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CEBM000601

Shop
Manual

SGD114E=i
SAID1
14E=l
SAAGD114E=i
SERIES ENGINE

SERIAL NUMBERS

45241940andw

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.

May 1997

Copyright 1997 Komatsu America International Company

CONTENTS
SHOP MANUAL

01

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

TROUBLESHOOTING

& REPAIR MANUAL

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

02

PRODUCT PUBLICATIONS

INFORMATION

VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SERVICE
MANUALS.

SPECIAL PUBLICATIONS
SUCH AS SERVICE TOOL, AIR CONDITIONING,
AND TURBOCHARGER
SERVICE
MANUALS ARE ALSO AVAIlABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN
LANGUAGES.

THE PUBLICATION

LISTED BELOW ARE AVAILABLE FOR THE 6D114E-1 SERIES ENGINE.

DESCRIPTION

FORM NUMBER

SHOP MANUAL SET: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

CEBM000601

& Repair Manual

PARTS AND SERVICE PUBLICATIONS CAN ONLYBEACQUIRED


BY AUTHORIZED
USING THE KOMATSU PARTS INVENTORY PROCESSING SYSTEM (PIPS).

KOMATSU DISTRIBUTORS,

IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR


LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM
KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.

PUBINFO.KOM

021596

REQUISITION

COMPLETE FORM
AND RETURN TO -

FOR TECHNICAL

SERVICE PUBLlCATlONS

AND SERVICE FORMS

Komatsu America International Company


440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Am: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME

SHIP TO -

ATTN.

TYPE or PRINT
ONLY

ORDER DATE

STREET ADDRESS

CITY, STATE, ZIP CODE


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PHONE NO.

SHIPPING METHOD

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IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S),


SERIAL NUMBER MUST BE SHOWN.

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PARTS ;FaFe;
g

KDC91 D 022597

M-Microfiche

PUBLICATION
DESCRIPTION

THE MODEL NUMBER AND MACHINE

MODEL NUMBER

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

Shop Manual
S6D114E-1
SAGDI 14E-1
SAAGDI 14E-1

Series Engine

6D114E-I

Series Engine

Foreword
This manual contains

complete

rebuild specifications

and information

for the 6D114E-1 Series engines.

The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent
in place of the recommended item.

product can be used

A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available
ordered through your distributor using the form in the front of this book.

and can be

The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Komatsu America International Company reserves the right to make any changes at any time without obligation. If
differences are found between your engine and the information in this manual, contact your Komatsu Distributor.
The latest technology and the highest quality components are used to manufacture
parts are needed, we recommend using only genuine Komatsu exchange parts.

Komatsu engines. When replacement

Engine - Exploded View by Groups

GROUP 02

GROUP b9

GROUP

16

Table of Contents
Page
Introduction

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

Engine Identification
Engine Disassembly

...........................................................
and Assembly

- Group 00 ..........................................

Cylinder

Block - Group 01

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

Cylinder

Head - Group 02

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

. . . . . . . . . . . . . . . . . 2

Rocker Levers - Group 03

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

. . . . . . . . . . . . . . . . . 3

Cam Followers

- Group 04 .......................................................

Fuel System - Group 05 .........................................................

Injectors and Fuel Lines - Group 06 .................................................

Lubricating

Oil System - Group 07 ......

. . .

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

. . .

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

Drive Units - Group 09 ..............

. . .

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

Air Intake System - Group 10 .........

. . .

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

10

Cooling System - Group 08

Exhaust System - Group 11


Air Equipment
Electrical

- Group 12

Equipment

..........

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

- Group 13

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

11
12
13

Engine Testing - Group 14 ......................................................

14

Instruments

15

Mounting

Adaptations

Specifications
Index

and Controls

- Group 15 ...............................................

- Group 16

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

and Torque Values - Group 18 ..........................................

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

16
18
X

Page i-l

Section i - Introduction

Section i - Introduction
Section Contents
Page
Aboutthe

Manual

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

i-2

Solvent and Acid Cleaning ....................................................


Steam Cleaning . . . . . . . ....................................................

i-8
i-8
i-8

General Repair Instructions ....................................................

i-7

General Safety Instructions ....................................................

i-6

Generic Symbols . . . . . . . ....................................................

i-4

Glossary of Terms . . . . . . ....................................................

i-9

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

i-3
i-3
i-3
i-3
i-3

Illustrations . . . . . . . . . . . ....................................................

i-5

General Cleaning instructions ..................................................

How To Use This Manual


Group Contents . . . . . .
Index . . . . . . . . . . . . .
Metric Information, . . . .
Table of Contents . . . .

.
.
.
.
.

Page i-2

Section i - Introduction

About the Manual


This 6D114E-1 Series Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding
and assembly of components of the 6D114E-1 Series engines. The manual is divided into sections. Section 00 outlines
the disassembly and assembly of the engine while the other section detail specific components.
The procedures in this manual were developed for a shop environment with engine disassembly and assembly being
performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and
systems. Refer to the Table of Contents (page i-l) for the various groups. The information is presented in very basic terms
to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when
needed.
Each group contains the following in sequence:
l

An Alphabetical Table of Contents (Index).

Exploded view(s) of all the components -in the group.

General Information Section(s) containing the basic service, maintenance, and design information necessary to assist
in the rebuild of the engine or a component.

Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an
engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These
repairs depend on the length of time an engine has been in service and the condition of the parts.

Page i-3

Section i - Introduction

How To Use This Manual


Table of Contents
The Table of Contents in the front of the manual contains a quick page reference for each group number.

Group Contents
Each group contains the following information:
l

A group index page at the beginning of each group to quickly aid in locating the information desired.

General information to aid in rebuilding the component and an explanation of design change differences.

Step-by-step rebuild instructions for disassembly, cleaning, inspection, and assembly of the component.

Symbols which represent the action outlined in the instructions. The definitions of the symbols, appear on pages
i-5 through i-8.

Index
An alphabetical index is in the back of the manual to aid in locating specific information.

Metric Information,
Both metric and U.S. customary values,are used in this manual. The metric value is listed first, followed by the U.S.
customary in brackets. An example is 60C [14OF].

Section i - Introduction

Page i-5

Illustrations
The illustrations used in the Repair Sections of this manual
are intended to give an example of a problem, and to show
what to look for and where the problem can be found. Some
of the illustrations are generic and might not look exactly
like the engine or parts used in your application.
The
illustrations
can contain
symbols
to indicate
an action
required, and an acceptable or not acceptable condition.

0+B
/

ca9OOsh

The illustrations are intended to show repair or replacement


procedures. The illustration can differ from your application,
but the procedure given will be the same.

kn9cswt

Section i - introduction

Page i-6

General Safety Instructions


Important Safety Notice
A

WARNING

Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting
motor if equipped to prevent accidental engine starting. Put a Do Not Operate tag in the operators compartment
or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler
cap and relieve the pressure from the cooling system.
Do not work on any thing that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fiiings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure,
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines
in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled
using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law
requires capture and recycling refrigerant.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not
be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with
skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact,
immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A
PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturers instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes
and compartments.
Always use tools that are in good condition, Make sure you understand how to use them before performing any
service work. Use ONLY genuine replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners, Do not use a fastener, of
lessor quality if replacements are necessary.
Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

Page i-7

Section i - Introduction

General Repair Instructions


This engine incorporates the latest diesel technology;
performed to quality standards.

yet, it is designed

to be repaired

using normal repair practices

Komatsu America International Company does not recommend or authorize any modifications or repairs to
engines or components except for those detailed in Komatsu Service Information. In particular, unauthorized
repair to safety-related components can cause personal injury. Below is a partial listing of components
classified as safety-related:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter
Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing
Turbocharger Oil Drain tine(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted In the Procedures.
Follow the manufacturers recommendations for cleaning solvents and there substances used during the repair of
the engine. Some solvents and used engine oil have been identified by
government agencies as toxic or
carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety
practices with tools and equipment.

Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine
components

and its components


must be kept clean
will cause premature wear.

during

any

repair.

Contamination

of the engine

and

Perform the Inspections Specified in the Procedures.


Use Genuine Komatsu Service Parts and Assemblies
Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
-

The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Komatsu
components. All of the repair services described in this manual are available from all Komatsu Distributors.

Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.

Complete rebuild instructions are available in the shop manual which can be ordered or purchased
Distributor. Refer to Section L, Literature, for ordering instructions.

from your Komatsu

Section i - Introduction

Page i-8

General Cleaning Instructions


Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Komatsu America International
Company does not recommend any specific cleaners. Always follow the cleaner manufacturers instructions.
Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95
Celsius 1160 to 200 Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning
solution will give the best results.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam
clean the parts before putting them in the cleaning tank.
Warning:

The use of acid can be extremely dangerous to personnel and can damage the machinery. Always
provide a tank of strong soda water as a neutralizing agent.

Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust-proofing compound. The rustproofing compound must be removed from the parts before installation on the engine.

Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way
to clean the oil drillings.
Warning:

Wear protective clothing to prevent personal Injury from the high pressure and extreme heat.

Do not steam clean the following parts:


1. Electrical Components
2. Wiring
3.

Injectors

4.

Fuel Pump

5.

Belts and Hoses

6.

Bearings

Glass or Plastic Bead Cleaning


Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning
process is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time.
Caution:

Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead
cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the
aluminum and result in premature wear. Valves, turbocharger shafts, etc. can also be damaged.
follow the cleaning directions listed in the procedures.

Follow the equipment manufacturers cleaning instructions. The following guidelines can be used to adapt to
manufactures instruction:
1. Bead size:

Use U.S. size No. 60 for general purpose cleaning with glass media.
Glass: Use 620 Kpa 190 psi] for general purpose cleaning.

2.

Operating Pressure:

3.

Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads
after cleaning. Rinse with hot water. Dry with compressed air.

4.

Do not contaminate the wash tanks with glass or plastic beads.

Page i-9

Section i - Introduction

Glossary of Terms
Definition
A. C.:

Alternating Current

AFC:

Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is
sufficient intake manifold pressure to allow for complete combustion.

ATDC:

After Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving downward on the power stroke or intake stroke.

BDC:

Bottom Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is at its lowest position in the cylinder.

BTDC:

Before Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving upward on the compression stroke or exhaust stroke.

Circumferential Direction:

In the direction of a circle in respect to the centerline of a round part or a bore.

Concentricity:

A measurement of the difference between the centers of either two or more parts or the
bores In one part.

Silicone Sealant:

This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive and
sealant material having high heat and oil resistance, and low compression set.
Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corning, Silastic
732, Loctite Supetflex, General Electric RTV108 and Three Bond Sealant.

D. C.:

Direct Current

Dye Penetrant Method:

A method used to check for cracks in a part by using a dye penetrant and a developer.
Use crack detection kit, Part No. 3375432, or its equivalent.

End Clearance:

The clearance in an assembly determined by pushing the shaft in an axial direction one
way and then pushing the shaft the other way.

E. S. N.

Engine Serial Number

Hammer:

A hand tool consisting of a hard steel head on a handle.

I. D.:

Inside Diameter

Loctite 290:

A single component, anaerobic, polyester resin, liquid sealant compound that hardens
between closely fitted metal surfaces producing a tough. hard bond. Equivalent products
are Komatsu 1232 273 Hl and Perma-Lok HL 126.

Loctite 609:

A single component anaerobic, liquid adhesive that meets or exceeds the requirements
of MIL-R-46082A (MN) TYPEl.
Some of the equivalent products are Komatsu 634 018 Cl, Loctite 601 and Permabond
HL 138.

Lubriplate 105:

A mineral oil base grease with calcium soap (2 percent to 6 percent), and zinc oxide (2
percent to 4 percent) additives.

Magnetic Particle Inspection:

A method of checking for cracks in either steel or iron parts. This method requires a
Magnaflux or equivalent machine that imparts a magnetic field on the part being checked.

Mallet:

A hand tool consisting of a sofi head, either wood, plastic, lead, brass, or rawhide, on
a handle.

Section i - introduction

Page i-10
Definition
MAX:

Maximum allowed

MIN:

Minimum allowed

No.:

Number

O.D.:

Outside Diameter

OS:

Oversize

Protrusion:

The difference in the height between two parts in the assembled state.

STD:

Standard

TC:

Torque Converter; used when referring to the torque converter cooler.

TDC:

Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The
piston is at its highest position in the cylinder. The rod journal is pointing straight up
toward the piston.

T.I.R.:

Total Indicator Runout; used when measuring the concentricity or the runout. The T.I.R.
refers to the total movement of the needle on a dial indicator, from the most negative
reading to the most positive reading.

Water Pump Grease:

A premium high temperature grease that will lubricate anti-friction bearings continually
from minus 40 C [minus 40 F] to plus 150 C [plus 350 F]. Some of the greases
meeting this requirement are Aeroshell No. 5, Chevron SRI, Amoco Rykon Premium No.
2, Texaco Premium RB, and Shell Dolium R. Aeroshell No. 5 is not compatible with the
other greases and must not be mixed. Aeroshell No. 5 is used on new engines and
components.

Section E - Enaine and Component Identification


Page E-l

Section E - Engine and Component Identification


Section Contents
Page
Engine Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Identification

.........................................................
Engine Dataplate ...........................................................
Fuel Injection Pump Dataplate ..................................................

General Engine Specifications ...................................................


Cooling System ............................................................
Fuel System ..............................................................
General Engine Data ........................................................
Intake Air and Exhaust System ..................................................
........................................................
Lubrication System..

2
3

4
5
5
4
5
4

Section E - Engine and Component Identification

Engine Identification
Page E-2

Engine Identification
Engine Dataplates
The engine dataplates show specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.
The engine dataplates are located on the front gear cover
housing, on the fuel pump side of the engine, oriented 90
degrees from horizontal. See drawing at left.

must not be changed

NOTE: The engine dataplate


approved by Komatsu.

6Cl

C.I.D/L

KOMATSU
Lmo.Lruhcr.,

Illcmr.,6W69

EUXN

CPL

-!3ERIAL

ND.

FAMILY
U.S.A.
TIMING

%a?

EC

KCMATSU
PART No.

+
+
Vo,-ntnp,In
vc, Y., R..ult
And Y.rron~
I*
Vo1d.d If b u.1 Rar. Rpy 0, Allrrudm
c xemd
PubLImhsd km,..
Vm1u.s For Tht.
Med.1 And
Appr LODI twl.
md&!!.A.

VALVE

LASH

nRING
LOU

COLD

INT.

Em.

RAE0

_
IDLE

-e

l+vKw

AT

FUEL RATE AT RATED IP

RANGE

GCTAG 1

Engine Dataplates
The. Komatsu model designation represent the
basrc desrgn and confrguratron of your engine.

(1)

Turbocharged

Example Engine Model Name:

(2)

Jacket water aftercooled


(2) or (3)

6D114E-1, S6D114E-1, SAGD114E-1 or SAAGD114E-1

S A (AA)
(1) (2) (3)

D114

(4) (8) (6)

E
(7)

(JWAC)

(3)

Charged air cooled

-1

(4)

Number of cylinders

(8)

(5)

Diesel

(6)

Cylinder

(7)

Emission&d

(8)

Engine Series

(CAC)

Bore Dia. in mm

MM3/STROKE

unless

Section E - Engine and Component Identification

Injection Pump Dataplate


Page E-3

Fuel Injection Pump Dataplate


The injection pump dataplate is located on the side of the
injection
pump.
It provides
information
for fuel pump
calibration.

The Bosch Injection

pump dataplate

1.

Pump Serial Number

2.

Bosch Ten Digit Number

3.

Bosch Designation

contains:

Code

PES6AlOOD32

The vendor
part number
for the fuel pump-governor
combination is located on the governor dataplate.

The Bosch governor

dataplate contains:

1.

Bosch Governor

2.

Vendor Pump Part Number

Designation

Code.

S/RSV425
CDC-NO
\

llOOAOC2190-8Ri
390

6541

Made In USA

fp901g

Section E - Engine Component Identification

General Engine Specifications

Page E-4

General Engine Specifications


General Engine Data
Bore ................................................................

114 mm [4.49 in]

Stroke ...............................................................

135 mm 15.32 in]

Displacement

8.27 liters 1504.5 in31

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

Compression

ratio

6D114E-1

16.4:1

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

S6D114E-1

17.3:1

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

SAGD114E-1

16.5:1

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

SAAGD114E-l *
High Torque
LowTorque..
Firing order

17.3:1

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

18:l

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

l-53-6-24

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

Valve clearance
Intake

0.30 mm [0.012 in]

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

Exhaust

.0.61 mm [0.024 in]

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

Engine rotation

(viewed from front of engine)

Clockwise

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

Aspiration
6D114E-1
S6D114E-1

Turbocharged

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

SAGD114E-1

Turbocharged

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

SAAGD114E-1
Engine weight

Naturally Aspirated

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

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

(with standard

Turbocharged

and Jacket Water Cooled

and Charged Air Cooled (CAC)

accessories)

Dry weight

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

603 to 612 kg [1330 to 1380 lb]

Wet weight

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

635 to 658 kg [1400 to 1450 lb]

Lubrication System
Oil pressure
At idle (minimum

allowable)

At rated speed (minimum

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

allowable)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]

Differential pressure to open oil filter bypass valve


Oil flow at rated speed (less flow though
Oil temperature

at rated speed

Oil temperature

thermostat

Fully open

69 kPa [lo psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]

pressure regulator

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

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

106.8 Ipm [28.2 gpm]

98.9 to 126.6C [210 to 26OF]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116C [241F]

Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104C [219F]


Oil pan capacity

(all engines)

(high - low)

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

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

18.9 to 15.1 liters [20 to 16 U.S. Qts.]

Total system capacity


6D114E-1
S6D114E-1
*

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

23.6 liters [25.0 U.S. Qts.]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8 liters [25.2 U.S. Qts]

All emission&d

engines with Charged Air Cooling are designed

as AA.

Section E - Engine Component Identification

General Engine Specifications


Page E-5

Cooling System
Thermostats
Begins to open
Fully open

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

81 to 83C [178 to 182F]

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

95C [203F]

Top tank temperature


Maximum

allowable

Minimum

recommended

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

Pressure cap for 99C [210 F] system

Water Pressure (Upper manifold)

Coolant capacity

50 kPa [7 psi]

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

103 kPa [15 psi]

at 2000 RPM engine speed

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

fully opened, engine speed 2000 RPM)

103 to 276 kPa 115 to 40 psi]

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

258 Ipm 168 gpm]

(engine only)

6D114E-1, S6D114E-1, SAAGD114E-1*


SAGD114E-1

70 C [158 F]

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

Pressure cap for 104C [220 F] system

Coolant flow (thermostats

100C [212F]

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

9.9 liters [lo.5

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

10.9 liters Ill.5

U.S. Qts.]
U.S. Qts.]

Intake Air and Exhaust System


Maximum

allowable

6D114E-1

intake restriction

at rated speed and load (with dirty air filter element)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 cm H,O 120 in H,O]

S6D114E-1, SAGD114E-1, SAAGD114E-l*


Maximum turbocharger

outlet restriction

6D114E-1, S6D114E-1, SAAGD114E-l*


6D114E-1, SAAGD114E-1*
SAGD114E-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 cm H,O [25 in H,O]

at rated speed and load


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2 mm Hg [3 in Hg]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 cm H,O [40 in H,O]

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

82 in H,O [S in Hg]

Fuel System
Fuel transfer pump maximum

inlet restriction

6D114E-1, S6D114E-1, SAGD114E-1, SAAGD114E-l*


Fuel transfer pump maximum

output pressure

6D114E-1, S6D114E-1, SAGD114E-1 Low Flow


SAAGD114E-l*

. . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Hg [4.0 in Hg]

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

83 kPa [12 psi]

High Flow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa 125 psi]

(maximum

pressure drop across filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]

Fuel filter restriction

Fuel pump gallery pressure minimum at rated speed high flow

. . . . . . . . . . . . . . . . . . . . . . . . . . 140 kPa 120 psi]

Fuel pump gallery pressure minimum at rated speed low Row . . . . . . . . . . . . . . . . . . . . . . . . . 48 kPa [7 psi]
Fuel return restriction
*

All emissionized

(maximum)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in Hg]

engines with Charged Air Cooling

are designed

as AA.

Section E - Engine Component

Engine Diagram
Page E-6

Identification

Engine Diagrams
The illustration which follow show the locations of the major external engine components, the filters, and other service
and maintenance points. Some external components will be at different location for different engines.

High Pressure
Fuel Lines

%[inch]NPTF

(Air)

Front Lifting

Fuel/Water

Fuel Transfer

%x lB(inch]UNF
Tap for Magnetic
Pick-up
Air

/Il7II

IHtl

II

II I

I HII

II II

II II

Front Engine
Mounting Bracket

FUEL PUMP SIDE VIEW

I IE--+d

Section E - Engine Component Identification

Engine Diagram
Page E-7

Crsnkcase Westha
Vent Tubs

I /

PilotBesrina

M&tin9

Housing

Rear View

Turbochar9er

Turbocha~e~
bi. lnkt

Engine Air
Inlet
/

Filter

Front View

Holes

Section E - Engine Component Identification

Engine Diagram
Page E-8

Turbocharger
Wastegate Actuator.

Turbocharger
Air Outlet

Turbocharger
Exhaust Outlet

Water Outlet
Connection

Lubricating

Oil

Provision for
Coolant Heater
Provision for
Cab Heater

Pressure (before

Turbocharger
Oil Drain
Coolant Inlet

Turbocharger

Side View

Engine Disassembly and Assembly - Group 00


Page O-l

Engine Disassembly and Assembly - Group 00


Section Contents
Page
Engine - Assembly ..........................................................

O-39
AFC Tube - Installation
.....................................................
O-l 12
Aftercooler - Installation
.....................................................
O-97
Air Compressor - Installation
.................................................
O-l 19
Air Crossover Tube - Installation ...............................................
O-101
Alternator Brace - Installation .................................................
O-104
Alternator - Installation
.....................................................
O-l 03
Alternator Mounting Bracket - Installation .........................................
O-l 03
Belt Tensioner Bracket - Installation
............................................
O-105
Belt Tensioner - Installation
..................................................
O-105
Camshaft - Installation
......................................................
O-65
Connecting Rod Bolt - Installation ...............................................
O-54
Coolant Filter - Installation ...................................................
O-102
Coolant Heater - Installation ...................................................
O-82
Coolant Inlet Connection - Installation
...........................................
O-103
Coolant Outlet Connection - Installation ..........................................
O-102
Coolant Vent Fitting - Installation
..............................................
O-102
Coolant Vent Petcock - Installation
.............................................
O-102
Coolant Vent Tube - Installation
...............................................
O-103
Crankcase Breather Tube - Installation ............................................
O-95
Crankshaft - Installation ......................................................
O-47
Cylinder Block - Installation onto Engine Rebuild Stand ................................
O-39
Cylinder Head - Installation
...................................................
O-85
Cylinder Liner - Installation
...................................................
O-40
Drive Belt - Installation
.....................................................
O-l 18
Engine Liiing Bracket - Installation
..............................................
O-96
Engine - Removal from the Rebuild Stand ........................................
O-105
Engine Support, Front - Installation .............................................
O-118
Exhaust Manifold - Installation
.................................................
O-97
Fan Hub Assembly - Installation ...............................................
O-106
Flywheel Bore Runout Measurement
.............................................
O-79
Flywheel Face Runout Measurement
.............................................
O-81
Flywheel Housing - Installation .................................................
O-72
Flywheel - Installation .......................................................
O-77
Fuel Drain Manifold - Installation ................................................
O-96
Fuel Filter Head - Installation
.................................................
O-111
Fuel Filter - Installation
.....................................................
O-111
Fuel Injection Pump - Installation
..............................................
O-106
Fuel Injection Pump Supply Line - Installation ......................................
O-l10
Fuel Lines, High Pressure - Installation
..........................................
O-112
Fuel Lines, Low Pressure - Installation ...........................................
O-l19
Fuel Pump Solenoid - Installation
..............................................
O-l19
Fuel Transfer Pump - Installation
..............................................
O-l 18
Gear Cover - Installation
....................................................
O-l 16
Gear Housing - Installation
...................................................
O-62
Injector - Installation ........................................................
O-95
Intake Manifold Cover - Installation
..............................................
O-96
Lubricating Oil Cooler - Installation
..............................................
O-84
Lubricating Oil Filter - Installation
...............................................
O-85
Lubricating Oil Pan - Installation ................................................
O-68
Lubricating Oil Pump - Installation
..............................................
O-64
Lubricating Oil Suction Tube - Installation
O-68
Main Bearing (Lower) - Installation
.....
: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ii47-02
Main Bearing (Upper) - Installation
..............................................
O-46
Main Bearing Cap - Installation .................................................
o-47
Piston Assembly - Installation ..................................................
O-58
Piston Cooling Nozzle - Installation ..............................................
O-6

Engine Disassembly and Assembly - Group 00


Page O-2
Piston Pin - Installation ......................................................
Piston Ring End Gap - Measurement .............................................
.....................................................
Piston Ring - Installation
......................................................
Push Rod - Installation
.............................................
Rocker Lever and Shaft - Assembly
Rocker Lever Assembly - Installation .............................................
Seal, Front Crankshaft - Installation .............................................
..............................................
Seal, Rear Crankshaft - Installation
...................................................
Starting Motor - Installation
Tachometer Drive - Installation ................................................
...........................................
Thermostat and Housing - Installation
Timing Pin Assembly - Installation ...............................................
................................
Turbocharger Exhaust Outlet Connection - Installation
Turbocharger - Installation ....................................................
.........................................
Turbocharger Oil Drain Tube - Installation
.....................................
Turbocharger Oil Supply Hose - Installation
Valve Arrangement .........................................................
Valve Clearance - Adjustment ..................................................
Valve Cover - Installation .....................................................
....................................................
Valve Tappet - installation
................................................
Vibration Damper - Installation
....................................................
Water Pump - Installation
...................................
Wear Sleeve, Rear Crankshaft Seal - Installation
Engine Accessories - Installation ...............................................

O-54
O-55
O-56
O-89
O-89
O-91
O-113
O-51
O-82
O-117
O-101
O-69
O-101
O-98
O-99
O-100-02
O-93
O-92
O-94
O-44
O-117
O-67
O-51-02
O-121

O-9
Engine - Disassembly .......................................................
O-12
AFC Tube - Removal .......................................................
O-17
Aftercooler - Removal .......................................................
O-14
Air Compressor - Removal ....................................................
O-17
Air Crossover Tube - Removal .................................................
O-21
Alternator Brace - Removal ...................................................
O-22
Alternator Mounting Bracket - Removal ...........................................
O-22
Alternator - Removal ........................................................
O-21
Belt Tensioner Bracket - Removal ...............................................
O-21
....................................................
Belt Tensioner - Removal
O-28
Camshaft - Removal ........................................................
O-10
Coolant - Draining .........................................................
O-10
Coolant Filter - Removal .....................................................
O-26
Coolant Heater - Removal ....................................................
O-24
.............................................
Coolant Inlet Connection - Removal
O-22
Coolant Outlet Connection - Removal ............................................
O-23
...............................................
Coolant Vent Petcock - Removal
O-23
Coolant Vent Tube Fitting - Removal .............................................
O-23
Coolant Vent Tube - Removal
Crankcase Breather Tube - Removal : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : O-l 6
O-36
Crankshaft - Removal .......................................................
O-23
....................................................
Cylinder Head - Removal
O-32
Cylinder Liner Carbon Deposits - Removal .........................................
O-37
Cylinder Liner Protrusion - Checking .............................................
O-37
Cylinder Liner - Removal .....................................................
O-21
.......................................................
Drive Belt - Removal
O-15
Engine - Installation onto Engine Rebuild Stand .....................................
O-9
Engine Lifting Equipment and Brackets ...........................................
O-9
Engine - Preparation for Steam Cleaning ..........................................
O-9
Engine - Steam Cleaning .....................................................
O-31
Engine Support, Front - Removal ...............................................
O-20
Exhaust Manifold - Removal ...................................................
o-39
Expansion Plug - Removal ....................................................
O-38
Expansion Plug - Replacement .................................................
O-24
Fan Hub Assembly - Removal .................................................
O-27
Flywheel Housing - Removal ..................................................
o-27
Flywheel - Removal ........................................................
O-18
Fuel Drain Manifold - Removal .................................................
o-11
Fuel Filter Head - Removal ...................................................
O-II
.......................................................
Fuel Filter - Removal

Engine Disassembly and Assembly - Group 00


Page O-3
Fuel Injection Pump - Removal .................................................
Fuel Injection Pump Supply Line - Removal ........................................
Fuel Lines, High Pressure - Removal .............................................
Fuel Lines, Low Pressure - Removal .............................................
Fuel Pump Solenoid - Removal ................................................
Fuel Transfer Pump - Removal .................................................
Gear Cover - Removal ......................................................
Gear Housing - Removal .....................................................
Injector - Removal .........................................................
Intake Manifold Cover - Removal ...............................................
Lubricating Oil Cooler - Removal ...............................................
Lubricating Oil - Draining ....................................................
Lubricating Oil Filter - Removal ................................................
Lubricating Oil Pan - Removal .................................................
Lubricating Oil Pump Gear Backlash - Measurement ..................................
Lubricating Oil Pump - Removal ................................................
Lubricating Oil Suction Tube - Removal ...........................................
Main Bearing (Lower) - Removal ................................................
Main Bearing (Upper) - Removal ................................................
Main Bearing Cap - Removal ..................................................
Piston Assembly - Removal ...................................................
Piston Cooling Nozzle - Removal ...............................................
Piston Pin - Removal .......................................................
Piston Ring - Removal ......................................................
Push Rod - Removal .......................................................
Rocker Lever Assembly - Removal ..............................................
Seal, Front Crankshaft - Removal ...............................................
Seal, Rear Crankshaft - Removal ...............................................
Starting Motor - Removal ....................................................
Tachometer Drive - Removal ..................................................
Thermostat and Housing - Removal .............................................
Turbocharger Exhaust Outlet Connection - Removal ...................................
Turbocharger Oil Drain Tube - Removal ...........................................
Turbocharger Oil Supply Hose - Removal .........................................
Turbocharger - Removal .....................................................
Valve Cover - Removal ......................................................
Valve Tappet - Removal .....................................................
Vibration Damper - Removal ..................................................
Wastegate Actuator Hose - Removal .............................................
Water Pump - Removal ......................................................
Cylinder Block - Removal from Engine Rebuild Stand ..................................

O-13
O-12
O-12
O-11
O-15
O-11
O-26
O-31
O-18
O-17
O-24
O-10
O-10
O-27
O-30
O-31
O-27
O-36
O-36
O-35
O-33
O-36
O-34
O-35
O-19
O-19
O-26
O-28
O-26
O-13
O-22
O-16
O-20
O-20
O-20
O-18
O-29
O-25
O-16
O-25
O-39

Engine Disassembly and Assembly - Service Tools ...................................

O-4

General Information .........................................................


Disassembly .............................................................
Assembly ...............................................................

O-8
O-8
O-8

Engine Disassembly and Assembly - Service Tools


Page O-4

Engine Disassembly and Assembly - Group 00

Engine Disassembly and Assembly - Service Tools

The following special tools are recommended to perform procedures in Group 00. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool Illustration

Tool Description

Tool No.

Used to remove drive pulleys, impellers, air compressor


counterweights,
etc.

Install cylinder

liner in cylinder

block.

Attaches to crankshaft flange to provide measuring


and flywheel housing runout with dial bore gauge.

of flywheel

Used to measure internal diameter bores from 78.5 mm [3.09


in] to 2.032 mm [8.0 in].

Universal Cylinder Liner Puller

3375629

Remove cylinder liners from cylinder block. Requires Part No.


3822786, Cylinder Liner Puller Plate.

Engine Disassembly and Assembly - Service Tools


Page O-5

Engine Disassembly and Assembly - Group 00

Tool No.

Tool
---..
--. -Descriation

Tool Illustration

C-----

Used to remove and install lubricating

oil filter.

Support cylinder block during engine rebuild. Used with Part


No. 3822807, Adapter Plate.

Aid in removal and installation


heavy components.

of crankshaft,

flywheel

and other

Universal Cylinder Liner Puller


Remove cylinder liners from the cylinder block. Requires two of
Part No. 3376649, Puller Arm Extension Feet.

Dial Indicator and Sleeve Assembly


Use with Part No. ST-1325 Dial Gauge Attachment to measure
flywheel and flywheel housing runout. Use with Magnetic Base,
Part No. 3377399, to measure gear end clearance and

Used to rotate the crankshaft.

Used with Part No. 3378050, Dial Indicator

and Sleeve

Used to clamp the liner into the bore of the cylinder block.
Note: Requires two cylinder head capscrews (not included in

Engine Disassembly and Assembly - Service Tools


Page O-6
Tool No.

Engine Disassembly and Assembly - Group 00

Tool Description

Tool Illustration

Used to lift the engine.

For mounting

the engine to Part No. 3375194, Engine Rebuild

Used to install piston rings onto pistons without


distorting the rings.

Used to pull the injection

damaging

or

pump gear.

Used to pull injectors.

Piston Ring Compressor

3823290

Used to compress the piston rings while installing the pistons


into the cylinder bores.

Crowfoot Wrench

3823425

Used to torque high pressure fuel line nuts on A and MW


Bosch fuel injection pumps. Size: 17mm, 3/8 in. drive.

Sealant, Three Bond (150 Gram Tube)


Used for sealing T joints and front gear cover.
3823494

Engine Disassembly and Assembly - Service Tools


Page O-7

Engine Disassembly and Assembly - Group 00

Tnnl

Nn

Tnnl
_

Measure cylinder

Used for torquing

__.

Descrintian

-___-.

liner protrusion

capscrews

Install the front crankshaft

Tad

_-_--

on the cylinder

by the torque

block.

plus angle

oil seal wear sleeve.

Fuel Injection Pump Mounting


Remove and install the fuel injection

pump inboard mounting

Main Bearing Rollout Tool


Used to remove and install main bearing with the crankshaft

Illustration

Engine Disassembly and Assembly - Group 00

General Information
Page O-8

General Information
These procedures apply to all 6D114E-1 Series engines. The differences between engine models due to the application,
the optional equipment on an engine, and the year an engine was built are included in the instructions. Omit the steps
that do not apply to the engine being rebuilt.

A
A

Warning: A Warning statement is included for any component or assembly that weighs more than 23 kg
[50 lb]. To avoid personal injury, use a hoist or get assistance when removing or installing these parts.
Caution: All fasteners are given in metric measurements. All fasteners have right-hand threads unless a
Caution states that a fastener has left-hand threads.

Disassembly
The instructions in this procedure are organized in a logical sequence to disassemble an engine. This is not the only
sequence to disassemble
an engine. Certain parts must be removed in the sequence indicated. Use this sequence until
you become familiar with the engine.

Discard all gaskets, seals, hoses, filters, and o-rings. Keep these parts if they are needed for a failure analysis.
Label, tag, or mark the parts for location as the parts are removed. This will help identify the parts that can be involved
in a failure and will simplify the assembly procedure.
Label, tag, mark, or photograph all special equipment prior to the removal from an engine.
procedure does not include the installation of special optional equipment.

This engine assembly

Use a mallet when force is required to remove certain parts. Make sure all of the fasteners are removed
force.
Avoid as much dirt as possible during disassembly.
the components.

The accumulation

of additional

before using

dirt will make it more difficult to clean

Assembly
This procedure assumes that all of the components
to be installed on the engine.

and assemblies have been cleaned, replaced, or rebuilt and are ready

Torque values are listed in each step. If a torque value is not specified, use the chart listed in the Specifications
Group 18, to determine the correct torque value.

Section,

Many of the gaskets and o-rings are manufactured from a material designed to absorb oil. These gaskets will enlarge and
provide a tight seal after coming in contact with oil. Use ONLY a recommended contact adhesive or a vegetable based
oil to install these parts.
When replacing capscrews, always use one of the same configuration,
either Metric or U.S. Customary. To prevent
damage to the engine or component, make sure the replacement capscrew is the same dimension, length and grade as
the capscrew removed.

Engine - Disassembly (O-01)


Page 6-9

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Engine Lifting Equipment and Brackets
Warning: The engine lifting equipment must be designed
to safely lift the engine as an assembly. The dry weight
of the engine with standard accessories is 666 kg 11335
lb].
Use a properly rated hoist and engine lifting fixture, such as
Part No. 3822152, attached to the engine mounted lifting
brackets to lift the engine.

Install the engine on two suitable engine support stands.

Engine - Preparation for Steam Cleaning


Install plastic caps or tape on all engine openings to prevent
moisture and dirt from entering
the engine: Cover all

electrical components. This will prevent water damage.

Engine - Steam Cleaning


Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Steam clean and dry with compressed

air.

A
RI

Engine - Disassembly (O-01)


Page O-10

Engine Disassembly and Assembly - Group 00

Lubricating Oil - Draining


17 mm
NOTE: The total system lubricating oil capacity including
lubricating oil filter is 23.8 liters [25.2 U.S. Qts.].
Remove the drain
washer.

plug

Drain the lubricating

oil.

and discard

the drain

plug

the

sealing

op9pxm.a

Coolant - Draining
Open the draincock
housing.

at the bottom of the lubricating

oil cooler

Coolant Filter - Removal


90-95 mm Filter Wrench
Remove and discard the coolant filter.

Lubricating Oil Filter - Removal


Part No. 3375049 Filter Wrench
Remove and discard the engine
failure analysis.

oil filter if not needed for a

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-l 1

Fuel Filter - Removal


75-80 mm Filter Wrench, 90-95 mm Filter Wrench
Remove and discard the fuel filters and the sealing rings.

Fuel Filter Head - Removal


24 mm
Remove the fuel filter head and discard the o-rings.

Fuel Lines, Low Pressure - Removal


20, 19, 17, 14 and 10 mm
Disconnect

the low pressure fuel lines.

NOTE: To avoid damage


wrenches when loosening

to the fuel transfer pump, use two


the low pressure line.

Discard all copper washers.

Fuel Transfer Pump

Removal

10 mm
Remove the fuel transfer pump.

\I Ilk

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-12

Fuel Lines, High Pressure


lo mm

17

Removal

mm and 19 mm

Remove the high pressure fuel lines.

Caution: Cover the injectors and fuel pump high pressure


outlet connections to avoid damage from contamination.

Fuel Injection Pump Supply Line - Removal


17 mm and 19 mm
Remove the fuel injection
line.

pump supply line and the fuel return

AFC Tube - Removal


13 mm, 17 mm
Remove the AFC tube.

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-13

Tachometer Drive - Removal


Remove the gear cover access cap or the tachometer drive,
if equipped.

bD900ma

Fuel Injection Pump - Removal


22 mm (PESGA Fuel Injection Pump)
27 mm (PESGMW Fuel Injection Pump)
30 mm (PESGP Fuel Injection Pump)
Remove the nut and lock washer from the fuel injection
pump shaft.

Part No. 3823259 Fuel Pump Gear Puller


Pull the fuel injection pump drive gear loose from the shaft.

10 mm, 13 mm
If the engine is equipped with a PESGP fuel injection pump,
the support brackets must be removed.

l9bkm

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-14

15 mm, Part No. 3823956 Fuel Pump Mounting Tool Kii


Remove the four mounting
Remove the fuel injection

nuts.
pump.

Air Compressor - Removal


Remove the
compressor.

inlet

and

outlet

air connections

from

the

air

from

the

air

15/16 Inch
Remove the
compressor.

inlet

and

outlet

9/16 Inch
Remove the oil supply line.

coolant

lines

Engine - Disassembly (O-01)


Page O-15

Engine Disassembly and Assembly - Group 00

19 mm, 15 mm, 14 mm
Remove the air compressor

support

bracket and capscrews.

Remove the air compressor.

Fuel Pump Solenoid - Removal

-1

10 mm
Disconnect

the fuel shutoff solenoid wiring.

Remove the hitch


shutoff solenoid.

pin

clip,

mounting

capscrews

and

fuel

Engine - Installation onto Engine Rebuild Stand


Part No. 3822512 Engine Lifting Fixture
NOTE: The dry weight of the engine is 623 kg [1350 lb]. Use
an engine lifting bracket, such as Part No. 3822512, to lift the
engine.

Use four (l/2 x 13 x l-l /2 inch) grade 5 capscrews to install


the Part No. 3822607, Adapter Plate, onto the Part No.
3375194, Engine Rebuild Stand.

Torque Value:

95 Nom 170 ft-lb]

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-16

Use four Ml0 x 1.5 x 20 mm and two M8 x 12.5 x 20 mm


capscrews to install the adapter plate to the side of the cylinder
block.

Capscrew
Location

Capscrew Size

Torque Value

M8

24 Nom [18 ft-lb]

B, C

Ml0

40 Nom [30 ft-lb]

Turbocharger Exhaust Outlet Connection Removal


7/16 inch, 15 mm
Remove the turbocharger

exhaust outlet connection.

Wastegate Actuator Hose - Removal


Screwdriver
Remove the wastegate

hose.

bSho

Crankcase Breather Tube - Removal


13 mm, 16 mm
Remove the crankcase
capscrews (A) and (B).

breather

tube

support

bracket

Engine - Disassembly (O-01)


Page O-17

Engine Disassembly and Assembly - Group 00

Air Crossover Tube - Removal


Screwdriver
Remove the air crossover

tube.

Intake Manifold Cover - Removal


10 mm
Remove the air intake cover plate.

Aftercooler - Removal
8mm
Remove the coolant
(2).

supply tube (1) and coolant

10 mm
Remove the aftercooler

housing

and gasket.

return tube

E2l

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-18

Fuel Drain Manifold - Removal


10 mm
Remove the fuel drain manifold. Discard the sealing washers.

Injector - Removal
10 mm, Part No. 3823276 Injector Puller
Remove the injectors.

fi9OOn

Remove and discard the sealing washers.

figwarn

Valve Cover - Removal


15 mm
Remove the valve cover.

Engine Disassembly and Assembly - Group 00

Remove
o-rings.

and

discard

the

and

Engine - Disassembly (O-01)


Page O-l9
capscrew

Rocker Lever Assembly - Removal


14

mm Screwdriver

Loosen the rocker lever adjusting screw locknuts


the adjusting screws until they stop.

and loosen

10 mm
Remove the rocker lever assemblies

Push Rod - Removal


Remove the push rods.

and oil manifold.

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-20

Turbocharger Oil Supply Hose - Removal


16 mm, 19 mm
Remove the turbocharger

oil supply line.

Turbocharger Oil Drain Tube - Removal

RI

10 mm, Screwdriver
Remove the turbocharger

oil drain tube.

CB
l

Turbocharger - Removal
15 mm
Remove the turbocharger.

Exhaust Manifold - Removal

Eiil
16

mm

Remove the exhaust

Q
63

manifold.

Engine Disassembly and Assembly - Group 00

Drive Belt - Removal


3/8 inch Square Drive
Remove the drive belt.

Belt Tensioner - Removal


13 mm
Remove the belt tensioner.

Belt Tensioner Bracket - Removal


5 mm Hex Wrench
Remove the belt tensioner

bracket.

Alternator Brace - Removal


10 and 19 mm
Remove the alternator
Remove the tail support

brace capscrew

(A).

bracket capscrew

(B).

Engine - Disassembly (O-01)


Page 0-21

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-22

Alternator - Removal
15, 18 and 19 mm
Remove the alternator

mounting

capscrews

and nuts.

Remove the alternator.

Alternator Mounting Bracket - Removal


13 mm
Remove the alternator

mounting

bracket.

Coolant Outlet Connection - Removal


10 mm
Remove the coolant outlet connection.

Thermostat and Housing - Removal


10 mm
Remove the thermostat

housing

and thermostats.

Engine - Disassembly (O-01)


Page O-23

Engine Disassembly and Assembly - Group 00

Coolant Vent Tube - Removal


9/16 inch
Remove the coolant vent tube.

Coolant Vent Petcock - Removal


7/16 inch
Remove the coolant vent petcock.

Coolant Vent Tube Fitting - Removal


l/2 inch
Remove the l/8 inch brass fiiing from the cylinder head.

El

0
c%

Cylinder Head - Removal


16 mm
Loosen and remove the cylinder head capscrews in the
illustrated sequence.
Q
C%

C--

Front

Engine - Disassembly (O-01)


Page O-24

Engine Disassembly and Assembly - Group 00


The component weighs 74 kg [163 lb]. To avoid personal
injury, use a hoist or get assistance to remove the cylinder
head.
To prevent damage to the combustion face, make sure the
head is removed in a direct upward motion.

Lubricating Oil Cooler - Removal


10 mm
NOTE: Due to the design of the present production lubricating
oil cooler cover, there is approximately 0.7 liter IO.75 U.S. Qts.]
lubricating oil that does not drain when the system is drained.
Place a container under the cooler to catch the oil when the
cover is removed.
Remove the oil cooler cover, element and gaskets.

Coolant Inlet Connection - Removal


Screwdriver
Remove the coolant inlet connection.

Fan Hub Assembly - Removal


13 and 10 mm
Remove the fan hub assembly.

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-25

Water Pump - Removal


13

mm

Remove the water pump.

Remove and discard the o-ring.

Part No. 3377371 Engine Barring Gear


Use the engine barring tool to prevent the
rotating when loosening the damper capscrews.

Vibration Damper - Removal


ia mm
Remove the vibration

damper.

engine

from

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-26

Gear Cover - Removal


10 mm
Remove the gear cover.

Seal, Front Crankshaft - Removal


Hammer, Punch
Drive or press the seal out of the gear cover.

ocesema

Starting Motor - Removal


12 mm
Remove the starting motor.

Coolant Heater - Removal


Remove the engine coolant heater.

Engine - Disassembly (O-01)


Page O-27

Engine Disassembly and Assembly - Group 00

Flywheel - Removal
18 mm
Remove two capscrews 180 degrees
M12X1.25X90 mm guide pins.

apart.

Install two

NOTE: If a clutch is used in the equipment, the threads in


the clutch pressure plate mounting capscrew holes can be
metric or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size and install
two T-handles in the flywheel at points (1) and (2).
Remove the remaining six flywheel mounting capscrews.
Remove the flywheel from the guide pins.

Flywheel Housing - Removal


15 mm
Remove the flywheel housing.

Lubricating Oil Pan - Removal


10 mm
Rotate the engine on the rebuild stand and remove the oil
pan and gasket.

Lubricating Oil Suction Tube - Removal


8mm
Remove the suction tube and gasket.

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-28

Seal, Rear Crankshaft - Removal


8 mm

Remove the rear seal housing

and gasket.

Support the rear seal housing

and press/drive

out the seal.

ks9semd

Camshaft - Removal
Gear Backlash Measurement
Position an indicator

on a tooth of the camshaft gear.

Note the camshaft gear backlash (A). Mark the camshaft gear
and crankshaft gear for further analysis if backlash exceeds
limits.

Camshaft Gear Backlash Limits


mm

in

0.080

MIN

0.003

0.33

MAX

0.013

NOTE: Hold the adjoining

gear from moving when checking


backlash or the reading will be the total for both gears.
ks9geia

Engine Disassembly and Assembly - Group 00


Rotate the crankshaft to align the timing
to remove the camshaft.

marks before trying

0a!3

Engine - Disassembly (O-01)


Page O-29

15 mm
Remove the camshaft thrust plate capscrews.

Remove

the

camshaft

and

thrust

plate

from

block. Take care not to drop the thrust plate.


Refer to
inspection.

Procedure

l-22

for

camshaft

the

cylinder
0
C%

cleaning

and

I,_=-!

Valve Tappet - Removal


Electric Pencil
Remove the
illustrated.

valve

tappets

and

mark

for

location

as

Caution: When reusing the camshaft and tappets, the @SQ


tappets must be matched to their companion lobe on the
camshaft to prevent accelerated camshaft wear. Discard
tappets that were not marked during removal.

/ /

cg900m,

Engine - Disassembly (O-01)


Page O-30

Engine Disassembly and Assembly - Group 00

Lubricating Oil Pump Gear Backlash Measurement


Position the indicator

on a tooth of the gear.

Note the drive gear backlash. Mark the drive gear and idler
gear for additional analysis if the limits are exceeded.
NOTE: Hold the adjoining gear from moving when checking
backlash or the reading will be the total of both gears.

Oil Pump Drive Gear Backlash (A)


mm

in

0.08

MIN

0.003

0.33

MAX

0.013

ld9geia

Position the indicator

Note the
crankshaft
exceeded.

on a tooth of the pump idler gear.

idler gear backlash.


gear for additional

Mark the idler


analysis
if the

gear
limits

and
are

NOTE: Hold the adjoining gear from moving when checking


backlash or the reading will be the total of both gears.

Oil Pump Idler Gear Backlash (A)


mm

ld9idia

in

0.08

MIN

0.003

0.33

MAX

0.013

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-31

Lubricating Oil Pump - Removal

A__

13 mm
Remove the lubricating
Refer to Procedure

oil pump.

7-08 for cleaning

and inspection.

Engine Support, Front - Removal


15 mm
Remove the front engine support.

Gear Housing - Removal


10 mm
Remove the capscrews,

gear housing and gasket.

NOTE: Do not remove the timing pin assembly unless the


gear housing is being replaced. Refer to page O-69 in this
section for replacing the timing pin assembly.

Pin

lt9plhb

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-32

Cylinder Liner Carbon Deposits - Removal

A
B
Li

Caution: Do not use emery cloth or sandpaper to remove


carbon from the cylinder liners and cylinder block cylinder
head mounting surface. Aluminum oxide or silicon particles
from emery cloth or sandpaper can cause serious engine
damage.
Rotate the crankshaft to expose the carbon
ring travel area in the cylinder liner.

ridge above the

Warning: When performing the following procedures, wear


eye protection. Also, if the brush is motor driven, make sure
the wire brush is rated for the RPM being used.

Use a rotary wire brush to remove the carbon ring from the top
of the cylinder liner.

LJ
B

Do not use the steel wire wheel in the piston travel area.
Operate the wheel in a circular motion to remove the deposits.
Use lint-free paper to remove all the broken wire bristles and
loose carbon from the cylinders.

IJ
B

If a rotary wire brush is not available,


an aluminum blade.

use a scraper that has

Use a fine fibrous abrasive pad such as Scotch-Brite@ 7447,


Part No. 3823258 or equivalent, to remove the remaining
carbon.

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-33

Piston Assembly - Removal


Mark each connecting rod cap according to cylinder.
NOTE: Engine serial numbers beginning with 3040000 have a
number from 1 to 7 stamped on the balancing lug. This
number is used as a connecting rod weight sort code and
does not designate cylinder number.

To avoid confusion
with serial number
cylinder number
removed. Mark the
cylinder No. 2 with

when disassembling an engine beginning


3040000, use double digits to identify the
from which the connecting rod was
connecting rod for cylinder No. 1 with 11,
22 and so on.

Also, the code used on engines beginning with serial number


3040000 to mark the connecting rod and connecting rod cap
as a matched set is a two letter code, such as AA, AB, AC,
etc. Instead of an alpha-number code.

Mark each piston according to the corresponding cylinder.


Catuion: Do not use a stamp on anodized pistons. A
stamp will damage the anodized coating. Use a scribe to
mark the pistons.

cx900ia

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-34

19 mm, Plastic Hammer


Remove the nuts from the connecting
Tap the connecting

rod capscrews.

rod bolts to loosen the connecting

rod cap.

Remove the lower connecting rod bearing. Mark the cylinder


number and the letter I
(lower) in the flat surface of the
bearing tang.

Catch the piston with one hand while pushing the connecting
rod and piston assembly out of the cylinder bore. Care must
be taken not to damage the crankshaft journal.

Place the connecting rod and piston assemblies


protect them from damage.

on a rack to

NOTE: The piston and connecting


rod assemblies must be
installed in the same cylinder number they were removed from
to be sure proper fit of worn mating surfaces if parts are used

again.
Use a tag to mark the cylinder number each
connecting rod assembly was removed from.

piston

and

Piston Pin - Removal


Use internal snap ring pliers to remove the retaining rings from
both sides of the piston.
Remove the piston pin.
NOTE: Heating the piston is not required.

Engine - Disassembly (O-01)


Page O-35

Engine Disassembly and Assembly - Group 00

Piston Ring - Removal


Part No. 3823137 Piston Ring Expander
Use piston ring expander,
piston rings.

Part No. 3323137, to remove the

Place a tag on the piston rings


number of the piston on the tag.

and

record

the

cylinder

pi9OOfb

Main Bearing Cap - Removal


19 mm
Rotate the engine to a horizontal
main bearing cap capscrews.

position

and remove the

The main bearing caps should be numbered.


Use a steel stamp to mark any main bearing caps without
number before the main bearing cap is removed.

0429

mb90owa

Remove the main bearing caps.

Do not pry on the main bearing caps to free them from


the cylinder block.
Use two main bearing cap capscrews to wiggle the main
bearing
cap loose,
being careful
not to damage
the
capscrew threads.

Engine - Disassembly (O-01)


Page O-36

Engine Disassembly and Assembly - Group 00

Main Bearing (Lower) - Removal


Remove the lower main bearing shells from the main bearing
caps.
Mark the main bearing shells with the journal number they were
removed from in the flat surface of the main bearing tang.
Do not mark on the main bearing to crankshaft mating surface.
Damage to the engine can result if the main bearings are used
again.

Crankshaft - Removal
The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.
Lii the crankshaft straight
crankshaft or cylinder block.

up to avoid damage to the

Install the Part No. 3375957, Nylon Lifting Sling, around the
number 3 and 4 rod bearing journals.
Attach the sling to a hoist and remove the crankshaft.

Main Bearing (Upper) - Removal


Use both thumbs to remove the upper main bearing shells.
Mark the main bearing shells with the journal number they were
removed from in the flat surface of the main bearing tang.
Do not mark on the main bearing to crankshaft mating surface.
Damage to the engine can result if the main bearings are used
again.

Piston Cooling Nozzle - Removal


3/16 Inch Pin Punch
Remove and discard the piston cooling nozzles.

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-37

Cylinder Liner Protrusion - Checking


Part No. 3823495 Liner Protrusion Gauge
Cylinder liner protrusion
is the distance the cylinder liner
protrudes above the block face. Before removing the liners,
check the protrusion in the unclamped
state.

xl

Cylinder Liner Protrusion


mm

in

0.025

MIN

0.001

0.122

MAX

0.0046

If the cylinder liner protrusion


is out
necessary to machine the counterbore
restore to the original specifications.

of limits, it will be
and add shims to

Cylinder Liner - Removal


Two service tools are available to remove the cylinder

liners:

Universal liner puller, Part No. 3376015, with extension


foot, Part No. 3376649.

Universal liner puller, Part No. 3375629 with plate, Part


No. 3376049.

Part No. 3376015 Cylinder Liner Puller


Caution: The cylinder liner puller must be installed and RI
used as described to avoid damage to the cylinder block.
The puller must not contact the block casting at points
U), (2), (3), and (4).

Insert the cylinder

liner puller in the top of the cylinder

block.

NOTE: The cylinder liner puller must be centered


of the cylinder block.

on the top

Turn the cylinder liner puller jackscrew clockwise


the cylinder liner from the cylinder block.

to loosen

Use both hands to remove the cylinder

liner.

------.I)

L/O

ck8slma

Engine Disassembly and Assembly - Group 00

Engine - Disassembly (O-01)


Page O-38

Part No. 3375629 Universal Liner Puller


Caution: The cylinder liner puller must be installed and
used as described to avoid damage to the cylinder block.
The cylinder liner puller plate must be parallel to the main
bearing saddles and must not overlap the cylinder liner
outside diameter.
Insert the cylinder

liner puller in the top of the cylinder

NOTE: The cylinder liner puller must be centered


of the cylinder block.

block.

on the top

Turn the cylinder liner puller jackscrew clockwise to loosen the


cylinder liner from the cylinder block.
Use both hands to remove the cylinder

Use Dykem@ or equivalent


each cylinder liner.

liner.

to mark the cylinder

number

on

Remove and discard the o-ring.

cklslwa

Expansion Plug - Replacement


All expansion plugs must be replaced if the component is
cleaned in a hot tank, spray washer or similar equipment.
This cleaning activity can interrupt the sealing capacity of the
sealant.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-39

Expansion Plug - Removal


To remove expansion

plugs:

Use a hammer
and center
expansion plug for drilling.

Drill a 3 mm [l/8

Use a dent puller to remove the expansion

Refer to Group
identification.

01

punch

to

mark

inch] hole in the expansion

for

expansion

plug

plug.

plug.
location

Cylinder Block - Removal from Engine Rebuild


Stand
13 mm
Remove the cylinder

block from the engine rebuild stand.

The component weighs 23 kg 150 lb] or more. To avoid


l
personal injury, use a hoist or get assistance to lift the @
component.
Refer to
inspection

Procedures
l-05
and
of the cylinder block.

l-06

for

cleaning

and

Engine - Assembly (O-02)


Cylinder Block - Installation onto Engine
Rebuild Stand
NOTE: The component weighs 23 kg [50 lb] or more. To
avoid personal injury, use a hoist or get assistance to lift
the component.
Use a hoist and Part No. 3375957, Engine Liiing
the cylinder block.

Use Part No. 3822607, Adapter


Engine Rebuild Stand.

Sling, to lift

Plate, with Part No. 3375194,

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-40

Use four Ml 0X15X20 mm and two M8X1.25X20 mm capscrews


to install the adapter plate to the fuel injection pump side of the
cylinder block:

Capscrew Location

Capscrew Size

Torque Value

M8

24 Nom [18 ft-lb]

Ml0

40 Nom [30 ft-lb]

B,

Cylinder Liner - Installation


Caution: Clean all deposits and debris from sealing
surfaces A, B and C. Use Scotch-Brite@7448 or equivalent
and cleaning solvent to polish the surfaces. However, due
to the critical machined tolerances, care should be taken
not to remove any additional material.
Refer to
inspection.
Lubricate

Procedure

l-06

for

cylinder

liner

counterbore

surfaces A and B with clean 15W-40 engine oil.

ck9brga

NOTE: When reusing liners, install them in the same cylinder


from which they were removed and rotate them 45 degrees
(l/8 turn) from their original position. When correctly installed,
any cylinder liner pitting should be positioned as illustrated so
the pitted surface is rotated away from the location where
pitting occurs.

Use clean 15W-40 engine oil to coat the cylinder


seals.
Install the o-ring seal on the cylinder

liner.

NOTE: The cylinder liner must be installed within


after applying oil to the cylinder liner o-ring seal.
Make sure the cylinder
during installation.

liner o-ring

15 minutes

liner o-ring is not twisted or damaged

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-41

Part No. ST-1229 Cylinder Liner Driver


Install the cylinder

liner into the cylinder

Use cylinder liner driver,


mallet to drive the cylinder

block.

Part No. ST-1229,


liner into the bore.

and

a leather

NOTE: If the cylinder liner does not rest on the cylinder


block counterbore seat, remove the cylinder liner. Inspect the
counterbore seat and cylinder liner for nicks, burrs, or dirt.
Install the cylinder liner again.

0
@

Part No. 3822503 Liner Clamps


Use two cylinder
head capscrews
cylinder liner clamps as illustrated.

and

position

the

two

Tighten the capscrews.

Torque Value:

68 Nom [50 ft-lb]

Remove the clamps and repeat this procedure


cylinder liners have been clamped and released.

until

all

Part No. 3823495 Liner Protrusion Gauge


Cylinder liner protrusion
is the distance the cylinder
protrudes above the block face. Measure the cylinder
protrusion at four points, 90 degrees apart:

liner
liner

\_

Cylinder Liner Protrusion


mm

in

0.025

MIN

0.001

0.122

MAX

0.0049

NOTE: If the cylinder liner protrusion


mm [O.OOlO inch] for 180 degrees:
l

Install and tighten the cylinder

varies more than 0.025


liner clamps again.

Engine Disassembly and Assemlbv - Group 00

Engine Assembly (O-02)


Page O-42
l

Inspect the cylinder

liner protrusion

NOTE: If the cylinder liner protrusion


0.025 mm [O.OOlO inch]:

_::z_-_-_i

more than

Remove the cylinder

Inspect the cylinder liner sealing edge for burrs, dirt or


damage.

Replace the cylinder

Install the cylinder

Inspect the cylinder

liner.

fTJ-+
pY_~~

still varies

69

again.

I
t

L-----_____

ck9cyda

aI9

liner if it is damaged.

liner again.
liner protrusion.

bp2cysb

Service Tip: If the out-of-limit condition is minimal, tolerance


stack-up may allow the cylinder liner protrusion limits to be
obtained by installing other new cylinder liners in the out-of-limit
bore.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-43

NOTE: If the cylinder liner protrusion still does not meet the
specifications,
machine the cylinder block liner counterbore
and add counterbore
shims to adjust the cylinder liner
protrusion to the proper specifications.

Use a feeler gauge to inspect the cylinder


clearance at the four block casting points.

liner to block

Cylinder Liner to Block Clearance


in

mm
0.229

MIN

NOTE: If the cylinder liner to block


0.229 mm to.009 inch]:

0.009

clearance

Remove the cylinder

liner.

Inspect the cylinder


damage.

liner and cylinder

is less than

block for dirt or

0a3

Engine Assembly (O-02)


Page O-44

Engine Disassembly and Assembly - Group 00


l

Replace the cylinder

Install the cylinder

liner if it is damaged.

liner again.

Measure the cylinder liner bore for out-of-roundness


at points
c,
D, B,
F and G. Measure each point in the
direction AA and BB. The cylinder liner bore must not be
more than 0.08 mm [0.003 inch] out-of-round.

NOTE: If the cylinder


inch] out-of-round:
l

-I-

-..&a

liner bore is more than 0.08 mm [0.003

Remove the cylinder liner so the cylinder


bore can be measured.

block liner

ck2cyj
i

Valve Tappet - Installation


Caution: Observe the
installation:

following guidelines

for tappet

When reusing the camshaft and tappets, the tappet


must be matched to their companion lobe on the
camshaft. If the tappets were not marked upon
removal, they must not be reused.

Do not install used tappets with a new camshaft.


Mixing of new and used tappets when reusing the
camshaft is permissible, providing the used tappets
are kept with their companion lobes of the camshaft.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-45

Lubricate
the tappet
LubripiateTM 105.

heads,

stem

and

sockets

Install the valve tappets.

Piston Cooling Nozzle - Installation

a
g

23 mm
Remove the main bearing caps.

+*
0%

l/2 Inch Center Punch


Install the piston cooling
bearing saddle surface.

nozzles

even with

NOTE: Due to the positioning


and
nozzles, there are no bores needed
bearing saddle.

or below

the

spray angle of the


for the No. 3 main

\ \

Be sure spray holes are clean and open.

NOTE: Be sure

the piston
damaged during cleaning.

cooling

nozzle

hole

is

not

0@B

Engine Assembly (O-02)


Page O-46

Engine Disassembly and Assembly - Group 00

Main Bearing (Upper) - Installation


The upper bearings contain two oil holes. The lower bearings
do not. Both upper and lower main bearings are marked on the
back to indicate either standard
(STD) or oversize (OS)
thickness.

NOTE: Main bearing shells are available for crankshafts which


are machined 0.1 mm [0.040-inch]
undersize the original
diameter. Crankshafts which are machined undersize in the
connecting rod and main bearing journals are marked on the
front counterweight. If the crankshaft is marked, check the main
bearing and connecting rod shell part numbers to make sure
the correct bearing size is used.

R-OSOmm

A
p
Of3

Caution: The tang (1) on the bearing shell must be in the


slot (2) of the bearing saddle to correctly position the
bearing and prevent engine damage.
Install the upper main bearing shells.

+I

6B

NOTE: If used bearing shells are to be installed, each must be


installed in its original location in the engine. The main bearing
journal numbers should have been marked in the bearing tangs
during disassembly.
NOTE: Do not install the combination
the center journal. Roll the combination
after the crankshaft is installed.

thrust/main
thrust/main

bearing in
bearing in

mb9OOwb

Da

Lubricate the main bearings with LubriplateTM 105.

Caution: Prevent dirt from mixing with the lubricant. Dirty


lubricant will accelerate main bearing wear.

cl

4 Do not lubricate the back of the main bearing.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-47

Crankshaft - Installation
Use a lint-free cloth. Clean the crankshaft bearing journals.

q
\

The component weighs 23 kg [50 lb] or more. To avoid


personal injury, use a hoist or get assistance to lift the
component.
Use a hoist and Part No. 3375957, Nylon Lifting Sling.
Install the sling around the numbers 3 and 4 connecting
rod bearing journals.

(@A
@ii

Do not damage or move the main bearing shells when the


crankshaft is installed.
Install the crankshaft.

After the crankshaft has been installed into the cylinder block
with the six upper shells in place, make sure the thrust
bearing is clean and serviceable.
Use clean LubriplaW
upper thrust bearing.

105 or its equivalent to lubricate the

Part No. 3823318, Main Bearing Rollout Tool


Position the new thrust bearing on the crankshaft and install
as far as possible by hand.
Use main bearing rollout tool Part No. 3823818, and engine
barring tool, Part No. 3377371, to finish pushing the bearing
in slowly, being sure it is aligned with the block.

-0

OK

Engine Assembly (O-02)


Page O-47-02

Engine Disassembly and Assembly - Group 00

Main bearing (Lower) - Installation


Install the lower main bearing shells with tang (1) in the slot
(2) of the main bearing cap.
Use Lubriplate@ 105, or equivalent,
diameter of the main bearing shells.

to

coat

the

inside

Main Bearing Cap - Installation


The main bearing caps are numbered for location. No. 1
starts with the front of the block and the numbers face the
camshaft side of the engine.
When correctly
installed, the main
should both be on the same side.

bearing

tangs

(slots)

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-48
Position

ai3

the main bearings

and main bearing

caps onto the

The thrust bearing iournal does not have tangs or slots. Care
should be taken to-be sure the number stamped on the main
bearing cap is positioned to the camshaft side of the engine.

Lubricate the main bearing capscrew threads and underside of


the capscrew head with clean engine oil.

mbscswa

RI
@
04B
mb900ha

Small Plastic or Rubber Mallet


Tap the main bearing cap gently into position.

Make sure the main bearing is still aligned with the cap.
When seated, the main bearing capscrews
by hand.

can be threaded in

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-49

19 mm
Tighten the main bearing
illustrated sequence.

capscrews

evenly

following

the

Torque Value:
Step
:
3

50 N*m [ 37 ft-lb]
119 N*m [ 66ft-lb]
176 N*m [129 ft-lb]

-Front
J

The crankshaft must rotate freely after the main bearings


have been torqued.
Check the main bearing installations and the size of the main
bearings if the crankshaft does not rotate freely.

Measure the end clearance

of the crankshaft

Install a dial indicator


oil pan flange.

Put the tip


counterweight.

Push the
block.

crankshaft

toward

Set the dial indicator

at zero.

Push the crankshaft


block.

toward

If the
end
clearance
is
[0.005-inch], do the following:

of

the

as follows:

such as Part No. 3376050, to the


gauge

against

the

crankshaft

the rear of the cylinder

u
the front
less

of the cylinder

than

0.127

mm

0423

mb9csha

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-50
l

Loosen the main bearing capscrews one turn.

Push the crankshaft toward the front and then toward


the rear of the cylinder block.

Tighten the main bearing capscrews in the sequence shown to


the torque values listed in the installation procedure.

Front
mbScsha

Measure the crankshaft end clearance. The end clearance


specification for a new or machined crankshaft with new thrust
bearings is 0.127m [O.OOSnch]to 0.32 mm [0.013-inch].

0.25 mm[O.OlO in.]

NOTE: Crankshafts that have been machined on the thrust


bearing surfaces are marked for oversize thrust bearings on the
rear crankshaft counterweight. If the crankshaft counterweight
is marked, check the thrust bearing part number to make sure
the correct bearing size is used.
Example: 0.010 = 0.25 mm [O.OlO-inch]

Engine Assembly (O-02)


Page O-51

Engine Disassembly and Assembly - Group 00


If the crankshaft end clearance is more than 0.54 mm
[0.021-inch] on a used engine, the crankshaft must be
removed from the engine and repaired.

Seal, Rear Crankshaft - Installation


Use crocus cloth to remove any rust or other deposits from
the crankshaft flange.
Use a clean cloth to clean the rear crankshaft flange.

q
\

ks9seeCi

Visually inspect the seal contact area for wear. If the seal
contact area has a groove worn deep enough to feel with a
fingernail or sharp object, it will be necessary to install a
wear sleeve over the sealing surface.
Refer to the following procedure:

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-51-02

Wear Sleeve, Rear Crankshaft Seal - Installation


Hammer, Chisel
If the crankshaft currently has a wear
removed before installing a new one.

sleeve,

it must be

0
Do not nick or gouge the crankshaft with the 6%
chisel. If the crankshaft is damaged, it must be replaced.
Caution:

Use a dull chisel that is only as wide as the wear sleeve.


Make one or two soft blows with a hammer to make chisel
marks across the wear sleeve. This will expand the wear
sleeve allowing the sleeve to be removed.

NOTE: The combination


crankshaft oil seal (A)/wear sleeve
(B) replacement
kii for service usage is installed on the
crankshaft as an assembly. The crankshaft rear seal should
not be removed from the crankshaft rear seal wear sleeve.

Install the rear cover and gasket.


NOTE: Install the rear cover capscrews. Do not tighten. If the
oil pan is installed, loosen the oil pan capscrews to allow
clearance for rear cover and gasket clearance.
NOTE: The seal installation is being used to properly align
the rear cover. Do not push or force the cover in any
direction to prevent irregular seal lip position after the seal
installation.

Engine Assembly (O-02)


Page O-52

Engine Disassembly and Assembly - Group 00

NOTE: For installation, the lubricating oil seal requires a mild


soap on the outside diameter of the seal case.

Use service tool, Part No. 3824078, to install oil seal/wear


sleeve assembly. Install two (2) threaded
studs into the
crankshaft capscrew holes.
Apply a small amount of clean 15W-40 engine oil to the
crankshaft,
threaded
studs, and inside diameter
of the
crankshaft rear seal/wear sleeve installation tool.

Position the chamfered end of the wear sleeve (A) onto the end
of the crankshaft (B). Position the counterbore
end of
installation tool (C) over threaded studs and align with wear
sleeve, perpendicular to the end of the crankshaft. Install the
washers (D) and nuts (E) onto the threaded studs.

Alternately tighten the nuts until the installation tool contacts the
end of the crankshaft.

NOTE: Do not exceed l/2 revolution of each nut to prevent


wear sleeve binding and irregular stretch.
Torque Value: 20 Nom [15 ft-lb]
Remove the installation tool and threaded studs.

Engine Assembly (O-02)


Page O-53

Engine Disassembly and Assembly - Group 00

NOTE: For installation, the lubricating oil seal requires a mild


soap on the outside diameter of the seal case.

Hammer, Seal Installation Tool


install the seal in the rear cover.
Use the installation tool and hammer to push the seal into
the rear cover until the outside diameter
of the seal
installation tool contacts the rear cover.

NOTE: Do not remove the crankshaft seal pilot tool.

NOTE: Do not use any kind of lubricant on the crankshaft to


install the seal. The lubricating oil must be installed with the
lip of the seal and crankshaft clean and dry.
Install two M6Xl.OOX50 mm guide
into the rear of the cylinder block.

pins

180 degrees

apart

Install the rear cover and gasket over the guide pins.

8mm
Align the rear cover to the crankshaft with the alignment tool
provided in the seal kii. Be sure the rear cover is even with
both sides of the oil pan rail on the cylinder block.

Engine Assembly (O-02)


Page O-54

Engine Disassembly and Assemlby - Group 00

Remove the guide pins.


@
l

Install the rear cover capscrews

V
*

@**

and tighten.

Torque Value: 9 Nom [80 in-lb]


Remove the rear crankshaft

seal pilot tool.

(K

rc9toma

Trim the rear cover gasket even with the oil pan mounting
surface.
Make sure the rear cover gasket trim does not fall into the
engine.

Connecting Rod Bolt - Installation

Eil

Plastic Hammer

0@

Tap the connecting rod bolts in until the head is aligned and
seated on the flat machined surface of the connecting rod.

Piston Pin - Installation


Use clean 15W-40 engine oil to coat the connecting
pin bore and piston pin.

rod piston

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-55

Caution: Be sure Front marking on piston and the


numbers on the connecting rod and connecting rod cap
are oriented as illustrated.

Snap Ring Pliers


NOTE: Pistons do not require heating to install the piston
pin; however, the pistons do need to be at room temperature
or above.

NOTE: The retaining ring must be seated completely in the


piston pin bore to prevent engine damage during engine
operation.
Install a new retaining

ring into the piston pin bore.

Align the piston pin bore of the connecting


rod with the
piston pin bore of the piston and install the piston pin. Install
the second retaining ring.

Piston Ring End Gap - Measurement


Rotate the engine on the rebuild stand until the crankshaft
vertical and the crank gear is facing upward.

NOTE: If the engine is rotated


valve tappets can fall out.

more than 90 degrees,

r=?
is
the

To check the piston ring gap, use the top end of a piston to
align the piston rings in the wear area of the cylinder liner in
which they will be used.

0a3

A = 89 mm [3.5 inches]

Jq
4

-I

-3

____

-9=-

pi9rita
-1

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-56

Use a feeler gauge to measure the piston ring gap. Replace the
ring if it does not meet the following specifications:
New Piston Ring Gap
in

mm
Top:

0.35
0.60

MIN
MAX

0.014
0.024

Intermediate:

0.35
0.66

MIN
MAX

0.014
0.026

Oil Control:

0.30
0.60

MIN
MAX

0.012
0.024

NOTE: Add 0.09 mm [0.004 in] for every 0.03 mm [O.OOlin] of


cylinder liner bore wear up to the maximum worn limit.
Identify the ring sets for installation in the cylinder in which the
end gap was measured.

pi9riga

Piston Ring - Installation


The top surface of the upper and intermediate rings are
identified either with the word TOP or a supplier identification
mark, such as a dot. Assemble with the word TOP or the
supplier mark facing upward.
The bottom or oil control ring can be installed with either side
up.

pi9rise

NOTE: The two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil ring. Do
not overlap the ends of the expander ring.

pt9riha

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-57

Part No. 3823137 Piston Ring Expander

RI

Install the rings on the piston.


Position the oil ring expander

in the oil control

ring groove.

Q
@.j.j

pi9rigb

Install the oil control


on the expander.

ring with the end gap opposite the ends

g
09
+a

pi9rrhc

NOTE: There
used:
Rectangular

are two

different

types

of intermediate

rings

(A)

Reverse Twist (B)


Refer to the appropriate
rings are required.
Install the intermediate

Parts Manual to see which

type of

ring.

Install the top ring.

PI901 a

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page o-58

Piston Assembly - Installation


install the connecting rod bearing shells into both the
connecting rod and connecting rod cap. Make sure the tang
on the conecting rod bearing shell is in the slot of the
connecting rod cap and connecting rod.
Connecting rod bearings are marked on the back to indicate
either standard (STD) or oversize (OS) thickness.
NOTE: If used connecting rod bearing shells are to be
installed, each bearing shell must be installed in its original
location.

Caution: Do not lubricate the back of the connecting rod


bearing shells.
Caution: Prevent dirt from mixing with the lubricant. Dirty
lubricant will accelerate connecting rod bearing wear.
Lubricate the connecting rod bearings with a light film of
Lubriplatem 105.

cx9oowa

Lubricate the piston rings and piston skirts with clean 15W-40
engine oil.

Position the ring gaps 120 degrees apart.

pi9rihb

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-59

Part No. 3823290 Piston Ring Compressor

lsl
0a9

Compress the rings using the piston ring compressor.

Use a clean
journals.

lint-free

cloth

to clean

the crankshaft

Use a clean lint-free cloth to wipe the cylinder


Lubricate the cylinder

bearing

bores.

bore with clean 15W-40 engine oil.

Part No. 3377371 Engine Barring Tool


Rotate the crankshaft
connecting
rod, which
center (BDC).

to position
the
is being installed,

journal
for the
at bottom dead

RI
0a-9
DC

Engine Assembly (O-02)


Page O-60

Engine Disassembly and Assemlby - Group 00

Caution: Be sure Front marking on the piston and the


numbers on the connecting rod and connecting rod cap are
oriented as illustrated.

Caution: Use care when installing the piston and connecting


rod so the cylinder bore is not damaged.
Position the piston and connecting
rod assembly into the
cylinder bore with the word Front on the piston toward the
front of the cylinder block.
Hold the piston ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the cylinder
liner.

NOTE: If the piston does not move freely, remove the piston
and inspect for broken or damaged rings.

Push the piston into the bore until the top of the piston is
approximately 50 mm [2 inches] below the top of the bore.
Then, pull the connecting rod onto the crankshaft journal.

Use clean 15W-40 engine oil to lubricate


connecting rod capscrews.

the threads

of the

Engine Assembly (O-02)


Page O-61

Engine Disassembly and Assembly - Group 00

NOTE: The numbers marked on the connecting rod and the


connecting rod cap must be the same. The tang slot side of
the conecting rod cap must be on the same side as the
tang slot in the connecting rod when the connecting rod cap
is installed.
Use Lubriplate@ 105, or equivalent,
to coat
diameter of the connecting rod bearing shell.
Install the connecting
Install the connecting
nuts.

rod bearing in the connecting

tighten
the connecting
rod cap into position.

rod

rod cap.

the connecting

nuts

inside

rod cap and start the connecting

Use clean 15W-40 engine oil to lubricate


nuts.

Alternately
connecting

the

to

pull

rod

rod

the

Ix

19 mm Socket, Torque Wrench


Tighten the connecting
Torque

rod cap to the connecting

rod.

Value:

Step 1 - 40 Nom [30 ft-lb]


Step 2 - 80 Nom [60 ft-lb]
Step 3 - 120 Nom [88 ft-lb]

(K

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-62
Shake the
clearance.

connecting

tightening

rod

Measure the side clearance


the crankshaft.

to

verify

between the connecting

side

rod and

Connecting Rod Side Clearance


mm

in

0.10

MIN

0.004

0.33

MAX

0.013

NOTE: The crankshaft must rotate freely.


Check for freedom of rotation as the connecting rod caps are
installed. If the crankshaft does not rotate freely, check the
installation of the connecting rod bearings and the bearing size.

er9OOda

Gear Housing - Installation


Install the two gear housing dowel pins, if removed.

NOTE: The tapered end of the dowel fiis into the cylinder
block. Drive the pin to the bottom of the hole.

Engine Disassembly and Assembly - Group 00

Position the gasket onto the alignment

Engine Assembly (O-02)


Page O-63

dowels.

15 mm
If the fuel injection
pump studs are damaged or being
installed in a new housing, coat the threads with Loctitem
242 and use two nuts locked together to remove and install.

ah9OOwz

Small Chisel and Hammer


If the gear housing is being
dataplate and install on the
Procedure l-25.

replaced, remove the engine


new gear housing. Refer to

13 mm
Caution: If a new gear housing or other than the original
gear housing is installed, the timing pin assembly must
be accurately located. Refer to page O-69 in this section.
Install the gear housing and capscrews.
Torque

Value:

M8 capscrews
Ml2 capscrews

24 Nom [18 it-lb]


60 Nom [44 ft-lb]

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-64

Trim the gear housing

gasket off even with the oil pan rail.

NOTE: Do not let the gasket trimmings fall into the engine.

gh9gkwa

Lubricating Oil Pump - Installation


Lubricate the lubricating

oil pump with clean 15W-40 engine oil.

NOTE: Fill the lubricating oil pump with oil during installation
to aid in quicker oil suction when the engine is started.

ip900wa

Make sure thelubricating


oil pump idler gear pin is installed
into the locating bore of the cylinder block.

The back plate on the lubricating oil pump seats against the
bottom of the bore in the cylinder block. When the pump is
correctly installed, the flange on the pump will not touch the
cylinder block.

Engine Assembly (O-02)


Page O-65

Engine Disassembly and Assembly - Group 00


13

mm

Tighten
shown.

the lubricating

oil pump capscrews

in the sequence

Torque Value:
Step 1 - 5 Nom [44 in-lb]
Step 2 - 24 Nom [18 ft-lb]

Use a dial indicator


idler gear backlash.

with

a magnetic

base to measure

the

Measure the gear backlash.


NOTE: Hold the adjoining gears from moving when checking
backlash or the reading will be the total of both gears.

Oil Pump and Idler Gear Backlash (A & B)


mm

in

0.08

MIN

0.003

0.33

MAX

0.013

1p9gena

Camshaft - Installation
Lubricate the camshaft bores with LubriplateTM 105.
Refer to Group 01 for camshaft bushing

Service Tip: The crankshaft

4
17

installation.

should be positioned with the


No. 1 cylinder at approximately
top dead center (TDC), so
the camshaft does not hit the crankshaft counterweights
during installation.

Engine Assembly (O-02)


Page O-66

Engine Disassembly and Assemlby - Group 00


Lubricatethe camshaft journals and lobes, and thrust plate with
LubriplateTM 105.

Install the camshaft and gear assembly into the cylinder block
up to the last journal.

Align the timing marks on the camshaft with the timing mark on
crankshaft.

423 the

Caution: If the enaine is in the vertical position, be sure the


camshaft assemgy does not drop on your fingers when
installing the thrust plate.

Engine Assembly (O-02)


Page O-67

Engine Disassembly and Assembly - Group 00

13 mm
Install the thrust plate capscrews.

Torque Value:

24 Nom [18 ft-lb]

Measure the camshaft end clearance.

End clearance is controlled by the thickness of the thrust


plate and the groove in the camshaft.
Camshaft End Clearance
in

mm
0.12

MIN

0.0047

0.46

MAX

0.018

Be sure the camshaft backlash is correct.


Use an indicator to measure backlash.

Camshaft Gear Backlash Limits


in

mm
0.08

MIN

0.003

0.33

MAX

0.013

Water Pump - Installation


13 mm
Install an o-ring into the groove on the water pump mounting
flange.
Position the water pump assembly into the pump cavity of
the cylinder
block. Align mounting
holes and install two
capscrews at 1l:OO oclock and 4:00 oclock position.
NOTE: The capscrew located in the 7:00 oclock position is
longer and is used for the alternator support brace, it will be
installed along with the alternator.

Torque Value:

24 N*m

[18 B-lb]

Engine Disassembly and Assemlby - Grow 00

Engine Assembly (O-02)


Page O-68

Lubricating Oil Suction Tube - Installation


Position the new lubricating oil suction tube gasket onto the
cylinder block.
Make sure the gasket is aligned correctly with the oil suction
hole in the cylinder block.

8mm
Install the lubricating oil suction tube over the gasket and align
the mounting holes.
Use the following sequence to tighten the capscrews:
Torque Value:
Step A Suction Tube to Block

9 N*m [80 in-lb]

Step B Brace to Block

9 N*m [80 in-lb]

Step C Brace to Suction Tube

9 Nom [80 in-lb]

Lubricating Oil Pan - Installation


Apply a 2 mm [l/16 inch] bead of Three Bond Sealant, Part
No. 3823494, to joints between the lubricating oil pan rail, gear
housing and rear seal housing.

NOTE:The lubricating oil pan and gasket must be installed


within 15 minutes after applying Three Bond Sealant.

Apply a 2 mm [l/16 inch] bead of Three Bond Sealant, Part


No. 3823494, to both sides of the new lubricating oil pan
gasket.
Install the gasket.
Install the lubricating oil pan.

Engine Assembly (O-02)


Page O-69

Engine Disassembly and Assembly - Group 00


10 mm
Assemble
lubricating

the washers
and
oil pan as illustrated.

Tighten
all capscrews
accompanying chart.

in

capscrews

the

sequence

to

secure

shown

in

the
the

21 17 13 9

%
@j@

7 11 15 19 23

24 Nom [18 ft-lb]

Torque Value:

Ir

Install the drain plug and a new drain plug sealing washer.

IQ1

80 Nom [59 ft-lb]

Torque Value:

w9nxh

Timing Pin Assembly - Installation


Caution: The timing pin assembly is precisely located on
;t~; ~y~;d;;~~~
?o correspond to top dead center (TDC) A
.

Engine
Timing Pin

The timing pin assembly must be relocated


other than the original is installed.

if a gear housing

Failure to locate the timing pin assembly to TDC for cylinder


No. 1 will result in incorrect injection timing.
.I\

13 mm, 18 mm
Rotate the
position.

engine

on the

engine

stand

to the

horizontal

To relocate the timing pin assembly, temporarily install the


vibration damper and a pointer fabricated from No. 16 gauge
wire. Put a flat washer between the pointer and gear housing
to prevent damage to the gear housing.

-Gear

Housing

it9pihb

Engine Assembly (O-02)


Page O-70

Engine Disassembly and Assemlby - Group 00


19 mm, Part No. 3822503 Liner Clamp
Assemble
bore.

two cylinder

Tighten the cylinder

liner clamps

over the No. 1 cylinder

liner clamps.

Torque Value: 68 Nom [50 ft-lb]

Position two flat washers on the piston so they will contact the
cylinder liner clamps.

Rotate the crankshaft clockwise until the washers on the piston


contact the cylinder liner clamps.
G

Mark the vibration

damper adjacent to the pointer.

Rotate the crankshaft in the opposite direction until the washers


on the piston contact the cylinder liner clamps.
Mark the vibration

damper adjacent to the pointer.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-71

Measure the distance and mark the vibration damper at


one-half the distance between the two pointer marks. This is
the TDC mark.

19 mm
Remove the cylinder liner clamps and washers. Rotate the
crankshaft in the direction of rotation until the nointer
with the TDC mark.

&5-l

Look through the back side of the gear housing for the
timing pin hole in the camshaft gear. If the hole is not
visible, rotate the crankshaft one complete revolution.

it9OOs

Lubricate the o-ring with clean 15W-40 engine oil and install
into the groove of the timing pin.
Install the timing pin assembly.

Engine Assembly (O-02)


Page O-72

Engine Disassembly and Assemlby - Group 00

T-25 Torx
Push the timing pin into the hole in the camshaft gear to align
the housing.
Hold the timing pin in while tightening

the timing pin assembly

TorxTMscrews.
Torque Value: 8 Nom 171 in-lb]
Check the timing pin to be sure it did not slip out of the
camshaft gear hole when the timing pin assembly screws were
tightened.
it900v

13 mm, 18 mm
Caution: To prevent damage to the pin and gear, be sure to
disengage the timing pin before rotating the crankshaft.
Remove the vibration

damper and wire pointer.

Flywheel Housing - Installation


Dry Clutch Application
Install the two dowel pins into the back of the cylinder

block.

Drive the dowels


bore.

of the

in until they are against

the bottom

Install two M12X1.75XlOO mm guide pins into the cylinder block


to help support and align the flywheel
housing
during
installation.

NOTE: Dry clutch applications

require a sealing ring on the


rear seal housing. Install the sealing ring in the machined
surface of the rear seal housing and lubricate with Lubriplatem
105.

Engine Disassembly and Assembly - Group 00

Visually inspect
flywheel housing
nicks or burrs.

the rear face of the cylinder


mounting surface for cleanliness

Engine Assembly (O-02)


Page O-73
block and
and raised

Install the flywheel housing. Be sure the flywheel housing


positioned onto the alignment dowels and guide pins.
NOTE: Be sure
installation.

the

sealing

ring

is not damaged

is

during

Remove the two M12Xi .75X100 mm guide pins.

15 mm
Install and tighten the flywheel housing
using the pattern shown in the chart.

Torque Value:

mounting

capscrews

77 Nom [57 ft-lb]

Flywheel Housing Bore - Concentricity Checking


Part No. ST-1325 Dial Gauge Attachment
Attach a dial indicator to the crankshaft. The dial indicator
can be mounted by any method that holds the extension bar
of the indicator rigid so it does not sag. If the bar sags or
the indicator
slips, the readings
obtained
will not be
accurate.
Position the indicator
the gauge.

in the 6:00 oclock

position

and zero

0a3

Engine Disassembly and Assemlby - Grow 00

Engine Assembly (O-02)


Page O-74

Part No. 3377371 Engine Barring Tool


Slowly rotate the crankshaft. Record the readings obtained at
the 9:00 oclock, 12:00 oclock, and 3:00 oclock positions as
[a], [b], and [c] in the concentricity work sheet. Check zero at
the 6:00 oclock position again.
The values for [a], [b], and [c] could be posltiie or negative.
Refer to the accompanying figure to determine the correct sign
when recording these values.

Rotate the crankshaft until the dial indicator is at the 12:00


oclock position and zero the gauge.
NOTE: Do not force the crankshaft beyond the point where the
bearing clearance has been removed. Do not pry against the
flywheel housing. These actions could cause false bearing
clearance readings.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as [d] in the concentricity work sheet.
This is the vertical bearing clearance adjustment and will always
be positive.

Use the concentricity work sheet to determine the values for


the total vertical and total horizontal values.

Concentricity Worksheet

The total horizontal is equal to the 9:00 oclock reading, [a],


minus the 3:00 oclock reading [cl.

)I

The total vertical is equal to the 12:00 oclock reading [b],


plus the bearing clearance Id].
Example:
6:00 oclock
9:00 oclock
12:00 oclock
3:00 oclock

12 oclock

=
=
=
=

ref
[a]
[b]
[c]

= 0.000 mm [O.OOOin].
= 0.102 mm [0.004 in].
= 0.076 mm [0.003 in.]
= -0.051 mm [-0.002 in.]

Using the work sheet and the numbers from the example, the
total horizontal value = 0.152 mm [O.OOSin.] and the total
vertical value = 0.127 mm [0.005 in.]
Mark the total horizontal value on the horizontal side of the
chart and the total vertical on the vertical side of the chart.
Use a straight edge to find the intersection point of the total
horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.

NOTE

Use the total horizontal and total vertical values from the
previous example, the intersection point falls within the shaded
area. Therefore, the flywheel housing concentricity is within
specification.
TOTAL HORIZONTAL

READING

oi9OOvg

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Paae 0-75

If the intersection point falls outside the shaded area, the ring
dowels must be removed and the housing repositioned.
NOTE: The ring dowels are not required to maintain
concentricity of the housing. The clamping force of the
capscrews holds the flywheel housing in position.
After the ring dowels are discarded,
housing on the engine.

install the flywheel

To position the housing, tighten the capscrews enough to


hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Check the
procedure.

concentricity

again

by

following

the

above

Use the pattern shown in the chart to install and tighten the
mounting flywheel housing capscrews.
Torque Value:

77 Nom [57 ft-lb]

Wet Clutch Application


Perform all the steps in the procedure
installation in addition to the following:

for dry

Coat the flywheel housing drain plug with pipe sealant and
install in the hole in the bottom of the flywheel housing.
Tighten the drain plug.
Refer to the pipe plug torque values in Group 18 for different
plug sizes.

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-76

Install the plastic plug in the tachometer

drive access hole.

fh9pxha

13 mm

Install the access plate and new access plate gasket.


Install the access plate capscrews

Torque Value: 24 N*m

and tighten.

118 ft-lb]

clean the flywheel housing and cylinder block


Thoroughly
mating surfaces. These surfaces must be clean and free of oil
or debris.

fh9bdea

holes on the flywheel housing


Coat set screws with
through.
drilled
are
pads
mounting
LoctiteTM 277 and install into holes.

NOTE: The center capscrew

Set Screw Installation Depth


in

mm

fh9pxhc

0.00

MIN

0.000

3.00

MAX

0.118

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-77

Apply a continuous bead of Three Bond Sealant around all


capscrew holes on the mounting
surface of the flywheel
housing.

Coat the threads


277.

of the mounting

capscrews

with

LoctiteTM

Install and tighten the capscrews. Follow the same tightening


sequence used for the dry clutch application.

Torque Value:

77 Nom [57 ft-lb]

Flywheel - Installation
NOTE: Use a new pilot
rebuilt clutch.

bearing

when

installing

a new or

Use a mandrel and hammer to remove the pilot bearing.


Use a Scotch-Brit@
clean the pilot bore.

7446 cleaning

pad,

or equivalent,

to

@z

q
B

Use a mandrel and hammer to install the pilot bearing.

NOTE: The pilot bearing must be installed even with the pilot
bore surface.
Refer to Group 16 for flywheel

ring gear replacement.

($!A
@ii

Engine Assembly (O-02)


Page O-78

Engine Disassembly and Assemlby - Group 00

Install two M12X1.25X90 mm guide


flange 180 degrees apart.

pins into the crankshaft

NOTE: If a clutch is used in the equipment, the threads in the


clutch pressure plate mounting capscrew holes can be metric
or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size and install two
T-handles into the flywheel at points (1) and (2).

Visually inspect the rear face of the crankshaft and flywheel


mounting flange for cleanliness and raised nicks or burrs.

The component weighs 23 kg [50 lb] or more. To avoid


personal injury, use a hoist or get assistance to lift the
component.
Install the flywheel

on the guide pins.

Lubricate the threads of the flywheel capscrews and the surface


of the washers with clean 15W-40 engine oil.

Install the six flywheel


Remove the T-handles

capscrews.
and guide pins.

Install the remaining flywheel capscrews


which the guide pins were removed.

into the holes from

Engine Disassembly and Assembly - Group 00

19 mm Socket, Torque Wrench, Part No. 3377371 Engine


Barring Tool
Hold the crankshaft when tightening the flywheel capscrews.

Engine Assembly (O-02)


Page O-79

RI
,

Tighten the flywheel capscrews in the pattern as illustrated.


Torque Value:

137 Nom [lo1 ft-lb]

fh9OOoa

Flywheel Bore Runout Measurement


Use the dial indicator gauge (1) Part No. 3373050, or its
equivalent and dial gauge attachment (2) Part No. ST-1325,
to inspect the flywheel bore (3) and the surface (4) runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside
diameter of the flywheel bore, and set the dial indicator at
zero.

Use the engine barring tool, Part No. 3377371, to rotate the
crankshaft one complete revolution (360 degrees).
NOTE: The total indicator reading (TIPi) must not exceed
0.20 mm [0.008-inch].

NOTE: If the TIR is greater than the specification, do the


following:
l

Remove the flywheel.

Engine Disassembly and Assemlby - Group 00

ingine Assembly (O-02)


age O-80
l

Inspect the
damage.

flywheel

mounting

surface

Inspect the crankshaft for dirt or damage.

Install the flywheel,


runout again.

Replace the flywheel if the flywheel


not meet specifications.

for

dirt

or

hvlbdsb

and

inspect

the flywheel

bore

bore runout does

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-81

Flywheel Face Runout Measurement


Install the contact tip of the indicator against the flywheel
face, as close to the outside diameter as possible, to inspect
the face (I) runout.
NOTE: Push the flywheel forward to remove the crankshaft
end clearance. Adjust the dial on the indicator until the
needle points to zero.

Use the engine barring tool, Part No. 3377371, to rotate the
crankshaft one complete revolution.
Measure the flywheel
runout at four equal points on the flywheel.
NOTE: The flywheel must be pushed toward the front of the
engine to remove the crankshaft end clearance each time a
point is measured.

The total indicator


reading
following specifications:

Flywheel
Radius (A)

(TIR)

must not exceed the


Maximum (TIR)
of Flywheel Face

mm

in

mm

in

203

0.203

0.008

254

10

0.254

0.010

305

12

0.305

0.012

356

14

0.356

0.014

406

16

0.406

0.016

If the flywheel face runout is not within specifications, remove


the flywheel.
Check for nicks, burrs, or foreign material
between the flywheel mounting surface and the crankshaft
flange.

fw9OOtd

Engine Assembly (O-02)


Page O-82

Engine Disassembly and Assemlby - Group 00

Starting Motor - Installation


Wet Housing
Apply a coat of Three Bond Sealant to the starter mounting
surface and both sides of the spacer and starting motor gasket,
if equipped.

12 mm
Coat the starting motor capscrews
PST.

with LoctiteTM pipe sealant

Install the starting motor. Tighten the starting motor capscrews.

Torque Value: 77 Nom [57 ft-lb]


Starting motor capscrews
require a lower torque.

that are precoated

with Vibra-Seal

Torque Value: 68 Nom [50 ft-lb]

Coolant Heater - Installation


Clean the expansion plug bore thoroughly. Make sure there
are no burrs or sharp edges that could cut the o-ring during
installation.

Lubricate the new heater o-ring with clean 15W-40 engine oil.

Engine Disassembly and Assembly - Group 00


The coolant heater locking
to the end of the bolt.

Engine Assembly (O-02)


Page O-83

channel T-Bar should be loosened

Hook the element and one leg of the channel T-Bar into the
hole as illustrated.

@@

Hook the other leg of the channel in the hole and push the
heater into the hole as far as possible by hand.

@@A

4v

4W

Plastic Hammer, 4 mm Hex Wrench


If necessary, use a plastic hammer to tap the heater into the
bore until the flange contacts the block. Make sure the o-ring
is not damaged during installation.
NOTE: Do not use the screw to pull the heater into position,
this could damage the threads.
NOTE: The cable insertion
9:OO oclock position.

socket should

be oriented to the

RI

Engine Assembly (O-02)


Page O-84

Engine Disassembly and Assemlby - Group 00

0(K

Tighten the retaining capscrew.


Torque

Value:

12 Nom [106 in-lb]

g@
o$
+s

Insert the power cord into the socket, being careful to align the
pins with the sockets of the power cord. Tighten the retaining
nut by hand.

Do not apply power until the cooling system is filled.

Lubricating Oil Cooler - Installation


07 for

Refer to Group
instructions.

oil

cooler

assembly

and

install two M8X1.25X80 guide pins into the cylinder

rebuild

block.

Assemble the cooler gasket, oil cooler, and oil cooler cover
gasket together over the guide pins.

If a new element is being installed, be sure to remove the


shipping plugs.
Install nine capscrews.
Ic900hS

10 mm
Remove the two
capscrews.

guide

pins and

install

the remaining

Tighten all the oil cooler and filter head capscrews.


Torque

Value:

24 Nom [18 ft-lb]

two

Engine Disassembly

and Assembly - Group 00

Engine Assembly (O-02)


Page O-85

Lubricating Oil Filter - Installation


Apply a light film of clean 15W-40 engine
sealing surface before installing the filter.
NOTE: The filter must be installed within
time oil was applied to the rubber seal.

oil to the gasket

15 minutes from the

Fill the oil filter with clean 15W-40 engine oil.

Caution:
Mechanical
over-tightening
may
threads or damage the filter element seal.
Install the filter as specified

distort

the

by the filter manufacturer.

Cylinder Head - Installation


The cylinder

block and head must be clean and dry.

NOTE: The maximum allowable piston protrusion above the


top of the block with a standard gasket is 0.40 mm [0.016
inch]. If the piston protrusion is greater than specified, refer
to Group 01 for information
pertaining
to thicker head
gaskets.
Make sure the gasket is correctly aligned
in the cylinder block.

q
B

with the holes

Position the gasket onto the dowels.


I

The component
personal injury,
component.

weighs 23 kg [50 lb] or more. To avoid


use a hoist or get assistance to lift the

Caution: Do not drop the cylinder head on the cylinder


head gasket. The gasket material will be damaged.
Carefully install the cylinder
head onto the gasket and
cylinder block. Make sure the cylinder head is installed
onto the dowels in the cylinder block.

0@Y

k&khb

Engine Assembly (O-02)


Page O-86

Engine Disassembly and Assemlby - Group 00


Use clean 15W-40
engine oil to coat the cylinder
capscrew threads and underneath the head flange.

head

Do not install the capscrews with painted head in the center


row that will be covered by the valve cover.
Allow the excess oil to drain from the capscrew threads before
installation.

Install the capscrews

into the cylinder

NOTE: Be sure to install


underneath the injectors.

the

head.

six capscrews

in the

holes

kn9csha

NOTE: The top of the cylinder head capscrew is identified with


an angle marking. The cylinder head capscrews must be
tightened by using the three-step torque plus angle method,
described as follows:

kn3csga

1.

Follow the numbered sequence and tighten all capscrews:

Torque Value:

(Step One) 70 Nom [52 ft-lb]

Follow the numbered


capscrews again.

C--

Front
kn3csob

sequence

and check the torque

on all

Engine Disassembly

2.

and Assembly - Group 00

Follow the numbered sequence


fourteen long capscrews:

Torque Value:

and tighten

Engine Assembly (O-02)


Page O-87
only the

(Step Two) 145 Nom [105 ft-lb]

Follow the numbered sequence


long capscrews again.

and check the torque

0%

on all

3.

Torque

Front

Value: (Step Three)

Follow the numbered sequence and turn all the capscrews


90 degrees as indicated on the capscrew head.

To accurately turn the capscrew to the desired angle, a small


dot and a window are marked on the capscrew head.

Window

kn9csvb

Mark the cylinder head adjacent to the dot on the capscrew


head. This mark will serve as an indexing aid.

Engine Assembly (O-02)


Page O-88

Engine Disassembly and Assemlby - Group 00

Rotate the capscrew until the mark that has been made on the
cylinder head falls into the window on the capscrew head.

Service Tip: Use a permanent marker to mark the socket


corresponding to one of the flats of the socket hex.

After the torque has been completed, mark the cylinder head
at the location of the dot.

Position the socket on the capscrew such that the mark on the
socket is at the same point as the window on the capscrew.

Engine Assembly (O-02)


Page O-89

Engine Disassembly and Assembly - Group 00


Turn the socket until the mark of the socket aligns with the
mark on the cylinder head.

Push Rod - Installation


Check the push rods for straightness.

Install the push rods into the sockets of the valve tappets
from which they were removed.
Lubricate the push rod sockets and valve stems with clean
15W-40 engine oil.

Rocker Lever and Shaft - Assembly


install the adjusting screw and locknut.

rh900fc

Engine Assembly
Page O-90

(O-02)

Engine Disassembly

and Assemlby - Group 00

Install a retaining ring, thrust washer and wavy spring washer

rh9OOaa

Lubricate the shaft with clean 15W-M engine oil.

rh9shw.a

Position the levers on the rocker shaft.

rh9OOae

Install the remaining wavy spring


retaining ring as illustrated.

rh900ac

washer,

thrust washer

and

Engine Disassembly and Assembly - Group 00

Compress the wavy spring washers


half of the pedestal as illustrated.

Engine Assembly (O-02)


Page 0-91

and install the bottom

rh900ad

Rocker Lever Assembly - Installation


Make sure the rocker
completely backed out.

lever

adjusting

screws

are

0
@

rh900da

Install the supports and


rocker lever oil manifold.

rocker

lever

assemblies

over the

Make sure the dowels in the pedestals are installed into


the dowel bores.

Use clean 15W-40 engine oil to lubricate


under the heads of the pedestal capscrews.
Install the retaining

clamps and capscrews.

@$

the threads

and

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-92

RI
A

0(K

10 mm
Caution: To prevent damage to the rocker lever or push
rod, make sure the adjusting screw ball is positioned in the
socket of the push rods when tightening.
NOTE: For engines with excessive oil carryover, rotate the
rocker lever shaft toward the push tube side of the engine
(clockwise when facing the front of the engine). This will reduce
the amount of oil to the overhead.
Tighten the retaining clamp capscrews.
Torque Value: 55 Nom [41 ft-lb]

Valve Clearance - Adjustment

RI

l/2 Inch Drive, Part No. 3377371 Engine Barring Tool


Locate top dead center (TDC) for cylinder No. 1 by rotating the
crankshaft slowly while pressing on the engine timing pin.

When the pin engages the hole in the camshaft gear, cylinder
No. 1 is at (TDC) on the compression stroke.

--=?h

Engine
Timing

cg9gewa

Caution: To prevent damage to the timing pin, be sure to


disengage the pin after locating top dead center.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-93

Feeler Gauge
Adjust the valves with engine cold (below 60C [14OF]).
The clearance is correct when slight resistance is felt as the
feeler gauge is moved between the valve stem and rocker
lever.

Valve Clearance Specifications


mm

in

0.30

Intake

0.012

0.61

Exhaust

0.024

Valve Arrangement
Beginning at the front of the cylinder head, the first valve is
intake, the second one is exhaust. The same orientation is
used for all cylinders.

IE

IE

IE

IE

IE

IE

0 Eront

14 mm, Flat Blade Screwdriver


Locate top dead center (TDC) for cylinder
Adjust the valves indicated

RI
@
0(K

No. 1.

for Chart A.

Tighten the locknut.

Torque Value:

24 Nom [18 ft-lb]

Check the valve clearance

Mark the end of the


crankshaft 360 degrees.
Caution:

again.

crankshaft

or flywheel.

Be sure the timing pin is disengaged.

Rotate

the

Chart A
Cylinder
Intake
Exhaust

1
x
X

2
x

3
X

4
X

5
X

Engine Assembly (O-02)


Page O-94

Engine Disassembly and Assemlby - Group 00

14 mm, Flat Blade Screwdriver


Adjust the valves indicated for Chart B.
Tighten the locknut.

Chart B
Cylinder
Intake
Exhaust

2
X

3
X

4
X

5
x

6
x
X

Torque Value: 24 N*m [18 ft-lb]


Check the valve clearance

again.

Valve Cover - Installation


Install the rubber seal into the groove in the valve cover. Start
the installation at the overlap area shown in the illustration. Do
not stretch the rubber seal. If the seal has more overlap than
shown in this illustration, trim the excess to provide the proper
overlap.

Install new sealing o-rings on the valve cover capscrews.

NOTE: Engines equipped with wastegate turbochargers must


have a studded capscrew installed in the third hole from the
front. This is for the wastegate actuator hose clamp.

15 mm
Install the valve cover capscrews
shown.
Torque

Value:

24 N*m

118 ft-lb]

and tighten

in the sequence

Engine Disassembly and Assembly - Group 00

Crankcase

Engine Assembly (O-02)


Page O-95

Breather Tube - Installation

13 mm, 18 mm
Install the breather tube

and hose clamps. Tighten


capscrews for the breather tube support brackets.

the

Torque Value:
A = 24 Nom [18 ft-lb]
B = 48 Nom [32 ft-lb]

Injector - Installation
Lubricate the sealing lips of the sleeve with anti-seize
compound.
Assemble the injector, sealing sleeve, a new
copper sealing washer and the holddown clamp.

0%

Use only one washer.


Service Tip: A light coat of clean 15W-40 engine oil between
the washer and injector will aid in holding the washer in
place during installation.

Install the injector assembly into the injector bore. The


injector leak-off connection must be toward the valve cover.

13 mm
Install the holddown

Torque Value:

capscrew.

24 Nom [18 ft-lb]

@@A
@

Engine Assembly (O-02)


Page O-96

Engine Disassembly and Assemlby - Group 00

Fuel Drain Manifold - Installation


10 mm
Install the fuel drain manifold and new copper sealing washer
as illustrated.

Torque Value: 9 Nom [80 in-lb]


NOTE: The banjo connector
installed as illustrated.

seal (Siamese washer)

must be

10 mm
Install new sealing washers and connect
the fuel filter head.

the drain manifold,to

Torque Value:
Filter Head Banjo
Injector Banjo

15 Nom [ll ft-lb]


9 Nom [80 in-lb]

ft9seha

Engine Lifting Bracket - Installation


18 mm
Install the front
cylinder head.

bracket

onto the front

exhaust

side of the

Install the rear bracket on the rear of the cylinder head. Tighten
the capscrews.

Torque Value: 77 Nom [57 ft-lb]

Intake Manifold Cover - Installation


Install the manifold cover, gasket and capscrews (charge air
cooled engines). Do Not install capscrews in the holes used

to secure the high pressure fuel line support brackets.


Torque Value: 24 Nom [18 ft-lb]

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-97

Aftercooler - Installation
Install the aftercooler,
gasket and capscrews, if equipped.
@
Apply 3-Bond to both sides of the aftercooler gasket. Do not &
install capscrews in the holes used to secure the high

0(K

pressure fuel line support brackets.


Torque Value:

24 Nom 118 ft-lb]

8 mm
Install the coolant supply tube
(2). Tighten the hose clamps.

Torque Value:

(1) and coolant

return tube

6 Nom [53 in-lb]

Exhaust Manifold - Installation


Assemble the exhaust manifold capscrews, new lock plates,
and gaskets on the manifold. Apply a thin coating of nickel
based,
high temperature,
anti-seize
compound
to the
capscrew threads.
NOTE: The exhaust manifold
direction.

gasket can be installed in either

The tabs in the holes of the gasket are designed


gasket in place during installation.

16

to hold the

mm

Is-l

Install the exhaust


manifold
and gaskets.
sequence shown and tighten the capscrews.

Torque Value:

@
@

Follow

the

\w

43 N l m [32 ft-lb]

After the capscrews are tightened to the correct torque value,


bend over the lockplates to prevent the capscrews from
loosening.

0\
r

xm9OOha

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-98

Turbocharger - Installation
Use precoated turbocharger mounting studs or apply a thin
coating of nickel based, high temperature, anti-seize compound
to the coarse threads of the stud.

tb9OOw

Use two nuts locked together to install the studs.


Torque Value:

10 Nom [89 in-lb]

tb900wd

15 mm
Install the turbocharger mounting gasket with the raised bead
facing the exhaust manifold.
Install the turbocharger.
Torque Value:

45 Nom [33 ft-lb]

13 mm
NOTE: It may be necessary to orient the turbocharger center
bearing housing and/or compressor outlet.
To orient the center bearing housing, bend the lockplates, if
equipped, and loosen the turbine housing capscrews and
position the bearing housing.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-99

Turbocharger Oil Drain Tube - Installation


Apply a thin coat of LoctiteTM 277 around the flanged end of
the lower drain tube. Use a tube driver and hammer to drive
the tube into the bore until the flange contacts the cylinder
block. Make sure the end of the tube is in the 12x10 oclock
position.

NOTE: If a tube driver is not available,


wrench can be used as illustrated.

a 22 mm open end

13 mm
Install the hose and clamps on the turbocharger drain tube
loosely.
Install
the
drain
tube
and
gasket
on the
turbocharger. Tighten the oil drain tube capscrews.
Torque

Value:

24 Nom 118 ft-lb]

Position the turbocharger


tube, tighten the clamps.

Torque Value:

drain

hose to connect

the drain

5 Nom [44 in-lb]

13 mm, Punch, Hammer


If loosened, tighten the turbine housing capscrews.
lockplates onto the flats to prevent loosening.

Torque Value:

20 Nom [15 ft-lb]

Bend the

Engine Assembly (O-02)


Page O-100

Engine Disassembly and Assembly - Group 00


7/16 inch, 10 mm
Orientation of the compressor outlet requires the compressor
housing V-band clamp to be loosened.
If required, loosen the compressor housing and position the
housing to align with the air crossover tube.
NOTE: When orienting the compressor outlet on turbocharger
with wastegate actuators, do not force the movement of the
housing. This will damage the actuator bracket and cause
internal damage to the turbocharger.

Snap Ring Pliers


For turbochargers with snap rings, loosen the snap ring and
align the compressor housing with the turbocharger air outlet
connection with snap ring pliers or channel locks.

7/16 inch, Plastic Hammer


Loosen the two capscrews that secure the actuator bracket
brace to the V-band clamp. After orientation, first tighten the
V-band clamp nut, tap around the V-band clamp with a plastic
hammer, then tighten the two capscrews on the brace.
Torque Value:
V-Band Clamp Nut

8 Nom [ 71 in-lb]

Actuator Bracket Brace Capscrews 13 Nom [115 in-lb]

NOTE: New or rebuilt turbocharger


before start-up.

must be prelubricated

Pour 50 to 80 cc [2 to 3 oz.] of clean 15W-40 engine oil into


the oil inlet fitting on top of the turbocharger while spinning the
turbocharger impeller to distribute the oil in the bearing.

Engine Assembly
Page O-l 00-02

Engine Disassembly

(O-02)

Turbochazer
16 mm Cro

and Assembly - Group 00

Oil Sup ly Hose - Installation

oot, 19 mm 8 ocket

Apply vegetable

oil to the o-rings of the adapter fittings.

Install the fittings into the oil filter


turbocharger bearing housing.
Tighten the fittings.
Torque Value: 24 Nom [18 ft-lb]
Install the oil supply line.
Torque

Value:

35 Nom [26 ft-lb]

head

and

top

of the

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-101

Turbocharger Exhaust Outlet Connection


Installation
install the exhaust outlet connection.
NOTE: Do not tighten the two mounting
band clamp has been tightened.

capscrews

until the

Torque Value:
Band Clamp
Capscrews

8 Nom

[71 in-lb]

43 N*m

132 ft-lb]

Air Crossover Tube - Installation


Screwdriver
Install the air crossover tube and clamps and tighten.
Torque

Value:

5 Nom 144 in-lb]

Be sure there is a minimum of 9.5 mm IO.375 inch]


the compressor outlet and the crossover tube.

between

Thermostat and Housing - Installation


Install two thermostats

into the bores as illustrated.

Refer to Group 07 for thermostat

testing procedures.

Install a new gasket and the thermostat housing. Install two


capscrews and do not tighten until after the coolant outlet
connection is installed.

0(K

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-102

Coolant Outlet Connection - Installation


10 mm
Install a new gasket and the coolant
Tighten the
capscrews.

thermostat

housing

outlet connection.
and

coolant

connection

Torque Value: 24 Nom [I8 ft-lb]

Coolant Filter - Installation


Apply a light film of clean 15W-40 engine
sealing surface of the coolant filter.

oil to the gasket

Caution: Mechanical over-tightening may distort the threads


or damage the filter head.
Install the coolant filter as specified

by the filter manufacturer.

Coolant Vent Fitting - Installation


9/16 inch
Coat the threads with pipe sealant with Teflon and install the
l/8 inch coolant vent fitting.
Tighten and orient the fitting
12:00 oclock position.
Torque

so the petcock

bore is at the

Value: 8 Nom [71 in-lb]

Coolant Vent Petcock - Installation


9/16 inch
Coat the threads with pipe sealant with Teflon and install the
vent petcock.
Torque

Value:

5 Nom [44 in-lb]

Engine Assembly (O-02)


Page O-l 03

Engine Disassembly and Assembly - Group 00

Coolant Vent Tube - Installation


7/16 inch
Coat the threads with
tube. Tighten the fitting.

Torque Value:

Teflon

and

install

the

coolant

vent

8 Nom [71 in-lb]

Coolant Inlet Connection - Installation


Install the
clamp.

new

Torque Value:

coolant

inlet

connection

and

tighten

the

@!!!
GB

5 Nom [44 in-lb]

The final positioning of the inlet connection may need to be


made after installation of the engine in the vehicle.

Alternator Mounting Bracket - Installation


13 mm
Assemble the alternator

Torque Value:

bracket to the thermostat

housing.

24 Nom [18 ft-lb]

Alternator - Installation
Position
mounting

the alternator
capscrews.

on

the

bracket

The capscrews
should be installed
toward the inside of the bracket.

Do not tighten at this time.

with

and
the

install
nuts

the

facing

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-104

Alternator Brace - Installation


13 mm
Install the capscrew into the alternator
Finger tighten the capscrew.

brace and water pump.

eh9cshc

Caution: Make sure the alternator brace is positioned


properly for correct belt alignment.
Connect the alternator
the capscrew.

brace to the alternator.

Tighten the water pump mounting

capscrew.

Torque Value: 24 Nom [18 ft-lb]

15 mm, 18 mm, 19 mm
Tighten the alternator

Torque Value:
A = 43 Nom [32 ft-lb]
B = 24 Nom [18 ft-lb]
C = 80 Nom [59 It-lb]

mounting

capscrew.

Finger tighten

Engine Assembly (O-02)


Page O-105

Engine Disassembly and Assembly - Group 00

Belt Tensioner Bracket - Installation


5 mm Hex Wrench
Install the tensioner
housing.

bracket

onto the front of the thermostat

Tighten the hex head screws.

Torque Value:

24 Nom 118 ft-lb]

Belt Tensioner - Installation


15 mm

I-S-l

Position the belt tensioner onto the bracket and secure it


with the capscrew. Make sure the tensioner locating tab is
positioned in the unthreaded hole of the tensioner bracket.

Iw

Torque Value:

43 Nom [32 ft-lb]

Engine - Removal from the Rebuild Stand


Part No. 3822512 Engine Lifting Fixture
Warning: To prevent personal injury, the engine lifting
equipment must be designed to safely lift the engine as
an assembly. The dry weight of the engine with standard
accessories is 612 kg [1350 lb].

il

Use a properly rated hoist and engine lifting fixture such as


Part No. 3822512, attached to the engine mounted lifting
brackets to lift the engine.

Warning: The engine can move or drop a small distance


as it is being removed from the rebuild stand. Use
extreme care to prevent personal injury.

Use the hoist and lifting fixture to apply lifting tension to the
engine.
Remove the six
adapter plate.

capscrews

that

hold

the

Use the hoist to lower the engine to suitable


stands or a shipping skid.

engine

to

the

engine support

Remove the hoist and lifting fixture from the engine.

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-106

Fan Hub Assembly - Installation


10 mm
Install the fan hub. Be sure the fan hub shaft assembly turns
freely. Tighten the capscrews.

Torque Value: 24 Nom [18 ft-lb]

Fuel Injection Pump - Installation


LoctiteTM is used to help retain the injection
studs.
Apply Loctitem

pump mounting

242 to the threads of the studs.

13 mm
Use two nuts locked together as illustrated

to install the studs.

fD900hl

Part No. 3377371 Engine

Barring Tool

Make sure the piston in cylinder No. 1 is at TDC.


NOTE: Rotate the crankshaft

only in the direction

of rotation.

Engine Assembly (O-02)


Page O-107

Engine Disassembly and Assembly - Group 00


The fuel injection pump also has a timing pin (l), located in
to position
the pump shaft to
the governor
housing,
correspond with TDC for cylinder No. 1. After the pump is
installed, the timing pin must be reversed and stored in the
governor housing (2).

24 mm
Remove the access plug.

Remove the timing pin.

fs9Dimi

If the timing tooth is not aligned with the timing


rotate the pump shaft until the timing tooth aligns.

pin hole,

Engine Assembly (O-02)


Page O-108

Engine Disassembly and Assembly - Group 00

Reverse the position of the pin so the slot of the pin will fit
over the timing tooth in the fuel injection pump.
Install and secure the timing pin with the access plug.

fs9piha

Make sure the o-ring seals for the fill orifice (A) and pilot
(B) are correctly installed and are not damaged.
Lubricate the mounting

(4

flange with clean engine oil.

NOTE: The fuel pump drive gear inside diameter and the shaft
outside diameter must be clean and dry before installing the
gear.
NOTE: The oil feed orifice o-ring for the Bosch
injection pump is found in the gear housing.

PESP.P fuel

fp9hssz

NOTE: The drive gear does not require a Woodruff key. If


using a new replacement pump, remove and discard the key.
Position the pump flange onto the mounting

studs.

15 mm and 13 mm, Part No. 3823956 Fuel Pump Mounting


Tool Kit
Install the mounting

nuts.

Torque Value:
Mounting

44 N l m [32 ft-lb]

nuts

Rear support

bracket:

M8 pump to bracket capscrews


Ml0 block and bracket capscrews
Upper support bracket

Engine Disassembly and Assembly - Group 00

22 mm (PESGA Fuel Injection Pump)


27 mm (PESGMW Fuel Injection Pump)
30 mm (PESGP Fuel Injection Pump)

Engine Assembly (O-02)


Page O-l 09

Caution: To prevent damage to the timing pins, do not


exceed the torque value given. This is not the final torque A
value for the retaining nut.
Install the fuel pump drive gear, retaining nut and washer.
Initial Torque Value: 12 Nom

[106 in-lb]

Disengage the engine timing pin.

24 mm
Remove the fuel pump timing pin plug. Reverse the position
of the pin and install the pin, plug and sealing washer.

Torque Value:

15 Nom [il

ft-lb]

22 mm (PESGA Fuel Injection Pump)


27 mm (PESGMW Fuel Injection Pump)
30 mm (PESGP Fuel Injection Pump)
Tighten the fuel injection pump drive gear nut.
Pump Model
PESGA
PESGMW
PESGP

Torque Value:
92 Nom [ 68 ft-lb]
104 Nom [ 77 ft-lb]
195 Nom [144 ft-lb]

Engine Assembly (O-02)


Page O-l 10
Oil Fill

Engine Disassembly and Assembly - Group 00

Caution: The governor housing must be prelubricated


before engine operation. Failure to do so will result in
premature governor weight wear.

10 mm hex drive
Remove the access plug.
Add the following quantity of clean 15W-40 engine oil:
l
RSV 450 ml [0.43 qt.]
l
RQV 750 ml [0.71 qt.]
l
RQVK 750 ml [0.71 qt.]
Install the access plug.

Torque Value: 28 Nom [21 ft-lb]

Position
gear.

an indicator

Note the total


backlash.

on a tooth

indicator

of the injection

travel as injection

pump drive

pump drive gear

Hold the adjoining camshaft gear from moving when checking


backlash or the readings will be the total of both gears.

Fuel Pump Drive Gear Backlash Limit


mm

in

0.08

MIN

0.013

0.33

MAX

0.03

Fuel Injection Pump Supply Line - Installation


17 mm and 19 mm
use new sealing washers and install the injection pump supply
@

zhten

the banjo fittings.

Install the fuel return line.

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-l 11

Fuel Filter Head - Installation


If the optional dual filter is to be used, install the adapter and
o-ring.
Torque Value: 11 Nom [97 in-lb]

Install the o-ring in the dual filter head. Lubricate the o-ring @A
and the center hole with clean 15W-40 engine oil.
@

24 mm
Install the dual filter head.
Tighten the nut.
Torque Value:

32 Nom [24 ft-lb]

Fuel Filter - Installation


Temporarily install the fuel filter(s).
When the engine is ready to be put into service, fill the
filter(s) with clean No. 2 diesel fuel and tighten l/2 turn
after the lubricated gasket contacts the filter head.

ff9etha

Engine Assembly (O-02)


Page O-112

Engine Disassembly and Assembly - Group 00

Fuel Lines, High Pressure - Installation


10 and 17 mm (PESGA and PESGMW Fuel Injection Pump)
10 and 19 mm (PESGP Fuel Injection Pump)
Loosen the vibration isolator capscrews so the fuel lines can be
easily moved.
NOTE: To prevent breakage to the fuel lines, they must be
connected to the injector and fuel injection pump in a free
state without forcing the connecting nuts. Since the fuel lines
are properly sized for specific application, bending should not
be necessary.

Caution: If removed, install the support clamp in the original


position and make sure the lines do not contact each other
or another component.
Install the high pressure fuel lines in the reverse order of
removal.
NOTE: Thoroughly clean the high pressure fuel lines to make
sure no debris is present before installing the fuel lines onto the
injectors or fuel injection pump.

Tighten all high pressure fuel line fittings


hardware.

and mounting

Torque Value:
1. Line Fittings 24 Nom [18 ft-lb]
2. Support Bracket Capscrews 24 Nom [18 ft-lb]
3. Vibration Isolator Capscrews 6 Nom [53 in-lb]

AFC Tube - Installation


17 mm, 13 mm
Install the AFC tube.
Torque Value:
Threaded Fitting

8 Nom

[71 in-lb]

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-l 13

Seal, Front Crankshaft - Installation


3824499 installation Tool

RI

Leave the plastic pilot installation

tool

in the lubricating

oil

seal.
position the seal on the service tool, Part No. 3824499, with
the lubricating oil seal dust lip facing outward.

NOTE: Properly support the front cover lubricating oil seal


flange to prevent damage to the lubricating oil seal and front
cover.
Press the lubricating oil seal into the front cover from the
back side of the cover toward the front side of the cover.
press the lubricating oil seal until the service
against the front cover.

tool

bottoms

Wear Sleeve, Front Crankshaft - Installation


NOTE: Visually
inspect
the seal contact
area of the
crankshaft for a wear groove. If the seal has worn a groove
deep enough to be felt with a sharp object or fingernail, it
will be necessary to install a wear sleeve to prevent an oil
leak.
NOTE: The oil seal used with the wear sleeve has a larger
inside diameter than the standard seal. The two seals are not
interchangeable.
Refer to the appropriate
Parts Manual for
the correct part number.

Part No. 3823908


Installation Tool

Crankshaft

Front

Wear

Sleeve

Use the driver to install the wear sleeve to the correct


position on the crankshaft. The kit consists of the following:

Ref.
No.

Description

QtY.

Driver

Spacer

3
4

Capscrew

Ml 4X1.5X60mm

Hair Pin Cotter

2
2

ksStolb

Engine Assembly (O-02)


Page O-114

Engine Disassembly and Assemlby - Group 00

Apply a thin coat of 15W-40 engine


diameter and capscrew threads.

oil to the driver

inside

Use crocus cloth or equivalent to remove rust and corrosion


deposits from the crankshaft flange.
Apply a thin coat of 15W-40 engine oil to the crankshaft flange.
Position the chamfered end of the wear sleeve onto the end of
the crankshaft.

Position
sleeve.

WEAR

the counterbore

end

of the driver

onto

the wear

Install two capscrews (without spacers or hair pin totters)


through the driver and into the crankshaft capscrew holes.
Align the wear sleeve and driver perpendicular
with the
crankshaft. Tighten the capscrews finger tight.

Engine

Disassembly

and Assembly

- Group 00

Engine Assembly (O-02)


Page O-l 15

Alternately tighten the capscrews until the sleeve is installed


to a depth of approximately
16 mm [0.625 inch].
NOTE: To prevent damage to the wear
exceed l/2 revolution of each capscrew.
Approximate

torque

value:

sleeve,

do

not

20 Nom [15 ft-lb]

Remove the capscrews


and install a
capscrew. Install the two capscrews again.

spacer

on

each

Continue to alternately tighten the capscrews until the bottom


of the driver contacts the end of the crankshaft.

Remove the driver. Use the hair pin totters to secure


capscrews and spacers to the tool during storage.

the

ks9tove

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-l 16

Gear Cover - Installation

B
q

Caution: The seal lip and the sealing surface on the


crankshaft must be free from all oil residue to prevent seal
leaks.
Thoroughly

clean and dry the front seal area of the crankshaft.

Use two M8X1.25X70 mm guide pins to aid in alignment of the


gasket. Apply a coat of Three Bond Sealant to both sides of
the gasket.
Install the gasket and gear cover,with
the nose of the crankshaft.

the seal pilot tool, over

NOTE: The seal pilot tool will align the cover and the nose of
the crankshaft.
Install the capscrews.

10 mm
Tighten the gear cover capscrews.

Torque Value: 24 Nom [18 k-lb]


Remove the seal tool pilot from the nose of the crankshaft.

Engine Assembly (O-02)


Page O-l 17

Engine Disassembly and Assembly - Group 00


Install the crankshaft oil seal dust shield, if used, as follows:
@&
0 Push the dust shield (1) onto the crankshaft with the @
part number facing out away from the engine.
l

The dust shield should contact the oil seal.

NOTE: Liquid soap will aid in installation.

Tachometer Drive - Installation


Install the tachometer drive and cable.

bp9OOha

Vibration Damper - Installation


21 mm, Part No. 3377371 Engine Barring Tool
Install the vibration damper.
Tighten the capscrews.
Torque Value:

200 Nom [148 ft-lb]

Use the engine barring tool to hold the engine from turning.

Install the fan hub pulley and secure with capscrews.


NOTE: It will be easier to tighten the capscrews after the belt
is installed.

0%
@!A
@

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-l 18

Drive Belt - Installation


3/8 inch Square Drive
Lii the tensioner and install the drive belt.
Service Tip: If difficulty

is experienced installing the drive belt


(the belt seems too short), position the belt over the fan hub
pulley first and then slide the belt over the water pump pulley
while holding the tensioner up.

13 mm
Tighten the fan hub pulley capscrews.

Torque Value: 45 Nom [33 ft-lb]

Engine Support, Front - Installation


15 mm
Install the front engine support.
Tighten the capscrews.

Torque Value:

112 Nom [82 ft-lb]

Fuel Transfer Pump - Installation


10 mm
Apply a coating of Three Bond Sealant to the gasket.
Install the fuel transfer pump and new gasket.
Tighten the capscrews.

Torque Value: 24 Nom [18 ft-lb]

Engine Assembly (O-02)


Page 0-l 19

Engine Disassembly and Assembly - Group 00

Fuel Lines, Low Pressure - Installation


14 mm, 17 mm, 20 mm
Install the fuel line to the fuel transfer pump. Use two
wrenches to tighten the connection to the fuel transfer pump.
Torque Value:

24 Nom [18 k-lb]

Fuel Pump Solenoid - Installation


8mm
Install the solenoid and connect the wires.
Torque Value:

8 N*m [70 in-lb]

Refer to Group 14 for engine testing.

Air Compressor - Installation


14 mm, 15 mm, 19 mm
Caution:
housing
the side
the gear

Make sure the oil drain notch in the gear


is not blocked. The gasket must be installed with
marked This Side Toward Gear Housing facing
housing.

Use a new gasket. Install the air compressor. Tighten the two @!!!!
dv
mounting nuts.
Torque Value:

77 Nom [57 ft-lb]

NOTE: It is not necessary to time the air compressor on the


6D114E-1 Series engine.

Install the mounting spacer to the engine block, use the 40 @j&
mm long capscrews and tighten finger tight.
@

cp900ha

Engine Disassembly and Assemlby - Group 00

Engine Assembly (O-02)


Page O-120

Install the air compressor brace (2) to the mounting spacer (1)
and adapter (3) on the air compressor using the 30 mm long
capscrews. Make sure the brace and spacer are aligned and
no parts are in a bind. Tighten evenly to the proper torque
value.

Torque Value: 43 Nom [32 ft-lb]

9/16 inch
Install the oil supply line.

Torque Value: 8 Nom [71 in-lb]

RI
A

@
**

15/16 inch
Caution: If rubber grommets are used on the coolant lines,
be sure they are installed carefully to prevent cuts or tears
to the grommets which will cause coolant leaks.
Install the coolant Ines.
Torque

Value:

35 Nom [26 ft-lb]

(+i

Install and tighten the inlet and outlet connections.


Torque

0K

5 Nom [48 in-lb]

Inlet
*Outlet
*l/2

Value:
24 Nom [18 ft-lb]

NPT fitting in the compressor

cylinder

NOTE: Torque value for the discharge


size and type.
Refer to the appropriate
torque value.

head.

line depends on the line

chassis Shop Manual for the correct

Engine Disassembly and Assembly - Group 00

Engine Assembly (O-02)


Page O-121

Engine Accessories - Installation


Install the
;rzeories

cover
plate or any additional
gear driven
(hydraulic
pump, freon compressor,
etc.) as

@A
av

NOTE: When gear driven accessories are installed, be sure


to install the correct support

bracket.

ah9olh;

Cylinder Block - Group 01

Page l-l

Cylinder Block - Group 01


Section Contents
Page
Camshaft Bore Expansion
Camshaft Bushing

23

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

Camshaft Bushing - Installation

Camshaft Camshaft
Camshaft
Camshaft

23

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

Bore - Cleaning

Camshaft Bushing - Removal

21

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

Plug Installation

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

Cleaning and Inspection for Reuse ......................................


- Cleaning ........................................................
Gear - Inspection ...................................................
- Inspection .......................................................

Camshaft Gear Camshaft Gear


Camshaft Gear
Camshaft Gear
Camshaft Gear-

.................................................
Replacement
- Cleaning ....................................................
- Inspection ...................................................
- Installation ...................................................
Removal ....................................................

Connecting Rod Bearings - Cleaning and Inspection for Reuse


Connecting Rod Bearings - Cleaning .............................................
Connecting Rod Bearings - Inspection ............................................

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

..........................................
Connecting
Rod Bushing - Replacement
.............................................................
Inspection..
..............................................................
Installation
.............................................................
Machining..
..............................................................
Removal..
Connecting Rods - Bend and Twist Inspection ......................................
Connecting Rod Alignment - Inspection ...........................................
..............................................
Connecting Rod Twist - Inspection
.........................................................
Fixture Calibration
Connecting
Rods - Cleaning and Inspection for Reuse ................................
..................................................
Connecting Rods - Cleaning
.................................................
Connecting Rods - Inspection
Crankshaft - Cleaning and Inspection for Reuse .....................................
Crankshaft - Cleaning .......................................................
Crankshaft - Inspection ......................................................
Crankshaft Gear - Replacement .................................................
..................................................
Crankshaft Gear - Inspection
Crankshaft Gear - Installation ..................................................
Crankshaft Gear - Removal
.....
: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
General Information
Cylinder Block - Cleaning

in a Hot Tank

Cylinder Block - Cleaning

with Solvent

Cylinder Block - Disassembly

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

.
.
111111111111111111 .
. . . . . . . _. . . . . . . . . . .
. . . . . . . . . . . _. . . . . . .
. . . . . _. . . . . . . . . . . . .

- General Information

Connecting Rods
Crankshaft
. . . .
Cylinder Block . .
Cylinder Liner . .

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

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

Cylinder Block - Exploded View


Cyl;Fli;:;ock

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

. . . _.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

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

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

i
9
ii
9

Cylinder Block - Group 01


Page 1-2
9
9
9

Oil Seals ................................................................


Pistons ..................................................................
.........................................................
Vibration Damper..
Cylinder Block - Inspection

16

For Reuse ............................................

Cylinder Block - Preparation for Cleaning


Cylinder Block - Service Tools

10

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

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

Cylinder Head Capscrews - Cleaning and Inspection for Reuse


Cleaning ................................................................
Free Length - Measurement ...................................................
Inspection ...............................................................

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

Cylinder Liners - Cleaning and Inspection for Reuse ..................................


Cylinder Liners - Cleaning ....................................................
Cylinder Liners - Inspection ...................................................
Dowel Pins (Cylinder

Head) - Removal

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

................................................
Engine Dataplate - Replacement
.................................................
Engine Dataplate - Installation
Engine Dataplate - Removal ...................................................
Engine

Lifting Brackets - Cleaning

and Inspection

for Reuse

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

Expansion Plug - Installation ...................................................


......................................................
Pipe Plug - Installation
Gear Cover - Cleaning and Inspection for Reuse ....................................
......................................................
Gear Cover - Cleaning
.....................................................
Gear Cover - Inspection
Gear Housing - Cleaning and Inspection for Reuse ...................................
Gear Housing - Cleaning .....................................................
Gear Housing - Inspection ....................................................
Main Bearing Caps and Capscrews - Cleaning and Inspection
..............................................................
Cleaning..
Inspection ...............................................................

for Reuse

Main Bearings - Cleaning and Inspection for Reuse ..................................


........................................................
General Information
....................................................
Main Bearings - Cleaning
...................................................
Main Bearings - Inspection
..................................................
Thrust Bearings - Inspection
Pistons - Cleaning and Inspection for Reuse .......................................
Piston Rings - Removal ......................................................
Pistons - Cleaning .........................................................
........................................................
Pistons - Inspection
Rear Cover - Cleaning and Inspection ............................................
..............................................................
Cleaning..
Inspection ...............................................................
Vibration
General
Rubber
Rubber
Viscous
Viscous

Damper - Cleaning and Checking for Reuse .................................


........................................................
Information
Element Vibration Damper - Inspection ......................................
Vibration Damper - Cleaning .............................................
Vibration Damper - Cleaning .............................................
Vibration Damper - Inspection ............................................

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

Cylinder Block - Group 01

Cylinder Block - Service Tools


Page 1-3

Cylinder Block - Service Tools

The following special tools are recommended to perform procedures in Group 01. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool Description

Tool No.

Measure connecting rod length, twist and bore alignment. Use


with Part No. 3823286, connecting rod checking mandrel kit.

Remove dowel pins.

Used when installing

pipe plugs, cup plugs, etc. on the engine

Used to measure internal diameter bores from 78.5 mm [3.09


in] to 2.032 mm [8.0 in].

Inspect components

for cracks.

Used to remove expansion

plugs.

Tool Illustration

Cylinder Block - Service Tools


Page 1-4
Tad

Cylinder Block - Grow 01

No.

Tnnl
. __- Illu~tratian
----__-__-_--

Tool Descrbtion

Aid in removal and installation


heavy components.

of crankshaft, flywheel

and other

Expansion Plug Driver Handle


Used with all expansion

plug drivers larger than 0.375 inch

Expansion Plug Driver


Install 1.00 inch expansion plug to specified depth. Used with
expansion plug driver handle, Part No. 3376795.

Expansion Plug Driver


Install 0.375 inch expansion

plug to specified depth.

Metric Thread Insert Kit


Repair damaged

Piston

internal metric threads.

Ring Expander

Used to install piston rings onto pistons without


distorting the rings.

damaging

or

Used with Part No. ST-561, connecting rod checking fixture, to


check length, twist and bore alignment.

Remove and install camshaft bushings.

Cylinder

Cylinder Block - Service Tools


Page l-5

Block - Group 01

Tool Illustration

Tool Description

Tool No.

Expansion Plug Driver


3823521

install 0.8125 inch expansion plug to specified depth. Used


with expansion plug driver handle, Part No. 3376795.

Expansion Plug Driver

3823522

Install 1.1875 inch expansion plug to specified depth. Used


with expansion plug driver handle, Part No. 3376795.

Expansion Plug Driver


3823523

Install 1.375 inch expansion plug to specified depth. Used with


expansion plug driver handle, Part No. 3376795.

Expansion

Plug Driver

Used to install 2.250 inch expansion

plug to specified depth.

3823524

Connecting

3823690

Rod Pin Bushing

Removal/installation

Remove and install service bushing


netting rod.

Tool

in the pin end of the con-

Capscrew Length Gauge


Used to measure capscrew free length.
3823921

Piston Ring Groove (Keystone Angle) Wear Gauge

3823965

Measure the wear of the intermediate


stone angle.

piston ring groove key-

Piston Ring Groove (Keystone Angle) Wear Gauge


3823966

Measure the wear of the top piston ring groove keystone


angle.

Cylinder Block - Group 01

Cylinder Block - Exploded View


Page 1-6

Cylinder Block - Exploded View

231

Cylinder Block - Group 01

Ref. No.

Cylinder Block - Exploded View


Page l-7

Description

QtY
1

Block, Cylinder

Cap, Main Bearing

Screw, Hex Head Cap (Flange)

Bushing,

Ref. No.

Description

Qv

38

Pin, Timing

39

Ring, Retaining

14

40

Screw, Round Head Cap

41

Gasket, Gear Cover

Plug, Expansion

42

Cover, Gear

Plug, Expansion

43

Seal, Front Crankshaft

Plug, Expansion

44

Screw, Hex Head Cap (Flange)

17

Plug, Expansion

45

Screw, Hex Head Cap (Flange)

Plug, Expansion

46

Cap, Front Cover

10

Plug, Expansion

47

Seal, Rectangular

11

Plug, Expansion

48

Screw, Hex Head Cap

12

Liner, Cylinder

49

Crankshaft

1
1

Camshaft

13

Plug, Pipe

50

Pin, Dowel

14

Plug, Pipe

51

Gear, Crankshaft

15

Draincock

52

Bearing, Main (Upper)

16

Plug, Pipe

53

Bearing, Flange (Thrust)

17

Pin, Dowel

54

Bearing, Main (Lower)

18

Pin, Dowel

55

Damper, Vibration

19

Nozzle, Piston Cooling

12

56

Screw, Hex Head

20

Plug, Pipe

57

Tube, Oil Gauge

21

Rod, Engine Connecting

58

Plug Expansion

22

Bolt, Connecting

Rod

59

Filler Cap

23

Nut, Rectangular

Hexagon

60

Tube, Oil Fill

24

Bushing

25

Bearing, Connecting

26
27

61

Plug, Expansion

12

62

Plug, Pipe

Piston, Engine

63

Sealing Ring

Pin, Piston

64

Camshaft

28

Ring, Retaining

12

65

Gear, Camshaft

29

Ring, Piston (Top)


Ring, Piston (Mid)

66

Support,

67

Screw, Hex Head Cap

31

Ring, Piston (Oil)

68

Wear Sleeve, Front Crankshaft

32

Gasket, Gear Housing

69

Wear Sleeve, Rear Crankshaft

33

Housing,

70

Capscrew,

34

Screw, Hex Head Cap (Flange)

71

Cover, Rear

35

Seal, Timing Housing

72

Gasket, Rear Cover

36

Housing, Timing Pin

73

Seal, Oil Rear Crankshaft

37

Seal, O-Ring

74

Seal, Rectangular

30

Rod

Gear

Camshaft Thrust

Hex Head (Flange)

1
1

Cylinder Block - General Information


Page 1-8

Cylinder Block - Group 01

Cylinder Block - General Information


Camshaft
The profile of the camshaft lobes is the same for all 6D114E-1 Series engines.
The camshaft end clearance is determined by the clearance between the camshaft and the thrust plate.
Camshafts that are damaged or worn on the fuel transfer pump or the valve lobes must be replaced. Komatsu America
International Company does not recommend grinding the camshaft lobes.

Crankshaft
The crankshaft is a balanced, forged steel, full fillet hardened unit with seven main bearing journals. The lower bearing
shells are all the same. All of the upper bearing shells are the same except for the No. 4 journal which has a flanged
upper bearing shell. The flanges on the bearing shell control the end thrust of the crankshaft.
Oversize main bearings and thrust bearings are available for service. Komatsu America International Company recommends regrinding ALL of the main or the connecting rod journals when ONE requires regrinding.

Cylinder Block
The cylinder block has provisions for the oil cooler housing, thermostat seats, coolant bypass line, water pump volute,
oil pump housing, water pump inlet and replaceable cylinder liners.

Cylinder Liner
The cylinder liner is a replaceable mid-stop design. The liner seat area is located midway of the length of the liner. Coolant
sealing between the liner and block is provided by a press fit at the top and by a sealing ring at the mid-stop of the liner.

Oil Seals
All crankshaft seals on the 6D114E-1 Series are the Teflonm lay-down lip (scroll) type. The Teflonm lay-down lip type seal
does not contain a spring on the back of the sealing lip. The sealing lip is a thin, stiff piece of Teflon.
Teflonm seals must be dry before installation. Do not lubricate the seal lip or the shaft. After the first few revolutions of
the shaft, a thin film of Teflon TMis transferred from the seal lip to the shaft. If the shaft is not clean and dry, this transfer
will not occur and the seal will leak. There are service replacement wear sleeves available for both front and rear
crankshaft oil seals.

Pistons
The pistons have a cast aluminum body, with both high swirl and low swirl combustion bowls and three ring grooves.
The top two ring grooves have a ni-resist insert with a Keystone profile. The pistons for the different engine configurations
are similar in appearance, but are not interchangeable. Always check the part number to be sure the correct piston is
used during piston replacement.

Vibration Damper
The vibration damper controls the twisting or torsional vibration of the crankshaft. The vibration damper is engineered for
use on specific engine models, depending on the horsepower rating and engine speed.
It is not economical to repair a vibration damper in the field. Install a new or a rebuilt vibration damper if the inspection
indicates that a damper is defective.

Connecting Rods
The connecting rods have replaceable bronze bushings.

Cylinder Block - Group 01

Cylinder Block - Preparation for Cleaning (l-01)


Page l-9

Cylinder Block - Preparation for Cleaning


(l-01)
It is necessary to thoroughly clean the cylinder block if it is
going to be reused. To properly clean the block, all pipe
plugs and expansion
plugs must be removed. It is also
recommended to remove the camshaft bushings.
Refer to Procedure

q
\

l-09.

Before beginning disassembly of the block, perform a visual


inspection to see if there is any damage that would prohibit
reuse.

Cylinder Block - Disassembly (I-02)


Remove the pipe plugs from the coolant

passages.

0
@

0
c%

Remove the pipe plugs from the oil passages.

ck9pxmc

Cylinder Block - Group 01

Dowel Pins (Cylinder Head) - Removal (l-03)


Page l-10

Part No. 3375784, Light Duty Dent Puller, Drill Motor, 3 mm


[l/8 inch] Drill Bit
Drill a 3 mm [l/8 inch] hole and use a slide hammer equipped
with a No. 10 sheet metal screw to remove expansion plugs.

Remove the expansion

plugs from the oil passages.

Remove the expansion

plugs from the coolant

passages.

Dowel Pins (Cylinder Head) - Removal


(I-03)
Use a dowel pin extractor, Part No. ST-1 134, or its equivalent.
Remove the two cylinder head dowel pins.
l

Put the split collet (1) over the dowel pin.

Slide the extractor

Use the slide hammer (3) to push the extractor


over the split collet tightly.

Use the slide hammer to remove the dowel pin.

collar (2) over the split collet.


collar

Cylinder Block - Cleaning with Solvent (l-04)


Page l-11

Cylinder Block - Group 01

Cylinder Block - Cleaning with Solvent


(I-04)
Cleaning Brush

RI

Use clean solvent and a brush to clean the main oil passage.

q
B

Cleaning Brush
Use clean solvent and a brush to clean the main bearing to
camshaft bore oil passage.
B
R

Cleaning Brush
Use clean solvent
nozzle passages.

and a brush to clean the piston

cooling

E2l
B
Ll

Cleaning Brush
Use clean solvent and a brush to clean the oil passage from
the camshaft bore to the rocker assemblies.

q
B

SW2037

Cylinder Block - Cleaning with Solvent (l-04)


Page 1-12

Cylinder Block - Group 01


Cleaning Brush
Use clean
passages.

solvent

and a brush to clean the oil cooler

Thoroughly

clean all gasket sealing surfaces.

Clean the cylinder block head deck with a Scotch-B&9


cleaning pad or equivalent and solvent.

oil

7448

Clean the top cylinder liner press surface (A) and the mid-stop
ledge (B) and (C) with a Scotch Britee 7448 cleaning pad or
equivalent and solvent.

ck9brga

Cylinder Block - Group 01

Cylinder Block - Cleaning with Solvent (l-04)


Page 1-13

Thoroughly clean all expansion plug bores with a Scotch


Brite@7448 cleaning pad, or equivalent, and solvent.

Inspect the coolant passages for rust or restriction. Use


bristle brushes to clean the coolant passages.
Warning: Use protective measures to prevent personal
injury.

Build-up of deposits in the coolant passages can cause


engine overheating.
NOTE: Excessive deposits may be cleaned in an acid tank,
but the camshaft bushings and piston cooling nozzles must
first be removed to prevent damage.

Warning: Use protective measures to prevent personal


injury.
NOTE: The block may be cleaned in a hot tank using a soap
and water solution without removing the camshaft bushings.

A
B
IJ

Cylinder Block - Cleaning in a Hot Tank (l-05)


Page 1-14

Cylinder Block - Group 01

Cylinder Block - Cleaning in a Hot Tank


(I-05)
The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.
Use a hoist or hydraulic arm to move the cylinder block into
the cleaning tank.

ck9bde

Follow the instructions of the manufacturer of the cleaning tank


and the manufacturer of the cleaning solution.
NOTE: Komatsu America International Company does not
recommend any specific cleaning solution.
A cleaning tank that will mix and filter the cleaning solution
gives the best results.
Remove the block from the cleaning tank.
Use a nylon bristle brush to clean the oil passages.
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam or solvent to clean the cylinder block. Dry with
compressed air.

ck9bdeC

Caution: Do not damage the machined gasket surfaces.


Use a gasket scraper to clean the cylinder block deck surface.
Use Scotch Brite@7448, or equivalent, and solvent to remove
any residual gasket material from the cylinder block gasket
surfaces.
Caution: When using compressed air to clean capscrew
holes, always wear safety glasses or a face shield to protect
the eyes. Personal injury can result. Be sure all of the water
and debris is removed from the capscrew holes and the oil
passages.
Use compressed air to dry the block.

NOTE: If the cylinder block is not going to be used


immediately, apply a coating of preservative oil to prevent rust.
Cover the block to prevent dirt from sticking to the oil.

Cylinder

Block - Group 01

Cylinder

Block - Inspection For Reuse (l-06)


Page l-15

Cylinder Block - Inspection For Reuse


(I-06)
NOTE: All measurements

of the cylinder block must be


made when the block is positioned on a flat surface. If the
block is mounted on the engine stand, the measurements
can be incorrect because of distortion.
Inspect all gasket surfaces.
Visually inspect for burrs or damage.
Use a medium grit hone or crocus cloth to remove burrs.

0a!3

Straight Edge and Feeler Gauge


Visually inspect the cylinder

block head deck for damage.

Check the cylinder


each cylinder.

head

block

deck

for flatness

RI

between
04B

Cylinder Block Flatness Specification


in
mm
0.075

End-to-End

0.003

0.075

Side-to-Side

0.003

Caution: Do not proceed with the repair if the cylinder


block head deck is damaged or not flat.

NOTE: The cylinder block head deck can be resurfaced in a


machine shop and a thicker surface cylinder head gasket
installed to keep the piston-to-valve clearance the same.

The upper right corner of the rear face of the block must be
stamped with an x when the block is resurfaced to 0.25
mm [O.OlO inch]. A second x must be stamped beside the
first when the block is resurfaced to 0.50 mm [0.020 inch].

ck9bdga

Cylinder Block - Inspection For Reuse (l-06)


Page 1-16

Cylinder Block - Group 01


Consult the 6D114E-1 Series parts catalog
gasket to be used with resurfaced
piston-to-valve clearance.

for the correct


blocks to be sure of proper

NOTE: The gaskets are notched and color coded to aid in


identification. The standard gasket is red and does not have a
notch.

A=

(Silver) Use where


resurfaced

cylinder

block

head deck has been

0.25 mm [O.OlO in] (two notches)

B
B=

(Blue) Use where


resurfaced

cylinder

block

head deck

has been

0.50 mm [0.020 in] (three notches)


Measure the upper press fit area of the cylinder

liner bore.

Cylinder Liner Bore in Block (Press Fit Bore)


mm

in

130.900

MIN

130.990

MAX

5.1535
5.1570

Part No. 3375432, Crack Detection Kit


Caution: Clean all deposits and debris from sealing
surfaces A, B and C. Use Scotch Brite 7448* or equivalent
and cleaning solvent to polish the surfaces. However, due
to the critical machined tolerances, care should be taken
not to remove any additional material.
Use a crack detection kit, Part No. 3375432, or its equivalent.
Check the counterbore ledge for cracks.
If surface C has signs of extreme wear, the counterbore will
require machining and the installation of shims for the correct
liner protrusion.
ck9brga

Cylinder

liner shims are available as follows:

Cylinder Liner Shim Thickness

bp900gf

mm

Part No.

in

0.25

1296 603 Hl

0.010

0.38

1296 604 Hl

0.015

0.51

1296 605 Hl

0.020

0.76

1296 698 Hl

0.030

1.oo

1296 699 Hl

0.040

Cylinder Block - Group 01

Cylinder Block - Inspection For Reuse (l-06)


Page 1-17

Measure the liner counterbore

depth.

Cylinder Block Counterbore Depth From Cylinder


mm
in
122.930

MIN

4.8397

123.000

MAX

4.8425

Cylinder Block Height From Cylinder Block Head Deck


mm
in
309.4

MIN

12.181

309.6

MAX

12.189

Cylinder Block Height From Cylinder Block Head Deck


mm

in

361.90

MIN

14.248

362.10

MAX

14.256

ck9bdr

Inspect the main bearing bores for wear or damage.


Install new main bearing and measure the bore diameter with
main bolts tightened.
Torque

Value:

176 Nom [129 ft-lb]


Main Bearing Bore Diameter
mm

With New Bearings


Without Bearings

98.079

MIN

3.8614

98.125

MAX

3.8632

104.982

MIN

4.1331

105.018
NOTE:The
maximum
[0.0005 inch].

in

bore

MAX
misalignment

is

4.1346
0.0127 mm

0a3
0%

Cylinder Block - Group 01

Expansion Plug - Installation (l-07)


Page 1-18

Inspect the camshaft bores for scoring or excessive wear.


Measure the camshaft bores. Use a bore gauge The bores
must be measured
in two positions.
Take a second
measurement 90 degrees from the first measurement.

Camshaft Bore Diameter (Maximum)


in

mm
64.01

(Without Bushing)

2.520

60.12

(With Bushing)

2.367

Inspect the tappet bores for scoring or excessive wear.

Tappet Bore Diameter


in

mm
16.000

MIN

0.630

16.055

MAX

0.632

Expansion Plug - Installation (I-07)

Caution: Do not install any expansion plugs or pipe plugs


in the block until the inspection and any necessary repair
procedures are completed. This will prevent dirt from being
trapped in the oil passages.
Caution: Excessive sealant can run back into the engine
and cause damage to other components. Allow the sealant
to dry for a minimum of 2 hours before operating the
engine. The plug can come out of the bore if the sealant is
not dry.

@ii

Apply a 2 mm [ l/16 inch] bead of expansion plug Lo&N Seal,


Part No. 3375068, or equivalent to the outside diameter of the
ro;znsion
plug and the inside diameter of the expansion plug
NOTE: Use an expansion plug driver to install the expansion
plug to the correct depth in the bore.
Use the following

expansion

plug drivers:
Exp. Plug Dimension

Tool P/N

Exp. Plug P/N

3822372

1240 151 Hl

0.375 inch

3823521

1240 200 Hl

0.8125 inch

3376816

6736-21-l 820

1.00 inch

3823522

1240 889 Hl

1.1875 inch

3823523

1240 979 Hl

1.375 inch

3823524

1240 154 Hl

2.250 inch

Expansion Plug - Installation (l-07)


Page 1-19

Cylinder Block - Group 01

Caution: Do not install the plug too deeply. The cross


drillings in the cylinder block may be blocked. If the plug
is not installed straight and flat, it must be replaced with
a new expansion plug.

0.5 to 1.0 mm

The expansion plug must be installed with the edge of the


plug 0.5 to 1 .O mm [0.020 to 0.040 inch] deeper than the
entrance chamber of the bore.

Pipe Plug - Installation


Apply a bead of pipe plug
equivalent to the threads.

sealant,

Part No. 3375066,

Install and tighten the pipe plugs. Refer to the following


for torque values:

or

chart

Tighten

pipe plugs to the appropriate

NOTE: The accompanying

torque values.

chart is also provided

Pipe Plug Torque Values

in Group 18

Size

Specifications.

ACblill

Thread

Pipe plug and expansion


block.

plug locations

1.

1 inch pipe plug

2.

13/16 inch expansion

plug

3.

l-3/8

inch expansion

plug

4.

l-l /8 inch expansion

plug

5.

l/2

ck8ppha

Thread

O.D.

Torque

Torque

In Aluminum

In cast IrOn or

Components

Steel Compnnentf

Nom

N-m

[ft-lbs]

8.1

Iin1
[0.32]

145 in-lb]

15

LlOl

118

10.4

[0.41]

15

PO]

20

[151

l/4

13.7

[0.54]

20

P51

25

I201

316

LO661
[O.SS]

25

1201

35

1251

112

173
21.6

35

1251

55

I401

3/4

26.7

[1.05]

45

[351

75

[551

33.5

]I .32)

60

1451

95

I701

t /4

42.2

[1.66]

75

I551

115

1/2

48.3

[1.90]

85

1651

135

in.

mm

l/16

[ft-IbS]

P51
PO01
ck6ppoa

in front of cylinder

inch pipe plug

1,

ck9PPg

Camshaft Bore Expansion Plug Installation

Cylinder

(l-08)

Block - Group 01

Page l-20

@7
@

ck9ppgt

@
w

Pipe plug and expansion plug locations,

right side of block.

1.

2.287 inch expansion

plug

2.

l-3/8

plug

3.

i/2

4.

13/16 inch expansion

5.

3/4 inch pipe plug

6.

l/4

7.

3/8 inch expansion

plug or dipstick tube

8.

7/8 inch expansion

plug or turbocharger

inch expansion
inch pipe plug

plug

inch draincock

Pipe plug and expansion

plug locations,

1.

l-3/1 6 inch expansion

2.

13/16 inch expansion

3.

Camshaft bore expansion

drain tube

rear of block.

plug or aftercooler

connections

plug
plug

ck9PPg

@&
@

Pipe plug and expansion


1.

l-3/8

inch expansion

2.

3/4 inch pipe plug

3.

l/8

4.

3/8 inch expansion

plug locations,

left side of block.

plug on side oil fill

inch pipe plug


plug or dipstick tube

ck9PPg

Camshaft Bore Expansion Plug Installation (I-08)


Apply a bead of Loctite
277 around the outside diameter of
the camshaft expansion plug.

Cylinder Block - Group 01

Camshaft Bushing - Removal (l-09)


Page 1-21

Position the plug with the convex side out.

@$?

Expand the plug with a large brass drift and a hammer

Expand the plug until the convex side is even with the
cylinder block.

043

Camshaft Bushing - Removal (I-09)


Camshaft Bushing Removal and Installation Tool, Part No.
3823509
Drive the bushings

from the cylinder

block bore.
0
C%

Earnshaft

Bushing

Cylinder Block - Group 01

Bore - Cleaning (l-10)

Page 1-22

Camshaft Bushing Bore - Cleaning (I-IO)


Use fine emery cloth and solvent
sharp edges from the bores.

to remove any burrs and

Camshaft Bushing - Installation (I-II)


Mark the camshaft bushings
holes.

and cylinder

block to align the oil

NOTE: The oil holes in the camshaft bushings should be


pointing at approximately the 7:00 oclock position when viewed
from the front of the engine.

Universal Bushing Installation Tool


NOTE: The front camshaft bushing should be installed to a
depth of 4.5 mm [0.177 inch] below the front face of the
cylinder block. All other bushings are to be installed even with
the web of the camshaft bore.

Be sure the oil holes are aligned.


A 3.2 mm [0.128 inch] diameter rod must be able to pass
freely through the camshaft bushing oil hole.

Cylinder Block - Group 01

Cylinder Liners - Cleaning and Inspection for Reuse (1-12)


Page 1-23

Measure the installed diameter of the camshaft bushings.

Camshaft Bushing Bore Diameter (Installed)


mm
in
60.058
60.112

MIN

2.3845

MAX

2.367

Cylinder Liners - Cleaning and Inspection


for Reuse (l-12)
Cylinder Liners - Cleaning
Caution: To prevent cylinder liner damage, do not use a
hone or any abrasives in the ring travel area of the liner.
Abrasives can damage the surface finish and the cross
hatch pattern, and can contaminate the cylinder liner.

Use a soft wire brush to clean the flange seating area.


Use a fine fibrous abrasive pad such as; Scotch Brite@ 7448,
Part No. 3823258,
scale and rust.

or equivalent

to

remove

the

remaining

bp?cyed

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Use a non-metallic bristle brush, detergent


water to clean the inside diameter,

Use a steam cleaner or a solvent


Dry with compressed air.
Use clean 15W-40 oil to lubricate
liners.

soap, and warm

tank to clean the liners.


the inside diameter

of the

Allow the oil to soak in the liner for five to ten minutes.

Use lint-free
the liners.

paper towels to wipe the oil from the inside of

Continue to lubricate the inside of the liners and wipe clean


until the paper towel shows no gray or black residue.

q
B

Liners - Cleaning and Inspection for Reuse (1-12)


Page 1-24

Cylinder

Cylinder Block - Group 01

Cylinder Liners - Inspection

0a9

OK

aB
0

Visually inspect the liners for cracks on the inside and outside
diameters.

Inspect for cracks under the flange.

ck2sISa

423
0

Visually inspect the outside


excessive corrosion or pitting.

diameter

and

seat

area

for

NOTE: Pits must not be more than 1.6 mm [0.06 inch] deep.
Replace the cylinder liner if the pits are too deep or if the
corrosion cannot be removed with fine emery cloth.

0
OK

a3
0

Inspect the inside diameters for vertical scratches deep enough


to be felt with a fingernail.
NOTE: If a fingernail
must be replaced.

catches in the scratch, the cylinder

Visually inspect the inside diameter for scuffing

or scoring.

liner

Cylinder Block - Group 01

Cylinder Liners - Cleaning and Inspection for Reuse (1-12)


Page l-25

Visually inspect the inside diameter for liner bore polishing.


A moderate polish (A) produces a bright mirror finish in the
worn area with traces of the original hone marks or an
indication of an etch pattern.

0ai3

A heavy polish (B) produces a bright mirror finish in the


worn area with no traces of hone marks or an etch pattern.

Replace the liner if:


l

A heavy polish is present over 20 percent of the piston


ring travel area.

30 percent of the piston ring travel area has both


moderate and heavy polish and one half (15 percent)
is heavy polish.

0@3

L15%

ck8slsd

Part No. 3375072, Dial Bore Gauge


Use a dial bore gauge to measure the liner inside diameter in
four places 90 degrees apart at the top and bottom of the
piston travel area.
Cylinder Liner I.D.
in

mm
114.000

MIN

4.4882

114.117

MAX

4.4928
ck8slna

Measure the outside diameter of the liner top press fit area.

Cylinder Liner O.D. (Top Press Fit)


mm

in

130.938

MIN

5.1550

130.958

MAX

5.1558

ck2slna

Pistons - Cleaning and Inspection for Reuse (1-13)


Page 1-26

Cylinder Block - Group 01

Pistons - Cleaning and Inspection for


Reuse (l-l 3)
Piston Rings - Removal
Part No. 3823137, Piston Ring Expander
Remove the piston rings.
Place a tag on the rings and record the cylinder number of the
piston on the tag.

p1900fb

Pistons - Cleaning
Caution: Be sure the cleaning solvent is approved for
aluminum. Damage to the pistons can result.
Allow the pistons to soak for a minimum of 30 minutes in a
tank containing an approved cleaning solvent for aluminum.
NOTE: For the best results, let the pistons
hours or overnight.

soak for several

Use a hot, soapy solution and a non-metallic


carbon deposits.

brush to remove

Caution: Do not use a metal brush. A metal brush will


damage the piston ring grooves. Do not use glass beads to
clean the grooves.

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam to clean the pistons.
Dry with compressed

air.

Pistons - Cleaning and Inspection for Reuse (1-13)


Page l-27

Cylinder Block - Group 01

Pistons - Inspection
Inspect the piston for damage and excessive wear. Check
the piston ring grooves, skirt and pin bore.

06B

NOTE: Dimensional inspection of the piston is required only


when the cause of the lack of sealing is not apparent.

Check the piston for rolled edges on the ring lands that
indicate ring beat-in. This can cause loss of sealing.

Visually inspect the piston bowl (l), pin bore (2) and skirt (3)
for cracks or damage.
NOTE: Do not use pistons with cracks.

Measure the piston pin bore when the piston temperature

is

at 20 C [68 F].

Piston Pin Bore I.D.


in

mm
45.006

MIN

1.7719

45.025

MAX

1.7726

NOTE: Add 0.013 mm [0.0005 inch] to the bore inside diameter per 5C [lOF] temperature rise up to 32C [gOoF].

0@3

Cylinder Block - Group 01

Pistons - Cleaning and Inspection for Reuse (1-13)


Page l-27-02

Visually

inspect

the

piston

pin for scratches, grooves, or

other damage.
Measure the piston pin outside diameter.
Piston Pin O.D.
in

mm
44.993

MIN

1.7714

45.003

MAX

1.7718

NOTE: Discard the piston


[O.OOl inch] out of round

pin if it is more than 0.03 mm

0423

Crankshaft - Cleaning and Inspection for Reuse (l-14)


Page 1-28

Cylinder Block - Group 01

Measure the piston skirt diameter as illustrated.

Piston Skirt O.D.


mm

in

113.814

MIN

4.4810

113.886

MAX

4.4840

pi9bdta

Use a micrometer and Part No. 3823966, piston ring groove


gauge, to measure the wear of the top ring groove keystone
angle. Use Part No. 3823965, piston ring groove gauge, to
measure the wear of the intermediate ring groove keystone
angle.

Piston Ring Groove (Keystone Angle)


Ring

mm

in

Top:

113.938

MIN

4.4857

Intermediate:

114.323

MIN

4.5009

Use a new piston ring and feeler gauge to measure the side
clearance of the rectangular intermediate and oil control ring
grooves.

Ezl
@

Piston Ring Clearance (Rectangular Groove)


Ring
mm
in

Intermediate:

Oil Control:

0.070

MIN

0.0028

0.150

MAX

0.0090

0.020

MIN

0.0008

0.130

MAX

0.0051

pi9oota

Crankshaft - Cleaning and Inspection for


Reuse (1-I 4)
Crankshaft - Cleaning
Use fine crocus cloth to polish the machined
Use a bristle brush to clean the oil drillings.

surfaces.

Crankshaft - Cleaning and Inspection for Reuse (1-14)


Page 1-29

Cylinder Block - Group 01

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Steam clean the crankshaft

and dry with compressed

Make sure to blow out the threaded


the crankshaft and the oil drillings.

air.

Use one of the following


holes:

capscrew
methods

holes for damage.


to repair any threaded

Chase the threads

Use the Part No. 3822709, Threaded

0a3

Insert Kit

NOTE: If more than two threaded holes are damaged


end, the crankshaft must be replaced.

Measure the front and rear oil seal contact


groove.

q
B

holes on each end of

Crankshaft - Inspection
Visually inspect the threaded

in one

areas for a wear

Crankshaft Front and Rear Oil Seal Wear Groove


in
mm
0.25

MAX

Front and rear wear sleeves


that is worn beyond the limit.

0.010

are available

Inspect the crankshaft connecting


deep scoring, overheating, etc.

for a crankshaft

rod and main journals

for

0623

Cylinder Block - Grow 01

Crankshaft - Cleaning and Inspection for Reuse (l-14)


Page l-30
Use a micrometer

to measure the connecting

rod journal.

Connecting Rod Bearing Journal Diameter (Min.)


in
mm
75.962

Standard

2.9906

75.712

Machined 0.25 mm

2.9808

75.462

Machined 0.50 mm

2.9709

75.212

Machined 0.75 mm

2.9611

74.962

Machined

2.9513

1.00 mm

Bearing Clearance = Connecting


rod inside diameter
bearing installed minus crankshaft journal diameter.
Maximum

0.1 17 mm [0.0046 inch]

Connecting Rod Bearing Journal


mm

Kll

-li-

Bearing Clearance:

with

in

Out-of-Roundness:

0.050

MAX

0.0020

Taper:

0.013

MAX

0.0005

ks900nt

Main Bearing Journal Diameter (Minimum)


in
mm
3.8568

97.962

Standard

97.712

Machined

0.25 mm

3.8469

97.462

Machined

0.50 mm

3.8371

Bearing Clearance = Main bore diameter with bearing installed


minus (-) crankshaft main journal diameter.
Maximum

Bearing Clearance:

0.134 mm [0.0053 inch]

Crankshaft Main Bearing Journal


mm

in

Out-of-Roundness:

0.050

MAX

0.0020

Taper:

0.013

MAX

0.0005

Crankshaft - Cleaning and Inspection for Reuse (1-14)


Page 1-31

Cylinder Block - Group 01

The following oversize service main and thrust bearings are


available for crankshafts that have been machined undersize:

Main Bearing Diameter


0.25 mm
0.000

Oversize
Journal

0.000

Diameter

0.25 mm

0.50 mm

0.75 mm

1.00 mm

0.50 mm
X

Measure the thrust face width.

Crankshaft Thrust Face Width (Standard)


in
mm
42.975

MIN

1.6919

43.076

MAX

1.6959

ks200nd

Measure the rear oil seal flange outside diameter.

Crankshaft Rear Oil Seal Flange O.D.


in

mm
129.975

MIN

5.1171

130.025

MAX

5.1191

ks200n

Measure the damper pilot outside diameter.

Crankshaft Damper Pilot O.D.


in

mm
23.924

MIN

0.9419

24.000

MAX

0.9449

ks200nl

Cylinder Block - Group 01

Crankshaft Gear - Replacement (1-15)


Page l-32

L4
cl

Use a light preservative


prevent rust.

oil to

lubricate

the

crankshaft

to

If the crankshaft is not going to be used immediately, protect


the part with a plastic cover to prevent dirt from sticking to the
oil.

ks200wb

Crankshaft

Gear - Replacement

(l-l 5)

General Information
There are two different crankshaft

gears used:

Steel gear for engines with a Bosch PESGP fuel injection


pump.

Austempered gear for engines without a Bosch PESGP fuel


injection pump.

ks9gega

Crankshaft Gear - Removal


Use a heavy duty bearing separator or gear puller as illustrated

to remove the gear.


NOTE: The bearing separator or gear puller must be used to
remove the steel gear; however, a gear splitter can be used to
remove the austempered gear if it is not intended to be used
again.
Refer to the following

RI
A

procedure:

Part No. 3823585, Crankshaft Gear Splitter


Caution: Safety glasses are required when using this tool.
Caution: Use care to avoid damage to the polished surfaces
of the crankshaft by driving the point of the tool into the
crankshaft.
NOTE: This tool will not work on a steel gear.
Steel gear Part No. 3918776.
Iron gear Part No. 3918380.

bp900gk

Cylinder Block - Group 01

Crankshaft Gear - Replacement (1-15)


Page 1-33

Place the point of the chisel between two gear teeth.


Strike the splitter with a two or three pound steel

hammer.

Repeat this step if necessary.


Use a dowel
dowel pin.

pin

extractor

to remove

Crankshaft

Gear - Inspection

the

gear alignment

0a!!3

Visually inspect for cracks and broken or chipped teeth.


The gear must be replaced if it is damaged.

0@9

Visually inspect the gear and keyway for nicks or burrs.


Use fine crocus cloth to remove nicks and burrs.

a
B

ks8gesb

Visually inspect the crankshaft gear journal and


alignment dowel pin hole for burrs or damage.
Use fine crocus cloth to remove burrs.

the

gear

0@

Cylinder Block - Group 01

Crankshaft Gear - Replacement (l-15)


Page 1-34
Measure the crankshaft

gear journal inside diameter.

Crankshaft Gear Journal I.D.


mm

in

75.898

MIN

2.9661

75.923

MAX

2.9691

Measure the crankshaft

gear journal outside diameter.

Crankshaft Gear Journal O.D.


mm

in

75.967

MIN

2.991

76.006

MAX

2.992

ksl getb

Crankshaft Gear - Installation


Use a soft hammer to install the gear alignment
the crankshaft.

dowel pin into

The pin must be 1.02 mm [0.040 inch] above the crankshaft


surface.

Caution: Do not exceed the specified heating time or


temperature. The crankshaft gear and teeth can be
damaged.
Heat the gear in an oven for a minimum of 45 minutes but not
more than six hours.
Austempered

Gear - Temperature:

Steel Gear - Temperature:

ks9oewl

149C [3OOF]

177 C [350 F]

Main Bearings - Cleaning and Inspection for Reuse (1-16)


Page 1-35

Cylinder Block - Group 01

Use Lubriplatee
No. 105, or equivalent
to
outside diameter of the crankshaft gear journal.

lubricate

the

Caution: Use insulated gloves, Part No. 3823730, when


handling heated parts. Personal injury will result.
Caution: The timing mark (1) and part number (2) on the
gear must be facing away from the crankshaft after the
gear is installed. Engine damage can result if the gear is
installed backwards.

Remove the gear from the oven.


Align the keyway of the gear with the alignment dowel pin in
the crankshaft and install the gear within 30 seconds.

@A
@

Caution: Do not use water or oil to reduce the cooling


time. The gear can crack. Allow air to cool the gear.

NOTE: If the gear cools and stops on the crankshaft before


it is fully installed, use a driver to complete the installation.

I I

ks9geh

Main Bearings - Cleaning and Inspection


for Reuse (1-I 6)
General Information
The engine has seven main bearings. The lower bearing
shells are all the same. The upper bearings have two oil
holes, the lower bearings do not have holes. All of the upper
bearing shells are the same except for the No. 4 journal. The
No. 4 journal uses a flanged upper bearing shell. The flanges
on the bearing control the end thrust of the crankshaft.
k:s

Cylinder Block - Group 01

Main Bearings - Cleaning and Inspection for Reuse (1-16)


Page l-36

Main Bearings

Cleaning

Make sure the bearings are marked for location.The

bearings

must be installed in their original location if used again.


Caution:
Do not use a scraper or a wire brush. The
bearings can be damaged.
Use solvent and a soft bristle brush.
Dry with compressed

air.

Main Bearings - Inspection


Visually inspect for nicks, scratches

or damage.

Replace any bearings with the following


l
l
l
l
l

mb200sa

damage:

Pitting
Flaking
Corrosion
Lock tang damage
Scratches (deep enough to be felt with a fingernail)

NOTE: For more detailed information of bearing damage, refer


to Analysis and Prevention of Bearing Failures, Bulletin No.
3810387.

Use an outside diameter ball tipped micrometer to measure the


main bearing shell thickness at the wear location.

Standard Main Bearing Shell Thickness (Used)


mm

in

3.340

MIN

0.131

3.454

MAX

0.136

Discard any main bearing


minimum specification.

shell if its thickness

is below the

Bearing shells are identified by steel stamped characters on the


back of the bearings to indicate either standard (STD) or the
amount of oversize (OS).

mb9begt

Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse (1-17)

Cylinder Block - Group 01

Page l-37
The following oversize service main and thrust bearings are
available for crankshafts that have been machined undersize:

Main Bearing Diameter


0.25 mm

Oversize

0.000

Journal

0.000

Diameter

0.25 mm

0.50 mm

0.75 mm

1.00 mm

0.50 mm
X

\!d-

ks900ad

Thrust Bearings - Inspection


Visually inspect the thrust bearings for wear, cracks or
damage on the front and rear face and also the crankshaft
journal contact area.

0
@

mb9bes

Measure the thrust bearing flange thickness.


the front and rear face contact areas.

Measure

both

Thrust Bearing Flange Thickness


mm

in

3.517

MIN

0.138

3.567

MAX

0.140

NOTE: Thrust bearings are available in 0.25 mm [O.OlO-inch]


and 0.50 mm [0.020-inch] oversize thicknesses. Refer to the
chart above.

e
mb900s

Main Bearing Caps and Capscrews Cleaning and Inspection for Reuse (1-17)
Cleaning
Use solvent and a soft bristle brush to clean the main
bearing cap, capscrews and bearings. Dry with compressed
air.

q
B

mb9caea

Connecting Rod Bearings - Cleaning and Inspection for Reuse (1-18)


Page 1-38

0629

mb9ben,

Cylinder Block - Group 01

Inspection
Visually inspect the main cap and capscrews

for damage.

Connecting Rod Bearings - Cleaning and


Inspection for Reuse (l-l 8)
NOTE: For future identification, the bearings must be marked
for location as they are removed. Each bearing must be
installed in its original location if the bearing is used again.

Connecting Rod Bearings - Cleaning


A

cx9beea

\
q

Caution: Do not use a scraper or a wire brush. The


bearings can be damaged.
Use solvent and a soft bristle brush. Dry with compressed

Connecting Rod Bearings

air.

Inspection

Visually inspect the bearings for damage.


Replace any bearings with the following
l
l
l
l
l

damage:

Pitting
Flaking
Corrosion
Lock tang damage
Scratches (deep enough to be felt with a fingernail)

Refer to the Parts Reuse Guidelines,


further information.

Bulletin No. 3810303, for

NOTE: Normal bearing wear produces a smooth finish which


will wear into the lining. An exposed lining does not always
indicate worn bearings. If large areas of the lining are visible in
the bearings before the engine has accumulated
240,000
kilometers [150,000 miles] or 3,750 hours, inspect the engine
for contamination
from fine dirt particles and correct the
problem.

Cylinder Block - Group 01

Visually
burrs.

inspect

the

Connecting Rods - Cleaning and inspection for Reuse (1-19)


Page 1-39

bearing

seating

surface

for

nicks

or
@I

If burrs can not be removed


bearings must be replaced.

with

a fine crocus

cloth,

the

For more detailed information of bearing damage, refer to


Analysis and Prevention of Bearing Failures, Bulletin No.
3810387.

Measure the connecting


rod bearing shell thickness
outside micrometer that has a ball tip.

with an

Standard Connecting Rod Bearing Thickness


mm

in

2.43

MIN

0.0956

2.471

MAX

0.0973

Discard a bearing shell if its thickness


specification.

is below the minimum

mfflbetb

NOTE: Oversize bearing shells are available for crankshafts


which are 0.25 [O.OlO-inch], 0.50 mm [0.020-inch], 0.75 mm
[0.030-inch], or 1.OO mm [0.040-inch] undersize.
Bearing shells are identified by steel stamped characters on
the back of the bearings to indicate either standard (STD) or
the amount of oversize (OS).
Refer to the appropriate

Parts Catalog.

0.25
0.50
0.75
1.00

Connecting Rods - Cleaning and


Inspection for Reuse (1-19)
Connecting Rods - Cleaning
NOTE: The letter or number on the connecting rod cap must
be the same as the letter or number on the connecting rod.
Do not assemble a new cap to a used connecting
used cap to a new connecting rod.
Remove the connecting
the connecting rods.

rod capscrew

rod or a

nuts and caps from

mm
mm
mm
mm

(.OlO
(.020
(-030
(.040

in.)
in.)
in.)
in.)

Connecting Rods - Cleaning and Inspection for Reuse (l-19)


Page l-40

B
q

Cylinder Block - Group 01

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use solvent or steam to clean the rods.
Use a soft bristle brush to clean the oil drilling.
Dry with compressed

air.

Connecting Rods - Inspection

a9
0

Visually inspect the connecting


on the mating surfaces.

The rod and cap must be replaced as an assembly


fretting damage is visible on either piece.
Replace the
damaged.

4B
0

connecting

rod

if the

l-beam

is nicked

or

for

rod piston pin bushing inside diameter.

Connecting Rod Pin Bore Diameter (Bushing


Installed)
mm

in

45.023

MIN

1.7726

45.060

MAX

1.7740

NOTE: Service replacement rod bushings are available.


to the appropriate parts catalog for part numbers.
cx9brta

if any

Visually inspect the connecting


rod pin bore bushing
damage or misalignment of the oil passage and bushing.

Measure the connecting

rod and cap for fretting damage

Refer

The bushing must be precision machined after installation. If


machining capability is available, the bushing can be replaced.
Refer to Connecting
Rod Bushing
- Replacement
in
Procedure l-21 _

Connecting Rods - Cleaning and Inspection for Reuse (1-19)


Page 1-41

Cylinder Block - Group 01

Tap the connecting rod bolts in until the head is aligned and
seated on the flat machined surface of the connecting rod.

0at3

cx9bosa

Install the bearing shells into the connecting


rod and cap.
Use clean 15W-40 oil to lubricate the capscrew threads.
Install the connecting rod caps and connecting rod nuts.

NOTE: The connecting


rod cap number must match
number on the connecting
rod and be installed with
numbers aligned.
Tighten the connecting
Torque

Value:

rod nuts in alternating

the
the

k
cl

sequence.

Step 1 - 40 N l m [30 ft-lb]


Step 2 - 80 Nom [60 ft-lb]
Step 3 - 120 Nom [88 ft-lb]

Measure the connecting rod crankshaft


with the bearing installed.

bore inside diameter

Connecting Rod Crankshaft Bore I.D. (With Bearing)


in

mm
76.046

MIN

2.9939

76.104

MAX

2.9962

Connecting Rod Crankshaft Bore I.D. (Without Bearing)


in

mm
80.987

MIN

3.1885

81.013

MAX

3.1895

Caution: The connecting rod must be assembled with the


capscrew nuts tightened to specifications before stamping
the cylinder identification number on the connecting rod.
If a new connecting rod is installed, always stamp the new
connecting
rod with the cylinder number of the rod being
replaced.

Connecting Rods - Bend and Twist Inspection (l-20)


Page l-42

Cylinder Block - Group 01

Connecting Rods - Bend and Twist


Inspection (I-20)
Fixture Calibration
Use a connecting rod checking fixture, Part No. ST-561, and a
connecting rod mandrel set, Part No. 3823286, to inspect the
bend and twist of the rods.
Calibrate the checking fixture with a new rod that has been
measured for correct center to center length, 215.975 mm to
216.025 mm [8.5029 inches to 8.5049 inches].
NOTE: Assemble the
described in Procedure

connecting
1-19.

rod

cap

to the

Install the piston pin mandrel from the connecting


set, Part No. 3823286, into the piston pin bore.

rod as

rod mandrel

NOTE: Use a mandrel, Part No. 3823283, if the piston pin


bushing has been removed or mandrel, Part No. 3823284, if the
bushing is still in place.
Install the mandrel, Part No. 3823303, into the crankshaft
and expand the mandrel.

bore

NOTE: Make sure the pin on the mandrel is pointed down and
locked in position in the center of the connecting rod.

Install the connecting

rod into the fixture.

Move the dial holder to position the contact points


indicators on the mandrel in the piston pin bore.
Tighten the bracket to hold the indicators
Set the dial indicators

Remove the connecting

of the

in position.

to read zero.

rod from the fixture.

Turn the rod 180 degrees horizontally,


the fixture again.

and install the rod into

Cylinder Block - Group 01

Connecting Rods - Bend and Twist Inspection (l-20)


Page 1-43

Check the dial indicators for the zero position again.


If the dial indicators show any change
dials to half the indicated reading.

from zero, adjust the

0a9

The fixture is now calibrated to allow the connecting rod to


be installed into the fixture in either direction, and the dials
will indicate an equal deflection on either side of zero.

Connecting Rod Alignment - Inspection


Install the mandrel
inspected.

and arbor into the connecting

Install the connecting

rod to be

rod into the fixture.

Measure the connecting

rod length and bend (alignment).

Connecting Rod Length


mm

in

215.975

MIN

8.5029

216.025

MAX

8.5049

Connecting Rod Bend (Alignment)


mm

in

Bushing Removed

0.20

MAX

0.008

Bushing Installed

0.15

MAX

0.006

Connecting Rod Twist - Inspection


Install a feeler gauge between
indicator holding plate as shown.

the

mandrel

and

the

dial

Connecting Rod Twist


mm

in

Bushing Removed

0.50

MAX

0.020

Bushing Installed

0.30

MAX

0.012

cx8OOnd

Connecting Rod Bushing - Replacement (1-21)


Page 1-44

Cylinder Block - Group 01

Connecting Rod Bushing - Replacement


(1-21)

Part No. 3823690, Connecting Rod Pin Bore Bushing


Removal/installation Tool

This tool is used to remove and install the bushings


correct position.

to the

Ref.
No.

Part No.

Description

QW

3823691

Anvil

3823693

Cup

3823692

Mandrel

3823694

Driver Ring (thick)

3823695

Knock-out-ring

(thin)

Hair Pin Cotter

1
1

Removal
Place the pin bore end of the connecting

a3

cx9tohc

rod on the mandrel.

Place the knock-out (thin ring) on the mandrel on top of the


connecting rod. Match up the angle surfaces.

Cylinder Block - Group 01

Connecting Rod Bushing - Replacement (l-21)


Page l-45

Install the cup on the mandrel


cotter.

and secure with the hair pin

cx9toh

Install the mandrel in the anvil. Place the connecting rod so


the angle on the rod matches with angle on the anvil. The
connecting rod will be in the horizontal position.

cx9toh:

Press the connecting rod bushing out by applying force on


top of the cup. Press the bushing through the bore.

cx9bshc

Remove the hair pin cotter.


Remove the
mandrel.

cup

and

slide

the

connecting

rod

from

the

0
C%

Cylinder Block - Group 01

Connecting Rod Bushing - Replacement (1-21)


Page l-46
Measure the connecting
removed.

rod bushing

bore with the bushing

NOTE: If the connecting


rod bushing bore is not
specifications, replace the connecting rod.
Connecting

within

Rod Pin Bore Diameter (Bushing

Removed)
mm

in

46.966

MIN

1.9286

49.012

MAX

1.9296

Installation
Before installing the connecting
rod bushing, submerge the
bushing and connecting rod pin end in clean 15W-40 engine
oil.

cx9oowc

Place the connecting

Place the knock-out

rod bushing

on the mandrel.

(thin ring) inside the driver ring.

Match the angles, place the angle side down and align the
notch of the knock-out (thin ring) to the pin in the driver ring
and slide on the mandrel.

Cylinder Block - Group 01

Connecting Rod Bushing - Replacement (1-21)


Page 1-47

Install the cap and secure with the hair pin cotter.

Insert the mandrel and components


of the connecting rod.
Align the angles
rings.

of the bushing,

into the chamfered


connecting

side

rod, and stop

NOTE: All connecting


chamfer
bushing,
area.

rods do not have a double chamfer. A


may be added to aid in the installation
of the
but should not result in an unsupported
bushing

Align the oil hole


groove
in the
components
into
contact is made.
the oil holes.

in the bushing and connecting rod (use the


mandrel)
and push the mandrel
and
the pin bore of the connecting
rod until
This contact helps maintain the alignment of

0eiE3
Bushing
Groove

Rod
cx9oogl

Place the connecting rod and mandrel assembly on the anvil


(position so that the angle on the connecting rod matches
the angle on the anvil). The connecting
rod is in the
horizontal position.

I-

cx9oowl

Connecting Rod Bushing - Replacement (1-21)


Page I-48

Cylinder Block - Group 01

Press the bushing into the connecting rod by applying force on


the top of the cup. Use either an arbor or hydraulic press.
Push through in a continuous motion until the driver ring makes
contact with the connecting rod.

cx9bshc

Check the alignment of oil holes. A 3 mm [l/8 in] diameter rod


must move freely through the connecting rod and the bushing
oil holes (A).
Check for clearance between the connecting
the connecting rod.

rod bushing and

Use a 0.025 mm [O.OOl inch] feeler gauge to make sure the


bushing is properly seated. The 0.025 mm [O.OOl inch] feeler
gauge must not enter between the bushing and the connecting
rod (B).

cx9bsnt

Machining
The inside diameter of new connecting rod bushings must be
machined with a rod boring machine such as Part No. 3823801
(Sunnen PM-300@) or Part No. 3375144 (Tobin Arp@).
When properly adjusted, a Sunnen PM-30Oe, or equivalent,
connecting rod boring machine is capable of maintaining all the
critical dimensions.
NOTE: Do not use a floating

rod type honing

machine.

Inspection
NOTE: After machining the connecting rod bushings, it will be
necessary to check all critical dimensions. Refer to Procedure
l-l 9 in this section for specifications and instructions.

Camshaft - Cleaning and Inspection for Reuse (l-22)

Cylinder Block - Group 01

Page 1-49

Camshaft - Cleaning and Inspection for


Reuse (I-22)
Camshaft - Cleaning
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Use solvent or
compressed air.

steam

clean

the

camshaft.

Dry

with

Caution: After the camshaft has been steam cleaned, do


not touch the machined surfaces with bare hands, this
will cause rust to form. Lubricate the camshaft with clean
15W-40 engine oil before handling.

Camshaft

Inspection

Visually inspect the fuel transfer pump lobe, valve lobes and
bearing journals for wear, cracking, pitting, scratches or other
damage.

0
@

NOTE: Komatsu America International Company does not


recommend repairing camshafts by grinding the valve lobes.
If the camshaft is damaged beyond the reuse guidelines,
camshaft must be replaced.
Tne following criteria defines
wear and edge deterioration
lobes.

the

the size of the pits, allowable


of the chilled iron camshaft

Pitting:
A single pit must not be greater than the area of a 2 mm
[0.079 inch] diameter circle.

0a!3

cg9shs.z

Camshaft - Cleaning and Inspection for Reuse (l-22)


Page l-50

Cylinder Block - Group 01

Interconnection
pit.

The total pits, when added together, must not exceed a circle
of 6 mm [0.236 inch].

Only one pit is allowed within


the camshaft lobe.

49

of pits is not allowable

and is treated as one

cg900sd

aI9

+ or - 20 degrees of the nose of

Measure across the peak of the camshaft

b
0
t

lobes.

Camshaft Lobe Wear Limits (Minimum)


mm

cg9oosg

in

51.774

Intake Valve

2.038

51.596

Exhaust Valve

2.031

41.31

Fuel Transfer Pump

1.626

Camshaft - Cleaning and Inspection

Cvlinder Block - Group 01

Measure across the camshaft journal.

Camshaft Journal Diameter


in

mm
59.962

MIN

2.3607

60.013

MAX

2.3627

NOTE: Replace the camshaft if the outside diameter of any


bearing surface is less than 59.962 mm [2.3607 inch].

Edge Deterioration

(Breakdown)

The area of edge deterioration must not be greater than the


equivalent area of a 2 mm [0.079 inch] circle within + or 20 degrees of the nose of the camshaft lobe.

Outside of the + or - 20 degrees of the nose of th


camshaft lobe, the areas of edge deterioration must not b
z;re$teer than the equivalent area of a 6 mm [0.236

04B

for Reuse (l-22)


Page l-51

Camshaft - Cleaning and Inspection for Reuse (l-22)


Page 1-52

QB

The folk

Cylinder Block - Group 01

This illustration shows normal grain pattern and a casting flaw within the nose
area. Both of these conditions are acceptable for reuse.

use:

Camshaft Gear - Inspection


Visually inspect the camshaft gear teeth for wear and damage.
Look for cracks at the root of the camshaft gear teeth. If the
gear is damaged, it must be replaced. Refer to Procedure l-23.

Camshaft Gear - Replacement (l-23)


Page 1-53

Cvlinder Block - Group 01

Camshaft Gear - Replacement (l-23)


Camshaft Gear - Removal
Caution: Place a wooden block under the camshaft to
avoid damage as the camshaft drops free from the
camshaft gear.
Place the camshaft and gear assembly

in the hydraulic

press.

A
Q
6s
cg9gefi

Push the camshaft from the gear.


Remove the camshaft dowel pin.

Camshaft Gear - Cleaning


Use solvent to clean the camshaft gear. Dry with compressed
air.

ca3aee

Camshaft Gear - Inspection


Visually inspect
broken teeth.

the camshaft

gear for cracks,

chipped,

or

Inspect the bore of the gear for fretting or burrs.


NOTE: If the fretting, burrs, or raised material cannot be
removed with Scotch-Brite@ 7448, or equivalent, replace the
gear.

0a3

Cylinder Block - Grouo 01

Camshaft Gear - Replacement (l-23)


Page 1-54

Inspect the camshaft gear keyway for burrs.


Remove burrs with Scotch-B&?@ 7448, or equivalent.
NOTE: If the keyway is damaged or the burrs cannot be
removed, the camshaft gear must be replaced.

Measure the camshaft gear bore inside diameter.

Camshaft Gear Bore I.D.


mm

in

41.480

MIN

1.633

41.505

MAX

1.634

Visually inspect the camshaft nose for fretting or burrs.


NOTE:
If fretting
or burrs cannot be removed with
Scotch-BriW
7448, or equivalent, replace the camshaft.

Measure the camshaft gear journal outside diameter.

Camshaft Gear Journal O.D.


mm

in

41.56

MIN

1.636

41.58

MAX

1.637

Cylinder Block - Group 01

Camshaft Gear - Replacement (l-23)


Page 1-55

Measure the camshaft thrust plate thickness.

Camshaft Thrust Plate Thickness


in

mm
9.34

MIN

0.368

9.58

MAX

0.377

Camshaft Gear - Installation


Use a leather hammer to install the camshaft gear dowel pin.

Lubricate the camshaft gear journal with Lubriplatem

105.

Steel Camshaft Gear


Warning: Use insulated gloves, Part No. 3823730, when
handling heated parts. Hot parts will cause serious
personal injury.
Heat the gear in an oven for a minimum
not longer than six hours.

Temperature: 177C [350F]

of 45 minutes,

but

Gear Housing - Cleaning and Inspection for Reuse (i-24)


Page 1-56

Cylinder Block - Grow 01

Austempered Camshaft Gear


Heat the gear in an oven for a minimum of 45 minutes, but not
longer than six hours.
Caution: The gear will be permanently distorted if over
heated. The oven temperature should never exceed the
specification.
Temperature: 149 C [300 F]

Caution: To prevent engine damage, the timing marks and


gear part number must be facing away from the camshaft
when the gear is installed.
Caution: Keep the camshaft in a vertical position with the
gear up until the gear has cooled. Do not use water to
reduce the cooling time. Using water will crack the gear.
NOTE: The gear must be installed within 30 seconds after it is
removed from the oven.
Remove the camshaft gear from the oven. Align the keyway in
the camshaft gear with the dowel pin in the camshaft and
install the gear on the camshaft. Be sure the gear is seated
against the camshaft shoulder.

Gear Housing - Cleaning and Inspection


for Reuse (l-24)
Gear Housing - Cleaning
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam or solvent
compressed air.

0+B

to clean the gear housing.

Dry with

Gear Housing - Inspection


Visually inspect the
sealing surfaces.

gear

housing

for

cracks

or damaged

Cvlinder Block - Group 01

Gear Housing - Cleaning and Inspection for Reuse (l-24)


Page 1-57

Inspect the timing pin housing and pin for damage.


Do not remove the timing pin assembly unless it is damaged
or leaking, or the gear housing is being replaced.

NOTE: The location

of the timing pin assembly on the gear


housing is critical for correct engine adjustments.
If the
original gear housing is being installed, it is unnecessary to
relocate the timing pin. If a new housing is being installed,
refer to Procedure
O-02 for timing
pin installation
and
adjustment.

/ it9OOvc

15 mm
Visually inspect
damage.

the fuel injection

To install or remove fuel injection


locked together on the stud.

pump

mounting

studs for

pump studs, use. two nuts

15 mm
If the fuel injection pump mounting studs are damaged or
being installed in a new housing, coat the threads with
LoctiteTM 242 and use two nuts locked together to remove
and install.

Small Chisel and Hammer


If the gear housing is being replaced, remove the engine
dataplate and install on the new housing. Refer to Procedure
l-25.

WI

fp900hz

Engine Dataplate - Replacement (l-25)


Page 1-58

Cylinder Block - Group 01

Engine Dataplate - Replacement

(I-25)

The engine dataplate shows specific information about the


engine. The engine serial number and engine part number
provide information for ordering parts and service needs.
The dataplate must remain with the engine. If the gear housing
is replaced, remove the dataplate and install it on the new
housing.

6CTAG2

Engine Dataplate - Removal


Small Chisel and Hammer
Remove
housing.

the

rivets

that

secure

the

dataplate

to the

gear

Engine Dataplate - Installation


NOTE: Be careful not to drive the rivets
damage the dataplate.

in too deep and

gh9plW

2.0 mm Drill Bit


If the dataplate is loose or has been damaged, drill new holes
and attach with new rivets. Mark the drill bit at 6.0 mm [0.236
inch] to avoid drilling too deep into the gear housing.

gh9ton

Cylinder Block - Group 01

Gear Cover - Cleaning and Inspection for Reuse (l-26)


Page 1-59

Drill the dataplate, taking care not to destroy any information


printed on the dataplate.

Drive the rivets in until they contact the dataplate.

gh9plh

Gear Cover - Cleaning and Inspection for


Reuse (I-26)
Gear Cover - Cleaning
Use a gasket scraper
gasket material.

or Scotch-Britee

Clean the gasket sealing surfaces


the oil seal and gear cover.

7448 to remove

and the surface

all

between

B
q

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
A
will cause serious personal injury.
Steam clean the gear cover. Dry with compressed

air.

Gear Cover - Inspection


Visually inspect the gear cover for flatness, cracks, dents, or
other damage.
If the gear cover is bent or cracked,

it must be replaced.

a9

(yy

m
-F

;
-9cvs

Cylinder Block - Group 01

Vibration Damper - Cleaning and Checking for Reuse (l-27)


Page l-60

Vibration Damper - Cleaning and


Checking for Reuse (l-27)
General Information
NOTE: There are two different design vibration

dampers used:

Viscous damper (A) for certain engines


above 2500 RPM.

rated at speeds

Rubber element damper (B) for engines rated at speeds


below 2500 RPM. The rubber damper is available either
with or without the crankshaft adapter.

da9puga

Rubber Vibration Damper - Cleaning


Use a mild detergent or solvent to clean the vibration

Ld
B

damper.

da900et

Rubber Element Vibration Damper - Inspection

4iB

Check the index lines (A) on the vibration damper hub (B) and
the inertia member (C). If the lines are more than 1.59 mm
[l/16 inch] out of alignment, replace the vibration damper.
Inspect the vibration damper hub (B) for cracks. Replace the
vibration damper if the hub is cracked.

da900se

a9
0

Inspect the rubber member for deterioration. If pieces of rubber


are missing or if the elastic member is more than 3.18 mm
[l/8
inch] below the metal surface, replace the vibration
damper.
NOTE: Also look for forward movement of the vibration damper
ring on the hub. Replace the vibration damper if any movement
is detected.

da9OOsb

Cylinder Block - Group 01

Vibration Damper - Cleaning and Checking

for Reuse (l-27)


Page 1-61

Viscous Vibration Damper - Cleaning


Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Clean the vibration damper with a solvent
clean. Dry with compressed air.

cleaner or steam

Viscous Vibration Damper - Inspection


Check the mounting web for cracks. Check the housing for
dents or raised surfaces. Replace the vibration damper if any
of these defects are identified.

0423

da90Osd

The viscous vibration damper is filled with a silicone fluid.


After many hours of use, the silicone fluid can become
thicker and expand. To determine if the vibration damper
thickness is correct, remove the paint from the vibration
damper in four locations
on either side of the vibration
damper. Measure and record the thickness of the vibration
damper in four places. Measure the thickness 3.18 mm
[0.125 inch] from the outside of the vibration
damper.
Replace the vibration damper if its thickness varies by more
than 0.25 mm [O.OlO inch].

Spray the vibration damper with spot check developer, Type


SKD-NF or its equivalent. Heat the vibration damper in an
oven (rolled lip side down) at 93C [2OOF] for 2 hours.

B
LJ

Rear Cover - Cleaning and Inspection (l-28)


Page 1-62

Cylinder Block - Group 01

A
@

Caution: Wear protective gloves to prevent personal injury


when handling parts that have been heated.
Remove the vibration damper from the oven and check for fluid
leakage. If there is leakage, replace the vibration damper.

a!3

da9OOsf

Rear Cover - Cleaning and Inspection


(I-28)

Q
63

Use a mandrel or drift to remove the crankshaft

oil seal.

Cleaning

B
LJ

Remove the gasket material from the rear cover gasket sealing
surface.

Use sovent to clean the rear cover. Dry with compressed

LJ
B

air.

Cylinder Block - Group 01

Cylinder Head Capscrews - Cleaning and Inspection for Reuse (l-29)


Page 1-63

Inspection
Inspect the rear cover for cracks or other damage.

Measure the rear cover crankshaft


The rear
checking.

cover

seal bore.

must be clamped

to

a flat

surface

for

Rear Cover Crankshaft Seal Bore I.D.


mm

in

149.99

MIN

150.04

MAX

Replace the rear cover


within specifications.

if the crankshaft

seal bore

is not

Cylinder Head Capscrews - Cleaning and


Inspection for Reuse (l-29)
Caution: Prevent damage to the capscrews. Nicks in the
body of the capscrew can cause an area of stress that
can fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will damage
the mating parts.

bpksba

Cleaning
Caution: Do not use caustic or acid solutions to clean the
cylinder head capscrews.
Use a petroleum-based
with compressed air.

solvent

to clean the capscrews.

Dry

Clean the capscrews thoroughly


with a wire brush, a wire
wheel (soft), or use a non-abrasive
bead blast to remove
deposits from the body and threads.

A
B
El

Cylinder Block - Group 01

Cylinder Head Capscrews - Cleaning and Inspection for Reuse (i-29)


Page 1-64

Inspection
Visually inspect the cylinder head capscrews for damaged
threads, corroded surfaces, or a reduced diameter (due to
capscrew stretching).
The capscrew
l
l
l

must be replaced if:

The threads are damaged


Rust or corrosion has caused pitting in the body
The body is nicked, galled, bent, or stretched

NOTE: The capscrew threads have been formed by a rolling


operation during manufacture. Repair of rolled threads by the
use of a thread die is not recommended. The thread die can
create a sharp corner on the minor diameter (root) of the
threads. This sharp corner can cause an area of increased
stress.
Do not reuse cylinder head capscrews under the following
conditions:
Visible corrosion or pitting
inch] in area. Example:

exceeds

-- Acceptable

3/8x3/8-inch

-- Unacceptable

1/2x1 /Pinch

Visible corrosion
in depth.

1 sq cm [0.155 sq.

or pitting exceeds 0.12 mm [0.005-inch]

Visible corrosion or pitting


[l/&inch]
of the fillet.

is located

within

3.2 mm

Visible corrosion
or pitting
[l/&inch]
of the threads.

is located

within

3.2 mm

Stretched beyond free length


measurement procedure below:

maximum.

Refer to the

Engine Lifting Brackets - Cleaning and Inspection for Reuse (l-30)


Page l-88

Cylinder Block - Group 01

Free Length - Measurement


Part No. 3823921, Capscrew Length Gauge
NOTE: If the capscrews are not damaged,

they can be
reused throughout the life of the engine unless the specified
free length is exceeded.

To check the capscrew free length, place the head of the


capscrew in the appropriate slot with the flange against the
base of the slot.

Cylinder Head Capscrew Free Length

0@9

in

mm
81.5

Short

3.2

162.6

Long

6.4

If the end of the capscrew touches the foot of the gauge, the
capscrew is too long and must be discarded.

Immediately after cleaning and inspecting, apply a film of


clean engine lubricating oil to all capscrews that are to be
used again.

Engine Lifting Brackets - Cleaning and


Inspection for Reuse (I-30)
Use solvent to clean the brackets and capscrews.
Visually inspect
and corrosion.

the engine

lifting

brackets

for cracks,

rust

0a!3

Cylinder Head - Group 2

Page 2-1

Cylinder Head - Group 02


Section Contents
Page
Cylinder Head Capscrew - Cleaning and Inspection

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

Cleaning..
.............................................................
Inspection ......................................

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

Cylinder Head - Cleaning and Inspection for Reuse


Cleaning..
.............................................................
Handling ..............................................................
Inspection ..............................................................
Cylinder Head - Exploded View..

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

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

Cylinder Head - General Information .............................................


Cylinder Head - Pressure Testing

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

Cylinder Head - Rebuild .....................................................


Assembly ..............................................................
Cleaning..
.............................................................
Disassembly ............................................................
Inspection ..............................................................
Valve - Grinding ..........................................................
Valve Guide - Inspection ....................................................
Valve - Inspection ........................................................
Valve Seat Insert - Grinding ..................................................
Valve Seat Insert - Inspection .................................................
Valve Spring - Inspection ...................................................
Valve Stem Seal - Inspection .................................................
Cylinder Head - Service Tools ..................................................

Cylinder Head - Vacuum Testing Valve Seating

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

Cylinder Head - Valve Guide Replacement ........................................


Assembly ..............................................................
Disassembly ............................................................
Inspection ..............................................................
Cylinder Head - Valve Seat Insert Replacement
Inspection ..............................................................
Installation .............................................................
Removal ...............................................................
Free Length - Measurement

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

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

2-37
2-37
2-38

2-9
I-;
2-10

2-6
2-8
2-34
2-11
2-26
2-12
2-11
2-l 3
2-21
2-17
2-20
2-22
2-18
2-19
2-19
2-2

2-36
2-28
2-29
2-28
2-29
231
2-33
2-33
2-31
2-39

Cylinder Head - Grow 02

Cylinder Head - Service Tools


Page 2-2

Cylinder Head - Service Tools

The following special tools are recommended to perform procedures in Group 02. The use of these tools is
shown in the appropriate procedure. These tools can be purchased from your local Distributor.

Used to compress

the valve springs to remove the valve

Grind the valve seats in the cylinder head. Used with Part No.
3823187, Valve Guide Arbor, and various valve seat grinding
stones. Refer to the appropriate grinding stone in this tool list.

Grind 15 degree exhaust seats (1.875 inch diameter).

Magnetic Crack Detector


Used to inspect the cylinder head combustion face for cracks
in the injector bore and valve seat areas. The kit includes Part
No. ST-1188-7, Powder Spray Bulb, used for spraying the
ST-1 188-8, Metal Powder.

Used with Part No. ST-12576 Vacuum Cup. Vacuum test the
cylinder head to determine if the valves are properly seated.

Valve Seat Extractor


Used to remove exhaust valve seats from the cylinder
Used with Part No. 3378817, Slide Hammer.

head.

Cylinder Head - Service Tools


Page 2-3

Cylinder Head - Group 02

Tool Description

Tool No.

Measure the cylinder

head valve spring tension.

Used to remove expansion

Grind cylinder

Tool Illustration

plugs from the cylinder

head.

head valves and resurface valve stems.

Used with Part No.s ST-1276-1 and 3377396, Valve Seat


Extractors and Part No. 3376467, cutter, to remove valve seats
from the cylinder head.

lide Hammer Assembly


Used with Part No.s ST-1276-1 and 3377396, Valve Seat
Extractors, to remove valve seats from the cylinder head.

Used to install 3/4 inch expansion

plug to the specified depth.

Used with Part No. 3376617, Slide Hammer Assembly,


remove the intake valve seats from the cylinder head.

to

Used to ream service valve guides to proper inside diameter


after installation.

Cylinder Head - Service Tools


Page 2-4
Tool No.

Cylinder Head - Group 02

Tool Description

Tool Illustration

Used to clean carbon from injector bores.

- Grind 15 degree intake seats (2.250 inch diameter)


- Grind 30 degree intake seats (2.125 inch diameter)
- Grind 45 degree exhaust seats (1.875 inch diameter)

- Grind 60 degree exhaust seats (1.75 inch diameter)


- Grind 60 degree intake seats (2.0 inch diameter)

Valve Seat Grinding Arbor


Used with Part No. ST-685, Valve Seat Grinding Machine, and
various grinding stones for proper alignment during the
grinding operation.

Valve Guide Driver Kit


- Used to install intake valve guides.
- Used to install exhaust valve guides.
- Used to remove intake and exhaust valve guides.

Used to measure the injector protrusion


the cylinder head.

Used to install 1 3/16 inch expansion

Used to install 2-l/4

inch expansion

and valve recess in

plug to the specified

plug to the specified

Cylinder Head - Group 02

Tool No.

Cylinder Head - Service Tools


Page 2-5
Tool Description

Capscrew Length Gauge


Used to check cylinder head capscrew free length.
3823921

Head Holding Fixture


Hold and revolve the cylinder head repair and assembly.
ST-583

Tool Illustration

Cylinder Head - Group 02

Cylinder Head - Exploded View


Page 2-6

Cylinder Head - Exploded View

43

-25

24

Cylinder Head - Exploded View


Page 2-7

Cylinder Head - Group 02

Part Name

Ref. No
1

Head, Cylinder

Plug, Expansion

Plug, Expansion

Plug, Expansion

Plug, Expansion

Guide, Valve Stem

Insert, Valve Seat (Exh)

Insert, Valve Seat (lnt)

Plug, Pipe

Plug, Pipe

10

Plug, Pipe

11

Seal, Valve Stem (lnt)

12

Valve, Intake

13

Collet, Valve

24

14

Valve, Exhaust

15

Washer, Sealing

16

Plug, Pipe

17

Spring, Valve (lnt)

la

Spring, Valve (Exh)

19

Retainer, Valve Spring

20

Seal, Valve Stem (Exh)

21

Plug, Expansion

22

Coupling,

23

Gasket, Cylinder

24

Screw, Hex Hd Cap (Flange)

12

25

Screw, Hex Hd. Cap (Flange)

14

Elbow
Head

12

12

Cylinder Head - General Information


Page 2-8

Cylinder Head - Grow 02

Cylinder Head - General Information


The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, valve stem seals, valve seat
inserts, cylinder head capscrews, collets and spring retainers.
The cylinder head is a one piece, crossflow design with two valves per cylinder. The valve guides and seats are
replaceable. The cylinder head has a cast intake manifold and fuel filter head. The injectors are mounted in the cylinder
head for direct injection of fuel into the cylinders.
The cylinder head gasket is a laminated design with a fire ring to seal the cylinder bores. Orifices in the gasket control
coolant flow. Thicker gaskets are available for cylinder blocks that have been resurfaced 0.25 mm [O.OlO inch] or more.
NOTE: Engines equipped with an exhaust brake that impose from 241 to 443 kPa [35 to 65 psi] exhaust back pressure
must use dual exhaust valve springs.
Mark, label, or tag the cylinder head parts such as valves and valve springs with the cylinder number and location from
which they were removed. This practice will prove to be a valuable aid in diagnosing any cylinder head or part failures
and to make sure the reuseable parts are installed in their original locations.

Cylinder Head - Group 02

Cylinder Head - Cleaning and Inspection for Reuse (2-01)


Page 2-9

Cylinder Head - Cleaning and Inspection


for Reuse (2-01)
Handling
The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.
Use a hoist or hydraulic

arm to lift the cylinder

NOTE: Place the cylinder


damage to the combustion

head on wood
surface.

head.

blocks to prevent

Cleaning
Remove the gasket material from the valve cover surface.
Use a gasket scraper to remove the heavy dirt and debris
from the cylinder head gasket surface and exhaust manifold
gasket surface.

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Use steam to clean the cylinder


air.

\
u

head. Dry with compressed

Caution: When using compressed air to clean capscrew


holes, always wear safety glasses or a face shield to
protect the eyes. Personal injury can result.

Use Scotch-Brite@ 7448, Part No. 3823258 or equivalent, to


clean the cylinder head combustion
surface and exhaust
manifold gasket surface.

\
R

Cylinder Head - Cleaning and Inspection for Reuse (2-01)


Page 2-10

Cylinder Head - Group 02

Clean the cylinder

head with solvent.

Inspection
Visually inspect the cylinder head for obvious damage that
would prohibit reuse. Check for cracks and damage to the
combustion surface that would result in loss of sealing.
If cracks or leaks in the cylinder head are suspected,
Cylinder Head - Pressure Testing (2-05).

refer to

Visually inspect the valves and valve springs for cracks, bent or
broken valve stems, broken valve spring collets or other
damage.
Visually inspect the valves for indications

of leakage or burning.

If cracked or damaged parts, or indication of leakage or


burning is found, the cylinder head must be rebuilt. Refer to
Cylinder Head - Rebuild (2-02).

Valve and Seat - Leakage Testing


NOTE: If a leaking valve is suspected, vacuum test the valves
and valve seats. The vacuum must not drop more than 25.4
mm Hg [l.O inch Hg] in 5 seconds.
Valve to Valve Seat Vacuum
mm Hg

kn900kb

in Hg

457

used

18

635

New

25

Cylinder

Head - Group 02

Cylinder Head - Rebuild (2-02)


Page 2-11

NOTE: If vacuum does not meet the specifications, the face


of the valves and the valve seat inserts must be resurfaced.
Refer to Procedure 2-02.

Cylinder Head - Rebuild (2-02)


Disassembly
Part No. ST-583, Cylinder Head Holding Fixture
Install the cylinder
head
Holding Fixture, as shown.

in the

Part

No.

ST-588

Head

kn9toha

NOTE: Before removing the valves, use paint or Dykemm to


identify the location of the valves and retainers. If the parts
are used again, they must be installed in their original
locations.

Part No. ST-448, Valve Spring Compressor


Place a wood block between
fixture to support the valves.
Use the
springs.

valve

spring

the valves and head holding

compressor

to

compress

the

valve

kn9vawa

Cylinder Head - Rebuild (2-02)

Cylinder Head - Group 02

Page 2-12
Use a pencil magnet to remove the valve collets. Discard the
valve collets.
Slowly release the pressure on the valve spring.

Remove the valve spring retainer.


Remove the valve spring.
Remove the valve.
Remove the valve spring seat/valve

seal assembly.

Keep the valves in a labeled rack.

kn2vaaa

Cleaning
Scrape the gasket material from all gasket surfaces.

Cylinder Head - Group 02

Cylinder Head - Rebuild (2-02)


Page 2-13

Clean the
cvlinder
head
combustion
Scotch-Brite@ 7448 pad, or an equivalent
solvent.

surface
cleaning

with
a
pad and

I\
u

Inspection
Straight Edge and Feeler Gauge
Use a straight edge and feeler gauge to check the cylinder
head combustion surface for flatness.

Cylinder Head Flatness Specifications


mm

in

0.20

End-to-End

0.008

0.076

Side-to-Side

0.003

Use a small 51 mm [2.0 inch] straight edge and a 0.001 inch


feeler gauge to measure local cylinder head combustion
surface flatness. Check between the cylinder bores and also
between the coolant passages. If the 0.001 inch feeler gauge
fiis under the 2.0 inch straight edge or if the cylinder head is
pitted, has grooves or wear greater than the maximum
specified, the cylinder head must be replaced or resurfaced.

NOTE: A maximum of 1.00 mm IO.040 in] can be machined


from the combustion surface of the cylinder head.
If the cylinder head is machined, place the valve in the
respective bore and check the valve depth dimension. If the
depth is less than the minimum soecification. the valve seat
wilj require machining. Refer to Valve Seat - .Grinding in this
section.
Install an injector with
injector tip protrusion.

an injector

seal to check for proper

Maximum

Cylinder Head - Rebuild (2-02)


Page 2-14

Cylinder Head - Group 02

Measure the cylinder


/8

head thickness.

Cylinder Head Thickness (New)


in

mm
115.75

MIN

4.557

116.25

MAX

4.577

Replace the cylinder


mm [4.518 inch].

head if the thickness

is less than 114.75

kn900na

El

q
B

Part No. 3822510, Injector Bore Brush


If the cylinder
head flatness
and thickness
specifications, continue with the cleaning operation.
Clean the carbon from the cylinder

is

within

head injector bore.

Expansion Plug - Removal


Clean the build-up of deposits from the coolant passages.
Excessive deposits may be cleaned in an acid tank but the
expansion plugs must first be removed.
Use a center punch to mark the expansion
Drill a l/8

69
l

inch hole in the expansion

plugs for drilling.

plugs.

Use a dent puller to remove the expansion

plugs.

Remove the pipe plugs.

Warning: Wear protective eye covering.


A

\
q

Clean carbon deposits from the valve pockets with a high


quality steel wire wheel installed in a drill or a die grinder.

NOTE: An inferior quality wire wheel will loose steel bristles


during operation, thus causing additional contamination.

Cylinder Head - Rebuild (2-02)


Page 2-15

Cylinder Head - Group 02

Place the
solution.

cylinder

head

and

parts

NOTE: Be sure to follow the cleaning


instructions when cleaning the parts.

in a tank
solution

of cleaning

manufacturers

d&

Remove the cylinder


Dry with compressed

head and parts from the cleaning


air.

kn900ed

tank.

Visually inspect all passages to make sure they are clean.

Use Scotch-Brite@ 7448, Part No. 3823258 or equivalent, to


clean the cylinder head combustion surface and the exhaust
manifold gasket surface.

kn900eb

Use the Part No. ST-1188 Magnetic Crack Detector, to find


cracks in the combustion surface and areas around the valve
ports and injector bores.
Place the magnetizing
shown, to check for
head.

head on the combustion surface as


cracks that run across the cylinder

Cylinder Head - Rebuild (2-02)


Page 2-16

Cylinder Head - Group 02

4B

Fill the magnetic crack detector


(l/3) full wsh metal powder.

powder

sprav bulb one-third


. *

Spray the powder lightly onto the combustion


Use compressed

surface.

air to remove the excess metal powder.

Air Pressure: 276 kPa [40 psi]


NOTE: The powder will remain in the cracks, if present, and
show as a white line.

4iB

Check for cracks on the combustion


surface. Cracks that
extend from the injector bore away from the valve seats and
are not over 10 mm IO.394 inch] long are acceptable.
A = 10 mm IO.394 inch]

kn9bdsa

Any cracks that extend from the injector bore toward the valve
seats are unacceptable
and the cylinder head must be
replaced.

kn9bdsd

Cracks between the valve seats are not acceptable


cylinder head must be replaced.

and the

Cylinder Head - Group 02

Cylinder Head - Rebuild (2-02)


Page 2-17

Place the magnetizing head on the combustion surface as


shown to check for cracks that run lengthwise of the cylinder
head.
Repeat the procedure

as outlined

0ai3

above.

Remove all magnetism and use solvent to clean the cylinder


head. Dry with compressed air.

NOTE: The cylinder head must be thoroughly cleaned after


using the magnetic crack detector to remove all of the metal
powder.

Valve Guide - Inspection


Visually inspect the valve guides for scuffing or scoring.
Use a small bore gauge to measure the inside diameter of
the valve guides in locations 13 mm [l/2 inch] from each
end and at the center as shown.

0a3

Valve Guide I.D. (Installed) (Used)


mm

in

9.539

MIN

0.3756

9.591

MAX

0.3776

Use a depth micrometer to measure the valve guide installed


height. Measure from the top of the valve guide to the
bottom of the recess area.

Valve Guide Height (Installed)


mm

in

Intake

20.66
21.16

MIN
MAX

0.813
0.833

Exhaust

22.50
23.01

MIN
MAX

0.886
0.906

If damage is found or the valve guide(s) do not meet the


limits specified, the valve guide(s) must be replaced. Refer to
Procedure 2-03.

Cylinder Head - Group 02

Cylinder Head - Rebuild (2-02)


Page 2-18

Valve Seat Insert - Inspection


Visually
spots.

no - I

inspect

the valve seat inserts for cracks

or burned

kn900kf

Measure the width of the valve seat area (1) of the valve seat
inserts.

Valve Seat Area (Width)


in

mm
1.5

MIN

0.059

2.0

MAX

0.079

NOTE: The sealing surface of the valve should


center of the valve seat insert.

seat in the

If the valve seat area is worn wider than the maximum


specified, refer to Valve Seat - Grinding or Cylinder Head Valve Seat Insert Replacement, in this section.

Part No. 3823495 Gauge Block


Install the valves in their respective
recess in the cylinder head.

bores and measure the

Make sure the seats are clean before measuring

the recess.

Valve Recess in Cylinder Head


in

mm
Exhaust

Intake

1.09

MIN

0.043

1.62

MAX

0.064

0.59

MIN

0.023

1.12

MAX

0.044

NOTE: If the valve recess is out-of-limits, before replacing the


valve seat, try replacing the old valve (A) with a new valve (B).
If the recess is within limits with the new valve, grind the old
valve seat and use the new valve. Refer to Valve Seat Grinding in this section.

kn9vana

Cylinder Head - Rebuild (2-02)


Page 2-19

Cylinder Head - Group 02

Valve Spring - Inspection


Inspect the valve springs for obvious damage (breaks, etc.).

0
@

Measure the valve spring.


Valve Spring Free Height (A)
in

mm
Standard Spring
Intake and Exhaust

65.66

Nominal

2.585

Dual Spring (Exhaust)


Outer Spring
Inner Spring

77.47
72.64

Nominal
Nominal

3.049
2.860

Valve Rotator Spring Intake and Exhaust

62.05

Nominal

2.44

Use the Part No. 3375182, Valve Spring Tester, to measure


the valve spring load at the opening height.
Valve Spring Opening height (B)
in

mm
Valve Rotator Springs Intake and
Exhaust

35.89

Nominal

1.413

All Other Springs

37.90

Nominal

1.492

Valve Spring Load for Opening Height (New)(C)


Standard Spring
Intake and Exhaust

Ibf

960

216
238

1060
Dual Spring (Exhaust)
Outer Spring
Inner Spring
Assembly

1023
111
1184

1084
Valve Rotator Spring Intake and Exhaust

995

1095

Nominal
Nominal
MIN
MAX

230
25
266
244

MIN
MAX

224
246

If the valve spring load for the opening height is less than
the minimum specified, the valve spring must be replaced.

kn8sptd

Cylinder Head - Rebuild (2-02)


Page 2-19-02

Cylinder Head - Group 02

Valve Stem Seal - Inspection


Visually inspect the valve spring retainers and valve stem
seals for damaged or worn areas.
Remove the valve stem seals from the valve stem seal
retainers, and visually inspect for damaged or worn areas.
Discard unserviceable parts.

@J

Cylinder Head - Grow 02

Head - Rebuild (2-02)


Page 2-20

Cylinder

0@

Valve - Inspection
Visually inspect the valves for damage. Replace the valves if
any of the following conditions are found:
l

Valve stems worn below specifications

(A)

Rust or pitting
(B)

Worn collet grooves (C)

Worn stem tip (D)

Bent valve stems (E)

Damaged valve heads (burned, cracked or broken) (F)

on the valve stem or sealing surface

kn9vakc

Measure the outside diameter of the valve stem.

Valve Stem O.D.


in

mm

2.5

9.46

MIN

0.372

9.50

MAX

0.374

ha-j

a3

NOTE: It may be possible to grind and reuse valves with the


following conditions:
l

Minor grooves on the valve sealing surface (A)

Fine pitting on the valve sealing surface (B)

Carbon or varnish buildup

on the valve stem (C)

Cylinder Head - Rebuild (2-02)


Page 2-21

Cylinder Head - Group 02

Valve - Grinding
Cleaning
NOTE: Any valves that are to be used again must have the
sealing surface machined.
Use Scotch-Britee 7448, Part No. 3823258, to clean the valve
stems. Clean the carbon deposits from the valve sealing
surface and head.

q
\

NOTE: The valves must be clean and free of carbon


deposits before they are refaced. Valves can be cleaned by
the bead blasting method in the head area only.
knlvaec

Use a valve facing machine, Part No. 3376256, to grind the


sealing surface of the valve.
NOTE: Follow the instructions supplied with the valve
grinding machine for the correct setup before grinding the e
valves.

Grind the intake and exhaust valves to the angle shown


below:
Valve Seat Angle
Angle

Valve
Intake

30 Degrees

Exhaust

45 Degrees

Use solvent to clean the metal particles from the valve. Dry
with compressed air.

Put the valve on a flat surface and measure the head


thickness (1) at the outside diameter.
Valve Head Thickness (at O.D.)
in

mm
Exhaust

2.22

MIN

0.087

Intake

3.01

MIN

0.119

NOTE: If the valve head is worn thinner than the minimum


specified, the valve(s) must be replaced.

q
\

Cylinder Head - Rebuild (2-02)


Page 2-22

Cylinder Head - Group 02

Use a lead pencil or Dykem to mark across the valve sealing


surface as shown. Install the valve in the valve guide.
Hold the valve against the valve seat, and rotate the valve
backward and forward three or four times. Correct contact
against the valve seat will break the pencil marks on the valve
sealing surface.
NOTE: Valves and valve seats that are correctly machined do
not require the use of lapping compound to make an air tight
seal. If lapping compound is required, inspect the adjustments
of the grinding machine and the condition of the grinding
stone.

Install the valves in the cylinder


under Cylinder Head - Rebuild.

head. Refer to Assembly

Use valve vacuum tester, Part No. ST-1257, to vacuum test the
valve seating. Refer to Cylinder Head - Vacuum Testing Valve
Seating 2-06.

kn900kb

Valve Seat Insert - Grinding


NOTE: If the valve guide inside diameter exceeds the maximum
worn limit, replace the valve guide before grinding the valve
seat.
Use the Part No. ST-685 Valve Seat Grinding Machine and the
Part No. 3823187, Valve Guide Arbor Set, when grinding the
valve seat inserts.
Install the valve guide arbor (1) in the valve guide with the
arbor puller (2).
Rotate the arbor to be sure that it is installed correctly.

Install a valve seat grinding

stone (3) on the grinding

machine.

NOTE: The grinding stone must be the correct size and have
the correct angle (Intake: 30 Degrees, Exhaust: 45 Degrees).
Refer to the Service Tool List in the front of this section.
Install the grinding

machine on the arbor.

NOTE: The grinding stone (3) must not touch the valve seat
insert when the drive unit motor is started.
Hold the drive unit in a vertical
position,
and use an
up-anddown
movement of 12.7 mm [0.50-inch] travel and light
pressure to grind the seat.
Remove the grinding

machine from the arbor.

Cylinder Head - Group 02

Install eccentrimeter
valve guide arbor.

gauge

Cylinder Head - Rebuild (2-02)


Page 2-23
(4), Part No. ST-665-4, on the

@A
GxW

Measure the valve seat to valve guide concentricity.

Concentricity (Per 360 Degrees)


in

mm
MAX

0.05

0.002

NOTE: If the valve

seat concentricity
does not meet the
specifications, grind the valve seat again. If the specifications
e
cannot be met, replace the valve seat insert. Refer to
Cylinder Head - Valve Seat Insert Replacement (02-04).

Install reconditioned valves in their respective


valve firmly against the valve seat insert.

bores. Hold the

Part No. 3823495, Gauge Block


Measure the valve recess in the head.

Valve Recess in Cylinder Head


in

mm
Exhaust

1.09
1.62

MIN
MAX

0.043
0.064

Intake

0.59
1.12

MIN
MAX

0.023
0.044

If the valve recess is


with a new valve (B)
recess is within limits
the new valve with the

OQn

out of limits, replace the old valve (A)


before replacing the valve seat. If the
with the new valve, proceed by using
old seat.

Cylinder Head - Rebuild (2-02)


Page 2-24

Cylinder Head - Group 02


If the valve recess is still out of limits, even with the new valve
(B), replace valve seat (C) with a new valve seat (D). After
replacing the seat, check the valve recess again with the old
valve (A) to determine if it can be reused. If not, proceed by
using the new valve (B).
(A)
(B)
(C)
(D)

=
=
=
=

Old Valve
New Valve
Old Valve Seat Insert
New Valve Seat Insert

Check the valve seat contact area on the valve sealing surface
to see if the valve seat contacts the center of the valve sealing
surface.
Use a pencil or DykemQ to put vertical
surface of the valve.

marks on the sealing

Install the valve in the valve guide. Hold the valve against the
valve seat insert.
Rotate the valve backward and forward three or four times.

Remove the valve and measure the valve seat width and the
seat contact area as indicated by the broken pencil lines.
The pencil or Dykem@ marks will be worn
valve contacted the seat.

away where the

Valve Seat Width Limit


mm

in

1.5

MIN

0.059

2.0

MAX

0.079

Cylinder Head - Group 02

Cylinder Head - Rebuild (2-02)


Page 2-25

Grind valve seat insert area (A) with a go-degree stone and
valve seat insert area (B) with a 15degree stone to center
the seat on the valve sealing surface and to obtain the valve
seat width limits.

The location of the broken pencil


surface is the key to determining
seat insert angle to grind.

lines on the valve sealing


how much of each valve

If the broken lines are at the bottom of the valve sealing


surface, the valve seat insert will require more grinding with
the 60degree stone than with the 15degree stone.

If the broken lines are at the top of the valve sealing surface,
the valve seat insert will require more grinding with the
15degree stone than with the 6Odegree stone.

After grinding the valve seat inserts, use a bristle


clean the inside diameter of the valve guides.
Use solvent to clean the cylinder
air.

brush to

head. Dry with compressed

q
\

knlvaxa

g;li;y2gHead

- Rebuild (2-02)

Cylinder Head - Group 02

Assembly

Eil

Expansion Plug Installation

Apply cup plug sealant,


diameter of the expansion

Part No. 3375058, to the outside


plugs.

NOTE: Use the correct expansion plug driver to make sure the
expansion plugs are installed to the correct depth in the
cylinder head. Drive the plug until the shoulder of the driver
contacts the cylinder head. Refer to the chart below:

Tool P/N

Exp. Plug P/N

Qty.

Location

3823522

156075

3823524

3900965

3823522

3032693

3376815

3912900

NOTE: If the engine


kn9ephb

is equipped with an air compressor,


expansion plug (D) is not used. A 90degree elbow coupling is
installed in this hole for the air compressor air inlet. Apply Part
No. 3375068, Cup Plug Sealant, and install the fiiing with the
beaded end pointing down to the 4:00 oclock position.

Pipe Plug Installation


If the pipe plugs are not already precoated, apply a coat of
Part No. 3375068, Cup Plug Sealant, to the pipe plug threads.
Install the pipe plugs, refer to the following chart:

Torque Value:
Location

kn9pxh

Size

Ft-lb

71 in-lb
106 in-lb

l/16

l/4

in. NPT

12

l/2

in. NPT

24

18 ft-lb

80

59 ft-lb

in. NPT

Nom

Hex Plug

NOTE: The hex plugs (D) require a copper sealing washer.

\
q

Use a bristle brush to clean the inside diameter


guide bores and blow out with compressed air.

of the valve

Cylinder Head - Rebuild (2-02)


Page 2-27

Cylinder Head - Group 02

Use SAE !3OW engine


and valve stems.

oil to lubricate

the valve guide bores

q
\

Install the valves in the valve


have smaller diameter heads.

guides.

The

exhaust

valves

NOTE: If any valves are being used again, the valves must
be installed in the same location

NOTE: The valves should


little or no resistance.

as they were removed.

drop

into the valve

guides

with

After the valves are installed, place the cylinder head on a


flat surface that will not damage the cylinder head surface.

Install the valve


valve stem.

spring

seat/valve

seal assembly

over the

as9

NOTE: To prevent oil carryover,


and must be installed as follows:

the seals are color

coded

Exhaust Valve (A): Orange (with 64 grooves per inch)


Intake Valve (B): Black (with 40 grooves per inch)

Install the valve springs.


Install the valve spring retainers.

Use valve spring compressor,


equivalent (refer to the Service
valve springs.

Part No. ST-448, or its


Tools list) to compress the

Install the new valve spring retainer collets.

NOTE: Use new valve spring


the cylinder head.

@@A

retainer collets when rebuilding

0a3

Cylinder Head - Group 02

Cylinder Head - Valve Guide Replacement (2-03)


Page 2-28

Warning: Wear eye protection. If the collets are not correctly


installed, they can fly out when the stems are hit with a
hammer.
Use a plastic hammer to gently hit the top of the valve stems
to make sure the valve collets are correctly seated in the spring
retainer.

Use valve vacuum tester, Part No. ST-1257, to vacuum test the
valve seating. Refer to Cylinder Head - Vacuum Testing Valve
Seating (2-06).

kn900kb

Cylinder Head - Valve Guide


Replacement (2-03)
Disassembly
NOTE: It will be necessary to grind _ the valve seats after
replacing the valve guides. Refer to Procedure 2-02 in tnis
section.
Use the Part No. 3823271, Valve Guide Driver (l), to remove
the old valve guides (2).

Use a flexible brush and solvent to clean the valve guide bores
in the cylinder head. Dry with compressed air.

Cylinder Head - Group 02

Cylinder Head - Valve Guide Replacement (2-03)


Page 2-29

Inspection
Measure the inside diameter
cylinder head.

of the valve guide

bore in the

Valve Guide Bore I.D.


mm

in

15.931

MIN

0.6272

15.971

MAX

0.6266

If the valve guide bore is worn larger than the


specified, the cylinder head must be replaced.

maximum

Assembly
Measure the outside diameter of the new valve guides.

Valve Guide O.D.


mm

in

15.988

MIN

0.6294

16.000

MAX

0.6299

kn2guth

The intake and exhaust valve guides are installed at


heights above the cylinder head top deck surface,
the following part numbers for the correct installation
Intake: Part No. 3823269
Exhaust: Part No. 3823270
Drive the valve guides into the cylinder head valve
bore until the driver contacts the cylinder head.

guide

Use a depth micrometer to measure the new valve guide


installed height above the cylinder head top deck surface.

Valve Guide Height (Installed)


mm

in

Intake:

20.65
21.16

MIN
MAX

0.813
0.833

Exhaust

22.50
23.01

MIN
MAX

0.886
0.906

Cylinder Head - Valve Guide Replacement (2-03)


Page 2-30

Cylinder Head - Group 02

Part No. 3822490, Valve Guide Reamer


Ream the valve guides with no lubricant and in one direction
only. Damage to the guide can result from pulling the reamer
back through the guide.

Lubricate the reamer with clean 15W-40 engine


the valve guide again in one direction only.

q
B

Clean the valve guide


cleaning solvent.

bore with

a nylon

oil and ream

bristle

brush

and

Cylinder Head - Group 02

Cylinder Head - Valve Seat Insert Replacement (2-04)


Page 2-31

Use a small bore gauge to measure the new valve guide


inside diameter in locations (1) 13 mm [l/2 inch] from each
end and at the center as shown.

(New) Valve Guide I.D. (Installed)


mm

in

9.539

MIN

0.3756

9.559

MAX

0.3763

If the valve guide is not within the specifications given, the


valve guide must be removed and a new valve guide
installed.
L

Cylinder Head - Valve Seat Insert


Replacement (2-04)
Removal
NOTE: If it is determined that both valve
guides need to be replaced, install and
guides first.

seats and valve


ream the valve

Part No. 3376405, Router; Part No. 3376407, Cutter


Adjust the cutter depth to approximately 1.4 mm IO.055 inch]
from the bottom of the valve seat pocket.

Cut a groove in the valve seats. Be sure the cutter motor


base remains flat against the cylinder head while rotating the
cutter motor in a circular motion.

Cylinder Head - Group 02

Cylinder Head - Valve Seat Insert Replacement (2-04)


Page 2-32

Caution: Shavings or debris between the cutter motor base


and the head deck can cause serious damage.

06B

Cut a groove deep enough for the expanding


tool to engage when expanded.

seat extractor

hnlltoxb

0GE3

Make sure the tool cuts only the valve seat inserts and not into
the machined valve pockets of the cylinder head.

kn9toxd

RI

Part No. 3376617, Slide Hammer


Part No. 3377396, Intake Seat Extractor
Part No. ST-1276-1, Exhaust Seat Extractor

0
c%

Remove the valve seat inserts.

Cylinder Head - Group 02

Cylinder Head - Valve Seat Insert Replacement (2-04)


Page 2-33

Use a wire brush and solvent to clean the deposits from the
valve seat insert bores.
Use solvent to clean the cylinder
air.

head. Dry with compressed

Inspection
Visually inspect
damage.
If cracks
replaced.

the

valve

or damage

seat

is found,

insert

bore

the cylinder

for

cracks

or

head must

be

04iD

Measure the inside diameter of the valve seat insert bore (A)
and the valve seat insert bore depth (B) in the cylinder head.
(A) Insert Bore I.D. (Standard

Insert)

Intake

53.93

MAX

in
2.123

Exhaust

47.03

MAX

1.852

mm

(B) Insert Bore Depth (Standard Insert)


mm
in
Intake
12.20
MAX
0.480
Exhaust
9.83
MAX
0.387
NOTE:
cylinder

If either dimension
is
head must be replaced.

out

of

specifications,

the

Installation
For easier installation, freeze the new valve seat inserts
18C [OF] for 30 minutes before attempting to install.

at

Remove the valve seat inserts from the freezer one at a time.

kn900hb

Cylinder Head - Pressure Testing (2-05)


Page 2-34

Cylinder Head - Group 02


NOTE: The valve seat insert chamfer
toward the bottom of the counterbore.

(1) must be installed

Use the Part No. 3376617, Slide Hammer, and a suitable driver,
refer to Cylinder Head - Service Tools, to drive the valve seat
insert into the counterbore.
Make sure the insert is at the bottom of the counterbore.

Use the Part No. ST-685, Valve Seat Grinding Machine, and
Part No. 3823187, Valve Guide Arbor and the appropriate
grinding stone (3), to grind the new valve seat inserts. Refer to
Valve Seat - Grinding in this section.

Cylinder Head - Pressure Testing (2-05)

Do not pressure test the cylinder head with the


valves and valve springs installed. Water entering the
cylinder head cannot be dried thoroughly and will damage
the valve guides and valve stems. Refer to Cylinder Head
- Disassembly (2-02).
Caution:

NOTE: A cylinder head test fixture can be fabricated from a flat


piece of steel or aluminum. Refer to the following table for test
fixture dimensions:
Test Fixture Dimensions
mm
861
190
16

kn9gknt

NOTE: Use the cylinder


the capscrew holes.

in
Length
Width
Thickness

33.5
7.5
0.625

head gasket as a pattern for drilling

Cylinder Head - Group 02

Install the cylinder

Cylinder Head - Pressure Testing (2-05)


Page 2-35

head water test fixture.

Install a new head gasket.


Install the test plate.
Install the 26 cylinder

head capscrews

and Ml4 X 2.0 nuts.

Tighten the nuts.

Torque Value:

0(K

45 N*m [35 ft-lb]

Connect a regulated
Apply air pressure.

air supply

hose to the text fixture

plate.

Use a nylon lifting strap and hoist to place the cylinder


in a tank of heated water.

head

q,
Q@

Air Pressure: 276 kPa [40 psi]

Temperature: 60C [14OF]


Completely

submerge the cylinder

head in the water.

kn900kd

Visually inspect for air bubbles

rising from the water.

If air bubbles are seen, replace or rebuild the cylinder


Refer to Procedure (2-02).

head.

0a3

kn900kt

Remove the test equipment.


Use compressed

air to dry the cylinder

Assemble the cylinder


- Assembly (2-02).

head.

head. Refer to Cylinder

@
Head - Rebuild

kn9toma

Cylinder Head - Vacuum Testing Valve Seating (2-06)


Page 2-36

Cylinder Head - Group 02

Cylinder Head - Vacuum Testing Valve


Seating (2-06)
Use the Part No. ST-1257, Valve Vacuum Tester, to inspect the
seal between the valve and the valve seat insert.
NOTE: The valve vacuum tester can be used to test all
Komatsu engine models. The Part No. ST-12576 Vacuum Cup,
is used on the 6D114E-1 Series cylinder heads.

kn900kb

Install the seal ring and vacuum cup to the vacuum line (hose).

kn2toaa

The valves and valve seat inserts must be clean and dry when
testing.

@ii3vacuum

g+*
@on

Cover the valve with the cup and seal.


NOTE: The seal must make a tight contact on the cylinder
head around the valve.

Move the toggle switch (1) to the ON position.


Turn the vacuum control valve (2) to the OPEN position.
NOTE: The vacuum control valve is in the OPEN position if
the vacuum gauge needle moves clockwise.

Cylinder Head - Group 02

Cylinder Head Capscrew - Cleaning and Inspection (2-07)


Page 2-37

Operate the vacuum


specified vacuum.

pump

until

the

gauge

indicates

the

Valve to Valve Seat Vacuum


mm Hg
New

USed

in Hg

508

MIN

20

635

MAX

25

457

MIN

18

Turn the toggle switch (1) to the OFF

position.

Use a stopwatch and start timing when


gauge indicates 457 mm Hg 118 in. Hg].

the needle on the

Stop timing when the needle on the gauge indicates


Hg [8 in. Hg].

203 mm

The elapsed time for the needle to move between


specified gauge readings must be 10 seconds or more.

the

is less than

the

If the elapsed times


following checks:

10 seconds,

perform

Repeat the test to be sure the equipment


properly.

is operating

Use a mallet to hit the valve stem lightly to make sure


the valve is seated. Repeat the test.

Apply a thin layer of grease on the outside diameters


of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.

A break in the grease seal pattern will indicate leakage


between the valves and valve seat or the valve seat insert
and the cylinder head. Refer to Cylinder Head - Rebuild.

Cylinder Head Capscrew - Cleaning and


Inspection (2-07)
Caution: Prevent damage to the capscrews. Nicks in the
body of the capscrew can cause an area of stress that
can fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will damage
the mating parts.

0ai!3

e
kn9OOkb

Cylinder Head Capscrew - Cleaning and Inspection (2-07)


Page 2-38

Cylinder Head - Group 02

Cleaning

Caution: Do not use caustic or acid solutions to clean the


cylinder head capscrews.
Use a petroleum-based

q
B

solvent to clean the capscrews.

Clean the capscrews thoroughly with a wire brush, a soft wire


wheel, or use a non-abrasive bead blast to remove deposits
from the shank and the threads.

Inspection

a!!3 Visually
threads,

inspect the cylinder head capscrews for damaged


corroded surfaces, or a reduced diameter (due to
capscrew stretching).

NOTE: Do not reuse a capscrew that has damaged threads or


a reduced diameter from having been stretched.

knlcssa

Do not reuse cylinder


conditions:
l

head capscrews

under the following

Visible corrosion or pitting exceeds 1 sqcm [0.155 sq.


inch] in area. Example:
- Acceptable

318-x 3/8-inch

- Unacceptable

1/2-x l/2-inch

Visible
corrosion
or
[0.005-inch] in depth.

pitting

exceeds

0.12

mm

Visible corrosion or pitting


[l/&inch]
of the fillet.

is located

within

3.2 mm

Visible corrosion or pitting


[l/&inch]
of the threads.

is located

within

3.2 mm

Stretched beyond free length maximum.


measurement procedure below:

Refer to the

Cylinder Head Capscrew - Cleaning and Inspection (2-07)


Page 2-39

Cvlinder Head - Group 02

Free Length - Measurement


Part No. 3823921, Capscrew Length Gauge
If the capscrews are not damaged, they can be reused
throughout the life of the engine
length is exceeded.

unless the specified

RI

free

To check the capscrew free length, place the head of the


capscrew in the appropriate slot with the flange against the
base of the slot.

0
@

Capscrew Free Length


in

mm
81.5

Short

3.2

162.6

Long

6.4
1

If the end of the capscrew touches the foot of the gauge, the
capscrew is too long and must be discarded.
The capscrew
can be used again if there is clearance
between the end of the capscrew and the bottom base of
the tool.

Immediately after cleaning and inspecting, apply a film of


clean engine lubricating oil to all capscrews that are to be
used again.
Immediately after cleaning and inspecting, apply a film of
clean engine lubricating oil to all capscrews that are to be
used again.

0a9

Rocker Levers - Group 03


Page 3-l

Rocker Levers - Group 03


Section Contents

Crankcase Breather Tube - Cleaning and Inspection for Reuse .........................


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

3-8

Rocker Assembly Oil Manifold - Cleaning and Inspection for Reuse ......................

3-7
3-7
3-7

Cleaning and Inspection

.............................................................
Cleaning..
Inspection ...............................................................

Rocker Lever Assembly - Cleaning and Inspection ..................................


Assembly ..............................................................
Cleaning.. .............................................................
Disassembly ............................................................
Inspection.. ............................................................

34
3-8

Rocker Lever Assembly - Exploded View .........................................

3-2

Rocker Lever Assembly - General Information

3-3

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

Valve Cover - Cleaning and Inspection for Reuse ...................................


.............................................................
Cleaning..
............................................................
Inspection..

3-8
3-8
3-8

Rocker Levers - Group 03

Rocker Lever Assembly - Exploded View


Page 3-2

Rocker Lever Assembly - Exploded View

Part Name

Ref. No.

QtY.
12

Screw, Twelve Point

Clamp, Rocker Retainer

Rod, Push

Support,

Lever, Rocker

Nut

Screw, Rocker Adjusting

Washer, Curved Spring

Shaft, Rocker

6
12

Rocker Lever

10

Plug, Expansion

11

Washer, Thrust

12

Manifold,

13

Ring, Retaining

Oil

Rocker Levers - Group 03

Rocker Lever Assembly - General Information


Page 3-3

Rocker Lever Assembly - General Information


The rocker lever group consists of the rocker lever assemblies,
breather.

rocker assembly oil manifold, valve cover and crankcase

Each cylinder of the engine has a separate rocker lever assembly. The pedestal support has drillings to route the oil flow
to the shaft and levers.
The rocker levers are push rod actuated and use an adjusting screw to control the clearance between the rocker lever
and valve stem. The rocker levers do not use a bushing in the bore for the rocker lever shaft. The rocker lever must be
replaced if the bore is damaged or worn beyond the specification limit.

Rocker Levers - Group 03

Rocker Lever Assembly - Cleaning and Inspection (3-01)


Page 3-4

Lever Assembly - Cleaning and


Inspection (3-01)

Rocker

Disassembly
Snap Ring Pliers

Ezl
69

Remove the retaining


washers.

rings, thrust washers and wavey spring

Remove the rocker levers.

G3

rh9OOfb

@
l

Remove the pedestal assembly.

rh900ha

Remove the locknut and adjusting

screw.

Rocker Lever Assembly - Cleaning and Inspection (3-01)


Page 3-5

Rocker Levers - Group 03

Cleaning
Clean all parts in strong solution
water.

of laundry

detergent

in hot

\
IJ

Use compressed
water.

rh900ea

air to dry the parts after rinsing in clean hot

rh9OOeb

Inspection
Inspect for cracks and excessive wear in the bore and the
contact surface for the valve stem.

0
@

NOTE: The levers do not use a bushing in the bore for the
rocker lever shaft. The lever must be replaced if the bore is
damaged or worn beyond the specification.

rh9bdsa

Measure the rocker lever bore.

Rocker Lever Bore Diameter


in.

mm
22.256

MIN

0.8762

22.301

MAX

0.878

rh9brta

Rocker Levers - Group 03

Rocker Lever Assembly - Cleaning and Inspection (3-01)


Page 3-6

@9

Visually inspect the rocker lever shafts for pitting,


other damage.

scoring

or

Measure the rocker lever shaft diameter.

CD

Rocker Lever Shaft Diameter


in.

mm
22.199

MIN

0.874

22.231

MAX

0.8752

bpSOOsa

Assembly
Install the adjusting

screw and locknut.

rh9OOfc

Install a retaining ring, thrust washer and wavey spring washer

rh9OOaa

Lubricate the shaft with engine oil.

rh9shw.3

Rocker Levers - Group 03

Valve Cover - Cleaning and Inspection for Reuse (3-03)


Page 3-7

Position the levers on the rocker shaft.

Install the remaining wavey spring washer, thrust washer and


retaining ring as illustrated.

Compress the wavey spring washers


half of the pedestal as illustrated.

rh900ab

@a
4W

and install the bottom

rh900ad

Rocker Assembly Oil Manifold - Cleaning


and Inspection for Reuse (3-02)
Cleaning
Use solvent
air.

to clean the oil manifold.

Dry with compressed

Inspection
Visually inspect the oil manifold for cracks, plugged oil holes,
or other damage. If the oil manifold is cracked or damaged,
it must be replaced.

q
\

q#
@dW

Rocker Levers - Group 03

Valve Cover - Cleaning and Inspection for Reuse (3-03)


Page 3-8

Valve Cover - Cleaning and Inspection


for Reuse (3-03)
Cleaning

z3
0
A

\
El

Inspect the valve cover seal for damage.


NOTE: The seal can be reused if it is not damaged.
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Steam clean and dry with compressed air.

Inspection

0a

Visually inspect the valve cover for cracks or damage and


replace if necessary.

NOTE: If the seal is not damaged, it can be used again.


If the seal is damaged, install a new seal.
Install the seal into the groove in the valve cover. Start the
installation at the overlap area shown in the illustration. Do not
stretch the rubber seal.
If the seal has more overlap than shown in the illustration, trim
the length to provide the correct overlap.

Crankcase Breather Tube - Cleaning and


Inspection for Reuse (3-04)
Cleaning and Inspection

El
B

ai!3

br9tbea

Use solvent to clean the hose and tube. Dry with compressed
air.
Visually inspect the hose and tube for restrictions, cracks or
other damage. Replace the hose and tube if damaged.

Valve Tappets and Push Rods - Group 04


Page 4-l

Valve Tappets and Push Rods - Group 04


Section Contents
Page
Push Rods - Cleaning and Inspection for Reuse .....................................
Cleaning..
Inspection..

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

Valve Tappet Cleaning and Inspection for Reuse ....................................


Cleaning..
inspection..

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

4-4
4-4
4-4
4-3
4-3
4-3

Valve Tappets and Push Rods - Exploded View .....................................

4-2

Valve Tappets and Push Rods - General Information ..................................

43

Valve Tappets and Push Rods - Exploded View


Page 4-2

Valve Tappets and Push Rods - Group 04

Valve Tappets and Push Rods - Exploded View

Ref. No.

Part Name

QW

Tappet, Valve

12

Rod, Push

12

Valve Taooets and Push Rods - Group 04

Valve Tappets and Push Rods - General information


Page 4-3

\i!!i

Valve Tappets and Push Rods - General


Information
The camshaft has lobes to operate the intake and exhaust
valves and a special lobe to drive the fuel transfer pump. The
valve lobes contact the valve tappets which lift the push rods
subsequently opening the valves.

The tappets are mushroom shaped and are positioned so the


centerline of the tappet is offset to the centerline of the
camshaft lobe. The offset position causes the tappet to rotate
as it lifts the push rod.

The ball end of the push rod fiis into the ball socket in the
tappet. The other end of the push rod has a ball socket in
which the ball end of the rocker lever adjusting screw
operates.

pr900sa

Valve Tappet Cleaning and Inspection for


Reuse (4-01)
Cleaning
NOTE: Do not mix the tappets.
Clean the tappets with solvent and dry with compressed

air.

Caution: Any time a new camshaft is installed, new


tappets must also be installed to prevent damage to the
mating surface.

q
\

Inspection
Inspect the socket, stem and face for excessive wear, cracks,
concavity and other damage.
Reuse Guidelines:
(A)

- Normal wear

(B) and (C)

- Abnormal

04iB

wear - Do not reuse

Valve Tappet Face Concavity (Maximum)


mm
0.025

in.
MAX

0.001

bp9tasa

Valve Tappets and Push Rods - Group 04

Push Rods - Cleaning and Inspection for Reuse (4-02)


Page 44

Measure the valve tappet stem.

Valve Tappet Stem Diameter


mm

a3

in.

15.925

MIN

0.627

15.980

MAX

0.629

Pit marks on the tappet face are acceptable.


The following

criteria defines the size of the pits allowed:

A single pit cannot be greater than 2 mm [0.078 inch].


Interconnection

of pits is not allowed.

Total pits when added together should not exceed 6 mm


IO.236 inch] diameter or a total of 4 percent of the tappet
face.

No pitting is allowable
the tappet.

on the edges of the wear face of

Push Rods - Cleaning and Inspection for


Reuse

(4-02)

Cleaning

q
B

Use solvent or hot soapy water to clean the push rods. Dry
with compressed air.

Inspection

@3

pr900sc

Visually
scoring,

inspect the push rod ball and socket


cracks, or other damage.

for signs

of

Push Rods - Cleaning and inspection for Reuse (4-02)


Page 4-5

Valve Tappets and Push Rods - Group 04

06B

Check the push rods for straightness.


Push Rod Straightness
in.

mm
0.50

MAX

0.020

Fuel Systems - Group 05


Page 5-l

Fuel Systems - Group 05


Section Contents
Page
Direct Link Shutdown Lever - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
..............................

5-12

Fuel System - General Information .............................................


Fuel Injection Pump .....................................................
Fuel Injection Pump - Data Tag Location .......................................
Fuel Injection Pump - Data Tag Information .....................................
Governor - Data Tag Information .............................................
Derivative Fuel Injection Pump - Data Tag Information ..............................
Fuel Shutoff Solenoid - Wiring Requirements .....................................

5-2
5-2
5-2
5-2
5-3
5-3
5-3

Fuel Transfer Pump - Exploded View ...........................................

5-4

Fuel Transfer Pump - Rebuild ................................................


Cleaning .............................................................
Assembly ............................................................

5-5
5-5
5-5

RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment ......................


Fuel Shutoff Solenoid - Orientation ...........................................
Fuel Shutoff Solenoid - Adjustment ...........................................

5-6
5-5
5-8

RQVK Governor Fuel Shutoff Solenoid - Adjustment

5-9

Fuel Injection Pump Gaskets and Seals - Replacement

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

Shutdown Lever or Spring - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System - General Information


Page S-2

Fuel Systems - Group 05

Fuel System - General Information


Fuel Injection Pump
The Robert Bosch Model PESGAfuel injection pump is used on 6D114-1, S6D114-1 and SAGD114-1series engine models.
The Model PESGMWpump is used on the higher rated SAGD114-1engines. The Model PESGPfuel injection pump is used
on the 6D114E-1, S6D114E-1, SAD114E-1 and SAAGD114E-1series engine.
The fuel injection pump is calibrated for a specified performance for the different engine applications and models. The
performance of the engine is defined by the engine part number and the fuel injection pump code.
During any fuel system repair, cleanliness is of utmost importance. Thoroughly clean all affected parts with solvent and
then blow dry with compressed air.
The fuel injection pump calibration must be within published specifications. The calibration is certified by several emissions
agencies. Tampering with the injection pump is a violation of law. Tampering with the fuel injection pump will void the
engine warranty and can lower the performance of the engine.
This manual does not cover fuel injection pump rebuild or calibration. Rebuild and calibration must be performed in a
facility certified in the rebuild and calibration of the fuel injection pumps. However, there are external repairs that can be
performed on the pumps without affecting the calibration. These repairs are included in this section of the manual.

Fuel Injection Pump - Data Tag Location


Fuel injection pumps have two and sometimes three data tags
(derivative pumps). These tags contain the information needed
to properly calibrate the pump (Bosch pump shown).

(4 Fuel Injection Pump


(B)Governor Data Tag

Data Tag

((3 Derivative Pump Data Tag

Fuel Injection Pump - Data Tag Information


1. Fuel Injection Pump Serial Number

fD901

al

2.

Bosch Ten Digit Number

3.

Bosch Designation Code

Fuel Systems - Group 05

Fuel System - General information


Page 5-3

Governor - Data Tag Information


1.

Bosch Designation

2.

Vendor Fuel Injection

Code
Pump Part Number
S/WV425
CDC-NO

1100AOC2190-8R
390

6541

fP90195

Derivative Fuel Injection Pump - Data Tag


Information
This tag is installed on the fuel injection pump when a base
fuel injection pump is converted to a derivative fuel injection
pump.

Fuel Shutoff Solenoid - Wiring Requirements

DUAL COIL SOLENOID


EXISTING
STARTING

USED WITH
SYSTEM

The solenoid must be wired properly. Refer to the chart


below to find the correct
gauge size and length
of
continuous wire for the white (pull-in) wire, which connects
the solenoid wiring. The black (ground) wire must be the
same gauge as the white (pull-in) wire regardless of its
length.

Length of Wires
O-4.5 ft

O-7.0 ft

O-11 ft

14

12

10

14 gauge wire is required for the red (hold-in) wire, which


connects to the RUN terminal on the ignition switch.

Wire Gauge Size*


mm

in

1.5

14

0.060

1.9

12

0.076

2.4

10

0.096

* Diameter of conductor
insulation.

only. Does not include

FUEL SOLENOID
WlRlNG DIAGRAM
FOR GROUNDED SYSTEM
es900af

Fuel Systems - Group 05

Fuel Transfer Pump - Exploded View


Page S-4

Fuel Transfer Pump - Exploded View


Low Flow

SM0050
High Flow
Ref. No.

Description

Quantity

Check Valve

Check Valve Gasket

O-Ring Seal

O-Ring Seal

Outlet Fitting Check Valve

Fuel Systems - Group 05

Fuel Transfer Pump - Rebuild (5-01)


Page 6-5

Fuel Transfer Pump - Rebuild (5-01)


20 mm, 26 mm Wrench

El

Caution: The hand-prime fitting and inlet fitting are spring


loaded, Sudden removal of these two fittings can cause
personal injury.
Secure the pump
pump housing.

in a vise, taking

care not to damage

Remove the rubber boot from the hand-prime

the

fitting.

Remove the three fittings as illustrated.


(A) Outlet Fitting
(B) Inlet Fitting
(C) Hand Primer Fitting
Remove all internal components

of the pump.

NOTE: Make sure the check valve gaskets are removed from
the inlet fitting.

Cleaning
Thoroughly
flush the
remove any debris.

pump

with

cleaning

solution

to

q
\

fsgooea

Assembly
20 mm, 26 mm Wrench
Assemble the pump
the rebuild kit.
1.
2.
3.
4.
5.
6.

with

the new components

supplied

in

Check valves
Check valve gaskets
O-ring seal
Outlet fitting/check
valve
O-ring seal (25 mm)
*O-ring seal (25 mm or 30 mm)

*O-ring required is determined


Discard unused o-ring.

by the size of the inlet fitting.

fs900aa

RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (5-02)


Page 5-6

Fuel Systems - Group 05

NOTE: Extreme caution must be used to make sure the check


valves are installed to open in the direction of the fuel flow.
Improper installation of the check valves will result in low
power.

Place the pump in a vise and tighten the fittings.


Torque Value:
(A) Outlet Fitting

30 N*m 122 ft-lb]

(B) Inlet Fitting

30 Nom 122 f&lb]

(C) Hand Primer Fitting 30 N*m [22 R-lb]

fs900wb

RSV Governor Fuel Shutoff Solenoid Orientation and Adjustment (502)


Fuel Shutoff Solenoid - Orientation
All 6D114E-1 series engines that are equipped with a fuel
shutoff valve solenoid use either a Synchro-Start or a Trombetta
solenoid.
NOTE: To prevent moisture induced failure, all Trombetta
solenoids must be oriented in the 6:00 oclock position
according to the following instructions:

Make sure all parts and mounting areas are free of dirt,
damage and other discrepant conditions. The plunger should
be free of rust.

Fuel Systems

RSV Governor

- Group 05

Fuel Shutoff Solenoid - Orientation

and Adjustment (5-02)


Page 57

Insert the solenoid through the bracket with the solenoid


shaft toward the fuel pump. Make sure the rubber bellows
vent hole is in the 6:00 oclock position.

fveoowa

Apply hand pressure to relieve the solenoid spring pressure


and align the capscrew holes. This must be done to align the
plunger on the shut down lever, which is not shown in this
illustration.

Insert the capscrews


into the bracket.

through

the

and

hand

fv900wb

start

fv9OOha

Tighten the capscrews.


Torque Value:
Connect the wiring

10 Nom 189 in-lb]


harness.

0@A

RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (502)


Page S-8

Fuel Systems - Group 05

Fuel Shutoff Solenoid - Adjustment


Synchro-Start
This procedure is for adjusting and maintaining Synchro-Start
fuel shutoff solenoids used to shut down Robert Bosch A/RSV
and MW/RSV fuel injection pumps.
NOTE: The adjustment for the Trombetta is similar, refer to the
procedure on the following page. Refer to Service Bulletin
381034801 for additional fuel pump identification information.

RI
0a3

8 mm
Adjust the solenoid mounting bracket so that the solenoid
plunger targets the center of the shutoff lever as shown in
the illustration.
Torque Value:

10 Nom [89 in-lb]

Activate the solenoid and check the plunger travel. The


a?
stroke length when retracted must be so that there
0 maximum
is a 1 to 3 mm [0.040 to 0.118 inch] gap between the acorn
nut and the shutoff lever (full run position). The plunger length
can be adjusted by hand tightening or loosening the acorn nut.

a!3

Deactivate the solenoid and check the plunger travel. The


plunger must be extended so that the shutoff lever hits the shut
down stop screw. If necessary, adjust the acorn nut so the
shutoff lever will hit the stop screw.

RQVK Governor Fuel Shutoff Solenoid - Adjustment (5-03)


Page 5-9

Fuel Systems - Group 05


Activate the ignition switch and check the plunger travel.
1.

2. Trombetta

Synchro-Start

A = 66.6 mm [3.4 in]

A = 91.4 mm [3.6 in]

B = 60.2 mm [2.4 in]

B = 63.5 mm [2.5 in]

The plunger must be retracted when the fuel shutoff solenoid


is activated to the RUN position B. The fuel shutoff solenoid
must operate without binding.

Direct Link Solenoid, Cylinder Block Mounted


l

Disconnect the solenoid linkage from the lever.

Activate the ignition


travel.

Measure distance B from the center of the ball socket


to the solenoid mounting flange.

switch and check the plunger

B = 117.1 mm [4.61 in]


The plunger must be retracted when the fuel shutoff
solenoid is activated to the RUN position B. The fuel
shutoff solenoid must operate with out binding.

RQVK Governor Fuel Shutoff Solenoid Adjustment (503)


Activate the ignition switch
solenoid plunger travel.
A =

and check the fuel shutoff

66.9 mm [2.64 in]

NOTE: Dimension A is measured from the bottom of the


mounting bracket to the top of the pivot pin.

04B

Fuel Systems - Group 05

Shutdown Lever or Spring - Replacement (5-04)


Page 5-10

Shutdown Lever or Spring - Replacement


(5-04)
10 mm

Remove the shutdown

lever retaining

screw.

Remove the shutdown


spring (C).

lever (A), spring housing

fv900ln

(8) and return

fv9lvm

Install the return spring as illustrated.


NOTE: The RSV governor direct link solenoid shutdown
does not use a return spring.

system

Install the spring housing over the return spring and align the
outside tip of the return spring with the outside hole in the
spring housing as illustrated.

Fuel Systems - Group 05

Direct Link Shutdown Lever - ReDlacement


(5-04)
.
Page S-11
I

Metal Awl or Pick


Load the return spring by rotating the return spring and
spring housing counterclockwise approximately l/4 turn.

10 mm
Hold the return spring in the loaded position and install the
shutdown lever.
Install the shutdown lever retaining screw making sure the
return spring (A) is installed into the hole in the shut down
lever.
Torque Value: 10 Nom [89 in-lb]

Direct Link Shutdown Lever Replacement


Install the cover cap without the spring.
Make sure the cover cap fits over the shutdown shaft.

10 mm
Install the new direct link shutdown lever.

SMCO5f

Fuel Injection Pump Gaskets and Seals - Replacement (5-05)


Page 5-12

Fuel Systems - Group 05

10 mm

RI

Install the retaining

screw.

Torque Value: 9 N*m [89 in-lb]

Fuel Injection Pump Gaskets and Seals Replacement (5-05)


Bosch Fuel Injection Pumps
Item

Type of Seal

(4

Sealing Washer

(B)

Gasket

((3

Gasket

P)

Sealing Washer Only

03

O-ring

(F)

O-ring

Torque Value
24 Nom [18 ft-lb]

15 Nom [ll

ft-lb]

lniectors and Fuel Lines - Group 06


Page 6-l

Injectors and Fuel Lines - Group 06


Section Contents
Page
Fuel Drain Manifold - Inspection ................................................

6-16

Fuel Lines, High Pressure - Cleaning and Inspection for Reuse ..........................

6-14

Fuel Lines - Cleaning and Inspection .............................................


General Information
........................................................

Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse

6-15
6-14
..........................

6-16

Injector - Chatter Testing .....................................................

6-14

Injector - Spray Testing ......................................................

6-13

Injectors and Fuel Lines - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

Injectors and Fuel Lines - Exploded View ..........................................

6-5

Injectors and Fuel Lines - Exploded View ..........................................

66

Injectors and Fuel Lines - General Information ......................................

6-7

Injectors and Fuel Lines - Service Tools

6-2

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

Injectors - Cleaning and Inspection for Reuse


General
Injector
Injector
Injector

......................................
Information
........................................................
- Assembly
........................................................
- Cleaning and Inspection
..............................................
- Disassembly
......................................................

6-6
6-6
6-12
6-10
6-6

Injectors and Fuel Lines - Group 06

Injectors and Fuel Lines - Service Tools


Page 6-2

Injectors and Fuel Lines - Service Tools

The following special tools are recommended to perform procedures in Group 06. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool Description

Tool No.

Used to test opening

pressure, leakage, chatter and spray

Used to clean injector nozzles.

Tool Illustration

Injectors and Fuel Lines - Group 06

Injectors and Fuel Lines - Exploded View


Page S3

Injectors and Fuel Lines - Exploded View

Injectors and Fuel Lines - Group 06

Injectors and Fuel Lines - Exploded View


Page 84

Part Name

Ref. No.

QW

Screw, Hex Flange Head Cap

Screw, Hex Flange Head Cap

Seal, Banjo Connector

Screw, Banjo Connector

Screw, Banjo Connector

Manifold,

Washer, Sealing

Washer, Plain

Brace, Tube

Fuel

10

Screw, Hexagon

11

Isolator, Vibration

12

Brace, Tube

13

Brace, Tube

14

Tube, Injector Fuel Supply

15

Tube, Injector Fuel Supply

16

Tube, Injector Fuel Supply

17

Brace, Tube

18

Brace, Tube

19

Isolator, Vibration

20

Brace, Tube

21

Tube, Injector Fuel Supply

22

Tube, Injector Fuel Supply

23

Tube, Injector Fuel Supply

24

Tube, Fuel Supply

Head Cap

Injectors and Fuel Lines - Group 06

Injectors and Fuel Lines - Exploded View


Page 6-5

Injectors and Fuel Lines - Exploded View

Ref. No.

Part Name
Head Cap

QtY.

Screw, Hexagon

Screw, Banjo Connector

Gasket, Cover Plate

Pump, Fuel Transfer

Washer, Sealing

Tube, Fuel Supply

Injectors and Fuel Lines - Group 06

Injectors and Fuel Lines - Exploded View


Page 6-6

Injectors and Fuel Lines - Exploded View

Ref. No.

Part Name

QtY-

Seal, Banjo Connector

Seal, Injector

Seal, Injector

Injector

Screw, Hex Flange Head Cap

Clamp, Injector

injectors and Fuel Lines - Group 06

Injectors and Fuel Lines - General Information


Page 6-7

Injectors and Fuel Lines - General Information


All 6D114E-1 Series engines use 17 mm closed-nozzle,

hole-type

injectors.

The injector needle valve and the nozzle tip are machined to a very precise tolerance.
valve. Never mix the needle valves and nozzle tips, they are matched sets.

Never replace only the needle

This group provides instructions for disassembly, cleaning, assembly and test of the injectors. This group also provides
data for the injector, high pressure fuel lines, and fuel transfer pump.

Injectors and Fuel Lines - Group 06

Injectors - Cleaning and inspection for Reuse (5-01)


Page 6-8

Injectors - Cleaning and Inspection for


Reuse (6-01)
General Information
All engines use 17 mm closed nozzles, hole-type injectors.
However, the injectors can have different part numbers for
different engine ratings. The last four digits of the Vendor part
number are used to identify the injectors.

Use only the specified injector for the engine.

Injector - Disassembly
Clean the carbon residue from the injector nozzle. Use a brass
wire brush and a piece of hardwood dipped in test oil.

Remove the injector seal and discard.

fi9waw

15 mm
Clamp an injector hold down clamp in a soft jawed vise to hold
the injector and remove the injector nozzle retaining nut.

fl9numt

Injectors and Fuel Lines - Group 06

Injectors - Cleaning and Inspection for Reuse (6-01)


Page 6-9

Remove the nozzle needle valve and intermediate

plate.

NOTE: To avoid damage, place the injector


needle valve in a suitable bath of clean test oil.

nozzle

and

NOTE: Hold the needle valve by the stem only. Secretions


from the skin will corrode the finely lapped surfaces.

fi9OOv:

NOTE: The needle valve and nozzle tip are


matched for fit. The parts must not be intermixed.

Remove the nozzle holder from the vise; then


pressure spindle, pressure spring and shims.

precisely

remove

the

Injectors - Cleaning and Inspection for Reuse (6-01)


Page 810
l

Injectors and Fuel Lines - Group 06

Remove and discard the injector sealing sleeve.

fiSslmi

Injector - Cleaning and Inspection

Rinse the nozzle bodies and needle valves in solvent to


thoroughly flush and completely remove all varnish and carbon
deposits.

RI
\
q

Nozzle

Cleaning Kit, Part No. 3376947

Dip the nozzle seat in clean test oil and use the scraper to
clean. Polish the needle seat with the piece of hardwood
dipped in test oil.

Caution: Never use emery paper or any other metal scraper


to clean the nozzle. The parts can be damaged.

Nozzle

Cleaning

Kit, Part No. 3376947

Clean the interior ring groove of the nozzle with the scraper as
shown. Rinse in solvent to remove all dirt and carbon residue
and dip in clean test oil.

Injectors and Fuel Lines - Group 06

Clean the spray


cleaning needle.

holes as shown

with the appropriate

Injectors - Cleaning and Inspection for Reuse (601)


Page 6-l 1
size

Remove burned-on combustion deposits on all nozzles with a


commercially available cleaner. Rinse all parts in clean test
oil.

fi900ef

Clean the needle valve tip with a brass brush. Inspect for
rough surfaces
or erosion.
The pressure shoulder
will
normally have a rough machined appearance.
NOTE: Deteriorated needle valves must be replaced
matched unit with their compatible nozzle body.

as a

fi9vas

Dip the needle valve in clean test oil and insert the needle
valve all the way into the nozzle body.

Pull the needle valve one-third of the way out of the nozzle
body. Wiih the needle valve in the vertical position, the
needle valve must slide all the way back into the nozzle
body under its own weight.

If the nozzle
again.

fails the slide test, clean and test the nozzle

NOTE: Any needle valve and nozzle body assembly which


does not pass this test must be replaced.

0a3

Injectors and Fuel Lines - Grouo 06

Injectors - Cleaning and Inspection for Reuse (6-01)


Page 6-12

Injector - Assembly
NOTE: Make sure all mating surfaces and pressure faces are
thoroughly cleaned and lubricated with test oil before assembly.
New nozzles must be cleaned and lubricated before assembly.

Install the shims and pressure spring.

NOTE: Install the same thickness of shims that were


removed in disassembly. Use the pressure spring to make
sure the shims are installed flat.

fi9sph:

Install the spindle.

fi9OOa;

Install the intermediate

plate.

Injectors and Fuel Lines - Group 06

Injector - Spray Testing (6-02)


Page 6-13

Install the needle valve and nozzle assembly.

15 mm
Install the nozzle retaining

Torque Value:

nut.

30 Nom [22 ft-lb]

fignut

Injector - Spray Testing (6-02)

IQI

Part No. 3376946, Injector Nozzle Tester

Warning: Keep your body clear of test spray. Test fluid can be injected into the bloodstream causing blood
poisoning and possible death.
NOTE: All nozzles must
chatter and spray pattern.

be tested

for

opening

pressure,

1 I,

0
\

.lOO

-.,0

200.

300,.-

fi900d

Check the injector opening

pressure.

(A)

Open valve

(B)

Operate the lever at one stroke per second

(C)

;;;l_the

pressure

indicated

when

the injector

spray

Injectors and Fuel Lines - Group 06

Injector - Chatter Testing (6-03)


Page 6-14
If the opening

pressure does not meet specifications:

1.

Add shims to increase pressure.

2.

Remove shims to decrease

pressure.

fi9smva

Leakage Test:
1.

Open valve (A).

2.

Operate the lever (B) to maintain a pressure


[290 psi] below opening pressure (C).

3.

No drops should fall from the tip (D) within

of 20 bar

10 seconds.

Injector - Chatter Testing (6-03)


The chatter test
move freely and
should be heard
optimized spray

indicates the ability of the needle valve to


correctly atomize the fuel. An audible sound
as the valve rapidly opens and closes. A well
pattern should be seen.

Used nozzles should not be evaluated for chatter at lower


speeds. A used nozzle can generally be used if it passes the
leakage test.

Fuel Lines, High Pressure - Cleaning and


Inspection for Reuse (6-04)
General Information
The high pressure fuel lines are designed and manufactured to
deliver fuel at injection pressure to the injectors. The high
pressure pulses cause the lines to expand and contract during
the injection cycle.
NOTE: The high pressure fuel lines must be clamped
securely and routed so they do not contact each other or
any other component.

Injectors and Fuel Lines - Group 06

Fuel Lines, High Pressure - Cleaning and Inspection for Reuse (6-04)
Page 615

Caution: Do not weld or substitute lines; use only the


specified part number for the engine.
The length, internal size and rigidity of the lines is critical for
smooth engine operation. An attached metal tag is used to
identify each line with a part number.

Fuel Lines - Cleaning and Inspection


Wash the fuel lines in clean solvent and blow dry
compressed air. Make sure all paint chips are removed.

with

Visually inspect the high pressure fuel lines for obvious


damage such as lines that have bent to facilitate injector
removal. High pressure pulses expand and contract the
injector lines which result in internal flaking at the bent areas.
Bent lines should be replaced.

Visually inspect for cracks at both ends of the fuel lines.

q
\

04t3

Fuel Drain Manifold - Inspection (6-05)


Page 6-16

Injectors and Fuel Lines - Group 06


Inspect all fuel line fiiings (l), support bracket capscrews (2)
vibration isolator capscrews (3) and isolators (4) for wear and
damage. Any damaged parts must be replaced.

Fuel Drain Manifold - Inspection (6-05)


Inspect the fuel drain manifold for cracks or damage.

Inspect the fuel drain manifold

banjo connections.

NOTE: The banjo connection seals must be discarded


removed. The seals must not be used again.

when

Fuel Lines, Low Pressure - Cleaning and


Inspection for Reuse (6-06)
Wash the low pressure fuel lines in clean solvent. Blow dry with
compressed air.

Injectors and Fuel Lines - Group 06

Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse (6-06)
Page 6-17

Visually inspect the fuel lines and banjo connections


obvious damage such as cracks, bends or worn areas.

NOTE: The

sealing
washer
must
be discarded
removed. The washer must not be used again.

for
GB
0
when

Lubricating Oil System - Group 07


Page 7-l

Lubricating Oil System - Group 07


Section Contents
Page
7-13

Lubricating Oil Dipstick - Calibration ............................................

7-5
7-5

Lubricating Oil Pan - Cleaning and Inspection for Reuse ..............................


Cleaning ................................................................
Inspection ..............................................................

Lubricating Oil Pump - Cleaning and Inspection for Reuse

7-5

7-14

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

7-15
7-14
7-15

.............................................................
Cleaning..
Disassembly
............................................................
Inspection ..............................................................

74

Lubricating Oil System - Exploded View ..........................................

7-3

Lubricating Oil System - General Information ......................................

7-3
7-3
7-3
7-3
7-3
7-3
7-3

Dipstick ...............................................................
Lubricating Oil Cooler and Filter Head ...........................................
Lubricating Oil Pump ......................................................
Oil Filter Head ...........................................................
Oil Pan ...............................................................
Oil Pressure Regulator
.....................................................
Oil Temperature Thermostat ..................................................

Lubricating Oil System - Service Tools

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

7-12

Lubricating Oil Temperature Thermostat - Cleaning and Inspection .......................


Cleaning..
Inspection

7-12
7-12

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

7-10
7-11
7-10
7-10

Oil Cooler Cover - Disassembly and Assembly .....................................


Assembly ..............................................................
Cleaning ...............................................................
Disassembly
............................................................

Oil Cooler Element - Cleaning and Inspection for Reuse ..................

7-2

: ...........

7-6
7-6
7-6
7-6

.............................................................
Cleaning..
Inspection ..............................................................
Pressure Test ...........................................................

Oil Filter Bypass Valve - Replacement ...........................................

7-9

Oil Pressure Regulating Valve - Cleaning and Inspection ..............................

7-7

Assembly ..............................................................
.............................................................
Cleaning..
............................................................
Disassembly
.............................................
Inspection..

: ..............

7-8
7-8
7-7
7-8

Lubricating Oil System - Service Tools


Page 7-2

Lubricating Oil System - Grouo 07

Lubricating Oil System - Service Tools

The following special tools are recommended to perform procedures in Group 07. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool No.

Tool Description

Used to remove and install the lubricating

Tool Illustration

oil filters.

Measures spring force at a given spring height.

Used to open the full-flow

oil filter for filter element inspection.

Used to pressure test the lubricating

oil cooler element.

Lubricating Oil System - Group 07

Lubricating Oil System - General Information


Page 7-3

Lubricating Oil System - General Information


The lubricating oil system group consists of the oil pan, oil suction tube, oil dipstick and tube, oil filter head, oil cooler
element, oil temperature thermostat, oil pressure regulator and the lubricating oil pump.
Instructions for pressure testing the lubricating oil cooler element are included in this section. The oil cooler does not have
a replaceable element and cannot be rebuilt in the field.

Lubricating Oil Cooler and Filter Head


The oil cooler cover and filter head are combined into one casting. The oil pressure regulator, oil temperature
and filter bypass valve are also located in this housing.

thermostat

Oil Pressure Regulator


A pressure regulator valve is used to provide pressure relief during cold starting and to regulate oil pressure after the oil
is warm.

Oil Filter Head


The oil filter head is an integral part of the oil cooler housing cover and includes a filter bypass valve. The filter bypass
valve is designed to maintain oil flow to the engine if the oil filter becomes plugged.

Oil Temperature Thermostat


An oil temperature thermostat is located in the top of the oil cooler housing. The thermostat modulates oil flow at
temperatures between 100 and 115C [212 and 239F] and full flow through the oil cooler at oil temperatures above
115C [239F]. The thermostat also incorporates a pressure relief feature which allows oil to bypass the cooler should
it ever become plugged.

Lubricating Oil Pump


It is not practical to rebuild the gerotor type lubricating

oil pump. It can be reused if it meets the inspection

criteria.

Dipstick
A center-mounted dipstick location is used on either side of the cylinder block for all oil pans. Service replacement oil
dipsticks do not have the high and low oil level marks indicated on the dipstick. The dipstick must be calibrated after
the engine is installed in the chassis.

Oil Pan
There are two oil pan options available. One oil pan provides a center sump arrangement. The other oil pan can be used
to provide either a front or a rear sump with the use of the corresponding internal oil suction tube. Both oil pans have
the same capacity.

Lubricating Oil System - Group 07

Lubricating Oil System - Exploded View


Page 7-4

Lubricating Oil System - Exploded View

Ref. No.

Description

Gasket, Suction Tube

2
3
4
5
6
7

QtY

Description

Ref. No.

QtY

23

Plug,Pipe

Tube, Lube Oil Suction

24

Seal,O-Ring

Screw, Socket Head Cap

2
2

25

Element,Lube Oil Filter

26

Screw, Hex Flange Head Cap

11

Spacer, Mounting
Brace, Suction Tube

27

Gasket, Oil Cooler Element

Screw, Hex Head Cap

28

Element, Oil Cooler

Screw, Hex Head Cap

29

Gasket, Lube Oil Cooler Cvr.

Washer, Plain

30

Plunger, Pressure Regulator

Nut, Hex Flange

31

Dowel, Ring

10

Gasket, Oil Pan

32

Gasket, Filter Head

11

Pan, Oil

33

Valve, Bypass

12

Screw, Hex Head Cap

34

Screw, Hex Flange Head Cap

13

Washer, Spring

32
32

35

Head, Lube Oil Filter

14

Washer, Plain

32

36

Cover, Lube Oil Cooler

15

Washer, Sealing

37

Thermostat,

16

Plug,Threaded

38

Plug, Threaded

17

Plug, Threaded

39

Plug, Expansion

18

Washer, Sealing

40

Dipstick

19

Spring, Compression

41

Tube, Oil Gauge

20

Seal, O-Ring

42

Pump, Lubricating

21

Plug, Pipe

43

Screw, Hexagon

22

Plug,Pipe

Lube

Oil
Head Cap

1
4

Lubricating Oil System - Group 07

Lubricating Oil Pan - Cleaning and Inspection for Reuse (7-01)


Page 7-5

Lubricating Oil Pan - Cleaning and


Inspection for Reuse (7-01)
Cleaning
Remove all gasket
surface.

material from the oil pan gasket sealing

\
R

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Use steam to clean the oil pan and suction
compressed air.

tube. Dry with

op9tbea

Inspection
Visually inspect the oil pan for cracks or damage.

0ai9

Visually inspect the oil drain plug threads for damage.


Do not use a damaged

oil drain plug or oil pan.

Visually inspect the oil suction tube and brace for cracks. Do
not reuse a cracked oil suction tube or brace.

0ai!3

Lubricating Oil System - Group 07

Oil Cooler Element - Cleaning and Inspection for Reuse (7-02)


Page 7-6
-

Oil Cooler Element - Cleaning and


Inspection for Reuse (7-02)
Cleaning
Plug the cooler element and soak it in a cleaning
remove the coolant deposits.

solution

to

Remove the plugs and soak the cooler element in solvent.


NOTE: The cooler element can be cleaned in a hot tank.
If the oil passages are contaminated
cooler must be replaced.
I.

I.

Back flush
compressed

the oil passages


air to dry.

with

by foreign material, the oil


clean

solvent

and

use

lc9eteb

Inspection
Inspect the soldered joints for corrosion

or cracks.

Check the element for flatness.


Oil Cooler Element Distortion

in

mm
0.8

MAX

0.031

lc9etka

Pressure Test
Part No. 3823876 Lubricating Oil Cooler Pressure Test Kit
Install the oil cooler test fixture to the cooler element.
Connect a regulated air line and apply 483 kPa [70 psi] air
pressure to the element.

IcStoha

Lubricating Oil System - Group 07

Oil Pressure Regulating Valve - Cleaning and Inspe


ction (7-03)
Page 7-7

Install the oil cooler element in a tank of water.

Temperature:

82 [18OF]

If leaks are found in the oil cooler element. the


element must
be replaced.

0@3

Remove the oil cooler form the tank of water.


Remove the pressure test equipment.

Check for leaks.

Use compressed

air to dry the oil cooler.

Cover all of the openings with tape to preven


t
entering the element when it is not in use.

dirt from

Oil Pressure Regulating Valve - Cleaning


and Inspection (7-03)
Disassembly
22 mm
Remove the threaded

plug and o-ring seal.

Ic9pxmb

Remove the spring and pressure regulator

plunger.

Q
c%

lc9oqma

Lubricating Oil System - Group 07

Oil Pressure Regulating Valve - Cleaning and Inspection (7-03)


Page 7-8

Cleaning
Clean all parts in solvent and use compressed

air to dry.

Inspection

a3

inspect the plunger bore for nicks or scratches.

NOTE: The plunger must move freely in the bore.

lc9pgka

Check the spring tension and free length. Replace the spring
if the measurements do not meet the specifications.

Lubricating Oil Pressure Regulator Spring Specifications


Valve Open
Height:
Load:

53.98 mm [2.125 inches]


190 N [42.8 Ibfl

Assembled
Height:
Load:

60.33 mm [2.375 inches]


153 N [34.4 Ibfl

Assembly
22 mm
Install the pressure regulating

plunger and spring.

Install a new o-ring seal and plug.


Torque

Value:

80 Nom 159 ft-lb]

Oil Filter Bypass Valve - Replacement (7-04)


Page 7-9

Lubricating Oil System - Group 07

Oil Filter Bypass Valve - Replacement


(7-04)
10 mm
Remove the oil filter head and discard the gasket.

lcehdma

Remove the oil filter bypass valve form the cooler cover.

Drive the new oil filter bypass valve in until it is fully seated
against the step int the bore.

@@A
439

10 mm
lnstal the
capscrews.

oil

Torque Value:

filter

head

and

new

gasket.

Tighten

the

24 Nom [18 ft-lb]

Ic9hdma

Lubricating Oil System - GrouP 07

Oil Cooler Cover - Disassembly and Assembly (7-05)


Page 7-10

Oil Cooler Cover - Disassembly and


Assembly (7-05)
Disassembly
10 mm
Remove the oil filter head and discard the gasket.

lcehdma

32

mm

Remove the oil temperature


Refer to Procedure

7-06

thermostat

for cleaning

and discard the o-ring.


and inspection.

lc900ma

Remove the pipe plugs form locations

(l), (2), (3) and (4).

Cleaning

1c%
Q

Remove the oil pressure


Discard the o-ring seal.
Refer to Procedure

7-03

regulator

plug, spring

in this section.

Clean all parts with solvent. Dty with compressed

lc9bdec

and plunger.

air.

Lubricating Oil System - Group 07

Oil Cooler Cover - Disassembly and Assembly (7-05)


Page 7-11

Assembly
Install and tighten all pipe plugs.

Torque Value:
(1) 10 Nom [89 in-lb]
(2) 10 Nom [89 in-lb]
(3) 45 Nom [33 ft-lb]
(4) 36 Nom [27 in-lb]

32 mm
Lubricate the oil temperature thermostat
oil. Install and tighten the thermostat.

Torque Value:

o-ring with vegetable

50 Nom [37 ft-lb]

IcSetha

10 mm
Install the oil filter head and a new gasket.

Torque Value:

24 Nom [18 ft-lb]

lcshdma

Install the oil pressure regulator plug,


Refer to Procedure 7-03 in this section.

spring

and

plunger.

Lubricating Oil Temperature Thermostat - Cleaning and Inspection (7-06)


Page 7-12

Lubricating Oil System - Group 07

Lubricating Oil Temperature Thermostat Cleaning and Inspection (7-06)


Remove the oil temperature thermostat
cover. Refer to Procedure 7-05.

from the oil cooler

lc900ma

Cleaning
Clean the thermostat

with solvent. Dry with compressed

air.

Inspection
Visually inspect
damage.

for a broken

or damaged

spring

or other

lc9etkb

Caution: The flash point of new lubricating oil is


approximately 221 [43OFj. Do not allow oil temperature in
the container to exceed 150C [3OOPj. Do not allow water
droplets to enter the container of hot oil. Water droplets will
cause a violent reaction which can cause personal injury.

Lubricating Oil Dipstick - Calibration (7-07)


Page 7-13

Lubricating Oil System - Group 07

Suspend the thermostat and a 116C [24OF] thermometer in


a container
of new lubricating
oil. Do not allow the
thermostat or the thermometer to touch the side or bottom
of the container.

Heat the lubricating

oil.

ICSOOSb

NOTE: Wriie down the temperature at which the thermostat


is fully extended. The thermostat must be fully extended to
at least 45.9 mm [1.80 inch] when the temperature reaches
116C [24OF].
Replace the thermostat

0@

if it does not operate as described.

116C [24OF] for Part No. 1295 151 H92

45.9 mm
[1.80 in]

105C [22OF] for Part No. 1310 134 Hl

Lubricating Oil Dipstick - Calibration


(7-07)
Install the dipstick

in the dipstick

tube housing.

Use clean 15W-40 engine oil to fill the oil


specified low
oil level. Refer to Lubricating
Specifications for engine oil capacity.

pan to the
Oil System

Caution: The dipstick will break if the scribe mark is too


deep.
Remove the dipstick and scribe a mark across the dipstick
and mark the low oil level with an I.
NOTE: If a new blank dipstick is being used, cut the dipstick
off approximately
38 mm [1.5 inches] below the low oil
level mark.

A
@z

Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)


Page 7-14
Install the dipstick

Lubricating Oil System - Group 07

into the dipstick tube housing.

Fill the oil pan to the specified high


oil level. Refer to
Lubricating Oil System Specifications for engine oil capacity.

Caution: The dipstick will break if the scribe mark is too


deep.
Remove the dipstick and scribe a mark across the dipstick and
mark the high oil level with and H.

Lubricating Oil Pump - Cleaning and


Inspection for Reuse (7-08)
Disassembly
Visually inspect the lubricating
or excessive wear.

oil pump gears for chips, cracks,

NOTE: It is not practical to rebuild the pump. If any of the


internal parts are worn beyond the specifications, the pump
must be replaced.
1p9gesa

Remove the back plate.

lpeplma

Lubricating Oil System - Group 07

Mark top

Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)


Page 7-l 5

on the gerotor planetary.

1p9oogtl

Remove the gerotor planetary.

69
l

Inspect for excessive wear of scoring.

4B

lp900ma

Cleaning
Clean all parts in solvent and use compressed

air to dry.

Inspection
Inspect the pump housing
excessive wear.

and gerotor drive for damage and

0
@

Ip9hssa

Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)


Page 7-18

Lubricating Oil System - Group 07

Install the gerotor planetary.


Be sure the gerotor planetary is installed in the original
position.

Ip900he

Measure the tip clearance.

Lubricating Oil Pump Gerotor Tip Clearance


mm

in

0.025

MIN

0.001

0.1778

MAX

0.007

Measure the clearance of the gerotor drive/gerotor


port plate.

planetary to

Oil Pump Gerotor Drive/Gerotor Planetary to Port Plate


Clearance
mm

in

0.025

MIN

0.001

0.127

MAX

0.005

Measure the clearance


bore.

of the gerotor

planetary

to the body

Oil Pump Gerotor Planetary to Body Bore


mm

1p900nc

in

0.127

MIN

0.005

0.381

MAX

0.015

Lubricating Oil System - Group 07

Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)


Page 7-17

Measure the gear backlash.


Oil Pump Drive Gear Backlash (Used Pump)
mm

in

0.08

MIN

0.003

0.45

MAX

0.018

NOTE: Hold the idler gear from moving when checking


backlash or the reading will be the total of both gears.
I

lP900nd

Install the back plate.

lp9plha

Cooling System - Group 08


Page 8-1

Cooling System - Group 08


Section Contents
Page
Belt Tensioner Inspection ....................................................

8-10

Coolant Filter Shutoff Valve - Cleaning and Inspection for Reuse ........................

8-10
8-11
8-l 1
8-l 0

Assembly ..............................................................
Cleaning..
.............................................................
............................................................
Disassembly

Cooling System Components - Exploded View .....................................

8-3

Cooling System - General Information ...........................................

8-4
8-4
8-4
8-4
8-4
8-4
8-4

Belt Tensioner ...........................................................


Cooling Fans ...........................................................
Fan Hub
..............................................................
Pressure Caps ...........................................................
Thermostats
............................................................
Water Pump ............................................................

Cooling System - Service Tools

8-2

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

Fan - Cleaning and Inspection for Reuse ........................................


Fan Hub - Cleaning and Inspection for Reuse
Cleaning..
Inspection..

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

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

Fan Hub- Rebuild .........................................................

Cleaning..
Inspection

8-7
8-7
8-8
8-8
8-9
8-8

Assembly ..............................................................
............................................................
Disassembly

Thermostat Housing - Cleaning and Inspection for Reuse

8-12

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

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

8-6
8-6
8-6

Thermostat - Inspection .....................................................

8-6

Water Outlet Connection - Cleaning and Inspection for Reuse ..........................

8-7

Water Pump Assembly - Cleaning and Inspection for Reuse

85
86
8-6

Cleaning..
Inspection

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

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

Cooling System - Grouta 08

Cooling System - Service Tools


Page 8-2

Cooling System - Service Tools

The following special tools are recommended to perform procedures in Group 08. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Use with Magnetic Base, Part No. 3377399, to measure the fan
hub and clearance.

Used with Part No. 3378050, Dial Indicator

and Sleeve

Cooling System Components - Exploded View


Page 8-3

Cooling System - Group 08

Cooling System Components - Exploded View

Description

Ref. No.

QtY

Ref. No.

Description

QtY

Pump, Water

21

Elbow, Male Adapter

Body, Water Pump

22

Plug, Pipe

Bearing, Water Pump

23

Draincock

Seal, Water Pump

24

Tube, Vent

Impeller

25

Support,

Pulley, Water Pump

26

Bearing, Shaft

Fan

O-ring

27

Hub, Fan

Screw, Hex Head Cap

28

Retainer, Fan Hub

Thermostat,

29

Screw, Hex Head Cap

1
4

Coolant

10

Gasket, Thermostat

30

Screw, Hex Head Cap

11

Housing, Thermostat

31

Pulley, Fan

1
1

Housing

12

Screw, Hex Head Cap

32

Plate, Clamping

13

Connection,

33

Screw, Cap

14

Gasket, Connection

34

Screw, Cap

Screw, Hex Head Cap

35

Bracket, Belt Tensioner

16

Seal, O-ring

36

Screw, Flat Head Cap

17

Shaft, Shutoff Valve

37

Tensioner,

15

Water Outlet

Belt

18

Screw, Hex Head Cap

38

Screw, Hex Head Cap

19

Adapter,

39

Belt, V-ribbed

20

Filter. Coolant

Filter Head

Cooling System - General Information


Page 8-4

Cooling

System - Group 08

Cooling System - General Information


Water Pump
The water pump is a belt driven, centrifugal
block.

type pump with the inlet and bypass line as an integral part of the cylinder

The coolant pressure can be measured from the vent petcock. At normal operating temperature (thermostats open) and
at 2,000 RPM the minimum pressure should be: 124 kPa [18 psi] with a 103 kPa [15 psi] pressure cap or 69 kPa [lo
psi] with a 46 kPa [7 psi] pressure cap. It is not practical to replace the parts in the pump, the water pump is serviced
as an assembly. Remanufactured water pumps are available from your Komatsu Distributors and Dealers.

Thermostats
The thermostat

housing

contains two identical thermostats.

Caution: Never operate the engine without the thermostats. The path of least resistance for the coolant
without thermostats is through the bypass to the water pump inlet. This will cause the engine to overheat.

Pressure Caps
The cooling system is designed to use a pressure cap to prevent boiling of the coolant. Different caps are specified for
the two recommended systems. The 104C [22OF] system requires a 103 kPa [15 psi] cap. The 99C [21OF] system
requires a 46 kPa [7 psi] cap.

Fan Hub
The fan hub is available in various drive ratios and fan center locations.

Belt Tensioner
The fan belt is tensioned
To prevent accidents,

by the spring loaded idler assembly and does not require adjustment.

always release the spring tension before replacing

the fan belt.

Cooling Fans
Check the fan for missing balance weights at each regular maintenance
fans, or fans with missing balance weights.

interval. Do not attempt to repair broken or bent

Most Komatsu powered equipment use a radiator and fan. The radiator and fan transfer heat from the coolant to the
atmosphere. The fan selection process must conclude that the fan, fan mounting arrangement, and fan drive system are
designed and matched for compatibility.
Upon request, Komatsu Application Engineering will assist in determining the proper selection. Refer any fan changes,
other than the direct replacement of a fan with precisely the same Komatsu part number, to the Komatsu Application
Engineering for prior approval.
Examples that require approval
1.
2.
3.
4.
5.

are:

Using an approved fan from one engine model on a different engine model.
Using an approved fan on an engine with a different fan mounting arrangement.
Using an approved fan on an engine with a different fan drive arrangement.
Converting an engine from on market model to another, an example is conversion of a Gdrive engine to a power
unit application.
Converting an engine model to a different model, an example is converting a 6D114E-1 to a S6D114E-1.

This list is not all inclusive.

Always contact Application

Engineering

for assistance.

At times, an existing fan can yield ONLY marginal cooling when being considered

for a new application.

Cooling System - Group 08

Cooling System - General Information


Page 8401

Caution: Never repitch (bend) the blades to obtain additional air delivery. Bending the blades or spider
creates stress in the material used for the construction of the fan. Repitching (bending) will cause fan
failure. The proper diameter fan must be selected. Never modify an existing fan.

Application Engineering will provide assistance in the selection of a fan with the correct pitch and diameter for proper
cooling.

Water Pump Assembly - Cleaning and Inspection for Reuse (8-01)


Page 8-5

Coolina System - Group 08

Water Pump Assembly - Cleaning and


Inspection for Reuse (8-01)
Cleaning
The water pump seal design requires a coolant film for
lubrication and cooling. Therefore, it is normal to observe a
minor chemical buildup or streaking at the weep hole. Before
cleaning the water pump: inspect the weep hole for large
amounts of chemical buildup. Replace the pump if large
amounts of chemical buildup is observed.

0
@

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Use solvent or steam to clean the water pump exterior.


with compressed air.

\
IJ

Dry

Inspection
Visually inspect the water pump body for cracks or damage.
Visually inspect the impeller for cracks, erosion, or damage.
Visually inspect the pulley for damage or wear.

Rotate the water pump shaft by hand to inspect the bearings


and the impeller for freedom of rotation.

NOTE: If damaged parts are found or the shaft does not


rotate freely in the water pump body, the water pump must
be replaced.
NOTE: Parts replacement
serviced as an assembly.

is not practical:

the water pump is

0a9

04B

Thermostat Housing - Cleaning and Inspection for Reuse (8-02)


Page 8-6

Cooling System - Group 08

Thermostat Housing - Cleaning and


Inspection for Reuse (8-02)
Cleaning
Use a gasket scraper to remove the gasket material from the
mating surfaces of the housing.

th9hsea

\
A

049

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use solvent or steam to clean the parts.
Dry with compressed air.

Inspection
Visually inspect the thermostat housing for cracks, corrosion,
or damage. Replace the thermostat housing if damaged.

th9hssa

Thermostat - Inspection (8-03)

OK

6B
0

Visually inspect the thermostats for damage.


Make sure both thermostats are clean and free from corrosion.

Cooling System - Group 08

Water Outlet Connection - Cleaning and Inspection for Reuse (&CM)


Page 8-7

Suspend the thermostats and a 100C [212 F] thermometer


in a container of well mixed water.

NOTE: Do not allow


touch the container.

the

thermostats

or thermometer

to

Heat the water slowly so the wax element in the thermostats


has sufficient time to react to the rising water temperature.
Check the thermostats as follows:

NOTE: The nominal


thermostat.

operating

temperature

Thermostat must begin


82C [18OF].

Thermostat must be fully


95 C [203 F] .

is stamped on the

to open within
open

within

1C

[2F]

of

1C

[2F]

of

0ai3

CB

NOTE: The fully open clearance between the thermostat flow


valve and flange must be 41.5 mm [1.63 inches] minimum.

Water Outlet Connection - Cleaning and


Inspection for Reuse (8-04)
Straight Edge
Use a gasket scraper to remove the gasket material from the
flange.
Clean with solvent. Dry with compressed
Check the water outlet connection
Visually inspect for corrosion,

RI

air.

for flatness.

0ai?

cracks or damage.

Fan Hub - Cleaning and Inspection for


Reuse (8-05)
Cleaning
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Use solvent or steam to clean the fan hub exterior.


compressed air.

B
R

Dry with

Fan Hub - Rebuild (8-06)


Page 8-8

Cooling System - Group 08

Inspection
Visually inspect the fan hub for indication

of oil seal leakage.

Visually inspect the fan hub for cracks or damage.

Turn the fan hub shaft by hand to check for freedom


rotation. The fan hub must spin freely without any wobble
excessive end clearance.

of
or

fa900sb

Measure the fan hub shaft end clearance.

Fan Hub Shaft End Clearance


mm
0.15

in
MAX

0.006

If damaged parts are found, the shaft does not rotate freely or
the shaft end clearance is not within the specifications, the fan
hub must be rebuilt or replaced.

Fan Hub - Rebuild (8-06)


Disassembly
16

mm

Secure the fan hub and remove the center bolt and retainer.

Cooling System - Group 08

Fan Hub - Rebuild (8-06)


Page 8-9

Install a bearing splitter as illustrated.


NOTE: Do not over-tighten the bearing splitter as it may RI
damage the shaft when the bearing is pressed out.
0
C%

3/4 inch Drift


Support the fan hub housing/splitter

and press out the shaft.

RI

2 inch Pipe
Support the fan hub housing and press out the bearing.

fa9bema

Assembly
Caution: Do not press on the inside diameter of the
bearing. The bearing could be damaged.

Press the new bearing into the fan hub housing even with
the front of the housing.
Fan Hub Bearing Installation Force
N
9000

Ibf
MIN

2023

Replace the fan hub housing if the installation force is less


than specified.

fa9beha

Cooling System - Group 08

lelt Tensioner Inspection (8-07)


age &lO

l-1/2 inch Pipe (inside diameter)


Caution: Make sure the inner race is adequately supported
to avoid damage to the bearing. Do not press on the fan
hub.
Support the bottom
until it is seated.

2lL

of the inner race and press the shaft in

Check the assembled height. if the assembled height


incorrect, disassemble and assemble with a new bearing.

is

Fan Hub Assembled Height


fa9shha

mm

in.

124.85

MIN

4.915

125.65

MAX

4.943

18 mm
Secure the fan hub assembly
retainer.

and install the center bolt and

Torque Value: 77 N*m 157 ft-lb]

Belt Tensioner Inspection (8-07)


Rotate the pulley to check for freedom of rotation
there are no rough spots on the bearing.
Check for a broken spring or damaged

locating

and that

tang.

NOTE: It is not practical to rebuild the belt tensioner,


damaged, the complete assembly must be replaced.

if

Coolant Filter Shutoff Valve - Cleaning


and Inspection for Reuse (8-08)
Disassembly
Remove the retaining capscrew (1) from the thermostat
(2) and remove the shutoff valve (3).
Remove and discard the o-ring (4).

th9boha

housing

Cocrlina Svstem - Group 08

Coolant Fitter Shutoff Valve - Cleaning and Inspection

for Reuse (8-08)


Page 8-l 1

Cleaning
Use solvent to clean the parts. Dry with compressed

air.
\
La

Visually inspect the water passages in the shutoff valve shaft.


Visually inspect the shaft for corrosion or pitting. Use 24.0 grii
aluminum oxide paper to remove the corrosion.

06B

If the parts are cracked or damaged, the filter head assembly


must be replaced.

th9vasa

Assembly
Install a new o-ring in the groove of the shaft.

th9orh.s

Use clean 15W-40 engine oil to lubricate the shaft and o-ring.

Belt Tensioner Inspection (8-07)


Page 8-12

Cooling System - Group 08

RI
0%

Install the shutoff valve shaft (3) in the thermostat housing (2).
Install the retaining capscrew (1) in the thermostat housing.
Tighten the capscrew.
Torque Value: 7 Nom [60 in-lb]

Fan - Cleaning and Inspection for Reuse


(8-09)
Cleaning
A

q
B

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use solvent or steam to clean the fan. Dry with compressed
air.

Inspection
A

a3

Warning: A bent or damaged fan blade can fail during


operation and cause serious personal injury or property
damage.
Visually inspect the fan for cracks, loose rivets and bent or
loose blades.

Warning: Do not straighten a bent fan blade or continue to


use a damaged fan. Replace the original equipment fan with
a fan of the identical part number. Komatsu must approve
any other fan changes.
Refer to page 8-4 for additional
installation and replacement.

information

about fan

Drive Units - Group 09


Page 9-l

Drive Units - Group 09


Section Contents
Page
Accessory Drive Adapter - Cleaning and Inspection for Reuse ..........................
Cleaning..
Inspection

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

46
4-5
4-5

Accessory Drive Adapter - Exploded View ........................................

4-3

Accessory Drive Adapter - Rebuild

.............................................
Assembly ..............................................................
Disassembly
............................................................

4-5

Accessory Drive - General Information ...........................................

4-4
4-4

Accessory

Drive Adapter

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

Drive Units - Service Tools ...................................................

1:

4-2

Drive Units - Group 09

Drive Units - Service Tools


Page 9-2

Drive Units - Service Tools

The following special tools are recommended to perform procedures in Group 09. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool
No.
__ _ _ _
__

Tool Descrbtion
Standard Puller
Used to remove drive gears.

ST-647

Tool Illustration

Accessory Drive Adapter - Exploded View

Drive Units - Group 09

Page 9-3

Accessory Drive Adapter - Exploded View

Part Name

Ref. No.
1

Adapter, Accessory

Drive

Bearing
Shaft, Accessory

Drive

Gear, Accessory

Drive

Gasket, PTO Drive Cover


Screw, Hex Head Cap
Gasket, PTO Drive Cover
Plate, PTO Drive Cover
Screw, Hex Head Cap

QtY.

Accessory Drive - General Information


Page 9-4

Drive Units - Group 09

Accessory Drive - General Information


Accessory Drive Adapter
The accessory drive is gear driven from the camshaft gear in the front gear train. The accessory drive is capable of driving
up to a maximum of 105 ft-lb of torque. The accessory drive is equipped with either SAE A or B flange adapters.
A cover plate is used for engines not equipped

with an air compressor

or hydraulic

pump.

Drive Units - Group 09

Accessory Drive Adapter - Cleaning and Inspection for Reuse (9-m)


Page 9-5

Accessory Drive Adapter - Cleaning and


Inspection for Reuse (9-01)
Cleaning
Clean the accessory drive adapter
blow dry with compressed air.

with

clean

solvent

and

ad900ea

Inspection
Visually inspect for obvious damage
teeth and damaged threads.

Rotate the gear and inspect


and excessive wear.

such as cracks,

broken

for rough spots in the bearing

0@3

0a3

ad900Sb

Accessory Drive Adapter - Rebuild (9-02)


Disassembly
ST-647 T Bar Puller
Remove the drive gear.

ad9OOfa

Drive Units - Grow 09

Accessory Drive Adapter - Rebuild (9-02)


Page 9-6
NOTE: The shaft/bearing
direction.

assembly will only press out in one

Press the shaft and bearing assembly

out as illustrated.

Press the shaft out of the bearing and discard the bearing.
The bearing must not be used again.

II

ad900fc

Assembly
1 l/2

inch ID Pipe Coupling

Support the inner race of the new bearing and press the shaft
into the bearing until the shaft seats on the inner race.

ad900aa

2 inch ID Pipe
Caution: To prevent damage to the bearing, do not press
on the inner race, only press on the outer race of the
bearing assembly.
Support the housing and press the bearing and shaft assembly
in until it is seated.

Drive llnits - Group 09

Accessory Drive Adapter - Cleaning and Inspection for Reuse (9-01)


Page 9-7

Position the gear with the lip facing down.

Q&
Qf@

--._-

900x

1 l/4 inch Pipe Coupling


Support the bottom of the shaft with a 1 l/4 inch pipe
coupling and press the gear on until it seats against the
inner-bearing race.

ad9OOad.

Air Intake System - Group 10


Page 10-l

Air Intake System - Group 10


Section Contents
Page
Aftercooler Assembly - Cleaning and Inspection for Reuse ............................
Inspection ...........................................................

lo-9
1O-l0

Aftercooler Assembly - Rebuild ..............................................

lo-10

Air Crossover Tube - Cleaning and Inspection for Reuse ............................


Cleaning ............................................................

lo-11
1O-l1
lo-11

Inspection...........................................................

Air Intake System - Exploded View ...........................................

10-3-01

Air Intake System - General Information .........................................


Inspection ............................................................

10-4
1O-5

Air Intake System - Service Tools

10-2

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

Air Transfer Pipe - Cleaning and Inspection for Reuse ..............................


Cleaning.. ..........................................................
Inspection...........................................................

10-l1
lo-11
lo-11

Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse

lo-12
lo-12
lo-12

Charge Air Cooler (CAC) - Pressure Testing .....................................

lo-13

........................
Cleaning.. ..........................................................
Inspection...........................................................

Intake Manifold Cover - Cleaning and Inspection for Reuse ...........................

lo-9
10-9

Turbocharger - Cleaning and Inspection for Reuse .................................

10-5
10-5

Inspection............................................................

Inspection............................................................

Air Intake System - Service Tools


Page 10-2

Air Intake System - Group 10

Air Intake System - Service Tools

The following special tools are recommended to perform procedures in Group 10. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool No.

Tool Description

Tool Illustration

Dial Depth Gauge


Measure the turbocharger

axial motion.

ST-537

Pressure Test Kit


Used to test the turbocharger
3823799

wastegate

actuator.

Air Intake System - Exploded View


Page 10-3-01

Air Intake System - Exploded View

Air Intake System - Group 10

Air Intake System - Exploded View


Page 10-3-02

Air Intake System - Group 10

Ref. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Description
Turbocharger
Gasket, Turbocharger
Stud
Nut, Regular Hex
Screw, Hex Head
Connector, Adapter
Screw, Flange Head
Washer, Plain
Clamp, V Band
Nut, Hex
Brace, Actuator
Nut, Lock
Actuator, Turbocharger
Bracket, Actuator
Screw, Hex Head
Washer, Plain
Nut, Hex Jam
Ring, Retaining
End, Adjusting Link
Connection, Air Intake
Screw, Hex Flange Head
Gasket, Connection
Screw, Hex Head
Cover, Intake Manifold
Gasket, Intake Mfd. Cover
Lock Plate
Manifold, Exhaust
Gasket, Exhaust Manifold
Screw, Hex Head Cap

QtY

Ref. No.

1
1
4
4
5
1
3
3
1
1
1
1
1
1
3
3
1
1
1
1
4
1
12
1
1
12
1
6
12

30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

Description
Gasket, Aftercooler
Aftercooler
Screw, Hex Head Cap
Hose, Plain
Clamp, Hose
Hose, Flexible
Connection, Female
Gasket, Turbo. Oil Drain
Tube, Turbo. Oil Drain
Screw, Hex Head Cap
Hose, Plain
Clamp, Hose
Tube, Turbo. Oil Drain
Elbow, Hose Adapter
Seal, O-Ring
Plate, Clamping
Screw, Hex Head Cap
Tube, Water Inlet
Tube, Water Outlet
Hose, Plain
Clamp, Hose
Flame and Plug, Start
Tube, Fuel
Tee
Solenoid, Fuel
Bracket
Screw, Hex Head Cap
Screw, Hex Head Cap
Hose, Fuel

QtY
1
1
18
1
2
1
1
1
1
2
1
2
1
2
2
1
1
1
1
4
8
2
2
1
1
1
3
2.
2

Air Intake System - Group 10

Air Intake System - General Information


Page 10-4

Air Intake System - General Information


The Air Intake System Group for charge air cooled engines consists of the intake manifold, charged air cooler and
associated hardware and turbocharger. On engine coolant aftercooled engines, consists of the aftercooler assembly,
aftercooler coolant tubes and the turbocharger.
The charge air cooler uses ambient air with the aid of the cooling fan to cool the intake air between the turbocharger
and the intake manifold during engine operation. Refer to the original equipment manufacturer for information on the
maintenance procedures for the charge air cooler.
On engine coolant aftercooled engines, the aftercooler utilizes engine coolant to cool the air between the turbocharger
and combustion chambers during engine operation. The aftercooler also performs as a starting aid by warming the intake
air, if the engine is equipped with an engine coolant heater.
Refer to the Hl Series Turbocharger Shop Manual, Bulletin No. 3810321 for rebuilding the turbocharger.
The turbocharger uses exhaust gas energy to turn the turbine
wheel. The turbine wheel drives the compressor impeller which
provides compressed air to the engine for combustion. The
additional air provided by the turbocharger allows for a more
complete combustion. Therefore, more fuel can be injected to
increase the power output from the engine.
NOTE: The correct turbocharger must be used. Providing too
much additional air will increase the cylinder pressures and
shorten the life of the engine.

The turbine and compressor wheels and the shaft are


supported by two rotating bearings in the bearing housing.
Passages in the bearing housing direct filtered, engine oil under
pressure to the shaft bearings and thrust bearings. The oil is
used to lubricate and cool the rotating components to provide
for smooth operation. The oil then drains from the bearing
housing to the engine sump through the oil drain tube.
NOTE: An adequate supply of good, filtered oil is very
important to the life of the turbocharger.

As the intake air is compressed by the turbocharger, the air is


heated. This heated air is then passed through the charge air
cooler which cools the air. Because cool air is more dense
than warm air, more air is compressed
into
yielding a much greater combustion efficiency.

the

cylinder,

Air Intake System - Group 10

Turbocharger - Cleaning and Inspection for Reuse (10-01)


Page 10-5

Turbocharger - Cleaning and Inspection


for Reuse (10-01)
Remove all carbon
deposits
surfaces (1) (2) and (3).

and

gasket

material

from

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Caution: Tape or plug all openings to prevent solvent or
steam from damaging the oil cavities in the turbocharger.
Use solvent
turbocharger.

or steam to clean the


Dry with compressed air.

exterior

of

the

Inspection
Visually inspect the housings

for damage.

Visually inspect the turbine wheel and compressor


(1) for fretting, cracked or broken vanes.

A
A

impeller

0a3

Turn the impeller in the direction shown with arrow (2) to


inspect the turbine shaft for freedom of rotation. The shaft
must rotate freely.
Replace damaged

parts.

Visually inspect the mounting


Cracks on the mounting
are not acceptable.

flange.

flange longer than 15 mm [OX inch]

Cracks must not reach the mounting

holes.

0@B

0GE@

tb900sb

Turbocharger - Cleaning and Inspection for Reuse (10-01)


Page 10-6

Air Intake System - Group 10

Two cracks must be separated by a minimum of 6.4 mm [0.25


inch].

0ai3

Visually inspect the wastegate actuator


cracks or bends. Replace if damaged.

Visually inspect the bracket mounting


damage.

mounting

bracket for

surface for cracks and

Visually inspect the wastegate valve assembly lever


Replace the turbine housing if it is worn excessively.

pin.

Actuate the wastegate assembly lever by hand to be sure that


the shaft rotates freely and is not seized.
Check for excessive
and bushing.

movement

between

the wastegate

shaft

Replace the turbine housing if the wastegate shaft and the


turbine housing bushing are damaged or seized.

Air Intake System - Group 10

Turbocharger - Cleaning and inspection for Reuse (10-01)


Page 10-7

Visually inspect the actuator air supply


or heat damage. Replace if damaged.

hose for cuts, cracks

Visually inspect the wastegate actuator


other damage. Replace if damaged.

for cracks, dents and

0a3

a9

0
OK

Part No. 3823799, Pressure Test Kit


Check the wastegate actuator by connecting
a regulated
shop air supply line to the actuator hose connection. Apply
103 kPa [15 psi] air pressure to the wastegate actuator and
listen for leaks. If any leaks are heard, the actuator must be
replaced.

Visually inspect the wastegate actuator rod for bends, cracks,


stripped threads and wear. Replace if damaged.

0et3

SM0075

Air Intake System - Group 10

Turbocharger - Cleaning and Inspection for Reuse (10-01)


Page 10-8

Part No. ST-537, Dial Depth Gauge


Measure the turbocharger

shaft end clearance.

Push the rotor assembly away from the gauge.


Set the gauge on zero.

Push the rotor assembly toward the gauge and record the
data.
For turbochargers

with serial number before 840638:

Turbocharger Shaft End Clearance


in.

mm
0.10

MIN

0.004

0.16

MAX

0.006

For turbochargers
840638:

with serial number after and including

Turbocharger Shaft End Clearance

0@3

mm

in.

0.03

0.001

0.08

0.003

Push the compressor


compressor housing.

impeller

by

hand

toward

the

Insert a wire feeler gauge, at the minimum clearance point,


between the impeller and the housing to measure the
clearance.
Record this clearance.

Intake Manifold Cover - Cleaning and Inspection for Reuse (10-02)

With the feeler gauge in the same location, push the turbine
wheel by hand away from the compressor housing.
Insert a wire feeler gauge, at the same point.

Air Intake System - Group 10


Page 10-9

06B

Record this clearance.


Subtract the smaller from the larger clearance.
Turbine Wheel Radial Clearance
mm
0.21
0.46

in.
[0.008]
[0.018]

MIN
MAX

If the radial clearance does not meet the above


specifications, the turbocharger must be rebuilt. Refer to the e
Hl Series Turbocharger Shop Manual, Bulletin No. 3810321.

lb2006

Intake Manifold Cover - Cleaning and


Inspection for Reuse (10-02)
Remove the air intake connection.
Remove all gasket material.

C%Q

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Use solvent or
compressed air.

steam

to

clean

the

parts.

Dry

with

q
\

im9cvea

Inspection
Visually inspect the intake manifold cover and intake
connection for cracks or damage. Replace damaged parts.

@J

im9cvsa

Aftercooler Assembly - Cleaning and


Inspection for Reuse (10-03)
Remove all gasket material from the mounting surfaces.
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Use solvent or steam to clean the aftercooler assembly. Dry
with compressed air.

q
\

q
B

Air Intake System - Group 10

Aftercooler Assembly - Rebuild (10-04)


Page lo-10

Inspection
Visually inspect the aftercooler
Replace if damaged.

assembly for cracks or damage.

Pressure Test the Aftercooler Core


Install the hose, hose clamps, and solid pipe plug (1) onto the
inlet tube.
Install the hose and hose clamps (2), and air pressure gauge
(3) onto the outlet tube.
Connect the air pressure gauge to a regulated

air supply.

Air Pressure: 552 kPa [50 psi]


Submerge the aftercooler

in a tank of water.

If air bubbles appear, the core is damaged


must be replaced.

c%
4

Remove the aftercooler

and the aftercooler

from the water tank.

Remove the test equipment.


Use compressed

air and dry the aftercooler.

Aftercooler Assembly - Rebuild (10-04)

Caution: The aftercooler is a unitized assembly and cannot


be rebuilt. Any attempt to repair the aftercooler core will
reduce the coolant flow and cause future engine damage.
Refer to Aftercooler
Reuse (1O-03).

at9OOkb

Assembly

- Cleaning

and Inspection

for

Air Intake System - Group 10

Air Crossover Tube - Cleaning and Inspection for Reuse (10-06)


Page 10-l 1

Air Transfer Pipe - Cleaning and


Inspection for Reuse (10-05)
Cleaning
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Use solvent or steam to clean the air transfer pipe. Dry with \
u
compressed air.

Inspection
Visually inspect the turbocharger compressor V-band outlet
and the air transfer pipe connection for dents or fretting.

0,
@

Replace the turbocharger compressor housing or air transfer


pipe, if damaged.

Air Crossover Tube - Cleaning and


Inspection for Reuse (10-06)
Cleaning
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Use solvent or steam to clean the air crossover tube. Dry
with compressed air.

q
B

Inspection
Visually inspect the air crossover tube for cracks or damage.
Visually inspect the hose sealing surfaces for pitting or
damage. Replace damaged parts.

0
@

ca9tbsa

Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse (10-07)
Page 10-12

Air Intake System - Group 10

Air Cooler (CAC) - Cleaning and


Inspection for Reuse (10-07)

Charge

Cleaning
If the engine experiences a turbocharger failure or any other
occasion where oil or debris is put into the CAC, the CAC
must be cleaned.
Remove the CAC from the vehicle. Refer to the vehicle
manufacturer for instructions.
SMLw76

Caution: do not use caustic cleaners to clean the CAC.


Damage to the CAC will result.
NOTE: Make sure that the tubes are in the vertical direction
when flushing.
Flush the CAC internally with solvent in the opposite direction
of normal air flow. Shake the CAC and lightly tap on the end
tanks with a rubber mallet to dislodge trapped debris. Continue
flushing until all debris or oil is removed.
NOTE: If internal debris can not be removed, scrap the CAC.
Use a flashlight and mirror to visually inspect the CAC for
internal debris.

After the CAC has been thoroughly cleaned of all oil and debris
with solvent, wash the CAC internally with hot soapy water to
remove the remaining solvent. Rinse thoroughly with clean
water.
Blow compressed air into the CAC in the opposite direction of
normal air flow until the CAC is dry internally.
Caution: the CAC must be rinsed, dried, and free of solvent,
oil and debris or engine damage will result.

Inspection
Visually inspect the CAC for cracks, holes or damage.
Inspect the tubes, fins and welds for tears, breaks or other
damage. If any damage causes the CAC to fail the air leak
check mentioned in Procedure (lo-08), the CAC must be
replaced.
Install the CAC on the vehicle.
manufacturer for instructions.

Refer to

the

vehicle

Air Intake System - Group 10

Charge Air Cooler (CAC) - Pressure Testing (10-08)


Page lo-13

Charge Air Cooler (CAC) - Pressure


Testing (10-08)
_
_

/D*

To check the charge air cooler for cracked tubes or header,


remove the inlet and outlet hoses from the CAC.
Remove the charge
air cooler.
manufacturer for instructions.

Refer to

the

vehicle

W
e

Install a cap over the outlet side of the CAC. Install a


pressure gauge, arr supply, and arr pressure regulator to the
inlet side of the cooler.

@@A
d,-

Warning: To prevent possible injury if either plug blows


off during test, secure safety chains on the test plugs to
any convenient capscrew on the radiator assembly. This
test must be performed with securely fastened safety
chains.

Apply 207 kPa [30 psi] of air pressure


the air pressure regulator.
Monitor the pressure gauge and
pressure decay with a stop watch.

to the cooler.

determine

the

Close
rate

of

If the pressure decay is 49 kPa [7 psi] or less in 15 seconds,


the cooler is okey. If the pressure drop is greater than 49
kPa [7 psi] in 15 seconds, check all connections again.
Determine if pressure decay is caused by a leak in the CAC
or from a leaky connection.
Use a spray bottle filled with
soapy water applied to all hose connections, and watch for
bubbles to appear at the location of the leak.

If the pressure decay is caused by a leaky connection, repair


the connection and repeat the test. If the leak is within the
CAC, repeat the test to verify the accuracy of the pressure
delay measurement. Similar pressure decay readings must
be obtained at least three consecutive
tests before the
reading can be considered accurate.

0a9

Charge Air Cooler (CAC) - Pressure Testing (10-08)


Page lo-14

Air Intake System - Group 10


If the pressure drop is greater than
seconds, the CAC must be replaced.
Refer to the manufacturers
instructions.

repair

49 kPa [7 psi]

manual

in 15

for replacement

NOTE: Charge air coolers are not designed to be 100% leak


free. If the pressure decay is less than 49 kPa [7 psi] in 15
seconds, than the CAC does not need to be replaced.

Exhaust System - Group 11


Page 11-1

Exhaust System - Group 11


Section Contents
Page
Exhaust Manifold - Cleaning and Inspection for Reuse ..............................
Cleaning . . . . . .........................................................
Inspection . . . . .........................................................

11-4
11-4
11-4

Exhaust Manifold - Exploded View .............................................

11-2

Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse .................

11-6

Cleaning . . . . . .........................................................
Inspection . . . . .........................................................

Exhaust Manifold Turbocharger Mounting Stud - Replacement .........................


Inspection . . . . .........................................................
Installation . . . .........................................................
Removal . . . . . .........................................................

Exhaust System - General Information ..........................................


Exhaust Manifold ........................................................

11-6
11-6
11-5
11-5
11-5
11-5
113
113

Exhaust Manifold - Exploded View

Exhaust System - Group 11

Page 11-2

Exhaust Manifold - Exploded View

Ref. No.

Part Name

QtY

Brace, Exhaust Outlet Connection

Screw, Hex Head Cap

Connection,

Clamp, V Band

Pipe, Plug

Gasket, Turbocharger

Stud

Nut

Manifold,

Exhaust Outlet

4
Exhaust

10

Screw, Hex Head Cap

11

Gasket, Manifold

12

Lockplate

1
12
6
12

Exhaust System - General Information


Page 11-3

Exhaust System - Group 11

Exhaust System - General Information


The exhaust system group consists of the exhaust manifold, turbocharger

mounting

studs, and exhaust outlet connection.

Any repairs relating to the exhaust pipe or muffler should be directed to the original equipment

manufacturer.

Exhaust Manifold
The engine uses a pulse-type
exhaust manifold with a divided turbocharger
The naturally aspirated engine uses the same manifold for parts commonality.

entry passage (exhaust manifold

outlet).

Exhaust System - Group 11

Exhaust Manifold - Cleaning and Inspection for Reuse (11-01)


age 11-4

Exhaust Manifold - Cleaning and


Inspection for Reuse (1 I-01)
Cleaning
Use a wire brush or 240 grit emery cloth to remove the carbon
from the gasket sealing surfaces.

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.

B
LJ

Use steam to clean the manifold.

Dry with compressed

air.

xm9OOeb

Ia3

Inspection
Visually inspect the manifold for cracks or damage.
Visually inspect the turbocharger
damaged threads.
Replace the manifold,

mounting

stud

holes

for

if damaged.

6iB
0

Place a straight edge across the exhaust


Inspect the mounting

surfaces for flatness.

If these surfaces are not within


replace the manifold.

CB

ports.

the flatness

specifications,

Exhaust Manifold Mounting Surface Flatness


in.
mm
0.20

MAX

0.008

Turbocharger Mounting Flange Flatness


mm
in.
0.13
MAX
0.005

Exhaust Svstem - Group 11

Exhaust Manifold Turbocharger

Exhaust Manifold Turbocharger


Stud - Replacement
(1 I-02)

Mounting

Stud - Replacement (11-02)


Page 11-5

Mounting

Removal
Apply penetrating
mounting stud to
instructions.

oil to the base of the turbocharger


be removed. Follow the manufacturers

xm900v

Use a standard stud extractor or two nuts locked together to


remove the turbocharger mounting stud(s) from the manifold.

c%
4

xm900ma

Inspection
Visually inspect for damaged
mounting stud holes.

threads

in the

turbocharger

0at3

Visually inspect the manifold for cracks or damage.

xm900sb

Installation
Use precoated turbocharger
mounting studs or apply a thin
coating
of nickel
based,
high
temperature,
anti-seize
compound to the coarse threads of the stud.
Install the studs in the mounting
Use two mounting
Torque

Value:

flange.

nuts locked together


10 Nom [89 in-lb]

to tighten the studs.

Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse (11-03)
Page 11-6

Exhaust System - Group 11

Exhaust Manifold Outlet Connection Cleaning and Inspection for Reuse


(1 I-03)
Cleaning

a
a\
B

Use a wire brush to remove carbon


mounting grooves.

from the v-band

clamp

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam to clean the outlet connection.
air.

Dry with compressed

Inspection

0@B

Visually inspect the outlet connection for cracks or damage to


the mounting surface or clamp grooves. Replace any part that
is cracked or damaged.

Air Equipment - Group 12


614 Series

Page 12-1

Air Equipment - Group 12

For air equipment service information see chassis shop manual.

Electrical Equipment - Group 13


614 Series

Electrical Equipment - Group 13

For electrical equipment service information see chassis shop manual.

Page 13-1

Engine Testing - Group 14


Page 14-1

Engine Testing - Group 14


Section Contents
Page
Blowby Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Engine Dynamometer Test - Engine Run-In

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17

Engine Dynamometer Test - installation of the Engine .................................


Engine Dynamometer Test - Performance Checking

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

14-9

14-21

Engine Painting ...........................................................

14-26

Engine Run-In Procedure - In-Chassis

14-24

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

Engine Run-In - General Procedures .............................................


Engine Storage - Long Term ..................................................
Engine Removal from Long Term Storage

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

Engine Storage - Short Term .................................................


Engine Removal From Short Term Storage ........................................
Engine Testing - Component Identification and Diagrams

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

Engine Testing - General Information .............................................


Engine Dynamometer Run-in ..................................................
In-Chassis Run-In ..........................................................

14-6
14-29
14-32

14-27
14-29

14-3
14-5
14-5
14-5

Engine Testing - General Specifications ...........................................

14-6

Engine Testing - Service Tools .................................................

14-2

Fuel Injection Pump - Idle Speed Adjustment ......................................


RSV Governor ...........................................................
RQV and RQVK Governor

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

General Engine Test Procedure - In Chassis

14-25
14-25
14-26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23

Engine Testing - Service Tools


Page 142

Engine Testing - Component Identification and Diagrams - Group 14

Engine Testing - Service Tools

The following special tools are recommended to perform procedures in Group 14. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool
No.
____ __--

Tool Descrhtion

Tool Illustration

Check the fuel filter restriction during the engine performance


test. Hose adapter, Part No. ST-434-2 and vacuum gauge, Part
No. ST-434-12, are used to perform the test.

Used with the blowby

check tool to measure engine crankcase

Used to measure the engine intake manifold

Pressure

Gauge

pressure.

(O-160 psi)

Used to measure lubricating

oil pressure.

Used to measure engine speed (RPM).

Used with manometer, Part No. ST-l 11 l-3, to measure the


engine crankcase pressure.

Engine Testing - Group 14

Engine Testing - Component Identification and Diagrams


Page 14-3

Engine Testing - Component Identification and Diagrams


The following illustrations contain information
for instrumentation and engine controls.

about engine components,

filter locations, drain points and access locations

The information and configuration of components shown in these illustrations


locations will vary depending on applications and installations.

High Pressure
Fuel Lines

are of a general nature. Some component

X[inch]NPTF

Front Lifting
Bracket

(Air)

M22 x 1.50 (Air)


Rear Lifting
) Bracket

Fuel
Injection -

Vi x lG[inch]UNF
Tan for Maanetic
Pick-up
Air
Compressor

Mounting Bracket

Fuel Pump Side View

Engine Testing - Group 14

Engine Testing - Component Identification and Diagrams


Page 14-4

Turbocharger
Wastegate Actuator
Turbocharger
Exhaust Outlet

Turbocharger
Water Outlet
Connection
Lubricating

Oil

Lubricating

Oil

Provision for
Coolant Heater
Provision for
Cab Heater

Pressure (before

Turbocharger
Oil Drain

Temperature

Turbocharger Side View

!%f9Sor

Engine Testing - Group 14

Engine Testing - General Information


Page 14-5

Engine Testing

- General

Information

This section outlines engine testing and engine run-in recommendations for 6D114E-1 Series engines. Ail engines must
be run-in after a rebuild or a repair involving the replacement of one or more piston ring sets, cylinder liners or cylinder
kiiS.

Caution: Incorrect or insufficient break-in of the piston rings will lead to early oil consumption or high
blowby complaints. Adherence to these run-in guidelines will allow the full durability of new rings to be
realized.

The engine test is a combination of an engine run-in and a performance check. The engine run-in procedure provides
an operating period that allows the engine parts to achieve a final finish and fit. The performance check provides an
opportunity to perform final adjustments needed to optimize the engine performance.
An engine test can be performed by using either an engine dynamometer or a chassis dynamometer.
is not available, an engine test must be performed in a manner that simulates a dynamometer test.

If a dynamometer

Check the dynamometer before beginning the test. The dynamometer must have the capability to test the performance
of the engine when the engine is operating at the maximum RPM and horsepower range (full power).
Before running the engine, make sure the engine is filled with the proper coolant and the lubricating
and primed.

oil system is filled

The engine crankcase pressure, often referred to as engine blowby, is an important factor that indicates when the piston
rings have achieved the correct finish and fit. Rapid changes of blowby or values that exceed specification more than 50
percent indicate that something is wrong. The engine test must be discontinued until the cause has been determined and
corrected.

In-Chassis Run-In
The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. However, light
load/high
speed operation must be avoided during the run-in period. The following in-chassis run-in guidelines are
recommended for 6D114E-1 Series engines after a repair involving replacement of one or more of the piston ring sets,
cylinder liners, or cylinder kits where engine or chassis dynamometer or load bank run-in cannot be performed.
SRT 14-704, Engine - Run-in and Test (in-Chassis), provides time for in-chassis run-in when there is no other way to
perform the run-in (chassis dynamometer, load bank or portable dynamometer) and the engine will be applied in a high
speed or low load operation immediately after the engine is returned to service.

Engine Dynamometer Run-in


This is the preferred method of run-in for engines that have been rebuilt out-of-chassis. It is not practical, nor
recommended, that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair has
been performed in-chassis. SRT 14-701, Engine - Run-In and Test (Engine Dynamometer) provides the time for this work.
There is no requirement, nor is it recommended for an engine that has been run-in and tested on an engine dynamometer
to be run-in again after it has been reinstalled in the vehicle or equipment.

Engine Testing - Group 14

Engine Testing - General Specifications


Page 14-6

Engine Testing - General Specifications


NOTE: Due to variations in ratings of different engine models, refer to the specific
engine model being tested.
Maintain the following

engine data sheet for the particular

limits during an engine run-in on a dynamometer:

Intake Restriction: (Maximum)


l
Clean Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 mm H,O [15 in. H,O]
l
Dirty Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H,O [25 in. H,O]
Air Inlet Temperature

(Maximum)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 C [loo F]

Exhaust Temperature

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

Exhaust Back Pressure: EPA Certified (Maximum)

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

114 mm Hg [4.5 in Hg]

Smoke:
...............................................
l
Bosch Smoke Meter (Maximum)
l
Celesco Smoke Meter (Maximum) ............................................
Coolant Temperature
Lubricating

Oil Temperature

2.5 Units
4% Opacity
100C 1212 F]

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

(Maximum)

(Maximum)

700 C [1290 F]

126.6 C 1260 F]

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

Lubricating Oil Pressure:


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa [lo psi]
l
Low Idle (Minimum Allowable)
l
Rated Speed (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]
Fuel Filter Restriction
Fuel Return Restriction

- Dirty Filter (Maximum)


(Maximum)

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

35 kPa [5 psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in. Hg]


*New (L/Min)
164

Blowby: All engines

*Used (L/Min)
226

* Blowby checking tool, Part No. 3822566, has a special 7.67 mm [0.302 in] orifice that must be used to obtain an
accurate reading.
Refer to the blowby conversion

chart on the following

page to convert liters/minute

into inches/water.

Blowby Measurement
Page 14-7

Engine Testing - Group 14

Blowby Measurement
Blowby is generally recorded in liters/minute.
Install the Part No. 3822566, Engine Blowby Tool, to the
crankcase breather tube in the valve cover.
Install a water manometer to the engine blowby tool.
Use the Blowby Conversion Chart to convert the manometer

reading to liters/minute.
NOTE: A pressure gauge can be used to record the engine

blowby.
Minimum Gauge Capacity: 1270 mm Ha0 [50 in H,O]

Blowby Conversion Chart (7.67 mm


[0.302in]) Orifice
Inches of
Water

Liters/Minute

50

84

103

119

133

145

155

164

172

10

180

11

187

12

193

13

200

14

206

15

211

16

217

17

222

18

226

19

229

20

235

21

239

22

242

23

246

24

248

Engine Testing - Group 14

Engine Run-In - General Procedures


Page 148

Engine Run-In - General Procedures

A
;n

Caution: Refer to Engine Test - General Specifications, page


14-6, before operating the engine to avoid internal
component damage.
Caution: The lubricating oil system must be pressurized
before operating the engine to avoid internal component
damage.
NOTE: The amount of time specified for the following

engine

run-in phases are minimums.


The engine can be operated for longer periods of time at each
operating range or phase with the exception of engine idling
which must be kept to 10 minutes or less.

a3

Start the engine and idle for initial check.

NOTE: Avoid long idle periods.

Operate the engine at low idle


only long enough (10 minutes maximum) to check for correct
oil pressure and any fuel, oil, water, or air leaks.
NOTE: Do not operate the engine at idle speed longer than
specified during engine run-in. Excessive carbon formation will
occur and cause damage to the engine.

6B

NOTE: To avoid internal component damage, do not allow the


engine speed to exceed 1,000 RPM before run-in.

aI3
0

While the engine is idling, listen for unusual noises; watch for
coolant, fuel, and lubricating oil leaks; and check for correct
engine operation in general.
NOTE: Repair all leaks or
continuing the engine run-in.

component

problems

before

Engine Testing - Group 14

Engine Dynamometer Test - Installation of the Engine (14-01)


Page 14-9

Caution: Do not shut off the engine immediately after the


run-in is completed. Allow the engine to cool by
operating at low idle for a minimum of 3 minutes to avoid
internal component damage.

Caution: On engines equipped with a wet clutch flywheel


housing, it will be necessary to replace the rear
crankshaft oil seal after engine testing. If the engine is
operated with a dry housing, the wet clutch oil seal will
be destroyed.

Engine Dynamometer Test - Installation


of the Engine (14-01)
Use engine lifting fixture, Part No. 3822512, to install
engine
to
the
test
stand.
Align
and
connect
dynamometer.
Refer to the manufacturers
instructions
aligning and testing the engine.

NOTE: Make sure the dynamometer

the
the
for

capacity is sufficient to
permit testing at 100 percent of the engine rated horsepower.
If the capacity is not enough, the testing procedure must be
modified to match the restrictions of the dynamometer.

Install the coolant temperature

sensor.

Minimum Gauge Capacity:

107C [225F]

Engine Dynamometer Test - Installation of the Engine (14-01)


Page 1410

Engine Testing - Group 14

Connect the coolant supply to the water inlet connection (1).


Connect the coolant return to the water outlet connection (2).
Install the drain plugs, close all the water drain cocks, and
make sure all the clamps and fiiings are tight.
Connect the vent tube to the vent connection on the thermostat
housing.

Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.

inspect the engine for coolant leaks at connections, fiiings,


plates, and plugs. Repair as necessary.

Engine Testing - Group 14

Engine Dynamometer Test - Installation of the Engine (14-01)


Page 14-11

The intake air piping must be plumbed through *an @@(I


aftercooler to control the temperature of the Intake air during 4~
the run-in procedure. Rig an aftercooler beside the engine,
and plumb the intake pipes from the turbocharger, through
the aftercooler and back to the intake manifold.
Use a temperature gauge (1) to measure the intake manifold
temperature.
NOTE: Maintain the intake manifold air temperature at 66C
[150 F] or below during the dynamometer testing or run-in; if
manifold temperature exceeds this limit, terminate the test
and idle the engine to let it cool down. Do not idle more
than 10 minutes. Testing can resume when the intake air
temperature can be maintained below 66C [15OF]. Under
no circumstances is the intake manifold air temperature
allowed to exceed 77 C [17OF].
Connect a water manometer to the turbocharger air inlet pipe @A
to test air restriction.
4V
NOTE: A vacuum gauge can be used in place of the water
manometer.
Minimum Gauge Capacity:

760 mm H,O [30 in. H,O]

Connect a *mercury manometer to a straight section of the @$A


exhaust prprng near the turbocharger outlet to check exhaust 4~
restriction.
NOTE: A pressure gauge can be used in place of the
mercury manometer.
Minimum Gauge Capacity: 254 mm Hg [lo in. Hg]

Remove the pipe plug from the bottom of the oil cooler and
install the lubricating oil temperature sensor.
Minimum Gauge Capacity: 150C [3OOF]

Engine Testing - Group 14

Engine Dynamometer Test - Installation of the Engine (1401)


Page 14-12
Attach the lubricating
drilling in the cylinder

oil pressure sensor to the main oil rifle


block.

Minimum Gauge Capacity: 1034 kPa [150 psi]

Caution: To avoid internal component damage, the


lubricating oil system must be pressurized before operating
the engine after any internal engine repairs or extended
engine storage (beyond 6 months).

A
g@
+*
OB

To pressurize the system using external pressure, connect the


supply to the lower pipe plug hole in the upper part of the oil
cooler cover as illustrated.

Use a pump capable of supplying


pressure.

210 kPa [30 psi] continuous

Use clean 15W-40 engine oil to pressurize the system until the
oil pressure registers on the gauge.
Remove the oil supply tube, and install the plug.

Make sure the lubricating oil has had time to drain to the pan
and fill the engine to the High mark as measured on the
dipstick.

NOTE: If the dipstick is new, it must be correctly calibrated.


Refer to Lubricating

op900wr

Oil Dipstick - Calibration

(7-07).

Engine Testing - Group 14

Engine Dynamometer Test - Installation of the Engine (M-01)


Page 14-13

If an external pressure pump is not available, pressurize


lubricating system according to the following procedure:
Fill the engine
dipstick.

Disconnect

with

oil to the

the turbocharger

High

lubricating

level

the

mark on the

oil supply tube.

Pour 50 cc to 60 cc [2.0 fl. oz. to 3.0 fl. oz.] of clean


15W-40 engine oil into the turbocharger oil supply hole.
Connect the oil supply tube to the turbocharger.

Torque Value:

35 Nom [26 ft-lb]

Remove the lubricating


engine oil.

oil filter and fill with

Screw the filter onto the filter


contacts the filter head surface.

head fitting

clean

15W-40

until the gasket

Use oil filter wrench, Part No. 3375049, to tighten


an additional 3/4 to 1 turn.

the filters

Make sure the fuel is shut off by removing the wire from the
fuel solenoid or the mechanical fuel shutoff is in the OFF
position. This is necessary to prevent the engine from
starting during the oil rifle pressure charging operation.

Engine Testing - Group 14

Engine Dynamometer Test - Installation of the Engine (1401)


Page 14-14

Caution: Do not crank the starting motor for periods longer


than 30 seconds. Excessive heat will damage the starting
motor.
Crank the engine until the oil pressure gauge indicates system
pressure.
NOTE: Allow 2 minutes between the
periods so the starting motor can cool.
NOTE: If pressure is not indicated,
problem before continuing.

30-second
find

and

cranking

correct

the

Allow the lubricating oil to drain into the oil pan, and measure
the oil level with the dipstick.
Add oil as necessary
mark.

to bring the level to the High

%
q

Lubricate the gasket on the fuel filter with clean 15W-40 engine
oil.

Caution: To prevent air leaks, make sure the filter is


installed tightly but not over-tightened. Mechanical overtightening can distort the threads or damage the filter
element seal.

Fill the fuel filter with clean No. 2 diesel fuel.

Install the filter as specified by the filter manufacturer.


are no instructions, refer to the following guidelines.
Screw the fuel filter onto the filter
contacts the filter head surface.
Tighten the filter an additional
+ Vi

to

3/

Turn

level

l/2

head

until

to 3/4 turn.

the

If there
gasket

Engine Dynamometer Test - Installation of the Engine (14-01)


Page 14-15

Engine Testing - Group 14

8mm
NOTE: Manual

venting is required
property filled prior to installation.

if the fuel filter

is not

RI

Open the vent screw.


Operate the plunger on the fuel transfer
flowing from the Wing is free of air.

pump until the fuel

Tighten the vent screw.

Check the voltage rating on the fuel pump solenoid before


connecting the electrical wires to it. Make sure the voltage
supply matches that of the fuel pump solenoid.

o
@

Attach
lever.

@&A
+*

the throttle

control

rod onto the fuel

pump throttle

To determine the amount of turbocharger boost, remove the


l/4 inch pipe plug in the cylinder head and install the intake
manifold
pressure
sensor or pressure
gauge, Part No.
ST-1 273.
Minimum

Gauge Capacity: 1905 mm Hg I75 in. Hg]

Checking Tool, Part No. 3822566


For accurate engine crankcase blowby measurement, insert
blowby checking tool, Part No. 3822566, in the crankcase
breather vent.
Connect a water manometer to the blowby tool. A pressure
gauge can be used in place of the manometer.

Minimum Gauge Capacity: 1270 mm H,O [50 in. HsO]

RI
W&
@@

Engine Dynamometer Test - Installation of the Engine (14-01)


Page 14-16

Engine Testing - Group 14

To measure fuel filter restriction, connect vacuum


No. ST-434, to the fuel transfer pump inlet line.

gauge, Part

Minimum Gauge Capacity: 760 mm Hg (30 in. Hg]


ON

To be able to unload the compressor, connect a source of


compressed air to the unloader (1). This air line must contain
a valve between the source and the unloader.

NOTE: All air compressors


run-in. All air compressors
engine performance check.

must be loaded during engine


must be unloaded during the

NOTE: The compressed


air load in the accompanying
illustration must be attached to the air compressor outlet (2).

To provide a load on the air compressor, connect an air tank


to the compressor outlet (2), using steel tubing or a high
temperature hose (1).
Install an air regulator (3) that can maintain tank air pressure of
345 kPa to 517 kPa [50 psi to 75 psi] at both the minimum
and the maximum engine speed.

Hose Temperature (Minimum): 260C [500F]

Check the voltage rating on the starting motor before installing


the electrical wiring.
Attach electrical
if used.

wires to the starting

motor and the batteries,

NOTE: If another method of starting the engine is used, follow


the manufacturers
instructions
to make the necessary
connections.

Engine Testing - Group 14

Engine Dynamometer Test - Engine Run-In (U-02)


Page 14-17

Engine Dynamometer Test - Engine


Run-In (14-02)
The engine run-in period allows the tester to detect assembly
errors and to make final adjustments needed for performance
that meets specifications.

0
@

NOTE: The amount of time specified for the following engine


run-in phases are minimums. Additional time can be used at
each phase except engine idle periods, if so desired.

Caution: On engines equipped with a wet clutch flywheel


housing, it will be necessary to replace the rear
crankshaft oil seal after engine testing. If the engine is
operated with a dry housing, the wet clutch oil seal will
be destroyed.

Measurements from these indicators and gauges must be


observed closely during all phases of the engine run-in
period. Refer to page 14-6 for specifications and acceptable
readings.

To correctly evaluate the engine performance, this additional


measurement must be observed during engine run-in phases.

0@

Engine Speed

Torque

Coolant Out
Temp.

Lube Oil
Temp.

Oil Pres.

Bowby eg8gasd

0a9
Intake Manifold
Pressure
(Turbocharger Boost)

Engine Dynamometer Test - Engine Run-In (14-02)


Page 14-18

Engine Testing - Group 14

It is a good practice to observe these measurements even if


engine performance meets specifications. If engine performance
does not meet specifications, these measurements can indicate
possible reasons for under-performance.
Fuel in Restriction

Air Inlet Restriction

Exh. Back Pres.

Coolant
Pressure I

Fuel Drain Pres.

oi9OOwi

Engine performance specifications and fuel system calibration


values are listed in the Engine Diagnostic Manual.

NOTE: Fuel pump calibration


an authorized ADS shop.

changes

must be performed

by

Caution: Do not crank the engine for more than 30


seconds. Excessive heat will damage the starting motor.
Crank the engine and observe the oil pressure when the engine
starts. If the engine fails to start within 30 seconds, allow the
starting motor to cool for 2 minutes before cranking the engine
again.

A
eB
0

Caution: If the lubricating oil pressure is not within


specifications, shut off the engine immediately. Either
excessively low or excessively high oil pressure will cause
engine damage.
Engine oil pressure must be between 69 kPa and 310 kPa [lo
psi and 45 psi] at 700 RPM.
Correct the
specifications.

problem

if

the

oil

pressure

is

not within

Engine Dynamometer Test - Engine Run-In (14-02)


Page 14-19

Engine Testing - Group 14

Caution: Do not operate the engine at idle speed longer


than specified during engine run-in. Excessive carbon
formation will cause damage to the engine.
Operate the engine
minutes.

700 RPM for 3 to 5

at approximately

NOTE: If the idle speed is incorrect,


for adjustment information.

refer to Procedure

14-06

Listen for unusual


noises; watch for coolant, fuel, and
lubricating oil leaks; and check for correct engine operation
in general.
NOTE: Repair all leaks or
continuing the engine run-in.

component

problems

before

Move the throttle to obtain 1,200 RPM engine speed, and set
the test load to 25 percent of the rated load.
Operate the engine
coolant temperature
record the data.

at this speed and load level until the


is 70C [160F]. Check all gauges and

NOTE: Do not proceed to the


blowby reading is obtained.

next

step

until

a steady

Test Load

1
Open the throttle to the speed at which peak torque occurs,
and adjust the dynamometer
load to 50 percent of rated
load. Operate the engine at this speed and load level for 2
minutes.
Check all gauges and record the data.
NOTE: Do not proceed to the
stable and within specifications.

next

step

until

blowby

is

0a!3

7oc

[I 60F]
oi802vr

Torque Peak
2x (Test Load)
(50% Rated Load)
2 Minutes
oi804vh

Engine Dynamometer Test - Engine Run-In (14-02)


Page 14-20

aI9

Torque Peak

Engine Testing - Group 14

With the engine speed remaining at torque peak RPM, increase


the dynamometer load to 75 percent of rated load. Operate the
engine at this speed and load level for 2 minutes. Check all
gauges and record the data.
NOTE: Do not proceed to the next step until blowby is stable
and within specifications.

3x (Test Load)
(75% Rated Load)
2 Minutes
oi804vi

Move the throttle lever to its fully opened position, and increase
the dynamometer load until the engine speed is at torque peak
RPM. Operate the engine at this speed and load level for 10
minutes or until the blowby becomes stable and within
specifications.

Full Throttle
Torque Peak

4B

Check all gauges and record the data.

Maximum Load
10 Minutes
oi804vj

Reduce the dynamometer load until the engine speed increases


to the engines rated RPM.

Full Throttle
Rated

@3

Operate the engine at rated RPM for 5 minutes.


Check all gauges and record the data.

Maximum Load
at Rated Speed
5

Minutes
oi804vk

Caution: Shutting off the engine immediately after operating


at full load will damage the turbocharger and internal
components. Always allow the engine to cool before
shutting it off.
Remove the dynamometer load completely and operate the
engine at 700 RPM for 3 to 5 minutes. This period will allow the
turbocharger and other components to cool.
NOTE: If the idle speed is incorrect,
for adjustment information.

refer to Procedure

14-06

Enaine Testing - Group 14

Engine Dynamometer Test - Performance Checking (14-03)


Page 14-21

Shut off the engine.

Make sure all instrumentation


is removed
the engine from the engine dynamometer.

before

removing

Engine Dynamometer Test - Performance


Checking (1 a-03)
Make sure the air compressor
performance check.
Apply regulated air pressure
compressor unloader (1).

will

be unloaded

during

the

of 655 kPa [95 psi] to the air

Caution: Do not crank the engine for more than 30


seconds. Excessive heat will damage the starting motor.
Crank the engine and observe the oil pressure when the
engine starts. If the engine fails to start within 30 seconds,
allow the starting
motor to cool for 2 minutes before
cranking the engine again.

0@

Engine Dynamometer Test - Performance Checking (14-03)


Page 14-22

Engine Testing - Group 14

Caution: If the lubricating oil pressure is not


specifications, shut off the engine immediately.
excessively low or excessively high oil pressure will
engine damage. Correct the problem if oil pressure
within specifications.

within
Either
cause
is not

Engine oil pressure must be between 69 kPa and 310 kPa [lo
psi and 45 psi] at approximately 700 RPM.

Make sure the engine is at operating

temperature.

Move the throttle lever to the FULL OPEN position. Adjust the
dynamometer load until the engine maintains the rated RPM.
Allow the readings to stabilize.

Read the horsepower.

Check all the gauges and record the readings.


NOTE: The horsepower reading will not be accurate if the
lubricating oil temperature and fuel temperature are not within
specifications.

Lubricating Oil Temperature: MIN WC

[lWF]

Fuel Temperature: MAX 32C [9OF]

aB

Check all gauges and record the data.

Caution: Do not shut off the engine immediately after it has


been loaded. It must be allowed to sufficiently cool.
Remove the dynamometer load completely and operate the
engine at idle speed for 3 to 5 minutes. This will allow the
turbocharger and other components to cool.
Idle periods longer than 5 minutes are to be avoided.

Shut off the engine after the cool-down

oi802vx

period.

General Engine Test Procedure - In Chassis (14-04)


Page 14-23

Engine Testing - Group 14

NOTE: If the horsepower is below specifications,


fuel pump and have the pump checked.

remove the

NOTE: The low idle speed is an external adjustment and can


be adjusted with the pump installed. Refer to Procedure
14-06. All other adjustments, such as; no-air setting and
governor
break speed are internal which requires pump
removal for adjustment.

Remove all test instrumentation.


dynamometer.
NOTE:

Remove the engine from the

If the engine

is to be stored temporarily and does


antifreeze, it is necessary to drain
all coolant.
Drain locations
are identified on the engine
diagrams, pages 14-3 and 14-4.

not have permanent-type

Prepare the engine for Engine


Storage (14-08) or (14-09).

Painting

(14-07) or Engine

General Engine Test Procedure - In


Chassis (14-04)
Caution: the following procedure assumes that the
lubricating oil and fuel systems were correctly primed, the
dipstick calibrated, and the engine filled to the correct
levels with oil and coolant during installation of the
engine into the chassis. If these systems
were not
serviced during installation of the engine, refer to Engine
Dynamometer Test - Installation of the Engine (14-01) for
instructions on priming the lubricating oil and the fuel
systems and calibrating the dipstick. Refer to the machine
Operation and Maintenance Manual for instructions on
filling the lubricating oil and the cooling systems.

A
w

SMOO8

The number of instruments and gauges required to perform a


test will vary according to the type and capability of the test
equipment used.
It is a good practice to observe these measurements even if
engine
performance
meets
specifications.
If
engine
specifications,
these
performance
not
meet
does
measurements
can indicate
possible
reasons for poor
performance.

Fuel In Restriction

Fuel Temp. Exh. Back Pre

~~

Air Inlet Restriction Fuel Drain Pres.


1Also: Coolant Pressure

SM0087

Engine Testing - Group 14

General Engine Test Procedure - In-Chassis (14-04)


Page U-23-01
To correctly monitor
following parameters:
Lubricating

an engines

performance,

record

oil pressure (vehicle instrument

Coolant temperature

(vehicle instrument

the

panel)

panel)

Coolant pressure
Intake manifold

pressure

Inlet air restriction


Blowby
Engine speed (RPM) (vehicle instrument
Wheel horsepower

(WHP) (dynamometer

panel)
controls)

Coolant Pressure
Measure the coolant
cylinder block.

pressure

at the

exhaust

side

of the

Minimum Gauge Capacity: 415 kPa [60 psi]

Fuel Inlet Restriction


Measure the fuel inlet restriction. Install a vacuum gauge, Part
No. ST-434, to the fuel transfer pump inlet line.

Minimum Gauge Capacity: 760 mm Hg [30 in Hg]

Charge Air Cooler Restriction


Measure the intake pressure drop across the charge air cooler.
manometer or two
separate gauges, Part No. ST-1273. If two gauges are being
used, calibrate both gauges on a common pressure source at
206 kPa (30 psi] to ensure consistency.

This test can be done with a mercury

Install one pressure gauge, Part No. ST-1273, in the fitting in


the turbocharger
compressor outlet elbow. Install the other
pressure gauge in the fitting in the intake manifold.

SMcml

Observe the reading on the gauges. Pressure drop must not


4.0 in Hg]
be greater than:
102 mm Hg
21 kPa
I3.0 PSI]

Engine Testing - Group 14

General Engine Test Procedures - In Chassis (14-04)


Page 14-23-02

NOTE: When measuring the pressure drop, operate the


dynamometer at the RPM that delivers the maximum horsepower of engines tested. Engine speed will be 1600 - 1700
RPM on most engines.

Lubricating Oil Pressure


Use pressure
gauge,
lubricating oil pressure.

Part

No.

3375275,

to

measure

Install the pressure gauge into the main oil rifle and observe
the oil pressure.
l

Low idle (minimum

allowable)

At rated speed (minimum

69 kPa [lo psi]

allowable)

207 kPa [30 psi]

Minimum Gauge Capacity: 1034 kPa [150 psi]

Intake Manifold Pressure


Measure the intake manifold pressure (turbocharger
boost).
Install a pressure gauge, Part No. ST-1273, in the location

shown.
Minimum Gauge Capacity: 1905 mm Hg [75 in Hg]

Intake Air Restriction


Connect a water manometer
to test air restriction.

to the turbocharger

air inlet pipe

NOTE: The manometer connection must be installed at a 90


degree angle to the air flow in a straight section of pipe, one
pipe diameter before the turbocharger.
NOTE: A vacuum
manometer.

gauge can be used in place of the water

Minimum Gauge Capacity: 760 mm H,O [30 in H,O]

MaximumHP RPM

Engine Testing - Group 14

General Engine Test Procedures - In Chassis (14-04)


Page 14-23-03

Crankcase Gases (Blowby)


Measure the blowby by installing blowby checking tool, Part
No. 3822566, in the crankcase breather vent. Connect the
blowby tool to a water manometer. refer to page 14-7 for
blowby specifications.
NOTE: Excessive blowby indicates an engine internal
components malfunction or a turbocharger malfunction,
allowing combustion gases to enter the crankcase.

NOTE: If a sudden increase in blowby occurs, or if blowby


exceeds the maximum allowable limit during any run-in step,
return to the previous step and continue the run-in. If blowby
does not reach an acceptable level, discontinue the run-in and
determine the cause.

NOTE: Avoid long idle periods. Operate the engine at low idle
only long enough (3 to 5 minutes) to check for correct oil
pressure and any fuel, oil, water or air leaks.

Caution: Do not allow the engine speed to exceed 1000


RPM before run-in. The internal components can be
damaged.

Engine Testing - Group 14


Caution: Do not shut off the engine immediately after the
last step of the run-in is completed. Allow the engine to
cool by operating at low idle for a minimum of 3 minutes
to avoid internal component damage.

General Engine Test Procedure - In Chassis (14-04)


Page 14-23-04

Engine Testing - Group 14

Engine Run-In Procedure - In-Chassis (14-05)


Page 14-24

Engine Run-In Procedure - In-Chassis


(14-05)

Caution: Refer to - General Engine Test Procedures - In


Chassis (14-04) before operating the engine to avoid
internal component damage.
Operate the engine
rebuild:

Hours
Hours

N
iours

Hours

as follows

during

the first 3 hours after

1.

Do not idle the engine for more than 5 minutes


one time.

2.

Operate the engine at 75 percent throttle while loaded.

3.

Do not operate the engine at rated speed (RPM) and full


load for more than 5 minutes at any one time.

at any

Hours
0ilOOvy

Hours

Change the lubricating oil and filter after 800 km (500 miles] or
20 hours of operation. Refer to the Operation and Maintenance
Manual.

Engine Testing - Group 14

Fuel Injection Pump - Idle Speed Adjustment (M-06)


Page 14-25

Fuel Injection Pump - Idle Speed


Adjustment (14-06)
RSV Governor
Idle adjustment for industrial engines requires the setting of
both the low idle screw (1) and the bumper spring screw (2)
on the fuel injection pump.

19 mm, Screwdriver, Tachometer


First, loosen the locknut and back out the bumper spring
screw on the fuel injection pump until there is no change in
engine speed.
The speed should drop
screw is backed out.

20-30 RPM as the bumper

spring

fP9000~

13 mm, Screwdriver, Tachometer


Loosen the locknut and adjust the low idle screw to 2030
RPM less than the desired speed. Turn the low idle screw
counterclockwise to decrease RPM; clockwise to increase
RPM. Tighten the low idle screw locknut.
Torque

Value:

8 Nom [72 in-lb]

Turn the bumper spring screw clockwise until the desired


idle speed is obtained. Tighten the bumper spring screw
locknut.

Torque Value:

8 Nom 172 in-lb]

Engine Testing - Group 14

Engine Painting (14-07)


Page 14-26

RQV and RQVK Governor


10 mm, Screwdriver and Tachometer
Low idle adjustment on automotive fuel
requires setting of the low idle stop screw.

injection

pumps

Loosen the low idle screw locknut and turn the low idle screw

counterclockwise to raise the RPM; clockwise to decrease the


RPM. Tighten the low idle screw locknut.

0@h

Torque Value: 8 Nom [72 in-lb]

Engine Painting (14-07)

c%
0

q
B

Remove all belts from the engine.

Cover the following


tape:

parts of the engine with

Exhaust and intake openings

Electrical

Fuel inlet and drain connections

Any exposed
terminals

plastic caps or

components

fittings,

threads,

and

electrical

wire

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam to clean the engine. Dry with compressed

air.

NOTE: Make sure all engine surfaces are clean and dry before
painting the engine.

Protect the following

components

from the paint:

All data plates; engine, turbocharger

Exhaust manifold

Turbocharger

Flywheel

Flywheel

turbine

and fuel pump

housing

housing transmission

mounting

surface

Engine Testing - Group 14

Engine Storage - Short Term (1408)


Page 14-27

Paint the engine.

Engine Storage - Short Term (14-08)


NOTE: This procedure describes the correct method for
preparing an engine for short-term (1 to 6 months) storage.
Be sure the cooling system and lubricating oil system are
properly filled.
Operate the engine at high idle until the coolant temperature
reaches 70 C [ 160 F] .
Shut off the engine.

Remove the fuel tube to the engine fuel filter (1) and the
injector fuel return tube (2).
NOTE: Fuel system preservative oil must meet Federal
Specification
W-L43OOC. (Example:
Daubert Chemical
NoxRust No. 518).
Fill two containers, one with diesel fuel and the other with
the preservative oil. Put both fuel tubes into the container of
diesel fuel.

Start the engine and run until it is operating smoothly, then


put the fuel supply tube into the container of preservative oil.
Remove the injector return tube from the diesel fuel
container. When preservative oil flows from the tube, shut off
the engine.
Connect the fuel supply tube to the fuel filter, and put a cap
on all other fuel tubes.

High Idle

Engine Storage - Short Term (14-08)


Page 14-28

Engine Testing - Grow 14


Drain the lubricating

oil pan, oil filters, and fuel filter.

Install the drain plug into the oil pan, and install new filters.
Tighten according to specifications.

Disconnect

the electrical wires from the fuel pump solenoid.

Drain the coolant

passages and jackets.

NOTE: It is not necessary

to drain the coolant if it is a


permanent-type antifreeze with a rust inhibitor. Do not drain the
coolant if the engine is installed in a vehicle.

Visually check the engine and cover all openings


prevent dirt and moisture from entering.
Install a WARNING tag which alerts others
engine and that it must not be started.

with tape to

of no oil in the

Engine Testing - Group 14

Engine Storage - Long Term (14-09)


Page 1429

Store the engine in a dry area of even temperature.

NOVEMBER
SMTWTFS

Rotate the crankshaft two to three revolutions every 3 to 4


weeks by using the engine barring tool, Part No. 3377371, to
rotate the crankshaft.

Engine Removal From Short Term Storage


Remove

the

tape

from

all

openings

and

remove

the

WARNING tag.

0
c%

Refill the oil filters with clean 15W-40 engine oil, and
pressurize
the
lubrication
system.
Refer
to
Engine
Dynamometer Test - Engine Run-in (14-02).
Use clean No. 2 diesel fuel to flush the preservative
the fuel system, and fill the fuel filters again.

oil from

Connect the electrical wiring to the fuel pump solenoid.


Prime and vent the fuel system. Refer to page 14-15.

Engine Storage - Long Term (14-09)


This procedure describes the correct method of preparing
engine for long-term (6 to 24 months) storage.

an

If the engine has been stored for 24 months, the cooling


system must be flushed with a solvent. Repeat the flushing
procedure a second time.

Engine Testing - Group 14

Engine Storage - Long Term (14-09)


Page 1430
Be sure the cooling
properly filled.

system

and lubricating

Operate the engine at the high idle throttle


coolant temperature is 70C [16OF].

oil system
position

are

until the

Shut off the engine.

High Idle

7oc
[160F]
oi803vs

Drain the lubricating oil pan. Install the drain plug, and fill the
level mark on the dipstick with
oil pan to the High
preservative oil.

NOTE: Lubricating system preservative oil must meet Military


Specification MIL-L-21260 Type E30-1 SAE 30. (Example: Shell
66202).

Disconnect the fuel supply tube at the fuel filter (1) and the
injector fuel return tube (2).
NOTE: Fuel system preservative
oil must meet Federal
Specification W-L-8OOC. (Example: Dauber-t Chemical NoxRust
No. 518).
Fill two containers, one with diesel fuel and the other with
preservative oil. Put both fuel tubes into the container of diesel
fuel.

Start the engine and run until it is operating smoothly, then put
the fuel supply tube into the container of presen/ative oil.
Remove the injector return tube from the diesel fuel container.
When the preservative oil flows from the tube, shut off the
engine.
Connect the fuel supply tube to the fuel filter, and put a cap on
the ends of all the other fuel tubes.

Engine Storage - Long Term (W-09)


Page 14-31

Engine Testing - Group 14

Drain the preservative oil from the lubricating


Install
the
drain
plug.
Tighten
filters.
specifications.
Drain and flush
rust inhibitor.

the

cooling

system,

using

oil pan and oil


according
to
a water-soluble

Remove the aftercooler assembly and the exhaust


Refer to Engine Disassembly (00-01).

manifold.

Spray preservative oil into the intake and exhaust


the cylinder head and into the aftercooler housing
exhaust manifold.
Install the aftercooler assembly
to Engine Assembly (00-02).

and exhaust

ports of
and the

manifold.

Refer

Remove the valve cover, and spray the rocker levers, valve
springs, valve stems, valve guides, and push rods with
preservative oil. Install the valve cover.
Spray preservative
oil into the intake port of the air @
compressor and on all exposed metal surfaces that are not a~@
painted.

NOTE: Use a preservative compound that meets


Specification MIL-C-16137C Type P-2 Grade 1 or 2.

Cover all openings with heavy


entrance of dirt and moisture.

paper

Put a WARNING tag


following information:

engine

on

the

Military

and tape to prevent


which

Date the engine was prepared for storage.

Crankshaft

Coolant has been drained.

Engine must not be operated.

contains

must not be rotated.

Store the engine in a dry area of even temperature.

the

Engine Storage - Long Term (14-09)


Page 1432

Engine Testing - Group 14

Engine Removal from Long Term Storage


Remove the paper and the tape from all openings.
Remove the WARNING tag.

Flush the fuel system with clean diesel fuel to remove


preservative oil.

II

In

-I

oi901
wk

Rotate the water pump to make sure it has not rusted in place.

Rotate the crankshaft two complete revolutions to make sure


the piston rings are free and no foreign objects are in the
engine.

Engine Storage - Long Term (14-09)


Page 14-33

Engine Testing - Group 14

Remove the intake manifold cover or aftercooler and visually


inspect the lower valve stem area for presence of rust. An
accumulation of rust requires disassembly and rebuild of the
cylinder head.

Q
C%

Install all drive belts.

Remove a plug from the


preservative oil from the
gallon] of light mineral
crankshaft three or four
flushed. Install the plug.

main oil rifle drilling and flush the


engine by pumping 3.8 liters [l.O
oil into the oil rifle. Rotate the
revolutions as the engine is being

Remove the oil drain plug and allow the mineral oil to drain
from the engine.

0
C%

0pSpxma

Engine Storage - Long Term (14-09)


Page 14-34

Engine Testing - Group 14


Remove the lubricating oil filter. Install a new filter according
the manufacturers specifications.

to

Pressure fill the engine with 15W-40 lubricating oil through the
pipe plug hole on the top side of the oil cooler housing directly
below the turbocharger oil supply connection. Use 207 kPa [30
psi] to pressure fill the system with a minimum of 3.6 liters [l
U.S. gal.].

Caution: Disconnect the fuel solenoid or position the shut


down lever in the STOP position to make sure the engine
does not start when the crankshaft is rotated.
Use the starter to rotate the engine for a maximum of 30
seconds, with two minute intervals, until oil pressure registers
on the lubricating oil gauge.

Fill the oil pan to the High

mark on the dipstick.

Engine Storage - Long Term (14-09)


Page 14-35

Enaine Testing - Group 14

Install a new coolant filter. Fill the cooling system with a


mixture
of 50% water
and 50% ethylene-glycol
type
antifreeze.

Adjust the valve clearance.

Refer to Engine Assembly

Tighten all capscrews, plugs and fittings


to the Specifications section.

(00-02).

as necessary.

Refer

instruments and Controls - Group 15


Page 151

Instruments and Controls - Group 15

For instruments and controls equipment service information see chassis shop manual.

Mounting Adaptations - Group 16


Page 161

Mounting Adaptations

- Group 16

Section Contents
Page
Engine Support Bracket, Front - Cleaning and Inspection for Reuse .......................
Cleaning ................................................................
Inspection ...............................................................

16-9
16-9
16-9

Flexplate Assembly - Cleaning and Inspection for Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6


Flywheel - Cleaning and Inspection for Reuse ......................................
Cleaning................................................................16Inspection ...............................................................

16-5
5
16-5

Flywheel Housing - Assembly (Wet Clutch Application) ................................

16-6

Flywheel Housing - Cleaning and Inspection for Reuse ................................


Cleaning................................................................16Inspection ...............................................................

16-7
7
16-7

Flywheel Ring Gear - Replacement ..............................................


Installation ..............................................................
Removal ................................................................

16-6
16-6
16-6

Mounting Adaptations - Exploded View ...........................................

163

Mounting Adaptations - General Information ........................................


Flywheel and Ring Gear .....................................................
Flywheel Housing ..........................................................

16-4
16-4
16-4

Mounting Adaptations - Service Tools ............................................

16-2

Mounting Adaptations
Page 16-2

Mounting Adaptations

- Service Tools

- Group 16

Mounting Adaptations - Service Tools

The following special tools are recommended to perform procedures in Group 16. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool No.

Tool Descrhtion
.
Crack Detection

3375432

Kii

This kii provides a convenient


engine component.

way to detect cracks in any

Tool Illustration

Mounting Adaptations - Group 16

Mounting Adaptations - Exploded View


Page 16-3

Mounting Adaptations - Exploded View

Ref. No.
1
2
3
4
5
6
7
8
9
10

Description
Screw, Hexagon Head Cap
Plug, Threaded
Housing, Flywheel
Plug, Pipe
Gasket, Cover Plate
Plate, Cover
Screw, Self Tapping Metal
Seal, O-ring
Plug, O-ring
Flywheel

QtY

Ref. No.

12
1
1
1
1
1
2
1
1
1

11

12
13
14
15
16
17
18
19

Description
Gear, Flywheel Ring
Screw, Hexagon Head Cap
Washer, Plain
Adapter, Crankshaft
Flexplate
Ring, Clamping
Screw, Hexagon Head Cap
Support, Engine, Front
Screw, Hexagon Head Cap

QtY
1

a
8
1
1
1
8
1
4

Mounting Adaptations - Group 16

Mounting Adaptations - General Information


Page 16-4

Mounting Adaptations - General Information


The mounting adaptations
engine support.

group consists of the flywheel housing, flywheel, flywheel ring gear, pilot bearing, and the front

Flywheel Housing
The flywheel housings are available in different sizes and styles for the various applications. Ring dowels are used to
locate the housing within 0.20 mm [O.OOS in] total indicated runout. Service housings are drilled for the dowels and
redowelling
is not required. Check the appropriate parts book and the engine parts listing for the correct part number
for the engine application being serviced.

Flywheel and Ring Gear


The flywheel is available only as an assembly.
available for service replacement.

The assembly

includes the flywheel

and the ring gear. The ring gear is

Mounting Adaptations - Group 16

Flywheel - Cleaning and Inspection for Reuse (16-01)


Page 16-5

Flywheel - Cleaning and Inspection for


Reuse (16-01)
Cleaning
Use a wire brush to clean the crankshaft pilot bore.
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Use steam or solvent to
compressed air.

clean the flywheel.

Dry with

Inspection
Visually inspect for nicks or burrs.

0@B

Use Scotch-Brite@ 7448, or equivalent, to remove small nicks


and burrs.
I\

Crack Detection Kit, Part No. 3375432


Warning: Komatsu America Inational Company does not
recommend resurfacing of the flywheel. Resurfacing of
the flywheel can cause possible personal injury, property
damage, or cause the flywheel to be too thin and result

in breakage.
Check the face of the flywheel at the clutch engagement
point for cracks or damage.

0BB

Use the crack detection kit, Part No. 3375432, to check for e
cracks in the flywheel. Follow the instructions provided with
the kit.

Inspect the flywheel ring gear teeth for cracks and chips.
NOTE: If the ring gear teeth are cracked or broken, the ring
gear must be replaced. Refer to Procedure (16-03).

04i!3

Flexplate Assembly - Cleaning and Inspection for Reuse (1602)


Page 16-6

\
El

0a3

aB

Mounting Adaptations - Group 16

Flexplate Assembly - Cleaning and


Inspection for Reuse (16-02)
Use solvent to clean the flexplate.
Check the ring gear for damaged or worn teeth. If the ring gear
is damaged or worn, it must be replaced. Refer to Procedure,
Flywheel Ring Gear - Replacement (16-03).

Use dye penetrant to check the crankshaft adapter for cracks.


There must not be any cracks in the crankshaft adapter.
Check the pilot on the crankshaft adapter for damage or wear.
If the pilot is worn, the flexplate must be replaced.

fw9adsa

Flywheel Ring Gear - Replacement


(16-03)
Removal
Caution: Do not use a cutting torch to heat the ring gear,
the flywheel can be damaged.
Heat the outside diameter of the ring gear with a heating torch.

Warning: Wear eye protection while driving the gear from


the flywheel.
Use a blunt chisel or brass drift and hammer to remove the
gear from the flywheel.

Installation
NOTE: Do not attempt to install the ring gear without
the ring gear first.

heating

0a!3

Use an oven to heat the new ring gear. Heat the ring gear for
a minimum of 30 minutes in a preheated oven. Do not heat the
ring gear for more than 6 hours.

NOTE: Do not exceed the specified time or temperature.


metal hardness will be changed.

Temperature: 177C [350 F]


The

Mounting

Adaptations

16

- Group

Flywheel Housing - Cleaning and Inspection for Reuse (16-04)


Page 167

Caution: Wear protective gloves to prevent personal injury


when handling parts that have been heated.
NOTE: The gear must be installed so the bevel on the teeth
is toward the crankshaft side of the flywheel.

Remove the gear from the oven, and install it on the flywheel
before it cools. Allow the air to cool the gear. Do not use
water or oil to reduce the cooling time.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 177C
[35OF]. Use a TempilstW crayon or its equivalent to check
the gear temperature before installing it on the flywheel.
fwlrQha

Flywheel Housing - Cleaning and


Inspection for Reuse (16-04)
Cleaning
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Use steam or solvent to clean the flywheel
compressed air.

housing.

Dry with

Inspection
Visually inspect all surfaces for nicks, burrs, or cracks.
Use Scotch
and burrs.

Britee 7443, or equivalent,

to remove small nicks

q
\

0a9

q
\

Inspect all threaded

capscrew

Repair or replace
damaged.

the

holes for damage.

housing

if the

capscrew

holes

are

0@B

fh900sb

Molrntina Adaptations - Group 16

Engine Support Bracket, Front - Cleaning and Inspection for Reuse (1606)
Page 16-9

Engine Support Bracket, Front - Cleaning


and Inspection for Reuse (16-06)
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.

Cleaning
Steam clean or use solvent, and dry with compressed air.

Inspection
Visually inspect the engine support bracket for cracks or
damage. If cracks or damage are found, the support bracket
must be replaced.

0
@

Saecifications and Torque Values - Group 18


Page V-i

Section V - Specifications and Torque Values - Group 18


Section Contents
Page
Air Compressor Inspection Specifications

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

V-37

Air Compressor Torque Values .................................................

V-37

Capscrew Markings and Torque Values ...........................................

V-45
V-46
V-46

Capscrew
Capscrew

Markings and Torque Values - Metric .....................................


Markings and Torque Values - U.S. Customary ...............................

Component Specifications and Torque Values ......................................


Cylinder Block - Rebuild Specifications ...........................................
Cylinder Block - Torque Values ................................................
Cylinder Head - Rebuild Specifications
...........................................
Engine Assembly - Specifications
...............................................
Engine Assembly - Torque Values ...............................................

V-3
V-15
V-21
V-22
V-3
V-5

V-33

Cooling System Specifications

.................................................
Air Intake System Specifications
................................................
Air Intake System Torque Values ...............................................
Cooling System Torque Values .................................................

V-35
V-35
V-34

Drive Belt Tension ..........................................................

V-41

Electrical System Specifications

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

V-38

Electrical System Torque Values ................................................

V-38

Engine Components - General Information .........................................


Engine

Testing - Test Specifications .............................................

V-2
V-39

Exhaust System Specifications .................................................

V-37

Exhaust System Torque Values .................................................

V-37

Fuel Systems - Rebuild Specifications ............................................

V-25

Fuel
Fuel
Fuel
Fuel

Injection Pump Sealing Washer .............................................


Shutoff Solenoid Adjustment
...............................................
System Specifications
...................................................
System Torque Values ...................................................

Lubricating Oil System Specifications

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

V-27
V-27
V-25
V-27

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

v-30

Lubricating Oil System Torque Values ..............

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

v-31

Mounting Adaptations - Torque Values

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

v-40

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

v-39
v-39

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

Mounting Adaptations Specifications ...............


Flywheel
Flywheel

Housing (Wet Application)


...............
Ring Gear Installation ...................

Newton-Meter

to Foot-Pound Conversion Chart

Pipe Plug Torque Values

.......

V-40

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . v-47

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

Rocker Lever Assembly - Rebuild Specifications .......

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

V-25

Tap-Drill Chart - U.S. Customary & Metric ...........

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

V-43

Valve Tappet - Rebuild Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-25

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

Weight and Measures - Conversion Factors ........................................

V-43

Engine Components - General Information


Page V-2

Specifications and Torque Values - Group 18

Engine Components - General Information


The specifications in this section are organized in the same sequence used in each group of this manual. The minimum
and maximum tolerance limit specifications are listed in both metric and U.S. Customary dimensions. The metric dimension
is given first, followed by the U.S. Customary dimension in brackets; for example: 0.50 mm [0.020 inch]. The assembly
and rebuild specifications and torque values are provided to be sure the parts are assembly correctly, fit properly, and
are secured with correct torque value.
Most of the capscrews used to assembly the 6D114E-1 Series engine are metric. Some components, such as the air
compressor and hydraulic pump, are installed using U.S. Customary capscrews. Capscrew torque value are listed in
newton-meters and foot pounds, unless otherwise specified. If a torque value is not listed, use the standard torque value
for the capscrew, refer to the Capscrew Markings and Torque Values, on page V-46.

Specifications
and Torque Values-Group

Component

or Assembly (Procedure)

Component Specifications

Component Specificationsand TorqueValues

18

Ref.No./Steps

PageV-3

U.S.

Metric

and Torque Values

Engine Assembly - Specifications


Cylinder Liner Protrusion

0.025 mm
0.122 mm

MIN
MAX

0.001 in
0.0048 in

0.229 mm

MIN

0.009 in

Note: Use Part No. 3822503, Cylinder Liner Clamp


Set to seat the liner into the bore. Check the liner
protrusion with the clamps removed.
Cylinder Liner-to-Block

Clearance

Cylinder Liner Out-of-Round

Cylinder Block Upper Liner Bore I.D.

Cylinder Liner Top Press Fit O.D.

Crankshaft
New

End Clearance

Used

0.08 mm

MAX

in

0.003

130.000
130.990

MIN
MAX

5.1535
5.1570

130.938

MIN
MAX

5.1550
5.1558

130.958

0.127

mm
0.330 mm

MIN
MAX

0.005 in
0.013 in

0.533 mm

MAX

0.021

in
ksZOO]ah

Piston Ring Gap (New)


Top Ring Gap
Inteimediate

Ring Gap

Oil Control Ring Gap

0.35 mm
0.60 mm
0.35 mm
0.65 mm
0.30 mm
0.60 mm

MIN
MAX
MIN
MAX
MIN
MAX

0.0138 in
0.024 in
0.0138 in
0.026 in
0.0118 in
0.0236 in

Component Specifications and Torque Values


Page V-4

Component
Connecting

Specifications and Torque Values - Group 18

or Assembly (Procedure)

Ref.No./Steps

Rod Bearing Side Clearance

Oil Pump Drive Gear Backlash


Oil Pump Idler Gear Backlash

Metric

U.S.

0.100 mm
0.330 mm

MIN
MAX

0.0039
0.0130

0.08 mm
0.45 mm

MIN
MAX

0.003 in
0.018 in

MIN
MAX

0.003 in
0.013 in

0.08 mm
0.33 mm

Camshaft Gear Backlash

0.08 mm
0.33 mm

MIN
MAX

0.003 in
0.013 in

Camshaft End Clearance

0.12 mm
0.46 mm

MIN
MAX

0.0047 in
0.0181 in

0.127 mm

MAX

0.0050 in

0.203
0,254
0.305
0.356
0.406

MAX
MAX
MAX
MAX
MAX

Flywheel Bore Runout T.I.R.

Flywheel Face Runout T.I.R.


2:3m
Radiusit?)
254 1:
305 12
356 14
406
16

Valve Adjustment
Intake Valve
Exhaust Valve

mm
mm
mm
mm
mm

0.008
0.010
0.012
0.014
0.016

in
in
in
in
in

Clearance
0.30 mm
0.61 mm

Nominal
Nominal

0.012 in
0.024 in

Specifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Component Specifications and Torque Values


Page V-5

Ref.No./Steps

Metric

U.S.

Vibration Damper Face Alignment


(Wobble) T.I.R.

0.28 mm

MAX

0.011 in

Vibration Damper Eccentricity

0.28 mm

MAX

0.011 in

T.I.R.

Engine Assembly - Torque Values


Cylinder Liner Clamps

68 Nom

50 ft-lb

50 N*m
119 Nom
176 N*m

37 f&lb
88 ft-lb
129 ft-lb

40 N*m
80 N*m
120 Nom

30 ft-lb
60 ft-lb
88 ft-lb

I!72

24 Nom
60 N*m

18 ft-lb
44 ft-lb

Oil Pump Mounting Capscrews

24 N*m

18 ft-lb

Main Bearing Cap Capscrews

Step 1
:

Connecting

Rod Nuts

Step 1
:

Gear Housing Mounting Capscrews

Component Specifications and Torque Values


Page V-8

Specifications and Torque Values - Group 18

Metric

U.S.

24 Nom

18 ft-lb

9 N*m
9 N*m
9 Nom

80 in-lb
80 in-lb
80 in-lb

Oil Pan Mounting Capscrews


Note: Tighten the capscrews in the sequence
shown. Start at the center of the oil pan and
alternate toward both ends.

24 Nom

18 ft-lb

Oil Pan Drain Plug

80 N*m

59 ft-lb

8 N*m

71 in-lb

Flywheel Housing Mounting Capscrews

77 Nom

57 ft-lb

Flywheel Housing Access Plate


Capscrews

24 Nom

18 f&lb

Component

or Assembly (Procedure)

Ref.No./Steps

Water Pump Mounting Capscrews

Oil Pump Suction Tube to Block


Brace to Block
Brace to Suction Tube

Timing Pin Torx Capscrews

A
:

Soecifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Component Specifications and Torque Values


Page V-7

Ref.No./Steps

Metric

U.S.

140 N*m

101 ft-lb

Starting Motor Mounting Capscrews

77 Nom

57 ft-lb

Coolant Heater

12 N*m

106 in-lb

Oil Cooler Mounting Capscrews


Oil Filter Head Mounting Capscrews

24 Nom
24 Nom

18 ft-lb
18 ft-lb

Flywheel Mounting Capscrews

Cylinder Head Mounting Capscrews

Step 1
:

52 ft-lb
70 N*m (All Capscrews)
145 N*m (Long Only)
105 ft-lb
Rotate 90 Degrees (Ail Capscrews)

Note: Tighten the capscrews in the sequence


shown. Start at the center of the cylinder head
and alternate toward both ends.

Rocker Lever Retaining Clamp Capscrews

55 Nom

41 ft-lb

Rocker Lever Adjusting Screw Locknut

24 Nom

18 ft-lb

Component
Page V-8

Specifications

and Torque

Specifications

Values

Values

- Group

18

Metric

U.S.

24 N*m

18 ft-lb

24 N*m
43 Nom

18 ft-lb
32 ft-lb

injection Nozzle Clamp Capscrew

24 Nom

18 ft-lb

Fuel Drain Manifold


Banjo Connector
l
Injector
l
Filter Head

9 Nom
15 Nom

80 in-lb
11 ft-lb

Engine Lifting Bracket Capscrews

77 Nom

57 ft-lb

Intake Manifold Cover Capscrews

24 Nom

18 ft-lb

Aftercooler

24 N*m

18 ft-lb

Component

or Assembly (Procedure)

Ref.No./Steps

and Torque

Valve Cover Capscrews


Note: Tighten the capscrews in the sequence
shown. Start at the center of the valve cover
and alternate toward both ends.

Crankcase Breather Tube


Support Bracket Capscrews

Assembly Capscrews

A
6

Specifications and Torque Values - Group 18

Component
Aftercooler
Capscrews

or Assembly (Procedure)

Ref.No./Steps

Component Specifications and Torque Values


Page V-9

Metric

U.S.

Coolant Supply Tube


6 Nom

53 in-lb

Exhaust Manifold Mounting Capscrews

43 N-m

32 ft-lb

Turbocharger

Mounting Studs

10 Nom

89 in-lb

Turbocharger

Mounting Nut

45 Nom

33 R-lb

Turbocharger
Capscrew

Oil Drain Mounting


24 Nom

18 ft-lb

Turbocharger

Oil Drain Line Hose Clamps

5 N*m

44 in-lb

Turbocharger

Turbine Housing Capscrews

20 Nom

15 ft-lb

Component Specifications and Torque Values


Page V-10

Component

or Assembly (Procedure)

Specifications and Torque Values - Group 18

Ref.No./Steps

Metric

U.S.

Turbocharger Compressor Housing Clamp


V-Band Clamp Nut
Actuator Bracket Brace Capscrews

8 N*m
13 N*m

71 in-lb
115 in-lb

Turbocharger Oil Supply Hose


Fittings
Hose Connection

24 Nom
35 Nom

18 ft-lb
26 ft-lb

Turbocharger
Band Clamp
Capscrews

Exhaust Outlet:
8 Nom
43 Nom

71 in-lb
32 ft-lb

Turbocharger

Air Crossover Hose Clamps

5 N*m

44 in-lb

24 Nom

18 ft-lb

Coolant Vent Line Fitting

8 Nom

71 in-lb

Coolant Vent Petcock

5 N*m

44 in-lb

Water Outlet Connection Capscrews

Snecifications

Component

and Torque

Values

- Group

or Assembly (Procedure)

Coolant Vent Line Tube

Coolant Inlet Connection

Hose Clamps

18

Ref.No./Steps

Component

Metric

Specifications

U.S.

8 Nom

71 in-lb

5 Nom

44 in-lb

Alternator

Mounting Bracket Capscrews

24 N*m

18 ft-lb

Water Pump Mounting Capscrew

24 N*m

18 ft-lb

Alternator

43 N*m
24 N*m
80 Nom

32 ft-lb
18 ft-lb
59 ft-lb

Mounting Capscrew

Belt Tensioner

Mounting Bracket

24 Nom

18 ft-lb

Belt Tensioner

Mounting Capscrews

43 Nom

32 ft-lb

and Torque Values


Page V-l 1

Component Specifications and Torque Values


Page V-12

Component

or Assembly (Procedure)

Specifications and Torque Values - Group 18


t

Flef.No./Steps

Fan Hub Mounting Capscrews

Fuel injection Pump


Mounting Nuts
Studs

Fuel Injection Pump Timing Pin Access


Plug

Fuel Injection Pump Drive Gear Nut


A Pump
MW Pump
P Pump

Fuel injection Pump Supply Banjo Fitting

Fuel Filter Head Adapter


Fuel Filter Adapter Nut

Fuel Filter
Install the filter as specified by the filter manufacturer.

Metric

U.S.

24 N*m

18 ft-lb

44 N*m
Hand Tight

32 ft-lb

15 Nom

11 fi-lb

92 N-m
104 N-m
195 Nom

32 Nern

11 Nom
32 Nom

68 ft-lb
77 ft-lb
144 ft-lb

24

ft-lb

8 ft-lb
24 ft-lb

SDecifications

and Torque Values - Group 18

Component

Specifications

and Torque Values

Page V-13
Component or Assembly (Procedure)
High Pressure Fuel Line Fittings

Ref.No./Steps

Metric
24 Nom

U.S.
18 ft-lb

High Pressure Fuel Line Support Bracket

Bracket Capscrews
Vibration Isolator Capscrews

Gear Cover Capscrews

Vibration Damper
Pulley to Vibration Damper

Fan Hub Pulley Mounting Capscrews

Front Engine Support Bracket Mounting


Capscrews
l
Without Support

Fuel Transfer Pump Mounting Capscrews

24 Nom

6 Nom

18 ft-lb
53 in-lb

24 Nom

18 ft-lb

200 Nom
77 N*m

148 ft-lb
57 ft-lb

45 N*m

32 ft-lb

112 Nom
60 N*m

83 ft-lb
44 ft-lb

24 Nmrn

18 ft-lb

Component Specifications and Torque Values


Page V-l 4

Component

or Assembly (Procedure)

Fuel Transfer Pump Fuel Line Fittings

Specifications and Torque Values - Group 18

Fief.No./Steps

Metric

U.S.

24 Nom

18 ft-lb

9 Nom

80 in-lb

77 Nom

57 ft-lb

43 Nom

32 ft-lb

8 N*m

71 in-lb

Air Compressor Coolant Supply Line


Fitting

35 Nom

26 in-lb

Air Compressor Connections


Inlet
Outlet

5 Nom
24 Nom

48 in-lb
18 ft-lb

Fuel Injection Pump Solenoid

Air Compressor

Mounting Nuts

Air Compressor Support Brace Capscrews

Air Compressor Oil Supply Line Fitting

Suecifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Ref.No./Steps

Component Specifications and Torque Values


Page V-l 5

Metric

U.S.

Cylinder Block - Rebuild Specifications


Cylinder Block Head Deck Flatness
End-to-End
Side-to-Side

Cylinder Block Upper Liner Bore I.D.

Cylinder Block Counterbore


Cylinder Block Head Deck

0.075 mm
0.075 mm

130.900 mm
130.990 mm

0.0030 in
0.0030 in

MIN
MAX

5.1535 in
5.1570 in

Depth From
122.930 mm
123.000 mm

MIN
MAX

4.8397 in
4.8425 in

309.40 mm
309.60 mm

MIN
MAX

12.181 in
12.189 in

361.90 mm
362.10 mm

MIN
MAX

14.248 in
14.256 in

98.079 mm
98.125 mm

MIN
MAX

3.8614 in
3.8632 in

104.982 mm
105.018 mm

MIN
MAX

4.1331 in
4.1346 in

Camshaft Bore Diameter


Without Bushing

64.01 mm

MAX

2.520 in

With Bushing Installed

60.12 mm

MAX

2.367 in

Cylinder Block Height From Head Deck


Surface to Top of Main Bearing Bore

Cylinder Block Height From Head Deck


;imfxe
to Centerline of the Main Bearing

Main Bearing Bore Diameter


With New Bearings
Without Bearings

Component Specifications and Torque Values


Page V-18

Component

Specifications and Torque Values - Group 18

or Assembly (Procedure)

Ref.No./Steps

Metric

Valve Tappet Bore Diameter

16.00 mm
16.05 mm

Cylinder Liner Inside Diameter

114.GfIOmm
114.140 mm

U.S.
MIN
MAX

MIN

MAX

0.630 in
0.632 in

4.4882
4.4898

in
in

Cylinder Liner Out-of-Round

0.08 mm

MAX

0.003 in

Cylinder Liner Taper

0.08 mm

MAX

0.003 in

Cylinder Liner Seat Area Depth

123.026 mm

MIN
MAX

4.8435 in
4.8445 in

MIN
MAX

5.1550 in
5.1558 in

123.052

mm

Cylinder Liner O.D. (Top Press Fit)

130.938 mm
130.958 mm

Piston Pin Bore Inside Diameter

45.006 mm
45.025 mm

MIN
MAX

1.7719 in
1.7726 in

Piston

44.993 mm
45.003 mm

MIN
MAX

1.7714 in
1.7718 in

Pin Outside

Diameter

Note: Discard the piston pin if it is more than


0.03 mm [O.OOl inch] out of round.

Soecifications

and Torque Values - Group 18

Component or Assembly (Procedure)


Piston

Skirt Outside

Diameter

Ref.No./Steps

Component

Metric

Specifications

U.S.

113.814 mm
113.886 mm

MIN
MAX

4.4810 in
4.4840 in

Top Ring Groove Keystone Angle Wear


Use micrometer and Part No. 3823966.

113.938 mm

MIN

4.4857 in

Intermediate
Ring Groove Keystone Angle
Wear
Use micrometer and Part No. 3823965.

114.323 mm

MIN

4.5009 in

0.020 mm
0.130 mm

MIN
MAX

0.0008 in
0.0051 in

0.025 mm

MAX

0.010 in

75.962 mm
76.013 mm

MIN
MAX

2.9906 in
2.9926 in

0.050 mm
0.013 mm

MAX
MAX

0.0020 in
0.0005 in

97.962 mm
98.013 mm

MIN
MAX

3.8568 in
3.8588 in

0.050 mm
0.013 mm

MAX
MAX

0.0020 in
0.0005 in

42.975 mm
43.076 mm

MIN
MAX

1.6919 in
1.6959 in

Oil Control Ring Side Clearance

Crankshaft Oil Seal Wear Groove, Front


and Rear

Crankshaft Connecting
l Outside
Diameter

l
l

Rod Journal

Out-of-Round
Taper

Crankshaft Main Bearing Journal


l Outside
Diameter

l
l

Out-of-Round
Taper

Crankshaft Thrust Face Width (Standard)

and Torque Values


Page V-17

Component Specifications and Torque Values


Page V-18

Component

Specifications and Torque Values - Group 18

or Assembly (Procedure)

Ref.No./Steps

Metric

U.S.

Crankshaft Rear Oil Seal Flange O.D.

129.975 mm
130.025 mm

MIN
MAX

5.1171 in
5.1191 in

Crankshaft Damper Pilot O.D.

23.924 mm
24.000 mm

MIN
MAX

0.9419 in
0.9449 in

Crankshaft Gear Journal O.D.

75.987 in
76.006 mm

MIN
MAX

2.991 in
2.992 in

0.157 mm
0.334 mm

MIN
MAX

0.0062 in
0.0131 in

Used

0.535 mm

MAX

0.0210 in

Crankshaft Gear Bore I.D.

75.898 mm
75.923 mm

MIN
MAX

2.9881 in
2.9891 in

Crankshaft End Clearance


New

- Austempered

Crankshaft Gear Installation


Gear:
l Temperature
l Time

149%
45 Min.
6 Hrs.

MAX
MIN
MAX

300F
45 Min.
6 Hrs.

- Steel Gear:
l Temperature
l Time

177%
45 Min.
6 Hrs.

MAX
MIN
MAX

35O=F
45 Min.
6 Hrs.

(Used)

3.446 mm
3.454 mm

MIN
MAX

0.1357 in
0.1360 in

Main Bearing Clearance With Plastigauge

0.066 mm
0.134 mm

MIN
MAX

0.0026 in
0.0053 in

Standard

Main Bearing

Thickness

Specifications

and Torque

Values

- Group

18

Component

Specifications

and Torque

Values

Page V-19

Component

or Assembly (Procedure)

Thrust Bearing Flange Thickness

Connecting Rod Piston Pin I.D.


With Bushing
Without Bushing

Connecting Rod Crankshaft


(With Bearings)

Connecting

Rod Bearing Side Clearance

Connecting
(Standard)

Rod Bearing Thickness

Connecting

Rod Length

Connecting Rod Bend (Alignment)


l
Without Bushing
With Bushing

U.S.

Metric
3.517 mm
3.567 mm

MIN
MAX

0.138 in
0.140 in

45.023 mm
45.060 mm

MIN
MAX

1.7726 in
1.7740 in

48.988 mm
49.012 mm

MIN
MAX

1.9286 in
1.9296 in

76.046 mm
76.104 mm

MIN
MAX

2.9939 in
2.9962 in

0.033 mm
0.117 mm

MIN
MAX

0.0013 in
0.0046 in

0.100 mm
0.330 mm

MIN
MAX

0.0039
0.0130

2.428 mm
2.471 mm

MIN
fvlAX

0.0956 in
0.0973 in

215.975 mm
216.025 mm

MIN
MAX

8.5029 in
8.5049 in

0.20 mm

MAX

0.008 in

0.15 mm

MAX

0.006 in

Bore I.D.

Connecting Rod Bearing Clearance (With


Plastiguage)

Ref.No./Steps

Component Specifications and Torque Values


Page V-20

Component

Specifications and Torque Values - Grow 18

or Assembly (Procedure)

Connecting Rod Twist


l Without
Bushing
l

With Bushing

Camshaft Bore Diameter


l With
Bushing

0
.I:i
4

Metric

U.S.

0.50 mm

MAX

0.020

in

0.30 mm

MAX

0.012

in

60.12

mm

2.367

in

l Without
Bushing
Note: If one of the bushings exceeds the
specifications, all of the bushingsmust be
replaced.

64.01

mm

2.520

in

Camshaft Journal Outside Diameter

59.962
60.013

mm
mm

MIN
MAX

2.3607
2.3627

in
in

51.774
52.251

mm
mm

MIN
MAX

2.0383 in
2.0571 in

51.596
52.073

mm
mm

MIN
MAX

2.0313 in
2.0501 in

41.310
41.829

mm
mm

MIN
MAX

1.6264
1.6468

in
in

41.562
41.580

mm
mm

MIN
MAX

1.6363
1.6370

in
in

MIN
MAX

0.3677
0.3772

in
in

MIN
MAX

1.6331
1.6341

in
in

Camshaft Lobe Diameter


Intake Lobe
Exhaust

Lobe

Fuel Transfer

Pump

Lobe

Camshaft Nose (Gear Mounting Surface)


Outside Diameter

Ref.No./Steps

Camshaft Thrust Plate Thickness

9.340
9.580

Camshaft Gear Bore Inside Diameter

41.480 mm
41.505 mm

!_a

mm
mm

--+I---

Specifications

and Torque Values - Group 18

Component or Assembly (Procedure)

Component

Ref.No./Steps

Camshaft Gear Installation


- Austempered Gear:

Metric

Specifications

U.S.

149%
45 Min.
6 Hrs.

MAX
MIN
MAX

300F
45 Min.
6 Hrs.

177%
45 Min.
6 Hrs.

MAX
MIN
MAX

350F
45 Min.
6 Hrs.

Vibration Damper Face Alignment


(Wobble ) T.I.R.

0.28 mm

MAX

0.011 in

Vibration Damper Eccentricity

0.28 mm

MAX

0.011 in

l
l

Temperature
Heating Time

- Steel Gear:
0 Temperature
l
Heating Time

T.I.R.

Vibration Damper Thickness


Measure the thickness at four locations 90 degrees apart approximately 3.18 mm [0.125 in] from
the outside diameter. The difference between any two of the four measurements must not exceed
0.25 mm [O.OlO in].

Rear Cover Crankshaft Seal Bore I.D.

149.96 mm
150.04 mm

MIN
MAX

5.904 in
5.907 in

Cylinder Block - Torque Values


Cylinder Block Pipe Plugs (Into Cast Iron)
Refer to chart on page V-47.

Cylinder Block - Main Bearing Calf


Capscrew

10
15
25
35
55
75
95

1
:

Nom
Nom
N*m
N*m
N*m
Nom
Nom

50 Nom
119 Nom
176 Nom

Size
l/l6 inch
118 inch
l/4 inch
318 inch
112 inch
314 inch
1 inch

7
11
20
25
40
55
70

ft-lb
f&lb
ft-lb
ft-lb
ft-lb
ft-lb
ft-lb

37 ft-lb
88 ft-lb
129 ft-lb

and Torque Values


Page V-21

Component Specifications and Torque Values


Page V-22

Component
Connecting

or Assembly (Procedure)
Rod Capscrew Nuts

Specifications and Torque Values - Chub 18

Ref.No./Steps
1
:

Metric

U.S.

40 Nom
120
80 Nom
N*m

30 ft-lb
88 ft-lb
60

Cylinder Head - Rebuild Specifications


fyi;;;r

Head Capscrew Free Length

Long

Cylinder Head Flatness


End-to-End
Side-to-Side
Local Flatness
(Within a 51 mm [2.0 inch] area)

Fy;lifr

Machined

yk:wGuide

3.21 in

162.6 mm

MAX

6.40 in

0.200 mm
0.076 mm

MAX
MAX

0.0079 in
0.0030 in

0.0254 mm

MAX

0.001 in

115.75 mm
116.25 mm

MIN
MAX

4.557 in
4.577 in

114.75 mm

MIN

4.518 in

3.0 mm
4.0 mm

MIN
MAX

0.118 in
0.157 in

9.539 mm
9.559 mm

MIN
MAX

0.3756 in
0.3763 in

9.591 mm

MAX

0.3776 in

20.65 mm
21.16 mm

MIN
MAX

0.813 in
0.833 in

22.50 mm
23.01 mm

MIN
MAX

0.886 in
0.906 in

I.D. (Installed)

Used

Krk;

MAX

Head Thickness

Injector Nozzle Tip Protrusion

81.5 mm

Guide Height (Installed)

Exhaust

Component Specifications and Torque Values


Page V-23

Specifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Ref.No./Steps

U.S.

Metric

Valve Guide Bore I.D.

15.931 mm
15.971 mm

MIN
MAX

0.6272 in
0.6288 in

Valve Guide (New) O.D.

15.988 mm
16.000 mm

MIN
MAX

0.6294 in
0.6299 in

0.05 mm

MAX

0.002 in

Valve Seat-to-Valve
(360 Degrees)

Guide Concentricity

Valve recess in Cylinder Head


Exhaust

1.09 mm
1.62 mm

MIN
MAX

0.043 in
0.064 in

Intake

0.59 mm
1.12 mm

MIN
MAX

0.023 in
0.044 in

Valve Insert Bore I.D. (Standard insert)


Intake

Exhaust

zFk;

Insert Bore Depth (Standard Insert)

Exhaust

Valve Sealing Surface Angle


Intake
Exhaust

53.930 mm

MAX

2.1231

in

47.027 mm

MAX

1.8515

in

12.20

mm

MAX

0.480

in

9.83 mm

MAX

0.387

in

Component

Component or Assembly (Procedure)

Ref.No.lSteps

Valve Seat Width Limit

Valve Seat Vacuum


New
Used
Acceptable

leakage rate in 10 seconds.

U.S.

Metric
1.5 mm
2.0 mm

MIN
MAX

0.060 in
0.080 in

508 mm Hg
635 mm Hg

MIN
MAX

20 in Hg
25 in Hg

457 mm Hg
254 mm Hg

MIN
MAX

Valve Spring Free Height (New)


(7-l /2 coils)
Standard Intake and Exhaust

65.66 mm

Nominal

2.585 in

Dual Spring (Exhaust)


Outer Spring
Inner Spring

A
A

77.47 mm
72.64 mm

Nominal
Nominal

3.049 in
2.860 in

62.05 mm

Nominal

2.440 in

B
B

78.79 mm
50.80 mm

Nominal
Nominal

1.92 in
2.00 in

689 N
71 N
710.1 N
811.1 N
464.5 N
513.5 N

Nominal
Nominal
MIN
MAX
MIN
MAX

154.9 Ibf
15.9 Ibf
159.6 Ibf
182.3 Ibf
104.4 Ibf
115.4 Ibf

450 N

MIN

101.2 Ibf

B
B

35.89 mm
37.99 mm

Nominal
Nominal

1.413 in
1.492 in

959.5 N
1060.5 N

MIN
MAX

215.7 Ibf
238.4 Ibf

940.0 N

MIN

211.3 Ibf

C
C
C

1023 N
111 N
1084 N
1184 N

Nominal
Nominal
MIN
MAX

230 Ibf
25 Ibf
244 Ibf
266 Ibf

995 N
1095 N

MIN
MAX

224 Ibf
246 Ibf

(New)

Valve Rotator Spring (New)


Valve Spring Working
Rotator Spring
All Other Springs

Height

Spring Force at Assembled


Outer Spring
Inner Spring
Assembly
All Other Springs

(New)

Height (New)
:
C

(New)

Standard Spring (Used)


Intake and Exhaust
Valve Spring at Opening
Valve Rotator Spring
Intake and Exhaust
All Other springs (New)
Spring Force at Opening
Standard Spring
Intake and Exhaust

Height (New)

Height

Standard Spring (Used)


Intake and Exhaust
Dual Spring (Exhaust) (New)
Outer Spring
Inner Spring
Assembly

Valve Rotator Spring (New)


Intake and Exhaust

(New)

Specifications

Component or Assembly (Procedure)


Valve Stem O.D.

Valve Head Thickness

Exhaust
intake

Component

and Torque Values - Group 18

Ref.No./Steps

Specifications

U.S.

Metric
9.46 mm

MIN

9.50 mm

MAX

0.372 in
0.374 in

2.22 mm

MIN
MAX

0.119 in

at O.D.
3.01 mm

0.087 in

and Torque Values


Page V-24-01

Specifications and Torque Values - Group 18

Component

or Assembly

(Procedure)

Rocker Lever Assembly - Rebuild Specifications


Page V-25
U.S.

Metric

Ref.No./Steps

Rocker Lever Assembly - Rebuild Specifications


Rocker

Lever Bore I.D.

22.256 mm
22.301 mm

MIN
MAX

0.8762 in
0.8780 in

Rocker

Lever Shaft O.D.

22.199 mm
22.231 mm

MIN
MAX

0.8740 in
0.8752 in

15.925 mm
15.980 mm

MIN
MAX

0.6270 in
0.6291 in

Valve Tappet - Rebuild Specifications


Valve Tappet

Stem O.D.

Valve Tappet Visual Limits


Inspect the socket stem and face
for excessive wear, cracks or damage
Concavity

Valve Tappet Face


1. A single pit cannot
2. Interconnection

be greater than 2 mm [0.078

(C)

Normal Wear
Abnormal (Do not use)
Abnormal (Do not use)

(A)

0.025 mm

in] in diameter.

of pits is not allowed and is treated as one pit.

3. Total pits when added together should not exceed 6 mm (0.236 in]
diameter or a total of 4 percent of the tappet face.
4. No pitting is allowed on the edges of the wear face of the valve tappet.

Fuel Systems - Rebuild Specifications


Note: This manual does not cover fuel injection pump rebuild or calibration.
Rebuild and calibration should be performed in a facility certified in the
rebuild and calibration of the fuel injection pumps.
Refer to Bulletin No. 3810348 for additional service and parts information.

Fuel System Specifications


Engine Low Idle Speed
Refer to the engine dataplate.

0.001 in

Fuel Rebuild - System Specifications


Page V-26

Component

Specifications and Torque Values - Group 18

or Assembly (Procedure)

Ref.No./Steps

Fuel Transfer Pump Inlet Restriction


Series Engine

6D114E-1

Fuel transfer Pump Outlet Pressure


at Rated Speed
6D114E-1 Series Engine

Fuel Injection Pump


Fuel Inlet Pressure at Rated Speed

Fuel Injection Pump


Fuel Return Line Restriction

Metric

U.S.

100 mm Hg

MAX

4 in Hg

High Flow

172 kPa

Low Flow

83 kPa

MIN
MAX

25 psi
12 psi

High Flow
Low Flow

MIN
MAX

20 psi

48 kPa

140 kPa

518 mm Hg

7 psi

MAX

20.4 in Hg

Fuel Filter Restriction


Pressure Drop Across Filter

35 kPa

MAX

5 psi

Fuel Drain Line Restriction

70 kPa

MAX

10 psi

MIN

0.125 in
0.250 in

Fuel Injection Pump Throttle Lever


BLeakover

3.18 mm
6.35 mm

MAX

Specifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Fuel Rebuild - System Specifications


Page V-27

Ref.No./Steps

Metric

U.S.

Fuel Shutoff Solenoid Adjustment


- Synchro-Start
l
Plunger Stroke Gap
l
Plunger Stroke Length

0.04 mm
25.4 mm

MAX
MAX

0.118 in
1 .O in

- Trombetta
l
Plunger Stroke Gap
l
Plunger Stroke Length

0.04 mm
33.3 mm

MAX
MAX

0.118 in
1.3 in

Fuel Shutoff Solenoid Adjustment


RQVK Governor

66.9 mm

2.64 in

Fuel System Torque Values


Air Fuel Control (AFC)

24 Nom

Banjo Fiiing

8 Nom

Threaded Fiiing

18 ft-lb
71 in-lb

Fuel Filter
install the filter as specified

by the filter manufacturer.

Fuel Injection Pump Sealing Washer


- Bosch Pump
l
l

Sealing Washer
Sealing Washer

Fuel Filter Head Adapter


Fuel Filter Adapter Nut

A
D

32 Nom

24 ft-lb

15 N*m

11 ft-lb

4 Nom
32 Nom

35 in-lb
24 ft-lb

Fuel Rebuild - System Specifications


Page V-28

Comoonent

Specifications and Torque Values -Group 18

or Assemblv (Procedure)

Ref .No./Steos

Fuel Filter Head Banjo Fittings

Metric

U.S.

24 N*m

18 h-lb

Fuel Injection Pump Solenoid Mounting


Capscrews

9 Nom

80 in-lb

Fuel Injection Pump Supply Banjo Fitting

32 Nom

24 ft-lb

Fuel Injection Pump


Mounting Nuts
Studs

Fuel Injection Pump Support


Lower Brackets
M8 Pump to Support Bracket Capscrew
Ml0

Support Bracket to block Capscrew

Upper Bracket

Fuel Injection Pump Drive Gear ,Nut


A Pump
MW Pump
P Pump

Fuel Injection Pump Timing Pin Access


Plug

44 Nom
Hand Tight

Nom

32 ft-lb

45 N*m

18 ft-lb
33 it-lb

24 N*m

18 ft-lb

24

92 N*m
104 N*m
165 N*m

68 ft-lb
77 ft-lb
122 ft-lb

15 Nom

11 ft-lb

Snecifications and Torque Values - Group 18

Fuel Rebuild - System Specifications

Page V-29
Component or Assembly (Procedure)

Ref.No./Steps

Metric

U.S.

Fuel Shutoff Solenoid Mounting Bracket


Capscrews

10 N*m

89 in-lb

Fuel Transfer Pump Fittings


- Outlet
- Inlet
- Hand Primer

30 N*m
30 N*m
30 N*m

22 ft-lb
22 ft-lb
22 &lb

Fuel Transfer Pump


Fuel Line Fittings

24 N*m

18 ft-lb

Fuel Transfer Pump Mounting Capscrews

24 N*m

18 ft-lb

High Pressure Fuel Line Fittings

High Pressure Fuel Line Support Bracket


Bracket Capscrews

Vibration Isolator Capscrews

Injector Opening Pressure


a. Open valve
b. Operate spray tester lever at one stroke per second
c. Read pressure indicated

when spray began

24 Nom

24 Nom

6 Nom

18 ft-lb

18 ft-lb
53 in-lb

Lubricating Oil System Specifications


Page V-30

Component

Specifications

or Assembly (Procedure)

Ref.No./Steps

and Torque Values - Group 18

Metric

U.S.

Leakage Test:
a. Open valve
b. Operate spray tester lever to hold pressure 20 bar [290 psi] below opening pressure
c. No drops should fall from the tip within 20 seconds

Injector Nozzle Clamp Capscrew

Injector Nozzle Banjo Fitting

24 Nom

18 ft-lb

9 Nom

80 in-lb

Lubricating Oil System Specifications


Lubricating Oil Thermostat
l
Fully Open Temperature
l
Maximum Opening Distance

Oil Capacity of Pan (All Engines):


- Low Level
- High Level

116%
45.9 mm

MAX
MAX

240F
1.80 in

15.1 liters
18.9 liters

16.0 U.S. Qts.


20.0 U.S. Qts.

23.6 liters
23.8 liters

25.0 U.S. Qts.


25.2 U.S. Qts.

T;&J ,!9y;t;m Capacity


S6D114E-1

Oil Cooler Distortion

Oil Cooler Element Pressure Test


Pressure
Temperature

0.8 mm

483 kPa
82%

MAX

0.031 in

70 psi
18OOF

Lubricating Oil System Specifications


Page V-31

Specifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Oil Pressure Regulator Spring


Spring Free Length
13-coils

Ref.No./Steps

Metric

86.63 mm

Spring Load at 53.98 mm [2.125 in]


Valve Open
Spring Load at 60.33 mm [2.375 in]
Assembled

U.S.

Nominal

3.411 in

190 N

MIN

42.8 Ibf

153 N

MIN

34.4 Ibf

Oil Pump Gerotor Tip Clearance

0.025 mm
0.178 mm

MIN
MAX

0.001 in
0.007 in

Oil Pump Port Plate Clearance

0.025 mm
0.127 mm

MIN
MAX

0.001 in
0.005 in

Oil Pump Body Bore Clearance

0.127 mm
0.381 mm

MIN
MAX

0.005 in
0.015 in

Oil Pump Drive Gear Backlash

0.08 mm
0.45 mm

MIN
MAX

0.003 in
0.018 in

Oil Pump Idler Gear Backlash

0.08 mm
0.45 mm

MIN
MAX

0.003 in
0.018 in

Lubricating Oil System Torque Values


Crankcase Breather Tube Bracket
M8 (Valve Cover)
Ml 2 (Cylinder Head)

24 N*m
80 N*m

18 ft-lb
59 ft-lb

Lubricating Oil System Specifications


Page V-32

Component

Specifications and Torque Values - Group 18

or Assembly (Procedure)

Ref.No./Steps

Oil Cooler Cover Mounting Capscrews


Oil Filter Head Mounting Capscrews

Metric

U.S.

24 Nom
24 Nom

18 ft-lb
18 ft-lb

Oil Cooler Cover Pipe Plugs


10
10
36
45

Nom
N*m
Nom
N*m

74 in-lb
74 in-lb
27 ft-lb
35 ft-lb

Oil Pressure Regulator Plug

80 N*m

59 ft-lb

Oil Drain Plug

80 N*m

59 ft-lb

Oil Pan Mounting Capscrews


Note: Tighten the capscrews in the sequence
shown. Start at the center of the oil pan and
alternate toward both ends.

24 N*m

18 ft-lb

9 Nom

80 in-lb

9 N*m
Nom

80 in-lb

24 Nom

18 ft-lb

Oil Pump Suction Tube Bracket


Suction Tube to Block
Brace to Block
Brace to Suction Tube

Oil Pump Mounting Capscrews

Specifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Oil Temperature

Ref.No./Steps

Thermostat

Cooling

Metric

U.S.

50 Nom

37 ft-lb

System

Specifications
Page V-33

Cooling System Specifications


Fan Hub Assembled

Height

MIN
MAX

4.915 in
4.946 in

9000 N

MIN

2023 Ibf

Fan Hub Shaft End Clearance

0.15 mm

MAX

0.006 in

Radiator Cap Pressure Test


104C [220F]
99C [210F]

103 kPa
48 kPa

MIN
MIN

15 psi
7 psi

81 =C
83%

ilN
MAX

178F
182=F

95%

MAX

203=F

MAX

1.63 in

Fan Hub Bearing Installation

124.85 mm
125.65 mm

Force

Thermostat Operating Temperature


Initial Opening Temperature
Fully Open Temperature
Maximum Open Distance

Viscous Fan Drive Operating Temperature


Start Modulation
Maximum Speed

41.5 mm

85OC
93OC

185OF
200F

Viscous Fan Drive


Operating Temperature
~w~
YisCDS
FanDrive

Y.imn
,,.-..

Cooling System
Page V-34

Specifications

Specifications

and Torque

Values

- Group

18

Metric

U.S.

Belt Tensioner Mounting Capscrew

43 Nom

32 ft-lb

Fan Hub Mounting Capscrew

24 Nom

18 ft-lb

Fan Hub Pulley Mounting Capscrews

45 Nom

33 ft-lb

5 N*m

44 in-lb

24 Nom

18 ft-lb

Water Pump Mounting Capscrews

24 Nom

18 ft-lb

Water Outlet Connection

24 Nom

18 ft-lb

Component

or Assembly (Procedure)

Ref.No./Steps

Cooling System Torque Values

Coolant Inlet Hose Clamps

Thermostat

Housing Mounting Capscrews

Specifications

and Torque Values - Group 18

Component or Assembly (Procedure)

Ref.No./Steps

Cooling System Specifications


Page V-35

Metric

U.S.

Air Intake System Specifications


Intake Air Restriction
Naturally Aspirated
Turbocharged

Turbocharger
to Side)

50.8 cm H,O
63.5 cm H,O

MAX
MAX

20.0 in H,O
25.0 in H,O

Shaft Radial Clearance (Side


0.21 mm
0.46 mm

MIN
MAX

0.008 in
0.018 in

0.03 mm
0.08 mm

MIN
MAX

0.001 in
0.003 in

21 kPa

MAX

3 psi

165 kPa
179 kPa

MIN
MAX

24 psi
26 psi

0.33 mm
1.3 mm

MIN
MAX

0.013 in
0.050 in

Note: Specifications and instructions for rebuilding


the turbocharger are provided in the HI Turbocharger
Shop Manual, Bulletin No. 3810321.

Turbocharger
Clearance)

Shaft Axial Clearance (End

Charge Air Cooler


Differential Pressure Across Cooler

Wastegate Actuator Calibration


l Air Pressure

Actuator

Rod Movement

Air Intake System Torque Values


Turbocharger

Mounting Nut

Turbocharger
Capscrew

Oil Drain Mounting

45 Nom

33 ft-lb

24 N*m

18 ft-lb

Specifications

Cooling System Specifications


Page V-36

Component or Assembly (Procedure)

Ref.No./Steps

and Torque Values - Group 18

Metric

U.S.

Turbocharger

Air Crossover Hose Clamps

5 Nom

44 in-lb

Turbocharger

Oil Drain Tube Hose Clamps

5 N*m

44 in-lb

Turbocharger

Turbine Housing Capscrews

20 Nom

15 ft-lb

Turbocharger
Nut

Compressor Housing Clamp

Turbocharger

Turbocharger

8 N*m

71 in-lb

Oil Supply Hose Connection

15 Nom

11 ft-lb

Discharge Elbow Clamp Nut

8 Nom

71 in-lb

Turbocharger Mounting Studs


Use two mounting nuts locked together

10 N*m

89 in-lb

Suecifications and Torque Values - Group 18

Componentor Assembly (Procedure)

Ref.No./Steps

Exhaust System Specifications


Page V-37

Metric

U.S.

Exhaust System Specifications


Exhaust Restrihions
l

EPA Certified

Exhaust Manifold Flatness

4.5 in Hg

114 mm Hg

0.20 mm

MAX

0.008 in

Exhaust System Torque Values


Exhaust Manifold Mounting Capscrews:
l
Flan ed Head
l
Hex 9-1ead

32 ft-lb
32 ft-lb

43 Nom
43 N*m

Air Compressor Inspection Specifications


Crankshaft End Clearance
l Single Cylinder Air Compressor
. Two Cylinder

Air Compressor

0.05 mm

0.15 mm
0.05 mm
0.19 mm

MIN
MAX
MIN
MAX

0.002 in
0.006 in
0.002 in
0.008 in

Note: Specifications and instructions for rebuilding


the two cylinder air compressor are provided in the
Air Equipment Rebuild Manual, Bulletin Nos. 3810242 and 3810257.

Air Compressor Torque Values


Air Compressor Brace to Air Compressor
Mounting Capscrews
Holset
Bendix
Midland

43 Nom
43 N*m
32 N*m

32 ft-lb
32 ft-lb
24 ft-lb

Air Compressor Brace to Cylinder Block


Mounting Capscrew

43 Nom

32 ft-lb

77 Nam
Hand Tight

57 ft-lb

Air Compressor Flange Mounting Nuts


Nut
Stud to Gear Housing

Electrical System Specifications


Page V-38

Specifications and Torque Values - Groun 18

Component

or Assembly (Procedure)

Air Compressor Oil Supply


Connection

Air Compressor

Flef.No./Steps

Metric

U.S.

15 N*m

12 ft-lb

35 N*m

26 ft-lb

Hose

Coolant Line Connection

Electrical System Specifications


Drive Belt
Engine has an automatic
adjustment necessary.

belt tensioner,

360 N
490 N

no

Batteries

Specific
at 27%
1.260 to
1.230 to
1.200 to
1.170 to
1.110 to

Gravity
[180F]
1.280
1.250
1.220
1.190
1.130

MIN
MAX

80 Ibf
100 Ibf

State of
Charge
100%
75%
50%
25%
Discharged

Electrical System Torque Values


Belt Tensioner Capscrew

Alternator Mounting
Ml 0 Capscrew
Lower Support Bracket
M8 Capscrew
Ml 0 Capscrew
Mounting

Capscrews

Starting Motor Mounting Capscrew

44 Nom

32 ft-lb

44 Nom

32 ft-lb

24 N*m
44 Nam

18 ft-lb
32 ft-lb

77 N*m

57 ft-lb

77 N*m

57 ft-lb

Specifications and Torque Values - Group 18

Component

or Assembly (Procedure)

Flef.No./Steps

Engine

Metric

U.S.

Coolant Heater

12 Nom

106 in-lb

Temperature Sensor
Installation - Cast Iron
Installation - Aluminum

50 Nom
30 N*m

37 ft-lb
22 ft-lb

120 Nom

89 ft-lb

16 N*m
10 Nom

12 ft-lb
89 in-lb

Oil Heater Element

Oil Pressure Switch


Installation - Cast Iron
Installation - Aluminum

Engine Testing - Test Specifications


Note: The specifications and instructions for testing
the engine are provided in this manual. Refer to
Engine Testing - Group 14, Page 14-1.

Crankcase Gases (Blowby) Limits


Refer to Engine Testing, Page 14-6.

Mounting Adaptations Specifications


Flywheel Housing (Wet Application)
Set Screw Installation

Depth

0.00 mm
3.00 mm

MIN
MAX

0.000 in
0.118 in

Testing

- Test Specifications
Page V-39

Mounting Adaptions - Torque Values


Page V-40

Component or Assembly (Procedure)

Specifications

Ref.No./Steps

and Torque Values - Group 18

Metric

U.S.

Flywheel Ring Gear Installation


l
l

Temperature
Time Interval

177%
30 Min.
6 Hours

MIN
MAX

350F
30 Min.
6 Hours

Mounting Adaptations - Torque Values


Flywheel Housing Access Plate
Capscrews

24 Nom

18 ft-lb

Flywheel Housing Mounting Capscrews

77 Nom

57 ft-lb

Flywheel Mounting Capscrews

140 Nom

101 ft-lb

Specifications

and Torque Values - Group 18

Drive Belt Tension


Page V-41

Drive Belt Tension


Belt Tension Gauge Part No.

* A belt is considered
* If used belt tension

Belt Tension New

Belt Tension

Range Used*

used if it has been in service for ten minutes or longer.


is less than the minimum value, tighten the belt to the maximum

used belt value.

FRACTION, DECIMAL,
Page V-42

MILLIMETER

CONVERSIONS

FRACTION,

CONVERSION

DECIMAL,

FACTOR: 1 INCH = 25.4MM

Specifications

MILLIMETER

CONVERSIONS

and Torque Values - Group 18

Specifications and Torque Values - Group 18

Weight and Measures - Conversion Factors


Page V-43

Weight and Measures - Conversion Factors


QUANTITY

U.S. CUSTOMA IY

Area

sq. inch

METRIC

Unit Name

FROM U.S.
CUSTOMARY
TO METRIC
MULTIPLY BY

FROM METRIC
TO U.S.
CUSTOMARY
MULTIPLY BY

Abbr.
mm2
cm2

m2

sa. foot
Fuel
Consumption

pounds per
horsepower
hour

Ib/hp-hr

Fuel
Performance

miles per gallon

mpg

gallons per mile

gpm

grams per
kilowatt hour

g/kw-hr

608.277

0.001645

kilometers per
liter

km/l

0.4251

2.3527

liters per

I/km

2.3527

0.4251

I kilometer
Force

pounds force

Ibf

Newton

Length

inch

in

millimeters

mm

foot

ft

millimeters

mm

Power

horsepower

kw

pounds force
per sq. in

hp
psi

kilowatt

Pressure

kilopascal

kPa

6.8948

inches of
mercury

in Hg

kilopascal

kPa

3.3769

0.29613

inches of water

in He0

kilopascal

kPa

0.2488

4.019299

inches of
mercurv

in Hg

millimeters
mercurv

of

mm Hg

inches of water

in H,O

millimeters
water

of

mm H,O
100.001

0.00999

750.06

0.001333

bars
bars

mm Hg

Temoerature

fahrenheit

Torque

pound force
oer foot

Nom

pound force
per inch

in lb

Newton-meter

0.145037

Nom

Velocitv

miles/hour

kph

Volume: liquid
displacement

gallon (U.S.)

gallon (imp*)
cubic inch

cubic inch

in3

cubic
I centimeter

cm3

Weight (mass)

pounds

lb

1 kiloarams

uVork

British Thermal
Unit

kg
i

(avoir.)

British Thermal
Unit
horsepower
hours

hp-hr

kilowatt-hour

kw-hr

0.000293

kw-hr

0.746

3414
1.341

Newton-Meter to Foot-Pound Conversion Chart


Page V-44

Specifications and Torque Values - Group 18

Newton-Meter to Foot-Pound Conversion Chart


Nom
1

ft-lb
I
8.660756 in-lb

Nom

ft-lb

Nom

ft-lb

55

41

155

114

44.0 in-lb

60

44

160

118

53.0 in-lb

65

48

165

122

62.0 in-lb

70

52

170

125

71.0 in-lb

75

55

175

129

80.0 in-lb

80

59

180

133

10

89.0 in-lb

85

63

185

136

0.737562 ft-lb

90

66

190

140

12

95

70

195

144

14

10

100

74

200

148

15

11

105

77

205

151

16

12

110

81

210

155

18

13

115

85

215

159

20

15

120

89

220

162

25

18

125

92

225

165

30

22

130

96

230

170

35

26

135

100

235

173

40

30

140

103

240

177

45

33

145

107

245

180

50

37

150

111

250

184

NOTE:

To convertfrom Newton-Meters to Kilogram-Meters


dive Newton-Meters by 9.803

Capscrew Markings and Torque Values


Page V-45

Soecifications and Torque Values - Group 18

Capscrew Markings and Torque Values

Caution: When replacing capscrew, always use a capscrew of the same measurement and strength as the
capscrew being replaced. Using the wrong capscrews can result in engine damage.

Metric capscrew and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S> Customary capscrews are identified by radial lines stamped on the head of the capscrews.
The following

M8
Major Thread
Diameter in
Millimeters

examples

indicate how capscrews

Metric - M&1.25 x 25
1.25
Distance
Between
threads in
Millimeters

are identified:

U.S. Customary [5/16 x 18 x l-1/2]


5116
18
l-1/2

25

Length in
Millimeters

Major Thread
Diameter in
Inches

Number
Threads Per
Inch

Length in
Inches

NOTES:
1.

Always use the torque values listed in the following

tables when specific torque values are not available.

2.

Do not use the torque values in place of those specified

3.

The torque values in the table are based on the use of lubricated

4.

When the ft-lb value is less than 10, give consideration to converting
with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.

in other section of the manual.


threads.
the ft-lb value to in-lb to obtain a better torque

Specifications

Capscrew Markings and Torque Values


Page V-48

and Torque Values - Group 18

Capscrew Markings and Torque Values - Metric


Commercial
Capscrew

Steel Class
8.8
Head Markings

10.9

Bodv

12.9

10.9

8.8

Size
Diam.
mm

12.9

Torque
Aluminum
Cast Iron
Nom
ft-lb
Nom
ft-lb

Torque
Cast Iron
Aluminum
Nom
ft-lb
Nom
ft-lb
12
9
7
4

14

11

18

14

11

23

18

11

8
10
12
14
16

25
45
80
125
180
230

18
33
60
90
130
170

18
30
55
90
140
180

14
25
40
65
100
135

33
60
105
165
240
320

25
45

18
30

75
122
175
240

55
90
140
180

14
25
40
65
100
135

40
70
125
195
290
400

29
50
95
145
210
290

18
30
55
90
140
180

18

Torque
Aluminum
Cast Iron
Nom
ft-lb
Nom
ft-lb
14
9
7
4
7
14
25
40
65
100
135

Capscrew Markings and Torque Values - U.S. Customary


SAE Grade Number

Capscrew
Head Markings
These are allSAE Grade 5(3)line

\'

./

Gm@

7 \-

Capscrew Body Size

- 20

- 28
5/16 - 18
- 24
318 - 16
- 24
7116 - 14
- 20
112 - 13
- 20
9/16 - 12
- 18
518 - 11
- 18
314 - 10
- 16
718 - 9
- 14
l-8
- 14

Cast Iron
N*m
ft-lb
9
12
20
23
40
40
60
65
95
100
135
150
180
210
325
365
490
530
720
800

7
9
15
17
30
30
45
50
*70
75
100
110
135
155
240
270
360
390
530
590

Capscrew Torquel/4

@
Grade 5 Capscrew
Alummum
N*m
ft-lb
8
9
16
19
25
35
45
55
75
80
110
115
150
160
255
285
380
420
570
650

6
7
12
14
20
25
35
40
55
60
80
85
110
120
190
210
280
310
420
480

Capscrew Torque - Grade 8 Capscrew


Alumlnum
Cast Iron
N*m
15
18
30
33
55
60
90
95
130
150
190
210
255
290
460
515
745
825
1100
1200

ft-lb
11
13
22
24
40
45
65
70
95
110
140
155
190
215
340
380
550
610
820
890

Nom
8
9
16
19
25
35
45
55
75
80
110
115
150
160
255
285
380
420
570
650

ft-lb
6
7
12
14
20
25
35
40
55
60
80
85
110
120
190
210
280
310
420
480

Specifications and Torque Values - Group 18

Pipe Plug Torque Values


Page V-47

Pipe Plug Torque Values


Thread
in

Size
Actual Thread O.D.
in

Torque
In Aluminum Components
Nom
ft-lb
5
45 in-lb

Torque
In Cast Iron or Steel Components
Nom
ft-lb
15

10

10

20

15

20

15

25

20

25

20

35

25

l/16

0.32

l/8

0.41

15

l/4

0.54

3P

0.68

l/2

0.85

35

25

55

40

3/4

1.05

45

35

75

55

1.32

60

45

95

70

l-1/4

1.66

75

55

115

85

l-1/2

1.90

85

65

135

100

index
Page X-l
About the Manual ..................................
Accessory Drive Adapter - Cleaning and Inspection for Reuse
Cleaning .......................................
Inspection ......................................
Accessory Drive Adapter - Exploded view ...............
Accessory Drive Adapter - Rebuild .....................
Assembly ......................................
Disassembly ....................................
Accessory Drive - General Information ..................
AccessoryDrive Adapter ...........................
Aftercooler Assembly - Cleaning and Inspection for Reuse . .
Inspection ......................................
Aftercooler Assembly - Rebuild .......................
...............
Air Compressor Inspection Specifications
Air Compressor Torque Values. .......................
Air Crossover Tube - Cleaning and Inspection for Reuse ...
Cleaning .......................................
Inspection ......................................
Air Intake System - Exploded View .....................
................
Air Intake System - General Information
Air Intake System - Service Tools ......................
Air Transfer Pipe - Cleaning and Inspection for Reuse .....
Cleaning .......................................
Inspection ......................................
Belt Tensioner Inspection ...........................
Blowby Measurement ...............................
Camshaft Bore Expansion Plug Installation ...............
Camshaft Bushing Bore - Cleaning
.....................
Camshaft Bushing - Installation ........................
Camshaft Bushing - Removal ..........................
Camshaft - Cleaning and Inspection for Reuse ............
...............................
Camshaft-Cleaning
Camshaft Gear - Inspection ..........................
Camshaft - Inspection ..............................
Camshaft Gear - Replacement .........................
Camshaft Gear - Cleaning ...........................
Camshaft Gear - Inspection ..........................
Camshaft Gear - Installation ..........................
Camshaft Gear - Removal ...........................
Capscrew Markings and Torque Values .................
Capscrew Markings and Torque Values - Metric ..........
Capscrew Markings and Torque Values - U.S. Customary ...
Component Specifications and Torque Values .............
Cylinder Block - Rebuild Specifications ................
Cylinder Block - Torque Values ......................
Cylinder Head - Rebuild Specifications. ................
Engine Assembly - Specifications ......................
Engine Assembly - Torque Values .....................
Connecting Rod Bearings - Cleaning and Inspection
for Reuse .........................................
Connecting Rod Bearings - Cleaning ...................
Connecting Rod Bearings - Inspection ..................
.................
Connecting Rod Bushing - Replacement
Inspection .......................................
Installation .......................................
Machining .......................................
Removal ........................................
............
Connecting Rods - Bend and Twist Inspection
Connecting Rod Alignment - Inspection .................
Connecting Rod Twist - Inspection .....................
Fixture Calibration .................................
Connecting Rods - Cleaning and Inspection for Reuse ......
Connecting Rods - Cleaning .........................
Connecting Rods - Inspection ........................
Coolant Filter Shutoff Valve - Cleaning and Inspection
for Reuse .......................................
Assembly .....................................
Cleaning ......................................
Disassembly ...................................
Cooling System Components - Exploded View ............
Cooling System - General Information ..................
Belt Tensioner ...................................
Cooling Fans ....................................

i-2
4-5
4-5
4-5
4-3
4-5
4-6

4-6
4-4
4-4
10-7
10-8
10-8
V-37
V-37
10-9
10-9
lO-9
10-3
10-4
10-2
10-9
10-9
1O-9
8-l 0
14-7
21
23
23

22
50
50

53
50
54
54
54
56
54
V-45
V-46
V-46
V-3
V-15
V-21
V-22
V3
V-5
39
39
39
45
49
47
49
45
43

44
44
43
40
40
41
810
8-11
8-11
810

8-3
8-4
8-4
8-4

.......................................
FanHub
Pressure Caps ...................................
Thermostats ....................................
Water Pump ....................................
Cooling System - Service Tools .......................
Cooling System Specifications ........................
Air Intake System Specifications ......................
Air Intake System Torque Values .....................
Cooling System Torque Values ......................
Crankcase Breather Tube - Cleaning and Inspection
for Reuse ........................................
Cleaning and Inspection ...........................
Crankshaft - Cleaning and Inspection for Reuse ...........
Crankshaft - Cleaning ..............................
Crankshaft - Inspection .............................
Crankshaft Gear - Replacement ........................
Crankshaft Gear - Inspection .........................
Crankshaft Gear - Installation .........................
Crankshaft Gear - Removal ..........................
General Information ................................
Cylinder Block - Cleaning in a Hot Tank .................
Cylinder Block - Cleaning with Solvent ..................
Cylinder Block - Disassembly ..........................
Cylinder Block - Exploded View ........................
Cylinder Block - General Information ....................
Camshaft .......................................
Connecting Rods ..................................
.....................................
Crankshaft..
Cylinder Block ....................................
Cylinder Liner ....................................
Oil Seals ........................................
Pistons .........................................
Vibration Damper. .................................
Cylinder Block - Inspection For Reuse ...................
Cylinder Block - Preparation for Cleaning ................
Cylinder Block - Service Tools .........................
Cylinder Head Capscrew - Cleaning and Inspection ......
Cleaning ......................................
Inspection .....................................
Cylinder Head Capscrews - Cleaning and Inspection
for Reuse .........................................
Cleaning ........................................
Free Length - Measurement ..........................
Inspection .......................................
Cylinder Head - Cleaning and Inspection for Reuse .......
Cleaning .......................................
Handling .......................................
Inspection .....................................
Cylinder Head - Exploded View .......................
Cylinder Head - General Information ...................
Cylinder Head - Pressure Testing .....................
Cylinder Head - Rebuild ............................
Assembly .....................................
Cleaning ......................................
Disassembly ...................................
Inspection .....................................
Valve - Grinding .................................
Valve Guide - Inspection ..........................
Valve - Inspection ...............................
Valve Seat Insert - Grinding ........................
Valve Seat Insert - Inspection .......................
Valve Spring - Inspection ..........................
Valve Stem Seal - Inspection .......................
Cylinder Head - Service Tools ........................
Cylinder Head - Vacuum Testing Valve Seating ..........
Cylinder Head - Valve Guide Replacement ..............
Assembly .....................................
Disassembly ...................................
Inspection .....................................
Cylinder Head - Valve Seat Insert Replacement ..........
Inspection .....................................
Installation .....................................
Removal ......................................

8-4

8-4
8-4
8-4
8-2
V33
V-35
V-35
V-34
3-8

3-8
29
29
30
33
34
35
33
33
15
12
10
7
9
9
9
9
9
9
9
9
9
16
10
4
2-37
2-37
2-38
64
64

66
65
2-9
2-9
2-9
2-10
2-6
2-8
2-34
2-11
2-26
2-12
2-11
2-13
2-21
2-17
2-20
2-22
2-18
2-19
2-19
2-2
2-36
2-28
2-29
2-28
2-29
2-31
2-33
2-33
2-31

Index
Page X-2
Cylinder Liners - Cleaning and Inspection for Reuse ...
Cylinder Liners - Cleaning ......................
Cylinder Liners - Inspection .....................
Dowel Pins (Cylinder Head) - Removal ..............
DriveBeltTension
.............................
Drive Units - Service Tools .......................
Electrical System Specifications ...................
Electrical System Torque Values ..................
Engine - Assembly .............................
AFC Tube - Installation .........................
Aflercooler - Installation ........................
Air Compressor - Installation ....................
Air Crossover Tube - Installation ..................
Alternator Brace - Installation ....................
Alternator - Installation .........................
Alternator Mounting Bracket - Installation ...........
Belt Tensioner Bracket - Installation ...............
Belt Tensioner - Installation .....................
Camshaft - Installation .........................
Connecting Rod Bolt - Installation ................
Coolant Filter - Installation ......................
Coolant Heater - Installation .....................
Coolant Inlet Connection - Installation .............
Coolant Outlet Connection - Installation ............
Coolant Vent Fitting - Installation .................
Coolant Vent Petcock - Installation ................
Coolant Vent Tube - Installation ..................
Crankcase Breather Tube - Installation .............
Crankshaft - Installation ........................
Cylinder Block - Installation onto Engine Rebuild Stand
Cylinder Head - Installation .....................
Cylinder Liner - Installation ......................
Drive Belt - Installation .........................
Engine Lifting Bracket - Installation ...............
Engine - Removal from the Rebuild Stand ..........
Engine Support, Front - Installation ...............
Exhaust Manifold - Installation ...................
Fan Hub Assembly - Installation ..................
Flywheel Bore Runout Measurement ..............
Flywheel Face Runout Measurement ..............
Flywheel Housing - Installation ...................
Flywheel - Installation ..........................
Fuel Drain Manifold - Installation .................
Fuel Filter Head - Installation ....................
Fuel Filter - Installation .........................
Fuel Injection Pump - Installation .................
Fuel Injection Pump Supply tine - Installation .......
Fuel Lines, High Pressure - Installation .............
Fuel Lines, .Low Pressure - Installation .............
Fuel Pump Solenoid - Installation .................
Fuel Transfer Pump - Installation .................
Gear Cover - Installation ........................
Gear Housing - Installation ......................
Injector - Installation ...........................
Intake Manifold Cover - Installation ................
Lubricating Oil Cooler - Installation ................
Lubricating Oil Filter - Installation .................
Lubricating Oil Pan - Installation ..................
Lubricating Oil Pump - Installation ................
Lubricating Oil Suction Tube - Installation ..........
Main Bearing (Lower) - Installation ................
Main Bearing (Upper) - Installation ................
Main Bearing Cap - Installation ..................
Piston Assembly - Installation ....................
Piston Cooling Nozzle - Installation ...............
Piston Pin - Installation ........................
Piston Ring End Gap - Measurement ..............
Piston Ring - Installation .......................
Push Rod - Installation .........................
Rocker Lever and Shaft - Assembly ...............
Rocker Lever Assembly - Installation ..............
Seal, Front Crankshaft - Installation ...............
Seal, Rear Crankshaft - Installation ................

. . . . 24
. . . . 24
. . . . 25
. . . . 11
. . . v-41
. . . 4-2
. . . V38
. * . V-38
.
.
.
.
.

.
.
.
.
.

. o-39
o-112
. o-97
o-119
O-101
9-104
O-103
o-103
o-105
O-105

..
..
..
..
..
...
. . . o-54
. . O-102
..9
. . O-193
. . O-102
. . O-102
. . c-102
. . O-103
. . . o-95
. . . o-47

. . . o-39
...
...
. . o-118
. . . o-96
. . O-105
. . O-l 18
. o-97
* . O-106
. . . o-79
. . . O-81
. . * O-72

. . . o-77
. . . o-96
. . o-111
. . o-111
. . O-106
. . O-110
. . o-112
* . o-l 19
. . o-l 19
. . O-l 18
. . O-116
. . . o-62
. . . o-95
. . . o-96
.. .
.. .
.. .
.. .
. .
. . . o-47

...
. . . o-47
. . . O-58
. . . o-45
.
.
.
.
.
.

.
.
.
.
.
.

..
..

. o-54
. o-55
. o-56
. o-89
.
. o-91
o-113
. o-51

Starting Motor - Installation .........................


Tachometer Drive - Installation ......................
Thermostat and Housing - Installation ................
Timing Pin Assembly - Installation ....................
Turbocharger Exhaust Outlet Connection - Installation ....
Turbocharger - Installation ..........................
Turbocharger Oil Drain Tube - Installation ..............
Turbocharger Oil Supply Hose - Installation ............
Valve Arrangement
...............................
Valve Clearance - Adjustment ........................
Valve Cover - Installation ...........................
Valve Tappet - Installation ..........................
Vibration Damper - Installation ......................
Water Pump - Installation ...........................
Engine Accessories - Installation ....................
Engine Components - General Information
...............
Engine Dataplate - Replacement
.......................
Engine Dataplate - Installation ........................
Engine Dataplate - Removal ..........................
Engine Diagrams
...................................
Engine - Disassembly ................................
AFC Tube - Removal ..............................
Aftercooler - Removal ..............................
Air Compressor - Removal ..........................
Air Crossover Tube - Removal .......................
Alternator Brace - Removal ..........................
Alternator Mounting Bracket - Removal .................
Alternator - Removal ..............................
Belt Tensioner Bracket - Removal .....................
Belt Tensioner - Removal ...........................
Camshaft - Removal ..............................
Coolant - Draining ................................
Coolant Filter - Removal ...........................
Coolant Heater - Removal ..........................
Coolant Inlet Connection - Removal ...................
Coolant Outlet Connection - Removal .................
Coolant Vent Petcock - Removal .....................
Coolant Vent Tube Fitting - Removal ..................
Coolant Vent Tube - Removal .......................
Crankcase Breather Tube - Removal ..................
Crankshaft - Removal .............................
Cylinder Head - Removal ...........................
Cylinder Liner Carbon Deposits - Removal ..............
Cylinder Liner Protrusion - Checking ..................
Cylinder Liner - Removal ...........................
Drive Belt - Removal ..............................
Engine - Installation onto Engine Rebuild Stand ..........
Engine Lifting Equipment and Brackets .................
Engine - Preparation for Steam Cleaning ................
Engine - Steam Cleaning ............................
Engine Support, Front - Removal .....................
Exhaust Manifold - Removal .........................
Expansion Plug - Removal ..........................
Expansion Plug - Replacement ......................
Fan Hub Assembly - Removal .......................
flywheel Housing - Removal ........................
Flywheel - Removal ...............................
Fuel Drain Manifold - Removal .......................
Fuel Filter Head - Removal ..........................
Fuel Filter - Removal ..............................
Fuel Injection Pump - Removal ......................
Fuel Injection Pump Supply Line - Removal .............
Fuel Lines, High Pressure - Removal ..................
Fuel Lines, Low Pressure - Removal ...................
Fuel Pump Solenoid - Removal ......................
Fuel Transfer Pump - Removal .......................
Gear Cover - Removal .............................
Gear Housing - Removal ...........................
Injector - Removal ................................
Intake Manifold Cover - Removal .....................
Lubricating Oil Cooler - Removal .....................
Lubricating Oil - Draining ...........................
Lubricating Oil Filter - Removal ......................

O-82
O-l 17
O-101

O-69
O-101
O-98

O-99
6-100
O-93
O-92
O-94

O-44
6-l 17
O-67
O-121
V-2
59

59
59
6

O-9
O-12
O-17
O-14
O-17
O-21

O-22
O-22
O-21
O-21
O-28
O-10
O-10
O-26
O-24

O-22
O-23
O-23
O-23
O-16

O-36
O-23
6-32
O-37
O-37
O-21
O-15
O-9
O-9

O-9
O-31

O-20
O-39

O-38
9-24
O-27
O-27
O-18
9-l 1
O-l 1
O-13
9-12
6-12
O-11

O-15
6-l 1
O-26
O-31
O-18
O-17
O-24
O-10
O-10

Index
Page X-3
O-27
Lubricating Oil Pan - Removal .......................
O-30
Lubricating Oil Pump Gear Backlash - Measurement ......
D-31
Lubricating Oil Pump - Removal .....................
O-27
Lubricating Oil Suction Tube - Removal ................
O-36
Main Bearing (Lower) - Removal .....................
O-36
Main Bearing (Upper) - Removal .....................
O-35
Main Bearing Cap - Removal ........................
O-33
Piston Assembly - Removal .........................
O-36
Piston Cooling Nozzle - Removal .....................
D-34
Piston Pin - Removal ..............................
O-35
Piston Ring - Removal .............................
O-19
Push Rod - Removal ..............................
O-19
Rocker Lever Assembly - Removal ....................
O-26
Seal, Front Crankshaft - Removal .....................
O-28
Seal, Rear Crankshaft - Removal .....................
O-26
Starting Motor - Removal ...........................
O-13
Tachometer Drive - Removal ........................
O-22
Thermostat and Housing - Removal ...................
O-16
Turbocharger Exhaust Outlet Connection - Removal .......
O-20
Turbocharger Oil Drain Tube - Removal ................
O-20
Turbocharger Oil Supply Hose - Removal ...............
O-20
Turbocharger - Removal ...........................
O-18
Valve Cover - Removal .............................
O-29
Valve Tappet - Removal ............................
O-25
Vibration Damper - Removal ........................
O-16
Wastegate Actuator Hose - Removal ...................
O-25
Water Pump - Removal ............................
O-39
Cylinder Block - Removal from Engine Rebuild Stand ......
O-4
Engine Disassembly and Assembly - Service Tools .........
14-17
Engine Dynamometer Test - Engine Run-in .............
14-9
Engine Dynamometer Test - Installation of the Engine .....
14-21
Engine Dynamometer Test - Performance Checking ......
2
...............................
Engine Identification..
2
Engine Dataplate ..................................
3
Fuel Injection Pump Dataplate ........................
Engine Lifting Brackets - Cleaning and Inspection
66
for Reuse .........................................
14-26
Engine Painting ..................................
14-24
...............
Engine Run-In Procedure - In-Chassis
14-6
Engine Run-In - General Procedures ...................
14-29
Engine Storage - Long Term .........................
14-32
Engine Removal from Long Term Storage .............
14-27
Engine Storage - Short Term ........................
14-29
Engine Removal From Short Term Storage ............
Engine Support Bracket, Front - Cleaning and Inspection for
16-9
Reuse ...........................................
16-9
Cleaning .......................................
16-9
Inspection ......................................
Engine Testing - Component Identification and Diagrams ... 14-3
14-5
Engine Testing - General Information ...................
14-5
Engine Dynamometer Run-in ........................
14-5
In-Chassis Run-In .................................
14-6
................
Engine Testing - General Specifications
14-2
Engine Testing - Service Tools ........................
V-39
...................
Engine Testing - Test Specifications
1 l-4
Exhaust Manifold - Cleaning and Inspection for Reuse ....
11-4
Cleaning ......................................
11-4
Inspection .....................................
1 l-2
Exhaust Manifold - Exploded View ....................
Exhaust Manifold Outlet Connection - Cleaning and Inspection
11-6
.......................................
forReuse
11-6
Cleaning ......................................
1 l-6
Inspection .....................................
Exhaust Manifold Turbocharger Mounting Stud 1 l-5
Replacement .....................................
11-5
Inspection .....................................
1 l-5
Installation .....................................
1 l-5
Removal ......................................
1 l-3
Exhaust System - General Information .................
1 l-3
Exhaust Manifold ................................
V-37
Exhaust System Specifications ........................
V-37
Exhaust System Torque Values .......................

Expansion Plug - Installation ..........................


Pipe Plug - Installation ..............................
Fan Hub - Cleaning and Inspection for Reuse ............
Cleaning .......................................
Inspection ......................................
................................
Fan Hub- Rebuild..
Assembly ......................................
Disassembly ....................................
Flexplate Assembly - Cleaning and Inspection for Reuse ...
Flywheel - Cleaning and Inspection for Reuse ............
Cleaning .......................................
Inspection ......................................
Flywheel Housing - Assembly (Wet Clutch Application) .....
Flywheel Housing - Cleaning and Inspection for Reuse .....
Cleaning .......................................
Inspection ......................................
Flywheel Ring Gear - Replacement
....................
Installation ......................................
Removal .......................................
Free Length - Measurement
.........................
Fuel Drain Manifold - Inspection
......................
Fuel Injection Pump Gaskets and Seals - Replacement ....
Fuel Injection Pump - Idle Speed Adjustment. ...........
RSV Governor ..................................
RQV and RQVK Governor .........................
Fuel Lines, High Pressure - Cleaning and Inspection
for Reuse ........................................
Fuel tines - Cleaning and Inspection ..................
General Information ...............................
Fuel Lines, Low Pressure - Cleaning and Inspection
for Reuse ........................................
Fuel System - General Information .....................
Derivative Fuel Injection Pump - Data Tag Information .....
Fuel Injection Pump ...............................
Fuel Injection Pump - Data Tag Information .............
Fuel Injection Pump - Data Tag Location ...............
Fuel Shutoff Solenoid - Wiring Requirements ............
Governor - Data Tag Information .....................
Fuel Systems - Rebuild Specifications ..................
Fuel Injection Pump Sealing Washer ..................
Fuel Shutoff Solenoid Adjustment ....................
Fuel System Specifications .........................
Fuel System Torque Values .........................
Fuel Transfer Pump - Exploded View ...................
Fuel Transfer Pump - Rebuild .........................
Cleaning .......................................
Assembly ......................................
Gear Cover - Cleaning and Inspection for Reuse ...........
Gear Cover - Cleaning ..............................
Gear Cover - Inspection .............................
Gear Housing - Cleaning and Inspection for Reuse .........
Gear Housing - Cleaning ............................
Gear Housing - Inspection ...........................
General Cleaning Instructions ........................
Solvent and Acid Cleaning ...........................
Steam Cleaning ..................................
General Engine Specifications
.........................
Cooling System ...................................
Fuel System .....................................
General Engine Data ...............................
Intake Air and Exhaust System ........................
Lubrication System ................................
General Engine Test Procedure - In Chassis ............
General Information .................................
Disassembly .....................................
Assembly .......................................
General Repair Instructions ..........................
General Safety Instructions ..........................
Generic Symbols ..................................
Glossary of Terms .................................
How To Use This Manual ............................
Group Contents ..................................
Index ..........................................

19

20
6-7
8-7
8-8
8-8
8-9

8-8
16-6
16-5
165
165
168
16-7
167
16-7
16-6
16-6
16-6
2-39
616
511
14-25
1425
1426
6-14
615
614
616
52
5-3
52
52
5-2

5-3
5-3
V-25
V-27
V-27
V-25
V-27

5-4
5-5
5-5
5-5

60
60
60
57

57
57
i-8
i-8
i-8
4
5

5
4

5
4
14-23

0.8
0.8
.
i-7
i-6
i-4
i-9
i-3
i-3
i-3

Index
Page X-4
Metric Information, ................................
Table of Contents ................................
lllustrations..
.....................................
Injector - Chatter Testing ............................
Injector - Spray Testing .............................
Injectors and Fuel Lfnes - Exploded View .................
Injectors and Fuel Lines - Exploded View .................
Injectors and Fuel tines - Exploded View .................
Injectors and Fuel tines - General Information ............
Injectors and Fuel tines - Service Tools .................
Injectors - Cleaning and Inspection for Reuse .............
General Information ................................
Injector - Assembly ...............................
Injector - Cleaning and Inspection ....................
Injector - Disassembly ..............................
Intake Manifold Cover - Cleaning and Inspection for Reuse .
Inspection ......................................
Lubricating Oil Dipstick - Calibration ..................
Lubricating Oil Pan - Cleaning and Inspection for Reuse ...
Cleaning .......................................
Inspection ......................................
Lubricating Oil Pump - Cleaning and Inspection for Reuse .
Cleaning ......................................
Disassembly ...................................
Inspection .....................................
Lubricating Oil System - Exploded View .................
Lubricating Oil System - General Information
............
Dipstick ........................................
Lubricating Oil Cooler and Filter Head .................
Lubricating Oil Pump ..............................
Oil Filter Head ...................................
Oil Pan ........................................
Oil Pressure Regulator .............................
Oil Temperature Thermostat ........................
Lubricating Oil System - Service Tools. .................
Lubricating Oil System Specifications
..................
Lubricating Oil System Torque Values ..................
Lubricating Oil Temperature Thermostat - Cleaning and
Inspection .......................................
Cleaning ......................................
Inspection .....................................
Main Bearing Caps and Capscrews - Cleaning and Inspection
Reuse ............................................
Cleaning ........................................
Inspection .......................................
Main Bearings - Cleaning and Inspection for Reuse ........
General Information ................................
Main Bearings - Cleaning ............................
Main Bearings - Inspection ...........................
Thrust Bearings - Inspection ..........................
Mounting Adaptations - Exploded View .................
Mounting Adaptations - General Information .............
Flywheel and Ring Gear ............................
FlywheelHousing
................................
Mounting Adaptations - Service Tools ..................
Mounting Adaptations Specifications ...................
Flywheel Housing (Wet Application) ...................
Flywheel Ring Gear Installation ......................
Mounting Adaptations - Torque Values .................
Newton-Meter to Foot-Pound Conversion Chart ..........
Oil Cooler Cover - Disassembly and Assembly ..........
Assembly .....................................
Cleaning ......................................
Disassembly ...................................
Oil Cooler Element - Cleaning and Inspection for Reuse ....
Cleaning .......................................
Inspection ......................................
Pressure Test. ...................................
Oil Filter Bypass Valve - Replacement
..................
Oil Pressure Regulating Valve - Cleaning and Inspection ...
Assembly ......................................
Cleaning .......................................
Disassembly ....................................

i-3
i-3
i-5
6-14
6-13

6-6
63
6-5
6-7
6-2

6-8
6-8
6-12
6-10
6-8
10-7
18-7
7-13
7-5
7-5
7-5
7-14
7-15
7-14
7-15
7-4
7-3
7-3
7-3
73
7-3
73
73
73
7-2
V-30
V-31
7-12
7-12
7-12
for
38
38

39
36
36
37
37

38
16-3
16-4
16-4
16-4
16-2
V-39
V-39
V-40
V-40
V-44
7-10
7-l 1
7-10
7-10
7-6
7-6
7-6

7-6
7-9
7-i
7-8
7-8

7-T

7-8
Inspection ......................................
V-47
Pips Plug Torque Values ............................
27
Pistons - Cleaning and Inspection for Reuse ..............
27
Piston Rings - Removal .............................
27
Pistons - Cleaning .................................
28
Pistons - Inspection ................................
4-4
Push Rods - Cleaning and Inspection for Reuse ...........
4-4
Cleaning ........................................
4-4
Inspection .......................................
63
Rear Cover - Cleaning and Inspection ...................
63
Cleaning ........................................
64
Inspection .......................................
Rocker Assembly Oil Manifold - Cleaning and Inspection for
3-7
Reuse ...........................................
3-7
Cleaning .......................................
3-7
Inspection ......................................
3-4
Rocker Lever Assembly - Cleaning and Inspection ........
3-6
Assembly ......................................
35
Cleaning .......................................
3-4
Disassembly ....................................
3-5
Inspection ......................................
3-2
Rocker Lever Assembly - Exploded view ................
33
Rocker Lever Assembly - General Information ............
V-25
Rocker Lever Assembly - Rebuild Specifications ..........
5-9
RQVK Governor Fuel Shutoff Solenoid - Adjustment .......
RSV Governor Fuel Shutoff Solenoid - Orientation and
5-6
Adjustment .......................................
5-8
Fuel Shutoff Solenoid - Adjustment ...................
5-6
Fuel Shutoff Solenoid - Orientation ....................
5-10
Shutdown Lever or Spring - Replacement
..............
V-46
Tap-Drill Chart - U.S. Customary & Metric ...............
8-6
Thermostat Housing - Cleaning and Inspection for Reuse ...
8-6
Cleaning .......................................
8-6
Inspection ......................................
8-6
Thermostat - Inspection .............................
16-5
Turbocharger - Cleaning and Inspection for Reuse ........
10-5
Inspection ......................................
3-8
Valve Cover - Cleaning and Inspection for Reuse .........
3-8
Cleaning .......................................
3-8
Inspection ......................................
4-3
Valve Tappet Cleaning and Inspection for Reuse ...........
..4- 3
Cleaning ......................................
4-3
Inspection .......................................
V-25
Valve Tappet - Rebuild Specifications
..................
4-2
Valve Tappets and Push Rods - Exploded View ............
4-3
Valve Tappets and Push Rods - General Information ........
61
Vibration Damper - Cleaning and Checking for Reuse .......
61
General Information ................................
61
Rubber Element Vibration Damper - Inspection ...........
61
Rubber Vibration Damper - Cleaning ...................
62
viscous Vibration Damper - Cleaning ...................
62
Viscous Vibration Damper - Inspection ..................
Water Outlet Connection - Cleaning and Inspection
8-7
for Reuse ........................................
8-5
Water Pump Assembly - Cleaning and Inspection for Reuse
8-5
Cleaning .......................................
8-5
Inspection ......................................
V-43
Weight and Measures - Conversion Factors .............

Trouble Shooting and


Repair Manual

S6D114E-1
SAGDI 14E-1
SAAGDI 14E-1
Series Engine

6D114E-1 Series Engine

Foreword
This manual provides instructions for troubleshooting and repairing the 6D114E-1 Series Engine in the chassis. Component
and assembly rebuild procedures are provided in the 6D114E-1 Series Engine Shop Manual. Refer to Page i-2 in the
introduction for instructions on how to use this manual.
The manual is organized
related to the engine.

to guide a service technician

This manual does not cover machine or equipment


repair procedures.

through

the logical steps of identifying

problems. Consult the appropriate

A series of specific service manuals (Shop, Specification, Alternative


ordered through your distributor using the form in front of this book.

and correcting

problems

machine chassis shop manual for

Repair, and so forth)

The repair procedures used in this manual are recommended by Komatsu America International
procedures require the use of special service tools. Use the correct tools as described.

are available

Company.

and can be

Some service

The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Komatsu America International Company reserves the right to make any changes at any time without obligation. If
differences are found between your engine and the information in this manual, contact your Komatsu Distributor.
The latest technology and the highest quality components are used to manufacture
parts are needed, we recommend using only genuine Komatsu exchange parts.

Komatsu engines. When replacement

Table of Contents
Page

Introduction

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

Engine Identification
Troubleshooting

1
E

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

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

Cooling System Repair

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

Lubricating Oil System Repair ......................................

Air Combustion

Compressed

System Repair

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

Air System Repair

Fuel System Repair

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

4
5

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

Electrical System Repair

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

Base Engine Components

System Repair

Engine Testing and Run-In

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

Engine Removal and Installation


Specifications
Index

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

and Torque Values

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

. . . . . . . . . . . . . . . . . . . . . ..~...............................

a
9
V
X

Section i - Introduction

Page i-l

Section i - Introduction
Section Contents
Page
About the Manual

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

i-2

Solvent and Acid Cleaning ....................................................


Steam Cleaning ...........................................................

i-8
i-8
i-8

General Repair Instructions ....................................................

i-7

General Safety Instructions ....................................................

i-6

Generic Symbols ...........................................................

i-4

General Cleaning instructions ..................................................

Glossary of Terms

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

HowTo Use This Manual .....................................................


.........................................................
Group Contents..
index..
................................................................
Metric Information, .........................................................
Table of Contents .........................................................

illustrations ...............................................................

i-9
i-3
i-3
i-3
i-3
i-3
i-5

Section i - Introduction
Page i-2

About the Manual


This 6D114E-1 Series Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related
problems and to provide recommended repair procedures. The manual is divided into sections by system. Each section
provides general information, specification, diagrams, and service tools, where applicable. The specific repair procedures
are referenced in the Troubleshooting
Logic Charts.

How To Use This Manual


The manual is organized to provide an easy flow from problem identification
to problem correction.
A list of
troubleshooting symptoms containing the most common engine problems is on Page T-2 in the Troubleshooting
Section.
Complete the following steps to locate and correct the problem:
(STEP 1.)

Locate the symptom

on the list.

Reference is made to the procedure


(STEP 2.)

provides a brief description

of the corrective

action with the reference

Locate the probable cause in the left column, and then turn to the procedure
The repair procedures are listed by system (Cooling, Lubricating
Electrical, and Base Engine Components).

(STEP 4.)

Logic Chart is found.

The left column of the Troubleshooting


Logic Chart indicates a probable cause, starting at the top with
the simplest and easiest to repair, and continuing downward to the most difficult.
The right column
repair.

(STEP 3.)

number where the Troubleshooting

The troubleshooting

Logic Charts are based on the following

1.

The engine has been installed to the proper specifications.

2.

The easiest repairs are done first.

3.

Generic

solutions

number for the

number in the right column.

Oil, Combustion

Air, Compressed

Air, Fuel,

assumptions:

to cover problems with the most common

applications.

Table of Contents
The Table of Contents

in the front of the manual contains a quick page reference for each group number.

Index
An alphabetical

index is in the back of the manual to aid in locating

specific information.

Metric Information,
Both metric and U.S. customary values are used in this manual. The metric value is listed first, followed
customary in brackets. An example is 60C [140 F].

by the U.S.

Section i - introduction
Page i-3

Generic Symbols
The following

group of symbols

have been used in this manual to help communicate

the intent of the instructions.

When one of the symbols appears, it conveys the meaning defined below.

WARNING - Serious personal injury or extensive property damage can result if the warning instructions
are not followed.
CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged if
the caution instructions are not followed,

Indicates a REMOVAL

or DISASSEMBLY

Indicates an INSTALLATION

INSPECTION

step.

or ASSEMBLY

step,

is required,

CLEAN the part or assembly.

PERFORM

a mechanical

LUBRICATE

or time MEASUREMENT.

the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN

PERFORM

to a specific torque,

an electrical

Refer to another location

MEASUREMENT.

in this manual or another publication

for additional

information,

The component weighs 23 kg [50 lb] or more, To avoid personal injury, use a hoist or get assistance
to lift the component.

Section i - introduction
Page i-4

Illustrations
The illustrations used in the Repair Sections of this manual
are intended to give an example of a problem, and to show
what to look for and where the problem can be found. Some
of the illustrations are generic and might not look exactly
like the engine or parts used in your application.
The
illustrations
can contain
symbols
to indicate
an action
required, and an acceptable or not acceptable condition.

The illustrations are intended to show repair or replacement


procedures with the engine in-chassis.
The illustration can
differ from your application, but the procedure given will be
the same.

Section i - Introduction
Page i-5

General
Important Safety Notice

Safety Instructions
WARNING

Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
Make sure the work area surrounding

the product

is safe. Be aware of hazardous

conditions

that can exist.

Always wear protective glasses and protective shoes when working.


Do not wear loose-fiiing

or torn clothing.

Remove all jewelry when working.

Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting
motor if equipped to prevent accidental engine starting. Put a Do Not Operate tag in the operators compartment
or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler
cap and relieve the pressure from the cooling system.
Do not work on any thing that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure,
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To prevent suffocation and frostbite, wear protective
in a well ventilated area.

clothing

and ONLY disconnect

liquid refrigerant

(freon) lines

To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg 150 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not
be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of
contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL
A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturers instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes
and compartments.

Always use tools that are in good condition,


service work. Use ONLY genuine

Make sure you understand


Komatsu replacement parts.

Always use the same fastener part number (or equivalent)


lessor quality if replacements

are necessary.

how to use them before performing

when replacing

fasteners,

any

Do not use a fastener, of

Section i - Introduction
Page i-6

General Repair Instructions


This engine incorporates the latest diesel technology;
performed to quality standards.
0

yet, it is designed

to be repaired

using normal repair practices

Komatsu America International Co. does not recommend or authorize any modifications or repairs to engines
or components except for those detailed in Komatsu Service Information. In particular, unauthorized repair
to safety-related components can cause personal Injury. Below Is a partial listing of components classified
as safety-related:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing Turbocharger Oil Drain Line(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted In the Procedures.
Follow the manufacturers recommendations for cleaning solvents and there substances
the engine. Always use good safety practices with tools and equipment.

used during the repair of

Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine
components

and its components


must be kept clean during
will cause premature wear.

any

repair.

Contamination

of the engine

and

Perform the Inspections Specified in the Procedures.


Use Genuine Komatsu Service Parts and Assemblies
Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Komatsu
components. All of the repair services described in this manual are available from all Komatsu Distributors.

Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased
Distributor. Refer to the front of this book for ordering instructions.

from your Komatsu

Page i-7

General Cleaning Instructions


Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Komatsu America International
Company does not recommend any specific cleaners. Always follow the cleaner manufacturers instructions.
Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95
Celsius [80 to 200 Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning
solution will give the best results.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam
clean the parts before putting them in the cleaning tank.

Warning: The use of acid can be extremely dangerous to personnel, and can damage the machinery. Always
provide a tank of strong soda water as a neutralizing agent.
Rinse all of the parts in hot water after cleaning.
all of the capscrew holes and the oil drillings.

Dry completely

with compressed

air. Blow the rinse water from

If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing
rustproofing compound must be removed from the parts before installation on the engine.

compound.

The

Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate
to clean the oil drillings.

the cleaning tank. It is a good way

Warning: Wear protective clothing to prevent personal Injury from the high pressure and extreme heat.
Do not steam clean the following
1.

Electrical

2.

Wiring

3.

Injectors

4.

Fuel Pump

5.

Belts and Hoses

6.

Bearings

parts:

Components

Glass or Plastic Bead Cleaning


Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning
process is controlled by the size of the plastic beads, the operating pressure and the cleaning time.

Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead
cleaning on aluminum ring groves. Small particles of glass or plastic will embed in the aluminum and result
in premature wear. Valves, turbocharger shafts, etc. can also be damaged. Follow the cleaning directions
listed in the procedures.
NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum
any bead blasting media on pin bores or aluminum skirts.

ring grooves. Do not use

Section

i - Introduction

Page i-7-01
Follow the equipment manufacturers
manufacturers instructions:
1. Bead size:

2. Operating

cleaning

instructions.

The following

guidelines

can be used to adapt to

Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No. 3822735.
Use U.S. size No. 70 for piston domes with glass media.
Use U.S. size No. 60 for general purpose cleaning with glass media.

Pressure:

Glass: Use 620 kPa 190 psi] for general cleaning.


Plastic: Use 270 Kpa [40 psi] for piston cleaning.

3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after
cleaning. Rinse with hot water. Dry with compressed air.
4. Do not contaminate

the wash tanks with glass or plastic beads.

Section i - Introduction
Page i-8

Glossary of Terms
Definition
A. C.:

Alternating

AFC:

Air Fuel Control; a device in the fuel pump that limits the fuel delivery
sufficient intake manifold pressure to allow for complete combustion.

ATDC:

After Top Dead Center; refers to the position of the piston or the crankshaft
The piston is moving downward on the power stroke or intake stroke.

rod journal.

BDC:

Bottom Dead Center; refers to the position of the piston or the crankshaft
The piston is at its lowest position in the cylinder.

rod journal.

BTDC:

Before Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving upward on the compression stroke or exhaust stroke.

Circumferential

Direction:

Current

In the direction

of a circle in respect to the centerline

until there is

of a round part or a bore.

Concentricity:

A measurement of the difference between the centers of either two or more parts or the
bores In one part.

Silicone Sealant:

This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive
sealant material having high heat and oil resistance, and low compression set.
Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corning,
732, Loctite Superflex, General Electric RTV108 and Three Bond Sealant.

and

Silastic

DC:

Direct Current

Dye Penetrant Method:

A method used to check for cracks in a part by using a dye penetrant and a developer.
Use crack detection kit, Part No. 3375432, or its equivalent.

End Clearance:

The clearance in an assembly determined by pushing the shaft in an axial direction one
way and then pushing the shaft the other way.

ESN

Engine Serial Number

Hammer:

A hand tool consisting

I. D.:

Inside Diameter

Loctite 290:

A single component, anaerobic, polyester resin, liquid sealant compound that hardens
between closely fitted metal surfaces producing a tough. hard bond. Equivalent products
are Komatsu 1232 273 Hl and Perma-Lok HL 126.

of a hard steel head on a handle.

Section i - Introduction
Page i-9
Definition

Loctite 609:

A single component anaerobic,


of MIL-R-46082A (MN) TYPEl.
Some of the equivalent
HL 138.

Lubriplate

Magnetic

105:

Particle Inspection:

liquid adhesive that meets or exceeds the requirements

products are Komatsu 634 018 Cl, Loctite 601 and Permabond

A mineral oil base grease with calcium soap (2 percent to 6 percent), and zinc oxide (2
percent to 4 percent) additives.

A method of checking for cracks in either steel or iron parts. This method requires a
Magnaflux or equivalent machine that imparts a magnetic field on the part being checked.

of a soft head, either wood, plastic, lead, brass, or rawhide, on

Mallet:

A hand tool consisting


a handle.

MAX:

Maximum

MIN:

Minimum allowed

No.:

Number

O.D.:

Outside Diameter

OS:

Oversize

Protrusion:

The difference in the height between two parts in the assembled

STD:

Standard

TC:

Torque Converter;

TDC:

Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The
piston is at its highest position in the cylinder. The rod journal is pointing straight up
toward the piston.

T.I.R.:

Total Indicator Runout; used when measuring the concentricity


refers to the total movement of the needle on a dial indicator,
reading to the most positive reading.

Water Pump Grease:

A premium high temperature grease that will lubricate antifriction bearings continually from
minus 40 C [minus 40 F] to plus 150 C [plus 350 F]. Some of the greases meeting
this requirement are Aeroshell No. 5, Chevron SRI, Amoco Rykon Premium No. 2, Texaco
Premium RB, and Shell Dolium R. Aeroshell No. 5 is not compatible with the other
greases and must not be mixed. Aeroshell No. 5 is used on new engines and
components.

allowed

used when referring to the torque converter

state.

cooler.

or the runout. The T.I.R.


from the most negative

Section E - Engine Identification


Page E-l

Section E - Engine and Component Identification


Section Contents

Engine Identification ..........................................................


Engine Dataplates ..........................................................
Fuel Injection Pump Dataplate ..................................................

2
2
3

General Engine Specifications ....................................................


General Engine Data ........................................................
Lubrication System.. ........................................................
Cooling System ............................................................
Intake Air and Exhaust System ..................................................
Fuel System ..............................................................
Electrical System ...........................................................
Batteries (Specific Gravity) .....................................................
Engine Diagrams .............................................................

Section E - Engine Identification


Page E-2

Engine Identification
Engine Dataplates
The engine dataplates show specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.
The engine dataplates are located on the front gear cover
housing, on the fuel pump side of the engine, oriented 90
degrees from horizontal. See drawing at left.
NOTE: The engine dataplate must not be changed unless
approved by Komatsu.
6CTAG2

GCTAG1

Engine Dataplates
The. Komatsu model designation represent the
basic design and configuratron of your engrne.
Example Engine Model Name:
6D114E-1, S6D114E-1, SAGD114E-1or SAAGD114E-1
S A (AA)
(1) (2) (3)

6 D114
(4) (6) (6)

E
(7)

-1
(6)

(1)
(2)

Turbocharged
Jacket water aftercooled (JWAC)

(2) or (3)
Charged
air cooled (CAC)
(3)
(4) Number of cylinders
(6) Diesel
(6) Cylinder Bore Dia. in mm
(7) Emissionized
(6) Engine Series

Section E - Engine Identification


Page E-3

Fuel Injection Pump Dataplate


The injection pump dataplate is located on the side of the
injection pump. It provides information for fuel pump
calibration.

The vendor part number for the fuel pump-governor


combination is located on the governor dataplate.

Section E - Engine Identification


Page E-4

General

Engine

Specifications

General Engine Data


Bore ................................................................

114 mm [4.49 in]

Stroke ...............................................................

135 mm [5.32 in]


8.27 liters [504.5 in31

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

Displacement
Compression

ratio
16.4:1

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

6D114E-1

17.3:1

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

S6D114E-1

16.5:1

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

SA6D114E-1
SAAGD114E-l *

High Torque

17.3:1

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

18:l

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

LowTorque..

l-5-36-2-4

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

Firing order

Valve clearance
Intake

0.30 mm [0.012 in]

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

Exhaust

.0.61 mm [0.024 in]

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

Clockwise

Engine rotation (viewed from front of engine) ..........................................


Aspiration
6D114E-1

Turbocharged

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

S6D114E-1
SAGD114E-1

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

SAA6Dll4E-1

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

Engine weight

Naturally Aspirated

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

Turbocharged
Turbocharged

and Jacket Water Cooled

and Charged Air Cooled (CAC)

(with standard accessories)


603to612kg[1330to138OIb]

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

Dryweight

635to658kg[14OOto1450Ib]

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

Wetweight..

Lubrication System
Oil pressure
At idle (minimum allowable)
At rated speed (minimum

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

allowable)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]

Differential pressure to open oil filter bypass valve


Oil flow at rated speed (less flow though
Oil temperature

at rated speed

Oil temperature

thermostat

69 kPa [lo psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]

pressure regulator

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

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

106.8 Ipm [28.2 gpm]

98.9 to 126.6C 1210 to 26OF]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116C [241"F]

Fully open

Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104%[219"F]

Oil pan capacity

(all engines)

(high - low)

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

18.9 to 15.1 liters 120 to 16 U.S. Qts.]

Total system capacity


6D114E-1
S6D114E-1
*

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

23.6 liters 125.0 U.S. Qts.]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8 liters [25.2 U.S. Cts]

All emissionized

engines with Charged Air Cooling are designed as AA.

Section E - Engine Identification


Page E-5

Cooling System
Thermostats
Begins to open
Fully open

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

81 to 83C 1178 to 182F]

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

95 C [203F]

Top tank temperature


Maximum

allowable

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

Minimum

recommended

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

Pressure cap for 99C [21OF] system

Water Pressure (Upper manifold)

Coolant capacity

50 kPa [7 psi]

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

103 kPa [15 psi]

at 2090 RPM engine speed

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

fully opened, engine speed 2000 RPM)

103 to 276 kPa [15 to 40 psi]

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

258 Ipm [68 gpm]

(engine only)

6D114E-1, S6D114E-1, SAAGD114E-1*


SAGD114E-1

70 C [158 F]

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

Pressure cap for 104C [220 Fj system

Coolant flow (thermostats

100C [212 F]

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

9.9 liters [lo.5

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

U.S. Cts.]

10.9 liters [11.5 U.S. Cts.]

Intake Air and Exhaust System


Maximum

allowable

6D114E-1

intake restriction

at rated speed and load (with dirty air filter element)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 cm H,O [20 in H,O]

S6D114E-1, SAGD114E-1, SAAGD114E-l*


Maximum turbocharger

outlet restriction

6D114E-1, S6D114E-1, SMGD114E-l*


6D114E-1, SAAGD114E-l*
SAGD114E-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 cm H,O [25 in H,O]

at rated speed and load


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2 mm Hg [3 in Hg]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 cm H,O [40 in H,O]

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

82 in H,O [6 in Hg]

Fuel System
Fuel transfer pump maximum

inlet restriction

6D114E-1, S6D114E-1, SAGD114E-1, SAAGD114E-l*


Fuel transfer pump minimum

output pressure at rated speed

6D114E-1, S6D114E-1, SAGD114E-1 Low Flow


SAAGD114E-l*
Minimum

High Flow

(maximum

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

83 kPa [12 psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]

pressure to fuel pump inlet (all in-line)

Fuel filter restriction

. . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Hg [4.0 in Hg]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Barr [18 psi]

pressure drop across filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]

Fuel pump gallery pressure minimum at rated speed high flow

. . . . . . . . . . . . . . . . . . . . . . . . . . 140 kPa [20 psi]

Fuel pump gallery pressure minimum at rated speed low flow . . . . . . . . . . . . . . . . . . . . . . . . . 48 kPa [7 psi]
Fuel return restriction
*

All em&ionized

(maximum)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in Hg]

engines with Charged Air Cooling are designed

as AA.

Section E - Engine Identification


Page E-6

Electrical System
Minimum Recommended Battery Capacity
12 Volt System
-18C [OF] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
(Reserve capacity amperes)*
0C

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (840)

[32F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1280


(Reserve capacity amperes)*

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (480)

24 Volt System**
-18C [OF] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .!300
(Reserve capacity amperes)*

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (320)

O^c [32 F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640


(Reserve capacity amperes)*
*

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (240)

The number of plates within a given battery size determining reserve capacity determines the length of time sustained
cranking can occur.

**

Per battery (two 12 volt batteries in series) CCA Ratings are based on -18C [OF].

Batteries (Specific Gravity)


Specific Gravity
at 27C [8OF]

State of Charge

1.280 - 1.280

100%

1.230 - 1.250

75%

1.200 - 1.220

50%

1.170 - 1.190

25%

1.110 - 1.130

Discharged

Section E - Engine Identification

Page E-7

Engine Diagrams
The illustration which follow show the locations of the major external engine components, the filters, and other service
and maintenance points. Some external components will be at different location for different engines.

High Pressure
Fuel Lines

!b[inch]NPTF

Front Lifting
Bracket

(Air)

M22 x 1.50 (Air)


Rear Lifting
_ Bracket

Fuel
Injection
Pump

3/4x lG[inch]UNF
Tap for Magnetic
Pick-up
Air
Compressor

Front Engine
Mounting Bracket

FUEL PUMP SIDE VIEW

Section E - Engine Identification


Page E-8

Turbocharger
Wastegate Actuator

Turbocharger

Exhaust Outlet

Water Outlet

Lubricating

Oil

Lubricating

Provision for
Coolant Heater
Provision for
Cab Heater

Oil

Pressure (before

Turbocharger
Oil Drain

emperature

Turbocharger

Side View

Sensor

Section E - Engine Identification


Page E-9
Turbocharaer

Crankcase
Vent Tube

Mounting Holes

Housing

REAR VIEW
Turbocharger
Air Outlet

Turbocharger

CoolantFilter

/Air

ldet

Engine Air
Inlet

fll
Fuel Pump
Drive Cover

Fan Pulley

Drive Belt
Water Pump Y

o nn

FRONT VIEW

Vibration
Damper

Section T - Troubleshooting Logic


Page T-l

Section T - Troubleshooting Logic


Section Contents
Page
Section T - Troubleshooting
Procedures

and Techniques

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

Troubleshooting Symptoms Charts ................................................


Air Compressor Operates with Excessive Noise .......................................
Air Compressor Pumping Excessive Lubricating Oil into Air System .........................
Air Compressor Air Pressure Rises Slowly ..........................................
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
.............
Air Compressor Will Not Pump Air Pressure .........................................
Air Compressor Will Not Stop Pumping Air ..........................................
Alternator Not Charging or Insufficient Charging
......................................
Compression Knock ........................................................
........................
Coolant Contaminated
CoolantLoss.......::::::::::::::::::::::::::::::
........................
Coolant Temperature Above Normal - Gradual Overheat ................................
Coolant Temperature Above Normal - Sudden Overheat ................................
Coolant Temperature Below Normal .............................................
Engine Crankcase Gases (Blowby) - Excessive ......................................
Engine Cranks, But Will Not Start - No Smoke from Exhaust .............................
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present .........................
Engine Idle Rough, Warm Engine ...............................................
Engine Misfiring ...........................................................
Engine Power Output Low ....................................................
Engine Noise Excessive
.....................................................
Engine Starts But Will Not Keep Running ..........................................
Engine Surges at Idle .......................................................
Engine Vibration Excessive
...................................................
Engine Will Not Crank or Cranks Slowly
..........................................
Engine Will Not Reach Rated Speed When Loaded ...................................
Engine Will Not Shut Off .....................................................
Exhaust Black Smoke Excessive Under Load .......................................
Exhaust White Smoke Excessive (Warm Engine) .....................................
Fuel Consumption Excessive ..................................................
Fuel or Oil Leaking from Exhaust Manifold .........................................
Lubricating Oil Contaminated
..................................................
Lubricating Oil Consumption Excessive ...........................................
Lubricating Oil Pressure Low ..................................................
Lubricating Oil Pressure High ..................................................
Engine Noise Diagnostic Procedures - General Information ..............................
Main Bearing Noise (Refer to Engine Noise Excessive - Main bearing System Chart) .............
Connecting Rod Bearing Noise (Refer to Engine Noise Excessive - Connecting Rod Symptom Chart)
Piston Noise (Refer to Engine Noise Excessive - Piston Symptom Chart)
....................
Fuel Consumption - General Information
..........................................
Fuel Consumption - Industrial Customer Complaint Form ...............................
Oil Consumption
..........................................................

3
4
5
6
7
8
9
10
11
12
14
17
18
19
20
21
23
24
25
29
30
31
32
33
34
35
36
38
39
40
41
42
44
46
47
47
47
47
47
48
49

._

Section T - Troubleshooting

Logic

Page T-2

Section

T - Troubleshooting

Procedures and Techniques


A thorough analysis of the customers complaint is the key to successful
about a complaint, the faster and easier the problem can be solved.

troubleshooting.

The more information

known

The Troubleshooting
Symptoms Charts beginning on Page T-3 are organized so that a problem can be located and
corrected by doing the easiest and most logical things first. Complete all steps in the sequence shown from top to
bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts should stimulate a thought
process that will lead to the cause and correction of the problem.
Get all the facts concerning

the complaint.

Analyze the problem thoroughly.


Relate the symptoms

to the basic engine systems and components.

Consider any recent maintenance


Double-check

before beginning

or repair action that may relate to the problem.

and disassembly.

Solve the problem by using the logic charts and doing the easiest things first.
Determine the cause of the problem and make a thorough

repair.

After repairs have been made, operate the engine to make sure the cause of the problem has been corrected.

Troubleshooting Symptoms Charts


Use the charts on the following pages of this section to aid diagnosing specific engine problems. Read each row of blocks
from top to bottom. Follow the arrows through the chart to identify the corrective action.

Section T - Troubleshooting

Logic
Page T-3

Air Compressor

Operates with Excessive Noise


Corrections

Cause
Excessive Carbon Buildup
c/--------j1
OK

Air compressor
train damaged

Check the air compressor

in the Air

drive gear or engine gear

for carbon buildup.

________1
Inspect condition of gears and repair as
needed. Refer to Procedure 4-05.

OK
c
Internal Air Compressor
I

Damage

Replace the air compressor.


~~~~~~~~~~~ Procedure 4-05.
I

Refer to
J

Section T - Troubleshooting
Page T-4

Air Compressor

Pumping Excessive Lubricating Oil into Air System


Corrections

Cause
Air Compressor
gt---------{Ii

Cylinder

Bore or Piston

Check air compressor

discharge

line. Refer to

Logic

Section T - Troubleshooting

Logic
Page T-5

Air Compressor Air Pressure Rises Slowly


Corrections

Cause
------_-__

Air System Leaks

1 Check for air compressor gasket leaks. Refer


4-02.
to
Procedure
Refer
to
the
manufacturers
instructions
for other
air
system leaks.

OK
+
Carbon Buildup
Excessive

in the Air Discharge

Line

Inspect the discharge


Procedure 4-01.

_________

line. Refer to

OK
+

Air System Component

OK

Air Compressor
Malfunctioning

Unloader Valve Assembly

OK
+

+~_________{I
Air Compressor

Intake or Exhaust Valve Air

Check operation of check valves, alcohol


evaporators, air driers, etc. Refer to the
chassis Shop Manual for instructions.

.____----

is Malfunctioning

_________
I
Check unloader valve operation.
Procedure 4-03.

Refer to

Inspect the intake and exhaust valve


assemblres. Refer to Procedure 4-01.

Section T - Troubleshooting
Page T-6

Air Compressor

Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)


Corrections

Cause
I

Check air system plumbing.


Refer to
Chassis Shop Manual for instructions.

_____-_-_

Air System Leaks Excessive


t
I

the

OK
+
Air Governor

is Malfunctioning

or Not Set

Check air governor.

Refer to Procedure

4-04

Logic

Section T - Troubleshooting

Logic
Page T-7

Air Compressor

Will Not Pump Air Pressure


Corrections

Cause

Check air system plumbing.


Refer to
~~~~~~~~~ chassis Shop Manual for instructions.

Air System Leaks Excessive

the

OK

Air Governor
Correctly

Malfunctioning

Check air governor


Procedure 4-04.

or Not Set

operation.

Refer to

I
Air Compressor
Malfunctioning

Unloader Valve Assembly

Check the unloader valve operation.


~~~~~~~~~ Procedure 4-03.
i

Refer to

Section T - Troubleshooting
Page T-8

Air Compressor Will Not Stop Pumping Air


Corrections

Cause
__---_----_

Air System Leaks

1 Check air compressor for gasket leaks. Refer


to Procedure 4-02. Refer to the chassis Shop
Manual for instructions for other air system
leaks.

OK
+
Air Compressor Unloader Valve is Not
Receiving Correct signal From the Air
Governor

Check the air governor


Procedure 4-03.

operation.

Refer to

OK
c
I
Air Compressor
Leaks

Unloader Valve Assembly

Check the unloader valve operation.


~~~~~~~~~ Procedure 4-03.
t
iI
I

Refer to

OK

+I---------{1
Air Compressor

Unloader Valve Spring

Check the unloader valve spring


specifications and application. Refer to

Logic

Section T - Troubleshooting

Logic
Page T-9

Alternator

Not Charging or Insufficient Charging


Corrections

Cause
Battery Condition

Load test the battery. If battery charge is low,


charge the battery and load test again. If the
battery fails the load test, replace the battery.

----------OK
+

I
Battery Connections

Loose or Corroded

Clean/tighten
battery connections.
~~~~~~~~~ Procedure 6-01.
t
iI

Refer to
I

OK
c
I
Alternator

Check/replace
belt tensioner.
Procedure l-04.

____----_

Belt Slipping

tI

iI

Refer to
I

OK
l

Alternator

Pulley Loose on Shaft


OK
*

Gauge or Lamp Malfunction

Check/replace the gauge or lamp. Refer to


~~~~~~~~~ Procedure 6-01.
t
iI

tl_________{l
Alternator

Wires Loose or Broken

it_________]--_

Replace alternator. Refer to Procedure


Refer to the chassis Shop Manual for

6-03.

Section T - Troubleshooting
Page T-10

Compression

Knock

___--_--_
I
Corrections

Ether Starting Aid Malfunctioning

Repair or replace ether starting aids.

Bleed fuel system and check for suction


leaks. Refer to Procedure 5-01.

Air in Fuel System


I

OK

Fuel Quality Poor

Verify by operating engine from a temporary


tank that contains good fuel. Refer to the
Operation and Maintenance Manual for fuel
specifications.

t--------OK
+

Use lower gear, verify that engine load rating


~~~~~~~~~ is not being exceeded.

Engine Overloaded

OK
+

Injection

Check injection pump timing.


~~~~~~~~~ Procedure 5-10.

Pump Timing Incorrect


I

Refer to

OK
+
I
Injectors Malfunctioning

Replace injectors. Test and repair. Refer to


~~~~~~~~~~~ procedure 5-07.

Logic

Section T - Troubleshooting

Logic
Page T-l 1

Coolant Contaminated
Corrections

Cause

It---------{1
Coolant Rusty, Operation Without Correct
Mtxture of Anttfreeze, DCA4 and Water

Drain and flush the cooling system, Fill with


correct mixture of antifreeze and water. Refer

OK

Review the coolant change interval. Refer to


Operation and Maintenance Manual for

/t_________
Transmission

Oil Cooler Leaking

11

Check/replace
oil cooler. Refer to Chassis
Shop Manual for Instructions.

OK

+/---------II

Oil Leaks From Oil Cooler, Cylinder Head


Gasket, Cylinder Head and Cylrnder Block

Refer to Troubleshooting

Logic Chart for

Section T - Troubleshooting
Page T-12

Coolant Loss
Corrections

Cause

Visually inspect the radiator, heater hoses and


connections
to locate the leak. Refer to

Radiator or Cab Heater Leaking


ci---------{I
OK

If oil is present in the coolant, check for a


transmission or lube oil cooler leak. Refer to
Procedure 2-03.

Engine External Leaks

I--------

Visually inspect the engine and components


for seal, gasket, or drain cock leaks. Refer
to Procedure 2-03.

_________

Refer to Troubleshooting
Logic Chart for
Coolant Temperature Above Normal.

OK
+
Overheating or Leaking Compression Gases
Resulting in Loss Through the Radiator
Overflow
OK
c

Check for mixing of coolant and

OK

II---------{1
Air Compressor

Head or Head Gasket

OK
+

(Continued)

Check for coolant in the oil. Check/replace


head or gasket. Refer to the Chassis Shop

Logic

Section T - Troubleshooting Logic


a

Coolant Loss (Continued)


Corrections

Cause

Check/replace the aftercooler. Check for


coolant in the intake manifold and in the oil.
Refer to Procedure 3-04.

Aftercooler Leaking
UK
+

Check/replace the oil cooler. Check for


coolant in the oil. Refer to Procedure 2-03.

Lubricating Oil Cooler Leaking

OK
*
_________ Check/replace the head. Refer to Procedure
7-09.

Cylinder Head Cracked, Porous, or


Expansion Plugs Leaking

OK

Remove the oil pan and check liner o-rings


for leakage. Refer to Procedure 2-13.

age T-13

Section T - Troubleshooting Logic


Page T-14

Coolant Temperature Above Normal - Gradual Overheat


Corrections

Cause

Add coolant. Refer to Procedure 141. Locate


___________ and correct the source of the leak. Refer to
Troubleshooting
Logic Chart for Coolant
Loss.

Coolant Level Low


OK
+

*t---------j1
Radiator Hose Collapsed,

Restricted or

Air flow to the Radiator Inadequate


-_i------------;-

or

Inspect hoses, replace 1 necessary.

Check and repair fan shroud


equipment

Water Pump or Fan Drive Belt Loose

manufacturers

___________ Check the belt tensioner.

Refer to

fan sensor and

instructions.

Refer to Procedure

l-04.

OK

+/________{I1
Lubricating

Oil Level Incorrect

Add or drain engine oil. Refer to Procedure

OK

Cooling Fan Shroud Damaged or Missing

Radiator Cap Incorrect

or Malfunctioning

OK
4

(Continued)

Inspect shroud, repair/replace


~~~~~~~~~~~ Refer to Procedure 142.

or install.

Section T - Troubleshooting

Logic
Page T-15

Coolant Temperature

Above Normal - Gradual Overheat


Corrections

Cause
Anti-freeze

(Continued)

I---------{

Check
concentration,
partially
drain
the
cooling system replace with water. Refer to
Procedure

Over Concentrated

1-ol:

OK
+
I

I
Temperature

Sensor or Gauge Malfunctioning

Test the gauge and sensor, repair or replace


if necessary. Refer to Procedure l-02.

--------t

iI

OK

I---------:,,..,11
Thermostat

Incorrect,

Check/replace

Missing or

thermostat

Refer to

OK
+

+t--------- jll
Radiator Shutters Are Not Opening
Completely or Cold Weather Radiator Cover

Inspect the shutters, repair or replace if


necessary Open radiator cover. Refer to

OK
+
Air Flow to the Radiator Inadequate
Restricted

Air or Combustion
~t---------{1

Gases in Cooling

or

System

-----------

Check and repair fan shroud, fan sensors


and fan clutch as required. Refer to the
Chassis Shop Manual for instructions.

Check hose clamps for leaks on the suctron


side of the pump. Make sure the fill rate is

OK

If aeration continues,
leak through cylinder
Procedure l-02.
(Continued)

check for compression


head gasket. Refer to

Section T - Troubleshooting Logic


Page T-16

Coolant Temperature Above Normal - Gradual Overheat (Continued)


Corrections

Cause
Radiator Fins Damaged or Obstructed With

OK

Measure cylinder block coolant pressure.

OK
I

Check/replace water pump. Refer to


Procedures l-02 and l-07.

t--------j1

Cooling Passages in Radiator, Cylinder Head,


Head Gasket or Cylrnder Block Plugged

Flush the cooling system, fill with new

Check/replace pump. Refer to Procedures

OK
+
Vehicle Cooling System Design

Confirm correct fan, radiator, and other


cooling system components replace as

Section T - Troubleshooting Logic

Page T-17

Coolant Temperature Above Normal - Sudden Overheat


Corrections

Cause

OK
+
Temperature Sensor Malfunctioning

Check/clean sensor and coolant passage.


Refer to Procedure l-01.

Test/replace sensor. Refer to procedure


l-02.

Test the gauge, repair or replace if

Temperature Gauge Malfunctioning

lt________-jj~

Check belt and tensloner. Refer to

OK
+

Radiator Cap Incorrect or Malfunctronrng.


[t---------j11
OK

Thermostat Incorrect or Malfunctioning

(Continued)

Check the radrator pressure cap. Refer to

_________
I
Check thermostat. Refer to Procedure l-02.

Section T - Troubleshooting Logic


Page T-17.1

Coolant Temperature Above Normal - Sudden Overheat (Continued)


Cause

Corrections
Inspect the shutters. Repair or replace if
necessary Open radiator cover. Refer to
Procedure l-02. Check shutterstat settrng.

Radiator Shutters Are Not Opening


Completely or Cold Weather Radiator Cover
Closed. Shutterstat Setting Incorrect

It

---------II

OK
+
Air or Combustion Gasses in the Cooling
System

Check for air or combustion gases in the


~~~~~~~~~ cooling system. Refer to Procedure l-02.

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

Check routing and operation of vent line.


~~~~~~~~~ Refer to Procedure l-l 2.
t
1I
I

OK

Water Pump Malfunctioning

Check water pump operation. Replace the


water pump. Refer to Procedure l-02.

Section T - Troubleshooting
Page T-18

Coolant Temperature Below Normal


Corrections

Cause

Check/repair fan clutch, and viscous fan, as


required Refer to the Chassis Shop Manual

Air flow Across Radiator Excessive


cl---------jl

OK
&
_________

Radiator Shutters Stuck in Open Position

Inspect the shutters, repair or replace if


necessary. Refer to Procedure l-02.

OK
+
Thermostat Broken, Damaged, Incorrect or
Malfunctioning

Fan Malfunctioning

Check thermostats and replace if necessary.


Refer to Procedures l-02 and l-07.

Check fan for continuous operation. Refer to


~~~~~~~~~~~Procedure l-02.
I
I

Logic

Section T - Troubleshooting

Logic
Page T-l 9

Engine Crankcase

Gases (Blowby) - Excessive


Corrections

Cause
Crankcase

________

Breather Vent Tube Restricted

Check breather tube restriction.


Procedures 7-03 and 8-01.

Refer

to

OK

Turbocharger

Check turbocharger
Procedure 3-01.

Seals Leaking

seals. Refer to

OK
+

Air Compressor

___________ Check air compressor.


4-02.

Malfunctioning

Refer to Procedure

OK
+
Cylinder
Worn

Head Valve Guides Excessively

______-__

Replace cylinder
7-09.

head. Refer to Procedure

[Piston

Rings Broken or Worn

I----------

Check piston rings and cylinder


to Procedure 7_,3.

liners. Refer

Section T - Troubleshooting Logic


Page T-20

Engine Cranks, But Will Not Start - No Smoke from Exhaust


Cause

Corrections

Check for loose wires and verify that the


Electrical or Manual Fuel Shutdown Not

Open

OK

/--------II

Loosen the bleed plug at the filter head end.


Operate the hand primer on the fuel transfer
pump to check for fuel. Clean/replace fuel
transfer pump if necessary. Refer to

Injection Pump Not Recervrng Fuel

Air in the Fuel System If the Condition


Occurs During initial Start, Followrng an
It-----------_1

Bleed the fuel system. Refer to Procedure

OK
+

1
Malfunctioning

Fuel Return Overflow Valve

Fuel Filter Plugged Wiih Water or Other


Contamination
OK
+
(Continued)

Check fuel pump return overflow valve. Refer


to Procedure 5-09.

---------

_----------

Drain fuel/water separator or replace fuel


filter. Refer to Procedure 5-01.

Section T - Troubleshooting Logic


Page T-20.1

Engine Cranks, But Will Not Start - No Smoke from Exhaust (Continued)
Corrections

Cause
Injection Pump Timing Incorrect

Injection Pump Worn or Malfunctioning

Check injection
~~~~~~~~~~~Procedure 5-l 0.

---------

OK
4
---------

pump

timing.

Refer to

delivered after bleeding the system. Refer to

Section T - Troubleshooting Logic


Page T-21

Engine Difficult to Start or Will Not Start - Exhaust Smoke Present


Corrections

Cause
Starting Procedure

Refer to
Manual.

Incorrect

the

Operation

and

Maintenance

OK
+

+t

--------OK

Electrical or Manual Fuel Shut Down Binds

11

Check engine cranking RPM. Refer to


Troubleshooting
Logic Chart for Engine Will

_________
I
Check for loose wires and verify that the
solenoid is functioning. Check to be sure
manual shutoff lever is not binding at the
injection pump. Refer to Procedure 5-01.

Improper Starting Procedure

Verify proper starting procedure. Refer to


Starting Instructions in the Operation and
Maintenance Manual.

I--______

OK

Check/repair
necessary.

Starting Aid Needed for Cold Weather or Not


Working Properly

or replace cold starting aid, if

OK

Bleed the fuel system and check for suction


~~~~~~~~~~ leaks. Refer to Procedure 5-01.

Air in the Fuel System

OK
+
________

Fuel Drain Back

Verify that the fuel return line is plumbed to


the bottom of the fuel tank.

Malfunctioning

Fuel Return Overflow Valve

OK
+

(Continued)

Check/replace
return overflow valve. Refer to
Procedure 5-09.

Section T - Troubleshooting Logic


Page T-22

Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Continued)
Corrections

Cause

Clean or replace pre-filters

and screens and

OK

Check intake air system for restrictions

Refer

OK
+

I
Fuel Contaminated
t

---------

Verii by operating
supply tank.

engine form a temporary

OK

Injection

Check top dead center (TDC). Refer to


Procedure 7-07. Check injection pump

Pump Timing Incorrect

the fuel injection pump using the spill port


timing if equipment is available. Refer to
rocedure 5-13.

Injectors Worn or Malfunctioning

Check/replace
5-07.

-----------

injectors.

Refer to Procedure

I
OK

Engine Compression

Low

Injection Pump Worn or Malfunctioning

---------

Perform compression check to identify


problem. Refer to Procedure 7-61.

calibration

checked.

Refer to Procedure

5-11.

Section T - Troubleshooting Logic


rage T-23

Engine Idle Rough, Warm Engine


Corrections

Cause
Idle Speed Set too Low (Below 700 RPM)

Fuel Return Overflow Valve Malfunctioning

Check/replace

Fuel Transfer Pump Malfunctioning


]I---------{1

---------

Injection

fuel transfer pump. Refer to

Clean pre-filters and screens and check fuel


line for restriction. Replace fuel filter. Refer to

Nozzles Plugged or Inoperative


OK
+

+/--------{I1
Injection

Pump Timing Incorrect

Check injection

pump timing.

I/_________{1
OK
+
(Continued)

Refer to

Section T - Troubleshooting Logic


Page T-23.1

Engine Idle Rough, Warm Engine (Continued)


Corrections

Cause
Valves Incorrectly

Adjusted

Engine Compression

Low
OK
+

Injection Pump Malfunctioning

I________

Adjust intake and exhaust valves. Refer


to Procedure 7-06.

_________
I
Perform compression check repair as
required. Refer to Procedure 7-01.

Remove the fuel injection pump, check


~________ calibration, check for debris in delivery valve.
Refer to Procedure 5-11.
i

Section T - Troubleshooting Logic


Page T-24

Engine Misfiring
Cause

Corrections
Bleed fuel system and check for suction

Cl--------- jl
OK
+

t----------

Verify by operating from a temporary supply


tank that contains good fuel.

OK
*
Fuel Injection Lines Leaking
t

Check for loose connections. Inspect and


_________ replace broken lines. Refer to Procedure
5-05.

-I

*t---------j1

Check/replace return overflow valve. Refer to

Malfunctioning Fuel Return Overflow Valve


OK

Check/replace fuel transfer pump. Refer to

Fuel Transfer Pump Malfunctionrng


OK

_________

Clean Pre-filters and screens and check fuel

OK
+
---------

Injection Nozzles Plugged or Inoperative


OK
+

(Continued)

Replace injectors. Refer to Procedure 5-07.

Section T - Troubleshooting Logic


Page T-24.1

Engine Misfiring (Continued)


Cause

Compression Low on One or More Cylinders

Corrections

---------

Perform compression check to identify cause


(piston rings, head gasket or valves). Refer to

--------OK
Camshaft, Tappets or Push Rods Damaged
_----------

Check/replace parts as required. Refer to


Procedures 7-22, 7-24 and 7-08.

Section T - Troubleshooting Logic


Page T-25

Engine Power Output Low


Corrections

Cause
-----____

Check and adjust throttle linkage for full


travel of the fuel control lever. Refer to

Throttle Linkage Incorrectly Adjusted


[l---------II

Check/adjust solenord Irnkage. Refer to

;t_________jjI
Mechanical Shutoff Lever Partially Engaged

OK
+
High Pressure Fuel Lines or Fittings Leaking

________I
Tighten/replace fittings or lines. Refer to
Procedure 5-05.

Bleed the fuel system and check for suction

OK
Fuel Supply Restricted
----------OK
+

(Continued)

Clean pre-filters and screens and check fuel


line for restriction. Replace fuel filter. Refer to
Procedure 5-01.

Section T - Troubleshooting Logic


Page T-26

Engine Power Output Low (Continued)


Corrections

Cause
I
Fuel Return Overflow Valve Malfunctioning

Check/replace fuel return


~~~~~~~~~ Refer to Procedure 5-99.
t
1

overfiow valve.

Check/replace fuel transfer pump. Refer to

Fuel Transfer Pump Malfunctioning


OK

-----------

Lubricating Oil Level Too High

Drain oil to proper level.


I

OK

Intake Air Temperature High - (Above 36 C


1166 FI)

Use outside air to turbocharger in warm


weather.

OK
Coolant passages plugged in the aftercooler

Check charge air cooler for internal


restriction. Replace restricted cooler.

Check/clean debris from front of charge air


cooler.

Intake or Exhaust System Restricted


un
+

(Continued)

Check intake and exhaust system for


restrictions, Inspect air filter and replace as
necessary. Refer to Procedure 3-01 and
Page 3-19.

Section T - Troubleshooting Logic


Page T-27

Engine Power Output Low (Continued)


Corrections

Cause
Fuel Temperature High - (Above 70 C [168

Fill tanks,
___________
weather.

turn

off fuel

heater in warm

OK
+
Check and correct leaks in the air crossover
tube, hoses or through holes in the manifold
cover. Refer to Procedure 3-88.

Air Leak Between Turbocharger and Intake


Manifold
OK
+

Check and correct leaks. Check for a

Exhaust Leak Between Turbocharger and

OK

Injector Nozzles Worn or Malfunctioning

Check/replace injectors. Refer to Procedure


5-87.

--------tI

1I

specifications on Page 34. Replace turbocharger if low. Refer to Procedure 3-l 1.

Turbocharger Worn or Malfunctioning


OK
+
I

Valves Incorrectly Adjusted

--------t

OK
+
I

Injection Pump Timing Incorrect


OK
+

_----------

(Continued)

Adjust valves. Inspect Push rods, springs,


etc. Refer to Procedure 7-06.

Check injection pump timing. Refer to


Procedure 5-l 1.

1
1

Section T - Troubleshooting Logic


Page T-28

Engine Power Output Low (Continued)


Corrections

Cause
I

Injection Pump Worn or Malfunctioning

Check/replace injection pump. Refer to


~~~~~~~~~ Procedure 5-11.
t
1I
I

OK
+
Engine Compression Low

-----------

Perform compression check to ident*@


malfunction. Repair as required. Refer to
Procedure 7-01.

Section T - Troubleshooting

Logic
Page T-29

Engine Noise Excessive


Corrections

Cause
Drive Belt Squeal, Insufficient

Check

Tension or

the tensioner

fan hub and alternator

and

inspect

the drive

turn freely.

OK
Check the tension of accessory drive belts.
Refer to the Operation and Maintenance for

Refer to Troubleshooting

Logic Chart for

OK
Adjust valves. Make sure the push rods are
not bent or the rocker levers are not
severely worn. Refer to Procedure 7-06.
OK
c

Turbocharger

Check turbocharger impeller and turbine


- wheel for housing contact. Refer to
Procedure 3-01.

Noise

OK
+
I

Check/replace vibration
~~~~~~~~~ Procedure 7-l6.
t
i

Gear Train Noise

damper. Refer to

OK

Visually inspect and measure gear backlash.


Replace gears as required. Refer to
Procedure 7-20.

I
Internal Engine Noise
I

Check/replace
connecting rod and main
~~-~~-~-~~~ bearings. Refer to Procedures 7-11 and 7-12.
I

Section T - Troubleshooting Logic


Page T-30

Engine Starts But Will Not Keep Running


Corrections

Cause
I

Under Load

_________ Disengage driven units and check for loading


from malfunctioning accessories.
tI
1I

OK

Engine Idle Speed Too Low (Below 700


RPM)

---------

Adjust idle speed. Refer to Procedure 5-12.

OK

Air in the Fuel System or the Fuel Supply is


Inadequate

Check the flow through the filter. Bleed the


_________ fuel system and check for suction leaks.
Refer to Procedure 5-01.
t
iI
I

OK

Fuel Filter Plugged or Fuel Waxing Due to


Cold Weather

--------tI

Drain fuel-water separator or replace filter.


Check for fuel waxing in cold weather. Refer
i I to Procedure 5-01.

OK
+
Fuel Supply Restricted

Clean or replace pre-filters screens and


check for fuel line restrictions. Refer to
Procedure 5-01.

----------L

OK
+

Injection Pump Timing Incorrect


tI

OK

Camshaft Timing Incorrect


1

Check and adjust injection pump timing.


~~~~~~~~~ Refer to Procedure 5-10.
I

Check/correct gear train timing alignment.


Refer to Procedure 7-22.

----------1

Section T - Troubleshooting Logic


Page T-31

Engine Surges at Idle


Corrections

Cause

---------

leaks. Refer to Procedure

5-l 1.

OK
+

Fuel Supply Restricted

Clean or replace pre-filters and screens and


check
fuel 5-o,
lines _for restriction . Refer to
procedure

I---------{

OK
+
Check/replace

Injectors Worn or Malfunctioning

injectors.

Refer to Procedure

OK

Injection

Pump Malfunctioning

or Worn

Check/replace
injection
Procedure 5-l 1.

----------I

pump. Refer to

Section T - Troubleshooting
Page T-32

Engine Vibration Excessive


Corrections

Cause
I

I
Engine Not Running Smoothly.
Speed Set Too Low.

Low Idle

Refer to Troubleshooting
Engine Misfiring.
Adjust
speed.

--------t

Logic Chart for


engine low idle

OK

Fan Damaged or Malfunctioning

Check/replace the vibrating component


(refer to Chassis Shop Manual for
instructions),

_-------

Accessories

OK

Vibration

OK
+

damper.

Refer

_________
I
Inspect/replace
the fan hub. Refer to
Procedure l-06.

Fan Hub Malfunctioning


OK
+

Alternator

Inspect/replace
the vibration
to Procedure 7-16.

__________

Damper Malfunctioning

Bearing Worn or Damaged

Check/replace the alternator.


~~~~~~~~~ Procedures 6-01 and 6-03.
t
iI

Refer to

OK

Check/correct
flywheel
~~~~~~~~~ Procedure 7-26.
t
i

Flywheel Misaligned

alignment.

Refer to

OK
I

Loose or Broken Internal Components

-----------

Inspect crankshaft and rods for damage that


causes an unbalance. Refer to Procedure
7-l 4.

----------

Check/repair according
Manual instructions.

OK
+
Drive Line Components

Worn or Unbalanced

to Chassis Shop
I

Logic

Section T - Troubleshooting

Logic
Page T-33

Engine Will Not Crank or Cranks Slowly


Cause

Corrections

*t____

_____ {_

Starting Circuit Connectrons


[t---------j-_

Loose or

tit

Check electrolyte level and specific gravity


charge as requtred. Refer to Procedure 6-01.

Clean and tighten

_________

connectrons.

Refer to

11

Check voltage to solenord. Refer to

Replace startrng motor. Refer to Procedure

--p-_________{I
Solenoid or Starting Motor Malfunction

OK
+

+t_________j1
Crankshaft

Rotate the crankshaft to check for rotational


resrstance. Refer to Procedure 7-12.

Rotation Restricted
OK
+

Engine Driven Units Engaged

-----------

+t---------{I
Starting Motor Operating

But Not Cranking

Disengage driven units and check for


loading from malfunctioning accessories.
Refer to the appropriate section.

Remove the starting motor and check for


broken tooth on the flywheel or broken
starting motor spring. Refer to Procedures

Section T - Troubleshooting Logic


Page T-34

Engine Will Not Reach Rated Speed When Loaded


Corrections

Cause

________- Check with hand or digital tachometer

Throttle Linkage Worn or Incorrectly

Adjusted

_________

St-_-____
Mechanical

Shut off Lever Partially Engaged

Check throttle linkage adjustment for full


travel to the high idle stop screw. Refer to
Procedure 5-l 1.

Check/adjust shutoff lever. Refer to


Procedure 5-01.
I

OK
+
Fuel Quality Poor or Diesel Fuel Grade No. 1
Used Above 0C [32 F]

_________

Vebiby by operating the engine from a


tempory tank No. 2 diesel fuel. Refer to the
Fuel Specifications in the machine 0 & M
Manual.

OK
+

Fuel Supply Inadequate

Change the fuel filter and check fuel line,


pre-filter and screens for restrictions, Refer
to Procedure 5-91.

or Restricted

t-------OK
+
Check/repair or replace fuel transfer pump.
Refer to Procedure 5-01.

Malfunctioning

Fuel Transfer Pump

Malfunctioning

Fuel Return Overflow Valve

OK
+

(Continued)

_________

Check/replace
return overflow valve. Refer to
Procedure 5-09.

Section T - Troubleshooting Logic


Page T-34.1

Engine Will Not Reach Rated S1teed When Loaded (Continued)


Cause
Air Fuel Control Tube Leaking and/or
Restricted Orifice, Wastegate Diaphragm
Ruptured

Corrections
Check orifice, tighten fittings. Replace tube if
necessary. Refer to Procedure 5-10. Injection
Pump Malfunction

OK
+
+/________i/
Fuel Injection Malfunctioning

Remove the fuel injection pump, check


calrbratlon. Refer to Procedure 5-07.

Section T - Troubleshooting Logic


Page T-35

Engine Will Not Shut Off


Cause

Corrections

Electrical or Manual Fuel Shutoff Not Closing

Verify the solenoid is not being energized by


a short in the wiring. Check the linkage to the
shutoff lever for binding. Check for the ability
of the spring in the pump to pull the lever to
the shutoff position. Refer to Procedure 5-08.

OK
+

I
Engine Running On Fumes Drawn into Air
Intake
I

I
Check the air intake ducts. Locate and
isolate the source of fumes.

________t
I

OK

Check for porosity between the fuel filter


~~~~~~~~~ mounting to the intake manifold.

Fuel Leaking to Intake Manifold


-

check calibration.

Refer to Procedure

5-l 1.

Section

T - Troubleshooting

Page T-36

Exhaust Black Smoke Excessive Under Load


Corrections

Cause

_________
OK
+
Inspect air cleaner.
t__________I
to Procedure 3-01.

Air Cleaner Plugged

Clean and replace. Refer

I
OK

Air Leak Between Turbocharger


or Exhaust Manifold

and Intake
I

Correct leaks in the air crossover tube,


hoses or through holes in the manifold
cover, Refer to Procedure 3-08.

--------I

OK

Charge Air Cooler Malfunctioning


OK

Exhaust Leak at the Manifold


Turbocharger

or

Check/correct
leaks in the manifold or
turbocharger gaskets. Look for a cracked
exhaust manifold, Refer to Procedure 3-12.

_________

OK
+
I
Turbocharger

Wastegate

Malfunctioning

I
Repair or replace wastegate.
Procedure 3-04.

--------tI

Refer to

OK
+
Turbocharger

Malfunctioning

More Than One Seal Washer Under Injector


Nozzle
t

OK
+

(Continue)

----_-_-_

Replace
turbocharger.
3_,
,.

_________

Remove extra washers.


5-07.
iI

Refer to Procedure

Refer to Procedure

Logic

Section T - Troubleshooting Logic


Page T-37

Exhaust Black Smoke Excessive Under Load (Continued)


Corrections

Cause

l---------

Remove and have nozzles tested. Replace


injectors if necessary. Refer to Procedure 507.

Injector Nozzle Malfunctioning


OK
+

Engine Running Too Cold (Below 88 C


W
FI)
OK
+

_________
1
Check thermostat and cooling system. Refer
to Procedures l-02 and l-08.

Check and adjust injection pump timing.


Refer to Procedure 5-11.

________

Injection Pump Timing Incorrect

Remove and test injection pump. Refer to


~~~~~~~~~ Procedure 5-l 1.

AFC Malfunction or Injection Pump


Overfueled

OK
+
Piston Rings Not Sealing
I

Perform a compression check, Repair as


~~~~~~~~~~ required. Refer to Procedure 7-01.
I

Section T - Troubleshooting Logic


Page T-38

Exhaust White Smoke Excessive (Warm Engine)


Corrections

Cause

Coolant Temperature Below Normal.


OK
+
Refer to Operation and Maintenance Manual
for shutter operation. Check intake air heater
operation (ii required).

Intake Air temperature Too Low


OK
+

Verify by operating engine from a temporary


---______

Fuel Quality Poor


OK
+

Check top dead center (TDC). Refer to


Procedure 7-07. Check/adjust injection
_________ pump timing. Refer to Procedure 5-11.
Check/time the fuel injection pump using the
spill port timing if equipment is available.
Refer to Procedure 5-13.

Injection Pump Timing Incorrectly Adjusted

OK
+
;t

_________

{I

Replace injectors Refer to Procedure 5-07

OK
+

Coolant Leaking Into Combustion Chamber

Refer to Troubleshooting Logic Chart for


~~~~~~~~~ Coolant Loss.
t
1I
I

(}---------{I
Injection Pump Malfunctioning

Remove fuel Injection pump. Have calrbratron


checked. Check for debris in delivery valves.

I
1

Section T - Troubleshooting

Logic
Page T-39

Fuel Consumption Excessive


Corrections

Cause
Additional Loading From Malfunctioning
Accessories.

Check/repair
accessories
and
machine
_________ components. Refer to Chassis Shop Manual
for instructions.

Check for external leaks and engine oil


the fuel transfer pump and injection pump.

OK

I
Refer to Troubleshooting Logic Chart for
Exhaust Smoke Excessive Under Load.

Intake Air or Exhaust Restriction


OK
+

Check/replace injectors. Refer to Procedure

OK

OK
+
Valves Not Seating

I----------

Check/adjust valves. Refer to Procedure


7-06.

Section T - Troubleshooting Logic


Page T-40

Fuel or Oil Leaking from Exhaust Manifold


Corrections

Cause
1
Operating For Extended
or No Load Conditions

Periods Under Light

I
---------

Review machine operation.

1I

OK
+

Check/replace filter element. Refer to


~~~~~~~~~ Procedure 5-81.

Intake Air Restriction


t
OK

Review operation

for excessive

idling.

1
Check/adjust

fuel injection

pump timing.

OK
+
Injector Needle Valve Stuck Open

Locate and replace malfunctioning


Refer to Procedure 5-87.

-----------

injector.

OK
+

Turbocharger

_-______

Drain Line Obstructed


t

Check/clean

line. Refer to Procedure

I
I

OK

+t--------- jl
Turbocharger

Check/replace

Seals Leaking Oil

turbocharger.

Refer to

OK
+
1
Crankcase Gasses (Blowby)

Excessive

I
Check for excessive
Procedure 8-81.

--------t

3-11.

blowby.

Refer to

Section T - Troubleshooting Logic


Page T-41

Lubricating Oil Contaminated


Corrections

Cause
Coolant in the Oil, Internal Engine
Component Leaks

-----------

Refer to Troubleshooting
Coo,ant Loss*

Logic

Chart

for

OK
+

OK

Make sure the correct oil is being used.


Refer to the Operation and Maintenance

Fuel in the Oil Engine Operating


/--------{Ii

Review the operation for excessive idling


resulting in the engine running below normal

Too Cold

Fuel Transfer Pump Seal Leaking

Injector Needle Valves Not Sealing


OK
+

Fuel Pump Internal Plunger Seal Leaking

__--_---_--

Replace
the fuel pump. Refer to Procedure
5_,
,.

OK

-t_________{~

Replace the fuel pump. Refer to Procedure

Section T - Troubleshooting Logic


Page T-42

Lubricating Oil Consumption Excessive


Corrections

Cause

Visually inspect for oil leaks.

External Leaks
OK

-t---------{l

Verify that the dipstick is correctly marked

Crankcase Being Overfilled (Dipstick

OK
+
Incorrect Oil (Specification or Viscosity)
_.

r----------

Make sure the correct oil is being used.


Refer to the Operation and Maintenance
1 Manual for oil specifications.

I
,

Check for reduced viscosity form dilution


with fuel. Refer to Procedure 2-02.

I
Review/reduce the oil change intervals. Refer
to the Operation and Maintenance Manual.
I

High Blowby Forcing Oil Out the Breather


Tube
t

OK
+
I

Check the breather tube area for signs of oil


_________ loss. Measure the blowby and perform the
required repairs. Refer to Procedures 8-01.

t
I

OK

OK
+

(Continued)

Check for oil in the coolant. Refer to


Procedures 2-02 and 2-l 1.

________

Oil Cooler Leak

Section T - Troubleshooting Logic


Page T-43

Lubricating Oil Consumption Excessive (Continued)


Corrections

Cause

Inspect the turbocharger inlet and outlet for


evidence of oil transfer. Refer to Procedure 301.

Turbocharger Leaking Oil to the Air Intake or


----------Exhaust
I

OK

Inspect/replace the vale seal. Refer to


6D114E-1 Series Engine Shop Manual.

Valve Seals Worn

Piston Rings Not Sealing (Oil Being


Consumed by the engine)

._-_____

Perform a compression check. Repair as


required. Refer to Procedure 7-61.

Section T - Troubleshooting Logic


Page T-44

Lubricating Oil Pressure Low

_-_-_____
1
Corrections

Cause

Add or drain engine oil. Refer to Procedures


2-04 and 245.

Oil Level Incorrect

Oil Diluted Wiih Fuel but Engine Operation


Normal

--------t

iI

Remove and check fuel transfer pump


plunger seal. Replace leaking pump. Change
oil. Refer to Procedure 5-04.

OK

Oil Diluted Wiih Fuel Accompanied

by Rough

Check for a stuck injector nozzle. If injectors

OK
+

Oil Diluted Wiih Coolant

(Anti-Freeze)

Oil Pressure Switch of Gauge Malfunction


tit---------/i

Oil Pressure Regulating

OK
+

Valve Stuck Open or

(Continued)

Check oil cooler, aftercooler, core plugs,


cylinder liner, head gasket, and cracked
passages in the block and head for leaks.
Replace leaking component and change oil.
Refer to Procedure 2-05.

Check 01 pressure gauge and swrtch. Refer

Section T - Troubleshooting Logic


Page T-45

Lubricating Oil Pressure Low (Continued)


Cause

Corrections

OK
+
I

_________
1
I

Oil Filter Plugged


t

OK

It

----_---{_

Check and replace 01 cooler. Refer to

OK
+
Cup Plug Internal Leak

-----------

Check oil rifle cup plugs, cup plug in front


and rear face of block. Refer to Procedure
731.

OK
+
Suction Tube Loose or Gasket Leaking

I,,,,,,,.,,

Replace gasket and tighten tube Refer to

----------

iLid-_____{-_

Check/replace 011pump. Refer to Procedure

--------OK
+
Connecting

Change oil and replace filter. Refer to


Procedures 2-04 and 2-05.

Rod or Main Bearing Worn

Check/replace bearings. Also, check/replace


piston cooling nozzles. Refer to Procedures
7-l 1 and 7-14.

Section T - Troubleshooting Logic


Page T-46

Lubricating Oil Pressure High


Corrections

Cause
Pressure Switch/Gauge Malfunctioning

Verify the pressure switch/gauge


are
functioning correctly. Refer to Procedure 2-03.

_----------

OK

tI

OK

Oil Viscosity Too Thick

Refer to Troubleshooting Logic Chart for


~~~~~~~~~ Coolant Temperature Below Normal.

Engine Running Too Cold

Make sure the correct oil is being used.


Refer to the Operation and Maintenance
Manual.

OK
+
Pressure Regulator Valve Stuck Closed.

Check/replace valve. Refer to Procedure


___________2_,o.

Section T - Troubleshooting Logic


Page T-47

Engine Noise Diagnostic Procedures - General Information


NOTE: When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air
compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate noise
caused by these units. Noise will also travel to other metal parts not related to the problem. The use of a stethoscope
can help locate engine noise.
Engine noises heard at the crankshaft speed, engine RPM, are noises related to the crankshaft, rods, pistons, and piston
pins. Noises heard at the camshaft speed, one-half of the engine RPM, are related to the valve train. A hand-held digital
tachometer can help to determine if the noise is related to components operating at the crankshaft or camshaft speed.
There is not a definite rule or test will positively

determine the source of a noise complaint.

Engine driven components and accessories, such as geardriven fan clutches, hydraulic pumps, beltdriven alternators,
air-conditioning
compressors, and turbochargers can contribute to engine noise. Use the following information as a guide
to diagnosing engine noise.

Main Bearing Noise (Refer to Engine Noise Excessive - Main bearing System Chart)
The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load. If all main
bearings are loose, a load clatter will be heard. The knock is heard regularly every other revolution. The noise is the
loudest when the engine is lugging or under a heavy load. The knock is duller than a connecting rod noise. Low oil
pressure can also accompany this condition.
If the bearing is not loose enough to produce a knock by itself, the bearing can knock if the oil is too thin, or if there
is no oil at the bearing.
An irregular noise can indicate worn crankshaft thrust bearing.
An intermittent sharp knock indicates
a change in the noise.

excessive

crankshaft

end clearance.

Repeated clutch disengagements

can cause

Connecting Rod Bearing Noise (Refer to Engine Noise Excessive - Connecting Rod
Symptom Chart)
Connecting rods with excessive clearance knock at all engine speeds, and under both idle and load conditions. When
the bearings begin to become loose, the noise can be confused with slap or loose piston pins. The noise increases in
volume with engine speed. Low oil pressure can also accompany this condition.

Piston Noise (Refer to Engine Noise Excessive - Piston Symptom Chart)


It is difficult to tell the difference between piston pin, connecting rod, and piston noise. A loose piston pin causes a loud
double knock which is usually heard when the engine is idling. When the injector to this cylinder is held down, a
noticeable change will be heard in the sound of the knocking noise. However, on some engines the knock becomes more
noticeable when the machine is operated at a steady speed condition.

Fuel Consumption - General Information


The cause of excessive fuel consumption is hard to diagnose and correct because of the potential
involved. Actual fuel consumption problems can be caused by any of the following factors:
-- Engine Factors
-- Vehicle Factors and Specifications
-- Environmental Factors

-- Driver Technique and Operating


-- Fuel System Factors
-- Low Power

number of factors

Practices

Before troubleshooting,
it is important to determine the exact complaint and whether the problem is real or perceived,
does not meet drivers expectations. The Fuel Consumption - Industrial Customer Complaint Form is a valuable list of
questions that can be used to assist the service technician in determining the cause of the problem. The form should be
completed before troubleshooting
the complaint. The form is on the next page. The following are some factors that may
be considered when troubleshooting.

Section T - Troubleshooting

Logic

Page T-48
Result of a Low Power Problem: An operator will change his driving style to compensate

for a low power problem.

Environmental and Seasonal Weather Changes: As a general rule, there can be as much as a 1 to 1.5 mpg difference
in fuel consumption depending on the season and the weather conditions.
Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending

on the engine idle speed.

Fuel Consumption - Industrial Customer Complaint Form


Customer Name/Company
Answer the following

Date

questions.

Some questions

1.

What fuel consumption

2.

What are the expatiations based on?


Original consumption
Previous engine owned

3.

is expected?

require making an X next to the appropriate

Expected

Competitive engines
Engine performance curve

Gradually

4.

Did the problem start after a repair?


If so, what was repaired and when?

5.

Is the machine also experiencing


IF ANSWERED

gph

Other units in fleet


Expectations only

When did the problem occur?


Since New
Suddenly

answer.

Yes

No

a Low Power / Poor Acceleration

Response?

Yes

YES, GO TO THE ENGINE POWER OUTPUT LOW TROUBLESHOOTING

No
SYMPTOM

CHART.

No

6.

Is the problem seasonal?

7.

Weather conditions during fuel consumption


Rain
Snow
Windy

Yes

check?
Hot Temperatures

Cold Temperatures

8.

How is the fuel consumption

9.

Do duty cycles vary between compared

10.

Have duty cycles changed for the engine being checked?

11.

What are the loads compared

12.

What is the altitude that the unit is operating

13.

How much of the time is the unit idling?

14.

Is operator technique or operating practices affecting fuel economy?


RPM
Operate at rated speed or above:
Incorrect shift rpm:
Shift RPM
Torque Peak
Believe compensating for low power

Month

measured? Tank
units?

to a comparison

Year

Yes

unit?

at?

Hourmeter

No
Yes
Heavier

No
Lighter

Below 10,000 feet

Above 10,000 feet

Hours/Day

IF AFTER FILLING OUT THIS FORM IT APPEARS THAT THE PROBLEM IS NOT CAUSED BY MACHINE FACTORS,
ENVIRONMENTAL
FACTORS OR OPERATOR TECHNIQUE,
GO TO THE FUEL CONSUMPTlON
EXCESSIVE
TROUBLESHOOTING
SYMPTOM CHART.

Section T - Troubleshooting

Logic
Page T-49

HI Consumption
ACCEPTABLE

OIL USAGE

ANY TIME DURING COVERAGE

PERIOD

ENGINE
FAMILY

HRS PER
QUART

HRS PER
LITER

HRS PER
IMPERIAL
QUART

MILES PER
QUART

MILES PER
LITER

MILES PER
IMPERlAL
QUART

KILOM PER
QUART

KILOM PER
UTER

KILOM
PER
IMPERlAL
QUART

6D114E-1
SERIES

10.0

10.6

12.0

400

425

475

650

675

775

Engine Lubricating Oil Consumption

Address

City State/Province

Engine Serial No.

Date of Delivery
Month

Owners Name

Zip

Report
Year

Day

Equipment Manufacturer

Engine Model & HP

Equipment Serial No.

Fuel Pump Serial No.

Engine Application
(Describe)

Oil & Filter Change Interval

Complaint Originally Registered


Filters

Oil

Date

Mile-Hours-Kilometers

I
Lubricating Oil Added
Brand & viscosity of Oil Used

Quarts - Liters
Oil Added

Engine Operation
Miles-Hours-Kilometers

Date Added Oil


Start Test

Last Mileage/Hours/Kilometer
Equals Test Mileage/Hours/Kilometers
Equals

Minus Start Mileage/Hours/Kilometers


Divided By Oil Added

Usage Rate

Customers Signature

Dealer

Distributor

Section T - Troubleshooting Logic


Page T-50

Oil Consumption

Dist./Dir.
Mi/Km/Hr
CPL No.
Date

Customer Name
Engine Model
Engine Serial No.
Machine Make/Model

1.

Review of maintenance

Report

history.

List any previous failures that could have had a detrimental effect on cylinder component life. Failures could include
fuel, coolant, and/or foreign abrasives in the oil, second ring groove beat-out, filter plugging, etc.

~~~~~~~~~~~~:~~~:~
ijl:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.~.:,~.:,:.:,:.:.~,:,:,:,:.:.:,:,:.:.
.,:,:,:.:.:.:.:,:.:.:.:.:.:.:.:.:.:.:.:,:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:,:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.

Brand

viscosity
Change Interval

Mi/Km/Hr

II

Model

11

Change Interval

II

Model

II

Change Interval

Element

II
Mi/Km/Hr

Element

11

II

2.

List any external engine leaks.

3.

Visually Check for any internal leaks and list. Check turbocharger

4.

Had the fuel pump been tampered with?


What is maximum rail pressure readings?
If Yes, the
pump must be reset to factory specifications and the customer sent out to re-evaluate his oil consumption rate and
the eligibility requirements must be met again.

5.

Drain and refill oil pan to check dipstick

6.

Only alter above checks are completed, leaks corrected and proper documentation
engine to determine cause for the failure and repair as required.

7.

State reason for oil consumption.

Signed:

seals, valve guides, air compressor,

etc.

markings and note findings.

is completed,

dis-assemble

Section 1 - Cooling System


Page l-l

Section 1 - Cooling System


Section Contents

l-27
l-28
1-27
l-28

Belt Tensioner - Replacement .................................................


Installation .............................................................
Removal ...............................................................
Removal and Installation ....................................................
Malfunctions
Cooling System - Diagnosing
. . . . . . . . . . . . . . 1:: :::::::::
. . .........
..........
BeltTension
Coolant Hose - Inspection ................................................
Coolant Pressure - Measurement
...........................................
Cooling System - Test for Combustion Gases ...................................
Fuel Pump Over-fueled ..................................................
Radiator Cap - Pressure Test ..............................................
Radiator, Fan and Shutters
...............................................
Temperature Gauge Operation .............................................
..................
Thermostat Leakage and Opening Temperature - Testing In-Chassis
....................
Thermostat Opening Temperature - Testing Thermostat Removed
Thermostat Operation and Testing
..........................................
Vehicle Overloaded
....................................................
Water Pump - Inspection .................................................
.....................................
Water Pump Seal Weep Hole - Inspection
Cooling System - Flow Diagrams

1::

:::::

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

1:

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

1-3

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

Cooling System - General Information


Cooling System - Maintenance
. . .
Additive Concentration - Checking
Antifreeze . . . . . . . . . . . . . . . . .
Antifreeze Concentration - Checking
Cooling System - Cleaning
. _. . .
Cooling System - Draining . . . . . .
Filling and Venting . . . . . . . . . . .

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

l-2

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

.
.
.
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.
.
.

.
.
.
.
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.
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1-13
1-18
1-19
1-21
1-14
l-26
1-14
1-21
l-26
1-24
l-25
l-23
1-27
1-19
1-19

. .
.
. .
. .
. .
.

.
.
.
.
.
.

.
.
.
.
.
.

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

.
.
.
.
.
.
.

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.
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.
.

l-7
l-7
l-7
l-7
l-8
1-7
1-12

Cooling System - Service Tools

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

l-6

Cooling System - Specifications

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

1-5

Drive Belt - Replacement

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

l-27

.
.

l-28
l-29

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

l-28

Fan Hub - Replacement


.................................................
Removal and Installation
................................................
Fan Pulley - Replacement

Thermostat - Replacement
...............................................
.........................................................
Cleaning..
Installation .........................................................
Removal ...........................................................
Water Pump - Replacement
..............................................
.........................................................
Cleaning..
Installation .........................................................
Removal ...........................................................

.
.
.
.

.
.
.
.

.
.
.
.

l-32
1-33
1-33
1-32

.
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.

.
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.
.

1-29
l-30
l-30
l-29

Section 1 - Coolina System


Page 112

Cooling System - General Information


The primary function of the cooling system is to remove the
heat created by the engine and its support components. The
excess heat energy that is not removed by the cooling system
is carried away by exhaust gases and radiation into the
atmosphere.

ck8hdpa

Rabiator

The accompanying charts illustrate the coolant flow through the


engine. For more detail refer to the cooling system flow
diagrams on page 1-3.

Section 1 - Cooling System

Page 1-3

Cooling System - Flow Diagrams


The following

illustrations

identify the significant

features of the cooling

system:

Coolant is drawn from the radiator by the integrally mounted water pump. The output from the water pump empties into
the bottom of the oil cooler cavity in the cylinder block.
From the cooler cavity, the coolant flows into the upper water manifold. A portion of coolant flows through the coolant
filter and returns to the lower manifold. The remainder flows through six cast openings up to the cylinder head.
A portion of the coolant flowing into the cylinder head is directed to the liner cavity and, by means of a diffuser plate cast
into the cavity, is circulated around the top portion of the liners. The remainder of the coolant flows across the valve
bridges around the injector bores and down into the liner cavities through two orificed holes per cylinder. The orificed
holes control the coolant flow around the liners.

Coolant System

Cylinder Block
1. Coolant Inlet
2. Pump Impeller
3. Coolant Flow to Cooler
4. Coolant Flow Past Oil Cooler
5. Upper Coolant Manifold
6. Coolant to Cylinder Head

Cylinder Head
1. Coolant Flow from
Upper Coolant Manifold
2. Coolant to Liner Cavity
3. Cylinder Head Gasket
4. Coolant Flow Orifice

Section 1 - Cooling System


Page 1-4

Cooling System - Flow Diagrams (Continued)


From the liner cavities the coolant flows through

cast openings

into the lower manifold and on to the thermostat

cavity.

When engine is below operating temperature, the thermostats are closed. Coolant is bypassed to the water pump inlet.
As the coolant temperature increases, both thermostats begin to open allowing some of the coolant to flow to the radiator.
At normal operating temperature, both thermostats are fully open and the bypass circuit is closed.

Coolant System
Thermostat

Closed

1. Coolant Flow
Past Cylinder Liners
2. Lower Coolant Manifold

_ Intermediate

5. Partial Coolant
1. Thermostats
Flow to Radiator
2. Coolant to
Pump Inlet
6. Restricted
Coolant Flow
3. Bypass Passage
to Bypass
4. Coolant From
Lower Coolant
Manifold

Open
7. Coolant to
Radiator
6. Bypass Closed

Section 1 - Cooling System


Page l-5

Cooling System - Specifications


Metric [U.S.]
Coolant Capacity (engine only)
S6D114E-1, SAGD114E-1 (air aftercooled)
SAAGD114E-1(water aftercooled)

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

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

9.9 liters [lo.5 U.S. Qts.]


10.9 liters [11.5 U.S. Qts.]

Thermostat
Starts to Open
Fully Open

81 to 83C [178 to 182F]

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

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

Maximum Allowable Top Tank Temperature

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

Minimum Recommended Top Tank Temperature


Minimum Allowable Pressure Cap

95C 1203F]

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

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

Supplemental Coolant Additives (SCA) Concentration

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

100 C [212 F]
70C [158F]
50 kPa [7.0 psi]
1.5 to 3.0 units per 3.7 liters [l U.S. Gallon]

Section 1 - Cooling System


Page l-6

Cooling System - Service Tools


The following special tools are recommended to perform procedures in Section 01. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

The Fleetguarde Refractometer is used to measure the freeze


point protection and antifreeze concentration.

Includes Part No. 3822986 Test Fluid, Part No. 3822987


Adapter, and Part No. 3877612 Instructions.

Section 1 - Cooling System


Page l-7

Cooling System - Maintenance

(I-01)

Antifreeze
Caution: Never use only water for engine coolant. In
tropical climates where antifreeze
availability
can be
limited, use a corrosion inhibitor (Liquid DCA) to protect
the engine cooling system.
Refer to the appropriate Chassis Operation and Maintenance
Manual for antifreeze concentration recommendations.

Antifreeze

Concentration

- Checking

The Fleetguard@ refractometer, Part No. CC-2800, provides a


reliable
and easy-to-read
measurement
of freeze
point
protection and glycol (antifreeze) concentration.
The freeze point protection must be checked if coolant is
added to the cooling system or annually when operating in
temperatures
below 0C [32 F]. Refer to the appropriate
Chassis Operation and Maintenance Manual for instructions.

Cooling System - Draining


Open the petcocks at the bottom of the radiator and at the
bottom of the oil cooler housing. Remove the lower radiator
hose. A 20 liter [4 U.S. gallons] drain pan will contain the
coolant in most applications.

Additive Concentration

- Checking

The cooling system must contain the proper coolant additive


units to provide the best chemical protection. Refer to the
appropriate Chassis Operation and Maintenance Manual.

Large Plastic
CUP

DCA4
Test
Kit: Use only
DCA4 Coolant
Test
Kit,
Fleetguarde Part No. CC-2626, to check the coolant additive
concentration in the cooling system.

Container
Svrinue

Section 1 - Cooling System

Cooling System - Cleaning


The following is the recommended procedure for flushing and
cleaning the engine cooling system of oil or fuel contamination.
It is assumed that the source of the contamination
has been
located and corrected:

Warning: Wait until the coolant temperature is below 50C


[122Fj before removing the coolant system pressure cap.
Failure to do so can cause personal injury from heated
coolant spray.

c%
0

Remove the pressure cap. Slowly overfill the top tank to flush
as much contaminated coolant as possible out the top of the
tank.

Completely drain the cooling system (block, radiator, heaters).


Do not remove the coolant filter. Use running water to quickly
flush the majority of the contamination,
leaving draincocks
open. Plugged radiators can require extra treatment beyond
these procedures. Consult local regulations concerning disposal
of antifreeze and oil.

Section 1 - Cooling System


Page l-9
Connect all hoses, close all draincocks.

NOTE: The performance of RESTORE is dependent on time,


temperature, and concentration levels. An extremely flow
restricted system, for example, can require higher
concentrations of cleaners, higher temperatures, or longer
cleaning times. RESTORE can be safely used up to twice the
recommended concentration levels. Extremely fouled systems
can require more than one cleaning.
Komatsu America International Company recommends using
FleetguardQ RESTORE or an equivalent.
Cooling systems
can also be cleaned using non-sudsing
washing soda or
automatic dish washer soap.
The product used must be alkaline (non-acidic).
Use of a
liquid cleaner will allow easier mixing and will not have the

possibility to cake or plug the cooling system.


If using a cleaner other than RESTORE, consult the label to
determine the amount of cleaner required for the cooling
system capacity. When using a powdered cleaner, thoroughly
mix the cleaner with water (an amount equal to the cooling
system capacity) in a separate
system with the mixture.

container.

Fill the

cooling

Caution: Fleetguarde RESTORE contains no antifreeze.


Do not allow the cooling system to freeze during the
cleaning operation.
Immediately add 3.8 liters [l

U.S. gallon] of Fleetguard@


RESTORE (or equivalent) for each 38 to 57 liters [lo to 15
gallons] of cooling system capacity, and fill the system with
plain water. Do not allow the cooling system to dry out.

RESTORE will not be as effective if the cooling system is


allowed to dry.

Section 1 - Cooling System


Page 1110
Turn the cab heater temperature
switch to high to allow
maximum coolant flow through the heater core. The blower fan
does not have to be on.

I
CoLD

HEATER -W
I

-3

\\

HOT

Operate the engine at 2100 RPM at normal


temperatures (at least 85C [185 F]) for 1 hour.

Shut off the engine, and drain the cooling

operating

system.

Use running water to flush the majority


mixture, leaving all draincocks open.

of the contaminated

Connect all hoses, close all draincocks


system with clean water (and neutralizer
requires).

and fill the cooling


if the cleaner used

Section 1 - Cooling System


Page 1-11
Operate the engine at high idle for 5 minutes
coolant temperature above 85C [185F].

with

the

Shut off the engine and completely drain the cooling system
again. Use running water to flush the remainder of the rinse
water.

Connect all hoses, close all draincocks


valves open.

and leave all heater

NOTE: If the drain water shows more than just a trace of


contamination, the cooling system must be flushed again.

Install a new coolant filter, and fill the cooling *system with a qb
fresh premixture of 50 percent low silicate antrfreeze and 50 0@,x,x
percent water.
NOTE: Use an initial charge filter to bring the coolant to the
correct DCA4 concentration
level of 1 unit per 3.8 liters [l
U.S. gallon]
of coolant
in the system.
Refer to the
appropriate Chassis Operation and Maintenance Manual.

50%
iVATER
50%
ANTIFREEZE

50%
WATER

50%
ANTIFREEZE

Section 1 - Cooling System

Page 1-12

install the pressure cap. Clean the engine compartment of any


contamination residue accumulated during the top tank overfills.
Operate the engine to check for leaks and normal operation.

Filling and Venting


The system is designed to use a specific quantity
If the coolant level is low, the engine will run hot.

of coolant.

If frequent addition of coolant is necessary, the engine or


system has a leak. Find and repair the leak.

The engine coolant passages must be completely filled with


coolant.
During operation, entrapped air mixes with the coolant which
results in cavitation corrosion and poor heat transfer. Highly
aerated coolant can cause localized overheating of the cylinder
head and block which can result in a cracked head, scored
cylinder or blown head gasket.

Caution: During filling, air must be vented from the engine


coolant passages. Open the engine venting petcock and the
petcock on the aftercooler for aftercooled engines. The
system must be filled slowly to prevent air locks. Wait 2 to
3 minutes to allow air to be vented, then add mixture to
bring the level to the top.
Refer to Cooling
recommendations.

System

Maintenance

for

coolant

Section 1 - Cooling System


Page l-13
Water will cause rust formation
smaller coolant passages.

The small holes in the


susceptible to plugging.

reducing

the flow

in the

head gasket are especially

Caution: These holes are orifices and their size is critical.


Do not enlarge the size of the orifices. To do so will
disturb the coolant flow and will not solve an overheating
problem.

Also, water used as a coolant for even a relatively short


period can result in the cup plugs rusting through allowing
the coolant to leak.

Caution: A sudden loss of coolant from a heavily loaded


engine can result in severe damage to the pistons and
cylinder bore.
NOTE: Use the correct amount of DCA4 corrosion inhibitor
to protect the cooling
system. Refer to the appropriate
Chassis
Operation
and Maintenance
Manual for DCA4
amounts.

Cooling System - Diagnosing


Malfunctions (I-02)
The function of the cooling system is to maintain a specified
operating temperature
for the engine. Some of the heat
generated by the engine is absorbed by the coolant flowing
through the passages in the cylinder block and head. Then,
heat is removed from the coolant as it flows through the
radiator.
When
troubleshooting
overheating
problems,
remember that too much oil in the oil pan can cause
additional
heat from friction
when the rod journals
are
submerged in oil.

Overfilling the oil pan raises the oil temperature


transferred to the coolant system at the oil cooler.

which

is

Section 1 - Cooling System


Page 1-14

Radiator Cap - Pressure Test


The system is designed
boiling of the coolant.

to use a pressure

cap to prevent

Different caps are specified for the two recommended

systems:

System

Cap

A - 104 C [220 F]

103 kPa [15 psi]

B - 99C [21OF]

48 kPa [7 psi]

Pressure test the radiator cap.


The pressure cap must seal within 14 kPa [2 psi] of the value
stated on the cap or it must be replaced.
An incorrect or malfunctioning
cap can result in the loss of
coolant and the engine running hot.

Cooling System - Test for Combustion

Gases

Overflow Method
Warning: Wait until the temperature is below 50C [122Fj
before removing the coolant system pressure cap. Failure
to do so can cause personal injury from heated coolant
spray.
Allow the engine to cool, and remove the radiator cap.

Install a radiator pressure cap which has had the spring and
the pressure relief valve removed to allow free flow from the
overflow tube.
Attach a rubber hose to the radiator overflow
Put the free end of the hose
container of water.

below

The pressure cap must be tightly


radiator fill neck.

connection.

the water

sealed

level

in a

in the top of the

Section 1 - Cooling System


Page l-15
Operate the engine
at rated
temperature of 82C [18OF].

RPM

until

it

reaches

Check for air bubbles in the water container. A combustion


gas leak is present if a continuous flow of air bubbles is
present.

0a!?3

NOTE: The engine coolant temperature must be stable to


perform this test. An increasing coolant temperature will give
a false indication of air due to expansion of the coolant in
the system.

Combustion

Gas Test

Use Part No. 3822985 Combustion Gas Tester or equivalent


to test for combustion gasses in the cooling system.
NOTE: It is recommended that the cooling system contain a
premixture of 50 percent antifreeze and 50 percent water
during the combustion gas leak test. The use of water only
can result in a color change in the test fluid from blue to
turquoise
or light green during the test. This is not an
indication of a combustion gas leak.

Drain the coolant level down approximately


50 mm [2 inch]
below the radiator cap seal ledge in the radiator fill neck.

04B

Pour the test fluid into the combustion gas test instrument
until it is up to the yellow fill line on the instrument.

0@Y

Section 1 - Cooling System


Page 1116
Insert the rubber tip of the combustion gas leak test instrument
in the radiator fill neck. Hold the instrument down firmly and
turn back and forth to make sure that an air tight seal is
formed between the tester and radiator fill neck.

Start the engine and operate at high idle for approximately 30


minutes. Monitor the engine temperature and color of the test
fluid during engine operation.
Do not allow the engine
temperature to exceed 100C [212F] during the test.

If the color of the test fluid changes from blue to yellow


anytime during the test, combustion gasses are leaking into the
cooling system. Discontinue the test if the color of test fluid
changes from blue to yellow.
Color Change
from Blue to

\
1

00

l!

I I

----z-z-

If a color of the test fluid does not change from blue to yellow
during the 30 minutes test period, return the engine to low idle.

3
.

30 Minutes

i-8

L-7

Section 1 - Cooling System


rage 1-17
Check the test instrument to
sealed in the radiator fill neck.

make

sure that

it is firmly

043

Insert the tip of the rubber ball into the hole in the top of the
test Instrument. Squeeze the rubber ball 2 to 3 mrnutes to
draw air from the radiator through the test fluid.

@A
4~

If the color of the test fluid remains blue, combustion gasses


are not entering the cooling system. If the color of the test
fluid changes from blue to yellow, combustion
gasses are
entering the cooling
system and further investigation
is
required to determine the source of the combustion leak.

NOTE: As the cooling system warms up to operating


temperature, air will be expelled through the combustion gas
tester in the form of bubbles in the test fluid. This is due to
normal expansion
of the coolant.
Do not mistake the
presence of air bubbles in the tester as combustion gasses
or air leaks into the cooling system. A change in the color of
the test fluid from blue to yellow is the only indication of
combustion gas in the cooling system.

A positive result from the combustion


the following:
l

Cracked cylinder

Cylinder

leak tester

indicates

head.

head or gasket leakage.

NOTE: Discard the tester fluid if it has indicated positive.

0@3

0
OK

Blue

0a3

Section 1 - Coolinrr System


Page l-18
A negative result from the combustion leak tester coupled with
a continuous
flow of air bubbles from the previous test
indicates the following:
l

Air entrained
incorrect fill.

due

to

faulty

thermostat

ball

valve

or

Air in the coolant can result in loss from the overflow


when the aerated coolant is hot. The heated air expands,
increasing the pressure in the system causing the cap to
open.

Similarly, coolant can be displaced through the overflow if


the head gasket leaks compression gasses to the coolant
system.

The operating pressure of the cooling system and the


lubricating system can result in the mixing of the fluids if
there is a leak between the systems: head gasket, oil
cooler. Refer to the Lubricating Oil System.

Transmission fluid can also leak into the coolant


through bottom tank oil coolers.
NOTE: If the cooling system is contaminated with oil, it must
be cleaned and flushed. Refer to Procedure l-01.

Belt Tension
The pump is belt driven from the crankshaft
pulley. An
automatic belt tensioner is used to prevent the belt from
slipping on the pump pulley. A malfunction of the tensioner will
cause the water pump impeller to rotate at a slower speed
reducing the amount of coolant flow.

Section 1 - Cooling System


,

Page 1-19

Coolant Hose - Inspection


The coolant flow can also be reduced if the inlet hose to the
water pump collapses. A hose will usually not collapse while
the engine is running at low speed. Check the hose while the
engine is running at rated speed.
Be sure the engine is warm, a minimum
the thermostat is open.

of 88C [190 F], so

Water Pump - Inspection


The water pump pulls coolant from the bottom of the radiator
and pumps it through the engine back to the top of the
radiator for cooling.

0et3

A worn or malfunctioning
water pump will not produce the
flow required to prevent the engine from running
hot.
However, be sure to check the other possibilities indicated in
the Troubleshooting
Logic Chart before checking the flow or
replacing the pump.

Water Pump Seal Weep Hole

Inspection

The water pump seal design requires a coolant film for


lubrication and cooling. Therefore it is normal to observe a
minor chemical build up or streaking at the weep hole.
NOTE: A streak or chemical build up at the weep hole is not
justification for water pump replacement.
Use the following
guidelines
replacement is necessary:

to determine

if water

pump

Make sure the weep hole is open.


A small screwdriver
any debris.

or a similar tool can be used to remove

06B
0
6s

Section

1 - Cooling

System

Page 1120'
If no leakage is observed from the weep hole under operating
conditions, do not replace the water pump.

If coolant
Large Plastic
CUP

is observed to be dripping

from the weep hole:

Use Fleetguard@ coolant test kit, Part No. CC-2626, to


check the coolant inhibitor
level, and adjust the
inhibitor level per the test kit chart.
NOTE: Supplemental coolant additive concentrations exceeding
2.0 units per gallon will cause water pump seal leakage.

Bottle
@$-zzzq*
Syringe

Small Plastic
Container
Ol.803VU

Use Fleetguard@ refractometer, Part No. CC-2800, to


check the antifreeze level of the coolant.
NOTE: Ethylene glycol type antifreeze concentration exceeding
70 percent will adversely affect freeze point protection and will
contribute to water pump seal leakage.

If the antifreeze concentration is above 60 percent, drain all the


coolant and add make up water to bring the antifreeze
concentration to a minimum of 40 percent to a maximum of 60
percent. Replace the coolant filter, add new coolant inhibitor to
the recommended levels as outlined in the Chassis Operation
and Maintenance Manual.

Section 1 - Cooling System

Page 1-21

Caution: If the coolant leakage is observed as a steady


stream upon start-up, stop the engine immediately and
replace the water pump.
Operate the engine at high idle for 15 minutes with the
proper inhibitor and antifreeze levels and check the water
pump for leakage again.

If the coolant is leaking after the above checks, replace the


water pump. Refer to Procedure 147.

0
@I

0a9

Coolant Pressure - Measurement


The coolant pressure can be measured from the vent
petcock to help determine the condition of the pump. At
normal operating temperature (thermostats open) and engine
operating at 2,000 RPM, the pressure should be:
Pressure Cap

Minimum Pressure

103 kPa [ 15 psi]

124 kPa [18 psi]

48 kPa [ 7 psi]

69 kPa [lo psi]

Radiator, Fan and Shutters


Air forced through the fins of the radiator by a fan cools the
coolant pumped through the radiator. Environmental debris
(paper, straw, lint, dust, and bugs) can obstruct the fins and
stop the flow of air which will reduce the cooling affect of the
radiator.
Caution: Wear appropriate eye and face protection when
using compressed air. Improper use can cause bodily
injury from flying debris and dirt.
Use compressed air to blow out the dirt and debris.
Air Pressure: 550 kPa [80 psi]

06B

Section 1 - Coolina System

Page 1-2~

If the fan is belt driven, a slipping belt will result in a slower fan
speed and reduced cooling. A malfunctioning
automatic belt
tensioner can be the problem.

Check the bearings in the fan hub and other pulleys to

make sure they are not causing excessive belt vibration and
a!?f slippage.

04iB

Interruption of the circuit to an electrically driven fan can result


in insufficient air flow and cause the engine to run hot.
Make sure that the temperature sensor is functioning
correctly.

Some applications use thermatic fans. These fans operate only


as needed to keep the coolant at the correct temperature. If
the fan does not operate when the temperature of the air flow
through the radiator increases, the engine will run hot.

@
0

Make sure that the temperature sensor is functioning


correctly.

Shutters are designed to control air flow across the radiator. If


the shutters fail to open when needed, the engine can run hot.
Failure of the shutters to close can result in too much air flow
and the engine running cold.

@3

Make sure that the coolant temperature sensor is


functioning correctly. Check the air operated shutter
controls. Check for air leaks.

Section 1 - Cooling System


Page 1-23
A missing or incorrect fan shroud or obstructions
air flow and cause the engine to run hot.

can reduce

Check to be sure
missing baffles.

Check

Thermostat
The engine
the engine
Overheating

air

is not

recirculating.

for

043

OK

Operation and Testing

thermostats must operate properly in order for


to operate in the most efficient heat range.
or overcooling will shorten engine life.

The thermostats controls the coolant temperature. When the


coolant temperature
is below operating
temperature,
the
thermostats are closed, and coolant is bypassed to the water
pump inlet. As the coolant temperature
increases to the
intermediate range, both thermostats will start to open, and
coolant flow to the bypass will start to be restricted. At
engine operating temperature the thermostat will be open
and the bypass will be closed.

Caution: Never operate the engine without a thermostat. If


operated
without
a thermostat,
the
path
of least
resistance for the coolant is through the bypass to the
pump inlet. This will cause the engine to overheat.

Two identical thermostats are used. An incorrect, damaged,


or malfunctioning thermostat can cause the engine to run too
hot or too cold.

F@zzL-lb

0a3

If%!!

Section 1 - Coolinn

System

Page 1-24

Thermostat Leakage and Opening Temperature


- Testing In-Chassis
Warning: Complete this
temperature below 49C
serious personal injury.

test with the engine coolant


[12OF], hot steam can cause

Remove the radiator hose from the thermostat

housing.

Install a thermocouple or temperature gauge which is known to


be accurate in the 3/4-inch pipe plug located at the front of the
cylinder block.

Install a hose of the same size on the thermostat housing outlet


long enough to reach a remote dry container used to collect
coolant.
Install and tighten a hose clamp on the housing

outlet.

Insert the end of the hose in a dry container.

Operate the engine at rated speed for 1 minute.


Shut off the engine and
collected in the container.

measure

The amount of coolant collected


liter [5.1 fl. ounces].

the

amount

of coolant

must not be more than 0.15

Section 1 - Cooling System


Page l-25
If more than 0.15 liter [5.1 fl. ounces] of coolant is collected,
the thermostats are leaking and must be replaced. Refer to
Procedure l-08.

Complete the following


opening temperature.

test in-chassis

to test the thermostat

Start the engine and monitor the water temperature gauge


and the container. The thermostat initial opening temperature
is:
81 to 83C [178 to 182F]
Shut off the engine when the coolant starts to flow.
NOTE: If coolant does not start flowing into the container
during the initial opening temperature range, the thermostat
must be replaced. Refer to Procedure l-08.

Thermostat Opening Temperature - Testing


Thermostat Removed
Remove the thermostats
to Procedure l-08.

and clean the gasket surfaces. Refer

NOTE: Do not let any debris fall into the thermostat


when cleaning gasket surfaces.

Visually inspect the thermostats

for damage.

cavity

Section 1 - Coolina Svstem


Page l-26.
Suspend the thermostats and a 100C [212F] thermometer
a container of well stirred water.

NOTE: Do not allow the thermostats


the container.

or thermometer

Heat the water and check the thermostats

95C

[203F]

NOTE: The nominal


thermostat.

operating

temperature

in

to touch

as follows:

is stamped

on the

Thermostat
[18OF].

must begin to open within 1C [2F] of 82C

Thermostat
[203 F].

must be fully open within 1C [2F] of 95C

NOTE: The fully open clearance between the thermostat flow


valve and flange must be 41.5 mm [1.63 inches] minimum.

Temperature Gauge Operation


Gauges and sensors are used in the system to measure the
coolant temperature. These can malfunction and provide an
incorrect temperature indication.

Fuel Pump Ovetfueled


Over-fueling can cause the engine to overheat. Make sure that
the fuel pump is calibrated correctly. Refer to Procedure 5-01.

Section 1 - Cooling System

Vehicle Overloaded
Constant
hot.

overloading

(lugging)

can cause the engine to run

Drive Belt - Replacement


3/S or l/2

(I-03)

Inch Square Drive Ratchet

Lift the tensioner


belt.

arm and pulley

Belt Tensioner

to remove and install the

- Replacement

Preparatory Step:
Remove the drive belt.

Removal
15 mm
Remove the belt tensioner

from the bracket.

(I-04)

lo4c
(22OOF)

Section 1 - Cooling System

Page 1-28

Installation
15 mm
Install the belt tensioner.

Torque Value: 43 Nom [32 ft-lb]

Fan Pulley - Replacement (I-05)


Preparatory Step:
Remove the drive belt. Refer to Procedure
e

l-03.

SERVICE TIP: Loosen the capscrews before removing the belt

and torque the capscrews

after the belt is installed.

Removal and Installation


10 mm
Remove the four capscrews,

fan and spacer.

Install the fan pulley in the reverse order of removal.

Torque Value: 24 Nom [18 ft-lb]

Fan Hub - Replacement (I-06)


Preparatory Steps:
e

Remove the drive belt. Refer to Procedure

l-03.

Remove the fan pulley. Refer to Procedure

l-05.

Section 1 - Cooling System


Page 1-29

Removal and Installation


10 mm
Remove the four capscrews

Torque Value:

and replace the fan hub.

24 Nom [18 ft-lb]

Water Pump - Replacement (I-07)


Preparatory Steps:
Drain the coolant.

Refer to Procedure

l-01.

Remove the drive belt. Refer to Procedure

Removal
10 mm, 19 mm
Remove the alternator

link.

10 mm
Remove the water pump.

l-03.

Ezl

Section

1 - Cooling

System

Page l-30

Cleaning
Clean the sealing surface on the cylinder

block.

Installation
install a new o-ring into the groove in the water pump.

10 mm, 19 mm
Install the water pump and alternator
Torque

Value:

(Water Pump)

24 Nom

[18 ft-lb]

(Alternator

43 Nom

[32 ft-lb]

Lift the tensioner

fn9bima

link.

Link)

arm and pulley to install the drive belt.

Section 1 - Cooling System


Page 1-31
During filling, air must be vented from the engine coolant
passages. Open the engine vent petcock. Also, be sure to
open the petcock on the aftercooler for aftercooled engines.
The venting will permit a fill rate of 19 liters/minute
gallons/minute].

Close the drain valves. Install all hoses previously

[5 U.S.

removed.

Fill the cooling system with a premixture of 50 percent water


and 50 percent ethylene-glycol
type antifreeze. Since the
ability of antifreeze to remove heat from the engine is not as
good as water, pouring antifreeze into the engine first could
contribute to an over heated condition before the liquids are
completely mixed. Refer to Procedure l-01 for the correct
amount of DCA corrosion inhibitor.
Refer to the Cooling
capacities.

System Specifications

on page 1-5 for

Install the pressure cap. Operate the engine until it reaches a


temperature of 80C [180 F], and check for coolant leaks.

50%

WATER
ANTF&zE

50%

WATER
50%
ANTIFREEZE

Section 1 - Cooling System


Page l-32

Thermostat - Replacement (I-08)


Preparatory Steps:
Disconnect the negative battery cable. Refer to Procedure 6-01.
Drain 2 liters (2.1 U.S. quarts) of coolant.

Refer to Procedure

l-01.

Remove the radiator hose from the outlet connection.


Remove the drive belt. Refer to Procedure

l-03.

Removal
19 mm
Loosen the alternator
Loosen the
equipped.

tail

link capscrew.

support

capscrew

if the

alternator

is so

18 mm, 19 mm
Remove the alternator
alternator.

mounting

bolts and nuts.

Lower the

10 mm
Remove the capscrews from the thermostat housing and water
outlet connection. Remove the water outlet connection.

Section 1 - Cooling System

Remove the thermostat

housing

Page 1-33
and belt tensioner

assembly.

Cleaning
Caution:Do not let any debris fall into the thermostat
cavity when cleaning gasket surfaces.
Remove the thermostats

and clean the gasket surfaces.

Installation
Install the new thermostats.

Position a new gasket over the thermostats.

A
0
C%

Section 1 - Cooling System


Page 1-34
Position the thermostat housing
thermostats and gasket.

and belt tensioner

over the

Make sure the gasket is aligned with the capscrew holes. Install
the capscrews and use your fingers to tighten.

10 mm
Install the water outlet connection.
Tighten all capscrews.
Torque Value:

24 Nom [18 ft-lb]

18 mm, 19 mm

Position the alternator

and install the mounting

bolts and nuts.

Torque Value:
(Alternator Mounting)

77 Nom

[57 ft-lb]

(Alternator

43 Nom

[32 ft-lb]

Link)

Section 1 - Cooling System


Page 1-35
Install the drive belt.

fn9blma

Install and tighten the battery electrical connectors.

Caution: During filling, air must be vented from the


engine coolant passages. Open the engine vent petcock if
equipped. Also, be sure to open the petcock on the
aftercooler for aftercooled engines. The system must be
filled slowly to prevent air locks. Wait 2 to 3 minutes to
allow air to be vented, then add coolant to bring the level
to the bottom of the radiator filler neck.
Fill the cooling system. Refer to Procedure l-01.

Operate the engine to normal operating temperature and


check for leaks.

Section 2 - Lubricating Oil System


Page 2-l

Section 2 - Lubricating Oil System


Section Contents
Page
2-11
2-11
2-11

Internal Engine Damage - Checking


.............................................
Lubricating Oil Analysis ......................................................
Lubricating Oil Filter Inspection
................................................
Lubricating Oil Cooler Element and Gasket - Replacement
Cleaning and Inspection .....................................................
Installation ..............................................................
Removal ................................................................
Lubricating

Oil Dipstick - Calibration

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

2-28
2-29
2-30
2-28
2-25

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

.......................................
Lubricating Oil Dipstick Tube - Replacement
Installation ..............................................................
Removal ................................................................

2-26
2-26
2-26

Lubricating

Oil Filter - Changing

2-24

Lubricating

Oil Leaks (External) - Checking

Lubricating

Oil Level - Checking

Lubricating

Oil Pan - Draining

Lubricating

Oil Pan - Filling

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

2-10

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

2-23

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

2-22

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

2-22

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

Lubricating Oil Pan, Suction Tube and Gasket - Replacement


..............................................................
Cleaning..
Oil Pan - Installation ........................................................
Oil Pan - Removal .........................................................
..................................................
Suction Tube - Replacement

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

Lubricating Oil Pressure Regulator, Valve and Spring - Replacement


Cleaning and Inspection .................................
Removal ............................................
Installation ..........................................
.........................
Lubricating Oil Pump - Replacement
.................................
Cleaning and Inspection
..........................................
Installation
Removal ............................................

Lubricating Oil System - Diagnosing Malfunctions


Aftercooler ..........................................
Bearings and Oil Pump ..................................
Coolant Diluted Oil .....................................
Cracked Cylinder Block ..................................
Cracked Cylinder Head ..................................
Cracked Cylinder Liner ..................................
Cylinder Head Expansion Plugs ............................
Cylinder Head Gasket ...................................
Cylinder Liner Seals ....................................
Fuel Diluted Oil .......................................
Fuel Leaking by Piston Rings ..............................
Fuel Transfer Pump ....................................
.....................................
High Oil Pressure
Injection Pump .......................................

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

. .

2-33
2-33
2-34
2-33
2-34

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

2-27
2-27
2-27
2-28

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

2-35
2-36
2-39
2-36

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

2-12
2-16
2-15
2-15
2-18
2-l 7
2-18
2-l 7
2-17
2-l 7
2-l 8
2-19
2-l 9
2-12
2-20

Section

2 - Lubricating

Oil System

Page 2-2
Low Oil Pressure ..........................................................
Oil Cooler ...............................................................
Oil Dilution ..............................................................
Oil Filter..
..............................................................
Oil Leaks ...............................................................
OilLevel................................................................2-1
................................................
Oil Pressure Gauge - Checking
Oil Pressure Regulating Valve .................................................
Oil Suction Tube ..........................................................
Oil Temperature Gauge - Checking ..............................................
Oil Temperature Thermostat ...................................................
...........................................

Lubricating

Oil System

- Flow Diagram

Lubricating

Oil System

- General

Information

Lubricating

Oil System

- Service

Tools

Lubricating

Oil System

- Specifications

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

2-12
2-16
2-15
2-13
2-20
2
2-13
2-12
2-15
2-14
2-14
2-6
2-4

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

2-3

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

2-5

Lubricating
Oil Temperature
Thermostat - Replacement
Inspection ...............................................................
Installation
..............................................................
Removal ................................................................

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

2-31
2-32
2-33
2-31

Section 2 - Lubricating Oil System


Page 2-3

Lubricating Oil System - Service Tools

The following special tools are recommended to perform procedures in Section 02. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tnnl

Nrr

Used to remove and install the lubricating

oil filters.

Measures spring force at a given spring height.

Used to open the full-flow

oil filter for filter element inspection.

Used to pressure test the lubricating

oil cooler element.

Section 2 - Lubricating Oil System

Lubricating Oil System - General Information


Use 15W-40 multi-viscosity
Classification

oil or equivalent
CE for turbocharged engines.

NOTE: CC/CD or CD/SF engine


where CE oil is not yet available;
must be reduced by 50 percent.

which

meets API

oils can be used in areas


however, the drain interval

p1800gb

'C -40-30-20-10
'F -40

All

-22

-4

10

20

30

14

32

50

66

66

10

20

30

40

14

32

50

66

86

104 122

40

50

104 122

Seasons

Winter

Conditions

Arctic Conditions

'C

-40

OF -40

-30-20-10
-22

-4

50

oi90Oda

Caution: Limited use of low viscosity oils, such as low-30


may be used to aid in starting the engine and providing
sufficient oil flow at ambient temperatures below -5C
[23F]. However, continuous use of low viscosity oils can
decrease engine
life due to wear. Refer to the
accompanying chart.

Section 2 - Lubricating Oil System


Page 2-5

Lubricating Oil System - Specifications


Oil Pressure - Low Idle (Minimum Allowable) ......................................
At Rated Speed (Minimum Allowable)

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

69 kPa [lo psi]

207 kPa [30 psi]

Differential Pressure to Open Oil Filter Bypass Valve .................................

138 kPa [20 psi]

Oil Flow at Rated Speed (Less Flow Through Pressure Regulator) .......................

57 Ipm [16 gpm]

Oil Temperature at Rated Speed ...................................

99 to 126.6 C [210 to 260 F]

Oil Capacity of Pan (All Engines):


- Low Level ....................................................

15.1 liters [16.0 U.S. Qts.]

- High Level ...................................................

18.9 liters [20.0 U.S. Qts.]

Total System Capacity


6D114E-1 .....................................................

23.6 liters 125.0 U.S. Qts.]

S6D114E-1 ....................................................

23.8 liters [25.2 U.S. Qts.]

Section 2 - Lubricating Oil Svstem


Page 2-6

Lubricating Oil System - Flow Diagram


The lubricating oil flow begins as the gerotor pump draws oil from the pan through the rigid, internal suction tube. The
pump then delivers the oil through an internal drilling in the cylinder block to the top of the oil cooler via the inner
channels of the cover. When the oil reaches the top of the oil cooler, it flows by the thermostat before entering the oil
cooler. If the oil is cold, the thermostat will open allowing some oil to bypass the cooler and flow to the filter. As the
temperature of the oil increases, the thermostat will close and force the oil to flow through the cooler element, thereby
regulating the oil temperature to the block. Coolant passing around the plates of the element cools the oil. From the
cooler, the oil is directed to the combination full flow/bypass oil filter and also to the pressure regulator. The regulator
valve remains closed until the oil pressure is approximately 518 kPa 175 psi]. At high pressure, the plunger moves toward
the plug and relieves the system by allowing some oil to return to the oil pan. The tapered shoulder on the plunger
creates a variable opening to regulate pressure. A combination full flow/bypass oil filter is used. The upper section of the
filter contains the full flow filter element while the lower section contains the bypass element. Oil which flows through the
full flow portion of the oil filter returns to the block. Oil that flows through the bypass returns to the oil pan. During normal
engine operation, oil circulates through the full flow section of the combination filter and into the main oil rifle. If the full
flow section of the combination filter becomes plugged to the point that a 137 kPa [20 psi] pressure difference exists
across the filter, the bypass valve opens in the oil filter head and routes unfiltered oil to the main oil rifle. This is done
to prevent oil starvation to the engine with a plugged filter.

Lubricating Oil System


Lubricating Oil Cooler;
Combination Full Flow
and Bypass Filter

Bypass Filter

2. To Oil Cooler
3. From Oil Cooler
5. From Filter
6. Filter Bypass Valv
7. To Main Oil Rifle
8. To Pan

Pressure Regulating
Valve

Filter Bypass Valve

Trermostat

Section 2 - Lubricating Oil System

Pai; 2-7

Lubricating Oil System Flow (Continued)


At the filter head, the oil flow is divided: A portion flows to the turbocharger;
block that connects to a cross drilling over the No. 3 main bearing.

the rest flows down a passage in the cylinder

Lubrication for Turbocharger

1. Filter

2. Turbocharger Supply
3. To Main Oil Rifle
4. Turbocharger Oil Drain

Section 2 - Lubricating Oil System


Page 2-8

Lubricating Oil System - Flow Diagram(Continued)


The oil has been cooled and filtered, it flows through the cross drilling over the No. 3 main bearing to the main oil rifle.
The main oil rifle is drilled through the length of the cylinder block and carries oil through individual drillings to the
overhead and lower end of the block. A transfer drilling from the main oil rifle intersects with a drilling between the main
bearing bore and the camshaft bushing bore. These drillings supply oil to the cam bushing and main bearing. The groove
in the upper main bearing shell supplies oil to the piston cooling nozzles located in the main bearing saddle. The spray
from the nozzle splash lubricates the piston pin. From the main bearings, the oil enters the crankshaft and lubricates the
connecting rod bearings through internal cross drillings.
Drillings in the cylinder block and gear housing connect to the external groove on the No. 1 camshaft bushing to supply
oil to the injection pump. An overflow hole located above the injection pump shaft allows oil to return to the oil pan.

Lubrication for the Power Components

1. From Oil Cooler


2. Main Oil Rifle
3. To Injection Pump
4. To Overhead
5. Injection Pump Drain
6. Crankshaft Main Journal
7. Rod Journal
8. To Carp Bore
9. Piston Cooling Nozzle

Section 2 - Lubricating Oil System


Page 2-9

Lubricating Oil System - Flow Diagram(Continued)


Oil for the overhead components is supplied by a vertical drilling through the cylinder head and block
external groove on the No. 7 camshaft bushing. The main oil rifle supplies oil to the camshaft bushing.
vertical drilling to an angle drilling in the cylinder head. From the angle drilling the oil flows through the
rocker lever supports are installed over the transfer tube. From a hole in the transfer tube the oil is
rocker lever support capscrews by the relieved area in the base of the support.

that intersects
Oil flows from
transfer tube.
transferred to

the
the
The
the

Oil flows around the capscrews up to the rocker lever shaft. Oil flows into the inside diameter of the shaft and along its
length. The ends of the shaft are sealed by cup plugs. Drillings in the shaft allow the oil to flow from the inside diameter
to the bores of the rocker levers. The rocker lever has a drilling that transfers oil from the bore to a trough on the top
of the lever. Oil flows along the trough to lubricate the push rod socket and the valve stem.
The front gear train assembly is lubricated from oil splash and carry-over. The oil pump idler gear is force lubricated.
the gear train assembly the oil drains back to the oil pan for recirculation.

Lubrication for the Overhead

1. Main Oil Rifle


2. No. 7 Cam Bushing
3. From No. 7 Cam Bore
4. Rocker Lever Support
5. Oil Transfer Tube
6. Rocker Lever Shaft
7. Rocker Lever
8. Oil Trough
9. Valve Cover

From

Section 2 - Lubricating Oil System


Page 2-10

Lubricating Oil Leaks (External) Checking (2-01)


The first step in diagnosing excessive lube oil consumption is
to verify that there are no external oil leaks.

\
Li

4B

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam can
cause serious personal injury.
Use a steam cleaner or high pressure washer to clean the
engine. Dry with compressed air.

Operate the engine until the coolant temperature reaches 82C


[180 F]. Inspect the exterior of the engine for leaking gaskets,
seals, o-rings, pipe plugs, or fiiings.
NOTE: Before replacing any gaskets, check the capscrews to
make sure they are tightened to the correct torque values.
Refer to Section V for capscrew torque specifications.

4B

Check the engine crankcase breather tube and hose for


restriction.
Refer to Procedure 7-83 for removal.
Use a solvent to clean the
compressed air.

a3

hose and tube.

Dry with

Check for a loose or missing oil dipstick tube, dipstick, or oil


fill cap.

Section 2 - Lubricating

Oil Svstem

Lubricating Oil System - Diagnosing


Malfunctions (2-03)
Be sure to check items related to oil pressure, such as:
gauges, high and low oil level, excessive oil contamination and
oil viscosity.

High Oil Pressure


High oil pressure
in cold weather.
start relief valve.
machined to a
created by cold

0a3

0a9

usually occurs after the engine is first started


The lubrication system does not have a cold
The pressure regulating valve components are
size that will relieve the excessive pressure
engine oil.

Oil Pressure Regulating Valve


The engine will have high oil pressure if the regulator sticks in
the closed position. Check the regulator for freedom of
movement.

Low Oil Pressure


Low oil pressure can be caused by several lubrication system
related malfunctions. To begin the investigation, determine the
engine operating conditions when the low pressure was first
observed.

Oil Level

0a!?

Low oil level can cause low oil pressure.


za;r

operate the engine with the oil level below the low (L)
.

Section 2 - Lubricating

Oil System
Page 2-13

Oil Filter

Filter Bypass Valve

A plugged filter will cause a gradual loss of oil pressure by


approximatelv
69 kPa 110 PSIl. This will cause the bvoass
v&e to open, allowing unfiltered oil to flow to internal eigine
components.
The oil pressure will remain low until a new
filter is installed.

Valve
Closed

Valve
Open

Oil Pressure Gauge - Checking

gage.

Check the oil gauge and sending unit to make sure they are
operating correctly by verifying the pressure with a manual

Check the following

Electrical wiring broken

Sending

Plumbing

unit malfunction
loose or broken

If a sending unit malfunction

0
l

for defects:

is found:

Use a master gauge of known accuracy


reading of the suspect gauge.

to verify the

Connect the line from the master gauge to the main oil
rifle on the fuel pump side of the engine.
Replace the sending

unit if it is defective.

@
@

0
@

Section 2 - Lubricating Oil System


Page 2-14

Oil Temperature

Gauge - Checking

Remove the pipe plug from the bottom of the oil cooler and
install the oil temperature gauge sending unit.
The maximum oil temperature
[260 F].

Check the following

for defects:

Electrical wiring broken

Sending

If a sending

at rated engine speed is 126.6C

unit malfunction

unit malfunction

is found:

Use a master gauge of known


reading of the suspect gauge.

Replace the sending

Oil Temperature

accuracy

to verify

the

unit if it is defective.

Thermostat

NOTE: The oil temperature thermostat cannot be checked


in-chassis, it must be removed for testing. Refer to Procedure
2-l 2.

Section 2 - Lubricating Oil System


Page 2-15

Oil Suction Tube


A loose suction tube, damaged gasket or crack in the
suction tube can cause a temporary loss of prime for the oil
pump. The engine will have low pressure or no oil pressure
at starting, followed by normal or low oil pressure.

Bearings and Oil Pump


A steady decrease in oil pressure over a long period of time
can be an indication of worn bearings or excessive oil pump
wear. Refer to Procedure 2-02 to check for internal engine
damage.

Oil Dilution

0 0

Check the condition

of the oil.

Thin, black oil is an indication

Milky discoloration

of fuel in the oil.

is an indication

of coolant in the oil.

(Thin Black)

Coolant Diluted Oil


Coolant in the oil results from a crack or leak between the
coolant and oil circuits.
The
possibility
components:

for

0
0
H*O & Oil

Fuel & Oil

Diluted oil can cause severe engine damage

intermixing

can

Oil cooler
Aftercooler
Core plugs in cylinder head
Cylinder liner seals
Head gasket
Cylinder liner (crack)
Cylinder head (cracked passage)
Cylinder block (cracked passage)
Air compressor (coolant cooled)

occur

in

these

Good Oil

Water In Oil
(Milk Color)

Section 2 - Lubricating

Oil System

The oil cooler design does not require gaskets


maintain the separation of oil and coolant.

or seals to

Page 2-16

Oil Cooler

If either the coolant or oil is contaminated,


element. Refer to the checking procedure

a3

043

check for a leaking


in this section.

During operation the oil pressure will be higher than coolant


pressure. A leak in the oil cooler will show as oil in the coolant.
However, following an engine shutdown, the residual pressure
in the coolant system can cause coolant to seep through the
leak path into the oil.

Aftercooler
An aftercooler
lubricating oil.

is also a source

Remove the aftercooler


the intake manifold.

for coolant

to get in the

and look for evidence

of leaking into

Plug the bottom inlet tube and pressurize the aftercooler with
348 kPa [50 psi] to check for leaks by submerging in water.

Section 2 - Lubricating Oil System


Page 2-17

Cylinder Head Expansion Plugs


The expansion plugs in the cylinder head under the valve
cover is another potential for oil dilution.
If possible, check for the leaks while the engine
remove the valve cover to look for signs of leaks.
It may be necessary
kPa [20 psi].

to pressurize

the coolant

is warm,

0
@r

system to 140

Cylinder Liner Seals


Coolant can enter the lubricating
damaged liner seal.

oil through

a deteriorated

Remove the oil pan and visually inspect the bottom


liners with the cooling system pressurized.

or

side of

0
@I

Cylinder Head Gasket


Coolant in the oil can also be caused by a damaged
head gasket.

cylinder

Pressurize the cooling system to check for leaks. It may be


necessary to remove the oil Dan to locate internal leaks.

Refer to Procedure 2-13.

0
@

Cracked Cylinder Head


A crack in the head from the water jacket to an oil passage
or to the top rocker lever area will cause oil dilution.
Pressurize the cooling
for leaks.

system to 140 kPa [20 psi] and check

0
@

Section 2 - Lubricating

Oil System

Page 2-18

04B

Cracked Cylinder Liner


A cracked cylinder liner can leak coolant into the lubricating oil.
Remove oil pan and look for coolant leaking from inside of liner
bore.
Air compressor leaks will produce the same symptoms, be sure
to perform Procedure 4-02 before concluding the leak is from
the cylinder liner.

Cracked Cylinder Block

0ai!3

A crack in the cylinder block from an oil drilling or passage to


the water jacket can cause oil dilution, and can normally be
found either as an external leak from a gasket, i.e. head gasket,
or from the oil pickup tube with the oil pan off.
The cooling system should be pressurized
to detect leaks.

Fuel Diluted Oil


Fuel dilution

is limited to three sources:

1. Fuel transfer pump


2. Fuel leaking by the rings
3. Injection

pump internal wear

to 140 kPa [20 psi]

Section 2 - Lubricating Oil System

Use the following

Page 2-19

logic to determine the source of the oil dilution

with fuel:

Power Normal

Verify the Rings are


Check/Replace

the

Sealing by Performing

Injectors

Compression
I

Fuel Transfer Pump


A worn or damaged seal around
to leak to the oil pan.

the plunger

can allow fuel

Fuel Leaking by Piston Rings


Incomplete
combustion
in the cylinders
unburned fuel draining into the oil pan.

Check

can

This condition
can be caused by a leaking
reduced compression
caused by inadequate
sealing.

result

in

injector or
piston ring

Section 2 - Lubricating Oil System


Page 2-20
An increase in white exhaust smoke during the first start of the
day is a symptom of an injector leaking.
An injector leak will also cause the engine to run rough and
have low power.
Remove and replace leaking injectors. Refer to Procedure 5-07.
Refer to the Shop Manual, for test and repair instructions.

Perform a compression check to verify piston rings are properly


sealing. Refer to Procedure 7-01.

Injection Pump
A worn or damaged injection pump can allow fuel to leak into
the lubricating oil as it passes through the pump.

Oil Leaks
Various gaskets, seals and plugs are used to contain the oil.
Most leaks can be identified during routine inspection of the
engine and vehicle.

Section 2 - Lubricating Oil System


Page 2-2i
A damaged rocker assembly oil manifold or blown expansion
plug can allow a large quantity of oil to escape resulting in a
sudden drop in the oil pressure.

If the oil cooler element ruptures, the oil pressure will force
oil into the cooling system. Oil in the coolant should be
visible when the radiator cap is removed. As the oil is forced
into the cooling system, coolant will be displaced through the
radiator overflow.

@B

Part No. 3823876 Lubricating Oil Cooler Pressure Test Kit


Leaks can be verified by pressure testing the oil cooler
element. Apply 483 kPa [70 psi] air pressure to the element
to check for leaks.

High intake air restriction and worn or damaged seals in the


turbocharger can also allow oil to leak into the air crossover
pipe and be burned in the engine. This condition can be
verified by removing the air crossover tube and looking for
oil.

06iB

/
sa

Section 2 - Lubricating Oil System


Page 2-22
inadequate sealing of the piston rings will result in combustion
gas and oil droplets being blown out the crankcase breather
tube and/or consumed by the engine. Refer to Procedure 8-01
for measuring crankcase gases (blowby).

4B

Oil can also be lost through a worn or malfunctioning


air
compressor. Look for carbon build up in the air line from the
compressor to the air tank and look for oil when draining the
tank. Refer to Compressed Air Section for additional diagnostic
procedures.

Lubricating Oil Pan - Draining (2-04)


17 mm
Warning: Hot oil can cause serious personal injury.
Warning: Avoid prolonged and repeated skin contact with
used engine oils. Such prolonged and repeated contact can
cause serious skin disorders or other bodily injury.
Operate the engine until the coolant temperature reaches 60C
[14OF]. Shut off the engine. Remove the oil drain plug. Drain
the oil immediately to make sure all the oil and suspended
contaminates are removed from the engine.
NOTE: Use a container
Qts.] of oil.

that will hold at least 22 liters [23 U.S.

Lubricating Oil Pan - Filling (2-05)


17 mm
Clean and check the oil drain plug threads and sealing surface.
Install the oil pan drain plug.

Torque Value: 80 Nom 159 ft-lb]

Section 2 - Lubricating Oil System

Page 2-23

NOTE: Use a high quality 15W-40 multi-viscosity oil. Choose


the correct oil for your operating climate as outlined in the e
appropriate Chassis Operation and Maintenance Manual.
l

Turbocharged engines

CE/SG

Naturally aspirated engines

CC/CD/SG

Lubricating Oil Level - Checking (2-06)


Fill the engine with clean oil to the proper level.
NOTE: When filling the oil pan, use the fill tube on the side
of the engine rather than on top of the valve cover.
Refer to Lubricating Oil System Specifications, page 2-5 for e
capacities.

Idle the engine to inspect for leaks at the drain plug.

Shut off the engine. Waft approximately 5 minutes to let the


oil drain from the upper parts of the engine. Check the level
again.
Add oil as necessary to bring the oil level to the H (High)
mark on the dipstick.

+B
01

iI

hf iii

Section 2 - Lubricating Oil System


Page 2-24

Lubricating Oil Filter - Changing (2-07)


Part No. 3375049 Filter Wrench
Use oil filter wrench,

Part No. 3375049, to remove the filter.

Clean the area around the lubricating oil filter head. Remove
the filter. Clean the gasket surface of the filter head.

Use clean 15W-40 oil to coat the gasket surface of the filter.
Fill the filter with clean 15W-40 oil.

Part No. 3375049 Oil Filter Wrench


Install the filter on the oil filter head. Tighten the filter until the
gasket contacts the filter head surface.
Use oil filter wrench, Part No. 3375049, to tighten the filter an
additional three-fourths to one turn, or follow the instructions
supplied with the filter.

Operate the engine and check for leaks.

Section 2 - Lubricating Oil System

Page 2-25

Lubricating Oil Dipstick - Calibration


(2-08)
Install the dipstick

in the dipstick tube housing.

Use clean 15W-40 oil to fill the oil pan to the specjfied low
oil level. Refer to Lubricating Oil System Specificatrons, page
2-5, for engine oil capacity.

Caution: The dipstick will break if the scribe mark is too


deep.

Remove the dipstick and scribe a mark across the dipstick


and mark the low oil level with an I.

0
C%

NOTE: If a new blank dipstick is being used, cut the dipstick


off approximately 38 mm [1.5 inch] below the low oil level
mark.

Install the dipstick

into the dipstick tube housing.

Fill the oil pan to the specified high oil level. Refer to
Lubricating Oil System Specifications, page 2-5, for engrne 011
.e
capacity.

Remove the dipstick and scribe a mark across the dipstick


and mark the high oil level with an H.

Section

2 - Lubricating

Oil System

Page 2-26

Lubricating Oil Dipstick


Replacement
(2-09)

Tube -

Removal
Clean the area around the dipstick tube before removing
prevent debris from entering the oil system.

to

Remove dipstick from the dipstick tube.


Remove dipstick tube from the cylinder

block.

Service Tip: Use a dent puller and a M8 X 1.25 X 21mm


self-tapping capscrew. Thread the capscrew into the dipstick
tube and remove the tube.

Installation
Apply a thin bead of LoctiteTM No. 277 around
the knurled end of the tube.

Place knurled end of tube into the dipstick


cylinder block.

the bottom of

tube bore in the

Use a flat washer and hex head capscrew to drive the tube into
the cylinder block.
Lightly drive the dipstick
casting.

tube until it seats against the block

Section 2 - Lubricating Oil System


Page 2-27
Install dipstick

into the dipstick tube.

Lubricating Oil Pressure Regulator, Valve


and Spring - Replacement (240)
Preparatory Steps:
Clean debris.

Removal
22 mm
Remove the plug and regulator valve.

Cleaning and Inspection


Clean and
assembly.

inspect

the

bore

and

regulator

The valve must move freely in the bore.

valve

before

q
\

0@

Section 2 - Lubricating Oil System


Page 2-28.

Installation
22 mm
Install the regulator and spring.

Torque Value: 80 Nom 159 ft-lb]

Lubricating Oil Cooler Element and


Gasket - Replacement (2-11)
Preparatory Steps:
Drain the coolant.

Refer to Procedure

l-01.

Remove the oil filter. Refer to Procedure

2-07.

Removal
Clean all debris from around the oil cooler.

18 mm
Disconnect
head.

the turbocharger

oil supply

line from the oil filter

Section 2 - Lubricating Oil System

Page 2-29

10 mm
.l
NOTE: Due to the design
of the present
production
lubricating oil cooler cover, there is approximately
0.7 liter
to.75 U.S. Qts.] oil that does not drain when the system is
drained. Place a container under the cooler to catch the oil
when the cover is removed.
Remove the oil cooler cover, element and gaskets.

32 mm
Remove the oil temperature
2-12.

thermostat.

Refer to Procedure

Cleaning and Inspection


Clean the sealing surfaces.

Pressure Test
Part No. 3823876 Lubricating

Oil Cooler

Pressure

Test Kit

Apply 483 kPa [70 PSI] air pressure to the element to check
for leaks.

0a!3

Section 2 - Lubricating Oil System


Page 2-30
Installation
10 mm

Assemble the oil cooler gasket, element, cooler cover gasket,


oil temperature thermostat and cooler cover to the cylinder
block.
Install the filter head and gasket if removed.
NOTE: Be sure to remove the shipping plugs from the new
cooler element.
Torque Value:
Oil Cooler Cover Capscrews 24 Nom [18 ft-lb]
l
Oil Filter Head Capscrews 24 Nom (18 ft-lb]
l

16 mm
Connect the turbocharger oil supply line.
Torque Value: 17 Nom [13 ft-lb]

32 mm
Install the lubricating oil temperature thermostat.
Torque Value: 50 Nom [37 ft-lb]

NOTE: Fill the filters with clean lubricating oil before installation.
Install a new oil filter.
Follow the manufacturers

instructions

for tightening.

Section 2 - Lubricating Oil System


Page 2-31
NOTE: Be sure to open the engine and aftercooler vents to
allow air to escape as the system is filled. Refer to Procedure
l-01.
Fill the cooling

system.

Operate the engine to check for leaks.

Shut off the engine and check the oil and coolant level.

Lubricating Oil Temperature Thermostat Replacement (2-12)


Removal
32 mm
Remove the oil temperature

thermostat.

Section 2 - Lubricating

Oil System

Page 2-32

0a3

Inspection
Visually inspect for a damaged
damage.

o ring, broken spring or other

Caution:
The flash point of new lubricating
oil is
approximately 221C [43OF]. Do not allow oil temperature
in the container to exceed 150C [3OOF]. Do not allow
water droplets to enter the container of hot oil. Water
droplets will cause a violent reaction which can cause
personal injury.

Suspend the valve and a 116C [240 F] thermometer in a


container of new lubricating oil. Do not allow the valve or the
thermometer to touch the sides of the container.
Heat the lubricating

et9

oil.

NOTE: Write down the temperature at which the thermostat is


fully extended. The thermostat must be fully extended to at
least 45.9 mm [1.80 inch] when the temperature reaches 116C
[240 F].
Replace the thermostat

4
45.9 mm
[1.80 in]
+

if it does not operate as described.

Section 2 - Lubricating Oil System

Installation
32 mm
Install the oil temperature

Torque Value:

thermostat.

50 Nom [37 ft-lb]

Lubricating Oil Pan, Suction Tube and


Gasket - Replacement (2-13)
17 mm

Remove the oil pan drain plug to drain the oil.

Oil Pan - Removal


10 mm

Remove the oil pan.

Cleaning
Clean the sealing surface.

Section 2 - Lubricating Oil System


Page 234

Suction Tube - Replacement


8 mm
Remove the suction tube and gasket.
Clean the sealing surface.

Position the lubricating oil suction tube gasket onto the cylinder
block.
Make sure the gasket is correctly installed and does not block
the hole for oil passage.

8 mm
Install the lubricating oil suction tube over the gasket and align
the mounting holes.
Use the following sequence to tighten the capscrews:
Torque Value:
Step A Suction tube to Block
Step B Brace to Block
Step C Brace to Suction Tube

9 Nom [80 in-lb]


9 Nom [80 in-lb]
9 Nom [80 in-lb]

Oil Pan - Installation


Be sure to fill the joints between the pan rail, gear housing and
rear cover with Three Bond RTV sealant, Part No. 3823494.
NOTE: The lubricating oil pan should be assembled and the
capscrews torqued within 15 minutes after applying the sealant.

Section 2 - Lubricating Oil System

Apply a 2 mm [l/16 inch] bead of Three Bond Sealant, Part


No. 3823494, to both sides of the new lubricating pan gasket.
Install the gasket.
Install the lubricating oil pan.

10 mm
Assemble the washers and capscrews to secure the lubricatin
oil pan as illustrated.

21 17 13

7 11

15 19 23

Tighten all capscrews in the sequence shown to the right.

25

29

Torque Value: 24 Nom [18 ft-lb]

27

31

26

32
30

26

0(T

22 16 14 10

12 16

20

24

Tmoo6

The rest of this page is blank.

Section 2 - Lubricating Oil System

Page 2-35

17 mm
Install the oil pan drain plug.

Torque Value:

80 Nom 159 ft-lb]

Fill the oil pan with clean 15W-40 engine oil.


Operate the engine and check for leaks.

Shut off the engine and check the oil level with the dipstick.

Lubricating Oil Pump - Replacement


(2-14)
Preparatory Step:
Remove the drive belt. Refer to Procedure

l-03.

06iB

0623

Section 2 - Lubricating

Oil System

Page 2-36

Removal
16 mm, Part No. 3377371,

Engine Barring Tool

Remove the vibration damper. Use the barring tool, Part No.
3377371, to keep the crankshaft from rotating.
Refer to Procedure

7-l 6.

10 mm
Remove gear cover cap/tachometer

drive adapter assembly.

Remove the gear cover. Refer to Procedure

7-17.

bp9OOm.a

10 mm
Remove the four lubricating

oil pump mounting

capscrews.

Cleaning and Inspection


Visually inspect the lubricating
or excessive wear.

oil pump gears for chips, cracks,

NOTE: Parts replacement is not practical if any of the internal


parts are worn beyond the specifications, the pump should be
replaced.

Section 2 - Lubricating Oil System


Page 2-37
Remove the back plate.

Mark TOP on the gerotor planetary.

Remove the gerotor planetary.


inspect for excessive wear or damage.

Clean all parts in solvent and dry with compressed

air.

Section 2 - Lubricating Oil System


Page 2-38

0623

inspect the pump housing and gerotor drive for damage wear.

@@#
@

Install the gerotor planetary.


Be sure
position.

the

gerotor

planetary

is installed

in the

original

@3

Oil Pump Gerotor Tip Clearance


mm

in

0.025

MIN

0.001

0.1778

MAX

0.007

Oil Pump Gerotor Drive/Gerotor Planetary to


Port Plate Clearance
mm

in

0.025

MIN

0.001

0.127

MAX

0.005

Section

2 - Lubricating

Oil System
Page 2-39

Oil Pump Gerotor

Planetary

to Body Bore

mm

in

0.127

MIN

0.005

0.381

MAX

0.015

Oil Pump Drive Gear Backlash

(Used Pump)

mm
0.08

in
MIN

0.003
0.013

Install the back plate.

Installation
Lubricate the pump with clean 15W-40 engine oil.
NOTE: Fill the pump with oil during installation
quicker oil suction when the engine is started.

to aid in

Section 2 - Lubricating Oil System


Page 2-40
Install the pump.
Make sure the idler gear pin is installed in the locating bore in
the cylinder block.

10mm
Tighten in the sequence shown.
Torque Value:
Step 1 5 Nom [44 in-lb]
Step 2 24 Nom [18 ft-lb]

The back plate on the pump seats against the bottom of the
bore in the cylinder block. When the pump is correctly
installed, the flange on the pump will not touch the cylinder
block.

Use a dial indicator with a magnetic base to measure the idler


gear backlash.
NOTE: Do not allow the mating gears to rotate while
measuring the backlash.
Oil Pump Idler Gear Backlash (A & B)
mm

in

0.08

MIN

0.003

0.33

MAX

0.013

Section 2 - Lubricating Oil System


Page 24
Lubricate the front gear train with clean 15W-40 engine oil.

Thoroughly clean the front seal area of the crankshaft.


If the contact area has a groove worn deep enough to feel
with a fingernail or sharp object, it will be necessary to install
a wear sleeve over the sealing surface.
NOTE: The seal lip and the sealing surface on the crankshaft
must be free from all oil residue to prevent seal leaks.

Use sealant, Part No. 3823494, on both sides of the front


cover gasket
Install the front cover and gasket.
Refer to Procedure 7-17.
Install the capscrews.
Torque Value: 24 Nom [18 ft-lb]
NOTE: Torque the
applying the sealant.

Install the
assembly.

gear

capscrews

cover

within

cap/tachometer

15 minutes

drive

after

adapter

Section 2 - Lubricating Oil System


Page 2-42
Install the vibration damper. Do not tighten the capscrews to
the correct torque value at this time. Refer to Procedure 7-16.

l/2

inch or 3/8 inch Square

Raise the belt tensioner

Drive

to install the belt.

18 mm, Part No. 3377371 Engine Barring Tool

Use engine barring tool, Part No. 3377371,


crankshaft when tightening the capscrews.
Use a star pattern torque sequence.
Torque

Value: 200 Nom [148 ft-lb]

to

hold

the

Section 3 - Combustion Air System


Page 3-l

Section 3 - Combustion Air System


Section Contents
Page
Aftercooler and Gasket - Replacement .............................................
Removal.. ..............................................................
Cleaning.. ..............................................................
Installation ..............................................................

3-24
3-25
3-25
3-25

Air Crossover Tube - Replacement ...............................................


Removal and installation .....................................................

3-22
3-22

Air System Flow - Diagrams ....................................................

3-4

Charge Air Cooler ...........................................................


Cleaning and inspection .....................................................

3-21
3-21

Charge Air Cooler (CAC) - Troubleshooting .........................................


Pressure Drop - Checking ....................................................
Checking - Air Leak ........................................................

3-18
3-18
3-20

Combustion Air System - Diagnosing Malfunctions ....................................


Clean Air ...............................................................
Intake Air Restriction - Checking ................................................
Damage From Non-filtered Air .................................................
Turbocharged Engines - Air Leaks, Pressure Side ....................................
Turbocharged Engines - Exhaust Leaks ...........................................
Turbocharger Boost Pressure - Measurement .......................................
Malfunctioning Turbocharger ..................................................
Oil Consumption and Leaks ...................................................
Turbocharger Noise ........................................................
Rotor Assembly Clearance - Measurement .....................................

3-7
3-7
3-7
3-8
3-8
3-9
3-9
3-l 0
3-10
3-l 1
3-12

T ...

Combustion Air System Flow - General Information ....................................

3-3

Combustion Air System - Service Tools ............................................

3-6

Exhaust Manifold and Gaskets - Replacement .......................................


Removal ................................................................
Cleaning and Inspection .....................................................
Installation ..............................................................
Intake Air and Exhaust System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Cover and Gasket - Replacement .....................................
Removal ................................................................
Cleaning.. ..............................................................
Installation ..............................................................
Turbocharger Boost Pressure Specifications .........................................

3-30
3-30
3-31
331
3-5
3-23
3-23
3-24
3-24
3-5

Turbocharger - Replacement ....................................................


Removal.. ..............................................................
Cleaning and Inspection .....................................................
Installation ..............................................................

3-26
3-26
3-27
3-28

Turbocharger Wastegate Actuator - Calibration .......................................


Exhaust Restriction - Measurement ..............................................

3-l 7
3-l 8

Turbocharger Wastegate Actuator - Functional Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

,,

Turbocharger Wastegate Actuator - Replacement .....................................


Air regulator with pressure gauge ...............................................

3-l 5
3-15

Turbocharger Wastegate Actuator - Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-l 3

Section 3 - Combustion Air System


Page 3-3

Combustion Air System Flow - General Information


The engine was designed as a turbocharged engine, but a naturally aspirated engine is available for certain applications.
Air is pulled into the engine from an air filter. Clean air is very important to the life of the engine. Ingested dust and dirt
can very quickly damage the cylinders.
Make sure that an excellent quality air cleaner is used and that it is periodically replaced according to the
manufacturers recommendations.
Intake air for the naturally aspirated engine flows from the air cleaner to the intake manifold. From the intake manifold,
the air is pulled into the cylinders and used for combustion. After combustion it is forced out of the cylinders and through
the exhaust manifold.
On the turbocharged engines the intake air is drawn through the air cleaner into the compressor side of the turbocharger
and then through the crossover tube and into the intake manifold. From the intake manifold the air is forced into the
cylinders and used for combustion. Energy from the exhaust gases is utilized by flowing the exhaust through the exhaust
side of the turbocharger to drive the turbine wheel. The turbine wheel and shaft drives the compressor wheel which forces
more air into the cylinders for combustion. The additional air provided by the turbocharger allows more fuel to be injected
to increase the power output from the engine.
On turbocharged-aftercooled engines, intake air from the turbocharger flows through the cooling fins of the aftercooler
before entering the intake manifold. The cooled air becomes more dense and contains more oxygen which allows more
fuel to be injected further increasing the power output from the engine.
The 1991 and 1994 engines use a chassis-mounted charge air cooler instead of an engine mounted aftercooler to provide
cooler charge air to the engine to improve engine performance and reduce emissions. This system also uses large
diameter piping to transfer the air from the engine turbocharger to the charge air cooler, then returns the air from the
charge air cooler to the engine intake manifold.
Some turbocharger engines use a wastegated turbocharger to limit the maximum boost pressure that the turbo can
develop. Wastegate operation is controlled by an actuator that senses compressor pressure and balances it against a
preset spring load. The wastegate valve is located in the turbine inlet passage. When open, it diverts a portion of the
exhaust gas around the turbine wheel, thereby controlling the shaft speed and boost.

Caution: The turbocharger is a performance part and must not be tampered with. The wastegate bracket
is an integral part of the turbocharger. Tampering with the Wastegate Components can reduce durability
by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure.
Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger
boost will not increase engine power.

The turbine and compressor wheels and shaft are supported by two rotating bearings in the bearing housing. Passages
within the bearing housing direct filtered, pressurized engine oil to the shaft bearings and thrust bearing. The oil is used
to lubricate and cool the rotating components to provide for smooth operation. The oil then drains from the bearing
housing to the engine sump through the oil drain line. A restricted or damaged oil drain line can cause the turbocharger
bearing housing to be pressurized causing oil to leak past the seals.
NOTE: An adequate supply of good, filtered oil is very important to the life of the turbocharger. Make sure that an
excellent quality oil is used and that it and the oil filter are changed according to the maintenance recommendations.

Section 3 - Combustion Air System


Page 3-4

Air System Flow - Diagrams

ir System
Exhaust System
6. Exhaust Valve
7. Exhaust Manlfold (Pulse Type)
6. Dual Entry to Turbocharger
9. Turbocharger Exhaust Outlet

Intake System
1. Intake Air Inlet to Turbocharger
2. Turbocharger Air to Charge Air Cooler
3. Charge Air Cooler
4. Intake Manifold
(Integral Part of Cylinder Head)
5. Intake Valve

Section 3 - Combustion Air System


Page 3-5

Intake Air and Exhaust System Specifications


Maximum allowable intake restriction
(;;;,;F,
air filter element)
S6D114E-1; SA6Dil%l

(compressor

inlet)

50.8 cm H,O [20 in HsO]


: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 63.5 cm H,O [25 in H,O]

Maximum turbocharger exhaust restriction (turbine outlet)


at rated speed and load
S6D114E-1, SAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 mm Hg [3 in Hg]
S6D114E-1, SAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 cm H,O [40 in H,O]
Wastegate calibration
Charge Air Cooler

air pressure SA6114E-1

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

165 to 179 Kpa [24.0 to 26.0 psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Kpa [3 psi]

Turbocharger
Refer to the following

Boost Pressure Specifications


table for the engine model, engine rating and corresponding

rated turbocharger

boost pressure.

Measurement of boost pressure is not a short cut to logical troubleshooting.


Low power can be caused by the fuel used,
filter maintenance and several engine components. Follow the logic charts for Engine Power Output Low and measure
boost pressure as indicated. Refer to page 3-10 for measurement instructions.

Caution: These pressures are valid only at rated conditions (rated speed and power). Any attempt to use
the values at engine speeds and loads other than those specified will result in an incorrect diagnosis.

ENGINE MODEL

ENGINE RATING

RATED BOOST PRESSURE


kpa

[in. Hg]

150 @ 2380

111 to 132

33 to 39

170 @ 2200

111 to 132

33 to 39

173 @ 2380

142 to 162

42 to 48

177 @ 2500

118 to 138

35 to 41

185 @ 2200

115 to 135

34 to 40

190 @ 2200

122 to 142

36 to 42

205 @ 2200

122 to 142

36 to 42

215 @ 2200

125 to 145

37 to 43

SAGD114E-1

215 @ 2000

142 to 162

42 to 48

SAAGD114E-1

230 @ 2200

115 to 135

34 to 40

(HP @ RPM)
S6D114E-1

Section 3 - Combustion Air System


Page 3-6

Combustion Air System - Service Tools

The following special tools are recommended to perform procedures in Section 03. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tool Description

Tool No.

Tool Illustration

Dial Depth Gauge


I
Measure turbocharger axial motion.
ST-537

Pressure Gauge (O-75 in. Hg.)


Used to measure the intake manifold pressure.
ST-1273

Turbocharger Wastegate Pressure Setting Kit


Use to set wastegate pressure.
3823799

Section 3 - Combustion Air System


Page 3-7

Combustion Air System - Diagnosing


Malfunctions (3-01)
Clean Air
The correct amount of clean air to the cylinders is required
for good performance. As discussed earlier in Air Flow System, ingested dust and dirt will damage the engine cylinders.
Dust and dirt can also damage the valve stems and guides
as well as wear down the turbocharger compressor vanes
affecting efficiency. Larger debris can damage the blades of
the turbocharger.

Air flow restriction results in excessive smoke and low


power.
Restriction increases as the filter removes contaminants from
the intake air. Restricted air flow changes the air-to-fuel ratio,
reducing power and increasing smoke from the engine. Verify
that the air cleaner is being maintained correctly.
Measurement of air intake restriction is described in this
Section.

Intake Air Restriction - Checking


Replace the air cleaner element when the restriction reaches
the maximum limit at rated engine power and speed.
Naturally Aspirated

Turbocharged

50.8 cm Hz0

63.5 cm Hz0

[20 in. H,O]

[25 in. H,O]

For turbocharged engines, measure the restriction just before


the turbocharger. Measure just before the intake manifold for
naturally aspirated engines.

I
I

Naturally
Aspirated

Section 3 - Combustion Air System


Page 3-8

Damage From Non-filtered Air


Loose connections or cracks in the suction side of the intake
pipe can allow debris to be ingested by the engine causing
rapid wear in the cylinders.
Leaks at the intake manifold, unsealed bolt holes or manifold
cover gasket can also allow dust and dirt to be ingested into
naturally aspirated engines.

0@

04B

Loose connections or cracks in the suction side of the intake


pipe on turbocharged engines can allow debris to be ingested
into the turbocharger compressor and forced into the engine.

Debris drawn into the air suction side can damage the compressor blades causing an imbalance resulting in bearing
failure.
To verify a bearing failure or damaged compressor, remove the
intake and exhaust piping and check for contact. The rotor
assembly must rotate freely and should not be damaged.
Measurement of axial and radial clearance is described in this
Section.

Turbocharged Engines - Air Leaks, Pressure


Side
Excess smoke and low power from a turbocharged engine can
be caused by pressurized air leaking from loose connections
or cracks in the crossover tube or intake manifold. This can
also cause a noise problem.

Section 3 - Combustion Air System


Page 3-9

04B

In addition to the visual inspection for cracks and loose


fittings, liquid soap can be applied to the manifold cover
sealing surfaces and connections to find the leaks. The leaks
will create bubbles that are easier to detect. Measurement of e
manifold pressure is described in this Section.

Turbocharged Engines - Exhaust Leaks


Inspect for exhaust leaks at the exhaust manifold and turbocharger, gasket leaks, or exhaust pipe restrictions. Leaks or
restrictions will cause the turbine and impeller to operate at a
lower speed and reduce the amount of air being forced into
the cylinders. Again, the symptom will be excess smoke, low
manifold pressure and low power.

0
@

Turbocharger Boost Pressure - Measurement


Measure the boost pressure at the intake manifold by using e
one of the tapped or plugged intake access holes shown in
the illustration. Refer to the specifications in this section.
NOTE: If the engine has charge air cooling, testing must be
done to be sure that the charge air cooler system is not
leaking or restricting the turbocharger boost pressure. Refer
to Procedure 3-06 for detailed charged air cooler testing.

Exhaust leaks can usually be detected audibly or visually by


a discoloration caused by the escaping hot gases.
Dont overlook exhaust restriction as a cause of low power. If
the exhaust gasses can not flow freely, the turbocharger will
not operate efficiently.

0a3

Section 3 - Combustion Air System


Page 3-10

Malfunctioning Turbocharger
Failure of the internal components of the turbocharger can
reduce its effectiveness and also cause excessive smoke and
low power. A bearing failure can produce friction which will
slow the speed of the rotor assembly. Failed bearings can also
allow the blades of the rotor assembly to rub the housings,
thus reducing the rotor assembly speed.
Malfunctioning turbocharger wastegate failure or miss-calibration
of the turbocharger wastegate can result in excessively high or
low boost pressures. Low boost pressure can cause excessive
smoke and low power. High boost pressures can cause major
engine damage.

Oil Consumption and Leaks


Engine lubricating oil is used to lubricate the bearings and
provide some cooling for the turbocharger. The oil supplied to
the turbocharger through the supply line is at engine operating
pressure. A return line connected to the bottom of the turbocharger routes the oil back to the engine oil pan.

Seal rings are used on each end of the rotor assembly. The
primary function of the seals is to prevent exhaust gases and
compressed air from entering the turbocharger housing. Oil
leakage from the seals is rare, but it can occur.
NOTE: Excessive crankcase pressure will not allow the oil to
drain from the turbocharger. This will load the bearing housing
and allow oil to leak past the compressor seals and into the
engine.
NOTE: If turbine seal leakage into the exhaust system occurs
on engines with catalysts, check the catalyst back pressure
during repair.

A restricted or damaged oil return line will cause the turbocharger housing to be pressurized causing oil to migrate past
the seals.

Section 3 - Combustion Air System

Page 3-I 1

Additionally, high intake or exhaust restrictions can cause a


vacuum between the compressor and the turbocharger
housing resulting in oil leaking past the seals.

To verify oil leakage past the seals, remove the exhaust pipe
and crossover tube and look for oil in the turbine casing and
the crossover tube. Locate and correct the restriction as
previously discussed.

0
@

Turbocharger Noise
It is normal for the turbocharger to emit a whine sound that
varies in intensity depending on engine speed and load. The
sound is caused by the very high rotational speed of the
rotor assembly. Consequently, the sound will be more audible at full speed.
If possible, operate the engine at full speed to verify the
noise level.

Leaks in the air system intake and/or exhaust components


can produce additional noises.
Pressurize the intake system and check for air intake and
crossover tube leaks.

0@

Section 3 - Combustion Air System

Page 3-12

Before removing the turbocharger, make sure that the noise


complaint is not caused by leaks in the air system compo
nents.
Look for loose turbocharger mounting, exhaust manifold gasket
leaks, and cracks in the exhaust manifold.

Lower pitch sounds or rattles at slower engine speeds


can
indicate debris in the system or the rotor assembly is touchin
g
the housings.

Rotor Assembly Clearance - Measurement


Part No. ST-537, Dial Depth Gauge
Measure the shaft end play.
End Play (A)
mm
*

**

in.

0.10

MIN

[0.004]

0.16

MAX

[O.OOS]

MIN

[O.OOl]

MAX

[0.003]

0.03
0.08

* For turbochargers with a serial number before 840638.


** For turbochargers with a serial number 846638 and after.

Section 3 - Combustion Air System


Page 3-13
Measure radial clearance of the shaft.
Radial Clearance (6)
mm

in.

0.21

MIN

[0.008]

0.48

MAX

[0.018]

The turbocharger must be removed for replacement or


rebuild if the clearances are beyond these limits. Refer to the
Turbocharger Shop Manual, Bulletin No. 3810321, for rebuild e
procedures.

Turbocharger Wastegate Actuator - Visual


Inspection (3-02)
Visually inspect the lever pin.

0a3

Replace the turbine housing assembly if worn excessively.


Refer to the Turbocharger Shop Manual, Bulletin No.
3810321.

W&l

X.

inspect the valve and valve seat for cracks or

Replace the turbine housing assembly if worn excessively.

0a3

Refer to the turbocharger Shop manual, Bulletin No. 3810321.

Actuate the lever by hand to be sure that the shaft moves


freely and is not seized.

fh~.~$r

excessive movement between the shaft and

Replace the turbine housing if the shaft and bushing are


damaged or seized.
Refer to the Turbocharger Shop Manual, Bulletin No.
3810321.

04B

Section 3 - Combustion Air System


Page 3-14
Visually inspect the wastegate actuator hose for cracks or
holes. Replace the hose if damaged.

Caution: Before making any adjustments to the wastegate


assembly, refer to the information on page 3-2.

Visually inspect the wastegate mounting bracket, actuator rod,


and lever for damage. A bent wastegate mounting bracket,
actuator rod, or lever can cause improper operation.
If the wastegate mounting bracket, actuator rod, or lever is
bent, it must be replaced. Refer to Procedure 3-04.

0a9

Turbocharger Wastegate Actuator - Functional Checking (3-03)


Connect regulated air pressure and an accurate pressure gauge
to the capsule. Apply 160 kPa [26 psi] to make sure the
wastegate is functioning properly. The actuating rod should
move approximately 5 mm [0.200 in] without sticking or air
leakage.
NOTE: A small amount of travel when air pressure is first
applied is normal, the tolerance is being removed from the
system.

0
@

Replace the actuator if no movement of the actuator rod and


lever is detected. Refer to Procedure 3-04.
If repair is not correct, refer to Procedure 3-05 for Turbocharger
Wastegate Actuator - Calibration.

Section 3 - Combustion Air System


Page 3-l 5

Turbocharger Wastegate Actuator Replacement (3-04)


NOTE: Prior to removal, note position length of the control
rod from the actuator housing and orientation of the actuator
hose connector in relation to the mounting bracket.

0ai9

Air regulator with pressure gauge


Remove the retaining clip from the control lever.

Disconnect the actuator rod end from the turbocharger


wastegate lever. This can be accomplished by applying
regulated air pressure to the actuator in a sufficient amount
to activate control rod movement.
Disconnect the control rod from the turbocharger wastegate
lever pin.
Caution: Be careful not to bend the control lever.
NOTE: If the actuator diaphragm material is ruptured and will
not hold air pressure other than by hand, manually pull the
control rod outward in order to overcome actuator spring
tension for removal of the control rod from the turbocharger
wastegate lever pin.

Loosen the actuator mounting capscrews and disconnect the


air supply hose and remove assembly from the mounting C%Q
bracket.

Section 3 - Combustion Air System


Page 3-16
_

Remove the adjusting link end from the actuator.

Install the adjusting link end onto the new replacement actuator
as;o;zy
into approximately the same position as originally

Fit the new actuator assembly to the actuator mounting bracket


and install the mounting capscrews.
Torque Value: 4.5 Nom [40 in-lb]

Section 3 - Combustion Air System


Page 3-17

Turbocharger Wastegate Actuator Calibration (3-05)


NOTE: The wastegate is set accurately from the factory.
Adjustment is not necessary unless the capsule is removed.
Attach a dial indicator as shown, so that its shaft is in line
with the wastegate actuator rod. Set the indicator to zero,
with no air pressure applied to the wastegate capsule.
Connect clean, regulated air pressure supply and an accurate
pressure gauge to the capsule.
For industrial rating apply 153 kPa 122.2 psi]. Measure the
rod travel and compare to the table below.
Wastegate Actuator Rod Movement
in.

mm
0.33

MIN

0.013

1.3

MAX

0.050

Replace the actuator if no movement of the actuator rod and


lever is detected. Refer to Procedure 3-04.

Caution: Do not pull, push or force alignment of the


clevis pin.
While pressure is being applied, adjust linkage as follows:
l
l

l
l

Pull the wastegate lever to the foremost closed


position (lever toward actuator).
Adjust the length of the clevis end of the control rod
to where the clevis pin hole aligns to the wastegate
lever.
Install the adjusting link and retaining clip.
After adjustment is completed, tighten actuator rod
locknut.

Disconnect regulated air pressure line from the actuator.


Connect the turbo boost line to the actuator and secure
hose clamp.

Section 3 - Combustion Air System


Page 3-18

Exhaust Restriction - Measurement


Install pressure gauge, Part No. ST-1273, to the pressure tap
in the exhaust head pipe or at the inlet to the catalyst / muffler
assembly.
Operate the engine at rated speed and load. Record the
exhaust restrictions.

If restriction exceeds specification, inspect catalyst and/or


muffler and replace per vehicle manufactures instructions.
Industrial
91 EPA certification
94 EPA certification

76 mm Hg [3 in Hg]
114 mm Hg [4.5 in Hg]
152 mm Hg [6 in Hg]

Char e Air Cooler CAC) Trou 4 eshooting (31b 6)


NOTE: The long term integrity of the charge air cooling system
is the responsibility of the vehicle and component manufacturers; however, the following symptoms can be checked by any
Komatsu Authorized Repair Location.

Pressure Drop - Checking


Preferred Method
Measure the CAC system pressure drop with a mercury
manometer.

Section 3 - Combustion Air System


Page 3-19
Install one end of the manometer into the l/8
in the turbocharger compressor outlet elbow.

inch pipe tap

Install the other end of the manometer into the l/8 inch pipe
tap in the intake manifold.

Operate the engine at the maximum advertised horse power


and correlating RPM. Record the readings on the manometer.
If differential pressure is greater than 156 mm Hg [6.0 in Hg]
or 21 kPa 13 psil, check the CAC and associated piping for
plugging. cifG or replace if necessary.

Install Fluke digital thermometer, Part No. 3822666, and


thermocouple wire kii, Part No. 3822688, into the intake
manifold at the l/8 inch NPT tap near the air horn connection with the intake manifold.
Install another thermocouple at the air cleaner inlet to measure the ambient temperature.

0a9

Section 3 - Combustion Air System


Page 3-20
Perform a test with the engine at peak power against a load.
Record the intake manifold temperature and the ambient air
temperature.
Calculate the differential temperature:
Intake Manifold - Ambient Air - Differential
Temperature
Temperature
Temperature

If the temperature differential is greater than 28C [5OF],


check the CAC for dirt and debris on the fins and clean as
necessary. If the problem still exists, check the CAC for debris
in fins or between the CAC and radiator. Confirm full fan
engagement.

Checking - Air Leak


To check the CAC for cracked tubes or header, remove the
inlet and outlet hoses from the cooler. The CAC does not have
to be removed from the chassis.

Install a plug or cap on the outlet side of the cooler. Install a


pressure gauge, air supply line, and air pressure regulator to
the inlet side of the cooler.
Warning: To prevent possible injury if either plug blows off
during the test, secure safety chains on the test plugs to
any convenient capscrew on the radiator assembly. This
test must be performed with securely fastened safety
chains.

Section 3 - Combustion Air System


Page 3-21
Apply 207 kPa [30 psi] of air pressure to the cooler. Close
the air pressure regulator.
Monitor the pressure gauge and determine the rate of pressure decay with a stop watch.

0a9

If the pressure decay is 49 kPa [7 psi] or less in 15 seconds,


the cooler is okay. If the pressure drop is greater than 49
kPa [7 psi] in 15 seconds, check all connections again.
Determine if pressure decay is caused by a leak in the CAC
or from a leaky connection. Use a spray bottle filled with
soapy water applied to all hose connections, and watch for
bubbles to appear at the location of the leak.

If the pressure decay is caused by a leaky connection, repair


the connection and repeat the test. If the leak is within the
CAC, repeat the test to verify the accuracy of the pressure
delay measurement. Similar pressure decay reading must be
obtained at least three consecutive tests before the reading
can be considered accurate.
NOTE: If a CAC leaks more than 49 kPa [7psi] in 15 seconds, it will appear as a major leak in a leak tank.

If the pressure drop is greater than 49 kPa [7 psi] in 15


seconds, the CAC must be replaced.
Refer to the manufacturers repair manual for replacement
instructions.
NOTE: Charge air coolers are not designed to be 100% leak
free. If the pressure decay is less than 49 kPa [7 psi] in 15
seconds, then the CAC does not need to be replaced.

Charge Air Cooler (3-07)


Cleaning and inspection
If the engine experiences a turbocharger failure or any other G9
occasion where oil or debris is put into the CAC, the CAC e
must be cleaned.
Remove the CAC from the vehicle. Refer to the vehicle
manufacturers instructions.

Section 3 - Combustion Air System


Page 3-22

B
q

Caution: Do not use caustic cleaners to clean the CAC.


Damage to the CAC will result.
NOTE: Make sure that the tubes are in the vertical direction
when flushing.
Flush the CAC internally with solvent in the opposite direction
of normal air flow. Shake the CAC and lightly tap on the end
tanks with a rubber mallet to dislodge trapped debris. Continue
flushing until all debris or oil is removed.
Use a flashlight and mirror to visually inspect the CAC for
internal debris.
NOTE: If internal debris cannot be removed, scrap the CAC.

\
q

After the CAC has been thoroughly cleaned of all oil and debris
with solvent, wash the CAC internally with hot soapy water to
remove the remaining solvent. Rinse thoroughly with clean
water.

Blow compressed air into the CAC in the opposite direction of


normal air flow until the CAC is dry internally.
Caution: The CAC must be rinsed, dried, and free of
solvent, oil, and debris or engine damage will result.

Visually inspect the CAC for cracks, holes or damage.

a9

Inspect the tubes, fins and welds for tears, breaks or other
damage. If any damage causes the CAC to fail the air leak
check mentioned earlier in this Procedure, the CAC must be
replaced. Install the CAC on the vehicle. Refer to the vehicle
manufacturer for instructions.

Air Crossover Tube - Replacement

(3-08)

Removal and installation


8 mm or Screwdriver
Loosen the hose clamps and position the hose so the crossover tube can be removed.
Use new hose and clamps as required to install the crossover
tube.
Torque Value: 5 Nom [44 in-lb]

Section 3 - Combustion Air System


Page 3-23

Intake Manifold Cover and Gasket Replacement (3-09)


Preparatory Steps:
l

Disconnect the cold starting aid, if used.

Remove the air crossover tube, if used.

Disconnect the charged air cooler hose, if used.

Removal
10 mm
Remove the manifold cover and gasket.

Section 3 - Combustion Air System


Page 3-24

Cleaning
Clean the sealing surface.
NOTE: Keep the gasket material and any other material out of
the air intake.

Installation
10 mm
Install the cover and a new gasket.
Torque Value: 24 Nom [18 ft-lb]

ssemble the intake piping and connect the cold starting aid

Aftercooler and Gasket - Replacement


(3-10)
Preparatory Steps:
l

Disconnect the cold starting aid, if used.

Remove the air crossover tube.

Drain 2 liters [2.1 U.S. quarts] of coolant.

Section 3 - Combustion Air System

Page 3-25

Removal
8mm
Remove the coolant supply tube (1) and the coolant return
tube (2).

10 mm
Remove the aftercooler housing and gasket.

Cleaning
Clean the sealing surface.
NOTE: Keep the gasket material and any other material out
of the air intake.

Installation
10 mm
Use sealant, Part No. 3823494, on both sides of the
aftercooler housing gasket.
Install the aftercooler housing and a new gasket.
For aftercoolers with a form-in-place gasket, apply a 4 mm
bead of sealant to the cylinder head.
Torque Value:

24 Nom [18 ft-lb]

Section 3 - Combustion Air System


Page 3-26
8mm
install the coolant supply tube (1) and coolant return tube (2).
Install the air crossover tube.
Torque Value: 5 Nom [44 in-lb]

Caution: During filling, air must be vented from the engine


coolant passages. Open the engine vent petcock. Also, be
sure to open the petcock on the aftercooler for aftercooled
engines. The system must be filled slowly to prevent air
locks. Wait 2 to 3 minutes to allow air to be vented, then
add coolant to bring the level to the bottom of the radiator
filler neck.
Fill the coolant system with a pre-mixture of 50 percent water
and 50 percent ethylene-glycol type antifreeze. Use the correct
concentration of supplemental coolant additive (DCA4). Follow
the recommendations given in Section 1.

Turbocharger - Replacement

(3-11)

Preparatory Steps:
l

Remove the air crossover tube, if used.

Disconnect the charge air cooler hose.

Disconnect the wastegate actuator hose.

Disconnect the intake and exhaust piping.

Removal
10 mm
Remove the capscrews from the oil drain tube.

Section 3 - Combustion Air System


Page 3-27
16 mm
Disconnect the oil supply line.

15 mm and 7/l&inch
Remove the exhaust clamp, turbocharger, and gasket.

Cleaning and Inspection


Clean the sealing surfaces. Inspect the sealing surface and
mounting studs for damage.

NOTE: If the turbocharger is not to be immediately replaced,


cover the opening to prevent any material from falling into
the manifold.
Inspect the turbocharger wastegate
module, and pressure signal line.

linkage, valve shaft,

Check to calibrate wastegate.


Refer to Turbocharger Shop Manual, Bulletin No. 3810321,
for calibration procedures.

Section 3 - Combustion Air System


*age 3-28

Installation
Install a new gasket and apply a high temperature anti-seize
compound to the mounting studs.

15 mm
Install the turbocharger.
Torque Value: 45 Nom [33 ft-lb]

10 mm and 7/1&inch
Use a new gasket and connect the oil drain tube.
Torque Value:
(Exhaust Clamp)
(Drain Tube)

8 Nom 171 in-lb]


24 Nom 118 ft-lb]

NOTE: New turbochargers


start-up.

must be prelubricated

before

Pour 50 to 60 cc [2 to 3 ounces] of clean engine oil into the


oil supply fiiing. Rotate the turbine wheel to allow the oil to
enter the bearing housing.

Section 3 - Combustion Air System


Page 3-29
16 mm
Connect the oil supply line.
Torque Value:

15 Nom [ll

ft-lb]

Loosen the snap ring and align the compressor housing


with the turbocharger air outlet connection.

Is-l

7116 inch

If required, loosen the compressor housing V-band clamp lm


and position the housing to align with the turbocharger air
outlet pipe.

7/16 inch, Plastic Hammer


Tighten the band clamp. Tap around the clamp with a plastic
hammer and tighten again.
Torque Value:

8 Nom [71 in-lb]

NOTE: Effective Oct. 1, 1990 all Holset Turbochargers use


silver plated nuts with the v-band clamp. The silver plated
nuts require a lower torque than the stainless steel nut to
provide the same v-band clamp load.

0\
(-

Section 3 - Combustion Air System


Page 3-30
Connect the wastegate actuator hose.

install the air inlet and exhaust piping.


Operate the engine and check for leaks.

Exhaust Manifold and Gaskets Replacement (3-12)


Preparatory Steps:
l

Remove the air crossover tube, if used.

Disconnect the charge air cooler hose.

Disconnect the air intake and exhaust piping.

Remove the turbocharger, if used.

Removal

RI

15 mm
Remove the exhaust manifold and gaskets.

Section 3 - Combustion Air System


Page 3-31

Cleaning and Inspection


Clean the sealing surfaces.

Inspect the
burn-out.

gasket

surfaces

for

gouges,

scratches,

or

Place a straight edge across the exhaust ports to check for


flatness.
Exhaust Manifold Flatness
in.

mm
0.20

MAX

0.008

Installation
15 mm
Install the exhaust manifold and new gaskets.
Use new lockplates on the capscrews.
Torque Value:

43 Nom [32 ft-lb]

Follow the tightening sequence shown in the illustration.


After the capscrews are tightened to the correct torque value,
bend over the lockplates to prevent the capscrews from
loosening.

0@

Section 3 - Combustion Air System


Page 3-32

I l%

**
83

0a9

Install the parts previously removed. Operate the engine and


check for leaks.

Section 4 - Compressed Air System


Page 4-l

Section 4 - Compressed Air System


Section Contents
Page
Air Compressor Carbon Buildup - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Air Compressor Gasket Leaks - Checking

4-7

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

Air Compressor - Replacement .................................................


Inspection ...............................................................
Installation
..............................................................
Removal................................................................4-1

4-10
4-12
4-12
1

Air Governor and Compressor Unloader Valve - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7

Air Governor - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8

Compressed Air System Flow Diagrams ...........................................

4-4

Compressed Air System General Information .......................................

4-2

Compressed Air System Specifications

4-3

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

Section 4 - Compressed Air System


Page 4-2
Res

Compressed Air System General


Information

f-

The compressed air system normally consists of a gear driven


air compressor, an air governor, air tanks and all necessary
plumbing.

(Wet Tank)
Reservoir

The Holset SS296 single cylinder air compressor is an engine-driven piston-type compressor which supplies compressed
air to operate air activated devices. The compressor runs continuously but has a loaded and unloaded operating mode.
The operating mode is controlled by a pressure-activated governor and the compressor unloading assembly.
The SS296 air compressor used on 6D114E-1 series engines uses an (E-type) unloader. The Economy (E-type) unloader
system was designed to reduce pumping losses and engine boost pressure losses through the compressor intake valve
while operating in unloaded mode.
When the air system reaches a predetermined pressure, the governor applies an air signal to the air compressor unloader
assembly causing the unloader cap to seal off incoming air at the intake valve, and compressed air stops flowing into
the air system.
NOTE: System pressure must be maintained on the outlet side of the discharge valve to keep the discharge valve closed.
As the air in the air system is used, the pressure drops. At a predetermined pressure the governor exhausts the air signal
to the compressor unloader assembly allowing the compressor to again pump compressed air into the air system.

Caution: Machines equipped with air dryers vented to atmosphere during unloaded compressor operation,
using the Holset (E-type) air compressor, require the installation of an Econ valve to prevent excessive
oil consumption.

If the air system pressure is not maintained on the discharge valve during unloaded operation, air will be pumped out
of the compressor cylinder causing a low pressure (vacuum) condition to form in the cylinder. With the intake valve sealed
off by the unloader cap, and the exhaust valve being a one-way pressure actuated valve, no air will be allowed to enter
the cylinder. When the compressor cylinder pressure falls below crankcase pressure, oil will be drawn past the piston rings
and pumped into the air system.

Other brands of compressors may be used on 6D114E-1 series engines. Troubleshooting procedures are very similar for
these air compressors compared to the Holset SS296. Refer to the appropriate Chassis Shop Manual for specific air
compressor detailed repair information and torque specifications.

Section 4 - Compressed Air System


Page 4-3

Compressed Air System Specifications


Holset SS296 Single Cylinder Air Compressor
Compressor Swept Volume @ 1250 RPM
Piston Displacement
Bore

6.2 L per sec. [13.20 CFM]

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

296 cc 118.06 C.I.D.]

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

92.08 mm [3.625 in.]

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

Stroke

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

Speed

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

Cooling

44.45 mm [1.750 in.]


1.135 times greater than Engine Speed
EngineCoolant

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

Lubrication

Engine Lubricating Oil

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

Plumbing Line Sizes


Coolant Inlet and Outlet (Pipe Fiiing)

3/8 in NPTF

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

19 mm [0.750 in]

Air Inlet (Inside Diameter) ................................................


Air Outlet (Minimum Inside Diameter)

l/2 NPTF 12.7 mm [0.50 in.]

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

Height, Overall (Approximate)

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

235 mm [9.25 in.]

Width, Overall (Approximate)

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

146 cm [5.75 in.]

Length, Overall (Approximate)


Weight (Approximate)

267 cm [lo.5 in]

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

20 kg [44.0 lb]

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

Holset SS336 Single Cylinder Air Compressor


Compressor Swept Volume @ 1250 RPM
Piston Displacement

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

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

[15.0 CFM]
338 cc

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

98.9 mm [3.875 in.]

Stroke

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

44.45 mm [1.750 in.]

Speed

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

Bore

Cooling
Lubrication

1.135 times greater than Engine Speed

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

Engine Coolant
Engine Lubricating Oil

Plumbing Line Sizes


Coolant Inlet and Outlet (Pipe Fitting)

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

Air Inlet (Inside Diameter) ..............................................


Air Outlet (Minimum Inside Diameter)

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

l/2 in NPTF
22.2 mm [0.875 in]
l/2 NPTF 12.7 mm [0.50 in.]

Height, Overall (Approximate)

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

236.6 mm [9.31 in.]

Width, Overall (Approximate)

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

133.4 cm [5.25 in.]

Weight (Approximate)

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

18 kg [40.0 lb]

Section 4 - Compressed
Page 4-4

Compressed Air System Flow Diagrams


Reservoir

Go&nor

Econ Valve

(Wet Tank)
Reservoir
Check Valve
(Normally Built into Dryer)

Air Dryer

-t
To Spitter Valve

With Air Dryer

Reservoir

(Wet Tank)
Reservoir
Without Air Dryer

Air System

Section 4 - Compressed Air System


Page 4-5

Air Compressor Carbon Buildup Checking (401)


Shut off the engine.
Open the draincock
air from the system.

on the wet tank to release compressed

0
@

Warning: When using a steam cleaner, wear protective


clothing and safety glasses or a face shield. Hot steam
can cause serious personal injury.

Use steam to clean the compressor.


Use compressed

air to dry.

Remove the air inlet


compressor.

and

Measure the total carbon


discharge line as shown.
The carbon
[l/16 inch].

deposit

outlet

connections

deposit

thickness

thickness

from

the air

inside

the air
ID of Discharge Line

must

not

exceed

1.6 mm

ID of Carbon Build Up

cE3tbla

Section 4 - Compressed Air System


Page 4-6

A
@

Warning: The air discharge line must be capable of


withstanding extreme heat and pressure to prevent personal
injury and property damage. Refer to appropriate Chassis
Parts Manual for replacement part number.
NOTE:
If the total carbon
deposit
thickness
exceeds
specification:
*
Remove and clean or replace the air discharge line. Refer
to appropriate Chassis Shop Manual.
*
Remove the air compressor
from engine,
refer to
Procedure 4-03 and inspect unloader components refer to
Air Compressor Shop Manual, Bulletin No. 3810242, for
detailed instructions on servicing the unloader.

0
c%

Warning: The air discharge line must be capable of


withstanding extreme heat and pressure to prevent personal
injury and property damage.Refer to appropriate Chassis
Parts Manual for replacement part number.
Continue to check for carbon buildup in the air discharge
connections up to the first or wet tank.

line

Clean or replace any lines and fittings with carbon deposits


greater than 1.6 mm [0.06 (1/16) inch]. Refer to the appropriate
Chassis Shop Manual for cleaning or replacement instructions.

Install and tighten the air inlet and outlet connections.

Torque Value:
Inlet

5 Nom [48 in-lb]

*Outlet

24 Nom [18 ft-lb]

* l/2

NPT fitting in compressor

cylinder

head.

NOTE: Torque value for the discharge line depends on the line
size and type. Refer to Chassis Shop Manual for the correct
torque value.

ez9

Close the wet tank draincock.


Operate the engine and check for air leaks.

Section 4 - Compressed

Air System
Paie 4-7

Air Compressor Gasket Leaks - Checking


(4-02)
Shut off the engine.
Open the draincock on the wet tank to release air from the
system. Close the draincock after the pressure is released.

ca800wb

Operate the engine to activate the air compressor.


With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
l

Air Compressor

Unloader

Air Compressor

cover gasket

body o-ring
cylinder

head gasket

If air leaks are found,


refer to Procedure
compressor will have to be removed for service.

4-05.

The

Air Governor and Compressor Unloader


Valve - Checking (4-03)
Air Compressor
Remove the air
unloader body.

Will Not Pump


governor

hose

from

the

air

compressor

0
Gz

Caution:
During this test, do not exceed maximum
machine
air system
pressure
1035 kPa
[150 psi]
whichever is lower. Refer to the appropriate Chassis Shop
Manual for maximum air system pressure.
Operate the engine to activate the air compressor.

Section 4 - Compressed Air System

.!.

Page 4-8
If the air compressor
does not pump, remove the air
compressor, clean and inspect the air compressor unloader
valve assembly. Refer to Air Compressor Shop Manual 3810242.

Caution: During this test, do not exceed maximum machine


air system pressure 1035 kPa [150 psi] whichever is lower.
Refer to the appropriate Chassis Shop Manual for maximum
air system pressure.
Install the air compressor.

Refer to Procedure

Operate the engine and check air compressor


the air governor removed.

Install the air governor

line to the unloader

4-05.
operation

with

body and tighten.

Air Governor - Checking (MM)


Air Compressor Pumps Continuously
Remove the accessory air lines from the air governor unloader
port.

NOTE: Do not disconnect the line from the air compressor


unloader valve. Do not disconnect the reservoir air line from
the air governor.

Section 4 - Compressed Air System


Page 4-9
Install pipe plugs in the air governor
accessory air lines were removed.

unloader

ports where

Operate the engine to activate the air compressor.


If the air compressor
stops pumping
(air
rising) at the governed air pressure, there
accessory or an accessory air line. Refer to
Chassis Shop Manual for troubleshooting
and

pressure stops
is a leak in an
the appropriate
repair.

If the air compressor does not stop pumping (air pressure


continues to rise) at the governed air pressure, connect a
regulated shop air pressure line the air compressor unloader
vale port.
NOTE: Be sure the signal line from the air governor
compressor unloader is not leaking.

to the

NOTE: Be sure the air pressure gauge is accurate


supply
line and fitting
are in good
condition
performing any air pressure checks.

an the
before

Use a master gauge


pressure gauge.

Apply 690 kpa [lo0


If the air
rising) the
repaired or
Manual for

of known

accuracy

to check the air

psi] air pressure to the unloader

port.

compressor
stops pumping
(air pressure stops
air governor
is malfunctioning
and must be
replaced. Refer to the appropriate Chassis Shop
instructions.

Section 4 - Compressed Air System


Page 4-10
If the air
to rise),
repaired
Refer to

compressor continues to pump (air pressure continues


the unloader valve is malfunctioning
and must be
or replaced. Remove the air compressor for repair.
Procedure 4-05.

Remove the pipe plug from the governor


accessory air line.
Remove the regulated

port used for the

shop air.

Install and tighten the accessory

air line.

Connect the line between the compressor


the air governor.

unloader

valve and

Operate the engine and check for air leaks.

Air Compressor - Replacement

(4-05)

Preparator Steps:
l

Steam clean the air compressor


air.

Drain the engine coolant.

and dry with compressed

Section 4 - Compressed Air System


Page 4-l 1

Removal
Remove the air connections

form the air compressor.

15116 inch
Remove the coolant lines form the air compressor.

9/16 inch
Remove the oil supply line.

19 mm, 15 mm, 14 mm
Remove the air compressor
Remove the air compressor

support

bracket and capscrews.

Section 4 - Compressed Air System


Page 412

Inspection
Visually inspect the compressor housing for cracks or damage.
Visually inspect the drive gear for cracks or damage.

Be sure the gasket surfaces of the gear housing and air


compressor are clean and not damaged.

Installation
14 mm, 15 mm, 19 mm
Caution: Make sure the oil drain notch in the gear housing
is not blocked. The gasket must be installed with the side
marked This Side Toward Gear Housing is facing the gear
housing.
Use a new gasket. install the air compressor. Tighten the two
mounting nuts.
Torque Value: 77 N l m [57 ft-lb]
NOTE: It is not necessary to time the air compressor on the
6D114E-1 Series engine.

Install the mounting spacer to the engine block, use the 46 mm


long capscrews and tighten finger tight.

Section 4 - Compressed Air System


Pagd 4-lf)
Install the air compressor brace (2) to the mounting spacer
91) and adapter (3) on the air compressor using the 30 mm
long capscrews finger tight. Make sure the brace and spacer
are aligned and no parts are in a bind. Tighten evenly to the
proper torque value.

Torque Value:

43 Nom [32 ft-lb]

9116 inch
Install the oil supply line.

Torque Value:

8 Nom [71 in-lb]

15/16 inch
Caution: If rubber grommets are used on the coolant
lines, be sure they are install carefully to prevent cuts or
tears to the grommets which will cause coolant leaks.
Install the coolant lines.

Torque Value:

35.m

[26 ft-lb]

@$

Install and tighten the inlet and outlet connections.

Torque Value:
Inlet

5 Nom [48 in-lb]


24 Nom 118 ft-lb]

*Outlet
*l/2

NPT fitting in the compressor

NOTE: Torque
size and type.

cylinder

value for the discharge

Refer to the appropriate


torque value.

head.

line depends

of line

Chassis Shop Manual for the correct

Section

4 - Compressed

Air System

Page 4-j4
Fill the engine cooling
Operate the engine
operation.

system.
to check

for

coolant

leaks and proper

After the system reaches governed air pressure, 690 to 862 kPa
[lo0 to 125 psi] check for air leaks.

Section 5 - Fuel System


Page 5-l

Section 5 - Fuel System


Section Contents
Page
AFCR;;Fvi

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-31
Installatio;l::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::5-31

Fuel Drain Manifold - Replacement ...............................................


Removal and Installation .....................................................

5-26
5-26

Fuel Filter Head Adapter - Replacement ............................................


Removal and Installation .....................................................

5-21
5-21

Fuek;,eoTtn

5-31
5-32

Pump - Replacement ...............................................

lnstallatio;l::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::5-33
5-30

Fuel Return Overflow Valve - Replacement ..........................................

5-28
Fuel Shutoff Solenoid - Replacement ..............................................
5-28
RSV Governor Fuel Shutoff Solenoid - Removal
RSV Governor Fuel Shutoff Solenoid - Installation : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 5-29
5-29
Direct Link Solenoid, Cylinder Block Mounted .......................................
5-29
RQVK Governor Fuel Shutoff Solenoid - Removal and Installation ..........................
5-3

Fuel System Components and Flow ...............................................

5-7
Fuel System Diagnosing - Malfunctions ............................................
5-7
Fuel Transfer Pump ........................................................
5-11
Air in the Fuel System ......................................................
5-13
Fuel Water Separator/Filter Unit ................................................
5-14
Fuel Injection Pump ........................................................
5-14
Governor Malfunctions
Air Fuel Control (AFC) hnalfunctibns : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 5-14
5-15
Fuel Control Lever Travel and Adjustment .........................................
5-15
Fuel Inection Pump Idle Adjustment Screws ........................................
5-15
Manua1 Shut Down Levers ....................................................
5-16
Electrical Shut Down Devices ..................................................
5-17
Fuel Injection Pump Timing ...................................................
5-18
High Pressure Fuel Lines ....................................................
5-19
..............................................................
Injectors..
5-20
Fuel Drain Manifold ........................................................
Fuel System - Service Tools ....................................................

55

Fuel System Specifications .....................................................

5-4

FuekF;;;;ar

Pump - Replacement/Rebuild

...

Rebuild : : : : : : : : : : : : : : : : : : : : : : : : : :
Cleaning ................................
Assembly ...............................
Cleaning Mounting Surface ...................
lnstallatron ........................
Hig;keoyayre

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

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

Fuel Lines - Replacement ...........................................

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

.
.
.
.
.
.
.

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

......

5-22
5-22
5-22
5-23
5-23
5-24
5-24
5-24
5-24

Installatio;l::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::5-25
5-38
Idle Speed - Adustment .......................................................
5-38
Bosch RSV b overnor
Bosch RQVK Governor. : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 5-39
Inje;~;r-v;fplacement

....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-26
Cleaning aid

if&&tib;l'

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5-26

Section 5 - Fuel System


Page S-2
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Wine Fuel Inection Pump Spill-Port Timing .........................................
Governor t ever Positioning ...................................................

5-39
5-41

Low Pressure Fuel Line - Replacement ............................................


Removal and Installation .....................................................

5-21
5-21

Section 5 - Fuel System


Page 6-3

Fuel System Components and Flow


A cam-actuated fuel transfer pump provides positive fuel pressure to the fuel injection pump. Fuel flow begins as the fuel
transfer pump pulls fuel from the supply tank. The system should have a pre-filter or screen to remove larger contaminants
from the fuel before reaching the fuel transfer pump. The fuel transfer pump supplies low pressure fuel through the fuel
filter head and filter to the fuel injection pump for Bosch A, MW, P and EP9 Nippondenso pumps.
The Robert Bosch PES6A fuel injection pump is used on all engine models. The Model PESGMWand PESGAfuel injection
pumps are used on the higher rated SAGD114E-1engines. The PESGPfuel injection pump is used on the 6D114E-1 &
S6D114E-1 engines. The fuel injection pump builds the high injection pressures required for combustion and routes the
fuel through high pressure fuel lines to each injector.
All 6D114E-1 series engines use Robert Bosch 17mm closed-nozzle, hole-type injectors. When the high-pressure fuel
reaches the injector, the pressure lifts the needle valve against the spring tension to allow fuel to enter the combustion
chamber.
Any leakage past the needle valve enters the fuel drain manifold. The manifold routes leakage from the injectors to the
fuel filter head. Fuel from the injection pump vent fitting is returned to the supply tank through the fuel return line.

Fuel System

4
3

a0

--

Fuel from Supply Tank


Pm-Filter or Screen
Fuel Transfer Pump
Fuel/Water Separator
Fuel Filter
Low Pressure Supply Line
Turbo Boost Control Line
Robert Bosch PES.MW
lnjectlon Pump
9. Robert Bosch PES.A
Injection Pump
10. Robert Bosch PES.P
Injection Pump
11. Fuel Drain Manifold
12. High Pressure Fuel Lines
13. Robert Bosch, 17mm ClosedNozzle, Hole Type Injectors
14. Fuel Return to Supply Tank
1.
2.
3.
4.
5.
6.
7.
6.

Section 5 - Fuel System


Page 5-4

Fuel System Specifications


Fuel transfer pump maximum inlet restriction
. . . .

. . 100 mm Hg [4 in Hg]

High flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . .

172 kPa [25 psi]

Lowflow

. . . .

. . . . .

83 kPa 112 psi]

6D114E-1, S6D114E-1, SAGD114E-1& SAAGD114E-1 . . . . . . . . . . . . . . . . . . .


Fuel transfer pump output pressure (minimum) at rated speed

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

Minimum pressure to fuel pump inlet (all in-line)


High flow ...........................................................

Lowflow

1.2 Bar 118 psi]

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

138 kPa [20 psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 kPa [7 psi]

Fuel filter restriction (maximum pressure drop across filters)


Fuel return restriction (maximum)

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

35 kPa [5 psi]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in Hg]

Section 5 - Fuel System


Page 5-5

Fuel System - Service Tools

The following special tools are recommended to perform procedures in Section 05. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.

Tnnl

Nn

Tnnl
..

fbar4ntinn
..P....

Used to test injection nozzles.

Used to clean injector nozzles.

Engine Barring Tool


Used to rotate the crankshaft.

Used to clean carbon from injector bores.

Fuel Pump Gear Puller


Used to pull the fuel pump gear.

Tnnl
.ww.

llhmtratinn
.
........

Section 5 - Fuel System


Page 5-8
Tool No.

Tool DescriDtion
Injector Puller
Used to pull injectors.

3823276

Wrench, Crowfoot
Used to torque high pressure fuel lines.

3823425

Tool Illustration

Section 5 - Fuel System

Fuel System Diagnosing - Malfunctions


(5-01)
The function of the fuel system is to inject a metered
quantity of clean, atomized fuel into the engine cylinders at a
precise time near the end of the compression stroke of each
piston. The components of the system contribute to the
delivery of fuel to the cylinders.
1. Fuel injection pump
2. High pressure fuel lines

Fuel Transfer Pump


The system design requires an inlet pressure of 131 to 172
kPa [19 to 25 psi] to the fuel injection pump.
The fuel transfer pump capacity is designed to deliver
pressure in excess of 138 kPa [20 psi]. The pressure relief
valve controls the inlet to the pump by dumping excess fuel
back to the supply tank.
1.
2.
3.
4.
5.
6.

Fuel injection pump


Fuel supply line
Fuel filter
Fuel transfer pump
Fuel tank
Pressure relief valve

The fuel transfer pump is mechanically driven by a plunger


running against a special lobe on the camshaft. The fuel
transfer pump contains a pumping piston and check valves
to control the flow of fuel, and bleed back during engine
shutdown.
Check valves A, B, C.
1.
2.
3.
4.

Low pressure supply line


Priming pump
Fuel inlet line
Piston

Caution: Make sure the wire to the fuel solenoid is


disconnected before performing the following check.
Residual fuel in the fuel injection pump may allow the
engine to start.
1.
;:

Synchro-start
Trombetta
Direct link, cylinder block mount

Section 5 - Fuel System


Page 8-8
To determine if the fuel transfer pump is delivering the correct
amount of fuel.

FUEL TRANSFER PUMPS

Measure the engine cranking RPM with a tachometer.

Measure the fuel transfer pump output for a 30 second


cranking cycle.

Use the data and the following charts to check the fuel
transfer pump performance.

(HIGH FLOW)

ml

FuelTransfer Pump
High Flow

Fuel Transfer Pump (High Flow)

[=I

Use the chart given in the illustration to find the correct flow
volume specification for the High Flow fuel transfer pump used
with the Robert Bosch PESGP (P7100) fuel injection pump.
Draw a straight vertical line above the measured
cranking RPM.
Draw a straight horizontal line from the measured flow
volume to the intersection point.
Any intersection point above the required flow line
indicates an acceptable flow.
Any intersection point below the required flow line
indicates unacceptable flow and a defective pump or
too much line restriction.

175

zoo

225

2sa

275

Engins Cmnklng Speed (RPM)


TRo117

Example 1

Engine cranking speed 210 RPM

Good Pump

Flow Volume

Example 2

Engine cranking speed 260 RPM

Bad Pump

Flow volume

360 ml [12.9 oz]

370 ml [12.5 oz]

Section 5 - Fuel System

Page 5-9

Fuel Transfer Pump (Low Flow)


Use the chart given in the illustration to find the correct flow
volume specification for the fuel transfer pump used with the
Robert Bosch PESGAand MW fuel injection pump.
l

Draw a straight
cranking RPM.

vertical

line above the measured

Draw a straight horizontal line from the measured flow


volume to the engine cranking RPM vertical line to find
the intersection point.

Any intersection point above the required flow line


indicates an acceptable flow.

Any intersection point below the required flow line


indicates an unacceptable flow and a defective pump
or too much restriction.

Example 1
Good Pump

Engine cranking speed 190 RPM


320 ml [lo.8 oz]
Flow volume

Example 2
Bad Pump

Engine cranking speed 260 RPM


290 ml [9.8 oz]
Flow volume

250
175

200

a5

250

275

Englna Cranking Speed (RPM)


TRO118

A quick check to determine if the fuel transfer pump is


delivering fuel is to measure the output pressure.

0a9

Fuel Transfer Pump Output


at Rated Speed
psi

kPa
172
83

MIN
(High Flow)

25

MIN

12

(Low Flow)

If the required volume is being delivered, look for a


restriction between the fuel transfer pump and the fuel
injection pump.
1. Supply line to filter
2. Filter
3. Supply line to fuel injection pump
If the required volume is not being delivered, measure the
transfer pump inlet restriction with a vacuum gauge between
the transfer pump inlet and the supply line from the tank.
Refer to the fuel system specification for inlet restriction.
4.

Inlet to transfer pump from supply tank.

0a3

Section 5 - Fuel System


Page 5-10
The pressure drop across the filter will increase as the filter
removes contamination from the fuel. Therefore, a worn fuel
transfer pump will have reduced capacity to force fuel through
a dirty filter. This can cause low engine power.
Frequent fitter replacement to get full power from the engine
can indicate a worn fuel transfer pump.

If the fuel is aerated or the volume is low, isolate the fuel


transfer pump by connecting the fuel transfer pump inlet to a
temporary supply and perform the same check as above.

If the fuel transfer pump delivers the required volume of fuel


from a temporary supply, check for restrictions or suction leaks
in the fuel circuit to the fuel transfer pump:
1. Supply line
2. Pre-filter
3. Supply line
4. Supply tank
5. Tank vent

a3

TRO124

Look for a plugged supply tank vent first.

Section 5 - Fuel System


Page 511
Replace or clean the pre-filter.
In cold weather look for gelled fuel blocking the pre-filter.

Look for kinks that can restrict the supply lines.


Remove and blow out supply lines.

Air in the Fuel System


The pressure relief valve arrangement in the supply side of
the fuel circuit creates a self-bleeding system on the PESGA
fuel injection pump for air introduced during replacement of
the supply side components.
Small amounts of air can be bled from the fuel injection
pump by operating the hand primer on the fuel transfer
pump or by cranking the engine.

NOTE: PESGMW fuel injection pumps without the fuel drain


arrangement on the engine side will require additional venting
prior to initial start up, fuel injection pump replacement, or if
the engine has been allowed to run out of fuel. Refer to
Procedure 5-10 for the discussion.

Section 5 - Fuel System


Page 512
The PESGMWand PESGPfuel injection pumps equipped with
engine side fuel drain arrangement creates a self-bleeding
system for air introduced during replacement of the supply side
components.
Small amounts of air can be bled from the pump by operating
the hand primer on the fuel transfer pump or by cranking the
engine.

Air from uncorrected leaks in the supply circuit will make the
engine: difficult to start, run rough, misfire, produce low power,
and can cause excessive smoke and a fuel knock.

a3

A source, which is often overlooked, for air to enter the fuel


system is between the inlet of the pre-filter and the suction tube
in the tank. Fuel tanks that have the outlet fiiing at the top will
have a suction tube that extends to the bottom of the tank.
Cracks or pin holes in the weld that joins the tube to the fiiing
can let air enter the fuel system.

Since the fuel transfer pump provides a positive pressure


the fuel filter and supply line to the fuel injection pump,
loose connections or defective seals should show as a fuel
leak.

689 through

Section 5 - Fuel System


Page 5-l 3

Fuel Water Separator/Filter Unit


Filtration and separation of water from the fuel is important
for trouble-free operation and long life of the fuel system.
Some of the clearances between the fuel injection pump
parts are very close. For this reason the parts can easily be
damaged by rust formation, contaminants, or loss of the
lubricating film of fuel.
Be sure to use the correct element.

The element has a valve which must be opened daily to


drain the collected water.

A dual water separator/filter adapter provides additional


filtering capacity. The fuel flows through the adapter to a
larger combination fuel water separator filter, and back to the
fuel filter for final filtering.

Regular maintenance, including draining moisture from the


fuel water separator/filter and supply tanks, is essential to
keep water out of the fuel.

Section 5 - Fuel System


Page S-14

Fuel Injection Pump


The fuel injection pump performs the three basic functions of:
1. Producing the high fuel pressure required for injection.
2. Metering the exact amount of fuel for each injection cycle.
3. Distributing the high pressure, metered fuel to each
cylinder at the precise time.

Individual plungers are used in the fuel injection pumps to


develop and distribute the high pressure required for injection.
A worn or damaged plunger in the fuel injection pump will
affect only one cylinder.

Governor Malfunctions
Balance between the flyweight governor and the control lever
position controls the metering of the amount of fuel to be
injected.
The fuel injection pump governor performance and setting can
affect engine power. Special equipment and qualified personnel
are required to verify governor performance. If the seals are
broken on the external adjustment screw, the fuel rate may be
out of adjustment.

Air Fuel Control (AFC) Malfunctions

Caution: The AFC is a performance part and must not be


tampered with after adjustment at the factory. Tampering
with the AFC could cause poor fuel economy and failure to
meet regulatory emissions laws.
The RQV and RQVK governors are equipped with an air fuel
control (AFC) device to help control emissions. The AFC
regulates the fuel to air mixture by sensing manifold pressure.
A malfunction of the AFC can cause low power and excessive
exhaust smoke under load. Leaks at the fittings or a restriction
in the tube from the intake manifold to the AFC can also cause
low power and excessive smoke.

Section 5 - Fuel System


Page S-15

Fuel Control Lever Travel and Adjustment


The amount of fuel injected and subsequently the speed and
power from the engine is controlled by the fuel control lever.
Restricted travel of the fuel control lever can cause low
power. Always check for full travel of the fuel control lever
when diagnosing a low power complaint.

Fuel Injection Pump Idle Adjustment Screws


The idle speed adjustment screw provides a stop for the fuel
control lever at low speed. The idle adjustment screw can be
used to increase idle speed for accessory loading or, if
required, to lower the idle speed.
The high speed adjustment screw is set at the factory and
can only be adjusted at a certified fuel pump shop.
1.

Idle Screw

2.

High Idle Screw

Manual Shut Down Levers


The mechanical shut down lever (1) is located on the
governor. These levers are spring-loaded in the run position.
Not all applications will use these manual shut down controls
and there will be no cable or rod connected to the lever.
Partial actuation of the mechanical
affect fuel flow and engine power.

shut down lever will

Low power or the inability to stop the engine with the


manual shut down control can be corrected by adjusting the
cable/rod length to permit stop-to-stop lever travel.

0
@

Section 5 - Fuel System


Page 6-16

Electrical Shut Down Devices


Engines using the RSV Governor are equipped with either the
Synchro-Start or Trombetta cylinder block mounted fuel shutoff
solenoid to actuate the shutoff lever. Both 12 VDC and 24 VDC
external fuel shut-off solenoids are available.

Warning: Solenoid surface temperature can exceed 175C


[347F] which can cause serious burns to the skin in event
of contact.
NOTE: Values are taken at 20C [63F] and rated voltage.
Minimum values are for 25 mm [l.OO inch] maximum plunger
travel. As the temperature of the solenoid increases the voltage
and resistance requirements increase, while the amperage
requirements decrease.
The solenoid specifications are as follows:
1. Synchro-Start Cylinder Block Mount

@ii

Voltage

Resistance
Min Ohms

Min Voltage

Battery

Pull-in

Hold-in

Pull-in

Hold-in

Min Amperes
Pull-in

Hold-in

12

7.5

3.0

0.28

19.9

44

0.61

24

15.0

6.0

1.04

79.9

23

0.30

2. Trombetta Cylinder Block Mount


Battery
Voltage

Resistance
Min Ohms

Min Voltage
Pull-in

Hold-in

Pull-in

Hold-in

Min Amperes
Pull-in

Hold-in

12

10

4.5

0.17

13.6

58.8

0.33

24

20

9.0

0.68

50

29.4

0.18

3. Direct Link, Cylinder Block Mount


Battery

Voltage

Resistance
Min Ohms

Min Voltage

Pull-in

Hold-in

Pull-in

Hold-in

Min Amperes

Pull-in

Hold-in

12

5.3

2.8

0.22

11.1

55

1.1

24

10.6

5.6

0.82

41.3

29

0.5

Engines using the Robert Bosch PESGP fuel injection pump


with the RQVK governor are equipped with the Synchro-Start
fuel shutoff solenoid to actuate the shutoff lever. Both 12 VDC
and 24 VDC external fuel shut-off solenoids are available.
The solenoid specifications are as follows:
Synchro-Start Governor Mount
Resistance
Min Ohms

Min Voltage
Battery
Voltage

Pull-in

Hold-in

Pull-in

Hold-in

Min Amperes
Pull-in

Hold-in

12

6.5

4.0

0.22

11.1

55

1.10

24

13.0

8.0

0.82

41.3

29

0.60

Section 5 - Fuel System


Page 5-17
Wiring Guidelines:
Refer to the chart below to find the correct gauge size and
length of continuous wire for the white (pull-in) wire, which
connects to the solenoid wiring. The black (ground) wire
must be the same gauge as the white (pull-in) wire
regardless of its length.
Wire Length
Ft. MAX
cm
0 to 137
0 to 213
0 to 335

Gauge
14
12
10

12v
5
9
14

24V
9
14
23

NOTE: 14 gauge wire is required for the red (hold-in) wire,


which connects to the Run terminal on the ignition switch.

Fuel Injection Pump Timing


Fuel injection pump-to-engine timing is extremely critical. Fuel
injection pump timing that is off by only a few crankshaft
degrees will cause:
1.

Poor performance -- starting and power

2.

Excessive smoke and emissions

3.

Poor fuel economy

4.

Excessive cylinder pressure

The governors have a provision for locking the fuel injection


pump shaft at a position corresponding to top dead center
(TDC) for No. 1 cylinder. New and reconditioned fuel
injection pumps should be received with the shafts locked in
this position.

The engine is equipped with an engine timing pin to locate


TDC for No. 1 cylinder.
If the timing pin is incorrectly located on the gear
housing, the timing procedure will not make sure that the
fuel injection pump is timed correctly.
The timing pin assembly is aligned to the gear housing to
correspond to a hole in the back side of the camshaft gear
when No. 1 cylinder is at TDC. If the gear housing or timing
pin assembly is removed, it will be necessary to relocate it
(refer to Procedure 7-07).

Section 5 - Fuel System

Page 518

High Pressure Fuel Lines


The high pressure fuel lines are designed and manufactured to
deliver fuel at injection pressure to the injectors. The high
pressure pulses will cause the lines to expand and contract
during the injection cycle.
The high pressure lines must be clamped securely and
routed so they do not contact each other or any other
component.

The length, internal size and rigidity of the lines is critical to


smooth engine operation. An attached metal tag is used to
identify each line with a part number.
Do not weld or substitute lines; use only the specified part
number for the engine.

Warning: The pressure of the fuel in the line is sufficient to


penetrate the skin and cause serious bodily harm.
Use cardboard to check for cracks and leaks. With the engine
running, move the cardboard over the fuel lines and look for
fuel spray on the cardboard. Fuel leaks can cause poor engine
performance.

Bleed the air from the high pressure line at the fitting that
connects the injector. Bleed one line at a time until the engine
runs smooth.
If the air cannot be removed, check the fuel injection pump
and supply line for suction leaks.

Section 5 - Fuel System


Page 5-19

Injectors
All engines use Robert Bosch, 17mm closed nozzles,
hole-type injectors. However, the injectors can have different
part numbers for different engine ratings.
Use only the specified injector for the engine, consult the e
appropriate Chassis or Engine Parts Book for injector part
numbers.

During the injection cycle, high pressure from the fuel


injection pump rises to the operating (pop) pressure which
causes the needle valve in the injector to lift. Fuel is then
injected into the cylinder. A shimmed spring is used to force
the needle valve closed as the injection pressure drops
below the pop pressure to seal off the nozzle after injection.
1.

High pressure fuel line

2.

Fuel drain manifold

Failure of the needle valve to lift and close at the correct


time or the needle valve stuck open can cause the engine to
misfire and produce low power. Fuel leaking from the open
nozzle can cause a fuel knock, poor performance, smoke,
poor fuel economy and a rough running engine.
1.

High pressure fuel line

2.

Fuel drain manifold

To find which cylinder is misfiring, operate the engine and


loosen the fuel line nut at one injector and listen for a
change in engine speed.
A drop in engine speed indicates the
delivering fuel to the cylinder.

injector was

Check each cylinder until the malfunctioning injector is found.


Be sure to tighten the fuel line nut before proceeding to
the next injector.

0ai9

Part Numbor

Section 5 - Fuel System


Page 5-20
Remove the malfunctioning injector to test or replace it.
Check for an extra sealing washer on the injector.

Warning: The pressure of the fuel in the line is sufficient to


penetrate the skin and cause serious bodily harm.
If the engine continues to misfire, use cardboard to check for
fuel leaks in the high pressure lines. With the engine running,
move the cardboard over the fuel lines and look for fuel spray
on the cardboard. Fuel leaks can cause poor engine
performance.

Carbon build up in the orifices in the nozzle will also cause low
power from the engine. Remove and check the spray pattern
or replace the injectors.

Fuel Drain Manifold


The fuel system is designed to use fuel to cool and lubricate
the fuel injection pump plungers and injectors. Fuel is
continually vented from the fuel injection pump and a small
amount of fuel leaks by the injector needle valve during
injection. This fuel is returned to the fuel filter head (1) by the
fuel drain manifold (2).

Section 5 - Fuel System


Page 5-21

Low Pressure Fuel Line - Replacement


(502)
Preparatory Step:
Clean debris from fittings.
NOTE: Thoroughly clean all fittings and components before
removal. Make sure that the debris, water steam or cleaning
solution does not reach the inside of the fuel system.

Removal and Installation


14

mm, 17 mm, 20 mm

Disconnect the fuel line from the fuel transfer pump and filter
head. Use two wrenches to disconnect the line from the fuel
transfer pump.
Install the fuel line to the fuel transfer pump and filter head.
Use two wrenches to tighten the connection to the fuel
transfer pump. Do not over torque, fuel leak may occur.
Torque Value:

24 Nom [18 ft-lb]

Fuel Filter Head Adapter - Replacement


(5-03)
Preparatory Steps:
Clean debris.

Removal and Installation


24 mm
Remove the fuel filters.

Remove the retaining nut, fuel filter head adapter and sealing
+
washers.
@
Install in the reverse order of removal.
Torque Value:

32 Nom [24 ft-lb]

Section 5 - Fuel System


Page 5-22

Fuel Transfer Pump - Replacement/


Rebuild (504)
Preparatory Steps:
Clean debris.
Disconnect the fuel lines.

Removal
10 mm

Remove the fuel transfer pump.

Rebuild
20 mm, 26 mm Wrench

Caution: The hand-prime fitting and inlet fitting are spring


loaded. Sudden removal of these two fittings can cause
personal injury.
Secure the fuel transfer pump in a vise, taking care not to
damage the pump housing.
Remove the rubber boot from the hand-prime fitting.
Remove the three illustrated fittings.

Remove all internal components of the fuel transfer pump.


NOTE: Make sure the check valve gaskets are removed from
the inlet fitting.
(A) Outlet Fitting
(B) Inlet Fitting
(C) Hand Primer Fitting

TRO167

Section 5 - Fuel System


Page 523

Cleaning
Thoroughly flush the fuel transfer pump with a cleaning
solution to remove any debris.

Assembly
20 mm, 26 mm Wrench
Assemble the fuel transfer pump with the new components
supplied in the rebuild kii.
1. Check valves
2. Check valve gaskets
3. O-ring seal
4. Outlet fitting/check valve
5. *O-ring seal (25 mm)
6. *O-ring seal (30 mm) or (25 mm)
* O-ring required is determined by the size of the inlet fitting.
Discard unused O-ring.
NOTE: Extreme caustion must be used to make sure the
check valves are installed to open in the direction of the fuel
flow.
Improper installation of the check valves will result in low
power from the engine.

Place the fuel transfer pump in a vise and torque the fittings
to the following values:
(A) Outlet Fiiing

30 Nom 122 ft-lb]

(B) Hand-Prime Fitting

30 Nom [22 ft-lb]

(C) Inlet Fiiing

30 Nom [22 ft-lb]

TR0171

Section 5 - Fuel System

Cleaning Mounting Surface


Clean the mounting surface on the cylinder block.

Installation
10 mm

Install the fuel transfer pump and a new gasket.


Connect the fuel lines.
Torque Value: 24 N*m [18 ft-lb]

Hi h Pressure Fuel Lines - Replacement


(535)
Removal
10 and 17 mm PESGA and PESGMW Fuel injection Pump)
10 and 19 mm I PESGP Fuel Injection Pump)
Clean debris from around the fuel lines.
NOTE: If individual lines are to be replaced, remove the
vibration isolators from the set of lines containing the line to be
replaced.
Disconnect the line(s) from the injectors.

17 mm PESGA and PESGMW Fuel injection Pump)


19 mm I PESGP Fuel Injection Pump)
Disconnect the line(s) from the fuel injection pump.

Section 5 - Fuel System


Page 525
Installation
10 and 17 mm (PES6A and PESGMW Fuel Injection
Pump)
10 and 19 mm (PESGP Fuel Injection Pump)

Loosen the vibration isolator capscrews so the fuel lines can


easily moved.
NOTE: To prevent breakage to the fuel lines, they must be
connected to the injector and fuel injection pump in a free
state without forcing the connecting nuts. Since the fuel
lines are properly sized for specific application, bending
should not be necessary.

Caution: If removed, install the support clamp in the


original position and make sure the lines do not contact
each other or another component.

Install the lines in the reverse order of removal.

Tighten all fittings and mounting hardware.


Torque Value:
1. Line Fittings

30 Nom [22 it-lb]

2. Support Bracket bolts

24 Nom [18 ft-lb]

3. Vibration Isolator Bolts

6 Nom [53 in-lb]

0\
r

Section 5 - Fuel System

Page S-26

Fuel Drain Manifold - Replacement

(506)

Removal and Installation


10 mm
Clean debris from around the fuel drain manifold.
Remove the banjo capscrews from the injectors and fuel filter
head.
Install the fuel drain manifold in the reverse order of removal.
Torque Value:
Filter Head Banjo
Injector Banjo

15 Nom [ll ft-lb]


9 Nom [66 in-lb]

Injector - Replacement (6-07)


Preparatory Steps:
Thoroughly clean around the injectors.
Disconnect the high pressure fuel lines. Refer to Procedure
5-05.
Disconnect the fuel drain manifold. Refer to Procedure 5-06.

Removal
10 and 13 mm, Part No. 3823276 Injector Puller
Remove the injectors.

Cleaning and Inspection


Part No. 3822510 Injection Bore Brush
Clean the injector nozzle bore.
NOTE: If the injector sealing sleeves are melted, it is an
indication the engine has been operating in an overheated
condition. Refer to the troubleshooting Logic Chart for Coolant
Temperature Above Normal.

Section 5 - Fuel System

Installation
Lubricate the sealing lips of the sleeve with anti-seize &
compound. Assemble the injector, sealing sleeve, a new LJ d
copper sealing washer and the holddown clamp.
Use only one washer.
Service Tip: A light coat of clean 15W-40 engine oil between
the washer and injector can help hold the washer in place
during installation.

Install the injector assemble into the injector bore. The


injector leak-off connection must be toward the valve cover.

10 and 13 mm
Install the holddown capscrew.
Torque Value:

24 Nom [18 ft-lb]

10 mm
Install the fuel drain manifold.
Torque Value:

9 Nom [80 in-lb]

NOTE: The banjo connector seal (Siamese washer) must be


installed as shown in the illustration.

Section 5 - Fuel System


Page 8-28
17

mm (PESGA and PESGMW Fuel Injection Pump)

19 mm (PESGP Fuel Injection Pump)


Install the high pressure fuel lines.
Torque Value: 30 Nom [22 ft-lb]

Fuel Shutoff Solenoid - Replacement


(508)
Preparatory Steps:
Label and disconnect the wiring.

RSV Governor Fuel Shutoff Solenoid - Removal


Cylinder Block Mount
10 mm
Remove the two mounting capscrews and remove the solenoid
from the bracket.
1. Synchro-Start
2. Trombetta
3. Direct link

Section 5 - Fuel System

RSV Governor Fuel Shutoff Solenoid Installation


Cylinder Block Mount
10 mm
NOTE: Make sure the acorn nut is tightened to be snug on
the fuel shutoff solenoid shaft (Synchro-Start only).
Install the new fuel shutoff solenoid and connect the wires. ,W&
Make sure the wiring harness on the Trombetta solenoid is as
08
installed in the 6:00 oclock position.
Torque Value: 10 Nom [89 in-lb]
1. Synchro-Start
2. Trombetta
3. Direct Link
Activate the ignition switch and check the plunger travel.
2. Trombetta

1. Synchro-Start
A = 66.6 mm [3.4 in]

A = 91.4 mm [3.6 in]

B = 60.2 mm [2.4 in]

B = 63.5 mm [2.5 in]

049

The plunger must be retracted when the fuel shutoff solenoid


is activated to the RUN position B. The fuel shutoff
solenoid must operate without binding.

Direct Link Solenoid, Cylinder Block Mounted


l

Disconnect the solenoid linkage from the lever.

Activate the ignition switch and check the plunger


travel.

Measure distance B from the center of the ball socket


to the solenoid mounting flange.
B = 117.1 mm [4.61 in]
The plunger must be retracted when the fuel shutoff
solenoid is activated to the RUN position B. The fuel
shutoff solenoid must operate without binding.

RQVK Governor Fuel Shutoff Solenoid Removal and Installation


10 mm

RI

Remove the hitch pin clip, mounting capscrews and the fuel
shutoff solenoid.
Install the new solenoid in reverse order of removal and
connect the wires.
Torque Value:

10 Nom [89 in-lb]

I)

Section 5 - Fuel System


Page 5-30

0@B

Activate the switch and check the plunger travel.


A = 66.9 mm [2&I in]
NOTE: Dimension A is measured from the bottom of the
mounting bracket to the top of the pivot pin.

Fuel Return Overfl w Valve Replacement (5-097


19 mm
Remove the pressure relief valve and copper sealing washers.

Use a small screwdriver to check that the check ball is not


sticking in the high pressure relief valve assembly.
Caution: A sticky check ball will result in engine low power.

TRo194

Thoroughly flush the high pressure relief valve with cleaning


solution.

TRo195

Section 5 - Fuel System

10 mm, 19 mm
Install the high pressure relief valve assembly in the reverse
order of removal.

AFC Tube - Replacement (5-10)


Removal
17 mm, 13 mm
Remove the AFC tube.

Installation
17 mm, 13 mm
Use new copper washers for the banjo fitting.
Install the AFC tube.
Torque Value:
Banjo Fitting

24 Nom 118 ft-lb]

Threaded Piiing

8 Nom [71 in-lb]

Fuel Injection Pump - Replacement (5-11)


Preparatory Steps:
Clean debris.
Remove all fuel lines. Refer to Procedures 5-05 and 5-66.
Remove control linkage.
Remove fuel shutoff solenoid. Refer to Procedure 5-08.

Page S-31

Section 5 - Fuel System


Page 6-32

RI

Removal
Part No. 3377371 Barring Tool
Locate TDC for No. 1 cylinder. Push the TDC pin into the hole
in the camshaft gear while slowly rotating the crankshaft.

NOTE: Be sure to disengage the pin after locating TDC.

22 mm PESGA Fuel Injection Pump)


27 mm PESGMW Fuel Injection Pump)
30 mm I PESGP Fuel Injection Pump)
RI

Remove the gear cover access cap.


Remove the nut and washer from the fuel injection

RI

Part No. 3824469 Fuel Pump Gear Puller

RI

13 mm

Pull the fuel injection

pump shaft.

pump drive gear loose from the shaft.

Engines equipped with the PESGP fuel


support brackets must be removed.

injection

pump

the

Section 5 - Fuel System

15 mm

Remove the four mounting nuts.


Remove the fuel injection pump.

Installation
Make sure the engine has No. 1 cylinder at TDC.

The fuel injection pump also has a timing pin (1) located in
the governor housing, to position the fuel injection pump
shaft to correspond with TDC for No. 1 cylinder. The timing
pin is to be reversed and stored in the housing (2) after the
fuel injection pump is installed.

24 mm
Remove the access plug.

Page 5-33

Section 5 - Fuel System


Page S-34
,

Remove the timing pin.

If the timing tooth is not aligned with the timing pin hole, rotate
the fuel injection pump shaft until the timing tooth aligns.

Reverse the position of the timing pin so the slot of the timing
pin will fit over the timing tooth in the fuel injection pump.
NOTE: PES.P fuel injection pump o-ring is located in the gear
housing.

-:

Install and secure the timing pin with the access plug.

Section 5 - Fuel System


Page S-35
Make sure the o-ring seals for the fill orifice and pilot are
correctly installed and are not damaged.
Lubricate the mounting flange with clean engine oil.
NOTE: The fuel pump drive gear inside diameter and the
shaft outside diameter must be clean and dry before
installing the gear.

Slide the fuel injection pump shaft through the drive gear and
position the fuel injection pump flange onto the mounting
studs.

15 mm and 13 mm
Install the mounting nuts.
Install the support bracket if so equipped.
Torque Value:
Mounting nuts

44 Nom [32 ft-lb]

Support bracket

32 Nom [24 f&lb]

22 mm PESGA Fuel Injection Pump)


27 mm PESGMW Fuel Injection Pump)
30 mm PESGP Fuel Injection Pump)
Install the retaining nut and washer.
Torque Value:

12 Nom [106 in-lb]

NOTE: To prevent damage to the timing pins, do not exceed


the torque value given. This is not the final torque value for
the retaining nut.

04B

Section 5 - Fuel System


Page 6-36
Disengage the engine timing pin.

24 mm
Remove the fuel injection pump timing pin plug. Reverse the
position of the timing pin and install the timing pin, plug, and
the sealing washer.
Torque Value:

15 Nom [ll

ft-lb]

22 mm PESGA Fuel Injection Pump)


27 mm PESGMW Fuel Injection Pump)
30 mm PESGP Fuel Injection Pump)
Tighten the fuel injection pump drive gear nut.
Torque Value:
PESGA Fuel Injection Pump
PESGMWFuel Injection Pump
PESGP Fuel Injection Pump

92 Nom [ 68 ft-lb]
104 Nom [ 77 ft-lb]
166 Nom [122 ft-lb]

Install the gear cover access cap hand tight.

Install the fuel lines and control linkage.


Torque Value:
1. High Pressure Fuel Lines

30 Nom [22 ft-lb]

2. Pressure Relief Valve Fitting

32 Nom [24 ft-lb]

3. Low Pressure Fuel Supply Fitting

32 Nom [24 ft-lb]

Section 5 - Fuel System

Caution: The governor housing must be prelubricated


before engine operation. Failure to do so will result in
premature governor wear.
10 mm hex drive
Remove the access plug.

RI

clean engine oil:

Install the access plug.


Torque Value:

28 Nom [21 ft-lb]

0(K

The PESGMW fuel injection pump not equipped with engine


side fuel return option must be vented after installation.
Loosen the vent screw located near the front on the side
nearest to the engine. Place the fuel control in the RUN
position. Crank the engine so air can bleed from the fuel
injection pump. Then, tighten the vent screw.
NOTE: Earlier PESGMW fuel injection pumps were not
equipped with a vent screw. Remove the large plug from the
location described above to vent the fuel injection pump.
PESGA fuel injection pumps are self venting. All PESGP
pumps were assembled with the engine side vent option.

17 mm (PES6A and PESGMW Fuel Injection Pump)


19 mm (PESGP Fuel Injection Pump)

E2l

Warning: The pressure of the fuel in the high pressure


line is sufficient to penetrate the skin and cause serious A
bodily harm.
Vent the high pressure fuel lines. Loosen the fitting at the
No. 1 injector. Place the fuel control in the RUN position.
Crank the engine so air can bleed from the fuel lines, then
tighten the fiiing.
Torque Value:

30 Nom [22 f&lb]

0(K

Warning: The pressure of the fuel in the line is sufficient


to penetrate the skin and cause serious bodily harm.
A
Vent each high pressure line separately until the engine runs
smoothly.

Section 5 - Fuel System


Page S-38

Idle Speed - Adjustment (5-12)


Bosch RSV Governor
idle speed adjustment on fuel injection pumps with the RSV
governor requires the setting of both the low idle speed screw
(1) and the bumper spring screw (2).

1-

19 mm, Screwdriver and Tachometer

l.su

First, loosen the locknut and back out the bumper spring screw
until there is no change in engine speed.

BJ
%
0

13 mm, Screwdriver and Tachometer


Loosen the locknut and adjust the idle speed screw to 20 to 30
RPM less than the desired speed. Turn the idle speed screw
counterclockwise to decrease RPM; clockwise to increase
RPM. Tighten the locknut.
Torque Value: 8 Nom 172 in-lb]

19 mm, Screwdriver and Tachometer


Turn the bumper spring screw clockwise until the desired idle
speed is obtained. Tighten the locknut.
Torque Value: 8 Nom 172 in-lb]

Section 5 - Fuel System


Page S-39

Bosch RQVK Governor


8 and 10 mm, Screwdriver and Tachometer
Idle speed adjustment on fuel injection pumps with the RQVK
governor require setting of the stop screw.
Loosen

the

locknut

and

turn

the

idle

speed

screw

counterclockwise to raise the RPM; clockwise to decrease


the idle speed. Tighten the locknut.

lqliqe Fuel Injection Pump Spill-Port


Tlmlng (5-I 3)
Use the No. 1 intake valve to make sure the engine is at top
dead center (TDC) on the compression
stroke for cylinder
No. 1. Refer to procedure 7-07.

Fabricate
This can
tightened
the wire
point for

a timing mark pointer for the front of the engine.


be done by forming a piece of wire that can be
under one of the gear cover capscrews. Sharpen
at the vibration damper end so that it comes to a
better accuracy.

Attach a degree wheel


vibration damper.

or degree

tape to the front

of the

Line the TDC mark up with the pointer.


The degree wheel/tape
least one degree.

should

measure to an accuracy

of at

Section 5 - Fuel System


Page 540
Install the fuel injection pump per the procedures for a new fuel
injection pump installation. If the fuel injection pump is already
installed, continue the procedures.

c
:_

Remove the No. 1 high pressure fuel line from the fuel injection
pump.
NOTE: Lines 2 through 6 must not be removed or loosened.

Caution: When attaching the fabricated tube, do not bend


the No. 1 high pressure fuel line. This could cause the
inside of the fuel line to flake and cause injector failure.
A short length of high pressure line that is compatible with the
fuel lines used on the engine should be bent in a U shape
and installed onto the delivery valve holder of the fuel injection
pump. The line is used to observe when the fuel is or is not
flowing through the delivery valve holder assembly. Place a
container under the tube to catch the fuel or drain the fuel
back into the spill port pump.

Remove the overflow valve from the fuel injection pump.


Install a 14 mm threaded plug and sealing washer into the fuel
port of the fuel injection pump.
NOTE: The fuel return port is located on the inboard front side
of the fuel injection pump for automotive inline application and
on the out board front side for most of the industrial
applications.

Section 5 - Fuel System


Page 5-41
Remove the supply line from the fuel filter head to the fuel
injection pump.
Attach the high pressure outlet hose from the spill port to the
fuel injection pump supply port.

Before continuing, make sure the fuel injection pump locktiming pin is disengaged.

Rotate the crankshaft counterclockwise, as viewed from the


front of the engine, to approximately 40 degrees before TDC.

Governor Lever Positioning


Caution: The governor lever must be positioned before
pressurizing the fuel injection pump.
The RQV governor throttle lever must be in the low idle lever
position.
The RQV-K governor throttle lever must be in the high idle
throttle position.

Section 5 - Fuel System


Page S-42
Both the RQV and RQV-K governor require the shut down lever
to be in the full run position.

The RSV governor throttle lever must be in the low idle position
and the shutdown lever needs to be wired or locked in a
suitable fashion to hold the shutdown lever in the l/2 travel
position.

Turn on the spill timing cart pump.


Check the fuel pressure.
The Pressure must be between 300 psi and 370 psi.

The fuel should be Rowing out of the tube attached to the No.
1 cylinder of the fuel injection pump. If the fuel is not flowing,
recheck the procedures carefully.

Section 5 - Fuel System


Page 543
Slowly rotate the crankshaft in the clockwise direction, as
viewed from the front of the engine, until the fuel flow from
the No. 1 cylinder begins.

0a9

The No. 1 plunger element is now approaching port


closure. Continue to rotate the crankshaft slowly until the
flow is reduced to a fast drip (more than one drip per
second). At the point where the steady stream of flow
changes from a solid flow to a fast drip, stop. This is the
static timing position of the fuel injection pump.

If the flow does not slow down to a drip, check the governor
position. Also make sure that the engine is before TDC on
the compression stroke. Turn off the spill port pump.

Check the degree wheel on the vibration damper to see what


engine degree the timing pointer is indicating. This is spill
port static timing. Compare this number to be the timing
specification for your particular application.

If the fuel injection pump static timing, as measured by the


above method, does not agree with the specifications you
have been given, remove the large nut that fastens the fuel
injection pump camshaft to the fuel pump drive gear. If the
crankshaft has rotated, turn on the spill port pump and rotate
the crankshaft to find port closure.
Turn off the spill port pump.

0@

0a9

Section 5 - Fuel System


Page S-44
Use a gear puller tool, pull the fuel injection pump drive gear
from the fuel injection pump camshaft taper.

TRo24a

Slowly rotate the crankshaft counterclockwise about 40 degrees


past the desired static timing specification. Slowly rotate the
crankshaft in the clockwise direction until the timing pointer is
indicating the desired static timing.

Tighten the fuel injection pump drive nut.


Make sure the static timing has not changed after the fuel
injection drive nut is torqued to the required specification.
Torque Value:
PESGA Fuel Injection Pump
PESGMWFuel Injection Pump
PESGPFuel Injection Pump

92 Nom [66 ft-lb]


104 Nom [77 ft-lb]
165 N*m [122 ft-lb]

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