Professional Documents
Culture Documents
January 2005
Systems Operation
Testing and Adjusting
400 Engine
HB11-Up (Machine)
HD11-Up (Machine)
HH11-Up (Machine)
HL11-Up (Machine)
HN11-Up (Machine)
HP11-Up (Machine)
HR11-Up (Machine)
i01658146
Lubrication System
Engine Oil Pressure - Test .................................... 43
Engine Oil Pump - Inspect .................................... 43
Excessive Bearing Wear - Inspect ........................ 44
Excessive Engine Oil Consumption - Inspect ....... 45
Cooling System
Cooling System - Check (Overheating) ................ 46
Cooling System - Inspect ...................................... 47
Cooling System - Test ........................................... 47
Water Temperature Regulator - Test ..................... 49
Water Pump - Inspect ........................................... 50
Basic Engine
Piston Ring Groove - Inspect ................................ 51
Connecting Rod - Inspect ..................................... 51
Connecting Rod Bearings - Inspect ...................... 52
Main Bearings - Inspect ........................................ 52
Cylinder Block - Inspect ........................................ 52
Cylinder Head - Inspect ........................................ 53
Piston Height - Inspect .......................................... 54
Flywheel - Inspect ................................................. 55
Gear Group - Inspect ............................................ 56
Electrical System
Alternator - Test .................................................... 57
Battery - Test ......................................................... 58
Belt Tension Chart ................................................ 58
4 SENR9972
Systems Operation Section
Systems Operation Section The front of the engine is opposite the flywheel end
of the engine. The left side and the right side of
the engine are determined from the flywheel end.
i02180281 Number 1 cylinder is the front cylinder of the engine.
402C-05 Engine
g00852304
Illustration 2
Cylinder and valve location
(A) Exhaust valve
g01111232 (B) Inlet valve
Illustration 1
Cylinder and valve location Bore ............................................. 67 mm (2.64 inch)
(A) Exhaust valve
(B) Inlet valve Stroke .......................................... 72 mm (2.83 inch)
Bore ............................................. 67 mm (2.64 inch) Displacement ................................. 0.762 L (46.5 in3)
Stroke .......................................... 72 mm (2.83 inch) Cylinder arrangement ..................................... In-line
Displacement ............................... 0.507 L (30.94 in3) Type of combustion ......................... Indirect injection
Cylinder arrangement ..................................... In-line Compression ratio ........................................... 23.5:1
Type of combustion ......................... Indirect injection Number of cylinders ................................................ 3
The front of the engine is opposite the flywheel end 403C-15 Engine
of the engine. The left side and the right side of
the engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine.
403C-11 Engine
g00852304
Illustration 4
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
Illustration 3
g00852304 Bore ............................................. 84 mm (3.31 inch)
Cylinder and valve location
Stroke .......................................... 90 mm (3.54 inch)
(A) Exhaust valve
(B) Inlet valve
Displacement .................................... 1.496 L (91 in3)
Bore ............................................. 77 mm (3.03 inch)
Cylinder arrangement ..................................... In-line
Stroke .......................................... 81 mm (3.19 inch)
Type of combustion ......................... Indirect injection
Displacement .................................... 1.131 L (69 in ) 3
g00296424 g00296424
Illustration 5 Illustration 6
Cylinder and valve location Cylinder and valve location
(A) Exhaust valve (A) Exhaust valve
(B) Inlet valve (B) Inlet valve
Displacement .................................... 1.508 L (92 in3) Displacement ............................... 2.216 L (135.2 in3)
Type of combustion ......................... Indirect injection Type of combustion ......................... Indirect injection
When the crankshaft is viewed from the front of When the crankshaft is viewed from the front of
the engine, the crankshaft rotates in the following the engine, the crankshaft rotates in the following
direction. ................................................... Clockwise direction. ................................................... Clockwise
When the camshaft is viewed from the front of When the camshaft is viewed from the front of
the engine, the camshaft rotates in the following the engine, the camshaft rotates in the following
direction. ................................................... Clockwise direction. ................................................... Clockwise
The front of the engine is opposite the flywheel end The front of the engine is opposite the flywheel end
of the engine. The left side and the right side of of the engine. The left side and the right side of
the engine are determined from the flywheel end. the engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine. Number 1 cylinder is the front cylinder of the engine.
SENR9972 7
Systems Operation Section
It is important to ensure the correct piston height so When you are lifting or moving the engine, use the
that the piston does not contact the cylinder head. following procedures in order to prevent engine
The correct piston height also ensures the efficient damage.
combustion of fuel which is necessary in order to
conform to requirements for emissions. 1. Do not tilt the engine to an extreme angle unless
the lubricating oil is first drained from the oil pan.
The crankshaft for the 402C-05 engine has two main
bearing journals. The crankshaft for the 403C-07, 2. Do not turn the engine onto a side or an end
403C-11 and 403C-15 engines have four main surface unless the lubricating oil is first drained
bearing journals. The crankshaft for the 404C-15, from the oil pan.
404C-22 and 404C-22T engines have five main
bearing journals. End play for all the engines is 3. If the oil is not drained prior to tilting the engine or
controlled by the thrust washers that are located on turning the engine onto a side or an end surface,
the rear main bearing. The 403C-11 and 404C-15 the lubricating oil from the oil pan can flow into the
engines have aluminium bearing caps on the rear inlet manifold and the cylinder bores. This situation
main bearing that act as thrust washers. could cause a hydraulic lock in the engine.
Hydraulic lock can severely damage the engine.
The timing gears are stamped with timing marks
in order to ensure the correct alignment of the 4. The engine oil should be refilled to the correct
gears during assembly. When the No. 1 piston is at level before the engine is started.
top center compression stroke, the teeth that are
stamped on the crankshaft gear and the camshaft
gear will be in alignment with the idler gear. Engine Model Views
The crankshaft gear turns the idler gear which then The following model views show typical features of
turns the camshaft gear. the 402C-05, 403C-07, 403C-11, 403C-15, 404C-15
and 404C-22/404C-22T Engines. Due to individual
The fuel injection pump and the fuel priming pump applications, your engine may appear different from
are mounted on the cylinder block. Both pumps are the illustrations.
operated by the camshaft lobes.
Note: Individual components are detailed on the
The fuel injection pump conforms to requirements for 404C-22T turbocharged engine only.
emissions. Adjustments to the fuel injection pump
timing and high idle should only be made by trained
personnel. The fuel injection pumps have mechanical
governors that control the engine rpm.
8 SENR9972
Systems Operation Section
g01109207
Illustration 7
Typical view of the 402C-05 Engine
g01109212
Illustration 8
Typical view of the 403C-11 Engine
SENR9972 9
Systems Operation Section
g01097209
Illustration 9
Left side view of the 404C-22T engine
(1) Engine oil filler cap (7) Exhaust manifold (13) Engine oil drain plug
(2) Coolant temperature switch (8) Turbocharger (14) Engine oil pan
(3) Crankcase breather (9) Starting motor solenoid (15) Crankshaft pulley
(4) Valve mechanism cover (10) Electric starting motor (16) Cover plate for the accessory drive
(5) Lifting eye (11) Alternator (17) Cooling fan
(6) Water temperature regulator housing (12) Fan drive belt (18) Water pump
10 SENR9972
Systems Operation Section
g01097214
Illustration 10
Right side view of the 404C-22T engine
(19) Fuel injector (24) Fuel injection pump (29) Flywheel
(20) Fuel return line (25) Fuel control lever (30) Flywheel housing
(21) Lifting eye (26) Engine oil level gauge (31) Fuel priming pump
(22) Fuel injection lines (27) Engine oil filter (32) Fuel shutoff solenoid
(23) Mechanical fuel shutoff (28) Engine oil cooler (33) Air inlet elbow
i02180872
Fuel System
g01103741
Illustration 11
Typical example
(1) Fuel tank (4) Fuel filter (7) Fuel return line from the fuel injection
(2) Hand primer (5) Fuel injection pump pump and the fuel injectors to the fuel
(3) Fuel priming pump (6) Fuel injectors tank
When the engine is cranking, the fuel is pulled from The fuel injection pump sends fuel at high pressure
the fuel tank (1) by the fuel priming pump (3). The to each fuel injector (6). The fuel injector sprays fuel
fuel priming pump forces the fuel through the fuel into a precombustion chamber which slows the rate
filter (4) to the fuel injection pump (5). of combustion in the cylinder. The following items
will result from reducing the rate of fuel combustion:
The fuel filter (4) also functions as a water separator. prevention of engine knock, reduction of noise, and
The fuel filter can be drained through a valve that is reduction of emissions.
located at the bottom of the filter housing.
12 SENR9972
Systems Operation Section
Governor
The fuel rack is connected to the linkage, which
controls the fuel injection pump. This linkage is
located in the timing case.
Excess fuel from the fuel injectors and the fuel g00822233
injection pump flows through the fuel return line (7) Illustration 13
and back to the fuel tank (1). The excess fuel aids the Governor control mechanism in the timing gear case
cooling of the fuel injectors. Also, the fuel return line (1) Connection for the linkage to the fuel injection pump
removes any air that is trapped in the fuel injectors (2) Mechanical stop control
and the fuel injection pump. (3) Lever return spring
(4) Control lever
(5) Start spring
The fuel injection pump needs fuel for lubrication. If (6) Arm
the precision parts of the pump are not adequately (7) Governor adjustment screw
lubricated, the components may be easily damaged.
The engine must not be started until the fuel injection The movement of the governor weight assembly
pump is full of fuel that is free of air. is transferred to the fuel rack on the fuel injection
pump by the control lever (4), the arm (6) and the
The system must be primed when any part of the linkage to the fuel injection pump. A spring connects
system is drained of fuel. The following list contains the arm and the control lever. This spring controls
examples of both service and repairs when you must the movement of the governor weight assembly on
prime the system: the camshaft. When the angle of the control lever
changes, tension on the spring changes. This action
• The fuel filter is changed. controls the linkage to the fuel rack on the fuel
injection pump, which controls the engine rpm.
• The low pressure fuel line is removed.
The maximum speed adjustment screw is mounted
• The fuel injection pump is removed. in the cylinder block. This adjustment limits the
movement of the arm (6). This adjustment should
• The fuel injectors are removed. only be made by personnel with the correct training.
• The fuel tank is drained. The maximum fuel adjustment screw is mounted in
the cylinder block. This adjustment regulates the fuel
• A leak exists in the low pressure side of the fuel injection at high engine rpm. This adjustment should
system. only be made by personnel with the correct training.
SENR9972 13
Systems Operation Section
A spring connects the linkage to the fuel injection The fuel injection pump is a pressurized system
pump and the mechanical stop control (2). When that is totally enclosed. The pump sends the correct
the engine is first started, the spring automatically amount of fuel under high pressure at the correct
increases the fuel flow to the cylinders. time through the fuel injectors to the individual
cylinders. The fuel injection occurs near the end
The fuel injection pump timing, the low idle, and the of the compression stroke. The fuel injection pump
high idle are preset at the factory. Adjustments to the regulates the amount of fuel that is delivered to the
pump timing and idle rpm should only be made by fuel injectors. This action controls the engine rpm by
personnel which have had the correct training. The the governor setting or the position of the throttle
timing for the fuel injection pump should only change control.
if the camshaft or the cylinder block are replaced.
The fuel injection pump timing should not change if The camshaft is driven by the idler gear in the timing
the fuel injection pump is reinstalled with a shim that case. Lobes on the camshaft cause the pushrod
is the same size. for each cylinder to reciprocate. The reciprocating
motion first draws the fuel. The reciprocating motion
The fuel rack automatically returns to the excess fuel then pressurizes the fuel. A fuel delivery valve (2)
position when the engine is stopped. The excess fuel for each cylinder acts as a check valve in order to
position aids the cold starting of the engine. prevent a loss of pressure to the fuel injector.
Fuel Injection Pump The correct operation of the fuel injection pump
requires the pump to be completely full of fuel and
empty of air. When the vent screw (5) is loosened, air
can escape from the fuel injection pump.
Fuel Injectors
g00746909
Illustration 14
Fuel injection pump (typical example) g00836660
Illustration 15
(1) Fuel line to the fuel injectors (1) Fuel injector
(2) Fuel delivery valve (2) Gasket
(3) Nuts and setscrews for mounting the fuel injection pump to
the cylinder block
(4) Shim The sealing washer (2) helps to prevent blowby.
(5) Vent screw for the fuel injection pump The sealing washer also sets the projection of the
(6) Fuel flow from the fuel transfer pump fuel injector (1) into the precombustion chamber.
This projection affects the time that is required
The electric fuel shutoff solenoid must be energized for combustion in the cylinder. If the projection is
in order for fuel to flow through the system. excessive, engine knock can occur at high rpm.
The fuel injection pump is a cassette type pump. Note: When a fuel injector (1) is installed in the
The cassette type pump contains the following cylinder head, a new sealing washer (2) should be
components: fuel delivery valves, fuel rack, and installed.
pushrods. The fuel injection pump is installed directly
into the cylinder block. The operating pressure of the fuel injector is set and
tested at the factory. Refer to Specifications, “Fuel
The part number and code letters for the fuel injection Injectors” for the pressure settings of the fuel injector.
pump are stamped on the front of the pump.
14 SENR9972
Systems Operation Section
The valve mechanism cover contains a closed A turbocharger is installed between the exhaust
breather assembly. The gases in the valve cover, and intake manifolds. The turbocharger is driven by
which are caused by blowby, pass from the crankcase exhaust gases which flow through the exhaust inlet
to the inlet manifold. The breather is sealed from the (11). The energy of the exhaust gas turns the turbine
outside air by a diaphragm. Above the diaphragm, wheel (8). Then, the exhaust gas flows out of the
the cover is vented to the outside air by a small vent turbine housing (7) through the exhaust outlet (9).
hole so that pressure does not build up.
The turbine wheel (8) and the compressor wheel (3)
are installed on the same shaft. Therefore, the turbine
Turbocharger wheel (8) and the compressor wheel (3) rotate at the
A turbocharger increases the temperature and the same rpm. The compressor wheel is enclosed by
the compressor housing (2). The compressor wheel
density of the air that is sent to the engine cylinder.
compresses the intake air. The intake air flows into
This condition causes a lower temperature of ignition
to develop earlier in the compression stroke. The the engine cylinders through the inlet valves of the
cylinders.
compression stroke is also timed in a more accurate
way with the fuel injection. Surplus air lowers the
temperature of combustion. This surplus air also The oil from the main gallery of the cylinder block
flows through the oil inlet port (5) in order to
provides internal cooling.
lubricate the turbocharger bearings (4) and (6). The
A turbocharger improves the following aspects of pressurized oil passes through the bearing housing
of the turbocharger. The oil is returned through the oil
engine performance:
outlet port (10) to the oil pan.
• Power output is increased. The turbocharger has a wastegate. The wastegate is
controlled by the boost pressure. This allows some
• Engine torque is increased. of the exhaust gases to bypass the turbine wheel at
higher engine speeds. The wastegate is a type of
• Engine efficiency is increased. flapper valve that automatically opens at a preset
level of boost pressure in order to allow the exhaust
gas to flow around the turbine. The wastegate allows
the design of the turbocharger to be more effective
at lower engine speeds.
g00302786
Illustration 17
Components of a turbocharger (typical example)
(1) Air intake
(2) Compressor housing
(3) Compressor wheel
(4) Bearing
(5) Oil inlet port
(6) Bearing g00905459
(7) Turbine housing Illustration 18
(8) Turbine wheel Cross section of the inlet and exhaust valves in the cylinder head
(9) Exhaust outlet (typical example)
(10) Oil outlet port
(11) Exhaust inlet
16 SENR9972
Systems Operation Section
• Valve springs
The camshaft gear is driven by the idler gear. The
camshaft gear, the idler gear and the crankshaft gear
are timed together. When the camshaft turns, the
valve lifters are moved up and down. The pushrods
move the rocker arm levers. The rocker arm levers
make the inlet valves and the exhaust valves open
and close. This is in sequence with the firing order of
the engine. The valve springs force the valves back
to the closed position.
i02181303
Lubrication System
The valves and the rocker shaft assembly control the • Oil level gauge
flow of air into the cylinders and out of the cylinders
during engine operation. The cylinder head assembly • Oil pressure switch
has two valves for each cylinder. Each valve has one
valve spring (3). The ports for the inlet valve (11) • An oil supply line to the cylinder head
and the exhaust valve (10) are on the left side of the
cylinder head. The oil pump is contained within the idler gear. The
engine oil relief valve is installed in the right side of
The valve moves along a steel valve guide (5). The the cylinder block.
valve guides can be replaced.
The oil filter is a spin-on filter that is disposable.
The inlet valve and the exhaust valve are opened
and closed by the rotation and movement of the
following components:
• Crankshaft
• Idler gear
• Camshaft
• Valve lifters
• Pushrods
• Rocker arms
SENR9972 17
Systems Operation Section
The water pump forces the coolant to flow to the The cylinder block does not have cylinder liners. The
water temperature regulator. When the engine is cold, cylinder walls are honed.
the water temperature regulator is closed. Then, the
coolant flows directly into the cylinder head. When The valve mechanism cover is made from aluminum.
the engine warms, the water temperature regulator The cover contains the following components:
begins to open. Then, the regulator allows some of
the coolant to flow to the top of the radiator. • A closed breather assembly
The regulator opens fully when the engine reaches • An oil filler cap
the normal operating temperature. When the
regulator is fully open, the flow to the radiator is the • A seal for the face toward the cylinder head
maximum. However, the regulator does not close the
flow of coolant into the cylinder head. • Holes for four cap nuts
Coolant flows continuously through the cylinder head • Holes for two setscrews
and the top of the cylinder block. This coolant flows
into the back of the water pump from the cylinder The cap nuts are threaded onto studs. The steel
block. This coolant then mixes with the coolant that is studs are threaded into the cylinder head.
pumped from the radiator by the water pump.
The setscrews are threaded onto the cover for the
The water temperature regulator maintains the rocker shaft assembly.
correct engine temperature by adjusting the direct
flow of coolant to the top of the radiator. The coolant The valve mechanism cover contains a crankcase
is cooled by the radiator. Heat is removed from the breather. The gases in the valve cover, which are
coolant by cooler air which passes over the radiator caused by blowby, pass from the crankcase to the
fins. The fan causes a high volume of air to flow inlet manifold.
between the radiator fins in order to provide sufficient
cooling. The coolant flows from the radiator through
the bottom hose to the coolant pump. Pistons and Connecting Rods
The engine has a housing for the water temperature The pistons of the engine have a combustion
regulator. The housing is installed on the left side of chamber in the crown of the piston in order to provide
the cylinder head. an efficient mix of the fuel and the air.
The water temperature regulator housing for The piston pin is off-center in order to reduce the
the 402C-05 and 403C-07 engines is mounted noise level.
horizontally. The water temperature regulator housing
for all other engine models is mounted vertically. The pistons have two compression rings and an oil
control ring.
SENR9972 19
Systems Operation Section
The correct piston height is important in order to The thrust washers are hemispherical in shape.
ensure that the piston does not contact the cylinder The 403C-11 and 403C-15 engines have two thrust
head. The correct piston height also ensures the washers that are located on both sides of the bottom
efficient combustion of fuel which is necessary in half of holder for the rear main bearing. The 404C-22
order to conform to requirements for emissions. The and 404C-22T engines have a third thrust washer
piston must not be machined in order to obtain the that is located on the rear side of the upper half of
correct piston height. the holder for the rear main bearing.
A piston and connecting rod are matched to each Note: The thrust washers on the 403C-11 and
cylinder. 403C-15 engine are machined into the aluminum
holder for the rear main bearing.
One height of piston is available. The inside of the
piston is marked “Shibaura”. This reference mark The crankshaft has a front oil seal and a rear oil seal.
faces the right side of the engine. Refer to Testing and
Adjusting, “Piston Height - Inspect” for procedures to The timing case is made of aluminum. The timing
measure the piston height. gears are stamped with timing marks in order to
ensure the correct assembly of the gears.
Identification marks on the connecting rod and the
connecting rod cap must align. The identification The number one piston is at the top center position
marks face the right side of the engine. on the compression stroke when the following timing
marks are aligned:
The main bearing caps have a chamfered edge on
one side. The chamfer faces the front of the engine. • Idler gear, crankshaft gear and camshaft gear
Timing Gear Case and Gears • Crankshaft pulley and timing case
The crankshaft gear turns the idler gear which then
The timing gear case contains the following
turns the camshaft gear.
components:
The idler gear contains the oil pump. The idler gear
• Front oil seal for the crankshaft pulley turns the gear for the tachometer.
• Bearing for the crankshaft gear The crankshaft pulley drives the pulley on the water
pump and the pulley which drives the alternator.
• Engine oil pump
• Adjustment screw for setting the maximum fuel
position
i02182150
Electrical System
g00916927
Illustration 21
Typical example
The electrical system has two separate circuits. • Wires for the battery
• Charging circuit The charging circuit is in operation when the engine
is running. An alternator converts mechanical energy
• Starting circuit to electrical energy for the charging circuit. A voltage
regulator in the circuit controls the electrical output in
Some of the electrical system components are used order to keep the battery at full charge.
in more than one circuit. The following items are
common in each of the circuits: NOTICE
The disconnect switch, if equipped, must be in the ON
• Battery position in order to let the electrical system function.
There will be damage to some of the charging circuit
• Circuit breaker components if the engine is running with the discon-
nect switch in the OFF position.
• Cables
SENR9972 21
Systems Operation Section
g00916841
Illustration 22
(1) Warning lamp (alternator) (7) Engine oil pressure switch (13) Glow plugs
(2) Regulator (8) Warning lamp (coolant temperature) (14) Fuel shutoff solenoid
(3) Alternator (9) Coolant temperature switch (15) Automatic shutdown device
(4) Battery (10) Fuse (16) Electrical connector
(5) Electric starting motor (11) Ignition switch (17) Delay fuse
(6) Warning lamp (oil pressure) (12) Signal for glow plugs
22 SENR9972
Systems Operation Section
g00916844
Illustration 23
(1) Warning lamp (alternator) (7) Warning lamp (coolant temperature) (13) Glow plugs
(2) Alternator (8) Coolant temperature switch (14) Fuel shutoff solenoid
(3) Battery (9) Fuse (15) Automatic shutdown device
(4) Electric starting motor (10) Fuse (16) Electrical connector
(5) Warning lamp (oil pressure) (11) Ignition switch (17) Delay fuse
(6) Engine oil pressure switch (12) Signal for glow plug
SENR9972 23
Systems Operation Section
g00916845
Illustration 24
(1) Warning lamp (alternator) (6) Engine oil pressure switch (11) Signal for glow plug
(2) Alternator (7) Warning lamp (coolant temperature) (12) Glow plugs
(3) Battery (8) Coolant temperature switch (13) Fuel shutoff solenoid
(4) Electric starting motor (9) Fuse (14) Automatic shutdown device
(5) Warning lamp (oil pressure) (10) Ignition switch (15) Electrical connector
24 SENR9972
Systems Operation Section
Alternator
g00841411
Illustration 25
Connector for the automatic shutdown device (typical example)
(1) Ignition switch (red wire)
(2) Ignition switch (orange wire)
(3) Fuel shutoff solenoid (red and black wire)
(4) Engine oil pressure switch (brown wire)
(5) Coolant temperature switch (blue wire)
(6) Ground (black wire)
1. Check the fuel level in the fuel tank. Ensure that • Check valves
the vent in the fuel cap is not filled with dirt.
Observe the fuel flow during engine cranking.
2. Check all fuel lines for fuel leakage. The fuel lines Look for air bubbles in the fuel. If there is no fuel
must be free from restrictions and faulty bends. that is present in the sight gauge, prime the fuel
Verify that the fuel return line is not collapsed. system. Refer to Testing and Adjusting, “Fuel
System - Prime” for more information. If the engine
3. Inspect the fuel filter for excessive contamination. starts, check for air in the fuel at varying engine
If necessary, install a new fuel filter. Determine the speeds. When possible, operate the engine under
source of the contamination. Make the necessary the conditions which have been suspect.
repairs.
i02182932
This procedure checks for air in the fuel system. This g00578151
procedure also assists in finding the source of the air. Illustration 31
(1) A steady stream of small bubbles with a diameter of
1. Examine the fuel system for leaks. Ensure that approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
the fuel line fittings are properly tightened. Check (2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
the fuel level in the fuel tank. Air can enter the are also acceptable if there is two seconds to three seconds
fuel system on the suction side between the fuel intervals between bubbles.
priming pump and the fuel tank. (3) Excessive air bubbles in the fuel are not acceptable.
28 SENR9972
Testing and Adjusting Section
g01110251
To avoid personal injury, always wear eye and face Illustration 32
protection when using pressurized air.
1. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
NOTICE Cover - Remove and Install”.
To avoid damage, do not use more than 55 kPa (8 psi)
to pressurize the fuel tank. 2. Remove the glow plugs. Refer to Disassembly
and Assembly, “Glow Plugs - Remove and Install”.
4. Pressurize the fuel tank to 35 kPa (5 psi). Do 3. Rotate the engine crankshaft until the exhaust
not use more than 55 kPa (8 psi) in order to valve for No. 1 cylinder is nearly closed and the
avoid damage to the fuel tank. Check for leaks in inlet valve for No. 1 cylinder is starting to open.
the fuel lines between the fuel tank and the fuel Rotate the crankshaft through approximately 360
priming pump. Repair any leaks that are found. degrees and align the timing mark (2) on the
Check the fuel pressure in order to ensure that crankshaft pulley with the “TOP” mark (1) on the
the fuel transfer pump is operating properly. For timing case.
information about checking the fuel pressure, see
Testing and Adjusting, “Fuel System Pressure - 4. Install the glow plugs. Refer to Disassembly and
Test”. Assembly, “Glow Plugs - Remove and Install”.
5. If the source of the air is not found, disconnect 5. Install the valve mechanism cover. Refer to
the supply line from the fuel tank and connect an Disassembly and Assembly, “Valve Mechanism
external fuel supply to the inlet of the fuel priming Cover - Remove and Install”.
pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
i02183020
g01105530
Illustration 33
(1) Delivery valve holder (3) Delivery valve (5) Drain tube
(2) Spring (4) Fuel injection pump
4. Remove the delivery valve holder (1) for the No. 5. Remove the delivery valve (5) from the holder.
1 cylinder.
6. Reinstall the delivery valve holder (1) and the
Note: Some fuel injection pumps may need to be spring (2). Tighten the fuel delivery valve to
removed to an upright position in order to remove 42 N·m (31 lb ft).
the fuel delivery valve. Refer to Disassembly and
Assembly, “Fuel Injection Pump - Remove”. Note: Fit the fuel injection pump to the engine if the
fuel injection pump was removed.
Note: All components of the fuel delivery valve must
be kept clean. Keep the components in clean diesel 7. Install the drain tube (3) to the delivery valve
fuel. holder (1) for the No. 1 cylinder.
30 SENR9972
Testing and Adjusting Section
g01105165
Illustration 34
(6) Timing mark (8) Hose (10) Fuel reservoir
(7) Suitable container (9) Control valve
10. Open the control valve (9) for the fuel reservoir
(10). If the fuel injection pump is set correctly, then
the fuel should flow through the drain tube (3).
g00826730
11. From the front of the engine, turn the crankshaft Illustration 35
in a clockwise direction until the flow of the fuel is (4) Fuel injection pump
reduced to 1 drop for every 7 to 10 seconds. This (11) Shim
should be the correct timing mark (6).
12. Ensure that the timing mark (10) is correct.
Compare the value by the timing mark (10) with
Table 1.
SENR9972 31
Testing and Adjusting Section
g00846800
Illustration 36
(1) Fuel injector
(2) Sealing washer
2. Loosen the nut for the fuel supply line at each fuel
injector (1). Listen for the low idle to decrease Illustration 37
g00470020
or become rough when the nuts are loosened at
(1) Adapter
each cylinder. (2) Fuel injector
(3) Tube Assembly
The fuel injector may be faulty if the following (4) Extension
items occur during the test: (5) Fuel Collector
(6) Filter
Note: If leakage at the nut for the fuel supply line Position fuel injector (2) so that the direction of
occurs, make sure that the fuel supply line and the the fuel spray is into the extension (4) and the
nut for the fuel supply line are correctly aligned with fuel collector (5).
the inlet connection of the fuel injector. Do not tighten
the nut for the fuel supply line on the high pressure 2. Pump the pressure to about 2030 kPa (294 psi)
fuel line more than the recommended torque. If the below the opening pressure of the fuel injector (2).
nut is tightened more, the fuel line may become
restricted or the threads of the fuel injector and the Refer to Specifications, “Fuel Injectors” for the
nut may be damaged. correct setting of the opening pressure.
Ensure that you wear eye protection at all times Note: This procedure is a test of the opening
during testing. When fuel injectors are tested, test pressure of the fuel injector.
fluids travel through the orifices of the nozzle tip
with high pressure. Under this amount of pres- 1. Connect the fuel injector (2) to suitable tooling that
sure, the test fluid can pierce the skin and cause is similar to the Illustration 38.
serious injury to the operator. Always keep the tip
of the fuel injector pointed away from the operator The spray from the fuel injector (2) must be
and into the fuel collector and extension. directed into the extension (4) and the fuel
collector (5).
3. Open the gauge protector valve. Slowly increase This procedure tests for the correct spray pattern for
the pressure until the valve in the fuel injector (2) the fuel injectors.
opens. Note the highest pressure indication on the
dial indicator before the pointer moves to 0 kPa 1. Connect the fuel injector (2) to suitable tooling that
(0 psi). This highest pressure indication is the is similar to the Illustration 39.
opening pressure of fuel injector (2). The opening
pressure occurs when the valve needle is lifted Position the fuel injector (2) so that the direction
from the nozzle seat. of the fuel spray is into the extension (4) and the
fuel collector (5).
Refer to Specifications, “Fuel Injection Nozzles”
for the correct pressure settings. If the opening 2. Close the gauge protector valve and the shutoff
pressure is not within the range of the setting valve. Open the pump isolator valve.
which is given in the table, the fuel injector (2)
must be replaced.
i01944302
NOTICE
Fuel Quality - Test Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
i02183880
g00836394
Illustration 42
Air Inlet and Exhaust 5. If the breather tube is made of plastic, use low
pressure air to check for a blockage in the breather
System tube. If a blockage is inside of the connector, the
cover assembly must be replaced. A broken valve
mechanism cover will result if you try to remove
i02251899 the connection.
Air Inlet and Exhaust System
- Inspect i02197856
Wastegate - Test
A general visual inspection should be made to the air
inlet and exhaust system. Make sure that there are
no signs of leaks in the system.
The boost pressure controls the maximum rpm of the • The battery is in good condition.
turbocharger, because the boost pressure controls
the position of the wastegate. The following factors • The battery is fully charged.
also affect the maximum rpm of the turbocharger:
• The starter motor operates correctly.
• The engine rating
• The valve lash is set correctly.
• The horsepower demand on the engine
• The compression gauge is accurate.
• The high idle rpm
• Inlet air restriction
• Exhaust system restriction
4. Slowly apply air pressure to the wastegate so 2. Connect a suitable compression gauge to the
that the actuator rod moves 1.0 mm (0.039 inch). cylinder.
The air pressure should be within 107 to 117 kPa
(15.5 to 17.0 psi). Ensure that the dial gauge 3. Disconnect the fuel shutoff solenoid.
returns to zero when the air pressure is released.
Repeat the test several times. This will ensure that 4. Operate the starter motor and record the pressure
an accurate reading is obtained. on the compression gauge.
5. Consult your nearest approved Perkins dealer or 5. Repeat for each cylinder.
your nearest approved Perkins distributor if the
operation of the wastegate is not correct. Note: Compression tests should only be used to
compare pressures between cylinders of an engine.
If one or more cylinders vary more than 350 kPa
i02184786 (51 psi) then those cylinders may be damaged.
Compression - Test Note: The cylinder compression test should not
be the only test for determining the condition of an
engine.
Compression
The following conditions can affect the results of the
cylinder compression test:
SENR9972 39
Testing and Adjusting Section
Table 3 • Excessive dirt and oil are present on the filters for
Standard at
the inlet air.
Repair Limit
Assembly
• Incorrect fuel settings on the fuel injection pump.
Compression 2940 kPa 2450 kPa
Pressure(1) (426 psi) (355 psi) • The load capacity of the engine is frequently
(1) The compression pressure is taken at 250 rpm. exceeded.
6. Repair procedures must be taken if the Too much valve lash can cause broken valve stems,
compression is lower than the repair limit. springs, and spring retainers. Too much valve lash
can be an indication of the following problems:
NOTICE
Be sure to measure the compression on all of the cylin- • Worn camshaft and valve lifters
ders. If all of the cylinders are not checked an improper
diagnosis may result. The compression pressure will • Worn rocker arms
vary with the change in engine rpm. It is necessary to
keep the engine rpm constant for all cylinders when • Bent pushrods
you are taking a compression reading.
• Broken socket on the upper end of a pushrod
• Loose adjustment screw for the valve lash
i02194225
If the camshaft and valve lifters show rapid wear,
Engine Valve Lash - look for fuel in the lubrication oil or dirty lubrication
Inspect/Adjust oil as a possible cause.
i01962876
g00314806
Illustration 46
(1) Valve guide
(2) Radial movement of the valve in the valve guide
(3) Valve stem
(4) Dial indicator
(5) Valve head
Note: A record of engine oil pressure at regular 2. Disassemble the engine oil pump. Refer to
intervals can be used as an indication of possible Disassembly and Assembly, “Engine Oil Pump
problems of the engine. A record of engine oil - Remove” for additional information. Do not
pressure at regular intervals can also be used as remove the bushing (9) from the idler gear (10)
an indication of possible damage to the engine. unless damage is observed.
The engine should be inspected and the problem
should be corrected if there is a sudden increase or a 3. Clean all of the parts and inspect the parts for
sudden decrease of 70 kPa (10 psi) in oil pressure. cracks in the metal or other damage. Look for
wear on the components. Ensure that the bushing
(9) is not loose in the idler gear (10).
44 SENR9972
Testing and Adjusting Section
g00459701
Illustration 48
Clearance between the inner rotor and the outer rotor
4. Install the idler gear and the inner rotor on the g00826185
Illustration 50
shaft. Measure the clearance (A) between the
inner rotor (6) and the outer rotor (8). Refer to
7. Install the components of the engine oil pump and
Specifications, “Engine Oil Pump”.
the front housing on the cylinder block. Make sure
that the two dowels align with the bushing, the
outer rotor, and the holes in the idler gear.
i01126690
i01794028
1. Check the coolant level in the cooling system. If 8. Check for loose drive belts.
the coolant level is too low, air will get into the
cooling system. Air in the cooling system will a. A loose fan drive belt will cause a reduction
cause a reduction in coolant flow and bubbles in the air flow across the radiator. Check the
in the coolant. Air bubbles will keep the coolant fan drive belt for proper belt tension. Adjust
away from the engine parts, which will prevent the the tension of the fan drive belt, if necessary.
transfer of heat to the coolant. Low coolant level is Refer to the Testing and Adjusting Section,
caused by leaks or incorrectly filling the expansion “Belt Tension Chart”.
tank.
b. A loose water pump drive belt will cause a
2. If contamination of the coolant is suspected, refer reduction in coolant flow through the radiator.
to Operation and Maintenance, “Maintenance Check the water pump drive belt for proper
Section”for the correct specification of coolant. belt tension. Adjust the water pump drive belt’s
tension, if necessary. Refer to the Testing and
3. Check for air in the cooling system. Air can enter Adjusting Section, “Belt Tension Chart”.
the cooling system in different ways. The most
common causes of air in the cooling system 9. Check the cooling system hoses and clamps.
are not filling the cooling system correctly and Damaged hoses with leaks can normally be seen.
combustion gas leakage into the cooling system. Hoses that have no visual leaks can soften during
Combustion gas can get into the system through operation. The soft areas of the hose can become
inside cracks, a damaged cylinder head, or kinked or crushed during operation. These areas
a damaged cylinder head gasket. Air in the of the hose can cause a restriction in the coolant
cooling system causes a reduction in coolant flow. Hoses become soft and/or get cracks
flow and bubbles in the coolant. Air bubbles keep after a period of time. The inside of a hose can
the coolant away from the engine parts, which deteriorate, and the loose particles of the hose
prevents the transfer of heat to the coolant. can cause a restriction of the coolant flow.
4. Check the sending unit. In some conditions, the 10. Check for a restriction in the air inlet system. A
temperature sensor in the engine sends signals restriction of the air that is coming into the engine
to a sending unit. The sending unit converts these can cause high cylinder temperatures. High
signals to an electrical impulse which is used by a cylinder temperatures require higher than normal
mounted gauge. If the sending unit malfunctions, temperatures in the cooling system.
the gauge can show an incorrect reading. Also if
the electric wire breaks or if the electric wire shorts 11. Check for a restriction in the exhaust system.
out, the gauge can show an incorrect reading. A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
5. Check the radiator.
a. Make a visual inspection of the exhaust system.
a. Check the radiator for a restriction to coolant
flow. Check the radiator for debris, dirt, or b. Check for damage to exhaust piping. Check for
deposits on the inside of the core. Debris, damage to the exhaust elbow. If no damage
dirt, or deposits will restrict the flow of coolant is found, check the exhaust system for a
through the radiator. restriction.
SENR9972 47
Testing and Adjusting Section
12. Check the water temperature regulator. A water Note: A small amount of coolant leakage across
temperature regulator that does not open, or a the surface of the water pump seals is normal. This
water temperature regulator that only opens part leakage is required in order to provide lubrication for
of the way can cause overheating. Refer to Testing this type of seal. A hole is provided in the water pump
and Adjusting, “Water Temperature Regulator - housing in order to allow this coolant/seal lubricant
Test”. to drain from the pump housing. Intermittent leakage
of small amounts of coolant from this hole is not an
13. Check the water pump. A water pump with a indication of water pump seal failure.
damaged impeller does not pump enough coolant
for correct engine cooling. Remove the water 3. Make sure that air flow through the radiator does
pump and check for damage to the impeller. not have a restriction. Look for bent core fins
between the folded cores of the radiator. Also, look
14. Consider high outside temperatures. When for debris between the folded cores of the radiator.
outside temperatures are too high for the rating
of the cooling system, there is not enough of 4. Inspect the drive belts for the fan.
a temperature difference between the outside
air and coolant temperatures. The maximum 5. Check for damage to the fan blades.
temperature of the ambient air that enters the
engine should not exceed 50 °C (120 °F). 6. Look for air or combustion gas in the cooling
system.
15. When a load that is applied to the engine is too
large, the engine rpm does not increase with an 7. Inspect the filler cap, and check the surface that
increase of fuel. This lower engine rpm causes seals the filler cap. This surface must be clean.
a reduction in coolant flow through the system.
This combination of less air and less coolant flow 8. Look for large amounts of dirt in the radiator core.
during high input of fuel will cause above normal Look for large amounts of dirt on the engine.
heating. Remove the dirt from the radiator core and the
engine.
16. Timing of the engine which is incorrect may also
cause overheating of the engine. Late timing 9. Fan shrouds that are loose or missing cause poor
creates more heat in the engine. Early timing air flow for cooling.
creates less heat in the engine.
i01964006
Note: If the timing of the engine is incorrect, the
exhaust valves may be burned and damage to the
exhaust manifold may occur.
Cooling System - Test
i01300404
Remember that temperature and pressure work
Cooling System - Inspect together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
be checked. The cooling system pressure will have
an effect on the cooling system temperature. For
Cooling systems that are not regularly inspected are an example, refer to Illustration 51. This will show
the cause for increased engine temperatures. Make the effect of pressure on the boiling point (steam) of
a visual inspection of the cooling system before any water. This will also show the effect of height above
tests are performed. sea level.
g00286266 g00296067
Illustration 51 Illustration 52
Cooling system pressure at specific altitudes and boiling points Typical schematic of filler cap
of water
(1) Sealing surface between the pressure cap and the radiator
3. Install the pressure cap onto a suitable • The reading on the gauge goes down.
pressurizing Pump.
• You do NOT observe any outside leakage.
4. Observe the exact pressure that opens the filler
cap. Make any repairs, as required.
4. Use the pressurizing pump to increase the 4. Keep the water at the correct temperature for ten
pressure to an amount of 20 kPa (3 psi) more than minutes.
the operating pressure of the filler cap.
5. After ten minutes, remove the water temperature
5. Check the radiator for leakage on the outside. regulator. Immediately measure the opening
of the water temperature regulator. Refer to
6. Check all connections and hoses of the cooling Specifications, “Water Temperature Regulator”
system for leaks. for the minimum opening distance of the
water temperature regulator at the fully open
The radiator and the cooling system do not have temperature.
leakage if all of the following conditions exist:
If the distance is less than the amount listed in the
• You do NOT observe any leakage after five manual, replace the water temperature regulator.
minutes.
i02193835
g01109205
Illustration 53
i02196171
Ring 1. Clean all carbon from the top of the cylinder bores.
1. Remove the piston rings and clean the grooves
2. Place each piston ring (2) in the cylinder bore.
and the piston rings.
3. Use a suitable feeler gauge (1) to measure piston
ring end gap. Refer to Specifications, “Piston and
Rings” for the dimensions.
i02193842
g01109213
Illustration 54 This procedure determines the following
(1) Feeler gauge characteristics of the connecting rod:
(2) Piston grooves
(3) Piston ring • The distortion of the connecting rod
2. Fit new piston rings (3) in the piston grooves (2). • The parallel alignment of the bores of the
connecting rod
3. Check the clearance for the piston ring by placing
a suitable feeler gauge (1) between piston
groove (2) and the top of piston ring (3). Refer
to Specifications, “Piston and Rings” for the
dimensions.
i01748770
• Appropriate gauges for measuring distance Main bearings are available with a smaller inside
diameter than the original size bearings. These
• Measuring pins (1) bearings are for main bearing journals that have
been ground.
Note: The connecting rod bearings should be
removed before taking the measurements. i02193978
2. Measure the connecting rod for distortion and Cylinder Block - Inspect
parallel alignment between the bores.
NOTICE
The flex-hone process must not be used on these en-
gines.
i02194218
1. Remove the bolts in the cylinder head in the
Cylinder Head - Inspect reverse sequence that is shown in Illustrations 58,
59 and 60.
g01112400
Illustration 58
Bolt tightening sequence for the 402C-05 engine
g00907442 g00842292
Illustration 59 Illustration 61
Bolt tightening sequence for the 403C-07, 403C-11 and 403C-15 Typical example
engines
4. Put the cylinder head (1) on suitable supports (2).
54 SENR9972
Testing and Adjusting Section
g00907448
Illustration 62
Typical example
i02194219
Table 6
1. Use the dial gauge (1) and the dial gauge holder
(2) in order to measure the piston height above
Required Tools the cylinder block. Use the cylinder block face to
zero the dial gauge (1).
Part Part Description Qty
Number 2. Rotate the crankshaft until the piston is at the
21825617 Dial gauge 1
approximate top center.
21825496 Dial gauge holder 1 3. Position the dial gauge holder (2) and the dial
gauge (1) in order to measure the piston height
If the height of the piston above the cylinder block above the cylinder block. Slowly rotate the
is not within the tolerance that is given in the crankshaft in order to determine when the piston
Specifications Module, “Piston and Rings”, the is at the highest position. Record this dimension.
bearing for the piston pin must be checked. Refer to Compare this dimension with the dimensions that
Testing and Adjusting, “Connecting Rod - Inspect”. are given in Specifications, “Cylinder Head”.
If any of the following components are replaced or
remachined, the piston height above the cylinder
block must be measured:
• Crankshaft
• Cylinder head
• Connecting rod
• Bearing for the piston pin
The correct piston height must be maintained in order
to ensure that the engine conforms to the standards
for emissions.
SENR9972 55
Testing and Adjusting Section
g00987752
Illustration 65
2. Set the pointer of the dial indicator to 0 mm 4. Calculate the difference between the lowest
(0 inch). measurement and the highest measurement of
the four locations. This difference must not be
3. Turn the flywheel. Read the dial indicator for every greater than 0.20 mm (0.008 inch).
90 degrees.
i01775427
g00907566
Illustration 66
Electrical System
i02195377
Alternator - Test
Table 7
Fault Conditions And Possible Causes
Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the Replace the alternator. Turn on all accessories. If the -
specifications Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications.
Turn on all accessories in
order to verify that the voltage
stays within specifications.
The voltage consistently Test the battery. Test the The alternator operates Replace the alternator.
exceeds specifications. alternator again. within the specifications. Test Inspect the battery for
the battery. damage.
5. After approximately ten minutes of operating the 6. After ten minutes of engine operation, the charging
engine at high idle, the output voltage of the current should decrease to approximately 10
alternator should be 14.0 ± 0.5 volts. Refer to the amperes. The actual length of time for the
Fault Conditions And Possible Causes in Table 7. decrease to 10 amperes depends on the following
conditions:
58 SENR9972
Testing and Adjusting Section
i01899136
Battery - Test
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
i02270231
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
SENR9972 59
Testing and Adjusting Section
Table 8
Belt Tension Chart
Gauge Reading
Initial Belt Tension(1) Used Belt Tension(2)
400 to 489 N (90 to 110 lb) 267 to 356 N (60 to 80 lb)
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
i02196181 i02196186
Alternator output should be 14 ± 0.5 volt. No 3. Repeat the previous step when the temperature of
adjustment can be made in order to change the rate the coolant is approximately 120 °C (248 °F). The
of charge on the alternator regulator. If the rate of resistance should not be less than 15 ohms.
charge is not correct, a replacement of the regulator
is necessary. For individual alternator output, refer to 4. If the resistance through the coolant temperature
Specification, “Alternator and Regulator”. switch is not within the given resistances, replace
the coolant temperature switch.
i02196199
Move the start control switch in order to activate the 1. Turn the ignition switch to the ON, but do not start
starter solenoid. The operation of the starter solenoid the engine. The warning light for low engine oil
can be heard as the pinion of the starter motor is pressure should turn on.
engaged with the ring gear on the engine flywheel.
If the warning light does not turn on, check the
If the solenoid for the starter motor will not operate, electrical circuit to the warning light and the engine
it is possible that the current from the battery did oil pressure switch for shorts or an open circuit.
not reach the solenoid. Fasten one lead of the Check the bulb for the warning light for damage.
multimeter to the connection (terminal) for the battery
cable on the solenoid. Connect the other lead to a If the circuit is correct, replace the engine oil
good ground. A zero reading indicates that there pressure switch. If the circuit is repaired or if the
is a broken circuit from the battery. More testing is engine oil pressure switch or warning lamp are
necessary when there is a voltage reading on the replaced, repeat this Step in order to ensure that
multimeter. the warning light turns on.
The operation of the solenoid also closes the electric Note: The engine oil pressure switch may be
circuit to the starter motor. Connect one lead of the mounted on either the cylinder block or the valve
multimeter to the solenoid connection (terminal) that mechanism cover.
is fastened to the starter motor. Connect the other
lead to a good ground. Activate the starter solenoid 2. Remove the engine oil pressure switch from
and look at the multimeter. A voltage reading of the cylinder block or from the valve mechanism
the battery shows that the problem is in the starter cover. Disconnect the wire connector on the
motor. The starter motor must be removed for further wiring harness from the engine oil pressure
testing. A zero reading on the multimeter shows that switch. Use a 12 volt battery as a power source.
the solenoid contacts do not close. This indicates the Connect the terminals of the battery, the engine oil
need for repair to the solenoid, or to the clearance for pressure switch and the leads of a suitable digital
the starter motor pinion. multimeter in series. Measure the current through
the engine oil pressure switch.
Perform a test. Fasten one multimeter lead to
the connection (terminal) for the small wire at the 3. The current should be 0.30 to 0.40 amperes. If the
solenoid and fasten the other lead to the ground. current through the engine oil pressure switch is
Look at the multimeter and activate the starting greater than 0.42 amperes, replace the engine
solenoid. A voltage reading shows that the problem oil pressure switch.
is in the solenoid. A zero reading indicates that the
problem is in the start switch or the wires for the start
switch.
i02196230
i02196770
g01115662
Illustration 67
(1) Positive “+” lead
(2) Electrical connector g01109557
Illustration 68
(3) Plunger
(4) Body of the fuel shutoff solenoid (1) Nut
(5) Negative “−” lead (2) Washer
(3) Connector
(4) Glow plug
This procedure tests the fuel shutoff solenoid for
correct operation.
Continuity Test
1. Remove the fuel shutoff solenoid from the engine.
Refer to Disassembly and Assembly, “Fuel Shutoff 1. Connect a suitable test light between a ground
Solenoid - Remove and Install”. and the terminal of the glow plug (4). Choose the
glow plug that is farthest away from the battery.
2. Use a 12 volt battery as a power source. Connect Turn the starting aid switch to the ON position.
the lead from the battery positive terminal (1) to
one of the pins in the electrical connector (2) on If the circuit is correct, the test light should turn on.
the fuel shutoff solenoid. Connect the lead from
the battery negative terminal (5) to the remaining If the test light does not turn on, inspect the circuit
pin in the electrical connector (2) on the fuel for loose connections, broken wires, and other
shutoff solenoid. damage.
The plunger (3) on the fuel shutoff solenoid (4)will 2. Loosen the nut (1) on each glow plug and then
extend the maximum distance when the leads are disconnect the connectors (3) from the glow
connected. plugs(4).
If the plunger does not move or if the plunger 3. Use a suitable digital multimeter to measure the
does not extend the maximum distance, replace resistance between the electrical terminal of the
the fuel shutoff solenoid. glow plug (4) and ground. The point for the ground
should be as close to the glow plug as possible.
3. Use a suitable digital multimeter to measure the
current through the fuel shutoff solenoid. Connect Maximum resistance for the glow plugs.
the battery, the fuel shutoff solenoid, and the leads
402C-05, 403C-07 and 404C-15 ...... 1.0 ohm
of the multimeter in series.
403C-11, 403C-15, 404C-22 and
404C-22T .................................... 0.0139 ohm
62 SENR9972
Testing and Adjusting Section
If the light does not turn on, replace the glow plug.
Index
A Engine Valve Lash - Inspect/Adjust ....................... 39
Valve Lash Adjustment ...................................... 39
Air in Fuel - Test..................................................... 27 Valve Lash Setting ............................................. 39
Air Inlet and Exhaust System .......................... 14, 37 Excessive Bearing Wear - Inspect......................... 44
Cylinder Head And Valves ................................. 15 Excessive Engine Oil Consumption - Inspect........ 45
Turbocharger ..................................................... 15 Engine Oil Leaks into the Combustion Area of the
Air Inlet and Exhaust System - Inspect.................. 37 Cylinders .......................................................... 45
Alternator - Test ..................................................... 57 Engine Oil Leaks on the Outside of the Engine.. 45
B F
Basic Engine.................................................... 18, 51 Finding Top Center Position for No. 1 Piston......... 28
Cylinder Head and Block ................................... 18 Flywheel - Inspect.................................................. 55
Pistons and Connecting Rods............................ 18 Alignment of the Flywheel Face......................... 55
Timing Gear Case and Gears ............................ 19 Flywheel Runout ................................................ 55
Battery - Test ......................................................... 58 Fuel Injection Timing - Check ................................ 28
Belt Tension Chart ................................................. 58 Fuel Injector - Test ................................................. 32
Inspection and Cleaning of the Fuel Injectors.... 32
Leakage Test...................................................... 32
C Pressure Test ..................................................... 33
Test for the Nozzle Spray Pattern ...................... 34
Charging System - Test ......................................... 59 Fuel Quality - Test.................................................. 35
Alternator Regulator........................................... 59 Fuel Shutoff Solenoid - Test .................................. 61
Compression - Test................................................ 38 Fuel System..................................................... 10, 27
Compression...................................................... 38 Fuel Injection Pump ........................................... 13
Connecting Rod - Inspect ...................................... 51 Fuel Injectors ..................................................... 13
Connecting Rod Bearings - Inspect....................... 52 Fuel Priming Pump ............................................ 14
Coolant Temperature Switch - Test........................ 59 General Operation of the Fuel System .............. 10
Cooling System ............................................... 17, 46 Glow Plugs......................................................... 14
Cooling System - Check (Overheating) ................. 46 Governor ............................................................ 12
Cooling System - Inspect....................................... 47 Fuel System - Inspect............................................ 27
Cooling System - Test............................................ 47 Fuel System - Prime .............................................. 35
Checking the Filler Cap...................................... 48
Testing The Radiator And Cooling System For
Leaks................................................................ 49 G
Cylinder Block - Inspect......................................... 52
Cylinder Head - Inspect ......................................... 53 Gear Group - Inspect............................................. 56
Gear Group (Front) - Time..................................... 36
General Information................................................. 7
E Engine Description............................................... 7
Engine Model Views ............................................ 7
Electric Starting System - Test............................... 59 Lifting the Engine ................................................. 7
Electrical System ............................................. 20, 57 Glow Plugs - Test................................................... 61
Automatic Shutdown System ............................. 21 Continuity Test ................................................... 61
Charging System Components .......................... 24 Glow Plug Circuit ............................................... 62
Engine Electrical System ................................... 20
Other Components............................................. 26
Starting System Components ............................ 25 I
Engine Design ......................................................... 4
402C-05 Engine ................................................... 4 Important Safety Information ................................... 2
403C-07 Engine ................................................... 4
403C-11 Engine ................................................... 5
403C-15 Engine ................................................... 5 L
404C-15 Engine ................................................... 6
404C-22 and 404C-22T Engine ........................... 6 Lubrication System .......................................... 16, 43
Engine Oil Pressure - Test..................................... 43
Engine Oil Pressure Switch - Test ......................... 60
Engine Oil Pump - Inspect..................................... 43
M
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 27
Wastegate - Test.................................................... 37
Inspection of the Wastegate .............................. 37
Water Pump - Inspect............................................ 50
Water Temperature Regulator - Test ..................... 49