SENR5156-02

October 2004

3508 & 3508B Engine Assembly Procedure

Bore 170 mm (6.7 inch) 5 Rod & Piston Group 11 Flywheel Housing
Stroke 190 mm (7.5 inch)

Number of Cylinders 8

Cylinder Arrangement V-8

Firing Order (Injection Sequence) 1-2-7-3-4-5-6-8

Direction of Rotation (Viewed from flywheel end) Counterclockwise

Note: Bolts A and B are on same end of rod
cap that has bearing tabs & location pin.
Literature References Typical Illustration (1) Location pin for correct installation of
Form No. Title connecting rod cap.
Top and Intermediate Ring Torque procedure for connecting rods.
SENR1126 3500B Engines for Caterpillar Built Machines (2GR, 7TR, 8BR)
Install piston rings with "UP" side toward top of Tighten connecting rod bolts as follows:
RENR1309 3508B Engine for Caterpillar Built Machines (2GR) piston
a. Put 6V-4876 Molykote Paste Lubricant on
RENR1308 3508B Engine for Caterpillar Built Machines (AMP1-Up, 7HR1-Up, 1JW1-Up, ADZ1-Up, (1) Top Ring has the mark "UP-1". bolt threads, shank & area under bolt’s head.
1GR1-UP) b. Sequentually tighten bolts A and B to
(2) Intermediate Ring has the mark "UP-2".
SENR2355 3500 Industrial Engine (49Y, 95Y) 90 ± 5 N·m (65 ± 4 lb ft). Flywheel Housing Bolt Installation Bolt Length (excluding head)
Oil Control Ring c. Sequentually tighten bolts C and D to
SENR2352 3500 Industrial Engine Systems Operation T&A (49Y, 95Y, 27Z, 65Z, 68Z, 71Z) (3) Install Oil Control Ring with the gap in the 90 ± 5 N·m (65 ± 4 lb ft). Dia. Bolt Location Part No. mm inch
SENR2351 3500 Industrial Engine Specifications spring 180o away from the gap in the ring. White d. Sequentually re-tighten bolts C and D to
portion of spring must be visible at ring end gap. 90 ± 5 N·m (65 ± 4 lb ft). 1/2 inch T 0S-1595 31.8 1.25
Q – Denotes Critical Checkpoint e. Torque-turn each bolt an additional 90 o ± 5o.
(4) Lubricate piston assembly and bearings with Note: The rod & piston group is to be 1/2 inch U 1A-1460 50.8 2.00
clean engine oil. assembled in an engine with the chamfer
Sub Assembly Sub Assembly Installation Parts Assembly Procedure
Parts (5) Ring gaps must be 120o apart. side of rod adjacent to the crank pin thrust 1/2 inch V 1D-4574 152.4 6.00
Sequence
Note: Tool required for installation is 1U-7616 surface. The opposite side is to thrust
against the mating rod on same crank pin. 5/8 inch X 5D-9514 158.8 6.25
Block Block Assembly Block cleaning SMHS8418. 1 Compressor Group.
Plugs Q–1 Clean oil passages. 5/8 inch Y 1D-4597 165.1 6.50
Mount block on rollover.
Seals Q -2 Install liners. Piston Cooling Jets 5/8 inch Z 5P-4626 266.7 10.50
Priority Valves Check liner projection.
Check piston cooling jets.
Cambearings
Main Bearings Install main bearings in block and caps. a. 24 mm (0.945 inch) a. 52.78 mm (2.078 inch)
3
Cylinder Liners Oil main bearings. 2 b. 242.67 mm (9.554 inch) b. 86.61 mm (3.410 inch)
4 Install cambearings.
Q–5 c. 227.86 mm (8.971 inch) c. 60 o
Install cooling jet priority valves.
d. 30 mm (1.181 inch) d. 60o
Crankshaft Crankshaft 6 Install crankshaft and thrust washers. 3
Thrust Washers Assembly Q–7 Install main bearing caps and torque. e. 73.14 mm (2.880 inch) e. 275.97 mm (10.865 inch)
Counterweights
f. 18.69 o f. 312.62 mm (12.308 inch)
Gears Q–8 Check end play and rotate crankshaft. 4

Connecting Rods Piston & Rod 9 Oil liners, rings and bearings.
Assembly
Rings 10 Install pistons and rod caps.
Pistons Q – 11 Torque rod bolts and rotate crankshaft to T.D.C. 5
#1 Cylinder.
Pins
Install piston cooling jets.
Rod Bearings 12
Install lower side covers.
13 Flywheel Housing Bolt Bolt Length Flywheel Housing Bolt Bolt Length
Installation (version 1) Installation (version 2) (excluding
(excluding head)
Camshafts Camshaft 14 Install camshafts and oil journals. head)
Spacers Assembly 15 Install camshaft timing pins.
Dia (in.) Bolt Part No. mm inch Dia Bolt Part No. mm inch
Bolts Location (in.) Location
Thrust Plates
Timing Pins 1/2 A 0S-1595 31.8 1.25 1/2 A 9X-8873 57.2 2.25

Shaft-Fuel Control Fuel Injector 16 Install fuel control shafts. 6 1/2 B 9X-8875 88.9 3.50 1/2 B 9X-8875 88.9 3.5
Cross Shaft
Control Group Q – 17 Install cross shaft, lever as., gov. lever, and
Supports As. adjust. 1/2 C 6M-9613 228.6 9.00 1/2 C 6M-9613 228.6 9
Bracket As.
Lever As. 1/2 D 9S-1374 203.2 8.00 1/2 D 9S-1374 203.2 8
Lever-Governor
6 Fuel Injection Control Linkage 1/2 E 8S-9089 114.3 4.50 1/2 E 8S-9089 114.3 4.5
Gaskets Cylinder Head 18 Install space plate gasket, spacer plate, water
(1) Tighten locknuts at each end of bellcrank to a torque of 8 ± 2 N·m (6 ± 1 lb ft). 5/8 F 1D-4590 120.7 4.75 5/8 F 1D-4590 120.7 4.75
Seals Group seals, O-ring seals, and cylinder head gaskets.
O-rings (2) Clearance between lever assemblies on front cross shaft side shafts 0.20 ± 0.10 mm (0.008 ± 0.004 in.).
Install cylinder heads.
Cylinder Heads 19
Q – 20 Torque cylinder head bolts.
Cam Followers 7

Fuel Injector Fuel Injector 21 Install injectors. 8

Holddown Clamps Q – 22 Torque Holddown bolts.
Fuel Control Rods 23 Install fuel control rod assemblies.
Bellcrank 24 Synchronize racks.
Assemblies

Inlet Elbows 25 Install inlet air elbows. 9

Exhaust Q – 26 Install exhaust manifolds

Aftercooler Core Aftercooler 27 Install aftercooler core and housing. 10

Aftercooler Assembly Q – 28 Torque bolts.
Housing
Tubes 29 Install water lines, air tubes, and adapters.
Lines
Adapters

30 Remove long block assembly from rollover

Long Block stand.
Assembly
31 Install on stands. 7 Cylinder Heads
Gears Flywheel Housing Bolt Bolt Length Flywheel Housing Bolt Bolt Length
Bearings Installation (version 1) (excluding head) Installation (version 2) (excluding
Gear Group 32 Install idler and cluster gears. head)
Shafts
Bolts
Dia (in.) Bolt Part No. mm inch Dia Bolt Part No. mm inch
Location (in.) Location
Housing Rear Housing 33 Install flywheel housing. 11
Rear Seal Group Q – 34 Torque bolts & install rear oil seats. 1/2 G 0S-1595 31.86 1.25 1/2 G 9X-8873 57.2 2.25

Flywheel Group 35 Install flywheel. 12 1/2 H 1D-4574 152.4 6.00 1/2 H 1D-4574 152.4 6.00
(Cont. on back) Q – 36 Torque bolts & check flywheel runout. Note: The plug at location (A) must be
installed on these engines. 1/2 I 9X-8878 133.4 5.25 1/2 I 9X-8878 133.4 5.25

(1) Coat cylinder head bolt threads with engine

1 Cylinder Liners oil and tighten them as follows:
5/8 J 1D-4597 165.1 6.50 5/8 J 1D-4597 165.1 6.50

a. Tighten bolts 1 thru 8 in numerical 5/8 K 1D-4602 241.3 9.50 5/8 K 1D-4602 241.3 9.50
Cylinder Liner Installation: sequence to 30 ± 5 N·m (22 ± 4 lb ft).
b. Tighten bolts 1 thru 8 in numerical 5/8 L 1D-4593 139.7 5.50 5/8 L 1D-4593 139.7 5.50
a. Put liquid soap on cylinder block liner bore surfaces
and rubber seals on the lower part of the liner. sequence to 200 ± 15 N·m (147 ± 11 lb ft).
c. Re-tighten bolts 1 thru 8 in numerical 1/2 M 2B-0947 57.15 2.25 1/2 N 1D-4574 152.4 6.00
b. Put the filler band completely in clean engine oil for sequence to 200 ± 15 N·m (147 ± 11 lb ft).
a moment.
d. Turn bolts 1 thru 8 in numerical Tools needed to install
c. Install filler band in the groove under the liner flange, sequence an additional 180o ±5 o.
without delay. Flywheel Housing Crankshaft Wear Sleeves & Quantity
(2) Install 2 cap plugs in top of cylinder head to Seals (Front & Rear)
d. Install the liner in the block immediately, before a depth of 9.0 ± 0.5 mm (0.35 ± 0.02 inch). Installation Steps:
expansion of the filler band. Apply 6V-6640 Sealant to cup bores prior 6V-4002 Forcing Bracket 2
Make reference to Flywheel Housing Runout
to assembly. & Flywheel Housing Bore Runout for correct
Cylinder Liner Projection methods of flywheel housing inspection.
6V-4001 Forcing Ring 1
(3) Height of cylinder head (new) is 142.00 ±
Make reference to Cylinder Liner Projection in Testing 0.15 mm (5.591 ± 0.006 inch). (1) Plug’s torque 70 ± 15 N·m (50 ± 11 lb ft). 1D-4716 Nut (5/16"-18 NC) 4
and Adjusting for the complete procedure. 3. Measure cylinder liner projection with dial
indicator (2) in 1P-2402 Gauge Body (3) as (4) Depth below bottom of chamfer, which (2) Install three dowels to a height of 6.0 ±
1. Install the gasket and spacer plate (5). Install copper 6V-4003 Locator 1
shown. Measure at four places around each remainder of cup plugs are installed in 0.5 mm (0.24 ± 0.02 inch).
washers and bolts (4) to hold the spacer plate. cylinder liner near the clamped area. head is 1.0 ± 0.5 mm (0.04 ± 0.02 in.).
(3) Install two dowels to a height of 3.5 ± 0.5 2N-5006 Bolt 1"-14NF X 63.5mm 2
Tighten bolts (4) evenly in four steps: Apply 6V-6640 Sealant to cup bores prior (2.5 inch) long
Average of our projection measurements mm (0.14 ± 0.02 inch).
1st step 14 N·m (10 lb ft) to assembly.
from any cylinder must be 0.059 to 0.199
2nd step 35 N·m (25 lb ft) (4) Put 6V-6640 Gasket Sealant on Guide Bolts 5/16"-18NC X 101.6 mm 4
mm (0.0023 to 0.0078 inch).
3rd step 70 N·m (50 lb ft) complete surface of flywheel housing that (4 inch) long
4th step 95 N·m (70 lb ft) Maximum permissible difference between all makes contact with the cylinder block.
6V-4977 Installer 1
2. Install tooling as shown. Tighten bolts for crossbar
four measurements around each cylinder
liner is 0.05 mm (0.002 inch). 8 Fuel Injection (5) Tighten bolts holding flywheel housing to
the rear face of the cylinder block.
evenly in four steps: 9S-8858 Nut 1
1st step 7 N·m (5 lb ft) (1) 3H-0465 Plate
Torque for 1/2 inch - 13 NC bolts is 135 ± 20
2nd step 20 N·m (15 lb ft) (6) 8B-7548 Push-Puller Crossbar (1) Torque for injector rocker arm adjustment screw N·m (100 ± 15 lb ft). 8T-3099 Installer 1
3rd step 35 N·m (20 lb ft) locknut is:
4th step 70 N·m (50 lb ft) 5/8 inch locknut: 120 ± 15 N·m (89 ± 11 lb ft) Torque for 5/8 inch - 11 NC bolts is 270 ± 40 Removal:
1/2 inch locknut: 70 ± 15 N·m (52 ± 11 lb ft). N·m (199 ± 30 lb ft).
a. Remove seal from each end of engine.
(2) Injector installation:
2 Cooling Jet Sequence a. Put 1P-0808 multipurpose grease in bore of
Note: Seals & wear sleeves cannot be
used again, after seals & wear sleeves
Valve 3 Cylinder Block cylinder head for lubrication of O-ring seals.
b. Put injector in bore. Use clamp to push
are separated.
injector into correct position. b. Remove wear sleeves with 5P-7409
(3) Fuel timing dimension set by gauge Distorter and 6V-3143 Distorter Adapter.
Note: Do not tap (hit) surface "Y" to install injector.
(Fuel setting information located on Drawing Installation:
c. Tighten bolt that holds fuel injector clamp to #16 of this chart.
65 ± 7 N·m (48 ± 5 lb ft). a. Do not separate wear sleeves (6) from
d. After clamp is tightened, injector rack "X" crankshaft seals (3) & (4). Once they are
must move freely. separated they cannot be used again.
b. Install sleeve and seal assembly with the
correct tools.
9 Exhaust Manifolds c. Clean outer surface of crankshaft and the
inner surface of wear sleeve (6) with
169-5464 Quick Cure Primer (Aerosol
spray).
Main Bearing Cap Bolt Torque Crankshaft Wear Sleeves & Seals d. Carefully put a thin coat of 4C-9507
6B-9202 Spring for cooling jet sequence valve Note: Assemble main bearing caps with (Front & Rear) Retaining Compound on the inner
(one at each end of block): “FRONT” & cast part no. toward front of block. (1) Flywheel housing. surface of wear sleeve (6) and on
Length under test force is 68.3 mm (2.69 inch). 1. Completely lubricate bolt threads with SAE crankshaft surface.
(2) Front housing.
Test force is 85 to 102 N (19 to 23 lb). 30 engine oil before assembly. e. Install seals (3) and (4) with wear sleeve
(3) 113-8433 Seal Group (rear). (6) as a unit on the end of the crankshaft
Free length after test is 112.7 mm (4.44 inch). 2. Start bolts in tapped holes “by hand”.
(4) 113-8432 Seal Group (front). with the correct tools.
Outside diameter is 24.60 mm (0.969 inch). 3a. If the main bearing cap bolts are 19.05 mm
(0.75 inch), then tighten in letter sequence to (5) Crankshaft seal installed from both ends
Both cooling jet sequence valves must start to 136 ± 14 N·m (101 ± 10 lb ft). Next, tighten of crankshaft 8.0 ± 0.5 mm (0.315 ± 0.020
open at a pressure difference of 130 ± 30 kPa bolts in letter sequence an additional 180 o ± 5°. in.).
(19 ± 4.5 psi) and must be fully open at Typical Example Crankshaft seals must be installed with lip of
200 ± 30 kPa (29 ± 4.5 psi). 3b. If the main bearing cap bolts are 22.23 mm the seal toward inside of engine as shown.
(0.875 inch), then torque in letter sequence to (1) Left exhaust manifold. Make sure correct seal is installed on each
190 ± 14 N·m (140 ± 10 lb ft). Next, tighten end of the crankshaft. Use 113-8432 Seal
bolts in letter sequence an additional 180 o ± 5°. (2) Put 5P-3931 Anti-Seize Compound on washer face & threads of all exhaust manifold bolts, then tighten
Gp on front & 113-8433 Seal Gp on rear.
to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Diagonally opposed bolts are to be tightened simultaneously.
(6) Wear sleeve.
(3) Right exhaust manifold.
(7) Dimension installed from both ends of
4 Crankshaft Specifications 10 Aftercooler
crankshaft 0.5 ± 0.5 mm (0.020 ± 0.020 in.).

Crankshaft Measurement Specifications

Out of
Main
Round
Main
Out of
Rod
Round
Rod
Taper
Main
Taper
Rod
Thrust
Face
Thrust
Face
Radius2
Main
Radius2
& Rod
Journal
Hardness 12 Flywheel Installation, Bolt Torque & Runout
Min. Max. Min. Max. Max. Max. Min. Max.1 Min. Max.

All 3500 Remanufactured (OR) Prefix Forging Numbers

Typical Illustration - top view
159.339 159.390 134.341 134.389 0.020 0.020 71.91 72.21 7/32 1/4 Rockwell
For the aftercooler shown above:
(6.2732) (6.2752) (5.2890) (5.2909) (0.0008) (0.0008) (2.831) (2.843) C48 Min. (1) Assemble seals to aftercooler core.
(2) Temporarily secure bottom seal with tape. Do not use RTV, adhesive or lubricant for seal retention.
All 3500 Production Prefix Forging Numbers
NOTICE Check Face Runout Of The Flywheel (Typical Example)
(3) Assemble aftercooler with seals to inlet manifold.
(4) Inspect bottom seal to ensure correct seating in recess. Flywheel Runout
159.974 160.025 134.9763 135.0243 0.020 0.020 71.91 72.11 7/32 1/4 Rockwell Make sure dash mark on flywheel is in
(5) Install aftercooler cover. Face Runout (Axial Eccentricity) of the Flywheel:
(6.2982) (6.3002) (5.3140) (5.3159) (0.0008) (0.0008) (2.831) (2.839) C48 Min.4 (6) Inspect upper seal to ensure correct seating in recess. alignment with the dash mark on the
(7) Install cover bolts and hand tighten crankshaft when flywheel is installed. (1) Install the dial indicator as shown. Always put a force
Note: All dimensions are in mm (inch). (8) Tighten bolts in numerical sequence to 24 N·m (18 lb ft). on crankshaft in same direction before dial indicator is
Make reference to Flywheel Runout read, which will remove any crankshaft end clearance.
(1) Thrust plates for center main bearing only. (9) Tighten bolts in numerical sequence to 47 N·m (35 lb ft). for the correct method of flywheel
(2) End play for crankshaft (new) is 0.17 to 0.63 mm (10) Remove tape. inspection. (2) Set the dial indicator to read 0.0 mm (0.00 inch).
(0.007 to 0.025 inch).
(3) Torque for straight thread plugs is 50 ± 7 N·m (1) Location of dash mark on flywheel. (3) Turn the flywheel and read the indicator every 90o.
(37 ± 5 lb ft). Put engine oil on threads of all (4) Take measurement at all four points. Find difference
(4) Make reference to Connecting Rod Bearing bolts before assembly. between lower & higher measurements. This value is
Journals. the runout. Maximum permissible face runout (axial
(5) Make reference to Main Bearing Journals. (2) Torque for flywheel mounting bolts eccentricity) of the flywheel must not exceed 0.15 mm
(6) Procedure to tighten counterweight bolts: 1150 ± 60 N·m (851 ± 44 lb ft). (0.006 inch).
The maximum permissible surface finish for the (3) Torque for spline mounting bolts
105 ± 20 N·m (75 ± 15 lb ft). Bore Runout (Radial Eccentricity) of the Flywheel:
bearing journals for all 3500 Family Engines is
0.125 µm (5 µ inch). The thrust face surface Maximum bore runout (radial eccentricity) off center bore
finish must be 0.45 µm (18 µ inch), or smoother. (total indicator reading) must not exceed 0.15 mm (0.006 in.).
Make sure there are no wear steps or marks from
grinding on the surface. See Guideline for Reusable Parts "Visual Inspection of Crankshafts", SEBF8043. Flywheel Clutch Pilot Bearing Bore Runout (Radial
Typical Illustration - right hand side view Eccentricity):
a. Before assembly, put 6V-4876 Molykote Paste Lubricant on bolt threads, shank, washer and bolt seat.
b. Tighten the bolts evenly to 200 ± 5 N·m (150 ± 4 lb ft). Maximum bore runout (radial eccentricity) for pilot bearing off
For the aftercooler shown above:
c. Loosen bolts. center bore (total indicator reading) must not exceed 0.13 mm
d. Tighten the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft). (1) Lubricate bores lightly with glycerin at assembly. (0.005 in.).
e. Tighten each bolt an additional 120 ± 5o. (2) Cut the ends of the gaskets even with the bottom of the housings for assembly.
NOTICE (3) Torque for bolts is 32 ± 7 N·m (24 ± 5 lb ft).

Each counterweight has a number and must be installed in the same position as the correct number on the (4) Torque for bolts that hold the aftercooler housings to the cylinder block is 55 ± 7 N·m (41 ± 5 lb ft).
crankshaft mounting pad to prevent damage to the crankshaft when the engine is run.
 3508 & 3508B Engine Assembly Procedure
Sub
Assembly Sub Assembly
Installation
Parts Assembly Procedure
13 (Continued) Flywheel Housing Runout 17 Trunnion
Parts Sequence

Flywheel Group Q – 37 Check flywheel housing bore (1) Tighten the bolts that hold the mount
(continued from and face runout. 13 assembly to the support to a torque
front) of 190 ± 30 N·m (140 ± 22 lb ft).
Q – 38 Install timing pin.
(2) Tighten the bolts that hold trunnion to
front drive housing to a torque of 135
Camshaft Drive 39 Install camshaft gears.
± 20 N·m (100 ± 15 lb ft).
Gears (Timing pins in place)
14 (3) Tighten the bolts that hold trunnion to
& Q – 40 Torque bolts. front engine support to a torque of
Front Balance Q – 41 Remove timing pins. 475 ± 60 N·m (350 ± 45 lb ft).
Gears
(Flywheel & Cams)

Bridge 42 Install bridge assemblies. 15

Adjustment Q – 43 Adjust bridge assemblies.
Screws 8T-5096 Dial Indicator Group Installed
Face Runout (Axial Eccentricity) Of (Typical Example)
Lock Nuts Valve Mechanism 44 Install rocker base and gasket. The Flywheel Housing:
Rocker Base
Push Rods
Group Q – 45 Install push rods. Make sure the
push rod is properly positioned
Note: If a different method is chosen
other than the method given here in
(3) With dial indicator set at 0.0 mm (0.00
inch) at location (A), turn the flywheel
18 Vibration Damper Group
in follower. steps (1) thru (4), then always and read the indicator at locations
Rocker 46 remember that the bearing clearance (B), (C), and (D).
Assembly Install rocker arm assemblies. must be removed in order to receive
correct measurements. (4) The difference between lower and
Valve Covers Lubricate push rod ball & cup. For 3508 only:
higher measurements taken at all
Adjustment nuts and screws (1) Fasten a dial indicator to the four points must not be more than (1) Crankshaft.
must be backed off before flywheel so the anvil of the 0.38 mm (0.015 inch), which is the
indicator will touch the face of the (2) Adapter.
Q – 47 installation. maximum permissible face runout
Torque rocker arm assemblies. flywheel housing. (axial eccentricity) of the flywheel (3) Damper.
(2) Put a force on the crankshaft housing. (4) Tighten the 1/2 inch bolts that hold
Q – 48 Adjust valve and injector 16 toward the rear before reading the damper (3) to adapter (2) to a torque of
dimensions. indicator at each point 105 ± 20 N·m (75 ± 15 lb ft).
49 Install valve covers. (5) Put mark on adapter (2) in alignment
with mark on end of crankshaft (1)
Covers Camshaft Covers 50 Install camshaft side covers. 14 Rear Gear Group before installation of bolts (6).
Housing Housing 51 Install front housing assembly. (6) Tighten adapter mounting bolts to a
Gears & Typical Illustration torque of 1150 ± 150 N·m (850 ± 110 lb
Torque front housing bolts. ft).
Washer Gear Gp Front
Bearing Note: If necessary, repeat Step 7e until the
Adapter bolts hold torque (cannot be moved) For 3508B only:
to make sure the drive gears are in (1) Crankshaft.
Accessory 53 Install front accessory drive. full contact with the taper on the
Drive Gp. camshafts. (2) Adapter.
Front (8) Tighten bolts to 240 ± 20 N·m (175 ± 15 (3) Damper.
lb ft). (4) Apply 4C-4030 Thread Lock Compound
Front 54 Install front trunnion if so 17
(9) Diameter of shaft (new) is 74.99 ± 0.010 to 3/8 inch bolt’s threads.
Trunnion equipped.
mm (2.952 ± 0.0004 inch). Use (4) Tighten the 3/8 inch bolts that hold
Q – 55 Torque mounting bolts.
1P-0520 Tool Group and a press to damper (3) to adapter (2) to a torque of
(1) Camshaft drive gears.
install bearing in cluster idler gear 55 ± 7 N·m (41 ± 5 lb ft).
Front Oil Seal Damper Q – 56 Install front oil seal. 18 (2) Plate. (balancer gear).
Damper (5) Align mark on damper with mark on
Group Install damper group. (3) Camshaft idler gears. Bore in bearing (after assembly) is
Adapter damper adapter.
Torque adapter to crankshaft 75.06 ± 0.01 mm (2.955 ± 0.0004 inch).
Bolts (4) Diameter of shafts (new) is 81 ± 0.01
bolts. (6) Tighten 1 inch adapter mounting bolts to
mm (3.189 ± 0.0004 inch). Use (10) Balancer gear marks must be in
a torque of 1125 ± 100 N·m (829 ± 74 lb
1P-0520 Tool Group and a press to alignment with crankshaft gear marks as
Manifold Upper Water 57 Install left and right water ft).
install the bearings in both camshaft shown for SAE standard rotation
Sections Lines Gp manifolds. engines.
idler gears until bearings are in the
Bolts center of their bores. (11) Crankshaft gear.
Seals & Bore in bearings (after assembly)
must be 81.06 ± 0.01 mm (3.191 ±
Gaskets
0.0004 inch). Front Balancer Group 19 Governor Preparation
Housing Regulator 58 Install regulator housing, related (5) Cluster idler gear (balancer gear).
Brackets Group water lines and brackets.
(6) Plate.
Regulators
(7) Bolts that hold camshaft drive gears
Valve As.
(1) in position.
Install the gears as follows:
Lines Fuel Injection 59 Install left and right fuel manifold
(a) Pin both camshafts and put (1) Balance gears.
Fittings assemblies.
Lines Gp. camshaft drive gears (1) in position
Manifolds (2) Diameter of shafts (new) is 74.900 ±
on each camshaft taper.
Connectors
(b) For correct timing, all gear 0.015 mm (2.9488 ± 0.0006 inch). Install Lever
clearance (backlash) must be Bore in bearings (after assembly) is
Housing Oil Pump 60 Install oil pump. For 3161 Governors with torque rise, the
removed. Turn camshaft drive gears 75.000 ± 0.053 mm (2.9528 ± 0.0021
Gears Group adjustable pin control is installed on the
(1) in the same direction as inch).
terminal shaft. Bolt (3) is then tightened to a
crankshaft rotation and hold in this Bearing joint must be in center of heavy Install cover on governor
Fuel Supply 61 Install fuel transfer pump. torque of 25 ± 7 N·m (18 ± 5 lb ft).
position. section in gear at assembly.
Pump Group Because of the close clearance between the Before the governor is installed on the
(c) Install plates (2) and (6) to the (3) Balancer gear marks must be in fuel control linkage cover and governor, the
hold camshaft drive gears (1) to each engine, tighten the pin lock bolt (4) enough
Water Pump 62 Install jacket water & aftercooler alignment with crankshaft gear marks as upper left hand bolt must be installed at
camshaft. to hold pin in position when the governor is
Group water pumps. shown for SAE standard rotation location (1) before cover (2) is put on the
(d) Tighten bolts (7) in steps to a installed on an engine.
engines. terminal shaft and the governor is bolted to
Cooler Cores Oil Cooler 63 Install engine and auxiliary oil torque of 360 ± 40 N·m (265 ± 30 lb the drive adapter housing. The other bolts After the governor is installed on an engine,
(4) Crankshaft gear.
Housing Group cooler and lines. ft). can be put in place after the governor is in the adjustable pin is turned to synchronize
(e) Tap plate (6) and again tighten position on the engine. the governor travel to the fuel control
Filter Bases Fuel Filter 64 Install fuel filter bases, brackets, the bolts to a torque of 360 ± 40 N·m linkage. See Governor Installation for the
(265 ± 30 lb ft). Put clean engine oil on the lip of the seal, correct adjustment and setting of these
Lines and lines. and install cover over the governor terminal
Group governors.
Filters shaft.
Brackets
NOTICE
Housing Scavenge Oil 65 Install scavenge oil pump,
Gears pickup & tubes. Before the governor is installed on an
Tube
Oil Pump Gp.
15 Valve Rocker Arms, Lifters, and Bridges engine, make sure the pin of adjustable
Pickup Screen control lever (4) is at the bottom of the lever
as shown. If the pin is not in this position,
Oil Pan Oil Pan Group 66 Install oil pan assembly & oil (1) Torque for valve adjustment screw the control lever can bind or become
Elbows pump supply tube. locknut is 70 ± 15 N·m (52 ± 11 lb ft). disconnected from the engine fuel control
Seal-O-Ring
Control Lever
Install dipstick guide. (2) Clearance for values: linkage. Engine overspeed can be the
Gaskets Intake Valves 0.50 mm (0.020 in.) The adjustable pin lever is used on 3161 result.
Housing-Oil Exhaust Valves 1.00 mm (0.039 in.) Governors with torque rise. It is used to
Screen synchronize governor torque rise set point
(3) Torque for bridge adjustment screw
Drain Adapter
locknut is 30 ± 4 N·m (22 ± 3 lb ft).
(balance point) position to engine fuel Alignment of Control Lever
Covers setting position.
Suction
The adjustable pin lever can be used on a
Screen
right hand or left hand mounted governor.
Dipstick &
To convert the lever from right hand
Guide
governor use to left hand governor use,
remove the lock bolt and lock from the
Filter Bases Oil Filter Group 67 Install oil filter group & related
adjustable pin. Remove the adjustable pin
Filters
by-pass
tubes.
16 Crankshaft Positions for Fuel Timing and Valve from the lever, turn it around and install it The lever (5) and pin (7) connect the
governor terminal shaft (6) to the fuel control
into the lever the opposite way. Install the
Valves
Tubes
Clearance Setting lock and bolt into the adjustable pin, and linkage stop lever (8). The lever pin (7)
moves in notch of the stop lever (8). This
tighten just enough to hold it in place. The
Elbows causes the two to move together.
lever can now be used on the other end of
Adapters
the terminal shaft for left hand mounted
Standard Rotation (Counterclockwise) - As Viewed From Flywheel End governors.
Housing Governor Drive Gp 68 Install governor drive assembly.
Gears Cylinder To Check/Adjust
Plate
Plugs Correct Stroke for No. 1 Piston Intake Exhaust Injectors
Coupling Engines at Top Center Position* Governor Alignment Procedure
Valves Valves
Governor Governor Group Q – 69 Install governor and zero with 19
injector control linkage. 3508 Compression 1-2-6-8 1-2-3-7 3-4-5-7
and
Rear Auxiliary Accessories 70 Install accessories. 3508B Exhaust 3-4-5-7 4-5-6-8 1-2-6-8
Drive Group
Air Put No. 1 piston at top center (TC) position and make identification for the correct stroke. Make reference to
Compressor Finding Top Center Position for No. 1 Piston. After top center position for a particular stroke is found and
Hydraulic adjustments are made for the correct cylinders, remove the timing bolt and turn the flywheel 360o in the
Pumps direction of normal engine rotation. This will put No. 1 piston at top center (TC) position on the other stroke.
Air Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
Conditioning
Compressor
Alternator
Starters
Fan Drive
Fan Hub
Idler Hub
Cylinder and Valve Location
Fuel Timing
Turbochargers Turbocharger Gp. 71 Install turbochargers & related 20
Lines intake & exhaust piping. NOTICE
Elbows
Pipes The camshafts must be correctly timed Note: Make sure governor output lever Note: Spring pressure in the Caterpillar 3161
with the crankshaft before an adjustment Procedure A (1U-8869 Digital Dial Indicator) is connected correctly to rack Governor should cause the output terminal
Heat Shield Group 72 Install heat shielding on exhaust of fuel timing is made. The timing pins (3) If the dial indicator reads the correct fuel fork lever (1). shaft to go back to the fuel-off position when
manifolds & turbos. must be removed from the camshafts timing dimension, as determined from released from the full-fuel position.
before the crankshaft is turned or (1) Position base of governor (8) so side
the Fuel Setting And Related
73 Install crankcase breathers. damage to the cylinder block will be the (A) of base is parallel with surface
Information Fiche for the engine being
result. (B) of governor drive housing (12).
checked, then no adjustment is (7) If output terminal shaft does not turn freely,
74 Install miscellaneous covers, Tighten governor mounting bolts do Steps 2 through 6 again.
necessary.
lines, accessories & compare (10).
Note: See chart Crankshaft Positions for Note: To insure an accurate fuel timing (8) Put bracket (6) in position with open slots
complete engine with dimension, make sure the top (2) Now loosen adapter bolts (13).
Fuel Timing And Valve over bolts (3). Install washers and bolts (2)
photographs. surfaces of the follower (3) and
Clearance Setting and put the (3) Move the governor and drive housing that hold bracket (6) to cover (5), but do not
engine in time. With the two shoulder (4) are clean and dry. as needed until holes in cover (5) are tighten these bolts.
crankshaft positions given in the (4) If the dial indicator does not read the correct in alignment with holes in accessory
chart, all of the injectors can be (9) Tighten bolts (3) that hold bracket to
and/or desired fuel timing dimension, as drive housing (11). Install, but do not
13 Flywheel Housing Bore Runout checked or adjusted. This will
make sure the pushrod lifters are
determined from the Fuel Setting And tighten, the seven cover bolts (9).
governor first, then tighten bolts (2) that
hold bracket to cover.
Related Information Fiche for engine being (4) Tighten the six adapter bolts (13).
off the lobes and on the base checked, do Steps 5 and 6.
circles of the camshafts. (5) Now tighten the seven cover bolts (9).
Note: See the Fuel Setting and Related (5) With 1U-8869 Digital Dial Indicator &
9U-5233 Timing Fixture in position on (6) After all bolts are tightened, check to
Information Fiche for the correct
injector to be adjusted, loosen push rod be sure governor terminal shaft (4)
fuel timing dimension to use.
adjustment screw locknut for injector to be has free rotation.
(1) After programming the digital dial adjusted.
indicator (1) place it and the 9U-5233
Timing Fixture (2) in position on the 6) Turn adjustment screw until desired fuel
injector to be checked. Make sure timing dimension is read on digital dial
indicator.
the magnetic base of the timing
fixture is on the top surface of Note: Turning the adjustment screw
20 Turbochargers
follower (3) and the extension rod is clockwise (CW) will lower the fuel
on the top surface of injector timing dimension (advance timing). (1) Lubricate threads of bolts that hold
shoulder (4). Turning the adjustment screw turbocharger to exhaust manifold with
(2) The digital dial indicator should now counterclockwise (CCW) will 5P-3931 Anti Seize Compound.
(1) Fasten the dial indicator to the read the actual fuel timing dimension increase the fuel timing dimension.
(2) Position turbocharger on exhaust
flywheel so the anvil of the indicator of the injector being checked. Tighten the adjustment screw locknut to a manifold.
will touch the flywheel housing bore. torque of 70 ± 15 N·m (50 ± 11 lb ft) and (3) Install bolts and washers or bolts and
With the dial indicator in position at check adjustment again. If necessary, locknuts, then torque to 54 ± 5 N·m (40 ±
(C), adjust the dial indicator to "0" repeat procedure until the adjustment is 4 lb ft).
(zero). Push the crankshaft up correct. (4) Repeat steps (1) thru (3) for the other
against the top bearing. Write the
turbocharger.
measurement for bearing clearance
on line 1 in column (C).
Note: Write the dial indicator
measurements with their
positive (+) and negative (-)
notation (signs). This notation
is necessary for making the
calculations in the chart
correctly.
(2) Divide the measurement from Step 1
by 2. Write this number on line 1 in
columns (B) & (D).
Chart for Dial Indicator Measurements
(3) Turn the flywheel to put the dial
indicator at (A). Adjust the dial
Position of
indicator to "0" (zero).
Dial indicator
(4) Turn the flywheel counterclockwise to
put the dial indicator at (B). Write the
Line
measurement in the chart.
No. A B C D
(5) Turn the flywheel counterclockwise to
put the dial indicator at (C). Write the Correction for I 0
measurement in the chart.
bearing
(6) Turn the flywheel counterclockwise to clearance
put the dial indicator at (D). Write the
measurement in the chart. Dial Indicator II 0
Reading
(7) Add lines together in each column.
(8) Subtract the smaller number from the Total of Line III 0 ** * **
larger number in columns (B) & (D). 1&2
The result is the horizontal
"eccentricity" (out of round) and * Total Vertical eccentricity (out of round)
place this number in Line III. Line III,
** Subtract the smaller number from larger
column (C) is the vertical eccentricity.
number. The difference is the total horizontal
(9) On the graph for total eccentricity find eccentricity.
the point of intersection of the lines
for vertical eccentricity and horizontal
eccentricity.
(10) If the point of intersection is in the
range marked "Acceptable" the bore
is in alignment. If the point of
intersection is in the range marked
"Not Acceptable" the flywheel

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