Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1,000 Hours or 1 Yea

r
Check the tensioner arm, pulley, and stops for cracks. If any cracks are noticed
, the tensioner must be replaced.
With the belt on, verify that neither tensioner arm stops are in contact with th
e spring casing stop. If either stop is touching, the drive belt must be replace
d. After replacing the belt, if the tensioner arm stops are still in contact wit
h the spring casing stop, replace the tensioner.

142 Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1,000 Hours or

1 Year
check the torque of the tensioner capscrew.
With the belt removed, verify that the tensioner arm stop is in contact with the
spring case stop. If these two are not touching, the tensioner must be replaced
.

143 Maintenance Procedures at 77,000 Kilometers [48,000 Miles], 2,000 Hours or

2 Years
Air Compressor Inspect
Change the coolant
Check the damper

144 Troubleshooting
145 Troubleshooting Procedures and Techniques
A thorough analysis of the customer s complaint is the key to successful troublesh
ooting. The more information known about a complaint, the faster and easier the
problem can be solved.
The Troubleshooting Symptom Charts are organized so that a problem can be locate
d and corrected by doing the easiest and most logical things first. Complete all
steps in the sequence shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; howe
ver, these charts are designed to stimulate a thought process that will lead to
the cause and correction of the problem.

146 Troubleshooting Procedures and Techniques

Follow these basic troubleshooting steps.
Get all the facts concerning the complaint.
Analyze the problem thoroughly.
Relate the symptoms to the basic engine systems and components.
Consider any recent maintenance or repair action that can relate to the complain
t.
Double-check before beginning any disassembly.
Solve the problem by using the symptom charts and doing the easiest things first
.
Determine the cause of the problem and make a thorough repair.
After repairs have been made, operate the engine to make sure the cause of the c
omplaint has been corrected.

147 Smoke, Black Excessive

Engine is being lugged down (Use lower gear ).
Load is excessive (Reduce the load. Check and clean the vessel bottom, or change
the propeller. Refer to manufacturer s instructions).
Plugged air filter (Inspect the air cleaner element. Replace as needed ).
AFC plunger not fully open (Inspect AFC air tube and fuel drain lines for restri
ction. Inspect the AFC operation ).
Intake air source is incorrect (If the vehicle is equipped with a valve to switc
h the intake source from under the hood to outside, position and set valve for t
he season )
Aftercooler restricted (if equipped) (Inspect for plugged passages in the afterc
ooler ).
Exhaust system restriction (Check the exhaust system for any restrictions ).
Charge air cooler is restricted or leaking (Inspect the charge air cooler for ai
r restrictions or leaks ).

148 Smoke, Black Excessive

Air leak between the turbocharger and the intake manifold (Check for leaks in th
e air crossover tube, charge air cooler connections, hoses, or through holes in
the manifold cover and repair or replace if necessary )
Exhaust leaks at the manifold or turbocharger (Check and correct any leaks in th
e exhaust manifold or turbocharger gaskets. Check for a cracked exhaust manifold
)
Turbocharger wastegate is malfunctioning (Check the wastegate for correct operat
ion )
Turbocharger is worn or malfunctioning (Check for the specified boost pressure.
Inspect the turbocharger. Replace if necessary )
Fuel contaminated (Verify by operating the engine with clean fuel from a tempora
ry tank ).
Injectors worn or malfunctioning (Remove and test the injectors. Replace as nece
ssary .

149 Smoke, Black Excessive

15?Injector sealing washer not correct (Check to see if an extra sealing washer
is installed under injector. Remove any additional sealing washer )
16?Injector sealing washer not correct (Remove injector and install the proper s
ealing washer )
17?Fuel injection pump timing is not correct (Put the engine at top dead center.
Check and adjust the fuel timing )
18?Fuel injection pump is malfunctioning (Remove the fuel injection pump. Check
the calibration of the fuel injection pump )
19?Piston rings not sealing (blue smoke) (Check for excessive blowby)

150 Smoke, White Excessive

Starting procedure is not correct (Verify the correct starting procedure )
Coolant temperature is below specification or the intake manifold air temperatur
e is below specification (Refer to the Coolant Temperature Below Normal symptom
tree )
Intake manifold heater wiring harness malfunctioning (Check the wiring harness )
Poor fuel quality or wrong fuel grade (Verify by operating the engine from a tem
porary supply of number 2 diesel fuel. Check fuel specifications for proper fuel
grade )
Fuel injection pump timing is not correct (Put the engine at top dead center. Ch
eck and adjust the fuel timing )
Injector sealing washer not correct (Remove injector and install the proper seal
ing washer )