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Engine Identification

1. 00900198 Remove the piston ring from the piston using piston x ring tool Part No 3823137 00900199 ex If the bushing is worn the connecting rod must be replaced Inside Diameter 30 00 mm 1 18 in NOTE Keep the pistons connecting rods bearings piston rings piston pins and bushings in sets for each cylinder number 00900200 Main Bearing Cap Rotate the cylinder block so that the bottom of the block is facing up 00900201 Diesel Engine 58 Complete Engine Diesel Engine Measure the end play of the crankshaft using a dial gauge NOTE The end play measurement is necessary for determining the wear of the thrust bearing and abnormal wear of the crankshaft Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 00900202 xc Remove the mounting capscrews of the main bearing cap Remove the main bearing cap and lower bearing NOTE e Mark the thrust bearings so that they can be installed into the correct position e The main bearing cap mounting capscrews must be replaced after each use xc Crankshaft CAUTION Be careful not to hit the crankshaft against the cylinder block and damage the sliding surface Remove the crankshaft Remove the upper main bearing NOTE Mark the main bearings and thrust bearing so that they can be installed into the correct position 00900205 59 Complete Engine x Tappet Remove the tappet L X 00900205 Di
2. 69 250 mm 2 726 in U S 0 75 U S 1 00 Inner Diameter of Cam Bushing 69 000 mm 2 717 in 90 500 mm 1 988 in 70 000 mm Sn 2 756 in 69 750 mm U S 0 25 2 746 in Inner Diameter of 69 500 mm Main Bearing oe 2 736 in Repair Limit 0 15 mm 0 006 in Repair Limit 70 200 mm 2 764 in Repair Limit 69 950 mm 2 754 in Repair Limit 69 700 mm 2 744 in Repair Limit 69 450 mm 2 734 in Repair Limit 69 200 mm 2 724 in Repair Limit 50 600 mm 1 992 in Diesel Engine 104 Specifications Camshaft and Camshaft Bushing 18900015 Ref Inspection Item Standard Remarks CAMSHAFT Naturally Aspirated Naturally Aspirated 0 03 mm Bend of Shaft 0 0012 in Repair Limit Intake u nn 42 20 mm Height oe 9 43 04 mm Repair Limit Exhaust 1 694 in 42 50 mm 1 673 in Repair Limit 0 50 mm 0 0197 in Thrust 0 150 to 0 350 mm Clearance 0 0059 to 0 0138 in CAMSHAFT BUSHING ie 0 040 to 0 140 mm m ei za 0 0016 to 0 0055 in on Diesel Engine 105 Specifications Crankshaft 18900019 Ref Inspection Item Standard Remarks CRANKSHAFT Thrust Clearance 0 131 to 0 351 mm Repair Limit 0 40 mm 0 0052 to 0 0138 in 0 016 in 70 000 mm Repair Limit 69 86 mm 2 756 in 2 750 in 69 75 mm Repair Limit 69 61 mm nn 2 746 in 2 741 in 69 50 mm Repair Limit 69 36 mm Main Journal U S 0 50 12 736 in 12 731 in 69 25 mm Repair Limit 69 11 mm
3. damaged Diesel Engine 22 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke This is symptom tree T 004 Cause Correction Replace the starting aid Verify drive units are not engaged Check the Battery and recharge or replace Drain fuel and replace with correct fuel Clean or replace the air cleaner element Clean the prefilter Clean or replace the fuel filter or strainer Repair and clean the fuel filter or strainer ee Injection pump timing is incorrect Retime the injection pump OK Continued Diesel Engine 23 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Overhead adjustments are not correct Measure and adjust the overhead settings Inspect the rocker levers rocker shafs and a SREO Overhead components are damaged valve for excessive damage Replace as necessary Replace the defective or clogged injection nozzle Repair or replace the injection pump Replace the worn piston ring or cylinder compression Diesel Engine 24 Troubleshooting Symptoms Engine Has Poor Respones This is symptom tree T 005 Cause 33 soi salah ubije vie va Glogged air cleaner element Defective contact of valve or valve seat Resulting in low compression Worn piston ring or cylinder resulting in low Compression Diesel Engine 25 Correction Clean or replace the air
4. Diesel Engine 99 Engine Testing Lubricating System Measuring Oil Pressure Re When measuring the oil pressure be careful not to get caught in rotating parts always remove or install plug or oil pressure gauges with the engine stopped Remove the oil pressure sensor and install the pressure gauge NOTE Measure the oil pressure while the engine is warm oil temperature minimum 82 C 180 F Start the engine and measure the oil pressure Lubricating Oil Pressure kPa ft lb 210 MIN 30 700 MAX 102 14900087 Diesel Engine 100 Engine Testing Specifications Valves Valve Guides and Springs 18900014 Ref Inspection Item Standard Remarks VALVES Tolerance 0 035 mm Intake 0 0014 in 0 050 mm me 0 0020 in 0 3130 in Tolerance 0 050 mm Exhaust 0 0020 in 0 065 mm 0 0026 in Intake s U en Clearance Limit Clearance Between Guide and Stem 0 20 mm ee 0 050 to 0 080 mm 0 0079 in 0 0020 to 0 0031 in Intake 1 40 to 1 60 mm Repair Limit 0 0551 to 0 0630 in 0 039 in Stem Diameter Head Thickness Exhaust 0 35 mm Valve Clearance Intake 0 0138 in an a Exhaust en 0 0008 in VALVE GUIDE Intake 145mm Tolerance Protrusion Above Cylinder Head Surface 0 2 mm 0 0079 in Repair Limit 49 2 mm 48 5 mm 1 94 in 1 90 in 40 5 mm 1 59 in 18 5 0 9 kg nep 6 5 a 40 8 2 0 Ib 36 4 Ib Repair Limit 1 85 Diesel Engine 101 Spec
5. Remove the fuel injector pump assembly adapter plate and o ring from the gear housing Discard the o ring 00900211 Remove the nut and washer from the fuel injection pump Remove the fuel injection pump gear from the fuel injection pump 00900210 Diesel Engine 51 Complete Engine ax _ Remove the two mounting nuts fuel injection pump and o ring from the adapter plate Discard the o ring 00900246 RI PTO Shaft if applicable Remove the two capscrews flange o ring and PTO shaft 00900177 NY NM _ Lubricating Oil Pan NL R h Remove the 24 capscrews lubricating oil pan and gasket Discard the gasket 00900178 E v Lubricating Oil Suction Tube SON a Remove the two mounting capscrews lubricating oil suction tube and o ring Discard the o ring 00900179 Diesel Engine 52 Complete Engine Diesel Engine ex Crankshaft Pulley Remove the capscrew and mounting plate 00900180 Remove the crankshaft pulley using flange puller x Part No 3397890 00900212 _ Gear Housing Cover B Remove the 17 capscrews and the gear housing cover 00900181 engines The noise damper must be removed prior to removing the front oil seal RI NOTE A noise damper is installed on some Remove the front oil seal from the gear housing cover 00900182 53 Complete Engine Diesel Engine ex Lubricating Oil Pump Remove the five capscrews and the lubricating oil pump Idl
6. Customary een 116 Capscrew Markings and Torque Values 115 Connecting Rod Piston Ring and Piston Pin 111 Grankshall ee ee eee te eer ere eee 106 Cylinder Block ccccceccseeseceeseeeeeseeeseeeeeeeeseas 104 Cylinder Head cccccccccsseseceeseeseeeeeeeeeeeeeeeeas 103 NI Eures een een een 109 FIVE ernennen 108 Fraction Decimal Millimeter Conversions 117 Newton Meter to Foot Pound Conversion CA ee ee nee 118 ONE UNV ee eine 112 Pipe Plug Torque Values uuu44444R ee 118 PI ON miese een 110 Regulator ValVe cccccccsseceeceeeeeeeseeeeeeaeeeesaees 113 Rocker Arm Shaft Push Rod and Tappets 102 Tap Drill Chart U S Customary and Metric 119 Tnermosl at u u usen eine 114 Timing Gear uussnseneneeennennnnennnnnnnnnnnnnennnne nenn 107 Valves Valve Guides and Springs 101 Weight and Measures Conversion Factors 120 Special Tool Special TOOL een 121 Index About the Manual This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures The material in this manual covers all Signature engines The manual is divided into sections Each section is equivalent to a group used in Cummins filmcard system Some sections contain reference numbers and procedure numbers Reference numbers provide general information specifications
7. Excessive Noise cccceseccceeeseecessseecseneeeesaaeees 39 Fuel consumption Is Excessive c cccceeeeees 33 Lubricating Oil Consumption Excessive 31 Lubricating Oil Contaminated 32 Lubricating Oil Pressure Is Low 36 Ol LevalRises nnan ei 37 Complete Engine Complete Engine ccccccccccceeseeeeseeeeeeeeeeaeeeeees 42 Engine Assembly es ee aa ee ee ee ee ee ee ere ee ere aaa nene 61 Engine Disassembly 1 111 ee ee ee ee ee ee ere ee enne 42 Diesel Engine Engine Testing Complete EnQine cccccsscsccccceseseeeeceeseeeeeseaeees 89 Measuring Compression Pressure 89 Testing and Adjusting the Fan Belt Tansion 91 Fuel System E EEEE 92 Checking and Adjusting Fuel Injection Timing 92 III SCION serrare reren seen ae een 95 ASSEMDIV nu feantewnssebtovnteansou enbievcdursumresened 98 DISASSEMDIV sicccncensdnccdwsdumonuicnitmandnebemassetcumentanonant 97 TSS WAG re RR EEVERENENEEURDERDECFE 95 Lubricating SYStOM cccccsseeeeeesesseeeeeeseeeeeees 100 Measuring Oil Pressure ccsseeeeeeeeeeeeeeeees 100 Rocker Levers ccccssscecceeseecceeeeeceeeeecsenseessaaees 87 Adjusting Valve Clearance u nenn 87 Specifications Camshaft and Camshaft Bushing 105 Capscrew Markings and Torque Values Metric115 Capscrew Markings and Torque Values U S
8. ees 2 726 in 2 721 in 69 00 mm Repair Limit 68 86 mm nt 2 717 in 2 711 in Baunanaes Repair Limit 0 020 mm 0 0008 in Claas 0 043 to 0 103 mm Clearance Limit 0 25 mm 0 0017 to 0 0041 in 0 0098 in STD 57 000 mm Repair Limit 56 91 mm 2 244 in 2 241 in 56 750 mm Repair Limit 56 66 mm a 2 234 in 2 231 in l 56 500 mm Repair Limit 56 41 mm Crank Pin Journal U S 0 50 2 224 in 2 221 in 56 250 mm Repair Limit 56 16 mm S 2 215 in 2 211 in 56 000 mm Repair Limit 55 91 mm A 2 205 in 2 201 in Repair Limit 0 020 mm Rowans o ae aaa ea nk ein jenmnal 0 029 to 0 089 mm Clearance Limit 0 22 mm 0 0011 to 0 0035 in 0 0087 in Repair Limit 0 09 mm Diesel Engine 106 Specifications Timing Gear 18900018 Ref Inspection Item Standard Remarks TIMING GEAR Naturally Aspirated Crankshaft gear 0 08 mm to 0 19 mm and idler gear 0 0031 in to 0 007 in Camshaft gear 0 08 mm to 0 19 mm and idler gear 0 0031 in to 0 007 in Replacement Injecti 0 07 mm to 0 29 zn Bend of Shaft a sh Sen 0 40 mm gear and idler gear 0 003 in to 0 011 in 0 0157 in Camshaft gear 0 07 mm to 0 29 mm and oil pump gear 0 003 in to 0 011 in Camshaft gear 0 15 mm to 0 30 mm and PTO gear 0 006 in to 0 012 in Replacement 0 015 mm to 0 050 mm Limit 0 0006 in to 0 002 in 0 10 mm 0 0039 in Replacement 0 03 mm to 0 09 mm Limit 0 0012 in to 0 0035 in 0 20 mm 0 0079 in Clearance
9. Between Bushing and Shaft End Play of Idler Gear Diesel Engine 107 Specifications Flywheel 18900013 Ref Inspection Item Standard Remarks FLYWHEEL Repair Limit Face Runout of Flywheel Housing en 0 30 mm 0 012 in 0 35 mm 0 014 in Repair Limit 0 0059 in Repair Limit 0 079 in Face Runout of Flywheel Radial Runout of Flywheel H Radial Runout of Flywheel Housing Diesel Engine 108 Specifications Cylinder UO Clary 18900020 Ref Inspection Item Standard Remarks CYLINDER ID Tolerance pole STD 95 00 mm 0 022 mm a 3 740 in 0 0008 in en Round f Cylind oundness of Cylinder Repair Limit 0 02 mm 0 0008 in Cylindricity of Cylinder in Diesel Engine 109 Specifications Piston 25 mm 0 98 in 18900020 Ref Inspection Item Standard Remarks PISTON Repair Limit ID Diameter STD 95 00 mm 3 740 in 94 85 mm 3 734 in Top Clearance 0 0024 to 0 0039 in 0 079 in 0 15 mm 0 0059 in Between Son Repair Limit Piston Ring Second 0 079 in 0 20 mm Groove and 0 03 to 0 07 mm 0 0079 in Piston Ring 0 0012 to 0 0028 in Am Repair Limit 0 158 in N 0 0059 in Width of Groove Nominal Diesel Engine 110 Specifications Connecting Rod Piston Ring and Piston Pin Standard PISTON PIN Nominal OD 30 00 mm 11 181 in Ref Inspection Item Outer Diameter a H Piston Ring Gap 0 004 to 0 0
10. Component The engine lifting equipment must be designed to lift the engine without causing personal injury Engine Weight approx 330 kg 660 Ib Remove the engine from the stand Remove the bracket Part No 3163625 from the ID Ar engine 00900207 S Install the starting motor NOTE The o ring is used only on wet flywheel housings 00900156 Install all the chassis components that were removed S during removal of the engine from the eguipment 84 Complete Engine S Connect the drive units to the flywheel housing and flywheel tr400wa Ro Connect the intake and exhaust system pipes _ Connect the starter cable engine ground straps cab or chassis to engine hoses tubing electrical wires and hydraulic lines A WARNING Always connect the negative cable last Connect the battery cables 9 A WARNING Some state and federal agencies in the United States of America have determined that used oil is carcinogenic and can cause reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil Always use the proper procedures to dispose of the oil Fill the engine with lubricating oil Engine Oil 6 5 liters 1 7 u s gal Diesel Engine 85 Complete Engine 50 PERCENT 50 PERCENT WATER WATER Sy A WARNING 50 PERCENT 50 PERCENT Coolant is toxic Keep away from children and ANTIFREEZE ANTIFREEZE animals Save for reuse or dispose of in accordanc
11. EL a os sg meter m 0 0928 10m Fuel pounds per grams per g kW miles per gallon TOMEI al km l 0 4251 2 352 Fuel liter kilometer SME s e NEIII 4 4482 0 224809 mn in mets mm 25 40 0 039370 Length 304 801 0 00328 kilowatt 0 746 1 341 pounds force per psi kilopascal 6 8948 0 145037 sq inch inches of mercury i kilopascal kilopascal 0 2488 4 019299 Pressure mercury bass kilopascals 100 001 0 00999 mercury Temperature fahrenheit centigrade F 32 1 8x C 32 Lorgue ound force per gallon US gal Tier l 187853 10 264799 Volume gallon Im gal liter fl 4546 0 219976 liquid cubicinch in Tier l 0 01639 161 055 displacement i cubic inch in CURIG cm 16 387 0 06102 centimeter pounds avoir avoir kilograms 0 4536 2 204623 MON Brist Mema uv kilowatt hour 0 000293 3414 kilowatt hour 0 746 1 341 Diesel Engine 120 Specifications SPECIAL TOOLS u ST 537 Dial Depth Gauge ST 1111 3 Seal Leakage Tester ST 1273 Pressure Gauge 3162745 Injector Connector Removal tool Diesel Engine 121 Special Tools Tool No Tool name 3163054 Camshaft Gear R amp l Tool 3163292 Valve spring compressor 3375072 Dial Bore Gauge Kit 3375432 Crack Detection Kit 3376579 Tube Filter Cutter Diesel Engine 122 Special Tools Injector nozzle tester Digital multimeter Fuel Pump Timing tool Digital optical tachometer Piston Ring Compressor Diesel Engine 123
12. Fuel Tank Water in Fuel Sensor WIF Fuel Filter Hand Priming Pump Engine Identification S enn mo U amp Ih Fuel Injection Pump 00900150 1 Pump Holder A Fuel Inlet from Fuel Tank 2 Fuel Injection Pump Drive Gear B To Fuel Tank number of teeth 52 C To Fuel Injection Pump 3 Drive Shaft D To Fuel Injection Nozzle 4 Fuel Injection Pump Body 5 Fuel Filter Fuel Injection Pump 6 Fuel Injection Pipe No 1 e Maker Zexel 7 Fuel Injection Pipe No 2 e Type VE 8 Fuel Injection Pipe No 3 e Lubrication Method Forced Lubrication with Fuel 9 Fuel Injection Pipe No 4 10 Spill Tube Governor e Type Mechanical All speed Type Diesel Engine 15 Engine Identification Fuel Drain Line Connector Nozzle Holder Adjusting Shim Nozzle spring Spring seat Intermadiate Plate Nozzle Body Retaining Nut Needle Oe Noo Se LYS Diesel Engine Fuel Injection Nozzle 16 00900151 A Fuel Inlet from injection pump B Fuel Injection to cylinder C Fuel Return to fuel tank Fuel Injection Nozzle e Maker Zexel e Injection Pressure 40 MPa Adjustment of Injection Pressure By Shim Engine Identification Radiator Thermostat BWV Ne Diesel Engine Water Temperature Gauge Water Pump Water Manifold as ES eS ee ee es ee Cooling System 00900147 6 Cylinder Head 7 Piston 8 Cylinder Block 9 Oil Cooler optional
13. Ro Be careful not to damage the inside of the cylinder Remove the carbon at the top of the cylinder using fine sandpaper with a dial gauge before removing the piston and connecting rod assembly Ra Measure the side clearance of the connecting rod Side Clearance mm in 0 20 MIN 0 0079 Ji 0 40 MAX 0 016 N 0900192 56 Complete Engine Ro Rotate the camshaft to set the piston at bottom dead center is Remove the mounting capscrews of the connecting ZE rod cap _ Check the number stamped on the connecting rod SK cap and the cylinder The numbers must match NOTE If there is no number stamped on the connecting rod cap stamp the correct number on the camshaft end of the cap Tap the cap with a plastic hammer and remove the connecting rod cap and bearing Push a wooden bar or hammer handle through the x cylinder from the lubricating oil pan side of the block Support the piston at the cylinder head side of the block and push the bar in far enough to remove the piston and connecting rod assembly X Piston and Connecting Rod Assembly Disassembly Remove the snap ring on one side of the piston using pliers 00900196 Remove the piston pin and separate the piston and x connecting rod NOTE If the pin does not come out place the assembly in hot water prior to disassembly i 00900197 Diesel Engine 57 Complete Engine x _ Remove the snap ring on the other side of the piston using pliers
14. Value 31 Nem 23 ft lb 14900078 Diesel Engine 94 Engine Testing Install the distributor head bolt and new copper RI Remove the dial gauge A washer into the injection pump SE Tighten the bolt Torgue Value 17 Nem 13 ft lb 14900074 AID Stamp a match mark on the injection pump and the OG timing gear case 14900080 Adjusting the Idle ne Move the governor control lever to the desired idling SE speed by using the idling adjustment screw 14900082 sm ar Injector Testing A WARNING Keep your body clear of test spray Fluid can be injected into the bloodstream causing blood poisoning and possible death NOTE All nozzles must be tested for opening pressure chatter and spray pattern fi900sa Diesel Engine 95 Engine Testing fi900de fi9000a in Els TE 10 Seconds E fi900df ui fi900dd Diesel Engine 96 Check the opening pressure a Open valve b Operate lever at one stroke per second c Read pressure indicated when spray begins f the opening pressure is out of specification disassemble the injector and change the shims in order to change the opening pressure NOTE 01 mm 0 0039 in shim thickness equals 41 bar 595 psi Leakage Test a Open the valve b Operate the lever to hold pressure 20 bar 290 psi below opening pressure c No drops should fall from the tip within 10 seconds Chatter Test The c
15. X 25 U S Customary 5 16 X 18 X 1 1 2 M8 1 25x 25 516 18 1 12 Major thread diameter in millimeters Major thread diameter In Inches me Distance between threads in millimeters Number of threads per Inch Length in millimeters Length In Inches 17800016 A ooo NOTE 1 Always use the torque values listed in the following tables when specific torque values are not available 2 Do not use the torque values in place of those specified in other sections of this manual 3 The torque values in the table are based on the use of lubricated threads 4 When the ft lb value is less than 10 convert the ft lb value to in Ib to obtain a better torque with an in lb torque wrench Example 6 ft lb equals 72 in lb Capscrew Markings and Torque Values Metric Commercial Steel Class 8 8 10 9 __12 9 Capscrew Head Markings Body Size Torque Torque Torque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm Nem ft Ib Nem ft Ib Nem ft lb Nem ft lb Nem ft lb Nem ft lb 6 9 5 7 4 13 10 7 4 14 9 7 4 7 14 9 11 7 18 14 11 7 23 18 11 7 8 23 17 18 14 33 25 18 14 40 49 18 14 10 45 33 30 25 65 50 30 25 70 50 30 25 12 80 60 55 40 115 85 55 40 125 95 55 40 14 125 90 90 65 180 133 90 65 195 145 90 65 16 195 140 140 100 280 200 140 100 290 210 140 100 18 280 200 180 135 390 285 180 135 400 290 180 135 20 400 290 a 550 400 Diesel Engine 115 Specifications Capscrew Markings and Torque Values U S Customary SAE Grade Numbe
16. checking and adjusting the fuel injection timing of an injection pump e The MATCH MARK ALIGNMENT method which is used when the injection pump is installed on the original engine and the pump is not being repaired e The MEASURING DEVICE method which is used when a repaired or replaced injection pump is installed on the engine Checking and Adjusting with the Match Mark Alignment Method NOTE Set the No 1 cylinder at compression top dead center TDC by aligning the pointer on the gear cover with the TDC line on the N u amp crankshaft pulley Confirm that the mark C can be seen on the idler gear If the mark C can not be seen rotate the crankshaft one complete revolution and confirm that Q C can be seen 14900070 NOTE Align the match mark C on the injection pump gear with the match mark C on the idler gear during installation for correct alignment Align the stamped line a on the injection pump with the stamped line b on the timing gear case during installation for correct alignment Install the injection pump Ne VA a Diesel Engine 92 Engine Testing SG If the stamp lines are out of alignment loosen nut 7 Align the stamp lines by rotating the coupling Tighten the nut 27 Torque Value 31 Nem 23 ft lb 14900072 ZN Checking and Adjusting with the Measuring Device Method NOTE Set the No 1 cylinder at compression to
17. cleaner element Clean the fuel tank breather Clean or replace the fuel filter or strainer Clean and repair the fuel piping Clean and adjust the overhead settings Measure and adjust the overhead settings Replace the cylinder head Replace the defective or clogged injection nozzle Repair or replace the injection pump Replace the worn piston ring or cylinder Troubleshooting Symptoms Engine Stops During Operation This is symptom tree T 006 Cause Correction un Chassis powertrain is damaged or overloaded Refer to the OEM s service manuals OK v Fill the supply tank Clean the fuel tank breather Clean the prefilter Clean and or replace the fuel filter or strainer Clean and repair the fuel piping Replace the feed pump Inspect the rocker levers rocker shafts and valves for excessive damage Replace as necessary Replace the injection pump Refer to OEM s service manuals Replace damaged piston or connecting rod a ram Crankshaft bearing is damaged Replace damaged crankshaft bearing Diesel Engine 26 Troubleshooting Symptoms Engine Runs Rough or Misfires This is symptom tree T 007 Cause Line between the fuel tank and feed pump are clogged or have air in them Line between the feed pump and the injector nozzle are clogged or have air in them een Injection pump is malfunctioning Diesel Engine 27 Correction Fillthe supply tank Clean the fuel tank b
18. diagrams and service tools where applicable Procedure numbers are used to identify and reference specific repair procedures for correcting the problem This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem The troubleshooting trees then direct the user to the correct repair procedure The repair procedures within a section are in numerical order However the repair steps within a given procedure are organized in the order the repair must be performed regardless of the numerical order of the steps The user must use the Section Contents pages or the Index at the back of the manual to locate specific topics when not using the troubleshooting trees How to Use the Manual This manual is organized to provide an easy flow from problem identification to problem correction A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms Section TS The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair Complete the following steps to locate and correct the problem Step 1 Locate the symptom on the Section Contents pages of Section TS Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title Step 2 The left column of boxes in the Troubleshooting Symptom Charts indicates a
19. ease the installation Complete Engine SI Install the other snap ring into the snap ring groove a NOTE Make sure the connecting rod moves freely forward and backward after installing the a last snap ring 00900196 S D Locate the end gaps of the piston rings as shown ayj 1 Top Ring 2 Second Ring 3 Oil Ring 4 Part Number Mark EXXXX XXXX Last Four Digits of the Part Number NA or T NA Naturally Aspirated T Turbocharged 00900225 SP NOTE Align the notch of the upper bearing with the VV notch of the connecting rod Install the upper connecting rod bearing into the connecting rod 00900226 NOTE Coat the inside face of the cylinder the piston rings and the surface of the connecting rod bearing with engine oil SAE 30 Install the piston and connecting rod assembly with the F mark on the piston facing the front of the engine NOTE The connecting rods are stamped with the number of the cylinder in which they are to be installed This match mark must be on 4 5 the camshaft side of the engine after ANS 7 Pad installation y AAN 00900228 Set the crankshaft pin to bottom dead center Install the piston and connecting rod assembly from the top of the cylinder block using piston holder Part No 3397773 f Le 5 i d te 6 Diesel Engine 65 Complete Engine 00900229 Diesel Engine 66 Align the notch of th
20. probable cause of the problem starting at the top with the simplest and easiest to repair and continuing downward to the most difficult The right column of boxes provides a brief description of the corrective action with a reference number to the correct procedure used to make the repair Step 3 Locate the probable cause in the left column then turn to the procedure referenced in the right column Step 4 The Troubleshooting Symptom Charts are based on the following assumptions 1 The engine has been installed according to the manufacturer s specifications 2 The easiest repairs are done first 3 Generic solutions cover problems with the most common applications and original equipment manufacturer OEM Diesel Engine 4 Introduction Symbols The following symbols have been used in this manual to help communicate the intent of the instructions When one of the symbols appears it conveys the meaning defined below WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed CAUSION Minor personal injury can result or a part an assembly or the engine can be damaged if the Caution instructions are not followed Indicates a REMOVAL or DISASSEMBLY step Indicates an INSTALLATION or ASSEMBLY step INSPECTION is required OE Y e gt CLEAN the part or assembly PERFORM a mechanical or time MEASUREMENT LUBRICATE the part or assembly Indicates that
21. the upper thrust bearing SI Tighten the mounting capscrews in the order shown SV Torque Value R Main Bearing Capscrews Step1 113 Nem 83 ft lb 2 Loosen all capscrews completely 3 132 Nm 98 ft Ib 00900220 After tightening the mounting capscrews make sure the crankshaft rotates smoothly es 00900222 Diesel Engine 63 Complete Engine KE 00900202 D EVA 00900223 00900198 A SA 00900197 u Diesel Engine 64 Ui Measure the crankshaft end play using a dial indicator Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 Piston Connecting Rod Assembly Assemble A CAUTION Be careful not to damage the piston or break the piston rings Install the piston rings on the piston using piston ring tool Part No 3823137 NOTE The rings must be set with the stamped mark near the end facing up The oil ring bottom ring must be set with matching part of the expander coil and the end gap of the ring 180 degrees apart Install one snap ring on one side of the piston into the snap ring groove NOTE The stamped F mark on the piston and the match mark or cast part number on the connecting rod must face in the same direction Assemble the piston on the connecting rod by installing the piston pin NOTE Pistons do not need to be heated prior to installing the piston pin However placing the piston in hot water prior to installing the pin will
22. value for thio modal Displacement in3 L This engine conforms to 1000 U S EPA and California regulations for large nom road compression ignition engines as applicable aa Tre Valve Lash Ta ta mm SEPA Gen Fam cold engine European Approval Number Made in Japan fo Date of Manufacture 0000 00900249 Diesel Engine 7 Engine Identification Specifications 2280 kW PS 43 4 59 2200 rpm od Max Torque Nike 202 20 6 1600 rom TorqueRising 7 4 for 2200rpm rating BSEC Rated Power g kWh 227 2200rpm Max Torque g kWh 219 1600rpm 2500 25 a at 2470 50 en 800 25 770 25 Engine Weight Dry Less Flywheel and Electronics Intake 0 35 mm 0 014 in Rotation Viewed from the Front of the Engine Lubrication System Naturally Aspirated Regulating Valve Opening Pressure 490 kPa 71 psi Nan l vo Total System 7 5 liters 8 0 qt Lubricating Oil Capacity Standard Oil Pan Only 7 0 liters 7 4 atl Lubricating Oil Pressure at Idle Minimum Allowable 69 kPa 10 psi Lubricating Oil Pressure at Rated Minimum Allowable 245 kPa 35 psi Oil Filter Differential Pressure to Open Bypass Valve 98 kPa 14 psi Number of liters qt from Low to High 1 5 liters 1 6 at Cooling System Naturally Aspirated Coolant Capacity Engine Only 4 5 liters 4 75 at Standard Modulating Thermostat Start 82 C 180 F Range Fully Open 95 C 203 F Maximum Pressure Cap Sea Level 50 k
23. 12 in 0 0035 in Replacement 0 015 mm to 0 050 mm Limit 0 0006 in to 0 002 in 0 10 mm 0 0039 in Replacement 0 03 mm to 0 09 mm Limit 0 0012 in to 0 0035 in 0 20 mm 0 0079 in Clearance Between Bushing and Shaft End Play of Idler Gear Diesel Engine 70 Complete Engine dy 00900182 00900181 Diesel Engine 71 SE CAUTION Temporarily position the fuel injection pump assembly and measure the backlash of the gears Measure the backlash of all the gears with a dial indicator Gear Housing Cover NOTE A noise damper is installed on some engines The noise damper must be installed prior to installing the front oil seal Install the front oil seal using tool Part No 3824498 Fill 40 to 60 percent of the space in the seal lip with grease Do not apply excessive force to the seal lip surface when aligning and installing the gear housing cover Damage to the engine will occur if the seal is damaged NOTE Apply gasket sealant Part No 3823494 to the gear housing cover mounting surface Install the gear housing cover and 17 capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb Measure the distance in height between the cylinder block and the gear housing cover Maximum Height Difference 0 15 mm 0 0059 in Complete Engine Crankshaft Pulley s o Align the crankshaft pulley with the crankshaft key Install the crankshaft pulley mounting plate and capscr
24. 18 mm 0 0002 to 0 0007 in PISTON RING 0 30 to 0 45 mm 0 012 to 0 018 in 0 30 to 0 45 mm 0 012 to 0 018 in CONNECTING ROD Maximum 0 20 0 30 mm 0 0078 0 0118 in 0 25 t0 0 45 mm 0 0098 to 0 018 in Bend B Torsion T H Inner Diameter of Bushing Hole 33 00 mm 1 299 in CONNECTING ROD BUSHING Nominal OD 30 00 mm 1 18 in 0 020 to 0 039 mm 0 0008 to 0 0015 in Clearance Between Bushing and Piston Ring Small End u Inner Diameter Diesel Engine 111 CONNECTING ROD BEARING 57 00 mm 2 244 in 18900022 Clearance Limit 0 05 mm 0 002 in Clearance Limit 2 00 mm 0 079 in Clearance Limit 2 00 mm 0 079 in Clearance Limit 1 50 mm 0 059 in Repair Limit 0 25 0 35 mm 0 0098 0 0138 in Tolerance 0 025 mm 0 001 in Clearance Limit 0 100 mm 0 0039 in Repair Limit 57 20 mm 2 252 in Specifications Oil Pump 18900017 Ref Inspection Item Standard Remarks 0 030 to 0 085 mm Clearance Limit 0 10 mm 0012 I 0 0012 to 0 0033 in 0 0039 in Clearance Limit 0 13 mm 0 0051 in Clearance of Pump Gear 0 045 to 0 090 mm 0 0018 to 0 0035 in Diesel Engine 112 Specifications Regulator Valve ii 18900023 Inspection Item Standard Standard Standard Clearance Size C snan Hole Clearance Limit Clearance Between 0 050mm 0 020 mm 0 030 to Valve and Body 44mm 9 977mm 0 020mm 0 097 mm 0 4
25. 3 in 0 002 in 0 0008 in 0 004 to 0 003 in 0 0008 in 0 004 in Standard Repair Limit Replace Free Installed Installed Free Installed Load Length Length Load Length Regulator Valve Spring 33 1 mm 27 8mm 2 44 kg 2 30 kg Naturally 1 30 in 1 09 in 5 38 Ib 5 07 Ib Aspirated Regulator Valve Set Pressure Repair or Standard 5 0 0 5 kg cm Replace Spring Diesel Engine 113 Specifications Thermostat 18900024 Ref Inspection Item Standard Remarks THERMOSTAT Cracking Temperature 82 C 2 C 180 F 2 F Fully Open Temperature Fully Open Shall open fully i when immersed in hot water a bath at a temperature between Replace 77 C 171 F and 95 C 203 F for 4 to 5 minutes Thermostat Fully Open Lift Minimum 8 mm 0 315 in when immersed in a hot water bath at 95 C 203 F for 4 to 5 minutes Diesel Engine 114 Specifications Capscrew Markings and Torque Values CAUTION When replacing capscrews always use a capscrew of the same measurement and strength as the capscrew being replaced Using the wrong capscrews can result in engine damage Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts U S Customary capscrews are identified by radial lines stamped on the head of the capscrew The following examples indicate how capscrews are identified Metric M8 1 25
26. 5 Engine Identification Engine Diagrams usnnunneennenenennennnennennnn nennen 9 Engine VIEWS eaneenneansnnnennennnennnnnnennnnnne nennen nenn 9 Engine Identification us0224400002n ernennen 7 Engine Dataplate cccccscseeessseeeeeeeeeeeseeeeeens 7 Specifications 2200000ssnnnnennnnnneeennnnnnnnnnnnee nennen 8 Troubleshooting Symptoms Procedures and Techniques uu en 20 Troubleshooting Symptoms Charts 20 Coolant Contamination ccccccccceeeeseseeeeeeeaeees 34 Coolant LOSSn ae ee 35 Coolant Temperature above Normal 38 Engine Cranks But Will Not Start No Exhaust Smoke ccccceecseeeeeeeeeeeeeaeeeeees 22 Engine Difficult to Start or Will Not Start Exhaust Smoke Continued 24 Engine Difficult to Start or Will Not Start Exhaust Smoke cceeeeeeecceeeeeseeeeeeeeeeesaeeeeees 23 _T0c62044401 Engine Has Poor Respones 25 Engine Power Output Low Continued 29 Engine Power Output LOW ccceeeeeeeeeees 28 Engine Runs Rough or Misfires 27 Engine Stops During Operation 26 Engine Vibration Excessive 0 cccecseeeeeeeeees 41 Engine Will Not Crank or Cranks Slowly 21 Excessive Exhaust Black Smoke 30 Excessive Noise Continued 40
27. A From Oil Pump oil 17 Engine Identification Air Intake System 00900227 1 Filtered Air 2 Intake Manifold 3 Intake Valve Port Diesel Engine 18 Engine Identification Exhaust System 00900232 1 Exhaust Valve Port 2 Exhaust Manifold Diesel Engine 19 Engine Identification Procedures and Techniques A thorough analysis of the customer s complaint is the key to successful troubleshooting The more information known about a complaint the faster and easier the problem can be solved The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first Complete all steps in the sequence shown from top to bottom lt is not possible to include all the solutions to problems that can occur however these charts are designed to stimulate a thought process that will lead to the cause and correction of the problem Follow these basic troubleshooting steps e Get all the facts concerning the complaint e Analyze the problem thoroughly e Relate the symptoms to the basic engine systems and components e Consider any recent maintenance or repair action that can relate to the complaint e Double check before beginning any disassembly e Solve the problem by using the symptom charts and doing the easiest things first e Determine the cause of the problem and make a thorough repair e After repairs have been made operate the engine to make sure the c
28. Filter 3 Fuel Injection Pump 7 Oil Fill Cap 4 Crankshaft Pulley Diesel Engine 9 Engine Identification Exhaust Side Naturally Aspirated 00900139 1 Oil Fill Cap 4 Dipstick 2 Thermostat Housing 5 Oil Filter 3 Alternator 6 Exhaust Manifold Diesel Engine 10 Engine Identification Front View Naturally Aspirated 00900140 Rear View Naturally Aspirated 00900141 Diesel Engine 11 Engine Identification Oil Strainer Oil Pump Oil Cooler Optional Regulator Valve Oil Filter Safety Valve Crankshaft NOOVOPOD Diesel Engine 12 cor 11 10 spissi Tasisi ba It 9 SLI Pu 6 7 5 a _ TI SI gt EIP Exhaust Side Naturally Aspirated 00900146 8 Camshaft 9 Piston 10 Intake and Exhaust Valve 11 Rocker Arm 12 Timing Gear 13 Cooling Water 12 Engine Identification Oil Pump 00900148 1 Bushing 8 Regulator Valve 2 Gear Drive number of teeth 7 9 Valve Spring 3 Pump cover 4 Oil Pump Drive Gear number of teeth 22 Oil pump 5 Driveshaft e Type Gear Type 6 Drivenshaft e Pump Speed Engine Speed x 1 182 7 Driven Gear number of teeth 7 Regulator Valve e Set Pressure 490 50kPa 71 7psil Diesel Engine 13 Engine Identification Fuel Injection Pump Overflow Valve Fuel Solenoid Fuel Injection Nozzle a N Diesel Engine Fuel System D 6 7 8 14 00900149
29. NG Be careful not to injure your fingers or damage the alternator when moving the alternator toward the cylinder block Loosen the mounting capscrew of the adjustment plate 1 Loosen the alternator mounting capscrew and nut Move the alternator toward the cylinder block and remove the belt 2 Remove the fan pulley Fan Remove the four capscrews retainer plate fan and spacer 00900157 Re Alternator Remove the adjusting capscrew and washer Remove the capscrew adjustment plate and spacer Remove the remaining capscrew and alternator 00900159 Diesel Engine 45 Complete Engine Diesel Engine SK Lubricating Oil Filter Remove the lubricating oil filter 00900155 _ Dipstick Guide Bo Remove the dipstick and dipstick guide Water Pump R Remove the mounting capscrews water pump gasket and o ring Discard the gasket and o ring 00900161 Ro Thermostat Remove the two mounting capscrews thermostat housing thermostat and seal 18900025 46 Complete Engine SK Exhaust Manifold Remove the eight capscrews exhaust manifold and gasket Discard the gasket 00900162 RI Fuel Injection Tubing Remove the clamp Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head Ra Intake Manifold Remove the eight capscrews intake manifold and air inlet connection Remove the grid heated if equipped Remove the
30. Pa 7 psi Air Induction System Naturally Aspirated Maximum Allowable Intake Restriction at Rated Speed and 762 mm H2O Load with Dirty Filter Element 30 in H20 Exhaust System Naturally Aspirated Maximum Allowable Exhaust Restriction at Rated Speed and 75 mm Hg Load with Dirty Filter Element 3 in Hg Fuel System Naturally Aspirated Maximum Allowable Restriction to the Fuel Transfer Pump 75mm Hg or Filter Head Must Not Exceed 3 in Hg Maximum Allowable Return Line Restriction Must Not Exceed 5 r Inlet Pressure to the Injection Pump Range 0 00 kPa 0 00 psi to 39 0 kPa 5 00 psi Electrical System Naturally Aspirated Minimum Recommended Battery Capacity with Light Accessories 12 VDC Starter 550 CCA Minimum Recommended Battery Capacity with Heavy 12 VDC Starter 730 CCA Accessories Maximum Allowable Resistance of the Starting Circuit 12 VDC Starter 0 0012 ohms Typical light accessories include Alternator small steering pump and disengaged clutch Typical heavy accessories include Hydraulic pump and torque converter Diesel Engine 8 Engine Identification Engine Diagrams Engine Views The following illustrations show the locations of the major external engine components filters and other service and maintenance points Some external components will be at different locations for different engine models Intake Side Naturally Aspirated 00900138 1 Intake Manifold 5 Fan 2 Starting Motor 6 Fuel
31. SB4135E01 Nov 2006 Serivce Manual B3 3 Diesel Engine Lift Trucks D20S 3 B3 3 D25S 3 B3 3 D30S 3 B3 3 D32S 3 B3 3 D33S 3 B3 3 D20G D25G D30G Important Safety Information Most accidents involving product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training skills and tools to perform these functions properly Read and understand all safety precautions and warnings before operating or performing lubrication maintenance and repair on this product Basic safety precautions are listed in the Safety section or the Service or Technical Manual Additional safety precautions are listed in the Safety section of the owner operation maintenance publication Specific safety warnings for all these publications are provided in the description of operations where hazards exist WARNING labels have also been put on the product to provide instructions and to identify specific hazards If these hazard warnings are not heeded bodily injury or death could occur to you or other persons Warnings in this publication and on the product labels are identified by the following symbol A WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and
32. Special Tools 3822476 Blow By tool use with ST111 3 3822666 Digital Thermometer Dual Input 3823137 Pistion ring expander 3164438 Depth Gauge Assembly tc ea om peta ine na u pom marine ensure 3823956 Fuel Pump Mounting Kit e Mao m andi pan eta Peer er Diesel Engine 124 Special Tools Oil Seal Sleeve Installation Tool rear Oil Seal Installation Tool Wear Sleeve Installation Tool Engine Barring Tool 3375193 Engine Rebuild Stand Diesel Engine 125 Special Tools 3375194 Engine Rebuild Stand Portable 3163625 Bracket 3397890 Flange Puller Fi CAKA Pe ey T a P ff E Diesel Engine 126 Special Tools
33. a WRENCH or TOOL SIZE will be given TIGHTEN to a specific torque PERFORM an electrical MEASUREMENT Refer to another location in this manual or another publication for additional information The component weighs 23kg 50lb or more To avoid personal injury use a hoist or get assistance to lift the component SO KI DI O Diesel Engine 5 Introduction Illustrations Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition The illustrations are intended to show repair or replacement procedures The procedure will be the same for all applications although the illustration can differ Diesel Engine Ca8vagc Introduction Engine Identification I ee Engine Dataplate The engine dataplate shows specific information about the engine The engine serial number ESN and control parts list CPL provide information for ordering parts and for service needs NOTE The engine dataplate must not be changed 1 unless approved by Cummins Engine 00900248 Company Inc Cummins Engine Company Inc Important ngine Information Columbus Indiana Mom B3 pay F d 47202 3005 www cummins com vtec Warning injury may result and warranty le RPM RPM volded H fuel rate rpm or altitudes exceed Fuel Rgting OO pubilehed maximum
34. ause of the complaint has been corrected Troubleshooting Symptoms Charts Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms Read each row of blocks from top to bottom Follow through the chart to identify the corrective action Diesel Engine 20 Troubleshooting Symptoms Engine Will Not Crank or Cranks Slowly This is symptom tree T 002 Cause Correction Nm Troubleshoot and repair starting circuit wiring Defective wiring of starting circuit I l including relays and switches OK EO E ees Battery voltage is low Out replace the battery OK v Staring motor is malfunctioning Replace the staring motor OK v Gi Ring gear tooth surface is chipped or damaged Replace ring gear Diesel Engine 21 Troubleshooting Symptoms Engine Cranks But Will Not Start No Exhaust Smoke This is symptom tree T 003 Cause Correction Fillthe supply tank Drain fuel and replace with correct fuel Clean the fuel tank breather Engine does start when voltage is applied to Troubleshoot and repair the circuit wiring the fuel cut solenoid valve p Ircuit wiring Engine does not start when voltage is applied Replace the fuel cut solenoid valve to the fuel cut solenoid valve p valve Clean the prefilter Clean or replace the fuel filter or strainer Clean and repair the fuel piping Replace the feed pump Replace the injectors Repair or replace the injection pump
35. could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on the product and in this publication DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or operating technique not specifically recommended by DOOSAN is used you must satisfy yourself that it is safe for you and others You should also ensure that the product will not be damaged or made unsafe by the operation lubrication maintenance or repair procedures you choose The information specifications and illustrations in this publication are on the basis of information available at the time it was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes can affect the service given to the product Obtain the complete and most current information before starting any job DOOSAN dealers have the most current information available Index Introduction About the Manual cccccccceccsseeeeeeeeeeeseeeeesaees 4 How to Use the Manual ccccsseeeeeeeeeeeeeeeeees 4 UC ge Ce ies 6 SYMIDOBS 2 ee
36. d 12 Adjusting Screw Rocker Arm Assembly NOTE Check that the ball of the adjustment screw is fitted properly into the socket of the pushrod before tightening the capscrews If the valve spring tension pushes against the rocker arm loosen the locknut and turn the adjustment screw back to prevent strain on the pushrod Install the rocker arm assembly and eight capscrews Tighten the capscrews 00900169 Torque Value 25 Nem 18 ft lb YA dp Diesel Engine 76 Complete Engine Ne VA a fi9slwb R 00900167 Diesel Engine 77 gt dlusting Valve Clearance Adjust the valve clearance Refer to Section 14 Rocker Lever Cover Install the o ring into the rocker lever cover Install the rocker lever cover three capscrews and isolator assemblies Tighten the capscrews Torque Value 9 Nem 7 ft lb Injector Coat the injectors with anti sieze compound Part No 3824879 before installation CAUTION Be careful not to damage the tip of the injector when installing NOTE When installing the injector clean around the injector and do not allow dust or dirt to enter the engine NOTE If there is no abnormality in the injector install it in the same position during assembly Install the injector washer and mounting capscrew Tighten the capscrew Torque Value 44 Nem 33 ft lb Complete Engine 00900166 00900164 00900163 AVO 00900162 Die
37. d O D In Aluminum Components Steel Components in in Nem ft lb N m ft lb 1 16 0 32 5 45 in Ib 15 10 1 8 0 41 15 10 20 15 1 4 0 54 20 15 25 20 3 8 0 68 25 20 35 25 1 2 0 85 35 25 55 40 3 4 1 05 45 35 75 55 1 1 32 60 45 95 70 1 1 4 1 66 75 55 115 85 1 1 2 1 90 85 65 135 100 Diesel Engine 118 Specifications Tap Drill Chart U S Customary and Metric NOTE ON SELECTING TAP DRILL SIZE The tap drill size shown on this card give the theoretical tap drill size for approximately 60 and 75 of full thread depth Generally it is recommended that drill sizes be selected in the 60 range as these sizes will provide about 90 of the potential holding power Drill sizes in the 75 range are recommended for shallow hole tapping less than 1 1 2 times the hole diameter in soft metals and mild steel Diesel Engine 119 M11x1 5 7 16 14 M12x1 75 M12x1 5 M12x1 25 112 13 1 4 18NPT 2116 12 Mi4x2 M14x1 5 M14x1 25 9116 18 UB 2TNPT 38 24 M10x1 5 7116 14 M1ix1 5 7116 20 M12x1 75 142 20 9116 12 M14x2 M14x43 5 18 18 M14x1 25 M24x2 1 8 M24x1 5 M26x2 x12 M20x1 5 17 14 M17x1 5 M18x2 5 M18x2 M24x2 v8 M24x1 5 M25x2 1 12 17 14 M25x1 5 17800013 Specifications Weight and Measures Conversion Factors From U S From Metric Customary To U S Quantity U S Customary To Metric Customary mat By Multiply By P Unt Name Abbreviation ee eas sa nines mm i676 om
38. e Normal Overheating or compression gases are leaking Resulting in loss through the radiator overflow Check for mixing of coolant and transmission fluid Check or replace the head gasket Check or replace the cylinder head eee Cytinder head is cracked or porous OK v pr Cylinder block coolant passages are leaking Check or replace the cylinder block Diesel Engine 35 Troubleshooting Symptoms Lubricating Oil Pressure Is Low This is symptom tree T 014 Cause Correction Check the oil level Verify the dipstick Re Lubricating oil lever is below specification calibration and the oil pan capacity Fill the system to the specified level Replace the oil lever or oil pressure sensor Replace the filter Refer to Oil Level Rises symptom tree Regulator or relief valve is not adjusted Correctly Adjust the regulator or relief valve Clean the strainer Repair or replace the suction tube Replace the oil pump ee Mainor rod bearing is worn or damaged Replace the bearing Diesel Engine 36 Troubleshooting Symptoms Oil Level Rises This is symptom tree T 015 Cause Rear crankshaft seal or seal surface is damaged er Cylinder block is cracked or porous Diesel Engine 37 Correction Repair or replace seal and surface Replace the auxiliary pump Refer to the OEM s service manual Replace the injector sleeve Replace the injector Remove and repair the injection pu
39. e lower bearing with the notch of the connecting rod cap Install the lower connecting rod bearing into the connecting rod cap NOTE Coat the lower bearing with engine oil SAE 30 The connecting rod cap is stamped with a number that must match both the number on the connecting rod and the cylinder in which it is being installed Install the connecting rod cap and capscrews NOTE Coat the connecting rod capscrew threads and seat face with engine oil SAE 30 Tighten the capscrews Torque Value Main Bearing Capscrews Step 1 39 Nem 29 ft Ib 2 Rotate 90 degrees NOTE The connecting rod capscrews can be reused five times Make a punch mark on the capscrew head each time the capscrew is used If there are already five marks on the capscrew head the capscrew must be replaced After installing the piston and connecting rod assemblies check the crankshaft for smooth rotation Connecting Rod Cap Side Clearance Measure the side clearance of the connecting rod cap mm in 0 20 MIN 0 0079 0 40 MAX 0 0160 Complete Engine Flywheel Housing AN Install the rear seal using oil seal installer Part No es ST 972 Fill 40 to 60 percent of the space in the seal lip with grease 00900189 A WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component A CAUTION Do not apply excessive force to the seal lip 00900188 surface when al
40. e with local regulations Fillthe engine with engine coolant ala NOTE Remove all tags that were put on all hoses MG lines linkage and electrical connections as they were removed to identify location during the removal process Diesel Engine 86 Complete Engine Rocker Levers Adjusting Valve Clearance Gala Remove the cylinder head cover OV Rotate the crankshaft in the normal direction While watching the movement of the intake valve of No 4 cylinder bring the No 1 cylinder into compression top dead center position Align the TOP engraved mark on the crankshaft pulley 1 with pointer 2 NOTE e The engraved mark on the crankshaft pulley will read 1 4 TOP e The No 4 intake valve will start to open when 0390076 the No 1 cylinder comes near compression top dead center Loosen the lock nut 3 on the adjustment screw 4 lt Insert the feeler gauge 5 between the valve stem 6 and the rocker arm 7 Adjust the clearance with the adjustment screw until u slight drag is felt on the feeler gauge Valve Clearance Engine Hot or Cold Intake Valve Exhaust Valve 0 014 in 0 020 in PAS f 0390077 Diesel Engine 87 Engine Testing 0390078 0390078 ID 0390080 Diesel Engine 88 NOTE Adjust intake and exhaust clearances in the following firing order by rotating the crankshaft 180 degrees in the normal direction 1 2 4 3 Adjust the valve clearances for
41. er Gear Bo Remove the capscrew retainer plate and idler gear NOTE Ifa PTO is installed the idler gear uses a bearing 00900184 _ Camshaft Assembly Bo Remove the two mounting capscrews through the casting holes in the camshaft gear 00900185 Remove the thrust plate and camshaft assembly NOTE When removing the camshaft lightly rotate the shaft while being careful not to damage the bushing 00900186 54 Complete Engine Diesel Engine ex 00900187 Ro 00900188 55 Flywheel WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component WARNING The pilot is short so the flywheel can come off suddenly Remove the six capscrews retaining plate coupling and flywheel Flywheel Housing A WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component Remove the nine capscrews rear oil seal and flywheel housing RI Remove the rear oil seal Block Water Heater NOTE Be sure the engine coolant has been drained Disconnect the block heater electrical cord Complete Engine Diesel Engine _ Loosen the block heater retaining nut Remove the block heater from the block cs900mb Piston Connecting Rod Assembly Turn the cylinder block on its side with cylinders positioned horizontally 00900190
42. er operating speeds and loads Check the fuel lines fuel connections and fuel filters for leaks Check the fuel lines to the supply tanks Refer to the OEM s service manual Assure good quality No 2 diesel fuel is being used Refer to troubleshooting logic for Exhaust Gas is Blake Replace the defective or clogged injection nozzle Adjust injection timing Injection pump is adjusted incorrectly causing excessive injection Adjust or replace the injection pump Diesel Engine 33 Troubleshooting Symptoms Coolant Contamination This is symptom tree T 013 Cause Correction Review the coolant change interval Drain and Coolant is rusty flush the system Fill the system with the Correct mixture of coolant and water Lubricating oil cooler for powertrain is damaged Refer to the OEM s service manual a a Cylinder head gasket is cracked or damaged Replace the cylinder head or gasket ee Cylinder block is cracked or porous Replace the cylinder block Diesel Engine 34 Troubleshooting Symptoms Coolant Loss This is symptom tree T 013 1 Cause Correction Inspect the radiator heater hoses and connection to locate the leak If oil is present in the coolant check for a transmission or lubricating oil cooler leak Inspect the engine and components for seal gasket or drain cock leaks Review the operation for overheating and low power Refer to troubleshooting logic for Coolant Temperature Abov
43. esel Engine 60 Complete Engine Engine Assembly Service Tools PartN PatNiame _ YOS 3375193 or Unit Repair Stand or Engine Overhaul Stand 33 5194 Bracket Valve Spring Compressor Piston Ring Expansion Tool Piston Ring Compressor GI Setting the Unit in the Repair Stand RS Install bracket Part No 3163625 to the cylinder block 00900213 O M This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component The engine lifting equipment must be designed to lift the engine without causing personal injury gt in X S bo Put the engine block on the stand Ny 00900214 lt 7 VA a Diesel Engine 61 Complete Engine Tappet NOTE Rotate the engine block so that the cylinder tse head side is down SY Coat the tappet with engine oil and install into the block Crankshaft CAUTION BO Confirm that there is no dirt or dust stuck to the rear face of the bearing before installation Debris behind the bearing can cause severe engine damage Ne VA a NOTE Coat the inside face of the bearing with engine oil SAE 30 before installation Align the protrusion of the upper main bearing with the notch in the cylinder block Install the upper main bearings 7 CAUTION V VA a Do not hit the crankshaft against the cylinder block Damage to the block or crankshaft can occur Position the crankshaft and gear i
44. ew Tighten the capscrew Torgue Value 93 Nem 69 ft Ib 00900180 Lubricating Oil Suction Tube Install a new o ring oil suction tube and two capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb 00900179 Ja it gt Lubricating Oil Pan f NOTE Apply a 1 mm 0 039 in bead of gasket sealant Part No 3823494 to the mounting surface of the lubricating oil pan Install a new gasket lubricating oil pan and 24 capscrews Tighten the capscrews Torque Value 32 Nem 24 ft lb If the oil drain plug was removed install the drain plug Torque Value 51 Nem 38 ft lb 00900178 PTO Shaft if applicable Ya a Align the gear of the PTO shaft with the surface teeth of the camshaft gear Install the o ring flange and two capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb 00900177 Diesel Engine 72 Complete Engine 00900246 00900210 00900211 00900176 Diesel Engine 73 Fuel Injection Pump CAUTION Do not allow dirt or dust to enter the oil and fuel inlet and outlet ports Severe engine damage will occur if contaminants are allowed to enter the engine Install new o ring fuel injection pump and two mounting nuts on the adapter plate Tighten the nuts Torque Value 31 Nem 23 ft Ib Install the fuel injection pump gear washer and nut on the fuel injection pump Tighten the nut Torque Value 70 Nem 52 ft lb NOTE Align the f
45. four capscrews air inlet connection and o ring Discard the o ring 00900164 Diesel Engine 47 Complete Engine xc Spill Tube Remove the spring hose clamps and hose Remove the spill tube 00900166 Injector Je A CAUTION Be careful not to damage the tip of the injector when removing Remove the mounting capscrew washer and injector NOTE When removing the injector clean around 00900167 the injector and insert a blind plug to prevent dust or dirt from entering the engine NOTE Mark the injectors with tags showing the cylinder number and keep it in a safe place If there is no abnormality in the injector install it in the same position during assembly 3 Rocker Lever Cover Remove the three capscrews isolator assemblies rocker lever cover and o ring Diesel Engine 48 Complete Engine _ 00900251 Rocker Arm Assembly Rocker Shaft Adjusting Screw Lock Nut Pedestal Mounting Capscrews Separating Spring Rocker Shaft Indexing Screw Pedestal Mounting Stud ne NG 2 00900169 Diesel Engine 49 7 Cup Plug 8 Snap Ring 9 Thrust Washer if eguipped 10 Rocker Lever Pedestal 11 Rocker Lever 12 Adjusting Screw Rocker Arm Assembly Remove the mounting capscrews and the rocker arm assembly NOTE When removing the rocker arm loosen the locknut and turn the adjustment screw counterclockwise 2 to 3 turns Complete Engine x Pushrods Remove the pushrods
46. from the cylinder head NOTE Mark the pushrods with tags showing the cylinder number and keep it in a safe place If there is no abnormality in the push rod install it in the same position during assembly 00900170 Cylinder Head Assembly A WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component Remove the mounting capscrews cylinder head assembly and gasket Discard the gasket _ Cylinder Head Assembly Disassembly Using the spring pusher Part No 3398179 compress the valve spring and remove the valve collets Loosen the spring and remove the spring seat and Ro valve spring 00900173 Diesel Engine 50 Complete Engine Ro Raise the cylinder head and remove the valve NOTE Mark the valves with tags to show the place of installation and keep in a safe place 00900174 Fuel Injection Pump A CAUTION Do not allow dirt or dust to enter the oil and fuel inlet and outlet ports Severe engine damage will occur if contaminants are allowed to enter the engine Remove the fuel supply tube from the fuel injection pump 00900176 Remove the mounting capscrew from the bracket and fuel injection pump NOTE The fuel injector pump adapter plate and gear are removed as an assembly The gear can then be removed from the pump if necessary Remove the mounting capscrews of the fuel injector pump adapter plate
47. hatter test indicates the ability of the needle valve to move freely and correctly atomize the fuel An audible sound should be heard as the valve rapidly opens and closes A well optimized spray pattern should be seen Used nozzles should not be evaluated for chatter at lower speeds A used nozzle can generally be used if it passes the leakage test Engine Testing RI Disassembly Remove the copper sealing washer and discard U fi900fb RI Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut Remove the nozzle needle valve and intermediate S plate NOTE To avoid damage place the injector nozzle and needle valve in a suitable bath of clean test oil fi900fc _ Remove the nozzle holder from the vise then remove x the pressure spindle pressure spring and shims fi900fd Diesel Engine 97 Engine Testing Diesel Engine fi900ha fi900ce fi900ad Assembly NOTE Make sure all mating surfaces and pressure faces are clean and lubricated with fuel oil before assembly A WARNING D AV 98 Install the same thickness of shims that were removed in disassembly Use the pressure spring to make sure the shims are installed flat Install the shims Clamp the nozzle holder in a soft jawed vise and install the spindle Install the intermediate plate Engine Testing fi Install the needle valve and nozzle assembly fi900ce Install the nozzle nut SP y fi9000b
48. ifications Exhaust 0 571 in VALVE SPRING Rocker Arm Shaft Push Rod and Tappets 18900016 Ref Inspection Item standard Remarks VALVE ROCKER ARM SHAFT a Tolerance Diameter of Shaft 0 75 in 0 020 mm 0 0008 in Tolerance Nominal 0 030 mm Diameter of Rocker Arm Shaft Hole 19 mm 0 0012 in 0 75 in 0 010 mm 0 0004 in 0 010 to 0 050 mm Clearance Limit Clearance Between Rocker Arm and Shaft 0 12 mm 0 0004 to 0 0020 in 0 0047 in Repair Limit Bend of Shaft 0 20 mm 0 0079 in PUSH ROD Repair Limit Bend of Push Rod 0 30 mm 0 012 in TAPPET Clearance Limit Clearance Between Tappet and Tappet Hole nn ah 0 12 mm 0 0005 to 0 0020 in 0 0047 in Diesel Engine 102 Specifications Cylinder Head 18900011 Ref Inspection Item Standard Remarks DD CYLINDER HEAD Repair Limit Surface Flatness Warpage Limit nae u BI 0 30 mm l l 0 012 in Intake 1 00 0 100 mm De oe 0 039 0 004 in 0 079 in ni Repair Limit Exhaust a2 2m gt mm 0 035 0 004 in re Tolerance Nozzle Protrusion Se co Tn 2 00 to 3 500 mm Ben 0 106 to 0 138 in l Repair Limit Judge Tolerance Valve Seat Angle 0 15 condition of contact u surface by vacuum test Diesel Engine 103 Specifications Cylinder Block 18900012 Ref Inspection Item Standard Remarks CYLINDER BLOCK 0 00 to 0 08 mm Surface Flatness Warpage Limit 0 00 to 0 003 in
49. igning and installing the flywheel Damage to the engine will occur if the seal is damaged NOTE Apply gasket sealant to the flywheel housing mounting surface Align the flywheel housing with the dowel pins Install the flywheel housing and capscrews Tighten the capscrews Torque Value 69 Nem 50 ft lb Measure the distance in height between the lubricating oil pan mounting surface and the flywheel housing flange Maximum Height Difference 0 15 mm 0 0059 in 00900235 Diesel Engine 67 Complete Engine Diesel Engine 00900236 00900187 00900237 KE SD 7 68 Measure the radial and face runout of the flywheel housing Radial Runout mm in 0 35 MAX 0 014 Face Runout mm in 0 30 MAX 0 012 Flywheel WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component Install the flywheel coupling retaining plate and six capscrews Tighten the capscrews Torque Value Main Bearing Flywheel Capscrews Step1 108 Nem 80 ft lb 2 191 Nem 141 ft Ib Measure the radial and face runout of the flywheel Radial Runout mm in 0 20 MAX 0 0079 Face Runout mm in 0 15 MAX 0 0059 Camshaft Assembly NOTE When installing the camshaft lightly rotate the shaft while being careful not to damage the bushing Install the thrust plate camshaft assembly and two capscrews Tighten the capscrews thro
50. ine long enough for the thermostats to open and ensure all the air has escaped Alternator Install the alternator and capscrew Install the spacer mounting capscrew and adjustment plate Loosely install the washer and adjustment capscrew Gala Fan Pulley Install the fan pulley Gla Position the fan belt 2 into the fan pulley groove gt and loosely tighten the adjustment capscrew 1 sont 58 Diesel Engine 82 Complete Engine Diesel Engine LA 00900257 00900157 00900209 83 A WARNING Be careful not to injure your fingers or damage the alternator when adjusting the belt tension Insert a bar or pipe between the alternator and the cylinder block Raise the alternator to adjust the fan tension NOTE The belt must deflect 7 mm to 10 mm 0 28 in to 0 39 in when pushed with finger pressure of 6 kg 13 Ib at a point midway between the fan pulley and the crankshaft pulley Tighten the adjustment capscrew 1 Torque Value Mounting 31 Nem 23 ft lb Capscrew Adjustment 31 Nem 23 ft lb Capscrew Fan Install the spacer fan four capscrews Tighten the capscrews Torque Value 31 Nem 23 ft lb Remove the covers on all the engine openings that were installed to prevent dirt and debris from entering the engine Complete Engine Diesel Engine ID A WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this
51. ing or cylinder Adjust injection timing Measure and adjust the overhead settings Troubleshooting Symptoms Lubricating Oil Consumption Excessive This is symptom tree T 010 Cause Correction Inspect the engine the external oil leaks eee Lubricating oil leak external Tighten the capscrews pipe plugs and fittings Replace the gaskets if necessary joyinder Remove and clean intake manifold Verify the dipstick is correctly marked Clean the breather and breather hose Repair or replace seal and surface Repair or replace the damaged component Replace the worn or broken piston ring or cylinder Diesel Engine 31 Troubleshooting Symptoms Lubricating Oil Contaminated This is symptom tree T 011 Cause Defective contact of valve or valve seat resulting in low compression Worn piston ring or cylinder resulting in low Compression Diesel Engine 32 Correction Clean the breather and breather hose Replace the filter Refer to Exhaust Gas Is Black Incomplete Combustion Repair the valve or valve seat Replace the worn piston ring or cylinder Troubleshooting Symptoms Fuel consumption Is Excessive This is symptom tree T 012 Cause Correction Bu Check and repair the accessories Refer to the en Overloading from malfunctioning accessories l OEM s service manuals OK v Refer to the operation and maintenance manual Operator technigue is not correct l for prop
52. intake valves No 1 and No 3 Adjust the valve clearances for exhaust valves No 1 and No 2 Rotate the crankshaft in the normal direction one revolution Adjust the valve clearances for intake valves No 2 and No 4 Adjust the valve clearances for exhaust valves No 3 and No 4 Tighten the locknut to secure the adjustment screw Locknut Torque Value N m ft lb 39 2 MIN 28 9 49 MAX 36 1 Engine Testing Complete Engine Measuring Compression Pressure A WARNING A WARNING Exhaust manifold and muffler are hot Do not To avoid personal injury keep hands long hair touch the exhaust manifold or muffler or personal jewelry and loose fitting or torn clothing away injury will occur from fans and other moving parts Adjust the overhead Refer to Adjusting Valve a Clearance procedure SK Remove the spill tube 0390166 Disconnect the fuel injection tubing axo NOTE Disconnect the fuel shut off solenoid 0390163 Diesel Engine 89 Engine Testing B Do not allow dirt or foreign matter to get into the cylinder Foreign objects in the cylinder can cause severe engine damage Remove the nozzle holder assembly for each cylinder Remove the injector 0390167 Lubricate the sealing lips of the sleeve with anti seize D i compound Assemble the injector sealing sleeve a Al new copper sealing washer and the hold down clamp SE Use only one washer NOTE A light coat of clean 15W 40 engine oil betwee
53. ipstick Complete Engine Diesel Engine GJA Lubricating Oil Filter Ray Install the lubricating oil filter NOTE Some engines will have an oil filter cooler mounted between the oil filter and the engine block Block Water Heater Clean the core plug hole thoroughly Make sure there are not burrs or sharp edges that might cut the o ring cs9pxea Lubricate the new heater o ring with clean engine oil ih cs9orwa The locking channel T Bar should be threaded out to the end of the bolt If so equipped do not remove the retaining wire used to position the channel T Bar cs900wg 80 Complete Engine SI Hook the element and one leg of the channel T Bar into the hole as illustrated Hook the other leg of the channel in the hole and SE r7 push the heater into the hole as far as possible by hand A CAUTION Do not pull the heater into location with the locking bolt as the channel T Bar can bend or cause the threads to strip If necessary use a plastic hammer to tap the heater in until the shoulder contacts the block cs900hb Tighten the locking bolt Torque Value 2 0 Nem 18 in Ib Do not over tighten the locking bolt O cs9bona Diesel Engine 81 Complete Engine Insert the power cord into the socket being careful to align the pins with the sockets of the power cord Tighten the retaining nut by hand Do not apply power until the cooling system is filled and run the eng
54. mp Replace the cylinder head or gaeket Replace the cylinder block Troubleshooting Symptoms Coolant Temperature above Normal This is symptom tree T 016 Cause Dr Goelant level is below specification OK Farrbelt is slipping or the fan pulley is worn v Thermostat is defective and does not open OK v ee Water pump IS damaged Cylinder head or head gasket is cracked or damaged Diesel Engine 38 Correction Inspect the engine and radiator for external coolant leaks Replace the fan belt or pulley Replace the water temperature gauge Clean repair or replace the radiator Clean and repair the radiator Replace the thermostat Replace the water pump Replace the cylinder head or graket Troubleshooting Symptoms Excessive Noise This is symptom tree T 017 Cause Continued Diesel Engine 39 Correction Check and adjust belt tension Make sure all the pulleys rotate freely Refer to Exhaust Gas is Black troubleshooting tree Adjust the backlash for the gear train Replace the idler gear bushing Replace the defective or clogged injection nozzle Measure and adjust the overhead settings Inspect the rocker levers rocker shafts and valves for excessive damage Troubleshooting Symptoms Excessive Noise Continued Cause compression Diesel Engine 40 Correction Adjust or replace the injection pump Replace the worn piston ring
55. n the cylinder block 00900204 Main Bearing Cap CAUTION 2 9 Confirm that there is no dirt or dust stuck to the NEMINI SP rear face of the bearing before installation Debris I 7 behind the bearing can cause severe engine SS damage NOTE Coat the inside face of the bearing with engine oil SAE 30 before installation The number stamped on the main bearing cap must be the same as the number stamped on the cylinder block Align the protrusion in the lower main bearing with the notch in the cap Install the lower main bearing into the main bearing cap 00900217 Diesel Engine 62 Complete Engine e Casting number or cast arrow on the main bearing cap must face toward the front of the engine e New main bearing mounting capscrews must be used e Coat the capscrew threads and seat face with engine oil Position the main bearing caps and capscrews CAUTION Install each thrust bearing with the oil groove on the outside Failure to do so will cause engine damage or failure CAUTION Do not let the thrust bearings slip out of place Engine damage or failure will result if the thrust bearings are not properly installed 00900219 NOTE Casting number or cast arrow on the main bearing cap must face toward the front of the engine The thrust bearing is located on the main bearing closest to the rear of the engine No 5 Align the lower thrust bearing with the dowel pin Install
56. n the washer and injector can help hold the washer in place during installation SE Install the adapter to the nozzle holder mounting r section of the cylinder to be measured Tighten the adapter Adapter Capscrews N m ft lb 39 MIN 29 49 MAX 36 SD Connect the compression gauge to the adapter a NOTE Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter Diesel Engine 90 Engine Testing Crank the engine with the starting motor Read the gauge when the pointer is stabilized Engine Compression kPa psi 1965 MIN 285 2944 NOM 427 Testing and Adjusting the Fan Belt Tansion Testing the Fan Belt Tension Check the amount the fan belt deflects when pushed with a force of 6 kg 13 2 Ib at a point midway between the fan pulley and the alternator pulley Fan Belt Deflection mm in Iip 7 0 MIN 0 28 WY 10 0 MAX 0 39 S AJI 62 s IGN ITS fa9blsh X Adjusting the Fan Belt Tension Loosen the mounting capscrew of the alternator 1 and belt tension adjustment capscrew 2 Using a bar raise the alternator and adjust the fan belt tension Tighten the adjustment capscrew and the mounting capscrew Torque Value Adjustment 31 Nem 23 ft lb Capscrew Mounting 66 Nem 49 ft lb Capscrew Diesel Engine 91 Engine Testing Fuel System Checking and Adjusting Fuel Injection Timing There are two methods for
57. ome state and federal agencies in the United States of America have determined that used oil is carcinogenic and can cause reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil Always use the proper procedures to dispose of the oil Drain the lubricating oil Engine Oil 7 5 liters 1 98 U S gal Disconnect the starter cable engine ground straps cab or chassis to engine hoses tubing electrical wires and hydraulic lines Disconnect the intake and exhaust system pipes J Disconnect the drive units from the flywheel housing and flywheel lt Remove all chassis components necessary to remove the engine from the equipment Complete Engine SI Prepare a stable stand Part No 3375193 or 3375194 a which will prevent the engine from falling over Engine Weight approx 255 kg 562 Ib X Remove the starting motor 00900156 aa Install the bracket Part No 3163625 on the engine cay 00900207 A WARNING GNA This component weighs 23 kg 50 Ib or more To gt avoid personal injury use a hoist or get assistance to lift this Component The engine lifting equipment must be designed to lift the engine without causing personal injury Put the engine on the stand 00900208 LN Diesel Engine 44 Complete Engine SD Cover all the engine openings to prevent dirt and debris from entering the engine 00900209 Fan Pulley A WARNI
58. or cylinder Troubleshooting Symptoms Engine Vibration Excessive This is symptom tree T 018 Cause damaged Diesel Engine 41 Correction Replace the engine mounting bolts or cushion Repair the alignment Refer to the OEM s service manual Adjust the backlash for the gear train Inspect the rocker levers rocker shafts and valves for excessive damage Replace as necessary Replace the cam bushing Adjust or replace the injection pump Replace the connecting rod or main bearing Troubleshooting Symptoms Complete Engine Engine Disassembly Service Tool Quantity 3375193 Unit Repair Stand or Engine Overhaul Stand or 3375194 i 3163625 Bracket 3163292 Valve Spring Compressor 3397890 Flange Puller 3823137 Piston Ring Expansion Tool ala Engine Removal Riv NOTE Put tag on all hoses lines linkage and electrical connections as they are removed to identify location and aid the installation process DJ wm Always disconnect the negative cable first Disconnect the battery cables A WARNING Allow the engine to cool before draining to avoid ea wrha burns from hot liquid A WARNING Coolant is toxic Keep away from children and animals Save for reuse or dispose of in accordance with local regulations Drain the engine coolant Diesel Engine 42 Complete Engine opsooli oi400hc tr400wa ra400ha Diesel Engine A WARNING S
59. p dead center TDC by aligning the pointer on the gear cover with the TDC line on the crankshaft pulley 14900073 Remove the distributor head bolt and copper washer be Jr A Ro from the injection pump Discard the copper washer oe DI Ape alae A 14900074 ZN Install the dial gauge Part No 3377259 into the distributor head NOTE Check that the stylus end of the dial gauge contacts the plunger head 14900075 Diesel Engine 93 Engine Testing Rotate the crankshaft opposite normal engine rotation counterclockwise slightly until the dial gauge does not move any longer Set the dial gauge pointer to 0 Rotate the crankshaft in the normal direction until the dial gauge reads 1 0 0 3 mm 0 04 0 01 in Look at the pointer on the crankshaft It should point to the timing mark in degrees as stamped on the dataplate The timing marks on the crank pulley range from 6 to 14 degrees in two degree increments NOTE Check the values on the data plate Values may change as new ratings are developed NOTE The gauge reading 0 03 mm 0 001 in is equivalent to 0 5 degrees fuel injection timing NOTE The crankshaft must be rotated in the normal direction clockwise looking from the front of the engine without stopping _ If the dial readings are not within the standard value loosen nut Adjust the fuel injection timing to within standard value by rotating the injection pump body Tighten the nut Torque
60. r 5 8 pscrew Head Markings These are all SAE Grade 5 3 line DD Capscrew Torque Grade 5 Capscrew rew Torque Grade 8 Capscrew s w Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum Nem ft lb Nem ft lb Nem ft lb Nem ft lb 1 4 20 9 7 8 6 15 11 8 6 28 12 9 9 7 18 13 9 7 5 16 18 20 15 16 12 30 22 16 12 24 23 17 19 14 33 24 19 14 3 8 16 40 30 25 20 55 40 25 20 24 40 30 35 25 60 45 35 25 7 16 14 60 45 45 35 90 65 45 35 20 65 50 55 40 95 70 55 40 1 2 13 95 70 75 55 130 95 75 55 20 100 75 80 60 150 110 80 60 9 16 12 135 100 110 80 190 140 110 80 18 150 110 115 85 210 155 115 85 5 8 11 180 135 150 110 255 190 150 110 18 210 155 160 120 290 215 160 120 3 4 10 325 240 255 190 460 340 255 190 16 365 270 285 210 515 380 285 210 7 8 9 490 360 380 280 745 550 380 280 14 530 390 420 310 825 610 420 310 1 8 720 530 570 420 1100 820 570 420 14 800 590 650 480 1200 890 650 480 Diesel Engine 116 Specifications Fraction Decimal Millimeter Conversions Conversion Factor 1 inch 25 4 mm Diesel Engine 117 Specifications Newton Meter to Foot Pound Conversion Chart Nm ftb Nm ftb Nm ftb 5 nb 4 160 8 6 5inb S S 8 nnb z3 15 1 9 inb 55 180 13 pt 0 737562 Rb 90 6 19 140 po HE 8H p20 d z2 1 Pipe Plug Torque Values Size Torque Torque In Cast Iron or Thread Actual Threa
61. reather Adjust the low idle speed Clean the prefilter Clean or replace the fuel filter or strainer Clean and repair the lines Clean and repair the lines Replace the injection pump Troubleshooting Symptoms Engine Power Output Low This is symptom tree T 008 Cause OK v Continued Diesel Engine 28 Correction Drain and replace the fuel with the correct fuel Clean or replace the air cleaner element Clean the fuel tank breather Repair or adjust the fuel lever linkage Clean the prefilter Clean and or replace the fuel filter or strainer Clean and repair the fuel piping Replace the feed pump Measure and adjust the overhead settings Troubleshooting Symptoms Engine Power Output Low Continued Cause Defective contact of valve or seat Resulting in low compression Worn piston ring or cylinder resulting in low compression Diesel Engine 29 Correction Replace the cylinder head Replace the defective or clogged injection nozzle Replace the injection pump Replace the worn piston ring or cylinder Troubleshooting Symptoms Excessive Exhaust Black Smoke This is symptom tree T 009 Cause ses ST NE Engine is bring lugged down Diesel Engine 30 Correction Use lower gear Clean or replace the air cleaner element Replace the muffler Refer to the OEM s service manual Adjust or replace the injection pump Replace the worn piston r
62. sel Engine 78 XD GNA Spill Tube Install the spill tube Intake Manifold NOTE Apply a 1 mm 0 039 in bead of gasket sealant Part No 3823494 to the mounting surface of the intake manifold Install the air inlet connection intake manifold and seven Capscrews Tighten the capscrews Torque Value 40 Nem 30 ft lb Fuel Injection Tubing NOTE Before installing the fuel injection tubing blow compressed air through it to clean it Position the fuel injection tubing and loosely install the sleeve nuts on the fuel injection pump and the cylinder head Tighten the clamp Tighten the banjo fittings Torque Value 20 Nem 15 ft lb Exhaust Manifold Install a new gasket the exhaust manifold and the eight capscrews Tighten the capscrews Torque Value 66 Nem 49 ft lb Complete Engine 18900025 00900161 AVO 00900160 Diesel Engine 79 SU Gala Thermostat Install seal thermostat thermostat housing and two mounting capscrews Tighten the capscrews Torgue Value 19 Nem 14 ft lb Water Pump Install the o ring gasket water pump and mounting capscrews Tighten the capscrews Torgue Value 19 Nem 14 ft lb Dipstick NOTE Apply Loctite sealant Part No 3375068 or equivalent to the outside of the dipstick tube CAUTION Excessive sealant can run back into the engine and cause damage to other components Install the dipstick guide Install the d
63. uel injection pump gear match mark C with the idler gear match mark C Install new o ring adapter plate fuel injection pump assembly and mounting capscrews to the gear housing Tighten the mounting capscrews Torque Value 19 Nem 14 ft lb Install the mounting capscrew on the fuel injection pump support bracket Tighten the capscrew Torque Value 19 Nem 14 ft lb NOTE The fuel supply tube has a 12 mm and 14 mm banjo fitting The 12 mm banjo fitting connects to the fuel injection pump The 14 mm banjo fitting connects to the fuel filter head which is installed later in the assembly process Install the fuel supply tube to the fuel injection pump Torque Value 20 Nem 15 ft lb Complete Engine Cylinder Head Assembly AN NOTE Coat the stems of the intake and exhaust DI valves and the inside of the valve guides with engine oil Install the valves 00900174 AID Install the valve spring and spring seat on the valve Gy stem 00900173 SD Install the valve cotter into the valve stem groove a while compressing the valve spring with spring pusher Part No 3398179 Gy A Pa al i LS Oy a 00900172 AID After releasing the valve spring tap the top of the MG valve stem with a plastic hammer to make certain the cotter is completely fitted 00900252 Diesel Engine 74 Complete Engine Ri Remove all carbon and dirt from the contact Si surfaces of the cylinder block and the c
64. ugh the casting holes in the camshaft gear Torque Value 19 Nem 14 ft lb Complete Engine Measure the end play 1 of the camshaft Camshaft End Play mm in 0 150 MIN 0 0059 0 350 MAX 0 0138 00900239 Oil Pump Install the lubricating oil pump and five capscrews Tighten the capscrews 00900183 Torque Value 19 Nem 14 ft lb Measure the end play of the lubricating oil pump drive gear Lubricating Oil Pump Drive Gear End Play mm in 0 020 MIN 0 0008 0 070 MAX 0 0028 00900240 Idler Gear Align the match marks of the idler gear crankshaft gear and camshaft gear The match marks are identified as follows e Crankshaft Gear and Idler Gear A e Idler Gear and Camshaft Gear B e Fuel Pump and Idler Gear C e Lower case letters identify oil pump and accessory drive which are not timed 00900241 Diesel Engine 69 Complete Engine SI Install the retainer plate and capscrew i Tighten the capscrew Torque Value 110 Nem 81 ft lb 00900184 Measure the end play of the idler gear 00900243 Match mark alignment Naturally Aspirated aoe 0 08 mm to 0 19 mm and idler gear 0 0031 in to 0 007 in Bo Camshaft gear 0 08 mm to 0 19 mm and idler gear 0 0031 in to 0 007 in Aspirated ce Replacement 0 07 mm to 0 29 mm Limit 0 003 in to 0 011 in 0 40 mm Injection pump Backlash C gear and idler gear and oil pump gear 0 006 in to 0 012 in co ser gt and PTO gear 0 00
65. ylinder head Remove all burrs and damage and clean out all the dirt from inside the cylinder block Failure to follow these steps will result in severe engine damage Install a new cylinder head gasket with the TOP mark 00900253 facing up WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component NOTE Coat the capscrew threads with antifriction compound Part No 3824879 Install the cylinder head using four head capscrews as guides Install the capscrews Tighten the capscrews in the sequence shown Torque Value Cylinder Head Capscrews Step 1 69 Nem 51 ft Ib 2 108Nem 80 ft Ib 3 Rotate 90 degrees NOTE The cylinder head capscrews can be reused five times Make a punch mark on the Intake Side capscrew head each time the capscrew is 00900245 used If there are already five marks on the capscrew head the capscrew must be replaced Push Rods SI ADI NOTE If there is no abnormality in the pushrods install them in the same position that they were removed from during disassembly 00900170 Diesel Engine 75 Complete Engine 00900251 Rocker Arm Assembly 1 Rocker Shaft 7 Cup Plug 2 Adjusting Screw Lock Nut 8 Snap Ring 3 Pedestal Mounting Capscrews 9 Thrust Washer only used on some engines 4 Separating Spring 10 Rocker Lever Pedestal 5 Rocker Shaft Indexing Screw 11 Rocker Lever 6 Pedestal Mounting Stu

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