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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
Engine
Engine
T
T
roubleshooting
roubleshooting
The following chart includes some of the problems
The following chart includes some of the problems
that an operator may encounter during the service
that an operator may encounter during the service
life of a
life of a
Cummins diesel
Cummins diesel
engine.
engine.
Always check
Always check
the easiest and obvious things first, such as the
the easiest and obvious things first, such as the
master disconnect switch, the neutral start switch,
master disconnect switch, the neutral start switch,
an empty fuel tank, closed fuel shut off, dead bat-
an empty fuel tank, closed fuel shut off, dead bat-
tery or
tery or
corroded terminals.
corroded terminals.
Study the
Study the
problem
problem
thoroughly before starting to work on the engine.
thoroughly before starting to work on the engine.
Ask yourself
Ask yourself
the following
the following
questions.
questions.
1.
1.
Wha
Wha
t wer
t wer
e the w
e the w
arn
arn
ing s
ing s
ign
ign
s pre
s pre
ced
ced
ing t
ing t
he
he
trouble?
trouble?
2.
2.
Has t
Has t
he en
he en
gin
gin
e bee
e bee
n sub
n sub
jec
jec
ted t
ted t
o rec
o rec
ent
ent
repair or maintenance?
repair or maintenance?
3.
3.
Has a
Has a
sim
sim
ila
ila
r tro
r tro
ubl
ubl
e occ
e occ
urr
urr
ed be
ed be
for
for
e?
e?
4.
4.
If t
If t
he engi
he engi
ne st
ne st
ill r
ill r
uns,
uns,
is it
is it
safe
safe
to co
to co
ntinue
ntinue
operation of the engine in an effort to diag-
operation of the engine in an effort to diag-
nose the trouble?
nose the trouble?
Check the items most easily and inexpensively cor-
Check the items most easily and inexpensively cor-
rected before proceeding to the more difficult, time
rected before proceeding to the more difficult, time
consuming and expensi
consuming and expensi
ve items
ve items
.
.
After a
After a
malfunc-
malfunc-
tion has been corrected, locate and correct the
tion has been corrected, locate and correct the
cause of the trouble to prevent recurrence of the
cause of the trouble to prevent recurrence of the
same trouble.
same trouble.
Engine Noise Diagnostic Procedures – General
Engine Noise Diagnostic Procedures – General
Information
Information
NOTE:
NOTE:
When diagnosing
When diagnosing
engine noise
engine noise
problems,
problems,
make sure that
make sure that
noises caused by
noises caused by
accessories,
accessories,
such as the
such as the
air compressor and
air compressor and
power take–off,
power take–off,
are not mistaken
are not mistaken
for engine noises.
for engine noises.
Remove the
Remove the
accessory drive belts to
accessory drive belts to
eliminate noise caused
eliminate noise caused
by
by
these units.
these units.
Noise will
Noise will
also travel
also travel
to other m
to other m
etal
etal
parts not related to
parts not related to
the problem.
the problem.
The use of a
The use of a
stethoscope can
stethoscope can
help locate
help locate
an engine
an engine
noise.
noise.
Engine noises heard at the crankshaft speed,
Engine noises heard at the crankshaft speed,
engine rpm, are noises related to the crankshaft,
engine rpm, are noises related to the crankshaft,
rods, pistons,
rods, pistons,
and piston
and piston
pins.
pins.
Noises heard
Noises heard
at
at
the camshaft speed, one–half of the engine rpm,
the camshaft speed, one–half of the engine rpm,
are related to
are related to
the valve
the valve
train.
train.
A handheld digital
A handheld digital
tachometer can help determine if the noise is
tachometer can help determine if the noise is
related to components operating at the crankshaft
related to components operating at the crankshaft
or camshaft speed.
or camshaft speed.
There is not a definite rule or test that will positive-
There is not a definite rule or test that will positive-
ly determine the source of a noise complaint.
ly determine the source of a noise complaint.
Engine–driven components and accessories, such
Engine–driven components and accessories, such
as gear–driven fan clutches, hydraulic pumps,
as gear–driven fan clutches, hydraulic pumps,
belt–driven alternators, air–conditioning compres-
belt–driven alternators, air–conditioning compres-
sors, and turbochargers, can contribute to engine
sors, and turbochargers, can contribute to engine
noise.
noise.
Use the follow
Use the follow
ing information as
ing information as
a guide to
a guide to
diagnosing engine noise.
diagnosing engine noise.
Main Bearing Noise
Main Bearing Noise
(Refer to Problem 40.)
(Refer to Problem 40.)
.
.
The
The
noise caused by a loose main bearing is a loud,
noise caused by a loose main bearing is a loud,
dull knock heard when the engine is pulling a
dull knock heard when the engine is pulling a
load.
load.
If all m
If all m
ain bearings are
ain bearings are
loose, a loud
loose, a loud
clatter
clatter
will be heard.
will be heard.
The knock
The knock
is heard regularly
is heard regularly
every
every
other revolution.
other revolution.
The noise
The noise
is the
is the
loudest when
loudest when
the engine is
the engine is
lugging or under
lugging or under
heavy load.
heavy load.
The
The
knock is
knock is
duller than
duller than
a connecting
a connecting
rod noise.
rod noise.
Low
Low
oil pressure can also accompany this condition.
oil pressure can also accompany this condition.
If the bearing is not loose enough to produce a
If the bearing is not loose enough to produce a
knock by itself, the bearing can knock if the oil is
knock by itself, the bearing can knock if the oil is
too thin or if there is no oil on the bearing.
too thin or if there is no oil on the bearing.
An irregular
An irregular
noise can
noise can
indicate worn crankshaft
indicate worn crankshaft
thrust bearings.
thrust bearings.
An intermittent, sharp
An intermittent, sharp
knock indicates excessive
knock indicates excessive
crankshaft
crankshaft
end clearance.
end clearance.
Repeated clutc
Repeated clutc
h disen-
h disen-
gagements can cause a change in the noise.
gagements can cause a change in the noise.
Connecting Rod Bearing Noise
Connecting Rod Bearing Noise
(Refer to Prob-
(Refer to Prob-
lem 39.)
lem 39.)
.
.
Connecting rods with excessive clear-
Connecting rods with excessive clear-
ance will knock at all engine speeds under both
ance will knock at all engine speeds under both
idle and
idle and
load conditions.
load conditions.
When the
When the
bearings
bearings
begin to become loose, the noise can be con-
begin to become loose, the noise can be con-
fused with pist
fused with pist
on slap or
on slap or
loose piston pins.
loose piston pins.
The
The
noise increases in volume with engine speed.
noise increases in volume with engine speed.
Low oil pressure can also accompany this
Low oil pressure can also accompany this
condition.
condition.
Piston Noise
Piston Noise
(Refer to Problem 41.)
(Refer to Problem 41.)
.
.
It is difficult
It is difficult
to tell the difference between piston pin, connect-
to tell the difference between piston pin, connect-
ing rod, and
ing rod, and
piston noise.
piston noise.
A loose
A loose
piston pin
piston pin
causes a loud double knock that is usually heard
causes a loud double knock that is usually heard
when the
when the
engine is
engine is
idling.
idling.
When the
When the
injector to
injector to
this cylinder is cut out, a noticeable change will be
this cylinder is cut out, a noticeable change will be
heard in the
heard in the
sound of
sound of
the knocking
the knocking
noise.
noise.
Howev-
Howev-
er, on some engines the knock becomes more
er, on some engines the knock becomes more
noticeable when the vehicle is operated on the
noticeable when the vehicle is operated on the
road at a steady speed.
road at a steady speed.
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