PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2. In-Line Engine Model Description, Rotation and Accessory Arrangement
Fig. 3. 6V Engine Model Description, Rotation and Accessory Arrangement
Fig. 4. Series 53 Cylinder Arrangement
Fig. 5. Typical Model and Serial Numbers as Stamped on Cylinder Block (In-Line Engine)
Cross Section Views of a Typical In-Line Engine
Cross Section Views of a Typical 6V-53 Engine
Fig. 1. Schematic Diagram of Typical Fuel System - In-Line Engine
Fig. 3. Removing Injector from Cylinder Head
Fig. 4. Typical Fuel Strainer and Filter Mounting
Fig. 5. Typical Spin-On Type Fuel Strainer and Fuel Filter Mounting
Fig. 7. Air Intake System Through Blower and Engine (6V-53 Engine)
Fig. 8. Light-Duty Oil Bath Air Cleaner
Fig. 10. Air Cleaner Tray (Plugged)
Fig. 12. United Specialties Dry Type Air Cleaner
Air Silencer
Figure 14. Typical In-Line Engine Oil Filter Mounting
Figure 16. Schematic Diagram of Typical In-Line Engine Lubricating System
Figure 17. Schematic Diagram of Typical 6V Engine Lubricating System
Figure 18. Typical Cooling System for In-Line Engines
Figure 19. Typical Cooling System for V-Type Engine
ENGINE COOLING SYSTEM MAINTENANCE
Cooling System Cleaners
Miscellaneous Cooling System Checks
Raw Water Pump
Figure 1. Typical Instrument Panel
Throttle Control
Figure 2. Mechanical Shut-Down System Schematically Illustrated
AUTOMATIC ELECTRICAL SHUT-DOWN SYSTEM
Figure 3. Automatic Electrical Shut-Down System Diagram
Figure 5. Alarm System Wiring Diagram
ELECTRICAL STARTING SYSTEMS
Figure 6. Schematic Diagram of Hydrostarter System Showing Oil Flow
Figure 7. Hydrostarter Remote Control System
LUBRICATION AND PREVENTIVE MAINTENANCE
Cold Weather Operation
Figure 8. Typical Fluid Starting Aid
Figure 9. Quick-Start Assembly
POWER TAKE-OFF ASSEMBLIES
TORQMATIC CONVERTERS
WARNER MARINE GEAR
PREPARATION FOR STARTING ENGINE FIRST TIME
Lubrication Fittings
Oil Pressure
Avoid Unnecessary Engine Idling
Fig. 1 . Location of Controls on Power Generator Set
PREPARING GENERATOR FOR LOAD
PARALLELING
LUBRICATION AND PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
TWIN DISC MARINE GEAR
SPECIFICATIONS
SPECIFICATIONS OIL QUALITY
COLD WEATHER OPERATION
STATEMENT OF POLICY ON FUEL AND LUBRICANT ADDITIVES
COOLANT REQUIREMENTS
Fig. 2 - Heat Transfer Capacity
Bulk Inhibitor Additives
GENERAL RECOMMENDATIONS
GENERAL RECOMMENDATIONS - Continued
ENGINE TUNE-UP PROCEDURES
EXHAUST VALVE CLEARANCE ADJUSTMENT
FOUR VALVE CYLINDER HEADS
Fig. 3 - Timing Fuel Injector
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
Position Injector Rack Control Levers
Fig. 6. Governor Spring Assemblies
Adjust Idle Speed
Fig. 7 Adjusting Buffer Screw
Adjust Governor Gap
Position Injector Rack Control Levers
Fig. 5. Checking Injector Control Rack "Spring"
Fig. 7. Governor Spring Assemblies
Fig. 8. Adjusting Engine Idle Speed
Fig. 1. Variable Speed Open Linkage Governor Mounted on Engine
Adjusting Screws
Adjust Maximum No-Load Speed
Fig. 7. Adjusting Buffer Screw
Fig. 1 - Checking Governor Gap
Injector Control Rack
Fig. 5 - Locating of Shims and Stops
Fig. 6 - Adjusting Idle Speed
Fig. 8 Adjusting Booster Spring
VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 3 Positioning No. 3L Injector Rack Control Lever
Fig. 6 - Location of Shims and Stops
Fig. 7 - Adjusting Idle Speed
Fig. 9 - Adjusting Booster Spring
Fig. 1 - Engine Load Limit Device
Fig. 4 - Throttle Delay Yield Lever (6V Engine)
Fig. 5 - Adjusting Throttle Delay Cylinder
Fig. 6 - Typical Variable Speed Governor Lever Position
Fig. 7 . Typical Limiting Speed Governor Lever Position
Fig. 1 - Hydraulic Governor Mounted on Engine
Fig. 3 - Adjusting Length of Fuel Rod
Fig. 5 - Adjusting Maximum Engine Speed
Fig. 1 - Hydraulic Governor Mounting
Fig. 1 - Checking Compression Pressure
Engine Out of Fuel
Crankcase Pressure
Air Box Pressure
Fig. 2 - Comparison of Column Height for Mercury and Water Manometers
PREPARING ENGINE FOR STORAGE
TURBOCHARGER
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
HYDROSTARTER
Built-In Parts Book
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
CONNECTING ROD, PISTON AND LINER
ACCESSORY DRIVE FOR DIRECT DRIVEN ACCESSORY (CAMSHAFT GEAR)
VALVE OPERATING MECHANISM (4 VALVE)
TYPICAL FUEL OIL STRAINER
AIR SHUT-DOWN HOUSING
BLOWER ASSEMBLY AND DRIVE (4 CYL.)
BLOWER ASSEMBLY AND DRIVE (6 CYL.)
OIL PUMP AND REGULATOR
OIL FILTER
OIL COLLER (6V-53)
FRESH WATER PUMP
FAN MOUNT (6V-53)
FAN MOUNT
WATER TEMPERATURE SHUTDOWN SWITCH
TACHOMETER DRIVE COVERS AND ADAPTORS
AIR COMPRESSOR AND DRIVE
OWNER ASSISTANCE
OWNER ASSISTANCE - Continued
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ENGLISH TO METRIC CONVERSIONS
Service Manual
FOREWORD
TABLE OF CONTENTS
SCOPE AND USE OF THE MANUAL
PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2 - In-line Engine Model Description, Rotation, and Accessory Arrangements
Fig. 3 - 6 and 8V Engine Model Description, Rotation and Accessory Arrangements
Fig. 4 - Cylinder Designation and Firing Order
Fig. 5 - Typical Model and Serial Numbers as Stamped on Cylinder Block (In-Line Engine)
GENERAL PROCEDURES
Rust Preventive
WORK SAFELY
Cross Sections of a Typical In-Line Engine
SECTION 1. ENGINE (less major assemblies)
Fig. 1 - Cylinder Block (Four Cylinder Block Shown)
Fig. 3 - Air and Water Passages in In-Line Cylinder Block
Remove and Disassemble Engine
Fig. 6 - Cylinder Head Gaskets and Seals in Place on Cylinder Block
Fig. 8 - Vertical Oil Passages in Top of Cylinder Block
Fig. 11 - Location of Block Bore Seal Ring Groove
Fig. 14 - Typical Cylinder Block Markings
Inspect Cylinder Block
Assemble and Install Engine
Fig. 1 - Cylinder Block Rear End Plate Mounting (In-Line Engine)
CYLINDER BLOCK END PLATE
Fig .1 Air Box Drain Tube Mounting (In-Line Engines)
Inspection
Fig. 1 - Typical Four-Valve Cylinder Head Assembly
Cylinder Head Maintenance
Disassemble Cylinder Head
Fig. 3 - Checking Bottom Face of Cylinder Head for Warpage
Fig. 5 - Correct Installation of Water Nozzles in Four-Valve Cylinder Head
Fig. 6 - Sequence for Tightening Cylinder Head Bolts
Install Cylinder Head
VALVE AND INJECTOR OPERATING MECHANISM
Fig. 3 - Removing Push Rod from Upper Side of Cylinder Head with Tool J 3092-01
Remove Cam Follower and Push Rod Assembly (Cylinder Head Not Removed from Engine)
Fig. 7 - Removing or Installing Cam Follower Roller and Pin with Tool J 5840
Fig. 10 Adjusting Cam-Follower Guide
Fig. 11 - Push Rod Spring Identification
Fig. 12 - Relationship Between Exhaust Valve Bridge and Valve Stems
Install Rocker Arms and Rocker Arm Shaft
EXHAUST VALVES
Remove Exhaust Valve Spring (Cylinder Head Installed)
Inspection
Fig. 5 - Removing Valve Guide
Fig. 7 - Removing Valve Seat Insert
Fig. 9 - Refacing Exhaust Valve
Fig. 12 - Relationship Between Exhaust Valve, Insert and Cylinder Head (4 Valve Head)
Fig. 14 - Checking Relative Concentricity of Valve Seat Insert with Relation to Valve Guide
Fig. 16 - Checking Valve Opening Pressure with Gage WRE-500-60
Fig. 1 - Typical Valve Rocker Cover Assembly
Fig. 1 - Crankshaft Details and Relative Location of Parts (Three Cylinder In-Line Engine Crankshaft Shown)
Fig. 3 - Removing or Installing Crankshaft
Fig. 4 - Typical Ridging of Crankshaft
Fig. 6 - Crankshaft Fatigue Cracks
Fig. 7 - Dimensions of Crankshaft Journals - In-Line Engine
Crankshaft Grinding
Fig. 10 - Standard Dimensions at Crankshaft Thrust Surfaces--in-Line Engines
Install Crankshaft
CRANKSHAFT OIL SEALS
Fig. 3 - Use of Rear Oil Seal Sleeve on Grooved Crankshaft (In-Line Engines)
Install Crankshaft Front Oil Seal
Install Crankshaft Rear Oil Seal
Fig. 1 - Main Bearing Shells, Bearing Caps and Crankshaft Thrust Washers -- In-Line Engines
Fig. 4 - Removing Upper Main Bearing Shell (Except Rear Main)
Fig. 6 - Comparison of Main Bearing Shells
Fig. 7 - Main Bearing Measurements
Fig. 9 - Crankshaft Thrust Washers in Place
Install Main Bearing Shells (Crankshaft in Place)
Fig. 1 - Engine Front Cover Mounting (Lower) -- In-Line Engine
Fig. 3 - Installing Lower Engine Front Cover -- In-Line Engine
CRANKSHAFT PULLEY
Fig. 3 - Cone Mounted Pulley
Fig. 1 - Removing Flywheel
Install Ring Gear
FLYWHEEL HOUSING
Fig. 3 -Flywheel Housing Bolt Sizes and Tightening Sequence (Operation 1)--In-Line Engine
Fig. 6 - Flywheel Housing Bolt Tightening Sequence (Operation 2)--In-Line Engine
Fig. 9 Checking Flywheel Housing Concentricity
Install Flywheel Housing
PISTON AND PISTON RINGS
Fig. 3 - Cleaning Piston
Fig 4 - Comparison of Pistons
Fig. 5 - Removing or Installing Piston Pin Bushings
Fig. 8 - Measuring Piston-to-liner Clearance
Fitting Piston Rings
OIL CONTROL RINGS
Fig. 1 - Connecting Rod Mounting
Fig. 3 - Magnetic Particle Inspection Limits for Connecting Rod
Fig. 4 - Removing or Installing Bushings
Fig. 8 - Reaming Bushings
Assemble Connecting Rod to Piston
CONNECTING ROD BEARINGS
Install Connecting Rod Bearing Shells
Fig. 1 Cylinder Liner
Fig. 4 - Checking Bore of Cylinder Liner
Fig. 6 Cylinder Liner Ridge Due to Wear
Fig. 7 - Checking Distance of Liner Flange Below Top Face of Block
Fig 9. - Cylinder Liner Seal ring Location in Cylinder Block Bore
Install Cylinder Liner, Piston and Connecting Rod Assembly
ENGINE BALANCE AND BALANCE WEIGHTS
Install Front Balance Weights
GEAR TRAIN AND ENGINE TIMING
GEAR TRAIN AND ENGINE TIMING - Continued
GEAR TRAIN AND ENGINE TIMING - Continued
ENGINE TIMING
ENGINE TIMING - Continued
Figure 1. Removing or Installing Nut on Camshaft or Balance Shaft
Figure 3. Removing End Bearing
Figure 4. Installing Intermediate Camshaft Bearing
Figure 5. Camshaft and Balance Shaft Bearing Identification
Install End Bearings
Figure 7. Removing and Replacing Camshaft or Balance Shaft Bearings
Figure 8. Camshaft and Balance Shaft Details and Relative Location of Parts
CAMSHAFT AND BALANCE SHAFT GEARS
Figure 2. Installing Camshaft Gear
Figure 1. Installing Idler Gear Hub
Figure 3. Idler Gear Details and Relative Location of Parts
Figure 1. Removing Crankshaft Timing Gear
Install Crankshaft Timing Gear
Figure 1. Accessory Drive Locations (In Line Engines)
Figure 3. Air Compressor Drive
Figure 5. Components of Accessory Drive for Belt Driven Accessory (Drive Hub Type)
Figure 7. Former and Current Drive Plate Type Accessory Drive
Install Accessory Drive
ENGINE FRONT COVER ( UPPER )
Install Cover
Fig. 1 - Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance
CAMSHAFT CUP PLUG INSTALLATION
TROUBLE SHOOTING
SPECIFICATIONS
TABLE OF SPECIFICATIONS, NEW CLEARANCE AND WEAR LIMITS
TABLE OF SPECIFICATIONS, NEW CLEARANCE AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCE AND WEAR LIMITS - Continued
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
TOOL NAME
TOOL NAME - Continued
SECTION 2. FUELS SYSTEM AND GOVERNORS
Fig. 1 Typical Fuel System for In- Line Engines
Fig. 1 Fuel Injector Assembly
Fig. 4 Phases of Injector Operation Through Vertical Travel of Plunger
Fig. 6 Fuel Injector Mounting
Fig. 8 Checking Rack and Plunger for Free Movement
Fig. 10 Spray Pattern Test
INJECTOR CONTROL RACK AND PLUNGER MOVEMENT TEST
INJECTOR HIGH PRESSURE TEST
Fig. 14 Injector Needle Valve Test with Auxiliary Test J 22640
Fig. 17. Placing Injector in Comparator J 7041
Fig 20. Position of Calibrator Fuel Flow Pipes
Fig. 21. Injector in Calibrator J 224410
Fig. 24. Removing or Installing Plunger Follower, Plunger and Spring
Fig. 26. Removing Spray Tip Injector Nut
Clean Injector Parts
Fig. 33. Lapping Spray Tip on Lapping Blocks J 22090
Fig. 35. Details of Injector Filters and Caps and Their Relative Location
FIG. 38. Comparison of former and New Design Injector Parts
Lapping Injector Parts
ASSEMBLE PLUNGER AND FOLLOWER
Test Reconditioned Injector
FUEL INJECTOR TUBE
Fig. 3 Upsetting Injector Tube
Fig. 5 - Reaming Injector Tube for Injector Nut
Fig. 1. Typical Fuel Pump Assembly
Fig. 2. Fuel Pump Valving and Rotation (Right Hand Pump Shown)
Fig. 4. Removing Oil Seals
Fig. 5 Fuel Pump Details and Relative Location of Parts ( Right Hand Pump Shown)
Fig. 7. Installing Outer Oil Seal
FUEL PUMP DRIVE
MECHANICAL GOVERNORS
LIMITING SPEED MECHANICAL GOVERNOR
Fig. 2 Governor Cover Details and Relative Location of Parts
Fig. 4 Removing Fork from Operating Shaft
Inspection
Fig. 5 - Governor Housings and Relative Location of Parts
Install Governor
Install Governor - Continued
SHOP NOTES-TROUBLE SHOOTING-SPECIFICATIONS-SERVICE TOOLS
Fig. 2 - Injector Rack-to-Gear Timing
Fig. 3 - Checking Fuel Output
Fig. 4. Types of Injector Plungers
LOCATING AIR LEAKS IN FUEL LINES
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
TROUBLE SHOOTING CHARTS (Needle Valve Injectors) - Continued
TROUBLE SHOOTING CHARTS (Needle Valve Injectors) - Continued
FUEL PUMP MAINTENANCE
SPECIFICATIONS
SERVICE TOOLS
SECTION 3. AIR INTAKE SYSTEM
Fig. 1 - Air Silencer Mounted on In-Line Engine
Fig. 1 - Typical In - Line Air Shut Down Housing Details and Relative Location Of Parts
Fig. 3 - Location of Air Shut-Down Housing Mounting Bolts (In-Line Engines)
Install Air Shut-Down Housing (In-Line Engines)
Fig. 1 - Blower Mounting (3-53 Engine)
Fig. 5 Removing Blower Rotor Gears
Disassemble Blower
Fig. 7 - Typical Blower Details and Relative Location of Parts (3-53 Engine Blower)
Fig. 9 - Installing Lip Type Oil Seal in End Plate
Fig. 13 - Installing Blower Rotor Gears
Fig. 15- Minimum Blower Rotor Clearance
Fig. 16 - Measuring Rotor Lobe to End Plate Clearance
Fig. 17 - Inserting Cam in Blower Drive Support
ENGINE BLOWER
SHOP NOTES - TROUBLE SHOOTING - SPECIFICATIONS - SERVICE TOOLS
Fig. 3 - Positioning Cutting Tool in Fixture Guide
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SECTION 4. LUBRICATION SYSTEM
Fig. 1 - Schematic Diagram of typical In-Line Engine Lubrication System,
Lubricating Oil Distribution
Cleaning Lubrication System
Fig. 1 - Typical Right - Hand Rotation Lubricating Oil Pump Mounting
Fig. 3 - Measuring Rotor Clearance
Fig. 5 - Lubricating Oil Pump Details and Relative Location of Parts (Current)
Fig. 7 - Removing Oil Pump Drive Gear pump body. Since the holes are offset, the cover plate
Install Oil Pump
LUBRICATING OIL PRESSURE REGULATOR
Fig. 1 Typical Oil Cooler Mounting (6V-53 Engine Shown)
Fig 3 - Oil Cooler Details and Relative Location of Parts (In-Line Engine)
Pressure Check Oil Cooler Core
Install Oil Cooler Core
Fig. 1 - Typical Oil Dipstick Mounting
Removing and Installing Oil Pan
Fig. 1 - Typical Crankcase Breather Mounting (In-Line Engine)
VENTILATING SYSTEM
SPECIFICATIONS - SERVICE TOOLS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SECTION 5. COOLING SYSTEM
WATER PUMP
Fig. 3 - Removing Pulley
Fig. 6. Fresh Water Pump Details and Relative Location of Parts
Fig. 7 - Comparison of Water Pumps
Fig. 2. Thermostat Housing Details and Relative Location of Parts (In-Line Engine)
Fig. 4. Method of Checking Thermostat Operation
Fig. 5. Bleed Hole in Thermostat Housing
ENGINE COOLING FAN
Fig. 3. Removing Fan Hub (Pulley)
Fig. 5 - Current Fan Hub Assembly (In-Line Engine)
Fig. 8. Typical Fan Hub and Adjusting Bracket Details and Relative Location of Parts (In-Line Engine)
IN-LINE ENGINES (CURRENT)
Install Fan, Hub and Adjusting Bracket
WATER FILTER AND CONDITIONER
WATER FILTER AND CONDITIONER - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SECTION 6. EXHAUST SYSTEM
EXHAUST MANIFOLD (AIR COOLED)
Install Exhaust Manifold
SECTION 7. ELECTRICAL EQUIPMENT, INSTRUMENTS AND PROTECTIVE
BATTERY-CHARGING GENERATOR (D.C. AND A.C.)
Fig. 2 - 30 DN Type 100 A.C. Self-Rectifying Generator (Alternator)
Alternator Precautions
Fig. 4. 20 DN Type 250 A.C. Self-Rectifying Generator (Alternator)
BATTERY-CHARGING GENERATOR REGULATOR
TRANSISTORIZED AND TRANSISTOR REGULATORS
TRANSISTOR REGULATOR
Fig. 5 - Transistor Regulator with Plug-In Connections
STARTING MOTOR
Fig. 2 - Cross-Section of Motor with Intermediate-Duty Clutch
Remove Starting Motor
SPECIFICATIONS - SERVICE TOOLS
CHECKING ENGINE ELECTRICAL GENERATING SYSTEM
SERVICE TOOLS
SECTION 13. OPERATION INSTRUCTIONS
ENGINE OPERATION INSTRUCTIONS
Storage Battery
Oil Pressure
Emergency Stopping
ENGINE OPERATING CONDITIONS
3-53 IN-LINE ENGINE (4-Valve Cylinder Head)
3-53 IN-LINE ENGINE (4-Valve Cylinder Head) - Continued
ENGINE RUN-IN INSTRUCTIONS
Instrumentation
BASIC ENGINE RUN-IN
ENGINE TEST REPORT
INSPECTION AFTER FINAL RUN-IN
DETROIT DIESEL FUEL OIL SPECIFICATIONS
DETROIT DIESEL LUBRICATING OIL SPECIFICATIONS
ENGINE COOLANT
INHIBITOR SYSTEMS
COOLANT INHIBITOR CHART
ANTIFREEZE
COOLANT RECOMMENDATIONS
SECTION 14. ENGINE TUNE UP
EXHAUST VALUE CLEARANCE ADJUSTMENT
EXHAUST VALUE CLEARANCE ADJUSTMENT
Fig. 2 - Adjusting Valve Clearance (Four Valve Head)
Fig. 1 - Timing Fuel Injector
Fig. 1 - Adjusting Governor Gap
Fig. 2 - Positioning the Rear Injector Rack Control Lever
Fig. 3 - Adjusting Maximum No-Load Engine Speed
Fig. 5 - Adjusting Engine Idle Speed
SECTION 15. PREVENTIVE MAINTENANCE - TROUBLE SHOOTING - STORAGE
LUBRICATION AND PREVENTIVE MAINTENANCE
LUBRICATION AND PREVENTIVE MAINTENANCE CHART
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
Exhaust Back Pressure
Fig. 2 - Comparison of Column Height for Mercury and Water Manometers
Trouble Shooting (Engine)
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
STORAGE
EXTENDED STORAGE (30 days or more)
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
PART III. ENGINE PARTS MANUAL
GROUP NOMENCLATURE
GROUP NOMENCLATURE - Continued
GENERAL INFORMATION
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
INDEX
MODEL DESCRIPTION CHART IN-LINE ENGINES
FIG. 1A INLIE 53 CYLINDER BLOCK (with head gasket)
FIGURE 2A. CYLINDER HEAD
FIGURE 3A. CRANKSHAFT (3-53)
fIG. 4D. LOWER FRONT COVER AND OIL PUMP
FIG. 5A. FLYWHEEL AND FLYWHEEL HOUSING (In-Line Models)
FIG. 6A. CONNECTING ROD, PISTON AND LINER
FIG. 7A. CAMSHAFT (In-Line Models)
FIG. 7C. GEAR TRAIN (Typical In-Line)
FIG. 8A. ACCESSORY DRIVE (Double Bell)
FIG. 9A. VALVE MECHANISM
ROCKER COVER
TYPICAL 4 CYLINDER FAN TO FLYWHEEL INDUSTRIAL UNIT
BLOCK ASSY., CYLINDER
BLOCK CYLINDER
HEAD ASSY. CYLINDER
COVER, CYLINDER HEAD WATER HOLE
HEAD ASSEMBLY, CYLINDER
CRANKSHAFT ASSY
SHELL, CRANKSHAFT MAIN BEARING
COVER, ENGINE FRONT-LOWER
FLYWHEEL
HOUSING, FLYWHEEL
CONNECTING ROD ASSY
PISTON ASSY
CYLINDER KIT
BEARING, CAM AND BALANCER SHAFT
WEIGHT, REAR BALANCER
ADAPTOR, ACCESSORY DRIVE
ARM ASSY. EXHAUST VALVE
BRACKET, ROCKER SHAFT
VALVE, EXHAUST
GASKET, ROCKER COVER
GROUP NOMENCLATURE
FIG. 1B. FUEL INJECTOR
FIG. 2B. FUEL PUMP DRIVE
FIG. 3B. FUEL FILTER (Canister Type Element)
FIG. 4A. TYPICAL FUEL SYSTEM (In-Line Engine)
FIG. 5D. MECHANICAL GOVERNOR HOUSING WEIGHTS AND LEVER (Closed Linkage)
INDUSTRIAL TYPE
FIG. 5H. MECHANICAL GOVERNOR COVER (Double Lever)
FIG. 5L. GOVERNOR WEIGHT SHAFT AND CARRIER
Figs. 7A of 2.0000
INJECTOR ASSY
SPRING, INJECTOR PLUNGER
RETAINER, INJECTOR GEAR
PUMP ASSY., FUEL
SEAL, FUEL PUMP OIL
GASKET, FUEL PUMP TO ENGINE
SPRING, FUEL PUMP VALVE RETAINING
STRAINER ASSY., FUEL
PLUG, FUEL STRAINER COVER
GASKET, FUEL FILTER COVER TO SHELL
PIPE, FUEL
VALVE, FUEL SUPPLY CHECK
GOVERNOR ASSY
LEVER, GOVERNOR COVER THROTTLE SHAFT
LEVER, GOV. OPERATING SHAFT
SPRING, GOVERNOR LOW SPEED
SCREW ASSY., GOV. BUFFER
SEAL, GOVERNOR
SHAFT, GOVERNOR WEIGHT CARRIER
SUPPORT, GOVERNOR WEIGHT SHAFT BEARING
BRACKET, INJECTOR CONTROL TUBE
PIN, GOVERNOR CONTROL WIRE SWIVEL
GROUP NOMENCLATURE
FIG. 3A. AIR INLET HOUSING
FIG. 4A. 3-53. BLOWER
HOUSING ASS ., AIR INIET
WIRE, AIR INIET HOUSING SHUTDOWN
BLOWER ASSY
SCREEN, BLOWER
SEAL, BLOWER HOUSING END PLATE
GROUP NOMENCLATURE
FIG. 1A. OIL PUMP AND PRESSURE REGULATOR (Inline Engine)
FIG. 2A. OIL DISTRIBUTION SYSTEM
FIG. 3A. OIL FILTER
FIG. 4C. OIL COOLER
FIG. 6A. DIPSTICK
FIG. 7B. OIL PAN (STAMPED)
FIG. 8A. BREATHER AND OIL FILLER
PUMP ASSY., OIL
VALVE, OIL PRESSURE REGULATOR
FILTER ASSY., OIL
GASKET, OIL FILTER COVER NUT
GASKET, OIL FILTER TUBE ADAPTOR
CORE ASSY., OIL COOLER
CAP, OIL FILLER TUBE
DIPSTICK
PAN, OIL
PIPE, BREATHER
GROUP NOMENCLATURE
FIG. 1A. TYPICAL COOLING SYSTEM (Inline Engines)
FIG. 2A. FRESH WATER PUMP
PUMP ASSY., FRESH WATER
GASKET, FRESH WATER PUMP- BODY COVER
ELBOW, WATER OUTLET
HOSE, WATER BY-PASS TUBE
ELBOW, OIL COOLER WATER OUTLET
BLADE, FAN
SEAL, FAN SHAFT
GROUP NOMENCLATURE
FIG. 1A. EXHAUST MANIFOLD (Center Outlet)
MANIFOLD, EXHAUST
FLANGE, EXHAUST
GROUP NOMENCLATURE
FIG. 1A. BATTERY CHARGING GENERATOR
GENERATOR ASSY
BRACKET, GENERATOR MOUNTING
MOTOR ASSY., STARTING
GENERAL DESCRIPTION
Fig. 2. In-Line Engine Model Description, Rotation and Accessory Arrangement
Fig. 3. 6V Engine Model Description, Rotation and Accessory Arrangement
Fig. 4. Series 53 Cylinder Arrangement
Fig. 5. Typical Model and Serial Numbers as Stamped on Cylinder Block (In-Line Engine)
Cross Section Views of a Typical In-Line Engine
Cross Section Views of a Typical 6V-53 Engine
Fig. 1. Schematic Diagram of Typical Fuel System - In-Line Engine
Fig. 3. Removing Injector from Cylinder Head
Fig. 4. Typical Fuel Strainer and Filter Mounting
Fig. 5. Typical Spin-On Type Fuel Strainer and Fuel Filter Mounting
Fig. 7. Air Intake System Through Blower and Engine (6V-53 Engine)
Fig. 8. Light-Duty Oil Bath Air Cleaner
Fig. 10. Air Cleaner Tray (Plugged)
Fig. 12. United Specialties Dry Type Air Cleaner
Air Silencer
Figure 14. Typical In-Line Engine Oil Filter Mounting
Figure 16. Schematic Diagram of Typical In-Line Engine Lubricating System
Figure 17. Schematic Diagram of Typical 6V Engine Lubricating System
Figure 18. Typical Cooling System for In-Line Engines
Figure 19. Typical Cooling System for V-Type Engine
ENGINE COOLING SYSTEM MAINTENANCE
Cooling System Cleaners
Miscellaneous Cooling System Checks
Raw Water Pump
Figure 1. Typical Instrument Panel
Throttle Control
Figure 2. Mechanical Shut-Down System Schematically Illustrated
AUTOMATIC ELECTRICAL SHUT-DOWN SYSTEM
Figure 3. Automatic Electrical Shut-Down System Diagram
Figure 5. Alarm System Wiring Diagram
ELECTRICAL STARTING SYSTEMS
Figure 6. Schematic Diagram of Hydrostarter System Showing Oil Flow
Figure 7. Hydrostarter Remote Control System
LUBRICATION AND PREVENTIVE MAINTENANCE
Cold Weather Operation
Figure 8. Typical Fluid Starting Aid
Figure 9. Quick-Start Assembly
POWER TAKE-OFF ASSEMBLIES
TORQMATIC CONVERTERS
WARNER MARINE GEAR
PREPARATION FOR STARTING ENGINE FIRST TIME
Lubrication Fittings
Oil Pressure
Avoid Unnecessary Engine Idling
Fig. 1 . Location of Controls on Power Generator Set
PREPARING GENERATOR FOR LOAD
PARALLELING
LUBRICATION AND PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
PREVENTIVE MAINTENANCE - Continued
TWIN DISC MARINE GEAR
SPECIFICATIONS
SPECIFICATIONS OIL QUALITY
COLD WEATHER OPERATION
STATEMENT OF POLICY ON FUEL AND LUBRICANT ADDITIVES
COOLANT REQUIREMENTS
Fig. 2 - Heat Transfer Capacity
Bulk Inhibitor Additives
GENERAL RECOMMENDATIONS
GENERAL RECOMMENDATIONS - Continued
ENGINE TUNE-UP PROCEDURES
EXHAUST VALVE CLEARANCE ADJUSTMENT
FOUR VALVE CYLINDER HEADS
Fig. 3 - Timing Fuel Injector
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
Position Injector Rack Control Levers
Fig. 6. Governor Spring Assemblies
Adjust Idle Speed
Fig. 7 Adjusting Buffer Screw
Adjust Governor Gap
Position Injector Rack Control Levers
Fig. 5. Checking Injector Control Rack "Spring"
Fig. 7. Governor Spring Assemblies
Fig. 8. Adjusting Engine Idle Speed
Fig. 1. Variable Speed Open Linkage Governor Mounted on Engine
Adjusting Screws
Adjust Maximum No-Load Speed
Fig. 7. Adjusting Buffer Screw
Fig. 1 - Checking Governor Gap
Injector Control Rack
Fig. 5 - Locating of Shims and Stops
Fig. 6 - Adjusting Idle Speed
Fig. 8 Adjusting Booster Spring
VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 3 Positioning No. 3L Injector Rack Control Lever
Fig. 6 - Location of Shims and Stops
Fig. 7 - Adjusting Idle Speed
Fig. 9 - Adjusting Booster Spring
Fig. 1 - Engine Load Limit Device
Fig. 4 - Throttle Delay Yield Lever (6V Engine)
Fig. 5 - Adjusting Throttle Delay Cylinder
Fig. 6 - Typical Variable Speed Governor Lever Position
Fig. 7 . Typical Limiting Speed Governor Lever Position
Fig. 1 - Hydraulic Governor Mounted on Engine
Fig. 3 - Adjusting Length of Fuel Rod
Fig. 5 - Adjusting Maximum Engine Speed
Fig. 1 - Hydraulic Governor Mounting
Fig. 1 - Checking Compression Pressure
Engine Out of Fuel
Crankcase Pressure
Air Box Pressure
Fig. 2 - Comparison of Column Height for Mercury and Water Manometers
PREPARING ENGINE FOR STORAGE
TURBOCHARGER
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
HYDROSTARTER
Built-In Parts Book
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
Built-In Parts Book - Continued
CONNECTING ROD, PISTON AND LINER
ACCESSORY DRIVE FOR DIRECT DRIVEN ACCESSORY (CAMSHAFT GEAR)
VALVE OPERATING MECHANISM (4 VALVE)
TYPICAL FUEL OIL STRAINER
AIR SHUT-DOWN HOUSING
BLOWER ASSEMBLY AND DRIVE (4 CYL.)
BLOWER ASSEMBLY AND DRIVE (6 CYL.)
OIL PUMP AND REGULATOR
OIL FILTER
OIL COLLER (6V-53)
FRESH WATER PUMP
FAN MOUNT (6V-53)
FAN MOUNT
WATER TEMPERATURE SHUTDOWN SWITCH
TACHOMETER DRIVE COVERS AND ADAPTORS
AIR COMPRESSOR AND DRIVE
OWNER ASSISTANCE
OWNER ASSISTANCE - Continued
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ENGLISH TO METRIC CONVERSIONS
Service Manual
FOREWORD
TABLE OF CONTENTS
SCOPE AND USE OF THE MANUAL
PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2 - In-line Engine Model Description, Rotation, and Accessory Arrangements
Fig. 3 - 6 and 8V Engine Model Description, Rotation and Accessory Arrangements
Fig. 4 - Cylinder Designation and Firing Order
Fig. 5 - Typical Model and Serial Numbers as Stamped on Cylinder Block (In-Line Engine)
GENERAL PROCEDURES
Rust Preventive
WORK SAFELY
Cross Sections of a Typical In-Line Engine
SECTION 1. ENGINE (less major assemblies)
Fig. 1 - Cylinder Block (Four Cylinder Block Shown)
Fig. 3 - Air and Water Passages in In-Line Cylinder Block
Remove and Disassemble Engine
Fig. 6 - Cylinder Head Gaskets and Seals in Place on Cylinder Block
Fig. 8 - Vertical Oil Passages in Top of Cylinder Block
Fig. 11 - Location of Block Bore Seal Ring Groove
Fig. 14 - Typical Cylinder Block Markings
Inspect Cylinder Block
Assemble and Install Engine
Fig. 1 - Cylinder Block Rear End Plate Mounting (In-Line Engine)
CYLINDER BLOCK END PLATE
Fig .1 Air Box Drain Tube Mounting (In-Line Engines)
Inspection
Fig. 1 - Typical Four-Valve Cylinder Head Assembly
Cylinder Head Maintenance
Disassemble Cylinder Head
Fig. 3 - Checking Bottom Face of Cylinder Head for Warpage
Fig. 5 - Correct Installation of Water Nozzles in Four-Valve Cylinder Head
Fig. 6 - Sequence for Tightening Cylinder Head Bolts
Install Cylinder Head
VALVE AND INJECTOR OPERATING MECHANISM
Fig. 3 - Removing Push Rod from Upper Side of Cylinder Head with Tool J 3092-01
Remove Cam Follower and Push Rod Assembly (Cylinder Head Not Removed from Engine)
Fig. 7 - Removing or Installing Cam Follower Roller and Pin with Tool J 5840
Fig. 10 Adjusting Cam-Follower Guide
Fig. 11 - Push Rod Spring Identification
Fig. 12 - Relationship Between Exhaust Valve Bridge and Valve Stems
Install Rocker Arms and Rocker Arm Shaft
EXHAUST VALVES
Remove Exhaust Valve Spring (Cylinder Head Installed)
Inspection
Fig. 5 - Removing Valve Guide
Fig. 7 - Removing Valve Seat Insert
Fig. 9 - Refacing Exhaust Valve
Fig. 12 - Relationship Between Exhaust Valve, Insert and Cylinder Head (4 Valve Head)
Fig. 14 - Checking Relative Concentricity of Valve Seat Insert with Relation to Valve Guide
Fig. 16 - Checking Valve Opening Pressure with Gage WRE-500-60
Fig. 1 - Typical Valve Rocker Cover Assembly
Fig. 1 - Crankshaft Details and Relative Location of Parts (Three Cylinder In-Line Engine Crankshaft Shown)
Fig. 3 - Removing or Installing Crankshaft
Fig. 4 - Typical Ridging of Crankshaft
Fig. 6 - Crankshaft Fatigue Cracks
Fig. 7 - Dimensions of Crankshaft Journals - In-Line Engine
Crankshaft Grinding
Fig. 10 - Standard Dimensions at Crankshaft Thrust Surfaces--in-Line Engines
Install Crankshaft
CRANKSHAFT OIL SEALS
Fig. 3 - Use of Rear Oil Seal Sleeve on Grooved Crankshaft (In-Line Engines)
Install Crankshaft Front Oil Seal
Install Crankshaft Rear Oil Seal
Fig. 1 - Main Bearing Shells, Bearing Caps and Crankshaft Thrust Washers -- In-Line Engines
Fig. 4 - Removing Upper Main Bearing Shell (Except Rear Main)
Fig. 6 - Comparison of Main Bearing Shells
Fig. 7 - Main Bearing Measurements
Fig. 9 - Crankshaft Thrust Washers in Place
Install Main Bearing Shells (Crankshaft in Place)
Fig. 1 - Engine Front Cover Mounting (Lower) -- In-Line Engine
Fig. 3 - Installing Lower Engine Front Cover -- In-Line Engine
CRANKSHAFT PULLEY
Fig. 3 - Cone Mounted Pulley
Fig. 1 - Removing Flywheel
Install Ring Gear
FLYWHEEL HOUSING
Fig. 3 -Flywheel Housing Bolt Sizes and Tightening Sequence (Operation 1)--In-Line Engine
Fig. 6 - Flywheel Housing Bolt Tightening Sequence (Operation 2)--In-Line Engine
Fig. 9 Checking Flywheel Housing Concentricity
Install Flywheel Housing
PISTON AND PISTON RINGS
Fig. 3 - Cleaning Piston
Fig 4 - Comparison of Pistons
Fig. 5 - Removing or Installing Piston Pin Bushings
Fig. 8 - Measuring Piston-to-liner Clearance
Fitting Piston Rings
OIL CONTROL RINGS
Fig. 1 - Connecting Rod Mounting
Fig. 3 - Magnetic Particle Inspection Limits for Connecting Rod
Fig. 4 - Removing or Installing Bushings
Fig. 8 - Reaming Bushings
Assemble Connecting Rod to Piston
CONNECTING ROD BEARINGS
Install Connecting Rod Bearing Shells
Fig. 1 Cylinder Liner
Fig. 4 - Checking Bore of Cylinder Liner
Fig. 6 Cylinder Liner Ridge Due to Wear
Fig. 7 - Checking Distance of Liner Flange Below Top Face of Block
Fig 9. - Cylinder Liner Seal ring Location in Cylinder Block Bore
Install Cylinder Liner, Piston and Connecting Rod Assembly
ENGINE BALANCE AND BALANCE WEIGHTS
Install Front Balance Weights
GEAR TRAIN AND ENGINE TIMING
GEAR TRAIN AND ENGINE TIMING - Continued
GEAR TRAIN AND ENGINE TIMING - Continued
ENGINE TIMING
ENGINE TIMING - Continued
Figure 1. Removing or Installing Nut on Camshaft or Balance Shaft
Figure 3. Removing End Bearing
Figure 4. Installing Intermediate Camshaft Bearing
Figure 5. Camshaft and Balance Shaft Bearing Identification
Install End Bearings
Figure 7. Removing and Replacing Camshaft or Balance Shaft Bearings
Figure 8. Camshaft and Balance Shaft Details and Relative Location of Parts
CAMSHAFT AND BALANCE SHAFT GEARS
Figure 2. Installing Camshaft Gear
Figure 1. Installing Idler Gear Hub
Figure 3. Idler Gear Details and Relative Location of Parts
Figure 1. Removing Crankshaft Timing Gear
Install Crankshaft Timing Gear
Figure 1. Accessory Drive Locations (In Line Engines)
Figure 3. Air Compressor Drive
Figure 5. Components of Accessory Drive for Belt Driven Accessory (Drive Hub Type)
Figure 7. Former and Current Drive Plate Type Accessory Drive
Install Accessory Drive
ENGINE FRONT COVER ( UPPER )
Install Cover
Fig. 1 - Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance
CAMSHAFT CUP PLUG INSTALLATION
TROUBLE SHOOTING
SPECIFICATIONS
TABLE OF SPECIFICATIONS, NEW CLEARANCE AND WEAR LIMITS
TABLE OF SPECIFICATIONS, NEW CLEARANCE AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCE AND WEAR LIMITS - Continued
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
TOOL NAME
TOOL NAME - Continued
SECTION 2. FUELS SYSTEM AND GOVERNORS
Fig. 1 Typical Fuel System for In- Line Engines
Fig. 1 Fuel Injector Assembly
Fig. 4 Phases of Injector Operation Through Vertical Travel of Plunger
Fig. 6 Fuel Injector Mounting
Fig. 8 Checking Rack and Plunger for Free Movement
Fig. 10 Spray Pattern Test
INJECTOR CONTROL RACK AND PLUNGER MOVEMENT TEST
INJECTOR HIGH PRESSURE TEST
Fig. 14 Injector Needle Valve Test with Auxiliary Test J 22640
Fig. 17. Placing Injector in Comparator J 7041
Fig 20. Position of Calibrator Fuel Flow Pipes
Fig. 21. Injector in Calibrator J 224410
Fig. 24. Removing or Installing Plunger Follower, Plunger and Spring
Fig. 26. Removing Spray Tip Injector Nut
Clean Injector Parts
Fig. 33. Lapping Spray Tip on Lapping Blocks J 22090
Fig. 35. Details of Injector Filters and Caps and Their Relative Location
FIG. 38. Comparison of former and New Design Injector Parts
Lapping Injector Parts
ASSEMBLE PLUNGER AND FOLLOWER
Test Reconditioned Injector
FUEL INJECTOR TUBE
Fig. 3 Upsetting Injector Tube
Fig. 5 - Reaming Injector Tube for Injector Nut
Fig. 1. Typical Fuel Pump Assembly
Fig. 2. Fuel Pump Valving and Rotation (Right Hand Pump Shown)
Fig. 4. Removing Oil Seals
Fig. 5 Fuel Pump Details and Relative Location of Parts ( Right Hand Pump Shown)
Fig. 7. Installing Outer Oil Seal
FUEL PUMP DRIVE
MECHANICAL GOVERNORS
LIMITING SPEED MECHANICAL GOVERNOR
Fig. 2 Governor Cover Details and Relative Location of Parts
Fig. 4 Removing Fork from Operating Shaft
Inspection
Fig. 5 - Governor Housings and Relative Location of Parts
Install Governor
Install Governor - Continued
SHOP NOTES-TROUBLE SHOOTING-SPECIFICATIONS-SERVICE TOOLS
Fig. 2 - Injector Rack-to-Gear Timing
Fig. 3 - Checking Fuel Output
Fig. 4. Types of Injector Plungers
LOCATING AIR LEAKS IN FUEL LINES
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
TROUBLE SHOOTING CHARTS (Needle Valve Injectors) - Continued
TROUBLE SHOOTING CHARTS (Needle Valve Injectors) - Continued
FUEL PUMP MAINTENANCE
SPECIFICATIONS
SERVICE TOOLS
SECTION 3. AIR INTAKE SYSTEM
Fig. 1 - Air Silencer Mounted on In-Line Engine
Fig. 1 - Typical In - Line Air Shut Down Housing Details and Relative Location Of Parts
Fig. 3 - Location of Air Shut-Down Housing Mounting Bolts (In-Line Engines)
Install Air Shut-Down Housing (In-Line Engines)
Fig. 1 - Blower Mounting (3-53 Engine)
Fig. 5 Removing Blower Rotor Gears
Disassemble Blower
Fig. 7 - Typical Blower Details and Relative Location of Parts (3-53 Engine Blower)
Fig. 9 - Installing Lip Type Oil Seal in End Plate
Fig. 13 - Installing Blower Rotor Gears
Fig. 15- Minimum Blower Rotor Clearance
Fig. 16 - Measuring Rotor Lobe to End Plate Clearance
Fig. 17 - Inserting Cam in Blower Drive Support
ENGINE BLOWER
SHOP NOTES - TROUBLE SHOOTING - SPECIFICATIONS - SERVICE TOOLS
Fig. 3 - Positioning Cutting Tool in Fixture Guide
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SECTION 4. LUBRICATION SYSTEM
Fig. 1 - Schematic Diagram of typical In-Line Engine Lubrication System,
Lubricating Oil Distribution
Cleaning Lubrication System
Fig. 1 - Typical Right - Hand Rotation Lubricating Oil Pump Mounting
Fig. 3 - Measuring Rotor Clearance
Fig. 5 - Lubricating Oil Pump Details and Relative Location of Parts (Current)
Fig. 7 - Removing Oil Pump Drive Gear pump body. Since the holes are offset, the cover plate
Install Oil Pump
LUBRICATING OIL PRESSURE REGULATOR
Fig. 1 Typical Oil Cooler Mounting (6V-53 Engine Shown)
Fig 3 - Oil Cooler Details and Relative Location of Parts (In-Line Engine)
Pressure Check Oil Cooler Core
Install Oil Cooler Core
Fig. 1 - Typical Oil Dipstick Mounting
Removing and Installing Oil Pan
Fig. 1 - Typical Crankcase Breather Mounting (In-Line Engine)
VENTILATING SYSTEM
SPECIFICATIONS - SERVICE TOOLS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SECTION 5. COOLING SYSTEM
WATER PUMP
Fig. 3 - Removing Pulley
Fig. 6. Fresh Water Pump Details and Relative Location of Parts
Fig. 7 - Comparison of Water Pumps
Fig. 2. Thermostat Housing Details and Relative Location of Parts (In-Line Engine)
Fig. 4. Method of Checking Thermostat Operation
Fig. 5. Bleed Hole in Thermostat Housing
ENGINE COOLING FAN
Fig. 3. Removing Fan Hub (Pulley)
Fig. 5 - Current Fan Hub Assembly (In-Line Engine)
Fig. 8. Typical Fan Hub and Adjusting Bracket Details and Relative Location of Parts (In-Line Engine)
IN-LINE ENGINES (CURRENT)
Install Fan, Hub and Adjusting Bracket
WATER FILTER AND CONDITIONER
WATER FILTER AND CONDITIONER - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SECTION 6. EXHAUST SYSTEM
EXHAUST MANIFOLD (AIR COOLED)
Install Exhaust Manifold
SECTION 7. ELECTRICAL EQUIPMENT, INSTRUMENTS AND PROTECTIVE
BATTERY-CHARGING GENERATOR (D.C. AND A.C.)
Fig. 2 - 30 DN Type 100 A.C. Self-Rectifying Generator (Alternator)
Alternator Precautions
Fig. 4. 20 DN Type 250 A.C. Self-Rectifying Generator (Alternator)
BATTERY-CHARGING GENERATOR REGULATOR
TRANSISTORIZED AND TRANSISTOR REGULATORS
TRANSISTOR REGULATOR
Fig. 5 - Transistor Regulator with Plug-In Connections
STARTING MOTOR
Fig. 2 - Cross-Section of Motor with Intermediate-Duty Clutch
Remove Starting Motor
SPECIFICATIONS - SERVICE TOOLS
CHECKING ENGINE ELECTRICAL GENERATING SYSTEM
SERVICE TOOLS
SECTION 13. OPERATION INSTRUCTIONS
ENGINE OPERATION INSTRUCTIONS
Storage Battery
Oil Pressure
Emergency Stopping
ENGINE OPERATING CONDITIONS
3-53 IN-LINE ENGINE (4-Valve Cylinder Head)
3-53 IN-LINE ENGINE (4-Valve Cylinder Head) - Continued
ENGINE RUN-IN INSTRUCTIONS
Instrumentation
BASIC ENGINE RUN-IN
ENGINE TEST REPORT
INSPECTION AFTER FINAL RUN-IN
DETROIT DIESEL FUEL OIL SPECIFICATIONS
DETROIT DIESEL LUBRICATING OIL SPECIFICATIONS
ENGINE COOLANT
INHIBITOR SYSTEMS
COOLANT INHIBITOR CHART
ANTIFREEZE
COOLANT RECOMMENDATIONS
SECTION 14. ENGINE TUNE UP
EXHAUST VALUE CLEARANCE ADJUSTMENT
EXHAUST VALUE CLEARANCE ADJUSTMENT
Fig. 2 - Adjusting Valve Clearance (Four Valve Head)
Fig. 1 - Timing Fuel Injector
Fig. 1 - Adjusting Governor Gap
Fig. 2 - Positioning the Rear Injector Rack Control Lever
Fig. 3 - Adjusting Maximum No-Load Engine Speed
Fig. 5 - Adjusting Engine Idle Speed
SECTION 15. PREVENTIVE MAINTENANCE - TROUBLE SHOOTING - STORAGE
LUBRICATION AND PREVENTIVE MAINTENANCE
LUBRICATION AND PREVENTIVE MAINTENANCE CHART
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
Exhaust Back Pressure
Fig. 2 - Comparison of Column Height for Mercury and Water Manometers
Trouble Shooting (Engine)
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
STORAGE
EXTENDED STORAGE (30 days or more)
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
PART III. ENGINE PARTS MANUAL
GROUP NOMENCLATURE
GROUP NOMENCLATURE - Continued
GENERAL INFORMATION
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
INDEX
MODEL DESCRIPTION CHART IN-LINE ENGINES
FIG. 1A INLIE 53 CYLINDER BLOCK (with head gasket)
FIGURE 2A. CYLINDER HEAD
FIGURE 3A. CRANKSHAFT (3-53)
fIG. 4D. LOWER FRONT COVER AND OIL PUMP
FIG. 5A. FLYWHEEL AND FLYWHEEL HOUSING (In-Line Models)
FIG. 6A. CONNECTING ROD, PISTON AND LINER
FIG. 7A. CAMSHAFT (In-Line Models)
FIG. 7C. GEAR TRAIN (Typical In-Line)
FIG. 8A. ACCESSORY DRIVE (Double Bell)
FIG. 9A. VALVE MECHANISM
ROCKER COVER
TYPICAL 4 CYLINDER FAN TO FLYWHEEL INDUSTRIAL UNIT
BLOCK ASSY., CYLINDER
BLOCK CYLINDER
HEAD ASSY. CYLINDER
COVER, CYLINDER HEAD WATER HOLE
HEAD ASSEMBLY, CYLINDER
CRANKSHAFT ASSY
SHELL, CRANKSHAFT MAIN BEARING
COVER, ENGINE FRONT-LOWER
FLYWHEEL
HOUSING, FLYWHEEL
CONNECTING ROD ASSY
PISTON ASSY
CYLINDER KIT
BEARING, CAM AND BALANCER SHAFT
WEIGHT, REAR BALANCER
ADAPTOR, ACCESSORY DRIVE
ARM ASSY. EXHAUST VALVE
BRACKET, ROCKER SHAFT
VALVE, EXHAUST
GASKET, ROCKER COVER
GROUP NOMENCLATURE
FIG. 1B. FUEL INJECTOR
FIG. 2B. FUEL PUMP DRIVE
FIG. 3B. FUEL FILTER (Canister Type Element)
FIG. 4A. TYPICAL FUEL SYSTEM (In-Line Engine)
FIG. 5D. MECHANICAL GOVERNOR HOUSING WEIGHTS AND LEVER (Closed Linkage)
INDUSTRIAL TYPE
FIG. 5H. MECHANICAL GOVERNOR COVER (Double Lever)
FIG. 5L. GOVERNOR WEIGHT SHAFT AND CARRIER
Figs. 7A of 2.0000
INJECTOR ASSY
SPRING, INJECTOR PLUNGER
RETAINER, INJECTOR GEAR
PUMP ASSY., FUEL
SEAL, FUEL PUMP OIL
GASKET, FUEL PUMP TO ENGINE
SPRING, FUEL PUMP VALVE RETAINING
STRAINER ASSY., FUEL
PLUG, FUEL STRAINER COVER
GASKET, FUEL FILTER COVER TO SHELL
PIPE, FUEL
VALVE, FUEL SUPPLY CHECK
GOVERNOR ASSY
LEVER, GOVERNOR COVER THROTTLE SHAFT
LEVER, GOV. OPERATING SHAFT
SPRING, GOVERNOR LOW SPEED
SCREW ASSY., GOV. BUFFER
SEAL, GOVERNOR
SHAFT, GOVERNOR WEIGHT CARRIER
SUPPORT, GOVERNOR WEIGHT SHAFT BEARING
BRACKET, INJECTOR CONTROL TUBE
PIN, GOVERNOR CONTROL WIRE SWIVEL
GROUP NOMENCLATURE
FIG. 3A. AIR INLET HOUSING
FIG. 4A. 3-53. BLOWER
HOUSING ASS ., AIR INIET
WIRE, AIR INIET HOUSING SHUTDOWN
BLOWER ASSY
SCREEN, BLOWER
SEAL, BLOWER HOUSING END PLATE
GROUP NOMENCLATURE
FIG. 1A. OIL PUMP AND PRESSURE REGULATOR (Inline Engine)
FIG. 2A. OIL DISTRIBUTION SYSTEM
FIG. 3A. OIL FILTER
FIG. 4C. OIL COOLER
FIG. 6A. DIPSTICK
FIG. 7B. OIL PAN (STAMPED)
FIG. 8A. BREATHER AND OIL FILLER
PUMP ASSY., OIL
VALVE, OIL PRESSURE REGULATOR
FILTER ASSY., OIL
GASKET, OIL FILTER COVER NUT
GASKET, OIL FILTER TUBE ADAPTOR
CORE ASSY., OIL COOLER
CAP, OIL FILLER TUBE
DIPSTICK
PAN, OIL
PIPE, BREATHER
GROUP NOMENCLATURE
FIG. 1A. TYPICAL COOLING SYSTEM (Inline Engines)
FIG. 2A. FRESH WATER PUMP
PUMP ASSY., FRESH WATER
GASKET, FRESH WATER PUMP- BODY COVER
ELBOW, WATER OUTLET
HOSE, WATER BY-PASS TUBE
ELBOW, OIL COOLER WATER OUTLET
BLADE, FAN
SEAL, FAN SHAFT
GROUP NOMENCLATURE
FIG. 1A. EXHAUST MANIFOLD (Center Outlet)
MANIFOLD, EXHAUST
FLANGE, EXHAUST
GROUP NOMENCLATURE
FIG. 1A. BATTERY CHARGING GENERATOR
GENERATOR ASSY
BRACKET, GENERATOR MOUNTING
MOTOR ASSY., STARTING
