Escolar Documentos
Profissional Documentos
Cultura Documentos
January 2004
System Operation
Testing and Adjusting
1004.4 NA Engine
6053S 01962-Up (Engine)
Important Safety Information
Most accidents that involve 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.
Improper operation, lubrication, maintenance or repair of this 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.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
Caterpillar 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 that is not specifically recommended by Caterpillar is used,
you must satisfy your self that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at anytime. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
Table of Contents
Electrical System
Systems Operation Section Alternator - Test ................................................ 63
Battery - Test .................................................... 64
Engine Design ................................................... 4 Belt Tension Chart ............................................ 64
General Information .......................................... 4 Charging System - Test .................................... 65
Fuel System ...................................................... 8 Electric Starting System - Test ......................... 66
Air Inlet and Exhaust System ............................ 11
Lubrication System ........................................... 12 Index Section
Cooling System ................................................ 14 Index ................................................................ 68
Basic Engine ..................................................... 15
Electrical System .............................................. 16
Troubleshooting
Troubleshooting ................................................ 18
Fuel System
Fuel System - Inspect ....................................... 30
Air in Fuel - Test ............................................... 30
Finding Top Center Position for No. 1 Piston ..... 31
Fuel Injection Nozzle - Test .............................. 32
Fuel Quality - Test ............................................. 36
Fuel System - Prime ......................................... 36
Fuel System Pressure - Test ............................. 37
Gear Group (Front) - Time ................................ 38
Lubrication System
Engine Oil Pump - Inspect ................................ 42
Excessive Bearing Wear - Inspect .................... 42
Excessive Engine Oil Consumption - Inspect .... 43
Increased Engine Oil Temperature - Inspect ..... 43
Cooling System
Cooling System - Check (Overheating) ............ 44
Cooling System - Inspect ................................. 45
Cooling System - Test ...................................... 46
Water Temperature Regulator - Test ................ 50
Basic Engine
Connecting Rod - Inspect ................................ 51
Connecting Rod Bearings - Inspect .................. 55
Main Bearings - Inspect ................................... 55
Cylinder Block - Inspect .................................... 55
Cylinder Head - Inspect ................................... 56
Flywheel - Inspect ............................................ 59
Flywheel Housing - Inspect .............................. 60
Gear Group - Inspect ......................................... 62
4
Engine
Systems Operation Section
When the crankshaft is viewed from the front of The crankshaft has five main journals. End play is
the engine the crankshaft rotates in the following controlled by thrust washers which are located on
direction: ................................................... Clockwise both sides of the center main bearing.
5
Engine
Systems Operation Section
Always use lift equipment of the approved type and of 3. If the engine oil is not drained prior to tilting
the correct capacity to lift the engine. It is recommended the engine or turning the engine onto a side or
that lift equipment of the type shown is used, to pro- an end surface, the engine oil from the engine
vide a vertical lift directly above the engine lift brackets. oil pan can flow into the intake manifold and
Never use a single lift bracket to raise an engine. the cylinder bores. This situation could cause a
hydraulic lock in the engine. Hydraulic lock can
Check the engine lift brackets for damage and that they damage the engine.
are secure before the engine is lifted. The torque for
the setscrews for the engine lift brackets is 44 Nm ( 33 4. The engine oil should be refilled to the correct
lbf ft ). level before the engine is started.
6
Engine
Systems Operation Section
Illustration 3 (Typical)
(1) Water temperature regulator housing (7) Fan drive housing (12) Engine oil level gauge
(2) Valve mechanism cover (8) Water pump (13) Engine oil filter
(3) Engine oil filler cap (9) Fuel injection pump
(4) Fuel injection nozzle (10) Crankshaft pulley
(5) Fuel filter (11) Engine oil cooler
7
Engine
Systems Operation Section
Illustration 4 (Typical)
Fuel System
SMCS Code: 1250
Illustration 5
1. Fuel tank 6. Fuel supply line from feed pump to fuel filters 11. Fuel injection nozzle
2. Fuel line from fuel tank to water separator 7. Fuel filters with base 12. Over flow pipe line
3. Water separator 8. Fuel supply line from filters to fuel injection pump 13. Fuel return line to tank
4. Fuel line from water separator to fuel feed pump 9. Fuel injection pump
5. Fuel feed pump 10. High pressure fuel lines to fuel injection nozzles
9
Engine
Systems Operation Section
While the engine is running, fuel is pulled from fuel Fuel Injection Nozzle
tank (1) by fuel transfer pump (5). Fuel transfer
pump (5) sends the fuel at a low pressure to fuel
filter base (7). The fuel then passes through fuel
supply line (8) to fuel injection pump (9). Fuel
injection pump (9) sends fuel through high pressure
fuel lines (10) to each fuel injection nozzle (11). Fuel
injection nozzle (11) sprays fuel into the cylinder.
The fuel that is not used by the fuel injection nozzles
passes through fuel return line (12) from the fuel
injection nozzles to fuel injection pump (9). The fuel is
then sent back to the fuel tank through fuel line (13).
Illustration 7
Typical example of the fuel injection pump components
(1) Control lever
(2) Bleed screw
(3) Feed pump
(4) Drive shaft
(5) Delivery valve holder
(6) High pressure pipe union nut
(7) Governor
Air Inlet and Exhaust System The valve mechanism cover contains an open
breather assembly. This device vents the gases,
which are caused by blowby, from the valve
SMCS Code: 1050 mechanism cover to the outside air. The breather
reduces emissions without reducing the power of
Naturally aspirated engines pull outside air through the engine.
an air cleaner directly into the inlet manifold. The
air flows from the inlet manifold to the engine
cylinders. The fuel is mixed with the air in the engine
cylinders. After the fuel combustion occurs in the Cylinder Head And Valves
engine cylinder, the exhaust gases flow directly to
the outside air through the exhaust manifold and
the exhaust system.
1. Intake
2. Compression
3. Power
Illustration 8 (Typical)
The mixture of air and fuel ignites at the top of
Cross section of the inlet valve and the exhaust valve in the
the compression stroke. The expansion of gases cylinder head
from the combustion forces the piston down
ward. This force creates the power of the engine.
4. Exhaust
Crankshaft
Idler gear
Camshaft
Valve lifters
Pushrods
Rocker arms
Valve springs
Illustration 10
Engine oil flow of the lubrication system
(1) Reduced oil pressure (5) Engine oil pump
(2) Splash lubrication (6) Suction line
(3) Full oil pressure (7) Engine oil cooler
(4) Coolant lines (8) Engine oil filter
Pressure for the lubrication system is supplied by The inner rotor has six lobes that mesh with the
a gerotor type pump (5) for engine oil. The engine seven lobes of the outer rotor. When the inner
oil pump is driven through an idler gear from the lobe rotates, the distance increases between the
crankshaft gear. The engine oil pump has an inner lobes of the outer rotor and the lobes of the inner
rotor and an outer rotor. The axes of rotation of the rotor in order to create suction. When the distance
rotors are off-center relative to each other. There is decreases between the lobes, pressure is created.
a key between the inner rotor and the drive shaft.
14
Engine
Systems Operation Section
Engine oil from the engine oil pan flows through Cooling System
a strainer and suction line (6) into the inlet of the
engine oil pump. The engine oil flows from the outlet
side of the engine oil pump through a line to an oil SMCS Code: 1350
pressure relief valve. The oil pressure relief valve
is installed near the bottom of the left side of the The coolant flows from the bottom of the radiator
cylinder block. to the gear-driven centrifugal water pump. The
water pump is installed on the front cover. The fuel
The oil pressure relief valve on the engine oil pump injection pump gear drives the gear of the water
opens if the engine oil pressure is too high. The pump.
engine oil is returned to the engine oil pan after the
engine oil flows through the oil pressure relief valve. The water pump forces the coolant through a
If the engine is equipped with an engine oil cooler passage in the front cover to the front of the cylinder
(7), the engine oil will flow from the oil pressure block. The coolant flows to a passage in the left
relief valve of the engine oil pump to the engine side of the cylinder block. The coolant then flows to
oil filter. The engine oil flows through the engine the rear of the cylinder block.
oil cooler. The engine oil cooler is cooled by the
water/antifreeze coolant that flows through coolant The engine oil cooler is installed on the left side of
lines (4). the engine. A line is connected between the housing
of the water temperature regulator and the engine
Engine oil cooler (7) and engine oil filter (8) are oil cooler. Some of the coolant from the water pump
installed on the left side of the cylinder block. flows through this line to the following components:
The engine oil flows from the engine oil filter through The plates in the engine oil cooler
a passage drilled across the cylinder block to the
engine oil gallery. The oil gallery is drilled through A line to the cylinder block
the total length of the left side of the cylinder block. The coolant passages for the cylinders
Engine oil flows from the engine oil gallery through The cylinder head
oil passages at full oil pressure (3) to the main
bearings of the crankshaft. The engine oil then flows The coolant exits the cylinder head at the front.
through passages in the crankshaft to the large end The coolant then flows into the water temperature
bearings of the connecting rod. The pistons and the regulator housing. If the water temperature regulator
cylinder bores are lubricated by splash lubrication is closed, the coolant goes directly through a
(2) and the mist of the engine oil. bypass to the inlet side of the water pump. If the
water temperature regulator is open, the bypass
Engine oil flows from the main bearings to the is closed and the coolant flows to the top of the
camshaft bearings through oil passages in the radiator.
cylinder block. The engine oil flows from the center
camshaft bearing journal through an oil passage The water temperature regulator opens fully when
in the cylinder block. The engine oil flows through the engine reaches normal operating temperature.
the passage in the cylinder block to the cylinder When the water temperature regulator is fully open,
head. The engine oil then flows into the rocker arm the flow to the radiator is maximum. However, the
shaft at a reduced oil pressure (1) to the rocker arm water temperature regulator does not close the flow
levers. The valve stems, the valve springs and the of coolant into the cylinder head.
valve lifters are lubricated by splash lubrication (2)
and the mist of the engine oil.
The cylinder head assembly has one inlet valve and A piston and connecting rod are matched to each
one exhaust valve for each cylinder. the inlet valve cylinder. The piston height is controlled by the
and the exhaust valve are controlled by a pushrod length of the connecting rod. Six different lengths
valve system. Each valve has double valve spring of connecting rods are available in order to attain
and an oil seal. The valve and the valve spring are the correct piston height. The different lengths
held in position by a valve spring cap and two of connecting rods are made by machining the
collets. The oil seal fits over the top of the valve small end bearing off-center in order to form an
guide. eccentric bearing. The amount of the eccentricity
of the bearing creates the different lengths of the
The ports for the inlet and for the exhaust valves are connecting rods. The piston heights match specific
on the right side of the cylinder head. lengths of connecting rods.
Illustration 11
Illustration 12
Starting Motor
Alternator
(1) Terminal for connection of the battery cable
(1) Shaft for mounting the pulley
(2) Terminal for connection of the ignition switch
The starting motor turns the engine flywheel. The The alternator produces the following electrical
rpm must be high enough in order to initiate a output:
sustained operation of the fuel ignition in the
cylinders. Three-phase
The starting motor has a solenoid. When the ignition Full-wave
switch is activated, voltage from the electrical Rectified
system will cause the solenoid to move the pinion
toward the flywheel ring gear of the engine. The The alternator has brushes. The alternator is an
electrical contacts in the solenoid close the circuit electro-mechanical component. The alternator is
between the battery and the starting motor barely driven by a belt from the fan drive pulley. The
before the pinion engages the ring gear. This alternator charges the storage battery during the
causes the starting motor to rotate. This type of engine operation.
activation is called a positive shift.
The alternator is cooled by an external fan which
is mounted behind the pulley. The fan forces air
through the holes in the front of the alternator.
The air exits through the holes in the back of the
alternator.
17
Engine
Systems Operation Section
The alternator converts the mechanical energy This heat causes a distortion of the metal disc. This
and the magnetic energy into alternating current distortion causes the contact points to open the
and voltage. This conversion is done by rotating a circuit. A circuit breaker that is open can be reset
direct current electromagnetic field on the inside of when the metal disc becomes cooler. Push the reset
a three-phase stator. The electromagnetic field is button (1) in order to close the contact points and
generated by electrical current flowing through a reset the circuit breaker.
rotor. The stator generates alternating current and
voltage.
Circuit Breakers
Illustration 13 (Typical)
Circuit Breaker With Reset Button
The list of problems, causes and corrections will Make sure that the gaskets, the insert and
only give an indication of the location of a possible the mating surface of the cylinder head are
problem. There is also a list that shows some of the clean. Make sure that the fuel injection nozzle is
repairs that are required. tightened to the correct torque in the threaded
hole of the cylinder head.
Sometimes additional repair work is required beyond
the repair which is recommended. Frequently, a 2. Make sure that extra gaskets were removed from
problem does not exist in isolation. The problem the threaded recess in the cylinder head for the
can be a result of wear or of damage to several fuel injection nozzle. Debris exists on the mating
parts which operate together as part of a system. surface of the cylinder head with the gaskets
or the insert.
Service personnel may remember similar complaints
which were corrected by a previous method of Remove any extra gaskets or debris.
troubleshooting. A similar complaint can have a
different cause. 3. The connections of the high pressure fuel line
leak.
Get a good description of the problem from the
operator and/or the person that owns the vehicle. Tighten the fittings of the high pressure fuel line.
Knowing the details of the problem can save time.
This will make the repair job faster and easier. 4. The fuel injection nozzle does not operate
correctly.
All possible problems and the probable causes
cannot be listed. The technician must follow a Make sure that the components of the fuel
logical process of eliminating possible causes and injection nozzle are tightened to the correct
of identifying the specific causes of the problems. torques. Make sure that the gaskets and the
insert are positioned correctly. Test the fuel
Troubleshooting The Fuel Injection injection nozzle on a nozzle tester in order to
measure the pressure setting.
Nozzles On The Engine
5. The incorrect fuel injection nozzle is installed.
Note: Be careful when you are handling the fuel
injection nozzles in order to prevent damage to the Make sure that all fuel injection nozzles are the
orifices, the threads, and other surfaces. When a correct replacement parts for the engine. Refer
fuel injection nozzle is installed, make sure that all to the Parts Manual for the correct replacement
surfaces and threads are clean. part.
19
Engine
Testing and Adjusting Section
Problem 2: Too much black smoke. Problem 4: The engine has the following
Probable Cause
symptoms:
The engine knocks.
1. Extra gaskets were not removed from the
threaded recess in the cylinder head for the fuel The engine runs uneven.
injection nozzle. Debris exists on the mating The engine misfires.
surface of the cylinder head with the gaskets
or the insert. Probable Cause
Remove any extra gaskets or debris. 1. The fuel injection nozzle does not seal in the
cylinder head.
2. The fuel injection nozzle does not operate
correctly. Refer to Problem 1.
Refer to Problem 1. 2. Extra gaskets were not removed from the
threaded recess in the cylinder head for the fuel
3. The incorrect fuel injection nozzle is installed. injection nozzle. Debris exists on the sealing
surface for the fuel injection nozzle.
Make sure that all fuel injection nozzles are the
correct replacement parts for the engine. Refer Remove any extra gaskets or debris.
to the Parts Manual for the correct replacement
part. 3. The connections of the high pressure fuel line
leak.
Problem 3: The engine has lost power
and the engine uses too much fuel. Tighten the fittings of the high pressure fuel line.
Remove any extra gaskets or debris. 6. A restriction exists in the high pressure fuel line.
3. The connections of the high pressure fuel line Inspect all high pressure fuel lines for damage.
leak.
Troubleshooting Fuel Injection
Tighten the fittings of the high pressure fuel line.
Nozzles On A Nozzle Tester
4. The fuel injection nozzle does not operate
correctly. Note: Be careful when you are handling the fuel
injection nozzles in order to prevent damage to the
Refer to Problem 1. orifices, the threads, and other surfaces. When a
fuel injection nozzle is installed, make sure that all
Test the fuel injection nozzle on a nozzle tester. surfaces and threads are clean.
5. The incorrect fuel injection nozzle is installed.
Only personnel that have the proper training
Make sure that all fuel injection nozzles have the should disassemble the fuel injection nozzles. Only
correct code for the engine. personnel that have the proper training should
perform repairs to the fuel injection nozzles.
6. A connection of the fuel return line leaks.
Replace the fuel injection nozzle if the fuel injection
Inspect all connections of the low pressure fuel nozzle cannot be adjusted in order to operate
line for tightening to the correct torque. correctly.
20
Engine
Testing and Adjusting Section
Problem 1: Back Leakage 4. The engine runs evenly, but the engine loses
power.
1. Fuel leaks through the threaded connection of
the body and the nozzle nut. 5. The engine lacks power.
Make sure that the threads are clean. Tighten 6. The engine has excessive vibration.
the body to the correct torque.
7. The engine has excessive combustion noise.
2. Debris or damage exists on the orifices.
8. The engine has excessive valve compartment
Visually inspect the components of the valve for noise.
carbon pitting, for scoring, or for other damage.
Clean the surface of the orifices with solvent. 9. Engine oil is in the cooling system.
Replace the fuel injection nozzles if corrosion
exists. 10. Engine knock occurs.
1. The setting of the opening pressure is incorrect. 14. The valve lash is less than the required
specification.
Test the setting of the opening pressure. Adjust
the setting to the correct pressure. 15. Engine components have early wear.
2. The fuel injection nozzle is stuck. 16. Coolant is in the lubrication oil.
Debris or damage exists on the fuel injection 17. The exhaust has too much black smoke or too
nozzle. much gray smoke.
18. The exhaust has too much white smoke or too
3. The orifices are blocked. much blue smoke.
19. The engine has low oil pressure.
Inspect the orifices for carbon buildup. The fuel
injection nozzle must be cleaned or replaced. 20. The engine oil pressure is too high.
4. The passage for the fuel return is obstructed. 21. The engine uses too much lubrication oil.
Clean the passage in order to remove any 22. The engine overheats.
carbon buildup or other debris.
23. The exhaust temperature is too high.
Troubleshooting The Engine 24. The starting motor does not turn or the starting
motor turns too slowly.
When you are troubleshooting the engine, refer to
the Specifications Module, and the Testing and 25. The starting motor turns, but the pinion gear
Adjusting Module for additional information. does not engage the flywheel ring gear.
1. The engine will not start. 26. The engine does not crank when the following
events occur:
2. The engine starts and the engine runs for a brief
period of time and the engine stops.
The starting motor is activated.
The pinion gear engages the ring gear.
3. The engine misfires or the engine runs rough.
The flywheel begins to turn.
21
Engine
Testing and Adjusting Section
27. The starting motor continues to run after the Make sure that the fuel shutoff solenoid operates
ignition switch is released. correctly. Replace a fuel shutoff solenoid that is
suspect.
28. The pinion gear does not disengage after the
engine starts to run. 8. The fuel transfer pump is not operating correctly.
The fuel transfer pump was installed when the
lobe of the camshaft was at maximum lift.
29. The alternator does not charge the battery.
Check the fuel pressure when the engine is
30. The alternator charge rate is slow or the cranking. Remove the fuel transfer pump if the
alternator charge rate is not regular. fuel pressure is too low. The fuel transfer pump
must be repaired or replaced.
31. The alternator charges the battery at a voltage
that is too high. Install the fuel transfer pump with the lobe of the
camshaft on minimum lift. Tighten the mounting
32. The alternator is noisy. bolts evenly.
Make sure that all of the fuel injection nozzles are 2. The operation of the fuel transfer pump is not
the correct type for the engine. Test the pressure correct.
setting of the fuel injection nozzles.
Refer to Problem 1.
Make sure that the fuel injection nozzles are
properly sealed in the threaded ports. Make 3. The air inlet or the exhaust system is restricted.
sure that the fuel injection nozzles are correctly Inspect the air inlet and the exhaust systems.
aligned in the threaded ports. Make sure that
the fuel injection nozzles are tightened to the Remove any restrictions.
correct torque. Ensure that the gaskets and the
4. Air is in the fuel system.
seat washers are installed on the fuel injection
nozzles correctly. Make sure that the bottom of
Find the air leak in the fuel system. Repair the
the threaded ports are clean and free of debris.
fuel system.
Make sure that the bottom of the threaded ports
do not contain extra gaskets. Problem 3: The engine misfires or the
engine runs rough.
13. The cylinders have low compression.
Probable Cause
Starting the engine may be difficult in warm
weather. The engine may not start in cold 1. The fuel pressure is low.
weather. Low compression is most frequently
caused by the following conditions: Make sure that the fuel tank has enough fuel.
Look for leaks or suspect bends in all of the fuel
Cylinder walls are worn or damaged.
supply lines. Test the outlet pressure of the fuel
Piston rings are worn or broken. transfer pump.
Ensure that the glow plugs become hot when the 6. The engine mounts are not correctly tightened or
ignition switch is in the START position. the engine mounts are not mounted correctly.
This condition also causes vibration.
Problem 2: The engine starts and the
engine runs for a brief period of time and Check the engine mounts for correct positioning.
the engine stops. Check the bolts of the engine mounts for correct
tightening.
Probable Cause
7. The fuel is contaminated with water, dirt, ice, or
1. The fuel filter or the fuel lines are restricted. wax.
Excess water has built up in the fuel filter.
Drain any water from the fuel tank and from
Check the fuel lines and the fuel filter. Replace the fuel filter. If the fuel is contaminated by
the fuel filter. Drain any water from the fuel filter. dirt, ice, or wax, replace the fuel. Refer to the
Disassembly and Assembly module.
23
Engine
Testing and Adjusting Section
8. The cylinders have low compression. 3. The governor and the fuel injection linkage is
damaged or the governor and the fuel injection
Refer to Problem 1. linkage is incorrectly assembled in the timing
gear case.
Problem 4: The engine runs evenly, but
the engine loses power. Adjust the linkage. Replace suspect parts.
5. Air is in the fuel system. 1. The bolts for the pulleys are loose.
Make sure that sufficient fuel is in the fuel tank. 3. The piston height is incorrect.
Look for leaks or suspect bends in the fuel line
between the fuel tank and the fuel transfer pump. Measure the piston height. To obtain the correct
Remove any air in the fuel system. Check the piston height, the piston, the piston pin, the
outlet pressure of the fuel transfer pump. bearings, or the connecting rod should be
replaced.
24
Engine
Testing and Adjusting Section
Problem 8: The engine has excessive Run the engine at the rpm that gives maximum
misfiring or rough running. Then, loosen a fuel
valve compartment noise. line nut on the injection line for each cylinder.
Loosen one nut at a time. Then, tighten that
Probable Cause nut before the next fuel line nut is loosened. If
loosening the fuel line nut does not affect the
1. Valve springs or locks are broken. operation of the engine, the fuel injection nozzle
is suspect. Test the fuel injection nozzle for
Install new parts. Broken locks can cause the that cylinder. Replace the suspect fuel injection
valve to slide into the cylinder. Major damage to nozzle.
the engine can occur.
Make sure that all of the fuel injection nozzles are
2. The bolts and nuts, which hold the rocker arm the correct type for the engine. Test the pressure
assembly, are loose. setting of the fuel injection nozzles.
3. The piston height is incorrect. 4. The valve lash exceeds the specification.
Check the piston height. Inspect the piston, the Measure the valve lash. Adjust the valve lash.
connecting rod, and the crankshaft for wear.
Check for correct installation. 5. The pushrods are worn.
4. The projection of the fuel injection nozzle in the If there is too much wear, install new pushrods.
Adjust the valve lash.
precombustion chamber is incorrect.
6. The valve lifters are worn.
25
Engine
Testing and Adjusting Section
If there is too much wear, install new valve lifters. Problem 15: Engine components have
Adjust the valve lash. early wear.
7. The lobes of the camshaft are worn. Probable Cause
Measure the valve lash. Check for free movement 1. Dirt is in the lubrication oil.
of the valves. Check for bent valve stems. Check
for wear on the valve lifters. Replace suspect Remove the dirty lubrication oil. Install a new oil
parts. Adjust the valve lash. filter. Put clean oil in the engine.
8. The bolts and the nuts that hold the rocker arm 2. Leaks exist in the air inlet system.
assembly are loose.
Inspect all gaskets and connections. The
Tighten the bolts and the nuts. components must be repaired or replaced.
Probable Cause Fuel leaks into the crankcase from the fuel
transfer pump.
1. The spring lock for the valve is broken.
Fuel leaks past the valve in a fuel injection
Replace the spring lock. Broken locks can cause nozzle.
the valve to slide into the cylinder. Major engine
damage can result. The pressure setting of the fuel injection
nozzles is too high.
2. The valve springs are broken or damaged. The drive is broken on the fuel injection pump.
Install new valve springs.
Adjust the component. Replace a damaged
component.
Problem 13: Oil condenses at the
exhaust.
Problem 16: Coolant is in the lubrication
Probable Cause oil.
1. The valve compartment contains too much oil. Probable Cause
Look at both ends of the rocker arm shaft. Be 1. The cylinder head gasket is suspect.
sure that a plug is installed in each end.
Install a new cylinder head gasket.
2. The valve guides are worn.
2. The cylinder head is cracked or damaged.
Install new valve guides. Recondition the cylinder
head. Install a new cylinder head.
3. The piston rings are worn. 3. The cylinder block is cracked or damaged.
Problem 14: The valve lash is less than Problem 17: The engine exhaust has too
the required specification. much black smoke or too much gray
smoke.
Probable Cause
Probable Cause
1. The valve seat or the face of the valve is worn.
1. The cylinders have low compression.
Adjust the valve lash. Refer to the Specifications
Module, Engine Design topic for the valve lash Refer to Problem 1.
setting.
26
Engine
Testing and Adjusting Section
2. The operation of the fuel injection pump is not Problem 19: The engine has low oil
correct. pressure.
Refer to Problem 1. Probable Cause
3. A fuel injection nozzle is not operating correctly. 1. The oil level is low.
Refer to Problem 1. Add oil to the correct level.
4. The inlet air is restricted. 2. The oil filter is restricted.
Check the air cleaner for restrictions. The air Install a new oil filter. Replace the lubricating oil
cleaner must be cleaned or replaced. in the engine with clean oil. Check the operation
of the bypass valve for the filter.
Problem 18: The engine exhaust has too
much white smoke or too much blue 3. Fuel is in the lubricating oil.
smoke.
Determine the source of the fuel. Refer to
Probable Cause Problem 15.
1. The engine contains too much lubrication oil. 4. Too much clearance exists between the bore of
the rocker arm and the rocker shaft.
Drain the excess oil from the oil pan.
Check for adequate lubrication of the rocker arm
2. The engine misfires or the engine runs rough. assembly. Replace parts which are worn.
Refer to Problem 3. 5. The suction pipe for the oil pump is suspect.
3. The fuel injection timing is not correct. Replace the suction pipe.
Adjust the timing of the fuel injection pump. 6. The engine oil bypass valve does not operate
correctly.
4. The valve guides are worn.
Clean the bypass valve. Replace the bypass
Replace the valve guides. Check the flatness of valve if the spring is broken or the plunger is
the cylinder head. Recondition the cylinder head damaged.
if the flatness is out of tolerance.
7. The oil pump does not operate correctly.
5. The piston rings are worn.
Check the distance of the face of the cover of
Replace the piston rings. the oil pump above the face of the idler gear.
Refer to Specifications, Engine Oil Pump.
6. The engine consistently runs below the normal Check the wear of the lobe on the oil pump. The
operating temperature. The water temperature components of the idler gear and the oil pump
regulator is suspect. must be repaired or replaced.
Replace the water temperature regulator. 8. Too much clearance exists between the
crankshaft and the crankshaft bearings.
7. The breather hose or the vent hole in the breather
assembly is obstructed. Replace the crankshaft or the crankshaft
bearings.
Clean the vent hole, the breather assembly, and
the breather hose. 9. Too much clearance exists between the camshaft
and the camshaft bearings.
Problem 20: The engine oil pressure is The water pump must be repaired or replaced.
too high. 7. The engine is operating with too much load.
Probable Cause
Reduce the load.
1. The engine oil bypass valve does not open.
8. The timing of fuel injection pump is incorrect.
The bypass valve must be cleaned or replaced.
Adjust the timing.
Problem 21: The engine uses too much
lubrication oil. 9. The oil supply line from the main oil gallery to the
cylinder head is damaged.
Probable Cause
Inspect the oil supply line for leaks or restrictions.
1. The engine contains too much lubrication oil. Make sure that the holes in the connection for
the banjo bolts are not restricted.
Drain the excess oil from the oil pan.
Problem 23: The exhaust temperature is
2. Oil lines have leaks.
too high.
Find the source of the oil leaks. Repair the line
or fitting. Probable Cause
3. The valve guides are worn. 1. A restriction exists in the air inlet or in the exhaust
system.
Refer to Problem 18.
Remove the restriction.
4. The piston rings are worn.
Replace worn parts. 2. The timing of the fuel injection pump is incorrect.
Inspect the battery cables and the battery Inspect the battery cables and battery terminals
terminals for loose connections, corrosion or for loose connections, corrosion or other
other damage. damage. Replace damaged parts.
Problem 25: The starting motor turns, 4. The overrunning clutch for the pinion drive slips.
but the pinion gear does not engage the
Replace the overrunning clutch.
flywheel ring gear.
Probable Cause
Problem 27: The starting motor continues
to run after the ignition switch is released.
1. The pinion drive or the overrunning clutch is
suspect. Probable Cause
Replace the pinion drive or the overrunning 1. The ignition switch, the start relay, or the starting
clutch. motor solenoid is suspect.
2. The ring gear of the flywheel is damaged. Replace the ignition switch, the start relay, or the
starting motor solenoid.
Replace the flywheel.
Problem 28: The pinion gear does not
3. The shift lever or the linkage is damaged. disengage after the engine starts to run.
Replace the shift lever or the linkage. Probable Cause
4. The starting motor solenoid is damaged. 1. The return spring of the pinion solenoid is
damaged.
Replace the starting motor solenoid.
Replace the return spring of the pinion solenoid.
5. The armature or idler gear of the starting motor
is damaged. 2. The shift lever or the linkage is damaged.
The starting motor is activated. Problem 29: The alternator does not
charge the battery.
The pinion gear engages the flywheel ring gear.
The flywheel begins to turn. Probable Cause
5. Inspect all cables and connections. All Problem 31: The alternator charges the
connections must be clean and tight. Apply battery at a voltage that is too high.
the 1U-8267 Battery Saver and Cleaner on the
cable terminals and the connections. Replace Probable Cause
suspect parts.
1. The alternator or the regulator has loose electrical
6. The regulator or the field winding of the rotor in connections.
the alternator are suspect.
The alternator must be repaired or replaced. Tighten all electrical connections to the alternator
and the regulator.
Problem 30: The alternator charge rate is
slow or the alternator charge rate is not 2. The regulator is suspect.
regular.
Replace the alternator.
Probable Cause
Problem 32: The alternator is noisy.
1. The drive belt for the alternator is loose.
Probable Cause
2. Inspect the drive belt for wear and for damage.
The drive belt must be adjusted or replaced. 1. The drive belt for the alternator is worn or
damaged.
3. The drive pulley for the alternator is loose or
worn. Replace the drive belt for the alternator.
Inspect the pulley for wear and for damage. 2. The drive pulley for the alternator is loose or
Tighten the nuts of the pulley to the correct worn.
torque. Replace a damaged pulley.
Inspect the pulley for wear and for damage.
4. The electrical cables and connections in the Tighten the nuts of the pulley to the correct
charging and starting circuits are loose or torque. Replace a damaged pulley.
damaged.
3. The drive belt and the drive pulley are not in
Tighten loose connections. Replace damaged alignment.
components.
Adjust the alignment.
5. Inspect all cables and connections. All
connections must be clean and tight. Apply the 4. The bearings of the alternator are worn or
1U-8267 Battery Saver and Cleaner to the cable damaged.
terminals and the connections. Replace faulty
parts. Replace the alternator.
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
4. Cut the old filter open with the 4C-5084 Oil Filter
Cutter. Inspect the filter for excess contamination.
Determine the source of the contamination. Make
the necessary repairs.
This procedure checks for air in the fuel system. 3. If excessive air is seen in the sight gauge in the
This procedure also assists in finding the source fuel return line, install a second sight gauge at
of the air. the inlet to the fuel transfer pump. If a second
sight gauge is not available, move the sight
1. Examine the fuel system for leaks. Ensure that gauge from the fuel return line and install the
the fuel line fittings are properly tightened. Check sight gauge at the inlet to the fuel transfer pump.
the fuel level in the fuel tank. Air can enter the Observe the fuel flow during engine cranking.
fuel system on the suction side between the fuel Look for air bubbles in the fuel. If the engine
transfer pump and the fuel tank. starts, check for air in the fuel at varying engine
speeds.
2. Install a 2P-8278 Fuel Flow Tube (Sight Gauge)
in the fuel return line. When possible, install the If excessive air is not seen at the inlet to the fuel
sight gauge in a straight section of the fuel line
transfer pump, the air is entering the system after
that is at least 304.8 mm (12 inches) long. Do not
the fuel transfer pump. Refer to the Testing and
install the sight gauge near the following devices
Adjusting, Fuel System - Prime.
that create turbulence:
31
Engine
Testing and Adjusting Section
If excessive air is seen at the inlet to the fuel 4. Remove the spring clip and the spacer from the
transfer pump, air is entering through the suction front of the rocker shaft. Release the fasteners of
side of the fuel system. the front two pedestals of the rocker shaft and
remove the front rocker lever; tighten the fasten-
ers of the rocker shaft pedestals.
To avoid personal injury, always wear eye and face 5. Remove the valve springs from the front valve with
protection when using pressurized air. the valve spring compressor PD.6118B and the
adaptor PD.6118-7, for pedestal studs, or the
adaptor PD.6118-8 for pedestal setscrews.
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi) CAUTION: Fit a suitable collar near the top of the
to pressurize the fuel tank. valve to hold the valve if the crankshaft is rotated too
far.
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not 6. Allow the valve to be held by the top of the
use more than 55 kPa (8 psi) in order to avoid piston.
damage to the fuel tank. Check for leaks in the
fuel lines between the fuel tank and the fuel 7. Fasten a dial test indicator with its plunger in
transfer pump. Repair any leaks that are found. contact with the top of the valve stem and with a
Check the fuel pressure in order to ensure that reading shown on the gauge. Rotate slowly the
the fuel transfer pump is operating properly. For crankshaft, clockwise from the front, until the
information about checking the fuel pressure, see clockwise movement of the dial gauge pointer
Testing and Adjusting, Fuel System Pressure just stops. Make a suitable mark on the crank
- Test. shaft pulley to align with the temporary pointer.
Continue to rotate the crankshaft, in the same
5. If the source of the air is not found, disconnect direction, until the gauge pointer just begins to
the supply line from the fuel tank and connect an move in a counter clockwise direction. Make
external fuel supply to the inlet of the fuel transfer another mark on the pulley to align with the
pump. If this corrects the problem, repair the fuel pointer. Mark the centre point between the two
tank or the stand pipe in the fuel tank. marks on the pulley and remove the other two
marks.
Special tools:
Valve spring compressor, PD.6118B
Stud adaptor for use with PD.6118B, PD6118B-7
Setscrew adaptor for use with PD.6118B,
PD.6118B-8
Set The Top Center Position By The 6. Rotate the crankshaft in a clockwise direction
by one or two degrees. Remove the spacer
Alternate Method that is between the valve stem and the rocker
arm. Rotate the crankshaft by 1/4 of a turn in a
counterclockwise direction. Put a spacer that is
approximately 5 mm (0.2 inch) thick between the
valve stem and the rocker arm.
2. Remove the valve mechanism cover. Refer to Fuel Injection Nozzle - Test
the Disassembly and Assembly Module, Valve
Mechanism Cover - Remove and Install topic. SMCS Code: 1254-081
3. Rotate the crankshaft clockwise when you face Table 1
the front of the engine. Rotate the crankshaft
Required Tools
until the pushrod for the inlet valve of the No. 4
cylinder begins to tighten. Part Part Name Qty
Number
Note: Be careful when you rotate the crankshaft. 5P-4150 Nozzle Testing Group 1
The inlet valve of the No. 1 cylinder will be held in 5P-7448 Adapter 1
position on top of the piston. If the crankshaft is 6V-2170 Tube 1
not positioned properly, the valve may fall from the
8S-2270 Fuel Collector 1
cylinder head.
1U-8857 Extension Tube 1
4. Rotate the crankshaft further by 1/4 of a turn 6V-6068 Calibration Fluid 1
in a clockwise direction. Insert a suitable lever
between the rocker arm and the valve spring
retainer of the No. 1 inlet valve. Open the inlet 1. Run the engine at low idle.
valve. Put a spacer that is approximately 5 mm
(0.2 inch) thick between the valve stem and the 2. Loosen the nut for fuel supply line at each
rocker arm. fuel injection nozzle. Listen for the low idle to
decrease or listen for the low idle to become
5. Slowly rotate the crankshaft in a counterclockwise rough at each engine cylinder.
direction until the piston makes contact with
the open valve. Make a temporary mark on 3. The fuel injection nozzle is faulty when fuel
the vibration damper or the pulley in order to supply line is loosened and the following
accurately align the tip of the pointer with the events occur:
mark on the vibration damper or the pulley.
33
Engine
Testing and Adjusting Section
3. Open the gauge protector valve. Slowly increase Fuel Injection Nozzle and Seat
the pressure until the valve in the fuel injection
nozzle opens. Note the highest pressure Test
indication on the dial indicator before the pointer
moves to 0 kPa (0 psi). This highest pressure 1. Connect fuel injection nozzle (9) to the fuel
indication is the opening pressure of the fuel injection nozzle testing group. Refer to Illustration
injection nozzle. The opening pressure is defined 16 in order to set up the fuel injection nozzle
when the needle valve is lifted from the valve testing group.
seat.
Position the fuel injection nozzle so that the
Refer to the table in the Specifications Module, direction of the fuel spray is into the 1U-8857
Fuel Injection Nozzles for correct pressure Extension Tube (11) and the 8S-2270 Fuel
settings. If the opening pressure is not within the Collector (12).
range of the setting that is specified in the table,
the fuel injection nozzle must be replaced. 2. Pump the pressure of the nozzle tester to
approximately 1030 kPa (150 psi) below the
opening pressure of the fuel injection nozzle.
Back Leakage Test Fuel should not collect on the tip of the fuel
injection nozzle in a sufficient quantity in order to
1. Connect fuel injection nozzle (9) to the fuel drip from the tip for at least ten seconds. A light
injection nozzle testing group. Refer to Illustration dampness is acceptable.
23 in order to set up the fuel injection nozzle
testing group. If the results of the tests are not acceptable,
replace the fuel injection nozzle.
Position the fuel injection nozzle so that the
direction of the fuel spray is into the 1U-8857
Extension Tube (11) and the 8S-2270 Fuel Test the Nozzle Spray Pattern
Collector (12).
If the time that is required for the pressure to The pressure adjustment must be correct before the
decrease to 0 kPa (0 psi) is less than 5 seconds, spray pattern is tested.
too much fuel is leaking around the valve needle.
Replace the fuel injection nozzle.
1. Connect fuel injection nozzle (9) to the fuel 6. Flush high pressure pipe thoroughly and connect
injection nozzle testing group. Refer to Illustration to injector.
16 in order to set up the fuel injection nozzle
testing group. Procedure for setting Injection Timing
on Engine
Position the fuel injection nozzle so that the
direction of the fuel spray is into the 1U-8857 Rotate the crankshaft till the first cylinder of the
Extension Tube (11) and 8S-2270 Fuel Collector engine is in the compression stroke (both push rods
(12). are free).
2. Close the gauge protector valve and the shutoff Align the injection timing mark on the flywheel with
valve. Open the pump isolator valve. the pointer on the clutch housing (on some engines
the timing mark is on the vibration damper/pulley and
3. Quickly pump the nozzle tester and look at the a pointer on the engine block.
spray pattern when the fluid begins to flow
through the orifices of the fuel injection nozzle. Mount the pump on the engine so that the mark on
the pump gear/coupling flywheel aligns with a pointer
The spray, which flows from all of the orifices, provided on the gear housing or on the pump. Hand
must have the same pattern. Refer to the correct tighten the mounting bolts.
spray pattern in Illustration 17. Any vertical
change or any horizontal change from the correct To check the commencement of delivery from the
spray pattern indicates a faulty fuel injection pump by spill-cut-off method, proceed as follows:
nozzle.
Remove delivery valve (DV) holder of No. 1 cylinder
Note: Be sure that the gauge protector valve is (from drive end), delivery valve pin, spring and peg.
closed before the fuel injection nozzle is removed Keep them in a clean container. Screw in the DV
from the nozzle tester. Closing the valve will prevent holder and connect a swan-neck pipe on it. Feed
damage to the pressure gauge. filtered fuel to the pump by gravity or by operating
the feed pump hand primer.
Installation of the Fuel Injection
Rotate the crankshaft in the opposite direction to a
Nozzles position slightly earlier to the commencement of
delivery. In this position, fuel should start flowing
1. The injector bore in the engine cylinder head continuously out of the swan-neck pipe. Now, rotate
must be free of carbon deposits especially at the the crankshaft in the normal direction and align the
seat. injection timing mark with the pointer. In this position,
the flow of fuel from the swan-neck pipe should
2. The nozzle body (shaft) must not come in contact reduce to approximately one drop in 10 seconds. If
with the bore in the cylinder head or the sealing
this is not achieved, swivel the pump towards or
washer where provided. This can be achieved
away from the engine to obtain the desired flow rate.
only by proper choice of fits and clearances by
the engine manufacturers and by an appropriate
aligning method. Secure the FIP mounting bolts and recheck the start
of delivery.
3. When refitting serviced / overhauled injector
replace the sealing washer, where provided with Remove swan-neck pipe and holder. Put back
a new one. Sealing washers which are likely to be delivery valve pin, spring, peg and DV holder. Tighten
deformed should not be used. Use correct the DV holder to the specified torque.
sealing washer.
Note: On pumps with RQ or RQV governor, keep the
4. Tighten the nozzle holders to the recommended control lever in the maximum position while checking
torque. Where two retaining nuts for the flange the pump timing.
mounted nozzle holders are provided tighten
them evenly to the recommended torque.
Fuel heaters
Fuel System - Prime
Blending fuel with additives
SMCS Code: 1258-548
Utilizing fuel with a low cloud point such as
kerosene
If air enters the fuel system, the air must be purged
before the engine can be started. Air can enter the
Refer to Operation and Maintenance Manual,
fuel system when the following events occur:
Fuel Recommendations for more information.
3. Check fuel API with a 5P-2712 The fuel tank is empty or the fuel tank has been
Thermometer/Hydrometer for low power
partially drained.
complaints. The acceptable range of the fuel API
is 30 to 45 when the API is measured at 15 O C The low pressure fuel lines are disconnected.
(60 O F), but there is a significant difference in
energy within this range. A leak exists in the low pressure fuel system.
The fuel filter is replaced.
A temporarily stopped system or one which has just Fuel System Pressure - Test
been put into operation should be vented with
particular care. If the feed pump is equipped with a
hand primer, the latter can be used to fill the suction SMCS Code: 1250-081; 1256-081
and supply lines, the fuel filter and injection pump.
The bleeder screws on the filter cover and on the The fuel transfer pump is located on the left side
injection pump should remain open until bubble-free of the engine.
fuel flows from all openings (control rack in STOP
position). The pressure test measures the output pressure
of the fuel transfer pump. Low fuel pressure and
After replacement of the filter insert fill the filter bowls starting difficulty may be indications of problems
again with fuel and bleed. If the system is not with the fuel transfer pump.
equipped with a feed pump with a hand primer, the
fuel is filled through the filter opening accessible after 1. Put a pressure gauge in the outlet of the fuel
removal of the filter plug. transfer pump.
The bleeder screws on the filter and on the injection 2. Disconnect the fuel injection pump solenoid wire
pump should also be opened. (if equipped). Put the fuel shutoff lever in the fuel
shutoff position.
Note: Damage to the fuel injection pump, the
battery, and the electric starting motor can occur if 3. Crank the engine for ten seconds. Record the
the electric starting motor is used excessively to maximum pressure. The pressure indication on
purge the air from the fuel system. the gauge should be in the following ranges:
The engine is now ready to start. If the engine Maximum pressure ..................... 70 kPa (10 psi)
stops or if the engine runs roughly, check for air
in the fuel system. If air is in the fuel system, Minimum pressure ..................... 30 kPa (4.5 psi)
leakage in the low pressure fuel system probably
exists. 4. Observe the amount of time for the maximum
pressure that was recorded during cranking to
Note: Operate the engine at low idle for a minimum decrease by one-half. If the time is less than
of five minutes immediately after air has been thirty seconds, the fuel transfer pump must be
removed from the fuel system. Running the engine replaced or repaired.
for this period of time will help ensure that the pump
is completely free of air. Damage to the internal 5. If the fuel pressure is less than the minimum
parts of the pump which is caused by metal to pressure, the fuel transfer pump must be
metal contact will be prevented. repaired or replaced.
Illustration 18
Hot engine components can cause injury from A very high temperature can indicate that too much
burns. Before performing maintenance on the fuel is flowing to the cylinder. A malfunctioning
fuel injection nozzle could cause this very high
engine, allow the engine and the components to
temperature.
cool.
Use the 123-6700 Laser Infrared Thermometer
to check this exhaust temperature. You can find
operating instructions and maintenance instructions
inside the Operators Manual, NEHS0630, 123-6700
Making contact with a running engine can cause
Infrared Thermometer II with Laser Sighting.
burns from hot parts and can cause injury from
rotating parts.
Compression - Test
When working on an engine that is running, avoid
contact with hot parts and rotating parts. SMCS Code: 1215
The valve lash is set correctly. Excessive dirt and oil are present on the air filter.
All fuel injection nozzles are removed. Incorrect fuel settings on the fuel injection pump.
The fuel supply is disconnected. The load capacity of the engine is frequently
exceeded.
1. Install a gauge for measuring the cylinder
compression in the hole for a fuel injection Too much valve lash can cause broken valve stems,
nozzle. valve springs, and valve spring retainers. Too much
valve lash can be an indication of the following
2. Operate the starting motor in order to turn the problems:
engine. Record the maximum pressure which is
indicated on the compression gauge. Worn camshaft and valve lifters
Table 4
To prevent possible injury, do not use the starter Valve Lash
to turn the flywheel. Valves Acceptable Clearance for Valve Lash
Inlet 0.20 mm (0.008 inch)
Hot engine components can cause burns. Allow
Exhaust 0.45 mm (0.018 inch)
additional time for the engine to cool before mea-
suring valve clearance.
Valve Lash Adjustment
If the valve lash requires adjustment several times
in a short period of time, excessive wear exists in a The valve lash is measured between the valve stem
different part of the engine. Repair the problem in and the rocker arm lever. Refer to the Systems
order to prevent more damage to the engine. Operation, Testing and Adjusting Module, Valve
Lash Check topic in this Module for the correct
Not enough valve lash can be the cause of rapid valve lash.
wear of the camshaft and valve lifters. Not enough
valve lash can indicate that the seats for the valves Note: The No. 1 cylinder is at the front of the engine.
are worn.
Lubrication System
Illustration 20
Cover of the engine oil pump Illustration 23
(1) Bolts for the cover Measure the end play of the rotor.
1. Remove the engine oil pump from the engine. 5. Measure the end play of the rotor with a straight
Remove the cover of the engine oil pump. edge and a feeler gauge.
2. Remove the outer rotor. Clean all of the parts. 6. Clean the top face of the engine oil pump and
Look for cracks in the metal or other damage. the bottom face of the cover. Install the cover on
the engine oil pump. Install the engine oil pump
on the engine.
An engine oil pressure indicator may show that there Increased Engine Oil
is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at Temperature - Inspect
the passage for the oil supply to the component. A
restriction in an oil supply passage will not allow SMCS Code: 1348-040
enough lubrication to reach a component. This will
result in early wear. When the engine is at operating temperature and
the engine is using SAE 15W40 oil, the maximum
Excessive Engine Oil oil temperature should be 110 O C (230 O F). This is
the temperature of the oil after passing through the
Consumption - Inspect oil cooler.
SMCS Code: 1348-040 If the oil temperature is high, then check for a
restriction in the oil passages of the oil cooler. A
Oil Leakage On Outside Of Engine restriction in the oil cooler will not cause low oil
pressure in the engine.
Check for leakage at the seals at each end of the
Determine if the oil cooler bypass valve is held in
crankshaft. Look for leakage at the oil pan gasket
the open position. This condition will allow the oil to
and all lubrication system connections. Look for any
pass through the valve instead of the oil cooler. The
oil that may be leaking from the crankcase breather.
oil temperature will increase.
This can be caused by combustion gas leakage
around the pistons. A dirty crankcase breather
will cause high pressure in the crankcase. A dirty
crankcase breather will cause the gaskets and the
seals to leak.
1. Check the coolant level in the cooling system. If 6. Check the filler cap. A pressure drop in the
the coolant level is too low, air will get into the radiator can cause the boiling point to be lower.
cooling system. Air in the cooling system will This can cause the cooling system to boil. Refer
cause a reduction in coolant flow and bubbles to Testing and Adjusting, Cooling System - Test.
in the coolant. Air bubbles will keep coolant
7. Check the fan and/or the fan shroud. The fan
away from the engine parts, which will prevent
shroud must be the proper size and the fan
the transfer of heat to the coolant. Low coolant shroud must be positioned correctly.
level is caused by leaks or incorrectly filling the
radiator. 8. Check for loose drive belts.
2. Check the mixture of antifreeze and water. The a. A loose fan drive belt will cause a reduction
mixture should be approximately 50 percent in the air flow across the radiator. Check the
water and 50 percent antifreeze with 3 to fan drive belt for proper belt tension. Adjust
6 percent coolant conditioner. If the coolant the tension of the fan drive belt, if necessary.
mixture is incorrect, drain the system. Put the Refer to the Testing and Adjusting Section,
correct mixture of water, antifreeze and coolant Belt Tension Chart.
conditioner in the cooling system.
b. A loose water pump drive belt will cause a
3. Check for air in the cooling system. Air can enter reduction in coolant flow through the radiator.
Check the water pump drive belt for proper
the cooling system in different ways. The most
belt tension. Adjust the water pump drive
common causes of air in the cooling system belts tension, if necessary. Refer to the
are not filling the cooling system correctly and Testing and Adjusting Section, Belt Tension
combustion gas leakage into the cooling system. Chart.
Combustion gas can get into the system through
inside cracks, a damaged cylinder head, or a 9. Check the cooling system hoses and clamps.
damaged cylinder head gasket. Air in the cooling Damaged hoses with leaks can normally be
system causes a reduction in coolant flow and seen. Hoses that have no visual leaks can soften
bubbles in the coolant. Air bubbles keep coolant during operation. The soft areas of the hose can
away from the engine parts, which prevents the become kinked or crushed during operation.
transfer of heat to the coolant. These areas of the hose can cause a restriction
in the coolant flow. Hoses become soft and/or
get cracks after a period of time. The inside of a
hose can deteriorate, and the loose particles of
the hose can cause a restriction of the coolant
flow.
45
Engine
Testing and Adjusting Section
10. Check for a restriction in the air inlet system. 18. The engine may be running in the lug condition.
A restriction of the air that is coming into the When the load that is applied to the engine is
engine can cause high cylinder temperatures. too large, the engine will run in the lug condition.
High cylinder temperatures require higher than When the engine is running in the lug condition,
normal temperatures in the cooling system. engine rpm does not increase with an increase
of fuel. This lower engine rpm causes a reduction
11. Check for a restriction in the exhaust system. in air flow through the radiator. This lower engine
A restriction of the air that is coming out of the rpm also causes a reduction in coolant flow
engine can cause high cylinder temperatures. through the system. This combination of less air
and less coolant flow during high input of fuel
a. Make a visual inspection of the exhaust will cause above normal heating.
system.
19. Timing of the engine which is incorrect may also
b. Check for damage to exhaust piping or for cause overheating of the engine. Late timing
a damaged muffler. If no damage is found, creates more heat in the engine. Early timing
check the exhaust system for a restriction. creates less heat in the engine.
12. Check the shunt line. The shunt line must be Note: If the timing of the engine is incorrect, the
submerged in the expansion tank. A restriction exhaust valves may be burned and damage to the
of the shunt line from the radiator top tank to the exhaust manifold may occur.
engine water pump inlet will cause a reduction
in water pump efficiency. A reduction in water
pump efficiency will result in low coolant flow Cooling System - Inspect
and overheating.
SMCS Code: 1350-040
13. Check the water temperature regulator. A water
temperature regulator that does not open, or Cooling systems that are not regularly inspected are
a water temperature regulator that only opens the cause for increased engine temperatures. Make
part of the way can cause overheating. Refer a visual inspection of the cooling system before any
to Testing and Adjusting, Water Temperature tests are performed.
Regulator - Test.
Cooling System - Test Personal injury can result from hot coolant, steam
and alkali.
SMCS Code: 1350-040; 1350-081
At operating temperature, engine coolant is hot
This engine has a pressure type cooling system. A
and under pressure. The radiator and all lines
pressure type cooling system has two advantages:
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
The pressure type cooling system can operate
safely at a higher temperature than the boiling
point of water at a range of atmospheric Remove filler cap slowly to relieve pressure only
pressures. when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
The pressure type cooling system prevents
cavitation in the water pump. Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
Cavitation is the sudden generation of low pressure
bubbles in liquids by mechanical forces. The The coolant level must be to the correct level in
generation of an air or steam pocket is more difficult order to check the coolant system. The engine must
in a pressure type cooling system. be cold and the engine must not be running.
Regular inspections of the cooling system should be After the engine is cool, loosen the pressure cap
made in order to identify problems before damage in order to relieve the pressure out of the cooling
can occur. Visually inspect the cooling system system. Then remove the pressure cap.
before tests are made with the test equipment.
The level of the coolant should not be more than
Remember that temperature and pressure work 13 mm (0.5 inch) from the bottom of the filler pipe.
together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
be checked. Cooling system pressure will have an
effect on the cooling system temperature. For an
example, refer to Illustration 24. This will show the
effect of pressure on the boiling point (steam) of
water. This will also show the effect of height above
sea level.
47
Engine
Testing and Adjusting Section
Table 5
Required Tools
Part Number Part Name Qty
4C-6500 Digital Thermometer 1
8T-2700 Blowby/Air Flow Indicator 1
9U-7400 Multitach Tool Group 1
9S-8140 Pressurizing Pump 1
1U-7297 Coolant/Battery Tester 1
1U-7298 Coolant/Battery Tester 1
Illustration 26
8T-2700 Blowby/Air Flow Indicator
Illustration 27
9U-7400 Multitach Tool Group
Illustration 25
The 9U-7400 Multitach Tool Group is used to
4C-6500 Digital Thermometer measure the fan speed. Refer to Operating Manual,
NEHS0605, 9U-7400 Multitach Tool Group for the
The 4C-6500 Digital Thermometer is used in the testing procedure.
diagnosis of problems that cause overheating or
overcooling in the engine. This tool can be used
to check the temperature in several areas of the
cooling system. The testing procedure is in Tool
Operating Manual, NEHS0554.
48
Engine
Testing and Adjusting Section
Table 6
Antifreeze Concentrations For Freeze Protection
Temperature Concentration
Protection to -15 O C (5 O F) 30% antifreeze and
70% water
Table 7
Required Tools
Part Number Part Name Qty
9S-8140 Pressurizing Pump 1
Illustration 29
1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery
Tester
Cooling System Conditioner contains alkali. Avoid Personal injury can result from hot coolant, steam
contact with skin and eyes. and alkali.
To check for the amount of pressure that opens the At operating temperature, engine coolant is hot
filler cap, use the following procedure: and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
1. After the engine cools, carefully loosen the filler steam. Any contact can cause severe burns.
cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap. Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
2. Inspect the pressure cap carefully. Look for enough to touch with your bare hand.
damage to the seal. Look for damage to the
surface that seals. Remove any debris on the Cooling System Conditioner contains alkali. Avoid
cap, the seal, or the sealing surface. contact with skin and eyes.
Carefully inspect the filler cap. Look for any
damage to the seals and to the sealing surface. 1. When the engine has cooled, loosen the filler cap
Inspect the following components for any foreign to the first stop. Allow the pressure to release
substances: from the cooling system. Then remove the filler
cap.
Filler cap
2. Make sure that the coolant covers the top of the
Seal radiator core.
Surface for seal 3. Put the 9S-8140 Pressurizing Pump onto the
radiator.
Remove any deposits that are found on these
items, and remove any material that is found on 4. Use the pressurizing pump to increase the
these items. pressure to an amount of 20 kPa (3 psi) more
than the operating pressure of the filler cap.
3. Install the pressure cap on the 9S-8140
Pressurizing Pump. 5. Check the radiator for leakage on the outside.
4. Observe the exact pressure that opens the filler 6. Check all connections and hoses of the cooling
cap. system for leaks.
5. Compare the pressure to the pressure rating that The radiator and the cooling system do not have
is found on the top of the filler cap. leakage if all of the following conditions exist:
6. If the filler cap is damaged, replace the filler cap. You do NOT observe any leakage after five
minutes.
The inside of the cooling system has leakage 3. Heat the water in a container. Stir the water
only if the following conditions exist: in order to keep all of the water at the same
temperature.
The reading on the gauge goes down.
4. Replace the water temperature regulator if the
water temperature regulator does not open at the
You do NOT observe any outside leakage. temperatures that are found in Specifications,
Water Temperature Regulator.
Make any repairs, as required.
NOTICE
All water is corrosive at engine operating temperature.
The cooling system should be protected with a 3% to
6% concentration of cooling system conditioner at all
times.
Basic Engine
Note: If the crankshaft or the cylinder block are Put the piston height tool on the face of the cylinder
replaced, the piston height for all cylinders must be block and rotate the gauge dial to the zero position.
measured. The grade of length of the connecting Rotate the crankshaft until the piston is approxi-
rods may need to be changed in order to obtain mately at top dead centre (TDC). Carefully put the
the correct piston height. tool over the top of the piston with the plunger of the
gauge in contact with the piston above the axis of
If the grade of length must be changed, one of the the gudgeon pin as shown. Rotate the crankshaft to
following actions must be taken: bring the piston to its highest position and make a
note of the gauge indication. The piston height above
New connecting rod assemblies that are the the face of the cylinder block should be 0.14 / 0.36
correct grade of length must be installed. Refer mm (0.005 / 0.014 in).
to Length of a Connecting Rod in this Module.
New piston pin bearings must be bored after Notes: Two "Quadram" piston heights can be used
in the factory: "H" - high grade, "L" - low grade. In
installation in the original connecting rods. Refer
service only "L" pistons are supplied. If an "L" piston
to Piston Pin Bearings in this Module.
is used instead of an "H" piston, the height may be
up to 0.19 mm (0.0075 in) below the bottom limit.
Note: When the piston pin is installed, always install
new retaining rings on each end of the piston pin. If
the piston pin cannot be removed by hand, heat the The top of the piston should not be machined.
piston to a temperature of 45 ± 5 O C (113 ± 9 O F) in
order to aid the removal of the piston pin. Heating If the original piston is used, ensure that it is
the piston to this temperature may also aid the assembled to the correct connecting rod and is
installation of the piston pin. There is a recess on used in the original cylinder.
the face of the connecting rod. The recess is for the
piston pin. The recess must always face the same
side as the bore for the journal bearing.
Special Tools:
The mark
The color
Illustration 32
Measuring the length Checking of piston ring grooves
4. Machine the ends of the piston pin to the correct 3. Remove the piston rings and clean the piston ring
length. Remove any sharp edges. Refer to the grooves and the piston rings.
Specifications Module, Connecting Rod topic
for more information. 4. Fit new piston rings in the grooves and check for
wear of the grooves with feeler gauges. Compare
the piston ring clearance in the groove to that
5. If the grade of length of the connecting rod
given for new components in the data and
is changed, the letter that is stamped on the
dimensions and renew the piston, if necessary.
connecting rod must be removed. Etch a letter
that is for the new grade of length on the side 5. Clean all carbon from the top of the cylinder
of the connecting rod. liners. Fit the piston rings in the top part of the
cylinder liner and measure the ring gap with feeler
Note: Do not stamp a new letter on the connecting gauges. The coil spring must be fitted to the oil
rod. The force of stamping could damage the control ring when the gap of this piston ring is
connecting rod. measured. The piston ring gaps for new
components are given in the data and
dimensions.
53
Engine
Testing and Adjusting Section
To ensure the best performance during the life of the A tool, known as a "Flex-Hone", is available to
engine it is important that worn or damaged cylinder correct the liner surface. This tool can be used with
liners are renewed. If a change of liner becomes an electric hand drill at low speed. The pistons and
necessary in service, a service liner is available. connecting rods must be removed and the piston
cooling jets, where fitted, must also be removed. Use
The condition of a cylinder liner is decided by: covers to protect all engine components from the
debris which is caused during the process.
1. The amount and location of any polished areas.
1. Grade 80SC Flex-Hone is to be used. A 4 inch or
2. Wear. 4 1/8 inch size Flex-Hone can be used according
to how badly the bore is glazed.
3. Damage to the liner wall. 2. New Flex-Hone must be operated in an old liner
before use on an engine to remove all loose
Notes: It will not be necessary to renew the liners if: material and sharp edges.
1. The honed finish can still be clearly seen. 3. Lubricate lightly the liner and the Flex-Hone with
clean engine lubricating oil.
2. The engine performance and oil consumption is
acceptable. 4. Put the tool in position on top of the liner, but do
not press the tool into the liner until the tool is
To check the condition of a cylinder liner operated.
1. Examine the liner surface for cracks and deep 5. Operate the tool and move it up and down the
scratches. liner bore once a second for 30-50 seconds.
Remove the tool while it rotates.
2. Check the liner wall for areas where the honed
finish has been polished away. Check especially 6. Clean thoroughly the liner bore to remove all dirt
the area around the top of the liner bore just from the operation, use a hard brush and
below the carbon ring. In this area, thrust from kerosene.
the top piston ring is at its maximum.
7. Dry the liners and remove carefully all the covers
CAUTION: used to protect the components. Clean
thoroughly all the engine components which have
1. Damaged or worn liners must be discarded. been affected by debris.
2. New piston rings must be fitted when the cylinder 8. Fit the piston cooling jets or the plugs. Ensure
liner is renewed. that new piston rings are fitted when the engine
is assembled in accordance with the relevant
3. An engine can have high oil consumption with sections of this workshop manual.
very little wear of the liner bores, if the surfaces of
the liners are glazed. CAUTION: After a glazed bore has been corrected,
these recommendations are advised for the first 240
km (150 miles) or 5 hours of operation:
Illustration 34
Measure the length of the connecting rod.
(1) Measuring pins
Illustration 35
(2) Connecting rod
(CRL) Connecting Rod Length Measure the connecting rod for distortion.
(1) Measuring pins
1. Refer to Illustration 34. Use the following tools in (2) Connecting rod
(L) The length between the center of the piston pin bearing and
order to measure the length of the connecting the center of the bearing for the crankshaft journal
rod:
2. Measure the connecting rod for distortion and
Appropriate gauges for measuring distance
parallel alignment between the bores.
Measuring pins (1)
The bores for the crankshaft bearing and the
2. Ensure that measuring pins (1) are parallel. bearing for the piston pin must be square and
CRL is measured when the bearing for the parallel with each other within the required limits.
crankshaft journal is removed and the original If the piston pin bearing is removed, the limit L
piston pin bearing is installed. is the following value: ± 0.25 mm (± 0.010 inch)
Connecting Rod Bearings - Inspect the main bearings for peeling, melting,
seizure or poor contact. If the main bearings are
Inspect worn or if the main bearings are damaged, replace
the main bearings.
SMCS Code: 1219-040
1. Measure the clearance between the main
bearings and the crankshaft journal.
Illustration 36 Table 9
Required Tools
Inspect the connecting rod bearings for peeling,
Part Number Part Name Qty
melting, seizure or poor contact. If the connecting
1P-3537 Dial Bore Gauge Group 1
rod bearings are worn or if the connecting rod
bearings are damaged, replace the connecting rod
bearings.
Table 10
Required Tools
Part Number Part Name Qty
8S-6691 Cylinder Head Repair Stand 1
3. Remove the valve springs and the valves. Measure the cylinder head for flatness.
(A) Side to side
(B) End to end
4. Clean the cylinder head thoroughly. Make sure (C) Diagonal
that the contact surfaces of the cylinder head
and the cylinder block are clean, smooth and flat.
Illustration 41 (Typical)
Diagonal
(1) Straight edge
(2) Feeler gauge
Illustration 39 (Typical)
Cylinder head on the 8S-6691 Cylinder Head Repair Stand
Illustration 42 (Typical)
Side To Side
(1) Straight edge
(2) Feeler gauge
57
Engine
Testing and Adjusting Section
8. Measure the cylinder head for flatness. Measure Note: In order to aid in the timing check of the
the flatness with a straight edge (1) and with a inlet valves and exhaust valves, the valve lash is
feeler gauge (2). increased. By loosening the tension on the No. 1
inlet valve, a more accurate determination of the
Measure the cylinder block from one end to valve lash is allowed if the mark on the crankshaft
the opposite end (B). pulley or the damper is within ±2.5 degrees of the
Measure the cylinder block from one side to pointer indicator. Refer to Step 4.
the opposite side (A).
4. Fasten a temporary pointer to the timing case
Measure the cylinder block from one corner to cover. The tip of the temporary pointer should
the opposite corner (C). be near the outer edge of the crankshaft pulley
or the damper. Make a temporary mark on the
Refer to the Specifications Module, Cylinder crankshaft pulley or the damper which aligns
Head topic for the maximum permissible amount with the temporary pointer.
of bow (curve of the cylinder head).
5. Remove the timing pin.
Resurfacing the Cylinder Head
6. When the engine is viewed from the front, rotate
The cylinder head face can be resurfaced by the crankshaft in a clockwise direction. Rotate
removing metal from the face if the following the crankshaft until the inlet valve of the rear
conditions exist. cylinder is fully open.
The cylinder head face is not flat within the 7. Set the valve lash of the No. 1 inlet valve to
specifications. 1.50 mm (0.059 inch).
The cylinder head face is damaged by pitting, 8. When the engine is viewed from the front, rotate
corrosion, or wear. the crankshaft in a clockwise direction until the
The thickness of the cylinder head must not pushrod of the inlet valve for No. 1 cylinder
be less than 102.79 mm (4.047 inch) after the begins to tighten. In this position, make sure that
cylinder head has been machined. the mark on the crankshaft pulley or the damper
is within ±2.5 degrees of the temporary pointer
If the cylinder head is resurfaced, the recesses for indicator.
the valve seat inserts must be machined to the
dimensions which are listed in the Specifications Note: Use the following formula in order to calculate
Module, Cylinder Head Valves. The valve seat the measurement which is equal to 2.5 degrees on
inserts must be ground on the side which is inserted the pulley or damper.
into the cylinder head. Grinding this surface will
Table 11
ensure that no protrusion exists above the bottom
Formula For Calculating The Measurement on
face of the cylinder head. Grind the outer edge of
The Pulley or The Vibration Damper
the cylinder head side of the valve seat insert to a
chamfer of 0.90 to 1.30 mm (0.035 to 0.051 inch) at
(C X P) / 360 = M
30 degrees to the vertical.
C is the circumference of the pulley or the vibration
Valve Tests damper.
35 mm (1.38 inch) at the circumference of a Service wear occurs on an engine which has
damper of 310 mm (12.20 inch) diameter been in operation. If the valve depth below the
cylinder head face on a used engine exceeds
37 mm (1.46 inch) at the circumference of a the specification for service wear, use new valves
damper of 327 mm (12.87 inch) diameter and valve seat inserts for replacement.
Replacing Valve Guides ( and Valve Remove all debris. Thoroughly clean the recess
Inserts - if applicable) for the valve seat insert.
Illustration 45 Illustration 46
Checking face runout of the flywheel Checking flywheel runout
1. Refer to Illustration 45 and install the dial 1. Refer to Illustration 46 and install the dial
indicator. Always put a force on the crankshaft indicator.
in the same direction before the dial indicator
is read. This will remove any crankshaft end 2. Set the dial indicator to read 0.00 mm (0.00 inch).
clearance.
3. Turn the flywheel at intervals of 90 degrees and
2. Set the dial indicator to read 0.00 mm (0.00 inch). read the dial indicator.
3. Turn the flywheel at intervals of 90 degrees and 4. Calculate the difference between the lowest
read the dial indicator. measurement and the highest measurement
of the four locations. This difference must not
4. The difference between the lower measurements be greater than 0.30 mm (0.012 inch). This
and the higher measurements that are performed dimension is the maximum permissible distance
at all four points must not be more than 0.20 mm for the outside diameter runout of the flywheel.
(0.008 inch), which is the maximum permissible
flywheel face runout.
Table 16
Bore Of The Housing Maximum Permissible
Flange Face Runout
362 mm (14.25 inch) 0.23 mm (0.009 inch)
410 mm (16.14 inch) 0.25 mm (0.010 inch)
448 mm (17.64 inch) 0.28 mm (0.011 inch)
Illustration 47 511 mm (20.12 inch) 0.30 mm (0.012 inch)
Face runout check 584 mm (22.99 inch) 0.36 mm (0.014 inch)
648 mm (25.51 inch) 0.41 mm (0.016 inch)
1. Position the magnetic base of the dial indicator
787 mm (30.98 inch) 0.48 mm (0.019 inch)
on the crankshaft flange. Position the contact
of the dial indicator on the face of the flywheel
housing.
Bore Runout (Radial Eccentricity)
2. Force the crankshaft to the rear in order to
remove the clearance for the main bearing. of the Flywheel Housing
Illustration 49
Bore runout check
Illustration 48
Locations for measuring the face runout of the flywheel housing
(A) Bottom
(B) Right side
(C) Top
(D) Left side
Illustration 50
Locations for measuring the bore runout of the flywheel housing Illustration 51
(1) Bottom (1) Camshaft gear
(2) Right side (2) Fuel injection pump gear
(3) Top (3) Crankshaft gear
(4) Left side (4) Idler gear
1. Fasten the magnetic base of the dial indicator to Note: If one or more of the gears need to be
the crankshaft flange. Adjust the contact of the removed for repair, refer to the Disassembly and
dial indicator in order to touch the bore of the Assembly Module, Gear Group (Front) - Remove
flywheel housing at location (1). Set the pointer topic in order to properly remove the gears. Refer
of the dial indicator to 0.0 mm (0.00 inch). to the Disassembly and Assembly Module, Gear
Group (Front) - Install topic in order to properly
2. Push the crankshaft to the rear in order to install the gears.
remove the main bearing clearance before the
measurement is taken at each location. 1. Inspect the gears for wear or for damage. If the
3. Turn the crankshaft. Record the dial indicator gears are worn or damaged, use new parts for
reading at locations (2), (3), and (4). replacement.
4. Calculate the difference between the lowest 2. Measure the backlash on camshaft gear (1).
measurement and the highest measurement Refer to the Specifications Module, Gear Group
of the four locations. This difference must not (Front) topic for the backlash measurement.
be greater than 0.30 mm (0.012 inch). This
dimension is the maximum permissible distance 3. Measure the backlash on idler gear (4). Refer to
for the bore runout of the flywheel housing. the Specifications Module, Gear Group (Front)
topic for the backlash measurement.
Electrical System
Alternator - Test
SMCS Code: 1405-081
Table 17
Required Tools
Part Number Part Name Qty
6V-7070 Digital Multimeter 1
8T-0900 Ammeter 1
Table 18
Fault Conditions And Possible Causes
Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the specifications Replace the alternator. Turn on all accessories. If the -
Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications. Turn
on all accessories in order to
verify that the voltage stays
within specifications.
The voltage consistently Follow the procedures that The alternator operates Replace the alternator.
exceeds specifications. are in the Tool Operating within the specifications. Inspect the battery for
Manual, SEHS7633 in order Follow the procedures in damage.
to test the battery. Test the the Tool Operating Manual,
alternator again. SEHS7633 in order to test
the battery.
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
65
Engine
Testing and Adjusting Section
Table 19
Belt Tension Chart
Gauge Reading BorroughsGauge Numbers
Initial Belt Tension(1) Used Belt Tension(2) Number of the Selected
Size of Belt Width of Belt
Gauge
3/8 10.72 mm (0.422 inch) 445 ± 22 N (100 ± 5 lb) 400 ± 22 N (90 ± 5 lb) BT-33-97
1/2 13.89 mm (0.547 Inch) 534 ± 22 N (120 ± 5 lb) 400 ± 44 N (90 ± 10 lb) BT-33-97
Measure the tension of the belt that is farthest from the engine.
Alternator Regulator
The charging rate of the alternator should be
checked when an alternator is charging the battery
too much. The charging rate of the alternator should
be checked when an alternator is not charging the
battery enough.
Illustration 52
Starting circuit for 12 volt system (typical example)
(1) Test point (4) Test point (W) Pull-in coil
(2) Test point (5) Test point
(3) Test point (X) Hold-in coil
The procedures for diagnosing the starting motor The pinion gear is engaged with the ring gear
are intended to help the serviceman determine if a of the flywheel.
starting motor needs to be replaced or repaired.
The procedures are not intended to cover all
The starting motor is rotated.
possible problems and conditions. The procedures
serve only as a guide. The most common 12 volt Problem 1: Armature does not rotate or
circuit is shown in Illustration 52.
rotates slowly, though the pinion has
engaged with the ring gear.
General Information
Probable Cause
All electrical starting systems have four elements:
Starting motor
67
Engine
Testing and Adjusting Section
3. Brushes worn out and not making proper contact Clean thoroughly deburr pinion and ring gear
with commutator dirty, oily or badly burnt com- teeth by filing.
mutator. Starter terminals or brush box having
earth fault. Defective Solenoid switch/ Armature/
Field coils.
Probable Cause
Remove by filing.
Probable Cause
1. Clutch slip.
Probable Cause
Table of Contents................................................ 3
Testing and Adjusting Section ........................... 18
Troubleshooting ................................................ 18
Introduction ................................................... 18
Troubleshooting Fuel Injection Nozzles On A
Nozzle Tester ............................................. 19
Troubleshooting Problems ............................ 21
Troubleshooting The Engine ......................... 20
Troubleshooting The Fuel Injection Nozzles On
The Engine ................................................. 18