Service Manual

Caterpillar
Service Manual
D353
Engine
S/n 46B3984 & Up
47B2731 & Up

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CT-S-ENG D353
D3531NDUST I L D
MARINE ENGI ES
SERIAL NUMBERS
46B3984-UP
47B2731-UP

SPECIFICATIONS - - - - - - - - - - . . . . . : . . . . . . .

SYSTEMS OPERATION - - - - - - - - -..........-

TESTING AND ADJUSTING ---~-------

ATTACHMENT SPECIFICATIONS --~--------

ATTACHMENTS --~--------

GENERAL INSTRUCTIONS (D & AJ - - - - - - - - - - -

DISASSEMBLY AND ASSEMBLY - - - - - - - - - - -

Undustrial Engine 46B3984-UPl

7231 MARINE TRANSMISSION - - - - - - - - - - - - - -

MG-521 MARINE TRANSMISSION ---~---..........~~~

0353 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS

INTRODUCTION

The specifications given in this book are on the When the word "permissible" is in the description,
basis of information available at the time the book the specification given is the "maximum or mini-
was written. These specifications give the torques, mum" tolerance permitted before adjustment,
operating pressure, measurements of new parts, repair and/or new parts are needed.
adjustments and other items that will affect the A comparison can be made between the measure-
service of the product. ments of a worn part, and the specifications of a
When the words "use again" are in the description, new part to find the amount of wear. A part that is
the specification given can be used to determine if worn can be safe to use if an estimate of the re-
a part can be used again. If the part is equal to or mainder of its service life is good. If a short service
within the specification given, use the part again. life is expected, replace the part.
NOTE: The specifications given for "use again" and "permissible" are in-
tended for guidance only and Caterpillar Tractor Co. hereby expressly denies
and excludes any representation, warranty or implied warranty of the reuse
of any component. 77200X1

INDEX
I
Accessory Drive Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Hydraulic Alr·Fuel Ratio Control ........................ 11
Alternator .......................................... 35
Alternator Regulators ................................. 35 Manifold ........................................... 14

Camshaft and Timing Gears ............................ 6 Oil Cooler and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19

Connecting Rod ..................................... 25 Oil Pump ........................................... 18
Crankshaft ......................................... 28 Oil Pump, Drive for the ................................ 18
Cylinder Block (with Spacer Plate) ....................... 21
Cylinder Block (without Spacer Plate) .................... 22 Piston and Rings .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27
Cylinder Head (for Engines with Spacer Plate) .............. 12 Pressure Cap for the Cooling System. . . . . . . . . . . . . . . . . . . . .. 20
Cylinder Head (for Engines without Spacer Plate) ........... 13 Primary Fuel Filter ................................... 11
Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23
Cylinder Liner Projection (with Spacer Plate) ............... 23 Regulator For Water Temperature ....................... 20
Cylinder Liner Projection (without Spacer Plate) ............ 24
Service Meter ....................................... 9
F1ywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Shut·off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35
F1ywheel Runout .................................... 31 Starter Solenoid ..............•...................... 34
F1ywheel Housing .................................... 30 Starting Motor ...................................... 34
Flywheel Housing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33
Flywheel Housing Runout ............................. 32 Turbocharger ....................................... 17
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Turbocharger Lubrication Valve ......................... 19
Fuel Injection Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
Fuel Pump and Governor Drive. . . . . . . . . . . . . . . . . . . . . . . . .. 5 Valves ............................................. 14
Fuel Transfer Pump .................................. 5 Valve Rocker Arms and Lifters .......................... 16
Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
Gear Group (Camshaft Idler and Power Take·Off Idler) ....... 7
Glow Plug Positioning ................................. 13 Water Pump ........................................ 20
Governor (Earlier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
Governor (Later) ..................................... 10

3·
D353 INDUSTRIAL & MARINE ErJmNES SPECI FICA nONS

FUel INJECTION EIlUIPMENT

Firing order (injection sequence) .................. 1,5,3,6, 2,4

Injection timing before TC (top center! ..... . . . . . . . . . . .. 12 ± 1°

(1) Length of pump
plunger ........... 2.9834 ± .0015 in. (75.778 ± 0.038 mm)

Minimum permissible length ......... 2.9769 in. (75.613 mm)

(2) Timing dimension for the fuel injection pumps:

On engine (piston at
top center! . . . . . . . . . . . .. 2.090 ± .002 in. (53.09 ± 0.05 mm)

Off engine ......... 2.1565 ± .0005 in. (54.775 ± 0.013 mm)

(3) Torque for bolt* ............... 32 ± 5 lb. ft. (43 ± 7 N·m)

'Put 8H5137 Sealer on bolt threads.

(4) Diameter of the

fuel rack . . . . . . . . . . . .6095:1: .0005 in. (15.481 ± 0.012 mm)

Bore in bearing for

the rack . . . . . . . . . . . . .6125 ± .0015 in. (15.558 ± 0.038 mm)

Maximum permissible clearance between bore

in the bearings and the rack . . . . . . . . . . . . . . . 006 in. (0.15 mm)

(5) 3S1252 Spring:

Length under test force ................. 1.73 in. (43.9 mm)

Test force ...................... 19 to 21 lb. (85 to 95 N)

Free length after tast ................... 1.98 in. (50.3 mm)

Outside diameter ...................... 1.'14 in. (29.0 mm)

(6) Bore in bearings for
.--'_---10
the camshaft ....... 2.4455 ± .0005 in. (62.116 ± 0.013 mm)

Diameter of bearing surface (journal) of

the camshaft ....... 2.4425 ± .0005 in. (62.040 ± 0.013 mm)

Maximurn permissibie clearance between bearing

and bearing surface (journal) of camshaft . . . . 006 in. (0.15 mm)
12
(7) Torque for nut for camshaft 35 to 45 lb. ft. (45 to 60 N'm)

(8) Torque for nut that holds

fuel lines ..................... 30 ± 5 lb. ft. (40 ± 7 N·m)

(9) Torque for nuts that

hold nozzles. . . . . . . . . . . . . . . .. 105 ± 5 lb. ft. (142 ± 7 N'm)
(10) Body.
826lJX3 13

(11) Torque for glow plugs 9± llb.ft.(12± 1 N·m)

(12) Tighten nozzie finger tight in body.

(13) Torque for precombustion chamber (Apply 9M3710 Anti-Seize

Compound on threads) ...... 225 ± 15 lb. ft. (300 ± 20 N·m)

NOTE: See Glow Plug Positioning.

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

4 PAGE OF SPECIFiCATiONS FOR GENERAL TIGHTENING TORQUES
0353 INDUSTRIAL & MARINE ENGINES SPECI FICA TlONS

GOVERNOR
(EARLIER)

(1) Bore in spring retainer

bearing. . . . . . . . . . . . . . . . .. .747 ± .001 in. (18.97 ± 0.03 mm)
Diameter of bearing
surface ...................741 ± .001 in. (18.82 ± 0.03 mm)
(2) 9F7651 Spring for governor:
Put force on spring of ...................... 251b. (110 N)
Then add more force to make
spring shorter by .......................625 in. (15.88 mm)
Total test force ............. 115.6 ± 2.5 lb. (514.5 ± 11.0 N)
Free length after test .................. 2.625 in. (66.68 mm)
Outside diameter ..................... 2.121 in. (53.87 mml
(21 1 H5646 Spring for governor (3% Regulation at 1000 rpml:
Put force on spring of ...................... 25 lb. (110 N I
Then add more force to make
spring shorter by .......................625 in. (15.88 mm)
Total test force ........... 76.9 to 79.4 lb. (341.5 to 353.0 Nl
Free length after test .................... 2.75 in. (69.9 mml
Outside diameter .................... , 2.086 in. (52.98 mml
(21 4H7390 Spring for governor (3% Regulation at 1200 rpml:
Put force on spring of ...................... 25 lb. (110 N)
Then add more force to make
spring shorter by .......................625 in. (15.88 mml
Total test force ............. 95.2 ± 1.70 lb. (423.0 ± 7.55 Nl
Free length after test .................. 2.689 in. (68.30 mm)
Outside diameter ..................... 2.099 in. (53.31 mm)
(2) 9F7653 Spring for governor (10% Regulation at 1200 to 1250
rpm)

Put force on spring of ...................... 25 lb. (110 N) (3) Diameter of shaft for
Then add more force to make rack lever. . . . . . . . . . .. .5003 ± .0002 in. (12.708 ± 0.005 mm)
spring shorter by .......................625 in. (15.88 mml Bore in bearing for shaft
for rack lever . . . . . . . . . .5040 ± .0005 in. (12.802 ± 0.013 mml
Total test force ............ 101.2 to 105 lb. (450.3 to 467 N)
Bore in bearing for shaft in opposite side
Free length after test. . . . . . . . .. 2.75 ± .03 in. (69.9 ± 0.8 mml
of rack lever. . . . . . . . .. .5027 ± .0003 in. (12.769 ± 0.008 mm)
Outside diameter ..................... 2.106 in. (53.49 mml
(4) Diameter of upper bearing surface
(2) 9F7650 Spring for governor: of spindle ......... '" .4918 ± .0002 in. (12.492 ± 0.005 mml
Put force on spring of ...................... 25 lb. (110 N) (51 Diameter of the pins for the
weights and rollers. . . .. .3126 to .3129 in. (7.940 to 7.948 mml
Then add more force to make
spring shorter by .......................625 in. (15.88 mm) Diameter of rollers for
the weights ............ .748 to .750 in. (19.00 to 19.05 mm)
Total test force ......... 128.7 to 133.7 lb. (572.5 to 595.5 N)
(61 Diameter of spindle bearing surface for
Free length after test ...........•.......• 2.72 in. (69.1 mm) the lower bearing. . . . .. .7493 ± .0003 in. (19.032 ± 0.008 mml
Outsid3 diameter . . . . . . . . . . . . . . . . . . . .. 2.160 in. (54.86 mm) Bore in lower bearing . . . . 7507 ± .0003 in. (19.068 ± 0.008 mml

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

8 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
D353 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS

GOVERNOR
(LATER)

(1) Torque for nut. . . . . .. . . . . . . . . . .. 9 ± 3 lb. ft. (12 ± 4 N·m)

(2) Torque for nut .............. , 40 ± 5 lb. in. (4.5 ± 0.6 N·m)

(3) 9L6422 Spring for collar guide:

Length under test force ................ .430 in. (10.92 mm)
Testforce .................... 35± .03Ib.(1.55± 0.11 N)

Free length after test ................... 1.12 in. (28.4 mm)

Outside diameter .......................370 in. (9.40 mm)

(4) Torque for plug. . . . . . . . . . . . . . .. 27 ± 5 lb. ft. (38 ± 7 N·m)

7M7244 Spring for speed limiter:

Length under test force .................. .49 in. (12.4 mm)
Test force ................... 1.48 ± .14 lb. (6.6 ± 0.62 N)

Free length after test ................... 2.00 in. (50.8 mm)

Outside diameter ......................507 in. (12.88 mm)

(5) NOTE: 2P9556 Washer must be assembled between the two wave
washers 2N828.
(6) 9L6448 Spring for governor:
Color code is ............... one green and one yellow stripe
Put force on spring of ...................... 6.5 lb. (29 N)

Then add more force to make

spring shorter by ......................900 in. (22.86 mm)
Test force ................... 16.6 ± .30 lb. (74 ± 1.35 N)
Free length after test. . . . . . . .. 2.24 ± .03 in. (56.9 ± 0.8 mm)
Outside diameter. . . . . . .. 1.387 ± .015 in. (35.23 ± 0.38 mm)
(7) 7L8696 Spring for bypass valve:
Length under test force ................. 1.13 in. (28.7 mm)
Testforce .... " .............. 7.22± .4 lb. (32.1 ± 1.8N)

Free length after test ..... 1.370 ± .010 in. (34.80 ± 0.25 mm)
Outside diameter ....................... 290 in. (7.37 mm)

(8) 9M6303 Spring:

Length under test force .................. 180 in. (4.57 mm)
Test force ..................... 10.0 ± .5 lb. (45 ± 2.2 N)

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

Outside diameter ..................... .480 in. (12.19 mm)
(12) 7 L8695 Spring for link:
(9) Outside diameter
of bearing .......... .8110 ± .0003 in. (20.599 ±0.008 mm) Length under test force . . . . . . . . . . . . . . . .. 1.50 in. (38.1 mm)

Inside diameter Test force .................. 9.02 ± .45 Ibs. (40.1 ± 2.0 N)
of gear ............. _.8130 ± .0005 in. (20.650 ± 0.013 mm)
Free length after test .................. ' 2.32 in. (58.9 mm)
(10) Height of gears ....... , .2500 ± .0003 in. (6.350 ± 0.008 mm)
Outside diameter ....................... .46 in. (11.7 mm)
Depth of counterbore .. .2515 ± .0003 in. (6.388 ± 0.008 mm)
(13) Outside diameter
(11) Outside diameter of pin .6235 ± .0005 in. (15.837 ± 0.013 mm) of shaft . . . . . . . . . . . . .6860 ± .0005 in. (17.424 ± 0.013 mm)

Diameter of bore .6255 ± .0005 in. (15.888 ± 0.013 mm) Diameter of bore. . . .. .6880 ± .0005 in. (17.475 ± 0.013 mm)

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

10 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
0353 INDUSTRIAL & MARINE ENGINES SPECI F ICATIONS

PRIMARY FUel FILTER

(1) Tighten nut to ....... ... ... .. ... 18 ± 31b. ft. (24 ± 4 N·m)
(2) 7S9323 Spring:
2
Length under test force ....•............. 1.10 in. (27.9 mm)
Test force ....•.•..•.......• 27.7 to 32.3 lb. (123 to 144 N)
Free length after test . . . . . . . . . . . . . . . . . . .. 1.68 in. (42.7 mm)
Outside diameter . . . . . . . . . . . . . . . . . . . . .. .682 in. (17.32 mm)

HYDRAULIC AIR-FUEL RATIO CONTROL

(1) 6N515 Spring:

Color code. . . . . . . . . . . . . . . . . . . . . . . . . . . .. One yellow stripe
Length under test force .. . ........... 1.81 in. (46.0 mm)

Test force ............. . . ... 6.84 ± .4 lb. (30.5 ± 1.8 N)

Free length after test .................... 2.95 in. (74.9 mm)

Outside diameter .......................810 in. (20.57 mm)
(2) 6N514 Spring:
Color code. . . . . . . . . . . . . . . . . . . . . . . . . . . .. One yellow stripe
Length under test force .................. 1.27 in. (32.3 mm)

Test force ..................... 19.8 ± 2 lb. (88.0 ± 9.0 N)

Free length after test .................... 1.49 in. (37.8 mm)

Outside diameter ..................... 1.788 in. (45.42 mm)

(2) 7N209 Spring:

Color code ............................ Two yellow stripes

Length under test force .................. 1.27 in. (32.3 mm)

Test force ............ ,........ 19.8 ± 2 lb. (88.0 ± 9.0 N)

Free length after test ..... . . . . . . . . . . . . . .. 1.49 in. (37.8 mm)

Outside diameter . . . . . . . . . . . . . . . . . . . .. 1.788 in. (45.42 mm)

88250-IX2 3

(3) 6N513 Spring:

Color code . . . . . . . . . . . . . . . . . . . . . . . . . . . .. One yellow stripe
Length under test force . . . . . . . . . . . . . . . . . .. .55 in. (14.0 mm)
Test force .................... 26.9 ± 21b. (119.5 ± 9.0 N)
Free length after test .................... 1.22 in. (31.0 mm)
Outside diameter ..................... 1.281 in. (32.54 mm)

11