3192 MARINE GEAR Caterpillar


Lubrication Components

Usage:

Oil Pump

Operation

The gear-type positive displacement oil pump is mounted on the oil manifold. The pump furnishes oil at all times to cool, lubricate and actuate the marine gear.

The pump is driven by a shaft splined to the clutch drive spider of the marine gear. The drive spider rotates any time the diesel engine is running and in the same engine direction.

NOTE: When it is desired to change a marine gear from a clockwise rotation to a counterclockwise rotation (as viewed from the front of the engine) it is necessary to make the following changes.

1. Remove the oil pump as outlined in the covering topic. Rotate it 180° and replace the pump on the oil manifold using the holes provided.

2. The plug inside the cover assembly must be removed from its position and placed in the hole in the high pressure side of the pump. The plug must always be in the high pressure side, regardless of pump rotation.

3. A new oil pump inlet tube is needed to allow for the difference in height of the oil pump inlet connection. A new outlet hose may be needed if the original hose will not reach the oil pump outlet connection at its new position.

Oil Pump Removal and Installation


1-Outlet hose. 2-Oil pump. 3-Inlet flange.

1. Remove the bolts securing the oil pump inlet flange (3) to the strainer retainer.


REMOVING OIL PUMP.
4-Oil pump inlet tube. 5-Oil pump drive sleeve.

2. Inspect the gasket behind the oil pump and replace if necessary.

3. Remove the oil pump inlet tube (4) from the oil pump.

4. Inspect the oil pump drive sleeve (5) and replace if worn or damaged.

5. Install in reverse order of removal using a new O-ring seal on the oil pump inlet tube.

Disassembly and Assembly


1-Cover assembly. 2-Plate. 3-Pump body.

1. Separate the parts evenly so as not to damage them.


2-Plate. 4-Drive gear assembly. 5-Plate. 6-Bearings. 7-Driven gear assembly.

2. Inspect the bearings (6) and replace if worn or damaged.


DISASSEMBLING OIL PUMP
4-Drive gear assembly. 5-Plate. 8-Lock rings. 9-Bearings. 10-Driven gear. 11-Shaft.

3. Inspect the bearings (9) and replace if worn or damaged.


DISASSEMBLING DRIVE ASSEMBLY
8-Lock ring. 12-Gear. 13-Lock ring. 14-Shaft. 15-Key.

NOTE: The gears (10) and (12) are a slip fit on the shafts (11) and (14).

4. Remove the lock ring (8) and gear (12) from the shaft (14) as shown. The gear (10) can be removed in a similar manner.

5. When assembling, be sure that the key (15) is aligned with the keyway and the lock ring is firmly seated in the mating groove in the shaft.

6. Inspect the plates (2) and (5) for excessive wear and replace if necessary.


OIL PUMP PLATES
16-Oil relief grooves.

NOTE: When assembling the oil pump, be sure the plate with the oil relief grooves (16) is placed between the head assembly and the pump body. The grooves face the pump gears.

Selector Valve

The selector control valve assembly is mounted on the marine gear and directs the flow of oil and also regulates the oil pressure being delivered to the marine gear. The pressure regulating section of the valve furnishes automatic regulation of the pressure, with a slight delay effect affording smooth transition from neutral pressure to engaged pressure.


SELECTOR VALVE

1 Selector valve body.

2 Load piston.

3 Check valve.

4 Directional spool valve.

5 Port to sump.

6 Port to sump.

7 Port to astern clutch.

8 Pressure regulating springs.

9 Port to oil cooler.

10 Ball check valve.

11 Inlet port to valve.

12 By-pass valve.

13 Damping valve.

NOTE: There are three small holes, one in each plug in the check valve (3), spaced at 180° with respect to each other. These holes are in the plugs for modulation of pressure build up as oil is directed through to the load piston.

Oil Flow in the Neutral Position

With the engine running and the directional valve (2) in the neutral position, the oil flow through the selector valve is as follows:


OIL FLOW IN THE NEUTRAL POSITION
1-Selector valve body. 2-Directional spool valve. 3-Pressure regulating springs. 4-Port to oil cooler. 5-Oil inlet port to selector valve. 6-By-pass valve. 7-Damping valve.

Oil flows from the oil filter to the inlet port (5), around the stem of the by-pass valve (6) and through a cored passage to the bore of the directional spool (2). Pressure is built up since the oil cannot escape from the neutral chamber of the spool valve. As the pressure rises, the oil will open the damping valve (7) and fill the bottom portion of the by-pass valve. When the pressure behind the by-pass valve (6) is great enough to overcome the pressure regulating springs (3), the by-pass valve is forced open and oil passes by it and out of the selector valve through the port (4) to the oil cooler.

The purpose of the damping valve is to dampen fluctuations in oil pressure. This keeps the by-pass valve from moving sharply with every small change in oil pressure.

Oil Flow in the Ahead Position


OIL FLOW IN THE AHEAD POSITION

1 Selector valve body.

2 Load piston.

3 Stop.

4 Orifice.

5 Check valve.

6 Directional spool valve.

7 Port to sump.

8 Port to sump.

9 Port to astern clutch.

10 Pressure regulating springs.

11 Ball check valve.

12 Port to oil cooler.

13 Port to ahead clutch.

14 Oil inlet port.

15 Port to sump.

16 By-pass valve.

With the engine running and the directional valve (6) in the ahead position, the oil flow through the selector valve body (1) is as follows:

Pressure oil from the filter flows through the by-pass valve (16), through the directional spool valve bore and to the ahead clutch port (13). Oil which leaks by the directional spool (6) is returned to the sump through the return ports (7) and (15).

At the same time, oil forces the ball check valve (11) against its upper seat and flows on to the main check valve (5). The oil forces the check valve (5) to its stop (3), flows through the small holes in the three plugs in the bore of the check valve, and then flows through the orifice of the check valve (5). The oil then flows to the top end of the load piston (2) and compresses the pressure regulating springs (10) until the forces on the load piston and the by-pass valve are in equilibrium. The by-pass valve (16) determines the maximum clutch engagement pressure while the check valve orifice (4) provides a gradual pressure build up to assure smooth clutch engagement. As oil enters the engaging clutch cavity, oil pressure also increases behind the load piston (2) forcing it down. When clutch engagement pressure is reached, the by-pass valve moves upward and oil not needed to maintain clutch engagement flows to the oil cooler.

When the directional spool valve is again moved to neutral, the oil in the ahead clutch drains through the dump valve to the sump. The decrease in pressure allows the ball check valve to move from its seat and the oil behind the check valve (5) will flow out to the sump through port (7). Since the pressure on the bottom side of the check valve (5) is now less than the pressure on the top of the check valve, the pressure oil on top of the load piston pushes the check valve open and allows the oil to flow out port (7) to the sump.

Oil Flow in the Astern Position


OIL FLOW IN THE ASTERN POSITION

1 Selector valve body.

2 Load piston.

3 Stop.

4 Orifice.

5 Check valve.

6 Directional spool valve.

7 Port to sump.

8 Port to sump.

9 Port to astern clutch.

10 Pressure regulating springs.

11 Ball check valve.

12 Port to oil cooler.

13 Port to ahead clutch.

14 Oil inlet port.

15 Port to sump.

16 By-pass valve.

With the engine running and the directional valve (6) in the astern position, the oil flow through the selector valve body (1) is as follows:

Pressure oil from the filter flows through the by-pass valve (16), through the directional spool valve bore and to the astern clutch port (9). Oil which leaks by the spool valve is returned to the sump in the same manner as in the ahead clutch.

The regulation of oil pressure is the same as in the ahead position, except that the ball check valve (11) is held at the opposite end of its bore.

Removal and Installation


1-Outlet oil line. 2-Selector valve. 3-Inlet oil line.


REMOVING SELECTOR VALVE

Disassembly and Assembly


1-Valve body. 2-Cover. 3-Pin. 4-Lever.

Install the selector valve in reverse order of removal using new O-ring seals.


2-Cover. 5-Detent.


NOTICE

Use extreme care when removing valves from the valve body. Nicked or scratched valves can cause improper operation of the selector valve.



6-O-ring seals. 7-Pressure regulating springs. 8-Spacers. 9-Load piston.


REMOVING BY-PASS VALVE
10-O-ring seals.

Use new O-ring seals (6) and (10) when assembling the selector valve.


11-Ring. 12-Retainer. 13-Spring. 14-Damping valve. 15-By-pass valve.


16-Check valve. 17-Stop. 18-Seal and bushing.

Inspect seal and bushing (18) and replace if worn or damaged.


REMOVING DIRECTIONAL VALVE

Inspect all of the valves and replace if they are worn or damaged.

Oil Filter And Oil Filter By-Pass Valve

Removal and Installation


1-Cover. 2-Housing.


3-Spring. 4-By-pass valve.


REMOVING OIL FILTER

When replacing the filter cover (1), inspect the O-ring seal and replace if damaged.

Install in reverse order of removal using a new oil filter element.

Filter By-Pass Valve Disassembly and Assembly


1-By-pass valve. 2-Ring.


3-Washer. 4-Spring. 5-Valve.

Inspect valve (5) and replace if worn or damaged.

Oil Strainer

The oil strainer (1) is located in the rear right of the marine gear housing and is inserted in the strainer retainer (2). It serves as a screen on the inlet side of the oil pump to provide longer pump life.

Check the strainer for damage and replace if necessary. Clean or wash strainer before installing if using the original one.

Install in reverse order of removal, being sure that the smaller diameter end of the strainer is properly seated in the strainer retainer.

Inspect gasket (3) and replace if damaged.


1-Strainer. 2-Strainer retainer. 3-Gasket.

Oil Manifold

Removal and Installation

1. Remove the oil pump and selector valve. See the covering topics.

NOTE: Force the manifold off evenly using forcing screws to avoid damaging the O-ring seal (2) and ferrule and the ring-type oil seals (7) located on the end of the oil pump drive shaft.


REMOVING OIL MANIFOLD
1-Oil manifold. 2-O-ring seal. 3-Passage to astern drive clutch. 4-Passage to ahead drive clutch. 5-O-ring seal. 6-Oil pump drive shaft. 7-Ring-type oil seals.

When installing the manifold, check to see that the ring-type oil seals (7) are in a locked position.

Inspect the O-ring seals (2) and (5) and replace if damaged.

Oil Cooler

The marine gear oil cooler is located on the left side of the marine gear housing and is interconnected with the diesel engine fresh water cooling system.

Marine gear oil is transmitted from the oil pump, which is located on the marine gear, to the marine gear oil filter. The oil is then directed to the marine gear control valve and to the clutches and oil cooler.

Removal and Installation

Drain the coolant from the engine and cooler. See the respective topics in the Operation and Maintenance Instructions.


1-Oil cooler. 2-Oil inlet tube. 3-Oil outlet tube.

Disassembly and Assembly


1-Bonnet. 2-Oil cooler. 3-Bonnet.

NOTE: The water lines to the oil cooler are connected to the bonnet (3).

Use a piece of 11/64" rod (5) to clean out the oil cooler tubes.


CLEANING OIL COOLER TUBES
5-Rod.

Prior to assembly, inspect and replace the gaskets between the bonnets and oil cooler body if they are damaged.

Caterpillar Information System:

3192 MARINE GEAR Lubrication, Hydraulic System and Operation
3192 MARINE GEAR Introduction and Application
3192 MARINE GEAR Cutaway
3192 MARINE GEAR Specifications
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