SERVICE MANUAL

DISASSEM BLY AN D ASSEM BLY

D379, D39EI A, DSs|s|
INIDIJSTFIIAL AND
MAFIII\IE EI\IGINES
SEBIAL NUMBERS
D379: 688254O-UP AND 6981227-UP
D398: 6683561-UP AND 6781391-UP
D399: 358688-UP AND 918387-UP
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

ALPHABETICAL INDEX

Page Oper.
No. No.

Accessory Drive Gears .......25-28 14

Accessory Drive Housing .....23,24 13
AftercoolerCores ....,|,|3 59
Aftercooler Housing ......1'11 ,112 58
Air Cleaner Housings .. . ... . .. 108 55
A¡rstarter ...115 61
Air Starter, Disassemble & Assemble . 116-1 18 62

Camshaft .127-129 67
Camshaft Bearings .. 130
.. 68
Connecting Rod Bearings ....43,44 24
Crankshaft 1 31 -135 69
Crankshaft Front Seal Ring and Thrower ... ...21 ,22 't2
Crankshaft Main Bearings ....45,46 25
Crankshaft Rear Seal Ring and Thrower . . . . ,121,122 64
Cylinder Heads .....98,99 48
Cylinder Liners . ..103,104 51

EfectricStartingMotors ......'114 60
Cooler
Engine Oil . . 35,36 19
ExhaustManifolds(lndustrial Engines) ..... ...72-74 37
Exhaust Manifolds (Marine Engines) .. .75,76 38
Expansion Tank .. . ... 13 o

Flywheel .119,120 63
Flywheel Hous¡ng .123,124 65
FreshWaterPump . ....37 20
FreshWaterPump, Disassemble&Assemble ....38-40 21
Fuel FilterHousing ....'14 7
Fuel njection Lines
f .......... 7'l 36
Fuel Inlection Pumps ......... 70 2E
Fuel nlection Pump Housing, Disassemble & Assemble
f . .79-87 .&^ó
Fuel Injection Pump Housing, Safety Shutoff, Governor,
andGovernorDriveAsaUnit. ......77,78 39
Fuel Injection Valves . .. . ..... . 90 42
Fuel Priming Pump . .......... 10 a
Fuel Priming Pump, Disassemble & Assemble ..... 11 4
Fuel RatioControl withOverr¡de .......50 28
Fuel RatioControlwithOverride,Disassemble&Assemble ........ 51 29
Fuel TransferPump. .-.,.,.,,..7 I

Fuel Transfer Pump, Disassemble&Assemble .....8,9 2

Generator 136,137 70
Governor ..... 52 30
Governor, Disassemble &Assemble ....53-61 31
Governor Drive Housing, Disassemble &Assemble ......88,89 41

f ntake Man¡folds ..... ........ 97 47

Marine Gear ......138,139 71

Oil Filter Housing ...... 15 I

Oil Pan Base .......... 48 27
Oil Pressure Regulat¡ng Valve .. . -....... 29 15
Oil Pressure Regulating Valve, Disassemble & Assemble .... 29 to
Oil Pumo .. ..30 17
Oil Pump,Disassemble&Assemble ... 31-34 18

Pistons . .. 100.101 49
Pistons,Disassemble&Assemble .......1O2 50
Piston Cooling Tubes . ......... 47 26
PrecombustionChambers ......9'l 43
PrefubricationOil Pump .......41 22
Prelubrication Oil Pump,Disassemble&Assemble ........ 42 23

RearTimingGears.. ......125,126 66
RockerShaftsandPushRods . .........92 44
RockerShafts, Disassemble&Assemble .......93,94 45
 AITD MARINE ENGINES
DISASSEMBLY AND

ALPHABETICAL INDEX

Page Oper.
No. No.

Safety Shutoff, Disassemble & Assemble 32

Sea Water Purnp 33
Sea Water Pump, Disassemble & Assemble I
Sump Pump 10
107 54
Turbochargers
Turbochariern"rtsr'¡Lli .'"" 110 57
"
rurbocharier r-uu'¡""iüi ü"j;; ::::::.::::.:::: 56
10e Turbocharier¡-uor¡caiionVatve,Disassemoleanssemlie 52
.:::::::::::::::l:::.: 53
133
Valve Covers
Valr¡eLifters ... 34
Vibration Damper 95,96 46
.. 20 11
Water Temperature Regulators
't2 5
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

SERVICE INDEX

OPERATION PAGE
NO. COMPONENT OPERATIONS OTHER NEEDED OPERATIONS NO.

1 Fuel Transfer Pump 7

2 Fuel Transfer Pump, Disassemble &

Assemble 1 8,9
3 Fuel Priming Pump 10
4 Fuel Priming Pump, Disassemble &
Assemble 3 11

5 Water Temperature Regulators 't2

6 Exoansion Tank 13

7 Fuel Filter Housing 6 14

8 Oil Filter Housing 6,7 15

9 Sea Water Pumo 16

10 Sea Water Pump, Disassemble & Assemble I 17-19
11 Vibration Damper (D398 & D399 Enginesl 20
12 Crankshaft Front Seal Ring and Thrower 11 21 ,22

13 Accessory Drive Housing 1'l 23,24

14 Accessory Drive Gears 11,12,13 25-28
15 Oil Pressure Regulating Valve 29
16 Oil Pressure Regulating Valve, Disassemble &
Assemble 15 29
17 Oil Pump 30
18 Oil Pump, Disassemble & Assemble 17 31-34
19 Engine Oil Cooler 35,36

) 20 Fresh Water PumD 37

21 Fresh Water Pump, Disassemble & Assemble 20 3840
22 Prelubrication Oil Pump (D399 Engine) 41

23 Prelubrication Oil Pump (D399 Enginel,

Disassemble & Assemble 22 42
24 Connecting Rod Bearings 15,17,',19,20 43,44
25 Crankshaft Main Bearings 15,17,19,20 45,46
26 Piston Cooling Tubes 15,17,19,20 47

27 Oil Pan Base 48

2A Fuel Ratio Control with Override 50

29 Fuel Ratio Control with Override,

Disassemble & Assemble 2A 51

30 Governor 52
31 Governor, Disassemble & Assemble 30 53-61

32 Safety Shutoff 62
33 Safety Shutoff. Diassemble & Assemble 32 63-68
u Valve Covers 69
35 Fuel Injection Pumps 70
36 Fuel Injection Lines 71

37 Exhaust Manifolds (lndústrial Enginesl 34,36 72-74

38 Exhaust Manifolds (Marine Enginesl 34,36,55 75,76
39 Fuel Injection Pump Housing, Safety
Shutoff, Governor, and Governor Drive,
Ac a I lnit 77.78
 trDt, E, re irousrRrAl AND MARTNE ENGTNEs
DISASSEMBLY AI\ ID

SERVICE IND EX
OPERATION
NO. COMPONENT OPERATIONS PAGE
OTHER NEEDED OPERATIONS NO.
40 Fuel Injection Pump Housing, Disassemble
& Assemble 30.32,34,36,37,38,39 79-87
41 Governor Drive Housing, Disassemble &
Assemble
30,32,34,36,37.38,39 88.89
42 Fuel Injection Valves
90
43 Precombustion Chambers
41
91
44 Rocker Shafts and Push Rods
34
92
45 Flocker Shafts, Disassemble & Assemble
34,43 93,94
46 Valve Lifters
15,17,19,20,26,30.32
34,36,37,38,39 95,96
47 Intake Manifolds
97
48 Cylinder Heads
u,36,43,46 98,99
49 l'tstons
1 5,1 7,1 9,20,34,36,43,
46,47 100,101
50 t'rstons, D¡sassemble & Assemble
1 5,17,1 9,20,34,36,43,
46,47,4A,49
102
51 Cylinder Liners 1 5,1 7 .1 9,20.34,36,43,
46,47,48.49 103 104
52 I urbocharger Lubrication Valve
105
53 Turbocharger Lubr¡cation Valve,
Disassemble & Assemble 51
106
54 Sump Pump
107
55 Air Cleaner Housings
108
56 Turbocharger Heat Shietd
109
57 Turbochargers
54,55 110
58 Aftercooler Housing 54.55 111,1't2
59 Aftercooler Cores
54,55,57 113
60 Electric Starting Motors
114
61 Atr Starter
115
62 Air Starter, Disassemble & Assemble 61
1 16-1 18
63 Flywheel
119,120
64 Crankshaft Rear Seal Ring and Thrower
62 121 .122
65 Frywheel Housing
54,55,57,59,60 123,124
66 tlear Timing Gears 54,55,57,59,60,64 125,126
67 Camshaft
1 I ,s6,37.38.39.54,
55,57,59,60,64 127-129
68 Camshaft Bearings
1 1,1 5,1 7,1 9,20,26,30,
32,34,36,37,38,39,il,
55,57,59,60,61 ,64,66 130
69 Crankshaft
11 ,12,19,46,V,55,57,
59,60,61',63,64 131-f35
70 Generator
r 36,137
71 Manne Gear
1 38,1 39

I
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FUEL TRANSFER PUMP

REMOVE FUEL TRANSFER PUMP 11_1256
l. Turn the fuel valve to the "OFF" position.

2. Remove the bolt (1) from the clamp that

holds fuel line to accessory drive housing.

3. Disconnect the fuel lines (2) from the

pump. Remove the two bolts (3) that hold
pump to accessory housing. Remove the
fuel transfer pump.

INSTALL FUEL TRANSFER PUMP 12_1256

l. Put the fuel transfer pump (l) on the en-
gine. lnstall the two bolts that hold pump
to housing.

2. Connect the fuel lines to the pump.

3. Install the bolt that holds clamp to housing.

4. Turn the fuel valve to the "ON" position.

tii
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSE

FUEL TRANSFER PUMP

DISASSEMBLE FUEL TRANSFER
PUMP 15-1256
Tools Needed

958099 Bushing Driver 1

start by:
a) remove fuel transfer pump
1. Remove the bolts (l) that hold cover to
body.

2. Remove the cover (2) from the body.

CAUTION: Do not cause damage to machined sur-

face of the cover or body.

3. Remove the lock ring (3) that holds cage to

shaft.

4. Remove the idler gear (6) and shaft (5)

from the body.

5. Remove caee (4) from the body.

6. Remove carbon seal and washer from case

(4\.

7. Remove bearing, lip-type seal, and retainer

from the cage with tool (A).

8. Remove O-ring seals from the cage and the

retainer.

9. Remove bearing from the body. e60;5x ¡

¿t
TX}79, D3S, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL TRANSFER PUMP

ASSEMBLE FUEL TRANSFER PUMP 16_1256
Tools Needed A B

958@9 Bushing Driver 1

1P529 Handle 1

1P462 Drive Plate 1

l. Clean all parts before assembly.

2. Install bearing (l) in cage (5) with driver

(A).
3. Install lip-type seal (2) in cage with lip of
seal toward pump end of cage using tooling
(B).

4. Put lubricant on O-ring seals and install seal

(4) on retainer (3).

5. Install retainer (3) in cage (5).

6. Install the O-ring seals on cage (5).

7. Install the bearing in body (6) with driver

(A).

8. Install the washer in body (6).

9. Put a small amount of clean oil on the in-
side diameter of rubber ring and wea¡ face
of carbon seal.

10. Put the carbon seal on body and install cage

( s).

ll. Put tape over the square edges of shaft to

protect seals. Install the shaft and idler gear
in body. Install lock ring.

12. Plut a small amount of 856747 Liquid Gas-

ket to machined surface of bodv.

CAUTION: Do not let liquid gasket get in the

pump.

13. Install cover and retaining bolts.

NOTE: Shaft must turn freelv after cover bolts are

tightened.

end by:
a) install fuel transfer pump
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND

FUEL PRIMING PUMP

REMOVE FUEL PRIMING PUMP 11_1258

1. Turn fuel valve to the "OFF" position'

2. Disconnect inlet lines (3) from the pump'

3. Remove outlet line (1) from the pump.

4. Remove the two bolts that hold the brack-

et. Remove the bolts (2) that hold the base'

5. Remove the fuel Priming PumP.

INSTALL FUEL PRIMING PUMP 12_1258

l. Put the pump (1) on filter housing. Connect

the outlet line for the fuel.

2. Install the bolts that hold base to fuel filter

housing.

3. Install the two bolts for the bracket.

4. Connect the inlet lines to the priming

pump.

5. Turn the fuel valve to the "ON" position.

lp
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL PRIMING PUMP

DISASSEMBLE FUEL PR¡MING PUMP 15_1258

start by:
a) remove fuel priming pump
l. Remove the tube (2) from valve body (l).

2. Remove bracket (3) and retainer from tube.

3. Remove knob, nut, plate, guide and spring.

Remove piston and rod from the tube.

4. Remove the rings (4) and O-ring seals from

piston (5).

5. Remove plug, washer, springs, valve, and O-

ring seal from valve body. ?r¿t3x!

ASSEMBLE FUEL PRIMING PUMP 16_1258

Tools Needed

Compressor 1

l. Install the O-ring seal, springs (3), valve (2),

washer and plug in the valve body ( l).

2. Put a small amount of 4L7464 Silicone

Grease on the rings and seals.
7t?l6xt

3. Put the O-ring seals on piston. Install the

rings over the O-ring seals.

- Install the piston in the tube with tool (A).

Install the spring, guide, plate, nut and knob
on the rod (4). Install the bracket and re-
tainer.

5. Put the tube (5) on the valve body.

end by:
a) install fuel priming pump

11
 D379, D398, D399 IN;USTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBL

WATER TEMPERATURE REGULATORS

REMOVE WATER TEMPERATURE
REGULATORS 11_1355

l. Remove coolant from engine to a level be-

low the regulator housing.

2. Remove the four bolts (1) that hold elbow

of the expansion tank to the cover. Remove
line (3) on Marine engines.

3. On Industrial engines only, disconnect the

water bypass line from the cover. Remove
the cover from the bottom. Remove the reg-
ulators from the cover.

4. Remove the cover (2).

5. Remove the regulators (4) from the hous-

ing.

6. Remove the seals from the housing.

INSTALL WATE R TEMPERATU RE

REGULATORS 12_1355
Tools Needed A

1P529 Handle 1

F 1P489 Drive Plate 1

F
l. Put new seals (l) in the housing with tool-
ing (A). Install seals with lip of seal away
from regulator.

2. Clean the machined surfaces and install new

., gasket for cover.

3. Install the regulators (2) in the housing on

the Marine engines. Install the cover.

4. On Industrial engines, install the regulators

in the cover and install cover. Connect the
bypass üne for the water.

5. Install the bolts that hold elbow of the ex-

pansion tank to cover.

6. Fill the engine with coolant.

t2
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

EXPANSION TANK (MARINE ENGINES)

REMOVE EXPANSION TANK
(MARINE ENGINES) 11-1354
1. Remove coolant from engine. Disconnect
lines for switch from expansion tank. Re-
move two bolts that hold switch to ex-
pansion tank. Remove the switch.

2. Remove the hose (l) and clamps from ex-

pansion tank. Remove ventilation line (3).
Remove bolts (2) that hold housine to ex-
pansion tank.

3. Fasten a hoist to expansion tank. Remove

bolts from the two braces that hold exDan-
sion tank in position.

4. Loosen clamp (5) that holds the tubes ro_

gether. Remove the bolts (4) thathold tube
(7) to expansion tank. Remove bolts that
hold brackets (6) to oil filter housing. Re_
move expansion tank. Weight is 220 lb.
(100 ke).

INSTALL EXPANSION TANK

(MARINE ENGINES) 12-13il
l. Use a hoist and put expansion tank in posi-
tion on engine. Install bolts that hold the
brackets to oil filter housing. Install bolts
that hold outlet tube (l) to expansion tank.
Tighten clamp that holds ouflet tubes to-
gether.

Install bolts that hold braces to expansion

tank. Remove hoist from expansion fank.

3. Install bolts that fasten temperature reg-

ulator housing and expansion tank together.
Install overflow hose and clamps on expan-
sion tank. Install the ventilation line.

A
T Install the switch (2) on expansion tank.
Connect the lines (3) to switch.

5. Fill the engine with coolant.

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND

FUEL FILTER
REMOVE FUEL FILTER
HOUSING 11-1262

start bY:
a) remove expansion tank (Marine en-
gines only)
b) remove fuel Priming PumP
1. Remove fuel from the filter housing'

2. Disconnect fuel line (2) for the pressure

gauge.

3. Disconnect inlet line (1) for the injection

pump housing.

4. Disconnect fuel line (3) for the transfer

pump.

5. Remove the four bolts (4) that hold the

housing on the oil filter housing'

6. Remove the fuel filter housing'

INSTALL FUEL FILTER HOUSING 12_1262

1. Put the fuel filter housing in position on the

engine. Install the bolts that hold housing to
oil filter housing.

2. Connect the fuel line for the transfer pump'

3. Connect inlet line for the injection pump

housing.

4. Connect fuel line for the pressure gauge'

end by:
a) install fuel Priming PumP
b) install expansion tank (Marine en-
gines only)
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

OI L FILTER HOUSI NG
REMOVE OIL FILTER HOUSING 11_1306

start by:
a) remove fuel filter housing
1. Remove oil from the filter housing.

2. Remove bolt that holds clamp (2) to mani-

fold.

3. Remove the clamp (1) that holds outlet

lines together. Install two 3lB"-16 NC
forged eyebolts, washers and nuts in brack-
et.

4. Fasten a hoist. Remove the four bolts (3)

that hold housing to block.

5. Remove oil filter housing. Weight is 1l0lb.

(s0 ke).

INSTALL OIL FILTER HOUSING 12-1306

l. Fasten a hoist to the filter housing.
2. Install a new seal in back of the housing.
3. Put the housing in position on engine. In-
stall bolts that hold housing on engine.
4. Install clamp that holds outlet lines to-
gether. Install bolt that holds clamp to the
manifold.
5. Check the oil level in crankcase. Fill to the
correct level.

a) install fuel filter housing

l5
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND

SEA WATER PUMP

REMOVE SEA WATER PUMP 11-1371

l. Remove plug from bottom of pump and re-

move sea water from PumP.

2. Disconnect inlet line from cover (3).

3. Remove elbow (1) and top tank (2) from

the pump.

4. Remove the retainer assembly (4).

5. Remove cover (3) and gaskets from the

pump.

6. Remove the six bolts that hold pump to

accessory drive housing.

7. Remove the sea water pump.

INSTALL SEA WATER PUMP 12-1371

l. Put the sea water pump (l) on the engine'

Install the bolts that hold pump to acces-
sory drive housing.

2. Install the retainer assembly (4).

3. Install the cover (2) with enough gaskets (5)

to have a clearance of .005 to .020 in. (0.13
to 0.51 mm) between cover (2) and face of
impeller (3).

4. Install the toP tank and elbow.

5. Connect the inlet line to cover (2). Install

1
I
the plug in bottom of PumP.
I
t
t
D379, D3fN, D399INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

SEA WATER PUMP

i-J
--]-
-ll-
T97915x2
 DISASSEMBLY AND
ENGINES
D379, D398, D399INDUSTRIAL AND MARINE

SEA WATER PUMP

DISASSEMBLE SEA WATER PUMP 15-1371
A

1P2321 Puller Assemblv 1

2
FT884 Les
1

start bY:
a) remove sea water PumP
-Needed that
1. Remove the cotter pin' nut and washer
hold imPeller to shaft'

even with end of sh-aft' In-

- Installtwothe5i nut
2.
16"-18 NC x 2 in' long bolts in
tl"fi
irr.- Itnptti.t. Loosen the impeller from
taper ofshaft with tooling (A)'

3. Remove tooling (A)' Remove nut' impeller'

plate and gasket (1)'

4. Remove the cotter pins (4) and ring (2)

from pins.

Remove the Plate (3) and bellows

(5) from
5.
the housing.

6. Remove six bolts and locks'

7. Remove the gear (6) from shaft'

8. four bolts (9) and locks that hold

-' Remove on
Ltuii"g retainer' Remove bearing (10)'

bolts (8) and locks that hold

-' Remove twohousing'
9.
i"tuin.t to Remove retainer assem-
bly (7).

10. Remove the bearing (11) from retainer'

I I . Remove the seal ( 12) from retainer'

l8
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

SEA WATER PUMP

ASSEMBLE SEA WATER PUMP 16-1371
Tools Needed B

1P529 Handle 1
,|

lP475 Drive Plate I

1P466 Drive Plate 1

I P483 Drive Plate 1

l. Install bearing in retainer with tooling (A)

Install bearing with oil hole in bearing in
alignment with oil hole in retainer.

2. Install seal in retainer with tooling (B). In-

stall seal with lip toward the bearing.

3. Put clean engine oil on lip of seal.

4. Install retainer assembly (3). Install the

bearing (4). Install the shaft (2).

5. Install the gear (l) on shaft.

6. Install the bellows and plate in housing. The

smooth side of plate must be away from
housing.

7. Install the ring (5) and cotter pins.

8. Install the gasket and plate. The smooth

side of plate must be away from impeller.

9. Install the impeller (6).

j Install the washer and nut (7). Tighten the

rrut to 55 t l0 lb.ft. (1.6¡ 1.4 mkg) and
install cotter pin. If cotter pin cannot be
installed, tighten nut until it can be in-
stalled.
end by:
a) install sea water pump

l9
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND

VIBRATION DAMPER (D398 and D399)

REMOVE VIBRATION DAMPER
(D398 & D399) 11-1205

1. On D398, remove the bolts (1). Put an

identification mark on bolts (3) and (4) and
housing. Remove the cover (2).

2. On D399, remove bolts that hold the cover.

Remove the cover.

J. On D398, remove the bolts that hold vibra-

tion damper. Install two 1P7407 Eyebolts
in the tapped holes of the vibration damper.
Fasten a hoist.

4. On D399, remove the bolts that hold vibra-

tion damper. Install two bolts (6) as a guide.
Move the vibration damper out on the guide
bolts with forcing screws (5). Fasten a hoist
and remove vibration damper. Weight of
D399 damper is 2'70 lb. (122 kg) and the
D398 is l30lb. (59 ke).

CAUTION: Do not hit the vibration damper.

INSTALL VIBRATION DAMPER

(D3e8 & D39e) 12-1205
t
li.
l. Install two bolts as guide. Fasten a hoist to
ftlitt the vibration damper. Put the damper in
position on the adapter.
tlriii
'11 2. Put 953263 Thread Lock on the threads of
bolts for vibration damper. Put thread lock
on the two bolts with a mark for cover on
Rrli,i
€,' r
the D398.
3. Install the bolts and remove guide bolts.
Tighten the 1 in. bolts (1) to 6701 50lb.ft.
(92.7 x 6.9 mkg) on D399. Tighten the
bolts (l) on D398 to 280 x 20 lb.ft.
(38.7 t 2.8 mkg).
4. Install cover (2) on D399. Install cover on
D398 with bolts that have a mark in respec-
tive place on housing.

20
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

CRANKSHAFT FRONT SEAL RING AND THROWER -f

REMOVE CRANKSHAFT FRONT SEAL
) RING AND THROWER 11_1160

5F7341 Adapter
8H684 Ratchet Box Wrencn
E87561 Step Ptate
1P2321 PullerAttachment

start by:
a) remove vibration damper (D39g and
D399 onty)
I. On D379 only, remove the cover (l). put a
mark on two bolts (2) for installation.

l. Remove the bolts that hold adapter (3) to

the crankshaft.

Use tooling (A) to remove the adapter (3).

Remove the baffle (4) from accessory drive

itoLlslng.

Remove ring (5) and spring from the

:1rower.

L-.stall tooling (B) on the thrower. put heat

-:: the outer diameter of thrower with an
-::n flame at a maximum temperature of
:-0'F (204"C). Remove the tñrower im-
- =.1iateiy with toolinC (B).

l..:-.oie the ring from the accessory drive

-:.- -

21
{
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DI SASSEMBLY AN D ASSEMBLY

CRANKSHAFT FRONT SEAL RING AND THROWER

INSTALL CRANKSHAFT FRONT SEAL
RING AND THROWER 12_1160
Tools Needed

FT105 Push Plate I

T603 Bolt 2

9H1031 Washer 2

1. Put 8M8060 Quick Cure Primer and 953265

Retaining Compound on ring. Install ring in
accessory drive housing.

2. Heat the thrower (l) in oil to a maximum

temperature of 400'F (205"C). Install
thrower on crankshaft. Use tooling (A) to
install thrower in correct location on crank-
shaft.

CAUTION: Do not install a used oil thrower. seal

ring or spring.

3. Put clean engine oil on the spring and ring.

Install spring and ring (2) on thrower with
the work "OIJT" on ring away from crank-
case. Put the gap of the ring, to top of
crankshaft when installed.

4. Put clean engine oil on inside diameter

baffle (3). Install the baffle (3).

l
: 5. Put 953263 Thread Lock on threads of
il
bolts for adapter.

Install the adapter (4) on D379 only. Put

7M7456 Loctite Sealant on two of bolts
for cover.

7. Install the cover on D379 only. Put bolts

with Loctite in location with X mark.
end by:
a) install vibration damper (D398 and
D399 only)

22
D379, D398. D399 INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

ACCESSORY DRIVE HOUSING

REMOVE ACCESSORY DRIVE
HOUSING 11-1207
Tools Needed A
487il8 Push puller 1

887550 Les 2
5F7341 Adapter 2
8H684 Ratchet Box Wrench 1

start by:
a) remove vibration damper (D399 &
D399)
b) remove fuel transfer pump
c) remove oil pressure regulating valve
l. On D379 only, remove the adapter cover.
Remove bolts for the adapter. Remove the
adapter (1) with tooling (A).
1 Remove the baffle (2) from the accessorv
drive housing.

3. Remove the seal ring and spring from the

thrower.

4. Remove the fuel lines (3) from fuel filter

housing. Remove eleven bolts (5) that hold
accessory drive housing to cylinder block.

5- Remove four bolts that hold plate (4) for

oil pump to oil pan base.
tó. Remove the four bolts (6) that hold water
pump to housing. Remove the four bólts (g)
that hold oil pump to housing.
T- Remove or disconnect all connections from
cylinder block to oil pan base.

'1, Remove the bolts that hold timing gear

plate to accessory drive housing on left side
of engine.
!l- Faen a hoist to front of engine. Loosen
fu bolts that hold cylinder block to oil pan
hE- Lift the engine enough to install
SÉTS (7) between cylinder block and oil
p base.

n- h{l ttro l12"-13 NC bolts as a guide. In

d tro 3/8"-16 NC forged eyibolts in
rel. ory drive housing. Fasten a hoist and
¡rr¡e the accessory drive housing. Weight
b ID Ib. l9l kg).
 DISASSEMBLY AND ASSEMBLY
D379, D398. D399 INDUSTRIAL AND MARINE ENGINES

ACCESSORY DR IVE HOUSING

INSTALL ACCESSORY DRIVE
HOUSING 12-1207

l. Install two I12"-13 NC bolts as a guide in

the cylinder block' Install two 3/8"-16 NC
forged eyebolts in drive housing' Fasteu a
hoist and put accessory drive housing on en-
gme.

2. Install the eleven bolts (5) that hold drive

housing to cYlinder block.

3. Install the bolts (1) that hold drive hottstug

to timing gear Plate (2).

4. Connect the fuel lines (3) to fuel filter hous-

ing.
Kts
5. Install bolts that hold the water pump and
oil pump to drive housrng.

6. Fasten a hoist and lift the front of engine

enough to remove the spacers from between
cyünáer block and oil pan base. Tighten the
bolts that hold cylinder block to base'

7. Install the four bolts that hold plate (4) for -ql
oil pump to oil pan base. Install or connect .\.. ''
ail óf the lines for engine between cylinder
?
block and oil Pan base.

8. Put clean engineoil on spring'and seal ring'

Install the spring and seal ring on thrower
with the word "OUT" on seal ring installed
away from crankshaft. Put the gap of seal
ring to top of crankshaft when installed'

9. Put clean engine oil on inside diameter of

baffle. Install the baffle'

10. Put 953263 Thread Lock on threads of {

bolts for adapter. Install the adapter on
D379 only. Put 7M7456 Loctite Sealer on
two of bolts for cover. Install the cover for
adapter. Put bolts with Loctite in locations
(6) and (7).
end by:
a) install vibration damper (D398 &
D399 onlY)
b) install oil pressure regulating valve
c) install fuel trausfer PumP

)/1
D379, D398. D399 INDUSTRIAL AND
MARINE ENGINES DISASSEMBLY AND ASSEMBLY

ACCESSORY DRIVE GEARS

/,2
tr
\
"3;-.t'

SAE STANDARD ROTATION ILLUSTRATION D379

D379, D398, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

ACCESSORY DRIVE GEARS

REMOVE ACCESSORY DRIVE
GEARS 11-1206
Tools Needed A

1P2321 Puller Assembly 1

FT884 Leg 3

start by:
a) remove accessory drive housing
l. Remove bolts and locks from water pump
drive gear (2). Remove gear from shaft.
2. Remove oil pump drive gear (4) from its
shaft.
3. Remove the main idler gear (l) and its
shaft. Turn the crankshaft to get bolts that
hold shaft to cylinder block and plate (3).
4. Remove bearings from gears (l), (2), and
(4).
5. On D379 only, install tooling (A) on the
thrower. Put heat on the outer diameter of
thrower with an open flame at a maximum
temperature of 400'F (205'C). Remove the
thrower immediately with tooling (A).
6. Remove the balancer gear (6).
1 Remove the bearing from balancer gear.
8. Remove oil tube (5) from plate. If plate is
to be removed, remove oil pump and fresh
water pump. Remove plate (3) from cyl-
inder block.
NOTE: Check the mark on plate for correct instal-
lation. The front of plate for SAE standard rota-
tion engine (counterclockwise as viewed from
flywheel end) is marked "FRONT STD. ROT."
The front of plate for SAE opposite rotation en-
gine (clockwise as viewed from the flywheel end) is
marked "FRONT REV. ROT."

26
D379, D398, D3gg INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

ACCESSORY DRIVE GEARS

INSTALL ACCESSORY DR IVE
GEARS 12-1206

1P473 Drive Plate

l. Install the plate (3) on cylinder block.

Tighten five ll2" bolts to 90 t 5 lb.ft.
(12.5 ¡ 0.7 mke).
!UTE: Be sure the plate is installed on correct side
¡indicated in removal.
l- Install the oil tube (1). Install small gaskets
unde¡ nuts that hold right end of tube. put
7M7260 Liquid Gasket Material on sealing
. surfaces of idler gear shaft oil tube (l), and
. shaft for main idler gear (2).
3- On D379 engine only, install bearing in bal-
ancer gear with toolinC (A). Install the bal_
:rncer gear and shaft. Tighten bolts to 40 x 4
Ib.ft. (5.5 t 0.6 mkg).
{ Install bearings in the gears for oil pump
and main idler gear.
: The gear train of accessory drive are the
1m the 8, 12, and 16 cylinder engines, except
bhnss¡ gear used on 8 cylinder engine. On
_sEndard ¡otation (counterclockwise)
,,B"
engines,
hbncer gear timing mark must be in
with the tooth on crankshaft gear with
naks (four, five or six punch marks).
5- I¡stall main idler gear and shaft. Install en- SAE Standard Rotation 8 Cylinder Engine
girc oil pump and fresh water pump. Install
¡cas for oil pump and water pump.
 DISASSEMBLY AN D ASSEMBLY
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

ACCESSORY DRIVE GEARS

sary.

SAE OPPOSITE ROTATION

8 CYLINDER ENGINE

cation on crankshaft.

CAUTION: Do not use anoldoil thtower' seal ring

or spring.
end bY:
a) install accessory drive housing

dt'
I
I
28
] J-9 D398, D399 INDUSTRIAL
AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

OIL PRESSURE REGULATING VALVE

::.,:OVE OIL PRESSURE REGULATING
- : ]-VE
11-1304
Remove the bolts (2) that hold valve to oil
:an.

- -1.,.ntove valve and tube from the tee fl).

: -: L L OIL PRESSURE REGULATING
,_ : 12_1304
: - -e valve and tube in the tee.

., the bolts that hold valve to oil pan.

. -:i::"BLE OIL pRESSURE
:: - - ---l\G VALVE 1b_1304

.:]to\¡e oil pressure regulating valve

. the bolts (2) that hold tube to
= Remove the tube (l).

guide from

L PRESSURE
\,/ALVE 16-1304
---t-
);Jl\.

,:._:rite oil in the bore of housing

_- .-,: (l). spring (3), and piston

. Install the tube (5) on hous_

' rjSSur€ regulating valve 6 ll76x 2

29
D379, D398, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMSLY

ol L PUMP
REMOVE OIL PUMP 11_1304

start by:
a) remove fuel transfer pump
l Remove six bolts that hold adapter. Re-
move the adapter (2).

2. Remove the drive gear (l) for the oil pump.

3. Remove the bolts (3) that hold elbow to the

tee. Remove three bolts that hold pipe (4)
to the oil pump. Remove two bolts that
hold oil pressure regulating valve to oil pan
base. Remove the valve, tube and tee as a
unit.
4. Fasten a hoist to the pump.

5. Remove the bolts (5) that hold pump to

accessory drive housing. Remove the oil
pump.Weight is 100Ib. (45 kg).

INSTALL OIL PUMP 12-1304

1. Fasten a hoist to the oil pump. Put the

pump in position on accessory drive housing
and oil pan base.

2. Install the pressure regulating valve, tube,

and tee as a unit (1).

3. Install drive gear assembly on the pump

shaft.

4. Install the adapter assembly on accessory

drive housing.
end by:
a) install fuel transfer pump

30
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

OIL PUMP
DISASSEMBLE OIL PUMP 15-1304 :: :

1P467 Drive Plate

1P471 Drive Plate
1P476 Drive Plate
1P479 Drive Plate

1112in.l.D. Pipe 6 in. long

start by:
a) remove oil pump
l - Remove seven bolts (2) that hold cover to
¡ear manifold (l). Remove the cover (3).

a Remove nine bolts (4) that hold rear mani-

fold to intake manifold (5). Remove the rear
manifold (l).

Put a alignment mark on manifolds and a

mark for longest bolt for installation.

!' }oove the pressure manifold (6).

ltnow the shaft (7). Remove the gear (8)

d kc-r from the shaft.

b¡e tro idle¡ gears (9) from the idler

rS,

¡Írn¡ bearings from the idler gears

r-{r-

3l
 ASSEMBLY
DISASSEMBLY AND
AND MARINE ENGINES
D379. D398, D399 INDUSTRIAL

OIL PUMP
the idler shafts
7. Use tooling (D) to {:T?ut
from the intake manllolo'

(10) and locks that hold

8. Remove the bolts manifold' Re-
retainer assembl; io intatte(11)'
*o"" ,tt" retainei assembly

the retainer with

9. Remove the bearing from
tooling (C)'

manr-
10. Remove the bearin-s1lt"T't|:itake (B)'
fold and rnunil"old with tooling
"u'
D379, D398, D399 INDUSTRIAL AND MAR!NE
ENGINES DISASSEMBLY AND ASSEMBLY

OIL PUMP
 DISASSEMBLY AND ASSEMBLY
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

olL PUMP
16-1304
ASSEMBLE OIL PUMP
Tools Needed A B c
1 I
1P529 Handle 1

1
1P467 Drive Plate
1
1P471 Drive Plate
1
1P475 Drive Plate
1P479 Drive Plate 1

1
1P482 Drive Plate

1P495 Drive Plate I

Use tooling (A) to install the bearing

in re-
l.
tainer ( 1).

mani-
2. Install the idler shafts (2 in the intake
fold.

3. Use tooling (B) to install the bearing in the

intake manifold'

in the
4. Use tooling (B) to install the bearings
idler gears (3).

5. Use tooling (C) to install bearing in rear

manifold.

6. Install the retainer (4), locks and bolts'

In-
7. Install the drive gear and key on shaft' (5)'
ttuff drive shaft(6) in the intake manifold

8. Install the idler gears (3) on the shafts'

9. Install the pressure manifold (7) on the in-

i;il manifold. Install rear manifold (8)that
on
pi"t.rrtt manifold. Install the nine bolts
irold manifolds together' Install the cover
(9) on the rear manifold'
end bY: 7AoÉzxl
a) install oil PumP

34
D(|79, D398. D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

ENGINE OIL COOLER

REMOVE ENGINE OIL COOLER 11-1378
l. Remove the coolant from the ensine.

l. Remove the oil from oil cooler.

3. Remove two bolts (4) and clamp (2). Re-

move the elbow (l).
.t. Remove two bolts from pipe (3).

Remove three bolts (5) that hold flange to

fl¡'wheel housing.

ó. Remove oil line (6) and clip for turbo-

charger lubrication valve.

'il_ Remove the bolts (7) that hold plate and

n¡pport to the block.

it, Fmen a hoist to the oil cooler.

fmove the four bolts that hold elbow to

tc rater pump.

bm the engine oil cooler. Weight is 90

l-{{l ks).

the support (8) and connector

o1 .-ooler (9).

hilG the elbow and tube assembly.

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

ENGINE OIL COOLER

INSTALL ENGINE OIL COOLER 12_1378
l. Install support (l) and connector on oil
cooler.

2. Install tube assembly (2) and elbow (3).

3. Fasten a hoist to oil cooler. Put the oil

cooler in position on engine. Install the oil
line (4) and clip for turbocharger lubrica-
tion valve.

4. Install the thrge bolts that hold flange to

flywheel housiñg.

5. Install bolts (5) that hold plate and support

to block.

6. Install two bolts that hold tube assembly

(6) to the tee.

7. Install elbow and clamp for oil line from oil

filter housing to the oil cooler.

8. Install the bolts (7) that hold elbow to

water pump.

9. Fill the engine with coolant.

10. Add oil to engine as needed.

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

FRESH WATER PUMP

REMOVE FRESH WATER PUMP 11_1361

l. Remove the coolant from ensine.

2. Remove the oil from ensine oil cooler.

Remove two bolts (2) and clamp that hold

oil line (l) to oil cooler. Move oil line awav
from oil cooler. Remove water line (3).

Remove the bolts that hold elbow to oil

cooler and water pump. Remove the elbow
( s).

5. Remove cover (4) and bearing cage.

6_ Fasten a hoist to the water pump.

Remove the six bolts (6) that hold water

pump to accessory drive housing.

Remove the fresh water pump. Weight is 86

lb. (39 kg).
L FRESH WATER PUMP 12_1361

Fasten a hoist to water pump. Put the pump

m engine. Install the six bolts that hold
F¡mp to accessory drive housing.

!- l¡sall the bearing cage (l) and cover (2).

bll the elbow (3).

k ¡üe oil line (4) on the oil cooler. Install

& ¡¡o bolts and clamp. Install water line
b ¡p from water temperature regulator
hg

t cagine with coolant.

D.qt|ne as needed.

37
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FRESH WATER PUMP

T96671X2
trD!. qTT8, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FRESH WATER PUMP

ÍISiASSEMBLE FR ESH WATE R
iIP 15-1361
Tools Needed A

lq4fz1 Puller Assembry 1

FIEa Les ¿

ürg) Step Plate 1

s¡art by:
a) remove fresh water pump
l - Remove the inlet elbow ( I ) from the water
pump.

' Remove the bolts (3) and locks from drive

!Ear. Remove the drive gear (2).

S- R¡move the cover (4) from pump housing.

t- lcmove the cotter pin from nut (5) that

Hds impeller. Loosen the nut.

n npeller.

H üe impeller (6) from taper of shaft

t tooling (A). Remove tooling (A), nut,
Ér- impeller, ring and seal.

b¡c the four bolts that hold bearing (8)

¡ =qiner. Remove the bearing (8). Re-
tüe úaft (9).

the bolt that holds retainer assem-

a Fmp housing. Remove the retainer
| -f -

rle seal from retainer. Remove the

üm the retainer (7).

qbm seal assembly from housing.

39
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FRESH WATER PUMP

ASSEMBLE FRESH WATER PUMP 16_1361
Tools Needed A B

1P529 Handle 1 1

1P471 Drive Plate 1

1P466 Drive Plate 1

1P479 Drive Plate

l. Install the bearing in retainer with tooling

(A). Be sure the hole in bearing is in align-
ment with hole in retainer for lubrication'

2. Use tooling (B) to install the seal in retainer

with lip toward bearing' Put clean engine oil
on lip of seal.

3. Install the carbon seal (3) in the housing.

4. Install the shaft ( 1).

5. Install ring and seal (4) with smooth surface

toward carbon seal (3)'

6. Install impeller (2), washer, and nut (5)'

Leave the nut loose.

7. Install the retainer assembly (8) and bearing

(7) on the housing.

8. Install the drive gear (6) on the shaft'

9. Turn the pump over and tighten the nut (5)

to 55 lb.ft. 0.6 mkg)' If cotter pin cannot
be installed, tighten enough to install'

10 Install cover (9) with enough gaskets (10) to

have a clearance of .005 to .020 in. (0.13 to
0.51 mm) between cover (9) and face of
impeller (2).
end by:
a) install fresh water PumP

40
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

PR E LUBR ICATION OIL PUMP (D399)

REMOVE PRELUBRICATION OI L
ruMP (D39e) 11-1319

l. Remove the bolts that hold inlet oil line (3)

to oil pan base.

2. Disconnect oil outlet line ( I ).

3. Remove the bolts (2) that hold pump to

pump motor. Remove the prelubrication oil
pump.

GTALL PRELUBR ICATION OI L

ifP (D399) 12-1319

l. Put the prelubrication oil pump on the

motor. Install the bolts.

Install bolts that hold inlet line to oil pan

base.

J- Connect oil outlet line.

TYPICAL EXAMPLE
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

PRELUBRICATION OIL PUMP (D399)

DISASSEMBLE PRE LUBR ICATION OI L
PUMP (D399) 15-1319

start by:
a) remove Prelubrication oil PumP
1. Remove inlet oil line (l) from pump.
ül
I 2. Remove bolts (2) that hold head assembly'
i Remove idler assembly from head assembly'
3. Remove rotor from PumP housing.
4. Remove seals from housing. Remove screw
(socket head) from housing.
ASSEMBLE PRELUBRICATION OI L
PUMP (D399) 16-1319
Tools Needed A

1P529 Handle 1

'1P482 Drive Plate 1

l. Use tooling (A) to install seals in housing.

Install seals with lips away from each other.
Install screw (socket head) in oil outlet
port.

2. Install idler on head assembly- Install rotor

in housing. Put head assembly (l) on hous'
ing and install bolts.

3. Check end clearance of rotor with thickness

gauge (2). The end clearance must be -003
to .005 in. (0.076 to 0.127 mm).

4. Remove head assembly again and add gasket

shims as needed to get the correct end clea¡-
ance.

5. Install inlet oil line on the pump,

end by:
a) install prelubrication oil pump

42
tr¡I. TXg, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

CONN ECTING ROD BEARINGS

RCTOVE AND INSTALL CONNECTING
trD BEARINGS 1O_121g

start by:
a) remove engine oil cooler
b) remove fresh water pump
c) remove starters
d) remove engine oil pump
e) remove oil pressure regulating valve
l- Faste a hoist and remove the prelubrica_
uon oil purnp and motor unit, (if so
as a
equipped). Weight is 105 lb. (4g kg).

I- Remove the wiring harness and plate for the

p'relubrication oil pump and moior.

^l- Rcmove the bolts (l) that hold inspection

€t¡r€rs to block. Remove the inspection
so¡ers (2) from each side of block.

fu¡ .-rankshaft (in the direction of normal

ua¡ion) until the rod caps (4) can be re-
through the openings.
-*d

¡-'ore the bolts (3) from each.rod cap.

bre the rod cap (4).

üe bearing (5) from the rod cap.

43
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

CONNECTING ROD BEARINGS

7. Push the connecting rods (6) away from !
I
crankshaft. r

8. Remove the upper half of bearings from the ¡

connecting rods. I
r¡
9. Install the upper half of new rod bearings in L--
the connecting rods. Put clean SAE 30 en-
gine oil on the bearings and crankshaftjour-
nal. Pull the connecting rods with bearing
into position on crankshaft.
NOTE: Be sure the tab on back of bearing fits in
tab groove (slot) in connecting rod.
10. Install lower half of new bearings in caps.
Put clean SAE 30 engine oil on bearings.
NOTE: Be sure the tab on back of bearing hts in
tab groove (slot) of cap.
ll. Install bearing cap on connecting rod. put
clean SAE 30 engine oil on th¡eads of rod
bolts. Install the rod bolts.

12. Tighten the rod bolts first to a torque oi

4O x 4lb.ft. (5.5 t 0.6 mkg). put a mark on
bolt heads and bearing caps. Tighten the
bolts again 120" from the ma¡k.
NOTE: Locks and cotter pins are not required *-ith
this method of tightening the bolts. even rhough
the bolt has a hole.
13. I nstall the inspection covers with ne$-
gaskets.
14. Install the plate and wiring harness for pre-
lubriaction oil pump and motor (if so equip-
ped). Install the prelubrication oil pump
and motor with a hoist. Weight is 105 lb.
(48 ke).
end by:
a) install fresh water pump
TYPICAL EXAMPLE
b) install engine oil pump
c) install engine oil cooler
d) install starters
e) install oil pressure regulating valve
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

CRANKSHAFT MAIN BEAR INGS

REMOVE CRANKSHAFT MAIN
BEARINGS N_12O3
Tools Needed A B

2P5517 Removal & Installation Tool 1

8M9379 Wrench 1

start by:
a) remove engine oil cooler
b) remove fresh water pump
c) engine oil pump
d) remove oil pressure regulating valve
e) remove starters

Fasten a hoist and remove the prelubrica-

tion pump and motor as a unit (is so equip-
ped). Weight is 105 lb. (4S kg).
Remove the wire harness and plate for pre-
lubrication oil pump and motor.

Remove the bolts (l) that hold inspection

covers to block. Remove the insoection
covers (2) from each side of block.

4- Remove the nuts for main bearing caps with

wrench (B). Remove the bearing cap with
lower half of main bearine.

5- Use tool (A) to roll the upper half óf main

bearing by turning crankshaft in normal di-
rection of rotation.
: On the bearing journal that
has no drilled
¡rt a thin piece of fiber, hardwood or plastic
i¡ end of bearing, opposite tab. Hit the bear- ;: ;e"ihx,ii
Ehty with the above until tab of bearine is
fuo cylinder block. Remove the upper half

45
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

CRANKSHAFT MAIN BEARINGS

INSTALL CRANKSHAFT MAIN
BEARINGS 12-1203
Tools Needed A B c D

2P5517 Removal & Installation Tool

,|

8M9379 Wrench 1

*
581161 Wire

852328 Dial Test Indicator Group 1

l. Put clean engine oil on bearing surfaces of

upper halves of bearings. Use tool (A) to
install upper half of bearing in cylinder
block. The bearing with oil hole is upper
half. TYPICAL EXAMPLE
2. Clean main bearing caps and install lower
halves of bearings in caps.
a
Use wire (C) to check bearing clearance. In-
stall caps and tighten both nuts with tool
(B) to 200 t l0 lb.ft. ( 27 .7 t 1.4 mkg). Put
a mark on nuts and end of studs. Tighten
nuts 120' from the mark. Remove caps and
check thickness or wire (C) to find bearing
clearance. Bearing clearance must be .005 to
.008 in. (0.127 to 0.203 mm) for new parts.
Maximum permissible clearance for used
parts is .015 (0.38 mm).
NOTE: Main bearing caps are numbered as to thei¡
location in cylinder block. Install bearing caps so
the number on cap is.same as number on cylinder
block. Both numbers must be on same side of cyl-
inder block.
4. Put clean engine oil on threads of studs and
seat for nut. Install main bearing caps and
nuts. Install thrust plates on dowels on rear
cap. The dowels must not be extended more
than .160 in. (4.064 mm) from counterbore
face of bearing cap. Tighten nuts with
wrench (B) to 200 t 10 lb.ft. (2'l-'7 ! 1.4
mkg). Put a mark on nuts and ends of studs.
Tighten nuts an extra 120' from mark.
5. Use indicator group (D) to check end play
of crankshaft as controlled by thrust plates.
End play with new parts must be .005 to
.021 in. (0.127 to 0.533 mm). Maximum
permissible end play with used parts is .035
in. (0.89 mm).
6. Install the inspection covers. Install the wire
harness and plate for prelubrication oil
pump. Fasten a hoist and install prelubrica-
tion oil pump and motor as a unit (if so
equipped).
end by:
a) install oil pump
b) install fresh water PumP
c) install engine oil cooler
d) install oil pressure regulating valve

46
 D379, D398, D399INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

PISTON COOLING TUBES

REMOVE PISTON COOLING
TUBES
11-1307
start by:
a) remove engine oil cooler
b) remove fresh water p mp
c) remove starters
d) remove engine oil pump
e) remove oil pressure regulating valve
l. Fasten a hoist and remove the prelubrica_
tion oil pump and motor a, u ,rril (if so
equipped). Weight is 105 tb. (48 kg).
2. Remove the wire harness and plate for pre_
lubrication cil pump and motoi.
3. Remove the bolts (l) that hold inspection
covers to cylinder block. Remove inspection
covers (2) fr< m each side of block.
4. Remove the bolt (3) and lock that hold
tube to bottom side of lifter bracket. Re_
move the piston cooling tubes (4).

GTALL PISTON COOLING

TIBES
l. Install the piston cooling tubes (l)12_1307
in posi-
tion on the lifter bracket. Install the locks
and bolts.
Of,UTION: Do not install a tube that is
bent or has
bge. Damage to the
"r,gin. "a;-rlrrli.
2 Install the inspection covers on engine.
3- Install wire harness and plate for prelubrica_
tion oil pump and motor. Fasten á hoist and
install prelubrication oil pump and motor
as
a unit (if so equipped).
end by:
a) install engine oil pump
b) install fresh water pump
c) install engine oil cooler
d) install oil pressure regulating valve
e) install starters

47
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

OIL PAN BASE

REMOVE OIL PAN BASE 11-1302

l. Remove the coolant from engine.

2. Remove the oil from oil pan base. Capacity
of D379 is 92 U.S. Gal. (348 liters); D398 is
I I 0 U.S. Gal. (41 6 liters); D399 is I 65 U.S.
Gal. (625liters).

3. Disconnect inlet water lines that are con-

nected to engine. Disconnect fuel lines for
fuel supply to engine.
4. Remove oil pressure regulating valve (l).
5. Remove the four bolts that hold plate (3)
for oil pump to the base.
6. Remove bolts (2) that hold cylinder block
to the base.
7. Lift the engine
Fasten a hoist to the engine.
from base. Weight of D379 is 8,000 lb.
(3629kú; D398 is 10,000 lb. (4559 kg);
D399 is 13,000 lb. (5 920 ke).
8. Move the oil pan base. Weight of base on
D379 is 2,100 lb. (953 kg); D398 is 3,000
lb. (1360 ke);D399 is 3,800 lb. (1496k9.
INSTALL OIL PAN BASE 12-1302

1 Install a new gasket on the oil pan base.

2. Fasten a hoist to engine. Put the engine in

position on oil pan base. Put 953263
Thread Lock on the threads of bolts for
base. Install the bolts that hold engine on
oil pan base.

3. Install the four bolts that hold plate for oil

pump to the base.

4. Connect inlet water lines to the engine.

5. Connect fuel supply and return lines to en-

gine.

6. Install oil pressure regulating valve on en-

gine.

7. Fill the engine with oil and coolant to cor-

rect levels.

48
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUE L RATIO CONTROL WITH OVERRIDE

REMOVE FUEL RATIO CONTROL
WITH OVERRIDE 11-1278
l. Remove the three bolts (2) that hold over-
ride assembly (l) to fuel ratio control.

2. Remove the override assembly (l).

3. Disconnect line (3) from fuel ¡atio control.

. 4. Remove the two bolts that hold the fuel

ratio control to governor. Move the fuel
ratio control (4) toward front of engine and
- remove it from governor.

INSTALL FUEL RATIO CONTROL

WITH OVERRIDE 12-1278
l. Install the fuel ratio control on the gover-
nor. Make sure the bott (l) engages the
groove (slot) in rack stop collar (2). Install
the two bolts that hold fuel ¡atio control in
place.

2. Connect line (3) for air to the fuel ratio

control.

3. Install the override assembly and bolts that

hold it in place.

-1. Make an adjustment to the fuel ratio con-

trol. See FUEL RATIO CONTROL
SETTING IN TESTING AND ADJUSTING.
E!', D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL RATIO CONTROL WITH OVERRIDE

ITSASSEMBLE FUEL RATIO CONTROL :::

rlTH OVERRIDE 15-1278

start by:
a) remove fuel ratio control with over-
ride
l. Remove the cover (l), spring (2), and
plunger (3) from override housing (4).

2. Remove the nut and screw that hold lever

assembly to the override housing (4). Re-
move the lever assembly and spring. Re- ,zá*igxl¡
move the seal from the housing.

3. Remove the cover (5) from the housing. Re-

move the two springs. Turn bolt (6) and
remove the washer, diaphragm, retainer and
bolt.

ASSEMBLE FUEL RATIO CONTROL

.ttt ovERRtDE 16_1278

l. Connect the bolt to the washer, diaphragm

and retainer. Put the diapfuagm assembly
and the two springs in housing. Install the
cover for fuel ratio control.

2. Install the seal in override housing with lip

of seal toward arm. Install the lever and
spring. Install the nut and screw that hold
the lever.

3. Install the plunger, spring and cover on the

override housing.
end by:
a) install fuel ratio control with override
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

GOVERNOR
REMOVE GOVERNOR 11-1264

l. Disconnect control linkage (1) from gover-

nor.

2. Disconnect line (3) for the fuel ratio con-

trol.

3. Remove the cable (2) for safety shutoff

control.

4. Disconnect oil lines (6) and (5) from the

governor.

5. Remove six bolts (4) that hold governor to

governor drive housing.

6. Remove the governor. Weight is 40 lb. (18

ke).

INSTALL GOVERNOR 12-12@'

l. Put the governor on engine with lever on

governor engaged in groove (slot) in rack.

2. Install the bolts that hold governor to gov-

ernor drive housing.

3. Connect line for the oil pressure gauge.

4. Connect the line for oil Dressure switch.

5. Connect the line to the fuel ratio control.

Install the cable for safetv shutoff control.

6- Connect control linkage to the governor.

f,1
TXl,!, T¡. tr!E!,TIiIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

GOVERNOR
DISASSEMBLE GOVERNOR

start by:
a) remove governor
b) remove fuel ratio control with over-
ride
l. Remove covers (l) and (2) from the gover-
nor.

2. Remove the high and low idle screws (3).

Remove the bolts (6) that hold levers to

shaft.

Remove the levers (7). Remove the shaft

(4).

5. Remove bolt (5) that holds housing to gov-

ernor. Remove housing (g).

6. Remove the seals from housing (g).

7. Remove the stop group (9).

8. Remove the screw that holds the stoD

collar. Remove the stop collar ( l0).

9. Remove the spring and seat.

10. Remove the four bolts (l l) that hold gover_

nor housing. Remove the governor housing
(12).

Il Remove speed limiter plug (l3), gasket

-
(14), spring (15), and plunger (16).

12. Remove the lever (I 7) from the shaft.

fXI'g, fxg, tX}99 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

GOVERNOR
13. Remove the governor spring, seat, spring
and washer.

14. Remove the bolt (19) that holds lever as-

sembly ( l8) on shaft.

15. Remove the shaft (20) from governor hous-

ing. Remove the bearings and seal from gov-
ernor housing.

16. Remove the lever assembly ( 18).

17. Push the pin (21) from lever (18).

18. Remove the spring (22) and plunger (23).

19. Remove the three bolts (27) and lock (28)

that hold weight assembly to governor drive
housing.

20. Remove the two bolts (26) and locks. Push

cover assembly (24) up and remove the
weight assembly (25).

'1. Remove the ring (3) f¡om the seat. Remove

the pin (29).
UT'g, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

GOVERNOR
22. Remove the seat (31), bolt (32), washers
(33) and spring (34).

23. Remove the sleeve and bearing assembly

from the weight assembly.

24. Remove the ring (37) that holds bearing as-

sembly on sleeve (35).

25. Remove bearing (38) and races (36) from

sleeve (35).

26. Remove the valve (42) from piston (41).

27. Remove the ring (39) that holds cylinder to

weight assembly. Remove the weight assem-
blv.

28. Remove piston (41) and sleeve (40) from

the cylinder (43).

29. Remove the O-ring seal from the sleeve

(40).

Remove the cover and shaft assembly (44)

unit from the drive housine.
as a

31. Remove gear (45) from the pin assembly.

)J
D379, D398, D399INDUSTRIAL AND MAR¡NE ENGINES DISASSEMBLY AND ASSEMBLY

GOVERNOR
32. Remove the bolt (47) and washer from
shaft assembly.

33. Remove the gear (46) from the shaft,

34. Push the bearings (50) and shaft (49) out of

the drive housing.

35. Remove the bearings, shaft, lever (48) and

pin assembly (51).

36. Remove the valve assembly (52) and gasket.

37. Remove the plug assembly (53) and gasket.

38. Remove the cover (54) from drive housing.

39. Remove the bushing from drive housing.

5ó
E!I. D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

GOVERNOR
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

GOVERNOR
ASSEMBLE GOVERNOR 16-126/-
Tools Needed A

1P529 Handle 1

1P460 Drive Plate 1

1P457 Drive Plate 1

l. Install the valve assembly ( l).

2. Install the plug assembly (2).

NOTE: For standard engine rotation, the valve (l)

must be located on the right side of governor drive
housing. For reverse engine rotation, change the
plug assembly (2) with the valve (l).

3. Install the cover (3).

4. Install the bushing in drive housing with

tooling (A).

NOTE: Install the bushing so it won't be extended

more than .465 to .475 in. (ll.8l to 12.96 mm)
above the bottom of pump bore.

5. Install the pin assembly (7).

6. Install the lever (4), bearings (6), and shaft

( s).

NOTE: Shaft (5) must turn freely in the bearings

with .02 to .06 in. (0.5 to 1.5 mm) end play.

7. Heat the drive gear (9) to 250"F to 300'F

( I 2 I " C to I 49'C), and install it on the shaft
and cover assembly (8).

$. [¡5t¡ll the washer and bolt (10).

5t
 ]S9 D3TIS, D399 INDUSTRIAL AND
MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

GOVERNOR
:. Install O-ring seal (13) on the sleeve (14).

Install.piston (12) and, sleeve (14) in the

cylinder ( I 1).

Put the weight assemblv ( l6) on cylinder

( I 7) and insrall
ring ( l5).

.1. Install the valve (19) in piston (12).

I 3. Install the bearing and races on sleeve,

i4. Install the sleeve and bearing assembly (lg)

on valve (19).

15. Put the seat (21), bolt (20),

washers and
spring on the valve.

I 6. Install the pin (22) and, rine (23).

59
T
D379, D3S, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY
;

GOVERNOR
17. Install gear (25) on the pin assembly.

18. Install the cover and shaft assembly (24)in

the diive housing.

19. Push the cover and shaft assembly up and

install the weight assembly (26) on the
cover.

20. Install the locks and bolts (27) that hold

cover and shaft assembly to drive housing.

21. Install lock (28) and bolts that hold weight

assembly.

22. Install spring and plunger in lever (29)'ln-

stall pin in lever.

23. Install bearings and seal in governor housing

(30).

24. Install lever (29), shaft (32) and bolt (31)

that holds lever to shaft.

25- Install speed limite¡ plunget, spring, gasket

and plug. Install rack stoP group'

60
 D379, D398. D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

GOVERNOR
26. Install the seat (35), spring (34) and washer
(36) in governor housing (30).

27. Install the spring (33) on the bolt (20).

18. Install the governor housing on drive hous-

ing and install the bolts.

19. Install the spring and collar. Install the rack

stop collar.

30. Install screw (38) that holds rack stop collar

(37\.

Install seals, shaft (42),lever assembly (40),

locks, and bolts in cover assembly. Install
the cover assembly (39). Install seals in
cover with lip of seal toward the inside.

-ll. Install high and low idle screws (41).

-:-i. Install covers (43) and (44) on governor

housing.

\tlTE: Be sure pin (45) is in slot of rack stoo

end by:
a) install governor
b) make adjustment to governor (See
GO VERNOR ADJUSTMENTS jn
TESTING AND ADJUSTING)
c) install fuel ratio control with over¡ide

6l
 DISASSEMBLY AND ASSEMBI-Y
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

SAF ETY SH UTOF F

REMOVE SAFETY SHUTOFF 11-7418

t. Remove cable (4) from lever. Remove bolt

that holds cable bracket to channel. Re-
move nut (l) that holds clip to governor.
2. Remove oil line (2) from governor to safety
3hutoff. Loosen oil line (3) at governor.
J. Remove five bolts that hold safety shutoff
to fuel injection pump housing.
4. Remove safety shutoff and cable as a unit.

INSTALL SAFETY SHUTOFF 12-7418

l. Put safety shutoff in position on fuel in-

jection pump housing. Install the bolts that
hold safety shutoff to injection pump
housing.

2. Install oil line to governor' Install oil line

from governor to safetY shutoff.

3. Install nut that holds clip for cable to gover-

nor. Install bolt that holds cable bracket to
the channel. Install cable to the lever'

* 62
rT,9, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

SAFETY SHUTO FF
DISASSEMBLESAFETYSHUTOFF 15_7418
Tools Needed

1P232O Puller Assembly

887560

start by:
a) xemove safety shutoff
l. Disassemble reset button and piston as fol_
lows:

a) Remove the screws and bolt (2) that

hold cover (l) to housing. Remove the
cover.

b) Remove pin (5), plunger (7) and, spring

(6) from cover (l).

c) Lift piston (3) out of its bore in housine.

d) Remove bearing (4) from cover (l).

Remove drive assembly as follows:

a) Remove two screws (g) that hold
adapter (9) to housing. Remove the
adapter.

b) Remove the snap ring (ll) and washer.

Remove the gear assembly (10).
I D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

SAF ETY SHUTOF F

c) Remove the pin ( l5) that holds gear ( 13)
to shaft ( 12). Remove the gear.
d) Slide shaft (12\ ottt of adapter (9)' Re-
move the two dowels (14) that hold gear
assemblY ( 1 0) together.
e) Remove the bushings from adapter and
gear'assembly.

3. Disassemble carrier and weight as follows:

a) Lift carrier (24) ftom the housing'
b) Remove screw (23) from carrier (24)'

NOTE: Remember the number of turns needed to

remove the screw ( 16) and use this same number
for installation.

c) Remove spring (17), weight (18), pin

(22) and nut (21).

d) Remove gear (19) from shaft (20) with

puller (A).

4. Remove emergency shutoff button as fol-

lows:
a) Remove button (27) and spring by loos-
ening screw (26).
b) Push plunger (28) down through housing
(3 t¡'

5. Remove plug (30) and gasket from housing'

Loosen nut (29) and remove gasket and

c¿ble assembly (25) as a unit.
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

SAFETY SHUTOFF
7. Remove two pins from collar (35). Remove
the collar (35) and spring (33).

8. Remove pin (32) and make a separation of

nut (34) from cable.

9. Remove two cotter pins (37), washers (39)

and springs.

10. Push latch (36) out of the way and lift the
guide (38) from housing.

I l. Remove plug (45) from end of housine.

12. Remove ring (41) from the shaft (43). Slide

shaft (43) and gear (42) from the housing.

13. Remove the pin that holds gear to the shaft.

Remove the gear (42) from shaft.

14. Remove bearing from the housing.

15. The foll (pressed)

into the the spring
(46), gu necessary
to cause

16. Remove plug (47) from the housing.

17. Remove the spring and latch (release lever).

65
D379. D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

SAFETY SHUTOFF
ASSEMBLE SAFETY SHUTOFF 16-7418
Tools Needed A

1 P529 Handle 1

'l
1P458 Drive Plate

1P455 Drive Plate

t. Install latch (release lever) (2) and spring (4)

into housing (l).

It is necessary to install new follower shaft

( s).

3. Install spacer, guide (3) and spring (6)

shaft (5).

4. Push (press) shaft (5) into housing ( 1).

5. Assemble worm shaft as follows:

a) Install bearing into housing ( I ) '
b) Install eear (7) on shaft (8) with pin.
c) Slide assembled gear and shaft (8) into
housing ( I ) and hold with ring.
d) Install plue (9) in end of housing ( l).

Push latch out of the way and install the

guide ( I l).

7. Install the springs (12), washers ( 13) and

cotter pins ( 14).

tl

6
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

SAFETY
8. Assemble the cable as follows:
a) Connect nut (15) to cable assembly (17)
with pin (16).
b) Install spring (19) and collar (20) with
two pins (23).
c) Install cable assembly and gasket ( l8)
into housing and tighten nut ( 15).
d) Install gasket (21) and plt¡e (22) into
housing.

Install emergency shutoff button as follows:

a) Push plunger (24) up through housing ( I ).
b) Install the spring (25) and button (26)
on the plunger. Tighten the screw (27).

741AZXI
[0. Assemble carrier and weight as follows:
a) Install gear (31) on shaft (32).
b) Install nut (33), pin (34),weight (30) and
spring (29).
c) Install the screws (28) and (35).

\-O-FF: Tighten screw (28) the same number of

nÍrnl ttrat was needed to remove it.

d) Put a mark (stake) around the screw (28)

with a punch and hammer.

I l Install the carrier assembly (36) in the hous-

ine.

67
D379, D398, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

SAF ETY SH UTOF F

12. Assemble the drive and adapter as follows:
a) Install bushing (37), two gears (39), with
two dowels (38).
b) Install two bushings in the adapter (41).
c) Slide shaft (40) into adapter (41).
d) Install gear (43) on shaft (40) with pin
(44) and make a mark (stake) with
punch and hammer.

e) Install gear assembly (42) into adapter

(41) with washer and snap ring.

Install drive assembly with two screws

that hold adapter (41) to housing ( 1).

t3. Install bearing into cover (46) with tooling

(A).

14. Install plunger (50) and spring (49) into

cover (46) with pin (47).

15. Install piston (45) into bore.

16. Install cover (48) with two screws and one

bolt that hold cover (46) to housing (1).
end by:
a) install safety shutoff

68
CB'!', E, Tllg INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

VALVE COVERS
REMOVE VALVE COVERS 11_1107
l. Remove the nuts (l), washers. and seals
from the studs.

2. Remove the valve cover.

INSTALL VALVE COVERS 12-1107

Il
I
1. Install a new seal in the valve cover. li
1l
l¡
I

t7:
I
iij
f1
it-' '
.t,
7a\
I" I

f,j í
Install the valve cover onthe engine. Install
the seals, washers and nuts on th" studs.

69
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FUEL INJECTION PUMPS

REMOVE FUEL INJECTION
PUMPS 11-1251

l Remove dampers from fuel injection lines.

2. Disconnect the fuel line (l) for the pump to

be removed by removing nut (2). Put a pro-
tective cover over the open end of fuel line.
Move the fuel lines ( 1) out of the way.

3. Remove the bolts (3).

4. Lift the pump body (5) straight up and re-

move body.

5. Slide the plunger (4) from yoke of lifter.

Remove the plunger (4). Keep the plungers
with their respective pump bodies.

INSTALL FUEL INJECTION

PUMPS 12-1251

l. Turn the pump plunger until tooth (2) of

plunger is in alignment with mark (l) on
rack. Install the plunger (3) by-sliding end
into yoke of lifter.

CAUTION: Be careful when installing pump bar-

rels and plungers. Do not put plunger of one pump
in barrel of another pump.

2. Install new seals. Install the pump body and

barrel carefully over plunger and dowels on
injection pump housing.

3. Install the bolts. Tighten bolts first one then

another a small amount to at time starting
alternately, with the two nearest the fuel
rack.Tighten to 321 5 lb.ft. (4.4 ¡ 0.7 mkg).
4. Remove covers from fuel lines. Connect fuel
lines. Tighten fuel line nut to 25 to 35 lb.ft.
(3.5 to 4.8 mkg).

5. Install dampers on fuel lines.

70
fx¡7g, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

FUEL INJECTION LINES

REMOVE FUEL INJECTION
TINES 11-1252
1. Remove the dampers (1) from the fuel lines
at fuel injection pumps. Disconnect the fuel
line from the pumps. Disconnect linkage
from governor and remove governor control
channel.
2. Remove the clips and remainder of the
dampers from fuel lines.
3. Disconnect fuel lines from fuel injection
valves. Remove the fuel injection lines. Put
covers and plugs over openings to keep dirt
and dust out.

INSTALL FUEL INJECTION

LINES 12-1252
l. Remove the covers and plugs from fuel lines
and openings.

Install the fuel lines (2) on the fuel injection

valves and pumps.

Tighten the fuel line nuts (3) to a torque of

25 to 35 lb.ft. (3.5 to 4.8 mkg). Instalt the
dampers and clips (1) on the fuel lines.

Install governor control channel. Corinect

linkage to governor.
 DISASSEMBLY AN D ASSEMBLY
D379, D398, D399INDUSTRIAL AND MARINE ENGINES

EXHAUST MANI FOLDS (INDUSTR IAL ENGINES)

REMOVE EXHAUST MANIFOLDS
(INDUSTRIAL ENGINES} 11--1059

start bY:
a) remove fuel injection lines
b) remove valve covers

l. Remove the plugs from the shield assembly'

2. Remove the bolts that hold shield (l) to

manifold. Put the shield (l) to the side of
manifold.

3. Remove tube (3) from the shields.

4. Install a 7f 16"-14 NC forged eyebolt in

hole (2).

5. Disconnect the elbows (5) from the shield'

6. Remove the bolts (6) that hold shields to-

gether.

7. Remove the oil line (4) from engine.

8. Install a 3f8"-16 NC forged eyebolt in

shield. Fasten a hoist and remove water
shield. Weight is 107 lb. (4S kg) on D379;
127 lb. (5S ke) on D398; 199 lb. (90 ke) on
D399.

9. Remove the bolts (8) that hold manifold to

turbocharger. Remove water line from back
of shield.

10. Fasten a hoist .o manifold. Remove the

bolts (9) and brackets (10) that hold mani-
fold to the cYlinder heads.
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

EXHAUST MAN I FOLDS (tNDUSTRtAL ENGTNES)

1 l. Remove the exhaust manifold ( I l) and
shield (7) as an assembly. Weight is 90 lb.
(41 ke) on D379; 120 tb. (54 ke) on D398;
165 lb. (75 kg) on D399.

12. Remove the bolts (12) that hold shield to

exhaust manifold.

13. Remove the shield (7) from manifold.

INSTALL EXHAUST MAN I FOLDS

(INDUSTRIAL ENGINES) 12_1059

l. Put new gaskets on the exhaust manifold

(2).

2. Install the shield (l). Tighten the bolts (3)

to l0 lb.ft. ( 1.4 mkg).

3. Put 9M3110 Anti-Seize Compound on the

threads of all bolts that hold exhaust máni-
fold to cylinder heads and turbocharger.

4. Fasten a hoist to the exhaust manifold. Put

the exhaust manifold in position on engine.

5. Put new gaskets between shield and cylinder

heads. Install the bolts (5) and brackets that
hold manifold to cvlinder heads.

6. Install the bolts (4) that hold turbocharger

to exhaust manifold. Tighten these bolts to
36 to 44lb.ft. (5.0 to 6.1 mkg).

7. Install the water line (6) on the shield.

73
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

EXHAUST MAN I FOLDS (TNDUSTRtAL ENGTNES)

8. Put grease on the seal (7) and bore of water
temperature regulator housing.

9. Install a 7 f 16"-14 NC forged eyebolt and a

318"-16 NC forged eyebolt in the water
shield. Fasten a hoist and put the water
shield on the exhaust manifold and elbow in
the water temperature regulator housing.

10. Install the oil line (8) for the turbocharger

lubrication valve.

I 1. Install bracket (1 1).

12. Install new gaskets for elbows. Install the

bolts that hold elbows (9) to water shield.

13. Install the bolts ( 10) that hold the shields

together.

14. Install the tube ( I 2) on front of shields.

15. Put the shield ( 13) in position and install

the bolts.

t6. Install the plugs.

17. Fill the engine with coolant to correct level.

end by:
a) install valve covers
b) install fuel injection lines
D379, D398, D399 INDUSTRIAL AND
MARINE ENGINES DISASSEMBLY AND ASSEMBLY

EXHAUST MANI FOLDS (MARINE ENGINES)

REMOVE EXHAUST MANIFOLDS
(MARINE ENGINES) 11-1059
start by:
a) remove turbocharger heat shield
b) remove fuel lines
c) remove valve covers
l. Remove the water line (3) from manifold.

2. Remove oil line (2) for turbocharger lubri_

cation valve (right side onlv).

3. Remove the shield (11.

4. Remove bolts that hold elbows (4) to ex_

haust manifold.

5. Hit the elbows with a soft hammer to dis_

connect them from manifold.

6. Remove four bolts that hold water con_

nectors (6) to the exhaust manifold.

7. Remove the bolt that holds brace (5) to

I
manifold. r: r

1l
{}
8. Remove bolts (7) that hold exhaust mani_ li
t
fold to the cylinder heads. i

.i

9. Remove bolts and nuts that hold exhaust

manifold to the turbocharger. :
ir,'
ri'
11,
i

iii
,ii ,

75
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

EXHAUST MANI FOLDS (MARINE ENGINES)

INSTALL EXHAUST MANIFOLDS 12_1059
(MARINE ENGINES)
l. Install a3f 8"-16 NC forged eyebolt and a
5/16"-18 NC forged eyebolt in manifold'
Fasten a hoist.

2. Install the (watercooled) exhaust manifold

on the engine with a hoist. Install new
gaskets.

3. Put 9M3710 Anti-Seize ComPound on

threads of bolts. Install the bolts that hold
manifold to cylinder heads. Tighten bolts to
a torque of I 10 t l0 lb.ft. (15.2 t 1.4
mkg).

4. Connect brace to exhaust manifold.

5. Put the elbow (l) in position. Install the

bolts that hold elbow to manifold.

6. Install the bolts that hold elbow (2) to ex-

haust manifold.

7. Put 9M3710 Anti-Seize Compound on

threads of bolts. Install the bolts (3) that
hold exhaust manifold to turbocharger.
Tighten the bolts to 40 t 4 lb.ft'
(5.5 t 0.5 mke).

8. Install the shield (4).

9. Install the water line for turbocharger heat

shield. Install the oil line for turbocharger
heat shield. Install the oil line for turbo-
charger lubrication valve.

end by:
a) install valve covers
b) install fuel lines
c) install turbocharger heat shield
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP HOUSING, SAFETY SHUTOFF,
GOVERNOR AND GOVERNOR DRIVE
REMOVE FUEL INJECTION PUMP
HOUSING, SAFETY SH UTO FF, GOVERNOR,
AND GOVERNOR DRIVE AS A UNIT

start by:
a) remove fuel injection lines
b) remove exhaust manifold (one side
only)
1. Remove the bolts (2) that hold exhaust
elbow to support (3).
2. Remove bolts (4) that hold support (3) and
lifting eye (l) to cylinder block. Remove
the support and lifting eye from engine.
3. Disconnect water line connection from
water temperature regulator housing and
the manifold. Fasten a hoist to regulator
housing. Remove the bolts that hold front
lifting eye and support to cylinder block.
Remove the water regulator housing, mani-
fold, and lifting eye as a unit. Weight is 150
lb. (68 ke).
4. Remove the line (5) for air to fuel ratio
control. Remove the oil line from back of
governor.

5. Remove fuel line (7) from injection pump I

housing. f
i

6. Remove the bolts (6) that hold housing to

cylinder block.
7. Install a 3f8"-16 NC forged eyebolt in ri
il
back of housing. Fasten a hoist and remove ii
f'
il
the fuel injection pump housing, safety tr i
shutoff, governor and governor drive as a t,'
unit. The weight for a D3l9 is 350 lb. ( 159 l;f
kg); for a D398 is 425 lb. (193 kg); for a
D39B is 500lb. (227 kü.
CAUTION: Do not cause damage to the oil tube
tor fuel pump and governor drive when unit is re-
noved.
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FUEL INJECTION PUMP HOUSING ' SAFETY SHUTOFF,

GOVERNOR AND GOVERNOR DRIVE HOUSING
INSTALL FUEL INJECTION PUMP
HOUSI NG, SAFETY SHUTOF F, GOVERNOR,
AND GOVERNOR DRIVE AS A UNIT

1. Put 7M7260 Liquid Gasket material on bot-

tom of housings and surface of contact with
cylinder block.

2. Put four 3/8"-16 NC bolts (l) for a guide

in the cylinder block.

3. Install a 3f8"-16 NC forged eyebolt in

back of housing. Fasten a hoist and put the
injection pump housing, safety shutoff, gov-
ernor, and governor drive in position on en-
gine.

4. Lower the unit on the guide bolts (l). In-

stall the bolts that hold unit to cylinder
block.

5. Fasten a hoist to water temperature regu-

lator housing, manifold, lifting eye and sup-
port (2). Install as a unit. Install the bolts
and connect the water lines.

6. Install the fuel line (3) on front of injection

pump housing.

7. Install oil line (6) on the governor, Install

air line to fuel ratio control.

8. Install the lifting eye and support (4) on

back of governor drive housing.

9. lnstall the bolts (5) that hold exhaust elbow

to support.

10.Make adjustment of timing; See TIMING

THE FUEL INJECTION PUMP CAM-
SHAFT iN TESTING AND ADJUSTING.

end by:
a) install exhaust manifold
b) install fuel injection lines

78
D379, D398, D399 INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP HOUSING

DISASSEMBLE FUEL INJECTION
PUMP HOUSING
15-1253

852241 Camshaft Bearing Removal and

I nstallation Tool
Group

IP459 Drive plate

1P456 Drive Ptate

start by:
aJ remove fuel injection pump housing
and governor as a unit
b) remove governor
c) remove safety shutoff (if so equipped)

I . Remove governor drive housing ( 1) from

fuel injection pump housing.

Remove plate assemblv (2) from fuel

jection pump housing. in-

3. Remove the cover (3) from side of housins.

Remo.ve^the cover (5). Remove the plug

and
seal (4) from housing.
 DISASSEMBLY AN D ASSEMBLY
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

FUEL INJECTION PUMP HOUSING

5. s and clamps that hold fuel in-
PS to the housing' Pull the
(6) straight uP to remove them
from housing.

the injection PumP housing'

in-
CAUTION: Be very careful when removing fuel
jection pumps to prevent damage to plunger sur-
fu".r. The body and plunger of each are put to-
géit at the factory and cannot be used with the
"t
bodies or Plungers of other PUmPS'

7. Remove the fuel rack (8) from housing'

8. Remove the three bolts (10) and locks that

hold thrust Plate. Remove the thiust Plate
(e).
 D379, D398, D3gg INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

FUE L INJECTION PUMP HOUSING

9. Use wrench (A) to hold yoke screw (11).
Loosen locknuts fi 2).

10. Remove yoke screws (ll). put identifica_

tion on each yoke screw by its location in
injection pump housing.

11. Install S1605 bolts (13) (3/8,,-24 NF x 3

| 14" long) and needed washers in the lifters.

I 2. Tighten the bolts ( l3)

enough to hold lifters
away from the camshaft.

13. Remove the camshaft from housine.

CAUTION: Be careful when removing the cam-

shaft. Do not cause damage to camshaft or
bearings.

8t
 DISASSEMBLY AN D ASSEMBLY
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

FUEL INJECTION PUMP HOUSING

14. Remove the bolts (13) from the fuel pump
lifters and remove lifters (14) and springs
( 15) from the bottom of the housing'

NOTE: Put identification on each of the lifters by

its location in the housing.

15 ' Use tool group (B) to remove camshaft

bearings from the housing.

16. Use tooling (C) to remove the bearings for

fuel rack from the housing'
qI79, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP HOUSING

 1t

D379, D398, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP HOUSING

ASSEMBLE FUEL INJECTION PUMP
HOUSTNG 16-1253
A B

9M4568 Wrench

1P529 Camshaft Bear¡ng Removal 1

and Installation Tool Grouo

852241 Cam Bearing Tool Group 1

1P529 Handle 1

1P456 Drive Plate 1

1P459 Drive Plate

l. Use tooling (C) to install bearings for fuel

rack in housing.

2. Use tool group (B) to install camshaft

bearings. Be sure the oil holes ( l) in
bearings are in alignment with oil hole in
housing.

CAUTION: Be sure the tool group (B) is in center

position on bearing while installing bearings, so no
damage will be caused to them.

3. Put clean engine oil on lifters (2). Install the

lifters (2) in their respective position in
housing.

4. Push the lifters in the housing against their

springs.

5. Install 51605 bolts (3) (3/8"-24 NF x3

ll4" long) and needed washers (4) in the
lifters.

Tighten the bolts (3) enough to hold lifters

up to install camshaft.

t4
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP HOUSING

7. Put clean engine oil on the camshaft
bearings.

8. Install the camshaft in the housine.

NOTE: If the engine has a counterclockwise rota-

tion, the camshaft is installed with the arrow and
the F-mark (5) at the front of pump housing as
shown. For clockwise rotation of engine, the cam-
shaft is installed with the F-mark and arrow at the
rear of pump housing.

9. Remove the bolts and washers that were

used to hold lifters up.

10. Install the thrust plate (6), locks and bolts

that hold camshaft in housine.

I l Install yoke screws (7) and locknuts in their

respective position in housing. Use wrench
(A) to hold yoke screw while locknut is
tightened.

12. Make adjustment to lifters. See FUEL

PUMP TIMING DIMENSION SETTING
(OFF ENGINE) in TESTING AND AD-
JUSTING.

85
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP HOUSING

13. Put clean diesel fuel on the fuel rack. Install
the fuel rack (8) in the pump housing.

14. Install fuel injection pumps in their respec-

tive positions as follows:

a) Remove the plunger (9) from the pump

(10) to be installed.

b) Put clean diesel fuel on the plunger and

barrel of the pump.

c) Install the pump in housing. Turn the

plunger until the mark (12) on gear is in
alignment with mark on fuel rack (11).

d) Slide the end of plunger into the yoke

screw of the lifter.

e) Install new seals for the pump and install

the pumps in the housing.

NOTE: Be sure the pumps are on flre dowels. In-

stall the bolts and clamps.

f) Tighten the bolts next to fuel rack first,

and then tighten bolts on other side.
Tighten the bolts to 32 t S lb.ft.
(4.4 t 0.07 mkg).

tó
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FUEL INJECTION PUMP HOUSING

15. Install the plug and seal. Install the cover
(13) for fuel rack.

16. Install plate (14) on side of pump housing.

17. Install governor drive housing (15) on the

fuel injection pump housing.

18. Install plate assembly on pump housing.

end by:

a) install safety shutoff (if so equipped)

b) install governor
c) install fuel injection pump housing
and governor as a unit

87
D379, D398. D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

GOVERNOR DRIVE HOUSING

DISASSEMBLE GOVERNOR DR IVE
HOUSING 15-1288
Tools Needed A

1P529 Handle 1

1P457 Drive Plate

start by:
a) remove fuel injection pump housing,
governor, and governor drive as a unit
b) remove governor
c) remove safety shutoff
l. Remove the governor drive housing from
the fuel injection pump housing with a
hoist. Weight of governor drive for D379 is
80 lb. (36 kg); for D398 andD399 is 125
lb. (57 kg). Remove coupling.

2. Remove ring, plunger, spring, and retainer

for safety shutoff.

3. Remove pin that holds shaft assembly. Re-

move lever (2), spring (4), key and shaft
assembly (5). Remove the seal from hous-
lns.

4. Remove governor drive pinion (3).

5. Use tooling (A) to remove gear from thrust

washer (l). Remove the bearing from hous-
rno
- ,s.

Remove ring (9). Remove bolts, locks, and

gear (8).

1. Remove thrust plate (10) and shims. Keep

shims together for installation.

8. Turn puller bolt ( l2) counterclockwise and

remove drive gear ( I 1) .

9. Remove locknut (6), gear (7) and key. Re-

move the drive shaft (13). Rernove bearings
for the shaft from the housine.
 GT'g, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

GOVERNOR DRIVE HOUSI NG

ISSEMBLE GOVERNOR DRIVE HOUSING 16-1288
Tools Needed A B

1P529 Handte 1

1P472 Drive Plate 'l

1P475 Drive Plate I

852328 Dial Test Indicator Grouo

l. Install the bearings (l) in housing with

toóling (A).Put clean engine óif on
bearings.
l. Install the drive shaft (2) and locknut. key
and gear (3).
3. Install the drive gear. Turn the puller bolt to
hold gear on shaft.

must be .015 to .045 in. (0.39 to 1.14 mm)

end clea¡ance.
5. Install seal (6) in housing with lip of seal to
inside. Install lever and shaff assemblv
(5). Install spring, key and pin.

\OTE: Be sure the pin is engaged with groove in

i¡aft and shaft turns freely. The spring must hook
r¡t'er the pin and around shaft lever.
ll.

6. Install plunger, spring, retainer and rins, for liil

safety shutoff. ir
i

7. Install rive pinion (g). Install l'

shims ak (7).Install bevel sear ilir

( l0) a play of drive shaft with l

new parts is .005 to .009 in. (0.13 to 0.23

mm). Maximum permissible end play with
used parts is .015 in. (0.3g mm).
8. Use the tool group (B) to check the clear_
'ance (backlash) between pinio
gear (10). Make adjusrment of
removing or adding shims (9) b
plate (7). Amount ck_
lash) between beve be
.002 to .006 in. (0.
9. Install coupling on shaft. Fasten a hoist and
install governor drive housing on the fuel
injection pump housing.
end by:
a) install safety shutoff
b) install governor
c) install fuel injection pump housing,
governor, and governor drive as a unit

89
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

FUEL INJECTION VALVES

REMOVE FUEL INJECTION
VALVES 11-12il
l. Remove the nut ( l) of the fuel line for valve
to be removed. Put a cover on end of fuel
line to keep dirt out.

2. Remove nut (3) that holds valve in the pre-

combustion chamber.

3. Remove the seals from the nut.

4. Lift fuel injection valve (2) from the pre-

combustion chamber.

5. Remove thenozzle from bodv.

INSTALL FUEL INJECTION

VALVES 12-1254

l. Turn the nozzle (1) on the threads of body

(2) finger tight.

2. Install the valve into the precombustion

chamber.

3. Install a new seal on the nut (4).

4. Install the nut (4) that holds valve in pre-

combustion chamber. Tighten the nut to a
torque of 100 to ll0 lb.ft. (13.8 to 15.2
mkg).

5. Install a new seal on top of nut between

valve body and the nut.

6. Install fuel line nút (¡) to valve. Tighten the

nut (3) to a torque of 25 to 35 lb.ft. (3.5 to
4.8 mkg).
 D379, D398, D399 INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

PR ECOMBUSTION CHAMBERS
REMOVE PRECOMBUSTION
CHAMBERS 11-1106
Tools Needed A
5F8353 Wrench 1

start by:
a) remove fuel injection valves
l. Remove coolant from engine.

2. Remove precombustion chamber (1) with

wrench (A).

3. Remove the gaskets from precombustion

chambers.

INSTALL PRECOMBUSTION
CHAMBERS 12-1106
Tools Needed A
5F8353 Wrench 1

l. Put 9M3710 Anti-Seize Compound on

threads of the precombustion chamber (2).

2. Put a small amount of grease on gasket (3)

to hold gasket on chamber.

3. Put liquid soap on the seal (l) and bore in

the cylinder head.

4. Tighten pre combustion chamber with

wrench (A) to a torque of 225 r 15 lb.ft.
(31.5 t 2.1 mke).

5. Fill the engine with coolant to correct level.

end by:
a) install fuel injection valves
 DISASSEMBLY AN D ASSEMBLY
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

ROCKER SHAFTS AND PUSH RODS

REMOVE ROCKER SHAFTS AND PUSH
RODS 11-1102 & 1208

start by:
a) remove valve covers
l. Loosen the adjustment screws (l) to get
maximum valve clearance. Disconnect oil
line (4) from shaft.

2. Remove nuts (3) and studs (2) that hold

shaft on head.

NOTE: If
studs (2) arc removed when nuts are
loosened, install the studs in the head. Tighten the
studs to a torque of 40 5 lb.ft. (5.5 t 0.7 mkg).
t

3. Remove rocker shaft. Remove the push rods

(5) from the cylinder head.

INSTALL ROCKER SHAFTS AND PUSH

RODS 12-1102 & 1208

l lnstall push rods (l) into position on the

lifters.

2. Install rocker shaft (2) on cylinder head'

3. Install the nuts and studs that hold rocker

i shaft to cylinder head. Connect oil line to
It the shaft.

NOTE: Be sure the studs and nuts are tightened to

a torque of 40 t 5 lb.ft. (5.5 t 0'7 mkg)'

4. Make an adjustment of the valve clearance'

The cold clearance must be: intake '015 in'
(0.4 mm) and exhaust .035 in' (0'9 mm)'
SEE VALVE CLEARANCE ADJUSTMENT
iN LUBRICATION AND MAINTENANCE.
end by:
a) install valve covers

9:
 D379, D398, D399 INDUSTRIAL AND
MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

ROCKER SHAFTS
DISASSEMBLE ROCKER SHAFTS 15_1102

start by:
a) remove rocker shafts and push rods
l. Remove cotter pins (l), washe¡s and
sprrngs.

2. Remove the intake rocker arms (5) from the

rocker shaft.

3. Remove the brackets (4) and exhaust rocker

arms (3) from shaft. Remove the fitting (6)
and spring (2).

4. Remove the bearings from the rocker arms

with toolinC (A). Remove the nut and screw
for the adjustment from the ur.r. R.-ou.
the rings and buttons from the arms.

ASSEMBLE ROCKER SHAFTS

16-1102
Tools Needed
A
1P529 Handte
1

1P466 Drive plate

1P469 Drive plate
1

NOTE: Be sure the oil holes of the bearings

are in
alignment with oil holes in arms.

2. Install the spring and fitting on the shaft.

3. Install the rocker arms, brackets, washers
(l), springs (2) and cotter pins on each end
of shaft.

NOTE: Be sure exhaust rocker arms and intake

¡ocker arms are installed in .orr".i--Lcation
on
shaft.

end by:
a) install rocker shafts and push rods

93
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

ROCKER ARMS. PUSH RODS AND VALVE LIFTERS

 D379, D398, D399INDUSTRIAL AND
MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

VALVE LI FTE RS
REMOVE VALVE LIFTERS 11-1209
start by:
a)
b) housing,
d gover-

c) remove valve covers

l. Loosen the adjustment screws for valves to
get maximum clearance.
)*IOTE: Flywheel housing removed for
illustration
only.
2. Remove the push rods (2).

3. Remove the oil tubes (1) away from the

brackets.
4. Put a wire or large rubber band around the
lifters (3) to hold them in place in bracket.
. 5. Remove the bolts and locks that hold brack_
et assembly to cylinder block. Remove the
brackets and lifters (3).

.¡s
D379, D398. D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

VALVE LIFTERS
INSTALL VALVE LIFTERS 12-1209
Tools Needed A

3P2243 Installer 1

I. Put clean engine oil on lifters. Install lifters

in bracket.

2. Put wire or large rubber bands (l) around

lifters to hold them in bracket.

3. Put the bracket and lifters in position on

dowels. Install the locks and bolts that hold
brackets to cylinder block. Remove the wire
or rubber band from lifters.

4. Put the oil tubes (2) on the brackets and

install locks and bolts.

5. Put the seals between the bracket assem-

blies.

Use installer (A) to put the seals in their

respective position.

'7 Install the push rods.

8. Make an adjustment of valves to get .015 in.

(0.38 mm) clearance (cold) on intake valves;
.035 in. (0.89 mm) clearance (cold) on ex-
haust valves. See VALVE CLEARANCE
ADJUSTMENT iN LUBRICATIOÑ AND
MAINTENANCE GUIDE.
end by:
a) install piston cooling tubes
b) install fu ction PumP housing,
safety sh governor, and gover-
nor drive, as a unit
c) install valve covers
 D379, D398, D399 INDUSTRTAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

INTAKE MANIFOLDS
REMOVE INTAKE MANIFOLDS 11_1058
l. Remove the bolts (2) that hold manifold to
housing (l).

NOTE: On the D399 Engines, the intake manifold

can be removed as one section for each
two cylin_
ders. Remove spacer that connects ihe
manifolds.

2. Remove the clamp (4) thatholds the oil line

for the oil cooler to the manifold.

3. Remove bolts (3) that hold manifold to the

cylinderheads. Remove the intake manifbld.

INSTALL INTAKE MANIFOLDS 12_1058

l. Install new manifold gaskets.

2. Put intake manifold ( I ) in position on engine.

Install the bolts that hold manifold to cytin_
der heads.

NOTE: On the D399 Engines, the manifolds can

be
installed as one section for each €wo cylinders.

3. Install the bolts that hold manifold to hous_

ing. Install the clamp that holds line for the
oil cooler to the manifold.

97
 TXT79. D3S, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

CYLINDER H EADS
REMOVE CYLINDER HEADS 11-1100

start by:
a) remove rocker shafts and push rods
b) remove intake manifolds
l. Remove the instrument panel from cylinder
head to be removed (if so equipped)'

2. Remove the coolant from engine.

3. Remove the eight bolts for each cylinder

head from the exhaust manifold on the
marine engines.

4. Remqve the bolts that hold the plate (2) on

bottoñ of exhaust shield. Let the plate lay
in the "V" of engine.

5. Remove the plugs (1) from the shield.

Remove the eight bolts that hold the ex-

haust manifold to each cylinder head.

1. Remove the fuel lines (5) for the head to be

F removed. Put covers on fuel valves, lines,
and pumps. Remove two elbows (4) for
each cylinder head. Remove the governor
control channel for cvlinder heads on left
F
É
hand side only.
r
8. Remove the oil line (3) for the rocker shaft.

9. Remove the nuts (6) from the cylinder

head.
q
t0. Install two lf 2"-13 NC forged eyebolts in
head.

ll. Fasten a hoist to the eyebolts and slowly

remove the cylinder head. Weight is l90lb.
(86 ke).
 D379, D398, D399 INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

CYLINDER HEADS
INSTALT CYLINDER HEADS
12-1100
1. Clean the block and cylinder head.Install
new head gaskets, new water seals,
and fer_
rules.

2. Install two lf 2,,_13 NC forged eyebolts in

head. Fasten a hoisf and slów1y lower
the
head ove¡ the studs until it iJ in
correct
position over head gaskets and
seals. Weight
is 190 lb. (86 ke).

3. Put 9M3710 Anti_Seize Compound on

threads of head studs, un¿ o"-tili
bolts fo¡
exhaust manifold. Install nut,
an¿ washers
on studs. Tighten nuts in following
quence:
step se_

Step I by number to a torque l4o ol5 too on \

tb.ft. (20.7 t 1.4 mig.
Step 2 ; by number to a torque
03 20 ot )
. of 250 t t0 lb.fr. (34.6 x l a mt!).
. Step 3 Tighten nuts again by number 07 60 05 80
(hand tgr-gr9 onty¡ to a torque
of
250 t 10 tb.fr. (34.6 t 1.4 mke).

4. Install new gaskets for the exhaust

mani_
fold. Install rtre bolts (f tfraifroiJ.rnuurt
)
manifold to head. Tighten Uoit, (l)
torque of 110 I 10 lb.ft. (15.2 to u
M.a1i1e Fngines. Tigfrtrn
; l'.4 mkg)
9n Uolt, (l)
dustrial Engines to 75 r o i¡.rt."iid.+ on t,r_
I
mkg). r.+ ,
5. Install the plate and plugs on the
shield for
the manifold bolts (if so équipp.Jl.'

6. Install the oil tine (2) fqr the rocker

shaft.
7. Install the two elbows (3). Install
Ure fuel
lines. Tighten nuts (4)'on fr.i*firr!.
torque of 25 to 35 lb.ft. (3.S to u
t; +.S _tgl.
Install governor control .t urrrr.t
hand side only). lán left

8. Install the instr

r'.uJl..áud?# H'd,|trp¿|"i on cvrinder
9. Fill the engine with coolant to
correct level.
end by:
a) install intake manifolds
b) install ¡ocker shafts aná push rods

99
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

PISTONS
REMOVE PISTONS 11-1214
start by:
a) remove cylinder heads
b) remove engine oil cooler
c) remove jacket water pump
d) remove engine oil pump
e) remove oil pressure regulating valve
l. Fasten a hoist and remove the prelubrica-
tion oil pump and motor as a unit (if so
equipped). Weight is 105 lb. (48 kg).

2. Remove the wire harness and plate for the

prelubrication oil pump and motor.

3. Remove the bolts (l) that hold inspection

covers to block. Remove the covers (2).

4. Turn the ft (in the direction of nor-

mal rota il the rod caps (4) can be
removed through the openings. Remove the
bolts (3) and rod caps (4).

5. Remove the carbon ridge (5) from the top

of the cylinder liner.

q,

Push the connecting rod and piston up until

rings arc out of the cylinder liner.

Remove the piston and connecting rod from

the cylinder liner. Weight is 45 lb. (21 kg).

100
 t T'g. D3S, D399 INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

PISTONS
INSTALL PISTONS 12-1214
ools Needed A
6H4140 Piston Ring Compressor I

Put clean SAE 30 engine oil on the piston,

rings, connecting rod bearings and walls of
cylinder liner. Install upper bearing in con-
necting rod.
Install piston in liner with compressor (A).
Use the liner as a guide.

3. Install the piston in the liner slowly on to

the journal of crankshaft. Be sure the ,.V,,
mark on piston is in alignment with the .,V,'
mark (2) on the block.
CAUTION: Be careful not to cause damage to con_
necting rod bearing or journal on crankshaft when
piston is installed.
4. Install the lower bearing (5) in the cap (3)
for the connecting rod (4). Be sure the tab
on back of bearing fits in groove for tab in
cap. Install the cap.

5. Put clean SAE 30 engine oil on threads of

rod bolts. Install rod bolts. Tighten the rod
bolts to a first torque of 40 t 4lb.ft. (5.5 t
0.6 mkg). Put a mark on bolt heads and
bearing caps. Tighten the I olts again l20.
from the mark.

6. Put inspection covers in position on engine.

Install the bolts that hold covers to cylinder
block.

7. Install the wire harness and the

prelubrica ion oil pump and f so
equipped).
(ñ
8. Put the prelubrication oil pump and motor
on engine with a hoist.
ryPICAL EXAMPLE
end by:
a) install oil pressure regulating valve
b) install engine oil pump
, c) install jacket water pump
d) install engine oil cooler
e) install cylinder heads

l0l
D379, D3S, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

PISTONS
DISASSEMBLE PISTONS 15-1214
Tools Needed A

5H9621 Piston Bing Expander 1

start by:
a) remove pistons
l. Remove the retainers (1) and pin (2) from
the piston. Remove the connecting rod (3).

a33&XZ

2. Use ring expander (A) to remove piston

rings from the piston.

3. Remove the carbon from ring grooves on

piston with a stick of hard wood.
.
CAUTION: Do not use a broken ring or carbon
scraper to clean carbon. They will cut the ring
grooves or cause damage to piston.

ASSEMBLE PISTONS 16-1214 ;1::',::::rr€r

Tools Needed A

5H9621 Piston Ring Expander 1

l. Use the ring expander (A) to install the pis-

ton rings.
2. Install spring for oil control ring (bottom
ring) in the bottom ring groove of piston.
Install oil control ring.
3. Install center ring in center groove of piston
so the mark "UP-2" on ring is toward top of
piston.
4. Install top ring in top groove ${ piston so
the mark "UP-I" on ring is tot,",ürd top of
pistch.
5. Turn the piston rings in the grooves so the
ring gaps arc l2O" apart.
6. Put the connecting rod (5) so the bearing
cap (4) is turned up. Put the piston with
¡elief (8) for valves is turned up and "V"
mark (10) is down. Install pin (7) and two
retainers (9). Each retainer (9) must fit in a
groove in piston on each end of pin (7).
end by:
a) install pistons

l0l
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

CYLINDER LINERS
REMOVE CYLINDER LINERS 11-1216
Tools Needed A

1P2399 Cylinder Liner Puller 1

1P2398 Puller Plate 1

start by:
a) remove pistons
1. Put a piece of gasket material or a cover
over crankshaft journals as a protection be-
fore liner is removed.

2. Put tooling (A) in the cylinder liner.

Use tooling (A) to remove the liner from its

seat in cylinder block.

CAUTION: Do not cause damage to piston cooling

tube (l) when installing tooling (A).

Remove the cylinder liner from its bore in

cylinder block.

5. Remove the seals from the liner. \

i.3

103
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

CYLINDER LINERS
INSTALL CYLINDER LIN ERS 12-1216
Tools Needed A ó

2Pa26O Cylinder Liner Installer 1

1P2398 Puller Plate 1

887548 Push Puller 1

1P5510 Liner Projection Tool Group 1

l. Clean the counterbore in cylinder block.

Clean the liner thoroughly.

2. Install new seals on the üner. Put liquid

soap on the seals and in the bore of cylinder
block. Put the liner in the bore of cvlinder
block.

3. Use liner installer (A) to put liner into cor-

rect position.

4. Put the puller plate of tooling (B) on the

liner. Install the remainder of tooling (B)
with two washers, two spacers 2 in. (51
mm) long. Tighten the two nuts for studs to
50lb.ft. (6.9 mke).

5. Measure liner projection as close as possible

to puller plate and at four locations around
the liner. Liner projection must be .004 to
.008 in. (0.102 to 0.203 mm).
end by:
a) install pistons
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

TURBOCHARGER LUBR ICATION VALVE

REMOVE TURBOCHARGER LUBR ICATION
VALVE 1 1-1309

l. Disconnect oil lines (l) and (2) from top of

turbocharger lubrication valve.

2. Loosen other ends and clips of upper oil

lines enough to move upper lines from
valve.

3. Disconnect the other three oil lines (5) from

valves.

4. Remove four nuts (3) that hold valve (4) to

channel. Remove the turbocharser lubrica-
tion valve.

INSTALL TURBOCHARGER LUBRICATION

VALVE 12-1309
l. Install turbocharger lubrication valve fl) to
channel with four bolts (2) and nuts.

2. Connect five oil lines to valve.

.i\
3. Tighten all connectors andt.,hos.

105
D379. D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

TURBOCHARGER LUBRICATION VALVE

DISASSEMBLE TU RBOCHARGER
LUBRICATION VALVE 15-1309

start by:
a) remove turbocharger lubrication
valve
1. Remove the bolts and cover (3).

2. Remove the body (2) and adapter (l). Re-

move the plunger and spring from body.

ASSEMBLE TURBOCHARGER
LUBRICATION VALVE 16-1309

l. Clean all parts before assembling valve.

2. Install spring (2) and plunger (l) in body

(3).

3. Install adapter, cover and bolts.

end by:
a) install turbocharger lubrication valve

lf5
 D379, D398, D399 INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

SUMP PUMP
REMOVE SUMP PUMP
11_1319
1. Remoye six bolts (I) that hold
cover (2) to
housing.

2. Remove cover from housing.

3. Remove rotor (6), vanes (5)

and springs
from housing.

4. Remove nut (3) from the shaft.

5. Remove handle (4) from shaft.

6. Remove packing nut and packing

covef.
from

7. Remove shaft from cover.

INSTALL SUMP PUMP

12-1319
1. Install shaft (7) in cover (2).

2. Install packing (6) and nut in

cover.

3. Install handle (l) on shaft.

4. Install nut on shaft.

\rl
5. Install three ca¡t (5)' sprines (3)
.and
rotor (4) i" ;:?."irffi

dñ
6. Install. cover (2) with pin
in shaft! (7)/,'
gaged in rotor. Install sii bolt;. --^$' \ en_

t07
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

AIR CLEANER HOUSINGS

REMOVE AIR CLEANER
HOUSINGS 11-1051

l. Loosen clamp (2) for turbocharger hose to

air cleaner housing.

2. Remove two bottom bolts (3) that hold air

cleaner housing to supports. Loosen two
upper bolts (4) that hold air cleaner housing
to supports.

3. Remove bolt (l) that holds brace to air

cleaner housing. Remove air cleaner housing
(s).

INSTALL AIR CLEANER

Éousrucs 12-1051

1. Install air cleaner housing by installing two

upper bolts into notches in support for air
cleaner housing.

Install bolt that holds brace to air cleaner

housing.

3. Install two lower bolts that hold air cleaner

housing to iupport and tighten two upper
bolts that hold air cleaner housing to sup-
port.
.'.V "ia.,
4. Tighten4¿lamp for turbochargér hose to air
cleaner housing.

r(B
 D379, D398, D399INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

TURBOCHARGER HEAT SHI E LD

REMOVE TURBOCHARGER HEAT
SHIELD
11-1073
1. Remove coolant from engine.

2. Remove the bolts that hold braces (l) for

air cleaner housings. Remove ifri two
shields from the heat shield.

3. Disconnect the water lines (2) and(4) from

the heat shield.

4. Loosen the three bolts (3) that hold heat

shield to afte¡cooler. Remóve the
bolts that
. hold heat shield to exhaust maniiotds.

5. Fasten a hoist and remove the

turbocharger
heat shield.

INSTALL TURBOCHARGER HEAT

SHf ELD .t2_1073

1. Put the three bolts (l) that hold

the heat
shield to aftercooler in the fieai
sfrief¿.
2. Fasten a hoist and install the heat shield
position on engine. Tighten in
the bolts to the
aftercrwler.
'At

3. Connect the water lines to the heat

shield.

4 Install that hold heat shield to

exhaus fnstall the two shields
(2) on

És. Install bolts that hold braces for

afu cleaner
housings.

6. Fill the engine with coolant to

cor¡ect level.

109
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

TURBOCHARGERS
REMOVE TURBOCHARGERS 11-1052
start by:
a) remove turbocharger heat shield
(Marine Engines only)
b) remove air cleaner housings
l. Remove the line (2) for oil supply to the
turbocharger. Remove return line (4) for oil
from turbocharger.

2. Remove shield (3) from turbocharger (Ma-

rine Engines only).

3. Loosen clamp (l) that holds coupling to ex-

haust elbow (Marine Engines only).

4. Loosen clamp that holds elbow to the after-

cooler.

5. Install covers in the openings for oil in

. turbocharger. Install a 3/8"-16 NC forged
eyebolt in top of turbocharger.

6. Remove bolts that hold turbocharser to ex-

haust manifold.
7. Fasten a hoist and remove turbocharser.
Weight is 50 lb. (23 kg.
INSTALL TURBOCHARGERS 12_1052

l. Put a 318"-16 NC forged eyebolt in top of

turbocharger. Fasten a hoist and put turbo-
er in position on engine.
2. 9M3710 Anti-Seize Compound on
threads of bolts (l) that hold turbocharger
to exhaust manifold. Install the bolts and
nuts. Tighten the bolts to a torque of 40 t 4
lb.ft. (5.5 t 0.6 mke).
3. Tighten clamp that holds elbow to after-
cooler.
4. Remove the covers from openings and in-
stall the supply line and return line (2) for
oil to turbocharger.
5. lnstall the shield for turbocharger. Tighten
the clamp that holds coupling (Marine En-
gines only).
end by:
a) install turbocharger heat shield (Ma-
rine Engines only)
b) install air cleaner housings

ll0
D379, D398, D399 INDUSTRIAL AND
MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

AFTERCOOLER HOUSING
REMOVE AFTERCOOLER HOUSING 11_1063

start by:
a) remove air cleaner housines
b) remove turbocharger heaishield (Ma_
rine Engines only)

l. Remove the coolant from engine. Loosen

the clamps (l) that hold air elbows to after_
cooler housing. Move the clamps away from
aftercooler housins.

3. Remove bolts (2) that hold aftercoole¡

housing to flywheel housing.

4. bolts (5) from top of after_

0
D'

5. Fasten a hoist to the aftercooler housing.

ds

Remove aftercooler housing from engine.

Weight of aftercooler housing is 2Oó lU.
(1 l8 kg).

lll
D379, D398, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

AFTERCOOLER HOUSING
INSTALL AFTERCOOLER HOUSING 12_1063

l. Fasten a hoist and put the aftercooler hous-

ing in position on engine.

2. Install the bolts that hold aftercooler hous-

ing to flywheel housing.

3. Put the tubes (l) in position on flywheel

housing. Install the bolts that hold the tubes
to aftercooler housing and the flywheel
housins.

4. Put the clamps (2) that hold air elbows to

aftercooler into position. Tighten the
clamps.

5. Fill the engine with coolant to correct level.

'f-lt'
endrúV:
a) install air cleaner housings
b) install turbocharger heat shield (Ma-
rine Engines only) :'
D379, D398, D399 INDUSTRIAL AND
MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

AFTERCOOLER CORES
REMOVE AFTERCOOLER CORES 11_1063
start by:
a) remove aftercooler housing
l. Remove channel (2) from aftercooler hous_
ve bolts that i
t
housing. Rem ¡

(3) that hold ¡

t

2. Remove the top housing.

3. Remove sleeves (4) from the cores.

4. Fasten a hoist to the cores and remove the

cores from bottom housing. Weight of each
core is 75 lb. (34 kg).

INSTALL AFTERCOOLER CORES 12_1069

Fasten a hoist and put the cores (l) in posi-

tion in bottom housins.

Install the top housing.

¡É
s!¡

Put clean engine oil in bores for sleeves. In-

stall sleeves in housings. Install bolts (2)
that hold housings together.

&
In3tall pipe (3) on the top housing. Install
the bolts that hold pipe in position.

Install channel on aftercooler housing.

end by:
a) install aftercooler housins

l t3
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

ELECTRIC STARTI NG MOTORS

REMOVE ELECTRIC STARTING
MOTORS 11-1453

1. Disconnect wires from the starting motor

and the solenoid.

2. Put identification on wires and terminals for

installation.

3. Fasten a hoist to starter. Remove the three

bolts (1) that hold starter to the flywheel
housing. Remove the electric starter. Weight
is 80 lb. (36 ke).

INSTALL ELECTRIC STARTING

MOTORS 12-1453

l. Fasten a hoist and put the starting motor on

ensine. Install the three bolts.

2. Connect the wires to starting motor and to

solenoid.
TYPICAL EXAMPLE

l14
D379, D398, D399 INDUSTRIAL +
AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

AIR STARTER
REMOVE AIR STARTER
11-1451
l. Turn the valve for.air supply to regulating
to ',OFF,, position.
valve
2. Remove the silencer (l) and elbow.
3. Remove the pressure regulating valve (2),
whistle valve (3), and oilei. t

4, Install a 1f2',_13 NC foreed I

starter housing. Fasten a ho"ist I
I
the three bolts that hold starter
housing. Remove the air starter.
Weight is
821b. (37 ke).

INSTALL AIR STARTER

12-1451
l. Fasten a hoist and put air starter
in position
on engine. Install the three bolts.

2. Instatl
.the oiler, whistle valve, and pressure
regulating valve.
.
3. Install the elbow and silencer.
4. Turn the valve f, supplv to regulating
varve to ',oN,,'"?irtXti

lt5
 D379, D398. D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

AIR STARTER
DISASSEMBLE AI R STARTE R 15-1451
Tools Needed A B U

5F7465 Puller 1

1P232O PullerAssembly 1

182716 Bolt ( 5" long) 2

484276 Washer 2
1P2852 Spanner Wrench 1

start by:
a) remove air starter
l Put marks on parts to make alignment easier
during assembly.

2. Remove bolts (2) and remove the drive

housing (l).

3 Remove rine(4) and the screw (6).

4 Remove the drive assembly (5).

5. Remove socket head screws (7) and remove

the cover (8).

6. Bend lockwasher (13) and remove nut (14)

with wrench (C).

7. Remove the gear (12).

8. Remove retainer (l l) and push shaft (9) out

of bearing (10).
q

9. Push bea¡inC (10) out of cover (8).

itó
 D379, D398, D399 INDUSTRIAL AND
MARINE ENGINES DISASSEMBLY AND ASSEMBLY

AIR STARTER
10. Remove the bolts (17) and (18).
Remove
the gear housing ( I 9).

I l Remove cover (3.¡.

12. Bend lockwasher and remove the nut with

wrench (C).

13. Remove plate assembly (16) and

bearing
( I 5) wirh tooling (A).

14. Remove ai¡ motor housine.

I 5. Remove vanes (22) from rotor (24).

16. Bend lockwasher (21) and, remove the nut

(23) with wrench (C).

q
17. Remove the gear (26) wtthpuller (B).

18. Remove snap ring (20) and bearing (25).

117
 D379, D398, D3gg INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

AIR STARTER
ASSEMBLE AIR STARTER 16-1451

I . Install bearing (7) and ring ( l).

2. Install gear (6),lockwasher (2) andnut(4).

3. Install vanes (3) into rotor (5).

NOTE: Assemble parts with marks in alignment.
See AIR STARTING MOTOR in TESTING AND
ADJUSTING for rotor clearance adiustment.

4. Install air motor housing (9).

5. Install gear housing (8).

6. Install plate assembly (10) and bearing (l l).

.7. Install lockwasher and nut.

8. Install the cover.

9. Install bearing (14) in the cover (12).

10. Install shaft (13) and retainer (15).

ll. Install gear (16), lockwasher ( 17) an<l the

nut ( l8).
'*u!ti'.r
12. Install cover ( 12\ onthe gear housing (8).

13. In¡tall the drive assembly (19).

F
d
14. Install the drive housing.
end by:
a) install air starter

ilt
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

FLYWH EE L
REMOVE FLYWHEEL 1 1-1 156 ..r';1,

Tools Needed A
FTl094 Flywheel L¡fting Bracket I

FT524 Lift¡ng Bracket I

l. Remove cover ( 1) from flywheel housing.

Remove pointer from tlywheel housing.

2. Remove two bolts (2) that hold flywheel in

position on crankshaft. Install two j 18,,-14
NF 8 in. long bolts as a guide, on D379 &
D398. On D399 only. use two l"-14 NF x
10 in. long bolts as a guide.

3. Install tooling (A) on the flywheel. Remove

the remainder of the bolts that hold flv-
wheel to crankshaft.

4. Remove the flywheel. For D379 and D398,

weight of the flywheel is 450 Ib. (204 kg.
For D399 only, weight of flywheel is 550
tb. (249 ks).

gl
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

FLYWHEEL
INSTALL FLYWHEEL 12-1156 .:,'

Tools Needed

FTl094 Flywheel L¡fting Bracket 1

Ff524 Lift¡ng Bracket 1

1. For D379 and D398, install two 718"-14

NF x 8 in. long bolts (1) as a guide, in the
crankshaft. On D399 only, install two
l"-14 NF x 10 in. long bolts as a guide.

2. Use a hoist and toolinC (A) to put the

flywheel in position on crankshaft.

3. Install the bolts that hold flywheel to crank-

shaft. Tighten bolts on D379, D398 to a
torque of 450 1 30 lb.ft. (62.2 x 4.1 mkg).
On D399 only, tighten bolts to a torque of
' 670 i 50 lb.ft. (92.7 t 6.9 mkg).

4. Remove tooling (A) from flywheel.

5. Install pointer (2) in flywheel housing. In-

stall cover on flywheel housing.

t:0
 D379, Ds98, D399 tNDUSTRI#AÍnDMAR|NE
ENGTNES DISASSEMBLY AND ASSEMBLY

CRANKSHAFT REAR SEAL RING AND THROWER

REMOVE CRANKSHAFT REAR SEAL
RING
AND THROWER
11_1161

start by:
a) remove flywheel
l. Remove twelve bolts (l) thathold baffle to
flywheel housing.

Remove the baffle (2) from housing.

Remove the seal ring and spring from

thrower.

5. Remove the ring from flywheel housing.

1*
4

121
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

CRANKSHAFT REAR SEAL RING AND THROWER

INSTALL CRANKSHAFT REAR SEAL RING
AND THROWER 12-1161
Tools Needed A

FT105 Push Plate 1

T603 Bolt 2
9H 1031 Washer 2

1. Put 8M8060 Quick Cure Primer and 953265

Retaining Compound on ring. Install the
ring in flywheel housing.

2. Heat the thrower in oil to a maximum tem-

perature of 300'F (149'C). Install thrower
on crankshaft. Use tooling (A) to install
thrower in correct location on crankshaft.

CAUTION: Do not use an old oil thrower, seal ring

or spring.

3. Put clean engine oil on spring and ring. In-

stall spring and ring ( l) on thrower.

NOTE: The work "OLIT" on ring must be installed

away from crankshaft. Put the gap of the ring to
the top of crankshaft when installed.

4. Put clean engine oil on inside diameter of

baffle (2). Install the baffle (2) on the
flywheel housing.
end by:
a) install flvwheel

!t
 l
D379, D398, D399 tN Rt¡ L AND MARTNE ENGTNES DISASSEMBLY AND ASSEMBLY ]]

FLYWHEEL HOUSING
REMOVE FLYWHEEL HOUSING 11_1157
start by:
a) remove aftercooler housins
b) remove flywheel
c.) remove starters
l. Loosen bolts (4) that hold cylinder block to
oil pan base. Remove oil préssure regulating
valve (5).

2. Remove the four bolts that hold flange for

oil pump to oil pan base..

4. Remove thE biffle seal ring and spring from

tne throweri-.
t.

6. /gt'_ll NC bolts 6,, long as a

two 3/9,'_16 NC forged eye_
en a hoist.
, i .t:'
: r.'
7. Refirové the bolts that hold lifting eye to
cylinder block and to the flywtreeiiousing.
8. Remove bolts that hold governor
drive
housing to flywheel housing.

_Remove flywheel housing

9. from engine.
Weight is 450 lb. (204 ke).

\h,

123
D379, D3S, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

FLYWHEEL HOUSING
INSTALL FLYWHEEL HOUSING 12_1157

l. Put 7M7260 Liquid Gasket Material on top

surface of housing that makes contact with
governor drive housing.

2. Install two 5/8"-11 NC bolts 6" long as a

guide in the cylinder block. Install two
318"-16 NC forged eyebolts and fasten a
hoist. Put the flywheel housing on the cylin-
der block. Install the bolts that hold fly-
wheel housing.

3. Install bolts that hold governor drive to

flywheel housing.

4. Install bolts that hold lifting eye.

5.. Install spring, ring, and baffle on thrower.

NOTE: The word "OIJT" on ring must be installed

away from crankshaft. Put gap of ring to top of
crankshaft when installed. Install bolts that hold
baffle to flywheel housing.

6. Fasten a hoist to engine. Lift the engine

enough to remove the spacers (1).

7. Install oil pressure regulating valve (2).

8. Install the four bolts (3) that hold flange for

oil pump to oil pan base.

9. Tighten bolts (4) that hold cylinder block

to oil pan base.
* end by:
a) install flywheel
b) install aftercooler housing
c) install starters

ll4
 D379, D398, D399INDUSTRIAL AND MARINE
ENGTNES DISASSEMBLY AND ASSEMBLY

I
REAR TIMING GEARS
REMOVE REAR TIMING GEARS 11-D-12O6

Tools Needed A B

'1P2321 PullerAssemblv 1

FT884 Leg
3
887561 Step Ptate 1

8F3672 Puller Ptate

887548 Push Puiler
887550 Les ¿

8H684 Ratchet Wrench I

484280 Washer 2
L1329 Botr 2

start by:
a) remove flywheel housing
l. Be sure the No. I piston is at top center on
the compression stroke. See TIlflNG THE
CAMSHAFT FOR THE FUEL INJECTIO\J
PUMPS in TESTING AND ADJUSTING.

. 2. Remove the pins. bolts (l) and locks that

hold large camshaft gear to small camshaft
gear. Remove the large camsh aft gear (2).

CAUTION: Do not turn the crankshaft with laree

camshaft gear removed and the camshaft instaileá.

3. Remove bolts and locks that hold thrust

washer to the cylinder block. Remove
thrust washer. Remove bolts and retainer.
4. Use tooling (B) to remove the small cam_
shaft gear (3) from camshaft.

5. On D379 on|y, remove the thrower (5) with

tooling (A). Remove bolts, lock and retainer
that hold balancer gear on its shaft. Remove
rear balancer gear (4). Remove bearins from
balancer gear.
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

REAR TIMING GEARS

INSTALL REAR TIMING GEARS 12.D.12O6
Tools Needed A B

1P529 Handle 1

1P473 Dr¡ve Plate ,|

1P478 Drive Plate 1

FT105 Push Plate 1

T603 Bolt 2
1031
9H Washer 2

- l. On D379 only, use tooling (A) to install the

bearing in balancer gear.

NOTE: Be sure No. I piston is at top center on the

compression stroke. See TIMING THE CAM-
SHAFT FOR THE FUEL INJECTION PUMPS iN
TESTING AND ADUSTING.

2. Install small camshaft gear (2), thrust

washer (3), lock and bolts. Install retainer
' (6). Tighten bolts (l) to a torque of 60 to
' 70 lb.ft. (8.3 to 9.7 mkg).

3. Put a mark with chalk on the camshaft gear

at the location of timing mark "C". Put a
mark with chalk on the tooth of crankshaft
gear with punch marks. The back of gears
can be marked so the marks can be seen
with a mirror (7) after installation.

4 Install the large camshaft gear (5). Be suie

the "C" mark on gear is in alignment with
punch mark on crankshaft gear. On D379
only, move large camshaft gear out enough
to turn the balancer gear until "4" marks
are in alignment.

5. Put large camshaft gear in position on the

dowel on small camshaft gear. Install locks,
bolts, and pin (4).

6. On D379, heat the thrower in oil to a maxi-

mum temperature of 300'F ( 149'C). Install
thrower on crankshaft. Use tooling (B) to
install thrower in correct location on crank-
shaft.

C-\L-TIO\: Do not use an old oil thrower, seal ring

or spnng.
 D379, D398, D399 INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

CAMSHAFT
REMOVE CAMSHAFT 11-1210
)

start by:
a) remove fuel injection pump housing,
safety shutoff, governor, and gover_
nor drive as a unit
b) remove flywheel housing
c) remove vibration damper (D399
only)
l. Loosen the adjustment screws for valves to
get maximum clearance.

2. Remove the push rods.

3. Disconnect the oil lines (l) from lifter

brackets (3).

4. Use a magnet and pull the lifters (2) up

enough to put rubber bands or wire on
them. This will hold lifters awav from cam-
shaft.

5. for vibration damper. if

ousing so
Remove powe¡ takeofl, if so

'(
6. Remove the service meter and tachometer
drive from front of engine. Install the alien-
ment tool (A).

7. Remove the large camshaft gear (4).

8. Remove the bolts and locks thathold th¡ust

washer (5). Remove the camshaft and small
camshaft gear (6). Weight for a D379 is 60
lb. (27 kg); for a D398 is 85 lb. (39 kg); for
a D399 is I 00 lb. (45 kg) .

9. Remove the plate, small camshaft gear, and

key from camshaft.

127
D379. D3S, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

CAMSHAFT
INSTALL CAMSHAFT 12-1210
Tools Needed A

FT751 Camshaft Alignment Tool 1

l. Put the key and small camshaft gear on the

camshaft. Put clean engine oil on camshaft.
NOTE: On SAE standard rotation engines,
(counterclockwise as viewed from flywheel end) in-
stall the small camshaft gear on the end opposite
the F-mark on camshaft. For SAE opposite rota-
tion engines (clockwise as viewed from flywheel
end) install this gear on end with the F-mark.
2. Install the plate, lock, and bolts that hold
small gear on camshaft. Tighten bolts to 60
to 70 lb.ft. (8.3 to 9.1 mkg). Install align-
ment tool (A) on end of camshaft. Install
camshaft in engine.

' 3. that hold

the thrust washer. locks. and bolts
Install
small camshaft sear in cvlinder
, block.
NOTE: Be sure the crankshaft is in position with
No. I piston at top center on compression stroke.
4. Put a mark with chalk on "C" mark of gear
(2) and tooth of crankshaft gear with punch
marks. Put a mark on back of gears so they
can be checked with a mirror after installa-
tion. Put the large gear (1) on small cam-
shaft gear. Be sure "C" mark and punch
mark of crankshaft gear are in alignment.
On D379, move gear ( 1) out enough to turn
balancer gear to make "A." marks in align-
ment.
D379, D398, D399 INDUSTRIAL
AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

CAMSHAFT

6. Remove rubbe¡ bands or wires from lifters.

Install the push rods (4). Connect the oil
lines (3) for rocker shaft assemblies.

7. Make adjustment of valve clearance. The

end by:
a) install flywheel housing
b) install fuel injection pump housing,
safety shutoff, governor, and gover_
nor drive as a unit
c) install vibration damper (D399 only)
D379. D3S, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

CAMSHAFT BEAR INGS

REMOVE CAMSHAFT BEAR INGS 11-1230 _=_=
Tools Needed A

85224'l CamshaftBearinglnstallation
and BemovalGroup 1

8H684 Ratchet Wrencn 1

5P1666 Puller Plate 1

5P1667 Spacer 1

858292 Extension 1

start by:
a) remove camshaft 776lXl
b) remove valve lifters

1. Remove the camshaft bearings with tooling

(A).
Use the extensions as needed.

INSTALL CAMSHAFT BEARINGS 12-1230

Tools Needed A

452241 CamshaftBearinglnstallation
and Removal Grouo 1

8H684 Batchet Wrench 1

5P1666 Puller Plate 1

5P1667 Spacer 1

858292 Extension 1

t. Put the bearings in the cylinder block with

tooling (A). Put clean engine oil on
bearings.

NOTE: Be sure the oil holes (1) in the bearings are

in alignment with oil holes in cylinder block.

end by:
a) install camshaft
b) install valve lifters

Itr
 D379,D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

CRANKSHAFT
REMOVE CRANKSHAFT 11-1202
Tools Needed A

8F2550 Engine Tilting Group 1

start by:
a) remove flywheel housing
b) remove accessory drive housing
c) remove intake manifolds
d) remove crankshaft front seal ring and
thrower
e) remove crankshaft rear seal ring and
thrower
O remove engine oil cooler
WARNING: Never use the engine tilting
group unless the base of engine is fastened
safely to its foundation.
Remove the inspection covers from both
sides of engine. Install 58l l8l Turnbuckles
(5) with left-hand threads to top of engine.
Put FT73l Left and FT735 Right Support
Beams (9) and FT734 Supports (10) on
their respective sides of engine. D398 and
D379 Engines use FTI l3A and FTl l3 Sup-
port Beams.
2.Install 8F4239 Blocks (l) and 8F4226
Yokes (7) on support beams (9). Tighten
the 8F4230 Studs (6) 14.5 in. (368.3 mm)
long into the 8F4226 yokes (7). Use the
nuts on studs as shown.
3. Turn the 58l l8l Turnbuckles (5) on'studs
(6). Turn 8F4231 Studs (4)9in.(229mm)
long into the turnbuckles.
CAUTION: The turnbuckles and studs must carry
the engine evenly and must be turned evenly or
restriction will be caused. If either turnbuckle is
extra hard to turn, correct the restriction before
proceeding. Turning with a force will cause damage
to threads.
4. Turn the top of 8F4231 Studs in 8F4226
Yokes (3) and install 8F4239 Yoke, block
(l), and FT736 Bracket (2) to the cylinder
heads.

5. Install 8F4225 Bolts (ll), (six for D398

and D399 Engines and four for D379 En-
gtnes) in place of bolts used to hold cylinder
block to oil pan base.
6. Install steel plates or steel pipes as a support
under the support beams (9).
UT'g. D3S, D3gg INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

CRAN KSHAFT
t- Lift the engine four inches ( 102 mm) with
the turnbuckles and install 8F4228 Hinge
Yokes (12) and 8F4233 Hinge Blocks.
WARNING: The engine must be kept level
while it is being lifted from base. If an ex-
tra amount of effort is needed to turn one
tumbuckle, or hinge block and holes do not have
alignment, check the opening around the base with
a scale. Make adjustments to keep the distance
equal between cylinder block and base.
8. Install 8F4228 Hinge Yokes and 8F4233
Hinge Blocks between block and oil pan
base. Use L1178 Bolts between yokes and
base. Use bolts removed to hold hinge
blocks to the block.
9. Remove the 8F4225 Bolts used as a guide in
Step 5.
10. Begin tilting the engine by turning the turn-
. buckles on both sides of engine. When the
ends of studs are even with inside base of
' turnbuckles, replace the 8F4230 Studs with
FTl l l-A studs 20.5 in. (521 mm) long.
Replace studs one at a time.
WARNING: Having the ends of studs ex-
tended farther than even with inside base
of turnbuckles can cause damage to threads
of studs and in turnbuckles. If damage is caused to
threads the engine can fall.

ll Tilt the engine until studs are extended the

permissible distance. Remove 8F4231 Studs
and replace with FT733-5 Studs 11.5 in.
(292 mm) long. Remove the FTl11-A Studs
and replace with FT733-10 Studs (18) 23.5
in. (597 mm) long. These replacements are
on the side being opened. Before tilting the
engine farther, remove 8F4230 Studs from
side of engine with hinges. Replace them
with FTl l I Studs lO in. (254 mm) long.
t2. Keep tilting engine until studs are again ex-
tended the permissible distance. Remove
FT733-5 Studs and replace with FT733-7
Studs 18.5 in. (47O mm) long.
Tilt engine again until studs are extended
the permissible distance. Remove the
F-1733-7 Studs and replace with FT733-9
Studs ( 16) 21.5 in. (546 mm) long. Move to
side of engine with hinges and remove the
FTlll Studs and replace with FT733-2
Studs (14) 8 in. (203 mm) long. Remove
the 8F 4231 S tud s and rePlace with
FT733-l Studs ( l3) 6 in. (152 mm) long.
 D379, D398, D399 INDUSTRIAL AND MARINE
ENGINES DISASSEMBLY AND ASSEMBLY

CRAN KSHAFT
I 14. Tilt the engine until there js l7 in. (432
mm) clearance. Install Lifting Channels ( I 5)
on cylinder heads.
I 5. Put a clean cover (20) on the oil pan
base to
lower crankshaft on.
16. Install pins or bolts as a guide (19) on each
end of crankshaft. Fasten a ratchet hoist to
each guide.
17. Remove the bearing caps from connecting
rods and push the pistons and rods to top oi
their stroke.Use wire or rope to hold rodi on
side of engine that has bien lifted so rods
will not drop.
CAUTION: Do not cause damage to piston cooling
tubes.
18. Remove main bearing caps and bearings.
Put tape on threads of ituds to prevent
damage to them during removal. Lower the
crankshaft with two hoists ( 17) on cover
(20) and ¡emove. Weight of crankshaft for
, D379 is 650 tb. (295 kg); D398 is 890 lb.
(404 kü;D399 is I 100 tb. (499 ks).

t
D379. D398, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

CRAN KSHAFT
INSTALL CRANKSHAFT 12-1202
Tools Needed A B c
8F2550 Engine Tilt¡ng Group 1

852328 Dial Test Indicator Group 1

581161 Wire

t. Fasten hoists and put the crankshaft in posi-

tion under the cylinder block.
2. Install new upper halves (with oil holes) of
main bearings in cylinder block. Install the
upper halves of connecting rod bearings. Put
clean engine oil on all bearings.
3. Lift the crankshaft in to position in the cyl-
inder block. Remove the tape from threads
of studs.
NOTE: Be sure the timing marks are in alignment.
SEe CAMSHAFT AND TIMING GEARS AND
FRONT ACCESSORY DRIVE in TESTING AND
AD.JUSTING.

. 4. Put new bearings in main bearing caps. Use

wire (C) to check bearing clearance. Install
caps and tighten both nuts to 200 t 10
lb.ft. (31.1 r l 4 mkg). Put a mark on nuts
and end of studs. Tighten nuts 120' from
the mark. Remove caps and check thickness
of wire (C) to find bearing clearance.
Bearing clearance must be .005 to .008 in.
(0.127 to 0.203 mm) for new parts. Maxi-
mum permissible clearance for used parts is
.015 in. (0.38 mm).
NOTE: Main bearing caps are numbered as to their
location in cylinder block. Install bearing caps so
the number on cap is the same as number on
cylinder block. Both numbers must be on same
side of cylinder block.
5. Put clean engine oil on threads of studs and
seat for nut. Install main bearing caps and
nuts. Install the thrust plates on dowels on
rear cap. The dowels must not be extended
more than .160 in. (4.064 mm) from
counterbore face of bearing cap. Tighten
the nuts to 200 I l0 lb.ft. (37.7 ¡ 1.4 mkg).
Put a mark on nuts and ends of studs and
tighten nuts an extra 120' from mark.
D379, D398. D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY

CRAN KSHAFT
6. Put the connecting rods on the crankshaft.
Install lowe¡ half of new rod bearings in
caps. Put clean engine oil on bearings.

7 Use tool group (B) to check crankshaft end

play as controlled by thrust plates. End play
must be .005 to .021 in. (0.127 to 0.533
mm). Maximum permissible end play is .035 TYPICAL EXAMPLE
in. (0.889 mm).
8 Lower the engine by replacing the studs in
tool group (A) in turnbuckles as required.
Replace studs one at a time.

WARNING: The turnbuckles and studs

must carry the engine evenly and must be
turned evenly or restriction will be caused.
If either tra hard to turn, correct
the restri ceeding. Turning with a
force will threads.
9. When engine is lowered to 4 in. ( 102 mm)
with turnbuckles and studs, remove the
8F4228 Hinge Yokes (2) and 9F4233 Hinge
Blocks.
10. Install 8F4225 Bolts (l) as a guide. Install a
new gasket on the oil pan base.
I l Lower the engine on the base with the turn_
buckles and necessary studs. Install the
bolts that hold cylinder block to oil pan
base.
12. Install the inspection covers on each side of
engine.
13. Remove the beams, supports, turnbuckles,
yokes, block, brackets, and studs of tool
g¡oup (A).
end by:
a) install crankshaft front seal rine and
thrower
b) install accessory drive housing
c) install engine oil coole¡
d) install intake manifolds
e) install flywheel housir_s
f) install crankshaft rea¡ seal rine and
th¡ower
D379, D3S, D399INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AND ASSEMBLY

GENERATOR REMOVAL
REMOVE GENERATOR FROM
ENGINE 114450
l. Remove adapter screen (l) and cover from
the generator by removing two bolts on the
right side of the screen for the generator '

2. Remove bolts (4) that fasten the plates to

the flywheel.

3. Remove bolts (3) that fasten the generator

to the flywheel housing.

4. Fasten a hoist to the generator. Remove

bolts (2) that hold the generator to the
mount or rails.

5. Remove the generator with a hoist. Weight

is 4200 lb. (1905 kg) for theD379 engine;
5100 lb. (2313 kg) for the D398 engine;
and '7560 lb. (3429 kg) for the D399 en-
eine.
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AN D ASSEMBLY

GEN E RATOR INSTALLATION

INSTALL GENERATOR ON
ENGINE 124450
1. Install the shims and plates in the following
step sequence:

Step I Make sure the crankshaft is in

the most forward postion. Mea-
sure dimension (A) from the
face of the flywheel where the
coupling plate fastens to the rear
face of the flywheel housing.
Step 2 a) If the face of the flywheel is in-
side the rear face of the flywheel
housing add .587 in. (14.91
mm) to dimension (A). Then
subtract the thickness of plate
(l).
b) If the face of the flywheel is
outside the rear face of the
flywheel housing subtract di-
mension (A) from.587 in.
(14.91 mm). Then subtract the s8760xr
thickness of plate ( l).

) Step 3 Install the number of shims (3)

needed to get the measured
thickness to the nearest .015 in.
(.38 mm). Tighten bolts (4) to a
torque of 370 t 35 lb.ft. (51.2¡
4.8 mkg).

Install a guide bolt (5) in the flywheel for

alignment.

3. Put generato¡ into position on engine with a

hoist. Install the bolts holding the plates to
the flywheel.

4. Install the bolts that hold the generator to

the flywheel housing. Install the adapter
screen and cover for the fan. E

5. Install the four bolts that hold the generator I

to the mount or rail.

r37
D379, D3S, D399 INDUSTRIAL AND MARINE ENGINES DISASSEMBLY AN D ASSEMBLY

MARINE GEAR REMOVAL

REMOVE MARINE GEAR 1 1-3300

l. Remove oil from marine gear housing.

2. Remove the coolant from the ensine.

3. Remove the water lines from marine gear oil

cooler.

4. Remove the output shaft from flange.

5. Disconnect the oil line (l) for sump pump

from bottom of marine sear.

6. Remove the boltb (4) that hold marine gear

to flywheel housing. Fasten a hoist to ma-
rine gear. Remove water lines (2) and (3).

7. Remove bolts (5) and shims that fasten ma-

rine gear to support rails.

NOTE: Keep the shims with their respective loca-

tion for installation.

8. Move the marine gear from flywheel hous-

ing until drive spider is away from drive
ring. Remove the marine gear. Weight is
from 4100 lb.(1860 kg) for D379,to 60001b.
(2722 kg) on D398 and D399.

9. Remove bolts that hold drive ring to

flywheel and remove drive ring (6).

-
 D379, D398, D399 INDUSTRIAL AND MARINE ENGINES DlSASSEMBLY AND ASSEMBLYF 't."

MARIN E GEAR INSTAL LATION

INSTALL MARINE GEAR 12-3300

l. Install the drive ring (l) on the flywheel.

2. Fasten a hoist and install marine gear in

alignment with engine. Be sure the rubber
blocks (2) are on the drive spider.

a
J. Move the marine gear to the engine. Make
the drive spider in alignment with drive ring.

NOTE: The cover on top of marine gear can be

removed to check alignment
if necessary.

4. Install the bolts that hold marine gear to

flywheel housing.

I Install original shims between maúne

5 gear
brackets and support rails. Install bolts and
lockwashers. See LUBRICATION AND
MAINTENANCE.

6 Install the oil lines to marine gear oil cooler

and sump pump.

7. Fill marine gear with lubricant as neeJ::

Fill engine with coolant to correct ier':,
Service Information For Balancers And Dampers
Caterpillar-Built Engines

This article explains the different types of vibration. It also tells how balance gears, balance shafts and
dampers are used to control vibration and it gives specific service recommendations for balance gears,
balance shafts and vibration dampers.

Two types of vibration, linear and torsional, can be found in engines. Linear vibration is movement of the
engine structure that can be seen, felt and heard. Torsional vibration is twisting vibration, it usually can not
be felt or seen but can sometimes be heard as gear teeth noise.

For more detailed information on engine vibrations, see Service Training Meeting Guide 403, Form
SESV1403, "Introduction To Vibration." Also see the other publications that are shown at the end of this
article.

Linear Vibration
Most Caterpillar engines are naturally balanced by design. Those engines that are not naturally balanced use
balance gears or balance shafts to keep vibration to an acceptable level.

All twelve and sixteen cylinder vee engines, eight cylinder 90° vee engines and in-line six cylinder engines
are naturally balanced. Because of their cylinder arrangement and crankshaft design, the D346, D379, 3204,
3304, 3408 and 3508 Engines are not naturally balanced.

Balance Gears And Shafts

To control linear vibration in engines that are not naturally balanced, balance gears and balance shafts are
used. The gears and shafts are timed to the crankshaft rotation. They produce a counter force to the
unbalanced forces produced by the engine during rotation. This action results in a balanced engine.

The balance gears or shafts are driven by the front or rear gear trains. The correct alignment of the timing
marks on the gears and shafts is very important during assembly. For example, if the balance gears or shafts
are installed with the timing marks 180° out of phase, the unbalance forces will double. This will cause a
large increase in the engine vibration. If the vibration is severe enough, it can cause parts to break loose and
can cause damage to the engine support structure.
During engine overhaul, it is very important to make sure the balance gears, shafts and bearings are
inspected for damage. Damaged parts must not be used again. Special Instruction, Form SEHS7914,
"Troubleshooting Engine Vibration In Vehicular Equipment" can be used to help troubleshoot linear
vibration problems.

Torsional Vibration

Torsional or twisting vibration is caused by the power impulses produced along the length of the crankshaft
during rotation. See Illustration 1. Every crankshaft has a natural frequency of vibration. This frequency will
remain constant if equipment is not added or removed from the engine. As rotation of the crankshaft starts,
torque is applied to each successive crankshaft throw by the power impulses. If the frequency of the
vibrations produced by the power impulses equals the natural frequency of vibration, a condition called
"resonance" will be the result. This condition will greatly increase the amplitude (size) of the torsional
vibrations. If not controlled, the torsional vibration will cause a failure of the crankshaft. To keep torsional
vibrations at an acceptable level, rubber and viscous dampers are used.

Illustration 1. Twisting vibration that results from the power impulses.

Rubber Dampers

Rubber dampers are usually found on smaller or older engines. This type of damper has a rubber ring that is
under compression between the outer damper weight and the inner damper hub. The assembly is then
fastened to the crankshaft as shown in Illustration 2. The rubber damper is tuned by design for a specific
vibration frequency. During the normal load speed range of the engine, the torsional vibrations are dampened
by the elasticity of the rubber and the inertia of the weight. Because rubber dampers are tuned to a specific
frequency, they are limited to the system for which they were designed. The addition of a marine gear, power
takeoff or a generator, which is not a part of the design package for that specific engine, will change the
natural frequency of crankshaft vibration. This will make the damper ineffective. Before a change is made to
a system with a rubber damper, a torsional vibration analysis should be made. For information on obtaining a
vibration analysis, refer to the Engine Price List and the Application and Installation Guides (shown in Chart
B.)

Illustration 2. Cross section of rubber damper.

Viscous Dampers

Viscous dampers are more effective over a wide range of engine speeds than rubber dampers. Viscous
dampers have a sealed housing that contains a heavy weight. The weight is suspended in a highly viscous
silicone fluid. See Illustration 3. As the crankshaft turns, the silicone fluid turns with the housing. The heavy
metal ring is driven by the fluid but, because of inertia, it has a resistance to any sudden change in the
direction or speed of rotation. The silicone fluid drags or pushes the heavy ring as a result of the vibrations
generated by the engine. The vibrations are dampened at most speeds and absorbed into the viscous fluid as
heat.

See Chart A for a summary of damper usage on Caterpillar engines.

Illustration 3. Cross section of viscous damper.

Chart A--Engine Summary And Damper Usage

Service Of Dampers
It is our recommendation to inspect rubber dampers at 3000 hour intervals on the 3208 Engine and 5000
hour intervals on all other engines. It is also our recommendation to replace rubber dampers for any of the
reasons that follow. For Steps 1 through 3, the inspection must be made during overhaul.

1. The engine has had a failure because of a broken crankshaft.

2. The crankshaft front bearing is badly worn.
3. There is a large amount of gear train wear that is not caused by a lack of oil.
4. Inspection shows slippage (movement) between the inner and outer member of the damper as
shown in Illustrations 4 and 5.
5. Inspection shows rubber deterioration because of cracking, spalling, splitting, etc. See Illustrations 6
and 7.

If none of the above conditions is found, rubber dampers can be used again at overhaul.

Illustration 4. Slippage between inner and outer member. DO NOT USE AGAIN.

It is our recommendation to inspect viscous dampers at 20,000 hour intervals. It is also our recommendation
that viscous dampers be replaced for any of the reasons that follow. For Steps 1 through 3, the inspection
must be made during overhaul.

1. The engine has had a failure because of a broken crankshaft.

2. The crankshaft front bearing is badly worn.
3. There is a large amount of gear train wear that is not caused by a lack of oil.

Illustration 5. Slippage between inner and outer member. Reference marks are not in correct alignment. Misalignment of
the reference marks can be 1.5 mm (.06") due to assembly. If there is evidence of movement. DO NOT USE AGAIN.
 Illustration 6. Rubber deterioration. DO NOT USE AGAIN.

Illustration 7. Rubber deterioration. DO NOT USE AGAIN.

4. Inspection shows fluid leakage or a dented (damaged) housing. Either condition can cause the metal
ring to make contact with the housing and cause damper operation that is not correct.

If none of the above conditions is found, viscous dampers can be used again at overhaul. Be careful not to
damage the damper during removal and installation.

For either rubber or viscous dampers, never exceed engine application guidelines without doing a vibration
analysis to determine if the damper is adequate. Refer to the Application and Installation Guides shown in
Chart B for the technical data required to perform a torsional vibration analysis. Chart B also shows
reference literature that discusses vibration, correct installation methods, troubleshooting, etc.
Caterpillar engines will perform properly when used in an application for which they are designed. The
torsional compatibility of the installation is the responsibility of the system designed. Caterpillar will provide
the customer, upon request and without charge, the necessary information to do a theoretical torsional
analysis. If the customer desires, Caterpillar will perform a torsional analysis for a nominal charge. See the
Engine Price List for cost information.

Copyright 1993 - 2012 Caterpillar Inc.

Todos los derechos reservados. Sat Sep 29 06:55:44 EST 2012
Red privada para licenciados del SIS.
 Cerrar SIS

Pantalla anterior

Producto: INDUSTRIAL ENGINE

Modelo: D398 INDUSTRIAL ENGINE 66B
Configuración: D398B ENGINE - ENGINES IN GENERAL ELECTRIC
LOCOMOTIVES FOR T 66B00001-UP

Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Vibration Damper (D398 and D399)

SMCS - 1205-11 ; 1205-12

Remove Vibration Damper (D398 & D399)

1. On D398, remove the bolts (1). Put an identification mark on bolts (3) and (4) and housing. Remove
the cover (2).

2. On D399, remove bolts that hold the cover. Remove the cover.

3. On D398, remove the bolts that hold vibration damper. Install two 1P7407 Eyebolts in the tapped
holes of the vibration damper. Fasten a hoist.

4. On D399, remove the bolts that hold vibration damper. Install two bolts (6) as a guide. Move the
vibration damper out on the guide bolts with forcing screws (5). Fasten a hoist and remove vibration
damper. Weight of D399 damper is 270 lb. (122 kg) and the D398 is 130 lb. (59 kg).

NOTICE
Do not hit the vibration damper.

Install Vibration Damper (D398 & D399)

1. Install two bolts as guide. Fasten a hoist to the vibration damper. Put the damper in position on the
adapter.

2. Put 9S3263 Thread Lock on the threads of bolts for vibration damper. Put thread lock on the two bolts
with a mark for cover on the D398.

3. Install the bolts and remove guide bolts. Tighten the 1 in. bolts (1) to 670 ± 50 lb. ft. (905 ± 70 N·m)
on D399. Tighten the bolts (1) on D398 to 280 ± 20 lb. ft. (377 ± 25 N·m).

4. Install cover (2) on D399. Install cover on D398 with bolts that have a mark in respective place on
housing.

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 06:57:40 EST 2012
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Red privada para licenciados del SIS.
 Cerrar SIS

Pantalla anterior

Producto: INDUSTRIAL ENGINE

Modelo: D398 INDUSTRIAL ENGINE 66B
Configuración: D398B ENGINE - ENGINES IN GENERAL ELECTRIC
LOCOMOTIVES FOR T 66B00001-UP

Especificaciones
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Vibration Damper
D399 Engine with one damper:
SMCS - 1205-11 ; 1205-12

D399 EARLY

(1) Torque for bolts that hold damper to adapter ... 32 ± 5 lb. ft.(43 ± 7 N·m)
(2) Torque for bolts that hold adapter and damper to crankshaft ... 670 ± 50 lb. ft.(905 ± 70 N·m)

NOTE: Put 8H5137 Sealant on threads of bolts that hold adapter and damper to crankshaft.

D399 LATER

D399 Engine with two dampers:

(3) Torque for nuts that hold dampers to adapter ... 32 ± 5 lb. ft.(43 ± 7 N·m)

NOTE: Spacers (A) must be installed between the dampers as shown.

(4) Torque for bolts that hold adapter to crankshaft ... 670 ± 50 lb. ft.(905 ± 70 N·m)

NOTE: Put 8H5137 Sealant on threads of bolts that hold adapter to crankshaft.
D398 EARLY

D398 Engines; effective in production with Serial Numbers 66B1 thru 66B4405 and 67B1 thru
67B1709:

(5) Torque for bolts that hold adapter to crankshaft ... 420 ± 60 lb. ft.(565 ± 80 N·m)

NOTE: Put 8H5137 Sealant on threads of bolts that hold adapter to crankshaft.

(6) Torque for bolts (3/4-10 NC) that hold damper to adapter ... 280 ± 20 lb. ft.(377 ± 25 N·m)
D398 LATER

D398 Engines; effective in production with Serial Numbers 66B4406 up and 67B1710 Up:

(7) Torque for bolts that hold adapter to crankshaft ... 460 ± 20 lb. ft.(624 ± 25 N·m)

NOTE: Put 8H5137 Sealant on threads of bolts that hold adapter to crankshaft.

(8) Torque for bolts (1/2-13 NC) that hold damper to adapter ... 75 ± 10 lb. ft.(100 ± 14 N·m)

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 06:58:51 EST 2012
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Red privada para licenciados del SIS.
 Cerrar SIS

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Producto: INDUSTRIAL ENGINE

Modelo: D398 INDUSTRIAL ENGINE 66B
Configuración: D398B ENGINE - ENGINES IN GENERAL ELECTRIC
LOCOMOTIVES FOR T 66B00001-UP

Información Técnica
1988/01/25
Número de medio -SEBD1851-00 Fecha de publicación -25/01/1988 Fecha de actualización -25/01/1988

SEBD18510032

8T5314 Socket Adapter Available To Correctly Install Alternator

Pulley Nut {0601}
SMCS - 0601

Machines And Engines Equipped With Delco Alternators

Reference: Service Magazine; November 23, 1987; Page 2, "Correct Torque Value For Alternator Drive
Pulley Retaining Nut Is Important."

The 8T5314 Socket Adapter is available to correctly install the pulley nut on 6N9294 (35 amp) and
5S9088 (50 amp) Alternators (Delco). The 8T5314 Socket Adapter is needed because the pulley
retaining nut is completely enclosed within the counterbore of the pulley. If the pulley is not correctly
secured, the pulley can slip on the rotor shaft. This could result in a loss of electrical charging and
damage to the rotor shaft. The illustration shows the tool arrangement, including the 8T5314 Socket
Adapter, used to correctly install the pulley nut.
Tool arrangement for correctly installing alternator pulley nut.

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:03:52 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Camshaft
SMCS - 1210-11 ; 1210-12

Remove Camshaft
Ver imagen

start by:

a) remove fuel injection pump housing, shutoff control, governor, and governor drive as a unit

b) remove flywheel housing

c) remove vibration damper (D399 only)

1. Loosen the adjustment screws for valves to get maximum clearance.

2. Remove the push rods.

Ver imagen
3. Disconnect the oil lines (1) from lifter brackets (3).

4. Use a magnet and pull the lifters (2) up enough to put rubber bands or wire on them. This will hold
lifters away from camshaft.

5. Remove housing for vibration damper, if so equipped. Remove power takeoff, if so equipped.

Ver imagen

6. Remove the service meter and tachometer drive from front of engine. Install the alignment tool (A).

7. Remove the large camshaft gear (4). Remove the bolts and locks that hold thrust washer (5).

Ver imagen

8. If small camshaft gear (6) is to be removed, bend the lock and remove the two bolts and plate from
the end of the camshaft.
Ver imagen

TOOLS (B) FOR REMOVING SMALL CAMSHAFT GEAR

9. Use tools (B) to remove the small camshaft gear (6) from the camshaft.

10. Remove the camshaft. Weight of the camshaft is approximately:

D379 Engine ... 60 lb.(27 kg)

D398 Engine ... 85 lb.(39 kg)

D399 Engine ... 100 lb.(45 kg)

Install Camshaft
Ver imagen

1. Put the key and small camshaft gear on the camshaft. Put clean engine oil on camshaft.

NOTE: On SAE standard rotation engines, (counterclockwise as viewed from flywheel end) install the
small camshaft gear on the end opposite the F-mark on camshaft. For SAE opposite rotation engines
(clockwise as viewed from flywheel end) install this gear on end with the F-mark.

Ver imagen
2. Install the plate, lock, and bolts that hold small gear on camshaft. Tighten bolts to 60 to 70 lb. ft. (80
to 95 N·m). Install alignment tool (A) on end of camshaft. Install camshaft in engine.

3. Install the thrust washer, locks, and bolts that hold small camshaft gear in cylinder block.

NOTE: Be sure the crankshaft is in position with No. 1 piston at top center on compression stroke.

Ver imagen

4. Put a mark with chalk on "C" mark of gear (2) and tooth of crankshaft gear with punch marks. Put a
mark on back of gears so they can be checked with a mirror after installation. Put the large gear (1) on
small camshaft gear. Be sure "C" mark and punch mark of crankshaft gear are in alignment. On D379,
move gear (1) out enough to turn balancer gear to make "A" marks in alignment.

5. Remove the alignment tool (A) from front of camshaft. Install the service meter and tachometer drive.
Install housing for vibration damper or power takeoff if so equipped.

Ver imagen
6. Remove rubber bands or wires from lifters. Install the push rods (4). Connect the oil lines (3) for
rocker shaft assemblies.

7. Make adjustment of valve clearance. The cold clearance must be: intake .015 in. (0.38 mm) and
exhaust .035 in. (0.89 mm). See VALVE CLEARANCE ADJUSTMENT in TESTING AND
ADJUSTING.

end by:

a) install flywheel housing

b) install fuel injection pump housing, shutoff control, governor, and governor drive as a unit

c) install vibration damper (D399 only)

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:12:18 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Camshaft Bearings
SMCS - 1230-11 ; 1230-12

Remove Camshaft Bearings

Ver imagen

Ver imagen

start by:

a) remove camshaft

b) remove valve lifters

Ver imagen
1. Remove the camshaft bearings with tooling (A). Use the extensions as needed.

Install Camshaft Bearings

Ver imagen

Ver imagen

1. Put the bearings in the cylinder block with tooling (A). Put clean engine oil on bearings.

Ver imagen
NOTE: Be sure the oil holes (1) in the bearings are in alignment with oil holes in cylinder block.

end by:

a) install camshaft

b) install valve lifters

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:14:09 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Especificaciones
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Camshaft And Timing Gears

Ver imagen

Ver imagen
(1) Torque for bolts ... 60 to 70 lb. ft.(80 to 95 N·m)

(2) End play for the camshaft .....006 to .010 in.(0.15 to 0.25 mm)

Maximum permissible play .....020 in.(0.51 mm)

(3) Diameter of bearing surface (journal) of the camshaft ... 2.966 to 2.967 in.(75.34 to 75.36 mm)

Bore in bearing for camshaft ... 2.970 ± .001 in.(75.44 ± 0.03 mm)

Maximum permissible clearance between bearing and camshaft bearing surfaces (journals) ....009 in.
(0.23 mm)

(4) Timing marks for camshaft and balancer (D379 Engines only).

(5) Timing marks for crankshaft and camshaft gears (All engines).

(6) SAE Opposite Rotation (clockwise engine), put cluster gear on end of camshaft with "F" mark.

(7) SAE Standard Rotation (counterclockwise engine), put cluster gear on end of camshaft without
"F" mark.

NOTE: Specifications (8) and (9) for D379 Engines only.

(8) Bore in bearing for balance gear ... 1.6036 ± .0019 in.(40.731 ± 0.048 mm)

Diameter of bearing surface (journal) of balance gear shaft ... 1.5998 ± .0002 in.(40.635 ± 0.005 mm)
Maximum permissible clearance between bearing and bearing surface (journal) .....006 in.(0.15 mm)

(9) End play of balancer gear ............................................................004 to .012 in.(0.10 to 0.30 mm)

Maximum permissible end play .................................................................................019 in.(0.48 mm)

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:17:11 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Especificaciones
D399, G399, D398, G398, D379, G379 ENGINES
Número de medio -REG00476-00 Fecha de publicación -01/11/1972 Fecha de actualización -10/10/2001

Camshaft And Timing Gears

Ver imagen

Ver imagen

(1) Torque for retainer plate bolts ... 60-70 lb. ft.(8,3-9,7 mkg)

(2) End clearance of camshaft ....006-.010 in.(0,15-0,25 mm)

Maximum permissible clearance .....020 in.(0,51 mm)

(3) Diameter of bearing journal ... 2.966-2.967 in.(75,34-75,36 mm)

Bearing bore ... 2.969-2.971 in.(75,41-75,46 mm)

Maximum permissible clearance between bearing and journal ....................................009 in.(0,23 mm)

(4) Timing marks for camshaft and balancer (D379 and G379 Engines only).

(5) Timing marks for crankshaft and camshaft gears (All engines).

(6) SAE Opposite Rotation (clockwise engine), place cluster gear on end of camshaft with F mark.

(7) SAE Standard Rotation (counterclockwise engine), place cluster gear on end of camshaft without F
mark.

NOTE: Specifications (8) and (9) for D379 and G379 Engines only.

(8) Bore in balance gear bearing ... 1.6019-1.6025 in.(40,688-40,705 mm) Diameter of shaft bearing

journal ... 1.5996-1.6000 in.(40,630-40,640 mm) Maximum permissible clearance between bearing

and journal ...................................................................................................................006 in.(0,152 mm)

(9) Balancer gear end clearance ............................................................0060-.0135 in.(0,152-0,343 mm)

Maximum permissible end clearance ............................................................................019 in.(0,48 mm)

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:18:54 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Crankshaft Main Bearings

SMCS - 1203-11 ; 1203-12

Remove Crankshaft Main Bearings

Ver imagen

start by:

a) remove engine oil cooler

b) remove fresh water pump

c) engine oil pump

d) remove oil pressure regulator valve

e) remove starters

1. Fasten a hoist and remove the prelubrication pump and motor as a unit (if so equipped). Weight is 105
lb. (47.3 kg).

2. Remove the wire harness and plate for prelubrication oil pump and motor.

Ver imagen
3. Remove the bolts (1) that hold inspection covers to block. Remove the inspection covers (2) from
each side of block.

Ver imagen

4. Remove the nuts for main bearing caps with wrench (B). Remove the bearing cap with lower half of
main bearing.

Ver imagen

5. Use tool (A) to move out the upper half of main bearing as the crankshaft is turned in the normal
direction of rotation.

NOTE: On the bearing journal that has no drilled hole, put a thin piece of fiber, hardwood or plastic
against end of bearing opposite tab. Hit the bearing lightly with the above until tab of bearing is free
from cylinder block. Remove the upper half of bearings.

Install Crankshaft Main Bearings

Ver imagen
1. Put clean engine oil on bearing surfaces of upper halves of bearings. Use tool (A) to install upper half
of bearing in cylinder block. The bearing with oil hole is upper half.

2. Clean main bearing caps and install lower halves of bearings in caps.

Ver imagen

TYPICAL EXAMPLE

NOTE: When the bearing clearance is checked and the engine is in a vertical position, such as in the
vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to
get a correct measurement with wire (C). The wire will not hold the weight of the crankshaft and give a
correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary
to hold the crankshaft up. Do not turn crankshaft when lead wire is in position to check clearance. If lead
wire is not available, PLASTIGAGE can be used to check bearing clearance.

Ver imagen

3. Use wire (C) to check bearing clearance. Install caps and tighten both nuts with tool (B) to 200 ± 10
lb. ft. (270 ± 14 N·m). Put a mark on nuts and end of studs. Tighten nuts 120° from the mark. Remove
caps and check thickness of wire (C) to find bearing clearance. Bearing clearance must be .0048 to .0090
in. (0.122 to 0.229 mm) for new parts. Maximum permissible clearance for used parts is .015 (0.38 mm).

Ver imagen
TYPICAL EXAMPLE

NOTE: Main bearing caps have numbers as to their location in cylinder block. Install bearing caps so
the number on cap is same as number on cylinder block. Both numbers must be on same side of cylinder
block.

4. Put clean engine oil on threads of studs and seat for nut. Install main bearing caps and nuts. Install
thrust plates on dowels on rear cap. The dowels must not be extended more than .160 in. (4.06 mm)
from counterbore face of bearing cap. Tighten nuts with wrench (B) to 200 ± 10 lb. ft. (270 ± 14 N·m).
Put a mark on nuts and ends of studs. Tighten nuts an extra 120° from mark.

5. Use indicator group (D) to check end play of crankshaft as controlled by thrust plates. End play with
new parts must be .005 to .021 in. (0.13 to 0.53 mm). Maximum permissible end play with used parts
is .035 in. (0.89 mm).

6. Install the inspection covers. Install the wire harness and plate for prelubrication oil pump. Fasten a
hoist and install prelubrication oil pump and motor as a unit (if so equipped).

end by:

a) install oil pump

b) install fresh water pump

c) install engine oil cooler

d) install oil pressure regulator valve

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:29:12 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Piston Cooling Tubes

SMCS - 1307-11 ; 1307-12

Remove Piston Cooling Tubes

start by:

a) remove engine oil cooler

b) remove fresh water pump

c) remove starters

d) remove engine oil pump

e) remove oil pressure relief valve

1. Fasten a hoist and remove the prelubrication oil pump and motor as a unit (if so equipped). Weight is
105 lb. (47.3 kg).

2. Remove the wire harness and plate for prelubrication oil pump and motor.

Ver imagen

3. Remove the bolts (1) that hold inspection covers to cylinder block. Remove inspection covers (2)
from each side of block.

Ver imagen
4. Remove the bolt (3) and lock that hold tube to bottom side of lifter bracket. Remove the piston
cooling tubes (4).

Install Piston Cooling Tubes

Ver imagen

1. check the alignment of the piston cooling tubes with tooling (A). See USE OF 5P8709 TOOL
GROUP FOR ALIGNMENT OF PISTON COOLING JETS, Form No. SMHS7267, for the correct
alignment procedure.

Ver imagen

2. Install the piston cooling tubes (1) in position on the lifter bracket. Install the locks and bolts.

3. Install the inspection covers on engine.

4. Install wire harness and plate for prelubrication oil pump and motor. Fasten a hoist and install
prelubrication oil pump and motor as a unit (if so equipped).

end by:

a) install engine oil pump

b) install fresh water pump

c) install engine oil cooler

d) install oil pressure relief valve

e) install starters

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:31:09 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Cylinder Liners
SMCS - 1216-11 ; 1216-12

Remove Cylinder Liners

Ver imagen

start by:

a) remove pistons

1. Put a piece of gasket material or a cover over crankshaft journals as a protection before liner is
removed.

Ver imagen

2. Put tooling (A) in the cylinder liner.

Ver imagen
 NOTICE
Do not cause damage to piston cooling tube (1) when tooling (A) is
installed.

3. Use tooling (A) to remove the liner from its seat in cylinder block.

Ver imagen

4. Remove cylinder liner (2) from its bore in cylinder block.

5. Remove filler band (3) and seals (4) from the liner.

Install Cylinder Liners

Ver imagen
1. Clean the cylinder liners and block. Install the liners in the block without the O-ring seals.

Ver imagen

2. Install tooling (A) on the liner. Tighten the nuts that hold tooling (A) evenly to a torque of 50 lb. ft.
(70 N·m).

3. Check the liner projection with tool group (B) at four locations around the liner. The difference
between the four measurements must not be more than .002 in. (0.05 mm). The liner projection must
be .004 to .008 in. (0.10 to 0.20 mm). The measurement between liners next to each other, must not be
more than .002 in. (0.05 mm) difference.

NOTE: The liner projection can change if the liner is turned in the bore.

4. Put a mark on the liner and block so the liner can be installed in the same position from which it was
removed.

Ver imagen
5. Install new seals (2) on the cylinder liners. Put liquid soap on the seals and in the bores in the cylinder
block.

Ver imagen

6. Put SAE 30 oil on filler band (1) and install it on the liner. Install the liner immediately in the cylinder
block with tooling (C).

end by:

a) install pistons

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:33:38 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Camshaft Bearings
SMCS - 1230-11 ; 1230-12

Remove Camshaft Bearings

Ver imagen

Ver imagen

start by:

a) remove camshaft

b) remove valve lifters

Ver imagen
1. Remove the camshaft bearings with tooling (A). Use the extensions as needed.

Install Camshaft Bearings

Ver imagen

Ver imagen

1. Put the bearings in the cylinder block with tooling (A). Put clean engine oil on bearings.

Ver imagen
NOTE: Be sure the oil holes (1) in the bearings are in alignment with oil holes in cylinder block.

end by:

a) install camshaft

b) install valve lifters

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:35:39 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Especificaciones
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Cylinder Block
Ver imagen

Ver imagen
(1) Torque for taperlock studs for cylinder head ... 120 ± 10 lb. ft.(160 ± 14 N·m)

(2) Depth to install front camshaft bearing .....31 in.(7.9 mm)

(3) Depth to install rear camshaft bearing .....66 in.(16.8 mm)

NOTE: Install camshaft bearings so oil holes in bearings are in alignment with oil passages in cylinder
block.

(4) Bore in cylinder block for camshaft bearings ... 3.2505 ± .0005 in.(82.563 ± 0.013 mm)

(5) Balancer gear shafts (V-8 Engines only).

Dimension from boss on cylinder block to end of shaft ... 2.686 ± .002 in.(68.22 ± 0.05 mm) NOTE:

Install shafts so centerline of two holes with threads is parallel with bottom face of cylinder
block.

(6) Depth of liner counterbore in block .................................................499 ± .001 in.(12.67 ± 0.03 mm)

Maximum permissible bore depth after reconditioning ...............................................545 in.(13.84 mm)

Height of liner over block (under installation pressure) ........................004 to .008 in.(0.10 to 0.20 mm)
(7) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 27.1875 ±
.0025 in.(690.563 ± 0.064 mm)

(8) Bore in block for main bearing ... 6.3725 ± .0005 in.(161.862 ± 0.013 mm)

Alignment for the bore in the block for the main bearings .......................000 to .003 in.(0.0 to 0.08 mm)

(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 7.9985
± .0015 in.(203.162 ± 0.038 mm)

(10) Torque for taperlock studs for main bearing cap ... 500 +50 -0 lb. ft.(680 +70 -0 N·m)

(11) Torque for nut holding cap for main bearings (lubricate stud threads):

a. Tighten all nuts to ... 200 ± 10 lb. ft.(270 ± 14 N·m)

b. Put mark on each nut and end of stud.

c. Tighten each nut from mark ... 120 ± 5°

(12) Clearance between main bearing caps and cylinder block

......................................................................................0010 (0.025 mm) tight to .0012 (0.030 mm) loose

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:37:45 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Especificaciones
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Cylinder Liner
Ver imagen

(1) Bore in liner (new) ... 6.251 ± .001 in.(158.78 ± 0.03 mm)

"Use again" maximum bore (when measured near upper end of the wear surface of the cylinder liner) ...
6.256 in.(158.90 mm)

(2) Thickness of flange on liner ......................................................5050 ± .0008 in.(12.827 ± 0.020 mm)

(3) Filler Band.

Installation procedure:

Put liquid soap on seals, liner grooves and bore in cylinder block. Install seals on bottom of liner. Put
filler band in SAE 30 oil for a moment, then install it on the liner. Install the liner in the cylinder block
immediately after the band is installed on the liner (before expansion of the band).

NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER
LINERS, FORM NO. SEBF8001.

Copyright 1993 - 2012 Caterpillar Inc.

Todos los derechos reservados. Sat Sep 29 07:39:48 EST 2012
Red privada para licenciados del SIS.
Especificaciones
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Cylinder Liner Projection

Ver imagen

Ver imagen

Make reference to CYLINDER LINER PROJECTION in Testing and Adjusting for the complete
procedure.
a. Install tooling as shown. Tighten bolts for crossbar evenly in four steps:

1st step ... 5 lb. ft.(7 N·m)

2nd step ... 15 lb. ft.(20 N·m)

3rd step ... 25 lb. ft.(35 N·m)

4th step ... 50 lb. ft.(70 N·m)

2. Measure cylinder liner projection with dial indicator (2) in 1P2402 Block (3) as shown. Measure at
four places around each cylinder liner near the clamped area.

Average of four projection measurements from any cylinder liner must be

...................................................................................................................004 to .008 in.(0.10 to 0.20 mm)

Maximum permissible difference between all four measurements ..................................002 in.(0.05 mm)

Maximum permissible difference between average projection of any two cylinder liners next to each
other under any one head ..................................................................................................002 in.(0.05 mm)

3. Depth of bore in block for liner ........................................................498 to .500 in.(12.65 to 12.70 mm)

Maximum permissible depth to machine counterbore to adjust cylinder liner projection

.........................................................................................................................................545 in.(13.84 mm)

Install a .030 in. (0.76 mm) shim plus any added shims necessary to get the correct cylinder liner
projection.

NOTE: Be sure that the .030 in. (0.76 mm) shim is directly under the cylinder liner flange.

Put 7M7260 Liquid Gasket on the top of the top shim and on the bottom of the bottom shim before
installing.

(1) 3H465 Plate.

(4) 8B7548 Push-puller Crossbar.

(5) 1P2398 Adapter Plate.

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 07:41:41 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Instrucción Especial
Using the 6V-7840 Deck Checking Tool Assembly {0701, 1201, 7225}
Número de medio -SEHS8187-06 Fecha de publicación -26/06/2012 Fecha de actualización -26/06/2012

i04934986

Using the 6V-7840 Deck Checking Tool Assembly {0701, 1201,

7225}
SMCS - 0701; 1201; 7225

Engine: 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All All 3500 Engines All 3600
All C280 C-10 All C-9 and C9 All C11 All C12 and C-12 All C13 and C-13 All

Introduction
Table 1

Revision Summary of Changes in SEHS8187

06
05
Updated Effectivity
04
03

© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law.

This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to
establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and
customers to benefit from cost reductions. Every effort has been made in order to provide the most
current information that is known to Caterpillar. Continuing improvement and advancement of product
design might have caused changes to your product which are not included in this publication. This
Reuse and Salvage Guideline must be used with the latest technical information that is available from
Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the
Service Information System. In order to address an urgent issue, please use the following resources in
order to communicate your request to Caterpillar Repair Process Engineering:

 Caterpillar Dealer Technical Communicator

 Dealer Solution Network

 Caterpillar Technical Representative

  Knowledge Network

Summary
When an engine is being rebuilt, it can be important to know if the top deck (surface) of the cylinder
block has been machined before, and if so, how much. The 6V-7840 Deck Checking Tool As can
accurately measure the distance from the centerline of the crankshaft to the top deck of the block. The
tool can measure all deck heights within a range of 200.0 to 625.0 mm (7.87 to 24.60 inch). Measuring
the top deck will also allow you to determine how much material can still be removed and keep the
engine within the minimum specifications.

References
ReferenceReuse and Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of
Cylinder Blocks"

ReferenceReuse and Salvage Guidelines, SEBF9213, "Measuring the Distance to the Top Deck of C15,
C-15, C-16, C18, 3400, C27, and C32 Engines"

Components of 6V-7840 Deck Checking Tool As

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Illustration 1 g02160934
(1) Lower Knob

(2) Lower Clamp

(3) Standard Stop

(4) Parallel Plate

(5) Micrometer

(6) Adjusting Collar

(7) Locknut

(8) Shaft Knob

(9) Lower bar

(10) 4B-9820 Wrench (1/8 inch), 7B-7640 Wrench (5/32 inch), 6B-7225 Wrench (3/16 inch)

(11) Standard Wrench

(12) Standard

(13) Measuring Standards

(14) Standard Extensions

Checking the Setting and Accuracy of the Tool

Before initial use of the tool (and anytime it is necessary to check the accuracy of the setting), the
position of standard stop (1) and the accuracy of micrometer (2) can be checked by using the following
information.

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Illustration 2 g02160953

1. To check the position of standard stop (1), put lower bar (3) in lower clamp (4) and tighten knob
(5). Use standard (6) [marked "STANDARD"] to check the distance between lower bar (3) and
standard stop (1). If necessary, adjust the position of standard stop (1) by loosening screws (7),
moving the stop as needed, then tightening screws (7) .

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Illustration 3 g02160957

2. To check the accuracy of micrometer (2), put a flat ground block (8) against the bottom of parallel
 plate (9). Adjust the micrometer until spindle (A) is against block (8). The micrometer should read
"0". If necessary, adjust the position of the micrometer by loosening screw (10), moving the
micrometer as needed, then tightening screw (10) .

Checking Distance From Crankshaft Centerline to Top Deck of

Cylinder Block
1. Look at the table 1 to find the correct tool reading for the engine being measured. Look at table 2
to find the measuring standards and extensions needed. For example, a new 3406 cylinder block
will have a tool reading of 360.50 ± 0.06 mm (14.193 ± 0.002 inch). This reading is in the 350 to
375 range, and will therefore take a 25 measuring standard plus one 150 extension.

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Illustration 4 g02160972

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 Illustration 5 g02160974

2. Install correct measuring standard (1) on standard stop (2). Use wrench (3) to tighten standard (1).
Do not tighten standard (1) too much. Adjust micrometer (4) until the micrometer it reads "0".
Loosen locknut (5), and put the tool assembly down into position in one of the end cylinder.

Note: Always check the crankshaft centerline to top deck distance (deck height) at both ends of
the cylinder block.

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Illustration 6 g02160989
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Illustration 7 g02160991

3. Put lower bar (6) in position in lower clamp (7). Make sure bar (6) is centered in clamp (7), then
tighten lower knob (8). Hold knob (9) and lift on the tool assembly until lower bar (6) is against
the top of the main bearing bores. Loosen setscrew (10) and slide parallel plate (11) down until the
plate is firmly against the top deck of the cylinder block. Tighten setscrew (10) .

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 Illustration 8 g02161554

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Illustration 9 g02161555

4. Hold knob (9) and gently move the tool back and forth while turning adjusting collar (12)
clockwise until all slack is removed: tighten collar (12) finger tight only. Adjust micrometer (4)
until the micrometer touches the measuring standard. Read the micrometer. Make a record of this
reading.

5. To find the tool reading, add the micrometer reading to the first number in the column "To
Measure Distance" in table 2. To calculate the actual deck height, add 1/2 the main bearing bore
(shown in column 3 of table 1) to the tool reading. IMPORTANT: If the main bearing bore has
been machined for oversize bearings, do not use the value shown in column 3. Instead measure the
bore and add 1/2 of this value to the actual tool reading (not the value shown in column 2). Both
main bearing bores in contact with the lower bar must be the same size.

EXAMPLE 1: If a 3406 cylinder block (with standard main bearing bores) has a micrometer
reading of 10.52, add this reading to the first number (350) to get a tool reading of 360.52. The
actual distance from the crankshaft centerline to the top of the block can be calculated by adding
1/2 x 129.891 + 360.52 to get a deck height 425.47.

EXAMPLE 2: If a 3406 cylinder block has 0.635 mm (0.0250 inch) over size main bearing bores
and a micrometer reading of 10.16, add this reading to the first number (350) to get a tool reading
of 360.16. To calculate the actual distance from crankshaft centerline to top of block, add 1/2 x
130.526 (bore measurement) + 360.16 to get a deck height of 425.42.

6. After the deck height has been calculated in the previous step, this value should be compared to
the value shown in column, "Crankshaft Centerline to Top of Cylinder Block" in table 1, to find if
 the top deck of the cylinder block has been machined. See the specifications In the Guideline for
reusable Parts for Cylinder Blocks for information on the machining of cylinder blocks.

Table 2

Dimensions For New Cylinder Blocks

Main Bearing Bore
Crankshaft Centerline To
Engine Tool Reading
± 0.013 mm ( 0.0005 Top of Cylinder Block
inch)

4 inch Bore - 4 368.38 ± 0.11 mm

88.890 mm (3.4996 412.83 ± 0.10 mm (16.253
Cylinder (14.503 ± 0.0043
inch) ± 0.004 inch)
inch)

4 1/2 inch Bore - 371.55 ± 0.11 mm

107.953 mm (4.2501 425.53 ± 0.10 mm (16.753
D315 & D318 (14.628 ± 0.0043
inch) ± 0.004 inch)
inch)

4 1/2 inch Bore - 345.24 ± 0.11 mm

96.926 mm (3.8160 393.70 ± 0.10 mm (15.500
D330 & D333 (13.592 ± 0.0043
inch) ± 0.004 inch)
inch)

4 1/2 inch Bore - V8 275.56 ± 0.09 mm

94.171 mm (3.7075 322.66 ± 0.08 mm (12.703
DI (10.849 ± 0.0035
inch) ± 0.003 inch)
inch)

4 1/2 inch Bore - 60 337.34 ± 0.06 mm

124.092 mm (4.8855 399.39 ± 0.05 mm (15.724
degrees V8 PC (13.281 ± 0.0024
inch) ± 0.002 inch)
inch)

4 3/4 inch Bore - 345.24 ± 0.13 mm

96.926 mm (3.8160 393.70 ± 0.11 mm (15.5000
D330C, D333C (13.592 ± 0.005 inch)
inch) ± 0.0043 inch)

4 3/4 inch Bore -

335.05 ± 0.11 mm
Spacer Plate 3304 & 96.926 mm (3.8160 383.51 ± 0.10 mm (15.099
(13.191 ± 0.0043
3306 inch) ± 0.004 inch)
inch)

4 3/4 inch Bore - 326.75 ± 0.08 mm

96.926 mm (3.8160 375.21 ± 0.06 mm (14.772
D334, 1674 (12.864 ± 0.003 inch)
inch) ± 0.0024 inch)
 365.15 ± 0.11 mm
5 1/8 inch Bore 120.640 mm (4.7496 425.48 ± 0.10 mm (16.751
(14.376 ± 0.0043
inch) ± 0.004 inch)
inch)

5.4 inch Bore - 90 442.80 ± 0.06 mm

130.411 mm (5.1343 508.00 ± 0.05 mm (20.000
degrees V8 (17.433 ± 0.0024
inch) ± 0.002 inch)
inch)

5.4 inch Bore - 6 Cyl. 407.85 ± 0.11 mm

124.092 mm (4.8855 469.90 ± 0.10 mm (18.500
(16.057 ± 0.0043
inch) ± 0.004 inch)
inch)

5.4 inch Bore - 6 Cyl. 394.59 ± 0.11 mm

124.092 mm (4.8855 456.64 ± 0.10 mm (17.978
Spacer Plate (15.535 ± 0.0043
inch) ± 0.004 inch)
inch)

5.4 inch Bore - 60

423.19 ± 0.06 mm
degrees V8, V12, V16 143.116 mm (5.6345 494.74 ± 0.05 mm (19.478
(16.661 ± 0.0024
inch) ± 0.002 inch)
inch)

360.50 ± 0.06 mm
3406 129.891 mm (5.1138 425.45 ± 0.05 mm (16.750
(14.193 ± 0.0024
inch) ± 0.002 inch)
inch)

354.15 ± 0.06 mm
3408 & 3412 129.891 mm (5.1138 419.10 ± 0.05 mm (16.500
(13.943 ± 0.0024
inch) ± 0.002 inch)
inch)

555.63 ± 0.10 mm
5 3/4 inch Bore 117.462 mm (4.6245 614.36 ± 0.09 mm (24.1874
(21.875 ± 0.004 inch)
inch) ± 0.0035 inch)

6 1/4 inch Bore - 6 551.00 ± 0.11 mm

126.716 mm (4.9888 614.35 ± 0.10 mm (24.187
Cylinder (21.693 ± 0.0043
inch) ± 0.004 inch)
inch)

6 1/4 inch Bore - V8, 609.70 ± 0.14 mm

161.862 mm (6.3725 690.63 ± 0.13 mm (27.190
V12, V16 (24.001 ± 0.0055
inch) ± 0.005 inch)
inch)

3500 Series
501.14 ± 0.17 mm 169.742 ± 0.020 mm 586.00 ± 0.15 mm (23.071
 (19.730 ± 0.0067 (6.6828 ± 0.0008 ± 0.006 inch)
inch) inch)

Note: If the main bearing bore has been machined for oversize bearings, subtract 1/2 of the bore from
the "Crankshaft Centerline to top of Cylinder Block" dimension to get the tool reading. Both main
bearing bores in contact with the lower bar must be the same size.

Table 3

To Measure Distances Use Measuring Standard Marked

25
200 to 225 mm (7.874 to 8.858 inch)

50
225 to 250 mm (8.858 to 9.843 inch)

75
250 to 275 mm (9.843 to 10.827 inch)

100
275 to 300 mm (10.827 to 11.811 inch)

125
300 to 325 mm (11.811 to 12.795 inch)

150
325 to 350 mm (12.795 to 13.780 inch)

25 Plus (1) 150 extension

350 to 375 mm (13.780 to 14.764 inch)

50 Plus (1) 150 extension

375 to 400 mm (14.764 to 15.748 inch)

75 Plus (1) 150 extension

400 to 425 mm (15.748 to 16.732 inch)

100 Plus (1) 150 extension

425 to 450 mm (16.732 to 17.717 inch)

125 Plus (1) 150 extension

450 to 475 mm (17.717 to 18.701 inch)

150 Plus (1) 150 extension

475 to 500 mm (18.701 to 19.685 inch)

25 Plus (2) 150 extension

500 to 525 mm (19.685 to 20.669 inch)

50 Plus (2) 150 extension

525 to 550 mm (20.669 to 21.654 inch)
 75 Plus (2) 150 extension
550 to 575 mm (21.654 to 22.638 inch)

100 Plus (2) 150 extension

575 to 600 mm (22.638 to 23.622 inch)

125 Plus (2) 150 extension

600 to 625 mm (23.622 to 24.606 inch)

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 08:01:39 EST 2012
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Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
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Oil Pan Base

SMCS - 1302-11 ; 1302-12

Remove Oil Pan Base

1. Remove the coolant from engine.

2. Remove the oil from oil pan base. Capacity of D379 is 92 U.S. gal. (348 liter); D398 is 110 U.S. gal.
(416 liter); D399 is 165 U.S. gal. (625 liter).

3. Disconnect inlet water lines that are connected to engine. Disconnect fuel lines for fuel supply to
engine.

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4. Remove oil pressure regulating valve (1).

5. Remove the four bolts that hold plate (3) for oil pump to the base.

6. Remove bolts (2) that hold cylinder block to the base.

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7. Fasten a hoist to the engine. Lift the engine from base. Weight of D379 is 8,000 lb. (3600 kg); D398
is 10,000 lb. (4500 kg); D399 is 13,000 lb. (5850 kg).

8. Move the oil pan base. Weight of base on D379 is 2,100 lb. (945 kg); D398 is 3,000 lb. (1350 kg);
D399 is 3,800 lb. (1750 kg).

Install Oil Pan Base

1. Install a new gasket on the oil pan base.

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2. Fasten a hoist to engine. Put the engine in position on oil pan base. Put 9S3263 Thread Lock on the
threads of bolts for base. Install the bolts that hold engine on oil pan base.

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3. Install the four bolts that hold plate for oil pump to the base.

4. Connect inlet water lines to the engine.

5. Connect fuel supply and return lines to engine.

6. Install oil pressure regulating valve on engine.

7. Fill the engine with oil and coolant to correct levels.

Copyright 1993 - 2012 Caterpillar Inc.

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Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
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Precombustion Chambers
SMCS - 1106-11 ; 1106-12

Remove Precombustion Chambers

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start by:

a) remove fuel injection valves

1. Remove coolant from engine.

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2. Remove precombustion chamber (1) with wrench (A).

3. Remove the gaskets from precombustion chambers.

Install Precombustion Chambers

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Ver imagen

1. Put 5P3931 Anti-Seize Compound on threads of the precombustion chamber (2).

2. Put a small amount of grease on gasket (3) to hold gasket on chamber.

3. Put liquid soap on the seal (1) and bore in the cylinder head.

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4. Tighten precombustion chamber with wrench (A) to a torque of 225 ± 15 lb. ft. (300 ± 20 N·m).

5. Fill the engine with coolant to correct level.

end by:

a) install fuel injection valves

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Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
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Cylinder Heads
SMCS - 1100-11 ; 1100-12

Remove Cylinder Heads

start by:

a) remove rocker shafts and push rods

b) remove intake manifolds

1. Remove the instrument panel from cylinder head to be removed (if so equipped).

2. Remove the coolant from engine.

3. Remove the eight bolts for each cylinder head from the exhaust manifold on the marine engines.

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4. Remove the bolts that hold the plate (2) on bottom of exhaust shield. Let the plate lay in the "V" of
engine.

5. Remove the plugs (1) from the shield.

6. Remove the eight bolts that hold the exhaust manifold to each cylinder head.

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7. Remove the fuel lines (5) for the head to be removed. Put covers on fuel valves, lines, and pumps.
Remove two elbows (4) for each cylinder head. Remove the governor control channel for cylinder heads
on left hand side only.

8. Remove the oil line (3) for the rocker shaft.

9. Remove the nuts (6) from the cylinder head.

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10. Install two 1/2"-13 NC forged eyebolts in head.

11. Fasten a hoist to the eyebolts and slowly remove the cylinder head. Weight is 190 lb. (86 kg).

Install Cylinder Heads

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Ver imagen

1. Clean the block and cylinder head. Install new head gaskets, new water seals, and ferrules.

2. Install two 1/2"-13 NC forged eyebolts in head. Fasten a hoist and slowly lower the head over the
studs until it is in correct position over head gaskets and seals. Weight is 190 lb. (86 kg).

3. Put 5P3931 Anti-Seize Compound on threads of head studs, and on the bolts for exhaust manifold.
Install nuts and washers on studs. Tighten nuts in following step sequence:

1 Tighten nuts by number to a torque of 150 ± 10 lb. ft. (205 ± 14 N·m).

2 Tighten nuts by number to a torque of 250 ± 10 lb. ft. (340 ± 14 N·m).

3 Tighten nuts again by number (hand torque only) to a torque of 250 ± 10 lb. ft. (340 ± 14 N·m).

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4. Install new gaskets for the exhaust manifold. Install the bolts (1) that hold exhaust manifold to head.
Tighten bolts (1) to a torque of 110 ± 10 lb. ft. (149 ± 14 N·m) on Marine Engines. Tighten bolts (1) on
Industrial Engines to 75 ± 10 lb. ft. (100 ± 14 N·m).

5. Install the plate and plugs on the shield for the manifold bolts (if so equipped).

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6. Install the oil line (2) for the rocker shaft.

7. Install the two elbows (3). Install the fuel lines. Tighten nuts (4) on fuel lines to a torque of 25 to 35
lb. ft. (35 to 45 N·m). Install governor control channel (on left hand side only).

8. Install the instrument panel on cylinder head removed (if so equipped).

9. Fill the engine with coolant to correct level.

end by:

a) install intake manifolds

b) install rocker shafts and push rods

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 17:46:13 EST 2012
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Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Valves
SMCS - 1105-11 ; 1105-12

Remove Valves
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start by:

a) remove cylinder head

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1. Install cylinder head (1) on tooling (A) as shown.

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2. Put identification on the valves and head for correct assembly. Use tooling (B) as shown to put valve
spring (4) under compression. Remove three locks (3). Slowly release compression from the valve
spring and remove tooling (B). Remove retainer (2), two springs (4), rotator, spacer and valve from the
head.

3. Do Steps 1 and 2 again for the remainder of valves.

Install Valves
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1. Check spring force with tool (B). For the correct spring force, see the subject VALVES in
SPECIFICATIONS.

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2. Inspect and make a replacement, if necessary, of the O-ring seals in the inlet valve retainers. Put the
valves, spacer, rotator, springs and retainer in position on the head. Put the springs under compression
with tool (C). Install three locks (1). The thick end of the lock goes toward the cylinder head.
 Locks can be thrown from the valve when tool (C) is released if they are
not in their correct position on the valve stem.

3. Remove tool (C) slowly. Hit the valve lightly with a soft hammer to be sure the locks are in their
correct position.

4. Do Steps 1 through 3 again for the remainder of the valves.

end by:

a) install cylinder head

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 17:51:03 EST 2012
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D379, D398, D399 INDUSTRIAL & MARINE ENGINES
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Valve Guides
SMCS - 1104-10

Remove And Install Valve Guides

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start by:

a) remove valves

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1. Remove old valve guides (1) with tool (A) as shown. If the valve guides have grooves, use tool (C).

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2. Install the valve guides with tools (A & B) as shown. If the valve guides have grooves, use tools (C &
D).

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3. Dimension (X) for the installed valve guide must be 1.750 ± .020 in. (44.45 ± 0.51 mm).
end by:

a) install valve

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 17:51:32 EST 2012
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Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
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Valve Seat Inserts

SMCS - 1103-10

Remove And Install Valve Seat Inserts

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start by:

a) remove valves

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1. Remove valve seat inserts (1) with tool group (A).

2. Clean and remove burrs from the valve seat bore.

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3. Install the new valve seat insert with tool group (A). Do not increase diameter of extractor in valve
seat insert when insert is installed in cylinder head.

4. Grind valve seat inserts (1) according to specifications given in SPECIFICATIONS SECTION.

end by:

a) install valves

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 17:51:57 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Desarmado y Armado
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Water Directors
SMCS - 1115-10

Remove And Install Water Directors

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start by:

a) remove cylinder head

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1. Remove water director (1) from cylinder head.

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2. Install new water director with tooling (A).

 NOTICE
Hole (2) in water director must be in alignment with "V" mark on
cylinder head.

end by:

a) install cylinder head

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 17:52:38 EST 2012
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Red privada para licenciados del SIS.
Pruebas y Ajustes
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

D379, D398I on Engine Attachments Testing And Adjusting

Troubleshooting
Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make a
repair to a problem, make reference to the cause and correction.

This list of problems, causes, and corrections, will only give an indication of where a possible problem
can be, and what repairs are needed. Normally, more or other repair work is needed beyond the
recommendations in the list. Remember that a problem is not normally caused only by one part, but by
the relation of one part with other parts. This list can not give all possible problems and corrections. The
serviceman must find the problem and its source, then make the necessary repairs.

1. Contactor Switch For Water Temperature Does Not Activate Shutoff Solenoid.
2. Contactor Switch for Water Temperature Activates Shutoff Solenoid at Wrong Temperature.
3. Contactor Switch for Oil Pressure Fails to Activate Shutoff Solenoid.
4. Contactor Switch for Overspeed Fails to Activate Shutoff Solenoid.
5. Contactor Switch for Overspeed Activates Shutoff Solenoid at Wrong Speed.
6. Shutoff Solenoid Fails to Stop Engine.
7. Shutoff Solenoid Prevents Engine Start.
8. Clutch Will Not Engage (Slips), Heats or Lever Moves to Released Position.
9. Clutch Shaft Has Too Much End Play.
10. Clutch Bearings Have Short Service Life.
11. Hydra-mechanical Shutoff Will Not Let Engine Start.
12. Hydra-mechanical Shutoff Will Not Let Engine Run Above 70% of Rated Engine Speed.
13. Hydra-mechanical Shutoff Activates With Engine Oil Pressure and Water Temperature
Normal.
14. Electrical Gauges Give Wrong Readings.
15. 2301 Nonparallel Control System.
a. Engine Will Not Start.
b. Engine Overspeeds On Starts.
c. Engine Overspeeds After Operation At Rated Speed For Some Time.
d. Low Idle Speed Potentiometer Gives No Adjustment.
e. Engine Does Not Return To Low Idle When The Idle (Oil Pressure) Switch Opens.
f. Engine Speed Does Not Have Stability.
g. Speed Trim Potentiometer Gives No Adjustment.
h. Rated Speed Potentiometer Gives No Adjustment.
i. Load Sharing Is Not Correct.
j. Engine Speed Is Not Isochronous.
16. 2301 Parallel Control System.
a. Engine Will Not Start.
b. Engine Overspeeds On Starts.
c. Engine Overspeeds After Operation At Rated Speed For Some Time.
d. Low Idle Speed Potentiometer Gives No Adjustment.
 e. Engine Does Not Return To Low Idle When The Idle (Oil Pressure) Switch Opens.
f. Engine Speed Does Not Have Stability.
g. Speed Trim Potentiometer Gives No Adjustment.
h. Rated Speed Potentiometer Gives No Adjustment.
i. Load Sharing Is Not Correct.
j. Engine Speed Is Not Isochronous.
k. System Does Not Have Stability When Paralleling Or In Parallel.
17. Woodward UG-8 Governors
a. Engine Speed Does Not Have Stability.
b. Fuel Control Response When the Engine Is Started Is Not Acceptable.
c. Engine Is Slow To Respond To A Change In Speed Setting or Load.
d. Load Sharing Between Paralleled Units Is Not Correct (One unit on zero droop all others
on droop).
e. Load Sharing Between Paralleled Units Is Not Correct (all units on droop).
18. Automatic Start/Stop Systems.

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Measuring Engine Speed
Measuring Engine Speed
5P2150 Engine Horsepower Meter or4S6553 Instrument Group or1P5500 Portable Phototach Group

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5P2150 ENGINE HORSEPOWER METER

The 5P2150 Engine Horsepower Meter can measure engine speed from the tachometer drive on the
engine. Special Instruction Form No. SMHS7050 has instructions for its use.

Special Instruction Form No. SEHS7341 is with the 4S6553 Engine Test Group and gives instructions
for the test procedure.

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4S6553 INSTRUMENT GROUP

1. Differential pressure gauges. 2. Zero adjustment screw. 3. Lid. 4. Pressure gauge. 5. Pressure tap fitting. 6. Tachometer. 7.
Manifold pressure gauge.

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1P5500 PORTABLE PHOTOTACH GROUP

The 1P5500 Portable Phototach Group can measure engine speed from the tachometer drive on the
engine. It also has the ability to measure engine speed from visual engine parts in rotation. Special
Instruction Form No. SMHS7015 has instructions for its use.

Pierce Output Shaft Governor

Four adjustments must be made: 1. linkage adjustment, 2. low speed setting, 3. high speed setting, 4.
regulation, and surge. For any given output shaft governor setting, the regulation is the range or spread
between the torque converter output shaft speed at no load and the output shaft speed at full load, with
the diesel engine governor control, in the full open position. If the regulation is too close, surging will
result.

The torque converter output shaft maximum speed is either a high speed setting or a low speed setting,
which is determined by changing the position of the speed change lever (4), normally by remote control.
The high speed screw (9) determines the maximum speed for the high speed setting, and the low speed
screw (8) determines the maximum low speed setting. Consult the operator's manual for the equipment
in which the engine is installed to be sure of the maximum permissible output shaft speed for the driven
equipment.

NOTE: Perform the first nine Steps with the engine stopped.

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OUTPUT SHAFT GOVERNOR ADJUSTMENT

1. Terminal lever. 2. Rate adjusting screw. 3. Adjustable linkage. 4. Speed change lever. 5. Governor spring. 6. Bumper
screw. 7. Lever. 8. Low speed adjusting screw. 9. High speed adjusting screw. 10. Bracket.

1. Disconnect the adjustable linkage (3) from the terminal lever (1) and the other adjustable linkage (12)
between the servo mechanism (14) and standard governor.

2. Position the speed change lever (4), with low and high speed adjusting screws (8 and 9) so the rate
adjusting screw (2) and the governor spring (5) are approximately parallel to lever (7).

3. Turn the rate adjusting screw until a slight tension is maintained on the governor spring. This will
position the governor weights in the closed position.

4. Adjust linkage (3) between terminal lever (1) and servo boost mechanism so that it moves .08 in. (2.0
mm) before lever (13) starts to move. Install linkage (3).

5. Retract the speed limiter and move the governor control to full speed position.

6. Rotate shutoff lever (11) until shutoff lever contacts the rack stop collar. This can be determined by
use of continuity tester connected to the insulated terminal of the standard governor.

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GOVERNOR LINKAGE ADJUSTMENT

1. Terminal lever. 3. Linkage. 11. Shutoff lever. 12. Linkage. 13. Servo lever. 14. Servo mechanism.

7. Adjust the linkage (12) to fit lever holes when shutoff lever contacts rack stop collar, then increase
linkage length .06 in. (1.5 mm) and install the linkage.

8. Back out bumper screw (6) until approximately 3/4 inch of the screw is protruding from the governor
housing.

9. Fill the output shaft governor to the proper level with SAE 30 lubricating oil. The proper level can be
checked by removing the small oil plug located in the drive cable end of the governor housing.

10. Start the diesel engine. After a reasonable warm-up period move the diesel engine governor control
lever to the full open position.

11. Adjust the output shaft speed to the maximum desired speed with the aid of the low speed adjusting
screw (8). Turn the screw clockwise to raise the speed and counterclockwise to lower the speed.

12. If a surging condition is encountered, back off the nut on the rate adjusting screw one full turn. Turn
the low speed adjusting screw clockwise to return the output shaft speed to the desired RPM. Continue
this procedure until all surge is removed. If it is not possible to remove all surge, set the governor at the
setting which will produce the least amount of surge and remove the remaining surge by turning the
bumper screw clockwise until it just makes contact with the rocker yoke.

NOTICE
Turning the bumper screw in beyond this point will raise the output
shaft speed and eventually damage the internal parts of the governor.
The bumper screw should not be used to remove speed surges of
greater than 50 RPM.

Turning the low speed adjusting screw clockwise will increase the leverage of the governor spring (5) on
the lever (7) and increase speed, with the result that minimum tension on the spring is now required.
This adjustment will provide the most sensitive regulation. When the load is removed suddenly, the
engine should not surge in excess of four (4) cycles. When the load is gradually removed, no surge
should be evident.

13. With the output shaft running at the desired speed setting, turn the high speed adjusting screw (9)
until the end of the screw contacts the stop bracket (10). Lock the high speed screw in this position.

Woodward SGT Governor

Engine Governor Low And High Idle Adjustment
Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE
SPEED.

1. Start the engine and run to get the engine to the normal temperature of operation.

2. Move governor control lever (2) against low idle stop (1) and check low idle speed.

NOTE: Make reference to the RACK SETTING INFORMATION for the correct low and high idle
speed.

3. If the low idle speed is not correct, loosen locknut and turn low idle stop (1) as needed. Tighten the
locknut.

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LOW IDLE ADJUSTMENT
1. Low idle stop. 2. Governor control lever.

4. Move the governor control lever to run the engine at high idle speed, and check the high idle rpm.

5. If the high idle speed is not correct, remove lockwire (3) and loosen the locknut on high idle screw
(4). Turn the high idle screw as needed to get the correct high idle speed. Tighten the locknut.

6. Move the governor control lever to change the engine speed and then return to high idle speed and
check the high idle speed again.

7. When the high idle speed is correct, install the lockwire and seal.

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HIGH IDLE ADJUSTMENT

3. Lockwire. 4. High idle screw.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.

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RACK POSITIONING TOOLS
1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.

2. Fasten bracket (1) to the fuel pump housing.

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TIMING PIN AND CLAMP

4. Timing pin. 5. Clamp.

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BRACKET INSTALLED
1. Bracket.

3. Disconnect the linkage from the governor terminal shaft and move the fuel rack to the FUEL-OFF
position. Install dial indicator (2) with contact point (3) on bracket (1).

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange towards the fuel pump
housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero.
Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the
hand. Remove the spacer.

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DIAL INDICATOR INSTALLED

1. Bracket. 2. Dial indicator. 6. Spacer.

5. Move the fuel rack to the FUEL-ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in
the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut
and move lock free of pin.

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COVER FOR RACK ADJUSTING SCREW

7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease
rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the
pin. Tighten the locknut and install the cover and lockwire and seal.

Engine Governor Speed Droop

1. Cut lockwire and remove the top cover of the governor.
2. Remove flexible coupling.

3. Move the droop lever of the engine governor to the center position.

4. Start the engine.

5. Move the governor linkage to cause a temporary engine speed increase. If the engine speed goes back
to the original speed with only two or three oscillations, the adjustment is satisfactory. If not, move the
droop lever in the direction of the rear of the engine to cause an increase in droop or move the droop
lever in the direction of the front of the engine to cause a decrease in droop.

6. Install flexible coupling and the top cover of the governor.

7. Install lockwire and seal.

Torque Converter Governor High Idle Speed Adjustment

NOTE: High idle, full load speed and no load speed for the torque converter can be found on the
information plate in the engine compartment of the machine.

1. Start the engine and engage the clutch.

2. Move the governor control lever to the high idle position.

3. Make adjustments to the high idle screw (1) of the converter governor to keep engine speed to
specifications.

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HIGH IDLE ADJUSTMENT

1. High idle screw for torque converter governor

Torque Converter Governor Speed Droop Adjustment

9S240 Rack Positioning Tool Group
1. Install the 9S240 Tool Group.

NOTE: Make reference to FUEL RACK ADJUSTMENT for WOODWARD SGT GOVERNORS for
installation instructions of the 9S240 Tool Group.

2. Cut the lockwire and remove the top cover of the governor.

3. Put a load on the engine according to the specifications for full load speed of the torque converter.
Engine speed at full rack position must be within 10 rpm of the specifications.

4. If the rack is open at a speed higher than full load speed, move the droop lever in the direction of the
rear of the engine to cause an increase in droop.

5. If the rack is not open at full load speed, move the droop lever in the direction of the front of the
engine to cause a decrease in droop.

6. Install lockwire and seal.

Govenror Linkage Adjustment

1P2385 Protractor Tool

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.

II. Horizontal or level to lever angle.
III. Lever to lever angle.

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1P2385 PROTRACTOR TOOL USAGE

A. Angle setting indicator. B. Protractor plate edge aligned with lever. C. Vertical housing face and extension arm alignment.
D. Level bubble. E. Angle setting indicator. F. Extension arm aligned with lever. G. Extension arm aligned with lever. H.
Plate edge aligned with second lever. I. Angle setting indicator.

1. Move lever (1) and lever (3) clockwise to the angles shown.

2. Adjust the length of linkage (2) to fasten to the outside holes of levers (1) and (3).

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GOVERNOR LINKAGE
1. Governor lever. 2. Linkage. 3. Lever.

Woodward UG8 Dial Governor

Compensating Adjustment
Although the governor may appear to be operating satisfactorily at no load, high overspeeds and
underspeeds after load changes and slow return to normal speed are the results of incorrect
compensation adjustments.

Make compensating adjustments after the temperature of the engine and the oil in the governor have
reached normal operating values and with the engine running at no load conditions.

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UG8 DIAL GOVERNOR
1. Nut. 2. Compensation pointer. 3. Plug.

1. Loosen the nut that holds the compensation pointer and move the pointer up as far as it will go.
Tighten the nut.

2. Remove the plug from the base of the governor.

3. Use a wide blade screwdriver and engage the wide screwdriver slot in the needle valve. Turn the
needle valve three or more turns in a counterclockwise direction.

4. Let the engine surge for approximately 30 seconds to help remove air from the governor.

5. Loosen the nut that holds the compensation pointer and move the pointer down as far as it will go.
Tighten the nut.

6. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

7. Check the number of turns the needle valve is open. To find the number of turns the needle valve is
open, close the valve completely and make a note of the number of turns needed to close the valve.

8. Open the needle valve to the same position at which the engine did not surge.

9. Move the governor linkage to change the engine speed. If the engine does not surge, and the needle
valve is 1/2 to 3/4 of a turn open, the governor adjustment is correct. Install the plug in the base. If the
needle valve is more than 3/4 of a turn open, do the steps that follow.

10. Loosen the nut that holds the compensation pointer and move the pointer up two marks on the
pointer scale.

11. Turn the needle valve three or more turns in a counterclockwise direction.

12. Let the engine surge for approximately 30 seconds to help remove air from the governor.

13. Slowly turn the needle valve in a clockwise direction until the engine does not surge.
14. Check the number of turns the needle valve is open. To find the number of turns the needle valve is
open, close the valve completely and make a note of the number of turns needed to close the valve.

15. Open the needle valve to the same position at which the engine did not surge.

16. Move the governor linkage to change the engine speed.

If the engine does not surge, and the needle valve is 1/2 to 3/4 of a turn open, the governor adjustment is
correct. Install the plug in the base. If the needle valve is more than 3/4 of a turn open do Steps 10 thru
16 again.

A needle valve that is opened less than 1/2 turn will cause the engine to be slow to return to normal
speed after a load change.

If the compensation pointer is too far toward the maximum position, the engine speed change will be too
great when the load changes.

High Idle Speed Adjustment

Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE
SPEED.

1. Start the engine and run to get the engine to the normal temperature of operation.

2. Use synchronizer control knob (5) to adjust the engine speed and check the high idle speed stop
adjustment.

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GOVERNOR ADJUSTMENTS (Typical Example)

1. Terminal lever. 2. Idler gear. 3. Load limit control. 4. Linkage. 5. Synchronizer control knob. 6. Gear. 7. Synchronizer
indicator knob.

3. If the high idle speed is not correct, remove the dial plate.
NOTE: Make reference to the RACK SETTING INFORMATION for the correct high idle speed.

4. Loosen the setscrew on synchronizer indicator knob (7), remove tapered pin if equipped and remove
the knob.

5. Pull gear (6) out of mesh with idler gear (2). Turn synchronizer control knob (5) until the correct high
idle speed is reached.

6. To set the high idle speed stop, turn gear (6) clockwise until the stop pin on the gear makes contact
with idler gear (2). Push gear (6) into mesh with idler gear (2).

7. Turn the synchronizer control knob counterclockwise to change the engine speed. Now turn the knob
to the high idle stop and check the high idle adjustment.

8. Install the synchronizer indicator knob and the dial plate.

NOTE: Low idle speed is not adjustable, but will change as high idle adjustment is made. If low idle is
not correct, an increase in high idle speed will increase low idle speed, and a decrease in high idle speed
will decrease low idle speed.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.

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RACK POSITIONING TOOLS

1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.

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TIMING PIN AND CLAMP
4. Timing pin. 5. Clamp.

2. Fasten bracket (1) to the fuel pump housing.

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BRACKET INSTALLED
1. Bracket.

3. Turn the governor load limit knob to ten and install dial indicator (2) with contact point (3) on bracket
(1).

NOTICE
Do not force the governor linkage toward increased fuel unless the load
limit knob is turned to TEN. The result will be damage to the governor.

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DIAL INDICATOR INSTALLED
1. Bracket. 2. Dial indicator. 6. Spacer.

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange toward the fuel pump
housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero.
Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the
hand. Remove the spacer.

5. Use the lever on the governor terminal shaft to move the fuel rack to the FUEL ON position until
contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in
the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut
and move lock free of pin.

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COVER FOR RACK ADJUSTING SCREW

7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease
rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the
pin. Tighten the locknut and install the cover and lockwire and seal.

Governor Linkage Adjustment

1P2385 Protractor Tool.

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.

II. Horizontal or level or lever angle.
III. Lever to lever angle.

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1P2385 PROTRACTOR TOOL USAGE
A. Angle setting indicator. B. Protractor plate edge aligned with lever. C. Vertical housing face and extension arm alignment.
D. Level bubble. E. Angle setting indicator. F. Extension arm aligned with lever. G. Extension arm aligned with lever. H.
Plate edge aligned with second lever. I. Angle setting indicator.

1. Turn governor terminal shaft to the FUEL-OFF position and install lever (1) on the shaft at the angle
shown.

2. Install lever (3) with the rack in the FUEL-OFF position at the angle shown.

3. With both levers at the FUEL-OFF position, adjust linkage (2) and install on the levers.

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GOVERNOR LINKAGE ADJUSTMENT
1. Governor lever. 2. Linkage. 3. Lever.

Woodward UG8 Lever Governor

Compensating Adjustment
Although the governor may appear to be operating satisfactorily at no load, high overspeeds and
underspeeds after load changes and slow return to normal speed are the results of incorrect
compensation adjustments.

Make compensating adjustments after the temperature of the engine and the oil in the governor have
reached normal operating values and with the engine running at no load conditions.

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UG8 LEVER GOVERNOR
1. Nut. 2. Compensation pointer. 3. Plug.

1. Loosen the nut that holds the compensation pointer and move the pointer up as far as it will go.
Tighten the nut.

2. Remove the plug from the base of the governor.

3. Use a wide blade screwdriver and engage the wide screwdriver slot in the needle valve. Turn the
needle valve three or more turns in a counterclockwise direction.

4. Let the engine surge for approximately 30 seconds to help remove air from the governor.

5. Loosen the nut that holds the compensation pointer and move the pointer down as far as it will go.
Tighten the nut.

6. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

7. Check the number of turns the needle valve is open. To find the number of turns the needle valve is
open, close the valve completely and make a note of the number of turns needed to close the valve.

8. Open the needle valve to the same position at which the engine did not surge.

9. Move the governor linkage to change the engine speed. If the engine does not surge, and the needle
valve is 1/2 to 3/4 of a turn open, the governor adjustment is correct. Install the plug in the base. If the
needle valve is more than 3/4 of a turn open, do the steps that follow.

10. Loosen the nut that holds the compensation pointer and move the pointer up two marks on the
pointer scale.

11. Turn the needle valve three or more turns in a counterclockwise direction.

12. Let the engine surge for approximately 30 seconds to help remove air from the governor.

13. Slowly turn the needle valve in a clockwise direction until the engine does not surge.

14. Check the number of turns the needle valve is open. To find the number of turns the needle valve is
open, close the valve completely and make a note of the number of turns needed to close the valve.

15. Open the needle valve to the same position at which the engine did not surge.

16. Move the governor linkage to change the engine speed.

If the engine does not surge, and the needle valve is 1/2 to 3/4 of a turn open, the governor adjustment is
correct. Install the plug in the base. If the needle valve is more than 3/4 of a turn open do Steps 10 thru
16 again.

A needle valve that is opened less than 1/2 turn will cause the engine to be slow to return to normal
speed after a load change.
If the compensation pointer is too far toward the maximum position, the engine speed change will be too
great when the load changes.

Low And High Idle Speed Adjustment

Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE
SPEED.

1. Start the engine and run to get the engine to the normal temperature of operation.

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LOW AND HIGH IDLE ADJUSTMENT

1. Low idle adjustment screw. 2. Locknut. 3. High idle adjustment screw. 4. Locknut. 5. Governor speed adjusting lever.

2. Move the governor speed adjusting lever (5) to run the engine at high idle speed. Loosen locknut (4)
and turn high idle adjustment screw (3). Turn adjustment screw (3) clockwise to decrease engine speed
and counterclockwise to increase engine speed.

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LOW AND HIGH IDLE STOP LEVERS

6. Low idle stop lever. 7. High idle stop lever.

3. After the high idle speed has been adjusted, tighten the locknut and check high idle speed again.
NOTE: Make reference to the RACK SETTING INFORMATION for the correct low and high idle
speed.

4. Move the governor speed adjusting lever (5) to run the engine at low idle speed. Loosen locknut (2)
and turn low idle adjustment screw (1). Turn adjustment screw (1) clockwise to increase low idle speed
and counterclockwise to decrease low idle speed.

NOTE: If the high idle stop lever (7) or the low idle stop lever (6) are removed, mark the levers and the
shaft so that the levers can be installed in the correct location.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.

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RACK POSITIONING TOOLS

1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.

1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.

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TIMING PIN AND CLAMP

4. Timing pin. 5. Clamp.

2. Fasten bracket (1) to the fuel pump housing.

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BRACKET INSTALLED
1. Bracket.

3. Disconnect the linkage from the governor terminal shaft and move the fuel rack to the FUEL-OFF
position. Install dial indicator (2) with contact point (3) on bracket (1).

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange towards the fuel pump
housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero.
Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the
hand. Remove the spacer.

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DIAL INDICATOR INSTALLED

1. Bracket. 2. Dial indicator. 6. Spacer.

5. Move the fuel rack to the FUEL-ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in
the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut
and move lock free of pin.

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COVER FOR RACK ADJUSTING SCREW
7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease
rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the
pin. Tighten the locknut and install the cover and lockwire and seal.

Speed Droop Adjustment

Adjustment for Zero Droop

8S2328 Dial Indicator Group.5P7264 Indicator Contact Point Group.

1. Disconnect linkage from governor terminal lever (4).

2. Remove cover from the top of governor.

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DIAL INDICATOR INSTALLED

1. Speeder plug. 2. Bracket. 3. Droop cam. 4. Governor terminal lever. 5. Screw.

3. Install 3S3269 Contact Point 1.00 in. (25.4 mm) long on the dial indicator and install as shown with
the contact point on bracket (2) of speeder plug (1). Adjust the dial of the indicator to zero.

4. Move the governor terminal lever from the maximum position to the minimum position. The dial
indicator must read .000 to .002 in. (0.00 to 0.05 mm) for zero droop.

5. If the droop adjustment is not correct, loosen screw (5) and move droop cam (3). Tighten screw (5).
Move droop cam (3) toward speeder plug (1) to increase droop, and away from the speeder plug to
decrease droop.

6. Check the speed droop adjustment again with the dial indicator.

Adjustment for Positive Droop

1. Remove the cover from the top of the governor.

2. Connect a tachometer with good accuracy to the engine. Make reference to MEASURING ENGINE
SPEED.

3. Loosen screw (5) and move droop cam (3) on droop lever (6) to get distance (A) for the droop
percentage needed. See the chart for Speed Droop to get the dimension needed.

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SPEED DROOP ASSEMBLY

3. Droop cam. 5. Screw. 6. Droop lever. A. Speed droop setting.

NOTE: Dimension (A) is an approximate dimension. The final adjustments must be determined with
the engine running.
4. Start the engine and get to the normal temperature of operation.

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5. Put a load on the engine to get maximum full load. Make a note of the full load rpm.

6. Remove all load from the engine and make a note of the no load high idle rpm.

7. Find the difference of the no load high idle rpm and the full load rpm. Divide the difference by the
full load rpm and multiply times 100. The result is the percent of speed droop.

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8. If the speed droop is not correct, stop the engine and move droop cam (3) toward speeder plug (1) to
increase speed droop, or move away from the speeder plug to decrease speed droop.

9. Do Steps 4 thru 8 to check the speed droop and adjust again if needed.

Governor Linkage Adjustment

1P2385 Protractor Tool

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.

II. Horizontal or level to lever angle.
III. Lever to lever angle.

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1P2385 PROTRACTOR TOOL USAGE
A. Angle setting indicator. B. Protractor plate edge aligned with lever. C. Vertical housing face and extension arm alignment.
D. Level bubble. E. Extension arm aligned with lever. G. Extension arm aligned with lever. H. Plate edge aligned with
second lever. I. Angle setting indicator.

1. Turn governor terminal shaft to the FUEL-OFF position and install lever (1) on the shaft at the angle
shown.

2. Install lever (3) with the rack in the FUEL-OFF position at the angle shown.

3. With both levers at the FUEL-OFF position, adjust linkage (2) and install on the levers.

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GOVERNOR LINKAGE ADJUSTMENT (TYPICAL ILLUSTRATION)
1. Governor lever. 2. Linkage. 3. Lever.

Woodward EG-3P Actuator

There are no inside adjustments on the EG-3P Actuator. The low and high idle adjustments are made on
the control panel.

Fuel Rack Adjustment

9S240 Rack Positioning Tool Group.

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RACK POSITIONING TOOLS

1. 9S227 Bracket Group. 2. 8S2283 Dial Indicator. 3. 8S3675 Contact Point .125 in. (3.18 mm) long.
1. Remove timing pin (4), clamp (5), and the plug and seal behind the clamp.

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TIMING PIN AND CLAMP

4. Timing pin. 5. Clamp.

2. Fasten bracket (1) to the fuel pump housing.

3. Disconnect the linkage from the actuator terminal shaft and move the fuel rack to the FUEL-OFF
position. Install dial indicator (2) with contact point (3) on bracket (1).

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BRACKET INSTALLED
1. Bracket.

4. Put spacer (6) between the flange on the rod and the bracket. Push the flange towards the fuel pump
housing to hold the spacer tight. Adjust the dial indicator so that the revolution counter is at zero.
Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the
hand. Remove the spacer.

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DIAL INDICATOR INSTALLED
1. Bracket. 2. Dial indicator. 6. Spacer.

5. Move the fuel rack to the FUEL-ON position until contact is made with the adjustment stop screw.

6. Read the rack travel measurement on the dial indicator and compare with the measurement given in
the RACK SETTING INFORMATION.

7. To adjust the rack travel, cut lockwire (7) and remove cover (8). Loosen the adjustment screw locknut
and move lock free of pin.

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COVER FOR RACK ADJUSTING SCREW

7. Lockwire. 8. Cover.

8. Turn the adjustment screw counterclockwise to increase the fuel rack travel or clockwise to decrease
rack travel. When the fuel rack is adjusted correctly, move the lock to engage the nearest notch with the
pin. Tighten the locknut and install the cover and lockwire and seal.

Actuator Linkage Adjustment

1P2385 Protractor Tool.

The three basic ways to use the 1P2385 Protractor Tool are shown:

I. Vertical housing face to lever angle.

II. Horizontal or level to lever angle.
III. Lever to lever angle.
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1P2385 PROTRACTOR TOOL USAGE

A. Angle setting indicator. B. Protractor plate edge aligned with lever. C. Vertical housing face and extension arm alignment.
D. Level bubble. E. Extension arm aligned with lever. G. Extension arm aligned with lever. H. Plate edge aligned with
second lever. I. Angle setting indicator.

1. Turn actuator terminal shaft to the FUEL-OFF position and install lever (1) on the shaft at the angle
shown.

2. Install lever (3) with the rack in the FUEL-OFF position at the angle shown.

3. With both levers at the FUEL-OFF position, adjust linkage (2) and install on the levers.

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ACTUATOR LINKAGE ADJUSTMENT
1. Actuator lever. 2. Linkage. 3. Lever.

2301 Control Systems

NOTE: For information on earlier 2301 control systems make reference to INDUSTRIAL DIVISION
ENGINE DATA SHEET Form No. LE021991-01.

Magnetic Pickup
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MAGNETIC PICKUP
1. Clearance dimension. 2. Magnetic pickup. 3. Wires. 4. Locknut. 5. Flywheel gear. 6. Adapter.

1. Crank the engine. Use a voltmeter to check the output of the magnetic pickup. Minimum cranking
voltage is 1.0V. Minimum voltage at 1500 rpm is 10V. If these voltages are not correct make an
adjustment as follows:

2. Loosen locknut (4).

3. Turn magnetic pickup (2) in until it just has contact with flywheel (5).

4. Turn the magnetic pickup out 1/2 revolution. This will make clearance dimension (1) .022 to .030 in.
(0.56 to 0.76 mm).

5. Tighten the locknut to 50 ± 10 lb. ft. (70 ± 14 N·m).

6. Do Step 1 again. If the voltages are still not correct make replacement of the magnetic pickup.

Woodward EG-3P Governor Actuator

Check for Actuator Coil Resistance

1. Remove the connection plug from the EG-3P actuator.

2. There are four terminals on the actuator. They have marks "A", "B", "C" and "D". Connect the probes
of an ohmmeter between terminals "A" and "B". Put a jumper wire between terminals "C" and "D".

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EG-3P ACTUATOR

3. If the coil resistance is not 30 to 40 ohms make a replacement of the actuator.

Potentiometer Adjustment (Parallel Or Nonparallel Control)

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2301 PARALLEL CONTROL

1. Speed potentiometer. 2. Stability potentiometer. 3. Gain potentiometer. 4. Ramp time potentiometer. 5. Low speed
potentiometer. 6. Load gain potentiometer. 7. Droop potentiometer. 8. De-droop potentiometer. 9. Load signal jacks.

Speed Potentiometer

Turn speed potentiometer (1) clockwise to increase or counterclockwise to decrease the full load rpm of
the engine.

Stability and Gain Potentiometers

1. Connect a DC voltmeter to terminals 16 (-) and 17 (+) on the parallel control [terminals 5 (-) and 6 (+)
on the nonparallel control].

2. Start the engine. Run the engine until the coolant temperature is normal.

3. Turn gain potentiometer (3) clockwise until the voltmeter does not have stability.
4. Turn stability potentiometer (2) either direction until the voltmeter has stability.

5. Do Steps 3 and 4 several times until the stability potentiometer will not give the voltmeter stability.

6. Turn the gain potentiometer a small amount counterclockwise. Adjust the stability potentiometer as
necessary.

Ramp Time Potentiometer

Turn ramp time potentiometer (4) clockwise to increase or counterclockwise to decrease the amount of
time it takes the engine to accelerate from low idle to full load rpm.

Low Speed Potentiometer

1. Make sure there is an open between terminals 14 and 15 (terminals 9 and 10 on the nonparallel
control).

2. Turn low speed potentiometer clockwise to increase or counterclockwise to decrease the low idle rpm.

Load Gain Potentiometer

NOTE: Stability and gain potentiometers must be correctly adjusted first.

1. Put the probes of a voltmeter in the load signal jacks (9).

2. Run the engine in single unit operation until the coolant temperature is normal.

3. Put a full load on the generator. Adjust load gain potentiometers until the load signal reading on the
voltmeter is 8V. If it is not possible to put a full load on the generator keep the ratio between the load
and the voltage signal constant. For example: if the load on the generator is 1/2 of its rated capacity
adjust the load gain potentiometer to get a load signal of 4V.

4. Do Steps 1, 2 and 3 to all the units in the system. The load signal for each unit in the system must be
the same.

5. If any of the units in the system have stability problems at this load gain setting, decrease the setting
for each unit a small amount. Keep the load signal for each unit in the system the same.

6. If the load signal at full load is decreased to 3V in Step 5 and the system still has a stability problem
do the steps that follow.

7. Parallel all of the units in the system at no load.

8. If the system has instability turn the stability potentiometer of each unit one mark counterclockwise.
Do this until the system has stability.

9. Put a load on the system. If the system has instability turn the stability potentiometer of each unit one
mark counterclockwise. Do this until the system has stability.
NOTE: The generator voltage regulator response may be too fast. Use a manual voltage regulator. If
this stops the instability, slow down the response of the generator voltage regulator.

Droop Potentiometer

The amount of speed droop adjustment available will vary with the application from 0 to 13%. The
desired speed droop will be different for different applications. Speed droop is the percent difference
between the engine speed at no load and full load. To calculate speed droop use the formula:

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1. Get the desired speed droop for the application.

2. Multiply the full load speed by the desired speed droop. Add the number from this multiplication to
the full load speed to get the no load speed.

3. Run the engine until the coolant temperature is normal.

4. Adjust the engine speed to get the no load speed for Step 2.

5. Connect a known load to the engine. The load must be less than the full capacity of the engine. Make
a record of the decrease in engine speed.

NOTE: Load on engine or load on generator can be used.

6. Make a ratio between the load on the engine and the full load capacity of the engine. This ratio must
be the same as the ratio between the decrease in engine speed from Step 5 and the number from the
multiplication in Step 2. For example:

7. If the ratios are not the same an adjustment of the speed droop is necessary. Remove the load and stop
the engine. If the engine speed decreases too much according to the ratio, decrease the amount of speed
droop. If the decrease in engine speed is not enough increase the amount of speed droop.

8. Turn droop potentiometer (7) clockwise to increase or counterclockwise to decrease the amount of
speed droop.

De-Droop Potentiometer

1. Set the system for isochronous operation at the desired rpm. Droop potentiometer at zero droop.

2. Put the maximum available load on the unit, up to 100% of rated capacity.

3. If there is a change in rpm use the de-droop potentiometer to return the engine to the desired rpm.
Governor Air Actuators
2N6006 Actuator
Air Pressure Adjustment

1. Remove linkage (1) between actuator and governor.

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ACTUATOR LINKAGE
1. Linkage.

2. Start the engine. Let the engine run until it is warm.

3. Check high and low idle rpm with a tachometer. If necessary, make adjustments to the governor high
and low idle screws to get correct rpm.

4. Stop the engine.

5. Install an air gauge (2) in the line between the actuator air control lever (3) and the actuator (4).

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ACTUATOR AIR PRESSURE ADJUSTMENT
2. Air gauge. 3. Actuator air control lever. 4. Actuator. 5. Nut. 6. Plunger. 7. Screw.

6. Start the engine.

7. Check the air pressure to the actuator. Minimum air pressure at high idle must be 65 psi (450 kPa).
Maximum air pressure must not be more than 80 psi (550 kPa).

8. Put the governor hand control lever in the low idle position.

9. Move the actuator air control lever (3) slowly to the high idle position. Look at the plunger (6). The
plunger must start to move at 10 psi (70 kPa).

NOTE: If plunger (6) moves at less than 10 psi (70 kPa) make the preload higher. If more than 10 psi
(70 kPa) air pressure is needed to move the plunger, make the preload lower.

10. Return the actuator air control lever (3) to the low idle position to change preload.

11. Turn screw (7) out until nut can be turned.

12. Turn nut (5) clockwise to make preload higher. Turn nut counterclockwise to make preload lower.

13. When plunger (6) moves at 10 psi (70 kPa) air pressure, turn the screw in until nut can not be turned.

NOTE: If necessary, turn nut until screw is in line with next notch in nut.

14. Install linkage between actuator and governor.

Setting Low Idle Stop

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ACTUATOR LINKAGE ADJUSTMENT

1. Linkage.

1. Start the engine. Let the engine run until it is warm.

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

3. Install a tachometer and check the low idle rpm.

4. If low idle rpm is not correct, remove linkage (1) between actuator and governor to make adjustment.

5. Make linkage (1) shorter to decrease rpm. Make the linkage longer to increase rpm.

Setting High Idle Stop

1. Warm up engine.

2. Remove two setscrews (9) for earlier actuators or loosen locknuts (10) for later actuators, and turn the
two high idle screws (8) out several turns.

3. Move the governor hand control lever to the high idle position.

4. Move the actuator air control lever (3) slowly to the high idle position.

5. Turn the high idle screws (8) in until they make contact with the plunger.

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HIGH IDLE ADJUSTMENT (EARLIER ACTUATOR)
3. Actuator air control lever. 6. Plunger. 8. High idle screws. 9. Setscrews.

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HIGH IDLE ADJUSTMENT (LATER ACTUATOR)

3. Actuator air control lever. 6. Plunger. 8. High idle screws. 10. Locknuts.

6. Install and tighten two setscrews (9) for earlier actuators or tighten two locknuts (10) for later
actuators to hold the high idle screws.

7. Return the actuator air control lever (3) to the low idle position.
8. Install a tachometer.

9. Make the governor high idle 30 rpm higher.

NOTE: Step 9 lets the actuator high idle stop control the engine rpm.

10. Return the governor hand control lever to the low idle position.

11. Move the actuator air control lever (3) to the high idle position.

12. Check the engine high idle rpm.

13. If necessary, make small adjustments to the actuator high idle screws (8) to get correct rpm.

NOTE: Turn actuator high idle screws (8) the same amount. The plunger must contact both high idle
screws at the same time.

1N9318 and 7L135 Actuators

Air Pressure Adjustment

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ADJUSTMENT OF ACTUATOR AIR PRESSURE

1. Air gauge. 2. Actuator air control lever. 3. Actuator. 4. Plunger. 5. Setscrew. 6. Screw. 7. Nut.

1. Start the engine. Let the engine run until it is warm.

2. Check high and low idle rpm with a tachometer. If necessary, make adjustments to the governor high
and low idle screws to get correct rpm.

3. Stop the engine.

4. Install an air gauge (1) in the line between the actuator air control lever (2) and the actuator (3). See
illustration.

5. Start the engine.

6. Check the air pressure to the actuator. Minimum air pressure at high idle must be 65 psi (450 kPa).
Maximum air pressure must not be more than 80 psi (550 kPa).

7. Put the governor hand control lever in the low idle position.

8. Move the actuator air control lever (2) slowly to the high idle position. Look at the plunger (4). The
plunger must start to move at 10 psi (70 kPa) air pressure.

NOTE: If plunger (4) moves at less than 10 psi (70 kPa), make the preload higher. If more than 10 psi
(70 kPa) air pressure is needed to move the plunger, make the preload lower.

9. Return the actuator air control lever (2) to the low idle position to change preload.

10. Remove setscrew (5) and turn screw (6) out until nut (7) can be turned.

11. Turn nut (7) clockwise to make the preload higher. Turn nut counterclockwise to make the preload
lower.

3N9125 Actuator
Linkage Adjustment

1. Adjust rod end (4) to get dimension (A).

2. Move governor lever (2) counterclockwise until contact is made with the low idle stop.

3. Adjust linkage (1) to fit between rod end (4) and governor lever (2).

4. Put air pressure to the actuator until governor lever (2) makes contact with the high idle stop. Loosen
the locknut and turn stroke stop (3) until contact is made with actuator piston. Tighten locknut.

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3N9125 ACTUATOR
1. Linkage. 2. Governor lever. 3. Stroke stop. 4. Rod end. A. 4.00 in. (101.6 mm)

Shutoff And Alarm System Components

Contactor Switch For Oil Pressure
3P1564 Pressure Gauge (0 to 60 psi).3B7734 Pipe Nipple, 1/8 in. X 3.5 in.3B6483 Cap.Two 3B7263
Pipe Nipples, 1/8 in. X 2 in.Two 3B9389 Shutoff Cock Fittings.Two 1F9369 Tees.44914 Tee.Two
5K3772 Hose Assemblies.8S4627 Circuit Tester.

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TEST EQUIPMENT
1. 3P1564 Pressure gauge (0 to 60 psi). 2. 3B7734 Pipe nipple. 3. 3B6483 Cap. 4. Oil supply line. 5. 3B7263 Pipe nipple. 6.
3B9389 Shutoff cock fitting. 7. 3B9389 Shutoff cock fitting. 8. 1F9369 Tees. 9. 5K3772 Hose assemblies. 10. 44914 Tee.

Test Procedure

1. Remove the cover of the contactor switch and disconnect the wires from the normally closed (B or
Blue) terminal.

2. Disconnect the oil supply line from the contactor switch and install the test equipment as shown.

3. Connect the 5K3772 Hose from tee (10) to the contactor switch. Put the end of the other 5K3772
Hose in a pan.

4. Connect the 8S4627 Circuit Tester between the common terminal and the normally closed terminal.
The light of the circuit tester will be activated.

5. Close shutoff fitting (7) and open shutoff fitting (6).

6. Look at the pressure gauge, start the engine and run it at low idle rpm. The light must go out, with an
increase in oil pressure, at the specification of the switch.

7. Close shutoff fitting (6) and slowly open shutoff fitting (7). The light must be activated, with a
decrease in oil pressure, at the specification of the switch.

8. Stop the engine.

9. Connect the wire(s) to the normally closed terminal.

10. On contactor switches with a button or a control knob either push the button or turn the knob to the
OFF position.

11. Close shutoff fitting (7) and open shutoff fitting (6).

12. Start the engine and run it at low idle rpm.

13. Put a jumper wire between the common terminal and the normally closed terminal. This will check
the system beyond the contactor switch.

14. Remove the jumper wire.

Adjustment of Earlier Type Switch

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CONTACTOR SWITCH FOR OIL PRESSURE (Earlier Type)

11. Adjustment screw. 12. Main spring.

1. Turn adjustment screw (11) counterclockwise to make a decrease in the tension of main spring (12).

2. Disconnect the wires from the normally closed terminal of the switch.

3. Start the engine and run it at low idle rpm.

4. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the pressure gauge shows the
pressure specification at which the switch must close with a decrease in pressure. Close shutoff fitting
(7).

5. Make sure the control knob is in RUN position. If so equipped.

6. Connect the 8S4627 Circuit Tester between the common terminal and the normally closed terminal.
The light of the circuit tester must not be activated.

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WIRING CONNECTIONS
A. Normally open terminal. B. Common terminal. C. Normally closed terminal.

7. Turn screw (11) clockwise until the light of the circuit tester is activated.

8. To check the adjustment, close shutoff fitting (7) and open shutoff fitting (6).

9. Connect the wires to the normally closed terminal.

10. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the engine stops or the alarm
operates.

11. The pressure gauge must show the correct pressure specification of the switch as the engine stops or
the alarm operates.

Adjustment of Micro Switch Type

1. Loosen locknut (16) and turn adjustment screw (14) counterclockwise to make a decrease in the
tension of spring (15).

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CONTACTOR SWITCH FOR OIL PRESSURE (Micro Switch Type)
13. Set for start button. 14. Adjustment screw. 15. Spring. 16. Locknut. 17. Contact button.

2. Disconnect the wires from the normally closed terminal of the spring.

3. Start the engine and run it at low idle rpm.

4. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the pressure gauge shows the
pressure specification at which the switch must close with a decrease in pressure. Close shutoff fitting
(7).

5. Make sure the set for start button (13) is in the RUN position.

6. Connect the 8S4627 Circuit Tester between the common terminal and the normally closed terminal.
The light of the circuit tester must not be activated.

7. Turn screw (14) clockwise until the light of the circuit tester is activated.

8. Tighten the locknut.

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WIRING CONNECTIONS
D. Normally closed B terminal. E. Normally open W terminal. F. Common R terminal.

9. To check the adjustment, close shutoff fitting (7) and open shutoff fitting (6).

10. Connect the wires to the normally closed terminal.

11. Close shutoff fitting (6) and slowly open shutoff fitting (7) until the engine stops or the alarm
operates.

12. The pressure gauge must show the correct pressure specification of the switch as the engine stops or
the alarm operates.

Contactor Switch For Water Temperature

Fabricated heat sink.2F7112 Thermometer.3J5389 Plug.8S4627 Circuit Tester.

Method of Checking
1. Make a heat sink as shown. Material can be brass, steel or cast iron. Drill a 23/32 in. hole through the
plate and use a tap to make 1/2 in. NPT threads.

2. Put marks on the two contactor wires that connect the contactor to the circuit. Disconnect the two
wires.

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HEAT SINK [Dimension in inches (mm)]

3. Remove the contactor and install a 3J5389 Plug. Install the contactor switch in the heat sink.

4. Put the heat sink and contactor in water as shown. Use blocks to support the heat sink at surface level.

5. Connect the 8S4627 Circuit Tester between the wires that connected the contactor to the circuit.

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TEST OF CONTACTOR SWITCH
1. 2F7112 Thermometer. 2. Fabricated heat sink.

6. Put the 2F7112 Thermometer in the water.

7. Use a torch to heat the water to the temperature range at which the contactor must activate. If the
circuit tester light does not come on within the temperature range given in the specifications make a
replacement of the contactor.

Rack Shut-Off Solenoid

The governor plunger shaft initial adjustment of distance from shaft shoulder-to-plate should be .70 in.
(17.8 mm).

Effective travel can be measured with rack setting gauges to be sure rack is moved to shutoff position.
Make an on engine check with a 30 amp ammeter to be sure only the hold in windings are energized
when the rack is held by the solenoid in shut-off position. Current draw shuld be less than 2 amp.

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PLUNGER SHAFT ADJUSTMENT
1. Shoulder-to-plate distance .70 in. (17.8 mm). 2. Effective travel .62 in. (15.7 mm). 3. Starting position of plunger plate
from mounting flange is .44 in. (11.2 mm) to measure effective travel of plunger.

Shut-Off Valve (Water Temperature)

3J5389 Plug.8B4509 Connector.3B9388 Connector.9M6543 Hose Assembly.4D6949 Hose
Assembly.3B7764 Reducing Bushing.Heat Sink.

NOTE: See the topic Contactor Switch for Water Temperature in TESTING AND ADJUSTING for
instructions to make a heat sink.

1. Remove oil lines.

2. Remove shut-off valve and install the 3J5389 Plug.

3. Install the oil lines using the bushing, hoses and connectors.

4. Start the engine and let it run at low idle.

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SHUT-OFF VALVE (WATER TEMPERATURE)

5. Put the heat sink and the shut-off valve in water. Use a torch to make the water hot and, by using a
thermometer, take note of the temperature at which the engine stops.

6. Install a new valve if necessary.

NOTE: If engine does not stop, look for a defect in the contactor switch for oil pressure.

Contactor Switch For Overspeed

The original setting of the contactor switch for overspeed will stop the engine when the engine rpm is
more than 18% above full load rpm. DO NOT check the adjustment of the contactor switch on the
engine.

Off Engine Adjustment

4S6553 Engine Test Group.8S4627 Circuit Tester.5L2277 Adapter.Reversible Variable Speed Drill.

1. Connect the 1P7443 or 4S6991 Tachometer of the 4S6553 Group to the tachometer generator (2).

2. Connect the 5L2277 Adapter (3) to the contactor switch and tachometer generator (2).

3. Install variable speed drill (4) to the adapter as shown.

4. Connect the 8S4627 Circuit Tester (5) between the NO and C terminals of the contactor switch. The
light must be off. If the light is on, push reset button (6).

5. Gradually make an increase in the rpm. Read the rpm on the tachometer at the moment the light of the
circuit tester is activated. The reading will give the engine rpm (2 rpm on the meter for each rpm the
input shaft is turned).

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CHECKING CONTACTOR SWITCH FOR OVERSPEED
1. 4S6553 Engine Test Group. 2. Tachometer generator. 3. 5L2277 Adapter. 4. Variable speed drill. 5. 8S4627 Circuit Tester.

6. If needed, make an adjustment to the contactor switch by loosening lock screws (7). Turn the cap
clockwise to lower the overspeed setting. Tighten the lock screws.

7. To check other components in the circuit, put a jumper wire between the C and NO terminals of the
contactor switch.

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OVERSPEED CONTACTOR SWITCH

6. Reset button. 7. Lock screws.

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Instruments And Gauges
Oil Pressure Sending Units
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SENDING UNIT FOR OIL PRESSURE

1. Terminal. 2. Fitting.

1. Connect the sending unit to a pressure source that can be measured with accuracy.

2. Connect an ohmmeter between fitting (2) and terminal (1).

3. Take resistance readings at the pressure shown in the chart.

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4. If a unit does not have the correct resistance readings make a replacement of the unit.

Water Temperature Sending Unit

1. Connect an ohmmeter between terminal (1) and nut (2). Put bulb (3) in a pan of water. Do not let the
bulb have contact with the pan.

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SENDING UNIT FOR WATER TEMPERATURE

1. Terminal. 2. Nut. 3. Bulb.

2. Put a thermometer in the water to measure the temperature.

3. Take resistance readings at the temperatures shown in the chart.

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4. If a unit does not have the correct resistance readings make a replacement of the unit.

Electric Gauges
1. Put the gauge in position with the letters horizontal and the face 30° back from vertical.

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WIRING DIAGRAM FOR TEST

1. Terminal (for test voltage). 2. Test resistance.

2. Connect the gauge in series with the power source and the middle test resistance shown in the chart.

3. Let the gauge heat at the middle resistance for 5 minutes, then check the pointer position for all of the
resistances given.

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Ver imagen

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Mechanical Gauges For Temperature

Two types of mechanical gauges are available. The first type has a direct reading face. The second type
has color codes on the face to show different ranges of operation. White, green and red show the cold,
normal and hot ranges respectively.

To check both types of gauges, put the bulb of the gauge in a pan of oil. Do not let the bulb touch the
pan. Put a thermometer in the oil to measure the temperature. Make a comparison of temperatures on the
thermometer with the temperatures on the direct reading gauge or with temperature as shown on the
chart for gauges with color codes.

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DIRECT READING GAUGE

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GAUGE WITH COLOR CODE

Mechanical Gauges For Oil Pressure

Two types of mechanical gauges are available. The first type has a direct reading face. The second type
has color codes on the face to show different ranges of operation. Red, white and green show the low
pressure, pressure at low idle rpm and normal pressure ranges respectively. Some of the direct reading
gauges are for gear oil pressure.

NOTE: Some gauges with color codes have only two ranges. Red for low pressure and green for normal
pressure.

To check both types of gauges connect the gauge to a pressure source that can be measured with
accuracy. Make a comparison of pressure on the gauge of test equipment with the pressures on the direct
reading gauge or with the pressures as shown on the chart for gauges with color codes.
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GAUGE WITH COLOR CODE

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GAUGE WITH COLOR CODE

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DIRECT READING GAUGE

Power Take-Off Clutches

Clutch Adjustment
The clutch engagement lever pull adjustment establishes the clutch plate pressure. The proper clutch
lever pull is indicated in the chart.

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The clutches use two types of adjustment lock pins. Pin (1) should be pushed in and the adjusting ring
rotated. Pin (2) should be pulled out and the ring rotated to adjust the clutch.

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CLUTCH ADJUSTMENT
1. Lock pin (push in type to unlock). 2. Lock pin (pull out type to unlock).

Assembly Adjustments
Tighten hub nut to torque of 30 lb. ft. (40 N·m) to remove all clearance between parts, then tighten
additional amount as shown in chart.

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Clutch Shaft Seal Wear Sleeve Installation

Clutches which have oil lubricated shaft bearings are equipped with oil seal wear sleeves (2) on the
shaft. Install wear sleeves with guide assembly (1) (part of 1P2410 Wear Sleeve Installation Tool
Group). Be sure the sleeve contours blend in with the shoulder fillets (3) on the shaft.

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WEAR SLEEVE INSTALLATION

1. Guide assembly. 2. Wear sleeve. 3. Shaft shoulder fillets.

Shaft Bearing End Clearance

Tighten adjusting nut to remove all clearance and seat bearing cups. At this point shaft should turn with
dry bearing at torque of 60 lb. in. (6.8 N·m) in addition to seal drag. Then back off the adjusting nut the
number of notches indicated in the chart and install the lock. Drive the front bearing cup to the front by
striking the output end of the shaft with a soft hammer. The end clearance should now be as indicated in
the chart.

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Where shim adjustment is used, tighten the retainer without shims until shaft turns with dry bearings at
torque of 60 lb. in. (6.8 N·m) in addition to seal drag. Measure the space between the retainer and carrier
and add .013 in. (0.33 mm) to this measurement. Remove the retainer, then install shims and retainer
and cap screws with locks. Drive the front bearing cup to the front by striking the output end of the shaft
with a soft hammer. The end play should now be .006 to 010 in. (0.15 to 0.25 mm).

Clutch and Mounting Adjustment Check

At time of installation, check the flywheel and flywheel housing face and bore run out.

Electronic Overspeed Switch

Wiring Diagram
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SHUTOFF SYSTEM WIRING DIAGRAM
1. Oil pressure switch. 2. Water temperature contactor. 3. Time delay switch. 4. Diode assembly. 5. 75% verify button. 6.
Reset button. 7. "LED" overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank terminate). 10. Rack
solenoid. 11. Magnetic pick-up. 12. Engine flywheel. 13. Voltage input. 14. Locknut. 15. Air gap.

Troubleshooting Procedure (Overspeed)

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Troubleshooting Procedure (Crank Terminate)
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Procedure A
Overspeed Setting Calibration
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ELECTRONIC OVERSPEED SWITCH

5. Verify button. 6. Reset button. 7. "LED" overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank
terminate).

1. Remove lockwire and seal from seal screws (8 & 9). Remove seal screw (8) from access hole for
overspeed adjustment screw.

2. Use a small screwdriver and lightly turn O.S. (overspeed) adjustment potentiometer twenty turns in
the direction of "MAX ARROW" (clockwise).

NOTE: The overspeed adjustment screw is made so that it can not cause damage to the potentiometer or
be removed if the adjustment screw is turned too much.

3. Run engine at 75% of desired overspeed setting rpm. Make reference to the SPEED
SPECIFICATION CAHRT.

4. With engine at 75% of overspeed setting rpm, push VERIFY pushbutton (5) and hold in. Turn O.S.
(overspeed) adjustment potentiometer in the direction opposite of "MAX ARROW" (counterclockwise)
slowly until "LED" overspeed light (7) comes on. Engine will shut down if speed switch is connected to
the fuel shutoff solenoid and/or air inlet shutoff solenoids.

5. To reset speed switch, push in reset button (6). Air inlet shutoffs must be manually reset.

6. Slowly turn O.S. (overspeed) adjustment potentiometer approximately one turn clockwise and do
Steps 3, 4 and 5 again.

NOTE: More adjustment may be needed to get the correct setting. Turn adjustment potentiometer
clockwise to increase speed setting and counterclockwise to decrease speed setting. Turn adjustment
potentiometer very slowly only a small amount at a time until adjustment is correct.

7. When the speed setting is correct, install seal screw (8) for overspeed adjustment hole and install
lockwire and seal.

Procedure B
Magnetic Pickup Adjustment
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MAGNETIC PICK-UP
12. Engine flywheel. 14. Locknut. 15. Air gap.

1. Stop engine.

2. Loosen magnetic pick-up locknut (14).

3. Turn the magnetic pick-up clockwise until contact is made with the teeth of the engine flywheel ring
gear (12).

4. Turn the magnetic pick-up counterclockwise one-half turn. This will give approximately .022 to .033
in. (0.56 to 0.84 mm) clearance at location (15), between the end of the magnetic pick-up and the teeth
of the flywheel ring gear.

5. After the clearance is correct, tighten the magnetic pick-up locknut to a torque of 50 ± 10 lb. ft. (70 ±
14 N·m).

NOTE: Be sure the magnetic pick-up does not turn when the locknut is tightened.

Procedure C
Crank Terminate Speed Adjustment
1. Remove lockwire and seal from seal screws (8 & 9). Remove seal screw (9) from access hole for
crank terminate adjustment screw.

2. Use a small screwdriver and lightly turn C.T. (crank terminate) adjustment potentiometer twenty turns
in the direction of "MAX ARROW" (clockwise).

NOTE: The crank terminate adjustment screw is made so that it can not cause damage to the
potentiometer or be removed if the adjustment screw is turned too much.

3. Turn the crank terminate adjustment potentiometer twelve turns in a direction opposite of "MAX
ARROW" (counterclockwise) for an approximate crank terminate setting.

4. Start engine and make a note of the speed at which the starter disengages. See the SPEED
SPECIFICATION CHART for the correct crank terminate speed for D379, D398 and D399 Engines.

NOTE: If setting is not correct do Steps 5 and 6. If setting was correct do Step 7.

5. Stop engine and turn adjustment potentiometer (clockwise to increase and counterclockwise to
decrease) crank terminate speed.

6. Start and make a note of the speed at which the starter disengages. If needed, make more small
adjustments until the crank terminate speed is correct.

7. Install seal screw (9) for crank terminate adjustment hole and install lockwire and seal.

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ELECTRONIC OVERSPEED SWITCH

5. Verify button. 6. Reset button. 7. "LED" overspeed light. 8. Seal screw plug (overspeed). 9. Seal screw plug (crank
terminate).

Procedure D
Overspeed Verify Test
1. Run engine at rated speed, push verify button (5) in for a moment. This will cause the speed switch to
activate and shut down the engine.
NOTE: Any time the engine speed is 75% or more of the overspeed setting, the engine will shut down if
the verify button is pushed.

EXAMPLE: For an engine with a rated speed of 1200 rpm the overspeed setting is 1416 rpm. The
overspeed verify test will shut down the engine at 75% of the overspeed setting of 1416 rpm. In this
example 75% of 1416 rpm is 1062 rpm. If the verify button is pushed at an engine speed of 1062 rpm or
above the engine will shut down.

The "LED" overspeed light (7) will come on and stay on until the reset button is pushed after an
overspeed switch shut down. To restart the engine, push in reset button (6) for a moment. This will reset
the speed switch and the rack shutoff solenoid. The "LED" overspeed light (7) will go off. The air inlet
shutoff must be manually reset.

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NOTE C: To verify overspeed shutdown system operation, push in for a moment the verify push button.
The engine must shut down at 75% or more of overspeed setting.

NOTE D: Input Voltage: Maximum 37 VDC Minimum 8 VDC.

NOTE E: The engine overspeed setting rpm is 118% of rated engine rpm.

NOTE F: The magnetic pick-up frequency (HZ) at the overspeed or cranking termination setting is
calculated with the formula that follows:

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If the rated speed of the engine is other than shown in the chart, the magnetic pick-up frequency for the
overspeed setting can be found according to NOTES E and F.

If a 2301 Governor is used, only one magnetic pick-up is needed. Use the magnetic pick-up from the
overspeed group. Connect the wires from the magnetic pick-up to the overspeed switch and then connect
wires from the speed switch to the 2301 Governor. The overspeed switch can be installed close to the
2301 Governor if needed.

To reset overspeed switch, push in reset button for a moment.

Copyright 1993 - 2012 Caterpillar Inc. Sat Sep 29 18:04:00 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
Pruebas y Ajustes
D379, D398, D399 INDUSTRIAL & MARINE ENGINES
Número de medio -SEBR0511-00 Fecha de publicación -01/08/1983 Fecha de actualización -11/10/2001

Testing And Adjusting

Troubleshooting
Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make a
repair to a problem, make reference to the cause and correction.

This list of problems, causes, and corrections, will only give an indication of where a possible problem
can be, and what repairs are needed. Normally, more or other repair work is needed beyond the
recommendations in the list.

Remember that a problem is not normally caused only by one part, but by the relation of one part with
other parts. This list can not give all possible problems and corrections. The serviceman must find the
problem and its source, then make the necessary repairs.

Troubleshooting Index
1. Engine Will Not Turn When Start Switch Is On.
2. Engine Will Not Start.
3. Misfiring or Running Rough.
4. Stall at Low rpm.
5. Sudden Changes In Engine rpm.
6. Not Enough Power.
7. Too Much Vibration.
8. Loud Combustion Noise.
9. Valve Train Noise (Clicking).
10. Oil In Cooling System.
11. Mechanical Noise (Knock) In Engine.
12. Fuel Consumption Too High.
13. Loud Valve Train Noise.
14. Too Much Valve Lash.
15. Valve Rotocoil or Spring Lock is Free.
16. Oil at the Exhaust.
17. Little or No Valve Clearance.
18. Engine Has Early Wear.
19. Coolant In Lubrication Oil.
20. Too Much Black or Gray Smoke.
21. Too Much White or Blue Smoke.
22. Engine Has Low Oil Pressure.
23. Engine Uses Too Much Lubrication Oil.
24. Engine Coolant Is Too Hot.
25. Starting Motor Does Not Turn.
26. Alternator Gives No Charge.
 27. Alternator Charge Rate Is Low or Not Regular.
28. Alternator Charge Too High.
29. Alternator Has Noise.
30. Exhaust Temperature Too High.

Engine Crankshaft Will Not Turn When Start Switch Is On

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Engine Will Not Start

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Misfiring Or Running Rough

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Stall At Low RPM

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Sudden Changes In Engine Speed (rpm)

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Not Enough Power

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Too Much Vibration

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Loud Combustion Noise (Sound)

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Valve Train Noise (Clicking)

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Oil In Cooling System

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Mechanical Noise (Knock) In Engine

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Fuel Consumption Too High

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Loud Valve Train Noise

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Too Much Valve Lash

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Valve Rotocoil Or Spring Lock Is Free

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Oil At The Exhaust

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Little Or No Valve Clearance

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Engine Has Early Wear

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Coolant In Lubrication Oil

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Too Much Black Or Gray Smoke

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Too Much White Or Blue Smoke

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Engine Has Low Oil Pressure

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Engine Uses Too Much Lubrication Oil

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Engine Coolant Is Too Hot

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Starting Motor Does Not Turn

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Alternator Gives No Charge

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Alternator Charge Rate Is Low Or Not Regular

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Alternator Charge Too High

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Alternator Has Noise

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Exhaust Temperature Is Too High

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Fuel System
Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system.
Many times work is done on the fuel system when the problem is really with some other part of the
engine. The source of the problem is difficult to find, especially when smoke comes from the exhaust.
Smoke that comes from the exhaust can be caused by a bad fuel injection valve, but it can also be caused
by one or more of the reasons that follow:

a. Not enough air for good combustion.

b. An overload at high altitude.
c. Oil leakage into combustion chamber.
d. Not enough compression.

Fuel System Inspection

A problem with the components that send fuel to the engine can cause low fuel pressure. This can
decrease engine performance.

1. Check the fuel level in the fuel tank. Look at the cap for the fuel tank to make sure the vent is not
filled with dirt.

2. Check the fuel lines for fuel leakage. Be sure the fuel supply line does not have a restriction or a bad
bend.

3. Install a new fuel filter. Clean the primary fuel filter if so equipped.

4. Remove any air that may be in the fuel system. If there is air in the fuel system, use the priming pump
and loosen the nuts holding the fuel lines to the outside of the cylinder head, one at a time. Do this until
fuel, without air, comes from the fuel line connection.

5. Inspect the fuel control valve to see that there is no restriction to good operation.

Checking Engine Cylinders Separately

An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to
come out of the exhaust pipe.

Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This
will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found
that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before
the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where
the loosened fuel line nut does not make a difference in engine performance, test the injection pump and
injection valve for that cylinder.

Temperature of an exhaust manifold port, when the engine runs at low idle speed, can also be an
indication of the condition of a fuel injection nozzle. Low temperature at an exhaust manifold port is an
indication of no fuel to the cylinder. This can possibly be an indication of a nozzle with a defect. Extra
high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also
caused by a nozzle with a defect.

The most common defects found with the fuel injection valves are:
 1. Carbon on tip of the nozzle or in the nozzle orifice.
2. Orifice wear.
3. Dirty nozzle screen.

Testing Capsule-Type Fuel Injection Nozzles For PC Engines

5P4150 Nozzle Testing Group
5P4720 Fitting5P8744 Adapter or5P4717 Adapter
8S2270 Fuel CollectorFT1384 Extension

NOTICE
Be sure to use clean SAE J967 Calibration Oil when testing. Dirty test
oil will damage components of the fuel injection nozzle. The
temperature of the test oil must be 65° to 75° F (18° to 24° C) for good
test results.

Order calibration oil by part number, in the quantities needed, according to the information that follows:

Kent-Moore Corp.
1501 South Jackson St.
Jackson, MI 49203

J-26400-5 [5 gal. (18.9 litre)]J-26400-15 [15 gal. (56.7 litre)]J-26400-30 [30 gal. (113.5 litre)]J-26400-
55 [55 gal. (208.2 litre)]

Viscosity Oil Company

3200 South Western Ave.
Chicago, IL 60608

Viscor Calibration Fluid1487C-SAE J-967CAvailable in 30 gal. (113.5 litre) or55 gal. (208.2 litre)
drums.

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5P4150 NOZZLE TESTING GROUP

A. 5P4721 Tube. B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa) used to test PC capsule valves. C. 2P2324 Gauge, 0 to
5000 psi (0 to 34 500 kPa) used to test DI capsule valves and pencil-type nozzles. D. Gauge protector valve for 5P4146
Gauge (B). E. Gauge protector valve for 2P2324 Gauge (C). F. On-off valve. G. Pump isolator valve. H. 5P4720 Fitting. J.
5P8744 Adapter for capsule nozzles. K. 5P4244 Adapter for pencil-type nozzles.

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EXTRA VALVE
L. Gauge protector valve (must be in open position at all times).

The test procedures that follow will give an indication of nozzle condition. A nozzle that has a defect is
not always the only cause for a specific engine problem.

When fuel injection nozzles are tested, be sure to wear eye protection.
Fuel comes from the orifices in the nozzle tip with high pressure. The
fuel can pierce (go thru) the skin and cause serious injury to the
operator. Keep the tip of the nozzle pointed away from the operator and
into the 8S2270 Fuel Collector and FT1384 Extension.

Nozzle Tester Preparation

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ILLUSTRATION I
1. Test nozzle (welded orifice). 2. Bottom part of 5P8744 Adapter (J). J. 5P8744 Adapter. M. FT1384 Extension. N. 8S2270
Fuel Collector.

Find an old capsule type fuel nozzle and weld the orifice closed. Keep this fuel nozzle with the tester
group for use in the future.
NOTE: Do not weld the fuel nozzles that are to be tested.

Illustration I shows the latest 5P8744 Adapter. Illustration II shows the former 5P4717 Adapter. Unless
some indication is made, the procedure is the same for use of either adapter.

1. Install the top part of adapter (J) that holds the capsule valve.

2. Put test nozzle (1) (with welded orifice) in the bottom part (2) of adapter (J) that holds the capsule
valve. Install and tighten bottom part (2) to top part of adapter (J).

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ILLUSTRATION II
1. Test nozzle (welded orifice). 2. Bottom part of 5P4717 Adapter (J). J. 5P4717 Adapter.

3. Close on-off valve (F). Open pump isolator valve (G). Open gauge protector valve (E).

4. Operate the tester pump until a pressure of 3500 psi (24 000 kPa) is read on 2P2324 Gauge (C). Now,
close pump isolator valve (G).

5. Check all connections for leaks. Tighten connections to stop any leaks that are found.

6. Open on-off valve (F) and remove test (welded) fuel nozzle.

Do not loosen the bottom half of the adapter to remove fuel nozzle until
on-off valve is opened and no pressure is read on the gauge. Unless the
high pressure is released in the pump, the fuel discharge from the
adapter can cause injury to the operator.

NOTE: To prevent fuel leakage, the top surface of the test (welded) nozzle, and all other nozzles that
are to be tested, must be free of scratches or burrs (sharp edges).

The procedure for NOZZLE TESTER PREPARATION must be done each time any of the conditions
that follow exist:

a. The complete 5P8744 or 5P4717 Adapter is removed and installed again.

 b. Before and after a series of tests.
c. There is an indication of a problem with the nozzle tester.

Fuel Nozzle Test Sequence

To test PC capsule-type fuel nozzles, use the sequence that follows:

I. Nozzle Installation
II. Pressure Loss Test
III. Valve Opening Pressure Test (VOP)

NOTICE
DO NOT use a drill or a reamer on the orifice of a nozzle. DO NOT use
a steel brush or a wire wheel to clean the tip of the nozzle. The orifice
and the valve can be damaged easily.

I. Nozzle Installation

1. Put one of the nozzles to be tested in the bottom part (2) of adapter (J). Install and tighten bottom part
(2) to top part of adapter (J).

2. Close on-off valve (F). Open gauge protector valve (D) one-half turn. Open pump isolator valve (G)
one-half turn.

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AIR REMOVAL FROM TESTER

2. Bottom part of adapter (J). J. 5P8744 Adapter.

3. Bleed (remove) air from the tester as follows:

a. Loosen bottom part (2) of adapter (J) one-half turn.

b. Operate the pump until clear oil (free of air bubbles) leaks past the threads at top of adapter (J).

NOTE: With some 5P8744 Adapters, pressure may start to increase before there is an indication of clear
test oil. To correct this condition, do Step C.
 c. Tighten bottom part (2) of adapter (J).

NOTE: The 5P8744 Adapter makes its own seal, and normally needs very little force when turned on
bottom part (2) of the adapter.

II. Pressure Loss Test

1. Open gauge protector valve (D) an extra amount of one-half turn (the total amount is now one turn
open).

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TESTER NOMENCLATURE
B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). D. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

2. Operate pump to increase pressure slowly to 300 psi (2050 kPa), and close pump isolator valve (G).
Now turn gauge protector valve (D) to adjust pressure again to 300 psi (2050 kPa).

3. After 30 seconds, take a pressure reading from the gauge. The pressure at this time must not be below
100 psi (690 kPa) reading on the dial face.

4. The valve must not lose more than 200 psi (1380 kPa).

5. If the pressure loss is not in the 200 psi (1380 kPa) range as shown, stop the test sequence. Do not use
the fuel nozzle again.

6. If nozzle is in specification range, see VALVE OPENING PRESSURE TEST (VOP).

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PRESSURE LOSS RANGE FOR GOOD NOZZLE

III. Valve Opening Pressure Test (VOP)

1. Open pump isolator valve (G) one-half turn.

2. Operate the pump to increase the pressure slowly until test oil comes from the nozzle tip.

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TESTER NOMENCLATURE
B. 5P4146 Gauge, 0 to 1000 psi (0 to 6900 kPa). D. Gauge protector valve. F. On-off valve. G. Pump isolator valve.

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VALVE OPENING PRESSURE (VOP) RANGE FOR GOOD NOZZLE

3. The pressure reading on the gauge at this time must be in the pressure range of 400 to 750 psi (2750
to 5200 kPa) as shown.

4. If the valve opening pressure (VOP) is not in the 400 to 750 psi (2750 to 5200 kPa) range as shown,
do not use the fuel nozzle again.

Fuel Injection Service

Injection Valve (Capsule-Type Nozzle)

If a fuel injection nozzle has been removed from the precombustion chamber, test the nozzle before it is
again installed in the precombustion chamber. See TESTING CAPSULE-TYPE FUEL INJECTION
NOZZLES FOR PC ENGINES.

Before installation of a fuel injection valve, inspect the valve and precombustion chamber for dirt or
damage on the surfaces that go together.

It is important to keep the correct torque on the nut that holds the fuel nozzle in the precombustion
chamber. Tighten the fuel injection valve on the body finger tight. Tighten the nut to 105 ± 5 lb.ft. (142
± 7 N·m). There will be damage to the nozzle if the nut is too tight. If the nut is not tight enough, the
nozzle can leak.

Removal of Injection Pump

When injection pump barrels and plungers are removed from the injection pump housing, keep the parts
of each pump together so they can be installed back in their original location.

Be careful when removing injection pumps. Do not damage the surface on the plunger. The plunger and
barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another
pump. If one part is worn, install a complete new pump assembly. Be careful when putting the plunger
in the bore of the barrel.

1. Remove the fuel injection line from the pump and install cover (1) and plug (3).

2. Lift the pump straight up to clear the dowel pins and the pump plunger. Install seals (4) and plug (2)
for protection from dirt.

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REMOVING FUEL INJECTION PUMP

1. Cover. 2. Plug. 3. Plug. 4. Seal.

3. Slide the end of the plunger out of the yoke in the lifter and lift out the plunger. Be sure the plunger is
installed in the barrel from which it was removed.

Be careful when injection pumps are disassembled. Do not damage the surface on the plunger. The
plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of
another pump. If one part is worn, install a complete new pump assembly. Be careful when the plunger
is put in the bore of the barrel.

An injection pump can have a good fuel flow output but not be a good pump becuase of slow timing that
is caused by wear on the bottom end of the plunger. When a test is made on a pump that has been used
for a long time, use a micrometer and measure the length of the plunger. If the length of the plunger is
shorter than the minimum length (worn) dimension given in the chart, install a new pump.

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Look for wear at the top part of the plunger. Check the operation of the plunger according to the
instructions for the Fuel Injection Test Bench.

When there is too much wear on the pump plunger, the lifter yoke may also be worn and there will not
be good contact between the two parts. To stop fast wear on the end of a new plunger, install new lifter
yokes in the place of those with wear.

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WEAR BETWEEN LIFTER YOKE AND PLUNGER

Fig. A illustrates the contact surfaces of a new pump plunger and a new lifter yoke. In Fig. B the pump plunger and lifter
yoke have worn considerably. Fig. C shows how the flat end of a new plunger does not make a good contact with a worn
lifter yoke. The result is rapid wear to both parts.

Installation of Injection Pump

The seal under the machined surface, around the large diameter of the pump must be in correct position
when the pump is installed. Also, there must be a seal around the fuel outlet ferrule on the fuel pump
housing. If either seal is damaged install a new one.

1. Remove the pump plunger from the barrel.

2. Wash the pump plunger and barrel with clean diesel fuel before installing.

3. Turn the pump plunger, until tooth (6) with a mark is in alignment with rack mark (5).

4. Slide the end of the plunger into the yoke in the lifter.

5. Lower the pump barrel onto the plunger, taking care that the pump plunger is straight in the barrel.
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INSTALLING FUEL INJECTION PUMP

5. Mark on rack. 6. Tooth mark.

6. Lower the pump onto the dowel pins and fasten in place. Tighten bolts (8) first and then tighten bolts
(7). Torque for bolts is 32 ± 5 lb.ft. (43 ± 7 N·m). Torque for the fuel line nuts is 30 ± 5 lb. ft. (40 ± 7
N·m).

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SEQUENCE TO TIGHTEN BOLTS

7. Bolts, tighten second. 8. Bolts, tighten first.

Start Up Procedure
Use this procedure when an engine is started for the first time after work is done on the fuel injection
pumps or governor.

1. Remove the air cleaner covers and air cleaner elements from the air inlets of both turbochargers.

2. Have a person in position near each turbocharger air inlet with a piece of steel plate large enough to
completely cover the turbocharger air inlet.

3. If the engine starts to run too fast or runs out of control, immediately put the steel plates against the
turbocharger air inlet. This will stop the air supply to the engine and the engine will stop.

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STOPPING THE ENGINE

Fuel Injection Lines

Fuel from the fuel injection pumps is sent through the fuel injection lines to the fuel injection valves.

Each fuel injection line of an engine has a special design and must be installed in a certain location.
When fuel injection lines are removed from an engine, put identification marks or tags on the fuel lines
as they are removed, so they can be put in the correct location when they are installed.

The nuts that hold a fuel injection line to an injection valve and injection pump must be kept tight. Use a
torque wrench and a 5P144 Socket to tighten the fuel line nuts to 30±5 lb.ft. (40±7 N·m).

Locating Top Center Compression Position For No. 1 Piston

5P7307 Engine Turning Tool Group or2P8300 Engine Turning Tool Group

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5P7307 ENGINE TURNING TOOL

2. 5P7306 Housing. 3. 5P7305 Gear.

No. 1 piston at top center on the compression stroke is the starting point for all timing procedures.

NOTE: The engine is seen from the flywheel end when the direction of crankshaft rotation is given.
Normal direction of crankshaft rotation for standard engines is counterclockwise, and for opposite
rotation engines is clockwise.

1. Remove the valve cover for No. 1 cylinder. The two valves at the front of the right bank are the intake
and exhaust valves for No. 1 cylinder.
2. Remove the timing mark cover from the right side of the flywheel housing.

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TIMING MARKS ON FLYWHEEL (16 Cylinder Engine Illustrated)

1. Pointer.

3. Remove the starter from the right side of the engine. Install 5P7307 or 2P8300 Engine Turning Tool.

NOTE: Put 5P906 Grease in bore of 5P7306 or 2P8294 housing before the pinion is installed.

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TIMING MARKS ON FLYWHEEL (8 and 12 Cylinder Engines Illustrated)

1. Pointer.

4. Turn the crankshaft in a direction opposite of normal 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.

5. Turn the crankshaft in the direction of normal rotation until the timing marks on the flywheel are in
alignment with the pointer in the flywheel housing.

NOTE: If the crankshaft is turned beyond the timing mark, turn the crankshaft in the direction opposite
of normal rotation a minimum of 30 degrees before the crankshaft is turned to the timing mark again.

6. The intake and exhaust valves for No. 1 cylinder will be closed if No. 1 piston is on the compression
stroke. You can move the rocker arms up and down with your hand. If the No. 1 piston is not on the
compression stroke, turn the crankshaft in the direction of normal rotation 360 degrees and make
alignment of the timing mark and the pointer.
Checking Fuel Injection Pump Timing With Timing Pin
1. Put No. 1 piston at top center in the compression position. Make reference to LOCATING TOP
CENTER COMPRESSION POSITION FOR NO. 1 PISTON.

2. Remove timing pin (2) from fuel inlet flange (1) and remove fuel inlet flange.

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TIMING PIN
1. Fuel inlet flange. 2. Timing pin.

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TIMING PIN LOCATED IN TIMING SLOT (Pump housing removed for better illustration)
2. Timing pin. 3. Timing slot.

3. Turn the timing pin into the timing hole in the fuel injection pump housing. If the timing pin goes into
the timing slot (3) of the fuel pump camshaft, the threads on the timing pin can not be seen.

4. If the timing pin goes into the timing slot of the fuel pump camshaft, the fuel pump camshaft is
correctly in time with the crankshaft. If the timing pin does not go into the timing slot of the fuel pump
camshaft, make reference to TIMING THE CAMSHAFT FOR THE FUEL INJECTION PUMPS.

Checking Timing By Measuring Timing Dimension (Depth

Micrometer)
6F6922 Micrometer Depth Gauge
1. Put No. 1 piston at top center (TC) in the compression position. Make reference to LOCATING TOP
CENTER COMPRESSION POSITION FOR NO. 1 PISTON.

2. Remove No. 1 fuel injection pump and plunger from the housing. Clean all dirt and paint from the
surface of the fuel injection housing.

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MEASURING LIFTER DIMENSION (Typical Illustration)

A. Distance to be measured.

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3. Install the 2 to 3 in. shaft in the depth micrometer. Put the depth micrometer on the fuel injection
housing as shown and measure dimension (A). See the chart for the correct ON ENGINE lifter setting
dimensions.

NOTE: If the timing dimension is not correct, check to see if the timing pin will go in the slot of the
fuel pump camshaft. If the timing pin will not fit, make reference to TIMING THE CAMSHAFT FOR
THE FUEL INJECTION PUMPS. If the timing pin does fit, make reference to SETTING FUEL
INJECTION PUMP TIMING DIMENSION: OFF ENGINE.

Checking Timing By Measuring Timing Dimension (Dial

Indicator)
5P4165 Dial Indicator Group8S3158 Indicator3P1565 Collet Clamp5P4156 Base5P4161 Contact Point,
2.75 in. (69.9 mm) long.5P4158 Gauge 2.00 in. (50.8 mm)5P4159 Gauge stand

1. Put No. 1 piston at top center (TC) in the compression position. Make reference to LOCATING TOP
CENTER COMPRESSION POSITION FOR NO. 1 PISTON.

2. Remove No. 1 fuel injection pump and plunger from the housing. Clean all dirt and paint from the
surface of the fuel injection housing.

3. Install 3P1565 Collet Clamp in 5P4156 Base. Put 8S3158 Indicator in collet. Be sure the indicator is
against the shoulder in the collet and tighten the nut to prevent the indicator from moving in the collet.
Put 5P4161 Contact Point 2.75 in. (69.9 mm) long on the indicator.

4. The indicator must be adjusted to zero before any measurements are taken. Put 5P4158 Gauge 2.00 in.
(50.8 mm) on the 5P4159 Gauge Stand and put indicator with contact point on the gauge until the
indicator base is even with the gauge. Loosen the screw on the dial clamp and turn dial face until the
zero is in alignment with the larger pointer. Tighten the clamp for the dial. Make a note of the position
of the revolution counter (small pointer). The indicator now reads zero for a measurement of 2.00 in.
(50.8 mm).

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MEASURING TIMING DIMENSION
A. Timing dimension.

5. Put the indicator assembly on the fuel injection housing as shown and measure dimension (A). See the
chart for the correct ON ENGINE lifter setting dimensions.

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NOTE: If the timing dimension is not correct, check to see if timing pin will go in the slot of the fuel
pump camshaft. If the timing pin will not fit, make reference to TIMING THE CAMSHAFT FOR THE
FUEL INJECTION PUMPS. If the timing pin does fit, make reference to SETTING FUEL INJECTION
PUMP TIMING DIMENSION: OFF ENGINE.

Checking Timing By The Fuel Flow Method

1P540 Flow Checking Tool Group3S2954 Engine Timing Indicator Group or5P6524 Engine Timing
Indicator Group9S215 Dial Indicator3P1565 Collet3S3270 Contact Point 1.75 in. (44.5 mm)
long3S3264 Rod 7.12 in. (180.9 mm) long5P7265 Adapter7M1999 Tube Assembly

1. Put No. 1 piston at top center (TC) in the compression position. Make reference to LOCATING TOP
CENTER COMPRESSION POSITION FOR NO. 1 PISTON.

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MEASURING PISTON TRAVEL
1. 3P1565 Collet. 2. 9S215 Dial Indicator with 3S3270 Contact Point. 3. 5P7265 Adapter. 4. Precombustion chamber. 5.
3S3264 Rod. 6. Inlet port. 7. Piston.

2. Disconnect the fuel line from No. 1 cylinder fuel injection valve body. Remove the valve body and
the fuel valve from the precombustion chamber.

3. Install 5P7265 Adapter (3) in precombustion chamber (4). Tighten the adapter finger tight only to
prevent damage to the fuel injection valve seat. Put a small amount of oil on 3S3264 Rod (5) and put the
rod in the adapter with the small end down.

4. Install 3P1565 Collet (1) on the adapter. Put the 3S3270 Contact Point on 9S215 Indicator (2) and put
the indicator in the collet.

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5P6524 ENGINE TIMING INDICATOR GROUP INSTALLED

5. Turn the crankshaft a minimum of 45 degrees in a direction opposite of normal rotation. Slowly turn
the crankshaft in the direction of normal rotation until a maximum reading is seen on the dial indicator.
Adjust the indicator up or down in the collet until the revolution counter is at +.300 in. (Black
Numbers). Tighten the collet to hold the indicator in this position. Loosen the bezel lock and turn the
bezel until the zero on the face of the dial is in alignment with the hand. Tighten the bezel lock.

6. Slowly turn the crankshaft in the direction of normal rotation until the dial indicator moves
beyond .020 in. Now turn the crankshaft in the opposite direction until the dial indicator is at .020 in.

7. Make a temporary mark on a rotating component (flywheel, vibration damper, or crankshaft pulley) in
relation to a stationary pointer or mark.

NOTICE
Do not use a hammer and punch to mark a vibration damper.

8. Turn the crankshaft in the direction opposite of normal rotation beyond the maximum indicator
reading and beyond .020 in. Now turn the crankshaft in the direction of normal rotation until the dial
indicator is at .020 in.

9. Make a second temporary mark on the rotating component in relation to the stationary pointer or
mark. Now make a mark on the rotating component that is one-half the distance between the two
temporary marks. This mark is the point of most accuracy for top center No. 1 piston.

10. Turn the crankshaft in the direction opposite of normal rotation approximately 45 degrees and then
turn the crankshaft in the opposite direction to the top center mark that was made in Step 9. If needed
adjust the dial indicator as in Step 5.

11. Turn the crankshaft in the direction opposite of normal rotation approximately 45 degrees. Move the
fuel rack to the full load position. If the engine has a hydra mechanical governor install a 9S8519 plug
and 9S8521 Rod, and push in the speed limiter plunger. Tighten the plug to hold the rod in this position.
Now the governor can be moved to the full load position.

12. Connect hose (8) from the fuel pressure tank (10) to the fuel pressure gauge connection on the left
side of the fuel filter housing. Disconnect fuel return line (11) at the fuel control valve and install a plug.
Disconnect the fuel line from No. 1 fuel injection pump and install 7M1999 tube Assembly (9). The
open end of the tube assembly must be at an upward slope.

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1P540 FLOW CHECKING TOOL GROUP

8. 5J4634 Hose assembly. 9. 7M1999 Tube Assembly. 10. Tank assembly.
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5J4634 HOSE ASSEMBLY INSTALLED

8. 5J4634 Hose assembly. 11. Fuel return line.

13. Fill the fuel tank with 1 gallon (3.8 litres) of clean diesel fuel. Keep the pressure in the tank at 15 psi
(105 kPa) by the use of the hand pump or shop air pressure.

NOTICE
If shop air is used, make an adjustment to the regulator so the air
pressure in the tank is a maximum of 15 psi (105 kPa).

14. With fuel pressure to the fuel injection housing, slowly turn the crankshaft in the direction of normal
rotation. When the fuel flow from the tube is 6 to 12 drops per minute, stop turning the crankshaft. This
is the point of inlet port (6) closing.

15. Use the chart to change the indicator reading to timing angle. The timing must be within ±1 degree
of the specified timing angle.

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NOTE: If the timing of the fuel system is different that the correct timing dimension given in the chart,
make reference to TIMING THE CAMSHAFT FOR THE FUEL INJECTION PUMP.
Timing The Camshaft For The Fuel Injection Pumps
9S6054 Socket

NOTE: The fuel pump camshaft timing gear (1) has a puller attached. The puller is used to loosen or
tighten the gear on the drive shaft. The puller has puller bolt (3), collar (6), and plate (2). The puller bolt
is held in the plate by the collar which is welded to the bolt. The plate is fastened to the gear with bolts.
When the puller bolt is turned counterclockwise, the collar pushes against the plate and pulls the gear
from shaft (4). When the puller bolt is turned clockwise, the bolt head pushes on the plate and pushes the
gear on the shaft.

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CAMSHAFT GEAR ASSEMBLY

1. Camshaft gear. 2. Plate. 3. Puller bolt. 4. Shaft. 5. Lock. 6. Collar.

1. Put No. 1 piston at top center (TC) in the compression position. Make reference to LOCATING TOP
CENTER COMPRESSION POSITION FOR NO. 1 PISTON.

2. Remove the pipe plug between the aftercooler supports on the flywheel housing. Bend lock (5) from
puller bolt (3) and turn puller bolt to loosen gear (1) from shaft (4).
3. Remove timing pin (7) and the fuel inlet flange.

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TIMING PIN IN TIMING SLOT OF CAMSHAFT

7. Timing pin. 10. Timing slot.

4. Install the timing pin finger tight.

5. Remove the breather from the front of the fuel injection housing.

6. Use a 9S6054 Socket and ratchet wrench (8) to turn the fuel pump camshaft. Put the socket and
wrench on the end of the fuel pump camshaft and turn the camshaft until timing slot (10) is at the top.
Tighten the timing pin into the timing slot.

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TIMING THE FUEL INJECTION PUMP CAMSHAFT

7. Timing pin. 8. Ratchet wrench handle (3/4 in. drive). 9. Breather opening.

7. Tighten the camshaft puller bolt (3) to push the gear on the shaft. Tighten bolt (3) to a torque of 265 ±
35 lb.ft. (360 ± 45 N·m). Bend the lock to the bolt.

8. Remove the timing pin and turn the crankshaft two revolutions in the direction of normal rotation
until the engine is again at top center (TC) compression position for No. 1 piston.

9. Install the timing pin. If the timing pin engages with the timing slot in the camshaft, the timing is
correct. If the timing pin does not engage with the timing slot, the timing is not correct and Steps 1 thru
8 must be done again.
10. Remove the timing pin. Install the breather, pipe plug in flywheel housing, fuel inlet flange, and the
timing pin.

Setting Fuel Injection Pump Timing Dimension: Off Engine

5P6600 or1P5600 Off Engine Lifter Setting Tool Group5P4165 Dial Indicator Group or6F6922 Depth
Micrometer

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5P6600 OFF ENGINE LIFTER SETTING TOOL GROUP SHOWN

1. 1P7410 Plate. 2. 5P6564 Shaft. 3. 1P7415 Pointer. 4. S1594 Bolt. 5. 2S6160 Washer. 6. S509 Bolt. 7. 9M4568 Wrench. 8.
9M4567 Wrench.

The fuel injection pump housing must be removed from the engine for the procedure that follows:

1. Remove the fuel injection pumps from fuel injection pump housing. Make reference to FUEL
INJECTION SERVICE; Removal of Injection Pump. Clean the top surface of the housing of all paint
and dirt.

2. Check the direction of rotation of the fuel pump camshaft. For an engine with standard rotation, the
"F" mark and arrow on the end of the fuel pump camshaft will be at the front end of the pump housing.
For an engine with opposite rotation the "F" mark and arrow on the end of the fuel pump camshaft will
be at the rear end of the pump housing.

3. Install timing plate (1) on shaft (2) with bolt (6) and washer (5). Put the timing plate and shaft on the
fuel pump camshaft at the rear of the pump housing. The key in shaft (2) must be in alignment and
engage in the slot in the camshaft.

4. Install pointer (3) over the dowel in the top of the pump housing at the rear. Install the bolt (4).

5. In the chart, find the timing plate setting for the lifter that is to be set. Turn the timing plate to this
setting in the direction of camshaft rotation. The direction of camshaft rotation as seen from the rear of
the pump housing is counterclockwise for standard rotation engines and is clockwise for opposite
rotation engines. The degree marking on the timing plate must be in alignment with the inside edge (9)
of pointer (3).

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TOOLS INSTALLED
1. 1P7410 Plate. 3. 1P7415 Pointer. 9. Edge of pointer. A. Timing dimension to be measured.

6. Use the 6F6922 Depth Micrometer or the 5P4165 Dial Indicator Group and measure timing
dimension (A). Timing dimension (A) is the distance from the top surface of the fuel pump housing to
the fuel pump plunger contact surface in the yoke of the lifter. The measurement for timing dimension
(A) is 2.1565 ± .0005 in. (54.775 ± 0.013 mm) for all engines. Use wrenches (7) and (8) to adjust the
yoke of the lifter to the correct timing dimension.

The fuel injection pumps are numbered in order from front to rear on all engines

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Ver imagen

7. Set each lifter in the firing order (injection sequence) of the engine. Make reference to the CHART
FOR FIRING ORDER. Check the timing dimension for each lifter again after an adjustment has been
made and the locknut tightened.

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5P4165 DIAL INDICATOR GROUP INSTALLED
A. Timing Dimension.

Fuel Rack Adjustment

9S240 Rack Position Tool Group

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9S240 RACK POSITION TOOL GROUP
1. 8S4627 Circuit Tester. 2. 9S227 Bracket Group. 3. 8S2283 Dial Indicator. 4. 8S3675 Contact Point, .125 in. (3.18 mm)
long. 5. 9S8519 Plug. 6. 9S8521 Rod.

1. Remove the air-fuel ratio control. Disconnect the governor control linkage from the governor lever.

2. Remove the speed limiter access plug. Install plug (5). Through the opening in the plug, install rod (6)
and push in the speed limiter plunger. Tighten the plug to cause a clamp action on the rod. This will let
the governor control lever move through its complete length of travel.

3. Remove timing pin (7), clamp (8), and the plug and seal behind the clamp.

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COMPONENT LOCATION
7. Timing pin. 8. Clamp.

4. Fasten bracket (2) to the fuel pump housing. Move the governor lever to the fuel on position and
install dial indicator (3) with contact point (4) on bracket (2).

5. Put spacer (9) between the flange on the rod and the bracket. Push the flange toward the fuel pump
housing to hold the spacer tight and adjust the dial indicator so that the revolution counter is at zero.
Tighten the clamp for the indicator. Turn the dial of the indicator until the zero is in alignment with the
hand. Remove the spacer.

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BRACKET GROUP AND INDICATOR INSTALLED

9. Spacer. 10. Dust cover.

6. Put the clip end of tester (1) on the brass terminal on the side of the governor. Put the other end of the
tester to a good electrical ground.

7. Remove dust cover (10) from the dial indicator. Move the governor control lever in the fuel on
direction until the tester light becomes bright and fasten lever in this position.

8. Push on the stem of the dial indicator that was under the dust cover to keep a small amount of
pressure on the fuel rack. Use a 1 1/4 in. open end wrench on rack shutoff lever (11) and move the lever
in the fuel off direction until the tester light becomes a dim light.

NOTE: The hydraulic servo-valve that moves the rack when the engine is running, does not have a
direct connection with the rack when the engine is not running. The rack can go beyond the set position
approximately .100 in. (2.54 mm). Because of this, the rack setting must be checked with an application
of force against the rack in the FUEL-OFF direction to remove the free movement between the rack and
the stop collar in the governor.

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RACK SHUTOFF LEVER

11. Rack shutoff lever.

9. Read the rack setting measurement on the dial indicator. Make reference to the RACK SETTING
INFORMATION for the correct rack setting dimension.

10. To adjust the fuel rack setting, loosen the locknut on adjustment screw (12) and turn as needed.
Tighten the locknut and check the rack setting again.

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FUEL RACK ADJUSTMENT

12. Adjustment screw.
11. After the adjustment procedure is done, tighten the adjustment screw locknut to a torque of 9 ± 3
lb.ft. (12 ± 4 N·m).

NOTE: The same tools that are used in this procedure are also used for the air-fuel ratio control
adjustment.

Air-Fuel Ratio Control Adjustment

NOTE: The same tools are needed for the air-fuel ratio control adjustment that were used for the fuel
rack setting. Make reference to the FUEL RACK ADJUSTMENT for the tools needed and instructions
to install the tools.

Air-Fuel Ratio Control Setting

The fuel rack setting must be correct before the air-fuel ratio control can be adjusted. Make reference to
FUEL RACK SETTING. The air-fuel ratio control setting is done with the control on the engine.

1. Remove the override control and cover (1).

2. Turn bolt (2) with cover (1) clockwise until the circuit tester light comes on.

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SETTING AIR FUEL RATIO CONTROL

1. Cover. 2. Bolt.

3. Use the 1 1/4 in. wrench and turn shutoff lever until light just goes off. Check the dial indicator
reading to be sure the fuel rack setting is at the specified setting.

4. Move the fuel rack until the tester light just comes on (dim light). Turn cover (1) counterclockwise
until the tester light goes out. Mark the cover and the air-fuel ratio control for reference.

NOTE: When cover (1) is used to turn bolt (2), one revolution of the cover counterclockwise will
cause .090 in. (2.29 mm) restriction of the rack. Rotation of the cover the distance of one hole will
give .015 in. (0.38 mm) adjustment.

5. Make reference to the RACK SETTING INFORMATION for the correct air-fuel ratio control setting,
and turn the cover counterclockwise the number of turns plus any part of a turn for better hole alignment
to get the correct dimension.
6. Install the cover, override control, and lock wire and seal. Remove the rack setting tools.

Override Control Lever Adjustment

The override control lever adjustment is made with the air-fuel ratio control off the engine.

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OVERRIDE CONTROL LEVER ADJUSTMENT

3. Override control lever. 4. Screw. 5. Nut.

1. Put the override control lever (3) in the start position.

2. Put bolt (2) in a vise and pull on the control. At first movement of the bolt, the control lever must
move fast to the run position.

3. If the control lever does not move correctly put a screwdriver in the slot of adjustment screw (4) and
loosen locknut (5). Turn the adjustment screw 1/4 of a turn counterclockwise and tighten the locknut.
Do this procedure until the control lever moves correctly.

Diaphragm Test

The diaphragm test is made with the air-fuel ratio control off the engine. An air supply and a pressure
regulator are needed to do this test.

1. Connect a line from the air pressure regulator to port (6) of the air-fuel ratio control.

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DIAPHRAGM TEST
2. Bolt. 6. Port. 7. Diaphragm.

2. Adjust the pressure regulator to 5 psi (35 kPa). Bolt (2) must start to move.

3. Adjust the pressure regulator to 16.5 to 20.5 psi (114 to 142 kPa). The bolt must now be fully
extended.

4. Adjust the pressure regulator to 35 psi (240 kPa) and turn off the air pressure to the air-fuel ratio
control. The air pressure must not drop more than 2 psi (14 kPa) in 10 seconds.

Governor Adjustments
4S6553 Instrument Group.
1P7448 Mechanical Tachometer Cable.

NOTICE
A mechanic with training in governor adjustments is the only one to
make the adjustment to the low idle and high idle rpm. The correct low
idle and high idle rpm, and the measurement for the adjustment of the
fuel rack are in the RACK SETTING INFORMATION and on the
ENGINE INFORMATION PLATE installed on the engine.

Engine rpm must be checked with an accurate tachometer. The 1P7443 Tachometer and the 1P7448
Mechanical Tachometer Cable (from the 4S6553 Instrument Group) can be used.

1. Connect one end of the 1P7448 Mechanical Tachometer Cable to the tachometer drive on the front of
the engine.

NOTE: On engines that have opposite rotation, connect the end of the tachometer cable to the side of
the tachometer drive that has the adapter.

2. Connect the other end of the tachometer cable to the instrument used to measure engine speed.

NOTE: The 1P7448 Mechanical Tachometer Cable can be connected to any of the instruments shown
in article MEASURING ENGINE SPEED.

To help prevent an accident caused by parts in rotation, work carefully

around an engine that has been started.

3. Start the engine and check the low idle and high idle rpm. See the RACK SETTING
INFORMATION, or look at the ENGINE INFORMATION PLATE installed on the engine, for the
correct low idle and high idle rpm.

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GOVERNOR ADJUSTMENTS
1. High idle screw. 2. Retainer holes. 3. Low idle screw. 4. Cover.
4. If an adjustment is necessary, remove cover (4) and use the procedure that follows:

a. Move the governor control to HIGH IDLE position and turn screw (1) to adjust HIGH IDLE
rpm. When the specific rpm setting is made, move the governor control to reduce engine speed,
then move the linkage to HIGH IDLE and check the setting again. Repeat this procedure until rpm
setting is correct.

b. To adjust the LOW IDLE rpm, move the governor linkage to LOW IDLE position and turn
screw (3). Increase the engine speed and then return linkage back to LOW IDLE position to check
the setting again.

c. When governor adjustment is correct, install the cover on the rear of the governor. When the
cover is installed on the governor, the idle adjustment screws fit into retainer holes (2) in the
cover. The shape of the holes will not let the idle adjustment screw turn after the idle adjustment is
done and the cover is installed.

d. Now install a new wire and seal to the cover bolt.

Measuring Engine Speed

5P2150 Engine Horsepower Meter or4S6553 Instrument Group or1P5500 Portable Phototach Group.

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5P2150 ENGINE HORSEPOWER METER

The 5P2150 Engine Horsepower Meter can measure engine speed from the tachometer drive on the
engine. Special Instruction Form No. SMHS7050 has instructions for its use.

Special Instruction Form No. SEHS7341 is with the 4S6553 Engine Test Group and gives instructions
for the test procedure.

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4S6553 INSTRUMENT GROUP
1. Differential pressure gauges. 2. Zero adjustment screw. 3. Lid. 4. Pressure gauge. 5. Pressure tap fitting. 6. Tachometer. 7.
Manifold pressure gauge.

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1P5500 PORTABLE PHOTOTACH GROUP

The 1P5500 Portable Phototach Group can measure engine speed from the tachometer drive on the
engine. It also has the ability to measure engine speed from visual engine parts in rotation. Special
Instruction Form No. SMHS7015 has instructions for its use.

Camshaft Cluster Gear Installation

1. Install the small cluster gear (2), the thrust washer and the retainer and tighten to torque of 60 to 70
lb.ft. (80 to 95 N·m).

NOTE: Make sure the No. 1 piston is at top center on the compression stroke.

2. Mark the cluster gear C-mark and the crankshaft gear punch marked tooth with chalk. The back of the
gears can be marked for checking with a mirror after installation.

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INSTALLING CLUSTER GEAR
1. Large cluster gear. 2. Small cluster gear. 3. Retainer. 4. A-marks. 5. Dowel. 6. Alignment mark for flywheel installation. 7.
Hole in crankshaft flange.

3. Install a large cluster gear (1) so the C-mark on the cluster gear is in alignment with the punch marks
on the tooth of the crankshaft gear. Do this by looking through the hole (7) in the crankshaft flange.

4. On 8 cylinder engines, tilt the large cluster gear and turn the balancer gear until the A-marks (4) are in
alignment.

5. With the timing marks in alignment, slide the large cluster gear over the dowel (5) in the small cluster
gear and install the mounting bolts.

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CHECKING ALIGNMENT WITH MIRROR AND CHALK ON BACK OF GEARS

Timing Balancer Gear In Accessory Drive (D379 Only)

NOTE: The gears of the accessory drive for 12 and 16 cylinder engines do not need to be timed.

V-8 Engines With Standard Rotation

Install the main idler gear with the "C" mark in alignment with the tooth of the crankshaft gear that has
four, five or six punch marks. Also, the "B" mark on the main idler gear must be in alignment with the
"B" mark on the balancer gear.

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SAE STANDARD ROTATION 8 CYLINDER ENGINE

V-8 Engines With Opposite Rotation

Install the idler gear with one of the "R" marks in alignment between two teeth on the crankshaft gear
that have two punch marks on each tooth.

The other "R" mark on the idler gear must be in alignment with the "R" mark on the balancer gear.

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SAE OPPOSITE ROTATION 8 CYLINDER ENGINE

Air Inlet And Exhaust System

Restriction Of Air Inlet And Exhaust
There will be a reduction of horsepower and efficiency of the engine if there is a restriction in the air
inlet or exhaust system.

Air flow through the air cleaner must not have a restriction (negative pressure difference measurement
between atmospheric air and air that has gone through air cleaner) of more than 30 in. (762 mm) of
water.

Back pressure from the exhaust (pressure difference measurement between exhaust at outlet elbow and
atmospheric air) must not be more than 27 in. (685 mm) of water.

Measurement Of Pressure In Inlet Manifold

The efficiency of an engine can be checked by making a comparison of the pressure in the inlet manifold
with the information given in the RACK SETTING INFORMATION. This test is used when there is a
decrease of horsepower from the engine, yet there is no real sign of a problem with the engine.

The correct pressure for the inlet manifold is given in the RACK SETTING INFORMATION.
Development of this information is done with these conditions.

a. 29.4 in. (747 mm) of mercury barometric pressure.

b. 85° F (29° C) outside air temperature.
c. 35 API rated fuel.

Any change from these conditions can change the pressure in the inlet manifold. Outside air that has
higher temperature and lower barometric pressure than given above will cause a lower horsepower and a
lower inlet manifold pressure measurement than given in the RACK SETTING INFORMATION.
Outside air that has a lower temperature and a higher barometric pressure will cause higher horsepower
and a higher inlet manifold pressure measurement.

A difference in fuel rating will also change horsepower and the pressure in the inlet manifold. If the fuel
is rated above 35 API, pressure in the inlet manifold can be less than given in the RACK SETTING
INFORMATION. If the fuel is rated below 35 API, the pressure in the inlet manifold can be more than
given in the RACK SETTING INFORMATION. BE SURE THAT THE AIR INLET AND EXHAUST
DO NOT HAVE A RESTRICTION WHEN MAKING A CHECK OF PRESSURE IN THE INLET
MANIFOLD.

Use the 4S6553 Instrument Group to check engine rpm and the pressure in the inlet manifold.

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4S6553 INSTRUMENT GROUP

1. Differential pressure gauges. 2. Zero adjustment screw. 3. Lid. 4. Pressure gauge. 5. Pressure tap fitting. 6. Tachometer. 7.
Manifold pressure gauge.

This instrument group has a tachometer to read engine rpm. It also has a gauge to read pressure in the
inlet manifold. Special Instruction Form No. SEHS7341 is with the tool group and gives instructions for
the test procedure.

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1P3060 PYROMETER GROUP

Use the 1P3060 Pyrometer Group to check exhaust temperature. Special Instruction Form No.
SMHS7179 is with the tool group and gives instructions for the test procedure.

Water Directors
There are eight water directors (1) pressed into each cylinder head to direct the flow of coolant. On the
exhaust side, coolant is directed toward the precombustion chambers and the exhaust valve ports; and on
the inlet side, toward the other side of the valve ports, as indicated by the V-marks.

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WATER DIRECTORS
1. Water director. 2. Ferrule. 3. Seal.

Water directors are pressed into place in the heads after aligning the notch on the director with the V-
mark on the head.

Replacement type seals (3) and ferrule (2) go between the head and top of the block. Put soap on the
inner surface of the seal and place the groove in the seal over the ridge on the ferrule before installing.
Use the FT117 Seal and Ferrule Assembly Tool to install the seal on the ferrule.

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FT117 SEAL AND FERRULE ASSEMBLY TOOL

4. 5H3182 Pin.

5. 2A3672 Spring.

6. Flat Washer.

7. Chain.

8. Upper Rod

9. Connecting Pin.

10. Bracket.

11. Connecting Joint.

12. Lower Rod.

13. Base.

A. Rubber Seals.

B. Ferrule.

Precombustion Chamber
Use the 5F9217 Tool Group to remove and install chamber. Coat threads with 5P3931 Anti-Seize
Compound and use either 1P8005 or 1P8004 gasket to position precombustion chamber.

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PRECOMBUSTION CHAMBER POSITIONING DIAGRAM
A. Parallel to centerline of crankshaft. B. No go range. C. Go (grey) range.

Install 1P8005 gasket marked "3J". Install precombustion chamber and tighten to torque of 225 ± 15
lb.ft. (305 ± 20 N·m). If the glow plug opening is not positioned in the grey range (C) remove the
chamber and replace gasket with the 1P8004 Gasket marked "3D".

Crankcase (Crankshaft Compartment) Pressure

Pistons or rings that have damage can be the cause of too much pressure in the crankcase. This condition
will cause the engine to run rough. There will also be more than the normal amount of fumes coming
from the crankcase breather. This crankcase pressure can also cause the element for the crankcase
breather to have a restriction in a very short time. It can also be the cause of oil leakage at gaskets and
seals that would not normally have leakage.

Compression
An engine that runs rough can have a leak at the valves, or have valves that need adjustment. Use the
test that follows for a fast and easy method to find a cylinder that has low compression, or does not have
good fuel combustion. Find the speed that the engine runs the roughest, and keep the engine at this rpm
until the test is finished. Loosen a fuel line nut at fuel injection pump to stop the flow of fuel to that
cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine
performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened.
This test can also be an indication that the fuel injection is wrong, so the cylinder will have to be
checked thoroughly.

A cylinder leakage test that uses air pressure in the cylinder can be used to indicate the condition of the
piston rings, valves, and valve seats. Make reference to SPECIAL INSTRUCTION FORM NO.
GMG00694 for a list of tools needed and the test procedure. Removal of the head and inspection of the
valves and valve seats is necessary to find those small defects that do not normally cause a problem.
Repair of these problems is normally done when reconditioning the engine.
Cylinder Head
The cylinder head has valves, valve seat inserts, and valve guides that can be removed when they are
worn or have damage. Replacement of these components can be made with the tools that follow.

Valves

The illustration shows the 5S1330 Valve Spring Compressor Assembly with the 5S1329 Jaw (1) to put
the valve spring under compression. When installing the valve keepers, use the 5S1322 Valve Keeper
Installer (2) with the compressor assembly.

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COMPRESSING VALVE SPRINGS

1. 5S1329 Jaw. 2. 5S1322 Valve Keeper Installer.

Valve Seat Inserts

Tools needed to remove and install seat inserts are in the 9S3080 Valve Insert Puller Group. Special
Instruction Form No. GMG02114 gives an explanation for this procedure. For easier installation, lower
the temperature of the insert before it is installed in the head.

Valve Guides

The intake and exhaust valves operate in replacement type valve guides. After the valves have been
removed, clean the valve stems and valve guides. Use the 5P3536 Valve Guide Measuring Group to
check the valve guides for wear. Instructions are in Special Instruction (GMG 02562).

The 4H446 Driver and 5P1726 Bushing is used for installation of new valve guides.

Valve Lash Adjustment And Check

Valve lash is checked and adjusted with the engine stopped.

NOTE: When the valve lash (clearance) is checked, adjustment is NOT NECESSARY if the
measurement is in the range given in the chart for VALVE CLEARANCE CHECK: ENGINE
STOPPED. If the measurement is outside this range, adjustment is necessary. See the chart for VALVE
CLEARANCE SETTING: ENGINE STOPPED, and make the setting to the nominal (desired)
specifications in this chart.

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To make an adjustment to the valve clearance, loosen the locknut on the adjustment screw. Turn the
adjustment screw to get the correct clearance shown in the chart VALVE CLEARANCE SETTING:
ENGINE STOPPED. Hold the adjustment screw and tighten the locknut to 40 ± 5 lb.ft. (55 ± 7 N·m).
Recheck the valve clearance. Valve clearance adjustment can be made by using the procedure that
follows:

1. Determine the normal direction of crankshaft rotation. See the decal on the flywheel housing.

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FLYWHEEL ROTATION DECAL

2. Put No. 1 piston at top center (TC) on the compression stroke. Make reference to LOCATING TOP
CENTER COMPRESSION POSITION FOR NO. 1 PISTON.

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ADJUSTING VALVE LASH

3. With No. 1 piston at top center of the compression stroke, adjust the clearance for the valves shown in
the chart NO. 1 PISTON ON COMPRESSION STROKE.

4. Turn the crankshaft one revolution in the direction of normal rotation and align the pointer and the
TC1 mark on the flywheel. The engine now is at top center exhaust stroke No. 1 piston.

5. With No. 1 piston at top center on the exhaust stroke, adjust the clearance for the valves shown in the
chart NO. 1 PISTON ON EXHAUST STROKE.

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CYLINDER AND VALVE LOCATION

Lubrication System
One of the problems in the list that follows will generally be an indication of a problem in the
lubrication system for the engine.

TOO MUCH OIL CONSUMPTION

OIL PRESSURE IS LOW

OIL PRESSURE IS HIGH

TOO MUCH BEARING WEAR

Too Much Oil Consumption

Oil Leakage on Outside of Engine

Check for leakage at the seals at each end of the crankshaft. Look for leakage at the oil pan gasket and
all lubrication system connections. Check to see if oil comes out of the crankcase breather. This can be
caused by combustion gas leakage around the pistons. A dirty crankcase breather will cause high
pressure in the crankcase, and this will cause gasket and seal leakage.

Oil Leakage Into Combustion Area of Cylinders

Oil leakage into the combustion area of the cylinders can be the cause of blue smoke. There are four
possible ways for oil leakage into the combustion area of the cylinders:

1. Oil leakage between worn valve guides and valve stems.

2. Worn or damaged piston rings, or dirty oil return holes.
3. Compression ring not installed correctly.
4. Oil leakage past the seal rings in the impeller end of the turbocharger shaft.

Too much oil consumption can also be the result if oil with the wrong viscosity is used. Oil with a thin
viscosity can be caused by fuel leakage into the crankcase, or by increased engine temperature.

Measuring Engine Oil Pressure

5P6225 Hydraulic Test Box.9S9102 Thermister Thermometer Group.

An oil pressure gauge that has a defect can give an indication of low oil pressure.

An 8M2744 Oil Pressure Gauge which is part of the 5P6225 Hydraulic Test Box can be used to check
oil pressure in the system.

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This procedure must be followed exactly for the pressure readings to have any value for comparison
with Engine Oil Pressure Chart.

1. Be sure that the engine is filled to the correct level with SAE 30 oil. If any other viscosity of oil is
used, the information in the Engine Oil Pressure Chart does not apply.

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5P6225 HYDRAULIC TEST BOX

2. Connect the 8M2744 Gauge from the 5P6225 Hydraulic Test Box to one of the ports in the back side
of the governor or governor drive housing. Remove the pipe plug on the oil outlet elbow on the oil
cooler and install a probe from the 9S9102 Thermistor Thermometer Group.

3. Start the engine and run to get the oil temperature to 200 ± 10° F (93 ± 6° C).

4. Keep the oil temperature constant with the engine speed at 1200 rpm. Make a comparison of the
gauge reading and the chart.

If the results do not fall within the pressure range given in the chart, find the cause and correct it. Engine
failure or a reduction in engine life can be the result if engine operation is continued with oil manifold
pressure outside this range.

Oil Pressure Is Low

Crankcase Oil Level

Check the level of the oil in the crankcase. Add oil if needed. It is possible for the oil level to be too far
below the oil pump supply tube. This will cause the oil pump to not have the ability to supply enough
lubrication to the engine components.

Oil Pump Does Not Work Correctly

The inlet screen of the supply tube for the oil pump can have a restriction. This will cause cavitation
(low pressure bubbles suddenly made in liquids by mechanical forces) and a loss of oil pressure. Air
leakage in the supply side of the oil pump will also cause cavitation and loss of oil pressure. If the
bypass valve for the oil pump is held in the open (unseated) position, the lubrication system can not get
to maximum pressure. Oil pump gears that have too much wear will cause a reduction in oil pressure.

Oil Filter and Bypass Valve

As the oil filters become filled with dirt, a reduction of engine oil pressure will be seen until oil filter
bypass valve (1) opens. When the bypass valve opens, unfiltered oil will go through the engine.

When the oil pressure on the clean side (inside) of the elements becomes 12 to 15 psi (85 to 105 kPa)
less than the oil pressure to the unfiltered side (outside) of the elements, filter condition indicator (2) or
(3) will move up approximately half way. This shows that the oil filter elements must be changed.

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OIL FILTER BYPASS VALVE

1. Valve.

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FILTER CONDITION INDICATOR

2. Later Indicator. 3. Earlier Indicator.

Too Much Clearance at Engine Bearings or Open, Broken or Disconnected Oil Line or
Passage in Lubrication System

Components that are worn and have too much bearing clearance can cause oil pressure to be low. Low
oil pressure can also be caused by an oil line or oil passage that is open, broken or disconnected.

Oil Cooler
Look for a restriction in the oil passages of the oil cooler.

If the oil cooler has a restriction the oil temperature will be higher than normal when the engine is
running. The oil pressure of the engine will become low if the oil cooler has a restriction.

Oil Pressure Is High

Oil pressure will be high if the pressure regulating valve for the oil pump can not move from the closed
position.

Too Much Bearing Wear

When some components of the engine show bearing wear in a short time, the cause can be a restriction
in an oil passage. A broken oil passage can also be the cause.

If the gauge for oil pressure shows the correct oil pressure, but a component is worn because it is not
getting enough lubrication, look at the passage for oil supply to that component. A restriction in a supply
passage will not let enough lubrication get to a component and this will cause early wear.

Turbocharger Lubrication Valve

(D379 and D398 Engines)

When the gauge for oil pressure shows the correct oil pressure and bearing failure or wear is present in
both turbochargers, check the operation of the turbocharger lubrication valve. The valve can be open and
allow unfiltered oil to constantly lubricate the turbocharger.

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TURBOCHARGER LUBRICATION VALVE AT RIGHT REAR OF ENGINE

Cooling System
The engine has a pressure type cooling system. A pressure type cooling system gives two advantages.
The first advantage is that the cooling system can operate at a temperature that is higher than the normal
point where water changes to steam. The second advantage is that this type system prevents cavitation
(air in inlet of pump) in the water pump. With this type system it is more difficult to have an air or steam
pocket in the cooling system.

The cause for an engine getting too hot is generally because regular inspections of the cooling system
were not done. Make a visual inspection of the cooling system before a test is made with test equipment.

Visual Inspection Of The Cooling System

1. Check coolant level in the cooling system.

2. Look for leaks in the system.

3. Look for bent radiator fins. Be sure that air flow through the radiator does not have a restriction.

4. Inspect the drive for the fan.

5. Check for damage to the fan blades.

6. Look for air or combustion gas in the cooling system.

7. Inspect the pressure relief valve and the sealing surface of the filler cap. The sealing surface must be
clean.

8. Look for large amounts of dirt in the radiator core and on the engine.

Testing The Cooling System

Remember that temperature and pressure work together. When making a diagnosis of a cooling system
problem, temperature and pressure must both be checked. Cooling system pressure will have an effect
on cooling system temperatures. For an example, look at the chart to see the effect of pressure and the
height above sea level on the boiling point (steam) of water.

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Test Tools for Cooling System

9S9102 Thermistor Thermometer Group.9S7373 Air Meter Group.1P5500 Portable Phototach

Group.9S8140 Cooling System Pressurizing Pump Group.

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9S9102 THERMISTOR THERMOMETER GROUP

The 9S9102 Thermistor Thermometer Group is used in the diagnosis of heating problems. The testing
procedure is in Special Instruction Form No. SMHS7140.

The 9S7373 Air Meter Group is used to check the air flow through the radiator core. The testing
procedure is in Special Instruction Form No. SMHS7063.

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9S7373 AIR METER GROUP

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1P5500 PORTABLE PHOTOTACH GROUP

The 1P5500 Portable Phototach Group is used to check the fan speed. The testing procedure is in
Special Instruction Form No. SMHS7015.

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9S8140 COOLING SYSTEM PRESSURIZING PUMP GROUP

The 9S8140 Cooling System Pressurizing Pump Group is used to test pressure caps and pressure relief
valves, and to pressure check the cooling system for leaks.

Water Temperature Regulators

Use the procedure that follows to check the operation of the water temperature regulator:

1. Remove the regulator from the engine.

2. Heat water in a pan until the temperature is correct for opening the regulator according to the chart.
Move the water around in the pan to make it all be the same temperature.

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 the water at the correct temperature for 10 minutes.

5. Remove the regulator from the water. Immediately make a measurement of the distance the regulator
is open.

6. If the regulator is open to a distance less than given in the chart, install a new regulator.

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Gauge for Water Temperature

9S9102 Thermistor Thermometer Group

To check the accuracy of the water temperature gauge, use the 9S9102 Thermistor Thermometer Group.
Special Instruction Form No. SMHS7140 has instructions for the use of the 9S9102 Thermistor
Thermometer Group.

Remove the plug next to the sensor unit for the water temperature gauge in the water outlet manifold.
Install reducing bushing and probe in this hole.

Start the engine and get the coolant warm. Make a comparison of the temperature at positions 1 and 2 on
the water temperature gauge and the temperature on the thermistor thermometer. Use the chart to find
the temperature at positions 1 and 2.

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Coolant Level Switch

Testing

Lower the coolant level in the system to cause the float (1) to lower and cause the switch points to make
contact. This can be done by removing some of the coolant or with application of 10 to 20 psi (70 to 140
kPa) of air pressure to the vent line connection (2) on top of the switch. Look at the float and switch as
the coolant level lowers. The float position on the later type switch is shown by the switch operating arm
(4). The device connected will be activated as the points make contact.

Adjustment

The terminal screw (3) on the bottom of the earlier switch can be turned in to raise and out to lower the
level at which the points will make contact.

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COOLANT LEVEL SWITCH (Earlier Type)
1. Float. 2. Vent line connection. 3. Terminal screw.

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COOLANT LEVEL SWITCH (Later Type)

2. Vent line connection. 4. Switch operating arm. 5. Switch.
Basic Block
Connecting Rods And Pistons
Use the 5H9621 Piston Ring Expander to remove or install piston rings.

Use the 5P3528 Piston Ring Compressor to install pistons into cylinder block.

Tighten the connecting rod bolts in the step sequence that follows:

1. Put crankcase oil on threads.

2. Tighten all nuts to 40 ± 4 lb.ft. (55 ± 5 N·m).

3. Put a mark on each nut and cap.

4. Tighten each nut 120° from the mark.

The connecting rod bearings should fit tightly in the bore in the rod. If bearing joints or backs are worn
(fretted), check for bore size as this is an indication of wear because of looseness.

Piston Ring Groove Gauge

A 5P3519 Piston Ring Groove Gauge is available for checking ring grooves with straight sides. For
instructions on the use of the gauge, see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND
CYLINDER LINERS, Form No. SEBF8001.

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5P3519 PISTON RING GROOVE GAUGE

Connecting Rod And Main Bearings

Main bearings are available with .050 in. (1.27 mm) smaller inside diameter than original size bearings.
These bearings are for crankshafts that have been "ground" (made smaller than original size).

Connecting rod bearings are available with .025 in. (0.64 mm) and .050 in. (1.27 mm) smaller inside
diameter than original size bearings. These bearings are also available with .010 in. (0.25 mm) larger
outside diameter than original size bearings. These bearings are for connecting rods that have been
"bored" (made larger than original size).

Cylinder Block
Bore in block for main bearings can be checked with main bearing caps installed without bearings.
Tighten the stud nuts to torque shown in the SPECIFICATIONS. Alignment error in the bores must not
be more than .003 in. (0.08 mm).

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1P3537 DIAL BORE GAUGE GROUP

Special Instruction Form No. GMG00503 gives the use of 1P4000 Line Boring Tool Group to machine
main bearing bores. 1P3537 Dial Bore Gauge Group can be used to check bores. Special Instruction
Form No. GMG00981 is with the group.

Cylinder Liner Projection

1P2398 Puller Plate8B7548 Push Puller Crossbar and three 3H465 Plates.8S3140 Cylinder Block
Counterboring Tool Arrangement.1P5510 Liner Projection Tool Group.

The correct cylinder liner projection is important to prevent a leak between the liner, cylinder head and
block. Use the procedure that follows to check cylinder liner projection.

1. Make sure that the bore and counterbore in the block and the liner flange are clean. Install the cylinder
liner without seals in the cylinder block.

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MEASURING LINER PROJECTION
1. 3H465 Plate. 2. Dial indicator. 3. 1P2402 Block. 4. Crossbar. 5. 1P2398 Puller Plate.

2. Put puller plate (5) on the cylinder liner and put plate (1) in the center of the adapter plate as shown.
Install crossbar (4) with nuts, washers, and 3H465 Plates as shown. Tighten the nuts evenly in four
steps: 5 lb. ft. (7 N·m), 15 lb. ft. (20 N·m), 25 lb. ft. (35 N·m), and 50 lb. ft. (70 N·m). The measurement
from the bottom of crossbar (4) to the top of cylinder block, must be the same on both sides of the
cylinder liners.

3. Install the 1P5512 Contact Point on dial indicator (2). Put the dial indicator in the 1P2402 Gauge
Body. To adjust the dial indicator to zero, put dial indicator and gauge body on the back of the 1P5507
Gauge. Move the dial indicator until the hand moves 1/4 turn. Tighten bolt on body to hold the dial
indicator in this position. Turn the dial face until the zero is in alignment with the hand.

4. Measure the cylinder liner projection as close as possible to the four corners of the adapter plate on
the liner. The liner projection must be .004 to .008 in. (0.10 to 0.20 mm). The difference between the
four measurements must not be more than .002 in. (0.05 mm). The maximum difference in height of
liners next to each other under the same cylinder head is .002 in. (0.05 mm).

NOTE: If the liner projection changes from point to point around the liner, turn the liner to a new
position in the bore. If the liner projection is still not to specifications, move the liner to a different bore.

5. When the cylinder liner projection is correct, put a temporary mark on the liner and the cylinder block
so at final installation the liner can be installed in the correct position.

Cylinder liner projection can be adjusted by the removal of material from (machining) the contact face
of the cylinder block with the use of the 8S3140 Cylinder Block Counterboring Tool Arrangement. The
instructions for the use of the tool group are in Special Instruction Form No. FM055228.
Shims are available for adjustment of the liner projection.

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Flywheel And Flywheel Housing

9S2328 Dial Indicator Group

Flywheel Ring Gear

Heat the ring gear to a maximum of 600° F (316° C) to install. Install the ring gear so the chamfer on the
gear teeth is next to the starter pinion when the flywheel is installed.

Face Runout (axial eccentricity) of the Flywheel Housing

If any method other than given here is used, always remember bearing clearances must be removed to
get correct measurements.

Make tool setup from parts of the 8S2328 Dial Test Indicator Group.

1. Fasten a dial indicator to the crankshaft flange so the indicator anvil will touch the flywheel housing
face.

2. Push the crankshaft to the rear to remove all end play before reading the indicator at each point.

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CHECKING FLYWHEEL HOUSING FACE RUNOUT
A. Bottom. B. Right side. C. Top. D. Left side.

3. With dial indicator set at .000 in. (0.0 mm) at point (A), rotate crankshaft and take readings at points
(B), (C) and (D).

4. The difference between the lowest and highest readings taken at all four points should not exceed .012
in. (0.30 mm), which is the maximum permissible flywheel housing face runout.

Bore Runout (radial eccentricity) of the Flywheel Housing

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CHECKING BORE RUNOUT OF THE FYWHEEL HOUSING

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8S2328 DIAL INDICATOR GROUP INSTALLED

NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation (signs).
This notation is necessary for making the calculations in the chart correctly.

1. With the dial indicator in position at (C), adjust the dial indicator to "0" (zero). Push the crankshaft up
against the top bearing. Write the measurement for bearing clearance on line 1 in column (C).

2. Divide the measurement from Step 1 by 2. Write this number on line 1 in columns (B) & (D).

3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0" (zero).

4. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the
chart.

5. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the
chart.

6. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the measurement in the
chart.

7. Add lines I & II by columns.

8. Subtract the small number from the larger number in line III in columns (B) & (D). The result is the
horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.

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9. On the graph for total eccentricity find the point of intersection of the lines for vertical eccentricity
and horizontal eccentricity.

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GRAPH FOR TOTAL ECCENTRICITY

10. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point
of intersection is in the range marked "Not Acceptable", the flywheel housing must be changed.

Face Runout (axial eccentricity) of the Flywheel

1. Install the dial indicator as shown. Move the flywheel to the front or rear to remove all end play.

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CHECKING FACE RUNOUT OF THE FLYWHEEL

2. Set the dial indicator to read .000 in. (0.0 mm).

3. Turn the flywheel and read the indicator every 90°. Be sure to remove end play the same way each
time.

4. The difference between the lower and higher measurements taken at all four points must not be more
than .006 in. (0.15 mm), which is the maximum permissible face runout (axial eccentricity) of the
flywheel.

Bore Runout (radial eccentricity) of the Flywheel

1. Install the dial indicator (3) and make an adjustment of the universal attachment (4) so it makes
contact as shown.

2. Set the dial indicator to read .000 in. (0.0 mm).

3. Turn the flywheel and read the indicator every 90°.

4. The difference between the lower and higher measurements taken at all four points must not be more
than .006 in. (0.15 mm), which is the maximum permissible bore runout (radial eccentricity) of the
flywheel.

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CHECKING BORE RUNOUT OF THE FLYWHEEL
1. 7H1945 Holding Rod. 2. 7H1645 Holding Rod. 3. 7H1942 Indicator. 4. 7H1940 Universal Attachment

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CHECKING FLYWHEEL CLUTCH PILOT BEARING BORE

5. Runout (eccentricity) of the bore for the pilot bearing for the flywheel clutch, must not exceed .005 in.
(0.13 mm).

Checking Crankshaft Deflection (Bend)

The crankshaft can be deflected (bent) because the installation of the engine was not correct. If the
engine mounting rails are not fastened correctly to the foundation mounting rails, the cylinder block can
twist or bend and cause the crankshaft to deflect. This deflection can cause crankshaft and bearing
failure.

The crankshaft deflection must be checked after the final installation of the engine. The check must be
made with the engine cold and also with the engine at the temperature of normal operation. The
procedure that follows can be used to check crankshaft deflection with the engine either cold or warm.

1. Remove an inspection cover from the cylinder block that will give access to the connecting rod
journal of the crankshaft nearest to the center of the engine.

NOTICE
Read the notice on the cylinder block covers before removal of the
covers on a warm engine.

2. Turn the crankshaft in the direction of normal rotation until the center of the counterweights just go
beyond the connecting rod.
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MEASURING DEFLECTION OF THE CRANKSHAFT

1. Dial gauge. 2. Mounting face.

3. Install a Starrett Crankshaft Distortion Dial-Gauge No. 696 with Starrett No. 696B Balancer
Attachment between the counterweights as shown. Put Dial Gauge (1) within .25 in. (6.4 mm) of
counterweight mounting surface (2). Turn the dial of the indicator to get alignment of the zero and the
pointer. Turn the indicator on its end points until the pointer of the indicator will not move from zero.

4. Turn the crankshaft in the direction of normal rotation until the indicator almost makes contact with
the connecting rod on the other side of the crankshaft.

NOTE: Do not let the indicator make contact with the connecting rod.

5. The dial indicator reading must not change more than .001 in. (0.03 mm) for the approximately 300
degrees of crankshaft rotation. Now turn the crankshaft in the opposite direction to the starting position.
The dial indicator must now read zero. If the dial indicator does not read zero, do the procedure again.

If the dial indicator reads more than .001 in.(0.03 mm), the cylinder block is bent. Loosen the bolts that
hold the engine mounting rails to the foundation mounting rails and adjust the shims to make the engine
straight again. Also check to see if the engine mounting bolts have enough clearance to let the engine
have expansion as it gets hot. The only bolts that can have a tight fit are bolts at the right hand rear of
the engine and the right hand rear bolt that holds the engine to the oil pan base.

Vibration Damper
Damage to or failure of the damper will increase vibrations and result in damage to the crankshaft.

If the damper is bent or damaged, or if the bolt holes in the damper are loose fitting, replace the damper.
Replacement of the damper is also needed at the time of crankshaft failure (if a torsional type).

Electrical System
Most of the testing of the electrical system can be done on the engine. The wiring insulation must be in
good condition, the wire and cable connections clean and tight and the battery fully charged. If on the
engine test shows a defect in a component, remove the component for more testing. The wire size, color
and recommendations of length are given in the WIRING DIAGRAMS in SYSTEMS OPERATION.
Battery
9S1990 Battery Charger Tester.

The battery circuit is an electrical load on the charging unit. The load is variable because of the
condition of the charge in the battery. Damage to the charging unit will result, if the connections, (either
positive or negative) between the battery and charging unit are broken while the charging unit is
charging. This is because the battery load is lost and there is an increase in charging voltage. High
voltage will damage, not only the charging unit but also the regulator and other electrical components.

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9S1990 BATTERY CHARGER TESTER

NOTICE
Never disconnect any charging unit circuit or battery circuit cable
from battery when the charging unit is charging.

Load test a battery that does not hold a charge when in use. To do this, put a resistance, across the
battery main connections (terminals). For a 6 volt battery, put a resistance of two times the ampere/hour
rating of the battery. For a 12 volt battery, put a resistance of three times the ampere/hour rating. Let the
resistance remove the charge (discharge the battery) for 15 seconds. Immediately test the battery
voltage. A 6 volt battery in good condition will test 4.5 volts; a 12 volt battery in good condition will
test 9 volts.

The Special Instruction Form No. SEHS6891 with the 9S1990 Charger Tester gives the battery testing
procedure.

Charging System
Battery

The condition of charge in the battery at each regular inspection will show if the charging system is
operating correctly. An adjustment is necessary when the battery is always in a low condition of charge
or a large amount of water is needed (one ounce per cell per week or every 50 service hours).

Test the charging units and voltage regulators on the engine, when possible, using wiring and
components that are a permanent part of the system. Off the engine (bench) testing will give an
operational test of the charging unit and voltage regulator. This testing will give an indication of needed
repair. Final testing will give proof that the units are repaired to their original operating condition.

Before starting on the engine testing, the charging system and battery must be checked. See the
following Steps.

1. Battery must be at least 75% (1.240 Sp.Gr.) full charged and held tightly in place. The battery holder
must not put too much stress on the battery.

2. Cables between the battery, starter and engine ground must be the correct size. Wires and cables must
be free of corrosion and have cable support clamps to prevent stress on battery connections (terminals).

3. Leads, junctions, switches and panel instruments that have direct relation to the charging circuit must
give proper circuit control.

4. Inspect the drive components for the charging unit to be sure they are free of grease and oil and are
able to drive the load of the charging unit.

Alternator Regulator

When an alternator is charging the battery too much or not enough, an adjustment can be made to the
charging rate of the alternator. Remove the hollow head screw (1) from the cover of the alternator
regulator and use a screwdriver to turn the adjustment screw. Turn the adjustment screw one or two
notches to increase or decrease the charging rate of the alternator.

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LOCATION OF ADJUSTMENT SCREW FOR THE 6L5397 and 6L3432 ALTERNATOR REGULATORS
1. Hollow head screw. 2. Connector.

Starting System
When the engine has a prelube system, check it first to be sure all components function correctly. See
PRELUBE SYSTEM. After checking the prelube system, put a wire temporarily between the
connections of the oil pressure switch. This will let the following checks be made which is the same as
checking engines that do not have a prelube system.
Use a D. C. Voltmeter to find starting system components which do not function.

Move the starting control switch to activate the starter solenoid. Starter solenoid operation can be heard
as the pinion of the starter motor is engaged with the ring gear on the engine flywheel. The solenoid
operation also closes the electric circuit to the motor. Connect one lead of the voltmeter to the solenoid
connection (terminal) that is fastened to the motor. Ground the other lead. Activate the starter solenoid
and look at the voltmeter. A reading of battery voltage shows the problem is in the motor. The motor
must be removed for further testing. No reading on the voltmeter shows that the solenoid contacts do not
close. This is an indication of the need for repair to the solenoid or an adjustment to be made to starter
pinion clearance. Pinion clearance is .36 in. (9.1 mm).

If the solenoid for the starting motor will not operate, current from the battery may not be getting to the
solenoid. Fasten one lead of the voltmeter to the connection (terminal) for the battery cable on the
solenoid. Ground the other lead. No voltmeter reading shows there is a broken circuit from the battery.
Further testing is necessary when there is a reading on the voltmeter.

Further test by fastening one voltmeter lead to the connector (terminal) for the small wire at the solenoid
and the other lead to the ground. Look at the voltmeter and activate the starter solenoid. A voltmeter
reading shows that the problem is in the solenoid. No voltmeter reading shows that the problem is in the
starter switch or wiring. Fasten one lead of the voltmeter to the battery wire connection of the starter
switch and ground the other lead. A voltmeter reading indicates a failure in the switch.

A starting motor that operates too slow can have an overload because of too much friction in the engine
being started. Slow operation of the starting motor can also be caused by shorts, loose connections
and/or dirt in the motor.

Pinion Clearance Adjustment (Delco-Remy)

Whenever the solenoid is installed, make an adjustment of the pinion clearance. The adjustment can be
made with the starting motor removed.

1. Install the solenoid without connector (1) from the MOTOR connection (terminal) on solenoid to the
motor.

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CONNECTION FOR CHECKING PINION CLEARANCE
1. Connector from MOTOR terminal on solenoid to motor. 2. SW terminal. 3. Ground terminal.

2. Connect a battery, of the same voltage as the solenoid, to the terminal (2), marked SW.

3. Connect the other side of battery to ground terminal (3).

4. Connect for a moment, a wire from the solenoid connection (terminal) marked MOTOR to the ground
connection (terminal). The pinion will shift to crank position and will stay there until the battery is
disconnected.

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PINION CLEARANCE ADJUSTMENT

4. Shaft nut. 5. Pinion. 6. Pinion clearance.
5. Push the pinion toward commutator end to remove free movement.

6. Pinion clearance (6) must be .36 in. (9.1 mm).

7. Pinion clearance adjustment is made by removing plug and turning nut (4).

Prelube System
The electrical components in this circuit are the pump motor, relay, oil pressure switch and starter
switch. Install a wire around the oil pressure switch to test the components. This must be done with
CAUTION.

Relay

Find the damaged component by first checking to see if there is AC current to the pump motor. Fasten a
wire from the positive (+) side of the battery to the relay terminal (1) to complete the circuit through the
relay coil. The relay must activate and complete the AC circuit and cause the pump motor to run. When
this is done, run the pump long enough to make pressure show on the pressure gauge. During checks
that will follow, engine parts will receive lubrication.

Remove the wire from around the oil pressure switch.

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CHECKING PRELUBE SYSTEM RELAY

1. Relay terminal.

Oil Pressure Switch

With a wire installed between both terminals (1) of the oil pressure switch, engage the starter switch a
moment. If the starter and solenoids engage, then the oil pressure switch has failed and must be replaced
with a new switch. Leave the wire in place if the switch has not failed and check the starter switch.

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PRELUBE SYSTEM OIL PRESSURE SWITCH
1. Terminals.

Starter Switch

Use a wire installed between the starter battery terminal (2) and starter relay terminal (1). If the starter
and solenoids engage, the failure is in the starter switch. If the starter switch has not failed, remove all
wires that were installed for testing. See, STARTING SYSTEM for further checks of the circuit
components of the starting system.

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CHECKING STARTER SWITCH

1. Starter relay terminal. 2. Starter battery terminal.

Engine Shutoff Control

Overspeed Control Adjustment
4S6553 Engine Test Group6L2211 Tachometer Drive GroupFT907 Drive AdapterReversible Variable
Speed Drill

Adjustment of the overspeed control is made at the factory and must not be changed unless the carrier
assembly has been disassembled or the adjustment changed in some way. The original setting of the
overspeed control will stop the engine when the engine rpm is more than 18% above full load rpm. DO
NOT check the adjustment of the overspeed control on the engine.

1. Remove the engine shutoff control and reset cable from the engine.
2. Connect the 1P7443 or 4S6991 Tachometer (part of the 4S6553 Engine Test Group) to 6L2211
Tachometer Drive (E) on control (A).

3. Use FT907 Adapter (C) and reversible variable speed drill (D) to drive the control as shown.

NOTE: When adjustment or check of the overspeed control is made and the oil pressure reset plunger is
not pushed in, a low oil pressure shutoff action will be the result.

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TEST OF OVERSPEED CONTROL

A. Shutoff control. B. 4S6553 Engine Test Group. C. FT907 Adapter. D. Reversible variable speed drill. E. 6L2211
Tachometer Drive Group.

NOTICE
All shutoff controls must be turned counterclockwise.

4. Read the rpm on the tachometer at the moment the control is activated. The reading will give the
engine rpm (2 rpm on the scale for each rpm the input shaft is turned).

5. The control is to activate at a rpm 18% higher than the full load rpm.

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Start, Stop Arrangement 8L5967 needs overspeed to activate at 1500 ± 25 rpm.

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ADJUSTMENT
1. Carrier assembly. 2. Weight adjustment screw. 3. Plug.

6. If an adjustment is needed, remove plug (3). If necessary, turn the drive shaft of the shutoff until the
screw (2) is in alignment with the hole for plug (3).

7. Use a screwdriver to make the adjustment to the overspeed carrier assembly (1). One full turn of
screw (2) will change the maximum overspeed limit 45 to 50 rpm. Turn the screw counterclockwise to
make the setting lower.

8. Check the setting of the overspeed control again after the adjustment is made.

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