* Crankshaft produced

produced earlier

Bearing Surface (Journal) for Main Bearing

Bearing Surface (Journal) for Main Bearing Original Size Undersize Journal Undersize Journal

Journal 0.25mm O.Slmm Dimension of 88.880?0.020 mm 88.626?0.020 mm 88.372?0.020 mm Journals (D)

Surface Finish of 0.25?m or more smooth Journals

5.74?0.20 mm (0.226?0.008 in)

Surface Finish of 1.6 ?m Radius (63 ?in or more smooth)

Max Width of All Journals Except 43.485 mm Front &Rear Width of Rear 40.475+0.140-0.064 mm

Journal Surface Finish of Thrust Face of Rear 0.46 ?rn or more smooth Journal

Undersize Journal 0.76mm

88.118?0.020 mm

*Radius must blend smoothly (have no with the machined surfaces of the journals.

l4

Bearing Surface (Journal) for Connecting Rods

G

Bearin~ Surface (Journal) for Connecting Rods Original Size Undersize Journal Undersize Journal Undersize Journal

Journal 0.25mm O.Slmm 0.76mm Diameter of Crankshaft

Journal (Bearing 76.180?0.020 mm 75.926?0.020 mm 75.672?0.020 mm 75.418?0.020 mm Surface) for Connecting

Rods (A) Surface Finish of 0.25 mm

Journals or more smooth *Radius 5.74?0.2Q mm

Surface Finish of 1.6 ?m Radius or more smooth

Wi of Journal 47.689?0.140 mm

*R'bdius (B) must blend smoothly (have no sh edges) wi the machined sface of the journals.

Main and Connecting Rod Bearings

Connectin2 Rod Bearin1 s Original Size Undersize Journal Undersize Journal Undersize Journal

Journal 0.25mm O.Slmm 0.76mm Diameter of Crankshaft

Journal (Bming Sface) 76.180?0.020 mm 75.926?0.020 mm 75.672?0.020 mm 75.418?0.020 mm for Connecting Rods Ctearanc Betwn 0.076 to 0.168 mm Beaiing and Journal (New) Mirnum Permissible

Clearance Between 0.25mm Bing and Journal

15

Main Bearing Original Size Undersize Journal Undersize Journal Undersize Journal

Journal .2Smm 0.51 mm 0.76mm) Diameter of Crankshaft

Journal (Bearing Surface) 88 .880?0.020 mm 88.626?0.020 mm 88.372?0.020 mm 88.118? 0.020 mm for Main Bearings Clearance Between

Baring and Journal (New) Maximum Permissible Clearanc Be1een

Bearing and Journal

15. RUN-OUT OF FLYWHEEL

Face Run-out (Axial Eccentricity) of Flywheel

(1) Install a dial indicator as shown. Put a force on the flywheel toward the rear.

(2) Set the dial indicator to read 0.0 mm.

(3) Turn the flywheel and read the indicator every 90 degrees. Put a force on flywheel toward the rear before the indicator is read every time.

(4) The difference between the lower and higher measurements taken at all four points must not be more than 0.15mm, which is ie maximum prmissible face run-out ial eccentricity) of the flywheel.

Bore Run-out (Radial Eccentricity) of Flywheel

(1) InsI e dial indicator( and aust universal attachmenti( so it makes contact as shown.

Set the dial indicator to read 0.0 mm.

16

0.076 to 0.165 mm

0.25mm

Check face run-out of flywheel

(2) Tum the flywheel and read the indicator eve 90 degrees.

(4) The difference between the lower and higher measements taken at all four points must not be morn m 0.15 mm, which is the maximum permissible bore run-out (radial eccentricity) of the flywheel.

Checking Bore of Flywheel

(5) Run-out (eccentricity) of the bore for the pilot bearing for e flywheel clutch, must not

exceed 0.13 mm.

Checking Bore for Pilot Beingfor Flywheel Clutch

16. RUN-OUT OF FLYWHEEL HOUSING

Face Run-out (Axial Eccentricity) of Flywheel Housing

(1) Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch the face of the flywheel housing.

17

(2) Put a force on the crankshaft toward the rear be for the indicator is read at each point.

(3) With the dial indicator set at 0.0 mm at location (A), tum the crankshaft and read the indicator at locations (B), (C) and (D).

Installation of Dial Indicator Group

(top)

C (TOP)

A ( BOTTM)

(Boom)

( 4) The diff erenc between lower and higher measements taken at all four points must not be more 0.30 mm, which .is the maximum permissible face run-out ial eccentricity) of the flywheel housing.

Bore of Flywheel Housing

NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation. This notation is necessary for ming the calculations in the chart correctly.

(1 ) With . the dial indicator in position at (C), adjust the dial indicator to 0(zero). Push the crankshaft up against the top of the bearing. Write the measurement for bearing clearancon line l in column (C) in the Chart for Dial Indicator Measurements.

(2) Divide e measurement from stp l by 2. Write this number on line 1 in column (D).

(3) Tum the crankshaft to put the dial indicator at (A).Aust the dial indicator 0zero).

(4) Tum the crankshaft counterclockwise to put the dial indicator at (B), write the measurements in the chart.

(5) Tum th crankshaft counterclockwise to put the dial indicator at (C), writemeasurements in the chart.

(6) Tum the crankshaft counterclockwise to put e dial indicator . at (D), write the measurements in the chart.

(7) Add lines I and II by columns.

(8) Subtract the smaller number om the larger number in line III in columns & (D). The result is the horizontal eccentricity (out of round). 1:-in column (C) is the vertical eccentrici Chart for Dial Indicator Measurements

Position of Dial Indicator Line No. A B c D

Corrction for Bearing Clearance

Dial Indicator II Reading

Total of Line 1 & 2 III ** * * *

*Total vertical eccentricity (out of round) Subtract the smaller No. from the larger No.

The difference is total horizontal eccentricity.

Al0234 l

(9) On the graph for total eccentricity find the point of intersection of lines for vertical eccentricity and horizontal eccen~ity.

18

(10) If the point of intersection is in the range marked "Accptable the bore is in alignment If th point of intersection is in the range marked Not acceptablee flywheel housing must b changed .

C (TOP)

6

A (BOTTOM)

735 '"

l ' .Olil

,,. t.010)

~

t.~I

1

i

... 0.10 0.15 l '. 004) IU lOlll

I

17. ALTERNATORS

3T6352 Alternator (24V 35A) (Delco-Remy No.1117647)

Rotation-------------------------------Either direction PolarityNegativ groundOutput at 28V &2600 r/min15AOutput at 28V &6500 r/min-------------35A Rated output (warm35 A Exciting current at"24V &27?C, (80?F)

-2.5 to 3.2 A

(1) Shaft nut torque 100?7 N.m

(2) Torque for negative terminal screw 2.3?0.6 N.m

Torque for positive trminal nut 7?1N.m

19

jllAlternator ~.... v ::iAJ

(Delco Remy No.1117248)

Polanty negative ground Speed for tsting (either direction5000 r/min Output (cooled): load the battery with a carbon

pile to get maximum output to ---54A

Rated output (warm.50AExciting current at 24V &27?C, (80?F)

2.5 to 2.9 A Regulator: Voltage regulating range 26to30VAdjust voltage setting to28 v Then increase sped to get maximum output of

50 A

(1) Shaft nut torque100?7 N.m

(2) Torque for tightening output terminal 14?1N.m

18. ELECTRIC STARTING MOTOR

8N2145 24V (Bosch No. 0-001-420-004)

Rotation as viewed for drive end----------clockwise Minimum no load speed------5500 r/min Current consumption (draw) at no load----140A Minimum clearance between pinion and ring ge(when not meshed1.5 mm

1. Torque for large terminal nuts --30?3 N.m

Torque for small terminal nuts 4 to 5 N.m

20

r J ~ii!'' ,z 1

r' i! : \. E Ii

(1) Valid use limit of th brush(minimum length -----------17.5 mm

(2) Valid use limit of the rectifier (minimum permissible diameter

-----4 7.5 mm

II. DESCRIPTION OF SYSTEMS

1. FUEL SYSTEM

11 12

Schematic Diagram of Fuel System

1. Fuel tank 2. Fuel return line 3. Priming pump 4. Fuel injction nozzle

5. Fuel inJon line 6. Fuel injction pump 7. Primary fuel filter 8. Check valve

9. Fuel transfer pump 10. Secondary fuel liter 11. Constant bleed orific

12. Fuel iction pump housing

Fuel is pulled from fuel tank rough primfuel filter ( and check valves ( by fuel transfer pump ( . From the fuel transfer pump the fuel is pushed rough secondary fuel filter and to the fuel manifold in fuel iection pump housing (12). The pumping spring- in e fuel transfer pump keeps the fuel pressure in the system at 17~ to 290 kPa (25 to 42 psi). Constant bleed. orifice (11) lets a constant flow of fuel goughfuel return line ( back to fuel tank (. Constant

21

bleed orifice send about 34 liters (9 gallons) fuel and air back to fuel tank per hour. This helps keep the fuel cool and ee of air. Fuel iectionmp ge fuel form e fuel manifold and pushes fuel at very high pressure rough fuel injection line ( to fuel iectio11 nozzle ( . The fuel injection nozzle has very small holes in the tip that change the flow of fuel to a very fine spray that gives good fuel combustion in cylinder.

2. LUBRICATION SYSTEM

Schematic Diagram of C6121 Lubrication System ngine Warm) 1. Oil passage (to front idler ge .2. 0 passage (to turbocharger and fuel injection pump)

3. Rocker m shaft 4. 0 pressur connection 5. Oil manifold 6. Piston cooling jets

7. Camshaft bearing bore 8. Oil coolr bypass valve 9. Oil filter bypass valve

10. Engin oi l cooler 11. Oil filter 12. Trbocharger 13. Oil pump 14. Oil pan

Oil pump (13) pulls oil from oil pan (14) and then pushes the oil to oil cooler ( . From e oil cooler, oil goes to oil filter (11) and then to oil manifold ( . From the C?il manifold, oil goes to all mn beings,and piston cooling jets (. Oil passages in the crankshaft send oil to the connecting rod bearings. Oil from the front main bearing goes through oil psage e bearing for fuel iectionpump idler ge and camshaft bearing bore (. The front camshaft bearing is e only bearing to get pr~ssure lubrication.

Oil passage om No. 4 main baring sends oil to turbochargr (12) and the fuel iection pump housing on the right side of the engine.

An oil passage from the rear of the cylinder block goes below the head bolt hole and connects with a

22

illed passage at goes up next to e head bolt hole. A hollow dowel connects e vertical oil passage in e cylinder block to the oil passage in the head. The spacer plate has a hole with a counterbore on each sid that the hollow dowel goes through. An 0-ring is in each counterbore to prevent oil leakage around hollow dowel. Oil flows through the hollow dowel into a vertical passage in the cylinder head t rocker m shaft bracket. The rocker m shaft has an orifice to restrict the oil flow e rocker ms. The rear rocker arm bracket also has an 0-ring that seals against the head bolt. This seal prevents oil from going down around the head bolt and leaking past th head gasket or spacer plate gasket. The 0-ring must be replaced each time the head bolt is removed from the re rocker m bracket.

s in the rocker shafts let the oil gi v Iubricat1on to the valve system components in the cylinder head. After the lubrication oil has done its work, it goes back to the engine oil pan.

There is a bypass valve in oil pump. This bypass valve controls pressure of e oil coming from the oil pump. The oil pump can put more oil into the

system m is needed. When there is more oil than needed, the oil pressure increases and the bypass valve will open. This .allows the oil that is not needed to go back to e engin oil pan.

e engine cold (starng conditions), bypass valves ( and ( will open and give immediate lubrication to all components when cold oil with high viscosity causes a restriction to the oil flow through oil cooler ( and oil filter (11). Oil pump (13nds e cold oil through the bypass valves around the oil cooler and oil filter to oil manifold in cylinderblock.

1(

When the oil gets warm, the pressure difference in the bypass valves decreases and the bypass valves close. Now there is a normal flow of oil through oil cooler and oil filtr.

The bypass valves will also open when ereis a resiction in the oil cooler or oil filter. This action does not let an oil cooler or oil filter with a restriction prevent lubrication of the engine.

Diagram of Rocker Arm Oil Supply

11

Diagram of Oil Flow (Engine Cold)

8. Oil cooler bypass 9. Oil filter bypass 10. Engine oil cooler U. Oil filter

12. Tbocharger 13: Oil pump 14. Oil pan

23

3. COOLING SYSTEM

6 7 8 9 10 11

Diagram of Coolant Flow for Radiator Cooling System 1. Radiator 2. Inlet line to radiator 3. Water tmperature regulator 4. Cylinder head

5. Cylinder block 6. Inlet line to water pump 7. Water pump 8. Internal bypass lin

9. Engine oil cooler 10. Elbow 11. Cylinder liner

The water pump ( is on e leont side of the engine. It is gear driven by the timing gears. The rotation of the impeller in thwater pump pushes the coolant through the system.

/ Coolant from the bottom of radr is sent through inlet line ( to engine oil cooler ( by wer pump (. Then the flo?' goes through elbow to e side of cylinder block (. Inside the cylinder block the coolant goes around the cylinder lj,ners (11) and up through the water direciors into cylinder head (. The watr directors send the flow of coolant around the valves and the passages for exhaust gases in thcylinder head. Then the coolant goes to the front of the cylindr head. Hre watrtemperature regulator ( controls the direction of the flow. If the coolant temperature is less than nprmal for engine operatione water tmperatur regulator is closed. Thi:; only way for the coolant to get out o.f the cylinder head is through the internal bypass line

24

When the coolant g to the correct temperature1e water temperature regulator opens and coolant flow is divided. Most goes through the radiator for cooling. The rest goes through e internal bypass line to the water pump.

NOTE: The water temperature regulato~ is an important pt of the cooling system. It divides e coolant flow between radiator ( and internal bypass line necess to mainn e correct operating temperature. If the regulator is not installediere is no mechanical conol,and most of the coolant will take the path of least resistance through internal bypass line. This will cause the engine to overheat in hot weather. In cold weather, even the small nount of coolant that goes through radiator is too much, and th engine will not get up to normal opratingtemperature.

4. WIRING DIAGRAM OF ELECTRIC STARTING

Chging System with Elecc Starter Motor

1. Start switch 2. Ammeter 3. Alternator 4. Battery 5. Starter motor

III. TORQUE FOR FASTENERS

Torques for Main Bolts

Description Torque Description Torque

Main bearing bolt 41?4.N.m

Trunnion bolt 135?5 N.m Retighten by 90 5

Cylinder head bo.lt Big bolt 250? 17 N.m Valve lash adjusting bolt 29?7N.m Small bolt 43?7 N.m

Connecting rod bolt 41?4N.m

Valve cover bolt 11?3 N.m Retighten by 90 5

Flywheel bolt 200?25N.m Crankshaft taper tube plug 23?4N.m Carns ha gear bolt 55?7 N.m Alternator pulley lock nut 112?10N.m Crankshaft sleeve bolt 312?27N.m Fiywheel housing bolt 100?15 N.m

Fuel pump ive gear bolt 270?25 N.m Torque converter 55?7 N.m connecting stud

25

General Tightening Torque for Standard Bolts, Nuts and 2Taperlock Studs The following chart gives standard torque for SAE 5- or higher grade bolts, nuts and taperlock studs. Exceptional torque is indicated as required in the other parts of this Manual.

Thread. Size Standard Torque Inch mm lb.ft N.m

Standard threads

For bolts and nuts with standard threads (the converted mm numbers are approximate values), use the following torques.

1/4 6.35 9?3 12?4 5/16 7.94 18?5 25?7 3/8 9.53 32?5 45?7 7/16 11.11 '50?10 70?15 1/2 12.70 75?10 lo0?15

9/16 14.29 110?15 150?20 5/8 15.88 150?20 200?25 3/4 19.05 265?35 360?50 7/8 22.23 420?60 570?80

25.40 640?80 875?100 1 1/8 28.58 800?100 1100? 150 1114 31.75 1000?120 1350?175 1 3/8 34.93 1200?150 1600?200 .1112 38.10 1500?200 2000?275

For bolts and nuts for hydraulic valves, use efollowing torques.

3/8 7.94 13?2 20?3 5/16 9.53 24?2 35?3 7/16 11.11 39?2 50?3 1/2 12.70 60?? 80?4 5/8 15.88 118?4 160?6

Taperloc).c studs

i rJ The following torques e used for studs with taperlock reads.

114 6.35 5?2 7?3 5/16 7.94 10?3 15?5 3/8 9.53 20?3 30~5

7/16 11.11 30?5 40?10 112 12.70 40?5 55?10

9/16 14.29 60?10 80?15 5/8 15.88 75?10 100?15 3/4 19.05 110?15 150?20 7/8 22.23 170?20 230?30

25.40 260?30 350?40 1118 28.58 320?30 400?40 11/4 31.75 400?40 550?50 13/8 34.93 480?40 650?50 11/2 38.10 550?50 750?70

* lNewton meter (N.m) is approximately the sne as O.lmkg.

26

Torque for Connectors wi Flare or 0 Ring

The Torques shown in the following chart e used for connectors .(for steel pipes) with 37?, 45? and reverse 45? flares as well as fo~ screw plugs and connectors with 0 ring.

3 ~Inverted 45? 37?flared ned 45?flared

Tube mm 3.18 4.78 6.35 7.92 9.52 Tube mm

OD* in 0.125 0.188 0.250 0.312 0.375 OD* in

Thread 5/16 3/8 7/16 112 9/16 Threaddia.

dia. (in) 5/8 (in) Torque 5 11 16 20 . 25 Torque (N.m) ?2 ?2 ?3 (N.m)

Torque 45 100 145 175 225 Torque (lb.in) ?10 ?10 ?20 ?20 ?25 b.in)

* OD =Outside diameter

Assembling of Fitting with Straight Threads and 0-Ring Seals

1. Hold locknut (, backup washer ( and 0-ring seal ( against as far back on fitting body ( as possible. Turn e fitting into the part it is used on, until the backup washer ( has just makes contact with the face of part it i~ used on.

Note: If the fitting is a straight connector or screw plug, there is a hexagon head in the adapter body instead of a locknut. When installing such fittings , tighten the hexagon head so it contacts e fit face of the connected part firmly.

2. In order to place e fitting in a correct position in installation, turn the fitting body counterclockwise a little (not more an 359?), then tighten e locknut ( according .to e toue given e cht.

27

12.70

0.500

3/4

50 ?5 35 ?4

t

P-ring Fitting-plug Swivel nuts

15.88 19.05 22.22 25.40 31.75 38.10 50.80

0.625 0.750 0.875 1.000 1.250 1.500 2.000

7/8 11/16 B'16 15"16 15"8 17/8 21/2 14

75 100 120 135 180 225 320 ?5 ?5 ?5 ?10 ?10 ?10 ?15 55 75 90 100 135 165 235 ?4 ?4 ?4 7 ?7 ?7 ?10

Elbow Assembling

1. End offitting body (connects to tube) 2. Fitting body 3. Locknut 4. Backup washer 5. 0-ring seal 6. End of fitting that goes into other pt

CHAPTER TWO

OPERATION AND ADJUSTMENT

I. FUEL, OIL AND COOLANT

Filling Capacity of Engine Oil and Coolant

liter I Gallon I Imperial gallon 27.5 I 7.25 I 6 20 I 5.25 I 4.5

1. FUEL

Generally the C121series diesel engine may use light diesel oil of the lowest cost. that meets the following

requirements.

Minimum cetane number: 40

Viscosity, kinematic at 38 1.4 2 .0 cSt

Pour point: 6 below ambient minimum

Water and sedimentary content: less than 0.1 %.

Mimum sulfur content: 0.5%; If there is more sulfur in the fuel oil, adjust e change interval of lube

oil as shown in the chart below.

4

m%%%

JW

-4-o-qJ

OE

----

-

l

l

c

%%%

MUnuA

nu

l--

h071

Change period of oil and filter Normal change interval

112 normal change interval

114 normal change interval

The following chart lists worldwide fuel standards which meets e requirements.

Specifications Fuel Description

U.S. standards No. 1-D & No. 2-D ASTMD975 Diesel fuel oil British Standards Classes Al, A2 &B 1 BS 2868 Engine fuels German standards

Diesel oil DIN 51601 ,, ,, '

Australian standards Automotive diesel oil , AS 3570

Japanese standards rpes l(spl), 1, 2, 3 & 3(spl) ns K2204 Gas oil

2. LUBEOIL

Engine oil performs functions of lubricating and cooling the moving parts and keeping the engine clean and

free from rust $Id corrosion. It is a critical factor to engine life. Use proper lube oil as specified in is

Manual.

28

Ambient Temperatures Which SAE Standard CD Grade Engine Oils Are Suitable To

Suitable'to temperatures from -3022?F) to +50122?F ). Ambient 30 -20 -10 0 +10 +20 +30 +40 +50

temperature ?F -22 -4 +14 +32 +50 +68 +86 +104 +122

SAESW-20

SAE40W

lv

p3 9u piv L

mD cc au n b

n EU SAE lOW - 30

SAE lSW-40

SAE30

SAE40

Ambient 30 -20 -10 0 +10 +20 +30 +40 +50 temperature I ?F -22 -4 +14 +32 +50 +68 +86 +104 +122

3. COOLANT

Use proper coolant for the engine which is mixture of:

Water for filling use

Antifreeze

Antirust for cooling system

Water for Filling '

Water for filling must contain antirust. Do not use pure water. For coolant mixture of glycol and water, use

water that meets the requirements 'listed in the following chart.

Minimqm Acceptable Water Characteristics for Use in Enltine Cooling Svstem Properties Limits ASTM Testing Methods Chloride (CI), grppm) 2A (40)max D512b, D512d, D4327 Sulfate (S04), gr/ga (ppm) 5.9 (iOO) niax D516b, D516d, D4327 Total hardness, gr/ga (ppm) 10 (170) max , D1126b Total solids, gr/ga (ppm) 20 (340) max D1888a .pH J 5.5~9.0 D1293

Antifreeze Use eylene glycol antifreeze. The ount of antifreeze should be appropriate so that the coolant water will not

be frozen at the lowest temperature anticipated. The percentage of mixing it with water is as follows:

Antifreeze Concentrations* Protection Temperatures Concentration

-15 30% antifreeze, 70%water

-24 40% antieeze, 60% water

-37 , 50% antifreeze, 50% water ,

-52 60% antieeze, 40% water

* Ethylene glycol-based antifreeze.

29

TI. ENGINE STARTING

1. INSPECTIONS BEFORE STARTING

Perform reqred daily and other periodic maintenance before starting the engjne. Make a walk-around inspection of the installation. It only takes a few minutes to make minor corrections. This can prevent mor reoairs at late date.

~

(1) Check the service indicator of air cleaner. If the red piston locks in the visible position, service the air cleaner.

(2) Check the coolant level. Maintain the coolant level within 1 cm below the bottom of the radiator fill pipe.

30

(3) Check the crankcase oil level. Maintain the oil level between the ADD and FOLL marks on the dipstick.

(4) Check the fuel level of the fuel tank.

(5) Drain water and sediment from the water segregator.

( 6) Disconnect om e electrical circuit all ba.ery charging equipment without a cut-off device of starter motor current.

(7) Make sure that all protective installation is secured in place. Repair or replace all broken proctive installation.

2 . ELECTRIC STARTING

If the ambient temperature is, below 16 it may be required to use a starg aid and/or other means to heat the crankcase oil. A jacket water heater is often used to assist the engine in starting at cold temperatures.

(1) Place the ansmission in NEUfRAL. For generator sets, open the main electrical circuit breaker.

(2) Move the throttle to approximately half engine speed.

(3) Turn the starter switch to START. If it is necessy to use starting fluid, spray it into the air cleaner inlet sparingly while the starting motor is cranking the engine. fthe engine fails to stt withiff. 30 seconds, release the starter switch and wait two minutes to allow the starter motor to cool before using it again.)

( 4) As soon as the engine stts , allow the engine to idle for 3 to 5 minutes, or until e water temperature gauge indicator has begun to rise.

(5) Do not apply load to e engine or increase engine speed until the oil pressure gauge indicates nonnal. (Oil pressure should rise to nonnal wiin 15 seconds after the engine starts. If oil pressure is not indicated o~ gauge within 15 seconds, stop engine immediately to prevent e engine from damage.)

(6) Operate the engine .at low load until all systems reach opera1g temperature. Check all gauges during the Wm-up period.

Electrical StargEnginewi Fixed Quantity Ether Spraying System

At temperatures of above O generally there is no need to use ether to start e engine. When starting the engine at temperares of O through . -18 Spray ether 1 to 6 times depending on eengine type and starting speed.

A new ether cylinder should be used to assure enough output pressure when starting the engine at temperatures of below -18

Spray ether only when stare engine.

At temperatures of below -18 it is needed to ~pray ether 3 to .6 times before the engine can be started. up. Aer the engine begins running and starting actions stop, keep spaying ether until the engine tuns smool This may need to spray ether 10 to 12 times.

Ether

When using ether from a pr1sure vessel, follow instructions of the manufacture to avoid personal lury.

WARNING

Avoid contact with the skin and eyes. Avoid breathing in any ether fumes.

31

Do not store ether cylinders in the cab. Do not store or use ether cylinders at

tempera tor of over93 Keep ether away from heat sources,

sparks and flames to avoid an explosion. Do not break or burn ether cylinders. Use ether sparingly and spray it oiily

when starting the engine.

3. APPLYING LOAD AFTER STARTING

(1) Move throttle to half engine speed.

(2) Engage the clutch to get the driven equipment in motion

(3) Check the engine gauges and equipment.

(4) Move throttle to high idle speed (full load).

(5) Apply load to the i'ven equipment.

III. ENGINE STOPPING

5 Minutes

Low Idle

IV.

Move the fuel control linkage to the Off position.

VALVE LASH ADJUSTING

INLET .015 in. (0.38 mm}

If the valve lash is in the range of ?0.07 mm, ajustment is not necessy. If the valve lash is

. outside is range, adjust it.

NOTICE

Stopping the engine immediately after it has been working under load can rult in overheating and accelerate wear of the engine components. Comply with the foil owing procedure so as to allow the engine to cool down before stopping to avoid coking of lube oil caused by too high temperare at eintermediate housing of turbocharger.

(1) Let the engine run 5 minutes in low idle speed.

(2) Stop the engine.

,

32

Ajust e valves when the engine is stopp~d and cooled.

Valve lash checking

(1) Stop the engine.

(2) Clean the bed of valve cover to prevent difrom entering the valve mechanism.

(3) Remove the valve cover.

(4) Remove e timing hole plug from the flywheel housing.

The engine cranking tool is available om SDEC. For coect use of the tool, consult SDEC.

(5) Turn the flrheel so at the intake and exhaust valves of No. 1 cylinder.e closed and the plug hole in e flywheel housing is in alignment with the hole in the flywheel. This will put e piston of No.l cylinder is at top dead center on the compression soke.

C6121 Closed valves when the No.1 cylinder is at the top dead center on the compression stroke

Valve Cylinder Inlet 1-2-4

Exhaust 1-3-5

33

(6) Through .the timing hole in th flywheelhousing, screw a 9.40 mm NF timing bolt, 63.5mm long, int9 the hole in the flywheel.

(7) Measure the valve clearances as listed in thcompression stroke cht

(8) Remove the timing bolt om the flywheel.

(9) Ture flywheel 360 degrees and install the timing bolt into the flywheel again.

(10) Measure the valve clearances as listed in the exhaust strokf'. chart.

(11) Remove the timing bolt from the flywheel and install th plug into hole in the flywheel housing.

(12) Remove the engine cranking tool and then install the starting motor.

C6121 Closed valves when the No.l cylinder is at the top dead center on the eiaust stroke

Valve Cylinder Inlet 3-5-6

Exhaust 2-4-6

Valve Adjustment

(1) Loosen the locknut on eajusting screw.

(2) Turn the adjusting screw to obtain coect valve clearance.

(3) Fix the austing screw and tighten e n~ to29?7N.m.

(4) Measure the valve lash.

Watching Valve Rotation

(2) Watch the rotation of the valve rotation mechanism.

(3) At each time the valves open, each valve should rotate a little. If not, check or replace the rotation mechanism.

(4) Sfop .the engine and then check the gasket of valve cover. If the gasket is damaged, replace it with a new one.

(5) Install the valve cover. Tighten the. bolts to 11 ?3 After the valve lash is adjusted and before the N.m. valve cover is installed:

34

V. CHECKING TIM~NG OF FUEL PUMP

Locating Top Center Compression Position for No. 1 Piston

Tools needed: 5P7307 Engine turning tool group.

The piston of No. 1 cylinder at top centerC) on the compression stroke is e starting point of all timing procedures.

NOTE: The engine is viewed from the flywheel end when direction of crankshaft rotation is given.

(1) Remove the staer motor.

(2) Install the tool as shown.

Engine Turning Tools Installed

1. 5P7036 Housing 2. 5P7035 Gear 3. Timing bolt

(3) Remove the valve cove

Valve Cover Removed 4. Rocker ms

35

(4) Rotate the crankshaft clockwise approximately 30 degrees. This step is to make sure free clearance of the timing geSis removed when the piston is at top center.

(5) Remove the plug from the timing hole in the flywheel housing. Rotate the crankshaft until a 3/8 in -- 16NC bolt, 50.Smm (2 inch) long, can be turned into the flywheel rough the timing hole in the flywheel housing. No. 1 piston is now at top center.

NOTE:If e crankshaft is turned beyond the top center, do steps 4 and 5 again.

(6) The intake and exhaust valves for No.l cylinder will be closed if No. 1 piston is on the compression stroke. You can move erocker ms up and down with yo hand.

(7) If No. 1 ston is not on compressionstroke, remove e timing bolt and rotate the crankshaft counterclockwise 360 degrees. Install the timing bolt again. The No. 1 piston is now at top center on ecompression stroke.

Checking Engine riming By Timing Pin Method

Tools needed: 8S2264 puller group 1B3680 boit (2) [ 3/8-24 NF, 95.3mm (3.75

in) long 4B5271 washer 8B7560 step plate OL1138 bolt [3/8-24 NF,12.7mm (0.5 in)

long 7N1048 timing pin

(1) Put No. 1 piston at top center on the compression stroke. !take reference to the previous pagraph Locating Top Center Compression Position for No.1 Piston) Remove the timing bolt and rotate the crankshaft clockwise 30 degrees.

Timing Pin. Cover

1. Timing pin cover 2. Cover for timing gear 3. Nut

(2) Remove. timing pin cover ( from the side of the fuel injection pump housing.

(3) Install timing pin 49AL002 ( .in the fuel injection pump housing as shown. Slowly rotathe crankshaft counterclockwise until timing pin ( goes into the slot in the fuel pump camshaft.

Timing Pin Installed

2. 7N1048 timing pin

(4) Put the timing bolt in th timing hole in the flywheel housing. If the bolt can be installed in the timing hole in the Hrheele ning 0f the fuel injection pump is coect.

(5) If the timing bolt does not go into the timing hole in the flywheel, the timing of the fuel injection pump is not coect. Do the steps that follow to aust e timing of fuel iection pump.

(6) Remove nut ( and cover om the timing ge housing.

(7) Loosen bolt at holds the timing gear to efuel pump Cnshaft.

36

Timing Gear for Fuel Injection Pump

5.Bolt

(8) Install puller group and loosen the timing gear from the fuel pump camshaft.

(9) Remove the tii;ning bolt om flywheel housing. Rotate the flywheel clockwise 60 dgrees before the top dead cnter of No. 1 piston.

(10) Tighten timing boltnger tight. Be sure timing pin ( is in the slot of the fuel pump cShaft.

Puller Tools Installed

6. 8S2284 puller group 7. 8B7560 step plate 8. 1B3680 bolt 3/8 -24 NF, 95.3 mm (3.75 in ) long 9. 4B5271 washer

(11) Slowly rotate the camshaft counter-clockwise until e timing bolt can be installed in the flywheel.

(12) Install 3/8-24 NF bolt [12.7 mm (0.5 in) long. ] into a hole of the timing gear and tighten it to a torque of 60 ~ 70 N.m. Hold the bolt with one torque wrench, keeping the wrench in line with e c.enter of timing gear and use another torque wrench to tighten the bolt holding e timing gear to 270 ?30 N.m.

(13) Remove e timing bolt in the flywheel and timing pin ( in the fuel injection pump.

(14) Rotate the crankshaft counterclockwise two revolutions. If the timing bolt can be installed in the flywheel and the timing pin can 'be installed in the fuel pump camshafte timing is corrct.

(15) If eier the timing pin or the timing bolt cannot be installed, do the step 7 through step 14 n.

VI. TESTING FUEL INJECTION NOZZELS

Notice

Testing of fuel injection nozzles must be done with proper tools.

The following tools e required for testing the . 8N7005 fuel iection nozzles:

5P4150 nozzle testing group 5P7448 fitting 8S2270 oil catcher Ff 1384 extension pipe 8S2~45 too} group for cleaning

8S2258 brass wire brush 8S2252 tool for carbon seal.

lFl 153 nipper fliers 5V2170 pipe group 7/64 hexagon spanner

37

Tightening Timing Gear Bolt

5P4150 Nozzle Tes1gGroup

A. 5P7448 fitngB. 5P4146 pressure gauge, 0- 6900 kPa C. 6V2170 pipe group D. 2P2324 presse gauge, 0 - 34500 kPa E. Safety valve for protection of 2P2324 pressure

gauge F. Ffl384 extension pipe G. Safty valve for protection of 5P4146 pressure

gauge H. Switch valve I. 8N7005 fuel 1ction nozzle assembly J. 882270 oil catcher K. Cut-off valye for fuel pnp

Additional Valve

L. Safety v.alve for pressure gauge (must.be open at any time)

Notice

Must use cl~n light fuel to test nozzles.. Dirty light fuel will damage parts of nozzl. To get proper tng re temperature for tgfuel should be in 18 - 24

. 8N7005 fuel iection nozzles cannot be tom open for cleaning or adjusted. Use the following tests to detennine if performance of nozzles is acceptable or not.

1. Nozzle opening pressure test 2. Flushing the nozzles 3. Tip leakage test 4. ifice restriction test 5. Bleed sew leakage test

PreparatoWork Before Nozzle T

It is necessy tp clean carbon particles und etip of no,zzle m 8S2258 brass wire brush (M) before test.

B

Removal of Carbon Seal

nu -n d

nu nu 10

niw M 2t n

LV

m pwLW

dudu

NK t

3

Remove carbon seal ring nipper pliers and dismantle seal element ( off nozzle.

Nce

Do not use steel wire brush or wheel to brush body or tip of nozzles. Using such toOls will cause slight deerse of nozzle diameter and result in much drop of power. Excessive use Qf 882258 brass wire brush will scrub off prot coag ofe nozzle.

Brush the slot of anti-carbon seal ring ( and fuel injection nozzle body below the slot 8S2258 brass wire brush (M). When brushing carbon deposits, be se not to damage nozzle body.

NOE: It is normal that at the place below the slot there are color changes, which will not affect fuel injection nozzle body.

8S2245 Cleaning Tool Box

M. 8S2258 brass wire brush N. 8S2252 tool for anti~carbon seal P. 852250 clamper for fuel inJon n0zzle

38

B34i:SX1

8N7001Fuel Injction Nozzle

3. Bleed screw and sl

Remove the bleed screw and seal om the fuel injection nozzle.

NOTE: Except for the test 5 (bleed screw leakage testie bleed screw and seal must be removed during all tests.

1. VALVE OPENING PRESSURE TEST

(1) Fit 6V2170 pipe group (C) on the tester.

(2) Install 8N7005 fuel iniection nozzle and 5P7448 fitting (A) on the pipe group (C). The position of the bleed screw hole should face the tester and be in line with 6V2170 pipe group (C), so horizon spray will be formed. Be sure that the tip of nozzle is facing downward and connected into FT1384 extension pipe (F) and 882270 fuel catcher (J).

WARNING

When U be sure to wear safe gogFuel injected out of nozzle, which has a vehigh prS will impale skin, and cause serious inju to e operator.

Do not aim the tip of nozzle at e operator. It must be put into 8S2270 fuel catcher and FT1384 extension pipe.

39

nrt

Nozzle Ready for Test

E. Safety valve for pressure gauge K.Cutff valve for fuel pnp

Notice

H. Switch valve

Have a rag around the upper part of nozzle to catch leaking fuel.

(3) Close switch valve for fuel pump (K).

en cut-

(4en safety valve for pressure gauge (E). Start fuel pump to increase pressure slowly until the fuel injection valve of nozzle just begins to open. Read e maximum presse from gauge at e moment fuel is just flowing out of the tip of nozzle.

NOTE: If fuel injection valve gives out a click.on openi the reading.shown by the pressure gauge will possibly drop rapidly or keep constant almost.

NOTE: During the forth step, fuel iectioQvalve of nozzle is perhaps abnormal and can not give out a click, or sprom the nozzle is not fine.

If e opning pressure is out of e limits specified, the fuel in ection nozzle can not be used any longer ..

Valve opening pressure (VOP) specifications

15170 1030 kPa

2. FLUSHING THE NOZZLE

(1) Close the safety valve for pressure gauge (E) and switch valve . Open the cut-off valve for fuel pump (K).

NOTE: The tip of nozzle must be put into FT1384 extension pipe (F) and placed under the top of the pip

(2) Start up e fuel pump fast to perform ree full strokes.

3. TIP LEAKAGE ~ST

(1) Clear off fuel on the tip and body of nozzle with a clean rag.

(2) Have a clean rag around the body of nozzle to catch fuel out of the bleed screw and prevent leaking fuel from dripping onto the tip of nozzle.

31

Nozzle Ready for Test

E. Safety valve for pressure gauge H. Switch valve K. Cut-off valve.for fuel pump

(3) Open e safety valve for pressure gauge(E). Close e switch valve . Op'en e cut-off valve for fuel pump (K).

(4) Set the opening pressure 1380 kPa lower than the measured value in the first test, and maintain it for 15 seconds. Record the number of leaking fuel drips within the time.

Specification for tip leakage

Not more than 5 drips within 15 seconds

(5) If the above ruirement is not met, never use the nozzle.

40 .

4. ORIFICE RESTRICTION TEST

( I) Close the safety. val ye for pressure gauge (E) and switch valve (H). Opeo the cut-off valve for fuel pump (K).

(2) Put the tip of nozzle into 8S2270 fuel catcher and FT1384 extension pipe. Be sure that the bleed screw is facing the nozzle and in line wi 6V2170 pipe group (C), so the nozzle will be 15 degrees from vertical and spray horizontally.

(3) When fuel begins to flow into the nozzle, slowly increase the pressure and watch the spray shape from orifices. Spray shapes from nine orifices must be e same. If the spray shapes, whether vertical or horizontal, are differente fuel pump proves in trouble.

Good Nozzle (Use again)

Typical Spray Shape of Restricted Orifice (Replace the nozzle)

Sin nvnu1

e.uh

nyuz UA

L

-Hmo sbn vydELMu

mD

nmA

lwa 30JAj kzq mrmR TH

Typical Spray Shape of Vertical Deformation (Replace the Nozzle)

5. BLEED SCREW LEAKAGE TEST

(1) Fit the bleed screw and seal element ( on the nozzle and tighten bleed screw with torque of0.9 0.1 N.

Notice

The torque to tighten the bleed screw can not exceed the above specification. Otherwise, the bleed screw and seal element will be damaged.

(2lt e tip of nozzle into 8S2270 fuel catcher and FT1384 extension pipe.

(3) Close switch valve . Open the safety valve for pressure gauge (E) and cut-off-valve for fuel pump (K).

(4) Run the tester until the fuel iection nozzle is full of fuel and the pressure gauge reads 27500-kPa.

NOTE: It is needed for the fuel pump to Cy out 15 or 20 strokes before the pressure can get to 27500 kPa.

Technical Requirement for Bleed Screw Leakage No leakage btween bleed screw and nozzle

(5) If there is leaka"ge, change 8N4147 seal lrnent. Check washer fac of the screw for damage, and change it if necessy.Then test the nozzle again. If leakage is still found, it is necessy to replace th nozzle.

(6) If no leakage is found, the nozzle can be used Fit a new seal element ( onto the nozzle Install a new anti-carbon seal ring into the slot of the nozzle with 8S2252 tool for anti-can seal

NOTE: The 8S2252 tool for anti-carbon nng must be calibrated before it can be used for treating the nozzle.

Install Carbon Dam

2. Carbon darn 3. Seal N. 8S2252 carbon seal tool

41

VII. CHECKING LUBRICATION SYTEM

One of the problems in the list that follows will gnerally be an indication of trouble in elubrication system for the engine.

Too much oil consumption Oil pressure is low Oil pressure is high Too much bearing wear

1. TOO MUCH OIL CONSUMPTION

Oil Leakage on Outside of Engine

Check for leakage at the seals at each end of crankshaft. Look for leakage at the oil pan gasket and all lubrication system con,nections. Check to see if oil comes . out of the crankcase breather. This can be caused by combustion gas leakage around the pistons. A dty crankcase breather will cause high pressure in the crankcase, and is will cause gasket and seal leakage.

Oil Leakage into Combustion Area of Cylinders

Oil leakage into the combustion a of the cylinders can be the cause of blue smoke. There are four possible ways for oil leakage into the combustion ea of the cylinders:

(1) Oil leakage between worn valve guides and valve stems;

(2) Worn or damaged piston rings or dirty oil return holes;

(3) Compression ring and/or intermediate ring not installed correctly;

(4) Oil leakage past the seal rings in the impIlerend of the turbocharger shaft.

Too much oil consumption can also be the result if oil with the wrong viscosity is used. Oil M athin viscosity can be caused by fuel leakage into the crankcase, or by increased engin temp~rature.

2. OIL PRESSURE IS LOW

An oil pressure indicator that has a defect can give an indication of low oil pressure. So a pressure gauge is needed to check engine oil pressure.

Take the following procedures to check oil pressure. Be sure to follow the procedures correctly. Otherwise, pressure measurements can not be well comped with data in the chart.

42

(1) Be sur that the ngine is filld to the correct level with e1er SAE or SAE30 oil. If any othr viscosity of oil is used, the information in the ngine oil pressure chart does not apply.

Oil Pressure Switch Location

1. Oil pressure switch

(2) Remove the oil pressure switch omthe re of cylinder block and install a thre-way. pipe in at location. Fit one of the probes of 9S9102 rrnistorthermometer group into on end of the three-way pip and connect 8M2744 gauge in 5P6225 hydraulic test case with the other end of,the pipe.

. .....,2

.d

5P6225 Hydraulic Test Case

(3) Run the ngine to gt the engin oil temperareat 99?C.

NOTE: A 3 ?C increase in temprature gives approximately 7 kPa decrease in engin oil pressure.

( 4) Keep the engine oil temperature constant. With the engine at the r/min from the chart, read thpressure indicator and compar indication with the minimum acceptable pressure in the chart. If the indication is below the minimum pressure, find the cause and adjust it. Engine failure or a reduction in engine life can be the result if engine operation is continued with too low pressure.

Chart for Oil Prssure

Minimum Permissible Test Test oil pressure

speed SAE No. kPa

1500 r/nn 10 140 or higher 30 165 600 ~ 10 40 800 r/rnin 30 59

Crankcase Oil Level

Check the level of oil in crankcase. Add oil if needed. It is possible for the oil level to be too far below the oil pump supply tube. This will cause the oil pump not to have ability to supply nough lubrication to the engine components.

Oil Pump Does Not Work Correctly

The inlet screen of the supply tube for th oil pump can have a restriction. This will cause cavitation (low pressure bubble suddenly made in liquids by mechanical force) and a loss of oil pressure. Air leakage in e supply side of ie oil pump will also ca us cavitation and loss of oil pressure. If thbypass valve for the oil pump is held in the open positione lubrication system cmot get to a maximum pressure. Oil pump gears that have too much wear will cause a reduction in oil pressure.

43

Oil Filter and Oil Cooler Bypass Valves

If th bypass valve for e oil filter or oil cooler is held in the open position, and e oil filter or oil cooler has a restriction, a rductionin oil pressure can. be resulted. Install a new catrpillar oil filter to solve the problem.

Too Much Clearance at Engine Bearings or Open Lubrication System (Broken or Disconnected

Oil Line or Passage)

Components that are worn and hav too much bearing clece can cause oil pressure to be low. Low oil pressure can also be caused by an oil line or oil passage at is open, broken or disconnected.

Oil Cooler

Look for .a resction in the oil passag of the oil cooler. If oil cooler has a restriction, oil temperare will be higher than normal when the engine is operated.. The oil pressure of the engine will not get low just because the oil cooler has a restriction.

3. OIL PRESSURE IS IDGH

Oil pressure will be high if the bypass valve for the oil pump cannot move from the closed position.

4. TOO MUCH BEARINGTEAR

When some components of. the engine show bearing wear in a short time, the cause can be a restriction in an oil passage. A broken oil passage can also be th cause.

If the gauge for oil pressure shows normal pressure, but a componnt is worn because it Cmot get enough lubrication, look at epassage for oil supply to the component. A restriction in a supply passage will not let enough lubrication get to a component, and this will cause early wear.

VIII. BELT TENSION ADJUSTMENT

(1 ) Check all ive belts for excessive wear, abrasion and break

When one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only thworn blt is replaced, the new belt will Callthe load. All the belts will fail in rapid succession.

(2) Measure the belt tension. Apply a force of 110 N vertically to the belt between the driving and iven pullys.

The normal deflection of belt should be 14 ~ 20 mm. Adjust belt tension as required.

Adjusting

(1) Loosen the retaining bolt. on the slotted bracket.

44

(2) Move the alternator in or out to get correct adjustment.

(3) Tighten the retaining bolt after adjustment.

CHAPTER THREE

MAINTENANCE

I. MAINTENANCE AS NEEDED

1. COOLING SYSTEM

Cleaning

WARNING

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine hbeen stopped and the filler cap is cool enough to remove with your bare hand.

Remove the cooling system filler cap slowly to relieve pressure.

Cooling system additive (conditioner) contains alkali. To preve personal injury, avoid contact with the skin and eyes.

(1) Iosen the radiator filler cap slowly to relieve pressure and remove the cap.

WARNING

Use all cleaning solutions with care.

45

Notice

If the engine is to be stored in, or shipped to, an area with freezing temperare, the cooling system must be protected to the lowest expected outside (ambient) temperare or coolant should be drained.

Never add coolant water to an overheated engine, engine damage can result. Allow "the engine to cool first.

(2) Remove the radiator drain plug.

(3) Remove e drn plug for water jacket of engine block.

(4) Install all drain plugs. Fill th cooling system with commercially available cleaner or thmixture of lkg NaHS04 per 40 L (10 US gal) clean watr.

(5) Start and run the engine for 30 minutes. Stop e engine and drain the cleaner.

(6) Flush the cooling system with clm water until the draining watr is clear. Do not run the engine during flushing.

(7) Install all drain plugs. Fill ie system with neutral so~ution or e mixture of 250 g Na2C03.lOH20 pr 40 L water.

(8) Start and run the engine for 10 minutes. Stop the engine and drain the neutral solution

(9) Flush the cooling system with clean water until the draining water is clear. Do not run the engine during flushing.

(lO)Install all drain plugs.

(l l)Fill e system with clm water. Start and run the engine for 10 minutes, then drain the water.

Repeat above steps until the draining water is cle

(12) Fill the cooling system no faster than 19 L per minute to avoid air locks.

2. AIR INLET SYSTEM

Single Stage Air Cleaner - Replacing Element

Notice

Service the air cleaner only when the engine stops.

Observe the air claner service indicator. Service the air cleaner when the red piston locks m visible position.

46

(1) Remove the air claner cover and element.

(2) Seal the turbocharger air inlet.

(3) Clean the insides of the air cleaner cover and body.

(4) Inspect the replacement element for damage, dirt or debris.

(5) Rmove the seal from the turbocharger inlet.

(6) Install a clean, undamaged element.

(7) Install the air cleaner cover.

(8) Reset the service indicator.

Tuo Stage Air Cleaner - Cleaning

(1) Loosen the clamp bolt on the lower body.

(2) Remove and empty the dust collector cup.

47

(3) Loosen the clamp bolt on the upper body.

(4) Remove the lower body and clean the tubes from both ends.

(5) Inspect the seal between the lower body and e dust collector cup and gasket between the lower and upper bodies. Install a new .seal and gasket if necessy.

(6) Install the lower body to the upper body and tighten the clamp bolt.

( 6) Install th dust collector cup and tighten the clamp bolt.

Installing The Replacement Element Of Two Stag~ Air Cleaner

(1) Remove the cover.

(2) Remove the inside cover and element. In cold weather, the cau~ht inside cover can be removed by heating the air cleaner cover to 21 24

(3) Clean all pts of the arr cleaner.

( 4) Inspect the replacement element for damage, dirt or debris.

(5) Install a clean undamaged element. Install the inside cover and wing nut. Tighten the wing nut.

(6) Install the cover.

Cleaning Air Cleaner Elements

WARNING When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa for cleaning purposes.

48

Notice

When using presse water for cleaning, the maximum pressure should be lower than 280 kPa (2.8 kg/cm2) ( 40 psi) to avoid damage of eelement.

COMPRESSED AIR - The ,pressure should be 205 kPa mimum.

(1) Direct prsure air along the length of the pleats inside of filter element.

Notice

Do not clean filter elements by bumping or tapping.

Do not use filter elements wi damaged pleats, . gaskets or seals. Engine damage could result.

Have spare elements on hand to use when cleaning e used filter elements.

Dry filter elements can. be' cleaned with pressure air, pressure water or detergent washing.

(2) Direct pressur air along the length of the pleats inside and then outside of filter element Inspect th filter element.

PRESSURE WATER - The pressure should be 280 kPa maximum.

(1) Direct water along the length of the pleats inside of filter element.

(2) Direct water along the length of the pleats outside of filter element. Air dry elementoroughly and inspect it.

DETERGENT WASHING

49

(2) Rinse inside and outside the pleats.

(3) Air dry the element thoroughly and inspects it before using.

(2) Wrap and store the clean filter elements in a cley plac

3. FUEL SYSTEM

New Scroll Fuel System

(1) Stop the engine.

(2) Shut off the supply valve of fuel tank.

(3) Loosen the nut ( on the primary filter cap and remove the filter housing (.

(4) Remove th~ element ( and wash it and the cap in clean, nonflammable solvent.

(5) Install the element and housing.

Final Fuel Filter

( 1) Remove and discard the final fuel filter.

(2) Clean the gasket sealing surface of the filter base.

Notice

Make sure all the old gaskets are removed.

(3) Apply clean diesel fuel to th new fuel filter gasket.

50

Notice

Do not fill the fuel filter with fuel before installing it. Prime the fuel system according to the instruction of Priming The . Fuel System.

(5) Install new filter. Spin filter until gasket contacts the filter base. Tighten the filter 1/2-3/4 tum by hand.

(5) Prime the fuel system.

Priming The Fuel System

(1) Move the fuel control linkage to the OFF osition.

(2en the 'vent valve on the fuel injection pump housing.

(3erate the priming pump until the flow of fuei from the vent valve is continuous and free of air bubbles.

Notice

If only one wrench is used to loosen or tighten the fuel line nuts, fuel injection nozzles can be permanently damaged by twisting. Use one wrench to hold the nozzle and another to loosen the nut.

(4) Close the vent valve and lock up e priming pump.

II. MAINTENANCE EVERY 10 HOURS

1. ENGE CRANKCASE

(1) Check oil level. Maintain the oil level between the FULL and ADD marks on the Running side of the dipstick.

(2) Add oil if necessary.

51

(5) Start the engine. If the engine continus to misfire or smoke, further priming is necessy.

(6) Loosen the fuel line nuts on the cylinder head. Crank the engine until the fuel flows fr of air bubbles.

(7) Tighten the fuel line nuts to 40 7N.m.

2. AIR CLEANER SERVICE INDICATOR

Check air cleaner service indicator. If the red piston locks in the rising position, service the air cleaner.

1. FUELTANK

Drain water and sediment.

4. COOLING SYSTEM

Checking Coolant Level

At operating temperaturee engine coolant is hot and under pressure.

Steam can cause personal irjury.

Check the coolant level only after e engine has been stopped and the filler cap is cool enough to remove with your bare hand.

ID. MAINTENANCE EVERY 50 HOURS

5. DUST COLLECTOR

Cleaning

(1) Remove the retaining wing nut from the top of dust collector.

52

Remov the radiator filler cap slowly to relieve pressure

Cooling systm additive (anti-rust) contains alkali. To prevent personal injury, avoid contact with the ski'n and eyes

If it is necessy to add coolant every day, check the cooling system for leakage.

(1) After the engine is stopped and cool, check the coolant level. Open the radiator filler cap slowly to relieve pressure. Watch coolant level.

(2) Maintain the coolant level within 1 cm below e bottom of the fill pipe. Check gasket of radiator filler cap and replace it if necessy.

(2) Remove and clean the dust collector cup.

(3) Install the collector cup.

6. BATTERIES

Checking Electrolyte Level

WARNING

Do not smoke when observing the battery electrolyte level. Batteries give off flammable fumes, which can explode.

Battery electrolyte contains acid, and can cause personal injury if it contacts the skin and eyes.

(1) Clean top of batteries.' Kep all baeryterminals clean and coat them with grease.

IV. MAINTENANCE EVERY 250 HOURS

7. ADJUSTING ALTERNATOR BELT TENSION

Aust it as required.

8. ENGINE CRANKCASE (TURBOCHARGED ENGINES ONLY)

Oil and Filter Change

53

(2) Remove all fill caps. Check electrolyte levI.

(3) Maintain electrolyte level to bottom on fill plug openings.

( 4) Install fill caps.

If addition of water is necessary, use distilled water. If distilled water is not available, use clean water that is low in minerals. Do not use artificially softned water.

WARNING

Take care to change oil and filter(s). The skin can be burned if hot oil and components are touched.

(1) Remove the crankcase oil drain plug and allow the oil to drain.

(2) Wipe off the dirt on the surface of oil filter(s).

(3) Remove and discard the filter.

( 4) Wipe the sealing surface of the filter mounting base. Make sure all of the old gasket is removed.

(5) Install a new filter, until the gasket contacts the base. Tighten the filter 3/4 of a tum more by tool. There may be marks at 90 intervals on the filter. When tightening the filter 3/4 of a tum more by toolese marks should be used.

54

(6) Use cleaning solution, which is clean and not easy to bum, to wash the oil drain plug, and then install it.

(7) Fill the crankcase with clean oil. See the chart for Filling Capacity of Engine Oil and Coolant'.

(8) Move the iel throttle to the OFF position.

Turn e engine cranksha until the oil pressure meter indicates pressure. Then set the throttle at the ON position and stt eengine.

(9) Stop the engine. Maintain the oil level to FULL mark.

9. CRANKCASE BREATHER

(1) Loosen the breather hose clamp and remove ehose.

(2) Loosen the breather retaining bolt and remove the breather.

(3) Check sealing gasket and replace it if necessary.

(4) Use cleaning solution, which is clean and not easy to bum, to wash the breather. Then dry the breather.

(5) Install the breather.

(6) Install the hose and hose clamp on the breather.

55

10. COOLING SYSTEM

Adding Coolant Anti-Rust

WARNING

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal iU

Check the coolant level only after the engine has been stopped and the uler cap is cool enough to remove with your bare hand.

Remove the radiator filler cap slowly to relieve pressure.

Cooling system additive (anti-rust) contains alkali. To prevent personal injury, avoid contact with the skin and eyes.

(1) Loosen the radiator filler cap slowly to relieve pressure and then remove it.

It may be necessy to drain enough coolant from the radiator to allow for the addition of the supplemental coolant anti-rust.

(2) Add coolant anti-rust to the cooling system. For the appropriate concenationof coolant anti-rust, refer to e instruction of th anti-rust manufacturer.

(3) Inspect the radiator filler cap gaskets. Replace the cap if the gaskets are damaged.

(4) Install the radiator filler cap.

V. MAINTENANCE EVERY 500 HOURS

11. ENGINE CRANKCASE (NATURALLY ASPIRATED ENGINES ONLY)

Oil and Filter(s) Change

Change the oil filter(s) and wash the breather. Refer to the relevant description in Section IV of this Chapter.

12. FAN BEARING

Lubricate one fing.

VI. MAINTENANCE EVERY 1000 HOURS

14. GOVERNOR

Lubricate two fit1gs.

15. ENGINE SHUTOFF CONTROLS

The ngine shutoff controls must be checked periodically so at they function properly when they are reqred. To prevent damage to ie engine while performing the test, only authorized personnel should prform e checks.

56

13. FUEL SYSTEM

New Scroll Fuel System

Clean primary filter and replace e element of final fuel filter every 500 engine operation hours or if e fuel meter gives abnormal indication while the engine is running. For the method of replacing and cleaning, refer to the Fuel System topic in the Maintenance As Needed .

Synchronous Motor

Fill oil cup.

16. TACHOMETER

Lubricate one fitting.

VII. MAINTENANCE EVERY 2000 HOURS

17. VALVE LASH

Adjust the engine valve lash as specified.

18. COOLING SYSTEM

Replacing the Coolant (Every 2000 Operating Hours or 2 Years)

WARNING

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personalinjury.

Check the coolant level only after the engine has been stopped and the filler cap is cool enough to remove with your bare hand.

Remove the radiator Iller cap slowly to relieve pressure.

Cooling system additive (anti-rust) contains alkali. To prevent personal injury, avoid contact with the skin and eyes.

(I) Loosen the radiator filler cap slowly to relieve pressure and then remove it.

57

(2) Remove the radiator drain plug(s). Allow coolant to drain.

(3) Remove the cylinder block drain plug(s). Allow the coolant to drain.

(4) Wash the drain plug(s).

(5) Install the drain plug(s).

(6) Fill coolant according as specified in Section 1.3 of Chapter Two.

CHAPTER FOUR

TROUBLESHOOTING

Troubleshooting can be difficult. The Troubleshooting index gives a list of possible problems. To make a

repair to a problem, make reference to the cause and correction on e pages that follow.

This list of problems, causes and corrections will only give an indication of where a possible problem can be, and

what repairs are needed. Normally, more or other repair work is needed beyond the recommendation in the list.

Remmber at a problem is not normally caused only by one part, but by the relation of one part with other pts .

This list is only a guide and cannot give all possible problems and corrections. Service personnel must find the

problem and its source, then make the necessy repairs.

Troubleshooting Index

No. Trouble

1 : ~ngine will not tum when start switch 1s on.

- - 2 : Engine will not start.

3 ~ Misfiring or running rough.

4 ' sl at low r/rnin.

5 I Sudder ar sin er r/6 ' Not enough power. ;

7 Too much vibration.

8 L Loud combustion noise (knock). '

0 ; Loud noise clicking ) from valve i : comptment

10 i Oil in cooing system.

11 '. Mechanical noise (knock) in engine.

12 Fuel consumption too high.

: Loud noise from valves or valv13 I

o?erating components.

Little movement of rocker m and too 14

much valve lash.

15 Valve rotocoil or spring lock is free.

No. Trouble

16 Oil at the exhaust.

17 1 Little or no valve lash. ,

1 18 : Engin

19 ; Coolant in lubrication oil.

20 : Too much black or gray smoke. ! L

21 Too much white or blue smoke.

22 : Engine has low oil pressure.

23 Ene uses too much lubrication oil. !

: 24 ! Engine coolant is too hot.

25 Startin~ motor dose not turn.

26 , Alternator ~ives no char~e.

Alternator charire rate is low or not ' 27 . I:> , ! regu1ar.

28 Alternator charge is too high.

29 Alternator has noise.

30 Exhaust temperature is too high.

58

~roblem 1: Engine WiJI Not Turn When Start Switch ls On

No. Probable Cause

Battery has low output

2 Wires or switchs have defect

3 Starter motor solenoid has a defect

4 Starter motor has a defect

5 Inside problem prevents engme crankshaft from turning

Problem 2: Engine Will Not Start

No. Probable Cause

Slow cranking speed

2 No fuel in the housing for the fuel 1ection pumps

3 Dirty fuel filter

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6 Poor quality or water in fuel

7 Fuel has cloud point higher than atmospheric temperature (cloud point= temperature which makes W form in fuel)

8 Wrong fuel injection timing

9 Overfueling spring not installed

Remedy

Make reference to Problem 26.

Make referenc to Problem 26.

Make reference to Problem 25.

Make reference to Problem 25.

If crankshaft cannot be turned after the drive equipment is disconnected, remove the fuel nozzles and check for fluid in the cinders while the cranksha is turned. If fluid in the cylindrs is not e problem, the ngine must be disassembled to check for other inside problems. Some of these inside problems are bearing seizure, piston seizure, wrong pistons installed in the engine, and valves making contact with pistons.

Remedy

Make reference to Problem 26.

Fill the housing for the fuel pumps with fuel using the priming pump. Remove the air with the bleed valve.

Install new fuel filter.

Clean or install new fuel lines as necessy.

Put fuel in fuel tank. Prime(remove throm the fuel system).

Remove fuel from the tank. Install a new fuel filter element. Put a good grade of clean fuel in thiel tank.

Drain the fuel tank, lines, and fuel injection pump housing. Change the fuel filter. Fill e tank with fuel which has the correct cloud point and remove the r from e system with the priming pump.

Make austment to timing.

Install overfueling spring.

59

Problem 3: Misfiring Or Running Rough

No. Probable Cause

Air in the fuel system

2 Fuel pressure is low

3 Leak or break in fuel line between fuel injection pump and fuel iection nozzle

4 Defect in fuel in ection nozzle(s) or in ection pump(s)

5 Fuel system not timed correctly to engine

6 Wrong valve lash

7 Bent or broken push rod

8 Wrong valve seat or face of valve

Problem 4: Stall At Low R/Min

No. Probable Cause

Idle r/min too low

2 Defect in fuel iction nozzle(s) or fuel injection pump(s)

Remedy

Find air leak in the fuel system and coect. Remove air from fuel system.

Make sure there is fuel in the tank. Look for leaks or bad bends in fuel line between fuel tank and fuel transfer pump. Lok for air in the fuel system. Check fuel pressure at the fuel iection pump housing. If fuel pressure at high idle is lower than 105 kPa (15 psi), install a new filter element. If fuel pressure is still low, check the pumping sp1g and the check valves in efuel transfer pump.

Install a new fuel line.

Run engine at r/min that gives maximum misfiring or rough running. Then loosen a fuel line nut on the fuel injection nozzle for each cylinder, one at a time. Find the cylinder where loosening e fuel line nut dose not change the way the engine runs. Test e fuel iction pump and fuel iectionnozzle for that cylinder. Install new pts where needed.

Mak ajustment to timing if necessary.

Make ajustment.

Replacement of push rod is ncessary.

Reconditioning of cylinder head is needed.

Remedy

Make adjustments to governor.

Run engine at r/min that gives maximum misfiring or rough running. Then loosen a fuel line nut on the fuel injection nozzle for each cylinder, one at a time. Find e cylinder where loosening the fuel

line nut do~e not change the way the engine runs.

60

Test . fuel injection pump and fuel iectionnozzle for that cylinder. Install new parts where needed.

Problem 5: Sudden Changes In Engine R/Min

No. Probable Cause

Failure of governor or fuel injection pump

Problem 6: Not Enough Power

No. Probable Cause

Air in the fuel system

2 Fuel pressure is low

3 Poor quality or water in fuel

4 Constant bleed valve stays open or closed

5 Leaks in air inlet system

6 Governor linkage

7 Wrong vale lash

8 Defect in fuel injection nozzle(s) or fuel injection pump(s)

9 Wrong fuel iection timing

10 Fuel setting too low

11 Turbocharger has carbon deposits or other cause for friction

Problem 7: Too Much Vibration

61

Remedy

Look for damaged or broken springs, linkage or other parts. Remove the governor. Chck for free travel of the fuel rack. Be sure fuel lctionpumps are installed correctly. Check for coect governor spring. Install new parts for those that have damage or defects.

Remedy

Find air leak in the fuel system and correct. Remove air from fuel system.

Make sure there is fuel in the tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure at e fuel injection pump housing. If fuel pressure at high idle is lower than 105 kPa), install a new filter elemnt. If fuel pressure is still low, check epumping spring and the check valves in the fuel transfer pump.

Remove fuel from the tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tInstall new pts if needed.

Check the pressure in the air inlet manifold. Look for restrictions in the air cleaner.

Make ajustment to get full travel of lin_kage. Install new pts for those that have damage or defects.

Make austment.

Run engine at r/min at gives maximum misfiring or rough running. Then loosen a fuel line nut on the fuel injection nozzle for each cylinder, one at a time. Find e cylinder where loosening the fuel line nut dose not change the way the engine runs. Test e fuel injection pump and fuel iectionnozzle for at cylinder. Install new pts where needed. Make austment to timing.

Makeaustment as specified.

Make inspection and repr of turbocharger as necessary.

No. Probable Cause

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2 Pulley or damper has a defect

3 Fan blade not in balance

4 Engine supports are loose, worn, or have a defect

5 Misfiring or running rough

Problem 8: Loud Combustion Noise (Knock)

No. Probable Cause

Poor quality or water in fuel

2 Defect in fuel iection nozzle(s) or fuel injection pump(s)

3 Wrong fuel iction timing

Remedy

Tighten bolt or nut

Install a nw pulley or damper.

Loosen or remove fan belts and operate engine for a short time at the r/min that the vibration was present. If vibration is not still present, make a replacement of the fan assembly. Tighten all mounting bolts. Install new components if necessy.Make reference to Problem 3.

Remedy

Rmove fuel from tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

Run engine at r/min th gives mimumcombustion noise. Then loosen a fuel line nut on the fuel iection nozzle for each cylinder, one at a time. Find the cylinder where loosening the fuel line nut stops combustion noise. Test the fuel iection pump and fuel iniection nozzle for atcylinder. Install new pts where needed.

Make austment to timing.

Problem 9: Loud Noise (Clicking) From Valve Compartment

No. Probable Cause

Damage to valve spring(s) or locks

2 Not enough lubrication

3 Too much valve lash

4 Damage to valves

Remedy

Install nW parts where necessary. Locks with defects can cause e valve to slide into ecylinder. This will cause much damage.

Check lubricati9n in valve compartment. There must be a strong flow of oil at engine high r/min, but only a small flow of oil at low r/min. Oil passages must be clean, especially those sending oil to the cylinder head.

Make adjustment.

Make a replacement of the valve(s) and make an adjustment as necessary.

62

Problem 10: Oil In Cooling System

No. Probable Cause Remedy

Defect in core of engine oil cooler Install a new core in the engine oil cooler.

2 Defect in head gasket Install a new head gasket.

Problem 11: Mechanical Noise (Knock) In Engine

No. Probable Cause

Failure of bearing for connecting rod

2 Damage to timing gears

3 Damage to crankshaft

Problem 12: Fuel Consumption Too High

No. Probable Cause

Fuel system leaks

2 Fuel and combustion noise (knock)

3 Wrong fuel injection timing

Remedy

Inspect the bearing for the connecting rod and ebearing surfac on the crankshaft. Install new parts when necessary.

Install new parts when necessy.

Replace the crankshaft.

Remedy

Inspect the fuel system for leaks and make repairs as necessy.

Small increases in fuel consumption may be the result of fuel nozzles with defects, rough running, or factors causing loss of power. See Problem 3 and Problem 6.

Make an austment to fuel injection timing.

Problem 13: Loud Noise From Valves Or Valve Operating Components

No. Probable Cause

Damage to valve spring(s)

2 Damage to Cnshaft

3 Damage to valve lifter

4 Damage to valve(s)

63

Remedy

Make replacement of parts with dnage.

Make replacement of pts with damage. Clean engine thoroughly.

Clean engine thorough Make replacement of e camshaft and valve lifters. Look for valves that do not move freely.

Make a replacement of the valve(s) and make an adjustment as necessary.

Problem 14: Little Movement.Of Rocker Arm And Too Much Valve Lash

No. Probable Cause

Too much valve lash

2 Not enough lubrication

3 Rockr i worn at face that makes contact with valve

4 End ofvalv stem worn

5 Worn push rods

6 Valve lifters worn

7 Damage to valve lifters

8 Worn cams on camshaft

Remedy

Make adjustment.

Check lubrication in valve compartment. Thermust be a strong flow of oil at high r/min, but only a small flow at low r/min. Oil passage must be clean, especially thos sending oil to the cylinder head.

If iere is too much wear, install new rocker ms.Make an adjustment to valve lash.

If there is too much wear, install new valves. Make an austment to valve lash.

If ther is too much wear, install new push rods. Make an austment to valve lash.

If there is too much wear, install new valve lifters. Make an adjustment to valve lash.

Install new valve lifters. Check camshaft for wear. Check for fr, movement of valves or bent valve stem. Clean engine thoroughly. Make an austment to valve lash.

Check valve lash. Check for free movment of valves or bent valve stem. Check for valve lifter wear. Install a new camshaft. Make austmentof valve lash.

Problem 15: Valve Rotocoil Or Spring Lock Is Free

No. Probable Cause

Damage to locks

2 Damage to vve spring(s)

Problem 16: Oil At The Exhaust

No. Probable Cause

Too much oil in the valve comptment

2 Worn valve guides

3 Worn piston rings

4 Running engine too long at low idle

64

Remedy

Locks wi damage can cause the valve to fall into the cylinder. This will cause much damage.

Install new valve spring(s).

Remedy

Look at both ends of the rocker m shaft. Be sure at there is a plug in each end.

Reconditioning of th cylinder head is needed.

Make a visual inspection of the piston rings. Install new pts if necessary.

Do n_ot let the engine run for long periods of time at low idle.

Problem 17: Little Or No Valve Lash

No. Probable Cause

Worn valve seat or face of valve

Problem 18: Engine Has Early Wear

No. Probable Cause

Dirt in lubrication oil

2 Air inlet leaks

3 Fuel leakage into lubrication oil

Problem 19: Coolant In Lubrication Oil

No. Probable Cause

Failure of engine oil cooler core

2 Failure of cylinder head gasket

3 Crack or defect incylinder head

4 Crack or defect of cylinder block

5 Failure of seals .for cylinder liners

'Problem 20: Too Much Black Or Gray Smoke

No. Probable Cause

Not enough air for combustion

2 Bad fuel injection nozzle(s)

3 Wrong fuel in ection timing

65

Remedy

Reconditioning of cylinder head is needed. Make an austment to valve lash.

Remedy

Remove dirty lubrication oil. Install a new en~ne oil filter element. Put clean oil in the engme.

Inspect all gaskets and connections. Make repairs if leaks are present.

This will cause high fuel consumption and low engine . oil pressure. Make repairs if leaks are present. Inall new pts' where needed.

Remedy

Install a new core for the engine oil cooler.

Install a n~w cylinder head gasket. Tighten the bolts holding cylinder head, according to Specifications.

Install a new cylinder head.

Install a new cylinder block.

Make a replacement of the seals.

Remedy

Check air cleaner for restrictions. Check inlet manifold pressure. Inspect turbocharger for coect operation.

Test all nozzles. Install new nozzles if test shows replacement is needed.

Make adjustment to timing.

Problem 21: Too Much White Or Blue Smoke

No. Probable Cause 1 Too much lubrication oil in engine

2 Misfiring or running rough

3 Wrong fuel iection timing

4 Worn valve guides

5 Worn piston rings .

6 Failure of turbocharger oil seal

Problem 22: Engine Has Low Oil Pressure

No. Probable Cause

Defect in oil pressure indicator

2 Dirty engine oil filter or engine oil cooler

3 Diesel fuel in lubrication oil

4 Too much clearanc between rocker mshaft and rocker

5 Oil pump suction pipe has a defect

6 Relief valve for oil pump dose not opratecorrectly

7 Engine oil pump has a defect

8 Too much clearanc between camshaft and camshaft bearings

9 Too much clearanc between crankshaft and crankshaft bearings

10 Too much cleararice for idler ge

11 Orifices for piston cooling not installed

~ernedy Rmove extra oil. Find where extra oil comes from. Put correct amount o( oil in engine. Do not put too much oil in engine.

Make reference to Problem 3.

Mak austment to tinung.

Reconditioning of the cylinder head is needed.

Install new piston rings.

Check inlet manifold for oil and make repair to turbocharger if necessary.

Remedy

Install new indicator.

Check th operation of bypass valve for the filter. Install new engine oil filter element if needed. Clean or install new engine oil co.oler core. Remove dirty oil om engine. Put clean oil in engine.

66

Find the place wher diesel fuel gets into the lubrication oil. Make repairs as needed. Rem~ve the lubrication oil at has diesel fuel in it. Install a new engine oil filter element. Put clean oil in the engine.

Check lubrication in valve comptment. Install new pts as necessy.

Replacement of pipe is needed.

Clean valve a,nd housing. Install new pts as necessary.

Make repair or replacement of engine oil pump if necessy.

Install new camshaft and camshaft beings if necessy.

Check oil filters fur proper operation. Install new parts as necessy.

Inspect bearings and make replacemnt as necessary.

Install piston cooling jets.

Problem 23: Engine Uses Too Much Lubrication Oil

No. Probable Cause

Too mu~h lubrication oil in engme

2 Oil leaks

3 Oil temperature is too high .

4 Too much oil in valve comptment

5 Worn valve guides

6 Worn piston rings and cylinder liners

7 Failure of seal rings in turbocharger

Problem 24: E~gine Coolant Is Too Hot

No. Probable Cause

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2 Not enough coolant in system

3 Pressure cap has a defect

4 Combustion gases in coolant

5 Water temperature regulator errnostat)or temprature indicator has a defect.

6 Water pump has defect

7 Too much load on the system

8 Wrong fuel in ection timing

Remedy

Rmove extra oil. Firid where extra oil comes from. Put coect amount of oil in engine. Do not put too much oil in engine.

Find all oil leaks. Make repair as needed.

Check operation of engine oil cooler. Install new parts if necess. Clean the core of the engine oil cooler.

Make reference to Problem 16.

Make reference to Problem 16.

Install new parts i( necessary.

Check inlet manifold for oil and i'nake rep totbochger if necessy.

Remedy

Remove all restriction to flow.

Add coolfil,lt to cooling system.

Check operation of pressure cap. Install a. new pressure cap if necessary.

Find out where gases get into the cooling system. Make repairs as needed.

Check water temperature regulator for correct operation. Check temperature indicator operation. Install new pts as necessy.Make repairs to the water pump as necessy.

Make a reduction in e load.

Make austrnent to timing.

67

Problem 25: Starting Motor Does Not Turn

No. Probable "Cause

Battery has low output

2 Wires or switch has defect

3 Starting motor solenoid has a defect

4 . Starting motor has a defect

Problem 26: Alternator Gives No Charge

No. Probable Cause

Loose drive belt for alternator

2 Ch~ging or ground return circuit or battery connections have a defect

3 Rotor (field c~il) has a defect

Remedy

Check condition of battery. Charge battery or make replacement as necessy.

Make repairs or replacement as necessary.

Install a new solenoid.

Make repr or replacement of starting motor.

~emedy

Make an adjustment to put the corrt tension on e drive belt.

Inspect all cables and connections. Clean and tighten all connection. Make reP,lacement of parts with defects.

Install new rotor.

Problem 27: Alternator Charge Rate Is Low Or Not Regular

No. Probable Cause Remedy

Loose drive belt for alternator Make an adjustment to put ie correct tension on le ive belt.

2 Charging or ground return circuit or ~J:~ all cables and connections. Clean and baery connections have a defect all connections. Make replacement of

Pts with defects.

3 Alternator regulator has a defect Install a new alternator regulator.

4 Rectifier diodes have a defect Make rlacement of rectifi has ade~t. ,

5 Rotor (field coil ) has a defect Install a new rotor. )

Problem 28: Alternator Charge Is Too High (The Light Is Burnt And The Batteries Need Too Much More Water)

No. Probable Cause

Alternator or regulator has loose connections

68

Remedy

Tighten all connections to alternator or alternator regulator.

2 Alternator regulator has a defect

Problem 29: AlternatorHas Noise

No. Probable Cause

Drive belt for alternator is worn or has a defect

2 Loose alternator ve pulley

'3 Drive belt and drive pulley for alternator are not in alignment

4 Worn alternator bearings

5 Armature or rotor shaft is bent

6 Rectifiers in the alternator e shorted

Problem 30: Exhaust Temperature Is Too. High

No. Probable Cause

Leaks in inlet system

2 Leaks in exhaust system

3 Air inlet or exhaust system has a resiction

4 Wrong fuel injection timing

69

Install a new alternator regulator.

Remedy

Install a new e:l.rive belt for ~ternator.

Check groove in pulley for key at holds pulley in place. If groove is worn, install a new pullTighten pulley nut according to spcification.

Make an ausent to put drive belt and drive pulley in correct alignment.

Install new bearings in the alternator.

Make a replacement of ~e parts.

Make a replacement of the diode assembly.

Remedy

Check inlet mfold pressure. Check air cleaner for restrictions. Make repairs for all les.

Find the cause of leaks. Make repairs if necessy.

Remove restriction.

Make an adjustment to the timing.

1

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