M.I. 259 *Rev.

A
ELECTRO-MOTIVE DIVISION l GENERAL MOTORS CORPORATION

SERVICE DEPARTMENT MAIlVTENAlVCE INSTRUCTION

LOW WATER AND CRANKCASE
PRESSURE DETECTORS

DESCRIPTION

Greater reliability and more consistent

operation have been provided in the engine
detectors now being furnished on EMD
engines, see Fig. 1. Operational and
functional differences between the low
water and crankcase pressure detectors
are explained below,

1. The low water reset button on detec-

tors is more difficult to latch and keep
latched on a dead engine and when
starting an engine, due to the fact that
the spring force under the button is
8-10 lbs. This means there is a greater
force provided to release the button
and it therefore requires a high water 1 4 9 6 9

level to keep the button latched. The Fig. 1 - Combination Low Water And
detectors require the water leveltobe Crankcase Pressure Detector
at the top of the sight glass. Since this
is the maximum height the water can a. Loss of water level.
reach, the latching of the detector will
b. Pump cavitation due to air entrain-
be marginal until the engine is started
ment, as when starting engine.
and water pump pressure is available.
c. Pump cavitation due to water being
The low water reset button may trip near boiling temperature.
on initially starting the engine (par- d. Excessive air box pressure due to
ticularly the 645 engine). After 1 to 2 turbine surging at low throttle
minutes depress reset button whether
speeds.
it has tripped or not. This willensure
positive latching. e. Air box pressure surge due to a
slipping clutch on turbocharged en-
2. The low water reset button will trip
gines.
when water pressure is within l/2 lb.
of airbox pressure. The following 3. The rate at which the largediaphragm
conditions will cause water pressure moves from trip to latch position on
to be less than air box pressure and the crankcase pressure portion is
will therefore trip the detector: dependent on pressures involved and

*This bulletin is revised and supersedes previous issues of this number.

T)F-T RTPR-1
M.I. 259

the freeness with which air can enter 6. Manual operation of crankcase pres-
the vent fitting at top of detector body. sure diaphragm through crankcase
opening must be done with caution to
When pressing the crankcase pressure avoid distorting a 1 u m i n u m backup
detector reset button on a dead engine, plates. Damaged detectors will not
the air pressure on the diaphragm is latch properly, if at all.
the same on both sides and only the
light spring force is available tomove 7. Both reset buttons actuate lube oil
diaphragm to a latched position. With valves which are sealed with “0”
the reset button held in to release rings, To ensure lubrication and free
the diaphragm, air must enter front movement of the valves, the “0”
of the diaphragm through the vent rings and retaining grooves are de-
fitting to permit the spring to move signed to seal only when normal oil
the diaphragm until the valve stem and pressure is present.
reset button remain latched. This
takes several seconds when detector When engine is being started or
is reasonably warm (60’ - 70” F.) and stopped and oil pressure falls below
longer when detector is cold. The 20 psi, the “0” rings will seep oil
reset button must therefore be pressed momentarily and thereby lubricate
and held in for several seconds to “0” ring, valve stem, and guide. No
ensure complete latching. leakage should occur when oil pres-
sure is above 20 psi.
4. The crankcase pressure portion of
the detector will trip when crankcase
pressure becomes positive. Condi-
MAINTENANCE
tions which cause the detector to
sense positive pressure are as follows:
The maintenance of these detectors is
a. Blockage of oil separator or aspi- very important and requires the use of
rator tube in exhaust. special tools and a test panel to assure
correct functioning of the detector at the
b. Cylinder compression leak to
time of assembly. In order to ensure
crankcase.
proper operation the detectors should be
c. Overheated part causing ignition of dismantled, cleaned, and inspected annu-
oil vapor. ally. Special care should be taken in
cleaning and handling the parts to avoid
d. incorrectly applied lube oil relief
scratching or marring the finish of the
valve in accessory gear train. Oil
valve shafts or surfaces mating with “0”
splash reaches the diaphragm.
rings or diaphragms.
e. Excessive oil level in crankcase.

5. The crankcase pressure portion is INSPECTION

designed to detect very low pressure.
Therefore, application of pressures Disassemble and clean all parts to remove
appreciably above the normal 0” - 5” foreign material. Do not remove vent cap.
of water may permanently damage Do not wire brush or use other means that
backup plates on diaphragm. A detec- may scratch or alter finish on valve shafts
tor with damaged backup plates can- or surfaces mating with “0” rings or
not be reset. diaphragms. Inspect parts as follows:

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 M.I. 259

VALVE SHAFTS LOW WATER PRESSURE SECTION

Sliding surfaces must be free of scratches

and tool marks. 1. Assemble diaphragm spacer block, air
box pressure diaphragm, spring seat
BALL CUP gasket and ball cup in that order with
Free of pits and brine11 marks. diaphragm positioned so that spacer
block fits within cavity formed by
BALL RETAINER diaphragm convolution. Thread at-
Ball passages must be free of tool marks taching bolts through parts and into
and dents and provide free movement of ball cup loosely. Position assembly
balls, Ball retainer must be checked for in centering fixture, see Maintenance
flush engagement of face into aluminum Data for part number, with ball cup
housing. If loose, tighten and secure with over center pilot and diaphragm posi-
single punch mark at intersection of tioned over four l/4” dowels. Lock
threads. Remove the “0” ring in the ball ball cup from rotating with clamp
retainer bore by spearing it with a sharp screw in fixture. Tighten retaining
pointed instrument such as a scribe, and bolts in assembly to 10 in.-lbs torque.
pulling it from the groove. Be extremely
careful not to scratch the bore. Install a 2. Place four l/4”-20 x 1” socket head
new “0” ring by inserting it in the bore screws through water pressure block,
and using the stem shaft to work it into gasket, low water diaphragm (with
place in the groove. convolution pointing away from block),
Replace the three steel balls in the crank- gasket, spacer ring (with l/S” dia-
case portion. of the detector with those meter vent opening ‘position at same
furnished in the replacement kit. side as water connection on block),
LOWER BLOCK (Containing water cavity) gasket, air box pressure diaphragm
assembly, and gasket.
Button or buttons controlling diaphragm
travel must be located .090” below gasket 3. Place three steel balls in ball pas-
face. Gasket face must be smooth and sages of ball retainer of center block,
free of nicks. All surfaces contacting using Lubriplate grease to hold in
diaphragm must have radius and be free place.
of nicks.
4. Position red diaphragm spring over
UPPER BLOCK (Containing oil valve) ball cup of air box pressure diaphragm
and center block assembly over spring.
Mounting face must be flat and square Position air box pressure connection
with bore within .003”. 90” counterclockwise of water con-
nection, when facing center block.
RESET BUTTON ENCLOSURE
Thread retaining bolts into center
Sliding “0” ring surface must be free of block and tighten to 40 in.-lbs torque.
tool marks, scratches, pits, and show Leave assembly set a minimum of
high polish. 24 hours and then retorque.
REASSEMBLY 5. Apply new “0” rings to upper block
Reassemble as follows using the equipment containing oil passages, and check fit
as listed in Maintenance Data, see Figs. 2 up with valve stem to ensure seating
and 3. of “0” ring without twisting.
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 OIL IN FROM
GOVERNOR
&A
Oil Valve Block

Reset Button
Enclosure
/

i’H,Valve Stem

Reset Button
Spring

Latch Position

tl Valve Stem
eset Button
pring

Trip Pos ition

*

Bleed Port
OIL RETURN TO
CRANKCASE
WATER AIR BOX
PRESSURE PRESSURE
LOW NORMAL

Fig. 2 - Cut Away View Of Combination Low Water

And Crankcase Pressure Detector

6. Apply new “0” rings to valve stems reset button spring, reset button and
and lubricate with Lubriplate grease. retaining screw. Tighten retaining
Insert stem guide housing and slide screw to 15 in.-Ibs torque.
back and forth to ensure seating of “0”
ring without twisting. Clamp stem at 7. Place upper block containing oil pas-
major diameter in manner that will sages over water and air box pressure
not damage valve stem. Apply new portion with new “0” ring gasket.

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 M.I. 259

See Maintenance Data page for part

number of diaphragm centering fix-
ture. Release plunger to pull dia-
phragm beyond trip position: tighten
retaining bolts to 20 in.-lbs torque
before removing centering fixture.

11. Apply replacement steel balls to ball

retainer in center block with Lubri-
plate grease to hold in place. Place
center block with crankcase pressure
diaphragm spring over ball cup in
diaphragm. Position center block so
that vent fitting is at top of assembly.
Fig. 3 - Tool Kit
12. Tighten l/4”-20 cap screws retain-
Align assembly through valve stem
ing diaphragms in low water block
opening with alignment tool, see Main-
assembly to 40 in.-lbs torque.
tenance Data page for part number,
inserted to full engagement. Apply
13. Apply low water block assembly to the
four l/4”-20 x l-1/4” retaining bolts crankcase pressure assemblywith new
and tighten to40 in.-lbs. torque. Align- “0” ring gasket. Align with alignment
ment tool must be free of bind. tool, see Maintenance Data page for
8. Install low water valve stem assembly part number, inserted in valve stem
into valve body with new “0” ring opening to full engagement. Apply
gasket.’ Apply retaining bolts finger four long l/4”-20 retaining bolts and
tight. Depress reset button for full tighten to 40 in.-lbs torque. Alignment
engagement and hold while tightening tool must be free of bind.
retaining bolts to 15 in.-lbs torque.
Valve stem must move freely without
14. tnsert valve stem and reset buttoninto
bind.
valve block with new “0” ring gasket.
Depress crankcase pr es s ur e dia-
CRANKCASE PRESSURE SECTION
phragm spring with pressure of finger
9. Assemble new crankcase pressure inserted through opening in mounting
diaphragm, which has an aluminum face, against backup plate on dia-
backup plate on each side, to ball cup. phragm, until valve stem drops into
Backup plates must have raised edge ball latch assembly. Release dia-
facing away from diaphragm. Tighten phragm and depress reset button and
attaching screws to 5 in.-lbs torque. hold until diaphragm moves to latch
position to hold button depressed.
10. Assemble crankcase pressure dia- Apply retaining bolts and torque to
phragm between mounting housing and 15 in.-lbs torque. Depress crankcase
cover, with gasket on each side. Start pressure diaphragm spring to release
retaining bolts but do not tighten. valve stem and reset button. Quickly
Install diaphragm centering fixture depressing and releasing reset button
into ball cup and secure before align- should not reveal any binding during
ing pilot of fixture with cover opening. movement.

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INSTRUCTIONS FOR TESTING

Mount detector on test panel, see Mainte-

nance Data for part number, and test in
accordance with thefollowinginstructions.
The complete instructions apply to testing
the combination detector, however, the
single detectors (crankcase pressure and
low water pressure) will only use the
applicable section as outlined in the in-
structions.

The test panel uses air pressure only for

all tests, therefore an air supply of not
less than 80 psi pressure is required. It
must be remembered whenever the in-
structions call for an oil or water test
that these are made with air pressure,
No water or oil supply should be connected I49 3 - l

to the test panel. Fig. 4 - Air Supply Connection

To Test Panel
TEST PANEL CONNECTIONS

1. Visually check ports to be sure none

are plugged.

2. Connect test panel, see Maintenance

Data for part number, to 80 lbs.
minimum of cl&n, dry air supply.
See Fig, 4.

3. Mount detector on panel with two nuts

at top and bottom corners and fasten
adapter to water, air, and oil hoses
as shown in Fig. 5.
4. Fasten water line to port No. 4.
5. Fasten air line to port No. 3.
6. Fasten oil line to port No. 1, Turn
water, air, and oil valves to ON posi-
tion, in this order only, see Fig. 6.

LOW WATER TEST

7. Turn water pressure regulator to

attain 10 psi pressure. Latch low
water button then raise pressure to Fig, 5 - Test Panel Showing
50 psi. Hose Connection

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 M.I. 259

8. Turn air pressure regulator to attain

20 psi pressure.

9. Turn oil pressure regulator to attain

80 psi pressure.

10. Check for leaks with soap and water.

(No air blow through oil return port.)

11. Reduce oil and air pressure to 0 psi.

12. Reduce water pressure to 1 psi on

water gauge, No. 3, Fig. 6, Leave on
water valve, No. 12, and turn on water
valve, No. 13, to read in inches H20,
water gauge, No. 4.

13. Reduce water pressure to trip point of

low water button (see Maintenance Data
for trip point).

14. Raise water pressure to 28” H 0 and

check low water button. (Reset 3 utton
must latch.) Raise pressure to 40”
1. Air Gauge H20 to ensure positive latching.
2. Oil Gauge
3. Water Gauge - ibs. per sq, in. 15. Repeat check of trip and latch points.
4. Water Gauge - inches of water
5. Crankcase Gauge - inches of water
6. Air Pressure Regulator
16. Check both crankcase and low water
7. Oil Pressure Regulator buttons for overtravel in latchedposi-
a. Water Pressure Regulator tion (must be .015” minimum).
9. Crankcase Pressure Regulator
10. Air Valve
11. Oil Valve CRANKCASE PRESSURE TEST
12. Water Valve - lbs. per sq. in.
13. Water Valve - inches of water 17. Reduce water pressure regulator to
14. Crankcase Valve 0” H20. Close oil, air, and water
15. Surge Load Valve, (Not Used)
16. Surge Release Valve valves, in that order (No’s. 11, 10,12,
17. Oil Hose Connection and 13, Fig. 6).
18. Air Hose Connection
19. Water Hose Connection 18. Be sure crankcase pressure regulator
20. Vent Cap is in a decreased pressure position to
21. Port No. 1 - (Oil)
22. Port No. 3 - (Air) avoid damage to crankcase gauge (peg-
23. Port No. 2 - (Oil Outlet) ging needle) when crankcase valve is
24. Port No. 4 - (Water) turned on.
19, Crankcase pressure button must be in
Fig. 6 - Test Pane1 With latched position. May require holding
Combination Detector In button in until crankcase gauge reads
Position For Testing zero.

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M.I. 259

20. Turn crankcase valve to ON position 29. Turn water valve, No. 12, Fig. 6, to
and adjust crankcase pressure regu- OFF position.
lator until crankcase gauge reads zero.
If the needle remains above zero this 30. Remove water line from detector.
may be due to air being trapped in
back of detector, loosen mountingnuts 31. Position detector on spring tester (if
slightly to release the air and retighten not available use 8 lbs. weight) with
nuts. If needle fluctuates move crank- reset buttons upward.
case pressure button in and out in the
latched position and turn surge release 32. Deflect water reset button with ram on
knob on and off to obtain stable condi- spring tester, to bottom position and
tions. raise ram .032” and hold. Springforce
to be 8 lbs. minimum.
21. Turn crankcase pressure regulator to
raise pressure slowly until crankcase 33. Deflect crankcase reset button with
pressure button trips (see Maintenance ram on spring tester, to bottom posi-
Data for trip point). Repeat test three tion and raise ram .032” and hold.
times and use third test for final Spring force to be 8 Ibs. minimum.
reading.
34. Check lo-24 NC-2B thread at six
22. Reduce crankcase pressure regulator holes, depth l/2” - l-1/4” center to
to 0” H20 and turn crankcase valve center.
to OFF position. 35. Check 11/32” drill through eight holes
for size and location onmountingface.
23. Remove oil and air lines from detec-
tor .
36. Check vent cap (on top of reset button
block) for freeness. (Must be loose.)
GENERAL TESTS
37. Check button labels for securemount-
24. Remove detector from test panel and
ing.
lay on side with port No. 3 up.
38. Replace closure caps at reset buttons
25. Turn water valve, No. 12, Fig. 6, to and ports.
ON position.
TROUBLESHOOTING
26. Turn water pressure regulator topro-
vide 10 psi pressure, water gauge The following are some conditions and
No. 3, Fig. 6. their causes that may be encountered in
testing and servicing these detectors.
27. While turning water valve, No. 12,
Fig. 6, on and off observe movement 1. Low water button latches and trips in
of ball latch cup, within spring, through area of 30” H 0 pressure.
2
port No. 3. Travel must be .050”
minimum with low water valve button Ans. Steel balls are not all in l-lace in
in tripped position. ball retainer.

28. Turn water pressure regulator to zero 2. Low water button latch point OK, trip
reading of water gauge, No. 3, Fig. 6 point low.

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 M.I. 259

AI-F,. Alignment of air box diaphragm Ans, Water diaphragm faulty.

incorrect or, convolution in dia-
phragm is reversed. 8. .4ir leaking from bleed hole in dia-
phragm spacer. (Pressure applied
3. LOW water button latch point OK, trip only at air box port.)
point high.
Ans. Air box pressure diaphragm
Ans. Valve stem only partially latched, faulty.

4. Low water button fails to trip with air 9 . Crankcase pressure button trips at
box pressure and no water pressure. too high pressure.

Ans. Lack of pretravel in diaphragm. Ans. Incorrect diaphragm spring.

Lack of overtravel in valve stem.
10. Crankcase pressure button trips at
Misaligned valve stem passages. too low a pressure.
Incorrect or broken reset button
Ans. Incorrect diaphragm spring.
spring.
Valve stem only partially latched.
5. Engine oil pressure fails to build up
with reset buttons latched.
11. Tripping of low water portion trips
crankcase button, when testing on test
Ans. “0” ring in valve body missing
panel.
or damaged.
Ans. Transfer seal on test panel for
6. Air box pressure portion full of oil
exhausting oil dump line, leaking.
and c arbon .
Ans. Small “0” ring at valve stem in 12. Crankcase pressure button refuses to
the ball retainer is damaged or latch.
missing.
Ans. Positive pressure not being re-
7. Air leaking from bleed hole in dia- lieved from test panel.
phr agm spacer. (Pressure applied
only at water port.) Vent on top of device is plugged.

Litho in U.S.A
 MAINTENANCE DATA

8402726
and
8358536 8358537 8358538 8362040 8370362
Port No. 1 Oil Inlet Oil Inlet Oil Inlet Crankcase Oil Inlet
(100 PSI Max.) (100 PSI Max.) (100 PSI Max.) Normally Negative (100 PSI Max.)
Port No. 2 Oil Outlet Oil Outlet Oil Outlet Oil Outlet
Port No. 3 Air Box Air Box Air Box Breather and
(0 to 20 PSI) (0 to 20 PSI) (0 to 20 PSI) Test
Port No. 4 Engine Cooling Engine Cooling Engine Cooling Crankcase
Water (0 to 60 PSI) Water (0 to 60 PSI) Water (0 to 60 PSI) Normally Negative
Port No. 5 Breather and
Test
Port No. 6 Crankcase
Normally Negative

Test Limits
8358536 Port No. 1 normally blocked from Port No. 2.
and Port No. 1 connected to Port No. 2 if Port No. 4 pressure does not exceed Port No. 3 pressure
8358537 by 10” to 20” H20.
Manually resetable when Port No. 4 pressure exceeds Port No. 3 pressure by 28” H20 maximum.
8358538 Port No. 1 normally blocked from Port No. 2.
Port No. 1 connected to Port No. 2 if:
a. Port No. 4 pressure does not exceed Port No. 3 pressure by 10” to 20” H20.
b. Crankcase pressure exceeds .8” to 1.7” H20.
Low Water Detector:
Manually resetable when Port No. 4 pressure exceeds Port No. 3 pressure by 28” H20 maximum.
Crankcase Explosion Detector:
Manually resetable when crankcase pressure does not exceed 0” H20.
 MAINTENANCE DATA (CONT’D)

8362040 Crankcase Explosion Detector:

Manually resetable when crankcase pressure does not exceed zero psi.
Trips from .8” to 1.7” H20.
Switch:
Single pole, double throw
Rating - 110 V AC - 2 Amps.
74 V DC - 6 Amps.
8370362 Crankcase Explosion Detector:
I Manually resetable when crankcase pressure does not exceed zero psi.
Y Shutdown or trip point .8” to 1.7” H,O.
kl
I 84027i.3 Port No. 1 normally blocked from Pozt No. 2.
Port No. 1 connected to Port No. 2 if Port No. 4 pressure does not exceed Port No. 3 pressure
by 5” to 10” H20.
Manually resetable when Port No. 4 pressure exceeds Port No. 3 pressure by 10” to 15”
H20 maximum.
This detector is physically identical to 8358537 detector except there is no red diaphragm spring.

EQUIPMENT LIST
Test Panel 8349133
Alignment Tool 8361214
Air Box Diaphragm Centering
Fixture 8361216
Crankcase Diaphragm Centering
Fixture 8361217
Torque and T-Bar Wrench Kit 8361215