Ia Caterpillar Specifications 3304 VehicularEngine Text

CATERPILLAR®

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p(i©Di©iifeira

3304 Vehicular Engine

FORM NO. SENR7590-01

FOR USE IN SERVICE MANUALS:VOLUME I SPECIFICATIONS, REG01312D4 TRACTOR, REG00632D4E TRACTOR, SENR7624D4 SA TRACTOR, REG00784D4E SA TRACTOR, SENR7636NO. 112F MOTOR GRADER, REG00885120G MOTOR GRADER, REG01654130G & 140G MOTOR GRADERS,REG01652225 EXCAVATOR, REG01578518SKIDDER, REG00971920 & 930 WHEEL LOADERS, REG00514941 TRACK-TYPE LOADER, REG00527950 WHEEL LOADER, REG00548951 TRACK-TYPE LOADER, REG00783955 TRACK-TYPE LOADER, REG00634955L TRACK-TYPE LOADER, SENR7364955L TRACK-TYPE LOADER, SENR7672

7Z1-UP

3304 VEHICULAR ENGINES SPECIFICATIONS

INTRODUCTION •'^

The specifications given in this book are on the basis

of infoniiation available at the time it was written. Thespecifications torques, pressures of operation, mea-

surements, adjustments and other items can change at

any time. These changes can effect the service given to

the product. Get the complete and most current infor-

mation before you start any job. Caterpillar Dealers

have the most current information which is available.

For a list of the most current modules and forni numbersavailable for each Service Manual, see the SERVICEMANUAL CONTENTS MICROFICHE REG I 139F.

When the words "use again" are in the description,

the specification given can be used to determine if apart

can be used again. If the part is equal to or within the

specification given, use the part again.

When the word "permissible" " is in the description,

the specification given is the "maximum or minimum"tolerance permitted before adjustment, repair and/or

new parts are needed.

A comparison can be made between the measure-

ments of a worn part, and the specifications of a newpart to find the amount of wear. A part that is worn can

be safe to use if an estimate of the remainder of its

service life is good. If a short service life is expected,

replace the part.

77200X2

NOTE: For Systems Operation and Testing and Adjusting, make reference to

3304 VEHICULAR ENGINES, Form No. SENR7591.

ENGINE DESIGN

Bore 4.75 in. (120.7 mm)Stroke 6.0 in. (152.4 mm)Number of Cylinders 4

Cylinder Arrangement 'in-line

Firing Order (Injection Sequence) 1, 3, 4, 2

Direction of Rotation

(when seen from flywheel end) Counterclockwise*No. 1 Cylinder Is Opposite Flywheel End.

^

EXHAUST VALVES

2 3

INTAKE VALVES

CYLINDER AND VALVE IDENTIFICATION

NOTE: This book has been completely changed from the former issue.^


INDEXAir Inlet and Exhaust System

Air Cleaner 43

Camshaft 37

Cylinder Head 42

Glow Plug Positioning 41

Exhaust Manifold 43

Exhaust Pipe and Muffler 43

Turbocharger 46-51

Turbocharger Impeller Installation 44, 45

Valves (Dl) 40

Valves (PC) 38, 39

Valve Cover 42

Valve Rocker Ar'ms and Lifters 37

Basic Engine ComponentsBearing Surface (Journal)

Connecting Rods 69

Main Bearings 68

Connecting Rod 66

Crankshaft 67

Crankshaft Hub 70

Cylinder Block

Counterbored Block 60

Spacer Plate Block 61

Cylinder Liner 62

Cylinder Liner Projection

Counterbored Block 62

Spacer Plate Block 63

Fan Drive 71

Flexible Drive Coupling 76, 77

Checking and Adjusting Alignment of the

Flexible Drive Coupling 78

Flywheel 73

Flywheel Housing 74

Flywheel Housing Bore 75

Flywheel Housing Tightening 72

Flywheel Ring Gear 72

Main Bearing and Connecting Rod Bearings 70

Pistons and Rings

Keystone 64

Straight Side 65

Cooling System

Coolant Flow Switch 59

Fan Drive 71

Radiator 58

V-Belt Tension Chart 57

Water Pump 57

Water Temperature Regulator 59

Electrical SystemAlternators 79-82

Alternator Regulator 83

Generator Regulators 85-87

Generators 84, 85

Starter Magnetic Switches 92

Starter Motors 88-92

Starter Solenoids 93-95

Engme Design 2

Engine Mounting Bolts 76

Fuel System

Fuel System Timing 6

Fuel System Usage Chart 6

Service Meter 7

Tachometer Drive 7

Fuel System — Scroll (Dl) 31

Fuel Injection 32

Fuel Injection Pump Housing 31

Fuel Transfer Pump 35

Governor 34

Governor Housing 33

Injection Nozzle 33

Fuel System — Scroll (PC) 27

Fuel Bypass Valve 30

Fuel Injection Equipment 27


Governor (Earlier) 28

Governor (Later) 29

Fuel System — Scroll {PC & Dl) 36

Timing Gears 36

Fuel System — Sleeve Metering (Dl) 18

Fuel Injection Equipment 18-20

Fuel Ratio Control 21


Governor Control {D4E) 23

Governor Control (120G & 130G) 22

Governor Control (225) 24


Injection Nozzle 21

Fuel System — Sleeve Metering (PC) 8

Fuel Injection Equipment 8-12

Fuel Ratio Control 13


Governor Control (920 & 930) 14



Governor Control (955L) 15

Fuel System — Sleeve Metering (PC & Dl) 25

Timing Gears 26

Water Separator 25

GaugesConverter Oil Temperature Indicator 97

Fuel Pressure Indicator 96

Oil Pressure Indicator 97

Water Temperature Indicator 96

General Tightening Torques 4

Lubrication SystemEngine Oil Pressure 55

Oil Breather Cap 56

Oil Filter 55, 56

Oil Pump 52-54

Oil Pressure Switch 97

Torque for Flared and O-Ring Fittings 5


GENERAL TIGHTENING TORQUE FOR


TORQUE FOR FLARED AND 0-RING FITTINGSThe torques shown in the chart that follows are to be used on the part of 37° Flared, 45° Flared and

Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.

INVERTED45° FLARED

E f̂e^&aE^^gp

37 FLARED

^^^p^^^r^^^^vsss)

oaa45 FLARED

O-RINGFITTING - PLUG

PBSWIVEL NUTS

TUBESIZE(O.D.)

3.18 4.78 6.35 7.92 9.52

.125 .188 .250 .312 .375

TUBESIZE(O.D.)

12.70 15.88 19.05 22.22 25.40 31.75 38.10 50.80

.500 .625 .750 .875 1.000 1.250 1.500 2.000

THREADSIZE (in.)

5/16 3/8 7/16 1/29/16

5/8

THREADSIZE (in.)

3/4 7/8 1 1/161 3/16

1 1/41 5/16 1 5/8 1 7/8 2 1/2

TORQUEN-m

5

±1

11

+116±2

20±2

30±2

TORQUENm

50±5

55±7

75±7

90±7

110+7

135±15

160±15

310±30

TORQUEIb.in.

45±10

100±10

145±20

175±20

265±25

TORQUElb .ft.

35 ±3 40 ±5 55 ±5 65 ±5 80 ±5 100 ±10 120 ±10 230 ±20

ASSEMBLY OF FITTINGS WITHSTRAIGHT THREADS AND O-RING SEALS

1. Put locknut (3), backup washer (4) and O-ring

seal (5) as far back on fitting body (2) as possible.

Hold these components in this position. Turn the

fitting into the part it is used on, until backupwasher (4) just makes contact with the face of the

part it is used on.

NOTE: If the fitting is a connector (straight fitting) or

plug, the hex on the body takes the place of the locknut.

To install this type fitting tighten the hex against the

face of the part it goes into.

2. To put the fitting assembly in its correct position

turn the fitting body (2) out (counterclockwise) a

maximum of 359°. Tighten locknut (3) to the

torque shown in the chart.

A71009X2

ELBOW BODY ASSEMBLY

1. End of fitting t>ody (connects to tube). 2. Fitting

body. 3. Locknut. 4. Backup washer. 5. 0-rlng seal. 6.

End of fitting that goes Into other part.


FUEL SYSTEM USAGE CHART


SERVICE METER

(EARLIER MODELS)

(II Torque for bolts which hold service meter or adapter

for service meter drive 96 ± 24 lb. in. (10.9 ± 2.8 Nm)

NOTE: Torque for cable nut 50 lb. in. (5.7 N-m)

AI756axl

ELECTRIC SERVICE METER

(LATER MODELS)

6N5906

Polarity is negative ground.

Operating voltage 24V DC only

TACHOMETER DRIVE

n(1) Torque for cable nut 100 ± 20 lb. in. (11.3 + 2.3 N-m)

10.9 ± 2.8 Nm)(2) Tighten bolts which hold adapter for

tachometer drive to 96 t 24 lb. in


(SLEEVE METERING FUEL SYSTEM — PC)

FUEL INJECTION EQUIPMENT

4 5 VIEW A-A

Firing order (injection sequence) 1,3,4,2

Injection timing before TC (top center):

Fuel pump serial numbers to 044, 899 12° 30' + 1°

Fuel pump serial numbers, 044, 900 and up 13° 30' ± 1°

Torque for bolt in tiole for

timing pin 108 ± 36 lb. in. (12.2 ± 4.1 Nm)

Torque for bolts that hold governor vi/eight carrier

tocamshaft 90 ± 101b. in. (10.2 ± 1.1 Nm)

(1) Diameter of rear bearing surface (journal) of the camshaft(new) 2.3720 ± .0005 in. (60.249 ± 0.013 mm)

Bore in the rear bearing for the

camshaft (new) 2.3750 ± .0005 in. (60.325 ± 0.013 mm)

Maximum permissible clearance between the bearingand the camshaft bearing surface (journal)

(worn) 006 in. (0.15 mm)

(2) Diameter of fuel control shaft

(new) 3530 ± .0003 in. (8.966 ± 0.008 mm)

Bore In the housing for fuel control shaft

(new) 3543 ± .0005 in. (8.999 ± 0.013 mm)

Maximum permissible clearance between the borein the housing and the fuel control shaft

(worn) 003 in. (0.08 mm)

(3) End play for camshaft with sleeve installed

(new) 023 ± .018 in. (0.58 ± 0.46 mm)

NOTE: When installing sleeve on end of camshaft, support the cam-shaft to prevent damage to parts inside of injection pump andgovernor housing.

(4) Governor spring:

Make reference to the chart "GOVERNOR SPRINGS."

(5) Bypass valve:

Make reference to the chart "BYPASS VALVE SPRINGS."

(6) Diameter of front bearing surface (journal) of the

camshaft (new) 9990 ± .0005 in. (25.375 ± 0.013 mm)

Bore in the front bearing for the camshaft(new) 1 .0005 ± .0005 in. (25.413 ± 0.013 mm)

Maximum permissible clearance between the bearingand the camshaft bearing surface (journal)

(worn) 003 in. (0.08 mm)

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRSTPAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES



Fuel Injection Equipment (Cont.)

GOVERNOR SPRINGS




A98051X1

((.OF LIFTER

Install guide pin (A) to deptti (B) [.642 ± .003 in. (16.31 ± 0.08 mm)].Slot in guide pin (A) must be in area shown from center of lifter.

(7) Torque for bushing 70 ± 5 lb. ft. (95 ± 7 Nm)

(8) 4N4318 Spring for injection pump:

Length under test force 1 .35 in. (34.3 mm)

Test force 12.5 ± 1.3 lb. (55.5 ± 5.8 N)

Free length after test 1.566 in. (39.78 mm)

Outside diameter 728 in. (18.49 mm)

(9) Torque for bolt holding sleeve oncontrol shaft 24 ± 2 lb. in. (2.8 ± 0.2 Nm)

(10) Torque for the nuts that hold the fuel lines

(Use 5P144 Fuel Line Socket) 30 ± 5 lb. ft. (40 ± 7 Nm)

(11) Torque for the nuts that hold

the nozzles 105 ± 5 lb. ft. (142 ± 7 N)

(12) Body.

(13) Put 5P3931 Anti-Seize Compound on threads of glow plugand tighten to 120 ± 24 lb. in. (13.6 ± 2.8 N-m)

(14) Tighten nozzle finger tight on body.

(15) Torque for precombustion chamber(put 5P3931 Anti-Seize Compoundon threads) 150 ± 10 lb. ft. (205 ± 14 Nm)

NOTE: See Glow Plug Positioning.

10NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRSTPAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES




TYPICAL ILLUSTRATION

(16) Torque tor bolts holding clamps on tuel Injection lines;

With rubber damper 84 ± 24 lb. in. (9.6 ± 2.8 Nm)Without damper 108 ± 36 lb. in. (12.2 ± 4.1 N-m)

(17) Lever assembly.

(18) Clearance between lever assembly (17) and governor

housing when shatt assembly (19) is pulled against

the governor housing 437 in. (1 1 .10 mm)

(20) Spring for the terminal shaft. Install the spring (20) for the termi-

nal shaft so that the end of the spring is in the 30° range as

shown.

9S8597 Spring for terminal shaft:

Color code (stripes) 1 white

Length under test force 584 in. (14.83 mm)

Test force 56.3 lb. (251 N)


Outside diameter 1.635 in. (41.53 mm)

Diameter of wire 135 in. (3.43 mm)

2P726 Spring for terminal shaft:

Color code (stripes) 1 red


Test force 109 lb. (485 N)

Free length after test 1 .04 in. (26.4 mm)

Outside diameter 1.635 in, (41,53 mm)


4N4366 Spring for terminal shaft:


Test force 156 lb. (692 N)

Free length after test 1,016 in. (25,81 mm)

Outside diameter 1-638 in, (41,61 mm)

Diameter of wire 168 in. (4,27 mm)

9L6508 Spring for terminal shaft:

Color code (stripes) 1 yellow

Put a load on spring of 5.00 lb. (22,2 N)

Then make spring shorter by 700 in, (17,78 mm)

Total test force 1970 ± ,52 lb. (87.63 ± 2.31 N)

Free length after test 1 .74 ± ,02 in, (44,2 ± 0,5 mm)

Outside diameter 1,518 in. (38,56 mm)

fet^^-^ZZZZ^

AI0Z90X1

11




) -^r-n

(21) 9S8632 Low Idle Spring:

Length under test force 1 .20 In. (30.5 mm)

Test force 40 ± 4 lb. ft. (180 ± 18 N)

Free lengttn after test 2.00 in. (50.8 mm)





FUEL TRANSFER PUMP

(1) Diameter of shaft for idler gear

(new) 4914 ± .0003 in. (12.482 ± 0.008 mm)

Bore in idler gear

(new) 4926 ± .0003 in. (12.512 ± 0.008 mm)

(2) Thickness of gears

(new) 3736 ± .0003 in. (9.489 ± 0.008 mm)

Depth of counterbore

(new) 3750 ± .0005 in. (9.525 ± 0.013 mm)

Clearance between end of gears and surface of pump body(new) 0006 to .0022 in. (0.01 5 to 0.056 mm)

FUEL RATIO CONTROL

SPRINGS FOR FUEL RATIO CONTROL



GOVERNOR CONTROL(920 & 930 Wheel Loaders)

OFF

L>nCIZI3-e,

B41 448X1

LINKAGE ADJUSTMENT PROCEDURE:

1 With the governor in the OFF position, install lever (1) at angle(B). Adjust the length of rod (6) by turning rod ends (2) and (3)

so lever (4) is at angle (C).

Move lever (1) to HIGH IDLE position and adjust rod (8) byturning rod ends (7) and (9) so pedal (5) is at angle (A).

3. Tighten nuts on rods (6) and (8).

Angle A is 19'"

Angle B is 20 + 5"

Angle C is 30 ± 5''



(SLEEVE METERING FUEL SYSTEM - PC)

GOVERNOR CONTROL(955L Track-Type Loader)


1

.

Put the governor control (2) in the OFF position (approximately

.47 in. (12 mm) from the end of slot in the guide.

2. Adjust length of rod (3) so lever (5) is in the OFF position at the

engine. Tighten nuts (4) on rod (3).

3. With lever (5) in the center between discs, tighten nut (6) soforce needed to move governor control lever (2) is 14.6 ± .9 lb.

(65 ± 4 N).

Angle A for lever (1) and governorcontrol (2) is 102 ± 5°

15



GOVERNOR CONTROL(950 Wheel Loader)

B41 450X1


1. With lever (1) in OFF position.

2. Adjust rod (2) so lever (5) is at angle (C).

3. Put pedal (4) in OFF position.

4. Adjust length of rod (3) and install pin (6). Tighten locknuts onrods.

Angle A is 37°

Angle B is 6°

Angle is 11"




GOVERNOR CONTROL(951 Track-Type Loader)

B41451X1


1. Make an adjustment to rod (4) so length of rod is 28.20 ± .12 in.

(71 6.3 ± 3. mm) at center of pins. Tighten nuts on rod and install

rod on machine.

2. Put governor control lever (2) in the LOW IDLE position, approx-

imately .25 in. (6.4 mm) from end of slot in guide.

3. Adjust length of rod (5) so lever (6) at the engine is in the OFFposition. Tighten nuts on rods.

4. Tighten nut (3) so force on knob (1) is 13 ± 1 lb. (58 ± 4 N).

Distance A is 28.20 ± .12 in. (716.3 ± 3.0 mm)

Angle B is 15"

17


(SLEEVE METERING FUEL SYSTEM — Dl)


4 5 VIEW A-

1, 3, 4, 2Firing order (injection sequence)


Direct Injection Engineswith turbocharger 23 ± 1

°

Direct Injection Engineswithout turbocharger 29 ± 1

°

Torque for bolts that hold

governor weight carrier to

camshaft 10 ± 2 lb. ft. (14 ± 3 Nm)

Make a mark (stake) the governor weight cover in four places 90°

apart directly over the groove in the camshaft.

(1) Diameter of rear bearing surface

(journal) of the camshaft(new) 2.3720 ± .0005 in. (60.249 ± 0.013 mm)

Bore in the rear bearing for the camshaft(new) 2.3750 ± .0005 in. (60.325 ± 0.013 mm)

Maximum permissible clearance between the

bearing and the camshaft bearing surface

(journal) (worn) 006 in. (0.15 mm)

Diameter of sleeve control shaft

(new) 3530 ± .0003 in. (8.966 ± 0.008 mm)(2)

Bore in the housing for the

fuel control shaft

(new) 3543 .0005 in. (8.999 ± 0.013 mm)

Maximum permissible clearance betweenthe bore in the housing and the sleeve

control shaft (worn) 003 in. (0.08 mm)

(3) End play for camshaft with sleeve installed

(new) 023 ± .018 in. (0.58 ± 0.46 mm)

NOTE: When installing sleeve on end of camshaft, support the cam-shaft to prevent damage to parts inside of injection pump and gover-

nor housing.

(4) Governor spring:

Make reference to the chart "GOVERNOR SPRINGS."

(5) Bypass valve:

4N605 Bypass Valve Spring:


Test force 3.53 ± .18 lb. (15.7 ± 0.8 N)



Pressure of fuel in housing for

fuel injection pumps,(Full Load) 30 ± 5 psi (205 ± 35 kPa)

(6) Diameter of front bearing surface

Oournal) of the camshaft(new) 9990 ± .0005 in. (25.375 ± 0.013 mm)

Bore in the front bearing for the camshaft(new) 1.0005 ± .0005 in. (25.413 ± 0.013 mm)

Maximum permissible clearance between thebearing and the camshaft bearing surface

(journal) (worn) 002 in. (0.05 mm)

18NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRSTPAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES




GOVERNOR SPRINGS




^lOF lifter

Install guide pin (A) to depth (B) [.642 ± .003 in. (16.31 ± 0.08 mm)].Slot in guide pin (A) must be in area shown from center of lifter.

(7)

(8)

Torque for bushing 70 ± 5 lb. ft. (95 + 7 Nm)

9N5862 Spring for injection pump:

Length under test force 1.38 in. (35.1 mm)

Test force 12.5 ± 1.4 lb. (56.7 ± 6.6 N)



Torque for bolts that

hold sleeves on control

shaft 24 ± 2 lb. in. (2.8 ± 0.2 Nm)

(10) Torque for the nuts that hold

the fuel lines (use 5P144 Fuel

Line Socket) 30 ± 5 lb. ft. (40 ± 7 N-m)

(11) Spring for the terminal shaft. Install the spring (1 1) for the termi-

nal shaft so that the end of the spring is in the 30° range asshown.

(9)

SPRINGS FOR TERMINAL SHAFT



FUEL RATIO CONTROL

SPRINGS FOR FUEL RATIO CONTROL



GOVERNOR CONTROL(120G and 130G Motor Graders)


NOTE: DO NOT use control lever (2) to shut OFF the engine.

To shut engine OFF, pull up on accelerator treadle (11).

1. Tighten nut (A) just enough so position of control lever (2) is

not affected by the operation of the accelerator treadle (11)and decelerator treadle (9).

2. With the parking brake ON and engine stopped, BE SURE dis-

connect sw/itch is OFF.

3. Remove pin (4).

4. Loosen LOW IDLE stop (7) and HIGH IDLE stop (5) so theydo not touch lever (12).

5. tvlove control lever (2) to LOW IDLE position.

6. Turn LOW IDLE stop (7) until it touches lever (12) and tighten

locknut (8).

7. Adjust length of rod (13) so distance from top of lever (15) to

bottom of floor plate (10) is 1.50 m. (38.1 mm) as shown

8. Loosen locknut (14) and adjust length of rod so top of de-celerator treadle (9) is .19 in. (4.8 mm) above floor plate (10)as shown. If machine is equipped with a thick floor insulation

pad, (used with enclosed cab), adjust decelerator treadle (9)

so top of treadle is .38 in. (9.7 mm) above top of floor plate andtighten locknut (14).

9. Move control lever (2) to HIGH IDLE position.

10. Turn HIGH IDLE stop (5) until it touches lever (12) and lightenlocknut (6).

11. Loosen locknut (16) and adjust accelerator treadle (11) so that

distance from bottom of plate on treadle to top of floor plate

(10) is 2.38 ± .12 in. (60.5 + 3.0 mm) as shown.

12. Move lever (3) to HIGH IDLE position and adjust length of

rod (1) so pin (4) can be installed.

13. Install pin (4).

22NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES



GOVERNOR CONTROL(D4E Tractor)

A48074X2


f^

NOTE: With control lever in high idle position and governor control

shaft in full on position, put lever (4) on shaft at angle (D).

Angle (D) is 40'

Dimension (A) (approximately) 14.2 in. (361 mm)

Tighten nut (1) to 18 ± 5 lb. ft. (24 ± 7 N-m)

Dimension (B) (approximately) 19.2 in. (488 mm)

Tighten nuts (2) to 18 ± 5 lb. ft. (24 ± 7 N>m)

Dimension (C) (approximately) 18.7 in. (475 mm)

Tighten nut (3) to 18 + 5 lb, ft. (24 ± 7 N-m)

1. With pin removed from lever (4) move lever (4) to high idle position

(rearward),

2. Move lever (Y) rearward until interference occurs in linkage.

3. Adjust rod end (Z) to position holes short of alignment [approx. .2

in. (5 mm)] with hole in lever (4).

4. t\/love lever (4) to shutoff position and lever (Y) forward until inter-

ference occurs. Holes In rod end (Z) must be forward of hole in

lever (4). If additional adjustment is required repeat Step 3, [.2 in.

(5 mm) dim. may be decreased],

5. Install pin and cotter.

23


(SLEEVE METERING FUEL SYSTEM - Dl)

GOVERNOR CONTROL(518 Skldder)

B42382X1


1

.

Move governor shaft (3) to SHUT OFF position and install lever

(2) on shaft (3) at angle (A).

2. Adjust length of rod (5) so stop (4) on pedal (1 ) is at dimension(B) from the floor plate.

Angle (A) is 28 + 5°

Dimension (B) is 2.25 ± .03 in. (57.2 ± 0.8 mm)

GOVERNOR CONTROL(225 Excavator)

B41452X1


Adjust distance (A) to 2.50 in. (63.5 mm) from inlay mounting holesto back edge of governor control handle (1 ) with engine running at

1400 t 50 rpm.



(SLEEVE METERING FUEL SYSTEM - PC & Dl)

AS7414X1

WATER SEPARATOR

(1) Torque for bolt 9 ± 3 lb. ft. (12 ± 4 N-m)

(2), (3), (5) and (6) Put 8M8058 Sealant on plug and fittings and

tighten to 12 ± 4 lb. ft. (17 + 5 N-m)

(4) Torque for bolts 17 ± 3 lb. ft. (23 ± 4 Nm)


(SLEEVE METERING FUEL SYSTEM — PC & Dl)

TIMING GEARS

Tighten bolts which fasten into

front plate to 17 ± 3 lb. ft, (23 ± 4 N-m)

Tighten nuts holding cover for

fuel pump drive gear to 20 + 5 lb. ft. (25 ± 7 N-m)

(1) With the timing pin and timing bolt

correctly installed, put a clockwise force of

50 lb. ft. (70 N-m) on the drive gearfor the fuel pump and tighten

bolt (1) to 110 ± 5 lb. ft. (149 + 7 N-m)

(2) End play for the idler

gear (new) 004 to .016 in. (0.10 to 0.41 mm)

Maximum permissible end play (worn) . . . .034 in. (0.86 mm)

Bore in bearing for the idler

gear (new) 1.3781 ± .0019 in. (35.004 ± 0.048 mm)

Diameter of shaft for idler

gear (new) 1.3741 ± .0005 in. (34.902 ± 0.013 mm)

Clearance between shaft andbearing (new) 0016 to .0064 in. (0.041 to 0.163 mm)

Maximum permissible clearance between shaft

and bearing (worn) 009 in. (0.23 mm)

(3) Camshaft gear.

(4) Crankshaft gear.

(5) End play for the balancershafts (new) 0035 to .0075 in. (0.089 to 0.191 mm)

Maximum permissible end play (worn) . . . .017 in. (0.43 mm)

Diameter of balancer shaft

bearing surface (journal)

(new) 2.0825 ± .0005 in. (52.896 ± 0.013 mm)

Bore in bearing for balancer

shaft (new) 2.0886 ± .0024 in. (53.050 ± 0.061 mm)

Maximum permissible clearancebetween balancer shaft andbearing (worn) 010 in, (0.25 mm)

(6) Idler gear for oil pump.

(7) Drive gear for oil pump.

A4SIS8X2

26NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRSTPAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES


(SCROLL FUEL SYSTEM — PC)


Firing order (injection sequence) 1 , 3, 4, 2

Injection timing before TO (top center) 13° 30' ± 1°

Torque for bushing 130 +10 or -5 lb. ft. (177 +14 or -7 N-m)

Thickness of spacers:

(1)

(2)

(3)

I (4)

9N6496 Spacer 161 in. (4.12 mm)

9N6495 Spacer 166 in. (4.22 mm)

5M2697 Spacer 170 in. (4.32 mm)

2M4208 Spacer 174 in. (4.42 mm)

2fv14209 Spacer 178 in. (4.52 mm)

2M4210 Spacer 182 in, (4.62 mm)

2M421 1 Spacer 186 in. (4.72 mm)

2M4212 Spacer 190 in. (4.83 mm)

5tV12691 Spacer 194 in. (4.93 mm)

5S7189 Spacer 198 in. (5.03 mm)

4N9839 Spacer 203 in. (5.16 mm)

4N9840 Spacer 207 in. (5.26 mm)

1S206 Spring;


Test force 15.4 ± .8 lb. (68.5 ± 3.6 N)



Timing dimension for the fuel injection pumps;

OFF Engine with 5P4158 or 8S7167Gauge 4.2675 ± .0020 in. (108.395

(5)

(6)

(7)

(8)

(9)

ON Engine with 5P4158 or 8S7167Gauge 4.2216 ± .0020 in. (107.229

0.051 mm)

: 0.051 mm)

Length of pumpplunger (new) 2,5934 ± .0015 in. (65.872 ± 0.038 mm)

Minimum permissible length (worn) 2.5869 in. (65.707 mm)

Bore in the bearings for the rack:

Bearing at the rear 5018 ± ,0018 in, (12,746 ± 0,046 mm)

Bearing at the front 5023 ± ,0015 in, (12,758 ± 0.038 mm)

Diameter of fuel rack 4985 ± .0002 in. (12.662 ± 0.005 mm)

fvlaximum permissible clearance between

rack and bearings (worn) 005 in. (0.13 mm)

Bore in bearings for the

camshaft 1.8755 ± .0005 in, (47,638 ± 0.013 mm)

Diameter of bearing surfaces (journals) of the

camshaft (new) 1.8730 ± .0005 in. (47.574 0.013 mm)

fâximum permissible clearance between the

bearings and the camshaft bearing surfaces

(journals) (worn) 010 in. (0.25 mm)

Torque for the nuts that hold the fuel lines (use

5P144 Fuel Line Socket) 30 ± 5 lb. ft. (40 ± 7 Nm)

Torque for the nuts that hold

the nozzles 105 ± 5 lb. ft. (142 ± 7 Nm)

(10) Body.

(11) Put 5P3931 Anti-Seize

Compound on threads of glow plug and

tighten to 120 ± 24 lb. in. (13.6 ± 2.8 Nm)

(12) Tighten nozzle finger tight on body.

A-5P4158 GAUGE ILLUSTRATED

(13 Put 5P3931 Anti-Seize Compoundon threads of precombustion chamber and

tighten to 150 ± 10 lb. ft. (205

NOTE: See Glow Plug Positioning.

14 Nm)

27



GOVERNOR(EARLIER)

(1) Torque for nut 9 ± 3 lb. ft. (12 ± 4 Nm)

(2) 1S9312 Spring for speed limiter:

Length under test force 86 in. (21 .8 mm)

Test force 2.38 ± .19 lb. (10.52 ± 0.76 N)



(3) 9M3160 Spring for governor:

Color code (stripes) 1 blue

Put force on spring of 5.0 lb. (22 N)

Then add more force to make spring

shorter by 900 in. (22.86 mm)

Total test force 19.4 ± .5 lb. (86.6 ± 2 N)

Free length after test 2.34 ± .03 in. (59,4 ± 0.8 mm)

Outside diameter 1.39 in, (35.3 mm)

(3) 9L3617 Spring For Governor;

Color code (stripes) 1 blue, 1 white

Put force on spring of 6,0 lb, (27 N)



Total test force 22.2 ± .5 lb. (100.8 + 2 N)

Free length after test 2.34 ± .03 in. (59.4 ± 0.8 mm)

Outside diameter 1 .39 in. (35.3 mm)

(3) 8IV19140 Spring for governor:

Color code (stripes) 1 green




Total test force 16.6 ± .3 lb. (74.0 ± 1.3 N)

Free length after test 2.34 ± .03 in. (59.4 + 0.8 mm)

Outside diameter 1 .38 in. (35.1 mm)


3304 VEHICULAR ENGINES


SPECIFICATIONS

GOVERNOR(LATER)


(2) 8M9140 Spring for governor:

Color code (stripes) 1 green




Total test force 16.6 + .3 lb. (74.0 ± 1 .3 N)

Free length after test 2.34 ± .03 in. (59.4 ± 0.8 mm)


(3) Collar for spring.

(4) 2S7235 Spring:


Test force 39 ± .03 lb. (1.75 + 0.13 IM)

Free length after test 68 in. (17.3 mm)


(5) 9M6303 Spring for over-fueling;


Test force 10.0 + .5 lb. (45 + 2.2 N)

Free length after test (approximate) 344 in. (8.74 mm)


29



FUEL TRANSFER PUIVIP

Pressure of fuel to injection

pump 25 to 32 psi (170 to 220 kPa)

(1) Bore of bearing (new) . , .4953 + .0003 in. (12.581 ± 0.008 mm)

(2) Depth of bore in body(new) 3750 + .0003 in. (9.525 ± 0.008 mm)

Thicl<ness of gear (new) . . .3730 ± .0003 in. (9.474 ± 0.008 mm)


(4) Clearance between gear andcover (new) 0014 to .0026 in. (0.036 to 0.066 mm)

Maximum permissible clearance between gear

and cover (worn) 0035 in. (0.089 mm)

(5) Shaft diameter (new) . . . .4937 ± .0001 in. (12.540 ± 0.003 mm)

Bore in shaft bearing

(new) 4953 ± .0003 in. (12.581 ± 0.008 mm)

Maximum permissible clearance betv\«en shaft


(6) 8M3210 Spring:


Test force 5.36 ± .13 lb. (23.8 + 0.58 N)



(7) Torque for plug when used with gasket:

2A1913 Gasket (copper) 110 ± 15 1b. ft. (149 ± 20 Nm)

4IM7465 Gasket (plastic) 27 + 3 lb. ft. (38 ± 4 Nm)

NOTE: Put a thin layer of 8S6747 Sealer on face of pump body before

installing pump cover. Do not let any of 8S6747 Sealer get into the

pump.

FUEL BYPASS VALVE


pump 25 to 32 psi (170 to 220 kPa)

(1) 4S6526 Spring for bypass valve:


Test force 3.16 ± .16 lb. (14.1 ± 0.71 N)




C^TO



(SCROLL FUEL SYSTEM — Dl)

1



FUEL INJECTION

A-5P4158 GAUGETYPICAL EXAMPLE

Firing order (injection sequence) 1 , 3, 4, 2


Direct Injection Engineswithout turbocharger 27 ± 1

°

(1) Torque for bushing 154 ± 11 lb. ft. (205 ± 15 N-m)

PUMP ASSEMBLY SPRINGS



Fuel Injection (Cont.)

(7) Bore in the bearings for the camshaft

(new) 1.8765 ± .0010 in. (47.663 ± 0.025 mm)

Diameter of bearing surfaces of the camshaft

(new) 1.8730 ± .0005 in. (47.574 ± 0.013 mm)

Maximum permissible clearance between the bearings

and the camshaft 010 in. (0.25 mm)

INJECTION PUMP & TIMING DIMENSION



GOVERNOR

B14464X1 5

(1) Torque for nut 9 ± 3 lb. ft. (12 ± 4 Nm)(2) 3P131 Spring:


Test force 21 ± .02 lb. (0.95 ± 0.09 N)

Free length

after test 85 in. (21.6 mm)


(3) Seat. Install a spring washer, flat washer and spring washerbetween seat (3) and spring (4) as shown.

(4) 9L6446 Spring for governor:

Color code (stripes) 1 blue, 1 green


Then add more force to make springshorter by 80 in. (20.3 mm)

Total test force 12.4 + .24 lb. (55 ± 1 N)

Free length

after test 2.24 ± .03 in. (56.9 ± 0.8 mm)

Outside diameter 1.371 In. (34.82 mm)

A81478X1

INSTALL SPRING WASHERS AS SHOWN

(4) 4N6681 Spring tor governor-

Color code (stripes) 2 purple


Then add more force to make springshorter by 90 in. (22.9 mm)

Total test force 14.8 ± .48 lb. (67 ± 2 N)

Free length

after test 2.24 ± .03 in. (56.9 ± 0.8 mm)


(5) 4N5549 Spring for over-fueling:


Test force 65 ± .03 lb. (2.9 ± 0.1 N)



(6) Diameter of the outer surface of the cylinder(new) 1.2172 ± .0005 in. (30.917 ± 0.013 mm)

Bore in the gear(new) 1.2192 ± .0005 in. (30.968 ± 0.013 mm)

NOTE: Governor weights must pivot freely.




FUEL TRANSFER PUMP(4N4864)


pump 25to32psi(170to220kPa)

(1) Bore of bearing (new) . . . .4953 ± .0003 In. (12.581 ± 0.008 mm)

(2) Deptti of bore In body(new) 3750 ± .0003 in. (9.525 ± 0.008 mm)

Tfilcknessof gear(new) . . .3730 ± .0003 in. (9.474 ± 0.008 mm)

(3) Torque for nut 22 ± 5 lb. ft. (28 ± 7 N-m)

(4) Clearance between gear and cover(new) 0014 to .0026 in. (0.036 to 0.066 mm)

Maximum permissible clearance betweengear and cover (worn) 0035 In. (0.089 mm)

(5) Shaft diameter (new) 4937 ± .0001 In. (12.540 ± 0.003 mm)

Bore In shaft bearing

(new) 4953 ± .0003 In. (12.581 ± 0.008 mm)

fvlaxlmum permissible clearance betweenshaft and bearing (worn) 003 In. (0.08 mm)

(6) 8M3210 Spring:

Length under test force 1.212 In. (30.79 mm)

Test force 5.36 + .13 lb. (23.8 ± 0.58 N)


Outside diameter 41 In. (10.4 mm)

(7) Torque for plug when used with gasket:

4N7465 Gasket . . . 27 ± 3 lb. ft.(38 ± 4 Nm)

NOTE: Put a thin layer of 8S6747 Sealer on face of pump body beforeInstalling pump cover. Do not let any of 8S6747 Sealer get Into the

pump.

35


(SCROLL FUEL SYSTEM — PC & Dl)

TIMING GEARS

Torque for two bolts that hold front

cover to plate 17 + 3 lb. ft. (23 ± 4

Torque for nuts holding cover for

accessory drive gear 20 ± 5 lb. ft. (27 ± 7

(1) Torque for nut holding

accessory drive gear 100 ± 10 lb. ft, (135 ± 14

(2) End play for the cannshaft

(new/) 007 ± .003 in. (0.18 ± 0.08

N-m)

N-m)

N'Oi)

Maximum permissible end play (worn)

mm)

025 in. (0.64 mm)

mm)

034 in. (0.86 mm)

Diameter of camshaft bearing surface

(journal) (new) 2.3110 ± .0005 in. (58.699 ± 0.013 mm)

Bore in bearing for camshaft(new) 2.3150 ± .0024 in. (58.801 ± 0.061 mm)

IVIaximum permissible clearance between bearing

and bearing surface (journal) (worn) 008 in. (0.20 mm)

(3) End play for the idler gear

(new) 004 to .016 in. (0.10 to 0.41

Maximum permissible end play (worn) .

Bore in bearing for the idler

gear (new) 1 .3781 ± .0019 in. (35.004 ± 0.048 mm)

Diameter of shaft for idler

gear (new) 1.3741 ± .0005 in. (34.902 ± 0.013 mm)



(4) Balancer shafts:

Diameter of balancer shaft bearing surface

(journal) (new) 2.0825 + .0005 in. (52.896 ± 0.013 mm)

Bore in bearing for balancer

shaft (new) 2.0886 ± .0024 in. (53.050 ± 0.061 mm)

Maximum permissible clearance between balancer

shaft and bearing (worn) 010 in. (0.25 mm)

End play for the balancer shaft

(new) 0035 to .0075 in. (0.089 to 0.191

Maximum permissible end play (worn)

mm)

017 in. (0.43 mm)

(5) Distance from front face of bushing to rear

face of cover 2.56 in. (65.02




CAMSHAFT

NOTE: Put a layer of graphite grease on lobes of camsfiaft wfieninstalling.

(1) Width of groove in cannshaft for thrust washer(new) 190 ± .002 in. (4.83 ± 0.05 mm)

Thickness of thrust washer(new) 183 ± .001 in. (4.65 ± 0.03 mm)

End play of the camshaft(new) 007 ± .003 in. (0.18 ± 0.08 mm)

Maximum permissible end play (worn) 025 in. (0.64 mm)

(2) Diameter of camshaft bearing surface (journal)

(new) 2.3110 ± .0005 in. (58.699 ± 0.013 mm)

(3) Bore in bearing for camshaft(new) 2.3150 ± .0024 in. (58.801 ± 0.061 mm)

Clearance between bearing and bearing surface(journal) (new) 002 to .006 in. (0.05 to 0.1 5 mm)

Maximum permissible clearance between bearing and bearingsurface (journal) (worn) 008 in. (0.20 mm)

NOTE; Make reference to CYLINDER BLOCK for installation dimen-sions.

(5) Height of camshaft lobes.

To find lobe lift, use the procedure that follows;

A. Measure camshaft lobe height (5).

B. Measure base circle (6).

C. Subtract base circle (STEP B) from lobe height (STEP A). Thedifference is actual lobe lift (4).

D. Specified camshaft lobe lift (4) is 3300 in. (8.382 mm)

Maximum permissible difference between actual lobe lift (STEP C)and specified lobe lift (STEP D) is 010 in. (0.25 mm) 74239- 1X1

VALVE ROCKER ARMS AND LIFTERS

(1) Bore in bearing for shaft

(new) 7263 ± .0005 in. (18.448 ± 0.013 mm)

Diameter of shaft

(new) 7245 ± .0005 in. (18.402 ± 0.013 mm)

Maximum permissible clearance between bearing and shaft(worn) 008 in. (0.20 mm)

(2) Torque for locknut on valve adjustmentscrew 21 ± 5 lb. ft. (26 ± 7 Nm)

(3) Clearance for valves;

Intake valves 015 in. (0.38 mm)

Exhaust valves 025 in. (0.64 mm)

(4) Diameter of valve lifter

(new) 1.3105 ± .0005 in. (33.287 ± 0.013 mm)

Bore in block for valve lifter

(new) 1.3145 ± .0010 in. (33.388 ± 0.025 mm)

Maximum permissible clearance between lifter and borefor valve lifter (worn) 012 in. (0.30 mm)

A156S6XI

37


VALVES(PC)

NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVESPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and

specifications necessary for checking used valves and valve springs.

(1) 7S7144 Spring for valves (new):

Length under test force 1.766 in, (44.86 mm)

Test force 57.7 ± 4.5 lb. (256 ± 20 N)

Use again minimum load at length under

test force 46.5 lb. (207 N)

Length of spring at valve open position 1.271 in. (32.28 mm)

Use again minimum load at valve open position. . 144 lb. (640 N)



Spring must not be bent more than 072 in. (1 .83 mm)

(2) Height to top of valve guide 875 in. (22.23 mm)

(3) Diameter of valve stem(new) 3717 ± .0003 in. (9.441 ± 0.008 mm)

Use again minimum diameter 3704 in. (9.408 mm)

Bore in valve guide with guide

installed in the head(new) 3733 ± .0010 in, (9.482 ± 0.025 mm)

râximum permissible bore (worn) 3771 in. (9.578 mm)

(4) Valve lip thicl<ness:

8N875 & 5S7232 Exhaust Valve

Use again minimum 106 in. (2.69 mm)

5S6449 Exhaust Valve


5S6452 Intake Valve


(5) Diameter of valve head:

Exhaust valve 1.896 ± .005 in. (48.16 ± 0.13 mm)

Intake valve 2.020 ± .005 in. (51.31 ± 0.13 mm)

(6) Angle of valve face 29 1/4"


PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES


Valves (Cont.)

(PC)

(7) Depth of bore in head for valve seat insert:

Exhaust (5S7221 &1P6837) 449 ± .005 in. (11.40 ± 0.13 mm)

Intake:

Earlier (5S7218) 449 ± .005 in. (11.40 ± 0.13 mm)

Later (7N4448) 349 ± .005 in. (8.86 ± 0.13 mm)

(8) Diameter of valve seat insert:

Exhaust (5S7221 &1P6837) 2.0035 ± .0005 in. (50.889 + 0.013 mm)

Intake:

Earlier (5S7218) . . . 2.1285 ± .0005 in. (54.064 ± 0.013 mm)

Later (7N4448) .... 2.0485 ± .0005 in. (52.032 ± 0.013 mm)

Bore in head for valve seat insert:

Exhaust (5S7221 &1P6837) 2.0005 ± .0005 in. (50.813 ± 0.013 mm)

Intake:

Earlier (5S7218) . . . 2.1255 ± .0005 in. (53.988 ± 0.013 mm)

Later (7N4448) .... 2.0457 ± .0005 in. (51.961 ± 0.013 mm)

(9) Angle of face of valve seat insert 30°

(10) Maximum permissible width of valve seat

(intake and exhaust) 076 in. (1.93 mm)

I\înimunn permissible width of valve seat

(intake and exhaust) 045 in, (1.14 mm)

(11) Dimension from top of closed valve to face of head:

Iviaximum permissible dimension for 5S6449 or

5S7232 Exhaust Valves 140 in. (3.56 mm)

Minimum permissible dimension for 5S6449 or

5S7232 Exhaust Valves 056 in. (1.42 mm)

Maximum permissible dimension for 8N875Exhaust Valve 163 in. (4.14 mm)

Minimum permissible dimension for 8N875Exhaust Valve 079 in. (2.01 mm)

Maximum permissible dimension for 5S6452Intake Valve 140 in. (3.56 mm)

Minimum permissible diameter for 5S6452Intake Valve 066 in. (1.68 mm)

(12) Outside diameter of the face of the valve seat or valve seatinsert:

Exhaust seat 1.810 in. (45.97 mm)

Maximum permissible, exhaust seat 1.860 in. (47.24 mm)

Intake seat 1.934 in. (49.12 mm)

Maximum permissible, intake seat 1.984 In. (50.39 mm)

(13) Angle to grind seat face of the insert to get

a reduction of maximum seat diameter 15°

39


VALVES(Dl)

NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVESPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and

specifications necessary for checking used valves and valve springs.

(1) 7S7144 Spring for valves {new):


Test force 57.7 ± 4.5 lb. (256.7 ± 20 N)

Use again minimum load at length under

test force 46.5 lb. (207 N)

Length of spring at valve openposition 1.271 in. (32.28 mm)

Use again minimum load at valve

open position 144.4 lb. (642 N)



Spring must not be bent more than 072 in. (1 .83 mm)

(2) Height to top of

valve guide 875 in. (22.23 mm)

(3) Diameter of valve stem(new) 3717 ± .0003 in. (9.441 ± 0.008 mm)

Use again minimum diameter 3704 in. (9.408 mm)

Bore in valve guide with guide installed in the head.

Minimum permissible (new) 3723 in. (9.456 mm)

Maximum permissible (worn) 3772 in. (9.581 mm)

(4) Valve lip thickness:

6N9916 Exhaust Valve.


6N9915 Intake Valve and 7N573 Exhaust Valve.


(5) Diameter of valve head:

Exhaust

valves 1.896 ± .005 in. (48.16 ± 0.13 mm)

Intake

valve 2.020 + .005 in. (51.31 ± 0.13 mm)

(6) Angle of valve face 29 1/4°

(7) Depth of bore in head for valve seat

insert 488 ± .005 in. (12.41 ± 0.13 mm)

(8) Diameter of valve seat insert for exhaust

valve 2.0035 ± .0005 in. (50.889 ± 0.013 mm)

Bore in head for valve seat insert for exhaust

valve 2.0005 ± .0005 in. (50.813 ± 0.013 mm)

Diameter of valve seat

insert for intake

valve 2.0485 ± .0005 in. (5.032 ± 0.013 mm)

Bore in head for valve seat

insert for intake

valve 2.0455 ± .0005 in. (51.956 ± 0.013 mm)

(9) Angle of face of valve seat insert 30°

(10) Maximum permissible width of valve seat


Minimum permissible width of valve seat


B9217X1

B9216X1

(11) Dimension from top of closed valve to face of head:

Minimum permissible dimension for 7N573 and6N9916 Exhaust Valve 026 in. (0.66 mm)

Minimum permissible dimension for

6N9915 Intake Valve . 006 in. (0.15 mm)

(12) Outside diameter of the face of the valve seat insert:

Exhaust seat 1.812 in. (46.02 mm)

Maximum permissible, exhaust seat 1.862 in. (47.29 mm)

Intake seat 1.940 in. (49.28 mm)

Maximum permissible, intake seat 1.990 in. (50.55 mm)

(13) Angle to grind seat face of the insert to get

a reduction of maximum seat diameter 15°

40NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST

PAGE OF SPECIFICATIONS- FOR GENERAL TIGHTENING TOROUES


GLOW PLUG POSITIONING

Cyl. Nos. 1, 2, and 3—3304*Cyl. Nos. 1 thru 4—3304"

Cyl. No. 4—3304*

'Engines with counterbored blocl(.

**Engines with spacer plate.

(A) Correct range for glow plug opening.

Put 5P3931 Anti-Seize Compound on the threads of the precom-bustion chamber.

Put 5M2667 Gasket, with "2C" on it, on the precombustion cham-ber. Install the precombustion chamber in the cylinder head andtighten to 150 ± 10 lb. ft. (205 ± 14 N-m)

NOTE: If the hole for the glow plug is not in range (A), remove the

precombustion chamber. Remove the gasket.

If the hole was in range (B) install 2S8959 Gasket, with "2S" on it,

on the precombustion chamber. Install the precombustion chamberin the cylinder head andtighten to 150 ± 10 lb. ft. (205 ± 14 N-m)

If the hole was in range (C) install 2S8960 Gasket, with "2X" on it,

on the precombustion chamber. Install the precombustion chamberin the cylinder head andtighten to 150 ± 10 lb. ft. (205 i 14 N-m)

41


CYLINDER HEAD

Thickness of cylinder head(new) 3.938 ± .030 in. (100.03 ± 0.76 mm)

NOTE: Dimension from top of closed valve to face of cylinder headmust be according to the specifications in VALVES.

Put 5P3931 Anti-Seize Compound on threads and tighten bolts in the

Step sequence that follov»/s:

Step 1. Tighten all bolts in numbersequence to 1 15 lb. ft. (155 Nm)

Step 2. Again tighten all bolts in numbersequence to 185 ± 13 lb. ft. (250 ± 17 N-m)

Step 3. Again tighten all bolts in numbersequence to 185 ± 13 lb. ft. (250 ± 17 Nm)

Step 4. Tighten all bolts in letter sequence(hand torque only) to 32 ± 5 lb. ft. (43 ± 7 Nm)

b0^ 03 02 06

.0VALVE COVER

77077X I

4

o o5

o

VIEW FROM RIGHT SIDEOF ENGINE

11

o

10

o

Put 5H2471 Cement on the face of valve cover and top side of gasket.

24 1b. in. (10.9 ± 2.8 Nm)Tighten bolts by number sequenceshow/n to 96


I


EXHAUST MANIFOLD

Put 5P3931 Anti-Seize Compound on all threads.

(1) Torque for studs 20 ± 3 lb. ft. (25 ± 4 Nm)

(2) Torque for nuts holding exhaustmanifold 32 ± 5 lb. ft. (43 ± 7 Nm)

EXHAUST PIPE AND MUFFLER

Put 5P3931 Anti-SeIze Compound on threadsof bolts for clamps andtighten to 20 ± 5 lb. ft. (25 ± 7 N-m)

AIR CLEANER

(1) Tighten nuts that hold air filter

to elbow 20 ± 5 lb. ft. (25 ± 7 Nm)

(2) Tighten wing nuts to 35 ± 5 lb. in. (4.0 ± 0.6 Nm)

43


TURBOCHARGER IMPELLER INSTALLATION

Schwitzer ONLY

Installation Procedure Chart

A. Put 6V1541 Quick Pure Primer on the nut and the shaft threads to clean them, if

necessary.

B. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.

CAUTION

Do not let the retaining compoun get into the compressor wheel bore on the shaft,

because it can make removal of the compressor wheel difficult during future turbo-

charger disassembly.

C. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the

compressor. Do not put lubricant on the threads.

D. Tighten the compressor wheelretainer nut to 44 ± 2 lb. ft. (60 ± 3 N-m)

NOTE: Do not bend or add stress to the shaft when the nut is tightened.




TURBOCHARGER IMPELLER INSTALLATION(AIResearch ONLY)

TEST FOR TYPE OF IMPELLER INSTALLATION

1. Install the proper thrust collar and seal carrier spacer on theshaft-wheel assembly to be used.

2. Install impeller on shaft by hand.

3. Measure the distance between impeller and seal carrier at thepoint where impeller no longer moves freely on shaft.

4. If the distance is:

(a) more than .31 in. (7.9 mm), use heat for installation.*

(b) .31 in. (7.9 mm) or less, use room temperature installation."


TURBOCHARGER(AiResearch T04B91)

46923-1X3

Make reference to ANALYZING TURBOCHARGER FAILURE, FormNo. FEG45138.

Make reference to GUIDELINES FOR REUSEABLE PARTS TURBO-CHARGERS, Form Nos. SEBF8018 & SEBF8019.

(1) Torque for impellernut 20 lb. in. (2.3 N-m)

Tighten nut an added 100°

NOTE: Do not bend or add stress to the shaft when nut is tightened.

(2) Torque for bolts holding

back plate 75 to 90 lb, in. (8.5 to 10.2 N-m)

(3) Put 5P3931 Anti-Seize Compound on threads

and tighten bolts holding compressor housing to center

section to 115 ± 15 lb. in. (13 ± 1.7 N-m)

(4) Put 5P3931 Anti-Seize Compound onthreads and tighten bolts holding turbine housing to

center section to 115 ± 15 lb. in. (13 ± 1.7 N-m)

(5) Put 5P3931 Anti-Seize Compound on

threads and tighten bolts holding turbocharger to

manifold to 40 ± 4 lb. ft. (55 ± 5 N-m)

(6) End play for shaft:

Minimum permissible end play 001 in. (0.03 mm)

Maximum permissible end play 004 in. (0.10 mm)

(7) Radial play for shaft:

Minimum permissible radial play 003 in. (0.08 mm)

Maximum permissible radial play 006 in. (0.15 mm)

(8) Bore in the

bearing 4010 to .4014 in. (10.185 to 10.196 mm)

Diameter of surface on shaft (journal)

for the bearing 3997 to .4000 in. (10.152 to 10.160 mm)

(9) Bore in housing... .6220 to .6223 in. (15.799 to 15.806 mm)

Outside diameter of the


(10) Clearance between ends of oil

seal ring 008 to .015 in. (0.20 to 0.38 mm)

Diameter of bore for oil

seal ring 709 to .71 1 in. (18.01 to 18.06 mm)




TURBOCHARGER(AIResearch T0490)


Make reference to GUIDELINES FOR REUSABLE PARTS TURBO-CHARGERS, Form Nos. SEBF8018 & SEBF8019.

(1) Torque for impeller nut 20 lb. in. (2.3 N-m)

Tighten nut an added 100°

NOTE: Do not bend or add stress to the shaft when nut is tightened.

(2) Torque for bolts holding backplate 50 ± 10 lb. in. (5.7 ± 1.1 N>m)

(3) Put 5P3931 Anti-Seize Compoundon threads and tighten bolt holding bandclamp to 60 ± 10 lb. in. (6.8 ±1.1 N-m)

(4) Put 5P3931 Anti-Seize Compound onthreads and tighten bolts holding turbine

housing to 115 ± 15 lb. in. (13 ± 1.7 N-m)

(5) Put 5P3931 Anti-Seize Compound onthreads and tighten bolts holding turbochargerto manifold to 40 ± 4 lb. ft. (55 ± 5 N-m)

(6) End play for shaft 001 to .004 in, (0.03 to 0.10 mm)

(7) Radial play for shaft 003 to .007 in. (0.08 to 0.18 mm)

Bore in the


Diameter of surface on shaft (journal)

for the bearing 3997 to .4000 in. (10.152 to 10.160 mm)

(8) Bore in housing . . . .6220 to .6223 in. (15.799 to 15.806 mm)





(10) Diameter of bore for oil

seal ring 709 to ,71 1 in. (18.01 to 18.06 mm)

47


TURBOCHARGER(AIResearch T1210 and T1224)

T98428X4



Put 5P3931 Anti-Seize Compound on tfireads of plug for exfiaust

elbow.

Put 5P3931 Anti-Seize Compound on bolts

holding support for exhaust andtighten to 45 ± 5 lb. ft. (60 ± 7 N-m)

(1) See TURBOCHARGER IMPELLER INSTALLATION.

(2) Torque for bolts holding thrust

plate 35 ± 4 lb. in. (4.0 ± 0,5 N-m)

(3) Tighten bolt holding bandclamp to 120 ± 10 lb. in. (13.6 ± 1.1 N-m)


of bolts holding turbine housing andtighten to 175 ± 15 lb. in. (19.8 ± 1.7 N-m)


of bolts holding turbocharger to

manifold and tighten to 40 ± 4 lb. in. (55 ± 5 N-m)

(6) End play for shaft

(new) 006 to .011 in. (0.15 to 0.27 mm)

(7) Bore in the


Diameter of surface on shaft (journal) for

the bearing 6250 to .6254 in. (15.875 to 15.885 mm)

(8) Bore in housing . . . .9827 to .9832 in. (24.961 to 24.973 mm)







ITURBOCHARGER

(Schwitzer 3LK)

73113X2



(1) End play for stiaft

(new) 0045 ± .0015 In. (0.114 ± 0.038 mm)

Maximum permissible end play (worn) . . .008 in, (0.20 mm)

(2) Thickness of thrust

bearing 21 1 ± .001 in. (5.36 ± 0.03 mm)

(3) Diameter of surface on shaft (journal) for

the bearing 44015 ± .00015 in. (11.1798 ± 0.0038 mm)

Bore in the

bearing 44165 ± .00015 in. (11.2179 ± 0.0038 mm)

Maximum permissible clearance betweenbearing and shaft 0018 in. (0.046 mm)

(4) Put 5P3931 Anti-Seize Compound onthreads and tighten bolt holding bandclamp to 120 lb. in. (13,6 N-m)

(5) Maximum permissible gap of oil seal ring,

measured in bore of housing 007 in, (0,18 mm)

(6) See TURBOCHARGER INSTALLATION,

(7) Bore in

housing 75025 ± ,00025 in, (19,0564 ± 0,0064 mm)


bearing 74625 ± ,00025 in, (18,9548 ± 0,0064 mm)

Maximum permissible clearance betweenbearing and bore in housing 0045 in, (0,114 mm)

(8) Thickness of each thrust

ring 1005 ± ,0005 in, (2,553 + 0,013 mm)


impeller housing 60 lb, in, (6,8 N-m)

(10) Put 5P3931 Anti-Seize Compound onthreads of bolts holding turbocharger to manifold

and tighten to 40 ± 4 lb, ft, (55 ± 5 N-m)

49


TURBOCHARGER(Schwitzer 3LM)

A22019X2

Make reference to ANALYZING TURBOCHARGER FAILURE, FormNo. FEG45138,


(1) End play for shaft (new) 002 to ,005 in. (0.05 to 0.13 mm)

(2) Put 5P3931 Anti-Seize Compound on threads and tighten

bolts holding impeller housing to 60 lb. in. (6.8 Nm)


and tighten bolts holding turbine

housing to 11 to 12 lb. ft. (15 to 17 Nm)


measured in bore of housing 007 in. (0.18 mm)

(5) See TURBOCHARGER IIVIPELLER INSTALLATION.

(6) Thickness of thrust


(7) Bearing:

Bore in housingfor bearing 7500 to .7505 in. (19.050 to 19.063 mm)

Diameter of surface of bearing

for housing 7460 to .7465 in. (18.948 to 18.961 mm)

Diameter of surface of

bearing for shaft 4415 to .4418 in. (11.214 to 11.222mm)

Diameter of surface of shaft for

bearing (journal) 4400 to .4403 in. (11.176 to 11.184 mm)

Length of bearing 2.425 to2.426 in. (61.60 to61.62 mm)




TURBOCHARGER(Schwitzer F444, 4LF504 and E Models)

T97594X1



(1) End play for stiaft

(new) 0045 ± .0015 in. (0.114 ± 0.038 mm)

Maximum permissible end play (worn) 008 In. (0.20 mm)

(2) Thickness of thrust bearing ... .211 ± .001 in. (5.36 ± 0.03 mm)

(3) Diameter of surface on shaft (journal) for thebearing (new) 5612 to .5615 in. (14.254 to 14.262 mm)

Bore in the bearing

(new) 5627 to .5630 in. (14.293 to 14.300 mm)

Maximum permissible clearance between bearing andshaft (worn) 003 in. (0.08 mm)

(4) Put 5P3931 AntiSelze Compound on threads andtighten bolt holding band clamp to 120 lb. in. (13.6 N-m)


measured In bore of housing 009 in. (0.23 mm)

(6) See TURBOCHARGER IMPELLER INSTALLATION.

(7) Bore In housing(new) 8762 to .8767 In. (22.255 to 22.268 mm)

Outside diameter of the bearing(new) 8718 to .8722 in. (22.144 to 22.154 mm)

Maximum permissible clearance between bearing andbore In housing (worn) 006 in. (0.15 mm)

(8) Thickness of each thrust

ring 1005 ± .0005 in. (2.553 ± 0.013 mm)

(9) Put 5P3931 Antl-Seize Compound on threads andtighten bolts holding turbocharger to

manifold to 40 ± 4 lb. ft. (55 ± 5 Nm)

51


OIL PUMP(2P7830, 5S3876 & 7S9840)

(1) Diameter of the drive

shaft (new) 7407 ± .0003 in. (18.814 ± 0.008 mm)

Bore in the bearings for the

drive shaft 7425 ± .0005 in. (18.860 ± 0.013 mm)

Clearance between drive shaft andbearing (new) 0018 ± .0008 in. (0.046 ± 0.020 mm)

Maximum permissible clearance betweenshaft and bearing (worn) 005 in. (0.13 mm)

(2) Length of gear 2.9955 ± .0005 in. (76.086 ± 0.013 mm)

Depth of counterborefor gear 3.0008 ± .0008 in. (76.220 ± 0.020 mm)

Clearance between end of gear andcover (new) 0053 ± .0013 in. (0.135 ± 0.033 mm)

(3) Length of gear 1 .9975 ± .0005 in. (50.737 ± 0.013 mm)

Depth of counterborefor gear 2,0008 ± .0008 in. (50.820 ± 0.020 mm)

Clearance between end of gear andcover (new) 0033 ± .0013 in. (0.084 ± 0.033 mm)

(4) Diameter of the shaft for the drive idler

gear (new) 1.1225 1 .0005 in. (28.512 ± 0.013 mm)

Bore in bearing of gear

(new) 1.1260 ± .0019 in. (28,600 ± 0.048 mm)

Clearance between shaft andbearing (new) 0035 ± .0024 in. (0.089 ± 0.061 mm)



(5) 1S3921 Spring for pressure relief valve (engine oil):


Test force 39.8 ± 3.2 lb. (177.5 + 14.0 N)



(6) Diameter of the shaft for the idler gear (clutch

pump) (new) 7407 ± .0003 in. (18.814 ± 0,008 mm)

Bore in the bearing 7425 ± .0005 in, (18,860 ± 0,013 mm)

Clearance between shaft and bearing

(new) 0.0018 ± .0008 in. (0.046 ± 0.020 mm)



(7) Diameter of the shaft for the idler gear (scavenge

pump) (new) 7407 ± .0003 in. (18.814 ± 0.008 mm)

Bore in the bearing of the

idler gear 7425 ± .0005 in. (18.860 ± 0.013 mm)




Length of gear 9975 ± .0005 in. (25.337 ± 0.013 mm)


(8) 4J4790 Spring for pressure relief valve (clutch oil):


Test force 12.27 lb. (54.6 N)



(9) Torque for nut holding drive gear 60 lb. ft. (80 N-m)

Tighten farther to get alignment for cotter pin.


I


OIL PUMP(781849 & 7S9461)

(1) Diameter of the drive shaft

(new) 8747 ± .0002 in. (22.217 ± 0.005 mnn)

Bore in the bearings for the

drive shaft 8763 ± .0003 in. (22.258 ± 0.008 mm)

Clearance between drive shaft andbearings (new) 0016 ± .0005 in. (0.041 ± 0.013 mm)



(2) Diameter of the shaft for the drive idler

gear (new) 1.1225 ± .0005 in. (28.512 + 0.013 mm)

Bore in the

bearing 1.1260 ± .0019 in. (28.600 ± 0.048 mm)




(3) Diameter of the shaft for the

idler gear (new) 8747 ± .0002 in. (22.217 ± 0.005 mm)

Bore in the bearing. .8763 ± .0003 in. (22.258 ± 0.008 mm)


Maximum permissible clearance betweenshaft and bearing (worn) 008 in. (0.20 mm)

(4) 1S3921 Spring for pressure relief valve:


Test force 39.8 ± 3.2 lb. (177.5 ± 14.0 N)



(5) Length of gear 1 .4988 ± .0010 in. (38.070 ± 0.025 mm)

Depth of counterbore

for gear 1.5038 ± .0008 in. (38.197 ± 0.020 mm)

Clearance between end of gear

and cover (new) 0050 ± .0018 in. (0.127 ±0.046 mm)

(6) Length of gear 2.0003 ± .0010 in. (50.808 ± 0.025 mm)


Clearance between end of gear

and cover (new) 0050 ± .0018 in. (0.127 ± 0.046 mm)

(7) Torque for nut holding drive gear 60 lb. ft. (80 N-m)

Tighten farther to get alignment for cotter pin.

53


OIL PUMP(2P1785 and 6N2642)

(1) Bore in bearing of idler

gear 1 .1260 ± .0024 in. (28.600 ± 0.061 mm)

Diameter of shaft for thie

idler gear 1.1255 ± .0005 in. (28.588 ±0.013 mm)

Clearance between bearing andstiaft 0035 + .0029 in. (0.089 ± 0.074 mm)

(2) Clearance between gears and bodyof pump 002 to .026 in. (0.05 to 0.66 mm)

(3) Diameter of shafts for

pump 8747 ± .0002 in. (22.217 ± 0.005 mm)

Bore in bearings for

shafts 8763 ± .0003 in. (22.258 ± 0.008 mm)

Clearance between shafts andbearings 0016 ± .0005 in. (0.041 ± 0.013 mm)

(4) Length of gears 2.0003 ± .0010 in. (50.808 ± 0.025 mm)

Depth of bore in pump body for

gears 2.0053 ± .0008 in. (50.935 ± 0.020 mm)

Clearance between end of gears andpump body 0050 ± .0018 in, (0.127 ± 0.046 mm)

(5) Length of gears 1 .4988 ± .0010 in. (38.070 ± 0.025 mm)

Depth of bore in pump body for

gears 1.5038 ± .0008 in. (38.197 ± 0.020 mm)

Clearance between end of gears andpump body 0050 ± .0018 in. (0.127 ± 0.046 mm)

(6) Torque for bolt holding drive gear to

drive shaft 32 ± 5 lb. ft. (43 ± 7 N-m)

ta-.^j„.^

I80o)



ENGINE OIL PRESSURE

All steps of this procedure must be followed for the pressure findings

to be usable.

Step 1. Besure that the engine is filled to thecorrect level with either

SAE 10 or SAE 30 oil. If any other viscosity of oil is used, the

information in the ENGINE OIL PRESSURE CHART doesnot apply.

Step 2. Find a location on the engine oil manifold to install a tee. Theeasiest method is to remove the sending unit for the present

gauge and install a tee at this location. Install a probe fromthe 9S9102 Thermistor Thermometer Group in one side of

the tee. Connect a 8M2744 Gauge from the 5P6225 Hydraulic

Test Box to the other side of the tee.

Step 3. Run the engine to get the oil temperature at 210° F (99° C).

NOTE: A 5° F (3° C) increase in oil temperature gives approximately

1 psi (7 kPa) decrease in oil pressure.

Step 4. Keep the engine oil temperature constant. With the engine at

the rpm from the chart, read the pressure gauge.

Make a comparison between the pressure reading on the test gaugeand the minimum permissible pressure from the ENGINE OIL PRES-SURE CHART. If the pressure reading on the test gauge is belowthe minimum permissible pressure, find the cause and correct it.

Operation of the engine with low oil pressure can be the cause of

engine failure or of a reduction in engine life.

ENGINE OIL PRESSURE CHART


OIL FILTER

(7S6638, 7S6639 & 9S1806)

(1

)

Torque for the bolt 20 + 5 lb. ft. (25 ± 7 Nm)

(2) 6F8007 Spring for oil filter bypass valve:

Length under test force 2.43 in. (61 .7 mm)

Test force 5.2 to 6.1 lb. (23 to 27 N)



7S6638 Filter only:

(3) 6F8007 Spring for oil cooler bypass valve:



Free length after test 3.61 In. (91.7 mm)


OIL BREATHER CAP

(1) Torque for bolt holding

breather cap 120+ 24 1b. in. (13.6 ± 2.8 N-m)



WATER PUMP

(1) Oil seal. Put engine oil on the seal lip. Assemble with the lip

toward the bearings.

(2) Water seal and ring.

a. Put water on the seal.

b. Install the seal and ring together in the housing bore, with the

shiny face of the ring outside.

(3) Seal assembly.

a. Remove the spring from the seal.

b. Put water inside the seal assembly.

c. Install the seal assembly around the shaft, with the 7N7843Installation Tool, (the tool is with the seal group) until the car-

bon face makes contact with the shiny face of the ring (2).

d. Install the spring.

(4) Torque for the bolt that holds the

impeller 28

(5) Torque for bolt that holds the

gear 32

1 lb. ft. (39 ± 1 Nm)

51b. ft. (43 ± 7Nm)

V-BELT TENSION CHART


RADIATOR

T93973

TOP TANK WITH 5S1218 PRESSURERELIEF VALVE

A59222XI

TIGHTENING PROCEDURE FOR TYPICAL TWO-ROVI/ TANK

Clean the threads of the studs with 8M8060 Quick Cure Primer.Then put 9S3265 Retaining Compound on the threads before in-

stalling them.

(1) Torque for stud for the

filler cap 40 l 5 lb. ft. (55 ± 7 N-m)

(2) 2S3080 Pressure Relief Cap:

Pressure valve must not leak at 11 .9 psi (82 kPa)

Pressure valve must be open at 15 psi (105 kPa)

Vacuum valve must be open at a pressure belowatmospheric of 0.6 psi (4 kPa)

or 1.22 in. Hg (31.0 mm Hg)or 16.6 in. Hs (422 mm HjO)

(2) 321464 Pressure Relief Cap:

Cap must not leak at 6.5 psi (45 kPa)

Cap must be open at 8 psi (55 kPa)

(2) 5S1218 Pressure Relief Valve:

Vacuum relief valve to openat a maximum of 1 psi (7 kPa)

Pressure relief valve must not leak at 14 psi (95 kPa)

Pressure relief valve must be open at 18 psi (125 kPa)

(3) Torque for bolts that hold baffles

and shields 15 ± 5 lb. ft. (20 ± 7 N-m)

(4) Bolt torque sequence for radiator tanks. Sequence 5 and 6 arenot required on the bottom tank.

i^ 5-O o O O

o o o o o o

O O O O O O Oo-I

TIGHTENING PROCEDURE FORTYPICAL THREE-ROW TANK



WATER TEMPERATURE REGULATOR

7N208 Regulator:

Temperature when completely open 195= F (90 " C)

Minimum open distance 375 in. (9.53 mm)77719X1

9S3808 and 4H1991 Regulator:

Temperature when completely open 185° F (85° C)

Minimum open distance 310 in. (7.87 mm)85312X1

COOLANT FLOW SWITCH

4N9072 SWITCH (John W. Hobbs Number 22258)

(1) Terminal connected to insulated contact. The other contact is

connected to the body of the switch. Switch contacts are nor-mally closed.

(2) With paddle in vertical position,

the force (F) on rivet head (2)

necessary to open contacts of

switch 1 .2 ± .1 oz. (34 ± 3 grams)

(3) Length of paddle 2.58 in. (65.5 mm)

NOTE: When the switch is installed in engine cooling system, theflow of coolant at cranking speed of the engine does not haveenough force to activate the switch. When the engine is running at

low idle the flow of coolant has enough force to activate the switch.

59


CYLINDER BLOCK(Counterbored Block)

(1) Depth of bore in block

for liner 401 ± .001 in. '10.19 ± 0.03 mm)

NOTE: For fieighit of liner over top of block make reference to CYL-INDER LINER PROJECTION.

(2) Camshaft bearing bore

installed 2.3150 ± .0020 in. (58.801 ± 0.051 mm)

Bore in block for camshaftbearings 2.5630:

Depth to install camshaftbearings at both ends of

block

.0010 in. (65.100 ± 0.025 mm)

... .06 ± .02 in. (1.5 ± 0.5 mm)

NOTE: The camshaft bearing at the front of the block must be in-

stalled with oil holes in a horizontal position and joint at the top

within ± 15° from vertical.

(3) Bore in block for

main bearings

(standard size) 3.8160: .0005 in. (96.926 ± 0.013 mm)

Bore in block for mainbearings .020 in. (0.51 mmoversize) 3.8360 ± .0005 in. (97.434 ± 0.013 mm)

(4) Dimension from center of mainbearing bore to top of cylinder

block (new) 15.5000 ± .0065 in. (393.700 : 0.165 mm)

(5) Dimension from center of mainbearing bore to bottom of cylinder

block (new) 6.0625 ± .0040 in. (153.988 ± 0.102 mm)

(6) Clearance between slot in block andbearing cap 0017 in. (0.043 mm) loose to

.0013 in. (0.033 mm) tight

Main bearing capwidth 6.4998 ± .0008 in. '165.095 ± 0.020 mm)

Width of cylinder block for main bearing

cap 6.5000 ± .0007 in. (165.100 :


balancer bearing .

0.018 mm)

2.2776 ± .0010 in. (57.851 ± 0.025 mm)

(8) Torque for bolts holding bearing caps for main bearings:

a. Put engine oil on threads and washer face.

b. Tighten all bolts to 30 ± 3 lb. ft. (40 ± 4 N-m)

c. Put a mark on each bolt and cap.

d. Tighten all bolts from mark 90°

NOTE: Install bearing caps with the part number toward the front

of the engine. Be sure that the mark (number) on the bearing cap

next to the bolt hole is in agreement with the mark in the cylinder

block.

CAUTIONThere are holes in the bores for the main bearings, betweencylinders 1 and 2, and 3 and 4 for piston cooler orifices. Theseholes must have either orifices (10) or plugs (9) installed.

NOTE: If a turbocharger is installed on the engine, be sure to install

orifices (10) and an engine oil cooler.

NOTE: If the engine has an engine oil cooler and no turbocharger,

be sure to install orifices (10).

(11) Distance to install dowels from

top of block 38 ± .02 in. (9.7 ± 0.5 mm)

(12) Distance to install stud from

face of block 62

(13) Distance to install dowels from

front face of block 88

± .02 in. (15.7 ±0.5 mm)

± .02 in. (22.4 ± 0.5 mm)

( 1

Llfir/-A261 07-1X3




CYLINDER BLOCK(With Spacer Plate)

(1) Thickness of \ r /

spacer plate 3925 ± .0010 in. (9.970 ± 0.025 mm)

Thickness of

spacer plate gasket . . . .0082 ± .0010 in. (0.208 ± 0.025 mm)

NOTE: For height of liner over top of spacer plate make reference to

CYLINDER LINER PROJECTION.

(2) Camshaft bearing bore

(installed) 2.3150 ± .0020 in. (58.801 ± 0.051 mm)

Bore in block for camshaftbearings 2.5630 ± .0010 in. (65.100 ± 0.025 mm)

Depth to install camshaftbearings at both ends of

block 06 ± .02 in. (1.5 + 0.5 mm)

NOTE: The camshaft bearing at the front of the block must be in-

stalled with oil holes in a horizontal position and joint at top within ±15° from vertical.


main bearings (standard

size) 3.8160 ± .0005 in. (96.926 ± 0.013 mm)

Bore in block for mainbearings .020 in. (0.51 mmoversize) 3.8360 ± .0005 in. (97.434 ± 0.013 mm)

(4) Dimension from center of mainbearing bore to top of cylinder

block (new) 15.099 ± .006 in. (383.51 ± 0.15 mm)

(5) Dimension from center of mainbearing bore to bottom of cylinder

block (new) 6.063 ± .004 in. (154.00 ± 0.10 mm)

(6) Clearance between slot in block andbearing cap 0017 in. (0.043 mm) loose to

.0013 in. (0.033 mm) tight

Main bearing capwidth 6.4998 ± .0008 in. (165.095 ± 0.020 mm)

Width of cylinder block for main bearing

cap 6.5000 ± .0007 in. (165.100 ± 0.018 mm)

(7) Bore in block for balancerbearing 2.2776 ± .0010 in. (57.851 ± 0.025 mm)

(8) Torque for bolts holding bearing caps for main bearings:

a. Put engine oil on threads and washer face.

b. Tighten all bolts to 30 ± 3 lb. ft. (40 ± 4 N-m)

c. Put a mark on each bolt and cap.

d. Tighten all bolts from mark 90°

NOTE: Install bearing caps with the part number toward the front of

the engine. Be sure that the mark (number) on the bearing cap nextto the bolt hole is in agreement with the mark in the cylinder block,

CAUTIONTtiere are holes in the bores for the main bearings, betweencylinders 1 and 2, and 3 and 4 for piston cooler orifices. Theseholes must have either orifices (10) or plugs (9) installed.

NOTE: If a turbocharger is installed on the engine, be sure to install

orifices (10) and an engine oil cooler.

NOTE: If the engine has an engine oil cooler and no turbochargerbe sure to install orifices (10).

(11) Distance to install dowels fromtop of block 780 ± .020 in. (19.8 ± 0.5 mm)

(12) Distance to install stud fromface of block 62 ± .02 in. (15.7 ± 0.5 mm)

B42697XI

Lltrr/J(13) Distance to install dowels from

front face of block

A261 07-1X3

+ .02 in. (22.4 ± 0.5 mm)

61


CYLINDER LINER

NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS: PIS-

TONS AND CYLINDER LINERS, Form No. SEBF8001.

(1)

(2)

Bore in liner

(new) 4.751 ± .001 in. (120,68 ± 0.03 mm)

Use again maximum bore when measured near upper end of tfie

wear surface of tfie cylinder liner 4.755 in. (120.78 mm)

Ttiickness of flange

on liner .4048 ± .0008 in, (10.282 ± 0,020 mm)

(3) Filler band.

Cylinder Liner Installation

Put liquid soap on bottom liner bore in block, on grooves in lower

liner, and on 0-rings. Install 0-rings on liner. Put filler band (3) in

engine oil for a moment and install on liner. Immediately install liner

in cylinder block (before expansion of filler band).

II

T8832I - 1X1

CYLINDER LINER PROJECTION(Counterbored Block)

IVIake reference to CYLINDER LINER PROJECTION in Testing and

Adjusting for tfie complete procedure.

1. Install tooling as sfiown. Tighten bolts (1) evenly in four steps:

1st step 5 lb. ft. (7 N-m)

2nd step 15 lb. ft. (20 Nm)

3rd step 25 lb. ft. (35 Nm)

4th step 50 lb. ft, (70 Nm)

2, fvleasure cylinder liner projection with dial indicator (7) clampedin 1P2402 Gauge Body (6) as shown, IVIeasure at four places

around each cylinder liner near the clamped area.

Cylinder liner projection measurement for any cylinder

liner must be 0020 to .0056 in. (0.051 to 0,142 mm)

IVIaximum permissible difference between all four

measurements 002 in, (0,05 mm)

Maximum permissible difference between average

projection of any two cylinders next to

each other 002 in, (0.05 mm)

Maximum permissible difference between average

projection of all cylinder liners under onecylinder head 003 in, (0,08 mm)

NOTE: If liner projection is not correct, turn the liner to a new position

within the bore. If projection can not be corrected this way, move the

liner to a different bore. If the projection can not be corrected this

way, make reference to Special Instruction, Form No, FM055228 for

complete instructions on the use of 8S3140 Counterboring Tool

Arrangement,

(1) Bolts [5/8" NC, 5.5 in, (140 mm) long).

(2) Crossbar (from 8B7548 Push-Puller)

(3) 4B4281 Washers

(4) 1 P2394 Adapter Plate

(5) 3H465 Plates

(6) 1 P2402 Gauge Body

(7) 1P2403 Dial Indicator

A34793Xt

SHIM THICKNESS, COLOR CODE, AND PART NUMBER


CYLINDER LINER PROJECTION(With Spacer Plate)

Make reference to CYLINDER LINER PROJECTION in Testing andAdjusting for the complete procedure.

1. Install gasket and spacer plate (2) witti bolts (3) and two 1S379Wasfiers. Tighiten bolts (3) evenly in four steps:

1st step 10 lb. ft. (14 Nm)

2nd step 25 lb. ft. (35 Nm)


4th step 70 lb. ft. (95 Nm)

2. Install tools as shown. Tighten bolts (4) evenly In four steps:

1st step 5 lb. ft. (7 Nm)

2nd step 15 lb. ft. (20 N-m)


4th step 50 lb. ft. (70 Nm)

3. Measure cylinder liner projection with dial indicator (6) in 1P2402Gauge Body (8) as shown. Measure at four places around eachcylinder liner near the clamped area.

Cylinder liner projection measurement for any cylinder

liner must be 00 13 to .0069 in. (0.033 to 0.1 75 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 002 in. (0.05 mm)

Maximum permissible difference between averageprojection of all cylinder liners under onecylinder head 003 in. (0.08 mm)

NOTE; If liner projection is not correct, turn the liner to a new position

within the bore. If projection can not be corrected this way, move the

liner to a different bore. If the projection can not be corrected this

way, make reference to Special Instruction, Form No. FM055228 for

complete instructions on the use of 8S3140 Counterboring ToolArrangement.

SHIM THICKNESS, COLOR CODE, AND PART NUMBER


PISTONS AND RINGS

Make reference to GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001.

PISTONS AND PISTON RINGS


PISTONS AND RINGSMake reference to GUIDELINE FOR REUSABLE PARTS: PISTONS AND CYLINDER LINERS. Form No. SEBF8001.


CONNECTING ROD

(1) Bore in bearing for piston pin (new):

5S6360 Rod 1 5017 ± .0003 in. (38.143 + 0.008 mm)

5S2793 Rod 1.7012 ± .0003 in. (43.210 + 0.008 mm)

8N1984 Rod(tapered) 1.5017 ± .0003 in. (38.143 ± 0.008 mm)

8N1721 Rod(tapered) 1.7012 ± .0003 in. (43.210 + 0.008 mm)

Maximum permissible clearance between bearing

and piston pin (worn) 003 in. (0.08 mm)

(2) Bore in connecting rod for

bearing 3.2500 ± .0005 in. (82.550 ± 0.013 mm)

(3) Distance between center of piston pin andcenter of crankshaft bearing

(new) 9.595 ± .001 in. (243.71 ± 0.03 mm)

(4) Diameter of piston pin (new):

9H4016 Pin 1.5003 ± .0002 in. (38.108 ± 0.005 mm)

7N9804 Pin 1.5003 ± .0002 in. (38.108 ± 0.005 mm)

8r^6487 Pin 1.6998 ± .0002 in. (43.175 ± 0.005 mm)

7N9805 Pin 1.6998 ± .0002 in. (43.175 ± 0.005 mm)

(5) Clearance between connecting rod bearing

and crankshaft bearing surface

(journal) 0030 to .0066 in. (0.076 to 0.168 mm)

Maximum permissible clearance between bearing and crankshaft

(worn) 010 in. (0.25 mm)

(6) Torque on nut for connecting rod:

a. Put engine oil on threads and nut seat.

b. Tighten both nuts to 30 ± 3 lb. ft. (40 ± 4 Nm)

c. Mark each nut and end of bolt.

d. Again tighten both nuts (from mark) 90°

Install the connecting rod in the piston with the slot for the bearing tab

on the same side as the V mark on the piston.

Make reference to Special Instructions, Form No. GMG02394 andSMHS7366 for information about checking and reconditioning connect-

ing rods.

B09139X2




CRANKSHAFT

) 2

(1) Thickness of thrust plates (new):

Without tabs

6N8940 1850 ± .0015 in. (4.699 ± 0.038 mm)

9S3037 2320 ± .0015 in. (5.894 ± 0.038 mm)

with tabs:

7N9342 2150 ± .0015 in. (5.461 ± 0.038 mm)

7N9343 2620 ± .0015 in. (6.655 ± 0.038 mm)

NOTE: Make reference to THRUST PLATE USAGE CHART for thecorrect thrust plate to use.

(2) Make reference to MAIN BEARINGS and BEARING SURFACE(JOURNAL) FOR MAIN BEARINGS.

(3) Make reference to CONNECTING ROD BEARINGS and BEAR-ING SURFACE (JOURNAL) FOR CONNECTING RODS.

(4) Tighten plugs to 17 ± 3 lb. ft. (23 ± 4 Nm)

Then "stake" the crankshaft to hold plugs in place. "STAKE" usea center punch and a hammer to change the shape of the holeas shown.

(5) Crankshaft gear:

Do not heat gear to more than 600°F (316°C).

(6) End play for crankshaft

(new) 0025 to .0145 in. (0.064 to 0.368 mm)

Maximum permissible end play for crankshaft(worn) 025 in. (0.64 mm)

(7) Wear sleeve and seal installation:

Push wear sleeve and seal into position with correct tooling.

Make reference to Special Instruction, Form No. SMHS7100 for

instructions and the correct tooling for installing wear sleevesand seals.

THRUST PLATE USAGE CHART


BEARING SURFACE (JOURNAL)

FOR MAIN BEARINGS

A06090X1

BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS


BEARING SURFACE (JOURNAL)

FOR CONNECTING RODS

A06090X1

BEARING SURFACE (JOURNAL) FOR CONNECTING RODS


MAIN BEARINGS AND CONNECTING ROD BEARINGS

Make reference to GUIDELINE FOR REUSABLE PARTS; MAIN BEARINGS AND CONNECTING ROD BEARINGS, Form No. SEBF8009.

CONNECTING ROD BEARINGS


I

FAN DRIVE

(1) Fill chamber between bearings half full of 1P808 Grease before

bolts are tightened.

V///

71


FLYWHEEL RING GEAR

(1) Ring gear.

(2) Flywheel.

(3) Pilot bearing bore.

(4) Chamfer side of ring gear (1).

Install ring gear (1) on flywheel (2) so that the chamfer side (4) of ring

gear (1) is as shown.

CAUTION: Do not heat ring gear to more than 600°F (316°C) beforeinstalling on the flywheel.

FLYWHEEL HOUSING

TIGHTENING

Tighten bolts in number sequenceto 75 ± 10 lb. ft. (100 ± 14 N-m)

(A) Timing bolt hole.

NOTE: On some engines the timing bolt hole is below the starter.

TYPICAL ILLUSTRATION

72NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRSTPAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES


FLYWHEEL

Face Runout (axial eccentricity) of the Flywheel:

1. Install the dial indicator as shown. Put a force on the flywheel

toward the rear.

2. Set the dial indicator to read .000 in. (0.0 mnn)

3. Turn the flywheel and read the indicator every 90°. Put a force onthe flywheel to the rear before each reading.

4. The difference between the lower and higher measurementstaken at all four points must not be more than .006 in. (0.15 mm),which is the maximum permissible face runout (axial eccentric-

ity) of the flywheel.

CHECKING FACE RUNOUT OF THE FLYWHEEL

CHECKING FLYWHEEL BORE

Bore Runout (radial eccentricity) of the Flywheel:

1. Install the dial indicator (3) and make an adjustment of the uni-

versal 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 measurementstaken at all four points must not be more than .006 in. (0.15 mm),which is the maximum permissible bore runout (radial eccentric-

ity) of the flywheel.

5. Runout (eccentricity) for the bore for the pilot bearing for the fly-

wheel clutch, must not exceed .005 in. (0.13 mm)

CHECKING FLYWHEEL CLUTCHPILOT BEARING BORE

73


FLYWHEEL HOUSING

8S2328 DIAL INDICATOR GROUP INSTALLED

Face Runout (axial eccentricity) of the Flywheel Housing:

1. Fasten a dial indicator to ttie cranl<shaft flange so the anvil of the

indicator will touch the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before reading the

indicator at each point.

3. With dial indicator set at .000 in. (0.0 mm) at location (A), turn the

crankshaft and read the indicator at locations (B), (C) and (D).

4. The difference between lower and higher measurements takenall four points must not be more than .012 in. (0.30 mm), which is

the maximum permissible face runout (axial eccentricity) of the

flywheel housing. C (TOP)

A (BOTTOM)



C (TOP)

FLYWHEEL HOUSING BORE

NOTE: Write the dial indicator measurements with their positive ( +

)

and negative (-) notation (signs). This notation is necessary formaking the calculations in the chart correctly.

1. With the dial indicator in position at (C), adjust the dial indicatorto "0" (zero). Push the cranl<shaft up against the top bearing.Write the measurement tor bearing clearance on line 1 in column(C).

2. Divide the measurement from Step 1 by 2. Write this number online 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 cranl<shatt counterclocl<wise to put the dial indicator at

(B). Write the measurement in the chart.

5. Turn the cranl<shaft 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 smaller number from the larger number in line III in

columns (B) (D). The result is the horizontal "eccentricity" (out ofround). Line III, column (C) is the vertical eccentricity.

CHART FOR DIAL INDICATOR MEASUREMENTS


ENGINE MOUNTING BOLTS

NOTE: Use a torque wrench to get the correct torque for all the engine

mounting bolts.

The chart for GENERAL TIGHTENING TORQUES has the correct

tightening torque for all the bolts except those in the list that follows.

D4 Tractor

Tighten the bolts which hold the front

support to the frame to 400 ± 40 lb. ft. (540 + 55 N

Solid rear brackets only:

Tighten the bolts which hold the rear

brackets together to 400 ± 40 lb. ft. (540 ± 55 N

Tighten the bolts which hold the rear

brackets to the frame to 225 + 25 lb. ft. (300 ± 35 N

225 Excavator

Tighten the bolts which hold the support

for the hydraulic pump drive housing to the

frame to 350 + 35 lb. ft. (470 ± 45 N

m)

941-951 Track Type Loaders

Tighten the bolts which hold the front support

to the frame to 460 ± 50 lb. ft. (624 t 70 Nm)

Tighten the bolts which hold thB block on the flywheel

housing to the frame to 460 ± 50 lb. ft. (624 ± 70 N-m)

955 Track Type Loader

Tighten the bolts which hold the front support

to the frame to 460 ± 50 lb. ft. (624 ± 70 Nm)

FLEXIBLE COUPLING DRIVE

(6P3983, 6P3984, 6P5020)

(1) Torque for bolts 80 ± 5 lb. ft. (1 10 ± 7 N-m)

(2) Torque for bolts 95 ± 5 lb. ft. (130 ± 7 Nm)

(3) Maximum permissible out of square of the face of

flange in relation to the input shaft of the

torque converter 026 in. (0.66 mm)

(4) Maximum permissible out of round of output flange in

relation to the input shaft of the

torque converter 080 in. (2.03 mm)

NOTE: Fill the grease lines and the area between the seals with

grease before installing in the vehicle.



FLEXIBLE DRIVE COUPLING

(Earlier; Two Piece Front Flange)

(1) Torque tor bolts 80 ± 5 lb. ft. (1 10 ± 7 Nm)

(2) Torque for bolt holding flange

to drive 160 ± 10 lb. ft. (219 ± 14 Nm)

(3) Maximum permissible "runout" axial alignment of face

(total indicator readingi 026 in. (0.66 mm)

(4) Maximum permissible "eccentricity" radial off

center of flywheel output flange rim to torque

converter shaft (total indicator reading) 080 in. (2.03 mm)

TO413

FLEXIBLE DRIVE COUPLING

(Earlier; One Piece Front Flange)

(1 ) Torque for bolts 80 ± 5 lb. ft. (1 10 ± 7 Nm)

(2) Maximum permissible "runout" axial alignment of face

(total indicator reading) 026 in. (0.66 mm)

(3) Maximum permissible "eccentricity" radial off

center of flywheel output flange rim to torque

converter shaft (total indicator reading) 080 in. (2.03 mm)

77


CHECKING AND ADJUSTING ALIGNMENT OF THEFLEXIBLE COUPLING DRIVE

A09406- 1X1

1

.

Remove the bolts, joints and torque converter flange.

2. Fasten a 3/8 in. (9.5 mm) diameter rod 3 in. (76.2 mm) long to the

torque converter input shaft with a 1J9778 Hose Clamp. Install a

7H1948 Snug onto the rod. Assemble a 7H1942 Indicator (with a

7m940 Universal Attachment), and 7H1945 Holding Rod into the

7H1948Snug.

3. Put the universal attachment on the outside diameter of the engine

output flange. Rotate the indicator until it stops on "0". Turn the

torque converter input shaft 360°. Record the indicator measure-

ment at each 90°of rotation.

4. The total indicator reading through 360° of rotation must not be

more than .080 in. (2.03 mm). The alignment can be made correct

by loosening the engine rear bolts and moving the engine from side

to side. If the alignment up and down is not correct, install or

remove shims under the engine rear supports.

5. If the holes for the support bolts have become larger because of

wear, dowels should be installed after the engine has been fastened

down. [See Step (8)1 .

6. Remove the universal attachment. Put the face of the 7H1942Indicator rod against the engine flange between the bolt holes andoutside diameter of the flange. Turn the indicator to "0".

7. Turn the torque converter input shaft 360°. Record the indicator

measurement at each 90° of rotation. The total indicator reading

through 360° of rotation must not be more than .026 in. (0.66

mm). The alignment can be made correct by loosening the engine

front support bolts and moving the front of the engine side to side.

8. Check the vertical and horizontal alignment again. When the align-

ment is correct, tighten the engine mount bolts:

Make reference to ENGINE MOUNTING BOLTS for the correct

torque for the bolts that hold the engine to the frame.

NOTE: If the alignment is off by a large amount, inspect for the cause.

If the frame is bent, it can be straightened. If the engine front support

is badly worn, a replacement is needed.

A09407- 1 X 1



ALTERNATORS

7S5897 24V 19A (Prestolite Number ANB6001)

9S4070 24V 19A (Prestolite Number ANB7001 )*


Rated output at 28V 19 A

Output at 1 500 rpm and 28V 1 A

Resistance of the rotor at 77° F (25° C) 18 to 20 ohm

Current consumption (draw) at 77° F (25° C)

and 24V 1 .2 to 1 .3 A

(1 ) Torque for nut holding pulley . . 85 to 90 lb. ft. (1 15 to 120 Nm)

(2) Torque for bolts 25 to 30 lb. in. (2.8 to 3.4 Nm)

(3) Torque for screws 10 to 15 lb. in. (1 .1 to 1 .7 N-m)

(4) Torque for terminal nuts 30 to 35 lb. in. (3.4 to 4.0 Nm)

(5) Torque for bolts holding the

regulator 45 to 50 lb. in. (5.1 to 5.7 Nm)

•Including the 9S2329 Regulator (Prestolite Number VSH6401)

2P1698 24V 19A (Prestolite Number ANB6002 or ANB6004)

2P1204 24V 19A (Prestolite Number ANB7002 or ANB7004)*



Output at 6000 rpm, 28V and 70° F (21° C) 25 to 30 A

Resistance of the rotor at 77° F (25° C) 18 to 20 ohms

Current consumption (draw)

at 77° F (25° C) and 24V 1 .20 to 1 .33 A

(1) Torque for nut holding pulley 75 ± 5 lb. ft. (100 ± 7 Nm)

(2) Torque for nuts for field and

ground terminals 25 to 30 lb. in. (2.8 to 3.4 N-m)

(3) Torque for screws holding

terminal plate 10 to 15 lb. in. (1 .1 to 1.7 Nm)

(4) Torque for bolts 25 to 30 lb. in. (2.8 to 3.4 Nm)


regulator 45 to 50 lb. in. (5.1 to 5.7 Nm)

(6) Torque for nut for terminal 45 to 50 lb. in. (5.1 to 5.7 Nm)

(7) Torque for nut for positive

terminal 225 to 250 lb. in. (25.4 to 28.3 Nm)

•Including 2P1699, 4N5938 or 6N3821 Regulator (Prestolite NumberVSH-6401A, VSH-6401B or VSH-6401C).

79


Alternators (Cont.)

6N9294 24V 35A (Delco-Remy Number 1117640)

Rotation can be either direction.

Polarity is negative ground-

Output at 28V and 2600 rpm 15 A

Output at 28V and 6500 rpm 35 A

Rated output, hot 35 A

Field current at 24V and 80 F (27 C) 2.5 to 3.2 A

(1) Torque for nut holding pulley 75 ± 5 lb. ft. (100 ± 7 N-m)

(2) Torque for cover screws 20 ± 5 lb. in. (2.3 ± 0.6 N-m)

Torque for output (POS) terminal ... 5 ± 1 lb. ft. (7 ± 1 N-m)



Alternators (Cont.)

n

5S9088 24V 50A (Delco-Remy Number 1117226)


Polarity is negative ground

Circuit B

Speed for testing 5000 rpm

Output when cold:

Fasten carbon pile to battery to get

maximum output 54 A

Rated output, hot 50 A

Field current at 24V and 80° F (27° C) 2.5 to 2.9 A

Voltage regulator:

Voltage setting range 26 to 30 V

Adjust voltage setting to 28 V

then Increase speed to get

maximum output 50 A

(1) Torque for nut holding pulley 75 ± 5 lb. ft. (100 ± 7 Nm)

(2) Torque for output terminal 10 ± 1 lb. ft. (14 + 1 Nm)

3P77 24V (Delco-Remy Number 1102398)



Output at 26V and 2600 rpm (cold) 25 A

Output at 26V and 7000 rpm (cold) 41 A

Rated output (hot) 40 A

(1) Torque for stud nut for battery

connection 25 to 40 lb. in. (2.8 to 4.5 Nm)

(2) Torque for pulley nut 60 + 5 lb. ft. (80 ± 7 Nm)

81


Alternators (Cont.)

5A8908 24V 20A (Mitsubishi Number AR4020A)

Rotation is clocl<wise when seen from drive end.



No load output at speed below 1150 rpm 28 V

Loaded output at speed below 2500 rpm and 28 V 20 A

Resistance of field coil at 68° F (20° CI 29.5 ohms

Tension of brush spring 1 1 to 14 oz. (3.1 to 3.9 N)

Minimum permissible tension of spring 7.4 oz. (2.1 N)

Brush length 75 in. (19.0 mm)

Minimum permissible brush length 25 in. (6.4 mm)

Torque for nut holding pulley 75 to 90 lb. ft. (100 to 120 Nm)

Torque for nut holding slip rings 35 lb. ft. (45 IMm)

3A1997 24V 19A (Paris-Rhone Number A13RH3T)


Rotation is clockwise when seen from drive end.

Output at 4,000 rpm (hot) 19 A

Output at 1,180 rpm (hot) 28 V

(1) Torque for pulley nut 75 to 90 lb. ft. (100 to 120 Nm)

(2) Tension of brush spring 2.25 to 2.75 lb. (10 to 12 N)

(3) Minimum brush length 44 in. (11.2 mm)

(4) Diameter of slip ring (new) 1.65 in. (42,0 mm)

Minimum permissible slip ring diameter 1.57 in. (40.0 mm)

(5) Torque for slip ring nut 18 to 22 lb. ft. (24 to 28 Nm)



ALTERNATOR REGULATOR

6N3821 24V (Prestolite Number VSH-6401C)

4N5938 24V (Prestolite Number VSH-6401B)

2P169g 24V (Prestolite Number VSH-6401A)

9S2329 24V (Prestolite Number VSH-6401)


Voltage setting range at 70° F (21°C) 27.3 to 28.7 V(1) Adjustment screw and washer.

•With voltage adjustment screw (Din position

"N" (center). When screw (II is in position

"L", voltage will be 0.5V less. When screw (1

)

is in position "H", voltage will be 0.5V higher.

5A9131 24V (Mitsubishi Number RM4140G)

Voltage range at 3000 rpm 28 to 31 V

L83


GENERATORS

4M9102 24V 20A (DelcoRemy Number 1106971)

Rotation is clocl<wlse when seen from tlie drive end.

Circuit A

Speed for testing 1 720 rpm

Field current at 24V and 80° F (27° C) 83 to .89 A

Output at 1 720 rpm and 26V wfien cold 20 A

Output wtien cold 26 V

(1

)

Tension of brusfi spring 20 oz. (5.6 N)


pulley 83 ± 8 lb. ft. (114 ± 11 Nm)

1S151 24V 15A (DelcoRemy Number 1105241)

Rotation is clockwise when seen from the drive end.

Circuit A


Field current at 24V and 80° F (27° C) 94 to 1 .02 A

Output at 1800 rpm and 28.5V when cold 15 A

Output when cold 28.5 V

(1

)

Tension of brush spring 16 oz. (4.4 N)


pulley 83 ± 8 lb. ft. (1 14 ± 1 1 IMm)

1S5134 24V and 25A (Oelco-Remy Number 1106887)


Circuit A


Field current at 24V 80° F (27° C) 83 to.89 A

Output at 1 700 rpm and 26V when cold 20 A

Output when cold 26 V

(1) Tension of brush spring 20 oz. (5.6 N)


pulley 60 ± 10 lb. ft. (80 ± 14 Nm)

1^

e a _


Generators (Cont.)

5A3033 & 5A6539 (Mitsubishi Number DR 350/24MR)


Speed for testing with a load (less than) 2000 rpm

Output with a load 28.5 V

Output at below 2000 rpm and 28.5V 1 5 A

Speed for testing with no load (less than) 1550 rpm

Output with no load (zero Amps) 28.5 V

Tension of brush spring 77 lb. (3.4 N)

5A7375 (Mitsubishi Number DT 600/24 ZR)


Speed for testing with a load (less than) 1600 rpm

Output with a load 28 V

Output at below 1600 rpm and 28\/ 25 A

Speed for testing with no load (less than) 1450 rpm

Output with no load (zero Amps) 28 V

Tension of brush spring 93 lb. (4.2 N)

GENERATOR REGULATORS

2M6497 24V 15A (Delco-Remy Number 1119626)

Polarity is negative ground or insulated.

Circuit A

(1) Cutout relay:

Air gap between armature and core 01 7 in. (0.43 mm)

Point gap 032 in. (0.81 mm)

Voltage closing range 22.8 to 25.2 V

(2) Current regulator:

Air gap between armature andcore 068 to .082 in. (1.73 to 2.08 mm)

Current setting range 14 to 16 A

(3) Voltage regulator:

Air gap between armature and core 067 in. (1 .70 mm)


Voltage setting range at 85° F (29° C):

Upper contacts 27.4 to 29.4 V' Lower contacts 2 to .6V less than upper contacts

(4) Torque for bolt 36 ± 6 lb. in. (4.1 ± 0.7 N-m)

85


Generator Regulators (Cont.)

4M9349 24V 20A (Delco-Remy Number 1119653)

Polarity is negative ground or insulated.

Circuit A

(1) Cutout relay:

Air gap between armature and

core 015 to .019 in. (0.38 to 0.48 mm)


Voltage closing range 22.8 to 25.2 V



core 068 to .082 in. (1 .73 to 2.08 mm)





Voltage setting range at 85° F (29° C):

Upper contacts 27.4 to 29.4 V

Lower contacts 2 to .6V less than upper contacts

(4) Torque for bolt 36 ± 6 lb. in. (4.1 ± 0.7 Mm)

3S5028 24V 25A (DelcoRemy Number 11 19306 and 1119306-E)


Circuit A

(1) Cutout relay:


core 015 to .019 in. (0.38 to 0.48 mm)


Voltage closing range 24 to 27 V



core 068 to .082 in. (1 .73 to 2.08 mm)




Voltage setting range at 85° F (29° C) 27.5 to 29.5 V

(4) Torque for bolts 36 ± 6 lb. in. (4.1 ± 0.7 Nm)




Generator Regulators (Cont.)

3A1874 24 V (Paris-Rhone Number 2T216)

(1) Cutout relay:

Air gap between armature and core 027 in. (0.69 mm)

Point gap 031 in. (0.79 mml

Closing range when cold 24.0 to 26.0 V


Air gap between armature and core 039 In. (0.99 mm)




Voltage setting range at 85° F (29° C) 26.8 to 28.2 V

(4) Torque for bolts 36 ± 6 lb. in. (4.1 + 0.7 N-m)

5A3061 (Mitsubishi Number RW-3B)

Cutout relay:


Back gap 030 to .047 in. (0.76 to 1 .19 mm)

Point gap 020 to .032 in. (0.51 to 0.81 mm)

Switch in 24.5 + 1 V

Reverse current (less than) 7 A

Voltage regulator:

Air gap between armature andcore 039 to .047 in.

Back gap 029 to .043 in.

Regulator setting (no load) at 3000 rpm

Current regulator:


Back gap 029 to .043 in. (0.74 to 1 .09 mm)

Current limiter setting range at 3000 rpm 14 to 16 A

(0.99 to 1.19 mm)

(0.74 to 1.09 mm)

. . 27.5 to 29.5 V

5A7385 (Mitsubishi Number RT4342E)

Cutout relay:

Air gap between armature and core 051 in. (1.30 mm)

Point gap 016 to .024 in. (0.41 to 0.61 mm)

Switch in 26 to 27 V

Reverse current (less than) 10 A

Voltage regulator:


Regulator setting (no load) at 3000 rpm 28 to 29 V

Current regulator:


core 051 to .069 in. (1 .30 to 1 .75 mm)

Current limiter setting range at 4000 rpm 24 to 26 A

87


STARTER MOTORS


9M1662 24V (Delco-Remy Number 1113967)

4N3182 24V (Delco-Remy Number 1114711)


Minimum speed with no load 5500 rpm

Maximum speed with no load 7500 rpm

Current consumption (draw) at no load:

Minimum with solenoid at 20V 75 A

Maximum with solenoid at 20V 95 A

Clearance between pinion and housing

(pinion clearance) 36 in. (9.1 mm)

(1) Tension of brush spring 56 oz. (15.6 N)

(2) Torque for screws holding nose housingto lever housing 13 to 17 lb. ft. (18 to 23 N-m)

(3) Torque for terminal nuts 20 to 25 lb. ft. (25 to 35 N-m)








Clearance between pinion and housing(pinion clearance) 36 in. (9.1 mm)

(1) Tension of brush spring' 36 to 40 oz. (10.0 to 11.1 N)

(2) Torque for screws holding nose housing to

lever housing 8 lb. ft. (11 N-m)


"Minimum for leaf springs 80 oz. (22 N)








Maximum with solenoid at 20V 1 12 A

Clearance between pinion and housing(pinion clearance) 010 to .140 in. (0.25 to 3.56 mm)

(1) Tension of brush spring 36 to 40 oz. (10.0 to 11.1 N)

(2) Torque for screws holding nosehousing to lever housing 13 to 17 lb. ft. (18 to 23 N-m)


3T2772 24V (Delco-Remy Number 1113540)













Starter Motors (Cont.)



iVIInimum speed witii no load 5500 rpm







(2) Torque for screws holding nose housingto lever housing 13 to 17 lb. ft. (18 to 23 N-m)











7S5900 and 2P2501 24V (Prestolite Number MFY 6201 K)

3P6 24V (Prestolite Number MFY 6401 K)

4N7901 24V (Prestolite Number MFY 6401 L)


Minimum no load speed 5000 rpm


Maximum at 20V 65 A


(2) Torque for bolts 8 lb. ft. (11 N-m)


(4) Clearance for the pinion . . . .020 to .050 in. (0.51 to 1 .27 mm)

7S2234 and 1P7839 24V (Prestolite Number MES6101K)

4N7752 24V (Prestolite Number MES6404K)

2P6162 24V (Prestolite Number MES6301K)

9G4338 24V (Prestolite Number MES6601K)



Current consumption (draw) with no load:

Maximum at 20V 77 A


(2) Torque for housing bolts 8 lb. ft. (1 1 N-m)


(4) Clearance between pinion and housing(pinion clearance) 020 to .050 in. (0.51 to 1 .27 mm)

89



9G4337 24V (Presfolite Number MFY6601K)

Rotation Is clockwise when seen from ttie drive end-



Maximum at 207 65 A

(1) Torque for bolts 8 lb. ft. (11 N-m)

(2) Torque tor terminal nuts 20 to 25 lb, ft. (25 to 35 N-m)

(3) Clearance for ttie pinion . . . .020 to .050 in. (0.51 to 1.27 mm)

3T6305 24V (Robert Bosch Number 0-001-430-03)

Rotation is clockwise wtien seen from ttie drive end.



Minimum 140 A

Permissible clearance betweenpinion and ring gear 06 to .22 in. (1.5 to 5.6 mm)

(1

)

Torque for terminal nuts 20 to 24 lb. ft. (27 to 33 N-m)

(2) Minimum permissible lengtti of

thie brusties 69 in. (17.5 mm)

(3) Minimum permissible diameter of

commutator 1.9 in. (48 mm)




r^

3A2035 24V (Paris-Rhone Number D13 E76)

3A 1872 24V (Paris-Rhone Number D13 E77)

Rotation is clocl<wise when seen from drive end.

iVIaximum speed with no load at 20 V 6000 rpm


Maximum with solenoid at 20 V and 6000 rpm 75 A

Minimum permissible diameter of the

commutator 2.05 in. (52.1 mm)

Clearance between pinion and support

(pinion clearance) 039 ± .020 in. (1.00 + 0.51 mm)

(1) Tension of brush spring 53.3 ± 5.3 oz. (14.8 i 1.5 N)

(2) Torque for screws holding support to

lever housing 15 ± 2 lb. ft. (20 ± 3 Nm)

(3) Torque for terminal nuts 20 to 25 lb. ft. (25 to 35 IMm)



flotation is clockwise when seen from drive end.

Maximum speed with no load at 20 V 6000 rpm

Current consumption (draw) with no load:

Maximum with solenoid at 20 V and 6000 rpm 75 A

Minimum permissible diameter of the


Clearance between pinion and thrust washer(pinion clearance) 039 ± .020 in. (1.00 + 0.51 mm)

(1) Tension of brush spring 53.3 ± 5.3 oz. (14.8 ± 1.5 N)

(2) Torque for screws holding support to

lever housing 15 + 2 lb. ft. (20 + 3 N-m)

(3) Torque for terminal nuts 20 to 25 lb. ft. (25 to 35 Nm)

5A6492 and 5A3031 (IMitsubishi Number MX 10/24 ZR)

5A6494 and 5A3196 (Mitsubishi Number MT 10/24 YR)




Maximum at 23V 110 A

Stall torque test:

Maximum current consumption (draw) at 9V(maximum) 1500 A

Stall torque at 9V (minimum) 79.6 lb. ft. (108.1 Nm)

(1 ) Minimum permissible diameter of the


(2) Tension of brush spring 2.29 ± .34 lb. (10.2 ± 1.50 N)

(3) Minimum permissible length of brushes 55 in, (14.0 mm)

(4) Clearance between pinion and housing(pinion clearance) 1 18 to .138 in. (2.99 to 3.51 mm)

91



5A6522 (Mitsubishi Number MRA 7 5/24 ER or IV1OO7T03774)

5A6495 (IVIitsubishi Number IVIRE 7 5/24 ER)

5A5744 (IVIitsubishi Number MTR 7 5/24 YR)




Maximum at 23V 1 10 A

Stall torque test:

Maximum current consumption (draw) at 9V(maximum) 1500 A

Stall torque at 9V (minimum) 80 lb. ft. (1 10 N-m)

(1) Minimum permissible diameter of the


(2) Tension of brush spring 4.6 ± .7 lb. (20.5 ± 3.1 N)

(3) Minimum permissible length of brushes 55 in. (14.0 mm)

(4) Clearance between pinion and housing

(pinion clearance) 1 18 to .138 in. (2.99 to 3.51 mm)

STARTER MAGNETIC SWITCHES

7N3621 24V

7M4291 24V (Delco-Remy Number 1119866)

Current consumption (draw) at 20 V 3.5 to 3.9 A

(1) 7M7553 Spring:





(2) 7M7622 Spring:


Test force 2.65 to 3.25 lb. (1 1 .60 to 14.00 N)



9F3099 24V (Delco-Remy Number 0001481)

Current consumption (draw) both

windings at 24 V 83 to .89 A

(1) Torque for large terminal nuts .. . 30 to 40 lb. in. (3.4 to 4.5 Mm)

5L5886 12V (Delco-Remy Number 0001486)

302266 or 9N964 12V (Delco-Remy Number 1119828)

Rating 12 V

Current consumption (draw) hold-in

windings at 8 V 2.1 to 2.4 A

(1) Torque for large terminal

nuts 30 to 40 lb. in. (3.4 to 4.5 Nm)

92NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST



STARTER SOLENOIDS

4M1812 24V (Delco-Remy Number 1119832 or 1119848)

Current consumption (draw):

Current pull in windings at 5V 10 to 11.5 A

Current pull in windings at 20 to 24V 40 to 55.2 A

Current hold in winding at 20 to 24V Maximum of 8.2 A

(1) 4M1815 Spring for contact release:


Test force 8.5 to 9.5 lb. (37.8 to 42.3 N)

Free length after test 83 ± .015 in. (21.1 ± 0.38 mm)

Outside diameter 375 ± .010 in. (9.53 ± 0.25 mm)

(2) 9M7609 or 8M1856 Spring to return the clutch lever:


Test force 14 ± .5 lb. (62 ± 2.2 N)


Outside diameter 1.393 ± .015 in. (35.38 ± 0.38 mm)

(3) Torque for terminal screws . . 16 to 30 lb. in. (1.8 to 3.4 N-m)

6NS123 24V (Delco-Remy Number 1115544)


Current at 20V 40 to 45.5 A

Current at 20 to 24V 40 to 54.6 A

(1) 4M1815 Spring for contact release:

Length under test force .• 42 in. (10.7 mm)




(2) 9M7609 Spring to return the clutch lever:


Test force 14 ± .5 lb. (62 ± 2.2 N)



(3) Torque for terminal screws . . 16 to 30 lb. in. (1 .8 to 3.4 N-m)

93


Starter Solenoids (Cont.)



Current at 20V 40 to 45.5 A

Current at 20V to 24V 40 to 54.6 A

(1) 4M1815 Spring for contact release;





(2) 9M7609 Spring to return the clutch lever:


Test force 14 + .5 lb. (62 ± 2.2 N)



(3) Torque for terminal screws . . 16 to 30 lb. in. (1.8 to 3.4 N-m)



Pull in winding at 5V 9 to 11.5 A

Hold in winding at 20V 6.8 A IVIaximum

(1) Torque for nuts 20 to 25 lb. ft. (27 to 33 N-m)

B38473X1




Starter Solenoids (Cont.)

3T868 24V (Robert Bosch Number 0331 410 002)

Resistance:

Pull in winding 513 to .567 ohm

Resistance:

Hold in winding 3.28 to 3.62 ohmB38474X1

r^3T3369 24V (Presfolite Number SAT-4105)

9S7976 24V (Preslolite Number SAT-4103)

8S1529 24V (Prestolite Number SAT-4101)


Current pull in windings at 12 V 23.2 to 26.6 A

Current pull in windings at 20 to 24 V 38.6 to 52.4 A

Current hold in windings at 12 V 4.1 to 4.8 A

Current hold in windings at 20 to 24 V 6.8 to 9.6 A

if=o

3A1555 24V (Paris-Rhone Number CED65I

Current Consumption (draw):

Current both windings at 20V 70 ± 7 A

Current hold in windings at 20V 11.2± 1.2 A

(1) Spring for contact release:


Test force 18.7 ± 1.9 lb. (83.0 ± 8.5 N)

Free length after test 433 i .010 in. (11.00 ± 0.25 mm)


(2) Spring to return the clutch lever:


Test force 13.2 ± 1.3 lb. (58.5 ± 5.8 N)

Outside diameter 45 in. (1 1.4 mm)

95


FUEL PRESSURE INDICATOR

6N3272 Indicator (Frank W. Murphy Mfr. Inc.)

Gauge with color code.

CALIBRATIOIM CHART


OIL PRESSURE INDICATOR

5M1065 Indicator (Stewart Warner Corp. Number 342-FR)

Gauge with color code.

CALIBRATION CHART

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CITERPILLAR®

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SENR7590-01Printed In U.S.A. (10/81)

Documents

Ia Caterpillar Specifications 3304 VehicularEngine Text