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Service Manual - Doosan Infracore

Contents

1. YOS Quantity 3375193 or Unit Repair Stand or Engine Overhaul Stand 33 5194 Bracket Valve Spring Compressor Piston Ring Expansion Tool Piston Ring Compressor Gia Setting the Unit in the Repair Stand O gt lt 1 Install bracket Part No 3163625 to the cylinder block 00900213 O ame SA 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 Put the engine block on the stand 00900214 Diesel Engine 66 Complete Engine Tappet NOTE Rotate the engine block so that the cylinder head side is down Coat the tappet with engine oil and install into the block Crankshaft CAUTION Confirm that there is no dirt or dust stuck to the SA rear face of the bearing before installation Debris 7 behind the bearing can cause severe engine damage 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 CAUTION Do not hit the crankshaft against the cylinder block Damage to the block or crankshaft can occur Position the crankshaft and gear in the cylinder block 00900204 Diesel Engine 67 Complete Engine Diesel Engine fa AIG a E gt
2. Flywheel Housing o S 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 00900188 Remove the rear oil seal 00900189 RI Block Water Heater NOTE Be sure the engine coolant has been drained Disconnect the block heater electrical cord cs900wf Loosen the block heater retaining nut x Remove the block heater from the block cs900mb Diesel Engine 60 Complete Engine Piston Connecting Rod Assembly Remove Rotate the crankshaft with an engine barring tool until the pistons are below the carbon deposits which are found above the ring travel area CAUTION Do not use emery cloth or sandpaper to remove carbon from the cylinder bores Aluminum oxide or silicon particles from these materials can cause serious engine damage Use a scraper or a blunt edged instrument to loosen the carbon deposits Do not damage the cylinder with the scraper Remove the remaining carbon deposits with an abrasive pad Part Number 3823258 or equivalent Diesel Engine 61 Complete Engine Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury i f BIS I URNS i 4i hy NS CAUTION Do not use the steel wire wheel in the piston travel area Operate the wheel in a circular motion to remove the de
3. nozzle OK v Injection pump is malfunctioning frrmmmmmmeeenm Repair or replace the injection pump OK v Worn piston ring or cylinder resulting in low j j ee a Replace the worn piston ring or cylinder compression Diesel Engine 28 Troubleshooting Symptoms Engine Has Poor Respones This is symptom tree T 005 Cause Clogged air cleaner element ____I7 OK v Clogged fuel tank air breather hole OK v Clogged prefilter 9 Frammmeemmenn OK v Clogged fuel filter or strainer Im OK v Clogged or leaking fuel piping Fr OK T Overhead adjustments are not correct _ F OK v Defective contact of valve or valve seat lt lt Resulting in low compression OK v Defective or clogged injection nozzle __ s OK v Injection pump is malfunctioning Ir OK v Worn piston ring or cylinder resulting in low Compression Diesel Engine 29 Correction Clean or replace the air 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
4. 00900217 00900219 68 Main Bearing Cap CAUTION 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 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 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 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 the upper thrust bearing Complete Engine ala Tighten the mounting capscrews in the order sh
5. 2 00 in 0 016 to 0 010 in Number3 0 006 in cg900tc Diesel Engine 108 Engine System Diesel Engine Measure the bend 1 of the camshaft Bend of Camshaft Mm in 0 03 MAX 0 0012 Measure the camshaft lobe height 2 and thrust clearance 3 Camshaft Lobe Height 2 1 681 in 1 661 in 1 694 in 1 673 in 01900247 Thrust Clearance Standard MIN Repair Limits MAX 3 0 150 to 0 350 mm 0 50 mm 0 0197 in 0 0059 to 0 0138 in NOTE When installing the camshaft rotate the lt A camshaft slightly while being careful not to damage the bushing Install the thrust plate camshaft assembly and two capscrews Tighten the capscrews through the casting holes in the camshaft gear Torque Value 19Nem_ 14 ft lb Measure the end play of the camshaft Camshaft End Play Mm in 0 150 MIN 0 0059 0 350 MAX 0 0138 00900239 109 Engine System Camshaft Bushings Initial Check Inspect the camshaft bore for damage and excessive wear 01900259 Measure the camshaft bore Camshaft Bore Diameter Mm in 53 53 MAX 2 107 01900260 Use a small bushing driver set Part Number 3823942 lt 3 or equivalent to remove the camshaft bushing from the number 1 camshaft bore 01900261 NOTE Make sure the camshaft bore in the cylinder block and the outside diameter of the bushing are clean of oil and dirt Mark the camshaft bushing and cylinder block and align the lubricating oil hol
6. OK v Main bearing or connecting rod is worn or l meee Replace the connecting rod or main bearing damaged Diesel Engine 46 Troubleshooting Symptoms Complete Engine Engine Disassembly Service Tool PartNo 0 PatNiam Quantity Unit Repair Stand or Engine Overhaul Stand 3375193 Or 33 5194 3163625 Bracket 3163292 Valve Spring Compressor 3397890 Flange Puller 3823137 Piston Ring Expansion Tool ea8wrha Diesel Engine Engine Removal NOTE Put tag on all hoses lines linkage and electrical connections as they are removed to identify location and aid the installation process DJ awane O Always disconnect the negative cable first Disconnect the battery cables WARNING Allow the engine to cool before draining to avoid 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 47 Complete Engine Diesel Engine tr400wa 48 axo 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 Drain the lubricating oil Engine Oil 7 5 liters 1 98 U S gal Disconnect the starter cable engi
7. _ Mann o mn n Denen _ een mann 42 Troubleshooting Symptoms Coolant Temperature above Normal This is symptom tree T 016 Cause Coolant level is below specification 1777 OK v Fan belt is slipping or the fan pulley is worn OK v Water temperature gauge is malfunctioning OK v Radiator fin is clogged or crushed fr OK v Radiator core is clogged jf OK Thermostat is defective and does not open OK v Water pump is damaged pmu OK v Cylinder head or head gasket is crackedor lt damaged Diesel Engine 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 Correction Belt is squeaking due to insufficient tension or lt lt lt _ Check and adjust belt tension Make sure all the abnormally high loading pulleys rotate freely OK v Refer to Exhaust Gas is Black troubleshooting Exhaust leaks 0 premmmememeeen tree OK v Gear train backlash is not adjusted correctly I Adjust the backlash for the gear train OK v Idler gear bushing is damaged or missing 77777 Replace the idler gear bushing OK
8. assembly and gasket 00900171 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 x valve spring 00900173 Diesel Engine 55 Complete Engine x 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 x Fuel Injection Pump Rotary CAUTION Do not drop the nut washer or key Failure to do so will result in the need to remove the front gear cover Remove the gear cover access cap 05900254 Rotate the engine until the keyway is vertical Remove the nut and washer from the fuel injection pump shaft Remove the injection pump support bracket Remove the two mounting capscrews Remove the fuel injection pump Remove the key PTO Shaft if applicable Remove the two capscrews flange o ring and PTO shaft 00900177 Diesel Engine 56 Complete Engine I BE I x Lubricating Oil Pan jaw PA Ki Ce KM gt Remove the 24 capscrews lubricating oil pan and gasket Discard the gasket 00900178 Lubricating Oil Suction Tube Remove the two mounting capscrews lubricating oil suction tube and o ring Discard the o ring 00900179 axo Crankshaft Pulley Remove the capscrew and mounting plate ur m a i ait a a a a
9. follow the manufacturer s recommendations for use Wear goggles and protective clothing to avoid personal injury A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury cg9geea Use solvent to clean the camshaft gear Dry with compressed air NOTE If nicks or burrs can not be removed with abrasive pad Part Number 3823258 or equivalent replace the camshaft and camshaft gear Refer to Procedure 001 008 for camshaft removal Inspect the camshaft gear for cracked chipped or broken teeth Inspect the camshaft gear teeth for discoloration or signs of excessive heat bluing cg9gesc lf any damage is present replace the camshaft and camshaft gear Refer to Procedure 001 008 for camshaft removal NOTE If there is damage to the camshaft gear teeth or there are signs of excessive heat make sure to inspect the associated idler and oil pump gears for damage Diesel Engine 112 Engine System Connecting Rod Diesel Engine bp8csba cx8bdea 113 A CAUTION Prevent damage to the capscrews Nicks in the body of the capscrew can cause an area of stress that can fail during engine operation Damage to the threads will cause torque values to be incorrect and will damage the mating parts A WARNING When using a steam cleaner wear safety glasses or a face shield as well as protective clothing Hot steam can cause serious i
10. v a Replace the defective or clogged injection Defective or clogged injection nozzle I j 7 I9 a nozzle OK Overhead adjustments are not correct 777777777 Measure and adjust the overhead settings OK v Inspect the rocker levers rocker shafts and Overhead components are damaged I p y valves for excessive damage OK v Continued Diesel Engine 44 Troubleshooting Symptoms Excessive Noise Continued Cause Correction Injection pump is adjusted incorrectly fr Adjust or replace the injection pump OK v Worn piston ring or cylinder resulting in low j K aiiis a Replace the worn piston ring or cylinder compression Diesel Engine 45 Troubleshooting Symptoms Engine Vibration Excessive This is symptom tree T 018 Cause Correction Engine mounting bolts are loose or the engine l j ia oe een Replace the engine mounting bolts or cushion mounting cushion is broken OK v _ Repair the alignment Refer to the OEM s Engine and powertrain is out of alignment s service manual OK v Gear train backlash is not adjusted correctly gt Adjust the backlash for the gear train OK v Inspect the rocker levers rocker shafts and Overhead components are damaged I valves for excessive damage Replace as necessary OK v Cam bushing is worn vr rrr rere ere Replace the cam bushing OK v Injection pump is adjusted incorrectly fr Adjust or replace the injection pump
11. 33 64 Diesel Engine 226 M24x2 v8 M24x1 5 M25x2 1x12 M20x1 5 T M17x1 5 M18x2 5 M18x2 M24x2 8 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 Multiply By Multiply By SS eee eS ee fai a pe tenis fer fee fos zn Si centimeters_ em _ 6 452_1 0 155 _ sq foot ft sq meter m 100989 10 764 Fuel ounds er rams per kW kilometers per miles per gallon per g liter Fuel Performance i liters per Length aen fin fees o 12506 foossern z lore per kilopascal kPa 6 8948 0 145037 kilopascal 3 3769 0 29613 kilopascal 0 2488 4 019299 Pressure inches of mercury of inches of mercury sna of 25 40 0 039370 kilopascals 100 001 0 00999 millimeters of Fi centigrade 1 C F 32 1 8 1 8x 0 32 Torque ound force per gallon US gl herr TI 37853 0 264179 Volume gallon Imp gl liter 4546 0 219976 liquid cubicinch in liter 001639 61 0055 displacement BEP 3 cubic 3 006100 Weight pounds avoir kilograms 0 4536 2 204623 mass u ih perme Pr kilowatt hour 0 000293 3414 kilowatt hour 0 746 1 341 Diesel Engine 227 Specifications Special Tools Standard Puller Lubriplate Multi Purpose Lubricant Dowel Pin Extractor Silicone Sealant Depth Gauge Assembly Diesel Engine Diesel Engine 22
12. 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 20 400 290 550 400 Diesel Engine 222 Specifications Capscrew Markings and Torque Values U S Customary SAE Grade Number apscrew Head Markings These are all SAE Grade 5 3 line DD Capscrew To ue Grade 5 Capscrew Capscrew Torque Grade 8 Capscrew Capscrew Body Size Diesel Engine Cast Iron Nem ft lb 9 7 12 9 20 15 23 17 40 30 40 30 60 45 65 50 95 70 100 75 135 100 150 110 180 135 210 155 325 240 365 270 490 360 530 390 720 530 800 590 223 Aluminum Nem ft lb 8 6 9 7 16 12 19 14 25 20 35 25 45 39 55 40 75 55 80 60 110 80 115 85 150 110 160 120 255 190 285 210 380 280 420 310 570 420 650 480 Cast Iron N m ft Ib 15 11 18 13 30 22 33 24 55 40 60 45 90 65 95 70 130 95 150 110 190 140 210 155 255 190 290 215 460 340 515 380 745 550 825 610 1100 820 1200 890 Aluminum Nem ft lb 8 6 9 7 16 12 19 14 25 20 35 25 45 35 55 40 75 55 80 60 110 80 115 85 150 110 160 120 255 190 285 210 380 280 420 310 570 420 650 480 Specifications Fraction Decimal Millimeter Conversions Conversion Factor 1 inc
13. Crankshaft Seal Front 42244 RR nennen 128 Crankshaft Seal Rear uunuunnseensennnennnneeeenn 129 Cylinder BIOCK ccccccceseccceceeeeseeeeeeeeeeeseeaeeeees 130 Gear Cover Front ccccceeeceeeceeeceeeeeeeeeeneeenees 134 Idle Gear Camshaft ccccceeeeceeeeeeeeneeeneeeaeees 136 PI NOM PO au E ai 139 PISTON RINGS ns een 142 Piston and Connecting Rod Assembly 146 Gear Train Backlash Front 4 2244444 gt 156 Camshaft Thrust Bearing ccccccccceeeeeeeeeeees 157 Cylinder Head cccccccceeeesseseeeeeeeeeseeeeeeeseeeeeeeaaes 158 HOcKer LIVEIS ee 164 Adjusting Valve Clearance cccceeeseeeeeeeeeaeees 164 Rocker Levers Assembly uus022440004enen nennen 166 Rocker Lever COver cccccccccssseseeeeeeeeesaaeseeeeeeees 169 Push Rods or TUD S ccccccseeeeeeeeeeeseeeeeeeeeeeees 170 TIDDel eee eee ere eee reer re eer eT eee 171 Complete Engine cccccccseseeeceeeeesseeeeeeeeeeeeeeaes 173 Measuring Compression Pressure 173 Testing and Adjusting the Fan Belt Tansion 175 PUEY E leere 176 Fuel Injection Pump Rotary 176 BA CUO ee app reset 181 WSSU e tee ee ee 181 Lubricating System uuussnsennneennennnnennnnnnnnee nenn 186 Measuring Oil Pressure uuss220uussnnneneeeeenenn 186 Lubricating Oil Cooler If equipted 186 Lubricating Oi
14. Install the rocker lever shaft and thrust washers if equipped Install the snap rings for each rocker lever 03900104 AN NOTE Check that the ball of the adjustment screw OS 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 NOTE Tighten the middle pedestal capscrew first Install the rocker lever assembly and mounting 00900169 capscrews Tighten the capscrews Torque Value 25n m 18 ft lb Diesel Engine 168 Engine System Rocker Lever Cover Remove the three capscrews isolator assemblies o axo rings and rocker lever cover Remove the gasket Discard the gasket AK DIELS A SE Re Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the rocker lever cover with a strong solution of detergent in hot water Dry the rocker lever cover with compressed air 03900109 Inspect the rocker lever cover for cracks and other 7 damage 03900110 Install the new gasket Install the rocker lever cover o rings isolator assemblies and three capscrews Tighten the capscrews Torque Value 9n m 80 in Ib lt gt alle gt gt gt C3 A gt ee Fi er A m 4 3 ppr ge a 3 Diesel Engine 169 Engine System Push Ro
15. Verify the dipstick Lubricating oil lever is below specification 1777 calibration and the oil pan capacity Fill the system to the specified level OK v Oil level or pressure sensor is damaged 1777777777 Replace the oil lever or oil pressure sensor OK v Lubricating oil filter is clogged Fremen Replace the filter OK v Fuel or coolant is in the lubricating ol f 77777777 Refer to Oil Level Rises symptom tree OK v Regulator or relief valve is n j i egulator or relief valve is not adjusted lt lt Adjust the regulator or relief valve Correctly OK v Lubricating oil pan strainer is clogged fr Clean the strainer OK v Lubricating oil suction tube is damaged T7 7 Repair or replace the suction tube OK v Lubricating oil pump is damaged free Replace the oil pump OK v Main or rod bearing is worn or damaged 77 Replace the bearing Diesel Engine 41 Troubleshooting Symptoms Oil Level Rises This is symptom tree T 015 Cause Rear crankshaft seal or seal surface is damaged OK Auxiliary equipment has damaged pump seal OK Injector sleeve is damaged OK Fuel injector is leaking inside cylinder head OK Injector pump seal is leaking OK Cylinder head or head gasket is cracked or damaged OK Cylinder block is cracked or porous Diesel Engine Correction een ai service manual
16. When using solvents acids or alkaline materials cx800kd for cleaning follow manufacturer s recommenda tions for use Wear goggles and protective clothing to reduce the possibility of personal injury A CAUTION The connecting rod must be demagnetized completely and cleaned thoroughly Any small metal particles will cause engine damage Demagnetize the connecting rod Use solvent or steam to clean the connecting rod Diesel Engine 117 Engine System This procedure describes the magnetic particle inspection for connecting rod capscrews bp8csse Use a Magnaflux or similar magnetic particle testing machine Use the continuous method Apply a head shot of 300 to 400 amperes direct current or rectified alternating Current bp8cssb Use an ultraviolet light Check for indications of cracks The magnetic particles tend to form on sharp corners and edges Do not mistake these for cracks Any indications of cracks are not acceptable Prepare the machine for a coil shot Make sure the capscrew is near one side of the coil and not in the center Apply 1000 to 1350 ampere turns bp8cssd Diesel Engine 118 Engine System ZN Use an ultraviolet light Check for indications of cracks Any indications of cracks are not acceptable A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to redu
17. both the connecting rod and the connecting rod cap cx9behd Make sure the tang on the bearing shells is in the slot of the connecting rod cap and connecting rod SA Lubricate the connecting rod bearings with clean amp 7 lubricating engine oil cx9bewa Diesel Engine 70 Complete Engine Immerse the pistons in clean 15W 40 engine lubricating oil until the rings are covered Allow the excess oil to drip off the assembly pi800hd SD Position the rings so that the ring gaps are 120 Os degrees apart pi9rihb A CAUTION If using a strap type ring compressor make sure the inside end of the strap does not hook on a ring gap and break the ring Use piston ring compressor Part Number 3164330 or equivalent to compress the rings 00900228 Lubricate the cylinder bore with clean 15W 40 engine lubricating oil The cylinder block must be clean before assembly Inspect the cylinder bores for reuse Diesel Engine 71 Complete Engine Diesel Engine YBDC 00900231 cx900ld cx9cswb cx9cshb 72 Position the connecting rod journal for the piston to be installed to bottom dead center BDC Take care to not damage the cylinder wall when inserting the connecting rod Carefully push the piston into the bore while guiding the connecting rod to the crankshaft journal Lubricate the threads and underside of the connecting rod capscrew heads with clean 15W 40 lubricating engine oil A WARNING
18. burrs or raised material can not be removed with an abrasive pad or equivalent the camshaft idler gear must be replaced Inspect the idler gear for cracked chipped or broken teeth Inspect the idler shaft bore for burrs Engine System NOTE If the burrs or raised material can not be removed with an abrasive pad or equivalent the camshaft idler gear shaft must be replaced Inspect the idler shaft nose for burrs Always connect the negative cable last Connect the battery cables cg900sj Align the match marks on the idler gear crankshaft gear and camshaft gear The match marks are identified as follows A Crankshaft gear and idler gear B Idler gear and camshaft gear C Fuel pump and idler gear NOTE Lower case letters identify oil pump and accessory drive which are not timed 00900241 NOTE If a PTO accessory drive is used on the engine the idler gear uses two bearings Install the idler shaft rear bearing rear spacer plate and idler gear Install the front bearing plate shim and capscrew Tighten the capscrew Torque Value 110 n m 81 ft lb 01900258 Measure the end play of the idler gear 00900243 Diesel Engine 137 Engine System Position the fuel injection pump assembly temporarily Measure the backlash of each gear with a dial indicator 3376050 or equivalent 00900244 138 Engine System Diesel Engine Piston Diesel Engine pi900ec pi900
19. connections and fuel Fuel leak filters for leaks Check the fuel lines to the supply tanks OK v Fuel inlet restriction 4 2 premmeemeeeeen Check for fuel inlet restriction OK v The pump output pressure Replace the fuel lift Fuel lift pump is malfunctioning frrmmmmemeeee j pt Br p pump if necessary OK v Fuel pump overflow valve is malfunctioning gt Check the overflow valve OK v u Check for air in the fuel system Repair source Air in the fuel system ss fps i of leak and bleed air from the system OK v Check the air intake system for restriction Clean or replace the air filter and inlet piping as necessary Air intake system restriction is above specification OK v Inspect the air intake and exhaust systems for Air are i en bial oO bs NE air leaks OK v Exhaust brake adjustment is not correct 7777777777777 Check the exhaust brake adjustment OK 4 Continued Diesel Engine 22 Troubleshooting Symptoms Engine Acceleration or Response Poor Continued Cause Correction Exhaust system restriction is above u Wr ee Check the exhaust system for restriction specification OK v us Perform a pop test on the injector s Injector is malfunctioning frrmmmmmmeeenn OK 5 Correction Sea the fuel quality is poor fuel OK v Check the fuel supply line from the fuel pump to E the cylinder head for sharp bends that can cause restriction OK v
20. crankshaft end play using a dial indicator Part Number 3824564 or equivalent and magnetic base Part Number 3377399 or equivalent Crankshaft End Play Mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 NOTE Mark the thrust bearings so the bearings can be installed in the correct position during assembly NOTE The main bearing cap mounting capscrews must be replaced after each use Remove the mounting capscrews of the main bearing cap Remove the main bearing cap and lower bearing Engine System Diesel Engine _mb200gb mb900si 0 25 mm 009 in 0 50 mm 019 in 0 75 mm 029 in 1 00 mm 039 in mb900gg 101 A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recom mendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury CAUTION Do not use a scraper or a wire brush The bearings can be damaged NOTE Make sure the bearings are marked for location The bearings must be installed in their original locations if used again Use solvent and a soft bristle brush to clean bearings Dry with compressed air Inspect all main bearing caps and main bearing crankshaft journals for dents cracks deep scoring overheating and other damage Determine the size of the
21. drain the cooling system if at ee oi800w10 If the water being drained is still dirty the system must be flushed again until the water is clean CAUTION The cooling system must be filled properly to prevent air locks in the cooling passages Failure to vent the cooling system properly can cause damage to the cooling system Adequate venting is provided for a fill rate of 10 liters minute 2 6 gal minute 08900314 50 PERCENT 50 PERCENT A CAUTION WATER WATER 50 PERCENT 50 PERCENT Do not use water alone for coolant Damage from ANTIFREEZE ANTIFREEZE corrosion can severely damage the engine cooling system Use a mixture of 50 percent water and 50 percent ethylene glycol antifreeze to fill the cooling system Diesel Engine 198 Engine System Diesel Engine ra900ve ID iy 199 A WARNING Do not remove the pressure cap from a hot engine Wait until the coolant temperature is below 50 C 120 F before removing the pressure cap Heated coolant spray or steam can cause personal injury Install the pressure cap Operate the engine until it reaches a temperature of 82 C 180 F and check for coolant leaks Check the coolant level again to make sure the system is full of coolant or that the coolant level has risen to the hot level in the recovery container on the system if equipped When you troubleshoot overheating remember that too much oil in the oil pan can c
22. filling the system The ability of antifreeze to remove heat from the engine is not as good as water so pouring antifreeze into the engine first could contribute to an overheated condition before the liquids are completely mixed A mixture of 50 percent ethylene glycol base antifreeze is required for operation of the engine in temperature environments above 37 C 35 F A mixture of 40 percent water and 60 percent antifreeze is recommended for temperatures below 37 C 35 F Do not use more than 60 percent antifreeze Refer to Cummins Coolant Requirements and Maintenance for additional cooling system information Engine System Water Only Diesel Engine ra900be ra900vf 201 CAUTION Never use water alone for coolant Damage from corrosion can be the result of using water alone for coolant The small holes in the head gasket are especially susceptible to plugging These holes are orifices and their size is critical Do not enlarge the size of the orifices To do so will disturb the coolant flow and will not solve an overheating problem Water will cause rust formation reducing the flow in the smaller coolant passages CAUTION A sudden loss of coolant from a heavily loaded engine can result in severe damage to the pistons and cylinder bore Also water used as a coolant for even a relatively short period can result in the cup plugs rusting through allowing the coolant to leak An inco
23. i 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 Aan Hook the element and one leg of the channel T Bar DE OS into the hole as illustrated cs900wh 88 Complete Engine Hook the other leg of the channel in the hole and lt a 7 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 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 engine long enough for the thermostats to open and ensure all the air has escaped cs900hc Diesel Engine 89 Complete Engine Diesel Engine Gia Alternator Install the alternator and capscrew Install the spacer mounting capscrew and adjustment plate Loosely install the washer and adjustment capscrew Fan Pulle L i IV Install the fan pulley 00900255 SA Position the fan belt 2 into the fan pulley groove G7 and loosely tighten the adjustme
24. inspect the gear Refer to starter manual Change the oil and filters Install an oil pan heater or drain the oil and fill the system with warm oil Remove the injectors and rotate the crankshaft Look for the source of fluid in the cylinder Troubleshooting Symptoms Engine Will Not Crank or Cranks Slowly Continued Cause Correction Check the oil level Verify the dipstick Lubricating oil level is above specification 17 calibration and oil pan capacity Fill the system to the specified level OK v Analyze the oil and inspect the filters to locate Internal engine damage Prrmmmmmmmeenm an area of probable damage Diesel Engine 25 Troubleshooting Symptoms Engine Cranks But Will Not Start No Exhaust Smoke This is symptom tree T 003 Cause Correction Fuel level low in the tank Fremen Fill the supply tank OK v Improper fuel is being used rrr rrr Drain fuel and replace with correct fuel OK v Clogged fuel tank air breather hole fr Clean the fuel tank breather OK v Engine does start when voltage is applied to gt a Pepper Troubleshoot and repair the circuit wiring the fuel cut solenoid valve OK v Engine does not start when voltage is applied j er Replace the fuel cut solenoid valve to the fuel cut solenoid valve OK Clogged prefilter 4 Frrmmmmemeeeen Clean the prefilter OK Clogged fuel filter or strainer _ _ Frrmmmemmmeenn Clean or replace the fuel filter
25. mm zur l l 0 40 mm Pana ORANAN 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 Between Bushing and Shaft End Play of Idler Gear Diesel Engine 214 Specifications Flywheel 18900013 Ref Inspection Item Standard Remarks FLYWHEEL Repair Limit 0 30 mm 0 012 in Face Runout of Flywheel Housing Repair Limit 0 35 mm 0 014 in Repair Limit 0 15 mm 0 0059 in Repair Limit 0 20 mm 0 079 in Face Runout of Flywheel Radial Runout of Flywheel a Radial Runout of Flywheel Housing Diesel Engine 215 Specifications Cylinder 18900020 Inspection Item Standard Remarks CYLINDER ID Tolerance ne 95 00 mm 0 022 mm 3 740 in 0 0008 in Roundness of Cylinder a Repair Limit 0 02 mm 0 0008 in Cylindricity of Cylinder Diesel Engine 216 Specifications Piston 2 25 mm 3 0 98 in A 18900020 Ref inspection Item Standard Remarks Diameter Between Piston Ring Groove and Piston Ring Clearance Diesel Engine PISTON Repair Limit ID 94 85 mm 3 734 in Repair Limit 0 15 mm 0 0059 in 20mm Repair Li
26. or severe engine damage can occur Use extreme care not to apply Loctite to the oil hole in the camshaft bushing Use a small camshaft bushing driver set Part Number 3823942 or equivalent to install the camshaft bushing even with the front face of the cylinder block Use a clean lint free cloth to wipe off any excessive Loctite CAUTION Make sure there is no Loctite in the oil hole or severe engine damage can occur Make sure the lubricating oil hole in the camshaft bushing is aligned with the camshaft oil hole in the cylinder block A 3 2 mm 0 126 in diameter rod must be able to pass through the lubricating oil hole Camshaft Thrust Bearing Install the thrust bearing Complete Engine Diesel Engine afa Camshaft I Install NOTE When installing the camshaft rotate the camshaft slightly while being careful not to damage the bushing Install the thrust plate camshaft assembly and two capscrews Tighten the capscrews through the casting holes in 00900238 the camshaft gear Torque Value 19 Nem 14 ft lb Measure the end play of the camshaft Camshaft End Play mm in 0 150 MIN 0 0059 0 350 MAX 0 0138 00900239 Idler Gear Camshaft 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 le
27. rpm Max Torque 219 1 600 rpm 2 500 25 em 2 470 50 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 a l _ Total System 7 5 liters 8 0 qt Lubricating Oil Capacity Standard Oil Pan Only 7 0 liters 7 4 at Lubricating Oil Pressure at Idle Minimum Allowable 69 kPa 10 psi Lubricating Oil Pressure at Rated Minimum Allowable 245 kPa 85 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 qt Cooling System Naturally Aspirated Coolant Capacity Engine Onl 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 kPa 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 Load with Dirty Filter Element 3 in Hg Maximum Allowable Restriction to the Fuel Transfer Pump Bina Maximum Allowable Return Line Restriction Must Not Exceed os gt Hii Hg 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 DO Starter 550 CCA Minimum Recommended Battery Capacity with Heavy 12 VDC Starter 730 CCA Accessories Max
28. speed is adjusted too low Irre Adjust the low idle speed OK Clogged prefilter 4 Frrmmmmemeeeen Clean the prefilter OK v Clogged fuel filter or strainer _ _ Prrmmmemmmnenn Clean or replace the fuel filter or strainer OK v Line between the fuel tank and feed pum w i K Poe ceeecceecte Clean and repair the lines are clogged or have air in them OK v Line between the feed pump and the injector w pae ER ia ee Clean and repair the lines nozzle are clogged or have air in them OK Injection pump is malfunctioning fr Replace the injection pump Diesel Engine 31 Troubleshooting Symptoms Engine Power Output Low This is symptom tree T 008 Cause Correction Improper fuel is being used vr rrr Drain and replace the fuel with the correct fuel OK v Clogged air cleaner element Irre Clean or replace the air cleaner element OK v Clogged fuel tank air breather hole fr Clean the fuel tank breather OK v Full throttle can not be achieved because the fuel lever linkage is bent or not adjusted 17777777 Repair or adjust the fuel lever linkage correctly OK v Clogged prefilter rrr rere rere j Clean the prefilter OK v Clogged fuel filter or strainer _ Irmmmmmememenn Clean and or replace the fuel filter or strainer OK v Clogged or leaking fuel piping 8 frrmmmmmmmeeem Clean and repair the fuel piping OK v Feed pump is defective ss frrrrtrtttrrne Replace
29. the manufacturer s recom mendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Some solvents are flammable and toxic Read the manufacturer s instructions before using A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the bearing and connecting rod caps with solvent Dry with compressed air Inspect the connecting rod caps connecting rod bearing saddles and capscrews for nicks cracks burrs scratches or fretting Inspect the bearings for damage Refer to Parts Reuse Guidelines for more information on bearing inspection Replace any bearings that have the following damage Pits Flakes Corrosion e Lock tang damage e Scratches e Heavy wear Engine System Inspect the bearing shell seating surface for nicks or 7 burrs gt If nicks or burrs can not be removed with an abrasive pad Part Number 3823258 or equivalent the bearings must be replaced If the bearings are damaged they must be replaced as a set For more detailed information on bearing damage see Analysis and Prevention of Bearing Failures cx9besa NOTE Connecting rod bearings are identified with the part number and size stamped on the back NOTE Oversize service rod bearings are available for use with a crankshaft that has been machined undersize Determine the size of the remo
30. the mounting bracket capscrews Torque Value 12 Nem 14 ft lb Torque Value 14 Nem 23 ft lb A Install the fuel pump drive access cover PN Q Tighten the two capscrews Q Torque Value 10mm 13Nem_ 10 ft Ib Torque Value 12mm 19Nem_ 14 ft Ib 14900071 Cylinder Head Assembly i A NOTE Coat the stems of the intake and exhaust gt gt valves and the inside of the valve guides 4 i i with engine oil Install the valves 00900174 Diesel Engine 81 Complete Engine Diesel Engine Install the valve spring and spring seat on the valve b gt QW stem 00900173 Gaa Install the valve cotter into the valve stem groove a 7 while compressing the valve spring with spring pusher Part No 3398179 00900172 CAN After releasing the valve spring tap the top of the OS valve stem with a plastic hammer to make certain the cotter is completely fitted AL 00900252 axo CAUTION Remove all carbon and dirt from the contact surfaces of the cylinder block and the cylinder ar 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 facing up 00900253 82 Complete Engine ame This component weighs 23 kg 50 Ib or more To J avoid personal injury use a hoist or get assistance to lift this component NOTE Coat the capscrew th
31. 008 0 070 MAX 0 0028 00900240 afa Gear Housing Cover ay 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 00900182 Diesel Engine 78 Complete Engine Diesel Engine Eu i Er f A i vn N E k at i i 5 E s i t 00900181 Gr a 00900180 00900179 ss A CAUTION Q 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 19Nem_ 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 Crankshaft Pulley Align the crankshaft pulley with the crankshaft key Install the crankshaft pulley mounting plate and capscrew Tighten the capscrew Torque Value 93 Nem 69 ft lb 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 Complete Engine Diesel Engine 00900178 00900177 fp900wi 80 Lubricati
32. 014 010 for blowby measurement A free floating hollow piston pin is used to attach the piston to the connecting rod Lubricating the pin and journal is accomplished by residual spray from piston cooling Rotate the crankshaft with an engine barring tool until the pistons are below the carbon deposits which are found above the ring travel area Engine System Do not use emery cloth or sandpaper to remove carbon from the cylinder bores Aluminum oxide or silicon particles from these materials can cause serious engine damage Use a scraper or a blunt edged instrument to loosen the carbon deposits Do not damage the cylinder with the scraper Remove the remaining carbon deposits with an abrasive pad Part Number 3823258 or equivalent lato at ie 2 sf 7 ere aie Ti a ae ge ir j pF or i a ct ea A ne Pi Z co LLA Se ES ck9bref A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury A CAUTION Do not use the steel wire wheel in the piston travel area Operate the wheel in a circular motion to remove the deposits NOTE An inferior quality wire wheel will lose steel bristles during operation thus causing additional contamination An alternative method to remove the carbon ridge is to use a high quality steel wire wheel installed in a drill or die grinder Diesel Engine 147 Engine System On pistons with anodized c
33. 13 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 Gear drive number of teeth 7 7 Driven Gear number of teeth 7 e Oil pump drive gear number of teeth 22 e Driven gear number of teeth 7 e Pump Speed Engine Speed x 1 182 Regulator Valve e Set Pressure 490 50kPa 71 7psil Diesel Engine 14 Engine Identification Fuel System 05900870 6 Fuel shutoff solenoid 7 High pressure fuel line Fuel supply from tank 2 Hand priming pump 3 Fuel filter 1 Injector 9 Fuel drain manifold 10 Fuel return to tank 8 4 Water in fuel sensor 5 Fuel pump Engine Identification 15 Diesel Engine LE 3 j al DT an oo binan ae oO amp ihl T su 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 Me
34. 2 to 0 0035 in 0 20 mm 0 0079 in Diesel Engine 156 Engine System Camshaft Thrust Bearing Diesel Engine Ro Remove the thrust bearing 00900186 The bearings can separate during engine operation Do not use room temperature vulcanized RTV sealant to hold the bearings together for assembly or the thickness can be too great when the room temperature vulcanized RTV sealant cures NOTE The camshaft thrust bearing has two 01400029 bearings Both have a steel back with an aluminum overlay The thrust bearing must be installed with the smooth sides against each other Inspect the thrust bearing for damage Measure the bearing thickness Camshaft Thrust Bearing Thickness mm in 0 150 MIN 0 0059 0 350 MAX 0 0138 AN Install the thrust bearing au 00900186 157 Engine System Cylinder Head axo 00900172 00900174 Diesel Engine 158 WARNING This component weighs 23 kg 50 Ib or more To reduce the possibility of personal injury use a hoist or get assistance to lift this component Remove the mounting capscrews cylinder head assembly and gasket Discard the gasket Use a valve spring compressor Part Number 3163292 or equivalent to compress the valve spring s and remove the valve collets Loosen the spring and remove the spring seat and valve spring NOTE When removing the valve s mark them in the location where the valve was installed This will aid in
35. 25 Pipe Plug Torque Values cccceceeeeeeeeeeeees 225 Tap Drill Chart U S Customary and Metric 226 Weight and Measures Conversion Factors 227 Special Tools Special TOONS snscssccacsossensnsieacannanaerunasacnemeniaavewentneane 228 Diesel Engine 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 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 t
36. 6 to 0 0055 in oe Diesel Engine 212 Specifications Crankshaft 18900019 Ret Inspection Item Standard Remarks CRANKSHAFT 0 131 to 0 351 mm Repair Limit 0 40 mm ES Trust Giearance 0 0052 to 0 0138 in 0 016 in STD 70 000 mm Repair Limit 69 86 mm 2 756 in 2 750 in 69 75 mm Repair Limit 69 61 mm en 2 746 in 2 741 in 69 50 mm Repair Limit 69 36 mm Main Journal U S 0 50 2 736 in 2 731 in 69 25 mm Repair Limit 69 11 mm aces 2 726 in 2 721 in 69 00 mm Repair Limit 68 86 mm re 2 717 in 2 711 in Repair Limit 0 020 mm Ei o ooo a abe i Basar 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 en 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 we 2 215 in 2 211 in 56 000 mm Repair Limit 55 91 mm Re 2 205 in 2 201 in 0 0008 in Bear En kPr Jane 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 213 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 Injection pump 0 07 mm to 0 29
37. 8 Special Tools Tools Crankshaft Seal Installer Thread Repair Inserts Abrasive Pad Diesel Engine Diesel Engine 229 Special Tools Tools Small Bushing Driver Set Precision Straightedge Injector Bore Brush Antiseize Lubricant Precision Straightedge Diesel Engine Diesel Engine 23 0 Special Tools Tools Standard Puller Digital Multimeter Digital Multimeter Pressure Vacuum Module Bearing Separator Tool Diesel Engine 231 Special Tools Digital Optical Tachometer Graduated Beaker OD Contact Cleaner Injection Timing Gauge Kit Fuel Pump Drive Gear Retention Tool Diesel Engine Diesel Engine 292 Special Tools Tools Fuel Return Flow Hose Fuel Pump Pressure Gauge Fuel System Leak Tester N aan Flow Hose fuel rail pressure Injector Remover Diesel Engine Diesel Engine 2839 Special Tools Tools Injection Nozzle Tester Injector Nozzle Cleaning Kit Fuel Filter Wrench Graduated Beaker Diesel Engine Diesel Engine 284 Special Tools Tools Antiseize Lubricant Black Light Lamp Silicone Sealant Pressure Vacuum Module Pressure Gauge Kit Diesel Engine Diesel Engine 285 Special Tools Tools Tube Filter Cutter Oil Filter Wrench Oil Filter Wrench Lubricating Oil Cooler Test Kit Refractometer Diesel Engine Diesel Engine 286 Special Tools Tools ayi Belt Tension Gauge Digital Multimeter Digital Multimeter Sealant Dial Indicator Assembly Diesel Engine DieselE
38. Analyze the oil and inspect the filters to locate Internal engine damage Prrmmmmmemeeen an area of probable damage Fuel supply line restriction between the fuel pump and the injection Diesel Engine 23 Troubleshooting Symptoms Engine Will Not Crank or Cranks Slowly This is symptom tree T 078 Cause Battery cables or connections are loose broken or corroded excessive resistance OK v Battery cables are not the correct gauge or lt length OK v Battery capacity is below specification fr OK v Starter interlock devices engaged fr OK v Battery voltage is low pemmmmmmeeen OK v Engine driven units are engaged free OK v Starting circuit component is malfunctioning OK v Starting motor pinion or ring gear is damaged f OK v Lubricating oil does not meet specifications for operating conditions OK v Lubricating oil temperature is below 20C fr OK v Hydraulic lock in a cylinder 4 4 remmmemeeen OK v Continued Diesel Engine 24 Correction Check the battery cables and connections Replace the battery cables with larger gauge or shorter length cables Replace the batteries if necessary Check the starter interlock devices Refer to the starter service manual Check the batteries and the unswitched battery supply circuit Disengage engine driven units Refer to the electric schematic Remove the starting motor and
39. Correction Chassis powertrain is damaged or overloaded Refer to the OEM s service manuals OK v Fuel level low in the tank Premmmeemeeeen Fill the supply tank OK v Clogged fuel tank air breather hole fr Clean the fuel tank breather OK v Clogged prefilter 4 Frrmmmmemeeeen Clean the prefilter OK v Clogged fuel filter or strainer _ _ Prrmmmemmmeenn Clean and or replace the fuel filter or strainer OK v Clogged or leaking fuel piping Irrmmmmmmmmeeen Clean and repair the fuel piping OK v Feed pump piston is damaged or seized 17 7 Replace the feed pump OK v Inspect the rocker levers rocker shafts and Overhead components are damaged I valves for excessive damage Replace as necessary OK v Injection pump is malfunctioning frrmmmmemmeeenm Replace the injection pump OK v Gear train damaged or seized Irmmmmmmmmmenn Refer to OEM s service manuals OK v Piston or connecting rod is damaged Ir Replace damaged piston or connecting rod OK v Crankshaft bearing is damaged ss Irrmmmmmmmmeeen Replace damaged crankshaft bearing Diesel Engine 30 Troubleshooting Symptoms Engine Runs Rough or Misfires This is symptom tree T 007 Cause Correction Fuel level low in the tank Premmmmmemeeen Fill the supply tank OK Clogged fuel tank air breather hole Tr Clean the fuel tank breather OK Low idle
40. Engine 178 Engine System NOTE Check that the stylus end of the dial gauge contacts the plunger head and is not bottomed out Ke Install the dial gauge Part Number 3377259 or SE equivalent into the distributor head 0 50 mm 5p9towa Rotate the crankshaft in the opposite direction of normal engine rotation counterclockwise slightly until the dial gauge stops moving Set the dial gauge pointer to zero 0 Slowly rotate the crankshaft in the normal direction of engine rotation until the dial indicator reads the following Measurements 14900077 mm in Distributor Head Timing 1 0 0 3 0 04 0 01 ZN Check the degree markings on the crankshaft pulley lt with the pointer and that is the timing of the engine lf the timing needs to be adjusted rotate the crankshaft approximately 45 degrees in the reverse direction of engine rotation Rotate the crankshaft in the normal direction of engine rotation until the pointer on the gear cover lines up with the correct timing mark on the crankshaft pulley as stated on the dataplate Loosen the fuel injection pump support bracket then loosen the injection pump mounting capscrews Rotate the fuel pump until the dial indicator reads 1 0 0 3 mm 0 04 0 01 in Tighten the fuel injection pump mounting capscrews then the support bracket Torque Value 31 n m 23 ft lb 14900078 Diesel Engine 179 Engine System Remove the dial gauge sine A Install the
41. L ERI en Contact 02900010 Immediately after cleaning and inspecting the capscrew Apply a film of clean lubricating engine oil to all capscrews that are to be used again kn9cswb Coat the stems of the intake and exhaust valves and the inside of the valve guides with clean lubricating engine oil SB Ray 00900174 Diesel Engine 161 Engine System SA Install the valve spring and spring seat on the valve stem Install the valve collet onto the valve stem groove while compressing the valve spring with the valve spring compressor Part Number 3163292 or equivalent 00900172 afa After releasing the valve spring tap the top of the OS valve stem with a plastic hammer to make sure the valve cotter is completely seated Measure the cylinder head valve seat recession 2 Valve Seat Specifications mm in Intake 1 00 0 100 NOM 0 039 0 004 Exhaust 0 90 0 100 NOM 0 035 0 004 Repair limit on the intake valve seat is 2 00 mm 0 079 in 00900130 Repair limit on the exhaust valve seat is 1 90 mm 0 075 in Valve seat angle 4 is 45 degrees with a tolerance of 0 15 Repair limit condition is judged by vacuum test Diesel Engine 162 Engine System Diesel Engine Measure the injector nozzle protrusion 3 on the cylinder head Injector Nozzle Protrusion mm In 2 84 MIN 0 112 3 40 MAX 0 138 The tolerance allowance on the nozzle protrusion is 2 700 to 3 500 mm 0 106 to 0 138 in CA
42. MIN 2 241 57 00 MAX 2 244 0 25 mm 56 66 MIN 2 231 56 75 MAX 2 234 0 50 mm 56 41 MIN 2 221 56 50 MAX 2 224 0 75 mm 56 16 MIN 2 211 56 25 MAX 2 215 1 00 mm 55 91 MIN 2 201 56 00 MAX 2 205 Diesel Engine 122 Engine System Diesel Engine 01900249 00900204 E gt 123 Measure the clearance of the crankshaft pin journal 3 Measurements mm in Bearing 0 0011 Clearance Bee to 0 0035 Check the roundness 3 of the connecting rod crankshaft pin journal Connecting Rod Crankshaft Pin Journal mm in Out of 0 020 MAX 0 0008 Roundness Measure the bend of the crankshaft 4 Measurements mm in Crankshaft 0 09 0 0035 Bend A WARNING This assembly weighs 23 kg 50 Ib or more To reduce the possibility of personal injury use a hoist or get assistance to lift this assembly A CAUTION Do not hit the crankshaft against the cylinder block Failure to do so can result in damage to the block or crankshaft Lubricate the upper main bearings with clean engine lubricating oil Install the upper main bearings Refer to Procedure 001 006 Position and install the crankshaft and gear into the cylinder block Install the lower main bearings and bearing caps Refer to Procedure 001 006 Engine System NOTE The crankshaft must rotate freely by hand 02900058 Diesel Engine 124 Engine System Crankshaft Gear Front Diesel Engine ks gesa 125 NOTE If there is damage to the front cra
43. SB4310E00 Jan 2008 Service Manual B3 3 Diesel Engine D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 D20S 3 D25S 3 D30S 3 D32S 3 D33S 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 co
44. Seal Wear Groove Mm in 0 25 MAX 0 010 If the wear groove exceeds the specification replace the crankshaft Inspect the crankshaft connecting rod and main journals for deep scoring overheating or other damage NOTE Oversize thrust bearings are available if the thrust distance is not within specifications If the crankshaft must be machined to use an oversize thrust bearing refer to the Alternative Repair Manual Bulletin 3379035 for machining instructions Measure the thrust clearance 1 Crankshaft installed or crankshaft thrust width minus block thrust width bearing width Crankshaft Thrust Clearance Mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 Engine System Measure the main journal 2 gt Connecting Rod Bearing Journal Diameter mm in Standard 69 86 MIN 2 750 70 00 MAX 2 756 0 25mm 69 61 MIN 2 741 01900249 69 75 MAX 2 746 0 50mm 69 36 MIN 2 731 69 50 MAX 2 736 0 75mm 69 11 MIN 2 721 69 25 MAX 2 726 1 00mm 68 86 MIN 2 711 69 00 MAX 2 717 Bearing Clearance 2 Main bearing inside diameter with bearing installed minus crankshaft journal diameter Refer to procedure 001 026 Measurements mm in Bearing 0 0 0017 to Clearance eases 0 0041 Check the roundness 2 of the bearing journal Connecting Rod Bearing Journal mm In Out of 0 020 MAX 0 0008 Roundness Measure the connecting rod crankshaft pin journal 3 Connecting Rod Crankshaft Pin Journal Diameter mm in Standard 56 91
45. Surface Flatness Warpage Limit oa ps os nl 0 30 mm l l 0 012 in 1 00 0 100 mm Repair Limit Intake 2 00 mm 0 039 0 004 in 0 079 in vave Seal Repair Limit 0 90 0 100 mm l Exhaust i 1 90 mm ena Ben 0 075 in Tolerance Nozzle Protrusion 5 2 00 to 3 500 mm 0 106 to 0 138 in l Repair Limit Judge Valve Seat Angle en condition of contact 7 surface by vacuum test Diesel Engine 210 Specifications Cylinder Block Ref Inspection Item CYLINDER BLOCK 0 00 to 0 08 mm 0 00 to 0 003 in a Surface Flatness Warpage Limit m 7000 nm 750 ner Diameter o 59 500 mr we en a 90 500 mm 1 988 in Inner Diameter of Cam Bushing Diesel Engine 211 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 18900012 Standard Remarks _ 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 a ial 42 20 mm Height Repair Limit Exhaust on an 42 50 mm ein 11 673 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 un 0 040 to 0 140 mm on nn a 0 001
46. System Diesel Engine 07900330 07900331 187 A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the lubricating oil cooler housing and hoses with a strong solution of detergent in hot water Dry the components with compressed air Inspect the lubricating oil cooler and hoses for cracks or other damage Install the lubricating oil cooler horizontal mount on the lubricating oil filter head adapter Torque Value 79 n m 58 ft lb Connect the two cooling lines to the cylinder block and the lubricating oil cooler Engine System Lubricating Oil Pressure Regulator Main Rifle Remove the pin that holds the regulator spring and axo valve in the lubricating oil pump Remove the lubricating oil pressure regulator from the lubricating oil pump 07900322 Inspect the valve spring and body for damage or excessive wear Inspect the valve for scoring Replace the lubricating oil pump if damage is found 07900323 Diesel Engine 188 Engine System Measure the clearance between the regulator body and valve 1 Valve and al Body If EI BERGERA ELED Clearance OL ELLE Le FILZ dk Standard Standard Tolerance Clearance A elal 0 050 mm 0 020 mm 0 030 07900324 to to to 0 077 mm 0 020 mm 0 097 mm 0 43 in 0 002in 0 008 in 0 001 in to to to 0 003 in 0 008 in 0 004 in Measure the va
47. The number stamped on the rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews Tighten the two capscrews in alternating sequence Torque Value Step 1 39n m 29 ft lb Step 2 Rotate each capscrew 90 degrees Complete Engine CP Do not measure the clearance between the connecting rod cap and crankshaft Measure the side clearance between the connecting rod and crankshaft Connecting Rod Cap Side Clearance Mm in 0 20 MIN 0 0079 0 40 MAX 0 0160 cx900tb CAUTION To reduce the possibility of engine damage the crankshaft must rotate freely A CAUTION If the connecting rod is not properly oriented tang opposite the camshaft it will contact the camshaft and lock the engine ks900wk If the connecting rod is not properly oriented tang opposite the camshaft it will contact the camshaft and lock the engine Camshaft Bushings Apply Loctite primer to the outside diameter of the camshaft bushing and the inside of the camshaft bore of the cylinder block Allow the primer to dry Apply a bead of Loctite 609 or equivalent to 270 degrees along the edge of the bushing that will be installed toward the rear of the cylinder block cg9bswe Diesel Engine 73 Complete Engine Diesel Engine 01900263 01900261 01900264 00900186 74 CAUTION Make sure there is no Loctite in the oil hole
48. UTION Remove all carbon and dirt from the contact surfaces of the cylinder block and cylinder head Remove all burrs and debris from the cylinder block Failure to do so can result in severe engine damage Install a new cylinder head gasket with the TOP mark facing up WARNING This component weighs 23 kg 50 Ib or more To reduce the possibility of personal injury use a hoist or get assistance to lift this component Coat the capscrew s threads with antiseize compound Part Number 3824879 or equivalent Install the cylinder head using four head capscrews as guides The cylinder head capscrews can be used up to 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 Install the capscrews Tighten the capscrews in the sequence shown Torque Value Step 1 69n m 51 ft lb Step2 108n m 80 ft lb Step 3 Rotate 90 degrees Engine System Rocker Levers Adjusting Valve Clearance IV SH ED K 4 I He 03900075 z gt f 0390076 Diesel Engine Remove the cylinder head cover 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 pulle
49. alent Assemble the injector sealing sleeve a new copper amp washer use only one washer and the injector hold gt down clamp A light coat of clean 15W 40 lubricating engine oil between the washer and the injector can help hold the washer in place during installation of the injector a Install the compression adapter Part Number 2 amp 3164627 or equivalent to the nozzle holder mounting section of the cylinder to be measured Tighten the compression adapter Torque Value 44 n m 33 ft lb 14900059 Diesel Engine 206 Engine System Diesel Engine applying a small amount of lubricating engine oil to the Glia Most compression leakage can be prevented by LV mounting section of the compression adapter i Connect the compression gauge to the compression adapter Start the engine With the pointer on the gauge stabilized check and read the gauge Engine Compression kPa psi 2944 NOM 427 Remove the compression gauge when test is complete Install the fuel drain line SA 06900274 GIA Install the high pressure fuel lines Ray Connect the fuel shutoff valve 00900163 207 Engine System Specifications Valves Valve Guides and Springs 18900014 Ref Inspection Item Standard Remarks VALVES Tolerance 0 035 mm Intake 0 0014 in 0 050 mm un 0 0020 in 0 3130 in Tolerance 0 050 mm Exhaust 0 0020 in 0 065 mm 0 0026 in In
50. alled in their original locations if used again Use solvent and a soft bristle brush to clean bearings Dry with compressed air NOTE If damage is found on any of the thrust bearings make sure to inspect the crankshaft block and main bearing caps for damage as well Inspect the thrust bearings for scratches galling uneven wear or other damage Replace the thrust bearings if damage is found 01c00324 Diesel Engine 105 Engine System FI Inspect the crankshaft journals for deep scratches indications of overheating and other damage Replace the crankshaft if excessive damage is found Determine the size of the thrust bearings removed and obtain the same size for installation Oversize Refer to Part Reuse Guidelines for the dimensions of 0 25 mm 009 in the standard and undersize main bearing journals 0 50 mm 019 in 0 75 mm 029 in 1 00 mm 039 in mb900gg CAUTION SA Confirm that there is no dirt or dust stuck to the amp W rear face of the bearing before installation Debris behind the bearing can cause severe engine damage Coat the inside face of the bearing with clean SAE30 engine lubricating oil before installation 00900216 Align the protrusion in the thrust bearing with the notch in the cylinder block Install the upper thrust bearing into the cylinder block Diesel Engine 106 Engine System Camshaft Remove the two mounting capscrews through the axo casti
51. and eight capscrews Tighten the capscrews 00900169 Torque Value 25 Nem 18 ft lb DRA Diesel Engine 84 Complete Engine gt Adjusting Valve Clearance Adjust the valve clearance Refer to Section 14 A Rocker Lever Cover Install the o ring into the rocker lever cover N Install the rocker lever cover three capscrews and isolator assemblies Tighten the capscrews Torque Value 9 Nem 7 ft lb AR Se gt aN le lt N Injector i Coat the injectors with anti sieze compound Part No 3824879 before installation O R fi9slwb es A CAUTION Q 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 00900167 assembly Install the injector washer and mounting capscrew Tighten the capscrew Torque Value 44 Nem 83 ft lb Diesel Engine 85 Complete Engine GJA Spill Tube Ray Install the spill tube 00900166 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 00900164 Fuel Injection Tubing NOTE Before installing the fuel injection tubing bl
52. ause additional heat from friction when the rod journals are submerged in oil Overfilling with oil raises the oil temperature that is transferred to the coolant system at the oil cooler The system is designed to use a specific quantity of coolant If the coolant level is low the engine will run hot NOTE The engine or system has a leak if frequent addition of coolant is necessary Find and repair the leak Engine System 50 PERCENT WATER 50 PERCENT ANTIFREEZE Diesel Engine 50 PERCENT WATER 50 PERCENT ANTIFREEZE ra900bd 200 CAUTION The engine coolant passages must be completely filled with coolant During operation entrapped air mixes with the coolant which results in cavitation corrosion and poor heat transfer Highly aerated coolant can cause localized overheating of the cylinder head and block which can result in a cracked head scored cylinder or blown head gasket During filling air must be vented from the engine coolant passages The air vents through the jiggle pin openings to the top radiator hose and out the fill opening Additional venting is provided for engines equipped with an aftercooler Open the petcock during filling NOTE Adequate venting is provided for a fill rate of 10 liters minute 2 6 gal minute NOTE Excess air in the cooling system can lead to overheating and low coolant levels NOTE A 50 percent mixture of antifreeze and water must be premixed before
53. ce Limit 0 10 mm 0 0012 to 0 0033 in 0 0039 in Clearance Limit padai 004510 0 080 mm oS 0 0051 in Clearance of Pump Gear Diesel Engine 219 Specifications Regulator Valve qa EEE fj AON j TER 18900023 Inspection Item Standard Standard Standard Clearance Size Clearance Limit Clearance shaft Hole Between 0 050mm 0 020 mm 0 030 to Valve and Body Itmi 0 077mm 0 020mm 0 097 mm 0 43 in 0 002 in 0 0008 in 0 001 to 0 003 in 0 0008 in 0 004 in Standard Repair Limit Replace Free Installed Installed Free Length Length Length Installed Load 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 Standard 5 0 0 5 kg cm Replace Repair or Set Pressure Spring Diesel Engine 220 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 R E when immersed in hot water 95 C 203 F 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 221 Specifications Capscrew Markings and Torque Values 4a CAUTION When replacing caps
54. ce the possibility of personal injury A WARNING bp8csea Wear eye and face protection when using compressed air Flying debris and dirt can cause personal injury A CAUTION The capscrew must be demagnetized completely and cleaned thoroughly Any small metal particles will cause engine damage Demagnetize the capscrew thoroughly Use solvent to clean the capscrew and dry with compressed air Diesel Engine 119 Engine System Crankshaft This assembly weighs 23 kg 50 Ib or more To ox reduce the possibility of personal injury use a hoist or get assistance to lift this assembly A CAUTION Be careful not to hit the crankshaft against the cylinder block and damage the sliding surface 00900204 Remove the main bearings Refer to Procedure 001 006 Remove the crankshaft from the cylinder block Use fine crocus cloth to polish the machined surfaces Use a bristle brush to clean the oil drillings ks200ec NOTE If more than two threaded holes are damaged in one end the crankshaft must be replaced A Inspect the threaded capscrew holes for damage Use one of the following methods to repair any threaded holes e Chase the threads e Use the threaded insert kit Part Number 3822709 or equivalent ks900sf Diesel Engine 120 Engine System Diesel Engine 01900249 121 Measure the front and rear oil seal contact areas for a wear groove Crankshaft Front and Rear Oil
55. ce the worn piston ring or cylinder Compression Diesel Engine 37 Troubleshooting Symptoms Fuel consumption Is Excessive This is symptom tree T 012 Cause Correction oo l Check and repair the accessories Refer to the Overloading from malfunctioning accessories i OEM s service manuals OK v l l Refer to the operation and maintenance manual Operator technique is not correct free i for proper operating speeds and loads OK v 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 Fuel leaks external manual OK v Assure good quality No 2 diesel fuel is bein Poor quality fuel or No 1 fuel is being used z 9 q y g used OK v neoaeae Ee Refer to troubleshooting logic for Exhaust Gas is Blake OK v Replace the defective or clogged injection Defective or clogged injection nozzle fr P I9 nozzle OK v Incorrect injection timing 4s frrttt ttt ttre Adjust injection timing OK v Injection pump is adjusted incorrectly causin one Re d a En Adjust or replace the injection pump excessive injection Diesel Engine 38 Troubleshooting Symptoms Coolant Contamination This is symptom tree T 013 Cause Correction Review the coolant change interval Drain and Coolant is rusty 0 Premmmeemeeeen flush the system Fill the system with the Correct mixture of coolant and water OK v Lubricati
56. chanical All speed Type Diesel Engine 16 Engine Identification Fuel Injection Nozzle 00900151 1 Fuel Drain Line Connector A Fuel Inlet from injection pump 2 Nozzle Holder B Fuel Injection to cylinder 3 Adjusting Shim C Fuel Return to fuel tank 4 Nozzle spring 5 Spring seat Fuel Injection Nozzle 6 Intermadiate Plate e Maker Zexel 7 Nozzle Body e Injection Pressure 40 MPa 8 Retaining Nut e Adjustment of Injection Pressure By Shim 9 Needle Diesel Engine 17 Engine Identification Cooling System 00900147 1 Radiator 6 Cylinder Head 2 Thermostat 7 Piston 3 Water Temperature Gauge 8 Cylinder Block 4 Water Pump 9 Oil Cooler optional 5 Water Manifold A From Oil Pump oil Diesel Engine 18 Engine Identification Air Intake System 00900227 Filtered Air Air Heater Intake Manifold Intake Valve Port u a Diesel Engine 19 Engine Identification Exhaust System 00900232 1 Exhaust Valve Port 2 Exhaust Manifold Diesel Engine 20 Engine Identification Troubleshooting Symptoms 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 s
57. connecting rod caps are installed If the crankshaft does not rotate freely check the installation of the connecting rod bearings and the bearing size Engine System Gear Train Backlash Front ZZN This check must be performed after the gear cover is removed or before installation The adjacent engaging gear must not turn as the gear being measured is turned Position a dial indicator so the tip is contacting the surface of the gear tooth as shown Do not allow the mating gear to turn Rotate the gear being measured clockwise Position the indicator to zero 0 Rotate the gear counterclockwise and read the indicator Measure the gear backlash 1 Timing Gear Backlash Repl Limit Crankshaft gear 0 08 to 0 19 mm and idler gear 0 0031 to 0 007 in Camshaft gear 0 08 to 0 19 mm and idler gear 0 0031 to 0 007 in 01900256 Injection pump gear and idler gear 0 07 to 0 29 mm 0 40 mm 0 003 to 0 011 in 0 0157 in Camshaft gear and oil pump gear 0 07 to 0 29 mm 0 003 to 0 011 in Camshaft gear 0 15 to 0 30 mm and PTO gear 0 006 to 0 012 in Measure the clearance between the idler gear bushing and shaft 2 Clearance Between Idler Gear Bushing and Shaft Standard Replacement Limit 0 015 to 0 050 mm 0 0006 to 0 002 in 0 10 mm 0 0039 in Measure the end play of the idler gear 3 End Play of Idler Gear Standard Replacement Limit 01900257 0 03 to 0 09 mm 0 001
58. crews 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 X 25 U S Customary 5 16 X 18 X 1 1 2 M8 1 25x 25 546 18 1 1 2 Major thread diameter in millimeters Major thread diameter in Inches Distance between threads In millimeters Number of threads per inch Length In millimeters Length in Inches 17800016 17800017 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 LE f a Torque Torque Torque Zn Diameter __Castlon Aluminum Cast Iron Aluminum Cast Iron Aluminum u mm Nem ftlb Nm ftlo _ Nem ftlb _ Nem ftlo Nem ftlb Neem ft lb 6
59. d When the tappets need to be replaced the corresponding push tubes must also be replaced a pr900sd Diesel Engine 171 Engine System Inspect the face of the tappet for excessive wear cracks and other damage Visual Limits A Normal contact exaggerated B and C Irregular contact do not reuse bp9tasa Pit marks on the tappet face are acceptable The following criteria defines the size of the pits allowed 1 A single pit can not be greater than 2 mm 0 078 in 2 Interconnection of pits is not allowed 3 Total pits when added together must not exceed 6 mm 0 236 in in diameter or total of 4 percent of the kf900sa tappet face 4 No pitting is allowed on the edges of the wear face of the tappet Measure the valve stem diameter 28 mm 1 1 in from the face of the tappet Valve Tappet Stem Diameter mm in 16 NOM 0 63 kf900to Lubricate the tappets with clean lubricating engine oil i Ri Install the tappets run ke Pa 00900206 Diesel Engine 172 Engine System Complete Engine Measuring Compression Pressure A WARNING To avoid personal injury keep hands long hair jewelry and loose fitting or torn clothing away from fans and other moving parts A WARNING Exhaust manifold and muffler are hot Do not touch the exhaust manifold or muffler or personal injury will occur SE Adjust the overhead Refer to Adjusting Valve Clearance procedure axo R
60. d 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 Rocker Lever Cover Remove the three capscrews isolator assemblies rocker lever cover and o ring Diesel Engine 53 Complete Engine ener ae 00900251 Rocker Arm Assembly Rocker Shaft Adjusting Screw Lock Nut Pedestal Mounting Capscrews Separating Spring Rocker Shaft Indexing Screw Pedestal Mounting Stud Oo ee a 00900169 Diesel Engine 7 Cup Plug 8 Snap Ring 9 Thrust Washer if equipped 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 54 Complete Engine x Pushrods Remove the pushrods 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
61. determine the proper piston grade for each cylinder Install the connecting rod and piston assembly into the Number 1 cylinder without the rings installed The number stamped on the connecting rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews to the connecting rod A CAUTION The connecting rods and connecting rod caps are not interchangeable The connecting rods and connecting rod caps are machined as an assembly Failure will result if the connecting rods and caps are mixed Install the bearing shells into both the connecting rod and the connecting rod cap Make sure the tang on the bearing shells is in the slot of the connecting rod cap and connecting rod Lubricate the connecting rod bearings with clean lubricating engine oil Engine System Immerse the pistons in clean 15W 40 engine lubricating oil until the rings are covered Allow the excess oil to drip off the assembly pi800hd Position the rings so that the ring gaps are 120 degrees apart pi9rihb A CAUTION If using a strap type ring compressor make sure the inside end of the strap does not hook on a ring gap and break the ring Use piston ring compressor Part Number 3164330 or equivalent to compress the rings 01d00296 Lubricate the cylinder bore with clean 15W 40 engine lubricating oil The cylinder block must be clean before assembly I
62. distributor head bolt and new copper washer into the fuel injection pump Torque Value 17 n m 13 ft lb 14900074 Gia Install the fuel pump drive access cover gt gt SV 10mm 13n m 10 ft lb 12mm 19 n m 14 ft lb i af 7 14900071 If the fuel lines are opened the low pressure lines can be vented by pumping the hand lever on the fuel filter head Diesel Engine 180 Engine System amp Injector Testing Diesel Engine 181 A WARNING Do not vent the fuel system on a hot engine this can cause fuel to spill onto a hot exhaust manifold which can cause a fire A WARNING Fuel is flammable Keep all cigarettes flames pilot lights arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system Vent the high pressure fuel lines Loosen the fitting at the number 1 injector Place the fuel control in the run position Crank the engine so air can vent from the fuel lines Tighten the fitting Torque Value 30 n m 22 ft lb Continue this process through the remaining three injectors until the engine runs smoothly 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 Engine System Check the o
63. dle pressure spring and shims fi900fd Diesel Engine 183 Engine System Assembly NOTE Make sure all mating surfaces and pressure faces are clean and lubricated with fuel oil before assembly fi900ab ID A WARNING 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 fi900ha SD Clamp the nozzle holder in a soft jawed vise and a 7_ install the spindle fi900ce Gla Install the intermediate plate Ray fi900ad Diesel Engine 184 Engine System Gia Install the needle valve and nozzle assembly iy fi900ce AN Install the nozzle nut Ray fi9000b Diesel Engine 185 Engine System Lubricating System Measuring Oil Pressure A WARNING 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 Ib 210 MIN 30 700 MAX 102 Disconnect the two cooling lines from the cylinder block and the lubricating oil cooler Remove the lubricating oil cooler horizontal mount from the cylinder block 07900329 Diesel Engine 186 Engine
64. ds or Tubes NOTE Mark the push rods with tags showing the location Keep the push rods from getting damaged Install the push rod in the same location during assembly Remove the push rods from the cylinder head 00900170 Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the push rods in a strong solution of detergent in hot water Dry with compressed air Inspect the push rod ball and socket for signs of scoring Check for cracks where the ball and the socket are pressed into the tube NOTE When a push rod is replaced the corresponding tappet must be replaced also Check the push rods for roundness and straightness Use a round feeler gauge on a flat surface Straightness or Bend of push Rod mm in pribdsb 0 30 MAX 0 012 Diesel Engine 170 Engine System Lubricate the push rod ends with clean lubricating engine oil Install the push rods into the cylinder head in the location as marked 00900170 NOTE Mark the location of the tappets if tappets are to be used again Remove the tappets Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the tappets with a strong solution of detergent in hot water Dry the tappets with compressed air 04900033 When a new camshaft is installed new tappets and push tubes must also be installe
65. e engine is running at rated speed NOTE Be sure the engine is warm a minimum of 95 C 203 F so the thermostat is open Ponoka A worn or malfunctioning water pump will not produce gt the flow required to prevent the engine from running hot However be sure to check the other possibilities indicated in the Troubleshooting Logic before checking the flow or replacing the pump wp900sc As stated in the coolant discussion an obstruction in the passages can interrupt flow The following steps are for troubleshooting the Radiator Fans and Shutters Air forced through the fins of the radiator by a fan cools the coolant pumped through the radiator Environmental debris paper straw lint dust etc can obstruct the fins and stop the flow of air which will reduce the cooling effect of the radiator If the fan is belt driven a slipping belt will result in slower fan speed and reduced cooling A malfunctioning automatic belt tensioner can be the problem a ra900sa Check the bearings in the fan hub and other pulleys to make sure they are not causing excessive belt vibration and slippage Diesel Engine 203 Engine System Shutters are designed to control airflow across the 7 radiator If the shutters fail to open when needed the engine can run hot Failure of the shutters to close can result in too much airflow and the engine running cold Make sure that the air temperature sensor is functioning correc
66. e in the cylinder block with the lubricating hole in the camshaft bushing 01900262 Diesel Engine 110 Engine System Diesel Engine cg9bswe 01900263 01900261 01900264 111 Apply Loctite primer to the outside diameter of the camshaft bushing and the inside of the camshaft bore of the cylinder block Allow the primer to dry Apply a bead of Loctite 609 or equivalent to 270 degrees along the edge of the bushing that will be installed toward the rear of the cylinder block CAUTION Make sure there is no Loctite in the oil hole or severe engine damage can occur Use extreme care not to apply Loctite to the oil hole in the camshaft bushing Use a small camshaft bushing driver set Part Number 3823942 or equivalent to install the camshaft bushing even with the front face of the cylinder block Use a clean lint free cloth to wipe off any excessive Loctite CAUTION Make sure there is no Loctite in the oil hole or severe engine damage can occur Make sure the lubricating oil hole in the camshaft bushing is aligned with the camshaft oil hole in the cylinder block A 3 2 mm 0 126 in diameter rod must be able to pass through the lubricating oil hole Engine System Measure the installed camshaft bushing 1 Camshaft Bushing Bore Inside Diameter Mm in 50 50 MIN 1 988 53 60 MAX 1 992 01900265 Camshaft Gear gt When using solvents acid or alkaline materials for cleaning
67. e piston ring expander Part Number 3823137 or ox equivalent to remove the piston rings pi901ac Diesel Engine 149 Engine System axo Remove the piston pin retaining rings cx9rrma BRI NOTE Heating the piston is not required Remove the piston pin Remove the connecting rod from the piston pi9pima y Make sure the FRONT marking on the piston and the numbers on the connecting rod and cap are oriented as illustrated pi900gd Gal Install the retaining ring in the pin groove on the front side of the piston P Diesel Engine 150 Engine System pi9rrhb Diesel Engine Lubricate the pin and pin bores with clean 15W 40 engine lubricating oil pi9piwa NOTE Pistons do not require heating to install the pin however the pistons do need to be at room temperature or above Install the connecting rod Install the piston pin Install the second retaining ring Use the piston ring expander Part Number 3823137 or equivalent to install the piston rings pi901ac 151 Engine System Diesel Engine cx900ha cx9behd cx9bewa 152 When rebuilding an engine with the original cylinder block crankshaft and pistons make sure the pistons are installed in their original cylinders If replacing the piston s make sure the replacement piston s are the same grade as the original piston s If a new cylinder block or crankshaft is used the piston grading procedure must be performed to
68. e pulley for cracks excessive wear in the belt grooves or other damage Inspect the mating surface and pulley bore areas for damage Align the crankshaft pulley with the crankshaft key ap 127 Install the crankshaft pulley mounting plate and capscrew Tighten the capscrew 14mm Capscrew With PTO 176 n m 130 ft Ib 14 mm Capscrew Without PTO 93 n m 69 ft Ib 18 mm Capscrew All 372 n m 274 ft Ib Engine System Crankshaft Seal Front NOTE A noise dampener is installed on some engines The noise dampener must be removed prior to removing the front crankshaft seal Use a pry bar or suitable tool to remove the front crankshaft seal from the front gear cover 00900182 Clean the gear cover seal bore and crankshaft surface of all oil dirt and seal residue ER NOTE If the crankshaft has excessive wear the crankshaft must be replaced gt Inspect the crankshaft for excessive wear Ta Fill 40 to 60 percent of the space in the seal lip with ey grease Use a crankshaft seal installer Part Number 3164900 or equivalent to install the seal in the front gear cover Install the noise dampener if equipped 00900182 Diesel Engine 128 Engine System Crankshaft Seal Rear Use a pry bar or suitable tool to remove the rear ORs crankshaft seal 00900189 A CAUTION The seal lip and the sealing surface on the crankshaft must be free from all residue to reduce the possibili
69. e solvents are flammable and toxic Read the manufacturer s instructions before using A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the front gear cover and cover gasket surface with solvent Dry with compressed air Clean the cylinder block gasket surface ZZN Inspect the front gear cover and cover plate for cracks or other damage 01900255 Diesel Engine 134 Engine System Diesel Engine 00900181 135 A CAUTION Apply gasket sealant Part Number 3164067 or equivalent to the gear cover mounting surface Install the new gasket gear cover and 17 capscrews Tighten the capscrews Torque Value 19n m 14 ft lb Engine System Idle Gear Camshaft 01900258 cg9geea cg9gesc Diesel Engine NOTE If a PTO accessory drive is used on the engine the idler gear uses two bearings Remove the capscrew plate shim and front bearing Remove the idler gear rear spacer plate rear bearing and idler shaft A WARNING When using solvents acid or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to avoid personal injury A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury Use solvent to clean the idler gear Dry with compressed air NOTE If the
70. e the end gap was measured pi9rige A CAUTION If a ring expander tool is being used be careful not to over expand the ring The top surface of the top and intermediate rings are identified as illustrated The oil control ring can be assembled with either side up pi9rise Position the oil ring expander in the control ring groove A A lt a ce pi9rigb a Install the oil control ring with the end gap 180 degrees from the ends of the expander pi9rihc Diesel Engine 144 Engine System Diesel Engine SA NOTE Make certain that the dot and the word Gy TOP are facing up when installing the piston rings Use piston ring expander Part Number 3823137 or equivalent to install the intermediate ring pi900ac GJA NOTE The top ring has a shiny chrome gt QY appearance Use piston ring expander Part Number 3823137 or equivalent to install the top ring pi900ad Position the rings so the ring gap are 120 degrees apart pi9rihb 145 Engine System Piston and Connecting Rod Assembly S S IN TEE TEEN SS ee EEE EEE pi900ka pi9piga E Diesel Engine 146 There are a number of power related problems including excessive lubricating oil consumption smoke blowby and poor performance that can be caused by inadequate sealing between the piston rings and the cylinder walls A blowby measurement can help detect the problem Refer to Procedure
71. ed 139 A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Some solvents are flammable and toxic Read the manufacturer s instructions before using A CAUTION Do not use the bead blast method to clean the piston The piston can be damaged by blast material embedded in the aluminum A CAUTION Do not clean the pistons in an acid tank The piston can be damaged by the acid Soak the pistons in cold parts cleaner Soaking the pistons overnight will usually loosen the carbon deposits A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Wash the pistons and rods in a strong solution of detergent in hot water Dry with compressed air Engine System Do not use a ring groove cleaner and make sure not to scratch the ring sealing surface in the piston groove Clean the remaining deposits from the ring grooves with the square end of a broken ring pi900ee Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury Wash the pistons again in a strong solution of detergent in hot water Dry with compressed air Cc pi900ed NOTE If severe piston damage has occurred check the turbocharger cylinde
72. ed x during removal of the engine from the equipment 92 Complete Engine axo Connect the drive units to the flywheel housing and flywheel tr400wa X 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 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 07900034 Engine Oil 6 5 liters 1 7 u s gall Diesel Engine 93 Complete Engine 50 PERCENT 50 PERCENT WATER WATER 50 PERCENT 50 PERCENT Coolant is toxic Keep away from children and ANTIFREEZE ANTIFREEZE animals Save for reuse or dispose of in accordance with local regulations A WARNING Fill the engine with engine coolant Gly NOTE Remove all tags that were put on all hoses OS lines linkage and electrical connections as they were removed to identify location during the removal process 1 _ 1 02 suit pauses t Diesel Engine 94 Complete Engine Engine System Bearing Connecting Rod Normally worn bearings can be detected by reduced oil pr
73. edestal 11 Separating spring 12 Pedestal mounting capscrews 03900103 NOTE When removing the rocker arm loosen the locknut and turn the adjustment screw counterclockwise 2 to 3 turns Remove the mounting capscrews and the rocker lever assembly 03900169 Remove the snap rings for each rocker lever Remove the rocker lever shaft and thrust washers if equipped Remove the rocker lever pedestals and rocker levers Remove the locknut and adjusting screw from rocker lever 03900104 Diesel Engine 166 Engine System Diesel Engine Clean all parts in a strong solution of detergent in hot water 03900105 Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury The pedestals are made from powdered metal and will continue to show wetness after they have been cleaned and dried Rinse parts with clean hot water Dry parts with compressed air Inspect the rocker lever for cracks excessive wear in the bore and the contact surface of the valve stem rh9bdsa Measure the rocker lever bore Rocker Lever Bore Diameter mm in 19 NOM 0 75 rh9brta 167 Engine System Inspect the pedestal and shaft bore Measure the pedestal shaft bore Rocker Lever Pedestal Bore mm in 19 NOM 0 75 03900107 Ro Install the locknut and adjusting screw in the rocker lever Install the rocker lever pedestals and rocker levers
74. eier 7 Engine Identification Engine Identification ccccccssseeeeeeeeeeeeeeeeeeeeeeeeeeas 8 Engine Dataplate ccccccccssseecsesseeseeseeesseeeeees 8 Specifications serere na EE 9 Engine Diagrams uuusssunneennenneennennnn nennen nennen 10 Engine VIewS n uueeenennnnenennnnnennnnnennnn nennen nennen 10 Troubleshooting Symptoms Troubleshooting Symptoms 2 22220s02222neee een 21 Procedures and Techniques uu nn 21 Troubleshooting Symptoms Charts 21 Engine Acceleration or Response Poor 22 Engine Acceleration or Response Poor Continued depots trea en ee 23 Engine Will Not Crank or Cranks Slowly 24 Engine Will Not Crank or Cranks Slowly Continued PEN NEE EEE NENNEN insane neauianieue seen vessseeayeeaes 25 Engine Cranks But Will Not Start No Exhaust SmOke ccccccceceeeeeeeeseeeeeeeeeeeaes 26 Engine Difficult to Start or Will Not Start Exhaust Smoke ccccccceeeeeeeeeeeeeeaaeseeeeeeeeeeeaas 27 Engine Difficult to Start or Will Not Start Exhaust Smoke Continued 28 Engine Has Poor Respones s0ccccceeeeeeseeeees 29 Engine Stops During Operation 30 Engine Runs Rough or Misfires 31 Engine Power Output LOW csseeseeeeeeeeeees 32 Engine Power Output Low Continued 33 Excessive Exhaus
75. emove the spill tube 0390166 axo Disconnect the fuel injection tubing NOTE Disconnect the fuel shut off solenoid Diesel Engine 173 Engine System u ss wd x ee wr F 7 Hy gt RE K os Diesel Engine ay CAUTION 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 compound Assemble the injector sealing sleeve a new copper sealing washer and the hold down clamp S45 Use only one washer NOTE A light coat of clean 15W 40 engine oil between the washer and injector can help hold the washer in place during installation R fi9slwb SA Install the adapter to the nozzle holder mounting fa section of the cylinder to be measured Tighten the adapter Adapter Capscrews N m ft lb 39 MIN 29 49 MAX 36 A Connect the compression gauge to the adapter Se NOTE Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter i 174 Engine System Crank the engine with the starting motor Read the 7 gauge when the pointer is stabilized Engine Compression kPa psi 1965 MIN 285 2944 NOM 427 Testing and Adjusting the Fan Belt Tansion SX u Testing the Fan Belt Tension Check the amount the fan belt deflects when p
76. engine damage A WARNING Do not let the thrust bearings slip out of place Engine damage will result if the thrust bearings are not properly installed The 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 number 5 Align the lower thrust bearing with the dowel pin Install the upper thrust bearing Tighten the mounting capscrews in the order shown in the illustration Torque Value Step 1 113 Nem 83 ft lb Step2 Loosen all capscrews completely Step 3 132 Nem 98 ft lb After the mounting capscrews are tightened make sure the crankshaft rotates smoothly Engine System xc NOTE Mark the lower main bearings and the two lower thrust bearings so that they can be installed in the correct position Remove the upper thrust bearing 00900205 Diesel Engine 104 Engine System Bearing Thrust When using solvents acids or alkaline materials for cleaning follow the manufacturer s recom mendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury CAUTION Do not use a scraper or a wire brush The bearings can be damaged NOTE Make sure the bearings are marked for location The bearings must be inst
77. essure but if this wear goes undetected the excessive clearance will increase the impact between the bearing and crankshaft causing a distinct knocking sound o PRESSURE cx9beva A connecting rod noise occurs when the engine is not loaded Check by first applying a load and then unloading and listening for the noise oi900vd The connecting rod bearing shells are identified by steel stamped characters on the back of the bearings The characters indicate either standard STD or the Standard amount of oversize OS Oversize 0 25 mm 010 in 0 50 mm 020 in 0 75 mm 030 in 1 00 mm 040 in mb900gb Use a barring tool to rotate the crankshaft to the bottom dead center BDC position of the connecting rod cx900wf Diesel Engine 95 Engine System lt x Remove the connecting rod capscrews and connecting rod caps Remove the lower bearing shell from the connecting rod cap and mark it with the letter L lower and the cylinder number from which it was removed Push the connecting rod away from the crankshaft to ex allow the upper bearing shell to be removed cx9beme Remove the upper bearing shell and mark it with the lt a letter U upper and the cylinder number from which it was removed cx9bega Diesel Engine 96 Engine System Diesel Engine cx9beecf cx900sg cx2besa 97 A WARNING When using solvents acids or alkaline materials for cleaning follow
78. fing and scoring on the piston rings indicates a breakdown of the oil film on the cylinder liner wall causing transfer of material from the piston ring face to the cylinder liner Oil ring plugging is indicated by deposits on the oil ring grooves B Oil ring plugging can be caused by e Low engine operating temperatures long periods of idling or a cooling system malfunction e Extended oil change intervals e Use of the wrong grade of engine oil e Use of a poor quality engine oil Plugging of the oil ring drains restricts oil drain back which floods the piston ring belt area resulting in a loss of oil control Engine System mm Top 2 0 Second 2 0 Oil Control 4 0 the ring groove pi900te mm Top 0 06 0 10 Second 0 03 0 07 Oil Control 0 03 0 07 bore pi9rita mm 0 30 0 45 0 30 0 45 0 25 0 45 Top Second Oil Control Diesel Engine 143 Width of Piston Groove NOM NOM NOM Piston Ring Clearance MIN MAX MIN MAX MIN MAX Piston Ring Gap MIN MAX MIN MAX MIN MAX in 0 079 0 079 0 158 Use a new piston ring to measure the clearance 0 0024 0 0039 0 0012 0 0028 0 0012 0 0028 Use a feeler gauge to measure the piston ring gap 0 012 0 018 0 012 0 018 0 0098 0 018 n Position each ring in the cylinder below the ring reversal area and use a piston to square it with the Engine System Identify the ring sets for installation in the cylinder wher
79. gine ESS ee J TLS ET NEL Np ph ck900wf ck9brei 131 The head surface of the block is also critical to sealing the cylinder bores Inspect the surface carefully during repair before assembly Use a strong solution of hot water and laundry detergent to clean the cylinder bores A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury A CAUTION Clean the cylinder bores immediately after deglazing or premature wear of the bores and rings can result Rinse the cylinder bores until the detergent is removed Dry the cylinder block with compressed air Engine System Diesel Engine cg900eb 132 NOTE Make sure to remove the tape covering the tappet and lubricating oil holes after the cleaning process is complete Check the cylinder bore cleanliness by wiping with a white lint free lightly oiled cloth If grit residue is still present repeat the cleaning process until all residue is removed NOTE Make sure to remove the covering from the piston cooling nozzles Remove the protective tape and cloth and clean the crankshaft journals A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Wear appropriate eye and face protection when using comp
80. h I T 00900180 24 Remove the crankshaft pulley using flange puller Part No 3397890 00900212 Diesel Engine 57 Complete Engine Diesel Engine 00900181 00900182 00900183 00900184 x Gear Housing Cover Remove the 17 capscrews and the gear housing cover x NOTE A noise damper is installed on some engines The noise damper must be removed prior to removing the front oil seal Remove the front oil seal from the gear housing cover Lubricating Oil Pum x g p Remove the five capscrews and the lubricating oil pump idler Gear R Remove the capscrew retainer plate and idler gear NOTE If a PTO is installed the idler gear uses a bearing 58 Complete Engine Diesel Engine AN X a A Ben gt n y i af E B AO na 00900185 B 00900186 R 00900187 59 Camshaft Assembly Remove the two mounting capscrews through the casting holes in the camshaft gear Remove the thrust plate and camshaft assembly NOTE When removing the camshaft lightly rotate the shaft while being careful not to damage the bushing Flywheel 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 WARNING The pilot is short so the flywheel can come off suddenly Remove the six capscrews retaining plate coupling and flywheel Complete Engine
81. h 25 4 mm Diesel Engine 224 Specifications Newton Meter to Foot Pound Conversion Chart Nm ftb Nm felb Nm ftb 5 _ nb tO 6 inb S 4 amp 8 a 12 8 nib 15 1 129 9 inb 838 53 180 13 pT 0737562ftb 90 66 19 f 140 C 9 In Cast Iron or Thread Actual Thread O D In Aluminum Components Steel Components a in in o Nm iH Nm ft Ib 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 15 55 115 85 1 1 2 1 90 85 65 135 100 Diesel Engine 225 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 VB ZINPT VB 24 M10x1 5 7116 14 M11x1 5 M11x15 7116 14 76 20 M12x1 75 M12x1 75 Mi2x1 5 M12x1 25 142 13 44 18NPT 11 75mm 11 50mm 442 20 29 64 9 16 12 15 32 Mi4x2 12 00m 12 25mm 9116 12 31 64 M34x2 Mi401 5 12 50mm 915 18 u2 M14x1 5 M14x1 25 12 75mm M14x1 25 13 00mm ar16 18
82. he same cylinder number from which they were removed to provide proper fit of worn mating surfaces if parts are reused Use a tag to mark the cylinder number from which each piston and rod assembly were removed Place the rod and piston assemblies in a container to protect them from damage 01c00167 Main Bearing Cap Rotate the cylinder block so that the bottom of the block is facing up 00900201 Measure the end play of the crankshaft using a dial 2 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 Remove the mounting capscrews of the main bearing cap Remove the main bearing cap and lower bearing i NOTE Mark the thrust bearings so that they can be installed into the correct position The main bearing cap mounting capscrews N must be replaced after each use m ap mme A 00900203 Diesel Engine 64 Complete Engine Crankshaft R 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 lt 9 NOTE Mark the main bearings and thrust bearing so that they can be installed into the correct position Tappet R Remove the tappet Diesel Engine 65 Complete Engine Engine Assembly Service Tools PartNo PatNiame _
83. hown 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 cause 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 21 Troubleshooting Symptoms Engine Acceleration or Response Poor This is symptom tree T 033 Cause Correction Fill th ly tank Refer to the OEM service ar jai i ae u nn Dan a EN Ra N RE manual OK vv Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Vehicle parasitics are excessive Check the fuel lines fuel
84. imum 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 9 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 Filter 3 Fuel Injection Pump 7 Oil Fill Cap 4 Crankshaft Pulley Diesel Engine 10 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 11 Engine Identification Front View Naturally Aspirated 00900140 Rear View Naturally Aspirated 00900141 Diesel Engine 12 Engine Identification Oil Strainer Oil Pump Oil Cooler Optional Regulator Valve Oil Filter Safety Valve Crankshaft NOOVOPOD Diesel Engine en 11 N i gimt E AANA hr 6 5 12 Exhaust Side Naturally Aspirated 00900146 8 Camshaft 9 Piston 10 Intake and Exhaust Valve 11 Rocker Arm 12 Timing Gear 13 Cooling Water
85. is malfunctioning Diesel Engine 35 Troubleshooting Symptoms Lubricating Oil Consumption Excessive This is symptom tree T 010 Cause Correction Inspect the engine the external oil leaks Lubricating oil leak external __ Irrmmmmemeeenn Tighten the capscrews pipe plugs and fittings Replace the gaskets if necessary Intake system is contaminated with dust gt gt gt Remove and clean intake manifold Dipstick is not calibrated correctly free Verify the dipstick is correctly marked Breather or breather hose is clogged fr Clean the breather and breather hose Rear crankshaft seal or seal surface is ee Repair or replace seal and surface damaged OK Valve stem guide or seal is damaged fr Repair or replace the damaged component Replace the worn or broken piston ring or Worn or broken piston ring or cylinder fr ane p j Diesel Engine 36 Troubleshooting Symptoms Lubricating Oil Contaminated This is symptom tree T 011 Cause Correction Breather or breather hose is clogged fr Clean the breather and breather hose Lubricating oil filter is clogged Irre Replace the filter Refer to Exhaust Gas Is Black Incomplete Exhaust gas is black prummmmemmmeen i l j Combustion l OK v Defective contact of valve or valve seat u RE Repair the valve or valve seat resulting in low compression OK v Worn piston ring or cylinder resulting in low j ji i Repla
86. jection pump Align the key in the fuel injection pump with the keyway in the injection pump gear Install the fuel injection pump CAUTION Do not attempt to pull the pump flange into the gear housing with the mounting nuts Damage to fuel pump housing can occur Hand tighten the mounting nuts The fuel pump must be free to move in the slots an Install the fuel injection pump washer and nut Torque Value 70 n m 52 ft Ib Refer to the rotary fuel injection timing in this procedure to make sure the fuel pump is timed gt correctly ip9nuhb Tighten the fuel injection pump mounting capscrews Torque Value 31 n m 23 ft lb Install the mounting bracket capscrews 12mm 19 n m 14 ft lb 14mm 31 n m 23 ft lb Diesel Engine 177 Engine System GJA Install the fuel pump drive access cover gt AV Tighten the two capcrews 10mm 13 n m 10 ft lb 12mm 19 n m 14 ft lb Set the number 1 cylinder at compression top dead center TDC by aligning the pointer on the gear cover to the TDC line on the crankshaft pulley ax The fuel pump drive access cover can be removed to confirm the timing marks are aligned between the fuel pump drive gear and the idler gear if easier than removing the valve cover This is to confirm that the engine is at TDC Remove the distributor head bolt and copper washer amp from the injection pump Discard the copper washer 14900074 Diesel
87. l Pressure Regulator Main Rifle 188 Index Lubricating Oil Suction Tube Block Mounted 191 Cooling Syse eeraa a e 192 Coolant Thermostat c ccccccecccceeeeseeseeeeeeeeeeeaes 194 Coolant Thermostat HOUSING ceeeeeeeeeeeeeees 195 Cooling System cccccccccesceseeeeeeeeeesesaaeeeeeeeeeeeeeaas 196 Cooling System Diagnostics ccseeeeeeeeeeeeeeees 199 Engine COMPSeSSION cccccccssssseeeeeeeeeeseeeseeeeeees 205 Specifications SPECIICATIONS 00 000c000scceceeeesectseecseevaensceesseeseeersnenes 208 Valves Valve Guides and Springs 208 Rocker Arm Shaft Push Rod and Tappets 209 Cylinder Had cccccccseceeececeeeeeeeseeeeeeeesseaeeeees 210 Cylinder BIOCK ccccccsseeeecceeeeeeeeeseeeeeeesseaeaeees 211 Camshaft and Camshaft Bushing 212 O29 oars ee een 213 WN Cc retetsce eeepc eatiecapiestvestrensBesane seb asteecaBesee 214 FIYWNBBl nennen nee hun 215 INOS nee an 216 22 1 0 E EE EE 217 Connecting Rod Piston Ring and Piston Pin 218 OIL Pumpe tee ee 219 Regulator Valve ccccccseseecceeeeeeceeseeeseeeeeessees 220 Thermostat nee nee 221 Capscrew Markings and Torque Values 222 Capscrew Markings and Torque Values Metric 222 Capscrew Markings and Torque Values U S SOT ee ee 223 Fraction Decimal Millimeter Conversions 224 Newton Meter to Foot Pound Conversion Chart 2
88. lve spring length 2 Valve Spring Length Dega Limit Free Installed Installed Free Installed Length Length Load Length Load 1 27 2 44 k 2 30 k aa 33 mim u g N A 30 kg 1 30 in 1 09 in 5 38 Ib 5 07 Ib Replace the lubricating oil pump if not within specification a Install the lubricating oil pressure regulator assembly D OS into the lubricating oil pump Install the retaining pin that holds the regulator in the lubricating oil pump 07900322 Diesel Engine 189 Engine System Ro Remove the five mounting capscrews 2 and spacer 3 Remove the lubricating oil pump 1 07900326 Inspect the lubricating oil pump housing for damage Measure the axial 1 and radial 2 clearance Axial and Radial Pump Gear Clearance Clearance Limit 0 10 mm 0 0039 in 0 045 to 0 090 mm 0 13 mm 07900327 0 0018 to 0 0035 in 0 0051 in Gir Install the lubricating oil pump 1 Ray Install the spacer 3 and five mounting capscrews 2 Tighten the capscrews Torque Value 19n m 14 ft lb 07900326 Diesel Engine 190 Engine System Lubricating Oil Suction Tube Block Mounted Remove the two mounting capscrews from the lt lt lubricating oil suction tube Remove the lubricating suction tube and o ring from the cylinder block Discard the o ring 00900179 A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommenda
89. main bearing removed and obtain the same size for installation Refer to Part Reuse Guidelines for the dimensions of the standard and undersize main bearing journals Engine System ZN NOTE If the crankshaft journals or main caps are damaged the engine will need to be removed to complete the overhaul Inspect the crankshaft journals for deep scratches indications of overheating and other damage ks9bds A CAUTION Gi Confirm that there is no dirt or dust stuck to the Y rear face of the bearing before installation Remove debris behind the bearing before installation Coat the inside face of the bearing with clean SAE30 3 engine lubricating oil before installation The number 00900217 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 NOTE New main bearing mounting capscrews must be used The casting number or cast arrow on the main bearing cap must face toward the front of the engine Coat the capscrew threads and seat face with clean SAE30 engine lubricating oil Position the main bearing caps and capscrews 00900218 Diesel Engine 102 Engine System 00900219 00900220 0090022 Diesel Engine 103 CAUTION Install each thrust bearing with the oil groove on the outside Failure to do so will cause
90. mit 0 20 mm 0 079 in 0 03t00 07mm Mn 0 0079 in 0 0012 to 0 0028 in Bes o 0 15 mm 0 158 in 0 0059 in Width of Groove Nominal ID 95 00 mm 3 740 in 0 06 to 0 10 mm 2 0 mm 0 0024 to 0 0039 in 0 079 in 217 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 e Piston Ring Gap 0 004 to 0 018 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 to 0 45 mm 0 0098 to 0 018 in Bend B Torsion T a 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 ES Inner Diameter Diesel Engine 218 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 Clearan
91. mmersed in hot water for 4 to 5 minutes ec900nc AN Install the seal and thermostat into water pump cavity 08900320 Coolant Thermostat Housing Remove the two capscrews and the thermostat housing from the water pump 08900325 ZN Inspect the thermostat housing for cracks or other 7 damage 08900326 Diesel Engine 195 Engine System Diesel Engine 08900325 oi900vb Ri 196 Install the thermostat housing onto the water pump A WARNING Do not remove the pressure cap from a hot engine Wait until the coolant temperature is below 50 C 120 F before removing the pressure cap Heated coolant spray or steam can cause personal injury WARNING Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with local environmental regulations Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet A drain pan with a capacity of 20 liters 5 gal will be adequate in most applications Check for damaged hoses and loose or damaged hose clamps Replace as necessary Check the radiator for leaks damage and buildup of dirt Clean and repair as necessary Engine System During filling air must be vented from the engine coolant passages The air vents through the jiggle pin openings to the top radiator hose and out the fill opening Additional venting is provided for engine equipped
92. ne ground straps cab or chassis to engine hoses tubing electrical wires and hydraulic lines x Disconnect the intake and exhaust system pipes Disconnect the drive units from the flywheel housing and flywheel Complete Engine Remove all chassis components necessary to remove the engine from the equipment ra400ha afa Prepare a stable stand Part No 3375193 or 3375194 Os which will prevent the engine from falling over Engine Weight approx 255 kg 562 Ib 00900154 x Remove the starting motor 00900156 An Install the bracket Part No 3163625 on the engine RE 00900207 Diesel Engine 49 Complete Engine oN ER 009 Diesel Engine 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 The engine lifting equipment must be designed to lift the engine without causing personal injury Put the engine on the stand Cover all the engine openings to prevent dirt and debris from entering the engine Fan Pulley A WARNING 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 space
93. ng Oil Pan 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 lf the oil drain plug was removed install the drain plug Torque Value 51 Nem 38 ft lb PTO Shaft if applicable 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 Fuel Injection Pump Rotary A CAUTION Make sure the key does not fall into the gear housing Failure to do so can result in engine damage Install the Woodruff key into the fuel injection pump Align the key in the fuel injection pump with the keyway in the injection pump gear Install the fuel injection pump CAUTION Do not attempt to pull the pump flange into the gear housing with the mounting nuts Damage to fuel pump housing can occur Hand tighten the mounting nuts The fuel pump must be free to move in the slots Complete Engine caf Install the fuel injection pump washer and nut Ray Tighten the nut Torque Value 70 Nem 52 ft lb Refer to the rotary fuel injection timing in this procedure to make sure the fuel pump is timed correctly ip9nuhb Ga Tighten the fuel injection pump mounting capscrews D RE Torque Value 31 Nem 23 ft Ib Q Install
94. ng holes in the camshaft gear 00900185 When using a steam cleaner wear safety glasses or a face shield as well as protective clothing Hot steam can cause serious personal injury A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recom mendations for use Wear goggles and protective clothing to reduce the possibility of personal injury cg900ea A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause bodily injury Use solvent or steam to clean the camshaft Dry with compressed air CAUTION Do not touch the machined surfaces with bare hands this can cause rust to form on the camshaft Before the camshaft is touched lubricate the camshaft with clean engine lubricating oil cg900va Diesel Engine 107 Engine System N NOTE When a new camshaft is installed new tappets and push tubes must be installed also Inspect the bearing journals for cracking pitting or scoring Contact a Cummins Authorized Repair Location for pitting reuse criteria cg9shsb Inspect the camshaft gear teeth for pitting Inspect for cracks at the roots of the teeth cg9grsa Measure the outside diameter of camshaft bearing journals Camshaft Bearing Journals Standard Tolerance Standard Clearance Journal Size Clearance Limit Number 1 0 040 to Numbere2 50 5 mm 0 140 mm 0 25 mm and
95. ng oil cooler for powertrain is damaged Refer to the OEM s service manual OK v Cylinder head gasket is cracked or damaged Replace the cylinder head or gasket OK v Cylinder block is cracked or porous fr Replace the cylinder block Diesel Engine 39 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 Radiator or cab heater is leakin Eaa 9 the coolant check for a transmission or lubricating oil cooler leak OK v Inspect the engine and components for seal External engine leak Prem j gt j gasket or drain cock leaks OK v Review the operation for overheating and low power Refer to troubleshooting logic for Coolant Temperature Above Normal OK v N on Check for mixing of coolant and transmission Transmission cooler is leaking if equipped 1 duid OK v Cylinder head gasket is leaking fr Check or replace the head gasket OK v Cylinder head is cracked or porous fr Check or replace the cylinder head OK v Cylinder block coolant passages are leaking 7 Check or replace the cylinder block Overheating or compression gases are leaking Resulting in loss through the radiator overflow Diesel Engine 40 Troubleshooting Symptoms Lubricating Oil Pressure Is Low This is symptom tree T 014 Cause Correction Check the oil level
96. ngine 287 Special Tools Tools Magnetic Base Indicator Holder Belt Tension Gauge Combustion Leak Test Kit Engine Coolant Analyzer Coolant Dam Pressure Tester Diesel Engine Diesel Engine 2388 Special Tools Tools
97. njury WARNING When using solvents acids or alkaline materials for cleaning follow manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Use solvent or steam to clean the capscrews connecting rod and connecting rod cap Dry with compressed air Use a soft bristle brush to clean the oil drilling Engine System A CAUTION Repair of rolled threads by use of a thread die is not recommended The die can create a sharp corner on the minor diameter root of the threads This sharp corner can cause an area of increased stress Inspect the capscrews for the following e Damaged threads e Rust or corrosion caused pitting e Nicks bent stretched or galled bp8cssa The capscrew must be replaced if it has any of the listed damage Inspect the connecting rod and connecting rod cap for damage Replace the connecting rod if the l beam or connecting rod cap is damaged Inspect the connecting rod and connecting rod cap for fretting damage on the mating surfaces The connecting rod and connecting rod cap must be replaced as an assembly if fretting damage is visible cx900sf i on either piece Check the bearing surface for nicks or burrs If it is not possible to remove any nicks or burrs with a fine eme
98. nkshaft gear teeth or there are signs of excessive heat make sure to inspect the associated idler gear for damage Inspect the crankshaft gear teeth for discolorations or signs of excessive heat bluing Inspect for cracks and broken or chipped teeth If any damage is present replace the crankshaft and crankshaft gear Refer to Procedure 001 016 for crankshaft removal Engine System Crankshaft Pulley U i I I la l i ee wi VV 00900180 01900251 Diesel Engine 126 Remove the capscrew and mounting plate Use a standard puller Part Number ST 647 or equivalent to remove the crankshaft pulley A WARNING When using a steam cleaner wear safety glasses or a face shield as well as protective clothing Hot steam can cause serious personal injury A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING Some solvents are flammable and toxic Read the manufacturer s instructions before using A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the crankshaft pulley with steam or solvent Dry with compressed air Engine System Diesel Engine ri Fl x a a a ol da2pusa W 00900180 Inspect th
99. nspect the cylinder bores for reuse ck9brwd Diesel Engine 153 Engine System N ir f Paar u Diesel Engine cx900ld cx9cswb cx9cshb 154 Position the connecting rod journal for the piston to be installed to bottom dead center BDC Take care to not damage the cylinder wall when inserting the connecting rod Carefully push the piston into the bore while guiding the connecting rod to the crankshaft journal Lubricate the threads and underside of the connecting rod capscrew heads with clean 15W 40 lubricating engine oil A CAUTION The number stamped on the rod and cap at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews Tighten the two capscrews in alternating sequence Torque Value Step1 39 n m 29 ft lb Step2 Rotate each capscrew 90 degrees Engine System Diesel Engine cx900tb 155 NOTE Do not measure the clearance between the connecting rod cap and crankshaft Measure the side clearance between the connecting rod and crankshaft Connecting Rod Cap Side Clearance mm in 0 20 MIN 0 0079 0 40 MAX 0 0160 A CAUTION To reduce the possibility of engine damage the crankshaft must rotate freely A CAUTION If the connecting rod is not properly oriented tang opposite the camshaft it will contact the camshaft and lock the engine Check for freedom of rotation as the
100. nt capscrew 1 J aN rol os 90 Complete Engine Diesel Engine 00900157 00900209 91 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 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 AN Remove the bracket Part No 3163625 from the OS engine 00900207 axo Install the starting motor NOTE The o ring is used only on wet flywheel housings 00900156 Install all the chassis components that were remov
101. o 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 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 man
102. oatings do not stamp the anodized coating on the outer rim Mark each piston according to the cylinder location pi900gc Rotate the crankshaft to position the connecting rod caps at bottom dead center for removal Mark each connecting rod and connecting rod cap according to the cylinder number location cx9cahb NOTE Do not remove the capscrews from the connecting rods at this time Loosen the connecting rod capscrews Use a rubber hammer to hit the connecting rod capscrews to loosen the caps 0100094 Remove the connecting rod capscrews Remove the connecting rod cap 0100095 Diesel Engine 148 Engine System axo Remove the lower connecting rod bearing Mark the cylinder number and the letter L lower on the flat surface of the bearing tang Push the connecting rod and piston assembly out of the cylinder bore Care must be taken not to damage the connecting rod or bearing Remove the upper rod bearing cx9beme Mark the cylinder number and the letter U upper on the flat surface of the bearing tang cx9bega The piston and connecting rod assemblies must be installed in the same cylinder number from which they were removed to provide proper fit of worn mating surfaces if parts are reused Use a tag to mark the cylinder number from which each piston and rod assembly were removed Place the rod and piston assemblies in a container to protect them from damage 01c00167 Us
103. oil seal is not damaged during installation Lubricate the crankshaft oil seal with Lubriplate 105 or equivalent Install the crankshaft oil seal into the flywheel housing Inspect the rear face of the cylinder block and flywheel housing mounting surface for cleanliness and raised nicks or burrs Install the flywheel housing over the two dowel pins Tighten the flywheel housing mounting capscrews in the sequence shown in the illustration Torque Value 69 Nem 51 ft lb Flywheel Install the guide pins Part Number 3376696 or equivalent into the empty capscrew holes 180 degrees apart Determine the capscrew thread design and size and install two T handles in the flywheel 180 degrees apart on a horizontal plane Install the coupling retaining plate and flywheel Coat all capscrews with clean lubricating engine oil Install four of the six mounting capscrews into the flywheel Hand tighten Remove the guide pins and install the remaining two mounting capscrews Hand tighten Complete Engine Tighten the mounting capscrews in the sequence J shown in the illustration Torque Value Step 1 108 Nem 80ft Ib Step2 191 Nem 141ft Ib 16900117 ID Oil Pump SIE Install the lubricating oil pump and five capscrews A 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 0
104. or a Burroughs gauge Part Number ST 1138 or equivalent Fan Belt Deflection n Ib New Belts 324 MIN 73 378 MAX 85 Used Belts 216 MIN 49 270 MAX 61 Loosen the mounting capscrew of the alternator 1 and belt tension adjustment capscrew 2 Using a breaker bar raise the alternator and adjust the fan belt tension to specification Tighten the adjustment capscrew and the mounting capscrew Adjustment Capscrew 31 n m 23 ft lb Mounting Capscrew 66 n m 49 ft lb F 00999257 Diesel Engine 193 Engine System Coolant Thermostat Remove the thermostat and seal from the water pump exc cavity 08900320 Do not let dirt or debris fall into the thermostat cavity when cleaning the gasket surfaces Failure to do so can cause engine damage Clean the mating surfaces 08900321 Inspect the thermostat 1 for damage such as obstructions caused by debris broken springs or stuck or missing vent pins Make sure the thermostat is clean and free from corrosion 08900322 Diesel Engine 194 Engine System lt gt NOTE Do not allow the thermostat or thermometer to touch the side of the container Suspend the thermostat and a 100 C 212 F thermometer in a container of well mixed water Heat the water slowly at a temperature of 77 C 171 F so the wax element in the thermostat has sufficient time to react to the rising water temperature The thermostat thermal open lift is 8 mm 0 315 in when i
105. or strainer OK Clogged or leaking fuel piping Irre Clean and repair the fuel piping OK Feed pump is damaged or seized Irre Replace the feed pump OK Injector are plugged Prrmmmemeeeenn Replace the injectors OK Injection pump driveshaft or driveshaft key is ee aaa Repair or replace the injection pump damaged Diesel Engine 26 Troubleshooting Symptoms Engine Difficult to Start or Will Not This is symptom tree T 004 Cause Does not become warm OK v Crank speed is too slow minimum crank Speed 150 rpm OK Improper fuel is being used OK Clogged air cleaner element OK Clogged prefilter OK Clogged fuel filter or strainer OK Leakage clogging air in fuel system OK Injection pump timing is incorrect OK v Continued Diesel Engine Start Exhaust Smoke Correction Zn i oe Pr Battery and recharge or replace a lt lt farm lt lt a lt a 27 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Overhead adjustments are not correct 777777777 Measure and adjust the overhead settings OK v Inspect the rocker levers rocker shafs and Overhead components are damaged I valve for excessive damage Replace as necessary OK v ER Replace the defective or clogged injection Defective or clogged injection nozzle fr z p 99
106. ow 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 00900162 Diesel Engine 86 Complete Engine Thermostat Install seal thermostat thermostat housing and two mounting capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb 18900025 Water Pump Install the o ring gasket water pump and mounting capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb 00900161 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 00900160 Install the dipstick guide Install the dipstick Lubricating Oil Filter Install the lubricating oil filter NOTE Some engines will have an oil filter cooler mounted between the oil filter and the engine block Diesel Engine 87 Complete Engine Diesel Engine 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
107. own I Torque Value Main Bearing Capscrews Step1 113 Nem 83 ft Ib 2 Loosen all capscrews completely 3 132 Nem 98 ft Ib 00900220 7a After tightening the mounting capscrews make sure the crankshaft rotates smoothly 00900222 CP Measure the crankshaft end play using a dial indicator Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 00900202 69 Complete Engine Diesel Engine AN Piston and Connecting Rod Assembly When rebuilding an engine with the original cylinder block crankshaft and pistons make sure the pistons are installed in their original cylinders If replacing the piston s make sure the replacement piston s are the same grade as the original piston s If a new cylinder block or crankshaft is used the piston grading procedure must be performed to determine the proper piston grade for each cylinder Install the connecting rod and piston assembly into the Number 1 cylinder without the rings installed Gir The number stamped on the connecting rod and cap ae at the parting line must match and be installed on the oil cooler side of the engine Install the connecting rod cap and capscrews to the connecting rod CAUTION The connecting rods and connecting rod caps are not interchangeable The connecting rods and connecting rod caps are machined as an assembly Failure will result if the connecting rods and caps are mixed Install the bearing shells into
108. ozzles OK v Throttle lever return spring linkage or air throttle cylinder damaged or improperly Check for proper operation of components adjusted OK gt 4 ost mn OK v Er Diesel Engine 34 Troubleshooting Symptoms Excessive Exhaust White Smoke This is symptom tree T 009 Cause Correction Verify the correct starting procedure Refer to Starting procedure is not correct Procedure Normal Starting Procedure in the Operation and Maintenance Manual Coolant temperature is below specification or the intake manifold air temperature is below specification Check the air heater or warm the coolant water by heater core Verify by operating the engine from a temporary Poor fuel quality or wrong fuel grade fr supply of number 2 diesel fuel Check fuel specifications for proper fuel grade OK v a hie Put the engine at top dead center Check and Fuel injection pump timing is not correct 777777 1 a adjust the fuel timing OK v Check to see if an extra sealing washer is Injector sealing washer not correct fr installed under injector Remove any additional sealing washer Only one is required OK v Injector I m l n l nin a ae ee ee 55 V J S eplac as OK v Coolant is leaking into the combustion chamber Refer to the Coolant Loss Internal symptom If equipted tree Remove the fuel injection pump Check the calibration of the fuel injection pump Fuel injection pump
109. pening pressure i a Open valve b Operate lever at one stroke per second c Read pressure indicated when spray begins Nominal Injector Opening Pressure 19 6 Mpa 2843 psi fi900de 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 fi9000a Leakage Test a Open the valve b Operate the lever to hold pressure 20 bar 290 psi below opening pressure 10 Seconds c No drops should fall from the tip within 10 seconds u fi900df Chatter Test The chatter 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 th fi900dd Diesel Engine 182 Engine System ex Disassembly Remove the copper sealing washer and discard amp gt Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut fi900fb Remove the nozzle needle valve and intermediate axo plate NOTE To avoid damage place the injector nozzle and needle valve in a suitable bath of clean test oil fi900fc ex Remove the nozzle holder from the vise then remove the pressure spin
110. posits NOTE An inferior quality wire wheel will lose steel bristles during operation thus causing additional contamination An alternative method to remove the carbon ridge is to use a high quality steel wire wheel installed in a drill or die grinder On pistons with anodized coatings do not stamp the anodized coating on the outer rim Mark each piston according to the cylinder location pi900gc Rotate the crankshaft to position the connecting rod caps at bottom dead center for removal Mark each connecting rod and connecting rod cap according to the cylinder number location cx9cahb Diesel Engine 62 Complete Engine NOTE Do not remove the capscrews from the connecting rods at this time Loosen the connecting rod capscrews Use a rubber hammer to hit the connecting rod capscrews to loosen the caps 0100094 Remove the connecting rod capscrews Remove the connecting rod cap 0100095 Remove the lower connecting rod bearing Mark the cylinder number and the letter L lower on the flat surface of the bearing tang Push the connecting rod and piston assembly out of the cylinder bore Care must be taken not to damage the connecting rod or bearing Remove the upper rod bearing cx9beme Mark the cylinder number and the letter U upper on the flat surface of the bearing tang Diesel Engine 63 Complete Engine The piston and connecting rod assemblies must be installed in t
111. r Complete Engine Diesel Engine RI Alternator Remove the adjusting capscrew and washer Remove the capscrew adjustment plate and spacer Remove the remaining capscrew and alternator 99900159 Lubricating Oil Filter R Remove the lubricating oil filter 00900155 Dipstick Guide Bi Remove the dipstick and dipstick guide 00900160 Water Pump Re Remove the mounting capscrews water pump gasket and o ring Discard the gasket and o ring 00900161 51 Complete Engine x Thermostat Remove the two mounting capscrews thermostat housing thermostat and seal 18900025 Exhaust Manifold Remove the eight capscrews exhaust manifold and gasket Discard the gasket 00900162 Fuel Injection Tubing Remove the clamp Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head Intake Manifold Remove the eight capscrews intake manifold and air inlet connection Remove the grid heated if equipped Remove the four capscrews air inlet connection and o ring Discard the o ring 00900164 Diesel Engine 52 Complete Engine x Spill Tube Remove the spring hose clamps and hose Remove the spill tube 00900166 Injector 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 an
112. r head and exhaust components for damage from debris Inspect the piston for damage and excessive wear Check the top ring grooves skirt and pin bore pi900sb Measure the piston skirt diameter Piston Skirt Diameter mm in 94 85 MIN 3 734 95 00 MAX 3 740 pi900tc Diesel Engine 140 Engine System Measure the pin bore NOTE Measure the pin bore in the center area of the bore The bore profile is tapered on the edges and will result in a measurement error Piston Pin Bore Diameter 30 00 NOM 1 181 pi9brtc Diesel Engine 141 Engine System Piston Rings Diesel Engine pi9risb pi9risc pi9risd 142 Inspect the piston rings for the following e Abrasive wear e Scuffing and scoring e Oil ring plugged with deposits Abrasive wear is indicated by concentrated vertical scratches B The chromium plating is worn through and the face of the ring has a brighter finish when compared to the dull satin finish of a new ring A Abrasive wear can be caused by e Ingested abrasive material e Inadequate cleaning during a previous repair e Particles embedded in the liner e Scuffing and scoring Scuffing and scoring is indicated by heavy scratches metal discoloration and voids B Scuffing and scoring can be caused by e Engine overheating e Oil dilution e Improper maintenance of the lubrication system e Piston cooling nozzle malfunction e Oil ring plugged by deposits Scuf
113. reads 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 Om 0iOm Om O10 Torque Value 22 cerns s es Cylinder Head O 00 80 50 9 Capscrews Step 1 69 N m 51 ft lb 2 108 Nem 80 ft lb 3 Rotate 90 degrees NOTE The cylinder head 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 Intake Side 00900245 replaced GIA OS Push Rods 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 83 Complete Engine m 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 Stud 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
114. res The procedure will be the same for all applications although the illustration can differ Diesel Engine th8sesa Ca8vagc Introduction Engine Identification Engine Dataplate ots S ed cold ne LExheuss ini mm European Approval Nu umber Fuel rei TTV 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 u of unless approved by Cummins Engine 00900248 Company Inc Cummins Engine Company Inc Important Yngine Information 5 Columbus Indiana Model 3 ESN 47202 3005 www cummins com Grose rafed HPA _ at rpm Warning Injury may result and warranty le voided If fuel rate rpm or altitudes exceed Tea ama published maximum values for thie model CPL S Displacement Ina This engine conforms to 1009 U S EPA and California regulations for large non road compression ignition engines as applicable This engine is certified to operate on diesel fuel Timing So degrees Valve Lash take n IN EPA Cert Family U cold engine European Approval Number i E gt Jess aT 00900249 Diesel Engine 8 Engine Identification Specifications All Models Rated Power kW PS 43 4 59 2 200 rom SS Max Torque S Nmekgf m 202 20 6 1 600 rpm Torque Rising ss 7 4 for 2 200rpm rating BSFC Rated Power 227 2 200
115. ressed air Flying debris and dirt can cause personal injury Use a solvent and a brush to clean any residue that possibly has splashed on the camshaft Inspect the camshaft lobes and tappet faces for signs of wear or damage Refer to Procedure 001 008 Engine System Measure the surface flatness 1 warpage limit Surface Flatness Standard Repair Limit 0 00 to 0 08 mm 0 00 to 0 003 in 0 15 mm 0 006 in Measure the inner diameter of the main bearing 2 Inner Diameter of Main Bearing Bearing Installed 01900252 mm In Standard 70 00 MIN 2 756 70 20 MAX 2 764 0 25 69 25 MIN 2 726 69 75 MAX 2 746 0 50 69 50 MIN 2 736 69 70 MAX 2 744 0 75 69 25 MIN 2 726 69 45 MAX 2 734 1 00 69 00 MIN 2 717 69 20 MAX 2 724 Measure the inner diameter of the camshaft bushing 3 Camshaft Bushing Inside Diameter Standard Repair Limit 50 50 mm 1 988 in 50 60 mm 1 992 in Cylinder Bore Dimensions Inside Repair Standard 95 00 mm 0 022 mm 95 15 mm Bore 3 740 in 0 0008 in 3 746 in Out of Diesel Engine 133 Engine System Gear Cover Front Remove the 17 capscrews front gear cover cover axo plate and gasket Discard the gasket 00900181 WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING 01900254 Som
116. rrect or malfunctioning cap can result in the loss of coolant and the engine running hot Engine System Air in the coolant can result in loss of coolant from the overflow when the aerated coolant is hot The heated air expands increasing the pressure in the system in j lt causing the cap to open B 5 Similarly coolant can be displaced through the hig TERS overflow if the head gasket leaks compression gases S to the coolant system The operating pressure of the coolant system and the lubricating system can result in the mixing of the fluids if there is a leak between the systems head gasket oil cooler etc Transmission fluid can also leak into the coolant through radiator bottom tank transmission oil coolers Water Pump The water pump pulls coolant from the bottom of the radiator and pumps it through the engine back to the top of the radiator for cooling Reduced or interrupted flow will result in the engine running hot wo9hoka The pump is belt driven from the crankshaft pulley An automatic belt tensioner is used to prevent the belt from slipping on the pump pulley A malfunction of the tensioner will cause the water pump impeller to rotate at a slower speed reducing the amount of coolant flow Diesel Engine 202 Engine System The coolant flow can also be reduced if the inlet hose to the water pump collapses A hose will usually not collapse while the engine is running at low speed Check the hose while th
117. ry cloth the connecting rod must be replaced cx8behf Diesel Engine 114 Engine System Diesel Engine 01000145 00900193 115 Inspect the connecting rod piston pin bushing for damage Replace any connecting rod piston pin bushing that has evidence of scoring galling or scuffing Replace any bushing that has turned in the bore Special tools and precision machining are required to replace bushings If Cummins Inc approved tools and procedures are not available the connecting rod must be replaced A CAUTION The connecting rod cap numbers must match the numbers on the connecting rod and must be installed with the characters aligned to prevent damage to the connecting rods and crankshaft A CAUTION Use a vise with brass jaws to hold the connecting rod Notches scratches or dents in the l beam area can cause engine failure Place the connecting rod into a vise with brass jaws Install the connecting rod cap onto the connecting rod Lubricate the threads of the capscrews with clean engine oil Thread the capscrews into the connecting rod and hand tighten Tighten the capscrews Torque Value Step 1 39n m 29 ft lb Step 2 Rotate each capscrew 90 degrees Engine System Measure the connecting rod crankshaft bore inside diameter with a bore dial indicator Connecting Rod Crankshaft Bore Inside Diameter Mm in 61 00 MIN 2 402 61 025 MAX 2 403 If the connecting rod crankshaft bore in
118. side diameter sabre is not within specifications the connecting rod must be replaced Measure the connecting rod piston pin bushing inside diameter Connecting Rod Piston Pin Bushing Inside Diameter Mm in 33 00 MIN 1 299 33 025 MAX 1 300 If the connecting rod crankshaft bore inside diameter is not within specifications the connecting rod must acibsib be replaced This procedure describes the magnetic particle inspection for the connecting rod and connecting rod cap Use a magnetic particle testing machine The connecting rod and connecting rod cap must be assembled during this process Use the residual method Apply head shot amperage Adjust the amperage to 1500 ampere direct current or cx8bdsc rectified alternating current Check for cracks The connecting rod must be replaced if any cracks are visible Diesel Engine 116 Engine System Use the residual method Apply coil shot amperage Amperage Ampere Turns Minimum 2600 amperage direct 2800 amperage direct current current Ampere turn is an electrical current of one ampere flowing through the coil multiplied by the number of 01400343 turns in the coil Check for cracks The connecting rod must be replaced if any indications are visible in the critical shaded areas 01400344 WARNING When using a steam cleaner wear safety glasses or a face shield as well as protective clothing Hot steam can cause serious injury A WARNING
119. surfaces or a reduced diameter due to capscrew stretching Do not use the cylinder head capscrews again under the following conditions e Corrosion or pitting that exceeds 1 sq cm 0 155 sq in in area e 10 mm 3 8 in x 10 mm 3 8 in is an acceptable area e 13 mm 1 2 in x 13 mm 1 2 in is not an acceptable area e Corrosion or pitting that exceeds 0 12 mm 0 005 in in depth e Corrosion or pitting is located with 3 2 mm 1 8 in of the fillet e Corrosion or pitting is located within 3 2 mm 1 8 in of the threads e Stretched beyond free length maximum Reference the following steps for capscrew lengths Diesel Engine 160 Engine System Flange If the capcrews are not damaged they can be used again throughout the life of the engine unless the specified free length is exceed tnt ee A ee To check the capscrew free length place the head enter of the capscrew in the appropriate slot with the flange against the base of the slot Refer to the manufacturer s specifications for the correct size of the cylinder head capscrews against Base 02900009 If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded and replaced all Cylltder Head Sr ran Length Gauge el eee F lp pe pis re la Le ber al ee To ie et mn Halte maai p rs kijana i maT mpra Bams cs rae u iga ai en C E Br Sar 5a irn m Let z E HAEA rege JAR
120. t Black Smoke 34 Excessive Exhaust White Smoke 35 Lubricating Oil Consumption Excessive 36 Lubricating Oil Contaminated 37 Fuel consumption Is Excessive cccsseeeeeeeeeees 38 Coolant Contamination cccccccsseeeeceeeeeeeaeeeeees 39 SOCAN LOSS enrera 40 Lubricating Oil Pressure Is Low 41 Oll Level RISES ee 42 Coolant Temperature above Normal 43 Excessive Noise ccccccssececcseeecceeeeecseeseessaasees 44 Diesel Engine Excessive Noise Continued 45 Engine Vibration EXC SSIVG cccseseeeseeeeeseeeees 46 Complete Engine Complete Engine uussss000ssnnnnneeennnnnnnnnnnee nenne 47 Engine Disassembly cccccseeeeeeseeeeeseeeeeeseeeees 47 Engine Assembly uuu0040nseennennne nennen nennen 66 Engine System ENGINE OY SCO aeg 95 Bearing Connecting Rod ussssnneenneeneeno 95 Bearing Main uuuusnnenneennennnennennnn nennen nennen 100 Bearing TIUS arena 105 Camshaft ccccccccseseceeceesseceesceesseeeeseeeeeeeeeeas 107 Camshaft Bushings cccccceeeseeeeeeeeeeeeeeeeeees 110 Camshaft Gear cccccccscccccceesesseeeeeeeeeeeseaeeeees 112 Connecting Role 113 Crankeh ie 120 Crankshaft Gear Front 125 Crankshaft Pulley cccccccccssssssseeeeeeeeeeeeeeeees 126
121. take ni ee en Clearance Limit Clearance Between Guide and Stem 0 20 mm Et aet 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 nn en ul Exhaust n 0 0008 in VALVE GUIDE Intake 145mm Tolerance Protrusion Above Cylinder Head Surface 0 571 in 0 2 mm Exhaust 0 0079 in VALVE SPRING Repair Limit 49 2 mm 48 5 mm 1 94 in 1 90 in 40 5 mm 1 59 in 18 5 40 9 kg bere i 40 8 2 0 Ib 36 4 Ib Repair Limit 1 85 Diesel Engine 208 Specifications Rocker Arm Shaft Push Rod and Tappets 18900016 Ref Inspection Item Standard Remarks VALVE ROCKER ARM SHAFT Tolerance Diameter of Shaft a 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 Clearance Limit Clearance Between Rocker Arm and Shaft 0 010 to 0 050 an 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 B Clearance Between Tappet and Tappet Hole S ey 0 12 mm 0 0005 to 0 0020 in 0 0047 in Diesel Engine 209 Specifications Cylinder Head 18900011 Ret Inspection Item Standard Remarks _ CYLINDER HEAD Repair Limit
122. the assembly procedure Raise the cylinder head and remove the valve Engine System Diesel Engine 02900072 159 A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Wash the cylinder head in hot soapy water solution After rinsing use compressed air to dry the cylinder head A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturer s recommendations for use Wear goggles and protective clothing to reduce the possibility of personal injury CAUTION Do not use caustic or acidic solutions to clean the cylinder head capscrews Use of this type of solvent can cause corrosion to the capscrews Use a petroleum based solvent to clean the capscrews Clean the capscrew thoroughly with a wire brush or a soft wire wheel or use a non abrasive bead blast to remove deposits from the shank and the threads Inspect the cylinder head for cracks If a crack is found and the crack does not extend into the valve seat the cylinder head can be used again Engine System Measure the cylinder head for surface flatness 1 c Cylinder Head Flatness warping limit mm in ekl el ted for 0 00 MIN 0 00 a l og 0 05 MAX 0 002 eb lt i The maximum repair limit on the cylinder head is 0 30 U u GUU UN UUU mm 0 012 in 02900128 Inspect the cylinder head capscrews for damaged threads corroded
123. the feed pump OK v Overhead adjustments are not correct 777777777 Measure and adjust the overhead settings OK v Continued Diesel Engine 32 Troubleshooting Symptoms Engine Power Output Low Continued Cause Correction Defective contact of valve or seat oe Replace the cylinder head Resulting in low compression OK v Replace the defective or clogged injection Defective or clogged injection nozzle fr z P 99 nozzle OK v Injection pump is malfunctioning frrmmmmmmeeenm Replace the injection pump OK v Worn piston ring or cylinder resulting In low ee eee Ls Replace the worn piston ring or cylinder compression Diesel Engine 33 Troubleshooting Symptoms Excessive Exhaust Black Smoke This is symptom tree T 009 Cause Correction Check for added loading from malfunctioning accessories or driven units brakes dragging and other changes in vehicle vessel or equipment loading OK v Inspect the air cleaner element Replace as Plugged air filter frrmmmeeeeeeen P p needed OK v Exhaust system restriction prrmmemeeeeeen Check the exhaust system for any restrictions OK v Intake air leak between turbocharger and S E nn Inspect for air leaks cylinder head OK v Engine is overloaded Check and correct any leaks in the exhaust Exhaust leaks at the manifold manifold gaskets Check for a cracked exhaust manifold OK v Clogged nozzles prummmeemmeenn Clean the n
124. tions for use Wear goggles and protective clothing to reduce the possibility of personal injury A WARNING op9tbeb Some solvents are flammable and toxic Read the manufacturer s instructions before using A WARNING Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause personal injury Clean the lubricating oil suction tube and o ring surfaces Dry with compressed air Inspect the lubricating oil suction tube for cracks or other damage 07900325 Diesel Engine 191 Engine System Install the o ring and lubricating suction tube onto the cylinder block Install the two mounting capscrews into the lubricating oil suction tube Tighten the capscrews Torque Value 19 n m 14 ft lb 00900179 24 Loosen the alternator mounting capscrew 3 and the belt tension adjustment capscrew 2 Move the alternator down the adjustment bar until the drive belt is loose Remove the drive belt 1 08900318 Inspect the drive belt for the following e Cracks e Glazing e Tears or cuts e Excessive wear fa8blsa Install the drive belt Using a breaker bar raise the alternator on the adjustment bar 1 and adjust the fan belt tension to specification Diesel Engine 192 Engine System CP Measure the belt tension in the center span of the pulleys Check the belt tension using a click type belt tension gauge Part Number 3822524 or equivalent
125. tly Check the air operated shutter controls Check for air leaks fn900kd Diesel Engine 204 Engine System Engine Compression gt A WARNING To reduce the possibility of personal injury keep hands long hair jewelry and loose fitting or torn clothing away from fans and other moving parts Measure the engine compression pressure while the engine is a minimum temperature of 50 C 122 F Adjust the overhead Refer to Procedure 003 004 03900077 Remove the fuel drain line 06900274 gt Vc Fuel is flammable Keep all cigarettes flames pilot E gt lights arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system Remove the high pressure fuel lines 00900163 Disconnect the fuel shutoff valve Diesel Engine 205 Engine System SD wm While testing the injectors keep hands and body parts away from the injector nozzle Fuel coming from the injector is under extreme pressure and can cause serious injury by penetrating the skin CAUTION 0090016 Do not allow dirt or debris to enter into the cylinder port Debris and foreign objects in the cylinder can cause severe engine damage Remove the nozzle holder assembly for each cylinder Remove the injector for each cylinder D Lubricate the sealing lips of the sleeve with antiseize compound Part Number 3824879 or equiv
126. tters identify oil pump and accessory drive which are not timed 00900241 lf a PTO accessory drive is used on the engine the idler gear uses two bearings Install the idler shaft rear bearing rear spacer plate and idler gear Install the front bearing plate shim and capscrew Tighten the capscrew Torque Value 110 Nem 81ft Ib 01900258 75 Complete Engine Measure the end play of the idler gear Position the fuel injection pump assembly temporarily Measure the backlash of each gear with a dial indicator 3376050 or equivalent 00900244 Match mark alignment Naturally Aspirated PR 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 Aspirated Replacement Injection pump 0 07 mm to 0 29 mm mil Backlash G gear and idler gear 0 003 in to 0 011 in a 0 0157 in Camshaft gear 0 15 mm to 0 30 mm and oil pump gear 0 006 in to 0 012 in Camshaft gear 0 03mm to 0 050mm and PTO gear 0 0012 in 0 0035 in 0 015 mm to 0 050 mm Replacement Limit 0 0006 in to 0 002 in 0 10 mm 0 0039 in Clearance Between Bushing and Shaft 0 03 mm to 0 09 mm Replacement Limit End PI nd Play of Idler Gear 0 0012 in to 0 0035 in 0 20 mm 0 0079 in Diesel Engine 76 Complete Engine 00900188 16900118 00900187 Diesel Engine 77 Fly Wheel Housing NOTE Make sure the crankshaft
127. ty of seal leaks Clean and dry the rear crankshaft sealing surface Clean and dry the flywheel housing seal bore Inspect the crankshaft sealing area and flywheel housing bore for burrs or raised material Remove the burrs or raised material with crocus cloth Fill 40 to 60 percent of the space in the seal lip with grease Use crankshaft seal installer Part Number 3164900 or equivalent to install the crankshaft seal 00900189 Diesel Engine 129 Engine System Cylinder Block Diesel Engine N ck9brwc ck900kb NN E ESS Ve 130 Diagnosis of cylinder block cooling and lubrication malfunctions has been discussed in those respective sections The potential problems with the cylinder the camshaft bore and the crankshaft main journals are discussed in this section Malfunctions of the cylinder block such as leaks or tappet bore wear require a visual or dimensional inspection to isolate the problem The cylinder bores are machined directly into the cylinder block during production The size and condition of the cylinder bore is critical to engine performance and life During repair make sure to inspect the cylinder bores carefully It will also be necessary to deglaze the cylinder walls before reassembly A 30 degree crosshatch pattern is needed to seat the new piston rings The cylinder bores can be rebored in a machine shop and fitted with an oversize service piston Engine System Diesel En
128. ufacturer OEM Diesel Engine 5 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 D 6 gt gt CLEAN the part or assembly PERFORM a mechanical or time MEASUREMENT LUBRICATE the part or assembly Indicates that 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 9 MORES Diesel Engine 6 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 procedu
129. uld 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 ccccccceccccceeeseeseeeeeesseeeesseeees 5 How to Use the Manual 22000s0200neeee nennen 5 NNDO sr nee ee ee 6 Illustrations
130. ushed with a force of 6 kg 13 2 lb at a point midway between the fan pulley and the alternator pulley Fan Belt Deflection mm in 7 0 MIN 0 28 10 0 MAX 0 39 ex Adjusting the Fan Belt Tension Loosen the mounting capscrew of the alternator 1 and belt tension adjustment capscrew 2 7 N En 4000068 da Seh Gir Using a bar raise the alternator and adjust the fan us 2 7 belt tension y TED 3 Tighten the adjustment capscrew and the mounting gt ANANO y capscrew ET ET P Pere Di cy Sy EX X YS ess Torque Value IN X Adjustment Capscrew NV gt Mounting Capscrew oe ae 60900257 j Diesel Engine 175 Engine System 31 Nem 23 ft lb 66 Nem 49 ft lb Fuel System Fuel Injection Pump Rotary ay CAUTION ex Do not drop the nut washer or key Failure to do so will result in the need to remove the front gear cover Remove the gear cover access cap Rotate the engine until the keyway is vertical 05900254 Remove the nut and washer from the fuel injection pump shaft Remove the injection pump support bracket Remove the two mounting capscrews Remove the fuel injection pump Remove the key Inspect the fuel injection pump body for cracks or other damage 05900868 Diesel Engine 176 Engine System CAUTION Make sure the key does not fall into the gear housing Failure to do so can result in engine damage Install the Woodruff key into the fuel in
131. ved rod bearing and obtain a set of the same size ks900ge Use an outside diameter ball tipped micrometer to measure the connecting rod bearing thickness B3 3 Connecting Rod Bearing Thickness mm in Standard 3 80 MIN 0 1496 4 00 MAX 0 1575 B3 3 Connecting Rod Bearing Thickness for Oversize Bearings mm in cx9beta 0 25mm 4 05 MIN 0 1594 4 25 MAX 0 1673 0 50mm 4 30 MIN 0 1693 4 50 MAX 0 1772 0 5mm 4 55 MIN 0 1772 4 75 MAX 0 1870 1 00mm 4 80 MIN 0 1890 5 00 MAX 0 1968 Diesel Engine 98 Engine System Diesel Engine Standard Oversize 0 25 mm 010 in 0 50 mm 020 in 0 75 mm 030 in 1 00 mm 040 in mb900gb 01900184 99 NOTE Bearing shells are identified by steel stamped characters on the back of the bearings to indicate either standard STD or oversize OS A crankshaft that is machined undersize on the connecting rod or main bearing journals is marked on the front counterweight If the crankshaft is marked check the bearing shell part number to make sure the correct bearing size is used NOTE Used bearings must be installed in the same location from which they were removed Refer to Procedure 001 054 for connecting rod bearing installation instructions Engine System Bearing Main Diesel Engine 00900202 100 NOTE The end play measurement is necessary for determining the wear of the thrust bearing and abnormal wear of the crankshaft Measure the
132. with a aftercooler Open the petcock during filling Adequate venting is provided for a fill rate of 10 liters minute 2 6 gal minute 08900314 NOTE Do not install the radiator cap The engine must be operated without the cap for this process Fillthe system with a mixture of sodium carbonate and water or a commercially available equivalent Use 0 5 kg 1 0 Ib of sodium carbonate for every 23 liters 6 gal of water A WARNING Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with local environmental regulations Operate the engine for 5 minutes with a coolant temperature above 82 C 180 F Shut the engine off and drain the cooling system CAUTION The cooling system must be filled properly to prevent air locks in the cooling passages Failure to vent the cooling system properly can cause damage to the cooling system Fill the cooling system with clean water Make sure to vent the engine and aftercooler if equipped for complete filling T rt ra900we Do not install the radiator cap Diesel Engine 197 Engine System A WARNING Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with local environmental regulations Operate the engine for 5 minutes with a coolant temperature above 82 C 180 F a fe tty i a Pr Br Tee j ee AM i a A PP ae hae NEUE Shut the engine off and
133. y will read 1 4 TOP e The No 4 intake valve will start to open when the No 1 cylinder comes near compression top dead center Loosen the lock nut 3 on the adjustment screw 4 Insert the feeler gauge 5 between the valve stem 6 and the rocker arm 7 Adjust the clearance with the adjustment screw until slight drag is felt on the feeler gauge Valve Clearance Engine Hot or Cold Intake Valve Exhaust Valve 0 014 in 0 020 in Engine System 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 0390078 and No 3 Adjust the valve clearances for exhaust valves No 1 and No 2 Adjust the valve clearances for intake valves No 1 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 0390078 Tighten the locknut to secure the adjustment screw CAV Locknut Torque Value 39 2 MIN 28 9 49 MAX 36 1 0390080 Diesel Engine 165 Engine System Rocker Levers Assembly The rocker lever assembly contains the following components 1 Rocker shaft 2 Adjusting screw locking nut 3 Rocker lever 4 Adjusting screw 03900102 5 Rocker lever indexing screw 6 Pedestal mounting stud 7 Cup plug 8 Snap ring 9 Thrust washer if equipped 10 Rocker lever p

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