Daewoo D25S-3(B3.3) Bedienungsanleitung

Service Manual B3.3 Diesel Engine Lift Trucks D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3), D32S-3(B3.3), D33S-3(B3.3) Skid Steer Loaders 450/450Plus, 460/460Plus SB4135E00 Jan. 2004[...]

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1 Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safet y rules or precautions. An accident can often be avoided by recognizing potentially ha zardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have [...]

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Diesel Engine Index 3 Index Introduction About the Manual ................................................... 4 How to Use the Manual ......................................... 4 Illustrations ............................................................. 6 Symbols ................................................................. 5 Engine Identificat[...]

Diesel Engine Introduction 4 About the Manual This T roubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems and to provide recommended repair procedures. The material in this manual covers all Signature engines. The manual is divided into sections. Each section is equivalent to a group used in Cummin[...]

Diesel Engine Introduction 5 Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: W ARNING – Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUSION – Min[...]

Diesel Engine Introduction 6 Illustrations Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or repl[...]

Diesel Engine Engine Identification 7 Engine Identification Engine Dat aplate The engine dataplate shows specific information about the engine. The engine serial number (ESN) and control parts list (CPL) provide information for ordering parts and for service needs. NOTE: The engine dataplate must not be changed unless approved by Cummins Engine Com[...]

Diesel Engine Engine Identification 8 Specifications Performance D20/25/30/32/33S-3 450/450Plus,460/460Pl us S tandard - SAEJ1995 Air Cleaner - without but with 3.0kPa intake restriction Muffler - without but with 10.0kPa exhaust restriction Alternator - without T est Condition Fan - without Rated Power kW(PS) 43.4 (59) @ 2200 rpm 48.5 (65) @ 2600 [...]

Diesel Engine Engine Identification 9 Engine Diagrams Engine Vi ews The following illustrations show the locations of the major external engine components, filters, and other service and maintenance points. Some external components will be at dif ferent locations for different engine models. 1. Intake Manifold 2. S tarting Motor 3. Fuel Injection P[...]

Diesel Engine Engine Identification 10 1. Oil Fill Cap 2. Thermostat Housing 3. Alternator 4. Dipstick 5. Oil Filter 6. Exhaust Manifold. 00900139 Exhaust Side (Naturally Aspirated)[...]

Diesel Engine Engine Identification 11 00900141 Front V iew (Naturally Aspirated) Rear View (Naturally Aspirated) 00900140[...]

Diesel Engine Engine Identification 12 1. Oil S trainer 2. Oil Pump 3. Oil Cooler (Optional) 4. Regulator V alve 5. Oil Filter 6. Safety V alve 7. Crankshaft 8. Camshaft 9. Piston 10. Intake and Exhaust V alve 11. Rocker Arm 12. T iming Gear 13. Cooling Water . 00900146 Exhaust Side (Naturally Aspirated)[...]

Diesel Engine Engine Identification 13 1. Bushing 2. Gear Drive (number of teeth: 7) 3. Pump cover 4. Oil Pump Drive Gear (number of teeth: 22) 5. Driveshaft 6. Drivenshaft 7. Driven Gear (number of teeth: 7) 8. Regulator V alve 9. V alve S pring. Oil pump • T ype: Gear T ype • Pump S peed: Engine S peed x 1.182. Regulator V alve • Set Pressu[...]

Diesel Engine Engine Identification 14 1. Fuel Injection Pump 2. Overflow V alve 3. Fuel Solenoid 4. Fuel Injection Nozzle 5. Fuel T ank 6. W ater-in-Fuel Sensor (WIF) 7. Fuel Filter 8. Hand Priming Pump. 00900149 Fuel System[...]

Diesel Engine Engine Identification 15 1. Pump Holder 2. Fuel Injection Pump Drive Gear (number of teeth: 52) 3. Drive Shaft 4. Fuel Injection Pump (Body) 5. Fuel Filter 6. Fuel Injection Pipe (No. 1) 7. Fuel Injection Pipe (No. 2) 8. Fuel Injection Pipe (No. 3) 9. Fuel Injection Pipe (No. 4) 10. S pill Tube A. Fuel Inlet (from Fuel T ank) B. T o. [...]

Diesel Engine Engine Identification 16 1. Fuel Drain Line Connector 2. Nozzle Holder 3. Adjusting Shim 4. Nozzle spring 5. S pring seat 6. Intermadiate Plate 7. Nozzle Body 8. Retaining Nut 9. Needle. A. Fuel Inlet (from injection pump) B. Fuel Injection (to cylinder) C. Fuel Return (to fuel tank). Fuel Injection Nozzle • Maker: Zexel • Injecti[...]

Diesel Engine Engine Identification 17 1. Radiator 2. Thermostat 3. W ater T emperature Gauge 4. W ater Pump 5. W ater Manifold 6. Cylinder Head 7. Piston 8. Cylinder Block 9. Oil Cooler (optional). A. From Oil Pump (oil). 00900147 Cooling System[...]

Diesel Engine Engine Identification 18 1. Filtered Air 2. Intake Manifold 3. Intake V alve Port. 00900227 Air Intake System[...]

Diesel Engine Engine Identification 19 1. Exhaust V alve Port 2. Exhaust Manifold 00900232 Exhaust System[...]

Diesel Engine T roubleshooting Symptoms 20 Procedures and Techniques A thorough a nalysis of the customer's complaint is th e key to successful troubleshooting. The more informa tion known about a complaint, the faster and easier the problem can be solved. The T roubleshooting Symptom Charts are organized so that a problem can be located and c[...]

Diesel Engine T roubleshooting Symptoms 21 Engine Will Not Crank or Cranks Slowly This is symptom tree T - 002. Cause Correction Defective wiring of starting circuit T roubleshoot and repair st arting circuit wiring including relays and switches. OK S pecif ic gravity of battery electrolytr is low , or Battery voltage is low Check the alternator . [...]

Diesel Engine T roubleshooting Symptoms 22 Engine Cranks But Will Not S t art (No Exhaust Smoke) This is symptom tree T - 003. Cause Correction Fuel level low in the tank Fill the supply tank. OK Improper fuel is being used Drain fuel and replace with correct fuel. OK Clogged fuel tank air breather hole Clean the fuel tank breather . OK Engine does[...]

Diesel Engine T roubleshooting Symptoms 23 Engine Difficult to St art or Will Not S t art (Exhaust Smoke) This is symptom tree T - 004. Cause Correction S tarting aid malfunctioning or heater mount Does not become warm Replace the starting aid. OK Crank speed is too slow (minimum crank S peed: 150 rpm) V erify drive units are not engaged. Check the[...]

Diesel Engine T roubleshooting Symptoms 24 Engine Difficult to St art or Will Not St art (Exhaust Smoke) (Continued) Cause Correction Overhead adjustments are not correct Measure and adjust the overhead settings. OK Overhead components are damaged Inspect the rocker levers, rocker shafs, and valve for excessive damage. Replace as necessary . OK Def[...]

Diesel Engine T roubleshooting Symptoms 25 Engine Has Poor Respones This is symptom tree T - 005. Cause Correction Clogged air cleaner element Clean or replace the air cleaner element OK Clogged fuel tank air breather hole Clean the fuel tank breather . OK Clogged prefilter Clean or replace the fuel filter or strainer . OK Clogged fuel filter or st[...]

Diesel Engine T roubleshooting Symptoms 26 Engine Stop s During Operation This is symptom tree T - 006. Cause Correction Chassis powertrain is damaged or overloaded Refer to the OEM’s service manuals. OK Fuel level low in the tank Fill the supply tank. OK Clogged fuel tank air breather hole Clean the fuel tank breather . OK Clogged prefilter Clea[...]

Diesel Engine T roubleshooting Symptoms 27 Engine Runs Rough or Misfires This is symptom tree T - 007. Cause Correction Fuel level low in the tank Fill the supply tank. OK Clogged fuel tank air breather hole Clean the fuel tank breather . OK Low idle speed is adjusted too low Adjust the low idle speed. OK Clogged prefilter Clean the prefilter . OK [...]

Diesel Engine T roubleshooting Symptoms 28 Engine Power Output Lo w This is symptom tree T - 008. Cause Correction Improper fuel is being used Drain and replace the fuel with the correct fuel. OK Clogged air cleaner element Clean or replace the air clea ner element. OK Clogged fuel tank air breather hole Clean the fuel tank breather . OK Full throt[...]

Diesel Engine T roubleshooting Symptoms 29 Engine Power Output Lo w (Continued) Cause Correction Defective contact of valve or seat Resulting in low compression Replace the c ylinder head. OK T urbocharger does not rotate freely Replace the turbocharger . OK Defective or clogged injection nozzle Replace the defective or clogged in jection nozzle. O[...]

Diesel Engine T roubleshooting Symptoms 30 Excessive Exhaust (Black Smoke) This is symptom tree T - 009. Cause Correction Engine is bring lugged down Use lower gear . OK Clogged air cleaner element Clean or replace the air clea ner element. OK Muffler is crushed or clogged Replace the muffler . Refer to the OEM’s service manual. OK Air leakage be[...]

Diesel Engine T roubleshooting Symptoms 31 Lubricating Oil Cons umption Ex cessive This is symptom tree T - 010. Cause Correction Lubricating oil leak (external) Inspect the engine the external oil leaks. T ighten the capscrews, pipe plugs, and fittings. Replace the gaskets if necessary . OK Intake system is contaminated with dust Remove and clean [...]

Diesel Engine T roubleshooting Symptoms 32 Lubricating Oil Cont aminated This is symptom tree T - 01 1. Cause Correction Breather or breather hose is clogged Clean the breather and breather hose. OK Lubricating oil filter is clogged Replace the filter . OK T urbocharger turbine oil seal is damaged Replace the turbine seal. OK T urbocharger turbine [...]

Diesel Engine T roubleshooting Symptoms 33 Fuel consumption Is Excessi ve This is symptom tree T - 012. Cause Correction Overloading from malfunctioning accessories Check and repair the accessories. Refer to the OEM’s service manuals. OK Operator technique is not correct Refer to the operation and maintenance manual for proper operating speeds an[...]

Diesel Engine T roubleshooting Symptoms 34 Coolant Cont amination This is symptom tree T - 013. Cause Correction Coolant is rusty Review the coolant change interval. Drain and flush the system. Fill the system with the Correct mixture of coolant and water . OK Lubricating oil cooler for powertrain is damaged Refer to the OEM’s service manual. OK [...]

Diesel Engine T roubleshooting Symptoms 35 Coolant Loss This is symptom tree T - 013.1 Cause Correction Radiator or cab heater is leaking Inspect the radiator heater , hoses, and connection to locate the leak. If oil is present in the coolant, check for a transmission or lubricating oil cooler leak. OK External engine leak Inspect the engine and co[...]

Diesel Engine T roubleshooting Symptoms 36 Lubricating Oil Pressure Is Low This is symptom tree T - 014. Cause Correction Lubricating oil lever is below specification Check the oil level. V erify the dipstick calibration and the oil pan capacity . Fill the system to the specified level. OK Oil level or pressure sensor is damaged Replace the oil lev[...]

Diesel Engine T roubleshooting Symptoms 37 Oil Level Rises This is symptom tree T - 015. Cause Correction Rear crankshaft seal or seal surface is damaged Repair or replace seal and surface OK Auxiliary equipment has damaged pump seal Replace the auxiliary pump. Refer to the OEM’s service manual. OK Injector sleeve is damaged Replace the injector [...]

Diesel Engine T roubleshooting Symptoms 38 Coolant T emperature above Normal This is symptom tree T - 016. Cause Correction Coolant level is below specification Inspect the engine and radiator for external coolant leaks. OK Fan belt is slipping or the fan pulley is worn Replace the fan belt or pulley . OK W ater temperature gauge is malfunctioning [...]

Diesel Engine T roubleshooting Symptoms 39 Excessive Noise This is symptom tree T - 017. Cause Correction Belt is squeaking due to insufficient tension or abnormally high loading Check and adjust belt tension. Make sure all the pulleys rotate freely . OK Air leakage between the turbocharger and head T ighten the clamp between turbocharger and head.[...]

Diesel Engine T roubleshooting Symptoms 40 Excessive Noise (Continued) Cause Correction Injection pump is adjusted incorrectly Adjust or replace the injection pump. OK Worn piston ring or cylinder resulting in low compression Replace the worn piston ring or cylinder .[...]

Diesel Engine T roubleshooting Symptoms 41 Engine Vi bration Excessive This is symptom tree T - 018. Cause Correction Engine mounting bolts are loose or the engine mounting cushion is broken Replace the engine mounting bolts or cushion. OK Engine and powertrain is out of alignment Repair the alignment. Refer to the OEM’ s service manual. OK Gear [...]

Diesel Engine Complete En gine 42 Complete Engine Engine Disassembly Service T ool Part No. Part Name Quantity 3375193 or 3375194 Unit Repair S tand or Engine Overhaul S t and 1 3163625 Bracket 1 3163292 V alve S pring Compressor 1 3397890 Flange Puller 1 3823137 Piston Ring Expansion T ool 1 Engine Removal NOTE: Put tag on all hoses, lines, linkag[...]

Diesel Engine Complete En gine 43 Some state and federal agencies in the United St ates of America have determined that used oil is carcinogenic and can cause reproductiv e toxicity . A v oid inhalation of vapors, ingestion, and prolonged cont act with used engine oil. Al ways use the proper procedures to dispose of the oil. Drain the lubricating o[...]

Diesel Engine Complete En gine 44 Prepare a stable st and, Part No. 3375193 or 3375194, which will prevent the engine from falling over . Engine We ight (approx.): 255 kg [562 lb] Remove the starting motor . Install the bracket, Part No. 3163625, on the engine. W ARN I N G This component weighs 2 3 kg [50 lb] or m ore. T o avoid personal injury , u[...]

Diesel Engine Complete En gine 45 Cover all the engine openings to prevent dirt and debris from entering the engine. Fan Pulley W ARN I N G Be careful not to injure your fingers or damage the alternator when moving the alternator toward the cylinder block. Loosen the mounting capscrew of the adjustment plate (1). Loosen the alternator mounting caps[...]

Diesel Engine Complete En gine 46 Lubricating Oil Filter Remove the lubricating oil filter . Dipstick Guide Remove the dipstick and dipstick guide. W ater Pump Remove the mounting capscrews, water pump, gasket, and o-ring. Discard the gasket and o-ring. Thermostat Remove the two mounting capscrews, thermostat housing, thermostat and seal. 00900155 [...]

Diesel Engine Complete En gine 47 Exhaust Manifold Remove the eight capscrews, exhaust manifold, and gasket. Discard the gasket. Fuel Injection T ubing Remove the clamp. Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head. Intake Manifold Remove the eight capscrews, intake manifold, and air inlet [...]

Diesel Engine Complete En gine 48 Spill Tube Remove the spring hose clamps and hose. Remove the spill tube. Injector CAU TIO N Be careful not to damage the tip of t he injector when remo ving. Remove the mounting capscrew , washer , and injector . NOTE: When removing the injector , clean arou nd the injector , and insert a blind plug to prevent dus[...]

Diesel Engine Complete En gine 49 Rocker Arm Assembly 1. Rocker Shaft 2. Adjusting Screw Lock Nut 3. Pedestal Mounting Capscrews 4. Separating S p ring 5. Rocker Shaft Indexing Screw 6. Pedestal Mounting S tud 7. Cup Plug 8. Snap Ring 9. Thrust W asher (if equipped) 10. Rocker Lever Pedestal 11. Rocker Lever 12. Adjusting Scre w . Rocker Arm Assemb[...]

Diesel Engine Complete En gine 50 Pushrods Remove the pushrods from the cylinder head. NOTE: Mark the pushrods with tags showing the cylinder number , and keep it in a safe place. If there is no abnormality in the push rod, install it in the same position during assembly . Cylinder Head Assembl y W ARN I N G This component weighs 2 3 kg [50 lb] or [...]

Diesel Engine Complete En gine 51 Raise the cylinder head, and remove the valve. NOTE: Mark the valves with tags to show the place of installation and keep in a safe place. Fuel Injection Pump CAU TIO N Do not allow dirt or dust to enter the oil and fuel inlet and outlet port s. Severe engine damage will occur if contaminant s are allow ed to enter[...]

Diesel Engine Complete En gine 52 Remove the two mounting nuts, fuel injection pump, and o-ring from the adapter plate. Discard the o-ring. PTO Shaf t (if applicable) Remove the two capscrews, flange, o-ring, and PTO shaft. Lubricating Oil Pan Remove the 24 capscrews, lubricating oil pan, and gasket. Discard the gasket. Lubricating Oil Suction T ub[...]

Diesel Engine Complete En gine 53 Crankshaft Pulley Remove the capscrew and mounting plate. Remove the crankshaft pulley using flange puller , Part No. 3397890. Gear Housing Cover Remove the 17 capscrews and the gear housing cover . NOTE: A noise damper is installed on some engines. The noise damper must be removed prior to removing the front oil s[...]

Diesel Engine Complete En gine 54 Lubricating Oil Pump Remove the five capscrews and the lubricating oil pump. Idler Gear Remove the capscrew , retainer plate, and idler gear . NOTE: If a PTO is installed, the idler gear uses a bearing. Camshaft Assembly Remove the two mounting capscrews through the casting holes in the camshaft gear . Remove the t[...]

Diesel Engine Complete En gine 55 Flywheel W ARN I N G This component weighs 2 3 kg [50 lb] or m ore. T o avoid personal injury , use a hoist or get assistance to lift t his component. W ARN I N G The pilot is short, so the fly wheel can come off suddenly . Remove the six capscrews, retaining plate, coupling, and flywheel. Flywheel Housing W ARN I [...]

Diesel Engine Complete En gine 56 Loosen the block heater retaining nut. Remove the block heater from the block. Piston, Connecting Rod Assembly T urn the cylinder block on its side with cylinders positioned horizontally . CAU TIO N Be careful not to damage the ins ide of the cylinder . Remove the carbon at the top of the cylinder using fine sandpa[...]

Diesel Engine Complete En gine 57 Rotate the camshaft to set the piston at bottom dead center . Remove the mounting capscrews of the connecting rod cap. Check the number stamped on the connecting rod cap and the cylinder . The numbers must match. NOTE: If there is no number stamped on the connecting rod cap, stamp the correct number on the camshaft[...]

Diesel Engine Complete En gine 58 Remove the snap ring on the other side of the piston using pliers. Remove the piston ring from the piston using pisto n ring tool, Part No. 3823137. If the bushing is worn, the connecting rod must be replaced. Inside Diameter: 30.00 mm [1.18 in] NOTE: Keep the pistons, connecting rods, bearings, piston rings, pisto[...]

Diesel Engine Complete En gine 59 Measure the end play of the crankshaft using a dial gauge. NOTE: The end play measurement is necessary for determining the wear of the thrust bearing and abnormal wear of the crankshaft. Crankshaft End Play mm in 0.131 MIN 0.0052 0.351 MAX 0.0138 Remove the mounting capscrews of the main bearing cap. Remove the mai[...]

Diesel Engine Complete En gine 60 T appet Remove the tappet. 00900205[...]

Diesel Engine Complete En gine 61 Engine Assembly Service T ools Part No. Part Name Quantity 3375193 or 3375194 Unit Repair S tand or Engine Overhaul S t and 1 3163625 Bracket 1 3163292 V alve S pring Compressor 1 3823137 Piston Ring Expansion T ool 1 3397773 Piston Ring Compressor 1 Setting the Unit in the Rep air S t and Install bracket, Part No.[...]

Diesel Engine Complete En gine 62 T appet NOTE: Rotate the engine block so that the cylinder head side is down. Coat the tappet with engine oil and install into the block. Crankshaft CAU TIO N Confirm that there is no dirt or dust stuck to the rear face of the bearing before installation. Debris behind the bearing can cause severe engine damage. NO[...]

Diesel Engine Complete En gine 63 NOTE: • Casting number or cast arrow on the main bearing cap must face toward the front of the engine. • New main bearing mounting capscrews must be used. • Coat the capscrew threads and seat face with engine oil. Position the main bearing caps and capscrews. CAU TIO N Install each thrust bearing with the oil[...]

Diesel Engine Complete En gine 64 Measure the crankshaft end play using a dial indicator . Crankshaft End Play mm in 0.131 MIN 0.0052 0.351 MAX 0.0138 Piston, Connecting Rod Assembly - Assemble CAU TIO N Be careful not to damage the piston or break the piston rings. Install the piston rings on the piston using piston ring tool, Part No. 3823137. NO[...]

Diesel Engine Complete En gine 65 Install the other snap ring into the snap ring groove. NOTE: Make sure the connecting rod moves freely forward and backward after inst alling the last snap ring. Locate the end gaps of the piston rings as shown. 1. T op Ring 2. Second Ring 3. Oil Ring 4. Part Number Mark - “EXXXX” - XXXX = Last Four Digits of t[...]

Diesel Engine Complete En gine 66 Align the notch of the lower bearing with the notch of the connecting rod cap. Install the lower connecting rod bearing into the connecting rod cap. NOTE: Coat the lower bearing with engine oil (SAE 30). The connecting rod cap is stamped with a number that must match both the number on the connecting rod and the cy[...]

Diesel Engine Complete En gine 67 Flywheel Housing Install the rear seal using oil seal installer , Part No. ST 972. Fill 40 to 60 percent of the space in the seal lip with grease. W ARN I N G This component weighs 2 3 kg [50 lb] or m ore. T o avoid personal injury , use a hoist or get assistance to lift t his component. CAU TIO N Do not apply exce[...]

Diesel Engine Complete En gine 68 Measure the radial and face runout of the flywheel housing. Radial Runout mm in 0.35 MAX 0.014 Face Runout mm in 0.30 MAX 0.012 Flywheel W ARN I N G This component weighs 2 3 kg [50 lb] or m ore. T o avoid personal injury , use a hoist or get assistance to lift t his component. Install the flywheel, coupling, retai[...]

Diesel Engine Complete En gine 69 Measure the end play (1) of the camshaft. Camshaf t End Play mm in 0.150 MIN 0.0059 0.350 MAX 0.0138 Oil Pump Install the lubricating oil pump and five capscrews. T ighten the capscrews. T orque V alue: 19 N•m [14 ft-lb] Measure the end play of the lubricating oil pump drive gear . Lubricating Oil Pump Dr ive Gea[...]

Diesel Engine Complete En gine 70 Install the retainer plate and cap screw . T ighten the capscrew . T orque V alue: 1 10 N•m [81 ft-lb] Measure the end play of the idler gear . Match mark alignment: Turbocharged and Naturally Aspirated A Crankshaft gear and idler gear 0.08 mm to 0.19 mm [0.0031 in to 0.007 in] B Camshaft gea r and idler gear 0.0[...]

Diesel Engine Complete En gine 71 T emporarily position the fuel injection pump assembly and measure the backlash of the gears. Measure the backlash of all the gears with a dial indicator . Gear Housing Cover NOTE: A noise damper is installed on some engines. The noise damper must be installed prior to installing the front oil seal. Install the fro[...]

Diesel Engine Complete En gine 72 Crankshaft Pulley Align the crankshaft pulley with the crankshaft key . Install the crankshaft pulley , mounting plate, and capscrew . T ighten the capscrew . T orque V alue: 93 N•m [69 ft-lb] Lubricating Oil Suction T ube Install a new o-ring, oil suction tube, and two capscrews. T ighten the capscrews. T orque [...]

Diesel Engine Complete En gine 73 Fuel Injection Pump CAU TIO N Do not allow dirt or dust to enter the oil and fuel inlet and outlet port s. Severe engine damage will occur if contaminant s are allow ed to enter the engine. Install new o-ring, fuel injection pump, and two mounting nuts on the adapter plate. T ighten the nuts. T orque V alue: 31 N?[...]

Diesel Engine Complete En gine 74 Cylinder Head Assembl y NOTE: Coat the stems of the intake and exhaust valves and the inside of the valve guides with engine oil. Install the valves. Install the valve spring and spring seat on the valve stem. Install the valve cotter into the valve stem groove while compressing the valve spring with spring pusher [...]

Diesel Engine Complete En gine 75 Remove all carbon and dirt from the cont act surfaces of the cylinder block and the cylinder head. Remove all burrs and damage, and clean out all the dirt from inside the cy linder block. Failure to follow these steps will result in severe engine damage. Install a new cylinder head gasket with the TOP mark facing u[...]

Diesel Engine Complete En gine 76 Rocker Arm Assembly 1. Rocker Shaft 2. Adjusting Screw Lock Nut 3. Pedestal Mounting Capscrews 4. Separating S p ring 5. Rocker Shaft Indexing Screw 6. Pedestal Mounting S tud 7. Cup Plug 8. Snap Ring 9. Thrust W asher (only used on some engines) 10. Rocker Lever Pedestal 11. Rocker Lever 12. Adjusting Scre w . Roc[...]

Diesel Engine Complete En gine 77 Adjusti ng V alve Clea rance Adjust the valve clearance. Refer to Section 14. Rocker Lever Cover Install the o-ring into the rocker lever cover . Install the rocker lever cover , three capscrews, and isolator assemblies. T ighten the capscrews. T orque V alue: 9 N•m [7 ft-lb] Injector Coat the injectors with anti[...]

Diesel Engine Complete En gine 78 Spill T ube Install the spill tube. Intake Manifold NOTE: Apply a 1-mm [0.039-in] bead of gasket sealant, Part No. 3823494, to the mounting surface of the intake manifold. Install the air inlet connection, intake manifold, and seven capscrews. T ighten the capscrews. T orque V alue: 40 N•m [30 ft-lb] Fuel Injecti[...]

Diesel Engine Complete En gine 79 Thermostat Install seal, thermostat, thermost at housing, and two mounting capscrews. T ighten the capscrews. T orque V alue: 19 N•m [14 ft-lb] W ater Pump Install the o-ring, gasket, water pump, an d mounting capscrews. T ighten the capscrews. T orque V alue: 19 N•m [14 ft-lb] Dipstick NOTE: Apply Loctite™ s[...]

Diesel Engine Complete En gine 80 Lubricating Oil Filter Install the lubricating oil filter . NOTE: Some engines will have an oil filter co oler mounted between the oil filter and the engine block. Block W ater Heater Clean the core plug hole thoroughly . Make sure there are not burrs or sharp edges that might cut the o-ring. Lubricate the new heat[...]

Diesel Engine Complete En gine 81 Hook the element and one leg of the channel (T -Bar) into the hole as illustrated. Hook the other leg of the channel in the hole and push the heater into the hole as far as possible by hand. CAU TIO N Do not pull the heater into location with the locking bolt as the channel (T -Bar) can bend or cause the threads to[...]

Diesel Engine Complete En gine 82 Insert the power cord into the socket being careful to align the pins with the sockets of the power cord. T ighten the retaining nut by hand. Do not apply power until th e cooling system is filled, and run the engine long enough for the thermostat s to open and ensure all the air has escaped. Alternator Install the[...]

Diesel Engine Complete En gine 83 Be careful not to injure your fingers or damage the alternator when adjusting the belt tension. Insert a bar or pipe between the alternator and the cylinder block. Raise the alternator to adjust the fan tension. NOTE: The belt must deflect 7 mm to 10 mm [0.28 in to 0.39 in] when pushed with finger- pressure of 6 kg[...]

Diesel Engine Complete En gine 84 This component weighs 2 3 kg [50 lb] or m ore. T o avoid personal injury , use a hoist or get assistance t o lift this component. The engine lifting equipment must be designe d to lif t the engine without causing per sonal injury . Engine We ight (approx.) 330 kg [660 lb] Remove the engine from the stand. Remove th[...]

Diesel Engine Complete En gine 85 Connect the drive units to the flywheel housing and flywheel. ` Connect the intake and exhaust system pipes. Connect the starter cable, engine ground strap s, cab or chassis to engine hoses, tubing, electrical wires, and hydraulic lines. W ARN I N G Always connect the negative (-) cable last. Connect the battery ca[...]

Diesel Engine Complete En gine 86 Coolant is toxic. Keep away from children and animals. Save for reu se or dispose of in accordance with local regulations. Fill the engine with engine coolant. NOTE: Remove all tags that were put on all hos es, lines, linkage, and electrical connections as they were removed to identify location during the removal p[...]

Diesel Engine Engine T esting 87 Rocker Levers Adjusting V alve Clearance Remove the cylinder head cover . Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of No. 4 cylinder , bring t he No.1 cylinder into compression top dead center position Align the TOP engraved mark on the crankshaft pulley (1) with[...]

Diesel Engine Engine T esting 88 NOTE: Adjust intake and exhaust clearances in the following firing order by rotating the crankshaft 180 degrees in the normal direction: 1-2-4-3. Adjust the valve clearances for intake valves No. 1 and No. 3. Adjust the valve clearances for exhaust valves No. 1 and No. 2. Rotate the crankshaft in the normal directio[...]

Diesel Engine Engine T esting 89 Complete Engine Measuring Compression Pressure W ARN I N G Exhaust manifold and muffler ar e hot. Do not touch the exhaust ma nifold or muffler or personal injury will occur . W ARN I N G T o avoid personal injury , keep hands, long hair , jewelry , and loose fitting or torn clothing a way from fans and other mov in[...]

Diesel Engine Engine T esting 90 Do not allow dirt or foreign m atter to get into the cylinder . Foreign object s in the cy linder can cause severe engine damage. Remove the nozzle holder assembly for each cylinder . Remove the injector . Lubricate the sealing lips of the sleeve with anti-seize compound. Assemble the injector , sealing sleeve, a ne[...]

Diesel Engine Engine T esting 91 Crank the engine with the starting motor . Read the gauge when the pointer is stabilized. Engine Compression kPa p si 1965 MIN 285 2944 NOM 427 T esting and Adjust ing the Fan Belt T ansion T esting the Fan Belt T ension Check the amount the fan belt deflects when pushed with a force of 6 kg [13.2 lb] at a point mid[...]

Diesel Engine Engine T esting 92 Fuel System Checking and Adjusting Fuel Injection Timing There are two methods for checking and adjusting the fuel injection timing of an injection pump. • The “MA TCH MARK ALIGNMENT” method, which is used when the injection pump is installed on the original engine and the pump is not being repaired. • The ?[...]

Diesel Engine Engine T esting 93 If the stamp lines are out of alignment, loosen nut (7). Align the stamp lines by rotating the coupling. T ighten the nut. T orque V alue: 31 N•m [23 ft-lb] Checking and Adjusting with the Measuring Device Method NOTE: Set the No. 1 cylinder at compression top dead center (TDC) by aligning the pointer on the gear [...]

Diesel Engine Engine T esting 94 Rotate the crankshaft opposite normal engine rot ation (counterclockwise) slightly , until the dial gauge does not move any longer . Set the dial gauge pointer to 0. Rotate the crankshaft in the normal direction until the dial gauge reads 1.0 ± 0.3 mm [0.04 ± 0.01 in]. Look at the pointer on the crankshaft. It sho[...]

Diesel Engine Engine T esting 95 Remove the dial gauge. Install the distributor head bolt and new copper washer into the injection pump. T ighten the bolt. T orque V alue: 17 N•m [13 ft-lb] S tamp a match mark on the injection pump and the timing gear case. Adjusting the Idle Move the governor control lever to the desired idling speed by using th[...]

Diesel Engine Engine T esting 96 Check the opening pressure. a. Open valve. b. Operate lever at one stroke per second. c. Read pressure indicated when spray begins. If the opening pressure is out of specification, disassemble the injector and change the shims in order to change the opening pressure. NOTE: .01 mm [0.0039 in] shim thickness equals 41[...]

Diesel Engine Engine T esting 97 Disassembly Remove the copper sealing washer and discard. Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut. Remove the nozzle needle valve and intermediate plate. NOTE: T o avoid damage, place the injector nozzle and needle valve in a suitable bath of clean test oil. Remove the nozzle holder fr[...]

Diesel Engine Engine T esting 98 Assembly NOTE: Make sure all mating surfaces and pressure faces are clean and lubricated with fuel oil before assembly . W ARN I N G Install the s ame thickness of shims that were removed in disassembly . Use the pressure spring to make sure the shims are installed flat. Install the shims. Clamp the nozzle holder in[...]

Diesel Engine Engine T esting 99 Install the needle valve and nozzle assembly . Install the nozzle nut. fi900ce fi900ob[...]

Diesel Engine Engine T esting 100 Lubricating System Measuring Oil Pressure W ARN I N G When measuring the oil pressure, be careful not to get caught in rotating part s. always remove or install plug or oil pressure gauges with the engine stopped. Remove the oil pressure sensor , and install the pressure gauge. NOTE: Measure the oil pressure while [...]

Diesel Engine Specifications 101 Specifications V alves, V alve Guides, and S prings Ref Inspection Item St andard Remarks VA LV E S Intake T olerance: -0.035 mm [-0.0014 in] -0.050 mm [-0.0020 in] S tem Diameter Exhaust Nominal: 8 mm [0.3130 in] T olerance: -0.050 mm [-0.0020 in] -0.065 mm [-0.0026 in] Intake 0.035 to 0.065 mm [0.0014 to 0.0026 in[...]

Diesel Engine Specifications 102 Rocker Arm Shaft, Push Rod and T appet s Ref Inspection Item St andard Remarks V AL VE R OCKER ARM SHAFT Diameter of Shaft 19 mm [0.75 in] T olerance: -0.020 mm [-0.0008 in] Diameter of Rocker Arm Shaft Hole Nominal: 19 mm [0.75 in] T olerance: 0.030 mm [0.0012 in] 0.010 mm [0.0004 in] Clearance Between Rocker Arm a[...]

Diesel Engine Specifications 103 Cylinder Head Ref Inspection Item St andard Remarks CYLINDER HEAD 1 Surface Flatness (W arpage Limit) 0.00 to 0.05 mm [0.00 to 0.002 in] Repair Limit: 0.30 mm [0.012 in] Intake 1.00 ±0.100 mm [0.039 ±0.004 in] Repair Limit: 2.00 mm [0.079 in] 2 V alve Seat Exhaust 0.90 ±0.100 mm [0.035 ±0.004 in] Repair Limit: 1[...]

Diesel Engine Specifications 104 Cylinder Block Ref Inspection Item St andard Remarks CYLINDER BLOCK 1 Surface Flatness (W arpage Limit) 0.00 to 0.08 mm [0.00 to 0.003 in] Repair Limit: 0.15 mm [0.006 in] STD 70.000 mm [2.756 in] Repair Limit: 70.200 mm [2.764 in] U/S 0.25 69.750 mm [2.746 in] Repair Limit: 69.950 mm [2.754 in] U/S 0.50 69.500 mm [[...]

Diesel Engine Specifications 105 Camshaf t and Camshaf t Bushing Ref Inspection Item St andard Remarks CAMSHAFT Naturally Aspirated Naturally Aspirated 1 Bend of Shaft — 0.03 mm [0.0012 in] Intake 42.69 mm [1.681 in] Repair Limit: 42.20 mm [1.661 in] 2 Cam Height Exhaust 43.04 mm [1.694 in] Repair Limit: 42.50 mm [1.673 in] 3 Thrust Clearance 0.1[...]

Diesel Engine Specifications 106 Crankshaf t Ref Inspection Item St andard Remarks CRANKSHAFT 1 Thrust Clearance 0.131 to 0.351 mm [0.0052 to 0.0138 in] Repair Limit: 0.40 mm [0.016 in] STD 70.000 mm [2.756 in] Repair Limit: 69.86 mm [2.750 in] U/S 0.25 69.75 mm [2.746 in] Repair Limit: 69.61 mm [2.741 in] U/S 0.50 69.50 mm [2.736 in] Repair Limit:[...]

Diesel Engine Specifications 107 Timing G ear Ref Inspection Item St andard Remarks TIMING GEAR Naturally Aspirated and Turbocharged A Crankshaft gear and idler gear 0.08 mm to 0.19 mm [0.0031 in to 0.007 in] B Camshaft gear and idler gear 0.08 mm to 0.19 mm [0.0031 in to 0.007 in] C Injection pump gear and idler gear 0.07 mm to 0.29 mm [0.003 in t[...]

Diesel Engine Specifications 108 Flywheel Ref Inspection Item St andard Remarks FL YWHEEL 1 Face Runout of Flywheel Housing — Repair Limit: 0.30 mm [0.012 in] 2 Radial Runout of Flywheel Housing — Repair Limit: 0.35 mm [0.014 in] 3 Face Runout of Flywheel — Repair Limit: 0.15 mm [0.0059 in] 4 Radial Runout of Flywheel — Repair Limit: 0.20 m[...]

Diesel Engine Specifications 109 Cylinder Ref Inspection Item St andard Remarks CYLINDER Bore STD ID: 95.00 mm [3.740 in] T olerance: 0.022 mm [0.0008 in] Repair Limit: ID: 95.15 mm [3.746 in] Roundness of Cylinder — 1 Cylindricity of Cylinder — Repair Limit: 0.02 mm [0.0008 in] 18900020[...]

Diesel Engine Specifications 11 0 Piston Ref Inspection Item St andard Remarks PISTON 1 Diameter STD ID: 95.00 mm [3.740 in] Repair Limit: ID: 94.85 mm [3.734 in] 2 T op 0.06 to 0.10 mm [0.0024 to 0.0039 in] 2.0 mm [0.079 in]* Repair Limit: 0.15 mm [0.0059 in] 3 Second 2.0 mm [0.079 in]* Repair Limit: 0.20 mm [0.0079 in] 4 Clearance Between Piston [...]

Diesel Engine Specifications 111 Connecting Rod, Piston Ring and Piston Pi n Ref Inspection Item St andard Remarks PISTON PIN Outer Diameter Nominal OD: 30.00 mm [1.181 in] — 1 Clearance 0.004 to 0.018 mm [0.0002 to 0.0007 in] Clearance Limit: 0.05 mm [0.002 in] PISTON RING A Top 0.30 to 0.45 mm [0.012 to 0.018 in] Clearance Limit: 2.00 mm [0.079[...]

Diesel Engine Specifications 11 2 Oil Pump Ref Inspection Item St andard Remarks 1 Axial 0.030 to 0.085 mm [0.0012 to 0.0033 in] Clearance Limit: 0.10 mm [0.0039 in] 2 Clearance of Pump Gear Radial 0.045 to 0.090 mm [0.0018 to 0.0035 in] Clearance Limit: 0.13 mm [0.0051 in] 18900017[...]

Diesel Engine Specifications 11 3 Regulator V alve Ref Inspection Item St andard Remarks Tolerance Standard Size Shaft Hole Standard Clearance Clearance Limit 1 Clearance Between Valve and Body 11 mm [0.43 in] -0.050mm -0.077mm [0.002 in] [0.003 in] 0.020 mm -0.020mm [0.0008 in] [0.0008 in] 0.030 to 0.097 mm [0.001 to 0.004 in] Standard Repair Limi[...]

Diesel Engine Specifications 11 4 Thermost at Ref Inspection Item St andard Remarks THERMOST A T 1 Thermostat Cracking T emperature: 82° C ±2° C [180° F ±2° F] Fully Open T emperature: 95° C [203° F] Fully Open Lift: Minimum: 8 mm [0.315 in] (when immersed in a hot water bath at 95° C [203° F] for 4 to 5 minutes) (Fully Open: Shall open f[...]

Diesel Engine Specifications 11 5 Cap screw Markings and T orque V alues CAU TIO N When replacing capscre ws, always use a capsc rew of the same measurement and strength as the capscr ew being replaced. Using the wrong cap screws can result in engine da mage. Metric capscrews and nuts are identified by the grade number st amped on the head of the c[...]

Diesel Engine Specifications 11 6 Cap screw Markings and T orque V alues - U.S. Customary Capscrew Bod y Size Cast Iron Aluminum Cast Iron Aluminum N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb 1/4 - 20 - 28 9 12 7 9 8 9 6 7 15 18 11 13 8 9 6 7 5/16 - 18 - 24 20 23 15 17 16 19 12 14 30 33 22 24 16 19 12 14 3/8 - 16 - 24 40 40 30 30 25 35 20 25 55[...]

Diesel Engine Specifications 11 7 Fraction, Decimal, M illimeter Conversions Fraction inch mm Fraction inch mm 1/64 0.0156 0.397 33/64 0.5156 13.097 1/32 0.0313 0.794 17/32 0.5313 13.494 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/32 0.0938 2.381 19/32 0.5938 15.081 7/64 0.1094 [...]

Diesel Engine Specifications 11 8 Newton-Meter to Foo t-Pound Conve rsion Chart N•m ft-lb N•m ft-lb N•m ft-lb 1 8.850756 in-lb 55 41 155 114 5 44 in-lb 60 44 160 118 6 53 in-lb 65 48 165 122 7 62 in-lb 70 52 170 125 8 71 in-lb 75 55 175 129 9 80 in-lb 80 59 180 133 10 89 in-lb 85 63 185 136 1 0.737562 ft-lb 90 66 190 140 12 9 95 70 195 144 14[...]

Diesel Engine Specifications 11 9 T ap-Drill Chart - U.S. Customary and Metric NOTE ON SELECTING T AP-DRILL SIZE: The t ap drill size shown on this card give the theoretical tap drill size for approximately 60% and 75% of full thread depth. Generally , it is recommended that drill sizes be selected in the 60% range as these sizes will provide about[...]

Diesel Engine Specifications 120 Weight a nd Measures - Conversion Factors Quantity U.S. Customary Metric From U.S. Customary To Metric Multiply By From Metric To U.S. Customary Multiply By Unit Name Abbreviation Unit Name Abbr. sq. inch in 2 sq. millimeters mm 2 645.16 0.001550 sq. centimeters cm 2 6.452 0.155 Area . sq. foot ft 2 sq. meter m 2 0.[...]

Diesel Engine Special T ools 121 SPECIAL TOOLS Style T ool No. T ool name ST 434 V acuum Gauge ST 537 Dial Depth Gauge S T 1111 - 3 S e a l Leakage T ester ST 1273 Pressure Gau ge 3162745 Injector/Connector Removal tool[...]

Diesel Engine Special T ools 122 Style T ool No. T ool name 3163054 Camshaft Gear R&I T ool 3163292 V alve spring compressor 3375072 Dial Bore Gauge Kit 3375432 Crack Detection Kit 3376579 T ube(Filter) Cutter[...]

Diesel Engine Special T ools 123 Style T ool No. T ool name 3376946 Injector nozzle tester 3377161 Digital multimeter 3377259 Fuel Pump T i ming tool 3377462 Digital optical tachometer 3397773 Piston Ring Compressor[...]

Diesel Engine Special T ools 124 Style T ool No. T ool name 3822476 Blo w By tool, use with ST111-3 3822666 Digital Thermometer (Dual Input) 3823137 Pistion ring expander 3164438 Depth Gauge Assembly 3823956 Fuel Pump Mounting Kit[...]

Diesel Engine Special T ools 125 Style T ool No. T ool name 3824078 Oil Seal/Sleeve Installation T ool (rear) 3824498 Oil Seal Installation T ool 3824500 Wear Sleeve Installation T ool 3824591 Engine Barring T ool 3375193 Engine Rebuild S tand[...]

Diesel Engine Special T ools 126 Style T ool No. T ool name 3375194 Engine Rebuild S tand (Port able) 3163625 Bracket 3397890 Flange Puller[...]