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Daewoo 21T2 CRT Television User Manual

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1. 0 0551 to 0 0630 in ae a VALVES Exhaust Intake 0 35 mihi Tolerance ae in 0 02 mm 50mm Exhaust 0 0197 in 0 0008 in VALVE GUIDE Intake 145 mm Tolerance Exhaust 0 571 in 0 2 mm 0 0079 in VALVE SPRING Repair Limit ao ee 43 5 mm Den 1 90 in 1 59 in 18 5 0 9 kg ae a 40 8 2 0 Ib ats Repair Limit 1 85 101 Specifications Rocker Arm Shaft Push Rod and Tappets 18900016 Ref Inspection Item Standard Remarks VALVE ROCKER ARM SHAFT ion Tolerance Diameter of Shaft 0 020 mm N 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 ee ae 0 12 mm 0 0004 to 0 0020 in 10 0047 in Repair Limit Bend of Shaft 0 20 mm 0 0079 in PUSH ROD Repair Limit Bend of Push Rod 0 30 mm 0 012 in TAPPET Clearance Limit Clearance Between Tappet and Tappet Hole ee ee dank 0 12 mm 0 0005 to 0 0020 in 0 0047 in Diesel Engine 102 Specifications Cylinder Head 18900011 Ref Inspection Item Standard Remarks CYLINDER HEAD Repair Limit Surface Flatness Warpage Limit u a u 0 30 mm l l 0 012 in intake 1 00 0 100 mm nn Ami 0 039 0 004 in 0 079 in Repair Limit 0 90 0 100 mm p l an 0 035 0 004 in 1 90 mm 0 075 in Tolerance Nozzle Protrusion a un 2 700 to 3 500 mm Bl 0 106
2. __ peeesesesesesne Fill the supply tank OK v Clogged fuel tank air breather hole fuser Clean the fuel tank breather OK v Low idle speed is adjusted too low esssesssesssesssesssess Adjust the low idle speed OK v Clogged prefilter Fersen Clean the prefilter OK v Clogged fuel filter or strainer prem Clean or replace the fuel filter or strainer OK v Line between the fuel tank and feed pump a e Clean and repair the lines are clogged or have air in them OK v Line between the feed pump and the injector p p n J ERTEILEN EE Clean and repair the lines nozzle are clogged or have air in them OK v Injection pump is malfunctioning pevesveseseses Replace the injection pump Diesel Engine 27 Troubleshooting Symptoms Engine Power Output Low This is symptom tree T 008 Cause Correction Improper fuel is being used freee Drain and replace the fuel with the correct fuel OK v Clogged air cleaner element freee Clean or replace the air cleaner element OK v Clogged fuel tank air breather hole here Clean the fuel tank breather OK v Full throttle can not be achieved because the fuel lever linkage is bent or not adjusted Repair or adjust the fuel lever linkage correctly OK v Clogged prefilter 0 eeessssessseessseessressses Clean the prefilter OK v Clogged fuel filter or strainer perjem Clean and or replace the fuel filter or strainer OK v Clogged or leaking fuel piping fr
3. Drain the engine coolant Diesel Engine 42 Complete Engine OS PS 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 engine ground straps cab or chassis to engine hoses tubing electrical wires and hydraulic lines xc Disconnect the intake and exhaust system pipes oi400hc Disconnect the drive units from the flywheel housing and flywheel tr400wa Remove all chassis components necessary to axo remove the engine from the equipment ra400ha Diesel Engine 43 Complete Engine SD Prepare a stable stand Part No 3375193 or 3375194 a which will prevent the engine from falling over Engine Weight approx 255 kg 562 Ib 4X Remove the starting motor 00900156 Install the bracket Part No 3163625 on the engine 00900207 A WARNING GIA This component weighs 23 kg 50 Ib or more To gt i he a avoid personal injury use a hoist or get assistance to lift this component The engine lifting equipment must be designed to lift the engine without causing personal injury Put the engine on the stand 00900208 i Diesel Engine 44 Complete Engine Cover all the
4. Madein Japan fT 00900249 Diesel Engine 7 Engine Identification Specifications Standard SAEJI99 E Air Cleaner without but with 3 0kPa intake restriction Test Condition Muffler without but with 10 0kPa exhaust restriction Alternator without Fan al without Oooo without Rated Power foe eed kW PS 43 4 59 2200 rpm 48 5 65 2600 rpm Max Torque ass Nm kgf m 202 20 6 1600 rpm 214 21 8 1600 rpm Torque Rising si 7 4 for 2200rpm rating 20 0 for 2600rpm rating BSFC Rated Power g kWh 227 2200rpm 236 2600rpm Max Torque g kWh 219 1600rpm 226 1600rpm General Engine Data Naturally Aspirated Engine Weight Dry Less Flywheel and Electronics 245 kg 540 Ib Compression Ratio 18 8 95 mm 3 74 in Stroke 115 mm 4 528 in Displacement 3 26 liters 199 in Firing Order 1 2 4 3 l Intake 0 35 mm 0 014 in Nase Exhaust 0 50 mm 0 020 in Rotation Viewed from the Front of the Engine Clockwise Lubrication System Naturally Aspirated Regulating Valve Opening Pressure 490 kPa 71 psi a Sn Total System 7 5 liters 8 0 qt 8 0 liters 8 5 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 35 psi Oil Filter Differential Pressure to Open Bypass Valve 98 kPa 14 psi Number of liters qt from Low to High 1 5 liters 1 6 qt Cool
5. 210 140 100 18 280 200 180 135 390 285 180 135 400 290 180 135 20 400 290 550 400 Diesel Engine 115 Specifications Capscrew Markings and Torque Values U S Customary SAE Grade Number 5 apscrew Head Markings These are all SAE Grade 5 3 line Capscrew Torque Grade 5 Capscrew Capscrew Torque Grade 8 Capscrew Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum Nem ft Ib Nem ft Ib Nem ft Ib Nem ft Ib 1 4 20 9 7 8 6 15 11 8 6 28 12 9 9 7 18 13 9 7 5 16 18 20 15 16 12 30 22 16 12 24 23 17 19 14 33 24 19 14 3 8 16 40 30 25 20 55 40 25 20 24 40 30 35 25 60 45 35 25 7 16 14 60 45 45 35 90 65 45 35 20 65 50 55 40 95 70 55 40 1 2 13 95 70 75 55 130 95 75 55 20 100 75 80 60 150 110 80 60 9 16 12 135 100 110 80 190 140 110 80 18 150 110 115 85 210 155 115 85 5 8 11 180 135 150 110 255 190 150 110 18 210 155 160 120 290 215 160 120 3 4 10 325 240 255 190 460 340 255 190 16 365 270 285 210 515 380 285 210 718 9 490 360 380 280 745 550 380 280 14 530 390 420 310 825 610 420 310 1 8 720 530 570 420 1100 820 570 420 14 800 590 650 480 1200 890 650 480 Diesel Engine 116 Specifications Fraction Decimal Millimeter Conversions Conversion Factor 1 inch 25 4 mm Diesel Engine 117 Specifications Newton Meter to Foot Pound Conversion Chart Nm ftb Nm ftb Nm _ ftib 5 nb 600 tO 8 6 Bnb 10650 12 8 nnb _
6. Fuel Injection Tubing Remove the clamp Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head 00900163 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 47 Complete Engine RI 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 and insert a blind plug to prevent dust or dirt from entering the engine NOTE Mark the injectors with tags showing the cylinder number and keep it in a safe place If there is no abnormality in the injector install it in the same position during assembly Rocker Lever Cover Remove the three capscrews isolator assemblies rocker lever cover and o ring gt Sells 03900075 Diesel Engine 48 Complete Engine _ 00900251 Rocker Arm Assembly Rocker Shaft Adjusting Screw Lock Nut Pedestal Mounting Capscrews Separating Spring Rocker Shaft Indexing Screw Pedestal Mounting Stud Oe Ola oe DI 00900169 Diesel Engine 49 7 Cup Plug 8 Snap Ring 9 Thrust Washer if
7. M18x2 M24x2 8 M24x1 5 M25x2 1 12 17 14 M25x1 5 17800013 Diesel Engine Specifications Weight and Measures Conversion Factors From Metric From U S Customary To U S Quantity U S Customary To Metric Customary Multiply By Multiply By P Brit Name Abbreviation Unit Name Abbr susie oooisso q millimeters mm 645 16 0 001550 a a a a E sg mete m 00929 10764 Fuel pounce per grams per g kW miles per gallon emer Pe lal 0 4251 2 352 Fuel liter EENSEDANEE I aons permie NEPA Ikm 2 352 0 4251 kilometer a a a sma 4 4482 0 224809 pinch fin millimeters mm 25 40 0 039370 Length foot ft millimeters mm 304 801 0 00328 kilowatt 0 746 1 341 ae per psi kilopascal 6 8948 0 145037 kilopascal 3 3769 0 29613 kilopascal 0 2488 4 019299 Pressure mercury Hg Millimeters of mm H2 25 40 0 039370 water O kilopascals 100 001 0 00999 mercury Hg fahrenheit F 32 1 8 1 8x C 32 sone pound force per Velocity a faa kloni nour 1 6093 0 6214 gallon U S gal iter 1 13 7853 0 264179 Volume gallon Imp eo o ter a NE 4 546 0 219976 inches of water in H O liquid in liter i ru 0 01639 61 02545 displ t See cubic inch ar 16 387 0 06102 centimeter a Thermal joules 1054 5 0 000948 Unit Work Tea Mama kilowatt hour 0 000293 3414 hours Diesel Engine 120 Specifications SPECIAL TOOLS u ST 537 Dial Depth Gauge ST 1111 3 Seal
8. Pump 9 Oil Cooler optional 5 Water Manifold A From Oil Pump oil Diesel Engine 17 Engine Identification Air Intake System 00900227 1 Filtered Air 2 Intake Manifold 3 Intake Valve Port Diesel Engine 18 Engine Identification Exhaust System 00900232 1 Exhaust Valve Port 2 Exhaust Manifold Diesel Engine 19 Engine Identification Procedures and Techniques A thorough analysis of the customer s complaint is the key to successful troubleshooting The more information known about a complaint the faster and easier the problem can be solved The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first Complete all steps in the sequence shown from top to bottom It 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
9. T 017 Cause Correction abnormally high loading the pulleys rotate freely OK v Tighten the clamp between turbocharger and head Repair leaks between turbocharger and head Air leakage between the turbocharger and head OK d Refer to Exhaust Gas is Black troubleshooting Exhaustleak fa aa ae ee 00000 Kos OK Turbocharger does not rotate freely freee Replace the turbocharger OK v Gear train backlash is not adjusted correctly He Adjust the backlash for the gear train OK v Idler gear bushing is damaged or missing Replace the idler gear bushing OK v PEE A Replace the defective or clogged injection Defective or clogged injection nozzle mene 99 J OK v Overhead adjustments are not correct Measure and adjust the overhead settings OK v Me EU Inspect the rocker levers rocker shafts and Overhead components are damaged valves for excessive damage OK v Continued Diesel Engine 39 Troubleshooting Symptoms Excessive Noise Continued Cause Correction Injection pump is adjusted incorrectly pevesvesesesese Adjust or replace the injection pump OK v Worn piston ring or cylinder resulting in low j j FINON er Replace the worn piston ring or cylinder compression Diesel Engine 40 Troubleshooting Symptoms Engine Vibration Excessive This is symptom tree T 018 Cause Correction Engine mounting bolts are loose or the engine a JE PSA Pu Replace the
10. aligning and installing the flywheel Damage to the engine will occur if the seal is damaged NOTE Apply gasket sealant to the flywheel housing mounting surface Align the flywheel housing with the dowel pins Install the flywheel housing and capscrews Tighten the capscrews Torque Value 69 Nem 50 ft lb Measure the distance in height between the lubricating oil pan mounting surface and the flywheel housing flange Maximum Height Difference 0 15 mm 0 0059 in 00900235 Diesel Engine 67 Complete Engine Diesel Engine 00900236 00900187 00900237 00900238 ara Ray AD Ray 68 Measure the radial and face runout of the flywheel housing Radial Runout mm in 0 35 MAX 0 014 Face Runout mm in 0 30 MAX 0 012 Flywheel 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 Install the flywheel coupling retaining plate and six capscrews Tighten the capscrews Torque Value Main Bearing Flywheel Capscrews Step 1 108Nem 80 ft lb 2 191 Nem 141 ft Ib Measure the radial and face runout of the flywheel Radial Runout mm in 0 20 MAX 0 0079 Face Runout mm in 0 15 MAX 0 0059 Camshaft Assembly NOTE When installing the camshaft lightly rotate the shaft while being careful not to damage the bushing Install the thrust plate camshaft assembly and two capscrews Tighte
11. engine openings to prevent dirt and QW debris from entering the engine 00900209 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 spacer 00900157 RI Alternator Remove the adjusting capscrew and washer Remove the capscrew adjustment plate and spacer Remove the remaining capscrew and alternator Tr i PM DE I GA E ES e beh AP et t R Ya we r o 4 j i s u Ach ur yi g7 e H 4 aw ae TEN RER i ku S U a oO een af a IM YW ka Are Nea aM ay 4 War ea HEE t 2 ti iva fa La of amp 00900159 Diesel Engine 45 Complete Engine Diesel Engine x Lubricating Oil Filter Remove the lubricating oil filter OR Dipstick Guide Remove the dipstick and dipstick guide RI Water Pump Remove the mounting capscrews water pump gasket and o ring Discard the gasket and o ring 00900161 RI Thermostat Remove the two mounting capscrews thermostat housing thermostat and seal 18900025 46 Complete Engine x Exhaust Manifold Remove the eight capscrews exhaust manifold and gasket Discard the gasket 00900162 axo
12. in 0 20 mm 0 0079 in Clearance Between Bushing and Shaft End Play of Idler Gear Diesel Engine 107 Specifications Flywheel 18900013 Ref Inspection Item Standard Remarks FLYWHEEL Repair Limit 0 30 mm 0 012 in Repair Limit 0 35 mm 0 014 in Face Runout of Flywheel Housing Radial Runout of Flywheel Housing 0 0059 in Repair Limit 0 20 mm 0 079 in Radial Runout of Flywheel Repair Limit 3 Face Runout of Flywheel 0 15 mm Diesel Engine 108 Specifications Cylinder Dm Or Hu Ba 18900020 Ref Inspection Item Standard Remarks CYLINDER ID Tolerance Pore STD 95 00 mm 0 022 mm aot ae 13 740 in 0 0008 in 13 746 in Round f Cylind ounaness ot Cylinder Repair Limit 0 02 mm ERBE 0 0008 in Cylindricity of Cylinder Diesel Engine 109 Specifications Piston 18900020 Ref Inspection Item Standard Remarks PISTON Repair Limit ID ID Diameter STD 95 00 mm 3 740 in 94 85 mm 3 734 in 0 06 to 0 10 mm 2 0 mm Mu mi 0 0024 to 0 0039 in 0 079 in 0 0059 in Between 20mm Repair Limit Piston Ring second 0 079 in 0 20 mm Groove and 0 03 to 0 07 mm 0 0079 in Piston Ring 0 0012 to 0 0028 in Repair Limit 4 0 mm 0 158 in 0 15 mm l 0 0059 in Width of Groove Nominal Clearance Diesel Engine 110 Specifications Connecting Rod Piston Ring and Piston Pin Standard PISTON PIN
13. openings that Bag were installed to prevent dirt and debris from entering the engine 00900209 Diesel Engine 83 Complete Engine Diesel Engine AD 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 ara Remove the bracket Part No 3163625 from the Os engine 00900207 SK Install the starting motor NOTE The o ring is used only on wet flywheel housings 00900156 Install all the chassis components that were removed x during removal of the engine from the equipment 84 Complete Engine exc Connect the drive units to the flywheel housing and flywheel tr400wa xc 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 lubricati
14. 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 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 Complete Engine e Casting number or cast arrow on the main bearing cap must face toward the front of the engine e New main bearing mounting capscrews must be used e Coat the capscrew threads and seat face with engine oil Position the main bearing caps and capscrews CAUTION Install each thrust bearing with the oil groove on the outside Failure to do so will cause engine damage or failure CAUTION Do not let the thrust bearings slip out of place Engine damage or failure will result if the thrust bearings are not properly installed 00900219 NOTE Casting number or cast arrow on the main bearing cap must face toward the front of the engine The thrust bear
15. 00181 NOTE A noise damper is installed on some x engines The noise damper must be removed prior to removing the front oil seal Remove the front oil seal from the gear housing cover 00900182 Diesel Engine 53 Complete Engine Diesel Engine 00900183 00900184 00900185 00900186 RI Lubricating Oil Pump Remove the five capscrews and the lubricating oil pump Idler Gear Ro Remove the capscrew retainer plate and idler gear NOTE Ifa PTO is installed the idler gear uses a bearing RI Camshaft Assembly Remove the two mounting capscrews through the casting holes in the camshaft gear axo Remove the thrust plate and camshaft assembly NOTE When removing the camshaft lightly rotate the shaft while being careful not to damage the bushing 54 Complete Engine Diesel Engine 00900187 00900188 cs900wf exc 55 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 Flywheel Housing A WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component Remove the nine capscrews rear oil seal and flywheel housing Remove the rear oil seal Block Water Heater NOT
16. 108 Fraction Decimal Millimeter Conversions 117 Newton Meter to Foot Pound Conversion Garn Geet ee nt am PI nee erteilte 118 OB Pumpe 112 Pipe Plug Torque Values 00220022402200 118 PISION 222 3 lesen 110 Regulator Valve ccccsccccsseeceseeceeseeceseesseseeseas 113 Rocker Arm Shaft Push Rod and Tappets 102 Tap Drill Chart U S Customary and Metric 119 Thermostat nioe r ib 114 MSTA GEA essen nike 107 Valves Valve Guides and Springs 101 Weight and Measures Conversion Factors 120 Special Tool Special Tool ES u ek 121 Index About the Manual This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures The material in this manual covers all Signature engines The manual is divided into sections Each section is equivalent to a group used in Cummins filmcard system Some sections contain reference numbers and procedure numbers Reference numbers provide general information specifications 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 secti
17. 35 15 19 9 nb 80 5 180 33 pt 0737562ftlb 9 66 19 1 0 BEE 7 SEE 8H 20 0 0 5 tO 0 2 13w PE Pipe Plug Torque Values Size Torque Torque In Cast Iron or Thread Actual Thread O D In Aluminum Components Steel Components in in Nem ft Ib Nem 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 75 55 115 85 1 1 2 1 90 85 65 135 100 Diesel Engine 118 Specifications Tap Drill Chart U S Customary and Metric NOTE ON SELECTING TAP DRILL SIZE The tap drill size shown on this card give the theoretical tap drill size for approximately 60 and 75 of full thread depth Generally it is recommended that drill sizes be selected in the 60 range as these sizes will provide about 90 of the potential holding power Drill sizes in the 75 range are recommended for shallow hole tapping less than 1 1 2 times the hole diameter in soft metals and mild steel 119 M11x1 5 7116 14 M12x1 75 M12x1 5 M12x1 25 142 13 144 18NPT 9116 12 M34x2 M14x1 5 M14x1 25 9 16 18 VB ZINPT 48 24 M10x1 5 16 14 M11x1 5 76 20 M12x1 75 112 20 16 12 Mi4x2 M14x4 5 8 16 18 M14x1 25 11 75mm ti 50mm 29 64 15 32 12 00m 12 25mm 31 64 12 50mm 112 12 75mm 13 00mm 33 64 M24x2 1 8 M24x1 5 M25x2 1 x12 M20x1 5 1 14 M17x1 5 M18x2 5
18. 71 Complete Engine Crankshaft Pulley t Align the crankshaft pulley with the crankshaft key Install the crankshaft pulley mounting plate and capscrew Tighten the capscrew Torque Value 93 Nm 69 ft lb an a on 00900180 Lubricating Oil Suction Tube Se ed z i NA a DA Install a new o ring oil suction tube and two DELZ capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb 00900179 Lubricating 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 If the oil drain plug was removed install the drain plug Torque Value 51 Nem 38 ft lb 00900178 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 00900177 Diesel Engine 72 Complete Engine Diesel Engine 00900246 00900210 00900211 00900176 73 Fuel Injection Pump CAUTION Do not allow dirt or dust to enter the oil and fuel inlet and outlet ports Severe engine damage will occur if contaminants are allowed to enter the engine Install new o ring fuel injection pump and two mounting nuts on the adapter plate Tighten the nuts
19. AMOINS 2 2 6 SYIIDO S nun ee es ee ee 5 Engine Identification Engine Diagrams cccccceceeseeeceeeeseeeeaeeeseeeeaeeees 9 ENGINE views 9 Engine Identification 002220002200 nennen 7 Engine Dataplate 220022000222002nne nennen 7 SPEEINCAHON Sn ecke 8 Troubleshooting Symptoms Procedures and Techniques ccccceeeeseeeeeees 20 Troubleshooting Symptoms Charts 20 Coolant Contamination 2 244044444e nennen 34 E00lant Eoss anne nen 35 Coolant Temperature above Normal 38 Engine Cranks But Will Not Start No Exhaust Smoke 2 22s02222200220nne en 22 Engine Difficult to Start or Will Not Start Exhaust Smoke Continued 24 Engine Difficult to Start or Will Not Start Exhaust SMOKE un anne 23 Engine Has Poor Respones un 25 Engine Power Output Low Continued 29 Engine Power Output Low uuesseseeenseneeenennnns 28 Engine Runs Rough or Misfires 2 Engine Stops During Operation 26 Engine Vibration Excessive ccseceeseeeeeeeees 41 Engine Will Not Crank or Cranks Slowly 21 Excessive Exhaust Black Smoke 30 Excessive Noise Continued 40 Excessive NOISE 2 au era 39 Fuel consumption IS Excessive ceeeenneee 33 Lubricating Oil Consumpti
20. 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 20 Troubleshooting Symptoms Engine Will Not Crank or Cranks Slowly This is symptom tree T 002 Cause Correction Defective wiring of starting circuit fever l l including relays and switches OK v Battery voltage is low Out replace the battery OK v OK v Ring gear tooth surface is chipped or damaged tee Replace ring gear Diesel Engine 21 Troubleshooting Symptoms Engine Cranks But Will Not Start No Exhaust Smoke This is symptom tree T 003 Cause Correction Fuel level low in the tank fressen Fill the supply tank OK v Improper fuel is being used fees Drain fuel and replace with correct fuel OK v Clogged fuel tank air breather hole hrs Clean the fuel tank breather OK v Engine does start when voltage is applied to 2 j a Troubleshoot and repair the circuit wiring the fuel cut solenoid valve OK v Engine does not start when voltage is applied et ne Replace the fuel cut solenoid valve to the fuel cut solenoid valve OK v Clogged prefilter free Clean the prefilter OK v Clogged fuel filter or strainer freer Clean or replace the fuel filter or
21. E Be sure the engine coolant has been drained Disconnect the block heater electrical cord Complete Engine Loosen the block heater retaining nut Remove the block heater from the block Piston Connecting Rod Assembly Turn the cylinder block on its side with cylinders positioned horizontally 00900190 T Acaurin Be careful not to damage the inside of the cylinder Remove the carbon at the top of the cylinder using fine sandpaper Measure the side clearance of the connecting rod x with a dial gauge before removing the piston and connecting rod assembly Side Clearance mm in 0 20 MIN 0 0079 0 40 MAX 0 016 Diesel Engine 56 Complete Engine Rotate the camshaft to set the piston at bottom dead center Remove the mounting capscrews of the connecting rod cap Check the number stamped on the connecting rod cap and the cylinder The numbers must match NOTE If there is no number stamped on the connecting rod cap stamp the correct number on the camshaft end of the cap Tap the cap with a plastic hammer and remove the connecting rod cap and bearing Push a wooden bar or hammer handle through the cylinder from the lubricating oil pan side of the block Support the piston at the cylinder head side of the block and push the bar in far enough to remove the piston and connecting rod assembly Piston and Connecting Rod Assembly Disassembly Remove the snap ring on one side of the piston using pli
22. Leakage Tester ST 1273 Pressure Gauge 3162745 Injector Connector Removal tool Diesel Engine 121 Special Tools Camshaft Gear R amp I Tool Valve spring compressor Dial Bore Gauge Kit Crack Detection Kit Tube Filter Cutter Diesel Engine 122 Special Tools Injector nozzle tester Digital multimeter Fuel Pump Timing tool Digital optical tachometer Piston Ring Compressor Diesel Engine 123 Special Tools 3822476 Blow By tool use with ST111 3 3822666 Digital Thermometer Dual Input 3823137 Pistion ring expander 3164438 Depth Gauge Assembly Deo Cylinder Head Capacrew Length Gauge 3823548 se penton ang eg ey Bi ee ae 3823956 Fuel Pump Mounting Kit im m Hiit in Diesel Engine 124 Special Tools Oil Seal Sleeve Installation Tool rear Oil Seal Installation Tool Wear Sleeve Installation Tool Engine Barring Tool 3375193 Engine Rebuild Stand Diesel Engine 125 Diesel Engine 425 Special Tools Tools 3375194 Engine Rebuild Stand Portable 3163625 Bracket 3397890 Flange Puller Diesel Engine 126 Special Tools
23. Nominal OD 30 00 mm 1 181 in Ref Inspection Item Outer Diameter 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 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 o Inner Diameter Diesel Engine 111 CONNECTING ROD BEARING 57 00 mm 2 244 in 18900022 Clearance Limit 0 05 mm 0 002 in Clearance Limit 2 00 mm 0 079 in Clearance Limit 2 00 mm 0 079 in Clearance Limit 1 50 mm 0 059 in Repair Limit 0 25 0 35 mm 0 0098 0 0138 in Tolerance 0 025 mm 0 001 in Clearance Limit 0 100 mm 0 0039 in Repair Limit 57 20 mm 2 252 in Specifications Oil Pump 18900017 Ref Inspection Item Standard Remarks 0 030 to 0 085 mm Clearance Limit 0 10 mm 0 0012 to 0 0033 in 0 0039 in Radial 0 045 to 0 090 mm en na 0 0018 to 0 0035 in o Clearance of Pump Gear Diesel Engine 112 Specifications Regulator Valve re na a NINAN IVC 18900023 Ref Inspection Item Standard Remarks Standard Tolerance Standard Clearance we sh
24. RS 0390077 Diesel Engine 87 Engine Testing 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 Adjust the valve clearances for intake valves No 1 and No 3 Adjust the valve clearances for exhaust valves No 1 and No 2 Rotate the crankshaft in the normal direction one revolution Adjust the valve clearances for intake valves No 2 and No 4 Adjust the valve clearances for exhaust valves No 3 and No 4 0390078 Tighten the locknut to secure the adjustment screw Locknut Torque Value Nem ft lb 39 2 MIN 28 9 49 MAX 36 1 0390080 Diesel Engine 88 Engine Testing Complete Engine Measuring Compression Pressure A WARNING Exhaust manifold and muffler are hot Do not To avoid personal injury keep hands long hair touch the exhaust manifold or muffler or personal jewelry and loose fitting or torn clothing away injury will occur from fans and other moving parts A WARNING GR Adjust the overhead Refer to Adjusting Valve Clearance procedure Xo Remove the spill tube 0390166 Disconnect the fuel injection tubing ex NOTE Disconnect the fuel shut off solenoid Diesel Engine 89 Engine Testing ET 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 e
25. SB4135E00 Jan 2004 Service Manual B3 3 Diesel Engine Lift Trucks D20S 3 B3 3 D25S 3 B3 3 D30S 3 B3 3 D32S 3 B3 3 D33S 3 B3 3 Skid Steer Loaders 450 450Plus 460 460Plus 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 thi
26. Torque Value 31 Nem 23 ft lb Install the fuel injection pump gear washer and nut on the fuel injection pump Tighten the nut Torque Value 70 Nem 52 ft lb NOTE Align the fuel injection pump gear match mark C with the idler gear match mark C Install new o ring adapter plate fuel injection pump assembly and mounting capscrews to the gear housing Tighten the mounting capscrews Torque Value 19 Nem 14 ft lb Install the mounting capscrew on the fuel injection pump support bracket Tighten the capscrew Torque Value 19 Nem 14 ft lb NOTE The fuel supply tube has a 12 mm and 14 mm banjo fitting The 12 mm banjo fitting connects to the fuel injection pump The 14 mm banjo fitting connects to the fuel filter head which is installed later in the assembly process Install the fuel supply tube to the fuel injection pump Torque Value 20 Nm 15 ft Ib Complete Engine Cylinder Head Assembly i Ta NOTE Coat the stems of the intake and exhaust valves and the inside of the valve guides with engine oil Install the valves 00900174 AN Install the valve spring and spring seat on the valve a stem 00900173 SA Install the valve cotter into the valve stem groove lt a 7_ while compressing the valve spring with spring pusher Part No 3398179 00900172 AIN After releasing the valve spring tap the top of the OG valve stem with a plastic hammer to make certain the cotter is co
27. ach cylinder Remove the injector 0390167 compound Assemble the injector sealing sleeve a new copper sealing washer and the hold down clamp OG 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 Lubricate the sealing lips of the sleeve with anti seize U Install the adapter to the nozzle holder mounting section of the cylinder to be measured Tighten the adapter Adapter Capscrews Nem ft Ib 39 MIN 29 49 MAX 36 SE Connect the compression gauge to the adapter a NOTE Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter nab SR LER IE gt ie Fu Diesel Engine 90 Engine Testing Crank the engine with the starting motor Read the gauge when the pointer is stabilized Engine Compression kPa psi 1965 MIN 285 2944 NOM 427 Testing and Adjusting the Fan Belt Tansion Testing the Fan Belt Tension Check the amount the fan belt deflects when pushed with a force of 6 kg 13 2 Ib at a point midway between the fan pulley and the alternator pulley Fan Belt Deflection mm in 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 Using a bar raise the alternator and adjust the fan belt tension Tight
28. alfunctioning pesesesvesesese Repair or replace the injection pump OK v Worn piston ring or cylinder resulting in low SE ma imam Replace the worn piston ring or cylinder Compression Diesel Engine 25 Troubleshooting Symptoms Engine Stops During Operation This is symptom tree T 006 Cause Correction Chassis powertrain is damaged or overloaded Te Refer to the OEM s service manuals OK v Fuel level low in the tank pressen Fill the supply tank OK v Clogged fuel tank air breather hol here Clean the fuel tank breather OK v Clogged prefilter pere Clean the prefilter OK v Clogged fuel filter or strainer perjem Clean and or replace the fuel filter or strainer OK v Clogged or leaking fuel piping een Clean and repair the fuel piping OK v Feed pump piston is damaged or seized teen Replace the feed pump OK v Inspect the rocker levers rocker shafts and Overhead components are damaged valves for excessive damage Replace as necessary OK Injection pump is malfunctioning pere Replace the injection pump OK v Gear train damaged or seized pevsssesessese Refer to OEM s service manuals OK v Piston or connecting rod is damaged hemmen Replace damaged piston or connecting rod OK v Crankshaft bearing is damaged fuer Replace damaged crankshaft bearing Diesel Engine 26 Troubleshooting Symptoms Engine Runs Rough or Misfires This is symptom tree T 007 Cause Correction Fuel level low in the tank
29. alve 6 Water in Fuel Sensor WIF 3 Fuel Solenoid 7 Fuel Filter 4 Fuel Injection Nozzle 8 Hand Priming Pump Diesel Engine 14 Engine Identification a Al a 238 ew b le Pers oO amp U SK ell Fuel Injection Pump 00900150 1 Pump Holder A Fuel Inlet from Fuel Tank 2 Fuel Injection Pump Drive Gear B To Fuel Tank number of teeth 52 C To Fuel Injection Pump 3 Drive Shaft D To Fuel Injection Nozzle 4 Fuel Injection Pump Body 5 Fuel Filter Fuel Injection Pump 6 Fuel Injection Pipe No 1 e Maker Zexel 7 Fuel Injection Pipe No 2 e Type VE 8 Fuel Injection Pipe No 3 e Lubrication Method Forced Lubrication with Fuel 9 Fuel Injection Pipe No 4 10 Spill Tube Governor e Type Mechanical All speed Type Diesel Engine 15 Engine Identification Fuel 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 16 Engine Identification Car Tat Ga S PEIEE mamme SURE ee RR Cooling System 00900147 1 Radiator 6 Cylinder Head 2 Thermostat 7 Piston 3 Water Temperature Gauge 8 Cylinder Block 4 Water
30. amp the nozzle holder in a soft jawed vise and install the spindle Install the intermediate plate Diesel Engine 98 Engine Testing GTA Install the needle valve and nozzle assembly RE fi900ce ara Install the nozzle nut Ray fi9000b Diesel Engine 99 Engine Testing Lubricating System Measuring Oil Pressure ey Am 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 14900087 Diesel Engine 100 Engine Testing Specifications Valves Valve Guides and Springs Ref Inspection Item Stem Diameter Clearance Between Guide and Stem Head Thickness Valve Clearance at Cold and Warm Protrusion Above Cylinder Head Surface Diesel Engine 18900014 Standard Remarks Tolerance 0 035 mm Intake 0 0014 in 0 050 mm Nominal 0 0020 in 8mm 0 3130 in Tolerance 0 050 mm Exhaust 0 0020 in 0 065 mm 0 0026 in 0 035 to 0 065 mm intake 0 0014 to 0 0026 inj 2 Iearance Emit 0 050 to 0 080 mm on Exhaust 0 0020 to 0 0031 in eau Intake 1 40 to 1 60 mm Repair Limit
31. at Hoe fo 0m Clearance Valve and Body kratoni 0 077mm 0 020mm 0 097 mm a 0 002 in 0 0008 in 0 001 to 0 003 in 0 0008 in 0 004 in Standard Repair Limit Free Installed Installed Free Installed Length Length Load Length Load Replace 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 a Valve 301mm 278mm 202kg 1 92 kg Turbocharged 1 18 in 1 09 in 4 45 Ib 4 23 Ib Regulator Valve Set Pressure Repair or Standard 5 0 0 5 kg cm Replace Spring Diesel Engine 113 Specifications Thermostat 18900024 Ref Inspection Item Standard Remarks THERMOSTAT Cracking Temperature 82 C 2 C 180 F 2 F Fully Open Shall open fully when immersed in hot water bath at a temperature between Replace 77 C 171 F and 95 C 203 F for 4 to 5 minutes Fully Open Temperature Thermostat septa lave va Fully Open Lift Minimum 8 mm 0 315 in when immersed in a hot water bath at 95 C 203 F for 4 to 5 minutes Diesel Engine 114 Specifications Capscrew Markings and Torque Values CAUTION When replacing capscrews always use a capscrew of the same measurement and strength as the capscrew being replaced Using the wrong capscrews can result in engine damage Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
32. e referenced in the right column Step 4 The Troubleshooting Symptom Charts are based on the following assumptions 1 The engine has been installed according to the manufacturer s specifications 2 The easiest repairs are done first 3 Generic solutions cover problems with the most common applications and original equipment manufacturer OEM Diesel Engine 4 Introduction Symbols The following symbols have been used in this manual to help communicate the intent of the instructions When one of the symbols appears it conveys the meaning defined below WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed CAUSION Minor personal injury can result or a part an assembly or the engine can be damaged if the Caution instructions are not followed Indicates a REMOVAL or DISASSEMBLY step Indicates an INSTALLATION or ASSEMBLY step INSPECTION is required 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 50Ib or more To avoid personal injury use a hoist or get assistance to lift the component SIBOKLTBEFOKESD Diesel Engine 5 Introduction Illustrations Some of t
33. e of the dipstick tube CAUTION Excessive sealant can run back into the engine and cause damage to other components Install the dipstick guide Install the dipstick Complete Engine 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 Block Water Heater Clean the core plug hole thoroughly Make sure there amp are not burrs or sharp edges that might cut the o ring Lubricate the new heater o ring with clean engine oil U cs9orwa The locking channel T Bar should be threaded out to the end of the bolt If so eguipped do not remove the retaining wire used to position the channel T Bar gd cs900wg Diesel Engine 80 Complete Engine Diesel Engine SA Hook the element and one leg of the channel T Bar a into the hole as illustrated cs900wh ala Hook the other leg of the channel in the hole and DAG push the heater into the hole as far as possible by hand cs900wi Ay 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 cs9bona 81 Complete Engine Insert the power cord into the socke
34. e stamp lines by rotating the coupling AN Tighten the nut E O Torque Value 31 Nem 23 ft lb 14900072 ZN Checking and Adjusting with the Measuring 7 Device Method NOTE Set the No 1 cylinder at compression top dead center TDC by aligning the pointer on the gear cover with the TDC line on the crankshaft pulley 14900073 X Remove the distributor head bolt and copper washer from the injection pump Discard the copper washer 14900074 distributor head NOTE Check that the stylus end of the dial gauge contacts the plunger head Install the dial gauge Part No 3377259 into the 14900075 Diesel Engine 93 Engine Testing Rotate the crankshaft opposite normal engine rotation counterclockwise slightly until the dial gauge does not move any longer Set the dial gauge pointer to 0 Rotate the crankshaft in the normal direction until the dial gauge reads 1 0 0 3 mm 0 04 0 01 in Look at the pointer on the crankshaft It should point to the timing mark in degrees as stamped on the dataplate The timing marks on the crank pulley range from 6 to 14 degrees in two degree increments NOTE Check the values on the data plate Values may change as new ratings are developed NOTE The gauge reading 0 03 mm 0 001 in is equivalent to 0 5 degrees fuel injection timing NOTE The crankshaft must be rotated in the normal direction clockwise looking from the front of the engine without stopping I
35. eee Clean and repair the fuel piping OK v Feed pump is defective fressen Replace the feed pump OK v Overhead adjustments are not correct Measure and adjust the overhead settings OK v Continued Diesel Engine 28 Troubleshooting Symptoms Engine Power Output Low Continued Cause Correction Defective contact of valve or seat I PS 02 20 Replace the cylinder head Resulting in low compression OK v Turbocharger does not rotate freely messen Replace the turbocharger OK v o Replace the defective or clogged injection Defective or clogged injection nozzle nennen nozzle OK v Injection pump is malfunctioning pues Replace the injection pump OK v Worn piston ring or cylinder resulting in low lt Replace the wom piston ring or cylinder compression Diesel Engine 29 Troubleshooting Symptoms Excessive Exhaust Black Smoke This is symptom tree T 009 Cause Correction ee i We soma nn OK v Clogged air cleanerelementt pues Clean or replace the air cleaner element OK v Replace the muffler Refer to the OEM s Muffler is crushed or clogged hereeneenesesesensnenn Pr u service manual OK v Tighten the clamp between turbocharger and head Repair leaks between turbocharger and Air leakage between the turbocharger and head head OK v Exhaust leak between turbocharger and kegeetend etange gastete SEEN On em p ge g OK v Turbocharger does not rotate freely freer Replace t
36. en the adjustment capscrew and the mounting capscrew Torque Value an 31Nem 23 ft lb Capscrew gt mouatnd 66 Nem 49 ft lb NE Capscrew N EN 60900257 Diesel Engine 91 Engine Testing Fuel System Checking and Adjusting Fuel Injection Timing There are two methods for checking and adjusting the fuel injection timing of an injection pump e The MATCH MARK ALIGNMENT method which is used when the injection pump is installed on the original engine and the pump is not being repaired e The MEASURING DEVICE method which is used when a repaired or replaced injection pump is installed on the engine NOTE Diesel Engine 92 Checking and Adjusting with the Match Mark Alignment Method Set the No 1 cylinder at compression top dead center TDC by aligning the pointer on the gear cover with the TDC line on the crankshaft pulley Confirm that the mark C can be seen on the idler gear If the mark C can not be seen rotate the crankshaft one complete revolution and confirm that C can be seen Align the match mark C on the injection pump gear with the match mark C on the idler gear during installation for correct alignment Align the stamped line a on the injection pump with the stamped line b on the timing gear case during installation for correct alignment Install the injection pump Engine Testing Ro If the stamp lines are out of alignment loosen nut 7 Align th
37. engine mounting bolts or cushion mounting cushion is broken OK v o Repair the alignment Refer to the OEM s Engine and powertrain is out of alignment fu service manual OK v Gear train backlash is not adjusted Correctly Tue Adjust the backlash for the gear train OK v Inspect the rocker levers rocker shafts and Overhead components are damaged valves for excessive damage Replace as necessary OK v Cam bushing is worn hemmen Replace the cam bushing OK v Injection pump is adjusted incorrectly 1 Adjust or replace the injection pump OK v Main bearing or connecting rod is worn or l l l m Replace the connecting rod or main bearing damaged Diesel Engine 41 Troubleshooting Symptoms Complete Engine Engine Disassembly Service Tool Quantity 3375193 Unit Repair Stand or Engine Overhaul Stand or 3375194 3163625 Bracket 3163292 Valve Spring Compressor 3397890 Flange Puller 3823137 Piston Ring Expansion Tool SD Engine Removal lt 1 NOTE Put tag on all hoses lines linkage and electrical connections as they are removed to identify location and aid the installation process R 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
38. eplace the bearing Diesel Engine 36 Troubleshooting Symptoms Oil Level Rises This is symptom tree T 015 Cause Correction Rear crankshaft seal or seal surface is a 2 Repair or replace seal and surface damaged OK v Replace the auxiliary pump Refer to the OEM s Auxiliary equipment has damaged pump seal fu service manual OK v Injector sleeve is damaged prs Replace the injector sleeve OK v Fuel injector is leaking inside cylinder head teen Replace the injector OK v Injector pump seal is leaking hemmen Remove and repair the injection pump OK v Cylinder head or head gasket is cracked or i ee es Replace the cylinder head or gaeket damaged OK v Cylinder block is cracked or porous freee Replace the cylinder block Diesel Engine 37 Troubleshooting Symptoms Coolant Temperature above Normal This is symptom tree T 016 Cause Coolant level is below specification prese OK v Fan belt is slipping or the fan pulley is worn en OK gt Water temperature gauge is malfunctioning fr OK gt Radiator fin is clogged or crushed frst OK d Radiator core is clogged mm pere OK s Thermostat is defective and does not OPEN fever OK v Water pump is damaged peeeeeeeeeee OK v Cylinder head or head gasket is cracked or damaged Diesel Engine 38 Correction Inspect the engine and radiator for external coolant leaks Troubleshooting Symptoms Excessive Noise This is symptom tree
39. 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 Complete Engine RI 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 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 50 Complete Engine RI Raise the cylinder head and remove the valve NOTE Mark the valves with tags to show the place of installation and keep in a safe place 00900174 Fuel Injection Pump CAUTION Do not allow dirt or dust to enter the oil and fuel inlet and outlet ports Severe engine damage will occur if contaminants are allowed to enter the engine Remove the fuel
40. erature Above Normal Overheating or compression gases are leaking Resulting in loss through the radiator overflow OK v Je NR l Check for mixing of coolant and transmission Transmission cooler is leaking if equipped Fe fluid OK v Cylinder head gasket is leaking peeeseseseses Check or replace the head gasket OK v Cylinder head is cracked or porous freee Check or replace the cylinder head OK v Cylinder block coolant passages are leaking pevessesesen s Check or replace the cylinder block Diesel Engine 35 Troubleshooting Symptoms Lubricating Oil Pressure Is Low This is symptom tree T 014 Cause Correction Check the oil level Verify the dipstick Lubricating oil lever is below specification calibration and the oil pan capacity Fill the system to the specified level OK v Oil level or pressure sensor is damaged Te Replace the oil lever or oil pressure sensor OK v Lubricating oil filter is clogged frees Replace the filter OK v Fuel or coolant is in the lubricating oil freer Refer to Oil Level Rises symptom tree OK v Regulator or relief valve is not adjusted lt lt lt Adjust the regulator or relief valve Correctly OK v Lubricating oil pan strainer is Clogged men Clean the strainer OK v Lubricating oil suction tube is damaged Teen Repair or replace the suction tube OK v Lubricating oil pump is damaged freee Replace the oil pump OK v Main or rod bearing is worn or damaged pre R
41. ers 00900196 Remove the piston pin and separate the piston and x connecting rod NOTE If the pin does not come out place the assembly in hot water prior to disassembly 00900197 Diesel Engine 57 Complete Engine Diesel Engine Remove the snap ring on the other side of the piston using pliers 00900198 Remove the piston ring from the piston using piston ring tool Part No 3823137 00900199 If the bushing is worn the connecting rod must be replaced Inside Diameter 30 00 mm 1 18 in NOTE Keep the pistons connecting rods bearings piston rings piston pins and bushings in sets for each cylinder number Main Bearing Cap Rotate the cylinder block so that the bottom of the block is facing up 00900201 58 Complete Engine Diesel Engine eel ed Measure the end play of the crankshaft using a dial gauge NOTE The end play measurement is necessary for determining the wear of the thrust bearing and abnormal wear of the crankshaft Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 Remove the mounting capscrews of the main bearing Cap Remove the main bearing cap and lower bearing NOTE e Mark the thrust bearings so that they can be installed into the correct position e The main bearing cap mounting capscrews must SQ y be replaced after each use Q I wat SE gt am Crankshaft CAUTION Be careful not to hit the crankshaft against the cy
42. f the dial readings are not within the standard value loosen nut Adjust the fuel injection timing to within standard value by rotating the injection pump body Tighten the nut Torque Value 31 Nem 23 ft lb 14900078 Diesel Engine 94 Engine Testing Remove the dial gauge he Ke Install the distributor head bolt and new copper a ia mm MEN washer into the injection pump a MAR ete 7 SA i aTe Warf mi w lighten the bolt Torque Value 17 Nem 13 ft lb 14900074 ara Stamp a match mark on the injection pump and the timing gear case 14900080 Adjusting the Idle Move the governor control lever to the desired idling Dr speed by using the idling adjustment screw i ST 14900082 H ee te Injector Testing A WARNING grr 4 Keep your body clear of test spray Fluid can be it i injected into the bloodstream causing blood zu 5 poisoning and possible death x b YKE NOTE All nozzles must be tested for opening N pressure chatter and spray pattern KD aN fi900sa Diesel Engine 95 Engine Testing Check the opening pressure a Open valve b Operate lever at one stroke per second c Read pressure indicated when spray begins fi900de If 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 Tes
43. ferent engine models Intake Manifold Starting Motor Fuel Injection Pump Crankshaft Pulley NS Diesel Engine Intake Side Naturally Aspirated 00900138 5 Fan 6 Fuel Filter 7 Oil Fill Cap 9 Engine Identification Exhaust Side Naturally Aspirated 00900139 1 Oil Fill Cap 4 Dipstick 2 Thermostat Housing 5 Oil Filter 3 Alternator 6 Exhaust Manifold Diesel Engine 10 Engine Identification Front View Naturally Aspirated 00900140 Rear View Naturally Aspirated 00900141 Diesel Engine 11 Engine Identification 12 Oil Strainer Oil Pump Oil Cooler Optional Regulator Valve Oil Filter Safety Valve Crankshaft OR No Diesel Engine Sog 11 10 Error 9 Blu ale U Us I 5 es gt CIR Exhaust Side Naturally Aspirated 00900146 8 Camshaft 9 Piston 10 Intake and Exhaust Valve 11 Rocker Arm 12 Timing Gear 13 Cooling Water 12 Engine Identification Oil Pump 00900148 1 Bushing 8 Regulator Valve 2 Gear Drive number of teeth 7 9 Valve Spring 3 Pump cover 4 Oil Pump Drive Gear number of teeth 22 Oil pump 5 Driveshaft e Type Gear Type 6 Drivenshaft e Pump Speed Engine Speed x 1 182 7 Driven Gear number of teeth 7 Regulator Valve e Set Pressure 490 50kPa 71 psil Diesel Engine 13 Engine Identification Fuel System 00900149 1 Fuel Injection Pump 5 Fuel Tank 2 Overflow V
44. h of the lower bearing with the notch of the connecting rod cap Install the lower connecting rod bearing into the connecting rod cap NOTE Coat the lower bearing with engine oil SAE 30 The connecting rod cap is stamped with a number that must match both the number on the connecting rod and the cylinder in which it is being installed Install the connecting rod cap and capscrews NOTE Coat the connecting rod capscrew threads and seat face with engine oil SAE 30 Tighten the capscrews Torque Value Main Bearing Capscrews Step1 39Nem 29 ft Ib 2 Rotate 90 degrees NOTE The connecting rod capscrews can be reused five times Make a punch mark on the capscrew head each time the capscrew is used If there are already five marks on the capscrew head the capscrew must be replaced After installing the piston and connecting rod assemblies check the crankshaft for smooth rotation Measure the side clearance of the connecting rod cap Connecting Rod Cap Side Clearance mm in 0 20 MIN 0 0079 0 40 MAX 0 0160 Complete Engine Flywheel Housing i AN Install the rear seal using oil seal installer Part No a ST 972 Fill 40 to 60 percent of the space in the seal lip with grease 00900189 A WARNING This component weighs 23 kg 50 Ib or more To avoid personal injury use a hoist or get assistance to lift this component CAUTION Do not apply excessive force to the seal lip 00900188 surface when
45. haust restriction essssssssssesseeeeeeeeeee is Blake OK d en Replace the defective or clogged injection Defective or clogged injection NOZZI pevesvesesesees ae OK d Incorrect injection timing 00 pesseseevesese Adjust injection timing OK v Injection pump is adjusted incorrectly causin J Pau J ee y n ee Adjust or replace the injection pump excessive injection Diesel Engine 33 Troubleshooting Symptoms Coolant Contamination This is symptom tree T 013 Cause Correction Review the coolant change interval Drain and Coolant is rusty flush the system Fill the system with the Correct mixture of coolant and water OK v Lubricating oil cooler for powertrain is damaged Refer to the OEM s service manual OK v Cylinder head gasket is cracked or damaged fen Replace the cylinder head or gasket OK v Cylinder block is cracked or porous tte Replace the cylinder block Diesel Engine 34 Troubleshooting Symptoms Coolant Loss This is symptom tree T 013 1 Cause Correction Inspect the radiator heater hoses and connection to locate the leak If oil is present in Radiator or cab heater is leakin J the coolant check for a transmission or lubricating oil cooler leak OK v Inspect the engine and components for seal External engine leak cesoosoosoosoosoosoosoooooo I gasket or drain cock leaks OK v Review the operation for overheating and low power Refer to troubleshooting logic for Coolant Temp
46. he illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition The illustrations are intended to show repair or replacement procedures The procedure will be the same for all applications although the illustration can differ Diesel Engine th8sesa Ca8vagc Introduction Engine Identification eel Engine Dataplate Emina E T Ge H era lat 7 ate cold engine i Eeheuse Bh or Fir RN Beeren 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 gt o unless approved by Cummins Engine ZEIT 00900248 Company Inc NG Cummins Engine Company Inc 0 gngine information fF Columbus Indiana B3 ESN 47202 3005 www cummins com Gross rafed HP Aw at Ss rpm Warning Injury may result and warranty is volded If fuel rate rpm or altitudes exceed FuelRgting oooO published maximum values for this model and application This engine conforms to 1999 U S EPA and California regulations for large non road compression ignition engines as applicable This engine is certified to operate on diesel fuel PA Cert Family cold engine uropean Approval Number
47. he turbocharger OK v Defective or clogged injection nozzle em Adjust or replace the injection pump OK v Worn piston ring or cylinder blue smoke Feen Replace the worn piston ring or cylinder OK v Incorrect injection timing freee Adjust injection timing OK v Overhead adjustments are not correct fen Measure and adjust the overhead settings Diesel Engine 30 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 Tighten the capscrews pipe plugs and fittings Replace the gaskets if necessary OK v Intake system is contaminated with dust en Remove and clean intake manifold OK v Dipstick is not calibrated correctly Nee Verify the dipstick is correctly marked OK v Breather or breather hose is clogged femme Clean the breather and breather hose OK v Turbocharger compressor or turbine oil sealis lt lt lt Replace tie compressoror urbina seal Leaking OK v Rear crankshaft seal or seal surface is See Repair or replace seal and surface damaged OK v Valve stem guide or seal is damaged fee Repair or replace the damaged component OK v l l Replace the worn or broken piston ring or Worn or broken piston ring or cylinder een ander Diesel Engine 31 Troubleshooting Symptoms Lubricating Oil Contaminated This is symptom tree T 011 Cause Correction Breather or breather
48. hose is clogged fuser Clean the breather and breather hose OK v Lubricating oil filter is clogged eres Replace the filter OK v Turbocharger turbine oil Seal is damaged Fee Replace the turbine seal OK v Turbocharger turbine oil seal is damaged Emmen Replace the turbine seal OK v Turbocharger turbine ollsealis J cz Replace tie turbine seal Damaged OK v Refer to Exhaust Gas Is Black Incomplete Exhaust gas is black kassieren Combustion OK v Defective contact of valve or valve seat Dr WE 0 5 Repair the valve or valve seat resulting in low compression OK v Worn piston ring or cylinder resulting in low P U ee Replace the worn piston ring or cylinder Compression Diesel Engine 32 Troubleshooting Symptoms Fuel consumption Is Excessive This is symptom tree T 012 Cause Correction o Check and repair the accessories Refer to the Overloading from malfunctioning accessories fen l OEM s service manuals OK v Refer to the operation and maintenance Operator technique is not correct essen manual 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 manual Fuel leaks external OK v l Assure good quality No 2 diesel fuel is being Poor quality fuel or No 1 fuel is being used teen used OK v i Refer to troubleshooting logic for Exhaust Gas Intake or ex
49. ing System Naturally Aspirated Coolant Capacity Engine Only 4 5 liters 4 75 qt 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 Exhaust System Naturally Aspirated Maximum Allowable Exhaust Restriction at Rated Speed and 75 mm Hg Load with Dirty Filter Element 3 in Hg or Filter Head Must Not Exceed 3 in Hg Maximum Allowable Return Line Restriction Must Not 190 5 mm Hg Exceed 7 5 in 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 Mininum Recommended Battery Capacity with Light Accessories 1 VDG Starter IE Minimum Recommended Battery Capacity with Heavy 12 VDC Starter 730 CCA Accessories Maximum Allowable Resistance of the Starting Circuit 12 VDC Starter 0 0012 ohms Typical light accessories include Alternator small steering pump and disengaged clutch Typical heavy accessories include Hydraulic pump and torque converter Diesel Engine 8 Engine Identification Engine Diagrams Engine Views The following illustrations show the locations of the major external engine components filters and other service and maintenance points Some external components will be at different locations for dif
50. ing 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 Tighten the mounting capscrews in the order shown Torque Value Main Bearing Capscrews Step 1 113Nem 83 ft lb 2 Loosen all capscrews completely 3 132Nem 98 ft lb 00900220 After tightening the mounting capscrews make sure the crankshaft rotates smoothly 00900222 Diesel Engine 63 Complete Engine Measure the crankshaft end play using a dial indicator Crankshaft End Play mm in 0 131 MIN 0 0052 0 351 MAX 0 0138 Piston Connecting Rod Assembly Assemble CAUTION Be careful not to damage the piston or break the piston rings Install the piston rings on the piston using piston ring tool Part No 3823137 NOTE The rings must be set with the stamped mark near the end facing up The oil ring 00900223 bottom ring must be set with matching part of the expander coil and the end gap of the ring 180 degrees apart Install one snap ring on one side of the piston into the snap ring groove 00900198 NOTE The stamped F mark on the piston and the match mark or cast part number on the connecting rod must face in the same direction Assemble the piston on the connecting rod by installing the piston pin NOTE Pistons do not need to be heated prior to installing the piston pin However placing the piston in hot water pri
51. linder block and damage the sliding surface Remove the crankshaft Remove the upper main bearing NOTE Mark the main bearings and thrust bearing so that they can be installed into the correct position 59 Complete Engine RI Tappet Remove the tappet Diesel Engine 60 Complete Engine Engine Assembly Service Tools 3375193 or Unit Repair Stand or Engine Overhaul Stand 3375194 Bracket Valve Spring Compressor Piston Ring Expansion Tool Piston Ring Compressor era Setting the Unit in the Repair Stand Pe 4y Install bracket Part No 3163625 to the cylinder block 00900213 O M gt This component weighs 23 kg 50 Ib or more To ar 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 61 Complete Engine Diesel Engine 00900204 00900217 62 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 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 Align the protrusion of the upper main bearing with
52. ments are not correct fen Measure and adjust the overhead settings OK v Inspect the rocker levers rocker shafs and Overhead components are damaged valve for excessive damage Replace as necessary OK v ae Replace the defective or clogged injection Defective or clogged injection nozzle kuss nozzle OK v Injection pump is malfunctioning free Repair or replace the injection pump OK v Worn piston ring or cylinder resulting in low j i y ITOW reer Replace the worn piston ring or cylinder compression Diesel Engine 24 Troubleshooting Symptoms Engine Has Poor Respones This is symptom tree T 005 Cause Correction Clogged air cleaner element frst Clean or replace the air cleaner element OK v Clogged fuel tank air breather hole fuser Clean the fuel tank breather OK v Clogged prefilter 0 enne Clean or replace the fuel filter or strainer OK v Clogged fuel filter or strainer Fee Clean and repair the fuel piping OK v Clogged or leaking fuel piping 2 peseeessesesese Clean and adjust the overhead settings OK v Overhead adjustments are not correct een Measure and adjust the overhead settings OK v Defective contact of valve or valve seat l I I EEE Replace the cylinder head Resulting in low compression OK v Turbocharger does not rotate freely freee Replace the turbocharger OK v Replace the defective or clogged injection Defective or clogged injection nozzle been i 99 J nozzle OK v Injection pump is m
53. mpletely fitted ar AL 00900252 Diesel Engine 74 Complete Engine 00900253 SAIH ICH 0 0 9990 CR Clee Sea Ss Intake Side 00900245 00900170 Diesel Engine 75 CAUTION Remove all carbon and dirt from the contact surfaces of the cylinder block and the cylinder 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 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 NOTE Coat the capscrew threads with antifriction compound Part No 3824879 Install the cylinder head using four head capscrews as guides Install the capscrews Tighten the capscrews in the sequence shown Torque Value Cylinder Head Capscrews Step 1 69 Nem 51 ft lb 2 108Nem 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 replaced Push Rods NOTE If there is no abnormality in the pushrods install them in the same position that they were removed from during disassembly Complete Engine ot 00900251 Rocker Arm Assembly 1 Rocker Shaft 7 Cup Plug 2 Adj
54. n STD 70 000 mm Repair Limit 69 86 mm 2 756 in 2 750 in 69 75 mm Repair Limit 69 61 mm MON 2 746 in 2 741 in 69 50 mm Repair Limit 69 36 mm M j ain Journal U S 0 50 12 736 in 12 731 in 69 25 mm Repair Limit 69 11 mm a VENE 2 726 in 2 721 in 69 00 mm Repair Limit 68 86 mm SON 2 717 in 2 711 in Repair Limit 0 020 mm owes o Clear 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 U S 1 00 rend EA Repair Limit spe EY Paundness Repair Limit 0 020 mm 0 0008 in Cisarance ot Crank Piidournal 0 029 to 0 089 mm Clearance Limit 0 22 mm 0 0011 to 0 0035 in 0 0087 in Repair Limit 0 09 mm Diesel Engine 106 Specifications Timing Gear 18900018 Ref Inspection Item Standard Remarks TIMING GEAR ae Aspirated and Turbocharged 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 Limit Injection pump 0 07 mm to 0 29 mm 0 40 mm BERG OLSEN 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
55. n the capscrews through the casting holes in the camshaft gear Torque Value 19Nem_ 14 ft Ib Complete Engine Diesel Engine Measure the end play 1 of the camshaft Camshaft End Play mm in 0 150 MIN 0 0059 0 350 MAX 0 0138 00900239 Oil Pump SA lt a 7 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 0008 0 070 MAX 0 0028 00900240 Idler Gear Align the match marks of the idler gear crankshaft gear and camshaft gear The match marks are identified as follows e Crankshaft Gear and Idler Gear A e Idler Gear and Camshaft Gear B e Fuel Pump and Idler Gear C e Lower case letters identify oil pump and accessory drive which are not timed 00900241 69 Complete Engine Pa 2 z Ku y Be 2 gt 00900184 00900243 Match mark alignment afa Install the retainer plate and capscrew gt gt ay Tighten the capscrew Torque Value 110 Nem 81 ft Ib Measure the end play of the idler gear Turbocharged and Naturally Aspirated Co 0 08 mm to 0 19 mm 0 0031 in to 0 007 in 0 08 mm to 0 19 mm 0 0031 in to 0 007 in Aspirated ear and idler 0 07 mm to 0 29 mm 0 003 in to 0 011 in Camshaft gear 0 15 mm to 0 30 mm and oil pump gear 0 006 in to 0 012 in Cra
56. ng oil 07900034 Engine Oil 6 5 liters 1 7 u s gal Diesel Engine 85 Complete Engine 50 PERCENT 50 PERCENT S WATER WATER O Ak WARNING 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 Fill the engine with engine coolant lines linkage and electrical connections as they were removed to identify location during the removal process AN NOTE Remove all tags that were put on all hoses 1 _ 1 02 suit pauses t Diesel Engine 86 Complete Engine Rocker Levers Adjusting Valve Clearance gas Remove the cylinder head cover iy Rotate the crankshaft in the normal direction While watching the movement of the intake valve of No 4 cylinder bring the No 1 cylinder into compression top dead center position Align the TOP engraved mark on the crankshaft pulley 1 with pointer 2 NOTE e The engraved mark on the crankshaft pulley will read 1 4 TOP e The No 4 intake valve will start to open when the 0390076 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
57. nkshaft gear A and idler gear Camshaft gear and idler gear Injection pump Backlash C Camshaft gear 0 03mm to 0 050mm and PTO gear 0 0012 in 0 0035 in 0 015 mm to 0 050 mm Clearance Between Bushing and Shaft 0 0006 in to 0 002 in 0 03 mm to 0 09 mm Say LADE 0 0012 in to 0 0035 in Diesel Engine 70 Replacement Limit 0 40 mm 0 0157 in Replacement Limit 0 10 mm 0 0039 in Replacement Limit 0 20 mm 0 0079 in Complete Engine Temporarily position the fuel injection pump assembly and measure the backlash of the gears Measure the backlash of all the gears with a dial indicator Gear Housing Cover NOTE A noise damper is installed on some engines The noise damper must be installed prior to installing the front oil seal Install the front oil seal using tool Part No 3824498 Fill 40 to 60 percent of the space in the seal lip with grease 00900182 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 00900181 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 Diesel Engine
58. 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 25 x 25 546 18 1 1 2 Major thread diameter in Inches Number of threads per inch Length in inches Major thread diameter in millimeters Distance between threade in millimeters Length in millimeters 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 Ib Capscrew Markings and Torque Values Metric Commercial Steel Class 8 8 10 9 12 9 Capscrew Head Markings FP Body Size Torque Torque Torque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm Nem ft lb Nem ft lb Nem ft lb Nem ft lb Nem ft lb Nem ft lb 6 9 5 7 4 13 10 7 4 14 9 7 4 7 14 9 11 7 18 14 11 7 23 18 11 7 8 23 17 18 14 33 25 18 14 40 49 18 14 10 45 33 30 25 65 50 30 25 70 50 30 25 12 80 60 55 40 115 85 55 40 125 95 55 40 14 125 90 90 65 180 133 90 65 195 145 90 65 16 195 140 140 100 280 200 140 100 290
59. on are in numerical order However the repair steps within a given procedure are organized in the order the repair must be performed regardless of the numerical order of the steps The user must use the Section Contents pages or the Index at the back of the manual to locate specific topics when not using the troubleshooting trees How to Use the Manual This manual is organized to provide an easy flow from problem identification to problem correction A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms Section TS The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair Complete the following steps to locate and correct the problem Step 1 Locate the symptom on the Section Contents pages of Section TS Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title Step 2 The left column of boxes in the Troubleshooting Symptom Charts indicates a 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 procedur
60. on Excessive 31 Lubricating Oil Contaminated 32 Lubricating Oil Pressure Is Low 36 Oil Level RISS erissa 37 Complete Engine Complete Engine see a ee ee Re ee ee eko ee ee kak aan ee 42 Engine Assembly cccccccssseeceeeeeceseeseeeeeseaees 61 Engine Disassembly ccccccccseeeeeeeeeeeeeeeeeaees 42 Diesel Engine Engine Testing Complete Engine ccccccsssceecsseseeceeeseeseeeeeeees 89 Measuring Compression Pressure 89 Testing and Adjusting the Fan Belt Tansion 91 Fuel Systems 92 Checking and Adjusting Fuel Injection Timing 92 IN SCOP ne een 95 ASSEMDIV taken 98 DISASSEMRIV eine 97 TESNO nen aana e a 95 Lubricating SYSteM cccccceceeeeeseeeesseeeeneeeesees 100 Measuring Oil Pressure c ccccceeeeeeeeeeeeeees 100 Rocker Levers ccccccccsecccececeeeceeeceueeseeeseueesaues 87 Adjusting Valve Clearance unn 87 Specifications Camshaft and Camshaft Bushing 105 Capscrew Markings and Torque Values Metric 115 Capscrew Markings and Torque Values U S CUSTOMARY raten endive 116 Capscrew Markings and Torque Values 115 Connecting Rod Piston Ring and Piston Pin 111 CRANKS aN sest stere ea 106 Cylinder Block erea a aa 104 Cylinder Head sicrie ankerren ir ena 103 Oe lg elo ae eee ee 109 PIV WICC sels st EP avs eine
61. or to installing the pin will ease the installation 00900197 Diesel Engine 64 Complete Engine 4 7 ANA KONO Diesel Engine SA Install the other snap ring into the snap ring groove QY NOTE Make sure the connecting rod moves freely forward and backward after installing the a last snap ring 00900196 AN Locate the end gaps of the piston rings as shown OG 1 Top Ring 2 Second Ring E 3 Oil Ring 4 Part Number Mark EXXXX XXXX Last Four Digits of the Part Number NA or T NA Naturally Aspirated T Turbocharged 00900225 Ca NOTE Align the notch of the upper bearing with the br notch of the connecting rod Install the upper connecting rod bearing into the connecting rod 00900226 NOTE Coat the inside face of the cylinder the piston rings and the surface of the connecting rod bearing with engine oil SAE 30 Install the piston and connecting rod assembly with the F mark on the piston facing the front of the engine NOTE The connecting rods are stamped with the number of the cylinder in which they are to be installed This match mark must be on the camshaft side of the engine after installation 00900228 Set the crankshaft pin to bottom dead center Install the piston and connecting rod assembly from the top of the cylinder block using piston holder Part No 3397773 65 Complete Engine gt Diesel Engine 66 Align the notc
62. s product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on the product and in this publication DAEWOO 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 DAEWOO 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 DAEWOO dealers have the most current information available Index Introduction About the Manual ccccssecseeeseseeeeeeseeeseeens 4 How to Use the Manual cccccseeeeseeeeeeeeeees 4 IIS P
63. sembly Install the injector washer and mounting capscrew Tighten the capscrew Torque Value 44 Nem 33 ft lb Complete Engine GA Spill Tube VG Er 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 blow compressed air through it to clean it Position the fuel injection tubing and loosely install the sleeve nuts on the fuel injection pump and the cylinder head Tighten the clamp Tighten the banjo fittings Torque Value 20 Nm 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 78 Complete Engine Diesel Engine 18900025 00900161 00900160 A 66 79 Thermostat Install seal thermostat thermostat housing and two mounting capscrews Tighten the capscrews Torque Value 19 Nem 14 ft lb Water Pump Install the o ring gasket water pump and mounting capscrews Tighten the capscrews Torque Value 19 Nem 14 ft Ib Dipstick NOTE Apply Loctite sealant Part No 3375068 or equivalent to the outsid
64. strainer OK v Clogged or leaking fuel piping prem Clean and repair the fuel piping OK v Feed pump is damaged or seized peesesesesee Replace the feed pump OK v Injector are plugged fees Replace the injectors OK v Injection pump driveshaft or driveshaft key is ee zetom Repair or replace the injection pump damaged Diesel Engine 22 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke This is symptom tree T 004 Cause Correction Starting aid malfunctioning or heater mount 9 9 cesssososooooooooosoosooooo Replace the starting aid Does not become warm OK v Crank speed is too slow minimum crank ucoVNV Verify drive units are not engaged Check the Speed 150 rpm Battery and recharge or replace OK v Improper fuel is being used hereeeeseseseneesenennene Drain fuel and replace with correct fuel OK v Clogged air cleaner element peveseseseeees Clean or replace the air cleaner element OK v Clogged prefilter pere Clean the prefilter OK v Clogged fuel filter or strainer pesssesesesese Clean or replace the fuel filter or strainer OK v Leakage clogging air in fuel system preven Repair and clean the fuel filter or strainer OK v Injection pump timing is incorrect hemmen Retime the injection pump OK Continued Diesel Engine 23 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Overhead adjust
65. supply tube from the fuel injection pump 00900176 Remove the mounting capscrew from the bracket and fuel injection pump NOTE The fuel injector pump adapter plate and gear are removed as an assembly The gear can then be removed from the pump if necessary Remove the mounting capscrews of the fuel injector pump adapter plate Remove the fuel injector pump assembly adapter plate and o ring from the gear housing Discard the o ring 00900211 Remove the nut and washer from the fuel injection pump Remove the fuel injection pump gear from the fuel injection pump 00900210 Diesel Engine 51 Complete Engine Diesel Engine ax Remove the two mounting nuts fuel injection pump and o ring from the adapter plate Discard the o ring 00900246 axo PTO Shaft if applicable Remove the two capscrews flange o ring and PTO shaft 00900177 RI Lubricating Oil Pan Remove the 24 capscrews lubricating oil pan and gasket Discard the gasket 00900178 axo Lubricating Oil Suction Tube Remove the two mounting capscrews lubricating oil suction tube and o ring Discard the o ring 00900179 52 Complete Engine x Crankshaft Pulley Remove the capscrew and mounting plate ti m LE aia me ME Mk s el yo ni 111 00900180 Remove the crankshaft pulley using flange puller x Part No 3397890 00900212 x Gear Housing Cover Remove the 17 capscrews and the gear housing cover 009
66. t a Open the valve b Operate the lever to hold pressure 20 bar 290 psi below opening pressure c No drops should fall from the tip within 10 10 Seconds seconds ool 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 a fi900dd Diesel Engine 96 Engine Testing ox Disassembly Remove the copper sealing washer and discard D U fi900fb Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut Xo Remove the nozzle needle valve and intermediate plate NOTE To avoid damage place the injector nozzle and needle valve in a suitable bath of clean test oil fi900fc Remove the nozzle holder from the vise then remove Q the pressure spindle pressure spring and shims fi900fd Diesel Engine 97 Engine Testing fi900ha ea fi900ce Ray fi900ad Assembly NOTE Make sure all mating surfaces and pressure faces are clean and lubricated with fuel oil before assembly 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 Cl
67. t 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 Alternator Install the alternator and capscrew Install the spacer mounting capscrew and adjustment plate Loosely install the washer and adjustment capscrew aa a Im s ze A nn me J A Be Me KC des s tf u A 4 en 4 oa 3 a 3 pra RL 00900159 Fan Pulley Install the fan pulley GI Position the fan belt 2 into the fan pulley groove a and loosely tighten the adjustment capscrew 1 Diesel Engine 82 Complete Engine AD 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 123 ft lb Capscrew Fan Install the spacer fan four capscrews Tighten the capscrews Torque Value 31 Nem 23 ft lb 00900157 ara Remove the covers on all the engine
68. to 0 138 in l Repair Limit Judge Tolerance Valve Seat Angle N condition of contact 0 15 surface by vacuum test Diesel Engine 103 Specifications Cylinder Block 18900012 Inspection Item Standard Remarks CYLINDER BLOCK 0 00 to 0 08 mm Surface Flatness Warpage Limit 0 00 to 0 003 in 70 000 mm 2 756 in UT u UT 50 500 mm 1 988 in STD Inner Diameter of Cam Bushing Diesel Engine 104 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 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 42 69 mm Repair Limit Intake 11 681 in 42 20 mm Cam i 1 661 in Height ir Limit g 43 04 mm Repair Limit Exhaust 11 694 in 42 50 mm 1 673 in Repair Limit 0 50 mm 0 0197 in Thrust 0 150 to 0 350 mm Clearance 0 0059 to 0 0138 in CAMSHAFT BUSHING zen 0 040 to 0 140 mm s il a 0 0016 to 0 0055 in en Diesel Engine 105 Specifications Crankshaft 18900019 Ref Inspection Item Standard Remarks CRANKSHAFT mae eara 0 131 to 0 351 mm Repair Limit 0 40 mm 0 0052 to 0 0138 in 0 016 i
69. usting 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 and eight capscrews Tighten the capscrews 00900169 Torque Value 25 Nem 18 ft lb O So O Diesel Engine 76 Complete Engine O R fi9slwb N 00900167 Diesel Engine 77 re djusting Valve Clearance Adjust the valve clearance Refer to Section 14 Rocker Lever Cover Install the o ring into the rocker lever cover Install the rocker lever cover three capscrews and isolator assemblies Tighten the capscrews Torgue Value 9 Nem 7 ft lb Injector Coat the injectors with anti sieze compound Part No 3824879 before installation CAUTION Be careful not to damage the tip of the injector when installing NOTE When installing the injector clean around the injector and do not allow dust or dirt to enter the engine NOTE If there is no abnormality in the injector install it in the same position during as

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