Caterpillar 3208 Diesel Engine Service Manual Copy One [PDF, ENG, 154 MB].pdf

CATERPILLAR’ roro san

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Service Manual

3208
Diesel Truck Engine

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3208 DIESEL TRUCK ENGINE

2Z1-UP

SPECIFICATIONS (Section 1)

SYSTEMS OPERATION (Section 2)

TESTING AND ADJUSTING (Section 3)
TROUBLESHOOTING GUIDE (Section 4)
GENERAL INSTRUCTIONS (D & A) (Section 5)

DISASSEMBLY AND ASSEMBLY (Section 6)

AIR COMPRESSORS (Section I ———————_—__—__—_—_-

RECONDITIONING PROCEDURES (Section 8)

STANDARD TORQUE FOR METRIC FASTENERS.

NOTE: Take care 10 avoid mixing metric and inch dimensioned fasteners. Mis-
matched or incorec fasteners can result in vehicle damage or malfunction, oF
possible injury. Exceptions to these torques are given nthe Service Manual where
needed,

NOTE: Priort installation of any hardware. be sure components ar in near nen
Condition. Bolt and nut threads must not be worn or damaged Hardware must be
ice of and corrosion Clean hardware witha non-corrosive cleaner and apply
engine el to threads and bearing face thread lock or other compounds are 10 be
Applied, do ot apply engine ol

METRIC NUTS AND BOLTS
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10200
er
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STANDARD TORQUE FOR INCH FASTENERS

Exceptions 0 these torques ae given inthe Service
Manual where needed

INCH NUTS AND BOLTS
"a STANDARD TORQUE |
_ cm
{m ss 927
Eid 2526 mozas
EN Arz 3627
76 70215 Er
we | 105220 75215
ne | 16030 | 120220
se | 21820 | 160230
aja | amzso | ers TT
Te | 62080 | 460260
1 900 100 | 680 # 75
TUE | 13002 150 | 050 + 100
aja | 1800 2 200 | 1325 + 150
1800 2 225 |
2000 = 250
[ INCH TAPERLOCK STUDS
| STANDARD TORQUE
[ha wm) em
a 623 622
Em mes 5524
EN ES Er
me ES ser
we | 65210 4827
38) 110 20 902%
EEE W522
TB] 260 + 40 190 = 20
300 2 45
| 370250

O-RING FACE SEAL FITTINGS

O-RING FACE SEAL FITTING nie

so naco 0-81 Por

ame ce sex mr Fe où

‘STRAIGHT THREAD O-RING
FITTING (FOR O-RING FACE
SEAL FITTING ONLY)

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O-RING FACE SEAL FITTING NUT

ET STANDARD TORQUE
= | en]
EAN 1222
Ten [ass]
66 ED
114 sox10 | 65%7
TR | mer | men]
men | W602 20 | men

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4

HYDRAULIC LINE INSTALLATION

1. For a metal tube 10 hose installation, install the
tube and tighten al bolts finger tight

€ bolts at the rigid end,

Tighten à
Install the hose and tighten all bots finger tight

4, Put the hose in a position so that it does not make
‘contact withthe machine or another hose,

3. Tighten the bolts on both connections
6. Stat the engine

7. Move the implement control levers 10 all
positions,

8. Look at the hose during
ment. Make sure hose is no i cont
‘machine or other hoses,

ovement of the imple
ct with the

9. Shut off the engine

10, If necessary, put the hose in a new postion where
it will not make contact when the implement is
moved,

ASSEMBLY OF FITTINGS WITH STRAIGHT
THREADS AND O-RING SEALS

This typeof iting isusedin many applications, The
tube end ofthe fiting willbe different in design so hat
ix can be used in many different applications. How-
fever, the installation procedure of the iting isthe
Same. If the tube end ofthe Fitting body isthe samc as
inthe illustration (either an elbow or straight body) it

FITTING INSTALLATION

1. Putlocknut (3). backup washer (4). and O-ring seal
Sas ar back on iting body (2) as possible. Hold
these components in this position. Turn the iting
into the part it is used on until backup washer (3)
just makes contact with the face of the part is
used on.

2. To put the fitting assembly in is correct postion,
turn the fitting body (2) out (counterclockwise) a
maximum of 359". Tighten locknut (3) to the
torque shown in the correct chart for the tin,
used

NOTE: IF the fitting is a connector (straight fitting

the her on the body Takes the place ofthe locknut To

install his type Fig, tighten the hex against the face
ofthe part i goes in.

‘TORQUES FOR FLARED AND O-RING FITTINGS.

"The torques shown in the charts that follow are 0 be
used on the nut part of 37" Flared, 45" Flared and
Inverted Flared fitings (when used with tel ubin).
(O-ring plugs. O-ring ittings and swivel nuts when used
in applications to 3000 ps (20 700 KPa).

HOSE CLAMP - BAND TYPE

il be necessary to assemble the sleve on the tube
before connecting the tube 10 the end
2 « ? CLAMP | TORQUEON | RETIGHTENNG
WIDTH | NEW HOSE TORQUE
79mm | 09202Nem | O7=02 Nem
5 8:20 CEA
4 135mm] 45z05Nm | 30205 Nem
(som | Cozsom | rs |
159mm| 75£05Nem | 45205 Nem
s (62510) | ron ‘025i

—_,

{Lada ting bay comects ande) 2-Ftng oy. 3 Lock
a Os: € Enea tgs

37° FLARED AND STRAIGHT THREAD O-RING FITTINGS

sales e

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TVGHTENING OTHER FITTINGS
+ Dar (Shear Sleeve) Tube Fitings =>

After tube has been put through the nut and makes
contact against the tube shoulder in the fitting body,
turn the nut with a wrench until a small decrease in
‘torque is felt, This isan indication that the sleeve has
been broken off the nut. Hold the tube to prevent
turning and tighten the nut 1-1/2 turas

Hi Seal Fittings

Put nut and sleve over the tubing with the short
heavy end ofthe sleeve facing the end of tubing. Put
the tube end against the counterbore in the body ofthe

ing and vghten until nut is over the last thread on
{he body. The remainder of space is used whenever the
fiting is removed and installed again,

FS

FLARED AND 45° INVERTED FLARE FITTINGS

SR

45° FLARED AND 45° INVERTED FLARE FITTINGS

Mama meson, mago mew |
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Em = En an fai
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TIGHTENING OTHER FITTINGS
Ermeto Tube Fitings

ng body as Fra possible Turn nut clock

Tighten the nut 11/4 turns more to sat secre and

fa locking action, When necessary 10 asemble
Again, put eve over tube and tighten mot until à

Sudden increase in torque is fet Then tighten 1/6 to

173 turn more to set the sleeve

Flex Fitings —

Put aut and eve over the tubing and push tube
into counterbore of fiting body as far as posible
Tighten the nut until ts against the ex par o the
Fiting body

AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS

O-RING 45" FLARE

AIR CONDITIONING FITTINGS
(O-RING FITTING END 45° FLARE FITTING END
THREAD = STEEL TUBES ALUMINUM TUBES
SIZE STANDARD TORQUE STANDARD TORQUE STANDARD TORQUE
inch Nem (ib ft) Nem (oft) | Nem (of) |
5/8 -18 1824 | 1323 30+3 | 222 2323 17:52
3/4-16 3724 27+3 5225 | +4 | 3324 2453
[ 7/8-14 4024 30+3 60%7 | 4425 | 3884 28+3
Cane: 4525 | 3x4 +8 | S546 | 50%5 374

TAPERED PIPE THREAD FITTINGS
STANDARD TORQUE,

o THREADS WITH THREADS WITHOUT
SIZE |_1E2200E SEALANT ‘SEALANT
inch Nem (ib ft) | Nem on

1/16 - 27 15 1 20 15

1/8-27 20 15 25 18

1/4-18 25 18 35 26

3/8-18 35 26 45 33

12-14 45 33 60 45

34-14 | 60 45 75 55
1-11172 75 55 90 65

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions, An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards, This
person should also have the necessary training, skils and tools to perform these functions properly

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. It these hazard
warnings are not heeded, bodily injury or death could occur to you or olher persons

The hazards are identified by the “Safety Alert Symbol" and followed by a "Signal Word" such as
“WARNING” as shown below

The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.

The message thal appears under the warning, explaining the hazard can be either wntten or pictorialy
presented,

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

Caterpilar cannot anticipate every possible circumstance that might involve a potential hazard. The
‘warnings in this publication and on the product are therefore not al inclusive. I a tool, procedure, work
method or operating technique not spectlically recommended by Caterpilar is used, you must satisty
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and ilustrations in this publication are on the basis of information
available at the time it was written, The specifications, torques, pressures, measurements, adjustments,
ilustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpilar
dealers have the most current information available. For a lst of the most current publication form.
numbers available, see the Service Manual Contents Microliche, REG 1 139F

‘SAFETY

Improper performance of lubrication or mainte-
‘nance procedures is dangerous and could result
in injury or death. Read and understand the lu-
brication and maintenance procedures, recom-
mended by Caterpillar, that are outlined in the
‘OPERATION MAINTENANCE GUIDE and/or OW-
NER'S MANUAL for this product before perform-
ing any lubrication or maintenance.

Do not operate this product unless you have
read and understood the instructions. Imp
‘operation is dangerous and could result in injury
or death.

“The serviceman or mechanic may be unfamiliar
with many of the components and systems of this
product. This makes it important to use caution when
performing service work. A knowledge of the system
and/or componentsis important before Ihe removal or
<isassembly of any component.

Because ofthe size of some components, the service
man or mechanie should check the weights noted ın
this Manual. Use proper lifting procedures when re
‘moving any components.

Following is a lst of basic precautions that should
always be observed

1. Read and understand all Warning plates and de
cals before operating lubricating or repairing this
product

Make sure the work area around the product is
made safe and be aware of hazardous conditions
that may exis.

3. Always wear protective glasses and protective
shoes when working. In particular, wear protec-
tive passes when a hammer or sledge is used for
pounding to make repairs. Use welders gloves,
hood/gogels,apron and other protective clothing
appropriate o the welding job being performed.
Do not wear loosefiting or torn clothing. Re:
move all rings from fingers when working on
machinery.

4, Nan engine must be started to make pressure or
speed checks, be sure all guards and shields are
installed, To help prevent an accident caused by
pars in rotation, work carefully around machin-
ny that has been put into operation.

If an engine has been running and the coolant is
‘ot, loosen the filer cap lowly and let the pressure
‘ut ofthe cooling system. before any caps, plugs or
lines are removed or disconnected

6. Corrosion inhibitor contains alkali, Avoid contact
‘with eyes. Avoid prolonged or repeated contact
‘with skin. Do not take internally. In case of con
tact, immediately wash skin with soap and wate.
For eyes, flush with large amounts of water for at
least 15 minutes. CALL PHYSICIAN. KEEP.
(OUT OF REACH OF CHILDREN

7. Do not smoke when an inspection ofthe battery
lciroyte level is made. Never disconnect any
‘harping unit circuit or battery circuit cable rom
‘the battery when the charging unit is operating. A
spark can cause an explosion from the flammable
vapor mixture of hydrogen and oxygen that is re.
leased from the eectrolyte through the battery out.
lets. Do not let electrolyte solution make contact
with skin oreyes Electrolyte solution isan acid. In.
case of contact, immediately wash skin with soap
nd water. For eyes, lush with large amounts of
‘water frat least 15 minutes. CALL PHYSICIAN
KEEP OUT OF REACH OF CHILDREN.

8. Disconnect battery and discharge any capacitors
before starting any repair work. Hang "Do Not
Operate” tag in the Operator'scompartment or on
the control

9. Donot work on anything thats supported only by
lit jacks or a host, Always use blocks or proper
stands 10 support the product before performing
any service work,

Relieve all pressure in ai, oil or water systems
before any ines, fittings or related items are dis.
connected or removed. Be alert for posible pres.
Sure when disconnecting any device rom a system
that utilizes pressure. Do not check for pressure
leaks with your hand, High pressure oil or fuel can
pierce the skin

5.

2.

Never bend a fuel injection line or install a tine
‘which hasbeen bent Keep the fue injection ines
And connections clean, e sre tonal cas and
‘overs anytime line removed or diconnected

During service work, do not hit the fuel injection
lines with wrenches or other toos When lines are
install, use the correct torque tighten conne
ons and be sure all clamps and dampers are cr
rectly instala,

Make sure al ue injection tines and pressure ol
lines have enough clearance o prevent contact
‘with anyother component. Do not put any fuel or
lines close 1 a hot component.

“To avoid back injury sea hoist or get help when
"img components which weigh 23 kg (50 1) or
more Make sure al chains, hook, inge, etc. are
in good condition and ae ofthe corre capacity.
Be sure hooks are positioned corecly, Lifting
eyes arc not 10 be side loaded during à lifting
operation

“To avoid burns be alert for ot pars on products
which have just been stopped and hot Muids in
Ties tubes and compartments.

Becarful when removing cove plates. Gradually
Back off the last two bolts or nuts located at oppo-
‘iteends othe cover or device and pry coer lose
To relieve any spring or ober pressure, before re
moving the last two bolts or nuts completely.

Be careful when removing filer caps, breathers
and plugs on the product Hold ara over the cap
‘or plug to prevent being sprayed or splashed by
Tiguids under pressure. The danger seven greater
fe product has recently bee stoped because
‘us an be Bot

Always use tools that are in good condition and be
Sure you understand how o we them Before per
Torming any service work, Use only Caterpillar
replacement pats

‘Reinstall fasteners with same part number. Do
ot use asser quality fastener f replacements are
eses

Before doing electrical work, disconnect battery
Do not damage wiring during removal operations.
‘Reinstall te wating si is not damaged or wil it
be damaged in operation by contacting sharp cor:
res. or by rubbing against some objector hot
Surface Do not connect wiringto lie containing
uid

"

21, Repairs which require welding should be per
formed only with the benefi ofthe appropriate
reference information and by personnel adequate
ly trained and knowledgeable in welding proce
dures. Make reference to Techniques of Struct
A Repair Course” form number SEGV2549
Determine typeof meal being welded and slot
correct welding procedure and electrodes, ods oF
reto provides weldmetal strength equivalent at
Teas to that of parent metal

22, Besureallprtecive devices including guards and
els are propery installed and funetioning cor.
ects before starting a repair. Ifa guard or held
‘must be removed to perform the repair work use
Extra caution, After the eparfcompleted, ten.
Stall any guard or shield that was removed.

23. Caution should be used 19 avoid breathing dust

‘that may be generated when handling components
‘containing asbestos ibers this dusts inhaled, it
fan be haratdous to your health. Components in
{Caterpillar products that may contain asbestos
‘bers are brake ads, brake band and ining assem-
lis, clutch plates and some gaskets. The asbestos
‘sed in these components is usually bound in a
sin or Sealed in some way. Normal handling is
‘not hazardous along as aifborne dust which co
ains asbestos isnot generate.

dust which may contain asbestosis presen, there
are several common sense guidelines that should be
Followed,

a. Never use compressed ar for cleaning.

Avoid brushing o grinding of asbestos cont
ing materials

For clean up, use wet methods or a vacuum

quipped with a high efficiency particulate ar
HEPA) fer
4. Use exhaust ventilation on permanent machin-

ing jobs.

Wear an approved respirator here iso other
ay 10 contol the dus,

{Comply with applicable rules and regulations
for the work pace (or example inthe USA.
OSMA requirements as st forth in 29 CPR
1910001)

2 Follow environmental rules and regulations for
Aisposa of asbestos

‘Avoid areas where asbestos maticles may be in
the aie

SPECIFICATIONS

3208 DIESEL TRUCK ENGINE

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3206 Diesel Truck Engine

13

Specifications
Engine Design

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3208 Diesel Truck Engine

‘Specifications

Fuel Transfer Pump

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‘Spectcations

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Fuel Filter Base

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3208 Diesel Truck Engine

‘Specicatons

Automatic Timing Advance Unit

3.5° and 5° unit

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Drive Gear For The Injection
Pump

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3208 Diesel Truck Engine 5 Speciiestions

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3206 Diesel Truck Engine

Valve Rocker Arms And Lifters

For Engines That Have Flat Face Liters

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3208 Diesel Truck Engine ve Speciications

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3206 Diesel Truck Engine vs ‘Specifications

c Valve Seats And Inserts
Intake Valve (with valve seat insert)

Intake Valve (without valve seat insert)

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pera Berm 0e)

(4) Dstanco rom an vale o cr has lc
Nara poste (ave cor) - 218m (085)
‘een parents (ave dose) 127m 0306)

Gang ana ace te ae sot ar … BH HE

(© Ouro amet of totes le ave set
for "Wr Fan (785+ 0050)

aru poms Amon

Ang 10 ga ace let net o et scion of

aan Sat rt) is

m

(0) Pa VIE oo Lean on ct a a
‘hon ota acer ot Head Tram Chart
ee

(i Seren,
Suomi

beet

atar
Et

ie

wein
wish

imeem

serum | serve
soon | @isen

en atten Y fr Kenn of EARUER and LATER

1208 Diesel Truck Engine

Valve Covers
(2) Hees et zas
None
“Te gra de esa trque may suse on arar
gras ONLY No bots ao rasage De te gra A
enge bts (seven sash mark onto Bt od, Ito
Baier bots ar genes toto inter torque spear,
‘he may ate ana oe Per cag free
ein + + y a
où | pan | tocante) | Lan amer
wea E TT]
zo | 793188 | menmarem
|" [iras [tema I nzmanm] Tonnen
| armas | ames
(0) Teran ts coger sm toun
HF E ET
sin

(9 Tciren of ess ear ute o
ec acta Fase card nc sd)
Now sa 160 18 mm 3785 06m)
Mur pose inne. . BACA)
Fates lt ce had Sad bo wenn 05 rm
(RO) ol ad mesial 008 mm (O02) or
een spa

3208 Diesel Truck Engine 536

Specifications

Crankcase Ventilation Valve

‘Turbocharger Impeller
Installation

(Schwitzer Only)
nation Procedure

nonce
‘nes re conn ait Use con maso em a
{he conpesor whet ation Suing Are ROGUE
essay

2020202
2420SKin mama

(0) Tonto hana camp
2 Tom rv

Exhaust Manifold

a—a oe

Ten irbot 43 7m € 5

‘edie eet igo nh

[mia Ao

O

3206 Diesel Truk Engine

vr

Specifications

© Son) 3
Mon part en ay nn) 02)
tan)

(eines of mat bee 53820030
CE

(2 Dario ts on a aura re
(ren TB Br (nz se

Br boat (eu) 420 1 Om

CE
ian partie core born Bang a
Eat eon) area men sy

(6) Pa are Comp en trace and ton
O]

(9 Meme permet go ol el, eased
Etes Eon

(© Materie es Tuch moe ati)

D Boe nna et ara

A
esa cami na ou
en Pm ea 87)
ad anon san ng
Etre Dre ae)
(8 men of ae str... 2489220019
TS 20850)

(0) ay un) 60100081 mm
no oso

(2) Ton ba at oc lo se vere
y EEE LE PE]

(8 Tan ans pa pos ers beng
5 er nem +20)

(0) Dart lan en ga oral ont
(ron Waren (stow sea)

None, Boa necesi re) 130280 13m
Dont end ar ads events a shat when atouts Russen
San (©) Be ram) 20175020 em
(ase en
usd samen oe bang
fe 08 0808 een
(© Toto ras, ee gn wen tt à
A OPUS
een
3206 Diesel Truck Engine ‘Specticaions

(9) PA2P206 eo Lat ote ra one and
ono eme AMO
Ferme =

None
Donation testo he salt ve cuna
Es

(2) ire nd ol ange ao when aan a

Beat ac nm (eats Gem
{inst ots)

(8) inet tren ose … 439104
‘Gite to)

COPAS! Ar Se Cort en ats na
congo He
‘iat

Engine Oil Cooler And Filter

sen tree at mes te ye a
= ee
(lesa rece na mat eo cotas
= EEE)
(7 1918 Sng (cr and Iran va)
Sam

Tac UE
En a st Samezn
‘sone Nam on

eS
(8) Tepe rat nt do coser oe a corps
en Er

NOTE get asno gages och Be vun
Map a ran Sino ware sn
poston

(6) cotas ane

3208 Diesel Truck Engine ET

2

NOTE: Ten tl a gs o 02 70m
CHI

(0 Frog aan

2 pap cor seb,

(8) TAB Sra (nar ren a ae)

Ling ot

Saosin 2800)
resin aso)

ee
(©) Gear oto pv tr to when mess wt ot

PE ates co cen
Kr

sérum part corr ol puro ar

> mon

Fowl it man

E am Bann

1208 sera war press el ae nono

sg det or etm e200 mac

ee Cor pise

Frog ari an (m asprin

dan Za O ns .

(0) wan cpm RATES On) Der en aran) 712842 005 0
hai ons)

Des cran tr erro (9 Peston ot man bung pen vrs

caos 0010) cone max

(9) Maun period cs pora

= moe

3208 Diesel Truck Engine va Sos

Oil Pan Water Pump

Ñ

(0) Ter rt ar pan Dzaron
LE
2) Tome tr tpan aan a mene en

NOTE: the ct bs 00. and mung bre mat

Oil Level Gauge os

being OD. and housing boro for asco.

(Capes tan e at ur rs a
ao

(0) Gace sey

a.
Seats

3208 Diesel Truck Engine va Specifications.

| eR pam en Le | u | | OD ANGE NO, | EW GAUGE
EINEN Dors Laa

Fees se far] se 90210] erasas rar

[sv eee as 1620600 90210] rares | orar
a [rae | e] eses pew
EME TE TETE] DEZA
10 [ass | ses] 200 | we | suse Dr

MEASURE TENSION OF BELT PARTIES! FROM TH NORE
"TEED ELT NERO er D whan na mer an 30 mes penn ar to legs aromas

© Water Temperature Regulators "371 1eme our

05121 an 708472 Temperature Regions

Teresa we core een
ASI! Wat Terna. SC 187)
TEST Wa Torpean Rebar CET)

(N Dares a compte coo gaze mu rte
ES mn a)

3200 Diesel Truck Engine 12 Spociatens

Temps nen core por
‘G71 Va Temper Reg. SC (SP)
nenn Coria dsares 83 en TS IN)

Cylinder Block

ea of he Cn or a hap anto

mae

le re wer
To commente ach mabe rte
{font ary ton e are ere

‘rooms otros DER
en ‘mega

‘ine tre [8 (er ann rr
en

Se ETS 00 am sab
ane ct ne rar o
recur Hosts aso
Be nck cams bg 232440013
NOTE: rst came cate wh Pl tra
Br
69 on man eur cap 16362: 0016 mm
Wa: mn

eam puesto won a ran erro
ee En sn

‘ie man ang e qn im ree
D ELIO mr Sto Se)
(fr nck man eno. 9447120019
‘errs en

Paras amo ot

‘947310942 mm (27051937000)

(3) Term rors king cas fr man bass
8 PA 272506 nad Lar en nes as
1 Fea ota num sequence
= nc ao
+ Ba anar noche ar can
Terma bots oe
me mes

3206 Diesel Truck Engine

Specifications

© Connecting Rod

(©) Omer (en) tom orten as ees
D LE o) 202 00m
CU

(0) Omen (ha) tom urn ol rsa e
E EERE Se

I bar lod 387.2 40849 rg De
‘cones ge eng stan nas Fe tas be
‘tema on E ong ages a te
Paton coi les we img tm 9208 ack
‘pes ec mn rs 25082 vo a
EEE
m TS)
An

o

o

©

o

‘ita HI
Br coming or ento Lon tres
Bre Pate EU ot + 005)

Detar ahnen corr of es Ir pin pin ant
a a

on ia tac pn

Fe “Ailes mm 7300 01)
Dana pan Bon 0006mm
Fees too)
har sonst conce between burg sc
on Garn
‘Suing ca lp ae a

o Torneo maso
© Rama on en nd xp
Horn

en 623)
os

3200 Diesel Track Engine va

© Pistons And Rings (two ring
piston)

Fam Va SES

3208 Diesel Truck Engine 125 Specifications

aR
mo os
ae ed
por BUS ran
maca | en
sneer a | fes
re | Sah ei
E | (En E
en 4.5000 8) re _
nn = ae
Tem ES ES
A SENT < Pistons And Rings (three ring
A]

apn De eg D a ton a gas no,
NOTE: Ue 0519 Pen ing ros ovas a
hak ie ap a pone ey E iS ne
Sse tre nes he Gude Fa Rasa
rx Asses Form SER

NOTE: Te ie rr ae nd 328 Tce
Dr On te aca me 01537 212
A Grin mo me rr penn sa ce
Anna non On) re
Beer on ee e pr
en

Piston Pin Bore

Boe npstn te pr wann
Em com coe)
[Strum permis sowarce brane nr
Band ame pn Wan... Om (0)

Mao ance o Cure Fr Rs Pa
For, Fam No SEO ard aden ar
En Pr Pin Pie od Rating Ange Fo
Fe sa

3208 Diesel Truck Engine vas ‘Speciicatons

‘Top And Intermediate Ring

‘ne USA Kc Pan fg Goon Gage à
SA fr ei ing raves ha ye
(tse Pr cert cons pue ra

Era Dao Car la mae aug Do

‘ntl pn ge ih U to tn,

©) Tape ta vom Wr

Gi macia eg as mai UP:

src ttn rl po ig wen eta na

enter

Le 27220100
m 0225 + 0075 i)

snc rare tate and ner ch

‘omen cont era cys nr oe
se en (039

Oil Control Ring

(tet ot cal wäh apne gern 60 =
1 mm ron gape og

SSI Pan Go Cn aa

‘Backing ig res var ang sce Fo matters on

Shean tne age en sin Fo Ant Pr

Pac Pom No SD

Od 106 + 006)
ess ton ng re 21963200137
Veen

ont oem
es Son won
ren"

2 EEE

nas can baton ers ot nn or cn
a

Piston Pin Bore
(0 Be mp to pn ENT
EA

(9 Pn mate … 34007 = 0005 mm 4008 00)
Dane ay
row 120 00 wm (2008 016
Mimi parmis crane Bt etn e
Crete en Coos)

A

Crankshaft Seals

(A) Th tan ra he ge le) he gat
en 99102 Som
(sno calm
(©) Te stan tem ye lero exa)
o mr 2 re
Verden

Use 17001 Ase Grup oer ses
BEI PPS Dar Go oven he ea

NOTE: Sit arg mes seves cant eran ater
‘Mees ard we daros soporte

3208 Diesel Truck Engine

var

‘Specifications

ral feta es cos gr a ons
à. Gene ar ae ot he crt art
See
Corn sas mat ea win ma pn al
Lena où Fas ol ne a ham Te SO Up
Ti Sou rá va FOR Frac ar Seal Ge a
cette he A ar Se
Dorel mga a sn om ase tal be
AS
NOTE: Sie Spcalnematon Form Na SAMTIIO oe
type sa atom ratón Soe Spc esr
‘Em shots ls a remiten pe ese

c Crankshaft

© Bearings For Connecting Rods
‘And Mains

ao aleros a Cies Fr Raat Par Man
Beato Aa Owen Rod Ber Form Ro
a,

messes
=> Be
sma | Savene

‘rare ane ag and ua

on GES mm (Or 085)

un emcee rc bins es wd

fa So
Fu Pre
E Biase Son
Er {Bates = 00m

men | nie
EE
nr
= BIE ea
a mg
bande ao iow or)
pi
pm cet
E FBT eo
à re torre
0 fierce rete Comer i
E
NOTE rta car oc
Ener = Sections

Pulley And Damper

sat ne der agen o aka le tb
‘ledge sae comer cote mth garen

a cn BONDY on na bt and rr a se
te carpe econo one Orina o Pa Sarge
ee

3 rire

(0) Toran ob rt os te ELN

CE
cae AA

Darton dl an mri oi at
eramos coh)

a tear et punts
PEN)

Fan Mounting Pulley
Assemblies

917243 Pulley Assembly

AL

Sr

N

(0) Epa apte … 0051002 (O1 20)
monton mart tee ee

© teen repay ty

oa
Dam (05)

320 Diesel Truck Engine

a

ENTES! Pulley Assembly (with hexagon
A and pinned shat

(0) Tee seen

NOTE: Th an toma (1) must D et tac

@ Tore tern
("Ena y ern py

rms
09812025
A
NOTE: A zo Bor nar man ty
"Seo 3208 Dest! Tuck En Tsing gusta teens
oy éme pas

(0) Pao toe

(6) Tere fy bots a rt i
Sonat Werumsssnn

NOTE: sn mark nes mat be ira in

3200 Diesel Truck Engine 130

‘Specitcations

Mounting Group For AT540,
MT643, and MT653 Allison
Transmission

(Mean cn ett mg

‘Seam
po 53 men (029)
sre ss Pr

Fac ro tac TR
Cees msg)
ee omnia
fre ss cia

(4 Tor rats mar tr date
En AA
(©) Boe nad cp DA
Toni)
ree ess

0251 Di)
mm (csi)

(9 Face rs apr men pata at nea
EB ren 0 Com our tr ta eae
room oem)

Flywheel Runout

Face Runout (Axial Eccentricity) Of The
Flywheel:

Converse]

1. pat da non a sion AA ae ono.
Su tor e

2, Sete inden 000 (OR)

2. Tun te el ans a calor ery 30 Pa
Ee Shee Bar a arte nc sg.

4: a cine beton mor ar ap
re an or Ports MA note rar
Fan mm BGE anche rm post
A as con el do ts.

3208 Diesel Truck Engine

var ‘Spectcations

Bore Runout Radial Eccentricity) OF
LT nem)

Flywheel Housing Runout

Face Runout (Axil Eccentricity) Of The
o Rousing on

3200 Diesel Truck Engine vaz Speciieatens

Flywheel Housing Bore

o + »
De oro —r
De Forro

3. Wen al cats 00 om (200 e aio,
o tw nse a ot 8

4. The tamos tte or and ger enero
eset pa melon mo man 05 en
(ON wach ren past Ice
(cs cn oe aros Nash

NOTE: Ws me dl cat meta win Pr
Peto () anceps (2) rin (sg) Ts oan e
Pa Yo ten be cat carey

1. Y e Galet pation
a Ale can pare
ti cau

2. Decne measures to Step 1 72 Weis
ra entr PR ur à 0)

3. Tun m era pre da a A) A

3200 Diesel Truck Engine va

Specifications.

$ Tan m réa cartero 1 pa cal
(late ate) wits vo cr te ot

1h re an toy rre

1 Sorc te unae unse te me gar ber
Sn came BE) meras ev an
‘ery ur ouf Iren caf) ave

]
N

a

E

E

I
an teh de 0%

Toone tere

8 One gap recent ra a por
REA et a
Ho nate operat Fe out at
tan à Da arg mes NA cpu e
‘Syne bai rat arg

3200 Diesel Truck Engine

Alternators And Regulators

Delco Remy Alternators,

ger (15235 inside Aerator)

age sone oca
Par atar ‘15
T6382 eat
erage ai 2
Pauvres egos
etn etrrDreeion
Spee eng) 25001650
ue co mem
ue) sem
Fes au (a ae sc sa
Faut to tage an 270 OOF). 2610328
Pont u ome to 621080Nem
Seren

(0) Gane ama we
@ Sutra.

RB ser

guar (6564 nid aerator)

ES] wenn Yo tr parara
767069 Aomaor
1
otage sv
Paty Nena
Speer tte m es R
Our (e09) mieu =
upon) er
Fated Po aac ped en
Fra corr os cota 27 ROM. TIRA Amar
one patio ento
(0) Gti que — 171029151281
2 Sta o D 10h 70.080)
3208 Diese Truck Engine vas Spociications

906078 A 1194 Aerators

vote rng a
Posy negara
Boon ETS
‘pu 2000 en) =
‘ou #00 rom (es sa
as ap Pet) om

ES "Lawasnem Son)
2) Torq ory me DEN MOSES

tage Peg SES) ra ets ar rot
ee

00% 8 671196 Atamatar

Party egos
Ron er racton
at a 260 (en za
(Gé a 700 ex, mn
am apa nr
xe tf a
Er oosshmesoobn pero an
(2 Tora o y 0 DET TSS) so
Vago Reta (7600 tray mou rr Votar au
DS Pas egos
so rer ecion
Soest ning m) 000
ue coa, an
Sun sa
Fa Ours a ana 25° CF) um
(0 Tern run 950 NON RN
(2) Torque op me + 7510 10m
IS
Tool gran teme 2110280121250
go mear sors?

3200 Diesel Tusk Engine vas Specilicaions

Bosch Regulators

967567 Regastor

tap ating zu

Panty Nog
‘20 Anemator Vota cet ra 267107839
Vote ntra PR TC] pn
Patty Nears asm
Aion SEES cates Regular
Speed a eng (om) sco Vola ate #
Op en mn Po nego
oa men 2 elugeseting ange asa
ak cura 28V nd 29 (7. zu Mavculpt at 200 sx
(1) To tr pay nu EEE)
@ Tape tr op ma ar
Tore fr De taal
(6) Toto pou (8) emi a. SED LOBO

CAES)

Tor Wan pt ow)
Pego tam
3208 Diesel Truck Engine 5 var Specifications

al a

à er Nippondenso Regulator
onu LE

E pasto Regulate Specifications

= eee —

‘gonad Tasten ETT | 2 2
ET EE Fer mer ee

3208 Diesel Truck Engine 1s 3 =

Starter Motors

\ Delco Remy

3208 Diesel Truck Engine 139 Specifications.

cd Te ve Eu Eu EN
Care | ne Eu a =a cm
formance ow on ow ow
Noss Sess
ES mono | wor | soo | comeun someon
rat won won 70101108 CUS wur
Es ee LS
sav.

EN Sur os Bon 107

ABS en

A 2700mENm EE" Bosch

@ Sew ere WERBEN

Cero been pen aci. 890 09m

wen

Prestolite

TE

ih Saving rn 8
Caen [eo] om [70m
ons sem or
ES ow

Fes ing Ma fume

tee Ea ES 00

ERA ‘ow [oem cer von

BE ] E

=o i = (0) Tomes rt tog 2780 (11101304

TE (Seven ls Miriam,
E Seve est ct conmtt carats 8m (1 9)

(0) Yous bot re A) Po is case Fes

(2 Toma rt tue … ZEN 010250) cs ines adele ee

(Charen tano pion nd
rao Do 127 mm (200 60

8208 Diesel Truck Engine

Ta ‘Specitcations

Starter Motor Solenoids

Delco-Remy

Prestolite

Vote

Carat Carron (a
Parme
Pere

CENT

HE
NUS an)

_ Ei
ee FE peach
een
re sen
ES antes
a mn
dee = di bp
Piedad Pa
pe ass Cu
(as gen cot —
TT men
ie Pe
AS
ee e)
oa gry a ele
a PE
ee Beret =
Pe un
en
nn nach
e (16103000)
a aga o En
BEN Men Pe
ri
pe e”
se: Heat
en
See
sero ak ae D Do

‘Shutoff Solenoids

$
À
- a

3208 Diesel Truck Engine va ‘Specicavons

Index

‘Systems Operation (Section 2)

Ait And Estare Sten zu
"Ae To Ar Alarcon Sa Bs
Tubocrame” zu

Buse ce 2m
Cana 22
ner Bk 22
ne ac 22
Bone ge ra main hin 1 Bar
Veen Depa 23

System, 22

nc Head an Vaves 2216

ate Sytem 228
‘Charging Sesion Compenes 23
(rer Component ==
‘Staring Syn Commons 5

Fuslinecten Purps 27
oma Tag Adan UA a
Fos ren Beck

Een)
Fat Fans Cor Wat Hyde
eerie 28
porton Gi Fuad inacion Page 28
ton 0 RATS And SRE Fu ction
28

Nees
Open 700 Saris Falcon
Ne,

29
ator Sipe ET
Fue Sytem 22
Contr ied i
Fon Of Fos Long The Pre Fame 26
Uresten 218

Sun
(Engines in Où er Bypass Vat in Oi Coney
ES

Base)
(Eng a iin Ox Flo Bypass Val in Où
Finer 218

3208 Diesel Truck Engine

a

Systems Operation

Fuel System

“Th Bone metering tal yam presa yp fl
System. The nam fx tho ei yt om ie

ad used to onto he unto lu ert ote
‚Sfndere Ths ue system as ancien pur for
Bach ede of re angie. lonas fuel anses
Puro onto fet ol neon pure heusg, The
estee son tha Year ote mjecon pump hosing.

“The rive gear rhe foe! enter perpen the Het
che carenat forthe injcten pump The carter fr
{he governor wogts 5 bated othe ea of he
Canabal or the ction purs. Te chen pur
fovang ha abearng a dach enc 10 aupa he
‘arena Tra camahaı fe sloove mein fl
Sata 8 ann 0, me Imng gone rot the
enga

‘Tho recon mps, rs and ors, and the
cachet are nae ofthe pump Pouëng, The pump
our anc te governor ang are flo fal at
rar pump pressure (el system press)

3208 Diesel Truck Engine

22

‘Systems Operation

Serra

ane O ron (1a alar sien pps JC a.
pe

a a

NOTICE
Diseluelis the ony ration forthe moving artsin
the transfor pump, injecon pump housing andthe
gorerer. The injection pump Rousing must bo ful of
Rel boire umi the camera

his ual system has governor weis. a tus colar
and to governor springs. One gover sing ft
Fight and te ter goes spring tw o.
lan fra sal for govrer cont compression
tne gars springs, movant of connecting
nang tha gore and moción pap Noe
‘Corr th amaun fut smo eng
nr

ren pr cora

ns (or es
name ive

on provi ofan
BEE

Fu rm tank (7) ple by to ranser pare
{Gt} trough water sea (Fo urge) and
{a titer) rom ut tr) to fa ges to
eng fo lu cie ups (10) The fa goes in
Rous (8 at the op and goes tough nda
Passage (2) to fl rar pur (1)

208 Diesel Truck Engine ES

GREEN mereces onu mommy oa
ia
e A

From ue verle pu (1) ue under prose, ths Whan vat (18) raved o gue mor ful he
ns nouang er o ul Mecton pures (14) Presse ange lever (2) wl ps governor Spenge 25)
al va foe mhowsng (14) 6 controles by typacevave compression and move Brust cola (2) rad AS
{12) Presa om fol FUL. LOAD à 8 = 35. {rust calar (2) moves Irre. he comectog

Pa 20 2 990) Fine resi o! el mos (4) rkagn wt cas dame corto sats (19) en
(ets 10 igh bypass valve (12) wi move (pen) et Wie meer oth eve cot sats, overs
Ferre cla rum to he it of fod vans puro (1) wi et Saeves (2) to make an notas nro
ro mo ote sont anna ends.

Lover (16) forthe gover scorned by kage en sarin he engine te fc oor fs,
‘ans gover spre D 1 the sone Corr Julia Sn LT) = rough pun os cola (28) One
(10. Any movement ovr (2) wi cane à ange ‘ston poston Te the eng Para the

1e Dosen else contol sats (18) Manu arent fa for nacio nen ering At

Approcmaty 40 em, over vers (90) mate
‘enough fe 1 pu sing (27 Loge, Trust cour
(28) a sung set (28 cora mo contact Fem the
‘rm on he gerne: woe fo cone sd ote
ee

3208 Diesel Truck Engine 24 Systems Operation

FESTE sg gone 20 pre hr cor
no eg Oe tn o mt

nen governor springs (25) are pd in compression.
tho pig soa at ho on of he govern Seng wil
‘ake contact wih oad sio lew (23) Rotation ofthe
[oad stp ever moves ea top pn (17) up rt the

load stop pn comas contact win sop Dar or

‘Slop screw. This ios the movement fs colar
(28) ta conecang eer, and eve cota sra
(19. Alt poston. the mani amour of ful or
stokes Dang nected by each clan pump,

Tre cartier for govern weight (30) a on the rear
camera (19 by bats hen ergo rpm goes wp.
{sion pure cama (19) tre laser Ary Change
‘of carta re wi change the rm an poston 9°
‘governor ag (20). Any change of governor weg
Beatin wh cae it oa are A
over agp (30) un fasta, ant car) s
Bed nas governor springs (2) When the toro
[St governor sping (23) balanced by te contigs
{orc the governor wots, dans (2) tra
Ingelen Pumps re had at a spect posten 1 send
poc amount of fut the gre onda

“Tho parts of he dashpot work ogee to make he
rem 8 1 enga sandy Te dato! works as sto
(22) moves na onde aie à fed win ul Te
‘movement of ton (2) m to fda ota ul ft
io the ord pes oun ator dren a
ou of tale trough oe E), Te rent tre
ou off by tie (E) gues the gover ts
Kasten

in the oad on te ni decreases, he enge
Stars to un fasta and governor walt (D) pat ec
Span! springs (5), The aod loco pus more
Ebrprossen on spinge (25) and sai to pu erg
{2a)' compression Spring (21) n compression
because the fu nr caer and piston (23) can
(ony go ut rough rc (E), Te ae of ou POUR
‘tice (E) corres ow fast ésto (23) moves AS
Te pshed ot of te tnd y ston 23), the
‘ompeosann of sing (2) Lecaros gradual iss

on sengs (25) an spring (24) are bot in
compresser locos werk gare agas he
{ore of weghts (30) Tras ques e ac of having a
governor epg win ag sping ate A governor
Sng we argh spring at hops th expe speed
Fe Pang cesiatons Ang nd charges

en he load on the engine increase, he ng
Sar o un donor Governor mois 0) pls oss
or against sung (2) Spring (25) arto push
‘sta (2) to vo more elo te ong. Sot (26) a
Connected to pstan (2) by sping (20 en set (26)
‘Sarto move, tne action us Song (2) ern.
As pan 29) starts o move. vacuum = made nio
{ho oie The cum wl pul ta io In einer
ron cio (2). ho ral ol 10 few trough ica
LE) agan control bow last piston (23 oven, Durng
thes conto, spring (24) pul agans springs
(25) ms makes the movement of seat (28) and
Sorngs 08) more ga Ths agan ques te eect
(ta governor spring witha igh sping as.

pres

(io ido ofan ten une (19 Se cant ont
{aioe we Seon

Wan the govrmr contr overs tunes toward he
FUEL OFF posten win tho eng umi, er à
reduction of fore on gosemo springs (23) The
tower ol kage the governor wi cae ft
‘ort salt (19) 10 move seves (22) down, ad ess
Fo ba acc nthe engi onde

To tp the ergo, tun ne gt such othe OFF
Posten Ths wi causo the shel sei o move
Enge in he I! pump Rausing, Mover of he
Ange wi causo Bone lovers (5110 move leves
(22) down, and et ent to te eng ones
Win n fal gang 1 the engine cinders the engine
vw op.

3208 Diesel Truck Engine

Flow Of Fuel Using The Priming Pump

‘nen the pane of ping pump 2) plac od,
Peg ar presse ping Dump (2) opens creck
‘ke (8) an ps ful hom ue a (7) Pai te
and in cocos check vale (A) and opers crack
‘valve (8). This pushes ar andor far hosing (14)
Through 1 passages en cock ve (6) More
paran of pring pmp (2) wi pu or o
tc) wt te otra fl te (2) ane Reusing
(1) ae Kofta De In urs tho fw oul ert
(manual ed var (5) seo of ar ues.

Constant Bleed Valve

Constant blog vate (4) is approximately 9 alone of
{al per Meur go Gace 1 fl ark (7). Ths ue goes
Back kong eur ne or constan?
‘Blood vato (9), Ths fow of fl romavos a rom
house (14) an ao habs to coo to lien
aro. Check vave (D) makes a esreton in ns tow
Sto! ets peau in housing (1) 5520
kPa 3 pa

2208 Diesel Truck Engine 25

Systems Operation

Fuel Injection Pumps

A 9N5357 Ful econ Pump uns a revere few
heck va RS) an
Pc

B. an Fue nein Pump uses an orto
Gay valve (DOY and ud enges with
Sel non, 2213790 o 22320,

©. W800 Fun! cho Pump ako haan rico
Gamer vale (01) This ls jess pump à
‘odin engines with smal os 27247510
ES

D. 708927 Fu necton Pump uses an oro
Teves fom chock Vave{ORFG) wen
lenges wih cal nos 2234221 UD

“The engines rate at 240 pat 200 pm and ne ir

to ar bros (ATAAC) ans above 250% tat
Fave 125° BTC tng use his el system.

3200 Diesel Truk Engine 27 Systems Operation

Operation Of Fuel Injection Pumps

The man components ofa fus injection purp ine
oo mete ue estem aro bare (A urge)
rd Same D) Png (8) moves up ard down ni
Dar (A) and seve D) Bal (A) sacar wre
Seve (Di mowed up ano Go on purgar (8) o
ro charge the act ol ls far ton

e pone cbusperr pre,
capos cove yon Pane Pn

e bre er the

Wen ie engine s unnng fl under presse tom
‘eal want pump gos th cote of pare 8)
trough flit (©) dag the down che pres
Fü cannot go tough fut oa () at ine
rca ls topped by Sue () (se poston)

Fuad icon sat (oe poston 2) wren purga (8)
had ip in bare (A) encug o coe fos 1),
“Trae & an nea nfl core Bor pe)
aha the psoas ed by casa Th et
shove Dinge (9) irc io the eng cinc

nection ut to (ee poston 3) wen eut Es
hea oso th lop edge of won (D) y camera
TR RE EE en
ir) go rmugh fol ute (E) aná tr
Fo cion pure pus

When sare D) rad on unge (Be ute €)
IS covres I a longer re, Cut mor fol abe
Id re ene einer. F eceve (0) ow en
ge () te cuts conrad ra enter ere,
ning ss ls tbe eco

Operation Of 9N3979 And 1W5829 Fuel
Injection Nozzles

The tet rt and no (13) ae pats of bo
nazi bsy (11 Vale (@) hed poston by sng
Farce, Force othe sp scores by PRE
acstmentsre (3) Lace (4 na preso
che sre (3) n potion. Te ovale (is
orale by ih essen! sero (2) Laca (10)
Fes Mt acpstmen cren (2) m postion Carre
al) goes one nozza body (11

‘Compression cel) goes against the ing ou
ino) rd present de eakago 0! corresson om
‘he onde. Carbon dam (12, ine lowe enc cl ne
‘boy (1) reverse dopant can Ne
bein tre endo mac

Fa unde gh press tom the a ion pure
9008 ecu ra rin a) Tr to then
068 rc valve (8, es Ie de ce nozze
Boay (and pures again ne vate gie Ven,
the force mado by the pressure 0 De ul mor an
es Ge cr a Wren va 0)
fol ndo non ten un go rouge te fox
(0365 mm (0128) ca (9) ma the cin, Wen
Ins fal sent to te inde, fore made bythe
passo dl io usin tho netz body wi como
foes The fro ol sr wl ran ba mor an the
foro of re press ano no none Be,
Varo (8) vi oe oo cose poston

3208 Diesel Truck Engine 28

Systems Operation

Vato () cose win th of oz 1 (19
tis makes à pose sea forte va,

en the us sen ote ind, avery sal
ay of fa leak y he vale guido. Tf
{es can tothe moving par tof
ton nozze

Operation Of 7000 Series Fuel Injection
Nozzle

‘Tho fat ncton rote goes trough he onder
‘ed mio comic charter The econ
‘ump sands ul win high pressure othe upon.
ote wner th li ae to a Io pry SS

>

=

prete
CHE nl Sep (ra ine
Ps Won M Gérer

Seal goes against yinderhasd ana prevents
anne 3 eargreaton hor the cee Corban dam
{hops carbon ut a Me or te cor peas
Terme ore

Fuel vin igh prsaue from he fa ection pump
909 to rit passage (6) Fue han goes mo
Passage (4) De aa below carat (8) ova)
‘non the pese of hota a putes aganet
‘arate voces ater tan the lr ol spin
(Gh vate (te up en ao (7) Mt te tp ei
aie comes of he ae sea and th ul wl go
‘rough the eur 029 mm (O11) eens (6) the
comision roe

“Te nacion l fs cones ut ne presse of
gant Samar (9 becomes ls an na foe ot
Sing With oss rs apart dare)
‘brig ©) putes vale (7) agar ho nazi sea and
‘Sept ow o th fol combustion rarer

‘Automatic Timing Advance Unit

The automatic tng advance u (2) nas o
he tet othe cams (9) Ins engine Me
“lora ing Blanco unt (2) ves ro qua (1) 0
the camhal fhe ul chen pump. Tis gan ©
‘he vo forthe eameal Ir al cn pure.

eg a
{Su encon cin zu (Atom eg
AS

Tre mag (4) ne tig advance ase ven by
two 6 (mat entonar made on an ange n
the ets. The lis (6) are vn y vo dowels
ich aren te ve gus or Ie engine camera AS
‘Serta fre tain) meros wants aa
gansta fool sings (5), he movement ofthe
‘ates mues (9) we cause the ic ake à
Change nthe angi betwen o mg sac 0 |
And In wo co owes nha ve gu lor
‘gto cams. Sco the ing advance unt res
{he ea’ (1) on tho carat for hata ton
Damp e ul yacion tng aso range.

3208 Diesel Truck Engine

23

Systems Operation

‘Tha ro mo diet tng acvanco uns used on
‘he 3208 Tk Enge. Onna il ue 8° Ang,
Lance ad e er ques 5 of ting adince.
She uring avance un bogie lo aros the teng
stow ie rpm and stops advance trated enge rpm
No ace can e mace Yo to aerate ering

Lian oe to tring advance uk comes em
Sted res at cont wth hot beng fhe

engine camara

(ri Sot Sa.

Fuel Junction Block

he Lion ofthe fu union tock e) a the gt
rear ofthe engi, Th fs Ios fom fal ian ang
the engin comet atl sien Bock

Matt
DE lay ne efron ren
ose ac ri sp no te

Water Separator

Some ongnes hv à wate sopra. Th
Sepaaa ie nal between fe fo! tr adhe est
line ls ape Fo ileaney n o action ot ne
‘rato aparto Do Lol tow ase come dirty om
tho (ar ar rogn re at apart Ths
causo the aston DI gang Waugh a Bump vives
betcha wate separo overs the alcoy of
wate separa.

“The wae separate can remoy 95% of he wale
{8 ow of upto 126 Ma (3 gory ine
‘Songer of he water e ols 10% ot ss 1
‘Simportn crack the war ve nthe we
separa Hoc. The maskrum amount tee
ion fo vr copar can na sO Mor (EP At
{RS pote water Tl les o 74h Do ott
the wale copa raves rach water bene
(faring te to Arto water vel la,
‘Ret severa ons aero) and the water
the fut ean go ecu tro separa’ and cause
amago toh ul pecto pam.

Dain te water om the water separator ver day o
‘hun tne war val ls 1 Ya Ts gos o
‘elon ren rot water nthe fol te fol has
‘ang concoraton mater # he fo rato ls
roch ha water spar a, the water Sartor
‘ile wit wae faster and mus be ana mor lr.

3200 Diesel Truck Engine

ET]

Systems Operation

Da an ano ne a ls ate
‘ter separator Choe ot var,

[ieee tes

Fuel Ratio Control With Hydraulic
Override

NOTE: The yr crore was aos oe fe
‘ato conato porn easer cold weathers",

‘Te os a conto ste mau ol to he
fing ance ise pes
nde to State erg

Bo (2) ma ol ato cont mts ae of he ue
‘ont ana in tha FUEL ONarseron any Asia
go acoserats to Wl core ra malas
rat wath bat (12) and ot go th
Posten Mino te WE gves enough ar
Eros to gue good conan te ona, he
et mal rare gon hough a I a ni
Go ar cube (10) the ar presto a
(amber (1 pushes on daphagrn (1) unen moves
Ba (12) cow When bu (12) ves down te fot
‘or aa an mo the Mt pon.

(noes ie oros 1 ptet over
Ste Bae ar ar

te tom oer crec o tt
Sal by he sare sn. Fm he mar te
ott onde head goes oun san (1) 1 |
nee 10), presen of ames (9) pushes on
pag (7 and unge (9) wneh mows bl (2)
‘Sou The a corr sa can nw g re I tu
‘atone ater ting

rasos. sore (1) casas an so ot how 1
amont (6) On ol camber 6) guet oun ein
(5) ocn (9), 06 ng e) Os rom goes ou a
"ib and ran to te It nae haa ith no
este in sharon (6) tt (12) an ong”)
‘ove up Ot (12) wa rom it Ihe movers ole
{os cor Sal wt ae mated ar peseure moves
PL dow

he eno stars we te starter sao

3200 Diesel Truck Engine

zu

Systems Operation

© Fuel Ratio Control Without Hydraulic
Override

AN

2 AS

PA Came Dar Et

The fe! ao cota its tho amar of othe
irc ding an reas ek engine epted
(Geceeraton) 10 rc omausl smoke

Bot @) mie ul ao contol mis heave ot.
fon corral sat nthe FUEL ON Green cry, Abe
engine acoserates, ol (3 wil ot tn us coe
Shalt go ott posten. Von the tocar
‘ves era ar perso 1 Qe good Come in
Fa andere. he mit mano presas goes trough
Enero as carter (1) Tre ar reese ma
name (1) puss on daphrage (2) when moves
St (@ down When Da (5) moros down, to fl
‘ont sal an move tot ul foo poste,

3208 Diesel Truck Engine Be

Systems Operation

Air Inlet And Exhaust System

‘et Aa ns en

EEE on ave ron apr (Turner (Ari ene mn (Em man

The 2208 Turbocharged Eng has a ubocharer
act a ro of he enge. To oma gas
rom al the cindor ar used 10 um the

Kabah Ar bes rough tho ar ear and
cap by te Bocage A
‘oes rr ne tzbochage eu a nt po () o
Parme mando cach senda ees

the indore the he valves pen

‘The stat gus go oto the onde aná to the
‘aunt prt nen o aba vos open, The

oo
“he exis gases ave
A rc e exa ate

Tr a pesto crankcase verwaton vate on auch
va Cora Tr vertan valves ar conciso 1
Ar ara ap cn ro ar it oe othe
pa

3206 Diesel Truck Engine

‘Systems Operation

ana encton fr raton ot bearnge. Olten
the trecenrger ges oxt rough the ication out
Passage (Yi ma tr e tn contr econ ac
‘oes back lo a egos Lan ya.

roms re rones

Fe ou
‘sg ror wm neato na pc.
Den

208 Diesel Truck Engine En “Systems Operation

Air To Air Aftercooled System

hi E ==
i) mer 1
! |
| En | mes
AA a IA ve
NT | Al lez
1
a ary

In hear 1 ar terco system, congresses
rvocherer ae drets o cassis mounted
(oak n Won la radar Aron tampa a
‘Stowe aeons te aero to ower Po ta
temporal to approumaay 45° (HO) The a
‘har gos tose ment (2) we part oo
cinder ness Cong ol tent ar creases,
onbuston sica, whch haps flower fal
‘nun an reas teapot’ Sel

ine nae ah 8) open, th a goes to te
angine onda and med wth he or
embusten When aus valves) open the
aa gna go ot of he engin onde ar to
aca mantel (1) From the west maid 56
sara gases go Mreug Ie Bades of tun
inca The autos he fro is and compresor
Weal orn The exaust aces hen go ot exaust
ie) fhe pochage Arne Bw Open See
HE re ct mas) eae
ut Tot nt ea
Eight E ve We te

3208 Diesel Truck Enaine 215 Systems Operation

‘Te moseren fh rc ms make the take
and exaust avs nthe eynde ead ope and
‘ose arcos to te ang ore (recon sequence)
‘tthe eae. Tue van spirgs fr cach aie Poo
fo the valves nthe closed posten

NOTE. Some 3208 engnas have camshals hat use
{Sher tere and tore ave cova tt of
{eos Mer

Tree ono ak and one eu va for each
jar Tre va sa nr re es ae can
Esrepcod. The nike valo seat may bea
repasse cat er othe sa may be machined
and part lie ord hand Wen he et te
intake viv nas boon aches 1 o más gen
Specials, int had can be bored
{sera lor aho sat nowt The ave gue
‘Se Mac iv and a par th edo nen.

3208 Diesel Truck Engine

27

Systems Operation

Lubrication System
ines With Oil Filter |
Suse Bypass Valve In

Systems Operation

‘Ot pum bypass ate () nthe cove: othe a
Pag} corri the pressure ofthe ol coming rom
Gi pump (9) The pump can pur mor et the
yaa Man rd. When re presi cine al
{ig mo the enge more ar 30010 880 Wa 5
(090 po) th bypass vv (wl open. This permits
the oat no! needed 1 Bypass te Sys

(Oro he ol pan spud tough he suction bel or
‘th ot pur (10) by of pump (8) The ols sent by the
‘ump lo a ol passage ne ont cover forthe
‘Engine (3) OF fom ths passago goes othe cinder
‘loc and ono the bate or Neos cose (5) The
base lr the ol cols onthe et so to orga,
ea re ont othe ergo. Où cod bypass valve
CU nine basa forth of coker wit et ha of go
round the où code (7) hen the ai scald or tho
Testen the of code is moro an the other pate
Sina sytem Acerence preso ct 81 105
KPa (1210 15 po) atwoen hoof it nd he ol
‘ube al open ho bypass va.

‘OL ram te où coo goes othe ol ers, O ter
pass valve (12) te o rs wi et ha Ol go
‘red the ites ther a resis the ars,

‘hate are two presse ote In the base fr tho
Cooter Tha pressure cute ao on ho owt se ot
{hol coder and où ters. Ma pressure cutee ar for
the sending al and such for e ol presa

Où tom theo ites (19) goes ough a passage in
‘he Oder Dock to ol man (4) The ce manok is
IR ia cae ofthe yirdor lec, above the Camera,
and goes tne tl nn of te yinder Dock Ol goes
‘fom the of manto othe bears lor ne Camara
‘Tare ae grooves nth bores nthe cuir Bock
around tne bearings forthe carat. The bearing
aces (rm) onthe cameaf et vere om
‘those groves though ate nthe Beans forthe
Comtat: Some ole ol goes sound tne grooves
land down though a passage to Ple and grove in
‘he top hal of tho man bearing. O rom Be how and
uo gues bremen tote Boag suraces
Rosal) oth carushat the main bearing.

(Où ges into N crankshaft trough hoes nthe
Dead surtace (auras rte ran bears.
Passages correct ne bearing surface (puma or the
‘main bering wih the Daring sarao (una) othe
mec 103 he pain ir ge ubican for ol
frown y other pars.

Ct or the oca arms comes tom the ol and ()
‘frou passages in he find ick. The passages

‘on hol aie note ot o he cinder ok
‘he passage o th fier Pas on he PSC Is
rahe ra ofthe evince Bock,

‘Tha passage each yinde had sons the ol eto
an où ale he bono e he mouring race ofthe
‘racket that nos the sar o toa ums Tha OÙ
da sin th Won back on tr lt ade ann ie
‘ar Drake onthe ight side The ol ren goes up
‘rough e bracket an nth carter le hat or
the rocas arme, O goes along the cet of te shal
{bth bearings or the rocker rms. From te roca
rms, he ole pushed rough smal nes fo gu
onen tote aves, push ods os, and
camera ober

‘ter the oran las don its wok, otra
to he engine où pan.

3208 Diesel Truck Engine

219

Lubrication System

(Engines With Oil Filter Valve Ir
a Bee vane Vaneln

1 2

The ain system uses à ie, ar ys ol on in being nthe ont corr ee engine
pure @) Bats na ne cove or a lp) en ha ceros goss ona er chat on ver for
Fe ont cover ring argo () Te ga’ on he the eng Te ven Oy te er lor

area res he ert Tho Ste ea as

320 Diesel Truck Engine 220 Systems Operation

O pur bypass vo () th cover or he ol
poro, Eros the pressure oreo coming tom
par 8} The pump ean ou mera cl no o,
Sytem than need Yan e ross oe ot
9908 no the engne mar an 380 o 80 kPa (55
15:80 pa) the opass valve (9) wt open Ths pets
‘he oth re ee pass tho eam

Où rom the of pan pu ough he son bt fx
tho ot pump (10) y olpump (6) Theo ser bythe
par fo ono stage te ot cover br he
Pe (9) O1 rom ts passage goes tte onder
‘Sk ar on to se forthe ot con (5), Ths awe for
the ol conn in af ol he erga, near fo
front ofthe enge Où coker bypass vave (I). nthe
thse or tne of cook tat Bogor te
ook (7) to ba où 20 a to res mine
‘Shere more han th ter paris of th saa À
rence prose 085 o 105 hPa (1210 "5 pa)
Between he ont and tho au a apen the
bypass ae

(tom hoof color gos o a otr. ON Ms
pas ao (1), the bas rte of cane va
tgs sound of ies (13) toro ares re
oie,

‘There ae wo rssur os nthe as forth oi
aor The posta otto ae the oa dde ot
{hoot con an ols. The pressure cuts are or
{he ng nt and se ta tho esse

Qu ram te ours (1 goes tvn a passage in
Teen Bock oof manu (Te cl mandas
IP ne corte of he cr Bock, above th camera.
and gos Ing ot heey lx. Ol go
frome of ant e bss tte camera
“hare are gout inthe boot iow ose
‘round ne bear orth cast The osea,
ane (pumas en the camera gt Vaio tom
‘hese grooves trou a hole nie beings fhe
‘rat Sone ool ques wound tha ros
Sra down trough apaseag oa Pl and ono n
{ho top al ofthe man bearing. Ol fem mo nos and
‘groove gues can ete bang sacs
(faunas) othe warachat orth man bonn

‘Ot gts et a nat ough oe in
‘oat surfaces (omas) or man Dean
Passages conato boat Sac (ua) fe the
mL th ne Bring srt asa fr ho
‘onnacing 108 Tha pon pra gt tc aton nom ot
‘frown by er ar

Cr me oser arms comes ram tb ol manto 1)
roo page In ne encor ck The passages
In ne nor Bloc te lgrman ith a passage
(nen cuna red, Tre passa ote Gyr head
ne et Se rer ont el hw nor Dock
‘he passago to the irr head on ma ro ae =
‘oa he rar ee yn! Dock

Tra passa in each inde ead sens te oo
an ol elo no ten ofthe mounting ace ol he
Be le wat le se aro The ot
fa ne ont racket onto a e ad Pa
rea ria on he ej side. Th a Pen ess p
"voca the brace’ anto the certe o eat or
raro ame. OF goes ag re ore oth sat
{the boss oo rociar arms. Fr oct
ma, 1 pues Eu eral Po 1 Que
unten ote wavs, posh os, Hs. and
erst bes

rio Mca el has doe is wo. tan
{oth engine par

3208 Diesel Truck Engine 221

‘Sag Sen ac
{ie En RER tm to wos (O Sc Oca nt metre mp Rtn ©

‘cease npn pan hos cn heron hr igen Raa
‘(2 Rar Str osa 13 Wer pare) Oust er ooo 18 Os net ro na Cpr Bock
(ten ewan Pas nat cov eg (rex nes

3208 Diesel Truck Engine 22 Systems Operation

KANNAN TN

yy
Ra

nr 4

aay Syren tn vein ase pr Ser

Sn
FRS ee Akad tone ne oar nie metre apts 0 Ban
{srs cera pi, (Cyn hose} ee woe, Se race ya Nag
‘erate pan hsp Cu Ga mn pour 190 Soe 0 ete rear (Oper Bak
(heen econ cy fess nee Oona ni

ar pur (1) siesta a tn ron ac of the
front covert he ange ae sen by Vat rom
the crane ply het opa of wae pomp
(lay conectes to rar bot ce (12, The
‘hte ow of coca hor ver pump (1) es
‘rough nido passages nt Wont cover one
engine

As the coat goes rom th water pump, cos
land goes tough o race passages be tort
over rt aie yin oe (17) to ole
an ss ep ende Book (17) and to
Sie Peas () From cide ads (7) the coca
900 fosas tough ies (A) oe Het com or
Heenan

Par of th conan’ go othe alt sido (as sen om
‘he ae) el ince lex (1) goes tough one
So ratte (18) an no a code (19 coa the
‘itor ican of be enge, an back 1 a ont
ove forte engine ug cat Ine (1)

From be tort cover fr th org, cont rer
nea tthe et for war par (19) of the aer

lt coats ak (ec, he water temperate
regates (18) wba closed Toa oocanı wt go
trough ce Dypas (10) o water pup (1) the
"sats warm Pa water mere roger (18)
be coon Whar the wal terperre lea
{18 ae con, toy rake areticton nto so
bypass (10) and ve colar ges rough rac co
8 and vo air op tank (2) ide are
(2) Coca thon goes och a ceo o! o dat
lolo radar bot lan (1): al non ch
tan (1), her apa Sort cach the Soir
Syston. À ra amount o RDA gore tro Rd
bypass (10) wren tampa rogues (18) a8
open.

3208 Diesel Truck Engine

Systems Operation

BA BestManuals.net

pen a a BoM san

Sen Wn Ga Faser es Seat Sg ve
‘Geen ya eae ur eae en rt oe rung ar ur enge ou. Ran
‘ott nr repr yeas) vet nny Soy unc O ne pay ng ae
‘be aes Wali tac on ne A.

Imperia pa le coco Syste Tey id
rt tow between actes (2) nd nse bypass
(ID) a necessary to manar to care emperairs
Nine wate lompertue equator are at nta ln
Ie tam, Poe ro machanca ont and mest
‘tha colt wl ae e pat fast este.
trough he bypass. The a cause a enge
‘reheat nat waver neo weather, ave he
ral amount of cout Pa gs trough he radar
‘Stoo much and ne engne wrt gett nal
puro ep

NOTE: Te torpe reg ran AA
mama,

CR and pe tank) Te cos tow ao à
‘ace tn a ot co ak (2) and arg ae nk (1),
paa by a nach ba, La spurte fem
{a radalo Vent une (8) concis tne surge an 3)

3208 Diesel Truck Engine 226 Systems Operation

Surge tank (9) has asu ne (4) that connects to the
let 0 ate pup (19) Su re) must aways o
‘own hil. Ths shunt ype system keeps a postive
pressure on th ol of water pomo (19) ata mos
‘When puting cesar n 10 cooing system, ceda
rom eure an (9) ges aug St ie (fe
‘tof water par (13) and i cyan Beck (17)
trom tho betöm. By ing to sy em to betem.
ary ath ye sd ut hcg at top
{ark (2, trough vent ube (8) to surge rk ©)

‘acter cap (1) uso to Koo te cor pressure in
the coding system. Ms pressure Kops a cons
‘Supply of court to wat’ pump (1) Fin pressure
‘00s foo fag ala dor cap (1) moves
{Gpene) 10 get a reducto of prose. men ne
res pressure be cos Syl, vas
FA ED (1 moves conn (oto sod po),

e he
af

“To vent va cat in he font housing ext
tne tempora eds. Tho vent valve od lo et
te aout o he cool sytem when the coc,
System fc When to engine pera, te
‘ont vail ces and not lt cocine go cua
‘This wi hop note he Lampert ol he out at
Ion engine lac.

Tho fics Routing as several pugs that he access 10
lar passages nce te hong. Foro CO
ecos ports 1 st hater non, seo e Locator
Of at Connectors peur

Basic Block

Cylinder Block

‘The yindes are a par of the yinder lock Thee are
o rolas finder ner. Te cinders ca
‘race Sao) up o 100 men (040) ose 1
recording, Tr eyindrs no ck ar 90%
lange 10 each oor Tha a Ivo man bearnge me
BOCK 1 support the canes

Cylinder Head

Tre is on or Ned or each ide oar ra
engine. One he an ane xfa valve uns lor
‘ch cer. Te valvo gues aro apar ofthe
finder head and can nt bo repaces. Valve set
Iter are use or o nte and exhaust ave ed
an be paced

Pistons, Rings And Connecting Rods

‘Tro 9208 Truck engine uss bth two and a ro
‘ng piston. Tre two ng palos havo two rings whch
te cated above th piston on bore. There sone
ompressn ing and ne ol contr ung. The ng
¡side one pce ard as an expansion spring
‘and it.The compression rings alo one paca and
‘oes rt an ren ban hat seas io Pr pen. BN
{he compression and theo cool enga ate othe
conventona type rot Keystone}

‘The te ing pitos an alumina cat with an
on band tr a two comoressan gs. Al ings are
located above ihe pion in Dre The Iwo.
compression Inge 00! re Keystone ype and sata
‘anon band that cast te pen Kayaan unge
fave à pere shape aretha movement ol gs
In Ina plo grove (ao ol lad ape) resus à
constant enanging eearance (scan akon)
Beton he rng andthe groove. Ths action ress in
‘eet o carbon depot and posable slcung o
figs. Tre ot ngs a star (Comentona) ype and
‘Swng lone.

‘Tho piston pi hall in ho pen by wo srap rings
which goin the piton on bow

3208 Diesel Truck Engine

20

‘Systems Operation

Pate wih trot compression aes ar use or
SE Tras enges, Th aon must ale
rara wit Batons 0 a c'en compression

“Te pen pn end ofthe connecting is tapered to
(Gre more Bang surtace sl Da tea of grt oa.
he 14 salon tha itn win tha bos on he
ornsstng vo on tho sar eds seo eae e
ton he cornecing rod boars are ha
Ancien win ta that goes m arom in he
earn ca

Crankshaft

‘The feof combustion nthe cylinders is changed to
Sale on power y De caian. The

arasre can have ar sxc” oa contemos
ear on ne nto the coral tera re ergo

aot gar and In enge 0 aro. The ene Bay

tte raha 0a by hah bearing on.
a man veses

Vibration Damper

The wating ofthe crankshaft. due o to reguar poner
impacts song tong, cal ing eso
‘eran. The Vean dampor tao on re Font
terol casa hi une oe abc oF
terca viratns and tcs ne vrai fom
icing upto mounts at ease damage

Te camper mace ofa tahoe ing (1) conectes to
oer Fu ya uber og (2), Te ua males
dose casing ana he hel rg andre

Electrical System

The actia system can nave ee spat cuts:
the cargng ara he Eng coca ac the ow
arpaage cout Some of te Bote tem
Es sre nd n mor Pan one er. The
Estoy (res), Cul beater, arar, cales and
vrs fom rebut ar al corm nn lo

Tra chargng creat opaaton wnen he engine
turning An arate maton eg lr ha charging
‘Seu A sage requir in the arc coals he
‘Serra! cpl to ep the bay al Caro

Tre srt excite m operan ai whan te start
Sid a rate

Tre fon amoerage croi andthe caging cut are
‘an Core oto samo de ott ammeter The
Sng ca corps he oppose ac otha
anno

NOTICE
‘Never operato he alternator without he battery inthe
rca. Making or breaking an aternator consecton
aa loaden he crc ce came damage tothe

regulator

3208 Diesel Truck Engine

za

“Systems Operation

Charging System Components
Atemator (Delco Remy)

‘Tro trator ven y Vb m te ran
Duley. Ths trator ro phase, schung,
Sharing nt, and he equator par oe aerator,

‘Tis alors den has one for up rings or
Dh. and he oy par nat as movement he
‘reer A esos thal cary eet ae
tsar The conduct ar the fd Whang tor
nds. sect ces and the ear ert
Components

Th ro ae has many magro pi he
ge ina space betwsen ese opposke pol Tre
pos have res magna e emanan
Fraga hat produc a smal aneurt of magnet ke
nos of eres (magnate a beten the pls AS
Aa oo! essary bagi um bean ra fd
‘nang ana he sir indnge. a mal amour ot
_uraing cue (AC) proce ha slo
nds om th smal magnates of eae made
Dye re mass ol tn pa Tas AC
‘ert changed fo cre carr (D) wre it
Deseo hou Te Boden ofthe acer zo Most
Sith arent questo charge th Batley and app
the ow amperage Cect and the emandar ert on
{oie ladies Tha DO can Fo hrsg the
thd windings its around an ron core) now
Ines the senil mate nas of xc.
‘hase songe eso fore now creas tho amount
SAG caret prcucod he sae wings The
areas spe th or asso aso cres
‘Ba curert ane vage ouput te ara

The votago regule a sd stat rans,
talar) sar) decrone nic fea te vage n
the syst and aches on and ot mary rc à
econ to conto! e Na eet (OC core the
fet nos) lo ara oak he mode
valgo ent

Altomator (Bosch)

‘otra’ ven by Ve to catho
ply. Ths aterator à Ivo aso, electro,
arg wnt ana th equa part of to aerate

Tre 789720 Atarao has an oa ot 7A. The
AS Alma as an aaa ADA

NE Se wang (Fe meteo Regu, at
‘ei ie tare Ree Rae en.

3208 Diesel Truck Engine

za

‘Tis alerts design has no ned fr sip ings or
Datos and tb ey part a has moveret the
‘or samy, A esas al cry ran re
onary. Tne conductor ve: the fed wiry. tate
GE, xro odes, ane he equate are
compares

The rotor asser nae many magpase ples ko
{Ingest a space betwee es oppose plo, Tho
oes nav rk magnet ke permanent
ag) tal procuro «sal aus ot magetike
{ew of rc (rage i) etna ap, 2
orto secon bogs 1 tum between ho fad
nenn ard vo it” wndnge à mal amount ©
ral euren (AC) prend ea
nie fom Ie ma magnet Ins ot ree made
bythe Tes! magn Os poi Tri AC
rent changed ort caer (DO) when it
css trough va esol ate: Sree Moat
Shs een goes to charge the bate and lo ay
Len ara eeu and to romain a
Ira fange. The DC can! Som tau he
feta windngs (res Sound an ro cr) rom.
‘oases the range a the mage ins eo
‘hase sorge Ine offre now Ica be amet
OFAC eurent produces nthe ser wages The
[read sped of he rotor assy ae creases
{he rn and vage ovat of e Arata

‘Alternator (ppondenso)

Tre Nppondenso alternate has two pase wave
rected cut. tie ose. Tho a and beats
‘te th any mung paris. Tho 24 ot, 904572
Amar Mi 3 amp cups ang a 12 OIL 87960)

Anar vain 5 amp ct

en th engine sais ant rt me nido
tro Sao ringe, eee phase alto iret
(GC) and rap ng vaga gerer

A era amount trat curar (AO) changed
(rc) eg nec Sant (DO) by e aer
des on rca accent, Ops ces tom
ines có add toto sal cron wn fe
trea o role ld cris om wm
‘rages, Thiet make o ara anger magnet
{fence ve aerate lo bc aches
tom, As rte specs, curt nd tags
‘crease, th lr Ta ren eres erg rt
‘he aerator becomes uty aca

‘The man batery chong eur cragos och)
rom AC 0 DO by te ihr postre ane rage
odes nthe rect and pes (man ct Socke)
‘ate perl tl rave tao estes cc

Aer ut om by eps, vhs

‘Alternator Regulator (Bosch)

‘The tape rato an stone een ode ne
vatag in he sytem ard ques ne necessary Tels
‘Ser (care th ls rset to mata)
dove Atrato make the ned vage The
vago requ’ comets he 1 cute the
Sematary sntchng en and o mary tines à
Econ

3208 Diesel Truck Engine

Systems Operation

[Aerator Regulator (Nippondenso)

The regueton othe aes y two
ern methode One met tastes e og 10
regueton separa by use da re and a
‘Sacto that goes to the rat.

ne votago regalos a sl sate actos sen
‘eos the vage th Sy and ques
cer 1 cure (caret lo De Je nds of
Lu erat) rt ato 1 mabe o noose
vale. The vage gue contras hea cert
lo vs ratos by swing on and may eras a
Second, Tors no vaage aan ri
Er

Starting System Components
Solenoid

A end a magnate sich tat dos two baso
opens:

1. Coses the igh cunt are meer et with a
Ion core sar gos or

. Engagos the tare mot rien wt he np ga

hen the tar sch opened. cuen otorgar
wa gh o winange Tho spring now pushes ro
‘Bunge back to the aga postion ee athe same
{ime moves he prion gar away om he Bye!

nen wo ts of wings inthe sole are sed,
thoy a Calo te PO wang and he pin
meting Bo rs he same rca ofr und
{he or bi the pain widen usos argo
(Cate we o rosie à ett agate ak.
‘hn the sia ae à cod, pr of he cent
‘ows tom to bar rau he hoon ng,

‘Sonos à uty scat (como aos bey
and motor ein i complete, cuen ut ot
trough pul wings. Now ol he sale pd
In wings arn carton fr to extended poros of
{ime tate o sr e eng. The soera wl rom
tak ss caer m a Dale, and Pet ade By
the sere wi be top a an acoapabe eve.

The stare motor used fo um he eng ye
{ast nought etre engne urn,

ES
SERA
Se

‘Tre soon sch à mode oan cectroragrat
(cre or wo vets of weeny) car a low onde.
Tate à à purger (Cor wih à song tad rage the
inde at ca rove lard and Back Mon
tho sat sche dose and OR sort PU
the ringe. a magnate ols uds that pls Ve

Bunga (od o onde Ths mews the sl

[ever connai lo tho fer ote pga to engage
tho pion re gen ins ung ur a Von
‘lth Burger ten mas contact cross to paty
‘mot’ Bas 1 un te yao henge.

(ee Sra ut Pon (Cama
(clown aise Oyama.

The starter moto as etna When the ar wen
2 nd the START posto th seed wie
‘tated octal. Me sena cor now move
16 ash te stats pon. bya méchant kage, ©
20009 wih the ri ger one wea of he
‘Sage. The starter pen wl enge win e in,
‘gear Daten ire carats nthe send ose
To Creu betwcon he Battry and he irte ler
‘When ere btwn D Emery aro tao
motel complet, pon wl nthe engine
"jaa, À cues proectn ote star motor
Strat the engi en stars on cannot um.
theater motas fet When o art enon
und o sare pro wl rave my hor he
nod rng gen

3208 Diesel Truck Engine

zar

‘Systems Operation

Magnetic Switch

A magnetismo) is usos cometas tr tr,
Sara seri cect. 1 cpm acia
fame ab he Bene. tonto trou De
ero on heat sth an cor cae ©
the sister sance

Other Components
Circuit rosker

‘Tho ere brake à a aut topan the bry
{rout he curt a eect system gous ghee
‘han o rat ote rc break

A hat actrato metal ie win a contact pont
Compass no asco rouge cra
Sr. tne cure no acces oytam gt too
igh causes ha mall o o gl, The has
calzas à délai of the mel doe wich cpens he
Sonate and bos to creo, A cu Eau rat
‘pen cabo ase aer col. Pu the oe lo
[Dor o contacts ar root o Orc bok

cs oe (0

3200 Diesel Truck Engine En

Systems Operation

Index

Testing And Adjusting (Section 3)
Al Into And Esa Syston 92
"AX To Al Alercocod Systems ... 32
Cinca Compression 32
Exhaust Tempera, 32

Measurement O! Pressure nei Mania 328

Procedure For Mensurng Camstall Lobes... 329
Resten Of Ar mit Ard Exnaust 3%
Turbocharger 32
Valve Cearence Sating 32

Basi Block 37
‘Connecting Rad And Main Bearings 337
Cormecing Rods And Pistons 38
Fiyi! And Fiyael Housing 38
1V6AST Keystone Psion Ring Grcave
Gage 397
Pasto Psion Ring Groove Gauge Ej

Cooing Systom 38
‘Dynamometer Tost Caution 3%
eater Connections 5%
Testing The Cooling System 3x
Visual epoction Of The Cooing System... 332
Water Pump Pressure Check 335

octal Sytem 3
E A 342
Grarging System 34
Staring Sem 2 3
Tost Too For Eecincal System 341

Fuel System 32
heck Ergo Gr Sapa 32
Grosso Levers ia
Engine Spee Measurement 32
Finding Top Center Compression Poston For No.
1Pston 33
Fue! nen Lines 32
Fuel jection Pumps 33
Fuel cie Testing 32
Fuel Pure Carton 35
Fel Rao Corl Adusiment an
Foal Set … 38
Fual System Adusiments EN
Fual System Inspection 52
Governor Adısimenis 320
Load Stop Adjustment 310

Lubrication System 32
Increased ON Temporaure ES]
Measuring Engne Ol Pressure 32
Où Pressure Ha 331
Ol Pressure is Low 331
Too Much Bearing Wear 331

=

Testing And Adjusting
Fuel System

Ether too much fuel er net enough ue or combustion
can be the cause ofa problem in ih fl system.

Many times works done onthe ful system when the
problm rey wih some other part ofthe engine
he source o the problems Gficu to Inc, especialy
when smoke comes rom the exhaust. Smoke that
‘comes from the exhaust can be caused by a bad fst
Injection valve but can ao be caused by one or
more of the reasons that olow

8. Not enough ater good combustion.
D. An oveioad a hgh altitude

€: Oileakage nto combustion chamber.
4. Not enough compression.

Fuel System Inspection

A problem wit the components that send falto the
engine can cause lou uel pressure, This can decrease
engine performance.

1. Chock the fue leven the fue tank. Look atthe
cap forte fuel ark to make sure the vont is
fot tad wei or

2. Check he fue! ws for ful leskage, Bo sure
the ful suppy Ino does not have a retrcton
cra bad bend

3. Instala now fue fer. Can the fuel screen
Tecate in he ist vales ofthe fel ranas
pure.

A. Remove any air that may bein the fue system.
‚Open the crn valve onthe function pump
housing. Operate the us img pomo unt
{el without ar comes fem the dain ines.
Close the rain vate.

‘To remove ar rom the ue injection nes, loosen the
fuel ine nuts 1/2 tun, Move the gover lever tothe
low ile poston. Crank the enge wth the starter
motor rt lu without ak comes from Ihe Tua Ine
‘connections, Tighten the fuel ine nus.

Check Engine Cylinders Separately

‘An easy check can be made o find the oyinde that
runs rough (ístrs) and causes Black amoko to come
Out ofthe exhaust pe

Run the engine at the speed that is the roughest
Loosen te tual in ru ta fl injection pump. Ths
‘wil stop the fw of fuel o that oyinder. DO th cr

each cylinder un a loosened fuel ie is found hat
‘makes no dfrence in engne performance. Be sur to
tighten each fue Ene nt after he test belore the nxt
‘Wal ine ru i loosened. Check eacn cyinder by the
method, When a evince found where the loosened
fuel ine nut docs not make a france in engine
Performance, ts ne injection pump and tel injection
oz for that Cancer

Temperature of an exhaust manifold prt, when the
engine runs at low ide speed, can abo be en
incleaton of the condon o a uel jection rozzke.
Low temperature at an exhaust mano por isan
incicaon of no fel othe cyinder. Tis can possty
be an ndicaton ofa nazze wih detect Extra hgh
temperature at an exhaust marek port can be an
incicaon of 100 much fue! to the cine, also caused
by anozze wih a detect.

‘The most common dafecs ound wih he fue nection
valves ate:
1. Carbon on tip ofthe nozze or inthe nozze
ones,
2. Orton wear
3. Dety nazze screen.

Fuel Injector Testing

“esting of ho injoctors must be done of ho engine,
{Usa 524180 Nozzle Testing Group. For use ofthe
PS1S0 Nozze Testing Group, rte to Spocal
Instruction, Form No, SEHS7282

Fuel Injection Lines

Fuel rom the fuel injection pumps goes tothe fue
Injecton nozze trough te fuel ijecton Ines,

nen fol injection Ines ara dsconnected or removed,
‘ays put caps o pugs on the ends to keep dt out
(ofthe Ines When ful nection Ines ar instal, be
Sur al clamps and dampers are installed in ther
‘tiga locaton.

Each ful injection Ine o an engine has special
design and must be insraled in a certain location.
nen tel jecton ines are removed from an engine,
put kontfication marks or tags onthe fuel Ines as thoy
[re removes, so they can e put in the corr locaton
‘wen they are instales.

‘The nuts that hold ful nection line to an injection
oz and injection pump must be tightened to tr,
‘Correct torque. he nur 8 loose fue! wl ak from the
‘connection tthe ni tightened too tit, he inside
‘Samar ol the Ine wl Become emaler and cause a
resticion to the Row of ue nthe ine. Use a torque
‘wrench and a SP148 Fun Line Socket fo taten the
Thal nection Ino nuts to 42 7 Nem (91 = 510M,

Fuel Injection Pumps

non injection pumps, osves and les are removed
From the nection pump housing, op the part or
teach Pump together so they can be instale back in
{hee orge ion

Be carolul when deassembing injection pumps. Do nat
<damage the surface onthe plunge. The plunger,
‘Steve and barrel or each pump are mace as a Set, Do
ot put the plunger of one pump nthe barrel ar lev
of another pump. Loro par worn, nta a complete
‘ew pump assomby. Be carla when puting he
plunger the bore ofthe bare or stave

Wen an inaction pump is instal conecte
‘lunge is trough the seove and the adustment lover
ls engagod win tho groove onthe Stave, The bushing
that hos the injection Pump inthe pump housing
must be kept tint Tien tho bushing 10 60 = 7 Nem
(80 + 5 1 1) Damage to tne housing wl rel the
Bushing i 100 Lg. the busing 1 not lg enough
the pump wil lak

NOTICE
I the sleeves on one or more of the fuel injection
Pumps have been installed wrong, damage tothe en-
{ie s possible if cautions are ro taken at fist start.
ing, When the fuainjection pumps have been removed
and instala with the fuel injection pump housing on
engine, take the folowing cautions wen fst starting
the engine.

a. Remove the al clean leaving thea inet pipe
penas shown
I. Set the governor conta at low ice

Be careful when plate Is put against air inlet open-
ing. Due to excessive suction, the plato can be
pulled quickly against air inlet pipe. To avoid
rushed fingers, do not put fingers between plato
and air inlet pipe.

€: Start the engine, and i enge tarts to
vorspose (un ut ol conto) puta ste!
Over In ar inet as shown lo stop the engine

Sia Th Enga

Finding Top Center Compression
Position For No. 1 Piston

No, 1 piston at op center (TDC) on the compression
stroke sio sarirg pont or al Img procedures.

1. Remove fig (1) rom th timing hat (3) in the
front cover. Put bot (2) Ling Pole (8)

fing Are Bt Location
(ers Bot

2. Turn the crankshaft COUNTERCLOCKWISE (as
son from rear of engine) unt ai (2) wil go into
the hol in the ceive gear forthe camshaft

3. Remove the valve cover onthe right side ofthe
‘engine (as Sean fom rar ot engine) The Se
Vals at the ight ron ofthe engine are Ih nta
and exhaust vaves fo No. evince

es

Int Bot
Bot Tmeg how

A. The intake and exhaust valves for No.1 cylinder
‘must now be closed and the timing pointer wil De in
ligament with I TDC- on the damper assemäy.
‘The No. 1 piston 1 now a oo center on the
‘compression stoke

Fuel System Adjustments
Checking Fuel Injection Pump Timing; On Engine
he timing of the fel injection pump can be checked

and changed i necessary, make compencation fo
movement in the taper Soave Or cr worn ing

gears. The timing can be checked and necessary
hanged using the folowing metros.

Checking Timing by Timing Pin Method

es |

DT 7
VEIA |

1. Remove bot (1) from the timing in ol.

2. Turn the erankshalt COUNTERCLOCKWISE (as
seen rom rear ol engine) unt Iming in (2) goes
int the notch the sasha forthe ful On
amps.

3. Remove the ing Im timing Poe (4) nthe front
cover. Put bolt (9) through the font cover and into
the note with thread inthe ting gear. The Bat
trom hole ($) can be used

ZUR 4
ES

Ting Pinna
A mos Pe,

JA

rt Bat
LS 104829 Bot 6/16 18 NC, 65 men (25 og (Tim
Re re

A. I the timig pin sn tho notch in the camshalt or
the fuel ijecton pumps, and bolt (3) goes into the
hole inthe timing goa rough ring Pole (2). the
timing f the Iu Mio pump le cock

NOTE: I boit (2) does not go in the oa in he ting
ear with Img pin (2) nthe notch te camehat
tse the procedure that kone

(6 Ge tr Be come ne ass, Mas

2. Remove rus (7) and th cover forthe
tachometer dto assemby (6).

1. Remove the tachometar Give shat (2) ane
washer 8) rom the camshal fr Ie fuel
Injection pumps.

NOTE: Tachometer dive att (9) and washer (8) are
removed as an assembly

ag

Loose One Gear
EDS Per Bas.

€. Put 6v4089 Pur (10) onthe cama fe the
tual injection pumps. Tighten ba (1) unt ne
dhe gear on In camshat or ne fuel injection
Dumps comes loose
1. Remove the 64060 Puler
8. Turn the crarkshatt COUNTERCLOCKWISE (as
seen rom fear of eng) uni ol () goes ito
the Poe in the ming gear Win mino pi (2)
inthe noten in tho eamshal lo ro fuel
injection Pumps, and bot ($) the hol inthe
tiring gear, re min Tor ne angie is cae.
Insta washer (3) and tachometer vo shat (9)
Torte tachometer ve shall 0 149 + 14 Nem
(110 = 10 1) Remove Imng pn (2)

Tear Ore Saft

9. Turn the earkshalt two complete revouions
(COUNTERCLOCKWISE (as seen rom rear of
engine) and put timing pin (2) an bat () in
again. timing pin (2) and bot (3) can not be
iestalod do Stops a through agan.

h Remove bolt (3) rom the tming gear and instal
In al ($) fetal te pug in timing hole (4)
Remove ining pin (2) anc instal Bet (1). tal
cover forthe tachometar ceive assembly (6),

Checking Engine Timing And Automatic Timing
‘Advance Unit With 815300 Timing Indicator Group
‘And 875301 Diesel Timing Adapter Group

TO Tem Gr 7
ES Desa Teg Ada Go 1

818500 Ten neater Grup
(ETS ENG Tg nr. 2 SP7OHE Can Avery
Hate nage Tante (P7562 Caso (6721098.
‘goes Taree opi. (6) nahe Fae.

The 875900 Ting Indicator Group must be used wih
an 875901 Diesel Ting Adapter Grow.

13301 Do Ting pega Goss
(1977 Roi 19 EVE da Cae 57498 Apt
ER ac. PS Aaa OIE

A high pressure fuel ine must be disconnected. To

avoid personal injury or fire from fuel spray, the

engine must be stopped before the fuel line is
connected.

hen checking the dynamic Img on an engine that
has a machancal advance, Cater recommends
thal the servceman calculate and pot tne dame
mig specticatone tes on a wockshoot xa Form No,
SEHSBIO Those worksheets are avails in pads of
50 shoe's, order one Form No, SEHSET40. See Special
Irstveton, Form No, SEHSB5E0 for information
routes calcite the timing curve, or the correct
timing specications to use, see the Engne Information
Pate forthe perermance specifcaton number ano
‘ako reference to the Fuel Setting And Plate
Information ice.

NOTE: For more information on acceptable tolerances
for dynamic ful injection timing, see Service
Magazines cated 41.85 and 10285

Aller the timing values are calovated and pated, the
‘amie tming shows be chackad wih te 815300
“ning indicator Group and the 818301 Diese Ting
Adapter Group, To co ths, the seraceman must
Opera the engine rom 1000 rpm (ase rm) I high
id and hom high i o 1000 rom (nase For
Unstable racings are often obtained beon 1000 rpm.
He must record the dynamic timing at each 100 rpm
and a he spectied spaeds durng bain accoeraton
and deceleration. Thon he shock pot ta resus on
the werkt.

Inspection ofthe poted values wil show ith fel
injection timing is win specication and itis
advancing corety

1. Make reetence to Special Instruction, Form No,
‘SEHS8580 for complete service information and use
1875300 Timing Inocator Group,

2. Loosen al ua ine clamps that hol No. 1 u
Injecton ine and disconect ual Ineción ne (12)
{or No.1 cylinder at the ue tion pump. Side
the nut up and out of the way. Pu P7436 Adapter
{@)inits pace and turn adapter (8) onto the ful
Pump bonnet uti the op ol he bonnet threads are
‘pproxmataly even wih the boom ofthe “window
in the adapter.

3. Put ine $7435 Adapter (11) on 8V7910 Transducer
(10) and put the end ofthe SP7435 Adapter (11) m
the “window ofthe 7436 Adapter (8)

ON var (1) Fu ton ie fr o. Y or

4. Put tal injection Ino (18) ontop of SP7435 Adaptor
7437 Adapter (7 and gto to 40
‘Nem (901.

5. Remove fing (14) rom the front housing. sta
transducer adapter (8) nto hoe ing (14) was
removed tom. Tighten only a small amount

6, Push the TOC magnetic transducer ($) ito the
ansducar adapta (6) unt makes contact with
the camsnalt gear Pu back ut 16 mn (06 n)
‘anc ight tgtton the knued loka

Lecston Ofte
AS

7. Connect tha cables rom the transcucers othe
Engine Timing lrdcato Make a calibration check of
tha necator Fr caon check o! tr incicater. For
caltraon procedure, make reference o Special
instchen, Form No, SEHSES80,

NOTICE
‘Be sure al test equipment cables are routed so they
wil not come into contact with the V-belts or other

rotaing components
=

arse aan
TEE magne nacer

Work carefully around an engine that is running.
Engine parts that are hot, or parts that are moving,
can cause personal injury.

8. Stat the engine and lat each operating
temperature. Then run the engine at approximately
one hall wot for ght to ton minutes before
‘measuring ting

9. Fun the engine a na speeds required to check low
ide, ting advance and high ide, Record the
‘engine timing indicator readings. the engine timing
3 not correct make reference to Fuel System
Agustrent. On Engine, Fuel Inaction Purp Timing
(Timing Pin Method) for state adjustment ofthe tu!
jection pump dive.

10. tthe timing advance is st not correct, ori the
operation of he advance 5 not emooth make à
ga or replacement ofthe automatic advance
tan. Thar sno adjustment o tho un.

Fuel Setting

Ts |
FANS Fa Sen Ton Gr

“Te procedure that folows or fuel seing can be done
th Ih housing or no fuel jection pumps einer on
ratte engine

NOTE: I! the fot injection pump group is equipped

‘wh af! ali control, the control must be removed
before the ue seing is checked or adjusted

ls

FERA sd (2 Top cover

NOTICE
Before any service work ls done on tis fue system,
the outside of he housing forthe fel injection pumps
and al parts connected tit must be especialy clean

1. Remove shuttt solenold (1) and cover (2

2, Put the SP0298 Zero Sat Pin (6), win 17.8507 on,
inthe pump housing

3. Put adapter (9) and spring (4) over zero set pin (5).
Uso a 104535 Bot and a 104598 Bat to aston
adapter (3) o the housing for ho fuel nection
Pumps.

testo Of Core
(G)3Pe002 Acero 0) E886 Sp 5) 52098 Zu Set Pr,
Sees sor ante

4. Put screw (fin the hole over pin (5) and sing (4).

Insta Or cr
Dr

5. Turm scrow (6) clockwise unt pin (6) held against
the housng forte uel injection pump. DO NOT
tighten screw (6) too tht

6. Put camo (7) in adapter (3,

7. Move the governor contra lover to FULL LOAD
postor.

Inston OF Ca, Later Seow 8)

San 32100 Coe me. (seeds wrens,
8. Put sP6591 Point (9) on cal indicator) Put the 1, Put the cp end of tho 810500 Gicut Tester toa
Indicator assembly in clamp (7) oc grand Put the tner and of the 870500.

rout Tester on the load step contact

12. Move the governercontal lave othe LOW ILE
positon.

18. Move the governor contra eve lo towar the
HIGH IDLE poston unt the contnaty hg fst
Comes on Make a note of the reacing on Ga
Indicator (8. DO th step several Imas to make
sure the reaing s correct

14. Make a comparison ot ti reading andthe tua!
sottng in th Fue Sting And Related Information
Fete

PSH a er (0 o 15. 1 o acing on into (li nl covet do
u = the othe folowing.
8. Adjust dal ndcato ($) co bath pones (10) are on

O(a}

10, Uso wrench (11) t tur the 887271 Screw (6)
Counterlockwse. Tur serew (6) sx ce more

Load Stop Adjustment
‘Stop Bar Torque Control Group
a. Use wrench (18) and lona (19).

Auger! O Fun Sting
6 Scenes (1 Acker ren. 18 Wen.

bo Use scrertor (16) to turn adjustment screw
(17) unl te reading on dal cate (8) e
Same asthe dimension gen inthe Fuel Seting
And Rite Information Fone.

€. Ven the adjusimert ls correct tighten lockrut
(19). Check Ine adjustment gain by dong
‘Steps 11 trough 15 again

NOTE: The same too that re used in Ihe procedure
ao ao used for he fuel alo control aciustmen.

=
SS IS

ner a

Rene Soren For Fun Sting
Raman sen. O La. (Lone spp

Coil Type Torque Control Group

À col ype spring contol group has been add to
3208 truck engines rated at 160 KW (215 np) @ 2200
‘em. The now AWO0OT Pin Assembly (deal A) a
rec replacement or the load top pin 4N0249
‘fective wth Engine Seria No, 2234221. Ths new pin
“assembly can be adapied to 3208 ruck engines
2218750 through 2234220, which have the above
enge rang specticators.

‘The col type torque coil group improves the torque
rise as the engin igs elo fl loa rpm. The pin and
orig assembly are maiched and must be kept
‘gether

Leaf Type Torque Spring

a. We down the dimension thats on dal indicator
@

1. Vite down he dimension given in he Fuel Sting
And Relates Information Fiche,

€: Remove the test ons [adapter (3). spring (4), anc
al cater (8) rom the housing lr foe act
pus.

mes .

Tao! Typ Tore Sr
2 Laon ae (19) Stop tr (Lest typ e
Se Lona sop pa

dl. Insta or remove shims at location (12) Lo get the
correct dimension as gven in the Fue Sting And
Fate information Fiche. The difference boton
the dimensions ina) and () 1 ne icknass anc
‘amount ol shuns lo remove or all 1 get the
corr sting.

€: Insta the correct amour o shims (12) ore
‘spring (14), and stop bar (13) onthe housing
‘Nel mecton pups.

Instale test os and do te test procedure agan.
Do ths uni the mension onthe dal ndcaor the
same as the dimension gven inthe Fue Setting And
Folate Information Fiche. Ar the fuel seing e
(rec, remove the 1a 1008 Install cover (2 and
‘Shutoff colenod (1)

Fuel Ratio Control Adjustment

NOTE: The same tools are needed or te tel ato
Control acjstment hat wer used or e fuel ating,
Hake reference to Fuel Seting fer the tools needle
and instructions tonsa tho teas.

NOTE: The ful salting must be correct betore an
adjustments made tothe tua ralo contral Make
feterence to Fue! Sting.

1. Remove shutot solano (1) and cover (2) ns
tools and "zer dal indicator as Shown in Fun
Seting Steps 2 troughi0,

sting. move the
‘governer lover sty to the high o postion. Make
record ol the reading on the dal ndicator
‘Compare the reading withthe specication gen in
the Fuel Sating And Rated normalon Fiche,

racing Fe Rao Corra Sarg,
ES

3. an acjstment is naaded, remove tree bolis (3)
tom the fuero contrl Hold the govern lever in
the hgh ke poston and turn ange (2) unt the
fuel ae contol sang i corres

ca
AN À 4
ment Fun Rato Corra Sang
Came

A. Move governor lever to louie and again move the
lever stow to high e 10 check the fel rato
contra set

5. Install bots (3) Flange (4) can be tuned sma
‘amount to ge algrment for bots (3)

6. Remove toos and instal cover (2) and shot
solnaid (1.

Crossover Levers

| |

ETES Socket Re

Checking Crossover Lovers

NOTE: The crossover lovers normaly do not nese
checking uess one o more ofthe folowing
cordons ext (alter th timing e checked and the
er comectons shown in Treubleshooting have been
macs):

A. The engine produces too much black smoke.

E The engine runs rough because fuel delivery is

©. Some cynders continue to fr at ual suo!
poston.

D. The compete njscton group is being
reconditioned.

NOTICE
Before any service work Is done on ths fuel system,
ne outside ofthe njection pump housing and al parts
‘connected to it must be clean

1. Remove te us tuto lancé (1) top cow
cf te fuel pure housing and the cover over the
Toxque contra group

2. Remove the fel hat is in the injection pump
housing ane the govenor housing

oh

LAN

eros! Cors
een Too ane,

3. Put the 3P1548 Calbration Pin (3) in calraton ole
as chown,

4. instal the 86602 Adapter (7) as shown. Fasten tin
postion win a 1D4538 Sot ($) ard a 104598 Bot
@

AP

ah.

Intl Catan Pr
SPIES easton Pn win 15.410 an

nating S002 Asset an 57271 Sere
(SEEN (6) 04559 Bat (NOUS Bat (00002 use

5. Put the 887271 Screw (4) (etre) inte hole
‘ver the calibration pin (9), Tien the setscren (4)
102310 28 Nem (20 0.25 Bn wih the 2P8264
Socket.

start OF Low sn Seo
on cove Bin

6. Adjust low ide screw (8) to poston ever (9) 10 89
10 mm (35 + 04 in) tom governor housing
boss.

Lun (11) Come ie. (12) 40 pr.
e os

7. Loosen th bolts that hol sleeve levers (A) and
side levers (A) out of the way

Instn 624209 Gage
1912208 Googe Ce) Sat (1) Sat

8. Put gauge (19) on shats (14) and (15). Side gauge
(13) toward crossover levers (10) ana (11) un
‘el pin (12) goes no ole in gauge (13),

9. done pin (12) must be ited to go int the hole
gauge (13), ne levers must be adjusted. See
‘gusiment Oi Crossover Levers

10. 1 gauge (13) most be ltd more than 0.20 mm
(08) ot dowel pen (12) go nto ne hole in
auge (13), ses Adjustment OF Crossover Levers

oca Carra OF Coso Lever
HER an (1) on us

1: To check the maximum clearance of 0.20 men
008 in) that fs accept under ane sige of
‘gauge (13), ol the center and one side of gauge
(13) agansiseovs lover chat (15, Use a loir
‘gauge o check cance

NOTE: Aller the checking ofthe crossover levers is
compete, In two fue nection purmps must be
abe where soove levers have been moved to
Install 5P4209 Gauge. See Fuel Pump Caltvatn.

Adjustment of Crossover Levers
1. Remove the fuel shut son (1) top cover (2) of

the fel pump housing an the cove ovr the
torque contol group.

2. Remove the ful that e in the ection pump
roving andthe governor housing.

3. Pu the GP1546 Caltxaon Fin ($) in caibaton
hob.

4. Install the $6602 Adapter (7), Fasten tin postion
with 104598 Bot (5) and a 104588 Bot (6).

5. Put th 887271 Scrow (4) (screw) in the hole
‘verte calbraton in (9) Tighten the sescre (4)
102310 28 Nem (20 0.25 In) with tho 298264
Socket

6. Adjust ow de acte (8) to postion eve (9) 0 88
21.0 mem (35 = DA in) Kom govemor housing
boss.

7. Loosen the bols that had see lovers (A) and
‘igo lovers (A) cut of the way

54209 Gage stags
(Piero ever (1) Donel in (19524200 Gauge

8. Loosen the bots that hold crossover lever (10) and
{HD and move lever (10) off Covel pn (12).

‘user’ O Crossover Leer
(eae (San 010 Sal. 16) $4206 wren

9. Put gauge (19) on sais (14 and (15), put
‘rossover lover (1) ina poston so dowel pn (12)
il fiin gauge hole, Hold gauge (13) down and!
torque th bot that his crossover lever (11)10 28,
202 Nem (24 + 2 in

10. Chock adjustment again withthe SPA209 Gauge
(19). Put gauge (19) on shafts (14) and (15), side
toward crossover lover (11) to engage
done pin (12) into hole in gauge (13).

11.1 dowel pia (12) must bette to go into gauge,
the iver must be adjusted again I gauge (13) 5
ed, a maximum of 0.20 mm (008 m) Garance
is accaplble under one side of gauge (13) Use a
fedler gauge to check cleerance.

12. Side crossover lover (10) on o dowel pin (12)
“Torque the bolt that lds crossover over 10) lo
28+02Nm@i+2bn).

anna Bo
EEE ne 12 Dow (10 ve

18. Chock the adusiment agan wi the SP4209
Gauge.

NOTE: After the adjustment ofthe crossover lovers ls
‘complete al of the fel injection pumps mus Da
‘allrates See Fue Pump Caloration

Fuel Pump Calibration

(Fee ee >}
ET 7
[[ssz24s wrench Y
In)
EPA Wenn Y

101539 Bot Y
101598 Bot Y
ESTE re = +
PTOS Socket Aer 1
izo ren 1
[erate camp |

PEE

NOTE: 3P1540 Caitraton pump must have the
156857 Soring installed instoa of ho 1P7377 Spring

dv

SEE quo aura
ae een
Pe
RE

‘Checking Fuel Pump Calibration

Tho folowing procedure for fue pump calbrion can
‘be done wt the housing forthe Tua mpcton pumps.
‘on oat he engine

NOTICE
Before any service work is done on this fue system,
{the outside othe injection pump housing and al parts
connected to it must be clean.

1. Remove the fuel shutot solencid (9), op cover (10)
fine fuel pump housing anc the cover over the
raue conto! group.

2. Remove the fue that i inthe injection pure
outing and the governor houang

Reno of Cover
GS sommes (10) Top come

3. lata 1546 Caltraon Pin (7) in the calbration

Inte catraton Pe
FTP Carton Pin ve 155010

4, Instat 5P6802 Acapte (19) as shown. Fasten tia
poston on the nection pump housng with 2
14635 Bot (12) and a 104838 Bot (14).

5. PA 857271 Screw (11) in tn hole over calibration
pin (D. Tighten sew (11) 1023 to 28 Nem (2010
on

Int POSI? Adapter And 65727 Ser,
{Bow 10 Bo (1) POE Roa (OHS

oma Of Low 18 Seren
Cros

6, Acht ou idle sere (15) 1 poston ever (16) to
89: 10mm (25 2 04 m) rom garer having

7. Use the 852243 Wrench ard remove the ful
anton pumps o be chockes

NOTE: I pumps removed caretul, the leave wil
remain o tbe Banger I the seve falls of the pump
‘lunge curing removal, find mmeciaely and raplace
Con the pump purger bete removal of another
Pump. The orginal seus must reman win tho same
Pump plunger

NOTE: When sleeve s instalas on pump plunger the
‘arrower of he uo lands onthe eve must De
toward top of pump (nearest the pump spring).

8. Clean tne barre! and plunger of carton pump.
(1. Pu lean iese fuel on he caibraton Pump lor
koresten.

NOTE: Be sur thatthe spring on Ihe csibraton pump
(0) the $6557 Spring nstoas oft 17877 Spring
‘which vas nal on ear aalbraon pumpe

P8857 Spring And P7977 Sp,

rio Caron Pre.

8. Put calration pump (1) inthe place ofthe pump to
be checked with the fal ace (20) on the plunger
toward tang (17) on leer (18) When the car
Pump (1) sal the way ln the bore, turn 180° in
ir Clocks or couterciocinibs direction Tang
(17) on lever (18) now in groove (79) of clan
Pump (1). Then instal ANZ1B Busting (2) Use the
882248 Wench and a toque wrench o tighten the
‘hing to 80: 7 Nem (60 = 501)

NOTE: Turning caibraton pump (1) 180° gives the
same reference pont oral measurements.

se

Cats Pure raies
(12150 Caron Pap. (17 Tang on oe (Lever
(Bone rennen pan Dr en gr

NOTE: Use 4N0218 Bushing (2) and calbratin pump
{D together. The contact suaces of the standard
‘bushing, tel injection pump ane the housing fr the
Tue injection Pumps are sealing surfaces Keep them
‘lean and tree o Seracres to prevent ak.

sting Dal seats On ero
og. (37088 Dalat win 2226 Cote
Fr (a Lora (29 928 Coe,

10. Put dal indicator (4 on microgauge (3) and pol
thom together tgl. Loosen loescrew (21) and
un In fac o dal ndiatr (4 1 pu ine pointer
at 0. Tigntenlockscrew (21)

Remove cal indicator (4) hom merogauge (3) Lock at
‘he face of cal indicator () and pat cal near (4)
on mirogauge (9) agan. The ponter must move
‘rough one fo one and one hal renoue before
‘stopping at exact D the rumor of evolution s
rot coed, loosen the loca on 392226 Col! (23)

and just the positon of the indicate ut the
adjustment is correct

NOTE: locknut (22) on the 3P2226 Colts too tht,
1 can cause terrence in the operation ofthe cial

189010 Cap rst
(2) ae SO Cer.

11. Put SVO190 Clamp (25) inthe position show, next
D the tanstor pump end, Camp (25) pushes salt
(24) down against the botom of is bearing. Tho
‘ther ond of shat (24) ished down against ts
bearing by 3P1546 Celaton Pin (7) when hola
y 887271 Screw (11). The combaten of forces
From clap (25) and calbraton pa (2) 8
necessary o hold anal (24) sin 1 naa
Sperating postion aganst ne fing tere ram the
beng In carton pump (7),

Dalinscater Poston
{ADS Da nse u 32226 Cae 25) Camp

NOTE: When checking pumps on te “slave” side
[sd opposite from governor cont lever (19), Put
Camp (25) on both ends af sleeve shal as shown.

12. Put dl Indicator (4) on the cart pump (1) as
shown, Hod bitin place. Move shal (24)

toward the governor end to remove end play. To
remove any Cesrance In he inkage, it he crossover
lever cowel anc rap le go. DO his several tes.
‘Than lok a Na reading on the cal ndesor (4),

trate Camp On “Saw Side
AS

19, i the cal indicator (a) reading is moro than &
0.080 mm tr 0.00 (cute ie Tota
Toleance), do Steps 17 tough 20, Adjusting Fue
Pump Caltraton

LS
/

Da et Raging
Beard er at pumps 8-0 060

Maximum permissible tolerance for pump
readings in any Fuel Injection Pump Group Is.
10.100 mm (-0.050 to +0.050 mm on dial indicator).

Maximum permissible differences between any
two Pumps in the same Fuel Injection Pump
Group Is 0.050 mm.

Total Tolerance shows the maximum permissible
range of pointer positions which are acceptable,
lt any reading is outside the range of Total
Tolerance, do Adjusting Fuel Pump Calibration for
all pumps,

Band is an example onl. It shows a 0.050 mm
range. This range shows the maximum
permissible difference between any two readings
for all the pumps. If any two readings are farther
apart than the 0.050 mm range, do Adjusting Fuel
Pump Callration for all pumps.

11 he dal Indicator (4) reading l pear either on ofthe
Total Tolerance, chock another pump. the next
eng outside the Total Tolerance or the two
cis have a ference of 0.050 mm cr more do
the Steps 15 trough 19, Agusiment Of Fuel Pump
Caibeaton,

NOTE: The mechanic doing the checking must make
the decisions of which and how many pumps to check
‘according othe symptoms ofthe fue Injection pump.
beng tested

14, 1 dal Indicator (4 ange fr athe pumps are
wt te ums in Step 13. ho calraion
acceptable. Remove In tooling, and instal the
parts whieh were verve

NOTE: For troubleshooting purposes. the dal
Indicator (4 eading 0 e mear” ihe albration of
the other pumps is probably in In tolerance

Adjustment ol Fuel Pump Calibration
15. Remove al pumps wih 892243 Wrench,
x

(Can the barrel and pump of caftraton pump (1)
Fut clean deco ful on he calibration pump (1)
‘er wericaton

17. nal calibration pump (1 in ine place of one of
‘the Pumps according 1 re procedure in Stop 9

Loosen bolt (26) wih 189836 Wronc (8 or
P4206 Wrench, Turn the ler (18) on shat (24)
enough 10 move the top of plunger (28) of
Calbeaton pump (1) beow top surlac (27 of
albraton pump (1) Tighten bot (26) ust enough
for tow (18) 1 hod plunger (28) statorary,

EF Bat A) 51206 Mic

NOTE: When bot (26) nas the correct torque, pushing
th a smal aroun of force on ver (18) tough the
rech moves purgor (28) in ealbraton pump (1.

19. Move shal (24) toward the governor to remove
end pay. Thon push down on lever (18) Iougn
the wronch unt top of plunger (6) I aması even
with lop surface (27) of calration pump (1) as
shown

Penge Poston
(Carr par. (Top surac carton pup.
e

20. Check cal inicator (4) according to Step 10. Ten
pa dal indicator (4) n place over the carter ol
Cabrio pumo (1) an hol it thre gi. Now
move plunge (28) of alain pump (1) By
Pushing on eve 18) ough the wench, Stop
moving tne plunger when the dal cal a
“approximately 0.008 mm past 0.000. Tighten batt
(26) 1028: 02 Nem (4 & 2 bin)

NOTE: When moving plunger (28), make sure nat the
last direction of plunger (28) movement isn tn un
Grecton I lunge (28) goes up 10 far, move plunger
(28) down lo a postion bow that ested. Then move
unger (28) up 1 the desred poston.

NOTE: The action of tightening bot (26) usualy
‘changes the reading on dal incicator (4) by
fpprocmately (0010 mm) in the minus arecton.

Move shaft (24 toward tof several mes to remove
Garance in the Inkage Dal nácator (4) reading mus
1e (0.000 0.010 mm) as shown

hen the pump ealrain ie correct make a ecard
an then do the same proben or al ine other
Pumps,

NOTE: When calbrating pumps on the “save” ide
ide opposite fem govern conta lever (16) ur
‘lamp 28) on both ands o he Sleeve shaft as chown,

Ins Cao On Save Se
en

Governor Adjustments

NOTICE
A mechanic with training in governor adjustments is
ne only one to make the adjustment to the st point
rom

Engine
facon

must ba checked with an accurate

Low Idle Adjustment

NOTE: The correct LOW DLE rpm is give in the Fuel
Seting And Reale Information Fo

To help prevent an accident caused by parts In
rotation, work carefully around an engine that has
been started,

Start the engine and run und the temperature of
formal operation 8 each, Check low e om wth
o load on ha engine. an adjustment & necessary,
Ute the procedure that flows

‘oyatnat OF Low I
une beer ow Lot

cutre OF Law se RP
amo a tro e.) Lea (Cone

just tre LOW DLE rpm, star! the angine anc
the governor inthe low de positon

Loosen lock (2 or ow idle screw (1) Turn the low
ide screw to get the corect low io rpm. crease
‘engine speed an return t low «de and chock low e
speed again. Tighten the lock

‘Checking Set Point (Balance Point)

The engine set points an adjusted special and is
important tothe correct operation of ho engine High
ide rpm is NOT an adjusted specticaion. Set paint
(formen balance pois fuload rom pus an
adktonal 20 rom. Sel point isthe rom at whch ho fuel
ating aclustment grew and stop or Het toquo sorna,
st sar 0 make contact. AL tsrpm the fue seting
Adjustment screw and stop or fst torque spring st
have movement between Iham. When action ad is
pon the engin, the (ul sting adjustment sere
and stop or fst torque spring wil become stable
against each other. Sel points controle bythe fuel
Sting an the high i adjustment sow.

‘There isa new and more accurate method or checking
tho "set pont fermerycaled th balance paint, ofthe
engine. th tools for the new method ar mot
valable, there fan alternate method for checking the
“set pont”

a

614080 Engne Set Port Inner Grau

‘Te 644060 Engine SetPoint Indicator Group with the
6V2100 Mttacn can be used fo check the sat pont
Spec hstucton, Form No. SEHS7931 gves
instuctons or insalaion and use of ths tool group.

I the set pont is comect and the high ide speed a
within specticaion, the fuel system operation ofthe
engines correct. The set pont lo th engine 8:
A. At 20 rom greater than u oad spo,
8. Too rm where the ua sting adjustment
Seren and SI 0 rs que Seng us make
contact.

Use the procedure that follows to check the st point
Make reference 1 Techniques For Load
SpecalInsiucton, Form No, SEHS70S0,

1. Connect tachometer which has good accuracy to
the acometer eve

2. Connect the cip eng of the 670500 Orc Teste to
‘ras terminal crow (4) onthe governer housing.

Connect he ther eco the tester o a aceon the

‘hal system whch 5a goed ground connection

(Bess ema sen

Work carefully around an engine that Is running.
Engine parts that are hot, or parts that are moving,
can cause personal injury.

3. Start the engine

4. With the engine at normal conditions fr operation,
ran te engine at high ide.

5. Make a record ol he speed of he engine at high
ide.

6. Add load on the engine sow ut tho reut tester
Sight ust comes on fminmam ight outa). Tis is
the sat point

7. Make a record ofthe speed (om) at the st point

8. Repeat Step 6 several ines o make eure that he
roading is comect

9. Stop the engine. Make a comparison of the records
from Stops 8 and 7 wi the inormaton from tro
Engine information ae. ho Engine information
Plate s po avaiable, soe tho Fuo Seti And
lato Information Fe. The tolerance forte cet
points 10 rm. Th tolerance or Ie high ide
pen is 80 rpm the reading trom Stops 5 and 7
Ar win te tolerance, no austment = needed.

NOTE: Is possible in some applications that he high
ice rom wi bo less than the loner mit Ths can De
caused by high parasite loads such as rule
Pumps, compressors, le

‘Adjusting Set Point (Balance Point)

1. Nine set point and he high ile rpm are within
tolerance, no adjustment sto be made.

2. It the set pont rpm snot core, remove cover 3)

|oosen loca (6). Tum adjustment crew (Sto
Just he set poli the mic pont of the
torres

3. When the at pints correct chock the high cle
rpm. The high ile pm most not be more than the
Ron Imt of te toerance

1 the high ile rpm is more than the high Im o the
tolerance, check he governor spring and Mgr I
the high id pm sees than the low mt of he
talerance, check for excess parasite loads and then
the governor spring and og.

Engine Speed Measurement

Tool Mesa
De 7

BD nan Une Soo Poms Bos

‘The 6Y3121 Mulitch Group can measur engine
specs rom atacrometar dive onthe engin, also
has the aby to measure engine speed rom visual
engine parts raion,

Sara Mama Coe

Special instuction, Form No, SEHS780 is wi the
8Y3121 Much Group and gives instructions forthe
test procedure

The 6V4950 injection Line Speed Pckup Group is
another diagnosis tol accessory that ean be used
‘th te 612100 Multach, can be used on al
Catrpilar Diesel Engines ogugpoe with 6 men (25 in)
Single wal fuel mecton ines. Win ths pickup gro,
tengo sposs can bo measured quickly. automaticly
and win an accuracy 0° 1 rpm.

6650 econ Lin Speed up Goes

Special instruction, Form No, SEHSB029 swith the
‘group and gives nsructons for use ofthe V4950
nection Line Speed Pickup Group.

Air Inlet And Exhaust System

Restriction Of Air Inlet And Exhaust

There willbe a reduction of horsepower and effsency
ofthe engine if there i à retscton in th ar nt oF
‘exhaust sytem.

‘Ar ow trough Ihe ar cleaner must not have a
testrition of more than 635 mm (25 In) ol water
torneo in pressure.

Back pressure from the exhaust (pressure ciference
measurement elween exhaust out obow and
Amesphere) must rote more than 685 men (27 ir) ot
‘water

Measurement Of Pressure In Inlet
Manifold

The efficiency of an engin can be checked by making
a comparison of he pressure Io nt mando wth
the information gwen inthe Fuel Settng And Reed
Information hehe. Ths last used when thre à
decrease of horsepower fom tho engine, yal ner s
o real ign ofa problem wih he enga

‘The correct pressure fo the inlet manos i oven in
the Foal Seting And Related formation Fee,
Development of hs information 1 done wih thes
condon.

a. 747 mm (294 ir) of mercury barometric pressure
D. 229°C (85°F) outside ar temperature
0. 35 AP rad ua

Any change fom these conditions can change the
Pressure nthe inet manto. Outs as that has
iger temperate and lower barometric pressure than
‘Given abono wil cause a louer horsepower and lower
il mantal pressure measurement than gven i ho
Fuel Seting And Reed information Fire. Quise ar
‘hat ha a lower temperatura anda er baronne
Pressure wil cause higher horsepower and a hgner
ie mantold pressure measurement

A rence in fuel rating wil alo change horsepower
tard the pressure n th met mano. the tues
fated above 35 APL, pressure tho ill mantol can
be less than given in he Fue Sting And Rated
Information Fie. I the fuels rated below 35 API, the
pressure nthe not manto can be more than given
Inthe Fo! Seting And Rated Information Fee. Be
Sure That The A inet Ang Exhaust DO Not Have À
Resten When Making A check Of Pressure In The
ret ano

Use the 105470 Engine Pressure Group to check the
pressure nthe et mals,

USO Epa Pro Grip

‘This group has a gauge 1 rad pressure In he net
‘marie. Special nstucien, Form No, SEHSBOOT 1
in he tool group and gies information forts vse,

TAS

Turbocharger

Every 7200 hours or any unusual sound or vibration
inthe urbochanger is rod a quick check of bearing
Condition can bo made winout isassembing the
turbocharger Ths can be done by removing the ping
{rom the Urbocharger and inspoctng the compressor
impel, turbine wheel and compressor cover. Potato
the compressor an tune whee! assemoy by hang
ard observe by ing excessive eno pay. The
‘orang assembly shoud rotate reel with no Tupi
or binding, I there i ny indication ofthe impeller
rubbng the compressor cover or the turbine wheel
‘bing the tuba housing econstion the
‘turbocharger or replace wih anew or rebult one

End clearance is best checked witha dal indicator
‘Attach a dal ndicaor withthe indicator point on the
end ofthe shat. Move the shaft Wom end to end
‘aking noe al he otal near racing,

For the correct end play forthe turbochargers soe tne
‘Specifications Section. enc pays mare than the
‘laxmum end play reould or replace the turbocrarger.
Ena play less than the minimum end play cole
diese carbon bu up onthe urbne whee! and
‘should be isassembled for loaning and inspection

(racing Tuboctarge Rating Asay En
2e Rain sry En oy

‘A mote relato check o bearing condition can be
maca only when the turbochargers dsassemoled anc
the bearings, shalt journal and housing bore amater
can actualy be moasurod,

Exhaust Temperature

5000 na Theoret Gop

Use the 6¥5000 intared Thermometer Group 10 check
‘haus temperature §pecalnsructon, Form No.
SEHSS 140 i with the tool group and gives instructions
forthe test procedure.

Air To Air Aftercooled Systems

FREE Aa To Ar ad Tesi GE, 7
Fiese Dyrumonetr Testng Atrooer D

Visual Inspection

Inspect al a Ines, hosos and gasket connections at
exo ol change, Male sure tbe Constant torque hose
‘camps ato ghtene tothe cores! torque, Check the
truck marulacturr'sspectications fer the correct

torque. Check welded jens for racks and make sure
al brackets aro tightened in poston and ae in good
orion. Uso compressed ar to clean cocker core
blockage caused by dads or dust ingpect the cooler
‘ore fs for damage, debr e sal coton. Use a
arise soe bush wih Soap and wate to rome

Pressure air can cause personal injury

When using pressure air or cleaning, wear a pro-
fective face shield, protective clothing and protec-
tive shoes.

NOTE: When ato ar aftercooler system pars are
repaid anor replace, a ca tests recommended!

The use of winter fonts or shuters s discouraged wih
ar o ar afro systems. Winter tots can ony De
‘Used on Tuck model where tosis have shown thatthe
‘engine jacket water il overheat before the inet
mania a temperature is excessive. On these tucks,
Sensors ana gauges or alarms ar sated o indicate
angine operating conditions lore exceseio inet
mania a temperatures are reached. Check wi the
truck marutacturer on wine ron and str
opinion

Air System Restriction

Prossure measurements shoud be taken atthe
‘wrbooharger oul and inet mano, Wnon tho total
pressure Gop of the Charged al system at manu
Ar fow excood 135 kPa 4 n Ho), no al nos anc

Sole cor must be nepacle for internal aston

‘and cleaned, repaved oF replaced as necessary.

‘Turbocharger Failure

Pressure air can cause personal injury.

When using pressure air for cleaning, wear a pro-
fective face shield, protective clothing and proiec-
tive shoes.

‘The maximum air pressure must be below 205 kPa
(20 pai or cleaning purpo

IL turbocharge aire occur, removo he ato ar
(0er eae ana fuen inernaly win a saven! at
Fomoves ol and oer foregn substances. Snake cooler

to erate any trapped debris. Wash with hal, soapy
valor ins thoroughiy with clean seater: and bow dy
Vin compressed az m reverse rection of normal ai
How Carey nspect the system to make sue ts

NOTICE
‘Do not use caustic cleaners or damage tothe ater:
cooler core wil result

Inlot Manifold Pressure

Normal net mario pressure with high exhaust
temperature can be caused by cooler core fn
‘blockage, Clean the cooler co Ins, see Visual
Inspection forthe cleaning procedure to use,

Low net mantos pressure and high exraust manos
{amperatures can be caused by any ol ho conditions
that foe

1. A plugged ar cleaner, Clan or replace the ai
oaner as neodes.

2. A blockage in he ai ines between the ar cleaner
And turbocharger. A retrctons mast be removed

Coole cote eskage. Pressure teat the cocer core
52e Atercoler Coe Leakage forth cores
Procedure Io use and repr or Fiac as roces

A. Leakage from th pressure side ofthe induction
system Check and rea oaks,

5. Int mano leak. Check for loose, missing and
damage figs or plugs. Also check the mantle
Lo chinde head gasket.

Attercooler Core Leakage

T1888 Ae Toe Aro Tes op
Cru. (Car. (9) But pugs (8 Neda) Rogue and
OS

low power problem i th engine cn be the resul of
atercooer leakage. Low power, low boost reset,
back smoke, and/or high exaust temperature can be
the rest ofan aftercooler system leakage

NOTICE
Remove ala leaks trom the system to prevent engine
(damage In some operating conditions, the engine can
pul amano vacuum for short periods of time. A leak
In the aftercooler or air Ines can let dt and other
foreign material into the engine and cause rapid wear
andjor damage to engine pars.

largo cooler cor Iak often can be oune by making
‘sual nepaclen. To check lor smal oaks use the
faloning procacurs

1. Dicomneet the al pipes om thee and out
08 ofthe atercoolor cor.

(Ga 1 nan. Out ga

2. Instat couolos (1) and dust pugs (3) hom the
FTIS8% Ar to A Alecocle Test Group as shown,
rn each sido ofthe altercocie coro. Instalaon of
‘cational hose clamps on zr hoes 6
recommended to prevent re posos tom bulging
ie te after core is bang pressurzed

‘Dust plug chains (2) must be installed to the after-
cooler core or the radiator brackets to prevent pos-
‘ibe injury while testing. Do not stand in front the
dust plugs while testing.

Presse Sen
(Segura ae ont

3. Irstalroguator and valve assembly (5) on the out
side ofthe atercadkr, attach a staph

NOTICE
Do nat use more than 240 kPa (35 ps) ir pressure or
damage the eftercooer core can be the result.

aie

. Open ai valv and pressurize the afterancer o 205
Ka CO pad, Sun of a supply.

5. Inspect al connections fe ai leakage.

6. System pressure should not crop mor than 35 kPa
(pad in 15 seconds

7. ie pressure crop is more than spsciied, use a
soin of soap and waler to chock al areas of
possible Iakage and look lr ar bubbles. Replace
hoses o repair the afro or core as Nees,

‘To help prevent personal injury when the tooling is
removed, relieve al pressure in the system siowiy
by using ar regulator and valve assembly (5).

Alte esting, remove FT Tooling ard connect air
pipes on each sido ofthe alercooter

Dynamometer Test

[Arto ar altrcooled chassis dynamometer tet, in hot
‘ambient temperatures, can add a greater heat lead to
the jacket water cooing system, tector the jacket
‘water cooing syste temperature must be monitor.
Also, mnie the net a tomporatuo as. may need a
power corection factor along wih ful A, fal
temperature and basometr pressure

For engine dynamometer ests, use the FT1438
DDynamometer Testing Atrcoder. FT1438 provides an
arto water altrcooer o cont! the net
temperature 1040 (1107)

Cylinder Compression

A engine hat uns rough can have a ak a the
Vales, o valves that need acjustment. Run the engine
altho speed tat gives rough running, To nd a
Oder that has low compression or does nat have
9004 fuel gin, loosen fuel ine nut ala tu
cho purr. This wi top Ino fo o uso tat
‘yinder. Do ths for each cylinder un a loosened fu
na found tha makes no difrenoe in engine rough
runing. Be sur tight each fel nent ater the
tostbolore the next fuel ine nuts iosened. This test
‘can also be an Inca tat the el meton ie
‘wrong, 50 more checking ofthe cyinder wal be
edad

{An anal of the engine cyincer condition can be
‘one with controla pressure al tvough the cyinder
head, SpecalInstucton, Form No, GMGOIEB4
explain the procedure

1. Remove the fu njocion nozzie.

2. Agapt anal hose to 1PSS61 Adapter rsa the
‘P5568 Adaptor nthe lu mecton nozze opening
in the cylinder head.

3. Start rarkshal cotton unt he piston inthe
‘oyinder beng inspected i at TC nt
Compression srake. In ths postion. the valves of
ths cyinder wi be against hor ste

4. Force te ar into the cyinder and than chack or ar
leakage. An ai lea rom the exhaust opening ie an
incicaten of enaust valve leakage ard an ar leak
ftom the ar Ceaner ret is an ndcaton cf intake
valve leakage I the ar leakage into the
c'arkcase curing is test, the piston or piston rings
an be the cause

Valve Clearance Setting
Check and at he vave carge wih enge
Soposs

Valve clearance is measured with a thickness gauge
between the top of Ihe valve stem and the rocker im.

NOTE. Wen he valve lash (clearance is checked,
acjstmen is NOT NECESSARY 1 ne meacuremont ls
in the range cien in the char for VALVE CLEARANCE
CHECK: ENGINE STOPPED. Il he measurement à
ice tis range adusiment is necessary See the
Char or VALVE CLEARANCE SETTING. ENGNE
STOPPED, and make the sting tothe nominal
(Gesto) speciicatons in Ins Chat

Vale Gerace Sein Eng Sopped

‘ust 08% mer L025)
ads LONE

To check and make adjustment 1 he valve lash, use
the procedure that follows:

1. Remove the valve covers.

(rer, Vamo And Pop Lector

2. Turn the crankshaft OOUNTERCLOCKWSE (as
seen fom rear of enga) unt No. 1 piston at top
Center onthe compression stoke. The TOC mark
on the camper assembly wil be in algrment wth
the timing pore.

6. Turn the crankshaft 180° COUNTERCLOCKWISE
{a soon rom rear of engine) Tha TOCA mark on
the damper assembly wi De in algment wih the
timing ponte. ake adrasmer o the valves te

3. Make agusiment tothe valves lor No. 1 and No. 2 No an No 5 cjndor.

cjinders. To make the adjustment, osent
(2), Tur he adjustment sere (1) unl the fete
‘Seago (3) wl go belwsen the end ofthe valve stom
Are ie rockr am.

7. Turn the xankshalt 180° COUNTERCLOCKWISE
(as seen trom roar of engine). The VS mark on
‘damper esserbly wi be in algnment wih the
mg pointe. Make adjustment tothe vales for
No, and No 8 oyinders

Ven the adjustment ofthe valve lash needs tobe
one several limes a shot poe ol tne, can be
anindcaton of wear in a fret part ol e engi.
Find the probem and make any necessary repare to
Provont more damage tothe engine.

‘Not enough vale las, nat corectelcan be the
causo ol raid wear of he camehaft and cam
‘olowers Not enough valve las” can ao be an
iraicañen of the soa forthe valves bang bad Some
reasons fo the seas for the valvos becoming bad are
fuel nection nozzles wth celecs,restrctons otro
inet aor arty afters, wrong fue seting, o sing
Va Lac Aguero the engine on toads trat ar 10 large or tho erg
(Ant sr. (Loco. (Fou pue

Too much valve lsh, nt corrected, can be the
cause fr broken valve stom, push 1668, or song!

4, Alter he adusiment is complete, hold adjustment Tetra. À fast increase in valve lsh can be an
Screw (1) and tigen lacknut (2) o 82 + 7 Nem (24 indcalon of ay ol the folowing
#5 19. After he lockrut is ightened, check the À Danse cam Her Vas,
adlusmont again. D. Rocke arms with wear

€. Push rods at ao ban

4. Loose adjustment screw fr the valve lash

8. Brohan socket on tho upper end et the push
rod

5. Turn ie crankshat 180° COUNTERCLOCKWNSE
{as seen from rear of engine) The VS mark on the
‘camper aseamay wil Bo algement with the
tig porter Make adjustment lo te valves for
No. Sand No. 7 cyinders.

the camshatt and cam fotower show sgns of rapid
‘wo, 10k fot fal inthe ui lor ty
lubricaion of as a possible causo when making the
necessary ropas

Procedure For Measuring Camshaft
Lobes
To find be ft (A) of camshaft, use the procedure that

solos:

1. Measurement lobe height (8) of one exaust and
one intake ibe.

2. Measure base ice (C) of one exhaust and one
take lobe.

3. Subtract base rele (C) dimension (Step 2) rom
lobe height (6) dimension (Sep 1. The aerence is
actual tbe it {A}

4. The spociie (new) lobe it (A)

a
8
e

ans Lone (Ro ite)
Le et Lobe Pg (0) Bae cc
Camshaft with ol Liters:

Le) Exhaust obe 940mm (370)

(6) Make lobe 938 men (387 in)

TZ

KA
a

‘Gamat Lone at Fac its)
A La 1) Lobo rage (ae cree

‘Camshaft with Flat Face Liter:
(a) Extaust be
(0) Inte eve.

940mm (370in)
‘8.061 (357 in)

5, The maximum possible diterence between
actual ode it (So 3) and specified lobe it (Step
lis 025 mm (910m.

Lubrication System

{One o he problems in tho folowing Ist wi general
be an indication o à problem in the kbrcation system
forthe engine.

Too Much Oil Consumption

Ol Pressure is Low

Oil Pressure I High

‘Too Much Bearing Wear

Increased Oil Temperature

Too Much Oil Consumption

Ol Leakage on Outside of Engine

(Chock tor aakage at the seals at each end ofthe
Crankshaft. Look for leakage atthe ol pan gasket and
all ubrcaton oystem connections. Check lo se où
Coming ut ofthe crankcase breathor. Tis can bo

caused by combuston gas leakage around ne pstons
À ty crankcase treater val cause hgh pressure ln

the crankcase, and this wil cause gasket and seal
leakage

Oil Leakage Into Combustion Area Of Cylinders

Cl leakage into the combustion area a he cyinders
can be the caus of ue smoke, Thee are four
possble ways or ol leakage into the combustión area
ofthe cyinders

1. Ol leakage between worn valve guides and valve
stone

2. Worn or damaged piston rings or city où return
holes.

3. Compression ing not instale correct.

A. Ol leakage past the seal rings in the impeler ang of
the turbocharger shat.

Too much al consumption can also be the resul ot
using ol wih the wrong viscosity. Ol with a thin Jom)
Vasco can ba caused fom dor tal gang the
rañkcase, o by the engine geting too het.

Measuring Engine Oil Pressure

An ol pressure gauge that has a detect can gue an
indication of ow ol pressure.

‘The 1U5470 Engine Pressure Group can be used to
check engine ol pressure.

1U6ETO engen Proa op

This tool group has a gauge to reac ol pressure inthe
angine Specal nsteton, Form No, SEMSESS th
the tool group and gues instruction fr the It.
procedure.

1. Bo sure hate engine is Id to the coe level
wi SAE IDD ok any other viscosity of ols
‘Used, he information inthe Engine OÙ Pressure
(Chart does not ap.

2. Connect the 11470 Engine Pressure Group to the
‘ain ol mao at locaton (A) or locaton (8,

Où Presa Tot Loca
(ROT run tico a ot cook

jee = \
(Qu Pressure Tet Laon
(Ol prone tart Eon at an of pt pice ha

3. Run the engine to got the ol temperature at 83 +
EC (200 = 10.

4. Keep the ol temperature constant wth the engine
atthe rel rpm tom the chart, and eae the
pressure gauge.

Engine Presa 12900
sad tance onto oc so OF)

est Location Pressure
A Sia 550 Pa 5 10D
o 345 0520 Pa (501075 pa)

lt results do not fall within the pressure range given
in the chat, find the cause and corel Engine
ce or a retin in engine I can bo tho result
engine operation is continued win ol pressure aus
tne ange

Oil Pressure Is Low
úCrankcase Oil Level

‘Cheek the level ofthe où in the crankcase, Ad oli
needed, possbie forthe cl lue 0 be 10 lar
Below the où pump supply ube. Thi wil rsut inthe
dl pump not having th aby fo suppy enough
Aubin 1 the ergie components.

Oil Pump Does Not Work Correctly

‘The int screen of he supply tube for he ol pump can
have a reaction. This wil tu in cavtaton and a
loss of ol pressure. ir leakage in the supol sde of
the ol pump wil lso causo caviaten and os 0 où
pressure. If the pressure reguaing valve forthe system
[s hal in the open (unseatod) poston the Iria
System can nol gt to maximum pressure. OÙ pump
as thal have 100 much Wear wel cause a reduction
Inox pressure.

OUI Filter and Olt Cooler

A ty où iter wal cause a reduction in ol pressure.
‘When the ol titers Hilo win a, aretriton of of
fw through the er and a redaction of Hill ol
Pressure à a resul

‘The bypass valve wil cause the Now of oto go around
the file cements when there isa reduction 1 the flow
trough the elements, When the bypass valve open,
‘ol that ot tee 6 period 1 fw through the
engine. To core ns problem, install a new
Capa ter

‘Look for a restriction inthe ol passages o he ol
‘coal. the ol cook has arestricton, the cooker
‘Bypass valve in he o ee baso wil open, This wil
cause the flow of otto go around the of cooler Theo
temperature wil be higher ran normal when the
engine running, The ol pressure ol the engins val
Become low he où cooler has rstricion

“Too Much Clearance at Engine Bearings or
‘Open, Broken or Disconnected Oil Line or
Passage in Lubrication System

(Components that are worn and have too much bearing
Clearance can cause oi pressure o below Lou ol
pressure can also be caused by an ot ne or al
passage tha open, broken or disconnected.

Oil Pressure Is High

Ol pressure wi bo high the bypass valve forthe ol
Pump can no move fro the ee postion.

Too Much Bearing Wear

hen some componanis of the engine show bearing
\wearin a shor time, the cause can bea restriction In
the 01 passage. À broken ol passage cen also be the

the gauge fro pressure shows the corec où
‘pressure, bu a component worn because is not
‘eting enough lutricaon ok al ine pascage 1 où
Sol lo thal component. A restriction à supply
Passage wi nat et enough ibicaton gt to à
‘Component and this wi cause ary wear

Increased Oil Temperature

Look for a restriction in th ol passages of the ol
(Cor. he ol coolr has a restriction, the ot
temperature val be nigra tran normal when the
‘engine s operated, The ol pressure ofthe engine will
ot got low jst Because the ol cocer has a estcion

Also check the ol cooler bypass valve to see if tis
holaa the open poston (unseated), Ths condition wil
Tat he où tough he valve instead ofthe 03 coo,
and où temperature wil increase.

Cooling System

‘The coding system i a pressure type wih regulators
atthe out, the cookng system i equipped wth a
shunt ine

A pressure type cooling system gives two advantages.
‘Theft advantage i al he cooing System can have
safe operation a à temperature thats higher than the
normal boing (steam) pont of water. The second
‘sovaniage i tra this type system prevents can
(fou pressure bubbles suddenly mado nids by
‘mechanical forces) nthe water pump. Win this type
System 8 mare dificult for an ay r sam pocket to
coating system.

‘The causo fer increased engine temperature i
‘generally because reguar Inspections of the cooing
System were not made. Make a usual Inspecton oho
(ing system Der a est is made wih test
equpment

Visual Inspection Of The Cooling
System

1. Check coolant vel in he coc syto.
2. Look foros the system.

3. Look tor bent radiator fins. Be sure that air flow
theough the radiator does not have aston.

4. Inspec ho dv bet forthe fan.
$. Check for damage tothe fan blades.

6. Look fo ai cr combustion gas inthe cooking
system.

T. Inspect the pressure cap and the seating surace for
the cap. The sealing surface must be clan,

Testing The Cooling System

Remember than temperature and pressure work
together. When making a dagnoss ola cooing system
Problem, temperature and pressure must both be
necked. Coding system pressure wil have an asc:
fn coalng system temperatures. For an example ok
tthe chart fo sue the Bt of pressure and Reg
above a lve on te bong (steam) point of water.

pons. cece Sst asun

Too sede
STORE Tarr Thomoneter Ge
{12760 612700 Bone Pow naar GOD
ZA AVR! Mann Groso

959140 Coaing Ste Prssunäng Pong Grup

The BTO470 Thermistor Thermometer Group's use in
the dagnoss of overeating (engine netter than
ema) er overccing (engine cooker than normal)
probiens. This group can be use to check
Temporales in several dort parts of te cooing
system. The testing oc is n Special nsructon,
Form No, SEHSBAA6.

STO mama remar Grup

"Tha 812700 Blowoy/Ai Flow Indicator Group is usec to
‚check thee tow through the radator core Te est
procedure In Special instruction, Form No,
ESS

872760 Bent Fou eto Grom

‘The 6V9121 Mutiach Group is used o check he fan
speed. The testing procedure fein SpeclInsructen,
Form No, SEHS7807

brates muaa ao

Pressure Cap Test

Took Needed ]

[Beat casing Spon Presa pomp Gam 1]

‘One cause lr a pressure loss inthe cooing system
(can bo a bad sea on the pressue cap o he syslom
Irspect the pressure cap caretly. Look for damage lo
the soa! of tothe suraco that seas. Any foreign
material or deposi on the cap, valve, Sal or surface
thal seals must be removed

“Te 958140 Cooling System Pressurizing Pump Group
is used fo test pressure caps and o pressure check
tho cooling system fr tak

Types Sourate O Frese Cap
(AF Sexi ae las an aa

To check Ih pressure cap for ho pressure that makes.
the pressure cap epen, use the procacure th oo

DO NOT loosen the flor or pressure cap on a hot
engine. Steam or hot coolant can cause severe
bums.

1. Alter the engine is cool. loosen tho pressure cap to
{he fst stop and la the pressure out ofthe cooing
‘system. Than remove the pressur cap

2. Put th pressure cap onthe 958140 Coding
System Pressuizng Pump Group.

852140 Con Sy Preset Pare Grp

3. Look at the gauge or the exact pressure that makes
the pressure cap open.

4. Make a comparison of the racing on the gauge
vin te conc pressure al which the pressure cap

NOTE: The correct pressure that makes Ih pressure
30 open onthe pressure cap ands also i he
Spectications.

5. Ifthe pressure cap is bed Ins a now pressure
cap.

Radiator and Cooling System Leak Tests
(Systems That Use Pressure Cap)

To test the racator and cooing system fr leaks. use

the procedure that olows:

DO NOT loosen the filler or pressure cap on a hot
engine. Steam or hot coolant can cause severe
bums.

1. Alter Ih engine is 0ol losen the pressure cap to
the fist stop and let the pressure out ofthe coding
system. Then remove the pressure ca,

2. Make sue the coolants over the top ofthe radiator

3. Put the 983140 Cooling System Pressurizing Pump
{Group onthe radar

4. Got the pressure reading on he gauge to 20 kPa (3
SI more than the pressure onthe pressure cap.

5. Check the radio lor cutside leakage,

8. Check al connections and hoses forthe coding
system for outside oskage,

7. you de not see any usd leakage and the
pressure reading on the gauge is si the same attr
5 mnutes, ne radiator and cocing system do not
Rave leakage. ne reading on the gauge goes
own and you do not see any curse leakage,
‘here i leakage on the inside ofthe cooling system.
Make repars as receseary.

Gauge for Water Temperatur

ifthe engine gets too hot and 2 loss of cocantis à
problem, a pressure ss inthe cooling system can be
{he cause. te gauge for vate temperatur shows
thatthe engine peng Lo ho, look or coolant
leakage.

Ita place can not be found where there is coolant
leakage, check ne accuroy o! he gauge for ater
temperature, Use the 870470 Themstor Thermometer
Group

(Work carefully around an engine that is running,
Engine parts that are hot, of parts that are moving,
‘can cause personal injury.

Start the engine. Put a cover over part ofthe racatr
The reading on the gauge for water temperature must
be the sare as the reading onthe thermistor
‘thermometer.

ypc Ex

Temperature Regulator
Test procedure for water temperate regulators
1. Remove the reguater trom the engine

2. Heal a pan of water to a temperature of 92°C
care

3. Hang the regulator in the pan f hat wale. Put he
regulator completely under water Do no! a the
reg make cons! uh he pan.

A. Keop the temperature ofthe water at 92°0 (197)
for en minus, Mak sur the water moves aroun
This keeps al of th vater atthe same temperaure.

5. After ton minutes, remove the equator and
inmedataly measure the distance th regalo is
‘pence, The distance must not be loss han 9785
en (1490

Water Pump Pressure Check

E |

er Busing al

The pressure at the cute for the water pump tes the
shunt system and waler pump are operating conecty,
To check the pur pressure, ital pressure gauge (2)
Inthe font cover. Me pressure must be minimum of
105 kPa (15 ps at 2800 rpm.

the Pump pressure I los than the minimum
pressure: Fe, check the vert lube between the
facto: top tak and th surge tank; must nave an
Inaide daretor of appxonmatey AB mm (19 in,

0d check to es that the shunt Ino has a minimum.
isi clameter of 18.1 men (75

wv

Phi; 7

om

ange nun
aero
BETT ar 21950198 Presse Gauge

oe O1 er Corne

Tho tron housing has several Pag thal give access Io
water passages sie the rousing, For he core
Ac008S pont o instal hoate hose, see the Locations
Of Heater Comactons pure.

Dynamometer Test Caution

To prevent possible damage to an engine while testing
on a dynamometer, the water temperature regulators
‘rust be installed and shunt Ene (2) connected a
shown

gui comm To rg
[or Eng Tower Gove. 1) run

E
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LORO TENSOR DU mo an 0 of pin ted nd tng. amer

Basic Block

Connecting Rods And Pistons

Use Ihe 589068 Piston Ring Expander to remove or
instal piston rings

Use the SP3524 Piston ing Compressor to instal
piston into coyincer bock

Tighten the connecting rod ms inthe folowing sep
sequence:

1. Put 22608 Thread Lubrient on bai treads and
seating surfaces of cap and nut

2. Tighten both nus to 40 4 Nem (80 31 9.
3. Puta mark on each nut and cap.
4. Tighten each nut 60° from the mark

‘The connecting rod bearings shou tightly inthe
‘bore inthe od. bearing nt or backs are worn
(trete), check for Dore Sze a ths is an inicien of
‘wear because of looseness.

5P3519 Piston Ring Groove Gauge

ASPO519 Pston Ping Groove Gauge is avale for
hacking rectanguar ng grooves. For ncrucbons on
the use of the gauge, see the Guideline For Reusable
Parts Pstons And Oyinder Liners, Form No.
EBRIO!

NOTE: The 5°3519 Piston Ring Groove Gauge is usec
10 check the lop ring groove only

Paca fg Grave Gage Chart

Connecting Rod And Main Bearings

Bearings are avaiable witha smal inside diameter
than the original size bearings. These bearings are for
‘rankshats that have been "ground" (made smaler
than the orga size) Man bearings ao avalane wth
‘larger ous diameter than the orginal size
bearings. These bearings ae or oyinder Docks that
ave had tho bore for he man bearings "bored"
(mado larger than tho orginal sz).

Flywheel And Flywheel Housing

Heat the rng gear o nal. Do not heat to more than
204°C (400°). Metal the ring gear so the chamfer on
the gear teth next Lo the starter pon when the
Ayamea instales.

Face Runout (axial eccentricity) of the
Flywheel Housing,

1 any method other than gwen hee is used, always

1. Fasten aca inceatr to tho crankshattfange so
‘the andino Indicator wi touch ne ace a ne
‘wheel housing

2, Foro the crankshaft othe rar before reaing the
incieater at each point

Frees Da acer Grp

3. Wah theca inceatr sot at 00 mm (00 i) at
locaton (A) tum the oanschaft and ead Ihe
Indcator at locators (8), (C) and (0).

4. The diferenoe between loner and higher
rmossurements taken ata four pots must not be
‘ore than 025 mm (O10 in), whch the main
Dermisibe face runout (axal eccentricity) o the
‘ywneel housing

ero»)

sens Aeorrom)

Face An OF Te yes an
en (hme sce (O Topo Lat ae

Bore Runout (Radial Eccentricity) Of The Fiywheet

Housing

1. With the dal ndcatr In postion at (C) adjust th.
al inccatr lo 0.0 mm (00 in), Push Ih crankshaft
D against the top bearing irte the measurement
‘er bearing clearance on ine in column (0)

2. Divide the measurement rom Step 1 by 2. White this
‘umber on Ino tn cours (8) & (0)

cero»,

nc Aworrom)

‘Gran Bo Pura OF mo pare Home

4. Tun the crankshaft courtarcockioe to put the di
indicator at (B) Write down tne measurement nthe
chart

NOTE: vto the cial idicator measurement with
ves postive (+ and negative (-) notation (sgns) Tis.
¡necessary for making Ihe cacas nthe chart
‘owecty,

5. Turn the crarkshaft counterclockwise to put the dal
incicato at (©), Write the measurement nthe chart.

6. Turn the crarkshaltcounterctockwie to put the dal
inciato at (D). Wits the measurement in tho chart

7. Ade ines 18 by cours,

8. Subtract the smal number rom the larger number
inne ln columns (8) & (D. The rests the
horizontal eccentricity” (et el round. Line
com (Ci tho vera! eccentric.

‘T2086 Der cnr Gras aod

3. Turn the crankshat to put the dial Indicator at (A).
Aust the dl incite lo 0.0 mn (00 i).

9. On the graph tor tol eccontcty na he point of
intrsecton o hs ines 10 verlcal con and
horizontal cccenticty

en

]

ES

3

ASCEPTABLE

=
\

E

ES

i
o)

TOTAL VERTICAL eocenrmicry
T

EEE
(ote (eo
TOTAL HORIZONTAL EGOENTRCITT

10. If the point of intersection iin the range marked
"Acseolae the bore isin agnor. the point
of intersecton Is inthe range markad "Not
Accoptabla" he Mae housing must be
changed

Face Runout (Axial Eccentricity) Of The Flywheel

1. Istal ho dalindiator as shown. Force the
‘rankshalt the same way betore the indicator is
‘ead 20 the crarkahalt end clearance (movement)
ways removed,

ot the cial near to read 0.0 mm (00)

4. The ference between the lower and higher
measurements taken ata four pots must not be
‘ore than 0.18 mm (006 1, uen ete maxima
pemisetlo face runout (axial eccentric) o the
ure)

Bore Runout (Radial Eccentricity) Of The Flywheel

1. instal te ia indicator (3) and make an acjustmert
ofthe universal attachment () so 1 makes contact
fs shown,

reci Face Run Part

3. Tum the hee anc read the inccator every 90"

ecc ore una OF The Pr!
rising ests Banane orne

cin Foret ach Pot Bering Bae

2. Sel the da Indicator to road 00 men 00 in)

3. Turn the fee! and read the indicator every 9°.

4. The diterenoe between the ower and higher
mossurements taken at al four ponts must act De
‘more than 0.15 mm (006 in, which no maman
ermssil bore runout rail accent) ofthe
wea

5. Runos (ecenticy) ofthe bot forthe pit

‘bearing forthe Ayo clutch, must rot exceed
(0.13 mem (005 i}

Electrical System
Test Tools For Electrical System

(Bes wary aa Teste

810800 AC/DC Cao. On mt

BVTOTO Honey Duty Da man a

ara

eur Day Data Matinee Y

‘Most ofthe tests of ne electrical system can be done
on the engin. The wring insulin must bein 9906
Condition, the wie and cable connections must ba
Clean and tight and the battery must be fly charged.
ithe avenge tet shows a else na compenant,
remove the component for more testing

‘The service manual Testing And Adustng Electrical
Components, Form No, REGDOSOS has compete
speciicaons and procedures fer tho components ot
the starting cxcul and the charging era

vas eatery Lan Tester

Tre 64890 Batery Load Testers a portable unt in a
metal cae or use under fa condilcns and hgh
temperatures. ean bo used to lo tat a 6,8 and
12V bañeres. Thi totor has two heavy dy oso
‘cables tht can easiy be fatenad to no ballory
terminals, and load adjustment kndb on the ent
‘pare! permits a current range up to a maximum ot 700
amperes. The fester aso has a thermometer o show
‘en the safe operating temperature mt ofthe unit
has been reaches.

NOTE: Make reference to Spocal instruction, Form
"No, SEHSH268 for compte information fr use of the
644390 Battery Load Tester.

‘T0200 ACIDE Comp On Anne

The 810900 AC/DC Ciamp.On Ammeteris a
compet porabl, sal contained instrument that
‘lows eotineal curert measurements to De made
“soul breaking the shout or dating the nsaton
‘on conductors. À cinta play located onthe
ammete or reading curentGtectinarange from 1
o 1200 amperes. Fan optional 66014 Cable
Gone betwen tis ammeto and one of the dial
‘multimetrs, current reacings of ess than 1 amparo
can then be read erect om the pay of the
tinier

‘A eves used to open the jaws over the conductor {up
lo a damator of 19 mm (75 m) and the song ade
Jaws are than closed around the Conducke or cure
mesurer. À tigger switch hat can be locked in
the ON or OFF positon i used to tum on the ammater
‘When the ur. on tigger is eased, the last curt
reading shal onthe dislay fr 5 seconds. This
‘lows accurate mezsuremont 10 be taken in Imiec
‘access areas where the digtl splay isnot is o
ho operator. À zero cont ls proved for DC
‘operation, ar power ortho ammeter is suppied by
batteries located incio the handle.

NOTE: Make reference to Special Instucton, Form
No, SEHS8420 for more complete information or Use
‘ofthe BT0900 Clamp-On Ammate.

TOTO Monay Daal timer

‘The 6V7070 Heavy Duty Digital Muitimeter is a
completely potable, hand held instrument win a Gta
spa. Ths matmeter ls Bult wih extra protection
against damage in eld appicatons, and saupped.
“th seven functors and 2 rangos. The 6V7070
Milimaer has an nstant ohms near trat ports
connus checks for fast eur Inspection. 1 iso can
De used lr trouteshootng small valve capacitor

‘The 6V7800 RegJar Duty Digital Mutimete (a low cost
pl othe Heavy Duty Multimeter) s aso aval,
Fowever, the 6Y7800 Multimeter does not have the 108
range oo stan ohms feature ofthe 6V7070
Mimet

NOTE: Make reletence to Special instruction, Form
No. SEHST734 for more complete information for use
line 6V7070 and 6V7600 Madtmates.

Battery

Never disconnect any charging unit circuit or bat-
tery circuit cable from battery when the charging
Unit is operated. A spark can cause an explosion
rom the flammable vapor mixture of hydrogen and
‘oxygen thatisreleased from the electrolyte through
‘the battery outlets. Injury to personnel can be the
result,

‘The battery cut is an electrical oad onthe charging
unt, The oad à vrable because ofthe concen of
‘the charge nthe battery. Damage 1 Ihe charging unt

vl result the connections (ther postie or negative)
between the batery and Crargng unt are broken wie
the charging unt operation. Tis because the
battery Bad lot and there san inca n charging
otage. igh vote wil damage, not ony the
rar un, but also the regale and ator oloctca!
‘components

Load test a batery that does not ho a charge when
in use. To do ths, put a resistance across the main
‘Connections (terminal) ofthe batery. For a6, Bar 12V
Battery, use atest load of Ines mes the amperc/rour
rating ine maximum ts! lad on any battery 500
pers). Let ne test ead remove the charge
(Bschargo) ofthe batter fr 15 seconds and ith the
{est ad stil apple, test the battery vollage. A BV
‘ater in good condíion wit show AV; and BV
Dates wil show U; 12V battery wil show SV. Each
Gel ofa batery in good condition must show 1 6V on
ner 26,810 12V Daten

Charging System

‘The coccion of charge in the battry at each roger
Inspector wil snow ne charging system operas
correctly. An aiment necessary when the batery
is constaty in a low condhian of charge or a large
‘amount ol vaterisnezcoó (more than ore ouncn of
‘water por col por week or per every SO sovoe hour)

en itis possibe, make a est of the charging unit
and vllge reguator onthe engine, ar use ng
land components nat ae a permanent part of he
System. Of engine (bench) losing wl give atest of
the charging unt and vltage regalor operation Ths
testing wil ge an nccaton of needed ro. Alter
repars are mado, again make a test Lo give pro! tral
the unis ar repare to thee original condition of
operation,

Before the star of onengine testing, he charging
System and battery must be chacked as shown in the
slaps that folow

1. Batery mat be at east 75% (1225 So Go uly
‘hargod and hel ight a place. The battery oler
‘ust nol pul 100 much sess on ro battery

2. Cabos betweon the battery, starter and engne
ground must be the correct size. Wes and cables
Must be re a coroson ang have cable support
‘lamps to prevent sress on battery connections
(temas)

3. Leads, junctions, switches and panel instruments
that have drectrltion to Ihe charging creat must
‘ive comes! ercut conto.

A. spect the ve components forthe charging unt
to be sue thay are ree ot grease and ol and have
the aby to opera the charging Ui.

Rares

40

=>

Alternator Nppondenso
Delco emy
No acjusiment can be made to change th rat ol

charge on hs alenator reguator. ao of charge ls
ol correct, a replacement 8 nocossary

ya

.
ma, at »

964574 Atar Stow,

No adjustment can be made to change the rato of
‘charge on th aerator eguatr ate of charge is
hot Conecta teplacoment necessary

Delco-Remy Alternator; Pulley Nut Tightening

‘Tighten ut that holes the pute to a torque of 100 + 7
‘Nem (795101) win tho loos shown

s Teck To pn Mera: Pay hut
(161781 Tre Men. 601898 Asse (alto w
er 0 Ira CF 16 Soc i) M1 Comtat Mero

Ferre Wrenn

No acfustment can be made to char
charge on this alrraorreguator. vate of charge is
nol comet, a replacement necessary

‘Starting System

Use the mutimeter in the DOY range to fina staring
system components which donot function.

‘Mowe the tart contro! suo to activate the starts
soienid. Starter solend operation can be heard as
‘he pion of the starter motor ls engaged with the rng
(eat on the engine mes,

11 he solenoid forth starter motor wil not opera, is
possible thal the euren rom the battery 6 not get to
‘he solenoid, Fasten one iad of he raster to o
connection (termina) forthe battery cable on the
solenod. Put the oer lead to a good ground. À zero
‘lading ls an indication that ther isa broken oust
trom the battery. More testing necessary when there
isa voltage reading on the mutimeter

The solenok operation also coses the electr circuit to
the motor. Connect one lead ofthe matimetr tothe
solenoid connection (termina) that i fastened lo the
motor Pat the te lead toa 9000 greung. Activate
the starter solenod and lok a the mutimetar A
reading of battery valtage shows the problem is othe
motor The motor most be removed or free testing.
zero reading on the mulimotar shows thatthe
Solano contacts de nl coge, Ts ı an nceaton of
the need for repair o the solano or an amant 10
‘be made 10 ho Starter pin clearance.

‘Make a teat with one multimeter ead fastened o the
‘connection (trial fo the smal wee at the solia
arc the creado the ground, Look atthe
‘ultimeler and activa the starte Soleras, À voltage
‘reading shows thal the problem i inthe sleno. A
Zero reading à an indication thatthe problem i inthe
‘tant Sch ce no wre for he start Seth

Fasten one mutimeter ead to the start swich atthe
‘connection (trina for the wie from the ballry.
Fasten the one lec toa good ground. À zero reading
indicate a broken cet tom the ballery Make a
(Check ol the circuit breaker and wing, hero isa
lage reading, the problem i nthe start sich or in.
the wos forthe sat san.

A starter motor that operates oo slow can have an
‘overoad because o! oo men tilo i he engine
eng started. Sow cporaon ofthe starter motor can
‘als be caused by a short cc, loose connections
‘andor din the motor

Pinion Clearance Adjustment (Delco-Remy)

nen the solenoid is instala, make an acjusimant of
the pinion clearance. Te adustrent can be made
vt the sarter mejor renewed

Conran or Chasing Pron Curae
(Dees fama rer oc tm ao

1. Insta the solenoid without connection (1 rom the
MOTOR connection (emnal on solenod to the
mater

2. Connect a batory,o he same voltage asthe
‘selene, 1 the terminal (2) marked SW

3. Connect the other ice of battery to ground terminal
®

4. Connect for a moment, a wo trom the solia
connection (termina) marked MOTOR to the ground
‘connection (terminal) The pion wil shit to crank
positon and wil say there u the bar ic
Sonne,

a

Ze

Prion Carre
Satan (oon) Pein race

5. Push the pion toward the commutater end to
remove tee movement

6. Pinion clearance (6) must be 831099 mm (33 0
0)

7. To adjust pinion clearance, remove plug and tum
nut

Pinion Clearance Adjustment (Prestolite)

There ar two acusimonts on this type mote. They are
end play forthe armature and pinion clearance.

End Play For The Armature

‘The correct end play forthe armature is 0.1310 076
men (005 10.080 in). The adjustment made by
adding or removing tet washers onthe commutator
fof the armatre shat.

Piion Clearance Adjustment

4. To adjust the pinion distance, connect the 24
soloed toa 12 val battery (12V solenod to a EV.
battery) as shown For à short moment, connect a
ire rom the ‘motor sts oF the solendia to the
Sd at (1) nthe commutator end, Ths moves the
Sono and vo into the cranking position

Disconnect the wie

NOTE: The ere is inthe cranking postion und the
battery is cisconnecte.

ormecsons Fer usen O Te Prion Gears
(see

2. Push the ive towar the commutator endothe
moto o eliminate any slack movement in the
rage and measure the distance Date I
outside edge of he ive slaeve and re thst
‘washer. The tance (3) must be O51 10 127 mm
(02010 050)

Pein Cesar Agusment
ng rt Batres

3. Remove the plug. Turn the acjustg nu (2) in or
ou as necessary to gel Ii distance

A. instal tne pia,

Index

‘Troubleshooting Guide (Section 4)
Cooing System 49
ic Staring Engine Granksaft Turns

Free) 40
Dict Sising Engine Garkahai Wit Not Tum,
Engine Crankana Turms Too Som) a
Fun Crankcase Où se
High Fuel Consumption Troubleshooting 432
Inrcuciton To The Troubleshooting Guide... 43
Loss Of Coaert 440
Low Power Toueshooting ans
Mtg Ans Running Rough 420
Primary Engne Tes For High Fuel Consumption 4-10
Primary Engine Test Fo Low Power 4
Probem With Vice Or Veh Operation... 416
Too Much Exhaust Smoke (Back Or Gray)... 422
Too Much Exhaust Smoke (White Or BG) 426

Vibration Treubleshocting (Engine) a

Troubleshooting

Introduction to the
Troubleshooting Guide

‘is troubleshooting quide, when flowed exacty as
shou, can be an ad lor ha sorveeman to find the
cause of existing problems. The information rom the
measurements wi lso show pro! theres any basis
forthe complaint

Bo ure to get a good deserption ofthe problem fra
the operator andjor the person who owns the vehicle,
‘What they el you about the problem can save you
time and make the repay jb fester and eas.

Low Power and High Fuel Consumption
Problems

Tre troubleshooting chars tha follow provide a
finite sequence to e folowed for a legal, one by
fone eimnabon of many varabies. The encia
Amber donot desipalo steps, but are roorences to
‘etaledinatuctons that can not be shown on the
‘chart Always read ne weiten material that
‘Corresponds with tre enced numbers on the charts.

The Primary Engine Tess consist of quick and easy
procedures that could dont tne problem with a
aim lees of te. Always make thes tests before
‘Staring the more involved troubleshooting charts.

The necessary instruments to check each problem in
‘sequence are shown on the chart. the corect
instrument & not avasabl or the tes, do not contin,
"The veni must be sent 1 a shop where the
necessary tools ae avaiable.

inensver a problem is found and coreces, always
run to test agan o that port o be sure there snot a
Comenatn 9! proems. When the problem has been
Conecta and the complaint resolved. soo te test. Do
fel continue through the compete procedure pt
because tis nero

‘When investigating possible causes, flow the ler
sequence shown, Possible causes are aranges in
‘ede om more prebablajeace! to check o lass
Erobable/more comple 1 check

Other Problems: Vehicle Or Vehicle
peration, Misfiring And Runni

Rough Teo Much Exhaust Smoke,
Difficult Starting, Cooling System, Loss
Of Coolant, Or Fuel In Crankcase Oil.

The probable causes ofa problem ar given nthe
‘rc they most common take place. Crack the
frobable causes in the same order thal they are oven
Vian troubleshooting. use the section on
recommended procedures which follow each chart to
{hack ane make the necessary caecions fe each
probable cause

Engine Vibration Problem

‘The troubleshooting chart provides a define sequence
to be lolowes for alogcal procedure to determine the
{tequency and ampitude of vation so thatthe source
col the ration can be locales and correcte

1
1
e!

Primary Engine Test for Low
Power

1. The customer must be asked many questions to
termine wether his complaint © val, or whether
hs clagross ofan actual problem correct

‘Some othe questions that must be asked are as
tolows:

a. Does poor performance occur hen the vehi is
‘peated at steady speed on a oval rad surface, or
‘hen von is puled up a grade?

A postie response to either or both of the above
Conditions woud indicate a low power (steady state)
robe, Begin with Low Power Dagnosis

b. Does the poor porormanos always oocur under the
same connie ors re problem items
(happens only occasional?

Tis isa very important ine of questionng te pursue.
‘Any constant pertrmange problem can normaly be
Agente and he problem corctes. tan mirent
problem exist, he mechanıe must be aware thal the
Eonction sony occasional. and must run certain tests
Several Les in an atom! 0 force the malluncion
condon. the condtion mol duplicated, he
Siagnoss tna! no problem ext we incorrect, and
the veni operator wal again be confonted with the
problem somewhere out on the oad.

€: Was the engine running rough or misfring when the
poor petormance was noticed?

A positive response to this questions wil indicate the
esa to sat the bad cylinders) and correct tne
problem, See socion Cyincer Misiee

2. Chock ne crankcase où level and th coolant level
‘ofthe racioor Start the orgie and get to norma
oerating temparlur. À sig loner rom (15 rom
Below ow link) shouldbe expected or he engine
in vec than the pm shown nthe Fuel Seting
{An Pate formation Fiche. This 5 caused by
‘he parasite loads ofthe angine cesos.
involved

3. With the engine running, the tote must have
travel or the governor conto lever break

‘er (go past the normal governor sop for high ide
poston) à smal amount when the rote peda is
y depreseed ll ravl snot avaiable,
‘acenneet tree Inkage tom governor lever. With
ot Inkage disconnected, fl travel governor
lever wil inate Inkage problems, andthe irknge
ave lobe acute. Limited travel ofthe
‘governor lever vil ndcat a problem wai the
‘governor.

4. On a mechane wth Ih correct raning should
(ange the se pont (balance point. Te procedure
is oven nthe Servez Manual under the subject
Governor Adusimants

5. ie set pont (banco poi) cannot be made
Gorect wth the high e adusmant sore, there 5
problem inside the governor Disasserte the
‘goiemor and check lor damaged parts 0 wong
Paris installed in he governor. Some common
problems are worn oushngs, worn spring seal, ra
Broken or wong governor png

. Before 870500 Cucul Tester instala be sure 10
teat the bh for comect operation. Test ight must
om on Men the cp othe weis places agas!
{he probe oF the ight replace batteries or DUD i
ght does not come on)

NOTE: Hight comes on and says on wien attached
to governor then ination is bad or nal wrong n
‘rq epeng group Or bras rma. This must Be
‘corracied Date tests pertomed.

7. With the coninuty ight installed. quick push
conlratorpocal al he vay 1 ho foo the (u
onto shat and govern funcions propery, the
ont it wil ome on during this tree
fccelraton uni nigh ise s maintained

Aime ight comes on, this an Indicaton that the
mechanical movement of he gover and fuel
Injection pump pats operate proper. The fu sting
‘shold now be checked. ho ight does nl come on
‘durng tee acceleration, check fora problem inside the
‘governor

8. tal 524203 Fa Service Too! Group. Check the
‘hel rao conto and the fue seting dimensions.
‘Compare th rose wh the drrensons guen
the Fal Sating and Relatos Information ihe.

ithe ft ato controlo the fue stings ae not
conecte must be adused o the setinge gven in
{he Fuel Sating and Read information Fiche. On a
‘mechan vith the carect traning shoud agus the
{bet rato conto and Tue setings The procedure 1
‘cheek ang aust he fuel ratio contol and the ue
Sang sn th Service Manual under the subject Fue
ato Control Adusimen and Fuel Sang

9. ih est pt til does ol como on. ths means
thatthe fel control shaft snot moving due 10a
problem ins tha governor or à problem ine fuel
Injcton pump housing, The governor sho be
Check Toro paris, The uel nition pump
Foushg shoudl be checked fora worn fue contol
‘haf fs ore, oF afl eo pump instala
in sleeve not engaged with the lover onthe tul
onto shat. The problem mus! be found and
oracles,

Low Power Troubleshooting

{Diagnosing with Chassis

1. Preparation o vai for wheel horsepower test
{consult dyeamometer manulacuor 6 operating
Inetactone ter apache datas on correct operation

NOTE: Aways perform the Primary Engine Tost
procedure peor vente 1 mal on chasse
‘Syramometer

Cat the alowabie its thal the customer can
‘expect from hs engine and present these figures to
in,

Carla engines ae rated wih he condition that,
lolo

Sure pene = 747 en 294 mot mery
Flora 2 20°C Sa ar co e
y 2 AP gay of 95 TOC O)

Measure and record these variables.

a. Pace vehicle on the chassis dynamometer. Ti the
ue n a way that wä not a any ad o the
ve wheels, Do no pul wheels down into
‘dynamometer div rl.

‘Check the radiator coolant eve, crankcase où leve, tre
Pressure, tre conden, remove rocks from he tre
read and connect exhaust system,

NOTICE
Recapped tres should be run on a chassis dynamo-
meter only atthe customer's own risk.

bo Operate vehicle at 60% of rated speed with
medate loc uni ol and coolant temperatures
teach ther normal ange or operation

NOTICE
there is a heavy vibration, drive shaft wip, tre
Dounce, et. do not continue with dynamometer ost
‘nti cause ot the problem is corected. Engines that
ave had newinternal parts instale shouldbe operat-
ed on à runán schedule before operation at ful ead.
For runin schedule Information, make reference to
¡General Instructions section ol this Servico Manual.

2. Put transmisson in direct gear and the cterental in
‘the Nest speed rai. Operate vell at
maximun engine speed and incase chassis
&namomete load url a Speed of SO rom ess than
ral speeds eached (continuty Ight shoud be
or. Maitan tie speed for one mite and record
the engne speed and whee horsepower.

NOTE: 1 horsepower is ow and poor mantenance is.
suspected remove ar cleanor and check horsepower
again to soe Ifa plugged ar coaner cou be the
problem.

‘a. Nine whoo horsepower is correct. ind he et
pola (balance pon the engins (pass at whch the
load sip pin jest touenes the torque sng e stop
bar), Arts por the connut ight shoud ickr (go
cf and on di)

tf tho set pont (balance point correct, then the low
[Power complant cannot be vacated, No further te or
repars ae necessary

the set point (balance point i low, see Procecure
Nod.

Ab. whee horsepower is below tho correct vale,
find the sal pont (balance pont) ol the engine (speed
al whieh the load stop pa ust touches the torque
Spring or tcp ba). At ths pont ho cont ght
‘Should eke (Go Of and on dim)

Hi setpoint (lance point) correct, see.
Procedure No 5

the setpoint (lance pol) slow, ses Procedure
Nod

4. the set pont balance oon ie low the hgh de
‘ull ave fo be increased o rls the sel pola
{balance point tothe correct rom (he pom at
‘which the Goninuiy ight pst comes on).

NOTE: Ifthe setpoint (lance po) is slow and
hgh dle has been adjusted lo maxi, disengage
ch whe maximum (rote postion maitanec,
[Now coser high ie rpm and lower than presousty
adjusted, check frameto-engine mount. À damaged or
loose engine mount may ou the Inkage in a bind and
‘Prevent maximum govern poston at ad conditions.

5. It the sot pein (balance point) was correct and the
hoe! horsepower was ow instal the 105270
Engine Pressure Group and do the wheel
horsepower let again as srown in Procedure No 2

At ful load rom, measure the boost and the fue
‘ressure. See Fuel Sting anc Related Information

Fiche to find the correct boost pressure fora parteuiar
engine (since the engine isn veri, be sure to make
reference o tne General Notes inthe Fudl Setting and
Related information Fiche to determine the corset

boost pressure with ar cleaner and mulfer installed) 1
Doostur, cneck conecten: ahead cf turbine side
of tbochargor for exhaust los and comectons alter
Compressor side of turbocharger for net a leaks.

(Check the ar inlet restriction and exhaust back
pressure.

Al fw through the air cleaner and pping must not
ave a vacuum resticton (nogatve pressure difference
Delneen almospheric ar and ar that has gone through
al cleaner) of mre than 635 mm (25 in) 0 water, Back
pressure rom the exhaus pressure diterence
Mossurement Dean exhaust ult bou and
aimospher ar) must not be mre than 1016 mm (40
ie) of water

Make a visual inspection ofthe ar int system and
check for damage to ping, rags or costructons inthe
Inet piping. or damage to tre rain cap or the cap,
‘Pushed 100 far on the ie pe. 1 no damage is found,
heck inet restrcion wih à new al cleaner element

Here is too much exhaust restriction, make a visual
Inspection of the extaust pping and mufr. no
sua damage can be Toure, the exhaust ping may
ave tobe removed and the exhaust restchon
measured again to soe problem is cores,

7. The fal transfer pump pressure (measured a plug
‘on tp of fuel Pump Rousing) mest not be less than
140 Pa (20 psa ul load condicrs Normal fal
pressure at loa rpm is 205 + 35 KPa (30 +5
PS), fuel pressure is kw or ora, crec for ho
onions tat folow in the order shown:

AL Air nine Fuel System... Dsconnect the fue return
ne a the tank Pace this end ofthe ine n'a
‘contaier of fuel o ee Y ak bubbles are present
‘wih te engne running I a bubbles are cbsorved,
‘heck for ose connections or other Ine asks
‘ead of fue ranster pump.

BB. Resticions …… Check fra plugged fal itr or
crimped (damaged uel Ines

©. Too Much Fuel Retured to Tank. lock the fue
return In to stop a fuel retuned o tank. Check
{uel pressure again, ane, a significant pressure
increase l observed, an incorrect constant bed
iles may be the problem. sal the correct
Seco

NOTICE
Do not run the engine under load for more than 5
minutes with return ine Bocked.

D. Damaged Fue! Transfer Pump Parts. . „Check
bypass vale to seo Gt or einer bs cous
make the valve slick. Clan or replace valve
‘amaged. bypass valve is good, remove and
isasserrbe fel anor pump to check fr wear in
the gears

8. A very eval amount ofa inthe fel may not alec:
tha anse pam fue pressure, bt cou alec he
Performance atthe nozzes. The 2P8278 Flow Tube
an be instal ahead ofthe fel transter puro.
‘This wi alow a vival check of arya m ine Wel
when the engine running, Anolner method to
check for arin the fl iso ut the ful tank end of
the uel retainer a container of Wel

Ina the 6V7925 Fl Rate Indestr according to
Special Instruction, Form No, SEHSSSEE. The
specified fue rate a fl pag gwen the Fue!
Seting An Related information Fiche.

othe whee! test again a shown in
Procedure No, 2, bu this ma recor Ihe fot ate and
‘om.

NOTE: This tu! system has a constant fow of fue
thal returned to th fal tank, Th nice must be
blocked belote accurate fal rate readings can be
taken Do not run the engine uncer bad for more than
‘Sines with ern hna Blocked.

10. 100 fuel rate was too fw, instal $4209 Fi
Service Tool Group and check the fue system
sting. The correct ful system seing gven in
Fuel Seting And Related infomation Fcne tel
System seting is at correct, the acjustmont
procedure le shown i the Testing and Agustin
ection ofthis Service Manual under the subject
Foal System Seting,

Ith ful rate was low, and te fuel system sating is
‘correct, check the tems thal flow nth seouencs
Shown

IA. Remove nozzie and check to ses hey are the
Correct nozies for your engine crf they have been
(ir Brushed. Ether concen wl aflct
perfomance

B. Chock for any restrictions to fl Row in ins.
between fue iter and nozzles. Any Sharp bend in
the Ines coud cause a restcion of fuel divers,

©. Check govern for worn pars. A worn bushing or
‘worn spring seat can change governor operation.
‘Also check to soe the cone governor sping
instal

1. Check tut injection pumps fr waar an forthe
‘orect carton Pu the ful eco pump
(rOUD onthe fuel injection test Bench, Prtorm a
{hel devery esto determina he correct amount
of uals delivered by each pump.

1, Use the 875300 Diesel Timing Indicator Group to
‘check the timing ofthe fel injection pump
‘camshaft tothe engine camshaft. See Fuel System
‘ofthe Testing and Adusing section of this Senso
Manual for In subject Checking Engine Ting
‘And Automate Ting Advance Uni With 818300
“Timing ndcater Group.

12. Uso the 878300 Timing incicator Group to chock
the automatic timing advance unt. Check to soo
thatthe advance 6 smooth and thatthe amount of
‘advance is coroct. See Fual System ofthe Testing
and Adjusting secon of this Saree Manual or
the subject Checking Engine Tming And
‘Automat Timing Advance Unt Win 818300
Timing Inicaor Group.

1 rpm timing, and fuel at ae found to be within
specticatons, the engine should produce acceptable
Power (les engine has excessive internal Ion.
Figh crankcase ci love). When all the above conctions
ara within spocticatons, and the wheel horsepower i
std lower than expected, some component ol the
vehicle must be absorbing 100 much power. Do not
Conte wih engne troubleshooting. but locate and
(ect the problem wth the veni. (Caterpllr is not
responsible for problems wth vehicle).

13. Measure the boost again as detaled in Procedure
No.5. rpm, ring. fel at and boos! are found
Lo bo wihin specications, the engine should
Produce acceptable power (ules engine has
fxcossve intemal fiction, 0. high cranácaso ol
leva) When al th above costas are within
specications, and the whoo horsepower i til
lower than expected, some component ofthe
vencio must be absorbing 00 much power. Do
ot continue wth engine troubleshooting, but
locale and corect the problem wth the vence.
(Catepilaris not response for problems wih
Veni)

14. bot low, chac inet manotd
omperauo temperature is oo gh, check the
aftercooler for passte restrictions 1 Ihe coolant
This conctionreauces the amount of ar in
‘finder for combustion (since warmer a's ess
‘once. manta temperature 6 corea, check
the turbocharger for mecranical problems (e,
wrong nozzles, worn bearings).

a

Primary Engine Test for High
Fuel Consumption

1. Fuel consumption records must be avale belore
the high fel consumption complaint can be
‘vented i Smplors indicate low power, then the
Lou power est shoud De conducted rt. because
‘cous be the cau ol the fel consumption
‘roblem Ths Primary Engin Tost for High Fue
‘Consumption isthe same as the Prmary Engine
Tost for Low Power

2. Visa ngpect the uel system tram the fel ak to
the ful nein nos 10 oe there ao any
Indications of Mel aks. Tighten any ose
connections found and, necessary replace Ines
‘hal can not be reparos.

3. Check ho erankease level and the coolant level
the rar. Sar the engine and goto normal
Operating temoeraur. À sag lower pm (15 rom
Bew ow) shouldbe expected forthe engine
in voice than the rpm shown nthe Fuel Satin
‘and Related Inormation Fiche. Ts is caused by
the paras loads ofthe engine accessones
involved.

4, With the engine ruming the thee must have
‘enough raval or the governor conta! ver fo break
‘ver (go pas the normal governor slop tr high le
positon) a small amount when the vote paca =
‘aly dopeessed fll ave nat avale,
(iseomnect rote linkage rom govern lever. With
{rot Inkage disconnected, ul travel of governor
layer wa ndente irkage probleme, andthe Inkage
‘wil have to bo agusted. Limited travel of the
‘govern leve wil Indico a problem within the
governar

5. Only a mechanic with he core raining should
change the so! pont balance port) adusimen.
‘The prccecure s guen in ths Sorvce Manual under
Ihe subject Governor Adfstments

6. High dl rom can not be made corect wth the
high e adusimont screw, ere 1 a problem ine
the governor Disassemble he governor and chock
oe damaged parts or wrong part nal inthe
‘governer. Some common problems are worn
Bashing, worn sping seal, oF a broken or wrong
governor spring

7. Belore 870500 Orcul Tester i stated. be sure to
teat the pt for rec! operation. Test ight ust
(Coma on wn the cp ofthe wie is paces aganst
the probe ofthe ight replace batteries or bub if
light does rot come on)

NOTE; light comes on and stays on when altached
lo governor the insulation is bad or installed wrong in
torque spring group or brass terminal. This must be
‘corte beloro tet pertormd

8. With the only bgt instal, quick push
accaeralor pedal al the way tothe lor. Hf the ust
Contra sat and governor function propery, he
‘Contin ight came on deg ns oe
fccalration unt igh is marian,

the gt comes on, hiss an indication that the

‘mechanical movement o ha governor ard fuel

inecton pump parts operate proper. The fel seting

‘Shou nom be checked. tro ight does al come on

‘ung free acceleration, check fora problem inside the

‘govern.

9. Insal $4203 Fed Service Too! Group, and check
the fu! seting dimension. Compare the resus wth
the mens gvon n the Fue Sting and
lied normalen Fine. the Ie! sting is
Correct, the vehicle wil now have tobe tested on à
Chassis djramamete Lo determino the cause for
high tual consumption

1 the fu stings not correct adjust to the cating
‘given n the Fuel Sting and ateo information Fehe,
Enya mechan wath the covect taining shoud just
the ful sting The procedure to check and agus ne
{tel song sn ths Sac Manual under the subject
Fuel Seting

10. the test ight tl does not come on, this means
thatthe (ud cont! shat is nt moving due to a
frebiem inside tro govern e problem nse
fel injection pump housing. The governor should
be checked for worn parts, Th ful nection
‘Bump housing should be checked fora wor fel
Conta eat or fs boro, Fa function pum
inated wih sleeve no engaged wit the ever on
the fuel conto shall The problem must be found
‘and correctos

ti

=

Te er

High Fue! Consumption
Troubleshooting

(Diagnosis with Chassis Dynamometer)

1. Preparation of vehicle or tual consumption test
(congut dynamometer manufacturer's operating
instucions fr specie deals on cores operation,

NOTE: Always perform tho Primary Engine Test
procedure before vehicle is instal on chassis
‘Syrarometr.

a. Place vehicle onthe chassis dynamometer. Ti the
vencio in a way that nat add any oa lo Ihe
Give wheels Do not pul ups dawn nto
“yramomeer tive rl

(Check Ie radiator coolant tve, crankcase ol level, re
Pressure, tro condiln, remove rocks Wom the e
fread and connect exhaust system

NOTICE
RRecapped tres should be run on a chassis dynamo-
‘meter ony at the customers own risk.

D. The maximum aoceptable fuel rate must be
callate or the customer's engine by use ofthe
Formada that talons:

1.080 (SFC & 010 pg, rt at onl
Fit Denny Te

Fin the rated brake spocii fuel consumption (bo
‘hpi rom the Fuel Song And Role information
Fiche and cd 0.28 mm (010 in) manulactuio,
Tolerance. Multiply INS value by tbe advertised engine
horsepower (pus 3% manulactures trance) and
ie bythe densay o he fuel s/Gal,

€. Celcuato the alowable its that the customer can
Espec! fom hs engine and present these figures to
hi. Caterilar ongnos ae rato wi he
ondiions thal flow

rari preste 747 mn 284 mercury

Measure and record these variables.

2. Operate vehicle at 60% of rated speed with
moderate load url oil and coolant temperatures
each ther normal range for operation

NOTICE
It there is a heavy vibration, drive shaft whip, tre
‘bounce, etc, do net continue with dynamometer test
ntl cause ofthe problem is corrected. Engines that
have had new internal parts installed should be operat-
es on à runin schedule before operation at fu load.

ut transmision in dt gear and the diterontal in
the highest speed ratio. Operate vehicle at maximum
‘engine speed and increase chasis dynamometor load
[ntl a speed of 50 rpm less tran rates poe is
‘ached (connut lt shoud be on) Maintain tis
‘Speed tor one minute and recor the engine speed,
‘wheel horsepower and fue! ate.

3. Ito tol rate and he whe horsepower are bath
acceptable, then the engine isnot the cause ofthe
Coma, or tho complaint ot va. Reter to
section Problem With Venice Or Vehicle Operation

4. the wheal horsoomer is ow, rogacies of how
{hs fs ata maasuros refor o the Low Power
Treubiesrootng Char: The low power problem
most be conectes Ire

5. I tho tual ao and whoo! horsepower are both too
gh, check the sel point balance pom) ofthe
engine (speed at wich the load stop pin just
ouenes tro torque spring o top ba) Ans point
the conta hgh shou Ticker (90 of and on
iy),

the set pont (balance point i high the high ie wa
have to be decreased tole’ the sel pom [blanco
fpr tothe correct rpm {pont at whic the continuiy
Font st comes en}. lth set point (balance poa) &
correct. see Procedure No. 8

6. If the ful at is high and the whoo! harsoponer is
acceplabl, use Ins 875300 Ting ndcator Group
10 check te ing ofthe fuel jection pump,
camaha o ne engine camsralt See Fuel Sytem
Dt the Testing and Adusing section of Ins Senco
Manual forthe suject Checking Engine Timing And
Automate Ting Advance Un! Win 815300 Tmng
indicator Group, A the mag i cere, 50
Procacure No.

7. Use the 810% Ting Indicator Group to check
the automatic timing advance unit. Check lo ses
thatthe advance smocin and thatthe amount of
advance s correc: Ses Fuel System of he Testing
and Adjusting section of Ins Service Manual for the
subject Checking Engine Timing And Automate
“Timing Advance Unt With 878300 Timing Incest:
Group,

8. I the fuertes sti too ig, install $4208 Fit
Service Tool Group and check the fuel sting, The
Correct ful seting given n Fuel Seting And
Related Information Fe. uel sting rot
corre, to acjustment procedure is shown in
Testing and Adjusting section ofthis Sence
Manual urder subject Fuel Sting, ua seling is
correct, ee Procedure No 8.

9, Chock the ful nozzls uth the 524150 Nozze
Tester. Testing of th injectors must be done ofthe
engine. Use 54150 Nozze Testing Group Fo use
of the SP4160 Nozze Testing Group, rater to
Specal Instruction, Form No. SEMS7292.

It the nozzes have been wr brushed or do not meet
Caterparspeciicaons, ey must be replaced.

It the nozzies are goed, remove the compete fue
Imection pump housing and check the fuel pump
calbration. See Fuel Pump Calbraton in Testing and
‘Rajusing secton of ths Service Manual

Problem With Vehicle Or
Vehicle Operation

PROBLEM WITH VEHICLE OR VEHICLE OPERATION

ENE

1. Tochomeier Boe

3, Engine Operated wt High Aliado

3. Brakes Do Not Completely Release

3 Vene Operate m Too High a Gear

FEU Engine Deven Equipe

DENT

7 Speci Too High

Free Voice

D High Moving Ress

TO. High Wind Resistance

[i Power om Gen

12, Wrong Gear Ratios

13 Cr Dynamometr Er

Ta, Trailers Tt re Dia Pa

TS. High Ile Ar Temperatur

“The problems in is cat se problema tardo come ab and re normal cas Yow poet Tres rate
a A pes mar camion an one problems but ey ere poste cde wc JO Neto es
{ind ches blo an egos asserted,

ad at to men ut maa ste rt our ao checked complet bear making ary engine test.

Problem With Vehicle Or
Vehicle Operation

Recommended Procedure

1. Tachomoter Estor To check, connect a
tachometer of known accuracy to the engin. Run
the engine and make a comparison ofthe reacings
‘ol the vehicle and test tachometers I vehicle
Tachometer is bad, make repars as necessary or
ira a new tachometer

2. Engine Operated at High Altitude. ..Less oxygen at
higher aludes causes the eng horsepower o
90 dou. There is no effect on the 225 horsepower
{gine for tho at 2280 m (7500 1) above sea level
‘of operation. There is no ffct on the 235 and 250
horsepower engines forthe fest 1524 m (5000 1)
Above sea level of operation. See the Fue Sting
And Related Information Fich or the comect tual
eting Tor ne higher alude of operation

3. Brakes Do Not Complet esse … Check Ino
‘rakes by long al the brake drums. the brakes
‘ta weal do not completely release, the brake
Sum for that whoo wl be hole han the brake
ums forthe other whee. With the tack Ha wth
“jack, the wheels must have fro rotation when
med by hand.

4. Vehicle Operated Too High a Gear... ithe
‘operator does not shit the tuck core, or
‘operates the truck ina "a" condition (using the
Tuck in too high a gear or engine rom 10 go up as
accelerator pedal is pushed farther down, cr using
‘the tuck I à gear where engine ıpm goes down
‘ith aocleralr pedal a maximum Wave), poor
vehicle performance I resul

$. Extra Engine Driven Equipment … Air compressors,
hydraulic Pumps, allrnators and other engine
‘ven equipment thal has damage, or that was not
inslled correct, or hat notin comact
acjustment can lake more horsepower to ve than
expected, necessary, disconnect the equipment
and test the engine

6. Sposdometer Error... A bad speedometer does not
‘Wve the correct speed or ne correct ndeston ol
{et consumption. An indican of low speed can
‘cause the operalr 1 fea that he has a power
Sn

7. Spcods Too High... The nood fer mor horeopower
|S easy to see as the spend ol Ihe vance is
increased. Ths is especialy tue ithe front ofthe
vehicle nas alge Surface area. Appicaion
personnel can gvo you the horsepowe necessary
for diferrt vehicle design at diferent speeds.

8. Overload on Vehicle. Application personne can
¡ve you the horsepower needs fr cert
‘onl,

9. High Moving Resistance... Soft ground conditions
cause a end or move horsepower. To see (he
Problem S the engine, tos the vicio on a surface
known tobe good, oF test ona chassis
amame

10. Hgh Wing Resstance… The horsepower needs
10° a tuck can be divided into two parts. Part of
the horeepotrr & use fo move the vehicle and
parts used to ge through the resistance ofthe
"ira, Th horsepower necessary to get trough
the resistance ofthe wind vil increas as Ihe
ehe used al higher speeds. Vehcies win
largo font ara havo a higher wind resistance and
fake more horsepower than those wih a al
‘rent area. Some types of tucks, or example.
‘those used fr the transportation of aulemebies.
and/or boats have nap wird resstarce even fine
Font area is smal. Moving agas! the wand has
the same effet on wind ressiance as does higher
vencio speee.

11. Power Loss in Dive Gears... Ris possible fora
trrsmesion or fear axe o Use era horsepower
because af damage, nl being in coect
acpustmont having the wrong type of or nt.
trough Mu in then, or an inside mecharical
Proben. a part ofthe cre rain unit operates at
A ge temperature than normal ican be the
Problem. Check this part ofthe dive train ut
Beter wi on any ater part of he iva tain
unit Powershit or automate ransmissions can
cause the vehicle performance to e low if they
aro out ol acjstment or not working coroct. Soo.
the transmission Service Manual for the correct,
agusiments.

12. Wrong Gear Ratios … The tke 620 rear ade at,
and transmission ger raños must be correct lo
et maxmum performance te transmission
ear alos are wrong, they can aus Ine engine
remo go low enough during shifting that the
angine can not have core “accelerton”
(nerease in speed, À reer axe gear año which
Suppies too high a voice speed with the engine
ata low rpm ding normal epic cperaton, wi
causo the engine to bo "ugging"(uhen the ruck is
Used in gear too high for engine rpm o go up as
Accelerator pedal is pushed farther down when
the tucks Used in à gear where engine rpm goes
‘own wih accelerator poca at maximum wave)
‘aplication personnel can give you the cores ire
‘920s ano guar ratios for your operation,

48, Chassis Dynamemater Exot... Chasse
‘oypamomaters can be a ret help in testing a
ende fr engine pertence if thy ae in good
ration and used come. When the
‘yramomater ig notin goed conan, ora bad
‘Sboraing procedure is use, ho resul wil be
"wong readings. For good comparison of
horsepower reacings ftom diferent veias, use
the same dynamometer wit the same opera

14, Tears Tht Are Dict o Pull... Some raiere
aro mot die o ull than ots because of
Shveral factors, Some ofthese factor ase: brakes
ot released completly, high wind resstance
(because of à age font area anajo the design of
tho vale”, aes no in algamen, entr as, and
low te pressure,

15. High ret Ar Temperature. Al coming into the
engine must be coo forthe engine to have ful
horsepower. ih ar inet system rt of correct
en 0 notin good mechanic! conston hat
fr can come into the engine causing aloes of
horenpaner. To check tho tar lemperate,
iestal the 810970 Tharmstor hermemater Group

Into the engine ar inet pos,

BA:

uals.net

Misfiring And Running Rough

MISFIRING AND RUNNING ROUGH

Probable Causo(s)

T Air in Fuel Sytem

2 Valve Adjustment Not Correct

3. Fuel Injection Timing Not Comet

3. Automat Timing Advance Does Not
Operate Correctly

3 Bad Fuel Neza,

5. Valve Leakage; Wear or Damage 10
Pistons and/or Piston Rings; Wear or
Damage to Cylinder Walls

7. Cylinder Head Gasket Leakage

3. Engine Camshaf timing Not Const

9. Fuel Leakage from Fuel Injection
Line Nut

10. Fuel Has a High “Cloud Poin”

Misfiring And Running Rough

Recommended Procedure

1. Akin Fue System ... With arin tho tol system the
engine vl roma Be fit to star, run ough
and release lago amount ol write smoke. To
remove tho air om tho ful syst, open ti
‘mania bleed valve on tre Tos injection pump
housing. Operate the priming pump unt the fow of
tual rom the manual lead valve fee of ar. Close
the manual bleed ve and fasten the ful prming
pump. Start te engne. I the engine sil doesnot
Fun smooth or leases a large amount of white
‘tok, loosen the Ie! ine nuls one a a ene a the
Oder heads, and permi the ful o come out un
i's eo ofa, Tighten the ful ing nuts Hat
removed in this way, ut 35 kPa (5 solar
pressure o the fue tank,

NOTICE
Do not use more than 55 KPa (8 ps of ai pressure in
the fuel tank or damage tothe tank may resul

(Chock tor leaks atthe connections between the fue
tank and the fel ransfer pump. leaks ar found,
onen the Connections or replace the ines. there are
1% visual leks, remove the fel supply Ino rom the
tank and connoct to an outs tel soppy. ns
corrects the problem, the sucton Ine (stancpps) inside
the fe! tank has a leak.

2, Valve Acjustment Not Correct. Check and make
[necessary acustments as per Tesing and
Aging Section of hs Service Manual. take
‘valve clearance 1 038 mm (16 m} and eas,
valo clearance 084 mm (025 in). Also check for
2 bent or broken push od.

3. Fuel Ijecton Taming Not Correct. Check and
make necessary acjutments as pr Testing and
Adusing Section ofthis Service Manual

4. Automatic Ting Advance Does Not Operato
Correct... Check wth ongne warn. Use the
{T5300 Timing Inca Group o check the
‘automatic timing advance unt. Check to ses that
the aovance smooth and that he amount of
Advances conect Soe Fuel System ofthe Testing
‘ang Aging section of ths Service Manual 10 he
‘Subject Checking Engine Ting And Automatic
Timing Advance Unt With 875900 Tuning indicator
Group. Ihe Imng ical à not avalabe, make
‘apd “accolraon (nerease in speed) tom ion de
Ko high de. Engine mus have smooth acceleration,

A ting advance that does nol operate correct can
cause delays of the engine accelraton at some rom
before hgh ide, or possi cause the engne To un
‘ough and have exhaust aise (Back) during
accélraton. This conc $ ic 10 Ind engine
fconlraton is slow ora constant engine rpm.

5. Bad Fucl Nozzi(e)… ind a bad nozzle by running
engine atthe rpm where R uns rough. Loosen the
{hal ne nat at he cyinder head enough to stop fuel
supply o thal cyandar Each cyinder must De
‘Checked this way, la cier found whore
Teosoning ofthe na makes no ference nthe
rough runing, test In nozzo fr that order. To
testa nazzo,temove the rozde Im he engine
and tet

6. Valve Leakage: Wear or Damage te Pistons andor
Psion ings: Wear or Damage to Oyinder
Walls... The condition ofthese pars can be
checked wih a candor leakage ester Spocal
Instruction, Form No, GMGOOGBS, gives he test
procedure. The components can be bad leakage
Sore than te speciieatons I enkage e hears
atthe int marae, ne take valves leak the
leakage is hoard al ihe exaust manto, the
‘extant valves leak. leakage is hoard atthe 01
flor opening, the piston rings tak

7. Oyler Hoad Gasket Leakago... Check with te
(ancrage tele I wakage is age than
‘pectfeatons, Crack atthe fue naze hai o the
‘ext cyinder lo goa the lei 1 baten evinders
{Teakage a he gasket ofthe eying head can
‘show as an outs leak of can cause loss of
‘octavo the radar overow.

8. Engine Camshal Ting Not Corect Engine
‘camshal ming can be checked by finding tne top
enter posilan for umo one cyinder as par
Testing and Adusing section ofthis Service
Manual if ting isnot corel remove the font
‘cover and check img marks. limng marks aro
“Sorel check lr a broken deve dowel nthe
‘camara ove gear.

8. Fuel Leakage ftom Fuel Injection Line
Na... Tighten nt to 42 = 7 Nam (3145101)
Again check for lago

10. Fuel Has a High “Cloud Point‘... The ue ‘coud
oi is the temperature at which wax begins to
form in tho ua the amosphore temperaturas
lower than the ‘oud pont” of the us, wax wi
form and pug he ter. Crange tre ter and
‘an tro tank an the complete fu! sysiem The
placement fuel must be cha better grace win a
Tower 2000 pair.

TOO MUCH EXHAUST SMOKE

Engine Runs Smoothly

BLACK OR GRAY

Engine Runs Rough

Probable Causa)

NETO

ine Used at an Aldo
Biber an 500162

Engine Used in a Lag
Condition

Diy Air Cleaner

‘Ar Inlet Piping Damage or
Restriction

Mishring Cylinder)

Fel Injection Timing
Not Comet

B

“Automatic Timing Advance
Does Not Operate Correctly

Ai in Fu system

EXTRA

Facl Injection Timing Not
Correct

Fuel Seting Is Not Correct

Low Quality Fuel

Valve Adjustment Not
Corrector Valve
Leakage

Bad Fuel Nowie()

Too Much Exhaust Smoke

Black or Gray

Engine Runs Smoothly
Recommended Procedure

1. Engine Used in a Lug Gonétion "Lagging? (when
{he tuck is used in a gear oo high or engine ‘pn
to go up ae accelerator pedals pushed farther
‘down, or when the tuck used in a gear were
engine rpm goes down with acosleralor pedal at
maximum Wave) he engine causes a reduction in
{he intake ofa wth (Tua ver 1 Ie
‘yinders. Because here not enough alto burn
Ale fos the ful tata not use comes cut the
‘exhaust as Dack smoke, To prevent ggg the
engine, use a gear whore engine can have
“deceleration (Increase in speed) under fad,

2. Dety Ar Gieaner… Nine al cleaner has a
restreton Indicators la od piston sn view.
there is no restriction Indico, rstrcton can be
checked th a water manomier or vacuum
‘gauge (wich measures n inches of wate), Make a
omecton to Ie pping betwnen e ar cleaner
‘andthe inet of na uocharger. Chock withthe
‘Engine running at fl led rer. Maximum restriction
15635 mm (25 m) of water a gauge isnot
“valla, visual check the ar cleaner element or
‘Get. the ements ory, clean the element or
Install a now element

3. Ai niet Piping Damage ar Restriction Make a
‘ysual nepecton ofthe att system and check
For damage topping, rags the et png. or
‘damage 1 tho ran cap o he cap pushed to fr
fon he inet pie. no damage is soon, check net
rastreo win 3 clean ar cleaner element

4. Exhaust System Reston... Make a visual
inspection ofthe exhaust sytem. Check for
damage to ppng ot ora Dad mut. I no damage
is found, you can check the system by checking he
Pack prössune irom the exhaust (pressure ference
‘measurement between oeraust outlet and
mosohere). The back pressure must rot be more
than 1016 mm (40 in of aer. You can also check
by removing the exnaust ppos rom the exhaust
manos. With te achausi pes removed, tat
and load the engine on a chassis dynamometer to
500 te problem is corrected

5. Fuel nection Taming Not Cort... Check and
make necessary acjustments as per Testing and
dung section of tis Sorvce Manual

7.

. Bad Fuel Nozzes

Fue! Sating fs Not Care! … Check and make
necessary acjatments as por Testng and
Adhstng Secten of ths Sersce Manual Soe the
Fuel Seting And Rated Informaton Fee forthe
correct tel sting,

Low Qualty Fue... Test the engine with lu!
according to recommendations by Caer.

. Valve Adjasiment Not Correct or Valve

Leakage... Check and make necessary
cpus as per Tesing and Adustng secton ol
ths Service Manual. take valve Cearance s 038,
mm (015) and exhaust valve cearance is 0 64
me (0.25 i, Valve leakage normaly causes the
engine 10 metre (mpcion not regular) and run
‘ough Vale loskago can be checked using the
Cynder leakage toser Special Instruction, Form No,
OMGODGSA gues the let procedure.

Bad fue nozzes wi normal
‘cause the engine 10 "miso" (recon net regu)
And run rough, but can cause too much smoke wth
angine sil ung smooth. Remove and test the
‘ol nozzles.

Engine Runs Rough
10. Misting Cyinders)... See string and Rurring
Rough

“11. Fuel nection Timing Not Correct. ‚Check and
make necessary adusimenis as per Testing and
‘Adjusting section of ths Service Manual

12. Automatic Taming Advance Does Not Operate
“Corre... Check wth engine warm. Use the
8TS300 Timing Inccator Group to check the
‘automatic rng advance unit. Check to ses that
the advance ls smooth and nat Ihe amcunt of
advance is correct See Fuel System af the Testing
land Adjusting secon of this Sence Manual for
the subject Checking Engine Timing And
‘Aulomato Tening Advance Unt With 875900
Timing indicator Group the timing indicators not
avalabe, make rap “acceleration” Increase in
Speed) fom low ie to hgh ide, Engine must have
smooth acceleration. A timing advance that does
‘ot operate correctly can cause delays ofthe
engine acceleration at some rpm before righ ide,
or possibly cause the engine fo run rough and.
have exhaust aise (backe) during acceleration.
Ths conan s fic to tna i engine
acoserton# sow o ala constan engine rpm,

19, Ati Fuel Systm. With arin the fuel system
the engine wil normaty be ed 0 star, run
‘ough and release a large amount o! white smoke,
‘To remove the atom the fue system open he
manual bleed valve onthe ful injection pum |
‘housing, Operate the peng pump unl he Bow
of fuel fom te manual bleed valve i eo o a.
‘Close the manual Died vale and fasten the Tue
priming pump, Star the engine the engine sil
3008 nol un smooth or releases a large amount of
‘white smoke, loosen the fol ine nuts ove ala.
time atthe oyinder heads, and permit the fuel o
‘come out unt tis ree af e. Ten the uel ne
ut. tai nt removed in tis way, put 35 kPa
(698) of ar pressure to the fue tan.

NOTICE
Do not use more than 55 kPa (8 ps) of air pressure in
‘the fel tank or damage to the tank may resul

‘Check fo leakage atthe connections between the ue
tank an the ful transfer pump. leks ar found
gen the connections or replace the Ines here are
1% visual leaks, remove the fol supply ine fom ine
{ark and connect to an outside fuel up. ts
corrects the problem, the sucion In (tandpipe) nse
the uel tank has a leak

Too Much Exhaust Smoke

White Smoke
Blue Smoke

= eee

TOO MUCH EXHAUST SMOKE

Probable Causes)
White Smoke Blue Smoke
1. Cold Outside Temperatures 10. Oi Level in Engine
Too High
3, Long lle Periode
11. Damage to Positive Crank
case Ventilator Valve or
Tow Qualıy Fa Valve Assembled Wrong
3 Ai Fuel System 12,_Womn Valve Guides
3 Fool Injcion Timing Not 13. Won Pinon Rings andlor
Correa Cylinder Walls
6. Automatic Timing 14. Wear or Damage to Pistons
‘Advance Does Not Operate
Conectty
7. Valve Adjustment Not
Cone
3 Bad Fuel Nome)
9. Misfiing Cylinder)

u — Zu

Too Much Exhaust Smoke

White Smoke
Recommended Procedure

1. Cold Outside Temperatures... When the ar outside
is cok the eyindortomporatue is cooler. Not all
the tal vl burn nthe eyiners. The fuel which
¿es not burn comes out the exhaust as white
smoke. White smoke is normal in cold temperatures
nl he engine operates long enough to become
warm. Thar wal bo los nto emako NO. 1 diesel
Tools used

2. Long lio Periods... When an engine runs alle
seed for a ong period of time, the cyinders cool
And al ofthe fel does not buen. Do note an
‘engine for a lang period of te. Sip an engine
‘wen itis not in use long de periods are
necessary, use No. 1 cose! us.

Low Quay Fue. Test he engine using fuel
according 1 recommendations by Carla.

Akin Fuel System … Wi ain the fuel som the
engine wa normal be cio lo sat. un rough
and release a large amount of white smoke. To
remove the ar rom the ful system open the
manual bleed valve cn the ue njecton pum
housing. Opera the priming pump unt the How of
fuel rom the manual bleed valve fee of ar. Coso
Ihe manual bleed valv and fasten the ful priming
pam. Sat the engne. I the angine stil does nl
Fan smooth or releases a large amount of hte
Smoke, loosen the Wal Ino ts one al tine a the
indie heads, and permi the fue! to come out un
Is ee ofa Tighten tho fuel ine ours fa not
removed in tvs wey, pu 35 kPa ps) of a
pressure o the fue tank,

NOTICE
Do not use more than 55 kPa (8 ps) of air pressure in
the fuel tank or damage tothe tank may result.

‘Check tor eakage at the connections between the ful
{tank an the fel raster puma flea ae found.
Hafen the connections oF replace the Ines there ae
mo visu leaks, remove the fualsuppy Ino irom the
tank and connect to an outside fue supply Is
(rec the problem. the suction ie (tarde) inside
the fal tank has a leak.

$. Fuel Inción ining Not Correct... Check and
make necessary adusiments as per Testing and
using section o! ths Service Manca.

6. Automatic Timing Advance Does Not Oporto
Correct... Check wth engine warm. Use the
815300 Timing Indicator Group o check the
‘automatic timing advance unt. Check to soe that
{he aovance 1 smooth and hat he amount of
‘advance corect See Fuel System ofthe Testing
‘ane Act sechen o ths Servos Manual for he
sect Checking Engine Timing And Automatic
Timing Advance Unt Win 815900 Timing Indcator
Group the ting ideas net avale, make
‘apd “accelerator Increase in spoec) from low e
to nigh ido, Engine mast have smooth acceleration.
‘ring advance that does nol operate corocty
an causo Golys of he engine accelraton at
Some rpm bere high ido, or possibly causo tho
naine 1 ru rough and have exhaust nose
backir) din acceleration. Ths condition is
tie 16 lind orgie acceleration is Sow or ata
‘constant engine rp

7. Valve Adtusimont Not Comet... Check and make
necessary adustments as per Testing and
Acjusing section of tis Servo Manual intake
‘ave clearance 0.38 mm (015 in) and exhaust
Valve clearanon i 0.64 mm (025 N).

8, Bad Fuel Nozze(s)… Bad Fue nozzles wil
normal cause the engine to "mitre" (injection not
regul) and run rough, out can cause too mich
"Smoke and ne enge sil be inning Soo.
Remove and test the fal razzie.

8. Ming Cyinders)... Ses Msltig and Running
Rough

Zt

Blue Smoke

10. Engine Ol Laval Too Hg... Do nat put too much
(fh tho crankeaso the où level Ihe crankcase
goes up asthe engine is used. cneck fr fon
{he crankcase. Seo Fue in Cranicase Ol

11: Damage to Postwe Crarkcase Venir Valve ce
Valve Assembled Wrong... The postive
crankcase ventiator valve must be assembled
corecty and the daptragm andjor gasket must
De ee of damage,

12. Worn Valve Guides... S00 the Spoctications
section ofthis Service Manual orth maxımım
‘ermigsbo wear of the vave guides, The repay
Procedure for valve guides is nthe Recendtening
Procedures section ol is Service Manual

18, Won PstonFings and/or tinge: Wal. Worn
‘ston rings andjor eyinder wals can be the
suse of Be smoke and can cause alos of
compression Check cyinder condtion with the
finder leakage tester. SpecalInstucton, Form
No. GMGO0SS4, gives te test procecure. Mako a
visual inspection of the oyinder wals and piston
ros. necessary measure the oyinder wale and
piston rings. For the cyinder and piston ring
pocicalons see the Spocicaion socton ofthis
Service Manual. NOTE: High wear at ow mieage
is normal caused by dt coming into the engine
vt eet a

14. Wear or Damage to Pens. Check piston ing
to groove clearance. Pistons which have wern
‘coves and itor with damage or delacs can
Cause bbe smoke and too much of consumption.
Make sure the ol alum les unde the ll ng are
open,

Difficult Starting

Engine Crankshaft Turns Freely

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Exhaust Smoke Can

DIFFICULT STARTING

Engine Crankshaft
‘Turns Freely

Exhaust Smoke Can Not

‘Seen While Starting Be Seen While Starting

‘Probable Cause)

Probable Gause(e)

Cold Outside Temperaures

9 No Fuel in Tank)

Air in Fuel System

10. No Fuel From Foe

Injection Pump

Tow Quality Fuel

Exhaust System Not Open

Low Fuel Pressure

Fuel Injection Timing Not
Correct

Valve Adjustment Not
Comest

Bad Fuel Nowe

Low Compression

Difficult Starting

Engine Crankshaft Turns Freely

Exhaust Smoke Can Be Seen While
Starting

Recommended Procedure

1. Cold Outside Temperature... may be necessary
10 use staring as, or o heat engine ol or coolant
A temperatures below 10°C (0)

2. Aisin Ful System. „Wi in the fue system the
engine normaly be dict to ar, run rough
fae release large aroun of ute smoke, To
remove the ai fom the fun system, open the
‘manual bleed valve on Ia fuel injection pump
fous. Operate the pring pump unl the Bow of
{uel rom the manual blood valve I oc af a. Close
the manual oso valve and laten the fuel ping
Pump. Start the engine. the engine sl os not
Fun smooth ar feleasos a large amount of ute
Smoke, loosen the fine nuts one ata time atthe
Sind Reads, and permit the fue to come out uni
A ros ofa Tige the fuel in rus. ari not
removed in ths way. put 35 KPa (Spi ol air
pressure othe fel tan

NOTICE
Do not use more than 55 kPa (8 ps) o ar pressure in
the fue! tank or damage tothe tank may result.

‘Check for lakage atthe connections between the fue
{ark and the fe tanto pump. I leaks ae found,
Aion the connections or oplaco the nes there are
o veua lake, remove the ual suppy Ine rom the
lank and connect to an outside fa! supply. tis
‘carrcts the probier, the suchen ine (sandpipe) nie
tha uel ark has aoa

3. Low Qualty Fuel... Remove a sal amount of fel
{rom the tank and check for water inthe fk.
re ter into fel, remove fel fro the tank
uni. ro of water and il with a good qua
{Wal Change th fal iter ana “primo” remove the
ar andjor ow ually fuel rom the fl system) the
fuel system withthe fel priming pump. thee iso
alor tho fuel prime and stat the engne by
Using an outside source of foe engine starts
Correctly using afore uo, remove a ie! rom
the tank and at good uy ue. Prime tho
fuel sytem Ht necessary

4. Low Fuel Pressure... Change the fl ie. the
pressure i sil on, chock the bypass valve nthe
{al ranstor pump. Dabes in the system can make
the vale become siatonary in the open postion.

5. Fuelingcton Timing Not Core. Check and,
make necessary adjustment as por Tesing and
‘gusting section ol tn Service Manual

8. Valve Adjustment Not Correct … Check and make
necessary adustarts as per Tesing and
‘pasting section of ths Service Marsal intake
‘ave clearance Is 0.38 mm (015 1) and exhaust
Vave carros 8 0.54 mm (025 1),

7. Bad Fuel Nozzels)....Romovo and est ne tual
ozs.

8. Low Compression... See Misting and Running
Rough

Exhaust Smoke Can Not Be Seen While

Starting

8. No Fun Tank(s)... Chock fuel evel visual (do
‘et use the fuel gauge ony). Be sure tank slecton
Yale s open tothe tak with flint. Be sure
vale in fue ine between the tarks is open.

10. No Fuel From Fuel nection Pump... Loosen a
fuel infection ne ut atthe pump housing Win
igniton etch in tro ON postion and accelerator
Inthe FUEL ON postion tun the engine wth the
Starr tobe sure tore tel from the fuel
Injection pump. To find the cause for no fu,
follow Steps (a) rough (0) uni the problem is
conectes.

a. Prime the fue system as shown in Procedure No.2

1. Check shut solenoid by turing ignition sch to
ÓN postion. You must hear a sound when the
unger opens. tro sound is heard, make sure
{here battery voltage a the solenoid the
Science does not or instal a new solenol.

€: 1 you are not using a good quali o ual a
temperatures below -12°C (10°F) tis possible that
‘the Tuan the system can “wax” (ot have correct
ftw characteristics) and cause a rsttion nthe
tual system. Insta a now fue fit may be
necessary lo rain tha complete ua system and
replace with No. 1 grade o ua.

1. Chock for tel suppy Ino restriction by removing
‘the fuel supply Ine for the fue fte base. Put 35
a 6 ps) a ai pressure othe fue! tank.

NOTICE
Do not use more than 55 kPa (8 pi) of ar pressure in
the fuel tank or damage to the tank may resul

I ihre isn fu, or nly a woak Row of fue fem the
fuel supply Ine, there isa resticton in ha fuel suppy
Ine anc the ual tank

11, Exhaust System Not Open... Loosen the exhaust
pe from ine exhaust manifold. engine wil row
Sar, check the extaust system or damage
andor restictions.

Difficult Starting

Engine Crankshaft Will Not Turn
Engine Crankshaft Turns Too Slowly

DIFFICULT STARTING

Engine Crankshaft Engine Crankshaft
Will Not Turn Tums Too Slowly
Probable Causa) Probable Cause

Low or No Battery Volage

E Low Battery voltage

Bad Switch, Bad Wiring or
Connection in Switch Circuit

9. Bad Cable or Connection:
Battery to Starter

Bad Cable or Connection:
Battery to Starter

10. Oil Too Thick for Free
Crankshaft Rotation.

Bad Starter Solenoid

Tr, Bad Starter Motor

Bad Starter Motor

12, Extra Outside Loads

Transmission or Power Take-
off Problem Prevents,
Crankshaft From Turning

13. Mechanical Problem Inside
Engine

Inside Problem Prevent
Engine Crankshaft From
Turing

Difficult Starting

Engine Crankshaft Will Not Turn
Recommended Procedure

1. Low or No Battery Voltage Check battery
voltage. I battery voltage ess than 8 vats for a
12 vol system, or 16 vals for a 28 vl system, put
a charge tothe battery battery wi not hak a
‚Charge, load test he vay as shown inthe
lineal System ofthe Testing and Adusing
faction of Ins Sorvice Manual

2. Bac Swich, Bas Wirng or Connection in witch
Cicut With gion sitchin START postion,
(Check vage al snitch conection on starter
Solenoë there is no vllage, cr! the volage is
Tow at this connection, creck wing, comestons,
ignition Swen, and magnetic such (used)

3. Bad Cable or Connection: Bator 1 Starter... With
igntion wich inthe START postion, check voltage
a connection of battory cable to stator thre
o vllage, or the votage is ow a nis connection
and there is good volage atthe battery, neck for
‘ad cable oe conecto between the Baer and
the sare.

4. Bac Starter Solenoid... Remove and repair a
ono ten does not werk when vallgo is
‘Correct at both the battery and gation serch
‘connections.

5. Bad Starter Mote... he solenoid works and the
starter motor does not ur the eranashat the
Starter motor bad, Balore remavng he starier
‘motor, tun the crankshaft by hand to be sue a
mechanical flute ins the engine, transmission,
or power take os not preventing the rankahaft
from turing. crankshalt turns Itchy by hand,
‘engage the starter motor again. the starter mater
SU a not work, remove the starter mot and
Fepaj 1, o instal a now starter mote.

6. Transmisson or Power Takeoff 0 equipped)
Problem Prever Crankshaft From Turing
(rankshat ca not be tuned by hand, disconnect
the transmisson and power take ll. crankshaft
‘al row tu, Ind the cause 0! In proben in e.
Transmssion or power take-off and make necessary
coroctions,

Inside Problem Provent Engine Crankshaft From
Turning le erarkahaft can no be ned aller
<disconnecing ho transmission and power tke of
emove th el nozzles and check for ud in the
Ofinders whe tung the crankenalt Hid othe
Singers 5 nt the problem, the engine must be
‘disassembled o check for other ins problems.
Some of these inside problems are bearing sere

Engine Crankshaft Turns Too Slowly

8. Low Batey Voltage... Check baltary voltage.
battery vltage sess than 8 vos fora 12 vot
System, oF 18 vols lora 28 vd system. pul à
Charge Lo the battery re battery wi rot pod a.
(Charge. oad les the battery as shown in ne
Ectrcal System of ne Testing and Aching
section of ts Service Manual

9. Bad Cable or Connection: Battery to Starter. With
‘wich in START positon, check votage a battery
able connection Yo sare voltage fw al is
Connection and thee is good voltage atthe battery,
hock for bad cable e connacton between the
Batey and tho starter.

10. Où Too Thick fr Free Crankshaft Rotation. Use
recommended Lubricant Vecosts as found In
the Operation And Mainterance Gude

11, Bae Starter Motor... Remove and test. Make
‘eps as necessary or esta à new starter moto

12. Extra Quisco Loads... Damage tothe power
take-llequpment so equipped) andlor
transmission can pu entra oad onthe engine
‘Ths prevents og rotation ofthe canst To
check, disconect the ransmisson and power
take, and star tne engne.

18. Mechanical Problem inside Engine... Take the
angine apart and Check el components for
damage,

COOLING SYSTEM

‘Above Normal Heating

Above Normal Heating (Cont

Probable Causet)

Taw Coolant Level

Bad Temperature Gauge

Diny Radiator

Loose Bel)

Bad Hose)

Shan Line Restriction

‘Shutters Not Opening Correctly

Probasie Cause)

13, Operation ar High Altitude

16. Engine Used in a Lug
Condition

Tale Reston

13. Exhaust Resiichon

19. Fuel Injection Timing
Not Correct

20. Transmission Problems

Below Normal Heating

Bad Water Temperature
Regulators

Bad Water Pur

10.

‘Air in Cooling System

‘Wrong Fan, Fan or Shroud
[Not in Correct Postion

Radiator Too small

| Not Enough Air Flow Through

Radiator Because of Restriction
in Engine Comparment

1.

igh Outside Temperature

ENE

21 Long lle Periods

22 Very Light Load

23 Bad Water Temperature
Regulators) and/or
Vent Valve

Cooling System

Above Normal Heating
Recommended Procedure

1. Low Coolant Loa. the coolant leva too low
‘ot enough coolant wi gp through the engne and
radar. Ti ack of cola wl ot take enough
heat rom the angine and there wi pot be enough
low of coolant treugh the radar to release the
heat into the coding ar. Low coolant eve caused
"by leaks or wrong ing ofthe radiator. Win the
engine coo! be uo tal coolant can be seen at
‘he low end of the fl neck onthe radio op tank

2. Bad Temperature Gauge … À temperature gauge
vic does nol werk eorect wi not show the
‘Correct temperature. tv temperature gage
howe thal the codant temperate isto hot but
‘ther conditions are normal, ether instal a que,
Jou knows good or ck the cooling system with
tha 670470 Thormister Thermometer Group.

3. Dry Radiator... Check Ie radiator for debris
between the sof the radiator core wich prevents
fee al ow though the radiator core. Check he
‘dato for dabei, or deposts on tho inside of
Ihe racíato oro which prevents re flow of coolant
through ine radiator.

4. Loose Betis)... Loose fan bell wil cause a
reduction in a ow. Tighten the bets according to
Vial Tension Chart thal is shown in Speciation
{ection ofthe Service Manual.

5. Bad Hose(s)...Bac hosos with leaks can normaly
De soon. Hoses thal nave no visual ek can,
colapsc’ (pul together) during operation and cause
rest i the fow of cooanı. Hoses became
Sol andjor gt cracks altra perio of time, Hoses
must bo changed after $0,000 mies or a year of
Use, The inside of a hose can deteriorate. and the
loose particles ofthe hose can cause a rs in
the fow of codant.

6. Shunt Line Restriction... restrction of he shunt
line rom the racial lop tank othe engine water
pump et. or a sunt In not insted correct, wi
Cause a reduction in water pump eficency. The
‘edt wl below codant tow and overheating,

7. Shutlrs Not Opening Correct Check the
‘opening temperaue of the shite, The sruters
trust be completly closed at a temperature below
the tay open temperature ofthe water temperature
regulators

8. Bad Water Tomporaur Regus)... A regulator
that doesnot open. o cr opens par of ne way.
an cause above normal Peatng, T test the
thormostas, so the Testing and Adjusing section
ff hs Sere Manual

9. Bac Water Pump. A water pump wih a loose or
damage impeder does not pump enough coolant
for comect engine cooing. Remove the wales pump
and check for damage to he mpole ne moeler
has no damage, check tre mpoter Garance. The
CGearanco boten the mpele and the housing =
62810084 mm (011 10 033 im)

10. Ar in Cooing System... Al can got into the
Coalng system in dffrent ways. The most
‘commen causes are not ling the cooing system
Correct, and Combustion gas leaking nto the
System. Combustion gas can get to the system
trough inde racks o Dad Ojinder head
(gaskets. Ain the cooing ejem causes a
Guen n coolant Now and bubbles in the
cola, bubbles hd coolant away fom
‘engine paris prevent heat ow.

‘Ar in the cooling system can be found by the Bote
Test. The oqupment needed to make this testis a one
pint bate a bucket of waler and a hose whic wilt
{he end of he overtow pos of he racatr

Before testing, make sre the cooing system is ied
‘correctly, Use a wee 10 no the ale valve n he
‘adator cap open stl the radar cap anc gen
Pathe nose over the enc of ne overiow pipe.

Start the engine and opera it thigh de rpm for a
‘minimum of ve minutes afer he engne at normal
Operating temperature Use a cover on the radiata core
10 kamp the engine at operating temperature. Alter Ivo
‘or mote minus a operating temperature, place the
loose end of the hose nthe bot ied with water. Put
the Bot nthe bucket of water at the top down.
the water ges ou ofthe bell ness than forty
Seconds, oros 00 much exhaust gas leakage into
the cooling system Find the cause othe ar or gas
{geting no the coding sytem and corec as
Pecessar.

1: Wrong Fan, Fan or Stroud Not in Corset
Postion … À wong fan, or alan or soudin à
"wrong poston wil cause a reduction or los of
Row trough the radiator. The fan mus be large
‘enough to send a through most ofthe area ofthe
‘acter core. Mako sure the Ian ize, an stroud
and postion of fan and are are according to
‘he recommendations ofthe Tuck Manufacturer

Radar Too Smal..Aradalor wich too
mal does not have enough arca to release the
heat tothe cooling ai. Ths wi cause the engine
10 un at nigher than normal temperatures Mako
Sur the radar 20 ls acooeang othe
recommendations ofthe Truck Manufachuer.

Not Enough Air Flow Through Raciator Because of
Resticton in Engine Compartment... The ar fou
rough tro radiator comes out ofthe engine
‘compartment. Mako sur to fiers, ar
ondtonars and smear ters ar not tale in a
way which prevents fre flow of ar into and out of
the engine compartment

High Outside Temperature... When outsise,
temperatures are 100 hgh forthe rating ofthe
cooling system, thee isnot enough temperature
‘erence between tho outsce ar and soda
temperatures To got batter cooing, use he Huck
In alone gen.

‘Operation at High Altudo.. The cooling
panty ofthe cooling system goes down as the
uk ls used at higher alludes. A system, under
prossuo, argo enough to kaop the coolant rom
Boling must be used

[Engine Usod in a Lug Condon. Lagging’
(Shen the truck used ina gar ioe high ee
nr tom 10 go up as accolrato pod
pushed farther Gown, or when the tacks used in
2 gear where engine rpm goes down th
‘scclraox pedal at maximum Wave) the engine
causes the engine rpm and an pm to be low.
Tis low rom causes a reduction in af tow trough
tha radar, and a region nte how of coolant
trough te system. Ti combinaton of essa
and ls coolant Row during righ input of fel vil
‘ate above normal heating

2

1.

1,

15,

17. Ait Restriction. Reetition o heat coming
ino the engine causes high oder temperatures
‘and mere than normal amount o est to pass to
‘he cooing system. Check for aretrction wth a
‘water manometer or a vacuum gauge (which
measures in inches of wate). Connect he gauge
{o he engine ar inet between the ar Gleaner and
tho il tthe Lrbocharger. Wi gauge instala,
run engine a ful Joa rpm and check the
resticion Macmum restrcton o a ines 635
ren (25 I) of alor. tre Indication is higher than
{he maximum permisible estiction, remo the

dit tom the titer element, or nta a naw titer
lement and check the restrcto again. he
indication stil too high, there must be a
restícion in In net ping
18, Exhauet Reston... Restriction inthe exhaust
system causes high cylinder temperatures and
‘ore than normal amount of heat to pass to the
Coal system. To soe theres an exaust
restrcion, make a vsualinspecion ofthe exhaust
system, Check for damage to piping o fora bad
mutes 1 no damage is fcund, check te system
{or back pressure tom the exhaust (pressure
diflerence measurement between exraustouset
‘and atmosphere). The back pressure must nt be
‘ore than 1016 mm (40 in) of water. You can aso
‘heck Ie system by removing the exaust pipes
{rom the exhaust mariolde With the exhaust
‘es removed, start and run the engine fo see it
the problem i corrected

Fuel jscion Timing Not Coroct.. Check and
"make necessary adustmonts as por Testing and
‘Adjusting section of his Service Manual.

. Transmission Problems... Power shit or
auomate vansmissions that are cole by tha
engine cooling system can cause above neal
heating they ase out ol acjstment or not working
corecty. Soe the transmision Servce Manual for
the cor edustments

19.

Below Normal Heating

21. Long I Periode... when the engines
with no load, only a smal quantity of felis burst
and engine heats removed too fst

Very ght Load... Very ght loads, and a very
Saw speed or Soul travel can cause below
normal eating because ofthe low heat input of
the engine. The nsalaton of stters helps to
comect this condon

. Bac Water Temperature Regulators) and/or vort
valo À regule that GC open (wll ot
‘ove to the closed poston) wil cause below
normal heating. A regater that is suck between
the open and closed postions, o à vet valve that
Is suck open, can cause below normal heating
whan the rock hs a igh ad

es

Loss Of Coolant

LOSS OF COOLANT

Probable Cause(s)

a

©. INSIDE LEAKAGE

> Leaks in Hoses or
Connections

and/or Expansion Tank

Teto the Radiator]

3. Leaks in the Healer

3 Le inthe Water Pump

3. Cylinder Head Gasker
Leakage

. COOLANT LEAKS AT THE
OVERFLOW TUBE

Probable Cause(s)

Had Pressure Cap

7. Engine Runs Too Hot

Expansion Tank Too Small

9. Cylinder Head Gasket
Leakage or Cracks) in
Cylinder Head or Cylinder
Block

Probable

E

10.

‘Cylinder
Leakage

Head Gasket

Grek)

Head

in Cylinder

Block

12. Crack) in Cylinder

Loss of Coolant

Recommended Procedure
A. Outside Leaks

1. Leake in Hoses or Connections … Check al hoses
and connections for visual signs of leakage. no
leaks aro soon ook lor damage to hoses or loose
Samos

2, Leake in the Radiator andjor Expansion
Tank... Put pressure 10 Ne radaor and/or
expansion tank win tro 958140 Coakng System
Pressurzing Pump Group and check for eas,

3. Loaks inthe Hear... Put pressure to the cooking
system wth the 958140 Cooling System
pressurzng Pump Group and check the heater or
kate.

4. Leaks in the Water Pump... Check ho water pump
forleaks Deore starting the ange, han sar the
engins al ook for ak. thre aro leaks a the
‘wale Pump, ropa oe instal a now water pump,

5. Cyinder Head Gasket Loskage … Lock frais
long the surface of the eyiner ead gash. you
820 aks, installa now head gaste,

B. Coolant Leaks at the Overtiow Tube

6. Bad Pressure Cap or Rl Vave Check he
sealng surlaoe ofthe pressure cap and the
facia: to be sure the capis sealing correct
Chock the opening pressure and sealing aby of
the pressure cap © role valve with the 958140
(Cooling System Pressuizng Pump Group.

7. Engine Runs Too Ho... coolant temperature is
100 high, pressure il be high enough to move the
ap of ofthe sealing surace in theradator and
‘case coolant oss through the ovrton tube. See
“Roove Normal Heatng in COOLING SYSTEM
Chart

8. Expansion Tank Too Sera or nstaled
Wrong. The expansion tark can bo other a part
‘ofthe radiator or can be stalled Separately om
the radiator. The expanson ark must be lago
‘enough to hed the expansion ofthe coolant as 4
ets warm cr has cuen changes in pressure,
Make sue the expansion tank i instaled correct,
and the zo ls according o he recommendations.
fl he Truck Manulacurer.

9. Qyindor Head Gasket Leakage, or Ceac) in
Oyarder Head or Oyinder Bock... Remove the
rater cap and wih the engine running lok or air
‘bubbles in ie coolant. Bubbos in the coolant are a
Sn of probable Waage atthe head gasket. Win
the engine not running, check each oynder win Ihe
‘finder lakage lester. Special nsrcton. Form No.
(GAGODBE4 ques the test procedure. I you see ar
‘bubbles in the coolant during ths tos, here sa
leak of combustion gas into the cooing system.
Famous the cylinder beads from the engine. Check
‘inde heads, cyincer was and head gasket
Frac ofthe cjander block fr cracks. When
irstaing heads, uso new head gastar

©. Inside Leakage

10. Oyinder Hoad Gaskot Leakage the cyinder
Read gasten leaks betwen a water passage anc
an opening tothe crankcase, coolant val et nto
the cankcase

11. Crack) Oyinder Head … Cracks) nthe upper
saco ofthe cyinder had, o an area between a
water passage and an opening into the crankease,
Can allow coon o get io the crankcase.

12. Cracks) in Oyinder Block... Cracks inthe
Singer block between a waler passage and the
‘rankcase wi le cooant got tothe crankcase,

ET EE TE

FUEL IN CRANKCASE OIL

Probable Cause(

T. Bad Seals on Fuel Injection Pump
Camshaft andr the Drain Line from the
Bottom of the Fuel Transfer Pump has
a Restriction

2. Loose Fuel Injection Nozzle Nut

3. Bad Fuel Nozzle)

Fuel in Crankcase Oil

Recommended Procedure

1. Bad Seals on Fuel Inscton Pump Camshalt andjor
the Dran Line trom tha boto ol he Fuel Transl
Pump has a Restriction .. I both seais onthe fuel
‘pump camshaft inthe body forthe fuel rer
Pump and/or the drin ine rom the bat of the
fos ranater puro has a reinen th fel can leak
by the soa Grec mio the engine. To core,
"otal now seals inthe body forthe tl ransler
amo and bo sue he dran ines open.

2. Loose Fuel nection Nozzle Nuts)... loose fuel
infection nozzi nut ora bad Osing Salon the
nozzle nel can cause [ua leakage. Tighten nozzle
nut) 10 422 7 Nem (BI + 5 ft) and check fora
ac Oving seal

3. Bad Fuel Nozzles)... Check tel nazz) or
‘racks in et iting, it ne, or nezzle body. you
6 not se0 à crack ar the engine and usual
inspsct each novle fot leaks. Cracks in to lt
fing and nozzie body are nozzle defects Cracks
in tho mat tno are caused by the nozze not being
tightened corecty. Check fr leakage at in fuel
nozzle cap. no leakage 6 sean Ie fel nozzes.
Can ba removed and cnocked.

rs

‘Sia Gas —

Engine Vibration
Troubleshooting

1. Tho customer must be asked questions to
öelermine whether his compat va, or whether
his clagnosi of the actual problem is cor

‘Some ofthe questions that must be asked are as
fotos:

a. What components are orang?

1. In what speed range does this viraton become
exceso?

6. Does duch operation affect the Woraton?
1. What the history ofthe proben?

2. Fun the engine trough tho ide speed range and
rote al Moral components. Lok tr any loose or
Broken mounts, brackets and laser, Rapar and
lighten any fours.

3. Check ie speed range with chtch dsengaged. I!
\ibralons subside, thee 5 a baanca prodem wth
tha cite dio. The cutch iso must be repare or
replaced,

4. Furtneranaysisrequtes the use ofa raten
Instuenent. Any instrument which can accurately
messur tne placement ofthe vibration (usualy
in misanch/ 1000) and the equency (eyes per
minute) wi be sufficient

NOTE: A vorn instrument such a the RD
Mochanalyis Vode! $20 cr an equivalent instrument
can be used o anayze viralen,

5. Measure vbraton of cab components which ha
the ddjctonabie vibration,

Fun engine lon trough the speed range and
measure vraion wh te instrument” OUT. When
peak amplitudes are found, run the engine at the
Speeds they occur and with he instrament ter IN, ind
the frequency ofthe Vibration,

He frequency of orten Is 4 times of engine rpm
(perder the orton à causes by a evince
misting. This must be correcte bere futher
‘bration analysis mace

the frequency ol ration 4 times engine rom, no
‘corrective acton can bo taken on the engine because
is the fng frequency ofthe 3208 Engine. The
Problem isin the cab or chassis resonance

I frequency is some order other than % or, thon
further measurements must be made on the engine

6. Measurements taken on the engine must be mada
perpendeuar o he Cranksnlt a ne font ana rear
Of the engine in vertical and horizontal ceci

7. Record al vibrations over 40 mis and te engine
rpm at wich A oocurs (100 rpm intervals are
Suffer) wih instrument or OUT. Not ary
sudden increase and decrease in ampitoces, These
(cur in resonant speed ranges.

tro amplitudes exceed 4.0 mis, the engine is within
“Carol Specs.

Harpies exceed 4.0 mis, te vibrations must bo
‘measured with the Instrument iter N o obtain the
frequency ofthe vations

8. Run tho engine at high ile. Wir the instrument
fitr IN, check the frequency range and record any
ampitudes over 40 mis andthe coresponcieg
frequency, Arayas of vixaons fer the posee
causes ie done by ¡doing the trequency of the
bration and where on the engine isthe Greatest
magne,

9. Before vation is rechecked, rta tho crankshaft
10 No. | oyinder top center poston. aa a 36-18
ball 134 ong wth à ru to the yuca! al the 9
lock pestion.

10. The location on the engine at maximum vibration
{ont er ea) can hab pirpon the cause ofthe
‘ration. High rear vibratons cou be caused by
the fared.

(Section Five)
Bates 57
Bears 56
‘amon 5
out Row. Tapered aor ss
Hestng Bearings 3
reisen. E
Pra 37
Seove Beurnge 37
Bots And Bot Tope se
"Torque Wrench Exención ES
THT Procedure EN]
Ceaninese 52
‘Gerworson Char chos To N 58
isassombiy And Assemby 52
Gaseis sr
rta Operation Aer Engine Reconetonng u... 53
{unes Ana wees
Lresten

Lien For À abt Engine
Procedure For Pressure Luca,

Pressing Paris 54
Removal Anstalt. 52
us Fer Use Ol Too E]
ust Prevent Compra 56
Seas tygogmame)
53
Bear Cup Ping Arche 5a
Bear Ping Atachment 54
Pier Assembly (2013 Am) 53
Push A Ss
sure 56

BestManuals. net

= Index

General Instructions (D & A)
3 mm (.125 in) THICK
FLAG WASHER

The folowing instruction wil prove pta to
Goasserbe and assembly engne corperert, The
iniomaton shou be 023 ard then rlaod os
necessary

Cleanliness

PT olor nes aro
‘Ssoomnecte, ean the pont of isconraclen and the
acens area As coon s he esconnecen © made,
ap, pig o lape the ine or opening fo prevent any
‘tiorign mate! Tho sme rocormandtons or
‘leaning and covering apply when access covers or
fspacten alates ae removed

¡an and inspect al parts. Be sur al passages anc

oes are open Cover al pars lo keep then Goan Be Fed eyebals ao avalable Each eyobat has a

Sire parts are clean when natale Leave rew pais. Mau oad recommendation.

Bonner ut ead lor assur

Removal And Installation Pe

ness omnia specie, al romane chou be al TE Et =

Becompienna using an asusiae ling beam Al

Supportng Members (chars and cabos) shoud be vera ww ans

paraa! o each cer and as near perpendicular as eae | as sos

Possible o ho top of Ine objet barged. vera | seas pa
m | so | aus
se Pr axes

(sacar
sac unt ‘Some removats require the use of Ming fitures to
Shan proper balance and o provide sale handing,

ita part reis removal, chek o be coran a nas
correct And bats have been removed and thal an adacort
Dare noter

isassembly And Assembly

en assembling an ange, complete sach step n
turn Do rot parialy assemble one part and start

nen ie necessary 1 remove a component on an coming some ober part Make a acıcunent a
ang, remember that ihe capacıy ofan eyebat recommended Amaya encc he ‚gb ltr.
‘Smnnanes 42 tho angle between the supporting Comptes to see Ia nctrng as been coke

‘members and the coe! becomes les han SO
jee ana bracts shale never bs bert an
hou on hive sess tension. length 0 pipe and
‘a ashor can be oes, se staan, 10 ho reve hese
Sees on ays

52 “General Instructions (D & A)

Lubrication For A Rebuilt Engine

Li very important fra rob enge 1 have
“adequate” (dee) oralen dg the Test
Second of operation A y sla thou needac
[Ubcaton) on a raul enge or an engine at has
‘been in og can causo beating damage.

To prevent the possi o "sy start and bearing
age dug the st few seconds of turning, use
the 1P0S40 Fw Chocking Ton Group anc shop ar
pressure to pressure bral (e anol

‘th ol unde rezsue) al ebult ongnes anda
‘gins hat have bean in storage

Procedure For Pressure Lubrication

1. Glan he tank o he 1POSAD Flow Orecking Toot
Group throughy and sat he pressure regulator to
240 À 35 kPa GE = 5 pa)

‘Air pressure should not be more than 345 KPa (50
si} at any time.

2. Pa the cone enge où int he tank Use a
‘inna of 30% a ne engine olcapasty. For
ora anges wn be nacaesary tof te take
‘overlies o got the caret amount of ain the
engen.

3. Connect the tong othe man où passage o he
engine.

1. Ad prmeurs 1 he tan, wh ne rege sot
1240 £95 KPa (95 + pa) Although re tak has
hand pump, ts cite to qe nou a
Pressure to doth job wth the hand pump,
Merle. use of Sp ar is ecor mended

$. Lat ne engine « How nto the où patsage under
pressure,

Fil ne crankcase with he correct engine où. The
amount of ol used n the presto ubrcator
Procedure most be subie rom fe racommendes
rat capacty nthe Operabon Maintenance Marval.
the Caine sot gong to be used or a ng tne, de
the above procodure agan bate te re stat,

shop ar not aval, er charging he tank, the
hard pump may be used to gat the mam que
presse,

NOTICE,
DO NOT use the same 1POSAO Flow Checking Too!
‘Group for both "pressure ubrication applicator and
{or checking tal ow Incrrec leaning 1 probable
‘the tools used for Boi ful andlubrcatn a Even a
‘mite amount of din the toa systom can cause tus
rose fle.

Initial Operation After Engine
Reconditioning,

‘Te ety of of cono! components used in
Coral enges 5 such Pat flowing engine
recontra with Cate Serve Parts), oi a
trl eperatona crack e nosenary batero contras

‘Te purpose of hs nal operational check so:
insure thatthe eng has boon assembles propa
éme | proper prossues and temperatures aro
marine ne Lion, coding and at
ya: mac amy as parlors taco
moni (such a va Ceara, gover igh
land iow ie Speeds, ec): check re St pot

To provi a sate, untrm ill eperaoal check, he
fol procedure recommande

1. Motor enge al ranking speed un ol pressure i
ane

2. Operate eng fr 10 mutes tow ie

3. Operate ongne or 15 minutes at halted and ja
‘ated engine speed

4. Operate engne for 30 minutes tate lose ane
speed

Service Tools

Poller Assembly (2 Or Arm)

Two or toe am pules assembles can be used to

LEON ge betray cage, he, Dears, at

Push Pullers

Puch Puters can ba usec to remove play, gar,
sats ete and can bo used me vary ol pulir

Bearing Puling Attachment
Beanng Pulng Atsenments can be used wih lg
bolls, 0 remove shafts, bearings, gears. et. They can
De used uth Push Puls 1 prude a vray of pl
Sonbesalons

Beating Cup Pulling Attachment

Bring Cup Puing Aachen are used to remove
‘bearing rates or cups, slave ype besngs. DearS,
Shas, ic. ang canbe used win Push Palas
Rules For Use Of Tools

Rule 1: Always use sate Too.

ule 2: Koop tots in ate working condition
Rule: Use the correct oo for o jo.

Rule 4: Common sense wit tool pays of.

Pressing Parts

When pressing ove par nto ance, ute 523031 Ant
Seize Compound ora moidanum dei vase
compound otage the ating suracee

Ascombie ‘apored pats cy. Bere sssembtng paris
‘nth aptes spin, e su te pines ae clean, ry
375 ro tom burs Peston the parts together by
and to mesh the spies Dee Spin pressure

lt par wich are tte together wn tazered spines
se ct gt inspect he pete spines an BCE

Bolts And Bolt Torque

‘bolt ac too tng may “voter bear the head
(stent agains th par lo ol, Tra regar can be
damaged aran a ong Dal remove

A aboli co short, there may rot be enough Ira
‘paged io hal he par seco

‘Aly proper loque vais toa bts and nuts wen
storing Cateriar Equipment When à socete
{orque vale required he values sted nthe
Specticatons Socton ot ns Server Maui Tighten
acer bots and ruts or general usage, rade
a bodies, o aperick tus othe torque values
{ven ine torque chars shown inthe Sen
Nerval

NOTE: Take care 10 avoid micng metic and inch
fasteners. Miematched rincon fasteners can fe
1 mecnancal damage a alluncien cr poesble
pesa my, Orgral aclner removed during
assembly shoud De save or astemtay ren
Possible 1 now ones are roqured, caution must be
‘axon 16 replace wi one inate ol same par amber
and grade

atric teas fastener ao identi by mater)
engin (rade) numbers on bot heads and ms
Number ón bls ville 85,109. ete Numbers on
mus wi be 8, 10, to

T-T-T Procedure

A torquetuntghan (TT) rocas fused in many
Speeteations ard matters

‘ean he bot and ut tenes

. Put bration of the treads ar the seat face of
the Bot and rut

3. Tur he bot or he nt tant acsorang to the ore
speateaton

4. Puta locaton mark onthe part and onthe Bot
ta ort

5. Tum the bal othe ru hier the amount ot
degrees corts tothe specications

| General instructions ( & A)

NOTE: The sie o a ut or bot head can be usa for
‘erence Y a mark can rok Be pur on

Torque Wrench Extension

nen a torque wrench entero used wih a torque
asc we traue ciation onthe ee wrench wi
Dele han the an torque

O

1. Puta maricon tr nance, Measure th hand Im
Ina mare 1 the ans ofthe org wench eve (47)

2, Measure the torque user extension tom the
torque wrench ar tothe an othe toque wrench
menso re (E)

3. To get rec toque indican (Men Ine ea
ordi (AT) ow

Ear W = 3048 mm (12: E « ESO mm (256
In) BT thom sions) = 17 Nem (12501

vous ll
o Nm

= or a
mr = BEAD or 030 A

=

4. Ho I or wench hand we the longest
tiger cf te rand ovr In mark on he hand to
get ra torque (AT) wi ur que aan
{ih on te toraue wrench

“General instructions (D & A)

Locks

Fat metal cc must be instale propery tobe
cie Bend ana end ofthe lock sound ne ge of
the part Bon te cho’ era aps ono at suis ol
the ur of Bal head.

‘Aways instal new locks in components which house
mo parts

Irocawashers ve instal on housings made of
‘tern, use a fal washer between Ins ookwesher
ana tha havens,

Lines And Wires

en rome 0 connect a group ones or
‘ites, fag each na o assure poper aster,

Lubrication

ire appieae, tH the compartments of he
Componente serviced wh tha amount, ype and race
St bseart recommenda inne Operation
Martenancs tual

Rust Preventive Compound

San the us praventve compouns tom al machined
Swacs of now parts bole sting te part

Shims

en shims ate removed e them together and
iden em as fo beaten. Keep ss Geen and fat
ur ay ar renales,

When an anti ton Boating reve covert to
Ha ot rt and abrasves, Wash tho bearing
onfanrrabie clearing souron and alow emo
Gain cy The bears may be Sreg win compressed
ut DO NOT SPN THE BEAANNG

ais

we Te)

Oscars tre bearings the aces and nat orales are
pie, secre er burned the bear ng teva
oar th of and wap in een pager. DO NOT
¡rap nen boarngs un tne of station

‘Tro Me lan an tacton bearing wa be shertenee #
not open bread

Double Row, Tapered Roller

Double rom. tapered rote’ bearings are prison ft
ng marutacire ara re components are not
interchangeable. The cups. cores and spaces re
sunt ta ut he same earl number an ter
‘osgratr na ker cescratars ae 10a. wre the
Companans eget 1 astur caret On.
esca boanng components shows be insta in
Mar ogra postone

Heating Bearings.

Bearngs which requre expansion for instataton shoud
be need n 01 ol o exe 121" © (250) When
AE nan on part Feat o udn ass. they
trust be alone. to coo and then presse together
Shan. Part On sopra s hey coat and sur.

Installation

Lubecate new or used bearings blere sale.
Bearings that ae 10 De racadd must have a Im ot
ft ova he ene asser 1 lan accurate
Probacıng Wan many a bearing, spacer o.
Vas against a Shouse’ on à safe are tho
Chanvered ade tours the shoud

q

Gaskets

Be sure the holes nthe gaskets correspond wth he
‘Mbscant pastagos in he mating par HL.
necessary make gaskets sal stock ofthe proper
pe and theknes. Be sut to cu holes propery.
‘Blane gastas can case serous mago

Batteries

Clean aller by servoing at a slut of ing
‘so and wate. Aso win Cor water. Alo clang,
‘ry oro, and coat temnals and comets
‘nth articoraen compound or reco

Wan engine ot be used lor along paros of tne
remove the batters Sor hem co. ey placa, À
mal charge shoud be introduces perde} fo keep
the space gray tang at he recommended ve

‘Seals (Lip-Type)

Generate toe or sorngtoaded lp ofan ol sea
faces tre of bang sele or he of Pang the higher
Presse The too ot ip of guasa anal aces away
from the worcart beng sealed, Ur otherwise
spoctod, use the preceding es fr nstling p-type

"Non pressag bearegs nto area’ obere, pty
Pressure o e oder race Ht the Dearing = pressed on

the sat, apply pressure onthe imer race

Proload

Preis an nal ore placed 0 In bearing the
temo como

Determine proc or end clewance fom tne
‘Spectcabans Scion othe Serves Mana Care
shoud be exercised in appvg preload. Msapphcañon
‘totes fo bearings reguning nd Garance can
en bearing faire

‘Sleeve Bearings

(00 NOT INSTALL SLEEVE BEARINGS wT à
HAMMER Use a press. posse and app the
pressure Arch nine wi te bore tm necessary
"oda on a beatng, iso a Quer ot à Dar wih à
“moot fat nd a soso bearng has a ol hoe,
Sign twin the ol tow n he mating pat

1G pe

FER a

The main parts of ao type seal are the case. sang
mari, and the garter gung, The tuaton shows
the consucton la simple Ip type seal Te cos
Scion shows th rma nea and 00" used te
"Ser the eso varus types of sels

Conversion Chart (Inches To MM)

La = | criss Vs
&

meme | mem re a CRE a

ae ah
Tan a

re a um u 0

. in “ =

| am u

me ros | veut nee | sem Toe e ni Se
u un

* a #“ ES

a um

EE en

at he ps ope sea bear instan we vum
Le ne came pe of bean nen me sal wide ae nn ge
parado, Do Nt se gras on any sa capa PURE CEE
‘rose > um
à a a Pi

Hcg intl, he seo 1 mus ass ve a hai ue =
hates apes shay. ough los ea che ae st aig
Se. Me can soy damage Sten sock of a de =
e min tel can be tomás so mama My 2 e
OR a smooth sic ove which o De ed is wm
. 2 ss

ae om

Seals (Hydrodynamic) a's LE
Tre yoga seas rent tom o piype at 17
seat Ta rence à Icom green the ae u

Seaing pol tis seal. These grooves move ubican Y
‘tack to to engine crenkcace asthe carta
uns. Bocuse ol hs sa! lo desgn. in on sa or
An eng e ret om the rar sel The nao
Postal he sal is importa because ne sea
roses so sense Yo the cretion of erankanat
(lo. Each ale martes wth an row o row he
‘Srechon cl engne rotation H tba sels nt nal
‘ome, olin the erarkease wi actualy De romanes
‘Specalfarcing ard instaleton procedures are ven
ln Spec nevutien, Form No SMeS8s08

2208 TRUCK ENGINE

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY (Section 6)

sr Teng Ares

‘Great Pa Sela Wear Se
Ge Mess
hace Neds, Dando Aso

Ens O Cod a OL Ft Base

en SG a lr a Dana à
Soin

pen Sn rn

Flat peter Pur Moving. Dos à
Taro

parrain Bs
Fi peter Par, Dari Aseo
tan Ps ho qu Go

en
Ed

Es

E

Fa! ton Pump Noung and Gover. Separa &
so Pur Hany
oda oi

Fit Ao Conta, Bastian À Kazaa
Fit Teter Pune

a Rts)
Rocker Sats an Pah Rose

Roster State, ananas € Assent
ran

tan San
Parad Pa ie

Sea vg

Prepon ove ano ame

Totes Siw aso 4 Art
ns
TEEN (een core à

ae Pur
ae Pur, Desamor
fa Sourate

‘aw Tenor Rr

À WARNING

DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WORK.

se serE

#2

3208 TRUCK ENGINE DISASSEMBLY AND ASSEMBLY

AIR INLET MANIFOLD
REMOVE AIR INLET MANIFOLD 1058-11

1. Loosen clamps (1) and (3). Disconnect

hoes.
2. Remove bolts (2) and elbow (4),

3. Loosen clamps (8) and then side the hose on to
the turbocharger.

4. Disconnect hose (9) from the manifold
5. Remove fue line (7) from the fuel ratio control.
6, Remove bolts (5). Loosen bolt (10).

NOTE: NOTE: Manifold (6) has an opening (slot)
in it for bot (10),

7. Remove manifold (6) and its gaskets
INSTALL AIR INLET MANIFOLD 1058-12

1. Put gaskets (3) and manifold (1) in position
nd install the bolts that hold it

2. Put hose (2)in position and tighten the clamps.

3. Install fue line (4) on the fuel ratio contro. Con-
ect hose (5) to the manifold

4. Put elbow (6) in position on the manifold and
install the bolts that hold it

5. Connect crankcase ventilator hoses (8) to the
elbow and tighten the hose clamps

6

Connect hose (7) 10 the manifold and tighten
the hose clamp.

3208 TRUCK ENGINE DISASSEMBLY AND ASSEMBLY

AIR INLET MANIFOLD (LATER)
REMOVE AIR INLET
‘MANIFOLD 1058-11

start by
3) remove turbocharger

1. Loosen elamps (1) and (2), Disconnect the
hoses (3) from the manifold.

2. Remove seven bolts (6). Loosen one bolt
{manifold has an opening {slot} in it for this
bolo.

3. Disconnect fuel line 5),

44. Remove air inet manifold (4) and its gaskets.

INSTALL AIR INLET
MANIFOLD 1058-12

1. Put the ai inlet manifold (1) in postion on
cylinder block and install the seven bolts that
hold the manifold in place. Tighten the one
bolt (one in manifold slot).

Connect the fuel

(8) to the manifold.

3. Connect hoses (4) 10 the manifold and tighten
clamps (2)
end by:
3) install turbocharger

3208 TRUCK ENGINE

DISASSEMBLY AND ASSEMBLY

WATER SEPARATOR

REMOVE WATER SEPARATOR 1263-11

NOTICE
Element (2) is free to fall when clamp (1) is
released.

1. Remove clamp (1) and element (2)

2. Disconnect line (4) from the water separator
base

3. Remove the two nuts and water separator base
@

4. Remove three bolts (6), bracket (5) and spacers

INSTALL WATER SEPARATOR 1263-12

1. Put bracket (1) and

Install the thee bolts. Tighten the bolts to a tor
que of 14 + 3 Nem (10 2 Ib).

2. Put base (2) in position and install the nus.

3. Connect line (3) to the base,

4, Patel

NOTE: Mal

Wis

ent (4) in position and ins
sure clamp (5) is tight because ele
do fal,

64

2208 TAUCK ENGINE DISASSEMBLY AND ASSEMBLY

OIL PAN
REMOVE OIL PAN 1302-11

1. Drain the oi from the engine.

2. Remove four bols (1) and sound suppression (2)
from the oil pan.

3. Remove four brackets 3)

4. Remove bolts (4), oi pan (5) and the gasket

INSTALL OIL PAN 1302-12
1. Inspect te ol pan gasket, Install a new gasket if
needed.

2. Put brackets (1) and oi pan (2) in position.

3. Install the bolts that hold the pan in place.
‘Tighten the bolts toa torque of 23 4Nem (17 +
3).

4. Put sound suppression (3) in position and instal
the bolts that hold it

5. Fill the engine with oil tothe correct leve.

Caterpillar 3208 Diesel Engine Service Manual Copy One [PDF, ENG, 154 MB].pdf

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Caterpillar 3208 Diesel Engine Service Manual Copy One [PDF, ENG, 154 MB].pdf

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