Introduction

NOTE: Specifications with illustrations, make reference to Specifications For 3208 Industrial Engine, SENR3687. If the Specifications in SENR3687 are not the same as in the Systems Operation and the Testing & Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

Troubleshooting

Troubleshooting can be difficult. On the following pages there is a list of possible problems. To make a repair to a problem, make reference to the cause and correction.

This list of problems, causes and corrections, will only given an indication of where a possible problem can be, and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations in the list. Remember that a problem is not normally caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs.

1. Engine Will Not Start.

2. Misfiring Or Running Rough.

3. Stall At Low rpm.

4. Sudden Changes In Engine rpm.

5. Not Enough Power.

6. Too Much Vibration.

7. Loud Combustion Noise.

8. Loud Noise (Clicking) From Valve Compartment.

9. Oil In Cooling System.

10. Mechanical Noise (Knock) In Engine.

11. Fuel Consumption Too High.

12. Loud Noise From Valves Or Valve Drive Components.

13. Little Movement Of Rocker Arm And Too Much Valve Lash.

14. Valve Spring Lock Is Free.

15. Oil At The Exhaust.

16. Little Or No Valve Lash.

17. Engine Has Early Wear.

18. Coolant In Lubrication Oil.

19. Too Much Black Or Gray Smoke.

20. Too Much White Or Blue Smoke.

21. Engine Has Low Oil Pressure.

22. Engine Uses Too Much Lubrication Oil.

23. Engine Coolant Is Too Hot.

24. Starting Motor Does Not Turn.

25. Alternator Gives No Change.

26. Alternator Charge Rate Is Low Or Not Regular.

27. Alternator Charge Is Too High.

28. Alternator Has Noise.

29. Exhaust Temperature Is Too High.

Problem 1. Engine Will Not Start

Probable Cause:

1. Empty Fuel Tank

Put fuel in fuel tank.

2. Poor Quality Fuel

Remove the fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

3. Dirty Fuel Filter

Install new fuel filter.

4. Dirty Or Broken Fuel Lines

Clean or install new fuel lines as necessary.

5. Linkage To Sleeve Control Shaft Is Held In Shutoff Position

Check the operation of the shutoff solenoid and the shutoff linkage. Solenoid must pull up to compress spring for fuel turn on. Check governor linkage for free movement. Sleeves must turn freely on fuel injection pump plungers in all positions of sleeve control shaft. The thrust collar must turn freely on the governor shaft at all positions between shutoff and full load. If linkage does not move freely under these conditions, clean all parts thoroughly. Inspect all parts for wear and make replacement where needed.

6. Fuel Pressure Is Too Low

Replace the fuel filter. Inspect the bypass valve for free movement. Install a new bypass valve if necessary.

7. Air In The Fuel System

Find the air leak in the fuel system and correct it. Remove air from the fuel system. Make reference to Removing Air From Fuel System in Testing & Adjusting.

8. Fuel System Not Timed Correctly To Engine

Make adjustment to timing if necessary.

9. Constant Bleed Valve Stays Open (not enough fuel pressure for starting)

Replace constant bleed valve.

10. No Overfueling Spring

Install an overfueling spring.

11. Fuel Ratio Control Has A Defect

Check fuel ratio control setting. Adjust if necessary. Check operation of solenoid.

Problem 2. Misfiring Or Running Rough

Probable Cause:

1. Fuel Pressure Is Low

Make sure there is enough fuel in the fuel tank. Look for leaks or severe bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 ± 35 kPa (30 ± 5 psi). If fuel pressure is lower than above pressure, install a new fuel filter element. Inspect the fuel bypass valve for free movement. Install a new fuel bypass valve if necessary.

2. Air In The Fuel System

Find the air leak in the fuel system and correct it. Remove air from the fuel system. Make reference to Removing Air From Fuel System in Testing & Adjusting.

3. Leak Or Break In Fuel Line Between Fuel Injection Pump And Fuel Injection Nozzle

Install a new fuel line.

4. Wrong Valve Lash

Make adjustment according to Testing & Adjusting.

5. Defect In Fuel Injection Nozzle

Run engine at rpm that gives maximum misfiring or rough running. Then loosen a fuel line nut on the injection line for each cylinder, one at a time. Find the cylinder where loosening the fuel line nut does not change the way the engine runs. Test the fuel injection nozzle for that cylinder. Install new parts where needed.

6. Wrong Fuel Injection Timing

Make adjustment to timing.

Problem 3. Stall At Low rpm

Probable Cause:

1. Fuel Pressure Is Low

Make sure there is enough fuel in the fuel tank. Look for leaks or severe bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 ± 35 kPa (30 ± 5 psi). If fuel pressure is lower than above pressure, install a new fuel filter element. Inspect the bypass valve for free movement. Install a new bypass valve if necessary.

2. Idle rpm Too Low

Make adjustment to governor so idle rpm is the same as given in the TMI (Technical Marketing Information) or Fuel Setting And Related Information Fiche.

3. Defect In Fuel Injection Nozzle

Install a new fuel injection nozzle.

4. Wrong Valve Lash

Make adjustment according to Testing & Adjusting.

5. Spring For Dashpot Governor Installed Wrong

Install spring correctly.

Problem 4. Sudden Changes In Engine rpm

Probable Cause:

1. Air In the Fuel System

Find the air leak in the fuel system and correct it. Remove air from the fuel system. Make reference to Removing Air From Fuel System in Testing & Adjusting.

2. Broken Torsion Spring On Sleeve Control Shaft

Install new parts as needed.

3. Linkage In Governor Does Not Move Freely

Clean all linkage and inside of governor housing. Install new parts for those parts that have damage.

4. Governor Springs Not Completely On Spring Seat

Put springs completely on spring seat.

5. Spring For Dashpot Governor Installed Wrong

Install spring correctly

Problem 5. Not Enough Power

Probable Cause:

1. Poor Quality Fuel

Remove the fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

2. Fuel Pressure Is Low

Make sure there is fuel in the fuel tank. Look for leaks or severe bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 ± 35 kPa (30 ± 5 psi).

If fuel pressure is lower than above pressure, install a new fuel filter element. Inspect the fuel bypass valve for free movement. Install a new fuel bypass valve if necessary.

3. Air In The Fuel System

Find the air leak in the fuel system and correct it. Remove air from the fuel system. Make reference to Removing Air From Fuel System in Testing & Adjusting.

4. Leaks In Air Inlet System

Check the pressure in the air inlet manifold. Look for restrictions in the air cleaner.

5. Wrong Fuel Setting

Make adjustments as necessary.

6. Governor Linkage

Make adjustment to get full travel of linkage. Install new parts for those that have damage or defects.

7. Defect In Timing Advance Unit

Replacement of timing advance unit is needed.

8. Wrong Valve Lash

Make adjustment according to Testing & Adjusting.

9. Defect In Fuel Injection Nozzle

Run engine at rpm that gives maximum misfiring or rough running. Then loosen a fuel line nut on the injection line for each cylinder, one at a time. Tighten each fuel line nut before loosening the next one. Find the cylinder where loosening the fuel line nut does not change the way the engine runs. Test the fuel injection nozzle for that cylinder. Install new parts where needed.

10. Wrong Fuel Injection Timing

Make adjusting to timing.

11. Fuel Shutoff Solenoid or Shutoff Linkage Causing A Restriction In The Travel Of The Shaft For The Sleeves

Check for correct full power with solenoid removed. If the engine has full power with the solenoid removed, the problem is in the solenoid or the shutoff linkage. Check for free travel of the linkage.

12. Constant Bleed Valve Stays Closed

Replace constant bleed valve.

13. Turbocharger Has Carbon Deposit

Inspect and repair turbocharger as necessary.

14. Fuel Ratio Control Has A Defect

Check fuel ratio control setting. Adjust if necessary. Check diaphragm in fuel ratio control.

Problem 6. Too Much Vibration

Probable Cause:

1. Loose Bolt Or Nut Holding Pulley Or Damper

Tighten bolt or nut.

2. Pulley Or Damper Has A Defect

Install a new pulley or damper.

3. Engine Supports Are Loose, Worn, Or Have A Defect

Tighten all mounting bolts. Install new components if necessary.

4. Misfiring Or Running Rough

Make Reference to Item 2.

Problem 7. Loud Combustion Noise (Sound)

Probable Cause:

1. Poor Quality Fuel

Remove the fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

2. Defect In Fuel Injection Nozzle.

Install a new fuel injection nozzle.

3. Wrong Fuel Injection Timing

Make adjustment to timing.

Problem 8. Loud Noise (Clicking) From Valve Compartment

Probable Cause:

1. Broken Valve Spring(s) Or Locks

Install new parts where necessary. Broken locks can cause the valve to slide into the cylinder. This will cause much damage.

2. Loose Bolts Holding Rocker Arm Assembly

Tighten to 24 ± 7 N·m (18 ± 5 lb ft).

3. Too Much Valve Lash

Make adjustment according to Testing & Adjusting.

Problem 9. Oil In Cooling System

Probable Cause:

1. Defect In Core Of Oil Cooler

Install a new core in the oil cooler.

2. Defect In Head Gasket

Install a new head gasket.

Problem 10. Mechanical Noise (Knock) In Engine

Probable Cause:

1. Failure Of Bearing For Connecting Rod

Inspect the bearing for the connecting rod and the bearing surface on the crankshaft. Install new parts where necessary.

2. Damage To Crankshaft

Make replacement of the crankshaft.

3. Defect In Attachment

Repair or install new components.

Problem 11. Fuel Consumption Too High

Probable Cause:

1. Fuel System Leaks

Replacement of parts is needed at points of leakage.

2. Defect In Timing Advance Unit

Replacement of timing advance unit is needed.

3. Wrong Fuel Injection Timing

Make adjustment to timing.

4. Fuel Setting Too High

Make adjustment to the fuel setting. Make reference to TMI (Technical Marketing Information) or the Fuel Setting And Related Information Fiche.

Problem 12. Loud Noise From Valve Or Valve Drive Components

Probable Cause:

1. Broken Valve Spring(s)

Make replacement of parts with damage.

2. Broken Camshaft

Make replacement of parts with damage. Clean engine thoroughly.

3. Broken Timing Advance Gear

Make replacement of timing advance unit.

Problem 13. Little Movement Of Rocker Arm And Too Much Valve Lash

Probable Cause:

1. Not Enough Lubrication

Check lubrication in valve compartment. There must be a strong flow of oil at high engine rpm, but only a small flow at low rpm. Oil passages must be clean, especially those sending oil to the cylinder head.

2. Rocker Arm Parts Worn

If there is too much wear, install new parts or rocker arms. Make adjustment of valve lash according to Testing & Adjusting.

3. End Of Valve Stem Worn

If there is too much wear, install new valves. Make adjustment of valve lash according to Testing & Adjusting.

4. Too Much Valve Lash

Make adjustment according to Testing & Adjusting.

5. Worn Push Rods

If there is too much wear, install new push rods, Make adjustment of valve lash according to Testing & Adjusting.

6. Camshaft Lifters Worn

If there is too much wear, install new camshaft lifters. Make adjustment of valve lash according to Testing & Adjusting.

7. Worn Lobes On Camshaft

Check valve lash. Check for free movement of valves or bent valve stems. Install new components as necessary. Make adjustment of valve lash according to Testing & Adjusting.

8. Loose Bolts Holding Rocker Arm Assembly

Tighten to 24 ± 7 N·m (18 ± 5 lb ft).

Problem 14. Valve Spring Lock Is Free

Probable Cause:

1. Broken Locks

Broken locks can cause the valve to slide into the cylinder. This will cause much damage.

2. Broken Valve Spring(s)

Install new valve spring(s).

Problem 15. Oil At The Exhaust

Probable Cause

1. Too Much Oil In The Valve Compartment

Look at both ends of the rocker arm shaft. Be sure that there is a plug in each end.

2. Worn Valve Guides

Reconditioning of the cylinder head is needed.

3. Worn Piston Rings

Inspect and install new parts as needed.

Problem 16. Little Or No Valve Lash

Probable Cause

1. Worn Valve Seat Or Face Of Valve

Reconditioning of cylinder head is needed. Make adjustment of valve lash according to Testing & Adjusting.

Problem 17. Engine Has Early Wear

Probable Cause:

1. Dirt In Lubrication Oil

Remove dirty lubrication oil. Install a new oil filter element. Put clean oil in the engine.

2. Air Inlet Leaks

Inspect all gaskets and connections. Make repairs if leaks are found.

3. Fuel Leakage Into Lubrication Oil

This will cause high fuel consumption and low engine oil pressure. Make repairs if leaks are found. Install new parts where needed.

Problem 18. Coolant In Lubrication Oil

Probable Cause:

1. Failure Of Oil Cooler Core

Install a new core for the oil cooler.

2. Failure Of Cylinder Head Gasket

Install a new cylinder head gasket. Tighten the bolts holding the cylinder head, according to the Specifications.

3. Crack Or Defect In Cylinder Head

Install a new cylinder head.

4. Crack Or Defect In Cylinder Block

Install a new cylinder block.

5. Failure Of Front Cover Gasket

Install a new front cover gasket.

Problem 19. Too Much Black Or Gray Smoke

Probable Cause:

1. Not Enough Air For Combustion

Check air cleaner for restrictions [Max. 635 mm (25 in) of water].

2. Defective Fuel Injection Nozzle(s)

Install new fuel injection nozzle(s).

3. Wrong Fuel Injection Timing

Make adjustment to timing.

4. Fuel Ratio Control Has A Defect

Check fuel ratio control setting. Adjust if necessary. Check for broken springs.

Problem 20. Too Much White Or Blue Smoke

Probable Cause:

1. Too Much Lubrication Oil In Engine

Remove extra oil. Find where extra oil comes from. Put correct amount of oil in engine Do not put too much oil in engine.

2. Misfiring Or Running Rough

Make reference to Problem 2.

3. Wrong Fuel Injection Timing

Make adjustment to timing.

4. Worn Valve Guides

Reconditioning of cylinder head is needed.

5. Worn Piston Rings

Install new parts as necessary.

6. Defect In Timing Advance Unit

Replacement of timing advance unit is needed.

7. Failure Of Turbocharger Oil Seal

Check air inlet pipes for oil. Repair turbocharger if necessary.

Problem 21. Engine Has Low Oil Pressure

Probable Cause:

1. Defect In Oil Pressure Gauge

Install new gauge.

2. Dirty Oil Filter Or Oil Cooler

Check the operation of bypass valve for the filter. Install new oil filter elements if needed. Clean or install new oil cooler core. Remove dirty oil from engine. Put clean oil in engine.

3. Diesel Fuel In Lubrication Oil

Find the place where diesel fuel gets into the lubrication oil. Make repairs as needed. Remove the lubrication oil that has diesel fuel in it. Install a new oil filter element. Put clean oil in the engine.

4. Too Much Clearance Between Rocker Arm Shaft And Rocker Arms

Check lubrication in valve compartment. Install new parts as necessary.

5. Oil Pump Suction Pipe Has A Defect

Replacement of pipe is needed.

6. Relief Valve For Oil Pump Does Not Operate Correctly

Clean valve and housing. Install new parts as necessary.

7. Oil Pump Has A Defect

Make repair or replacement of oil pump if necessary.

8. Too Much Clearance Between Crankshaft And Crankshaft Bearings

Check the oil filter for correct operation. Install new parts if necessary.

9. Too Much Clearance Between Camshaft And Camshaft Bearings

Install new camshaft and camshaft bearings if necessary.

Problem 22. Engine Uses Too Much Lubrication Oil

Probable Cause:

1. Too Much Lubrication Oil In Engine

Remove extra oil. Find where extra oil comes from. Put correct amount of oil in engine. Do not put too much oil in engine.

2. Oil Leaks

Find all oil leaks. Make repairs as needed.

3. Oil Temperature Is Too High

Check operation of oil cooler. Install new parts if necessary. Clean the core of the oil cooler. Check oil cooler bypass valve.

4. Too Much Oil To Inlet Valve Guides

Make reference to Problem 15.

5. Worn Valve Guides

Make reference to Problem 15.

6. Worn Piston Rings

Install new parts as necessary.

7. Failure Of Turbocharger Oil Seal

Inspect turbocharger and repair if necessary.

Problem 23. Engine Coolant Is Too Hot

Probable Cause:

1. Restriction To Air Flow Through Radiator Or Restriction To Flow Of Coolant Through The Heat Exchanger

Remove all restrictions of flow.

2. Not Enough Coolant In System

Add coolant to cooling system.

3. Pressure Cap Has A Defect

Check operations of pressure cap. Install a new pressure cap if necessary.

4. Combustion Gases In Coolant

Find out where gases get into the cooling system. Make repairs as needed.

5. Water Temperature Regulators (Thermostats) Or Temperature Gauge Has A Defect

Check water temperature regulators for correct operation. Check temperature gauge operation. Install new parts as necessary.

6. Water Pump Has A Defect

Install a new water pump.

7. Too Much Load On The System

Make a reduction to the load.

8. Wrong Fuel Injection Timing

Make adjustment to timing.

9. Shunt Line Has A Defect

Make repairs as needed.

10. Drive Belts Loose

Adjust drive belts.

Problem 24. Starting Motor Does Not Turn

Probable Cause:

1. Battery Has Low Output

Check condition of battery. Charge battery or make replacement as necessary.

2. Wiring Or Switch Has A Defect

Make repairs or replacement as necessary.

3. Starting Motor Solenoid Has A Defect

Install a new solenoid.

4. Starting Motor Has A Defect

Make repair or replacement of starting motor.

Problem 25. Alternator Give No Charge

Probable Cause:

1. Loose Drive Belt For Alternator

Make an adjustment to put the correct tension on the drive belt.

2. Charging Or Ground Return Circuit Or Battery Connections Have A Defect

Inspect all cables and connections. Clean and tighten all connections. Make replacement of parts that have a defect.

3. Alternator Brushes (if equipped) Have A Defect

Install new brushes.

4. Rotor (Field Coil) Has A Defect

Install a new rotor.

Problem 26. Alternator Charge Rate Is Low Or Not Regular

Probable Cause:

1. Loose Drive Belt For Alternator

Make an adjustment to put the correct tension on the drive belt.

2. Charging Or Ground Return Circuit Or Battery Connections Have A Defect

Inspect all cables and connections. Clean and tighten all connections. Make replacement of parts that have a defect.

3. Alternator Regulator Has A Defect

Make repair or replacement of alternator regulator.

4. Alternator Brushes (if equipped) Have A Defect

Install new brushes.

5. Rectifier Diodes Have A Defect

Make replacement of rectifier diode that has a defect.

6. Rotor (Field Coil) Has A Defect

Install a new rotor.

Problem 27. Alternator Charge Too High

Probable Cause:

1. Alternator Or Alternator Regulator Has Loose Connections

Tighten all connections to alternator or alternator regulator.

2. Alternator Regulator Has A Defect

Install a new alternator regulator.

Problem 28. Alternator Has Noise

Probable Cause:

1. Drive Belt For Alternator Is Worn Or Has A Defect

Install a new drive belt for the alternator.

2. Loose Alternator Drive Pulley

Check key groove in pulley for wear. If groove is worn, install a new pulley. Tighten pulley nut according to Specifications.

3. Drive Belt and Drive Pulley For Alternator Are Not In Alignment.

Make an adjustment to put drive belt and drive pulley in correct alignment.

4. Worn Alternator Bearings.

Install new bearings in the alternator.

Problem 29. Exhaust Temperature Is Too High

Probable Cause:

1. Air Inlet Or Exhaust System Has A Restriction

Remove restriction.

2. Wrong Fuel Injection Timing

Make an adjustment to the timing.

3. Air Inlet System Has A Leak

Check pressure in inlet system. Find leaks and correct.

4. Exhaust System Has A Leak

Find cause of exhaust leak and correct.

Fuel System

Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system.

Many times work is done on the fuel system when the problem is really with some other part of the engine. The source of the problem is difficult to find, especially when smoke comes from the exhaust. Smoke that comes from the exhaust can be caused by a defective fuel injection nozzle, but it can also be caused by one or more of the reasons that follow:

a. Not enough air for good combustion.

b. An overload at high altitude.

c. Oil leakage into combustion chamber.

d. Not enough compression.

Fuel System Inspection

A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance.

1. Check the fuel level in the fuel tank. Look at the cap for the fuel tank to make sure the vent is not filled with dirt.

2. Check the fuel lines for fuel leakage. Be sure the fuel supply lines does not have a restriction or a severe bend.

3. Install a new fuel filter. Clean the fuel screen located in the inlet valve of the fuel transfer pump.

4. Remove any air that may be in the fuel system. Open the drain valve on the fuel injection pump housing. Operate the fuel priming pump until fuel without air comes from the drain lines. Close the drain valve.

To remove air from the fuel injection lines, loosen the fuel line nuts 1/2 turn. Move the governor lever to the low idle position. Crank engine with the starting motor until fuel without air comes from the fuel line connections. Tighten the fuel line nuts.

Check Engine Cylinders Separately

An easy check can be made to find the cylinder that runs rough (misfires) and causes black smoke to come out of the exhaust pipe.

Run the engine at the speed that is the roughest. Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that cylinder. Do this for each cylinder until a loosened fuel line is found that makes no difference in engine performance. Be sure to tighten each fuel line nut after the test before the next fuel line nut is loosened. Check each cylinder by this method. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance, test the fuel injection pump and fuel injection nozzle for that cylinder.

Temperature of an exhaust manifold port, when the engine runs at low idle speed, can also be an indication of the condition of a fuel injection nozzle. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can possibly be an indication of a fuel injection nozzle with a defect. Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder, also caused by a fuel injection nozzle with a defect.

The most common defects found with the fuel injection nozzle are:

1. Carbon on tip of the nozzle or in the nozzle orifice.

2. Orifice wear.

3. Dirty nozzle screen.

NOTICE
Do not test or disassemble fuel injection nozzles unless you have the correct service tools.

Testing Fuel Injection Nozzles

Testing of the fuel injection nozzles must be done off the engine. Perform the following tests using the 5P4150 Nozzle Testing Group to determine if fuel injection nozzle performance is acceptable.

Valve Opening Pressure TestFlush The NozzleTip Leakage TestOrifice Restriction TestBleed Screw Leakage Test

Refer to Special Instruction, SEHS7292, for operation of the 5P4150 Nozzle Testing Group.

Fuel Injection Lines

Fuel from the fuel injection pumps goes to the fuel injection nozzles through the fuel injection lines.

When fuel injection lines are disconnected or removed, always put caps or plugs on the ends to keep dirt out of the lines. When fuel injection lines are installed, be sure all clamps and dampers are installed in their original location.

Each fuel injection line of an engine has a special design and must be installed in a certain location. When fuel injection lines are removed from an engine, put identification marks or tags on the fuel lines as they are removed, so they can be put in the correct location when they are installed.

6N0037 Nut (For use with 7000 series nozzle).

Engines with “Pencil-Type” fuel injection nozzles use fuel injection lines which have 6.35 mm (.250 in) outside diameters, 1.60 mm (.063 in) inside diameters, and use a 5M7418 Nut.

Engines with “7000 series” fuel injection nozzles use fuel injection lines which have 6.35 mm (.250 in) outside diameters, 1.83 mm (.072 in) inside diameters and use a 6N0037 Nut. The “7000 Series” fuel injection lines appear to be identical to the fuel injection lines of the “Pencil-Type” fuel injection nozzles. However, they are not interchangeable because of the difference in the inside diameter and can be identified by the notch in the nuts on the “7000 Series” fuel injection lines. The fuel injection lines for “Pencil-Type” fuel injection nozzles do not have notches on the nuts.

The nuts that hold a fuel injection line to a fuel injection nozzle and fuel injection pump must be tightened to the correct torque. If the nut is loose, fuel will leak from the connection. If the nut is tightened too tight, the inside diameter of the line will become smaller and cause a restriction to the flow of fuel in the line. Use a torque wrench and a 5P0144 Fuel Line Socket to tighten the fuel injection line nuts to 40 ± 7 N·m (30 ± 5 lb ft).

Fuel Injection Pumps

When fuel injection pumps, sleeves and lifters are removed from the fuel injection pump housing, keep the parts of each fuel injection pump together so they can be installed back in their original location.

Be careful when disassembling fuel injection pumps. Do not damage the surface on the plunger. The plunger, sleeve and barrel for each fuel injection pump are made as a set. Do not put the plunger of one fuel injection pump in the barrel or sleeve of another pump. If one part is worn, install a complete new fuel injection pump assembly. Be careful when putting the plunger in the bore of the barrel or sleeve.

When a fuel injection pump is installed correctly, the plunger is through the sleeve and the adjustment lever is engaged with the groove on the sleeve. The bushing that holds the fuel injection pump in the fuel injection pump housing must be kept tight. Tighten the bushing to 80 ± 7 N·m (60 ± 5 lb ft). Damage to the housing will result if the bushing is too tight. If the bushing is not tight enough, the fuel injection pump will leak.

Air Inlet Pipe

NOTICE
If the sleeves on one or more of the fuel injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken at first starting. When the fuel injection pumps have been removed and installed with the fuel injection pump housing on engine, take the cautions that follow to stop the engine, if it starts to overspeed (run out of control).

a. Remove the air cleaner leaving the air inlet pipe open as shown.

b. Set the governor control at low idle.

Be careful when plate is put against air inlet opening. Due to excessive suction, the plate can be pulled quickly against air inlet pipe. To avoid crushed fingers, do not put fingers between plate and air inlet pipe.

c. Start the engine, and if engine starts to overspeed (run out of control), put a steel plate over the air inlet as shown to stop the engine.

Stopping The Engine

Finding Top Center Compression Position For No.1 Piston

No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.

Fitting And Bolt Location
(1) Fitting. (2) Bolt.

Installing Bolt
(2) Bolt. (3) Timing hole.

1. Remove fitting (1) from the timing hole (3) in the front cover. Put bolt (2) in timing hole (3).

2. Turn the crankshaft Counterclockwise (as seen from rear of engine) until bolt (2) will go into the hole in the drive gear for the camshaft.

3. Remove the valve cover on the right side of the engine (as seen from rear of engine). The two valves at the right front of the engine are the inlet and exhaust valves for No.1 cylinder.

4. The inlet and exhaust valves for No.1 cylinder must now be closed and the timing pointer will be in alignment with the TC-1 on the damper assembly. The No.1 piston is now at top center on the compression stroke.

Fuel System Adjustments

Checking Fuel Injection Pump Timing; On Engine

The timing of the fuel injection pump can be checked and changed if necessary, to make compensation for movement in the taper sleeve drive or worn timing gears. The timing can be checked and if necessary, changed using the following method.

Checking Timing by Timing Pin Method

Timing Hole Bolt
(1) Bolt.

1. Remove bolt (1) from the timing pin hole.

Timing Pin Installed
(2) 3P1544 Timing Pin.

Installing Bolt
(3) 1D4539 Bolt, 5/16 in-18 NC, 63.5 mm (2.50 in) long. (4) Timing hole. (5) Hole.

2. Turn the crankshaft Counterclockwise (as viewed from rear of engine) until timing pin (2) goes into the notch in the camshaft for the fuel injection pumps.

3. Remove the fitting from timing hole (4) in the front cover. Put bolt (3) through the front cover and into the hole with threads in the timing gear. The bolt from hole (5) can be used.

4. If the timing pin is in the notch in the camshaft for the fuel injection pumps, and bolt (3) goes into the hole in the timing gear through timing hole (4), the timing of the fuel injection pump is correct.

NOTE: If bolt (3) does not go in the hole in the timing gear with timing pin (2) in the notch in the camshaft, use the procedure that follows.

Location Of Cover
(6) Cover for the tachometer drive assembly. (7) Nuts.

a. Remove nuts (7) and the cover for the tachometer drive assembly (6).

b. Remove the tachometer drive shaft (9) and washer (8) from the camshaft for the fuel injection pumps.

NOTE: Tachometer drive shaft (9) and washer (8) are removed as an assembly.

Location Of Bolt
(8) Washer. (9) Tachometer drive shaft.

Loosening Drive Gear
(10) 6V4069 Puller. (11) Bolts.

c. Put 6V4069 Puller (10) on the camshaft for the fuel injection pumps. Tighten bolts (11) until the drive gear on the camshaft for the fuel injection pumps comes loose.

d. Remove the 6V4069 Puller.

e. Turn the crankshaft Counterclockwise (as viewed from rear of engine) until bolt (3) goes into the hole in the timing gear. With timing pin (2) in the notch in the camshaft for the fuel injection pumps, and bolt (3) in the hole in the timing gear, the timing for the engine is correct.

f. Install washer (8) and tachometer drive shaft (9). Tighten tachometer drive shaft to 149 ± 14 N·m (110 ± 10 lb ft). Remove timing pin (2).

g. Turn the crankshaft two complete revolutions Counterclockwise (as viewed from rear of engine) and put timing pin (2) and bolt (3) in again. If timing pin (2) and bolt (3) can not be installed do Steps a through f again.

h. Remove bolt (3) from the timing gear and install in hole (5). Install the plug in timing hole (4). Remove timing pin (2) and install bolt (1). Install cover for the tachometer drive assembly (6).

Checking Engine Timing And Automatic Timing Advance Unit With 8T5300 Timing Indicator Group And 8T5301 Diesel Timing Adapter Group

8T5300 Timing Indicator Group
(1) 8T5250 Engine Timing Indicator. (2) 5P7366 Cable Assembly. (3) 6V2197 Magnetic Transducer. (4) 5P7362 Cable. (5) 6V2199 & 6V3093 Transducer Adapters. (6) 8K4644 Fuse.

The 8T5300 Timing Indicator Group must be used with an 8T5301 Diesel Timing Adapter Group.

8T5301 Diesel Timing Adapter Group
(7) 5P7437 Adapter. (8) 6V2198 Cable. (9) 5P7436 Adapter. (10) 6V7910 Transducer. (11) 5P7435 Adapter. (12) 6V3016 Washer.

A high pressure fuel line must be disconnected. To avoid personal injury or fire from fuel spray, the engine must be stopped before the fuel line is disconnected.

When checking the dynamic timing on an engine, Caterpillar recommends that the service technician calculate and plot the dynamic timing specifications first on a worksheet like SEHS8140. These worksheets are available in pads of 50 sheets, order one SEHS8140. See Special Instruction, SEHS8580 for information required to calculate the timing curve. For the correct timing specifications to use, see the Engine Information Plate for the performance specification number and make reference to the TMI (Technical Marketing Information) and Fuel Setting And Related Information Fiche.

NOTE: For more information on acceptable tolerances for dynamic fuel injection timing, see Service Magazine dated 4-1-85 and 10-28-85.

After the timing values are calculated and plotted, the dynamic timing should be checked with the 8T5300 Engine Timing Indicator Group and the 8T5301 Diesel Timing Adapter Group. The engine must be operated from 1000 rpm (base rpm) and from high idle to 1000 rpm (base rpm). Unstable readings are often obtained below 1000 rpm. Record the dynamic timing at each 100 rpm and at the specified speeds during both acceleration and deceleration. Then he should plot the results on the worksheet.

Inspection of the plotted values will show if the fuel injection timing is within specifications.

Transducer In Position
(10) Injection transducer. (13) Fuel injection line for No. 1 cylinder.

1. Make reference to Special Instruction SEHS8580 for complete service information and use of 8T5300 Timing Indicator Group.

2. Loosen all fuel line clamps that hold No.1 fuel injection line and disconnect fuel injection line (13) for No.1 cylinder at the fuel injection pump. Slide the nut up and out of the way. Put 5P7436 Adapter (9) in its place and turn adapter (9) onto the fuel injection pump bonnet until the top of the bonnet threads are approximately even with the bottom of the “window” in the adapter.

3. Put the 5P7435 Adapter (11) on 6V7910 Transducer (10) and put the end of the 5P7435 Adapter (11) in the “window” of the 5P7436 Adapter (9).

4. Put fuel injection line (13) on top of 5P7435 Adapter (11). Install 5P7437 Adapter (7) and tighten to 40 N·m (30 lb ft).

Location Of Fitting
(14) Fitting.

5. Remove fitting (14) from the front housing. Install transducer adapter (5) into hole fitting (14) was removed from. Tighten only a small amount.

Transducer In Position
(3) TC magnetic transducer.

6. Push the TC magnetic transducer (3) into the transducer adapter (5) until it makes contact with the camshaft gear. Pull it back out 1.6 mm (.06 in) and lightly tighten the knurled locknut.

7. Connect the cables from the transducers to the Engine Timing Indicator. Make a calibration check of the indicator. For calibration procedure, make reference to Special Instruction SEHS8580.

NOTICE
Be sure all test equipment cables are routed so they will not come into contact with the belts or other rotating components.

Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury.

8. Start the engine and let it reach operating temperature. Then run the engine at approximately one-half throttle for eight to ten minutes before measuring timing.

9. Run the engine at the speeds required to check low idle, timing advance and high idle. Record the engine timing indicator readings. If the engine timing is not correct, make reference to Fuel System Adjustments: On Engine, Fuel Injection Pump Timing (Timing Pin Method) for static adjustment of the fuel injection pump drive.

10. If the timing advance is still not correct, or if the operation of the advance is not smooth, make a repair or replacement of the automatic advance unit. There is no adjustment to the unit.

Fuel Setting (SMFS)

The procedure that follows for fuel setting can be done with the housing for the fuel injection pumps either on or off the engine.

NOTE: If the fuel injection pump group is equipped with a fuel ratio control, the fuel ratio control must be removed before the fuel setting is checked or adjusted.

NOTE: If a fuel temperature compensated torque control group is used, the temperature of the fuel must be less than 52°C (125°F) when checking or adjusting the fuel setting.

Removal Of Covers
(1) Shutoff solenoid. (2) Top cover.

NOTICE
Before any service work is done on this fuel system, the outside of the housing for the fuel injection pumps and all parts connected to it must be clean.

1. Remove shutoff solenoid (1) and top cover (2).

Installation Of Cover
(3) 5P6602 Adapter. (4) 3J6956 Spring. (5) 5P0298 Zero Set Pin, (with 17.8507 on it).

2. Put the 5P0298 Zero Set Pin (5), in the fuel injection pump housing.

3. Put 5P6602 Adapter (3) and 3J6956 Spring (4) over 5P0298 Zero Set Pin (5). Use a 1D4533 Bolt and a 1D4538 Bolt to fasten 5P6602 Adapter (3) to the fuel injection pump housing.

Installation Of 8S7271 Setscrew
(6) 8S7271 Setscrew.

4. Put 8S7271 Screw (6) in the hole over 5P0298 Zero Set Pin (5) and 3J6956 Spring (4).

5. Turn 8S7271 Screw (6) clockwise until 5P0298 Zero Set Pin (5) is held against the fuel injection pump housing. DO NOT tighten 8S7271 Setscrew (6) too tight.

Installation Of Clamp
(3) 5P6602 Adapter. (7) 3P1565 Collet Clamp.

6. Put 3P1565 Collet Clamp (7) in 5P6602 Adapter (3).

7. Move the governor control lever to Full Load position.

Installation Of 3P1567 Dial Indicator
(7) 3P1565 Collet Clamp. (8) 3P1567 Dial Indicator. (9) 5P6531 Contact Point, 57.2 mm (2.25 in) long.

8. Put 5P6531 Contact Point (9) on 3P1567 Dial Indicator (8). Put the indicator assembly in 3P1565 Collet Clamp (7).

Indicator Set On Zero
(8) 3P1567 Dial Indicator. (10) Pointers.

9. Adjust 3P1567 Dial Indicator (8) so both pointers (10) are on “0” (zero).

Loosening 8S7271 Setscrew
(11) 5P4205 Wrench.

10. Use 5P4205 Wrench (11) to turn the 8S7271 8S7271 Setscrew (6) counterclockwise. Turn 8S7271 Setscrew (6) six or more turns.

8T0500 Circuit Tester

11. Put the clip end of the 8T0500 Circuit Tester to a good ground. Put the other end of the 8T0500 Circuit Tester on the load stop contact.

12. Move the governor control lever to the LOW IDLE position.

13. Move the governor control lever slowly toward the HIGH IDLE position until the continuity light just comes on. Make a note of the reading on dial indicator (8). Do this step several times to make sure the reading is correct.

14. Make a comparison of this reading and the fuel setting in the TMI (Technical Marketing Information) and Fuel Setting And Related Information Fiche.

15. If the reading on 3P1567 Dial Indicator (8) is not correct, do the following.

Load Stop Adjustment

Adjustment Of Fuel Setting
(16) Screwdriver. (17) Adjustment screw. (18) Wrench.

Adjustment Screw For Fuel Setting
(17) Adjustment screw. (19) Locknut. (20) Load stop pin.

Adjustment Screw For Fuel Setting
(17) Adjustment screw. (19) Locknut. (20) Load stop pin.

a. Use wrench (18) and loosen locknut (19).

b. Use screwdriver (16) to turn adjustment screw (17) until the reading on 3P1567 Dial Indicator (8) is the same as the dimension given in the TMI (Technical Marketing Information) and Fuel Setting And Related Information Fiche.

c. When the adjustment is correct, tighten locknut (19). Check the adjustment again by doing Steps 11 through 15 again.

NOTE: The same tools that are used in this procedure are also used for the fuel ratio control adjustment.

Fuel Setting (HSMFS)

The procedure that follows for fuel setting can be done with the housing for the fuel injection pumps either on or off the engine.

NOTE: If the fuel injection pump group is equipped with a fuel ratio control, the fuel ratio control must be removed before the fuel setting is checked or adjusted.

NOTE: If a fuel temperature compensated torque control group is used, the temperature of the fuel must be less than 52°C (125°F) when checking or adjusting the fuel setting.

Removal Of Covers
(1) Top cover. (2) Shutoff solenoid. (3) Fuel ratio control.

NOTICE
Before any service work is done on this fuel system, the outside of the housing for the fuel injection pumps and all parts connected to it must be clean.

1. Remove fuel ratio control (3) and shutoff solenoid (2) and top cover (1).

Remove Torque Control Cover
(4) Torque control cover. (5) High idle adjustment cover.

2. Remove torque control cover (4) and high idle adjustment cover (5).

Remove Spring And Bypass Valve
(6) Spring. (7) Bypass valve.

3. Remove spring (6) and bypass valve (7).

Installation Of 5P0298 Zero Set Pin
(8) 5P0298 Zero Set Pin, (with 17.8507 on it).

4. Put the 5P0298 Zero Set Pin (8), in the fuel injection pump housing.

Installation Of 145-1853 Calibration Fixture
(9) 145-1853 Calibration Fixture. (10) 3J6956 Spring.

5. Put 145-1853 Calibration Fixture (9) and 3J6956 Spring (10) over 5P0298 Zero Set Pin (8). Use the bolts from the torque cover (4) to fasten 145-1853 Calibration Fixture (9) to the fuel injection pump housing.

Installation Of 8S7271 Setscrew
(11) 8S7271 Setscrew.

6. Put 8S7271 Setscrew (11) in the hole over 5P0298 Zero Set Pin (8) and 3J6956 Spring (10).

7. Turn 8S7271 Setscrew (11) clockwise with a 5P4205 Wrench until 5P0298 Zero Set Pin (8) is held against the fuel injection pump housing. Do Not tighten 8S7271 Setscrew (11) too tight.

NOTE: If the fuel injection pump housing is installed on the engine a 146-1853 Hex Key (ball-end) is required to turn the 8S7271 Setscrew (11).

Installation Of 3P1565 Collet Clamp
(9) 145-1853 Calibration Fixture. (12) 3P1565 Collet Clamp.

8. Put 3P1565 Collet Clamp (12) in 145-1853 Calibration Fixture (9).

9. Move the governor control lever to Full Load position.

Installation Of 3P1567 Dial Indicator
(12) 3P1565 Collet Clamp. (13) 3P1567 Dial Indicator (with 5P4809 Contact Point, 50.8 mm (2.00 in) long).

Indicator Set On Zero
(13) 3P1567 Dial Indicator. (14) Pointers.

10. Put 3P1567 Dial Indicator (13) in 3P1565 Collet Clamp (12).

11. Adjust 3P1567 Dial Indicator (13) so both pointers (14) are on “0” (zero).

Loosening 8S7271 Setscrew
(15) 5P4205 Wrench.

12. Use 5P4205 Wrench (15) to turn the 8S7271 Setscrew (11) counterclockwise. Turn 8S7271 Setscrew (11) six or more turns.

NOTE: If the fuel injection pump housing is installed on the engine a 146-1853 Hex Key (ball) is required to turn the 8S7271 Setscrew (11) instead of the 5P4205 Wrench.

8T0500 Circuit Tester

13. Put the clip end of the 8T0500 Circuit Tester to a good ground. Put the other end of the 8T0500 Circuit Tester on the load stop contact.

14. Move the governor control lever to the Low Idle position.

15. Move the governor control lever slowly toward the High Idle position until the circuit tester (continuity) light just comes on. Make a note of the reading on 3P1567 Dial Indicator (13). Do this step several times to make sure the reading is correct.

16. Make a comparison of this reading and the fuel setting in the TMI (Technical Marketing Information) or Fuel Setting And Related Information Fiche.

17. If the reading on 3P1567 Dial Indicator (13) is not correct, do the following.

Load Stop Adjustment

Adjustment Of Fuel Setting
(16) Screwdriver. (17) Adjustment screw. (18) Wrench.

Adjustment Screw For Fuel Setting
(17) Adjustment screw. (19) Locknut. (20) Load stop pin.

Adjustment Screw For Fuel Setting
(17) Adjustment screw. (19) Locknut. (20) Load stop pin.

a. Use wrench (18) and loosen locknut (19).

b. Use screwdriver (16) to turn adjustment screw (17) until the reading on 3P1567 Dial Indicator (13) is the same as the dimension given in the TMI (Technical Marketing Information) and Fuel Setting And Related Information Fiche.

c. When the adjustment is correct, tighten locknut (19). Check the adjustment again by doing Steps 13 through 17 again.

NOTE: The same tools that are used in this procedure are also used for the fuel ratio control adjustment.

Fuel Ratio Control Adjustment (SMFS)

NOTE: The same tools are needed for the fuel ratio control adjustment that were used for the fuel setting. Make reference to Fuel Setting for the tools needed and instructions to install the tools.

NOTE: The fuel setting must be correct before an adjustment is made to the fuel ratio control. Make reference to Fuel Setting.

Removal Of Covers
(1) Shutoff solenoid. (2) Cover.

1. Remove shutoff solenoid (1) and cover (2). Install tools and “zero” 3P1567 Dial Indicator as shown in Fuel Setting Steps 2-10.

2. To check the fuel ratio control setting, move the governor lever slowly to the high idle position. Make a record of the reading on the 3P1567 Dial Indicator. Compare the reading with the specification given in the TMI (Technical Marketing Information) and Fuel Setting And Related Information Fiche.

Checking Fuel Ratio Control Setting
(3) Bolts.

3. If an adjustment is needed, remove three bolts (3) from the fuel ratio control. Hold the governor lever in the high idle position and turn flange (4) until the fuel ratio control setting is correct.

Adjustment Of Fuel Ratio Control Setting
(4) Flange.

4. Move governor lever to low idle and again move the lever slowly to high idle to check the fuel ratio control setting.

5. Install bolts (3). Flange (4) can be turned a small amount to give alignment for bolts (3).

6. Remove tools and install cover (2) and shutoff solenoid (1).

Fuel Ratio Control Adjustment (HSMFS)

NOTE: The same tools are needed for the fuel ratio control adjustment that were used for the fuel setting. Make reference to Fuel Setting for the tools needed and instructions to install the tools.

NOTE: The fuel setting must be correct before an adjustment is made to the fuel ratio control. Make reference to Fuel Setting.

Removal Of Shutoff Solenoid And Covers
(1) Shutoff solenoid. (2) Torque control cover. (3) High idle adjustment cover.

1. Remove shutoff solenoid (1), torque control cover (2), and high idle adjustment cover (3). Install tooling and “zero” 3P1567 Dial Indicator as shown in Fuel Setting Steps 2-12.

2. To check the fuel ratio control setting, move the governor lever slowly to the high idle position. Make a record of the reading on the 3P1567 Dial Indicator. Compare the reading with the specification given in the TMI (Technical Marketing Information) and Fuel Setting And Related Information Fiche.

Checking Fuel Ratio Control Setting
(4) Bolts.

3. If an adjustment is needed, remove three bolts (4) from the fuel ratio control.

Adjustment Of Fuel Ratio Control Setting
(5) Flange. (6) Governor lever.

4. Hold the governor lever (6) in the high idle position and turn flange (5) until the fuel ratio control setting is correct. Move governor lever to low idle and again move the lever slowly to high idle to check the fuel ratio control setting.

5. Install bolts (3). Flange (4) can be turned a small amount to give alignment for bolts (3).

6. Remove tools and install torque control cover (2), and high idle adjustment cover (3), and shutoff solenoid (1).

Crossover Levers