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Y JENSALES INC. WITHOUT THE AUTHORIZATION OF

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CT-S-E
NOTES
(
FOREWORD
This Owner's Manual contains operation instructions, lubrication and
maintenance information, the basic systems operations and minor repair·
information. Application of this information should help obtain maximum
performance and life of the engine; and keep the costs of engine operation
to a minimum.
Continuing improvement and advancement of product design may reflect

changes made to your engine which may not be included in this publication.
Each publication is reviewed and revised, as required, to update and in-
clude these changes in later editions.
Whenever a question arises regarding your Caterpillar engine, or this

publication, please consult your Caterpillar dealer for the latest available
information.
The services of authorized Caterpillar dealers are recommended; he is

staffed with personnel who are equipped with proper tools, necessary
Caterpillar parts, and are trained in the latest service procedures.
3412 MARINE ENGINE
SERIAL NUMBERS
60M1-UP
MODEL VIEWS
SAFETY
OPERATION INSTRUCTIONS
ATTACHMENTS
LUBRICATION AND MAINTENANCE
SYSTEMS OPERATION
TROUBLESHOOTING
EMERGENCY REPAIRS
SPECIFICATIONS
NOTES
MODEL VIEWS
TEMPERATURE REGULATOR
AFTERCOOLER
HOUSINGS
INSTRUMENT PANEL
GAUGES
FUEL
PRIMING
PUMP
OIL FILTERS
FILLER CAP
------AIR CLEANER
WATER PUMP
CRANKCASE DRAIN
*ATTACHMENT
3
NOTES
THIS SYMBOL WARNS OF POSSIBLE
PERSONAL INJURY
To prevent personal injury, install guards over all Do not attempt repairs you do not understand.
exposed rotating parts. Follow instructions.
Replace or repair broken or damaged servicing

equipment. Use proper tools.
Stop engine before adjusting or repairing engine
or driven equipment. Remove all tools, electrical cords and other loose
items from the engine before starting.
Do not wear loose clothing whenever working

around engines or machinery. Wipe up spilled oil, fuel or coolant.
Provide adequate and safe waste oil disposal.
To prevent hearing damage, wear ear protective Store oily rags in fireproof containers. DO NOT
devices if working inside an enclosed engine room leave rags on engine.
with engine running.
Never store flammable liquids near the engine.
Wear protective glasses, clothing, hat, respirator or

other protective items when necessary.
Do not use carbon tetrachloride fire extinguishers.
Fumes are toxic. Also, the liquid has a deteriorating
effect on insulation.
I.,:
'.f.
When using pressure air, wear protective face All electrical equipment must be grounded accord-
shield and clothing. Use 30 PSI (205 kPa) maximum ing to U.S. Coast Guard regulations.
air for cleaning purposes. Check all electrical connections periodically for
tightness and insulation.
Always inspect cooling system with engine stopped. Insulate all electrical connections and disconnected
wires.
Disconnect and tape the battery ground lead before

If equipped with jacket water cooling system, re- working on an engine to prevent accidental starting.
move filler cap slowly to relieve pressure. Steam Be sure an automatic start-stop system, if equipped,
may cause personal injury. cannot operate and start the engine while working
on it.
Cooling system inhibitor contains alkali, avoid con- Never start an engine with the governor linkage
tact with skin and eyes to prevent personal injury. disconnected.
When starting an engine after repair, make pro-

Do not smoke while refueling. Fumes from fuel are visions for shutting off air supply, to stop engine,
flammable. in case there is an overspeed on start up.
Always disconnect the engine starter circuit when

Do not smoke when observing battery electrolyte working on the generator.
level. Batteries give off flammable fumes.
Do not touch the heat sink on the generator regu-
lator when the generator is running. It is electrically
"hot".
Do not allow electrolyte solution to contact skin
or eyes. Electrolyte solution is an acid. Do not work on electrically "hot" equipment.
5
NOTES
:•
INDEX
After Engine Starts ......................... 11 Operating Under Abnormal Conditions ........ 18

Come - Home Method ................... 20
After Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Jacket Water Pump Failure ......... 18
Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Lubricating Oil Pump Failure ........ 19.
Engine Sea Water Pump Failure ............ 19
Engine Operation .......................... 11
Calibrated Gauges . . . . . . . . . . . . . . . . . . . . . . . 12
Piston or.................................
Towing Connecting Rod Failure .......... 20
22
Turbocharger Failure ..................... 21
1··.•··:
Standard Gauges . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine and Marine Transmission Operation. . . . 14 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . 8

Full Load Operation . . . . . . . . . . . . . . . . . . . . . . 14
Reduce Speed Operation . . . . . . . . . . . . . . . . . 14
Temporary Stopping . . . . . . . . . . . . . . . . . . . . . 14
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . 9
Trolling ................................. 14
Air Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electric Starting . . . . . . . . . . . . . . . . . . . . . . . . . 9
Generator Operation . . . . . . . . . . . . . . . . . . . . . . . 16 Generator Set, if Equipped With ........... 10
Generator Storage . . . . . . . . . . . . . . . . . . . . . . . 17 Glow Plugs, if Equipped With.............. 9
Load Division. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Starting Aid Chart . . . . . . . . . . . . . . . . . . . . . . . . 9
Load Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 When Starting Fluid is Required ........... 10
Paralleling .............................. 16
Standby Generator Sets .................. 16
Starting Single Unit ...................... 16 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electric Shutoff Solenoid ................. 15
To Parallel .............................. 16 Emergency Stopping ..................... 15
Mechanical Governor Control ............. 14
Marine Transmission Operation . . . . . . . . . . . . . . 13 Woodward PSG Governor . . . . . . . . . . . . . . . . . 14
7
PRE-START INSPECTION
Make a "walk-around" inspection of the engine and components for oil, water or fuel leaks and general
appearance. Correct minor adjustments before they develop into major repair jobs.
,& WARNING
Always inspect cooling system with en-
gine stopped. Remove filler cap slowly to
relieve pressure. Steam may cause per-
sonal injury.
1. Measure the crankcase oil level. Maintain the oil

level to the FULL mark on the ENGINE RUNNING
side of dipstick. Do not overfill.
6. Observe the engine jacket coolant level. Slowly

turn the pressure cap until the cap is removed.
Maintain coolant level to the base of the fill pipe.
2. Measure marine transmission oil level. Oil level

must be at, or slightly above the FULL mark, with
engine stopped. Add oil if necessary.
7. If equipped with Low Oil Pressure Shut-Off, reset

by pushing in button until it latches.
3. Check the fuel supply. Keep fuel tanks full, as

partially filled tanks will collect moisture.
4. Open the fuel supply valve. If the engine has
not run for some time, it may be necessary to prime
the system. See the topic, PRIMING THE FUEL
SYSTEM.
5. Open the raw water valve on the engine jacket
heat exchanger system (if so equipped). f:>rime
the raw water pump if the raw water system has
been drained.
8. If equipped with Overspeed Shut-Off, push reset

button in.
8
CAUTION
It the engine fails to start after 30 seconds of crank-
ing, allow the starter to cool for 2 minutes before
repeating the starting procedure.
NOTE
Prolonged cranking at low oil pressure can activate the mechan-
ical safety shut-off. If the reset lever is in the shut-off position,
reset the machanical shut-off control.
CAUTION
If engine again does not start, let starter cool for
2 minutes, then repeat starting procedure.
9. If the engine is equipped with an air shutoff

control, and was tripped to the shutoff position, If Equipped With Glow Plugs
reset the latch to the run position.
10. Disconnect any battery charger which is not
protected against starting motor drain.
11. Place marine transmission control lever in
NEUTRAL or, on a generator set, open the circuit
breaker.
1. If equipped with HEAT-START switch and glow

plugs, push in and turn switch to HEAT for the time
shown in the STARTING AID CHART.
12. Move governor control lever to approximate STARTING AID CHART

half engine speed position.
STARTING TEMPERATURE HEATING TIME
Above 60°F ( 16°C) None
STARTING THE ENGINE 60°F to 32°F
1 Minute
( 16°C to 0°C)
CAUTION
Do not engage the starter when the flywheel is 32°F to 0°F
turning. 2 Minutes
(0°C to -18°C)
Do not start engine under load. Below 0°F ( -18°C)* 3 Minutes
Electric Starting *NOTE

Heating of jacket water and crankcase oil, use of starting aid
1. :flush START button, if equipped. fluid and/or use of extra battery capacity may be required at
temperatures below 0°F (-18°C). Contact your Caterpillar
If the engine does not start after 10 seconds, move dealer before installing a dipstick crankcase oil heater.
the governor control lever to the fuel off position, A jacket water heater can maintain the water temperature at
then continue to crank for 10 seconds. This will approximately 90°F (32°C). This will keep the oil warm enough
clear the cylinders of unburned fuel. to flow when starting.
9
2. Turn HEAT-START switch to START positioo. 2. If equipped with generator set with a Caterpillar
Release switch as soon as the engine starts. control panel, place the AUTO-MAN switch in the
MAN position to crank the engine. As soon as
NOTE the engine starts, and the engine speed reaches
If engine does not start after 10 seconds, move the HEAT-START 600 rpm and oil pressure is approximately 22 psi
switch to HEAT for 30 seconds, then to START.
(150 kPa), the starter motor will disconnect from
If the engine does not run smoothly after it starts, the circuit.
turn the HEAT-START switch to the HEAT position.
NOTE
Hold the switch in this position until the engine If the engine is equipped with a Woodward PSG Governor,
does run smoothlv. Then release switch. see the topic, WOODWARD GOVERNORS for the governor
operation instructions.
CAUTION
Do not move HEAT-START switch to HEAT when
engine is warm and running. Air Starting
1. Open the bleed valve on the bottom of the air
When Starting Fluid is Required tank to drain condensation and oil carryover. Close
the valve.
& WARNING 2. Check the air supply pressure. The air start must
have 100 PSI (690 kPa1 to operate properly.
Starting fluid is volatile and must be stored
away from heat and direct sunlight. If an
aerosol container is used, follow the in-
structions on the container.
NOTE
Heat the glow plugs (if equipped) for the approximate heating
time shown in the STARTING AID CHART.
1. Push or turn appropriate control to begin crank-
ing engine.
2. Spray starting fluid for 1 second while cranking
engine. Wait at least 2 seconds before spraying
starting fluid again.
CAUTION
3. Keep the oiler jar at least half full of oil. Add oil
Spray starting fluid only while cranking the engine.
if necessary. See the LUBRICATION AND MAIN-
Otherwise, damage to the engine can result.
TENANCE PROCEDURES, Filling Motor Oiler.
3. When engine starts release start control.
4. If necessary, repeat starting procedure.
If Equipped With a Generator Set
4. Push the air valve control in to crank the engine.

Release the valve control as soon as the engine
starts.
10
AFTER ENGINE STARTS ENGINE OPERATION
After the engine starts, and at frequent intervals
&_ WARNING while the engine is operating, observe the gauges'.
Stop the engine if any repairs or adjust- Determine the normal reading for each gauge. In-
ments are required. Do not work on vestigate the cause whenever there is a significant
machinery while the engine is running. change in the reading.
1. Observe the oil pressure gauge immediately Standard Gauges - Tachometer

after starting.
The tachometer indicates engine RPM. The high
idle RPM and the full load RPM are stamped on the
CAUTION engine's information plate.
If oil pressure is not indicated on gauge within
CAUTION
5 seconds, stop the engine, investigate and correct
Prolonged operation at high idle with little or no
cause.
load can cause adverse engine operation.
2. As soon as oil pressure is indicated, increase
engine speed and observe sea water discharge.
CAUTION
If water is not visible, or if water flow is restricted,
stop the engine.
a. With engine stopped, inspect inlet screen and

sea water strainer for debris. Remove any debris,
if present.
The engine can be operated between high idle and

full load for long periods of time without shortening
engine life.
Engine Oil Pressure

If the gauge reading fluctuates after the load is
stable:
1. Remove the load.
2. Reduce engine spe.ed to low idle.
b. Loosen plug on inlet pipe. If water begins to

flow, tighten plug.
c. If water does not begin to flow, remove plug.
d. Fill pump body with water until water begins
to flow from plug opening.
e. Start engine and observe water flow from sea
water discharge.
f. If water flow is still restricted, stop engine.
g. Inspect cooling system and perform all neces-
sary repairs before operating engine. 3. Measure the oil level. Maintain the oil level
between the ADD and FULL mark on the dipstick.
3. If water flow is normal, move the governor con- If the reading continues to fluctuate when the
trol to low idle and allow the engine to warm oil level is correct, stop engine and consult your.
usually several minutes. Caterpillar dealer.
11
Engine Jacket Water Temperature Ammeter
The engine should operate within the NORMAL The ammeter reading is normal when the indicator
(green) range. is at or on the ( +) side of zero.
If indicator is to the left(-) side of zero, investigate

CAUTION
and correct cause.
Reduce engine RPM and load if indicator is in red
range. Also, inspect for coolant leaks.
Never add coolant to an overheated engine, allow
engine to cool first. Air Cleaner Service Indicator
When the gauge indicator locks in the red range,
If the gauge indicates in the HOT (Red) range and service the air cleaner.
steam is visible, determine if the engine must be
shut down immediately, or if the engine can be
safely cooled by reducing the load.
If the temperature gauge reading registers in or

near the cold (white) range, while operating under
load:
1. Test the water temperature gauge for accuracy.
2. Test the temperature regulators for proper tem-
perature range. Replace regulators if necessary.
NOTE
See COOLING SYSTEM in MAINTENANCE section for detailed
information.
Fuel Pressure To service air cleaner see AIR INDUCTION AND

EXHAUST SYSTEM in MAINTENANCE section.
If the fuel filter gauge registers in the OUT range,
with the engine running, clean the primary fuel
filter, if so equipped.
Calibrated Gauges
Calibrated gauges are used on some engines to
monitor the engine systems. If an abnormal engine
condition develops, determine, analyze and correct
the cause before failure and downtime occurs.
Install new secondary of final fuel filter elements

if gauge still registers OUT. See FUEL SYSTEM in
MAINTENANCE section.
12
Gauge readings recorded on a continuous basis 1. Move the marine transmission selector lever
from initial operation, will provide an engine and in the required direction to the fully engaged
marine gear history. This history will aid in iden- position.
tifying deteriorating conditions in engine or marine 2. Wait one second to allow complete engage-
gear systems. ment of the clutch.
The operating limits are given on an information 3. Gradually increase engine speed as required.
plate attached to the engine. The operating limits
given are for each individual engine and equip- To reverse direction when docking or traveling:
ment, working under normal or average operating 1. Reduce engine speed to low idle.
conditions, at rated speed and load.
2. Move the marine transmission selector lever
to the neutral position.
3. Wait two seconds to allow the clutch plates to
completely release, and the propeller to stop
turning.
CAUTION
A direct through-shift will cause severe shock loads
to the engine, marine transmission and hull; and
may cause the engine to reverse its rotation.
4. Move the marine transmission control lever
to the engaged position. Gradually increase
engine speed, as the clutch, is engaged, to pre-
vent the propeller from stalling, or the engine
reversing.
If any of the gauges register at, or outside of the 5. Allow at least one second to allow complete
operating limits, investigate and correct any mal- engagement of the clutch.
function. See TROUBLESHOOTING GUIDE section. 6. Gradually increase engine speed as needed.
When the marine transmission is engaged, the en-
_&WARNING gine torque must overcome the propeller, drive
line and marine transmission inertia, and the
propeller slip stream torque.
Stop engine to work on or around engine.
On small horsepower engines, the operator can
usually control the reversing direction. Careless
operation, however, can cause damage to the
CAUTION equipment.
Do not operate the engine, for extended period, with
gauge indicators at or outside the limits. On large horsepower engines, a sequenced en-
gine control system may be required. This equip-
ment consists of a throttle boost with an optional
MARINE TRANSMISSION OPERATION
shaft brake.
The marine transmission selector valve can be The throttle boost system momentarily increases
manually operated at the marine transmission, or engine speed as the marine transmission selector
from the pilot house. Controls in the pilot house lever is moved from NEUTRAL to the engaged
must be adjusted to permit full travel of the selector position. Upon completion of the clutch engage-
lever on the marine transmission, and full engagement, the governor replaces the throttle boost to
ment of the clutch plates. regulate the engine speed.
NOTE
With the remote controls in the pilot house properly adjusted,
The shaft brake stops the propeller shaft rotation
periodic clutch adjustment is not required. when both clutches are disengaged, with the se-
lector lever in the NEUTRAL position. The shaft
To get underway after the engine has started and brake should stop the shaft within 3 seconds during
is warm: a full power reversal.
13
ENGINE AND MARINE TRANSMISSION
OPERATION
3. Increase engine speed to no more than half
Full Load Operation speed. Idle for at least 5 minutes in order to cool
Move the governor control to full engine speed. An .the engine.
engine set for continuous operation can operate at 4. Reduce engine speed to low idle.
full engine speed for a long period without shortening 5. Measure the crankcase oil level with the engine
engine life. idling. Maintain the oil level between the ADD and
FULL marks on the ENGINE RUNNING side of
Reduce Speed Operation the dipstick.
If the front power take-off is to be operated, or a 6. Engage the marine transmission. Measure the
slower vessel speed is required, reduce engine marine transmission oil level at low idle. Maintain
speed. For operation of equipment powered by the oil level between the ADD and FULL marks on the ~-
front power take-off, see the Operation Instructions dipstick. Shift to NEUTRAL.
for the equipment.
7. The engine may be stopped by using one of the
following engine mounted controls:
Trolling
Mechanical Governor Control
The trolling valve is a marine transmission attach-
ment, and operates only in the forward direction.
Engine speed must not exceed 650 RPM when
trolling valve is engaged.
The marine transmission oil temperature must not

exceed 180°F (82°C). Marking the tachometer and
Oil temperature gauges at these two limits will serve
as a warning. Monitoring these gauges and take
corrective measures if overheating occurs.
Trolling at reduced load for several hours may

cause excessive oil consumption and carbon build
up. Every 4 hours, apply load at full engine speed
to help burn the carbon out.
Pull upward on the handgrip and move the control

Temporary Stopping to the shutoff position.
For a temporary stop, during which time the engine
is to continue running:
Woodward PSG Governor
1. Reduce engine speed to low idle.
2. If water current conditions permit, shift into
NEUTRAL.
3. Maintain engine speed at no more than half
speed.
4. After 5 minutes, reduce engine speed to low
idle, if water conditions permit.
5. To resume travel, shift into forward or reverse
with engine at low idle speed. Increase engine
speed gradually.
STOPPING
1. Reduce engine speed to low idle and continue Move the shutoff lever forward, or hold the lever
on to anchorage. up, depending upon installation. Hold the lever in
2. Shift into neutral and secure the vessel. this position until the engine stops.
14
Electric Shutoff Solenoid
6. Perform the required periodic maintenance on
all other equipment as outlined in the equipment
manufacturer's instructions.
Engine Storage
If the engine is not started for several weeks, the
lubricating oil drains from the cylinder walls and
piston rings. This will result in shorter engine life.
To prevent excessive engine wear:
1. Be sure all lubrication points listed in the
LUBRICATION AND MAINTENANCE CHART
are serviced.
2. Once a week, start and run the engine until it
Turn engine control switch to STOP or OFF position. is thoroughly warm. (For unattended automatic
start-stop systems, the engine may have an exer-
Emergency Stopping ciser for this purpose.)
In an emergency situation, stop the engine as 3. Stop the engine, perform required servicing.
quickly as possible; see Step 7 of STOPPING. 4. Check the cooling system for adequate pro-
tection if freezing temperatures are expected.
A 50-50 solution of permanent type antifreeze
AFTER STOPPING and approved water will give protection below
1. Fill the fuel tank. See the LUBRICATION AND -20°F (-29°C).
MAINTENANCE PROCEDURES. If it will be impossible to start the engine every
2. Drain the sea water system if below freezing week, see your Caterpillar dealer for instructions to
temperatures are expected; see the LUBRICATION prepare your engine for extended storage periods.
AND MAINTENANCE PROCEDURES.
3. If below freezing temperatures are expected,
allow the engine jacket water expansion tank to
cool; then check the coolant for proper antifreeze
protection. Add permanent-type antifreeze if re-
quired; see LUBRICATION AND MAINTENANCE
PROCEDURES.
4. Repair any leaks, perform minor adjustments,
tighten loose bolts, etc.
5. Observe the service meter reading. Perform

periodic maintenance as instructed in the LUBRI-
CATION AND MAINTENANCE CHART.
15
GENERATOR OPERATION
Starting Single Unit Operation

1. Make engine pre-start inspections. 4. Using the governor control, adjust the speed
2. Be sure the main or line circuit breaker is open. until the lights blink very slowly.
3. Start the engine and allow it to warm up. 5. The lights are off when the voltages of the two
units are in phase. At this point, very quickly close
4. Close the main circuit breaker. the breaker while the lights are out.
5. Apply the load. Do not try to apply full load in NOTE
one step, apply the load in increments to maintain The frequency of the incoming unit should be slightly greater
system frequency at a constant level. than the line frequency. This will allow the incoming unit to
assume some of the load rather than add to the system load.
Standby Generator Sets Load Division

Most standby units are automatic. They start, pick- Once two units have been paralleled, their share
up the load, run and stop without an operator in of the load is determined by the gov~rnor control
attendance. setting. If two units of the same capacity and the
Standby units can not change the governor control same governor characteristics have the same
setting automatically. The throttle must be preset governor control setting, they will share the load
for the proper operation of that unit. Whenever the equally.
set is exercised or operated manually, be sure the To add load to one engine, slowly increase the
throttle is reset correctly for automatic operation. governor control setting of that engine, or slowly
Observe all switches to determine they are properly decrease the governor control setting of the engine
set: Start Selector Switch in AUTOMATIC position giving up load.
and any Stop Switches in RUN position.
Load Transfer
Paralleling At this point open the circuit breaker to remove any
Units may be paralleled with no load on units or remaining load on the outgoing generator set.
with units under load. To parallel two or more units, NOTE
the units must have: The total load must not exceed the capacity of the engine.
1. Same phase rotation. 1. Increase the governor speed control of the unit
to assume the load to the high idle position.
2. Same voltage level.
2. Reduce the governor speed control of the out-
3. Same voltage droop.
going unit until the generator amperage is at a
4. Same frequency. minimum. (The amperage may never be zero due
5. Voltages in phase. to circulating currents.) At this point transfer the
load.
The first condition is established by "phased" wiring
connections at initial installation. Stopping
The second and third conditions are usually es- To remove a generator from the line do the following:
tablished by semi-permanent adjustments to the 1. Check the load. It must be less than the rated
generator controls. capacity of remaining units.
The fourth and fifth conditions are controlled by NOTE
the operator in manual paralleling systems (or under If removing a generator from the line will cause overloading of
automatic control in automatic paralleling systems). the remaining units, remove some of the load first.
2. Be sure the NEUTRAL of one of the remaining
To Parallel units is grounded.
1. Start the unit to be paralleled. 3. Remove the load from the outgoing unit
2. Turn the synchronizer lights on. as described in LOAD DIVISION, and LOAD
TRANSFER.
3. After the engine has run long enough to warm
up, bring it up to synchronous speed (the same 4. Open the circuit breaker.
frequency as the unit on the line). The synchro- 5. Run the engine for 5 minutes without a load,
nizing lights will begin to blink. to allow it to cool. Stop the engine.
16
Generator Storage
When a generator is stored for an extended period
of time, moisture condenses in the windings. Mini-
mize the condensation by storing it in a dry place.
To remove moisture caused by high humidity or
dampness, dry the generator by one of the following
methods:
1. Place the generator in an oven and bake at
a temperature not above 185°F (85°C) for four
hours.
CAUTION
Use a forced air type rather than a radiant type.
Radiant ovens can cause localized overheating.
2. Enclose the generator and heating lamps in
canvas to raise the temperature. Leave an open-
ing in the top for the moisture to escape.
3. Pass a low voltage current through the wind-
ings to raise the temperature of the windings to
185°F (85°C).
If there is a possibility the insulation resistance
has deteriorated to a dangerously low level, contact
your Caterpillar engine dealer.
17
OPERATING UNDER ABNORMAL CONDITIONS
Certain worldwide marine classification societies 2. Open valve (2).
require sea going propulsion engines to be equipped
to allow continuous operation if the engine water
pump or oil pump should fail.
Engine Jacket Water Pump Failure

If the engine jacket water pump should fail, fresh
water can be supplied to the engine jacket using
the emergency water system.
3. Move and secure valve handle in the EMER-

GENCY position.
4. Start the emergency jacket water pump (3).
Allow the air to escape from the emergency cool-
ing system. Observe the coolant level. Add fresh
water as required.
5. Start the engine.
6. Engage the marine transmission; operate the
vessel at normal speed.
Emergency Jacket Water Connections
1 - Tee Connector If the jacket coolant water is lost (such as when a
2-Valve water line fails) and an insufficient supply is avail-
3 - Emergency Jacket Water Pump
able to replenish the jacket water coolant while at
4 - Tee Connector sea, sea water may be pumped through the engine
5-Valve
jacket if necessary.
1. Stop the engine and make the necessary water

pump and lines connections for pumping sea water
into the jacket water system and back to the sea.
2. Remove the temperature regulating thermo-
stats from the regulator housing, and install the
housing cover.
3. Start the emergency pump and/or start the engine.
NOTE
The sea water should be pumped through the engine jacket and
returned to the sea.
4. With the governor control at low idle, engage

the marine transmission forward clutch.
1. Stop the engine. If the water pump bearing has 5. Operate the engine at the lowest speed for
failed, the water pump need not be removed. existing sea conditions.
18
6. Maintain engine temperatures as low as possible 4. Start the emergency sea water pump (2).
to minimize salt deposits in the engine and cor- ·
5. Start the engine, engage the marine trans-
rosion of engine parts.
mission, and continue at normal speed.
7. Upon reaching port, have the engine jacket
water system completely disassembled, cleaned
and inspected. Replace all parts which are corroded Engine Lubricating Oil Pump Failure
or damaged. If the engine oil pump fails, oil pressure will drop
and the engine water temperature gauge readings
Engine Sea Water Pump Failure may be above normal. If equipped, the shutoff
The sea water pump circulates sea water through controls will stop the engine.
the engine jacket water heat exchanger. On turbo- To use the emergency lubricating pump:
charged-aftercooled engines, the sea water also
cools the aftercooled air. 1. Move the marine transmission selector lever
to NEUTRAL, and stop the engine.
2. Measure the engine oil level. Maintain the
level at the FULL mark on the dipstick.
3. Reset the oil pressure shutoff control. Start
the standby lubricating pump (3).
1 - Valve - normally closed 7 - Normal - operation sea

2 - Emergency sea water pump water inlet
3 - Emergency sea water inlet B - Valve - normally open
4 - Valve - normally closed 9 - Sea water pump
5- Emergency sea water 10 -Jacket·water heat TYPICAL STANDBY OIL SYSTEM
strainers exchanger
6 - Normal - operation sea 11 - Sea water outlet 1. 011 Pan 4. Check Valve
water strainers 12 - Aftercooler 2. Oil Strainer 5. Oil Cooler
3. Standby Lubricating 6. Engine Oil Filter
Oil Pump 7. Engine Lube Pump
If the sea water pump should fail:
1. Stop the engine. If the shaft bearing has failed, 4. Observe the oil pressure gauge; be sure the
the damaged pump need not be removed. oil pressure shutoff control reset knob has turned
2. Close the inlet valve (8) to the sea water pump. to the RUN position. Start the engine.
3. Open the inlet valve (4) to the emergency sea 5. Engage the marine transmission; operate the
water pump. vessel at normal speed.
19
Towing CAUTION
If the vessel cannot continue under its own power, Use the come-home method only in an emergency.
it must be towed. If pressurized oil cannot be sup- If the marine transmission lubricatiog oil pressure
plied to the marine transmission shaft bearings is lost, travel with extreme care and at minimum
while being towed, the propeller shaft must be engine speed to avoid damaging the bearings.
secured to prevent the shaft turning.
1. The engine must be warm. If necessary, start
CAUTION and idle the engine until it is warm.
Turning of the propeller shaft without proper lubri-
cation will damage the marine transmission shaft 2. Stop the engine.
bearings.
After the shaft has been secured, tow at slow speed

to minimize the windmilling force on the propeller.
The correct method of preventing shaft rotation
depends upon the turning force of the propeller,
and the construction of the propeller shaft tunnel.
Use the method best suited for the type of installation:
Wrapping Propeller Shaft:

1. On small vessels, wrap a heavy rope around
the propeller shaft. The number of wraps needed
will depend upon the mass of the propeller and
propeller shaft.
2. Secure the rope in the opposite direction of
3. Remove the cover from the top of the marine
shaft rotation.
transmission.
Securing Companion Flange:
1. Remove one or more bolts from the companion
flange coupling.
2. Bolt a chain to the companion flange.
3. Wrap the chain several times around the pro-
peller shaft.
4. Secure the loose end of the chain at a right
angle to the shaft and in opposite direction of
shaft rotation.
Applying Air Actuated Shaft Brake:

For vessels equipped with a s.haft brake, the shaft
brake may be applied if there is air pressure
available. 4. Remove the oil line and the bearing cap.
Come - Home Method 5. On transmissions with 1/2" -13 holes: Install two
If the marine transmission loses oil pressure, and if bolts opposite each other in the tapped holes of
there is no other means for returning to port, the the clutch pressure plate. Alternately tighten the
come-home method can be used. bolts to 75 + 10 lb. ft. (100 + 15 N·m).
20
10. To stop the vessel, stop the engine. Remove
the bolts engaging the clutch when the engine 'is
stopped.
11. Upon reaching port, disassemble and inspect

the clutch plates for warpage and cracking. Damage
can occur by having them mechanically engaged. 1f
Under severe operating conditions, the marine trans-
mission should be disassembled and all bearings
inspected.
Turbocharger Failure
On transmissions with 3/8" - 16 holes: Install three F\ ~=
bolts equally spaced in the tapped holes of the JI.It

clutch pressure plate. Alternately tighten the bolts
it-~!
to 32 + 5 lb. ft. (43 ± 7 N·m).
6. Install the bearing cap, oil line and the trans-

mission cover.
7. Measure the marine transmission oil level. Main-

tain the oil level 5 to 6 inches (125 to 150 mm)
above the FULL mark on the dipstick.
8. Start the engine.

1. Remove the air cleaner and the hump hose be-
tween the air cleaner and the turbocharger inlet.
CAUTION
The starter motor will be turning the diesel engine,
marine transmission propeller shaft and propeller
while cranking. Damage can result from excessive
heat in the starter caused by overcranking.
9. After starting, travel with caution, at minimum

speed. Watch for overheating of transmission case
and oil.
CAUTION
The transmission can not be reversed or neutralized.
Before reaching port ask for assistance in docking.
TURBOCHARGER CARTRIDGE REMOVAL

1. Clamp. 2. Bolt. 3. Turbocharger compressor. 4. Oil supply
line. 5. Cartridge. 6. Turbine housing. 7. Oil drain line.
21
2. Remove oil supply line (4) from top of the turbo- Piston or Connecting Rod Failure
charger and from the cylinder block. Plug the oil
supply opening at the cylinder block location. 1. Remove the failed piston, connecting rod and
connecting rod bearings.
3. Remove oil drain line {7). Plug the oil drain open-
ing in the flywheel housing. 2. Provide some method of closing off the oil supply
holes in the crankshaft for the removed connecting
4. Remove four bolts (2) at the aftercooler. rod. It must be remembered that whatever materials
5. Remove clamp (1) while supporting compressor are used to plug the oil holes will have to be re-
{3) and piping to aftercooler. Remove piping, com- moved at the time permanent repairs are made.
pressor {3) and cartridge {5) as a unit. 3. The fuel injection line for the affected cylinder
6. Provide some means of attaching a flat, steel must be disconnected at the valve cover base. This
plate {large enough to cover the opening com- fuel injection line then must be directed away from
pletely) against the opening in turbine housing {6) the engine and into some type of fuel collecting
where cartridge (5) was removed. If a round plate device.
of the correct diameter and thickness can be
fabricated, it can be attached to housing (6) with
clamp (1). &, WARNING
Be careful when operating engine with
&, WARNING fuel injection line disconnected. High
pressure fuel will be coming from the dis-
DO NOT ALLOW EXHAUST GAS TO DIS- connected end when the engine is oper-
CHARGE INTO ENGINE ROOM. ating. Use extreme care to avoid injury
or fire.
7. Clean the engine room of any materials that
could possibly be drawn into engine air inlets. With
the turbocharger removed, there will not be a filter 4. The engine can now be started, but must be
operated at greatly reduced speed and load.
in the air inlet system.
8. Providing that all other engine systems are in
operating condition, the engine can now be started.
9. The engine must be operated at greatly reduced
speed and load.
22
· \ ·.
ATTACHMENTS
INDEX
Alarms and Emergency Shutoff Devices ................................... . 27

Air Shutoff Control .................................................. . 28
Alarm Switches ..................................................... . 27
Electronic Overspeed Shutoff Switch .................................. . 30
Emergency Shutoff Devices .......................................... . 27
High Water Temperature Shutoff ...................................... . 27
Low Oil Pressure Shutoff Switch ...................................... . 27
Oil Pressure Switch ................................................. . 28
Overspeed Shutoff .................................................. . 28
Overspeed Shutoff Switch (Electro-Mechanical) ......................... . 30
Testing Alarms ...................................................... . 27
Automatic Start-Stop ................................................... . 26

Overcranking ....................................................... . 26
Shutting Down .......................... : .......................... . 26
Starting Engine After Shutdown ....................................... .
Determining Cause of Shutdown or Alarm ................................. .

Engine High Jacket Water Temperature ..............................•..
High Oil Temperature ................................................ .
Inlet Air High Temperature ........................................... .
26
31
31
32
31
I
Low Oil Pressure .................................................... . 32
Generator Set Control Panel ............................................. . 24
Manual Operation ...................................................... . 25

After Stopping ...................................................... . 25
Starting the Engine ................................................. . 25
Stopping the Engine ................................................ . 25
Woodward PSG Governor ............................................ . 25
23
ATTACHMENTS
GENERATOR SET CONTROL PANEL

The generator set control panel is located on top of the generator, and is equipped with the following
controls and gauges.
CONTROL PANEL
1. Panel lights 2. Panel lights ON/OFF switch. 3. Alternating current ammeter. 4 Frequency meter. 5. Alternating current
voltmeter. 6. Voltmeter/Ammeter phase selector. 7. Engine control switch. 8. Voltage level rheostat. 9. Oil pressure gauge.
10. Water temperature gauge. 11. Engine failure light/reset switch. 12. Shutdown indicators. 13. Pre-alarm module (if equipped).
14. Direct current ammeter (if equipped). 15. Heat switch (if equipped). 16. Governor motor control switch (if engine is equipped
with PSG governor).
Panel lights (1) are controlled by an ON/OFF When in AUTOMATIC or MANUAL positions, the
switch (2). engine will stop if commercial power has been
An ammeter (3), frequency meter (4) and a volt- restored or if the engine has a fault.
meter (5) show output of the generator. The The voltage level rheostat (8) replaces the rheostat
voltmeter/ammeter phase selector switch (6) in the generator regulator assembly.
selects which phase (T1, T2 or T3) of generator out- Gauge (9) indicates engine oil pressure and gauge
put will be monitored on the ammeter (2) or the (10) indicates engine water temperature.
voltmeter (5).
If the engine has a fault, the engine failure light/
The engine control switch (7) allows manual or reset switch (11) will activate a shutdown relay to
automatic operation of the engine and generator stop the engine. The shutdown indicators (12) in-
set. dicate if the fault was either oil pressure, water
The engine control switch has four positions; temperature, overspeed or an overcrank condition.
MANUAL, AUTOMATIC, STOP and OFF. Placing The pre-alarm module (13), if equipped, provides
the control in MANUAL will start the engine and an audible and visual indication for low oil pressure,
allow the operator to manually connect the gen- high water temperature, low fuel supply and low
erator to the load. water temperature before the condition becomes
critical.
24
The direct current ammeter (14), if equipped, moni- 4. Regulate frequency and voltage output of gen-
tors the engine alternator output. erator with the Governor Motor Raise-Lower
switch.
If the engine is equipped with glow plugs, they are
controlled by an ON/OFF switch (15).
If engine is equipped with a PSG governor, gover-

nor motor switch (16) allows the operator to control
the engine RPM from the panel. Stopping the Engine
1. Remove the load. See GENERATOR OPERA-

MANUAL OPERATION TION if equipped with a GENERATOR SET.
Woodward PSG Governor 2. Reduce engine speed to low idle. Push down
The Woodward Governor is usually electrically and hold Governor Motor Raise-Lower switch in
operated from a control panel. the Lower position.
Starting the Engine 3. Release switch when low idle is reached.
1. Perform all pre-start inspections. See PRE- 4. While the engine is at low idle, measure the
START INSPECTION. engine oil level. Oil level must be maintained be-
tween the ADD and FULL mark on the ENGINE
RUNNING side of the dipstick.
5. After engine cools, turn Engine Auto. Control

Selector switch to STOP.
NOTE
If necessary, the engine may be stopped by using the PSG
Governor shutoff lever.
2. Turn Engine Auto. Control Selector switch to

MAN. position.
3. After engine starts and its systems have stabi-

lized, apply the load.
Move the shutoff lever forward. Hold lever in this

position until engine stops.
After Stopping
Refer to AFTER STOPPING instructions in the

ENGINE OPERATION section.
25
AUTOMATIC START-STOP
An automatic start-stop system is used when an If the engine does not start before the time has
engine must start with no one in attendance. elapsed, the fuel system will shutoff, the overcrank
To start the engine when unattended, the ambient indicator vyill be extended and the engine failure
(engine room) temperature must be at least 70°F and reset light will come on.
(20°C) or, the engine jacket water temperature must
be at least 90°F (32°C).
NOTE
One or two 3kw jacket water heaters can maintain this
temperature.
Shutting Down
A timer allows the transfer switch to transfer the
load to another source and the engine to continue
running for up to 2 minutes for cooling purposes,
before stopping.
If the unit is used for standby application with a
remote transfer switch, place the Engine Auto.
Starting Engine After a Shutdown Caused
Control Selector switch in the AUTO. position, and
the Governor Motor Switch at full load position for By Engine Failure
proper operation of the generator with load after
starting.
In the AUTO. position, the engine will automatically

start and take up the load when commercial power
has stopped.
The automatic start-stop system will also remove
the load, cool and stop the engine.
NOTE
When in the AUTO. position, the engine will automatically stop
1. Turn engine control switch to either STOP or
if commercial power has been restored or if the engine has
a fault. OFF position.
2. Find cause of shutdown and correct it.

Placing the Engine Auto. Control Selector in the
OFF position will stop the engine. 3. Push the shutdown indicator light.
4. Push engine failure and reset button.

Overcranking
A timer allows the engine to crank either once 5. Operate the engine with the engine control
for 30 seconds, or through 5 ten-second cranking switch in MANUAL. Make tests as necessary to
cycles (depending upon the device used) while make sure the condition that caused the shutdown
unattended. has been corrected.
26
ALARMS AND EMERGENCY SHUTOFF DEVICES
Alarm Switches Emergency Shutoff Devices

Alarm switches are set at a less critical temperature, The operation of all electric shutoff controls is
pressure, or level limit than the shutoff controls. similar: A critical operating condition actuates a
The purpose of the alarm switch is to warn the switch to stop the engine. The shutoff control may
operator an unsafe operating condition is starting require resetting before the engine can start.
to occur, and that corrective measures should be
taken to avoid possible damage to, and/or possible Emergency shutoff devices may be electrically,
shutdown of, the engine. mechanically or hydraulically operated. Familiarize
Marine engines can be equipped with either alarm yourself with the types and locations of the shutoff
or shutoff systems. However, in many operations devices, the conditions which cause each control
an uncontrolled shutdown may cause an accident to function, and the resetting procedure required
far more serious than the damage to the engine, to start your engine.
particularly on propulsion engines.
Marine propulsion engines are usually equipped CAUTION
with various alarm systems. The most common Do not use an emergency shutoff device for a normal
alarm systems indicate high jacket water tempera- stopping procedure.
ture, high inlet air temperature, high oil temperature
Always determine the cause of the shutdown, and
and low oil pressure.
have the necessary repairs made before restarting
When an alarm is activated, corrective measures the engine. See TROUBLESHOOTING GUIDE.
should be taken before the situation becomes an
emergency. Or if equipped, a corresponding shutoff
device will automatically stop the engine.
High Water Temperature Shutoff
CAUTION
Corrective measures must be taken before engine The shutoff switch is located in the water tempera-
damage occurs. ture regulator housing. Excessive water temperature
closes the switch. No resetting procedure is required:
Each alarm switch is electrically connected to an As the coolant cools, the switch opens.
indicator light, bell or horn. The alarm will continue
until the condition is corrected. Then the light will CAUTION
turn off and the bell or horn will be silenced. Coolant level must be maintained in order for the
shutoff to function, because the sensing element
To silence the bell or horn while repairs are being
must be submerged in the coolant to operate.
made, a two-way switch and a red indicator light
may be installed. Then when the alarm is turned off,
the red indicator light will come on.
CAUTION
If the switch is left in the OFF position after the
repairs have been made, the red light will stay on to
indicate that the engine is not protected.
Testing Alarms
All alarms on the engine should be tested twice a
year for proper operation by authorized Caterpillar
dealer personal.
CAUTION Low Oil Pressure Shutoff Switch

During testing abnormal operating conditions must CAUTION
be simulated, which could cause engine damage if The switch will not protect system from rapid oil
the tests are incorrectly performed. loss, caused by failures such as line breakage.
27
This device is usually mounted on the side of the This switch is also used with the electric governor.
engine, and oil lines are connected to the switch. On start-up, oil pressure will close the switch to
Low oil pressure closes the switch. allow the electric governor to increase engine
speed.
This switch does not require resetting.
Air Shutoff Control
To reset the switch, push the button until it latches.

After the engine starts and develops oil pressure,
the button will move to the extended (running)
position.
CAUTION
The button must be in the RUN position to protect
the engine. The air shutoff control is an attachment to the
shutoff devices. When an emergency condition
If the button remains in the off position, the engine occurs, the solenoid pushes the rack into the shut-
oil pump may not be developing normal oil pressure off position and a solenoid trips a butterfly valve,
and proper checks should be made. located in the inlet manifold, to the closed position,
cutting off intake air to the engine. Th is control must
Manually operated systems require resetting of be reset before starting.
this switch before starting. Automatic start-stop
systems use a pressure switch which resets itself.
Oil Pressure Switch Overspeed Shutoff
This switch is mounted in the oil manifold. Low

oil pressure opens this switch to disconnect the
electrical circuit to the shutoff solenoid. This pre-
vents the battery from continuously energizing the This switch uses a magnetic pick-up mounted in the
solenoid while the engine is stopped. flywheel housing to sense engine speed.
28
Should the engine overspeed, the magnetic pick-up
will close the circuit to the fuel shutoff solenoid and
stop the engine.
The shutoff switch can be checked for proper oper-
ation at 75% overspeed condition:
1. Determine the full load RPM of the engine from
the serial number plate.
2. Operate the engine at the corresponding speed
shown in the OVERSPEED TEST RPM Column of
the chart below.
ACTUAL
FULLLOAD OVERSPEED OVERSPEED As the engine stops, the yellow light will light. The
RPM TEST RPM RPM RESET button must be pushed before starting
1500 1328 1770 the engine.
1800 1593 2124 If the engine is equipped with a CAT Generator Set
Control Panel, the safety devices on the panel must
2100 1859 2478 be reset:
NOTE
The Overspeed Test RPM is slower than the Full Load RPM:
FULL LOAD RPM x .885 = OVERSPEED TEST RPM
1. Turn the Engine Auto. Control Selector switch

to OFF or STOP position.
3. While maintaining test RPM, push and hold the 2. Push the Engine Failure and Reset button in to
VERIFY button. The engine should stop. the reset position.
If the engine does not stop at the specified test 3. Push in on the OVERSPEED indicator to the
RPM, contact your Caterpillar dealer. reset position.
29
,,
~.:·
Electronic Overspeed Shutoff Switch Overspeed Shutoff Switch
With Cranking Termination (Electro-Mechanical}
This switch has a 75% VERIFY button, a RESET This switch is mounted either on the tachometer
button and an indicator light similar to the speed drive or on the governor. Excessive engine speed
switch just discussed. The operation of this portion closes the switch by centrifugal force.
of the switch is identical in all respects to the one
just described.
In addition, this switch has a second sensing circuit
which prevents the starter pinion from remaining
engaged in the flywheel at excessive RPM.
After the starting motor has cranked ,the engine, To reset the switch, push the button marked RE-
the pinion gear can remain engaged with the fly- SET. The knob will remain down until the engine
wheel as engine speed increases. At 600 RPM, overspeeds.
the magnetic pickup opens the circuit to the starter
motor which allows the pinion to disengage. The
circuit remains open until the flywheel stops. This
prevents energizing the starter motor again while
the flywheel is turning.
30
,.
DETERMINING CAUSE OF SHUTDOWN OR ALARM

Listed below are the different conditions that cause On multi-engine powered vessels, one engine may
the alarm systems, usually found on an engine, to be shut down for repairs while proceeding at re-
be activated. Several causes for the alarm to func- duced power on the remaining engine(s).
tion are listed, followed by corrective measures An authorized Caterpillar dealer should analyze
which should be performed. Additional measures major engine problems.
may be required by the operator, depending upon
circumstances and conditions present.
Engine High Jacket Water Temperature

Condition Corrective Measure
1. Engine operating in lug condition. 1. Increase engine speed or reduce load.
2. Vessel operating in trolling condition for long 2. Increase engine speed to allow engine to cool.
periods.
3. Ambient sea water temperature is above the 3. Reduce engine speed to reduce amount of en-
normal expected. gine heat being generated.
4. Jacket water coolant level is low. 4. Stop engine and allow engine to cool; carefully
remove filler cap and fill to proper level.
5. Sea water strainer, keel cooler or heat ex· 5. Reduce engine speed until repairs can be mode;
changer is plugged. stop the engine and clean the system; or use emer-
gency water pump and strainer if so equipped.
See the topic, Emergency Operation.
6. Sea water pump or jacket water pump is 6. Repair pump; use emergency cooling system if
defective. so equipped; or be towed to port.
7. Water temperature regulator is defective. 7. Install new regulators; or remove regulators

and proceed to port.
8. Engine oil cooler is plugged. 8. Stop and clean oil cooler if possible; or reduce
engine heat and proceed to port for repairs.
9. Hot combustion gasses leaking into jacket water 9. Reduce speed and proceed to port for repairs.
coolant.
Inlet Air High Temperature

1. Hot air being drawn into the air cleaner. 1. Change the air intake so as to bring in cooler
air; or if this is a temporary situation, reduce
engine speed.
2. High jacket or sea water temperature in the 2. Take corrective action to lower jacket water
oftercooler. temperature; reduce speed if sea water tempera-
ture is above normal; repair sea water pump if
defective or use emergency sea water pump.
3. Aftercooler is plugged. 3. Reduce engine speed; or stop and clean after-

cooler if possible.
31
High Oil Temperature
1. Engine operating in lug condition. 1. Increase engine speed or reduce load.
2. Vessel has been trolling for a long period. 2. Increase engine speed to allow engine to cool.
3. Oil cooler is plugged. 3. Stop and clean oil cooler; or reduce engine
speed to reduce engine heat and proceed to port
for repairs.
4. Oil pump is defective. 4. Stop the engine. Either make repairs, use emer-
gency oil pump if so equipped, or be towed.
5. Engine jacket water temperature is above 5. Check the causes listed above and take neces-
normal. sary action to lower jacket water temperature.
Low Oil Pressure
1. Low oil level and, or, high aeration in the 1. Maintain oil level at FULL mark on dipstick.
crankcase. Check for oil leaks.
2. Oil temperature is above normal. 2. See discussion pertaining to high oil tempera-
ture alarm.
3. Engine oil filter is plugged. 3. Install new filter elements.
4. Crankcase oil may be diluted with fuel. 4. Determine if there is a strong fuel odor in crank-
case oil, coused by fuel leaking into the crankcase
lube system. Make repairs and change oil.
5. Oil pump relief valve is stuck and is dumping 5. Stop the engine. Repairs must be made.
oil back into engine crankcase.
6. Oil pump strainer is plugged. 6. Stop the engine. Clean the oil strainer, use
emergency oil pump if so equipped or be towed
to port.
7. Oil pump is defective. 7. Stop the engine and make repairs, use emer-
gency oil pump if so equipped or be towed to port.
32
LUBRICATION AND MAINTENANCE INSTRUCTIONS
INDEX
Air Induction and Exhaust ................... 62 Fuel Specifications ........................ 35

Restrictions ............................. 67
Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . 67 Fuel System .............................. 56
Fuel Injection Pumps ..................... 60
Air Starting Motor .......................... 47 Install Fuel Injection Valve ................ 60
Remove Fuel Injection Valve .............. 59
Coolant Specifications ...................... 35

General Maintenance Instructions ............ 36
Cooling System ........................... 50 Generator Storage . . . . . . . . . . . . . . . . . . . . . . . . . 75
Electrical System .......................... 69 Lubrication Instructions ...................... 36

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Booster Batteries, Connect . . . . . . . . . . . . . . . . 70 Lubrication and Maintenance Chart ........... 38
Booster Batteries, Disconnect ............. 71 Lubrication Procedures ................... 38
Charge Rate ............................ 70 Maintenance Instructions ................. 39
Charging the Battery ..................... 70
Glow Plugs ............................. 74
Lubrication Specifications ................... 34
;I,.
Installing Battery ........................ 70
Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Marine Transmission . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Crankcase ......................... 41

Power Coupling System .................... 48
Engine Oil Viscosity ........................ 34
Engine Storage ............................ 75

Refill Capacities ........................... 34
Woodward PSG Governor ................... 47

!
33
LUBRICATION AND MAINTENANCE INSTRUCTIONS
LUBRICATION SPECIFICATIONS
Engine Oils (CD) Marine Transmission (7231)
Use oils that meet Engine Service Classification Use oils that meet Engine Service Classification
CD (MIL-L-2104C). CD (MIL-L-2104C).
The proper SAE grade of oil to select is determined
by the ambient temperature at which the engine is Lubricating Grease (MPG)
started and the maximum ambient temperature in Use Multipurpose-type Grease (MPG). Multipur-
which the engine will be operating. See chart for pose-type grease which contains 3% to 5% molyb-
recommended viscosity and temperature range. denum disulfide is -also acceptable and preferred.
To determine if the oil in the crankcase will flow NLGI No. 2 Grade is suitable for most temperatures.
in cold weather, remove the oil dipstick before Use NLGI No. 1 or No. 0 Grade for extremely low
starting. If the oil will flow off, the oil is fluid enough temperatures.
to circulate properly.
RECOMMENDED ENGINE OIL VISCOSITY
~STARTING) AMBIENT TEMPERATURES (OPERATING •

oc -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +43 +49
OF -10 o +10 +20 +3o +4o +5o +60 +10 +so +9o +100 +110 +120
RECOMMENDED
SAE
VISCOSITY
*SAE 40 is preferred for sustained operation above 90°F (32°CJ.
Air Starting Motor Oiler: Use SAE 1OW in all Marine Transmission: Use SAE 30 in all temperatures.
temperatures.
REFILL CAPACITIES
U.S. METRIC IMPERIAL
COMPARTMENT MEASURE MEASURE MEASURE
Engine Crankcase 36.5 gal. 138 litres 30 gal.
Marine Transmission (7231) 24 gal. 91 litres 20gal.
Cooling System 33.7 gal. 128 litres 28gal.
34
FUEL SPECIFICATIONS
Diesel Fuel
Sulphur Content: As sulphur content increases, the
Distillate fuels (those which conform to ASTM No. 1 crankcase oil change periods should be reduced.
or No. 2 Fuel Oil or No. 1D or No. 2D Diesel Fuel Fuel containing 0.4% or less sulphur content, use
Oil Specifications) are the preferred fuels and pro- normal oil change periods. If the fuel contains 0.4%
vide proven maximum engine service life. to 1.0% sulphur, oil change periods should be re-
duced to one-half normal time. If the fuel contains
Some crude oils and blended fuels are regarded as more than 1.0% sulphur, oil change periods should
permissible and can be used with extra fuel filters be reduce to one-fourth normal time.
and adjusted oil change periods. However, this will
result in less than maximum engine service life.
Gravity: Gravity is the measurement of heat units
Contact your Caterpillar dealer regarding the in a certain amount of fuel. The heavier the fuel (the
Caterpillar SPECIAL INSTRUCTION titled "FUELS lower the number) the more heat units per volume.
FOR CATERPILLAR DIESEL ENGINES", FORM If a fuel with a higher AP.I. gravity is used the
SEHS7067, which specifies requirements for other power produced will be lower. Select fuels wit.h
preferred and permissible fuels. the lower AP.I. gravity reading.
Use distillate fuel which meets the following

requirements.
COOLANT SPECIFICATIONS
Water used in the jacket water cooling system must
be clean water that is low in scale forming minerals,
Cetane No: This is an indication of a fuel's ignition not softened water. The use of auxiliary water filters
quality. It should not be less than 35 for the Precom- is not recommended.
bustion Chambered engine and 40 for the Direct
Injection engine. For high altitude operation or When permanent antifreeze and water solutions are
cold weather starting, a higher cetane number is used in the cooling system, the solution should be
required. drained and replaced every 2000 hours, or yearly.
However, when additions of inhibitor are made

Water and Sediment: A good clean fuel will con- to the cooling system every 500 hours, or three
tain no more than 0.1 % sediment and water. Dirty months, it is not necessary to drain and refill yearly.
fuels lead to early filter plugging and, in addition, The antifreeze change period can then be extended
can result in the formation of gums and resins that to 4000 SERVICE HOURS or 2 YEARS.
will reduce filter and engine life.
Add enough Caterpillar Cooling System Inhibitor,
or equivalent, so that cooling system will have a
Pour Point: The pour point of the fuel has no effect 3% concentration of inhibitor.
on engine performance, as long as the fuel is fluid
enough to flow from the fuel tank to the engine. NOTE
1 pint (.5 litre) of Caterpillar Cooling System Inhibitor per 4 U.S.
The pour point of the fuel should be at least 10°F gallons (15 litres) of coolant will give the 3% concentration.
(6°C) below the lowest atmospheric temperature at
which the engine must start and operate. In ex- Follow instructions on cooling system inhibitor
tremely cold temperatures it may be necessary to container.
use No. 1 fuel oil or No. 1D diesel fuel.
This 3% concentration must be maintained in cool-
ing systems which are either filled with water or
Cloud Point: Cloud point is the temperature at which protected with ethylene glycol antifreeze mixture,
wax crystals become visible, which is generally regardless of antifreeze concentration.
above the pour point of the fuel. To keep the fuel
filter elements from plugging with wax crystals, For efficient and satisfactory corrosion protection
the cloud point should be no higher than the lowest for the cooling system, maintain the correct mixture
atmospheric temperature at which the engine must of cooling system inhibitor and antifreeze, and the
start. proper coolant level.
35
LUBRICATION INSTRUCTIONS
Regular service intervals, along with close daily It will show the first signs of excessive wear, mean-
visual inspection and the adherence to the instruc- ing a possible upcoming failure, thus allowing time
tions and schedules, will assure many hours of for a scheduled repair.
trouble-free service. If the necessary steps are It will warn maintenance personnel of improper (or
taken immediately on discovery of any abnormal lack of) maintenance, fuel dilution or presence of
condition, fewer forced stops and more economical coolant in oil.
operation will result.
It is particularly helpful in preventing wear due to
Caterpillar scheduled oil sampling is a program dirt entry from air cleaner or inlet piping.
which analyzes oil samples taken from an engine
at regular intervals (usually at oil change periods). Regular sampling is especially advantageous for
This oil analysis does not indicate the condition of new engines to establish wear trends from the
the oil;' but rather, it is a procedure to determine beginning. The results of the oil analysis are inter-
engine condition, at regular intervals, by analyzing preted by experienced, highly trained personnel.
lubricating oil for foreign and wear particles. Contact your authorized Caterpillar dealer for
detailed information.
The scheduled oil sampling will give the following
benefits: The Lubrication and Maintenance Chart is intended
as a guide. Adjustments in the schedule may be
It assures the owner that maintenance has been necessary, depending on conditions under which
performed. the engine is operating. A thorough analysis
should be made before adjusting the maintenance
schedule.
GENERAL MAINTENANCE INSTRUCTIONS

These instructions are a review of many items which are encountered in servicing and maintaining
engines.
Safety Cleanliness
Your safety and that of others is always the number The most important single item in assuring long
one consideration when servicing or maintaining engine life is to keep dirt out of vital working parts.
engines. Safety is a matter of thoroughly under- Precautions have been taken at the factory to safe-
standing the job to be done and the application of guard against this. Enclosed compartments, seals
good common sense. It is not just a matter of "do's" and filters have been provided to keep the supply of
and "don'ts". air, fuel, coolant and lubricants clean. It is important
that these safeguards be maintained.
Problem Analyzing
Whenever fuel, lubricating oil, coolant lines or air
In analyzing a system malfunction, use this system- lines are disconnected, clean the point of discon-
atic procedure to locate and correct the problem. nection as well as the adjacent area. As soon as the
1. Determine problem. disconnection is made, cap, plug or tape the line
2. List possible causes. and/or opening to prevent entry of foreign material.
The same recommendations for cleaning and cover-
3. Devise checks. ing apply when access covers or inspection plates
4. Conduct checks ·in logical order to determine are removed.
cause. Clean and inspect all parts. Be sure all passages
5. Consider remaining service life against cost of and holes are open. Cover all parts to keep them
parts and labor. clean. Be sure parts are clean when they are in-
6. Make necessary repair. stalled. Leave new parts in their containers until
ready for assembly.
7. Recheck.
36
Removal and Installation Locks
Use a hoist to remove heavy components. Lift the LockWashers, flat metal locks or cotter pins are
engine by using an adjustable lifting beam. All sup- used to lock nuts and bolts.
porting members (chains and cables) should be Flat metal locks must be installed properly to be
parallel to each other, and as near perpendicular as effective. Bend one end of the lock around the edge
possible to the top of the object being lifted. of the part. Bend the other end against one flat
When it is necessary to remove a component on surface of the nut or bolt head.
an angle, remember that the capacity of an eyebolt
diminishes as the angle between the supporting
members and the object becomes less than 90°.
Eyebolts and brackets should never be bend and
should only be under stress when a load is applied.
a
rr1~
Always install new locks in compartments which
house moving parts.
When installing lockwashers on housings made of
aluminum, use a flat washer between the lock-
washer and the housing.
Lines and Wires

Some applications require the use of lifting fixtures
to obtain proper balance, and to provide safe When removing or disconnecting a group of lines
handling. or wires, tag each one to assure proper assembly.
If a part resists removal, check to be certain all Shims
nuts and bolts have been removed and that an adja-
When shims are removed, tie them together and
cent part is not interfering.
identify them as to location. Keep shims clean
Disassembly And Assembly and flat until they are reinstalled.
When servicing or repairing the engine, complete Rust Preventive Compound
each step in turn. Do not partially assemble one part
Clean the rust preventive compound from all ma-
and start assembling some other part. Make all
chined surfaces of new parts before installing them.
adjustments as recommended. Always check the
job after it is completed to see nothing has been Gaskets
overlooked. Be sure the holes in the gaskets correspond with
Bolts And Bolt Torque the lubricant passages in the mating parts. If it is
necessary to make gaskets, select stock of the
Use bolts of the correct length. A bolt which to too
proper type and thickness. Be sure to cut holes in
long may "bottom" before the head is tight against
the right places. Blocking holes with gaskets can
the part it is to hold and result in failure. Also, the
cause serious damage.
threads in the assembly can also become damaged
when a "long" bolt is used. When removed, always install new cylinder head
and manifold gaskets, using recommended gasket
If a bolt is too short, there may not be enough
compound on head gaskets to allow uniform
threads to hold the part securely.
sealing.
Apply proper torque values to all bolts and nuts
when assembling Caterpillar equipment. When a Lubrication
specific torque value is required, the value is given Where applicable, fill the compartments of the
in the instructions. Tighten all other bolts and nuts components serviced with the amount, type and
for general usage or taperlock studs to the torque grade of lubricant recommended in the Lubrication
values given in the TORQUE SPECIFICATIONS. Instructions.
37
LUBRICATION AND MAINTENANCE CHART
The LUBRICATION AND MAINTENANCE CHART lists all serviceable items commonly installed on
this engine.
The maintenance time intervals are expressed in Service Meter Units. The Service Meter on the engine
shows the total number of units the engine has run. Use the Service Meter readings for determining
your maintenance schedules. Perform the maintenance at multiple intervals of the units shown. For
example, when the Service Meter shows "100" on the dial, all items listed under "EVERY 10 SERVICE
METER UNITS" should be serviced now for the tenth time, and all items under "EVERY 50
SERVICE METER UNITS" should be serviced for the second time, as well as all items under "EVERY
100 SERVICE METER UNITS".
SERVICE ITEM SERVICE METER UNITS
PAGE AS
LUBRICATION PROCEDURES NO. 10 50 125 250 500 1000 2000 YEAR REQ.
ENGINE CRANKCASE
Measure Oil Level 41

•
Draining Engine Oilm 41 •
Changing Oil Filters'2) 41
•
Cleaning the Breather 42
•
Duplex Oil System Filters'2) 43 •
MARINE TRANSMISSION
Measure Oil Level 45
•
Draining Oil 45
•
Changing Filter Element'3) 45 •
Cleaning Oil Strainer 46
•
Cleaning the Breather 46
•
Output Shaft Seal 46
•
WOODWARD PSG GOVERNOR
Synchronizing Motor 47
•
AIR STARTING MOTOR
Adjusting Oiler Feed 47

•
Emptying Oil Collector Jar 47
•
POWER COUPLING SYSTEM
Front Clutch Engaging Collar 48

•
Control Lever Shaft Bearings 48
•
Clutch Shaft Bearings 48
•
Clutch Adjustment 48
•
SR4 Generator Rear Bearing 49 •
"'This is the normal engine oil change interval to use when fuel sulphur content is 0.4% or less. When sulphur content is 0.4%
to 1.0%, reduce oil change interval to one-half the normal interval. When sulphur content is above 1.0%, reduce oil
change interval to one-fourth the normal interval.
""Regardless of Service Meter Units, change oil filters every 6 months.
(3)Change after first 50 Service Meter Units of operation for new or reconditioned units.
38
PAGE AS
MAINTENANCE INSTRUCTIONS NO. 10 50 125 250 500 1000 2000 YEAR REQ.
COOLING SYSTEM
Observe Coolant level 50 •

Adding Corrosion Inhibitor 50 •
Changing Antifreeze Solution 51
•
Cleaning the Cooling System 52
•
Water Temperature Regulators 53
•
Cooling System Hoses 53
•
Water Pump 54
•
Sea Water Pump 54
•
Zinc Rods 54 •
Sea Water Strainer 55
•
Aftercooler 55 •
FUEL SYSTEM
Primary Fuel Filter 56 •

Final Fuel Filterm 56 •
Priming the Fuel System 57 •
Duplex Fuel Filter System 57
•
Fuel Injection Systems 59 •
Testing Fuel Injection Valves 59
•
Governor(2) 61 •
Air-Fuel Ratio Control 61 •
Fuel Tank 61
•
<"Check fuel pressure gauge daily. Replace when fuel pressure gauge registers OUT or 20 PSI (140 kPa).
mcheck high and low idle RPM at the first oil change period and every 1250 Service Meter Units thereafter.
39
PAGE AS
MAINTENANCE INSTRUCTIONS NO. 10 50 125 250 500 1000 2000 YEAR REQ.
AIR INDUCTION AND EXHAUST SYSTEMS
Observe Air Cleaner Indicator 62
•
Changing Filter Elementm 62
•
Cleaning Filter Element 63
•
Engine Valve Lash 64
•
Bridge Adjustment 65
•
Valve Adjustment 66
•
Valve Rotation 67
•
Turbocharger
ELECTRICAL SYSTEM
68
•
Cleaning Batteries 69
•
Testing Electrolyte Solution 69 •
Cold Weather Maintenance 71
•
Starter 72 •
Pinon Clearance Adjustment 72
•
Charging System 72
•
Alternator Belt 73
•
Glow Plugs 74
•
"'The element can be cleaned three (3) times. Carefully inspect the element after each cleaning. If the engine is not equipped
with an air cleaner service indicator, inspect element every 250 Service Meter Units. If after servicing the air cleaner,
the exhaust smoke and/or loss of power continues, install a new element.
40
ENGINE CRANKCASE
The Lubrication and Maintanance Charts list the 1. Remove the crankcase oil drain plug.
normal oil change periods as determined by fuel 2. Allow the oil to drain.
sulphur content. (Make an initial oil and filter
change after the first 10 service meter units of 3. Clean and install the drain plug.
operation for reconditioned engines). OR, if a sump pump is used:
Measure Oil Level

CAUTION
Be sure to read the correct side of the dipstick.
The ADD and FULL levels are not the same when
checking the oil while stopped as when while idling.
1. Connect a suitable drain line and container to

the pump outlet (D.
2. With engine stopped and oil warm, open the
sump pump valve ® to which the engine crank-
case drain line is attached. The two marks on the
valve must be turned so that one mark points to
The dipstick is stamped on both sides of the blade.
One side is marked and to be read when measuring the pump, and the second mark points to the
the oil level with the ENGINE STOPPED. The other engine drain line.
side is marked and to be read with the ENGINE 3. Close the engine to marine transmission
RUNNING, at low idle with warm oil. Do not overfill. valve®·
4. Operate the sump pump handle until the
Draining Engine Oil crankcase is empty.
With engine stopped and oil warm: 5. Close valve® (to the engine crankcase drain
line).
Changing Oil Filters
& WARNING
1. Remove and discard two filters.
Do not allow hot oil to contact skin. Hot NOTE
oil can cause burns. If equipped with Duplex Oil Filter System refer to page 43 to
change oil filters.
41
Filling the Crankcase
2. Be sure all of old gaskets are removed. 1 . Remove cap assembly.

3. Clean the filter bases. 2. Fill the crankcase to the safe starting range on
the ENGINE STOPPED side of the dipstick. See
the Lubrication Specifications for refill capacity.
3. Start the engine and observe for oil leaks.
4. After the engine is warm, measure oil level with
the engine idling.
5. Add oil, if necessary, to maintain the oil level at
the FULL mark on the ENGINE RUNNING side of
the dipstick. Stop engine.·
4. Apply a film of clean engine oil to filter gaskets.

Cleaning the Breather
5. Install two new filters. Hand tighten filters an 1. Loosen hose clamp and breather assembly
additional 3/4 turn after the gaskets contact the clamp.
base. 2. Disconnect fumes disposal tube from breather
NOTE
assembly.
Use the rotation index marks, on the filter, as a guide for proper 3. Wash breather in clean non-flammable solvent.
tightening.
4. Allow to drain dry and then wipe assembly with
a clean dry cloth.
42
0
0
0
0
--~ 7
5. Observe condition of seal. Install new seal if

necessary. 1. Move selector lever to LH FLOW - RH OFF
6. Install breather assembly. Tighten breather position.
assembly clamp. NOTE
The crankcase oil is now flowing through the left filters only.
7. Connect fumes disposal tube to breather
assembly. Tighten hose clamp. 2. When the right oil pressure gauge @ shows
8. Perform steps 1 through 7 for breather assembly zero (0) pressure, remove the two filters @ on
on opposite side of engine.
the right side of the valve.
Duplex Oil Filter System 3. Make certain all of old gaskets are removed.
4. Clean filter bases thoroughly.
5. Apply a film of clean oil to the gaskets of the
new filters.
6. Install two new filters. Hand tighten filters an
additional 3/4 turn after the gaskets contact the
bases.
NOTE
Use the rotation index marks, on the filters, as a guide for proper
tightening.
Marine propulsion engines and marine auxiliary

electric set engines, which operate under the juris-
diction of international marine classification so-
cieties, are required to be equipped with a duplex
oil filter system.
The duplex oil filter system permits changing oil
filters without stopping the engine.
Changing Oil Filters - Duplex System
&, WARNING 7. Move selector lever to LH FLOW - RH FILL.

This will fill the two right filters with oil and bleed
Do not allow hot oil or components to out the air.
contact skin. Hot oil or components can
cause burns. 8. When the right oil pressure gauge @ indicator
stops rising and stabilizes ...
43
0
0
0
0
--
... move the selector lever to RH FLOW - LH OFF NOTE

position. With the selector lever in FLOW - BOTH position, engine oil
NOTE will flow through all the filters.
The crankcase oil is now flowing through the right filters only.
16. Observe for leaks.
9. When the left oil pressure gauge© shows zero
(0) pressure, remove the two filters @ on the left
side of the valve.
10. Make certain all of old gaskets are removed.
11. Clean filter bases thoroughly.
12. Apply a film of clean oil to the gaskets of the
new filters.
13. Install two new filters. Hand tighten filters an
additional 3/4 turn after the gaskets contact the
bases.
NOTE
Use the rotation index marks, on the filters, as a guide for proper
tightening.
0 0
--- \
14. Move selector lever to RH FLOW - LH FILL.

This will fill ·the two left filters with oil and bleed
out the air.
15. When the left oil pressure gauge © indicator
stops rising and stabilizes, move the selector lever
to FLOW - BOTH.
44
MARINE TRANSMISSION
a. Connect a drain line to the top outlet @ of
Measure Oil Level the sump pump.
:',.
l
Check the oil level with the engine warm, idling, and b. Be sure the valve @ on the engine oil pan
the clutch engaged.
line is closed. Marks on the valve must be turned
at right angles to the direction of the oil line.
c. Open the valve © on the transmission oil

line.
d. Operate the sump pump handle @ until the

oil is drained.
1. Maintain oil level at FULL mark on dipstick.
2. Remove breather. Add oil, if necessary, through

opening on top of cover. Refer to LUBRICATION
and MAINTENANCE CHART for the proper oil
to use.
Draining Oil and Changing Filter Element

3. Remove filter housing drain plug. Remove filter
housing cover and element.
1. Remove the marine transmission drain plug.
4. Loosen and remove the element retaining bolt

G) and plate ®·Discard the element @.
5. Wash the cover and the inside of the filter housing.

Clean and install the filter housing drain plug.
6. Inspect seal ©and cover gasket @. Install

new ones if necessary.
7. Place new filter element on stud. Install retaining

plate and bolt. Tighten bolt to torque of 10 + 2 lb. ft.
(14 + 3 N·m).
2. If a sump pump is used: 8. Install filter element and cover.
45
Cleaning Oil Strainer f
1. Remove strainer cover and washer. Remove and ... or the sump pump valve © to marine trans-
inspect the cover seal. Replace seal if damaged. mission oil drain line has been closed.
2. Fill to FULL mark on dipstick.
Cleaning The Breather
2. Remove screen and magnetic tube assembly.
3. Wash screen and tube assembly in clean non- 1. Remove and wash breather in clean non-flammable
flammable solvent. solvent. ~;_
2. Install clean breather.
4. Install tube assembly, screen and washer.
Output Shaft Seal
5. Clean and install the cover.
Filling The Marine Transmission

CAUTION
Be sure the sump pump valves are closed. Other-
wise, a transfer of oil during filling may occur and
damage could result.
1. Be sure the marine transmission drain plug has

been installed ...
Lubricate the output shaft seal, 1 fitting at top rear
of marine gear output shaft. Slowly rotate the output
shaft while lubricating the seal.
46
WOODWARD PSG GOVERNOR
Synchronizing Motor
Fill the oil cup on the synchronizing motor with a. Turn the needle valve (the uppermost knob on
clean engine oil (the same oil as used in the engine). the oiler) counterclockwise to increase the number
of drops per minute.
AIR STARTING MOTOR
The motor oiler lubricates the vanes of the starting b. Turn the needle valve clockwise to decrease
motor, with a fine oil mist, as the motor is operating. the number of drops per minute.
Emptying Oil Collector Jar

Empty the oil collector jar whenever the jar be-
comes half full.
CAUTION
Never allow the jar to become empty. The starting
motor will be damaged by lack of proper lubrication.
When the oil jar becomes half empty, remove the
oil filler plug and fill the jar with clean engine oil
{the same oil, as used in the engine).
The collector jar collects both the oil after it has
Adjusting Oiler Feed lubricated the starting motor vanes, and the moisture
If necessary, adjust the oiler to release approxi- condensation from the compressed air.
mately four drops of oil per minute into the starting CAUTION
motor air stream. Do not fill the oiler jar with this used oil.
1. Operate the engine long enough to have the oil
warm. Then stop the engine.
2. Move the governor control lever to the SHUT-
OFF po_sition.
3. Push in on the air start control and crank the
engine.
4. Count the drops of oil released per minute into
the air stream.
47
POWER COUPLING SYSTEM
Front Clutch Engaging Collar Clutch Adjustment

While engaging the clutch to pick up the load, check
the clutch adjustment. The clutch should engage
with a hard push and distinct snap. If engagement
is "soft", adjust the clutch.
Lubricate through 1 fitting - 2 strokes.
Control Lever Shaft Bearings

1. Stop the engine and remove the clutch inspec-
tion cover.
Lubricate through 2 fittings - 2 strokes.
Enclosed Clutch Shaft Bearings 2. Turn the clutch until the lock pin, engaged in the
locking ring, is visible.
3. Pull the lock pin out and rotate the locking ring
clockwise until the lock pin pops into the next
notch.
4. Test the clutch adjustment. If still too "soft",
rotate the ring to the next notch. If the adjustment
is too tight-turn the ring back one notch.
5. Install the cover.
Lubricate the shaft bearings through 2 fittings.
48
S R4 Generator Rear Bearing
3. Install a grease fitting in the upper hole.
4. Lubricate with grease until clean lubricant be-
gins to come out of lower hole.
5. Install a plug in the lower hole and wipe off
excess grease.
6. Remove grease fitting from the upper hole, start
engine and allow grease to expand from the uppEfr
hole.
7. Stop engine, install plug and wipe off excess
grease.
8. Install lower panels.
1. Remove lower panels, if necessary, from the
rear of the generator.
2. Remove two plugs.
49
COOLING SYSTEM
Observe Coolant Level Adding Corrosion Inhibitor
_& WARNING _& WARNING

Always observe coolant level with engine Remove filler cap slowly to relieve pres-
stopped and cool. sure. Steam can cause burns.
Remove filler cap slowly to relieve pres- Do not allow corrosion inhibitor to con-
sure. Steam can cause burns. tact skin or eyes.
CAUTION
Do not use Caterpillar Cooling System Inhibitor
with Dowtherm 209 coolant.
NOTE
1 pint (.5 litre) of Caterpillar Cooling System Inhibitor per 4 U.S.
gallons (15 litres) of coolant will give a 3% concentration.
First 500 SERVICE METER UNITS on a new or

reconditioned engine: Add enough Caterpillar
Cooling System Inhibitor, or equivalent, so that the
cooling system will have a 3% concentration of
inhibitor.
1. Remove filler cap slowly to relieve pressure. Add 8.5 pints (4 litres) of inhibitor to the cooling
Observe coolant level. system.
Every 500 SERVICE METER UNITS thereafter:

Add 2.5 pints (1.1 litres) of Caterpillar Cooling
System Inhibitor, or equivalent, to this cooling
system. This will maintain the required 3% concen-
tration of inhibitor.
1. Loosen filler cap slowly to relieve pressure.

Remove filler cap.
NOTE
It may be necessary to drain enough coolant to allow for the
addition of cooling system inhibitor.
2. Add Caterpillar Cooling System Inhibitor, or

equivalent. See above for amount of inhibitor
2. Maintain coolant level to the base of the fill pipe. to add.
CAUTION 3. Install filler cap.

Never add coolant to an overheated engine. To pre-
vent possible damage, allow engine to cool first.
NOTE
Make-up coolant should be with water free as possible from
scale forming minerals (not softened water) and a permanent
type antifreeze. Add Caterpillar Cooling System Inhibitor, or
equivalent, to maintain a 3% concentration of inhibitor.
3. Observe condition of filler cap gasket. Replace

cap if damaged.
NOTE
Observe condition of filler cap gasket whenever filler cap is
removed.
4. Install filler cap.
50
Changing Antifreeze Solution
,&.WARNING
Remove filler cap slowly to relieve pressure.

Steam can cause burns. Always observe
coolant level with engine stopped.
Do not allow corrosion inhibitor to con-
tact skin or eyes.
CAUTION
If the ambient temperature is expected to go below
freezing, the cooling system must be protected to
the lowest expected ambient temperature, or drained 2. Remove engine block drain plug. Allow coolant
completely. to drain.
When permanent antifreeze and water solutions are
used in the cooling system, the solution should be
drained and replaced every 2000 SERVICE METER
UNITS or 1 YEAR.
However, when additions of inhibitor are made to
the cooling system every 500 SERVICE METER
UNITS, it is not necessary to drain and refill Yearly.
Cooling system antifreeze change period can then
be extended to 4000 SERVICE METER UNITS or
2 YEARS.
Do not use Caterpillar Cooling System Inhibitor with
Dowtherm 209.
NOTE 3. Remove oil cooler drain plug and allow coolant

Add 1 pint (.5 IHre) Caterpillar Cooling System Inhibitor, or to drain.
equivalent, per 4 U.S. gallons (15 litres) of coolant to give a 3%
concentration of cooling system inhibitor to the cooling system. 4. Clean and install all drain plugs.
5. Mix antifreeze and water solution.
Draining and Filling the Cooling System CAUTION
To help avoid air locks, add coolant slowly, at 5 U.S.
gallons (19 litres) per minute or less, to within
1/2 inch (1 cm) of bottom of fill pipe.
6. Add antifreeze solution.
NOTE
Do not completely fill cooling system. Allow for addition of
Caterpillar Cooling System Inhibitor, or equivalent.
7. Add 8.5 pints (4 litres) of Caterpillar Cooling

System Inhibitor, or equivalent, so that the cooling
system will have 3% concentration of inhibitor.
8. Start and run engine with filler cap removed.
1. Loosen expansion tank filler cap, if equipped, Allow coolant to warm and level to stabilize. Add
slowly to relieve pressure, and remove cap. coolant if necessary. Stop engine.
51
9. Observe condition of filler cap gasket. Replace 6. Start and run engine for 1/2 hour. Stop engine
cap if gasket is damaged. and drain cleaning solution.
10. Install filler cap. 7. Flush system with clean water, until draining
water is clean. Do not run engine while flushing.
8. Clean and install all drain plugs. Fill cooling
Cleaning the Cooling System system with neutralizing solution.' 2'
9. Start and run engine for 10 minutes. Stop engine
& WARNING .. and drain neutralizing solution.
1O. Flush system with clean water, until draining
· Remove filler cap slowly to relieve pressure.
water is clean. Do not run engine while flushing.
Steam can cause burns. Always observe
coolant level with engine stopped. 11. Install all drain plugs.
Do not allow corrosion inhibitor to con- 12. Mix antifreeze and water solution.
tact skin or eyes.
CAUTION
CAUTION To help avoid air locks, add coolant slowly, at 5 U.S.
If the ambient temperature is expected to go below gallons (19 litres) per minute or less, to within
freezing, the cooling system must be protected to 1/2 inch (1 cm) of bottom of fill pipe.
the lowest expected ambient temperature, or drained
completely. NOTE
Do not completely fill cooling system. Allow tor addition of
Do not use Caterpillar Cooling System Inhibitor with Caterpillar Cooling System Inhibitor, or equivalent.
Dowtherm 209.
NOTE 13. Add antifreeze solution.
Add 1 pint (.5 litre) Caterpillar Cooling System Inhibitor, or
equivalent, per 4 U.S. gallons (15 litres) of coolant to give a 3% 14. Add 8.5 pints (4 litres) of Caterpillar Cooling
concentration of inhibitor to the cooling system. System Inhibitor, or equivalent, so that this cooling
system will have a 3% concentration of inhibitor.
1. Loosen expansion tank filler cap, if equipped, 15. Start and run engine with filler cap removed.
slowly to relieve pressure, and remove cap. Allow coolant to warm and level to stabilize.
2. Remove engine block drain plug. Allow coolant 16. Add coolant, if necessary, to bring coolant level
to drain. to bottom of fill pipe. Stop engine.
3. Remove oil cooler drain plug and allow coolant 17. Observe condition of filler cap gasket. Replace
to drain. cap if damaged.
4. Install all drain plugs. 18. Install filler cap.
"'2 lb. Sodium Bisulfate (NaHSO.) per 10 U.S. gallons (1 kilo-

gram per 40 litres) water.
' 21 1/2 lb. Sodium Carbonate Crystals (Na,COa • 10 H,O) per
10 U.S. gallons (250 grams per 40 litres) water.
Use all cleaning solutions with care.
NOTE
Most commercial cooling system cleaners may be used.
5. Fill cooling system with cleaning solution.m
52
'\.
Water Temperature Regulators

Exhaust gas leakage into the system causes similar
conditions. Exhaust gas can enter through internal
cracks or defective cylinder head gaskets.
Most of the causes can be checked by a visual
inspection, while others require disassembly or a
simple test.
Air in the cooling system is one cause of overheat.::
ing which can be located by a simple test known as
the "bottle test".
The equipment required to perform such a test
consists of a 1 pint (.5 litre) bottle, a bucket of water,
and a length of hose with an inside diameter large
1. Remove the water temperature regulator from
enough to fit over the end of the overflow pipe.
the engine.
2. Heat water in a pan until the temperature is Fill the cooling system to proper level. Wire open
197°F (92°C) (correct for opening the regulator). the relief valve in the filler cap. Install the cap
Move the water around in the pan to make it all and tighten. Install the rubber hose on the end of
be the same temperature. the overflow pipe.
3. Hang the regulator in the pan of water. The
regulator must be below the surface of the water
and it must be away from the sides and bottom of
the pan.
4. Keep water at the correct temperature, 197°F
(92°C), for 10 minutes.
5. Remove the regulator from the water. Imme-
diately make a measurement of the distance the
regulator is open.
6. If the regulator is open to a distance less than
.375 inch (9.53 mm), install a new regulator.
Cooling System Hoses

Inspect all cooling system hoses and line connec-
tions yearly. Replace hoses if they show signs of
cracking or leakage. Start the engine and operate it at high idle speed
for at least five minutes after the engine reaches,
Air, Gases and Steam In The System and maintains operating temperature.
Incomplete or improper filling is a major cause of Fill the bottle with water and put it, inverted, in the
air in the cooling system. Also, leaks in various bucket of water. After the temperature has sta-
components such as the aftercooler, and hoses bilized and all expansion air has vented out, place
allow air to enter the cooling system, especially on the loose end of the hose in the water filled bottle
the inlet side of the water pump. (which is inverted in the bucket of water).
Air in the system produces aeration and affects If it takes less than a minute to displace the water
water pump performance. The air bubbles insulate in the pint bottle, leakage into the cooling system
various parts of the engine from the coolant, and is excessive.
hot spots form. As the air bubbles circulate or break
up, coolant contacts the hot surfaces, creating Loose precombustion chambers, faulty precom-
steam. The steam pockets have basically the same bustion chamber seals, a loose cylinder head, or a
effect as air bubbles, accelerating the formation damaged head gasket are possible causes of air in
of more steam. Consequently, coolant discharges the cooling system. In any cause, the cause should
through the overflow. be corrected immediately.
53
Water Pump Zinc Rods (Salt Water Only)
The water pump circulates the coolant through the Zinc rods are inserted in the engine's cooling sys-
engine and back to the expansion tank. When tem to help prevent the corrosive action of salt (sea)
the temperature becomes high enough to open the water. The reaction of the zinc to the sea water
regulators, the coolant flow is to the keel cooling causes the rods to deteriorate.
system and back to the expansion tank. Therefore, the zinc rods must be inspected Every
Poor coolant circulation causes overheating A badly 50 Service Meter Units, and replaced when they
corroded, worn or loose water pump impeller re- have deteriorated.
duces coolant circulation and efficiency.
NOTE
The zinc rod plugs are painted red for easy identification.
Depending on the engine and attachments, their

location may be in the oil cooler heat exchanger
bonnet, sea water heat exchanger bonnet, after-
cooler lines, sea water pump or in the sea water
lines.
>s >ihli&'0<
:fo ,;,,mis ~
--~
f)ddk"&i% -
JS
% '
~
~
~
...
'"'
' ,
'fl
'
Every 2000 Service Meter Units inspect the water

pump and rebuild as necessary.
Sea Water Pump
Location of zinc rod on the Sea Water Pump

(Auxiliary) is in the outlet elbow.
When the engine is cooled by a heat exchanger

system, an auxiliary water pump is used to con-
stantly pump filtered sea water through the heat
exchanger.
Every 2000 Service Meter Units, inspect the sea Location of zinc rods on bonnet of marine gear
water pump. oil cooler.
54
1:
Inspecting Zinc Rods Aftercooler

1. Remove and observe condition of all zinc rods. Some engines are equipped with an aftercooler.
2. Tap the zinc rods lightly with a hammer. If a The aftercooler resembles a small radiator core.
rod has deteriorated, or flakes apart when tapped, Water from the engine cooling system passes
install a new zinc rod. through the core tubes. Engine inlet air is directed
through the core and around the tubes.
The temperature of the water is lower than the air,
therefore, the air is cooled as it leaves the after-
cooler, and becomes more dense as it enters the
intake manifold. Thus more air (oxygen) is available
for combustion, resulting in more fuel being burned
and more power produced.
NOTE
One degree increase in inlet air temperature increases exhaust
temperature approximately three degrees. Restrictions to either
coolant or air flow reduce aftercooler efficiency and seriously
affect the engine and cooling system.
When engine is being rebuilt, remove the aftercooler and clean
core, water and air passages.
1. Unscrew or drill the existing rod from the plug
base.
2. Install a new rod in the plug base.
3. Install the plug.
Sea Water Strainer

Inspect the sea water strainer for plugging. The
interval for inspection and cleaning will depend
upon the depth and cleanliness of the water.
To clean the strainer perform the steps outlined
below:
1. Remove the sea water strainer.
2. Clear the screen of dirt and debris.
3. Install the strainer.
4. Fill strainer and pump suction line with water
to prime the system.
55
FUEL SYSTEM
Fuel Filtering System Final Fuel Filters
As the element of either the primary fuel filter or the

final fuel filter element becomes clogged, lack of
horsepower will be noticed and the position of the
indicator, on the color coded fuel pressure gauge,
will move from the NORMAL (Green) range to the
OUT (Red) range. (Less than 20 PSI (140 kPa) on
the calibrated fuel pressure gauge.)
Every 250 Service Meter Units or when the indi-
cator shows in the OUT (Red) range, the primary
fuel filter element (if equipped) should be removed
and washed. If the indicator still shows OUT (Red)
range, the final filter element should be replaced
with a new element.
Stop engine and close fuel supply valve (if equipped).
Primary Fuel Filter - If Equipped 1. Remove and discard fuel filters @.

2. Clean the filter mounting base@. Make certain
all of old gaskets are removed.
Stop engine and close the fuel supply valve (if

equipped). 3. Lubricate the gaskets of the new filters with
1. Loosen the nut on filter cover and remove case. clean diesel fuel.
2. Remove element from the case.
3. Wash element and case in clean non-flammable
solvent.
4. Dry element and case.
5. Clean filter mounting base and inspect gasket.
Use new gasket if necessary.
6. Install clean element in case. Install case.
7. Open fuel supply valve.
8. Start engine and observe for leakage.
9. Stop engine.
CAUTION
Do not pour fuel into new filter elements before
installing.
4. Tighten the filters by hand until the gaskets con-

tact the base, then tighten 1/2 to 3/4 turn more.
56
NOTE
Use the rotation index marks, on the filter, as a guide for proper
tightening.
5. Open fuel supply valve.
6. Prime the fuel system. See Priming the Fuel

System, outlined below.
7. Start engine and observe for leaks.
8. Stop engine.
With engine running, loosen fuel line nuts, one at

a time, several times in succession. Allow fuel to
run until free of bubbles.
Tighten fuel line nuts to 30 ± 5 lb. ft. (40 + 7 N·m).
NOTE
If engine is stopped, use the priming pump to supply fuel to the
fuel injection lines.
Priming the Fuel System Duplex Fuel Filter System

1. Be sure the fuel supply valve is open. The duplex fuel filter system will allow continuous
operation while the fuel filters are being changed.
2. Move the governor shaft to shut off position.
3. Unlock the fuel priming pump. When the fuel pressure gauge indicator is in the
OUT (Red) range (less than 20 PSI, 140 kPa, on
4. Operate priming pump until increased resistance calibrated gauge) the fuel filters must be changed.
is felt.
To change the filters, perform the following steps:
5. Lock fuel priming pump.
6. Start the engine. If engine fails to start or does
not run smoothly, bleed the fuel injection lines.
57
1. Move lever to the RUN R position. ... move the lever to RUN BOTH. Observe for
leaks.
NOTE
Fuel will flow through the right filters only.
2. When the left fuel pressure gauge indicator

is to the extreme left edge of the OUT (Red)
range, remove and discard the left fuel filter.
3. Clean the filter mounting base. Be certain all
of old gasket is removed.
4. Lubricate the new filter gasket with clean
diesel fuel.
5. Install new filter. Hand tighten filter an addi-
tional 1/2 to 3/4 turn after filter gasket contacts
base.
8. Move lever to RUN L.
NOTE NOTE
Use the rotation index marks, on the filter, as a guide for proper Fuel will flow through the left filter only.
tightening.
9. When the right fuel pressure gauge indicator
is to the extreme left edge of the OUT (Red)
6. Move lever to RUN R - FILL L. This will fill range, remove and discard the right fuel filters.
the left filter with fuel and bleed out the air. 10. Perform steps 3 through 5.
7. When the left fuel pressure gauge indicator is 11. Move lever to RUN L - FILL R. This will
in the NORMAL (Green) ... fill the right filters with fuel and bleed out the air.
58
for precombustion chamber engines, except that
a fuel valve adapter wrench is used to remove the
injection valve adapter.
The seal on the adapter should be inspected and
replaced if damaged.
Testing Fuel Injection Valves

Whenever a fuel injection valve is suspected of
causing trouble, test all fuel injection valves.
12. When the right fuel pressure gauge indicator

is in the NORMAL (Green) range move the lever
to RUN BOTH.
NOTE
Fuel will again be flowing through all filters.
13. Observe for leaks.
i··
Fuel Injection Systems l.
When improper fuel injection is affecting engine

operation, check to determine the cause. The most To test the injection valves, loosen the fuel injection
likely cause is dirt or water in the fuel. Drain the line nut at the fuel injection pumps, one at a time,
sediment from the fuel tank. while the engine is running.
Check the fuel pressure gauge as mentioned in the When a nut is loosened and the exhaust smoking
topic, Fuel Filtering System. Replace the filters if is completely or partially eliminated and the irregu-
necessary. Then prime the fuel system. If the fuel larity in running is not affected, this valve is prob-
system is air bound, prime the system.· ably defective, and a new one should be installed
If the engine is running irregularly, smoking, or in thatcylinderto determine if the valve is defective.
knocking, a fuel injection valve may not be func- Never wire brush or scrape a fuel injection nozzle
tioning properly. assembly. This will damage the finely machined
orifice. Your authorized dealer has the proper tools
for cleaning and testing fuel injection valves.
Precombustion Chamber and Direct Remove Fuel Injection Valve

Injection Systems Clean dirt from around the valve cover and remove
The fuel systems of direct injection and precom- it, before removing an injection valve. Clean the
bustion chamber engines are essentially the same. dirt from around the valve and line connections.
The absence of the precombustion chamber Disconnect the lead wire from the glow plugs. (If so
requires a different fuel injection valve and an equipped.)
adapter.
Clean dirt from around the valve cover and remove
Externally the direct injection fuel nozzle is longer it, before removing an injection valve. Disconnect
in length than the precombustion chamber nozzle. the lead wire from the glow plugs. (If so equipped.)
Nozzle testing and replacement procedure for Clean the dirt from around the valve and line
direct injection engines is the same as illustrated connections.
59
Loosen the fuel injection line at the valve housing 2. Insert the nozzle assembly and valve body as
and disconnect it from the valve. Install plugs a unit into the precombustion chamber opening.
immediately, to prevent dirt from entering the Turning the body in a clockwise direction and at
fuel injection line. the same time pressing down will assure align-
ment of the serrations.
Remove the valve retainer nut and lift out the fuel 3. Install the retainer nut and tighten to 55 + 5
injection nozzle assembly and body as a unit. lb. ft. (75 + 7 N·m) to prevent leaks between the
NOTE nozzle assembly and the nozzle assembly seats.
To make removal of fuel valves easier, an extractor, Caterpillar CAUTION
part number 5P6229, is available from your Caterpillar engine
dealer.
Do not overtighten. Use torque wrench.
If the fuel injection valve will not be installed imme- 4. Connect the fuel injection · 1ine and tighten
diately, caps should be put on the valve body to the nuts to 30 ± 5 lb. ft. (40 + 7 N·m).
prevent dirt entering the valve assembly.
Installing Fuel Injection Valves Fuel Injection Pumps

Before installation of a fuel injection valve, be sure To check or replace fuel injection pumps, to check
the wrench is clean. Install the fuel injection valve fuel injection timing, injection pump lifter setting,
in the following manner: fuel rack setting and governor adjustments, it is
1. Screw the valve body into the fuel injection recommended the work be performed by an
valve nozzle assembly only finger tight. authorized Caterpillar engine dealer.
60
Governor Fuel Supply
Check the engine high and low idle RPM at the It is important to buy clean fuel and keep it clean.
first oil change period and every 1,250 Service Even the best fuel can be rendered unsatisfactory
Meter Units thereafter. by improper storage facilities or careless handHng.
To check, remove tachometer drive cable (or cap) Reduce the number of times the fuel must be
from the tachometer drive housing, located in front handled, to help prevent contamination of the fuel.
of the fuel pump housing. See the information plate Fuel should be delivered by the distributor to
on the engine for engine RPM. This adjustment storage tanks and then pumped from the storage
should be made by an authorized dealer. tank to the engine's fuel tank, to reduce handling
to a minimum.
NOTE
Tachometers on the panel are usually not sufficiently accurate to
check high and low idle engine RPM. Always use an accurately
calibrated tachometer. Fuel Tank
Open the drain cock and drain off any sediment or
water in the fuel tank before starting the engine.
Air-Fuel Ratio Control Remove the strainer in the fuel tank filler opening
The air-fuel ratio control is a device to control the regularly and clean it.
smoke emission of an engine during its operation, Fill the fuel tank at the end of the day. The incoming
when low inlet manifold pressure exists. fuel will drive out the moisture-laden air and prevent
condensation.
AIR-FUEL RATIO CONTROL In temperatures below freezing, drain the tank
shortly after the engine has stopped, to prevent
water freezing in the bottom of the tank and other
low points in the system.
GOVERNOR
Low inlet manifold pressure occurs during operation

at low torque output. During this type of opera-
tion the air-fuel ratio control regulates the maximum
fuel injected into each cylinder. If the controlling
diaphragm within the air-fuel ratio control is rup-
tured, the fuel system will be restricted.
Slow engine response and low power may indicate
a need for adjustment or repair. Authorized dealers
are equipped to perform these services properly.
61
Air Cleaners Changing Filter Element

Service and inspect the air cleaner at regular inter- CAUTION
vals, to ensure proper cleaning of the engine inlet Service the air cleaner only with the engine stopped.
air. The service interval will vary with the weather
and working conditions.
Arrange the exhaust and air cleaner inlet pipes

so that exhaust and/or oil fumes do not enter the
engine air cleaner, in order to obtain maximum
service life of the elements.
Any dirt allowed to enter the engine, accelerates

wear throughout the engine. Replace any seal or
gaskets whose condition is questionable. If the
sealing ends of the filter element or the element
pleats are damaged, replace the element.
Extra filter elements should be kept on hand for

1. Remove the air cleaner cover and element.
replacement as a spare for use in the air cleaner
while an element that has been removed is being
cleaned.
The air service cleaner indicator is connected to

the air inlet pipe between the air cleaner and the
turbocharger. It contains a red piston, which rises
with restriction to the air flow.
2. Cover the air inlet opening to prevent foreign

objects from entering the engine.
3. Clean the inside of the air cleaner cover and
body.
4. Clean or discard the used element.
5. Inspect the clean replacement element for
damage.
When the entire piston is visible, it indicates a need
NOTE
for air cleaner service. The piston will remain in this
Have a replacement element on hand to install and use while
position until reset. After servicing the air cleaner, cleaning the dirty element. This will save you down time.
depress the plunger in the bottom of the indicator
to reset the piston. 6. Remove the covering from the air inlet opening.
CAUTION
Excessive engine exhaust smoke and/or loss of Install the air cleaner element as shown in the illus-
power may indicate the need for servicing the air tration. Note the arrows indicating air flow on the
cleaner. side of the element, and the position of the gasket.
62
1. Hold the nozzle at least one inch (25 mm) from
the element and at a slight angle.
fl
7. Install the clean element.

8. Install the air cleaner cover.
2. Direct the air stream along the complete length

of each pleat on the CLEANEST side of the ele-
ment. (This will loosen the dirt from the dirtier side}.
3. Blow the loosened dirt from the DIRTY side.
4. Direct the air from the CLEAN side through to
the DIRTY side to remove dirt blown into the
pleating.
Cleaning Elements With Water
1. Use clean water at no more than 40 PSI (275

kPa). Do not use a nozzle.
2. Direct the water along the complete length of
9. Reset the service indicator button by pushing
each pleat on the CLEAN side of the element.
on the reset button.
10. Clean the used air cleaner element. See the
instructions for cleaning.
Cleaning Filter Elements
&, WARNING
When using pressure air, wear safety
face shield and protective clothing. Use
30 PSI (205 kPaJ maximum pressure air
far cleaning purposes.
3. Direct water along the complete length of each
pleat on the DIRTY side of the el~ment.
Cleaning Elements With Pressure Air
4. Rinse the CLEAN side of the element.
Use clean, dry air with maximum pressure not to
exceed 30 PSI (205 kPa). 5. Allow the cleaned element to dry thoroughly.
63
Cleaning Elements With Detergent Locating Top Center Compression
1. Wash both sides of the element in a solution of Position For No. 1 Piston
warm water and non-sudsing detergent.
2. Rinse the CLEANEST side of the element with
clean water 40 PSI (275 kPa) maximum along with
the complete length of each pleat.
3. Rinse the opposite side of the element along the
complete length of each pleat.
4. Rinse the first side again to remove all loosened
dirt.
5. Allow the cleaned element to dry thoroughly.
Inspecting Cleaned Elements

Place a lighted electric bulb behind the cleaned,
dried filter element. Carefully check each pleat for
rips or tears. If a rip or tear is found, discard that LOCATING TOP CENTER (LEFT SIDE OF ENGINE)
element. 1. Timing bolt. 2. Timing bolt location. 3. Storage location.
Storing Cleaned Elements

1. Wrap usable elements in heavy paper.
2. Store the wrapped element in a dry, clean place.
Engine Valve Lash
There are two rocker arms @, per cylinder. One
rocker arm for the two exhaust valves and one rocker
arm for the two inlet valves.
Each pair of valves is connected by a bridge @,
which is actuated by the rocker arm.
The valves in each pair are adjusted simultaneously
by the adjusting screw©, in the rocker arm. LOCATING TOP CENTER (RIGHT SIDE OF ENGINE)
4. Timing bolt location.
Each bridge is adjusted by adjusting screw@.
The timing bolt (1) is kept in storage at location (3),
and can be installed in either the left side of the
engine at location (2) or in the right side of the engine
at location (4).
NOTE
The engine is viewed from the flywheel end when direction of
crankshaft rotation is given.
• 0
INTAKE
.015" (0.38mm)
EXHAUST
.030" (0. 76mm)
11--9--7--5--3--. 1
@@@@@@
FUEL
®@CD©©CD
INJECTIO~
PUMPS
With engine stopped and cold, inspect and adjust

©®©©®@
the bridges and valves.
Clean the dirt from the base of the valve covers and
/90\/90\/90\/90\/90\/90\
~9)~QJ'-.QJ'-.QJ'-_Q)"->_Q)
then remove covers. 12--10-- 8 - - 6 - - 4 - - 2
64
Remove the play from the timing gears by turning 1. Put engine oil on the bridge dowel in the cylind~r
the flywheel clockwise (opposite the direction of head and in the bore in the bridge.
engine rotation) approximately 30 degrees. 2. Install the bridge with the. adjustment screw to-
ward the exhaust manifold.
Next, turn the flywheel counterclockwise until the 3. Back off adjusting screw several turns (counter-
hole in the flywheel is in alignment with the timing clockwise), making sure it is not in contact with
bolt. When the timing bolt can be turned freely in the valve stem.
the threaded hole in the flywheel, the No. 1 piston 4. Firmly press straight down on the rocker arm
is on top center. above point of contact with bridge.
To determine if No. 1 piston is on the compression 5. Turn the adjusting screw clockwise until contact
stroke, look at the valves of No. 1 cylinder. The is made with the valve stem. Turn the adjusting
valves should be closed. You should be able to screw an additional 30° (one-twelfth turn).
move the rocker arms up and down with your hand.
If No. 1 piston is not on the compression stroke, turn
the flywheel 360° and install the timing bolt.
If the hole in the flywheel is turned beyond the
hole in the flywheel housing, turn the flywheel
back (clockwise) a minimum of 30° beyond the
hole in the flywheel, before turning counterclock-
wise toward the hole again.
Bridge Adjustment
Adjustment of the bridge will be necessary only
after grinding the valves or other reconditioning of
6. Hold the adjusting screw in this position and
the cylinder head is done. Make an adjustment to
tighten the locknut to 22 + 3 lb. ft. (30 ± 4 N·m).
the bridge using the following procedure.
7. Put engine oil at the point where the rocker
arm makes contact with the bridge.
NOTE
Valves must be fully closed. NOTE
If bridge was removed perform steps 1 and 2 that follow. If bridge After checking the bridge adjustment, make the valve lash ·
was not removed, proceed to step 3. adjustment.
65
Valve Adjustment
0
INTAKE
.015" (0.38mm)
•
EXHAUST
.030" 10.76mm)
2. With No. 1 piston at top center (TC) on com-
pression, and timing bolt installed, measure lash
11--9--7--5--3--1
between the bridge and rocker arm on exhaust
@@@@@@ valves for cylinders 1, 4, 5, 8, 9 and 12, and

inlet valves for cylinders 1, 3, 4, 6, 7 and 12.
3. Adjust valves if necessary.
®@<D©©©
FUEL
INJECTION
4. To adjust, loosen valve adjusting locknut and
PUMPS
©@©©@©
turn adjusting screw © to allow feeler gauge,
of proper size, to pass between top of bridge and
<:8)<:8)(3(3(3(3
12--10-- 8 - - 6 - - 4 - - 2
valve rocker arm.
VALVE CLEARANCE SETTING:

ENGINE STOPPED AND COLD
Exhaust........................... .030 in. (0.76 mm)
Intake.. . . . . . . . . . . . . . . . . . . . . . . . . . . .015 in. (0.38 mm)
VALVE ADJUSTING SEQUENCE

NO. 1 PISTON TDC NO. 11 PISTON TDC
ON COMPRESSION ON COMPRESSION
VALVES ADJUST VALVES ADJUST VALVES
EXHAUST 1-4-5-8-9-12 2-3-6-7-10-11
INTAKE 1-3-4-6-7-12 2-5-8-9-10-11
5. Tighten adjusting screw locknut to 22 + 3
lb. ft. (30 ± 4 N·m) and measure lash. Readjust
if necessary.
6. Remove the timing bolt and turn the flywheel
To make an adjustment to the valve clearance, turn 360° in the direction of engine rotation. This will
the adjustment screw in the rocker arm. It is not put No. 11 piston at top center (TC) on the com-
necessary to change the bridge adjustment for pression stroke. Install the timing bolt in the
normal valve clearance adjustments. Adjust valve flywheel.
clearance by using the following procedure:
7. Make an adjustment to the valve clearance on
exhaust valves for cylinders 2, 3, 6, 7, 10 and 11,
inlet valves for cylinders 2, 5, 8, 9, 10, and 11.
8. Tighten the valve adjusting screw locknut to
22 ± 3 lb. ft. (30 + 4 N·m), and measure lash.
Readjust if necessary.
9. Remove the timing bolt from the flywheel
when all valve clearances are correct.
1O. Remove engine turning tool.
11. Install cover, bolts and plug.
1. Put No. 1 piston at top center (TC} on the

compression stroke. REFER TO TOP CENTER
COMPRESSION POSITION FOR NO. 1 PISTON.
66
Valve Rotation
After checking valve lash, and before the valve Restriction of the exhaust system (back pressure)
covers are installed, check the valves for rotation. is measured with a differential pressure gauge or
1. Mark a line on each valve retainer. manometer.
2. Start the engine and run at low idle.
3. Watch the line mark on each valve retainer.
Each valve retainer should turn slightly each time
the valve closes. If they do not turn, contact your
Caterpillar dealer.
This pressure difference is measured between the

turbocharger outlet and ambient air, and should
be no more than 27 inches (685 mm) of water. An
exhaust pressure tap is provided in the turbo-
charger outlet elbow. This check should be per-
4. Stop the engine. formed with the engine at operating temperature
5; Inspect the valve cover gaskets and install new and developing full rated power.
ones if necessary.
6. Install rocker arm covers. Tighten bolts to 18 + 5
lb. ft. (24 + 7 N·m). Crankcase Pressure
Excessive crankcase pressure can be a result of
combustion gas leaking past broken or damaged
Restriction Of Air Inlet pistons, worn cylinder liner walls and/or piston
And Exhaust rings.
,,·.,·
If an air inlet restriction is suspected in the piping This condition will usually be accompanied by irreg- f.
or air filter element, check with a differential pres- ular engine operation and excess fumes from crank-
sure gauge or manometer. case breather opening. This pressure can cause
the breather element to become restricted in an
unusually short time. In addition, it can cause en-
gine oil to leak past gaskets and seals that would
function properly under normal conditions.
Remove the air cleaner service indicator and con-

nect differential pressure gauge or manometer in
the service indicator connection. The air inlet piping
or air cleaner should not restrict air flow more than
30 inches (762 mm) of water difference in pressure.
67
Turbocharger
End Clearance Radial Clearance
Every 4000 Service Meter Units or when any un- Radial clearance can also be checked with a dial
usual sound or vibration in the turbocharger is indicator. Remove the oil return line from the turbo-
noticed, a quick check of bearing condition can be charger. Attach a dial indicator with an extension
made without disassembling the turbocharger. This indicator point long enough to contact the shaft
can be done by removing the piping from the turbo- through the oil return hole. Make sure the contact
charger and inspecting the compressor impeller, point is centered on the shaft (highest indicator
turbine wheel and compressor cover. reading).
Rotate the compressor and turbine wheel assembly
by hand and feel for excess end play and radial
clearance. The rotating assembly should rotate
freely with no rubbing or binding. If there is any
indication of the impeller rubbing the compressor
cover or the turbine wheel rubbing the turbine
housing, recondition the turbocharger or replace
with a new or rebuilt one.
Raise both ends of the shaft all the way, then push
down in the opposite direction.
NOTE
Care must be taken not to cock (tilt) the shaft, or a false reading
will be obtained.
Total movement of the indicator should be between

.005 in. (0.13 mm) and .009 in. (0.23 mm). If radial
clearance exceeds .009 in. (0.23 mm) or minimum
Check end clearance with a dial indicator. Attach
clearance is under .005 in. (0.13 mm) the turbo-
a dial indicator with the indicator point on the end
charger should be disassembled and the bearings
of the shaft. Move the shaft from one end to the
checked.
other end, making note of the total indicator reading.
If a turbocharger fails, try to determine and elimi-
End play should be between .003 in. (0.076 mm) nate failure before installing a rebuild or new turbo-
and .008 in. (0.203 mm). If end play exceeds .008 in. charger. When installing a new or rebuilt turbocharger
(0.203 mm) rebuild or replace the turbocharger. always perform the following steps:
End clearance less than .003 in. (0.076 mm) could
1. Inspect the air induction and exhaust system
indicate build-up on the turbine wheel and the
for the presence of foreign particles which could
turbocharger should be disassembled for cleaning
result in repeat failure.
and inspection.
2. Change the air cleaner element.
A more reliable check of bearing condition can be 3. Change the oil filters.
made only when the turbocharger is disassembled
and the bearings, shaft journal and housing bore 4. Drain and refill the engine crankcase.
diameters can actually be measured. This service 5. Pre-lubricate the replacement turbocharger by
is available from an authorized dealer. filling the center housing with oil.
68
\,,
ELECTRICAL SYSTEM
In the event of failure or improper operation of the 1. Mix a weak solution of baking soda and water.
electrical system, it is essential to check the entire Apply solution with a soft bristle brush.
system, as a defect in one component can cause 2. Thoroughly rinse the battery and battery tray
damage to another. with clean water.
Many electrical system problems are caused by 3. Apply grease to the battery cable clamps and
loose or corroded connections. Keep connections terminals and to all threads.
clean and tight. Make sure the wiring insulation is
in satisfactory condition. Testing The Electrolyte Solution
Most of the electrical system testing can be per- The general condition of a battery is determined by
formed while the components are on the engine. the specific gravity of the electrolyte solution at
If a malfunction is found, the component must be 80°F (27°C). If the electrolyte level is too low to
removed for further testing, repair or replacement. allow taking a hydrometer reading, add make-up
water to the correct level, charge the battery 2 to 4
NOTE hours and then take a reading.
Some installations may have electrical components not
furnished by Caterpillar. Consult the manufacturer's manual
for maintenance procedure. &, WARNING
Do not smoke when observing battery
Batteries electrolyte level. Batteries give off
Every 250 Service Meter Units check the elec- flammable fumes.
trolyte level of each cell and the general condition
of the battery. Maintain the electrolyte level to the
base of each filler opening. The make-up water must
be one of the following (in order of preference):
1. Distilled water.
2. Odorless, tasteless drinking water.
3. Iron free water.
&, WARNING
To prevent possible injury, do not add
electrolyte solution or acid.
1. Insert the hydrometer into a cell. Fill the hydro-

meter barrel while holding it vertically. The float
Cleaning Batteries must not drag on the wall of the barrel.
2. Read the hydrometer:
1.265 = 100% charged
1.225 = 75% charged
1.190 = 50% charged
1.155 = 25% charged
1.120 = Discharged
1.000 = Water
3. Test each cell in the same manner.
4. If there is more than .050 (50 gravity points)
variation between the highest and lowest reading,
the battery should be replaced.
5. Adjust the readings to 80°F (27°C).
CAUTION a. For every 10°F (5.5°C) the electrolyte tem-
Do not allow cleaning solution to get into the perature is above 80°F ( 27°C), add .004 (4 gravity
batteries. points) to the specific gravity readings.
69
Charging the Battery
b. For every 10°F (5.5°C) the electrolyte tem-
perature is below 80°F (27°C), subtract .004 & WARNING
(4 gravity points) from the specific gravity
To prevent personal injury, do not smoke
reading. in, or near, the area where batteries are
The corrected reading is of most importance during being charged. Batteries give off flammable
cold weather when the hydrometer reading is fumes.
always corrected to a lower specific gravity reading.
A low reading signifies the battery has less avail- 1. Connect positive ( +) charger clamp to positive
able power to crank the engine and that booster ( +) battery terminal.
batteries may be required. 2. Connect negative(-) charger clamp to negative
Installing Battery (-) battery terminal.
1. Be sure the battery tray is clean and free of 3. Connect charger power cord to proper outlet.
foreign objects.
CAUTION
2. Be sure terminal posts and cable clamps are If battery is charged too rapidly, the battery will be
clean. damaged.
3. Place the battery in the tray. Tighten the hold
down clamps evenly until the battery is snug. Do 4. Allow battery to charge slowly.
not overtighten. 5. After the battery is charged, disconnect charger
power cord from outlet; remove charger clamp from
negative(-) battery terminal; remove charger
& WARNING clamp from positive ( +) battery terminal.
Always connect the terminal which is
electrically "hot" first to prevent arcing. Connecting Booster Batteries
CAUTION
Keep red and black terminals from touching each
4. Connect the "hot" terminal first. Be sure the top other.
of the cable terminal is pushed down even with +
the top of the terminal post. Tighten the clamp
firmly. ·
5. Connect the "grounded" terminal last. Be sure
the top of the cable terminal is pushed down even
with the top of the terminal post. Tighten the clamp
firmly.
6. Apply a thin coating of grease over the cable
clamps, terminals and hold down fasteners.
Checking Charge Rate 24 VOLT BOOST STARTING, USING 12 VOLT

1. After starting the engine, the ammeter indicator BATTERIES.
should be to the right ( +) side of zero, but should
not be to the extreme right (pegged).
2. After the engine has been running, the indicator
should be just to the right ( +) side of zero.
CAUTION
If the indicator remains far to the right of zero, or
remains to the left of zero with an increase of en-
gine speed, have the electrical charging system
checked.
24 VOLT BOOST STARTING, USING 6 VOLT
BATTERIES.
70
1. Disconnect black jumper cable from engine.
2. Disconnect red jumper cable from engine.
3. Disconnect black cable from booster battery.
4. Disconnect red cable from booster battery.
NOTE
Charge booster batteries to full capacity with a battery charger.
30 VOLT BOOST STARTING, USING 6 VOLT Cold Weather Battery Maintenance

BATTERIES.
After adding make-up water, charge the battery.
1. Remove all filler caps from all batteries before
The added water could dilute the electrolyte
connecting jumper cables.
enough, without charging, to cause freezing and
permanent damage to the battery.
&, WARNING Keep the batteries fully charged either by the
charging system on the engine or by using a battery
Attach ground cable last, and remove charger.
first, to prevent sparks from occurring Keep the battery warm when not in use. In an un-
near the battery, which could cause heated area, the heat from a lighted electric bulb
battery vapors to explode. is usually sufficient.
CAUTION CAUTION
When using jumper cables be sure to connect in Use only a shop cord with a heavy wire guard around
parallel: POSITIVE ( +) to POSITIVE ( +) and the light bulb.
NEGATIVE (-) to NEGATIVE ( -). Do not lay a lighted bulb directly on a battery case;
the heat at point of contact could melt the battery
2. Connect red cable to positive ( +) terminal of case.
booster battery. Do not lay cloth or flammable material in contact
3. Connect black cable to negative ( - ) terminal of with a lighted bulb; charring and/or fire could result.
booster battery.
4. Connect opposite end of red cable to positive If a battery is not going to be used for a period of
( +) terminal of engine battery. time, be sure the battery is fully charged while
stored.
5. Connect opposite end of black cable to the
starter ground terminal, if equipped with a starter Use a battery hydrometer to check the specific
to ground cable. gravity of each cell. Use a battery charger to keep
the battery charged.
CAUTION
If the starter is not grounded with a cable, attach Voltage Test (After Load)
the black cable terminal to a good ground on the A load test should be made on a battery that dis-
engine or engine frame, at a point away from, and charges very rapidly when in use.
below the battery.
To do this, apply a resistance of three times the
6. Start engine. ampere/hour rating of the battery across the battery
main terminals. Allow the resistance to discharge
the battery for 15 seconds, and immediately test the
Disconnecting Booster Batteries battery voltage.
Disconnect jumper cables as soon as engine starts. A 6 volt battery in good condition will test 4.5 volts;
a 12 volt battery in good condition will test 9 volts
and a 24 volt battery will test 18 volts.
71
Starter
No periodic service is indicated for the electric 2. Connect a battery, of the same voltage as the
starter brushes between general reconditioning solenoid, to the terminal marked SW.
periods. The brushes should only need to be in-
3. Connect the other side of battery to ground
spected after removal of the starter from the engine,
terminal or to solenoid frame.
and removal of the commutator end bearing frame.
4. MOMENTARILY flash a jumper wire from the
The starter commutator end and drive end bearings
solenoid terminal marked MOTOR to the frame
are equipped with wicks for lubrication purposes.
or ground terminal. The pinion will shift into
The wicks should be saturated with oil whenever the
cranking position and will remain there until
electric starter is removed or disassembled.
the battery is disconnected.
It is suggested that cleaning and reconditioning
5. Push pinion towards commutator end to elimi-
be entrusted to your authorized dealer.
nate free movement.
Pinion Clearance Adjustment 6. Pinion clearance should be .36 in. (9.14 mm).
Whenever a solenoid is installed, the pinion clear-

ance should be adjusted. The adjustment should be
made with the starting motor removed from the
engine.
7. Adjust clearance by removing plug and turn-

ing shaft nut.
Bench test and adjust the pinion clearance at in- Charging System - Alternator Regulator
stallation of solenoid as follows:
The alternator regulator is adjusted at the factory
1. Install the solenoid without connecting a lead for average operating conditions. However it may
from the MOTOR terminal on the solenoid to the require readjustment to provide the proper charging
starter motor. rate for the particular operating conditions.
The condition and state of charge of the battery at
each regular inspection will indicate if the alternator
is operating efficiently.
An adjustment is necessary when the battery is
usually in a low state of charge, or an excessive
amount of water must be added to the battery
(more than one ounce of water per cell per week
or per every 50 Service Meter Units).
When the alternator is either charging the battery
too much or not enough, an adjustment can be
made to the alternator charging rate.
72
Alternator Regulator (Delco-Remy)
Earlier
To make an adjustment to the voltage output re- 3. Remove the rubber sealant covering the
move the plug from the cover. Turn the internal adjustment screw.
adjustment screw one or two notches to change
the alternator charging rate. 4. Turn the adjustment screw counterclockwise
to lower the voltage setting. Turn the adjustment
Later screw clockwise to raise the voltage setting.
The voltage adjustment screw for the later alter- 5. Put a coating of rubber sealant (Caterpillar
nator is located under the end plate. part number 3S6252) on the adjustment screw.
To make an adjustment to the voltage output use
the following procedure:
CAUTION
1. Remove the end plate. Be sure that the wire G) is not on the pins (D. The
pins can make a hole in the insulation of the wire.
6. Install the cover and the end plate.
Alternator Regulator (Motorola)

To make an adjustment to the voltage output, re-
move the cap G) from the alternator regulator and
change the regulator adjustment with a screwdriver.
2. Remove the cover.
73
To check belt-apply 25 lbs. (11.5 kg) force midway
between the pulleys. Correctly adjusted belt will
deflect 1/2 in. (12.5 mm) to 3/4 in. (19 mm) for the
initial check. Maintain later adjustments at 7/8 in.
(23 mm).
The adjustment screw under the cap (1) has five

positions (number 1 is the last postion clockwise).
To increase the voltage turn the adjustment screw
clockwise.
Adjustment To adjust, loosen mounting bolts and locknut on

1 2 3 4 5 adjusting bolt. Turn adjusting nuts to increase or
Position
decrease alternator belt tension. Tighten locknut
Regulator 29.25 28.6 28.0 27.4 26.8 and mounting bolts.
Voltage ± .35 ±.3 +.3 ±.3 +.3
Glow Plugs - Testing
Never operate the charging alternator with an open
circuit between it and battery.
1. Disconnect the wire lead from the glow plug
terminal on the HEAT-START switch.
CAUTION
Do not attempt to polarize the alternator. If an 2. Install an ammeter, in series, between the dis-
accidental connection is made between the ( +) connected lead and the terminal on the switch.
terminal and either one of the ( F) terminals on 3. Push in, turn and hold HEAT-START switch to
the alternator, the rectifiers in the alternator and HEAT. Observe ammeter.
the transistors in the regulator will be damaged. NOTE
The ampere draw of one glow plug multiplied by the number
Alternator Belt of engine cylinders will be the total ampere draw of the glow
plugs in the engine.
Every 250 Service Meter Units examine the drive
belt for wear or damage and replace if necessary. 4. Pull the lead from a glow plug and observe the
ammeter reading.
Adjustment NOTE
If the ammeter reading decreases, the glow plug is working
Check the new belt after the first 10 Service Meter properly.
Units and every 250 Service Meter Units thereafter. If the ammeter reading did not change, the glow plug was not
drawing current when connected and, may be defective.
5. Release the HEAT-START switch.

6. Connect lead removed to glow plug.
7. Test each glow plug individually.
Replacing
1. Disconnect the lead from the glow plug and
unscrew the glow plug from the precombustion
chamber.
2. Apply antiseizure compound to the thread of a
new glow plug and install glow plug.
3. Tighten glow plug to 10 + 2 lb. ft. (14 ± 3 N·m).
74
STORAGE
Engine Storage Generator Storage

If the engine is not started for several weeks, the When a generator is stored for any length of time
lubricating oil drains from the cylinder walls and moisture condenses in the windings. Minimize the
piston rings. This will result in shorter engine life. condensation by providing a dry storage space.
To prevent excessive engine wear: To remove moisture caused by high humidity or
1. Be sure all lubrication points mentioned in the dampness, dry the generator by one of the following
LUBRICATION AND MAINTENANCE CHART methods:
are serviced. 1. Place the generator in an oven and bake at a
2. Once a week, start and run the engine until temperature not above 185°F (85°C) for four
it is thoroughly warm. (For unattended automatic hours.
start-stop systems, the engine may have an exer-
ciser for this purpose.) CAUTION
If an oven is used for drying, use a forced air type
3. Stop the engine, perform required servicing.
rather than a radiant type. Radiant ovens can cause
4. Check the cooling system for adequate pro- localized overheating.
tection if freezing temperatures can be expected.
CAUTION 2. Enclose the generator and heating lamps in
If the ambient temperature is expected to go below canvas to raise the temperature. Leave an open-
freezing, the cooling system must be protected to ing in the top for the moisture to escape.
the lowest expected ambient temperature, or 3. Pass a low voltage current through the wind-
drained completely. ings to raise the temperature of the windings to
If it will be impossible to start the engine every 185°F (85°C).
week, see your Caterpillar dealer for instructions If there is a possibility the insulation resistance
for preparing your engine for extended storage has deteriorated to a dangerously low level, contact
periods. your Caterpillar Dealer.
75
NOTES
. ~
. ~
.. ,:
-,.
SYSTEMS OPERATION
INDEX
Air Induction and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Aftercooled Engines .................................................. 90
Cooling System ......................................................... 81

Heat Exchanger Cooled System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Keel Cooled System .................................................. 81
Electrical System ....................................................... 91
Fuel System .......................................................... . 83

Air-Fuel Ratio Control ............................................... . 86
Direct Injection System .............................................. . 85
Fuel Injection Pump ................................................. . 83
Governor Operation ................................................. . 85
Precombustion Chamber Injection System .............................. . 84
General Information .................................................... . 79
Generator ............................................................ . 94
Parallel Operation ................................................... . 97
Single Unit Operation ............................................... . 96
Voltage Connections ................................................ . 95
Lubrication System ..................................................... . 87
77
SYSTEMS OPERATION
Maximum engine service depends a great deal on a personnel, with a thorough understanding of the
good maintenance schedule, performed by trained systems.
PISTON
PISTON COOLING
OIL JETS
CRANKSHAFT
78
GENERAL INFORMATION
This engine is offered either with direct injection The engine coolant is circulated through the engine
(DI) or with precombustion chamber (PC). Iden- by a water pump. The coolant goes to the oil cooler
tification of the combustion system used is attached first, then to the engine block and head. One .regu-
to the fuel injection pump housing. lator for each cylinder bank restricts coolant flow
Individual injection pumps, one for each cylinder, for quick engine warm-up and then opens to allow
meter and pump fuel under high pressure to an free circulation of coolant after operating tempera-
injection valve for each cylinder. An automatic ture has been reached.
timing device advances or retards fuel injection. Lubrication of the engine is accomplished by a
The faster the engine turns, the earlier the injection gear-type pump. The pump provides full pressure
takes place (before a piston reaches top center on lubrication to the engine internal and external parts.
the compression stroke). The lubricating oil is both cooled and filtered. By-
A governor controls the fuel injection pump out- pass valves provide unrestricted flow of lubrication
put to maintain the engine RPM selected by the oil to the engine parts when oil viscosity is high
operator. or, if either the oil cooler or the oil filter elements
The air-fuel ratio control located on the governor becomes clogged.
restricts the movement of the fuel rack, allowing Your engine may be equipped with direct electric
only the proper amount of fuel to be injected into (24 or 32 volt) or air starting.
the cylinders during acceleration, to minimize
exhaust smoke.
Inlet air, filtered by an air cleaner, is compressed
by a turbocharger before entering the engine cyl-
inders. The turbocharger is driven by the engine
exhaust.
There are four in-head valves (two inlet and two
exhaust) for each cylinder. The camshaft, actuates
the rocker arms and valves through mechanical
lifters and push rods.
INFORMATION PLATE LOCATION

ENGINE SPECIFICATIONS
Configuration 65°V-12
Bore 5.4 in (137 mm)
Stroke 6 in (152 mm)
Firing Order 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12
Displacement 1649 cu in (27.0 litres) NOTE
Specifications were current at time ot printing;
Weight (net dry- however, due to continuous testing and
Approximate) 4100 lb (1860 kg) improvements, specifications may change
without notice.
Crankcase Lube Capacity 36.5 gal ( 138 litres)
Engine Rotation
(Viewed from flywheel) Counterclockwise
Horsepower Rating and RPM - On Information Plate
79
Engine Horsepower Ratings Standby Rating
There are two general' housepower ratings for Horsepower settings for this rating allows the en-
marine engines and two for generator set engines. gine to start upon demand and immediately supply
They are: intermittent or continuous; standby or rated horsepower with no engine warm-up.
prime. These ratings are the recommended engine
horsepower settings based upon load requirements Full Load Operation
and type of operation. The governor control lever should remain in the
CAUTION
full governed position while powering full load.
Horsepower settings should only be made by autho- Reduced Load Operation
rized personnel.
If the load varies, or is cyclic, the governor will
Continuous and Prime Ratings adjust the engine speed as required. If a slower
Horsepower settings for these two ratings allow constant speed is desired, move the governor con-
the engine to operate a constant load at full speed trol lever to desired speed position.
for long periods of time without shortening engine CAUTION
life. Be sure to increase engine speed before increasing
the load.
Intermittent Rating
Horsepower settings for this rating allows the en- No Load Operation
gine to be operated at full load and speed for pe- If the load is temporarily removed, engine speed
riods up to an hour, followed by an equal time of may be reduced. However, the engine may be oper-
operation at reduced load and speed. ated at high idle without causing shortened engine
life.
CAUTION CAUTION
If an engine is set for an intermittent rating and Never operate a generator set below 2/3 full load
is operated for long periods of time at constant RPM: Overheating and possible damage could occur
full load, the engine life will be shortened. to the generator below this RPM.
80
COOLING SYSTEM
Keel Cooled System When the temperature becomes high enough to

With this cooling system an expansion tank is used. open the regulators, the water flow is directed out
The water flows through the engine and back to the through a connection to the keel cooling sy~tem,
expansion tank in a constant cycle. then back to the expansion tank. The engine water
is cooled as it flows through the keel circuit by the
sea water flowing past the cooling pipes on the keel.
14
EXAMPLE OF KEEL COOLER SYSTEM
1. Water cooled turbocharger. 2. Aftercooler. 3. Inlet connection for engine water return {either side). 4. Vent lines. 5. Water
temperature regulator {both sides). 6. Connection for auxiliary tank. 7. Outlet connection for engine water. 8. Engine water pump.
9. Keel cooler. 10. Duplex filter. 11. Bypass filter. 12. Oil cooler bypass or marine gear cooler. 13. Oil cooler. 14. Water cooled
exhaust manifold.
81
Heat Exchanger Cooled System When the engine reaches a temperature high
enough to open the regulators, the water flow is
When the engine is cooled by the heat exchanger
directed around the heat exchanger core and then
system, an extra (auxiliary) water pump is used
back to the expansion tank. The cooled water in
to constantly pump filtered water from another
the expansion tank is circulated back through the
source (either sea water or storage water) through
engine by the engine water pump.
the heat exchanger.
EXAMPLE OF HEAT EXCHANGER COOLED SYSTEM
1. Water cooled turbocharger. 2. Attercooler. 3. Inlet connection for engine water return (either side). 4. Vent lines 5. Temperature
regulator (both sides). 6. Auxiliary water pump. 7. Outlet connection for engine water (either side). 8. Engine water pump.
9. Duplex filter. 10. Heat exchanger. 11. Oil cooler bypass or marine gear cooler. 12. Engine oil cooler. 13. Water cooled
exhaust manifold.
82
FUEL SYSTEM
The fuel system consists of the transfer pump, fuel return line from the fuel injection pump fuel mani-
filter, injection pumps, injection lines and nozzles, fold to the fuel tank provides a constant bypass
fuel return line and governor. of fuel.
The fuel transfer pump is gear driven by the fuel A priming pump is mounted on the fuel filter base
injection pump camshaft. The transfer pump draws to remove the air in the system after servicing the
fuel from the supply tank through a junction block filter, or whenever air is allowed to enter the system.
and primary filter, then delivers it to a filter, and to Air is vented by loosening the fuel line nuts one at
a manifold in the fuel injection pump housing, which a time and operating the pump until a stream of fuel,
supplies fuel to the individual injection pumps. A without air bubbles, flows from the fuel lines.
3
2
1
( 1. FUEL INLET
·~ 2. DAMPER
5 3. FUEL RETURN ORIFICE
4. FUEL INJECTION PUMP
5. FUEL RETURN
6. JUNCTION BLOCK
6 7. FUEL TANK
8. FUEL SUPPLY LINE
9. PRIMARY FUEL FILTER
10. FUEL TRANSFER PUMP
11. PRESSURE RELIEF VALVE
12. PRIMING BYPASS VALVE
13. PRIMING PUMP
7 14. SECONDARY FUEL FILTER
15. FUEL PRESSURE GAUGE
9
11
14
Fuel Injection Pump Operation

Fuel enters the fuel injection pump housing from
the fuel filter, through an external line, and enters
the fuel injection pump through the inlet port. The
injection pump plungers and lifters are lifted by the
cam lobes, on the fuel system's own camshaft, and PUMP
!,..,' PLUNGER
always make a full stroke. The lifters are held
against the cam lobes by springs. Each pump mea-
sures the proper amount of fuel to be injected into
its respective cylinder and delivers it to the fuel
injection nozzle.
The amount of the fuel pumped per stroke is varied
by turning the plunger in the barrel. The plunger
is turned by the governor action through the gear
segmented sliding fuel rack, which turns the
gear segment on the bottom of the pump plunger.
The position of the scroll on the plunger determines
the amount of fuel injected into the cylinder.
83
CAMSHAFT
PRECOMBUSTION
CHAMBER
Precombustion Chamber Injection

System
Fuel, under high pressure from the injection pumps,
is transferred through the injection lines to the
injection valves. As high pressure fuel enters the
nozzle assembly, the check valve within the nozzle
opens and permits the fuel to spray into the pre-
combustion chamber where it mixes with the
compressed air.
The precombustion chamber serves several pur-
poses: It provides an effective chamber for the
mixing of fuel and air before it enters the cylinder
for final combustion, thus permitting the use of a
wider range of fuels. It also permits the use of easy
replaceable fuel nozzles, and the use of glow plugs
to assist in cold weather starting.
These engines can be started in low temperatures
with the use of glow plugs, which provide heat for
initial ignition of the fuel in the precombus_tion
chamber.
The nozzle assembly requires no adjustment, and PRECOMBUSTION CHAMBER
can be quickly removed and replaced. VALVE ASSEMBLY
84
Direct Injection System
Fuel is directed to the injection valves from the Pressurized lubricating oil, directed through pas-
transfer pump and through the injection pumps sages in the fuel injection pump housing, enters a
and injection valves in much the same manner as passage in the governor cylinder. The oil encircles
for the precombustion chamber engines. A direct a sleeve within the cylinder. The oil is then directed
injection adapter takes the place of the precom- through a passage in the piston where it contacts
bustion chamber. The nozzle tip projects from the the valve.
head directly into the cylinder. Atomized fuel is
sprayed through small orifices directly into the
cylinder.
LEVER CONNECTED TO
RACKS THROUGH LINKAGE
When the engine load increases, the revolving

DIRECT INJECTION weights slow down. The weights move toward each
VALVE ASSEMBLY other and allow the governor spring to move the
valve downward.
As the valve moves, an oil passage around the
piston opens to pressure oil. The oil flows through
Governor Operation
GOVERNOR
The full range governor operates over the entire SPRING
speed range. The governor automatically compen-
sates for load to maintain a constant speed.
Use of a hydro-mechancial governor results in quick
engine response.
When the engine is operating, the balance between
the centrifugal force of revolving weights and the CYLINDER
force of the control lever on the compressed spring,
controls the movement of a valve and indirectly,
the fuel rack. The valve directs pressure oil to either
side of a rack positioning piston. Depending on the
position of the valve, the rack is moved to increase
or decrease the fuel to the engine to compensate
for load variation.
85
this passage and fills the chamber behind the Air-Fuel Ratio Control
piston. The pressure forces the piston and pin
A air-fuel ratio control is a device which resists the
downward. This downward movement will move the
movements of the fuel rack during acceleration. It
racks to increase the amount of fuel to the engine.
coordinates the movements of the fuel rack (amount
Engine RPM increases until the revolving weights of fuel) with the amount of air available in the inlet
move out enough to balance the force of the manifold.
governor spring.
A diaphragm in the control senses boost pressure
When the engine load decreases, the revolving from the inlet manifold, positioning the control
weights move out and the toes on the weights move valve which meters oil to the piston, limiting the
the valve up. This closes the pressure oil passage fuel rack travel.
above the piston, allowing the oil above the piston
After the engine is started, the fuel ratio control
to flow through a drain passage at the top of the
requires a combination of sufficient inlet manifold .)
piston that was opened.
boost and oil pressure to operate the control. When
the control is in operation and the governor control
is moved to the increase engine speed position, the
rack will move until the movement is stopped by
the stop collar. However, the increase in engine
speed is enough to increase the inlet manifold
boost, allowing the engine speed to increase. The
boost and control work together until the rack is not
restricted, thus allowing full engine RPM.
PISTON
PRESSURE OIL
At the same time, the pressure oil is trapped below

the piston, and the piston and pin are forced up-
ward. This moves the racks to decrease the fuel to
the engine and the engine slows down. When the
force of the revolving weights balances the gov-
ernor spring force, the RPM of the engine will be
the same as before.
86
LUBRICATION SYSTEM
The lubrication system consists of a sump (oil forces it through the oil cooler, oil filters and then
pan), oil pump, oil cooler and oil filters. The engine into the oil manifold. Oil flows through connecting
contains an oil manifold and oil passages to direct passages to lubricate the engine components. A
lubricant to the various components. regulating valve in the pump body controls the
The oil pump draws lubricant from the sump and maximum pressure of the oil from the pump.
~::t:::~E:::::~ 8
15
16
17 18
19--
20 22
FLOW OF OIL (ENGINE WARM)
1. To rocker arm shaft. 2. To flywheel housing. 3. Plug (on rear left) or to air-fuel ratio control on front right). 4. To fuel injection
pump housing and governor. 5. Rocker arm shaft. 6. To valve lifters. 7. Camshaft bearings. 8. Piston cooling tubes. 9. To timing
gear housing. 10. Bore for idler gear shaft. 11. Oil manifold. 12. Main bearings. 13. Oil supply line to turbocharger. 14. Oil supply
line to manifold in cylinder block. 15. Bypass valve for oil filter. 16. Bypass valve for oil cooler. 17. Turbocharger. 18. Engine oil
cooler. 19. Oil return line from turbocharger. 20. Oil filter. 21. Oil pan. 22. Oil pump.
87
When the engine is first started, the lubricating oil in Oil manifolds, cast into the cylinder block, directs
the pan is cold (thick). This oil will not flow imme- lubricant to the main bearings, valve rocker arm
diately through the oil cooler and oil filter. This cold shafts, camshaft journals, and the camshaft idler
oil forces bypass valves, in the oil cooler and oil (drive) gears.
filter base, to open which allows an unrestricted Oil spray orifices in the cylinder block spray oil on
· oil flow through the engine. the underside of the pistons. This cools the pistons
and provides lubricant for the piston pins, cylinder
walls and piston rings.
OIL MANIFOLD The connecting rod bearings receive oil through
passages in the crankshaft, between the main bear-
ing journals and connecting rod journals.
When the engine is warm and running at rated
speed, the oil pressure gauge should register in
the "operating range". A lower pressure reading
is normal at idling speeds.
SUMP
OIL FLOW (COLD START) FROM

TURBOCHARGER
As oil temperature increases, oil viscosity and pres-

sure decrease and the oil filter bypass valve closes.
Then, only filtered oil is delivered to the engine
components. Oil temperature continues to increase
and the oil cooler bypass valve closes. Oil then
flows through the oil cooler and oil filter before
reaching the engine components. SUMP
Contaminated or restricted oil filter elements will
not prevent lubricating oil from being delivered OIL FLOW (NORMAL OPERATION)
to the engine components. These conditions will
cause the oil filter bypass valve to open, allowing
oil to bypass the element.
88
The air induction system provides air to the en- RPM of the impeller increases the quantity of inlet
gine, while the exhaust system discharges exhaust air. As the turbocharger provides additional inlet a,ir,
gases. Engine horsepower and efficiency will be more fuel can be burned; hence more horsepower
reduced if either the air inlet or exhaust becomes derived from the engine.
restricted. Good maintenance practice cannot be The turbocharger bearings are pressure-lubricated
over emphasized. by engine oil.
This engine has an exhaust driven turbocharger to The high idle speed and the rack setting are not the
provide compacted air to the cylinders. same for all altitudes. Maximum turbocharger speed
The exhaust gases are directed through the blades is determined by the rack setting, the high idle
of a turbine wheel, causing the turbine wheel and a speed setting and the altitude at which the engine
compressor wheel to rotate. is operated.
Filtered inlet air from the air cleaner is drawn through CAUTION
the air inlet of the compressor housing by the rotating If the high idle speed or the rack setting is greater
compressor wheel. than specified for the altitude at which the engine
The air is forced through the aftercooler (if equipped) is operated, damage to engine or turbocharger parts
to the inlet manifold of the engine and is compressed can result.
by action of the compressor impeller. The fuel pump rack has been set by qualified per-
When engine load increases, more fuel is injected sonnel for a particular engine application. The
into the engine cylinders. The increased volume of governor housing and turbocharger are sealed to
exhaust gas causes the turbocharger turbine wheel prevent unqualified personnel from tampering with
and compressor impeller to rotate faster. The higher the adjustments.
AFTERCOOLER
TURBINE WHEEL
89
AIR INLET 'R~~.....,
AIR O U T L E T ~
OIL OUTLET PORT
EXHAUST INLET
CROSS SECTION OF THE TURBOCHARGER
The engine can be operated at a lower altitude than service is necessary. The service indicator will
specified without danger of engine damage. In this prevent unnecessary filter changes and reduce
situation the engine will not perform at maximum maintenance costs, while ensuring proper engine
efficiency. When operated at a higher altitude than operation.
for which it is set, the rack setting and high idle
speed setting must be changed.
The principle cause of fouled valves, damaged
bearings, worn piston rings and cylinder liners is
foreign matter introduced into the engine cylinders.
Therefore it is necessary to incorporate an efficient Aftercooled Engines
air cleaner in the system. The intake ducts should Coolant from the engine passes through the core
be located away from areas of dust and exhaust tubes and the compressed air is directed around
concentration. The importance of cleaning or filter- the tubes of the aftercooler. Since the tempera-
ing the air entering the engine cannot be over- ture of the coolant is lower than the compressed
emphasized. air, the air is cooled as it leaves the aftercooler.
Caterpillar recommends the use of an air cleaner This means more air (oxygen) is available for com-
service indicator for dry-type air cleaners. A red bustion, therefore more fuel is burned and more
cylinder in the indicator will remain visible when power is produced.
90
ELECTRICAL SYSTEM
The electrical system is a combination of two The starting circuit operates only when the disco11-
separate electric circuits: the charging circuit and nect switch is ON and the start switch is actuated.
starting circuit. The battery (batteries), disconnect
switch, circuit breaker, ammeter, cables and wires The direct electric starting circuit may include a
from the battery are common in each of the circuits. glow plug for each engine cylinder. Glow plugs are
heating elements in the precombustion chambers
CAUTION which promote fuel ignition. They are used when
The disconnect switch must be ON to allow the elec- the engine is started in low temperatures.
trical system to function. Some charging circuit com-
ponents will be damaged if the engine is operated
with the disconnect switch OFF. CAUTION
The electricity producing (charging) unit is an alter- Never operate the alternator without the battery
nator which is operated by the engine. An alternator in the circuit.
regulator in the circuit senses the state of charge in Making or breaking an alternator connection with a
the battery and regulates the alternator output to heavy load on the circuit will sometimes result in
keep the battery fully charged. regulator damage.
91
F + BATTERY
000000
REGULATOR
ALTERNATOR CHARGING CIRCUIT

(NEGATIVE GROUND SYSTEM ILLUSTRATED)
The electric starting motor incorporates a solenoid. An overrunning clutch protects the starting motor
The solenoid engages the pinion with the ring gear from being over-speeded when the engine starts.
on the engine flywheel, when energized. The pinion Releasing the start-switch disengages the pinion
always engages before the starting motor is energized. from the ring gear on the flywheel.
COMMUTATOR
24 VOLT STARTING MOTOR
92
A solenoid is a magnetic switch that utilizes low
current to close a high current circuit. The solenoid
has an electromagnet with a movable core. There
are contacts on the end of the core. The contacts
are held open by a spring that pushes the core away
from the magnetic center of the coil. Low current
will energize the coil and form a magnetic field. The
magnetic field draws the core to the center of the
coil and the contacts close.
CORE
TO COMPONENT
93
GENERATOR
Voltage Setting Generator lead Numbering

Generators are set at the factory for the voltage Each coil lead is marked according to the following
and type of operation specified. Voltage control diagram.
initial adjustment instructions are located inside Numbering is clockwise from the top and from the
the generator exciter and regulator access cover. outside in. Terminal TO is the neutral lead on all high
These instructions are for adjusting the generator voltage connections with T4, T5, and T6 to form the
output to nameplate ratings. neutral terminal. The standard generator diagram
Generator Serial Number and the terminal connections are on the nameplate
of each generator.
The engine serial number is stamped on the engine
information plate and on a plate on the left side
of the block toward the rear. The generator serial
number is stamped on the generator nameplate and
on the right side of the generator frame forward of
the terminal box. Requests for information and
orders for parts should be accompanied by the
engine and generator serial numbers.
1. The group of numbers before the letters indi-
TB'
cates generator frame size. T6 T5
2. The letter B is the symbol for Caterpillar Stati- ,__,.) T9
cally Regulated Brushless Excited Generators. T3_,...t'- T2
3. The next letter indicates the voltage rating of
the generator as follows:
Three Phase Neutral Connections
L 120-240 volts . . . . . . . . . . . . . . . . . . . . . . 60 Hz or Single Units
125-250 volts-Single Phase ........... 60 Hz Three Wire: In a three phase, three wire system,
S 208-416 volts . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz the generator should be grounded according to
H 240-480 volts ...................... 60 Hz or local wiring codes. In some cases, however, it is
200-400 volts . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz undesirable to ground the neutral wire. For ex-
G 300-600 volts . . . . . . . . . . . . . . . . . . . . . . 60 Hz or ample, on boats a grounded neutral may increase
240-480 volts . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz the problem of electrolysis. In applications where
4. The last group of numbers are the actual serial definite measures are taken to prevent grounds to
numbers of the generator in the frame size and the load leads, an ungrounded neutral can be used.
voltage rating. Always use the complete serial Be sure to check your local wiring codes. Generator
number. frames should always be grounded.
Four Wire: In a three phase, four wire system, the
neutral wire should be grounded according to local
wiring codes. For only single unit operation, there
Voltage should never be a need for a disconnect switch, or
according device, in the neutral line.
to chart
Multiple Units
Indicates generator Operation of multiple generators in parallel, having
frame size Serial No. all neutrals grounded, may result in current circu-
within this lating through the neutral connections. To eliminate
frame size and the possibility of circulating currents, ground the
voltage rating neutral of only one generator. If multiple generators
are alternated on line, a single pole single throw
\ 1/
50 BH 101
knife switch can be installed in the neutral ground
circuit of each generator, so all but one neutral
ground circuit can be opened. Be sure one neutral
ground circuit is closed. The switch should be
capable of carrying 1.5 times the rated line current
of the generator.
94
Voltage Connections i
T3 To• T3, Ts, AND Tg ARE NOT
USED FOR SINGLE PHASE
SERVICE AND EAQ-1 SHOULD
Three Phase BE CAREFULLY INSULATED.
The connections for both high and low voltage are

given in the following chart. T9
The terminals must be connected securely and in-

sulated with a good quality electrical tape.
REQUIRED CONNECT LINE

VOLTAGE LEADS TO NEUTRAL CONNECT
3 Phase T4 to T7
High Voltage T1 T2 T3 TO T5 to TB
T6 to T9 Three phase (230-460V, 115-230V*, 240-460V,
T4, T5, T6 125-250V and 208-416V) generators can be con-
3 Phase T4, T5, T6
Low Voltage T1 & T7 T2&TB T3 & T9
& TO
& TO nected for two or three wire service at either vol-
For Neutral
tage. When generators are connected for three wire
service both high and low voltages may be obtained
Single Phase Current From A simultaneously without reconnecting the leads. In
this case DO NOT ground TO. Generator neutral is
Three Phase Generator not TO but a point in the windings electrically half
Three phase and single phase current can be taken way between T1 and TB. This point is not wired to
simultaneously from a generator connected to three a terminal.
phase service. Connecting a single phase lead to To reconnect the generator for single phase vol-
any two of the phase leads will provide single phase tage service only, follow the chart. Wrap all connec-
current at the same voltage as three phase power. tions and unused terminals with a good grade of
Connecting a single phase lead to one phase lead insulation.
and to neutral will produce current at 58% of the
three phase voltage. DO NOT exceed the name- TAPE
plate current rating for any one phase. Typical REQUIRED CONNECT LINE INDIVID-
VOLTAGE LEADS TO CONNECT UALLY
commercial voltage designations of this system are
T3
277/480, 230/400, 127/220. Single-Phase
T6
2Wire T2 & TB T1 & T7 T4 & T5
Low Voltage T9
TO
T1 THREE-PHASE LINE Single-Phase T3

3Wire T1 &TB T7 T4 & T5 T6
SINGLE-PHASE ..,·..
;,
...... Low/High
Voltage
T2
Neutral T9
TO
AT 58'i'o OF
GENERATOR
· ...
~T4 Single-Phase
T3 '
~i;
CONNECTED
VOLTAGE
T7~
C'>
. SINGLE-PHASE
AT GENERATOR
2Wire
High Voltage
T2 T7 T1 & TB
T4 & T5
T6
T9
TO
CONNECTED
NEUTRAL :~
·-=- VOLTAGE
*Only the 7L69 and 8L50 generators can be connected for
115-230 service.
Generator Loading
T3
A three phase load is usually balanced and pre-
sents no problem when kept within the rated line
LINES amperage limits. However, single phase power
taken from a three phase source can be a problem
unless the single phase loading is equally distri-
buted within about 10%.
Single Phase
When a generator is installed or reconnected, be
When a generator is connected for single phase
sure the total current in one phase does not exceed
service only, do not exceed these limits:
the nameplate rating. Each phase should carry the
1. The nameplate amperage limits. same load, allowing the engine to work at its rated
2. Fifty-eight percent of the KVA and KW ratings. capacity. An electrical unbalance can result in an
(The engine will only work about half as hard.) electrical overload and overheating if one phase
exceeds the nameplate amperage.
95
Power Factor
Power factor may be thought of as the efficiency Generator sets require higher low idle setting than
of the load-the ratio of apparent power to total do industrial engines. Low idle must not be below
power. Power factor is expressed as a decimal and 2/3 the full load speed of 60 Hz units (4/5 full load
denotes that portion of current supplied to a system speed of 50 Hz units).
doing useful work. The portion of current not doing On generator sets with Woodward Governors, there
useful work is absorbed in maintaining the magnetic is no low idle stop. On generator sets with mechan-
field in motors. This current, although it is called the ical governors, the low idle is set at the factory,
reactive load, does not require engine horsepower and should only be adjusted by your Caterpillar
to maintain it. Horsepower (KW) consumed in a dealer if adjustment is required.
reactive load is the actual power needed to drive,
for example, an electric motor. Single Unit Operation
At motor start, the inrush current will be very high, Final adjustments for a new installation are given
usually 6 times the normal running current. How- here.
ever, this current is supplied at a very low power 1. Remove the exciter regulator cover and loosen
factor, usually around 0.4 to 0.3. As the motor starts the locknuts on the voltage level, voltage droop
and builds up speed, inrush current reduces, but the and regulator gain controls.
power factor increases. The actual power (KW),
supplied by the engine through the generator, is 2. Turn the voltage droop control counterclockwise
to zero droop and tighten the locknut.
that which is required to accelerate the motor and
its load.
When large motors are started across the generator
line leads, high inrush currents will cause gener-
ator voltage to fall momentarily. This is called
voltage "dip". Normally, voltage "dips" should be
limited to about 30%. Voltage "dips" greather than
30% can cause magnetic motor starters to chatter,
or drop off the supply line.
Large motors are commonly started through a re-
duced voltage starter which limits the motor inrush
current.
In most applications, electric motors and trans-
formers determine the power factor of the system.
Induction motors usually have a .8 power factor. VOLTAGE ADJUSTMENT CONTROLS
1. Voltage Droop 2. Voltage Level 3. Voltage Gain
Incandescent lighting is a resistive load of about
1.0 power factor, or unity.
The power factor of a system may be determined
3. Run the engine at full governed speed.
by a power factor meter or by calculations. Deter-
mine the power requirement in KW by multiplying 4. Using the voltage level control, adjust the open
the power factor by the KVA supplied to the system. circuit (no load) voltage to equal nameplate voltage.
As the power factor goes up the total current sup- 5. Apply rated load and adjust the governor control
plied to a constant power demand will go down. for rated speed.
A 100 KW load at .8 power factor will draw more
6. Adjust the regulator gain control until the line
current than a 100 KW load at .9 power factor. A
voltage is equal to rated voltage at rated load.
higher power factor increases the possibility of
overloading the engine. A lower power factor in- 7. Allow the electric set to operate about one hour
creases the possibility of overloading the generator. until temperature in the generator has stabilized.
Low Idle Adjustment 8. Repeat steps 4, 5 and 6.
CAUTION 9. Tighten the locknuts on the voltage level and
Disconnect the exciter circuit by removing fuse Fl regulator gain controls, and install the exciter-
(on SR 4) before operating the engine below the low regulator assembly access cover.
idle rating. Failure to do this will result in generator The generator set is now properly adjusted for
damage. single unit operation.
96
Parallel Operation &, WARNING
Preparing a generator for parallel operation re-
quires special attention. Before attempting to par- Never attempt to work on electrically hot
allel units, all units must be checked to be sure the wiring. Stop the generator set before re-
following three conditions are met: wiring generator leads. Open circuit
breakers before working on the equip-
1. Same phase rotation.
ment which they control.
2. Same speed capabilities.
3. Same voltage characteristics. b. If lights blink in unison, the phase rotation of
both engines is the same, and condition 1 has been
These three conditions may be compared to similar
met.
conditions required for engagement of two gears.
To mesh as smoothly as possible, two gears must Engine Speed
meet the following three conditions: The speed of units to be paralled must be the same.
1. Correct rotation. Speed refers to the alternating current frequency.
2. Same rotation speed. 1. Allow each generator set to run under load long
3. The tooth of one segment must fit the root of enough for the internal temperatures to stabilize
the engaging segment. (about one hour).
2. Adjust the governor control to give rated fre-
Phase Rotation quency at full load.
The phase rotation must be the same. A set of three
3. Remove the load and check the high idle speed;
light bulbs is used to determine whether the phase
it should be approximately 3% above full load speed.
rotation of the incoming unit and the phase rotation
If these speeds can not be obtained, cootact your
of the line are the same. Caterpillar dealer.
1. Connect the light bulbs between the generator
4. For the most consistent results repeat steps 2
leads and the corresponding line phase, i.e., ter-
and 3. Condition 2 has been met.
minal 1 to line 1 across the open circuit breaker.
2. Start the units to be paralleled and bring them Voltage Adjustment
up to speed. As they approach the same speed the The voltage level and voltage droop adjustments
lights will start to blink. determine the amount of circulating currents be-
tween generators. Carefully matched voltage reg-
ulator adjustments will reduce the circulating
currents. Adjustments to the voltage droop control
~-----------+------2 should be made to give a 2% droop for load of unity
power factor (load composed primarily of lighting),
--j-+----------+-~----3 or when adjustment is made with a resistance bank
or brine tank. Loads of .8 power factor (primarily
motors) require a generator voltage droop of about
FUSED KNIFE I 5%. Voltage droop is expressed as the percentage
SWITCH OR CIRCUIT ,.,.,--~...,
BREAKER-OPEN of voltage change from no load to full load.
1. Remove the exciter-regulator access cover and
loosen the locknuts of the voltage level and droop
controls and the regulator gain control.
SYNCHRONIZING LIGHTS
a. If the lights blink in sequence one of the units

is connected backward. To correct this remove gen-
erator leads 1 and 3 at the circuit breaker and ex-
change them. This reverses the direction of phase
rotation. Line 2 should always be connected to
line 2. DROOP ADJUSTMENT
97
2. Turn the droop control counterclockwise to zero. In a cold unit, circulating current may be as high
3. Run the engine at high idle. as 25% of rated·amperes without being considered
harmful. Circulating current is part of the total
4. Adjust the open circuit voltage level to equal genera_tor currentwhich must not exceed the rated
nameplate rated voltage. amperage.
5. Apply full load and adjust the governor control
to the rated fu II load speed.
Load Bank Testing
The most popular and inexpensive method used
6. Adjust the regulator gain control to equal name-
to check generator set power output is the brine
plate rated voltage at full speed.
tank load test. This simple test uses a salt water
7. Run the generator set at full load until internal solution for a resistive load between the terminals
temperatures have stabilized (about 1 hour) remove of a generator. The equipment required is relatively
the load and repeat steps 4, 5, and 6. easy to acquire and assemble. See your Caterpillar
8. Tighten the locknut on the regulator gain control. dealer for additional information.
9. With the engine running at high idle, turn the CAUTION
voltage droop clockwise about 1/4 of full range. Rated generator KW occurs at 0.8 PF. Therefore, to
obtain generator rated KW the line current should be
10. Readjust the voltage level control until the vol-
80% of the nameplate ampere rating of the generator.
tage is about 5% above rated voltage.
Operation at full rated current would result in a
11. Apply full load at .8 power factor. 25% overload.
NOTE For any current reading, the power output of a
If a generator is paralleled with other generators, the voltage three phase generator can be calculated using the
droop of each generator must be the same to satisfactorily divide
reactive load.
following formula:
12. Readjust the voltage droop control to get rated EX IX 1.73

voltage with full load at .8 power factor. KW=----xPF
1.000
13. Repeat steps 10, 11 and 12 until line voltage is
equal to nameplate rating at .8 power factor and Where: KW = Kilowatt output
open circuit voltage is approximately 5% above E = Voltage (average of 3 lines)
rated voltage. I = Amperes (average of 3 lines)
14. Tighten the locknuts on all controls and install PF = Power Factor
the access cover. Condition 3 has been met. A brine tank or resistance bank is a 1.0 power factor
load.
Circulating Currents
When two units are paralleled there will be circu- _&WARNING
lating current. These currents are not doing useful
work, but are flowing between the generators. By To avoid electrical shock, be sure the
determining the total generator amperage and sub- tank or any of its metallic support is con-
tracting the amperage going to the load, the amount nected to a good earth ground.
of circulating current can be determined. A brine tank test should not be used for
Circulating currents are caused by voltage differ- any generator above 480 volts. If the
ences between the two units. As the oncoming generator voltage is greater, use reduc-
generator warms up the circulating current will be tion transformers. Avoid any possible
reduced. flash over between electrodes and tank.
98
TROUBLESHOOTING
INDEX
Abnormal Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Alternator Charging Rate High .......................................... 108
Alternator Charging Rate Low or Unsteady ................................ 108
Alternator Fails to Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Alternator Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Coolant in Engine Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Engine Fails to Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Erratic Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Excessive Black or Grey Smoke ......................................... 106
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Excessive Valve Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Excessive Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Excessive White or Blue Smoke ......................................... 106
Heavy Combustion Knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

High Lubricating Oil Consumption ........................................ 107
Loud Valve Train Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Low Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Mechanical Knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Misfiring .............................................................. 101
Oil in Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Premature Engine Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Slobber .............................................................. 105

Stalls at Low Speed .................................................... 101
Starting Motor Fails to Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Valve Lash Close-up ..................... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Valve Spring Retainer Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Valve Train Clicking Noise ............................................... 103
I
99
TROUBLESHOOTING
PROBLEM PROBLEM
1. Engine Fails to Start 16. Valve Lash Close-up
2. Misfiring 17. Premature Engine Wear
3. Stalls at Low Speed 18. Coolant in Engine Lubricating Oil
4. Erratic Engine Speed 19. Excessive Black or Grey Smoke
5. Low Power 20. Excessive White or Blue Smoke
6. Excessive Vibration 21. Low Engine Oil Pressure
7. Heavy Combustion Knock 22. High Lubricating Oil Consumption
8. Valve Train Clicking Noise 23. Abnormal Engine Coolant Temperature
9. Oil in Coolant 24. Starting Motor Fails to Crank
10. Mechanical Knock 25. Alternator Fails to Charge
11. Excessive Fuel Consumption 26. Alternator Charging Rate Low or
12. Loud Valve Train Noise Unsteady
13. Excessive Valve Lash 27. Alternator Charging Rate High
14. Valve Spring Retainer Free 28. Alternator Noisy
15. Slobber
1. Engine Fails To Start

Possible Causes Remedy
No Fuel to Engine Check for empty fuel tank, plugged fuel tank connections,
obstructed or kinked fuel suction lines, fuel transfer pump
failure, or plugged fuel filters.
Shutoff Solenoid Sticking Solenoid must be energized to shut off engine. Actuate
(if equipped) the control that operates the shutoff solenoid and listen
for a clicking sound. If clicking sound is not evident and
engine will not start, remove the solenoid. Again try to
start the engine. If the engine starts, the solenoid is bad.
Replace the solenoid.
Fuel Transfer Pump At cranking speed, the fuel transfer pump should supply
fuel to the engine at 3 PSI (20 kPa). If fuel pressure is less
than 3 PSI (20 kPa), replace the fuel filter. Check for air
in fuel system, sticking, binding or defective fuel bypass
valve. If pressure is still low, replace the fuel transfer
pump.
Engine Improperly Timed See your authorized dealer.
Glow Plug Failure Check glow plugs.
Automatic and Safety Shutoff Controls Check shutoff controls to ensure they are set properly.
See Starting· Procedures.
*Authorized dealers are equipped with the necessary tools and personnel familiar with disassembly and assembly procedures to
perform these services.
100
'" ----,
2. Misfiring
Fuel Injection Nozzle Run the engine at the speed where the misfiring is most
or Fuel Pump Malfunction pronounced. Momentarily loosen the fuel line nut on the
injection pump to "cut out" that cylinder. Check each cyl-
inder in this manner. If one is found where loosening
makes no difference in irregular operation, the pump and
nozzle for only that cylinder need be serviced.
Improper Valve Lash Set to specified clearance.
Incorrect Fuel Injection Timing See your authorized dealer.
Low Fuel Supply Pressure Check fuel supply line for leaks or kinks, air in fuel system,
sticking, binding, or defective fuel bypass valve. Replace
fuel filter. Check fuel pressure. Fuel transfer pump should
supply fuel at 20 to 30 PSI (14 to 20 kPa) to the engine
when the engine is fully loaded.
Broken or Leaking High Pressure Replace the line.
Fuel Line
Air in Fuel System Find source of air entry and correct. Bleed system.
Bent or Broken Push Rod Replace push rod.
3. Stalls At Low Speed

Idle Speed Too Low See your authorized dealer.
sticking, binding, or defective fuel bypass valve. Replace
fuel filter. Check fuel pressure. Fuel transfer pump shall
supply fuel to 20 to 30 PSI (14 to 20 kPa) to the engine
when the engine is fully loaded.
Fuel Nozzle Malfunction Replace nozzle.
Excessive Wear or Damage to Fuel Replace worn or damaged parts.*
Injection Pumps
High Parasitic Loads Check for excessive loading due to auxiliary attachments.
4. Erratic Engine Speed

Governor Control Linkage Adjust external linkage to obtain sufficient travel. Replace
if damaged, bent, or linkage is too short.
Governor Failure Look for damaged or broken springs, linkage, or other
components. Determine if the rack can be moved
manually. Replace any defective components.*
101
5. Low Power
Fuel Nozzle Failure Run the engine at the speed where the defect is most
pronounced. Momentarily loosen the fuel line nut on the
injection pump to "cut out" that cylinder. Check each cyl-
inder in .this manner. If one is found where loosening
makes no difference in irregular operation, the pump and
nozzle for only that cylinder need be tested.
Poor Quality Fuel Drain, clean and bleed fuel system. Replace fuel filter.
Fill fuel tank with proper grade of fuel.
Turbocharger Carboned or Inspect and repair or replace turbocharger as necessary.*

Otherwise Dragging
Leaks in Air Induction System Check inlet manifold pressure. Check air cleaner for
restriction.
Excessive Valve Lash Set to specified clearance.
sticking, binding or fuel bypass valve malfunction. Re-
place fuel filter. Check fuel pressure. Fuel transfer pump
should supply fuel to 20 to 30 PSI (14 to 20 kPa) to the
engine when the engine is fully loaded.
6. Excessive Vibration
Loose, Worn or damaged Engine Mounts Tighten all mounting bolts securely. Replace components
as necessary.
Loose Pulley and Damper Retighten.
Loose or Worn Coupling on Inspect, align and tighten coupling to driven equipment.
Driven Equipment
Worn or Damaged Damper or Pulley Replace damper or pulley.
Misfiring See PROBLEM 2.
102
7. Heavy Combustion Knock
Air in Fuel System Bleed air from system.
Malfunction of Fuel Injection Pump Replace.*

Plunger and Barrel Assembly
Malfunction of Fuel Injection Nozzle Replace.*
Incorrect Fuel Injection Timing See your authorized dealer.*
8. Valve Train Clicking Noise

Excessive Valve Lash Set to specified clearance.
Broken Valve Spring(s) Replace valve spring(s) and all other damaged compo-
nents.*
Insufficient Lubrication Check lubrication in valve compartment, it should be very

wet at all speeds. Oil passages should be cleaned, espe-
cially those leading to the cylinder head.
9. Oil In Coolant
Failed Oil Cooler Core Replace oil cooler core.
Failed Head or Spacer Plate Gaskets Replace head and spacer plate gaskets.
Cracked or Defective Cylinder Block Replace cylinder block.*
Cracked or Defective Head Replace cylinder head.*
10. Mechanical Knock

Engine Connecting Rod Bearing Failure Replace the bearing. Check the connecting rod and
crankshaft. Replace if necessary.*
Main Bearing Failure Replace bearings.*
Damaged Timing Gear Train Replace components as necessary.*
Broken Crankshaft Replace crankshaft.*
Fuel Dilution of Crankcase Oil Correct fuel leakage into crankcase oil.
103
11. Excessive Fuel Consumption
Fuel System Leaks Large changes in fuel consumption may result. Internal
leaks will probably be accompanied by low engine oil
pressure and increased oil level in the engine oil sump.
Replace leaking components.
Fuel and Combustion Knock Small but measurable increases in fuel consumption may
be the result of malfunction of fuel nozzles, misfiring or
factors contributing to loss of power. See PROBLEM 2
and 5.
12. Loud Valve Train Noise

Bent or Broken Valves Replace damaged parts.*
Broken Camshaft Replace all damaged parts. Clean engine thoroughly.
Broken or Severely Worn Valve Lifters Replace camshaft and valve lifters. Check for sticking
valves and bent valve stems. Clean engine thoroughly.
Set valve lash to specified clearance.
13. Excessive Valve Lash

Severely Worn Cam Lobes Check valve lash. Replace camshaft and all lifters. Clean
engine thoroughly. Set valve lash to specified clearance.
Broken or Severely Worn Valve Lifters Replace valve lifters. Check camshaft for wear. Check
for sticking valves and bend valve stems. Clean engine
thoroughly. Set valve lash to specified clearance.
Valve Tip Wear Set valve lash to specified clearance. If wear is excessive,
replace valve.
Roller Lifters If any wear is visible, replace the worn roller lifters.
Push Rod Wear Set valve lash to specified clearance. If wear is excessive,
replace push rod.
Rocker Arm Anvil Wear Set valve lash to specified clearance. If wear is excessive,
replace rocker arm.
Insufficient Lubrication Check lubrication in valve should be very wet at high idle
speeds, but only damp at low idle. Oil passages should be
cleaned, especially those leading to the cylinder head.
104
14. Valve Spring Retainer Free
Broken Keepers Extensive engine damage may result from dropped' valve.
Replace all damaged part.*
Broken Valve Spring Replace valve spring.*
Broken Valve Replace valve and any other damaged parts.*
15. Slobber
Excessive Valve Guide Wear Recondition cylinder head assembly.*
Excessive Lubricating Oil in Valve Check rocker arm shaft and plugs to assure that they are
Compartment in place.
Worn Piston Rings and/or Liners Inspect and replace components as necessary.*
16. Valve Lash Close-Up

Valve Face and/or Seat Wear Adjust valves to specified clearance. Recondition cylinder
head.
17. Premature Engine Wear

Intake Piping Failure (Air Cleaner) Inspect all gaskets and piping for leaks. Repair all leaks.
Excessive Fuel Dilution of Replace leaking components. This will probably be ac-
Lubricating Oil companied by high fuel consumption and low engine oil
pressure.
Tighten fuel injection line fittings under valve cover.
Dirt in Lubricating Oil Locate and correct source of dirt entry. Change lubricating
oil. Change oil filter.
18. Coolant In Engine Lubricating Oil

Oil Cooler Failure Replace oil cooler core.
Cylinder Head Gasket Failure Replace gasket. Maintain proper torque on cylinder head
bolts.
Cracked or Damaged Cylinder Head Replace cylinder head.*
Cracked or Damaged Cylinder Block Replace cylinder block.*
Cylinder Liner Seal Leaking Replace seals.*
Cracked or Damaged Cylinder Liners Replace cylinder liners.*
105
19. Excessive Black Or Gray Smoke
Insufficient Combustion Air Check air cleaner for restriction. Check inlet manifold
pressure. Inspect turbocharger for proper operation.
Fuel Nozzle Plugged or Leaking Replace nozzle.
Fuel Ratio Control Improperly Adjusted Adjust fuel ratio control.*
20. Excessive White Or Blue Smoke

Valve Guides Worn Recondition cylinder head assembly.*
Piston Rings Worn, Stuck or Broken Replace.*
High Crankcase Oil Level Avoid overfilling. Determine cause and drain excess oil.
Misfiring See PROBLEM 2.
Fuel Injection Pump Timing Wrong See your authorized dealer.
Air in Fuel System Bleed fuel system.
21. Low Engine Oil Pressure

Engine Oil Diluted with Fuel Oil Check lip-type seal on fuel transfer pump drive shaft.
Drain crankcase and refill with clean lubricant.
Excessive Crankshaft Bearing Replace bearings and/or crankshaft.* Check oil filter
Clearances operation.
Excessive Timing Gear Bearing Inspect bearings and replace components as necessary.
Clearances
Excessive Rocker Arm Bore or Check lubrication. Replace components as necessary.

Rocker Arm Shaft Wear
Defective Oil Pump Repair or replace.*
Defective Suction Bell Replace.
Clogged Oil Filter or Cooler Repair or replace as necessary.
Oil Pump Relief Valve Stuck Clean valve and housing. Replace if necessary.
106
22. High Lubricating Oil Consumption
Oil Leaks Replace gaskets or seals and tighten all connections.
Excessive Oil to Intake See PROBLEM 15.
Excessive Valve Guide Wear See PROBLEM 15.
Crankcase Oil Level Too High Avoid overfilling. Determine cause and drain excess oil.
High Oil Temperature Check oil cooler bypass valve. Replace if defective. Clean
oil cooler core.
Worn Piston Rings and/or Liner Replace components as necessary.*
23. Abnormal Engine Coolant Temperature

Combustion Gases in Coolant Determine point at which gases enter the system. Repair
or replace components as necessary.
Water Temperature Regulator or Check temperature regulator for proper opening tempera-
Temperature Gauge Malfunction ture and correct installation. Check temperature gauge.
Replace if necessary.
Coolant Level Low Determine cause-replace leaking gaskets and hoses.

Tighten connections. Add coolant.
Worn or Damaged Water Pump Repair water pump as necessary.
Coolant Flow Through Heat Exchanger Determine cause-remove any restrictions.

Restricted
24. Starting Motor Fails To Crank

Low Output from Battery Check battery and charge or replace.
Damaged Wiring or Inoperative Switch Repair or replace.
Inoperative Solenoid Replace.
Inoperative Starting Motor Repair.
107
25. Alternator Fails To Charge
Drive Belt Loose Adjust belt.
Open or High Resistance in Charging or Inspect all cables and connectors. Clean, retighten or
Ground Return Circuits or replace defective parts.
Battery Connections
Excessively Worn, Open or Replace brush assembly.*

Defective Brushes
Open Rotor Field Coil Replace rotor assembly.*
26. Alternator Charging Rate Low Or Unsteady

Drive Belt Loose Adjust belt.
Intermittent or High Resistance in Inspect all cables and connectors. Clean, retighten or
Charging or Ground Return Circuits replace defective parts.
or Battery Connections
Excessively Worn, Sticky, or Replace brush assembly.*

Defective Brushes
Faulty Regulator Replace regulator.*
Shorted or Open Rectifier Diodes Replace rectifier diode assembly in alternator.*
Grounded or Shorted Rotor Replace rotor assembly.*
27. Alternator Charging Rate High

Loose Connections Tighten connections to alternator and regulator.
Regulator Malfunction Replace regulator.
28. Alternator Noisy

Worn or Damaged Drive Belt Replace belt.
Misaligned Belt or Pulley Align drive pulley and alternator pulley and belt.
Loose Pulley Tighten pulley nut. If keyway is worn, install a new pulley.
Worn Bearings Replace bearings.
Shorted Rectifiers in Alternator Replace diode assembly.*
Armature or Rotor Shaft Bent Replace component.*
108
REPAIR OPERATIONS
INDEX
Aftercooler Core ...................................................................................... 144, 145

Connecting Rod Bearings ........................................................................ 137-140
Cylinder Head ... .... ...... ... . .. ...... ....... .. ..................... ........................ ...... ..... 127-133
Engine Oil Cooler and Oil Cooler Lines .. ..... ....... .. ............... .................. 142, 143
Exhaust Manifold ... .......... ................ ... ....... .. ......... .......... ........................ 125, 126
Fuel Injection Lines ............... .. ..... .... ....................... .. ...... ...... ..... .. ................ .. . 113
Fuel Injection Valve ............................. ... .. ........ .... ............ ....................... 115-117
Fuel Transfer Pump ........................................................................................ 114
Oil Cooler (Engine) ................................................................................. 142, 143
Oil Filter Base ........................... ............ .. ... ....... ... ... ........................................ 141
Piston and Connecting Rod .... .......... .. ......... ... ..... .... ... .... ... ... .. ................. 137-140
Precombustion Chamber/Direct Injection Adapter ................................. 118, 119
Replacement Parts to be Carried On~Board a Deep Sea
Navigating Vessel .. ............... ........................ ...................... .... ..... ....... 110, 111
Thermostat .............................................................................................. 146, 147
Tool Requirement List ..................................................................................... 112
Top Center Compression for No. 1 Piston ............................................. 135, 136
Turbocharger ..... ...... ...................... ....... ....... ......... ... .... ... ........ ... ..... ......... 122-124
Valve Adjustment .... ..... .. .. .. ............. .......... ................... ... .... .. .. .. ........ ............ .. 134
Valve Bridge .................................................................................................... 120
Valve Covers ................................................................................................... 121
Water Pump (Jacket-Water) ................................................................... 148, 149
Water Pump (Sea Water) ....................................................................... 150, 151
Water Temperature Regulator (Thermostat) ........................................... 146,147
I
109
SUGGESTED LIST OF REPLACEMENT PARTS TO BE CARRIED
ON-BOARD A DEEP SEA NAVIGATING VESSEL
Vessels using diesel engines for main propelling or

auxiliary power are required by the various Marine
Shipping Societies to carry a supply of replacement
parts for on-board repairs. Although individual require-
ments may differ, the following list takes into considera-
tion the requirements of all Shipping Societies. Consult
your dealer for requirements that affect your particular
operation.
There are several items on the list that are not re-
quired by the Shipping Societies, but are recommended
by Caterpillar.
CYLINDER HEAD PARTS FUEL SYSTEM PARTS

1. One complete service head assembly.
2. Six cylinder head bolts and washers. 1. One fuel injection pump group.
3. Four intake valve inserts. 2. One of each of the fuel injection lines.
4. Six exhaust valve inserts. 3. Thirteen fuel nozzle assemblies, fuel bodies and
5. One exhaust manifold stud and nut. nuts.
4. Thirteen fuel injection valve seals (DI engine only).
VALVE PARTS 5. One seal for PC chamber/DI adapter.
6. One seal, lock and adapter assembly for valve cover
1. Four intake valves. base.
2. Six exhaust valves. 7. One fuel transfer pump.
3. Ten valve guides.
4. Ten rotocoil assemblies. CAMSHAFT DRIVE PARTS
5. Ten valve springs.
6. Twenty locks. 1. One idler gear assembly.
2. One shaft and thrust washer for idler gear assembly.
PISTON PARTS-POWER 3. One crankshaft gear.
4. One camshaft gear and key.
1. One piston group.
2. One connecting rod assembly. SCAVENGE SYSTEM PARTS
3. One connecting rod crankshaft bearing.
4. One connecting rod pin bearing. 1. One complete turbocharger group.
5. One piston pin. 2. Four turbocharger mounting studs and locknuts.
6. Two piston pin retainers. 3. One air cleaner element.
7. One complete set of rings for one piston. 4. One aftercooler core (if so equipped).
8. One crankshaft main bearing.
9. Two main bearing cap bolts and washers. LUBRICATION SYSTEM PARTS
1O. Two thrust plates.
11. One cylinder liner. 1. One of each of the bypass valves in oil valve body.
12. Three cylinder liner seals. 2. One bolt for oil pan.
13. One cylinder liner filler band. 3. One engine oil cooler core.
4. One marine gear oil coole~ core.
110
SUGGESTED LIST OF REPLACEMENT PARTS TO BE CARRIED
ON-BOARD A DEEP SEA NAVIGATING VESSEL
COOLING SYSTEM PARTS
1. One temperature regulator.

2. One vee belt set (if so equipped).
3. One jacket water pump.
4. One sea water pump.
,;
.\,
MARINE GEAR PARTS
1. One spider drive bearing.

2. One complete bearing between ahead shaft and
clutch hub.
3. One complete bearing between ahead shaft and
astern shaft.
4. One complete bearing that fits either front of ahead
shaft or rear of countershaft.
5. Two complete bearings for rear of ahead shaft.
6. Two complete bearings for rear of astern shaft.
7. One complete bearing for idler gear.
8. Two complete bearings for front of countershaft.
9. Two bearing assemblies for planet gears.
10. One shaft assembly for planet gear.
11. One planet gear.
12. One bearing assembly for output shaft.
13. One gasket for output shaft.
14. One spacer for front of countershaft.
15. One spacer for rear of astern shaft.
16. One spacer for rear of ahead shaft.
17. One complete sealing kit.
18. One complete locking kit.
MISCELLANEOUS PARTS
1. One complete engine gasket kit.

2. One flywheel to crankshaft bolt.
3. One bolt for valve cover.
4. One repair kit for piston and rings of engine driven
air compressor (if so equipped).
5. One repair kit for valves, seats, plungers and
gaskets for engine driven air compressor (if so
equipped).
6. One starting motor.
111
REPAIR OPERATIONS
TOOL REQUIREMENT
The following Caterpillar special service tools were CYLINDER HEAD AND VALVES
used while performing the repair procedures included in
this manual. The tools are listed by usage and can be 1. FT1322 Lever Assembly for valve bridges. (Tool
purchased from your Caterpillar dealer. must be fabricated; see drawing below).
9M3710 Anti-Seize Compound 2. 5S1330 Valve Spring Compressor.
8H5137 Sealer 3. 9S9082 or 5P7307 Engine Turning Tool Group.
7M7260 Liquid Gasket 4. 7S8859 Driver and 5P2396 Bushing for valve
guides.
FUEL SYSTEM 5. 5P127 Socket (PC Engine only) for glow plugs.
6. 8S225 Wrench for prechamber or 5P961 Wrench for
1. 5P6229 Extractor for fuel injection valve. direct injection adapter.
2. 5P4 755 Guide (DI Engines only) for fuel injection
valve seal.
3. 5P326 Crowfoot Wrench for fuel injection line nuts. PISTONS AND RINGS
COOLING SYSTEM 1. 7M3978 Piston Ring Expander.

2. 5P3526 Piston Ring Compressor.
1. 8B7560 Step Plate and 1P2320 Puller Assembly for 3. 1P1858 Snap Ring Pliers.
sea water pump gear removal. 4. 5P4812 Keystone Piston Ring Groove Gauge.
1.34"
DIMENSIONS IN INCHES (mm) .25" X45o
(6.4)
1-4----- (34.0)
.19" .38" 50"

(12.7) X45o
(4.8)
(9.5)7~--A,.---,,---,p,,_~
18.00"7
(457.0)
. 750 ± .031"
1 - - - - -..... [ ~] (i9.0TBOI
'
.125 ± .020"
2.75" (3.18 ± 0.52)
I._____
.50"
(12.7) U
i-+-
1.00"
(25.4)
.3...
(9.5)
_J I
~ A58769X1
FT1322 LEVER ASSEMBLY

A, B. . 12 in. (3.0 mm) fillet welds.
112
FUEL INJECTION LINES
REMOVAL
&WARNING
Shut off the diesel fuel supply and discon-

nect the starting system before perform-
ing any repair procedures.
1. Remove two bolts (2) that hold fuel injection line

dampers to aftercooler cover.
INSTALLING FUEL INJECTION LINES

1. Damper bracket. 2. Fuel injection line end. 3. Fuel in-
jection line end.
3. Connect fuel injection line ends (2) to injection

pumps and fuel injection line ends (3) to adapters.
Tighten the nuts to 30 ± 5 lb. ft. (40 ± 7 N-m)
CAUTION
If new fuel lines are used for replacement, remove
the identification tags from the lines. The tags can
cause wear on the fuel injection lines.
4. Install the two bolts that hold fuel injection line
damper brackets (1) to aftercooler.
FUEL INJECTION LINE REMOVAL
1. Nut. 2. Bolt. 3. Nut. 5. Connect the starting system and turn on the diesel
fuel supply.
6. Prime the fuel system. See subject PRIMING THE
FUEL SYSTEM on page 57.
2. Disconnectfuel injection line nuts (3) atfuel injection
pumps with a 5P326 Crowfoot Wrench. Disconnect
fuel injection line nuts (1) at adapters.
3. Remove the fuel lines as a unit. Put protective cov-
ers on the ends of all fuel lines, pump openings and
adapter openings.
INSTALLATION
1. Remove all protective covers from fuel injection

lines, pumps and adapters.
2. Position fuel lines on engine.
113
FUEL TRANSFER PUMP
REMOVAL INSTALLATION
1. Inspect 0-ring seal on nose end (2) of fuel transfer
_&WARNING pump (1) and replace if necesssary.
Shut; off t;he diesel fuel supply and disconnect;

t;he st;art:ing syst;em before performing any
repair procedures.
1. Remove tachometer drive cable from its connection

(2). Put protective covers on end of cable and on
connection (2).
INSTALLING FUEL TRANSFER PUMP

1. Fuel transfer pump. 2. Nose end (fuel transfer
pump). 3. Protective caps. 4. Housing.
NOTE: Be sure the gears mesh together correctly be-

fore tightening bolts of fuel transfer pump to housing.
2. Put engine oil on O-ring seal and install fuel transfer

pump (1) into housing (4).
3. Remove protective caps (3) and connect the fuel

inlet and outlet lines.
SERVICE METER AND TACHOMETER DRIVE REMOVAL
1. Service meter. 2. Tachometer drive cable connec- 4. Inspect O-ring seal on service meter (5) and/or
tion. 3. Tachometer drives. 4. Fuel transfer pump. 5. tachometer drive (8).
Screw.
5. Put engine oil on seal and install in fuel transfer
2. Remove screws (5) and clamps. Remove service pump. Tighten screws (6) to 8 ± 2 lb. ft. (11 ± 3
meter (1) and/or tachometer drive (3). N-m). Tighten screws (9) to 12 ± 5 lb. ft. (17 ± 7
3. Remove fuel inlet line (6) and fuel outlet line (7). Put N-m).
protective covers on ends of fuel lines and on fuel
NOTE: The service meter can be positioned with 360°
transfer pump (4) openings.
rotation. Set the position that is the most convenient to
4. Remove bolts (8) and remove fuel transfer pump (4). read.
6. Remove protective cap (7) and install tachometer

cable.
FUEL TRANSFER PUMP REMOVAL

INSTALLING SERVICE METER AND TACHOMETER DRIVE
4. Fuel transfer pump. 6. Fuel inlet line. 7. Fuel outlet
line. 8. Bolt. 5. Service meter. 6. Screw. 7. Cap. 8. Tachometer drive.
9. Screw.
114
FUEL INJECTION VALVE
REMOVAL 4. Remove nut (5) that holds valve (3) in PC
chamber/DI adapter (4).
&, WARNING
NOTE: Two types of fuel injection are available for this
Shut off the diesel fuel supply and disconnect engine. These are: PRECOMBUSTION CHAMBER
the starting system before performing any (PC) and DIRECT INJECTION (DI). See the FUEL IN-
repair procedures. JECTION section of SPECIFICATIONS in this manual
for a visual cutaway to see the differences of these two
types of fuel injection.
This story is written to include both types of fuel injec-
1. Remove the valve cover. See subject VALVE tion with the understanding that the user must deter-
COVER REMOVAL on page 121. mine which type is applicable for the particular engine
involved.
2. If so equipped, disconnect the glow plug wire from
the glow plug and clip (2) from fuel line (1).
EXTRACTOR INSTALLED ON FUEL VALVE

A. 5P6229 Extractor.
FUEL LINE REMOVAL

1. Fuel line. 2. Glow plug wire clip. 5. Install extractor (A) on fuel injection valve (3). Re-
move valve (3) by pulling it straight out of the PC
chamber/DI adapter.
3. Remove line ( 1) with a 5P326 Crowfoot Wrench. Put
6. Nozzle ( 6) of fuel injection valve is threaded on valve
protective covers on the ends of the fuel line open-
body (7) finger tight. Remove nozzle (6) from valve
ings.
body (7).
FUEL INJECTION VALVE SEPARATED

NUT FOR FUEL INJECTION VALVE (PC TYPE SHOWN)
3. Fuel-injection valve. 4. Prechamber or adapter. 5. Nut. 6. Nozzle. 7. Valve body.
115
INSTALLATION
1. Install nozzle (3) on valve body (2) finger tight.

2. Install extractor (A) to the top of fuel injection valve.
3. Position the fuel injection valve in PC chamber/DI
adapter (4). Make sure the grooves (serrations) on
valve body (2) are in alignment with grooves in PC
chamber/DI adapter (4). Remove extractor (A).
INSTALLING SEAL ON DIRECT INJECTION

(DI) VALVE BODY
1. Seal. 2. Valve body. B. 5P4755 Guide.
The DI fuel injection valve has a seal on the valve

body. Remove the old seal and install a new seal using
INSTALLING FUEL INJECTION VALVE
(DI TYPE SHOWN)
(a) Put a new seal (1) on guide (B) by placing seal
4. PC chamber/DI adapter. A. 5P6229 Extractor.
over tapered end of guide (B). Push the seal
over the guide to opposite end as shown.
(b) Put guide (B) over valve body (2).
(c) Push seal (1) off the guide (B) into position on
valve body (2).
4. Install nut (5) that holds the fuel injection valve in the
PC chamber/DI adapter. Tighten nut (5) to 55 ± 5
lb. ft. (75 ± 7 N-m).
NOTE: The above procedure applies to DIRECT IN-
JECTION (DI) type engines only.
A327!;2JC2.t
FUEL INJECTION VALVE INSTALLING FUEL VALVE NUT

2. Valve body. 3. Nozzle 5. Nut.
116
FUEL INJECTION LINE INSTALLED

6. Fuel injection line. 7. Glow plug wire. 8. Glow plug wire
clip.
5. Remove protective covers from fuel line openings.

Install fuel line (6). Tighten nuts to 30 ± 5 lb. ft. ( 40 ±
7N-m).
6. On PC type engines, install the glow plug wire clip
(8) to fuel line (6) and the glow plug wire (7) to the
glow plug.
7. Install the valve cover. See subject VALVE COVER

INSTALLATION on page 121.
8. Connect the starting system and turn on the diesel
fuel supply.
117
PRECOMBUSTION CHAMBERS/DIRECT INJECTION ADAPTERS
REMOVAL 6. Install the correct wrench (B) [88225 Wrench for PC
chamber or 5P961 Wrench for DI adapter]. Remove
PC chamber/DI adapter (2) from cylinder head.
&WARNING
7. Remove O-ring seal and gasket from PC
Shut off the diesel fuel supply and disconnect
the starting system before performing any
repair procedures.
INSTALLATION
1. Remove the valve cover. See subject VALVE
COVER REMOVAL on page 121. 1. Install new O-ring seal (3) and gasket (1) on PC
REMOVING GLOW PLUG

(PC TYPE ONLY) INSTALLING PC CHAMBER/DI ADAPTER
1. Glow plug wire. A. 5P127 Socket. (PC CHAMBER SHOWN)
1. Gasket. 2. PC chamber/DI adapter. 3. O-ring seal.
2. If so equipped, remove glow plug wire (1). Remove

glow plug with 5P127 Socket (A).
2. Put liquid soap in the bore of the cylinder head and
3. Remove the fuel injection valve. See subject FUEL on seal (3).
INJECTION VALVE REMOVAL on page 115.
3. Put 9M3710 Anti-Seize Compound on the threads
4. Remove the valve bridges. See subject VALVE of PC chamber/DI adapter (2) and install in cylinder
BRIDGE REMOVAL on page 120. head.
5. Drain the coolant from the cylinder heads.
INSTALLING WRENCH INSTALLING WRENCH

. (PC SHOWN) (DI SHOWN)
2. PC chamber/DI adapter. B. Wrench. 2. PC chamber/DI adapter. B. Wrench.
118
PRECOMBUSTION CHAMBERS/DIRECT INJECTION ADAPTERS
4. Install the correct wrench (B} [88225 Wrench for PC

chamber or 5P961 Wrench for DI adapter]. Tighten
to a torque of 150 ± 10 lb. ft. (205 ± 14 N-m).
5. Install the fuel valve. See subject FUEL VALVE
6. Install the valve bridges. See subject VALVE
BRIDGE INSTALLATION on page 120.
INSTALLING GLOW PLUG

(PC ENGINE ONLY)
4. Glow plug. 5. Clip. 6. Wire.
7. If PC type engine, put 9M3710 Anti-Seize Com-

pound on the threads of glow plug (4). Install glow
plug ( 4) and tighten with 5P127 Socket to a torque of
10 ± 2 lb. ft. (14 ± 3 N-m).
8. Install clip (5) on the fuel line and install wire (6) on
glow plug (4).
9. Install the valve cover. See subject VALVE COVER
fuel supply.
119
VALVE BRIDGE
1. Putcleanengineoilon bridge dowel (4). lnstallvalve

&_WARNING bridge (3) in its correct location on the cylinder head.
repair procedures.
INSTALLING VALVE BRIDGE

1. Push rod. 2. Rocker arm. 3. Valve bridge. 4. Bridge
dowel.
2. Put clean engine oil on top of push rod (1).

SEPARATING ROCKER ARM FROM PUSH ROD
1. Push rod. 2. Rocker arm. 3. Valve bridge. A. FT1322 3. Put lever assembly (A) in position and compress
Lever Assembly. valve springs. Make a connection between push rod
(1) and rocker arm (2).
COVER REMOVAL on page 121.
2. Position lever assembly (A) on rocker arm (2) as

shown and pull on lever assembly (A) to compress
valve springs.
NOTE: Due to camshaft lobe position, engine flywheel

may have to be rotated to allow push rod removal.
3. Separate push rod (1) from rocker arm (2) and

slowly release pressure on valve springs.
4. Put identification on valve bridge as to its location on

cylinder head. Rotate rocker arm (2) out of the way CONNECTING PUSH ROD TO ROCKER ARM
and remove valve bridge (3). 1. Push rod. 2. Rocker arm. A. FT1322 Lever Assembly.
5. Repeat this procedure for each valve bridge to be 4. Check the valve clearance. See subject VALVE AD-
removed. JUSTMENT on page 134.
120
VALVE COVERS
1. Remove tube from breather (1) and remove gauge 1. Install a new seal in the valve cover.
panel (if so equipped).
2. Remove bolts (2) from the valve cover. Remove
valve cover (3).
3. Remove the seal from the valve cover.
INSTALLING VALVE COVER

1. Breather. 2. Valve cover.
PREPARING TO REMOVE VALVE COVER

1. Breather. 2. Bolts. 3. Valve cover.
2. Position valve cover (2) on the engine and install the
bolts. Tighten the bolts in number sequence shown
to a torque of 18 ± 5 lb. ft. {24 ± 7 N-m).
----0------0----
2 3
o'/"""
6 _____ oI ______ o7
A34713XI
TIGHTENING SEQUENCE FOR COVER
3. Install breather tube to breather (1 ).

4. Install gauge panel {if so equipped).
121
TURBOCHARGER
REMOVAL
&, WARNING
Shut off the diesel fuel supply and disconnect .,-.
the starting system before performing any 5

repair procedures.
1. Drain the coolant from the engine.
2. Loosen clamp (5) and remove the air cleaner and

the hump hose (7).
3. Remove the bolts from top of the exhaust elbow.
4. Remove four bolts (2) that hold elbow to aftercooler

air inlet. Remove elbow and air pipe from tur-
bocharger.
OIL LINE REMOVAL
9. Clip. 10. Nut. 11. Oil supply line.
9. Remove bolts from clip (9). Remove oil supply line

(11). Cover all openings with tape.
10. Remove fournuts (10) from the turbocharger mount-

ing studs. Remove turbocharger (13). Tur-
bocharger weighs approximately 92 lbs. (42 kg).
DISCONNECTING TURBOCHARGER LINES

1. Coolant line. 2. Bolt. 3. Coolant line. 4. Bolt. 5.
Clamp. 6. OIi drain line. 7. Hump hose. 8. Coolant supply
line.
5. Disconnect coolant line (3) from the turbocharger

and from the exhaust manifold. Remove coolant
line (3).
6. Disconnect coolant lines (1) and (8) from tur-

bocharger. TYPICAL TURBOCHARGER REMOVED
12. Elbow. 13. Turbocharger.
7. Remove bolts for oil drain line (6) from turbocharger
and nuts from flywheel housing. Remove oil drain
line (6). Cover all oil openings with tape. 11. Remove exhaust gasket from manifold.
8. Remove bolts (4) from turbocharger and disconnect 12. Remove exhaust elbow (12) from turbocharger
oil supply line (11) from cylinder block. housing.
122
TURBOCHARGER
INSTALLATION
1. Install exhaust elbow (2) in turbocharger housing.
2. Install new exhaust gasket (3) on studs of exhaust

manifold.
3. Coat the threads of turbocharger mounting studs (4)

with 9M3710 Anti-Seize Compound.
OIL SUPPLY LINE INSTALLED

4. Stud. 5. Clip. 6. Oil supply line.
6. Remove protective covers from oil supply line (6)

and remove tape from turbocharger lubrication
holes. Connect bottom of oil supply line (6) to cylin-
der block.
INSTALLING TURBOCHARGER (TYPICAL) 7. Install a new gasket at top of turbocharger and install
1. Turbocharger. 2. Exhaust elbow. 3. Gasket. 4. Stud. top end of oil supply line to turbocharger with bolts
(9). Install bolt to clip (5).
NOTE: If studs have been removed, install new studs
and tighten to a torque of 20 ± 3 lb. ft. (25 ± 4 N-m). 8. Inspect the 0-ring seals on the air pipe (11) and
replace if necessary.
4. Remove all protective covers from air inlet and
exhaust openings. 9. Put a thin layer of oil in the bore of turbocharger air
5. Position the turbocharger (1) on the exhaust man- outlet. Install air pipe (11) in bore of turbocharger
ifold and install nuts to studs (4). Tighten nuts to 40 and install bolts and washers that hold elbow to
± 4 lb. ft. (55 ± 5 N-m). aftercooler inlet.
123
TURBOCHARGER
TURBOCHARGER LINES INSTALLED

7. Coolant line. 8. Bolt. 9. Bolt. 10. Coolant line. 11. Air
pipe. 12. Clamp. 13. Hump hose. 14. Oil drain line. 15.
Coolant supply line. 16. Air cleaner.
10. Install four bolts (8) that hold elbow to aftercooler

inlet.
11. Remove protective covers from oil drain line (14).

Put engine oil on O-ring seal and install oil drain line
(14) in flywheel housing.
12. Put a new gasket between turbocharger and oil

drain line (14). Install bolts to turbocharger.
13. Connect coolant line (10) to turbocharger and install

bolts at manifold.
14. Connect coolant lines (7) and (15) to turbocharger.
15. Install the bolts at the top of the exhaust elbow.
16. Install air cleaner (16) and hump hose (13) to the
turbocharger inlet. Tighten clamp (12).
17. Fill the engine with coolant to the correct level.

fuel supply.
124
EXHAUST MANIFOLD
REMOVAL
A WARNING
repair procedures.
1. Remove the oil filter base. See subject OIL FILTEA

BASE REMOVAL on page 141.
INSTALLING EXHAUST MANIFOLD
1. Gasket. 2. Stud. 3. Exhaust manifold.
1. Put 9M3710 Anti-Seize Compound on studs (2).
NOTE: If a stud for the exhaust manifold was removed,

install a new stud and tighten to 35 ± 5 lb. ft. ( 45 ± 7
N-m).
2. Install new gasket (1). Put exhaust manifold (3) in

position on the studs and install spacers, washers
and nuts (7) finger tight.
EXHAUST MANIFOLD REMOVAL 3. Put new gasket (8) between manifold flanges and
1. Breather cap. 2. Exhaust manifold. 3. Bolt. 4. Adap-
install the three bolts in the holes. Install nuts (5) on
ter. 5. Elbow. 6. Elbow. 7. Nut. 8. Elbow. the bolts finger tight.
2. Drain coolant from engine.

3. Remove tube from breather cap ( 1).
4. Remove bolts from elbows (5) and ( 8). Remove
elbow (5), adapter (4) and elbow (8) as a unit.
5. Remove elbow (6) from end of manifold.
6. Remove bolts (3) and nuts (7).
7. Remove manifold. Manifold weighs approximately
60 lbs. (27 kg).
MANIFOLD INSTALLED
INSTALLATION
4. Elbow. 5. Nut. 6. Adapter. 7. Nut. 8. Gasket. 9. Elbow.
Clean all gasket mounting surfaces before installing
manifold.
4. Tighten the nuts (7) in the number sequence shown

to 38 ± 5 lb. ft. ( 49 ± 7 N-m). Tighten nuts (7) again
in the number sequence shown to 38 ± 5 lb. ft. ( 49 ±
7N•m).
125
EXHAUST MANIFOLD
: :=:
9 5 1 2 6 10
•:
11 3 4 8 12
A33747X1
TIGHTENING SEQUENCE FOR

EXHAUST MANIFOLD
5. Tighten nuts (5) on bolts to 32 ± 5 lb.ft. (43 ± 7 N-m).

6. Put elbow (4), adapter (6) and elbow (9) in position
and install bolts.
NOTE: If the elbows and adapter were separated, lubri-

cate the bores in the elbows with engine oil before
installing together.
INSTALLING COOLANT ELBOW

10. Elbow. 11. O-ring seal.
7. Inspect seal (11) and replace it if necessary. Put

engine oil on seal (11) and install elbow (10).
8. Install the oil filter base. See subject OIL FILTER
BASE INSTALLATION on page 141.
9. Install breather tube to breather cap.
fuel supply.
126
CYLINDER HEAD
REMOVAL
/A WARNING
repair procedures.

2. Remove the oil filter base. See subject OIL FILTER
BASE REMOVAL on page 141. ROCKER SHAFT ASSEMBLY
3. Remove the exhaust manifold. See subject 6. Bolt. 7. Wiring harness. 8. Rocker shaft assembly.
EXHAUST MANIFOLD REMOVAL on page 125.
COVER REMOVAL on page 121.
5. Disconnect inner fuel injection lines between adap- 10. Remove the push rods from the cylinder head.
ter (3) and PC chamber/DI adapter (5). Put protec- 11. Remove three bolts (6) for each rocker shaft as-
tive plugs in the ends of fuel lines and protective sembly (8) and remove both rocker shaft as-
caps on adapters (3) and on PC chambers/DI adap- semblies (8).
ters (5). 12. Remove bolts that hold wiring harness (7) to cylinder
6. Disconnect fuel injection line nuts (2) from the fuel head. Remove both wiring harnesses (7).
line adapters (3). Put protective plugs in all fuel line
openings and caps on all fuel line adapters.
VALVE COVER BASE REMOVAL REMOVAL OF SUPPORT BRACKETS

1. Glow plug connector. 2. Nut. 3. Adapter. 4. Bolt. 5. PC 9. Spacer. 10. Bracket. 11. Bracket. 12. Bolt. 13. Bolt.
chamber/DI adapter.
7. Disconnect glow plug connector (1 ).from each valve 13. Remove bolt from the automatic timing advance
cover base. housing to bracket (10). Remove spacer (9).
8. Remove bolts (4) that hold base to cylinder head. 14. Remove bolts (12) and bracket (10). Remove brac-
Remove both valve cover bases. ket(11).
9. Remove the valve bridges. See subject VALVE 15. Remove the remainder of the 3/8" bolts (13) from
BRIDGE REMOVAL on page 120. the cylinder head.
127
CYLINDER HEAD
NOTE: The cylinder head is positioned on two dowels.

The head must be raised evenly and straight away from
the cylinder block face until free from the dowels.
20. Remove cylinder head bolts (20). Remove the cylin-
der head. Weight of the cylinder head is 300 lbs.
(135 kg).
NOTE: Do not set cylinder head on a flat surface or
damage may occur to nozzles which protrude from bot-
tom of head.
REMOVAL OF COOLANT ELBOW BOLTS

14. Bolt.
16. Remove bolts (14) from coolant elbow at front of

cylinder head.
REMOVING COOLANT SEALS

21. Seal. 22. Spacer plate.
21. Remove coolant seals (21) from spacer plate (22).

22. Install six 3/8"-16 NC forcing screws (23) in the
spacer plate. Tighten the screws evenly until the
REMOVAL OF COOLANT LINES
spacer plate (22) is free of the dowels in the cylinder
block.
15. Elbow. 16. Coupling. 17. Elbow. 18. Lifting bracket.
CAUTION
17. Remove lifting bracket (18). Do not cause damage to dowels (24) when the
18. Remove coolant elbows (15) and (17) and coupling spacer plate is removed.
(16) at rear of cylinder head.
19. Install three 5/16" -18 NC forged eye bolts (19) in the
cylinder head as shown. Attach lifting equipment to
eye bolts (19).
. SPACER PLATE REMOVAL

23. Screw. 24. Dowel.
CYLINDER HEAD REMOVAL 23. Remove spacer plate (22) and gasket. Clean the
19. Eye bolt. 20. Head bolt. surfaces of spacer plate and cylinder block.
128
CYLINDER HEAD
DISASSEMBLY
REMOVING VALVE GUIDE

B. 7S8859 Driver.
VALVE SPRING REMOVAL

4. If a valve guide shows signs of excessive wear or
1. Spring. 2. Rotocoil. A. 5S1330 Valve Spring Compressor.
damage, remove the valve guide with driver (B).
1. Install valve spring compressor (A) as shown and

put springs (1) in compression. ASSEMBLY
1. Put engine oil on outside of valve guide.

2. Install the new valve guide using bushing (C) and
driver (B). The distance (X) that the guide must
extend above the cylinder head surface is 1.27 ±
.03 in. (32.3 ± 0.8 mm).
REMOVING LOCKS FROM VALVE STEM

3. Locks. A. 5S1330 Valve Spring Compressor.
2. Remove locks (3) from the valve. There are two INSTALLING VALVE GUIDE
locks for each valve. 8. 7S8859 Driver. C. 5P2396 Bushing. X. 1.27 ± .03 in.
(32.3 ± 0.8 mm).
3. Remove tool (A), rotocoil, spring and valve.
NOTE: If valves can be used again, put identification on NOTE: Intake and exhaust valve guides are inter-
the valves for location at installation. changeable and either end can be driven into cylinder
head. However, the specified driver and bushing must
be used to be sure guide is installed without damage.
129
CYLINDER HEAD
7. Repeat Steps 1 through 6 for all other valve guides,
valves or valve springs that need replacement.
INSTALLATION
1. Make sure the spacer plate and the machined sur-

face (3) of the cylinder block are clean and free of
dirt and foreign material.
INSTALLING VALVE SPRING

1. Rotocoil. 2. Spring.
3. Put clean engine oil on valve stem. Install valve,

spring (2) and rotocoil (1).
4. Put valve spring compressor (A) in position and
compress valve spring (2).
PREPARING CYLINDER BLOCK FOR SPACER PLATE

1. 0-ring seal. 2. Dowel. 3. Machined surface.
2. Install the two O-ring seals (1 ).

3. Put a new gasket in position over the two seals (1 ),
dowels (2), and on the cylinder block.
CAUTION
Both surfaces of the spacer plate and the top of the
cylinder block must be clean. Do not use a gasket
adhesive on these surfaces.
INSTALLING LOCKS
3. Locks (two). A. 5S1330 Valve Spring Compressor.
5. Install locks (3) with the thick end up.
& WARNING
Locks can be thrown from the valve when the
spring compressor is released if the locks are
not in their correct position.
INSTALLING SPACER PLATE
6. Remove valve spring compressor (A) and hit valve 4. Spacer plate.
with a soft hammer to be sure the locks are in their 4. Install the spacer plate (4). Install new coolant seals
correct position. in the spacer plate.
130
CYLINDER HEAD
INSTALLING COOLANT SEALS INSTALLING CYLINDER HEAD

5. Head bolts.
8. Put clean engine oil on the threads of cylinder head

5. Thoroughly clean the bottom surface of the cylinder bolts (5). Install cylinder head bolts and washers.
head. Tighten the bolts as shown below in the CYLINDER
6. Install a new head gasket. Do not use any adhe- HEAD BOLT TIGHTENING SEQUENCE DIAG-
sives. RAM using the following procedure:
7. Position the cylinder head on the spacer plate. (a) Tighten bolts 1 through 20 in number sequence
(b) Tighten bolts 1 through 20 in number sequence
NOTE: The use of guide bolts will help to put the cylinder
(c) Tighten bolts 1 through 20 again in number
head in alignment with the dowels.
sequence to a torque of 330 ± 15 lb. ft. (447 ±
20 N-m).
0 0 0 0 0 0 0 0 0 0 0 0 0
0® 0
1
@
0
@
0
@
0 ® 0 @
@
0 0
0 0 0 0
0 0 0
®0 20
® 0 ® 0 @ ® ® ®
A36659-1X1
CYLINDER HEAD BOLT TIGHTENING SEQUENCE DIAGRAM
131
CYLINDER HEAD
9. Install both glow plug harnesses (8) [if so equipped].
SUPPORT BRACKETS INSTALLED

9. Spacer. 10. Bracket. 11. Bracket. 12. Bolt. 13.
Bolt. 14. Bolt. 15. Bolt.
ROCKER SHAFT ASSEMBLIES INSTALLED 13. Tighten bolt (15) finger tight. Tighten bolt (12) to
6. Rocker shaft assemblies. 7. Bolt. 8. Harness. standard torque. Tighten bolt (15) to a torque of 32
± 5 lb. ft. (43 ± 7 N-m).
14. Tighten the remainder of small bolts ( 14) to a torque
of 32 ± 5 lb. ft. (43 ± 7 N-m).
10. Position rocker shaft assemblies (6) on the cylinder
head. Put clean engine oil on the threads of bolts 15. Install the bolts in elbow at front of cylinder head.
(7). Install bolts and washers. Tighten the bolts as 16. Install the coolant elbows and coupling at rear of
shown on previous page in the CYLINDER HEAD head.
BOLT TIGHTENING SEQUENCE DIAGRAM using
17. Install the lifting bracket.
(a) Tighten bolts (21) through (26) in number

25 N-m).
(b) Tighten bolts (21) through (26) in number
20 N-m).
(c) Tighten bolts (21) through (26) in number
sequence again to a torque of 330 ± 15 lb. ft.
(447 ± 20 N-m). 8 4
0 o,
A34714X1
11. Install front bracket (10) and spacer (9). Tighten VALVE COVER BASE TIGHTENING SEQUENCE
bolts ( 13) finger tight. Tighten the bolt that holds the
automatic timing advance housing to bracket (10) to
standard torque. Tighten bolt (13) to a torque of 32 18. Inspect the seal in valve cover base and install new
± 5 lb. ft. (43 ± 7 N-m). seal if necessary. Put clean engine oil on seal.
19. Install valve cover base (16). Tighten bolts (20) in
12. Put bracket (11) in position and install bolts (12) and the number sequence shown to a torque of 18 ± 5
(15). lb. ft. (24 ± 7 N-m).
132
CYLINDER HEAD
20. Remove protective covers from fuel injection lines

and from fuel line adapters on outside of valve cover
base. Connect fuel injection line nuts (17) to adap-
ters and tighten nuts to a torque of 30 ± 5 lb. ft. (40
± 7 N-m).
INSTALLING INNER FUEL INJECTION LINES

21. Adapter. 22. Fuel injection line.
25. Valve clearance must be checked and adjusted if

necessary; See subject VALVE ADJUSTMENT on
page 134.
FUEL INJECTION LINES INSTALLED 26. Install the valve covers. See subject VALVE
16. Valve cover base. 17. Fuel injection line nut. 18. Ter• COVER INSTALLATION on page 121.
minal. 19. Valve bridge. 20. Bolt.
27. Install the exhaust manifold. See subject EXHAUST
MANIFOLD INSTALLATION on page 125.
28. Install the oil filter base. See subject OIL FILTEA
21. Connect wire from glow plug wiring harness (if so BASE INSTALLATION on page 141.
equipped) to terminal (18) on valve cover base (16).
29. Check the engine oil level and fill to the correct level.
22. Put clean engine oil on ends of push rods and install
push rods in cylinder head.
23. Install the valve bridges. See subject VALVE
fuel supply.
BRIDGE INSTALLATION on page 120.
24. Remove protective covers from inner fuel injection NOTE: If engine will not start, or continues to misfire
lines and fuel line adapters (21 ). Install fuel injection after starting, it will be necessary to bleed the air from
lines (22) and tighten to a torque of 30 ± 5 lb. ft. (40 the fuel injection lines. See subject PRIMING THE
± 7 N-m). FUEL SYSTEM on page 57 for the complete procedure.
133
VALVE ADJUSTMENT
VALVE CLEARANCE SETTING
VALVE CLEARANCE SETTING: ENGINE STOPPED

Exhaust .................................................... 030 in. (0.76 mm)
Intake ....................................................... 015 in. (0.38 mm)
NOTE: Valve clearance is measured between the

rocker arm and the bridge for the valves.
To make an adjustment to the valve clearance, turn

the adjustment screw in the rocker arm. It is not neces-
sary to change the bridge adjustment for normal valve
clearance adjustments. Valve clearance adjustments
can be made by using the following procedure: VALVE ADJUSTMENT
4. Make an adjustment to the valve clearance on the

intake valves for cylinders 2, 5, 8, 9, 10 and 11.
Make an adjustment to the valve clearance on the
exhaust valves for cylinders 2, 3, 6, 7, 10 and 11.
5. After each adjustment tighten the nut for valve ad-

justment screw to 22 ± 3 lb.ft. (30 ± 4 N-m), and
check the adjustment again.
6. Remove the timing bolt from the flywheel when all
valve clearances are correct.
VALVE CLEARANCE CHECK

A37425X1
0
INTAKE
.015" (0.38mm)
•
EXHAUST
.030'" I0.76mml
1. Put No. 1 Piston at top center (TC) on the compres-

sion stroke. Make reference to FINDING TOP
CENTER COMPRESSION POSITION FOR NO. 1
PISTON on page 135.
2. Make an adjustment to the valve clearance on the FUEL
®@ill®©©
intake valves for cylinders 1, 3, 4, 6, 7 and 12. Make INJECTION
PUMPS
an adjustment to the valve clearance on the exhaust
©@©©®©
valves for cylinders 1, 4, 5, 8, 9, and 12.
3. Remove the timing bolt and turn the flywheel 360° in
the direction of engine rotation. This will put No. 11
piston at top center (TC) on the compression stroke.
~~(;8)(;8)(;8)(;8)
12--10-- 8 - - 6 - - 4 - - 2
Install the timing bolt in the flywheel. CYLINDER AND VALVE LOCATION
134
TOP CENTER COMPRESSION
FINDING TOP CENTER COMPRESSION NOTE: There are two threaded holes in the flywheel.
POSITION FOR NO. 1 PISTON These holes are in alignment with the holes with plugs in
the left and right front of the flywheel housing. The two
No. 1 piston at top center (TC) on the compression holes in the flywheel are at a different distance from the
stroke is the starting point for all timing procedures. center of the flywheel so the timing bolt cannot be put in
the wrong hole.
LOCATION FOR 9$9082 OR 5P7307 ENGINE TURNING TOOL
LOCATING TOP CENTER (RIGHT SIDE OF ENGINE)

4. Timing bolt location.
The timing bolt(1) is kept in storage at location (3) and
can be installed in either the left side of the engine at
location (2) or in the right side of the engine at location
NOTE: The engine is seen from the flywheel end when
(4).
direction of crankshaft rotation is given.
To find top center compression stroke for No. 1 pis-

ton, first turn the flywheel clockwise (opposite the direc~ •
tion of engine rotation) approximately 30 degrees. The
reason for making this step is to be sure the play is
removed from the timing gears when the engine is put
on top center.
Next, turn the flywheel counterclockwise until the hole

LOCATING TOP CENTER (LEFT SIDE OF ENGINE) in the flywheel is in alignment with the timing bolt. When
1. Timing Bolt. 2. Timing bolt location. 3. Storage loca- the timing bolt can be turned freely in the threaded hole
tion. in the flywheel, the engine No. 1 piston is on top center.
135
TOP CENTER COMPRESSION
.··... •.,
To see if No. 1 piston is on the compression stroke, ·,.
look at the valves of No. 1 cylinder. The valves will be
closed if No. 1 cylinder is on the compression stroke.
You should be able to move the rocker arms up and
down with your hand.
If No. 1 piston is not on the compression stroke, turn

the flywheel 360" and install the timing bolt.
If the hole in the flywheel is turned beyond the hole in

the flywheel housing, turn the flywheel back (clockwise)
a minimum of 30" beyond the hole in the flywheel before
turning counterclockwise toward the hole again .
A37425X1
0
INTAKE
.015" 10.38mm)
•
EXHAUST
.030" (0. 76mm)
11--9--7--5--3--1
@@@@@(8#)
FUEL
®@CD©©©
INJECTION
PUMPS
©@©@®©
~~<:B);g)~<:B)
12--10-- 8 - - 6 - - 4 - - 2
CYLINDER AND VALVE LOCATION
136
PISTON, CONNECTING ROD AND CONNECTING ROD BEARINGS
REMOVAL If only the connecting rod bearings are being re-

placed, proceed to Step 6 in PISTON, CONNECTING
ROD AND CONNECTING ROD BEARINGS INSTAL-
LATION story on page 139. If piston removal is neces-
A WARNING sary, continue with Step 7 below.
the starting system before performing any 7. Remove the cylinder head. See subject CYLINDER
HEAD REMOVAL on page 127.
repair procedures.
8. Remove the carbon ridge from the top, inside sur-
face of the cylinder liner.
1. Drain the engine oil from the oil pan.

2. Remove the oil pan.
3. Remove the oil pump (if necessary).

4. Turn the crankshaft until the journal for the sus-
pected cylinder is at bottom center.
REMOVING PISTON AND CONNECTING ROD

2. Piston.
9. Push the connecting rod and piston (2) up until the

piston rings are out of the cylinder liner. Remove the
assembly from the top.
CONNECTING ROD CAP REMOVAL

1. Connecting rod caps. DISASSEMBLY
1. Use 7M3978 Piston Ring Expander (A) to remove

the rings from the piston.
5. Remove connecting rod cap (1) and remove the 2. Remove the carbon from the piston ring grooves. A
bearing from the cap. Put pieces of rubber hose or stick of hardwood is a good tool for removing carbon
tape on the threads of the connecting rod bolts as because it will not scratch the piston.
protection for the crankshaft journal.
6. Push the connecting rod away from the crankshaft CAUTION
and remove the upper bearings from the connecting Do NOT use a broken ring or carbon scraper as they
rod. . may cut the ring grooves or scratch the piston.
NOTE: This engine has the KEYSTONE type rings.

Both of the compression rings (top and middle) and their
respective grooves in the piston have a tapered design.
CAUTION
Be careful not to damage the crankshaft journals.
Do NOT turn the crankshaft while any of the connec- 3. If the piston is damaged, a new piston must be
tion rod caps are removed. installed.
137
(b) The middle piston ring has the mark "UP-2."

Install this ring in the middle groove so that the
"UP-2" mark is toward the top of the piston.
(c) The top ring has the mark "UP-1." Install this ring
so that the mark "UP-1" is toward the top of the
piston.
2. After the rings are installed, rotate the top two rings
so that the ring gaps of all three rings are 120° apart.
Do not rotate the oil control (bottom) ring.
DISASSEMBLING PISTON AND

CONNECTING ROD ASSEMBLV
1. Retaining ring. 2. Piston pin. 3. Ring. 4. Connecting
rod. C. 1P1858 Snap Ring Pliers.
4. Use snap ring pliers (C) to remove retaining ring ( 1).

Remove piston pin (2) from connecting rod ( 4) and
piston.
5. Inspect piston pin (2) and pin bearing in eye of
connecting rod. If bearing is damaged, a new con-
necting rod must be used.
ASSEMBLING CONNECTING ROD TO PISTON
1. Connecting rod. 2. Pin. 3. Piston. 4. Retaining ring.
ASSEMBLY
3. Put clean engine oil on pin bores in piston (3), on pin

bearing in connecting rod (1) and on pin (2).
4. Put connecting rod ( 1) in position between the pin
bores in piston (3).
5. Install pin (2) and retaining ring ( 4). Make sure ring
( 4) is completely in the groove.
ASSEMBLING PISTON RINGS

A. 7M3978 Piston Ring Expander.
1. Use piston ring expander (A) to install new rings on

the piston with the following procedure:
(a) Install spring for oil control ring (bottom ring) in

the bottom groove of the piston. Then install oil
control ring in the same groove with the gap of
the ring 180° away from the gap in the spring.
138
INSTALLATION 4. Carefully push piston into cylinder liner while mak-

ing sure each ring goes into the cylinder liner without
1. Put clean engine oil on the piston rings and cylinder catching on the top edge of the cylinder liner. ·
liner bore. 5. Push the piston down inside cylinder liner until con-
necting rod approaches crankshaft journal.
6. Install the new upper bearing half in the connecting
:c-.
rod. Be sure the tang of the bearing is positioned
correctly in the groove of the connecting rod.
7. Put pieces of rubber hose or tape over rod bolt
threads (5) to protect the crankshaft journal.
8. Put clean engine oil on the bearing and on the
journal. Slowly pull the connecting rod down onto
the crankshaft.
9. Install the new lower bearing half in cap (3) with the
bearing tang in the cap groove. Put clean engine oil
on the bearing and on the threads of the connecting
rod bolts {5).
INSTALLING PISTON IN CYLINDER LINER
1. Piston. A. 5P3526 Piston Ring Compressor. 10. Install bearing cap (3).
2. Make sure the crankshaft journal is in the bottom NOTE: Be sure that the number en
on the cap is on the
position. Put connecting rod and piston in position in same side as the number on the connecting rod. If more
the cylinder liner. than one cap was removed, the stamped numbers on
the cap and the connecting rod must be the same.
3. Use the piston ring compre§sor {A) to install piston
(1) in the cylinder liner.
CAUTION
The piston and connecting rod assembly must be
positioned with the flat surface (2) of the rod toward
the adjacent rod. Put the chamfered side (4) toward
the crankshaft counterbalance weight.
BEARING CAPS INSTALLED

6. Nut. 7. Number.
11. Put engine oil on seat of nut (6). Install nuts (6).
INSTALLING CONNECTING ROD BEARING Tighten the nuts using the following procedure:
2. Flat surface. 3. Connecting rod cap. 4. Side with
chamfer.- 5. Connecting rod bolt. {a) Tighten each nut to a torque of 60 ± 6 lb. ft. (80 ±
BN•m).
{b) Put a mark across each nut and bolt as shown.
Tighten the nuts 120" more {each point on the
hexagon nut is equivalent to 60").
139
120°
A31068Xt
NUT AND BOLT MARKED FOR

FINAL TORQUE
12. Use the same procedure for all pistons and connect-
ing rod bearings that are replaced.
13. Install oil pump (if removal was necessary}.
14. Clean the gasket surfaces on the bottom of the
cylinder block and the top of the oil pan.
15. Position a new gasket on the oil pan and install the
oil pan to the cylinder block.
16. Install the cylinder head. See subject CYLINDER
HEAD INSTALLATION on page 130.
17. Fill the engine with oil to the correct level.
fuel supply.
140
OIL FILTER BASE
1. Put clean engine oil on seals (2) and install seals (2)
A WARNING on tube (1 ). Install tube on oil filter base (3).
repair procedures.
1 . Remove the oil filters (3) from oil filter base.
TUBE INSTALLED ON OIL FILTER BASE

1. Tube. 2. Seal. 3. Oil filter base.
2. Position oil filter base (3) and tube (1) and install
bolts (4) and bolts (5) and (6).
OIL FILTER REMOVAL 3. Put clean engine oil on O-ring seals of tube (8) and
1. Tube. 2. Elbow. 3. Oil filters. install on elbow (7). Install elbow (7) and tube (8) as
a unit.
2. Remove bolts from elbow (2). Remove elbow (2)
and tube (1).
3. Remove bolts (5) and bolts (6). Remove two bolts
(4) while supporting oil filter base (7).
4. Remove oil filter base (7) and tube (8) as a unit.
5. Remove tube (8) from oil filter base. Remove and
inspect all O-ring seals.
OIL FILTER BASE INSTALLED

4. Bolts. 5. Bolt. 6. Bolt. 7. Elbow. 8. Tube.
4. Install two new Caterpillar oil filters according to the

instructions on the oil filters.
OIL FILTER BASE REMOVAL 6. Connect the starting system and turn on the diesel
4. Bolts. 5. Bolt. 6. Bolt. 7. Oil filter base. 8. Tube. fuel supply.
141
ENGINE OIL COOLER AND COOLER LINES
REMOVAL
,& WARNING
repair procedures.

2. Remove the oil filter base. See subject OIL FILTER
BASE REMOVAL on page 141. ENGINE OIL COOLER REMOVAL
7. Spacer. 8. Water line. 9. Bonnet. 10. Oil cooler.
7. Disconnect water line (8) from bonnet (9).

8. Remove the six bolts that hold bonnet (9) to engine
block. Remove bonnet (9) and oil cooler (10) as a
unit from the bonnet at other end of oil cooler (10).
9. Remove spacer (7) and gasket from engine block.
10. Separate bonnet (9) from oil cooler (10). Remove
and inspect O-ring on bonnet (9) and oil cooler
adapter.
11. The tube bundles in the engine oil cooler can be
cleaned with a .125 in. diameter rod as shown.
COOLANT BYPASS TUBE AND OIL LINE REMOVAL
1. Elbow. 2. Body. 3. Oil tube. 4. Bolt. 5. Oil elbow. 6.
Coolant bypass tube.
3. Remove bolts (4) from elbow (1). Remove elbow (1)

and coolant bypass tube (6) as a unit from bonnet at
other end of bypass tube (6).
4. Separate elbow (1) from bypass tube (6) and re-
move O-ring from elbow (1).
5. Remove the bolts that hold body (2) and elbow (5) to
engine and engine oil cooler. Remove body (2),
elbow (5), and oil tube (3) as unit.
6. Separate oil tube (3) from body (2) and elbow (5).
Remove and inspect O-rings from oil tube (3), body
(2) and elbow (5). CLEANING OIL COOLER CORE
142
ENGINE OIL COOLER AND COOLER LINES
INSTALLATION
4. Install oil tube (5) in body (4) and elbow (6).
1. Put clean engine oil on the O-ring seals for bonnet 5. Put body (4), elbow (6) and oil tube (5) in position on
(1 ), adapter (3), body (4), oil tube (5), elbow (6) and the cylinder block and oil cooler (2). Install the bolts.
coolant elbow (7).
COOLANT BYPASS TUBE INSTALLED

O-RING SEALS INSTALLED
7. Coolant elbow. 8. Bypass tube. 10. Coolant line.
1. Bonnet. 2. Oil cooler. 3. Adapter. 4. Body. 5. Oil
tube. 6. Elbow. 7. Coolant elbow. 8. Bypass tube. 9.
Plate.
6. Position bypass tube (8), plate (9) and coolant elbow

2. Install oil cooler (2), adapter (3) and bonnet (1) on (7) and install the bolts.
the side of the engine block. Be sure to install a new 7. Install the oil filter base. See subject OIL FILTER
gasket and the spacer behind bonnet (1). BASE INSTALLATION on page 141.
3. Connect coolant line (10) to bonnet (1). 8. Fill the engine with coolant to the correct level.
fuel supply.
INSTALLING OIL LINE TO OIL COOLER

4. Body. 5. Oil tube. 6. Elbow.
143
AFTERCOOLER CORE
REMOVAL
&,. WARNING
repair procedures.
1. Drain the coolant from the aftercooler and the water

lines.
REMOVAL OF COOLANT ELBOWS
2. Remove the fuel line damper brackets (2) from the
6. Adapter. 7. Adapter. 8. Elbows. 9. Bolts.
fuel injection lines and aftercooler cover (1 ).
7. Remove bolts (9). Remove aftercooler core (10)

from housing by raising front end and pulling core
forward to disengage inlet and outlet tubes from
housing.
AFTERCOOLER COVER REMOVAL

1. Aftercooler cover. 2. Damper brackets. 3. Bolts. 4. Air
inlet pipe. 5. Bolts.
REMOVING AFTERCOOLER CORE

3. Remove the four bolts (3). Remove air inlet pipes (4) 10. Aftercooler core.
from aftercooler cover (1) and from turbocharger air
outlet.
4. Remove bolts (5) from the aftercooler cover (1). INSTALLATION
Remove cover.
5. Remove two coolant elbows (8).
6. Remove adapters (6) and adapters (7) from both the
coolant inlet and outlet of the aftercooler housing.
INSTALLING AFTERCOOLER CORE

1. Aftercooler core. 2. 0-ring seals.
144
AFTERCOOLER CORE
1. Put clean engine oil on O-ring seals (2). Install seals 6. Put clean engine oil in bore of inlet elbow (10) and
(2) on inlet and outlet tubes of aftercooler core (1). install over O-ring seal (3). Install the bolts that hold
2. Position aftercooler core (1) in housing and install inlet elbow (10) and adapters (7 and 8) to housing'.
the bolts (4). 7. Put clean engine oil on O-ring seal of outlet elbow
CAUTION (11) and install elbow in sleeve (6). Install bolts that
Be careful not to damage O-ring seals when inlet hold outlet elbow (11) and adapters to housing.
and outlet tubes of aftercooler core are being 8. Install a new aftercooler cover gasket.
positioned in housing.
3. Inspect O-ring seal (3) and replace if necessary. Put

clean engine oil on O-ring seal (3) and in bore of
sleeve (6).
COOLANT ELBOWS INSTALLED

10. Inlet elbow. 11. Outlet elbow.
9. Position the cover and install bolts (15). Put air inlet
AFTERCOOLER CORE INSTALLED
pipe (17) in position and install bolts (14).
3. 0-ring seal. 4. Bolts. 5. Coolant inlet opening. 6.
Sleeve. 10. Position fuel injection line damper brackets ( 13) and
install bolts (16). Tighten bolts to 40 ± 10 lb. in. (4.5
± 1.1 N-m).
4. Put clean engine oil on O-ring seals (9) and in the
bores of both adapters. Install adapter (7) and adap-
ter (8) in the coolant inlet side of the aftercooler
housing.
AFTERCOOLER COVER INSTALLED

12. Cover. 13. Damper brackets. 14. Bolts. 15. Bolts. 16.
Bolts. 17. Air inlet pipe.
INSTALLING ADAPTERS
7. Adapter. 8. Adapter. 9. 0-ring seals.

5. Repeat the procedure of Step 4 for both adapters for 12. Connect the starting system and turn on the diesel
the coolant outlet side of the aftercooler housing. fuel supply.
145
WATER TEMPERATURE REGULATOR {THERMOSTAT)
REMOVAL 4. Remove temperature regulator (4).

5. Do Steps 2 through 4 for the other temperature
regulator.
&_ WARNING
repair procedures.
INSTALLATION
1. Drain the jacket water cooling system to a level
below the regulators. 1. Clean all gasket surfaces and install new gaskets.
2. Install temperature regulator ( 1) into regulator_hous-
ing (2) as shown.
WATER TEMPERATURE REGULATOR

REMOVAL
1. Bolts. 2. Regulator housing. 3. Elbow.
INSTALLING REGULATOR HOUSING
1. Temperature regulator. 2. Regulator housing.
2. Remove elbow (3) and remove four bolts (1).

3. Remove bolts from housing (2). Remove regulator
housing (2). 3. Position regulator housing (2) on the expansion tank
as shown. Install bolts (3) and (4).
REGULATOR HOUSING REMOVED

4. Temperature regulator.
146
WATER TEMPERATURE REGULATOR (THERMOSTAT)
REGULATOR HOUSING INSTALLED

2. Regulator housing. 3. Bolt. 4. Bolt. 5. Manifold. &.
0-rlng seal.
4. Inspect O-ring seal (6) and replace if damaged. Put

clean engine oil on O-ring seal (6).
5. Install the elbow over O-ring seal (6) and to regulator
housing (2).
6. Do steps 1 through 5fortheotherwatertemperature
regulator.
7. Fill the expansion tank with coolant to the correct
level.
8. Connect the starting system and tum on the diesel
fuel supply.
147
JACKET WATER PUMP
REMOVAL DISASSEMBLV
1. Remove O-ring seal (1) from adapter (2).

& WARNING
repair procedures.
1. Drain the jacket water cooling system.
,::·
!l
·i>.1~afi4x3
WATER PUMP ADAPTER REMOVAL

1. 0-ring seal. 2. Adapter.
2. Remove adapter (2) with a screw driver by prying (in

small amounts) at three or more places around the
REMOVAL OF COOLANT PIPING circumference.
1. Elbow. 2. Elbow. 3. Pipe. 4. Bolts. 3. Remove the O-ring seal from the outside diametP.r
of adapter ( 2).
2. Remove the bolts from elbow ( 1) atthe expansion

tank and the bolts from elbow (2) at the water pump.
Remove elbows (1) and (2) and pipe (3) as a unit.
ASSEMBLY
1. Put clean engine oil on 0-ring seals ( 1) and (3) and

install on adapter (2). Put a thin layer of oil around
the bore in the water pump.
WATER PUMP REMOVAL

5. Cover. 6. Water pump. 7. Nut. 8. Bolt.
3. Remove bolts ( 4) from water pump outlet.

4. Remove three nuts (7) and bolt (8). Remove water
pump (6). INSTALLING ADAPTER
5. Remove cover (5) from water pump (6). 1. 0-ring seal. 2.Adapter. 3. 0-ring seal. 4. Dowel.
148
JACKET WATER PUMP
2. Install adapter (2) in the pump housing. The notch in 4. Install elbows (3) and (4) and pipe (5) as a unit to
adapter (2) must be in alignment with dowel (4). water pump and expansion tank.
5. Fill the jacket water system to the correct level with
coolant.
INSTALLATION 6. Connect the starting system and turn on the diesel
fuel supply.
1. Install cover (1) on water pump (2).
INSTALLING WATER PUMP

1. Cover. 2. Water pump.
2. Position water pump (2) on the studs. The pump

drive gear must mesh with gear in the timing gear
cover.
3. Install four bolts (6) to the water pump outlet.
WATER PUMP INSTALLED

3. Elbow. 4. Elbow. 5. Pipe. 6. Bolt.
149
SEA WATER PUMP
REMOVAL DISASSEMBLY
NOTE: Caterpillar tools recommended to remove the

&, WARNING gear are the 1P2320 Puller Assembly and the 887560
Shut off the diesel fuel supply and disconnect Step Plate.
repair procedures.
1. Remove the plug from sea water pump ( 4) and drain

the sea water system.
NOTE: Close the sea water valve if necessary.
REMOVING DRIVE GEAR

1. Housing. 2. 8B7560 Step Plate. 3. Gear. 4. Pump. A.
1P2320 Puller Assembly.
1. Remove bolt and washer from end of gear ( 3).

2. Install step plate (2) and puller (A). Remove drive
gear (3).
SEA WATER PUMP REMOVAL
3. Remove housing (1) from pump (4).
1. Outlet elbow. 2. Inlet elbow. 3. Oil inlet to pump. 4. Sea
water pump. 5. Bolt. 6. Oil supply to pump.
ASSEMBLY
2. Remove the inlet and outlet water lines from elbows
(2) and (1). 1. Inspect O-ring seal ( 1) and replace if damaged. Put
clean engine oil on O-ring seal (1) and install on
3. Remove the oil supply line. The line goes between pump.
location (3) and location (6).
4. Remove bolt (5) and nuts and washers. Remove
sea water pump ( 4). Weight is approximately 60 lbs.
(27 kg).
5. Loosen clamps and remove inlet elbow (2) and out-
let elbow (1).
O-RING SEAL INSTALLED

1. 0-rlng seal.
150
SEA WATER PUMP
2. Position housing (2) on sea water pump (6) and 2. Position sea water pump (1) on studs (2). Make sure
install nuts (3) and washers. the pump gear teeth mesh with accessory drive
gear in timing gear housing.
3. Install bolt and install washers and nuts.
4. Install oil supply line to sea water pump (1).
5. Clean gasket surfaces of elbows and water lines
and install new gaskets.
6. Install inlet and outlet water lines. Tighten clamps on
elbows
7. Open the sea water valve or fill the sea water cooling
system.
fuel supply.
HOUSING AND GEAR INSTALLED

2. Housing. 3. Nuts. 4. Gear. 5. Bolt. 6. Sea water pump.
3. Put gear ( 4) in position on the tapered shaft and

install washer and bolt (5).
4. Tighten bolt (5) to a torque of 40 ± 5 lb. ft. (55 ± 7
N-m). Hit the bolt with a punch and a hammer.
Tighten bolt (5) again to 40 ± 5 lb. ft. (55 ± 7 N-m).
INSTALLATION
1. Install inlet and outlet elbows in their correct loca-

tions. Allow clamps to remain loose enough so el-
bows can be rotated.
INSTALLING SEA WATER PUMP

1. Sea water pump. 2. Studs.
151
_ __,,
NOTES
------·-··-----------·-···
SPECIFICATIONS
INDEX
Alternators and Regulators ..................................................................... 165, 166
Connecting Rod ............ ........ ... .......... .... ....... ... ......................... ................. ..... 163
Cylinder Heads ... ....................... ........ ..... ... ... ................ ............................. ... .. 159
Exhaust Manifold .. ...... ...... .. .. ... .. .. .. ... .. .. .. . .. .... .... .. ...... .... ... .. .. .. .. .. .. . .. .. .. .. ... . .. .. . 159
Flywheel .. ... ......... ........... .. .................................. ... ...... ................................ ... . 164
Fuel Filter {Primary) ........................ .... .. .... ..... ................. .... ...... ................. .... . 156
Fuel Injection .. ... ... ............................................ ... .. .... ... ....... . .. .. .. .. ... .. .. ..... . .. ... 155
Fuel Injection Lines .................. :................................' ...................................... 156
Gauges {Electric) ............. ................. ... ....... ..... .................... .... ........... ..... ..... .. 169
Gauges (Mechanical) ....... ....... ............ ... .... ... .. .. ................... .............. ............. 170
Glow Plugs ........ ...... ........ ........ ........... .... .... ... ........................... ......... .............. 155
Pistons and Rings .. .. .. .. .. .. ..................................... ... ..... ...... .... .. ... .. ... .. .. ... .. ... .. 162
Precombustion Chamber/Direct Injection Adapter .......... ... .. .. .. ..... .. .......... ... .. 155
Pressure Caps ................................... ..... ... ........ ...................... .................. ... .. 160
Resistor .. .. ...... .. .. ... ... ..... .. ..... .. ... .. ............. .... ... ... .. .. ... ... ...... ... .. .... .. ... .... ..... . .. . .. 169
Sending Units ... .... .... ............... .......... .... .... ... ................................ ...... ....... ..... 171
Solenoids (Shut-off) ............ .... ....... ............ ..... ............ ............ ........ ....... ...... ... 167
Solenoids (Starter) .. .. .. ..... .. .. ... . .. ........... ... .. .. ..... .. .......... .. .. .. .. .. .. .. .. . .. .. .. .... .. .. ... 168
Starting Motor (Air) ... .. .. .. .... ... .. ... ... . .. ... ... .. . .. .. . .. .. ... .... ... ... ... . .. .. .. .. .. ....... ... . .... .. 173
Starting Motors (Electric) ............. ...... ..... ..... ... .. ........................... ...... ............. 166
Starting Motor (Hydraulic) ............................................................................... 174
Switches (Magnetic) ..... ..................... ............ ..... ....... .............. ................. ...... 167
Switches (Pressure) ........................................................................................ 172
Switches (Temperature) ................................................................................. 172
Tachometer ..................................................................................................... 168

Thermostat ...................................................................................................... 161
Torques (General Tightening) ........................................................................ 154
Turbocharger ................... ................... .... .. ..... ............................ .... .............. ... 160
Valve (Air Pressure Regulating) ..................................................................... 173

Valve Covers .................................................................................................. 157
Valve Cover Base ........................................................................................... 157
Valve Rocker Arms, Lifters and Bridges ........................................................ 158
Water Pump .................................................................................................... 161

Water Temperature Regulator (Thermostat) .................................................. 161
I
153
SPECIFICATIONS
GENERAL TIGHTEN! NG TORQUE FOR

BOLTS, NUTS AND TAPERLOCK STUDS
~~
~-~ .
-:3 ./
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
Use these torques for bolts and nuts with stan-
~ fil{fil{(iOO dard threads (conversions are approximate).
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 70 ± 15
1/2 12.70 75 ± 10 100 ± 15
9/16 14.29 110±15 150 ± 20
5/8 15.88 150 ± 20 200 ± 25
3/4 19.05 265 ± 35 360 ± 50
7/8 22.23 420 ± 60 570 ± 80
1 25.40 640 ±BO 875 ± 100
1 1/8 28.58 800 ± 100 1100 ± 150
1 1/4 31.75 1000 ± 120 1350 ± 175
1 3/8 34,93 1200 ± 150 1600 ± 200
1 1/2 38.10 1500 ± 200 2000 ± 275
Use these torques for bolts and nuts on

hydraulic valve bodies.
5/16 7.94 13 ± 2 20 ± 3
3/8 9.53 24 ± 2 35 ± 3
7/16 11.11 39 ± 2 50± 3
1/2 12.70 60 ±3 80 ± 4
5/8 15.88 118 ± 4 160 ± 6
Tapertock stud
0-, Use these torques for studs with Taperlock threads.
1/4 6.35 5±2 7±3

5/16 7.94 10 ± 3 15 ± 5
3/8 9.53 20 ±3 30± 5
7/16 11.11 30 ±5 40 ± 10
1/2 12.70 40 ±5 55 ± 10
9/16 14.29 60 ± 10 80 ± 15
5/8 15.88 75 ± 10 100 ± 15
3/4 19.05 110±15 150 ± 20
7/8 22.23 170 ± 20 230 ± 30
1 25.40 260 ± 30 350 ± 40
1 1/8 28.58 320 ± 30 400 ± 40
1 1/4 31.75 400 ± 40 550 ± 50
1 3/8 34.93 480 ±40 650 ± 50
1 1/2 38.10 550 ± 50 750 ± 70
*1 newton meter (N•m) is approximately the same as 0.1 mkg. T95416-7
154
SPECIFICATIONS
FUEL INJECTION
DIRECT INJECTION
Firing order (injection sequence) .............. 1-4-9-8-5-2-11-10-3-6-7-12 4

Injection timing before TC (top center):
Precombustion Chamber (PC) ........ ........... .. ..... ...... ..... .. 11 ± 1°
Direct Injection (DI) .. ................. .. ... ........... ...... ... ..... ...... .. 30 ± 1°
(1) Torque for all nuts that hold
the fuel lines ...................................... 30 ± 5 lb. ft. (40 ± 7 N·m)
(2) Torque for the nuts that hold
the nozzles ........................................ 55 ± 5 lb. ft. (75 ± 7 N·m)
(3) Body.
(4) Nozzle. Tighten nozzle finger tight on body (3).
(5) Torque for precombustion chamber or direct
injection adapter ........................ 150 ± 10 lb. ft. (205 ± 14 N·m) PRECHAMBER
(6) Torque for glow plug .............. 120 ± 24 lb. in. {13.6 ± 2.7 N•m)
155
_J
SPECIFICATIONS
FUEL INJECTION LINES
( 1) Torque for the the nuts that hold

the adapter locks .............................. 10 ± 2 lb.ft. (14 ± 3 N·m)
(2) Torque for all bolts that hold the fuel
injection line clamps ................... 40 ± 10 lb.in. (4.5 ± 1.0 N·m)
(3) Torque for all nuts that hold the
fuel injection lines ............................. 30 ± 5 lb.ft. (40 ± 7 N·m)
PRIMARY FUEL FILTEA
(1) Torque for nut ................................... 18 ± 3 lb.ft. (24 ± 4 N·m)

(2) 7S9323 Spring:
Length under test force ................................. 1.1 O in. (27.9 mm)
Test force ................................... 27.7 to 32.3 lb. (123 to 144 N) 2
Free length after test ..................................... 1.68 in. (42.7 mm)
Outside diameter ............................................. .68 in. (17.3 mm)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE
156 OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
SPECIFICATIONS
A3S523XI 4
VALVE COVERS
j 0
5
A35524X1
TIGHTENING SEQUENCE FOR BASE

18 ± 5 lb. ft. (24 ± 7 N·m)
----0
3
------0
'}
----
5 1 4
( 1) Torque for three studs (for locks of
fuel injection lines) ............................ 10 ± 3 lb. ft. (14 ± 4 N·m)
------,0------0
(2) Bore for adapter or plug. For installation, clean contact surfaces of 4
bore and adapter or plug with 8M8060 Quick Cure Primer and put
9S3265 Retaining Compound on the surfaces. TIGHTENING SEQUENCE FOR COVER
18 ± 5 lb. ft. (24 ± 7 N·m)
(3) Tighten the bolts for the base in the
number sequence shown to .............. 18 ± 5 lb. ft. (24 ± 7 N•m)
(4) Tighten the bolts for the cover in the
number sequence shown to .............. 18 ± 5 lb. ft. (24 ± 7 N-m)
157
SPECIFICATIONS
VALVE ROCKER ARMS, LIFTERS, AND BRIDGES
6
1_r
Ji
t- ,-J
I
/
/
I
---j
I
I
(1) Bore in rocker arm "'f

for shaft (new) ............... 9765 ± .0005 in. (24.803 ± 0.013 mm)
(2) Put engine oil on all the threads of bolts that hold rocker arm shafts
88249X4
and tighten the bolts in the following step sequence:
Step 1. Tighten bolts from 1 to 6 in number
sequence to .................. 200 ± 20 lb. ft. (270 ± 25 N•m)
sequence to .................. 330 ± 15 lb. ft. (447 ± 20 N·m)
sequence again to ........ 330 ± 15 lb. ft. (447 ± 20 N·m)
(3) Torque for locknut for valve
adjustment screw .............................. 22 ± 3 lb.ft. (28 ± 4 N·m)
(4) Torque for locknut for bridge
adjustment screw ......... ..................... 22 ± 3 lb.ft. (28 ± 4 N·m)
(5) Clearance for valves:
Intake valves ................................................. .015 in. (0.38 mm)
Exhaust valves .............................................. .030 in. (0.76 mm)
(6) Height to top of dowel ..... ......... 2.10 ± .02 in. (53.3 ± 0.5 mm)
(7) Diameter of dowel
(new) .. :........................ .4334 ± .0001 in. (11.008 ± 0.003 mm)
Bore in bridge for
dowel (new) ................. .4350 ± .0012 in. (11.049 ± 0.030mm) TIGHTENING SEQUENCE FOR ROCKER ARM BOLTS
Bore in head for
dowel .......................... .4322 ± .0008 in. (10.978 ± 0.020 mm)
(8) Diameter of valve lifter
(new) ................. 1.09850 ± .00025 in. (27.9019 ± 0.0064 mm)
Bore in block for valve
lifter (new) ................. 1.1005 ± .0008 in. (27.953 ± 0.019 mm)
(9) Guide spring.
SPECIFICATIONS
CYLINDER HEADS
--o------0-0--o--o--o--o--o--o--o-o--J
24
os0 0
26
0
13
0 10 0 14
011° 019°
A36659XI
r--___3
Step 5. Tighten bolts from 21 to 26

in number sequence
(1) Large bolts(¾ inch). Put engine oil on all bolt threads and tighten the
to ..... ........................ .. .... 200 ± 20 lb. ft. (270 ± 25 N•m)
bolts in the following step sequence:
in number sequence
in number sequence
to ................................... 330 ± 15 lb. ft. (447 ± 20 N•m)
to ................................... 200 ± 20 lb. ft. (270 ± 25 N•m)
in number sequence again
in number sequence
to ................................... 330 ± 15 lb. ft. (447 ± 20 N·m)
to ................................... 330 ± 15 lb. ft. (447 ± 20 N·m)
Step 8. Tighten the thirteen small bolts (2)
to ........................................... 32 ± 5 lb. ft. (43 ± 7 N•m)
in number sequence again
to ................................... 330 ± 15 lb. ft. (447 ± 20 N·m) (2) Small bolts (3/8 inch). See Step 8, above.
Step 4. Install the rocker arm shaft assemblies for the engine valves. (3) Torque for twelve studs in each
cylinder head .. .............. ...... .... ........... 20 ± 3 lb. ft. (25 ± 4 N•m)
EXHAUST MANIFOLD
9
11
5
7
:=: 3
2
4
•:
6
8
10
12
A33747X1
(1) Torque for nuts (put 9M3710 Anti-Seize Compound on threads):

a. Tighten nuts in sequence to ......... 38 ± 5 lb.ft. (49 ± 7 N·m)
b. Tighten nuts again in

sequence to ................................... 38 + 5 lb.ft. (49 + 7 N·m)
159
. ._)
SPECIFICATIONS
TURBOCHARGER
Schwitzer
( 1) End play for shaft
(new) .......................................003 to .006 in. (0.08 to 0.15 mm)
Maximum permissible end play .
(worn) ...............................................................008 in. (0.20 mm)
(2) Radial movement of shaft and bearings
(new) ............................... 0056 to .0074 in. (0.142 to 0.188 mm)
Maximum permissible radial
movement (worn) ............................................. 009 in. (0.23 mm)
Ai Research
( 1) End play for shaft
(new) .......................................003 to .010 in. (0.08 to 0.25 mm)
Maximum permissible end play
(worn) ...............................................................012 in. (0.30 mm)
(2) Radial movement of shaft and bearings
(new) ............................... 0054 to .0072 in. (0.137 to 0.183 mm) 4
Maximum permissible radial
SCHWITZER MODEL 4MFW SHOWN
movement (worn) ............................................. 009 in. (0.23 mm)
Schwitzer and AiResearch
(3) Torque for clamp bolts ....................... 10 ± 1 lb.ft. (14 ± 1 N·m)
(4) Torque for four nuts (put 9M3710 Anti-Seize Compound

on threads) .......................................... 40 ± 4 lb.ft (55 ± 5 N·m)
PRESSURE CAP OF COOLING SYSTEM

(Radiator or Expansion Tank)
X2646 A22492X1
PRESSURE CAPS
Part No. 6L8617 6L9850 4N3311
Pressure that opens the cap relief valve 6.5 to 8 psi 3.5.to 4 psi 6to8psi
(45 to 55 kPa) (22 to 28 kPa) (40 to 55 kPa)
Maximum vacuum that opens the suction 1 psi 1 psi 1 psi
valve (7 kPa) (7 kPa) (7 kPa)
SPECIFICATIONS
WATER PUMP
-!"\-1- --- -·
.-----1'
'
::.:~- ~-=-+-~--=--_--=- ~ ::: --

(1) Torque for three long studs in
cylinder block ................................... 20 ± 3 lb. ft. (25 ± 4 N·m) '
I
Put 8H5137 Sealer on threads of short stud in front housing.

(2) Oil seal. Put engine oil on the seal lip. Assemble with the lip toward
the bearings. I
(3) Seal. Put a thin layer of engine oil in the bore for the seal.
(4) Water seal and ring:
a. Put water on the seal.
b. Install the seal and ring together in the housing bore, with the
shiny face of the ring outside.
(5) Seal assembly:
a. Remove the spring from the seal.
b. Put water inside the seal assembly.
c. Install the seal assembly around the shaft until the carbon face A22.B01XI
r-----------.J I
makes contact with the shiny face of the ring (4).
d. Install the spring.
(6) Torque for the nut that holds
the impeller ...................................... 28 ± 1 lb. ft. (38 ± 1 N·m)
WATER TEMPERATURE REGULATOR

(THERMOSTAT)
(6L5851, 9N2894, 9N3711}
5l865X I
Approximate temperature when completely

open ................................................................................. 197°F (92°C)
Distance regulator is opened
at 197°F (92°C) .................................................•.... .375 in. (9.53 mm)
161
..,/"
,--- __ , --- ,: ------·--.
SPECIFICATIONS
PISTONS AND RINGS
PISTONS AND PISTON RINGS

(1)TOP RING (2)INTERMEDIATE RING (3) OIL CONTROL RING
Part No. *3N603 *2P2817 **4N5692
Width of groove in piston for ... ... .1255 ± .0005 in .
piston ring (new).
Thickness of piston ring (new).

...- ...- (3.188 ± 0.013 mm)
.1235 ± .0005 in .
- - (3.137 ± 0.013 mm)
Clearance between groove and ... ... .0020 ± .0010 in.
piston ring (new). - - (0.051 ± 0.025 mm)
Maximum permissible clearance ... ... .006 in .
(worn). - - (0.15 mm)
Clearance between ends of
piston ring when installed in a .0285 ± .0075 in. .0425 ± .0075 in . .0225 ± .0075 in.
cylinder liner with a bore size of (0.724 ± 0.191 mm) (1.080 ± 0.191 mm) (0.572 ± 0.191 mm)
5.401 in. (137.19 mm).
Increase in clearance between
ends of piston ring for each .001 .003 in.
in. (0.03 mm) increase in cylin- (0.08 mm)
der liner bore size.
*Install piston ring with "UP" side toward top of piston.
NOTE: 3N603 Top Ring (1) has the mark "UP-1."

2P2817 Intermediate Ring (2) has the mark "UP-2."
**Install 4N5692 Oil Control Ring (3) with the gap in the spring 180" away from the gap in the ring.
***"Keystone" style piston rings and grooves in pistons. The 5P4812 KEYSTONE PISTON RING GROOVE GAUGE is necessary for
measuring these grooves. Put the pin end (A) of gauge "1" in the groove at four places around the circumference. Do this to both
grooves. The flat edge (B) of the gauge must be between grooves (1) and (2). If there is clearance between the flat eage (B) of the
gauge and the piston at all test locations, for both grooves, the piston is reusable. If the flat edge (B) is in contact with the piston, at
any of the test locations, the piston is not reusable. Install a new piston.
(4) Bore in piston

for pin ......................... 2.0005 ± .0002 in. (50.813 ± 0.005 mm)
Clearance between pin and bore
in piston ......................... .0003 to .0011 in. (0.008 to 0.028 mm)
Maximum permissible clearance (worn) ......... .002 in. (0.05 mm)
Pin diameter ............... 1.9998 ± .0002 in. (50.795 ± 0.005 mm)
NOT REUSABLE REUSABLE
SPECIFICATIONS
CONNECTING ROD
(1) Bore in bearing for piston

pin {new) ................ 2.0010 to 2.0015 in. (50.825 to 50.838 mm)
Maximum permissible clearance between
48748X 1
bearing and piston pin {worn) ......................... .003 in. (0.08 mm)
(2) Bore in connecting rod for bearing,
with nuts tight to specifications
(6) ............................. 4.0748 ± .0005 in. (103.500 ± 0.013 mm)
(3) Distance between center of
bearings ......................... 10.300 ± .002 in. (261.62 ± 0.05 mm)
(4) Diameter of piston pin
{new) .......................... 1.9998 ± .0002 in. (50.795 ± 0.005 mm)
(5) Bore in bearing for
crankshaft ............... 3.8236 to 3.8258 in. (97.119 to 97.175 mm)
Clearance between bearing and crankshaft
{new) ..... ................. ........ .0028 to .0066 in. (0.071 to 0.168 mm)
Maximum permissible clearance between bearing
and crankshaft {wom) .....................•................010 in. (0.25 mm)
(6) Torque on nut for connecting rod:
a. Put engine oil on threads and nut seat.
b. Tighten both nut$ to ..... ..... ........... .. 60 ± 6 lb.ft. (82 ± 8 N-m)
c. Mark each nut and end of bolt.
d. Again tighten both nw (from mark) ................................. 120°
NOTE: The connecting rod must be installed so the chamfer on the edge
of bore (5) is near the comer on the crankshaft. The flat side of bore (5)
must be against the other connecting rod on the same crankshaft pin.
Side clearance between two connecting rods
on same crankshaft pin
{new) ........................................... .003 to .033 in. (0.08 to 0.84 mm)
163
_____ .,,
SPECIFICATIONS
FLYWHEEL
92618X1
(1) Torque for the bolts that hold the flywheel to the
crankshaft .................................. 200 ± 20 lb. ft. (270 ± 25 N•m)
NOTE: Put engine oil on threads before assembly.
'<L. ..
SPECIFICATIONS
ALTERNATORS AND REGULATORS
(1) Nut.
(2) Output tenninal.
Polarity is negative ground.
ALTERNATORS
Supplier Delco-Remy Motorola
Voltage Rating 12V 24V 30 or 32V 24V
Part No. 5S6698 4N3986 5S9088 4N3987 2N6397
'-~
1117227 1117226 MA24-902A
Supplier Part No. 1117228 1117734 1117733
1117236 8MA3006F
1117242
Service Bulletin or 1G-280 REG01221
1G-275 1G-280 10-275
Fonn No.
Circuit B B B B B
Rotation (as seen Either Either Either Clockwise
Either
from drive end)
Speed for testing 5000 5000 1800 2500
5000 5000
(rpm)
21.5 A* 31 A•
Output (cold) 77 A.. 58 A .. 54 A.. 56 A .. at at
28V 28V
Rated output (hot) 75A 60A 50A 60A 35 A
Field current at
rated voltage and 4.1 to 4.5 A 2.5 to 2.9 A 2.5 to 2.9 A 1.5 to 1.6 A 1.7 A
80°F (27°C)
75 ± 5 lb.ft. 75 ± 5 lb.ft. 75 ± 5 lb.ft. 75 ± 5 lb.ft. 45 ± 5 lb.ft.
Torque for nut ( 1)
(100 ± 7 N·m) (100 ± 7 N·m) (100 ± 7 N·m) (100 ± 7 N·m) (60 ± 7 N·m)
Torque for output 10 ± 1 lb.ft. 66 ± 6 lb.in. 10 ± 1 lb.ft. 66 ± 6 lb.in. 66 ± 6 lb.in.
tenninal (2) (14 ± 1 N·m) (7.5 ± 0. 7 N·m) (14 ± 1 N·m) (7.5 ± 0.7 N·m) (7.5 ± 0.7 N·m)
Tension of brush 6 to 8 oz.
brushless brushless brush less brushless
springs (1.5 to 2 N)
REGULATORS
Part No. inside alternator inside alternator inside alternator 6N3160
Voltage setting
13 to 15V 26 to 30V 26 to 30V 33.7 to 37.7V
range
Adjust voltage to: 14V 28V 28V ... (See ALTERNATOR
REGULATOR for
adjustment range)
then increase
speed to get max. 75A 60A 50A 60A
output of:
•6.5. to 9.3% higher with no regulator.

.. Fasten carbon pile to battery to get maximum output.
... For 32V alternators, adjust to .............................................. 36.7V
... For 30V alternators, adjust to ...................................•.......... 34.7V
165
SPECIFICATIONS
ALTERNATOR REGULATOR
6N3160 24V (Motorola Number 8RD3019)

Polarity is negative ground or insulated.
Voltage setting range ..................................................... 26.8 to 29.2 V
(1) Remove cap to adjust voltage.
Tum the adjustment screw clockwise to increase voltage. There are
five adjustment positions.
Position 1 .................................................... ..•........ 29.25 ± .35 V
Position 2 ...•........................•....................................... 28.6 ±.3 V
A18833Xl
Position 3* ............................ ............ ............... .......... 28.0 ± .3 V
Position 4 ............................................................•...... 27.4 ± .3 V
Position 5 ................... ................................................ 26.8 ± .3 V
*New regulators are adjusted at the factory to Position 3.
STARTING MOTORS
Clearance between pinion and housing

(pinion clearance) ...................................................... .36 in. (9.1 mm)
(1) Tension of brush spring .......................................... 80 oz (22 N)
(2) Torque for screws holding nose housing
to lever housing ............................ 13 to 17 lb.ft. (18 to 23 N·m)
(3) Torque for terminal nuts ............... 20 to 25 lb.ft. (25 to 35 N·m)
Rotation of all motors is clockwise when seen from drive end.
TESTING SPECIFICATIONS WITH NO LOAD APPLIED

24 V 32 V
Part No. 4N3349 9L6474 8L5937 6N3226

4N959
C.T.Co. Delco-Remy ,'
...,,;"
Speed (rpm) min. 5500 5500 7500 7500
Voltage Rating Part No. No. Bun,un No. max. 7500 7500 10500 10500
9L6474 1109647 1~ ~153 Current
min. 140A* . 95A* 100A** 100A**
consumption max. 170A* 120A*
24V 4N959 1109638 1'1/.153 125A** 125A**
(draw)
4N3349 1109642 1M-153
Used with solenoid 4M1812 6N5123 5L6427 5L8595
8L5937 1109627 1M-153 *Solenoid at 20V
32V
6N3226 1109769 1M-153 **Solenoid at 28V
';\;_.,. __ _
SPECIFICATIONS
SHUT-OFF SOLENOIDS
(1) Torque for terminal nuts ............... 14 ± 3 lb.in. (1.6 ± 0.4 N·m)
(2) Terminal marked "S".
NOTE: Do not attach leads to terminal marked "S".
(3) 5L8983 Spring for the shaft:
Length under test force .................................. 1.25 in. (31.8 mm)
Test force ............................................................ 2.00 lb. (9.0 N)
Free length after test ..................................... 2.25 in. (57.2 mm)
Outside diameter ....................................... 1.750 in. (44.45 mm)
(4) Distance between shaft and plate .............. 1.39 in. (35.3 mm) ..
(5) Distance of plunger travel [start with dimension
of .44 in. (11.2 mm) at (6)) .............................. .62 in. (15.7 mm)
••on engine a test can show need for more adjustment. Hold-in test on
engine must take less than 2 A.
CURRENT CONSUMPTION (DRAW)

Current
C.T. Co. Delco-Remy
Part No. Part No.* Voltage Settings Pull-in windings Hold-in windings
12V 2N2384 1115523

5V 8.4 to 9.5 A -
10to12V 16.8 to 22.8 A 1 A max.
24V 2N2385 1115524

9V 5.5 to 6.3 A -
20 to 24 V 12.2 to 16.8 A .45 A max.
Bulletin No. 1S-120
STARTER MAGNETIC SWITCHES
30707X2
9F3099 24V (Delco-Remy Number 0001481)

Current consumption (draw) both windings at 24 V ........ .83 to .89 A
(1) Torque for large terminal nuts ........... 35 ± 5 lb.in. (4 ± 1 N·m)
167
SPECIFICATIONS
STARTER SOLENOIDS
(1) 4M1815 Spring (contact release):

(2) 9M7609 Spring (to return the clutch lever):
(3) Torque for terminal
screws .............................................. 16 to 30 lb.in. (2 to 3 N•m)
CURRENT CONSUMPTION (DRAW)

Current
C.T.Co. Delco-Remy
Part No. Part No.• Voltage Settings Pull-in windings Hold-In windings
4M1812 1119832 5V 10 to 11.5 A -

1119848 20 to 24 V 40 to 55.2 A 8.2 A max.
24V
6N5123 1115544 20V (no pull-in windings) 40 to 45.5
20 to 24 V 40 to 54.6
9V 7.4 to 8.3 A -
5L8595 1119836 27 to 32 V 22.2 to 29.5 A 4.6 to 6.1 A
32V
28V - 4.8 to 5.3 A
9V 7.4 to 8.3 A -
5L6427 1119861 27to32V 22.2 to 29.5 A 4.6 to 6.1 A
28V - 4.8 to 5.3 A
*Bulletin No. 1S-120
ELECTRIC TACHOMETER
3N7288 (Faria No. B-1594-2); Use with sending unit 3N4430.

Output to input ratio ... ...................... ... ... ... ....... ...... ... .. ... .... ......... 2 to 1
Range .. ... ..... ...... ... ...... ... ..... .... .... ....... ... ......... ..... ..... ..... .. O to 2500 rpm
Check at normal engine operating speed.
Amount of adjustment available (dial reading) .......................•... :t: 5%
Maximum external circuit resistance ......... .... .......... ... .. .......... 20 ohms
A33181X1
\ 3
Maximum temperature rating .. ......... ......... .. ...... ...... ...... ... 180°F (82~C)
(1) Adjustment screw.
(2) Sealed cap.
(3) Rubber washer.
168 0 F SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
-~-~---- -
SPECIFICATIONS
ELECTRIC GAUGES
95584XI
48735XI
ENGINE OIL PRESSURE WATER TEMPERATURE
Type Oil Pressure Water Temperature

Rating 12 V 24-32 V 12 V 24-32 V
Part No. 5L7455 5L7456 5L7446 5L7444
Range o to 80 psi o to 80 psi 100 to 240°F 100 to 240°F

(0 to 550 kPa) (0 to 550 kPa) (38 to 115°C) (38 to 115°C)
Check Dial Dial Dial Dial

points Face No. Ohms Face No. Ohms Face No. Ohms Face No. Ohms
tolerance ± .03 in. 170
20 13.5 20 13.5 170 84 1050
(± 0.76 mm)
Inspection
14 V 28.5 V 14 V 28.5 V
voltage
Use with sender 5L7450 5L7450 5L7443 5L7442
Resistor None 5L7441* None 5L7441*
The gauge must be heated for a minimum of 5 minutes at the center scale
resistance before the check points are inspected.
Check gauges with dial face position at 30° angle back from vertical.
*For 32 volt systems, a resistor. must be connected in series with the
gauge to function correctly.
5L7441 RESISTOR
(For Use With 32 V Systems)
./
Approximate resistance ............ .. .. ......... ........... ......... .... ..... ... 65 Ohms
169
SPECIFICATIONS
MECHANICAL GAUGES
(Color Code Dial Face)
A26135X2
FUEL PRESSURE
2
ENGINE OIL PRESSURE WATER TEMPERATURE
Type 011 Pressure Fuel Pressure Water Temperature

Part No. 2N2414 4S6574 2N2413 I 7H9604
Range Oto 30 psi Oto 28 psi 100 to 240°F

(0 to 205 kPa) (Oto 195 kPa) (38 to 115°C)
10 ± 1 psi. 17 ± 1 psi 160 ± 10°F
1
(70 ± 7 kPa) (115 ± 7 kPa) c11 ± s°C)
Check Points
20±1psi 210 + 8 - 0°F
2
(140 ± 7kPa)
- (99 + 4 - 0°C)
SPECIFICATIONS
SENDING UNITS FOR

WATER TEMPERATURE
Rating 12 V 24 V
Part No. 5L7443 5L7442
Range 100 to 240°F 100 to 240°F

(38 to 11s°C) (38 to 115°C)
48736X1
Dial Dial
Face No. Ohms Face No. Ohms
Check
points 160 129 :l: 9 200 850 :l: 50
Torque for 20 lb.in. 20 lb.in.
connection (2 N•m) (2N•m)
-use with
5L7446 5L7444
gauge
SENDING UNIT FOR

ENGINE OIL PRESSURE
(12V - 24V - 32V)
5L7450 Sending Unit; Use with 5L7455 and .5L7456 Gauges

Rating ..•.•....................................................................................... 24V
Pressure range ........................:................. Oto 80 psi (0 to 550 kPa)
Resistance at:
0 psi (0 kPa) ...... ............................ .............. ........ ...... ... .. 0 Ohms
80 psi (550 kPa) ..........•...................... ... .. ..... ......... ....... 30 Ohms
171
SPECIFICATIONS
WATER TEMPERATURE CONTACTOR
Rating when operating alarm or switch

115 Volt AC ............................................................................. 5 A
230 Volt AC .......................................................................... 2.5 A
600 Volt AC ......................................, ...................................... 1 A
120 Volt DC ...............................................................................5A
240 Volt DC ......................................................................... .25 A
48 Volt DC ......................................................................... 1.25 A
29 Volt DC ........................................................................... 2.5 A
12 Volt DC .............................................................................. 5 A
SWITCH OPERATING
TEMPERATURE
with an increase with a decrease
In temperature In temperature
5L6435* ............. 209°F (98°C) 197°F (92°C)
3N4690 ............... 15D°F (65°C) -
*Standard for sea level operation.
PRESSURE SWITCHES
78589-IXI
Rating when used with alarm or switch:
32 Volts DC .···················'··"··················································· 4 A
24 Volts DC .. ........ ......... .. .. ... .... .............. .. ... .. .. .... ....... ...... ..... 6 A
2L3402 Swltch(John W. Hobbs Number M-1422)
With an increase in pressure, switch
closes at .... ........ .. ........ ...... .... ... ..... ...... ..... .... 3 to 4 psi (20 to 28 kPa)
2N.n44 Switch (Metals and Controls Number 20PS66-1)
________ J
With an increase in pressure, switch
closes at a maximum of . ......... ...... .... .. .... .. .. .. .. ..... ...... 12 psi (85 kPa) Al8826X1
With a decrease in pressure, switch

opens at a minimum of ........ .............. .... .......... .... ...... ... 5 psi (35 kPa)
SPECIFICATIONS
••.·
V
PRESSURE REGULATING VALVE

FOR AIR STARTING MOTOR
(1) Adjusting screw.

(2) Maximum permissible inlet
pressure........................................................ 250 psi (1720 kPa)
(3) Maximum permissible outlet
pressure ........................... ,............................ 150 psi (1030 kPa)
Minimum permissible outlet
pressure ...... ..... ... ...... .... .............. ... .. ............... 100 psi (690 kPa)
AIR STARTING MOTOR
6N4558 (Ingersoll-Rand No. VRSM 110/6N4558)

6N4562 (Ingersoll-Rand No. VRSM 110/6N4562)
(1) Torque for bolts ............................. 20 to 25 lb.ft. (25 to 35 N·m)
(2) Pinion retainer screws:
Step 1. Tighten screws evenly in small
increases until torque is ................. 100 lb.in. (11.3 N·m)
Step 2. Hit retainer with hammer.
Step 3. Torque screws again to ................. 100 lb.in. (11.3 N·m)
173
r •- -- ----
SPECIFICATIONS
HYDRAULIC STARTING MOTOR

7L8657 (American Bosch Model CMD3A111)
Maximum permissible pressure
for operation ..... ..... ... ...... ........ ..... ................ .... 3000 psi (20 700 kPa)
Normal pressure for
operation ............................ 1500 to 3000 psi (10 300 to 20 700 kPa)
Output torque with pinion speed of 2500 rpm:
With oil pressure at 3000 psi
(20 700 kPa) ................................................. 118 lb.ft. (159 N·m)
(10 300 kPa) ..................................................... 50 lb.ft. (70 N·m)
Output torque with pinion at stall:
(20 700 kPa) ················································· 120 lb.ft. (160 N·m)
(10 300 kPa) .................................................... 60 lb.ft. (80 N·m)
CHARGING PUMP FOR HYDRAULIC STARTER
6L8719 (American Bosch Number RPA300363)

Pressure adjustment range 1500 to 3000 psi (10 300 to 20 700 kPa)
Normal pressure to start the pump
automatically (cut-in) ....................................... 2500 psi (17 000 kPa)
Normal pressure to stop the pump
automatically (cut-out) ..................................... 3000 psi (20 700 kPa)
Output at 3000 rpm of pump and pressure
of 3000 psi (20 700 kPa) ...................... .65 U.S. gpm (2.46 litre/min)
Maximum suction height (head) ..................................... 3 ft. (0.91 m)
NOTE: The oil RETURN passage near the mounting flange must be
above the horizontal center line. This position makes correct lubrication of
pump parts.
HAND PUMP FOR HYDRAULIC STARTER
2L8342 (American Bosch Number HPA300118)

Working pressure .... ...... ... ..... ..... ... ....... ........... 3000 psi (20 700 kPa)
Force to move handle ................................................ 48.5 lb. (215 N)
Output per stroke ................................................. 1.22 in. 3 (20.0 cm3 )
PRESSURE ACCUMULATOR,_ FOR

HYDRAULIC STARTER
3N9503 (American Bosch Number ACC30A231)

Nitrogen preload pressure 1500 to 1625 psi (1 O 300 to 11 200 kPa)
NOTES
,. .1
FORD
INTERNATIONAL
r\EW HOLLAI\D HARVESTER
ALLIS-CHALMERS
CATERPILLAR
TR.A.CTOR.S
[B Caterpillar and Cat are Registered Trademarks of Caterpillar Tractor Co.
All the above are Trademarks of others, used here in a descriptive

sense to refer to the products of others.
(lEJSALEJ)
Printed in the United States of America
No patent liability is assumed with respect to the use of the information contained in this manual. While every precau-
tion has been taken in the preparation of this manual, the producer assumes no responsibility for errors or omissions.
Neither is any liability assumed for damages resulting from use of the information contained in this manual.
All instructions and diagrams have been checked for accuracy and ease of application; however success and safety in
working with tools depend to a great extent upon individual accuracy, skill and caution. For this reason, the producers
are not able to guarantee the result of any procedure contained in this manual. Nor can they assume responsibility for
any damages to property or injury to persons occasioned from the procedures. Persons engaging in the procedures do
so entirely at their own risk.

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...

200 Main St., Manchester, MN 56007-5000

Y JENSALES INC. WITHOUT THE AUTHORIZATION OF

MES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,

Continuing improvement and advancement of product design may reflect

Whenever a question arises regarding your Caterpillar engine, or this

The services of authorized Caterpillar dealers are recommended; he is

LUBRICATION AND MAINTENANCE

Replace or repair broken or damaged servicing

Do not wear loose clothing whenever working

Wear protective glasses, clothing, hat, respirator or

Disconnect and tape the battery ground lead before

When starting an engine after repair, make pro-

Always disconnect the engine starter circuit when

After Engine Starts ......................... 11 Operating Under Abnormal Conditions ........ 18

Engine and Marine Transmission Operation. . . . 14 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . 8

1. Measure the crankcase oil level. Maintain the oil

6. Observe the engine jacket coolant level. Slowly

2. Measure marine transmission oil level. Oil level

7. If equipped with Low Oil Pressure Shut-Off, reset

3. Check the fuel supply. Keep fuel tanks full, as

8. If equipped with Overspeed Shut-Off, push reset

9. If the engine is equipped with an air shutoff

1. If equipped with HEAT-START switch and glow

12. Move governor control lever to approximate STARTING AID CHART

Electric Starting *NOTE

If Equipped With a Generator Set

4. Push the air valve control in to crank the engine.

1. Observe the oil pressure gauge immediately Standard Gauges - Tachometer

a. With engine stopped, inspect inlet screen and

The engine can be operated between high idle and

Engine Oil Pressure

b. Loosen plug on inlet pipe. If water begins to

If indicator is to the left(-) side of zero, investigate

If the temperature gauge reading registers in or

Fuel Pressure To service air cleaner see AIR INDUCTION AND

Install new secondary of final fuel filter elements

The marine transmission oil temperature must not

Trolling at reduced load for several hours may

Pull upward on the handgrip and move the control

5. Observe the service meter reading. Perform

Starting Single Unit Operation

Standby Generator Sets Load Division

Engine Jacket Water Pump Failure

3. Move and secure valve handle in the EMER-

1. Stop the engine and make the necessary water

4. With the governor control at low idle, engage

1 - Valve - normally closed 7 - Normal - operation sea

After the shaft has been secured, tow at slow speed

Wrapping Propeller Shaft:

Applying Air Actuated Shaft Brake:

11. Upon reaching port, disassemble and inspect

bolts equally spaced in the tapped holes of the JI.It

6. Install the bearing cap, oil line and the trans-

7. Measure the marine transmission oil level. Main-

8. Start the engine.

9. After starting, travel with caution, at minimum

TURBOCHARGER CARTRIDGE REMOVAL

Alarms and Emergency Shutoff Devices ................................... . 27