00 E

Op~ration ~anal
.Series C6121 Diesel Engines
i21-SM-02+B

~ SHANGHAI DIESEL ENGINE CO.,LTD.

Operation Manual Of C121
Series Diesel Engine,s

121-SM-02+B

SHANGijAI DIESEL ENGINE .CO., LTD.

January 2008
 FOREWORD

SDEC s C6121 series diesel engines e the products that adopt 3300 series .diesel
engines technologies introduced from Caterpillar .Inc. of America and had been
produced under license from Caterpillar Inc. for 20 yes by the end of 2007. To meet
the need of users, this Manual is compiled and published which brlefly describes
operation and maintenance of the engine.

Cl21 series diesel engines e multi-purpose engines. It is.possible, thereforeat the

diagrams and illustrations given in this Manual differ om yow:. engine for a specific
application. Nevertheless, .these diagrams and illustrations have their universality and
thus can be referred to for proper use.

Since the design of the product is improved om time to time, the technical
specifications shown in the Manual e subject to change without notice. Whenever a
question arises regding your engine or the Manual, please consult sales' service
center. When doing so, please indicate the model and date marked on e nameplate of
your engine, so thJtt you could be served better. ,
 IMPORTANT SAFETY INFORMATION

'ro prevent accidental personal injury, all external rotating parts should be
provided with protective guds and covers.
The engine mu~t be stopped before the engine and its driving devices can be
adjusted or repaed.
Do not we loose clothing when working around the ~hgine or machine.
During work in an enclosed shop, put on e plugs to prevent hurt of !iearing
while the engine is running.
Wear protective glasses, work clothing, safety hats and other protective
equipment when necessy.
Put on protective glasses and work clothing while cleaning with compressed a
The maximum air pressure should not exceed 205 ~a.
Do not smoke when refilling fueli so as to avoid burning of fuel fumes.
Do not smoke when checking electrolyte level 'of a battery because the 'battery
might emit flammable fumes.
Be surethereis proper ventilation in the shop where the engine operates.
Electrolyte is an acid. Avoid contact with your eyes and skin.
Do not attempt to do a repair which you do not understand. Read and co.mply
with the Manual.
Make replacements or repairs to the maintenance and repa equipment with
defect. Use appropriate tools.
Take off all tools, wires and other articles from the engine before it starts.
Wipe off any overflowing of lube oil, fue1 oil, coolant and other liquids.
Make sure that there is an appropriate, safe and reliable way for disposal of waste
011.
Keep oily rags in a fireproof container. Do Iiot place rags on the engine.
Do not leave any combustible liquids ne the engine.
To prevent unexpected engine starting, disconnect the grounding wire of the
batteries and insulate it with tapes before repairing the engine . .
It is absolutely prohibited to stt the engine when the speed control linkage of
the governor is removed.
Before staring the engine which has been just repaired, be ready to cut o a
supply so that the engine can be stopped as soon as it runs away after stting .
 CONTENTS

Chapter One Main Technical Specifications

AtIqL
I. General Engine Specifications
1. Engine Design
2. Main Engine D.ata

JA
3. Cylinder Block.

4. Cylinder Liner

A 3
5. Cylinder Liner Projection
6. Connecting R6~i.

UQOOY1A1i1A1itl
7. Timing Gears
8. Valves
9. Camshaft

nut h
10. Valve Rocker Arms and Liers
11. Cylinder Head
12. Valve Cover
13. Pistons and Piston Rings

A
14. Crankshaft, Main Bearings and Connecting Rod Bearings

A1A
15. Run-Out of Flywheel

OOnu ti 1
16. Run~Out of Flywheel Housing

17. Alternators

L hqL L 4
18. Electric Starting Motor
II. Description of Systems
1. Fuel System

hzJfoU
2. Lubrication System
3. Cooling System
4. Wrring Diagrn of Electric Starting
ill. Torque for Fasteners
222333333333
99901222344
Chapter Two Operation and Adjustment
I. Fuel, Oil and Coolant
1. Fuel
2. Lube Oil
3. Coolant
II. Engine Starting
1. Inspections before Starting
2. Electric Starting
3. Applying Load after Starting
Engine Stopping
IV. Valve Lash Ajusting
V. Checking Timing of Fuel Pump
VI. Testing of Fuel Iniection Nozzles
1. Valves Opening Pressure Test
J
2. Flushing the Nozzle
3. Tip Leakage Test
4. Orifice Restriction Test
5. Bleed Screw Leakage Test
VII. Checking Lubrication System
1. Too Much Oil Consumption .
2.. Oil Pressure Is Low
3. Oil Pressure Is High
4. Too Much Bearing Wear
VID. Belt Tension Adjustment

A A 3
Chapter Three Maintenance

l1dA
Maintenance As Needed
II. Maintenance Every 10 Hours

3JZJ
Jnxuoony
m. Maintenance Every 50 Hours
IV. Maintenance Every 250 Hours
v. Maintenance Eve500 Hours

3
VI. Maintenance Every 1000 Hours

d
VII. Maintenance Eve2000 Hours

6666666rhv

1Jtiq
Chapter Four Troubleshooting
Problem 1: Engine Will Not Turn When Start Switch Is On
Problem 2: Engine Will Not Start

Problem 3: Misfiring Or Running Rough
Problem 4: Stall At lw R/Min

31
Problem 5: Sudden Changes In Engine R/Min
Problem 6: Not Enough Power

A
Problem 7: Too Much Vibration

A
Problem 8: Imd Combustion Noise (Knock)

A
Problem 9: Loud Noise (Clicking) From Valve Compartment

JJ
Problem 10: Oil In Cooling System
Problem 11: Mechanical Noise (Knock) In Engine

JZJ
Problem 12: Fuel Consumption Too High
Problem 13: 1id Noise From Valves Or Valve Operating Components

U U U7
Problem 14: Little Movement Of Rocker Arm And Too Much Valve Lash
Problem 15: Valve Rotocoil Or Spring Ick Is Free
Problem 16: Oil At The Exhaust
Problem 17: Little Or No Valve Lash
Problem 18: Engine Has Early Wear

I
I Ioooooynynununut
Problem 19: Coolant In Lubrication Oil
Problem 20: Too Much Black Or Gray Smoke
Problem 21: ' Too Much White Or Blue Smoke
Problem 22: Engine Has Low Oil Pressure
Problem 23: Engine Uses Too Much Lubrication Oil
Problem 24: Engine Coolant Is Too Hot
Problem 25: Stig Motor Does Not Tum
Problem 26: Alternator Gives No Charge
Problem 27: . Alternator Charge Rate Is Iw Or Not Regular
Problem 28: Alternator Charge Is Too High

i$1

Problem 29: Alternator Has Noise

Problem 30: Exhaust Temperature Is Too High
CHAPTER ONE

MAIN TECHNICAL SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

1. ENGINE DESIGN

Model C4121 C6121

Bore 120.7mm 120.7mm
Stroke 152.4 mm 152.4mm
Number of Cylinders 4 6
Cylinder Arrangement *In-line
Firing Order (Injection Sequence) 1,3,4,2 1,5,3,6,2,4
Direction of Rotation (Viewed um
Counterclockwise Counterclockwise
Flywheel End) ,

*The No. 1 cylinder is opposite the flywheel end.

Exhaust valve

dMZELFJhk

Inlet valves

Schematic diagram of C6121 cylinders and valves

Exhaust valves
Jub

Inlet valves

Schematic diagram of C4121 cylinders and valves

2. MAII' ENGII'E DATA

Perform Parameters of Main Engine Model

C612IZG09c
C6121ZG09b
Model C6121ZGOI C6121ZGO!a C6121ZG02 C6121ZG03 C6121ZG03a C6121ZG05 C6121ZG05c C6121ZG06a C6121ZG09f
C6121ZG09d
C6121ZG09

C6121ZG09c
C6121ZG09f
General Assembly No C6ZF01 C6ZGOla C6ZG02 C6ZG03 C6ZG03a C6ZG05 C6ZG05c C6ZG06a C6ZG09b C6121ZG09e
Performance Spec. CT6394 3T9902 OT4784 2T7901 2T9i36 2T9136 2T9136 3T9907 3T9903 3T9901
Rated Power ( kW ) 114 131 160 174.5 174.5 130 131 172 158 162
Net Power ( kW ) 104 121 149 161 161 120 122 160 150 154
Rated Speed (r/min) 1 900 1900 2000 2200 2200 1850 1850 2100 2200 2200
SBFC ( g/k:Wh) 230.5 224 228 238 238 219 224 235 240 240
Smoke ( FSU) 2 2 2 2 2 2 2 2 2 2

Pec ~~~0~peed
1400 1400 1500 1400 1400 1200 1300 1400 1400 1400
Peak Torque (nm) 687 790 814 912 912 816 812 938 823 840
Torque Rise(%) 20 21 20 21. 3 21. 3 20 . 7 20 20 22 20
SBFC ( g/k:Wh) 226 215 228 226.8 226.8 223.4 225 225 22 8 225
Smoke ( FSU) 2.5 2 .5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
.2.5

Oil ~~~~jtion 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
High Idle (r/min ) 2050 2070 2120 2402 2402 2059 2030 2310 2360 2360
Low Idle ( r/min ) 750 750 750 750 750 765 680 750 750 750
Injection Timing
(BTDC) 210 210 210 210 210 210 210 210 210 210
Altitude ( m) 3750 3000 2250 2250 2250 2000 2000 2000 2400 2400
First Overhaul ( h) 8000 8000 8000 8000 8000 8000 8000 8000 8 000 8000
Net Weight (kg) 980 980 980 960 960 980 980 980 960 980

2
 Perforrna of Main Engine Models (continued)
Model C6121ZG09h 09i C6121ZG09g C6121ZGJOb.d.g C612JZG!Oa.c.f C6121ZGJ3a C6121ZG50a.50b C6121ZLG02 C6121ZDOI C6121ZLDOI C6121ZLD02 C6121ZLGOI
General Assemblv N C6ZG009h,i C6ZG09 C6ZG!Ob,d,g C6ZG10a,c,f C6ZGl3a C6ZG50a,50b C6ZLG02 C6ZDOI C6ZLDOI C6ZL 2 C6ZLGOI
Performance Soec. 3T9910 217901 217901 3T9901 3T9908 3T9950 3T9909 3T9906 217906 3T991 I 212

Rated Power (kW) 155 174. 5 174. 5 162 156 162 194 166(1h) 221(lh) 235(111) 216
Net Power (kW) 147 161 161 154 14 154 184 158 203 215 201
Rated seed (r/rrtln) 2200 2200 2200 2200 2200 2200 2200 1500 1500 1800 2100
SBFC ( g/kWh) 240 238 238 240 235 228 225 220 219. 5 219. 5 220 . 7
Smoke ( FSU) 2 2 2 2 2 2 2 2 2 2 2

Peak Toque Speed ( r/nn) 1400 1400 1400 1400 1400 1400 1400 1400
Peak Torque ( nm ) 807 912 912 840 828 844 ' 1011 1217
Toraue Rise(%) 20 21. 3 21. 3 20 22. 3 20 20 23. 8
SBFC ( g/kWh) 228 226 . 8 226. 8 225 225 215 215. 4 222. 9
Smoke (FSU) 2 .5 2. 5 2. 5 2. 5 2. 5 2. 5 2. 5 2 . 5'

Oil Consumption (glkwh) 0.5 o. 5 0. 5 0. 5 0. 5 0.5 0. 5 0. 5 o.5 0. 5 0.5

High Idle (r/rrtln ) 2360 2402 2402 2360 2340 2420 2410 1545 1545 1854 2310
Low Idle ( r/min) 750 750 750 750 650 750 750 850 1200 1200 725
lnjectin Timing ( BTDC ) 21 21 21 21 21 24 14 14 14 18 14

Altitude ( m) 24 00 2250 2250 2400 2150 3000 2000 1500 2675 1500 2000
First Overhaul (h ) 8000 8000 8000 8000 8000 8000 8000 8000 8000 8000 8000
Net Wei!!ht (kg) 960 960 960 960 960 960 980 960 9 980 9
3. CYLINDER BLOCK
(3) Bore in block for main bearings
(standard size) 96.926 0.013 mm

Bore in block for main beanngs

( 0.51 mm, i.. 0.020 in oversiz
97.436 0.013 mm

(4) Dimension from center of main beanng

bore to top of cylinder block
(new) 383.515 0.15 mm

(5) Dimension from center of main bearing

bore to bottom of cylinder block
(new) .. ..... ......... 153.99 0:10 mm

(6) Torque for bolts holding bearing caps for

main bein gs:

Front end view of C6121 cylinder block

(1) Thickness of spacer plate: 9.970 0.025 mm

Thickness of spacer gasket: 0.208 O.Q25 mm

NOTE: For height of liner over top of spacer plate,

refer to Cylinder Liner Projection.

(2) Camshaft bearing bore (installed)

58.80 o.09mm

Bore in block for camshaft bearings

.. 65.100 0.025 mm
Depth to install camshaft bearin_gs at both ends
of block 0.5 0.5 mm

NOTE: The camshaft bearing at the front of the

block must be installed with oil holes in a horizontal
position and joint at top within 15 from
vertical.

4
a. Put Thread Lubricant on threads and washer 4. CYLINDER LINER
face .
b. Tighten all bolts to 41 4N.m. (1 ) . Bore in liner (new) 120.675 0.025 mm
c. Make a mark on each bolt and cap.
d. Tighten all bolts from mark 90 5 Use-again maximum bore when measured
near upper end of the wear surfac of the
NOTE: Install the bearing caps with e part cylinder liner 120.78 mm
numbr toward the front of the engine. Be sat
the mark (number) on the bearing cap next to th (2) Thickness of liner flange
bolt hole is in agreement with e mark in the 10.282 0.020 mm
cylinder block.

(7) Clearanc between main bearing cap and (3) Filler band.
cylinder block
0.033 mm tight to Installation of Cylinder Liner
0.043 mm loose
Put liquid soap on bottom liner bore in block, on
Width of main bearing cap grooves in lower liner and on Orings. Install
165.095 0.020mm 0 -rings on lin
for a moment and install it on th liner. Then
install liner in cylinder block immediatly (bfore
Width of cylinder block for main beanng cap expsion of the fillr band).
165.095 0.020 mm

(8) Bore of bearing for balance shaft

(installed) 53.050 0.061 mm

Bore in block for bearings

57.8510.025 mm

Depth to install bearings at b ends of block

0.8 0.5 mm

NOTICE

There are holes in the bores for main bearings, 5. CYLINDER LINER PROJECTION
between the cylinders for piston cooler orifices.
piston cooling jets. These holes should have (1) Install the gasket and the spacer plate ( with
cooler orifices. the bolt ( and two washers. Tighten bolt
( evenly to a torque of 95 N.m in four ps .

5
 tttt NNNN
mmmm

A
nv

1
uwL M L V L M

JnuqJ
d I nJ
A

L
nw
unbF \
-

A
DAny

(2) Install the tool as shown in the diagram.

Tighten the bolt ( evenly in four steps.

Step 1 7N.m
Step 2 20N.m
Step 3 35N.m
Step 4 70N.m

(3) Use the dial indicator ( installed to e gauge

body ( as shown in the diagram to measure
liner projection. Measure at four positions close (I) Crossbeam
(2) Spacr plate
to the pressing plate around each cylinder liner. (3) Sl589 bolt with two 1S379 washers.
(4) 1D4595 bolt
The liner specifications are as follows: (5) pressing plate
(6) dial indicator
Liner projection 0.033 to 0.175 mm (7) connecting plate
(8) gauge body
Maximum variation in each cylinder
0.05mm
NOTE: Make sure that the gasket of 0.76 mm is
Maximum average variation between adjacent just under the flange of liner.
cylinders 0.05mm
6. CONNECTING ROD
Maximum variation between all cylinders
.. 0.102 mm ( 1) Bore in bearing for piston pin
(new 43 .2 105 0.0076mm
(4) To adjust liner projection, the depth of
counterbore to be machined
Diameter of piston pin
(new) 43.175 0.005 mm
(minimum)... ... .. 0.76mm
Maximum pernsible clearance between
(maximum) ...... .. .. .... 1.14mm
bearing and piston pin
(worn)... .... .. 0.08mm
Install a gasket of 0.76mm and an additional
gasket as required to get a proper liner
projection.

6
(2) Bore in connecting rod for bearmg (3) Fuel pump idler gear
82.550 0.013 mm
Clearance between idler gear and plat
(3) Distance between center of piston pin and center (new ) 0.10 to 0.41 mm
of crankshaft bearing
(new 243.71 0.03 mm Maximum permissible clearance between
idler gear and plate
(4) Torque on nut for connecting rod: (worn)....... 0.86mm

a. Put Thread Lubricant on threads and Bore in bearing for idlr ge shaft
nut seat. (new) ...... ........ 35.004 0.048 mm
b. Tighten two nuts to 404N.m
Diameter of idler gear shaft
c. Mark each nut and end of bolt. (new)" .............. .... .. 34.902 0.020 mm

d. Tighten both nuts (from mk 905

Install the connecting rod in the piston in such a

way that the etched cylinder number on the
connecting rod is on the sne side as the V" mark
on e piston.
Clearance btween idler ge shaft and bearing
7. TIMING GEARS bore
(new) ..... .. 0.033 to 0.168 mm
Timing Gears (C6121 Engine)
Maximum permissible clearance between idler
(1) Fuel pump ive gear ge sha and bearing bore
(worn) ............... . 0.23mm
Wie timing pin and timing bolt correctly
(4) Crankshaft gear
installed, put a clockwise forc of 70 N.m on the (5) Idler gear for the oil pump
drive gear for th fuel pump and tighten bolt (6) Drive gear for oil pump
to a torque of 270 25 N.m

(2) Camshaft ge

Tighten bolts to a torque of- .. 55 7N.m

7
8. VALVES

(1) Valve spring (new):

Length under test force 44.86mm

Test force 257 25N

Use-again minimum load at length under test

force 207N
4
Length of spring at valve open position
32.28 mm

Use-again minimum load at valve open

position :...... .. 642N

Free length after test52.07 mm

Outside diameter 35.21 mm

Spring must not be bent more m

1.82 mm

(2) Height to top of valve guide

22 .23 0.25mm

901
munu
nye tM ti
ihn vuem um
Lb
k u

(3) Dieter of valve stem

.I
m
(new) 9.4410.008 mm
m

L
A
A


-
mT

2b0Yin inu
U

tn
Z

Use-again minimum diameter 1

.M
m
nb

9.408 mm
m
L
U
- nJ

Bore in valve guide with guide installed in the

head: (2) Diameter of valve head:

Minimum permissible Exhaust valve 48.16 0.13 mm

(new).............................. 9.456mm

Maximum permissible Inlet valve ...... . 51.31 0.13 mm

(worn) 9.581 mm

(1) Valve lip thickness: (6) Angle of valve face

29 15 15
6N9916 Exhaust Valve
Useagn minimum (7)Dpth of bore in head for valve seat insert
2.69 mm 12 .28 0.13mm

7N0573 Exhaust Valve

Use-again minimum
2.44 mm

8
(8) Diameter of valve seat insert for exhaust valve
9. CAMSHAFT
50.889 0.013 mm
NOTE: Camshaft lobes should be coated with
Bore in head for valve seat insrt for xhaust lubricant or graphite grease prior to
valve 50 .813 0. 030rnrn installation of followers.

Diameter of valve seat insert for inlet valve (1) Width of groove in camshaft for thrust washer
52.032 0.013rnm (new) 4.83 0.05 mm

Bore in head for valve seat insert for inlet T~ckness of thrust washer
valve .. 51.956 0.030mm (new) ....... -4.65 0.03 mm

(9) Angle of face of valve seat insert End play of camshaft

.. 30 15 30 ' (new) .......... .............. 0.18 0.08 mm

(10) Maximum permissible width of valve seat Maximum permissible end play
(inlet and exhaust) ... ............ 1.93 mm (worn)...................... .... ... .. ..0.64 mm

Minimum prrnissible width of valve seat (inlet

and exhaust)............ u4 mm

(11) Dimension from top of closed valve to face of

head:

Minimum permissible dimension for e1aust

valve .... .. ... .. ... ........... 0.66 mm

Minimum permissible dimension for inlet

valve .....................0.. 66mm

(12) Outside diameter of face of valve seat insert:

Exhaust seat 46.02mm (2) Diameter of camshaft bearing surface

ournal)
Maximum permissible, e1aust seat (new):........... 58.699 0.013 mm
47.29 mm
(3) Bore in bearing for camshaft
Inlet seat ................. 49.28mm (new) .... .... 58.80 0.06 mm

Maximum permissible, inlet seat Clearance between bearing and bearing

50.55 mm surface Uournal)
(new).... .. .. 0.03 to 0.17 mm
(13) Angle to grind seat face of the insert to get a
reduction of maximum seat diameter Maximum permissible clearance between
... 15 degrees bearing and bearing surface Uournal)
(worn).... .... 0.20 mm

9
(4) Height of camshaft lobes. (2) Tighten locknut on intake and exhaust valve
adj ustment screw to a torque of
To find lob lift, us the following procedure 297N.m

A. Measure camshaft lobe height ( . (3) Valve lash:

B. Measure base circle ( .
C. Subact base circle (Step B) from lobe Inlet valves .. 0.38 mm
height (Stp A). The difference is actual
lobe Ii Exhaust valves 0.64mm
D. Specified camshaft lobe M
8.382 mm (4) Diameter of valve lifter .
(new)...... 33.287 0.013 mm
Maximum permissible difference betwen
actual lobe lift (Step C) and specified lobe lift Bore in block for valve lifter
(Step D) 0.25mm. (new 33.388 0.025 mm

Maximum permissible clearance between lifter

and bore for valve lifter
(worn) ... .... . 0.30 mm

10. VALVE ROCKER ARMS AND LIFTERS

(1) Bore in bearing for shaft

(new) .... .... 18.448 0.013mm

Diameter of shaft
(new) 18.402 0.013 mm

Maximum permissible clearance between

bearing and shaft
(worn )....... 0.20mm

io
11. CYLINDER HEAD 12. VALVE COVER

Thickness of cylinder had Put 5H2471 Cement on face of valv cover and
(new) 100.03 0.76 mm topside of gasket.
Tighten bolts in number sequence shown to
Put 5P3931 Molykote Paste Lubricant on e 10.9 2.8 N.m
threads. Tighten all bolts in following sequence:

Step 1. Tighten all bolts in number sequence

to 155 N.m

Step 2. Again tighten all bolts in number

sequence 01 01 02 ~
to 250 17N.m

Step 3. Again tighten all bolts in number

sequence (hand torque only)
0 0
to 250 17 N.m

Step 4. Tighten all bolts in letter sequence

Top view of valve cover of C6121 engine
(hand torque only)
to 3 7N.m


u
jM
v
L

2
U

Top view of cylinder head of C6121 engine

11
13. PISTONS AND PISTON RINGS

Pistons and Piston Rings

( Top Ring ( Intermediate Ring ( Oil Control Ring
Part No. *1006694 *1006695 6 10499
Width of groove in piston for pist9n ring
(new)
~ ~
4.033 0.013 rnm
Thickness of piston ring (new) ***
3.982 0.008 mm
Clearanc between groove and piston ring
(new) *** .
0.051 0 .026 mm
Maximum pennissible clearancworn) *** *** 0.15 mm
Clearance be:twen ends of piston ring when
installed in a cylinder liner with a bor size 0.47 0.13 mm 0.73 0.13 mm 0.5 0 .'12 mm
of 120.650 mm
Increase in clearance between ends of
piston ring for each 0.03 mm increase in 0.08 mm
cylinder liner bor size .

* Install piston ring with UP side toward the top of the piston.
NOTE: Top piston rings ( ( 1006694 ) have mark UP-1 . Irrnediate piston rings ( ( 1006695)
have the mark UP

Install oil control rings ( with spring gap 180 degrees away from ring gap.

*** Use dedicated tools to dimensions of Keystone style piston rings and grooves in th piston .

(4) Bore in piston for pm

Diameter 43.195 0.008 mm

Clearance betwen bore and pin

0.007 to 0.033 mm

Pin diametr 43.175 0.005 mm

NOTE: When installed in the enginee V mark

on top of the piston must be in alignment with the
V mark on the cylinder block.

Do not use again Use again

12
14. CRANKSHAFT, MAIN BEARINGS AND CONNECTING ROD BEARINGS

(1) Thickness of thrust plates (new): Then stake the crankshaft to hold plugs m
place. For STAKE , use a center punch and a
1003652 or 7N93425.461 ?0.038mm hammer to change the shape of holes as
shown.

NOTE: For coect use of the plates, see (5) Crankshaft gear:
Instruction Card of Thrust Plates. Do not heat gear to more than 316?C (600

(2) Refer to Bearing Surface (Journal) for (6) End play for crankshaft
Main Bearing\ (new0.122 to 0.579mm

(3) Refer to Bearing Surface (Journal) for Maximum pennissible end play for crankshaft
Connecting Rod\ (worn0.85mm

(4) Tighten plugs to a torque of 23?4N.m (7) Installation of we sleeve and seal:

Push we sleeve and seal in place with correct

tools.

Instruction Card of Thrust Plates

Tidth of Crankshaft Journals Part No. of Thrust Plates
40.475 + 0.140 ~ 0.064mm
7N9342
1.5935 + 0.0055 ~ 0.0025 in)
42.863 ? 0.064 mm
7N9343
1.6875 ? 0.0025 in)

13
 * Crankshaft produced cuently
Crankshaft produced earlier

Bearing Surface (Journal) for Main Bearing

Bearing Surface (Journal) for Main Bearing

Original Size Undersize Journal Undersize Journal Undersize Journal
Journal 0.25mm O.Slmm 0.76mm
Dimension of
88.880?0.020 mm 88.626?0.020 mm 88.372?0.020 mm 88.118?0.020 mm
Journals (D)
Surface Finish of 0.25?m or more smooth
Journals
5.74?0.20 mm
*Radius
(0.226?0.008 in)
Surface Finish of 1.6 ?m
Radius (63 ?in or more smooth)
Max Width of All
Journals Except 43.485 mm
Front &Rear
Width of Rear 40.475+0.140-0.064 mm
Journal
Surface Finish of
Thrust Face of Rear 0.46 ?rn or more smooth
Journal

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

l4
 Bearing Surface (Journal) for Connecting Rods

Bearin~ Surface (Journal) for Connecting Rods

Original Size Undersize Journal Undersize Journal Undersize Journal
Journal 0.25mm O.Slmm 0.76mm
Diameter of Crankshaft
Journal (Bearing
76.180?0.020 mm 75.926?0.020 mm 75.672?0.020 mm 75.418?0.020 mm
Surface) for Connecting
Rods (A)
Surface Finish of 0.25 mm
Journals or more smooth
*Radius 5.74?0.2Q mm
Surface Finish of 1.6 ?m
Radius or more smooth
Wi of Journal 47.689?0.140 mm

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

Main and Connecting Rod Bearings

Connectin2 Rod Bearin1 s

Original Size Undersize Journal Undersize Journal Undersize Journal
Journal 0.25mm O.Slmm 0.76mm
Diameter of Crankshaft
Journal (B ming Sface) 76.180?0.020 mm 75.926?0.020 mm 75.672?0.020 mm 75.418?0.020 mm
for Connecting Rods
Ctearanc Betwn
Beaiing and Journal (New) 0.076 to 0.168 mm
Mirnum Permissible
Clearance Between 0.25mm
Bing and Journal

15
 Main Bearing
Original Size Undersize Journal Undersize Journal Undersize Journal
Journal .2Smm 0.51 mm 0.76mm)
Diameter of Crankshaft
Journal (Bearing Surface) 88.880?0.020 mm 88.626?0.020 mm 88.372?0.020 mm 88.118? 0.020 mm
for Main Bearings
Clearance Between
Baring and Journal (New)
0.076 to 0.165 mm
Maximum Permissible
Clearanc Be1een 0.25mm
Bearing and Journal

15. RUN-OUT OF FLYWHEEL

Face Run-out (Axial Eccentricity) of Flywheel

(1) Install a dial indicator as shown. Put a force

on the flywheel toward the rear.

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

(3) Turn the flywheel and read the indicator

every 90 degrees. Put a force on flywheel
toward the rear before the indicator is read
every time.

(4) The difference between the lower and higher

measurements taken at all four points must not
be more than 0.15mm, which is ie maximum
Check face run-out of flywheel
prmissible face run-out ial eccentricity) of
the flywheel.
(2) Tum the flywheel and read the indicator eve
Bore Run-out (Radial Eccentricity) of Flywheel
90 degrees.
(1) InsI e dial indicator ( and aust (4) The difference between the lower and higher
universal attachmenti( so it makes contact as measements taken at all four points must not
shown. be morn m 0.15 mm, which is the maximum
permissible bore run-out (radial eccentricity) of
Set the dial indicator to read 0.0 mm. the flywheel.

16
 (2) Put a force on the crankshaft toward the rear
be for the indicator is read at each point.

(3) With the dial indicator set at 0.0 mm at

location (A), tum the crankshaft and read the
indicator at locations (B), (C) and (D).

Checking Bore of Flywheel

(5) Run-out (eccentricity) of the bore for the pilot

bearing for e flywheel clutch, must not
exceed 0.13 mm.

Installation of Dial Indicator Group

(top)

C (TOP)

Checking Bore for Pilot Being
A ( BOTTM )
for Flywheel Clutch

(Boom)
16. RUN-OUT OF FLYWHEEL HOUSING
(4) The differenc between lower and higher
Face Run-out (Axial Eccentricity) measements taken at all four points must not
of Flywheel Housing be more 0.30 mm, which .is the maximum
permissible face run-out ial eccentricity) of
(1) Fasten a dial indicator to the crankshaft flange the flywheel housing.
so the anvil of the indicator will touch the face
of the flywheel housing. Bore of Flywheel Housing

NOTE: Write the dial indicator measurements with

their positive (+) and negative (-) notation. This
notation is necessary for ming the calculations in
the chart correctly.

17
(1 ) With . the dial indicator in position at (C), (10) If the point of intersection is in the range
adjust the dial indicator to 0(zero). Push the marked "Accptable the bore is in alignment
crankshaft up against the top of the bearing. If th point of intersection is in the range
Write the measurement for bearing clearanc marked Not acceptablee flywheel housing
on line l in column (C) in the Chart for Dial must b changed .
Indicator Measurements.

(2) Divide e measurement from stp l by 2.

Write this number on line 1 in column
(D).

(3) Tum the crankshaft to put the dial indicator at

(A).Aust the dial indicator 0zero).

(4) Tum the crankshaft counterclockwise to put

the dial indicator at (B), write the
measurements in the chart.

(5) Tum th crankshaft counterclockwise to put

the dial indicator at (C), write C (TOP)
measurements in the chart.

(6) Tum the crankshaft counterclockwise to put

e dial indicator .at (D), write the
measurements in the chart.

(7) Add lines I and II by columns. 6

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

eccentrici
Chart for Dial Indicator Measurements
Position of Dial Indicator A (BOTTOM)

Line No. A B c D
Corrction for
735 ' "
Bearing Clearance

l ' .Olil

Dial Indicator II
,,.
Reading t.010)

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

~
*Total vertical eccentricity (out of round)
Subtract the smaller No. from the larger No.
t.~I
The difference is total horizontal eccentricity.
1
Al0234 l
i

(9) On the graph for total eccentricity find the

point of intersection of lines for vertical ... 0.10 0.15
l '. 004) IU lOlll
eccentricity and horizontal eccen~ity.

18
17. ALTERNATORS jllAlternator ~.... v ::iAJ

(Delco Remy No.1117248)

3T6352 Alternator (24V 35A)
(Delco-Remy No.1117647) Polanty negative ground
Speed for tsting (either direction5000 r/min
Rotation-------------------------------Either direction Output (cooled): load the battery with a carbon
PolarityNegativ ground pile to get maximum output to
Output at 28V &2600 r/min 15A ---54A
Output at 28V&6500 r/min ------------- 35A Rated output (warm.50A
Rated output (warm35 A Exciting current at 24V &27?C, (80?F)
Exciting current at"24V &27?C, (80?F) 2.5 to 2.9 A
-2.5 to 3.2 A Regulator:
Voltage regulating range 26to30V
(1) Shaft nut torque Adjust voltage setting to28 v
100?7 N.m Then increase sped to get maximum output of
50 A
(2) Torque for negative terminal screw
2.3?0.6 N.m (1) Shaft nut torque 100?7 N.m

Torque for positive trminal nut

7?1N.m (2) Torque for tightening output terminal
14?1N.m

19
18. ELECTRIC STARTING MOTOR

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

r J~i !' ,z
Rotation as viewed for drive end----------clockwise 1
Minimum no load speed------ 5500 r/min r' i! : \.
E
Ii
Current consumption (draw) at no load---- 140A
Minimum clearance between pinion and ring ge
(when not meshed 1.5 mm

1. Torque for large terminal nuts (1) Valid use limit of th brush
--30?3 N.m (minimum length -----------17.5 mm

Torque for small terminal nuts (2) Valid use limit of the rectifier
4 to 5 N.m (minimum permissible diameter
-----47.5 mm

20
II. DESCRIPTION OF SYSTEMS

1. FUEL SYSTEM

11 12

Schematic Diagram of Fuel System

1. Fuel tank 2. Fuel return line 3. Priming pump 4. Fuel inj ction nozzle
5. Fuel inJon line 6. Fuel inj ction pump 7. Primary fuel filter 8. Check valve
9. Fuel transfer pump 10. Secondary fuel liter 11. Constant bleed orific
12. Fuel iction pump housing

Fuel is pulled from fuel tank rough prim bleed orifice send about 34 liters (9 gallons) fuel
fuel filter ( and check valves ( by fuel transfer and air back to fuel tank per hour. This helps
pump ( . From the fuel transfer pump the fuel is keep the fuel cool and ee of air. Fuel iection
pushed rough secondary fuel filter mp ge fuel form e fuel manifold and
and to the fuel manifold in fuel iection pump pushes fuel at very high pressure rough fuel
housing (12). The pumping spring- in e fuel injection line ( to fuel iectio11 nozzle ( .
transfer pump keeps the fuel pressure in the system The fuel injection nozzle has very small holes in
at 17~ to 290 kPa (25 to 42 psi). Constant bleed. the tip that change the flow of fuel to a very fine
orifice (11) lets a constant flow of fuel gough spray that gives good fuel combustion in
fuel return line ( back to fuel tank (. Constant cylinder.

21
2. LUBRICATION SYSTEM

Schematic Diagram of C6121 Lubrication System ngine Warm)

1. Oil passage (to front idler ge .2. 0 passage (to turbocharger and fuel injection pump)
3. Rocker m shaft 4. 0 pressur connection 5. Oil manifold 6. Piston cooling jets
7. Camshaft bearing bore 8. Oil coolr bypass valve 9. Oil filter bypass valve
10. Engin oi l cooler 11. Oil filter 12. Trbocharger 13. Oil pump 14. Oil pan

Oil pump (13) pulls oil from oil pan (14) and then illed passage at goes up next to e head bolt
pushes the oil to oil cooler ( . From e oil cooler, hole. A hollow dowel connects e vertical oil
oil goes to oil filter (11) and then to oil manifold ( . passage in e cylinder block to the oil passage in
From the C?il manifold, oil goes to all mn beings, the head. The spacer plate has a hole with a
and piston cooling jets (. Oil passages in the counterbore on each sid that the hollow dowel
crankshaft send oil to the connecting rod bearings. goes through. An 0-ring is in each counterbore to
Oil from the front main bearing goes through oil prevent oil leakage around hollow dowel. Oil
flows through the hollow dowel into a vertical
psage e bearing for fuel iection
passage in the cylinder head t rocker m shaft
pump idler ge and camshaft bearing bore (. The bracket. The rocker m shaft has an orifice to
front camshaft bearing is e only bearing to get restrict the oil flow e rocker ms. The rear
pr~ssure lubrication.
rocker arm bracket also has an 0-ring that seals
against the head bolt. This seal prevents oil from
Oil passage om No. 4 main baring sends oil to going down around the head bolt and leaking past
turbochargr (12) and the fuel i ection pump th head gasket or spacer plate gasket. The 0-ring
housing on the right side of the engine. must be replaced each time the head bolt is
removed from the re rocker m bracket.
An oil passage from the rear of the cylinder block
goes below the head bolt hole and connects with a

22
s in the rocker shafts let the oil gi v Iubricat1on to When the oil gets warm, the pressure
the valve system components in the cylinder head. difference in the bypass valves decreases and
After the lubrication oil has done its work, it goes the bypass valves close. Now there is a
back to the engine oil pan. normal flow of oil through oil cooler and
oil filtr.
There is a bypass valve in oil pump. This bypass
valve controls pressure of e oil coming from the The bypass valves will also open when ere
oil pump. The oil pump can put more oil into the is a resiction in the oil cooler or oil filter.
system m is needed. When there is more oil than This action does not let an oil cooler or oil
needed, the oil pressure increases and the bypass filter with a restriction prevent lubrication of
valve will open. This .allows the oil that is not the engine.
needed to go back to e engin oil pan.

e engine cold (starng conditions), bypass valves

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

Diagram of Rocker Arm Oil Supply

11

1(

Diagram of Oil Flow (Engine Cold)

8. Oil cooler bypass 9. Oil filter bypass 10. Engine oil cooler U. Oil filter
12. Tbocharger 13: Oil pump 14. Oil pan

23
3. COOLING SYSTEM

6 7 8 9 10 11

Diagram of Coolant Flow for Radiator Cooling System

1. Radiator 2. Inlet line to radiator 3. Water tmperature regulator 4. Cylinder head
5. Cylinder block 6. Inlet line to water pump 7. Water pump 8. Internal bypass lin
9. Engine oil cooler 10. Elbow 11. Cylinder liner

The water pump ( is on e leont side When the coolant g to the correct
of the engine. It is gear driven by the timing temperature1e water temperature regulator
gears. The rotation of the impeller in th opens and coolant flow is divided. Most
water pump pushes the coolant through the goes through the radiator for cooling. The
system. rest goes through e internal bypass line
/ to the water pump.
Coolant from the bottom of radr
is sent through inlet line ( to engine oil NOTE: The water temperature regulato~ is an
cooler ( by wer pump (. Then the important pt of the cooling system. It
divides e coolant flow between radiator
flo?' goes through elbow to e side of
( and internal bypass line
cylinder block (. Inside the cylinder block
necess to mainn e correct operating
the coolant goes around the cylinder lj,ners
temperature. If the regulator is not
(11) and up through the water direciors into
installediere is no mechanical conol,
cylinder head (. The watr directors and most of the coolant will take the path
send the flow of coolant around the valves of least resistance through internal bypass
and the passages for exhaust gases in th line. This will cause the engine to overheat
cylinder head. Then the coolant goes to the in hot weather. In cold weather, even the
front of the cylindr head. Hre watr small nount of coolant that goes through
temperature regulator ( controls the radiator is too much, and th engine will
direction of the flow. If the coolant not get up to normal oprating
temperature is less than nprmal for engine temperature.
operatione water tmperatur regulator is
closed. Thi:; only way for the coolant to get
out o.f the cylinder head is through the
internal bypass line

24
4. WIRING DIAGRAM OF ELECTRIC STARTING

Chging System with Elecc Starter Motor

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

III. TORQUE FOR FASTENERS

Torques for Main Bolts

Description Torque Description Torque

41?4.N.m
Main bearing bolt Trunnion bolt 135?5 N.m
Retighten by 90 5
Big bolt 250? 17 N.m
Cylinder head bo.lt Valve lash adjusting bolt 29?7N.m
Small bolt 43?7 N.m
41?4N.m
Connecting rod bolt Valve cover bolt 11?3 N.m
Retighten by 90 5
Flywheel bolt 200?25N.m Crankshaft taper tube plug 23?4N.m
Carns ha gear bolt 55?7 N.m Alternator pulley lock nut 112?10N.m
Crankshaft sleeve bolt 312?27N.m Fiywheel housing bolt 100?15 N.m
Torque converter
Fuel pump ive gear bolt 270?25 N.m 55?7 N.m
connecting stud

25
 2
General Tightening Torque for Standard Bolts, Nuts and
Taperlock Studs
The following chart gives standard torque for SAE 5- or higher grade
bolts, nuts and taperlock studs. Exceptional torque is indicated as
required in the other parts of this Manual.
Thread.Size Standard Torque
Inch mm lb.ft N.m
Standard threads

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

1/4 6.35 9?3 12?4

5/16 7.94 18?5 25?7
3/8 9.53 32?5 45?7
7/16 11.11 '50?10 70?15
1/2 12.70 75?10 lo0?15
9/16 14.29 110?15 150?20
5/8 15.88 150?20 200?25
3/4 19.05 265?35 360?50
7/8 22.23 420?60 570?80
25.40 640?80 875?100
1 1/8 28.58 800?100 1100? 150
1114 31.75 1000?120 1350?175
1 3/8 34.93 1200?150 1600?200
.1112 38.10 1500?200 2000?275
For bolts and nuts for hydraulic valves, use e
following torques.
3/8 7.94 13?2 20?3
5/16 9.53 24?2 35?3
7/16 11.11 39?2 50?3
1/2 12.70 60?? 80?4
5/8 15.88 118?4 160?6
Taperloc).c studs
The following torques e used for studs with
i rJ taperlock reads.

114 6.35 5?2 7?3

5/16 7.94 10?3 15?5
3/8 9.53 20?3 30~5
7/16 11.11 30?5 40?10
112 12.70 40?5 55?10
9/16 14.29 60?10 80?15
5/8 15.88 75?10 100?15
3/4 19.05 110?15 150?20
7/8 22.23 170?20 230?30
25.40 260?30 350?40
1118 28.58 320?30 400?40
11/4 31.75 400?40 550?50
13/8 34.93 480?40 650?50
11/2 38.10 550?50 750?70
* lNewton meter (N.m) is approximately the sne as O.lmkg.

26
 Torque for Connectors wi Flare or 0 Ring

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

3 ~ t

Inverted 45? 37?flared P-ring
ned 45?flared Fitting-plug Swivel nuts

Tube mm 3.18 4.78 6.35 7.92 9.52 Tube mm 12.70 15.88 19.05 22.22 25.40 31.75 38.10 50.80
OD* OD*
in 0.125 0.188 0.250 0.312 0.375 in 0.500 0.625 0.750 0.875 1.000 1.250 1.500 2.000
Thread 9/16 Threaddia. B'16
5/16 3/8 7/16 112 3/4 7/8 11/16 15"16 15"8 17/8 21/2
dia. (in) 5/8 (in) 14
Torque 5 11 16 20 . 25 Torque 50 75 100 120 135 180 225 320
(N.m) ?2 ?2 ?3 (N.m) ?5 ?5 ?5 ?5 ?10 ?10 ?10 ?15
Torque 45 100 145 175 225 Torque 35 55 75 90 100 135 165 235
(lb.in) ?10 ?10 ?20 ?20 ?25 b.in) ?4 ?4 ?4 ?4 7 ?7 ?7 ?10
* OD =Outside diameter

Assembling of Fitting
with Straight Threads and 0-Ring Seals

1. Hold locknut (, backup washer ( and 0-ring

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

Note: If the fitting is a straight connector or screw plug,

there is a hexagon head in the adapter body
instead of a locknut. When installing such
fittings, tighten the hexagon head so it contacts
Elbow Assembling
e fit face of the connected part firmly.

1. End offitting body (connects to tube)

2. In order to place e fitting in a correct position in 2. Fitting body 3. Locknut 4. Backup
installation, turn the fitting body washer 5. 0-ring seal 6. End of fitting that
counterclockwise a little (not more an 359?), then goes into other pt
tighten e locknut ( according .to e toue given
e cht.

27
CHAPTER TWO

OPERATION AND ADJUSTMENT

I. FUEL, OIL AND COOLANT

Filling Capacity of Engine Oil and Coolant

liter I Gallon I Imperial gallon

27.5 I 7.25 I6
20 I 5.25 I 4.5

1. FUEL

Generally the C121series diesel engine may use light diesel oil of the lowest cost. that meets the following
requirements.
Minimum cetane number: 40
Viscosity, kinematic at 38 1.4 2 .0 cSt
Pour point: 6 below ambient minimum
Water and sedimentary content: less than 0.1 %.
Mimum sulfur content: 0.5%; If there is more sulfur in the fuel oil, adjust e change interval of lube
oil as shown in the chart below.
h

l
%%%

m%%%
MUnu A nu

JW

OE
4
c

- Change period of oil and filter

071

--
4
----
-o Normal change interval
l

-qJ 112 normal change interval
l

- 114 normal change interval

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

Specifications Fuel Description

U.S. standards No. 1-D & No. 2-D
ASTMD975 Diesel fuel oil
British Standards Classes Al, A2 &B 1
BS 2868 Engine fuels
German standards ,, '
,, Diesel oil
DIN 51601
Australian standards ,
Automotive diesel oil
AS 3570
Japanese standards rpes l(spl), 1, 2, 3 & 3(spl)
ns K2204
Gas oil

2. LUBEOIL

Engine oil performs functions of lubricating and cooling the moving parts and keeping the engine clean and
free from rust $Id corrosion. It is a critical factor to engine life. Use proper lube oil as specified in is
Manual.

28
Ambient Temperatures Which SAE Standard CD Grade Engine Oils Are Suitable To

Suitable'to temperatures from -30 22?F) to +50 122?F ).

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

SAESW-20

SAE40W
n naucc
mD
L

EU
b

lv

piv9up3

SAE lOW - 30

SAE lSW-40

SAE30

SAE40

Ambient 30 -20 -10 0 +10 +20 +30 +40 +50

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

3. COOLANT
Use proper coolant for the engine which is mixture of:
Water for filling use
Antifreeze
Antirust for cooling system

Water for Filling '

Water for filling must contain antirust. Do not use pure water. For coolant mixture of glycol and water, use
water that meets the requirements 'listed in the following chart.

Minimqm Acceptable Water Characteristics for Use in Enltine Cooling Svstem

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

Antifreeze
Use eylene glycol antifreeze. The ount of antifreeze should be appropriate so that the coolant water will not
be frozen at the lowest temperature anticipated. The percentage of mixing it with water is as follows:

Antifreeze Concentrations*
Protection Temperatures Concentration
-15 30% antifreeze, 70%water
-24 40% antieeze, 60% water
,
-37 , 50% antifreeze, 50% water
-52 60% antieeze, 40% water
* Ethylene glycol-based antifreeze.

29
TI. ENGINE STARTING
(3) Check the crankcase oil level. Maintain the
oil level between the ADD and FOLL marks
1. INSPECTIONS BEFORE STARTING on the dipstick.

Perform reqred daily and other periodic (4) Check the fuel level of the fuel tank.
maintenance before starting the engjne. Make a
walk-around inspection of the installation. It only
takes a few minutes to make minor corrections. (5) Drain water and sediment from the water
This can prevent m or reoairs at late date. segregator.
~

(6) Disconnect om e electrical circuit all

ba.erycharging equipment without a cut-off
device of starter motor current.

(7) Make sure that all protective installation is

secured in place. Repair or replace all
broken proctive installation.

2. ELECTRIC STARTING

If the ambient temperature is,below 16 it may

(1) Check the service indicator of air cleaner. If
be required to use a starg aid and/or other
the red piston locks in the visible position ,
means to heat the crankcase oil. A jacket water
service the air cleaner.
heater is often used to assist the engine in starting
at cold temperatures.

(2) Check the coolant level. Maintain the coolant

level within 1 cm below the bottom of the
radiator fill pipe.
(1) Place the ansmission in NEUfRAL. For
generator sets, open the main electrical
circuit breaker.

(2) Move the throttle to approximately half

engine speed.

(3) Turn the starter switch to START. If it is

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

30
(4) As soon as the engine stts , allow the engine to
idle for 3 to 5 minutes, or until e water Do not store ether cylinders in the cab.
temperature gauge indicator has begun to rise. Do not store or use ether cylinders at
tempera tor of over93
(5) Do not apply load to e engine or increase Keep ether away from heat sources,
engine speed until the oil pressure gauge sparks and flames to avoid an explosion.
indicates nonnal. (Oil pressure should rise to Do not break or burn ether cylinders.
nonnal wiin 15 seconds after the engine Use ether sparingly and spray it oiily
starts. If oil pressure is not indicated o~ gauge when starting the engine.
within 15 seconds, stop engine immediately
to prevent e engine from damage.)
3. APPLYING LOAD AFTER STARTING
(6) Operate the engine .at low load until all systems (1) Move throttle to half engine speed.
reach opera1g temperature. Check all
gauges during the Wm-up period.

Electrical Starg Enginewi Fixed Quantity

Ether Spraying System

At temperatures of above O generally there is no

need to use ether to start e engine. When
starting the engine at temperares of O through .
-18 Spray ether 1 to 6 times depending on e
engine type and starting speed.

A new ether cylinder should be used to assure

enough output pressure when starting the engine
at temperatures of below -18 (2) Engage the clutch to get the driven
equipment in motion
Spray ether only when stare engine.

At temperatures of below -18 it is needed to

~pray ether 3 to .6 times before the engine can be
started. up. Aer the engine begins running and
starting actions stop, keep spaying ether until the
engine tuns smool This may need to spray
ether 10 to 12 times.

Ether

When using ether from a pr1sure vessel, follow

instructions of the manufacture to avoid personal
lury. (3) Check the engine gauges and equipment.

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

Avoid contact with the skin and eyes. (5) Apply load to the i'ven equipment.
Avoid breathing in any ether fumes.

31
III. ENGINE STOPPING

5 Minutes

Low Idle

NOTICE

Stopping the engine immediately after it has been

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

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

(2) Stop the engine.

Move the fuel control linkage

to the Off position.

IV. VALVE LASH ADJUSTING

INLET
.015 in. (0.38 mm}

If the valve lash is in the range of ?0.07 mm, Ajust e valves when the engine is stopp~d and
ajustment is not necessy. If the valve lash is cooled.
. outside is range, adjust it.
, Valve lash checking

(1) Stop the engine.

(2) Clean the bed of valve cover to prevent di

from entering the valve mechanism.

32
(3) Remove the valve cover. (6) Through .the timing hole in th flywheel
housing, screw a 9.40 mm NF timing bolt,
63.5mm long, int9 the hole in the flywheel.

(7) Measure the valve clearances as listed in th

compression stroke cht

(8) Remove the timing bolt om the flywheel.

(9) Ture flywheel 360 degrees and install the

timing bolt into the flywheel again.

(4) Remove e timing hole plug from the (10) Measure the valve clearances as listed in
flywheel housing. the exhaust strokf'. chart.

The engine cranking tool is available om SDEC. (11) Remove the timing bolt from the flywheel
For coect use of the tool, consult SDEC. and install th plug into hole in the
flywheel housing.
(5) Turn the flrheel so at the intake and
exhaust valves of No. 1 cylinder. e closed and (12) Remove the engine cranking tool and then
the plug hole in e flywheel housing is in install the starting motor.
alignment with the hole in the flywheel. This
will put e piston of No.l cylinder is at top
dead center on the compression soke.

C6121 C6121
Closed valves when the No.1 cylinder is at the top Closed valves when the No.l cylinder is at the top
dead center on the compression stroke dead center on the eiaust stroke
Valve Cylinder Valve Cylinder
Inlet 1-2-4 Inlet 3-5-6
Exhaust 1-3-5 Exhaust 2-4-6

33
 Valve Adjustment

(1) Loosen the locknut on eajusting screw. (2) Watch the rotation of the valve rotation
mechanism.

(3) At each time the valves open, each valve should

rotate a little. If not, check or replace the
rotation mechanism.

(2) Turn the adjusting screw to obtain coect

valve clearance.

(4) Sfop .the engine and then check the gasket of

valve cover. If the gasket is damaged, replace it
with a new one.

(3) Fix the austing screw and tighten e n~ to

29?7N.m.

(4) Measure the valve lash.

Watching Valve Rotation

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

34
V. CHECKING TIM~NG OF FUEL PUMP

Locating Top Center Compression Position (4) Rotate the crankshaft clockwise
for No. 1 Piston approximately 30 degrees. This step is to
make sure free clearance of the timing geS
Tools needed: is removed when the piston is at top center.
5P7307 Engine turning tool group.
(5) Remove the plug from the timing hole in the
The piston of No. 1 cylinder at top centerC) on flywheel housing. Rotate the crankshaft
the compression stroke is e starting point of all until a 3/8 in -- 16NC bolt, 50.Smm (2 inch)
timing procedures. long, can be turned into the flywheel
rough the timing hole in the flywheel
NOTE: The engine is viewed from the flywheel housing. No. 1 piston is now at top center.
end when direction of crankshaft rotation is given.
NOTE:If e crankshaft is turned beyond the
(1) Remove the staer motor. top center, do steps 4 and 5 again.

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

(7) If No. 1 ston is not on compression

stroke, remove e timing bolt and rotate the
crankshaft counterclockwise 360 degrees.
Install the timing bolt again. The No. 1
piston is now at top center on e
compression stroke.

Checking Engine riming

By Timing Pin Method
Engine Turning Tools Installed
Tools needed:
1. 5P7036 Housing 2. 5P7035 Gear 8S2264 puller group
3. Timing bolt
1B3680 boit (2) [ 3/8-24 NF, 95.3mm (3.75
in) long
4B5271 washer
(3) Remove the valve cove
8B7560 step plate
OL1138 bolt [3/8-24 NF,12.7mm (0.5 in)
long
7N1048 timing pin

(1) Put No. 1 piston at top center on the

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

Valve Cover Removed

4. Rocker ms

35
 Timing Pin.Cover Timing Gear for Fuel Injection Pump

1. Timing pin cover 2. Cover for timing gear 3. Nut 5.Bolt

(2) Remove.timing pin cover ( from the side of the (8) Install puller group and loosen the timing
fuel injection pump housing. gearfrom the fuel pump camshaft.

(3) Install timing pin 49AL002 ( .in the fuel (9) Remove the tii;ning bolt om flywheel
injection pump housing as shown. Slowly rota housing. Rotate the flywheel clockwise
the crankshaft counterclockwise until timing pin 60 dgrees before the top dead cnter of
( goes into the slot in the fuel pump camshaft. No. 1 piston.

(10) Tighten timing bolt nger tight. Be sure

timing pin ( is in the slot of the fuel
pump cShaft.

Timing Pin Installed

2. 7N1048 timing pin

(4) Put the timing bolt in th timing hole in the

Puller Tools Installed
flywheel housing. If the bolt can be installed in
the timing hole in the Hrheele ning 0f the 6. 8S2284 puller group 7. 8B7560 step plate
fuel injection pump is coect. 8. 1B3680 bolt 3/8 -24 NF, 95.3 mm (3.75 in ) long
9. 4B5271 washer
(5) If the timing bolt does not go into the timing hole
in the flywheel, the timing of the fuel injection (11) Slowly rotate the camshaft
pump is not coect. Do the steps that follow to counter-clockwise until e timing bolt
a ust e timing of fuel i ection pump. can be installed in the flywheel.

(6) Remove nut ( and cover om the timing

ge housing.

(7) Loosen bolt at holds the timing gear to e

fuel pump Cnshaft.

36
(12) Install 3/8-24 NF bolt [12.7 mm (0.5 in) long. ]
into a hole of the timing gear and tighten it to a
torque of 60 ~ 70 N.m. Hold the bolt with one
torque wrench, keeping the wrench in line with
e c.enter of timing gear and use another torque
wrench to tighten the bolt holding e timing gear
to 270 ?30 N.m.

(13) Remove e timing bolt in the flywheel and

timing pin ( in the fuel injection pump.

(14) Rotate the crankshaft counterclockwise two

Tightening Timing Gear Bolt
revolutions. If the timing bolt can be installed
in the flywheel and the timing pin can 'be
installed in the fuel pump camshafte timing is
corrct.

(15) If eier the timing pin or the timing bolt cannot

be installed, do the step 7 through step 14 n.

VI. TESTING FUEL INJECTION NOZZELS

Notice

Testing of fuel injection nozzles must be done

with proper tools.

The following tools e required for testing the .

8N7005 fuel iection nozzles:

5P4150 nozzle testing group

5P7448 fitting
8S2270 oil catcher
Ff 1384 extension pipe
5P4150 Nozzle Tes1gGroup
8S2~45 too} group for cleaning
8S2258 brass wire brush A. 5P7448 fitng
8S2252 tool for carbon seal. B. 5P4146 pressure gauge, 0- 6900 kPa
lFl 153 nipper fliers C. 6V2170 pipe group
5V2170 pipe group D. 2P2324 presse gauge, 0 - 34500 kPa
7/64 hexagon spanner E. Safety valve for protection of 2P2324 pressure
gauge

F. Ffl384 extension pipe

G. Safty valve for protection of 5P4146 pressure
gauge
H. Switch valve
I. 8N7005 fuel 1ction nozzle assembly
J. 882270 oil catcher
K. Cut-off valye for fuel pnp

37
 B

Additional Valve
Removal of Carbon Seal
L. Safety v.alve for pressure gauge

(must.be open at any time) NKdudu 2tM 10nunu nnu

pwLW
-
niw

d

mn

LV
Notice
Remove carbon seal ring nipper pliers
Must use cl~n light fuel to test nozzles.. Dirty and dismantle seal element ( off nozzle.
light fuel will damage parts of nozzl. To get
proper tng re temperature for tg
fuel should be in 18 - 24 Nce

Do not use steel wire brush or wheel to brush

. 8N7005 fuel iection nozzles cannot be tom open body or tip of nozzles. Using such toOls will
for cleaning or adjusted. Use the following tests to cause slight deerse of nozzle diameter and
detennine if performance of nozzles is acceptable or result in much drop of power. Excessive use
not. Qf 882258 brass wire brush will scrub off
prot coag of e nozzle.
1. Nozzle opening pressure test
2. Flushing the nozzles Brush the slot of anti-carbon seal ring ( and
3. Tip leakage test fuel injection nozzle body below the slot
4. ifice restriction test
8S2258 brass wire brush (M). When brushing
5. Bleed sew leakage test carbon deposits, be se not to damage nozzle
body.
PreparatoWork Before Nozzle T
NOE : It is normal that at the place below the
It is necessy tp clean carbon particles und e slot there are color changes, which will not affect
tip of no,zzle m 8S2258 brass wire brush (M) fuel injection nozzle body.
before test.

8S2245 Cleaning Tool Box

M. 8S2258 brass wire brush

N. 8S2252 tool for anti~carbon seal
P. 852250 clamper for fuel inJon n0zzle

38
 B34i:SX1
nrt

Nozzle Ready for Test

8N7001Fuel Inj ction Nozzle
E. Safety valve for pressure gauge H. Switch valve
3. Bleed screw and sl K.Cutff valve for fuel pnp

Remove the bleed screw and seal om the fuel Notice

injection nozzle.
Have a rag around the upper part of nozzle to
NOTE: Except for the test 5 (bleed screw leakage catch leaking fuel.
testie bleed screw and seal must be removed
during all tests. (3) Close switch valve en cu
t-
for fuel pump (K).
1. VALVE OPENING PRESSURE TEST
(4en safety valve for pressure gauge (E).
Start fuel pump to increase pressure slowly
(1) Fit 6V2170 pipe group (C) on the tester. until the fuel injection valve of nozzle just
begins to open. Read e maximum
(2) Install 8N7005 fuel iniection nozzle and 5P7448 presse from gauge at e moment fuel is
fitting (A) on the pipe group (C). The position just flowing out of the tip of nozzle.
of the bleed screw hole should face the tester
and be in line with 6V2170 pipe group (C), so NOTE: If fuel injection valve gives out a click.
horizon spray will be formed. Be sure that on openi the reading.shown by the pressure
the tip of nozzle is facing downward and gauge will possibly drop rapidly or keep constant
connected into FT1384 extension pipe (F) and almost.
882270 fuel catcher (J).
NOTE: During the forth step, fuel iectioQ
WARNING valve of nozzle is perhaps abnormal and can not
give out a click, or sprom the nozzle is not
When U be sure to wear safe gog fine.
Fuel injected out of nozzle, which has a vehigh
prS will impale skin, and cause serious If e opning pressure is out of e limits
inju to e operator. specified, the fuel in ection nozzle can not be
used any longer..
Do not aim the tip of nozzle at e operator. It
must be put into 8S2270 fuel catcher and FT1384
extension pipe.
Valve opening pressure (VOP) specifications
15170 1030 kPa

39
2. FLUSHING THE NOZZLE 4. ORIFICE RESTRICTION TEST

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

NOTE: The tip of nozzle must be put into FT1384 (2) Put the tip of nozzle into 8S2270 fuel catcher
extension pipe (F) and placed under the top of the and FT1384 extension pipe. Be sure that
pip the bleed screw is facing the nozzle and in
line wi 6V2170 pipe group (C), so the
(2) Start up e fuel pump fast to perform ree full nozzle will be 15 degrees from vertical and
strokes. spray horizontally.

3. TIP LEAKAGE ~ST (3) When fuel begins to flow into the nozzle,
slowly increase the pressure and watch the
(1) Clear off fuel on the tip and body of nozzle spray shape from orifices. Spray shapes
with a clean rag. from nine orifices must be e same. If the
spray shapes, whether vertical or horizontal,
(2) Have a clean rag around the body of nozzle to are differente fuel pump proves in
catch fuel out of the bleed screw and prevent trouble.
leaking fuel from dripping onto the tip of
nozzle.

31

Good Nozzle
Nozzle Ready for Test (Use again)
E. Safety valve for pressure gauge H. Switch valve
K. Cut-off valve.for fuel pump

(3) Open e safety valve for pressure gauge(E).

Close e switch valve . Op'en e cut-off
valve for fuel pump (K).

(4) Set the opening pressure 1380 kPa lower than

the measured value in the first test, and maintain
it for 15 seconds. Record the number of
leaking fuel drips within the time.

Specification for tip leakage Typical Spray Shape of Restricted Orifice

Not more than 5 drips within 15 seconds (Replace the nozzle)

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

the nozzle.

40 .
 Technical Requirement for Bleed Screw Leakage
No leakage btween bleed screw and nozzle

(5) If there is leaka"ge, change 8N4147 seal

lrnent. Check washer fac of the screw
for damage, and change it if necessy.
Then test the nozzle again. If leakage is still
found, it is necessy to replace th nozzle.

nm
TH lwa sbn
mrmR
kzq Hmo
e Sin
nyuz (6) If no leakage is found, the nozzle can be used
mD
30JAj -

vydELMu

nvnu
UA
A
.
uh Fit a new seal element ( onto the nozzle

Install a new anti-carbon seal ring into the

1
L slot of the nozzle with 8S2252 tool for

anti-can seal

NOTE: The 8S2252 tool for anti-carbon nng

must be calibrated before it can be used for
treating the nozzle.

Typical Spray Shape of

Vertical Deformation
(Replace the Nozzle)

5. BLEED SCREW LEAKAGE TEST

(1) Fit the bleed screw and seal element ( on the

nozzle and tighten bleed screw with torque
of0.9 0.1 N .
Install Carbon Dam
Notice
2. Carbon darn 3. Seal
N. 8S2252 carbon seal tool
The torque to tighten the bleed screw can not
exceed the above specification. Otherwise, the
bleed screw and seal element will be damaged.

(2lt e tip of nozzle into 8S2270 fuel catcher

and FT1384 extension pipe.

(3) Close switch valve . Open the safety

valve for pressure gauge (E) and cut-off-valve
for fuel pump (K).

(4) Run the tester until the fuel iection nozzle is

full of fuel and the pressure gauge reads 27500-
kPa.

NOTE: It is needed for the fuel pump to Cy out

15 or 20 strokes before the pressure can get to
27500 kPa.

41
VII. CHECKING LUBRICATION SYTEM

One of the problems in the list that follows will (1) Be sur that the ngine is filld to the
gnerally be an indication of trouble in e correct level with e1er SAE or SAE30
lubrication system forthe engine. oil. If any othr viscosity of oil is used,
the information in the ngine oil pressure
Too much oil consumption chart does not apply.
Oil pressure is low
Oil pressure is high
Too much bearing wear

1. TOO MUCH OIL CONSUMPTION

Oil Leakage on Outside of Engine

Check for leakage at the seals at each end of

crankshaft. Look for leakage at the oil pan gasket
and all lubrication system con,nections. Check to
see if oil comes . out of the crankcase breather.
This can be caused by combustion gas leakage Oil Pressure Switch Location
around the pistons. A dty crankcase breather will
1. Oil pressure switch
cause high pressure in the crankcase, and is will
cause gasket and seal leakage.
(2) Remove the oil pressure switch om
Oil Leakage into Combustion Area of Cylinders the re of cylinder block and install a
thre-way. pipe in at location. Fit one of
Oil leakage into the combustion a of the the probes of 9S9102 rrnistor
cylinders can be the cause of blue smoke. There are thermometer group into on end of the
four possible ways for oil leakage into the three-way pip and connect 8M2744 gauge
combustion ea of the cylinders: in 5P6225 hydraulic test case with the
other end of,the pipe.
(1) Oil leakage between worn valve guides and .
valve stems; ..... , 2

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

holes;
(3) Compression ring and/or intermediate ring not
installed correctly;
(4) Oil leakage past the seal rings in the impIler
end of the turbocharger shaft.
.d
Too much oil consumption can also be the result if
oil with the wrong viscosity is used. Oil M a
thin viscosity can be caused by fuel leakage into the
crankcase, or by increased engin temp~rature.

2. OIL PRESSURE IS LOW

5P6225 Hydraulic Test Case
An oil pressure indicator that has a defect can give
an indication of low oil pressure. So a pressure
gauge is needed to check engine oil pressure.

Take the following procedures to check oil pressure.

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

42
(3) Run the ngine to gt the engin oil temperare Oil Filter and Oil Cooler Bypass Valves
at 99?C.
If th bypass valve for e oil filter or oil
NOTE: A 3?C increase in temprature gives cooler is held in the open position, and e oil
approximately 7 kPa decrease in engin oil pressure. filter or oil cooler has a restriction, a rduction
in oil pressure can.be resulted. Install a new
catrpillar oil filter to solve the problem.
( 4) Keep the engine oil temperature constant. With
the engine at the r/min from the chart, read th Too Much Clearance at Engine Bearings or
pressure indicator and compar indication with
Open Lubrication System
the minimum acceptable pressure in the chart. (Broken or Disconnected
If the indication is below the minimum pressure,
Oil Line or Passage)
find the cause and adjust it. Engine failure or a
reduction in engine life can be the result if engine Components that are worn and hav too much
operation is continued with too low pressure. bearing clece can cause oil pressure to be
low. Low oil pressure can also be caused by
an oil line or oilpassage at is open, broken
or disconnected.

Chart for Oil Prssure Oil Cooler

Minimum Permissible
Test Test oil pressure Look for .a resction in the oil passag of the
speed SAE No. oil cooler. If oil cooler has a restriction, oil
kPa
temperare will be higher than normal when
1500 r/nn 10 140 the engine is operated.. The oil pressure of
or higher 30 165 the engine will not get low just because the oil
600 ~ 10 40 cooler has a restriction.
800 r/rnin 30 59
3. OIL PRESSURE IS IDGH
Crankcase Oil Level
Oil pressure will be high if the bypass valve
Check the level of oil in crankcase. Add oil if for the oil pump cannot move from the closed
needed. It is possible for the oil level to be too far position.
below the oil pump supply tube. This will cause the
oil pump not to have ability to supply no ugh 4. TOO MUCH BEARING TEAR
lubrication to the engine components.
When some components of. the engine show
Oil Pump Does Not Work Correctly bearing wear in a short time, the cause can be
a restriction in an oil passage. A broken oil
The inlet screen of the supply tube for th oil pump passage can also be th cause.
can have a restriction. This will cause cavitation
(low pressure bubble suddenly made in liquids by If the gauge for oil pressure shows normal
mechanical force) and a loss of oil pressure. Air pressure, but a componnt is worn because it
leakage in e supply side of ie oil pump will also Cmot get enough lubrication, look at e
caus cavitation and loss of oil pressure. If th passage for oil supply to the component. A
bypass valve for the oil pump is held in the open restriction in a supply passage will not let
positione lubrication system cmot get to a enough lubrication get to a component, and
maximum pressure. Oil pump gears that have too this will cause early wear.
much wear will cause a reduction in oil pressure.

43
VIII. BELT TENSION ADJUSTMENT

(1 ) Check all ive belts for excessive wear,

abrasion and break

When one belt in a set requires replacement,

always install a new matched set of belts.
Never replace just the worn belt. If only th
worn blt is replaced, the new belt will Call
the load. All the belts will fail in rapid
succession.

(2) Measure the belt tension. Apply a force of 110

N vertically to the belt between the driving and
iven pullys.
(2) Move the alternator in or out to get correct
adjustment.
The normal deflection of belt should be 14 ~ 20
mm. Adjust belt tension as required.

Adjusting

(3) Tighten the retaining bolt after adjustment.

(1) Loosen the retaining bolt. on the slotted

bracket.

44
CHAPTER THREE

MAINTENANCE

I. MAINTENANCE AS NEEDED

1. COOLING SYSTEM
Notice
Cleaning
If the engine is to be stored in, or shipped to, an
WARNING area with freezing temperare, the cooling
system must be protected to the lowest expected
At operating temperature, the engine coolant is outside (ambient) temperare or coolant
hot and under pressure. should be drained.
Steam can cause personal injury. Never add coolant water to an overheated
engine, engine damage can result. Allow "the
Check the coolant level only after the engine h engine to cool first.
been stopped and the filler cap is cool enough to
remove with your bare hand.

Remove the cooling system filler cap slowly to

relieve pressure.

Cooling system additive (conditioner) contains

alkali. To preve personal injury, avoid contact
with the skin and eyes.

(2) Remove the radiator drain plug.

(1) Iosen the radiator filler cap slowly to relieve

pressure and remove the cap.

WARNING

Use all cleaning solutions with care.

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

45
 th coolin g system
(4) Install all drain plugs. Fill
with commercially available cleaner or th
mixture of lkg NaHS04 per 40 L (10 US gal)
clean watr.

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

e engine and drain the cleaner.

(6) Flush the cooling system with clm water until

the draining watr is clear. Do not run the
engine during flushing.

(7) Install all drain plugs. Fill ie system with (1) Remove the air claner cover and element.
neutral so~ution or e mixture of 250 g
Na2C03.lOH20 pr 40 L water.

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

the engine and drain the neutral solution

(9) Flush the cooling system with clean water until

the draining water is clear. Do not run the
engine during flushing.

(lO)Install all drain plugs.

(l l)Fill e system with clm water. Start and run

the engine for 10 minutes, then drain the water.
(2) Seal the turbocharger air inlet.
Repeat above steps until the draining water is
cle

(12) Fill the cooling system no faster than 19 L

per minute to avoid air locks.

2. AIR INLET SYSTEM

Single Stage Air Cleaner - Replacing Element

Notice

Service the air cleaner only when the engine

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

(4) Inspect the replacement element for damage,

dirt or debris.

(5) Rmove the seal from the turbocharger inlet.

(6) Install a clean, undamaged element.

Observe the air claner service indicator. Service

the air cleaner when the red piston locks m
visible position.

46
(7) Install the air cleaner cover. (3) Loosen the clamp bolt on the upper body.

(8) Reset the service indicator. (4) Remove the lower body and clean the tubes
from both ends.
Tuo Stage Air Cleaner - Cleaning
(5) Inspect the seal between the lower body and
e dust collector cup and gasket between
the lower and upper bodies. Install a new
.seal and gasket if necessy.

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

(2) Remove and empty the dust collector cup.

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

47
 Notice

When using presse water for cleaning, the

maximum pressure should be lower than 280
kPa (2.8 kg/cm2) (40 psi) to avoid damage of e
element.

COMPRESSED AIR - The ,pressure should be

205 kPa mimum.

(6) Install th dust collector cup and tighten the

clamp bolt.

Installing The Replacement Element Of Two

Stag~ Air Cleaner

(1) Direct prsure air along the length of the

pleats inside of filter element.

Notice

Do not clean filter elements by bumping or

tapping.

(1) Remove the cover. Do not use filter elements wi damaged pleats,
. gaskets or seals. Engine damage could result.
(2) Remove the inside cover and element. In cold
weather, the cau~ht inside cover can be removed Have spare elements on hand to use when cleaning
by heating the air cleaner cover to 21 24 e used filter elements.

(3) Clean all pts of the arr cleaner. Dry filter elements can. be' cleaned with pressure
air, pressure water or detergent washing.
(4) Inspect the replacement element for damage,
dirt or debris.

(5) Install a clean undamaged element. Install the

inside cover and wing nut. Tighten the wing nut.

(6) Install the cover.

Cleaning Air Cleaner Elements

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

48
(2) Direct pressur air along the length of the pleats (2) Rinse inside and outside the pleats.
inside and then outside of filter element
Inspect th filter element. (3) Air dry the element thoroughly and inspects it
before using.
PRESSURE WATER - The pressure should be
280 kPa maximum.

(1) Direct water along the length of the pleats inside

of filter element.

(2) Direct water along the length of the pleats

outside of filter element. Air dry element (2) Wrap and store the clean filter elements in a
cley plac
oroughly and inspect it.

DETERGENT WASHING 3. FUEL SYSTEM

New Scroll Fuel System

(1) Stop the engine.

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

49
(3) Loosen the nut ( on the primary filter cap and Notice
remove the filter housing (.
Do not fill the fuel filter with fuel before
(4) Remove th~ element ( and wash it and the installing it. Prime the fuel system according
cap in clean, nonflammable solvent. to the instruction of Priming The . Fuel
System.
(5) Install the element and housing.

Final Fuel Filter

(5) Install new filter. Spin filter until gasket

contacts the filter base. Tighten the filter
1/2-3/4 tum by hand.

(1) Remove and discard the final fuel filter. (5) Prime the fuel system.

Priming The Fuel System

(1) Move the fuel control linkage to the OFF

osition.

(2) Clean the gasket sealing surface of the filter

base.

Notice (2en the 'vent valve on the fuel injection pump

housing.
Make sure all the old gaskets are removed.

(3 erate the priming pump until the flow of

(3) Apply clean diesel fuel to th new fuel filter
gasket. fuei from the vent valve is continuous and free
of air bubbles.

50
 Notice

If only one wrench is used to loosen or tighten

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

(5) Start the engine. If the engine continus to

misfire or smoke, further priming is necessy.

(6) Loosen the fuel line nuts on the cylinder head.

Crank the engine until the fuel flows fr of air
bubbles.

(4) Close the vent valve and lock up e priming (7) Tighten the fuel line nuts to 40 7N .m.
pump.

II. MAINTENANCE EVERY 10 HOURS

1. ENGE CRANKCASE 2. AIR CLEANER SERVICE

INDICATOR

Check air cleaner service indicator. If the red

(1) Check oil level.
Maintain the oil level between the
piston locks in the rising position, service the
FULL and ADD marks on the Running side of the
air cleaner.
dipstick.

(2) Add oil if necessary.

51
1. FUELTANK Remov the radiator filler cap slowly to
relieve pressure

Cooling systm additive (anti-rust) contains

alkali. To prevent personal injury, avoid
contact with the ski'n and eyes

If it isnecessy to add coolant every day,

check the cooling system for leakage.

Drain water and sediment.

4. COOLING SYSTEM

Checking Coolant Level

At operating temperaturee engine coolant is hot and

under pressure. (1) After the engine is stopped and cool, check
the coolant level. Open the radiator filler
Steam can cause personal irjury. cap slowly to relieve pressure. Watch
coolant level.
Check the coolant level only after e engine has been
stopped and the filler cap is cool enough to remove (2) Maintain the coolant level within 1 cm
with your bare hand. below e bottom of the fill pipe. Check
gasket of radiator filler cap and replace it if
necessy.

ID. MAINTENANCE EVERY 50 HOURS

5. DUST COLLECTOR

Cleaning

(1) Remove the retaining wing nut from the top of dust (2) Remove and clean the dust collector cup.
collector.

52
(3) Install the collector cup.
(2) Remove all fill caps. Check electrolyte
levI.
6. BATTERIES
(3) Maintain electrolyte level to bottom on fill
Checking Electrolyte Level
plug openings.
WARNING

Do not smoke when observing the battery electrolyte

level. Batteries give off flammable fumes, which
can explode.

Battery electrolyte contains acid, and can cause

personal injury if it contacts the skin and eyes.

(4) Install fill caps.

If addition of water is necessary, use distilled

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

(1) Clean top of batteries.' Kep all baery

terminals clean and coat them with grease.

IV. MAINTENANCE EVERY 250 HOURS

7. ADJUSTING ALTERNATOR BELT TENSION WARNING

A ust it as required. Take care to change oil and filter(s). The

skin can be burned if hot oil and
8. ENGINE CRANKCASE (TURBOCHARGED components are touched.
ENGINES ONLY)

Oil and Filter Change

53
(1) Remove the crankcase oil drain plug and allow the
(6) Use cleaning solution, which is clean and
oil to drain. not easy to bum, to wash the oil drain plug,
and then install it.

(2) Wipe off the dirt on the surface of oil filter(s). (7) Fill the crankcase with clean oil. See the
chart for Filling Capacity of Engine
(3) Remove and discard the filter. Oil and Coolant'.

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

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

(4) Wipe the sealing surface of the filter mounting base.

Make sure all of the old gasket is removed.

(5) Install a new filter, until the gasket contacts the base.
Tighten the filter 3/4 of a tum more by tool. (9) Stop the engine. Maintain the oil level to
There may be marks at 90 intervals on the filter. FULL mark.
When tightening the filter 3/4 of a tum more by
toolese marks should be used.

54
9. CRANKCASE BREATHER 10. COOLING SYSTEM

Adding Coolant Anti-Rust

WARNING

At operating temperature, the engine

coolant is hot and under pressure.

Steam can cause personal iU

Check the coolant level only after the

engine has been stopped and the uler cap is
cool enough to remove with your bare hand.
(1) Loosen the breather hose clamp and remove e
hose. Remove the radiator filler cap slowly to
relieve pressure.

Cooling system additive (anti-rust) contains

alkali. To prevent personal injury, avoid
contact with the skin and eyes.

(2) Loosen the breather retaining bolt and remove the

breather.

(1) Loosen the radiator filler cap slowly to

relieve pressure and then remove it.

It may be necessy to drain enough

coolant from the radiator to allow for the
addition of the supplemental coolant
anti-rust.

(2) Add coolant anti-rust to the cooling

(3) Check sealing gasket and replace it if necessary.
system. For the appropriate concenation
of coolant anti-rust, refer to e instruction
(4) Use cleaning solution, which is clean and not easy to
of th anti-rust manufacturer.
bum, to wash the breather. Then dry the breather.
(3) Inspect the radiator filler cap gaskets.
(5) Install the breather.
Replace the cap if the gaskets are
damaged.
(6) Install the hose and hose clamp on the breather.
(4) Install the radiator filler cap.

55
V. MAINTENANCE EVERY 500 HOURS

11. ENGINE CRANKCASE (NATURALLY 13. FUEL SYSTEM

ASPIRATED ENGINES ONLY)
New Scroll Fuel System
Oil and Filter(s) Change

Change the oil filter(s) and wash the breather. Refer

to the relevant description in Section IV of this
Chapter.

12. FAN BEARING

Clean primary filter and replace e element of

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

Lubricate one fing.

VI. MAINTENANCE EVERY 1000 HOURS

14. GOVERNOR Synchronous Motor

Lubricate two fit1gs.

Fill oil cup.
15. ENGINE SHUTOFF CONTROLS

The ngine shutoff controls must be checked

periodically so at they function properly when they 16. TACHOMETER
are reqred. To prevent damage to ie engine while
performing the test, only authorized personnel should Lubricate one fitting.
prform e checks.

56
VII. MAINTENANCE EVERY 2000 HOURS

17. VALVE LASH

Adjust the engine valve lash as specified.

18. COOLING SYSTEM

Replacing the Coolant (Every 2000 Operating

Hours or 2 Years)

WARNING

At operating temperature, the engine coolant is hot

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

Steam can cause personalinjury.

Check the coolant level only after the engine has

been stopped and the filler cap is cool enough to
remove with your bare hand.

Remove the radiator Iller cap slowly to relieve

pressure.

Cooling system additive (anti-rust) contains alkali.

To prevent personal injury, avoid contact with the
skin and eyes.

(3) Remove the cylinder block drain plug(s).

Allow the coolant to drain.

(4) Wash the drain plug(s).

(5) Install the drain plug(s).

(6) Fill coolant according as specified in Section

1.3 of Chapter Two.

(I) Loosen the radiator filler cap slowly to relieve

pressure and then remove it.

57
CHAPTER FOUR

TROUBLESHOOTING

Troubleshooting can be difficult. The Troubleshooting index gives a list of possible problems. To make a
repair to a problem, make reference to the cause and correction on e pages that follow.

This list of problems, causes and corrections will only give an indication of where a possible problem can be, and
what repairs are needed. Normally, more or other repair work is needed beyond the recommendation in the list.

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

This list is only a guide and cannot give all possible problems and corrections. Service personnel must find the
problem and its source, then make the necessy repairs.

Troubleshooting Index

No. Trouble No. Trouble

1 : ~ngine will not tum when start switch
16 Oil at the exhaust.
1s on.
- -
2 : Engine will not start. 17 1 Little or no valve lash. ,
3 ~ Misfiring or running rough. 1 18 : Engin
4 ' sl at low r/rnin. 19 ; Coolant in lubrication oil.
5 I Sudder ar sin er r/ 20 : Too much black or gray smoke.
L
!

6 ' Not enough power. ; 21 Too much white or blue smoke.

7 Too much vibration. 22 : Engine has low oil pressure.
8 LLoud combustion noise (knock). '
23 Ene uses too much lubrication oil. !

0 ; Loud noise clicking ) from valve

: 24 ! Engine coolant is too hot.
i : comptment

10 i Oil in cooing system. 25 Startin~ motor dose not turn.

11 '. Mechanical noise (knock) in engine. 26 , Alternator ~ives no char~e.
Alternator charire rate is low or not '
12 Fuel consumption too high. 27 . I:>
, ! regu1ar.
: Loud noise from valves or valv
13 I 28 Alternator charge is too high.
o?erating components.
Little movement of rocker m and too
14 29 Alternator has noise.
much valve lash.
15 Valve rotocoil or spring lock is free. 30 Exhaust temperature is too high.

58
~roblem 1: Engine WiJI Not Turn When Start Switch ls On

No. Probable Cause Remedy

Battery has low output Make reference to Problem 26.

2 Wires or switchs have defect Make referenc to Problem 26.

3 Starter motor solenoid has a defect Make reference to Problem 25.

4 Starter motor has a defect Make reference to Problem 25.

5 Inside problem prevents engme If crankshaft cannot be turned after the

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

Problem 2: Engine Will Not Start

No. Probable Cause Remedy

Slow cranking speed Make reference to Problem 26.

2 No fuel in the housing for the fuel Fill the housing for the fuel pumps with fuel using
1ection
pumps the priming pump. Remove the air with the bleed
valve.

3 Dirty fuel filter Install new fuel filter.

k

45DN
unu nnl 1n pa
oeKVd
evu
wd

I
nu

HULM
LVV

uv
An

Clean or install new fuel lines as necessy.

G

lv

Put fuel in fuel tank. Prime(remove

E

thr
uw

om the fuel system).

6 Poor quality or water in fuel Remove fuel from the tank. Install a new fuel
filter element. Put a good grade of clean fuel in
thiel tank.

7 Fuel has cloud point higher than Drain the fuel tank, lines, and fuel injection pump
atmospheric temperature (cloud point= housing. Change the fuel filter. Fill e tank
temperature which makes W form in with fuel which has the correct cloud point and
fuel) remove the r from e system with the priming
pump.

8 Wrong fuel injection timing Make a ustment to timing.

9 Overfueling spring not installed Install overfueling spring.

59
Problem 3: Misfiring Or Running Rough

No. Probable Cause Remedy

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

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

3 Leak or break in fuel line between fuel Install a new fuel line.
injection pump and fuel iection nozzle

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

5 Fuel system not timed correctly to engine Mak ajustment to timing if necessary.

6 Wrong valve lash Make ajustment.

7 Bent or broken push rod Replacement of push rod is ncessary.

8 Wrong valve seat or face of valve Reconditioning of cylinder head is needed.

Problem 4: Stall At Low R/Min

No. Probable Cause Remedy

Idle r/min too low Make adjustments to governor.

2 Defect in fuel iction nozzle(s) or fuel Run engine at r/min that gives maximum misfiring
injection pump(s) or rough running. Then loosen a fuel line nut on
the fuel injection nozzle for each cylinder, one at a
time. Find e cylinder where loosening the fuel
line nut do~e not change the way the engine runs.
Test . fuel injection pump and fuel i ection
nozzle for that cylinder. Install new parts where
needed.

60
Problem 5: Sudden Changes In Engine R/Min

No. Probable Cause Remedy

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

Problem 6: Not Enough Power

No. Probable Cause Remedy

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

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

3 Poor quality or water in fuel Remove fuel from the tank. Install a new fuel
filter element. Put a good grade of clean fuel in
the fuel t
4 Constant bleed valve stays open or closed Install new pts if needed.

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

6 Governor linkage Make ajustment to get full travel of lin_kage.

Install new pts for those that have damage or
defects.

7 Wrong vale lash Make austment.

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

10 Fuel setting too low Makea ustment as specified.

11 Turbocharger has carbon deposits or other Make inspection and repr of turbocharger as
cause for friction necessary.
Problem 7: Too Much Vibration

61
No. Probable Cause Remedy
IMAU nu -aL t . nul AUl nuob DsHUII VJ

u
OE - hu

LV
nu

nur
nu nuHU hu

t


-
Tighten bolt or nut

iw
A
A
2 Pulley or damper has a defect Install a nw pulley or damper.

3 Fan blade not in balance Loosen or remove fan belts and operate engine for
a short time at the r/min that the vibration was
present. If vibration is not still present, make a
replacement of the fan assembly.
4 Engine supports are loose, worn, or have Tighten all mounting bolts. Install new
a defect components if necessy.
5 Misfiring or running rough Make reference to Problem 3.

Problem 8: Loud Combustion Noise (Knock)

No. Probable Cause Remedy

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

2 Defect in fuel iection nozzle(s) or fuel Run engine at r/min th gives mimum
injection pump(s) combustion noise. Then loosen a fuel line nut on
the fuel iection nozzle for each cylinder, one at a
time. Find the cylinder where loosening the fuel
line nut stops combustion noise. Test the fuel
i ection pump and fuel iniection nozzle for at
cylinder. Install new pts where needed.

3 Wrong fuel iction timing Make austment to timing.

Problem 9: Loud Noise (Clicking) From Valve Compartment

No. Probable Cause Remedy

Damage to valve spring(s) or locks Install nW parts where necessary. Locks with
defects can cause e valve to slide into e
cylinder. This will cause much damage.

2 Not enough lubrication Check lubricati9n in valve compartment. There

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

3 Too much valve lash Make adjustment.

4 Damage to valves Make a replacement of the valve(s) and make an

adjustment as necessary.

62
Problem 10: Oil In Cooling System

No. Probable Cause Remedy

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

2 Defect in head gasket Install a new head gasket.

Problem 11: Mechanical Noise (Knock) In Engine

No. Probable Cause Remedy

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

2 Damage to timing gears Install new parts when necessy.

3 Damage to crankshaft Replace the crankshaft.

Problem 12: Fuel Consumption Too High

No. Probable Cause Remedy

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

2 Fuel and combustion noise (knock) Small increases in fuel consumption may be the
result of fuel nozzles with defects, rough running,
or factors causing loss of power. See Problem 3
and Problem 6.

3 Wrong fuel injection timing Make an austment to fuel injection timing.

Problem 13: Loud Noise From Valves Or Valve Operating Components

No. Probable Cause Remedy

Damage to valve spring(s) Make replacement of parts with dnage.

2 Damage to Cnshaft Make replacement of pts with damage. Clean

engine thoroughly.

3 Damage to valve lifter Clean engine thorough Make replacement of

e camshaft and valve lifters. Look for valves
that do not move freely.

4 Damage to valve(s) Make a replacement of the valve(s) and make an

adjustment as necessary.

63
Problem 14: Little Movement.Of Rocker Arm And Too Much Valve Lash

No. Probable Cause Remedy

Too much valve lash Make adjustment.

2 Not enough lubrication Check lubrication in valve compartment. Ther

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

3 Rockr i worn at face that makes If iere is too much wear, install new rocker ms.
contact with valve Make an adjustment to valve lash.

4 End ofvalv stem worn If there is too much wear, install new valves.
Make an a ustment to valve lash.

5 Worn push rods If ther

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

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

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

8 Worn cams on camshaft Check valve lash. Check for free movment of
valves or bent valve stem. Check for valve lifter
wear. Install a new camshaft. Make austment
of valve lash.

Problem 15: Valve Rotocoil Or Spring Lock Is Free

No. Probable Cause Remedy

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

2 Damage to vve spring(s) Install new valve spring(s).

Problem 16: Oil At The Exhaust

No. Probable Cause Remedy

Too much oil in the valve comptment Look at both ends of the rocker m shaft. Be
sure at there is a plug in each end.

2 Worn valve guides Reconditioning of th cylinder head is needed.

3 Worn piston rings Make a visual inspection of the piston rings.

Install new pts if necessary.

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

64
Problem 17: Little Or No Valve Lash

No. Probable Cause Remedy

Worn valve seat or face of valve Reconditioning of cylinder head is needed. Make
an austment to valve lash.

Problem 18: Engine Has Early Wear

No. Probable Cause Remedy

Dirt in lubrication oil Remove dirty lubrication oil. Install a new

en~ne oil filter element. Put clean oil in the
engme.

2 Air inlet leaks Inspect all gaskets and connections. Make

repairs if leaks are present.

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

Problem 19: Coolant In Lubrication Oil

No. Probable Cause Remedy

Failure of engine oil cooler core Install a new core for the engine oil cooler.

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

3 Crack or defect incylinder head Install a new cylinder head.

4 Crack or defect of cylinder block Install a new cylinder block.

5 Failure of seals .for cylinder liners Make a replacement of the seals.

'Problem 20: Too Much Black Or Gray Smoke

No. Probable Cause Remedy

Not enough air for combustion Check air cleaner for restrictions. Check inlet
manifold pressure. Inspect turbocharger for
coect operation.

2 Bad fuel injection nozzle(s) Test all nozzles. Install new nozzles if test shows
replacement is needed.

3 Wrong fuel in ection timing Make adjustment to timing.

65
Problem 21: Too Much White Or Blue Smoke

No. Probable Cause ~ernedy

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

2 Misfiring or running rough Make reference to Problem 3.

3 Wrong fuel iection timing Mak austment to tinung.

4 Worn valve guides Reconditioning of the cylinder head is needed.

5 Worn piston rings Install new piston rings.

.
6 Failure of turbocharger oil seal Check inlet manifold for oil and make repair to
turbocharger if necessary.

Problem 22: Engine Has Low Oil Pressure

No. Probable Cause Remedy

Defect in oil pressure indicator Install new indicator.

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

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

4 Too much clearanc between rocker m Check lubrication in valve comptment. Install
shaft and rocker new pts as necessy.

5 Oil pump suction pipe has a defect Replacement of pipe is needed.

6 Relief valve for oil pump dose not oprate Clean valve a,nd housing. Install new pts as
correctly necessary.

7 Engine oil pump has a defect Make repair or replacement of engine oil pump if
necessy.

8 Too much clearanc between camshaft Install new camshaft and camshaft beings if
and camshaft bearings necess y.

9 Too much clearanc between crankshaft Check oil filters fur proper operation. Install new
and crankshaft bearings parts as necessy.

10 Too much cleararice for idler ge Inspect bearings and make replacemnt as
necessary.

11 Orifices for piston cooling not Install piston cooling jets.

installed

66
Problem 23: Engine Uses Too Much Lubrication Oil

No. Probable Cause Remedy

Too mu~h lubrication oil in engme Rmove extra oil. Firid where extra oil comes
from. Put coect amount of oil in engine. Do
not put too much oil in engine.

2 Oil leaks Find all oil leaks. Make repair as needed.

3 Oil temperature is too high . Check operation of engine oil cooler. Install new
parts if necess. Clean the core of the engine
oil cooler.

4 Too much oil in valve comptment Make reference to Problem 16.

5 Worn valve guides Make reference to Problem 16.

6 Worn piston rings and cylinder liners Install new parts i( necessary.

7 Failure of seal rings in turbocharger Check inlet manifold for oil and i'nake rep to
tbochger if necessy.

Problem 24: E~gine Coolant Is Too Hot

No. Probable Cause Remedy

mubr
m

dw
d
o

n wf El nMh
uea

3n
vAVAVA

-
nvnu
puv

TARM

2nbAUU

Remove all restriction to flow.

mM ....

Ahu

-
E

2 Not enough coolant in system Add coolfil,lt to cooling system.

3 Pressure cap has a defect Check operation of pressure cap. Install a. new
pressure cap if necessary.

4 Combustion gases in coolant Find out where gases get into the cooling system.
Make repairs as needed.

5 Water temperature regulator errnostat) Check water temperature regulator for correct
or temprature indicator has a defect. operation. Check temperature indicator operation.
Install new pts as necessy.
6 Water pump has defect Make repairs to the water pump as necessy.

7 Too much load on the system Make a reduction in e load.

8 Wrong fuel in ection timing Make austrnent to timing.

67
Problem 25: Starting Motor Does Not Turn

No. Probable "Cause Remedy

Battery has low output Check condition of battery. Charge battery or

make replacement as necessy.

2 Wires or switch has defect Make repairs or replacement as necessary.

3 Starting motor solenoid has a defect Install a new solenoid.

4 . Starting motor has a defect Make repr or replacement of starting motor.

Problem 26: Alternator Gives No Charge

No. Probable Cause ~emedy

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

2 Ch~ging or ground return circuit or Inspect all cables and connections. Clean and
battery connections have a defect tighten all connection. Make reP,lacement of
parts with defects.

3 Rotor (field c~il) has a defect Install new rotor.

Problem 27: Alternator Charge Rate Is Low Or Not Regular

No. Probable Cause Remedy

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

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

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

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

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

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

No. Probable Cause Remedy

Alternator or regulator has loose Tighten all connections to alternator or alternator

connections regulator.

68
2 Alternator regulator has a defect Install a new alternator regulator.

Problem 29: AlternatorHas Noise

No. Probable Cause Remedy

Drive belt for alternator is worn or has a Install a new e:l.rive belt for ~ternator.
defect

2 Loose alternator ve pulley Check groove in pulley for key at holds pulley in
place. If groove is worn, install a new pull
Tighten pulley nut according to spcification.

'3 Drive belt and drive pulley for alternator Make an ausent to put drive belt and drive
are not in alignment pulley in correct alignment.

4 Worn alternator bearings Install new bearings in the alternator.

5 Armature or rotor shaft is bent Make a replacement of ~e parts.

6 Rectifiers in the alternator e shorted Make a replacement of the diode assembly.

Problem 30: Exhaust Temperature Is Too. High

No. Probable Cause Remedy

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

2 Leaks in exhaust system Find the cause of leaks. Make repairs if

necessy.

3 Air inlet or exhaust system has a Remove restriction.

resiction

4 Wrong fuel injection timing Makean adjustment to the timing.

69


1

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