Usage:
The hydra-mechanical shut-off groups can be installed according to group number and serial number, as given in the chart. Each shut-off group has the parts needed for one engine. Only one of the control groups given in the chart will be needed for each engine, and the control group used will be according to the rated speed of the engine. The control group, solenoid valve group and/or air control valve group must be ordered separately because they are not part of the shut-off group.
NOTE: For System Operation and Troubleshooting information for hydra-mechanical shut-off, see Service Manual FORM SEBR0511.
Reconditioning Of Engine Oil Pump And Installation Of The Control Group
(1) Disconnect the engine starting system and shut off the fuel supply.
NOTE: Installation of the hydra-mechanical shut-off group will be made easier if the intake manifold for the right side of the engine is removed.
(2) Some engine oil pumps must have parts removed and new parts installed. See the following four illustrations for the engine serial numbers and parts to be removed:
Remove manifold assembly (1) and shaft (2).
Remove cover assembly (3) and shaft (4).
Remove cover assembly (5) and shaft (6).
Remove plate (7) and cover assembly (8).
(3) Install a new shaft (9) as a replacement for shaft (2), (4) or (6) according to the model and serial numbers that follow:
D379 68B2540 - 68B5182; install a 5N3796 Shaft (9).
D398 66B3561 - 66B4180; install a 5N3796 Shaft (9).
D398 66B4181 - 66B6058; install a 5N3800 Shaft (9).
D399 35B688 - 35B1274; install a 5N3800 Shaft (9).
D399 35B1275 - 35B3634; install a 5N3804 Shaft (9).
(4) For all engines with serial numbers given on illustrations 1, 2 and 3 install 1N9349 Seal (10) (seal lip toward inside of oil pump) in the new 5N3806 Housing Assembly (11). Install housing assembly (11). On all engines not already so equipped, install 5N3810 Gasket (12) and 8N1839 Cover Assembly (13). [Some late model engines already have the 8N1839 Cover Assembly (13).]
NOTE: For D379, 68B3060-68B5182 and D398, 66B4163-66B4180, one additional 7F8698 Bolt and nine 5L6267 Washers are needed to install housing assembly (11). For D379, 68B2540-68B5182, D398, 66B3561-66B6058 and D399, 35B688-35B3634, use the L2070 Bolt and S1590 Bolts with 5M2894 Washers to install cover assembly (13).
(5) Put a 5N3813 Coupling on the end of the oil pump shaft. For D379-68B5183-up, D398, 66B6059-up and D399, 35B3635-up use the 5N3812 Gasket and the former bolts and washers that fastened plate (7) to cover assembly (8) (see step 1, illustration 4), to fasten control group (14) to cover assembly (13). For earlier engines, use nine 5M2894 Washers and one T573 Bolt, four L1143 Bolts and four 1A2029 Bolts, to fasten control group (14) to cover assembly (13).
(6) Remove the three plugs from the rear of cover assembly (13). Remove the 3J5389 Pipe Plug from the oil pan (in front of the oil pressure regulating valve) and install 17003 Connector (15). Install 5N3936 Tube (16) with a 7L2224 Seal, in the rear of cover (13), 5N3814 Tube (17) and 8S9941 Joint Assembly (18).
(7) Remove the 1F7603 Screw and gasket from the front accessory drive, use the 5N4687 and 5N4688 Gasket on each side of ferrule (A), and install 5N1887 Screw (19). Tighten screw (19) to a torque of 35 ± 5 lb.ft. (47 ± 7). Install 307946 Elbow (20) with a 335853 Seal, in cover (13). Install 2N1287 Elbow (21) in screw (19), then install 309386 Hose (22). Use an 8M2773 Clip as shown at location B-B to fasten hose (22).
(8) Install 307950 Elbow (23) with a 3D2824 Seal, in the bottom port of control group (14). Remove the plug from 8N1839 Cover Assembly (13) and install 5N5266 Tube (24) with a 9M4618 Seal into cover (13), and connect it to elbow (23).
(9) Remove two of the bolts that fasten a cylinder block inspection cover, and use two S1591 Bolts with 5M2894 Washers and one 6H7127 Spacer to install 5N2325 Bracket (25).
(10) Install 5P4478 Adapter (26) (view A-A), 16498 Fitting (27) and five 321268 Elbows (28). Connect 5N2368 Hoses (29), (30) and (31), hose (B), 2G7552 Hose (32) and 5N2367 Hose (33) for D398 and D399 [3N4847 Hose (33) for D379] to fittings (27) and (28). [For D379 and D398 Engines, hose (B) is a 5N2368 Hose. For D399 Engines, hose (B) is a 7N3761 Hose.] For D398 Engines, use an S1588 Bolt, 5M2894 Washer and a 6F6405 Spacer with 8M2773 Clip (34) to hold hose (33) as shown. For the correct method to fasten hose (33) in position on D379 and D399 Engines, see the illustrations that follow.
(11) To fasten hose (33) on D379 Engines, use a 3B1915 Bolt, 5M2894 Washer and 6F6405 Spacer with 8M2773 Clip (34) as shown above. For D399 Engines, use an S1571 Bolt, 5M2894 Washer and 6F6405 Spacer with 8M2773 Clip (34) to fasten hose (33) as shown. On all engines, install a 7K4129 Connector (35) on the loose end of hoses (29), (30), (31), (32) and hose (B).
(12) Remove the 9S4185 Plug and 8L2786 Seal from the top of 5N3806 Housing (11), and install 54362 Fitting (36) with a 3K360 Seal and hose (37). [Hose (37) is as follows: D379, 8S1162 Hose; D398 and D399, 5N2367 Hose.]
(13) For D379 and D398 Engines, use an S1588 Bolt, 5M2894 Washer and 6F6405 Spacer with 8M2773 Clip (38) to hold hose (37) in position. For D399 Engines, install hose (37) as shown. Use an 8M2773 Clip (38) with an existing bolt to fasten the hose in position.
NOTE: At time of hose installation, be sure that each hose does not rub (make contact with) other hoses, or other parts of the engine.
(14) Install 5K9235 Elbow (39) and 321268 Elbow (40) in 4L7108 Valve (41). Remove the 3J5389 Plug from tube (42) and install valve (41) as shown. Remove the 5M6213 Plug from breather plate assembly (43) and install 5K9246 Connector (44). For D398 and D399 Engines connect 3N2657 Tube (45) to elbow (39) and connector (44). [For D379 Engines, use a 5N5128 Tube for tube (45).]
(15) Remove the 5M6214 Plug from oil filter housing (46) and install 6L9781 Connector (47). Connect 5N2459 Tube (48) to connector (47) and the connector on hose (28). Connect 5N2460 Tube (49) to elbow (40) and the connector on hose (29).
(16) Remove a bolt from water passage cover (50). Use an S1590 Bolt, 5M2894 Washer and spacer (51) [D379 and D398 Engines use an 8L4852 Spacer; D399 Engines use a 1L5081 Spacer] to hold tube (48).
(17) Use two 9M1974 Washers, two 5M5689 Clamps and a 1D4716 Nut with each 1B7182 Bolt (52), to fasten tubes (48) and (49) together. Use a 1B7182 Bolt, 6H4485 Spacer, 9M1974 Washer and a 1D4716 Nut with 5M5926 Clamp (53) to fasten tubes (48) and (49) to bracket (24).
Installation of Air Shut-off Housings
(1) Install a 7F9504 Plug in the bottom of the housing (1) that will be installed on the intake manifold for the left side of the engine.
(2) Install a 5N3089 Cylinder (2) in each 5N3084 Flange (3), and tighten nut (4). Turn knob (5) so plate (6) in each housing (1) is in the closed position, then use two S1615 Bolts with 5P537 Washers and the 8L3873 Gasket to fasten each flange, with cylinder (2), to each housing. See the illustrations at the top of page 19 so the ports in each cylinder (2) can be put in the correct position for later installation of connecting lines.
(3) Remove the original housings (7) and (8) from the intake manifolds of the engine.
(4) Install the new housing assemblies (1) on the intake manifolds as shown. Use the former bolts with new 4L7890 Gaskets. Install new 5H6733 Seals as needed for elbows (9) and (10). Install 321267 Connectors (11), 6K9194 Elbow (12) and 321268 Elbow (13). Connect air-fuel ratio line (14) to the right manifold housing.
Installation of Rack Shut-off Group
(1) Remove cover (1) and install rack shut-off group (2). Remove plug (3) and install a 6L9781 Adapter in the hole where the plug was removed.
Assembly Of Solenoid Valve To The Diverter Valve - D379 And D398 Engines With Electric Start
Before installation of 5N5756 Diverter Valve (1) on the above engines, assemble the necessary parts to the diverter valve according to the procedure that follows.
For engines that have an electric starting motor on the left side, install parts to diverter valve (1) as follows: 321267 Connector (2) in the IN port; 321268 Elbow (3) in the CYL port; 2N1931 Elbow (4) with 2D7325 Tee (5) in the DR port. Install a 2D7325 Tee (6) with 321268 Elbow (7) and 3B7739 Nipple (8) in the OUT port. Connect valve (9) to nipple (8) so the IN port of the valve connects to nipple (8), then install 5J7303 Elbow (10). Connect 6S2274 Hose (11) to elbow (10) and tee (5) as shown.
For D379 Engines that have an electric starting motor on the right side, install parts to diverter valve (1) as shown: 321267 Connector (2) (IN port); 321268 Elbow (3) (CYL port); 2N1931 Elbow (4) (DR port); 2D7325 Tees (5) and (6); 321268 Elbow (7); 3B7739 Nipple (8); valve (9); 5J7303 Elbow (10); 6S2274 Hose (11); 3D8884 Elbow (12); 6K1972 Elbow (13) and 321267 Connector (14).
For either method of parts installation, use L1143 Bolts with 5M2894 Washers to fasten diverter valve (1) to 5N2345 Plate (15).
NOTE: Engines with air starting have a valve (9) that is different from the one shown for electric start. Wires (A) shown above are for connection to an electrical switch. Installation and connection of either valve in this procedure is the same.
Connection of wires (A) for engines with electric start, is given in the WIRING DIAGRAMS FOR OVERRIDE SWITCH. For engines that have air start, see INSTALLATION OF AIR CONTROL VALVE GROUP.
Assembly Of Solenoid Valve To The Diverter Valve - D379 Engine With Air Starting Motor On Right Side
NOTE: Parts must be installed to the diverter valve as given in the information that follows, for this engine. This same procedure can also be used if desired, for D398 and D399 Engines that have air start.
Parts shown in the illustration are: 6S2274 Hose (1), Valve (2), 5J7303 Elbow (3), 2D7325 Tee (4) (OUT port), 321268 Elbow (5) (CYL port), diverter valve (6), 5N2345 Plate (7), 321267 Connector (8) (IN port), 2N1931 Elbow (9) (DR port), 321267 Connector (10), 2D7325 Tee (11), 3B7739 Nipple (12), 4S6399 Connector (13), 321268 Elbow (14) and 2N1287 Elbow (15). Use L1143 Bolts with 5M2894 Washers to fasten valve (6) to plate (7).
Installation of Low Oil Pressure Override Switch - Engines with Electric Start and Standard Instrument Panel (5N6406 Solenoid Valve Group)
(1) If the instrument panel is on the right side of the engine, remove two bolts, as shown, from manifold (1) on the right side of the engine. Use two 1A1460 Bolts, and a 9B1006 Washer on each side of 5N6405 Bracket (2), to fasten the bracket in position. Install 8L5000 Switch (3) on bracket (2).
(2) If the instrument panel is on the left side of the engine, remove two bolts as shown, from manifold (4) on the left side of the engine. Use two 1A1460 Bolts, and a 9B1006 Washer on each side of 5N6405 Bracket (2), to fasten the bracket in position. Install 8L5000 Switch (3) on bracket (2).
Installation of Low Oil Pressure Override Switch - Engines with Electric Start and Premium Instrument Panel (5N6669 Solenoid Valve Group)
NOTE: Illustration (A) has the instrument panel on the right side of the engine and illustration (B) has the instrument panel on the left side.
Use two S509 Bolts with 1D4717 Nuts to fasten 8L9725 Bracket (1) to 3N4555 Bracket (2). Remove two S1594 Bolts, 3B4506 Lockwashers and 1D4717 Nuts to install bracket (2) at the location shown. To fasten bracket (2) in position, use the 1D4717 Nuts and two 1A2029 Bolts. Install 8L5000 Switch (3) to bracket (1).
Wiring Diagrams For Low Oil Pressure Override Switch (Electric Start)
Engines Without Glow Plugs
Connect switch (1) and valve (2) into the electrical system as shown. Identification of parts shown is as follows: (1) Override switch, (2) Override valve, (3) Engine start switch, (4) Existing wire to starting motor, (5) Existing positive wire, (6) New negative wire to 1/2" thread negative terminal on starting motor.
Engines With Glow Plugs
Connect switch (1) and valve (2) into the electrical system as shown. Identification of parts shown is as follows: (1) Override switch, (2) Override valve, (3) Heat-start switch, (4) Wire to glow plugs, (5) Existing positive wire, (6) Existing wire to starting motor, (7) New negative wire to 1/2" thread negative terminal on starting motor.
Installation Of Diverter Valve And Lines - D379 Engines
(1) Use two L1143 Bolts with 5M2894 Washers to fasten diverter valve (1) to 5N2345 Plate (2). Remove three bolts from cover (3) and use three L2070 Bolts with 5M2894 Washers and 8L4852 Spacers to install plate (2) as shown. Remove two more bolts from cover (3) and use two S1591 Bolts and 6H7127 Spacers to install 5N5679 Bracket (4).
(2) Install and connect lines (5), (6), (7), (8), (9) and (10) as shown. Use 321267 Connector to connect line (9) to the tee. At location (A) use a 1B7182 Bolt, 6H4485 Spacer, 9M1974 Washer and a 1D4716 Nut with each 5M5926 Clamp to fasten the lines to the plate as shown.
NOTE: Connector (11) is in the lower port of the shut-off cylinder on the new housing assembly that has already been installed on the right side air inlet manifold.
(3) Remove a bolt from cover (12) and use an 8L4852 Spacer, 5M2894 Washer, S1590 Bolt and 7N3718 Clip (13) to hold line (7). If it has not already been done, use a 3B1915 Bolt, 6F6405 Spacer and 5M2894 Washer with 8M2773 Clip (14) to hold line (8).
(4) Use a 1B7182 Bolt, 9M1974 Washer, 1D4716 Nut and a 5M5689 Clamp at location (B) to fasten lines (5) and (6) to bracket (4). Use a 2H3755 Bolt, two 9M1974 Washers, a 1D4716 Nut and two 5M5926 Clamps at location (C) to hold lines (5) and (6).
NOTE: If the intake manifold was removed for installation of the shut-off group, use the new gaskets and install the manifold on the engine.
(5) Use 7K4129 Connectors (15) and (16) to connect line (5) to 5N2433 Line (17) and 5N2435 Line (18). Connect line (18) to elbow (19). Use 7K4129 Connector (20) to connect 5N2434 Line (21) to 5N2436 Line (22), then connect the lines to connectors (23) and (24) on the cylinders that are on the new shut-off housing for the intake manifolds. Use 7K4129 Connector (25) to connect 5N2430 Line (26) to line (10). Connect the loose end of line (26) to connector (27) in the rack shut-off.
(6) Remove one bolt from each location under the aftercooler, where the aftercooler housing is fastened to the flywheel housing. At location (D) use a 5N5678 Plate, S1571 Bolt with 5M2894 Washer, 1B7182 Bolt, 9M1974 Washer and 1D4716 Nut with a 5M5689 Clamp to fasten lines (17) and (21). At location (E) use a 5N5680 Plate, S1571 Bolt with 5M2894 Washer, 1B7182 Bolt, 9M1974 Washer and 1D4716 Nut with a 5M5689 Clamp to fasten lines (17) and (21). See view B-B.
(7) At location (F) use an S1594 Bolt, 5M2894 Washer and a 1D4717 Nut to fasten 5N5741 Bracket (28) to channel (29). Fasten line (26) to bracket (28) with an S1594 Bolt, 5M2894 Washer, 1D4717 Nut and a 5P9297 Clip. See view C-C.
Installation Of Diverter Valve And Lines - D398 Engines
(1) Remove three bolts from 8L4857 Cover (1) and use three L2070 Bolts with 5M2894 Washers and 8L4852 Spacers to install 5N2345 Plate (2). Remove two more bolts from cover (1) and cover (3), in the area shown and use two S1591 Bolts and 6H7127 Spacers to install each 5N5679 Bracket (4).
(2) Use two L1143 Bolts with 5M2894 Washers to install the 5N4820 Diverter Valve at location (A) on plate (2).
(3) Install and connect lines as follows: 5N2432 Line (5), 5N2426 Line (6), 5N2429 Line (7), 5N2367 Hoses (8) and (9) and 5N2425 Line (10) as shown. Use a 321267 Connector to connect line (9) to the tee. At location (B), use a 1B7182 Bolt, 6H4485 Spacer, 9M1974 Washer and a 1D4716 Nut with each 5M5926 Clamp to fasten the lines to the plate as shown.
NOTE: Connector (11) is already installed in the lower port of the shut-off cylinder on the new housing assembly that is on the right side air inlet manifold.
(4) Remove a bolt from cover (1) and use an 8L4852 Spacer, 5M2894 Washer, S1590 Bolt and 7N3718 Clip (12) to hold line (7). Use an S1588 Bolt, 6F6405 Spacer and 5M2894 Washer with 8M2773 Clip (13) to hold line (8). Remove a bolt from cover (3) and use an S1591 Bolt, 5M2894 Washer, 1L5081 Spacer with 5P9297 Clip (14) to hold line (10).
(5) Use a 1B7182 Bolt, 9M1974 Washer and a 1D4716 Nut with a 5M5689 Clamp at each location (C) to fasten lines (5) and (6) to brackets (4).
NOTE: If the intake manifold was removed for shut-off group installation, use the new gaskets and install the manifold on the engine.
(6) Use 7K4129 Connectors (15) and (16) to connect line (5) to 5N2433 Line (17) and 5N2435 Line (18). Connect line (18) to elbow (19). Use 7K4129 Connector (20) to connect 5N2434 Line (21) to 5N2436 Line (22), then connect the lines to connectors (23) and (24) that are on the cylinders on the new shut-off housings in the inlet manifolds. Use 7K4129 Connector (25) to connect 5N2430 Line (26) to line (10). Connect the loose end of line (26) to connector (27) in the Rack Shut-Off.
(7) Remove one bolt from each location under the aftercooler in the area shown, where the aftercooler housing is fastened to the flywheel housing. At location (D) use a 5N5678 Plate, S1571 Bolt with 5M2894 Washer, 1B7182 Bolt, 9M1974 Washer and 1D4716 Nut with a 5M5689 Clamp to fasten lines (17) and (21). At Location (E) use a 5N5680 Plate, S1571 Bolt with 5M2894 Washer, 1B7182 Bolt, 9M1974 Washer and 1D4716 Nut with a 5M5689 Clamp to fasten lines (17) and (21). See view (B-B).
(8) At location (F) use an S1594 Bolt, 5M2894 Washer and a 1D4717 Nut to fasten 5N5741 Bracket (28) to channel (29). Fasten line (26) to bracket (28) with an S1594 Bolt, 5M2894 Washer, 1D4717 Nut and a 5P9297 Clip. See view (C-C).
Installation Of Diverter Valve And Lines - D399 Engines
(1) Remove the necessary bolts from covers (1), (2) and (3) for installation of 5N5679 Brackets (4) and 5N5920 Block (5). Use S1591 Bolts and 6H7127 Spacers for installation of brackets (4). Install 321267 Connector (6), 3B7739 Nipple (7) and 321268 Elbow (8) and 5M6213 Plug (9) in block (5). Install the IN port of solenoid valve (10) on nipple (7), then install 16498 Elbow (11) in the OUT port of valve (10). Use T573 Bolts to fasten block (5) in position on covers (2) and (3). Connect 5N2367 Line (12) to elbow (8), and 5N2367 Line (13) to elbow (11).
(2) Connect 5N2491 Line (14), 5N5918 Line (15) and 5N2489 Line (16) to connectors (17). Connect 5N2493 Line (18) to connector (6). Use a 1B7182 Bolt, 9M1974 Washer, 1D4716 Nut and 5M5689 Clamp at each location (A) to fasten lines (14) and (16) to brackets (4). At the three locations (B), use a 1B7182 Bolt, two 9M1974 Washers, a 1D4716 Nut and two 5M5689 Clamps to fasten the lines together for support. At locations (C) and (D), use an S1588 Bolt, 5M2894 Washer and 2M7077 Spacer with a 7N3718 Clip to give support to lines (15) and (18).
(3) At location (E), use 1B7182 Bolts, 6H4485 Spacers, 9M1974 Washers and 1D4716 Nuts to fasten lines (14), (15) and (16) to bracket (19). Install the four 7K4129 Connectors (20), then connect 5N2490 Line (21) to line (14), 5N2488 Line (22) to line (16), 5N4460 Line (23) to line (15), and 5N2492 Line (24) to line (18). Connect the loose end of line (22) to the 321267 Connector (25) that is already installed in the hydraulic cylinder on the new air shut-off housing of the air inlet manifold on the right side of the engine.
(4) At location (F) use a 1B7182 Bolt, two 9M1974 Washers, 1D4716 Nut and two 5M5689 Clamps to fasten lines (21) and (22) to the bracket.
(5) At location (G), use an S1588 Bolt, 5M2894 Washer, 2M7077 Spacer and a 7N3718 Clip to hold tube (24). At each location (H), use a 1B7182 Bolt, two 9M1974 Washers, a 1D4716 Nut and two 5M5689 Clamps to fasten lines (23) and (24) together for support.
(6) For 5N5756 Diverter Valve (26), install 321268 Elbows (27), (28) and (29) in the ports with the marks OUT, IN and DR. Install a 321267 Connector in the port with the mark CYL. Use two T573 Bolts (30) with 5M2894 Washers and fasten diverter valve (26) to 5N5914 Bracket (31).
(7) Remove three of the bolts that fasten the right side of the fuel injection pump and governor drive housing to the top of the cylinder block, and use three S1591 Bolts with 5M2894 Washers to fasten 5N5914 Bracket (31) in position. Connect line (23) to elbow (27) and line (24) to elbow (29).
NOTE: If the intake manifold was removed for shut-off group installation, use the new gaskets and install the manifold on the engine.
(8) Use 7K4129 Connectors (32) and (33) to connect 5N2433 Line (34) and 5N2435 Line (35) to line (21) and 6K9194 Elbow (36). Use 7K4129 Connector (37) to connect 5N2434 Line (38) to 5N2436 Line (39). Connect lines (38) and (39) to 321267 Connectors (40) and (41).
NOTE: Elbow (36) and connectors (40) and (41) were already installed in the hydraulic cylinders of the new air inlet shut-off housings.
(9) Remove one bolt from each location under the aftercooler, in the area shown, where the aftercooler housing is fastened to the flywheel housing. At location (J) use a 5N5678 Plate, S1571 Bolt with 5M2894 Washer, 1B7182 Bolt, 9M1974 Washer and 1D4716 Nut with a 5M5689 Clamp to fasten lines (34) and (38). At location (K) use a 5N5680 Plate, S1571 Bolt with 5M2894 Washer, 1B7182 Bolt, 9M1974 Washer and 1D4716 Nut with a 5M5689 Clamp to fasten lines (34) and (38). See view (B-B).
(10) At location (L), use an S1590 Bolt, 2B941 Spacer and 5M2894 Washer with a 5P9297 Clip to hold line (23).
(11) Connect 5N4987 Line (42) to 321267 Connector (43) in the CYL port of the diverter valve and 6L9781 Connector (44) in the rack shut-off housing. Remove a 5M6213 Plug from plate (45) of the breather group and install 321268 Elbow (46).
NOTE: If the engine has a duplex filter, install a 2D7325 Tee instead of elbow (46) and use a 321267 Connector to connect 5N5892 Line (47).
(12) Install 5N5892 Line (47), 7K4129 Connector (48) and 5N5915 Line (49). The end of line (49) that cannot be seen connects to the elbow in the DR port of the diverter valve.
(13) Use the former bolt and a 5M2894 Washer with 8S8819 Clip (50) to fasten line (49). See view (C-C). Use a 3B1915 Bolt with a 3L9689 Washer (51), 5M2894 Washer and 8S8819 Clip (52) to fasten lines (47) and (49). See view (D-D).
Installation Of Air Control Valve Group - Engines With Air Start
When a hydra-mechanical shut-off group is installed on the engine, it is also necessary to install an air control valve group. The purpose of the air control valve group is, to not let the low oil pressure contactor activate until after the engine is started. Installation procedure for the air control valve group according to engine model, is on the pages that follow.
 |
Always shut off the air supply to the starting motor before installation of an air control valve group. |
 |
5N6445 Air Control Valve Group - D379 With Air Start Motor on Right Side
(1) Disconnect hose (1) at air start valve (2), then remove valve (2), nipple (3) and elbow (4). [Some starters do not have nipple (3) and elbow (4), but do have a bushing which must be removed.] Assemble the parts that follow, according to the illustration shown above: original control valve (2) for air starter, 2N1287 Elbow (5), 3B8822 Elbow (6), 44914 Tee (7), 8B2283 Nipple (8), 3B8822 Elbow (9), 8L6557 Connector (10), 5N6411 Valve (11) and 5N6444 Bracket (12).
(2) Remove two of the bolts and lockwashers that fasten the air starter to the flywheel housing, and use two S1589 Bolts with 5P8247 Washers to fasten bracket (12) in position. Install 2N1287 Elbow (13) in the bottom of 5N6394 Valve (14) (installed earlier with the diverter valve), then connect 5N6414 Tube (15) to elbow (13) and connector (10). Remove a bolt from the cylinder block side cover and use a 3B1915 Bolt, 5M2894 Washer and 6F6405 Spacer with 8M2772 Clip (16) to hold tube (15) in position.
(3) Install 5P2657 Elbow (17) in the hole for the former elbow (4). Install 6S2274 Hose (18) and connect it to elbows (5) and (17). Connect the loose end of hose (1) to elbow (6).
5N6396 Air Control Valve Group - D379 With Air Start Motor on Left Side
(1) Disconnect hose (1) and remove elbow (2) from existing air start valve (3). Install 44914 Tee (4), 8B2283 Nipple (5), elbow (2), 5N6411 Valve (6), 5N6398 Bracket (7) and 8L6557 Connector (8) as shown. Connect hose (1) to tee (4).
(2) Install 2N1287 Elbow (9) in the bottom of 5N6394 Valve (10) (installed earlier with the diverter valve). Connect 5N6410 Tube (11) to elbow (9). Use 3J7355 Union (12) to connect 5N6408 Tube (13) to tube (11), then connect tube (13) to connector (8).
(3) At locations (A), use 7D1728 Clips (14), as shown at (A-A), with existing bolts to hold tubes (11) and (13). At location (B), use a 7D1728 Clip and an existing bolt in the area shown to hold tube (13). At location (C), remove a bolt from the cylinder block side cover and use a 3B1915 Bolt, 5M2894 Washer and 6F6405 Spacer with an 8M2772 Clip to hold tube (11).
5N6446 Air Control Valve Group - D398 With Air Start Motor on Right Side
(1) Disconnect hose (1) at air start valve (2), then remove valve (2), nipple (3) and elbow (4). [Some starters do not have nipple (3) and elbow (4), but do have a bushing which also must be removed.] Assemble the parts that follow, according to the illustration shown above: original control valve (2) for air starter, 2N1287 Elbow (5), 3B8822 Elbow (6), 44914 Tee (7), 8B2283 Nipple (8), 3B8822 Elbow (9), 8L6557 Connector (10), 5N6411 Valve (11) and 5N6444 Bracket (12).
(2) Remove two of the bolts and lockwashers that fasten the air starter to the flywheel housing, and use two S1589 Bolts with 5P8247 Washers to fasten bracket (12) in position. Install 2N1287 Elbow (13) in the bottom of 5N6394 Valve (14) (installed earlier with the diverter valve), then connect 5N6413 Tube (15) to elbow (13) and connector (10). Remove a bolt from the cylinder block side cover and use a 3B1915 Bolt, 5M2894 Washer and 6F6405 Spacer with 8M2772 Clip (16) to hold tube (15) in position.
(3) Install 5P2657 Elbow (17) in the hole for the former elbow (4). Install 6S2274 Hose (18) and connect it to elbows (5) and (17). Connect the loose end of hose (1) to elbow (6).
5N6397 Air Control Valve Group - D398 With Air Start Motor on Left Side
(1) Disconnect hose (1) and remove elbow (2) from existing air start valve (3). Install 44914 Tee (4), 8B2283 Nipple (5), elbow (2), 5N6411 Valve (6), 5N6398 Plate (7) and 8L6557 Connector (8), as shown. Connect hose (1) to tee (4).
(2) Install 2N1287 Elbow (9) in the bottom of 5N6394 Valve (10) (installed earlier with the diverter valve). Connect 5N6409 Tube (11) to elbow (9). Use 3J7355 Union (12) to connect 5N6408 Tube (13) to tube (11), then connect tube (13) to connector (8).
(3) At locations (A) use 7D1728 Clips (14) as shown at (A-A), with existing bolts, to hold tubes (11) and (13). At location (B), use a 7D1728 Clip and an existing bolt in the area shown, to hold tube (13). At location (C), remove a bolt from the cylinder block side cover and use a 3B1915 Bolt, 5M2894 Washer and 6F6405 Spacer with an 8M2772 Clip to hold tube (11).
5N6665 Air Control Valve Group - D399 With Air Start Motor on Right Side and Air Driven Pre-lubrication Pump
(1) Disconnect coupling (1) and remove elbow (2) from whistle valve (3). Connect 1H2815 Nipple (4) and 1L2782 Tee (5) to valve (3) as shown, then connect coupling (1). At location (A), install a 6F7732 Bushing, 7B2176 Bushing and 8L6557 Connector.
(2) Use two S1590 Bolts with 5M2894 Washers and 1D4717 Nuts to fasten 5N6650 Plate (6) in position. Install 8L6557 Connectors (7) and (8) in 5N6411 Valve (9), then install valve (9) on plate (6) as shown. Connect 6N8659 Hose (10) to connector (7) and the connector at location (A).
(3) Install 2N1287 Elbow (11) in the bottom of 5N6394 Valve (12) (installed earlier with diverter valve) then connect 5N6662 Tube (13) to connector (8) and elbow (11).
(4) Remove three bolts from the cylinder block side covers at locations (B). Use a 6H7127 Lug, 8M2772 Clip, 5M2894 Washer and S1591 Bolt at each location (B) to give support to tube (13).
5N6664 Air Control Valve Group - D399 With Air Start Motor on Left Side and Air Driven Pre-lubrication Pump
(1) Disconnect coupling (1) and remove elbow (2) from whistle valve (3). Connect 1H2815 Nipple (4) and 1L2782 Tee (5) to valve (3) as shown, then connect coupling (1). At location (A) install a 6F7732 Bushing, 7B2176 Bushing and 8L6557 Connector.
(2) Use two S1590 Bolts with 5M2894 Washers and 1D4717 Nuts to fasten 5N6650 Plate (6) in position. Install 8L6557 Connector (7) and 2N1287 Elbow (8) in 5N6411 Valve (9), then install valve (9) on plate (6) as shown. Connect 6N8659 Hose (10) to connector (7) and the connector at location (A).
(3) Install 2N1287 Elbow (11) in the bottom of 5N6394 Valve (12) (installed earlier with diverter valve), then connect 5N6657 Tube (13) to elbow (11). Remove a side cover bolt at each location (B) and use an S1591 Bolt, 6H7127 Lug, 5M2894 Washer and 8M2772 Clip for support of tube (13).
(4) Use 3J7355 Union (14) and connect 5N6658 Tube (15) to tube (13). Connect the loose end of tube (15) to elbow (8). At locations (C) use a 7D1728 Clip (16) as shown at (A-A), and existing bolts to hold tube (15). At location (D), use a 7D1728 Clip and an existing bolt in the area shown, to hold tube (15).
Installation Of 5N6651 Solenoid Valve Group (D399 With Air Start Motor and Electric Pre-lubrication Pump)
(1) For those engines that have the instrument panel (1) on the right side of the engine, remove two manifold bolts and washers at the location shown. Use two 1A1460 Bolts with 9B1006 Washers to install 5N6647 Bracket (2). Tighten the manifold bolts to a torque of 50 ± 5 lb. ft. (68 ± 7 N·m). Two 4B1238 Screws with 4B2049 Nuts are needed to fasten 3N2419 Switch (3) to bracket (2).
(2) For those engines that have the instrument panel (1) on the left side of the engine, remove two manifold bolts and washers at the location shown. Use two 1A1460 Bolts with 9B1006 Washers to install 5N6647 Bracket (2). Tighten the manifold bolts to a torque of 50 ± 5 lb. ft. (68 ± 7 N·m). Two 4B1238 Screws with 4B2049 Nuts are needed to fasten 3N2419 Switch (3) to bracket (2).
(3) See WIRING DIAGRAM FOR OVERRIDE SOLENOID-ENGINES WITH AIR START AND ELECTRIC PRE-LUBRICATION PUMP. [The solenoid valve (5N6677) was installed earlier with the diverter valve and lines.]
Wiring Diagram For Low Oil Pressure Override Solenoid - Engines With Air Start And Electric Pre-Lubrication Pump
Existing components that are shown in the above wiring diagram are as follows: pre-lubrication pump motor (1), relay (2), switch (3) [for pre-lubrication pump motor (1)], solenoid valve (4), oil pressure switch (5), air starting motor (6), wiring (7) and (8).
New additional components that are shown in the wiring diagram are: solenoid valve (9) (installed earlier with the diverter valve and lines) and override switch (10). Use number 14 wire to connect the new components into the electrical system.
Installation Of Operation Instruction Films
Instruction films are needed to give the correct operation procedure of the shut-off group controls. These instruction films are available in single languages. See the chart that follows for the film name, quantity needed and the part number according to language. The illustrations that follow the chart show the films (English only) installed, for the purpose of correct installation location.
