Cummins B Series Repair Manual

 

c

Trou

Four Cylinder

Oopy rlqh t= 1993 Cummins Engine Company   I n c . All righ servedd rightt s r e serve

 

B u ll etin 366 36666 0 8 7 P ri n ted 1 1/93

Foreword This manua   provides instructions for troubleshooting and repairi n g the B S er es E n g i ne i n the c hasss. Comp onent and assembly r ebuild procedures are p rovided i n the B Ser ies Engin e Shop M anual. R efer t o P a g e i - 2 in t he In troduction for in structions o n how to use this m anu al. Th e p r o ced ures given in this this m a n u a l a r e a p p l i cable fo r t he B Seri es engines produced i n 1991 and n e wer. R efe r to B ul l e t i n No   3810 2 07 to find find the p ro c e dures app li c a bl e to B Series engines introduced p rior to 1991 1991.. The manual is organized to guide a ser vice techn i cian problems r elated to the engin e.

hrou oug h the l ogical steps of id entify ng a n d c o r r ecti n g thr

c e or equipment p r obems   C o n s u lt th e ve h ic e or equi p me This manual does no nott cover veh ehc men nt r epair procedures.

man ma nufactur e r for

A series of specific service m anua s ( Shop, S p e c ification ations, s, Alterna tiv ive e R e pair, a nd s o o n . ) a re av a il ab e a nd ca cann be ordered by filling out and mailing the Literature Order Form located i n the Ser vi ce Li ter atu re S e ct o n L. The r epai ended d b y C ummi epairr p rocedures used used in this m an u a   are re commende min ns E n gine C o ., procedures require th the e u se of special service too ools ls   U se th e correct tool s as d es esc cr i bed. tools

I nc   S o m e

serv c e

Reporting of e r rors, omission s, and recommen dations for im pro v i ng this pub i cation b y the u ser i s e ncour age aged. d. t ma co Please use the postage paid, self-addressed L i teratu re S u r v e y Form in th e b a ck of h is n u a   for mmu mmunica t i ng your comments. The specifications and rebuild i nformation in this manua   is base d o n the inform a t i o n in e ffect a t the ti m e of p ri n t ing. based Cummins Engine Company, I nc. reserves the r i ght to m a ke any changes a t any tim e without o bligat io n. If diff erences are found between your engine a n d th e i n form a ti o n in this m a nual, c o ntac ntactt a Cumm ins Autho r i zed Repair L o catio cationn , a C u mmins D i vision Office, o r t h e factory. The latest technology and the highest quality com ponen ts are used to m a n u facture Cumm mmiins engines. When r eplacement parts are needed, we reco m mend u sin sing g only gen gen ui n e C ummin s or R e C o n ® exc h a nge part s. Th e se part s can be i dent fied b y the fo ll o w i n g tr adem a r ks :

c

-

 

( HDLSET) ®

e e tg u a r d ®

Ill

Prearniiuarn

_a.lue

®

T a ble of Contents Section I n troduc duction tion

.

Engine I dentification

.

E

Troub leshooting

.

T

C o oling System Repair

.

1

I I I I

Lubricating Oil Sy Sys ste m R e pair

..

2

I

Ai r Combustion System R e pair

..

3

Compressed Air System R e pair

..

4

F u el S yste m Repair

.

5

E l ectric a l System R epair

.

6

I I I I

Base Engine Engine C omponents System Repair

..

7

I

Engine Testing a n d Run-In

.

8

I

Engin e Removal and I n stallatio n Engin

.

9

I

v

I

Specifications and Torque Values

:· · · · · · ·

.. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·

Component M anufact cturer urers

.

c

Ad ditional S ervice

.

L

.

x

I nde x

l terrature te

 

Page 4

Table of Contents

I I

I

NOTES

 

Section i - Introduction B S e ries

P a g e l-t

Section i - Introduction Sec Se ction Contents Page i-2

About the Manual.. . . . . .. . .. . . . . . ........ . .. . . .... .. .. . . ............. ...... . ..... . .. .. . . . .. ........ .. . . . . . ..... .. . . .. . .. . . .. . .. . .. . . .. .. .. . . ........ . . .... .. .......

Definition of Term s . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-8 Genera l Cleaning Instr u c tion s Genera ass or P l astic B ead C l eaning eaning G l ass Solvent So lvent an d A c id Cleani n g. g... . . .. . . .. . . . .. .... . .. . ............. . .. . .. . .. .. . . .. . . . . .. .. . . .. .. . .. . .. .. . . .. . ..... . .. .... . . .. . .. . . .. . . .. . ..................

-10 i- 1 0 i- 1 0

eaninn g S t eam C l eani G e nera   R e pair Instruction s

i -1 0 i-1 1

General Safety In structions I m p o rt rta an t Sa ety N o ti ce. .... . .. . . . .. . .. . . . . . ....... . .. . .......... ..... . . . .. . .. . . .. .. .. . .......... ...... . .. . ................... .................................... ................. .......

i-9 i-9

H o w to Use the Manual

i -2

Illu strations

i -7

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

. . . . . . . . . . . . . . . .. . . . .

. . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . .

 

Section i

About the Manua   Page i - 2

-ntroduction

B Series

Ab o ut th e Manual T h i s B Se Serr ies Tro u bleshooting and Repair Manua   is i n tended to aid in deter mining the cause of engine-related engine-related

i -3

probl ems and to provi provide de recommended re pa ir procedur es. The manu al is divided into i nto sections by system. Each

formatio section provides genera  genera   i n for mation , specifi cation s, d i agrams, and service tools, where applicable. The specific repair procedures are referenced i n th e Tr oubeshoo oubeshootting L o g i c Cha Charr ts.

How to U se the M a nua l The m a n u al i s o r ganized t o provi d e a n easy flow from problem identificat on to problem correction. A list of troublesh ootin g sy m ptom s contain i ng the m o s t co mmo n engin e problems is on Page T-2 in the Troubleshooting Sect on. Complete the following s te p s to l o ca catte a n d c o rrect th e problem: ( S TE P

Locatte th e sy mptom o n th e li s t. Loca

1 .)

R e ference i s made to the pro ce d u r e number where the "Troubleshooting Logic Chart" is found. (S TEP 2. )

The left co umn o f th e "Troubl e s h o o tin g L ogic Chart" indicates a probable cause, starting at the top with the simplest and e a s i est t o r epair, and continuing downward to the most difficult. The r ight column p r ovides a br e f descr descrii ption of th e corrective action with the reference number for the repair.

(STEP 3.)

Locate th e probab probab le cause in th e l e ft colu mn, a nd then turn to the procedure number in the right colu mn. The repair proced u r es a r e l is ted b y system ( C o o l ing, Lubricating C o m pressed Air, F uel, Electri ca , a n d B ase E n g in e C omponents).

(S TEP 4 . )

Oil, Combu Combustion stion Air,

The T r oubleshoot in g L o g ic C h a r t s are b as e d o n th e fo ll o w i ng assumptions: h as b een instal l e d a c c ordin g

1.

The e n g i n e

2.

The easiest r e p ai rs a r e d o n e fir first. st.

3.

"Generic"

E q uipm e n t

to th e man ufacturer's specifications.

solu tio n s to c o ve r proble ms w th the m o s t common applications and Original M a nufac actu ture r s (O E M ' s).

 

Symbols

Section i - Introducti on B S e ries

Page i-3

S ym bols The following s ymbols have b een us e d i n th i s man u al to h e l p c ommunicate the i ntent o f the in s tructio n s . one of the symbols appears   it co nveys the meaning d e fi n ed below  

W h en

WARNING - S e r i o us perso n al i njury o r extensi ve p r o p erty d amag amagee can r e s ult if the w a rn ing i n s tr uctions are not fo ll o w e d .

~

EE~ ~

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CAUTION - M i n o r p e r s o n a l in ju r y can r e su l t or a part   an a s s em emb b y, or the engin enginee can be d a maged i f the cauton i nstr uctions a r e not foll follow owe d . Indicates a R E M O V A L

o r D I SASSEMBLY step.

Indicat atee s a n INSTALLATI ON or AS S EMBLY ste ste p. ASS

INSPECTION is r e qu qurr e d. CLEANthe parto rauemb~

(1)

P ERFORM a m e chanical or time M E ASU R E MENT  

6]

LUBRICATE t he p a r t or assembly.

~

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~

Indi cates that that a WRENC H o r TOOL S IZE w i ll be g ive n . TIGHTEN to a spec fic torque   PERFORM a n e l e c tr ical M EAS U R E M E N T  

R e fer to a n o ther l oca tion in th i s m a n u a l

o r an ano ot h e r p u b l i ca cattio n

for addit i o na  information .

ersonn al i njury   use a h o is t or g e t ass The co m p o n ent w e i g h s 23 kg [ 50 l b ] o r mor e . T o a v o i d p erso assst stance to l i ft th e c o mponent.

 

Section i - Introductio n B S e r i es

Symbols Pag Pa ge i - 4

Simbolos L os s imbo l os s i g u ie n tes son usados e n este man ua   para c l a r i fificc ar el proceso d e l as in strucciones   C ua n d o parece e uno de e s tos s fmb o l o s , s u s i g nifica do se esp ecififii ca en l a parte inferior. a parec cado

AD V E RTENCIA- S e r i es d afios per s onales o dafio a a p r o p iedad puede r e s ul tar si la s instruccio n e s d e Adve r ten cia no se c o n s id e r a n.

A

PRECAUCION - D a n os m e n ores p u e den r esultar , o de p i ezas del c onj unto o o el motor puede onjunt a ve r i arse s   las i n s t r ucci ones de P r e c a uc 6n nose siguen  

EE~

l n d i c a un pa s o de REMOCION o DESMONTAJE.

ln dica u n pa s o de IN S TALACION o MONTAJE.

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Se r e q u ie re IN S P E CCION. LIMPIE SE la p i eza o el m ont a j e . EJECUTESE un a MEDICION meca a o d e l ti e mpo. canic nica

L U B RIQUESE

la p i e z a o el mon montta j e.

lndic a que se dara u n a LLAVE DE TUERCAS o e l TAMANO DE HERRAMIENTA. APRIETESE h a s ta un p ar to r s or esp ec ffi co . ecffi E JECUTESE un a MED I CION e l ectrica, P ara i n form ormac aci6n adicional r e fi e r a se a otro empl emplazam azamie nto de est e m a n ua l a n terior.

o a o tra p ublicaci6n

E l compone n t e p e s a 2 3 k g [ 50 lb] o ma mas s   P a r a evitar d ano cor mplee een un a cabri a u o b te n gan orpp o r a l e mpl ayuda par a e l e va r el compone nte.

 

ntrod rodu ct o n Section i - I nt

S ym ymb bols P ag e i -5

8 S e r ies

Symbole In d i esem H andbuch werden d i e fo l genden edeutu utun g : S y m bole haben fo gen de B ede

WARNUNG

- W rd d ie Beschadi qunqsqefahr ;

Symbo l e v e rwe n d e t  

Warnun g

nich t

d i e wese ntliche

b e ach t et,

dan n

F un k t i o n e n

beste ht

h ervorh e b e n .

e r h o h te

U n fal l-

D ie

und

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Q) ~

VORSICHT - W e r d e n d i e V o r s i c htsmas sna h m e n

chadiqu nqsqetahr ;

d an n

b e steht U n fall-

und Be s

AUSBAU bzw. Z E R L EG E N . EINBAU bzw. Z U SAMMENBAU. SPEKTI KTIO N IN SPE

e r forder lich.

T e il o d e r B augr uppe REIN I G E N .

DIMENSION - o d e r ZEITME S S U N G. Te il o d e r B a ugruppe OLEN  

wird a n g e g e b e n .

~

WER KZEUGGROSSE

($)

AN ZUG a uf v orgesch r iebenes

@

E l ektris ch e

~

nicht b each te t ,

M ESSU N G

We i t ere l n format i o n en

Dre h m o m ent

e r forde rlich.

D U RC H F U H R EN 

an a n d e r e r Ste ll e b z w. in an and de ren H a ndbOchern  

D as te il w e i g t 2 3 k g [50 l b] o d e r m e h r . Zur verme id un g von ko e rperv rpervee r l e t z ung h ililff e b e i m heben d e s t e i l s in a n s pruch n e h m en  

w n d e benutze n o d e r

 

S P ym i-6 agebols

S e ction

i - I ntroduction B Series

Sym bol es Les s ymboles suivants sont utilises dans ce man u e l p o u r a ider a comm un i quer l e b ut des i n s t ructi ons. Quand l'un de ces symboles apparalt, ii evo que le s ens d e fini ci- dessous: AVER TISSEMEN T - D e g r aves l e sions corpore ll e s o u d e s d o mmages m aterie s con siderab es peuvent s urve n i r si les instructio n s d onnees s o us l es r u b riques "Avert ssem e n t " ne sont pas su i vies  

corp rpo r elle s p e u v e n t s ur urv venir, ou bien une piece, un ensemble o u ATTENTI ON - De petites les ons co le moteur peuvent etre endornrnaqes s i l e s i nstr u c t io n s donnees s ous les rubr iques "Attention" ne sont pas s uivies.

~~ ~

@

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lndique u n e operation de DEPOSE. lndique une operation de M ONTAGE. L' IN SPEC TION

est n ecessaire,

NETTOYER l a p iece ou ' ensemb l e . E F FECTU ER u ne MESUR E rn e canque ou de tem p s .

G RAISSER la p iece o u ' e nsemble  

EJ ®

~

f J1

ln d i que qu une DIMENSI ON DE CLE ou D'OUTIL s era d o nnee   SERRER

a

u n c oup l e specifique  

EFFECTUER une MESURE e l e ctr i que . S e r epor t e r i nfor m a t ions

a

un a utre e n d r o i t d ans ce m a n u e l p l us comp l etes .

ou

a

un e a utr e p u b l i ca catt o n

p o ur obte obte n i r d e s

Le c o m p osant pese 2 3 kg [ 50 lb] o u d a van tage   P o ur e viter to ute b l e s s ure, e m p l o yer un a p p a r ie l d e l e v a g e ou deman d e r de l 'ald e p our l e sou l e ve r ,

 

Section i - Introduction B Series

Illustratons The illustrations used i n the "Repai r Sec Secttions" o f thi s manual are intended to give an example of a problem , a nd to show what to look for and where the problem can be found   Some of the illustrations are "generic" and will not found look exact y like the engine or parts u se d in your appli cation. Some i llustrations contain symbo s to i n d i cat e a n act on required, and an acceptable or not acceptab le condition.

Illustr a t i ons

P ag e i -7

The illustrations are intended to show repair or r eplace ment procedures with the engine "in-chassis. " The i llus tration can differ from your application, but the procedure given will be the same  

dw 8 pu sa

 

Definition

of Terms

Section

Page i -8

B Serie s

Definitio n

ASTM

Air Fuel Control American Petroleum I nstitute Air Signal Attenuator American Soc ety of T e s ting a n d

c

Ce sius

AFC AP I

ASA

C ARB

C.I.D.

i - Introd uction

Materiass Materia

California Air Resources Board Cubi c Inch Displacement

of T e r ms i n -lb

kg km km/I kP a I

m mm

I n ch P o und K ilo g r a m s K i lo m e te r s

K il o m e t e rs per Lite r K i l o p a s ca l L ite r M eter Millimee t e r Millim

Cm CPL

Centimeter Control Parts List

est

ft-lb GVW Hg

Centi stokes Diesel Coolant Add tive Electronic Control Module Emission Control System Environmental Protection Agency E ngine Position Sensor Fahrenheit Foot Pound Gross V e h i cle Weight Mercury

HP

Horsepower

H 20

Water

DCA ECM E.C.S.

EPA EPS F

MPa MPH MPQ

N•m OEM pp m p si

PTO R PM S.A.E. S TC vs vss

Mega pas ca   M il es P e r H o ur M il e s P e r Quart N e wto n - met er O r ig in a l E q ui p m e nt M an u fa cture r P a r t s P e r Mill o n P o u n ds P e r S q uar e In ch P o w e r Ta k e o ff R e vo l u ti o n s P e r M inute S ocie ty o f Au t omoti tiv ve E ngine ngineee r s S t ep T i m i n g C o ntrol Va r i a b l e S p e e d Ve hicle Spee d S ensor

 

G enera   Safety I n s tructions Page i - 9

Section i - n trodu ctio n B Seri es

General Safety Instructions Imp Im po rta nt Safe ty Notice

A

W A R N I NG

A

Read and understand a ll o f the sa fe ty precau precauttio n s a nd warnings b e fo r e performing any repair . Th i s l is t conta ns the general safety p r ecautio n s th a t must be fo ll o w e d t o pro v i de p ersonal safe safetty . Spec al safety precautions are thee pr i n c l uded in th proced ocedu res whe n th e y apply   • Make s ur e t h e w o r k ar e a s urrou n d i n g

th e p r o d u c t i s sa fe. B e a w a r e of h a za r d o us condititii ons that can e x i st.

• Always wear p r o te c ti ve g l asses a n d p r o te c ti ve s h oes w h e n w o r ki n g . • D o not wear l o o se- fitting o r t o rn c l o thing. R e m ove a ll j e w e lry w h e n w orki n g .

thei f beat capacit e fore b e gPut Disconnec r s bstar a ny i n n inag"Doany pa i r r awork. • starti Disconnect the air accd te " tag n g m ottor q ut ery i p p e da ndt o dpisr ecvhearge nt acc d e ncapaci t a l e n tgoi ne ti n g. N otr e Ope Oper i n the operator 's compart ment or o n th e co n tr o l s.

• Use ONLY the proper e n g i n e barring tech n i ques for m anua anually lly rotati n g t he engine. Do not attempt to rotate the engin e by p u llllii ng o r p ryin g o n the fa n . T h i s p r a ct ctice ice c a n ca us e se ri o u s persona   inju r y, property damage, or damage to t he fan b l ade(s) ca using p r e mature fa n fa ililuu r e . coolann t i s hot, allow th e e n g in e to cool before you slowly loosen the • I f an engine has been o p e r a t ing a n d the coola fifillllee r cap and re l ieve th e p r e ss ur e fro m th e cooli n g sy s te m .

• Do n ot w o rk on anything tha thatt i s support e d ONLY by lifting jac k s o r a h o i s t. Alwa ys use blocks or proper stands to supp o rt th e produc t b e fo r e perfo rming any se rv i c e work   • R e l i eve a ll p r e ss u r e in th e a i r , o i l, a nd t he c o o l i ng s y s te m s before a n y li n e s , fitt n gs, o r r e l a ted items a r e removed o r d i scon n e c t e d. B e al alee rt fo r p o ss ib l e p r e ss u r e w h e n d i sc o n n e c ting a n y d evice from a system th at utilizes p r e ss u r e . D o not c h e ck for p r e ss ure l e a k s with y o ur h a nd. H i gh p r e ss u re o il o r fu el can cause persona   i n jur y. • To p r e ve nt s uffo c a t i on a nd fr o s tbite, we ar prot e ctive c l othing a n d O N LY d i sc o n n e c t li q u i d r e fr i g e r a nt ( fr eo n ) l in es in a w e ll v e ntil ntilaa ted a r e a. oistt or g e t a ss i s ta n c e when lifting com p o n e n t s th a t weigh 23 kg [50 lb] or more. • To av o id p e r so n a l injury, u se a h ois M ake s u r e a ll l ifting d e vic vicee s such as c h ains, h o o ks, o r s li n gs are in g o o d co n d ititii on a n d are o f th e co rr e c t c a p ac ity. Make s ure h ooks a r e p o s i tioned correctly   Always u s e a s p r e a der bar when n e c essar y . T h e l ifting h ooks must not be s id e - l o a d ed. inhibitorr contains a lkali. Do not g e t the s u bstance in your e y e s . A vo i d prol o n g ed o r r epeated co n t act • C o r rosi on inhibito with s k i n . Do n o t swallow intern a lly. I n c a s e of c o n ta c t   i mmedi ately was h s k i n with so ap a n d wate r . In c ase of co n tact, i m m e d ia tel y flood eyes with l arge a m o unts o f water fo r a minim u m of 1 5 minutes   I M M E D I ATELY C A L L A PHYSICI A N . K E E P OUT OF REACH OF C H ILDREN.

• N apt apthh a a nd M e thyl E t hyl K e tone (MEK) a r e flammab l e materia s a nd must b e u sed w i th cau t io n . F o ll ow th e m a n ufac tur turee r 's i n s tr u c tions to provid e comple te safety w h e n us ing th ese m a ter als. K EEP OUT O F R E A C H OF C H IL D R E N . • T o a void b ur n s, be a l e r t for h o t p a r ts o n p r o d uc ts th a t h a v e ju s t b e e n tu rned OFF, and h o t fl ui ds i n li n e s , tubes , and compartm e n ts . • Alwa ys us e to o l s th a t a r e in good c o n d i t o n . M a k e s u re y o u u n d e r s tand how t o u s e them b e fo r e p e rforming partts . a n y serv ice wo r k. U se ONLY g e nuine Cummins or Cummi ns R econ® r e p l acem e nt par

• Alwa ys use the same fas te n e r p a r t numbe r (or equival equivalee nt) whe n r e pl acing fa s t e n e r s . of le s so r q u a l i ty if replacem e n ts a re n e c essary .

Do not use a fa s tener

 

G e n e r al C l e a n in g Page i - 10

In str u c tions

Section i - I n troduction B S e r i es

G enera l Cleaning Instructions S o l ve nt a n d Acid C l eaning Sever al so l v e n t and a ci d - t y p e c l eaners can be used to c l ean the engine parts. C u mm ns Engine C om p a ny, I n c . does not r ecommen d any specific c l eaners. Always follow the c l eaner manufac acttu r e r ' s i n s t r u c ti ons   E x p e r i e n ce h as s h o wn th a t th e best results can be obtained using a cleaner that can be h e a te d to 90 to 95 degr ees C e l s i us ( 180 t o 200 degrees F ah r enheit]. A cleaning tank that prov des a constant m i xing a n d fi l te r in g o f th e c l eaning so lu t i o n w i ll give t he b e s t results. ~

Remove a ll th e gask e t mat er a l , o-rin gs, and the deposits of sludge, carbon, e tc., w i th a w i re brus h or scrape scraperr before putting t he parts in a cleaning tank. Be careful not to damage any gasket surfaces   When poss ble, steam clean t he parts before p utting them in the cleaning tank   Warnin g : The u s e of a cid c a n b e e x tremely dangerous to personnel, an d c a n d a m a g e the m ac hin hiner ery. Alway s provi de a ta n k o f s tro n g soda water as a neutralizing agent.

froo m R i nse al alll of the p a rt s i n h ot water after cleaning. Dry completely with compressed air. B l ow the r i n se w a t er fr a ll o f th e capscrew h o l es and the oil drillings drillings  

If the parts are n o t to be u sed i mmediately after clean i ng, dip them i n a suitable r us t proofing co m pou n d . The r ustproofing c o m p o u n d m u s t be r emoved from t he parts before insta ll a tion on the e n g in e .

S t e a m C l e a n i ng Steam cleanin g ca cann be u sed to r em emo ov e a ll types of dirt that can contam nate the c l eanng ta n k . I t i s a g ood way t o c l e a n the oil drillings.

A

W arnin ing: g: W e a r prote ctive clo thing to preve nt p erson a l i n jury fr o m the h ig h pressure a nd e x tr e me h e at. D o n ot s t e a m c l ean th e f o llow i ng p a r t s:

~

E lect r i ca  

1.

onentss C o m p onent

2. Wring .

4

I n ject or orss F u e l P um p

5.

B el t s and H oses

6.

B e arings

3

G la s s or P l astic B e ad Cleaning G l ass or plast plastic b e a d c l e a n i ng c a n be u s ed on m an any y e n g i n e components to r e m o v e c a rbon d e p o s i ts . T h e c l e a n in g pro c e ss is controlle d by the s i z e of the g l ass or p l astic beads   th e o p e r a tin tingg p ress ure , and th e c l ean i ng time.

A ..U ~

1111111

Caution:

D o not use glass or plas tic bead c l eaning on a l uminum piston skirts. D o not us usee glass b e ad cleaning o n a lu luminum minum r i ng grooves. Small partic le s o f glass or pl plast astic will embed in the alumin um a n d result i n p rematu re wear. Valves, turbocharge r s h a ft s, e tc ., c a n al also so be d a maged. F o ll ow th e clea cleann ing directi ons lis ted in the proce dures.

NOTE: Pl as t i c b e a d b l a sting m e d ia , P a rt N o . 38 22 735, can be u se d to c l e a n a l uminum ri ng groove s . Do n o t use any bead b l a sting m e d i a on pin b o re s or al umin u m s kirt s. F o ll o w the e quipmen mentt manufa ctu cturr er' s cl ean in g i n s truc ti o n s . The fo llllow owin g g u id e li n e s c an b e u s e d to adapt to m a n u facture r ' s instructions   1.

B e a d s i z e:

2.

Ope r a ting P r e ss ur e:

3.

S t e a m c l e a n or w a s h th e p a r t s with s o l ve n t t o r e m o v e a ll o f the fo r e i gn b e ad s a fter cl e a n i n g . R i n s e w th h o t water   Dry with comp resse ressedd a i r .

4.

Do n o t c o ntamina te th e w as h t a n k s with g l ass or p l a s ti c b ead s .

-

U s e U .S . s i ze N o . 1 6 - 2 0 for p i s to n c l e a n i n g w th p l asti tic c b e a d m e d i a , P a r t N o . 3822 7 3 5. U s e U . S . s ize N o . 7 0 for p i ston d o m es w i th g l ass m e d i a . Use U . S. s i z e No. 6 0 for g e n e r a l p ur p o s e c l ean in g with g l ass media   - G l a ss : U s e 6 2 0 k Pa ( 9 0 p s i] f or g e n e r a l pur p ose c l e a ning. - P l as t ic: U se 2 7 0 k P a ( 40 psi] f or p i s to n c l ean in g.

m a te r i a l

a n d g l ass or p l a s t c

 

General Repair Instr uctions Page -11

S e cti on i - Introduction B Seri e s

G e n e r a l R e p a i r I nstructions Th i s e n g i ne in c orporates the a t est diesel technol ogy; yet, t is designed to b e repaired u s ing norma l repair prac tices p e rformed to q uality standards.

•

C ummins E n gine C ompa ny, I nc. does does n ot rec reco ommend or auth orize any modificat ions o r repairs to compo e n gin e s or nents exc ept for those detailed in Cummins Service Information . I n particular, u n a uthoriz ed r e p a i r to s afety-r e late ated d components c an cause per sonal injury. Betow is a partial listing of com po n ents classified as safety-rel ated: Air Compressor Air Control s Air S hutoff Assembl i e s Bal a nc nce e Weights C ooling Fan F a n H u b Assembly F a n M ounting Bracket( s ) F a n Mounting Capscrews

F an Hub Spindle Flywheel Flywhee F lywheel C ran rank ks h aft Adapter F l ywheel M ounting C apscr ews Fuel Shut Shutoff off Assembli es Fuel S upply Tubes Lifti ng Bracket ets s Throttle Controls Turboc h arger Compr Compree sso r C asing Tu r bocha harg rge r Oil Dra i n L in e(s ) ine( harg Turbocha rge r Oil Supp ly L ine(s) Turbocharger Turb in ine e Casing Vibrati on D ampe r M o unting C a ps cre ws

•

F ollow All Safety I n s tructio ns

Note d in the Proce dures.

Follow the m a nufactu r e r 's r ecom m e n d a ti ons fo r c l e a n i ng so lv e n t s and o t h er s ubstances used d u r ing th e r e p ai r o f th e engine. Always use goo d sa saffety p r ac ti ces with too s and equ pment. •

Provide A Clean Environm Environmee nt and F o llow the C l e aning I nstr u c tions -

Specifie d i n the P roce du res dures

Th e engine a n d its comp o n e n t s mus t be k e pt cl e a n d u ring a n y r epair. C o n ta m i nat o n c o m p onents will c a use premature wear wear..

o f the e n g in e and

e

Perform the In spe ctions S p ecifie d i n th e Proc edures.

•

Replace Replac e all Components or Assemblies Which are Damaged or Worn Beyond the Specifications

•

es U se Genuine Cummins New or ReCon® Service P a rts and Assembli lies -

•

The a ssem b l y in s tru c ti o n s h a v e b e e n writte n to u se agan as m a n y c omp onents a n d assem assemblie blies as assemb mby, poss ible. Wh Whee n it i s n ecess a ry to r e p l ace a comp o n e n t or asse y, th e p roced u re i s based o n th e use of new Cummins o r C u m m i ns R e C o n ® compo n e n t s. All of th e r epair se rv i ce s descri b e d in this m a n u a l aree av a il abl e from a ll C u m m in s D i s tributo r s and m o st D ea e r loca ti o ns   ar

F o llo w Th e Specified D isa isass ssembl y and Ass embly Procedures to Avoi d D a mag e to the Comp o nents.

Comp ete rebuild instruct io ns a r e a vail able in the s h o p m a n ual which c a n be o r d ered o r p u r ch ased fro m a Cummin s Authorized R e p a ir L o c a t o n . R e fe r to S ecti o n L , Li tera ture, fo r o rder i n g i nstruct o n s .

 

eneral Page i - 12

Section i - Introduction B Series

Instructions

NOTES

 

S e ctio n E - E n g in e B Series

Id en t ification

P age E - 1

S e ction E - E n g i n e Id e ntificato n Section C ontents

P a ge A u tomotive E ngine S pecific ati ons . . . .. . . . .. . .. . . .. .. . . . . .. . . .. . . ..... . . . .. . . . .. .. . . . . . .. .. . . . . .. . . .. . .. . . . .. . . . . . .. . .. . . .. . . . .. .. . . .. . .... .. . . . . . .. .

E -4

Engin e D i agrams.. . . . .. . . .... .. .. . . . . .. .. .. . .. .. . ........ .. . .. . .. ............ .. . ...... ............ ...... .. . . ........ . . .. . . .. .. . .... . . . .. . .. . . . .. .. . ...... .. .. . .. . .... .. . . .. . . ..... .. . . . . . F ro n t V i e w . .. . . . . . . . .. .. . . . .. . . . . .. .. . . . .. . . . .. . .. .. . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. F u e l P u m p S i d e V iew ............... ....... .. · R ear V i e w . . .. . .. .. .. .. .. . . . .. . .. . .. .. . . . .. .. . .. .. . . .. . .. . .. . . ........ . .. . .. . . . .. .. . .. .. . .. .. . .. .. . .. . .. . .. .. . .. .. .. . . . . . . . .. .. . .. .. . . .. .. . .... .. . .. ........ Tu rboc bocha ha g e r Si d e V i e w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .

E-8 E -9 E-8 E-8 E-9

ation . .. . . . . .. . . . . . .. .. .. . . . . .. . . . .. . . . .. . .. . . . . . . .. . .. .. . .. . . . . .. . . .. .. . . . . . . . . . .. .. .. . . .. . . . . .. . . . . .. .. . .. . . .. .. . . . .. . . . . .. .. . . . . . . . .. . . . . E - 2 E n gin e Id entific ntifica E ngin e D at apl ate ate .. . . . .. .. .. . .. E -2 E n gi n e N o men clatu r e .. . .. . .. .. . . . .. . .. . . . . . . . .. .. . .. . . . . . . . . . . . .. . . . . .. . . .. . . . . .... . .. . . .. . . . . .. . . .. . . . . . . . . . ........ . . . . .... .. . . . . . . . . . . . . . . .. .. . . . . .. . . . . . . . E -2 Fuel Pump D a t a pl ate (N a m eplate)

N o n -Automoti ve Eng n e Specifi cation s

.. . .

. .. . .. . . .. .

.. .. . .. . ..

.

..

. . . . .. .. .. . . . . E -3

E-7

 

Section

Engine Identification Page E - 2

E - E ngine Identifica tion B S e rie s

E n g ine Identificati on E n gine Dataplate The e n g in e da datta p l a te s h o ws spe cific i n fo r m a ti o n a b o ut your engin e. The e n gine seri a l number (1) and C o n tro l P a r t s Li st ( C P L ) ( 2 ) p r ov d e i n form at ion fo r o rd e ri n g p a r t s and servi ce n e e d s .

cp

ummins Engine Company, Inc . C o l umbus, I n d i ana 47202-3005

En g i ne Cert. l. D . Cert ifi ca t

C . I.D./ L. Pouce Cube/L Cube /L

F am ily Fa mille

CPL

f

M o del M o dale

Ca ta l y st No .

I

( j) FEL

EPA

C AR S

c

Q

ade in U.S.A.

3925422

W ARN IN G Injury may resu k and warranty a voided W fuel ral e rp m or a l iludes exceed published maximum v alues lor this model and applicatio n .

A VE RTIS S E ME N T : Danger de blessures et d'annulal i o n de la g a r a n c i e , Ii debil combus t i b l e , tr / mn cu ak~ude   dapassa,l les valeUI$ m aximum annoncoes an noncoes pour ca

modale et so n utift S a t i o n . Date ol M fg . Date ol F a b r i cat i o n

d'identite

C ata l yseur N o .

Trn ng-T.D . C. Calage-P.M . H .

E n g i ne No . M o te u r N o .

Valve l as h cold J eu x Soup .a F ro i d F i ring Order ag e O r d r e d ' A llum llumag Idle Speed (rpm ) V i tesse R a lenti

Ex h . Ech

Int.

Ad m .

E . C. S .

I

-,

NO X PM

R af . N o .

c: : : : : r -

Fu e l ra te at ad v . H P Debit combus t. a puis s . indfquee

mm3 s tr ok e at a

Advertised H P Pu i ss. ln dfquee ( c h )

rp m

ap9 .plgb

Engin e N omen omencl clature The model n ame for e n gine s i n a u tomotiv e applicati o n s p r o v i des th e d ata shown i n t h e e x a m p l e .

E xa m p l e B 3 . 9-105 R a ted Horsepower Displa lacement cement in Li te r s E n g i n e S e r ies

The fo llllow owin g e xa mp e s hows a mod e l n a m e of an engin e for n o n -autom o t i v e a ppli cations  

E xa mple 4

B

T

A

li

3.9

L

D i spl ace ment Afte rcoo e d Turbochar ged E n g in e S er e s Numbe r of Cylinde rs

in Litr es

 

Section E - Engine Identification 8 Series

Fue Fu e   Pump Dataplate (Nameplate) The fuel pump dataplate is located on the side of the fuel pump. It provides information for fuel pump ca ibration.

This illustration shows the dataplate location on a Bosch rotary injection pump.

Th s illustration shows the dataplate location lo cation and a Lucas

CAV rotary injection pump.

F u e l P ump Data plate (Nameplate)

Page E-3

Th i s i llustration shows the dataplate location on a Bosch in-l i ne i n jection pump. The Nippondenso EP~9 dataplate i s l ocated in approxi mately the same l ocation as the il  l u s trat tratee d B osc oschh datapl a te .

The Cummins p a rt numbe r f o r the in- line pump and gov erno r c o mbina ti o n i s l ocate d on the g o vernor d a ta p l a te.

 

Automotive E n g i ne Specifications Page E-4

Section E - Engine Identification 8 Series

Aut uto omotive Engine Specifications G en e r al

85.9 83 9 -------------------------- - - - - - - - - -- - -- - - ---- - ------102 4. 02]--- - - - - - - - - ------ - - - - ----------------- - ----------

E n gin e D a ta

Bore - m m [ in.] . S t roke - m m [i n.] .. - - ---- - - -- - - - -- - - -- - - - ----- -------------------- - - -120 [ 4 . 72 ) -- - --------- - - -- - ----- - - - ---- - -- - ---- - - - - - -------- - D i sp l acement - l i t re [ in . 3] .. 3 . 9 [239] 5.9 [ 359] Engine Weight (Dry) Less F l ywhee   and E l ectr ics-kg [ lbs] .. 308-329 [680-725] 388-4 1 1 [855-905] Firi ng Orde . Orderr 1. 3.4.2 1 .5.3. 6.2.4 Valve Clearances - ---- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Intake- mm [ in .] . .. . .. . . .. . . .. . . . . . .. .. - - - ----- - -- - - ---------------- - -------- - -----------0. 5 [ 0. 01 O J - - - - - -----Exhaust - m m [ in . ] . . . . . . . . . . . . . . . . . . . . . . - - - -- - - -- - ----- - - -- - - - -- --------- - - -- ---- - - - ------0. 51 [ 0 . 02 0 ] ---- - - - - - - - - - - - ----- - -------- -- ----------- - -- - - - - Compress on R a t i o .. .. .. . ......... . .... .... (Rotary Pump) 17 . 6:1 (In-Line Pump) 17.9 1 Ro t at i on, viewed from the F r ont o f t h e Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - - -- -- - - ------ - --------------------- - - - - -----------Clockwise--- --------- - ---------- - - - ----- - - - - - - - - ----- -- - - ---Aspi ration - Turbocharged - Charge A i r Cooled

L u b ri rication cation

.

.

System

x x

L u b r icating O i l Pressur e a t I dle -

(M in i m u m Allowab Allowabee ) k P a [ P S I ] .. .

---------- - - - - - - - - - - - - - - - - - - - ---- -- - - - - - - - --------------- -69 [

x x O J - - - - - - - ---- - - - - - - --- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 

L u b ri catng Oil P r e ss u re at R a t e d ( M in m u m All owab e) k P a [ P S ] ..

- - - - - - - - - - - - - -------------- -- - - - - ---------- - ---------207 30] - - - - ---- - - -------- - -- ---- - ------- - - - - - - ------- - - -- - 

Regu at n g Valve Opening P re s s ur e kPa [PS ] . . . . . . . . . . . . . . . . . . . . . -- -- -- - - - - -- -- - ---- - - -- --------------- - -- - - ---- 449 [65) - - - - - -- - -- - - - - -- ----------- - - - - - - -------- - --------- - D i fferentia   Pressur e t o Open the Bypass Valve - kP a [ P S I ] . . . . . . . . . . . . --------- -- - ------ - - - - -- - -- --- ---- - - - -- - - - - - -- - 1 38 [ 20) ----- - - - -- - - - -- - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - ----L ubri cating O il C a pac i ty S t a n dard P a n O n ly L it e r [ U . S . Q u a rt s ]

Total Sys t em - Liter [ U . S. Quart s ]

N u mb mbe er of L it e r s [ U . S . fro m Low t o H igh

.

. 5 [ 10)

1 4 .2 [15]

..

1 [ 11. 6 ]

1 6 . 4 [ 17 . 3]

..

.9 [ 1 J

1. 9 [ 2 ]

'.

Quarts]

C ool in g System C o o l a n t C a p a city ( E ngin nginee O n l y ) s. J Li tre - [ U . S . Qt Qts. .. . [ 7 .4 ) 1 0. 5 [ 1 1 . 1] S t a n d a r d M o d ul a ti ting ng The r m o s t a t - R a n ge - ° C [ °F J .. ...... - - - -- -- -- - ---- - - -- Start 83 [ 18 1] - - -- - - ------- - - - - - - - -- Fully Ope n 95 [ 20 3) -- - - - - - - ---- - ---- - - P r e s su r e Cap ( kP a [PSI]) 1 0 4 ° C [ 2 2 0 ° F J S yste ms . . . . . . . .. . . . - - - - - - ----- - - - -- - -- - - -------- - - - - - - ------- - - - -------103 [ 5 ] - - - - - - - - - -- - - - -- -- -- - - - - - -- - - - - ----- - ---- - - - - - - - - - - -99 ° C [ 2 10 ° F ] S y s t e m s ........ . .. .. . .. . . . . 99° - - ----- - - ------ -- --- - - - -- - - - -- -- - -- -- -- ---48 [ 7) -- ------ - - - - ----- - - - - - - -- - - - - - - - -- - - ---- - -- - - - - - - - -

 

S e ction E - E n g i n e B S e r ies

I dentificati on

Automotive

ir Indu c tion System

3.9

Engine Specificat i ons Page E-5

85.9

M a xi m um Allo w a b l e Intake R e s t r ic tio n a t R a te d S p e e d and

L o a d wit h D i rty Air F i l te r E l e m e n t -

mm H 20 [ i n . H 20 

.

635 [25]

635 [25]

E xhaust S ystem M a x i mum A ll owa bl e Ex Exhh a u s t

Restri c tio n a t R a te d Speed and Load -

mm H g [i n . H g] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-------------------------------- -- -- - - - - - - - - - - - 6. 2 [ 3] ------ - -- - - - - ----------------------------------- -- --- ----- - ------------- -------------- 152.4 [6] with catalyst ------ - ---- -- - -- - - - - - - -- - - - -- - - - - -- --

F u e l S y stem stem

(D i stri buto butorr T y pe F uel In jection Pumps) M a xi m u m In e t R es esttr iction to to th e F u e l T r ansfer P u m p M u s t Not Exceed - mm Hg [ i n H g ]

- - -------------------- - - - - - - - - - - - - - - - - - - - - - - - - -- --------- - 100 4] -------- - -------------------- - -------------- - ---- -

M axi m um A ll owa bl e R e turn Line R e s tric- ------------------------------ ----------- - ------518 20 41------ - - - ----------------------------- - -------- ti o n - m m H g [ i n H g ] M ax axm m um Al o w a bl ble e P r essu r e Dro p A c oss F u e l F il t e r - k P a [ p si ]

----------- - ---------- - -----··--· - -·-·----------------- - - -- --35 5 1 ------ - -- - ------------- - - -- ---------------------------- -- -

M a x im um I n l e t P r essu re to the the In ject io n Pump Pu mp M u s t N o t E xcee ceedd - kPa [ p s i ]

-- - ---- - · - - - - -- --------------------------- - - --··- 0 [

O J - - - - - - ---------- - - - - - - - - - - - - - ----- - --------------

(I n - L i ne T yp e F u e l In jection P umps)

M a x   m u m I n e t R e s tr trii s t o n to the Fue T r an sf sfee r P u mp Mus t N o t E x ceed - mm

- -------------------------- - - - - - ------ - - - -----------------1100 [4] --------- - - - - - ------------------------ - -----------

F u e l T r a n s fe r P u m p Minimum Output P r e s s u r e - kP a [ p s i] @ R a t e d RPM F u e F i It e r R estriction ( M a x m u m P r essu re Drop Across F il t e rs ) - kP a [ p si ]

-- ------------------ -- -- - -- - - - - ------ ------- 1 72 [ 2 51- - - - - - - - ----------------- - -- - -- -------- - - -- ------ - ------ -

[in H g ]

--------------------------- - -- - ------ - -- - - - -- - - -- - - - - - - - - - -- -- -- - - - - - -- - -- - - - - - - - -- - - --35 [ 5 1 - - ----- - -- - -- -- - - - - - - -----------

Fue Pum p Ga Gallll e r y P ress u r e - kP a [psi] Minim u m @ R a ted RPM

- - - - -- - - - -- - - - - ---- - - - -- - - - - - -- -- - -- - -- - - - - - -- - - - 1 40 [ 2 0 ] - -- -- - - - - -- - - - - -- -- - - - -- - - - - - - - - - -- -- - - -- - - - -- - - -

F ue l Ret u rn M a x mum R estriction - mm Hg [i n H g ]

- - - - -- -- - - - - - - - - -- - - ---- - - - -- - - -- - - - -- - - - -- - 5 1 8

E l ectrical Sys te m

Minim u m R e c omm e nd nde ed

0.4]--- - - ------ - - - -- -- - ---- - - - -- -- - - - -- - -- - - - - - - - - -  [ 2 0.4]-

Battee ry C a pa city Batt

Wit h L i ght Acc Accee s so r i e s * - 1 2 V S ta r te r

.

2 5C 5CC CA

800CCA

2 4 V S tar t e r

.

00C C A

47 5 C C A

- 1 2 V S ta rte r

.

800CCA

950CCA

- 2 4 V S t art artee r

..

40 0C 0CC CA

475 CCA

With H e a vy Acc e s s o r i e s**

M a xi m um Allowable Resistan Resistanc ce of Starting Circuit - W i th 1 2 V S ta r t e r - O h m s

- -- -- - -- - - - - - -- - - -- - - -- ---- - - - - -- - - - -- - - - - - - - --- 0 . 0 0 1 2

- W th 2 4 V Sta rter - Ohms

- - - - - - -- -- - - - - - - ---- - - - - - - - - -- -- - - - ---- - - -- - -- - - -- 0.0 0 2 0- - - - - -- - - - - - - - - - -- - - - -- - - - - - - - -- - - - - - -- - - - ------

* T yp i c a l

l ig ht a ccessor i es i nc ud e ( al te r n a to r ,

-- - - ---- -- -- - - ---- -- - - - - - --------- - - - - - -- - - - - ---- -

s m a ll s te er ng pump pump,, and d i sen gag e d cl u tch)

* *Typ c a l h e a vy acc e s s o ri es i nclude ( h ydr au l ic p u mp a nd to rque conve rt rtee r )

 

Section

Engine Specifications

Non-Automotive Page E -6

E • E ng ngin ine

Id e n tifi ca tion B S e ri es

Non-Automoti ve Engin e S p ec eciificatio n s 4BT3.9 4BT A 3 . 9 483. 9 E n g i . . . . . . . Data . . . . . . . . . . . . . . . . . . . . . . . ------- - --------- - ---- - -- - ----- -- - - - -------- -- -- - -- - 1 02 Bore - mm [ i n.] .ne

6 B T5. 9 685. 9 6 B T A 5 .9 [ 4 . 02)-- -- - ---- -- - - ---------- - - - - - -- - -- - -- - ---- -- - - -- -- --

S troke - mm [ in . ]........... . .. . . .......... . .

[ 4. 72) - - -- - - - - - - - - - - ------- -- - - -- - -- - ---- -

G e n eral

Displacemen t - li tre [i n.

3]

------------- ------ -- - - - - - - - - - ------- - - - --------- - -- 1 2 0

. .. . . .. . . .. .. .. .

- - - - - - - - - - - - - - - - - - -- - 3. 9 [ 239] -- - -- - - - ---- - -------- -

Engin e Weight (Dry} Less Flywhee   and Electrics-kg [lbs] . . . . .. .... . . .. ... . 308 [680]

i ri n g

Order

320 [ 705]

- - - --------- - - - - - ---- 5

329 [ 725]

388 [ 8 55]

1.3.4.2

-- - -- - -- - - -----

.8 8 [ 3 59] -- -- -- -- - - - ---------

3 99 [ 88 880 0]

41 1 [ 9 05 ]

1 . 5.3 6 . 2.4

Valve Clearances - Intake-

mm [in.] . . . . . . . . . . . . . . . . . . . . . . . . .

-Exhaust- mm [in.] . . . . . . . . . . . . . . . . . . . . . .

Compression

Ratio

------ - - - ------------------- - - -- - -------------- - - - --.

25 [ . 0 1 O J

----- -- ------ - -- - -- - ---------- - ----- - - -- - - ---- - - - -- -.

51

18 . 5:1

17.5:1

[.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - -

020] - -- - -- - - ---- - - - - - - - ------ - -- - - - - ---- - -- - - - - - - - - - - - --

1 6.5:1

18 . 5 : 1

1 7 . 5 :1

16.5 1

Rotation, viewed from the Front of the Eng n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . - ------ - --------------------------------------------CI ockw i se-- - - - ----------------- ----------- - -----------------As pi ration -Naturally Aspirated -Turbocharged

.

-Aftercooled

L u brication Lubricating

..

System

x x

Oil Pressure at Idle -

( Minim um All owable}

L u bricatin g

x

.

kPa [PS ] ..

O J - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ------ - - - - - - - - - - 

----------------------------- - ---- - - - - - - -- - - - - - -- -- -- - - 6 9

[1

------- - - - - - - - - - - -- - ------- -- - - -- -- - ---- - -- - -- - - - - - - - 2 0 7

[ 30] - - -- -- - - -- - - - - - - ------ - - -- ---- - -- ------- ---- - - - - - - -- 

O i l Pressur e at R ated -

(M i nimum All owab e}

k Pa [ P S I ] . ..

Reg u ati n g Valve Opening Pressure kPa [ PS I] . . . . . . . . . . . . . . . . . . . . . O iff eren erenti tia l

---------- - -- - -- - -- -- - ------- - - - -- - - - - ---- - -- -- - - - - - -449

[ 65] - - ---- - - - - - -- -- - - ---- - - - - - -- - - -- - - - -- ---- - - - - - - - - - - - -

- ----- - - - ---- - - - - - -- - -- - - - -- - - -- - - - - -- - -- - - - - - - - -- - - -138

[ 2 0] -- - - - - - -- - ---- - - -- -- - - - - - -- - -- - - - - -- - ------------- ---

P r essure to Open the

B yp ass Va l ve - k Pa [ PSI] . . .. . . .. .. . . L u bric bricaa t i ng Oil Capacit y

S tanda tandarr d P a n O n ly Liter [ U .S. Q u a rt s ]

9.5 [1 0 ]

To t a l Syste m - Lite r [U .S . Qua r t s ] .... ..... .. . ...... ........ ...

1 0 .9 [11. 5 ]

Numbe Num berr of Lite r s [U . S. Qua rts ] f ro m L o w to H ig h

. 5 [10]

11

[11.6]

0 . 9 [1]

. 9 [ 1)

7 [ 7.4)

[ 7 .4]

. 5 [ 10]

4.2( 15]

[1 5 ]

14 . 2 ( 15 ]

1 6.3 [ 1 7 .2 ]

16.4 [17.3]

1 6 .4

0 .9 [1]

1 .9

1.9 [ 2]

1 .9 [2 ]

9   7 [10.3]

10 . 5 [11 [11.. 1]

10 . 5 [1 1 . 1 ]

14.5 [15.3 ]

1

[11.6]

42

[2 ]

[1 7 .3]

C o o li ng S y s te m tem C o o l an t

C apacity (E n g i n e

Litre - [U.S .

Qts . ]

S tandar d M o d ul at n g Th e r m os ostta t P r e s s ure

O nly) -

i ;/fY

- R a n ge - °C [ °F] ....  

- - - - - - ----- - - - ----- -- - Sta rt

83 [ 180] - - - -- ---- -- ----- - - - - -- F ully

Ope n

95 [ 203] - - - - -- - -- -- - - ---- - - -- 

C ap ( k P a [ P SI ]}

1 04 ° C [ 220 ° F] S y s tems:: · , . . . . . . . .

..

 ....... . . 99 ° C [ 21 O ° F ] S ys te ms . ~

- ---- -- ------ -- ---- -- - - - - - - - -- ---- - - -- - - ---- -- - -1 0 3

-- - - ----- - - - - - -- - - ------ - - - - - - - ----- - - -- - ------ - ---- - 48

[ 1 5 ] - ------- - - -- - - - - ----- -- -- - -- -- -- -- - - - -- -- - - -- - - -- - ---

[

7 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ---

 

entifi fication Section E - Engine Identi B S e ries

on-- Automotive N on

ir Inductio n S ystem Maximum Al owab e I ntake R e s t riction at Rated Spe ed and L oad with Dirty Air F i lter Element m m H 20 [ in. H 20 ]

.

E xh a u s t Sys tem

83. 9

BT3.9

508 [ 2 0]

635 63 5 [25 ]

BTA3.9

635 [ 25]

E n g i ne

Specifica tion s P a g e E -7

85.9

B T 5.9

6 B T A 5 .9

508 [ 20]

635

635 [ 25]

[2 5 ]

M a x i m u m Allowa b l e E x h au s t R e strictio n at R a te d

S p e e d and Load m m Hg [ in . H g ]

F u e System

,.... . .........

------------- - -- ---- ----- - - - - - - ---- - - ------------------------------ - ---- --------------------76. 76.2 2 (3. 0 1- - ------ ---- ------------ - -- - - -- ----

(Distributor Type Fuel Injection Pumps) M a x im um Allo w a b l e R e s tric t io n t o the F u e l Tr a n s fer P ump M u s t Not E xceed mm Hg [in H g ]

- - -- - - -- -- ----------- - ------ - - ----------- - ------- - 100 [ 4 ] ---------- - - ----------------- - ------------------ - -

--------Maxim um Allowable Return L in e R e s tric - - - ------- - ----------- ---- - - --------- -- - --------518 [ 20.4 ---------- - - - - - - - - - - ------- - - ---------- - ----- --  t o n - mm Hg [in Hg]

M a x imum Allowable Pressure Drop A c r o s s Fuel Filte r - kPa [psi]

-------- - ------------------------------ - - - - - -- - - - -- - - - - - - -------35 [ 5 ] - -- - ----- - --------------------- - - -- - - --------------

Maximum I n let P re ss ure to the Injection Pump M u st N o t E x c eed - kPa [ps ] (I n - L i ne T ype F u e l Injection Pumps) M a x im u m I n l e t R e s t r i cti o n t o the Fuel Trans f er P u mp M u s t Not Exceed - mm

---- - ----- - -- - - ---- - -- -- - - - - - - - ----------- - - - - - -- - -- -- - 70 [ O ] - - -------- - -------- - - - - - - - - ----- - - ---- - - ---- - - --

[in H g]

-- - - ---- - -- - - - - - ---- - ---- - - - -- - - - - - - ------ --------------- 10 0

-----------[ 4 ] -------- - - - ----------- -- - - -- - ------- - -- ---- -- - ---

F ue l Transfer P ump Minimum Output P r e s sure - kPa [psi] @ Rated RPM

-- ---------------- - - - -- - - ----- ---- - - - - ---- - - - ---- 1 72

[ 2 5 1 - - -- - -------------- - ------- -- -- -- -------- - -------

Fue F i I t er Restr c ti o n (M a xi m u m Pres-

------- - ----------- - ---- -- ---- - - -- --------- - - - - -- - -- - - - 3 5 [ 5] ------ - -- - ------------- ------------- - - - - - - - ---- - -- - -- - --

sure D r o p Ac r oss F i l t ers) - k Pa [ p s i] Fuel Pump G a llllee ry P r e ssure - kPa [psi] -- - -------- -- ------ - - - - - - --------- -- -- - - -- - - -- - 1 40 [ 201-- - --------- - ----- - ---- - ----- - -- - -- - - - - - -- - - - -- -Minimum @ R a t ed RPM F u e R e t u rn M a x mu m Rest i ct   on - m m -- - - -- - --------------------------- -- - - -- - -- - - - -- -------- - - - -51 8 [ 2 0 .41---- - -- ---- - - - - ------- - -- - - -- ---------- ----- - - -  H g [in H g ] E l e ctrical S yste m mme ended B a tte ry C apacity M i n i mum R e c omm With Light Ac cess ori es* - 1 2 V S t a r ter. . . .. . . .. .. .......... . . . . . . . .. . . . .. . . . ...... . 6 2 5CCA 6 2 5CCA 625CCA 800CCA 800CCA 800C CA 800CCA - 2 4 V S t a rt e r ...... . . . . . . .. . . ........ .............. . . ...... . ...... 312CCA 400CCA 475CCA 475CCA 475CCA 4 0 0C CA With H e avy Acce ssories** - 12 V Starter..... ... .. . .. . . . . .... .. .. . . ...... . .. .... 800CCA 800CCA 800CCA 950 C C A 950C C A 950CCA 950CC A - 24 V S tart e r... .. .... ...... .. . .. . . . . . . . . ...... ..... . . .. . . 400CCA 400CC A 40 0C 0CCA CA 475 CCA 475CCA 475 CCA 4 00 C CA Maximum Allowable Resistance of Starting Circuit - With 1 2 V S t a rt e r - Oh ms . . . . . . . . . . . . . . . . .

- - -- - - -- -- - - -- -- - ---- -- - -- - - - ---- - ---- - - - - - - - -----0. 001 2 - - - -- - - - -- - -------------- ----- -- - ------------ - - ---

- With 2 4 V S t a rt e r - Ohms

------- - - -- - ------ - - - ----- - ------- -- -- - - - - ---- - - - - 0.002 0 -- ---- - - - - - - -- -- - ---- -- -- - - - - - - ---- ---------- -----

..

..

* T y p ic a l l i g h t accessori es includ includee ( a lt e rn a tor   s m a ll s t eerin g p ump, and disengag disengagee d cl u tch) draa ul i c p u mp a n d t orqu e con verter) * *Typical heavy a ccessories i ncl ude (h y dr

 

S ection

Engine Diagram s Page E - 8

E - E n gin e

I d entification

B Series

Engine Diagrams ustrationn s s h o w the l ocatio n s of the major e x terna l e n g i ne c o mponents, t he fil filtte r s , and oth er service The followin g ililll ustratio ll n r r en s. ent ffer ffe p n t compo w b d i ff e l t d i e o c a and maintenance o i Some external s e at nt ions for entt e n gine m odels   N O TE: T h e illustr ations a r e o n l y a re fe r e n c e to s how a ty p i c a l e n g i n e. E ngine Air In l et High Pressure Fuel Li nes

I ntake A r P r e h eater (o ptional)

Fuel F ilter/ Water Separator 3 1 4 N PTF tinch) Water

(Heater)

1/4 N F T F (inch) Fuel I n l e t Connection

M agnetic Pickup Picku p Location 3/4- 1 6 U N F

F uel Lift P u m p

ngine Data Pl a te

1 /8 N F T F (inch ) Oi l Pressure

D i pstick

e w 900gb

Fuel Pump Side View R e a r E n gi n e Liftin g Bra c ket T u r bo Ex ha u st O utl e t

F u el Return C o nn ec ectt ion

Flexplat e M ou n ti n g Holes

F lyw heel

Flywhee l H ou si n g

Rear View

 

Section E - Engine Identificatio  B Seri es

Engine Diagrams Page E-9

uel In jection Nozzles

Turbo Wastegate Oil Fill

Water Outlet

Lubricating Oil Filter

L ubricating O i l C o o l e r

Water Inlet

Starter Motor

and Solenoid ----

Provision or Oil Immersion Heater Oil

D a n

~ --

Turbochager S i d e View

TurboAir Inle t

1 /2 NPTF Water (Heater Return)

F an Pull e y

ltlternator ernator

F ue l P um p D ri ve Cover

A r Compresso r

A i r O u tl e t

F r on t Gear Cove r

V ibration Dampe r

Fan Dr i ve B elt

Front Vie w

 

Section E - Engine I dentification 8 Series

Engine Diagrams Page E-10

NOTES

 

Section T - Trouble shooting B S e r ies

L o g ic

Sect on T - T r o u bleshooting S e ction Contents

Page T - 1

L og c P a ge

S e ction T - T r o ublesh ooting P r o c e d u res and Tech n i q u e s

T -2 T -2

T rou b l e shooti ng Symptoms Charts A l t e r n ator Not C h arging Or I n suffi ufficc ie n t C h a r g i n g C o m p ress i on K n o cks C o o l a n t C o n t a m i n a ted C o o l an t L oss C o o l a nt T e m p e r at u r e Above N o r m a l - G r ad ua l O ve r heat C o o l an t Te m p e r a ture A b ove N o r m a l - S u d d e n O v e rh ea t .. . . . .. .. . .. . . . . . . . . . . . . . .. .. . . .. . . . . . .. .. . .. . . .. .. . . . .. .. . . . . . .. . . . . . . . .. . . . C o o l a nt T em p e r a t ur e Be low N o rm a l... . . .. . . . . . ..... . . . .. .. ........ . . . .. ... ........ . . ...... . .. ......... . ..... ...... . . . . . . . . . . . . ..... ...... .. . . . . .. . . ... . E n gi n e Cran k s B u t W ill N o t S tart - No S m o k e F r o m E x h a u st.. E n g i n e H a rd To S ta rt Or Will N o t S t art - S m o k e F rom E x h a us t.. E n g in e I dle R o ugh (Irr e gularly F i ri n g O r E n g in e S h ak in g ) E n g i n e N o i ses Excess iv e E n g i n e Power O u t p ut Low N o t ORr eM E n gi g i ne R P a cishfirRi nat R oillugh g ed S p eed unMs W E n g in e S t a rt s B u t Will N o t K eep R u n n in g E n g in e Surg ing ( S p e e d C h a n g e) Vibraa tio n E x c e ss ive E n g in e Vibr E n g in e W i ll Not C ra nk Or C r a nks Sl o wly E n g i n e W ill Not S h ut Off... . . .. .. . . . . ...... . ... . . . . . . . . . ... . ...... . . . . . . . . . . . . .. . . . . .. ... ... . . . . . .. ..... .. . ... .. . . . . ..... . .. . . . . ... . . .. . . . . ... . .. . . . .. . .. . .. . E x h au s t Bl ac k Smoke E x c e s si ve E x h au s t White Smoke E x ce s siv e Fuel C o n s u mption Exce s si ve F u e l Or Oil L e ak i ng From E xh a ust Manifold .. .. . .. .. ...... . .. . .. ... ........ . . .. . . . .... .. . . ..... . . .... .. .. Lubric at ing Oil Consumption Excessive. . . .. . .. .. ... . . . . . . . . ........... . .. ..... .. . . . . . . ..... . . . .... L u b r i c at i ng O i l Conta min a ted . . .. . . . . . .. . . . .. . . . .. . .. .. .. . L ub r ic a ting O i l P r e ss ur e H ig h Lubric at ing O i l P r essure Low

T -2 T -48 T-41 T -38 T-3 1 T - 25 T - 28 T - 30 T -4 T -6 T -1 1 T -47

T-17 -

T - 15 13 T -9 T-1 0 T -45

T-3

T - 44 T - 21 T - 23 T -42

.. .. .. .

T-40 T - 36

T - 39

T-35 T-33

 

Section T • T r ou bleshooting Page T-2

Section T • Troubleshooting

Logic B Series

Section T • Troublesh o oting P r o cedures a n d Te c hn hniques iques A thorough anaysis of the customer's complaint i s th e key to successful tr troo ub l e s h o o t n g . k n own about a complain t , the faster and easier the problem can be so l ve d.

Th e more info inforr m a tion

The Troubl eshooting Sym p toms Charts beginn ng on Page T-4 are organ z e d so th a t a probl e m c a n be located and c o r rect ed by d o i ng the easi est and most logica   th ings fi rst. C o m p l ete a ll s teps i n th e seq u ence s hown from top to bo bott ttom.

It i s n ot poss ble to i nclude all the solutions to problems t hat can occur; h o we ver   these c h a rts should stimulate a thought process that will lead to the cause and correcti on of the probl em. Follow these basc tr oubleshooting

steps  

• Get a ll th e fact s co n cern ng the complaint. • Anayze the problem th o r o u g h l y . • Relate the symptoms to th e b asic engine systems and components.

• Consider any recent maintenance or repair action that may relate t o th e problem   • Double-ch eck before beginning any disassembly. • Solve the problem by using the logic charts and d o i ng the easiest thing thingss f rs t. • D etermine t he cause of the problem and make a thorough r e p air. • After r ep ai r s h ave been made, operate the engine to make s ur e th e c a us e o f th e probl e m h a s been corrected 

T r o u bleshooting Symptoms C h a rts ownn g pages of this secti on to h e l p yo u to d i a gnose a nd r e p a ir a p roblem with your U s e th e c harts g iv e n on th e fo llllow rrows s throu gh t h e c h a rt to ident fy the corrective e n g in e . R ead eac eachh row of b l ock s fro m top to bottom . F ollow the a rrow

action.

 

Section T • Troubleshooting Logic

Troubleshooting Symptoms

B Series

Engine Will Not Crank Or Cranks S l owly Cause Starting Motor Operating Operating

Cranking the Engine

Corrections

Remove the starting motor and check for broken teeth on the ring gear or broken starting motor spring. Refer to Procedure 6-10.

But Not

OK

•

Starting Circuit Connections Corroded

1---------·

Loose or

Clean and tighten connections.

OK

•

----------B-att_e_ry __ _ h _ a _ r g _ e__ __ _ o w

l

I

__.~----- - -

_

_ h _ e _ c _6-01. k _ b _ a _ t t _ e _ r y _ v _ o _ l t _ a _ g _ e . _ R _ e _ f _ e _ r - t o ___ r o _ c _ e _ - _ _ _ _ . . _ _ _ __dure

OK

•

No Voltage Voltage to Starter Solenoid

Check voltage to solenoid. Procedure 6-03.

Refer to to

OK

•

Crankshaft

Rotation Restricted

Bar the engine to check for rotational resistance.

OK

•

Sol e noid

or Sta rtng

Motor M a l fu nction

R epla ce s ta rtng P r o cedure 6 - 10.

m otor. R e fer to

Charts Page T-3

 

T roubleshooting P ag e T - 4

Symptoms C harts

Section T - Troubleshooting Logic B Series

Engine C r a nks But Will Not Start - No Smoke From Exhaust ause

................_N _ o __ u - e l _ i _n_s_u_p _ p _ l y - - T a _ n _ k

Corrections

...... --------

...

..._

C _ h _ e c - k / ---- -r- r e - p -l- l e -n -n - isis _ h _ f _ u _ e _ l _ s u _ p _ p - lyly

OK Check for loose wires and verify that the valve is functioning. Check to be sure manual shutoff lever is in the run position. Refer to Procedures 5-05 or 5-11.

Electri cal or Manual Fue   Shutoff N ot Ope n

...

OK Verify proper starting procedure   Refer to the Operation and Maintenance Manual.

I mproper Starti ng Proce d u re

...

OK F u el F il ter P lugged With Water or O the r C o n taminat i on

~ -- - - - - - -·

Drain fuel/water separator o r r epl ace fuel filter. Refer to Procedure 5-04.

...

OK In s p e c t Fuel T r a n s fe r Pump Op Opera erat i on

- --  -- ·

Refer to Procedure 5-02.

...

OK F ue l In je ctio n Pump N o t G etting F ue l o r F u e l i s A e r a ted

...

OK

Check fuel flow/b l e e d fue l sy sys stem. R e fer to Procedu res 5-03 a n d 5 - 1 5 .

__.

Max Ma xi mum inlet restriction to fuel transfer pump must not exceed 100 mm Hg [4 in . Hg].

C h e ck F u e l In l et R estrction

...

OK Visually check; remove the obstruction. Che ck exhaust sys tem for obstruction .

Air I n t ake or E xhau st System P lu gged

...

OK

(C ontinued)

 

Sectio n T - T roubleshooting B Series

L o g . ic ic

Troubleshooting

Symptoms Charts Page T-5

E n gine C r a nks But W ill Not S ta r t - N o Smoke F r o m Exhaust (Continued) Cause

I.

F _ u _ e _ l _ D - r a _ i _ n _ B _a _ c _ k

C o r rections

I

__.~- - -·· ···

...

OK

p l umb umbed e t -bottom o fe _the e -r i -f ed a_ t h _ e _f_u_ l - r e - t fue u _ r _ n  _ tank l - i n _ e _ i  _s~~~.....i '-~-~y_ t_tho_th

C h eck/repl ace return overflow valve   R e fe r t o Procedur e 5 - 27.

M a lfunctioning F u e l R e turn O ve rflow Va lve (lnline fuel pump only)

...

OK

Worn o r Malfunct Malfunctoo ning Fuel In j e ctio ctionn P u mp

•- -••• • •

V i suall y check fue l delivery with an externally c o n nected injector to one of the pump outlet s. Remove t he fuel injection pump. H a v e calibrati on checked.

...

OK In jection Pump T ming Incorrec ectt

V e r i fy/time the pump. R e fer to P r oce dures 5 - 3 6.

...

OK

Engine Camshaft Out of Time

corrr ec C h e c k/cor ectt gea gearr train timing align m e n t. R efer to P r ocedur ure e 7- 1 9.

 

Troubleshoot i ng Symptoms Charts P age T-6

S e ction T - Troubleshooti n g

L ogi c B Serie s

Engine Hard T o Start Or Will N o t S tar t - S m o ke F r o m E xha ust Cause

S t a rt ing Procedure Incorrect

Correction s

R e f er to t h e O p e r ation an d M a inte nance M anual.

OK

•

C r a n k in g Speed Too Slow (Minimu m C ra n k in g S p e e d = 1 5 0 R PM)

V e r i fy th a t th e driven u n its a re n o t en g ag e d

OK Check t he b atte r y , st a r t i n g m o tor, a nd lo o k fo r l oose o r corro d e d wir ng co n n e ct i on s . R e fer to Pr o ce d u r e 6 - 02 .

Bar the e n gine to c h e ck fo r i n te rn a l rotatt io n a l r e s is ta rota tance. nce.

C o l d S tart ng A i ds N o t W o r k ing or Are Ne e d e d

V e ri fy the a ids are o p e r a t n g . R e fe r to O & M m a n ua l fo r re comme n d a ti o n s.

OK

•

I n ta ke A r In s uffic e nt

Insp e c t o r re p l ace f lt e r a n d ch e c k for o b s t r uc t o n s to t he ai r su p p l y tube  

OK

•

Air i n th e F ue l Syste m o r the Fuel S u p p ly In ad e q uate

C h e c k the flow thro throu u g h th e filter a nd bleed t he system . L o c a te and corre ct t h e a i r s o u rc e. R e f e r to P roce d ur e s 5 - 0 3

and 5 - 1 5 .

OK

•

V e ri fy by o p e r a ting the e n g i n e w it h cl ea n fuel fr o m a te m p o r a ry tank of N o . 2 d i e sel fuel. R e fer to the "F ue l R e c o m m e n dat i o ns/ Spe c ifi c a tions " i n the O p e r a t i o n an d M a i n t e 

F u e l i s C o n ta m i n at e d or D iese l F uel G r a de N o . 1 U s e d A b o v e 0 °C [ 32° F] 32°F

OK

n a n ce M a n u al, Bulletin N o . 38 10205 - 1 0 .

•

(Con t i n u e d )

 

Section T - T r o u b leshooting Logic B Series

Troubl eshooti eshootinn g Symptoms Charts P age T-7

Engine Hard T o Start Or Will Not S ta r t - S m o ke From E x h a u st (Continued) ause

F _ u _ e , _D--r a-in _ _a_c_k

,..__

OK

....

C o rr rrections ections

I

......-l······ ·· ._

u _e_l-re_ ,e --- t o v_ef y_of b ottroi -m   tan k. f_fue tu _ r _n _ -in_ e _ _ s _ p _ l u- m -

R e fer to to P r o ce d u re 5 - 02.

I n s p ect Fuel T r a nsfer Pump Operation

OK

....

valve. C h e c k/replac e re turn overfl ow valve. 7. Refer to P r o c e d u re 5- 2

Malfun ctio n in g F u e l R e t u rn O ve rflow

Valve

OK

....

C h e ck F uel In le t R e s tr iction

-- 

·

Maximu Maxim u m i n let r estri estrict ct o n to fue l transfer p ump m us ustt not exc exceed eed 10 0 m m Hg [4 i n .

Hg].

OK

....

OK

Check to topp dead ce nter (TDC). Refer to 7 - 2 1. C heck/adj djust ust i n je ction p u mp tim in g. Refer to Proced cedur uree 5 - 36   C heck/t me thee fue   i njecti th njectinn p u mp u si n g th thee s pill p o rt e. R e fer t o tim i ng i f e q uipment is a vai ab abe. P r oced ure 5 - 3 6

Valves I ncor ncorrect rect y Adjusted

A d just val ves   R e fer to P r o ce dure 7- 0 4.

F u e l I n jection P u mp Out of Time

....

, . _ _ ••

• P r o ce dur e

OK

....

O n e o r Mor e In je ject ctors Wo rn o r M a l fun c t o ning

C h eck/re p l ace in jectors. Refe r to P r o cedures 5 -13 a n d 5-40.

OK

....

(Contin ue d)

 

Section T - T r oublesho o ting L ogic B S e r ies

T r oubleshooting Symptoms C h a rt rts s Page T-8

Engine Hard To Start Or Will Not Start - Smoke F rom Exhaust (Continued) Corrections

Cause

Engine Compression Low

P e rform a c ompr ompree ss i o n c h e c k to identify the problem. R e fer to Procedure

7-01.

OK

•

F u e l In jec ection tion P u m p Malfunc tioning/ Delive ry V a l ves M a lfunctio ning

R e move fue l in j e c tion pump. H a ve ca libration checked  

 

Troubleshooting Symp Symptoms toms Charts Page T-9

Section T - Troubleshooting Logic

B Series

Engine Starts Starts Bu t Will Not Keep Running ause

.._

Corrections

L _ o _ w__- u e _ l _ L _ e _ v _ e _ l

...

OK Engine

Starting

Under

------------~--------1

c _ h _ e _ c k / - - - - f i l - l - f u - e - l - t a - n - k - . __

Di sengage

Load

-------------1

d r i ven units

...

OK Adjust the idle speed. Refer to Proce dures 5-38 and 5-39.

Idle Speed Too Low for Accessories

OK

...

ntake Air or Exhaust Restricted

System

1---------

...

Visually check for exhaust restriction and inspect the air intake. Refer to page 3-11 and 3-23 .

OK Air in the Fuel System System or the Fuel Supply is Inadequate

••••••••••

...

Check the flow flow through the filter and bleed the system. Locate an d correct th e air source.. Refer to Procedures 5-03 source and 5-15.

OK Ve r i f y b y inspecti n g th e fue l filter   Clean the system a n d use c l i matized fuel o r fuel heater s .

Fuel W ax i n g D ue to E x t r e m e ly Cold

W ea th er

...

OK V e r i fy b y o p er a t ng the en g i n e with cl e a n .._ _

F _ u _ e - l C _ o _n _ t _ a _ m - i n - a -t e _ d

...

OK

__. • · · ·----~

i_n ._ __ l _ f rs_ho _ mthe __ae _m a _ry-- st ank. u _ p _ p _ l y - - t a _ n _ k _ . _ D _ r a ____ aun_de _flu fu_ eol _rs_upply

..,_

I · · · ·· · · ·

P -l u_g _g - e_d _ u _ e _ F _ i _ l t _e _ r

._

....

- 16e. . _ R _ e -e _r _ t _ o _ P _ r _ o c _ e _ - ~ dCur t-e[_ _hes _ e _5c-_0k 4/ _ r _aen_ dp _ l - ia_5l-

OK

...

Fu e l D r a in M an i fo l d or R e turn R es tr i c te d (L u cas C AV O n l y )

C h e ck/corre c t the r e s triction. P ro ce dure 5- 14 .

L in e

R efer to

 

Troubleshooting Symptoms Page T- 1 0

Charts

Secti on

T - Troubleshoot e shootng Logic B Series

ngine ine S u rging (Speed Chang e ) E ng ause

______

Corrections

F _u _e _l _L _ e - v e _l _ L _ o _ w  ---~ - - - - - -

..

OK

--1

..

_l a_n _ k _ . C _ h - e c _ k / _ f -il   u_ e-

A d just the i d l e . 5 - 38 a n d 5 - 39  

I f the Cond i ti on O ccurs at I d l e , the Id l e Speed S e t Too Low for A ccess ories

..

__,

rocedur R e fe r to P roced ures

OK

Throttle L i nkage Misadju djuss ted D a mag e d

Ad just or r epair lilink nkage   R e fer to Proced u r es 5 - 05 a nd 5 - 10 .

or

OK

.. ..

I nspe ct/corre ct l eak s in the h i gh pressu r e li n e s, fittings   injector sealing was hers o r d e l i ve ry valves. R efer to Proce d u r e 5 - 1 2.

H i gh Pressure Fuel L e a k

OK Blee d the fue l s ys te m an d corre ct sour ce ------A-e - r a _ t - e d _ F _u _ e _ i

..

..

_._ - --- - - ~

._ 5 -of 15_. t_h _ e _l _ e a _ k _. _ R _ e _ f_e r_ t_ o _ P _ r _ o _ce_d _ u _ r_ e _ s _ 5 _ - o _ 3_a_n _ d _ __

OK One or M o re I njectors Malfunctioning

C h eck/replace the injectors. R e fer to P rocedure s 5 - 13 an d 5-40  

Wo rn or

..

OK

Fue   I n ject on P u m p Ma functioning/ Deliv Deli very V a lv e s M alfu ncti oning

I, R e move fuel injectio n calibration ch eck e d.

pump. Have

 

Section T - T r ou blesho bleshooo ting Logic B Series

Troubleshooting

E n g i ne I dle Rough ( I rregu larl y

Enginee Shaking) Firing Or Engin Corrections

ause

All ow eng ine to warm to ope r ating E _ n _ g _ i .ne--is___ o _ l d

..

5 0K

...

Symptoms Charts Page T - 1 1

--- --- --

_. ~

te mpera-

rature e_fllne_ T rt_r oubl ting o gto i cn __. --if_ee _. n _R g_re_ _e_r_Lat _g ... _etmp u -eeratur n_ wo _ e _ a _es c _ hoo h _o _p emperr ature B e low No Norr m al. fo r C o olant Tempe

C h eck/a d j u s t lo w i d l e scr e w   R efer to P roce rocedu dures 5 - 38 and 5-39.

Speee d Too L o w for t h e Accessor i es Idle Spe

...

OK mount unts . Refer to Ve ri fy condtio n o f mo equ ipment m a nufactur service turee 's servic

E n g in e M o unt s Over- Tightene d , D a m a ged or Loo Loos se

instructi ons . instruc

...

OK Inspec Insp ect/corre ct l eaks in the h i gh pre press ssu re lines lin es, fittings i n je ction s e a l ing washers or delive ry valve sea l s . Refer to Procedures 5 -12 a n d 5 -33.

H i gh Pressure F u e l L e a k

...

OK B l e e d the fue l sys tem and correct the ir-in--th A--ir -in--th _e _F _ u _e _ l _S _y_s -t-t e _m

..

...

OK functio ctio ning F ue   R e turn O verfl ow Valv lve e Malfun

_.• - - - - - --~

. . . . _ s _ o _ u _ r c _ e ~ o f _ t _ h _ e _ a _ i r _ . _ R _ e -e _ r _ t _ o _ P _ r _ o c _ e _ d _ u _ r _ e s_ _ - o _3__,

_ and 5 - 1 5 .

Chec k/re place fuel r e turn o ve rf ow eck/ valve   Refer to Proce dure 5 - 27.

...

OK F ue   Tr ansfer Pump M alfunctio n i n g

Check/r ep ace fuel tran sfe r Refer to P rocedure 5 -02.

p ump.

...

OK F u e l S uppl y

Restr icted

Clean p r e - fifill ters an d s cree eenn s a nd che ck fuel li ne for restriction. R epl ace fu el filter ter.. cedurr e 5 - 04. Refer to Procedu

OK

...

(Cont nued)

 

Troubleshoot i ng Symptoms Charts Page T- 12

Section T - Troubleshooting L o g ic B Series

Engine Idle R o u gh (Irre gularly F i ring O r E ngine Shaking) (Continued) C a u se I n j ector N e e d l e Valve S ti cking

Corrections

- - --- - - -

C h eck/rep ace the injecto r . Refer to

- ------ -

Remove fuel injection pump. Have calibration checked.

Procedure 5-40.

...

OK F uel Injec ti o n P u mp o r D e li very V a l ve M alfuncto n i ng

...

OK

I

Valves N o t Seali n g

f--- --- - -

Adjust va l ve s . Refer to Procedure 7-04 .

...

OK

C o m p ressio n in One or More C y li n ders Low

1 - - - - - ----

P e rform a compression check and r ep a ir as r e qu i r e d . R efer t o P rocedure 7 - 0 1 .

 

Section T • Troubleshooting L ogic B Seri es

Troubleshooting Symptoms

Charts Page T- 1 3

Engine Runs Rough Or Misfiring Cause

Correctons

R e fer to the tr ouble s h oot n g l ogic Rough Id l e .

Condi tion On ly Occu r s a t Id l e

..

OK

.

E _n _ g _ i - n e - - i s_ _C _ o _ l d

..

I

.....~-- · ·· ··

tAe  _ _ w _ e _ ne._g -in-m   ___, e _ r _ a - t i -ng ..._ mpe mp _leoratur -in-ee -to _w_ _ o-o-p

OK I n spect/correc ectt le a k s i n the high press ure line s , fittin g s i n j ector s ealing was hers, or deli very valve s . R e fer to P r o cedure s 5-12  

Fuel Injection Lines Leaki ng

..

OK u gh the filter and Chec thesfyl ow the b l eed kthe s te mthro . Locate and cor rect the ai r s o u r ce   Refe r to P r ocedu r es 5-03 a nd 5 - 1 5 .

Air i n the F uel o r the F uel Supply i s I n adequate

..

OK Che ck/re p l ace re tu rn overflo w val ve . Refe r to Procedu re 5-27  

Malfunctioning F u e l R e turn Ove rflo w

Valve

..

OK Che ck/repla ce fuel tr a nsfer p ump . Refer to P r ocedure 5 - 0 2 .

F u e l T r a nsfer Pump Malfunctionin g

..

OK C l ean p r e - fi lte r s and scre e n s an d che ck fuel li ne for restriction. R e p l ace fu fuee l filte r . Refer to to P r o ce dur e 5 - 04  

F u e l Supply Restricte d

..

OK

F-ue_l _C _o _ n _t a n- a-e_d m 

..

..

OK ue d ) ( Con tin tinu

~ • • • • • ••• .

n i-fufyecl ea lb fryo_o_ m ap-er temporary tat hn_k.e _ v_ e- -i_n_g_ -g__, _ i _n _ e _w-it_h

 

Troubleshootin g Sym ptoms Charts

Page T-14

S ection T - T r ou oubl bleshoo ti ng Logic B Seri e s

Engine R u n s Rough Or Misfiring (Con tinued) Cause V a l ve Adjustment In correct

...

Corrections Check for a bent push r od and a d just valves   R e fer to P rocedures 7 - 0 3 and 7 - 04  

OK In ject on Pump Tim ng I n co r r e ctly Adjust ed

...

OK

Compre ssion in One or More C yl i n d ers Compre Low

C h e ck t o p dead cente r (T D C ) . Refer to Procedure 7 - 21. C h eck/adjus t inject on pump t iming. Refer to P r ocedu edure re 5-36   Ch Che eck/time the fue l in jection pump u si ng the spill port tim i ng if equipmen t i s availab le. R efer to P r o cedure 5 - 3 6

Perform a c o mpr e ssio n ch eck a n d r epa ir a s requ re d . Refe r to P r o cedu cedurr e 7 -01.

...

OK

I n j ecto ectorr s M a l function ng

Che ck/re place in j ectors. R e f e r to Procedu Proced u res 5-13 a nd 5-40.

...

OK Injecti tion on Pump (Deliv (Delivery Valves)

Defective

Remove fuel inje ct on pump. Ha Hav ve calibration checked.

...

OK

C a msha ft O u t of T me

Check/c orrect gear train t m i ng alig alignn  m e n t. Refer to P r o ce d ure 5-36  

...

OK

C a m s haft o r Tappets Damaged

In s p ect camshaft a n d tappet s. R e fer to P roced rocedu u r e 7 -19.

 

g L ogic Section T • Troubleshootin ing B S e r i es

Symptoms s Charts T roublesho oting Symptom Page T-15

Engine RPM W ill N o t R e a ch R a ted S p e e d C a u se T a ch o m e t e r

Corrections

Verify e n gine speed with h and tach o m  e ter. Corr ect as r e q u ired.

M a lfunct o ning

K O

.. ..

V e ri f y high i d l e speed wit h o u t l oad

E _n _ g -n _e_ e_o o_v_ e _ r _ lo l o _a _d _e _ d _. _ - - --- - - -

..

~

_ o--b n ._ __ _ e si s_ t -being i g _ a __ t e- p eused _ r _a -  t i o_ e _ _ u _ r e _ c _o _ r _ r e _ c _ t_ t _ __, gn e_ var

OK Thrott e Link age Worn or I ncorr rrect ectly

Adjusted

..

Ad jus t l i nkage for st o p -t o -s top fuel control ceduress 5-05 and lever t rave l. Refer to P r o cedure 5 -10.

OK

M E nechan gagedca   S h u t off L e v e r P a r t i a lly

..

Check/pl ace shutoff l e ver in ru n p osit o n . R e f er t o P rocedu res 5 - 0 5 a n d 5 - 1 1 .

OK

Fuel Qualit y P o o r o r D iese   F u e l G r a de No. 1 Used Above 0°C [ 32°F ]

..

OK

V e r if ify y by ope operr a ting the engine from a •• _ • • • _ • • temp orary tank o f N o. 2 diese   fue l. R e f e r t o the "Fuel R e commendations ommendations//Specifica tions" i n the B S e r ies O p e r a t i o n and M a i n ten ance Man u a l, B ulle tin N o . 38102 0 5 - 10 .

Check th e flow thr oug oughh th e filter to l ocate the so urce o f the r e s trictio n . R e f er to P r ocedures 5 - 01 a n d 5 -02.

F u e lSupp~ln ad ade eq u~e

..

OK

Fuel R eturn Overflow Va l ve M a lfunctioning

Check/r e p l ace f u e l return overflow valve  

..

OK

F ue l T r ansf er P um p M a l f u nctio n i ng

..

OK ( C o n t i nued)

Check/replace fue l t r ansfer pump. R e fer to P r ocedure 5 - 0 4 .

 

T rou roubl bleshooting symptoms

Page T-16

C h arts

Section T • Troubleshooting Logic B Series

Engine R P M Will Not R e a ch Rated S p e e d ( Continu ed) Cause

C o r recti o n s

Check/repair l eak. Check/clean AFC

Air-Fuel Co ntrol Leak/Obs tructions

tubing and fittings fo r obstru ction  

OK

.. ..

I f t he Conditio n is lnt lntee r m itta n t   M a n i fold Dra i n L in e R e s tricted (L ucas CAV D PA Only)

Check/remove restrcti on. Refer Refer to Procedure 5 - 1 4.

.•

OK Turboc ochh arg e r Wastega te Ac tu a tor

...__o_,_·a _ p _ h _ r a _g _m _R_u_ p_ t u _ r _ed

..

- - - -- -- -

j

f ..._

Repair turbocharger.

.;;....

OK

uel Injec tion Pump Malfunctioning

R e m ove fu e l injectio ectionn pump. H a ve cali b r at i o n checked. cali

I

_ _ _ .·

 

Section T • Troubleshooting Logic

Troubeshooting Symptoms Charts

B.Series

Page T-17

Engine Power Output Low Cause

Correcton s

Check fo r added loading from malfunctioning

_c _other s -o --i e _in _r _di cle _e _n _u _n-it -, _ b _ r _ a _ke -  c_e _changes s _ oveh _ r _ i vloading r_a_ and   - - - - - - - - - ... a

E_n_g-i n _ e _ O _ v e _ r _ l o _ a _ d _ e _ d

..

~

...

OK

Fuel Control Lever Misadjusted

--·-----·

Check/correct f or stop-to-stop travel. Refer to Procedures 5-05 and 5 - 1 0.

...

OK

Check/replace shutoff lever in run run position. Refer to procedures 5-05, 5-11, and 5-31.

Mechanical/Shutoff Lever Partially Engaged

...

OK

Verify by operati ng the engine from a temporary tank of No. 2 diesel fuel. Refer to the "Fuel Recommendat ons/Specificatons" in the B Seri es Oper a tion and Maint ena enann ce Manua , Bulletin No. 381 0205-1 0.

Fuel Quality Poor or Diesel Fuel Grade N o . 1 Used Above 0°C [32°F]

...

OK

If the Condition is Slow Throttle Response   Air Fuel Tube Leaki ng, Wastegate Diaphram Ruptured, Wastegate Plumbing Damaged

Tighte ghtenn the fitti ngs, r epair plum b i ng or repair wastegate diaphram  

...

OK C h e c k t h e AFC li n e and fi tt n g b e t ween the inta k e m a nifold and fuel i n ject io n pump.

AFC P lumb i ng Obstru cted

...

OK

H i g h P r essure F u e l L e a k

---- ·

I n s p e ct/cor rec rectt l eaks in the h i g h press essur ure lilinn e s , fittin fittingg s injector s e a l i ng washe rs o r de ive ry va ve s e a l s .

...

OK

C h e ck the f ow th rough the fil t e r to locat locatee th e s ource o f the r e s triction   R e fer to P r o ce dures 5 - 0 1 a nd 5-02  

F u e l S upply In a d e q u a te

...

OK B le e d the fu e l sy s t e m a nd check fo r s u ction l eaks . R e fer to Proce dure s 5 - 03

A r in the F u e l S ys t e m

...

a nd 5 - 1 5 .

OK ontinu (C ontin u e d)

 

Troubleshooting Symptom s C h a rts P ag e T - 1 8

S e ction T - Trouble Troublesh shooting ooting L o gic B S e r i es

E n g i ne P o wer O utput L o w ( C o n tinued) Corr ecti ons

C a u se

C h eck/r e p la c e fue l transfer pump   R e fe r to P r o c e d u res 5- 0 1, 5-0 5- 0 2, 5 -22 a n d 5- 2 1 .

Fuel T r ansfer P um p M alfunctioning OK

-

eplac lace r e turn o ve rflow v a l ve . C h e ck/rep R e fe r to P r oc ocee d u re 5- 27.

M a l funct ioning F u el R eturn Overflow V a l ve

-

OK

._

__ 0 - - i l _ L _ e _ v - l_ l_ n _c _o - r r - e c - t --~~---- ----

-

C _ h _ e - c_ k / _ o - rr- e c _ t _ o _ i _l _ l e _v_ e _l.

~

OK

In take Air In a d e q u ate or Overheated

I nspe ct/ t/re re place air clea ner e l e m e nt. L ook age e fo r o t her r e s tri ctions. R e fe r to p ag

3 - 11.

OK I f t he v e h icle is e q u i p p ed with a v a lve to s witch the in ta the e hood takk e s ource from u n d e r th t o outsi de, position th e va l v e for the the season.

Cool an t p a ss age ages s plugged i n th the e afterco o l e r .

Check c h a rge ai r c o o l er fo r i n t erna l re s triction. R e p l ace r e s t ri cte d cooler.

C heck/c e a n debris from front of char ge air cooler .

(C o n t i n u e d)

 

Section T - Troubleshooting B S e r ies

T r o u bleshooti hootinn g

Logic

Symp toms Charts P age T- 19

Engine Power Output Low (C tinued  (Co on tinued   C a use

Corree cti ons Corr

C h e ck/correct leak s i n the a ir c ro ss o ve r tu be, h oses , o r _ . •• - - • • • • • ch a rg e a ir coole r connections,

A i r L eak B e tw e e n th e T ur b o c ha r g e r and t h e I n tak e M a n i fold

through hol e s in the m anifol anifoldd P ro ce dure 3-08 .

co v e r . R e fe r to

OK

....

._

l ...,. I - - - - - - - -

E _ x _ h _ a _ u _ st _ _ e -t-r-ic-ti _ o _ n

C h e c k/correct

exhaust s y st e m . C h e c k

......_ _ca _ _ a _ly _s _ t _fo _r _ _ e s _ t _ r i - c t - i o _ n _ . _ R __e __ af _ eg _ re__to 3 _ - 2 _ 3 _ . __.

OK

....

V e rify th a t fu e l h e ater is o ff d u r in g warm we at h e r . Check for a restr i cted fue l d r a in line .

Fuel Temp er at ure H i gh. G r ea t e r T h a n 71 °C [ 1 60°F]

OK

....

C h e ck/correct leaks i n th e m a n i fo l d or turbocharger g a s k e ts . L o o k fo r a crack e d

E xha us t L e a k a t the M a nifo l d or

Tu r bocharg e r

manifold .

OK

....

E x t ra I njec to r S e a li n g Washer Install e d U nder Injec t o r .

Remove extra i n je ctor

s e a ling w a s h e r .

OK

....

._

1 _ n 1 - · e - c -t- t o_ r _ s _ w _ o _ r _ n _o _r_M __ l f u _ n _ c _ t - i o - n - i n _ g

OK

....

 

( C o n t i n ued)

-------

-1 ..

C _ h _ e _ c _ k _ i _n _ j e - c - t o _ r _ s _ .

.....

Troubleshooting Symptoms Charts

Section T - Troubleshooting Logic

Page T-20

B Series

Engine Power Output Low (C (Continued) ontinued) Cause

Corrections

Turbocharger M a lfunctioning

Check for the specified boost pressure. Refer to turbocharger boost pressure specifications   Section 3.

OK Inspect/replace turbocharger. Refer to Procedures 7-05, 3-01, and 3-13.

Valve Clearances Incorrect

Check/adjust valves. Refer to Proce dure 7-04.

...

OK

Fuel Injection Pump Ti m i ng Incorrect

Check/time fuel injection pump. Refer to Procedures 5-36.

...

OK

F u e l Injection P u m p M a l funct oning

Remove fuel injection pump. Have

calibr ation checked  

...

OK P e rfo rm c o m press o n ch e ck to ide n ti fy m a l function   Corr Corree ct a s r equire d.

E n g in e C ompre ss ion L ow

 

Se c tion T - T r ou b l esh esho oo ting

B Series

L o g ic

T roubleshooting

Sympto ms Charts Page T. 2 1

Exhaust B l ack Smoke E xc e s sive ause

Correction s Correction

E n g i n e B e i n g L u g g e d Down

..

-  . _ .

..

.J

OK

1

u_s_e   o _w_e _ r _ g _e _a _ r ·

.

... ..... ·

I nspect/ch ange a ir c ea eann e r. L ook fo r o t h e r restrict ons. R e fe r to page 3- 11.

I ntake Air R estricte d

..

OK

E _x _ h _a_u _s _t_R _e _s t_ r -c-ti_ o_ n

..

l,

_ _ . l ···· · · · ·

. _ _ Cp age _h _e 3-23. _ c _ k _ e _ x _ h _ a _ u _s _ t-e -- t r-ic- t-io _n _ . _ R _ e _fer __.

  o

OK Air Leak B etween th e Tu rbochar ger a nd the Intake M an fo l d

..

1- - - - - - - - -

Ch eck/co r rect l eaks i n th e a i r crossove r tube, h oses   or throu gh ho es in the m a n i fo d . cover . Refer to P r ocedures 3 - 1 0 and 3- 1 1 .

OK Charge A r Coo l er

ooler, er, C h e ck for p lugg e d ch ar ge air cool interna   charge a ir r estriction, or l e aking ch arge air cool er.

Malfunct on

..

OK Exhaust leak at the M an i fold orTu rbochar ger

- -  - - - - ·

..

Check/cor r e ct l e aks i n the manfold or turbochar ger ga ske sketts . Look for a crack e d m a n i fold .

OK Turbo charge r Wastegate M alfun ctioning

- -- -- - - - -

Repair or r e p lace was asttegate   P ro ced cedu u re 3- 02  

R e fer to

I nspect/replace turboc ochh a rge r. Procedure 3- 13 .

Refe r to

..

OK Tu r bocharger

M alfuncti oning

..

OK (Continued)

 

Troubeshoot ng

P age T-22

Symptoms Charts

Section T - Tr ou b eshooting

E xhau st Smo ke Black Excessive Excessive (Continued) aus

Log c

8 Series

C a u se

Corrections

R e m ove extra was h e r . Refe r t o Proce dure 5 - 4 0 .

I n je c t o r I nstalled With M o r e T h a n O ne S e a li n g Washer

OK

....

7 mm Injector Installed With a 9 mm Sealing Washer

to r and t he in jec Remove   R einstall proper sealing washer f e r to t he Pr o ced ure 5- 4 0 .

OK

....

. . - - ------

Injectors M a lf u ncti onin oning g

Replace injectors. R e f e r t o Procedure 5-40.

OK

....

F ue l Inje c ti on P u m p M a lfun c ti o n i n g O v erfue l ed

or

-- 

-----·

R e m o ve fuel i n je ction pump   H a v e ca l i bration che check ckee d.

OK

....

Perfo rm a comp comprr e s s ion c h e ck   C o r r e c t as requ i r e d . R e f er to P r o ce dure 7- 01 01..

Piston R i ngs N o t S e a li n g ( B lu e

S m o k e)

OK

....

F ue l I n j e ction

P u mp T im i ng I ncorrect

1 - - - -- - - - -

C h e ck/time fue l i nject i o n p um p . R e fer to pro ce dure 7 - 20 an d 5 -3 6 .

 

Troubl esh o oting

Section T - Troubleshooting Logic B Series

Exhaust White Smoke Excess ive

Symptoms Charts Page T-23

C o rrecti o n s

Cause

Verify proper starting proced u r e . Refer to procedu the starti startinn g procedure in the Operation and Maintenance Manual.

I mproper Start ng Procedur e

..

OK Refer to Troubleshoot ng Logic C h art for "Coolant Temperature B e l ow Normal".

Coolant Temperature Too Low

..

OK Refe r to vehicle o peration manual for s hutter operation.

In t a ke Air Temperature Too Low

..

OK Verify by operat ng engine from a temporary

F _ u _ e _ i _ a _ u _ a _ l i _ t y _P _ o _ o _ r

~

..

..

--- - - --

tanks w th lu _ s _h__, i ese   _ fuel h_ g _ o _ ol y_ d -u _ a  _ U l _se ity--fau _d_ ee_a_ _l._nC , _ _ the a _ n _ fuel k _ w _ i - t supp a _ n _d_f_ cetann e valu e o f 42-50. ceta

OK Injection Pump Timing Incorrectly Adjusted

OK

1

Tr o u b l eshoot th e KSB (Bosc schh VE Pump O n l y)

Check top dead center (TDC). Refer to Procedure 7-21. Check/ad Check/adjjust i n jection pump timing. Refer to Procedur e 5-36. Check/time the fuel in jection pump usi usinn g the spill p o rt timing if equipment is a va il able   Refer to Procedure 5-36.

R e fer to P r o cedure 5 - 07 , 5 - 08 a nd 5 - 09  

OK

•

In je cto r in sta stallllee d w th mor moree tha n one s e a l i ng washer

Remove extra wa sher. R e fe r to Proce dure 5 - 40.

OK

•

Check/replace in je jector ctors . R efer to Procee d u r es 5 -1 3 an d 5 - 40   Proc

I n jec ecto tors rs M al functio n i n g

OK

•

( Continued)

 

Troubleshooting Symptoms Charts Page T-24

Se ction T • Troub Troubll e s hooting L o g ic B S e ries

Exhaust White S m oke Exce Excess sive (Continued) Cause

Corrections

Coolant L eaking Into Combustion Chamber

..

R e fe r to Tr o ub l e s h o oting Coolant L o s s .

Logic fo r

OK F ue l Injection Pump Malfunctioning/ D e l ivery Valves Malfunctioning

R emove fue l in j ecti o n pump. Have cali bration c h ecke d.

 

Section T • Troubleshooting B Series

Logic

Coolant T emperature A b o ve N o r m a l ause

T r oubleshootin g Symptoms Charts Page T-25

- Gradual Overheat C o rrections

L . .. . . . - ._ _ _

c_o _o -a _ n _ t_L _ e _ v _ e l _L _o _w

..

P_rho_ce r ek/ _1 -r0-6e .p _ l__ e_-_ e _dcu_ n i_ as_ n_ _ht _. _cR _ e _ f_,e_ _r   ___.

OK L ocate a n d corre c t th e so ur ce of th e coola n t l eak. Refe r to t ro ubles h oo ting fo r Cool a n t Loss .

- - C - h a _ rlugged _ g _ e , _ R _ a _ (Automotive d - i a - t - o r - A - i r _ C _ o Only) _o_le_r_F_i-ns

• • • • • •••

..

.

I

J ..

lo gic

B _ l o _ w _ dd - b -- s-fr-m - f - i n _ s _ .

____.

OK A i r Flow t o the R ad i ator I nadequate Restricted

C h eck/ eck/rr ep ai r fa n s hroud, sh utt ttee rs , fan se n s o r s, an d fa n c lu t c h a s r e q u ired. R e fe r to turee r ' s p r o c e d u r es. t h e e q uip m e n t m a n u fa c tur

or

OK

..

C h e c k/correct

Wate r Pump or Fa n Driv e B e l ts L o o se

b e l t te n s i on.

OK R ad i a tor L e ak in g

H ose C o ll apsed,

R e s tr i c t e d

or

• •••• • • •

J

I

C h e c k/ r e p l a ce

h o se.

__

__,

OK

L ubri ubrica ca ti n g O il Leve l H ig h

C h e c k/drain

o il to c o r r e c t l e ve l.

..

OK C o o l i ng Fan Shroud D am ag ed o r M i ss ing

..

I n sp e ct s h r o ud ,

r e p a ir /re pl ace

or i n s ta l l.

OK (C ontin ue d )

 

Troubleshooting Symp Symptoms toms Charts

Page T-26

Section T - Troubleshooting Logic

B Series

ed)) Coolant Te mpe rature Above N orm a l ·- Gra dua l Overheat (Continued C ause

Pressure Cap Incorrect or

M a lf uncti o n i ng

C orr e ctions R e p l ace cap w i th t he cor r e c t r a ti n g fo r t he sy s t e m. R e fe r to P r oced ure 1- 01.

...

OK R e m ove part o f t he coolant fro m co o li ng sy s tem and r e p l ace w i th w a ter.

O ve r concentration o f A n t i- F r eeze

...

OK

Verify that the gauge and tempe temperr a t ure r sensor are accurate. R e f e to Pr o ced u re

Temperature Sensor or Gage Malfunctioning

1 -01.

...

OK

T h ermostat M a l fun c t io n i n g , Missi n g

In co r r e c t o r

----  ·

Check/replace th e th e r m o s t a t. R e fe r to P roc e d ur e 1-08 .

OK

...

Aree N o t Ope n in g R adiator Shutters Ar Compl e te l y or C o ld We a th e r R ad i a tor C ove r Closed

--- - - -  ·

In sp e ct th thee s hutte r s , r e p ai r o r r e p la ce if n ecessar y. O p en radi ator co v e r .

...

OK Make s u re t he fi ll rate is n o t b e i ng ex ceeded and t h e correct v e nted th e rmostat i s in st a ll ed. Refer t o P r ocedu ocedurr e 1 - 01.

Air o r Combus ti on Gases i n t h e C o o ling System OK

I f aer at i on continue d , check fo r a compres s i on l e ak through the h ead gaske gasket. t. Refe r to Procedure 7- 0 1 .

(C o n tinue d }

 

Section B Series T -

Troubl shooting

e

Lo

g ic

Troubleshooting Symptoms Charts Page T- 27

Coolant Tempe r a tu turre Above Norma   - Gradua  Overheat ( Continued) Cause W a t e r Pump Malfunc tio n in g

OK

Corrrections Co

Check/replace the water p u m p. R efer t o P roc e du r e 1-07.

... C ooli n g P a ss a ges i n R a d i a to r , Head, H e a d G a s k e t or Block Block P lugged

F l ush the system and fill with clean coolant.

...

OK

V e hicle C o o li n g S y s t e m Design

Contact vehicle manufacturer for confirma tion of correct fan, radiator, and o ther cool ng system components.

...

OK Verify fu e l injec injecti tio n pump timing m a r k s are aligned. R e fe r to Procedure 5-36 .

Fuel In j e ction Pump Timing In c orre ct

...

OK Remove fu e l i nject ion p um p. H ave calibrati o n c h ecked.

Fuel Injection Pump Overfue l e d

 

Troubleshooting Symptoms Charts

Section T - Troubleshooting Logic

Page T-28

B Series

Coolant Temperature Above Normal - Sudden Overheat ause

.

c_o_o_la_n_t

_ L _ e - v e _ l_ L _ o _ w

...

OK

Corrections

_.~ - - - - - - - •

Add coolant. Refer to Procedure

1-06. __J

Verify that the gauge and temperature sensor are accurate. Refe r to Procedure 1-01. .

Temperature Sensor or Gauge Malfunctioning

...

OK

.I

F_a_n_D-ri_v_e_B_e_l_t -Lo_o_s_e

_.~ - - - - • - -

-1 .

C _ h _ e _ c _k _ b_ e - l t - t e _ n _ s- i o _ n _ .

...

OK

i a - t o _ r _ H - o s _ e _ C _ o _ l l _ a _ p s _ e _ d _ . _ R _ e _ s _ t r - i c _ t _ e _ d _ , _ _. •• __ R _r a _Ld -eaking •••• ••••••

..

JI

------l'

I nspect hoses. __

...;.._

_ __ __ J

...

OK Check the r adiator pressure cap. Refer t o Procedure 1 -01.

R ad i ator Cap Incorrect or Malfunction  i ng. Cap Rated Pressure Too Low

...

OK T h e rmostat

Check th e r m o s tat. 1-01.

Inco r r e ct or M a l fu n ctioning

R e fer to P r o c e d u re

...

OK R a d ia tor S hutt e r s A re N o t O p e n in g C o m p le t e l y o r C o l d Weathe r R a di a t o r

C ov e r C l osed .

S h u tt ersta t S e tt i n g Wron g .

In s p e c t the sh utters. R e p a ir or repl a c e if - - - - - - - - . n ecessa r y . O p e n r adia to r cove r . C h e c k s hutt e r st a t se ttin g . R e fe r t o P r o c e d u r e 01.. 1 - 01

...

OK

A i r or C o m b u s titioo n C o oling S y s t e m

G ases in th e

...

C h e ck fo r air or c o m b u s tion g a se s in the co o li n g s y s t e m . R e fe r t o P ro ce d ur e 7-01.

... .. . . .

OK (C o n t i n u e d )

 

Troubleshooting

Section T • Troubleshooting Logic B Series

Symptoms Charts Page T-29

Coolant Temperature Above Normal - Sudden Overheat (Continued) Corrections

Cause

Check routing and operation of vent line.

Vent Line From Engine and/or Radiator Plugged or Incorrectly Routed

...

OK

I,. •••••••••

Check water pump operation. Replace

Water Pump Malfunctioning

the water pump. Refer to Procedures 1-09 and 1-07.

...

OK Leak Between the Top Tank and the Auxiliary Tank

Check for coolant leakage between radiator auxiliary tank and radiator top tank.

 

Troubleshooting Symptoms Charts

Section T - Troubleshooting Logic

Page T-30

B Series

Coolant Temperature Below Normal Cause A ir Flow Across the Radiator Excessive

Corrections

Check/repair shutters   fan c l utch, v i scous fan as required. R e fer to t he equipment manufacturer's procedures.

OK

....

Thermostat Broken, Damaged, Con taminated or Not Sealing

Check/replace Thermostat. Refer t o Procedures 1- 0 1 and 1-08.

OK

....

emperature Sensor or Gauge Malfunctioning

I- ••••••••

Verify that the gauge and sensor are accurate. Refer to Procedure 1 -01.

OK

....

Coolant N o t Flowing by Temperature Sensor

Check/cl ean co o l ant passages  

 

Section

B Series

Troubles hoo hooing ing SymptomsCharts Page T-31

T • Troubleshooting L ogic

Coolant Loss Cau se

R a d i a to r or Cab Heater Leaking

Corrections

Visually inspect the radiator heater, hoses and connections to locate the l eak.

OK If oil is present in the coolant, check for a transmission or lube o i l cooler leak

- -  - - - - - -

External Engine Leak

Visually inspect the engine and compo nents for seal, gasket, or drain cock leaks.

OK

•

Review the operation for overheating a n d low power. Refer to troubleshooting logic fo r Coolant Temperatur e Above Normal.

O verheatin g or Compression Gases L e a k ing R e s ult in g i n L oss Throu gh the R adiator Overflow

OK

•

I f Equipp ed, Tr a n s m i ss i o n Cool e r L eak

- - - - ---- ·

Check for mixing o f coolant and t ransm is s i on fluid. Refer to P r ocedure 2-03.

1 --- - - - - - - ·

L ook fo r c o o lant in the o i l. C h e c k/ r e p l ac e h ead o r gask e t. R e fer to t he e q u i p m e n t manufacturer's p r o c edures .

1-  -

Check/replace the aftercoole aftercoolerr . Look for coolant in th e intake manifold and in th e oil.

OK

•

withh a W a ter C o oled A i r I f E q u ip p e d wit Compre ss o r , H e a d or H e a d G a s k et L e a k in g

..

OK If the E n g i ne i s Coolant Aftercooled,

Aftercooler Leak

..

- 

OK ... . . . . . . . .

L ubricating Oil Cool er L e a k

..

Check/replace the oil cooler. L o ok for coolant in the oil. R e fer to P r ocedure 2-05.

OK ( C o n t inued )

 

Troubleshooting Page T-32

Section T - Troubleshooting

Symptoms Charts

Coolant Loss (Continued) Corrections

Cause

Check/replace the head gasket. Refer

Cy inder Head Gasket Leak

to Procedure 7-07 .

...

OK

ylinder H ead Cracked or Porous

...

OK

Logic

B Series

1 --- - - - - - -

Check/replace the head. Refer to P roc e du r e 7-07.

Cylinder Block C o o l ant Passages Leaking

--------·

Check/r eplace the cylinder b lock.

 

Troubleshooting Symptoms Charts

Section T • Troubleshooting Logic

Page T-33

B Series

Lubricating Pressur ssur e Low ubricatingOil Oil Pre Cause

Corrections

Check/replenish lubricating oil. Refer t o page 2-08.

Lubricating Oil Level L ow

OK Check for a severe external oil leak that could reduce the pressure.

Lubricating Oil Viscosity Thin; Diluted

1---------

Verify the correct oil is being used. Check

for oil dilution. Refer to troubleshooting logic for Contaminated Lubricating Oil.

or Does Not Meet Specification

...

OK Engine Temperature High (Above 95°C [203°F])

'" • •••••••

Refer to troubleshooting logic for Coolant Temperature Above Normal.

...

OK

Pressure Switch or Gauge Malfunctioning

Verify the pressure switch is functioning correctly.

...

OK Pressure Regulat o r Valv e S t uck O pen

Check / re pl a c e v al ve . Refe r to P r oc oce e d ure 2- 04 .

...

OK L ub r i c atin g

lugg g ed Oil Filt e r P lu

C h a n ge l ub ricatin g c h ange in t e r v a l.

o i l filt filtee r ; r e vi e w

catin ting R e p l ace l ub ri ca P r o cedu r e 2-05.

o il c o o l e r . R e fe r to

...

OK Lubri cat i ng Oil C o o l e r Pl u g g e d

...

OK ( C on t i n ue d)

 

Troubleshooting Symptoms Charts Page T-34

Section T - T roub leshooting Logic B Series

Lubricating Oil Pressure Low (Continu ed} Cause

If Lubricating Oil Cooler was Replaced, Shipping Plugs Left in Cooler

Corrections

Check/remove shippin g p l ugs.

OK

....

If Replaced, Four Cylinder Lubricating Oil Pump Installed in a Six Cylinder Engine

Verify that the correct lubricating o i l pump is installed. Refer to Procedur e 2-07.

OK

....

If Replaced, a Pre-1991 Lubricating Oil Pump Installed in a 1991 or Later Engine.

Verify that the correct lubr lubrii cating o i l pump is installed. Refer to P r ocedure 2-07.

OK

....

Check/replace expan sion p l u g s. Refer to Procedure 2-08.

Cylinder Block or Cylinder Head Plugs Loose or Missing

OK

....

Suction Tube Loose or Broken Seal Leaking

Check/replace seal. seal. Refer to to Proc ocee dure 2-06.

· - - - - - - - ·

OK

....

Check/repl replace ace lubrica ti ng o i l p um ump p. R e fe r to P r o c e d ure 2 - 0 7 .

Lubri catng O i l P u m p Worn Lubri

OK

....

C h eck/in s ta ll n ew b e arin gs and tigh ten cap. R e fe r to P r oc ocedu edur e 7 - 1 3 .

Mai n B ear i ng C ap L o ose

....

OK I n s p ect/re p l ace bearings; also check/

..... ..... .................-_ e _ a _r -n _g _ s _ w _ o _r _n .......... ..

----  ...,1 -

~

,___

p _ i _st_o _ n_ _ z _o_lin gs ._R _ e ___ rPeroc _p _ec_7e- _ _ _o c_o z _ l _e_ f_ e _r_to_ ure 13. e daur

 

Troubleshooting Symp Symptoms toms Charts

Section T - Troubleshooting Logic

Page T-35

B Series

LubricatingOil Pressure High Cause Pressure Switch or Gauge Malfunctioning

Corrections

•-------

Verify the pressure switch is functioning correct y.

...

OK

Engine Running Too Cold

Refer to troubleshooting logic for Coolant Temperature Below Normal

OK

...

Lubricating Oil Viscosity Too Thick OK

Make sure the the correct lubricating oil is being used. Refer to O&M manual.

... Pressure Regulator Valve Stuck Closed

---------

Check/replace valve. Refer to Proce dure 2-04.

...

OK If Replaced, Six Cylinder Lubricating 0 1 1 Pump, Installed in Four Cylinder

Verify that the correct lubricating oil pump is installed. Refer to Procedure 2-07.

 

Trou bl eshooting P a ge T-3 6

Symptoms

Charts

Section T • Troubleshooting Logic

B Series

Lubricating O i l Consumption Excessive a u se

Corrections

I

~---- E x_t_e -n _a _l_L _e _a _ k s _ - --------.___v _s -- l-y _i _ n - s p _ e _c _ t _fo _r_ l _ u _b _ r i c _ a _ t - i n _g _o _ i _ l l _ e _ a - k s _ . _ _ _ .

OK

•

Cran kcase Be i ng Overfilled (Dipst ck C a li b r a t e d Incorrectly)

Verify that the dipstick is correctly marked.

OK

•

I ncorrect L ub r icating Oil (Speci fication o r V i scosity)

OK

Make sure the correct l ubricati ng oil is

b e i n g used.

Look for r educed viscosity from dilution with f uel. Fuel dilution in lubricating o i l can ori g i n a te from fuel i njection p u mp driveshaft seal or fuel transfer pump.

R e v i ew/reduce the lubr icating oil change i ntervals  

tubee a r ea for si g n s of C h e ck the b r e a the r tub l ubricating oil l o s s. M e a sure the blowb y a nd perform th e required repa rs . Refer to Procedure 8 - 05  

H i g h B l owby Forcing L ubr cating O i l O ut th e B r e a ther

OK

•

C h e c k fo r lubricating o i l i n the co o l a n t. R efer to P r ocedur e 2-03.

L u b rica t i n g Oil C o o l e r L e a k

OK I f E quippe d ,

•

C h e c k/ k/rre p l ace a ir co m p r e ssor   R e fe r to P r ocedure 4-06.

Air C o m p r e s sor Pumping L u b r i c a ting Oil

OK

•

( C o ntinue d)

 

Section T - Troubleshooting B Series

Troubleshooting

L o gic

Lubricating Oil C o n s umptio n

Excessive ( Continued) Corrections

Cause Turbocharger Leaki n g L ub ri ca t ing Oil to the Air I ntake or E x h au st

Symptoms Charts Page T-37

- - - - - ---

Inspect the air crossover tube for e vidence of lu bricating oil transfe r .

...

OK

I

Va l ve S eals Worn

~ --------

Inspect/replace the valve seals. Refer to

P rocedure 7- 0 1 .

...

OK P i s ton R i n g s Not S e a ling - L ub ri ca ti ng Oil Bein g C o n su med by the E n g i ne

- - ---- - -

Perform a compression check. Repair as required. Refer to Procedure 7-01.

 

Section T - Troubleshooting Logic 8 Series

Troubleshooting Symptoms Charts Page T-38

Coolant Contaminated Corrections

Cause

Drain and flush the cooling system. Fill with correct mixture of antifreeze and water.

Coolant Rusty, Operation Without Corr ect Mixture of Antifreeze and Water OK

Review the coolant change interval. Refer to the Operation and Maintenance Manual.

If Equipped   Tran s mission Lubricating Oil Cool Coolee r Leaking

--------·

Check/replace lubricating oil cooler. Refer to equipment manufacturer's procedures.

...

OK Lubricating Oil Leaks from Lubricating Oil Cooler, Head Gasket, Head and Cylinder Block

- - -  - - - - ·

Refer to troubleshooting troubleshooting logic for Lubricating Oil Loss  

 

ooting Section T - Troublesh

B Series

Logic

Trouble ubles shooting

S ymptoms C h a rts P ag e T- 39

Contaminated ted L u br icating O il Contamina C ause

C o o l an t in the Lubricating Oil, I n t e r n a l E n gi n e Compone Component nt L e a k s

Corre ctions

1 - - - - - - ---·

troo ub l es h o o tin g R e fe r to tr C oola nt L os s.

l ogic for

...

OK

Lubricating Oil Sludge Excessiv e

R evie w lubrica t n g o i l and filte r c h a n g e in t e rv a l s

OK

M a k e s ure t he corre c t l ub r ic a ti n g b ei ng u se d

F ue l in the L ubricat i ng O il , E n gine Operati n g Too Cold

OK

o i l is

R evie w th e o p e r a tion for e x cessi ve id l i n g r e s ul ultiti ng in t he e ngine ru n n i ng b e low n ormal t e m p e r a ture .

... R e p ai r or r e p l ac e fuel t r an s fer p u mp. R e fer to Procedures 5 - 03 and 5 - 2 1 .

F ue l T ra n s fe r Pump Se al L e a ki ng

...

OK

F u e l In jecti o n Pump S eal L eakin g (R o ta r y)

--------

R e m ove the fu e l i n j e ct ion p um p and h av e r epair epaired. ed. R e fe r to P r o c e dure 5 - 3 5 .

...

OK Remove th e fuel inject i o n p u m p an d have re p a ir e d . R e fe r to P ro c edure 5-37.

Intern a l P l u n ger S e al Leaking ( In - L in e )

...

OK Lo c ate a n d r eplace m a l fun ct io n ing i n je c to r . R e fer to P roced u r es 5 - 13 and 5-40.

Injector N e e d l e V al v es Not S e a l i n g

 

Troubleshooting Sym Symptoms ptoms Charts Page T- 40

Section T • Troubleshooting Logic B Series

Fuel Or Oil Leaking From Exhaust Manifold Cause Operating for Extended Periods Under Light or no Load Conditions

Corrections

--------

R e v i ew operating procedure with o p e r ator.

OK

....

Review operation for excess i ve idling.

Intake Air Restriction OK

Check/replace filter Procedures 5-05 andelement. 5-16. Refer to

I njecto r Needle Valve Stuck Open

OK

....

--------

Locate and replace malfunctioning injector. Refer to P r ocedures 5-13 and 5-40.

Turbocharger Lubricati ng Oil Drain Line Obstructed

Check/clean line  

--------i

....

OK

Tu r b o ch a r g er S e al s L e a ki ng Oil

- --- --- -

C h e c k/repl a ce turboc h a r ger. Refer to P r o c e dure 3 - 13.

~ - - ---- - -

C h e c k for e xcessi ve blowby. R e fe r to Pr o ce dure 8 - 0 5 .

OK

....

I

Bl o wb y E x cess cessive ive

OK

....

F ue l I n jection Pump T im i ng In c orre c t

--------

C h e c k/time the in j e ctio ctionn pump. Refer to P r ocedu ocedure re 5-36.

 

T • Troubleshooting ogic B Series

Troubleshooting ymptomsCharts Page T-41

Section

Compression Compre ssion Knocks Cause I f Equipped, Starting Aid

Corrections

M alf alfunctioning unctioning

Repair

Ether

OK

•

-----A-ir_i_n-th_e_F_u-el_S_y_s-te_m ..

L - . . __ _

.....

OK

or replace

eth er

starting starting

aids.

dures _ l - e e - d- t h5-03 _ e _ f _ u _ and e _ l - s y5-15. -s-te_m_. -R-ef_e_r-to-P-ro_c_e_-___.

•

.__ _

f

P_o_o_r_a_u_a_l_ity-F-ue_l

__. _ - - - - - - - - · ... w supply _ i t _ h _ g _ o _ o _tanks. d_fu_e_l_;

OK

•

L

I

Verify by operating

I

E _n _g -n _e _o_v _e _ r_ lo _a _d -d _.~-------·

from a temporary

tank

_ c 1 _ e _ a n _ a _ n _ d _ t _ 1 u _ s _ h _ t - h e - f u _ e _ 1 _ __.

_

.__ __being _ e - r i _ f y _ texceeded. _ h _ a _ t _ e - n g _ i _ n _ e _ l o _ a _ d - r a - t i _ n _ g - i s _ n _ o t __

OK

•

F ue l Injection

Pump T i m ing

I ncorrect

Check/time fuel injection to Procedure 5-36.

pump.

Refer

--1

•

OK I njectors

-- ---·

M a l functi o ning

Replace

injecto r s. Refer to Procedures

5-13 and 5 - 40.

OK

•

C o o l a n t O p e r a ting In co r r ec t

R e fe r to troubl e s h o o ti n g C o o l an t Te m p e r a tu re.

T e m p e r a t ure

logi c for Low

 

Troubleshooting Sym Symptoms ptoms Charts P age T-42

Section T • Troubleshooting Logic

B Series

Fuell Consumptio n Excessive Fue Cause Addit ional Loading from Malfunctioning Accessories

Corrections

----- - - -

..

Check/repair accessories and vehicle components   Refer to the equipment manufacturer's procedures.

OK

I I

Operator Technique

~--------

Review operation for correct gear shifts deceleration, and idling '

~--------

Check for external leaks and engine lubricating oil dilution.

..

OK

Fuel Leaks OK

For fuel dilution, check for internal e~ks.at the fuel transfer pump and l njectton pump.

P o o r Quality F ue l or N o . 1 F ue l U se d

... . . . . . .

Make sure quaity No. 2 fuel is being used.

OK

.. ..

n t ak e Air or E x h a us t R e s tr i ct i o n

·--- - - - - -

R e fe r to tr troo ubleshoo ting l o g ic fo r E xc e ss i ve E xh a ust S m o ke

OK C h e ck/re plac placee in j ectors. R e f e r to P ro c e d ures 5 - 1 3 a nd 5 - 4 0 .

In je ct o r s Wo rn or M alfu n c t io n i ng

..

OK

( C o n tin ued )

 

Section T - Troubleshooting Logic B Series

Troubleshooting Sym Symptoms ptoms Charts Page T - 43

Fuel Consumption Excessve (Continued) Cause

C orrectons

.........

Fuel Injection Pump T m i ng Incor Incorrr ect

Check/t me t h e fu e l in jectio n p u m p. Refe r to Procedure 5-36.

OK

....

Check for broken adjustment seals on the fuel inject ion pump. If the seals are broken, remove and r ecalibrate fuel injection pump   Refer to Procedures 5-35 and 5 - 37.

- ••••• - -

Fuel Injection Pump Settings Incorrect OK

....

..

----------~-a-lv-es __ _ o _ t _ s _ e _ a - t i n _ g

OK

....

Power Functions Malfunctioning

 

_

__.l······· · L..- ~C-h c _k/_a _d _j u _ s _t _v_a _ l v _ e _ s . _R _e _f _ e _ r -to~P-ro_c_e__e _7-04. dure

C h eck/repa r power functio n s.

 

Troubleshooting Page T-44

Symptoms Charts

Section T - Troubleshooting

L ogic B S e r i es

Engine Will Not Shut Off Cause Fuel Shutoff Valve Inoperative

C o r recti ons

Stop the engine mechanically w i th lever on the fuel pump   Check for co r rec rectt so l enoid operation . Refer t o P r ocedures 5-05, 5 - 1 1 and 5-31.

OK

....

Fuel Injection Pump Malfunctioning

Remove the fuel i njection pump and have checked/repaired. Refe r to P r ocedur es 5-35 and 5-37.

OK

....

Engine Runni ng on Fumes Drawn into the Air Intake

Check the air i ntake ducts fo r the source of the fumes.

 

Troubleshooting Symp Symptoms toms Charts

Section T - Troubleshooting Logic

Page T-45

B Series

Engine VibrationExcessive Cause

Corrections

Refer to troubleshooting logic for Rough Running or Misfiring.

Engine Not Running Smoothly

OK

....

Adjust engine low idle speed. Refer to Procedures 5-38 and 5-39.

Engine Low Idle Speed Too Low

OK

....

Fan Damaged or Accessories Malfunctioning

·--------·

Check/replace the vibrating component. Refer to equipment manufacturer's service instructions.

OK

....

Fan Hub Malfunctioning

---------

Inspect/Replace the fan hub. Refer to Procedure 1-05.

OK

....

Alternator Bearing Worn or Damaged

Check/replace the alternator. Ref er to Procedure 6- 11 .

OK

....

V i brati o n Damper Malfunc t i o n i ng (Six-Cyl i nder O n l y )

I n s p ect/r eplace the v ib r ation damper er.. Refer to P r oce d ure 7 - 1 5 .

...

OK Time Tim e cou n te r b a l a ncer ncer.. R e fer t o Shop M a n ua l 3810206.

E n g i n e C o u n ter B a la n ce r N o t Time d Correctl y ( 4 C yl i n der O nly)

...

OK F lywh e e l H o u s in g M i sa ig n e d

...

OK

--

- -  - - - - ·

C h eck/corr e c t flywhe e l a li g n m e nt. R e fe r to P roc e dure 7-24.

(C o n tinue d)

 

Troubeshooti ng

Page T-46

Symptoms

Charts

Section T - Troubleshooting Logic

B Series

E n g i ne V i b ration Excessive (Continued) C a use P ow e r C o m p onent s L oose o r B r o k en

Corrections

Inspect the crankshaft and r ods for damage that cause and unbalance. Refer t o Procedure 7-11.

OK

•

Engine Mount s L oose or Broken

Check/replace engine mounts. Refer to the equipment manufacturer 's service instru ctions.

OK

•

D r i ve Li ne Compon ents Worn o r Unba anced

Check/repa r according to the equip m e n t manufacturer's procedures  

 

T r oubleshoo ti n g S ym p toms Charts P ag e T - 4 7

Section T - T r o ubleshooting Logi c B Series

Engine N oises E xce ssive Correction s

ause

C h e c k t h e te n s i o n e r a nd i n s p e c t the d ri ve b e l t for dete r i o r a ti o n . M a k e sure water pump   altee rnato r tu rn te n s io n er p u ll e y , fa n h ub and alt fr e e l y .

Drive B e l t S q u eal , In su ffffii c e nt Tension o r A b n ormall y H i gh L o ad i n g OK

Check fo r p a in t /o il o r o th e r m a t e r i a l p u ll eys.

on

accesss o ry dr v e b e ltltss . C h e c k the te n s ion o f acces R e f e r t o the equipme n t m an ufactur turee r' r'ss p r o c e d ur es. M a k e sure th e accessori e s turn fre e l y .

In t a k e A i r o r E x h a us t L e a k s

. . . .... . ... . . . . .

R e fe r t o tro ublesh o o t i ng l ogic for Excessi v e E xh au s t Smok Smokee

OK

•

V al v e L a s h E x cessi ve

~ - - -----·

A d jus t va l v e s . M a ke s ure the p ush r o d s are n ot b e nt or th e ro c ke r l e v e rs a r e not seve r e l y w o rn . R e fe r to P r o cedur e 7 - 0 4 .

~ -- -- -- --

turbb ine Check Chec k t ur b o c h a r ger i m p e ll e r a nd tur whee l fo r h ousi n g c o n t a ct. R e fer to P r ocedur e 3- 01.

OK

•

Turbocharger N o i se

OK

•

V is u a ll y in s p e ct and measur e gear backlas h . R e p l ace g e a r s as re q ui r e d. Refer t o page 7- 0 5 .

~ ---- - - --

Gear Train Noise OK

•

C h e c k/ r epl a ce r o d a n d m a i n b e a rings . R e fe r t o Pr o c edures 7 - 1 1 a nd 7 - 13.

- - - - - ---

P o w e r F unction Knock

 

Troubleshootig

Page T-48

Section T - Troubleshootng ng

Logic B Series

Symptoms Charts

Charging Or InsufficientCharging Al ternator Not Charging Cause Battery Connections C o r roded

Corrections

Check/tighten battery co n nections. Refe r to Procedure 6- 02.

L oose or

...

OK Load test the battery . If battery ch a r ge is lo w , B - a t t _ e _ r y _ C _o _ n _ d - i t-io_n

..

...

~

tens_ dt,_ l_replace c - h a _ r _ g _ e _ ft -ails h e - b - athe t t _ e _ load r_ y_a _ _ t _ a _ gbattery _ al f -_ it n_ h_ -. . 1 e . - - - - - - - - ' - - battery o a -- t e _ sthe

OK

Alternator

Check/replace belt te ns i oner. Refe r to Procedure 1-03.

Belt Sl i pping

...

OK A l t e rn at o r

...

OK

.._

R e pa i r / tighte n

P u ll ey Loose o n S h a ft

i.

_ o __o _s _e _ - -o -_r- _- B- _ - r•_o _ke _n w  _i-re _s_a _ t_ A _ -e _rn _a _t - r  

...

OK

Alternator

Malfunction i n g

p ull e y .

----.....1

R  p _aw_i_rr -n _g _   i_

R e fer to the vehicle m a n u f ac turer's instructions for troub l eshsoot i n g th e a l t e rnator an d c h ar g i n g ci r cuit.

Replace a lt er n at o r . R e fe r to P r oced u re

6 -1 1 .

 

Section 1 - Cooling System B Series

Page 1-1

Section

1 -

Cooling System

Section Contents Page B e lt Tensioner - Replacement

1-12

Cool a n t .. . .. .. .. . .. . . . . . . . . .. . .. .. . .. . . . . . .. .. .... . . . . . .. .. . .. . . D r aining .. . . . .. .. .. .. .. .. . Filling. . . . . ...... ............. ... ............... ............... . . .................... ........ ........... ............ ............. ...... ........... . ........ .. ................ .......... . . .......... Cool ant System Components and Flow . . .. . . .. . . .

.. .. . .. .. ..

. .. .. . .. .. 1 - 14 . . .. . . 1-14

1-15

. . .. .. .. .. . . . .. . . .. .. . . .. . .. .. . . . .. . . . .. . .. .. . . .. .. .. .. . . .. . . . .. . .. .. . .. .. . . .

1 -2

Coolant System Malfunctions .. . .. .. .. .. .. .. .. . .. . . .. . . . .. . .. . .. .. .. .. . .. . .. .. .. . . . .. . . .. .. . .. . .. .. . .. . 1-4 .. .. .. Diagnosis 1-4 Gauges, Overfueling and Loading 1 -1 1 Pressure Caps .. .. .. .. . .. .. . . .. .. .. .. . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. . .. .. . . . . .. . .. .. .. . . .. . . .. . .• . .. . .. .. .. . . . .. . . .. .. .. .. . .. .. . . . .. . 1-6 Radiator, Fans and Shutters 1-8 Thermostat . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . . . . . .. . . . . .. .. . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 1-1 O Water (Coolant) Pump 1-7 Cooling System Specifications Drive Belt - Replacement

- ................................... ...... ......... . . ....... .... .. .. ...............

.. .. .. .

..

.. .. . .

.. ..

..

..

..

.. .. ..

..

.. .. .. .. . . . . . .

.. .. .. .. . .. .. .. .. . .. .. . . . .. . .

1-3 .. ..

Expansion Plugs - Replacement

1-18

Fan Hub - Replacement . . . .. . . .. . . Fan Pulley - Replacement

. .. .. . .. ..

T hermostat - Replacement

.

W ater Pump Pump - R eplacement

1-12

. ..

.. .

..

.. .. .. .. .. .. .. .

..

.. ..

.. .. ..

..

.. .. .. .

..

..

. . .. . . . .. . . . . .. .. .. . .. . . . .. .. .. . . .. .. .. . .. . . .. .. .. . .. .. . ..

1-13

.. ..

.. .. . . .. .. .. . . . .. . . . .. . . . . .. .. .. .. . . .. .. . . . .. .. . . .. .. .. . . .

1-13

..

. .. .. . . . .

..

. . .. .

.. . .. .. . .

. .. . .

1-17 1-15

 

C oolant S yste m P a ge 1-2

C ompon ents

and F low

Section

ooll i n g 1 - C oo

Syste m B S e ries

Coolant System Components and Flow ident nti fi es the s i g nificant fea featu tures of th e cool ant system. Th e following i ll ustration ide A   Cool a n t i s drawn from the rad ia iattor by the integrall y moun ted wate r p um ump p. The o utp tpu u t from the water pump empt es in to the o i l cooler cavity of t h e cyl i n der block.

B . The coolant th e n circulates around eac eachh cy in d er and crosses the b l ock to the fuel pump side of the engine. C. Coolant then fl ows up into th e cyl i nde r h ead , c rosses over the val ve bridges and d o wn the ex exhh aust manifold side of the engi ne to the integr a l the r m os ostta t housing.

D. As the cool ant fl ows across th e h ead toward th e th e rmos ta t h ou sin g, it pr pro ovides cooling for th e injector. When th e engine is b e l ow operatin g tempe rature, th e th erm ostat is closed, an d the cool a nt fl ow bypasses the r ad iator and goes to the water pump i n l et th ro u g h inte r n a l dri llings in th e b l ock an d cylinder h ead . When operat ing temperature is reac h ed, th e th e r m ostat o pe n , blockin g th e bypass passage to the water pump a n d opening the outl et to the radiato r . ~

C a uti o n: N e ver operate th e engi ne wi thout a th e rmostat. With ou t a thermosta t, the c ool a n t will n ot flow to th e ra dia tor and the en gine will ov ovee rh e at  

Cool a n t S ystem

B Cylind er Block 1 . C oola n t I n l et 2. Pump Im p elle ellerr 3. C oola nt F lo w P ast Oil C o o ler 4 . C o o l a nt Fl o w P ast Cylinde r s 5. Coolan t to Cyli Cylinn der H ea d

D

1 . Coolan t F lo w fro m C y linder Bl ock 2 . Coola n t to The The rmos ta t H o u si n g

1 . C oola n t F low Past In jecto r 5. B y- P ass C losed 6 . Coolant F low B ack to 2. Thermostat R adiator 3. Coola nt B y- P ass Passage , ,..,,- ,.,, , ....., 4 . Coola nt F low to P ump Inl Inlet' et',... • . , · ,,..,,-

5

 

Cooling System Specifications Page 1-3

Section 1 - Cooling System 8 Series

Cooling System Specifications 83.9, 48 483 39

48T3 9

Coolant Capacity (Engine Only)- Litre [U.S. O ts . J . .

7 [7.4)

7 [7.4)

Standard Modulating Thermostat - Range o c [OF) .

- - --- ---- -- - - ------

Pressure Cap (kPa [PSI]) 104°C [220°FJ Systems .

103 [15]

103(15)

03 [15]

03 [15]

103 [15]

Pressure Cap (kPa [PSI]) 99°C [210°F] Systems .

48 [7]

48 [7]

8 [7]

8 [7]

48 [ 7 ]

Cooling System Specifications

Start 83 [181]

8TA3.9

685.9, 68T5.9, 85. 9

.7 [10.3)

10.5 [11.1)

---- - - - ----------

68TA5.9

\

, 1 4.5 [ 1 5.3)

Fully Open 95 [203) ------------ --------

 

Coolant System Malfunctions (1-01) Page 1 - 4

ling g System Secti o n 1 - C oolin B S e r i es

104°C (220°F)

Coolant System Malfunctio ns (1-01) Diagnosis systtem i s to m a inta i n a spec The func uncttion of th e cool a n t sys forr the engine. S o m e o f th e i fied operating temperature fo heat generated by the engi ne is absor bed by th e cool a n t

e a 9ga va

flowing through the passages i n th e cylinder b lock and head. Th en, heat is removed from the coolant a s i t fl ows through the radiator . When you t r o u b leshoot overheat ing, remember th at too much oil in the o i l pan can cause additional heat from friction when the r od journals a re submerged in oil.

Overfilling with o i l raises the o i l temperatur e w h ic h transferred to the coolant system at the o i l cooler.

is

The system i s desi gned to use a spe cif c q ua ntity o f coolant. I f th e coolant l evel i s lo w   th e e n g i ne will r un hot. NOTE: T h e engine o r sy s t e m h a s a leak if fr eque nt ad d i ti o n of co o l ant is necessa r y . F i n d an d r epair t h e l e a k .

ra900ve

C aution :

The engine coola n t

passag es m u st b e com 

pletely filled with cool ant. D u r i ng operation e n trapped a ir m i x es w i th th e co o l a nt which r e sults in cav tati o n corrosion a n d p o o r h e a t t r a n s fer   Highly aerated c oolant can causeloca ized overh e a t i ng of the cy i n d e r h e ad and block w h i c h can r e s ult i n a gasket.t. c r a c k e d h e ad, scored cyinder o r b l own head gaske