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Service Manual for M..

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1. Apply MOLYKOTE RAG650 to locations marked with Pinion stopper Pinion stopper Stopper ring Installing the stopper ring 4 5 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY Adjusting the pinion shaft end play Adjust the end play thrust gap to 0 5 mm 0 02 in or less as illustrated by inserting an appropriate washer between the center bracket and the reduction gear Install reduction gear washers and a snap ring onto the pinion shaft complete with the center bracket Measure the pinion shaft end play by moving the shaft in the axial direction If the measured value exceeds 0 5 mm 0 02 in correct by adding adjusting washers Installing the lever Install the lever in the correct orientation Inspecting the pinion gap With the pinion fully pulled out to the rear gently push back the end of the pinion with a finger and measure the distance that the pinion has moved back If the measured distance is out of the 0 5 to 2 0 mm 0 02 to 0 08 in range add or reduce the packings mounted at the magnetic switch If the pinion gap is too great add the packings If the pinion gap is too small reduce the packings Reduction gear Adjusting washer mh Wash
2. S3L S3L2 Oil filler Thermostat Hanger Exhaust manifold Alternator Starter Fan Front end Rear end V belt heel Oil pan io Left hand side Engine LH side view Fuel injection nozzle Fuel injection pump i ater pump Stop solenoid Coolant drain plug Inlet cover Rear end Front end nkshaft pull Flywheel housing Di pulley Oil filter Oil level gauge Oil drain plug Right hand side Engine RH side view GENERAL S4L S4L2 Hanger i oo Alternator A Fan Front end Fuel injection pump Oil filler Exhaust manifold 1 fl lo YQ eke od oad gR tp In j l i j i Starter p co asa Rear end 4 J 25 z i ite os Flywheel E i Left hand side Engine LH side view Fuel injection nozzle Water pump
3. Stop solenoid eee Z Coolant drain plug aTi Inlet cover pa Rear end H bo N Front end L C i Q ee he Flywheel housing AO 6 A Crankshaft pulley Oil filter h Oil level gauge Oil drain plug Right hand side Engine RH side view GENERAL 1 2 Fuel System Schematic Fuel leak off pipe Fuel injection pipe To fuel tank qm Fuel injection nozzle Fuel pump Fuel injection pump Fuel filter From fuel tank Fuel system schematic 1 3 Oil System Schematic Relief valve Oil pump Oil strainer Oil drain plug Oil system schematic GENERAL 1 4 Cooling System Schematic Water pump Water bypass valve Thermostat Cooling fan Cooling system schematic 1 5 Inlet Exhaust System Schematic Exhaust gas lt I Intake air Air breather pipe positive crankcase Blow by gas ventilation Intake air from air cleaner Exhaust gas to muffler Inlet cover Exhaust manifold Inlet exhaust system schematic GENERAL 1 6 Engine Serial Number A ASA hs Engine serial number _ The engine serial number is stamped on the top face of the fuel injection pump bracket on the right hand side of the cylinder block 1 7 Engine Model and Application Codes 1 The engine model code is embossed on the side of
4. Inspecting the injection valve opening pressure Nozzle tip end Replacing the fuel injection nozzle tip assembly Good Bad Bad Bad Bad Diffused Dribbling Deflected Feathering eS F rom ik Fuel spray patterns ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 3 Clean or replace when spraying badly a Loosen the nozzle retaining nut and remove the nozzle tip assembly Clean the needle valve and the nozzle tip body A CAUTION When removing the nozzle tip assembly never tap on the end of the assembly b Wash the needle valve and the nozzle tip body in clean wash oil Reassemble them in clean light oil Note The needle valve and the nozzle tip body are precision machined parts Handle with care and never change their combination c Assemble the fuel injection nozzle tightening the nozzle retaining nut to the specified torque d If the fuel spray pattern is still not good replace the nozzle tip assembly Note a Never touch the sliding surface of the needle valve with your hands b If the nozzle tip assembly is replaced remove the seal peel synthetic resin film from the new nozzle tip assembly and slide the nozzle and needle valve in clean wash oil to completely remove the anti corrosive agent 4 Installing the fuel injection nozzles a Install a new gasket onto the fuel injection b Insert the fuel injection nozzle into the
5. Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 lbf ft These areas should be free of sealant 0 15 to 0 50 mm 0 006 to 0 008 in Shaft Threaded portion Apply sealant Installing the stop solenoid Inspecting the glow plug ELECTRICAL SYSTEM INSTALLATION 1 Glow Plug Sajak ewe A AEAT A bbws ve A A nnbe bbe A A S A we celne 7 26 2 Stop Solenoid BAS ENO CCS E SITCOM OGRE ORCS CET CCCCCTICIM CORO CCIOTO CORPO EC CRCCCC IMC CIr Cr cera itn 7 27 3 Alternator aie ataate ewes Wiwiwia ece acwiGtaa wa w e E AAA OA AE A A A AA AAA wate mw E 7 28 4 Starter AA A a a A a A A EE A DEEE 7 29 ELECTRICAL SYSTEM INSTALLATION 1 Glow Plug Tightening torque 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 8 to 14 5 lbf ft Installation of the glow plug lt Installation sequence gt gt ELECTRICAL SYSTEM INSTALLATION 2 Stop Solenoid w rubber cap and plugs Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 lbf ft Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 lbf ft l l l w 3 pole waterproof connector Installation of the stop solenoid lt lnstallation sequence gt ELECTRICAL SYSTEM INSTALLATION 3 Alternator Tightening torque 9 81 to 11 8 N m 1 0 to 1 2 kgf m 7 2 to 8 7 Ibf ft Installation of the alternator lt Installation sequence
6. 3 After correction lap the valve face against the 60 valve seat using lapping compound Valve seat angle and width ENGINE MAIN PARTS INSPECTION AND CORRECTION 1 11 Note 1 12 1 Lapping the valve face against the valve seat If the valve seat is corrected or the valve is replaced be sure to lap the valve face against the valve seat in the following manner Apply a light coating of lapping compound evenly over the valve face a Take care not to allow lapping compound to attach to the valve stem b Use medium lapping compound 120 to 150 mesh first then finish off with fine lapping compound 200 mesh or above c Lapping compound spreads more evenly if it is mixed with a small amount of engine oil Using a valve lapper lap the valve face against the valve seat repeatedly while rotating it gradually Wash away the lapping compound in light oil or other similar liquid Apply engine oil onto the lapped faces and lap them again Check the lapped faces for correct contact Replacing the combustion jets Replace the combustion jets only when they are cracked or faulty To extract the combustion jet insert a round rod with a diameter of approx 6 mm 0 23 in into the glow plug mounting hole and gently tap the periphery of the combustion jet bore To install the jet tap it into the mounting hole using a plastic hammer or other similar tool Ensure that the nozzle hole faces the cente
7. 95 C 203f Replace At 111 3 5 C Th itch crmoswne 231 8 6 3f 30 MQ when dipped in oil of 105 C 221 Replace Fan belt deflection when pressed with a force of approx 98 N 10 kgf 22 between crankshaft and alternator pulleys and between crankshaft and fan pulleys 1 14 10to 12 0 4 to 0 5 Replace SERVICE STANDARDS Unit mm in 2 Item Nominal Standard value Limit Remarks 6 value 5 Paper element type ai Repl z aper element type air eplace every o eisance Clean every 100 hours 300 hours o eo j Inlet exhaust manifold _ 0 15 0 006 Grind or e mounting face distortion or less replace Pinion ga 0 5 to 2 0 _ Adjust with gap 0 02 to 0 08 packing Terminal MO001T68281 M008T70471A M008T81071A No load voltage lV lV 23 V character Current 110A 130A 80A 2 Inspect istics or less or less or less Rotation 2400 3600 3000 SS speed min min min MO08T70471A 5 OEE 16 5 18 0 MOOIT68281 ooBTS1071A TE E rush leng 0 65 0 71 10 0 11 0 eplace n 0 39 0 43 17 5 to ea 29 4 to 39 2 N 6 90 N 13 7 N Brush spring load 2 41 kef 3 0 to 4 0 kgf 0 70 kgf 1 40 kgf Replace E 3 9 to 5 3 6 6 to 8 8 lbf 1 6 lbf 3 1 lbf v lbf o Commutator radial 0 05 0 03 0 10 Correct or S runout 0 002 0 001 0 004 repl
8. 3 Removing the stator core and the rectifier a Unsolder the stator core leads at the rectifier Remove the stator core INNO ie Unsoldering must be finished as quickly as possible Extended heating will damage the diodes b Loosen the retaining screws and remove the rectifier Separating the front bracket from the stator core Rectifier Soldered lead Removing the stator core 7 19 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 2 Inspecting and correcting the alternator 1 Inspecting the diodes Perform continuity test on each of the rectifier diodes in the following manner a Connect a tester between the diode lead terminal and the casing of that diode A great resistance should be indicated in one direction and a small resistance in the opposite direction b If the same level of resistance is indicated in both directions replace the rectifier Perform Inspecting the diodes this test on all diodes 2 Inspecting the field coils a Measure between the slip rings Replace if no continuity is indicated open circuit b Measure between the slip ring and the shaft or the core Replace if continuity is indicated Testing the field coils for continuity ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 3 Inspecting the stator core a Measure between the stator leads in various combinations Replace if no continuity is indicated open circuit b
9. Square with piston pin pN Nominal Standard Limi imit y value value lt 78 00 Standard Cylinder 78 to 78 03 value bore 3 07 3 0732 0 2 to 3 0743 0 0080 A Parallel with piston pin Measurement Cylinder bore No 2 Engine Inspection Sheet Engine number Item to be Valve stem to guide clearance and measured valve stem diameter Measuring location Standard value Inlet 6 6 6 600 to 6 615 Valve guide 0 260 0 2600 to 0 2606 inner diameter 6 6 6 600 to 6 615 0 260 0 2600 to 0 2606 6 565 to 6 580 Valve stem 0 2586 to 0 2592 diameter Exhaust 988 6530t06 550 6 500 aust 9 960 0 2572 to 0 2580 0 256 So sun me attest A sc oie 0 0008 to 0 0020 0 004 0 050 to 0 085 0 150 o 020 ro 0 0033 0 006 clearance Exhaust Measurement Valve stem to guide clearance Engine Inspection Sheet No 3 Engine model S csom E o ae Measuring location Valve seat width A IE Measurement Valve seat width No 4 Engine Inspection Sheet Engine number Item to be measured Cylinder head bottom face distortion Unit mm in Measuring location Standard value 0 05 bottom face 0 002 distortion or less Measurement Cylinder head bottom face distortion a Romarks S Remas d by Confirmed by Measured by Engine Inspection Sheet No 5 Customer Engine model Engine model Engine numb
10. Oil Filter Relief Valve and Oil Pressure Switch vrrrsrrrrsrteretrereettereeeteeees 4 10 1 1 Installing the oil pressure switch pun e s a s A a ne Wiw hiW Nin wpe p s i e n n w h Wi Ri in wiwin w e w hn w wlw Wie 4 1 0 1 2 Installing the relief valve Gi fw ln www Swi Ww A A A 4 11 SCSRERSSUDDCESC PPD AATSDERDEGOG SS DEDS SD EMERE CSSD A ee eee 4 11 1 3 Installing the oil filter 2 Oil Pan and Oil Strainer siete EE E be bikik w vie e a wi GU wn ne E EE elena etn nee E we weit e sec Wete 4 12 OIL SYSTEM INSTALLATION 1 Oil Filter Relief Valve and Oil Pressure Switch Tightening torque 44 1 to53 9N m 4 5 to 5 5 kgf m 32 5 to 39 8 lbf ft Tightening torque 10 8 to 12 7 N m 1 1 to 1 3 kgf m 8 0 to 9 4 lbf ft D o ime Tightening torque G 7 85 to 11 8N m G S 0 8 to 1 2 kgf m 5 8 to 8 7 lbf ft Installation of the oil filter relief valve and oil pressure switch lt Installation sequence gt 1 1 Installing the oil pressure switch 1 Using the special tool Oil Pressure Switch Socket Wrench tighten the switch to the specified MD998054 torque Special tool Part number MD998054 Oil Pressure Switch Socket Wrench Tightening torque 7 85 to 11 8 N m Apply sealant here 0 8 to 1 2 kgf m 5 8 to 8 7 lbf ft 2 Apply sealant ThreeBond 1102 onto the threaded portion of the switch A CAUTION a Apply proper amount of sealant so that it will not b
11. Removal of the oil filter relief valve and oil pressure switch lt Removal sequence gt Oil filter Relief valve Oil pressure switch OIL SYSTEM REMOVAL 1 1 Removing the oil filter 1 Place an drip pan under the oil filter 2 Using a filter wrench remove the oil filter 1 2 Removing the relief valve Remove the relief valve Removing the relief valve 1 3 Removing the oil pressure switch Using the special tool Oil Pressure Switch Socket Wrench remove the switch MD998054 Special tool Part number MD998054 Oil Pressure Switch Socket Wrench Removing the oil pressure switch OIL SYSTEM REMOVAL 2 Oil Pan Oil Strainer Removal of the oil pan and oil strainer lt Removal sequence gt Oil pan Oil strainer OIL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Oil Pump ATE E TELL LER RR RETIRE TREE LTT EEE TERT COCO A a torr 4 6 Inspecting the oil pump AAA DSRS CUUSSEDERUN OD A nb ease eee bee 4 6 2 Relief Valve LRP ERE REET ECC TEER OTE A 4 ic 6 Inspecting the relief valve nin Dw Wis a e A Wn e nan nce Win n ebisipiew salu wiulule E Winn ole E a T 4 6 3 Oil Pressure Switch BASSES A COCO C CSTR OCCT CCCrR CR CCOSC CMCC orn tremor rrr riy 4 2 7 Inspecting the oil pressure switch E E TAE A AAAA O A 4 5 7 OIL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Oil Pump Inspecting the oil pump Check the oil pump for any damage and whether Inspect for da
12. mew oo Ao i A jit Fuel spray patterns Nozzle tip body Cleaning the fuel injection nozzle tip components aati FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY c Assemble the fuel injection nozzle tightening the nozzle retaining nut to the specified torque d If the fuel spray pattern is still not good replace the nozzle tip assembly Note a Never touch the sliding surface of the needle valve with your hands b If the nozzle tip assembly is to be replaced remove the seal peel synthetic resin film from the new nozzle tip assembly and slide the nozzle and needle valve in clean wash oil to remove the anti corrosive agent completely 1 3 Reassembling the fuel injection nozzle E S 49 0 to 58 8 N m wW 5 0 to 6 0 kgf m 36 2 to 43 4 lbf ft O1 D Tightening torque 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 Ibf ft Reassembly of the fuel injection nozzle lt Reassembly sequence gt 8 8 0 3 12 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 Fuel Injection Pumps 2 1 Inspecting the fuel injection pump on vehicle Do not disassemble the fuel injection pump unless it is necessary If the pump is suspected to be faulty it is recommended that the entire pump assembly be replaced Inspection item Description PASS criteria Low idle speed Inspect the low idle speed 10
13. pistons and oil pan lt Disassembly sequence gt Oil pan Piston Oil strainer Remove to as an assembly Connecting rod cap O Connecting rod bearing upper Connecting rod bearing lower O Main bearing cap Connecting rod O Main bearing lower Piston pin O Crankshaft No 1 ring O Main bearing upper No 2 ring O Cylinder block Oilring Note If the crankcase is to be replaced carefully remove the relief valve and other parts from the old crankcase for reassembly onto the new crankcase 2 12 3 1 Removing the oil pan 1 Turn the engine upside down 2 Remove the oil pan by tapping it on the bottom corners with a plastic hammer A CAUTION Do not insert a chisel or a screwdriver between the oil pan and the cylinder block to remove the oil pan Otherwise the oil pan flange face will be deformed 3 2 Removing the oil strainer Loosen the nut to remove the oil strainer 3 3 Removing the connecting rod caps 1 Place the cylinder block on the side 2 Mark the cylinder numbers on the connecting rods and caps to ensure that they will be reassembled in original pairs 3 Remove the connecting rod caps ENGINE MAIN PARTS DISASSEMBLY Removing the connecting rod caps 2 13 ENGINE MAIN PARTS DISASSEMBLY 3 4 Removing the pistons 1 Rotate the crankshaft to place the piston being removed at the top dead center 2 Using a wooden piece such as the stem of a ham
14. teeth of rack and sleeve 3 The delivery valve holders have been overtightened Disassemble and inspect c After reassembly check the fuel injection timing Inspecting the control rack for smooth operation 3 19 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 3 Governor 3 1 Disassembling and inspecting the governor Levers should operate smoothly Worn or damaged weights Sliding sleeve wear damage The sleeve should slide smoothly Worn or damaged lever contact with sliding sleeve A A g Spring fatigue Disassembly and inspection of the governor lt Disassembly sequence gt Tie rod spring Remove to as an assembly Tie rod Governor lever Speed control lever Start spring Spring pin Tension lever Grooved pin Governor spring Governor shaft O Governor spring lever O Governor case FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 3 2 Reassembling the governor 1 Install the levers first 2 Install the O ring onto the governor shaft 3 Insert the governor shaft into the governor case and combine it with the levers 4 Hold the grooved pin and the spring pin in place and knock them in with a soft hammer 5 Install the tie rod and the tie rod spring 3 3 Installing the torque spring set Speed Torque Prior to installation adjust the low and high idle conl See Notched line
15. the rod bend and twist 3 When measuring connecting rod bend with the piston installed to the connecting rod place the piston rod assembly on a surface plate such that the top of piston lies on the plate Then insert a round rod with the same diameter as the crank pin into the connecting rod large end Using a dial gauge measure the top of the round rod for any variation in height Using a dial gauge to measure 2 28 the connecting rod for bend ENGINE MAIN PARTS INSPECTION AND CORRECTION 3 6 Measuring the connecting rod end play Install the connecting rod and the rod cap onto the mating crank pin Tighten the cap nuts to the specified torque Using a thickness gauge measure the gap end play If the measured value exceeds the limit replace the connecting rod and the rod cap Unit mm in oo Standard value 0 10 to 0 35 0 004 to 0 014 Connecting rod end play 3 7 Inspecting the oil clearance for connecting rod bearings 1 Install the connecting rod bearings upper and lower into the connecting rod large end Tighten the cap nuts to the specified torque Measure the inner diameter of the bearings 2 Measure the diameter of the mating crank pin The difference between the bearing inner diameter and the crank pin diameter is the oil clearance for the bearings Unit mm in Standard value value 48 47 950 to 47 964 1 8912 1 8892 to 1 8897 0 025 to 0 072 0 0010 to 0 0028 Nomi
16. 2 The coolant temperature which should be 75 to 85 C 167 to 185 3 The temperature of engine oil in the oil pan which should be 60 to 95 C 140 to 194 4 There should be no leakages of oil coolant or fuel Pay particular attention to the turbocharger lubrication oil pipe connections 5 Diesel knock should disappear as the coolant temperature rises Other than that there should be no noise 6 The exhaust gas for any abnormal color or smell 8 12 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 3 Performance Test While a number of methods exist for testing the performance of engines the following are excerpts from Earth moving machinery Engines Part 1 Test code of net power JIS DO006 1 and Earth moving machinery Engines Part 2 Standard format of specifications and tests methods of diesel engines JIS DO006 2 Test items will need to be expanded in a manner appropriate for specific applications The performance of the engine should be determined based on the overall test results 3 1 Standard ancillaries The engine being tested should be equipped with those ancillaries that are essential for the engine to operate normally including the radiator fan air cleaner and alternator 3 2 Test items and purposes 1 Working load test This test is aimed at obtaining the output torque fuel consumption and governor performance under various loading 2 Conti
17. 25 53 9 to 73 5 5 5 to 7 5 39 8 to 54 2 Equivalent to 7T Fuel system Hollow screw fuel injection pump Delivery valve holder fuel injection pump Air bleeder plug fuel injection pump Nozzle retaining nut M16x 0 75 34 3 to 39 2 3 5 to 4 0 25 3 to 28 9 Nozzle holder M20x 1 5 49 0 to 58 8 5 0 to 6 0 36 2 to 43 4 Fuel injection pipe nut M12x 1 5 24 5 to 34 3 2 5 to 3 5 18 1 to 25 3 Fuel leak off pipe nut M12x 1 5 20 6 to 24 5 2 1 to 2 5 15 2 to 18 1 Sliding sleeve shaft M10x 1 25 29 4 to 41 2 3 0 to 4 2 21 7 to 30 4 Torque spring set special nut M12 x 1 0 14 7 to 24 5 1 5 to 2 5 10 8 to 18 1 Oil system Oil relief valve M22 x 1 5 44 1 to 53 9 4 5 to 5 5 32 5 to 39 8 Oil pan drain plug M14x 1 5 34 3 to 44 1 3 5 to 4 5 25 3 to 32 5 Oil filter M20x 1 5 10 8 to 12 7 1 1 to 1 3 8 0 to 9 4 Oil pressure switch PT1 8 7 85 to 11 8 0 8 to 1 2 5 8 to 8 7 Oil pan mounting bolt M8 xX 1 25 9 80 to 12 7 1 0 to 1 3 7 2 to 9 4 Equivalent to 4T Oil strainer nut M16 x 1 5 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Cooling system Thermoswitch M16x 1 5 18 6 to 26 5 1 9 to 2 7 13 7 to 19 6 Thermostat cover bolt M8 x 1 25 16 to 20 1 6 to 2 0 11 8 to 14 8 Thermo case bolt M16x 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 1 Inlet and exhaust systems Inlet cover bolt M8x 1 25 14 7 to 21 6 1 5 to 2 2 10 8 to 15 9 Exhaust manifold bolt M8 xX 1 25 14 7 to 21 6 1 5 to 2 2 10 8 to 15 9 Electrical system Starter terminal B M8x 1 25 9 81 to 11 8 1 0 to 1 2 7 2 to 8 7 Stop solenoid fixin
18. 4 corners 0 20 in 5mm Apply oil pan liquid gasket here top face Sealant application pattern Cut here Cutting the end of sealant tube 2 Tighten the oil pan retaining bolts diagonally in several steps and finally to the specified torque Tightening torque 9 80 to 12 7 N m 1 0 to 1 3 kgf m 7 2 to 9 4 lbf ft Installing the oil pan ENGINE MAIN PARTS REASSEMBLY 2 Flywheel Timing Gear Camshaft To reassembly follows the disassembly sequence in reverse 2 1 1 2 3 2 4 Installing the front plate Completely scrape off any remaining gasket from the cylinder block and the front plate Install the front plate onto the cylinder block Tighten the four retaining bolts Apply sealant onto the side of the gasket that is to be mated to the front plate Attach the gasket onto the front plate The sealant will prevent the gasket from moving Installing the oil pump Ensure that the oil pump is correctly fitted with packing Install the oil pump onto the crankcase Tighten the three retaining bolts evenly Ensure that the oil pump gear rotates smoothly Rotating the engine Install two studs M12 1 25 into the flywheel mounting holes in the crankshaft Place a bar between the studs and rotate the crankshaft until the No 1 cylinder comes to the top dead center Tapping the fuel injection pump camshaft into place Insert the fuel injection pump camshaft complete wit
19. 67380 14 96 7 380 14 96 z5 cY Air cleaner Type Paper element 79 Voltage Polarity 12 V ground 24 V ground Type M001T68281 MO08T70471A MO08T81071A Manufacturer Mitsubishi Electric Corporation aon Pinion shift reduction Starter engagement Output V kW 12 V 1 7 12 V 2 0 24 V 3 2 No of units 1 Reduction ratio 13 120 pinion ring gear Type 3 phase alternator w built in IC regulator Manufacturer Mitsubishi Electric Corporation E Output V A 12 50 24 25 v Alternator Speed at which 2 rated voltage is min 5000 13 5 V 47 A 5000 27 0 V 22 A g generated 3 Regulated voltage V 14 7 0 3 12 50 26 5 0 5 24 25 D Type Sheathed plug 12 V plug 24 V plug ENEE E A 10 5 9 7 22 5 5 30 second application 25 second application Operating y 12 V ETR 12 V ETS 24 V ETR 24 V ETS voltage 8 or less 10 to 15 16 or less 20 to 30 Insulation resistance Be eee ate see Stop at ordinary temperature and humidity solenoid Stroke mm in 13 5 0 5 0 53 0 01 Working 40t0120 30t0120 40t0120 30 to 120 apent C O 40 to 248 22 to 248 40 to 248 22 to 248 temperature GENERAL 3 Disassembly Reassembly Notes This Service Manual specifies various procedures recommended by Mitsubishi Heavy Industries Ltd for servicing Mitsubishi diesel engines These procedures include wherever appropriate required special tools and related safety precautions The instructions provided in this manual however ca
20. 9039 to 0 9062 0 006 to 0 018 0 050 Piston pin to boss clearance 0 0002 to 0 0007 0 002 f 0 035 to 0 086 0 300 Piston to cylinder clearance 0 0014 to 0 0034 0 012 Bore or replace No iam 0 09 to 0 11 0 300 Pist n 8 0 0035 to 0 0043 0 012 ring to groove No 2 rin OOOO 0200 Replace piston rin Fesa Ane 0 0028 to 0 0043 0 008 prace p 8 2 Oil rin 0 03 to 0 07 0 200 z 8 0 0012 to 0 0028 0 008 g No 1 rin 0 15 to 0 30 a es 0 006 to 0 012 Piston ring gap No 2 ring n 5 ite ee Replace Oil ri 0 20 to 0 40 me 0 008 to 0 016 ep 0 05 100 0 15 100 oo pee 0 002 3 940 0 006 3 940 2o a 0 10 to 0 35 0 50 Replace connecting O aid 0 004 to 0 014 0 020 rod 1 13 SERVICE STANDARDS Item Nominal value Standard value Unit mm in Remarks Engine main parts Crank journal diameter STD 52 2 0488 51 985 to 52 000 2 0482 to 2 0488 Crank pin diameter 9 48 1 8912 47 950 to 47 964 1 8892 to 1 8897 Crankshaft bend 0 025 0 0010 0 050 0 0020 Correct or replace Main bearings oil clearance Crankshaft 0 030 to 0 077 0 0012 to 0 0030 0 100 0 0040 Replace main bearings Connecting rod bearings oil clearance 0 025 to 0 072 0 0010 to 0 0028 0 150 0 0059 Replace connecting rod bearings End play 0 050 to 0 175 0 0020 to 0 0069 0 500 0 0197 Replace flanged No 3 main bearings Crank gear to
21. A AA wen S a bin b s eine A A T A wee slau 7 Z 2 2 Alternator BESTE E OCC CITO CSO RCICOICC COGS HO ROCCO C ECOG E a CCC RICCO CCreorrici G 7 rs 3 3 Stop Solenoid wines ANA ANEA AAAA AEA A A AEE EE w ew E E A E E 7 a 4 4 Glow Plug a A aa A A a 8 e m aW e u e ew A E A A wine 6a daca mie ee a a a aA 7 5 ELECTRICAL SYSTEM REMOVAL 1 Starter Removal of the starter lt Removal sequence gt Harness Bolt Starter ELECTRICAL SYSTEM REMOVAL 2 Alternator Removal of the alternator lt Removal sequence gt Harness Retaining bolt Adjusting plate Adjusting bolt Alternator ELECTRICAL SYSTEM REMOVAL 3 Stop Solenoid w rubber cap and plugs i w 3 pole waterproof connector Removal of the stop solenoid lt Removal sequence gt Stop solenoid Nut ELECTRICAL SYSTEM REMOVAL 4 Glow Plug Removal of the glow plug lt Removal sequence gt Glow plug Connection plate ELECTRICAL SYSTEM REMOVAL ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Starter Shweta tm a am ww a es we a a oe ie ee ae eee A weit ee 7 8 1 1 Removing the starter ete ew Sane e eee Meee aa A T E E Re O T O ace ane 0 6a e ele a mma wate e 7 a 8 1 2 Inspecting and correcting the starter EAA REE AA EAAS AA A E aan 7 1 2 1 3 Reassembling the Starter tt rrrr trrrrrsnrrnnnnnnunnnnunnnnnunnununnnnnnnnnnnnnnnnnnnnnnnnnnn 7 1 6 2 Alternator aa a e fa fa uw win rate ear
22. DISASSEMBLY INSPECTION AND REASSEMBLY ELECTRICAL SYSTEM INSTALLATION Engine Inspection Adjustment Running in Trial and Performance Test ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL PERFORMANCE TEST Others Supplement Engine Inspection Sheets DISASSEMBLY AND REASSEMBLY OF GENERAL PARTS SAFETY CAUTIONS Warning Risk of fire and explosion 0 2 o Never use open fire srrrrrrrrrtrrrenrnnnnnnnnnnnnn 0 2 Keep things tidy around the engine 0 2 Do not open the crankcase until it has cooled dqown tttt rrrsssssnnnnnnnnnnnnnnnnnnnnnnnn 0 2 Pay attention to fuel and oil leakage 0 2 e Use explosion proof light annnnannnnnnonnnnannnnnn 0 2 8 Prevent short circuit 11st rrrttrrrrrrrsrrrsrenennnnn 0 2 Keep fire extinguisher and first aid kit at hand rtrrrrrrrsssrsrensnnnnnnnnnnnnnnnnunnnnnnnnnn 0 2 Warning Risk of entanglement into the machine ssssnanassunosnonnonnnns 0 3 Keep guards on the rotating parts str 0 3 Ensure safety in the surrounding area when starting the engine annnnannnnnnonnnnnnnnnan 0 3 Keep away from rotating parts while the engine is running annnnanonnnnannnnanonnnnannnnnnnnn 0 3 o Lockout tagout annnnannnnanannnnannnnannnnannnnnnnnn 0 3 Always stop the engine before any inspection service annnnannnnnnannnnannnnannnnannnnn 0 3 Remove the turning gear after use ttt 0 3 Warning Risk of burn erette 0 4 Do not touch the engine whi
23. Dip the temperature sensing element of the thermoswitch in oil as illustrated While warming the oil measure the resistance at the oil temperature of 105 C 221f If the measured value is substantially out of the standard value replace the thermoswitch Unit MQ Temperature Standard value 105 C 221f 30 A CAUTION This is a hot operation Pay every attention to prevent burns and fire Inspecting the thermoswitch 3 Water Pump Inspecting the water pump Rotate the impeller and the shaft for any noise or binding If faulty replace the entire pump assembly Inspecting the impeller and shaft for smooth rotation COOLING SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY COOLING SYSTEM INSTALLATION 1 Water Pump pW inna recuistGnbmne he PeccUN sub T A A Min new eaice ween belie A E A wees wee 5 1 0 Installing the water p mp Aa presse ae E recedes NEEE RE Eeee e EEEE iaei 5 1 0 2 Thermostat and Thermoswitch E Ree dees eoe E LENS T cua lame nae ele bate A 5 11 21 Installing the thermostat case t ttrrrssrrsrsersnnnnnnnnnnnuunnnuunnununnuunnnnunnunnnnnnn 5 11 22 Installing the th hermoswitch tr rsrsssssssnnunnnnunnnuunnnuununuunnununnnunnununnnnnnnnn n 5 11 3 Cooling Fan Fan Pulley and V Belt BRS CO SOCIO E E CCC E a A 5 12 Installing the cooling fan TREE O ETA A O N 5 1 2 COOLING SYSTEM INSTALLATION 1 Water Pump Installation of the water pump lt Installation sequence
24. Do not run the engine while at the same time washing it Otherwise cleaning fluid water may be sucked into the engine If the engine is started with water trapped in the combustion chambers water hammering will result causing the engine to fail and possibly leading to a serious accident SAFETY CAUTIONS Air cleaner maintenance precautions Wear of engine parts is accelerated largely by the dust contained in the intake air Worn engine parts will lead to various problems such as increased oil consumption reduced power and poor starting Air cleaner is effective in removing dust in the intake air When maintaining the air cleaner observe the following precautions O Never attempt to service the air cleaner while the engine is running When removing the air cleaner take care not to allow the dust trapped on the air cleaner to enter into the inlet port If the engine is equipped with the dust indicator clean the air filter only when the indicator shows clogging Unnecessary maintenance removal installation of the filter element runs the risk of allowing dust into the inlet port or damaging deforming the filter element Observe safety rules at work sites Whenever running or servicing the engine always observe the relevant safety rules in place If you are not in good shape do not operate the engine Consult the site supervisor Poor physical conditions are accompanied by reduced attention Do not operate the en
25. O rings E I AAA A E A A A A a AA a A A eR Ccr 9 2 1 3 Bearings A AAA A AAAA A A A 9 z 3 1 4 Lock plates a AAA A ET A A EAEAN 9 3 1 5 Split pins Spring pins SOS COCO OCOD TOC OCLCLEC EE OCR EE CO COOCU TC AAA TOOT 9 2 3 MISCELLANEOUS 1 Disassembly and Reassembly of General Parts 1 1 Oil seals When installing oil seals pay particular attention to the following points Installing oil seals into the housing a b c Check the seal including for damage to the lip When installing the seal ensure that the lip faces the correct direction Before installing the seal lightly coat the seal s outer periphery which contacts the housing with grease Use a seal installer like the one illustrated that is designed to guide the seal lip as well as hold the outer face of the seal Using such a tool install the seal straight into the housing Do not try to tap the seal into place with a hammer or other similar tool as the seal can be damaged resulting in oil leakage Installing oil seals onto the shaft a Apply grease onto the seal lip b When installing a seal onto a stepped splined or threaded portion or onto a surface with a key groove use a guide like the one illustrated 1 2 O rings When installing an O ring onto a stepped splined or threaded portion or onto a surface with a key groove use a guide like the one illustrated Before installation lightly coat the O ring with grease Oil se
26. a valve lifter 2 Remove the retainers valve springs and valves Note If the valves are reusable mark them so that they can be reassembled back onto their original locations This will ensure that the mated pairs of valves and their seats are maintained 1 6 Removing the valve stem seals Remove the valve stem seals by holding each of them with a pair of pliers Note Replace the old valve stem seals with new parts upon reassembly Removing the cylinder head assembly Removing the valve stem seal ENGINE MAIN PARTS DISASSEMBLY 2 Flywheel Timing Gear Camshaft Flywheel end of engine Replace Gasket Oil seal wear damage deterioration Cracks Damage Frictional surface streak stepped wear cracks Ring gear damage abnormal wear Disassembly of flywheel lt Disassembly sequence gt Flywheel Rear plate Flywheel housing Oil seal case Oil seal ENGINE MAIN PARTS DISASSEMBLY Timing gear end of engine Cam lobe wear damage Ball bearing wear noise Wear damage of each gear Replace Gasket ROSY AN a Speedometer driven gear damage Cam lobe wear Bent shaft Cracks Damage Distortion Disassembly of timing gear and camshaft lt Disassembly sequence gt Tappet PTO gear Crankshaft pulley Timing
27. arm bore and the rocker shaft diameter to obtain the arm to shaft clearance If the clearance is between the standard value and the limit replace the rocker arm If the clearance is equal to or exceeds the limit replace both the rocker arm and shaft Unit mm in Nominal valde Standard value Rocker arm 919 18 910 to 18 930 inner diameter 0 749 0 7450 to 0 7458 Rocker shaft 19 18 880 to 18 898 diameter 0 749 0 7438 to 0 7445 Arm to shaft 0 012 to 0 050 clearance 0 0005 to 0 002 1 3 Measuring the valve squareness and free length Measure the valve spring for squareness free spring for length etc If any of the measured values exceeds the limit replace the spring Unit mm in Limit 46 1 81 A 0 5 0 0197 across the entire length Standard value 47 1 85 6 2 0 or less A gap 0 2 0 0079 Lf or less Free length Squareness Lf 47 1 8504 39 0 1 536 131 to 145 13 3 to 14 7 29 to 33 30 1 1 185 279 to 309 28 5 to 31 5 63 to 69 mm in N A kgf lbf 2 18 Measuring locations and directions Measuring the cylinder head bottom face for distortion Measuring direction Measuring location Measuring direction Measuring the rocker arm inner diameter and the rocker shaft diameter Spring squareness gap LZ ae Q Free length p Se CG can CG
28. bleeder screw 2 When fuel with air bubbles no longer comes out tighten the screw Press the push button several times oe C DO Cock lever open Bleeding the fuel filter of air push button type A ion U A Air bleeder screw N Bleed air with screw 1 first then with screw 2 Bleeding the fuel filter of air cartridge type ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 8 Adjusting the low and high idle speeds 1 Preparations a Warm up the engine until the coolant temperature reaches 60 C 140f or above Note Ensure that the valve clearance and the fuel injection timing are correctly adjusted and that the nozzles operate normally 2 Adjusting the low idle speed Loosen the lock nut for the idling set bolt Screw in or out the bolt to set the low idle speed to specification Tighten the lock nut Low idle speed 1000 25 min 3 Adjusting the high idle speed Loosen the lock nut for the high speed set bolt Screw in or out the bolt to set the high idle speed to specification Tighten the lock nut High idle speed 2700 ymin High speed Low speed position position low idle Idling set bolt Lock nut High speed set bolt Adjusting the idle speeds ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 9 Inspecting the fuel injection nozzle Perform the following inspections and if faulty repair or replace as req
29. cylinder head and tighten to the specified torque 8 10 Nozzle tip body Cleaning the fuel injection nozzle tip components Tightening torque 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 lbf ft Tightening torque 49 0 to 58 8 N m 5 0 to 6 0 kgf m S 36 2 to 43 4 lbf ft Installing the fuel injection nozzle ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 10 Inspecting the V belt tension 1 Press the V belt at the midpoint of the alternator S Adjusting bolt pulley and the crankshaft pulley and measure the p3 ee A i Nye 10 to 12 mm deflection of the belt p SfPen 0 4 to 0 5 in Unit mm in Standard value Deflection of 10 to 12mm 0 4 to 0 5 in when pressed with a force of approx 98 N 10 kgf 22 0 Ibf V belt tension belt deflection when pressed with a 10 to 12 force of approx 98 N 10 kgf 22 0 0 4 to 0 5 Ibf Adjusting the V belt tension 2 If the measured deflection does not conform to the standard value loosen the adjusting bolt and move the alternator for adjustment 8 11 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 2 Running in Trial 2 3 Running in timetable Whenever the engine is reassembled after overhaul The following table shows the running in run in the engine on a dynamometer While the phases together with the relevant load and time engine is being run in also p
30. gear case Idler gear Camshaft gear Thrust plate Camshaft Remove to as an assembly oomoo gA OO o Fuel injection pump camshaft gear Ball bearing Fuel injection pump camshaft Remove to as an assembly Oil pump Front plate 2 1 Removing the flywheel Have an assistant lock the flywheel pulley using a wrench or other similar tool to prevent the flywheel from rotating Remove one of the flywheel retaining bolts A CAUTION The person who locks the crankshaft pulley should do so with extreme care Each worker should pay attention to the safety of the other Install a safety stud M12 X 1 25 into the hole from which the retaining bolt has just been removed With the stud installed remove the remaining flywheel retaining bolts While holding the flywheel with both hands rock the flywheel towards you and away to pull it out straight towards you A CAUTION a When pulling off the flywheel be careful not to cut your hands with the ring gear b Be careful not to damage the flywheel by dropping it or bumping it against hard objects c The ring gear has been shrink fit onto the flywheel Do not attempt to remove the ring gear unless it is faulty 2 2 Removing the flywheel housing Remove the flywheel housing retaining bolts Remove the flywheel housing ENGINE MAIN PARTS DISASSEMBLY Safety stud Removing the flywheel Removing the flywheel housing ENGINE MAIN PARTS DISAS
31. idler gear Idler gear to valve camshaft gear Idler gear to pump camshaft gear 0 040 to 0 120 0 0015 to 0 0047 Valve camshaft gear to PTO gear 0 080 to 0 190 0 0032 to 0 0075 Timing gear backlash Pump camshaft gear to oil pump gear 0 070 to 0 200 0 0028 to 0 0079 0 300 0 0120 Replace Camshaft cam height including lobe 35 720 0 1 1 4073 0 0394 34 720 1 3679 Replace Fuel injection pump shaft cam height including lobe 44 0 1 1 7336 0 0039 43 1 6942 Replace Flywheel flatness 0 150 0 0059 or less 0 500 0 0197 Correct Tappet to guide clearance 0 150 0 0059 Replace tappet Camshaft journal to bushing clearance 0 050 to 0 125 0 0020 to 0 0049 0 150 0 0059 Replace bushing Idler gear to shaft clearance 0 020 to 0 070 0 0008 to 0 0028 0 200 0 0079 Replace idler gear or idler shaft Fuel system Injection valve opening pressure MPa kgf em psi 14 22 to 15 00 145 to 153 2062 to 2176 Adjust with washer Oil system Relief valve opening pressure MPa kgf cm psi 0 35 0 05 3 5 0 5 50 7 2 Replace Oil pressure switch closing pressure MPa kgf em psi 0 05 0 01 0 5 0 1 7 1 4 Replace Cooling system Valve opening temperature 82 1 5 C 179 6 2 7f Thermostat 8 mm 0 32 in valve lift temperature
32. is indicated replace the armature f Armature coil open circuit Measure between the segments in various combinations There should be continuity If no continuity replace the armature 3 Inspecting the field coils M008T70471A M008T81071A a There should be no continuity between the coil end brush and the yoke b There should be continuity between the coils brushes c The pole shoes and the coils should not be loose If faulty replace the yoke Inspecting the field coils 4 Inspecting the bearings Ensure that the bearings rotate smoothly without abnormal noise If faulty replace 5 Inspecting the rear bracket If the metal is worn replace the rear bracket 71a 6 a b ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY Inspecting the overrunning clutch The shaft should rotate smoothly in one direction but should not rotate in the opposite direction Check the pinion for wear or damage If faulty replace A CAUTION Do not wash the overrunning clutch in wash oil 10 lt Front bracket The ball bearing should rotate smoothly without abnormal noise If faulty replace the entire front bracket Internal gear planetary gears and armature shaft gear Replace if worn or damaged Lever As the lever s friction surface with the overrunning clutch wears the pinion gap goes out of the standard value If so adjust or replace the lever Magnet
33. on pump body speeds of engine Stop the engine for installation and adjustment of the torque spring set 1 Remove the tie rod cover 2 Pull the speed control lever to the high idle speed position and hold it there 3 Pull the tie rod in the direction of the arrow until H Notched line on control rack a slight resistance is felt Note This is the initial resistance by the governor spring Do not pull the tie rod further to try to Installing the torque spring set overcome the resistance Special nut 4 While holding the tie rod in this position screw Sealing cap Tightening torque in the torque spring set until the notched line on 14 7 to 24 5 N m th rolra k isali d with that th 1 5 to 2 5 kgf m e control rack is aligned wi at on the pump 10 8 to 18 1 lbf ft body 5 With both notched lines aligned lock the torque spring set by tightening the special nut to the Governor lever specified torque 6 Place the torque set sealing cap over the torque spring set and stake it in place Adjusting and sealing the torque spring set FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 4 Fuel Pump Inspecting the fuel pump The engine is equipped with one of the following three types of fuel pump depending on the engine specifications 1 Plunger type fuel pump There are two types one is the standard with a
34. or engine oil or cleaning parts in wash oil do not light a match smoke or use any other open fire nearby Doing these is extremely dangerous as fuel and oils can catch fire Completely wipe off any spilt fuel or engine oil as they are flammable and can be a fire hazard Store fuel and engine oil in a well ventilated place Firmly tighten the cap of the container Keep things tidy around the engine Keep fuel engine oil or any other flammables as well as explosives and other dangerous materials away from the engine These materials can ignite and explode Keep the engine and the surrounding area free of waste dirt foreign matter etc These substances can be a fire hazard and invite overheating In particular ensure that the top of the battery is clean after service operations Any waste left on the battery can cause short circuit Keep a running engine at least 1 m 3 3 ft away from the surrounding building or equipment to eliminate the risk of fire Do not open the crankcase until it has cooled down Do not attempt to open the crankcase side cover immediately after the engine is stopped Wait at least 10 minutes until the engine has sufficiently cooled down If fresh air flows into the crankcase with the engine still hot the remaining mist of oil may ignite and cause explosion Pay attention to fuel and oil leakage If leakage of fuel or oil is found immediately take measures to stop it If leaking fuel or eng
35. replace the bushing Unit mm in Standard value 0 050 to 0 125 0 0020 to 0 0049 0 0059 Camshaft journal to bushing clearance Measuring the camshaft bushing inner diameter ENGINE MAIN PARTS INSPECTION AND CORRECTION 2 7 Extracting the camshaft bushing 1 Remove the camshaft bushing using the special tool Camshaft Bushing Installer in the following manner Special tool Part number Camshaft Bushing Installer ST332340 2 Remove the oil pan 3 Using the punching side of the installer punch the bushing off and into the cylinder block Take it out of the block by slightly deforming it 2 8 Press fitting the camshaft bushing Press fit the bushing while ensuring that the oil holes of the bushing align with the oil galleries in the cylinder block 2 9 Measuring the camshaft cam height Measure the camshaft cam height as illustrated If the measured value is less than the limit replace the camshaft Unit mm in Standard value Camshaft cam height 35 7204 0 1 including lobe 1 4073 0 0039 1 3679 2 10 Measuring the fuel injection pump shaft cam height Measure the cam height as illustrated If the measured value is less than the limit replace the fuel injection pump shaft Unit mm in Standard Limit value 44 0 1 43 1 736 0 0039 1 6942 Fuel injection pump shaft cam height including lobe Cylinder block Camshaft front face bushing Camshaft bushing
36. ring and the ring groove 1 2 27 3 3 Measuring the piston ring gap PERELE RE RETR CR TERETE CLICC RTE TERRIA RI ER TICE ICI 2 27 3 4 Measuring the clearance between the piston pin and the pin boss t1 2 28 3 5 Measuring the connecting rod bend and twist streets 2 28 36 Measuring the connecting rod end play OPEIR ETRE Teer eee ete eee eee 2 29 3 7 Inspecting the oil clearance for connecting rod bearings tt ttttttttttttttttt 2 29 3 8 Inspecting the main bearings Oil clearance trt ttrrrsrsssssnnnnunuunununnnnnnnnnunnnn 2 30 3 9 Measuring the crankshaft for beng ttr rrrssssrsssnsssnnnnnnnnnnnuununuunnununnunnnnnnn 2 31 3 10 Removing the crankshaft gear AAAA AAAA A E A er i 2 31 3 11 Installing the crankshaft gear ALLA AANA AAA AAEE 2 31 3 12 Measuring the cylinder bore TLL TTT REEE LCE REE LiT eT ERECT er error 2 32 3 13 Measuring the cylinder block top face for distortion sts tttttttttttttttttrttttttttte 2 32 ENGINE MAIN PARTS INSPECTION AND CORRECTION 1 Cylinder Head Valve Mechanism 1 1 Measuring the cylinder head bottom face distortion Using a straight edge across the bottom face of the cylinder head and a thickness gauge measure for any distortion If the measured distortion exceeds the limit correct with a surface grinder Unit mm in Standard value 0 05 less 0 002 less Cylinder head bottom face distortion 1 2 Measuring the rocker arm bore and the rocker shaft diameter Measure the rocker
37. switch Measure between M terminal and the body If no continuity is indicated replace the magnet switch Measure between B and M terminals If continuity is indicated replace the magnet switch Inspecting the overrunning clutch S terminal M terminal Inspecting the magnet switch 7 15 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 3 Reassembling the starter Reassembly follows the disassembly procedures in reverse while observing the following Lubrication When the starter is overhauled apply grease to the following sliding surfaces gears and bearings G Multemp PS2 KYODO YUSHI ia CO LTD or equivalent oO man Nn mS O Armature shaft gear reduction gears Bearings Pinion shaft washer and stopper ring Pinion Lever s sliding surfaces A CAUTION Ensure that the starter mounting face the brushes the commutator and other current carrying parts are not smeared with grease Note 7 1 Installing the stopper ring Install a new stopper ring into the ring groove on the pinion shaft Using a puller pull the pinion stopper until its groove engages with the stopper ring On reassembly use a new stopper ring 6 M008T70471A M008T81071A Apply grease to the contact faces of the overrunning clutch and the lever
38. to the specified torque if provided in the manual Be sure to use a torque wrench 5 Gaskets packing and O rings should be replaced with new parts unless specified otherwise 1 10 SERVICE STANDARDS 1 Service Standards Table SITE ER TT ERE TER CORE EIR CCR ERE eer reer rr rae 1 1 2 2 Tightening Torques Table EE a A eee eRe a a are 1 1 6 21 Major Bolts and Nuts ttr rrrrrrrressnnnnnnnnnnnuuuuunnnnuuuuunnnnnnnnunnnnuuunuunnnnnnnnnn 1 1 6 2 2 Standard Bolts and Nuts cere e cece eee seeeeeeeeaeeeeeeeeeeaeeoeeeeeagaaeoees 1 1 7 2 3 Standard Eyebolts ween eee OEE EERE RRR EERE EEE EE EES 1 17 2 4 Standard Union Nuts tc cce cece esse eececeeeseeeeeeeeseeeeeeeeaeaeeneeeeeanaaeoens 1 18 25 Taper Bolts tr trrrsssnssnnnnnnnnnnnnuununnnnnunnnuuunuuuunnunnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnn 1 1 8 3 Sealants List T A EEE A CC eT a a A eee CO 1 19 SERVICE STANDARDS 1 Service Standards Table Item Nominal value Standard value Unit mm in Remarks Max speed based on the rated speed 2700 min Min speed 1000 25 min Compression pressure at 290 min 2 9 MPa 30 kgf cm 421 psi or above 2 6 MPa 27 kgf cm 377 psi or less Both oil and coolant temperatures at 20 to 30 C 68 to 86f Rated speed 0 29 to 0 39 MPa 3 0 to 4 0 kgf cm 42 07 to 56 57 psi Engine oil pressure Low idle speed 0 098 MPa 1 0 kgf em 14 22 psi Oil
39. trrrsssssssnssnnnunnnnunnununnuuununuununuunnuunnnuunnnnnnnnn 2 34 1 3 Installing the main bearing e A seen sneacienes sta tene ise 2 34 1 4 Inserting the side Seals r rr srserrsssnssunnnnnunnnnnununuunnuunnnuunnuuunnuunnnnunnnnnnn 2 35 1 5 Assembling the piston onto the connecting rod ssssrrrerrerrrtreererrrreeneereeeennnn 2 36 1 6 Installing the piston rings POTTPTTTOTITTTTTeTITTTeeer iri rietr iri iirer iri i ttt iit 2 37 1 7 Installing the piston connecting rod assemblies rrrrrrtererrttrererrrerreeeererenenen 2 37 1 8 Installing the connecting rod CAS Pe eir neess anang eee eaaa aa enea neS Eaa Eiin 2 38 1 9 Installing the oil strainer t ttrrtttrrrtrrtrrnrtsnnnnnnnnnnnnnnnnunnnnuununnnnnnnnnnunnnnnnnnnn 2 38 1 10 Installing the oil eeo a a att cnes 2 38 2 Flywheel Timing Gear CamsShattrrrtrtrtrctttcrstrrsestesseessnesssneenensenenaenees 2 40 21 Installing the front plate uzunuuunununununununuuunuuunununununnnunnnunnnnnnnnnnnnnnnn 2 40 22 Installing the oil SOU 8 Maa taal aaa aa ae E he aaa a a 2 40 23 Rotating the engine TOTP TPTTT TTT TTT ere 2 40 2 4 Tapping the fuel injection pump camshaft into place sstttrtttttttttetssttttsseeseeees 2 40 25 Installing the camshaft rr tsrrrssssssnnennnuunnnunnuunnnuuununuunununnnunnnnunnnnnnnnnn 2 41 26 Installing the idler elete e eaaa aa a aa a a AA 2 41 27 Installing the timing GEE CASE rss n Eee e R aa EER recat EE Se 2 41 28 Tightening the crankshaft pulley QUt
40. 0 Correcting the valve Seap ttrrrtrrrrrrrrrrnnnnnnunnnunnnnuunnununnnuunnnnunnnnnnnnnnnnnnnnnnnnn 2 21 1 11 Lapping the valve face against the valve Seat rtrrrrrrrrrsnnrrnnnnnunnnnnunnnnuunnnnnnn 2 22 1 12 Replacing the combustion jets A AA COREE A CORR AA 2 22 2 Flywheel Timing Gear Camshaft e a E a a a Otek EAE 2 23 21 Measuring the flywheel flatness A A A E I OCC eect 2 23 22 Replacing the ring gear A AA A AA TT 2 23 23 Measuring the timing gear backlash E AAAA 2 23 2 4 Measuring the clearance between the idler gear and the idler shaft 2 24 25 Replacing the idler shaft AAA A A A A A A TCL 2 24 2 6 Measuring the clearance between the camshaft journal and the bushing 2 24 27 Extracting the camshaft bushing e AA T AANT 2 25 28 Press fitting the camshaft bushing Pere eee ee Peete etree treet reer reer erie eee eee eee eee 2 25 29 Measuring the camshaft cam height OPE EEPECE EEE OTe e Teeter eee eter etree teeter eee 2 25 2 10 Measuring the fuel injection pump shaft cam height sttrtttrtttttttttsttstte tee eeeees 2 25 211 Inspecting the cam to tappet Contact stttrrtrrtrseerennnnnnunnnnuunnnnnnnunnnnnnnnnnnnnnn 2 26 2 12 Measuring the clearance between the tappet and the tappet guide 1 2 26 3 Cylinder Block Crankshaft Pistons Oil Pantsrrssstrrrrttttttttereteteeteee teen ees 2 27 3 1 Measuring the piston diameter t trrtrrrssssnrnnnnnnnnnunnunnnnnuunuuuununnnnnnnnnnnnn 2 27 3 2 Measuring the clearance between the piston
41. 00 25 min Exhaust gas color 1 Observe the exhaust gas color during no load No excessive black smoke rapid acceleration 2 Observe the exhaust gas color under load Nozzle injection pattern To inspect the spray pattern remove the nozzle Good spray pattern from the engine and then place the nozzle outside by correcting the injection pipe Crank the starter and check the spray pattern 2 2 Disassembling the fuel injection pumps Tappet guide pin Lock plate Tappet Tappet adjusting shim Spring lower seat Plunger Plunger spring Spring upper seat Control sleeve Control rack Delivery valve holder O ring Delivery valve spring Delivery valve gasket Delivery valve Plunger barrel Pump housing OOOOMIMII FO OG H OMOHHO Disassembly of the fuel injection pumps 3 13 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Removing the tappets a Open the claws of the lock plate using a screwdriver or other similar tool b Rotate the tappet and the guide pin by 180 to align the guide pin cutout with the mating portion of the pump housing c While pressing the tapped down remove the tappet guide pin using a pair of pliers A CAUTION Hold the tappet otherwise it will jump out Be careful not to drop the tappet 2 Removing the plungers a Remove the tappet adjusting shim Using a pair of tweezers pull out the spring lower seat and the plunger togethe
42. 145 to 153 2062 to 2176 Change in washer thickness by 0 1 mm 0 004 in results in a pressure change of 1 0 MPa 10 kgf cm 145 psi Washers 10 different thicknesses at intervals of 0 05 mm 0 002 in in the range between 1 25 and 1 70 mm 0 049 and 0 067 in ZA CAUTION Never touch the spray of fuel from the fuel injection nozzle Injection valve opening pressure are available in 2 Inspecting the fuel spray pattern from the fuel injection nozzle a When inspecting the injection valve opening pressure using the nozzle tester also check for such as clogged nozzle hole fuel spray pattern and fuel leakage from the nozzle hole When the tester handle is pumped at a rate of approx one cycle per second fuel should be sprayed in a fairly straight pattern 3 a Clean or replace when spraying badly Loosen the nozzle retaining nut to remove the nozzle tip assembly Clean the needle valve and the nozzle tip body ZA CAUTION When removing the nozzle tip assembly never tap on the end of the assembly b Wash the needle valve and the nozzle tip body in clean wash oil Reassemble them in clean light oil Note The needle valve and the nozzle tip body are precision machined parts Handle with care and never change their combination Nozzle tip end Replacing the fuel injection nozzle tip assembly Bad Bad Bad Bad Diffused Dribbling Deflected Feathering
43. 3 3 3 Removing the connecting rod Caps Nee eee ee nL LL aa 2 1 3 3 4 Removing the pistons ere eee reer reer reer reer reer reer rier e etree rere eee ete eee tee 2 1 4 35 Measuring the crankshaft end play Peer Peete eee etree treet reer reer rete tet reer eet rete 2 1 4 36 Removing the main bearing or a aa ak a alee 2 1 4 3 7 Removing the crankshaft s ssrrsssssrssrennnnnnnnunnunnnnuuununuununnunnunnnnnunnnnnnnnn 2 1 4 38 Separating the piston from the connecting rod PERE REED ERC RCE ELLER RE Rr Re Rice 2 1 5 ENGINE MAIN PARTS DISASSEMBLY 1 Cylinder Head Valve Mechanism Spring fatigue Clogged oil hole End face wear damage Damaged threads o Q O Bend Worn rocker shaft he p o Clogged oil hole 9 Pa 2 Spring fatigue 5 damage e Valve guide wear damage Bottom face distortion Cracks Damage Coolant leakage Oil leakage Scale formation Gasket Carbon deposit Wear Valve seat contact damage wear Dent Wear Disassembly of cylinder head and valve mechanism lt Disassembly sequence gt Rocker cover Cylinder head Retainer Rocker shaft assembly Cylinder head gasket Valve Push rod Valve cap O Valve spring Cylinder head bolt Valve lock O Valve stem seal 1 2 1 3 Note Removing the rocker shaft assembly Loosen th
44. AARAA nO 8 11 Running in Trial TTR RTT Ce CETTE RET EELE LEP T TC EEC TC LERELT PETE LTTE Perri eee re 8 12 21 Starting the engine TETTETETT eee errr reer reer reer reer reer rier ere treet eee eee etree eee eee eee 8 1 2 22 Inspecting the engine during running in E AAAA IASA ELC ETE Er Ce 8 1 2 23 Running in timetable POTEET CEE LUO ETC A a A 8 1 2 24 Inspection and adjustment after running in AAA EAD mc 8 1 2 Performance Test A a a A A T 8 1 3 3 1 Standard ancillaries t rr rtrrrrssrsssnnnnnnnnunnnnnuunnnuunnnnunnunnnnnunnnnnnnnnnnnnn n 8 1 3 3 2 Test items and DUI DOSES s Fe Sie ern tet e a a aaa te eeeee eee 8 1 3 3 3 Other testg t trrrrrrrrrssrsnsnnnnnnuununnnnuunnnuuununuunuunnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnn 8 1 3 3 4 Adjusting the engine power TRTELEE REED EER COCR ICCC RCE TER CES RR MRR TRE Dnt ti 8 1 3 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 Inspection and Adjustment of Engine 1 1 Preparations for valve clearance inspection and adjustment 1 Inspection and adjustment of valve clearance should be performed when the engine is cold 2 Slightly loosen the cylinder head bolts Then es Tightening torque tighten them to the specified torque in the order 83 4 to 93 2 N m illustrated 8 5 to 9 5 kgf m 61 5 to 68 7 lbf ft S3L S3L2 Tightening order for the cylinder head bolts 1 2 Inspecting the valve clearance 1 Move the piston of the N
45. Close ATDC 10 3 Engine mounting 4 mounts Starting method Starter Type Bosch M Manufacturer DENSO eee Plunger ee diametet mm in 5 5 0 21 MS retard go crank angle 2 Cam lift mm in 15 0 59 Z Governor Governing method Centrifugal fly weight type D Type Throttle nozzle m Manufacturer Bosch Automotive Systems Corporation Injection Spray angle mm in 15 nous Opening nas 14 22 to 15 00 145 to 153 pressure 2062 to 2176 psi Fuel filter Type Paper element cartridge Separate type w cock Lubrication method Forced circulation pressure feed by trochoid pump Grade CD Class API Classification Paan e E US gal 3 7 1 0 4 2 1 1 5 4 1 4 6 0 1 6 5 Type Gear pump Oil pump 0 U S gal G Displacement pate 18 4 8 O Type Piston valve Relief valve Opening MPa 0 35 0 05 3 60 5 pressure kgf cm 517 psi Oil filter Type Paper element spin on type GENERAL Engine Type S3L S3L2 S4L S4L2 Cooling method Water cooled forced circulation Capacity engine proper U S gal 1 8 0 5 2 5 0 7 Type Centrifugal pump A ha eae Displacement PE a 30 8 0 up 2000 min engine speed 2 Type Wax Cc Soe Penne C 7 82 1 5 179 64 2 7 O temperature Type Pusher suction PP fan Cooling fan No of blades OD 5 340 13 39 6 320 12 6 6 340 13 39 mm in 6 360 14 17
46. Cotter eee eee eee eeaneeeeeeeeeenaee 2 42 29 Installing the PTO gear Aeir Pear es senna este ants NAEK A espa ane mnsnnegetesssetnese tte 2 42 21 0 Inserting the tappets cia tvatwataluraietw E w attalw ecw AAAA A AAA Kine miavoe bcainaie wieww mineral 2 42 211 Installing the oil seal cage t ttrrrsrssrrnrennnunnununnunnnnuuunuuuunuuuunnunnnnunnnnnnnnnn 2 42 212 Installing the rear plate usuuuuunununununununununununununununuuununnnnnnnnnnnnnnnn 2 43 213 Installing the flywheel housing TEPTPPTITTTTTTTTT Tri iret rit iert rite rt iti 2 43 214 Installing the flywheel u unuuunuuunuuunununnNuNENNNENNNENNNENNNENNNNNNNENENENNNNNNNENNNENNNENNNnE 2 43 3 Cylinder Head Valve Mechanisms srrrrrrrrsrrnsssennnnnnunnnnnnnnnnnunununnnnnnnnn 2 44 3 1 Cleaning the bottom face of the cylinder head s sttsttttttttttttttstttttteeeeseesaeesees 2 44 32 Installing the valve stem seals rs ssrsssssssnnunnununnnuunnnuunuuuunnuunnnuunnununnnn 2 44 3 3 Installing the valve springs TIPTTTPTIIT IT TTT TTT eee 2 44 3 4 Installing the valve locks ttt tree eee ccrrseeseceeeeseeeceeeceeseeenceeeeesageeeereeaaane 2 44 35 Installing the cylinder head gasket TIPTPPTTTT TTT TTT ett 2 45 36 Installing the cylinder heaq titre teeter esse seeeeeeeeeecceeeeeeeeeaoeeeeenaaeneeeeneeaaaae 2 45 3 7 Tightening the cylinder head bolts trrsrssrrsssnnnnnnnnnunnnnuunununnuuunnnunnnnuunnnn 2 45 3 8 Inserting the push TOUS tittrr re eeeee ee eeeeeeeeeeeeeaseaeceeeeeeacoeeeen
47. EASSEMBLY 3 Stop Solenoid 3 1 Reassembling the stop solenoid Tightening torque Stop solenoid with rubber cap and plugs me ee on These areas must be 0 to 5 0 kgf m 1 Apply sealant onto the threaded portion of the 28 9 to 36 2 lbf ft pee stop solenoid Note Apply sealant only to the area that will be concealed by the governor case when installed ThreeBond 1212 me A Clearance A Shaft 2 Loosely install the stop solenoid and the nut onto 0mm the governor case 0 in 0 15 to 0 20 mm 0 006 to 0 008 in 3 Move the fuel injection pump control rack fully n E to the stop position Apply sealant 4 While pushing the plunger screw in the stop There should be no intrusion leak of cleaning solenoid until the plunger contacts the control fluid through the gap into the solenoid rack At this position the clearance A should be 0 mm 0 in the position where the plunger is Installing the stop solenoid screwed in along with the stop solenoid 5 Back off the stop solenoid by 30 to 45 from the position achieved in step 4 above until the clearance between the rack and the plunger becomes 0 15 to 0 20 mm 0 006 to 0 008 in Tighten the nut to the specified torque 6 Start the engine When the plunger is fully pushed in the engine should stop 7 Install the rubber cap so that the arrow points Rubber cap upwards the water drain faces downwards as illustrated A CAU
48. EMBLY INSPECTION AND REASSEMBLY 1 2 Inspecting and correcting the starter 1 Inspecting the brushes a Brush wear Measure the length of the brushes If the measured value is equal to or less than the limit replace both the brush assembly and the brush holder assembly Unit mm in Standard value 16 5 0 65 M008T70471A 18 0 MO008T81071A 0 71 M001T68281 b Measuring the brush spring load Using a new brush and a spring balance as illustrated measure the spring load at which the spring lifts from the brush If the measured value is equal to or less than the limit replace the spring Unit N kgf lbf Standard value 17 5 to 23 7 M001T68281 1 78 to 2 41 3 9 to 5 3 29 4 to 39 2 3 0 to 4 0 6 6 to 8 8 M008T70471A M008T81071A c Brush holder insulation Measure between each brush holder and the brush holder base for continuity If continuity is indicated replace the entire brush holder assembly Check the brush holder for looseness 7 12 Replace if the measured brush length is equal to or less than the limit Inspecting the brushes Measuring the brush spring load Brush holder Checking the brush holder insulation ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 Inspecting the armature a Using a dial gauge measure the commutator for radial runout If the measure value is equal to or exceeds the limit correct within the
49. FOREWORD This service manual describes the specifications as well as the maintenance and adjustment procedures for Mitsubishi diesel engines This manual also includes the detailed information on basic and special tools as the need arises The Mitsubishi diesel engines can offer highly efficient and reliable performance for many years to come which however only can be achieved through the proper handling and the periodical inspection maintenance work exercised in according to the procedures of disassembly inspection adjustment and reassembly described in this manual Before attempting any work on your engine thoroughly read this manual to familiarize with the engine and the required procedures of the work All information contained in this manual is based on the engine produced at the time of publication and is subject to change as the engine improved without notice Pub No 99619 12140 HOW TO USE THIS MANUAL This Service Manual describes the specifications of Mitsubishi diesel engines land and standard applications and relevant service standards as well as the procedures for servicing the engines such as for disassembly inspection repair and reassembly This manual is divided into Groups Each Group covers a specific area of the engine The fuel injection pump the governor and the turbocharger are handled in a separate manual Major contents of Groups are listed on the General Contents page Detailed contents of
50. Measure between each lead and the stator core Replace if continuity is indicated 4 Inspecting the brushes a Measure the brush length Replace if the measured value is equal to or less than the limit Unit mm in eee Standard value 18 5 0 73 Brush length b To remove the brush and the spring unsolder the brush lead Ne iD AY Ky ae ONG Gul i R By Testing the stator core for continuity 18 5 mm 0 73 in Dag Limit 5 0 mm 0 20 in Inspecting the brush length Soldered lead Removing the brush ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY c Push a new brush into the brush holder before soldering the brush lead 2 3 Reassembling the alternator To reassembly follows the disassembly sequence in a reverse and do the following steps The rear bearing has an eccentric groove around the periphery The deepest portion of this groove should be aligned with the lug on the snap ring When replacing the rear bearing a new bearing should be press fitted so that the groove on its periphery is placed to the slip ring side Heat the rear bracket before press fitting the rear bearing into the bracket When installing the rotor into the rear bracket insert a wire through a small hole in the bracket to lift the brushes After installation remove the wire Reassembling the alternator ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND R
51. No 12 install the valve stem seal on the valve guide Ensure that the seal has been correctly installed the valve guide Note Incorrectly installed stem seals will lead to oil leaking down through the seal to guide gap and into the combustion chamber 3 3 Installing the valve springs Install the valve spring with the white enamel coated end facing up 3 4 Installing the valve locks Install the valve lock by compressing the valve spring using a valve lifter A CAUTION Do not compress the valve spring too hard as the bottom of the retainer may contact and damage the stem seal White enamel coating Installing the valve lock Installing the cylinder head gasket Ensure that the cylinder block top face and the piston top faces are clean Insert two guide studs M10 1 25 into the bolt holes in the cylinder block Install the cylinder head gasket through the studs and onto the cylinder block A CAUTION Do not use liquid packing or other similar sealant 3 6 Installing the cylinder head Install the cylinder head through the guide studs and onto the cylinder block Tightening the cylinder head bolts Remove the guide studs head bolts Install the cylinder Tighten the cylinder head bolts in the order illustrated in a couple of steps and finally tighten to the specified torque Inserting the push rods Insert the push rods into the holes in the cylinder head Ensure that the b
52. Oil level gauge guide ThreeBond 1102 Cylinder block Cylinder head Cylinder head Cylinder block Cylinder block Holes in the cylinder head and block Side seal Main bearing cap front and rear ThreeBond 1212 Cylinder block Main bearing cap Outer periphery Oil pan ThreeBond 1207C Cylinder block Contact faces with the cylinder block Oil pan sealing face 1 19 SERVICE STANDARDS 1 20 TOOLS LIST 1 General Tools prewinneGuiene wwe Wiee eeee Cates T A A a awa Wiebe boca nw estabhiew ew elsen eens whee cece 1 22 2 Special Tools A A a N E E E A EA A E A A E A A rick ir 1 23 TOOLS LIST 1 General Tools No Description Part number Remarks Tool set MM413 900 Consists of items to Spanner MK96008010 Width across flats 8 X 10 mm 0 31 x 0 39 in Spanner MK96012014 Width across flats 12x 14 mm 0 47 0 55 in Spanner MK96017019 Width across flats 17 19 mm 0 67 X 0 75 in Screwdriver MM300110 Tool bag MM300783 1 22 2 Special Tools Description Part number TOOLS LIST Application Piston Pin Setting Tool 31A91 00100 Piston pin removal installation Camshaft Bushing Installer T332340 Punching press fitting of front camshaft bushing Compression Gauge Adapter T332270 Compression measuring Oil Pressure Switch
53. RCP E EEOC CTL TERE Cer Te Tre 5 T 6 1 1 Disassembling the thermostat A r AA AAA ANAT AN TA ee CTT TTT 5 n 6 1 2 Inspecting the thermostat wanhan pipiaraan aai errr er CCT 5 i 6 2 Thermoswitch MERE ARRAN NSEC WRT a MAE EE ON ie UENO be WHER ERE EE 5 i 7 Inspecting the thermoswitch ts srrrrrsssssnnsnnnnunununnnuunnuuununuunnunnnnuunnunnnnnnnnnnn n 5 5 7 3 Water Pump a AA A A A A A A EAT ei 5 k 7 Inspecting the water pump a A A a A A A err ee Ter 5 2 7 COOLING SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Thermostat 1 1 Disassembling the thermostat Replace Gasket Disassembly of the thermostat lt Disassembly sequence gt Thermostat cover Thermostat Gasket Thermostat case 1 2 Inspecting the thermostat Place the thermostat in a container filled with Stir thie Water for eventemperature water While heating the water measure the water temperature at which the thermostat starts to open and also the water temperature at which the valve lift reaches 8 mm 0 315 in If the measured temperatures do not conform to the standard values replace the thermostat Unit C Valve opening 8 mm 0 315 in temperature valve lift temperature Inspecting the thermostat 82 1 5 179 64 2 7 95 203 A CAUTION This is a hot operation Pay every attention to prevent burns and fire COOLING SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 Thermoswitch Inspecting the thermoswitch
54. SEMBLY 2 3 Removing the rear plate The rear plate has been located into position with knock pins Therefore the plate needs to be removed by pulling it straight towards you 2 4 Removing the oil seal case Remove the oil seal case retaining bolts Then ply away the case from the cylinder block using a screwdriver or other similar tool A CAUTION When removing the oil seal case be careful not to damage the oil seal 2 5 Removing the tappets While holding the push rods remove the tappets from the cylinder block Note The camshaft should not be removed before removing the tappets Otherwise the tappets will drop into the oil pan 2 6 Removing the crankshaft pulley 1 Lock the crankshaft so that it will not rotate To rock the camshaft install two safety studs M12 1 25 into the threaded holes at the rear end of the crankshaft and then place a bar between the studs 2 Remove the crankshaft pulley NATON While trying to remove the crankshaft pulley the bar may dislodge from the studs Pay sufficient attention to ensure safety Removing the crankshaft pulley ENGINE MAIN PARTS DISASSEMBLY 2 7 Removing the timing gear case Remove the timing gear case retaining bolts Then remove the timing gear case A CAUTION The front plate is bolted in place separately from the timing gear case Do not attempt to tap away the front plate together with the timing gear case 2 8 Measuring the timing gear back
55. Socket Wrench 26 MD998054 Oil pressure switch removal installation Piston Ring Pliers 31391 12900 Piston ring removal installation 1 23 TOOLS LIST 1 24 OVERHAUL TIMING 1 Identifying the Timing for Overhaul Saeed REbN bin ner Wh deen cela bhi enw e neeuise baw awww eee 1 26 2 Measuring the Compression Pressure E AA A A wim E E E E E E winia a ave mimi 1 27 OVERHAUL TIMING 1 Identifying the Timing for Overhaul Generally when the compression pressure has dropped below the specified value overhaul of the engine needs to be considered Other parameters should also be considered in making the decision as to whether or not to overhaul the engine such as engine oil consumption and blow by gas volume Some of the phenomena that may suggest but are not necessarily the criteria for the need to overhaul the engine include reduced power increased fuel consumption oil pressure drop difficulty in starting and higher noise level More specifically reduction in compression pressure creates various types of phenomena in various combinations and this is why it is difficult to make a correct decision Typical phenomena include a Reduced power b Increased fuel consumption c Increased engine oil consumption d Increased blow by gas through the breather due to worn parts such as cylinder liners and pistons e Increased blow by gas due to poor seating of inlet exhaust valves Poor startin
56. TION Ensure that the solenoid terminals and inner parts wiring and shaft will not be exposed to cleaning fluid Installing the rubber cap ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY Stop solenoid with 3 pole waterproof connector 1 Apply sealant onto the threaded portion of the stop solenoid Note Apply sealant only to the area that will be concealed by the governor case when installed ThreeBond 1212 2 Loosely install the stop solenoid and the nut onto the governor case 3 Move the fuel injection pump control rack fully to the stop position 4 While pushing the plunger screw in the stop solenoid until the shaft contacts the tie rod 5 Back off the stop solenoid by 30 to 45 from the position achieved in step 4 above until the clearance between the rack and the plunger becomes 0 15 to 0 20 mm 0 006 to 0 008 in Tighten the nut to the specified torque 6 Start the engine pushed in the engine should stop When the plunger is fully 3 2 Checks after reassembly 1 Start the engine and turn the key OFF The solenoid should trip causing the engine to stop 2 With the engine running ground the oil pressure switch terminal to the switch body The engine should stop 4 Glow Plug Inspecting the glow plug Measure between the terminal and the body Replace if no continuity is indicated or the resistance measured is too great Unit Q Standard value Resistance 0 55
57. a lf any of the crank journals need grinding grind all crank journals on the same crankshaft to the same dimension b Finish the fillets to a radius of 2 5 mm 0 098 in 3 9 Measuring the crankshaft for bend Support the crankshaft at the front and rear crank journals with a V block Using a dial gauge measure the center journal for a swing of the gauge needle to both directions If the measured value moderately exceeds the standard value correct the bend by grinding If the measured value far exceeds the standard value correct the bend using a press or other similar equipment If the measured value exceeds the limit replace the crankshaft Unit mm in oo __ Standard value Limit Crankshaft bend 0 025 0 0010 0 050 0 0020 3 10 Removing the crankshaft gear Use a gear puller to remove the crankshaft gear Note Do not remove the crankshaft gear unless the crankshaft or the gear is faulty 3 11 Installing the crankshaft gear 1 Install the key to the crankshaft 2 Align the keyway in the crankshaft gear with the key on the crankshaft and press fit the gear fully until it stops R2 mm 0 08 in 0 08 in Measuring the crankshaft bend Gear puller Align these Installing the crankshaft gear 2 31 ENGINE MAIN PARTS INSPECTION AND CORRECTION 3 12 Measuring the cylinder bore Using a cylinder gauge measure the cylinder bore and cylindricality If any of the cylinders exceeds the
58. ace 5 29 4 32 0 28 8 31 4 5 Commutator diameter 1 16 1 26 1 13 1 24 Replace Mica undercutting 0 5 0 2 Cenc depth 0 02 0 01 ses IC regulator A007T02071C A007TA8571 controlled voltage R T at 20 C 68f 14 7 0 3 V 2854 0 5 V g 2500 Terminal 13 5 V 27 0 V _ 2 min voltage E 5g less Current 32 A or above 18 A or above silks lt g 9 eS 5000 Terminal 13 5 V 27 0 V S min voltage S 5 or less Current 47 Aor above 22 A or above Brush length 18 5 0 73 5 0 0 20 Replace Clearance between stop 0 15 to 0 20 c i solenoid plunger and rack 0 006 to 0 008 eee Glow plug resistance 0 55 Q Replace 1 15 SERVICE STANDARDS 2 Tightening Torques Table 2 1 Major Bolts and Nuts Thread diameter Tightening torque Fittings Remarks A pitch m kgfm Ibfct mm Engine proper Cylinder head bolt M10x 1 75 83 4 to 93 2 8 5 to 9 5 61 5 to 68 7 Rocker cover bolt M8 x 1 25 9 81 to 12 7 1 0 to 1 3 7 2 to 9 4 Rocker shaft bracket bolt M8 x 1 25 9 81 to 19 6 1 0 to 2 0 7 2 to 14 5 Thrust plate bolt M8 x 1 25 9 8 to 11 8 1 0 to 1 2 7 2 to 8 7 Main bearing cap bolt M10x 1 25 49 0 to 53 9 5 0 to 5 5 36 2 to 39 8 Connecting rod cap nut M9x 1 0 32 4 to 37 3 3 3 to 3 8 23 9 to 27 5 Flywheel bolt M12 x 1 25 127 to 137 13 0 to 14 0 94 0 to 101 3 Crankshaft pulley nut M18x 1 5 147 to 196 15 0 to 20 0 108 5 to 144 6 Rear plate mounting bolt M12x 1
59. aft Mark on er pulley timing gear calipers or other similar tool to confirm the R thickness Add shims Reduce shims A CAUTI N thicker thinner Apply sealant to both sides of the shim to prevent oil leakage c Verify the fuel injection timing after adjustment d Close the fuel filter cock Install the delivery i Advatice valve spring and the fuel injection pipe Adjusting the fuel injection timing ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 5 Note 1 6 1 a b c d Ss a 2 Alternative adjustment method Removing the delivery valve to check and adjust the fuel injection timing is a sure way to observe fuel coming out and stop However this also runs the risk of allowing foreign matter to enter into the system The following alternative method can be tried which allows you to check the fuel injection timing without removing the delivery valve Disconnect the No 1 fuel injection pipe at the nozzle holder end Slowly rotate the crankshaft clockwise while observing the open end of the pipe When fuel starts to bulge out from the pipe end check the location of the IT mark on the crankshaft pulley In this case allow for approx 1 from the specified fuel injection timing Bleed the system of air before rotating the crankshaft Replacing the fuel filter Fuel filter with selector cock Close the cock lever Loosen the ring nut then remove t
60. al installer Oil seal guide O ring guide MISCELLANEOUS 1 3 Bearings 1 When installing a bearing always tap on the inner or outer race whichever will seat against a stop Use a tool like the one illustrated that aligns with the inner or outer race whichever is appropriate 2 With a press the installation will be smoother and more accurate Using a press to install a bearing 1 4 Lock plates Lock plates should be bent correctly as illustrated Typical lock plates and their correct use are re illustrated on the right Q Good Good Bad 1 5 Split pins Spring pins Ol KO ae On every disassembly split pins should be H Bad replaced with new parts Ensure that spring pins are clinched aa Ensure that spring pins are correctly installed Good Bad Good Correct use of lock plates MISCELLANEOUS No 0 Engine Inspection Sheet Engine Inspection Sheets Cylinder bore Valve stem to guide clearance and valve stem diameter Valve seat angle and width Cylinder head bottom face distortion Connecting rod bearings oil clearance Rocker arm inner diameter and rocker shaft diameter Piston pin boss inner diameter and piston pin diameter Valve clearance Fuel injection nozzle opening pressure Camshaft journal diameter and camshaft bushing inner diameter Crankshaft end play See a ey Se Engine Inspection Sheet No 1 jeune ien Pate Cylinder bore Measuring location Standard value ABC
61. all end of the push rod rests on the recess of the tappet y WV G K KY iw ENGINE MAIN PARTS REASSEMBLY Installing the cylinder head gasket A KX M al CCC V MU A i ato mu amp li hi a a J CIP O Tightening torque 83 4 to 93 2 N m 8 5 to 9 5 kgf m 61 5 to 68 7 lbf ft S3L S3L2 ENGINE MAIN PARTS REASSEMBLY 3 9 Assembling the rocker shaft assembly 1 Assemble the rocker shaft components to ensure the correct reassembly and tighten the retaining bolt 2 Ensue that the rocker arms move smoothly 3 10 Installing the rocker shaft assembly 1 Install the valve caps 2 Install the rocker shaft assembly onto the cylinder head Tighten the mounting bolts to the specified torque 3 11 Adjusting the valve clearance Refer to 1 3 Adjusting the valve clearance on Page 8 3 3 12 Installing the rocker cover 1 Ensure that the rocker cover is correctly fitted with gasket 2 Tighten the rocker cover retaining bolts to the specified torque Retaining bolt Tightening torque 9 81 to 19 6 N m 1 0 to 2 0 kgf m 7 2 to 14 5 Tightening torque 9 81 to 12 7 N m 1 0 to 1 3 kgf m C An QD Yy ANS Lt R cS GS 2 iN MUR 4 a K a NAN iG ait Ki NE re aa Y ard f D gt a UE Q K Installing the rocker cover FUEL SYSTEM REMOVAL 1 Fuel Injectio
62. alve seat width 1 30 to 1 80 0 0512 to 0 0709 2 5 0 0985 Valve head margin 1 35 to 1 65 0 0531 to 0 0650 0 5 0 0197 Valve seat width Valve seat angle Valve Valve head head sinkage margin Valve seat and valve Installed valve guide protrusion 112 9 5 to 10 5 0 3743 to 0 4137 SERVICE STANDARDS Unit mm in a 3 Item Nominal Standard value Limit Remarks 6 value Free length 47 1 85 46 1 81 8 2 0 A 0 5 eD A 0 2 0 0197 z Squareness T 0 0079 pene the v L47 entire length 1 8518 Installed length load a en pe 15 13 3 to 14 7 28 5 to 31 5 mmn in N kgf Ibf 29 to 33 63 to 69 Push rod Bend 0 3 0 011 Replace Cylinder head SOO oS Eaa 0 10 0 004 Correct distortion or less 3 Cylinder block top face 0 05 0 002 gs distortion or less AOO EO gt 78 0 03 0 0012 Bore 3 07 78 09 3 079 78 2 3 08 Bore or replace Out of roundness p oa STD 78 00 77 93 to 77 95 77 80 3 07 3 070 to 3 071 3 065 78 25 78 18 to 78 20 78 05 g TPAIS O08 3 08 3 080 to 3 081 3 075 2 0 50 OS 78 50 78 43 to 78 45 78 30 3 09 3 090 to 3 090 3 085 7 g a eas variation 4 5 0 177 02 E e B ght among pistons on the l same engine Or 6S5 z Piston pin diameter qa A oa a 0 9062 0
63. coefficient acl fa fa Atmospheric coefficient fm Engine coefficient a Calculating the atmospheric coefficient Engine with no charger or engine with mechanical supercharger 99 T 0 7 Boe Turbo charged engine with no charge cooler or turbo charged engine with air to air charge cooler 9 T f Fa aps Turbo charged engine with water to air charge cooler 0 7 0 7 T Oy te Pd 298 b Calculating the engine coefficient f m fm 0 036 qc 1 14 qc Corrected fuel delivery rate qe t r z X Fuel flow rate g s Cylinder capacity 4 x Engine speed min z 120000 4 cycle engine r Ratio of the outlet pressure of supercharger or q charge cooler to the atmospheric pressure r 1 on non charged engine 8 13 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST Application range of engine coefficient 37 25 gc 65 mg cycle qc 37 2 mg cycle fm 0 2 constant amp mg cycle S qc fm 1 2 constant c Application range of correction equation Application range of correction ae coefficient 0 9S aeS 1 1 If the correction coefficient used is outside the range record the corrected outputs together with the testing conditions on the performance test form 8 14 MISCELLANEOUS 1 Disassembly and Reassembly of General Parts s rrrtsrrrsrtssrssseretereeeees 9 2 1 1 Oil seals TUE RRR LLL RC KPPA LIL ETE CR OC RETE TTT ETE ESENE ET enor 9 is 2 1 2
64. de clearance Exhaust Installed valve guide protrusion clearance remove carbon from the valve and the valve guide 2 19 ENGINE MAIN PARTS INSPECTION AND CORRECTION 1 7 Replacing the valve guide 1 Using a punching tool remove the valve guide from the bottom to the top of the cylinder head 2 Using a press insert a new valve guide from the top of the cylinder head so that the valve guide protrusion above the cylinder head face is to the indicated dimension 3 With the valve guide press fit into position insert a new valve to verify that it slides smoothly inside the valve guide 4 Check the valve face to seat contact 1 8 Inspecting the valve face 1 Apply a thin coating of red lead onto the valve face Then using a valve lapper available on the market check the valve face to seat contact 2 The valve face contact area with the valve seat should be uniform and in the middle of the face If not reface with valve facer 3 If the measured valve head margin valve head thickness is less than the limit replace the valve Unit mm in Standard value 1 35 to 0 65 0 0531 to 0 0650 0 0197 Valve head margin Valve guide 10 0 5 mm 0 39 0 20 in if Cylinder head 15 mm 0 59 in LI Valve guide protrusion above the cylinder head face k Valve lapper lt lt Red lead Contact area in
65. diameter limit or replace Unit mm in Limit Standard value 0 05 M001T68281 0 002 0 10 M008T70471A 0 03 0 004 MO008T81071A 0 001 Commutator radial runout b Measure the commutator diameter If the measured value is equal to or less than the limit replace Unit mm in Standard value 29 4 MO001T68281 1 16 MO008T70471A 32 0 MO08T81071A 1 26 Commutator diameter c Measure the depth of undercutting between the commutator segments If the measured value is equal to or less than the limit correct or replace Unit mm in Standard value M001T68281 undercutting M008T70471A MO008T81071A 0 5 0 02 d Armature coil short circuit Using a growler test the armature coil for short circuit Replace if short circuit is indicated How to inspect Before debris from the armature coil With inspection remove any a thin iron plate positioned parallel with the armature coil slowly rotate the armature coil While the coil is running the iron plate should not be pulled onto the coil or vibrate Commutator Measuring the commutator diameter Segment Undercutting Testing the armature coil for short circuit 7 13 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY e Armature coil continuity Measure between the commutator segment and the armature coil There should be no continuity If continuity
66. e PCCP eet rere rer errr errr rere rere rer rs FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Fuel Injection Nozzles 1 1 Disassembling the fuel injection nozzles Replace Gasket 7 Wear O 6 Fatigue Perpendicularity 9 Wear Damage Carbon deposit Clogged nozzle hole D A 7 Disassembly of the fuel injection nozzle lt Reassembly sequence gt Nozzle retaining nut Pin Nozzle holder Nozzle tip assembly Spring Gasket Piece Washer 1 2 Inspecting the fuel injection nozzle Conduct the following inspections and if faulty Nozzle tester repair or replace as required 1 Injection valve opening pressure a Install the fuel injection nozzle onto the nozzle tester Pump the tester handle up and down to bleed air b Pump the tester handle at a rate of approx one cycle per second while observing the needle of the tester Note The needle should rise slowly and during fuel Inspecting the injection valve injection should vibrate The pressure at which Opening pressure the needle starts to vibrate is the injection valve opening pressure 3 10 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY c If the measured pressure does not conform to the standard value disassemble and adjust by changing the thickness of the washer Unit MPa kgf cm psi Standard value 14 22 to 15 00
67. e rocker stay bolts Remove the rocker shaft assembly together with the rocker stay bolts Remove the valve caps Keep the rocker shaft assembly with the rocker stay bolts Disassembling the rocker shaft assembly In the course of disassembly place removed valve rockers as well as the other parts neatly in the order of disassembly so that they can be reassembled back onto their original locations Doing so original clearances between the valve rockers and the rocker shaft is restored upon reassembly Removing the cylinder head bolts Loosen the cylinder head bolts in the order of the numbers illustrated Do not loosen one bolt completely before moving to the next bolt Loosen the bolts in a couple of steps Before removing the cylinder head bolts check the cylinder head components for any fault If faulty check the bolts for tighteness with a torque wrench ENGINE MAIN PARTS DISASSEMBLY og o6 04 S3L S3L2 010 oll o9 Tightening order for cylinder head bolts ENGINE MAIN PARTS DISASSEMBLY 1 4 Removing the cylinder head assembly Remove the cylinder head assembly by lifting it straight up Note If the bonding of the cylinder head gasket prevents the head assembly from being separated from the cylinder block tap the cylinder head side face on a relatively thick portion with a plastic hammer 1 5 Removing the valves and valve springs 1 Remove the valve caps and locks by compressing the springs using
68. e shafts Removing the pump camshaft 2 10 ENGINE MAIN PARTS DISASSEMBLY 2 13 Removing the oil pump Remove the oil pump retaining bolts Then remove the oil pump from the cylinder block 2 14 Removing the front plate Remove the four front plate retaining bolts Then gently tap the plate with a plastic hammer to remove the gasket Removing the front plate 2 11 ENGINE MAIN PARTS DISASSEMBLY Cc 3 Cylinder Block Crankshaft Pistons Oil Pan Piston ring wear damage Ring gap clearance Piston wear seizure streak Ring groove wear Connecting rod bend twist Big end thrust clearance OC r Cylinder damage stepped wear 4 e L gt lt Be D gt gt ZI FO Top face distortion ES I Be P S 4 e Oo b Y gt Y NA Dirty or clogged oil and DIANNA 0 a water galleries Y 9 Q E Q 4 G A gern A Crank journal pin damage ere plugs and N uneven wear cracks bend SC EPS Clogged oil hole Caution Damaged crankshaft The main bearings may be seized gear teeth due to poor oil maintenance etc In that case the crankshaft must be replaced KS Replace Side seal Pealing Scoring D Seizing S KF O O ef aX r OM DA NO A at 8 Disassembly of cylinder block crankshaft
69. e squeezed out to the tip of the threaded portion b Do not overtighten Installing the oil pressure switch 4 10 1 2 Installing the relief valve Install the relief valve onto the side face of the cylinder block tightening it to the specified torque Installing the oil filter Apply a thin coating of engine oil to the oil filter gasket Screw in the filter until the gasket contacts the mounting face Then tighten to the specified torque OIL SYSTEM INSTALLATION gt Tightening torque 44 1 to 53 9 N m 4 5 to 5 5 kgf m 32 5 to 39 8 Ibf ft Tightening torque 10 8 to 12 7 N m 1 1 to 1 3 kgf m 8 0 to 9 4 lbf ft Apply engine oil Installing the oil filter 2 4 11 OIL SYSTEM INSTALLATION 2 Oil Pan and Oil Strainer Tightening torque 9 8 to 12 7N m 1 0 to 1 3 kgf m 8 7 2 to 9 4 1bf ft Installation of the oil pan and oil strainer lt Installation sequence gt 4 12 COOLING SYSTEM REMOVAL 1 Cooling Fan Fan Pulley AN V Belteccccccscccecseeseeeeeeeeeeeeeeseeneeeeneneeeeneneas 5 2 Removing the cooling fan SO eT ECR TTT REET ETO TET TT CREN TTT CRER ST ETE CERT rer ree 5 Ls 2 D Thermostat and Thermoswitch A AAAA A CCRT ECC a 5 2 3 Removing the thermostat cage ttrr rrrrsrrrrssrsnnnunnnnuununuunnnnuuuunnnnuuuuuuunnnnnnnn n 5 is 3 3 Water Pump PGceeSeUeuaee eee Cenc see UUSRNEGR REG bUe LEE Ube eee e eee ec sleeew r A eee se T 5 i 4 Remov
70. e tool Coat the connecting rod small end with engine oil 3 Install the piston onto the connecting rod so that the arrow on the top face of the piston faces the side of the connecting rod that has the engine type embossed Insert the piston pin slightly into the pin boss 4 Using the push rod of the tool press the piston pin into the pin boss A CAUTION When the hydraulic press needle almost exceeds the 50 kgf 110 23 Ibf while the piston pin is being pressed stop pressing the pin Reset the push rod and start pressing again 5 With the piston and the connecting rod assembled together check that they slide smoothly about the piston pin N E EA ER E Check that the piston and the connecting rod slide smoothly about the piston pin 1 6 Note Installing the piston rings Using the special tool Piston Ring Pliers install the No 1 ring No 2 ring and oil ring onto the piston Special tool Part number Piston Ring Pliers 31391 12900 a Install the rings so that T mark faces the top of the piston b The oil ring should be installed so that the butt joint of the coil spring is located at 1800 relative to the ring gap as illustrated Installing the piston connecting rod assemblies Apply engine oil onto the periphery of the piston and the piston rings Position the piston ring gaps as illustrated The gaps should not face the same direction as the piston pin o
71. each Group are listed on the first page of that Group For information on the operations and recommended inspection maintenance schedule of forklift trucks please refer to the operator s manual for the forklift truck For information on components parts and spares ordering procedures refer to the parts catalogue For information on structures and functions refer to appropriate training materials 1 Notes on descriptions 1 Parts shown in Figures as well as in the text are numbered in the order of disassembly 2 Inspecting points during disassembly are shown in the Disassembly figures by enclosing in the box 3 Service standards for inspection and repair are listed on the appropriate pages of this manual where the relevant descriptions are made Also a comprehensive listing of service standards is provided in Group 1 4 Parts reassembly sequence is provided below the Figure of that reassembly in the form of gt gt gt gt 5 In this manual the following marks are provided to draw the reader s attention to the safety notes described under the marks VAN DYNAN L This indicates a dangerous situation which can highly likely result in death or serious injury unless avoided VAN WAVPANPA NTN Gp This indicates a potentially dangerous situation which may possibly lead to death or serious injury unless avoided VAN Oy NG MEO Nie II This indicates a potentially dangerous situation which may cause minor to moderate i
72. eaeooeeeeeneaanenenens 2 45 3 9 Assembling the rocker shaft assembly TIPTTTTTTI TIT TTT TTT TT 2 46 3 10 Installing the rocker shaft assembly sunununununununununuuunuuunuuunununnnnnnnnnnnnnnnnn 2 46 3 11 Adjusting the valve clearance tt tsrrrssrssssrsnnunnnunnnnuunnnuuunununnuuunnnunnunnnnnnn 2 46 3 12 Installing the rocker COVEY TEE r rt eeececreessseneeeeeaceaeeeeeeeaccoereeeaneoooeeeenaaaae 2 46 ENGINE MAIN PARTS REASSEMBLY 1 Cylinder Block Crankshaft Pistons Oil Pan To reassembly follow the disassembly sequence in reverse 1 1 Installing the main bearings 1 Install the main bearings upper and lower onto the cylinder block and the main bearing cap ensuring that the lugs engage with the lug grooves 2 The flanged main bearings should be installed onto the No 3 crank journal 3 Lightly coat the inner surface of each bearing with engine oil 1 2 Installing the crankshaft 1 Wash the crankshaft thoroughly in wash oil Dry the crankshaft using compressed air 2 While holding the crankshaft horizontally lower it slowly onto the cylinder block 3 Lightly coat the crank journals with engine oil 1 3 Installing the main bearing caps 1 Apply sealant onto the mating faces of the front and rear main bearing caps and the cylinder block ThreeBond 1212 2 Install the main bearing caps so that their arrow VLO E marks point the front of the engine and that the cap numbers are in
73. ear damage rust seizure DX Q Control rack operation Inspection of the fuel injection pumps 3 16 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 4 Reassembling the fuel injection pumps Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 lbf ft Replace O ring 3 a D ey Tightening torque T 19 6 to 24 5 N m 1 2 0 to 2 5 kgf m 14 5 to 18 1 lbf ft Replace Lock plate Air bleed plug Z Tightening torque 9 81 to 13 7N m D 1 0 to 1 4 kgf m 7 2 to 10 1 Ibf ft Q 3 Reassembly of the fuel injection pumps To reassembly follows the disassembly sequence in reverse and do the following steps 1 Inserting the plunger barrels Ensure that the plunger barrel groove is aligned with the knock pin of the pump housing Note If the plunger barrel groove is not aligned with the knock pin the O ring will not seat properly in the pump housing when the delivery valve holder is being loosely tightened in the next operation 2 Installing the delivery valves Install the delivery valve gasket spring and O ring Loosely tighten the delivery valve Delivery holder valve A CAUTION a Discard the old O ring Replace with a new part b While reassembling take care not to cut the O ring with the threaded portion of the valve holder Installin
74. ed immediately stop the engine Otherwise bearings etc may seize Inspect the oil system and components Stop the engine immediately upon broken fan belt If the fan belt has broken immediately stop the engine Otherwise the engine will overheat Also coolant vapor will gush out from the reserve tank and radiator and you may get burned NCaution Never alter or modify the engine Altering or modifying the engine in any way will nullify the warranty A modified engine may not only break but also lead to injury Do not tamper with sealing To help ensure trouble free operation of the engine the fuel control link has been sealed to achieve the correct fuel injection volume and engine speed If the sealed setting is tampered with the following will result and the correct functioning of the engine is no longer guaranteed O Sliding and rotating parts will wear faster Various parts will seize become damaged The engine will consume more fuel and oil The governor and fuel injection volume go out of balance reducing the engine performance Daily and periodical inspection Perform the daily and periodical inspection in accordance with the Operation and Maintenance Manual Failure to observe the instructions of the manual may lead to many problems and the various engine parts may eventually fail possibly causing a serious accident Running in period A brand new engine requires a running in pe
75. ediment is the entire assembly Replace the fuel filter n accumulated inside assembly approx every 500 hours However it ll ll is recommended that the fuel filter be checked i every 100 hours and if faulty replace at that Inspect every 100 hours time Replace every 500 hours Inspecting the fuel filter FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY FUEL SYSTEM INSTALLATION 1 Fuel Injection Pumps pide ee we T netnte nia nae es se A A A www ee 3 26 Installing the fuel injection pumps TEC TTT ETE LECCE TET CRC ERTL LCE PEP CTR ELE COTE Eee 3 27 2 Governor DACRE LUNE PEC E EE E RCMOE Oa RTE TREE CER GbE Sen BRE OUR E E meme ee we ere be A A E 3 28 21 Installing the governor weights AAEE A A AA AAAA 3 29 22 Installing the sliding sleeve O AANE AAA A A eRe AAAA O 3 29 23 Installing the governor assembly A A a a Re Ore 3 29 3 Fuel Injection Pipes Fuel Leak off Pipe Fuel Injection Nozzles 3 30 3 1 Installing the fuel injection nozzles TPR PRT EEOC T ET TCR TTL P DTT ORR ELEC OORT Te CTE 3 31 32 Installing the fuel pipes inte w wh in A A a A 3 31 FUEL SYSTEM INSTALLATION 1 Fuel Injection Pumps Installing the fuel injection pumps lt Installation sequence gt FUEL SYSTEM INSTALLATION Installing the fuel injection pumps 1 Install the fuel injection pump housing complete with the pumps onto the cylinder block and tighten the retaining bolts Installin
76. eee eee 2 7 22 Removing the flywheel housing ETEEEETETETETEETETEETELELELEELEELLELLELELEELELELELEETEELTEELE 2 x 7 23 Removing the rear plate EETTTETETEETEETEEELETETELELEEETELETEEELEELELELELELLELELEELELELELEELELEE 2 8 24 Removing the oil Seal cage t ttrr rrsrrssressnnnnunnunnununnuunnuuuunununnuunnnnunnnnnnnnnn 2 a 8 25 Removing the tappets PEEP Pee e eee error Tree reer reer reer terrier terre ttre etree eee 2 8 26 Removing the crankshaft pulley ETEEEETETETETEEEETEETEEETELTELEELLELLELELEELELELELEETEELTEELE 2 8 27 Removing the timing g arcase feitesscniras ceneettescansser roU En innuna teen eeecennceansey 2 x 9 28 Measuring the timing gear backlash rr rssssssssssnunnunuunnuunnnuuunununnuunnnnunnnnnnn 2 z 9 29 Removing the idler gap e reeeo e nnee Ei aa e REEE aee eE sects 2 1 0 210 Removing the Camshafts creer cect cress eeeeeeeeseseeceeeesaseceeeeeeeeseoeeeenaaaee 2 1 0 211 Removing the fuel injection pump Camshaft tsr trrrrsssrssnnsennnnnnnuunnuunnnnunnnn 2 1 0 2 12 Separating the gears from the shafts as required stttsstrrtttttttttttettttteetesee es 2 10 213 Removing the oil PUR tte tee anette a e a a a enn 2 11 214 Removing the front plate Pee eee eee reer eerie etree treet eet reer eee eee ee 2 11 3 Cylinder Block Crankshaft Pistons Oil Parts sttrrtststteesteereteeee ees 2 12 3 1 Removing the oil pAn Anani ie e ne ath a eean eee eE e 2 1 3 32 Removing the oil Strainer setter eee ee eeeeeeeeseeceeeeeaaeceeee enna gee 2 1
77. er Snap ring E Max 0 5 mm 0 02 in End play Adjusting the pinion shaft end play Front bracket Lever spring Packing AL J Gently push back Pinion gap i 0 5 to 2 0 mm 0 02 to 0 08 in Adjusting the pinion gap 7 17 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 Alternator 2 1 Disassembling the alternator Dirty damaged or seized slip rings Coil resistance Binding Cracks Damage Binding Cracks Damage Open or short circuit Brush slidability wear Coil open continuity Disassembling the alternator lt Disassembly sequence gt Through bolt Rear bearing Stator core Nut washer Bearing retainer Regulator assembly Pulley spacer Front bearing O Rectifier assembly Rotor Front bracket O Rear bracket 7 18 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Separating the front bracket from the stator core With flat head screwdrivers positioned between the front bracket and the stator core pry them away from each other A CAUTION Do not insert the screwdrivers too deep as it can damage the stator core 2 Removing the pulley a Protecting the rotor with cloth place the front bracket and rotor assembly in a vice Remove the pulley nut then remove the pulley and the spacer b Pull out the rotor from the front bracket
78. er ene mess _____ Item to be Connecting rod bearings oil E Measuring location Standard value Nominal Standard Limit value value Connecting rod bearings inner p 48 47 950 to 47 965 diameter 1 89 1 8892 to 1 8898 6 ag 48 47 950 to 47 964 Crank pin diameter 1 89 1 8892 to 1 8897 Connecting rod bearings oil 0 025 to 0 072 0 150 clearance 0 0010 to 0 0028 0 0059 Measurement Name Connecting rod bearings inner Crank pin diameter Oil diameter ee ee ese p Romarks SS a Rommarks rove by Confirmed by Measured by No 6 Engine Inspection Sheet rEngine number HENT ee Rocker arm inner diameter and rocker shaft diameter Unit measured Measuring location Standard value N Nominal Standard Te value value igo 19 18 910 to 18 930 diameter 0 749 0 7450 to 0 7458 Rocker shaft 19 18 880 to 18 898 diameter 0 749 0 7438 to 0 7445 Peirce 0 012 to 0 050 0 200 0 0004 to 0 0019 0 0079 clearance Measurement Location Min mw O O e ww O O O Engine Inspection Sheet No 7 Engnenumoer Item to be PNR Piston pin boss inner diameter and piston pin diameter Unit Measuring location Standard value ae oe value value Piston PIN 23 23 006 to 23 012 diameter 0 91 0 9057 to 0 9060 Piston pin 23 22 994 to 23 000 diameter 0 9062 0 9039 to 0 9062 bia 0 006 to 0 018 0 050 P 0 0002 to 0 0007 0 002 clearance Measurement ani l eo Piston pin to bos
79. erform the inspections duration for each phase listed below Running in timetable 2 1 Starting the engine Engine speed ae 1 Before starting the engine check the levels of PS lan il and fuel Also bleed th Idle speed No load coolant engine oil and fuel Also bleed the 1200 No load fuel and cooling systems of air Rated speed 25 2 With fuel shut off operate the starter for varies depending on 50 approx 10 seconds to crank the engine in order engine specifications 75 100 to distribute oil throughout the engine 3 Move the control lever slightly in the direction of increased fuel delivery moving the leverto 2 4 Inspection and adjustment after the full delivery position is not recommended running in Turn the starter key switch to the START a Adjust the valve clearance position to start the engine b Inspect the fuel injection timing 4 With the engine started move the control lever c Check the external bolts and nuts for to the no load low idle position tightness 2 2 Inspecting the engine during running in While the engine is being run in check the followings If faulty stop the engine Locate the cause and take appropriate actions to eliminate it 1 Oil pressure at the rated and low idle speeds The oil pressure should be 0 29 to 0 39 MPa 3 0 to 4 0 kgf cm 42 07 to 56 57 psi at the rated speed and 0 098 MPa 1 0 kgf cm 14 22 psi or above at the low idle speed
80. ert the tool s push rod into the piston pin hole Heng a press against the push rod extract the Push rod piston pin 3 Use the Piston Pin Setting Tool again to Piston pin Connecting rod Piston Identification mark reassemble the piston and the connecting rod arrow mark IZZZA f f i j A r PASS SSA A Va ezz i Yas Q he Piston X A CAUTION Do not try to remove the piston pin by tapping it If the piston has been agglutinated and requires a great force to remove replace it with a new part Removing the piston pin 2 2 15 ENGINE MAIN PARTS DISASSEMBLY 2 16 ENGINE MAIN PARTS INSPECTION AND CORRECTION 1 Cylinder Head Valve Mechanism TPT PCR E IEEE a a ee eT eer 2 1 8 1 1 Measuring the cylinder head bottom face distortion s t tttttttttttttttttttttettees 2 18 1 2 Measuring the rocker arm bore and the rocker shaft diameter tse eee 2 18 1 3 Measuring the valve spring for squareness and free length stttttttttttttttttte 2 18 1 4 Measuring the push rod for bend TL CCCE OEE a G aa EP EER RT RCC TT eer 2 1 9 1 5 Measuring the valve stem diameter A AALA AA A OAA A AAE AAA ri 2 1 9 1 6 Measuring the clearance between the valve stem and guidest ttttttttttttttttt 2 19 1 7 Replacing the valve guide TIERCE ELEC EERE REECE EERE CULL EEC CC Cece 2 20 1 8 Inspecting the valve face Pee nanna Disan DD TTC REAR CSE ere eer i i 2 20 1 9 Correcting the valve face A AAA AA AAAA A 2 21 1 1
81. fall Secure your foothold when carrying out service Use a stable stool or platform when working on the top of the engine or other areas of the engine difficult to reach Do not use a rickety stool nor substitute a box of parts Otherwise you may fall and become injured Do not leave anything on the stool SAFETY CAUTIONS NCaution engine oil and LLC Only use the specified fuel engine oil and coolant LLC Only use the fuel engine oil and coolant LLC that Handle them with Use correct are specified in this manual sufficient care Using fluids other than those specified in this manual or incorrect use of those specified in this manual will lead to many problems and may possibly cause failures Use the specified engine oil and LLC according to the instructions of MSDS Material Safety Data Sheets manufacturers issued by and available from the Handle LLC with care LLC is a strong alkali Be careful not to drink it by mistake or allow it to contact your eyes Old coolant containing LLC that has been drained off is toxic Do not dispose of it carelessly Dispose of it in accordance with the applicable laws and regulations Lawful disposal of waste oil and coolant Do not dispose of waste oil or coolant carelessly Doing so is harmful to the environment and is prohibited by law Harmful substances such as waste oil and coolant should be disposed of in a manner that complies with the ap
82. filter element and the other compact size without a filter element As for standard type remove the cover and clean or replace the filter element On either pump ensure that the pump operates normally without fuel leakage Diaphragm type fuel pump Never attempt to disassemble this type of fuel pump Like the compact size plunger fuel pump ensure that the pump operates normally without fuel leakage Replace filter element every 400 hours Check for external damage fuel leakage Check for external damage fuel leakage FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 5 Fuel Filter 5 1 Disassembling inspecting and Do not remove reassembling the fuel filter with a selector cock 1 Normally only remove the filter element Do not disassemble the cock lever unless so required 2 If the cock lever is disassembled clean it and apply silicon oil to the O ring before reassembly Wash in light oil every 100 hours Replace every 500 hours Check for accumulation of water or sediment Replace O rings and M Disassembling inspecting and reassembling the fuel filter Ring nut Cock lever Cup O ring O ring Spring Element Valve O ring Filter body 5 2 Inspecting the fuel filter cartridge type If water or sediment is accumulated on the i j Replace the entire assembly bottom of the case or in the filter element replace if water s
83. fm SF EC 721087 lbf ft p 0 O i O AR Installing the timing gear case Sess Ae ENGINE MAIN PARTS REASSEMBLY 2 8 Tightening the crankshaft pulley nut a ia Il 1 Use the studs and the bar described in Section e in 2 3 to lock the crankshaft 2 While locking the crankshaft tighten the crankshaft pulley nut to the specified torque A CAUTION The locking studs and bar should be sufficiently strong to avoid any accident 2 9 Installing the PTO gear Drive the PTO gear into the timing gear case Ensure that the side of the gear with no oil hole faces the rear of the engine 2 10 Inserting the tappets Apply engine oil to the periphery of the tappets and insert them into the tappet holes in the cylinder block 2 11 Installing the oil seal case 1 Install a new oil seal case gasket 2 Apply engine oil to the entire periphery of the oil seal lips and install the oil seal and case onto the cylinder block Installing the oil seal case ENGINE MAIN PARTS REASSEMBLY 2 12 Installing the rear plate 1 Install a new rear plate gasket 2 Install the rear plate aligning it with the dowel pins Tighten the retaining bolts to the specified torque Note Install the rear plate complete with the starter This will facilitate the subsequent reassembly G j S oe 5 5 to 7 5 kgf m 39 8 to 54 2 lbf ft 2 13 Installing the flywheel housing Install the flywheel housing aligning it wit
84. g g Increased noise levels of various engine parts h Abnormal color of exhaust gas after warm up Some of those listed above are directly related to the deterioration of the engine and some are not Items b and f are heavily influenced by fuel injection pump displacement fuel injection timing wearing of plungers nozzle conditions and conditions of electrical equipment such as battery and starter The most reliable criterion for engine overhaul is reduced compression pressure due to the wearing of cylinder liners and pistons item d This should be combined with other items for comprehensive review to reach a rational conclusion 1 26 OVERHAUL TIMING Measuring the Compression Pressure Move the control lever to STOP position am N 2 Remove the glow plugs from all cylinders Install the special tool Compression Gauge Adapter and a compression gauge onto the cylinder being measured Part number ST332270 Special tool Compression Gauge Adapter 3 While cranking the engine with the starter read the compression gauge Note the reading at Measuring the compression pressure which the gauge needle stabilizes 4 Ifthe measured value is at or below the limit overhaul the engine NETTO a Measure all cylinders for compression pressure Do not measure only one cylinder and make assumption about the other cylinders as this will lead to a wrong conclusion b Compression pressure varies de
85. g disassembly If a new connecting rod without mating marks is being installed ensure that the lug grooves designed to prevent the bearings from turning are assembled on the same side Tighten the connecting rod cap nuts alternately in several steps and finally to the specified torque Check the connecting rod end play Installing the oil strainer Position the cylinder block with the oil pan mounting face up Install the oil strainer so that the tip of the strainer will not contact the oil pan when installed Tighten the nut to the specified torque Installing the oil pan Clean the mating faces of the cylinder block and the oil pan Apply sealant to the entire periphery of the oil pan mounting face of the cylinder block ThreeBond 1207C Dl Dy Tightening torque 32 4 to 37 3 N m 3 3 to 3 8 kgf m 23 9 to 27 5 lbf ft Tightening torque E 24 5 to 29 4 N m 2 5 to 3 0 kgf m Installing the oil strainer Applying sealant to the oil pan mounting face of the cylinder block ENGINE MAIN PARTS REASSEMBLY Note a Apply sealant in a bead of 4 mm 0 1575 in R17 4 front and rear locations in total Apply sealant as lined and in the illustrated pattern b Cutting the end of the sealant tube at the illustrated location will provide a 4 mm 7in R7 from hole center i mm same for all 17 holes 0 1575 in bead 1 42 in R40 corresponding to hole centers same for all
86. g nut M30x 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 1 Stop solenoid blind plug M30x 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 1 Glow plug M10x 1 25 14 7 to 19 6 1 5 to 2 0 10 8 to 14 5 M14 x 1 5 19 6 to 24 5 2 0 to 2 5 14 5 to 18 1 39 2 to 49 0 4 0 to 5 0 28 9 to 36 1 M8 x 1 25 9 81 to 13 7 1 0 to 1 4 7 2 to 10 1 1 16 SERVICE STANDARDS 2 2 Standard Bolts and Nuts Thread 4T 7T diameter x pitch mm NEm kgfm lbf ft NEm kgf m llofLift M6x 1 0 2 94 to 4 90 0 3 to 0 5 2 2 to 3 6 7 85 to 9 80 0 8 to 1 0 5 8 to 7 2 M8 1 25 9 80 to 12 7 1 0 to 1 3 7 2 to 9 4 14 7 to 21 6 1 5 to 2 2 10 8 to 15 9 M10 1 25 17 7 to 24 5 1 8 to 2 5 0 7 to 1 0 29 4 to 41 2 3 0 to 4 2 21 7 to 30 4 M12 1 25 29 4 to 41 2 3 0 to 4 2 21 7 to 30 4 53 9 to 73 5 5 5 to 7 5 39 8 to 54 2 Note a The above table shows the tightening torques for standard bolts and nuts b The values in the table apply when tightened together with spring washers c The above table shows standard values for which a tolerance of 10 is allowed d Unless otherwise specified standard bolts and nuts should be tightened to the torques in the table e Do not apply oil to threaded portions Tighten under dry conditions 2 3 Standard Eyebolts Thread diameter Property class x pitch mm Nom kgffim lbfLi
87. g on the right hand side face of the cylinder block to drain coolant from the engine Coolant drain cock Zig a 1 3 Draining the Engine Oil Remove the engine oil drain plug from the oil pan to drain the engine oil Install and tighten the drain plug to the specified torque Oil pan capacity 3 7 to 6 0 1 0 to 1 6 U S Tightening torqe 34 3 to 44 1N m ce atig 0 5 tA SKE Z CAUTION Drain piug 1233 to 325 Ite Do not touch the engine oil which may be extremely hot as it can cause burns Drain plug on the oil pan 1 30 ENGINE MAIN PARTS DISASSEMBLY 1 Cylinder Head Valve Mechanism A A See eaten 2 2 1 1 Removing the rocker shaft assembly ree PE Pee e Teeter etree treet teeter etree eee teeter 2 3 1 2 Disassembling the rocker shaft assembly PEEP eeT Peete et Terre errr treet eee eee eee 2 n 3 1 3 Removing the cylinder head bolts trr sssrsssesssnnnnnnnunnununnnuununuunuuunnnunnnnnnnn 2 4 3 1 4 Removing the cylinder head assembly Peer Pee Tere reer reer reer reer reer eee tree eee eee 2 4 1 5 Removing the valves and valve springs POPPE Peete reer rete tee 2 4 1 6 Removing the valve stem seals s ssrrssserrssnunnununnuunnnuuunuuuunuuunnnuunnuuunnnn 2 4 2 Flywheel Timing Gear Camshaft a E cela d winikiebia betel nusineiee Meee hr we nee 2 5 21 Removing the flywheel ere e ee Peet reer reer reer reer re etree ree ere etree re etree
88. g set O Overrunning clutch Planetary gears O Front bracket Lever O Washer set ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY M0011T68281 Coil open shorted continuity Bearing loose noisy Rough surface of commutator binding worn Gear damaged worn Worn pinion gear Gear worn damaged Worn metal Worn brush Spring rust fatigue Holder insulation Overrunning clutch operation Worn brush Disassembly of the starter lt Disassembly sequence gt Pinion set Packing Snap ring Magnet switch Packing O Stopper Rear bracket Plate O Overrunning clutch Brush holder O Ball O Internal gear Brush assembly Planetary gears O Gear shaft Armature O Lever Yoke O Front bracket ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Removing the magnet switch a Loosen the nut at M terminal and disconnect the connector b Loosen the two magnet switch retaining bolts and remove the magnet switch 2 Removing the rear bracket Loosen the two through bolts and the two brush holder retaining bolts Remove the rear bracket Note There is an adjusting washer in the rear bracket Do not lose it 3 Removing the brush holder While lifting the two brushes remove the yoke and brush holder assembly Pull out the armature from the yoke 4 Removing the cover Re
89. g the delivery valve 3 17 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 3 Installing the control sleeves a Assemble the control sleeves onto the control rack so that each sleeve is aligned with the notched line b Insert the plungers into the sleeves A CAUTION Insert the plungers so that their cuts face the adjusting plates 4 Installing the tappets While pressing the tappet down move the control rack When the tappet groove is aligned with the tappet guide pin hole in the pump housing install the lock plate and the tappet guide pin ZA CAUTION Do not use the old lock plate Replace with a new part 5 Tightening the delivery valve holders Tighten the delivery valve holders to the specified torque A CAUTION a Do not overtighten the plungers as they will seize b Do not undertighten neither as it will cause the fuel to mix in the engine oil 3 18 Center tooth the only tooth visible when viewed from the bottom Face the pin Lock Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 lbf ft Tightening the delivery valve holder FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 6 Inspecting the control rack for smooth operation a With the fuel injection pumps assembled ensure that the control rack slides smoothly b If not possible causes include the following 1 The elements do not slide smoothly 2 Foreign matter is trapped between the
90. g the fuel injection pump housing complete with the pumps 2 Install the governor assembly inserting the tie rod and the tie rod spring into the fuel injection pump housing Installing the tie rod FUEL SYSTEM INSTALLATION 2 Governor Installing the governor lt Installation sequence gt 2 1 2 2 Installing the governor weights Install the governor weights onto the rear end of the pump camshaft and tighten the sliding sleeve shaft to the specified torque Installing the sliding sleeve Install the sliding sleeve onto the sliding sleeve shaft Ensure that the sleeve slides smoothly Installing the governor assembly Install the governor assembly onto the pump housing Connect the tie rod and the tie rod spring to the pumps Install the tie rod cover FUEL SYSTEM INSTALLATION Tightening torque 29 4 to 41 2 N m 3 0 to 4 2 kgf m 21 7 to 30 4 lbf ft Installing the governor assembly FUEL SYSTEM INSTALLATION Fuel Injection Pipes Fuel Leak off Pipe Fuel Injection Nozzles Tightening torque for fuel leak off pipe nut 20 6 to 24 5 N m 2 1 to 2 5 kgf m Tightening torque for 15 2 to 18 1 Ibf ft fuel injection pipe nut 24 5 to 34 3 N m 2 5 to 3 5 kgf m 18 1 to 25 3 lbf ft Tightening torque 49 0 to 58 8 N m 5 6 to 6 0 kgf m 40 5 to 43 4 lbf ft Installation of the fuel injection pipes fuel leak off pipe and fuel injection nozzles lt Installat
91. gine if you are not feeling well Otherwise you may incorrectly handle the engine and cause an accident When working jointly with other people on the same task use signals to coordinate actions involved Wear appropriate clothes and protective gear Whenever appropriate including when using compressed air wear protective gear such as helmet face mask safety shoes dust mask goggles and gloves Working without appropriate protective gear may lead to serious injury Use appropriate tools when carrying out service When carrying out any service use appropriate tools and in correct ways Damaged tools should be replaced with new ones Do not starter continuously Do not operate the starter more than 10 seconds per operate the starting attempt If the engine fails to start at the first attempt wait for at least 30 seconds before trying again Do not run the starter continuously if the engine will not start Otherwise the battery will go flat or the starter will seize The battery switch must be kept ON while the engine is running Do not turn off the battery switch while the engine is running Otherwise the instruments will become inoperative and the diode or transistor of the alternator may deteriorate Precautions for road transport When transporting the engine on public roads the weight width and height of the electric power generator should be taken into account while observing the relevant
92. gt 8 8 Installing the water pump Install the water pump with a new gasket onto the cylinder block Installing the water pump 5 10 COOLING SYSTEM INSTALLATION 2 Thermostat and Thermoswitch Tightening torque 18 6 to 26 5 N m 1 9 to 2 7 kgf m 13 7 to 19 5 lbf ft Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 lbf ft lt Installation sequence gt 2 7 2 1 Installing the thermostat case uu f Cover bolt tightening z Case bolt tightening torque torque 1 Assemble the thermostat into the thermostat case 39 2t049 0N m WD 16to20N m 4 0 to 5 0 kgf m 1 6 to 2 0 kgf m 2 Using a new gasket install the thermostat 28 9 to 36 2 lbf ft ieee GQ assembly onto the cylinder head Installing the thermostat assembly 2 2 Installing the thermoswitch Tightening torque 18 6 to 26 5 N m Apply sealant to the threaded portion of the 1 9 to 2 7 kgf m switch and tighten it to the specified torque 13 7 to 19 5 Ibf ft ThreeBond 1104 Apply sealant Installing the thermoswitch 5 11 COOLING SYSTEM INSTALLATION 3 Cooling Fan Fan Pulley and V belt Installation of the cooling fan fan pulley and V belt lt Installation sequence gt 7 Installing the cooling fan 1 Install the pulley onto the water pump 2 Install the cooling fan onto the water pump pulley and tighten the retaining bolts 3 Loosen the al
93. gt 8 8 ELECTRICAL SYSTEM INSTALLATION 4 Starter a Ve SSRAN A 7 on RO a Q QI es iy Q a Y IZ OZ 9 81 to 11 8 N m i 1 0 to 1 2 kgf m se D N f I 7 2 to 8 7 Ibf ft a oe K Installation of the starter 9 2 7 R A lt lnstallation sequence gt 7 ELECTRICAL SYSTEM INSTALLATION 1 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST Inspection and Adjustment of Engine AAA Sei c eee tees T tate 8 2 1 1 Preparations for valve clearance inspection and adjustment esetere 8 2 1 2 Inspecting the valve clearance t ttr rtsrrrsreresnnnnnnnnnnuunnuuunnuunnnununnuunnununnnnn 8 2 2 1 3 Adjusting the valve clearance tt tttsrrssrsssssrsnnunnununnnuunnnuunnununnnunnnuunnunnnnnnn 8 2 3 1 4 Inspecting and adjusting the fuel injection timing s tttttttttttttttttttttetttettte ee 8 4 1 5 Alternative adjustment Method t rrtrrssssssnnnnnnnnnnnnnnnuunnnuunnunnnnnunnnnunnnnnnnnn n 8 6 1 6 Replacing the fuel filter sttrrrrrrrttrrrrrrrrrsnrrsnnnnnnnnnnnnnnnnuuunnnunnunnnnnunnnnnnnunnnnnnn 8 5 6 1 7 Bleeding the fuel filter of ajr s srssrttrrrtrrrrrrrrrrrrsrsnrennnnnnnnnnnnnnnnnnununuununnnnnnnnnn 8 lt 7 1 8 Adjusting the low and high idle speeds OPI EPEIE ETE e Tee errata terete eee eee 8 a 8 1 9 Inspecting the fuel injection NOZZ E ttrrrrstrsnnnnnnnnnnnunnnnnnnnnunnnnunnnnnnnnnnnnnnnn 8 9 1 10 Inspecting the V belt tension AAS EAA
94. h the knock pins Tighten the retaining bolts evenly Note Replace the knock pins with new parts if the knock pins are worn or if a new flywheel housing is being installed 2 14 Installing the flywheel 1 Screw in a safety stud M12 1 25 into one of the flywheel retaining bolt holes at the rear end of the crankshaft 2 Insert the flywheel through the safety stud and onto the crankshaft 3 Loosely tighten the three flywheel retaining bolts 4 Replace the safety stud with the 4th retaining bolt and loosely tighten it 5 Using a torque wrench or other similar tool lock A Tightening torque the crankshaft pulley nut l 137 to E Ne m 6 Tighten the flywheel retaining bolts to the 13 0 to 14 0 kgf m 94 0 to 101 3 lbf ft specified torque A CAUTION The person who locks the crankshaft pulley nut should do so with extreme care Communicate with each other closely to prevent accidents Tightening the flywheel bolts ENGINE MAIN PARTS REASSEMBLY 3 Cylinder Head Valve Mechanism To reassembly follows the disassembly sequence in reverse 3 1 Cleaning the bottom face of the cylinder head Scrape off any gasket from the mating faces of the cylinder head and the cylinder block taking care not to damage the faces Note Use a scraper to roughly remove the remaining gasket Then using an oil stone and engine oil polish away fine residue 3 2 Installing the valve stem seals Using a box wrench
95. h the bearing and the gear into the cylinder block Tap the gear with a plastic hammer until the bearing is completely inserted into the mounting hole in the cylinder block Ensure that the fuel injection pump camshaft rotates smoothly Tighten the stopper bolt 2 40 gt aK I Tapping the fuel injection pump camshaft into place 2 5 1 2 Installing the camshaft Apply engine oil to the journals and cams Insert the camshaft complete with the camshaft gear into the cylinder block A CAUTION Take care not to damage the journals or cams when inserting the camshaft into the cylinder block Using an appropriate torque wrench and socket tighten the thrust plate mounting bolts to the specified torque Ensure that the camshaft rotates smoothly Also ensure that there is some end play by sliding the camshaft to the front and rear Installing the idler gear Apply engine oil to the idler shaft Install the idler gear so that the timing marks are aligned with those of the meshing gears Check the backlash between the gears Refer to Measuring the timing gear backlash on Page 2 23 Installing the timing gear case Apply sealant onto the gasket and stick it in place Then install the timing gear case onto the front plate Apply engine oil to the oil seal lips Tighten the timing gear case retaining bolts ENGINE MAIN PARTS REASSEMBLY Tightening torque 9 8 to 11 8 Nem Des 1 0 to 1 2 kg
96. he filter element Install a new filter element Using a new O ring tighten the ring nut Open the cock lever Bleed the filter of air Fuel filter cartridge type Replace the entire fuel filter assembly After replacement bleed the filter of air Counter mark on gear case Cock lever closed Filter element Replace O ring Replace every 500 hours Ring nut Replacing the fuel filter Replace also when water or sediment has accumulated inside C Replace every 500 hours Replace also when water or sediment has accumulated inside ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 7 Bleeding the fuel filter of air 1 a 2 a b Fuel filter with selector cock push button type Open the cock lever and press the push button several times Fuel will automatically come down into the filter With the engine equipped with the fuel pump turning the key ON will cause fuel to enter into the filter Repeatedly press the button until fuel with air bubbles no longer comes out Air trapped in the fuel injection pipe and the nozzle will be bled automatically by cranking the engine Fuel filter cartridge type With the engine equipped with the fuel pump turn the key ON Fuel will automatically come down into the filter Loosen the air bleeder screw 1 When fuel with air bubbles no longer comes out tighten the screw Loosen the air
97. ighten the cap bolts to the specified torque Measure the inner diameter of the main bearings 2 Measure the diameter of the mating crank journal The difference between the main bearings inner diameter and the crank journal diameter is the oil clearance for the main bearings bearings Tightening torque 49 0 to 53 9 Nm 5 0 to 5 5 kgf m 36 2 to 39 8 lbf ft Measuring direction 1 Measuring location Unit mm in Nominal value Standard value Crank journal diameter STD 52 2 0488 51 985 to 52 000 2 0482 to 2 0488 Oil clearance for main bearings 0 030 to 0 077 0 0012 to 0 003 0 100 0 0040 Measuring Measuring location direction If the measured oil clearance exceeds the limit replace the main bearings With the new bearings installed measure the oil clearance again If the measured oil clearance still exceeds the limit use the undersize bearings 0 25 mm 0 0098 in 0 50 mm 0 0197 in 0 75 mm 0 0295 in U S Also grind the crank journal accordingly to the finished dimension shown below Measuring the crank journal diameter Crank journal ground dimensions Unit mm in Finished dimension 51 759 a15 2 0374 9 sng P 51 50515 2 0276 9009 51 25 0015 2 017700 0 25 0 0098 0 50 0 0197 0 75 0 0295 Crank journal undersize ENGINE MAIN PARTS INSPECTION AND CORRECTION A CAUTION
98. ine oil spills over the heated engine fire may start possibly leading to bodily injury or equipment damage Use explosion proof light When checking fuel engine oil coolant battery electrolyte etc use explosion proof light If ordinary light is used these fluids may ignite and explode Prevent short circuit Before inspecting or servicing the electrical electronic system disconnect the negative cable from the battery terminal Failure to observe this can cause the circuit to short possibly starting a fire Loose terminals and damaged cables wires can cause short circuit or even fire Before carrying out service operation check for loose or damaged components and repair or replace as required Keep fire extinguisher and first aid kit at hand Keep a fire extinguisher at hand Become familiar with the handling of the fire extinguisher Store a first aid kit at the designated place The kit should be kept fully supplied so that it can serve the purpose at any time Establish a set of actions to take in the event of fire or accident including emergency contact numbers and means of communication SAFETY CAUTIONS N Warning Risk of entanglement into the machine Keep guards on the rotating parts Ensure that all guards are correctly UN installed over the rotating parts of the engine Damaged or loose MeT guards should be repaired Never attem
99. ing the water pUMp trettterstssscercseseesenesrsssssscssccsereerersarenssenssucacrersereneas 5 4 COOLING SYSTEM REMOVAL 1 Cooling Fan Fan Pulley and V Belt Cracks elongation wear and damage Cracks deformation and damage Removal of the cooling fan fan pulley and V belt lt Removal sequence gt Cooling fan Water pump pulley V belt Removing the cooling fan 1 While holding the cooling fan with your hand loosen its retaining bolts to remove the fan and fan spacers 2 Be sure to record the installation directions and positions of the fan spacers Removing the cooling fan COOLING SYSTEM REMOVAL 2 Thermostat and Thermoswitch Cracks water leaks damage Replace Gasket Cracks deterioration damage Removing the thermostat and thermoswitch lt Removal sequence gt Bolt Gasket Thermostat Thermoswitch Removing the thermostat case Remove the thermostat case with thermostat Removing the thermostat case COOLING SYSTEM REMOVAL 3 Water Pump S Cracks water leaks damage Removing the water pump lt Removal sequence gt Bolt Water pump plate Water pump Gasket Gasket Removing the water pump Remove the water pump Removing the water pump COOLING SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Thermostat Se Te Tee T EE TEC RTT TTT ET EER CET CCT OTST IC EE E
100. installer Extracting the camshaft bushing 1 mm 0 04 in Notch on the bushing 1 mm 0 04 in gt Mating mark Measuring location OF Measuring direction Measuring location om Measuring direction Measuring the fuel injection pump shaft cam height 2 25 ENGINE MAIN PARTS INSPECTION AND CORRECTION 2 11 Inspecting the cam to tappet contact Inspect the tappet contact face with the cam If abnormally worn replace the tappet a Good Bad Bad Cam to tappet contact 2 12 Measuring the clearance between the Measuring Measuring direction direction tappet and the tappet guide Measure the tappet diameter Measure the tappet guide bore in the cylinder block If the difference between them exceeds the limit replace the tappet Unit mm in Limit Tappet to guide clearance 0 150 0 0059 Measuring the clearance between the tappet and the tappet guide ENGINE MAIN PARTS INSPECTION AND CORRECTION 3 Cylinder Block Crankshaft Pistons Oil Pan 3 1 Measuring the piston diameter Using a micrometer measure the piston diameter across the piston skirt and squarely with the piston pin as illustrated If the measured value is less than the limit replace with a new part The maximum allowable variation in weight among the pistons on the same engine is 5 grams 0 18 02 Unit mm in Nominal Standard value value 78 00 77 93 to 77 95 3 07 3 070 to 3 071 Pis
101. ion sequence gt 8 8 0 Installing the fuel injection nozzles Install the gaskets onto the fuel injection nozzles Insert the fuel injection nozzles into the cylinder head and tighten to the specified torque Installing the fuel pipes Install the fuel leak off pipe onto the fuel injection nozzles Install the fuel injection pipes and hold them in place with clamps Tighten the fuel leak off and fuel injection pipe nuts to the specified torques FUEL SYSTEM INSTALLATION Tightening torque 49 0 to 58 8 N m 5 0 to 6 0 kgf m 36 2 to 43 4 lbf ft Replace Gasket Tightening torque for fuel injection pipe nuts 24 5 to 34 3 N m 2 5 to 3 5 kgf m 18 1 to 25 3 lbf ft l Installing the fuel pipes FUEL SYSTEM INSTALLATION OIL SYSTEM REMOVAL 1 Oil Filter Relief Valve and Oil Pressure Switch s srrtsstttrsttsttsrstestreeeeeees 4 2 1 1 Removing the oil filter 1 trrrr rrtrrrrrrsrsrrnnnnnnnnnnnuuunnnnnnuuunnnnnnnnnnnnnnuunnunnnnnnnn 4 3 1 2 Removing the relief Valve t ttttrrrrrrtrrrnrrnnnnnnuuuunnnnuuuuunnnnnnnuuuunnnununuunnnnnnn 4 3 1 3 Removing the oil pressure SWitch rrtrrrrrrsssnnuuuunnnnnuuuunnnnunuuuunnnnunuuunnnnnnn 4 3 2 Oil Pan Oil Strainer PPOCTTOCTOOCOTOCCOTOCOTOCOTICOTICTTICTTTTT LTTE LTTE TTT T ITT TTT tee 4 4 OIL SYSTEM REMOVAL 1 Oil Filter Relief Valve and Oil Pressure Switch Replace Gasket a Replace Gasket
102. l Te a N inner diameter diameter J g clearance mofem xe fe me me a ae re ee ee eee ee tet Engine Inspection Sheet No 11 Engine number Item to be Crankshaft end play Unit Measuring location Standard value 0 050 to 0 175 0 500 Crankshaft end play 0 0020 to 0 0069 0 0197 Measurement On disassembly On reassembly
103. l injection pipe The injection timing IT is just when the fuel stops coming out Note When fuel has stopped coming out slightly rotate the crankshaft in the reverse direction and then slowly rotate it clockwise to let fuel come out This will show more exactly when fuel stops coming out c Just when fuel stops coming out the IT mark on the crankshaft pulley should be aligned with the counter mark on the gear case Injection timing BTDC 17 pee Counter mark on gear case IT mark Timing marks 2 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 3 Adjusting the fuel injection timing a Ifthe fuel injection timing does not conform to above specified BTDC adjust the shim thickness under the fuel injection pump housing Changing the shim thickness by 0 1 mm 0 004 in will change the fuel injection timing by approx 1 b Increasing the shim thickness will retard the Adjusting fuel injection timing Reducing the shim shims thickness will advance the fuel injection timing z Advanced by Adjustment range Standard value 1 5 TDC mark this angle Retarded by this angle Shims are available in thicknesses of 0 2 mm 0 008 in 0 3 mm 0 012 in 0 4 mm 0 016 i i j IT mark in and 0 8 mm 0 031 in Thicknesses are ae division Sac not indicated on shims Measure the thickness corresponds j f Crankshaft to2 of the shim being used with a pair of vernier Cranksh
104. lash Measure the backlash between the gears and use the measurements as references upon reassembly If any of the measured values exceeds the limit replace all gears unless otherwise specified Unit mm in Standard value Crank gear idler gear Measuring the timing gear backlash Idler gear valve 0 04 to 0 12 camshaft gear 0 0016 to 0 0047 Idler gear pump 0 30 camshaft gear 0 0118 Valve camshaft 0 08 to 0 19 gear PTO gear 0 0031 to 0 0075 Pump camshaft 0 07 to 0 20 oil pump 0 0028 to 0 0079 lt S n i Q Ss Oo H lse o on on g sm am ENGINE MAIN PARTS DISASSEMBLY 2 9 Removing the idler gear KI AX Remove the idler gear by sliding it out along the oF 2 CVA es helical teeth 2 10 Removing the camshaft 1 Remove the thrust plate retaining bolts 2 Gently pull out the camshaft taking care not to damage it A CAUTION When pulling out the camshaft pay attention to the cams as they tend to be caught by the surrounding parts 2 11 Removing the fuel injection pump camshaft 1 Remove the stopper bolt one place 2 Using a copper rod or other similar tool tap the rear end of the fuel injection pump camshaft Then pull it out to the front of the engine 2 12 Separating the gears from the shafts as required Using a hydraulic jack remove the camshaft gear and the fuel injection pump camshaft gear from the respectiv
105. laws regarding road traffic restrictions and and haulage and vehicle requirements GENERAL 1 Overview nonsnonnunuunonnnonnunuunounnunnunnuneonnuununnunnonnnunuununnpunnunnuNEuNBENNENNNNEENEEENEDN 1 2 1 1 Outline Drawing Peer ere etree t reer reer reer reer reer reer rere r errr rere errr rere tee ete eee 1 e 2 1 2 Fuel System Schematic rrr rrsrsrsnrennnunnunnnnuunnnuuunuuunnnunnnnnunnnnnnnnnnnnnnnnn n 1 z 4 1 3 Oil System Schematic errr t cer rreeeeeeceeeessseeeeeeseeeceeeeerseaeeeeeeeeaganare 1 4 1 4 Cooling System Schematic ccc rt reese cr cceeeseceeeeeesseceeeereseaeereeeesanaeee 1 S 5 1 5 Inlet Exhaust System Schematic trr trrrssssrrnnnnnnnnnnnuunnnuuunununnuunnnnunnnnnnn 1 5 1 6 Engine Serial Number tt trrrrssssssnunnnnuunnununnuunnnuunununuunnuunnnuunuununnunnnnnnnnn n 1 6 1 7 Engine Model and Application Codes ttr rsrsrsssnnnnunnnnnunnuunnnnunnnnnnnunnnnnnnnnn 1 6 2 Specifications ET TERT ETE T TELE Tee LTTE TET TE CLE TEER E RET OE LEER Teer eee 1 7 3 Disassembly Reassembly Notes AT AAAA AAAA LEAL AETA se 1 9 3 1 Disassembly Pree eee eee etree treet reer reer reer reer reer rere rier rere ere etree ete eee eee ee 1 a 9 32 Reassembly TELE CA LEE TEETER EEL CLEC ET TE TULTE MRE RTE CCCOLLE ETC rT Eee Tn 1 2 9 GENERAL 1 Overview 1 1 Outline Drawing
106. le it is running or for a while after it is stopped 0 4 Be careful when opening closing the radiator CF 0 la ele al ial eee aa 0 4 Replenish coolant only when the coolant in the system is Cold vere 0 4 Do not remove heat insulating material 0 4 Warning Exhaust gas is poisonous annnnnnannnnnnnannnnnnnannn 0 4 Ensure good ventilation while the engine is running ssssssnnnnssnnnnnnnnnnnnnnnnnnnnnn 0 4 Warning Hearing difficulty eee 0 4 Wear ear protector See ee ae ees e es wae e eee eee ee ae een 0 4 Warning Beware of falling engine 0 5 Exercise caution when lifting the engine 0 5 Do not climb on the engine teresen 0 5 Secure your foothold when carrying out Seryjce rt ttrrrrrrrrrssnnnnnnnnnnnunnnnnnnnnnunnnnnnn 0 5 Caution Use correct engine oil and LLC E E E E 0 5 Only use the specified fuel engine oil and coolant LLC E A ine cwiee e ein leew 0 5 Handle LLC with care sscscttttssssstsssssseeees 0 5 Lawful disposal of waste oil and COOlAN ttt ttre tet eeeseeeeeeeeeeee eee eeeee 0 5 Caution Handling of battery 0 6 Handle the battery with caress ttttttttttte 0 6 Caution How to handle emergencies ERT ET ETE EET TCE 0 6 Engine overheat Idle to cool down then stop the engine eee eee eens eee eee 0 6 Never restart the engine after a sudden stop unless the cause is eliminated 0 6 Stop the engine immediately upon oil pressure drop wee eens eee eee 0 6 Stop the engine im
107. limit bore all cylinders of the same engine and replace the pistons and the piston rings with oversize parts Measure at 3 locations as shown in the fig each in directions A and B Unit mm in Pistons and piston rings available Cylinder bore Size Code Standard Limit value 0 783 3 07 Standard 0 78 250 value 3 08 0 2 P 78 50 0 0080 3 09 0013 0 01 0 0004 max STD STD 0 25 OS 25 0 50 OS 50 Cylinder bore out of cylindricality 3 13 Measuring the cylinder block top face for distortion Using a straight edge across the top face of the cylinder block and a thickness gauge measure for any distortion If the measured distortion exceeds the limit correct by grinding the top face Unit mm in Standard Limit value Cylinder block top face 0 05 0 002 distortion A CAUTION The combined grinding limit for the cylinder block top face and the mating cylinder head bottom face is 0 2 mm 0 008 in 0 10 0 004 Measuring direction Measuring location Measuring the cylinder bore Measuring location Measuring direction Measuring the cylinder block top face for distortion ENGINE MAIN PARTS REASSEMBLY 1 Cylinder Block Crankshaft Pistons Oil Parnss srssrrttersstretesretteeeteeeees 2 34 1 1 Installing the main bearings PTTITTTTPTIT TTT ITT erie rr ite 2 34 1 2 Installing the crankshaft srr
108. m nut Using a thickness gauge set the valve clearance to the standard value by screwing in or out the adjusting screw Unit mm in Standard value Inlet 0 25 0 01 Exhaust 0 25 0 01 Valve clearance Adjusting the valve clearance 2 While holding the adjusting screw to prevent it from turning tighten the nut A CAUTION If the valve clearance is adjusted during engine overhaul check the valve clearance again after rotating the crankshaft a couple of turns ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 4 Inspecting and adjusting the fuel injection timing 1 Preparations a Close the fuel filter cock b Disconnect the No 1 fuel injection pipe at both ends c Remove the No 1 delivery valve holder Take out the delivery valve and the spring Install the delivery valve holder only d Reconnect the No 1 fuel injection pipe at the pump end only to see the fuel flow e Set the speed control lever to LOW speed 2 Inspecting the fuel injection timing SA a Open the fuel filter cock If the engine is fe equipped with a fuel pump turn the key ON Rex S Fe t Note Place a container under an open end of the fuel VAN S A gt injection pipe to collect fuel coming out in the l A oY AN a ls next step On the engine equipped with a fuel pump be prepared as fuel will come out fiercely b Slowly rotate the crankshaft clockwise Fuel will come out of the fue
109. mage and smooth rotation or not it rotates smoothly If faulty replace the entire pump assembly 2 Relief Valve Inspecting the relief valve 1 Inspect for proper valve to seat contact spring fatigue breakage or any other damage If faulty replace 2 Measure the relief valve opening pressure at rated engine speed If the measured pressure exceeds the standard value remove the cap nut and adjust by shimming 3 Engine oil pressure port Right hand side of Inspecting the relief valve engine 0 35 0 05 MPa Relief valve opening pressure 3 5 0 5 kgf cm 504 7 2 psi OIL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 3 Oil Pressure Switch Inspecting the oil pressure switch 1 Connect a tester ohm meter between the oil pressure switch terminal and the switch body The tester should indicate continuity If not replace the switch 2 With the tester still installed insert a thin rod into the oil hole and gently press the rod The tester should indicate no continuity If continuity is indicated replace the switch 3 With the tester still installed apply an air pressure of 0 05 MPa 0 5 kgf cm 7 psi into the oil hole The tester should indicate no continuity Check also for any air leakage If air is leaking the diaphragm is broken Replace the switch Inspecting the oil pressure switch 2 OIL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY OIL SYSTEM INSTALLATION 1
110. mediately upon broken fan el ttrrrrrrrrrrrrrrrrrrsnnnnnnnnnnnnnnnnnnnnnnnnnn 0 6 Caution How to handle emergencies sdevanewsietsaessentad 0 6 Engine overheat Idle to cool down then stop the engine sence eens eee eee 0 6 Never restart the engine after a sudden stop unless the cause is eliminated 0 6 Stop the engine immediately upon oil pressure drop eee ee eee eee eee 0 6 Stop the engine immediately upon broken fan el ttsrrrrrttrrrrrrrrrrrnnnnnnnnnnnnnnnnnnnnnnnnnn 0 6 Caution Other considerations 0 7 Never alter or modify the engine ee 0 7 Do not tamper with sealing strstr 0 7 Daily and periodical inspection 11 0 7 e Running in period eee eter Pere reer rrr rere rere 0 7 Warming up the engine tnsnnnnnnnnnnnnnnnnnnnnnnn 0 7 Do not overload the engine teere 0 7 Cooling down the engine see eeeeeeeeeeeeeeeeeeees 0 7 Do not spill water onto the engine 51 0 7 Air cleaner maintenance precautions 0 8 Observe safety rules at work sites ttt 0 8 Wear appropriate clothes and protective QOar tt ttrtteteeeteeeeeeeteeeeeneeeeeeeeeeenereneees 0 8 Use appropriate tools when carrying out service 0 8 Do not operate the starter continuously 0 8 The battery switch must be kept ON while the engine is running Perret ree er eter errr rerrryy 0 8 Precautions for road transport eee 0 8 SAFETY CAUTIONS Z Warning Risk of fire and explosion Never use open fire When topping up or replacing fuel
111. mer push the piston and connecting rod assembly on the mating face with the connecting rod cap to remove the assembly from the cylinder block 3 5 Measuring the crankshaft end play With a dial gauge installed onto the end of the crankshaft measure the shaft end play If the measured value exceeds the limit replace the flanged No 3 bearing Unit mm in Standard value Crankshaft end 0 050 to 0 175 play 0 0020 to 0 0069 3 6 Removing the main bearing caps 1 Place the engine so that the cylinder block mating surface with the oil pan faces upwards 2 Loosen the main bearing cap bolts Then remove the caps 3 On the front and rear main bearing caps remove these using a sliding hammer 3 7 Removing the crankshaft 1 Remove the crankshaft by slowly lifting it straight up A CAUTION When lifting the crankshaft take care not to damage the main bearings 2 The main bearings may fall down making it not possible to identify their original locations Removing the crankshaft Once the crankshaft is removed place the main bearings neatly and in the original pairs so that they can be reassembled back onto their original locations 2 14 ENGINE MAIN PARTS DISASSEMBLY 3 8 Separating the piston from the connecting rod 1 Remove the piston pin using the special tool Piston Pin Setting Tool Special tool Part number ig Piston Pin Setting Tool 31A91 00100 Piston Pin Setting Tool 2 Ins
112. move the cover and take out the snap ring and the washer 7 10 Ka Cum 6 O Through bolt Brush holder retaining bolt Removing the rear bracket Brush holder Removing the cover ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 5 Removing the center bracket Loosen the bolt and remove the center bracket Behind the center bracket there is a washer for adjusting the pinion shaft end play 6 Removing the pinion a Place an appropriate tube on the pinion stopper Tap the tube with a hammer to drop the pinion stopper to the clutch side This will expose the stopper ring b Using a pair of pliers remove the stopper ring Remove the pinion Note The stopper ring should not be reused on reassembly 7 Removing the pinion shaft Pull out the spring lever reduction gear and pinion shaft from the front bracket Note To facilitate reassembly note the correct installations of the lever and the spring as they are removed 8 Removing the bearings Using a bearing puller or other similar tool remove the ball bearings at both ends of the armature The ball bearing that has been press fit into the front bracket cannot be replaced If the bearing is worn or faulty replace the entire front bracket assembly Center bracket Tube Stopper Qx Pinion stopper Stopper ring Front bracket Pinion shaft Reduction gear Removing the pinion shaft rat ELECTRICAL SYSTEM DISASS
113. n Pipes Fuel Leak off Pipe Fuel Injection Nozzles 3 2 1 1 Removing the fuel injection pipes E ATA AA N 3 is 3 1 2 Removing the fuel injection nozzles TREC RT CLERC ECR CCC erie 3 lt 3 2 Governor EEEE EE Waw wietelacoei aie A AAAA AAA biklela wie AA wie se uieiavecueWieta a wae etaaiore 3 4 21 Removing the governor assembly A A AAAA re G er TOT 3 5 22 Removing the governor weights A A A a T a AA 3 5 5 3 Fuel Injection Pumps a A E E A a A E A E A alata ww wie eee 3 a 6 Removing the fuel injection pumps a a E a a A nn BiSie e m 3 5 7 FUEL SYSTEM REMOVAL 1 Fuel Injection Pipes Fuel Leak off Pipe Fuel Injection Nozzles Replace Gasket Removal of fuel injection pipes fuel leak off pipe and fuel injection nozzles lt Removal sequence gt No 1 fuel injection pipe No 4 fuel injection pipe No 2 fuel injection pipe Fuel leak off pipe No 3 fuel injection pipe Fuel injection nozzle A CAUTION To prevent dirt from entering into the fuel system plug the injection pump openings the nozzle inlet connectors and the injection pipes 1 1 Removing the fuel injection pipes Remove the fuel injection pipes and the fuel leak off pipe Note To prevent dirt from entering into the system plug the fuel injection pump openings and the fuel injection nozzle connectors 1 2 Removing the fuel injection nozzles Using a wrench loosen the fuel injection nozzles Remove the nozzles and gaskets Note U
114. n a alfa Ga um mtoreierns e w e a aa a 0l a e R a A a wi wm ww 7 1 8 21 Disassembling the alternator A AAE E CRC RR RT pen tit 7 1 8 22 Inspecting and correcting the alternator A A S Winiwin Ww visinn win wien 7 20 23 Reassembling the alternator SOOEERC CC nOOO CCRC CRC ICCC Cir eric 7 22 3 Stop Solenoid nA E AEE E E A T E E E A r E E E AA TT 7 23 3 1 Reassembling the stop solenoid PRE Neha nw RONG ea enieiee nna MU whn Win Wie Wii Sin n wine OE 7 23 32 Checks after reassembly nin i Wn wlnia n Winn B 0 n ein n inte W a nie npn We A Win a n mein A a ein awn wln ele 7 24 4 Glow Plug E E ETIT E a E T T EA S a E A pe ee 7 24 Inspecting the glow plug E TEE ETE E E A LORE TEC ET ETE A A A T 7 24 ELECTRICAL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 1 1 Starter Removing the starter M008T70471A M008T81071A Worn pinion gear Magnet switch circuit Armature bend runout open or shorted open or short circuit Bearing loose noisy binding Brush wear insulation Bearing loose noisy binding Overrunning clutch operation Yoke circuit open or shorted Gear worn damaged lt Disassembly sequence gt Pinion set Magnet switch Rear bracket Brush holder Yoke Armature Disassembly of the starter Ball bearing O Gear shaft Ball O Internal gear Packin
115. n location Measuring the piston diameter No 1 piston ring to groove clearance No 2 piston ring to groove clearance Measuring the piston ring gap ENGINE MAIN PARTS INSPECTION AND CORRECTION 3 4 Measuring the clearance between the piston pin and the pin boss Measure the piston pin diameter Measure the bore size of the piston pin boss If the difference between them exceeds the limit replace with Measuring new parts Measuring direction location Unit mm in Nominal Standard value value Piston pin 23 22 944 to 23 000 diameter 0 9062 0 9039 to 0 9062 Measuring the piston pin to boss clearance Piston 0 006 to 0 018 ete 0 0002 to 0 0007 3 5 Measuring the connecting rod bend and twist 1 Measure C and as illustrated If measured C is more than 0 05 mm 0 0020 in per 100 mm 3 937 in of measured correct the connecting rod using a press Unit mm in oo __ Standard value Limit 0 05 100 Connecting rod 0 15 100 0 002 3 940 or less 0 006 3 940 bend and twist 2 Normally a connecting rod aligner is used to Tightening torque measure the connecting rod for bend and twist for connecting Note Before measuring the connecting rod for bend rod cap nut 32 4 to 37 3 N m a2 3 3 to 3 8 kgf m specified torque 23 9 to 27 5 lbf ft tighten the connecting rod cap nuts to the Using a connecting rod aligner to measure
116. nal Crank pin diameter Oil clearance for connecting rod bearings 3 If the measured oil clearance exceeds the limit replace the bearings With the new bearings installed measure the oil clearance again 4 If the measured oil clearance still exceeds the limit use the undersize bearings 0 25 mm 0 0098 in 0 50 mm 0 0197 in 0 75 mm 0 0295 in U S Also grind the crank pin accordingly to the finished dimension shown below Crank pin ground dimensions Unit mm in Finished dimension P 47 75 5659 1 881 po000 P 47 50 5650 1 871 po000 P 47 2525 1 8610014 0 050 0 0020 0 25 0 0098 0 50 0 0197 0 75 0 0295 Crank pin undersize Tightening torque 32 4 to 37 3 N m 3 3 to 3 8 kgf m 23 9 to 27 5 lbf ft Tightening torque 32 4 to 37 3 N m 3 3 to 3 8 kgf m 23 9 to 27 5 lbf ft Measuring Measuring direction location Measuring the connecting rod bearings inner diameter Measuring Measuring direction location H Measuring the crank pin diameter ENGINE MAIN PARTS INSPECTION AND CORRECTION A CAUTION a lf any of the crank pins need grinding grind all crank pins on the same crankshaft to the same dimension b Finish the fillets to a radius of 2 mm 0 08 in 3 8 Inspecting the main oil clearance Place the main bearings upper and lower onto the cylinder block and the main bearing cap Assemble them together and t
117. nifold tr rrrrsssrsssnrennnnnnnnunnuunnnuunnunuunununnnunnnnunnnnnnn 6 5 8 2 Inlet Cover Godad Spee arn Wis G ea G ash eS tM RIrel T E G EG a We OceLn E E mie min ere we O a we ore E 6 _ 9 Installing the inlet COVEY tr t eet ttreeeseeeeeeeasseeneeeesaneaeoeeeeeaneaeeeeeananenereeeauanenes 6 i 9 INLET AND EXHAUST SYSTEMS INSTALLATION 1 Exhaust Manifold Tightening torque 14 7 to 21 6N m 1 5 to 2 2 kgf m 10 8 to 15 9 lbf ft Installation of the exhaust manifold and gasket lt Installation sequence gt gt Installing the exhaust manifold Install the exhaust manifold and tighten the retaining bolts to the specified torque Installing the exhaust manifold INLET AND EXHAUST SYSTEMS INSTALLATION 2 Inlet Cover Tightening torque 14 7 to 21 6 N m 1 5 to 2 2 kgf m 10 8 to 15 9 lbf ft Installation of the inlet cover and air pipe lt lnstallation sequence gt gt 9 gt 9 gt 9 gt l Installing the inlet cover Install the inlet cover and tighten the retaining bolts to the specified torque C j iI j C K Q A Al ty N o m JRS a C K i C i W K X 15 D i DO gJ Ko a KO Ka A al Q a Q D Q i D q all Installing the inlet cover INLET AND EXHAUST SYSTEMS INSTALLATION 6 10 ELECTRICAL SYSTEM REMOVAL 1 Starter EE E A ee ata We iw wee AA O
118. nifold and gasket lt Removal sequence gt Exhaust manifold Gasket Removing the exhaust manifold Remove the exhaust manifold Removing the exhaust manifold INLET AND EXHAUST SYSTEMS REMOVAL INLET AND EXHAUST SYSTEMS DISASSEMBLY INSPECTION AND REASSEMBLY 1 Inlet Cover and Exhaust Manifold a aia ae SS wine eS eee e eel eee ee WO ee nie ew Cee ee weitere cee dele 6 2 6 1 1 Inspecting the inlet cover and exhaust Manifoldsttstttttttttttttttttetttttttet ete eeeees 6 6 1 2 Measuring the exhaust manifold mounting face distortion tttttttttttttttttttt 6 6 INLET AND EXHAUST SYSTEMS DISASSEMBLY INSPECTION AND REASSEMBLY 1 Inlet Cover and Exhaust Manifold 1 1 Inspecting the inlet cover and exhaust manifold 3 Cracks Cracks Damage Inspecting the inlet cover and exhaust manifold 1 2 Measuring the exhaust manifold mounting face distortion Using a straight edge across the exhaust manifold Thickness gauge mounting face and a thickness gauge measure any distortion If the measured distortion exceeds the limit correct by grinding or replace the manifold Unit mm in Limit 0 15 0 006 or less Measuring the exhaust manifold mounting face distortion Exhaust manifold mounting face distortion INLET AND EXHAUST SYSTEMS INSTALLATION 1 Exhaust Manifold A AAAI Se ee SE tb T A Benn Wines be Saleen wane www A A E A A T 6 _ 8 Installing the exhaust Ma
119. njury unless avoided CAUTION OMM This indicates a potential danger in which property damage may result unless avoided Note This stresses important points or provides useful tips on engine operations and service 6 Wherever hardware tightening requires the application of engine oil WET is mentioned If not mentioned tighten the hardware dry engine oil should not be applied 2 Terms Nominal value This is the nominal dimension of the part being measured Standard value This is the dimension of the individual part being measured the clearance between the parts in question or the standard performance in question Standard values have been arranged within the range appropriate for the inspection being carried out and are not necessarily the design values Limit eeeeee reese Parts that have reached the limit value should be replaced or repaired whichever is 3 0 0 0 0 0 0 0 0 0 0 0 0 4 appropriate Abbreviations and standards BTDC Before Top Dead Center ATDC After Top Dead Center BBDC Before Bottom Dead Center ABDC After Bottom Dead Center TIR Total Indicator Reading API American Petroleum Institute ASTM American Society for Testing and Materials JIS Japan Industrial Standards LLC Long Life Coolant MIL Military Specifications MSDS Material Safety Data Sheets SAE Society of Automotive Engineers Units Values shown in this manual are based
120. nnot fully guarantee safety as potential risks beyond ordinary imagination are hidden everywhere When conduct any work the following points should also be observed in addition to the instructions this manual 3 1 Disassembly 1 Use tools and equipment that are appropriate for the work being carried out 2 Whenever necessary use workbenches to work on or sort parts out Disassemble in accordance with the disassembly sequence given in the manual 3 As parts are disassembled place them neatly in the order of removal to eliminate missing parts on reassembly 4 During disassembly note the assembly marks Remember to respect these marks on reassembly Whenever appropriate put additional assembly marks to aid reassembly 5 Before and during disassembly as well as during subsequent washing carefully check for any abnormality or other fault which otherwise may likely remain unnoticed afterwards 6 Pay sufficient attention to ensure safety especially when lifting or carrying heavy components and parts Use a jack or a chain block as required 3 2 Reassembly 1 Parts excluding oil seals O rings rubber sheets etc should be thoroughly washed in wash oil and completely dried using compressed air 2 Use appropriate tools and equipment 3 Use good quality oil and grease Never fail to apply oil grease sealant and adhesive to the relevant locations if so instructed in the manual GENERAL 4 Tighten hardware
121. nozzles su uunnununnnnnnnunnnununununununununununnnunnn 1 2 Inspecting the fuel injection nozzle sunununnnnnunuunnnnununnunnununnnnnununuunnununnnnnnnunnn 1 3 Reassembling the fuel injection nozzle nusunununnnununnnnnnnnnunnnnnununuunnunununnnnnunnn 2 Fuel Injection Pumps CCCCEEC ewe UNCUR DONC NERCCRGO TORE TOT OEE eadd a T T ee eOtene ewe 2 1 Inspecting the fuel injection pumps on vehicle nunnnnnunuunnununnnnnnnununununununnnnnnnn 22 Disassembling the fuel injection pumps PTOPTCUCCOCOOTOTOCCCOCCOOOTICCOCOCOOTOT eT Tee eee 2 3 Inspecting the fuel injection pumps sunununnnnnunuunnnnununnnnnanunnnnnununnnnnunununnnnnunnn 24 Reassembling the fuel injection pumps PTOPTCUCCOCCOTOTOCCCOOCOOOTOCCCCOOOOT OT Te ere 3 Governor Pe eT iaaa T EERE ere a a ara 3 1 Disassembling and inspecting the governor susununnnnnununnnunununununnnnnununnnnnnnnnnn 3 2 Reassembling the governor s nsnununnnunununnnnnnnununnnunununnnununununnnunununununununnnnnn 3 3 Installing the torque spring set nussnunnnnnnnununnnununununnnununununununununununununnnnnnnnnnn 4 Fuel Pump a a E E a A E E Inspecting the fuel pump sunusunnnnnununnnununununnnunununnnnnunnnnnnnnunnnnuunununununununununununnnN 5 Fuel Filter eC RET eT RCC RET eer re Te RTT SE CRETE errr rer rrr 5 1 Disassembling inspecting and reassembling the fuel filter with a selector cock ssssssunnnuuununuusssnnnnunnnununssuunnnnnnnunnnnnnnnuuunssnnnnununuNENENNE 5 2 Inspecting the fuel filter cartridge type Pree ee
122. nuous load test This test in which the engine is run continuously for 10 hours under a 90 continuous load at the engine speed achieving the nominal net brake power is aimed at obtaining the fuel consumption and other operating conditions as well as determining as to whether or not the engine can withstand continuous operation 3 No load minimum speed test This test is aimed at confirming as to whether or not the engine can run stably at the specified speed under no load 3 3 Other tests Check for and correct any leakage of exhaust gas coolant or oil abnormal odor hunting etc 3 4 Adjusting the engine power Engine power can be affected by the atmospheric pressure temperature and humidity The power of the engine being tested should be atmospheric conditions adjusted for normal 1 Normal atmospheric conditions are Reference temperature 298 K 25 C 77f Atmospheric total pressure 100 kPa 750 mmHg Reference dry atmospheric pressure 99 kPa 743 mmHg 2 Correcting the engine output Measured brake power and torque should be corrected by multiplying them by the diesel engine correction coefficient described below Corrected output correction coefficient a X measured brake output Atmospheric conditions for testing Temperature T 283 K 10 C SOf J amp E TS 313 K 40 C 104f Dry atmospheric pressure 80 kPa 600 mmHg S PS 110 kPa 825 mmHg 3 Calculating the correction
123. o 1 cylinder to the top dead center of the compression stroke This is achieved by aligning the TDC mark on the crankshaft pulley with the counter mark on the gear case 2 To verify that the No 1 piston is at the top dead center of the compression stroke rotate the crankshaft approx 20 in both forward and reverse directions If the relevant rocker arm does not move while rotating the crankshaft the No 1 piston is at the top dead center of the compression stroke 3 If the rocker arm moves the piston of the No 1 cylinder is at the exhaust top dead center Try again to set the No 1 piston at the top dead center of the compression stroke by rotating the crankshaft one more turn 4 Starting with the No 1 cylinder and moving to TDC mark for No 1 and No 4 pistons Counter mark on gear case other cylinders in the firing order inspect and adjust the valve clearance With the valve clearance for the No 1 cylinder adjusted set the piston of the next cylinder in the firing order to the top dead center of the compression stroke To do this rotate the crankshaft in the forward direction clockwise when facing the timing gear case by 180 TDC mark for No 2 and No 3 pistons Firing order Crankshaft rotation Cylinder No angle Timing marks 1 3 2 240 1 3 4 2 180 ENGINE INSPECTION ADJUSTMENT RUNNING IN TRIAL AND PERFORMANCE TEST 1 3 Adjusting the valve clearance 1 Loosen the rocker ar
124. on SI units International System of Units The corresponding metric values are shown in immediately after the SI values The SI to metric conversions are based on the following U L 0 0 0 0 0 Pressure 1 MPa 10 197 kgf cm Torque 1 Nim 0 10197 kgf Im Force 1 N 0 10197 kgf Horsepower 1 kW 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 7 cmHg Meter of water 1 kPa 10 197 cmH O cmAq Rotational speed 1 min 1 rpm GENERAL CONTENTS Group No Group Name 0 SAFETY CAUTIONS GENERAL SERVICE STANDARDS TOOLS LIST OVERHAUL TIMING REMOVAL PREPARATIONS Engine Main Parts ENGINE MAIN PARTS DISASSEMBLY ENGINE MAIN PARTS INSPECTION AND CORRECTION ENGINE MAIN PARTS REASSEMBLY Fuel System FUEL SYSTEM REMOVAL FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY FUEL SYSTEM INSTALLATION Lubrication System OIL SYSTEM REMOVAL OIL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY OIL SYSTEM INSTALLATION Cooling System COOLING SYSTEM REMOVAL COOLING SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY COOLING SYSTEM INSTALLATION Inlet and Exhaust Systems INLET AND EXHAUST SYSTEMS REMOVAL INLET AND EXHAUST SYSTEMS DISASSEMBLY INSPECTION AND REASSEMBLY INLET AND EXHAUST SYSTEMS INSTALLATION Air starter System ELECTRICAL SYSTEM REMOVAL ELECTRICAL SYSTEM
125. otherwise specified Unit mm in Standard value Crank gear idler gear Idler gear valve 0 040 to 0 120 camshaft gear 0 0015 to 0 0047 Idler gear pump camshaft gear Valve camshaft 0 080 to 0 190 gear PTO gear 0 0032 to 0 0075 Pump camshaft 9 970 to 0 200 ae oil pump 9 0028 to 0 0079 Measuring the timing gear backlash 0 300 0 0120 S N S rm x Q S H x D N on S E E ENGINE MAIN PARTS INSPECTION AND CORRECTION 2 4 Measuring the clearance between the Aiens idler gear and the idler shaft direction Measure the inner diameter of the idler gear A Measure the idler shaft diameter If the AA difference between the two exceeds the limit y Measuring replace the idler gear or the idler shaft location Unit mm in Standard Limit value Idler gear to shaft 0 020 to 0 070 0 200 clearance 0 0008 to 0 0028 0 0079 Measuring the idler gear to shaft clearance 2 5 Replacing the idler shaft When installing the idler shaft into the cylinder 26 5 0 5 mm block observe the dimension indicated 1 04 0 02 in Replacing the idler shaft 2 6 Measuring the clearance between the camshaft journal and the bushing Measuring location Measure the camshaft journal diameter Measure the inner diameter of the bushing on the cylinder gt block If the difference between them exceeds Measuring direction the limit
126. pending on the engine speed Keep the specified engine speed when measuring the compression pressure Standard value Limit 290 min Engine speed Compression pressure 2 9 MPa 30 kgf cm 421 psi 2 6 MPa 27 kgf cm 377 psi Tolerable difference between cylinders 0 29 MPa 3 0 kgf cm 42 psi or less A CAUTION It is important to regularly check the compression pressure so that you can tell the difference 0 0 New or overhauled engines have slightly higher compression pressure The compression pressure settles to the standard value as the piston rings and valve seats fit in As wear progresses compression pressure drops further the 1 27 OVERHAUL TIMING 1 28 REMOVAL PREPARATIONS 1 Preparations A AEA A AAAS OAA 1 30 1 1 Removing the Electric Wiring nonsnsonnunnununnonnnunnununnonnnunnunuunonnnannunuununneunnunnnnn 1 30 1 2 Draining the Coolant PPOeETICCTTCCTTCTOTCTTTCTTTeTITeereeereeerererecererererere rere ret ete e tite tee 1 30 1 3 Draining the Engine Oil PED RUUR SSE O00 8 RONEN Nb OEE 60b b o bnaee ee E Den be 86n e b ob Ree bee 1 30 REMOVAL PREPARATIONS 1 Preparations 1 1 Removing the Electric Wiring Remove the wiring harnesses from the following equipment Before removal attach mating tags etc onto the terminals to aid reassembly Starter Switches Starter wiring 1 2 Draining the Coolant Loosen the coolant drain plu
127. plicable laws and regulations SAFETY CAUTIONS NCaution battery Handle the battery with care Batteries emit Handling of hydrogen and oxygen gases both of which are flammable Never use open fire or generate sparks near the battery Otherwise these gases may ignite and explode Do not use the battery if the electrolyte level has dropped below the minimum line Otherwise the battery may explode Be careful not to inadvertently place a metal object such as tool between the battery terminals O Always disconnect the negative terminal first then the positive terminal from the battery Always connect the positive terminal first then the negative terminal to the battery Recharge the battery in a well ventilated place with all battery plugs removed The battery terminals should have a positive connection Loose terminals can generate sparks possibly causing the battery to explode Before servicing or performing electric welding on the electrical electronic system position the battery switch in the OPEN OFF position or disconnect the negative terminal of the battery to isolate the electrical electronic circuit The battery electrolyte contains dilute sulfuric acid Incorrect handling may lead to loss of eyesight or burn Never drink battery electrolyte O Wear protective goggles and rubber gloves when maintaining the battery replenishing recharging etc O If yo
128. pt to remove the camshaft cover rocker cover or any other guards form rotating parts while the engine is running Never leave exposed the drive belts and related couplers for auxiliaries and radiator They should also be covered with guards Never remove these guards Ensure safety in the surrounding area when starting the engine Before starting the engine ensure that no one is near the electric power generator and that no tools or foreign matter are left behind Shout to people around you so that they will know you are starting the engine Never start the engine if a Do not start tag or any other similar message is posted on the starter switch etc Keep away from rotating parts while the engine is running Never stand near the rotating parts while the engine is running cx Do not place objects near the rotating C Should any part of human body or tool is caught by parts that are likely to be caught by these parts the rotating parts dismemberment or other bodily injury will result Lockout tagout Perform lockout tagout before carrying out any inspection service Lockout tagout is an ideal way of disconnecting the machine equipment from the power source To lockout tagout remove the starter switch key place the battery switch in the OFF position and post a Do not start tag or other similar message on the starter switch The starter switch key should then be carried by the per
129. r O na Remove the plunger spring Remove the spring upper seat and the control sleeve together e Pull out the control rack Removing the plunger 3 14 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 3 Removing the delivery valve a Place the pump upwards in a vice b Remove the delivery valve holder c Remove the delivery valve gasket d Using a pair of tweezers remove the delivery valve A CAUTION The delivery valves are an ultra precision part They should be free of dirt or damage 4 Removing the plunger barrels Pull out the plunger barrel A CAUTION a The plunger barrels are an ultra precision part They should be free of dirt or damage b Keep the plunger barrels and the plungers in the original pairs for each of the cylinders Do not use them in wrong pairs Note a When replacing the plunger barrels or the delivery valves do not loosen the adjusting plates between the cylinders b If the barrels or valves are to be replaced fuel injection volume must be measured The measurement requires pump tester cam box c Keep the parts removed in clean light oil Do not loosen these plates 3 15 FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 2 3 Inspecting the fuel injection pumps Delivery valve wear damage CN 0 C 0 2 2 S a g OD fo O OO Tappet contact wear o Plunger fit w
130. r of the cylinder Valve lapper Lapping compound Lapping the valve face against the valve seat Tapping the combustion jet into place ENGINE MAIN PARTS INSPECTION AND CORRECTION 2 Flywheel Timing Gear Camshaft 2 1 Measuring the flywheel flatness Place the flywheel on a surface plate Run a dial gauge over the frictional surface of the flywheel to measure the flatness If the measured value exceeds the limit grind the frictional surface Unit mm in Standard Limit value 0 150 0 0059 or less 0 50 0 0197 Flywheel flatness 2 2 Replacing the ring gear Check the ring gear for fractured or excessively worn gear teeth If faulty replace in the following manner 1 Removing the ring gear a Using an acetylene torch or other similar equipment heat the ring gear evenly ko Yi i i l A b Using a hammer and a rod tap the ring gear IW Y fu Li evenly on the entire periphery until the gear comes off 2 Installing the ring gear Removing the ring gear Using a piston heater or other similar equipment heat the ring gear to approximately 150 C 302 f or less With the gear warmed up install it onto the flywheel with the un chamfered side first 2 3 Measuring the timing gear backlash Measure the backlash between the gears and use the measurements as references upon reassembly If any of the measured values exceeds the limit replace all gears unless
131. r squarely with the piston pin Install the connecting rod bearing upper onto the connecting rod ensuring that the lug engages with the lug groove Rotate the crankshaft until the crank pin onto which the piston connecting rod assembly is being installed comes to the top dead center Face the piston connecting rod assembly so that the arrow mark on top of the piston points to the timing gear case side front of the engine Using a piston guide available on the market insert the piston connecting rod assembly from the top of the cylinder block down A CAUTION Do not tap the piston too hard Doing so may break the piston rings or damage the crank pin ENGINE MAIN PARTS REASSEMBLY ae Top face mark No 1 compression ring Oil ring gap Assembling the oil ring Oil ring gap C Front of engine 4 lt No 1 ri 2 Dain eee No 2 ring coil spring butt joint Locating the piston ring gaps Installing the piston connecting rod assembly ENGINE MAIN PARTS REASSEMBLY 1 8 1 2 3 Note 1 10 1 Installing the connecting rod caps While pressing the top of piston down to keep the connecting rod large end attached to the crank pin rotate the crankshaft 180 Install the connecting rod bearing lower onto the connecting rod cap ensuring that the lug engages with the lug groove Install the bearing cap onto the connecting rod observing the mating marks made durin
132. re not to direct the exhaust gas towards nearby plants or animals if any Engine exhaust gas contains carbon monoxide and other substances that are harmful to humans Running the engine in a poorly ventilated place can cause exhaust gas poisoning Z Warning Hearing difficulty Wear ear protector Wear ear protector whenever entering Otherwise the combustion and mechanical noises the engine room may cause you to develop hearing difficulty Z Warning Beware of falling engine Exercise caution when engine The wire rope used to lift the engine should have withstand the weight of the engine lifting the enough strength to Attach the specified lifting gear onto the lifting hangers on the engine Ensure that the engine is well balanced when it is lifted by taking into account the engine s center of gravity The angle of wire rope relative to the lifting hangers should be maintained at 60 or less Above this the hangers may be subjected to overload and break If direct contact between the wire rope and the engine is anticipated protect them from damage by covering them with cloth or other soft material Do not climb on the engine Do not climb onto the engine nor place a foot on the components on the side of the engine Otherwise you may not only break the engine components but also fall and become injured Use a stool or a platform to work on the top of the engine Be careful not to slip and
133. riod of 50 hours during which never put the engine under severe load Otherwise the service life of the engine will be reduced SAFETY CAUTIONS Other considerations Warming up the engine Before starting work warm up the engine by running it at low idle for 5 to 10 minutes Warming up the engine will not only smoothen the operation of various engine parts but also help extend its service life It also helps maximize the performance and achieve economical running of the engine Do not warm up the engine longer than necessary Doing so facilitates carbon deposit on the cylinders possibly leading to poor combustion Do not overload the engine Do not continue to run the engine if it emits black smoke Overloaded running of the engine accompanied by black smoke not only consumes excessive fuel but also facilitates carbon deposit and thus shortens the service life of the engine Cooling down the engine Before stopping the engine cool it down by running it at low idle for 5 to 6 minutes Stopping the engine suddenly while it is heavily loaded will result in some areas of the engine remaining extremely hot for a while which is detrimental to the long service life of an engine While the engine is being run at low idle for cooling check the engine for any problems Do not spill water onto the engine Ensure that no rainwater etc enters into the engine from the exhaust or inlet manifold or via any other routes
134. s Piston pin inner diameter Piston pin diameter Al o S T S ee ee ee pat TU A No 8 Engine Inspection Sheet Engine model csom e o ae Standard value 0 25 0 01 Valve clearance 025 001 Measurement Valve clearance Exhaust Ne See adjustment adjustment adjustment adjustment adjustment adjustment adjustment adjustment Remarks Approved by Confirmed by Measured by Engine Inspection Sheet No 9 Bienes Engine model Date Engine number Item to be PEEN l MPa kgf cm Fuel injection nozzle opening pressure Unit psi Measuring location Standard value Nominal Standard Nozzle tester value value 14 22 14 22 to 15 00 145 145 to 153 2062 2062 to 2176 Valve opening pressure Measurement Valve opening pressure Hours used Valve opening pressure Before adjustment h After adjustment No 10 Engine Inspection Sheet T Engine model Date Engnenumoer Item to be Camshaft journal diameter and camshaft bushing inner diameter Unit mm in Measuring location Standard value re Nominal Standard Limit y value value Y Camshaft bushing No 1 45 45 000 to 45 055 x inner diameter 4 77 107730 to 1 7751 Camshaft journal No 1 45 44 930 to 44 950 diameter 1 77 1 7702 to 1 7710 ce Bens aa 0 050 t0 0 125 0 15 OLA i 0 0020 to 0 0050 0 0060 clearance OLA Measurement Name Camshaft bushing Camshaft journa
135. se a wire or a screwdriver to remove the fuel injection nozzle gaskets from the cylinder head Faulty gaskets should be replaced FUEL SYSTEM REMOVAL Removing the fuel injection nozzle FUEL SYSTEM REMOVAL 2 Governor Replace Gasket Removal of the governor lt Removal sequence gt Bolt Governor assembly Gasket FUEL SYSTEM REMOVAL Removing the governor assembly Remove the tie rod cover Using a pair of cutting pliers remove the tie rod spring Disconnect the tie rod from the pumps Remove the governor assembly Removing the governor weights Remove the sliding sleeve Remove the sliding sleeve shaft and then the governor weights Removing the governor weights FUEL SYSTEM REMOVAL 3 Fuel Injection Pumps Removal of the fuel injection pumps lt Removal sequence gt Bolt Fuel injection pump Shim FUEL SYSTEM REMOVAL Removing the fuel injection pumps 1 Remove the tie rod cover 2 Using a pair of cutting pliers remove the tie rod spring Disconnect the tie rod from the pumps 3 Removing the fuel injection pumps Note Note the thickness of shim pack for the adjustment of the fuel injection timing Removing the fuel injection pump FUEL SYSTEM REMOVAL FUEL SYSTEM DISASSEMBLY INSPECTION AND REASSEMBLY 1 Fuel Injection Nozzles NESS RO COCR ee RUC ORC ECCT OCCOC Cr rer re RT OnerrTrE e rir 1 1 Disassembling the fuel injection
136. sible burn wear thick rubber gloves or cover the cap with cloth to protect your hands from escaping vapor Tighten the radiator cap firmly Coolant is extremely hot while the engine is running or for a while after the engine is stopped You may become burned by extremely hot vapor or coolant that will gush out if the radiator cap is opened Replenish coolant only when the coolant in the system is cold Do not replenish coolant for a while after the engine is stopped Replenish coolant when the coolant in the system is sufficiently cold Otherwise you may become burned Do not remove heat material The exhaust system components become extremely insulating hot and therefore are covered with heat insulating material Never remove the material If the material needs to be removed at all for inspection service be sure to install it again after the operation Z Warning Exhaust gas is poisonous Ensure good ventilation while the engine is running If the engine is installed inside a building and the exhaust gas is a directed outside through a duct regularly check the duct for any leakage through the joints etc Do not run the engine in a building warehouse tunnel etc confined space or other poorly ventilated places if the engine is used for a portable generator If the engine needs to be run in a building at all ensure to direct the exhaust gas outside and provide sufficient ventilation Also take ca
137. son who is going to perform inspection service If an air start system is used close the air tank source valve and post a Do not open tag or other similar message Always stop the engine before any inspection service Always stop the engine before performing any inspection service Never attempt to adjust belt tension while the engine is running Otherwise the operator runs a great risk of becoming entangled into the rotating parts and seriously injured Remove the turning gear after use Be sure to remove the turning gear after use Never start the engine with the turning gear still installed or engaged Otherwise the engine will break and possibly someone may become injured SAFETY CAUTIONS Z Warning Risk of burn Do not touch the engine while it is running or for a while after it is stopped Never touch any part of the engine while it is running or for a while after Sees it is stopped Otherwise you may become burned cio Use a coolant temperature gauge to confirm that the engine has sufficiently cooled down before performing any inspection service Be careful when opening closing the radiator cap Never attempt to open the radiator cap while the engine is running and for a while after it is stopped Stop the engine and wait until the coolant temperature has sufficiently dropped before opening the cap Slowly open the radiator cap to allow the internal pressure to escape To prevent pos
138. t M8x 1 25 8 1 0 8 0 1 5 9 0 7 M10x 1 25 1542 1 5 0 2 11 1 1 5 M12x 1 25 25 3 2 54 0 3 18 44 2 2 M14x 1 5 34 4 3 5 0 4 25 14 3 0 M16x 1 5 44 5 4 5 0 5 32 543 7 M18x 1 5 7445 7 54 0 5 54 64 3 7 M20x 1 5 98 10 10 0 1 0 72 3474 M24x 1 5 147 15 15 0 1 5 108 4 10 8 M27x 1 5 226 20 23 0 2 0 166 7 14 8 Dry conditions ea SERVICE STANDARDS 2 4 Standard Union Nuts Nominal diameter 63 M14x 1 5 80 M16x 1 5 M20x 1 5 M22x 1 5 M27 1 5 M30 1 5 M30 1 5 M33 x 1 5 M36xX 1 5 Cap nut size Dry conditions 2 5 Taper Bolts Tightening into aluminum Tightening into iron Nim kgfm lbf ft NEm kgfm lbfLft NPTF1 16 4 90 to 7 85 0 5 to 0 8 3 6to5 8 7 85 to 11 8 0 8 to 1 2 5 8 to 8 7 PT1 8 7 85 to 11 8 0 8 to 1 2 5 8to8 7 14 7 to21 6 1 5to2 2 10 8 to 15 9 PT1 4 NPTF1 4 19 6 to 29 4 2 0to3 0 14 5 to 21 7 34 3 to 44 1 3 5to4 5 25 3 to 32 5 PT3 8 53 9 to 73 5 5 5to7 5 39 8 to 54 2 Size 1 18 3 Sealants List Sealing item Sealant SERVICE STANDARDS Mating component Applied location Threaded part Stop solenoid ThreeBond 1212 Governor case Water drain joint Oil pressure switch ThreeBond 1102 Torque spring set ThreeBond 1212 Governor case Threaded portion Press fit part Sealing cap Expansion plug
139. temperature at 60 to 95 C 140 to 194f Inlet valve open Engine general BTDC 15 Valve timing with santo ay e closed ABDC 41 clearance on the valve side cold Exhaust valve open BBDC 54 eneme Exhaust valve closed ATDC 10 The theoretical valve timing figures for inspection vary from the actual valve timing Inlet valve 0 25 0 01 Valve clearance Exhaust valve 0 25 0 01 Cold engine Fuel injection timing BTDC 17 Rocker arm inner diameter 18 910 to 18 930 0 7450 to 0 7458 Rocker shaft diameter 18 880 to 18 898 0 7438 to 0 7445 Arm to shaft clearance oil clearance 0 012 to 0 050 0 0004 to 0 0019 0 200 0 0079 Replace rocker arm Inlet Q 6 6 0 260 6 565 to 6 580 0 2586 to 0 2592 6 500 0 256 Valve stem diameter Exhaust 6 6 0 260 6 530 to 6 550 0 2572 to 0 2580 6 500 0 256 he Inlet Valve guide inner S 6 6 0 260 6 600 to 6 615 0 2600 to 0 2606 diameter Exhaust 6 6 0 260 6 600 to 6 615 0 2600 to 0 2606 Inlet Engine main parts Valve stem to guide 0 020 to 0 050 0 0008 to 0 0020 0 100 0 004 clearance Exhaust 0 050 to 0 085 0 0020 to 0 0033 0 150 0 006 Replace valve and valve guide Valve seat angle Valve head sinkage 0 25 to 0 75 0 0098 to 0 0295 1 5 0 0591 V
140. ternator adjusting bolt Attach the V belt over the water pump pulley alternator pulley and crankshaft pulley 4 Correctly tension the V belt by moving the alternator and tightening the adjusting bolt 5 Check the V belt tension V belt tension 10 to 12 mm when pressed with a force of j approx 98 N 10 kgf 22 Ibf 0 4 to 0 5 in 0 4 to 0 5 in Deflection of 10 to 12 mm 0 4 to 0 5 in when pressed with a force of approx 98 N 10 kgf 22 Ibf Adjusting the V belt tension 5 12 INLET AND EXHAUST SYSTEMS REMOVAL 1 Inlet Cover we aieia we s e etn ete wleta etnnii d wwe este e ewtn A A a Wil ete Wis A A wce ste wie Min ela e ee eee 6 _ 2 Removing the inlet cover tt trrtrssessnnnnnnnnnnnnununuunnuunnnuunnununnunnnnnnnnnnnnnnnn nnna 6 5 2 2 Exhaust Manifold DUGG eeet Dee EEO T r nnn nda A GN bidledejaua EET T a a AE 6 3 Removing the exhaust manifold RETIREE R TEPER ERR E TREE CC nr CCT 6 2 3 INLET AND EXHAUST SYSTEMS REMOVAL Inlet Cover 1 Replace Gasket iP Removal of the inlet cover and air pipe lt Removal sequence gt Inlet cover Gasket Breather pipe Air pipe Gasket ia AM ito la Vi DD TODD N J i i a Removing the inlet cover Remove the inlet cover m D Q Removing the inlet cover INLET AND EXHAUST SYSTEMS REMOVAL 2 Exhaust Manifold Replace Gasket Removal of the exhaust ma
141. the fuel injection pump mount on the right hand side of the cylinder block 2 The engine model code consists of the following alphanumerical digits Model coding Example S 4 L 2 L Engine model code Type 2 Type 2 Series L bore size 78 mm 3 07 in No of cylinders 4 4 cylinders S Sagamihara Machinery Works GENERAL 2 Specifications Engine Type S3L S3L2 S4L S4L2 Type Water cooled 4 stroke cycle Diesel powered No of cylinders 3 Combustion Swirl chamber type Valve mechanism Overhead valve type Cinder bossi anti 78X 78 5 78X 92 78X 78 5 78X 92 3 07X 3 09 3 07X 3 62 3 07X 3 09 3 07X 3 62 7T 1 125 1 318 1 500 1 758 5 Total displacement U S gal 0 297 0 348 0 396 0 464 o Compression ratio 22 0 1 Fuel Diesel fuel JIS K2204 Special 1 3 Firing order 1 3 2 1 3 4 2 Direction of rotation Counterclockwise when viewed from the flywheel end Overall length mm in 536 21 10 620 24 40 Dimensions Overall width mm in 433 17 04 433 17 04 Overall height mm in 572 22 52 572 22 52 Dry mass kg Ib 135 297 6 155 341 7 3 Piston ring No of rings se ee 1 2 Open BTDC 15 E a Inlet valve Clos ABD C i i pen 2 hot engine Exhaust valve
142. the middle of the valve face Valve seat to face contact Valve head sinkage Valve head margin Valve head sinkage ENGINE MAIN PARTS INSPECTION AND CORRECTION 4 Ifthe measured valve head sinkage exceeds the limit correct the valve seat or replace the cylinder head assembly Unit mm in Standard value 0 25 to 0 75 1 5 0 0098 0 0295 0 0600 Valve head sinkage 1 9 Correcting the valve face If the valve face is excessively worn correct with a valve refacer Note a When grinding set the refacer at 45 relative to the valve face Refacer set at 45 ht i A relative to the N above the limit If it appears that the valve face b The valve head margin should be maintained minimum margin cannot be maintained after refacing replace the valve Correcting the valve face 1 10 Correcting the valve seat 1 Before correcting the valve seat check the valve stem to guide clearance and if necessary replace the valve guide 2 Grind with a valve seat cutter available on the market or a valve seat grinder until the valve seat width and angle meet specification Note Valve seat correction should be limited as minimum as possible Correcting the valve seat Unit mm in in Valve contact width 1 3 to 1 8 mm 0 05 to 0 07 in St 30 f 45 Standard value Valve seat angle 45 1 30 to 1 80 0 0512 to 0 0709 Valve seat width
143. the order from the front to the rear of the engine 3 Loosely tighten the cap retaining bolts A CAUTION Install the front and rear main bearing caps so that they are flush with the cylinder block Installing the main bearing cap ENGINE MAIN PARTS Tighten the main bearing cap bolts progressively in diagonal sequence and tighten to the specified torque at the final step Tightening torque 49 0to53 9N m M 5 0 to 5 5 kgf m 36 2 to 39 8 lbf ft Ensure that the crankshaft rotates smoothly without any binding Measure the crankshaft end play refer to Page 2 14 If the measured value exceeds the limit loosen and retighten the main bearing cap bolts REASSEMBLY Ensure that the crankshaft rotates smoothly Inserting the side seals Apply sealant to the periphery of new side seals Side seal ThreeBond 1212 With the seal radius faced outside insert the side Radius seals with your hand into the front and rear of the cylinder block X Radius Face the side seals correctly Using a flat piece push the last portion of the side seals fully into the cylinder block taking care not to bend the seals Inserting the side seal ENGINE MAIN PARTS REASSEMBLY 1 5 Assembling the piston onto the connecting rod 1 Install the special tool Piston Pin Setting Tool onto a hydraulic press Special tool Part number Piston Pin Setting Tool 31A91 00100 2 Place the connecting rod on th
144. ton 78 25 78 18 to 78 20 diameter 3 08 3 080 to 3 081 78 50 78 43 to 78 45 3 09 3 090 to 3 090 Max allowable variation in 5 g 0 18 oz weight among pistons on the same engine at less 3 2 Measuring the clearance between the piston ring and the ring groove 1 Measure the piston ring to groove clearance If the measured value exceeds the limit replace the piston ring Unit mm in Standard value Limit 0 09 to 0 11 0 0035 to 0 0043 0 300 0 012 0 07 to 0 11 0 0028 to 0 0043 0 200 0 008 0 03 to 0 07 0 0012 to 0 0028 0 200 0 008 2 With the new piston ring installed measure the ring to groove clearance again If the measured value still exceeds the limit replace the piston 3 3 Measuring the piston ring gap Install the piston ring being measured into the gauge or a new cylinder Then using a thickness gauge measure the piston ring gap If the measured value exceeds the limit replace all rings of the relevant piston as a set STD 78 mm 3 07 in Gauge bore i OS 78 25 mm 3 08 in 50 OS 78 50 mm 3 09 in Note To install a piston ring into the gauge use a piston to push the ring evenly Unit mm in Standard value No 1 ring 0 15 to 0 30 0 006 to 0 012 No 2 ring 0 15 to 0 35 0 006 to 0 014 Oil ring 0 20 to 0 40 0 008 to 0 016 oe Measure squarely with piston pin FEA sei
145. uired 1 Injection valve opening pressure a Install the fuel injection nozzle onto the nozzle tester Pump the tester handle to bleed air b Pump the tester handle at a rate of approx one cycle per second while observing the needle of the tester Note The needle should rise slowly and during fuel injection should vibrate The pressure at which the needle starts to vibrate is the injection valve opening pressure c If the measured pressure does not conform to the standard value disassemble and adjust the thickness of the washer Unit MPa kgf cm psi Standard value 14 22 to 15 00 145 to 153 2062 to 2176 d Change in washer thickness by 0 1 mm 0 004 in results in a pressure change of 1 0 MPa 10 kgf cm 145 psi Washers are available in 10 different thicknesses at intervals of 0 05 mm 0 002 in in the range between 1 25 and 1 70 mm 0 049 and 0 067 in A CAUTION Never touch the spray of fuel from the fuel injection nozzle as it can cause severe burn Injection valve opening pressure 2 Inspecting the fuel spray pattern from the fuel injection nozzle a When inspecting the injection valve opening pressure using the nozzle tester also check for such as clogged nozzle hole fuel spray pattern and fuel leakage from the nozzle hole b When the tester handle is pumped at a rate of approx one cycle per second fuel should be sprayed in a fairly straight pattern Nozzle tester
146. ur skin or clothing has come into contact with battery electrolyte immediately wash the affected area with plenty of water and then thoroughly clean with soap Should your eyes come into contact with battery electrolyte loss of eyesight may result Immediately wash your eyes with plenty of fresh water and seek medical attention immediately O Should you inadvertently drink battery electrolyte repeatedly gargle with plenty of water and then drink plenty of water Seek medical attention immediately 0 6 Z Caution emergencies Engine overheat Idle to cool down then stop the engine In the event of engine overheat do not stop the How to handle engine immediately Doing so may cause the coolant temperature to rise quickly and the engine may seize Instead run the engine at low idle for a while to cool it down Then stop the engine Do not attempt to replenish coolant for a while after the engine is stopped Otherwise the cylinder head etc which may still be hot is cooled down rapidly and may break Wait until the engine is sufficiently cold and then top up slowly Never restart the engine after a sudden stop unless the cause is eliminated If the engine has suddenly stopped with some alert signals do not restart immediately Otherwise the engine may seriously become damaged Locate and eliminate the cause before restarting Stop the engine immediately upon oil pressure drop If the oil pressure has dropp
147. v Measuring the spring for squareness and free length ENGINE MAIN PARTS INSPECTION AND CORRECTION 1 4 Measuring the push rod for bend If the measured value exceeds the limit replace the push rod Unit mm in Limit Push rod bend 0 3 0 012 Note Use a dial gauge to measure the push rod for bend 1 5 Measuring the valve stem diameter Measure the valve stem diameter If the Measuring measured value is less than the limit replace with direction anew part Replace also when the valve stem has excessively uneven weat Unit mm in Nominal Standard value value 6 565 6 6 to 6 580 0 260 0 2586 Measuring location Valve stem to 0 2592 Measuring the valve stem diameter diameter 6 530 Q 6 6 to 6 550 0 260 0 2572 to 0 2580 Exhaust 1 6 Measuring the clearance between the valve stem and guide Measuri easuring Measure the valve guide inner diameter using an direction inside micrometer 5 The valve guide wears at the top and bottom ends Therefore both ends need to be measured orthogonally If the measured value exceeds the limit replace with a new part Measuring location Unit mm in Nominal Standard value value 0 020 to 0 050 0 0008 to 0 002 0 050 to 0 085 0 002 to 0 003 9 5 to 10 5 0 3743 to 0 4137 Note Before measuring the valve stem to guide Measuring the valve guide inner diameter Valve stem to gui

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