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Service Manual - Ampac Machinery

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1. Note1 The EPA emission regulation under 19kW is mentioned above Note2 As for Model year the year which a regulation is applicable to is shown Transient smoke standards 96 opacity Engine Classilcation acceleration lug peak modes Constant speed engine Not regulated Variable speed engine 20 15 50 or less 2 California ARB Emission Regulation The ARB emission standard is based on that of the EPA 1 General 1 6 2 Engine identification With the regulations on engine emission worldwide it has become necessary to identify engines in a manner to determine which regulations they comply with hence Emission control information label as shown below which will contain IMPORTANT ENGINE INFORMATION IMPORTANT ENGINE INFORMATION Thi D EE TER US Wi EA REGULATIONS EH Fam wert EE AMD U EPA me HSE 8 TIFIED TO OPERATE ON T FUEL nm T CERTIFIED TO OPERATE OH Type D FUEL ENGINE FAHU Y C DISPLACEMENT XK LITERS ENGINE FANILY KR DISPLACEMENT CG LITERS ENGINE M DEL E EMISSION CONTROL SYSTEM F ENGIME MODEL CC EMISSION CONTROL STSTEM D FUEL RATE 6 THANA gu W CH FUEL RATE E M C STRIKE BTE MEG RPA REFER OWNER MANUAL FOR MAINTENANCE SPECIFICATIONS AND REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND MAUSTIENTS ADJUSTWEHTS p s p EPA Emis
2. 1 Disassembly drawing Housing 7 Needle bearing 2 Structure When the starting switch is turned on a magnet switch takes a voltage and a pinion projects The pinion engages with the ring gear of a engine and the engine is started Magnetic switch Shift Jever Pinion uig Assy tar H EE mW Pinion case E ie d Gi Au E afe IEN F YP Armature Assy i Yoke Assy End flame cover 8 The specifications of a starting motor and the characteristics 8 2 2 Wiring diagram of a starting motor 1 When a starting switch is turned on a magnet switch is charged and a moving core is Starting switch absorbed and a pinion clutch is moved forward through a lever and the pinion engages with a ring gear 2 When the pinion engages the ring gear because a main contact point is closed and the main electric current flows and a pull coil is short circuited by the main contact point and it stops being charged with electricity the pinion is kept at the position by a hold ing coil during the start 3 When the starting switch is turned off the main con tact point becomes open and the pinion Starter clutch is returned to the stop position by a return spring 8 3 Performance The specified characteristics of a starting motor at 20 deg C 1 No load Less than electric current 90 A more than rotation speed 3000 min 1 at voltage 11 5 V 2 Load More than rotation speed 1130 min 1
3. SAFETY LABELS Most accidents are caused by negligence of basic safety rules and precautions For accident prevention it is important to avoid such causes before development to accidents Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident It is impossible to cover every possible danger in repair or maintenance in the manual Sufficient consideration for safety is required in addition to the matters marked AcAUTION Especially for safety precautions in a repair or maintenance job not described in this manual receive instructions from a knowledgeable leader e Safety marks used in this manual and their meanings are as follows A DANGER DANGER indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING indicates a potentially hazardous situation which if not Ax WARNING avoided COULD result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury e NOTICE inaicates that if not observed the product performance or quality may not be guaranteed 1 SERVICE AREA A WARNING A CAUTION A CAUTION A CAUTION Safety Precauti
4. 46 982 to 47 002 2 009 to 2 014 Clearance 0 020 to 0 050 3 Thrust bearing Inspection item Standard Reference page Crankshaft side gap 0 111 to 0 250 Metal thickness 1 930 to 1 980 4 4 5 3 11 Service Standards 4 Piston and ring Piston Inspection item Standard Reference page Piston outside diameter Measure in the direction vertical to the piston pin 2CA1 3CA1 69 960 to 69 990 2CA1 3CA1 75 955 to 75 985 Piston diameter measure position Upward from the bottom end of the piston 2CA1 3CA1 3CB1 22 to 25 Piston pin Hole inside diameter 22 000 to 22 009 Pin outside diameter 21 995 to 22 000 Clearance 0 000 to 0 014 11 Service Standards Piston ring Model Inspection item Standard limit Reference page Ring groove width 1 550 to 1 570 Ring width 1 470 to 1 490 1 450 Top ring Side clearance 0 060 to 0 100 End clearance 0 15 to 0 30 0 39 Ring groove width 1 540 to 1 560 1 660 2CA1 Ring width 1 470 to 1 490 1 450 3CA1 Second ring Side clearance 0 050 to 0 090 0 210 End clearance 0 18 to 0 33 0 42 Ring groove width 3 010 to 3 030 3 130 Ring width 2 970 to 2 990 2 950 Oil ring Side clearance 0 020 to 0 060 0 180 End clearance 0 20 to 0 45 0 54 4 4 5 4 Ring groove width 1 550 to 1 570 S
5. L A WARNING e Charging Batteries Charging wet celled batteries produces hydrogen gas Hydrogen gas is ei extremely explosive Keep sparks open flame and any other form of FX ignition away Explosion may occur causing severe personal injury eBattery Electrolyte A WARNING Batteries contain sulfuric acid Do NOT allow it to come in contact yU with clothing skin and or eyes severe burns will result 7 WASTE MANAGEMENT l A CAUTION Observe the following instructions with regard to hazardous waste disposal Negligence of these will have a serious impact on environmental pollution concerns 1 Waste fluids such as lube oil fuel and coolant shall be carefully put into separate sealed containers and disposed of properly 2 Do NOT dispose of waste materials irresponsibly by dumping them into the sewer overland or into natural waterways 3 Waste materials such as oil fuel coolant solvents filter elements and batteries must be disposed of properly according to local ordinances Consult the local authorities or reclamation facility 8 FURTHER PRECAUTIONS A WARNING j A WARNING awy TAA eee A WARNING EF A WARNING e e Fueling Refueling Keep sparks open flames or any other form of ignition match cigarette etc away when fueling refueling the unit Fire and or an explosion may result e Hot Surfaces Do NOT touch the engine or any of its component
6. 0 3 0 4 0 5 10 kgf cm when the adjusting shim thickness is increased by 0 mm 2 20 2 Inspection and Adjustment Informative Fuel injection valve structure Mozzle spring pes Nozzle valve ut ecg V 4 Nozzle Doch b Spray pattern inspection After adjustment to the specified valve opening pressure use a nozzle tester and check the spray pattern and seat oil tightness Seat oil tightness check e After injecting a few times increase the pressure gradually Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1 96 MPa 20kgf cm and check to see that oil does not drip from the tip end of the nozzle If extreme oil leak from the overflow joint exists during injection by the nozzle tester check after retightening If much oil is leaking replace the nozzle assembly 2 21 D Nozzle spring seat UNS Sg Valve stop spacer i IM d Mozzie i L3 G Bo cl tc Normal spray pattern 2 Inspection and Adjustment Spray and injection states Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection e If normal injection as shown below cannot be obtained replace the fuel injection valve No extreme difference in angle 0 e Finely atomized spray A s Excellent spray departure p eg pud tA m o Abnormal spray pattern c Nozzle valve s
7. A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start 8 1 1 Specifications Manufacturer s model Denso P1 1 Part Number kW 586400 7490 Nominal output kg 1 1 Weight 3 Revolution direction as viewed from pinion 2 Clockwise Engagement system Magnetic shift Terminal voltage current V A 11 5 90 or less No load Revolution rpm 3000 or above Terminal voltage current V A 2 5 325 or less Loaded Torque Nm kgf m 8 24 0 84 Clutch system Overrunning Pinion projection voltage at 100 C V 8 0 or less Pinion DP or module number of teeth M2 54 9 Application Standard 8 1 2 Characteristics e Fi e g STARTER E zi Sr STANDARD PERFORMANCE 12V 11kW E ui pc DI H GENEE E E Ee EAA a S EE OR a pa i SE m oo ME WEITE Ek a p E si ste Lal ieget zm SE Ab fede be tie um ge Spo ll es i oe ee i AI 60004 244 12 12 van 5000 20 10 Dt DN e i 4000 163 08 or v 3000 3142 oe 6l 200 8d o4 4H 10004 44 024 2 EON EE MERLO pt D 40 200 300 CURRENT A 8 1 8 The specifications of a starting motor and the characteristics 8 2 The structure of a starting motor and the wiring diagram 8 2 1 Structure
8. Cooling water pump Note This figure shows the 3CB1 6 1 6 Cooling System 6 3 Disassembly Reverse the procedure below for assembly 1 Remove the alternator See 4 2 2 1 in Chapter 4 2 Remove the fan V belt and pulley See 4 2 2 2 in Chapter 4 3 Remove the cooling water pump Point 1 in below 6 4 4 Remove the thermostat Point 2 in below 6 4 6 4 Servicing Points Point 1 Disassemble Reassemble Check to see that the cooling water pump bearing is free from abnormal noise sticking or play and water leakage from the bearing If replacement is necessary replace the whole cooling water pump assy NOTICE Replace the O ring of the installation part to the cylinder block of the cooling water pump with new one when disassembling And be sure to use the special O ring for each engine model because the material is different although the dimension is the same as a commercial part Refer to the right figure Point 2 Disassemble Check the thermostat function See 2 7 in Chapter 2 for the inspection method 6 2 7 Fuel Injection Pump Governor 7 FUEL INJECTION PUMP GOVERNOR Only the outline of the MP fuel pump is explained in this chapter Refer to the MP pump service manual of the separate volume for the disassembly and assembly 7 1 Introduction A fuel injection pump is the most important device which adjusts an injection quantity precisely corresponding to the change of eng
9. Drain cock 1 General 1 3 2 Lubricating oil IMPORTANT Only use the recommended engine oil to keep the durability of the engine 1 Selection of engine lube oil Engine oil should comply with the following specifications 1 Classification e AbDldasebieatieon CD CF CF 4 Cl 4 TBN value gt 9 CD gt 9 CF gt 7 CF 4 7 Cl 4 e ACEA classification eese E 3 E 4 E 5 TBN value 10 E 3 gt 10 E 4 gt 10 E 5 e JASO classification eee DH 1 TBN value gt 10 DH 1 The oil must be changed when the Total Base Number TBN has been reduced to 2 0 TBN mgKOH g test method JIS K 2501 5 2 2 HCI ASTM D4739 HCI DO NOT use The following engine oils API CG 4 CH 4 ACEA E 1 E 2 B grade e JASO DH 2 DL 1 Reason API CG 4 CH 4 In case CG 4 CH 4 is to be used for 2AC1 3CA1 3CB1 diesel engine there is a possibility that excessive wears occur on the valve train system due to the content of oil ACEA E 1 E 2 B These fuels are developed for the different type of diesel engines JASO DH 2 DL 1 These fuels are developed for the different type of diesel engines 2 Viscosity Selection of viscosity SAE Service grade ambient temperature e Mul gt Refer to the chart on the right Selection of viscosity will be determined depending on the The following requirements are also need to be fulfilled Standard engine oil service interval is 250 hrs or every 12 months
10. e When disassembling complicated portions put match marks and other marks at places not adversely affecting the function for easy reassembly 4 Precautions in Disassembly Each time a parts is removed check the part installed state deformation damage roughening surface defect etc Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again Parts to be used again shall be washed and cleaned sufficiently Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump 5 Precautions for Inspection and Measurement Inspect and measure parts to be used again as required to determine whether they are reusable or not 6 Precautions for Reassembly e Reassemble correct parts in correct order according to the specified standards tightening torques and adjustment standards Apply oil important bolts and nuts before tightening when specified Always use genuine parts for replacement Always use new oil seals O rings packing and cotter pins Apply sealant to packing depending on the place where they are used Apply of grease to sliding contact portions and apply grease to oil seal lips 7 Precautions for Adjustment and Check Use measuring instruments for adjustment to the specified service standards How to Read this Manual 1 Range of Operation Explanation This manual explains the trou
11. 5 1 5 2 Troehoid Bun eegen 5 2 5 3 Disassembly Reverse the procedure below for assembhy 5 2 5 4 Servicing Points tedio e il eo eed ir lora eee ta ene eee eee E Edna ERR tae 5 2 5 5 Paris Inspection and Measurement uoc oce tre redire pe nests Cep exert orga deeg Lp e dune 5 3 5 5 1 Trochoid pump inspection and measurement ssssessisssisriiseiittstinntiintitatntinntinnrinanatnnnennnea 5 3 6B COOLING SYSTEM xar o geesde Ee lese et ondes 6 1 63 Gooling Water Systemi EE 6 1 6 2 Cooling Water Pump Compongeris oret tree eee eg ee eosin dele 6 1 6 3 Disassembly Reverse the procedure below for assembhy 6 2 6 4 Servicing PONS asians ol ut tei oed cte boe eee ered pesa ut ie abes eta 6 2 7 FUEL INJECTION PUMP GOVERNONH tetro Eau etu E ob ceca 7 1 F e inus e EE 7 1 Z2 Fuel Iniectior Tu EE 7 1 7 2 1 Fuel Systermi diagram oRPPROBROPRPERPERPPPBPOPRPORPPROPEPPeBOpOBO Ge 7 1 7 2 2 External view and components AA 7 2 7 2 3 Disassembly procedur th n enin 7 3 7 2 4 Reassembly procedure inne anana aaa enne entren nnne nnne entree nere nennen 7 3 7 2 5 Confirmation and adjustment of fuel injection Uming 7 4 7 2 6 Confirmation and adjustment of no load maximum and minimum speed 7 4 8 The specifications of a starting motor and the characteristics 8 1 8 1 The specifications and the characheretcs un 8 1 BT TSO Te zs us it eth i i ce ec co n nem m d e RR d d eie aqu ne 8 1 8 1 2 Char
12. DO NOT add any additives to the engine oil E poi i i 20 10 0 10 20 30 40 50 DO NOT mix the different types brand of engine oil Atmospheric temperature C DO NOT use synthetic oil almost throughout the year 15W 40 10W 30 can be used almost throughout the year 1 7 1 General 2 Handling of engine oil Keep the engine oil carefully in store in order to prevent any dust or dirt entrance e When filling the engine oil to the engine avoid the spillage and pay attention to be clean around the filler port A CAUTION Contact with engine oil may result in the roughened skin Care should be taken so as not to contact with engine oil wearing protective gloves and clothing If contact wash with soap and water thoroughly When handling the engine oil make sure to use the protective gloves at any time In case of contact wash your hand or body with soap and water thoroughly 1 3 3 Coolant water Use clean soft water and always be sure to add LLC Long Life Coolant in order to prevent rust built up and freezing Do not use water only The recommended LLC conform to the following specifications e JIS K 2234 SAEbJ814C J1941 J1034 J2036 ASTM D4985 IMPORTANT e Always be sure to add LLC to soft water In particular in cold season to add LLC is important Without LLC e Cooling performance will decrease due to scale and rust in the cooling water system e Cooling water may freeze to form ice
13. Fuel pipe and coolant water pipe inspection and maintenance Inspection and adjustment of governor lever and accelerator 1 2 3 4 Coolant water level check and replenishment 5 6 7 Warning lamp amp instruments function check 1 Visual check around engine If any problem is found do not use before the engine repairs have been completed Oil leak from the lubrication system Fuel leak from the fuel system Coolant water leak from the cooling water system e Damaged parts Loosened or lost bolts Fuel radiator rubber hoses V belt cracked loosened clamp 2 Fuel tank level check and fuel supply Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary Refer to 1 3 1 3 Lube oil level check and replenishment a Checking oil level Check the lube oil level with the dipstick after Set Ze i l adjusting the posture of the machine unit so that an s PN PI Filler part EE MO i y lube oil engine may become a horizontality Insert the dipstick fully and check the oil level The oil shall not be contaminated heavily and have appropriate viscosity No coolant water or diesel fuel shall be mixed When lube oil is supplied after the engine running check the lube oil level after about 10 minutes pass after the engine shutdown so that the lube oil inside may be retuned the oil pan Standard The level shall be between the upper
14. Lubrication System 5 5 Parts Inspection and Measurement 5 5 1 Trochoid pump inspection and measurement 1 Outside diameter clearance and side clear ance of outer rotor Gear case Outer rotor Insert a gap gauge between the outer rotor and the gear case cover and measure outside diameter gap Put a ruler on the end face of the gear case cover and insert a gap gauge between rotor and measure a side gap Outside clearance mm Standard Limit 0 12 to 0 21 0 30 Inner rotor Outer diameter clearance Side clearance mm Standard Limit 0 02 to 0 07 0 12 2 Tip clearance between outer rotor and inner rotor e Insert a gap gage between an outer rotor and an inner Outer rotor rotor and measure the tip clearance Side clearance Tip clearance mm Standard Limit 0 16 3 Outside diameter clearance of inner rotor centering location part Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover Calculate the clearance from that difference Inspection item Standard Limit Gear case cover D 46 13 to 46 18 Inner rotor O D 45 98 to 46 00 Rotor clearance 0 13 to 0 20 0 25 5 3 6 Cooling System 6 COOLING SYSTEM 6 1 Cooling Water System Thermostat Cylinder head ESAE Sub tank Radiator Cylinder block Cooling water pump 6 2 Cooling Water Pump Components Thermostat cover
15. Ring width 1 470 to 1 490 1 450 Top ring Side clearance 0 060 to 0 100 End clearance 0 15 to 0 30 0 390 Ring groove width 1 580 to 1 595 1 695 Ring width 1 430 to 1 450 1 410 3CB1 Second ring Side clearance 0 013 to 0 165 0 285 End clearance 0 18 to 0 33 0 420 Ring groove width 3 010 to 3 025 3 125 Ring width 2 970 to 2 990 2 950 Oil ring Side clearance 0 020 to 0 055 0 175 End clearance 0 20 to 0 45 0 540 11 Service Standards 5 Connecting rod Inspection item Standard Reference page 4 44 Thrust clearance Rod small end 0 2 to 0 4 Item Standard Limit Reference page Bushing inside diameter 22 025 to 22 038 22 068 Pin outside diameter 21 991 to 22 000 21 963 4 4 5 5 Clearance 0 025 to 0 047 0 105 6 Tappet Inspection item Standard Reference page Tappet hole block inside diameter 21 000 to 21 021 Tappet stem outside diameter 20 927 to 20 960 Clearance 11 3 Lubricating oil system Trochoid pump 0 040 to 0 094 1 Outside clearance of outer rotor mm Standard Limit Reference page 0 12 to 0 21 0 30 5 5 1 2 Side clearance of outer rotor mm Standard Limit Reference page 0 02 to 0 07 0 12 5 5 1 3 Outside clearance of inner rotor centering location part mm Standard Limit Reference page 0 13 to 0 20 0 30 5 5 1 4 4 5 6 12 Tigh
16. STANDARD CHARACTERISTICS 13 5V CONSTANT L AMBIENT TEMP 25 C z LJ c a 2 Q e 2 nm H 2 o A H Sg OTI 0 123 45 6 7 8 ALTERNATOR SPEED X10 min 9 2 5 Inspection Perform the same procedure as that of 9 1 5 in Chapter 9 9 7 9 Alternator 9 3 Troubleshooting o ejqeandde osje si peau yaya ay lE SSE G aso youag aui OA DE 910 apwo a iz Klang patieys Anni e asp EL SEU b aDEOA EUI T TA aeyos uwa Ju A A JoygnBo g DHD A0 8 UJ NO EE EE suonewejqqe uo vonguejdx3 JJ han EE See O wor e Ux n a E Bupe Buunp Moo 1 77 uas WD ayy vun 1 ENO auo L Es V E 5 H 21 Sedan eps apoipe ant ta Nic od nid PAJORIOR e j Ago TA gA Je yupun Su BUS au IA euius vg ie gA wasesa SS 146 ay un pue uidi pos NER wdi og RPE SoG pU eim Se EE Da cp DL mI Dun WT GER hoo GE Buung mm E i L Lie 1A HE HA Schi Pe irs dwe aul n duwe afupuz on sang ri dA PNE OE Me EE EE eet m eua opis neq pue yg di Lama doup afgon 9AISSS2X3 x AGO lt 1A gt GA E i NE OI uates AP poads oumius ou BSE QU y ee eee 7 Gel i Jup 8 E st duie ayl 440 Tv me mE E OEY SE z P da0 S908 epis j apolp ot yoadsu Soe EE E dwel ayl L
17. Valve guide replacement esssssssssssseeeeeeeeneee nennen nnne n nennen 4 23 4 2 8 Valve stem seal replacement sessssssseseseeee eene enne nennen nnne 4 24 4 3 Gear Train and Camshaft ir er HERE e Rae rue Rer re e Ra ur oua 4 25 Reen is ice eite seen uten UST Tran pM M M En omn ubi es 4 25 4 3 2 Disassembly procedure z oie eite dee E eee ERE EE say 4 25 4 3 3 Heassembly procedure Siena eel 4 25 2 3 4 Servicing POMS secure eere eee etre re e eee eei ee ede et 4 26 4 3 5 Parts inspection and measurement esesssssssseseeeneee nnne nennen 4 29 4 3 6 Oil seal replacement Gear case side ssnssssteeteettetttttttrtttrttntttnntnnnttnrttnntennrnn nenene 4 31 4 3 7 Camshaft bushing replacement a rr ERR CERERI RE REEF RE ERRARE ERE 4 31 4 4 Cylinder Bloek gue ero eene een ENNEN ERR FU REA ERR RR pA Ra vue 4 32 WR eege Seen ene ee ene ere eate tede etd RC ean Tomo MRE mar 4 32 4 4 2 Disassembly ee 4 32 4 4 3 Reassembly procedure mee e ne n nas 4 32 AAA SERVICING POME tooo cL 4 33 4 4 5 Parts inspection and measurement esses nnne 4 37 4 4 6 Cylinder bore correction i deese eta ee lean epo festen Posee ee Ae Ete eee 4 47 4 4 7 Piston pin bushing replacement nennen nennen nennen 4 48 4 4 8 Oil seal replacement Flywheel housing side eeeeeeeeneeeene 4 48 5 EE ER HUET EEN ER EE 5 1 bd eelere Be LE EE
18. adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is the nearest to the top dead center after turning and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240 A adjustment method of reducing the flywheel turning numbers for 3 cylinder engines for reference Set No 1 cylinder to the compression T D C and adjust the clearance of the mark of the below table Next turn the flywheel once the suction exhaust valve of No 1 cylinder is in the position of the overlap T D C at this time and adjust the clearance of the O mark Ignition order of 3 cylinder engines 1 3 2 Oylinder No 1 2 3 Valve Suction Exhaust Suction Exhaust Suction Exhaust No 1 compression e e e e The first time T D C No 1 overlap a Q The second time T D C 2 18 2 Inspection and Adjustment b Valve clearance inspection and adjustment 1 Loosen the lock nut and adjusting screw and check the valve for any inclination of valve cap dirt or wear r7 L1 2 A Valve cap 2 Measuring valve clearance Normal Abnormal Insert a 0 2 mm thickness gage between the rocker arm and valve cap and adjust the valve clearance Tighten the adjusting screw mm Standard valve clearance 0 15 0 25 3 Apply oil to the contact surface between adjusting screw and push rod 4 Adjust the other cylinder s in the order V
19. ae UR aede qd eer n e kate td aed 11 2 Tio L OVnder Tid etui eon ote cote ten nhe aet ae eser Lcnu cede eene Loue ee t 11 2 11 2 2 Gear train and camshaft EAEE EE EEEE EEEE 11 4 11 2 3 Cylinder EE 11 5 11 3 Lubricating oil system Trochoid pump rte dre RUE DEEN 11 8 12 TIGHTENING TORQUE for BOLTS and NUTS sss 12 1 12 1 Tightening Torques for Main Bolts and Nuts sssssnneeeessesneensseeenrrrnrrrnrrnnrresererneneserrenne 12 1 12 2 Tightening Torques for Standard Bolts and Nuts sssossnnnnneeennerrnersserrnnrreserennnreserrnne 12 2 1 General 1 General 1 1 Engine Nomenclature 3 C OO O OO Destination code Nominal engine speed or output code Cylinder bore in mm Model series Number of Cylinders The engine specification class Notation Available engine speed min Intended uses VM 3200 3600 Lawn mower constructive industrial machine CL 2000 or 3000 Agricultural constructive industrial machines etc CH 3000 or 3600 2 pole generator sets irrigation pumps CL 1500 or 1800 4 pole generator sets irrigation pumps etc VM Variable Medium speed VH Variable High speed CL Constant Low speed CH Constant High speed 1 2 Specifications NOTE 1 The information described in the engine specifications tables the next page and after is for standard engine To obtain the information for the engine installed in each machine unit refer to t
20. and lower limit lines on the dipstick Dipsiick Lower limit 2 2 2 Inspection and Adjustment Unit liter Total volume L Effective volume L 1 7 0 7 2 8 1 3 3 4 1 6 Engine oil capacity may differ from the above volume depending on an engine installed on a machine unit b Replenishing oil pan with lube oil If the remaining engine oil level is low fill the oil pan with the specified engine oil to the specified level through the filler port NOTICE The oil should not be overfilled to exceed the upper limit line Otherwise a naturally aspirated engine may intake lube oil in the combustion chamber during the operation then white smoke oil hummer or urgent rotation may occur because the blowby gas is reduced in the suction air flow In case of turbo charged engine oil may jet out from the breather or the engine may become faulty 4 Coolant water Inspection Daily inspection of coolant water should be done only by Coolant recovery tank s Never open the radiator filler cap while the engine and radiator are A WARNING still hot Steam and hot water will spurt out and seriously burn Se 4 you Wait until the radiator is cooled down after the engine has stopped wrap the filler cap with a rag piece and turn the cap e slowly to gently release the pressure inside the radiator Securely tighten the filler cap after checking the radiator Steam can spurt out during operation if the ca
21. b Intake exhaust cam height measurement mm Model Standard 2CA1 3CA1 34 535 to 34 665 3CB1 34 135 to 34 265 c Camshaft outside diameter and bearing hole diameter measurement Measure the camshaft Cam height outside diameter with a micrometer The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the camshaft bushing inside diameter after insertion to the cylinder measured with a cylinder gage 4 28 4 Disassembly Inspection and Reassembly of Engines Item Standard Bushing LD 40 000 to 40 075 Gear side Camshaft O D 39 940 to 39 960 Oil clearance 0 040 to 0 135 Bushing LD 40 000 to 40 025 Intermediate position Camshaft O D 39 910 to 39 935 Oil clearance 0 065 to 0 115 Bushing D 40 000 to 40 025 Flywheel side Camshaft O D 39 940 to 39 960 Oil clearance 0 04 to 0 085 2 Idle gear Mainly check the bushing seizure and wear and gear damage MH E Idle gear Shaft outside diameter and bushing inside diameter tz a measurement Item Standard Shaft outside diameter 44 950 to 44 975 Shaft diameter Inside diameter Bushing inside diameter 45 000 to 45 025 Idle gear Clearance 0 025 to 0 075 3 PTO drive gear Mainly check sticking of bearings on both sides gear damage and looseness and gear shaft damage and wear 4 29 4 Disassembly Inspection and Reassembly of Engines 4 3 6
22. below the warranty shall not be deemed to apply Please be sure to read these conditions carefully when planning to use it with other equipment Also be certain to give appropriate guidance on usage to the user 1 When the battery cable can be connected backwards The alternator diode will be damaged and recharging made impossible if the plus and minus ends of the battery cable are confused The stator coil will also be burned as a result To prevent this supply the user with a cable of such a length or structure that the plus and minus ends cannot be confused Also warn the user not to connect the cable backwards 2 When charging output voltage is used for control purposes The engine speed at starting is not proportional to the output voltage of the alternator so this output voltage must not be used for any control systems It is especially wrong to use it for the control signal of the safety relay for cutting the starter motor because this will damage the starter motor and cause engine starting failure 3 When the L line is used for control purposes Consult with Isuzu first before connecting any load other than the charge lamp to the L line Damage to the alternator and related equipment will not be warranted without such prior consultation 4 Non use of the Isuzu wiring diagram Use without prior consultation of any wiring diagram other than that provided by Isuzu removes any breakdown of any electrical equipment from the warranty
23. end mm Item Standard Crankpin O D 41 952 to 41 962 Metal I D 41 982 to 42 002 Metal thickness 1 508 to 1 509 Clearance 0 020 to 0 058 4 45 4 Disassembly Inspection and Reassembly of Engines 6 Tappet Mainly check the tappet contact surface with the cam and push rod Slight surface defects shall be corrected with an oilstone a Tappet stem outside diameter measurement The outside diameter of the tappet stem is measured by a micrometer The clearance is calculated from the measured tappet hole and the measured stem diameter Abnormal contact Normal contact Item Standard Limit surface surface Tappet hole LD 21 000 to 21 021 21 041 Tappet Stem O D 20 927 to 20 960 20 907 Clearance 0 040 to 0 094 0 134 4 4 6 Cylinder bore correction 1 Slight uneven worn flawed etc shall be corrected by honing only If the cylinder is unevenly worn partially flawed or otherwise damaged and cannot be repaired simply by honing rebore the cylinder first and then hone See 4 4 5 1 c for the boring dimension Wa Fleactric ani 2 Items to be prepared for honing 50 oil ka oil e Flex Hone see No 8 of 4 1 2 in Chapter 4 f et Electric drill Flex Hone Honing fluid e Honing fluid Items to be prepared for honing 50 50 mixture of lube oil and diesel oil 4 46 4 Disassembly Inspection and Reassembly of Engines 3 Apply the honing fluid to the Flex Hone and turn the elect
24. fan mounting bolt and then remove fan 2 Loosen adjusting bolt for the V belt adjuster and then remove V belt 3 Remove alternator 4 Remove the spacer for cooling fan and V pulley 1 Never turn down alternator vigorously toward the cylinder block Otherwise your finger may be nipped and alternator broken 1 Remove lubricating oil filter assembly 2 Extract dipstick form the oil dip stick hole 1 Disconnect fuel return pipes to 2 Remove fuel filter 4 7 4 Disassembly Inspection and Reassembly of Engines Removal Parts Remarks 1 Disconnect coolant water pipe from the cooling water pump Remove thermostat assembly Remove cooling water pump Remove oylinder head tightening bolt Remove cylinder head assembly Remove cylinder head gasket 2 3 1 2 3 1 Lay a cardboard or the like on the floor and place cylinder head assembly on it so as not to damage the combustion surface 2 Order of loosening the cylinder head tightening bolts Disassembly Camshaft side B le vi A8 j a Ex Se Ek ons 4 covets ub i D 20 D OMM M Head bolt disassembly order 3 cylinder head Was 7 8 2 Qu Disassemhly Camshaft side Fan side Read bolt disassembly order 2 cylinder head 3 To remove the intake exhaust valves from cylinder head assembly take the following steps a Using a valve spring compressor see Chapter 4 1 2 1 compress valve spring and rem
25. figure shows the 3CB1 7 Fuel Injection Pump Governor 7 2 3 Disassembly procedure The procedure to remove a fuel injection pump from the gear case is shown NOTICE Be sure to remove a flange and a fuel injection pump drive gear with a pair without loosening the flange installation bolts 1 Remove fuel injection pipes fuel pipes and a 4 remote control wire Block the entrance with tape fuse Fuel injection so that trash may not enter the fuel injection PON WA TS De deat pipes and the fuel injection pump M MER 2 Mark the position of the timing marks of a fuel pump and a gear case Or put a mark on the gear case at the position to agree the timing mark of a fuel pump 3 Remove a pump cover from the gear case Pump drive gear nut 4 Give the marks on a fuel injection pump drive gear and a idle gear with paint or the like 5 Loosen fuel injection pump installation nuts three nuts 6 Loosen a installation nut of a fuel injection pump drive gear 7 Move a pump drive gear and a flange with a pair to your side by gear puller 8 Remove an installation nut and a washer 9 Remove a fuel injection pump Leave the pump drive gear in the gear case 7 2 4 Reassembly procedure NOTICE Use anew O ring on the fuel pump flange and apply grease Confirm whether the marks 7 2 3 4 of the pump drive gear and the idle gear is correct 1 Turn a cam shaft so that the key of the pump cam shaft may almos
26. filter hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping If you spill fuel wipe such spillage carefully 3 Install a new fuel filter element and tighten the S retainer ring Mechanical From water Fuel injection LU Tightening torque 13 to 16 N m 1 3 to 1 6 kgfm Fuel feeding pump separatr pump Priming lever Applicable fuel filter Part No pons return 586400 7780 e E 4 Bleed the fuel system Refer to 2 2 3 3 IMPORTANT Deg d ieee Be sure to use genuine ISUZU part super fine mesh Retaining ring filler Otherwise it results in engine damage Fuel cock uneven engine performance and shorten engine life Fuel filter 3 Air cleaner cleaning and element replacement Replace the air cleaner element periodically even if it is not damaged or dirty When replacing the element clean inside of the dust pan at the time If having the air cleaner with double elements do not remove the inner element If the engine output is still not recover or the dust indicator still actuates if having the air cleaner with a dust indicator even though the outer element has replaced with new one replace the inner element with new one 2 15 2 Inspection and Adjustment 2 2 6 Inspection every 1 000 hours or one year Be sure to check the following points every 1 000 hours or one year operation whichever comes first Inspection Item Coolant water replacement
27. from lubricating oil piping system Q Q Repair 5 Insufficient delivery capacity of trochoid pump a Check and repair See 5 5 in Chapter5 E Clogged lubricating oil filter OO Clean or replace bai i Defective pressure regulating valve a Clean adjust or replace 5 Insufficient lubricating oil level a a Add proper lubricating oil See 2 2 1 3 in Chapter2 Too early timing of fuel injection pump oiala Q Check and adjust See 2 2 7 4 in Chapter2 Too late timing of fuel injection pump qa jqaiaqia a Q Check and adjust See 2 2 7 4 in Chapter2 Improper properties of fuel oil Qailoan0idg a Use proper fuel oil See 1 3 1 in Chapter1 Water entrance in fuel system a Q Q Q qaqiaia Perform draining from the fuel filter See 2 2 3 and 2 2 5 in Chapter2 Clogged fuel filter Q a a Clean or replace See 2 2 5 in Chapter2 E Air entrance in fuel system Q a Q Perform air bleeding See 2 2 3 in Chapter2 Clogged or cracked fuel pipe ene Q Clean or replace i Insufficient fuel supply to fuel injection pump OO a Check the fuel tank cock fuel filter fuel pipe and fuel feed pump 2 Uneven injection volume of fuel injection pump Oo doOicd OQ aO aia Check and adjust Excessive fuel injection volume Q Qa Qa O Q Check and adjust Poor spray pattern from fuel injection nozzle OIOIO0 qa qaiaqaia a Check and adjust See 2 2 6 in Chapter2 SA Foreign matter trapped in the valve inside the priming pump SERIE salute Q Disassemble and clean Cl
28. if necessary Do not strongly move the accelerating wire or High idling speed accelerating pedal It may deform the governor lever Ear Belt or stretch the wire to cause irregular engine speed Governor lever control Accelerating wire mE Accelerating wire bracket Checking and adjusting procedure are as follows Ge 1 Check that the governor lever of the engine Te makes uniform contact with the high idling and low idling limiting bolt when the accelerating devices is in the high idling speed or low idling speed position 2 If either the high or the low idling speed side does not make contact with the limiting bolt adjust the accelerating wire Loosen the accelerating wire fixing nut and adjust the wire to contact with the limiting bolt A CAUTION Never release the limiting bolts It will impair the safety and performance of the product and functions and result in shorter engine life 5 Air cleaner cleaning and element replacement A CAUTION Beware of dirt from air blowing m Wear protective equipment such as goggles to protect your eyes when blowing compressed air Dust or flying debris can hurt eyes The engine performance is adversely affected when ir cl the air cleaner element is clogged by dust So OMM ONE periodical cleaning after disassembly is needed M Arrow IREI Element mark 1 Undo the clamps on the dust pan and remove the f o dust pan 2 Loosen the wing bolt on the element
29. limiter to earth any other electrical equipment 10 4 10 Electric Wiring 10 1 4 Section area and resistance of electric wire 1 Allowable maximum cable length Terminal resistance is not included Cable construction Cable size Resistance 2mq 20mQ Pe 50mQ mM Element No Cable dia cum m m m 3 41 0 32 0 005590 0 36 3 58 8 94 5 65 0 32 0 003520 0 57 5 68 14 20 8 50 0 45 0 002320 0 86 8 62 21 55 15 84 0 45 0 001380 1 45 14 49 36 23 20 41 40 80 0 000887 2 25 22 55 56 37 30 70 40 80 0 000520 3 85 38 46 96 15 40 85 40 80 0 000428 4 67 46 73 116 82 50 108 40 80 0 000337 5 93 59 35 148 37 0 000287 0 000215 0 000168 Note1 Allowable maximum resistance of Battery cable Note2 Allowable maximum resistance of Starting motor circuit 2 Terminal resistance Generally a terminal resistance is 15mO per coupler and OQ per screw setting This resistance should be included in allowable maximum resistance when the cable length is planned 10 5 11 Service Standards 11 SERVICE STANDARDS 11 1 Engine Tuning No Inspection item Standard Limit SES page 4 Gap at intake exhaust valve heads nym 0 15 to 0 25 2 2 6 3 Between alternator Used part 10 to 14 2 and crank pulley Direction A New part 8 to 12 V belt tension Between alternator
30. months operation whichever comes first Inspection Item Water separator cleaning Fuel filter element replacement Air cleaner cleaning and element replacement 1 Water separator cleaning The cup of an water separator is translucent and the inside can be seen The float ring rises when water collects at the bottom of the cup Air bleeding bolts Periodically wash the water separator element and inside d i Oullet cup with clean fuel oil T 1 Close the fuel cock oa 2 Loosen the retaining ring and remove the cup x N Take the water and trash in the cup out Fuel cock M E 3 Wash the element with clean fuel oil Replace the Fuel cock element with new one if any damaged Sea d zl Float ring Eu Water separator Applicable element Part No 586400 8320 4 Insert the element to the bracket and put the float ring and spring in the cup Tighten the retaining ring Tightening torque 13 to 16 N m 1 3 to 1 6 kgf m 5 Bleed the fuel system Refer to 2 2 3 3 2 14 2 Inspection and Adjustment 2 Fuel filter element replacement Replace the fuel filter element at specified intervals before it is clogged with dust to adversely affect the Fuel filter Fuel return hose fuel flow Do this work after an engine gets cold fully i 1 Close the fuel filter cock 2 Loosen the retainer ring and replace the fuel filter element Take the water and trash in the cup out When removing the fuel
31. not to drop tappets off when the cylinder block is turned upside down because the tappet is cylindrical 1 Remove idle gear shaft and then remove idle gear 2 Remove mounting bolt of thrust bearing through the hole of the camshaft gear Remove camshaft assembly 1 Turn the cylinder block aside and carefully prevent tappet from jamming on the cam 2 Preheat camshaft gear and camshaft assembly to 180 200 before removing them because they are shrink fitted 1 Remove gear case flange 1 Remove lubricating oil strainer 1 While turning crankshaft place piston in the bottom dead center BDC 2 Remove crankpin side cap of the connecting rod 4 9 1 Remove carbon deposits from the upper wall of the cylinder using fine sandpaper before extracting pistons Taking care not to damage the inner surface of the cylinder 2 Make sure than cap No of connecting rod meets with cylinder No 3 Take care not to drop the crankpin metal when removing the crankpin cap of the connecting rod 4 Disassembly Inspection and Reassembly of Engines Removal Parts Remarks 1 Remove main bearing cap bolt While shaking main bearing cap remove main bearing cap together with lower main bearing metal 2 Extract crankshaft taking care not to damage it 3 Remove upper main bearing metal 1 Before extracting crankshaft measure the side gap around it Dial gauge Grankshaft Apply a
32. on the market Camshaft bushing tool for extracting camshaft bushing D L2 df 18 70 45 48 Allowance dijs d2 Locally manufactured Flex Hone For re honing of cylinder liner Cylinder bore Parts No mm Available on the market COSE Piston insertion tool for inserting piston Available on the market XThe above piston insertion tool is applicable to 60 125 mm diameter pistons Piston ring replacer for removal installation of piston ring Available on the market 4 3 4 Disassembly Inspection and Reassembly of Engines 2 Measuring instruments No Instrument name Application Illustration Measurements of shaft bending and strain and gap of surfaces Nae 7 cP Sas 1 Dial gage ege Measurements of narrow or deep portions that cannot be measured by dial gage I 2 Test indicator p X For holding the dial gage when measuring P H a using a dial gage standing angles ug adjustable H 50 IHE 3 Magnetic stand j KS Jj LU 2 B JS For measuring the outside diameters of crankshaft pistons piston pins etc 4 Micrometer For measuring the inside diameters of cylinder liners rod metal etc 5 Oylinder gage TORUDE For measuring outside diameters depth thickness and width EN 6 Calipers TP For measuring of valve sink SN Ve S 7 Depth micrometer ech NM Y For measuring valve spring inclination and
33. returns to the radiator when the engine is cooled down If the water level is normal in the Coolant recovery tank but low in the radiator check loosened clamping of the rubber hose between the radiator and Coolant recovery tank or tear in the hose Standard Engine The radiator shall be filled up Unit liter Coolant water volume In an engine 0 6 0 9 Engine coolant water capacity may differ from the above volume depending on an engine installed on a machine unit 5 Fuel pipe and coolant water pipe inspection and maintenance Check the rubber hoses for fuel and coolant water pipes cracked If the cracked hose is found replace it with new one Check the loosened clamp If found tighten it 6 Inspection and adjustment of governor lever and accelerator Make sure the accelerator of the machine unit can be operated smoothly before starting the engine If it feels heavy to manipulate lubricate the accelerator cable joints and pivots Adjust the accelerator cable if there is a dislocation or excessive play between the accelerator and the governor lever Refer to 3 2 3 7 Warning lamp amp instruments function check Before and after starting the engine check to see that the alarm function normally Failure of alarm cannot warn the lack of the engine oil or the coolant water Make it a rule to check the alarm operation before and after starting engine every day Refer to each manual for machine units in details 2 2 2 in
34. system the E fuel injection pump will not be able to function 1 Check the fuel oil level in the fuel tank Refuel if insufficient 2 Open the fuel cocks of the water separator and the fuel filter 3 Loosen the air bleeding bolt on the water separator by turning 2 to 3 turns to the counter clockwise by using a screw driver N Mechanical From oil water Fuel injection 4 When the fuel coming out is clear and not mixed Fuel feed pump separator pump with any bubble tighten the air bleeding bolt 5 Feed the fuel with the fuel priming pump or electro magnetic fuel feed pump In case of an engine installed with a fuel priming pump Move the priming lever by hand up and down and feed fuel until the fuel surface inside the fuel filter cup goes up and the air disappears inside Move the lever until feeling your hand slightly heavy In case of an engine using the electro magnetic fuel feed pump Turn the starter switch to the ON position and Priming lever Close Air bleeding bolts hold it in the position and operate the electro magnetic fuel feed pump for 10 to 15 Water separator seconds to bleed the fuel system automatically WG A the piping line Retainer ring Note Fuel cock Don t do air bleeding by a starting motor Fuel filter 4 Battery electrolyte level check and battery recharging r Fire due to electric short circuit i A WARNING J Make sure to turn off the battery swi
35. to 1 490 1 450 Top ring Side clearance 0 060 to 0 100 End clearance 0 15 to 0 30 0 39 Ring groove width 1 540 to 1 560 1 660 Ring width 1 470 to 1 490 1 450 Ronee second nng Side clearance 0 050 to 0 090 0 210 End clearance 0 18 to 0 33 0 42 Ring groove width 3 010 to 3 030 3 130 CA Ring width 2 970 to 2 990 2 950 Oik ring Side clearance 0 020 to 0 060 0 180 End clearance 0 20 to 0 45 0 54 Ring groove width 1 550 to 1 570 TOT Ring width 1 470 to 1 490 1 450 Side clearance 0 060 to 0 100 End clearance 0 15 to 0 30 0 390 Ring groove width 1 580 to 1 595 1 695 Ring width 1 430 to 1 450 1 410 SC SSES Side clearance 0 013 to 0 165 0 285 End clearance 0 18 to 0 33 0 420 Ring groove width 3 010 to 3 025 3 125 x Ring width 2 970 to 2 990 2 950 erring Side clearance 0 020 to 0 055 0 175 End clearance 0 20 to 0 45 0 540 4 43 4 Disassembly Inspection and Reassembly of Engines 5 Connecting rod a Appearance inspection Inspect the portion near the boundary of the chamfered portion and I beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks deformation and discoloration b Twist and parallelism measurement Use a connecting rod aligner and measure the twist and bend mm Item Standard dimension Limit dimension Twist and 0 03 or less 0 08 parallelism per 100mm c Rod small end measurement Measure
36. torque 6 86 N m 0 70 kg fm at voltage 8 7 V and electric current 230 A 3 Restraint Less than electric current 325 A torque 8 2 N m 0 84 kgf m at voltage 2 5 V 4 Operation voltage In the position of a ring gear less than 8 V Since the characteristics of a starting motor can be confirmed easily in the no load test comparatively perform the test by the next point No load test Fix the starting motor on a test bench and connect wiring When the switch is closed a current flows in the starting motor which is rotated at no load Measure the current voltage and number of revolutions then and check if they satisfy the specified characteristics 8 3 9 Alternator 9 ALTERNATOR As a representative example of alternator the alternators of 20A and 40A are shown in this chapter 9 1 20A Alternator 9 1 1 Specifications Manufacturer s model Kokusan GP9191 Part Number 586400 2400 Rating Continuous Battery voltage V 12 Nominal output A 20 Rated revolution min 3 500 Operating revolution min 1 400 6 600 Grounding characteristics Minus side grounding Direction of revolution viewed from pulley Clockwise Integrated regulator IC regulator Weight kg 1 8 Pulley outside diameter mm 65 for A belt or 58 for special M belt Belt shape Type A or type special M 9 1 9 Alternator 9 1 2 Structure Coil Plate Coupl
37. valve caps Point 11 Remove the cylinder head assy and head gasket Point8 12 Remove the fuel injection valves and fuel return pipe Point9 13 Remove the intake exhaust valves stem seals and valve springs Point10 14 Remove the rocker arms from the rocker shaft 4 2 3 Reassembly procedure Reverse order of the disassembly procedure E UM plier head p 13 3 Theemosion SE Cooling sweater pun Nate Tris figure snows the 3TNVZR 2 Valve cylinder head T Recker arm caver H e um 1 Rocker arm suport e M H z A cua Ne d c d iRockeram G Sd L i ud ES 1 8 whi oe UR P Racker arm 08 E haf RU d snan Mu v Valve cap A S dE EEN IN ec E E Cotter RSA R Spring holder 7 Valve sprin P Stem seal E D og vane m guide j d JJ 8 5 Q S W 3 Qe ER 2 p Wo H r PM Cylinder head d Exhaust valve Suction valve 4 Disassembly Inspection and Reassembly of Engines 4 2 4 Reverse order of the disassembly procedure Servicing points Adjust the V belt tension inserting a bar Point1 j Disassemble Fs ai Loosen the mounting bolt while supporting the 2A alternator A CAUTION Do not tilt the alternator toward the cylinder block in haste since it may damage the alternator or pinch a finger Reassemble The belt deflection shall be checked according to 2 2 2 in Chapter2 Reassemble Replace the
38. valve timing Incorrect valve clearance Adjust the valve clearance See 2 2 6 3 in Chapter 2 Cylinder head gasket Gas leak from gasket Replace the gasket e Retighten the cylinder head bolts to the specified torque See 4 2 2 12 in Chapter 4 Intake exhaust vale Gas leak due to worn Lap the valve seat Valve seat valve seat or foreign See 4 2 6 in Chapter 4 matter trapping Replace the intake exhaust valve e Sticking valve Piston Gas leak due to Perform honing and use an oversized part Piston ring scratching or wear See 4 4 5 and 4 4 6 in Chapter 4 Cylinder 3 6 4 Disassembly Inspection and Reassembly of Engines 4 Disassembly Inspection and Reassembly of Engines 4 1 Complete disassembly and reassembly 4 1 1 Introduction Make preparation as follows before starting engine inspection and service 1 Fix the engine on a horizontal base A CAUTION Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work 2 Remove the coolant water hose fuel oil pipe wire harness control wires etc connecting the driven machine and engine and drain coolant water lubricating oil and fuel 3 Clean soil oil dust etc from the engine by washing with solvent air steam etc Carefully operate so as to prevent any foreign matter from entering the engine A CAUTION Always wear glasses or other prot
39. volume Preferably it should be below 0 05 For alternative fuel Bio fuel such as FAME JP 8 please contact ISUZU Water and sediment in the fuel oil should not exceed 0 05 by volume Ash should not exceed 0 01 by mass 10 Carbon residue content of the fuel It should not exceed 0 35 by volume Preferably it should be below 0 1 96 Aromatics total content of the fuel It should not exceed 35 by volume Preferably it should be below 30 and aromatics PAH content of the fuel preferably it should be below 10 PAH polycyclic aromatic hydrocarbons DO NOT use Biocide DO NOT use Kerosene residual fuels DO NOT mix winter fuel and summer fuel Note Engine breakdown can be attributed to insufficient quality of fuel oil Fuel handling 2 Fuel handling e Water and dust in the fuel oil can cause operation failure Use containers which are clean inside to store fuel oil Store the containers away from rain water and dust Pump up only the fuel Before supplying fuel let the fuel container rest for in the upper half to s 4 leave dregs near the bottom several hours so that water and dust in the fuel are deposited on the bottom Pump up only the clean fuel 1 5 1 General 3 Fuel tank Be sure to attach a drain cock precipitation trap and primary strainer to the fuel tank as shown illustration right 1 6 Filler port Fuel return connection Primary strainer Outlet to engine
40. 400 6970 Pin machining dimension Pin machining dimension mm 41 702 to 41 712 Crank journal mm Item Standard Journal O D 46 952 to 46 962 Oil clearance 0 020 to 0 050 Roundness 0 01 or less If the clearance limit is exceeded use an undersized bearing and machine the crank journal into the valve of the below table Undersized bearing 0 25mm Code No assy 586400 8740 Crankshaft Journal machining dimension Journal machining dimension mm 46 702 to 46 712 4 39 4 Disassembly Inspection and Reassembly of Engines e Dimension R and finishing precision of crankshaft journal and pin As for grinding processing of journal and pin ET pelismng machine it by using the grinding wheel of the y dimension R of below table AX i of Hyd es Thnest face Jacq Finishing precision standard of dimension R 3 5 0 3 0 lg d 1 IK Surface finishing precision standard on journal Crank Pin Crank Journal and pin Crankshaft R machining Ry 0 8S super polishing Surface finishing precision standard on the thrust side of crankshaft arm 16 v NOTICE 1 If the oil clearance is excessive though the thicknesses of the journal and crankpin metals are normal or if partial uneven wear is observed re grind the crankshaft and use an oversized metals 2 If rust or surface roughening exists on the rear side of the metals coat it w
41. 5 Regarding lamp control Once the charge lamp goes out after the start of charging it does not come on again even if the engine speed falls and charging is insufficient The lamp will not light again if the charging circuit is normal The lamp only comes on during operation if the alternator itself is broken or the drive V belt breaks However when an LED is used for the charge lamp the LED will shine faintly even during normal operation This is due to the control system for the alternator lamp and is not an abnormality 6 Use of a non specified V belt Use of a non specified V belt will cause inadequate charging and shorten the life of the belt Use a belt of the specified type 7 Direct high pressure washing is prohibited Water will enter the brush if the alternator is washed directly at high pressure causing inadequate charging Warn users not to use direct high pressure washing 8 Use of agricultural or other chemicals direct contact or airborne Adhesion of agricultural and other chemicals especially those with high sulfur content to the IC regulator corrodes the conductor on the substrate leading to over charging battery boiling and charging malfunctions Consult with Isuzu prior to use in such an environment Use without prior consultation removes any breakdown from the warranty 10 2 10 Electric Wiring 10 1 2 Starter In the cases listed below the warranty shall not be deemed to apply Please be sure to read th
42. 605 3815 High idling mi 25 25 25 25 25 25 25 25 25 25 25 25 25 Engine mass dry with flywheel housing kg 83 P T O position Flywheel side Direction of rotation Counter clockwise viewed from flywheel side Cooling system Water cooled radiator Lubricating system Forced lubrication with trochoid pump Starting system m Electric starting Starter motor DC12V1 0kW Alternator DC12V18A 9 Sy Recommended battery capacity 12V36Ah 5h rating for 12V1 0kW S motor Dimensions LxW xH mm 504x427x506 504x427x536 504x427x506 GE capacity L 2 8 1 5 Dipstick upper limit lower limit 8 5 20 2 8 1 5 Cooling water L 0 9 capacity engine 310mm O D Cooling fan std 5 blades pusher type Engine mass and dimensions without radiator 1 3 1 General 3 3CB1 Engine model 3CB1 Version VM Type Gem Vertical inline water cooled diesel engine Combustion system swirl chamber ball type Aspiration Natural No of cylinder 3 Bore x Stroke mm 76x82 Displacement L 1 115 Max rated output net kW min 11 8 2000 13 2 2200 14 3 2400 15 5 2600 16 7 2800 17 9 3000 Engine speed PS 16 1 16 1 19 5 21 1 22 7 24 3 High idling min 2160 25 2355 25 2570 25 2780 25 2995 25 3210 25 sith fioel honig 2 tp P T O position Flywheel side Direction of rotation Count
43. Diaphragm assy inspection Intake exhaust valve clearance adjustment Fuel injection nozzle pressure inspection 1 Coolant water replacement Coolant water contaminated with rust or water scale reduces the cooling effect Even when antifreeze agent LLC is mixed the coolant water gets contaminated due to deteriorated ingredients Replace the coolant water at least once a year Fill the radiator and coolant recovery tank with the cooling water as following 1 Remove the radiator cap Never open the radiator filler cap while the engine and radiator are still hot i A WARNING Steam and hot water will spurt out and seriously burn you g Wait until the radiator is cooled down after the engine has stopped wrap the filler cap with a rag piece and turn the cap e slowly to gently release the pressure inside the radiator Securely tighten the filler cap after checking the radiator Steam can spurt out during operation if the cap is tightened loosely 2 Loosen the drain plug at the lower portion of the radiator and drain the coolant water OPTION 3 After draining the coolant water tighten the drain plug 4 Fill radiator and engine with coolant water Before filling check to be sure the drain plug is closed Bromide the radiator cap of the radiator by turning the radiator cap counter clockwise about 1 3 of a turn a Pour the cooling water slowly into the radiator up to the lip of the filler port so that ai
44. EE 1 1 1 3 Fuel Oil Lubricating Oil and Coolant Water ENNEN 1 6 EH E Ke TT P etree ey 1 6 1 3 2 Lubricating Oil nc neha tie ee OA RN et ad cee e ER 1 8 ee AT 1 9 1 4 Engine External MEWS ss eraot etras Ee asd eoo doped eb pg aee Deep sto pee m pet re rag ue pi eoo 1 10 1 5 Structural Brew onion rr net ment 1 11 1 6 Exhaust gas emission regulation EEN 1 12 1 61 The Emission Standard RI NET iot eroe tte tle eoe oett ole oat wall cat act ita la at 1 12 16 2 en le nee eee 1 13 1 6 3 Guarantee Conditions for the EPA Emission Standard sss 1 14 2 Inspection and Ad uslmehl EE 2 1 2 1 Periodic Maintenance Gchedule AAA 2 1 2 2 Periodic Inspection and Maintenance Procedure ssessssssserreeesssrrrrresssrrrnnresserrrnnreserrenne 2 3 2 2 1 Check before Dally ODBISUOIT s caos roto etas rot cessa ntes ntt esee Lat eode 2 3 2 2 2 inspection after initial 50 hours operation emen 2 5 2 2 3 Inspection every E Al IC 2 8 2 2 4 Inspection every 250 hours or 3 months enne 2 12 2 2 5 Inspection every 500 hours or 6 months emen 2 15 2 2 6 Inspection every 1 000 hours or one year 2 17 2 2 7 Inspection every 2000 hours or 2 years ssssssessseeeneeeen emere 2 24 2 3 Adjusting the no load maximum or minimum speed 2 26 2 A OCNSOMINSDOGUON RR p c EE 2 27 241 Oi EE 2 27 2 4 2 Thermo Ee BE 2 27 2 5 Water leak check in cooling wate
45. IDE 2397 PRINTED IN JAPAN TWANVIN dOHSXHOM N o gt P o gt P IT UJ INDUSTRIAL DIESEL ENGINE 2CA1 3CA1 3CB1 MODELS WORKSHOP MANUAL ISUZU MOTORS LIMITED PREFACE This manual describes the service procedures for the 3C series engines of indirect injection system that have been certified by the US EPA California ARB and or the 97 68 EC Directive for industrial use Please use this manual for accurate quick and safe servicing of the said engine Since the explanation in this manual assumes the standard type engine the specifications and components may partially be different from the engine installed on individual work equipment power generator pump compressor etc Please also refer to the service manual for each work equipment for details The specifications and components may be subject to change for improvement of the engine quality without notice If any modification of the contents described herein becomes necessary it will be notified in the form of correction information each time California California Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts terminals and related constituents are known to the State of accessories contain lead and lead California to cause cancer birth defects compounds chemicals known to the and other reproductive harm state of California to cause cancer and reproductive harm Wash hands after handling
46. NTED SURFACE MAY NOT BE USED FOR EARTHING AVOIDING THE MISS CONTACT 2 BATTERY TREATMENT MUST BE OBSERVED AS FOLLOWS OTHERWISE IT MAY CAUSE BURNING OF ELECTRIC EQUIPMENTS OR COMPONENTS ALTERNATOR DIODES BURNING CAUSED BY BATTERY CABLE CONNECTION REVERSELY IS NOT WARRANTED 2 1 BATTERY SHOULD BE FIXED BY FITTING NOT TO MOVE 2 2 BATTERY CABLE LENGTH SHOULD BE ADJUSTED PROPERLY AND CLAMPED NOT TO BE CONNECTED REVERSELY 2 3 NOT LOOSE THE BATTERY CABLE TERMINAL NOR TURN THE BATTERY SWITCH OFF DURING THE ENGINE RUNNING 3 ONLY THE SPECIFIED LOAD SHOULD BE APPLIED ON THE ALTERNATOR L AND TE LINE IT IS NOT ALLOWED TO CONNECT ANY LOAD UNSPECIFIED WITHOUT YANMAR APPROVAL 4 CHECK ANY SURGE CURRENT OR VOLTAGE OCCURED UNDER NORMAL OPERATIONS AND EXPECTIVE ERRONEOUS OPERATIONS AND CONFIRM THE CIRCUIT NO SURGE OCCURS ESPECIALLY PROVIDE THE FLYWHEEL DIODE FOR C LOAD AND DIODE FOR L LOAD w 180 0442 0443 JUL DF GU nu 1511 Bass vini mo YAZAKI WO niae 023 228 GR B3 ne RF PRE HEAT LAMPCAF TER 15 DFF LESS THAN 34V 00 cepe ss iA Mt REMARKS Sumi TOMO NO ere We E 6196 0021 10 1 CONNECTED TO BATTER GROUND SHOULD BE DIRECTLY 1 X MARKED PARTS ARE NOT PROVIDED BY vatari NO ELECTRICAL FEED PUMP ssa ruse HN UE od m een SI E pito LAM Eat Pian pae a od ia 00 E p 9 o Prof LAMP i THAN A E van e UES SEC zm T123 024 40 Bgu
47. Oil seal replacement Gear case side 1 Replace the oil seal with a new one when the gear case is disassembled Cronkehalt Gear case Extract the used oil seal S 2 Insert a new oil seal by using the oil seal insertion tool on the position of the gear case end face Refer to the right figure 3 Apply lithium grease to the oil seal lips 4 When wear is found on the oil seal contact part of a crankshaft pulley replace the pulley with a new one Carefully install the pulley so as not to damage the oil seal Replacement of a gear case oil seal 4 3 7 Camshaft bushing replacement Replace the bushing using the special service tool Refer to No 7 of 4 1 2 in Chapter 4 4 30 4 Disassembly Inspection and Reassembly of Engines 4 4 Cylinder Block 4 4 1 Components Note Te figu shaws he 2CB1 4 4 2 Disassembly procedure Disassemble in the order of the numbers in the illustration 1 Perform steps 1 to 15 in the cylinder head disassembly procedure 2 Perform steps 1 to 12 in the gear train disassembly procedure 3 Remove the oil pan and the spacer See Point 1 of 4 4 6 4 Remove the lube oil suction pipe 5 Remove the piston w rod See Point 2 of 4 4 6 6 Remove the mounting flange See Point 3 of 4 4 6 7 Remove the bearing metal caps See Point 4 of 4 4 6 8 Remove the crankshaft See Point 5 of 4 4 6 9 Remove the tappets 10 Remove the rings from the piston See Point 6 of 4 4 6 11 Remov
48. Sod polt 719g 2 mm and radiator fan 2 2 2 2 at 98 N 10 kgf Direction S New part 5108 Between radiator Used part 9 to 13 2 fan and crank pulley Direction C New part 7 to 11 Fuel injection pressure 11 8 to 12 8 3 MPa kgf cm 120 to 130 uia Fuel injection timing FID Refer to 2 2 7 4 in 3 degrees bTDC chapter 2 MAE Compression pressure 2CA1 3CA1 3 24 33 0 1 1 2 55 26 0 1 1 5 at 250 min 3 3 MPa kgf cm 3CB1 3 43 35 0 1 1 2 75 28 0 1 1 Cooling water Capacity 2CA1 0 6 z 6 Only engine body 2 2 1 4 Liter 3CA1 3CB1 0 9 Model Total Effective 2CA1 VM 1 7 0 7 Lube oil capacity 3CA1 VH VM 2 8 1 3 7 ol pan 2 2 1 3 Liter 3CA1 CH 3 8 1 7 3CB1 VM VH 3 5 1 6 3CB1 CH 4 4 2 1 Lube oil pressure at rated speed at low idle speed 8 0 29 3 0 to 0 44 MPa kgf cm 4 5 0 06 0 6 or above S 9 Oil pressure switch operating pressure 0 05 0 01 MPa kgf cm 0 5 0 1 valve opening Full opening lift temperature mm 10 Thermostat deg C temperature 2 7 8 or above 69 5 to 72 5 85 deg C 11 Thermo switch actuating temperature 107 to 113 2 4 2 deg C 11 Service Standards 11 2 Engine Body 11 2 1 Cylinder head 1 Cylinder head mm Inspection item Standard Limit Reference page Combustion surface distortion mm 0 05 or less 0 15 Valve sink Intake 0 4 to 0 6 0 9 4 2 5 1 mm Exhaust 0 4 to 0 6 0 8 In
49. acteristics ek 8 1 8 2 The structure of a starting motor and the wiring diagram seeeeeeeeeeeese 8 2 8 2 ASTUCE cec t t MRC URN rr RITE MR a a SM RoR Coto Pet Sr ROTTS ER To ete 8 2 8 2 2 Wiring diagram of a starting motor emm nenne 8 3 S S PENONNENGO voc oed uh cU uM Ae eee RE Ee EUR 8 3 9 ALTERNATOR E 9 1 S ZAA 21 CS E 9 1 SEH eegene eege ee 9 1 SA ERI iU Os Sata ae nce esate EE P ERN 9 2 9 1 3 Wining diagram DEED BPO DEO Pee mene 9 3 9 1 4 Standard outputeharacteristibS aae a et cet e es 9 3 9 1 54nspection zs em cete e o Ett bete Pe 9 4 9 2 A0A Altertiator ane Ra e RR Ria 9 5 9 2 1 Comporignits i st e REOR DEED OO EDD E o SEO Leld cd 9 5 9 2 2 SMECHICAMOMS eut SEENA Ricco ete tete eeu et bott ote ah alt hla ollie ete ele latte tcl eed e eS hd 9 6 9 2 3 Wiring CAG EI 9 6 9 2 4 Standard Ke tieren e 9 7 9 2 5 Inspection o pspRROPRERRROERPIHROPOOOOOROPOOOOPERPOPODPOOOOOB RICE ei et beets 9 7 9 3 TroubleshoOllng eee et e inb tempo n Se eu tr EE eile See 9 8 10 ELEGTRIG WIRING EE 10 1 10 1 Electric Wiring Diagram sco iE OR eere pe eate veo Ber Deere i Benet e i abt eee eos 10 1 AR WE Ee EE 10 2 le WE e E EE 10 3 10 153 Current Mile EE 10 4 10 1 4 Section area and resistance of electric wire seen 10 5 TL SERVICE STANDARDS Ehe des dtt in eof edad she diode 11 1 UR Dag SENG ING LINING a soos oro i tese td eaters ROM asia e E du AE M 11 1 11 2 Engine Body n teen a
50. adiator Lubricating system m Forced lubrication with trochoid pump amp rartirsvetem m Electric starting Starter motor DC12V1 0kW Alternator DC12V18A 9 sy Recommended battery capacity 12V36Ah 5h rating for 12V1 0kW S motor Me EHE mm 416x427x484 504x427x536 416x427x484 GE capacity L 1 6 0 8 Dipstick upper limit lower limit 2 3 1 3 1 6 0 8 4 Cooling water L 0 6 capacity engine 290mm O D Cooling fan std 5 blades pusher type 1 2 1 General 2 3CA1 Engine model 3CA1 Version CL VM CH VH Type Vertical inline water cooled diesel engine Combustion system Swirl chamber ball type Aspiration Natural No of cylinder E 3 Bore x Stroke mm 70x74 Displacement L 0 854 in 6 09 7 29 8 16 9 76 Continuous rated output kW min 1500 1800 3000 3600 Engine speed PS 8 27 9 91 16 5 19 7 int 6 69 8 02 8 97 9 93 11 0 11 8 12 8 13 7 13 3 16 0 14 0 14 7 15 4 Max rated output net KW min 1505 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 Engine speed PS 9 1 10 9 12 2 13 5 14 9 16 1 17 4 18 6 18 1 21 7 19 0 20 0 21 0 Kat ce 1 1585 1880 2160 2355 2570 2780 2995 3210 3165 3760 3390 3
51. alve clearance adjustment 2 19 2 Inspection and Adjustment 4 Fuel injection nozzle pressure inspection A CAUTION Wear protective glasses when testing injection from the fuel injection valve Never approach the injection nozzle portion with ahand The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it a Injection pressure measurement Standard Mpa kgf cm 11 8 to 12 8 120 130 NOTICE e Nozzle tester As for the opening pressure of the brand new fuel nozzle about 0 5Mpa 5kgf cm declines by the engine operation for about 5 hours because of the initial wear out of a spring etc Therefore adjust 0 5MPa 5kgf cm higher than the standard value of the above table when adjusting a new fuel nozzle of a spare part Injection pressure measurement with nozzle tester Remove carbon deposit at the nozzle hole thoroughly before measurement 1 Connect the fuel injection valve to the high pressure pipe of the nozzle tester 2 Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from the nozzle starts 3 If the measured injection pressure is lower than the standard level replace the pressure adjusting shim with a thicker one Thickness of pressure adjusting shims Injection pressure adjustment mm The injection pressure is increased by approx 6 9 to 9 8 MPa 7 to 0 1 0 2
52. and pull out the element 2 12 2 Inspection and Adjustment 3 Blow air 0 29 0 49MPa 3 0 5 0kgf cm from inside the element to blow dust off as shown in the illustration right Apply the air blowing pressure as low as possible so as not to damage the element If having the air cleaner with double elements never remove and clean the inner element The aim of installing the inner element is for back up protecting from intake dust during engine running when leaving the outer element to reinstall after removing it or when damaging the outer element unexpectedly during engine running 4 Replace the element with new one If the element is damaged excessively dirty or oily 5 Clean inside of the dust pan 6 Reinstall the element inserting into the air cleaner And install the dust pan to the air cleaner case matching the arrow marks or the dust pan and air cleaner case then fasten the dust pan with the latches IMPORTANT When the engine is operated in dusty conditions clean the element more frequently Do not run the engine with removed air cleaner or element as this may cause foreign material to enter and damage the engine 2 13 Dust indicator optional Air cleaner case Arrow mark Double elements type air cleaner eie with inner and outer element 2 Inspection and Adjustment 2 2 5 Inspection every 500 hours or 6 months Be sure to check the following points every 500 hours or 6
53. belt with a new one if cracked worn or damaged Carefully prevent the belt from being smeared with oil or grease Point2 Reassemble Check the thermostat function See2 7 in Chapter 2 for the check procedure E Pont3 f M Reassemble x Kee Sa with thum e Replace the fuel filter element with a new one Disassemble e Cover the fuel pipe opening with tape to prevent Spring e intrusion of foreign matters Center plate Point4 Diaphragm lt gt Reassemble e Replace the oil filter with a new one After fully tightening the filter manually retighten it d wrench see 4 1 2 1 in Chapter 4 by Baffle plate sat Mte Tr anilnrid Point5 Disassemble Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of foreign matters 3 Diaphragm cover lt er gt ibd Rocker arm cover t Ss M DUE Breather system componert Point6 Breather system A reductor to intake air system of Ae blowby gas Ew a E Emitting blowby gas is harmful to natural ECH E environment Therefore blowby gas reductor is l Spring adopted to 3C series naturally aspirated engines gee deeg apivegm cover as breather system zi earam sp cover Cylinder head i Blowby gas flow 4 13 4 Disassembly Inspection and Reassembly of Engines The system of model 3CB1 is shown as a representative of that breather system in the right figure Some of the combus
54. bleshooting installation removal replacement disassemble reassembly inspection adjustment and adjusting operation procedures for the 3C series engines with direct injection system Refer to the manufacturer s manual for each of the fuel injection pump governor starting motor and alternator except for their installation 2 How to Read the Explanations Precautions and key points for disassembly and reassembly of parts are described as points An exploded view sectional views a system diagram etc are shown at the beginning of each the explanation for each point detailed operation method information standard and precautions section as required for easy understanding of the mounted states of the components For the removal installation of each part the procedure is shown with the procedural step No in the illustration are described In Description Example Gear case flange Flywheel Flywheel hausing Fuel injection pump Ki amp dle gear Camshaft T5 Cooling water pump Starter d Ae P li d Tis ha j V yw ds ex La T Camshaft driving gear Ew E 2 EFF 7 Sa Se Ca A a p e As d Gi Sab ef S de Y f ol Pump tage E 5 OV J A ar ai as te f Gearcase FA Fuel pump drive gear Flange bolt DOil seal Don t disassemble Crankshaft pulley Note This figure shows the model 3CD1 The job contents are d
55. by the next troubleshooting guide and find out the cause of sincerity 3 1 3 Troubleshooting 3 2 Quick Reference Table for Troubleshooting The following table summarizes the general trouble symptoms and their causes E o 2 D gt a o E o c Ww Cooling Water System Trouble symptom Improper clearance of intake exhaust valve Starting failure Insufficient engine output Poor exhaust color Engine starts but stops soon Exhaust color During work Exhaust smoke High knocking sound during combustion Uneven combustion sound Hunting During idling During work Large engine vibration Difficulty in returning to low speed Excessive fuel consumption Lubricating oil Cooling water Air intake Excessive consumption Dilution by fuel oil Mixture with water Low L O pressure Much blow by gas Low water temperature Overheat Pressure rise If any trouble symptom occurs take corrective action before it becomes a serious problem so as not to shorten the engine service life Corrective action Q Engine does not start Adjust the valve clearance See 2 2 6 in Chapter2 Compression leakage from valve seat Q Q Exhaust temperature rise Lap the valve seat See 4 2 6 in Chapter4 Seizure of intake exhaust valve Q Q Q Q Abnormal engine sound Q O Q Q Pressure drop Correct or replace Blowout from cyl
56. c gravity of battery electrolyte is defined with 20 C as the standard Since the specific gravity increases or decreases by 0 0007 when the temperature varies by 1 C correct the value according to the equation below S20 St 0 007 t 20 Electrolyte temperature at measurement Specific gravity at measurement Converted specific gravity at 20 C Battery charge measurement with a hydrometer c Specific gravity and remaining battery charge Specific Discharged Remaining Rubber bulb gravity quantity charge of electricity 20 C Glass tube 1 28 100 1 26 90 1 24 80 1 23 75 Hydrometer structure 3 Terminals Clean if corroded or soiled 4 Mounting bracket Repair or replace it if corroded Retighten if loosened 5 Battery appearance Replace the battery if cracked or deformed Clean with fresh water if contaminated How to read hydrometer 2 10 2 Inspection and Adjustment 2 2 4 Inspection every 250 hours or 3 months Be sure to check the following points every 250 hours or 3 months operation whichever comes first No Inspection Item 1 Lube oil and filter replacement 2 Radiator fin cleaning 4 Inspection and adjustment of governor lever and accelerator 1 2 3 V belt tension check 4 5 5 Air cleaner cleaning and element replacement 1 Lube oil and filter replacement The second replacem
57. container filled with water Heat it while measuring the water temperature and see that the thermostat is actuated at temperature of following table Valve opening Full open lift Model Temperature Temperature Thermostat deg C mm All models 69 5 72 5 8 or more 85deg C Valve opening temperature is carved on the flange 2 27 2 Inspection and Adjustment 2 8 Adjusting Operation Perform the adjusting operation of a engine as follows after the maintenance job 1 Supply the fuel oil lubricating oil and coolant water Note Check the levels of the lubricating oil and coolant water again after test running for about 5 minutes and add as required 2 Start the engine and carry out idling at a low revolution 700 to 900 rpm for a few minutes 3 Run in the engine for about five minutes at the rated revolution no load Check any water fuel or oil leak and existence of abnormal vibration or noise Also check the oil pressure coolant water temperature and exhaust gas color 4 Adjust the no load minimum and maximum revolutions Refer to 2 3 in chapter2 5 Perform loaded operation as required 2 9 Long storage Observe the following instructions when the engine is to be stored for a long period without operation 1 Be sure to use clean soft water added Long Life Coolant Antifreeze LLC in the cooling water system and do not drain the coolant before long term storage If drain the cooling water it wil
58. d engine oil d B Lap with engine oil only 2 If the seat is heavily roughened but the width is almost normal correct with a seat grinder or seat cutter first Then perform lapping A and B Cylinder head correction angle I CN intake Exhaust Seat cutter angle 120 90 3 If the seat is heavily roughened and the width is much enlarged grind the seat inner surface with a seat grinder whose center angle is 40 then grind the seat outer surface with a grinder whose center angle is 150 to make the seat width match the standard Then perform seat correction as described in 2 and then carry out lapping A and B Seat cutter 01 02 40 150 Grinding wheel angle Seat grinder 4 21 4 Disassembly Inspection and Reassembly of Engines 4 2 7 Valve guide replacement 1 Use a valve guide extraction tool 1 1 2 1 in Chapter 4 and extract the valve guide from the cylinder head 2 Put liquid nitrogen or ether or alcohol with dry ice added in a container and put the valve guide for replacement in it for cooling Then insert it in with a valve guide inserting tool Refer to No 2 of 4 1 2 in Chapter 4 A CAUTION Do not touch the cooled valve guide with bare hands to avoid skin damage 3 Check the inside diameter and finish to the standard inside diameter as required with a reamer 4 Check the projection from the cylinder head mm Projection 9 8 to 10 0 4 22 Valve
59. defects and wear Slight surface defects shall be corrected with an oilstone Items Standard Limit Arm hole diameter 12 000 to 12 020 12 07 Shaft O D 11 966 to 11 984 11 94 Clearance 0 016 to 0 054 0 13 6 Rocker arm shaft Mainly inspect seizure and wear at the surface in sliding contact with the arm The rocker shaft diameter shall be as specified in 5 above Rocker shaft outside diameter 7 Push rod Mainly inspect the surface in contact with the tappet and adjusting screw Slight defects shall be corrected with an oilstone 8 Valve clearance adjusting screw Mainly inspect the surface in contact with the push rod Slight defects shall be corrected with an oilstone Push rod bend 9 Rocker arm spring Mainly inspect surface defects and corrosion 4 20 4 Disassembly Inspection and Reassembly of Engines 4 2 6 Valve seat correction NOTICE Always check the oil clearance between the valve and valve guide before correcting the valve seat If it exceeds the limit replace the valve or valve guide first to make the clearance satisfy the standard After correction wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder or compound 1 If the seat surface is slightly roughened perform z A and B below We angle s A Lap the valve and seat with a mixture of i d aif qe Grp NEMA Y ET e g Bs e T T t valve compound an
60. dial gauge to the end of crankshaft Force the crankshaft on both sides in the axial direction to measure the thrust gap Alternatively insert a thickness gauge directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap Refer to 4 4 4 in chapter 4 If the limit size is exceeded replace the thrust metal with a new one 2 Notice on the removal of thrust metal a When removing thrust metal ascertain the position and direction where thrust metal is installed in relation to the cap b Make sure that the thrust metal groove is outward in relation to the cap 1 Remove piston and connecting rod assembly 1 To selectively remove a desired piston and connecting rod assembly without extracting crankshaft take the steps itemized below a Remove carbon deposits from the upper wall of the cylinder using fine sandpaper taking care not to damage the inner surface of the cylinder b While turning the crankshaft with the connecting rod cap removed raise the piston up to the top dead center TDC c Extract the piston connecting rod assembly while tapping the connecting rod at the large end with the handle of a plastic hammer or the like 2 Remove tappet 4 10 4 Disassembly Inspection and Reassembly of Engines 4 1 4 Precautions before and during reassembly To reassemble engine components reverse the procedure of disassembly However follow the precautions bel
61. diameter Piston outside diameter Outside diameter Model Standard 69 960 to 69 990 75 955 to 75 985 mm Measurement position H 22 to 25 22 to 25 Clearance between piston and cylinder 0 030 to 0 050 0 035 to 0 055 2CA1 3CA1 3CB1 If the piston outside diameter exceeds the limit replace the piston with new one If necessary use an oversized piston Refer to the tables of oversized pistons oversized piston rings and cylinder boring dimension in 4 4 5 1 c Selective pairing of cylinder and piston Piston must be paired with cylinder according to the below table The size mark of a piston is shown on the top surface of the piston and the size mark of a cylinder block is shown on the non operating side of the cylinder block The service parts of pistons are provided mm Piston outside diameter D2 SC 40 015 max below 0 005 below 0 below 0 005 0 005 min 0 min 0 005 min 0 015 min Size mark L ML MS S 40 030 max Oylinder 0 020 min S Q Q s a Inside below 4 0 020 Diameter 40 010 min M Q Q d D1 below 40 010 0 min S s Q Q mm Model Cylinder inside diameter Piston outside diameter D1 D2 2CA1 3CA1 70 69 975 3CB1 76 75 970 4 41 4 Disassembly Inspection and Reassembly of Engines b Piston pin hole measurement Measure the outside diameter of piston pin and the inside diameter of piston pin hole Ca
62. disassembly Peripheral parts such as air cleaner muffler and radiator differ in installation and types for each application Therefore description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed Removal Parts Remarks 1 Thoroughly remove sand dust dirt and soil from the surface of the engine 2 Drain coolant water and lubricating oil from the engine 1 Remove exhaust manifold 2 Remove intake manifold Close the fuel cock valve of the fuel tank Remove high pressure fuel pipe Remove fuel return pipe Remove fuel injection nozzle Fuel injection nozzle for Indirect injection System is screwed type 1 If nozzle seat is left on the cylinder head remove the cylinder head before extracting nozzle seat 2 To prevent dust from entering fuel injection nozzle fuel injection pump and high pressure fuel pipe seal their respective threads with a tape or the like 3 Whenever extracting fuel injection nozzle replace nozzle protector with a new one 1 Remove rocker arm cover assembly 1 Remove valve rocker arm shaft assembly 2 Remove push rod 1 Attach a tag to push rod for each cylinder No to put the push rod in order 2 Remove valve cap from the intake exhaust valve head 3 Tappet can be removed at the same time when push rod is extracted 4 Attach a tag to tappet for each cylinder No to put the tappet in order 1 Remove
63. e i H de 6rey5 ay seg 2 SS Lom a sete BEE z i JOEL aur joedsur pue j Bupi yy Heq uei aui PEN 10 o ur dna E Ee eer SE PE es or NIS pA NO pe m i SE sd 4 EN REL eme sues ouibus aul AE lawl a D uojuws Ao ayy Mb UPL KEN ul LST be RUNE jesse mu Sd es pue ao 9 40104 aw eu NO NO Aejnpoegnugu SUSEL us up BY ME wi e geue e ss due sBleus ay p j EMO 805 X duet afugua eu sao Se y AS Ee LNG 3ulo23 Ye a o dwg aen au saejda l gin ees dive seya ej saog B da0 A Jaidnoo apis aunpew vaaup Ss aide NO 19euucosiq ddO MOO Aus fay un MA ER EE a Pe ig AEC ke x SU JO teunuda punoimr 7 AES EM E AGAR ACCRUE 9 8 10 Electric Wiring 10 ELECTRIC WIRING 10 1 Electric Wiring Diagram AU C BR Be STARTOH ototo e KEY SW DIAGRAM Av 3 MARK COLOR B Black W White R Red G jGreen CC Br Brown pum Sb Sky blue O jOrange P Pink Gr Gray Red White NOTES 1 WIRING OF STARTER MUST BE OBSERVED AS FOLLOWS OTHERWISE IT CAUSES MISS STARTING UR DAMAGE 1 1 TOTAL ELECTRIC RESISTANCE OF BATTERY CABLE SHOULD BE LESS THAN 2 10000 REFERENCE AVI5 1 4m AV20 2 2m AV30 3 B8m AVA40 4 6m 1 2 TOTAL ELECTRIC RESISTANCE OF WIRING FOR STARTER SHOULD BE LESS THAN 5 1000 REFERENCE OF TERMINAL RESISTANCE 15710009 PER COUPLER OQ PER SCREW SETTIG 1 3 BATTERY EARTH CABLE Chi CONNECTION SHALL BE ENSURED PAI
64. e A K PF T Camshat driving gean S Fuel mjeclion pump pt J yo ei AN T w KE Pi Crankshaft gear D pU E i C y 7 r Pump TT ad iJ d Don t disassemble Fuel pump drive gear Flange bolt Note This figure shows the 3CB1 3 Crankshaft pulley 4 3 2 Disassembly procedure Disassemble in the order of the numbers in the illustration 1 Perform steps 1 to 12 of the cylinder head disassembly procedure 3 Remove the crankshaft pulley See Point 1 of 4 3 4 4 Remove the gear case cover See Point 2 of 4 3 4 5 Remove the fuel injection pump See Point 3 of 4 3 4 6 Remove the idle gear assy See Point 4 of 4 3 4 7 Remove the PTO drive gear See Point 5 of 4 3 4 8 Remove the starting motor 9 Remove the flywheel See Point 6 of 4 3 4 10 Remove the camshaft assy See Point 7 of 4 3 4 11 Remove the gear case See Point 8 of 4 3 4 12 Remove the oil seal from the gear case cover See 4 3 6 4 3 3 Reassembly procedure Reverse of the disassembly procedure 4 24 4 Disassembly Inspection and Reassembly of Engines 4 3 4 Servicing points Point1 Disassemble e Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley set bolt When removing the pulley using the gear puller use a pad and carefully operate so as not to damage the thread Set the gear puller securely to prevent the pulley from being damaged Reassemble When installing the cran
65. e crankshaft gear is shrink fitted heat to 180 to 200 C when extraction is necessary a Shaft portion color check After washing the crankshaft inspect it by means of color check or a magnaflux inspector Replace it if cracked or heavily damaged Slight defects shall be corrected by grinding b Crankshaft bend Support the crankshaft journals at both ends with V blocks Use a dial gage and measure the runout at the center journal while rotating the shaft to inspect the bend The bend is half of the run out value 0 01 mm or less Deflection Dial gage Wat V block V block Crankshaft bend measurement c Crankpin and journal measurement Measure the outside diameter roundness and taper at each crankpin and journal Correct by grinding if unevenly wear roundness exceeding the limit or insufficient outside diameter is found Replace if the defect is excessive Crankshaft A journal Crankpin Measuring position of the crankpin and crank journal 4 38 4 Disassembly Inspection and Reassembly of Engines Crankpin If a clearance is necessary measure the inside diameter by following 5 d Rod big end measurement and calculate it Model amp Item Standard Pin outside diameter 41 952 to 41 962 Oil clearance 0 020 to 0 050 Roundness 0 01 or less If the oil clearance exceeds the limit use an undersized bearing Undersized crankpin bearing 0 25 mm Code No assy 586
66. e the oil seal from the flywheel housing See 4 4 8 Fo wa 4 4 3 Reassembly procedure Reverse of the disassembly procedure 4 31 4 Disassembly Inspection and Reassembly of Engines 4 4 4 Servicing points Point Oil pan Disassemble Sealant is applied to the oil pan mounting surface on the block Carefully operate so as not to damage or distort the bonding surface Reassemble Apply sealant TB1207B or equivalent before reassembly Point2 Piston w rod Disassemble Measure the connecting rod side gap mm Standard 0 20 to 0 40 d ooo Connecting rod side gap Carefully remove the carbon deposit on top of the cylinder so as not to damage the inner side of the cylinder Set the piston at the BDC position and remove the connecting rod cap Then set the piston at the TDC position and push the connecting rod big end with the wooden shaft of a hammer Proceed carefully so as not to cause the cylinder block catch the rod big end Set the rod caps and crankpin metals in their correct combinations Reassemble Apply oil especially carefully to the sliding contact surfaces of the pistons rods and rings Use the piston insertion tool see 4 1 2 1 in Chapter 9 to insert each piston w rod in the cylinder block and install the bearing metal cap Rod bolt tightening torque N m kgf m Standard apply lube oil 22 6 to 27 5 2 3 to 2 8 Point3 Fl
67. e tightened in two steps in the reverse of the order for disassembly Head bolt disassembly order 3 cylinder head Assembl Camshaft side au D f 43 PR 3 D e Tightening torque et j za P lt A j i Nm kgf m am TY Tightening torque 9 L First step 26 0 to 30 0 2 7 to 3 1 it tightni d Second step 53 9 to 57 9 5 5 to 5 9 codem ar Point9 Disassembly Disassemble Carefully remove the fuel injection valve so as not to leave the top end protector from being left inside the cylinder Camshaft side Reassemble e Replace the fuel injection valve protector with a new one Head bolt disassembly order 2 cylinder head Assembly Camshaft side Fan side Head bolt tightning order 2 cylinder head 4 15 4 Disassembly Inspection and Reassembly of Engines Point10 Disassemble e When removing each intake exhaust valve from the cylinder head use a valve spring compressor see 4 1 2 4 in Chapter 4 and compress the valve spring and remove the valve cotter Keep each removed intake exhaust valve after attaching a tag showing the corresponding cylinder No f cotter burr is seen at the shaft of each intake exhaust valve stem remove it with an oilstone and extract the valve from the cylinder head Reassemble e Replace the stem seal with a new one when an intake exhaust valve is disassembled e Carefully install each val
68. earing caps cap side bearings and thrust metals Place each thrust metal with identification of the position and direction Carefully install each thrust metal so that the grooved one is positioned away from the cap Reassemble Do not confuse the upper and lower main bearing metals The upper main bearing metal block side has an oil hole and the lower one does not The wheel and arrow marks on the cap shall face the flywheel Main bearing cap bolt tightening torque apply lube oil N m kgf m Standard 75 5 to 81 5 7 7 to 8 3 Point5 Crankshaft Disassemble Remove the crankshaft Remove each main bearing metal upper block side and pair it with the metal cap side lower metal A CAUTION Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is heavy 4 34 4 Disassembly Inspection and Reassembly of Engines Point6 Piston pin and rings Rep Disassemble Using the piston ring replacer see 4 1 2 in Make the punched manufacturer s A Chapter 4 remove the piston rings eee S e Remove the circlip and remove the piston pin by pushing it out Reassemble Install each piston ring on the piston with the punched manufacturer s mark facing upward Piston ring Reassemble The piston ring joints shall be staggered at by Second 120 intervals Do not position the top ring joint ring joint vertical to the piston pin The coil
69. eat it to 180 C 200 C for extraction For camshaft removal raise the engine with its mounting flange at the bottom After removing the thrust metal mounting bolt from the camshaft gear hole extract the camshaft carefully so as not to damage the bearing bushing e Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam After removing the camshaft set the engine horizontal and fix it on the base A CAUTION Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the horizontal position Proceed carefully so as not to lose balance Point8 Gear case Reassemble Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case Apply sealant TB1207B or equivalent and install the gear case by matching the two dowel pints 4 27 4 Disassembly Inspection and Reassembly of Engines 4 3 5 Parts inspection and measurement 1 Camshaft Mainly check the contact between the tappet and cam contact surface bearing seizure and wear and gear damage a Shaft bend measurement Support the camshaft with V blocks Rotate the camshaft and measure the runout at the center of the Dial gage camshaft and at each journal with a dial gage Half of N the runout is the bend Item Standard Limit Bend 0 to 0 02 0 05 eV EN V block AR Camshaft bend
70. ectors when using compressed air or steam to prevent any foreign matter from getting in the eyes NOTICE Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit shall be replaced Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use should be replaced even when the measured value then satisfies the standard or limit 4 1 4 Disassembly Inspection and Reassembly of Engines 4 1 2 Special service tools 1 Special Tools Tool name Applicable model and tool size Illustration Valve guide tool for extracting valve guide mm L1 L2 d d2 20 75 5 5 9 5 Locally manufactured Valve guide tool e SE valve E I2 di 10 60 11 Locally manufactured Connecting rod a bushing replacer for removal L1 L2 di d2 installation of 25 85 22 25 connecting rod bushing Allowance dif d2 93 X Locally manufactured Valve spring compressor for removal installation of valve spring XLocally manufactured Stem seal inserter for inserting stem seal mm di d2 d3 Li L2 L3 15 21 12 11 65 4 or more XLocally manufactured 4 2 4 Disassembly Inspection and Reassembly of Engines Tool name Applicable model and tool size Illustration Filter wrench for removal installation of L O filter Available
71. ent and after Replace the engine oil every 250 hours operation from 2nd time and on Replace the engine oil filter at the same time Refer to 2 2 1 1 2 Radiator fin cleaning i A CAUTION Beware of dirt from air blowing d Wear protective equipment such as goggles to protect your eyes when blowing compressed air Dust or flying debris can hurt eyes Dirt and dust adhering on the radiator fins reduce the cooling performance causing overheating Make ita rule to check the radiator fins daily and clean as needed Blow off dirt and dust from fins and periphery with compressed air 0 19MPa 2kgf cm or less not to damage the fins with compressed air If contaminated heavily apply detergent thoroughly clean and rinse with tap water shower IMPORTANT Never use high pressure water or air from close by fins or never attempt to clean using a wire brush Radiator fins can be damaged Radiator fins 3 V belt tension check The second time and after Check and adjust the V belt tension Refer to 2 2 2 2 2 11 2 Inspection and Adjustment 4 Inspection and adjustment of governor lever and accelerator The governor lever and accelerating devices accelerating lever pedal etc of the machine unit are connected by an accelerating wire or rod If the wire becomes stretched or the connections loose the deviation in the position may result and make operation unsafe Check the wire periodically and adjust
72. er 9 2 9 Alternator 9 1 3 Wiring diagram Standard circuit composition for output confirmation lev Charge lamp Battery IC Regurator 3 i Generator NOTICE 1 Don t do mis connecting and short circuit of each terminal 2 Don t remove a battery terminal and a B terminal when rotating 3 Shut out a battery switch during the alternator stop 9 1 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure m T tn e ke 09 c ul um s lt c st I o a ce x a SZ Ka Gen bed eh e Kessel ei nn 3030750 DES Ee E oe E D dco za leie us v LNAYYND LAdLNO ALTERNATOR SPEED min 9 3 9 Alternator 9 1 5 Inspection 1 V belt inspection 1 Inspect the matter whether there are not crack stick iness and wear on the belt visually Check that a belt doesn t touch the bottom part of the pulley groove If necessary replace the V belt set 2 V belt tension Clearance Refer to 2 2 2 2 in Chapter 2 Defect 2 Visual check of wiring and check of unusual sound 1 Confirm whether wiring is right or there is no loose ness of the terminal part 2 Confirm that there is no unusual sound from the alternator during the engine operation Inspection of V pulley 3 Inspection of charge lamp c
73. er clockwise viewed from flywheel side Cooling system Water cooled radiator Lubricating system m Forced lubrication with trochoid pump Starting system Electric starting Starter motor DC12V1 1kW Alternator DC12V18A Recommended battery capacity 12V52Ah 5h rating for 12V1 1kKW S motor EE mm 485x436x535 pe capacity L 3 4 1 8 Dipstick upper limit lower limit Cooling water L 0 9 capacity engine Cooling fan std 335mm O D 6 blades pusher type Engine mass and dimensions without radiator 1 4 1 General 1 3 Fuel Oil Lubricating Oil and Coolant Water 1 3 1 Fuel oil IMPORTANT Only use the recommended fuel to obtain the best engine performance and prevent damage of parts also prevent air pollution 1 Selection of fuel oil Diesel fuel oil should comply with the following specifications The fuel specifications need to comply with each national standard or international standards ASIMD975 No 1 D e No 2 D for USA e EN590 90 for EU SO8217 DMX International BS 2869 A1 or A2 for UK JISK2204 for JAPAN The following requirements also need to be fulfilled Cetane number should be equal to 45 or higher Sulphur content of the fuel It should not exceed 0 5 by
74. escribed in the disassembly procedure for Nos not shown in the illustration 1 Follow steps 1 to 15 of the cylinder head disassembly procedure e Disassembly procedure 2 Remove the cooling water pump 3 Remove the crankshaft pulley Point 1 Operation point to be explained on a later page Operation points Disassemble Service point for removal Reassemble Service point for installation Disassemble Reassemble Service point required in both removal and installation Contents omitted in this manual Though the following jobs are omitted in the explanation in this manual they should be conducted in actual work 3 Jacking up and lifting 4 Cleaning and washing of removed parts as required 5 Visual inspection 3 Definition of Terms NOTICE Instruction whose negligence is very likely to cause an accident Always observe it Standard Allowable range for inspection and adjustment Limit The maximum or minimum value that must be satisfied during inspection or adjustment 4 Abbreviations Abbreviation Meaning Abbreviation Meaning Assy assembly T D C top dead center Sub Assy sub assembly B D C bottom dead center a T D C after top dead center OS oversize b T D C before top dead center US undersize Standard Min revolutions per minute Intake PS Output metric horsepower Exhaust T Bolt nut tightening torque CONTENTS Eeleren 1 1 1 1 Engine eene E 1 1 1 2 een
75. ese conditions carefully when planning to use it with other equipment Also be certain to give appropriate guidance on usage to the user 1 Starting performance in the case of using an untested battery The starting performance of the engine is closely dependent on the battery capacity This battery capacity is itself affected by the climate and the type of equipment installation The details regarding ambient temperature and equipment installation vary depending on the OEM so Isuzu cannot decide the battery capacity on its own Confer with Isuzu in advance after checking these conditions and fix the battery capacity on the basis of confirmatory tests 2 When the resistance of the battery cable exceeds the specified value The combined total resistance of the battery cable in both directions between the starting motor and battery should be within the value indicated on the wiring diagram The starting motor will malfunction or break down if the resistance is higher than the specified value 3 When the resistance of the starter circuit exceeds the specified value The combined total resistance of the wiring between the starting motor and key switch or power relay or safety relay depending on the application should be within the value indicated on the wiring diagram Engine starting will be difficult if the resistance is higher than the specified value This can also cause welding of the magnet switch at the point of contact and resultant burnin
76. expander joint Ns JAY Top ring jouit shall be opposite to the oil ring joint NS Z Reassemble e When installing the piston pin to the rod and piston the punched match mark on the big end of the connecting rod shall be opposite to the size mark on the piston top Reassemble Install the piston in the cylinder block The embossed mark on the connecting rod shall be on the flywheel side Ring joints Piston ID mark de Flywheel side Nozzle side Camshaft side Cylinder size mark Piston ID mark Embossed mark Flywheel side Match mark Assembly direction of connecting rod and piston 4 35 4 Disassembly Inspection and Reassembly of Engines 4 4 5 Parts inspection and measurement 1 Cylinder block Especially clean head surface cylinder bores and oil holes and check the below items after removing any carbon deposit and bonding agent a Appearance inspection Check if there is any discoloration or crack If crack is suspected perform color check Sufficiently clean the oil holes and check they are not clogged b Cylinder bore and distortion Measure at 20 mm below the crest of the liner at 20 mm from the bottom end and at the center Roundness Roundness is found as follows though it is the simple method Measure cylinder diameters of the A direction and the B direction on each section of a b and c Roundness is the maximum value among those difference values Cy
77. ft and carefully operate so as not to Flange damage the thread y Fuel injection Le A dnve gear NOTICE aR Flange boll Be sure to remove a flange and a drive gear with a Wr A cp a Spring pair without loosening flange installation bolts Sa washer Reassemble p e Tightening torque for fuel pump drive gear nut Ce without lube Cil Pump drive gear nut N m kgf m Tightening torque 58 8 to 68 8 6 0 to 7 0 Point4 Reassemble Assemble crankshaft gear A fuel injection pump drive gear B and camshaft gear C at the same time by aligning with idle gear A B and C marks Install the idle gear shaft with the oil hole facing upward Point5 Reassemble Install the PTO drive gear with its inner spline side facing the flywheel Fuel injection pump drive gear Point6 S Disassemble Crankshaft gear Install a bolt as a handle in the hole at the end face of the flywheel and remove carefully so as not to damage the ring gear Reassemble Flywheel mounting bolt apply lube oil Camshaft gear N m kgf m E Tightening torque Fa IR metal 80 4 to 86 4 8 2 to 8 8 ll Point r Disassemble cM e Measure the camshaft side gap C mm Item Standard Limit Side gap 0 05 to 0 15 0 25 e f the measured side gap exceeds the limit X Side gap replace the thrust metal Camshaft side gap 4 Disassembly Inspection and Reassembly of Engines Disassemble e Since the camshaft gear is shrink fit h
78. g of the armature coil 4 When there is no safety relay Over running when the electric current flows for too long is a major cause of starting failure This burns the armature coil and causes clutch failure Excessive work and failure of the key switch to return properly are the main causes of over running The user must be given sufficient warning about this Be sure to use the safety relay to prevent over running This safety relay is supplied as an option Consult Isuzu first when planning to install a safety relay at your own company In the case of failure to consult with Isuzu our warranty will not be applied to all the electrical equipment 5 When there is too much rust due to the entry of water The water proofing of the starting motor is equivalent to R2 of JIS D 0203 This guarantees that there will be no damage from the sort of exposure encountered in rain or when water is poured on from a bucket You should however avoid the use of high pressure washing and steeping in water 6 Regarding the heat resistance of the starter motor The starter motor has heat resistance for an ambient temperature of 80 C and surface temperature of 100 C Insulators must be installed to prevent overheating when used near high temperature parts such as the exhaust system 7 Corrosion of magnet switch contact point by corrosive gas When using equipment with a dry clutch ammonium gas generated by friction is liable to corrode the contact of
79. guide extracting A inserting tool I i 4 5 Cylinder head Z Projection E7 e ra N Valve guide E Valve guide replacement 4 Disassembly Inspection and Reassembly of Engines 4 2 8 Valve stem seal replacement Always use a new seal after the intake exhaust valve is disassembled Since the one for the exhaust valve Valve stem seal inserting tool is marked with yellow paint do not confuse the intake and exhaust valves NOTICE Painting is applied to the springs of both intake exhaust valve stem seals for the distinction because both parts are different Be careful because it causes oil down when the attachment of intake exhaust is mistaken Sie Distinction coloration for the intake is white and for 4 P the exhaust black A Nalve quide 1 Apply engine oil to the lip A T Cylinder head 2 Push with the inserting tool Refer to No 5 of 4 1 2 in Chapter 4 for installation Stem seal insertion 3 Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem seal mm Projection 10 9 to 11 2 Clearance Valve guide projection Stem seal projection 4 23 4 Disassembly Inspection and Reassembly of Engines 4 3 Gear Train and Camshaft 4 3 1 Components Flywheel Flywhael hausing Gear case Gildie gear Camshaft Jetzen 42 Ggohna walet pump 97 Ce Au SE KEE re 4 2 gt S
80. hat either the operation hours or years shown in the table come first in the condition that the maintenance inspection was carried out based on the List of Periodic Inspections o Maintenance period Quality Guarantee Period Fuel nozzle cleaning Adjustment cleaning For nozzle fuel pump repairs for fuel nozzle fuel turbocharger pump turbocharger electronic control unit etc Power Rating KW 19 Every 1500 hours Every 3000 hours 1500 hours 2 years And constant speed engines beyond 3000min under 37kW 2 Inspection and Adjustment 2 Inspection and Adjustment 2 1 Periodic Maintenance Schedule The engine periodic inspection timing is hard to determine as it varies with the application load status qualities of the fuel and lubricating oils used and handling status General rules are described here Q User maintenance Parts replacement Shop inspection Maintenance period Every Every Every Every rA Every 250 500 1000 2000 Classification Item Daily 50 Bas Paus hers hoire hours or 3 or 6 orone ortwo months months year years Whole Visual check around engine Q Fuel tank level check and fuel supply Q Fuel tank draining Q Fuel oil Water separator Option draining a system Bleeding the fuel system Q Water separator cleaning Q Fuel filter element replacement Lube oil leve
81. he manual provided by the equipment manufacturer 2 Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric condition Room temp 25 C Atmospheric press 100 kPa 750mm Hg Relative humidity 3096 Fuel temp 40 C Fuel injection pump inlet e With cooling fan air cleaner exhaust silencer ISUZU standard parts After running in hours Output allowable deviation 3 1 1 1 General 1 2CA1 Engine model 2CA1 Version CL CH VH Type Vertical inline water cooled diesel engine Combustion system Swirl chamber ball type Aspiration Natural No of cylinder 2 Bore x Stroke mm 70x74 Displacement L 0 570 Continuous rated output kW min _ C M Engine speed PS 11 4 133 wc 5 96 6 62 7 28 7 87 8 53 9 12 8 97 10 7 9 34 9 78 10 3 Max rated output net kW min 3500 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 Engine speed PS 8 10 9 00 9 90 10 7 11 6 12 4 12 2 14 6 12 7 13 3 14 0 High idling min 2160425 2355225 2570225 2780325 2995 25 3210 25 3165225 3800 25 3390 25 3605 25 3815425 Engine mass dry with flywheel housing kg 66 P T O position Flywheel side Direction of rotation Counter clockwise viewed from flywheel side Cooling system Water cooled r
82. he summer and the fluid level should be checked earlier than the specified times e If the engine cranking speed is so slow that the engine does not start up recharge the battery e If the engine still will not start after charging replace the battery e Remove the battery from the battery mounting of the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at 15 C or less And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature 2 Battery charge Use a battery tester or hydrometer and check the battery condition If the battery is discharged recharge it a Measurement with a battery tester When checking the battery with the batter tester connect the red clip of the tester to the battery positive terminal and black clip to the battery negative terminal by pinching them securely and judge the battery charge level from the indicator position Green zone Normal Yellow zone Slightly discharged Red zone Defective or much discharged UPPER LEVEL m LOWER LEVEL Lower limit Excessive Electrolyte level Battery charge measurement with battery tester 2 9 2 Inspection and Adjustment b Measurement with hydrometer When using a hydrometer the measured specific gravity must be corrected according to the temperature at the time of measurement The specifi
83. hragm assy on the rocker arm cover every 1000 hours or 2 years Refer to 4 2 4 point 6 Diaphragm cover O for the function of the diaphragm Spring amp Rocker arm cover 1 Loosen screws and remove a diaphragm assy Center plate amp 3 and check whether oil and so on doesn t enter Diaphragm EJ hau KGS between the diaphragm and the cover If oil bo PA e and so on enters into the diaphragm assy the diaphragm doesn t work well Breather baffie 2 Check the damages of the diaphragm rubber Baffle dues i and the spring If necessary replace with new A Intake maniforld ones Breather system componert NOTICE e When a diaphragm is damaged pressure control inside the crankcase becomes insufficient and troubles such as combustion defect and so on occur At lubricating oil replacement or lubricating oil supply the amount of lubricating oil isn t to be beyond the standard upper limit If the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur 3 Intake exhaust valve clearance adjustment Make measurement and adjustment while the engine is cold a Valve clearance measurement 1 Remove the rocker arm cover above cylinder head 2 Set the No 1 cylinder in the compression TDC Turn the crankshaft to bring the piston of the No 1 cylinder to
84. il filter counter clockwise using a filter wrench customer procured to remove it Clean the mounting face of the oil filter Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface and tighten it further to 3 4 of a turn with the filter wrench Tightening torque 20 24N m 2 0 2 4kgf m Applicable oil filter Part No 586400 6320 c Filling oil and inspection Fill with new engine oil until it reaches the specified level IMPORTANT Do not overfill the oil pan with engine oil Be sure to keep the specified level between upper and lower limit on the dipstick Warm up the engine by running for 5 minutes while checking any oil leakage Stop the engine after warming up and leave it stopping for about 10 minute to recheck the engine oil level with dipstick and replenish the engine oil If any oil is spilled wipe it away with a clean cloth 2 5 2 Inspection and Adjustment 2 V belt tension check When there is not enough tension in the V belt the V belt will slip making it impossible for the alternator to generate power and cooling water pump and cooling fan will not work causing the engine to overheat Check and adjust the V belt tension deflection in the following manner NOTICE Be especially careful not to splash engine oil on the V belt because it will cause slip
85. imiter may malfunction if the battery cable and or battery are removed during operation depending on the kind of electrical equipment being used causing loss of control over the output voltage In such cases the current limiter and other electrical equipment will be damaged by the generation of a continuous high voltage of 24 43V for 5 000rpm dynamo All electrical equipment falls outside the scope of the warranty under these circumstances Be sure to warn the user not to remove the battery cable and or battery during operation 4 If the battery cable can be attached in reverse The current limites SCR diode will be destroyed if the plus and minus ends of the battery cable are connected the wrong way around This causes charging malfunctioning and burns the harness Give the user a cable of such a length that it cannot be connected the wrong way and warn the user against connecting the cable backwards 5 Non use of the Isuzu wiring diagram Use without prior consultation of any wiring diagram other than that provided by Isuzu removes any breakdown of any electrical equipment from the warranty 6 Installation environment Observe the following when installing the current limiter 1 Do not install it on the engine 2 Place it in a well ventilated place with an ambient temperature of 65 C or less 3 Ensure that the cooling air flows in the right direction for the current limiter s cooling fins 4 Do not use the earth wire of the current
86. inder head gasket OQ Q IQ Q Ordinary Replace the gasket See 4 2 2 11 in Chapter4 Seized or broken piston ring Q Replace the piston ring See 4 2 2 5 10 in Chapter4 Worn piston ring piston or cylinder Perform honing and use oversize parts See 4 4 5 1 4 and 4 4 6 in Chapter4 Seized crankpin metal or bearing Q Repair or replace Improper arrangement of piston ring joints Correct the ring joint positions See 4 4 4 6 in Chapter4 Reverse assembly of piston rings Reassemble correctly See 4 4 4 6 in Chapter4 Worn crankpin and journal bearing Measure and replace See 4 4 5 2 in Chapter4 Loosened connecting rod bolt Tighten to the specified torque See 4 4 4 2 in Chapter4 Foreign matter trapped in combustion chamber Disassemble and repair Excessive gear backlash Adjust gear meshing See 4 3 4 2 in Chapter4 Worn intake exhaust valve guide Measure and replace See 4 2 5 2 and 4 2 7 in Chapter4 Defective governor Make adjustment Improper open close timing of intake exhaust valves Adjust the valve clearance See 2 2 6 3 in Chapter2 Excessive cooling effect of radiator Defective thermostat kept closed See 2 2 7 in Chapter2 Insufficient cooling effect of radiator Defective thermostat kept opened See 2 2 7 in Chapter2 or slipping fan belt See 2 2 2 2 in Chapter2 Insufficient coo
87. ine load Therefore not only a very precise machining should be necessary all parts but also the assembling adjustment which top level is excellent in should be necessary The careful consideration to avoid dust and rust at the time of disassembly adjustment reassembly of the fuel injection pump in the market is necessary Fuel injection pumps manufactured by Yanmar YPES ML type series are inline type A cam shaft is driven through the timing gear and mechanical type fuel feed pump driven by a cam shaft sends fuel to the fuel filter from the fuel tank The fuel which passed through the fuel filter is supplied to the storeroom of the pump housing and the pressure of the fuel rises by the plunger The fuel passes through the fuel high pressure pipe and the fuel is injected to each cylinder from the fuel injection nozzle The manual of the separate volume is referred to for the disassembly and assembly adjustment procedure of only the YPES ML type fuel pump 7 2 Fuel Injection Pump 7 2 1 Fuel system diagram Fuel injection valve Fuel injection pipe Fuel return pipe To fuel tank Fuel injection pump Fuel filter OU water separator Option From fuel tank Feed pump 7 1 7 Fuel Injection Pump Governor 7 2 2 External view and components Exhaust manifold Gear case flange Idle gear Purnp flange Fuel pump drive gear Don t disassemble Drive gear nut Note This
88. ioN dn eoueuioped JoussA05 jueuueAoJdu Ameno J yaa Siow uy duind O7 uononpas asioN uononposd ui uwy uoinaefui jan Jo jueureAoJdui WOIE uononpoaud ui Ajquenb uonaafui ent jo juauraAOJdul uoisiDalg adA 3N pasinay dund jan eui ui jews MaN wononpes uorssiui3 eizzou epio40 Jade JAQWEYS uonsnquioao MaN Lonsnpay gen uononpey voista Bnjd MojB amb sadns Guiqddy iueursAocudui aa3ueuuoped Duuee 1 10 1 General 1 6 Exhaust gas emission regulation The engines in this manual have been certified by the US EPA California ARB and or the 97 68 EC Directive California Proposition 65 Warning Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer birth defects and other reproductive harm California Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm 1 6 1 The Emission Standard in USA 1 EPA Nonroad Diesel Engine Emission Standards g kW hr g bhp hr Engine Power Tier Model Year NOx HC NMHC NOx CO PM kW 8 Tier 1 2000 10 5 7 8 8 0 6 0 1 0 0 75 hp 11 Tier 2 2005 S 7 5 5 6 8 0 6 0 0 80 0 60 8 lt kW lt 19 Tier 1 2000 9 5 7 1 6 6 4 9 0 80 0 60 11 lt hp lt 25 Tier 2 2005 S 7 5 5 6 6 6 4 9 0 80 0 60
89. ircuit 1 Move a start switch to the position of on Confirm lighting of the charge lamp 2 Start an engine and confirm the lights out of the lamp Repair a charge lamp circuit when a lamp doesn t work 9 4 9 Alternator 9 2 40A Alternator 9 2 1 Components 1 Parts related to the alternator Sch Bearing cover y Bearing x NZ Retainer plate oe Bearing a Rear flame Assy 9 5 9 Alternator 9 2 2 Specifications Manufacturer s model Denso ACFA68 Part Number 586400 2840 Rating Continuous Battery voltage V 12 Nominal output 13 5 V heat A 40 Rated revolution min 5 000 Operating revolution min 1 350 to 18 000 Grounding characteristics Minus side grounding Direction of revolution viewed from pulley Clockwise Integrated regulator IC regulator Weight kg 2 8 Pulley outside diameter mm 69 2 Belt shape Type A 9 2 3 Wiring diagram WIRING DIAGRAM Charge lamp Max 34W Battery A t i ALTERNATOR ASSY NOTICE ZC IC REGURATOR 1 Don t do mis wiring and short circuit of each terminal 2 Don t remove a battery terminal and a B terminal when rotating 3 Shut out a battery switch during the alternator stop 9 6 9 Alternator 9 2 4 Standard output characteristics The standard output characteristics of this alternator are shown as the right figure
90. it expands approx 9 in volume e This causes serious damage in the cooling system e Be sure to use the proper amount of coolant concentrate specified by the LLC manufacturer depending on the ambient temperature LLC concentration should be 30 as a minimum and 60 as a maximum DO NOT mix the different types of brand of LLC otherwise harmful sludge may yield DO NOT use hard water e Water should be free from sludge and or particles e Replace the coolant every once a year A CAUTION When handling LLC use protective gloves to avoid skin contact NEEN d In case you have a contact with your skin or eyes wash out it with clean water 1 8 1 General 1 4 Engine External Views Lifting eye Cooling water pump Fuel filter Ss Air intake port PN 2 irom air cleaner e Intake manifold D m SCH Fuel injection pump SS Governor lever XLI Dipstick lube oil Fuel priming lever Filler port lube oil Mechanical fuel feeding pump Drain plug lube oil Fuel oil inlet Bonnet Rocker arm cover Engine name plate Filler port dube oil i Flywheel Exhaust manifold Starter motor 1 9 1 General sjuiod a amp ueua uie adh y jo 1jeq A e Guiqddy uaumAojduir Ayyiqeing uoisid payeod winuepgAjoyy uonanpes SSION 1 5 Structural Description S Lui ajnpoui Jajeus YM seas uoionpay asioN sseugis 3245y jo Oo 1epun uogonpas as
91. ith blue or minimum Then assemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque to check the metal for contact If the contact surface occupies 75 or more the metal is normal If the contact surface is insufficient the metal interference is insufficient Replace the metal with a new one 3 Thrust metal inspection a Inspect any damage or wear b Measure side gap and thrust metal thickness Side gap and thrust metal thickness mm Side ga Thrust metal thickness Standard Standard Limit 0 111 to 0 250 1 930 to 1 980 1 850 If the side gap is exceeded use an oversized thrust metal Oversized metal 0 25mm Code No Standard thickness 586400 7740 2 055 to 2 105 4 40 4 Disassembly Inspection and Reassembly of Engines 4 Piston Especially clean the combustion surface circumference ring grooves and piston pin bosses and check after removing any carbon deposit Any burr at a ring groove or snap ring groove shall be removed If crack is suspected inspect by color check a Piston outside diameter measurement Measure the long diameter at H mm from the bottom end of the piston of the oval hole in the vertical SSS direction to the piston pin hole H The clearance between a piston and a cylinder is d SET Hmm calculated by using a measured piston outside diameter and a cylinder inside diameter measured according to 4 4 5 1 b Piston outside
92. its compression top dead center while watching the rocker arm motion timing scale and the top mark position of the crankshaft 1 pulley H ef Ca Position where both the intake and exhaust Rolational direction valves are closed Top mark No 1 cylinder _ Crankshal pullay 2 17 2 Inspection and Adjustment Notes e The crankshaft shall be turned clockwise as seen from the radiator side e The No 1 cylinder position is on the opposite side of the radiator Since there is a clearance between the rocker arm Rocker arm Adjusting screw and valve at the compression top dead center the Valve A posi tion of TDC can be checked by hand Also Lock nut see that the top mark on the crankshaft pulley aligns with the mark on the gear case If there is no valve clearance disassemble and inspect around the valve seat since the valve seat may be worn abnormally 3 Valve clearance measurement Insert a thickness gage between the rocker arm and valve cap and record the measured valve clearance Use it as data for estimating the wear state 4 Adjusting other cylinders Then in case of 3 cylinder engines turn the crank shaft clockwise viewed from radiator side at 240 degree and adjust the valve clearance for the No 3 cylinder Then adjust the No 2 cylinders in this order In case of 2 cylinder engines turn the crankshaft clockwise at 180 degree with 1 turn after the No 1 cylinder s adjustment The cylinder to be
93. kshaft pulley apply lube oil to the set bolt to tighten and carefully assemble so as not to damage the oil seal NOTICE Clean by wiping off any oil on both taper surfaces of crankshaft and pulley using detergent N m kgf m Material of pulley Tightening torque 83 3 to 93 3 8 5 to 9 5 113 to 123 11 5 to 12 5 Point2 Reassemble e When installing the gear case do not forget to install the two reinforcing bolts at the center Measure the backlash of each gear mm Standard Crankshaft gear Camshaft gear Fuel injection pump gear Es Sie Idle gear PTO gear Apply sealant after checking that oil doesn t stick on either surface of the cylinder block and the gear case flange and also the gear case flange and the gear case Install the gear case by correctly positioning the two dowel pins 4 25 Fuel injection pump _ Gdnve gear f TE T E gt SL CH Camshaft gear wech jw weit TS ke Lubricating oil 1 pump gear Idle gear JOEN x P OS PTO gear j Crankshaft Direction of rotation Gear train 4 Disassembly Inspection and Reassembly of Engines Point3 Refer to 7 2 5 in chapter 7 Disassemble e Remove the mounting nut of the fuel injection pump drive gear remove the gear using the gear puller and remove the fuel injection pump When Za _ Fuel injection pump extracting the gear using the gear puller use a x S pad at the sha
94. l cause to built up rust due to the residual water in the cooling water system 2 Remove the mud dust and oil deposit and clean the outside 3 Perform the nearest periodic inspection before the storage 4 Drain or fill the fuel oil fully to prevent condensation in the fuel tank 5 Disconnect the battery cable from the battery negative terminal 6 Cover the silencer air cleaner and electric parts with PVC cover to prevent water and dust from depositing or entrance 7 Select a well ventilated location without moisture and dust for storage 8 Perform recharging once a month during storage to compensate for self discharge 9 When storing an engine for long time run the engine or do motoring periodically according to the following procedure Because the rust occurrence inside the engine the rack agglutination of the fuel pump and so on are likely to occur In case that the engine is equipped with a machine unit a Replace the lube oil and the filter before the engine running b Supply fuel if the fuel in the fuel tank was removed and bleed the fuel system C Confirm that there is the coolant in the engine d Operate the engine at the low idling speed for about five minutes If it can be done one a month 2 28 3 Troubleshooting 3 TROUBLESHOOTING 3 1 Preparation before troubleshooting If the signs of a trouble appear it is important to lecture on the countermeasure and treatment before becoming a big accident
95. l check and replenishment a Lubricating Lube oil replacement Ke oil system mo 2 time Lube oil filter replacement Tatime and thereafter Coolant water level check and replenishment Q Radiator fin cleaning Q Cooling M water Cooling fan V belt tension check e eme time and system thereafter Coolant water replacement Coolant water path flushing and e maintenance Rubber Fuel pipe and coolant water pipe a e house inspection and maintenance Governor Inspection and adjustment of a a governor lever and accelerator Mech e and element a e Air intake system Diaphragm assy inspection 2 years Turbocharger blower cleaning e Warning lamp amp instruments function Electrical check Q system Battery electrolyte level check and Q battery recharging l Intake exhaust valve head clearance pda adjustment e can Intake exhaust valve seat lapping e Fuel Fuel injection nozzle pressure inspection e injection Fuel injection timing adjustment pump and Fuel injection pump inspection and e nozzle adjustment EPA allows to maintain the emission related parts as shown in 1 6 3 of chapter1 2 1 2 Inspection and Adjustment 2 2 Periodic Inspection and Maintenance Procedure 2 2 1 Check before Daily Operation Be sure to check the following points before starting an engine every day No Inspection Item Visual check around engine Fuel tank level check and fuel supply Lube oil level check and replenishment
96. lant water level Check water leakage from cooling water system See 2 2 1 4 in Chapter2 Cracked water jacket Repair or replace Slackened fan belt Adjust the belt tension See 2 2 2 2 in Chapter2 Defective thermostat Check or replace See 2 2 7 in Chapter2 3 2 3 Troubleshooting A Insufficient Poor 5 TNT Cooling Air Trouble symptom Starting failure engine output exhaust 9 Hunting T Lubricating oil water intake color 2 D E d Engine starts Exhaust During 8 9 SE color wok 2 g 8 o soon Sol 3 E p E E 3 5 2 c g amp o o K o 2 Le 2 0 E pubs EH EE Ga EENS Iz 5 Corrective action 8 aj 2 8 gE 8 5 s S S 8R 3 z e ollz S E EECH KH KK dE lt a o 9 es lEIS 27 238 2 g 82 952 9 9o 9E S ai8 5 o o t o lo zl l9 8 5 l9 8 o gt oe Bg lc 92 5 z 85 2 glS g 9 9 2 Soc Si Zi ei oi o 3S 98 0 lo Si 3 l92 2 EE o I E x Ki Ka o 2 E E o Oo o o E gen x e eo o el c 9 o g o o c c o EF EF Die ol i 5 2 sl 8 of s i ete c o zm 23 9g co t cdo o o c 35 zial sl sei l el zl zl el 2 21 KEE HEH AER OESCH EECH ES EECH Ber Of s ll eg Improper properties of lubricating oil Q a a a o pko Use proper lubricating oil See 1 3 2 in Chapter1 E Leakage
97. lculate the Measure at positions a b and c clearance between piston pin and piston pin hole If in directions A and B any data exceeds the limit replace the part with a new one Standard 22 000 to 22 009 21 995 to 22 000 Clearance 0 000 to 0 014 Piston pin outside diameter c Piston ring ring groove and end clearance measurement Except for the top ring to measure the piston ring En groove width first measure the width of the piston La ring Then insert the piston ring into the ring Then SS insert the piston ring into the ring groove Insert a Second ring thickness gage in between the piston ring and groove to measure the gap between them Obtain the ring groove width by adding ring width to the Oil ring measured side clearance To measure the end clearance push the piston ring into the sleeve using the piston head insert a thickness gage in end clearance to measure The ring shall be pushed in to approx 30 mm above the bottom end of the cylinder For the top ring measure only the piston ring joint end clearance in normal state Thickness Measuring side clearance Approx 30mm Joint end clearance Ring joint end clearance measurement 4 42 4 Disassembly Inspection and Reassembly of Engines Piston ring dimension Model Part Item Standard Limit Ring groove width 1 550 to 1 570 S E Ring width 1 470
98. liding test Wash the nozzle valve in clean fuel oil Place the nozzle body vertically and insert the nozzle into the body to about 1 3 of its length The valve is normal if it smoothly falls by its own weight into the body In case of a new nozzle remove the seal peel and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust preventive oil before using the nozzle Note that a new nozzle is coated with rust preventive oil and is pasted with the seal peel to shut off outer air Nozzle valve sliding check by gravity d Nozzle punch mark Y DN OS D YD1 code No cade pintle type D throttle type Size size P size S Injection angle Type pintle type YANMAR Identification number 2 22 2 Inspection and Adjustment 2 2 7 Inspection every 2000 hours or 2 years Be sure to check the following points every 2 000 hours or two years operation whichever comes first Inspection Item Coolant water path flushing and maintenance Fuel pipe and coolant water pipe inspection and maintenance Intake exhaust valve seat lapping Fuel injection timing adjustment Fuel injection pump inspection and adjustment 1 Coolant water path flushing and maintenance Rust and water scale will accumulate in the cooling system through many hours of operation This lowers the engine cooling effect Oil coolers attached to turbocharged engines and
99. lindricity Oylindricity is found as follows though it is the simple method Measure oylinder diameters of a b and c sections in the A direction and calculate the difference in maximum value and minimum value of the Xo measured diameters Gg In the same way measure and calculate the Measure in two directions 3 i 2 E j A and B at points a b and c difference in the B direction KI Ai Oylindricity is the maximum value between those difference values Cylinder bore measurement positions Item Model Standard 2CA1 3CA1 70 000 to 70 030 Oylinder inside diameter 3CB1 76 000 to 76 030 Roundness Oylinder bore 0 01 or less Oylindricity 4 36 4 Disassembly Inspection and Reassembly of Engines c If the limit is exceeded or any surface defect is found repair by boring and honing Use an oversized piston and new piston rings as required Oversized piston 0 25 mm with piston rings Model Code No Standard mm 2CA1 3CA1 Not Applicable 70 250 3CB1 586400 6900 76 250 Piston ring assy for oversized 0 25mm Model Piston ring code No 2CA1 3CA1 Not Applicable 3CB1 586400 6930 Cylinder boring dimension Model Boring dimension mm 2CA1 3CA1 70 250 to 70 280 3CB1 76 250 to 76 280 4 37 4 Disassembly Inspection and Reassembly of Engines 2 Crankshaft Mainly check seizure and wear of the crankpins and journals Since th
100. m wee LN A T CHPMA vua TI Dot CN e RN N p eB eee JB GC lej el T en DV 408 1123 2028 Dr ww 7123 2228 Foo vane pe regeeues ieocv NOTES FOR ENGINE STOP SOLENOID 1 PERMISSIBLE RESISTANCE OF SOLENOID CIRCUIT SHOULD BE LESS THAN 0 070 TO GUARANTEE PERMISSIBLE LOWEST VOLTAGE 9V TO WORK SOLENOID PULL COIL TERMINAL RESISTANCE 15 1000Q PER COUPLER DU PER SCREW SETTING OLENOID DOESN NEED TO BE COUNTED AV2 0 0088N m 8 0m WITHOUT TERMINAL RESISTANCE WHEN YOU EXCEED PERMISSIBLE RESISTANCE ADOPT THE CIRCUIT IMPRESSED FROM THE POWER SUPPLY TO THE SOLENOID DIRECTLY USING A RELAY REFER TO 2 HIGH TEMPERATURE PARTS SUCH AS AN EXHAUST PIPE SHOULD NOT APPROACH FOR THE PULL POWER FALL OF SOLENOID AND HEATING PREVENTION OF INNER COIL TEMPERATURE PERMISSIBLE AMBIENT TEMPERATURE 30 100t 3 INSTALL FUSE TO PROTECT THE HARNESS AGAINST TROUBLES SUCH AS SHORT CIRCUIT OR CONTINUOUS DRIVE OF PULL COIL P OF ALTERNATOR TIA XCITATOR A N_TH AWING COTHERWISE SOLENOID MAY LOOSE STOP FUNCTION DUE TO THE POWER UPL REFERENCE ISTANC PLY FROM AT ib AL 5 IN CASE OF WATERPROOF CONNECT OR APPLICATION CONNECTOR SHOULD B IX BY FITTING TO PREVENT LEAD BREAK ed PASE Dt COR GENT SpE 3E MAG AINE FOR SAFETY WILL BE APPLIED W HL HOUL H 7 IN CASE OF THE SOLENOID CIRCUIT RESISTANCE WOULD BE LIMIT WIRING IS APPLICABLE ISUZU 10 Electric Wiring 10 1 1 Alternator In the cases listed
101. ning 2 3 Bleeding the fuel system 4 Battery electrolyte level check and battery recharging 1 Fuel tank draining 1 Prepare a waste oil container 2 Remove the drain plug of the fuel tank to drain water dust etc from the fuel tank bottom 3 Drain until fuel with no water and dust flow out Then tighten the drain plug firmly Drain plug 2 Water separator draining Drain off the water separator whenever there is a lot of Clase drain collected in the water separator at the bottom of T Air bleeding bolts the cup even if not the time for periodic inspection Outlet hour The cup of the water separator is made from Vine D semi transparency material and in the cup the red i Ch S colored float ring which rises on the surface of the Kn drain is installed to visualize the amount of drain prd S e Drain off the water separator in the following manner Bere Retaining ring 1 Close the fuel cock 2 Loosen the retainer ring and remove the cup then throw collected water and trash away 3 Put a float ring and a spring in the cup and tighten the retainer ring Water separator Tightening torque 13 16 N m 1 3 1 6 kgf m 4 Be sure to bleed air in the fuel system Fuel cock 2 7 2 Inspection and Adjustment 3 Bleeding the fuel system Bleed the fuel system according to the following Fuel filter Fuel return hose procedures When there is air in the fuel
102. not to shorten the engine life When the signs of a trouble appear in the engine or a trouble occurs grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting Then repair the trouble and prevent the recurrence of the trouble 1 What s the occurrence phenomenon or the trouble situation e g Poor exhaust color 2 Investigation of the past records of the engine Check a client control ledger and examine the history of the engine Investigate the engine model name and the engine number Mentioned in the engine label Examine the machine unit name and its number in the same way When was the engine maintained last time How much period and or time has it been used after it was maintained last time e What kind of problem was there on the engine last time and what kind of maintenance was done 3 Hear the occurrence phenomenon from the operator of the engine in detail 5W1H of the occurrence phenomenon the investigation of when when where where who who what what why why and how how When did the trouble happen at what kind of time Was there anything changed before the trouble Did the trouble occur suddenly or was there what or a sign e Was there any related phenomenon E e g Poor exhaust color and starting failure at the same time 4 After presuming a probable cause based on the above investigation investigate a cause systematically
103. nspect and change the battery See 2 2 3 in Chapter2 3 4 3 Troubleshooting 3 3 Troubleshooting by measuring Compression Pressure Compression pressure drop is one of major causes of increasing blowby gas lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon or starting failure The compression pressure is affected by the following factors 1 Degree of clearance between piston and cylinder 2 Degree of clearance at intake exhaust valve seat 3 Gas leak from nozzle gasket or cylinder head gasket In other words the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring Measure the compression pressure to diagnose presence of any abnormality in the engine 1 Compression pressure measurement method 1 After warming up the engine remove the fuel injection pipe and valves from the cylinder to be measured 2 Crank the engine before installing the compression gage adapter 1 Perform cranking with the stop handle at the stop position no injection state 2 See 4 1 2 2 No 18 in Chapter 4 for the compression gage and c
104. ogged strainer at feed pump inlet a Clean the strainer Clogged air filter Q Q Q Q Q Clean See 2 2 4 in Chapter2 5 Engine used at high temperatures or at high altitude Q a Q Q Q Study output drop and load matching 5 Clogged exhaust pipe a Q Q Q Clean o D 2 bai E Ee Es 3 3 3 Troubleshooting Electrical System Starting motor defect Trouble symptom ae Poor Insufficient Starting failure engine output exhaust color Engine starts Exhaust During but stops color work soon Exhaust smoke oO o flax E 2 x o x SIE SIEZISIE S z au l2 0o zimi z m High knocking sound during combustion Abnormal engine sound Uneven combustion sound Hunting SIS mo 9s D D EE 5 5 aja Large engine vibration Difficulty in returning to low speed Excessive fuel consumption TNT Cooling Air Lubricating oil i g water intake c o o 5 EI D o no S 25 o 2 5 S9 Ed elo 8 Elo o 8 le2 c g E 2292 KN SE D Fen EE colla ejeje o c o l ol gi 5 5 Be ae es EE El RE 2 2 2 8 2 5 el ele Ier CH fer d CH e alala Exhaust temperature rise Corrective action Repair or replace See Chapter8 Alternator defect Repair or replace See Chapter9 Open circuit in wiring Repair See Chapter10 Battery voltage drop OQ 1O Q IQ Engine does not start I
105. ompression gage adapter 3 Install the compression gage and compression gage adapter at the cylinder to be measured Measurement of the compression pressure 1 Never forget to install a gasket at the tip end of the adapter 4 With the engine set to the same state as in 2 1 crank the engine by the starter motor until the compression gage reading is stabilized 2 Standard compression pressure Engine compression pressure list reference value Compression pressure at 250 min MPa kgf cm Standard Limit 2CA1 3CA1 3 24 0 1 33 1 2 55 0 1 26 1 0 2 to 0 3 2 to 3 Deviation among cylinders Engine mode MPa kgf cm 3CB1 3 43 0 1 35 1 2 75 0 1 28 amp 1 0 2 to 0 3 2 to 3 3 5 3 Troubleshooting 3 Engine speed and compression pressure for reference T E 3 92 9 oO E o 3 43 zl 1 Hu pa 2 1 2 94 a i c 9 i 9 4 3 2 45 a i E i 8 1 1 96 MPa 200 250 300 350 400 Engine speed min 4 Measured value and troubleshooting When the measured compression pressure is below the limit value inspect each part by referring to the table below Item Cause Corrective action Air cleaner element Clogged element Clean the element Broken element Replace the element Defect at element seal portion Valve clearance Excessive or no Adjust the valve clearance clearance See 2 2 6 3 in Chapter 2
106. ons e Sufficient ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health Running engines welding sanding painting and polishing tasks should be only done in well ventilated areas e Safe Adequate Work Area The service area should be clean spacious level and free from holes in the floor to prevent slip or trip and fall type accidents e Bright Safely Illuminated Area The work area should be well lit or illuminated in a safe manner For work in enclosed or dark areas a drop cord should be utilized The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances e Safety Equipment Fire extinguisher s first aid kit and eye wash shower station should be close at hand or easily accessible in case of an emergency 2 WORK WEAR GARMENTS A CAUTION Safe Work Clothing Appropriate safety wear gloves special shoes boots eye ear i protection head gear harness clothing etc should be used worn to eC H match the task at hand Avoid wearing jewelry unbuttoned cuffs ties or loose fitting clothes around moving machinery A serious accident may occur if caught in moving rotating machinery f ees We Dien P 3 TOOLS A WARNING Pe peep ale Lifting Holding en lifting an engine use only a lifting device crane jack etc with sufficient lifting capacity Do not overload the device U
107. ove the delivery holder 5 Check the fuel discharge from the delivery holder while turning the crankshaft clockwise as seen from the radiator and stop turning it at the same time when the fuel comes out Wipe out the fuel of the delivery holder exit Next turn the crankshaft in the opposite direction counterclockwise and return it to about 20 degrees before top dead center 6 Check again the fuel discharge from the delivery holder while turning the crankshaft clockwise and stop turning it at the same time when the fuel comes out TUR 2 23 2 Inspection and Adjustment 7 Read the timing scale on the flywheel from the hole on the flywheel housing It is standard fuel injection timing if the timing mark position meets the fuel injection timing of the below table Class VM CH VH Model 2000 2300 2700 3000 3100 3500 name Engine speed min to 2200 to to to to 2100 2600 3000 3600 3400 3600 2CA1 njection timing 15 16 18 i i 3CA1 FID bTDC Deg 15 16 18 21 20 21 3CB1 t 1 deg 15 16 18 21 20 21 8 Repeat steps 5 to 7 a few times Note Injection timing check for one cylinder is generally sufficient If it is to be checked for all cylinders of 3 cylinder engine check each cylinder in the ignition order of 1 3 2 1 by turning at each 240 degrees The cylinder to be checked is not limited to the No 1 cylinder and any cylinder may be checked 9 If
108. ove valve cotter b Remove valve retainer and valve spring c Remove intake valve and exhaust valve 1 Remove crankshaft V pulley clamping bolt 2 Using a puller extract crankshaft V pulley 1 Extract crankshaft V pulley by hitting the bolt of the puller using a plastic hammer or the like 1 Remove oil pan mounting bolt under gear case 2 Remove gear case mounting bolt 3 Remove gear case 1 Never fail to removes stiffener bolt at the center of the gear case 2 When removing the gear case carefully protect oil seal from damage 1 Remove the nut from fuel injection pump drive gear Extract fuel injection pump drive gear using a puller 4 8 1 Before removing fuel injection pump make sure of the position of the arrow of the pump body for adjusting fuel injection timing as well as the position of the scribed line of the gear case flange 4 Disassembly Inspection and Reassembly of Engines Removal Parts Remarks 1 Remove lubricating oil pump 1 Remove starting motor from flywheel housing 1 Remove flywheel mounting bolt 2 Remove flywheel 1 Carefully protect the ring gear from damage mage 1 Remove flywheel housing 2 Remove oil seal 1 Carefully protect the oil seal from damage 1 Put the cylinder block upside down and remove a oil pan and spacer 1 Carefully protect the combustion surface of the cylinder block from damage 2 Be careful
109. ow and the precautions from in chapter 4 to in chapter 7 particularly before and during reassembly 1 Cleaning the component Use particular care to clean the cylinder block cylinder head crankshaft and camshaft Ensure that they are free from chips dust sand and other foreign matter 2 Parts to be replaced during reassembly Be sure to replace the following parts with new ones during assembly Valve stem seal Head gasket packing Nozzle protector and nozzle seat of the fuel injection valve Various copper packing O rings and gasket packing 4 1 5 Adjusting operation Make sure to perform adjusting operation after completing reassembly Refer to section 2 5 in chapter 2 for the operation procedure 4 11 4 Disassembly Inspection and Reassembly of Engines 4 2 Cylinder Head Disassembly Inspection and Reassembly 4 2 1 Components Cylinda black e amp Qu ally 4 2 2 Disassembly procedure Disassemble in the order of the numbers shown in the illustration 1 Remove the alternator assy Point1 of 4 2 4 2 Remove the fan pulley and V belt 3 Remove the thermostat case Point2 4 Remove the fuel filter and fuel oil piping Point3 5 Remove the oil level gage 6 Remove the oil filter Point4 7 Remove the fuel injection pipes Point5 8 Remove the exhaust manifold assy 9 Remove the rocker arm cover Assy Point6 10 Remove the rocker shaft assy push rods and
110. p is tightened loosely a Checking coolant water volume Check the coolant water level in the Coolant recovery tank If the water level is close to the LOW mark open the Coolant recovery tank cap and replenish the Coolant recovery tank with clean soft water to the FULL mark Standard The water level of the Coolant recovery tank shall Upper limit be between the upper and lower limit lines P Lower limit Jk ev d Coolant recovery tank b Replenishing engine with water If the Coolant recovery tank water level is lower than the LOW mark open the radiator cap and check the coolant water level in the radiator Replenish the radiator with the coolant water if the level is low Check the coolant water level while the engine is cool Checking when the engine is hot is dangerous Ke And the water volume is expanded due to the __ AE A heat EE KS Loosen Daily coolant water level check and replenishing FHAA shall be done only at the Coolant recovery tank EE Usually do not open the radiator cap to check or VN M replenish Radiator cap 2 3 2 Inspection and Adjustment IMPORTANT If the coolant water runs short quickly or when the radiator runs short of water with the Coolant recovery tank level unchanged water may be leaking or the air tightness may be lost Increase in the Coolant recovery tank water level during operation is not abnormal The increased water in the Coolant recovery tank
111. ping stretching and aging of the belt LE 1 Press the V belt with your thumb approx 98N 10kgf at the middle of the V belt span to check the tension deflection Available positions to check and adjust the V belt tension deflection are at the A B or C direction as shown in the illustration right You may choose a position whichever you can easily carry out the check and adjustment on the machine unit New V belt refers to a V belt which has been used less than 5 minutes on a running engine Used V belt refers to a V belt which has been used on a running engine for 5 minutes or more Crankshaft Wi The specified deflection to be measured at each position should be as follows Unit mm Direction A For used V belt 10 to 14 For new V belt 8 to 12 2 If necessary adjust the V belt tension deflection To adjust the V belt tension loosen the set bolt and move the alternator to tighten the V belt 3 After replacing with a new V belt and adjusting it run the engine for 5 minutes and readjust the deflection to the value in the table above Tension adjustment 4 Visually check the V belt for cracks oiliness or wear If any replace the V belt with new one 2 6 2 Inspection and Adjustment 2 2 3 Inspection every 50 hours Be sure to check the following points every 50 hours operation No Inspection Item 1 Fuel tank draining Water separator drai
112. r bubbles do not develop b After supplying the cooling water surely tighten the radiator cap To fasten the radiator cap align the detents on the back face of the radiator cap with the slot of the filler port and turn clockwise pushing it downward approx 1 3 of a turn until contact with each other Drain plug c Remove the cap of the coolant recovery tank supply the cooling water to the FULL mark and fasten the cap d Check the rubber hose connecting the coolant recovery tank to the radiator Be sure the rubber is securely connected and there is no looseness or damage When the rubber hose is not water tight an excessive amount of cooling water will be consumed e When filling with the cooling water for the first time or replacing the air contains in the cooling water system So as the air in the cooling water system is made self bleeding during engine operation the cooling water level in the radiator and coolant recovery tank will be lowered Replenish the cooling water into the radiator and coolant recovery tank until it reaches the FULL mark of the coolant recovery tank Rubber hose Min limit Drain plug location depends on the machine unit 2 16 2 Inspection and Adjustment i A CAUTION Beware of scalding by hot water Wait until the temperature goes down before draining the coolant water E Otherwise hot water may splash to cause scalding ahihi 2 Diaphragm assy inspection Inspect the diap
113. r system 2 27 26 Radiator c p INSPeClOM ae coepere ditus eae oq t coe Lope ee pee qp ede epe 2 28 2 7 Thermostat Inspection T CT 2 28 2 8 Adjusting Operation s 5 us cota hice cae tat m mondi ded d 2 29 2 9 Long storage eee e e ere seed eoa m atic tra eee a dicte es exe ERR ter See edle 2 29 3 Ha EH 3 1 3 1 Preparation before troubleshooting ceo etri te rg reno rn Er crie Dope teen 3 1 3 2 Quick Reference Table for Troubleshooting ssssssssessssssesnrrrnrersnrrrnrressrrrnnntssrrennnrnnnnesnne 3 2 3 3 Troubleshooting by measuring Compression Pressure 3 5 4 Disassembly Inspection and Reassembly of Engines 4 1 4 1 Complete disassembly and reassembiv AEN 4 1 E De Mine ele e WEE 4 1 4 1 2 Special service tools 5 e oii Eo e e ep eo ee e e P e Eo e E ER ee 4 3 4 1 3 Complete le E 4 8 4 1 4 Precautions before and during reassembly essen 4 12 4 1 5 Adj stirig Operatlonis a a c dt RR RE UHR RE a SNR ERR RE eR 4 12 4 2 Cylinder Head Disassembly Inspection and Heassembhy 4 13 APA Reie 4 13 4 2 2 Disassembly procedure hei eee Se Se a he ee e Se he Se ia edu 4 13 4 2 3 Reassembly procedure esses entente entren nnne nn trennt nene nnne nennen 4 13 4 2 4 Reverse order of the disassembly procedure Servicing Points 4 14 4 2 5 Parts Inspection and measurement eene 4 18 4 2 6 Valve Seat COMO OM sez i idi en e Ee P ERE PR RE ER ees 4 22 4 2 7
114. rance 0 040 to 0 135 Bushing inside diameter 40 000 to 40 025 Intermediate No bushing Camshaft outside diameter 39 910 to 39 935 Clearance 0 065 to 0 115 Bushing inside diameter 40 000 to 40 025 Wheel side No bushing Camshaft outside diameter 39 940 to 39 960 Clearance 0 04 to 0 085 2 Idle gear shaft and bushing mm Inspection item Standard Limit Reference page Shaft outside diameter 45 950 to 49 975 45 900 Bushing inside diameter 46 000 to 46 025 46 075 4 3 5 2 Clearance 0 025 to 0 075 0 175 3 Backlash of each gear Inspection item Standard Reference page Crank gear cam gear idle gear fuel injection 0 06 to 0 12 l 4 3 4 pump gear and PTO gear 11 Service Standards 11 2 3 Cylinder block 1 Cylinder block Inspection item Standard Reference page 2CA1 3CA1 70 010 to 70 020 Oylinder inside diameter 3CB1 76 010 to 76 020 Roundness Cylinder bore Cylindricity 2 Crankshaft Inspection item 0 01 or less Standard Reference page Bending 1 2 the dial gauge reading Roundness 0 01 or less Pin outside diameter 41 952 to 41 962 Metal inside diameter 41 982 to 42 002 Crank pin Metal thickness 1 503 to 1 509 Clearance 0 020 to 0 050 Journal outside diameter 46 952 to 46 962 Metal inside diameter Crank journal Metal thickness
115. ric drill at 300 to 1200 rpm Then insert the Flex Hone into the cylinder bore while turning it and move it up and down for about 30 sec to obtain a honing mark with a cross hatch angle of 30 to 40 NOTICE 1 Avoid faster revolution than 1200 rpm since it may cause breakdown 2 Do not insert or extract the Flex Hone in stopped state because the cylinder will be damaged Honing cross hatch 4 4 7 Piston pin bushing replacement Replace metal by using the special service tool see 4 1 2 No 3 in Chapter 4 4 4 8 Oil seal replacement Flywheel housing side 1 Replace an oil seal with new one when a flywheel housing is removed Extract the used oil j Cylinder black seal gt P Flywheel f i A housing 2 Insert a new oil seal by using the oil seal insertion tool on the position of the flywheel housing end face Refer to the right figure 3 Apply lithium grease on the lip 4 Install the flywheel housing on the cylinder block with being careful not to damage the oil seal DO seal af 7 Crank shafi j Replacement of a flywheel housing oil seal 4 47 5 Lubrication System 5 LUBRICATION SYSTEM 5 1 Lubrication System Diagram Fuel injection pump Regulator valve Lube oil pump Crank journal metal Intermediate gear shaft Oil suction pipe in metal strainer p 5 1 5 Lubrication System 5 2 Trochoid Pump Components Co
116. s during running or shortly after shutting it down Scalding serious burns may result Allow the engine to cool down before attempting to approach the unit e Rotating Parts Be careful around moving rotating parts Loose clothing jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury e Preventing burns from scalding 1 Never open the radiator filler cap shortly after shutting the engine down Steam and hot water will spurt out and seriously burn you Allow the engine to cool down before attempt to open the filler cap 2 Securely tighten the filler cap after checking the radiator Steam can spurt out during engine running if tightening loose Precautions for Service Work 1 Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work 2 Preparation for Service Work Preparation is necessary for accurate efficient service work Check the customer ledger file for the history of the engine Preceding service date Period operation hours after preceding service Problems and actions in preceding service e Replacement parts expected to be required for service e Recording form check sheet required for service 3 Preparation before Disassembly Prepare general tools special service tools measuring instruments oil grease non reusable parts and parts expected to be required for replacement
117. se only a chain cable or lifting strap as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do not overload this device serious injury may result Never run an engine without being properly secured to an engine support stand test bed or test cart serious injury may result e Appropriate Tools L A CAUTION B Always use tools that are designed for the task at hand Incorrect 1 usage of tools may result in damage to the engine and or serious a personal injury 4 GENUINE PARTS and MATERIALS A CAUTION Genuine Parts Always use genuine ISUZU parts or ISUZU recommended parts and goods Damage to the engine shortened engine life and or personal injury may result 5 FASTENER TORQUE A WARNING Torqueing Fasteners Always follow the torque values and procedures as designated in the service manual Incorrect values procedures and or tools may cause damage to the engine and or personal injury d d 6 Electrical A WARNING Short Circuits Always disconnect the Negative battery cable before working on the e e electrical system An accidental short circuit may cause damage fire and or personal injury Remember to connect the Negative battery cable back onto the battery last Fasten the terminals tightly
118. sion Control Label EPA ARB OR Emission Control Label 1 General 1 6 3 Guarantee Conditions for the EPA Emission Standard The following guarantee conditions are set down in the instruction manual In addition to making sure that these conditions are met check for any deterioration that may occur before the required periodic maintenance times 1 Requirement on engine installation condition a Intake air depression KPa mmAq Initial Permissible 2 94 300 6 23 635 b Exhaust gas back pressure kPa mmAq Initial Permissible lt 12 75 1300 lt 15 3 1560 2 Fuel oil Fuel The diesel fuel oil US No 2 diesel fuel oil 3 Do not remove the seals restricting injection quantity and engine speed Sealing cap 2 4 Gaskal Z Gapnut JL Q Gasket Yor Plate 2 t a Nut at Injection quant CE FEN limit be WY ex j l e s Tamper Sealwasher O resistance Assy Tamper resistance device for engines certified by ARB EPA 1 General 4 Perform maintenance without fail Note Inspections to be carried out by the user and by the maker are divided and set down in the List of Periodic Inspections and should be checked carefully 5 Maintenance period and Quality guarantee period for exhaust emission related parts The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period as shown in the below table A guarantee period is t
119. some of naturally aspirated engines quickly deteriorate the lube oil The cleaning and maintenance of the following parts are necessary in accordance with the coolant water replacement Cooling system parts radiator cooling water pump thermostat cylinder block cylinder head oil cooler 2 Fuel pipe and coolant water pipe inspection and maintenance Regularly check the rubber hoses of the fuel system and cooling water system If cracked or degraded replace them with new one Replace the rubber hoses at least every 2 years even if 2 000 hours doesn t come 3 Intake exhaust valve seat lapping The adjustment is necessary to maintain proper contact of the valves and seats Refer to 4 2 6 in Chapter 4 4 Fuel injection timing adjustment Fuel injection pump inspection and adjustment The fuel injection timing and the fuel injection pump are adjusted so that engine performance may become the best condition As for the inspection and adjustment of the fuel pump it is based on the service manual of the ML pump of the separate volume The fuel injection timing is adjusted by the following procedure 1 Complete air bleeding from the fuel line and set the engine ready for starting Flywheel 2 See that the timing marks on fuel pump mounting poe VM housing flange and gear case are aligned 3 Set the speed control lever at the operating position 4 Disconnect the injection pipe on the fuel pump side for the No 1 cylinder Do not rem
120. spection after initial 50 hours operation Be sure to check the following points after initial 50 hours operation thereafter every 250 hours or 3 months operation Inspection Item Lube oil and filter replacement V belt tension check 1 Lube oil and filter replacement A CAUTION When an engine is still hot be careful with a splash of engine oil which may cause burns Replace engine oil after the engine oil becomes warm S It is most effective to drain the engine oil while the engine is still warm hiii 2 4 2 Inspection and Adjustment In early period of use the engine oil gets dirty rapidly because of the initial wear of internal parts Replace the engine oil earlier Lube oil filter should also be replaced when the engine oil is replaced The procedure of lube oil and lube oil filter replacement is as follows a Drain engine oil Prepare a waste oil container collecting waste oil e Remove the oil filler cap to drain easily while draining the lube oil Loosen the drain plug using a wrench customer procured to drain the lube oil The location depends on the engine Securely tighten the drain plug after draining the EECHER lube oil NOTICE Use a socket wrench or a closed wrench when removing or tightening a drain plug Don t use a spanner because it has the possibility that the spanner will slip and it will get hurt b Replacing oil filter e Turn the lube o
121. straightness of parts 8 Square 4 4 4 Disassembly Inspection and Reassembly of Engines Instrument name Application Illustration For measuring shaft bend For tightening nuts and bolts to the specified torque Torque wrench For measuring gaps between ring and ring groove and shaft joints during assembly Thickness gage For checking water leakage Cap tester For checking concentration of antifreeze and the battery electrolyte charge status Battery coolant tester For measuring injection spray pattern of fuel injection nozzle and injection pressure Nozzle tester For measuring temperatures Digital thermometer 4 5 4 Disassembly Inspection and Reassembly of Engines Instrument name Application Illustration Contact type For measuring revolution by contacting the mortise in the revolving shaft Speedometer Photoelectric type For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft Revolving shalt Lem Reflection mark Circuit tester For measuring resistance voltage and continuity of electrical circuits Compression gage adaptor For measuring compression pressure Locally manufactured 4 6 3 Hole Penetration 16mm x 18thread M20 x P1 5 4 Disassembly Inspection and Reassembly of Engines 4 1 3 Complete
122. t agree in a position of the key groove of a pump drive gear 2 Insert a fuel injection pump into the installation hole of the gear case straight to prevent the damage of the O ring Insert a fuel pump with confirming whether the key of a camshaft and the key groove of a drive gear agree 3 Assemble a pump drive gear installation nut and a washer together temporarily 4 Turn a fuel injection pump to the position where the marks 7 2 3 2 of the fuel injection pump and the gear case agrees 5 Fasten pump installation nuts three nuts 6 Tighten the pump installation nut which was assembled temporarily by the specified standard torque Tightening torque of the gear installation nut with lube oil Nem kgfem Tightening torque 58 8 to 68 8 6 to 7 7 3 7 Fuel Injection Pump Governor 7 2 5 Confirmation and adjustment of fuel injection timing Refer to 2 2 7 in Chapter 2 7 2 6 Confirmation and adjustment of no load maximum and minimum speed Refer to 2 3 in Chapter 2 And fuel injection pipes fuel pipes and a remote control wire are installed in the former condition NOTICE Monitor the oil and fuel leakage from the fuel pump system or the oil leakage from the fuel pump flange during the engine running 74 8 The specifications of a starting motor and the characteristics 8 The specifications of a starting motor and the characteristics 8 1 The specifications and the characteristics
123. take 120 Seat angle Deg Valve seat Exhaust 90 4 2 6 Seat correction angle deg 40 150 2 Intake exhaust valve and guide Inspection item Standard Reference page Guide inside diameter 6 000 to 6 012 Intake Valve stem outside diameter 5 960 to 5 975 Clearance 0 025 to 0 052 Guide inside diameter 6 000 to 6 012 Exhaust Valve stem outside diameter 5 945 to 5 960 Clearance 0 040 to 0 067 Valve guide projection from cylinder head 9 8 to 10 0 Valve guide driving in method Cold fitted 3 Valve spring Inspection item Standard Reference page Free length 37 8 4 2 5 4 Inclination 11 Service Standards 4 Rocker arm and shaft Inspection item Standard Limit Reference page Arm shaft hole diameter 12 000 to 12 020 12 07 Shaft outside diameter 11 966 to 11 984 11 94 4 2 5 5 Clearance 0 016 to 0 054 0 13 5 Push rod Inspection item Standard Limit Reference page mm Bend 0 03 4 2 5 7 11 Service Standards 11 2 2 Gear train and camshaft 1 Camshaft Inspection item Standard Reference page Side gap 0 05 to 0 15 4 3 4 Bending 1 2 the dial gage reading 0 to 0 02 4 8 5 1 Cam height 34 135 to 34 265 Shaft outside diameter Metal inside diameter Bushing inside diameter 40 000 to 40 075 Gear side Camshaft outside diameter 39 940 to 39 960 Clea
124. tandard Continuous contact all around E za Valve seat contact 4 Disassembly Inspection and Reassembly of Engines 2 Valve guide Mainly check damage and wear on the inside wall Apply the service part code when replacing a part Measuring positions Service part code d Ki 586400 6800 S L HUA VE Valve guide inside diameter Measuring positions Valve stem outside diameter Valve stem clearance Part name Place Standard Guide LD 6 000 to 6 012 Intake value Stem O D 5 945 to 5 975 Clearance 0 025 to 0 052 Guide LD 6 000 to 6 012 Exhaust value Stem O D 5 940 to 5 960 Clearance 0 040 to 0 067 4 18 4 Disassembly Inspection and Reassembly of Engines 3 Intake exhaust valve Mainly clean and check damage and wear at the valve stem and seat a Seat contact See 1 d above b Stem outside diameter See 2 above c Valve head thickness Part Standard Intake 0 9 to 1 1 Exhaust 1 0 to 1 2 Thickness emm Valve head thickness d Valve stem bend mm e Overall length Intake Exhaust 86 8 to 87 2 4 Valve spring Mainly inspect damage and corrosion mm Free length Inclination limit 37 8 1 3 Valve spring 4 19 4 Disassembly Inspection and Reassembly of Engines 5 Valve rocker arm Mainly inspect valve head cap contact surface inside surface
125. tch or disconnect the negative cable before inspecting the electrical system Failure to do so could cause short circuiting and fires e Always disconnect the Negative battery cable first before disconnecting the battery cables from battery An accidental Short circuit may cause damage fire and or personal injury And remember to connect the Negative battery cable back onto the battery LAST Proper ventilation of the battery area Keep the area around the battery well ventilated paying attention to keep away any fire source During operation or charging hydrogen gas is generated from the battery and can be easily ignited Do not come in contact with battery electrolyte T Pay sufficient attention to avoid your eyes or skin from being in contact with the fluid The battery electrolyte is dilute sulfuric acid and causes ie burns Wash it off immediately with a large amount of fresh water if you get any on you 2 8 2 Inspection and Adjustment Battery structure j Cathode plate Separator Glass mat N Anode plate 1 Electrolyte level Check the level of fluid in the battery When the amount of fluid nears the lower limit fill with battery fluid available in the market to the upper limit lf operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Upper limit e Battery fluid tends to evaporate more quickly in t
126. tening Torque for Bolts and Nuts 12 TIGHTENING TORQUE for BOLTS and NUTS 12 1 Tightening Torques for Main Bolts and Nuts Thread Lubricating oil diameter Tightening torque application Reference FOIT X pitch thread portion page mm N m kgf m and seat surface Cynder haad Boli M9 x 1 25 i E F Applied 4 2 4 Connecting rod bolt M7 x 1 0 E S Applied 444 Piywheel set Dolt M10 x 1 25 n E AEN Applied 4 84 Bearing cap set bolt M10 x 1 25 ice Applied 444 Crankshaft 83 3 to 93 3 FC250 pulley set port M12 x 1 25 E Z 2al Applied 4 3 4 S48C 11 5 to 12 5 Fuel pump drive gear nut M12 x 1 75 p e 20 Applied 434 Fuel pump gear bolt M8 x 1 0 ee SEH Not applied Fuel injection pipe sleeve nut M12 x 1 25 GE a SCH Not applied Fuel injection nozzle nut M20 x 1 5 t s GH Not applied Governor weight support nut M12 x 1 25 a a dd Applied i slow pug M10 x 1 25 us S 20 Not applied 12 1 12 Tightening Torque for Bolts and Nuts 12 2 Tightening Torques for Standard Bolts and Nuts Nominal thread diameter X pitch Tightening torque N m kgf m Remarks Hexagon bolt 7T and nut M6 x 1 9 8 11 8 1 0 1 2 M8 x 1 25 22 6 28 4 2 3 2 9 M10 x 1 5 44 1 53 9 4 5 5 5 M12 x 1 75 78 4 98 0 8 0 10 Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for AT bolts and lock n
127. the injection timing is out of the standard value loosen the fuel pump mounting nut and incline the fuel injection pump toward or away from the engine for adjustment Incline toward the engine to delay the tim ing and away from the engine to advance it One graduation of the timing scale on gear case corresponds to two degrees in injection timing 2 24 2 Inspection and Adjustment 2 3 Adjusting the no load maximum or minimum speed 1 After warming the engine up gradually raise the speed and set it at the no load maximum revolution 2 If the no load maximum revolution is out of the standard adjust it by turning the high idle limiting bolt 3 Then set the no load minimum speed by High idling speed adjusting the low idle limiting bolt lenting elk Governor lever Accelerating wire Accelerating wire bracket Low idling speed limiting bolt Standards Unit min Engine application class Rating speed EES EEN t 25 25 2000 2160 2100 2250 2200 2355 2300 2460 2400 2570 2500 2675 2600 2780 2700 2890 2800 2995 2900 3100 3000 3210 3000 3600 3100 3200 3300 3400 3500 3600 Note The engine speed may differ from the above standard depending on an engine installed on a machine unit 2 25 2 Inspection and Adjustment 2 4 Sensor Inspection 2 4 1 Oil pressure switch Disconnect the connector from
128. the magnet switch Be sure to install a vent in the clutch case 10 3 10 Electric Wiring 10 1 3 Current limiter In the cases listed below the warranty shall not be deemed to apply Please be sure to read these conditions carefully when planning to use it with other equipment Also be certain to give appropriate guidance on usage to the user 1 When an over discharged battery is used Use of booster starting with an over discharged battery when the voltage has dropped to 8V or less will destroy other electrical equipment by generating an abnormally high voltage A specialized battery charger should be used to recharge such an over discharged battery when the voltage has dropped to 8V or less 2 When checks for malfunctioning are not performed When high voltage noise from other electrical equipment is impressed on the current limiter upon turning off the key switch the current limiter can be damaged and cause loss of control over the output voltage Other electrical equipment may also be damaged if this happens so surge killers should be fitted to the electrical equipment whenever necessary Be sure to check prior to mass production whether electrical noise might damage the current limiter by turning the key switch and other electrical equipment on and off while the engine is running using both the vehicle and the wire harness that will be used in mass production 3 Removal of the battery cable during operation The current l
129. the oil pressure switch Keep the voltammeter probes in contact with the switch terminal and cylinder block while operating the engine It is abnormal if circuit is closed 2 4 2 Thermo switch Place the thermo switch in a container filled with antifreeze or oil Heat it while measuring the fluid temperature The switch is normal if the voltammeter shows continuity when the fluid temperature is 107 113 deg C Check coolant water leakage from the cooling water system visually If any problem is found Inspect as follows 1 Fill coolant water to the normal level in the radiator and install the cap tester on the radiator 2 Operate the manual pump to set the pressure to 0 09 0 015MPa 0 9 0 15kgf cm If the cap tester pressure gage reading drops then water is leaking from the cooling water system Check the water leaking point 2 26 Cylinder block l Oil pressure switch E flywheel side Tester probes V P A Continuity test Thermometer EZ er switch A Hot water A Cap tester Water leak check in cooling water system 2 Inspection and Adjustment 2 6 Radiator cap inspection Install the radiator cap on the cap tester Setthe tester pressure to 0 09 0 015MPa 0 9 0 15kgf cm and see that the cap is opened If the cap does not open replace the cap since it is abnormal Radiator cap Radiator cap inspection 2 7 Thermostat Inspection Place the thermostat in a
130. the pin outside diameter according to 4 4 5 4 b described above mm Item Standard Limit D pin 22 025 to 22 038 22 068 D bushing Pin O D 21 991 to 22 000 21 963 Clearance 0 025 to 0 047 0 105 Connecting rod aligner UH i Twist measurement using connecting rod aligner If the bushing is to be replaced because the oil clearance exceeds the limit use spare part Service part code 586400 6980 Connecting rod small end 4 44 4 Disassembly Inspection and Reassembly of Engines d Rod big end measurement Measure the crankpin outside diameter The oil clearance is calculated as the difference in the crankpin outside diameter and the crank pin metal inside diameter refer to 4 4 5 2 c Replace the crankpin metal if a clearance becomes close to the limit value in the table below If wear and unevenly wear on the crankpin is found correct by grinding the crankpin and apply the undersized bushing refer to 4 4 5 2 c NOTICE Cylinder gage When measuring the inside diameter of the rod big end install the bushing in the rod big end not to mistake top and bottom of the crankpin metal and fasten the rod bolts by the standard torque shown in the table Rod bushing LD measurement Tightening torque of rod bolt Tightening torque Lubricating oil application N m kgf m threaded portion and bearing seat surface 22 6 to 27 5 2 3 to 2 8 Lube oil applied Standard of rod big
131. tion gas passes through the clearance between the cylinder and the piston piston ring and flows to the crankcase This is said as blowby gas While it passes into the cylinder head and the rocker arm cover the blowby gas mixes with splash oil and becomes oil mist blowby gas mixes with splash oil and becomes oil mist blowby gas ith passing through the baffle plate inside a rocker arm cover And it passes through a diaphragm assy and a intake manifold and is reduced in the combustion chamber Pressure inside a crankcase is controlled by the function of the diaphragm assy and suitable amount of blowby gas is reduced in intake air system Disassemble When a rocker arm cover is taken off check whether oil or the like enter the diaphragm space from a small hole on the side of a diaphragm cover or not without disassembling the diaphragm NOTICE 1 When a diaphragm is damaged pressure control inside the crankcase becomes insufficient and troubles occur When the internal pressure of the crankcase decreases too much due to the damage of a spring much blowby gas containing oil is reduced in intake air system and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and so on it is considered that oil leakage from the joint of a oil pan a oil seal and so on
132. uts 1 8 9 8 1 0 1 4 19 6 2 0 3 8 29 4 3 0 1 2 58 8 6 0 Pipe joint bolt M8 12 7 16 7 1 8 1 7 24 5 34 3 2 5 3 5 39 2 49 0 4 0 5 0 49 0 58 8 5 0 6 0 Note Lubricating oil is not applied to threaded portion and seat surface 12 2 Copyright reserved This manual may not be reproduced or copied in whole or in part without the specific written consent of ISUZU MOTORS LIMITED WORKSHOP MANUAL INDUSTRIAL INDUSTRIAL DIESEL ENGINE 2CA1 3CA1 3CB1 IDE 2397 Issued by ISUZU MOTORS LIMITED POWERTRAIN SERVICE amp PARTS DEPARTMENT POWERTRAIN SALES DIVISION 6 26 1 Minami Oi Shinagawa ku Tokyo Japan 140 8722 TEL 03 5471 1111 First edition Dec 2004 412 01K
133. ve after oil application so as not to damage the stem seal e Different stem seals are provided for the intake and exhaust valves Do not confuse them since those for exhaust valves are marked with yellow paint After assembling the intake exhaust valve stem seal valve spring seat and cotter tap the head of the valve stem lightly for settling Do not forget to install the valve cap 4 16 4 Disassembly Inspection and Reassembly of Engines 4 2 5 Parts Inspection and measurement 1 Cylinder head Clean the cylinder head mainly the combustion surface valve seats and intake exhaust ports remove carbon deposit and bonding agent and check the surface state a Appearance check Check mainly discoloration and crack If crack is suspected perform color check b Combustion surface distortion Apply a strait edge in two diagonal directions and on four sides of the cylinder head and measure distortion with a thickness gage Standard Limit 0 05 or less 0 15 c Valve sink E D Thickness gage mm Distortion at combustion surface Measure with the valve inserted to the cylinder head Depth micrometer Standard Limit Intake 0 4 to 0 6 0 8 Exhaust 0 4 to 0 6 0 8 Te T Valve sink Valve sink depth d Seat contact Apply a thin coat of minimum on the valve seat Insert the valve in the cylinder and push it against the seat to check seat contact S
134. ver Outer rotor Control a i valve Tiny Inner rotor 11 2 Gear case cover aw on 5 3 Disassembly Reverse the procedure below for assembly 1 Loosen the belt and remove the radiator pulley fan and V belt See 4 2 2 2 in Chapter 4 2 Remove the crankshaft pulley See 4 3 2 3 in Chapter 4 3 Remove the gear case cover See 4 3 2 4 in Chapter 4 4 Remove the lube oil cover from gear case cover 5 4 Point 1 5 Remove the pressure regulating valve from the lubricating oil pump cover 5 4 Point 2 5 4 Servicing Points Point 1 Disassemble Check if the pump rotates smoothly and see that there is no play between the shaft and gear and inner rotor Reassemble Rotor outer inner insertion part is to apply lube oil For installation on the gear case cover tighten the lube oil pump cover by the standard torque N m kgf m Lube oil application Tightening torque threaded portion and bearing seat surface 5 9 to 7 9 0 6 to 0 8 Lube oil applied e When replacing the lube oil pump replace the whole assy including the outer inner rotor NOTICE Always check if the pump rotates smoothly after installation on the gear case Running the engine when the pump rotation is heavy may cause the pump to be burnt Point 2 Disassemble Reassemble Only wash the pressure regulating valve Disassembly is unnecessary unless any abnormality in operation is detected 5 2 5
135. will occur When a diaphragm is damaged blowby is discharged from the breathing hole on the side of diaphragm cover and not reduced in the intake manifold Therefore be careful of the diaphragm trouble 2 At lubricating oil replacement or lube oil supply The amount of lubricating oil isn t to be beyond the standard upper limit in the engine horizontality the upper limit mark of the dip stick Since the blowby gas reductor is adopted be careful that the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur when the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine Reassembly Replace the diaphragm with new one when it is damaged 4 14 4 Disassembly Inspection and Reassembly of Engines Point Disassemble Keep the removed push rods by attaching tags showing corresponding cylinder Nos Reassemble e Always apply oil to the contact portions of the push rods and clearance adjusting screws Point8 Disassemble Loosen the cylinder head bolts in two steps in the illustrated order Place the cylinder head assy on a paper board to prevent the combustion face from any damage Disassembly Camshaft side 44 Reassemble e Remove the head gasket with a new one e Uniformly install the head bolts manually after applying oil on the threaded and seat portions e They shall b
136. ywheel housing Disassemble Place the engine on a stable base with the cylinder block upper surface facing down and remove the flywheel housing carefully so as not to damage the combustion surface 4 32 4 Disassembly Inspection and Reassembly of Engines Reassemble Apply sealant TB1207B or equivalent and install the flywheel housing by matching the two dowel pins After assembly raise the engine with its flywheel housing on the bottom side A CAUTION Unforeseen injury may arise due to falling of slipping when raising or reversing the engine Carefully operate so as not to lose balance Point4 Journal bearing cap Disassemble Before removing the journal bearing measure the crankshaft side gap Measure it in either method because there are the next two methods 1 Install a dial gage on the cylinder block and move a crankshaft in front and back and measure the side gap as shown in the right figure 2 Put a thickness gauge in the clearance between thrust metal and crankshaft directly and measure it Side gap standard mm Standard Limit 0 13 to 0 23 0 28 Reassemble If the side gap exceeds the standard replace the thrust metal with an oversize one Side gap measurement 2 0 25mm Oversized thrust metal 0 25DS mm Thrust metal assy code Standard thickness 586400 7740 2 055 to 2 105 4 Disassembly Inspection and Reassembly of Engines Disassemble Remove the b

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