Usage:
Engine Crankshaft Turns Free
Exhaust Smoke Can Be Seen While Starting
Recommended Procedure
1. Cold Outside Temperatures It can be necessary to use starting aids, or warm engine oil or coolant, at temperatures below 10° F (-12° C).
2. Air in Fuel System With air in the fuel system the engine will normally be difficult to start, run rough and release a large amount of white smoke. Remove the air from the fuel system by either loosening the cap on the tee at the fuel filter, or by loosening the fuel line nuts one at a time at the cylinder heads. Turn the engine with the starter until the fuel flow at this connection is free of air. If air is not removed in this way put 5 psi (0,35 kg/cm2) [CAUTION do not use more than 8 psi (0,56 kg/cm2)] of air pressure to the tank and check for leaks at connections between the fuel tank and the fuel transfer pump. If there are no leaks at the connections, remove the fuel supply line from the tank and connect to an outside fuel supply. If this corrects the problem the suction line (standpipe) inside the fuel tank has a leak.
3. Low Quality Fuel Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with a good quality fuel. Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system as per the Operation Guide (FEO45119). If there is no water in the fuel, using an outside supply of fuel, prime and start the engine. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel and prime the fuel system.
4. Fuel Injection Timing Not Correct Check and make necessary adjustments as per Testing and Adjusting section of the Service Manual.
5. Valve Adjustment Not Correct Check and make necessary adjustments as per Testing and Adjusting section of the Service Manual. Intake valve adjustment is .015 in. (0,38 mm) and exhaust valve adjustment is .025 in. (0,64 mm).
6. Bad Fuel Nozzle(s) Remove the fuel nozzles and test as per Testing and Adjusting section of the Service Manual.
7. Low Compression See the chart Misfiring and Running Rough.
Exhaust Smoke Can Not Be Seen While Starting
8. No Fuel in Tank Check fuel level visually (do not use the fuel gauge only). Be sure tank selection valve is open to the tank with fuel in it. Be sure valve in fuel line between the tanks is open.
9. No Fuel From Fuel Injection Pump Loosen one or more of the fuel injection line nuts at the cylinder heads. With ignition switch on and accelerator in the fuel on position, turn the engine with the starter to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, follow Steps (a) through (e) until problem is corrected.
a. Prime fuel system as per Operation Guide (FEO45119).
b. Check solenoid by turning on ignition switch. You must hear a sound when the plunger opens. If no sound is heard, make sure there is battery voltage at the solenoid and that the voltage is no less than 8 volts. If voltage is less than 8 volts, the problem is low charge in batteries or bad wiring. If voltage is 8 or more volts, loosen the cap on the tee at the fuel filter and release the fuel pressure at the solenoid. If the solenoid now works, the fuel transfer pump is holding fuel pressure at the solenoid. Clean the fuel transfer pump or install a new fuel transfer pump. If solenoid does not work when pressure is released, install a new solenoid.
c. Check for a dirty fuel filter by checking fuel pressure at the fuel filter outlet while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2) check fuel pressure at the outlet of the fuel transfer pump. If fuel pressure at the outlet of the fuel transfer pump is more than the fuel pressure at the fuel filter outlet install a new fuel filter.
d. Check for a bad fuel transfer pump by checking fuel pressure at the outlet of the fuel transfer pump while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2), clean the primary fuel filter (if truck is so equipped). If fuel pressure is still low, connect a vacuum gauge to the inlet side of the fuel transfer pump and turn the engine with the starter. If the inlet vacuum is less than 9 inches (228,6 mm) of mercury, install a new fuel transfer pump. If the inlet vacuum is more than 9 inches (228,6 mm) of mercury, there is a restriction in the fuel supply line and/or the fuel tank.
NOTE: While the fuel transfer pump is removed from the engine, turn the engine with the starter and look through the hole, in the housing of the fuel injection pump, from which you removed the fuel transfer pump. Make sure the camshaft for the fuel injection pump is turning. If the camshaft does not turn, check and adjust the timing of the camshaft to the engine. Tighten the nut of the drive adapter shaft to 32 ± 2 lb. ft. (4,4 ± 0,3 mkg).
e. Check for fuel supply line restriction by removing the fuel supply line from the fuel transfer pump. Put 5 psi (0,35 kg/cm2) [CAUTION do not use more than 8 psi (0,56 kg/cm2)] of air pressure to the fuel tank. If there is no fuel, or only a weak flow of fuel from the fuel supply line, there is a restriction in the fuel supply line and/or the fuel tank.
10. No Air to Engine Loosen the air inlet at the engine. If engine will now start, check air inlet system for damage and/or restrictions.
11. Exhaust System Not Open Loosen the exhaust pipes from the exhaust manifolds. If engine will now start, check the exhaust system for damage and/or restrictions.
Engine Crankshaft Will Not Turn
Recommended Procedure
1. Low or No Battery Voltage Check battery voltage. If battery voltage is less than 8 volts, put a charge to the battery. If battery will not hold a charge, install a new battery.
2. Bad Switch, Bad Wiring or Connection in Switch Circuit With ignition switch in START position, check voltage at switch connection on starter solenoid. If there is no voltage, or if the voltage is low at this connection, check wiring, connections, ignition switch, and magnetic switch (if used).
3. Bad Cable or Connection; Battery to Starter With ignition switch in the START position, check voltage at connection of battery cable to starter. If there is no voltage, or if the voltage is low at this connection and there is good voltage at the battery, check for bad cable or connection between the battery and the starter.
4. Bad Starter Solenoid Remove and repair a solenoid which does not work when voltage is correct at both the battery and ignition switch connections.
5. Bad Starting Motor If the solenoid works and the starting motor does not turn the crankshaft, the starting motor is bad. Before removing the starting motor, turn the crankshaft by hand to be sure a mechanical failure inside the engine, transmission, or power take-off is not preventing the crankshaft from turning. If crankshaft turns freely by hand, engage the starting motor again. If the starting motor still will not work, remove the starting motor and repair it or install a new starting motor.
6. Transmission or Power Take-Off Problem Prevents Crankshaft From Turning If crankshaft can not be turned by hand, disconnect the transmission and power take-off. If crankshaft will now turn, find cause of the problem in the transmission or power take-off and make necessary corrections.
7. Inside Problem Prevents Engine Crankshaft From Turning If the crankshaft can not be turned after disconnecting the transmission and power take-off, remove the fuel nozzles and check for fluid in the cylinders while turning the crankshaft. If fluid in the cylinders is not the problem, the engine must be disassembled to check for other inside problems. Some of these inside problems are bearing seizure, piston seizure, wrong pistons installed in the engine, and valves making contact with pistons.
Engine Crankshaft Turns Too Slowly
8. Low Battery Voltage Check battery voltage. If battery voltage is less than 8 volts, put a charge to the battery. If battery will not hold a charge, install a new battery.
9. Bad Cable or Connection; Battery to Starter With switch in START position, check voltage at battery cable connection to starter. If voltage is less than 8 volts check the cables and connections.
10. Oil Too Thick For Free Crankshaft Rotation Use SAE 10W/30, 10W/40, or SAE 30 grade oils for temperatures above 32° F (0° C). Use SAE 10W, 10W/30, or 10W/40 grade oils for temperatures below 32° F (0° C). At temperatures below -10° F (-23° C) it may be necessary to warm the oil for free crankshaft rotation.
11. Bad Starting Motor Remove and test. Make repairs as necessary or install a new starting motor.
12. Extra Outside Loads Damage to the power take-off equipment and/or transmission can put extra load on the engine. This prevents free rotation of the crankshaft. To check, disconnect the transmission and power take-off and start the engine.
13. Mechanical Problem Inside Engine Take the engine apart and check all components for damage.