SENR1092-01

August2002

33068 Generator Set Engine

• 9NR1-Up
EPS1-Up

•
 lmportant Safety lnformation

Most accidents invotving product operation, maintenance and repaK are caused by h*R to a:iser.ie
basic safety rules or precautions. An accident can often be avoided by recog.:zl'lg ~
hazardous situations before an accident occurs. A person must be alert to potential haZa"ds ihís
person should also have the necessary training, skills and tools to perform these foodloras propeny.

lmproper operation, lubrication, maintenance or repair of this product can be dangerous 8Dd
•
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. lf these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signa! Word" such as
"WARNING" as shown below.

A WARNING

The meaning of this safety alert symbol is as follows:

Attentionl Become Alert! Your Safety is lnvolved.

The message that appears under the warning, explaining the hazard, can be either written or pictof'ially
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 invotve a potentiaJ hazard. The
warnings in this publication and on the product are therefore not ali inclusive. lf a tool, procedure, work
method or operating technique not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changas can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microficha, REG1139F.

•
 lndex lntroduction

• Bearing Surface (Journal) For Connecting Rods ................. 30

Bearing Surface (Journal) For Main Bearings ...................... 30
Belt Tension Chart ................................................................ 24
Camshaft .............................................................................. 14
Camshatt Bearings ............................................................... 26
Connecting Rod ................................................................... 27
When the words ·use again" are in the description, the
specification given can be used to determine if a part can be
used again. tf the part is equal to or within the specification
given, use the part again.
When the word "permissible" is in the description, the
Connecting Rod and Main Bearings .................................... 31 specification given is the "maximum or mínimum" tolerance
Crankshatt .... ........................................................................ 29 permitted before adjustment, repair and/or new parts are
Cylinder Block .............................. ........................................ 24 needed.
Cylinder Head ....................................................................... 16 A comparison can be made between the measurements of a
Cylinder Liner ....................................................................... 26 worn part and the specifications of a new part to find the
Engine Design ........... .......... ......... .... ..... ... ...... .............. ........ 4 amount of wear. A part that is worn can be safe to use if an
Engine Front Support ........................................................... 31 estimate of the remainder ot its service life is good. lf a short
Engine Oil Pressure .............................................................. 22 service lite is expected, replace the part.
Exhaust Manifold .................................................................. 17 REFERENCE: See 33068 Generator Set Engines,
Flywheel ................................................................................ 32 SENR1093, for Systems Operation, Testing & Adjusting.
Flywheel Housing ................................................................. 32
Fuel Filler Base ..................................................................... 10
Fuel lnjection .... .......... .... .......... ............................. ............... 4
Fuel lnjection Unes ............................................................... 12
Fuel lnjection Pump ... ......... ............. .. .......................... ...... ... 4
Fuel Priming Pump And Primary Fuel Filler ......................... 11
Fuel Ratio Control ................................................................. 10
Fuel Transfer Pump .............................................................. 9
Fuel lnjection Pump Housing .. .............. .......... ........... ...... ..... 6
Governor ............................................................................... 7

•
Oil Breather Cap ................................................................... 21
Oíl Fil ter ................................................................................ 21
Oil Pump ...... ..................................... ...... .................... .......... 20
Pistons And Rings ................................................................ 27
Shutoff Pivot Lever ............................................................... 9
Timing Gear Cover ............................................................... 31
Timing Gears ........................................................................ 13
Turbochargers
S38 ............................................................................... 18
S4D ........................... ................. ................ ................... 19
Valve Cover .......................................................................... 17
Valve Rocker Arms And Litters ............................................ 15
Valves ................................................... ................................ 15
Water Pump .......................................................................... 23
Water Temperature Regulator ........................................... ... 24

• lndex
33068 Gen Set Engine 3
Specifications Fuel lnjection Pump
Engine Design

2
EXHAUST VALVU
4
1 2 •
J

2 3 4 5 1
A76354P1 IHTAKl VALVES

4
Cytinder And Vafve ldentification

Bore ............................................................ 120.7 mm (4.75 in)

Stroke ......................................................... 152.4 mm (6.00 in)
Number of Cylinders ......................... ..... ... ... ........ .... .. .......... 6
Cylinder Arrangement .................................................... in-line
Firing Order (lnjection Sequence) ..... ...................... 1-5-3-6-2-4
Direction of Rotation (when seen from flywheel
end) ................. ............................................ Counterclockwise
The No. 1 Cylinder Is Opposite Flywheel End.

Fuel lnjection
Firing order (injection sequence) ............................. 1-5-3-6-2-4
Torque for the nuts that hold the tuel lines (use 5P144 Fuel
025309

Une Socket) ...................................... 40 ± 7 N•m (30 ± 5 lb ft)

(1) Torqueforbushing ........... 16s±14N•m (1 20± 101bft)
•
lnjectíon Timing Before TC (Top Center)
(2) 8N1415 Spring (reverse flow check):
Fuel lnjection Pump And Governor Group: Length under test force ........................ 8.69 mm (.342 in)
7C9201 ....................................................... 18 ± 1 degree Test force .............................. 111 .21 ± 6.45 N (25 ± 1 lb)
7W9365 ...................................................... 14 ± 1 degree Free length after test .......................... 12.12 mm (.477 in)
7W9823 ..... ................................................. 18 ± 1 degree Outside diameter .................................. 9.78 mm (.385 in)
(3) Thickness of 4W6869 Spacer ............. 5.049 ± 0.005 mm
(.1988±.0002in)
(4) 7N1067 Spring:
Length under test force .................... 43.52 mm (1.713 in)
Test force ............................ 116.5±5.8N (26.2± 1.31b)
Free length after test ........................ 48.73 mm (1.918 in)
Outside diameter .................................. 25.9 mm (1.02 in)
(5) Length of pump plunger (new) .......... 73.886 ± 0.013 mm
(2.9089 ± .0005 in)
Minimum permissible length (worn) ............... 73.873 mm
(2.9084 in)

33068 Gen Set Engine 4 Specifications

 6

(6) Oistance from housing to end of rack when rack and

gears are engaged at center of fourth tooth
position .......................... 7.24 ± 0.08 mm (.285 ± .003 in)
(7) Torque for plugs ........................ . 5±1 N•m (44 ± 9 lb in)

•
33068 Gen Set Engine 5 Sf**• ....
Fuel lnjection Pump Housing
I
2 3 4

n
7 ----1~1
8

(1) Diameter of the rack bearing in the governor end alter (5) lnside diameter of the camshaft bearing in the governor
assembly ............. 12.746 ± 0.045 mm (.5018 ± .0018 in) end of the pump housing alter
Diameter of fuel rack ......................... 12.662 ± 0.005 mm assembly ........... 70.089 ± 0.039 mm (2. 7594 ± .0015 in)
(.4985 ± .0002 ín) Diameter of the camshaft bearing
journal ................ 70.000 ± 0.013 mm (2.7559 ± .0005 in)
(2) Distance from the governor end of the pump housing to
Instan the camshaft bearing in the pump housing with
the end of the rack bearing .................... 7 .16 ± 0.13 mm
the bearing joint at the top of the vertical center1ine.
(.282 ± .005 in)
(6) Oistance from the govemor end of the pump housing to
(3) Distance from the drive end of the pump housing to the
the end of the camshaft bearing ............ 0.25 ± 0.20 mm
end of the rack bearing ........................... 0.25 ± 0.25 mm
(.010 ± .010 in) (.01 O± .008 in)
(7) Distance from the drive end of the pump housing to the
(4) Oiameter of the rack bearing in the drive end after
end of the camshaft bearing .................. 1.00 ± 0.25 mm
assembly ............. 12.767 ± 0.058 mm (.5026 ± .0023 in)
(.039 ± .010 in)
(8) lnside diameter of the camshaft bearing in the drive end
of the pump housing .................... ..... 55.090 ± 0.039 mm
(2.1689 ± .0015 in)
Oiameter of the camshaft bearing
journal ................ 55.000 ± 0.013 mm (2.1654 ± .0005 in)
Instan the camshaft bearing in the pump housing with
the bearing joint at the top of the vertical centerline.

33068 Gen Set Engine 6 Specifications

 Governor

• 9----1

2 3

10

• (9) Distance from the centerline of the pump bore to the end
of the dowel ................. 15.03±0.25mm (.592± .010in)
(10) lnstall the rack bearing with the flat surface (as shown) to
an angle of .......................................... ........... 15 degrees
(11) Distance from the end of the dowel to the opposite wall
of the bore ......... 26.492 ± 0.100 mm (1.0430 ± .0039 in)

(1) Springs (governor):

4W8915
Puta force on spring of ........................... 12.2 N (2.74 lb)
Then add more force to make spring shorter
by ........................................................ 15.49mm(.610 in)
Total test force .............. 22.24 ± 0.29 N (4.998 ± .065 lb)
Free length after test ....... 76.0 ± 1.0 mm (3.00 ± 0.04 in)
Outside diameter ....... 34.26 ± 0.38 mm (1.349 ± .015 in)
Color code ............................................. two green stripes
7N1295
Puta force on spring of ................................ 26.7 N (6 lb)
Then add more force to make spring shorter
by ........... ............................................. 13.97 mm (.550 in)
Total test force ................ 45.66±0.53 N (10.26 ± .12 lb)
Free length after test ..... 68.58 ± 1.02 mm (2.70 ± .04 in)
Outside diameter ....... 32.64 ± 0.38 mm (1.285 ± .015 in)
Color code ...................................................... one orange

• 3306B Gen Set Engine 7 Specifications

7N1228

•
Put a force on spring of ...... .......................... 22.3 N (5 lb)
Then add more force to make spring shorter
by .... .................................................... 22.23 mm (.875 in) 5
Total test force ................ 65.10 ± 0.89 N (14.63 ± .20 lb)
Free length after test ..... 68.58±1.02 mm (2.70 ± .04 in)
Outside diameter ....... 32.64 ± 0.38 mm (1.285 ± .015 in)
.----·
Color code ... .............................................. one light green
8L8234
Pul force on spring of ................................... 13.4 N (3 lb)
©
Then add more force to make spring shorter
by ....... ...... ........................................... 22.86 mm (.900 in)
Total test force .................. 43.39 ± 1.38 N (9.75 ± .31 lb)
Free length after test ..... 59.44 ± 1.02 mm (2.34 ± .04 in)
Outside diameter ....... 32.33 ± 0.38 mm (1.273 ± .015 in)
Color code ..... ................ ...................... .... one white stripe
7C2193
Put force on spring of ..................................... 8.5 N (2 lb)
Then add more force to make spring shorter
by ........................................................ 13.22 mm (.520 in)
Total test torce .................. 14.15 ± 0.18 N (3.18± .04 lb) C04790P3
Free length after test ............... 76 ± 1 mm (3.00 ± .04 in)
Outside diameter ....... 32.03 ± 0.38 mm (1 .261 ± .015 in)
Color code .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... ... .. . two dark blue stripes
(2) 2W2216 Spring (broken link): (8) Oistance tour dowels extend above the surface of
Length under test force ........... ......... 26.33 mm (1.033 in) governor housing (5) ............. 6.0 ± 0.5 mm (.24 ± .02 in)
Test force .. .................... 13.34 ±0.66 N (3.002 ± .149 lb)
Free length after test ........................ 58.77 mm (2.313 in) (9) Distance two dowels extend above the surface of the
Outside diameter ................................ 11.32 mm (.446 in) governor housing .................. 3.0 ± 0.5 mm (.12 ± .02 in)
Color code (stripes) .................................................. none
(3) 4N6410 Spring (dashpot):
Length under test force .................... 26.16 mm (1.030 in)
Test force ............................. 4.5 ± 0.4 N•m (40 ± 4 lb in)
Free length after test ........................ 31 .24 mm (1.230 in)
Outside diameter ................................ 14.83 mm (.584 in) ~
7
Color code (stripes) ...... .......... ........ ..................... one pink
(4) 3K5733 Spring (centering):
Length under test force ............ .............. 19.3 mm (.76 in)
Test force .................................... 61±5N(13.7±1.1 lb)
Free length after test ......... 31.0 ± 2.0 mm (1.22 ± .08 in)
Outside diameter ................................ 14.35 mm (.565 in)
Color code (stripes) ........ ............ .................... .......... none
(5) Governor housing assembly.
(6) 1W4243 Spring (bumper): 10 - CCM791P3
Length under test force ........................ 26.3 mm (1.04 in)
Test force ............................ ................. 0.194 N (.0437 lb)
Free length after test ................................. 32 mm (1.3 in)
Outside diameter ...................................... 8.3 mm (.33 in) (10) Distance from the surface of block (7) to the end of the
Color code (stripes) .......................................... one yellow dowel ..................... 62.00±0.75mm (2.4419±0.030 in)
(7) Full load stop block.

33068 Gen Set Engine 8 Specifications

 Fuel Transfer Pump
11

14

(11) Tighten the plug to a torque of ...................... 11±2 N•m

(97±18 lb in)
(12) Tighten the body to a torque of ............ 6.25±1.35 N•m
(55±12 lb in) (1) Clearance between guide and
tappet ................ 0.0025 to 0.0101 mm (.0001 to .0004 in)
(13) Tighten the insulator to a torque of ........... 3.4 ± 0.5 N• m
(30 ± 41b in) ~OTE: The guide and tappet are a matched set. lf one part
1s worn, a new gu1de and tappet assembly must be installed.
(1 4) Tighten bolts to a torque of ....... ................ 3.5 ± 0.4 N• m
(31 ±4 lb in) (2) Bore in sleeve for the piston ............. 34.000 ± 0.015 mm
(1.3386 ± .0006 in)
Diameter of piston ............................. 33.972 ± 0.008 mm
(1.3375 ± .0003 in)
(3) 7W134 Spring:
Shutoff Pivot Lever Length under test force .................... 33.67 mm (1.326 in)
Test force ................................ 221 ± 11 N (49.7 ± 2.5 lb)
Free length after test ............................ 56.1 mm (2.21 in)
Outside diameter .............................. .. 27.36 mm (1.08 in)
(4) Fuel inlet port.
(5) Check valves.
(6) Fuel outlet port.

C43106PI

•
(1) Tighten locknut to a torq ue of ............... 1.70 ± 0.25 N•m
(15±21bin)

33068 Gen Set Engine 9 S; z e

Fuel Ratio Control Fuel Filter Base

2 3
•
5 043500 C4789P1

(1) 7W2826 Spring: (1) Stud. Put 9S3263 Thread Lock on the tapered end of the
Puta force on spring of ................. ..... ... 62.4N (14.02 1b) stud to a distance of ............. 7.6± 1.5 mm (.30 ± .06 in)
Then add more force to make spring shorter Tighten the stud to a torque of ................... 68± 14 N• m
by ........................................ ............. ..... 3.68 mm (.145 in) (50 ± 10 lb ft)
Total test force ........ .......... 77.4±0.5N (17.40±0.11 lb)
Free length after test ........................ 32.56 mm (1 .282 in)
Outside diameter .. .... ........ .. ...... ........ 35.12 mm (1.383 in)
Color code (stripes) .............................................. two red
(2) 9N1754 Spring:
Length under test force ............................. 12 mm (.47 in)
Test force ...... .................. 6.22 ± 0.44 N (1.398 ± .099 lb)
Free length after test .............................. 17.5 mm (.69 in)
Outside diameter .................................. 4.57 mm (.180 in)
(3) 7W2827 Spring:
Puta load on spring of ...... .................. ..... 77.4 N (17.4 lb)
Then make spring shorter by ............... 3.68 mm (.145 in)
Length under test force ...................... 37 .O mm (1.456 in)
Total test force ................ 98.50 ± 1.06 N (22.13 ± .24 lb)
Free length after test ............................ 50.5 mm (1.99 in)
Outside diameter ................................ 24.45 mm (.963 in)
(3) 7W2828 Spring:
Puta force on spring of .............. ........... 77.4 N (17.39 lb)
Then add more force to make spring shorter
by .................... ...................................... 3.68 mm (.145 in)
Total test force .......... 107.69± 1.51 N (24.200± .3391b)
Free length after test ............................ 46.4 mm (1.83 in)
Outside diameter ................................ 24.45 mm (.963 in)
Color code (stripes) ... .......... ............................. two yellow
(4) 8N5765 Spring:
Length under test force .................. ...... 24.0 mm (.944 in)
Test force ................... .......... ...... 22.25 ± 4 N (5.0 ± .9 lb)
Free length after test ............. ............... 80.5 mm (3.17 in)
Outside diameter .............................. 35.57 mm (1.400 in)
(5) Tighten bolts to a torque of ...... 9 ± 3 N•m (80 ± 27 lb in)

33068 Gen Set Engine 10 Specificati?ns

 Fuel Priming Pump And Primary

• Fuel Filter

¡
4

VIEW A-A

C2"°39PI

Typical Example

(1) Fuel priming pump.

(2) Primary fuel filter base.
(3) Nut. Tighten to ........................... 24 ± 4 N•m (20 ± 3 lb ft)
(4) Check valve. Stake three places.
(5) Primary filter element.

•
33068 Gen Set Engine 11 Specifications
Fuel lnjection Lines

042482

~--!--~

042465

33068 Gen Set Engine 12 Specifications

 A WARNING Timing Gears

• Be sure the fuel injection line clamps are installed in the

correct locations. lncorrectly installed clamps may anow
the injection lines to vibrate and become damaged. The
damaged lines may leak and cause a fire . 3

(1) Clamp locations (A,B, and C) are in reference to a

5
horizontal centerli~e (1) through the center of the fuel
pump outlets.
(2) Clamp locations (O through F) are in reference to a
vertical centerline (2) through the center of the number
five fuel pump outlet.
(3) Clamp locations (G through J) are in reference to a
vertical centerline (3) through the center of the number
ene fuel pump outlet.
(4) Tighten the fuel line nuts to a torque of ....... 40 ± 7 N•m
(30 ± 5 lb ft)
NOTE: Nozzle assembly must be supported with wrench.
10-----....,

(A) ................................................ ... 84 ± 6 mryi (3.31 ± .24 in)

(B) .......... ..... ........ .... ...... .............. .... 97 ± 6 mm (3.82 ± .24 in)
(C) .................. ............................... 110 ± 6 mm (4.33 ± .24 in) 11-
(O) ................... .............................. 125 ± 6 mm (4.92 ± .24 in)
(E) ............... ....... ..... ...................... 221 ± 6 mm (8.70 ± .24 in)
(F) ............•:.. ......... .............................. 415.39 mm (16.354 in)
..,, . . . C69098P1
(G) ........................... ......... ..... ........ ............ .. 119.7mm (4.71 in)
(H) .................................... ............. 165 ± 6 mm (6.50 ± .24 in)
(1) ...... .............................................. 195±6mm(7.68 ± .24in)
(1) Fuel pump drive gear.
(J) ...... .. ................ ........................ 365 ± 6 mm (14.37 ± .24 in) ...
(2) Washer. Assemble with large diameter away from gear.
(3) Bolt. With the timing pin and timing bolt correctly
installed, puta clockwise force of 70 N•m (50 lb ft) on
the drive gear for the fuel pump and tighten bolt (3) to a
torque of ............................ 270 ± 25 N•m (200 ± 20 lb ft}
(4) Fuel pump idler gear.
Bore in idler gear for bearing ......... ... 41.288 ± 0.008 mm
(1.6255 ± .0003 in)
Depth to instan bearing in gear ...... ......... 3.00 ± 0.25 mm
. 0
. (.118± .010in)
Diameter of idler gear shaft (new) ..... 34.955 ± 0.013 mm
(1.3762 ± .0005 in)
Clearance between shaft and bearing
(new) ...................... 0.050 to 0.076 mm (.0020 to .0030 in)
Maximum permissible clearance between shaft and
bearing (worn) ...... :........ ................... 0.230 mm (.0090 in)
(5) Tighten two bolts to a torque of ...... ............ 50 ± 10 N•m
(37 ± 7 lbft)
(6) Tighten nut to a torque of ... ....... 30 ± 7 N•m (22 ± 5 lb ft)
(7) Plate. Assemble machined side of plate adjacent to the
shaft.

•
Clearance between gear (4) and plate
(7) ............................. ..... 0.1O to0.42 mm (.004 to .017 in)

33068 Gen Set Engine 13 Specifications

Specif ications
(8) Camshaft gear.
(9) Tighten bolts to a torque of ..... 55±10 N•m (40 ± 7 lb ft)
(10) Crankshaft gear.
Maximum temperature of the gear for installation on the
crankshaft .................................................. 315ºC (600°F)
•
Align camshaft gear (8) and crankshaft gear (10) using
timing marks.
(11) ldler gear for the oil pump.
(12) Orive gear for oíl pump.
5

Camshaft

74239-1P1

(4) Camshaft lobe lift (4).

(5) Height of camshaft lobes.
To find lobe lift, use the following prooedure:
A. Measure camshaft lobe height (5).
B. Measure base circle (6).
C. Subtract base circle (STEP 8) from lobe height (STEP
A). The drtference is actual lobe lift (4).
D. Specified camshaft lobe lift (4) is:
a. Exhaust lobe ......................... . 8.382 mm (.3300 in)
b. lntake lobe ............................. 8.382 mm (.3300 in)
(1) Width of groove in camshaft for thrust washer
(new) .............................. 4.83 ± 0.05 mm (.190 ± .002 in) Maximum permissible drtference between actual lobe lift
Thickness of thrust washer (new) ........... 4.65 ± 0.03 mm (STEP C) and specified lobe lift (STEP D) is ............. 0.25 mm
(.183 ± .001 in) (.010 in)
End play of the camshaft (new) .............. 0.18 ± 0.08 mm
(.007 ± .003 in)
Maximum permissible end play (worn) .............. 0.64 mm
(.025 in)
(2) Diameter of camshaft bearing surtace (journal)
(new) ......... ......... 58.699 ± 0.013 mm (2.311 O± .0005 in)
(3) Bore in bearing for camshaft (new) ...... 58.80 ± 0.06 mm
(2.315 ± .002 in)
Clearance between bearing and bearing surface
(journal) (new) ............... 0.03 to 0.17 mm (.001 to .007 in)
Maximum permissible clearance between bearing and
bearing surface (journal) (worn) ........... 0.20 mm (.008 in)

33068 Gen Set Engine 14 Specifications

 Valve Rocker Arms And Lifters Valves
NOTE: Guideline For Reusable Parts; Valves And Valve
Springs, SEBF8002 and SEBF8034 have the procedures and
specitications necessary for checking used valves and valve
2 springs.
3

~~-~~ ( 1
2

~ 1

Jl1-
1
1
1
1
_J
A

C04831P2

(1) 484910 Spring (new): (1) 7$7144 Spring for valves (new):
Length under test force .................... 69.85 mm (2.750 in) Length under test force .................... 44.86 mm (1.766 in)
Test force ............................... 62.3to71.2N(14to161b) Test force ................................ 257 ± 25 N (57.7 ± 4.5 lb)
Free length after test .......................... 101.6 mm (4.00 in) Use again mínimum load at length under test
Outside diameter .................................... 24.6 mm (.97 in) force ........................................................ 217N(48.83lb)
(2) Valve lash: Length of spring at valve open position .......... 32.28 mm
lntake valves ......................................... 0.38 mm (.015 in) (1.271 in)
Exhaust valves ...................................... 0.64 mm (.025 in) Use again minimum load at valve open position .... 658 N
(148.5 lb)
(3) Tighten locknut on intake and exhaust valve adjustment Free length atter test .......................... 52.07 mm (2.05 in)
screw to a torque of ................. 29 ± 7 N•m (22 ± 5 lb tt) Outside diameter .............................. 35.21 mm (1.386 in)
(4) Bore in bearing for shatt (new) ......... 18.448 ± 0.013 mm Spring must not be bent more than ..... 1.82 mm (.072 in)
(.7263 ± .0005 in) (2) Height to top of valve guide .......... ........ 22.23 ± 0.25 mm
Diameter of shaft (new) ................ ..... 18.402 ± 0.013 mm (.875 ± .010 in)
(.7245 ± .0005 in)
(3) Diameter of valve stem (new) ............. 9.441 ± 0.008 mm
Maximum permissible clearance between bearing and (.3717 ± .0003 in)
shaft (worn) .......................................... 0.20 mm (.008 in)
Use again mínimum diameter .......... 9.408 mm (.3704 in)
(5) Diameter of valve lifter (new) ............ 33.287 ± 0.013 mm Bore in valve guide with guide installed in the head.
(1.3105 ± .0005 in) Minimum permissible (new) .............. 9.456 mm (.3723 in)
Bore in block for valve litter (new) .... 33.388 ± 0.050 mm Maximum permissible (worn) ........... 9.581 mm (.3n2 in)
(1.3145 ± .0020 in)
(4) Valve lip thickness:
Maximum permissible clearance between litter and bore
for valve lifter Exhaust Valve
(worn) ................................................... 0.30 mm (.012 in) Use again minimum .............................. 2.69mm (.106in)

•
lntake Valve
Use again minimum .............................. 2.69 mm (.106 in)

33068 Gen Set Engine 15 Spedfications

(5) Diameter of valve head:
Cylinder Head

•
Exhaust valve .. ..... ..... 48.16 ± 0.13 mm (1.896 ± .005 in)
lntake valve ................ 51.31 ± 0.13 mm (2.020 ± .005 in)
(6) Angle of valve face ........ ........ .... ..... .... 29 Y• ± Y• degrees

77084P1
View From Right Side Of Engine

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

(3.938 ± .O~O in)
Put 6V4876 Thread Lubricant on the washer faces and
threads of ali bolts except bolt (25). Tighten ali bolts in the
sequence that follows:
(7) Depth of bore in head for valve seat Step 1. Tighten ali bolts in number sequenoe
insert ............................ 12.28 ± 0.13 mm (.483 ± .005 in) to ........................................................ 155 N•m (115 lb ft)
Step 2. Again tighten ali bolts in number sequence
(8) Diameter ot valve seat insert for exhaust to ....................................... 250±17 N•m (185±13 lb ft)
valve .................. 50.889 ± 0.013 mm (2.0035 ± .0005 in) Step 3. Again tighten ali bolts in number sequence (hand
Bore in head for valve seat insert for exhaust torque only) to ................... 250 ± 17 N•m (185 ± 13 lb ft)
valve .................. 50.813 ± 0.030 mm (2.0005 ± .0012 in) Step 4. Tighten ali bolts in letter sequence (hand torque
Diameter of valve seat insert for intake only) to ....................................... 43 ± 7 N•m (32 ± 5 lb ft)
valve .................. 52.032 ± 0.013 mm (2.0485 ± .0005 in)
Bore in head for valve seat insert for intake
valve .................. 51.956 ± 0.030 mm (2.0455 ± .0012 in)
(9) Angle ot tace of valve seat insert ............ 30 ± 1 degrees
(10) Maximum permissible width of valve seat (intake and
exhaust) ......... .. ..................................... 1.93 mm (.076 in)
Mínimum permissible width of valve seat (intake and
exhaust) ................................................ 1.14 mm (.045 in)
(11) Dimension from top of closed valve to tace of head:
Mínimum permissible dimension for Exhaust
Valve ..................................................... 0.66 mm (.026 in)
Mínimum permissible dimension for lntake
Valve ..................................................... 0.15 mm (.006 in)
(12) Outside diameter ot the tace of the valve seat insert:
Exhaust seat ..................................... 46.02 mm (1.812 in)
Maximum permissible, exhaust seat ................ 47.29 mm
(1.862 in)
lntake seat ........................................ 49.28 mm (1.940 in)
Maximum permissible, intake seat .. . 50.55 mm (1.990 in)
(13) Angle to grind seat face of the insert to gel a reduction
of maximum seat diameter .............. .... ........ ... 15 degrees

33068 Gen Set Engine 16 Specifications

 Valve Cover Exhaust Manifold

12 011 01 03 02 06

9
o
77083P1

View From Right Side Of Engine

Put 5H2471 Cement on the tace of valve cover and top side
of gasket. Put 5P3931 Anti-Seize Compoll'ld on ali threads.
Tighten bolts by number sequence shown to ...... 11 ± 3 N•m (1) Torque for nuts that hold exhaust manifold .. 47 ±9 N•m
(96 ± 27 lb in) (35 ± 7 lb ft)
(2) Torqueforstuds ........................ 27± 4N•m (20±3lbft)

••
33068 Gen Set Engine 17 Specifications
Turbochargers

•
NOTICE
The impeller shaft nut is a left hand thread (CCW).

S38
(5) lnstall the compressor wheel (at room temperature) as
follows:
a. Put compressor wheel on the shaft.
b. Put a small amount of clean engine oil on the threads.
c. Tighten the nut (CCW) to 14 to 17 N•m (125 to 150 lb
in).
d. Remove nut from shaft and apply 6V1541 Quick Cure
Primer on the threads of the shaft and nut followed by
application of 9S3263 Retaining Compound.
e. Loosen nut and tighten again to 9 ± 2 N•m (80 ±
18 lb in) plus an additional 60 ± 5 degrees.

NOTICE
Do not bend or add stress to the shaft when nut is loosened
or tightened.

(6) Thickness of each thrust ring ...... ...... .. 2.553 ± 0.013 mm

(1) End play for shaft (new) ...................... 0.102 ± 0.025 mm (.1005 ± .0005 in)
(.004 ± .001 in)
Maximum permissible end play (worn) .. ............ 0.20 mm (7) Bore in housing (new) ..................... 20.744 to 20.757 mm
(.008 in) (.8167 ± .8172 in)
Outside diameter of the bearing
(2) Thickness of thrust bearing (where thrust rings contact (new) .................. 20.630 to 20.643 mm (.8122 to .8127 in)
bearing) ......................... 5.36 ± 0.03 mm (.211 ± .001 in) Maximum permissible clearance between bearing and

•
(3) Oiameter of shaft (new) ................... 12.697to12.705 mm bore in housing (worn) ......................... 0.15 mm (.006 in)
(.4999 to .5002 in) Torque for tour nuts (put 5P3931 Anti-Seize Compound on
Bore in bearing (new) ...................... 12.741to12.748 mm threads) and bolts that hold turbocharger to exhaust
(.5016 to .5019 in) manifold ............................................ 55 ± 5 N•m (40 ± 4 lb ft)
Maximum permissible clearance between bearing and
shaft (worn) .......................................... 0.05 mm (.002 in) lnstall the band clamps to hold the cartridge to the
compressor housing as follows:
(4) Maximum permissible gap of oil seal ring, measured in a. Tighten clamps to ............ 14±1 N•m (125 ± 10 lb in)
bore of housing .................................... 0.25 mm (.010 in) b. Tap (hit) clamp lightly all around.
c. Tighten again to ............. 14±1 N•m (125±10 lb in)
NOTE: Put clean engine oil in the oil inlet of the turbocharger
after assembly or before installation to provide start up
lubrication and/or storage protection.

33068 Gen Set Engine Specifications

 S4D (7) Bore in housing (new) ..................... 24.994 to 25.006 mm

•
(.9840 to .9845 in)
Outside diameter of the bearing
(new) .................. 24.882 to 24.892 mm (.9796 to .9800 in)
2 3 4 Maximum permissible clearance between bearing and
bore in housing (wom) ......................... 0.15 mm (.006 in)
Tighten both band clamps (that hokl the compressor and
turbine housings to the cartridge group) with the procedure
that follows:
a. Tighten to ........................ 14±1 N•m (125 ± 10 lb in)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ............... 14±1 N• m (125 ± 10 lb in)

NOTI CE
Do not over tighten the clamps.
C3o&711P1

Torque for four nuts (put 5P3931 Anti·Seize Compound on

threads) and bolts that hold the turbocharger to the exhaust
(1) Endplayforshaft(new) ...................... 0.114±0.038mm manifold ............................................ 55 ± 5 N•m (40 ± 4 lb ft)
(.0045 ± .CX:>15 in)
NOTE: Put clean engine oil in the oil inlet of the turbocharger
Maximum permissible end play (worn) .............. 0.20 mm
(.008 in) after assembly or before installation to provide start up
lubrication and/or storage protection.
(2) Thickness of thrust bearing (where thrust rings contact
bearing) ......................... 5.36 ± 0.03 mm (.211 ± .001 in)
(3) Diameter of shaft (new) ............ 15.997 mm to 16.005 mm
(.6298 to .6301 in)
Bore in the bearing (new) ................ 16.035to16.043 mm
(.6313 to .6316 in)
Maximum permissible clearance between bearing and
shaft (worn) .......................................... 0.05 mm (.002 in)
(4) Maximum permissible gap of oil seal ring, measured in
bore of housing .................................... 0.25 mm (.010 in)
(5) lnstall the compressor wheel (at room temperature) as
follows:
a. Put compressor wheel on the shaft.
b. Put a small amount of clean engine oil on the threads.
c . Tighten the nut to a torque of ............... 14 to 17 N•m
(125to 1501bin)

NOTICE
Do not bend or add stress to the shatt when nut is loosened
or t ightened.

d . Remove nut from shaft and apply 6V1541 Quick Cure

Primer on the threads of the shaft and nut followed by
application of 9$3265 Retaining Compound.
e. Tighten the nut to a torque of .................... 4 ± 2 N •m
(35 ± 18 lb in)
f . Tighten nut an additional 90 ± 5 degree rotation.
(6) Thickness of each thrust ring ............. . 2.553±0.013 mm
(.1005± .0005in)

33068 Gen Set Engine 19 Specifications

Oil Pump

6 66310P4

-!.
•
33068 Gen Set Eng1ne
. 20 ,.._ :, Specifications
.
•.
 NOTE: On later oíl pumps, the alignment dowel has been
Oil Filter

•
removed .
(1) Bore in bearing of idler gear ............. 28.600 ± 0.048 mm
(1 .1260 ± .0019 in)
Diameter of shaft for the idler gear ... 28.512 ± 0.013 mm
(1 .1225± .0005 in) 1 2
Clearance between bearing and
shaft ....................... 0.028 to 0.150 mm (.0011 to .0059 in)
(2) Clearance between gear and body of
pump ............................. 0.05 to 0.66 mm (.002 to .026 in)
(3) Diameter of shafts for pump ............. 22.217 ± 0.005 mm
(.8747 ± .0002 in)
Bore in bearings for shafts ................ 22.286 ± 0.051 mm
(.877 4 ± .002 in)
(4) Length of gears ................. ............ .. .. 50.808 ± 0.025 mm
(2.0003 ± .001 Oin)
Depth of bore in pump body for
gears .................. 50.935 ± 0.020 mm (2.0053 ± .0008 in)
Clearance between end of gears and pump
body ...................... 0.081 to 0.173 mm (.0032 to .0068 in)
(5) Length of ge.ars ..... ............................ 38.070 ± 0.025 mm
(1.4988 ± .0010 in) Oil cooler bypass valve and oíl filter bypass valve must open
Depth of bore in pump body for at a pressure difference of ........ 172 ± 21 kPa (24.9 ± 3.0 psi)
gears .................. 38.197 ± 0.020 mm (1.5038 ± .0008 in)
Clearance between end of gears and pump (1), (2) 8M3182 Spring for bypass valves:
body ...................... 0.081 to 0.173 mm (.0032 to .0068 in) Length under test force .......................... 63.5 mm (2.5 in)
Test force .................................................... 40 N (8.92 lb)
(6) Torque for bol! that holds drive gear to drive
Free length after test ............................ 91.7 mm (3.61 in)
shatt .... .. ..................................... 47 ± 9 N•m (35 ± 5 lb ft)
Outside diameter .......... .......................... 20.6 mm (.81 in)

•
NOT E: Instan the bearings in the cover and body for the oil
(3) Torque for stud:
pump so the bearing junctions (joints) are in the position
shown. Put 7M7456 Thread Lock Compound on threads to 7.6 ±
1.5 mm (.30 ± .06 in) from the taperlock end of the stud.
Tighten the stud to a torque of ........ 68 ± 7 N•m (50 ± 5 lb ft)

Oil Breather Cap

,-
1
1
1

1
A22037P1

(1) Torque for bolt that holds breather cap .. ...... 14 ± 3 N • m

(10 ± 2 lb tt)

33068 Gen Set Engine 21 Specifications

Engine Oil Pressure
All steps of this procedure must be followed for the pressure 700
(100)
findings to be usable.
1. Be sure that the engine is filled to the correct level with
600
SAE 1OW30 oil. lf any other viscosity of oil is used, the (88)
information in the Engine Oil Pressure Graph does not
apply.
o; 500
.B
2. Remove the oil pressure switch and connect the 1U5470 .., (72)
Engine Pressure Group to the main oil manifold at the Q.
-"
location from which the oil pressure switch was removed. 400
w (58)
3. Aun the engine to get the oil temperature at 99ºC (210ºF) a:
::::l
(/)
NOTE: A 3ºC (5ºF) increase in temperature gives (/)
300
w
approximatefy 7 kPa (1 psi) decrease in engine oil pressure. a: (44)
Q.
.....1
NOTE: Make sure engine oil temperature does not go above
115ºC (239ºF)
o 200
(29)
4. Keep the engine oil temperature constant with the engine
at its rated rpm and read the pressure gauge.
100
(15) NOT ACCEPTABLE
5. On the Engine Oil Pressure Graph, find the point that the
lines for engine rpm and oil pressure intersect (connect).
400 800 1200 1600 2000 2400

ENGINE RPM

C27341P1

6. lf the results do not fall within the "ACCEPTABLE"

pressure range given in the graph, find the cause and
correct it. Engine failure or a reduction in engine lite can
be the result if engine operation is continued with oil
manifold pressure outside this range.
NOTE: A record of engine oil pressure, kept at regular
intervals, can be used as an indication of possible engine
problems or damage. lf there is a sudden increase or
decrease of 70 kPa (10 psi) in oil pressure, even though the
pressure is in the "ACCEPTABLE" range on the graph, the
engine should be inspected and the problem corrected.

·33068 Gen Set Engine 22 Specifications

 Water Pump

•
5

(1) Oíl seal. Do not lubricate the seal lip. Assemble with the
tip toward the water pump drive.
(2) Water seat and rit'!Q:
a. Pul water on the seal.
b. Use the 7N7843 Seal lnstaltation Tool to install the
seal and ring together in the housing bore, with the
shiny lace of the oeramic ring toward the carbon seal.
(3) Seal assembly:
a. Remove the spring from the sea!.
b. Put clean water inside the seal assembly.
c. Use the 7N7843 Seal lnstallation Tool and hand
pressure to install the seal assembly on the shaft until
the carbon laoe makes light contact with the shiny
lace of ceramic ring.
d. lnstall the spring.
(4) Torque lor bolt thal holds the impeller .... 32.0± 1.5 N•m
(24 ± 1 lb ft)
(5) Torque lor bolt that holds the gear ............... 97 ± 7 N•m
(72±5 lb ft)

33068 Gen Set Engine 23 Specifications

Belt Tension Chart

BELT
S IZE
WIDTH
BELT TOP
BELT TENSION CHART
BELT TE NS ION
GAUGE READING
BELT TENS ION
BORROUGHS GAUGE NUMBERS
OLD NEW
•
"INITIAL"• "USED"** GAUGE NUMBER GAUGE NUMB ER
MM IN N LB N LB
3/8 10.72 0.422 445 ± 22 100 ± 5 400 ± 22 90 ± 10 BT-33-95 BT-33-97
1/2 13.89 0.547 53 4 ± 22 120 ± 5 400 ± 44 90 ± 10 BT-33-95 BT-33-97
5V 15.88 0 .626 534 ± 22 120 ± 5 400 ± 44 90 ± 10 BT-33-72 BT-33-72C
11/16 17.48 0.688 534 ± 22 120 ± 5 400 ± 44 90 ± 10 BT-33-72 BT-33-72C
3/4 19.05 0.750 534 ± 22 120 ± 5 400 ± 44 90 ± 10 BT-33-72 BT-33-72C
15/16 23.83 0.983 534 ± 22 120 ± 5 400 ± 44 90 ± 10 BT-33-72 BT-33- 77
8K 27.92 1.099 800 ± 22 180 ± 5 489 ± 44 110 ± 10 ------- BT - 33-109
6PK 20.94 0.824 667 ± 22 150 ± 5 467 ± 44 105 ± 10 -- ----- BT-33-109
. I

ME ASURE TE NSION OF BELT FARTHEST FROM ENGINE

• BELT TENSION " I NITIAL" is for o new bel t.

•• BELT TENSION "USED" is for o belt with o ver

30 minutes of oper o tion ot roted speed. 001599

Water Temperature Regulator Cylinder Block

'
2

3
4

5
026791 _L o
C24041P1

Temperature when completely open ................... 91°Q (196ºF) (1) Thickness of spacer plate ..... .............. 9.970 ± 0.025 mm
(.3925 ± .0010 in)
Mínimum completely open distance .............. 9.5 mm (.374 in)
Thickness of spacer plate gasket ....... 0.196 ± 0.025 mm
(.0077 ± .0010 in)
NOTE: Refer to Cylinder Liner Projection in Systems
Operation, Testing & Adjusting to find height of cylinder liner
over top of spacer plate.

33068 Gen Set Engine 24 Specificatioos

'
 (2) Camshaft bearing bore (installed) ......... 58.80 ± 0.06 mm

•
(2.315 ± .002 in)
Bore in block for camshaft 11
bearings ............. 65.100 ± 0.025 mm (2.5630 ± .001 O in)
(3) Bore in block for main bearings (standard
size) ................... 96.926 ± 0.013 mm (3.8160 ± .0005 in)
Bore in block for main bearings 0.51 mm (.020 in)
o o
oversize ............. 97.436±0.013mm (3.8361 ±.0005in)
(4) Dimension from center of main bearing bore to top of ~o @

cylinder block (new) ........................ 383.515 ± 0.165 mm

(15.099 ± .0064 in)
o
(5) Dimension from center of main bearing bore to bottom of
cylinder block (new) ............................ 153.99 ± 0.1 Omm
(6.063 ± .004 in)
C2-4042P1
(6) Torque for bolts holding bearing caps for main bearings:
a. Put 6V4876 Thread Lubricant on threads and washer
face.
b. Tighten all bolts to ............... 41 ±4 N•m (30±31bft) (9) Distance two dowels extend from the surface of the
c. Put a mark on each bott and cap. cylinder block ...................... 19.8 ± 0.5 mm (.78 ± .02 in)
d. Tighten ali bolts from mark ,.......... ...... 90 ± 5 degrees (10) Distance hollow dowel extends from the surface of the
NOTE: lnstall bearing caps with the part number toward the cylinder block ..... .......... .. ..... 16.0 ± 0.5 mm (.63 ± .02 in)
front of the engine. Be sure that the mark (number) on the (11) Depth to instan two dowels below the surtace of the
bearing cap next to the bolt hole is in agreement with the cylinder block (apply 6V6640 Sealant) ....... 1.0 ± 0.5 mm
mark in the cylinder block. (.04 ± .02 in)
(7) Clearance between main bearing cap and cylinder (12) Distance dowels extend from the front face of the
block .............. ....... 0.033 mm (.0013 in) tight to 0.043 mm cylinder block ...................... 22.4 ± 0.5 mm (.88 ± .02 in)
(.0017 in) loose
(13) Distance stud extends from the front tace of the cylinder
Main bearing cap width .................. 165.095 ± 0.020 mm
block .................................... 15.7 ± 0.5 mm (.62 ± .02 in)

•
(6.4998 ± .0008 in)
Width of cylinder block for main bearing (14) Distance two dowels extend from the rear face of the
cap ..... ......... ... . 165.100 ± 0.018 mm (6.5000 ± .0007 in) cytinder block ...................... 12.7 ± 0.5 mm (.50 ± .02 in)

C24040P1

(8) Piston cooling orifice. Check piston cooling jets by passing a 2.29 mm (.090 in)
diameter drill rod thru jet anda 12.7 mm (.50 in) circle located
at J. Dimensions for location J are:
NOTICE (A) 49.8 mm (1.96 in)
There are holes in the bores for the main bearings, between
the cylinders for piston cooling orífices. These holes must (B) 12.7 mm (.50 in)
have orífices (8) installed. (C) 108.0 mm (4.25 in)

33068 Gen Set Engine 25

 I

Camshaft Bearings Cylinder Liner

u o o ·uuo
º~~~ 3

,, 11 . • , 11" n r nr·
. .. - -- ·- · - ·--1 --~

T88321-1P1

A31973-1P1

NOTE: Make reference to Guideline for Reusable Parts;

Pistons and Cylinder Liners, SEBF8049 and SEBF8068.
Depth to install camshaft bearings:
(1) Bore in liner (new) ........................... 120.675±0.025mm
Dimensíon A ............... .................. 0.5 ± 0.5 mm (.02 ± .02 in) (4.7509 ± .0010 in)
Dimension B ................. .......... 154.0 ± 0.5 mm (6.06 ± .02 in) Use again maximum bore when measured near upper
end of the wear surface of the cylinder
Dímension e .. ······. .... .. .......... 303.2 ± 0.5 mm (11.94 ± .02 in) liner ................................................. 120.78 mm (4.755 in)
Dimension D ......................... 601 .7 ± 0.5 mm (23.69 ± .02 in) (2) Thickness of flange on liner .............. 10.282 ± 0.020 mm
Dímension E ......................... 903.4 ± 0.5 mm (35.57 ± .02 in) (.4048 ± .0008 in)
NOTE: The camshaft bearing at the front of the block must (3) Filler band.
be installed with oíl holes in a horizontal position and joint at
top within ± 15 degrees from vertical.
Cylinder Liner lnstallation
Put liquid soap on bottom liner bore in block, on grooves in
lower liner, and on 0-rings. lnstall 0-rings on liner. Put filler
band (3) in engine oíl for a moment and install on liner.
lmmediately install liner in cylinder block (before expansion of
filler band).

'I

33068 Gen Set Engine 26 Specifications

 Connecting Rod Pistons And Rings

• Make reference to Guideline For Reusable Parts; Pistons,

SEBF8049; Cylinder Liners, SEBF8068; and Piston Pins And
Retaining Rings, SEBF8051.

B89946P1

B9139Pl 4

(1) Bere in bearing fer pisten pin

(new) ............ 43.2105 ±0.0076 mm (1.70120 ± .0003 in)
Diameter ef pisten pin (new) ............. 43.175 ± 0.005 mm
(1.6998 ± .0002 in)
Maximum permissible clearance between bearing and
(1) Top piston ring. See the Piston And Piston Rings chart.
pisten pin (wern) .................... ............. . 0.08 mm (.003 in)
(2) lntermediate pisten ring. See the Piston And Piston Rings
(2) Bere in connecting rod for bearing ... 82.550 ± 0.013 mm
chart.
(3.2500 ± .0005 in)

•
(3) Oíl control ring. See the Piston And Piston Rings chart.
(3) Distance between center ef piston pin and center of
crankshaft bearing (new) .................... 243.71 ± 0.03 mm (4) Bore in pisten for pin ......................... 43.195 ± 0.008 mm
(9.595 ± .001 in) (1.7006 ± .0003 in)
(4) Torque en nut for connecting rod: Clearance between pin and bore in
piston ..................... 0.008 to p .033 mm (.0003 to .0013 in)
a. Put 6V4876 Thread Lubricant on threads and nut
Maximum permissible clearance (wern) ..... .... .. . 0.05 mm
seat.
(.002 in)
b. Tighten both nuts to .......... .. 40 ± 4 N•m (30 ± 3 lb ft)
Pin diameter ...... 43.175 ± 0.005 mm (1.6998 ± .0002 in)
c. Mark each nut and end of bolt.
d. T.ighten both nuts (from mark) ............ 90 ± 5 degrees NOTE: When installed in the engine. the ·v· mark en top of
lnstall the connecting rod in the piston with the slot for the
the piston must be in alignment with the ·v· mark on the
cylinder block.
bearing tab on the same side as the ·v·
mark en the piston.
Make reference to Special lnstructions, GMG02394 and
SMHS7366 for information about checking and reconditiening
connecting rods. Also see Guideline Fer Reusable Part~ ,
Salvage of Nen-Serrated Connecting Rods, SEBF8064. \

33068 Gen Set Engine 27 Specifications

 PISTON ANO PISTON RINGS
(1) Top Ring (2) lntennediate Ring (3) Oil Control Ring
Width of groove in pistan for pistan 3.188 ± 0.013 mm
ring (new). 3 3 (.1255 ± .0005 in)
3.137 ± 0 .013 mm
Thíckness of pistan ring (new). 3 3 (.1235 ± .0005 in)
Clearance between groove and pistan 0.051 ± 0 .025 mm
ring (new). 3 3 (.0020 ± .0010 in)
0.15mm
Maximum permissible clearance (worn). 3 3 (.006 in)
Clearance between eods of pistan ring 0 .622 ± 0.191 mm 0.622 ± 0.191 mm 0.572 ± 0.191 mm
when installed in a cylinder liner with a (.0245 ± .0075 in) (.0245 ± .0075 in) (.0225 ± .0075 in)
bore size of 120.650 mm (4.7500 in).
lncrease in ciearance between eods of O.OS mm
pistan ring for each 0.03 (.001 in) (.003 in)
increase in cylinder liner bore size.
1 lnstall piston ring with "UP" side toward the top of the pistan. The 2W1707 Top Pistan Ring has the mark "UP-1". The 2W1708
lntermediate Pistan Ring has the mark "UP-2". ·
2 1nstall the 7E6047 Oíl Control Ring with the gap in the spring 180 degrees away frorn the gap in the ring.
3 "Keystone• style piston rings and grooves in the pistan. The 1 U6431 Keystone Pistan Ring Groove Gauge is necessaty' for measuring
these grooves. For correct use of the gauge group, see the instruction card that is supplied with the gauge group.

l ...
• I~

33068 Gen Set Engine 28 Specifications

 Crankshaft

• 2 3

C43103P1
1

(1) Thickness of thrust plates (new) ......... 5.461 ± 0.038 mm lnstall front and rear seal groups as follows:
(.2150 ± .0015 in) a. Clean the oute< surface of the crankshaft with 6V1541
(2) Diameter of the main bearing journals Quick Cure Primer.
(new) .................. 88.880 ± 0.020 mm (3.4992 ± .0008 in) b. Crankshaft seals must be installed with the lip of the
seal toward the inside of the engine as shown. Make
(3) Diameter of the connecting rod journals sure the correct seal is installed on each end of the
(new) .................. 76.180 ± 0.020 mm (2.9992 ± .0008 in) crankshaft.
(4) Tighten plug~ to a torque of ...... 23 ± 4 N•m (17 ± 3 lb ft) NOTE: No lubrication is needed to install wear sleeves and
Then •stake" the crankshaft to hold plugs in place. seals.
"STAKE" use a center punch and a hammer to change c. Do not separate seals from sleeves. Instan the seal
the shape of the holes as shown. groups as a unit on each end of the engine as shown
(5) Crankshaft gear: with the correct tools.
Do not heat gear to more than .................. 316ºC (600ºF) NOTE: See Special lnstruction SMHS7100 for front seal
assembly installation and SMHS8508 for rear seal assembly
(6) End play for crankshaft (new) ............. 0.122 to 0.579 mm
installation procedures.
(.0048 to .0228 in)
(7) Wear sleeve and seal installation:
Remove front and rear seal groups as follows:
NOTE: Seals and wear sleeves cannot be used again, after
the seals and wear sleeves are separated.
a. Use the 1U7600 Puller Group to remove the seals.
b. Use the 5P7318 Distorter Group to remove the wear
sleeves.

33068 Gen Set Engine 29

Bearing Surface (Journal) For Bearing Surface (Journal) For
Main Bearings Connecting Rods

A A

· .~
-1- - ·1 -- i-

2 3

B6985P2 5 B6985P1

(A) Oistance from the centerline of the main bearing (A) Measurement ....... ......... .................... 6.045 mm (.2380 in)
journal ............................................. 14.262 mm (.5615 in)
(B) Measurement .................................... 6.045 mm (.2380 in)
(B) Dimension from line (A) ................ 28.524 mm (1.1230 in)
(1) Diameter of the connecting rod journals
(1) Diameter of the main bearing journal at (A) and (B) (new) .................. 76.180 ± 0.020 mm (2.9992 ± .0008 in)
(new) .................. 88.880 ± 0.020 mm (3.4992 ± .0008 in) Difference in diameter at (A) and (B) must not be more
Oifference in the diameter at (A) and (B) must not be than .................................................. 0.015 mm (.0006 in)
more than ......................................... 0.015 mm (.0006 in)
(2) Radius ............................ 4.74±0.20mm(.187± .008in)
(2) Radius-Rear journaJ ....... 4.74 ± 0.20 mm (.187 ± .008 in)
NOT E: Radius must blend smoothly (have no sharp edges)
(3) Radius-All others (minimum) ................... 4.74 ± 0.20 mm with the machined surfaces of the journals.
(.187 ± .008 in)
(3) Widt~ of journals ... 47.668 ± 0.140 mm (1 .877 ± .006 in)
NOTE: Radius must blend smoothly (have no sharp edges)
with the machined surfaces of the journals.
(4) Width of rear journal ... .......... 40.475 + 0.140- 0.064 mm
(1 .594 + .006 - .003 in)
(5) Width of ali journals except rear (maximum) ... 45.16 mm
(1.78in)

33068 Gen Set Engine 30 Specifications

 Connecting Rod and Main Timing Gear Cover
• Bearings
Make reference to Guidelines for Reusable Parts: Main
Bearings and Connecting Rods. SEBF8009; and Crankshaft
Measurement, SEBF8041

Connecting Rod Bearings

Diameter of crankshaft journal (bearing surface)
for connecting rod
Original Size 76.180 ± 0.020 mm
Journal (2.9992 ± .0008 in)
Undersize Joumal 75.926 ± 0.020 mm
0.25 rrm (.010 in) (2.9892 ± .0008 in)
Undefsize Journa1 75.672 ± 0.020 mm
0.51 mm (.020in) (2.9792 ± .0008 in)
Undersize Jot.ma1 75.418 ± 0.020 mm
O.76 mm (Jl30 in) (2.9692 ± .0008 in)
1
Clearance bernee ~ a:x: arna.i
(new) ····- :...::-O xi O ~sa~ .0025U>.CXE6S\)
Maxinun oe:r zssile :::aeara.-x:e DelWeeP oeamg and
journal ... -··· .... 025 mm (.010 in)
(1) Torque for nuts that hold cover tor tuel pump drive
gear ........................................... 27 ± 7 N•m (20±5 lb ft)

• Diamatu ol aenbhatt journal (bearing surface)

OriQina' Size
Joumal
tor main bearings

Under size JoornaJ

88.880 ± 0.020 mm
(3.4992 ± .0008 in)
88.626 ± 0.020 mm
(A) Tighten two bolts to a torque of .................... 23 ± 4 N•m

Engine Front Support

(17 ±3 lb ft)

0.25 mm (.010 in) (3.4892 ± .0008 in)

Undersize Joumal 88.372 ± 0.020 mm
0.51 mm (.020 in) (3.4792 ± .0008 in)
Undersize Journal 88.118 ± 0.020 mm
0.76 mm (.030 in) (3.4692 ± .0008 in)

Clearance between bearing and journal

(new) ............................. 0.076 to 0.165 mm (.0030 to .0065 in)
Maximum permissible clearance between bearing and
journal ..................................... .............. ....... . 0.25 mm (.010 in)

043705

(1) Torque for (~in) bolts ...... 135 ± 20 N• m (100±15 lb ft)

•
(2) Torque for (%in) bolts ............ 55±10 N•m (40 ± 7 lb ft)

33068 Gen Set Engine 31 Specifications

Flywheel Flywheel Housing

040121
Ct&t93Pt

(1) Aing gear. Tighten flywheel housing bolts in number sequence

to .............. .................................. 105 ± 20 N•m (75±15 lb ft)
NOTE: Do not heat ring gear to more than 320ºC (608ºF)
before installing on the flywheel. (A) Timing bolt hole.
(2) Torque for flywheel bolts ... 215 ± 40 N•m (160± 30 lb ft) NOTE: Refer to Aywheel Housing Runout and Flywheel
Housing Bore in Systems Operation, Testing & Adjusting for
NOTE: Refer to Flywheel Runout in Systems Operation,'
the correct methods of flywheel housing inspection.
Testing & Adjusting for the correct method of flywheel
inspection.

33068 Gen Set Engine 32 Specifications

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