITCH 2. R e m o v e sh ut-off valve and install the 3 J53 89

1. 2F7112 Therm om eter. 2. Fabricated heat sink.
Plug.
3. Install the oil lines using the bu shin g, hose s and

co nnectors.
6. Put the 2 F 7112 T h e rm o m e t e r in the water. 4. Start the en gine and let it run at low idle.
5 -8 5
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.
th erm o m e te r, take note o f the tem perature at

which the engine stops. 6. If n eed ed , m ak e an a d ju stm ent to the contactor
switc h by loose ning lock sc re ws (7). Turn the cap
6. Install a new valve if necessary. c lockw is e to low er the oversp ee d setting. T ighten
the lock screws.
NOTE: If en g in e does not stop, look for a defect in the
contactor switch for oil pressure. 7. T o ch eck other co m p o n e n ts in the circuit, put a
j u m p e r wire between the C and N O term in als of
CONTACTOR SWITCH FOR OVERSPEED
the c on tactor switch.
The original setting o f the co ntacto r switch for o v e r
speed will stop the engine w h en the engine rp m is m ore
than 189t above full load rpm . D O N O T ch eck the
adjustm ent o f the contactor switch on the engine.
Off Engine Adjustment

Tools Needed:
4S6553 Engine Test Group.
8S4627 Circuit Tester.
5L2277 Adapter.
Reversible Variable Speed Drill. O VERSPEED CO NTACTOR SW ITCH
6. Reset button. 7. Lock screws.
1. C o nn e ct the 1P7443 o r 4 S 6 9 9 1 T ac h o m e te r of the
4 S 6 5 5 3 Gro up to the tacho m eter g enerator (2).
2. C o n nect the 5L 2277 A dapter (3) to the co ntactor

switch and ta cho m eter g en erator (2).
3. Install variable speed drill (4) to the adapter as

show n.
4. C on nect the 8S4627 Circuit T ester (5) betw een

the N O and C term inals o f the contactor switch.
O VER SPEED AD JUSTM ENT
T he light must be off. If the light is on, push reset
ENGINE rpm
button (6).
FULL LOAD rpm O VERSPEED SETTING
5. Grad ually make an increase in the rpm. R ead the 1000 ± 10 1180 ± 20
rpm on the tachom eter at the m om en t the light o f 1100 ± 10 1298 ± 20
the circuit tester is activated. T h e readi ng will give
1200 ± 10 1416 ± 20
the en gin e rpm (2 rp m on the m eter for each rp m
1300 ± 10 1534 ± 20
the input shaft is turned).
INSTRUMENTS AND GAUGES TESTING AND ADJUSTING
INSTRUMENTS AND GAUGES

OIL PRESSURE SENDING UNITS
SENDING UNIT FOR W ATER TEM PERATURE

1. Term inal. 2. Nut. 3. Bulb.
2. Put a t h erm o m e te r in the w ater to m easure the

SENDING UNIT FOR OIL PRESSURE
temperature .
1. Term inal. 2. Fitting.
3. T ake resistance readings at the tem per atures
1. Co nn ect the sending unit to a pr essure source that sh ow n in the chart.
can be m easure d with accuracy.
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
100“ F (38“ C) 403 to 493

3. Take resistance readings at the pressure sho w n in 5L7443
118 to 138
160“ F (71° C)
the chart.
4. If a unit does not have the corre ct resistance r ead

5L7449 SENDING UNIT FOR G EAR OIL PRESSURE ings m ak e a r ep lacem en t o f the unit.
PRESSURE RESISTANCE (OHM S)
0 psi (0 kPa) 0 to 1
60 psi (415 kPa) 4.5 to 6.5
300 psi (2050 kPa) 28 to 31
5L7450 SENDING UNIT FOR OIL PRESSURE

ELECTRIC GAUGES
PRESSURE RESISTANCE (OHMS)
0 psi (0 kPa) 0 1. Put the gaug e in position with the letters h o r iz o n
20 psi (140 kPa) 13.5 tal and the face 30° back fro m vertical.
80 psi (550 kPa) 30
4. If a unit does not have the correct resistance r ead

ings make a repl acem ent o f the unit.
W IRING DIAGRAM FOR TEST

1. Term inal (for test voltage). 2. Test resistance.
2. C o n n e ct the ga ug e in series with the p o w e r source

WATER TEMPERATURE SENDING UNIT and the m iddle test resistance show n in the chart.
l. C o nn e ct an oh m m e te r betw een terminal (1) and 3. L et the gauge heat at the m iddle resistance for 5
nut (21. Put bulb (3) in a pan o f water. Do not let m in utes, then check the p o in ter position for all o f
the bulb have contact with the pan. the resistances given.
5 -8 7
CHART FOR TESTING TEM PERA TUR E GAUGE

GAUGE TEST TEST
PART NUMBER VO LTAGE RESISTANCE TEM PERA TUR E SENDER •RESISTOR
14 349 Ohms 100°F (38°C) 5L7443 NONE
5L7446 14 84 Ohms 170°F (77°C) 5L7743 NONE
14 30 Ohms 240°F (1 16°C) 5L7443 NONE
28.5 3388 Ohms 100°F (38°C) 5L7442 5L7441

5L7444 28.5 1050 O hm s 170°F (77°C) 5L7442 5L7441
28.5 460 Ohms 240°F (1 16°C) 5L7442 5L7441
*ln 32 volt systems the resistor is needed.
CHART FOR TESTING ENGINE O IL PR ESSURE GAUGE
GAUGE TEST TEST

PART NUMBER VO LTAGE RESISTANCE PRESSURE SENDER •RESISTOR
14 0 Ohms 0 psi (0 kPa) 5L7450 NONE

5L7455 14 13.5 Ohms 20 psi (140 kPa) 5L7450 NONE
28.5 0 Ohms 0 psi (0 kPa) 5L7450 5L7441

5L7456 28.5 13.5 Ohms 20 psi (140 kPa) 5L7450 5L7441
28.5 30 Ohms 80 psi (550 kPa) 5L7450 5L7441
'In 32 volt systems the resistor is needed.
CHART FOR TESTIN G GEAR O IL PR ESSUR E GAUGE
GAUGE TEST TEST

PART NUM BER VOLTAGE RESISTA NC E PRESSUR E SENDER •RESISTOR

5L7454 14 15 O hm s 150 psi (1030 kPa) 5L7449 NONE
28.5 0 Ohms 0 psi (0 kPa) 5L7449 5L7441

5L7451 28.5 15 Ohms 150 psi (1030 kPa) 5L7449 5L7441
28.5 30 Ohms 300 psi (2050 kPa) 5L7449 5L7441
'In 32 volt systems the resistor is needed.
5 -8 8
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.
202 to 210 94 4 to 98.8
GAUGE W ITH COLOR CODE
MECHANICAL GAUGES FOR OIL PRESSURE

T w o types o f m echan ical gauges are available. T he
first type has a direct readi ng face. T he second type has
co lor co des on the face to sh o w different rang es o f
oper ation. R e d, white and green sh ow the low p r e s
sure, pr ess ure at low idle rp m and norm al pressure
ranges respectively. S om e o f the direct re ading g au g es
are for g ear oil pressure.
5 -8 9
POWER TAKE-OFF CLUTCHES TESTING AND ADJUSTING
POWER TAKE-OFF CLUTCHES

CLUTCH ADJUSTMENT
The clutch en gagem en t lever pull adjustm ent es tab
lishes the clutch plate pressure. T he proper clutch lever
pull is indicated in the chart.
Clutch Engagem ent Lever M easured From

Assem bly Pull Adjustm ent Center of Shaft
2N6961 123 to 163 lb. (545 to 725 N) 21.3 in. (541 mm)
2N7080 155 to 204 lb. (690 to 908 N) 39.7 in. (1008 mm)
7L7490 155 to 204 lb. (690 to 908 N) 39.7 In. (1008 mm)
The clutches use two types o f adjustm ent lock pins.

Pin (1) sh ould be push ed in and the adjusting ring W EAR SLEEVE INSTALLATION
rotated. Pin (2) should be pulled out and the ring rotated
1. Guide assem bly. 2. W ear sleeve. 3. Shaft shoulder
to adjust the clutch. fillets.
Shaft Bearing End Clearance

T ig h ten adju sting nut to r em o v e all clearance and
seat bearing cups. At this point shaft should turn with
dry bearin g at torque of 60 lb. in. (6.8 N-m) in addition
to seal drag. T hen back of f the adju sting nut the n u m b er
o f notches indicated in the chart and install the lock.
Drive the front bearing cup to the front by striking the
o utp ut end o f the shaft with a soft ham m er. The end
clearance should now' be as indicated in the chart.
CLUTCH ADJUSTM ENT
1. Lock pin (push in type to unlock). 2. Lock pin (pull out
type to unlock).
Clutch Shaft Bearing Notches Backed

ASSEMBLY ADJUSTMENTS Assem bly End Play Off From Tight
2N6961 .006 to .010 in. (0.15 to 0.25 mm) 2 3 /4 to 3 3/4

T ig hten hub nut to torque o f 30 lb. ft. (40 N-m) to 2N7080 Non Adjustable
re m ove all clearance betw een parts, then tighten ad d i 7L7490 .010 to .012 in. (0.25 to 0.30 mm) 5 to 6
tional am ount as show n in chart.
W h er e shim adjustm ent is used, tighten the retainer

Additional A m o u n tto T ig h ten
Clutch After Initially Tightening without shim s until shaft turns with dry bearings at
Assem bly to 30 lb. ft. (40 N m ) torque o f 60 lb. in. (6.8 N-m) in addition to seal drag.
2N6961 150° to 180' M easu re the spa ce betw een the retainer and carrier and
2N7080 210° to 240c add .013 in. (0 .33 m m ) to this m easu rem en t. R e m o v e
7L7490 270° to 300c
the retainer, then install shim s and retainer and cap
screw s with locks. Drive the front bearing cup to the
front by striking the output end of the shaft with a soft
Clutch Shaft Seal Wear Sleeve Installation h am m e r . T h e end play should no w be .006 to 01 0 in.
Clutches which have oil lubricated shaft bear ings are (0 .1 5 to 0 .2 5 mm).
eq uipped with oil seal w ear sle eves (2) on the shaft.
Install w ear sleeves with guide as em bly ( l ) (part of Clutch and Mounting Adjustment Check
l P 2 4 1 0 W ear Sleeve Installation Tool Group). Be sure
the sleeve contours blend in with the shoulder fillets (3) At time o f installation, ch eck the flywheel and fly
on the shaft. wh eel h ou sin g face and bore run out.
5 -9 0
ELECTRONIC OVERSPEED SWITCH TESTING AND ADJUSTING
ELECTRONIC OVERSPEED SWITCH

WIRING DIAGRAM
SH UTO FF SYSTEM W IRING DIAGRAM

1. Oil pressure switch. 2. W ater tem perature contactor. 3. Tim e delay switch. 4. D iode assem bly. 5. 75% verify
button. 6. Reset button. 7. “LE D” overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank
term inate). 10. Rack solenoid. 11. M agnetic pick-up. 12. Engine flywheel. 13. Voltage input. 14. Locknut. 15. Air
gap-
5 -9 1
TRO UBLESHOOTING PROCEDURE (O VERSPEED)
A 9 3749X1
5-92
TROUBLESHOOTING PROCEDURE (CRANK TERMINATE)
NOTE A: D O NOT EEAVE STA RTER M OTOR ENGAGED W IT H THE

ENGINE RUNNING.
T o p e r f o r m te s t m e a s u r e m e n ts u s e o n e o f th e th r e e m e th o d s th a t f o llo w s to
d is e n g a g e th e s ta r te r m o to r:
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.
2. U se a to g g le s w itc h to c o n tr o l th e m a g n e tic s w itc h . C o n n e c t to g g le s w itc h in

s e r ie s w ith th e m a g n e tic s w itc h c o il le a d .
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
PROCEDURE A
OVERSPEED SETTING CALIBRATION
ELECTRO NIC O VER SPEED SW ITCH

5. Verify button. 6. Reset button. 7. “ LED” overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank
terminate).
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.
4. With en gine at 7 5 T o f o v erspee d setting r pm ,

push V E R I F Y p ush button (5) and hold in. T urn
O .S . (overspeed) adju stm en t p o tentio m eter in the
direction opposite o f " M A X A R R O W ” ( co u n
terclock wise) slowly until " L E D ” ov ersp eed
light (7) co m es on. Engine will shut d o w n if sp eed
switch is co n nected to the fuel shutoff solenoid
an d/o r air inlet shutoff solenoids.
5. T o reset speed sw itch, push in reset button (6). Air

inlet shutoffs must be m anually reset.
6. Slowly turn O .S . (overspeed) ad justm ent po ten ti

o m e te r approxim ately one turn clockw ise and do MAGNETIC PICK-UP
Steps 3, 4 'a n d 5 again. 12. Engine flywheel. 14. Locknut. 15. Air gap.
5-94
1. Stop engine. (crank terminate) adju stm en t p o tentio m eter t w e n

ty turns in the direction of " M A X A R R O W
2. L oosen magnetic pick-up locknut (14). (clockwise).
3. T urn the mag netic pick-up clo ckw ise until co ntact NOT E: T h e crank term in ate adju stm ent screw is m ade
is m ade with the teeth of the en gine flywheel ring so that it can not cause d am ag e to the po tentio m eter or
g ear (12). be rem o v ed if the adjustm ent screw' is turned too m uch.
4. T urn the m agnetic pick-up co un terclo ck w ise one- 3. T urn the crank term in ate adjustm ent p o te n tio m
half turn. This will gi ve approxim ately .022 to eter tw elve turns in a direction opposite ot " M A X
.033 in. (0 .5 6 to 0 .8 4 m m ) clearance at location A R R O W " (counterc lo ckwise ) for an app ro xi
(15), b etw een the end o f the m ag netic pick-up and mate cr an k term inate setting.
the teeth of the flywheel ring gear.
4. Start engine and m ake a note o f the speed at which
5. After the clearance is co rre ct, tighten the m agnetic the starter dise ngag es. See the S P E E D S P E C IF I
pi ck-up locknut to a torque o f 50 ± 10 lb. ft. (70 ± C A T I O N C H A R T for the correct cr an k te r m i
14 N-m). nate speed for D 3 79 , D3 98 and D 3 99 Engine s.
N O T E: Be sure the m agnetic pick-up does not turn NOT E: If setting is not correct do Steps 5 and 6. It
when the locknut is tightened. setting was corre ct do Step 7.
5. Stop en gin e and turn adju stm en t po tentiom eter

(clockw ise to increase and cou n terclo ck w ise to
PROCEDURE C decrease) crank term in ate speed.
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.
ELECTRO NIC O VER SPEED SW ITCH

5. Verify button. 6. Reset button. 7. "L E D ” overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug
(crank terminate).
5 -9 5
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.
SPEED SPEC IFICA TIO N CHART

CRANKING
O VERSPEED SETTING 75% O VER SPEED (VERIFY) TERM INATION SETTING
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
D399 1200 1416 4319 ± 25 1062 3239 ± 25

D398 183 400 1220 ± 25
D379 1000 1180 3599 ± 25 885 2699 ± 25
N O T E F: T h e mag netic pick -u p fre q uency (HZ)

at the oversp ee d or cranking term in ation setting is
-B A R E - 2 SHLD
calculated with the fo rm u la that follows:
-B L A C K O 3 COM
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
O 10 NO If the rated sp eed of the eng ine is other than

_
O
/ C R A N K IN G
11 C O M ) T E R M IN A T IO N
sh ow n in the char t, the m agnetic pick-u p f req u e n
\ R E LA Y
O 12 NC \
cy for th e o v erspee d setting can be fo un d a cco r d
ing to N O T E S E and F.
N O T E C: T o verify oversp ee d sh u td o w n system If a 2301 G o v e r n o r is used, only one mag netic

operation, push in for a m o m e n t the verify push pick-u p is n eed ed . U se the m ag netic pi ck-up fro m
button. T h e en gine m u st shut d o w n at 7 5% or the o v ersp ee d group. C o n n e ct the wires from the
m ore o f overspee d setting. m agnetic pick -u p to the o versp ee d switch and
th en co n n ect wires fro m the speed switch to the
N O T E D: Input Voltage: M a x i m u m 37 V D C 2301 G o vern or. The o versp ee d switch can be
M inim um 8 VDC. installed clos e to the 2301 G o v e r n o r if needed .
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
B a tt e r ie s ............................................................................................... 6-8 L in e s a n d W ire s .......................................................................................... 6 -6
B e a r in g s ............................................................................................... 6-7 L o c k s ................................................................................................................. 6 - 6

A n ti-F r ic tio n ..................................................................................... 6-7 L u b r ic a t io n ...................................................................................................... 6-7
D o uble Row. Tap ere d R o lle r .................................................... 6-7 L u b r ic a tio n F o r a R e b u ilt E n g in e ..................................................... 6 -2
H e ating B e a rin g s ........................................................................... 6-7 P ro c e d u r e F o r P re s s u re L u b r ic a t io n .......................................... 6 -3
In s ta lla tio n ....................................................................................... 6-7
P re s s in g P a r t s ............................................................................................... 6-5
Preload ............................................................................................. 6-7
Sleeve B earings ............................................................................. 6-7
R e m o v a l a n d I n s t a lla t io n ........................................................................ 6 -2
B o lts and B o lt T o rq u e .................................................................... 6-5
R u le s f o r U se o f T o o l s ............................................................................ 6 -5
T o rq u e W rench E x te n s io n .......................................................... 6-6
R u s t P re v e n tiv e C o m p o u n d ................................................................. 6 -7
T -T -T P ro c e d u re ............................................................................. 6-5
S e a ls ( L ip - T y p e ) .......................................................................................... 6 -8
C le a n lin e s s ........................................................................................... 6-2
S e rv ic e T o o l s ................................................................................................. 6 -3
C o nversion C h a rt (Inch es to m m ) .............................................. 6-8
B e a rin g C u p P u llin g A t t a c h m e n t ................................................... 6 -5
B e a rin g P u llin g A t t a c h m e n t ............................................................ 6-5
D isassem bly and A s s e m b ly ............................................................ 6-2
P u lle r A s s e m b ly (2 o r 3 a r m ) .......................................................... 6 -3
G a s k e ts ................................................................................................. 6-7 P u s h P u lle r s ............................................................................................... 6-4
S h i m s ................................................................................................................. 6-7
In itia l O p e ra tio n A fte r E n gine R e c o n d itio n in g ....................... 6-3
GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY
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
d i s c o n n e c t i o n is m a d e . cap . p lu g o r t a p e th e line or 5 /1 6 " — 18 1P7404 1125 5 1 0 .6

o p e n i n g to p rev en t entry o f f o re ig n m a t e r i a l . T h e V — 16 1P7405 1625 7 3 7 .6
sa m e r e c o m m e n d a t i o n s for c l e a n i n g a n d c o v e r i n g
7 /1 6 " — 14 1P7406 2250 1 0 2 1 .3
a p p l y w h e n ac cess c o vers o r i n sp e c tio n plates are
'•/'— 13 1P7407 3000 1 3 6 1 .7 .
remov ed.
W ’— 11 2D 1201 5000 2269 5
C lea n a n d in sp ect all parts. Be su r e all p as sag es
/." — 10 1P7409 6250 2 8 3 6 .9
a n d holes ar e o p e n . C o v e r till p a r ts to keep t h e m
clean. Be su r e p a r t s are clean w h e n in stalled . Leave
1 / 8 IN . (3 M M ) T H IC K
new p a r t s in t h e ir c o n t a i n e r s u ntil r e a d v for F L A T W ASHER
as sem b ly.
REMOVAL AND INSTALLATION

I 'n l e s s o t h e r w i s e specified, till r e m o v a l s s h o u l d
be a c c o m p l i s h e d using a n a d j u s t a b l e lifting b eam .
All s u p p o r t i n g m e m b e r s ( c h a in s a n d cables) sh o u l d
be p arallel to each o t h e r a n d as n e a r p e r p e n d i c u l a r
as p ossib le to th e to p o f the o b ject b e in g lifted.
CORRECT
DISASSEMBLY AND ASSEMBLY
1 T 6 0 8 8 4_______________
W h e n a s s e m b l i n g a n eng in e, c o m p l e t e each step

in t u r n . D o n o t p a r t i a l ly a s s e m b l e o n e p a r t a n d
W h e n it is n eces sa ry to rem ov e a c o m p o n e n t o n s t a rt a s s e m b l i n g s o m e o t h e r p art. M a k e all a d j u s t
a n angle, r e m e m b e r t h a t th e c a p a c it y o f a n e y e b o lt m e n t s as r e c o m m e n d e d . A lw a y s ch eck th e job a f te r
d i m i n i s h e s as th e a n g le b e tw e e n th e s u p p o r t i n g it is c o m p l e t e d to see n o t h i n g has b een o v e r l o o k e d .
m e m b e r s a n d th e ob ject b e c o m e s less t h a n 90°.
L y eb o lts a n d b r a c k e t s s h o u l d n ever be b ent a n d
s h o u l d o nly hav e stres s in te n s io n . A l e n g th o f pi pe LUBRICATION FOR A REBUILT ENGINE
a n d a w a s h e r c a n be used, as s h o w n , to help relieve It is very i m p o r t a n t for a rebu ilt e n g in e to h av e
these stres ses o n ey eb olts. “a d e q u a t e ” ( n e e d e d ) l u b r i c a t i o n d u r i n g th e first
h o r g e d e v e b o lts arc a v a ila b le . E ach si/e e y e b o lt s e c o n d s o f o p e r a t i o n . A " d r y s t a r t " (w i t h o u t needed
h a s a m a x i m u m lo ad r e c o m m e n d a t i o n . l u b r i c a t i o n ) o n a r eb uilt en g in e can ca u s e b e a r in g
dam age.
S o m e r e m o v a l s r e q u i re th e use o f lifting fix tu r e s W h e n a n e n g in e is reb uilt w ith new p a r t s , oil is
to o b t a i n p r o p e r b a l a n c e a n d to p r o v i d e safe p u t o n e a c h p a r t as it is installed. This is g en erally
h a n d lin g . e n o u g h l u b r i c a t i o n f o r en g i n e s t a r t - u p . H o w e v e r .
6-2
this l u b r ic a t io n may n o t be e n o u g h o r m a y be lost T h e p u r p o s e ot this initial o p e r a t i o n a l c h eck is

it the reb u ilt en gin e is p laced in s t o r a g e fo r a n y to: in su re t h a t the e n g in e has been a s s e m b l e d
le n g th o f time. p r o p e r l v . d e t e r m i n e if p r o p e r p r e s s u re s a n d t e m
p e r a t u r e s a r e m a i n t a i n e d in the l u b r i c a t i o n , co o lin g
l o p r e v e n t th e po ssib ility ot a "dry s t a r t ” a n d a n d fuel sy stem s; c o r re c t any leaks : p e r l o r m
b e a r i n g d a m a g e d u r i n g th e lirst s e c o n d s ot r u n n i n g , n ec e s sa ry a d j u s t m e n t s (su ch as \ a l \ e c l e a r a n c e ,
use the 1 P5 40 Flow C h e e k i n g 'Fool G r o u p a n d s h o p g o v e r n o r hig h a n d low idle sp e ed s, etc.); ch eck the
air p r e s s u re to p r e s s u re lu b r ic a t e (iill the m a i n oil p o w e r se t ti n g o f the eng ine.
p a s sa g e w ith oil u n d e r p r e ss u re ) all reb uilt engines.
T o p r o v i d e a safe, u n i f o r m initial o p e r a t i o n a l
Procedure for Pressure Lubrication c h e c k , the f o l lo w in g p r o c e d u r e is r e c o m m e n d e d :
1. C l e a n th e t a n k o f the 1 P5 40 F l o w C h e c k i n g
1. M o t o r e n g in e at c r a n k i n g sp e ed until (til
’F ool G r o u p t h o r o u g h l y , a n d set the p r e s s u re
p r e s s u re is o b s e r \ e d .
r e g u l a t o r to 35 t . 5 psi (240 ± 35 k P a ) .
2. O p e r a t e e n g in e for 10 m i n u t e s at low idle.
A WARNING
3. O p e r a t e en g i n e for 15 m i n u t e s at h alf-lo ad
Air pressure should not be more than 50 psi a n d 3 4 rated sp eed.
(345 kPa) at any time.
4. O p e r a t e e n g in e t o r 30 m i n u t e s at ra te d lo ad
2. P u t e n g in e oil in th e t a n k . a n d speed.
3. C o n n e c t the t o o l i n g to t h e m a i n oil p a s s a g e SERVICE TOOLS

o f th e engine.
Puller Assembly (2 or 3 Arm)
4. A d d a i r p r e s s u r e to th e t a n k , w ith th e r e g u l a t o r
set at 35 ± 5 psi (240 ± 35 k P a ) . A l t h o u g h t h e T w o o r t h r e e a r m pu ller as s e m b l i e s ca n be used
t a n k d o e s h a v e a h a n d p u m p , it is di fficult to t o r e m o v e g ears, b e a r i n g cages, h u b s, bearin g s,
get e n o u g h air p r e s s u re t o d o th e j o b w ith th e sh a fts , etc.
h a n d p u m p . T h e r e f o r e , use o f s h o p air is
reco m m en d ed .
5. Fet th e e n g in e oil flow into th e oil p a s s a g e
u n d e r p ressu re.
Fill th e c r a n k c a s e w i t h th e c o r r e c t oil. T h e
a m o u n t o f oil use d in th e p r e ss u re l u b r i c a t i o n
procedure m ust be s u b t r a c t e d from the
r e c o m m e n d e d refill cap ac ity in th e L u b r i c a t i o n a n d
M a i n t e n a n c e G u i d e . If th e en g in e is n ot g o i n g t o be
use d for a l o ng tim e, d o the a b o v e p r o c e d u r e a g a i n
b efo re th e first sta rtin g .
11 s h o p air is n ot a v a i l a b l e for c h a r g i n g th e t a n k , 17124«

th e h a n d p u m p may be used to get th e m i n i m u m
TY P IC A L EXAMPLE
re q u i re d p ressure.
1. Puller.
CAUTION
Do not use the same 1P540 Flow Checking Tool
Group for both “pressure lubrication applica
tion” and for checking fuel flow. Incorrect
cleaning is probable if the tool is used for both
fuel and lube oil. Even a minute amount of dirt
in the fuel system can cause fuel nozzle failure.
INITIAL OPERATION AFTER ENGINE
RECONDITIONING
I he q uality ol oil c o n t r o l c o m p o n e n t s use d in
C a t e r p i l l a r e n g in es is suc h t h a t , f o llo w in g en g i n e TY PIC A L EXAMPLE
r e c o n d i t i o n i n g (w ith C a t e r p i l l a r S erv ice P a r t s ) , 1. Puller. 2. Step Plate.
o nly a n initial o p e r a t i o n a l ch e c k is ne c e s sa ry b e f o re
c o n t i n u e d o p e r a t i o n in n o r m a l service.
6-3
TY PIC A L EXAMPLE TY P IC A L EXAMPLE

1. Puller. 2. Step Plate. 1. Ratchet Box W rench. 2. Push Puller. 3. Reducing
Adapter.
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
Bearing Pulling Attachment PRESSING PARTS
B e arin g P u llin g A t t a c h m e n t s c a n be u se d w ith W h e n p r e ss in g o n e p a r t into a n o t h e r , use 5P3931

fo rc i n g b olts, to r e m o v e sh a fts , be a r in g s, gears, etc. A n t i - S e i / e C o m p o u n d o r a m o l y b d e n u m disu lfid e
T h e y c a n be used w ith P u s h P ullers to p r o v i d e a base c o m p o u n d to l u b r ic a t e the m a t i n g surfaces.
v ariety o f p ullin g c o m b i n a t i o n s . A s s e m b l e t a p e r e d p a r t s dry. B efo re a s s e m b l i n g
p a r t s w ith t a p e r e d splines , be su r e th e splines a r e
c lean , d ry a n d tree f r o m b u r rs . P o s i t i o n th e p a r t s
t o g e t h e r by h a n d to m e s h th e sp lines b efo re
a p p l y i n g p ressure.
If p a r t s w h ich a r e fitted t o g e t h e r w ith t a p e r e d
sp lin es a r e n o t tig ht, in sp e ct the t a p e r e d splines
a n d d i s c a rd if w o r n .
BOLTS AND BOLT TORQUE

A bolt w h ic h is t o o lo n g m ay " b o t t o m ' ' b efo re
the h e a d is tig ht a g a i n s t th e p a r t it is to h o ld . T h e
t h r e a d s can be d a m a g e d w h e n a " l o n g " bolt is
TY P IC A L EXAMPLE re m o v e d .
1. Bearing Pulling Attachm ent. 2. Forcing Bolts.
If a bolt is to o s h o r t , t h e r e may n o t be e n o u g h
t h r e a d s e n g a g e d to h o ld th e p a r t se cu re ly .
A p p l y p r o p e r t o r q u e v alu es to all bo lts a n d n u ts

Bearing Cup Pulling Attachment w hen assem bling C a terpillar equipm ent. W hen a
B e arin g C u p P u llin g A t t a c h m e n t s a r e used to specific t o r q u e valu e is r e q u i r e d , th e v a lu e is listed
re m o v e b e a r i n g races o r cu p s , sleev e-ty pe b e a r in g s, in th e S P E C I F I C A ! I O N S se ctio n o f th e S ervice
be a r in g s, se ats, etc. a n d c a n be use d w ith P u s h M a n u a l . T i g h t e n all o t h e r b o lts a n d n u t s f o r g e n e r a l
Pullers. usa g e, h y d r a u l i c v alve b o d ie s , o r t a p e r l o c k s t u d s to
th e t o r q u e v a lu e s given in th e t o r q u e c h a r ts.
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
N O N : T h e side o f a n u t o r h o lt h e a d can be used E x a m p le : W = 12 in. (304.8 m m ): E - 2.56 in.

t o r refe rence it a m a r k c a n n o t he p u t on. (65.0 m m ): R T ( f r o m s p e c ific a tio n s ) -- 125 lb.
ft. (170 V m ) .
125 x 12
II o r 103 lb. ft.
12 + 2.56
(170 x 304.8) , , ,,n v ^

T l = (304.8 + 6 5 T } 1-’1 1140 N " "
4. H o l d th e t o r q u e w r e n c h h a n d l e w ith th e longest
f inger o f t h e h a n d o v e r th e m a r k o n t h e h a n d l e
to get th e real t o r q u e ( R T ) w ith low t o r q u e
i n d i c a t i o n (T I) o n th e t o r q u e w r e n c h .
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 :
LINES AND WIRES

RT x W W h e n r e m o v i n g o r d i s c o n n e c t i n g a g r o u p o f lines
W o r wires, t a g e a c h o n e to a s s u r e p r o p e r a s se m b ly .
6-6
LUBRICATION Heating Bearings

W h e r e a p p l i c a b l e , till the c o m p a r t m e n t s o f th e B e arin gs w h ich r e q u i re e x p a n s i o n t o r in st a l l a t i o n
c o m p o n e n t s serv iced w ith th e a m o u n t , ty p e a n d s h o u l d be h e a t e d in oil n o t to ex cee d 250 E.
m a d e of l u b r ic a n t r e c o m m e n d e d in th e L u b r i c a t i o n ( 1 21 ° C .). W h e n m o r e t h a n o ne p a r t is h e a t e d to
a n d M a i n t e n a n c e ( i u id e . a id in as s e m b l y , th ey m u s t be a llo w e d to co o l a n d
t h e n p ressed t o g e t h e r a g a in . P a r t s o l t e n s e p a r a t e as
RUST PREVENTIVE COMPOUND t h ey co ol a n d sh r in k .
C lean the rust p r e \ e n t i c e c o m p o u n d l r o m all Installation

m a c h i n e d su r f a c e s ot new p a r t s b e l o r e in sta llin g
them. L u b r i c a t e n ew o r use d b e a r i n g s b e l o r e i n s t a l l a
tion . B e aring s t h a t are to be p r e l o a d e d m u st h av e a
SHIMS film o f oil o v e r th e en tir e as sem ble tv) o b t a i n
a c c u r a t e p r e l o a d i n g . W h e n installin g a be a r in g ,
W h e n sh im s are r e m o v e d , tie t h e m t o g e t h e r a n d s p a c e r o r w a s h e r a g a i n s t a s h o u l d e r o n a sh a ft, be
i dentify t h e m as to lo c a t i o n . Keep sh i m s clean a n d su re th e c h a m f e r e d side is t o w a r d th e s h o u l d e r.
flat unt il t h e \ are r einstalled.
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 .
W h e n p ress in g b e a r i n g s into a r e t a i n e r o r b o re,

a p p l y p r e s s u r e to th e o u t e r race. If t h e b e a r i n g is
p ressed o n t h e sh a ft, a p p l y p r e s s u re o n th e in n er
race.
Preload
P r e l o a d is a n initial f o rce pla c e d o n th e b e a r i n g
at th e t im e o f a s sem b ly .
D e t e r m i n e p r e l o a d o r e n d c l e a r a n c e f ro m the
S P E C I F I C A T I O N S . C a r e s h o u l d be ex ercise d in
a p p l y i n g p r e l o a d . M i s a p p l i c a t i o n o f p r e l o a d to
D i s c a r d the b e a r i n g s if the races a n d balls o r b e a r in g s r e q u i r i n g e n d c l e a r a n c e c a n resu lt in
r olle rs are p itte d , sc o re d o r b u r n e d . If th e bearing b e a r i n g failure.
is se rvicea ble , c o at it w ith oil a n d w r a p it in clean Sleeve Bearings
p a p e r . D o n o t u n w r a p n ew b e a r in g s until tim e o f
i n s t a lla tio n . DO NOT IN STA TE SLEEV E B E A R IN G S
W I T H A H A M M E R . Use a press, if p o ssib le, a n d
1 he hie o f a n a n t i - fr i c t i o n b e a r i n g will be a p p l y th e p r e ss u re d irectly in line w ith th e bo re.
s h o r t e n e d il not p r o p e r l y lu b r ic a te d . If it is n e c e s sa ry t o d riv e o n a b e a r in g , use a d r i v e r
o r a b a r w ith a s m o o t h flat end . If a sleeve b e a r i n g
Double Row, Tapered Roller h as a n oil hole, align it w ith t h e oil hole in th e m a t i n g
D o u b l e row , t a p e r e d ro lle r b e a r in g s a r e p r e c isio n p art.
fit d u r i n g m a n u f a c t u r e a n d th e c o m p o n e n t s ar e n o t
i n t e r c h a n g e a b l e . T h e cu p s , c o n e s a n d sp a c e r s a r e GASKETS
usu a lly e tc h e d w ith the s a m e serial n u m b e r a n d Be su r e th e holes in th e g a s k e t s c o r r e s p o n d w ith
letter d e s i g n a t o r . If no letter d e s i g n a t o r s a r e f o u n d , the l u b r ic a n t p a s s a g e s in th e m a t i n g parts. If it is
wire the c o m p o n e n t s t o g e t h e r t o a s s u r e c o r re c t n e c e s sa ry to m a k e g a s k e ts, select stock o f the
in s t a l l a t i o n . R e u s a b l e b e a r i n g c o m p o n e n t s s h o u l d p r o p e r ty p e a n d th ic k n e s s. Be su r e to c u t holes
be installed in th eir o r i g in a l p ositio n s . p r o p e r l y . B lank g a s k e ts c a n cau s e s e rio u s d a m a g e .
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
BATTERIES 11, d u r i n g in s t a l l a t i o n , th e seal lip m u s t pass over

a s h a ft t h a t h a s sp lines, a key w a y . r o u g h su r f a c e o r
C lean b a tte r ie s by s c r u b b i n g w ith a s o l u t i o n o f
a s h a r p edg e, th e lip ca n be easily d a m a g e d . S h im
b a k i n g s o d a a n d w ater. R inse w ith clear w ater.
s to c k o r o t h e r su c h m a t e r i a l ca n be f o r m e d a r o u n d
A l t e r c le a n in g , dry t h o r o u g h ly a n d c o at te r m in a ls
t h e a r e a to p r o v i d e a s m o o t h su r f a c e o v er w h ich to
a n d c o n n e c t i o n s w ith a n t i - c o r r o s i o n c o m p o u n d o r
slide th e seal.
grease.
If a n e n g in e is not to be used l o r a long p e r io d

o! tim e, r e n u n c th e batteries. S t o r e t h e m in a cool,
d ry place. A sm all c h a r g e s h o u l d be i n t r o d u c e d
periodically to keep th e specific g r a \ i t y r a t i n g at CONVERSION CHART (inches to mm)
r e c o m m e n d e d level.
in c h e s m m in c h e s m m
SEALS (Lip-Type) 6'4 ,016 0.40 64 .516 13.10
A ,031 0.79 21 .531 13.49
G e n e r a l l y the to e o r s p r i n g - l o a d e d lip o f a n oil _3_.
.047 1.19 A .547 13.89
seal laces th e oil being sealed or the oil h a v i n g the A .062 1.59 562 14.29
h igh er p ressu re. T h e to e o r lip o f a g r e a se seal faces A .078 1.98 .578 14.68
3
j 2 .094 2.38 A .594 15.08
away f ro m the lu b r ic a n t bein g sealed. Unles s o t h e r
.100 2.54 .600 15.24
wise specified, use the p r e c e d i n g rul es for in stallin g if .109 2,78 A .609 15.48
lip-ty pe seals. Vb 125 3.18 5'8 .625 15.88
54 .141 3.57 A .641 16.27
.156 3.97 - 656 16.67
A .172 4.37 A .672 17.07
A .188 4.76 A .688 17 46
A .203 5.16 A 703 17,86
12 .219 5.56 32 .719 18.26
j. 5 .734 18.65
.234 5.95
'/4 .250 6.35 3A .750 19.05
64 .266 6.75 A .766 19.45
: 5
3*2 .281 7.14 .781 19.84
it .297 7.54 A .797 20.24
_s__ .812 20.6 4
.312 7.94 -i
64 .328 8 .3 3 ■] .828 21.03

.344 8.73 2 .844 21.4 3
23 .359 9 .1 3 .859 21.8 3
.375 9.53 % .875 22.2 3
%
T87198 ii .391 9.92 If .891 22.62
,400 10.16 .900 22.8 6
T h e m a i n p a r t s of a lip -typ e seal a r e th e case, 3
32 .406 10.32 31 .906 23.02
sealing e l e m e n t , a n d g a r t e r sp ring . T h e p ic tu r e 2J_ .422 10.72 .922 23.42
11
illustrates the c o n s t r u c t i o n o f a s im p le lip-ty pe 7'6 .438 11.11 -f .938 23.81
64 .453 11.51 .953 24.21
seal. 1 he cross se ctio n s sh ow th e t e r m s “ h e e l ” a n d . .969 24.61
32 .469 1 1,91
" t o e " used to identify th e sides o f v a r i o u s ty p es of A .484 12.30 .984 25.0 0
V2 .500 12.70 1 1.000 25.4 0
T 9 3 9 6 7 -A
L u b r i c a t e the lips o f lip -typ e seals b e f o re i n s t a l

latio n. Use th e s a m e ty pe lu b r ic a n t in w h i c h the
seal will be o p e r a t i n g . D o n o t use g rease o n a n y
seal ex c e p t a g rease seal.
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
DISASSEM BLY A N D ASSEMBLY (Section 7)

A c c e s s o ry D riv e G e a rs ............................................................................................................................................ 7 24
A c c e s s o ry D riv e H o u s in g ........................................................................................................................................ ^ 4
A fte r c o o le r C o re s ...................................................................................................................................................... 7 132

A fte rc o o le r H o u s i n g ................................................................................................................................................. 7 1 24
A ir C le a n e r ....................................................................................................................................................................
. . 7 -1 3 6
A ir S t a r t e r .......................................................................................................................................... 7 -| 4 4
A ir S ta rte r, A s s e m b le ............................................................................................................................................ 7 13«
A ir S ta rte r, D is a s s e m b le ........................................................................................................................................
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
E le c tric S ta rtin g M o to r s ........................................................................................................................................ 7 -1 3 5

E n g in e O il C o o le r ........................................................................................................................................................ 7 -3 8
E x h a u s t M a n ifo ld (In d u s tria l E n g in e s ) ............................................................................................................... 7 -7 2
E x h a u s t M a n ifo ld s (M a r in e E n g in e s ) ................................................................................................................. 7 7 5
E x p a n s io n T a n k (M a r in e E n g in e s ) ..................................................................................................................... 7 -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
M a rin e G e a r ..................................................................................... S ee S p e c ia l In s tru c tio n F o rm G E G 0 0 9 6 9
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
Oil Filter Housing ......................................................................................................................................... 2 12

Oil Pan B a s e ................................................................................................................................................... 7 50
Oil Pressure Relief Valve .......................................................................................................................... 7-30
Oil Pressure Relief Valve Disassem ble & Assem ble ....................................................................... 7 -3 0
Oil P u m p ......................................................................................................................................................... 7-31
Oil Pump, A s s e m b le ..................................................................................................................................... 7-36
Oil Pump, D is a s s e m b le .............................................................................................................................. 7-36
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
Rear Tim ing G e a r s ..................................................................................................................................... 7-1 5 8

Rocker Shafts and Push R o d s .................................................................................................................. 7-99
Rocker Shafts and Push Rods, D isassem ble & A s s e m b le .............................................................. 7-1 0 0
Turbocharger ............................................................................................................................................... 7-126

Turbocharger, A s s e m b le .......................................................................................................................... 7-130
Turbocharger, Disassem ble .................................................................................................................... 7-126
Turbocharger Lub rication Valve ............................................................................................................ 7-121
Turbocharger Lubrication Valve. D isassem ble & A ssem ble ........................................................ 7-122
T urbocharger Heat S h ie ld ........................................................................................................................ 7-125
Sea W ater P u m p ........................................................................................................................................... 7-13

Sea W ater Pump, Assem ble ..................................................................................... 7 16
S e a W a te r Pump, D is a s s e m b le ................................................................................................................ 7-15
Service M eter and Tachom eter Drive ....................................................................... 7-22
S h utoff Control .................................................................................................................. 7-63
S h utoff Control, A s s e m b le ........................................................................................................................ 7-67
S h utoff Control, D isassem ble .................................................................................................................. 7-64
Sh utoff Control G ro u p ................................................................................................................................ 7 90
S h utoff Control Group, A s s e m b le ............................................................................................................ 7-94
S h utoff Control Group, D is a s s e m b le ...................................................................................................... 7-91
Sump Pump ................................................................................................................................................. 7-123
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
W ater D ir e c to r s ........................................................................................................................................... 7-115

W ater Tem perature R e g u la to rs .................................................................................................................. 7-9
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
FUEL TRANSFER PUMP

R E M O V E A N D IN STALL
FU E L T R A N S F E R P U M P 1 2 5 6 — 10 Il
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 .
\
3. D i s c o n n e c t th e fuel lines (2) f r o m t h e p u m p .

R e m o v e th e t w o b o lts (3) t h a t h o l d p u m p t o
ac c e sso ry h o u sin g . R e m o v e fuel t r a n s f e r
p u m p (4).
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
FUEL TRANSFER PUMP
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
FUEL TRANSFER PUMP

D I S A S S E M B L E FUEL
TRANSFER PUMP 1 2 5 6 — 15
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.
4. R e m o v e t w o lip ty p e seals f r o m th e in sid e o f

cage (5).
5. R e m o v e th e b e a r i n g f r o m the cage w ith

t o o l i n g (A).
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
FUEL TRANSFER PUMP

A S S E M B L E FU E L
TRANSFER PUMP 12 56-16
Tools Needoc A B
9S8UOO Tool Group 1

1 P51 0 Dnvur Group
1. Install th e b e a r i n g in b o d y (1) w ith t o o l i n g

(A t until th e b e a r i n g is ev en w i t h th e insid e
su r f a c e o f the body.
2. Install the b e a r in g in cag e (2) w ith to o l i n g
t \ ) until the b e a r i n g is e \ e n w ith th e o u t s i d e
s 11:1 ;n. e oi the cage. Install t w o lip t \ p e seals
m the cag e with, t o o l i n g (B). See th e i l lu str a
tion ot the p u m p on P a g e 7-4 l o r c o r re c t seal
i n s t a lla tio n . Install th e s m a lle r o u t s i d e d i
a m e t e r lip t \ p e seal u n til it is 1.45 in. (36.83
m m ) t r o m th e in sta l l a t i o n e n d o f the cage.
Install the o t h e r lip t\ pe seal unt il it is .69 in.
( P . 53 m m ) f ro m th e in s t a l l a t i o n e n d o f the
Cd L?C.
3. I n stall t w o O - rt n g seals (3) o n th e cage. P u t a
t h in lay er o f S A E 30 oil on t h e O - r i n g seal
a n d th e seal lips. In stall th e cag e in b o d y (1)
as sh o w n .
4. In stall idler g e a r (4) a n d sh a ft (5) in th e b o d y .
I n stall r e t a i n e r ring (6) o n th e sh aft.
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
FUEL PRIMING PUMP

REMOVE FUEL PRIMING PUMP 1258—11
1. T u r n fuel valve to the ' ‘O F F ” po sitio n .
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 .
4. R e m o v e the twin b olts that ho ld th e b r a c k

et. R e m o v e the b olts ( 2 ) t h a t h o ld the base.
5. R e m o v e the fuel p r im in g p u m p .
INSTALL FUEL P R I M I N G PUM P 1 2 5 8 — 12
l. P u t the p u m p ( I ) on filter h o usin g . C o n n e c t

th e o u t l e t line for the fuel.
2. Install the b o lts t h a t h o ld base t o fuel filter

housing.
3. Install the t w o b o lts for th e b r a c k e t .
4. Connect the inlet lines to th e p r im in g

pum p.
5. f u r n th e Kiel valve to the “O N ” p o s itio n .
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
FUEL PRIMING PUMP

D IS A S S E M B L E FUEL P R IM IN G
PU MP 1 2 5 8 — 15
st a rt by:
a) r em o v e fuel p r im in g p u m p
1. R e m o v e the t u b e (2) f ro m valve b o d y (1).
2. Remove bracket (3) and retainer from tube.
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 .
4. R e m o v e the rings (4 ) a n d O-ring seals f ro m

pisto n (5).
5. R e m o v e plug, w as h er, spring s, valve, a n d O-

rina seal f ro m valve b o d v .
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
1. In stall th e O-ring seal, springs ( 3 ) , valve ( 2 ),

w a s h e r a n d p lug in th e valve b o d y ( l ) .
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.
3. P u t th e O-ring seals o n p is t o n . Install th e

rings o ver th e O-ring 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
WATER TEMPERATURE REGULATORS

R EM O VE WATER TEM PERATURE
REGULATORS 1 3 5 5 — 11
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
1P489 D rive Plate 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.
6. Fill th e eng ine w i t h c o o l a n t .
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
EXPANSION TANK (MARINE ENGINES)

R E M O V E E X P A N S IO N TA N K
(M A R IN E E N G IN ES ) 1 3 5 4 — 11
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.
2. Install b o lts t h a t h o l d b races to e x p a n s i o n

tan k . R e m o v e hoist fro m e x p a n s i o n ta n k .
3. Install b o lts t h a t fa ste n t e m p e r a t u r e r eg

u l a t o r h o u sin g a n d e x p a n s i o n t a n k t o g e t h e r .
Install ov e r flo w ho se a n d c l a m p s o n e x p a n
sion t a n k . Install the v e n t i l a t i o n line.
4. Install the sw it c h (2) o n e x p a n s i o n ta n k .

C o n n e c t th e lines (3 ) to sw itc h.
5. Fill th e en gine w ith c o o l a n t .
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
FUEL FILTER HOUSING

R E M O V E FUEL FILTER
H O U S IN G 1 2 6 2 — 11
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
1. R e m o v e fuel f r o m th e filter ho u sin g .
2. D i s c o n n e c t fuel line ( 2 ) f o r t h e p ress ure

gauge.
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 .
6. R e m o v e th e fuel f ilte r h ou 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 .
4. C o n n e c t fuel line f o r t h e pr e ss u re gauge,

en d by:
a) install fu el p r i m i n g p u m p
b) install e x p a n s i o n ta n k (M a r in e e n
gines o n ly )
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
OIL FILTER HOUSING

R E M O V E OIL FILTER H O U S I N G 1 3 0 6 — 11
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 .
5. R e m o v e oil filter h o using . W eig ht is 1 1 0 1 b .

( 5 0 kg).
IN S T A L L O IL FILTER H O U S I N G 1 3 0 6 — 12
1. F a s t e n a h oist t o th e filter h ousing.
2. Install a n e w seal in b a c k o f t h e h o usin g .
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 .
5. C h e c k the oil level in cra n k c a s e . Fill t o th e

c o r r e c t level.
e nd by:
a) install fu el filter h o u s i n g
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
SEA WATER PUMP

R E M O V E SEA W ATER P U M P 1 3 7 1 — 11
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 .
2. D i s c o n n e c t inlet line f ro m cov er (3 ).
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 ).
5. Remove co v er (3 ) a n d gas k ets f ro m the

pump.
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
l. P u t the sea w a t e r p u m p (1 ) o n t h e en gin e.

Install th e b olts t h a t h o ld p u m p to acce s
so ry drive ho u sing .
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 .
5. C o n n e c t th e in let line t o c o v e r (2 ). Install

th e plug in b o t t o m o f p u m p .
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
SEA WATER PUMP
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
SEA WATER PUMP

D IS A S S E M B L E SEA W A TE R P U M P 1 3 7 1 — 15
T o o ls Needed
1P2321 P uller A ssem bly
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.
2. Install the n u t even w ith en d o f sh a ft. I n

stall t w o 5 / 1 6 ” —18 NC x 2 in. lo n g b o l t s in
t h e im p eller. L o o s e n th e i m p e lle r f r o m
t a p e r o f s h a ft w i t h to o l i n g (A).
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).
4. R e m o v e th e c o t t e r pin s ( 4 ) a n d ring (2)

f ro m pins.
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 .
6. R e m o v e six b olts a n d locks.
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).
10. R e m o v e the b earing ( 1 1 ) f r o m r e t a i n e r.
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
SEA WATER PUMP

A S S E M B L E SEA W A T E R P U M P 1 3 7 1 — 16
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
1. Install bearin g in r e t a i n e r w ith to o l i n g (A ).

Install b earing w ith oil hole in b earin g in
a l i g n m e n t w ith oil hole in re ta in e r.
Inmall seal in r e t a i n e r w ith to o l i n g (B). I n

stall seal w ith lip t o w a r d th e bearing.
3. Put clean en g ine oil on lip o f seal.
4. Install re t a i n e r a s se m b ly (3). Install the

b earin g (4 ). Install th e s h a ft (2 ).
5. Install th e gear ( 1 ) on sha ft.
6. Install the b ello w s a n d plate in h o u sin g . T h e

s m o o t h side o f plate m u s t be a w a y f ro m
h ousing.
7. Install th e ring (5 ) a n d c o t t e r pins.
8. Install th e g as ket a n d p late. T h e s m o o t h

side o f plate m u s t be a w a y fro m im peller.
9. Install th e i m p e lle r (6).
10. Install the w a s h e r a n d n u t (7). T i g h t e n the

nut to 55 ± 10 lb. ft. ( 7 5 ± 14 N * m ) a n d install
c o t t e r pin. If c o t t e r pin c a n n o t be in stalled,
tig h ten nu t until it ca n be in stalled .
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
VIBR A TIO N DAMPER (D398 and D399)

R E M O V E V IB R A T IO N D A M P E R
(D398 & D399) 12 0 5-1 1
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 ).
4. Install c o ver ( 2 ) o n D 3 9 9 . In stall c ov er o n

D 3 9 8 w ith b o l t s t h a t have a m a r k in r e s p e c
tive place o n h o u sin g .
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
CRANKSHAFT FRONT SEAL RING AN D THROWER

R E M O V E C R A N K S H A F T F R O N T SEAL
RING A N D T H R O W E R 1 1 6 0 — 11
T o o ls Needed A B
8B7548 Push P uller 1
8B 7550 Leg 2
5 F73 4 1 A d a p te r 2
8H684 R a tch e t B o x W rench 1
8B7561 S tep Plate 1 1
1P2321 P u lle r A tta c h m e n t 1
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 ).
4. R e m o v e the b affle ( 4 ) f ro m ac c e ss o ry drive

h ou sing .
5. Remove ring (5) an d sprin g from the

throw er.
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. R e m o v e th e ring f ro m th e acce ss o ry drive

h ousing.
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
CRANKSHAFT FRONT SEAL RING AND THROWER

IN S TA LL C R A N K S H A F T F R O N T SEAL
RIN G A N D T H R O W E R 1 1 6 0 — 12 \
T o o ls Needed A
FT105 Push Plate 1
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.
P u t clean eng in e oil o n th e sp rin g an d ring.

In stall spring a n d ring ( 2 ) o n t h r o w e r w i t h
th e w o r k “ O U T ” on ring a w a y f r o m c r a n k
case. P u t th e gap o f t h e ring, t o t o p o f
c r a n k s h a f t w h e n in stalled.
4. P u t clean e ng in e oil o n in side d i a m e t e r o f

baf fle (3 ). In stall th e b affle (3).
5. Put 9S 3263 T hread Lock on threads o f

b o lts f o r a d a p t e r .
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. In stall t h e c o ver o n D 3 7 9 o n l y . P u t b o lts

w i t h L o c t it e in l o c a t i o n w i t h X m a r k .
e n d by:
a) in stall v ib r a t io n d a m p e r ( D 3 9 8 a n d
D 3 9 9 o n ly )
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
CRANKSHAFT FRONT SEAL (LIP TYPE) A N D

WEAR SLEEVE
REMOVE CRANKSHAFT
F R O N T S E A L (LIP T Y P E )
A N D W E A R S LE E V E 1160—11
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 .
2. R e m o v e ten b o lts (3) a n d r e m o v e a d a p t e r (4)

R e m o v e eight b o lts (5) a n d sp a cers.
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
CRAN KSHAFT FRONT SEAL (LIP TYPE) A N D

WEAR SLEEVE
INSTALL C R A N K S H A F T F R O N T SEAL
( L I P TYPE) A N D W E A R SLEEVE 1 1 6 0 — 12
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 .
2. P u t a t h i n la y e r o f S A E 30 oil o n t h e seal lip.

In stall th e seal o v e r t o o l i n g (A). T h e seal lip
goes t o w a r d t h e inside o f t h e en g in e. I n s t a l l
sp a c e r s a n d b o lts w h i c h h o l d t h e se al in t h e
a d a p t e r . T i g h t e n th e b o l t s in t h e n u m b e r se
q u e n c e s h o w n . T i g h t e n e a c h b o lt a m a x i m u m
o f t h r e e t u r n s e a c h r o u n d u ntil all th e b o l t s
ar e tight.
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
SERVICE METER A N D TACHOMETER DRIVE

R E M O V E S E R V IC E M E TE R A N D
T A C H O M E T E R D R IV E 7 4 7 8 -1 1
Tools Needed
1 P510 Driver G roup
1. R e m o v e t w o b o lts (1) a n d se rv ice m e t e r (2).
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).
4. R e m o v e th e lip ty p e seal f r o m h o u s i n g (6)

w ith t o o l i n g (A).
5. R e m o v e tw o b o lts (7) a n d a d a p t e r (8).
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
SERVICE METER A N D TACHOMETER DRIVE
B e nd th e locks.
2. Install the lip type seal in housing (3) w ith

tooling (A). Install the seal w ith the seal lip
toward the engine. Put a thin layer o f SAE 30
oil on the seal lip and the seal bore in the
housing.
3. Install a new gasket and housing (3) on the

engine w ith fo u r bolts and lockwashers.
4. Inspect and make a replacement, if neces

sary, o f O -ring seal (4) on tachometer drive
(5). Install the tachometer drive on the hous
ing w ith two clamps, lockwashers and bolts.
5. Inspect and make a replacement, if neces

sary, o f O -ring seal (6) on service meter (7).
Put a thin layer o f SAE 30 o il in the counter
bore o f the tachometer drive. Install the ser
vice meter w ith two clamps, lockwashers and
bolts. Tighten the bolts to a torque o f 8 ± 2 lb.
ft. (11 ± 3 N.m).
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
ACCESSORY DRIVE HOUSING

R E M O V E A C C E S S O R Y D R IV E
H O U S IN G 1 2 0 7 — 11
T o o ls Needed
8B7548 Push P uller
8B7550 Leg
5F 73 4 1 A d a p te r
8 H 684 R a tch e t B o x W rench
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).
2. R e m o v e th e baffle (2 ) fro m th e acce sso ry

drive housing.
3. R e m o v e th e seal ring a n d spring f ro m th e

th r o w e r .
4. R e m o v e the fuel lines (3 ) f ro m fuel filter

h ou sin g. R e m o v e eleven b o lts (5 ) t h a t hold
a cce ssory drive h o u sin g to c y l i n d e r blo ck .
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.
8. R e m o v e the b o lts t h a t h old t im in g gear

p late to ac c e ss o ry drive h o u s i n g o n left side
o f engine.
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.
10. Install t w o 1 / 2 ” -1 3 NC b o l t s as a gu ide. In

stall t w o 3 / 8 ” - 1 6 NC fo rg ed e y e b o l t s in
a cce ss o ry drive h o u sin g. F a s t e n a h o ist a n d
r e m o v e the acce ss o ry drive h o u sin g . Weight
is 2 0 0 lb. (91 ka).
7-24
D IS A S S E M B L Y A N D A S S E M B L Y
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
1. Install t w o I / 2 " 13 NC b o lts as a gu ide in

the c y l i n d e r b lock. Install t w o 3 / 8 ” - 16 NC
fo rged e y e b o l t s in drive h o u sin g. F a s t e n a
h oist and p u t accessors' drive h o u s i n g on e n
gine.
2. Install th e eleven b o lts (5 ) t h a t h o ld drive

h o u sin g to c y l i n d e r block.
3. Install th e b olts ( 1 ) t h a t hold drive h o u sin g

to t im in g gear p late ( 2).
4. C o n n e c t th e fuel lines ( 3) t o fuel filter h o u s

ing.
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 .
6. F a s t e n a ho ist an d lift th e f r o n t o f en gin e

e n o u g h to r e m o v e th e spa cers f r o m b e t w e e n
c y l i n d e r b l o c k a n d oil p a n base. T ig h t e n th e
b o lts t h a t h o ld c y l i n d e r b l o c k to base.
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.
8. P u t clean eng ine oil o n sprin g a n d seal ring.

Install th e sp rin g a n d seal ring o n t h r o w e r
w ith the w o r d ' ‘O U T ” o n seal ring in stalled
aw ay f ro m c r a n k s h a f t . P u t th e gap o f seal
ring t o t o p o f c r a n k s h a f t w h e n installed.
9. P u t clean en gine oil o n in side d i a m e t e r o f

baf fle. Install th e baffle.
10. Put 9 S 3263 T hread Lock on threads o f 3 7

b o lts fo r a d a p t e r . Install t h e a d a p t e r 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 Sealer o n
t w o o f b o l t s for cover. Install th e c o ver f o r
a d a p t e r . P u t b olts w i t h L o c t it e in lo c a t i o n s
( 6 ) an d (7).
e n d by:
a) install v i b r a t io n d a m p e r ( D 3 9 8 &
D 3 9 9 o n ly )
b) install oil pressu re regu latin g valve
c) install fuel tr a n sf e r p u m p
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
ACCESSORY DRIVE GEARS
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
1P2321 P u lle r A ssem bly 1
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
ACCESSORY DRIVE GEARS

INSTALL A C C E S S O R Y D R IV E
GEARS 1206 - 1 2
T ools A B
1P529 Handle 1
F T 105 Push Plate 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 : Be sure th e plate is installed o n c o r r e c t side

as i n d ic a te d in rem o val.
2. Install th e oil t u b e ( 1). Install small g a s k e ts

u n d e r n u t s t h a t h old right e n d o f t u b e . P ut
7 M 7 2 6 0 L iq u id G a s k e t Material o n sealing
su rfaces o f id ler gear s h a f t oil t u b e ( 1 ) . a n d
sh a ft for m ain idler gear ( 2).
3. O n 0 3 7 9 e n g in e only , in stall b e a r i n g in b a l
a n c e r g e a r with to o l i n g (A). Install th e b a l
a n c e r g e a r a n d sh a ft. T ig h t e n b olts to 40 + 4
lb. ft. (55 ± 5 N u n ) .
4. Install bearings in the gears for oil p u m p
an d m ain idler gear. PLATE POSITION
INDICATION MARK
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.
5. Install m ain idler gear an d sh a ft. Install e n

gine oil p u m p a nd fresh w a t e r p u m p . Install
gears for oil p u m p a n d w a t e r p u m p .
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
ACCESSORY D RIVE GEARS

N O T E : O n SAH o p p o s i t e r o t a t i o n ( c lo c k w ise ) e n
gine. th e b a l a n c e r gear t im in g m a r k “ R ” m u s t be in
a l i g n m e n t w i t h th e “ R ” o n th e sm all idler gear.
T h e o t h e r “ R ” o n t h e sm all idler g ear m u s t be in
a l i g n m e n t b e t w e e n t w o t e e t h o n c r a n k s h a f t g ear
w i t h t w o p u n c h m ark s. O n 12 a n d 16 c y l i n d e r e n
gines. n o tim in g o f acce ss o ry dr ive gear s is n e c e s
sary .
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
OIL PRESSURE RELIEF VALVE

R EM O VE OIL PRE SS URE
RELIEF VALVE 1 3 1 5 — 11
1. R e m o v e t h e b o lts (2) t h a t h o l d v alv e t o oil

p an.
2. R e m o v e valve a n d t u b e f r o m th e tee (l).
INSTALL OIL PRESSURE

1. Slide valve a n d t u b e in th e tee.
2. Install th e b o l t s t h a t h o l d v alve t o oil p an .
D IS A S S E M B L E OIL PRESSURE
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 .
ASS EM BLE OIL PRE SS URE

RELIEF VALVE 1 3 1 5 — 16 © © © ©
l . I nstall new seals.
2. P u t clean en gin e oil in t h e b o r e o f h o u s i n g .

(I).
j •
3. In stall th e g u id e (2), s p r i n g (3), a n d p i s t o n (4)

in h o u s i n g . In stall th e t u b e (5) o n h o u s i n 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
I. R e m o v e six b o lts (!) a n d a d a p t e r (2).
2. R e m o v e oil p u m p d riv e g e a r (3) f r o m t h e a c

c es sory d riv e h o u s i n g .
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
1. I n stall a n ew g a s k e t b e t w e e n oil p u m p (1) a n d

ac c e ss o ry driv e h o u s i n g . I n s p e c t a n d m a k e a
re p l a c e m e n t o f O - ri n g seal (2) if necessa ry.
F a s t e n a h oist to th e oil p u m p a n d in stall it.
Install th e six b olts w h ic h f a s te n t h e p u m p t o
th e ac c e ss o rv dr ive. T h e w eig h t o f oil p u m p is
110 lb. (49.5 kg).
2. I nstall b olt (3) a n d r e m o v e hoist.
3. In sp ect 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
seals o n th e t u b e , tee a n d oil p r e s s u r e r e g u l a
tor. Install t u b e (5). tee (4) a n d oil p r e s s u r e
r e g u l a t o r (7). In stall c l a m p (6) w ith t w o bolts.
4. I n stall oil p u m p d riv e g e a r (8) in th e a c c e s

so r y d riv e h o u sin g .
5. Use a press a n d t o o l i n g (A) to install t h e b e a r
ing in a d a p t e r (9).
6. In stall a new' g as k et b e t w e e n t h e a c c e s s o ry
driv e h o u s i n g a n d a d a p t e r (9). In stall th e
a d a p t e r w'ith six bolts.
en d by:
a) in stall fuel t r a n s f e r p u m p
7-32
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
Pipe, 1 1 2 " inside diam eter

6' long 1
1 P510 Driver G roup 1
s t a rt by:
a) r e m o v e oil p u m p
l. Remove bolts (l) and plate (2).
2. R e m o v e b o lts (3) a n d c o v e r (4).
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).
5. R e m o v e lip ty p e seal (10) a n d b e a r i n g (9)

f r o m h o u s i n g (6).
A82842X1
A82844X1
7-34
OIL PUMP
6. R e m o v e s h a ft a s s e m b l y (13 ),g e a r s (12) a n d

r e t a i n e r (11) f r o m m a n i f o l d (8).
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 .
8. Use a press a n d t o o l i n g (B) t o r e m o v e t h e

b e a r i n g f r o m r e t a i n e r (11).
9. Use a p ress t o r e m o v e g e a r (16) f r o m s h a ft

(13).
10. Use a p ress a n d t o o l i n g (B) t o r e m o v e t h e

b e a r i n g s f r o m g ears (12). x* %
A82837X1
7 -35
OIL PUMP
A S S E M B L E O IL P U M P 1 3 0 4 — 16
Tools Needed
1P510 Driver Group
Use t o o l i n g (A) a n d a press t o install b e a r i n g

(1) in r e t a i n e r (2).
2. In stall t w o b e a r i n g s in e a c h g e a r (3) w ith

t o o l i n g (A) a n d press. I n s t a l l t h e b e a r i n g s u n
til t h e y a r e ev en w i t h t h e su r f a c e o f t h e gear.
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 .
5. I n stall lip t y p e seal in h o u s i n g (8) w i t h t o o l i n g

(A). In stall th e seal w i t h th e seal lip t o w a r d
th e in side o f th e p u m p . P u t a t h i n l a y e r o f
S A E 30 oil o n th e seal lip.
7-36
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
7. I n sta ll r e t a i n e r (2) o n m a n i f o l d (7) w i t h five

b olts a n d t w o locks. P u t a t h i n l ay er o f S A E
30 oil o n t h e gears, b e a r i n g s a n d sha fts . I n
stall t w o g ears (3) a n d s h a ft a s s e m b l y (4) in
th e m a n if o ld .
8. In stall t w o O - r i n g se als (10) o n m a n i f o l d (9).

I n stall m a n i f o ld (7) a n d h o u s i n g (8) o n
m a n i f o ld .
9. P u t a t h i n lay er o f S A E 30 oil o n t h e seals in

n ine w a s h e r s (12). In stall n in e b o lts (11), w a
sh e rs a n d seal w a s h e r s (12) w h i c h f a s t e n t h e
m a n i f o ld s a n d h o u s i n g t o g e t h e r .
10. I n stall a new g a s k e t b e t w e e n c o v e r (15) a n d

h o u s i n g (8). I n stall t h e c o v e r w i t h se v en b o l t s
(13). In stall a n ew g a s k e t b e t w e e n t h e c o v e r
a n d p la te (14). In stall th e p la te o n t h e co v er;
w ith nin e bolts.
e n d by:
a) in stall oil p u m p .
« * -
7-37
ENGINE OIL COOLER

R E M O V E E N G IN E O I L CO O LE R 11-1378
1. R e m o v e th e c o o l a n t f ro m th e engine.
2. R e m o v e th e oil fro m oil coo ler.
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 ).
5. R e m o v e th r e e b o lts ( 5 ) t h a t h old Range to

fly w heel housing.
6. R e m o v e oil line ( 6 ) a n d clip f o r t u r b o -

ch a r g e r l u b r ic a t io n valve.
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 .
8. F a s t e n a ho ist to th e oil co o ler.
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 .
10. R e m o v e th e eng ine oil co o ler. W eight is 9 0

lb. (41 kg).
11. R e m o v e the s u p p o r t (8) an d connector

f r o m oil c o o l e r ( 9).
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
ENGINE OIL COOLER

I N S T A L L E N G I N E O IL C O O L E R 1 3 7 8 — 12
I. Install s u p p o r t (l) and c o n n e c t o r o n oil

co oler.
2. In stall t u b e a ssem b ly ( 2 ) a n d e l b o w ( 3 ).
3. F a s t e n a ho ist t o oil co o ler. P u t t h e oil

c o o l e r in p o s i t i o n o n engine. Install t h e oil
line ( 4 ) an d clip f o r t u r b o c h a r g e r l u b r ic a
tion valve.
4. Install the t h r e e b o l t s t h a t h o ld flange to

fl y w h e e l h o u sin e .
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.
7. In stall e l b o w a n d c l a m p f o r oil line f r o m oil

filter h o u s i n g t o t h e oil co o ler.
8. In stall th e b o lts ( 7 ) that ho ld elbow to

water pum p.
9. Fill th e en gin e w ith c o o l a n t .
I 0. A d d oil t o en gin e as n e e d e d .
7 -3 9
FRESH WATER PUMP

R E M O V E FRESH W A TE R P U M P 1 3 6 1 — 11
1. R e m o v e th e c o o l a n t f r o m engine.
2. R e m o v e the oil fro m en g in e oil coo ler.
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 ).
4. R e m o v e the b o lts t h a t ho ld e l b o w to oil

c o o l e r a n d w a t e r p u m p . R e m o v e the elb o w
(5).
5. R e m o v e co ver (4) a n d b e a r in g cage.
6. F aste n a ho ist to the w a t e r p u m p .
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.
2. Install th e bearin g cage ( l ) a nd c ov er (2 ).
3. Install the e lb o w (3).
4. P u t the oil line (4 ) on the oil co o ler . Install

the t w o b o lts a n d c la m p . Install w a t e r line
to p u m p f ro m w a t e r t e m p e r a t u r e r e g u l a t o r
h ou sin a .
5. Fill th e eng ine w ith c o o l a n t .
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
FRESH WATER PUMP
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
FRESH WATER PUMP

D IS A S S E M B LE FRESH W ATER
PUMP 1 3 6 1 — 15
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
I. R e m o v e b o lts (4) a n d g e a r (2) f r o m s h a f t (5).

R e m o v e bo lts (3) a n d b e a r i n g ( l ).
2. R e m o v e f o u r b o lts (9) a n d e l b o w (8). R e

m o v e b olts (6) a n d c o v e r (7).
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
FRESH WATER PUMP
5. R e m o v e sh a ft (5) f r o m s p r i n g (13) a n d seal

a s s e m b l y (14).
© — /
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
FRESH WATER PUMP

A S S E M B L E FRESH W A TER
PUMP 1 3 6 1 -1 6
T o o ls N e ed e d
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.
1. In stall th e lip ty p e seal in r e t a i n e r (1) w i t h

t o o l i n g (A). T h e seal lip goes t o w a r d t h e i n
side o f th e r e t a i n e r. P u t a t h i n la y e r o f S A E
30 oil o n th e seal lip.
2. In stall the h e a r i n g in r e t a i n e r ( I ) w ith to o l i n g

(A). Install the h e a r i n g un til it is even w ith
the s u r l a e e o f re ta in e r. P u t a t h in layer o f
SAL. 30 oil on th e h earin g.
3. I n sta ll n ew g a s k e t (2) b e t w e e n h o u s i n g (3)

a n d r e t a i n e r (1). P u t th e r e t a i n e r in p o s i t i o n
o n th e ho u sin g .
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
FRESH WATER PUMP
Install spring (9) and im peller (8) on the

shaft. Install the washer and nut which hold
the impeller on the shaft. Tighten the nut to
55 lb. ft. (75 N.m). Then tighten the nut more
un til the cotter can be installed.
7. Install gasket (10) between the housing and

cover (11). Install the eight bolts which fasten
the cover to the housing.
8. Use thickness guage (12) to check the clear

ance betwen the cover and impeller. Use
gasket(s) (10) as needed to get a clear
ance of .005 to .020 in. (0.13 to 0.51 mm).
9. Install gear (13) on the shaft w ith six bolts

and three locks. Bend the locks.
10. Install elbow (14) on the pump assembly w ith

fou r bolts.
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
PRELUBRICATION OIL PUMP (D399)

R E M O V E P R E L U B R I C A T I O N OIL
PUMP (D 399) 1 3 1 9 — 11
1. R e m o v e t he bol t s t ha t hol d i nlet oil line (3)

t o oil pan base.
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
l. Put t he p r e l u b r i c a t i o n oil pump on t he

mo t o r . Install t he bol t s.
2. Install bol t s t hat hol d inlet line t o oil p a n

base.
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
PRELUBRICATION OIL PUMP (D399)

D I S A S S E M B L E P R E L U B R I C A T I O N O IL
PUMP (D 399) 1319- 15
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
1P482 Drive Plate 1
Use t o o l i n g ( A) t o i nstall seals in hous i n g.

Install seals wi t h lips a w a y f r o m e a c h o t h e r .
Install s cr ew ( s o c k e t he a d) in oil o u t l e t
por t .
2. Install idler o n h e a d a s s embl y. Install r o t o r

in housi ng. P u t h e a d as s e mb l y ( l ) o n h o u s
ing a n d install bol t s.
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
4. R e mo v e head ass.embly again a n d a d d gas k et

s hi ms as n e e d e d t o get t h e c o r r e c t e n d c l ear
ance.
5. Install inlet oil line on t he p u m p . "i
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
CONNECTING ROD BEARINGS

R E M O V E A N D IN S TA LL C O N N E C T IN G
R O D B E A R IN G S 1 2 1 9 — 10 < "lJ*" '■
T o o ls N e e d e d
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.
5. R e m o v e t h e bol t s (3) f r o m e a c h r o d cap.

R e m o v e t he r o d c a p (4).
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
CONNECTING ROD BEARINGS
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.
9. Inst al l t he u p p e r ha l f o f new r od b e a r i ngs in

t he c o n n e c t i n g r ods. P u t cl ean S A E 30
engi ne oil o n t he be a r i ngs a n d c r a n k s h a f t
J o u r n a l . Pull t he c o n n e c t i n g r od s wi t h b e a r
ing i nt o pos i t i o n o n c r a n k s h a f t .
N O TE: Be sur e t he t a b o n ba c k of b e a r i n g fits in t a b

g r o o v e (slot) in c o n n e c t i n g rod.
10. Inst al l l owe r h a l f o f ne w b e a r i n g s in caps. P u t

cl ean S A E 30 engi ne oil o n bear i ngs.
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.
11. C h e c k t he b e a r i n g c l e a r a n c e wi t h wire (A).

Instal l b e a r i n g c a p on c o n n e c t i n g r od. P u t
cl ean S A E 30 engi ne oil o n t h r e a d s of r od
bolts. Inst all t he r od bolts, l ight en t he r od
bol t s first to a t o r q u e o f 40 ± 4 lb. ft. (55 ± 5
Nu n ) . P u t a m a r k o n bolt h e a d s a n d b e a r i n g
caps. l i ght en t he bol t s a g a i n 120° f r o m t he
ma r k .
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
OIL PAN BASE

R E M O V E O IL P A N B A S E 1 3 0 2 — 11
P378
1. R e m o v e t he c o o l a n t f r o m engi ne.
2. R e m o v e t he oil f r o m oil p a n base. C a p a c i t y
o f D3 7 9 is 92 U.S. gal. (348 liter); D3 9 8 is 110
U. S. gal. (416 liter); D3 9 9 is 165 U. S. gal.
(625 liter).
3. Di s c o n n e e t inlet w a t e r lines t h a t are c o n

ne c t e d t o engi ne. Di s c o n n e c t fuel lines f or
fuel s u p p l y to engi ne.
4. R e mo v e oil pr ess ure r egul at i ng valve ( 1).

5. R e m o v e t he f our bol t s t h a t hol d pl at e (3)
for oil p u m p t o t he base.
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.
7. F a s t e n a hoi st t o t he e ngi ne. Lift t he engi ne

f r o m base. We i g h t of D3 7 9 is 8. 000 lb. ( 3600
kg); D3 9 8 is 10.000 lb. (4500 kg); D3 9 9 is
13.000 lb. (5850 kg).
8. M o v e t he oil p a n base. We i g h t o f bas e on

1)379 is 2.100 lb. (945 kg); D3 9 8 is 3.000 lb.
(1350 kg); D 3 9 9 is 3.800 lb. ( 1750 kg).
IN S T A L L O IL P A N B A S E 1 3 0 2 — 12
1. Install a n e w gas ket o n t he oil pa n base.
2. F a s t e n a hoi st t o engi ne. P u t t he engi ne in

pos i t i on on oil pan base. P u t 9 S 3 2 6 3
T h r e a d L o c k o n t he t h r e a d s o f bo l t s f or
base. Install t he bol t s t h a t hol d eng i ne on
oil pa n base.
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.
4. C o n n e c t inlet w a t e r lines to t he engi ne.
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.
6. Install oil pr ess ur e r egul at i ng valve o n e n

gine.
7. Fill t he engi ne wi t h oil a n d c o o l a n t t o c o r

rect levels.
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
FUEL RATIO CONTROL WITH OVERRIDE

R E M O V E 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 — 11
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 ).
3. Di s c o n n e c t line (3) f r o m fuel r at i o c o n t r o 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.
I. C o n n e c t line (3) for air t o t he fuel r at i o

c ont r ol .
3. Install t he over r i de a s s e mb l y a n d bol t s t h a t

ho l d it 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
FUEL RATIO CONTROL WITH OVERRIDE

D I S A S S E M B L E 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 — 15
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.
3. R e mo v e t he cover ( 5) f r o m t he hous i ng. R e D ©

m o v e t he t w o springs. T u r n bol t ( 6) a nd
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
1. C o n n e c t t he bol t t o t he was her , d i a p h r a g m

a n d r et ai ner. P u t t h e d i a p h r a g m a s s e mbl y
an d t he t w o spri ngs in housi ng. Install t he
cover for fuel rat i o co n t r o l .
2. Install t he seal in over r i de h o u s i n g wi t h lip

o f seal t o w a r d a r m. Inst al l t he lever a nd
spring. Install t he n u t a n d s cr ew t h a t ho l d
t he lever.
3. Install t he pl unger , s pr i ng a n d c over on t he

over ri de housi ng.
end by:
a) install fuel r at i o c o n t r o l wi t h over r i de
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.
2. Di s c o n n e c t line ( 3) for t he fuel r at i o c o n

trol.
3. R e r m n e the cabl e (2) t or s h u t o f f cont r o l .
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.
6- R e mo v e t he gover nor . Wei ght is 4 0 lb. ( 1 8

kg).
IN S T A L L G O V E R N O R 1 2 6 4 -1 2
l . Put t he g o v e r n o r o n engi ne wi t h lever o n

go v e r n o r eng a g e d in gr oove ( sl ot) in r ack.
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.
3. C o n n e c t line for t he oil pr ess ure gauge.
4. C o n n e c t t he line f or oil pr ess ure swi t ch.
5. C o n n e c t the line to t he luel r at i o co n t r o l .

Instal l t he cabl e l or s h u t o f f c ont r ol .
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.
2. R e m o v e t he high a n d l ow idle s cr ews ( 3).
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. R e m o v e s pe ed l i mi t e r plug ( 1 3 ) , gas ket

( 1 4 ) . spr i ng ( 1 5 ) , a n d p l u n g e r ( 1 6 ) .
1 2. R e m o v e t he lever (1 7) f r o m t he shaft .
7-55
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.
14. R e m o v e t he bol t ( 1 9 ) t ha t h ol ds lever as

s e m b l y ( 1 8) o n shaft.
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
16. R e mo v e t h e lever a s s e mb l y ( 18) .
17. Push t he pin ( 2 1 ) f r o m lever ( 18 ) .
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 ) .
19. R e m o v e t he t hr ee bol t s ( 2 7 ) a n d l ock ( 2 8 )

t h a t hol d wei ght as s e mb l y t o g o v e r n o r dri ve
housi ng.
20. R e m o v e t he t w o bol t s ( 2 6 ) a n d l ocks. Push

cover a s s e mb l y ( 2 4 ) up a n d r e mo v e t he
we i g h t a s s e mbl y ( 25) .
21. R e m o v e t he r i ng (30) f r o m t he seat. R e m o v e

t he pin (29).
7-56
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.
24. R e m o v e t he ring ( 3 7 ) t h a t h ol d s b ear i ng as

s e mb l y o n sleeve ( 35) .
25. R e m o v e bear i ng ( 3 8 ) a n d r aces ( 3 6 ) f r o m

sleeve ( 35) .
26. R e m o v e t he valve ( 4 2 ) f r o m pi s t o n ( 41) .
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) .
29. R e mo v e t he O- ri ng seal f r o m t he sleeve

( 40) .
30. R e mo v e t he c over a n d s ha f t a s s e mbl y ( 4 4 )

as a u ni t f r o m t h e drive housi ng.
31. R e m o v e gear ( 4 5 ) f r o m t h e pin a s s embl y.
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.
33. R e m o v e t he gear ( 4 6 ) f r o m t he shaft .
34. Push t he bear i ngs ( 5 0 ) a n d s ha f t ( 4 9 ) o u t o f

t he drive housi ng.
35. R e m o v e t he beari ngs, shaf t , lever ( 4 8 ) and

pin as s embl y ( 51) .
36. R e m o v e t he valve as s e mb l y ( 5 2 ) a n d gas ket .
37. R e m o v e t he pl ug as s e mb l y ( 5 3 ) a n d gasket .
38. R e mo v e t he cove r ( 5 4 ) f r o m dri ve housi ng.
39. R e mo v e t he bu s h i n g f r o m dri ve housi ng.
7-58
GOVERNOR
ASSEMBLE GOVERNO R 1 2 6 4 —16
T o o ls Needed A
© ©
1P529 H andle 1

i a i
1. Install t he valve as s e mb l y ( 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).
3. Inst al l t h e cover ( 3).

r * ©
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).
6. Install the lever (4), bearings (6 ), and shaft

(5).
N O T E : S h a f t (5) m u s t t ur n freely in t he be a r i ngs

wi t h .02 t o .06 in. (0.5 t o 1.5 m m ) e n d play.
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).
10. Install p i st on ( 1 2 ) a nd sleeve ( 1 4 ) in t he

e v l i n d e r ( 11) .
11. Put t he wei ght a s s e mbl y ( 1 6 ) o n c yl i nde r

( 1 7) a n d install ring (15) .
1 2. Install t he valve (1 9) in pi s t on ( 12) .
1 3. Install t he bear i mt a n d races o n sleeve.
14. Install t he sleeve a n d bear i ng a s s e mbl y ( 1 8 )

on valve ( 19) .
15. Put t he seat ( 2 1 ) . bol t ( 2 0 ) , wa s h e r s a nd

spr i ng on t he valve.
16. Install t h e pin ( 2 2 ) a n d ring ( 23) .
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 .
18, Install t he cover a n d sha f t a s s e mbl y ( 2 4 ) ii

t he drive housi ne.
16 Push, the ver and. shaft a s sembl y u p a nd

install hi x\ f 1il i i i ,i 's'st; m b l y ( 2 6 ) on t h e
co\ cr.
X). Install t he l ocks a nd bol t s ( 2 7 ) t h a t hol d

c over a n d sha f t a s s e mbl y t o drive housi ng.
21. Install l ock ( 2 8 ) a nd b ol t s t h a t h o l d we i g h t

assembly.
2. Install spr i ng a n d p l ung e r in lever ( 2 9 ) . I n

stall pin in lever.
23. Install bear i ngs a n d seal in g o v e r n o r h o u s i ng

( 30) .
24. Inst all lever ( 2 9 ) . s ha f t ( 3 2 ) a n d b ol t ( 3 1 )

t hat h o l ds lever t o shaft .
15. Install spe ed l i mi t er pl unger , spr i ng, gas ket

a nd plug. Install r ack s t o p g r oup.
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) .
27. Install t he spr i ng ( 3 3 ) o n t he b ol t ( 2 0) .
28. Install t he g o v e r n o r h o u s i n g o n drive h o u s

ing a n d install t he bol t s.
26. Install t he s pr i ng a nd collar. Install t h e r ack

s t o p collar.
30. Install s c r ew ( 3 8 ) t ha t h o l d s r ack s t o p col l ar

( 37) .
31. Install seals, sha f t ( 4 2 ) . lever a s s e mbl y ( 4 0 ) ,

l ocks, a n d bol t s in cover a s s e mbl y. Install
t he cover as s e mb l y ( 3 9 ) . Install seals in
c over wi t h lip o f seal t o w a r d t h e inside.
32. Install high a nd l ow idle s cr ews (4 1 ) .
33. Install covers ( 4 3 ) and (44) on governor

housi im.
NOT H: Be sur e pin ( 4 5 ) is in slot o f r a c k s t o p

collar w h e n c over ( 4 4 ) is i nst al l ed.
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
SHUTOFF CONTROL
R EM OVE SHUTOFF CON TR O L 7 4 1 8 — 11
1. R e m o v e cabl e (4) f r o m lever. R e m o v e b ol t

t ha t hol ds ca bl e b r a c k e t t o c h a n n e l . R e m o v e
nut ( l) t h a t h o l d s clip to g o v e r n o r .
2. Re mo v e oil line (2) f r o m g o v e r n o r t o s h u t o f f

c ont r ol . L o o s e n oil line (3) at g o v e r n o r .
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.
2. Inst al l oil line t o g o v e r n o r . Inst al l oil line

f r o m g o v e r n o r t o s h u t o f f c on t r ol .
3. Inst all nut t h a t h ol ds clip f or c a b l e to g o v e r

nor . Inst all bol t t h a t h ol d s ca bl e b r a c k e t to
t he ch a n n e l . Inst all cabl e t o t he lever.
7-63
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:
a) R e m o v e t h e s cr ews a nd bol t (2) t h a t

hold c over ( 1 ) t o housi ng. R e mo v e t he
cover.
b) R e mo v e pin (5). pl unge r ( 7) a n d s pr i ng

(6) f r o m c over ( 1).
4 l.ift pi st on (o) o u t o f its bore in housi ng.
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 ).
2. R e mo v e drive as s embl y as follows:

a I R e m o v e t w o screws (<S) that hol d
a d a p t e r DO t o housi ng. R e m o v e t he
a d ap t er .
b) R e m o v e t he snap ring ( 1 1 ) ami washer.

R e m o v e t he gear a s s e mbl y ( 10).
- 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 .
e) Remove the b u s hi ng s f r o m a d a p t e r and

near a s s e m b l e . 13)
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.
c) R e mo v e spr i ng ( 1 7 ) . wei ght ( 1 8 ) . pm

( 72) and nut ( 71) .
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) .
5. R e mo v e pl ug ( 2 0 ) and gas ket f r o m housi ng.
b. L o o s e n nut ( 7 9 ) a nd r e m o v e gas ket a nd

cabl e assembl e ( 72) as a unit.
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.
10. Push lat ch ( 3 6 ) o u t o f t he wa y a n d lift t he

gui de ( 3 8 ) f r o m housi ng.
1 1. R e m o v e pl ug ( 45 ) f r o m e n d o f hous i ng .
12. R e m o v e ring ( 4 1 ) f r o m t he s h a f t ( 4 3 ) . Slide

sha f t ( 4 3 ) a nd gear ( 4 2 ) f r o m t he housi ng.
1 3. R e m o v e t he pin t h a t h o l d s gear t o t h e shaft .

R e m o v e t he gear ( 4 2 ) f r o m shaft .
14. R e mo v e bear i n g f r o m t he housi 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
16. R e m o v e pl ug ( 4 7 ) f r o m t he housi ng.
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
l. Inst all l at ch (rel ease lever) ( 2) a n d spr i ng ( 4)

i n t o h o u s i n g ( l).
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).
3. Install spacer , gui de (3) a n d s pr i ng ( 6) o n

s ha f t ( 5).
4. Pus h ( press) sha f t (5) i nt o h o u s i n g ( l).
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. Install t he s pr i ngs (12). w a s h e r s (14) a n d

co t t e r pins (13).
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).
c) Install cable assembly and gasket (18)

i n t o h o u s i n g a n d t i g h t e n n u t I 15) .
d I Install gasket (31) and plug (33) into

housing.
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).
c) Install the s cr ew s ( 38) a n d ( 3 5) .
N O T b : T ig h ten screw (38) the same number of

t u r n s t h a t w a s n e e d e d t o r e m o v e it.
74 7 0 S X 2
d) Put a m ark (stake) aro u n d the screw (38)

with a p u n ch and ham m er.
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
Av.cU! Me Ti i-' ijiil,- snM adj nC-l i nhoW'

Cl I n s t a l l i '! is; i i ! , ! 3 1 1 V. ; : C C . O s 1 ' ^K Vv j i
in :ii i : 11 i5 \ \ n I* ; i . jn : j., ; • i a p i e r ! 4 1 (39)

■ .
0 ' S l i i It- ; l i .f ! i ; i ■ >,u !.1 -a 1j 1 n t 01 >, 4 ! t
d ) I i l 1 1 11 . 4 .''.) <o; ni i 'f ! 10 f w it h P'
<-14 I a n d u u! k •■ : : ■!' !! I ■ ! - 4 a I, ■ > w 11
ia m .-n ;in,i a . a a M r
fs
: ' I I ' - n :d I ■■ s..-!' I ; - I • i !a ! l!lt( I . I ’.! i n t a i
1I I list id iji ;\ i- 1s v ’!!)!: n. u ;th ! ’ s>. ! 0 0 ■

th at ia iln C'Cm i • i i U) i e -a n a i I.T i ! )
(m
13. Install hearing cowo Idn't With tooling

142}-. ju )
( A ).
I 0 I n s t a l l )' 1s 1 •' n t l o into n
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

R E M O V E FU E L I N J E C T I O N
PUMPS 1 2 5 1 — 11
l . R e m o v e d a m p e r s f r o m fuel i nj ect i on lines.
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 .
5. Slide t h e pl unge r ( 4) f r o m y o k e o f lifter.

R e m o v e t h e p l unge r ( 4). K e e p t h e pl unger s
wi t h t hei r r especti ve p u m p bodi es.
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.
2. Install ne w seals. Install t h e p u m p b o d y a nd

barrel car ef ul l y over p l u n g e r a n d d o we l s oil
i nj ect i on p u m p housi ng.
3. I nstal l t he bol ts. l i ght en bol t s, first one t h e n

a n o t h e r a small a m o u n t , al t er nat el y. S t a r t
wi t h t he t w o near es t t he fuel rack. T i g h t e n to
32 r 5 lb. ft. (43 ± 7 V m ) .
4. R e m o v e c over s f r o m fuel lines. C o n n e c t fuel

lines. T i g h t e n fuel line n u t t o 25 t o 35 lb. ft.
(35 to 45 V m ) .
5. Instal l d a m p e r s o n fuel lines.
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
FUEL INJECTION LINES

L IN E S 1 2 5 2 — 11
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
I . R e m o v e t he cover s a n d pl ugs f r o m fuel lines

a n d o peni ngs .
2. Install t he fuel lines (2) o n t h e fuel i nj ect i on

valves a n d p u m p s .
3. l i ght en t he fuel line n u t s (3) t o a t o r q u e o f

25 to 35 lb. ft. (35 to 45 N u n ) . Instal l t he
d a m p e r s a n d clips ( ! ) o n t he fuel lines.
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
. n - ji- u M /M J ir o i n s (IN D U S T R IA I B 'M U IM I 'M
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
l !:'ii h e i : ! I ii : t i <; l i 111 !
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
5. l V v m n c e r » ?>.■ - I b o v . ■« ( " ) Mom t he shield
ii, i ’e m o w ici* ((«> ih ii h o i j shields to-
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 ;
I ' Id I s d ! !’ I ' I I I I d >S j «! «! I), ( U() I;,,) „ n
|) ; *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 .
Md l a - k m -i lensi in mai nU' l d. R e mo v e the

l«idts MM and d r e - h r i-, t I ()t the! Ini|d inani-
h d d !i i Ile- , \ ! M I - 1e i he ,d
Ij ' i / 9 . \.iA:m ia :; I M i »« i a i HI A1 A?-*'- M f t h l i M f c sJ-OiliMES
t X H A U S I M A N I F O L D S (IN DUS! UIAI eWuHOd

1 h e in o - .• i ii. i \ iu! i i-o i <; : ; 11 11 old ( 1 1 ) and
shield i ) ,i- a n a. v- ei i i bh- . W e i g h t is ‘H) ib.

( -} 1 k u i o n l ) <"'■ > i 20 Hi. i. 5 4 k g ) o n | ) 3 9 8 ;
in-' l b. l j.L-i m i n a i ‘i
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
1 I’lll :,e" Kiskeis Ml O m o.diaiisi manifold
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
3. I’ d! 5 i ’ .v-)M Anu-Sei/e ( ompound on the
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.
11v a ' .i o. v i . ; e e i i - . i oei d a n d i a l i m l e i

d-. b e n d! (Ill i < "o a n d ht a e t e b , i b a i
n inst al l ! lie noi l s 14 1 ih at in del t u i b o e l i a i gei

to e s h a i o i hi . u i d o k i ! igliien t hese bol l s t o
40 ' 4 !h ji (ad - a fail i
D3 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 ASSEMBLY
EXHAUST MANIFOLDS (IN DU STRIAL ENGINES)

8. Put grease on t he seal ( 7) a n d b o r e o f w a t e r
t e m p e r a t u r e r e gu l a t or housi ng.
9. Install a 7 / 1 6 " - 14 NC for ged e y e b o l t a n d a

3 / 8 " 16 NC forged e y e b o l t in t h e wa t e r
shield. F a s t e n a h oi st a nd p u t t he w a t e r
shield o n t he e x h a u s t ma n i f o l d a n d e l b o w in
t he w a t e r t e m p e r a t u r e r e g u l a t o r housi ng.
10. Install t he oil line (8) for t he t u r b o c h a r g e r

l ubr i c at i on valve.
11. Install b r a c k e t (1 1).
12. Install n e w gas ket s f or el b ows . Install t he

bol t s t ha t hol d e l b o ws ( 9) t o w a t e r shield.
13. Install t he bol t s ( 1 0 ) t h a t hol d t he shi elds

t oge t he r .
14. Install t he t u b e ( 1 2) on f r o n t o f shields.
15. Put t he shi eld ( 1 3 ) in po s i t i o n a n d instal

t he bolts.
16. Inst al l t he plugs.
17. Fill t he engi ne wi t h c o o l a n t t o c o r r e c t level.
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
EXHAUST M ANIFOLDS (MARINE ENGINES)

R E M O V E EXH A U S T M A N IF O L D S
(M A R IN E E N G IN ES ) 1 0 5 9 — 11
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 .
2. R e mo v e oil line ( 2) f or t u r b o e h a r g e r l ubr i

c a t i o n valve ( r i ght side o nl y) .
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 .
10. Install a 3 / 8 ” —16 NC f or ged e y e b o l t a n d a

5 / 1 6 ” —18 NC f or ged e y e b o l t in ma n i f o l d .
F a s t e n a hoi st a n d r e m o v e ( w a t e r c o o l e d ) e x
haus t ma n i f o l d . Wei ght is 2 0 0 lb. (91 kg)
f or D 3 7 9 : 285 lb. ( 1 2 9 kg) f or D 3 9 8 ; 3 9 0
lb. ( 1 7 7 kg) for D 3 9 9 .
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 .
I a -1 di na. i ,iia.-1■■ ik'd,) c.-.luiHsi ma ni f ol d

-.a: 1 ii;i .; hoist install new
■in..Mi'- m I an!' , i nwul i the bel t s t h a t hold

. ; : : : , . 11•.:. 1 ! . . • l i u j i i' head: - i t u h t c n boll s to
a o a -. pi e , u i o ■ I o i!. o ; 14 9 9 14 \ * m ) .
4. ( ahi!- el I ! .[-■■. |... . ,!;j'h i , n ., a ]114. i .
Ian ! i a. .1 - a - -I; ; i] - i i ]- , n. I n s t a l l (he

i -i; M ! h 11 l i a 1.! . h u - > - ; mani! o l d .
o. I n >!.. i 1 111;. i.i ■i i ih.-i i : 1.1 d h o " ; ill to c w
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
FUEL INJECTION PUMP H O U SIN G, SHUTOFF CONTROL,

G O VERNO R A N D G O VERNO R DRIVE
R E M O V E FU E L I N J E C T I O N P U M P
H O U S IN G , SHUTO FF C O N TR O L, G O V E R N O R ,
A N D G O V E R N O R D R IV E AS A U N IT
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 .
5. R e mo v e fuel line ( 7) f r o m i nj ect i on p u m p

housi ng.
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.
7. Inst al l a 3 8 ” 16 N C f or ged e ye bol t in back

o f hou s i n g . F a s t e n a hoi st a n d r e m o v e t he
fuel i nj ect i on p u m p hou s i n g , s h u t o f f c o n t r o l ,
g o \ e r n o r a n d g o v e r n o r dr i ve as a unit. T h e
wei g ht f or a 1)379 is 350 lb. (158 kg); f or a
1)398 is 425 lb. (191 kg); f o r a L)399 is 500 lb.
(225 kg).
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
FUEL INJECTIO N PUMP H O U S IN G , SHUTOFF CONTROL,

GO VER NO R A N D GO VERN O R DRIVE H O USIN G
INSTALL FUEL IN J E C T IO N PU M P J Y
H O U S IN G , SHUTO FF C O NTRO L, G O V E R N O R , # v
A N D G O V E R N O R DR IV E AS A UNIT
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.
3. Inst al l a 3 8" 16 N C f or ged e yebol t in ba c k

of hous i ng. F a s t e n a hoi st a n d p u t t he i nj ec
t 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 , g o v e r
nor . a n d g o v e r n o r dr i ve in pos i t i o n on
engi ne.
4. L o w e r t he uni t on t h e gui de bo l t s ( 1). I n

stall t he bol t s t h a t hol d u n i t t o c y l i nde r
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.
6. Install t he fuel line (3) o n f r o n t o f i nj e c t i on

p u m p housi ng.
7. Install oil line ( 6) on t h e go v e r n o r . Install

air line t o fuel r at i o c ont r o l .
8. Inst al l t h e li fti ng eye a n d s u p p o r t ( 4 ) on

ba c k o f g o v e r n o r drive housi ng.
9. Install t he bol t s (5) t h a t h o l d e x h a u s t e l b o w

to support.
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
FUEL INJECTION PUMP HOUSING

D I S A S S E M B L E FU E L I N J E C T I O N
P U M P H O U S IN G 1 2 5 3 — 15
T o o ls Needed A B C
9M 4568 W rench 1
8S2241 C a m sh aft B earing R em oval and 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.
2. R e m o v e plat e a s s e mbl y ( 2) f r o m fuel i n

j e c t i o n p u m p housi ng.
3. R e m o v e t he cover ( 3) f r o m side o f housi ng.
4. R e m o v e t he c over (5). R e m o v e t h e pl ug and

seal ( 4) f r o m 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

5. R e m o v e bol t s and cl a mp s t h a t hol d fuel i n
ject i on p u m p s to t he housi ng. Pull t he
p u m p bodi es ( 6) st r ai ght up to r e m o v e t h e m
I'rom housi ng.
6. Slide the end o f eaeii pl ung e r o u t o f t he

\ o k e in t he l ifter a n d pull o u t t he pl ung er
I 1 ). Install t he pl unger in its r especti ve
p u m p b o d y . Make i d e n t i t i e a t i o n on e ach ot
tiie fuel i nj ect i on p u m p s by its l ocat i on in
t he i nj ect i on p u m p housi ng.
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.
R e m o v e t he fuel r ack (8) f r o m housi ng.
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
11. Install SI 6 05 bol t s ( 1 3 ) ( 3 / 8 ” - 2 4 N F x 3

1 / 4 ” long) a nd n e e d e d wa s h e r s in t h e lifters.
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 .
13. R e mo v e t he c a m s h a f t f r o m housi ng.
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

14. R e m o v e t he bol t s ( 1 3 ) f r o m t h e f uel p u m p
lifters a nd r e m o v e l ifters ( 1 4 ) a n d springs
( 15) f r o m t h e b o t t o m o f the housi ng.
N O T ! 7.: P u t i d e nt i f i c a t i o n o n e ach o f t he lifters by

its l o c a t i on in t he housi ng.
15. Use t ool g r o u p ( B) to r e m o v e camshaft

bear i ngs f r o m t h e housi ng.
16. Use t ool i ng ( C) t o r e m o v e t he bear i ngs for

fuel r ack f r o m t he housimi .
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 S S E M B L E FU E L I N J E C T I O N P U M P
H O U S IN G 1 2 5 3 — 16
A B C
9M 4568 W rench 1
8 S2741 Ca m sh aft B earing R em oval 1
and In s ta lla tio n T o o l G ro u p
1P529 Handle 1
l. Use t ool i ng ( C) t o install bear i ngs f or fuel

rack in housi ng.
2. Use t ool g r o u p (B) t o install c a m s h a f t

bearings. Be sure t he oil hol es ( l ) in
bear i ngs are in a l i g n m e n t w i t h oil hol e in
housi ng.
CAUTION
Be sure the tool group (B) is in center position
on bearing while installing bearings, so no
damage will be caused to them.
3. Put cl ean engi ne oil o n lifters ( 2). Install t he

lifters ( 2) in t hei r r especti ve p o s i t i on in
housi ng.
4. Push t he lifters in t he h o u s i ng agai nst t hei r

springs.
5. instal l SI 605 bol t s (3) ( 3 / 8 ” - 2 4 N F x 3

l / 4 ” long) a nd n e e d e d was her s ( 4) in t he ■S» «
lifters.
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

7. P u t clean engi ne oil on t he camshaft
heari ngs.
8. Install t h e c a m s h a f t in t h e housi ng.
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.
1 1. Install y o k e scr ews ( 7) a n d l o c k o u t s in thei r

r especti ve po s i t i o n in hous i ng. Use w r e n c h
( A) t o hol d y o k e s cr ew whi l e l o c k o u t is
t i ght e ne d.
12. Ma k e a d j u s t m e n t t o lifters. See F U E L

P U M P TIMING DIMENSION SETTING
( O F F E N G I N E ) in T E S T I N G A N D A D
JUSTING.
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

13. Put cl ean diesel fuel o n t he fuel r ack. Install
t he fuel rack ( 8) in t he p u m p housi ng.
14. Install fuel i nj ect i on p u m p s in t hei r r e s p e c

tive p o s i t i ons as f ollows:
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 .
c) Install t he p u m p in hous i ng. T u r n the

pl unger until t he m a r k ( 1 2 ) on gear is in
a l i g n me n t wi t h m a r k o n f uel r ack (1 1).
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.
e) Install n e w seals f or t h e p u m p a n d install

t he p u m p s in t he housi ng.
N O T E : Be sure t h e p u m p s are o n t h e dowel s . I n

stall t h e b ol t s an d cl amps .
f) Tight en t he bol t s next t o fuel r ack first,

a n d t h e n t i g h t e n bol ts o n o t h e r side.
I ight en t he bol t s to a t o r q u e o f 32 ± 5 lb.
ft. (43 ± 7 \ * m ) .
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

15. Install t he pl ug a n d seal. Install t he cover
(13) for fuel r ack.
16. Install pl at e ( 1 4 ) on side o f p u m p hous i ng.
17. Install g o v e r n o r drive h o u s i ng ( 1 5 ) on t he

fuel i nj ect i on p u m p housi ng.
18. Install pl at e a s s e mbl y on p u m p housi ng.
e nd by:
a) install s hut of l c o n t r o l (if so e q u i p p e d )

b) install g o v e r n o r
c) install fuel i nj ect i on p u m p h o us i ng
a n d g o v e r n o r as a uni t
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
GOVERNOR DRIVE HOUSING

D IS A S S E M B L E G O V E R N O R D R IV E
H O U S IN G 1 2 8 8 — 15
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.
2. R e m o x e ring, pl unger , spr i ng, a n d r et ai n er

for s h u t o f f cont r ol .
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).
5. Use t ool i ng ( A) t o r e m o v e gear f r o m t h r u s t

wa s h e r ( l). R e m o v e t he bear i ng f r o m h o u s
ing.
6. R e mo v e ring (9). R e m o v e bol t s, l ocks, a nd

gear ( 8 ).
7. R e m o v e t h r u s t plat e ( 10) a n d shi ms. K e e p

shi ms t o g e t h e r for i nst al l at i on.
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) .
9. R e mo v e l o c k n u t ( 6) , gear (7) a nd key. R e

mo v e t h e drive s hut t ( 13). R e m o v e bear i ngs
80155X1
f or t he sha f t f r o m t he housi ng.
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
GOVERNOR DRIVE HOUSING

A S SE M B L E G O V E R N O R D R IV E
H O U S IN G 12 8 8 — 16
T o o ls Needed A B
1P529 Handle 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).
3. Install t he drive gear. T u r n t h e p ul l e r b ol t t o

ho l d gear o n shaft .
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.
6. Instal l p l un ger , spr i ng, r e t a i ne r a n d ri ng for

s h u t o f f cont r ol .
7. Inst al l g o v e r n o r drive p i n i o n ( 8) . Inst al l
s h i ms a n d t h r u s t pl at e ( 7) . Inst all bevel gear
( 1 0 ) a nd ring. E n d pl ay o f drive s h a f t w i t h
n e w par t s is .005 t o . 009 in. ( 0 . 1 3 t o 0 . 2 3
m m ) . M a x i m u m per mi ss ibl e e n d pl ay wi t h
used par t s is . 015 in. ( 0 . 3 8 m m ) .
8. Use t he t o o l g r o u p ( B) t o c h e c k t h e cl ear
ance ( b a c kl a s h ) b e t w e e n p i n i o n a n d bevel
gear ( 1 0 ) . Ma ke a d j u s t m e n t o f ba c k l a s h b y
r e mo v i n g or a d d i n g s h i ms ( 9) b e h i n d t h r u s t
pl at e ( 7). A m o u n t o f free m o v e m e n t ( b a c k
lash) b e t w e e n bevel gear a n d p i n i o n m u s t be
. 00 2 t o . 00 6 in. ( 0 . 0 5 t o 0 . 15 m m ) .
9. Install c o u p l i n g o n shaft. F a s t e n a h oi s t a n d
install g o v e r n o r drive h o u s i n g o n t h e fuel
e n d by:
a) i nstall s h u t o f f c o n t r o l
b) install g o v e r n o r
c) install fuel i nj e c t i on p u m p h ous i ng,
go v e r n o r , a n d g o v e r n o r drive as a u n i t
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
SHUTOFF CONTROL GROUP

REMOVE A N D INSTALL
1. P u t i dent i f i ca t i on o n six hoses (1). Di s

c o n n e c t t he si x h o s e s f r o m t h e s h u t o f f
c on t r ol .
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 .
4. I nst al l a n e w gas ket b e t we e n t he s h u t o f f c o n

t r ol a n d 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. C o n n e c t six hos e s (1) t o t he s h u t o f f co n t r o l .
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
SHUTOFF CO NTRO L GROUP

DISASSEMBLE SHUTOFF
CONTROL GROUP
T o o ls N e ed e d
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 .
2. R e m o v e ei ght bol t s (3). R e m o v e a c t u a t o r

val ve (4) a n d p r e s s u r e c o n t r o l val ve (5).
A WARMING
There is spring pressure on cover (6). Use
caution when the cover is removed.
3. R e m o v e eight bol t s (7) a n d c o v e r (6) f r o m

t he a c t u a t o r valve.
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
SHUTOFF CO NTROL GROUP
6. L o o sen the nut a n d r e m o v e k n o b (15) a n d

nut trom \al\e (10). R e r r u n e a d a p t e r (16)
an d spring (IS) tr o m the \a l\e .
7. Remove lip t vpe seal (17) f r o m a d a p t e r

(16).
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).
12. R e m o v e s pe ed s e ns i n g val ve (27), s p r i n g

(26) a n d seat f r o m t he b o dy.
13. R e m o v e r e t a i n e r r in g (30), ra ce (29),

b e a r i n g ( 28) a n d r a c e ( 31) f r o m v a l v e
(27).
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

ASSEMBLE SHUTOFF CONTROL GROUP
T o o ls N e ed e d
1PI 855 S n a p R in g P lie rs
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 .
2. Inst al l r ace (9). b e a r i n g (6) a n d r ace (7)

o n s peed s ensi ng val ve (5) wi t h r e t a i n e r
r i ng (8).
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 .
4. Inst al l w a s h e r (13) o n c o v e r (14). Inst al l

c a r r i e r a s s e m b l y (12) in t h e c o v e r as
s h o w n a n d i nst all t he key in t h e c a r r i e r
a s s e m b l y shaft.
5. Install O- r i n g seal ( 15) in oil p u m p h o u s i n g

(20). Put a t hi n l ayer of S A L 30 oil on seal
(15) a n d t he bo r e in t he hous i ng. Install
p l u n g e r ( 16). s p r i n g (21) a n d seat ( 17) in t he
h ou s i ng. Install r e t a i ne r ri ng (19) wi t h t ool
(A). Install g e r o t o r a s s e m b l y (18) in t he
housmu.
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
6. Put a t hi n l ayer o f 7 M 7 2 6 0 Li qui d G a s k e t

Ma t e r i a l on t he c o n t a c t sur f a c e s of c o v e r t 14)
a n d oil p u m p h o u s i n g (20). Install the c o v e r
a s s e m b l y on t he h o u s i n g as s e mb l y . Be sur e
t he key in t he c a r r i e r shaft is in a l i g n me n t
wi t h t he g r o o v e (slot) for key in t he g e r o t o r
a s s e mbl y. Inst al l w a s h e r (23) a n d r e t a i ne r
ring (22) wi t h t ool (A).
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 .
8. I nst al l t he lip t y p e seal i n a d a p t e r (24)

wi t h t o o l i n g (B). I nst al l t h e seal wi t h t he
seal lip t o w a r d t h e i nsi de o f t h e p r e s s u r e
c o n t r o l valve. P u t a t h i n l ayer o f S A E 30
oil o n t h e seal lip.
9. Inst al l s p r i n g (29). a d a p t e r (24). n u t (27)

a n d k n o b (25) o n val ve (26). Inst al l O- r i n g
seal (28) on t he a d a p t e r .
10. Inst al l t hr ee O - r i n g seals (35) on val ve

as s embl i es (31) a n d (36). Inst al l t he val ve
as s embl i es in t h e b o d y . T i g h t e n t he val ve
as s embl i es t o a t o r q u e of 43 ± 3 lb. ft. (58
± 4 » m ) . Inst all O- r i n g seal (33) on pl ug
(34). Inst al l s p r i n g (30). val ve (32) a n d pl u g
(34) in t he b ody. Instal l val ve a s s e m b l y (26) A 82761X1
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
1 1. Install t o u r val ves (37) in t he a c t u a t o r val ve

b od y. Install t o u r spr i ngs (38). Install a new
gas ket b e t we e n t he b o d y a n d c o v e r (39).
Instal l t he co v e r o n t he b o d y wi t h ei ght bol ts
a n d was her s .
12. Instal l a new gas ket be t we e n t he b o d y a n d

pr es s u r e c o n t r o l valve a s s e m b l y (41). P u t the
pr e s s u r e c o n t r o l val ve in po s i t i o n on t he
bodv. Install a new gas ket b e t we e n t he p r e s
s ur e c o n t r o l val ve a n d a c t u a t o r val ve a s s e m
bly (40). F a s t e n t he a c t u a t o r val ve a n d p r e s
sur e c o n t r o l val ve t o t he bodv wi t h eight
bol ts a n d was her s .
13. Inst all t wo t u b e s (42) on t he s hut of f c o n t r o l

valv e.
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
FUEL INJECTION VALVES

VALVES 1 2 5 4 — 11
I . R e mo v e t he n u t ( I ) o f t he fuel line f o r valve

t o be r e m o v e d . Put a c over on e nd o f fuel
line t o k e e p di r t o ut .
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.
3. R e mo v e the seals f r o m t he nut .
4. Lift fuel inj ect i on valve (2) f r o m t he p r e

co mb us ti o n 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.
1. Install t he valve i nt o t h e precombustion

chamber.
3. Install a n e w seal o n t h e n u t (4).
4. Instal l t h e nut (4) t ha t h ol ds val ve in p r e

c o m b u s t i o n c h a m b e r . T i g h t e n t he n u t t o a
t o r q u e of 100 to 110 lb. ft. (135 t o 149 N*m).
3s) f]
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 .
6. Instal l fuel line n u t (3) t o valve. T i g h t e n t he

n u t (3) t o a t o r q u e of 25 t o 35 lb. ft. (35 t o 45
N*m).
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).
3. R e m o v e t he gas ket s f r o m precombustion

c h a mbe r s .
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
l. Put 5P3931 Anti-Seize C o m p o u n d on

t h r e a d s of t he p r e c o m b u s t i o n c h a m b e r (2).
2. P u t a small a m o u n t o f grease o n gas k et (3)

-Air fiair
t o ho l d aas ket o n c h a m b e r .
3. Put liqui d soap o n t he seal (1) a n d bo r e in

t he c y l i n d e r head.
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) .
5. Fill t he engi ne wi t h c o o l a n t t o c o r r e c t level,

e nd by:
a) install fuel i nj ect i on valves
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
ROCKER SHAFTS AND PUSH RODS

REM O VE ROCKER SHAFTS A N D
PUSH R O D S 1 1 0 2 & 1 2 0 8 — 11
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).
4. M a k e a n a d j u s t m e n t of t he val ve c l ear ance.

T h e col d c l ea 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 J E S T I N G A N D A D J U S T I N G .
e nd by:
a) install valve cover s
7-99
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.
ASSEM BLE ROCKER SHAFTS 1 1 0 2 — 16
T o ols Needed A
1P529 Handle 1
1P469 Drive Plate 1
1. Install rings a nd b u t t o n s o n r o c k e r ar ms. I n

stall s cr ews a n d n u t s for t he valve a d j us t
m e n t o n t he ar ms. Inst al l t h e bear i ngs in t he
a r m s wi t h t ool i ng (A).
N O T E : Be sure t he oil hol es o f t he bear i ngs are in

a l i g n me n t wi t h oil hol es in arms.
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
ROCKER ARMS. PUSH RODS AND VA LVE LIFTERS
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
1. P u t cl ean engi ne oil o n lifters. Install lifters

in br a c ke t .
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.
6. Use i nst all er ( A) t o p u t t h e seals in t hei r

r especti ve posi t i on.
7. Inst al l t he p us h rods.
8. M a k e a n a d j u s t m e n t o f valves t o get .015 in.

(0.38 m m ) c l e a r a n c e ( cold) o n i n t a k e valves;
.035 in. (0.89 m m ) c l e a r a n c e ( col d) o n e x
ha u s t val ves. 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 E S T I N G A N D A D
JU STING.
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
1. R e m o v e the bol t s ( 2) t h a t hol d ma n i f o l d t o

h o u s i n e ( 1).
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 .
INS TALL INTA KE M A N IF O L D S 1 0 5 8 — 12
1. Install ne w ma n i f o l d gaskets.
2. P u t i nt ake ma n i f o l d ( l ) in p o s i t i on o n engi ne.

Install t he b ol t s t h a t hol d m a n i f o l d t o c yl i n
de r heads.
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.
3. Install t he bol t s t ha t hol d m a n i f o l d t o h o u s

ing. Install t he c l a mp t h a t h o l d s line f or t h e
oil c ool e r t o t he ma n i f o l d .
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
2P5517 R e m o v a l & In s ta lla tio n T o o l 1

\ '
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
1. Fasten a hoist and remove the prelubrication

pump and m otor as a unit ( if so equipped).
Weight is 105 lb. (47.3 kg).
2. Remove the wire harness and plate fo r pre

lubrication oil pump and m otor.
3. Remove the bolts (1) that hold inspection

covers to block. Remove the inspection co
vers (2) from each side o f block.
4. Remove the nuts fo r main bearing caps w ith

wrench (B). Remove the bearing cap w ith
lower half of main bearing.
5. Use tool (A ) to move out the upper ha lf of

main bearing as the crankshaft is turned in
the norm al direction o f rotation.
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
2P5517 R e m o v a l & In s ta lla tio n T o o l 1
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
1. P u t cl ean eng i ne oil o n b e a r i n g sur f a c e s o f

u p p e r hal ves o f bear i ngs. Use t oo l ( A) t o i n
stall u p p e r h a l f of b ea r i n g in c y l i n de r bl ock. TYPICAL EXAM PLL
T h e b e a r i n g wi t h oil hol e is u p p e r half.
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 ).
6. I n sta ll t h e i n s p e c t io n covers. I n s t a l l t h e w ire

h a r n e s s a n d p l a t e f o r p r e l u b r i c a t i o n oil
p u m p . F a s t e n a h o ist 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 i t (if so
equipped).
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
PISTON COOLING TUBES

RE M O V E PISTON C O O LING
TUBES 1 3 0 7 — 11
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).
INSTALL PISTON C O O LING

TUBES 1 3 07-12
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
VALVE COVERS
R E M O V E VALVE C O VE R S 1 1 0 7 — 11
1. R e m o v e the n u ts ( l ). w a s h e rs a n d seals fro m

th e studs.
2. R e n u n e \ a l v e e o \ e r (2).
INSTALL VALVE COVE R 1 1 0 7 — 12
I. In stall a n ew seal in th e valve co ver . P u t th e

c o v e r in p o s i t i o n o n th e engine.
2. I n s t a l l th e seal a n d w a s h e r (1) o n e a c h stu d .

In stall a n d t i g h t e n n u t s (2) u n t i l c o n t a c t is
m a d e w ith w a s h e r (1). T h e n t i g h t e n t h e n u t t o
a t o r q u e o f 10 ± 3 lb. ft. (14 ± 4 N .m ).
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.
3. R e m o v e t h e eight b o lts f o r each c y l i n d e r

h ead f ro m th e e x h a u s t m a n i f o ld o n th e
m a r i n e engines.
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 .
8. R e m o v e th e oil line (3 ) f o r t h e r o c k e r sh a ft.
9. R e m o v e the n u t s (6 ) from the cylinder

h ead .
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.
11. F a s t e n a h oist t o the e y e b o l t s a n d slo w ly

re m o v e th e c y l i n d e r h e a d . W eig ht is 1 90 lb.
( 8 6 kg).
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).
5. I nstall th e p la te a n d plu gs o n th e shield t o r

th e m a n i f o l d bo lts (if so e q u i p p e d ) .
6. I n stall th e oil line (2) for th e r o c k e r sh aft.
7. I nstall th e t w o e l b o w s (3). I nstall t h e fuel

lines. T ig h t e n n u t s (4) on fuel lines to a
t o r q u e o f 25 to 35 lb. ft. (35 to 45 N -m ). I n
stall g o v e r n o r c o n t r o l c h a n n e l ( o n left h a n d
side only).
8. Install the i n s t r u m e n t p a n e l o n cylinder

h e a d r e m o v e d ( if so e q u i p p e d ) .
9. Fill th e eng ine w i t h c o o l a n t t o c o r r e c t level.

en d by:
a) install i n t a k e m a n i f o ld s
b) install r o c k e r s h a ft s a n d p u sh ro d s
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
FT8 06 C y lin d e r H ead R e p a ir B e n ch 1
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
1. I n stall c y lin d e r h e a d ( l ) o n t o o l i n g (A) as

sh o w n .
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
1. C h e c k sp r i n g f o rce w ith t o o l (B). F o r t h e

c o r r e c t s p r i n g f o rce , see th e s u b j e c t V A L V E S
in S P E C I F I C A T I O N S .
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.
3. R e m o v e to o l (C) slow ly. H it t h e v alv e lig htly

w ith a soft h a m m e r t o be su r e t h e lo ck s a r e in
th e i r c o r r e c t p o s i t i o n .
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
3. D i m e n s i o n (X) for th e in sta lle d va lve g uid e

m u s t be l .750 ± .020 in. (44.45 ± 0 . 5 1 m m ).
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
VALVE SEAT INSERTS, WATER DIRECTORS

R E M O V E A N D INSTALL VALVE
SEAT INSERTS 1 1 0 3 — 10
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
1 P 510 D riv e r G ro u p 1
s t a r t by:
a) remove cylinder head
Remove water director (1) fro m 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
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.
2. In stall p i s t o n (1) in t o o l (A). P u t t h e p i s t o n

a n d t o o l (A) in p o s i t i o n o n t h e c y l i n d e r lin er
as sh o w n .
3. Install the p isto n in the liner slo w ly o n to th e

j o u r n a l o f c r a n k s h a f t . Be su r e th e " V ” m a r k
on p isto n is in a l i g n m e n t w ith th e " V ” m a r k
(2) on the block.
CAUTION
Be careful not to cause damage to connecting
rod bearing or journal on crankshaft when
piston is installed.
4. I n sta ll th e l o w e r b e a r i n g (5) in th e c a p (3)

f o r the c o n n e c t i n g r o d (4). Be su r e t h e t a b o n
b a c k o f b e a r i n g fits in g r o o v e f o r t a b in cap.
I n sta ll t h e cap.
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
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.
2. Use to o l (A) to r e m o v e th e p i s t o n rin g s f r o m

th 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 .
4. Use tooling (B) to rem ove and install the piston

pin bearing. See Special Instruction, F orm
S M H S 7 2 9 5 , for m ore information.
5. Use t h e rin g e x p a n d e r (A) t o in stall t h e pis

t o n rings.
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
5P8665 C y lin d e r L in e r P u lle r 1
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 .
2. P u t t o o l i n g (A) in t h e c y lin d e r liner.
CAUTION
Do not cause damage to piston cooling tube (1)
when tooling (A) is installed.
3. Use t o o l i n g (A) t o r e m o v e t h e lin er f r o m its

s e a t in c y l i n d e r b lo c k .
4. R e m o v e c y lin d e r lin er (2) f r o m its b o r e in

c y lin d e r b lo c k .
5. R e m o v e filler b a n d (3) a n d se als (4) f r o m t h e

liner.
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
2P8260 C y lin d e r L in e r In s ta lle r 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.
2. I n sta ll t o o l i n g (A) o n t h e liner. T i g h t e n th e

n u t s t h a t h o l d t o o l i n g (A) e v en ly t o a t o r q u e
o f 50 lb. ft. (70 N .m ).
3. Ch eck the liner projection with tool gro u p (B) at

four locations around the liner. The difference
betw een the to ur m easu re m en ts must not be more
than .002 in. (0.05 m m ). The liner projection
must be .004 to .008 in. (0.10 to 0 . 2 0 m m ). The
m easu rem ent b etw een liners next to each other,
must not be m ore than .002 in. (0.05 m m )
difference.
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.
4. But a m a r k on th e liner a n d b lock so th e liner

ca n be in stalled in the s a m e p o si t i o n f ro m
w h ich it was r e m o \ e d .
5. In stall n ew seals (2) o n t h e c y l i n d e r liners.

P u t liq uid s o a p o n th e seals a n d in t h e b o r e s
in t h e cy lin d e r b lo ck .
6. P u t S A E 30 oil o n filler b a n d (1) a n d install it

o n th e liner. In stall t h e lin er i m m e d i a t e l y in
th e c y lin d e r b l o c k w ith t o o l i n g (C).
e nd by:
a) in stall p i s t o n s
7-120
TURBOCHARGER LUBRICATION VALVE

R E M O V E T U R B O C H A R G E R LUBRICATIO N
VALVE 1 3 0 9 — 11
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.
3. D i s c o n n e c t the o t h e r t h r e e oil lines ( 5 ) f r o m

valves.
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.
INSTALL T U R B O C H A R G E R L UBRIC ATIO N

VALVE 1 3 0 9 —12
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 .
2. C o n n e c t five oil lines t o valve.
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
TURBOCHARGER LUBRICATION V A LVE

D IS A S S E M B L E T U R B O C H A R G E R
LU B R IC A TIO N VALVE 1 3 0 9 — 15
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
l. Clean all p a r t s b e f o re as sem b lin g valve.

©
% \
In stall spring (2) a n d p l u n g e r ( l ) in b o d y '
(3 ).
*
'* • , W
■tfsY
©
3. In stall a d a p t e r , co v e r a n d bo lts,
e n d by:
a) install t u r b o c h a r g e r l u b r i c a t i o n valve
7-122
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.
6. R e m o v e packing nut and packing f ro m

cover .
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
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
TURBOCHARGER HEAT SHIELD

R E M O V E A N D IN S TA LL
TU R B O C H A R G E R HEAT
S H IE L D 1 0 7 3 — 10
I. R e m o v e c o o l a n t f r o m th e engine.
2. R e m o v e six b o lts a n d t w o shield a s se m b lie s

(3). R e m o v e t w o b r a c e s (1) a n d (2) f r o m t h e
shield.
3. D i s c o n n e c t w a t e r lines (4) a n d (5) f r o m t h e

shield.
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 .
5. R e m o v e t w o w a t e r lines (7) a n d (9) f r o m th e

shield.
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).
1. I n sta ll t h r e e b o l t s (6) in t h e sh ield . P u t th e

t u r b o c h a r g e r shie ld in p o s i t i o n o n t h e eng in e.
9. In stall f o u r b o lts (8) 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 e x h a u s t m a n i f o l d sh ield .
C o n n e c t w a t e r lines (7) a n d (9) t o t h e shield .
10. T i g h t e n t h r e e b o l t s (6). Install t w o braces

(1) a n d (2). C o n n e c t t w o w a t e r lines (4) a n d
(5) t o th e shield. I n sta ll t w o shie lds (3) o n
the t u r b o c h a r g e r shield w i t h six b o lts.
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
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).
2. R e m o v e t u r b o c h a r g e r oil s u p p l y line (2).
3. R e m o v e t u r b o c h a r g e r oil r e t u r n line (5).

R e m o v e f o u r bo lts (4) 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 t o th e e x h a u s t m a n i f o ld .
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).
9. In stall shield (3) a n d c l a m p (1) ( M a r i n e

E n g in e s only).
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
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).
2. P ut a m ark on the c o m p resso r cover and

housings for installation purposes.
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. R e m o v e seal rin g (6) f r o m t h e t u r b i n e wheel.
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 .
9. Push th e sleeve (9) o u t o f th e in se rt. R e

move the t w o seal rings f ro m th e sleeve.
10. R e m o v e d e f l e c t o r ( 1 0 ) , ring ( 1 5 ) , sleeve

( 1 1 ) . bearin g ( 1 2 ) . ring ( 1 6 ) , sn a p ring (1 3),
b earing ( 1 7 ) and sn a p ring ( 1 4 ) f r o m th e
ho u sing . R e m o v e snap rings ( 1 3 ) a n d ( 1 4 )
w ith to o l (C).
VO TE: C h e c k the oil hole in bearin g ( 1 2 ). If th e

hi hole is n o t o p e n this will cause a b earin g failure.
11. T u r n the h o u sin g a r o u n d a n d r e m o v e snap

ring ( 1 8 ) a nd s h r o u d ( 2 2).
1 2. R e m o v e s n a p ring ( 1 9 ) . sleeve ( 2 0 ) , b earin g

( 2 1 ) . an d snap ring ( 2 3 ) . R e m o v e t h e t w o
sn a p rings w ith to o l (C).
13. In s p e c t all p a r ts a n d install n e w p a r t s as

9605 5X 1
needed.
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
9S 6343 Fixture A ssem bly 1
9S 6363 Turbocharger Fixture G roup 1
1. M a k e sure all oil p a s s a g e s are o p e n a n d

clean. P u t c lean en g in e oil o n all p a r t s b e f o re
a s sem b ly .
2. In stall s n a p r in g (4), b e a r i n g (3), sleeve (2)

a n d s n a p ring (1). In stall t h e t w o s n a p rings
w ith to o l (A).
N O T E : In stall th e s n a p rings w ith th e r o u n d side

t o w a r d th e b earin g .
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).
N O T E : In stall th e s n a p rings w ith t h e r o u n d side

t o w a r d th e b earin g .
6. P ut 41.7464 S ilico n e G r e a s e in th e g r o o v e for

seal ring (7). M a k e sure th e g rease fills th e
g r o o \ e a p p r o x i m a t e l y o n e h a lf o r m o r e ol
th e g r o o x e d e p t h for th e c o m p l e t e c i r c u m
fe re nce of th e g r o o \ e to help m a k e a c a r b o n
d a m u n d e r the seal ring. In stall seal ring (7)
on th e sh aft. In stall t u r b i n e wheel (8) a n d
sh a ft in the h o u sin g .
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
9. In stall th e seal rings o n sleeve (15). I n sta ll

sleeve in inse rt (14).
! 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).
11. In stall c o m p r e s s o r w h eel (16) o n sha ft.
CAUTION
When nut is tightened do not put a side force on
the shaft.
12. P u t c lean en g i n e oil o n t h e t h r e a d s o f t h e sh a ft.

I n sta ll t h e n u t (18) a n d t i g h t e n t o a t o r q u e o f
15 ± 1 lb.ft. (20 ± 1 N .m ).
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 .
3. P u t th e t u b e s (1) in p o s i t i o n o n flyw h eel

h o u s i n g . I n sta ll t h e b o lts t h a t h o l d t h e t u b e s
to a f t e r c o o l e r h o u s i n g a n d t h e f l y w h e e l
h o u sin 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:
a) rem ove aftercooler h ousing
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 .
3. R e m o v e sleeves (4) f r o m th e co res.
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 .
3. P u t clean en g i n e oil in b o r e s f o r sleeves.

I n s t a l l sleeves in h o u s in g s . I n sta ll b o l t s (2)
t h a t h o l d h o u s i n g s t o g e t h e r a n d t i g h t e n as
follows:
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.
4. I n sta ll p ip e (3) o n t h e t o p h o u s i n g . In stall

th e b o lts t h a t h o l d p ip e in p o s i t i o n .
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
ELECTRIC STARTING MOTORS

R E M O V E ELECTRIC S T A R T IN G
MOTORS 1 4 5 3 — 11
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 .
2. D i s c o n n e c t s t a r t e r a i r inlet line at u n i o n (2).
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 .
5. C o n n e c t t h e s t a r t e r a i r in let line (2) t o th e

air sta rter.
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
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
l . M a k e a mark to show the position o f housing

A42324X1
as se m bly ( l ) respec tive to co v er (2) for as se m bly
purposes.
2. R e m o v e the bolts that hold the hou sing as se m bly

in position and rem ov e the h ou sing assembly
from the cover.
3. R e m ov e drive assem bly (4), spring (5) and seat

(3) from the ho using as sembly.
4. R e m ov e plug (7). oiler and bu shing (6) trom

housing (8).
7 -1 3 8
AIR STARTER
5. Disa ss em ble the drive assem bly as follows:
a) R e m o ve seal ring (9) from piston (10).
b) R e m o v e retainer (13) fro m the piston with

tool (A).
e) Slide the piston tow ard the g ear end o f clutch

as se m blv (12).
d) R e m ov e spacer (14) and two shift rings (11)

from the clutch assembly.
N O T E: Do not clean the clutch assem bly in kerosene or

oth er solvent.
e) R e m o ve piston (10) from clutch assem b ly

( 1 2 ).
6. M a ke a m ar k to sh ow the position o f c o ver (2)

respective to the h ousing for assem bly purposes.
R e m o ve the bolts that hold the c o v e r in place.
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).
8. R em ov e the shaft assem b le from the cover.
9. R e m ov e seal (1 8) and O-ring seal (19) from the

cover.
N O T E: Som e air starters have a snap ring on top o f seal

(18) to hold the seal in place. R e m o ve this snap ring
before the seal is rem oved.
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.
M ake a mark to sh ow the position o f case a s s e m

bly (15) respec tive to ho using (24) for as sem bly
purposes. R e m o v e the bolts and nuts that hold
case assem bly (15) in position.
13. R e m o v e the case as se m bly from h ousing (24).
14. R e m o ve needle bearing (25) from the case a s

sembly.
15. R e m o v e the loekwire, bolts and g ear retainer A42338X1

(26) from the rotor.
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.
18. R em ov e the bolts that hold c o ver assem b ly (28)

on the oppo site end o f housing (24).
A4 2341 X I
20. R e m o ve w ash er (31) from the plate bearing.
R em ov e lock (32) from nut (33) and rem ove the

nut from the rotor with tool (C).
7-142
AIR STARTER
22. R e m ov e lock (32). plate (35). cy linder (34),
dowel (38) and spacer (37) fro m rotor (36).
23. R e m ov e bearing (39) from plate (35).
24. R e m ov e four retainers (40) from the cylinder .
25. R e m ov e five vanes (41) from the rotor.

D 379 , D 3 9 8 , D 3 9 9 IND USTRIAL A N D MA R IN E ENGINES D IS ASS EMBLY A N D ASSEM BLY
ASSEMBLE AIR STARTER 1451-16

Tools Needed A B C D E F G
Tube 1 3 /4 ” diam eter x 3/1 6 "
thick x 4 1 /2 " long 1
1P2851 Spanner W rench 1
1P463 Plate 1
1P467 Plate 1
1P531 Handle 1
1P510 Driver Group 1
1P1861 Retaining Ring
Pliers 1
Close Nipple 2 in. 1
Close Nipple 1 in. 1
A42350X1
Reducer
Coupling 2" to 1" 1
FT834 Nozzle 1 1
NOTE:: Clean all parts thoroughly. Put 5 P 9 6 0 M u l

tipurpose Type G rease on all bearings and the drive
assembly . Put a thin layer o f S A P . 10 W oil on all
other parts before as sem bly.
1. Install spacer ( l ) and plate (3) on the end o f rotor

(2) that has a taper.
2. Make sure the side o f bearing (4) that has a

shield, is in a d ow n position. Install the bearing
in the plate with tool (A) and a press.
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.
4. Install fo ur retainers (9) in cylinder (8).
5. Install dowel (10) in the plate and install the

cylinder on the dow el and rotor.
NO T E: M a ke sure the dowel is installed in two holes

(6) in either end o f the cylinder. T w o holes (7) in the
cy linder must be in alignm ent w ith two left holes (11) in
the plate. T w o right holes (12) are not used for this
model o f air starter.
6. Install spacer (15) on the rotor.
7. Install plate (13) on the cylinder. M a k e sure hole

(14) in the plate is in ali gnm en t with the dow el.
8. M a k e sure the side o f bearing (16) that has a

shield is in a d o w n position. Install the bearin g in
the plate and install the lock on the rotor.
9. Install the nut with its large c h am fer in a d ow n

position. T ig h ten the nut with tool (B) and bend
the lock into one o f the g rooves o f the nut to hold
the nut in position.
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.
11. F-our retainers (9) in the cylinder must be in

alignm en t with four holes (20) in the housing.
Also, dowel (10) m ust be in alignm ent with hole
(18) in the housing. Install rotor and cylinder
as sembly (21) in the housing.
12. Install washer (23) on the plate bearing.
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.
14. Turn the ho using ov er and install gear (26) on the

rotor. M a ke sure key (27) is in alignm ent with
notch (25) on the gear as show n.
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.
16. Use this procedure to tighten the tw o bolts:

a) R e m o ve the plug t'rom the c o v e r as se m bly.
b) Install a ratchet and extens ion in the end o f
the rotor as show n.
c) Tig hten the bolts to stand ard tor que and hit
the retainer with a h am m er. T ig hten the bolts
again to standard torque.
17. Put the idenufieation m arks o f the needle bearing

in an up position. Install the needle bearing in
case assembly (30) with tooling (C). T h e top of
the bearing must be even with surface (29).
18. Install the case assem bly in its original position

on hou sing (19) and install the bolts and nuts that A42363X1
hold the case assem bly 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
20. Install k c \ ( 34) on the shaft.
21. Install gear (33) on the shaft with a press as

shown. M ake sure the ke\ is in correct alignm ent
with the groove in the gear.
23. Install shaft assem bly (36) on the w ash er o f the

ease assembly.
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).
NO T E ; S om e air starters have a snap ring to hol d seal

(39) in position. In this type of starter, the seal must be
installed below the snap ring groove in the c o ver and
the snap ring must be installed on top o f the metal
surface o f the seal.
25. Install O-ring seal (40) on the cover.
26. Install the co ver in its original position on the

case as sem bly. Use a seal pick to put the lip o f the
seal in its correct position on the shaft. Install the
bolts that hold the co v er in position.
27. A ssem b le the drive as se m bly as follow's:

a) Install piston (41) on clutch as sem b ly (42) as
showm.
b) Install tw o shift rings (44) in the groove o f the
clutch as sem bly.
c) Install spacer (43) on the shift rings.
7 -149
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.
29. Install seal ring (49) on the piston.
d b
'55
30. Install spring (47) and seat (48) on the drive

assem bly.
N O T E: The co unterbore o f the seat m ust be in a d ow n

position.
31. Install the b u shin g in h ousing (50) with tool ( D ) .

Put the notch in the bu shing in align m ent with the
hole in the housing.
7-150
1
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 ASSE MBL Y
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.
33. Install housing as sem bly (53) in its original p osi

tion on co v er (38).
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).
35. T ighten plug (52).
36. Use this procedure to see if the c y lin der is instal

led correctly:
a) Install tooling (F) on the inlet side o f the
housing.
b) Put air press ure into the housing to ca use the
rotor to turn.
c) From the drive as se m bly end o f the air star
ter. the shaft will turn in a clockw ise d ir e c
tion.
NOTH: If the shaft turns in a cou nterclo ck w ise direc

tion, rem ove the cylinder and rotor assem b ly from the
h ou sing and turn the cvlinder end for end on the rotor.
' \
"X
v ^
37. Use this procedure to make a check o f the m o v e
ment o f the drive assembly:
a) Put air pressure into the housin g assem bly
through hole (55) with tool (G).
b) The drive assem bly w ill m ove to the e n gaged
position and the exhaust air will co m e out
through hole (54) in the hou sing assem bly .
N O T E: If the drive assem bly does not m o v e, d i s a s s e m

ble the ho using and drive as sem bl ies and m ake a check
o f the seals in these assemblies. Also, m ake sure the
drive as sem bly has correct lubrication. Use 5 P 9 6 0 M u l
tipurpose T yp e G rease on the drive as sem bly,
end by:
a) install air starter
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
F T 1094 F lyw h e e l L if tin g B ra cket 1
FT524 L iftin g B ra cket 1
1. R e m o v e co ver (1) f r o m fl y w h e e l h ou sing .

R e m o v e p o i n t e r f ro m f ly w h e e l h o using .
2. R e m o v e t w o b o lts (2 ) t h a t hold fly w h eel in

p o sitio n on c r a n k s h a f t . In stall t w o 7 / 8 ” —14
N F 8 in. long b o l t s as a gu ide, on 1 )379 &
L)398. O n D 3 9 9 o n l y , use t w o 1 ” —14 N F x
10 in. long bo lts as a guide.
3. In stall t oo lin g (A ) o n th e fly w h eel. R e m o v e

the r e m a i n d e r o f th e b o lts t h a t h o ld f ly
w h eel to c r a n k s h a f t .
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
FLYWHEEL
INSTALL FLYWHEEL 1 1 5 6-1 2
T o o ls Needed A
F T 1094 F lyw h e e l L iftin g B ra cket 1
FT524 L iftin g B ra cke t 1
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.
2. Use a h o ist a n d to o l i n g ( A ) t o p u t the

fl y w h e e l in p o s i t i o n on c r a n k s h a f t .
3. I n stall t h e b o lts t h a t h o l d flywheel t o c r a n k

sh a ft. T ig h t e n b o lts o n D37 9, D 3 9 8 to a
t o r q u e o f 450 ± 30 lb. ft. (610 ± 40 N*m). O n
D 3 99 on ly, ti g h t e n bolts t o a t o r q u e o f 670 ±
50 lb. ft. '(905 ± 70 N -m ).
4. R e m o v e to o l i n g (A ) front fly w heel.
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
CRANKSHAFT REAR SEAL RING AND THROWER

RE M O V E C R A N K S H A F T REAR SEAL RING
A N D TH R O W ER 1 1 6 1 — 11
T o o ls Needed A
1P2321 P uller A ssem bly 1
FT884 Leg 3
8B 7561 S tep Plate 1
sta rt by:
a) r em o v e fly w h eel
1. R e m o v e tw elve b o lts ( 1) t h a t h o ld baffle t o

f ly w h eel h o usin g.
2. R e m o v e th e baffle ( 2 ) f r o m h o u sing .
3. R e m o v e th e seal ring and spring f ro m

throw er.
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
CRANKSHAFT REAR SEAL RING AND THROWER

INSTALL C R A N K S H A F T REAR SEAL R IN G
A N D T HRO W ER 1161 12
T o o ls Needed A
T603 B o lt 2
9 H 10 3 1 W asher 2
Put 8M 8 0 6 0 Q uick Cure Prim er and 9S3 2 6 5

R e ta in i n g C o m p o u n d o n ring. Install th e
ring in fly w h eel hou sin g.
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
spring.
3. P u t clean en gin e oil o n sprin g a n d ring. I n

stall spring a n d ring (1 ) o n t h r o w e r .
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.
4. P u t clean en gin e oil o n in side d i a m e t e r o f

baffle (2 ). Install t h e b affle ( 2 ) o n t h e
fly w h e e l ho usin g .
en d by:
a) install f lv w h e e l
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.
3. h a s t e n a hoist a n d lift e n g in e e n o u g h t o in

stall sp a cer s o n each side o f oil p a n base.
A p p r o x i m a t e w eig ht o f D 3 7 9 is 8,000 lb.
(3600 kg): D 3 98 "is 10.000 lb. (4500 kg):
1)399 is 13.000 lb. (5850 kg).
4. R e m o v e the ba ffle seal ring a n d sp rin g f ro m

th e t h r o w e r.
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 .
6. Install t w o 5 / 8 " —1 1 NC b o lts 6 ” l o n g as a

g uide. Install t w o 3 / 8 " —16 NC forg ed eye-
b o lts a nd fasten a h o ist.
7. R e m o v e th e b o lts t h a t h old lifting ey e to

c y l i n d e r b lo c k a nd to th e f ly w h e e l h o using .
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.
9. R e m o v e fly w h eel h o u s i n g from engine.

W eight is 4 5 0 lb. ( 2 0 4 kg).
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.
3. Install b olts t h a t hold governor drive t o

f ly w h e e l h o u sin e .
4. Install b o lts t h a t h o l d lifting eye.
5. In stall spr ing, ring, a n d baffle o n t h r o w e r .
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 ).
7. Install oil pressure r e g u la tin g valve (2).
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
REAR TIM IN G GEARS

R E M O V E REAR T IM I N G
GEARS 1 2 0 6 — D — 11
T o o ls Needed A B
1P2321 P uller A ssem bly 1
FT884 Leg 3
8B 7561 S tep Plate 1
8F3672 P uller Plate 1
8B7548 Push P uller 1
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 .
2. R e m o v e th e pins, bo lts ( l ) an d locks t h a t

hold large c a m s h a f t gear to sm all c a m s h a f t
gear. R e m o v e the large c a m s h a f t gear (2 ).
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.
4. Use too lin g (B ) t o r em o v e the small c a m

sh a ft gear (3 ) f ro m c a m s h a ft .
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
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 ).
3. P u t a m a r k w ith c h a lk o n the c a m s h a f t gear

at th e l o c a t i o n o f t im in g m a r k “ C ” . P u t a
m a r k w i t h ch alk on th e t o o t h o f c r a n k s h a f t
gear w ith p u n c h m a r k s. T h e b a c k o f gears
can be m a r k e d so t h e m a r k s can be seen
w ith a m i r r o r ( 7 ) a f t e r i n s t a lla tio n .
m
4. Install th e large c a m s h a f t gear (5 ). Be su re
th e “ C ” m a r k o n gear is in a l i g n m e n t w i t h
p u n c h m a r k on c r a n k s h a f t gear. O n D 3 7 9
o n l y , m o v e large c a m s h a f t g ear o u t e n o u g h
to t u r n th e b a l a n c e r gear u n til “ A ” m a r k s
are in al i g n m e n t .
« ■ I»
5. P u t large c a m s h a f t gear in p o s i t i o n o n t h e
d o w e l on sm all c a m s h a f t gear. Install locks,
b o lts, a n d pin (4 ).
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
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
7F9540 H y d ra u lic P u lle r 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.
3. D isconnect the oil lines (1) f r o m lifter

b r a c k e t s (3).
4. Use a m a g n e t a nd pull th e lifters (2 ) up

enough to put ru b b e r b a n d s o r wife on
th e m . T h is will ho ld lifters aw ay f ro m cam -
' shaft.
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
FT751 C a m sh aft A lig n m e n t T o o l 1
1. P u t th e key a n d sm all c a m s h a f t gear o n th e

c a m s h a f t . P u t clean en gin e oil o n c a m s h a f t .
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.
3. Install th e t h r u s t w ash er, locks, a nd b o l t s

t h a t h o ld small c a m s h a f t gear in c y l i n d e r
bl ock .
N O T E : Be sure th e c r a n k s h a f t is in p o s i t i o n w ith
No. 1 p isto n at to p c e n t e r o n c o m p r e s s i o n s t r o k e .
4. P ut a m a r k w ith ch alk on “ C ” m a r k o f g ear

(2 ) a n d t o o t h o f c r a n k s h a f t gear w ith p u n c h
m ark s. P u t a m a r k o n b a c k o f gears so t h e y
can be c h e c k e d w ith a m ir r o r a f t e r in stalla
tio n. P u t th e large gear ( 1 ) o n small c a m
sh a ft gear. Be su re “ C ” m a r k a n d p u n c h
m a r k o f c r a n k s h a f t gear are in a l i g n m e n t .
O n D 3 7 9 . m ov e gear ( 1) o u t e n o u g h t o t u r n
b a la n c e r gear to m a k e “ A ” m a r k s in align
m ent.
7- 161
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
8S2241 C a m sh aft B earing In s ta lla tio n

and R em oval G ro u p 1
§ sk * jja
9 1
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
1. R e m o v e th e c a m s h a f t bearings w ith t o o lin g

( A ). Use th e e x t e n s i o n s as n e e d e d .
INSTALL C A M S H A F T B EA RING S 1 2 3 0 — 12
T o o ls Needed A
8S2241 C a m sh aft Bearing In s ta lla tio n

and R em oval G ro up 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.
N O T H : Be su re th e oil ho les (1 ) in th e b earin g s are

in a l i g n m e n t w ith oil h oles in c y l i n d e r b lo c k .
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
I 8F2550 Engine T iltin g G ro u p 1
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.
7-164
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.
7-165
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
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
8 S 2328 Dial Test Indicator G roup 1

5B1 161 W ire *
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 .
2. I n sta ll n ew u p p e r h alv es ( w ith oil h o les ) o f

m a i n b e a r i n g s in c y lin d e r b lo ck . I n sta ll t h e
u p p e r h alv es o f c o n n e c t i n g r o d b e a r i n g s . P u t
clean e n g in e oil o n all b e a r in g s.
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 .
7. Use to o l g r o u p (B) to c h eck c r a n k s h a f t end

play as c o n t r o l l e d by t h r u s t plates . E n d play
m u s t be .005 to .021 in. (0.13 to 0.53 m m ).
M a x i m u m p e r m iss ib le e n d p lay is .035 in.
(0.89 m m ).
8. C h a n g e th e s t u d s in t o o l g r o u p (A) in t u r n
b u c k le s as n e c e s sa ry a n d low er th e engine.
C h a n g e st u d s o ne at a tim e.
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
From the library of Barrington Diesel Club

CAT D399 Workshop Manual

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Service Manual

D379, D398, D399

From the library of Barrington Diesel Club

SYSTEMS OPERATION (Section 2)

TESTING AND ADJUSTING (Section 3)

ATTACHMENT SPECIFICATIONS (Section 4)

GENERAL INSTRUCTIONS (D & A) (Section 6)

DISASSEMBLY AND ASSEMBLY (Section 7)

Individual Service Manuals are available

Sea W ater P u m p .................................................................................. 1-20

SYSTEMS OPERATION (Section 2)

Basic B lo c k ............................................................................................. 2-18

SYSTEMS OPERATION Cont. (Section 2)

Engine Protection Devices ................................................................. 2-33 Fuel Ratio C o n tr o l............................................................................. 2-6

TESTING AND ADJUSTING (Section 3)

Lubrication S y s te m ............................................................................... 3-40

Engine Shutoff Control ....................................................................... 3-56

ATTACHMENT SPECIFICATIONS (Section 4)

Cable A d ju s tm e n t (A ir Inlet S h u to ff) ......................................... 4-1 Pressure S w itc h e s ........................................................................ 4-14

ATTACHMENT SYSTEMS OPERATION (Section 5)

ATTACHMENT TESTING AND ADJUSTING (Section 5)

2301 Control S y s te m s ......................................................................... 5-77 Power Take-off C lu tc h e s ..................................................................... 5-90

Cleanliness ....................................... 6-2

DISASSEMBLY AND ASSEMBLY (Section 7)

THREAD DIAMETER STANDARD TORQUE

inches millimeters lb. ft. N-m *

Use these torques for bolts and nuts on

Use these torques for studs with Taperlock threads.

newton meter (N-m) is approximately the same as 0.1 mkg.

TORQUE FOR FLARED AND O-RING FITTINGS

' E f e " It-' BD

TUBE 3.18 4.78 6.35 9.52 TUBE 22.22 38.10 50.80

TO RQ UE TO RQ UE 110 135 160 310

TORQUE 45 80 145 155 190 TORQUE

ASSEMBLY OF FITTINGS WITH

1. Put lo ck nu t (3), b a cku p w as h er (4) and O-ring

N O T E : If the fitting is a c o n n ecto r (straight fitting) or

2. T o pu t the fitting assem b ly in its corre ct po sition

IMPORTANT SAFETY NOTICE

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

Operation s that may result only in m echanical d am ag e are identified by labels on

T he inform ation, specifications and illustrations in this bo ok are on the basis o f

4. If an en gin e m ust be started to m ake pr ess ure or

7. D o not sm o k e when an inspection of the battery

A ftercooler .............................................................................................. 1-10 G eneral Tightening Torques ................................................................... 6

Engine Design ......................................................................................... 1-2 Sea W ater P u m p .................................................................................. 1-20

D ire c tio n o f R o ta tio n (w hen seen fro m fly w h e e l end).

SAE O p p o site R o t a t io n ............................................................... C lo ckw ise

S AE O p p o site R o t a t io n .................................................... 1-4-5-2-7-6-3-8

D ire c tio n o f R o ta tio n (w hen seen fro m fly w h e e l end ).

S A E O p p o s ite R o t a t io n ............................................................... C lo ckw ise

F irin g O rd e r (In je c tio n Sequence).

S AE S ta n da rd R o t a t io n ............................. 1 -1 2-9 -4 -5 -8 -1 1-2-3-1 0 -7 -6

S AE O p p o site R o t a t io n ............................. 1 -4 -9-8-5-2-1 1 -1 0-3-6 -7 -1 2

D399 Engine ........................................................................................... V16

F irin g O rd e r (In je c tio n Sequence).

S AE O p p o site R o ta tio n . . 1 -6 -5 -4-3-10 -9 -1 6-15 -1 2-11 -1 4-13 -8 -7 -2

Pump lim in g before TC (top center):

D 399 E n g in e ........................................................................... 14±1°

D 398 and D379 E n g in e s .................................................... 12 ± 1 °

(1) Torque for b o l t s ................................. 32 ± 5 lb. ft. (43 ± 7 N-m)

N O T E : T o rq u e b o lt on the side w ith th e rack firs t.

M in im u m p e rm issib le length 2.9781 in. (7 5 .6 4 4 m m )