c

Trou

Four Cylinder

Oopy rlqh t= 1993 B u ll etin 366

36666 0 8 7
Cummins Engine Company I n c . P ri n ted 1 1/93
All righ
rightt s r e serve
servedd
 Foreword
This manua provides instructions for troubleshooting and repairi n g the B S er es E n g i ne i n the c hasss. Comp onent
and assembly r ebuild procedures are p rovided i n the B Ser ies Engin e Shop M anual. R efer t o P a g e i - 2 in t he
In troduction for in structions o n how to use this m anu al. Th e p r o ced ures given in this this m a n u a l a r e a p p l i cable fo r
t he B Seri es engines produced i n 1991 and n e wer. R efe r to B ul l e t i n No 3810 2 07 to find
find the p ro c e dures app li c a bl e
to B Series engines introduced p rior to 1991
1991..
The manual is organized to guide a ser vice techn i cian throug h the l ogical steps of id entify ng a n d c o r r ecti n g
hrou
problems r elated to the engin e.
This manual does no nott cover veh
ehcc e or equipment p r obems C o n s u lt th e ve h ic e or equi p me
men
nt nufactur e r for
man
ma
r epair procedures.
A series of specific service m anua s ( Shop, S p e c ifications, Alterna tiv
ations, e R e pair, a nd s o o n . ) a re av a il ab e a nd ca
ive cann
be ordered by filling out and mailing the Literature Order Form located i n the Ser vi ce Li ter atu re S e ct o n L.
The r epai used in this m an u a are re commende
epairr p rocedures used endedd b y C ummi ns E n gine C o .,
min I nc Som e serv c e
procedures require th e u se of special service too
the ls U se th e correct tool
ools s as d es
tools cr i bed.
esc
Reporting of e r rors, omission s, and recommen dations for im pro v i ng this pub i cation b y the u ser i s e ncour age
aged. d.
t
Please use the postage paid, self-addressed L i teratu re S u r v e y Form in th e b a ck of h is man u a for mmu
communica t i ng
your comments.
The specifications and rebuild i nformation in this manua is base d o n the inform a t i o n in e ffect a t the ti m e of p ri n t ing.
based
Cummins Engine Company, I nc. reserves the r i ght to m a ke any changes a t any tim e without o bligat io n. If
diff erences are found between your engine a n d th e i n form a ti o n in this m a nual, c o ntac ntactt a Cumm ins Autho r i zed
Repair L o catio
cationn , a C u mmins D i vision Office, o r t h e factory.
The latest technology and the highest quality com ponen ts are used to m a n u facture Cumm mmiins engines. When
r eplacement parts are needed, we reco m mend u sin sing gen ui n e C ummin s or R e C o n ® exc h a nge part s. Th e se
g only gen
part s can be i dent fied b y the fo ll o w i n g tr adem a r ks :

c e e tg u a r d ®
Prearniiuarn

( HDLSET)
®
_a.lue

- Ill
®
 T a ble of Contents
Section

I n troduc
duction
tion .
I
Engine I dentification . E
I
Troub leshooting . T
I
C o oling System Repair . 1
I
Lubricating Oil Syste m R e pair
Sys .. 2
I
Ai r Combustion System R e pair .. 3
I
Compressed Air System R e pair .. 4
I
F u el S yste m Repair . 5
I
E l ectric a l System R epair . 6
I
Engine C omponents System Repair
Base Engine .. 7
I
Engine Testing a n d Run-In . 8
I
Engin e Removal and I n stallatio n
Engin . 9
I
v
Specifications and Torque Values :· · · · · · · .. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
I
Component M anufact
cturer
urers . c
I
Ad ditional S ervice lterrature
te . L
I
x
I nde x .
I

Table of Contents
Page 4
 NOTES

Section i - Introduction
B S e ries P a g e l-t
 Section i - Introduction
ction Contents
Sec
Se
Page
About the Manual.. . . . . .. . .. . . . . . ........ . .. . . .... .. .. . . ............. ...... . ..... . .. .. . . . .. ........ .. . . . . . ..... .. . . .. . .. . . .. . .. . .. . . .. .. .. . . ........ . . .... .. ....... i-2
Definition of Term s . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-8
Genera l Cleaning Instr u c tion s
Genera -10
ass or P l astic B ead C l eaning
G l ass eaning i- 1 0
Solvent
So lvent an d A c id Cleani n g.
g... . . .. . . .. . . . .. .... . .. . ............. . .. . .. . .. .. . . .. . . . . .. .. . . .. .. . .. . .. .. . . .. . ..... . .. .... . . .. . .. . . .. . . .. . .................. i- 1 0
S t eam C l eani
eaninn g i -1 0
G e nera R e pair Instruction s i-1 1
General Safety In structions i-9
I m p o rt
rtaan t Sa ety N o ti ce. .... . .. . . . .. . .. . . . . . ....... . .. . .......... ..... . . . .. . .. . . .. .. .. . .......... ...... . .. . .................................... .......
.................................... i-9
H o w to Use the Manual i -2
Illu strations i -7

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . i -3

About the Manua Section i -ntroduction

Page i - 2 B Series

Ab o ut th e Manual
Serr ies Tro u bleshooting and Repair Manua is i n tended to aid in deter mining the cause of engine-related
T h i s B Se engine-related
probl ems and to provi de recommended re pa ir procedur es. The manu al is divided into
provide i nto sections by system. Each
section provides genera i n formation , specifi cation s, d i agrams, and service tools, where applicable. The specific
formatio
oubeshootting L o g i c Cha
repair procedures are referenced i n th e Tr oubeshoo Charr ts.

How to U se the M a nua l

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

( S TE P 1 .) Locatte th e sy mptom o n th e li s t.
Loca
R e ference i s made to the pro ce d u r e number where the "Troubleshooting Logic Chart" is found.
(S TEP 2. ) The left co umn o f th e "Troubl e s h o o tin g L ogic Chart" indicates a probable cause, starting at the
top with the simplest and e a s i est t o r epair, and continuing downward to the most difficult.
The r ight column p r ovides a br e f descr
descrii ption of th e corrective action with the reference number
for the repair.
(STEP 3.) probab le cause in th e l e ft colu mn, a nd then turn to the procedure number in the right
Locate th e probab
colu mn.
The repair proced u r es a r e l is ted b y system ( C o o l ing, Lubricating Oil, Combu
Combustion
stion Air,
C o m pressed Air, F uel, Electri ca , a n d B ase E n g in e C omponents).
(S TEP 4 . ) The T r oubleshoot in g L o g ic C h a r t s are b as e d o n th e fo ll o w i ng assumptions:
1. The e n g i n e h as b een instal l e d a c c ordin g to th e man ufacturer's specifications.

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

first.
st.
3. "Generic" solu tio n s to c o ve r proble ms w th the m o s t common applications and Original
E q uipm e n t M a nufac ture r s (O E M ' s).
actu

Section i - Introducti on Symbols

B S e ries Page i-3

S ym bols
The following s ymbols have b een us e d i n th i s man u al to h e l p c ommunicate the i ntent o f the in s tructio n s . W h en
one of the symbols appears it co nveys the meaning d e fi n ed below
 WARNING - S e r i o us perso n al i njury o r extensi ve p r o p erty d amag
amagee can r e s ult if the w a rn ing
i n s tr uctions are not fo ll o w e d .

CAUTION - M i n o r p e r s o n a l in ju r y can r e su l t or a part an a s s emb y, or the engin

emb enginee can be d a maged
~ i f the cauton i nstr uctions a r e not foll owe d .
follow

EE~ Indicates a R E M O V A L o r D I SASSEMBLY step.

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

@ INSPECTION is r e qu
qurr e d.

CLEANthe parto rauemb~

~

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

6] LUBRICATE t he p a r t or assembly.

Indi cates that

that a WRENC H o r TOOL S IZE w i ll be g ive n .
~

® TIGHTEN to a spec fic torque

® PERFORM a n e l e c tr ical M EAS U R E M E N T

R e fer to a n o ther l oca tion in th i s m a n u a l o r anot h e r p u b l i ca

ano cattio n for addit i o na information .
~

The co m p o n ent w e i g h s 23 kg [ 50 l b ] o r mor e . T o a v o i d p erso

ersonn al i njury use a h o is t or g e t ass stance
assst
to l i ft th e c o mponent.

Symbols Section i - Introductio n

ge i - 4
Pag
Pa B S e r i es

Simbolos
L os s imbo l os s i g u ie n tes son usados e n este man ua para c l a r i fificc ar el proceso d e l as in strucciones C ua n d o
a parec
parecee uno de e s tos s fmb o l o s , s u s i g nificado se esp ecififii ca en l a parte inferior.
cado
 AD V E RTENCIA- S e r i es d afios per s onales o dafio a a p r o p iedad puede r e s ul tar si la s instruccio n e s
d e Adve r ten cia no se c o n s id e r a n.

PRECAUCION - D a n os m e n ores p u e den r esultar , o de p i ezas del c onjunto

onjunto o el motor puede
A a ve r i arse s las i n s t r ucci ones de P r e c a uc 6n nose siguen

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

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

~

@ Se r e q u ie re IN S P E CCION.

LIMPIE SE la p i eza o el m ont a j e .

~

Ci) EJECUTESE un a MEDICION meca

canica o d e l ti e mpo.
nica

6J L U B RIQUESE montta j e.
la p i e z a o el mon

lndic a que se dara u n a LLAVE DE TUERCAS o e l TAMANO DE HERRAMIENTA.

~

® APRIETESE h a s ta un p ar to r s or esp ecffi co .

ecffi

® E JECUTESE un a MED I CION e l ectrica,

P ara i n formaci6n adicional r e fi e r a se a otro empl

ormac azamie nto de est e m a n ua l
emplazam o a o tra p ublicaci6n
a n terior.

E l compone n t e p e s a 2 3 k g [ 50 lb] o mas P a r a evitar d ano cor

mas orpp o r a l e mpl
mplee
een un a cabri a u o b te n gan
ayuda par a e l e va r el compone nte.

Section i - I ntrodu ct o n
ntrod S ym
ymb bols
8 S e r ies P ag e i -5

Symbole
In d i esem H andbuch werden d i e fo l genden Symbo l e v e rwe n d e t d i e wese ntliche F un k t i o n e n h ervorh e b e n . D ie
S y m bole haben fo gen de B ede
edeutu
utun g :

WARNUNG - W rd d ie Warnun g nich t b e ach t et, dan n beste ht e r h o h te U n fal l- und

Beschadi qunqsqefahr ;
 a VORSICHT - W e r d e n d i e V o r s i c htsmas sna h m e n
chadiqu nqsqetahr ;
nicht b each te t , d an n b e steht U n fall- und Be s

EE~
AUSBAU bzw. Z E R L EG E N .

EINBAU bzw. Z U SAMMENBAU.

~

@ IN SPEKTIO N
SPEKTI e r forder lich.

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

~

Q) DIMENSION - o d e r ZEITME S S U N G.

Te il o d e r B a ugruppe OLEN
~

~ WER KZEUGGROSSE wird a n g e g e b e n .

($) AN ZUG a uf v orgesch r iebenes Dre h m o m ent e r forde rlich.

@ E l ektris ch e M ESSU N G D U RC H F U H R EN

We i t ere l n format i o n en an a n d e r e r Ste ll e b z w. in ande ren H a ndbOchern

and
~

D as te il w e i g t 2 3 k g [50 l b] o d e r m e h r . Zur verme id un g von ko e rperv

rpervee r l e t z ung w n d e benutze n o d e r
h ililff e b e i m heben d e s t e i l s in a n s pruch n e h m en

S
P ym
agebols
i-6 S e ction i - I ntroduction
B Series

Sym bol es
Les s ymboles suivants sont utilises dans ce man u e l p o u r a ider a comm un i quer l e b ut des i n s t ructi ons. Quand l'un
de ces symboles apparalt, ii evo que le s ens d e fini ci- dessous:

AVER TISSEMEN T - D e g r aves l e sions corpore ll e s o u d e s d o mmages m aterie s con siderab es

peuvent s urve n i r si les instructio n s d onnees s o us l es r u b riques "Avert ssem e n t " ne sont pas
su i vies
 ATTENTI ON - De petites les ons corpo r elle s p e u v e n t s ur
corp venir, ou bien une piece, un ensemble o u
urv
le moteur peuvent etre endornrnaqes s i l e s i nstr u c t io n s donnees s ous les rubr iques "Attention" ne
sont pas s uivies.

lndique u n e operation de DEPOSE.

~~

lndique une operation de M ONTAGE.

~

@ L' IN SPEC TION est n ecessaire,

NETTOYER l a p iece ou ' ensemb l e .

~

E F FECTU ER u ne MESUR E rn e canque ou de tem p s .

~

G RAISSER la p iece o u ' e nsemble

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

® SERRER a u n c oup l e specifique

f J1 EFFECTUER une MESURE e l e ctr i que .

S e r epor t e r a un a utre e n d r o i t d ans ce m a n u e l ou a un e a utr e p u b l i ca

catt o n p o ur obte
obte n i r d e s
i nfor m a t ions p l us comp l etes .

Le c o m p osant pese 2 3 kg [ 50 lb] o u d a van tage P o ur e viter to ute b l e s s ure, e m p l o yer un a p p a r ie l

d e l e v a g e ou deman d e r de l 'ald e p our l e sou l e ve r ,

Section i - Introduction Illustr a t i ons

B Series P ag e i -7

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

dw 8 pu sa

Definition of Terms Section i - Introd uction

Page i -8 B Serie s

Definitio n of T e r ms

AFC Air Fuel Control i n -lb I n ch P o und

AP I American Petroleum I nstitute kg K ilo g r a m s
ASA Air Signal Attenuator km K i lo m e te r s
ASTM American Soc ety of T e s ting a n d km/I K il o m e t e rs per Lite r
Materiass
Materia kP a K i l o p a s ca l
c Ce sius I L ite r
C ARB California Air Resources Board m M eter
C.I.D. Cubi c Inch Displacement mm Millimee t e r
Millim
Cm Centimeter MPa Mega pas ca
CPL Control Parts List MPH M il es P e r H o ur
est Centi stokes MPQ M il e s P e r Quart
DCA Diesel Coolant Add tive N•m N e wto n - met er
ECM Electronic Control Module OEM O r ig in a l E q ui p m e nt M an u fa cture r
E.C.S. Emission Control System pp m P a r t s P e r Mill o n
EPA Environmental Protection Agency p si P o u n ds P e r S q uar e In ch
EPS E ngine Position Sensor PTO P o w e r Ta k e o ff
F Fahrenheit R PM R e vo l u ti o n s P e r M inute
ft-lb Foot Pound S.A.E. S ocie ty o f Au t omoti tiv
ve E ngine
ngineee r s
GVW Gross V e h i cle Weight S TC S t ep T i m i n g C o ntrol
Hg Mercury vs Va r i a b l e S p e e d
HP Horsepower vss Ve hicle Spee d S ensor
H 20 Water

Section i - n trodu ctio n G enera Safety I n s tructions

B Seri es Page i - 9

General Safety Instructions

po rta nt Safe ty Notice
Imp
Im

A W A R N I NG A
Read and understand a ll o f the sa fe ty precau
precauttio n s a nd warnings b e fo r e performing any repair . Th i s l is t conta ns
the general safety p r ecautio n s th a t must be fo ll o w e d t o pro v i de p ersonal safe
safetty . Spec al safety precautions are
i n c l uded in th
thee pr ocedu res whe n th e y apply
proced
• Make s ur e t h e w o r k ar e a s urrou n d i n g th e p r o d u c t i s sa fe. B e a w a r e of h a za r d o us condititii ons that can e x i st.
• Always wear p r o te c ti ve g l asses a n d p r o te c ti ve s h oes w h e n w o r ki n g .
• D o not wear l o o se- fitting o r t o rn c l o thing. R e m ove a ll j e w e lry w h e n w orki n g .
 • startin g m ottor
Disconnec thei f beat
q ut ery
i p p e da ndt o dpisr ecvhearge a ny
nt acc
accd t a l e n tgoi ne
d e ncapaci
capacit e fore
r s bstar b e gPut
ti n g. N otr e Ope
i n n inag"Doany pa i r r awork.
Oper Disconnect
te " tag the air
i n the operator's
compart ment or o n th e co n tr o l s.
• Use ONLY the proper e n g i n e barring tech n i ques for m anua anually
lly rotati n g t he engine. Do not attempt to rotate the
engin e by p u llllii ng o r p ryin g o n the fa n . T h i s p r a ct
ctice
ice c a n ca us e se ri o u s persona inju r y, property damage, or
damage to t he fan b l ade(s) ca using p r e mature fa n fa ililuu r e .
• I f an engine has been o p e r a t ing a n d the coola coolann t i s hot, allow th e e n g in e to cool before you slowly loosen the
fifillllee r cap and re l ieve th e p r e ss ur e fro m th e cooli n g sy s te m .
• Do n ot w o rk on anything tha
thatt i s support e d ONLY by lifting jac k s o r a h o i s t. Alwa ys use blocks or proper stands
to supp o rt th e produc t b e fo r e perfo rming any se rv i c e work
• R e l i eve a ll p r e ss u r e in th e a i r , o i l, a nd t he c o o l i ng s y s te m s before a n y li n e s , fitt n gs, o r r e l a ted items a r e removed
o r d i scon n e c t e d. B e al alee rt fo r p o ss ib l e p r e ss u r e w h e n d i sc o n n e c ting a n y d evice from a system th at utilizes
p r e ss u r e . D o not c h e ck for p r e ss ure l e a k s with y o ur h a nd. H i gh p r e ss u re o il o r fu el can cause persona i n jur y.
• To p r e ve nt s uffo c a t i on a nd fr o s tbite, we ar prot e ctive c l othing a n d O N LY d i sc o n n e c t li q u i d r e fr i g e r a nt ( fr eo n )
l in es in a w e ll v e ntil
ntilaa ted a r e a.
• To av o id p e r so n a l injury, u se a h ois
oistt or g e t a ss i s ta n c e when lifting com p o n e n t s th a t weigh 23 kg [50 lb] or more.
M ake s u r e a ll l ifting d e vicvicee s such as c h ains, h o o ks, o r s li n gs are in g o o d co n d ititii on a n d are o f th e co rr e c t
c a p ac ity. Make s ure h ooks a r e p o s i tioned correctly Always u s e a s p r e a der bar when n e c essar y . T h e l ifting
h ooks must not be s id e - l o a d ed.

• C o r rosi on inhibito
inhibitorr contains a lkali. Do not g e t the s u bstance in your e y e s . A vo i d prol o n g ed o r r epeated co n t act
with s k i n . Do n o t swallow intern a lly. I n c a s e of c o n ta c t i mmedi ately was h s k i n with so ap a n d wate r . In c ase
of co n tact, i m m e d ia tel y flood eyes with l arge a m o unts o f water fo r a minim u m of 1 5 minutes I M M E D I ATELY
C A L L A PHYSICI A N . K E E P OUT OF REACH OF C H ILDREN.
• N apt
apthh a a nd M e thyl E t hyl K e tone (MEK) a r e flammab l e materia s a nd must b e u sed w i th cau t io n . F o ll ow th e
turee r 's i n s tr u c tions to provid e comple te safety w h e n us ing th ese m a ter als. K EEP OUT O F R E A C H
m a n ufac tur
OF C H IL D R E N .
• T o a void b ur n s, be a l e r t for h o t p a r ts o n p r o d uc ts th a t h a v e ju s t b e e n tu rned OFF, and h o t fl ui ds i n li n e s , tubes ,
and compartm e n ts .
• Alwa ys us e to o l s th a t a r e in good c o n d i t o n . M a k e s u re y o u u n d e r s tand how t o u s e them b e fo r e p e rforming
a n y serv ice wo r k. U se ONLY g e nuine Cummins or Cummi ns R econ® r e p l acem e nt par partts .
• Alwa ys use the same fas te n e r p a r t numbe r (or equival equivalee nt) whe n r e pl acing fa s t e n e r s . Do not use a fa s tener
of le s so r q u a l i ty if replacem e n ts a re n e c essary .

G e n e r al C l e a n in g In str u c tions Section i - I n troduction

Page i - 10 B S e r i es

G enera l Cleaning Instructions

S o l ve nt a n d Acid C l eaning
Sever al so l v e n t and a ci d - t y p e c l eaners can be used to c l ean the engine parts. C u mm ns Engine C om p a ny,
I n c . does not r ecommen d any specific c l eaners. Always follow the c l eaner manufac acttu r e r ' s i n s t r u c ti ons
E x p e r i e n ce h as s h o wn th a t th e best results can be obtained using a cleaner that can be h e a te d to 90 to
95 degr ees C e l s i us ( 180 t o 200 degrees F ah r enheit]. A cleaning tank that prov des a constant m i xing a n d
fi l te r in g o f th e c l eaning so lu t i o n w i ll give t he b e s t results.
~ Remove a ll th e gask e t mat er a l , o-rin gs, and the deposits of sludge, carbon, e tc., w i th a w i re brus h or scrape
scraperr
before putting t he parts in a cleaning tank. Be careful not to damage any gasket surfaces When poss ble,
steam clean t he parts before p utting them in the cleaning tank
Warnin g : The u s e of a cid c a n b e e x tremely dangerous to personnel, an d c a n d a m a g e the m ac hinery.
hiner
Alway s provi de a ta n k o f s tro n g soda water as a neutralizing agent.
 R i nse alalll of the p a rt s i n h ot water after cleaning. Dry completely with compressed air. B l ow the r i n se w a t er fr
froo m
a ll o f th e capscrew h o l es and the oil drillings
If the parts are n o t to be u sed i mmediately after clean i ng, dip them i n a suitable r us t proofing co m pou n d . The
r ustproofing c o m p o u n d m u s t be r emoved from t he parts before insta ll a tion on the e n g in e .

S t e a m C l e a n i ng
Steam cleanin g ca cann be u sed to r emov e a ll types of dirt that can contam nate the c l eanng ta n k . I t i s a g ood
emo
way t o c l e a n the oil drillings.
A W arnin
ing:
g: W e a r prote ctive clo thing to preve nt p erson a l i n jury fr o m the h ig h pressure a nd e x tr e me h e at.
D o n ot s t e a m c l ean th e f o llow i ng p a r t s:
~ 1. E lect r i ca C o m p onent
onentss
2. Wring
.
3 I n ject or
orss
4 F u e l P um p
5. B el t s and H oses
6. B e arings
G la s s or P l astic B e ad Cleaning
G l ass or plast
plastic b e a d c l e a n i ng c a n be u s ed on m an
any
y e n g i n e components to r e m o v e c a rbon d e p o s i ts . T h e
c l e a n in g pro c e ss is controlle d by the s i z e of the g l ass or p l astic beads th e o p e r a tin
tingg p ress ure , and th e
c l ean i ng time.
A Caution: D o not use glass or plas tic bead c l eaning on a l uminum piston skirts. D o not us usee glass b e ad
..U cleaning o n a luluminum
minum r i ng grooves. Small partic le s o f glass or pl astic will embed in the alumin um a n d
plast
~ result i n p rematu re wear. Valves, turbocharge r s h a ft s, e tc ., c a n al
also
so be d a maged. F o ll ow th e clea
cleann ing
directi ons lis ted in the proce dures.
1111111
NOTE: Pl as t i c b e a d b l a sting m e d ia , P a rt N o . 38 22 735, can be u se d to c l e a n a l uminum ri ng groove s . Do n o t use
any bead b l a sting m e d i a on pin b o re s or al umin u m s kirt s.
F o ll o w the e quipmen
mentt manufa ctu cturr er' s cl ean in g i n s truc ti o n s . The fo llllow
owin g g u id e li n e s c an b e u s e d to adapt to
m a n u facture r ' s instructions
1. B e a d s i z e: - U s e U .S . s i ze N o . 1 6 - 2 0 for p i s to n c l e a n i n g w th p l asti
tic
c b e a d m e d i a , P a r t N o . 3822 7 3 5.
U s e U . S . s ize N o . 7 0 for p i ston d o m es w i th g l ass m e d i a .
Use U . S. s i z e No. 6 0 for g e n e r a l p ur p o s e c l ean in g with g l ass media
2. Ope r a ting P r e ss ur e: - G l a ss : U s e 6 2 0 k Pa ( 9 0 p s i] f or g e n e r a l pur p ose c l e a ning.
- P l as t ic: U se 2 7 0 k P a ( 40 psi] f or p i s to n c l ean in g.

3. S t e a m c l e a n or w a s h th e p a r t s with s o l ve n t t o r e m o v e a ll o f the fo r e i gn m a te r i a l a n d g l ass or p l a s t c

b e ad s a fter cl e a n i n g . R i n s e w th h o t water Dry with comp resse ressedd a i r .
4. Do n o t c o ntamina te th e w as h t a n k s with g l ass or p l a s ti c b ead s .

S e cti on i - Introduction General Repair Instr uctions

B Seri e s Page -11

G e n e r a l R e p a i r I nstructions
Th i s e n g i ne in c orporates the a t est diesel technol ogy; yet, t is designed to b e repaired u s ing norma l repair prac tices
p e rformed to q uality standards.
• C ummins E n gine C ompa ny, I nc. does does n ot recommend or auth orize any modificat ions o r repairs to
reco
e n gin e s or compo nents exc ept for those detailed in Cummins Service Information . I n particular, u n
a uthoriz ed r e p a i r to s afety-r e lated components c an cause per sonal injury. Betow is a partial listing of
ated
com po n ents classified as safety-rel ated:

Air Compressor
Air Control s
Air S hutoff Assembl i e s
Bal a nc
ncee Weights
C ooling Fan
F a n H u b Assembly
F a n M ounting Bracket( s )
F a n Mounting Capscrews
 F an Hub Spindle
Flywheel
Flywhee
F lywheel C ran ks h aft Adapter
rank
F l ywheel M ounting C apscr ews
Fuel Shut off Assembli es
Shutoff
Fuel S upply Tubes
Lifti ng Bracketets
s
Throttle Controls
Turboc h arger Compr
Compree sso r C asing
Tu r bocharge r Oil Dra i n L in
harg e(s )
ine(
Turbocha rge r Oil Supp ly L ine(s)
harg
Turbocharger Turb in ine
e Casing
Vibrati on D ampe r M o unting C a ps cre ws
• F ollow All Safety I n s tructio ns Note d in the Proce dures.
Follow the m a nufactu r e r 's r ecom m e n d a ti ons fo r c l e a n i ng so lv e n t s and o t h er s ubstances used d u r ing th e
r e p ai r o f th e engine. Always use goo d sa saffety p r ac ti ces with too s and equ pment.
• Environmee nt and F o llow the C l e aning I nstr u c tions
Provide A Clean Environm Specifie d i n the P roce dures
dures
- Th e engine a n d its comp o n e n t s mus t be k e pt cl e a n d u ring a n y r epair. C o n ta m i nat o n o f the e n g in e and
c o m p onents will c a use premature wear
wear..
e Perform the In spe ctions S p ecifie d i n th e Proc edures.
• e all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
Replace
Replac
• U se Genuine Cummins New or ReCon® Service P a rts and Assembli es
lies
- The a ssem b l y in s tru c ti o n s h a v e b e e n writte n to u se agan as m a n y c omp onents a n d assem blies as
assemblie
poss ible. Wh Whee n it i s n ecess a ry to r e p l ace a comp o n e n t or asse
assemb
mby, y, th e p roced u re i s based o n th e use
of new Cummins o r C u m m i ns R e C o n ® compo n e n t s. All of th e r epair se rv i ce s descri b e d in this m a n u a l
aree av a il abl e from a ll C u m m in s D i s tributo r s and m o st D ea e r loca ti o ns
ar
• F o llo w Th e Specified D isassembl y and Ass embly Procedures to Avoi d D a mag e to the Comp o nents.
isass
Comp ete rebuild instruct io ns a r e a vail able in the s h o p m a n ual which c a n be o r d ered o r p u r ch ased fro m a Cummin s
Authorized R e p a ir L o c a t o n . R e fe r to S ecti o n L , Li tera ture, fo r o rder i n g i nstruct o n s .

eneral Instructions Section i - Introduction

Page i - 12 B Series

NOTES
S e ctio n E - E n g in e Id en t ification
B Series P age E - 1

S e ction E - E n g i n e Id e ntificato n
Section C ontents
P a ge
A u tomotive E ngine S pecific ati ons . . . .. . . . .. . .. . . .. .. . . . . .. . . .. . . ..... . . . .. . . . .. .. . . . . . .. .. . . . . .. . . .. . .. . . . .. . . . . . .. . .. . . .. . . . .. .. . . .. . .... .. . . . . . .. . E -4
Engin e D i agrams.. . . . .. . . .... .. .. . . . . .. .. .. . .. .. . ........ .. . .. . .. ............ .. . ...... ............ ...... .. . . ........ . . .. . . .. .. . .... . . . .. . .. . . . .. .. . ...... .. .. . .. . .... .. . . .. . . ..... .. . . . . . E-8
F ro n t V i e w . .. . . . . . . . .. .. . . . .. . . . . .. .. . . . .. . . . .. . .. .. . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. E -9
F u e l P u m p S i d e V iew E-8
· R ear V i e w . . .. . .. .. .. .. .. . . . .. . .. . .. .. . . . .. .. . .. .. . . .. . .. . .. . . ........ . .. . .. . . . .. .. . .. .. . .. .. . .. .. . .. . .. . .. .. . .. .. .. . . . . . . . .. .. . .. .. . . .. .. . .... .. . .. ........
...................... .. E-8
Tu rboc
bochaha g e r Si d e V i e w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . E-9
E n gin e Id entific ation . .. . . . . .. . . . . . .. .. .. . . . . .. . . . .. . . . .. . .. . . . . . . .. . .. .. . .. . . . . .. . . .. .. . . . . . . . . . .. .. .. . . .. . . . . .. . . . . .. .. . .. . . .. .. . . . .. . . . . .. .. . . . . . . . .. . . . . E - 2
ntifica
E ngin e D at apl ate
ate .. . . . .. .. .. . .. E -2
E n gi n e N o men clatu r e .. . .. . .. .. . . . .. . .. . . . . . . . .. .. . .. . . . . . . . . . . . .. . . . . .. . . .. . . . . .... . .. . . .. . . . . .. . . .. . . . . . . . . . ........ . . . . .... .. . . . . . . . . . . . . . . .. .. . . . . .. . . . . . . . E -2
Fuel Pump D a t a pl ate (N a m eplate) .. . . . .. . .. . . .. . .. .. . .. . .. . .. . . . . .. .. .. . . . . E -3

N o n -Automoti ve Eng n e Specifi cation s E-7

Engine Identification Section E - E ngine Identifica tion
Page E - 2 B S e rie s

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

cp ( j)
ummins Engine Company, Inc .
C o l umbus, I n d i ana
En g i ne
Cert. l. D .
C . I.D./ L.
Pouce Cube/L
Cube /L
F am ily
Fa mille
CPL f M o del
M o dale I FEL EPA C AR S
47202-3005 Cert ifi ca t Ca ta l y st No .
Q
c ade in U.S.A.
W ARN IN G Injury may resu k and warranty a voided
W fuel ral e rp m or a l iludes exceed published
maximum v alues lor this model and applicatio n .
3925422 d'identite
Trn ng-T.D . C.
Calage-P.M . H .
C ata l yseur N o .
E n g i ne No .
M o te u r N o .
I
-,
NO X

PM
c: : : : : r -
Valve l as h cold Int. Ex h .
A VE RTIS S E ME N T : Danger de blessures et d'annulal i o n J eu x Soup .a F ro i d R af . N o .
Ad m . Ech
de la g a r a n c i e , Ii debil combus t i b l e , tr / mn cu ak~ude
dapassa,l les valeUI$ m aximum annoncoes an noncoes pour ca F i ring Order Fu e l ra te at ad v . H P mm3
modale et so n utift S a t i o n . O r d r e d ' A llum ag e
llumag Debit combus t. a puis s . indfquee s tr ok e
Date ol M fg . Idle Speed (rpm ) E . C. S . Advertised H P at rp m
Date ol F a b r i cat i o n V i tesse R a lenti Pu i ss. ln dfquee ( c h ) a

ap9 .plgb

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

E xa m p l e
B 3 . 9-105

R a ted Horsepower
Displa lacement
cement in Li te r s
E n g i n e S e r ies
The fo llllow
owin g e xa mp e s hows a mod e l n a m e of an engin e
for n o n -autom o t i v e a ppli cations
E xa mple
4 B T A 3.9

li L D i spl ace ment

Afte rcoo e d
Turbochar ged
E n g in e S er e s
in Litr es

Numbe r of Cylinde rs

Section E - Engine Identification F u e l P ump Data plate (Nameplate)

8 Series Page E-3

Fue
Fu e Pump Dataplate (Nameplate)
The fuel pump dataplate is located on the side of the fuel
pump. It provides information for fuel pump ca ibration.
This illustration shows the dataplate location on a Bosch
rotary injection pump.

Th s illustration shows the dataplate location

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

The Cummins p a rt numbe r f o r the in- line pump and gov

erno r c o mbina ti o n i s l ocate d on the g o vernor d a ta p l a te.

Automotive E n g i ne Specifications Section E - Engine Identification

Page E-4 8 Series

Aut
utoomotive Engine Specifications
G en e r al
Bore - m m [ in.]
E n gin e D a ta
.
--
83 9
--
85.9
------------------------ - - - - - - - - -- - -- - - ---- - ------102 4. 02]--- - - - - - - - - ------ - - - - ----------------- - ----------
S t roke - m m [i n.] .. - - ---- - - -- - - - -- - - -- - - - ----- -------------------- - - -120 [ 4 . 72 ) -- - --------- - - -- - ----- - - - ---- - -- - ---- - - - - - -------- - -
D i sp l acement - l i t re [ in . 3] .. 3 . 9 [239] 5.9 [ 359]
Engine Weight (Dry) Less F l ywhee
and E l ectr ics-kg [ lbs] .. 308-329 [680-725] 388-4 1 1 [855-905]
Firi ng Orde
Orderr . 1. 3.4.2 1 .5.3. 6.2.4
Valve Clearances
- Intake- mm [ in .] . .. . .. . . .. . . .. . . . . . .. .. - - - ----- - -- - - ---------------- - -------- - -----------0. 5 [ 0. 01 O J - - - - - ----- - ---- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
-Exhaust - m m [ in . ] . . . . . . . . . . . . . . . . . . . . . . - - - -- - - -- - ----- - - -- - - - -- --------- - - -- ---- - - - ------0. 51 [ 0 . 02 0 ] ---- - - - - - - - - - - - ----- - -------- -- ----------- - -- - - - - -
Compress on R a t i o .. .. .. . ......... . .... .... (Rotary Pump) 17 . 6:1 (In-Line Pump) 17.9 1
Ro t at i on, viewed from the F r ont o f
t h e Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - - -- -- - - ------ - --------------------- - - - - -----------Clockwise--- --------- - ---------- - - - ----- - - - - - - - - ----- -- - - ----
Aspi ration
- Turbocharged . x x
- Charge A i r Cooled . x x
L u b ri
rication
cation System
L u b r icating O i l Pressur e a t I dle -
(M in i m u m Allowab
Allowabee ) k P a [ P S I ] .. . --------- -69 [
---------- - - - - - - - - - - - - - - - - - - - ---- -- - - - - - - - ------- O J - - - - - - - ---- - - - - - - --- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 
L u b ri catng Oil P r e ss u re at R a t e d -
( M in m u m All owab e) k P a [ P S ] .. - - - - - - - - - - - - - -------------- -- - - - - ---------- - ---------207 30] - - - - ---- - - -------- - -- ---- - ------- - - - - - - ------- - - -- - 
Regu at n g Valve Opening
P re s s ur e kPa [PS ] . . . . . . . . . . . . . . . . . . . . . -- -- -- - - - - -- -- - ---- - - -- --------------- - -- - - ---- 449 [65) - - - - - -- - -- - - - - -- ----------- - - - - - - -------- - --------- - -
D i fferentia Pressur e t o Open the
Bypass Valve - kP a [ P S I ] . . . . . . . . . . . . --------- -- - ------ - - - - -- - -- --- ---- - - - -- - - - - - -- - 1 38 [ 20) ----- - - - -- - - - -- - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - -----
L ubri cating O il C a pac i ty
S t a n dard P a n O n ly -
L it e r [ U . S . Q u a rt s ] '. . . 5 [ 10) 1 4 .2 [15]
Total Sys t em - Liter
[ U . S. Quart s ] .. 1 [ 11. 6 ] 1 6 . 4 [ 17 . 3]
N u mber of L it e r s [ U . S .
mbe Quarts]
fro m Low t o H igh .. .9 [ 1 J 1. 9 [ 2 ]
C ool in g System
C o o l a n t C a p a city ( E ngin
nginee O n l y ) -
Li tre - [ U . S . Qt
Qts.s. J .. . [ 7 .4 ) 1 0. 5 [ 1 1 . 1]
S t a n d a r d M o d ul a ti
ting
ng
The r m o s t a t - R a n ge - ° C [ °F J .. ...... - - - -- -- -- - ---- - - -- Start 83 [ 18 1] - - -- - - ------- - - - - - - - -- Fully Ope n 95 [ 20 3) -- - - - - - - ---- - ---- - -
P r e s su r e Cap ( kP a [PSI])

1 0 4 ° C [ 2 2 0 ° F J S yste ms . . . . . . . .. . . . - - - - - - ----- - - - -- - -- - - -------- - - - - - - ------- - - - -------103 [ 5 ] - - - - - - - - - -- - - - -- -- -- - - - - - -- - - - - ----- - ---- - - - - - - - - - - --

99 ° C [ 2 10 ° F ] S y s t e m s ........ . .. .. . .. . . . .
99° - - ----- - - ------ -- --- - - - -- - - - -- -- - -- -- -- ---48 [ 7) -- ------ - - - - ----- - - - - - - -- - - - - - - - -- - - ---- - -- - - - - - - - -

S e ction E - E n g i n e I dentificati on Automotive Engine Specificat i ons

B S e r ies Page E-5

ir Indu c tion System 3.9 85.9

M a xi m um Allo w a b l e Intake
R e s t r ic tio n a t R a te d S p e e d and
L o a d wit h D i rty Air F i l te r E l e m e n t -
mm H 20 [ i n . H 20 . 635 635
[25] [25]
E xhaust S ystem
M a x i mum A ll owa bl e Ex
Exhh a u s t
Restri c tio n a t R a te d
Speed and Load -
mm H g [i n . H g] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -------------------------------- -- -- - - - - - - - - - - - 6. 2 [ 3] ------ - -- - - - - ----------------------------------- -
-------- -------------- 152.4 [6] with catalyst ------ - ---- -- - -- - - - - - - -- - - - -- - - - - -- --
-- --- ----- - ------
F u e l S y stem
stem
butorr T y pe F uel In jection Pumps)
(D i stri buto
M a xi m u m In e t R es
esttr iction to
to th e F u e l - - --------- -- - - - - - - - - - - - - - - - - - - - - - - - - -- --------- - 100 4] -------- - -------------------- - -------------- - ---- -
-----------
T r ansfer P u m p M u s t Not Exceed - mm
Hg [ i n H g ]
M axi m um A ll owa bl e R e turn Line R e s tric- ------------------------------ ----------- - ------518 20 41------ - - - ----------------------------- - --------
ti o n - m m H g [ i n H g ]
M ax
axmm um Al o w a bl ble
e P r essu r e Dro p - - ---------- - -----··--· - -·-·----------------- - - -- --35 5 1 ------ - -- - ------------- - - -- ---- -----------
----------- ----------
------ -- -
A c oss F u e l F il t e r - k P a [ p si ]
M a x im um I n l e t P r essu re to the
the In ject io n -- - ---- - · - - - - -- --------------------------- - - --··- 0 [ O J - - - - - - ---------- - - - - - - - - - - - - - ----- - --------------
Pump
Pu mp M u s t N o t E xceeceedd - kPa [ p s i ]
 (I n - L i ne T yp e F u e l In jection P umps)
M a x m u m I n e t R e s tr
trii s t o n to the Fue ---------1100 [4] --------- - - - - - ------------------------ - -----------
- -------------------------- - - - - - ------ - - - ---------
sfee r P u mp Mus t N o t E x ceed - mm
T r an sf
[in H g ]
F u e l T r a n s fe r P u m p Minimum Output -- ------------------ -- -- - -- - - - - ------ ------- 1 72 [ 2 51- - - - - - - - --------
---------- - -- - -- -------- - - -- ------ - ------ -
P r e s s u r e - kP a [ p s i] @ R a t e d RPM
F u e F i It e r R estriction ( M a x m u m P r es- - - -- - - - -- - - -- - - - - - - - - - -- -- -- - - - - - -- - -- - - - - - - - -- - - --35 [ 5 1 - - ----- - -- - -- -- - - - - - - -----------
--------------- ----- - -- - ------
---------
su re Drop Across F il t e rs ) - kP a [ p si ]
Fue Pum p Ga
Gallll e r y P ress u r e - kP a [psi] - - - - -- - - - -- - - - - ---- - - - -- - - - - - -- -- - -- - -- - - - - - -- - - - 1 40 [ 2 0 ] - -- -- - - - - -- - - - - -- -- - - - -- - - - - - - - - - -- -- - - -- - - - -- - - -
Minim u m @ R a ted RPM
F ue l Ret u rn M a x mum R estriction - mm - - - - -- -- - - - - - - - - -- - - ---- - - - -- - - -- - - - -- - - - -- - 5 1 8 [ 2 0.4]-
0.4]--- - - ------ - - - -- -- - ---- - - - -- -- - - - -- - -- - - - - - - - - - 
Hg [i n H g ]
E l ectrical Sys te m
Minim u m R e c omm e nded
nde Battee ry C a pa city
Batt
Wit h L i ght Acc
Accee s so r i e s *
- 1 2 V S ta r te r . 2 5CCA
5CC 800CCA
2 4 V S tar t e r . 00C C A 47 5 C C A
With H e a vy Acc e s s o r i e s**
- 1 2 V S ta rte r . 800CCA 950CCA
- 2 4 V S t art
artee r .. 40 0CCA
0CC 475 CCA
M a xi m um Allowable Resistance of Starting Circuit
Resistanc
- W i th 1 2 V S ta r t e r - O h m s - -- -- - -- - - - - - -- - - -- - - -- ---- - - - - -- - - - -- - - - - - - - --- 0 . 0 0 1 2 -- - - ---- -- -- - - ---- -- - - - - - --------- - - - - - -- - - - - ---- -
- W th 2 4 V Sta rter - Ohms - - - - - - -- -- - - - - - - ---- - - - - - - - - -- -- - - - ---- - - -- - -- - - -- 0.0 0 2 0- - - - - -- - - - - - - - - - -- - - - -- - - - - - - - -- - - - - - -- - - - ------
* T yp i c a l l ig ht a ccessor i es i nc ud e ( al te r n a to r , s m a ll s te er ng pump
pump,, and d i sen gag e d cl u tch)
* *Typ c a l h e a vy acc e s s o ri es i nclude ( h ydr au l ic p u mp a nd to rque conve rt
rtee r )

Non-Automotive Engine Specifications Section E • E ngine

ngin Id e n tifi ca tion
Page E -6 B S e ri es

Non-Automoti ve Engin e S p ec
eciificatio n s
G e n eralE n g i . . . . . . . Data
Bore - mm [ i n.] .ne
483. 9 4BT3.9 4BT A 3 . 9
. . . . . . . . . . . . . . . . . . . . . . . ------- - --------- - ---- - -- - ----- -- - - - -------- -- -- - -- - 1 02
685. 9 6 B T5. 9 6 B T A 5 .9
[ 4 . 02)-- -- - ---- -- - - ---------- - - - - - -- - -- - -- - ---- -- - - -- -- --
S troke - mm [ in . ]........... . .. . . .......... . . ------------- ------ -- - - - - - - - - - ------- - - - --------- - -- 1 2 0 [ 4. 72) - - -- - - - - - - - - - - ------- -- - - -- - -- - ---- - -- - -- - -- - - -----
3]
Displacemen t - li tre [i n. . .. . . .. . . .. .. .. . - - - - - - - - - - - - - - - - - - -- - 3. 9 [ 239] -- - -- - - - ---- - -------- - - - - --------- - - - - - ---- 5 .8 8 [ 3 59] -- -- -- -- - - - ---------
Engin e Weight (Dry} Less Flywhee
and Electrics-kg [lbs] . . . . .. .... . . .. ... . 308 [680] 320 [ 705] 329 [ 725] 388 [ 8 55] 3 99 [ 880]
880 41 1 [ 9 05 ]
i ri n g Order 1.3.4.2 1 . 5.3 6 . 2.4
Valve Clearances
- Intake- mm [in.] . . . . . . . . . . . . . . . . . . . . . . . . . ------ - - - ------------------- - - -- - -------------- - - - --. 25 [ . 0 1 O J - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - -
-Exhaust- mm [in.] . . . . . . . . . . . . . . . . . . . . . . ----- -- ------ - -- - -- - ---------- - ----- - - -- - - ---- - - - -- -. 51 [. 020] - -- - -- - - ---- - - - - - - - ------ - -- - - - - ---- - -- - - - - - - - - - - - --
Compression Ratio 18 . 5:1 17.5:1 1 6.5:1 18 . 5 : 1 1 7 . 5 :1 16.5 1
Rotation, viewed from the Front of
the Eng n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . - ------ - --------------------------------------------CI ockw i se-- - - - ----------------- ----------- - ------------------

As pi ration
-Naturally Aspirated . x
-Turbocharged . x
-Aftercooled .. x
L u brication System
Lubricating Oil Pressure at Idle -
( Minim um All owable} kPa [PS ] .. - - - - - - -- -- -- - - 6 9
----------------------------- - ---- - - - - - - -- [1 O J - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ------ - - - - - - - - - - 
L u bricatin g O i l Pressur e at R ated -
(M i nimum All owab e} k Pa [ P S I ] . .. ------- - - - - - - - - - - -- - ------- -- - - -- -- - ---- - -- - -- - - - - - - - 2 0 7 [ 30] - - -- -- - - -- - - - - - - ------ - - -- ---- - -- ------- ---- - - - - - - -- 
Reg u ati n g Valve Opening
Pressure kPa [ PS I] . . . . . . . . . . . . . . . . . . . . . ---------- - -- - -- - -- -- - ------- - - - -- - - - - ---- - -- -- - - - - - -449 [ 65] - - ---- - - - - - -- -- - - ---- - - - - - -- - - -- - - - -- ---- - - - - - - - - - - - -
O iff erentia l
erenti P r essure to Open the

B yp ass Va l ve - k Pa [ PSI] . . .. . . .. .. . . - ----- - - - ---- - - - - - -- - -- - - - -- - - -- - - - - -- - -- - - - - - - - -- - - -138 [ 2 0] -- - - - - - -- - ---- - - -- -- - - - - - -- - -- - - - - -- - ------------- ---

bricaa t i ng Oil Capacit y
L u bric
tandarr d P a n O n ly -
S tanda
Liter [ U .S. Q u a rt s ] 9.5 [1 0 ] . 5 [10] . 5 [ 10] 4.2( 15] 42 [1 5 ] 14 . 2 ( 15 ]
To t a l Syste m - Lite r
[U .S . Qua r t s ] .... ..... .. . ...... ........ ... 1 0 .9 [11. 5 ] 11 [11.6] 1 [11.6] 1 6.3 [ 1 7 .2 ] 16.4 [17.3] 1 6 .4 [1 7 .3]

Numbe
Num berr of Lite r s [U . S. Qua rts ]
f ro m L o w to H ig h 0 . 9 [1] . 9 [ 1) 0 .9 [1] 1 .9 [2 ] 1.9 [ 2] 1 .9 [2 ]
C o o li ng S y s tem
tem
C o o l an t C apacity (E n g i n e O nly) -
Litre - [U.S . Qts . ] 7 [ 7.4) [ 7 .4] 9 7 [10.3] 10 . 5 [11
[11.. 1] 10 . 5 [1 1 . 1 ] 14.5 [15.3 ]
S tandar d M o d ul at n g i ;/fY
ostta t
Th e r m os - R a n ge - °C [ °F] .... - - - - - - ----- - - - ----- -- - Sta rt 83 [ 180] - - - -- ---- -- ----- - - - - -- F ully Ope n 95 [ 203] - - - - -- - -- -- - - ---- - - -- 
P r e s s ure C ap ( k P a [ P SI ]}
1 04 ° C [ 220 ° F] S y s tems:: · , . . . . . . . . .. - ---- -- ------ -- ---- -- - - - - - - - -- ---- - - -- - - ---- -- - -1 0 3 [ 1 5 ] - ------- - - -- - - - - ----- -- -- - -- -- -- -- - - - -- -- - - -- - - -- - ---
99 ° C [ 21 O ° F ] S ys te ms . ~
....... .. -- - - ----- - - - - - -- - - ------ - - - - - - - ----- - - -- - ------ - ---- - 48 [ 7 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ---

Section E - Engine Identi

entifi
fication on-- Automotive
N on E n g i ne Specifica tion s
B S e ries P a g e E -7

ir Inductio n S ystem 83. 9 BT3.9 BTA3.9 85.9 B T 5.9 6 B T A 5 .9

Maximum Al owab e I ntake
R e s t riction at Rated Spe ed and
L oad with Dirty Air F i lter Element -
m m H 20 [ in. H 20 ] . 508 635
635 635 508 635 635
[ 2 0] [25 ] [ 25] [ 20] [2 5 ] [ 25]
E xh a u s t Sys tem
M a x i m u m Allowa b l e E x h au s t
R e strictio n at R a te d
S p e e d and Load -
m m Hg [ in . H g ] ,.... . ......... ------------- - -- ---- ----- - - - - - - ---- - - ----------
-- ----------- ----------76.
76.22 (3. 0 1- - ------ ---- ------------ - -- - - -- ----
-------------
--------- - ---
F u e System
(Distributor Type Fuel Injection Pumps)
M a x im um Allo w a b l e R e s tric t io n t o the - - -- - - -- -- ----------- - ------ - - ----------- - ------- - 100 [ 4 ] ---------- - - ----------------- - ------------------ - -
F u e l Tr a n s fer P ump M u s t Not E xceed -
mm Hg [in H g ]
Maxim um Allowable Return L in e R e s tric - - - ------- - ----------- ---- - - --------- -- - --------518 [ 20.4 ---------- - - - - - - - - - - ------- - - -----
---------
------ - ----- -- 
t o n - mm Hg [in Hg]
M a x imum Allowable Pressure Drop -------- - ----
--------
-------- ----- - - - - - -- - - - -- - - - - - - -------35 [ 5 ] - -- - ----- - --------------------- - - -- - - --------------
---------
A c r o s s Fuel Filte r - kPa [psi]
Maximum I n let P re ss ure to the Injection ------- - - - - - -- - -- -- - 70 [ O ] - - -------- - -------- - - - - - - - - ----- - - ---- - - ---- - - --
---- - ----- - -- - - ---- - -- -- - - - - - - - -----
Pump M u st N o t E x c eed - kPa [ps ]
(I n - L i ne T ype F u e l Injection Pumps)
M a x im u m I n l e t R e s t r i cti o n t o the Fuel --------- 10 0
-- - - ---- - -- - - - - - ---- - ---- - - - -- - - - - - - ------ ------- [ 4 ] -------- - - - -----
------------
------- -- - - -- - ------- - -- ---- -- - ---
Trans f er P u mp M u s t Not Exceed - mm
[in H g]
 F ue l Transfer P ump Minimum Output -- ---------------- - - - -- - - ----- ---- - - - - ---- - - - ---- 1 72 [ 2 5 1 - - -- - -------------- - ------- -- -- -- -------- - -------
P r e s sure - kPa [psi] @ Rated RPM
Fue F i I t er Restr c ti o n (M a xi m u m Pres- ------ - - - - -- - -- - - - 3 5 [ 5] ------ - -- - ------------- ------
------- - ----------- - ---- -- ---- - - -- ---- -------- - - - - - - - ---- - -- - -- - --
sure D r o p Ac r oss F i l t ers) - k Pa [ p s i]
Fuel Pump G a llllee ry P r e ssure - kPa [psi] -- - -------- -- ------ - - - - - - --------- -- -- - - -- - - -- - 1 40 [ 201-- - --------- - ----- - ---- - ----- - -- - -- - - - - - -- - - - -- --
Minimum @ R a t ed RPM
F u e R e t u rn M a x mu m Rest i ct on - m m -- - - -- - ----
--------- ------ -- - - -- - -- - - - -- -------- - - - -51 8 [ 2 0 .41---- - -- ---- - - - - ------- - -- - - -- ---------- ----- - - - 
-----------
H g [in H g ]
E l e ctrical S yste m
M i n i mum R e c omm mme ended B a tte ry C apacity
With Light Ac cess ori es*
- 1 2 V S t a r ter. . . .. . . .. .. .......... . . . . . . . .. . . . .. . . . ...... . 6 2 5CCA 6 2 5CCA 625CCA 800CCA 800CCA
800C CA 800CCA
- 2 4 V S t a rt e r ...... . . . . . . .. . . ........ .............. . . ...... . ...... 312CCA 4 0 0C CA 400CCA 475CCA 475CCA 475CCA
With H e avy Acce ssories**
- 12 V Starter..... ... .. . .. . . . . .... .. .. . . ...... . .. .... 800CCA 800CCA 800CCA 950 C C A 950C C A 950CCA
950CC A
- 24 V S tart e r... .. .... ...... .. . .. . . . . . . . . ...... ..... . . .. . . 400CCA
400CC A 4 00 C CA 40 0C0CCA CA 475 CCA 475CCA 475 CCA

Maximum Allowable Resistance of Starting Circuit

- With 1 2 V S t a rt e r - Oh ms . . . . . . . . . . . . . . . . . - - -- - - -- -- - - -- -- - ---- -- - -- - - - ---- - ---- - - - - - - - -----0. 001 2 - - - -- - - - -- - -------------- ----- -- - ------------ - - ---
- With 2 4 V S t a rt e r - Ohms .. .. ------- - - -- - ------ - - - ----- - ------- -- -- - - - - ---- - - - - 0.002 0 -- ---- - - - - - - -- -- - ---- -- -- - - - - - - ---- ---------- -----
* T y p ic a l l i g h t accessori es includ
includee ( a lt e rn a tor s m a ll s t eerin g p ump, and disengag
disengagee d cl u tch)
* *Typical heavy a ccessories i ncl ude (h y dr
draa ul i c p u mp a n d t orqu e con verter)

Engine Diagram s S ection E - E n gin e I d entification

Page E - 8 B Series

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

E ngine Air In l et

High Pressure I ntake A r P r e h eater

Fuel Li nes (o ptional)

Fuel F ilter/
Water Separator

3 1 4 N PTF tinch) Water (Heater)

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

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

F uel Lift P u m p

ngine Data Pl a te D i pstick

1 /8 N F T F (inch )
Oi l Pressure e w 900gb
 Fuel Pump Side View

R e a r E n gi n e
Liftin g Bra c ket
T u r bo Ex ha u st O utl e t
F u el Return C o nn ec
ectt ion

F lyw heel Flexplat e M ou n ti n g

Holes

Flywhee l H ou si n g

Rear View

Section E - Engine Identificatio Engine Diagrams

B Seri es Page E-9

uel In jection Nozzles Turbo Wastegate

Oil Fill

Water Outlet

Lubricating Oil Filter

L ubricating O i l C o o l e r

Starter Motor Water Inlet

and Solenoid
1 /2 NPTF Water
---- (Heater Return)

Provision or Oil
Immersion Heater

Oil Dan --
~

Turbochager S i d e View

TurboAir Inle t
 F an Pull e y

ltlternator
ernator F ue l P um p D ri ve Cover

A r Compresso r
A i r O u tl e t

V ibration Dampe r F r on t Gear Cove r

Fan Dr i ve B elt

Front Vie w

Engine Diagrams Section E - Engine I dentification

Page E-10 8 Series

NOTES
Section T - Trouble shooting L o g ic
B S e r ies Page T - 1

Sect on T - T r o u bleshooting L og c
S e ction Contents
P a ge
S e ction T - T r o ublesh ooting T -2
P r o c e d u res and Tech n i q u e s T -2
T rou b l e shooti ng Symptoms Charts T -2
A l t e r n ator Not C h arging Or I n suffi
ufficc ie n t C h a r g i n g T -48
C o m p ress i on K n o cks T-41
C o o l a n t C o n t a m i n a ted T -38
C o o l an t L oss T-3 1
C o o l a nt T e m p e r at u r e Above N o r m a l - G r ad ua l O ve r heat T - 25
C o o l an t Te m p e r a ture A b ove N o r m a l - S u d d e n O v e rh ea t .. . . . .. .. . .. . . . . . . . . . . . . . .. .. . . .. . . . . . .. .. . .. . . .. .. . . . .. .. . . . . . .. . . . . . . . .. . . . T - 28
C o o l a nt T em p e r a t ur e Be low N o rm a l... . . .. . . . . . ..... . . . .. .. ........ . . . .. ... ........ . . ...... . .. ......... . ..... ...... . . . . . . . . . . . . ..... ...... .. . . . . .. . . ... . T - 30
E n gi n e Cran k s B u t W ill N o t S tart - No S m o k e F r o m E x h a u st.. T -4
E n g i n e H a rd To S ta rt Or Will N o t S t art - S m o k e F rom E x h a us t.. T -6
E n g in e I dle R o ugh (Irr e gularly F i ri n g O r E n g in e S h ak in g ) T -1 1
E n g i n e N o i ses Excess iv e T -47
E n g i n e Power O u t p ut Low T-17
-
g i ne R P
E n gi unMs W N o t ORr eM
R oillugh a cishfirRi nat
g ed S p eed T - 15
13
E n g in e S t a rt s B u t Will N o t K eep R u n n in g T -9
E n g in e Surg ing ( S p e e d C h a n g e) T-1 0
E n g in e Vibr Vibraa tio n E x c e ss ive T -45
E n g in e W i ll Not C ra nk Or C r a nks Sl o wly T-3
E n g i n e W ill Not S h ut Off... . . .. .. . . . . ...... . ... . . . . . . . . . ... . ...... . . . . . . . . . . . . .. . . . . .. ... ... . . . . . .. ..... .. . ... .. . . . . ..... . .. . . . . ... . . .. . . . . ... . .. . . . .. . .. . .. . T - 44
E x h au s t Bl ac k Smoke E x c e s si ve T - 21
E x h au s t White Smoke E x ce s siv e T - 23
Fuel C o n s u mption Exce s si ve T -42
F u e l Or Oil L e ak i ng From E xh a ust Manifold .. .. . .. .. .. T-40
Lubric at ing Oil Consumption Excessive. . . .. . .. .. ... . . . . . . . . ........... . .. ..... .. . . . . . . ..... . . . .... ...... . .. . .. ... ........ . . .. . . . .... .. . . ..... . . .... .. .. T - 36
L u b r i c at i ng O i l Conta min a ted . . .. . . . . . .. . . . .. . . . .. . .. .. .. . .. .. . T - 39
L ub r ic a ting O i l P r e ss ur e H ig h T-35
Lubric at ing O i l P r essure Low T-33
Section T • T r ou bleshooting Section T • Troubleshooting Logic
Page T-2 B Series

Section T • Troublesh o oting

P r o cedures a n d Te c hn
hniques
iques
A thorough anaysis of the customer's complaint i s th e key to successful tr troo ub l e s h o o t n g . Th e more info
inforr m a tion
k n own about a complain t , the faster and easier the problem can be so l ve d.
The Troubl eshooting Sym p toms Charts beginn ng on Page T-4 are organ z e d so th a t a probl e m c a n be located and
c o r rect ed by d o i ng the easi est and most logica th ings fi rst. C o m p l ete a ll s teps i n th e seq u ence s hown from top
to bo ttom.
bott
It i s n ot poss ble to i nclude all the solutions to problems t hat can occur; h o we ver these c h a rts should stimulate
a thought process that will lead to the cause and correcti on of the probl em.
Follow these basc tr oubleshooting steps
• Get a ll th e fact s co n cern ng the complaint.
• Anayze the problem th o r o u g h l y .
• Relate the symptoms to th e b asic engine systems and components.
• Consider any recent maintenance or repair action that may relate t o th e problem
• Double-ch eck before beginning any disassembly.
• Solve the problem by using the logic charts and d o i ng the easiest thing
thingss f rs t.
• D etermine t he cause of the problem and make a thorough r e p air.
• After r ep ai r s h ave been made, operate the engine to make s ur e th e c a us e o f th e probl e m h a s been corrected

T r o u bleshooting Symptoms C h a rts

U s e th e c harts g iv e n on th e fo llllow
ownn g pages of this secti on to h e l p yo u to d i a gnose a nd r e p a ir a p roblem with your
eachh row of b l ock s fro m top to bottom . F ollow the a rrow
e n g in e . R ead eac rrowss throu gh t h e c h a rt to ident fy the corrective
action.
 Section T • Troubleshooting Logic Troubleshooting Symptoms Charts
B Series Page T-3

Engine Will Not Crank Or Cranks S l owly

Cause Corrections

Remove the starting motor and check for

Starting Motor Operating
Operating But Not broken teeth on the ring gear or broken
Cranking the Engine starting motor spring. Refer to Procedure
6-10.
OK
•
Starting Circuit Connections
Corroded
Loose or 1---------· Clean and tighten connections.

OK
•
----------B-att_e_ry __ _ h _ a _ r g _ e__
__ _ o w I
__.~----- - - _
. _ _ _ __dure k _ b _ a _ t t _ e _ r y _ v _ o _ l t _ a _ g _ e . _ R _ e _ f _ e _ r - t o ___ r o _ c _ e _ - _ _ _ _ .
_ h _ e _ c _6-01.

l OK
•
No Voltage
Voltage to Starter Solenoid Check voltage to solenoid. Refer to
to
Procedure 6-03.

OK
•
Crankshaft Rotation Restricted Bar the engine to check for rotational
resistance.

OK
•
Sol e noid or Sta rtng Motor M a l fu nction R epla ce s ta rtng m otor. R e fer to
P r o cedure 6 - 10.
T roubleshooting Symptoms C harts Section T - Troubleshooting Logic
P ag e T - 4 B Series

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

ause Corrections

................_N _ o __ u - e l _ i _n_s_u_p _ p _ l y - - T a _ n _ k ...... -------- ..._ C _ h _ e c - k / ---- -r- r e - p -l- l e -n

-n - isis _ h _ f _ u _ e _ l _ s u _ p _ p - lyly __.

...
OK

Check for loose wires and verify that the

Electri cal or Manual Fue Shutoff N ot valve is functioning. Check to be sure
Ope n manual shutoff lever is in the run position.
Refer to Procedures 5-05 or 5-11.

...
OK

Verify proper starting procedure Refer

I mproper Starti ng Proce d u re to the Operation and Maintenance
Manual.

...
OK

F u el F il ter P lugged With Water or

O the r C o n taminat i on
~ -- - - - - - -· Drain fuel/water separator o r r epl ace
fuel filter. Refer to Procedure 5-04.

...
OK

Refer to Procedure 5-02.

In s p e c t Fuel T r a n s fe r Pump Operat i on
Opera --- -- ·

...
OK

F ue l In je ctio n Pump N o t G etting F ue l Check fuel flow/b l e e d fue l sy

sys
stem.
o r F u e l i s A e r a ted R e fer to Procedu res 5-03 a n d 5 - 1 5 .

...
OK
 xi mum inlet restriction to fuel transfer
Max
Ma
C h e ck F u e l In l et R estrction pump must not exceed 100 mm Hg [4 in .
Hg].

...
OK

Air I n t ake or E xhau st System P lu gged Visually check; remove the obstruction.
Che ck exhaust sys tem for obstruction .

...
OK
(C ontinued)

Sectio n T - T roubleshooting L o g . ic
ic Troubleshooting Symptoms Charts
B Series Page T-5

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

Cause C o r rections

I.
F _ u _ e _ l _ D - r a _ i _ n _ B _a _ c _ k
I
__.~- - -·· ··· p l umb
'-~-~- umbed
e -r i -f ed
y_ t_tho_th
a_e t -bottom o fe _the
t h _ e _f_u_ u _ r _ n _ tank
l - r e - t fue l - i n _ e _ i _s~~~.....i

...
OK

M a lfunctioning F u e l R e turn O ve rflow C h eck/repl ace return overflow valve

Va lve (lnline fuel pump only) R e fe r t o Procedur e 5 - 27.

...
OK

V i suall y check fue l delivery with an externally

Worn o r Malfunct
Malfunctoo ning Fuel In j e ctio
ctionn P u mp •- -••• • • c o n nected injector to one of the pump
outlet s. Remove t he fuel injection pump.
H a v e calibrati on checked.

...
OK

In jection Pump T ming Incorrec

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

OK
...
Engine Camshaft Out of Time corrr ec
C h e c k/cor ectt gea
gearr train timing align
m e n t. R efer to P r ocedur ure
e 7- 1 9.
Troubleshoot i ng Symptoms Charts S e ction T - Troubleshooti n g L ogi c
P age T-6 B Serie s

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

Cause Correction s

S t a rt ing Procedure Incorrect R e f er to

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

OK
•
C r a n k in g Speed Too Slow (Minimu m V e r i fy th a t th e driven u n its a re n o t
C ra n k in g S p e e d = 1 5 0 R PM) en g ag e d

OK

Check t he b atte r y , st a r t i n g m o tor, a nd lo o k

fo r l oose o r corro d e d wir ng co n n e ct i on s .
R e fer to Pr o ce d u r e 6 - 02 .

Bar the e n gine to c h e ck fo r i n te rn a l

rotatt io n a l r e s is ta
rota tance.
nce.

C o l d S tart ng A i ds N o t W o r k ing or Are V e ri fy the a ids are o p e r a t n g . R e fe r to

Ne e d e d O & M m a n ua l fo r re comme n d a ti o n s.

OK
•
I n ta ke A r In s uffic e nt Insp e c t o r re p l ace f lt e r a n d ch e c k for
o b s t r uc t o n s to t he ai r su p p l y tube

OK
•
C h e c k the flow thro u g h th e filter a nd
throu
Air i n th e F ue l Syste m o r the Fuel bleed t he system . L o c a te and corre ct t h e
S u p p ly In ad e q uate a i r s o u rc e. R e f e r to P roce d ur e s 5 - 0 3
 and 5 - 1 5 .
OK
•
V e ri fy by o p e r a ting the e n g i n e w it h cl ea n fuel
F u e l i s C o n ta m i n at e d or D iese l F uel fr o m a te m p o r a ry tank of N o . 2 d i e sel fuel.
G r a de N o . 1 U s e d A b o v e 0 °C [ 32° F]
32°F R e fer to the "F ue l R e c o m m e n dat i o ns/
Spe c ifi c a tions " i n the O p e r a t i o n an d M a i n t e 

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

• (Con t i n u e d )

Section T - T r o u b leshooting Logic eshootinn g Symptoms Charts

Troubl eshooti
B Series P age T-7

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

ause C o rr
rrections
ections

I
......-l······ ·· ._
,..__ F _ u _ e , _D--r a-in
_ _a_c_k b ottroi -m
v_e- f y_of
f_fue tan k.
u _e_l-re- tu _ r _n _ -in_ e _ _ s _ p _ l u- m --_ ,e --- t o

OK
....
I n s p ect Fuel T r a nsfer Pump Operation R e fer to
to P r o ce d u re 5 - 02.

OK
....
Malfun ctio n in g F u e l R e t u rn O ve rflow C h e c k/replac e re turn overfl ow valve.
valve.
Valve Refer to P r o c e d u re 5- 2 7.

OK
....
Maximu
Maxim u m i n let r estrict o n to fue l transfer
estrict
C h e ck F uel In le t R e s tr iction -- · p ump m us
ustt not exc
exceed
eed 10 0 m m Hg [4 i n .
Hg].

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

Valves I ncor rect y Adjusted

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

OK
....
O n e o r Mor e In je ctors Wo rn o r
ject C h eck/re p l ace in jectors. Refe r to
M a l fun c t o ning P r o cedures 5 -13 a n d 5-40.
 OK
.... (Contin ue d)

T r oubleshooting Symptoms C h a rt
rts
s Section T - T r oublesho o ting L ogic
Page T-8 B S e r ies

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

Cause Corrections

P e rform a c ompr
ompree ss i o n c h e c k to
Engine Compression Low identify the problem. R e fer to Procedure
7-01.

OK
•
F u e l In jec
ection
tion P u m p Malfunc tioning/ R e move fue l in j e c tion pump. H a ve
Delive ry V a l ves M a lfunctio ning ca libration checked
Section T - Troubleshooting Logic Troubleshooting Symptoms Charts
Symptoms
B Series Page T-9

Engine Starts
Starts Bu t Will Not Keep Running

ause Corrections

.._ L _ o _ w__- u e _ l _ L _ e _ v _ e _ l
------------~--------1 c _ h _ e _ c k / - - - - f i l - l - f u - e - l - t a - n - k - . __
-------------1
OK
...
Engine Starting Under Load Di sengage d r i ven units

...
OK

Idle Speed Too Low for Adjust the idle speed. Refer to Proce
Accessories dures 5-38 and 5-39.

OK

ntake Air or Exhaust

... System 1---------
Visually check for exhaust restriction
and inspect the air intake. Refer to
Restricted page 3-11 and 3-23 .

...
OK

flow through the filter and

Check the flow
Air in the Fuel System
System or the Fuel •••••••••• bleed the system. Locate an d correct th e air
Supply is Inadequate source.. Refer to Procedures 5-03
source
and 5-15.

...
OK

Ve r i f y b y inspecti n g th e fue l filter Clean

Fuel W ax i n g D ue to E x t r e m e ly Cold
the system a n d use c l i matized fuel o r fuel
W ea th er heater s .

...
OK

V e r i fy b y o p er a t ng the en g i n e with cl e a n
.._
_ F _ u _ e - l C _ o _n _ t _ a _ m - i n - a -t e _ d __. • · · ·----- aun_de _flu
._ __ __ae _m
l _ f rs_ho _ mthe fu_ u _ p _ p _ l y - - t a _ n _ k _ . _ D _ r a ____
a _ry-- st ank.
eol _rs_upply i_n
~

...
OK
 ..,_ P -l u_g _g - e_d _ u _ e _ F _ i _ l t _e _ r I · · · ·· · · ·
.... ._ dCur _ e _5c-_0k 4/ _ r _aen_ dp _
_hes l - ia_5l-
- 16e. . _ R _ e -e _r _ t _ o _ P _ r _ o c _ e _ - ~
t-e[_

OK
...
Fu e l D r a in M an i fo l d or R e turn L in e C h e ck/corre c t the r e s triction. R efer to
R es tr i c te d (L u cas C AV O n l y ) P ro ce dure 5- 14 .

Troubleshooting Symptoms Charts Secti on T - Troubleshoot

e shootng Logic
Page T- 1 0 B Series

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

ause Corrections

______ F _u _e _l _L _ e - v e _l _ L _ o _ w ---~ -- -- -- .. C _ h - e c _ k / _ f -il - _l a_n _ k _ .

-u _ e - __,

..
OK --1
I f the Cond i ti on O ccurs at I d l e , the Id l e A d just the i d l e . R e fe r to P rocedures
rocedur
Speed S e t Too Low for A ccess ories 5 - 38 a n d 5 - 39

..
OK

Throttle L i nkage Misadju

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

OK

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

OK
..
Blee d the fue l s ys te m an d corre ct sour ce

------------A-e - r a _ t - e d _ F _u _ e _ i _._ - --- - - - _ __

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

..
.. ~
OK

One or M o re I njectors Wo rn or C h eck/replace the injectors. R e fer to

Malfunctioning P rocedure s 5 - 13 an d 5-40

..
OK

I,
Fue I n ject on P u m p Ma functioning/ R e move fuel injectio n pump. Have
very V a lv e s M alfu ncti oning
Deliv
Deli calibration ch eck e d.
Section T - T r ou blesho
bleshooo ting Logic Troubleshooting Symptoms Charts
B Series Page T - 1 1

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

Enginee Shaking)

ause Corrections

All ow eng ine to warm to ope r ating te mpera-

E _ n _ g _ i .ne--is___ o _ l d _. --- --- -- ... _etmp --if_ee _. n _R

u -eeratur
rature g- _re_
e_fllne_ to
n_wo _
T rt_r
oubl ting
h _o _p
c _ hoo
e _ a _es _e_r_Lat i cn __.
o g- _g
.. 5 0K ~ fo r C o olant Tempe
emperr ature B e low No
Norr m al.

...
Idle Spe
Speee d Too L o w for t h e Accessor i es C h eck/a d j u s t lo w i d l e scr e w R efer to
P roce dures 5 - 38 and 5-39.
rocedu

...
OK

Ve ri fy condtio n o f mo unts . Refer to

mount
E n g in e M o unt s Over- Tightene d ,
equ ipment m a nufacturturee 's servic
service
D a m a ged or Loo se
Loos
instructi ons .
instruc

...
OK

ect/corre ct l eaks in the h i gh pre

Inspec
Insp ssu re
press
H i gh Pressure F u e l L e a k lines
lines, fittings i n je ction s e a l ing washers or
delive ry valve sea l s . Refer to Procedures
5 -12 a n d 5 -33.

...
OK

B l e e d the fue l sys tem and correct the

--------A--ir-in--th _e _F _ u _e _ l _S _y_s -t-t e _m

ir-in--th _.• - - - - - --- . . . . _ s _ o _ u _ r c _ e ~ o f _ t _ h _ e _ a _ i r _ . _ R _ e -e _ r _ t _ o _ P _ r _ o c _ e _ d _ u _ r _ e s_ _ - o _3__,
_ and 5 - 1 5 .
.. ~

...
OK

F ue R e turn O verfl ow Valv

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

...
OK

Check/r ep ace fuel tran sfe r p ump.

F ue Tr ansfer Pump M alfunctio n i n g
Refer to P rocedure 5 -02.

...
OK

Clean p r e - fifill ters an d s creeeenn s a nd che ck

F u e l S uppl y Restr icted fuel li ne for restriction. R epl ace fu el filter ter..
Refer to Procedu cedurr e 5 - 04.
 OK

... (Cont nued)

Troubleshoot i ng Symptoms Charts Section T - Troubleshooting L o g ic

Page T- 12 B Series

Engine Idle R o u gh (Irre gularly F i ring O r E ngine Shaking) (Continued)

C a u se Corrections

I n j ector N e e d l e Valve S ti cking - - --- - - - C h eck/rep ace the injecto r . Refer to

Procedure 5-40.

...
OK

F uel Injec ti o n P u mp o r D e li very V a l ve - ------ - Remove fuel injection pump. Have

M alfuncto n i ng calibration checked.

...
OK

I Valves N o t Seali n g
f--- --- - -
Adjust va l ve s . Refer to Procedure 7-04 .

...
OK

P e rform a compression check and r ep a ir

C o m p ressio n in One or More C y li n ders 1 - - - - - ---- as r e qu i r e d . R efer t o P rocedure 7 - 0 1 .
Low
Section T • Troubleshooting L ogic Troubleshooting Symptoms Charts
B Seri es Page T- 1 3

Engine Runs Rough Or Misfiring

Cause Correctons

Condi tion On ly Occu r s a t Id l e R e fer to the tr ouble s h oot n g l ogic -

Rough Id l e .

..
OK

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

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

I n spect/correc ectt le a k s i n the high press ure

Fuel Injection Lines Leaki ng line s , fittin g s i n j ector s ealing was hers, or
deli very valve s . R e fer to P r o cedure s 5-12

..
OK

b l eed kthethesfyl ow
the
Chec u gh the filter and
Air i n the F uel o r the F uel Supply i s s te mthro
. Locate and cor rect the
I n adequate ai r s o u r ce Refe r to P r ocedu r es 5-03
a nd 5 - 1 5 .

..
OK

Malfunctioning F u e l R e turn Ove rflo w Che ck/re p l ace re tu rn overflo w val ve .

Valve Refe r to Procedu re 5-27

..
OK

F u e l T r a nsfer Pump Malfunctionin g Che ck/repla ce fuel tr a nsfer p ump .

Refer to P r ocedure 5 - 0 2 .

..
OK

C l ean p r e - fi lte r s and scre e n s an d che ck

F u e l Supply Restricte d fuel li ne for restriction. R e p l ace fu fuee l filte r .
Refer to to P r o ce dur e 5 - 04

..
OK

F-ue_l _C _o _ n _t a -m n- a-e_d ~ • • • • • ••• . cl ea

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

..
..
OK
( Con tinue d )
tinu
Troubleshootin g Sym ptoms Charts S ection T - T r ou
oubl
bleshoo ti ng Logic
Page T-14 B Seri e s

Engine R u n s Rough Or Misfiring (Con tinued)

Cause Corrections

Check for a bent push r od and a d just

V a l ve Adjustment In correct valves R e fer to P rocedures 7 - 0 3 and 7 - 04

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

Perform a c o mpr e ssio n ch eck a n d r epa ir

Compre ssion in One or More C yl i n d ers
Compre
a s requ re d . Refe r to P r o cedu
cedurr e 7 -01.
Low

...
OK

ectorr s M a l function ng
I n j ecto Che ck/re place in j ectors. R e f e r to
Procedu
Proced u res 5-13 a nd 5-40.

...
OK

Injecti
tion
on Pump (Deliv
(Delivery Valves) Remove fuel inje ct on pump. Have
Hav
Defective calibration checked.

...
OK

C a msha ft O u t of T me Check/c orrect gear train t m i ng alig

alignn 
m e n t. Refer to P r o ce d ure 5-36

...
OK

C a m s haft o r Tappets Damaged In s p ect camshaft a n d tappet s. R e fer to

P roced
rocedu u r e 7 -19.
Section T • Troubleshooting L ogic
ing T roublesho oting Symptom
Symptoms
s Charts
B S e r i es Page T-15

Engine RPM W ill N o t R e a ch R a ted S p e e d

C a u se Corrections

T a ch o m e t e r M a lfunct o ning Verify e n gine speed with h and tach o m 

e ter. Corr ect as r e q u ired.

..
O
V e ri f y high i d l e speed wit h o u t l oad
E _n _ g -n _e_
e_o l o _a _d _e _ d _. _ - - --- - - -
o_v_ e _ r _ lo ._ __ _ e si s_ t -being
gn e_ var i g _ a __ _ r _a - t i o_
t e- p eused _ o--b
n e _ _ u _ r e _ c _o _ r _ r e _ c _ t_
t _ __,

..
.. ~
OK

Ad jus t l i nkage for st o p -t o -s top fuel control

Thrott e Link age Worn or I ncorrectly
rrect
lever t rave l. Refer to P r o cedure
ceduress 5-05 and
Adjusted 5 -10.

..
OK

Check/pl ace shutoff l e ver in ru n p osit o n .

M gagedca S h u t off L e v e r P a r t i a lly
E nechan R e f er t o P rocedu res 5 - 0 5 a n d 5 - 1 1 .

..
OK

V e r if
ifyy by ope
operr a ting the engine from a
Fuel Qualit y P o o r o r D iese F u e l G r a de •• _ • • • _ • • temp orary tank o f N o. 2 diese fue l. R e f e r t o
No. 1 Used Above 0°C [ 32°F ] the "Fuel R e commendations
ommendations//Specifica tions"
i n the B S e r ies O p e r a t i o n and M a i n ten ance

..
OK
Man u a l, B ulle tin N o . 38102 0 5 - 10 .

Check th e flow thr oug

oughh th e filter to l ocate
F u e lSupp~ln adeq u~e
ade the so urce o f the r e s trictio n . R e f er to
P r ocedures 5 - 01 a n d 5 -02.

..
OK

Fuel R eturn Overflow Va l ve Check/r e p l ace f u e l return overflow valve

M a lfunctioning

..
OK

F ue l T r ansf er P um p M a l f u nctio n i ng Check/replace fue l t r ansfer pump.

R e fer to P r ocedure 5 - 0 4 .

..
OK
( C o n t i nued)
T roubleshooting symptoms
roubl C h arts Section T • Troubleshooting Logic
Page T-16 B Series

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

Cause C o r recti o n s

Air-Fuel Co ntrol Leak/Obs tructions Check/repair l eak. Check/clean AFC

tubing and fittings fo r obstru ction

OK

I f t he Conditio n is lnt ..
lntee r m itta n t
M a n i fold Dra i n L in e R e s tricted
Check/remove restrcti on. Refer
Procedure 5 - 1 4.
Refer to
(L ucas CAV D PA Only) .•

..
OK

ochh arg e r Wastega te Ac tu a tor

Turboc j Repair turbocharger. I
...__o_,_·a _ p _ h _ r a _g _m _R_u_ p_ t u _ r _ed - - - -- -- - f ..._ .;;.... _ _ _ .·

..
OK

R e m ove fu e l injectio
ectionn pump. H a ve
uel Injec tion Pump Malfunctioning cali b r at i o n checked.
cali
Section T • Troubleshooting Logic Troubeshooting Symptoms Charts
B.Series Page T-17

Engine Power Output Low

Cause Correcton s

Check fo r added loading from malfunctioning

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

...
OK

Check/correct f or stop-to-stop travel.

Fuel Control Lever Misadjusted --·-----· Refer to Procedures 5-05 and 5 - 1 0.

...
OK

Mechanical/Shutoff Lever Partially Check/replace shutoff lever in run

run position.
Refer to procedures 5-05, 5-11, and 5-31.
Engaged

...
OK

Verify by operati ng the engine from a

Fuel Quality Poor or Diesel Fuel Grade temporary tank of No. 2 diesel fuel. Refer to
N o . 1 Used Above 0°C [32°F] the "Fuel Recommendat ons/Specificatons"
in the B Seri es Oper a tion and Maint ena
enann ce
Manua , Bulletin No. 381 0205-1 0.
...
OK

If the Condition is Slow Throttle Response

Air Fuel Tube Leaki ng, Wastegate ghtenn the fitti ngs, r epair plum b i ng or
Tighte
Diaphram Ruptured, Wastegate repair wastegate diaphram
Plumbing Damaged

...
OK

C h e c k t h e AFC li n e and fi tt n g b e t ween

AFC P lumb i ng Obstru cted the inta k e m a nifold and fuel i n ject io n
pump.

...
OK

I n s p e ct/cor recrectt l eaks in the h i g h press ure

essur
H i g h P r essure F u e l L e a k ---- · fittingg s injector s e a l i ng washe rs o r
lilinn e s , fittin
de ive ry va ve s e a l s .

...
OK

C h e ck the f ow th rough the fil t e r to locat

locatee
F u e l S upply In a d e q u a te th e s ource o f the r e s triction R e fer to
P r o ce dures 5 - 0 1 a nd 5-02

...
OK

B le e d the fu e l sy s t e m a nd check fo r
A r in the F u e l S ys t e m s u ction l eaks . R e fer to Proce dure s 5 - 03
a nd 5 - 1 5 .

...
OK
(C ontinu e d)
ontinu
Troubleshooting Symptom s C h a rts S e ction T - Trouble
Troubleshooting L o gic
shooting
P ag e T - 1 8 B S e r i es

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

C a u se Corr ecti ons

C h eck/r e p la c e fue l transfer pump

Fuel T r ansfer P um p M alfunctioning R e fe r to P r o c e d u res 5- 0 1, 5-0
5- 0 2, 5 -22
a n d 5- 2 1 .

OK

-
M a l funct ioning F u el R eturn Overflow
V a l ve
C h e ck/rep
eplac
lace r e turn o ve rflow v a l ve .
ocee d u re 5- 27.
R e fe r to P r oc

-
OK

._ 0 - - i l _ L _ e _ v - l_ l_ n _c _o - r r - e c - t ----------~~---- ----
__ k / _ o - rr- e c _ t _ o _ i _l _ l e _v_ e _l.
C _ h _ e - c_ ~

-
OK

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

I nspe ct/ re place air clea ner e l e m e nt. L ook
t/re
fo r o t her r e s tri ctions. R e fe r to p ag
age
e
3 - 11.
OK

I f t he v e h icle is e q u i p p ed with a v a lve to

s witch the in ta takk e s ource from u n d e r ththe
e hood
t o outsi de, position th e va l v e for the the season.

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

Check c h a rge ai r c o o l er fo r i n t erna l

re s triction. R e p l ace r e s t ri cte d cooler.

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

air cooler .

(C o n t i n u e d)
Section T - Troubleshooting Logic hootinn g
T r o u bleshooti Symp toms Charts
B S e r ies P age T- 19

Engine Power Output Low (Con tinued

(Co

C a use Corree cti ons

Corr

C h e ck/correct leak s i n the a ir c ro ss o ve r tu be,

A i r L eak B e tw e e n th e T ur b o c ha r g e r _ . •• - - • • • • • ch a rg e a ir coole r connections, h oses , o r
and t h e I n tak e M a n i fold through hol e s in the m anifol
anifoldd co v e r . R e fe r to
P ro ce dure 3-08 .
OK
....

._ E _ x _ h _ a _ u _ st _ _ e -t-r-ic-ti _ o _ n
l
...,. I - - - - - - - -
C h e c k/correct exhaust s y st e m . C h e c k

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

3 _ - 2 _ 3 _ . __.

OK
....
V e rify th a t fu e l h e ater is o ff d u r in g warm
Fuel Temp er at ure H i gh. G r ea t e r T h a n
we at h e r . Check for a restr i cted fue l d r a in
71 °C [ 1 60°F]
line .

OK
....
C h e ck/correct leaks i n th e m a n i fo l d or
E xha us t L e a k a t the M a nifo l d or
turbocharger g a s k e ts . L o o k fo r a crack e d
Tu r bocharg e r
manifold .

OK
....
E x t ra I njec to r S e a li n g Washer Install e d Remove extra i n je ctor s e a ling w a s h e r .
U nder Injec t o r .

OK
....

._ 1 _ n 1 - · e - c -t- t o_ r _ s _ w _ o _ r _ n _o _r_M
__ l f u _ n _ c _ t - i o - n - i n _ g ------- -1 .. C _ h _ e _ c _ k _ i _n _ j e - c - t o _ r _ s _ . .....

OK
....
( C o n t i n ued)
Troubleshooting Symptoms Charts Section T - Troubleshooting Logic
Page T-20 B Series

Engine Power Output Low (C

(Continued)
ontinued)

Cause Corrections

Check for the specified boost pressure.

Turbocharger M a lfunctioning Refer to turbocharger boost pressure
specifications Section 3.

OK

Inspect/replace turbocharger. Refer to

Procedures 7-05, 3-01, and 3-13.

Valve Clearances Incorrect Check/adjust valves. Refer to Proce

dure 7-04.

...
OK

Fuel Injection Pump Ti m i ng Incorrect Check/time fuel injection pump. Refer

to Procedures 5-36.

...
OK

F u e l Injection P u m p M a l funct oning Remove fuel injection pump. Have

calibr ation checked

...
OK

E n g in e C ompre ss ion L ow P e rfo rm c o m press o n ch e ck to ide n ti fy

Corree ct a s r equire d.
m a l function Corr

Se c tion T - T r ou b l eshoo ting

esho L o g ic T roubleshooting Sympto ms Charts
B Series Page T. 2 1
 Exhaust B l ack Smoke E xc e s sive

ause Correction s
Correction

E n g i n e B e i n g L u g g e d Down .
---------------- ._ . .J u_s_e o _w_e _ r _ g _e _a _ r · ... ..... ·
..
..
1
OK

I ntake Air R estricte d

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

..
OK

E _x _ h _a_u _s _t_R _e _s t_ r -c-ti_ o_ n _ _ . l ···· · · · · . _ _ Cp age

_h _e 3-23.
_ c _ k _ e _ x _ h _ a _ u _s _ t-e -- t r-ic- t-io _n _ . _ R _ e _f-__.
er o

..
l,

OK

Ch eck/co r rect l eaks i n th e a i r crossove r tube,

Air Leak B etween th e Tu rbochar ger 1- - - - - - - - - h oses or throu gh ho es in the m a n i fo d .
a nd the Intake M an fo l d cover . Refer to P r ocedures 3 - 1 0 and 3- 1 1 .

..
OK

C h e ck for p lugg e d ch ar ge air cool

ooler,
er,
Charge A r Coo l er Malfunct on interna charge a ir r estriction, or l e aking
ch arge air cool er.

..
OK

Check/cor r e ct l e aks i n the manfold or

Exhaust leak at the M an i fold
orTu rbochar ger
-- ----· turbochar ger ga skesketts . Look for a crack e d
m a n i fold .

..
OK

Turbo charge r Wastegate M alfun ctioning - -- -- - - - -

Repair or r e p lace was
asttegate R e fer to
P ro cedu re 3- 02
cedu

..
OK

Tu r bocharger M alfuncti oning I nspect/replace turboc

ochh a rge r. Refe r to
Procedure 3- 13 .

..
OK
(Continued)

Troubeshoot ng Symptoms Charts Section T - Tr ou b eshooting Log c

P age T-22 8 Series

E xhaust Smo ke Black Excessive

aus Excessive (Continued)
 C a u se Corrections

I n je c t o r I nstalled With M o r e T h a n O ne R e m ove extra was h e r . Refe r t o Proce

S e a li n g Washer dure 5 - 4 0 .

OK
....
7 mm Injector Installed With a 9 mm Remove
proper t he in jec
sealing to r and
washer R einstall
f e r to t he
Sealing Washer
Pr o ced ure 5- 4 0 .

OK
....
Injectors M a lf u ncti onin
oning
g . . - - ------ Replace injectors. R e f e r t o Procedure
5-40.

OK
....
F ue l Inje c ti on P u m p M a lfun c ti o n i n g
O v erfue l ed
or -- -----· R e m o ve fuel i n je ction pump H a v e
ca l i bration che ckee d.
check

OK
....
Piston R i ngs N o t S e a li n g ( B lu e Perfo rm a compcomprr e s s ion c h e ck C o r r e c t
S m o k e) as requ i r e d . R e f er to P r o ce dure 7- 01
01..

OK
....
F ue l I n j e ction P u mp T im i ng I ncorrect 1 - - - -- - - - - C h e ck/time fue l i nject i o n p um p . R e fer
to pro ce dure 7 - 20 an d 5 -3 6 .

Section T - Troubleshooting Logic Troubl esh o oting Symptoms Charts

B Series Page T-23

Exhaust White Smoke Excess ive

 Cause C o rrecti o n s

Verify proper starting proced

proceduu r e . Refer to
I mproper Start ng Procedur e the starti
startinn g procedure in the Operation
and Maintenance Manual.

..
OK

Refer to Troubleshoot ng Logic C h art

Coolant Temperature Too Low for "Coolant Temperature B e l ow
Normal".

OK
..
In t a ke Air Temperature Too Low Refe r to vehicle o peration manual for
s hutter operation.

..
OK

Verify by operat ng engine from a temporary

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

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

1
Tr o u b l eshoot th e KSB (Bosc
schh VE Pump R e fer to P r o cedure 5 - 07 , 5 - 08 a nd 5 - 09
O n l y)

OK

•
In je cto r in sta
stallllee d w th mor
moree tha n one Remove extra wa sher. R e fe r to Proce
s e a l i ng washer dure 5 - 40.

OK
•
I n jec
ecto
tors
rs M al functio n i n g Check/replace in je ctors . R efer to
jector
Procee d u r es 5 -1 3 an d 5 - 40
Proc

OK
• ( Continued)

Troubleshooting Symptoms Charts Troubll e s hooting L o g ic

Se ction T • Troub
Page T-24 B S e ries

Exhaust White S m oke Exce

Excess sive (Continued)

Cause Corrections
 Coolant L eaking Into Combustion R e fe r to Tr o ub l e s h o oting Logic fo r
Chamber Coolant L o s s .

..
OK

F ue l Injection Pump Malfunctioning/ R emove fue l in j ecti o n pump. Have

D e l ivery Valves Malfunctioning cali bration c h ecke d.

Section T • Troubleshooting Logic T r oubleshootin g Symptoms Charts

B Series Page T-25

Coolant T emperature A b o ve N o r m a l - Gradual Overheat

ause C o rrections
 ..
c_o _o -a _ n _ t_L _ e _ v _ e l _L _o _w L . .. . . . - ._ _ _ P_rho_ce r ek/ _1 -r0-6e .p _ l__ e_-_
e _dcu_ n i_
as_ n_ _ht _. _cR _ e _ f_,e_
_r ___.

OK

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

- - C - h a _ rlugged
_ g _ e , _ R _ a _ (Automotive
d - i a - t - o r - A - i r _ C _ o Only)
_o_le_r_F_i-ns • • • • • ••• J .. I d - b -- s-fr-m - f - i n _ s _ .
B _ l o _ w _ d- ____.

..
.
OK

eck/rr ep ai r fa n s hroud, sh utt

C h eck/ ttee rs , fan
A i r Flow t o the R ad i ator I nadequate or se n s o r s, an d fa n c lu t c h a s r e q u ired. R e fe r to
Restricted t h e e q uip m e n t m a n u fa c tur
turee r ' s p r o c e d u r es.

OK

..
Wate r Pump or Fa n Driv e B e l ts L o o se C h e c k/correct b e l t te n s i on.

OK

J
R ad i a tor
L e ak in g
H ose C o ll apsed, R e s tr i c t e d or • •••• • • •
I __
C h e c k/ r e p l a ce h o se.
__,

OK

C h e c k/drain o il to c o r r e c t l e ve l.
L ubri ca ti n g O il Leve l H ig h
ubrica

..
OK

C o o l i ng Fan Shroud D am ag ed o r I n sp e ct s h r o ud , r e p a ir /re pl ace or i n s ta l l.

M i ss ing

..
OK
(C ontin ue d )

Troubleshooting Symptoms Charts

Symptoms Section T - Troubleshooting Logic
Page T-26 B Series

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

ed))

C ause C orr e ctions

Pressure Cap Incorrect or R e p l ace cap w i th t he cor r e c t r a ti n g fo r

M a lf uncti o n i ng t he sy s t e m. R e fe r to P r oced ure 1- 01.
 ...
OK

O ve r concentration o f A n t i- F r eeze R e m ove part o f t he coolant fro m

co o li ng sy s tem and r e p l ace w i th w a ter.

...
OK

Temperature Sensor or Gage Verify that the gauge and tempe

temperr a t ure
Malfunctioning sensor are accurate. R e f e to Pr o ced u re
r
1 -01.

...
OK

T h ermostat M a l fun c t io n i n g , In co r r e c t o r Check/replace th e th e r m o s t a t. R e fe r to

Missi n g ---- · P roc e d ur e 1-08 .

OK

R adiator Shutters Ar ...

Aree N o t Ope n in g In sp e ct th
thee s hutte r s , r e p ai r o r r e p la ce if
Compl e te l y or C o ld We a th e r R ad i a tor --- - - - · n ecessar y. O p en radi ator co v e r .
C ove r Closed

...
OK

Air o r Combus ti on Gases i n t h e Make s u re t he fi ll rate is n o t b e i ng ex

C o o ling System ceeded and t h e correct v e nted th e rmostat
i s in st a ll ed. Refer t o P r ocedu
ocedurr e 1 - 01.

OK

I f aer at i on continue d , check fo r a compres

s i on l e ak through the h ead gaske
gasket.t. Refe r
to Procedure 7- 0 1 .

(C o n tinue d }

Troubl shooting Lo
Section
B Series T - e g ic Troubleshooting Symptoms Charts
Page T- 27

turre Above Norma - Gradua Overheat ( Continued)

Coolant Tempe r a tu

Cause Corrrections
Co

W a t e r Pump Malfunc tio n in g Check/replace the water p u m p. R efer t o

P roc e du r e 1-07.

OK
 ...
C ooli n g P a ss a ges i n R a d i a to r , Head, F l ush the system and fill with clean
H e a d G a s k e t or Block
Block P lugged coolant.

OK
...
Contact vehicle manufacturer for confirma
V e hicle C o o li n g S y s t e m Design tion of correct fan, radiator, and o ther
cool ng system components.

...
OK

Fuel In j e ction Pump Timing Verify fu e l injectio n pump timing m a r k s

injecti
In c orre ct are aligned. R e fe r to Procedure 5-36 .

OK
...
Fuel Injection Pump Overfue l e d Remove fu e l i nject ion p um p. H ave
calibrati o n c h ecked.

Troubleshooting Symptoms Charts Section T - Troubleshooting Logic

Page T-28 B Series

Coolant Temperature Above Normal - Sudden Overheat

ause Corrections

. c_o_o_la_n_t _ L _ e - v e _ l_ L _ o _ w _.~ - - - - - - - •
Add coolant. Refer to Procedure 1-06.

__J

...
OK
 Verify that the gauge and temperature
Temperature Sensor or Gauge
sensor are accurate. Refe r to Procedure
Malfunctioning 1-01. .

...
OK

.I F_a_n_D-ri_v_e_B_e_l_t -Lo_o_s_e _.~ - - - - • - - -1 . C _ h _ e _ c _k _ b_ e - l t - t e _ n _ s- i o _ n _ . ------l'

OK
...
JI
I nspect hoses.
i a - t o _ r _ H - o s _ e _ C _ o _ l l _ a _ p s _ e _ d _ . _ R _ e _ s _ t r - i c _ t _ e _ d _ , _ _. ••
__ R _r a _Ld -eaking ••••••
••••
__ ...;.._ _ __
__ J
..

...
OK

R ad i ator Cap Incorrect or Malfunction  Check the r adiator pressure cap. Refer
i ng. Cap Rated Pressure Too Low t o Procedure 1 -01.

...
OK

T h e rmostat Inco r r e ct or M a l fu n ctioning Check th e r m o s tat. R e fer to P r o c e d u re

1-01.

...
OK

In s p e c t the sh utters. R e p a ir or repl a c e if

R a d ia tor S hutt e r s A re N o t O p e n in g
- - - - - - - - . n ecessa r y . O p e n r adia to r cove r . C h e c k
C o m p le t e l y o r C o l d Weathe r R a di a t o r
s hutt e r st a t se ttin g . R e fe r t o P r o c e d u r e
C ov e r C l osed . S h u tt ersta t S e tt i n g Wron g . 1 - 01
01..

...
OK

C h e ck fo r air or c o m b u s tion g a se s in the

A i r or C o m b u s titioo n G ases in th e ... .. . . .
co o li n g s y s t e m . R e fe r t o P ro ce d ur e 7-01.
C o oling S y s t e m

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

Section T • Troubleshooting Logic Troubleshooting Symptoms Charts

B Series Page T-29
Coolant Temperature Above Normal - Sudden Overheat (Continued)
Cause Corrections

Vent Line From Engine and/or Radiator Check routing and operation of vent
Plugged or Incorrectly Routed line.

...
OK

I,. •••••••••
Check water pump operation. Replace
 Water Pump Malfunctioning the water pump. Refer to Procedures
1-09 and 1-07.

...
OK

Check for coolant leakage between

Leak Between the Top Tank and the radiator auxiliary tank and radiator top
Auxiliary Tank tank.

Troubleshooting Symptoms Charts Section T - Troubleshooting Logic

Page T-30 B Series

Coolant Temperature Below Normal

Cause Corrections

Check/repair shutters fan c l utch, v i scous

A ir Flow Across the Radiator Excessive fan as required. R e fer to t he equipment
manufacturer's procedures.

OK
....
Thermostat Broken, Damaged, Con Check/replace Thermostat. Refer t o
taminated or Not Sealing Procedures 1- 0 1 and 1-08.
 OK
....
emperature Sensor or Gauge I- •••••••• Verify that the gauge and sensor are
Malfunctioning accurate. Refer to Procedure 1 -01.

OK
....
Coolant N o t Flowing by Temperature Check/cl ean co o l ant passages
Sensor

Section T • Troubleshooting L ogic Troubles hooing SymptomsCharts

hooing
B Series Page T-31

Coolant Loss

Cau se Corrections

Visually inspect the radiator heater,

R a d i a to r or Cab Heater Leaking hoses and connections to locate the
l eak.

OK

If oil is present in the coolant, check for

a transmission or lube o i l cooler leak
 Visually inspect the engine and compo
External Engine Leak -- ------ nents for seal, gasket, or drain cock leaks.

OK
•
O verheatin g or Compression Gases Review the operation for overheating a n d
L e a k ing R e s ult in g i n L oss Throu gh the low power. Refer to troubleshooting logic
R adiator Overflow fo r Coolant Temperatur e Above Normal.

OK
•
I f Equipp ed, Tr a n s m i ss i o n Cool e r Check for mixing o f coolant and t ransm is
L eak
-------- · s i on fluid. Refer to P r ocedure 2-03.

OK
•
I f E q u ip p e d wit
withh a W a ter C o oled A i r L ook fo r c o o lant in the o i l. C h e c k/ r e p l ac e
Compre ss o r , H e a d or H e a d G a s k et 1 --- - - - - - - · h ead o r gask e t. R e fer to t he e q u i p m e n t
L e a k in g manufacturer's p r o c edures .

..
OK

Check/replace the aftercoole

aftercoolerr . Look for
If the E n g i ne i s Coolant Aftercooled, --
1- coolant in th e intake manifold and in th e
Aftercooler Leak oil.

..
OK

Check/replace the oil cooler. L o ok for

L ubricating Oil Cool er L e a k ... . . . . . . . .
coolant in the oil. R e fer to P r ocedure 2-05.

..
OK
( C o n t inued )

Troubleshooting Symptoms Charts Section T - Troubleshooting Logic

Page T-32 B Series

Coolant Loss (Continued)

Cause Corrections

Cy inder Head Gasket Leak Check/replace the head gasket. Refer

to Procedure 7-07 .

...
OK

ylinder H ead Cracked or Porous 1 --- - - - - - - Check/replace the head. Refer to

P roc e du r e 7-07.

...
OK
Cylinder Block C o o l ant Passages Check/r eplace the cylinder b lock.
Leaking --------·

Section T • Troubleshooting Logic Troubleshooting Symptoms Charts

B Series Page T-33

LubricatingOil Pre
ubricatingOil Pressur
ssur e Low

Cause Corrections

Lubricating Oil Level L ow Check/replenish lubricating oil. Refer t o

page 2-08.

OK

Check for a severe external oil leak that

could reduce the pressure.

Verify the correct oil is being used. Check

Lubricating Oil Viscosity Thin; Diluted 1---------
 for oil dilution. Refer to troubleshooting
or Does Not Meet Specification logic for Contaminated Lubricating Oil.

...
OK

Engine Temperature High (Above 95°C '" • ••••••• Refer to troubleshooting logic for
[203°F]) Coolant Temperature Above Normal.

...
OK

Pressure Switch or Gauge

Malfunctioning Verify the pressure switch is functioning
correctly.

...
OK

Pressure Regulat o r Valv e S t uck O pen Check / re pl a c e v al ve . Refe r to P r oc

oce
e
d ure 2- 04 .

...
OK

L ub r i c atin g Oil Filt e r P lu

lugg g ed C h a n ge l ub ricatin g filtee r ; r e vi e w
o i l filt
c h ange in t e r v a l.

...
OK

Lubri cat i ng Oil C o o l e r Pl u g g e d R e p l ace l ub ri ca

catin
ting o il c o o l e r . R e fe r to
P r o cedu r e 2-05.

...
OK
( C on t i n ue d)

Troubleshooting Symptoms Charts Section T - T roub leshooting Logic

Page T-34 B Series

Lubricating Oil Pressure Low (Continu ed}

Cause Corrections

If Lubricating Oil Cooler was Replaced, Check/remove shippin g p l ugs.

Shipping Plugs Left in Cooler

OK
....
If Replaced, Four Cylinder Lubricating Verify that the correct lubricating o i l
Oil Pump Installed in a Six Cylinder pump is installed. Refer to Procedur e
Engine 2-07.

OK
....
If Replaced, a Pre-1991 Lubricating Oil Verify that the correct lubr
lubrii cating o i l
Pump Installed in a 1991 or Later pump is installed. Refer to P r ocedure
Engine. 2-07.
 OK
....
Cylinder Block or Cylinder Head Plugs Check/replace expan sion p l u g s. Refer
Loose or Missing to Procedure 2-08.

OK
....
Suction Tube Loose or Broken Seal Check/replace seal.
seal. Refer to
to Proc
ocee dure
Leaking · -------· 2-06.

OK
....
Lubri catng O i l P u m p Worn
Lubri Check/replreplace
ace lubrica ti ng o i l p ump.
ump
R e fe r to P r o c e d ure 2 - 0 7 .

OK
....
Mai n B ear i ng C ap L o ose C h eck/in s ta ll n ew b e arin gs and tigh ten
cap. R e fe r to P r oc edur e 7 - 1 3 .
ocedu

....
OK

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

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

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

Section T - Troubleshooting Logic Troubleshooting Symptoms Charts

Symptoms
B Series Page T-35

LubricatingOil Pressure High

Cause Corrections

Pressure Switch or Gauge Malfunctioning •-------

Verify the pressure switch is functioning
correct y.

...
OK

Engine Running Too Cold Refer to troubleshooting logic for

Coolant Temperature Below Normal

OK

...
Lubricating Oil Viscosity Too Thick Make sure the
the correct lubricating oil is
being used. Refer to O&M manual.

OK
 ...
Pressure Regulator Valve Stuck Closed --------- Check/replace valve. Refer to Proce
dure 2-04.

...
OK

Verify that the correct lubricating oil

If Replaced, Six Cylinder Lubricating pump is installed. Refer to Procedure
0 1 1 Pump, Installed in Four Cylinder 2-07.

Trou bl eshooting Symptoms Charts Section T • Troubleshooting Logic

P a ge T-3 6 B Series

Lubricating O i l Consumption Excessive

a u se Corrections

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

OK
•
Cran kcase Be i ng Overfilled (Dipst ck Verify that the dipstick is correctly
C a li b r a t e d Incorrectly) marked.

OK
•
I ncorrect L ub r icating Oil (Speci fication Make sure the correct l ubricati ng oil is
o r V i scosity) b e i n g used.

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

R e v i ew/reduce the lubr icating oil

change i ntervals

C h e ck the b r e a the r tub

tubee a r ea for si g n s of
H i g h B l owby Forcing L ubr cating O i l l ubricating oil l o s s. M e a sure the blowb y a nd
O ut th e B r e a ther perform th e required repa rs . Refer to
Procedure 8 - 05
OK
•
L u b rica t i n g Oil C o o l e r L e a k C h e c k fo r lubricating o i l i n the co o l a n t.
R efer to P r ocedur e 2-03.

OK

•
I f E quippe d , Air C o m p r e s sor Pumping k/rre p l ace a ir co m p r e ssor R e fe r to
C h e c k/
L u b r i c a ting Oil P r ocedure 4-06.

OK
• ( C o ntinue d)

Section T - Troubleshooting L o gic Troubleshooting Symptoms Charts

B Series Page T-37

Lubricating Oil C o n s umptio n Excessive ( Continued)

Cause Corrections

Turbocharger Leaki n g L ub ri ca t ing Oil to - - - - - --- Inspect the air crossover tube for
the Air I ntake or E x h au st e vidence of lu bricating oil transfe r .

...
OK

Inspect/replace the valve seals. Refer to

I
Va l ve S eals Worn ~ -------- P rocedure 7- 0 1 .

...
OK

P i s ton R i n g s Not S e a ling - L ub ri ca ti ng - - ---- - - Perform a compression check. Repair

Oil Bein g C o n su med by the E n g i ne as required. Refer to Procedure 7-01.
Troubleshooting Symptoms Charts Section T - Troubleshooting Logic
Page T-38 8 Series

Coolant Contaminated

Cause Corrections

Coolant Rusty, Operation Without Drain and flush the cooling system. Fill
Corr ect Mixture of Antifreeze and with correct mixture of antifreeze and
Water water.

OK

Review the coolant change interval.

Refer to the Operation and
Maintenance Manual.

If Equipped Tran s mission Lubricating Check/replace lubricating oil cooler.

Oil Cool
Coolee r Leaking
--------· Refer to equipment manufacturer's
procedures.

...
OK

Lubricating Oil Leaks from Lubricating Oil Refer to troubleshooting

troubleshooting logic for
Cooler, Head Gasket, Head and Cylinder --- ----· Lubricating Oil Loss
Block
Section T - Troublesh
ooting Logic Troubleshooting
ubles S ymptoms C h a rts
B Series P ag e T- 39

L u br icating O il Contamina
Contaminated
ted

C ause Corre ctions

C o o l an t in the Lubricating Oil, I n t e r n a l 1 - - - - - - ---· R e fe r to tr

troo ub l es h o o tin g l ogic for
E n gi n e Compone
Component nt L e a k s C oola nt L os s.

...
OK

Lubricating Oil Sludge Excessiv e R evie w lubrica t n g o i l and filte r c h a n g e

in t e rv a l s

OK

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

R evie w th e o p e r a tion for e x cessi ve id l i n g

F ue l in the L ubricat i ng O il , E n gine
ultiti ng in t he e ngine ru n n i ng b e low
r e s ul
Operati n g Too Cold
n ormal t e m p e r a ture .

OK
 ...
F ue l T ra n s fe r Pump Se al L e a ki ng R e p ai r or r e p l ac e fuel t r an s fer p u mp.
R e fer to Procedures 5 - 03 and 5 - 2 1 .

...
OK

F u e l In jecti o n Pump S eal L eakin g (R o ta r y) -------- R e m ove the fu e l i n j e ct ion p um p and

h av e r epair
epaired.
ed. R e fe r to P r o c e dure 5 - 3 5 .

...
OK

Intern a l P l u n ger S e al Leaking ( In - L in e ) Remove th e fuel inject i o n p u m p an d

have re p a ir e d . R e fe r to P ro c edure 5-37.

...
OK

Lo c ate a n d r eplace m a l fun ct io n ing i n je c to r .

Injector N e e d l e V al v es Not S e a l i n g R e fer to P roced u r es 5 - 13 and 5-40.

Troubleshooting Symptoms Charts

Symptoms Section T • Troubleshooting Logic
Page T- 40 B Series

Fuel Or Oil Leaking From Exhaust Manifold

Cause Corrections

Operating for Extended Periods Under R e v i ew operating procedure with

Light or no Load Conditions -------- o p e r ator.

OK
....
Intake Air Restriction Review operation for excess i ve
idling.

OK

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

Locate and replace malfunctioning injector.

I njecto r Needle Valve Stuck Open -------- Refer to P r ocedures 5-13 and 5-40.

OK
....
 Turbocharger Lubricati ng Oil Drain Line Check/clean line
Obstructed
--------i
....
OK

Tu r b o ch a r g er S e al s L e a ki ng Oil - --- --- - C h e c k/repl a ce turboc h a r ger. Refer to

P r o c e dure 3 - 13.

OK
....
C h e c k for e xcessi ve blowby. R e fe r to

I
Bl o wb y E x cess
cessive
ive ~ - - ---- - - Pr o ce dure 8 - 0 5 .

OK
....
F ue l I n jection Pump T im i ng In c orre c t -------- C h e c k/time the in j e ctio
P r ocedu
ocedure re 5-36.
ctionn pump. Refer to

Section T • Troubleshooting ogic Troubleshooting ymptomsCharts

B Series Page T-41

Compression
Compression Knocks

Cause Corrections

I f Equipped, M alf
alfunctioning
unctioning Ether Repair or replace eth er starting
starting aids.
Starting Aid

OK
•

..
-----A-ir_i_n-th_e_F_u-el_S_y_s-te_m ..... L - . . __ _ _ l - e e - d- t h5-03
dures e _ l - s y5-15.
_ e _ f _ u _ and -s-te_m_. -R-ef_e_r-to-P-ro_c_e_-___.

OK
•
Verify by operating from a temporary tank

.__
_ P_o_o_r_a_u_a_l_ity-F-ue_l

OK
f
__. _ - - - - - - - - · ... w supply
_ i t _ h _ g _ o _ o _tanks.
d_fu_e_l_; _ c 1 _ e _ a n _ a _ n _ d _ t _ 1 u _ s _ h _ t - h e - f u _ e _ 1 _ __.

•
L

I
E _n _g -n _e _o_v _e _ r_ lo _a _d -d _.~-------· I _
.__ __being _ h _ a _ t _ e - n g _ i _ n _ e _ l o _ a _ d - r a - t i _ n _ g - i s _ n _ o t __
_ e - r i _ f y _ texceeded. --1

OK
•
F ue l Injection Pump T i m ing I ncorrect Check/time fuel injection pump. Refer
to Procedure 5-36.
 •
OK

Replace injecto r s. Refer to Procedures

I njectors M a l functi o ning -- ---· 5-13 and 5 - 40.

OK
•
C o o l a n t O p e r a ting T e m p e r a t ure R e fe r to troubl e s h o o ti n g logi c for Low
In co r r ec t C o o l an t Te m p e r a tu re.

Troubleshooting Symptoms Charts

Symptoms Section T • Troubleshooting Logic
P age T-42 B Series

Fuell Consumptio n Excessive

Fue

Cause Corrections

Check/repair accessories and vehicle

Addit ional Loading from Malfunctioning ----- - - - components Refer to the equipment
Accessories
manufacturer's procedures.

..
OK

Review operation for correct gear shifts

~--------
I
Operator Technique
deceleration, and idling '

..
OK

Check for external leaks and engine

I
Fuel Leaks ~-------- lubricating oil dilution.

OK

For fuel dilution, check for internal

e~ks.at the fuel transfer pump and
l njectton pump.

P o o r Quality F ue l or N o . 1 F ue l U se d ... . . . . . . Make sure quaity No. 2 fuel is being

used.
 OK

..
n t ak e Air or E x h a us t R e s tr i ct i o n ·--- - - - - - R e fe r to tr
troo ubleshoo ting l o g ic fo r
E xc e ss i ve E xh a ust S m o ke

..
OK

In je ct o r s Wo rn or M alfu n c t io n i ng placee in j ectors. R e f e r to

C h e ck/re plac
P ro c e d ures 5 - 1 3 a nd 5 - 4 0 .

..
OK
( C o n tin ued )

Section T - Troubleshooting Logic Troubleshooting Symptoms Charts

Symptoms
B Series Page T - 43

Fuel Consumption Excessve (Continued)

Cause C orrectons

Fuel Injection Pump T m i ng Incor

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

OK
....
Check for broken adjustment seals on the
Fuel Injection Pump Settings Incorrect - ••••• - - fuel inject ion pump. If the seals are broken,
remove and r ecalibrate fuel injection pump
Refer to Procedures 5-35 and 5 - 37.
OK
....

_
----------~-a-lv-es __ _ o _ t _ s _ e _ a - t i n _ g dure
__.l······· · L..- ~C-h c _k/_a _d _j u _ s _t _v_a _ l v _ e _ s . _R _e _f _ e _ r -to~P-ro_c_e_-
_e _7-04.
..
OK
....
Power Functions Malfunctioning C h eck/repa r power functio n s.
Troubleshooting Symptoms Charts Section T - Troubleshooting L ogic
Page T-44 B S e r i es

Engine Will Not Shut Off

Cause C o r recti ons

Stop the engine mechanically w i th lever on

Fuel Shutoff Valve Inoperative the fuel pump Check for co r recrectt so l enoid
operation . Refer t o P r ocedures 5-05, 5 - 1 1
and 5-31.
OK
....
Remove the fuel i njection pump and have
Fuel Injection Pump Malfunctioning checked/repaired. Refe r to P r ocedur es
5-35 and 5-37.

OK
....
Engine Runni ng on Fumes Drawn into Check the air i ntake ducts fo r the
the Air Intake source of the fumes.
Section T - Troubleshooting Logic Troubleshooting Symptoms Charts
Symptoms
B Series Page T-45

Engine VibrationExcessive

Cause Corrections

Engine Not Running Smoothly Refer to troubleshooting logic for Rough

Running or Misfiring.

OK
....
Engine Low Idle Speed Too Low Adjust engine low idle speed. Refer to
Procedures 5-38 and 5-39.

OK
....
Check/replace the vibrating component.
Fan Damaged or Accessories
Malfunctioning ·--------· Refer to equipment manufacturer's service
instructions.

OK
....
Inspect/Replace the fan hub. Refer to
Fan Hub Malfunctioning --------- Procedure 1-05.

OK
....
Alternator Bearing Worn or Damaged Check/replace the alternator. Ref er to
Procedure 6- 11 .

OK
....
V i brati o n Damper Malfunc t i o n i ng I n s p ect/r eplace the v ib r ation damper
er..
(Six-Cyl i nder O n l y ) Refer to P r oce d ure 7 - 1 5 .
 ...
OK

E n g i n e C o u n ter B a la n ce r N o t Time d Time

Tim e cou n te r b a l a ncer
ncer.. R e fer t o Shop
Correctl y ( 4 C yl i n der O nly) M a n ua l 3810206.

...
OK

C h eck/corr e c t flywhe e l a li g n m e nt. R e fe r

F lywh e e l H o u s in g M i sa ig n e d -- -- ----· to P roc e dure 7-24.

...
OK
(C o n tinue d)

Troubeshooti ng Symptoms Charts Section T - Troubleshooting Logic

Page T-46 B Series

E n g i ne V i b ration Excessive (Continued)

C a use Corrections

Inspect the crankshaft and r ods for

P ow e r C o m p onent s L oose o r B r o k en damage that cause and unbalance. Refer
t o Procedure 7-11.

OK
•
Check/replace engine mounts. Refer to the
Engine Mount s L oose or Broken equipment manufacturer 's service
instru ctions.

OK
•
D r i ve Li ne Compon ents Worn o r Check/repa r according to the equip
Unba anced m e n t manufacturer's procedures
Section T - T r o ubleshooting Logi c T r oubleshoo ti n g S ym p toms Charts
B Series P ag e T - 4 7

Engine N oises E xce ssive

ause Correction s

C h e c k t h e te n s i o n e r a nd i n s p e c t the d ri ve
Drive B e l t S q u eal , In su ffffii c e nt Tension b e l t for dete r i o r a ti o n . M a k e sure water pump
o r A b n ormall y H i gh L o ad i n g te n s io n er p u ll e y , fa n h ub and alt altee rnato r tu rn
fr e e l y .
OK

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

C h e c k the te n s ion o f acces

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

In t a k e A i r o r E x h a us t L e a k s . . . ....
. ... . . . . . R e fe r t o tro ublesh o o t i ng l ogic for
Excessi v e E xh au s t SmokSmokee

OK
•
A d jus t va l v e s . M a ke s ure the p ush r o d s are
V al v e L a s h E x cessi ve ~ - - -----· n ot b e nt or th e ro c ke r l e v e rs a r e not
seve r e l y w o rn . R e fe r to P r o cedur e 7 - 0 4 .

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

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

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

Troubleshootig Symptoms Charts Section T - Troubleshootng

ng Logic
Page T-48 B Series

Al ternator Not Charging

Charging Or InsufficientCharging

Cause Corrections

Battery Connections L oose or Check/tighten battery co n nections.

C o r roded Refe r to Procedure 6- 02.

OK
...
Load test the battery . If battery ch a r ge is lo w ,

B - a t t _ e _ r y _ C _o _ n _ d - i t-io_n c - h a _ r _ g _ e _ ft -ails
- - - - - - - - ' - - battery h e - b - athe
t t _ e _ load tens_ dt,_ l_replace
r_ y_a _ _ t _ a _ gbattery
o a -- t e _ sthe _ al f -_ it n_ h_ -. . 1 e .
.. ~

...
OK

Alternator Belt Sl i pping Check/replace belt te ns i oner. Refe r to

Procedure 1-03.

...
OK

A l t e rn at o r P u ll ey Loose o n S h a ft R e pa i r / tighte n p ull e y .

...
OK

.._ _w_i-re _s_a _ t_ A _ -e _rn _a _t - r o __o _s _e _

- -o -_r- _- B- _ i.
- r•_o _ke _n R p _aw_-
i_rr -n _g _
i_ ----.....1
OK
...
R e fer to the vehicle m a n u f ac turer's
Alternator Malfunction i n g instructions for troub l eshsoot i n g th e
a l t e rnator an d c h ar g i n g ci r cuit.

Replace a lt er n at o r . R e fe r to P r oced u re
 6 -1 1 .

Section 1 - Cooling System

B Series Page 1-1

Section 1 - Cooling System

Section Contents
Page
B e lt Tensioner - Replacement 1-12
Cool a n t .. . .. .. .. . .. . . . . . . . . .. . .. .. . .. . . . . . .. .. .... . . . . . .. .. . .. . . . .. .. . .. .. 1 - 14
D r aining .. . . . .. .. .. .. .. .. . . . .. . . 1-14
Filling. . . . . ......
...........
............ ...... ........... . ........ .. ................ .......... . . ..........
............. ... ............... ............... . . .................... ........
............. 1-15
Cool ant System Components and Flow . . .. . . .. . . . .. .. . .. .. .. . . .. .. .. .. . . . .. . . .. .. . . .. . .. .. . . . .. . . . .. . .. .. . . .. .. .. .. . . .. . . . .. . .. .. . .. .. . . . 1 -2
Coolant System Malfunctions .. . .. .. .. .. .. .. .. . .. .. .. .. . . .. . . . .. . .. . .. .. .. .. . .. . .. .. .. . . . .. . . .. .. . .. . .. .. . .. . 1-4
Diagnosis 1-4
Gauges, Overfueling and Loading 1 -1 1
Pressure Caps .. .. .. .. . .. .. . . .. .. .. .. . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. . .. .. . . . . .. . .. .. .. . . .. . . .. . .• . .. . .. .. .. . . . .. . . .. .. .. .. . .. .. . . . .. . 1-6
Radiator, Fans and Shutters 1-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . . . . . .. . . . . .. .. . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 1-1 O
Water (Coolant) Pump 1-7
Cooling System Specifications - ................................... ...... ......... . . ....... .... .. .. ............... 1-3
Drive Belt - Replacement .. .. .. . .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. . . . . . . .. .. .. .. . .. .. .. .. . .. .. . . . .. . . .. .. 1-12
Expansion Plugs - Replacement 1-18
Fan Hub - Replacement . . . .. . . .. . . . .. .. . .. .. . . .. . . . .. . . . . .. .. .. . .. . . . .. .. .. . . .. .. .. . .. . . .. .. .. . .. .. . .. 1-13
Fan Pulley - Replacement . .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. . . . .. . . . .. . . . . .. .. .. .. . . .. .. . . . .. .. . . .. .. .. . . . 1-13
T hermostat - Replacement . . .. .. .. . .. .. . .. .. . . . . .. . . .. . .. . .. .. . . . .. . . 1-17
W ater Pump
Pump - R eplacement 1-15
C oolant S yste m C ompon ents and F low Section ooll i n g
1 - C oo Syste m
P a ge 1-2 B S e ries

Coolant System Components and Flow

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

B . The coolant th e n circulates around eaceachh cy in d er and crosses the b l ock to the fuel pump side of the engine.
C. Coolant then fl ows up into th e cyl i nde r h ead , c rosses over the val ve bridges and d o wn the ex
exhh aust manifold
side of the engi ne to the integr a l the r m os
ostta t housing.
D. As the cool ant fl ows across th e h ead toward th e th e rmos ta t h ou sin g, it pr ovides cooling for th e injector. When
pro
th e engine is b e l ow operatin g tempe rature, th e th erm ostat is closed, an d the cool a nt fl ow bypasses the r ad iator
and goes to the water pump i n l et th ro u g h inte r n a l dri llings in th e b l ock an d cylinder h ead .
When operat ing temperature is reac h ed, th e th e r m ostat o pe n , blockin g th e bypass passage to the water pump
a n d opening the outl et to the radiato r .
C a uti o n: N e ver operate th e engi ne wi thout a th e rmostat. With ou t a thermosta t, the c ool a n t will n ot flow
~ to th e ra dia tor and the en gine will ov
ovee rh e at

Cool a n t S ystem

B
Cylind er Block

1 . C oola n t I n l et
2. Pump Im p elle ellerr
3. C oola nt F lo w P ast
Oil C o o ler
4 . C o o l a nt Fl o w P ast
Cylinde r s
5. Coolan t to Cyli Cylinn der
H ea d 1 . Coolan t F lo w fro m C y linder Bl ock
2 . Coola n t to The
The rmos ta t H o u si n g

D 1 . C oola n t F low Past In jecto r 5. B y- P ass C losed

2. Thermostat 6 . Coolant F low B ack to
3. Coola nt B y- P ass Passage R adiator
4 . Coola nt F low to P ump Inl et',... • . , · ,,..,,-
Inlet' , ,..,,- ,.,, , .....,

5
Section 1 - Cooling System Cooling System Specifications
8 Series Page 1-3

Cooling System Specifications

Cooling System 83.9, 4839

483 48T3 9 8TA3.9 685.9, 68T5.9, 85. 9 68TA5.9
Specifications

Coolant Capacity (Engine \

Only)- Litre [U.S. O ts . J . . 7 [7.4) 7 [7.4) .7 [10.3) 10.5 [11.1) , 1 4.5 [ 1 5.3)

Standard Modulating
Thermostat - Range -
o c [OF) . - - --- ---- -- - - ------ Start 83 [181] ---- - - - ---------- Fully Open 95 [203) ------------ --------

Pressure Cap (kPa [PSI])

104°C [220°FJ Sys-
tems . 103 [15] 103(15) 03 [15] 03 [15] 103 [15]

Pressure Cap (kPa [PSI])

99°C [210°F] Sys-
tems . 48 [7] 48 [7] 8 [7] 8 [7] 48 [ 7 ]
Coolant System Malfunctions (1-01) Secti o n 1 - C oolin
ling
g System
Page 1 - 4 B S e r i es

104°C Coolant System Malfunctio ns (1-01)

(220°F)
Diagnosis
The func
uncttion of th e cool a n t sys
systtem i s to m a inta i n a spec
i fied operating temperature fo forr the engine. S o m e o f th e
heat generated by the engi ne is absor bed by th e cool a n t
flowing through the passages i n th e cylinder b lock and
head. Th en, heat is removed from the coolant a s i t fl ows
through the radiator . When you t r o u b leshoot overheat
ing, remember th at too much oil in the o i l pan can cause
additional heat from friction when the r od journals a re
submerged in oil.
e a 9ga va

Overfilling with o i l raises the o i l temperatur e w h ic h is

transferred to the coolant system at the o i l cooler.

The system i s desi gned to use a spe cif c q ua ntity o f

coolant. I f th e coolant l evel i s lo w th e e n g i ne will r un hot.
NOTE: T h e engine o r sy s t e m h a s a leak if fr eque nt ad d i ti o n
of co o l ant is necessa r y . F i n d an d r epair t h e l e a k .

ra900ve

C aution : The engine coola n t passag es m u st b e com 

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

<® a 900bc

Section 1 - Cooling System Coolant System Malfunctions (1·01)

B Series Page 1-5

During filling, air must

must be vented from the engine coolant
passages. The air vents through the "jiggle pin" open
ings to the top radiator hose and out the fill opening.
Additional venting is provided for engines equipped with
an aftercooler. Open the petcock during filling.
NOTE: Adequate venting is provided for a fill rate of 14
liters/minute (3.5 U.S.
U.S. Gallon/minute].

NOTE: A 50 percent mixture of antifreeze and water must 51 J% 50%

be premixed before filling the system. The ability of anti WATER WATER
freeze to remove heat from the engine is not as good as
50% 50%
water, so pouring antifreeze into the engine first could con ANTIFREEZE ANTIFREEZE
tribute to an over heated condition before the liquids are
completely mixed.

A mixture
quired for of 50% ethylene-glycol
operation of the engine base antifreeze is
in temperature re
envi

---
ronments above -37°C [-34°F]. A mixture of 400/o water
and 600/o antifreeze is recommended for temperatures
below -37°C (-34°F] . Never use more than 600/o
antifreeze. --
--;- ,1 r
lra800wn

Caution: Never use water alone for coolant. Damage

from corrosion can be the result of using water alone for Water Only
coolant. The small holes i n the head gasket are espe
ally su scep tible to p l u gging. Th
ciall
ci These
ese h ol es are orifi ces
and their sizsizee is critical . Do not enlarge the si ze of the
orifices. To do so w il l disturb the coolan t flow and will
n o t s olve an over heating problem
W a te r w ill cause r ust formatio n re d u ci ng the flo w i n the
small er c oolant p a s s a ge s .

A l so, wa te r u se d as a coo l a nt for eve n a r e l a tiv

tivee l y short
p eriod can r e su lt in the cup plugs ru st i ng through a llow
in g the c o o lant to le ak.
 N O T E : A sudden l oss of coola nt fr o m a h eavil y l o a d e d
e n g in e ca n r es ult in se v e r e d am age to th e p i st o n s and
cy l in d e r b o r e.

C oola n t S ystem M a lfunctions (1 - 01 ) Section 1 - Cooling System

Page 1 - 6 B Series

Pressure Caps
B
The system is designed to use a pressure cap to prevent
boiling of the coolant.
Differentt caps are specified for the two recommended
Differen
systems
System Cap
A (Normal Duty)
Duty) 104°C [220°F] 103kPa [15 P S I ]
B (Light Duty) 99°C [2 1 0°F] 48kPa [7 P S I ]

malfunctioning cap can r esult in the loss

An incorrect or malfunctioning
of coolant and the engine running hot.

Air in the coolant can result i n loss o f coolant from the

overflow when the aerated coolan t is hot. The h eated air
expand s, i n c r easi ng th e pressure in th e s ys te m causing
the ca p to ope n .
cap
coolant c an be d i s placed through the ove rfow
Similarly, coolant
if the head g a sket l e aks compressi
compressioo n gasse s to the coo 
ant system

The ope r ating pre s s ur uree of the co olant syste m a nd the

lubrica ting s ys t e m can r esul t in the m i xi ng of the f u id s i f
ther
ere e i s a l eak b e tween the s yste m s :
eak head gas k e t, o i l
co o l e r, e tc (r efer t o th
the
e Lub
Lubrica
ricating Sys tem).
ting
 N O T E : Tra n s m i ss ion flud ca n al s o l e ak in t o th e c o o l a nt
through ra dia
diattor bottom tank transmiss ion o i l c o o l e r s.

ra900vh

Section 1 - Cooling
Cooli System Systee m Malfunctions (1
Coolant Syst (1-- 01)
B Series Page 1 - 7

Water (Coo ant) P u mp

The water pump pulls coo ant from the bottom bottom of the
radiator an d pumps i t through the e n g i ne b ack to
ack t o the top
Reduced or inte rrupted flow
of the radiator for cool ing. Reduced
runnn in g h ot.
will result i n the engine run

The pump is belt driven from the crank s h a ft p u ll e y An ~

automatic belt tensio n er is used to prevent
prevent th e belt from ~
slipping on the pump p u ll ey. A m a l f unct io n of the te n -
sioner w ll cause the water pump impelle r to ro ta tate
te at a
slower speed reducing th e am amoount o f co ola n t fl ow

coolant fl ow can a l so b e r e d u ced if the in l e t hose to

The coolant ~
the water p u m p co ll a p ses. A hose will us ual ly n o t co l - ~
l a p s e whi l e t he e n gin
gine running at low spe ed. Chec
e is running Check k the
h ose whi l e t he e n g i ne is r un n i ng at r a ted s p eed.
NOTE: Be sure the e n g i n e i s war warm m , a m in i mum o f 95°C
95°C
[203°F], s o th e t h e r m o stat is o p e n .

A worn or malfun c tio n i ng wa ter pump w ll n ot prod

produceuce the
flow re qui r e d to preven
preventt the engin e from running hot.
Howeve r , b e sure to c h eck th e other poss i b i l i ties in di
c a ted in th e Troublesh oot n g L o g i c before c h ecki ng the
flow o r repla cing the p ump.