6D34-TL diesel engine

Dealer training

Andy Lau
 Contents

General information---------------------------2
Basic engine----------------------------------14
Lubrication system---------------------------89
Inlet and exhaust system------------------123
Fuel system----------------------------------143
Electrical system----------------------------208
Cooling system------------------------------224
Troubleshooting-----------------------------273

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 General information

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 Major products
SY330C/360C
SY205C
SY65C/SY75C SY135C SY215C
SY230C

SY700C/SY850 SY2000C
SY420C/460C

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 Specification
 For detail information, please refer to service manual.

Item Specification
Engine model 6D34-TL
Type 6-cylinder, in line, water-cooled, 4-stroke
Injection type DI
Valve mechanism Over-head valve (OHV) type
Stroke mm 115
Cylinder bore mm 104
Total displacement cc 5861
Compress ratio 16.5
Net weight kg 450
Fire order 1-5-3-6-2-4

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 Engine power
 Engine is allowed to work at 110% rated power for 1 hour.

Item Engine speed (rpm) Power (kw)

1500 115

1800 138
Rated power
2000 153
(kw)
2200 159

2500 162

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 Engine serial number

Engine serial number location: it is etched on the left side

cylinder block, as the above images indicated.

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 Engine nameplate

Engine nameplate is located on

the valve cover as indicated.

A. Engine model

B. Displacement

C. Rated power

D. Valve lash

E. Fire order

F. Injection timing

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 Related concepts

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 Displacement

Displacement = Area x Stroke x Cylinder Numbers

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 Fuel consumption rate
Fuel consumption rate:

Ne: rated power.

G: fuel rate at rated
power.
n: load factor (0.3-0.8)
For example:

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 Overview

Cooling Fuel

Electrical Inlet & exh

Lubrication Basic engine

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 Basic engine

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 Engine structure
1. Rocker arm
2. Spring
3. Camshaft
4. Liner/sleeve
5. Cylinder head
6. Flywheel
7. Crankshaft
8. Exhaust valve
9. Piston
10. Con-rod
11. Timing gear
12. Lifter
13. Inlet valve
14. Push-rod

A: Rotation direction

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 Timing gear
1. Camshaft gear

2. Pump gear

3. Crankshaft gear

4. Oil pump gear

5. Idler gear

6. Idler shaft

7. Idler gear sleeve

8. Bolt

9. Thrust plate

A: Oil hole

Timing mark on the gears was used to ensure all the gears
were installed correctly.
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 Piston

A. Component number

B. Mark “ T ”

C. Batch number

D. Size exceed mark

(0.50, 1.00)

Δ: mark of toward front

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 Cylinder pressure
Check the cylinder pressure:
 The decrease of the cylinder pressure indicates the wear of engine.

 If the cylinder pressure decrease to the repair limit, it is a signal to repair

the engine.

 Suggest to check the cylinder pressure and make a record. This will be
helpful for troubleshooting.

 Before testing the cylinder pressure, be sure that engine oil level, starting
motor, and battery are in normal status.

Item Specification Repair limit Suggestion

Cylinder pressure 2550 kPa 1960 kPa
Inspect
Cylinder （2000 rpm） (26 kgf/cm ) 2
(20 kgf/cm ) 2

Pressure Pressure difference 390 kPa

- Inspect
between cylinders (4 kgf/cm ) 2

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 Test the cylinder pressure
Start the engine and allow the coolant temp increase to about 75oC – 85oC.
Shut off engine, remove the injector.
Using a clean cloth to plug up the injector hole. Crank engine to check if there is
foreign material on the cloth or not. Coolant, fuel, oil, or metal debris?
Install the gauge adapter 3 to the hole where the injector was removed.
Connect the pressure gauge 4 to the adapter 3.
Start the engine to test the cylinder pressure for each cylinders one by one.
The tested cylinder pressure value and the pressure difference between cylinders
should be higher than the specification list in former slide.

If the test result is lower than specification,

insert a little oil into the cylinder and test again.
If the tested value increased, it means the liner
or piston rings was worn.
If the tested value not changed, it maybe the
cylinder head gasket leaked, or valves failed.
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 Check/adjust valve lash
 Valve lash should be checked/adjusted when engine was cold.

Crank engine to the No.1 or No.6 TDC in the

compress stroke.
 Crankshaft rotation direction should be the same
as the one when the engine was running.
 Mark “ 1.6 ” on the flywheel aligned with pointer
A in the inspection hole of the flywheel housing.
 If over cranked, crank back at least 30o to
eliminate the gear backlash, and then crank to
make the mark “ 1.6 ” aligned with the pointer A.
 When No.1 or No.6 is put in TDC of compress
stroke, check/adjust the valve lash for the related
valves
 Valve lash should be 0.4 mm.

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 Check/adjust valve lash
Check/adjust valve lash according to the below chart.
 If the feeler is loose when checking the valve lash, it means the valve lash is
incorrect. Valve lash adjustment was required.

 Make marks for the valve before the check/adjustment was done.

 Loose the locknut.

 Adjust the setting screw to adjust valve lash.

 When the feeler is not too loose, tighten the nut.

 Check the valve lash again to check the whether

the adjustment is correct or not.

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 Cylinder head & valve mechanism
Disassembly sequence:
1. Filler cap
3. Valve cover
2. Gasket of valve cover
4. Bolt of cylinder head
5. Rocker arm assembly
6. Push rod
7. Cylinder head assembly
8. Cylinder head gasket
9. Lifter
Parts can not be re-used
Lubricate with engine oil
Torque needed
Crankcase

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 Cylinder head & valve mechanism
Service specification
Location Service Item Standard Service Limit Service Repair
6 Push rod Bending - 0,4 Replace
9, * Clearance between the
0,05 to 0,09 0,2 Replace Lifter
lifter and lifter hole

Push rod bending:

 If the tested value is larger than the
specification, replace the push rod 6.

Remove the cylinder head

 Before removing the cylinder head bolt, the
setting screw on the rocker arm should be
loosed to release the valve spring.

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 Cylinder head
Remove the cylinder head:
 Loose and remove all the bolts of cylinder head as the sequence indicated
in the below image.

 Bolts of cylinder head can only be reused for three times if there was no
obvious defection.

 Make a mark on the bolt head before it was used to install the cylinder
head. This mark indicated how many times the bolt was reused.

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 Cylinder head gasket
Installation: cylinder head gasket
 Observe the following tips to select gasket.
 Measure the piston protrusion value of all
cylinders. The piston protrusion value will
change after replacing the piston and rod
etc, be sure to measure the projection.
 Select the cylinder head gasket thickness
which fits for maximum piston protrusion
from the following table after measurement.
 In addition, if the piston protrusion value
(even only one cylinder) exceeds the
average protrusion value by 0.05 mm or
more, use the gasket that the thickness of
which is 1 grade higher (A→B, B→C).
(mm)
 Distinguish the dimension of the cylinder
head gasket by the jag.
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 Cylinder head
Install the cylinder head:
 If the bolt has a mark of reused for three times, it should be discarded and
replaced with a new one.

 Install and tighten the bolts of the cylinder head as the sequence indicated
in the below image.

 Torque the bolts to 145 N.m, and then plus 90o±5o.

 Install the rocker arm assembly onto the cylinder head.

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 Rocker arm as

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 Rocker arm as

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 Rocker arm as
Inspection: clearance between the rocker
arm bush and the rocker arm shaft.
 Measure the inner diameter of the rocker
arm bush with the vernier caliper.

 Measure the outer diameter of the rocker

arm shaft with the micrometer.

 Calculate out the clearance between the

rocker arm shaft and the rocker arm bush.

 If the measured value exceeds the limit,

replace the bushing.

Replacement of the rocker arm bush

 Remove the rocker arm bush with the
special tool as shown in the illustration.

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 Rocker arm as
INSTALLATION: rocker arm bush.
 Set the parts as shown in the
illustration, align the oil hole of the
rocker arm bush with the oil hole of
the rocker arm.
 Install the bush until the special tool
touches the chamfering of the rocker
arm.
 Check the clearance again after
installation.
 If the measured value is less than the
standard value, the bush needs to be
reamed.

Installation: the rocker arm shaft

 Install the rocker arm shaft.
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 Cylinder head as
1. Valve Cap 2. Valve Lock Clip
3. Rotocoil 4. Ex. Spring
5. In. spring 6. Valve Seal
7. Intake valve 8. Exhaust valve
9. Injection Nozzle Cap
10. Injector (See Section 6-4)
11. O-ring
12. Injection Nozzle Shim
13. Linking Board
14. Heating plug
15. Intake Valve Guide
16. Exhaust Valve Guide
17. Intake Valve Seat
18. Exhaust Valve Seat
19. Water Director
20. Double Ended Stud
21. Cylinder head
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 Timing gear
1. Nut
: Parts can not be reused ( 3, 6 ) 2. Taper sleeve
3. O-ring
4. Pulley
5. Bolt
6. Seal
7. Front housing
8. Bolt
9.Thrust plate
10. Idler gear ass
11. Sleeve
12. Idler gear
13. Idler shaft
*1. Crankshaft gear
*2. Oil pump gear
*3. Camshaft gear
*4. Injection pump gear
*5. Plate
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 Timing gear
Service specification: Unit: mm
Service Service
Location Service item Specification
limit repair
Between the idle gear and
- 0.07 to 0.15 0.3 Replace
the crankshaft gear
Between the idle gear and
- 0.07 to 0.17 0.3 Replace
the camshaft gear
Backlash
Between the idle gear and
- 0.07 to 0.17 0.3 Replace
the injection pump gear
Between the oil pump gear
- 0.10 to 0.18 0.3 Replace
and the crankshaft gear
- Endplay of the idle gear 0.05to 0.15 0.3 Inspect
11, 13 Clearance between idle shaft & its sleeve 0.03 to 0.06 0.1 Replace

Torque specification: Unit: N.m (kgf.m)

Location Fastener name Torque specification Note
1 Nut 490 (50) Oil lubricated
8 Bolt 24 (2,4) -
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 Timing gear
Before dismantling the timing gear:
 Check the backlash of the timing gears. Tested the backlash for each gear
at least three points. If the tested result is out of specification, replace it.

 Checked endplay of the idle gear assembly. If the tested result is out of
specification, replace the failed parts.

Removing the taper sleeve “ 2 ”: Using the taper pliers to remove it.

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 Timing gear
Install the front housing:

 If the seal can be reused, install

it back correctly.

 Install the front housing within 3

minutes after the gasket maker
was applied to the front housing.

 Notice:
 Front housing should be installed properly and correctly to avoid the liquid
gasket maker damaged.
 Before the liquid gasket maker was smeared to the sealing surface of the
front housing, it should be free of oil and other foreign material.
 Once the bolt 5 was removed, the gasket should be replaced.
 After the front housing was installed, waiting for at least 1 hour to start the
engine.
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 Timing gear
Install the thrust plate “ 9 ” with the
chamfer end outward.

Install the idle gear assembly 12:

 Timing mark 1, 2, 3 on the idle gear
should be aligned with the related
gear:

*1: Crankshaft gear.

*3: Camshaft gear.

*4: Fuel injection pump.

 Align these three timing marks when

No.1 and No.6 piston are in the TDC
position.

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 Idle shaft and gear

Clearance specification:

 Normal: 0.06 – 0.03 mm

 If larger than 0.1 mm, replace

the failed parts.

Measurement of the clearance between idle shaft and its sleeve:

 Measure the inner diameter of the idle gear sleeve with it installed.

 Measure the outer diameter of the idle shaft.

 Calculate the clearance between the shaft and the sleeve.

 If the clearance is out of specification, replace the failed parts.

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 Camshaft
1. Bolt 2. Camshaft ass.
3. Bolt 4. Washer
5. Camshaft drive gear
6. Plate 7. Key
8. Camshaft
9. No.1 sleeve of camshaft
10. No.2 sleeve of camshaft
11. Seal Cap
12. No.4 sleeve of camshaft
13. No.3 sleeve of camshaft
Can not be reused parts: 7
Should be lubricated with engine oil: 3, 9, 10, 12, 13.
 Except that obvious defection detected, gear 5 should not be removed.
 Do not remove the camshaft bush, unless it is determined to be abnormal.
Torque for bolt 3 is 175 N.m or 18 kgf.m.
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 Camshaft
Camshaft specification unit: mm
Service Service
Location Service Item Specification
limit repair
- Camshaft endplay 0,05 to 0,22 0,3 Replace
Replace
Lobe height
Inlet 7,195 ± 0,05 6,70 47,105
Basic diameter
Lobe 39,910
8 Camshaft stroke Replace
Lobe height
Exhaust 7,321 ± 0,05 6,82 47,105
Basic diameter
39,910
Bending Below 0,02 0,05 Replace
Clearance No.1 journal 0,03 to 0,08 0,15
between
9, 10 No.2 journal 0,03 to 0,08 0,15
camshaft
Replace
sleeve No.3 journal 0,03 to 0,08 0,15
12, 13
and
journals No.4 journal 0,03 to 0,08 0,15

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 Camshaft
Check the camshaft endplay before
removing it from the cylinder block.

If the endplay is out of specification,

inspect for the failed parts and
replace it.

Removing the camshaft:

 Rotate the camshaft gear 5 to remove
the bolt 1.

 Pull out the camshaft assembly slightly

 Avoid damaging the sleeve 9, 10, 12,

and 13 when pulling out the camshaft.

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 Camshaft

Measurement before the camshaft was installed:

 Clearance between the thrust plate 6 and the camshaft 8, replace the
failed parts if the measurement is out of specification.

 If any of the lobe height is smaller than the specification, replace the
camshaft 8.
A. Measure position. B. Lobe height.

C. Basic diameter D. Front end of engine.

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 Camshaft
Measurement of camshaft bending:
 No.1 and No.4 bearing journal were supported on the V block.
 Measure the bending value on the No.2 and No.3 bearing journals.
 If the measured value is out of specification, replace the failed camshaft.
Half of the reading on the gauge is the bending value when camshaft
is rotated one complete turn.

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 Camshaft

Measure the camshaft sleeve tolerance:

A. Measure the outer diameter of the camshaft journals.

B. Measure the inner diameter of the camshaft sleeves.

C. Calculate out the tolerance of each camshaft sleeve. ( B – A )

D. If the tolerance is out of specification, replace the defected parts.

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 Camshaft bush removal
Tool

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 Camshaft bush install
Tool

Align the No.4 bush oil hole and the crankcase

oil hole. Install the No.4 bush to the crankcase
by tapping in front of the engine until it is
positioned as shown in the illustration.
Align the No.5 bush oil hole and the crankcase
oil hole. Install the No.5 bush to the crankcase
by tapping it from the back of the engine until it
is positioned as shown in the illustration.
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 Camshaft bush install
Align the No.3 bush oil hole and
the crankcase oil hole. Install the
No.3 bush to the crankcase by
tapping it in front of the engine
until it is positioned as shown in
the illustration.

Align the No.1 bush oil hole and

the crankcase oil hole. Install the
No.1 bush to the crankcase by
tapping it in front of the engine
until it is positioned as shown in
the illustration.

Install the seal cover to crankcase

with the specified depth.

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 Piston, con-rod, and liner
Piston, con-rod, and liner:
1. Bolt
2. Lower bearing of con-rod
3. Cap of con-rod
4. Upper bearing of con-rod
5. Piston & con-rod group.
6. Liner / sleeve
*1. Crankshaft.
*2. Crankcase.
*3. Oil pan
Lubricated with engine oil: 1, 2,
4, and *2.
Torque for bolt 1: 29 N.m, plus
90o±5o
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 Piston, con-rod, and liner
Service specification unit: mm

Service
Location Service item Specification Service limit
repair

Piston project 0,43 to 0,69 - Measured

-
Endplay of con-rod 0,15 to 0,45 0,6 Check
Bearing
0,04 to 0,09 0,2 Replace
clearance
2
Rod bearing Upper half:64,5
4 Span in free
state - Replace
Lower half: 64,27
Clearance between
5, 6 0,07 to 0,11 - Replace
piston and liner
Inner
104 to 104,03 104,25 Replace
diameter
6 Liner Roundness Below 0,01 - Replace

Cylindric Below 0,03 - Replace

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 Piston, con-rod, and liner
Before removing the piston and con-rod
group:
 Measure the piston project: distance from the
top surface of piston to the top surface of
crankcase when piston is crank to TDC
position. This parameter affect the engine’s
performance and must be measured.
 Measure at two points for each piston, and
then calculate the average project.
 If the average project is out of specification,
check for clearance of related parts.
 A: engine front end.
 Measure the con-rod endplay, if the endplay
is out of specification, replace the failed parts.
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 Con-rod
Inspection: clearance between the
rod bearing and crankshaft (Oil
clearance)
 Install the rod bearing upper and
lower half to con-rod and the rod
cap, then tighten bolts with torque
29 N.m (3kgf.m).
 Measure the inside diameter of
con-rod bearing and the outer
diameter of the crankshaft rod
bearing journal.
 If the clearance is above the limit
value, replace the failed parts.
 If the rod bearing journal was
worn and can be reused, the outer
diameter of rod bearing journal
should be corrected to specified
downsized value and using the
oversized bearing.

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 Piston, con-rod, and liner
Inspection: clearance between the piston
and the liner sleeve
If the measured value exceeds the specification,
measured sleeve and piston at different position:
 A: Parallel to the axis of crankshaft
 B: Vertical to the axis of crankshaft
 C: Piston measure position (Vertical to piston hole)

If the inner diameter of the liner sleeve exceeds

the limit value, the sleeve should be bored to
oversized dimension, and replace the oversized
piston and piston ring.
 Even though only one sleeve is poor, all cylinders
must be bored to the same oversized dimension.
If the inner diameter of sleeve is within standard
valve, replace the piston and piston ring.

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 Piston, con-rod, and liner
Set piston oversized dimension
 Oversized dimension value: 0.50 and 1.00 mm (2 types)
 Measure the inner diameter of all cylinders, oversized dimension can be

determined based on the cylinder that has the largest inner diameter.
 Measure the outer diameter of oversized piston.

 Bore the cylinders according to the standard clearance value between the piston

and cylinder liner.

 In order to avoid deformation due to the increasing temperature when boring,
please follow the orders 1, 5, 3, 6, 2, 4 to bore the cylinder.
 Bore cutting process size (Tolerance: 0.005) = oversized piston outer
diameter (Measured value) + clearance between the piston and cylinder
(Maintaining basis medium value) - 0.02 mm (Hone allowance)
 Hone it after boring, then as the final process size (Tolerance: 0.005).

 Final process size (Tolerance: 0.005) = oversized piston outer diameter

(Measured value) + clearance between the piston and cylinder (Maintaining

reference medium value)
 Honing process surface roughness: 2-4μm
 Honing intersection angle: 15-25°
 Cylinder inner diameter squareness: 0.05 mm

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 Piston, con-rod, and liner
Replacement of cylinder liner [REMOVAL]
 Fix and center the boring machine on the crankcase. Centering should be
done on the lower side of cylinder liner where there exists little uneven
wear.

 Bore the cylinder liner to make its thickness reach 0.5 mm.

 Insert the tool (The process tool, like screwdriver, etc.) between crankcase
and cylinder liner, tap it lightly while you open the cylinder liner to remove.

 Place the circular bead end of

tool to crankcase side. Without
placing it to crankcase side,
scratch damage will happen.

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 Piston, con-rod, and liner
Inspection
 Check for scratch on the cylinder
liner bore of crankcase.
 Measure the inner diameter of the
sleeve bore at the position shown in
the illustration.
 Measure the liner sleeve outer
diameter at the points shown in the
illustration which should be within
specification.
 Calculate out the average sleeve
tolerance. ( Tolerance = D-d<0 )
 If the average tolerance is within the
specification, install the liner sleeves
into the crankcase.

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 Piston, con-rod, and liner

Liner sleeve installation:

Press the cylinder liner sleeve from chamfering side into crankcase with special
tool.

Hone the cylinder liner after pressing until its inner diameter reaches standard
value.

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 Con-rod
Install the con-rod bearing 2 and 4.
 Align the tab on the bearing with the
groove in the con-rod or rod cap.

 Upper bearing half has a oil hole,

while the lower bearing half has not.
Please do not confuse the upper and
lower bearing half.

 Measure the bearing span in free

state, if the measured value is below
the specification, replace the bearing
2 and 4 in pair.

 Caution: do not expand the bearing

by hand if span is out of specification.

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 Piston and con-rod group
Install the piston and con-rod group:
 Be careful not damage the oil jet C.
 Avoid damaging the top surface of the piston.
 Check that the piston ring closed end is in the specified position.
A: No.1 Compression Ring closed end
B: No.2 Compression Ring closed end
C: oil ring closed end
D: oil ring support spring corresponding part
: forward mark on the piston

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 Piston and con-rod group
Install piston and con-rod group:
 Make the piston forward mark △
toward the front of the engine.
 Install the piston ring compress tool
to piston skirt, and adjust with bolt to
match it with the piston skirt.
 Remove it from piston skirt after
adjusting properly, then install it to
piston ring after applying engine oil
to the following parts.
 Outer circumference of piston
 Inner circumference of the tool.
 Inner circumference of the liner.

 Using a wood or rubber stick to rap

the piston into the liner sleeve.

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 Piston and con-rod group
Align the matching marks of the
con-rod and con-rod cap, tighten
bolts alternately according to the
following orders after installing
piston and connecting rod.
 Tighten bolts with torque 29 N.m
{3kgf.m}.

 Tighten bolts further 90o±5o.

Thread section of the bolt should

be lubricated before installation.

Con-rod bolt can be reused for

three times if no obvious defection.

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 Piston and con-rod group
Disassembly sequence:
1. Snap ring
2. Piston pin
3. Con-rod bush
4. Con-rod
5. No.1 compression ring
6. No.2 compression ring
7. Oil ring
8. Piston
9. If the bush 3 was not failed, inner
diameter is within specification,
and not shifted, it should not be
removed from the con-rod.
9. Assembly sequence is the reverse
order of disassembly sequence.
9. Con-rod bolt can be reused for 3
times if no defection existed.

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 Piston and con-rod group
Specification unit: mm

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 Piston and con-rod group
Removing the piston ring
 Using the special tool show in the illustration to
remove the piston rings.

 Also that the special tool was needed to install

the piston rings.

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 Piston and con-rod group

Separate piston and con-rod group:

 Remove the snap ring.

 Tap out piston pin with press stick.

 If piston pin cannot be tapped out easily, put it in hot water or heat it with
heater and then remove it.

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 Piston and con-rod group
Inspection: piston ring closed end clearance
 Insert 3 piston rings into the liner horizontally
using piston top. Insert it into the lower part
where the uneven wear is little.
 Do not move piston ring when measuring the
closed end clearance.
 If the measured value is above the limit value,
replace the complete set of piston rings.

Inspection: the clearance between the piston ring and piston ring groove
 Clean all carbon-deposit in the ring groove.
 Install a brand new No.1 compression ring.
 Measure along the circumference of the piston
ring groove.
 If the measured value is above the limit value,
replace the worn parts.
 A complete set of piston rings should be
replaced when replacing the piston ring.
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 Piston and con-rod group
Inspection: clearance between piston pin

and piston

 If the measured value is above the limit

value, replace the poor parts.

Inspection: clearance between piston pin

and connecting rod bush

 If the measured value exceeds the limit

value, replace the bush.

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 Piston and con-rod group
Remove the con-rod bush
 Using special tool shown in the
illustration to remove the bush.
 Remove the con-rod upper bearing
in the big end.
 Fix the connecting rod on the base
and lock it in the proper position
with carrier and base board.
 Install spacer A to the remover
following the direction shown in the
illustration, then gradually apply
about 49 kN (5000 kgf) pressure
until the connecting rod bush is
pressed out.

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 Piston and con-rod group
Install the con-rod bush:
 Clean the con-rod bush bore and the
outer circumference of bush.
 Install spacer B to the remover
following the direction shown in the
illustration, put to con-rod bush and
spacer A on it, and fix a series of
parts with nuts.
 Align the con-rod bush with the con-
rod oil hole, apply about 49 kN
pressure gradually, using the press
machine until the bush is pressed in
proper position.
 Measure the clearance after installing.
If it is below the standard value,
ream out the bush.
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 Piston and con-rod group
Inspection: bending and twist of

con-rod

 Install con-rod upper bearing, and

con-rod cap.

 Tighten the con-rod cap nut to the

specified torque 69 N.m {7kgf.m}.

 Install the piston pin.

 Install con-rod to con-rod aligner.

Set the instrument reading to zero.

 Measure bending and twist of con-

rod. If the measured value is above

the limit value, replace the con-rod.

Andy Lau 68
 Piston and con-rod group
Installation: piston and
connecting rod
 Make sure that the quality of
each cylinder is equal when
replacing the con-rod and/or
piston.
 Apply engine oil to piston pin
and install the piston and con-
rod following the direction
shown in the illustration.
 " △ ": onward mark
 If piston pin can’t be installed
easily, put the piston in hot
water or heat it with piston
heater and then install the pin.

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 Piston and con-rod group
Installation: piston ring
 When installing the piston ring,
make the mark near piston ring
closed end upward and set each oil
ring closed end in the direction
shown in the illustration.
 A: Upward mark.
 B: No.1 compression ring closed end
 C: No.2 compression ring closed end
 D: oil ring closed end
 E: oil ring support spring close end.
 F: "△": piston onward mark. The
mark only exits on the No.1 and
No.2 compression ring closed end.
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 Flywheel
Disassembly sequence:
1. Bolt
2. Keeper
3. Bearing ?
4. Flywheel assembly
5. Gear ring
6. Flywheel
7. Plate
8. Rear crankshaft seal
9. Flywheel housing
10. Aligning pin
*a: Crankshaft
Assembly sequence is the
disassembly sequence in
reverse order.

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 Flywheel
Service specification
unit: mm
Location Service Item Specification Service Limit Service Repair

Flywheel rubbing Correct or

4 - 0,2
surface run out replace

Flywheel housing Correct or

9 - 0,2
eccentricity replace

Torque specification
unit: N.m (kgf.m)
Location Tightened parts Torque specification Note

1 Flywheel bolt 39 (4) + 450 ± 50 Lubricated

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 Flywheel
Inspect the rubbing surface run out
before the flywheel was removed.
 If the measured value exceeds the
limit value, check that the bolt is
properly tightened and check the
mounting surface between the
flywheel and the crankshaft. Then
correct or replace the flywheel as
necessary.
Removal: flywheel
Magnetic Base  Remove the flywheel by screwing the
bolt into flywheel removing hole.
Removal: ring gear
 If the ring gear is failed, heat it to
200oC with gas burner evenly and
remove it from the flywheel.
 Never touch it with hands, as the
heated part has a high temperature.
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 Flywheel housing
Inspect the eccentricity of flywheel
housing
 Crank the crankshaft, inspect the
flywheel housing eccentricity at the
area shown in the illustration.
 If eccentricity exceeds the specified
limit value, reassemble it.
 If eccentricity still out of specification
after reassembling, replace the failed
parts.
Installation: gear ring
 Heat the gear ring evenly to 200oC by
gas burner, etc..
 Install the gear ring with the non-
chamfering side of gear the ring
facing the flywheel.
 Never touch it with hands, as the
heated part has a high temperature.
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 Flywheel housing
Install the rear oil seal.
 Apply engine oil to the lip part of
the rear oil seal.
 Clean the oil seal surface.
 Apply the sealer along the line of
the rear oil seal evenly and
continuously.
 Install the seal within 3 minutes
after applying the sealer. Keep the
sealer in the right position.
 Do not start the engine within 1
hour after installing the rear oil seal.
 Apply the sealer again after
releasing or removing the bolts.
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 Cylinder block & crankshaft
1. Rear Oil Seal
2. Main Bearing Cap Bolt
3. Side Oil Seal
4. Thrust Plate
5. Lower Main Bearing
6. Main Bearing Cap
7. Crankshaft Gear
8. Key
9. Rear Oil Seal Stop Ring
10. Crankshaft
11. Front End Plate
12. Gasket
13. Upper Main Bearing
14. Hollow bolt
15. Oil Jet Tube
16. Cylinder Block
Aligning Pin
Non-reusable Part
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 Cylinder block & crankshaft
Service specification unit: mm

Torque specification unit: N.m (kgf.m)

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 Crankshaft endplay
Inspection: crankshaft end play
 If the measured value exceeds the limit
value, replace the thrust plate with an
oversize one and make adjustment.

 Oversize type: +0.15, +0.30, +0.45mm

 If the end play cannot be adjusted fully,

inspect and replace the crankshaft.

Removal: main bearing lid

 Because there is side oil seal between the
main bearing cap in the end and the
crankcase, remove it with special tool .

 Main bearing cap bolt can only be reused

for three times without obvious defection.

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 Crankshaft endplay

Andy Lau 79
 Crankshaft
Removal: crankshaft gear
 Do not remove the crankshaft gear
if there is not defection and can be
reused.
 Do not remove the crankshaft gear
by tapping it or it may be damaged.
Removal: rear oil seal stop ring
 Disengage the rear oil seal stop
ring with chisel or similar tool. Be
careful not damage the crankshaft.
Inspection: main bearing span in
the free state
 If the measured value is less than
the limit value, replace the upper
and lower main bearing.
 Do not expand the bearing by hand.

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 Crankshaft
Inspection: clearance between
the main bearing and the
crankshaft
 Install the main bearing and main
bearing cap to the crankcase.
 Tighten the main bearing cap
bolt to 59N.m {6kgf.m}.
 Measure the inner diameter of
the main bearing and the outer
diameter of the main bearing
journal.
 If the measured value exceeds
the limit value, remove the main
bearing, clean the main bearing
bore with the fine sand paper.
 Measure again, the clearance
should be within specification.
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 Crankshaft
Inspection: crankshaft
1. Bending
 Support NO.1 and No.7 crankshaft
journal first, then measure at NO.4
crankshaft journal.
 If the measured value exceeds the

limit value, replace the crankshaft.

 The bending of the crankshaft is
half reading of the dial indicator
when the camshaft turn one turn.
2. Cylindricity and roundness of
the main bearing and rod
bearing journals
 If the measured value exceeds the
limit value, grind the crankshaft to
small size or replace it.
 Grinding crankshaft journals is not
recommended.

Andy Lau 82
 Crankshaft & cylinder block
Inspection: deformation of the

crankcase top surface

 If the measured value exceeds the

limit value, correct it with surface

grinder.

 keep the pistion projection within

the specified value when grinding.

Installation: rear oil seal stop ring

 Install the rear oil seal stop ring

until the installation tool touches

the guide.

Andy Lau 83
 Crankshaft & cylinder block
Installation: crankshaft gear
 Heat the crankshaft gear to about
100oC with gas burner nozzle.
 Be careful not to be burn.
 Align the key fixed with the jag part

of the crankshaft gear, and install it

by tapping the gear end surface
with plastic hammer.
Installation: main bearing
 Install the main bearing with the
tabs inserted into the grooves. In
addition, the main bearing should
be small size if the crankshaft has
been corrected to small size. Small
size type: 0.25, 0.50, 0.75, 1.00mm
 Engine will be stuck if the upper
bearing and lower bearing are
assembled reversely since the upper
bearing has oil hole while the lower
bearing doesn't.
Andy Lau 84
 Crankshaft
Installation: main bearing cap
 Before installing the main bearing cap
bolt, first check the stamped marks on
the tip of the bolt.
 Stamped marks indicates the assembly
times in the plastic area of bolts in the
past. If there are 3 stamped marks
(Which indicates that they have been
assembled 3 times), replace them with
new bolts.
1. Line the protruding number "1"~ “6",
mark "R“, and front mark as shown in
the illustration and install the main
bearing caps according to the number
sequence from the front of the engine.
Andy Lau 85
 Crankshaft
2. Apply engine oil to the thread of the bolt
and the seat surface, tighten them with
torque 59 N.m, and then go on rotating
90oC according to the following steps.
3. Turn the bolt of the tool left to make the
inner spring active.
4. Adjust the socket to apply spring force to
the crankshaft by connecting rod .
5. Align any of the scales on the socket seat
with any of the scales on the socket.
( Serve as the position of 0°)
6. Make the aligned position as benchmark,
tighten the socket as shown in illustration,
making the scale of the socket side at
90°position. Every scale on the socket
side equals to 5°.
7. Stamp the mark on the bolt to record the
usage times. Confirm that you can turn
the crankshaft by hand after installation.
Andy Lau 86
 Crankshaft
Installation: install the side oil seal
 Fill the mounting groove for the side
oil seal of the main bearing lid with
sealer.
 Apply sealer to the top and install the
side oil seal between the main bearing
lid and crankshaft case as shown in
the illustration.
A: crankshaft side
B: crankcase side
 Apply sealer to the area shown in the
illustration after installation. Make
sure that there is no engine oil
leakage from all the parts.

Andy Lau 87
 Crankshaft
Installation: thrust plate
 Install the thrust plate in
the main bearing cap
position, which is in the
rear end of the engine,
to make the oil groove
outside.

Aligning Pin

 Be careful not to install the oil groove of the thrust plate reversely, which will
cause the engine stuck.

Install oversize thrust plate when adjust the crankshaft end play. In this case, it
is OK even the left size and right size is different, however, the upper and lower
thrust plates must be the same size.

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 Lubrication system

Andy Lau
 Lubrication system

Andy Lau 90
 Lubrication system

Andy Lau 91
 Lubrication system
Specification

Andy Lau 92
 Lubrication system
The gear-type oil pump is
driven by the crankshaft
with the crankshaft gear
and oil pump gear
engaged.

To prevent oil pressure of

the lubrication system
from becoming too high,
the relief valve installed
on the oil pump will return
some of the oil to the oil
pan when the output
pressure of the pump is
over the specified range.

Andy Lau 93
 Lubrication system
1. Oil pressure switch
2. Oil cooler
3. Adjusting valve
4. Shunt flow filter element
5. Oil filter
6. Full flow filter element
7. By pass valve
8. Oil cooler by pass valve
9. Oil by pass switch
A: Oil cooler outlet port
B: Oil cooler inlet port
C: Passage to oil cooler
D: Passage to oil pan
E: Passage to main oil gallery

Andy Lau 94
 Lubrication system
By-pass Valve
 The flowing resistance of the oil
increases when the oil viscosity is
too high or the oil cooler element
is blocked. In this case, the by-
pass valve installed on the oil
cooler opens to make the engine
oil flow directly into (not through
the oil cooler) the oil filter.

Adjusting Valve
 If the oil pressure of the main oil
gallery is higher than the specified,
the adjusting valve opens to make
some of the oil flow into the oil
pan to adjust the oil pressure.
Andy Lau 95
 Lubrication system
Engine oil pressure switch
 If the oil pressure in the main oil gallery
is lower than the specification, the
electrical contact point in the engine oil
pressure switch closes.
 The warning light turns on to inform
the driver of the abnormity.
Engine oil by-pass warning switch
 If the oil filter is blocked, adhesive wear
will occurred. To prevent it, the oil by-
pass warning switch installed.
 If the oil filter is blocked, the oil bypass
warning switch makes the oil flow into
the main oil passage directly. In
addition, if the oil by-pass warning
switch operates, the warning light
comes on to inform the driver that the
oil filter is blocked.

Andy Lau 96
 Lubrication system
Oil filler uses the spin-on paper
filter with the by-pass filter and
full flow filter integrated.

The by-pass valve is located at

the bottom of the filter. The valve
opens when the element is
blocked to prevent the engine
form being stuck.

 Oil filter should be dry installed to

prevent contamination enter into
the center hole of the filter during
the filter replacement.

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 Lube of con-rod

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 Lube of timing gear
1. Thrust plate
2. Camshaft
3. Idle gear bush
4. Timing advance mechanism
5. Timing gear case
6. Idle gear
7. Idle shaft
8. Camshaft gear
9. No.1 camshaft bush
10. Main bearing
11. Oil pipe
A. Come from main oil gallery
B. Oil jet
Oil came from the main oil
gallery, flows through the
camshaft 2 and idle shaft 7.
At the same time, supply oil
to oil jet B to lubricate timing
advance mechanism 4.
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 Lube of valve mechanism
After lubricating the camshaft
No.1 bush, the oil is sent to the
rocker arm shaft through the oil
passage which goes through the
crankcase and the cylinder head.

The oil of the rocker arm shaft

lubricates the rocker arm bush
through the rocker arm shaft
carrier and jets out from the oil
hole of the rocker arm.

After lubricating, oil goes along

the push rod, then returns to the
oil pan from the oil hole of the
lifter.
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 Lube of piston
Check valve and oil jet tube
 The check valve, which can open or close in the specified oil
pressure range, in the oil jet tube closes when the engine speed is
low to keep the oil amount needed by the parts of engine lubrication
system enough and to prevent the decrease of the oil pressure.

 The oil jet tube is installed under

the main oil passage of each
cylinder.

 The oil jet tube jets oil towards

the inner side of the piston to
cool it.

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 Lube of turbocharger
Engine oil from the main
oil gallery is sent to the
bearing bush through
the oil pipe to lubricate
the interior of bearing
bushing.

The piston rings

installed on the two
sides of the turbine
shaft seals oil.

Return oil come out

from the cartridge out
port and goes to the oil
pan through the oil tube.

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 Lube of injection pump

The oil from the main oil passage lubricates the pump main
body by the leading of oil pipe and lubricates the governor
through the automatic advancer.
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 Troubleshooting of lube sys

Andy Lau 104

 Replace oil filter
Removal: oil filter
Clean the oil filter base before the filter is removed to
prevent the abrasive drop into filter.
Remove the oil filter with the filter wrench.
 Do not spill the oil onto the fan belt when filling it into the
engine. Otherwise, the belt will skid, decreasing the cooling
efficiency. The spilling engine oil may cause a fire, so you
should clean it carefully and thoroughly.
Installation: oil filter
Clean the oil filter mounting surface of the oil filter seat.
Apply a light coat of oil to the seal of the filter.
Install the oil filter by hand until the filter seal touch the
seat, then turn it ¾ turn.
After installing, start the engine and check whether the oil
leaks from the filter seal or not. If yes, reinstall it.
Stop the engine and check the oil level. If the amount of oil
is insufficient, fill some more.
Andy Lau 105
 Replace engine oil
Warm up engine to about 55oC.

Stop engine, open the cock

valve or remove drain plug 2
to drain oil to a container.

After the oil was drained

thoroughly, close the cock
valve or install plug to the oil
pan using torque of 69N.m.

Fill about 18 liters oil to the

crankcase to normal level.

 Clean the spill out oil on the

engine. Do not spill oil on the
fan belt to prevent slippage.

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 Engine oil pressure

Andy Lau 107

 Engine oil pressure
Remove the engine oil pressure
switch.
Install the oil pressure gauge to the
engine through a proper connector.
Warm up engine oil up to 70-90oC.
Measure the oil pressure when the
engine speed is at both low idle and
high idle speed.
If the measured value is lower than
the specification, lubrication system
should be checked thoroughly.
After measuring, wind the strip
sealer to the pressure switch thread,
install it and tighten to the specified
torque.

Andy Lau 108

 Oil pan
1. Drain plug
2. Bolt
3. Oil pan
4. Suction bell
5. O-ring seal
6. Check valve
7. Oil jet
8. Oil level switch
9. O-ring seal
*. Crankcase
Torque for drain plug: 69N.m

Torque for check valve: 38N.m

 Do not over torque the check

valve, to avoid the failure of
piston seizure occurred.

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 Oil pan
Installation: oil pan
 Clean the sealing face of every parts.
 Apply the sealer to the mounting
face of the oil pan uniformly and
continuously as shown in the
illustration.
 Install the oil pan in 3 minutes after
applying the sealer. Be careful not to
make the sealer come off.
 Do not start the engine within 1 hour
after installing the oil pan. In
addition, the sealer must be apply
once again when loosen or remove
the oil pan mounting bolts after
installation.
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 Oil pump
1. Cotter pin

2. Valve seat

3. Relief valve spring

4. Relief valve

5. Oil pump cover

6. Driven gear

7. Pump gear and housing

8. O-ring seal

*a. Drive gear

*b. Crankshaft gear

Can not be reused.

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 Oil pump
Service standard unit: mm

Andy Lau 112

 Oil pump
Inspection: oil pump cover, driven gear, drive
gear, gear and case
 Perform the following inspections. If abnormal,
replace the oil pump.

1. Droop of each gear and gear and case end face.

2. Clearance between gear tip and gear, clearance

between gear tip and pump housing.

 Measure the clearance between gear shaft and oil

pump cover, the clearance between gear shaft
and oil pump cover and the clearance between
gear shaft and case.

 If the measured value is greater than the standard

value, replace the failed components.

Andy Lau 113

 Oil pump
Installation: oil pump cover
 Place 2 pins whose outer diameter
are 9mm into the mounting area
(On the cross) and align the gear,
case and oil pump cover.
 Install the bolts in the area where
there is no pin and tighten them to
the specified torque.
 Take the pins out and tighten the
leftover bolts.
 After installation, turn the gear of
the oil pump by hand to make sure
the gear rotates smoothly.
 If abnormal, remove and install it
once again.

Andy Lau 114

 Oil filter
1. Oil Hose 2. Connector 3. Cap 4. Oil Hose
5. Connector 6. Plug 7. Drain Plug 8. Oil Filter

9. By-pass Warning Switch 10. O-ring 11. Plug

12. Oil Filter Seat 13. O-ring 14. O-ring
15. Oil Filter Junction Accessory

Andy Lau 115

 Oil cooler
1. Plug 2. O-ring
3. By-pass Valve Spring
4. By-pass Valve 5. Plug
6. O-ring 7. Plug
8. O-ring
9. Adjusting Valve Spring
10. Adjusting Valve
11. Plug
12. Connector
13. Plug 14. O-ring
15. Adjusting Valve Spring
16. Adjusting Valve
17. Plug 18. O-ring
19. Plug 20. O-ring
21. Engine Oil Pressure Switch
22. Oil Cooler Core
23. O-ring
24. Oil Cooler Body
25. O-ring 26. Gasket
Andy Lau 116
 Oil cooler specification

Andy Lau 117

 Oil cooler leakage test
Inspect: oil cooler element
 Using a plug, block the outlet
of the cooler core. Connect a
hose to the oil cooler inlet and
put the oil cooler core into the
water trough.
 Apply 980 kPa (10 kgf/cm2) air
pressure to the cooler for 15
seconds and check if there is
any air leakage from any part
of the oil cooler or not.
 If the oil cooler core leaked air,
replace it.
Inspect: oil pressure switch
 With no air pressure applied,
check whether the switch is
shorted or not.
 Increase air pressure gradually
from 0 kPa to check the switch
close pressure. If failed or out
of specification, replace it.
Andy Lau 118
 Lubrication system
Key function of lube system:
 Provide lubrication for the motive parts and components to prevent
the adhesive wear.
 Provide cooling for the high temperature components, such as
turbocharger, to prevent the adhesive.
 Cleaning the debris or foreign material float on the metal contact
surface to prevent the abrasive wear.
 Seal the clearance between the mating face.
 Coat metal surface to prevent metal rust.
Correct operation extended hex service life:
 Proper idle time was required for the hex. Never accelerate engine
speed rapidly just after starting.
 Do not stop engine immediately after long time full load working.
Especially, engine can not be stopped at rated speed and rated
load.
 Do the lube system maintenance timely and correctly.

Andy Lau 119


Oil viscosity in cold
weather.
Six stage: 0W, 5W, 10W,
15W, 20W, 25W.
W – first letter of winter.
The smaller the number
before W, the better the
fluidity at low temperature.
Andy Lau
Engine oil viscosity
Oil viscosity under high
temperature.
Five viscosity stage: 20,
30, 40, 50, 60.
Oil has a larger number
will have higher viscosity
and better performance
at high temperature.
High speed engine should
use high viscosity lube oil.
120
 Engine oil selection

Andy Lau 121

 Engine oil key function
Lubrication: provide lubrication for the moving parts.
Cooling: remove heat to prevent parts from adhesive
wear.
Neutralization: TBN (Total Base Number) is a important
parameter which indicated the oil ability to neutralize the
acid produced by the SO2 and vapor during engine
working.
Cleaning: dispersant in the oil clean dirty in the oil from
the moving parts.
 A drop of around 50% of fresh oil TBN indicates that the
oil is almost at the end of its useful life.
 Can the hydraulic oil used as engine oil?
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 Inlet and exhaust system

Andy Lau
 System operation

Andy Lau 124

 System operation
The components of the air inlet and exhaust system control the quality and the
amount of available air for combustion.

The air inlet and the exhaust system consist of the following components: Air
cleaner, Inlet manifold, Cylinder head, Valves, Valve components, Exhaust
manifold, and Turbocharger.

Turbocharger compressor wheel pulls clean air from the air cleaner. The rotation
of turbocharger compressor wheel causes compression of the air and forces the
air through inlet manifold to the inlet valves in the cylinder head. The inlet valves
control the air flow into each engine cylinder.

There is one inlet and one exhaust valve for each cylinder. The inlet valves open
when the piston moves down on the intake stroke. Compressed air from inlet
manifold is pulled into engine cylinder. The inlet valve closes. The piston starts to
move up on the compression stroke.

Andy Lau 125

 System operation
When the piston is near the top of the compression stroke, fuel is injected into
the engine cylinder. The fuel mixes with the air and combustion begins. The force
of combustion pushes the piston downward. The piston is pushed downward on
the power stroke. The piston moves up again on the exhaust stroke. The exhaust
valve opens and the exhaust gases are pushed through the exhaust port into
exhaust manifold. After the piston makes the exhaust stroke, the exhaust valve
closes and the cycle starts again. The cycle consists of the following items: intake,
compression, power and exhaust.

Exhaust gases from exhaust manifold go into the turbine side of turbocharger
and the exhaust gases cause turbocharger turbine wheel to turn. Turbocharger
turbine wheel and turbocharger compressor wheel are connected to the same
shaft. The exhaust gases travel through the exhaust outlet. The exhaust gases
travel through the exhaust system.

Andy Lau 126

 Inlet & exh system

Power
Compress

Exhaust Intake
Andy Lau 127
 After-cooler
Natural aspiration: air density and
the inlet air temperature are the
lowest and the power is the lowest.
Turbocharger: temperature of the
boosted air increased, effect of the
turbocharger is weakened.
Turbocharger plus the water cooled
after-cooler: inlet boosted air was
cooled down, air density increased
and engine power improved.
Turbocharger plus the air to air after-
cooler: cooling effect to the boosted
air improved. Density of the inlet air
is the highest. Much more air can be
supplied to the combustion chamber.

Andy Lau 128

 System operation

Engine slobbering.
Excessive engine
oil consumption.
Maintenance of the
Aftercooler valve lash and air
cleaner.
Exh valve Correct start/stop
procedure prolongs
the service life of
the turbocharger.

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 Inlet & exh system

Andy Lau 130

 Air cleaner
Air cleaner includes following parts: inner
and outer filter element, end cap, rubber
sealing, housing, and the air cleaner
indicator.
When the boost pressure increased, the
vacuum valve is closed. When the boost
pressure decreased, the vacuum valve
opened. Collected dust in the vacuum
valve dropped down automatically.
When the engine is stopped, nip the
vacuum valve to discharge the dust in it. If
there are heavy dust in it, check the air
cleaner and perform maintenance for it.
If the filter elements is blocked severely,
the diaphragm in the indicator was moved
in sight to warn the operator. Air filters
must be cleaned.

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 Air filter indicator

Andy Lau 132

 Air cleaner

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 Air cleaner

Outer element can be cleaned up to six times, and the inner element should be
replaced with the outer element at the same time.
Blow the element with compressed air which is lower than 685kPa from inner
side outward. Blow along the element flexure part with compressed air again and
again until the element becomes clean.
Put the light in the inside of the outer element. If the filter is worn, broken, or
abnormal, replace the element.
Apply negative pressure to the indicator slowly and measure the vacuum when
the terminal 1 and 2 was closed. If the measured value exceeds the standard
value 6.23±0.57kPa, replace the indicator.
Andy Lau 134
 Turbocharger

Andy Lau 135

 Turbocharger
Turbocharger is installed on the center of the exhaust manifold. All of the
exhaust gases from the engine travel through turbocharger. The compressor side
of turbocharger is connected to the inlet pipe by a rubber hose.
The exhaust gases travel into the turbine housing through exhaust inlet. The
exhaust gases push the blades of turbine wheel. Turbine wheel and compressor
wheel have the same shaft.
Clean air from the air cleaners is pulled through the air inlet of the compressor
housing by the rotation of the compressor wheel. The inlet air is compressed by
the movement of the blades of the compressor. The compression allows engine
to burn more air and fuel. The result is greater power for the engine.
More fuel is injected into the cylinders when the load on the engine increases.
More exhaust gases are produced and turbine wheel and compressor wheel of
the turbocharger turn faster. More air is forced into the engine as compressor
wheel turns faster. The engine burns more fuel with greater efficiency because of
the increased air flow. More engine power is the result.

Andy Lau 136

 Turbocharger
The maximum rpm of the turbocharger is controlled by the fuel setting, the high
idle speed setting, and the height above sea level of the engine.
The fuel setting adjustment is performed at the factory for a specific engine
application. The governor housing is sealed in order to prevent changes in the
adjustment of the fuel. The governor housing is also sealed in order to prevent
changes of the high idle speed setting.
Bearings of the turbocharger use engine oil under high pressure for lubrication.
The oil passes through the oil inlet port. The oil then travels through the
passages in the center section for the lubrication of the bearings. Oil from the
turbocharger travels through the oil outlet port in the bottom of the cartridge.
The oil then travels back to the engine lubrication system.
 Damage will result when increased heat and/or friction due to the higher engine
output goes beyond the engine cooling and lubrication systems abilities. A
mechanic that has the proper training is the only one to make the adjustment of
fuel setting and high idle rpm setting.

Andy Lau 137

 Turbocharger

Since the cartridge is non-removable parts.

replace it if the turbine wheel or compress
wheel were damaged and can’t be reused.
Andy Lau 138
 Turbocharger
Make a matching mark on the turbine
housing, compressor housing and the
cartridge before dismantling.

Tap with a rubber hammer around the

housing slightly to remove the housing,
be careful not to damage it.

 Since the blade of the turbocharger is

easily bent. Therefore, be careful not
to touch them with the housing.

Visually check the removed parts for

ablation, scratch, crack, and foreign
materials before cleaning. Replace the
failed parts if they can not be reused
again.

Andy Lau 139

 Turbocharger
Check and make sure there is no oil residual and
carbon deposits on the turbocharger wheels before
the cartridge was reused again.

Radial clearance measured on the turbine wheel

end should be within 0.40 – 0.53 mm, if it is larger
than 0.56 mm, replace the failed parts.

Radial clearance measured on the compress wheel

end should be within 0.55 – 0.66 mm, if it is larger
than 0.72 mm, replace the failed parts.

Axial clearance of the turbo shaft should be within

0.05 – 0.09 mm. If the measure value is larger
than 0.1 mm, replace the failed cartridge.

Rotate the wheels of the cartridge to make sure

that it can turn smoothly.
Andy Lau 140
 Failure case

Large size material entered into the inlet hose before turbocharger, compressor
wheel and compressor housing were damaged severely.

Valve is broken. The broken valve piece was found in the inlet manifold. Piston
and turbine wheel were impacted and resultant damaged.

Andy Lau 141

 What will happen?
If the clamps for hose or tube before the
compressor wheel was loosed……
If the air cleaner was blocked by dust
severely……
If a grease fitting entered into the hose
before the compressor wheel……
If the hose or tube after the compressor
wheel was loosed……
If the air to air after-cooler was damaged
and leaked air……
If the fresh air was restricted severely…
If fan belt slipped……
If the exhaust manifold leaked gas……
If the exhaust pipe after the turbine
wheel leaked gas……
If the valve lash was incorrect......
If a valve head was broken down and
dropped into combustion chamber……
Andy Lau 142
 Fuel system

Andy Lau
 Fuel system operation

Andy Lau 144

 Fuel system operation
1. Secondary fuel filter

2. Fuel supply for fuel

injection nozzle

3. Fuel injection nozzle

4. Supply line for the

secondary fuel filter

5. Fuel tank

6. Valve for the fuel

return

7. Fuel injection pump

8. Fuel transfer pump

9. Fuel return line

Andy Lau 145

 Fuel system operation
The fuel in the fuel tank are pumped out by the fuel transfer pump which is
driven by the camshaft of the fuel injection pump.

Foreign matters in the fuel are then filtrated by the fuel filter.

The filtrated fuel enters into the fuel injection pump. Fuel pressure was then
increased by the fuel injection pump.

High pressure fuel is injected into the combustion chamber through the high
pressure fuel pipe and fuel injectors.

The leftover fuel in the injector flows back through the fuel return pipe and
fuel return hose to the fuel tank to move the heat away from the fuel injectors.

 At least two times the quantity of fuel that is needed is delivered to the fuel
injection pump by the fuel transfer pump.

If the fuel pressure in the fuel injection pump is over the specified, the spill
valve opens to let the fuel return to the fuel tank.

Andy Lau 146

 Fuel tank
1- Fuel Tank
2- Seat
3- Tube
4- Plug
5- Cover
6- Sensor
7- O-Ring
8- Bolt
9- Washer
10- Director
11- Cover
12- Float
13- Screen Filter
14- Elbow
15- Tube
16- Grommet
17- Bolt
18- Bolt
19- Washer
20- 1.0 mm Shim
Andy Lau 147
 Fuel tank
In case of low fuel level, unscrew the fuel tank cap F
and add fuel to the tank till the float level meter G
reaches the highest point.

● Fuel tank capacity: 340L

When the fuel tank is full, top of the float level meter
G is positioned at about 50mm.

Press down the float level meter G with fuel tank cap
opened when refueling. Be careful not to let the
level meter G be stuck on the cover plate of cap F.
Screw on the cap F tightly.

● Pressure of fuel tank will drop gradually if the vent 3

of the cap is blocked. As the vacuum increased, fuel
will not be pumped out and engine will be shut down
automatically. Clean the vent whenever necessary.
Andy Lau 148
 Fuel filter

The foreign matters in

the fuel are filtrated
by the fuel filter.

The priming pump is

designed and installed
on the fuel filter base
which is used to bleed
air before starting or
after filter replaced.

 No by pass valve for

the fuel filter.

Andy Lau 149

 Fuel injection pump
The fuel injection
pump is equipped
with the unit which
can send high
pressure fuel to the
injector and control
the volume of the fuel.

The spilling fuel may

cause a fire, so you
should check and
replace the failed pipe
and/or hose, and
clean fuel thoroughly
and timely.

Andy Lau 150

 Fuel injection pump
1. Press-delivery
When the spiral groove (slot) meets
fuel in the feed port, fuel was
extruded out through the feed port
when the plunger is raising. No fuel
can be delivered by the plunger
raising.
As the slot is separated from the fuel
in the feed port, the effective stroke
of the plunger started.
As the plunger moved up much more,
the fuel pressure increased rapidly.
High pressure fuel can be sent to the
fuel injectors and sprayed into the
combustion chamber.
Andy Lau 151
 Fuel injection pump
2. Injection volume adjustment
The flange at the lower portion of the plunger
is inserted into the groove of the control
sleeve. The teeth on the upper portion of the
control sleeve are engaged with the teeth of
the fuel rack.
As the load of the engine changed, fuel rack
moved leftward or rightward. Control sleeve
was driven by the fuel rack and rotated at an
angle. As the meeting position of the fuel feed
port and the slot of the plunger changed,
effective stroke of the plunger changed. Fuel
injection volume changed.
Every plunger has one control sleeve and
turns the same amount of angle.
Andy Lau 152
 Fuel injection pump
3. Outlet valve
As the delivery valve moved up but not opened, fuel
chamber from the delivery valve to the injector
decreased and fuel pressure increased.
Once the delivery valve was opened by the action of
plunger, high pressure fuel was supplied to the injector
and sprayed into the combustion chamber.
As the delivery valve moved down but not closed, the
fuel chamber from the delivery valve to the injector
increased and fuel pressure decreased.
The fuel pressure is reduced in order to prevent
leakage of fuel after the fuel injection nozzle is closed.
Delivery valve prevents reverse flow of fuel from the
fuel injection line to the plunger barrel. The prevention
of reverse flow occurs after the plunger finishes the
delivery of fuel.

Andy Lau 153

 Fuel injection pump

4. Spill valve
The function of the spill valve is: the
ball is pushed upward when fuel
pressure in the fuel injection pump
reached to some extent, then the fuel
returns to the fuel tank from injection
pump. Fuel temperature and
temperature distribution in the fuel
injection pump can be stabilized in this
way, providing constant fuel volume to
the cylinders.

Andy Lau 154

 Fuel transfer pump
The movement of the camshaft is transmitted

through the tappet and the pushrod to the piston.

The piston spring acts to return the piston of the

supply pump. The reciprocating motion of the

piston creates a suction and a discharge cycle.

The mesh filter can filtrate the big impurity in the

fuel which is sucked from the fuel tank. The mesh

filter should be washed with light oil periodically.

(1) Priming pump (2) Check valve

(3) Check valve (4) Piston

(5) Camshaft (6) Tappet

(A) Suction (B) Discharge

Andy Lau 155

 Fuel transfer pump
When sucking When delivering
Piston is pushed back by the piston The camshaft pushes the push rod.
spring force as camshaft rotated.
Inlet check valve is closed while the
Outlet check valve is closed while the outlet check valve is opened. Fuel is
inlet check valve is opened. Then the
delivered to the fuel filter.
fuel is sucked into the fuel chamber.
When stopping: If the fuel pressure on the discharge side increases abnormally,
check valve for the suction port closes and the further pickup of fuel is prevented.

Andy Lau 156

 Governor
1. Injection control rack
2. Governor spring
3. Swivel lever
4. Tension lever
5. Spring for starting
6. Control lever
7. Camshaft
8. Guide lever
9. Idler sub-spring
10. Torque control spring
11. Roller for flyweight
12. Bolt for stopping at
full load
13. Flyweight
14. Sleeve
15. Shifter
16. Floating lever
Andy Lau 157
 Governor

Andy Lau 158

 Governor

Andy Lau 159

 Governor
Flyweight (13) is attached to camshaft (7) of the fuel injection pump on the RSV
Governor. The roller for the flyweight (11) pushes sleeve (14) in an axial
direction when flyweight (13) opens outward. Sleeve (14) is connected to shifter
(15) via bearings. Sleeve (14) will move only in an axial direction.
Shifter (15) is connected to guide lever (8). Guide lever (8) is mounted on a pin.
The pin is incorporated with the governor cover. Floating lever (16) is attached
to guide lever (8) by a pin at the lower end of guide lever (8). The pin acts as a
fulcrum. Floating lever (16) is connected to the injection control rack by a link.
The spring for starting (5) is attached to the top of floating lever (16) so that
injection control rack (1) is always pulled toward the direction for increasing fuel.
The shaft for the swivel lever is connected to the governor cover by bushings.
One end of governor spring (2) is connected to swivel lever (3). The other end
of governor spring (2) is connected to tension lever (4). The lower end of
tension lever (4) will contact the adjustable bolt for stopping at full load (12)
when governor spring (2) is extended. The swivel lever will contact the guide
lever and the swivel lever will move guide lever (8) when the engine is stopped.
Andy Lau 160
 Governor
Floating lever (16) is attached to guide lever (8). Floating lever (16) will move
and floating lever (16) will place injection control rack (1) in a position for no
injection.
The movement of the position of control lever (6) will alter the position of swivel
lever (3) and the tension of governor spring (2). This occurs when the following
two items have eccentric motion: the center of revolution of swivel lever (3) and
the point of attachment of tension lever (4) on governor spring (2)
An adjustment screw is attached to the opposite end of swivel lever (3). The
tension of governor spring (2) and the drop in speed can be adjusted by the
adjustment screw.
Torque control spring (10) regulates the quantity of fuel injection within a
specific range in order to ensure the optimum quantity of fuel injection between
idling speed and maximum speed.
Constant idling speed is maintained through the installation of idler sub-spring
(9). Idler sub-spring (9) is part of the governor cover. Idler sub-spring (9)
contacts tension lever (4) at idle.
Andy Lau 161
 Governor
Mechanical stop lever
1. Injection control rack
16. Floating lever
17. Spring for starting
18. Mechanical stop lever
19. Return spring
20. Lever for supporting
21. Pin

The governor may be equipped with a device for stopping in order to return
injection control rack (1) to the stop position regardless of the position of the
control lever. Pin (21) in the bottom of floating lever (16) is inserted into the slot
of supporting lever (20).
Injection control rack (1) is moved to the position of no injection by floating
lever (16) when mechanical stop lever (18) is moved to the stop position.
Andy Lau 162
 Starting engine
Swivel lever 11 is connected to control
lever. Prior to starting the engine, swivel
lever 11 extends governor spring 10 to
move tension lever 9 until it contacts the
bolt for stopping at full load.

Start spring 6 holds floating lever 7 in

the fuel increasing position as flyweights
12 are not moving.
The roller for the flyweights is held by the shifter and the sleeve 13 as flyweights
12 are not moving. The distance between tension lever 9 and the shifter is
greater than the distance at full load operation as a result. A larger quantity of
fuel injection and easier starting result. Immediately after starting, centrifugal
force of flyweights 12 exceeds the force of the start spring. The shifter pushes
the tension lever 9 and the quantity of fuel injection is reduced.

Andy Lau 163

 Idling control
After engine is started, flyweight 12 opens
under low engine speed. Movement of the
shifter and sleeve are transmitted to tension
lever 9. Tension lever 9 moves to the right to
contact idler sub-spring 15. Floating lever 7
moves the fuel control rack 8 to idling position
3. The supplied fuel decreased.

The centrifugal force of the flyweights decreases when the engine rpm decreases.
The force of the idler sub-spring moves tension lever 9 and the shifter. The guide
and floating lever 7 will move to the left. Fuel rack 8 moves to the direction of
increasing fuel to return the engine to the required condition for idling. Start
spring 6 moves floating lever 7 and fuel rack 8 in the direction of increasing fuel
if the engine rpm drops further. The engine is prevented from stopping and the
engine maintains constant idling.
Andy Lau 164
 Speed control
The control lever maintains constant
engine rpm. The governor adjusts
engine rpm if engine load changes.

The tension of the governor spring

increase if the control lever contacts
the bolt for stopping at full load 14.
Tension lever 9 contacts the bolt for
stopping. The shifter and sleeve 13
move to the left.

Injection control rack 8 moves in the direction of increasing fuel through guide
lever 16 and floating lever 7. When the quantity of fuel injection is increased, the
rpm and the centrifugal force of the flyweights increase until the centrifugal force
of the flyweight is balanced with the force of the governor spring. The required
rpm will be maintained as a result.
Andy Lau 165
 Torque control

The force of the spring for torque control is greater than the centrifugal force of
the flyweights at low rpm. The shifter and sleeve 13 move away from the spring
for torque control. The movement is transferred to guide lever 16 and floating
lever 7. The movement is called the stroke for torque control. Injection control
rack 8 moves to the direction of increasing fuel.
The centrifugal force of the flyweights increases as the engine rpm increases.
The spring for torque control is compressed when the centrifugal force of the
flyweights is greater than the force of the spring for torque control. The shifter
then moves tension lever 9 to the direction of decreasing fuel injection.
Andy Lau 166
 High idle operation
The centrifugal force of the flyweights 12
increases in order to exceed the force of
the governor spring if the engine rpm
exceeds the rated rpm. The shifter moves
tension lever 9 to the right. The quantity
of fuel injection and rpm are decreased.
Tension lever 9 stops moving when the
force of the governor spring and the
centrifugal force of the flyweights 12 are
balanced. Then engine maintains the
correct quantity of fuel injection.
The centrifugal force of the flyweights increases when the engine rpm increases.
Governor spring 10 extends. Tension lever 9 moves to the right until tension lever
9 contacts idler sub-spring 15. Injection control rack 8 moves to the direction of
maximum rpm at no load in order to maintain engine rpm.
Andy Lau 167
 Fuel injector
Pressure spring sets the pressure of injection
at starting. The needle valve of the fuel
injector is pushed upward and fuel is injected
into the combustion chamber when the fuel
pressure overcomes the tension of pressure
spring of the fuel injector. The needle valve is
pushed down by the pressure spring and fuel
injection stops when the fuel pressure
decreased and smaller than the spring force.

After cooling and lubricating the sliding parts

between the fuel nozzle tip and the needle
valve, the remainder of the fuel comes out of
fuel injector and returns to the fuel tank.

Andy Lau 168

 Injection nozzle tip
The fuel injection nozzle has several

orifices. The tip of needle valve 9 is

located in the body for fuel injection

nozzle 10. The shape of the tip is a

cone. The spray angle is determined by

the number of the orifices and the angle

of the orifices. The diameters of fuel

injection nozzle orifices 11, the number

of orifices, and the angle of injection

depend on the type of combustion

chamber of the engine.

Andy Lau 169

 Troubleshooting

Andy Lau 170

 Troubleshooting
In these two charts,
some possible fuel
system problems are
listed. For each
problems, there are
so many possible
suspected factor are
listed. These two
charts will help to do
the troubleshooting
when the fuel
system problems
occurred.

Andy Lau 171

 Troubleshooting

Different engine will have different fuel injection timing. Fuel injection
timing can be found in the engine specification. It can also be found on
the nameplate as shown in the No.7 slide.

Andy Lau 172

 Checking the fuel timing

Andy Lau 173

 Fuel timing
Inspection: fuel timing
1. Remove injection pipe, lock
plate, delivery valve holder,
spacing collar, delivery valve
spring and fuel delivery
valve from the No.1 cylinder
of the fuel injection pump.

2. Install delivery valve holder

properly after removing all
the parts.

Put the removed parts in the

light fuel to prevent them
from contamination.

Andy Lau 174

 Fuel timing
3. Install the prepared injection
pipe to No.1 cylinder. Make
the other end of the injection
pipe downward, so the flow
state can be seen clearly.

4. Turn the crankshaft more

than 180o clockwise by hand,
set the No.1 cylinder 30o
away from the compressing
stroke TDC (Top dead
center).

5. Using a cup to collect the

fuel to prevent fuel spill to
the engine.

Andy Lau 175

 Fuel timing
5. Operate the priming pump, making the
fuel flow from the injection pipe while
cranking the engine clockwise by hand.
 The engine shut down lever located on
the governor must be set in the engine
starting position.
6. When fuel discharge from the injection
pipe is going to be interrupted, go on
cranking the engine by hand slowly.
Stop cranking when the fuel discharge
stops fully.
7. Check that the needle is away from
about 1o to the injection timing reticle.
 Fuel timing is about 1o advanced than
the specification since that the delivery
valve spring was removed.
Andy Lau 176
 Fuel timing
8. If the injection timing deviates from the
specification, adjust it according to the
following tips.

Adjustment: fuel injection timing

1. Loose the mounting nuts (four nuts A and
one nut B) of the fuel injection pump.
2. Push to rotate the fuel injection pump in C
direction toward the crankcase as shown
in the illustration when the injection timing
is retard.
3. Pry to rotate the fuel injection pump away
from the crankcase in the D direction as
shown in the illustration when the
injection timing is advanced.

Andy Lau 177

 Fuel timing
4. Rotate the fuel injection pump a
proper degree relative to the scale
on the timing advance case as
shown in the illustration.

5. Tighten the nuts to the specified

torque and measure the injection
timing again after adjustment.

6. Install the delivery valve, delivery

valve spring, spacing collar, valve
holder, the lock plate, and injection
pipe when make sure the injection
timing is the specified value.

7. Tighten all the parts to the specified

torque.

Andy Lau 178

 Bleed air from fuel system
Turn the air bleed plug counterclockwise to
loose or release the plug of the fuel filter.
Turn the handle of the priming pump
counterclockwise to release it, making the
hand outside.
Operate the priming pump up and down to
deliver the fuel.
If no bubble can be found in the fuel,
tighten the plug to the specified torque
while the priming pump is still operated.
 Air bleeding should be done when the filter
is replaced or when the engine is difficult
to start.
 Before bleeding air, find out the root cause
and failed parts where the air leaked into
the fuel system.
Andy Lau 179
 Bleed air from fuel system
Operate the priming pump
up and down 5 to 6 times
and fix it by tightening the
handle clockwise.

After bleeding, clear the

spilled fuel away and then
start the engine. Make sure
that there is no leakage.

Pressure should be felt by

hand before locking the
priming pump. This will help
to start engine since the
primary fuel pressure is built
up.

Andy Lau 180

 Fuel filter
1. Joint Bolt

2. Fuel Pipe

3. Fuel Filter

4. Plug

5. O-ring

6. Fuel Filter Base

Torque for the joint bolt 1

is 34 N.m or 3.5 kgf.m

Torque for the air bleed

plug is 9.8±2 N.m

 If O-ring or copper gasket

5 is failed, air will leaked
into fuel system via it.

Andy Lau 181

 Fuel filter replacement
Clean the mounting surface of the fuel filter base.
Apply a light coat of the engine oil to the contact
surface of the fuel filter evenly.
Spin on the fuel filter to the fuel filter base until the
C touches the surface B of the fuel filter base by
hand. Turn another 3/4 to 1 round again by the
filter wrench to tighten it.
Start the engine and make sure that there is no
leakage between the fuel filter and filter base.
 The counterfeit inferior fuel filter will lead to fuel
leakage and fire and also components failure, so
you should use high quality genuine filter.
 To prevent the injector failure and failure caused by
the failure injector, make sure that there is no
contamination entered into the fuel filter and fuel
pipe during the filter replacement.
Andy Lau 182
 Fuel injection pump
1. Joint Bolt Cover the connectors and plug the pipes and hoses once
2. Fuel Pipe
the pipe / hose is removed to prevent contaminations
3. Joint Bolt
4. Fuel Pipe enters into fuel system to damage the fuel pump.
5. Joint Bolt
6. Oil Pipe
7. Joint Bolt
8. Air Pipe
9. Joint Bolt
10. Fuel Pipe
11. Fuel Return Pipe
12. Spill Valve
13. Connector
14. Injection Pipe
15. Pump Carrier
16. Fuel Injection Pump
17. O-ring
*a: Front Case

Andy Lau 183

 Fuel injection pump

Do not hold the injection pump assembly’s control levers and allow the assembly
hang from them. Always hold its main body when picking up the pump assembly.
Suggest to contact the BOSCH service station or other authorized service dealers
to do the fuel injection pump service repair.
Andy Lau 184
 Fuel injection pump
Installation: fuel injection pump
1. Crank the engine to let the needle align
with the scale 1.6 on the flywheel.

 If the push rod of the No.1 cylinder

inlet and exhaust valve do not stick up,
the No.1 cylinder will be at the TDC of
compression stroke. Otherwise, turn
the crankshaft another 360°.

 Engine’s No.1 cylinder piston is set at

the TDC of the compression stroke.

2. Align the timing mark on the advancer

housing with the gear jag of the fuel
injection pump.

Andy Lau 185

 Fuel injection pump
3. Insert the guild pin of the advancer case into
the guild hole of the front end plate, then
align the gear of the fuel injection pump with
the bevel wheel of the timing gear group and
push it forward.

4. Make sure whether the gear jag of the fuel

injection pump aligns with the timing mark of
the advancer housing or not, further insert
the fuel injection pump to engage with the
timing gear fully. The pump gear jag will be
turned in the direction indicated by the arrow
in the illustration.

5. Install and tighten the bolts and nuts, hose

and pipe properly to finish pump installation.

Andy Lau 186

 Fuel injection pump
Any more method to install the fuel injection
pump accurately and quickly?

Andy Lau 187

 Fuel injector
1. Injection Pipe 2. Fuel Return Pipe
3. Retainer For Fuel Injector
4. Retaining Nut 5. Gasket
6. Straight Pin 7. Needle Valve
8. Injection Nozzle 9. Pressure Pin
10. Spring 11. Shim
12. Holder assembly
13. O-ring 14. Seat Washer

The disassembly, assembly, and adjustment of the injector can be operated only
after clearing the carbon deposits on it. VOP, spray pattern, and leakage test
must be done before dismantling. Please do not dismantle it if there is abnormal.
Needle valve and other parts of the injector can not be mixed and interchanged
with the one of other cylinder’s. All the parts should be protected careful to avoid
damage after the fuel injector is dismantled.

Andy Lau 188

 Fuel injector
Service standard

Name Service Item Standard Value Correction

VOP 21.6 Mpa

Injector Adjustment
(valve open pressure) (220kgf/m2)

Torque specification

Symbol Service Item Specified torque

Nut of injection pipe 24N.m (2,5kgf.m)

Retainer bolt 24N.m (2,5kgf.m)

34±5N.m
Retaining nut
(3.5±0.5kgf.m)

Andy Lau 189

 Fuel injector
1. Start the engine and run the engine at low idle.
2. Loosen the nut for fuel supply line at each fuel injector. Listen for the low idle
to decrease at each cylinder. Also, listen for the low idle to become rough at
each cylinder.
3. The fuel injector may be damaged if the items that follow occur:
Engine rpm does not decrease.
The engine continues to run properly.
4. Remove the fuel injector from the engine cylinder head for additional testing.
 If leakage at the nut for fuel supply line occurs, make sure that the fuel supply
line and the nut for the fuel supply line are correctly aligned with the inlet
connection of the fuel injector. Do not tighten the nut for the fuel supply line
on the high pressure fuel line more than the recommended torque. If the nut
is tightened more, the fuel line may become restricted or the threads of the
fuel injector and the nut may be damaged.

Andy Lau 190

 Fuel injector
Inspection of injector before removal
 Install the injector to the injector tester
and then check the following items.
 Operate the lever of the injector tester
before inspection to pump out the air
after spraying 2 to 3 times.
 The spray from the fuel injector must
Valve Open pressure test (VOP) be directed into the fuel collector.

 Press the level of the injector tester at the speed of 1 to 2 second every
stroke, after the pressure gauge needle raising gradually, record the value
when the pressure drops suddenly.

 If the measured value exceeds the specified value, you should disassemble
the injector and adjust it after disposure. If it is still abnormal after adjusting,
replace the failed injector.

Andy Lau 191

 Fuel injector
Inspection: spray pattern
Quickly pump the nozzle tester to check
the spray pattern when the fluid begins
to flow through the orifices of the fuel
injection nozzle.
The spray, which flows from all of the
orifices, must have the same pattern. A
difference in the nozzle spray patterns
indicates that fuel injection nozzle is
A: 5 spray-holes spray evenly (good)
damaged.
B: even and symmetry (good)
 High pressure sprayed out test fluid can
pierce the skin and cause serious injury C: dissymmetry (bad)
to the operator. Always keep the nozzle D: Forking during the spraying (bad)
tip pointed away from the operator and
E: poor spraying (bad)
into the fuel collector. And wear the
eyeglass all the time during the testing. F: ladder like spray (bad)

Andy Lau 192

 Fuel injector
Inspection: fuel leakage
Make the pressure inside the injector is
1960 kPa (20 kgf/cm2) lower than the
specified needle valve opening pressure
and keep this pressure. Make sure there
is no fuel leakage from the tip of nozzle
within 10 seconds.
Look for any leakage from the nozzle tip and the retaining nut of the fuel
injection nozzle. If leakage is visible, make sure that the components are
tightened to the correct torque.

If leakage continues to occur, unscrew the retaining nut from the body. Inspect
the threaded surfaces for foreign particles and damage. If the faces are clean
and undamaged, test the fuel injection nozzle. Replace the failed injection nozzle.

Andy Lau 193

 Fuel injector cleaning
Remove retaining nut from the holder
assembly. Remove the tip assembly of
fuel injection nozzle. Wash the needle
valve and the body.
After cleaning the needle valve and body
in kerosene, carbon deposits on the top
of the needle valve can be disposed with
cleaning rods.
Do not dispose them with wire brush and
hard metal and so on.
Do not mix the needle valve and bodies
of different nozzles. The components of
the nozzle tip assembly are a precise fit.
The components must not be exchanged
with other components.
Do not touch the sliding surfaces of the
needle valve. After cleaning, install the
needle valve and the body in clean fuel.
Andy Lau 194
 Fuel injector cleaning
Carbon deposits on the spray-hole of
the injection nozzle can be cleaned
by turning around again and again
along the spray-hole with body
cleaner.

Body cleaner diameter should be less

than or equal to 0.23mm

The seat surface of the needle valve

can be cleaned with cleaning scraper.

Using the carbon deposit remover to

clean the burned hard carbon deposit.

 Part number of the injector cleaning

tool is 105789-0010 which is provided
by Bosch.
Andy Lau 195
 Fuel injector
Inspect: injector
Assembly the needle valve and injection
nozzle after cleaning them with washer fluid
(light oil, and so on).

Pull out 1/3 part of the needle valve and

inspect if it can drop by its weight. (Inspect
for several times by turning.)

If the needle valve cannot drop, then inspect several times again after cleaning it
up. Replace with the new needle and nozzle body if there is defection existed.

Injection nozzle, straight pin, needle valve and injection nozzle gasket should be
placed with injection nozzle repair set when replacing the nozzle.

Pre-set pressure should be tested and adjusted after replacing the fuel injection
nozzle, making the valve opening pressure is the standard value.

Andy Lau 196

 Fuel injector

Clean all the parts in the clean kerosene. Assembly

the fuel injector in the order as shown in the left
illustration. Tighten the retaining nut to 34±5N.m.
Measure the injector VOP, If the pressure is out of
specification, replace and adjust the shim.
Clean the injector installing hole completely, ensure
that old washer is removed from the cylinder head
and the new seat washer 14 is undamaged.
Install the injector to the cylinder head properly.

Andy Lau 197

 Fuel characteristic
The primary characteristics that affect engine
operation and performance in cold temperatures are
the following characteristics:
 Lubricity

 Viscosity

 Cetane Number

 Cloud Point

 Pour Point

 Moisture Content

Andy Lau 198

 Lubricity
The fuel lubricity is important. You should consider the fuel's lubricity whenever
you operate the equipment in arctic weather.
The fluid's lubricity describes the ability of the fluid to reduce the friction between
surfaces that are under load. This ability reduces the damage that is caused by
friction. Fuel injection systems rely on the lubricating properties of the fuel.
All low sulfur fuels do not have a low lubricity. The fuel's lubricity may be
enhanced with additives. Many fuel suppliers treat the fuel with these additives.
Do not use a fuel lubricity additive before you consult the fuel's supplier.
As the fuel lubricity decreased, the fuel is less tolerant of contamination by water
and dirt. The lower fuel lubricity can be seen as abrasive wear of fuel system
components. Fuels that have a low lubricity may not provide adequate lubrication
to plungers, to barrels, and to injectors.
Maximum life of the fuel system can be achieved by performing the following
tasks: using a reliable fuel supplier, performing proper maintenance of the fuel
system and installing the genuine fuel filters in the fuel system.
Andy Lau 199
 Viscosity

The viscosity of the fuel is significant because the fuel serves

as a lubricant for fuel system components. Arctic fuels need
to have sufficient viscosity.

The fuel must lubricate the fuel system at a temperature of

0°C (32°F) or below freezing.

If the kinematic viscosity of the fuel is lower than 1.4 cSt as

supplied to the fuel injection pump or to the unit injectors,
excessive scuffing and seizure can occur.

Andy Lau 200

 Cetane number
The cetane number of the fuel has an effect on the ability of the engine to start.
Also, the cetane number has an effect on the interval of time before the engine
runs smoothly.
Generally, an increase of ten in the cetane number will allow the engine to be
started at a lower temperature. The starting temperature can be improved
approximately 7 to 8°C for every increase of ten in the cetane number.
After the engine reaches the normal operating temperature, a change in the
cetane from 40 to 50 will have a minimal effect on engine performance.
Most fuels that have a cetane number above 40 will permit acceptable engine
starts in warmer outside temperatures. The engine will start satisfactorily with
this fuel when the engine is kept warm. The engine can be kept warm by using
either a heated room or a coolant heater.
During average starting conditions, direct injection engines require a minimum
cetane number of 40. A higher cetane value may be required for operation in
high altitudes or for cold weather operation. The minimum fuel cetane number
that is required for the pre-combustion engine is 35.
Andy Lau 201
 Cloud point
It is important to understand that the cloud point of a fuel is different from the
pour point. There is no relationship between cloud point and the pour point.

The cloud point is the temperature that allows some of the heavier components
in the wax to solidify in the fuel. This wax is not a contaminant in the fuel.

The cloud point of the fuel is important because the cloud point can limit the
performance of the fuel filter. The wax can alter the fuel characteristics in cold
weather.

Solid wax can fill the fuel filters and stop the flow of fuel. Fuel filters are needed
in order to remove dirt from the fuel. The filter block foreign material and protect
the parts for the fuel injection system.

Since fuel must flow through the filters, installing a fuel heater is the most
practical way to prevent the problem. A fuel heater will keep the fuel above the
cloud point as the fuel flows through the fuel system. The fuel heater will permit
the wax to flow through the filters with the fuel.
Andy Lau 202
 Cloud point
You can lower the cloud point of a fuel
by mixing the diesel fuel with a different
fuel that has a lower cloud point. Such
as kerosene.
The efficiency of this method is not good
since the mixture does not have a direct
relation to the improvement in cloud
point. The amount of fuel with low cloud
point that is required makes the process
less preferable to use.
You must know the exact fuel cloud
point of each fuel. This specification is
normally available from personnel at the
source of the fuel supply.
When the lower cloud point fuel is not
available, this method can not be used.

Andy Lau 203

 Pour point
The fuel's pour point is a temperature below the fuel's cloud point. Fuel stops
flowing below the pour point. The pour point is the temperature which limits
movement of the fuel with pumps.

To measure the pour point, the fuel temperature is lowered below the cloud
point in steps of 3°C (5°F) at a time. The temperature is lowered until the fuel
does not flow. The pour point is the last temperature that is shown before the
flow stops.

At the pour point, the wax has solidified out of the fuel. This makes the fuel more
solid than liquid. The pour point of the fuel can be improved. This does not
require the removal of important elements. This process is the same process that
is used to improve the cloud point of a fuel.

A fuel's pour point should be at least 6°C below the lowest ambient temperature
that is required for engine start-up and for engine operation.

Andy Lau 204

 Pour point
1. Obtain the fuel cloud point of both fuels
from your fuel supplier.
2. Locate the cloud point of the heavier
fuel on the left side of the table.
3. Locate the cloud point of the lighter fuel
on the right side of the table.
4. Draw a line A between the two points
that were established.
5. Determine the lowest outer temperature
for machine operation. Find this point on
the left side of the table. Mark this point.
Draw a horizontal line C from this point.
Stop the line at the intersection of line A.
6. Line C and line A intersect. Mark this
point. Draw a vertical line B from this
point. Stop the line at the bottom. The
point at the bottom of line B reveals the
percent of lighter fuel that is required to
modify the pour point.
Andy Lau 205
 Moisture content
Problems with fuel filters can occur at any time. The cause of the problem can be
water in the fuel or moisture in the fuel. At low temperatures, moisture causes
special problems.
There are three types of moisture in fuel: dissolved moisture, free and dispersed
moisture in the fuel and free and settled at the bottom of the tank.
Most diesel fuels have some dissolved moisture. Just as the moisture in air, the
fuel can only contain a specific maximum amount of moisture at any one
temperature. The amount becomes less as the temperature is lowered.
For example, a fuel could contain 100 ppm (0.010 percent) of water in solution at
18°C. This same fuel can possibly hold only 30 ppm at 4°C. After the fuel has
absorbed the maximum possible amount of water, the additional water will be
free and dispersed.
Free and dispersed moisture is fine droplets of water that is suspended in the
fuel. Since the water is heavier than the fuel, the water will slowly become free
and settled at the bottom of the tank. In the above example, when the fuel
temperature was lowered from 18°C to 4, 70 ppm of water became free and
dispersed in the fuel.

Andy Lau 206

 Moisture content
The small drops of water cause a cloudy appearance in the fuel. If the change in
temperature is slow, the small drops of water can settle to the bottom of the
tank. When the fuel temperature is lowered rapidly to freezing temperature, the
moisture that comes out-of-solution changes to very fine particles of ice instead
of small drops of water.
The particles of ice are lighter than the fuel, and the particles of ice will not settle
to the bottom of the tank. When this type of moisture is mixed in the fuel, this
moisture will fill the fuel filters and plug the fuel filters in the same way as wax
plugs the fuel filters.
The moisture which is free and settled at the bottom of the tank can become
mixed with the fuel. The pumping action will mix the moisture with the fuel
whenever fuel is transferred. This moisture then becomes free and dispersed
water. This moisture can cause ice in the filters.
Generally, the same force that mixes the water into the fuel will also mix dirt and
rust from the bottom of the tank with the water. The result is a dirty mixture of
fuel and water which can also fill the filters and stop fuel flow.
Andy Lau 207
 Electrical system

Andy Lau
 Electrical system

Starting circuit:
 Control circuit: signal current attract and hold the solenoid of
starting motor.
 Main circuit: electric power was sent to the starting motor through
the attracted solenoid.
Charging circuit: charge battery and supply electric power.
Andy Lau 209
 Alternator
Type: brushless
alternator
Model: A4TU7686
Output: 24-50 V-A
1 Rectifier
2 Stator
3 Rotor
4 Fan
5 Pulley
6 Front Bearing
7 Front Carrier
8 Field Coil
9 Rear Carrier
10 Adjuster
11 Rear Bearing
B, E, L, R - Terminal

Andy Lau 210

 Alternator
1. Pulley and fan 2. Spacing collar
3. Rear bearing 4. Rotor
5. Cap 6. Front bearing
7. Front carrier 8. Magnetic coil
9. Stator 10. Adjuster
11. Rectifier 12. Rear carrier

Andy Lau 211

 Alternator

Alternator with the neutral emitting diode is the same as multipurpose alternator
except adding the neutral emitting diode. Via these neutral emitting diodes, the
alternator will provide greater DC output power than the one without neutral
emitting diode when the alternator is operating at a high speed.
Andy Lau 212
 Alternator

The potential of neutral point changes up and down depending on neutral point
DC voltage (1/2 of output voltage), the neutral point as shown in the illustration.
Neutral point voltage will increase to greater than output voltage (28 V) and
decrease to lower than ground voltage (0 V) when the alternator is operating at
a high speed. To adjust these over voltage and lower voltage (shaded area in the
illustration), the current from the over voltage is picked up and is applied to DC
output by the neutral emitting diode.
Andy Lau 213
 Starting motor

Andy Lau 214

 Starting motor
3. Pinion 1. Blocking Ring
4. Spring 2. Pinion Retainer
10. Brush (-) 5. Magnetic Switch
12. Brush (+) 6. Adjusting Shim
17. Ball 7. Rear Carrier
18. Cap 8. Taper Washer
15. Washer 9. Brush Spring
23. E-ring 11. Brush Seat
25. Washer 13. Yoke Iron
14. Rear Bearing
16. Armature
19. Rubber Grommet
20. Planetary Gear
21. Rubber Grommet
22. Steel Sheet
24. Gear Shaft
26. Internal Gear
27. Overdrive Clutch
28. Lever
29. Front Bearing
30. Oil Seal
31. Front Carrier
Andy Lau 215
 Starting circuit

Pull-in coil Hold-on coil

Andy Lau 216

 Heating plug

Turn the starter switch off.

Connect the check light (24V-1.8W) with the heating plug.

Turn the start switch to the heating position, if the check light does not come on,
check the heating plug and the heating relay

If there abnormality, replace the related failed parts.

Andy Lau 217
 Safety relay

Safety relay is used to monitor the alternator rotation speed. When the alternator
rotation speed is higher than the specified value, safety relay will interrupt the
starting circuit which will cause the starter no action even that the starter switch
was turn to START position.
When the start switch 2 is closed, current flows through the coil of start relay 5
to the terminal S of the safety relay, and then flows via terminal E to the ground.
Start relay 5 is engaged and starting motor begins to crank engine.
After the engine is started, voltage of terminal P is higher than specified value,
current flows from terminal S to ground via terminal E is interrupted, no current
flows through start relay, engine can not be cranked even that switch 2 is closed.
Andy Lau 218
 Safety relay

Andy Lau 219

 Safety relay
Check: the output
voltage of terminal P
Measure the voltage
between terminal P of
safety relay and the
ground when engine is
stopped and running
at low idle speed. If
the measure valve is
out of specification, do
the troubleshooting
and replace the failed
parts.

Andy Lau 220

 Safety relay
Check output voltage
of terminal R
Measure the voltage
when the engine is
running. If measured
value exceeds standard
value, troubleshoot out
the failed the parts or
wiring; if there is any
abnormality, replace
the failed parts.

Andy Lau 221

 Safety relay
Check output voltage
of terminal S
Turn the starter switch to
START position, measure
the voltage at terminal S
during cranking. If tested
value exceeds the standard,
replace the failed parts.
Start the engine and run in
idle speed (more than 600
rpm). Measure the voltage
of terminal P, if it is out of
specification, replace the
alternator. Make sure the
indicator does not come on
at idle speed. When the
indicator light comes on
and the voltage of terminal
P is normal, replace the
safety relay.
Andy Lau 222
 Electrical circuit
Thermostat switch: 105±2oC

Oil pressure switch: NC; opened when >50±10kpa

Andy Lau 223
 Cooling system

Andy Lau
 Cooling system
Best coolant temperature range (6D34): 78℃~93℃

40-60% of engine problems are cooling system related

 Overheating

 Overcooling

 Loss of coolant

Engine heat dissipation required

 33% – useful power.

 30% – cooling system.

 30% – exhaust gas.

 7% – radiated.

Andy Lau 225

 System operation

Andy Lau 226

 Coolant flow chart

Andy Lau 227

 Cooling system

100Kpa = 14.5 PSI

Andy Lau 228

 System operation
The engine has a pressure type cooling system. A pressure type cooling system
gives two advantages.
 The pressure type cooling system can have safe operation at a temperature
that is higher than the normal boiling point of water.
 The pressure type cooling system prevents water pump cavitation. Cavitation
is the sudden making of low pressure bubbles in liquids by mechanical forces.
With a pressure type cooling system, it is more difficult for an air or steam
pocket to be made in the cooling system.
Under normal operation, water pump sends coolant into cylinder block. Coolant
travels through cylinder block into cylinder head. Coolant then travels through
water outlet pipe to the housing for water temperature regulator.
 When water temperature regulator is open, the coolant travels through the
outlet hose to radiator. The coolant is cooled as the coolant travels through
radiator. When the coolant gets to the bottom of the radiator, the coolant
travels through the inlet hose to water pump.
Andy Lau 229
 System operation
 When the engine is cold, water temperature regulator is closed. The coolant
does not travel to radiator. The coolant travels from the housing for the
water temperature regulator through a hose to water pump.

 When the water temperature regulator is opened but not opened fully, part
of coolant goes to water pump through the by pass hose, and others travel
to the water pump inlet port through the radiator.

 Water temperature regulator is an important part of the cooling system. The

water temperature regulator divides coolant flow between the radiator and the
bypass in order to maintain the correct temperature. Water temperature
regulator must be installed in order to mechanically control the system. Most of
the coolant will travel through the bypass if the water temperature regulator is
not installed. The engine will overheat in hot weather if water temperature
regulator is not installed. In cold weather, the engine will not obtain operating
temperature if even small amounts of coolant travel through the radiator.

Andy Lau 230

 Regulator
The core of water temperature
regulator is filled with wax. This
wax core regulator utilizes the
volume change of the wax
while it melts as the coolant
temperature rises.

The valve opens and closes

while the coolant temperature
changes, the movement of the
valve adjusts the amount of
coolant which flows to radiator
and water pump (bypass side),
so as to control the coolant
temperature.

Andy Lau 231

 Regulator
1.Regulator Cover
2. Gasket
3. Regulator
4. Coolant Temperature Sensor
5. Coolant Temperature Sensor
6. Water Faucet
7. Regulator Housing
8. Gasket
9. O-ring seal
10. O-ring seal
11. By-pass pipe
Keep the O-ring free from the oil.
Otherwise it will be expanded and
causing difficult installation.

Andy Lau 232

 Regulator

Andy Lau 233

 Regulator
Inspection: regulator
Using a stick to stir the water to
ensure even temperature in the
container and do the following
inspections at the same time.
If the measured value is not within
the standard, replace the regulator.

1. Valve opening temperature

Fix the regulator with steel wire to keep it away from the heat source.
Water is heated gradually to reach the temperature which can open the valve.
Keep the state for 5 minutes, and check that the valve opens.
Check that the valve is fully closed when the water temperature drops to 65C.
2. Valve lift
Make the water temperature be above the valve fully open temperature a little
and keep the valve open for 5 minutes, then measure the valve lift.
Andy Lau 234
 Regulator

Andy Lau 235

 Regulator
If an engine had the failure of overheating, removing the regulator will help to
improve or resolve the problem?
Cooling system had two circuits :
Cooling cycle circuit: water pump  cylinder block  cylinder head 
regulator  radiator  water pump inlet hose.
Bypass cycle circuit: water pump  cylinder block  cylinder head 
regulator  bypass hose  water pump inlet hose.
If the regulator was removed:
Cooling cycle circuit was always functioned, coolant temperature was not
easy to be increased to the normal temperature.
Bypass cycle circuit was always functioned, part of coolant went to the
water pump inlet port directly without cooling. The overheating phenomena
will be worsen severely. No way to improve it!
Removing the regulator just prolong the time to arrive the regulator opening
temp, but once the coolant temperature is higher than the regulator opening
temperature, it will rise quicker than normal.
Andy Lau 236
 Troubleshooting chart

Andy Lau 237

 V-belt tension
Inspection
Apply 98 N force to the middle of the belt
as shown in the illustration to measure the
belt deflection.
A: alternator pulley
B: crankshaft pulley
C: water pump pulley
Position the O-ring (Small) of the tool at
the point 98N (Pushing force) of the
vernier.
Position the O-ring (Big) of the tool at the
point (the specified maximum value of the
belt deflection) of the vernier.
 The belt tension should be 10-15 mm.

Andy Lau 238

 V-belt tension
Position the vernier at the middle of the belt
as shown in the illustration, press and push it
until the part indicated by the arrow touches
the O ring.

Measure the belt tension. If the measured

value is out of specification, adjust the belt
tension according to following steps.

Loosen the alternator nut and bolt, pry out the

alternator properly. And then tighten the
alternator nut and bolt to specified torque.

Measure again to be sure that the bolt tension

is within specification.

 Excessive belt tension may damage the belt

and related bearing.
Andy Lau 239
 Fan belt
If the fan belt is not maintained properly, problems will be occurred in
the cooling system which results in the engine poor performance and
even the parts failure occurred.
 Always keep the V-belt a proper tension. If the belt is too loose, the belt will
slip. Abnormal noise will be detected. Coolant temperature will be increased
due to insufficient air flow pass through the radiator to cool the coolant.
 If the belt is too tightened, the related bearing maybe damaged, and also
that the service life of the belt will be shortened.
 Keep the grease and oil away from the V-belt always. If the grease or oil was
spilled onto the V-belt, the fan belt will also slip even that the belt tension is
within the specification.
 Fan belt should always be replaced by whole set, even that one belt of the
belt set still can be reused. Otherwise the new belt and used belt will have
different belt tension which man cause the belt slippage.
 Friction surface of the fan belt located at both side, not the bottom surface.
If the belt was worn excessive, bottom surface contact the pulley, slippage
will be occurred. At this time, the belt must be replaced.
Andy Lau 240
 Radiator
Hot coolant came from the engine flow through the
radiator core from the top tank to the bottom tank, and
cooled by the fresh air blew or suck by the fan.

Radiator cap was used to keep a proper pressure in the

cooling system and increase the boiling temperature.

After the engine is started, the coolant temperature rise

gradually and the cooling system pressure increased. If
the cooling system is higher than the pressure setting of
the radiator cap. The valve of the radiator cap opened
and part of coolant overflowed to the sub-tank through a
small hose. If the cooling system pressure decreased,
the suction valve in the cap will be opened, coolant in
the sub-tank then flows back to supplement the radiator
to balance the system pressure.

Andy Lau 241

 Cooling system flush
If the radiator has been used for a long time,
the rust and scale deposit will cause
overheating, so the cooling system should
be cleaned regularly.
Drain the coolant
Before draining the coolant, unscrew the
pressure cap to release the pressure in the
cooling system. In addition, drain the
coolant in the storage tank.
Do not drain the coolant before cooling
down completely to prevent engine damage.
If the coolant is hot, it may spray out when
the cap is opened. When open the pressure
cap, cover it with a piece of rag etc. and
unscrew it slowly to release pressure, then
remove it.
Andy Lau 242
 Cooling system flush
Cleaning key point
Filling the soft water and radiator cleaner into the cooling system properly and
fully. Do not fill the system too fast, otherwise air will be blocked in the cooling
system which will cause the insufficient coolant.
Keep the coolant cycling in the cooling system at about 90 degrees. The water
temperature regulator open, and the cleaning fluid cycled in the whole cooling
system. Scales and rust will be removed by the cooling system cleaner.
Pay more attention to the time that the cleaner remained in the cooling system
according to the user guide of the cleaner. If it is longer than the required time,
the surface of the cooling system components may be removed severely by the
cleaner. If it is shorter than the specified time, maybe the scale can not be
removed completely by the cleaner.
 To raise the coolant temperature rapidly, cover the front of the radiator with a
paper board or equivalent.
 The radiator may leak after cleaning if a lot of rust / scale exists in it, so perform
a leakage test carefully after cleaning the cooling system.

Andy Lau 243

 Cooling system flush
Filling coolant into the radiator fully.
As the cleaning time is out, drain the cleaning fluid completely from the cooling
system after the engine is cooled down completely. Do not forget to remove the
drain plug on the cylinder block to drain the cleaning fluids.
Fill the cooling system fully with the soft water. Allow the engine to idle for 10
minutes while the coolant temperature is at 90o.
Drain the water completely after the engine is cooled down.
Add coolant as soon as possible after the cooling system is cleaned.
To prevent coolant freeze and cooling system corrosion, add FUSO diesel long
effect coolant in the coolant according to specified proportion.

Air bleeding in cooling system

Remove the pressure cover, idle the engine with the coolant temperature at 90C
and bleed all the air in the cooling system.
Add coolant to the storage tank if necessary after bleeding the cooling system.

Andy Lau 244

 Cooling system flush
Check for air leakage
Corrosion in the cooling system will accelerate if the coolant is
mixed with air and waste gas.

Remove the pressure cap properly after engine is cooled down.

Start the engine to raise the coolant temperature to about 90oC.

If bubbles appear continuously in the coolant under this

condition, there are air or waste gas in the coolant.

If there is air in the coolant, it is possible that the cylinder head bolt, water pump
set bolt or hose connection are loose, or the hose is broken.

If there is waste gas in the coolant, it is possible that the cylinder head gasket is
broken or the cylinder head is cracked.

 Another way to check the air leakage in the coolant: insert the overflow hose into
the water of the glass bottle to check the air bubbles.

Andy Lau 245

 Radiator assembly

Andy Lau 246

 Leakage test
Inspection: A/C condenser leakage

Plug one air opening of the intercooler that

is submerged in the water groove and apply
specified air pressure to the other opening.

If there is air leak, repair/replace condenser.

 150kpa air was used to do the leakage test.

Inspection: hydraulic oil cooler leakage

Plug one opening of the oil cooler that is

submerged in the water groove, apply
specified air pressure to the other opening.

If there is air leak, repair/replace oil cooler.

 1.5Mpa air was used to do the leakage test.

Andy Lau 247

 Radiator
Inspection: radiator leakage
Cleaning deposits on the outside of the
radiator carefully and properly.
Install hose, radiator cap gauge and plug
on the upper radiator water tank.
Screw plugs on the lower water tank and
submerge them in the water groove.
Using radiator cap gauge, apply specified
air pressure and check for air leak.
If there is air leak, repair or replace the
failed radiator.
Inspection: cap opening pressure
The opening pressure of the radiator
should be 49±9.8kPa. If the measured
value is out of specification, replace the
radiator cap.
Andy Lau 248
 Fan belt
 There are 2 belts installed, replace them together
to prevent the belt tension difference.
 The belt should not be oily. It may slip if it's oily,
which may decrease cooling effect.

Andy Lau 249

 Water pump
There is O-ring seal between the pump
housing and the cylinder block. When
installing the water pump, lubricate the O-
ring seal with liquid soap not the engine oil.
Otherwise the O-ring seal will be expanded
which causing the seal failed to be installed.

Impeller and flange were pressed onto the

shaft. After installation, be sure that the
pump shaft can be rotated freely.

Weep hole was used to determine whether the pump was failed or not. In
normal conditions, both coolant and grease should not be found in the weep hole.
If the coolant was found in the weep hole, it means the seal group was failed.
The water pump should be removed and rebuilt.
If water pump failed to work normally, cooling system will have problem occurred.
Andy Lau 250
 Water pump

For the water pump equipped with grease fitting, grease should be added to the
water pump according to maintenance interval in the OMM.

Clean up the spilled grease always after maintenance, otherwise it will be melted
and stick to the fan belt which will cause the belt slippage and other problems.
Andy Lau 251
 Water pump
 Magnitude of interference range of impeller
and water pump shaft should be 0.03-0.06
mm. Reassemble twice at most .
 Magnitude of interference range of flange
and water pump shaft should be 0.03-0.08
mm. Reassemble twice at most.
If coolant or grease was found leaked out
through the weep hole, the water pump
should be rebuilt.
Disassembly the water pump using special
tool as shown in the illustration.
If wear groove was found on the pump shaft
at the seal section, shaft can not be reused.
Measure the outside diameter of the pump
shaft and the inner diameter of the impeller
and the flange to calculate the magnitude of
interference.
Andy Lau 252
 Water pump
Installation: flange
 Before installing the flange, check the mark
stamped as shown in the illustration. It can
be reused if there is only 1 stamped mark.
Another mark should be stamped for this
disassembly and assembly.

Stamped mark indicates the times of flange

was dismantled and assembled before. If
there are 2 marks, replace the flange.

Using a press machine on the pump shaft to

install the flange until it touches the bearing.

 The water pump housing will be damaged if

the flange is installed without using a spacer.
Andy Lau 253
 Water pump
Installation: impeller
 Before installing the impeller, check the mark
stamped as shown in the illustration. It is
reusable if there is only 1 stamped mark.
Another mark should be stamped for this D&A.
 Stamped mark indicates the times of impeller
dismantled and assembled before. If there are
2 marks (2 times dismantled and assembled
before), replace the impeller.
After the installation of the seal group, install
the pump impeller.
Using a press machine on the impeller through
a spacer to install the impeller and ensure the
dimension between the pump housing and the
impeller as shown in the illustration.
Turn the flange by hand to make sure it turns
smoothly after installation.

Andy Lau 254

 Troubleshooting problems

Three basic cooling system problems:

 Overheating

 Overcooling

 Loss of coolant

Andy Lau 255

 Overheating
Typical Overheating Problems
Coolant related Airflow related
 Low coolant level  Reduced airflow through
 Coolant overflow radiator
 Low heat transfer through  High inlet air temperature or
scale build-up restriction
 Over concentration of  Exhaust restriction
additives

System problem Related components

 Insufficient cooling system  Excessive engine load
pressure  Water pump or temperature
 Insufficient coolant flow regulator failure
 Loose fan belts

 Improper machine operation

Andy Lau 256

 Overheating

How to Diagnose Overheating

Visual Inspection
 Radiator clogging

 Low coolant level

 Low fan RPM

 Coolant leaks

 Steam when engine stopped

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Extensive Inspection
Accuracy of temperature
gauge
Air restrictions
Bent, damaged, or loose fins
Engine idle speed
Shutter opening temperature
Fan belts and pulley grooves
Shroud condition
Andy Lau
Overheating
Hose condition or collapse
Water pump leaks
Radiator gasket
Transmission and steering
clutch slippage
Brake condition
Glycol content of coolant
Damaged fins or baffles
258
 Overheating

Overheating Diagnosis
Testing
 Water temperature regulators

 Air velocity

 Air, gases or steam

 Relief valve

 Temperatures during operation

Andy Lau 259

 Overcooling

Overcooling Problems
Coolant bypasses
water temperature
regulator – flows
directly to radiator

Andy Lau 260

 Overcooling

Identifying Overcooling
Normal engine operating temperature
cannot be reached
 More critical with high sulfur fuel

Low ambient air temperature and light

load applications

Andy Lau 261

 Overcooling

Overcooling Diagnosis
Defective or missing water temperature
regulator

Defective temperature gauge or

temperature sensor

Andy Lau 262

 Loss of coolant

Check closely - loss of coolant

 Can cause overheating

 Can be result of overheating

Identifying loss of coolant

 Sudden loss of coolant

 Check coolant level

Andy Lau 263

 Loss of coolant

Loss of Coolant Diagnosis

Faulty or missing pressure cap

Radiator damage

Hose leak

Improper maintenance

Andy Lau 264

 Periodic maintenance

Follow O&M Manual

 Make necessary adjustments

10 SMU / daily check

 inspect coolant level

 clean radiator core

Andy Lau 265

 250H / monthly check

Perform 10 SMU checks

Inspect fan belts

Add SCA to standard coolant

Test coolant for glycol level protection

Inspect radiator cap & gasket

Inspect hoses & engine electrical grounds

Check water temperature regulator

Andy Lau 266

 Maintenance tips
Check coolant monthly
 Appearance and odor
 Tests

Fill cooling system properly

 Premix water, glycol and SCA’s for standard heavy duty
coolant
 Rinse container three times to reduce contamination
 Fill no faster than 19 liters (5 gal) / minute
 Run engine with cap off
 Install and run at low idle
Andy Lau 267
 Maintenance tips

Operator and mechanic participation

 Awareness and responsibility are the keys to
good maintenance program.

40-60% of engine problems are cooling

system related

These problems can be avoided with

good maintenance practices!

Andy Lau 268

 Management
Seven Elements of Cooling System Management
Preventive maintenance

Fluid analysis

Inspections

Repair management

Training

Scheduling

Record keeping

Andy Lau 269

 Preventive maintenance
Save money
Plan downtime
Maximize equipment life
Increase resale value

Fix small problems instead of major

failures

 Your operators and mechanics are the keys!

Andy Lau 270

 Failure case analysis
Background:
 SY210C8A, or 07SY21302087; SMU=1151 H.
 Cummings engine, EC-7 controller, OPUS46 monitor, PFC hyd system.
Failure phenomena:
 High coolant temperature alarm after working for less than half an hour.
Displayed coolant temperature on the monitor is 110oC.
 Engine speed dropped obviously after the high coolant temperature alarmed.
Possible root cause of the failure:
 Regulator failed to open timely and properly.
 Water pump failed to work normally.
 Coolant insufficient severely.
 Coolant temperature sensor shorted to the ground.
Troubleshooting:
 Check the coolant level before starting the engine, it is normal. OK.
 Drained the coolant, remove the regulator, tested and found the regulator
can work normally.
Andy Lau 271
 Failure case analysis
 Inspect the water pump with the naked eyes, no water or lubricant leaked
out from the weep hole of the water pump. It means the water seal and the
oil seal of the water pump were not failed.
 Remove the water pump from the machine, interchange with another same
machine, tested and proved no overheating phenomena occurred. This
means the water pump worked. Normally.
 Checked the resistance of the coolant temperature sensor, it is within the
specification. This means the coolant temperature sensor was normal.
 The displayed coolant temperature is 110oC, but the paint color of the engine
cylinder head was normal, not turned to the brown or heavy red.
 Tested with the infrared thermoscope, the actual temperature is 93oC. it is
suspected that wire of the coolant temperature sensor was shorted to the
ground.
 Trace the wire started from the coolant temperature sensor gradually, it is
finally found that the sensor wire had the insulation rubber worn out and
contacted with the relay mounting plate. Repair the wire, problem solved.
Root cause of the failure: sensor wire was not arranged properly which
cause the abrasive wear of the insulation rubber, and overheating later.

Andy Lau 272

 Troubleshooting

Andy Lau
 Probable cause
The Engine Crankshaft Will Not Turn When The Start Switch Is On. - 1
 Low Output From The Battery - Check the condition of the battery. Charge the
battery or replace the battery, if necessary.
 Damaged Wires or Switches - Repair any parts or replace any parts, if necessary.
 Damaged Starting Motor Solenoid - Install a new solenoid.
 Damaged Starting Motor - Repair or replace the starting motor.
 An Internal Problem Prevents The Turning Of The Engine Crankshaft. -
Disconnect the driven equipment. Remove the fuel injection nozzles if the
crankshaft cannot be turned. Inspect the cylinders for fluid while the crankshaft
is being turned. If fluid in the cylinders is not the problem, the engine must be
disassembled. After you disassemble the engine, inspect the engine for other
internal problems. Possible internal problems include the following conditions:
A. Bearing seizure
B. Piston seizure
C. Incorrect pistons are installed in the engine.

Andy Lau 274

 Probable cause
The Engine Will Not Start. - 2
 The fuel tank is empty. - Put fuel in the fuel tank.
 Low Quality Fuel - Remove fuel from the fuel tank. Install a new fuel filter
element. Put a good grade of clean fuel in the fuel tank.
 Dirty Fuel Filter - Install a new fuel filter.
 Broken Fuel Lines Or Dirty Fuel Lines - Fuel lines should be cleaned or new fuel
lines should be installed, if necessary.
 The Fuel Pressure is Too Low. - Replace the fuel filter. Inspect the bypass valve
for free movement. Install a new bypass valve, if necessary.
 Air is in the Fuel System. - Find the air leak in the fuel system and correct the
leak. Remove air from the fuel system.
 Wrong Fuel Injection Timing - Adjust the fuel injection timing, if necessary.
 Slow Cranking Speed - Check condition of battery. Replace the battery, if needed.
 No Fuel In The Housing For The Fuel Injection Pumps - Use the priming pump in
order to fill the housing for the fuel injection pumps with fuel.
 The Fuel Has A Cloud Point That Is Higher Than The Atmospheric Temperature.
(The Cloud Point Is The Temperature That Causes Wax To Form In Fuel.) - Drain
the fuel tank, the lines and the fuel injection pump housing. Change the fuel filter.
Fill the tank with fuel that has the correct cloud point.

Andy Lau 275

 Probable cause
The Engine Is Misfiring Or The Engine Is Running Rough. - 3
 Low Fuel Pressure - Ensure that there is enough fuel in the tank. Inspect the fuel
system for leaks. Inspect the fuel line between the fuel tank and the fuel transfer
pump for bad bends. Inspect the fuel system for air. Check fuel pressure. The
outlet pressure of the fuel transfer pump at full load speed is 176 to 245 kPa. If
the fuel pressure is lower, install a new fuel filter element.
 Air In Fuel System - Find the air leak in the fuel system and correct the air leak.
Remove the air from the fuel system.
 Leakage Or Breakage In Fuel Line Between Fuel Injection Pump And Injector -
Install a new fuel line.
 Wrong Valve Lash - Adjust the valve lash correctly.
 Worn Fuel Injection Nozzle - Run the engine at an rpm that gives the maximum
misfiring or rough running. Loosen a fuel line nut on the fuel injection nozzle for
each cylinder one at a time. When a fuel line nut is loosened, the misfiring or
rough running will increase. If loosening a fuel line nut does not affect the
misfiring or rough running, test the fuel nozzle for that cylinder.
 Wrong Fuel Injection Timing – Inspect / Adjust the fuel injection timing.
 Bent Pushrod Or Broken Pushrod - Replace the pushrod.
 Worn Valve Seat Or Face Of Valve – Repair the cylinder head is necessary.
Andy Lau 276
 Probable cause
The Engine Stalls At Low RPM. – 4
 Fuel Pressure is Low. - Ensure that enough fuel is in the fuel tank. Inspect the
fuel system for leaks. Inspect the fuel line between the fuel tank and the fuel
transfer pump for bad bends. Inspect the fuel system for air. Check the fuel
pressure. The outlet pressure of the fuel transfer pump at full load speed is 176
to 245 kPa (25.5 to 35.5 psi). If the fuel pressure is lower, install a new fuel filter
element.

 Low Engine Idle RPM - Make adjustment to the governor. Ensure that the idle
speed setting matches the value listed on the valve cover.

 Worn Fuel Injection Nozzle - Install a new fuel injection nozzle.

 Wrong Valve Lash – Inspect and adjust the valve lash. Refer to the Fuel Setting
and Related Information for the correct valve lash. Valve lash can also be found
on the valve cover as shown in the slide 7.
Andy Lau 277
 Probable cause
The Engine Does Not Have Enough Power. - 5
 Low Quality Fuel - Remove fuel from the fuel tank. Install a new fuel filter. Put a
good grade of clean fuel in the fuel tank.
 Low Fuel Pressure - Ensure that there is enough fuel in the tank. Inspect the fuel
system for leaks. Inspect the fuel line between the fuel tank and the fuel transfer
pump for bad bends. Inspect the fuel system for air. Check fuel pressure. The
outlet pressure of the fuel transfer pump at full load speed is 176 to 245 kPa. If
the fuel pressure is lower, install a new fuel filter element.
 Air in the Fuel System - Correct the failure and bleed air from the fuel system.
 Leaks In Air Inlet System - Check the pressure in the air inlet manifold. Look for
restrictions in the air cleaner.
 Wrong Fuel Setting - Adjust the fuel setting, if necessary.
 Governor Linkage - Make an adjustment in order to obtain the full travel of the
linkage. Install new parts to replace the failed parts.
 Wrong Valve Lash - Adjust the valve lash.
 Worn Fuel Injection Nozzle – Do the manual cut out test to find out the injector
which is failed. Replace the failed injection nozzle.
 Wrong Fuel Injection Timing - Adjust the fuel injection timing.
 Carbon Deposits On Turbocharger Inspect / Repair the turbocharger, if necessary.
 Plugged Screen Of the Fuel Transfer Pump - Clean the screen.
Andy Lau 278
 Probable cause
The Engine Has Too Much Vibration. - 6
 A Loose Nut is Holding The Pulley. - Tighten the nut.
 The Pulley Is Worn. – Replace with a new pulley.
 The Engine Supports are Loose, Worn, or Damaged. - Tighten all mounting bolts.
Install new components, if necessary.
 The Engine Is Misfiring Or The Engine Is Running Rough. - Refer to Problem 3.
 The Fan Blade Is Not Balanced. - Loosen the fan drive belts or remove the fan
drive belts. The vibration occurred at a specific rpm. Operate the engine for a
short time at this rpm. If the vibration is not present, replace the fan assembly.

There Are Sudden Changes In Engine RPM. - 7

 Air in the Fuel System - Find the air leak in the fuel system and correct the leak.
Remove air from the fuel system.
 The Linkage in The Governor Does Not Move Freely. - Clean all linkages. Clean
the inside of the governor housing. Replace all damaged parts with new parts.

Andy Lau 279

 Probable cause
The Engine Has A Loud Combustion Noise (Sound). - 8
 Low Quality Fuel - Remove fuel from the fuel tank. Install a new fuel filter. Put a
good grade of clean fuel in the fuel tank.
 Worn Fuel Injection Nozzle – Replace the failed fuel injection nozzle.
 Wrong Fuel Injection Timing - Correct the fuel injection timing.
The Engine Has A Valve Train Noise (Clicking). - 9
 Broken Valve Spring(s) or Broken Locks – Replace the failed parts and related
parts. Broken locks can cause the valve to slide into the combustion chamber
which will cause the severe resultant damage.
 The Bolts On The Rocker Shaft Brackets Are Loose. - Tighten the bolts to the
specified torque.
 Too Much Valve Lash – Check and adjust the valve lash correctly.
 Not Enough Lubrication - Check the lubrication in the valve compartment. There
must be a strong flow of oil at engine high rpm. There must be a small flow at
low rpm. Oil passages must be clean. The oil passages that send the oil to the
cylinder head are particularly important.
Andy Lau 280
 Probable cause
Oil Is In The Cooling System. - 10
 Damaged Core Of Engine Oil Cooler - Install a new core in the oil cooler.
 Damaged Head Gasket - Install a new head gasket.
 Obstruction in Weep Hole of Water Pump And Damaged Oil Seal in Water Pump -
Free the weep hole of the water pump from obstruction. Replace the oil seal.
Mechanical Noise (Knock) Is In The Engine. - 11
 Failure Of Bearing For Connecting Rod - Inspect the bearings for the connecting
rods and the bearing surfaces on the crankshaft. Install new parts, if necessary.
 Damaged Crankshaft - Replace the crankshaft.
 Damaged Attachment - Repair / replace the failed components.
Fuel Consumption Is Too High. - 12
 Fuel System Leaks - Replacement of parts is needed at points of leakage.
 Fuel And Combustion Noise (Knock) - Small increases in fuel consumption may be
the result of worn fuel injection nozzles, rough running or factors that cause a
loss of power. Refer to Problem 3 and refer to Problem 5.
 Wrong Fuel Injection Timing - Adjust the fuel injection timing.
 The Fuel Setting Is Too High. - Adjust the fuel setting. Refer to the Related
Information for the correct idle rpm.
Andy Lau 281
 Probable cause
Little Movement Of Rocker Arm And Too Much Valve Lash Is Present. - 13
 Not Enough Lubrication - Check the lubrication in the valve compartment. There
must be a strong flow of oil at engine high rpm. There must be a small flow of oil
at low rpm. Oil passages must be clean. The oil passages that send the oil to the
cylinder head are particularly important.
 Worn Rocker Arm - If there is too much wear, replace the failed parts and adjust
the valve lash.
 The End Of The Valve Stem Is Worn. - If the end of the valve stem has too much
wear, replace with new valves and adjust the valve lash.
 Too Much Valve Lash - Adjust the valve lash.
 Worn Pushrods - If the pushrods have too much wear, replace the failed pushrods
and adjust the valve lash.
 Worn Tappets – if the tappets are worn too much, replace them and adjust the
valve lash.
 Worn Lobes on Camshaft – Check/adjust the valve lash. Check for free movement
of valves or bent valve stems. Replace the failed parts.
 The Bolts For The Rocker Arm Bracket Are Loose. - Tighten to specified torque.
Andy Lau 282
 Probable cause
Loud Noise From The Valves Or From The Valve Drive Components. - 14
 Broken Valve Spring(s) - Replace the failed parts and related parts.
 Broken Camshaft - Replace the failed parts. Clean the engine thoroughly.
 Damaged Valve Tappets - Clean the engine thoroughly. Replace the camshaft
and the tappets. Look for valves that do not move freely. Adjust the valve lash to
the correct clearances.
 Damage To Valve(s) - Replace the failed valves and adjust the valve lash.
The Valve Keeper Or The Spring Is Broken. - 15
 Damaged Valve Keepers - Locks with damage can cause the valve to fall into the
cylinder. This will cause severe damage.
 Damage To Valve Spring(s) - Install the new valve spring(s).
Oil Is At The Exhaust. - 16
 Too Much Oil In The Valve Compartment - Be sure that the plugs are installed in
the ends of the rocker arm shaft.
 Worn Valve Guides - Reconditioning of the cylinder head is required.
 Worn Piston Rings - Inspect piston rings and replace the failed rings.
 Damaged Seal In Turbocharger - Recondition the turbocharger.
 Plugged Air Cleaner Element - Replace the air cleaner element.
Andy Lau 283
 Probable cause
Little Valve Lash Or No Valve Lash Is Present. - 17
 Worn Valve Seat Or Worn Valve Face - Rebuild of the cylinder head is required.
The Engine Has Early Wear. - 18
 Dirt In Lubrication Oil – Replace the engine oil and engine oil filter.
 Air Inlet Leaks - Inspect all gaskets and connections and repair the leakage found.
 Fuel Leaks Into Lubrication Oil - This will cause high fuel consumption and low
engine oil pressure. Find out the root cause and repair the leakage.
Coolant Is In The Lubrication Oil. - 19
 Failure Of Engine Oil Cooler – Replace the failed engine oil cooler.
 Failure Of The Cylinder Head Gasket – Replace the failed cylinder head gasket.
Tighten the cylinder head bolts according to specification.
 Cracked Cylinder Head Or Damaged Cylinder Head – Replace the cylinder head.
 Cracked Cylinder Block Or Damaged Cylinder Block – Replace the cylinder block.
 Failure Of Front Cover Gasket – Replace the gasket and related parts.
 Obstruction In Weep Hole Of Water Pump And Damaged Water Seal Of Water
Pump - Free the weep hole of the water pump. Replace the water seal.

Andy Lau 284

 Probable cause
Too Much Black Smoke Or Gray Smoke Is Present. - 20
 Not Enough Air For Combustion - Check the air cleaner for restrictions. The max
pressure of the air cleaner is 7.5 kPa (30 inch of water).
 Damaged Fuel Injection Nozzles – Replace the failed fuel injection nozzles.
 Wrong Fuel Injection Timing - Make adjustment to timing.
Too Much White Smoke Or Blue Smoke Is Present. - 21
 Too Much Lubrication Oil In Engine - Remove extra oil. Find the source of the
extra oil. Put the correct amount of oil in engine.
 The Engine Is Misfiring Or The Engine Is Running Rough. - Refer to Problem 3.
 Wrong Fuel Injection Timing - Adjust the timing.
 Worn Valve Guides - Reconditioning of the cylinder head is required.
 Worn Piston Rings – Replace the failed piston rings and related parts.
 Failure Of Turbocharger Oil Seal - Check the turbo for oil leakage. Replace the
failed parts, rebuild the turbocharger.
 Breather Is Plugged Severely – Clean the breather thoroughly, or replace it.

Andy Lau 285

 Probable cause
The Engine Has Low Oil Pressure. - 22
 Damaged Oil Pressure Gauge – Replace with a new gauge.
 Dirty Oil Filter Or Oil Cooler - Check the operation of the bypass valve for the oil
filter. Install a new engine oil filter. Clean the oil cooler or install a new oil cooler.
Replace the engine oil.
 Diesel Fuel In Engine Oil - Find the source of the leakage of the diesel fuel into
the engine oil and repair it. Remove the oil that has been diluted by the diesel
fuel. Install new oil filters. Put clean oil in the engine.
 Too Much Clearance Between Rocker Arm Shaft And Rocker Arms - Check the
lubrication in valve compartments. Replace the failed parts.
 Damaged Oil Pump Suction Pipe – Replace/repair the failed suction pipe.
 Improper Operation Of Pressure Relief Valve For Oil Pump - Clean the valve and
housing. Replace the failed parts.
 Damaged Oil Pump – Repair/replace the oil pump.
 Too Much Clearance Between Crankshaft And Crankshaft Bearings - Inspect the
crankshaft bearings and make replacement as required.
 Too Much Clearance Between Camshaft And Camshaft Bearings - Inspect the
camshaft and the camshaft bearings. Replace the failed parts.
 Too Much Bearing Clearance For Idler Gear – Replace the failed parts.
 Piston Cooling Jets Are Broken - Replace the piston cooling jet.
Andy Lau 286
 Probable cause
The Engine Uses Too Much Lubrication Oil. - 23
Too Much Lubrication Oil In Engine - Remove the extra oil. Find the source of the
extra oil. Put the correct amount of oil in the engine.
Oil Leaks - Find all oil leaks. Make repairs, as needed.
High Oil Temperature - Check operation of oil cooler. Install new parts, if
necessary. Clean the oil cooler cores.
Too Much Oil To Inlet Valve Guides - Refer to Problem 16.
Worn Valve Guides - Refer to Problem 16.
Worn Piston Rings - Install new parts, if necessary.
Failure Of Turbocharger Oil Seal - Inspect the turbocharger. Repair the
turbocharger, if necessary.
The Starting Motor Does Not Turn. - 24
Low Output From The Battery - Check the condition of the battery. Charge or
replace the battery, if necessary.
Damaged Wires Or Switches - Repair the wires or the switches or replace the
wires or the switches, if necessary.
Damaged Starting Motor Solenoid - Install a new starting motor solenoid.
Damaged Starting Motor - Repair the starting motor or replace the starting motor.
Andy Lau 287
 Probable cause
The Alternator Gives No Charge. - 25
 Loose Drive Belt For The Alternator - Adjust the drive belt in order to obtain the
correct tension.
 Damaged Ground Return Circuit Or Battery Connections - All connections should
be cleaned and tightened. Replace the failed cables and connections.
 Damaged Brushes In Alternator – Replace the failed brushes.
 Damaged Rotor (Field Coil) – Replace the failed rotor.
The Alternator Charge Rate Is Low Or Is Not Regular. - 26
 Loose Drive Belt For The Alternator - Adjust the drive belt to correct tension.
 Damaged Ground Return Circuit Or Battery Connections - All connections should
be cleaned and tightened. Replace the failed cables and connections.
 Damaged Alternator Regulator – Repair/replace the alternator regulator.
 Damaged Brushes In Alternator – Replace the failed brushes.
 Damaged Rectifier Diodes - Replace the damaged rectifier diode.
 Damaged Rotor (Field Coil) – Replace the failed rotor.

Andy Lau 288

 Probable cause
The Alternator Has Noise. - 27
Drive Belt For The Alternator That Is Worn Or Damaged - Install a new drive belt
for the alternator.
Loose Alternator Drive Pulley - Check the groove in the pulley for a key that holds
the pulley in place. If the groove is worn, install a new pulley. Tighten the pulley
nut according to Specifications.
Misaligned Drive Belt And Drive Pulley For The Alternator - Align the drive belt
and the drive pulley.
Worn Alternator Bearings - Replace bearings in the alternator.
Bent Rotor Shaft on Armature - Replace the rotor shaft.
Shorted Rectifiers In The Alternator - Replace the rectifiers.
The Exhaust Temperature Is Too High.- 28
Restriction At The Air Inlet System Or The Exhaust System - Remove restriction.
Wrong Fuel Injection Timing - Adjust the fuel injection timing.
Leak In Air Inlet System - Check the pressure in the air inlet system. Find the
leakage and repair it.
Leak In Exhaust System - Find the leakage in the exhaust system and repair it.
Andy Lau 289
 Probable cause
The Engine Coolant Is Too Hot. - 29
 Restricted Flow Of Air Through the Radiator Or Restricted Flow Of Coolant
Through the Radiator - Remove all of the flow restrictions.
 Low Coolant Level - Add coolant to the cooling system.
 Damaged Pressure Cap - Test the pressure cap. If it is failed, replace it.
 Combustion Gases In Coolant - Find the source of the leakage of combustion gas
into the cooling system, and repair it.
 Damaged Water Temperature Regulators Or Temperature Gauge - Check water
temperature regulators for correct operation. Check the water temperature
gauge for correct operation. Replace the failed parts.
 Damaged Water Pump – Repair/replace water pump.
 Too Much Load On The System - Reduce the load on the system.
 Wrong Fuel Injection Timing - Adjust the fuel injection timing.
 Loose Drive Belts - Adjust the drive belts properly.
 The Antifreeze Concentration Is Too High. - 50 percent antifreeze concentration
is acceptable for most applications.

Andy Lau 290

Andy Lau 291