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RENR9337

July 2006

Specifications
Preliminary Information

C175-16 Generator Set Engine


WYB1-Up (Generator Set)

i01658146

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this


product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

RENR9337

Table of Contents
Specifications Section
Engine Design ....................................................... 4
Fuel Filter (Primary) ................................................ 4
Fuel Filter (Secondary) ........................................... 5
Fuel Transfer Pump ............................................... 5
Fuel Injector ............................................................ 6
Fuel Lines ............................................................... 7
Fuel Lines ............................................................... 8
Camshaft .............................................................. 11
Lifter Group ........................................................... 12
Valve Mechanism ................................................. 13
Cylinder Head ...................................................... 13
Cylinder Head Valves ........................................... 15
Turbocharger ....................................................... 16
Air Lines ................................................................ 17
Exhaust Manifold ................................................. 17
Exhaust Manifold ................................................. 18
Exhaust Fitting ...................................................... 18
Exhaust Fitting ...................................................... 19
Air Cleaner ........................................................... 19
Engine Oil Pump .................................................. 19
Pressure Control Valve (Oil Regulator Valve and Oil
Bypass Valve) ..................................................... 20
Engine Oil Pan ..................................................... 21
Water Pump ......................................................... 21
Auxiliary Water Pump .......................................... 23
Cylinder Block ...................................................... 24
Cylinder Liner ....................................................... 27
Piston and Rings .................................................. 28
Connecting Rod ................................................... 30
Connecting Rod and Main Bearing Journals ........ 31
Crankshaft ........................................................... 32
Crankshaft Wear Sleeves and Seals ................... 33
Gear Group (Front) ............................................... 35
Gear Group (Front) ............................................... 37
Gear Group (Rear) ................................................ 38
Fan Drive ............................................................. 39
Flywheel ............................................................... 40
Flywheel Housing ................................................ 40
Vibration Damper ................................................. 41
Fastener Group (Vibration Damper) ..................... 42
Fastener Group (Vibration Damper) ..................... 42
Belt Tension Chart ............................................... 42
Belt Tensioner ....................................................... 44
Alternator and Regulator ...................................... 44
Electric Starting Motor ......................................... 45
Engine Harness .................................................... 46
Engine Speed Sensor ........................................... 47
Engine Speed Sensor ........................................... 47
Pressure Sensor ................................................... 47
Pressure Sensor ................................................... 48
Temperature Sensor ............................................. 48
Temperature Sensor ............................................. 48

Index Section
Index ..................................................................... 50

3
Table of Contents

4
Specifications Section

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Specifications Section

i02525081

Fuel Filter (Primary)


i02524923

Engine Design

SMCS Code: 1260


Part No.: 247-2696

SMCS Code: 1000

Illustration 1

g01262912

Cylinder and valve location


(A) Inlet valves
(B) Exhaust valves

Number and arrangement of


cylinders ............................................ 60 degree V-16
Valves per cylinder .................................................. 4
Displacement ................................. 85 L (5187 cu in)
Bore ............................................. 175 mm (6.7 inch)

Illustration 2

g01262978

Stroke .......................................... 220 mm (7.5 inch)

(1) O-ring

Compression ratio .............................................. 14:1

Lubricate the O-ring with clean diesel fuel prior to


installation.

Combustion ........................................ Direct injection


When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
Firing order (injection sequence)
Standard rotation
CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.

(2) Element
(3) Filter housing
Do not use an air wrench.
Torque ............................ 55 5 Nm (41 4 lb ft)

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5
Specifications Section

i02525340

i02525379

Fuel Filter (Secondary)

Fuel Transfer Pump

SMCS Code: 1261

SMCS Code: 1256

Part No.: 249-2345

Part No.: 286-4580

Illustration 4

g01263179

(1) Inlet port


(2) Outlet port
Illustration 3

g01263123

(1) O-ring
Lubricate the O-ring with clean diesel fuel prior to
installation.
(2) Element
(3) Filter housing
Do not use an air wrench.
Torque ............................ 55 5 Nm (41 4 lb ft)

(3) Priming port


Minimum requirements
Volume per minute at 650 kPa (94 psi) and 2860
RPM .......................................... 36 L (10 US gal)
Volume per minute at 650 kPa (94 psi) and 2412
RPM ............................................ 34 L (9 US gal)
Volume per minute at 650 kPa (94 psi) and 1740
RPM ............................................ 21 L (6 US gal)
Volume per minute at 450 kPa (65 psi) and 108
RPM .................................... 0.6 L (0.159 US gal)
The setting for the cracking pressure for the
bypass valve is the following value: ....... 793 kPa
(115 psi)
The setting for the full open pressure for the
bypass valve is the following value: ....... 862 kPa
(125 psi)

6
Specifications Section

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i02525593

Fuel Injector

6. Remove hold-down stud (1) for the fuel injector.


Note: As the stud is removed, the stud will extract
the fuel injector.

SMCS Code: 1290

Fuel injector installation

Part No.: 239-6105

1. For lubrication of the O-ring seals, lightly coat


1P-0808 Multipurpose Grease in the bore of the
cylinder head.
2. Seat the fuel injector and tighten the hold down
clamp nut (2).
3. Tighten bolts (A) and bolts (B) hand tight.
4. Tighten hold down clamp nut (2).
Torque .......................................... 5 Nm (44 lb in)
5. Evenly tighten bolts (A) from the fuel line to the
cylinder head.
Torque ........................................ 20 Nm (15 lb ft)
6. Evenly tighten bolts (B) from fuel line to the fuel
supply rail.
Illustration 5

g01263277

(1) Stud
Torque .......................... 60 12 Nm (44 9 lb ft)
(2) Nut
(3) Fuel injector
(4) Fuel injector tip ........................ Protect the spray
tip from debris and from damage.
(A) Bolts
(B) Bolts
Fuel injector removal
1. Loosen bolts (A) from the fuel line to the cylinder
head.
2. Loosen bolts (B) from the fuel line to the fuel
supply rail.
3. Ensure that bolts (A) and bolts (B) are completely
loose.
4. Retract the fuel line from cylinder head
approximately 8 mm (0.315 inch).
5. Remove the hold-down nut (2) for the fuel injector.

Torque ........................................ 20 Nm (15 lb ft)


7. Tighten clamp nut (4) for the fuel injector.
Torque ........................... 100 2 Nm (74 1 lb ft)
8. Again, evenly tighten bolts (A) and bolts (B) in
pairs.
Torque ........................................ 40 Nm (30 lb ft)

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7
Specifications Section

i02564673

Fuel Lines
SMCS Code: 1274
Part No.: 284-8351

Illustration 6

g01283929

(1) O-ring seal


Lubricate the bore for the O-ring seal lightly with
5P-3975 Rubber Lubricant.
(2) Connector
Torque ............................ 40 4 Nm (30 3 lb ft)
(3) Tube

8
Specifications Section

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i02564838

Fuel Lines
SMCS Code: 1274
Part No.: 286-4595

Illustration 7

g01284044

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9
Specifications Section

Illustration 10

g01284193

Figure C

Note: Ensure that all parts are extremely clean. All


of the parts must not be contaminated with any dirt
or debris.
Illustration 8

g01284189

Reference: Reuse and Salvage Guidelines,


SEBF9109, Cleaning and Handling Procedures for
the Common Rail Fuel System Components

Figure A

Procedure for the installation of the rails and the quill


tubes
1. Tighten the bolts that hold rail (1) and rail (7) to
the cylinder block in the following order: A1, A2,
B1, B2, D1, D2, C1, and C2
Again tighten the bolts that hold rail (1) and rail (7)
to the cylinder block in the following order. A1, A2,
B1, B2, C1, C2, D1, and D2
2. If the bolts are already installed, remove the bolts
that attach quill tubes (5) to the rails. If the bolts
are already installed, remove the bolts that attach
the quill tubes to the cylinder head.

Illustration 9
Figure B

g01284191

3. Apply clean engine oil to joint (13) at the collar to


quill tube. Refer to Illustration 8. Slide the collar
away from the cylinder head and the rail prior to
disassembly.
4. Apply clean engine oil to O-rings (14). Refer to
Illustration 8.
5. Lubricate both ends of quill tube (12) with 10 cu cm
(0.61 cu in) 6V-4876 Lubricant prior to assembly.
Refer to Illustration 8. Assemble the quill tubes
into the cylinder head and the rail.
6. Evenly hand tighten the bolts into the cylinder
head.

10
Specifications Section

7. Evenly hand tighten the bolts into the rail.


8. Evenly tighten the bolts into the cylinder head.
Torque ........................................ 20 Nm (15 lb ft)
9. Evenly tighten the bolts into the rail.
Torque ........................................ 20 Nm (15 lb ft)
10. Evenly tighten the bolts into the cylinder head.
Torque ........................................ 40 Nm (30 lb ft)
11. Evenly tighten the bolts into the rail.
Torque ........................................ 40 Nm (30 lb ft)
Procedure for the installation of the lines
1. Lubricate the O-ring that seals the collar of the
line (10) with clean engine oil. Refer to Illustration
9. Lubricate the end of line (10) with 10 cu cm
(0.61 cu in) 6V-4876 Lubricant prior to assembly.
Refer to Illustration 10.
2. Off the engine, insert line (10) into block (6).
3. Evenly tighten line (10) to block (6) with the
washers and the bolts.

RENR9337

12. Install adjustable bracket (11) and tighten


adjustable bracket (11) by using the adjustable
brackets mounting hardware.
13. Lubricate the O-ring that seals the collar of the
line (9) with clean engine oil. Refer to Illustration
9. Lubricate the end of line (10) with 10 cu cm
(0.61 cu in) 6V-4876 Lubricant prior to assembly.
Refer to Illustration 10.
14. Evenly hand tighten line (9) to the pump with the
washers and the bolts.
15. Evenly hand tighten line (9) to block (6) with the
washers and the bolts.
16. Evenly tighten line (9) to the pump.
Torque ........................................ 20 Nm (15 lb ft)
17. Evenly tighten line (9) to block (6).
Torque ........................................ 20 Nm (15 lb ft)
18. Evenly tighten line (9) to the pump.
Torque ........................................ 40 Nm (30 lb ft)
19. Evenly tighten line (9) to block (6) to the pump
adapter.

Torque ........................................ 10 Nm (89 lb in)

Torque ........................................ Standard torque

4. Lubricate the O-ring that seals the collar of the


line (10) with clean engine oil. Lubricate the end of
line (10) with 10 cu in in cm (0.61 cu in) 6V-4876
Lubricant prior to assembly. Refer to Illustration 9.

20. Lubricate the O-ring that seals the collar of the


line (4) with clean engine oil. Refer to Illustration
9. Lubricate the end of line (4) with 10 cu cm
(0.61 cu in.) 6V-4876 Lubricant prior to assembly.
Refer to Illustration 10.

5. On the engine, insert line (10) into rail (1).


6. Evenly hand tighten line (10) to rail (1) with the
washers and the bolts.
7. Evenly hand tighten block (6) to the pump adapter.
8. Evenly tighten line (10) to rail (1).
Torque ........................................ 20 Nm (15 lb ft)
9. Evenly tighten block (6) to the pump adapter.
Torque ........................................ 20 Nm (15 lb ft)
10. Evenly tighten line (10) to rail (1).
Torque ........................................ 40 Nm (30 lb ft)
11. Evenly tighten block (6) to the pump adapter.
Torque ........................................ Standard torque

21. Insert line (4) into rail (1) and into rail (7).
22. Evenly hand tighten line (4) to rail (1).
23. Evenly hand tighten line (4) to rail (7) with the
washers and the bolts.
24. Install the low pressure fuel line and the mounting
hardware for the low pressure fuel line that
connects to rail (1) and to rail (7).
25. Evenly hand tighten clamps (3) and hardware to
line (4).
26. Evenly hand tighten clamps (2) and hardware to
line (4).
27. Evenly tighten line (4) to rail (1).
Torque ........................................ 20 Nm (15 lb ft)
28. Evenly tighten line (4) to rail (7).

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11
Specifications Section

Torque ........................................ 20 Nm (15 lb ft)


29. Evenly tighten clamps (3) and hardware to line
(4).
Torque ........................................ 20 Nm (15 lb ft)
30. Evenly tighten clamps (2) and hardware to line
(4).
Torque ........................................ 20 Nm (15 lb ft)
31. Evenly tighten line (4) to rail (1).
Torque ........................................ 40 Nm (30 lb ft)
32. Evenly tighten line (4) to rail (7).
Torque ........................................ 40 Nm (30 lb ft)
33. Evenly tighten clamps (3) and hardware to line
(4).
Torque ........................................ Standard torque
34. Evenly tighten clamps (2) and hardware to line
(4).
Torque ........................................ Standard torque
i02527814

Camshaft

(2) Inlet lobe (odd numbers cylinders)


(3) Exhaust lobe (odd numbers cylinders)
(4) Exhaust lobe (even numbers cylinders)
(5) Inlet lobe (even numbers cylinders)
(6) Journal surface
Diameter of surface (journals) for new camshaft
bearings .. 91.88 0.02 mm (3.617 0.001 inch)
Bore in bearings for camshafts after
assembly ............................. 92.152 0.015 mm
(3.628 0.0006 inch)
(7) Rear camshaft
(8) Thrust washer
Thickness of a new thrust
washer ...... 8.50 0.05 mm (0.335 0.002 inch)
Thickness of the groove in a new
camshaft ... 8.75 0.05 mm (0.344 0.002 inch)
End play for new camshafts ..... 0.15 to 0.35 mm
(0.006 to 0.014 inch)
(9) Dowel
The dowel extends from the end of
the front camshaft by the following
distance: .... 11.5 0.5 mm (0.453 0.0197 inch)
(10) Studs

SMCS Code: 1210

Torque ............................ 35 5 Nm (26 4 lb ft)

Part No.: 274-7725

Illustration 11

(1) Front camshaft

g01264753

Illustration 13

Illustration 12

g01265223

(12) Camshaft lobe height

g01265150

12
Specifications Section

RENR9337

In order to determine the height, use the following


procedure:
1. Measure camshaft lobe height (12).
2. Measure base circle (13).
3. Subtract the base circle (Step 2) from the lobe
height (Step 1). The difference is the actual lobe
lift.
4. Specified camshaft lobe lift (11)
Inlet lobe ................ 12.447794 mm (0.4901 inch)
Exhaust lobe .......... 17.183920 mm (0.6765 inch)
i02563171

Lifter Group
SMCS Code: 1209

Illustration 15

g01283285

(4) Bolts

Part No.: 283-9354

(4) Bolt
Torque .......................... 55 10 Nm (41 7 lb ft)

Illustration 16

Illustration 14

g01283284

(1) Bolts
(2) Housing As
(3) Lifter As

(1) Bolt
Torque .......................... 55 10 Nm (41 7 lb ft)

g01283372

(A) Hollow dowel .. Install the hollow dowel to 8 0.5


from the top of the dowel to the housing surface.
(B) Hollow dowel .. Install the hollow dowel to 7.5 1
from the top of the dowel to the housing surface.

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13
Specifications Section

i02530414

i02531323

Valve Mechanism

Cylinder Head

SMCS Code: 1102

SMCS Code: 1100

Part No.: 273-1225

Part No.: 273-1221

Illustration 17

g01265938

(1) Bolt
Torque .................... 240 40 Nm (177 30 lb ft)
(2) Locknut
Torque ...................... 120 15 Nm (89 11 lb ft)
(3) Valve lash
Inlet ................................... 0.8 mm (0.0315 inch)
Exhaust ............................. 1.3 mm (0.0512 inch)
(4) Rocker arm shaft
Bore in the bearings for the rocker arm shaft
After the 254-5922 Bushing is installed in the
rocker arm the bearing must be machined to
size. .. 50.086 0.015 mm (1.972 0.0006 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
Diameter of the rocker arm shaft .. 50 0.013 mm
(1.9685 0.0005 inch)
Maximum roughness average
(Ra) ............. 0.125 micrometer (4.875 microinch)

Illustration 18

g01266761

Use the following procedure to tighten cylinder head


bolts (1).
1. Coat the threads of the cylinder head bolts with
clean engine oil.
2. Tighten bolts A through F in the lettered sequence
that is pictured in Illustration 18.
Torque ............................. 30 5 Nm (22 4 lb ft)
3. Tighten bolts A through F again in the lettered
sequence.
Torque ..................... 190 15 Nm (140 11 lb ft)
4. Tighten bolts A through F again in the lettered
sequence.
Torque ..................... 190 15 Nm (140 11 lb ft)
5. Tighten bolts A through F again to the following
rotation.
Rotation for bolts ........................ 180 5 degrees

14
Specifications Section

RENR9337

Apply 6V-6640 Sealant to the outside of injector


sleeve (2) within area (A).
(3) O-rings ... Coat the O-rings with clean engine oil.
(4) Plugs
Use 6V-6640 Sealant in the plug bores prior to
assembly.
Two plugs are installed in the top of the cylinder
head to the following depth: ....... 1.25 0.25 mm
(0.0492 0.0098 inch)
(5) Plugs
Use 6V-6640 Sealant in the plug bores prior to
assembly.
Two plugs are installed in the top of the cylinder
head to the following depth: ................ 0.750 mm
(0.0295 inch)
(6) Height of new cylinder head ............. 208.00 mm
(8.1890 inch)

Illustration 19

g01266843

Illustration 20

g01266856

(2) Injector sleeve

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15
Specifications Section

i02532590

Cylinder Head Valves


SMCS Code: 1105
Part No.: 273-1221, 274-7704, 283-1684,
283-1686

g01267114

Illustration 21

(1) Valve stem diameter and valve guide bore


Diameter of the new valve stems in the area of
the valve guide ...................... 12.573 0.01 mm
(0.4950 0.0004 inch)
When the valve guides are installed in the
cylinder head the bore in the valve guides is the
following value: .................... 12.626 0.020 mm
(0.4971 0.0008 inch)
When the valve guides are installed in the
cylinder head the maximum bore that can be
used again in the valve guides is the following
value: ............................ 13.16 mm (0.5181 inch)
(2) 236-0550 Spring
Length under test force ...... 66 mm (2.5984 inch)
Test force ...................... 900 45 N (202 10 lb)
Free length after test .. 109.06 mm (4.2937 inch)
Outside diameter .......... 48.91 mm (1.9256 inch)

(3) 256-5986 Spring


Length under test force ...... 55 mm (2.1654 inch)
Test force ........................ 450 22 N (101 5 lb)
Free length after test .... 97.12 mm (3.8236 inch)
Outside diameter ........ 34.398 mm (1.3542 inch)
(4) Height to the top of the valve
guides ... 42.0 0.50 mm (1.6535 0.0197 inch)
(5) Diameter of the valve heads
Inlet ....... 58.5 0.15 mm (2.3031 0.0059 inch)
Exhaust .. 56.5 0.15 mm (2.2244 0.0059 inch)
(6) Angle of the valve faces:
Inlet ................................... 70.75 0.25 degrees
Exhaust ............................. 45.60 0.25 degrees

16
Specifications Section

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i02535620

Turbocharger
SMCS Code: 1052
Part No.: 254-6777, 263-1454

Illustration 22

g01267505

(7) Depth of bore in head for valve seat


inserts ..... 16.00 0.15 mm (0.630 0.006 inch)
(8) Diameter of valve seat inserts:
Inlet ..... 62.1 0.013 mm (2.4449 0.0005 inch)
Exhaust .................................. 61.12 0.013 mm
(2.4063 0.0005 inch)
Bore in head for valve seat inserts
Inlet ..... 62.0 0.025 mm (2.4409 0.0010 inch)
Exhaust .................................... 61.0 0.025 mm
(2.4016 0.0010 inch)
(9) Angle of face of valve seat inserts
Inlet ........................................ 20 0.25 degrees
Exhaust .................................. 45 0.25 degrees
(10) Outside diameter of the face of the valve seat
inserts ... 55.0 0.25 mm (2.1654 0.0098 inch)

Illustration 23

g01269136

(1) V-band clamp


1. Tighten the V-band clamp.
Torque ........................................ 20 Nm (15 lb ft)
2. Loosen the V-band clamp by 2 to 3 turns.
3. Tighten the V-band clamp again.
Torque ............................. 19 1 Nm (14 1 lb ft)
(2) Bolts
Torque ............................ 40 3 Nm (29 2 lb ft)

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17
Specifications Section

i02564541

i02536571

Air Lines

Exhaust Manifold

SMCS Code: 1058; 1071

SMCS Code: 1059

Part No.: 283-9364

Part No.: 243-2972, 253-7723, 282-8533

Illustration 24

g01283877

(1) Clamps

Illustration 26

g01269432

(1) V-band clamps

Lubricate the nut face and threads 5P-3931


Anti-Seize Compound before assembly.
Torque .............................. 12 2 Nm (9 1 lb ft)

Torque .............................. 12 2 Nm (9 1 lb ft)


(2) Washers

(2) O-ring

Lubricate the washers with 5P-3931 Anti-Seize


Compound before assembly.

Lubricate the bore lightly with 5P-3975 Rubber


Lubricant.

(3) Bolts
Lubricate the bolts with 5P-3931 Anti-Seize
Compound before assembly.
Torque ............................ 65 5 Nm (49 4 lb ft)

Illustration 25

g01283879

(3) Bolts
Torque ...................... 100 20 Nm (74 15 lb ft)

18
Specifications Section

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i02536701

i02536935

Exhaust Manifold

Exhaust Fitting

SMCS Code: 1059

SMCS Code: 1061-X6

Part No.: 254-2062, 254-2063, 282-8534

Part No.: 269-2551

Illustration 27

g01269497

(1) V-band clamps


Torque .............................. 12 2 Nm (9 1 lb ft)
(2) Washers

Illustration 28

g01269830

(1) V-band clamp


1. Tighten all the V-band clamps.
Torque ................................. 8.5 1 Nm (6 1 ft)

Lubricate the washers with 5P-3931 Anti-Seize


Compound before assembly.

2. Gently tap around the V-band clamps with a soft


faced hammer.

(3) Bolts

3. Tighten all the V-band clamps again.

Lubricate the bolts with 5P-3931 Anti-Seize


Compound before assembly.
Torque ............................ 65 5 Nm (49 4 lb ft)

Torque ................................. 8.5 1 Nm (6 1 ft)

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19
Specifications Section

i02536750

i02537004

Exhaust Fitting

Air Cleaner

SMCS Code: 1061-X6

SMCS Code: 1051

Part No.: 245-4875

Part No.: 276-5929

Illustration 29

g01269533

(1) V-band clamp


1. Tighten all the V-band clamps.
Torque ............................... 12 2 Nm (9 1 lb ft)
2. Gently tap around the V-band clamps with a soft
faced hammer.
3. Tighten all the V-band clamps again.

Illustration 30

g01269901

(1) Clamp
Torque .......................... 4 0.6 Nm (35 5 lb in)

Torque ............................... 12 2 Nm (9 1 lb ft)

i02537201

Engine Oil Pump


SMCS Code: 1304
Part No.: 255-4846

Illustration 31

g01270117

20
Specifications Section

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(6) The bearings are installed in the housing at the


following depth. .. 1.5 0.5 mm (0.06 0.02 inch)
(7) Distance from the end of the idler shafts to gear
faces ....... 41.5 0.5 mm (1.6339 0.0197 inch)
(8) The location of each bearing joint is shown.
Position the bearing joint from the centerline
through the bearing bores to the following
angle. ................................................ 30 degrees
Bench test specifications
Unrestricted flow rate per minute at 2394
rpm ..................................... 1296 L (342 US gal)
Note: Before you install the pump, lubricate the
moving parts with engine oil. Rotate the pump by
hand in order to ensure that the pump rotates freely.

Illustration 32

g01270121

i02538181

Pressure Control Valve


(Oil Regulator Valve and Oil
Bypass Valve)
SMCS Code: 1315; 1319-VL
Part No.: 274-2148

Illustration 33

g01270122

(1) Distance from the end of the drive shaft to gear


face ......... 47.9 0.5 mm (1.8858 0.0197 inch)
(2) Length of new gears ..... 121.92 mm (4.800 inch)
Depth of bores for new gears ............... 122.055 mm
(4.8053 inch)
(3) The dowels (not shown) extend from the cover by
the following distance. ................... 8.0 0.5 mm
(0.3150 0.0197 inch)
(4) The bearings are installed in the cover at the
following depth. .. 1.5 0.5 mm (0.06 0.02 inch)
(5) Diameter of new gear shafts ............. 50.795 mm
(1.9998 inch)
Bore in bearings for gear shafts after
assembly ............................ 55.655 mm (2.1911 inch)

Illustration 34

g01270636

(1) Shim
Thickness ......................... 1.0 mm (0.0394 inch)
Used with the 288-4597 Spring
Pressure change with one shim ... 21 kPa (3 psi)

RENR9337

21
Specifications Section

Used with the 285-6589 Spring


Pressure change with one shim ... 14 kPa (2 psi)

Apply 5P-3975 Rubber Lubricant to the bore for the


O-ring prior to assembly.

(2) 288-4597 Spring for the oil regulator valve


Length under test force ... 85.5 mm (3.3661 inch)
Test force .................. 1871 126 N (421 28 lb)
Free length after test .... 105.4 mm (4.1496 inch)
Outside diameter .......... 48.20 mm (1.8976 inch)
(3) 285-6589 Spring for the oil bypass valve

i02544912

Water Pump
SMCS Code: 1361
Part No.: 248-4129

Length under test force ... 87.6 mm (3.4488 inch)


Test force .................... 1669 83 N (375 19 lb)
Free length after test .... 148.3 mm (5.8386 inch)
Outside diameter .......... 48.20 mm (1.8976 inch)
i02539560

Engine Oil Pan


SMCS Code: 1302
Part No.: 256-5970, 274-7697, 281-9400,
288-8770

Illustration 35

(1) O-ring

g01271269

Illustration 36

g01274088

Illustration 37

g01274062

22
Specifications Section

RENR9337

Torque .... 4 1.25 Nm (35.4030 11.0634 lb in)


Follow this procedure for assembly:
1. Install bearing assembly (5) onto the shaft.
2. Tighten locknut (6) according to the specified
torque.
Note: The seal installation tool is part of the
replacement seal assembly. Install the oil seal within
two minutes of the removal from the tube for shipping.
3. Install oil seal (7) into the pump housing. Install the
oil seal dry. Do not lubricate the sealing lip. Use
the correct installation tool and use a slow, even
motion to press the seal into the pump housing.
4. Install shaft (3) through the oil seal.
5. Install retainer plate (4).
Illustration 38

g01274086

View A-A

(1) O-ring seal


Lubricate the bore for the O-ring seal with clean
engine oil prior to assembly.
(2) Stud
Torque ............................ 35 5 Nm (26 4 lb ft)
(3) Shaft
Shafts outer diameter for
impeller ... 25.4 0.01 mm (1.000 0.0004 inch)
(4) Retainer
(5) Bearing assembly
(6) Oil seal
(7) Locknut
Torque .................... 300 30 Nm (221 22 lb ft)
(8) O-ring seal
Lubricate the O-ring with 1U-6396 O-Ring Assembly
Compound prior to assembly.
(9) Seal assembly
(10) Impeller
Diameter of impellers bore .... 25.35 0.012 mm
(0.9980 0.0005 inch)
(11) Setscrew

6. Tighten setscrews (11) according to the specified


torque.
7. Install seal assembly (9). Use the seal installation
tool and hand pressure to install the seal assembly
onto the shaft.
8. Lubricate the shaft with clean engine oil. Place the
shaft onto a fixture that will absorb the load and
press impeller (10) onto the shaft until the face of
the impeller is flush with the face of the shaft.
Maximum leakage per minute for the water seal at
138 kPa (20 psi) of air pressure ..... 20 cc (1.22 cu in)
Maximum leakage per minute for the oil seal at
138 kPa (20 psi) of air pressure ..... 24 cc (1.46 cu in)

RENR9337

23
Specifications Section

i02547236

Auxiliary Water Pump


SMCS Code: 1371
Part No.: 250-6720

g01275298

Illustration 39

Diameter of impellers bore .. 25.342 0.013 mm


(0.9977 0.0005 inch)
(4) Shaft
Shafts outer diameter for
impeller ................................ 25.400 0.013 mm
(1.0000 0.0005 inch)
Width of shafts groove for thrust
washer ...... 8.75 0.05 mm (0.345 0.002 inch)
(5) Stud
Torque ............................ 35 5 Nm (26 4 lb ft)
Illustration 40

g01275612

Area B

(1) Stud
Torque ............................ 35 5 Nm (26 4 lb ft)
(2) O-ring seal
(3) Impeller

(6) Nut
Torque ............................ 27 4 Nm (20 3 lb ft)
(7) Thrust washer
Thickness .................................. 8.50 0.05 mm
(0.3346 0.0020 inch)
(8) O-ring seal
(9) Oil seal

24
Specifications Section

(10) Ring assembly


(11) Ceramic ring and rubber seal
(12) Seal assembly

RENR9337

Maximum leakage per minute for the water seal at


138 kPa (20 psi) of air pressure ..... 20 cc (1.22 cu in)
Maximum leakage per minute for the oil seal at
138 kPa (20 psi) of air pressure ..... 24 cc (1.46 cu in)

(13) Spring

i02550794

Follow this procedure for assembly:

Cylinder Block

Note: The seal installation tool is part of the


replacement seal assembly.

SMCS Code: 1201

1. Install ring assembly (10) and oil seal (9) into


the pump housing. Install the oil seal dry. Do
not lubricate the sealing lip. Use the correct
installation tool and use a slow, even motion to
press the seal into the pump housing.

Part No.: 283-9344

2. Install shaft (4) through the oil seal and through


the ring assembly.
3. Install thrust washer (7).
4. Lubricate the outside diameter of the ceramic
ring and rubber seal (11) with clean water or with
207-1600 Rubber Lubricant.
5. Orient the polished face of the ceramic ring toward
seal assembly (12). Use the installation tool and
hand pressure to seat the ceramic ring and the
rubber seal into the pump housing.
6. Remove spring (13) from the seal assembly.
Lubricate the inside diameter of the seal assembly
with clean water or with 207-1600 Rubber
Lubricant.
7. Use the seal installation tool and hand pressure
to install the seal assembly onto the shaft until the
face of the seal assembly makes light contact with
the face of the ceramic ring and rubber seal.
8. Install the spring onto the seal assembly.
9. Lubricate the shaft with clean engine oil. Place the
shaft onto a fixture that will absorb the load and
press impeller (3) onto the shaft until the face of
the impeller is flush with the face of the shaft.
10. Lubricate the bore for O-ring seal (2) with clean
engine oil.
11. Lubricate the bore for O-ring seal (8) with clean
engine coolant.
12. Tighten studs (5) according to the specified
torque.
13. Tighten nuts (6) according to the specified torque.

Illustration 41
Pictorial view

g01277012

RENR9337

Illustration 42

25
Specifications Section

g01276834

Front view

Illustration 43

Illustration 44

g01276824

Rear view

g01276831

Right side view

Illustration 45
Front view

g01276830

26
Specifications Section

RENR9337

(10) Cylinder 2
(11) O-ring seal
Lubricate the O-ring seal with clean engine oil prior
to assembly.
(12) Dowel
The dowels extend from the face by the following
distance: ....... 16 1 mm (0.6299 0.0394 inch)
(13) Centerline through the oil holes in the camshaft
bearings
Install the camshaft bearings so the oil holes are
horizontal.
(14) O-ring seal

Illustration 46

g01276840

Right side view

(1) 248-7585 Orifice


Orifice (1) must be fully seated in the bore and
flush with the head face of the cylinder block. After
you start the orifice into the bores, apply 4C-9507
Retaining Compound to the outside diameter of the
orifice. Install the outside diameter of the orifices
chamfer toward the cylinder block. Orifice (1) is only
for the number eight cylinder (2) through the number
three cylinder (6).
(2) Cylinder 8
(3) Cylinder 7
(4) Cylinder 4
(5) Cylinder 6
(6) Cylinder 3
(7) Cylinder 4
(8) 248-7584 Orifice

Lubricate the O-ring seal with clean engine oil prior


to assembly.
(15) Dowel
The dowels extend from the face by the following
distance: ....... 19 1 mm (0.7480 0.0394 inch)
(16) Cup Plug
Apply 6v-6640 Sealant to the outside diameter of
the cup plug prior to assembly.
(17) New dimension from centerline of crankshaft
bearing bore to the top of the block ....... 650 mm
(25.5905 inch)
(18) Depth of all cup plugs from the face of the holes
for the cup plugs. ........................... 3.4 1.8 mm
(0.1339 0.0709 inch)
(19) Main bearing cap
(20) Washer
(21) Bolt
(22) Nut
(23) Stud

Orifice (8) must be fully seated in the bore and


flush with the head face of the cylinder block. After
you start the orifice into the bores, apply 4C-9507
Retaining Compound to the outside diameter of the
orifice. Install the outside diameter of the orifices
chamfer toward the cylinder block. Orifice (8) is only
for the number one cylinder (9) and for the number
two cylinder (10).

Use the following procedure to tighten the main


bearing cap bolts:

(9) Cylinder 1

1. Tighten studs (23) again.

(24) Bore in the block for the main bearings


Standard, original new size ........ 210 0.02 mm
(8.2677 0.0008 inch)

Torque ....................... 100 20 Nm (74 15 lb ft)

RENR9337

2. Assemble main bearing caps (19) with the part


number toward the front of the cylinder block.
3. Lubricate the treads of studs (23) and the face of
nuts (22). Assemble and hand tighten the nuts.
4. Lubricate the threads of bolts (21) and both sides
of washers (20). Assemble and hand tighten the
bolts and the washers in the side of the cylinder
block.

27
Specifications Section

i02550061

Cylinder Liner
SMCS Code: 1216
Part No.: 286-4564

5. Start at the front of the engine (number one main


bearing cap). Tighten all the side bolts on the right
hand side (same side as the bearing tab slots) of
the cylinder block.
Torque ....................... 100 20 Nm (74 15 lb ft)
6. Use the 249-6717 Stud Tensioner Tool Group.
Start at the front of the engine (number one
main bearing cap). Tension both studs (23)
simultaneously.
Pressure ... 135000 1000 kPa (19580 145 psi)
7. Hand tighten both nuts (22) with the use of the
gear drives on the tensioner.
8. Release the hydraulic pressure on the tensioner.
9. Repeat Step 6 through Step 8 for main bearing
caps 2 through 9.
10. Repeat Step 6 through Step 8 again for all the
main bearing caps.
11. Start at the front of the engine (number one main
bearing). Tighten all the side bolts on the left hand
side (opposite side as the bearing tab slots) of the
cylinder block.
Illustration 47

Torque ....................... 100 20 Nm (74 15 lb ft)


12. Start at the front of the engine (number one main
bearing cap). Tighten all the side bolts on the right
hand side (same side as the bearing tab slots) of
the cylinder block.
Torque ... 530 70 Nm (390.9068 51.6292 lb ft)
13. Start at the front of the engine (number one main
bearing). Tighten all the side bolts on the left hand
side (opposite side as the bearing tab slots) of the
cylinder block.
Torque ... 530 70 Nm (390.9068 51.6292 lb ft)

g01276565

28
Specifications Section

RENR9337

i02558469

Piston and Rings


SMCS Code: 1214
Part No.: 270-6823

Illustration 48

g01276570

(1) Cylinder liner


(2) 246-7264 O-Ring Seal
(3) 253-9950 O-Ring Seal

Illustration 49

g01280888

Illustration 50

g01280890

(4) Thickness of flange on liner ........ 114.7 0.1 mm


(4.5157 0.0039 inch)
(5) Diameter for the sleeve ............. 184.5 0.2 mm
(7.2638 0.0079 inch)
(6) Bore in new liner .................. 175.025 0.08 mm
(6.8907 0.0031 inch)
(7) Sleeve
(8) Outside diameter of the
sleeve .................................. 185.45 0.025 mm
(7.3012 0.0010 inch)
(9) Inside diameter of the
sleeve .................................. 174.025 0.25 mm
(6.8514 0.0098 inch)
(10) Thickness of the sleeve .......... 23.1 0.25 mm
(0.9094 0.0098 inch)
Cylinder Liner Installation
1. Put liquid soap on the cylinder block liner bore
surface. Also, put liquid soap on the O-ring seals.
2. Install the liner in the cylinder block immediately,
before the O-ring seals expand.

RENR9337

29
Specifications Section

After all of the piston rings have been installed, rotate


the rings so that the end gaps are separated by 120
degrees. The ring gap for the oil ring must be aligned
in the plane of the pin bore.
(4) Pin
Outside diameter ........................... 75.0 0.005 mm
(2.9527 0.0002 inch)
Inside diameter .................................. 31.0 0.3 mm
(1.2205 0.0118 inch)
Length ....... 102.0 0.25 mm (4.0157 0.0098 inch)
(5) Piston pin bore
Diameter ............................... 75.113 0.008 mm
(2.9572 0.0003 inch)
(6) Retainer
Illustration 51

g01138425

(1) Top ring


Install the top ring with the Up-1 side toward the
top of the piston.
When the piston ring is installed in a cylinder liner with
a bore size of 175 mm (6.8898 inch), the clearance
between the ends of the piston ring is the following
value. ...... 0.625 0.125 mm (0.0246 0.0049 inch)
(2) Intermediate ring
Install the intermediate ring with the Up-2 side
toward the top of the piston.
When the piston is installed in a cylinder liner with
a bore size of 175 mm (6.8898 inch), the clearance
between the ends of the piston ring is the following
value. .......... 1.0 0.125 mm (0.0394 0.0049 inch)
(3) Oil control ring
Width of groove in piston for the new oil control
ring ................ 4.06 0.1 mm (0.1598 0.0039 inch)
Maximum thickness of new oil control
ring ...................................... 4.0 0.01 to 0.03 mm
(0.1575 0.0004 to 0.0012 inch)
When the oil control ring is installed in a cylinder
liner with a bore size of 175 mm (6.8898 inch), the
clearance between the ends of the piston ring is the
following value. ................................... 0.5 to 0.8 mm
(0.0197 to 0.0315 inch)
Install the oil control ring so that the gap in the spring
is 180 degrees away from the gap in the ring. The
white portion of the spring must be visible at the ring
gap.

(7) Area A
Assemble the retainer with the opening within area A.
Refer to Table 1 for the part numbers of the tools that
are used in servicing the piston.
Table 1

Service Tools
Pt. No.

Description

271-0504

Piston Ring Expander Gp

255-8897

Piston Ring Compressor Gp

1P-1861

Retaining Ring Pliers

30
Specifications Section

RENR9337

i02557016

Connecting Rod

Diameter of new piston pin ............ 75.0 0.005 mm


(2.9527 0.0002 inch)
Deburr the connecting rod around the very edge of
the bore for the rod eye bushing prior to assembly.

SMCS Code: 1218


Part No.: 293-2260

The rod eye bushing must be cooled for the


installation of the rod eye bushing.
Cool the rod eye bushing with the use of liquid
nitrogen to the following temperature. ......... 195 C
(319 F)
After assembly, the rod eye bushing can not cover
the oil hole in the connecting rod. The oil hole must
be completely open.
The ends of the rod eye bushing must not extend
more than the connecting rod by the following
value: .................................... 0.25 mm (0.0098 inch)
(2) Distance between center of bearings .... 420 mm
(16.5354 inch)
(3) Bore in bearing for
crankshaft .......................... 150.197 0.016 mm
(5.9133 0.0006 inch)
(4) After the bolts are tightened, the bore in the
connecting rod for the bearing is the following
dimension. ................................ 157 0.013 mm
(6.1811 0.0005 inch)
(5) Spacer
(6) Bolt
Clearance between bearing and new
crankshaft ................................... 0.181 to 0.213 mm
(0.0071 to 0.0084 inch)

Illustration 52

g01280244

The side clearance between two connecting rods


on the same new crankshaft pin is the following
value. ...... 0.850 0.332 mm (0.0335 0.0131 inch)
The word FRONT on the shank of the connecting
rod must face the front of the engine in the cylinder
bank with an odd number in a standard rotation
engine.
The word FRONT on the shank of the connecting
rod must face the rear of the engine in the cylinder
bank with an odd number in a reverse rotation engine.

Illustration 53

g01280245

(1) Bore in bearing for new piston


pin ..... 75.04 0.008 mm (2.9543 0.0003 inch)

RENR9337

Careful handling of the connecting rod is required


at all times. The fracture face of the connecting rod
and the fracture face of the connecting rod cap must
not make contact with any surface. The connecting
rod and the connecting rod cap must be laid flat on
the sides. When possible, the rod assembly should
be kept together in order to protect the fracture face
when the connecting rod is out of the engine.

31
Specifications Section

i02560298

Connecting Rod and Main


Bearing Journals
SMCS Code: 1230
Part No.: 286-5799, 286-5801

The connecting rod and the connecting rod cap must


be marked only with a mechanical etcher with the
number of the cylinder. The cylinder number must be
etched on the same surface as the part number and
the serial number for the connecting rod.

Refer to Guidelines For Reusable Parts, SEBF8009,


Main Bearings And Connecting Rod Bearings for
more information.

Procedure for Tightening


Connecting Rod Bolts

Table 2

1. Before assembly, put 6V-4876 Lubricant on the


threads of bolt (5), spacer (6) and all surfaces that
make contact between the bolt and the cap.
2. Install the spacers and the bolts. Hand tighten the
bolts.
3. Tighten bolts A and B.
Torque ............................. 80 5 Nm (59 4 lb ft)
4. Tighten bolts C and D.

Connecting Rod Bearing Journals

Diameter Of Crankshaft Journal (Bearing Surface)


For Connecting Rod Bearings
Original Size Journal

150 mm (5.9055 inch)

Undersize Journal
0.63 mm (0.025 inch)

149.37 mm (5.8807 inch)

Undersize Journal
1.27 mm (0.050 inch)

148.73 mm (5.8555 inch)

Clearance between bearing and new


journal .... 0.172 to 0.295 mm (0.0068 to 0.0116 inch)
Main Bearing Journals
Table 3

Torque ............................. 80 5 Nm (59 4 lb ft)


5. Tighten bolts E and F.
Torque ............................. 80 5 Nm (59 4 lb ft)
6. Repeat Step 9 through Step 6.
7. Tighten bolts C and D.
Torque ........................................ 180 5 degrees
8. Tighten bolts E and F.
Torque ........................................ 180 5 degrees
9. Tighten bolts A and B.
Torque ........................................ 180 5 degrees

Diameter Of Crankshaft Journal (Bearing


Surface) For Main Bearings
Original Size Journal

200 mm (7.8740 inch)

Undersize Journal
0.63 mm (0.025 inch)

199.37 mm (7.8492 inch)

Undersize Journal
1.27 mm (0.050 inch)

198.73 mm (7.8240 inch)

Clearance between bearing and new


journal ... 0.145 to 0.262 mm (0.0057 to 0.0103 inch)

32
Specifications Section

RENR9337

i02559833

Crankshaft
SMCS Code: 1202
Part No.: 285-3719

g01281321

Illustration 54

Refer to Specifications, Connecting Rod And Main


Bearing Journals.
(2) Main bearing journal
Refer to Specifications, Connecting Rod And Main
Bearing Journals.
(3) Bolt
Note: Do not reuse counterweight bolts.
(4) Thrust plates for the rear main bearing
(5) End play for a new crankshaft
End play .. 0.17 to 0.63 mm (0.007 to 0.025 inch)
(6) Plug
Torque ............................ 50 7 Nm (37 5 lb ft)
Illustration 55

(1) Connecting rod journal

g01281755

Use the following procedure to tighten the


counterweight bolts:

RENR9337

33
Specifications Section

1. Prior to assembly, put 6V-4876 Lubricant on the


bolt threads, on the shank, and on the underside
of the bolt head.
2. Tighten the bolts evenly.
Torque ..................... 220 20 Nm (162 15 lb ft)
3. Tighten each bolt again to the following rotation.
Rotation ........................................ 90 5 degrees
i02560387

Crankshaft Wear Sleeves and


Seals
SMCS Code: 1160
Part No.: 248-4115
Illustration 57

g01281911

(1) 245-3574 Crankshaft Seal Gp


Install the245-3574 Crankshaft Seal Gp in the front
housing on a standard rotation engine.
Install the 245-3574 Crankshaft Seal Gp in the
flywheel housing on a reverse rotation engine.
(2) 245-3575 Crankshaft Seal Gp
Install the 245-3575 Crankshaft Seal Gp in the
flywheel housing on a standard rotation engine.
Install the 245-3575 Crankshaft Seal Gp in the front
housing on a reverse rotation engine.
(3) Flywheel housing
Illustration 56

g01281910

(4) Front housing


Make sure that the correct seal is installed on each
end of the crankshaft.
(5) Depth of the crankshaft seal and the wear sleeve
The crankshaft seal and the wear sleeve is
installed from both ends of the crankshaft at the
following distance. ......................... 0.5 0.5 mm
(0.0197 0.0197 inch)
(6) Crankshaft
Removal
1. Remove the seal from each end of the engine.
Note: Seals and wear sleeves cannot be used again,
after the seals and the wear sleeves are separated.

34
Specifications Section

RENR9337

2. Remove the wear sleeves with the 5P-7409


Sleeve Distorter and the 6V-3143 Distorter
Adapter.
Installation
1. DO NOT separate the wear sleeves from the
crankshaft seals. Once the wear sleeves and
crankshaft seals are separated, the crankshaft
seals cannot be used again.
Note: For a complete procedure with illustrations,
refer to the Disassembly And Assembly Manual.
2. Install the sleeve and the seal assembly with the
correct tools.
3. Clean the outer surface of the crankshaft and the
inner surface of the wear sleeve with 169-5464
Quick Cure Primer (Aerosol Spray).
4. Carefully, put a thin coat of 4C-9507 Retaining
Compound on the inner surface of the wear sleeve
and on the crankshaft surface.
5. Install the crankshaft seals and the wear sleeves
as a unit. Install the unit on the end of the
crankshaft with the correct tools. Refer to Table 4.
Table 4

Tools for the Installation of the Crankshaft Seal


Part Number

quantity

250-4586 Seal Locator

250-4587 Seal Installer

258-0933 Bolt

9S-8858 Nut

RENR9337

35
Specifications Section

i02563409

Gear Group (Front)


SMCS Code: 1206
Part No.: 250-9959

g01283463

Illustration 58

(1) Shaft
Diameter of new shaft .......... 74.900 0.015 mm
(2.9488 0.0006 inch)
(2) Idler gear
After the bearing is installed in the gear the
bearing must be machined to size.
Bore in bearings after assembly .. 90.0 0.01 mm
(3.5433 0.0004 inch)
(3) Crankshaft gear
(4) Adapter

After the bearing is installed in the gear the


bearing must be machined to size.
Bore in bearings after
assembly ............................. 75.000 0.055 mm
(2.9528 0.0022 inch)
(5) O-ring
Lubricate the bore for all O-rings with clean engine
oil prior to assembly.
(6) Drive gear
(7) Bolt
Torque ...................... 120 20 Nm (89 15 lb ft)
(8) Bolt
Torque .................... 190 30 Nm (140 22 lb ft)

36
Specifications Section

(9) Shaft
Diameter of new shaft .......... 89.880 0.020 mm
(3.5386 0.0008 inch)
Note:
(10) Adapter
After the bearing is installed in the gear the
bearing must be machined to size.
Bore in bearings after
assembly ............................. 75.000 0.055 mm
(2.9528 0.0022 inch)
Maximum roughness average (Ra) for all bearings
that are machined to size .................. 0.8 micrometer
(32 microinch)

RENR9337

RENR9337

37
Specifications Section

i02564515

Gear Group (Front)


SMCS Code: 1206
Part No.: 277-6909, 282-8771

g01283826

Illustration 59

(1) Shaft
Diameter of new shaft .......... 74.900 0.015 mm
(2.9488 0.0006 inch)
(2) Idler gear
After the bearing is installed in the gear the
bearing must be machined to size.
Bore in bearings after assembly .. 90.0 0.01 mm
(3.5433 0.0004 inch)
(3) Crankshaft gear
(4) Adapter

After the bearing is installed in the gear the


bearing must be machined to size.
Bore in bearings after
assembly ............................. 75.000 0.055 mm
(2.9528 0.0022 inch)
(5) O-ring
Lubricate the bore for all O-rings with clean engine
oil prior to assembly.
(6) Drive gear
(7) Bolt
Torque ...................... 100 20 Nm (74 15 lb ft)
(8) Bolt
Torque .................... 190 30 Nm (140 22 lb ft)

38
Specifications Section

RENR9337

(9) Shaft
Diameter of new shaft .......... 89.880 0.020 mm
(3.5386 0.0008 inch)
Note:
(10) Adapter
After the bearing is installed in the gear the
bearing must be machined to size.
Bore in bearings after
assembly ............................. 75.000 0.055 mm
(2.9528 0.0022 inch)
Maximum roughness average (Ra) for all bearings
that are machined to size .................. 0.8 micrometer
(32 microinch)
i02562764

Gear Group (Rear)


SMCS Code: 1206
Part No.: 254-2074

Illustration 60

g01283065

(1) Shaft
Diameter .................................. 74.99 0.01 mm
(2.9524 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.4 micrometer (16 microinch)
(2) Camshaft drive gear
(3) Camshaft idler gear

After the bearing is installed in the gear the


bearing must be machined to size.
The bore in the bearings after machining is the
following value: ........................ 75.06 0.01 mm
(2.9551 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
(4) Alignment mark
The mark on the cluster idler gear must be in
alignment with the mark on the crankshaft gear.
(5) Crankshaft gear

RENR9337

39
Specifications Section

i02563615

Fan Drive
SMCS Code: 1359
Part No.: 259-9221

g01283594

Illustration 61
(1) Key
(2) Yoke end
(3) Set screw

(4) Bearing cap


(5) Joint group
(6) Bolts

1. Install yoke adapter (7) prior to installing joint


group (5).
2. Bearing caps (4) need to be removed from yoke
end (2) in order to allow the joint group to be
installed.
3. Install the yoke end onto the pulley shaft.
4. Turn the fan in order to provide proper alignment
between the bearing cross and the yoke.
5. Install the bearing caps.
Tighten the bolts that support the cover for the
bearing cap.
Torque ............................. 28 7 Nm (21 5 lb ft)
6. Apply 4C-9506 Retaining Compound to the set
screw (3).
7. Install the set screw.

(7) Yoke adapter

40
Specifications Section

RENR9337

i02550818

i02564826

Flywheel

Flywheel Housing

SMCS Code: 1156

SMCS Code: 1157

Part No.: 282-8773

Part No.: 287-7079

Illustration 62

g01276832

Refer to Testing And Adjusting, Flywheel - Inspect


for the correct method of flywheel inspection.
(1) Flywheel
(2) Gear
(3) Bolts
Use clean unused engine oil on the bolt threads
and the bolt seats before assembly.
Torque .................. 1100 60 Nm (811 44 lb ft)

Illustration 63

g01284043

(1) Joint surface for the flywheel housing

For information on inspecting the flywheel housing,


refer to Systems Operation/Testing and Adjusting.
Note: Before installation of the flywheel housing,
inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
water, gasket adhesive, assembly compounds, and
any other foreign material.
To seal the joint between the flywheel housing and
the cylinder block, apply a 6 mm (0.250 inch) of
4C-5300 Gasket Sealant or 185-3984 Gasket
Sealant to the mating surface of the flywheel housing.

RENR9337

41
Specifications Section

i02550922

Vibration Damper
SMCS Code: 1205
Part No.: 283-1678

Illustration 64

g01284018

(X) 6V-3532 Bolts


(Y) 259-9148 Bolts
Apply 4C-5300 Gasket Sealant uniformly to the
surface that joins with the engine block.

Illustration 66

g01277026

Note: Apply 9S-3263 Thread Lock Compound to


the bolt threads.
(1) Tighten the bolts to the following
torque. ........................... 55 7 Nm (40 5 lb ft)
(2) Damper
Illustration 65

g01284019

View A-A

(A) Dowel pins ... 5 0.5 mm (0.1969 0.0197 inch)

42
Specifications Section

RENR9337

i02550925

i02550951

Fastener Group (Vibration


Damper)

Fastener Group (Vibration


Damper)

SMCS Code: 1205-FG

SMCS Code: 1205-FG

Part No.: 249-6399

Part No.: 266-2193, 270-6862, 283-1676,


288-9940

Illustration 67

g01276986

Illustration 68

(1) Damper
(2) Spacer
(3) Bolts
Torque .................... 625 50 Nm (461 37 lb ft)

g01277000

(1) Damper
(2) Spacer
(3) Bolts
lubricate the bolt threads, bolt head and the
spacer plate with clean engine oil.
Torque .................... 700 50 Nm (516 37 lb ft)
i01617888

Belt Tension Chart


SMCS Code: 1357
Note: Do not use the belt tension charts for belts with
tensioners that are spring loaded.

RENR9337

43
Specifications Section

Table 5

Belt Tension Chart


Kent-Moore Gauge
Numbers

Gauge Reading
Size of
Belt

Width of Belt

3/8

Belt Tension
Initial(1)

Belt Tension
Used(2)(3)

Number
of the Old
Gauge

Number of the
New Gauge

10.72 mm (0.422 inch)

534 111 N
(120 25 lb)

400 22 N (90 5 lb)

BT-33-97

BT 3397

1/2

13.89 mm (0.547 Inch)

578 111 N
(130 25 lb)

445 44 N (100 10 lb)

BT-33-97

BT 3397

5V

15.88 mm (0.626 Inch)

712 111 N
(160 25 lb)

445 44 N (100 10 lb)

BT-3372C

BT 3372C

11/16

17.48 mm (0.688 Inch)

712 111 N
(160 25 lb)

445 44 N (100 10 lb)

BT-3372C

BT 3372C

3/4

19.05 mm (0.750 Inch)

712 111 N
(160 25 lb)

445 44 N (100 10 lb)

BT-3372C

BT 3372C

15/16

23.83 mm (0.938 Inch)

712 111 N
(160 25 lb)

445 44 N (100 10 lb)

BT-33-77

BT 3372C

8PK

27.82 mm (1.095 inch)

1068 111 N
(240 25 lb)

890 44 N (200 10 lb)

BT-33109

BT 33109

6PK

20.94 mm (0.824 Inch)

801 111 N
(180 25 lb)

667 44 N (150 10 lb)

BT-33109

BT 33109

Measure the tension of the belt that is farthest from the engine.
(1)
(2)
(3)

Belt tension Initial is for a new belt.


Belt tension Used is for a belt that has operated for 30 minutes or more of operation at the rated speed.
If a belt falls below the Used belt tension, the belt should be tightened again to the high side of the Used belt tension.

Table 6

For DAYCO Supplied Belts Only

(1)
(2)
(4)

Size of Belt

Belt Tension
Initial(1)

Belt Tension
Used(2)(4)

.380 (V-Belt)

623 22 N (140 5 lb)

245 - 534 N (100 5 lb)

.440 (V-Belt)

667 22 N (150 5 lb)

245 - 534 N (100 5 lb)

.500 (V-Belt)

712 22 N (160 5 lb)

245 - 534 N (100 5 lb)

.600 (V-Belt)

779 22 N (175 5 lb)

245 - 534 N (100 5 lb)

.660 (V-Belt)

890 22 N (200 5 lb)

245 - 534 N (100 5 lb)

.790 (V-Belt)

890 22 N (200 5 lb)

245 - 534 N (100 5 lb)

4 - RIB PVK

623 22 N (140 5 lb)

267 - 445 N (90 5 lb)

5 - RIB PVK

779 22 N (175 5 lb)

334 - 556 N (100 5 lb)

6 - RIB PVK

934 22 N (210 5 lb)

400 - 667 N (130 5 lb)

8 - RIB PVK

1157 22 N (260 5 lb)

534 - 890 N (180 5 lb)

10 - RIB PVK

1557 22 N (350 5 lb)

667 - 1112 N (230 5 lb)

12 - RIB PVK

1869 22 N (420 5 lb)

800 - 1335 N (270 5 lb)

15 - RIB PVK

2336 22 N (525 5 lb)

1000 - 1669 N (350 5 lb)

Belt tension Initial is for a new belt.


Belt tension Used is for a belt that has operated for 30 minutes or more of operation at the rated speed.
If a belt falls below the Used belt tension, the belt should be tightened again to the Initial belt tension.

44
Specifications Section

RENR9337

i02561293

Belt Tensioner
SMCS Code: 1358
Part No.: 190-0642

Illustration 69

g01282318

Illustration 71

g01282267

(1) Limited travel .................. 71 degrees (minimum)

Voltage ............................................................... 24 V

(2) Spring force at assembly 25.4 2.6 Nm


(19 2 lb ft) at 30 degrees from the free arm stop

Amperage ..................................................... 75 Amp

i02561119

Alternator and Regulator

Note: Load the battery with a carbon pile 4C-4911


Battery Load Tester in order to get the maximum
alternator output.
Polarity ............................................ Negative ground

SMCS Code: 1405

Rotation ............................................ Either direction

Part No.: 276-8899

The minimum full load current at 5000 rpm is the


following value: .......................................... 67.5 Amp
The minimum full load current at 2000 rpm is the
following value: ............................................. 26 Amp
Output voltage .......................................... 28 1.0 V
(1) Bolt
Torque ....................... 6.2 0.6 Nm (55 5 lb in)
(2) Shaft nut
Torque .......................... 102 7 Nm (75 5 lb ft)

Illustration 70

g01282265

(3) Positive terminal nut


Torque ....................... 6.2 0.6 Nm (55 5 lb in)
(4) R terminal ............................................ Optional
alternating current from the stator
(5) I terminal
Torque ............. 2.25 0.25 Nm (20.0 2.2 lb in)

RENR9337

45
Specifications Section

i02100780

Electric Starting Motor


SMCS Code: 1453
Part No.: 276-8900, 276-8901

g01093018

Illustration 72
Typical example

Rotation of the starting motor when viewed from the


pinion end ................................................. Clockwise
The following performance specifications are rated at
no load at 25 C (77 F):
Speed ............................................ 6950 1650 rpm
Current draw ....................................... 115 25 Amp
Voltage ............................................................... 23 V
(1) Large terminal nuts
Torque ...................... 30.5 3.5 Nm (22 3 lb ft)
(2) Solenoid

Current consumption (draw) at 20 V


Pull-in windings ........................... 49.3 3.3 Amp
Hold-in windings ............................ 6.8 Amp max
(B) Allowable range from the horizontal plane for the
position of the solenoid
(3) Small terminal nut (ground)
Torque ................... 2.25 0.25 Nm (20 2 lb in)
(4) Small terminal nut (switch)
Heat shrink tubes must be used to insulate
terminals for the switch terminal. Do not use
molded terminals.
Torque ................... 2.25 0.25 Nm (20 2 lb in)
(5) Large terminal nut

46
Specifications Section

RENR9337

There can be no more than three cable or wire


terminals between nuts. Only two of the cable or
wire terminals can be larger than 0 AWG.
Torque ...................... 30.5 3.5 Nm (22 3 lb ft)
(6) Clearance between the pinion and the housing
with the pinion in the extended position .. 9.1 mm
(0.36 inch)
Note: Twelve point bolts are required for the
mounting of the starting motor.
i02580020

Engine Harness
SMCS Code: 1408
Part No.: 285-3991, 285-3993

Illustration 73

(4) Nuts
M40
Torque ......................... 15 1 Nm (132 9 lb in)
(1) Nuts
M20
Torque ............................. 5 1 Nm (45 9 lb in)
(3) Nuts
M12
Torque ............................ 1 0.5 Nm (9 5 lb in)
(2) Nuts
M16
Torque .......................... 3 0.5 Nm (27 5 lb in)
(5) Connector
Torque ............................. 6 1 Nm (53 9 lb in)

g01292329

RENR9337

47
Specifications Section

i02425985

Engine Speed Sensor

(1) Bolt
Torque ............................ 28 7 Nm (21 5 lb ft)
(2) Clearance between the sensor and the gear
tooth ........................... 0.5 mm (0.0197 inch)

SMCS Code: 1907


Part No.: 191-8304, 191-8305

Note: The wiring harness must be tied down and


supported less than 102 mm (4 inches) from the
sensor. Twisting of the wires minimizes the effect of
the electrical noise.
i02577495

Pressure Sensor
SMCS Code: 7400-NS; 7450-NS
Part No.: 287-1866

Illustration 74

g01075831

(1) Sensor assembly


Torque ............................ 25 5 Nm (18 4 lb ft)
Clearance between the sensor and the gear
tooth ................ 1.0 0.4 mm (0.04 0.016 inch)
i02562514

Illustration 76

g01291168

(1) Sensor assembly


Torque .......... 45 6 Nm (33.1902 4.4254 lb ft)

Engine Speed Sensor

Supply voltage ....................................... 5 0.5 volts

SMCS Code: 1907

Output signal ................................................. Voltage

Part No.: 244-5544

Operating temperature ...................... 40 150 C


( 40 270 F)
Sensed media ......................... Engine oil, and diesel

Illustration 75

g01282732

Note: Lubricate the O-ring with clean unused engine


oil.

48
Specifications Section

RENR9337

i02562825

i02562983

Pressure Sensor

Temperature Sensor

SMCS Code: 7400-NS; 7450-NS

SMCS Code: 7400

Part No.: 241-1798, 274-6721

Part No.: 238-0112

Illustration 77

g01282909

(1) Sensor assembly


Torque ........................ 10 2 Nm (90 18 lb in)
Operating temperature ...................... 40 125 C
( 40 225 F)
Supply voltage ....................................... 5 0.5 volts
Sensed media ................... Engine oil and diesel fuel
Note: Install the sensor so that the input pressure
port is lower than the connector end and as close to
the vertical position as possible. This reduces the
possibility of ice that forms on the diaphragm in the
sensor.

Illustration 78

g01283059

Note: Do not connect the sensor directly to battery


voltage.
(1) Sensor assembly
Torque ............................ 20 3 Nm (15 2 lb ft)
Operating temperature ...................... 40 150 C
( 40 270 F)
Sensed media .................................. Engine coolant,
engine oil, fuel, air, and hydraulic oil
i02576336

Temperature Sensor
SMCS Code: 7400
Part No.: 247-7635

Illustration 79

(1) Fitting

g01291434

RENR9337

Torque ............................ 45 5 Nm (33 4 lb ft)


Operating temperature ........................ 40 to 850 C
(40 to 1562 F)
Supply voltage .................................... 8.0 0.5 volts
Output type ............... Pulse width modulated (PWM)
Output frequency ................................. 500 100 Hz
Sensed media .............................................. Exhaust

49
Specifications Section

50
Index Section

RENR9337

Index
I

A
Air Cleaner.............................................................
Air Lines.................................................................
Alternator and Regulator .......................................
Auxiliary Water Pump ............................................

19
17
44
23

B
Belt Tension Chart ................................................. 42
Belt Tensioner........................................................ 44
C
Camshaft ................................................................ 11
Connecting Rod..................................................... 30
Procedure for Tightening Connecting Rod
Bolts ................................................................. 31
Connecting Rod and Main Bearing Journals ......... 31
Crankshaft ............................................................ 32
Crankshaft Wear Sleeves and Seals..................... 33
Cylinder Block........................................................ 24
Cylinder Head........................................................ 13
Cylinder Head Valves ............................................ 15
Cylinder Liner ........................................................ 27
E
Electric Starting Motor ........................................... 45
Engine Design ......................................................... 4
Engine Harness ..................................................... 46
Engine Oil Pan....................................................... 21
Engine Oil Pump.................................................... 19
Engine Speed Sensor............................................ 47
Exhaust Fitting................................................. 1819
Exhaust Manifold ............................................. 1718
F
Fan Drive ............................................................... 39
Fastener Group (Vibration Damper) ...................... 42
Flywheel ................................................................ 40
Flywheel Housing .................................................. 40
Fuel Filter (Primary)................................................. 4
Fuel Filter (Secondary) ............................................ 5
Fuel Injector............................................................. 6
Fuel Lines ............................................................ 78
Fuel Transfer Pump ................................................. 5
G
Gear Group (Front).......................................... 35, 37
Gear Group (Rear) ................................................ 38

Important Safety Information ................................... 2


L
Lifter Group............................................................ 12
P
Piston and Rings ................................................... 28
Pressure Control Valve (Oil Regulator Valve and Oil
Bypass Valve) ...................................................... 20
Pressure Sensor.............................................. 4748
S
Specifications Section ............................................. 4
T
Table of Contents..................................................... 3
Temperature Sensor .............................................. 48
Turbocharger ......................................................... 16
V
Valve Mechanism .................................................. 13
Vibration Damper................................................... 41
W
Water Pump........................................................... 21

RENR9337

51
Index Section

2006 Caterpillar
All Rights Reserved

Printed in U.S.A.