YALE MAZDA TM DIESEL SERVICE WORKSHOP MANUAL Copy, free download

ENGINE MAINTENANCE MANUAL For

YALE TM DIESEL 4 CYLINDER ENGINE

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 www.HeavyEquipmentRestorationParts.com

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DESCRIPTION OF ADVISORY LABELS USED IN THIS PUBLICATION

THE READER MAY FIND ANY OR ALL OF THE FOLLOWING LABELS USED IN THIS PUBLICATION. AN UNDERSTANDING OF THEIR USE, AS GIVEN BELOW WILL AID THE READER.

NOTE An advisory procedure, practice, condition, etc., which is essential to emphasize.

·l&cAUTION

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Directs attention to hazards or unsafe practices which may result in minor personal injury, product or property damage if the proper precautions are not taken.

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) WARNING'

Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken.

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DANGER

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Directs attention to unsafe practices and/or existing hazards which WILL result in severe personal injury or death if proper precautions are not taken.

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Industrial Trucks This Ma intenance Manual is divided into major sections which are listed on this page. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

SECTIONS

I I I I I I I I I I I I I I I I I i- 1

INTRODUCTION

2

3

ENGINE INSPECTION AND ADJUSTMENT '

ENGINE DISASSEMBLY/ REASSEMBLY

4

LUBR�CATION SYSTEM

5

COOLING SYSTEM

6

FUEL SYSTEM

7

ELECTRICAL SYSTEM

8

USER SUPPORT INFORMATION

9

ALPHABETICAL INDEX

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SECTION 1

INTRODUCTION

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Industrial Trucks

INTRODUCTION TM

Engine model Type .,

Quantity

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Cyclone filter paper type 1

Fuel line material

Rubber and steel

Fuel filter type

Full flow (with filter paper) Zexel corporation

Manufacturer Type

Bosch A in�line type °

Injection timing Injection Pump

9 BTDC (cam lifted 1 mm)

Plunger diameter

mm/ (in)

<I> 9.5 I (.374)

Cam lifting amount

mm/ (in)

9.0 I {.3543)

Speed regulator

Centrifugal type

Injection timing regulator

Centrifugal type

Nozzle supporter type

Flange Multiple hole type

Nozzle type

4

Quantity ! _ : Diameter

Injection Nozzle

Injection pressure

mm I (in)

0.31 I (0.0122}

kg/cm2 I (psi)

200 I (2844.6} 12 volt negative ground

Voltage

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:-.. Start ;- Heater System

Charging system

Type Current Draw

190 Amps @ 11 volts

Type

Alternator

Output

50 Amps @ 12 volts

Voltage and current regulators Starter motor

Coil type - Intake manifold mounted

IC regulator

Type

Electromagnetic push-in type (auxiliary rotating type)

Output

2.2 kw

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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INTRODUCTION

ENGINE IDENTIFICATION ILLUSTRATION

. Engine type, manufacturing number are embossed here.·

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'.>.1_.y\·Lo_;::c. J_atlon t,. /.ahd . identification of' M (automatic transmission) ,)

�-.-,and MfT (manual transmission) reference points Classification position Speeil!t"tlotu

Engi11e rear seal

End plate classification marl<inas

Single lip seal A/T

�•Ide

A

. , Dou_ble Hp seal

wr

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M

NOTE: All trucks manufactured for the North American market are only available with automatic transmissions.

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INTRODUCTION

ENGINE INTRODUCTION The TM engine is a water cooled, overhead valve four-cylinder diesel engine with timing gears. The main specifications and outline of each part are described below.

Engine Model

TM

Combustion Chamber

Direct Injection Type

Cylinder Liner

Dry Type

Bore X Stroke

109.0mm x 122.0mm {4.29 in x 4.80 in)

Total Displacement

4,553 cc /.(277.8 c·u i_n)_

Compression Ratio

18:1

Compression Pressure

30kg/cm�.J@ 270 rpni (426.7 psi@ 270 rpm)

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CYLINDER HEAD COVER

A

Seal rubber

Oil pump A'

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Seal cover se�tion A-A' _,

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The cylinder head cover is a double structure design. A large seal cover has been added on to·p of the cylinder head cover and the injection nozzles. This second cover reduces noise levels and improves the engine appearance.

CYLINDER B!-OCK ·,..

The cylinder.block incorporates a deep skirt form c1nd a stiffener plate for impr9ved rigidity. The design offers reduced vibration and excellent resistance to the high combustion pressures generated in a larg_e displacement diesel engine. The end plate and the cylinder block are manufactured of special cast iron to reduce vibration and twist.

TIMING GEAR AND TIMING GEAR CASE The timing gear case is m ade of special cast iron. The timing gear cover is made of aluminum. The TM engine timing gears are helical and manufactured of chrome steel. To reduce gear backlash and noise, a friction gear is used in conjunction with the · cam gear. Noise _levels are further reduced by the installation of the seal cover on top of the gear c·over.

der block pecial cast iron)

_

Stiffener plate (steel)

Seal cover (steel) __

Cylinder head cover (alumin,um) .' ' .

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PISTONS AND CRANKSHAFT The pistons are niade of ah aluminum alloy. The depression in the center of th_e �iston· iif called the re-entrant combustion chamber. The re-entrant design j:iroduces high efficiency while realizing a reduct_io � i� ·�9,inbusti�n noise. . } J,'1

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A special (nickel.-a.Listenite cast iron) carrier is provided on the top ring groove, hil,prolii�g the wearability of the piston ring and ring groove. A ring _·groove cooling cavity (cooling channel) is provided in the ring1groove to improve durability.

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Each piston has two compression rings and one oil ring. A half-keystone ring is used for the top ring to prevent sticking. A tapered inner cut design is used for the second ring. The outer and inner circumference of the top ring and the second ring are 1-4

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treated with hard chrome plating. Thei oil ring is also chrome plated and incorporates a piano wire coil spring expander on the inner circumference to ensure that ample surface pressure is maintained.

The crankshaft is made pf carbon steel, and has eight balance counterweights to reduce engine vibration and sound. The ,·

INTRODUCTION

crank pins and journals have been processed with file! hardening to improve durability. The crank gear for the timing gear train is shrink fitted onto the front of the crankshaft to improve the reliability of the crank gear and crank pulley.

Re-entrant combustion chamber.

Top ring (half-keyston':.--7( Cr Insert Great type) c___JJ Increase . 11 • l .· In wear Sticking prevention resistance plating Seco11d � Cr ring L__J (tapered Inner · cut type)

. Carrier r--,====,---,

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Oil rin�· �

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. :/ �r plating Oil expander

tlotch tor piston cooling jei'relief

Connecting rod nut for fleidble area angle tightening ··· Connecting rod metal c��necting rod c·ap Connecting rod bolt for ·. flexible area angle tightening

CYLINDER HEAD

The cylinder head is made of special cast iron to withstand the strong combustion pressure of the direct injection method. Cast iron construction also improves heat fatigue_ resistance and durability while allowing reduced engine h�ight do to the reduction in the thickness of the head itself.

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Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

VALVE SYSTEM

··· The TM diesel engine incorporates the OHV (overhead valve) design. The r·ocker shaft. is 21 rTin, i (.8268 in) in diameter and made of special steel for qurability. The surface pressure of the push rod has been r.���'d;a by using a spherical shape for the tip of the rocker arm's adJli�tmeint screw. The upper and lower ends of the push ro{���- c�ri:,on!zed, (hardened) to increase the wear resistance. The valve weight has been reduced by incorporating hollow centers.

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INTRODUCTION

The valve springs are an unequal pitch double spring to minimize valve float at high rpm. lfhe springs are common for both the intake ·and exhaust sides.

Lock nut

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Adjustment.sere� .

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A water cooled centrifugal·circulation type water pump is used t_o circulate the engine coolant. A seven blade cooling fan moves air through the radiator. The water pump and fan are belt driven by the crankshaft pulley. A wax•type thermostat made of stainless steel is used to regulate engine temperature.

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COOLING SYSTEM

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Push rod

Rocker arm

Tappet

INTAKE AND EXHAUST SYST_EMS The intake manifold has been designed with an offset intake to provide uniform swirl between cylinders .and to imp.r'ove · efficiency. To aid in. cold startinm .. an air heater has ·been installed in the intake manifold collection area. The air hea�er is used in place of conventional glo,,.,, plugs. The operation of the air heater is automatically controlled by the temperature of the coolant at engine start up.

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The exhaust system is of a conventional design.

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INTRODUCTION

LUBRICATION SYSTEM The engine is lubricated by a gear type pressure feed oil pump. The oil pump is driven by the idler gear. Oil filtration is provided by a main oil filter and a bypass filter.

LUBRICATION SYSTEM DIAGRAM Gears for oil pump drive

Main filter

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INTRODUCTION

FUEL SYSTEM

. The fuel injection pump is a high pressure in-line type (Bosch A type). Fuel is filtered through a full flow spin on paper filter.

A manual priming pump on the injection pump and a bleed screw on top of the fuel filter mounting base are provided to aid in ble_eding air from the fuel system.

The fuel feed pump is an integral part of the injection pump unit. The feed pump tappet is moved by a special cam lobe on the pump camshaft. The tappet is connected· to a piston by a rod. The reciprocating action of the piston creates fuel pressure.

A mechanical all-speed governor with a small lever r�action {low accelerator pedal effort) and built in torque cam is used. Starting pressure is adjusted automatically.

FUEL SYSTEM DIAGRAM

CAUTION:

Fuel lines are pressurized

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INJECTION PUMP ASSEMBLY

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Fuel Filter

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Feed Pump

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ELECTRICAL S'(S,JEM ,\.

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Electrical system ve>ltage: 12 volt Battery: 160F51 maintenance free 108 amp hour/ 5 hour I

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The starter is an improv·ed version of the conventional high output 2.2 kw starter. It is an electromagnetic push-in with 1-8

auxiliary rotation reduction type starter.

The battery is charged by a high output 50 amp alternator. An integral IC voltage regulator controls alternator output and system voltage..

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NOTES

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Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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ENGINE INSPECTION AND ADJUSTMENT

ENGINE INSPECTION AND ADJUSTMENT Periodic inspection and maintenance are necessary to keep engine performing at peak efficiency.

For regular inspections and visual checking, ordinary tools, measuring tools and special testers are used. When using any special tester or tool, be sure to understand its proper use. See: "Recommended Schedule of Preventive Maintenance" for information regarding the inspection and maintenance intervals of each item.

Item

Procedure

Value

Oil Level Inspection

1. Check that oil is not leaking from any of the engine parts. If any leaks are found, repair the [eak or replace the part. ..

Oil level between F (Full) and L (Low)

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2. Check for deterioration and contamination of the oil. Replace the engine oi_l when !1�cessary. ·. r· •.

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3. Inspect the oil level, ;:i.nd rT)ake sure t�at it is between F and Lon the oil level gauge:(dipstick). Refill the oil when necessary. ,.

Oil Change and Refill

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1. Remove the drain plug and drain the oil.

Oil pan capacity At F (Full) position 7.0 litres I (7.4 qt) Total Capacity

2. Remove the oil cap and refill the oil.

3. Use the specified oil. Classifi!:!d accordif")g to API, grade CD SAE 1 0W-30 (for all seasons). DO NOT OVERFILL.

Oil Filter Replacement

2.0 litres I (2.11 qt)

9.3 litres / (9.8 qt)

1. A dual filter method (main oil filter, bypass oil filter) is used.

2. Replace the main oil filter and bypass oil filter at the same time.

1. Use an oil filter wrench, and remove the main oil filter and bypass oil filter.

(Wrench for main filter: commercial product)

(Wrench for bypass filter: special tool 9224473-00)

2. Appiy a light co�t of engi�e oil o� the O-ring �f the new filters.

3. Install the filters on tlie filter body. Hand tighten the filter until it stops. Tighten it another 1/4 turn with the oil filter wrench.

(Reference tightening torque)

Main oil filter: i .8-2.3 kgm / (156�200 lbf in) Bypass oil filter: 2.0-2.5 kgm /-(174-217 lbf in)

NOTE: Do not over tighten the filter. (The filter can be damaged.)

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ENGINE INSPECTION AND ADJUSTMENT Procedure

Value

1. Remove the seal cover and cylinder head cover.

2. Remove the floor plate.

3. Using a screwdriver or other suitable tool, rotate the crank shaft forward (CCW). Take care not to bend th'e timing indicator pin. Set the number 1 or number 4 cylinder at Top Dead Center, compression stroke.

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4. With cylinder number 1 at Top Dead Center, measure the clearance of the valves indicated by (1) in the above illustration.

• With cylinder number 4 at Top Dead Center, measure the valves · · , indicated by (4).

Valve Clearance Adjustment

Use the following procedure if adjustment is required.

1. Loosen the lock nut and tur,n the adjustment_ screw to adjust.

2. lighten the lock nut, and measure the valve clearance again to verify that the clearance is correct.

Valve clearance (cold) Intake: 0.30 mm/ (.012 in) Exhaust: 0.45 mm/ (.018 in)

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Tightening torque ; ...', j , .

3. Turn the cra�k.-shaft forward' one turn, and inspect the remaining valve clearances, and adjust as necessary.

4. Install the floor plate.

5. Install the cylinder head cover and seal cover.

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Cylinder head cover 0.35-0.55 kgm (30-48 lbf in) Seal cover · 0.35-0.55 kgm (30-48 lbf in)

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ENGINE INSPECT!ON AND ADJUSTMENT

Procedure

Item

Value

Alternator Belt

Beii

Pulley )·_

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Belt Inspection

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1. Inspect for_WE:l13-I'. and cracks. If defective, replace the belt.

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2. Check the adjustment of the belt by pressing down between the

water pump arid alternator (pressure, 1 o kg/ 22 lbs). Adjust the belt tension if the deflection is out ot'the specified range. � . . .

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Belt Adjustment

1: Loosen the alternator bolts· and adjust the belt deflection to the specified val_ue by moving the_ alternator.

Belt Replacement

2. Loosen the alternator bolts to loosen the belt. Remove the belt and replace it. Adjust the belt tension and tighten the mounting bolts.

NOTE: Measure the belt deflection between the alternator and the fan pulleys as illustrated below when checking deflection using a straight edge (without a ND tension gauge).

Deflection amount pressure 10 kg/ (22 lbs) For a new belt: 10-11 mm/ (.39-.43 in) For adjustment: 11-12 mm/ (.43-.47 in)

MOTE: When checking belt tension with the ND tension gauge, the belt tension can be measured between any two pul­ leys.

Apply

Straightedge Alternator Pulley

During adjustment Crankshaft Pulley

Deflection amount/ pressure @ 1 o kg/ (22 lbs) For a new belt: 10-11 mm/ (.39-.43 in) For adjustment: 11-12 mm/ (.43-.47 in) NOTE: When installing a new belt, adjust the belt tension to the mid point of the given value for a new belt.

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When set '.');

· NOTE: Standard tension values listed below are for use with a ND tension gauge'.

Belt Type

Alternator

Standard Value Engine Model

When installing new belt kg/ (lbs)

When inspecting kg/ (lbs)

TM

29.4-33.9 (65-75)

24.9-29.4 (55-65)

NOTE: When installing a new belt, adjust the belt tension to the mid point of the given value for a new belt.

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ENGINE INSPECTION AND ADJUSTMENT

Item

Procedure

Fuel Filter Replacement '

The fuel filter is located below air cleaner .

1. Remove the filter cartridge using arr oil filter wrench (commercial product).

Fuel filter

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2. Apply a light coat of fuel to the O-ring on the filter cartridge before installing. Tighten the filter se'clirely by hand, and then tighten an additional one-third turn with the oil filter wrench. · 3. After installing the filter, bleed.the air in the fuel, and verify that there are no fuel leaks. See: "BLEEDING AIR FROM THE FUEL

SYSTEM".

Air Cleaner SeNice

1. Remove the air cleaner cover. Remove the wing nut and the element.

2. Clean the element from the inside with compressed air.

Air Cleaner Replacement

1. Replace the air filter if it is heavily clogged.

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Value

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ENGINE INSPECTION AND ADJUSTMENT

Item

Procedure

Idle Inspection

1. Place a piece of reflective tape on the crank shaft pulley or· flywheel.

Value

2. Start the engine and allow it to reach operating temperature.

3. Check the accelerator cable adjustment at the fuel injection pump. The throttle arm on the fuel injection pump must be allowed to completely return to the idle posrrion with the accelerator pedal in the full up position. The throttle arm on the fuel injection pump must move to the.'full speed position with the accelerator pedal in the full down posrrion. · · · 4. Idle the engine: ·.. ·· ..

Idle speed: 825-875 rpm

5. Using a photoelectric tachometer, shine the light on the reflective tape to check the.id_le speed.·.. · · · · ·6. Alternate Meth�d: ·1n�tall the ta'cti dweil tester (9125483-58) to the fuel injection· pipe, to check the idle speed.

Idle Adjustment

1. If not within the specified value, loosen the lock nut of the idle adjustment bolt over the injection pump.Turn the bolt to adjust the speed.

2. Tighten the lock nut after adjustment.

3. Accelerate the engine two or three times and verify that the idle speed returns to the specified value.

Tightening torque: 1.0-1.4 kgm / (87-122 lbf in)

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ENGINE INSPECTION AND ADJUSTMENT

Item Injection Pump Timing Inspection

Procedure

Value

NOTE: The injection timing is very critical in a direct injection engine. Incorrect adjustment can cause increased engine noise (knock) and / or power loss. Always check the injection timing after installing the pump, and verify that it is correct.

The actual injection timing is g• BTDC. Inspection must be performed as follows fo verify the correct injection timing:

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Injection timing ° 9 BTDC

1. Remove !he floor plate.

2: Rotate the fly�heel C�W,,and set the in�icatcir pin to 30 ° BTDC. , End plate� J I

Indicator pin

;Ring gear

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° - 9· Flywheel . BTDC30 C

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Affor MIT housing

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3. Remove the �cc�s� cove·r ori the pump side of the timing gear case. Verify that the ma�kings on the case pointer and the timer circumference are aligl)�a.. IJ qoth match, the number 1 cylinder ° is 30 BTDC, and t�·e injection timing is correct. (Injection pump ° timing is set at 9 BTDC.)

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Timing gear case

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Injection Pump Timing Adjustment

2-6

See: "INSPECTION AND ADJUSTMENT OF THE INJECTION TIMING"(FUEL SYSTEM SECTION for the adjustment procedure.

Maximum allowable ° variation: ±2

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ENGINE INSPECTION AND ADJUSTMENT

Item

Procedure

Compression Test

1. Verify that the battery is completely charged.

2. Start the engine and allow it to·reach operating temperature.

3. Turn off the ignition key to stop the engine.

4. With the key switch off, unplug and completely disconnect the wiring harness connector at the fuel stop motor to disable the fuel· supply to the fuel injectors.

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Value

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5. Remove all the injector nozzles. Crank the engine to purge any fuel from the cylinders. Install the compression gauge adapter (9225423-19) and the compression gauge (9125483-71).

NOTE: All the injector nozzles must be removed to insure . · · '..::. · accurate results during the compression test.

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WARNING: Diesels are self igniting engines, using ...� , only the heat of compression to ignite the diesel fuel.

Accidental starting can occur if the engine cylinders are not .completely free of fuel before installing the compression . gauge or performing any testing. To prevent accidental starting, be sure to remove all the injector nqz�les and then crank the engine before installing the compression gauge.

Compression pressure: 30 kg/cm2@ 270 rpm 426.7 psi@ 270 rpm Limit: (90% of standard value): 27 kg/cm2@ 270 rpm 384 psi@ 270 rpm Difference· between cylinders: 3 kg/cm2@ 270 rpm 43 psi@ 270 rpm

6. Crank the engine and measure the compression pressure.

7. Repeat steps (4) to (6) for the remaining cylinders. If the measurement value is below the limit value, the cylinder, piston, or piston rings may be worn or damaged. A valve or valve seat may be defective, or the cylinder head gasket may be leaking.

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ENGINE INSPECTION AND ADJUSTMENT

BLEEDING AIR FROM THE FUEL SYSTEM

Overflow valve

1. Loosen the air vent plug on the top of the tu.el filter body.

Air vent plug

· 5. After bleeding the air out of the fuel filter and injection plug, press down the top of the priming pump plunger, and tighten tt securely.

2. Loosen the top of the priming pump. The priming pump is located on the side of the fuel injection pump.

3 . Pump the priming pump until fuel without air bubbles is discharged from the air vent plug on the fuel filter body.

Close the air vent plug on the fuel filter body.

Tightening torque: 0.6-0.9 kgm / (52-78 lbf in)

... 1 CAUTION: If you forget to tighten the priming pump plunger after completing the air bleeding pro!=ess, fuel leaks can occur and/ or t_he fuel injection pump can receive an insufficient fuel supply. A loose prim­ ing pump plunger can cause a hazardous situation (fuel leaks, fire hazard) or result in improper engine operation (low output, stalling, rough idling). Always push down the priming pump plunger and tighten it securely after completing the bleeding proc·ess.

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6. After completing air bleeding, verify that there is no fuel leaking from the air vent plug or the overflow valve.

7. Loosen the four flare nuts on the injection nozzle side of the injector fuel lines.

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4. Next, loosen the injection pump's overflow valve, �nd pump the priming pump until fuel wtthout air bubbles is discharged from the overflow valve. Close the overflow valve .

Tightening torque: 1.2-1.5 kgm / (104-130 lbf in)

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8. Crankthe engine until fuel without air bubbles is discharged from the injector fuel lines.

NOTE: Do not crank the engine for extended periods wtthout allowing the starter to cool.

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9. Install the injector fuel lines.

Tightening torque: 2.5-3.0 kgm / (217-260 lbf in) \,

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10. Start the engine and verify that there are no fuel leaks.

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ENGINE INSPECTION AND ADJUSTMENT

RECOMMENDED SCHEDULE OF PREVENTIVE MAINTENANCE Periodic inspections of the engine related parts allow the functions and performance of the engine related parts to be maintained at their best condition through inspection, adjustment, cleaning and replacement. Perform the periodic inspections according to the following· table.

Inspection item

Daily or every hours

Initially every 50 hours See Note

Every 200 hours or monthly

Valve clearance inspection and adjustment

0

Fan belt tension adjustment

0

0

Engine oil replacement

0

0

Engine oil filter element replacement Main and bypass filters

0

Every 400 hours or 2 months

Every 600 hours or 3 months See Note

Every 1200 hours or 6 months

Every 2400 hours or 12 months

0

0

Oil level inspection

Coolant level inspection (Inspection of reserve tank level)

0

0

Coolant replacement and cleaning of the radiator

Once every 2 years

Air cleaner cleaning (dust pan and element)

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Air cleaner element replacement Fuel filter element replacement

0 0

Fuel feed pump strainer cleaning Fuel tank drain and refill

Once a year

Sedimentor draining (optional)

0

Injection pump adjustment (injection pressure and timing) Fuel injector inspection (check injection nozzle pressure and condition)

0

Battery fluid specific gravity

0

Battery fluid level and terminal inspection

NOTE:

0

0 Indicates the procedures for new engines or initial maintenance after an overhaul.

NOTE: U Indicates inspection �nd maintenance for parts in dusty places.

Mazda brand antifreeze, rust preventive agent and oil should be used when possible.

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Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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SECTION 3 - CONTENTS ENGINE DISASSEMBLY/ ASSEMBLY PAGE NUMBER

DESCRIPTION

ENGINE DISASSEMBLY ........................ '. ... : ....... : .. :·:: .. 3-1 SPECIAL T(JOlS REOl..flF}E_D (EN(]�N.E_SfAND) ...... ...·,·.: ...... 3-1: _ MOUNTING THE ENGINE TO ENGINE STAND ....... : .':............. 3-1 ENGINE DISASSEMBLY··:; ...... · ; ............ ' : .... '............... 3-2 ORDER OF DISASSEMBLY..-· . : .. ; 3-2 SPECIAL TOOLS REQUIRED (ENGINE DISASSEMBLY) ..... : ....... 3-2 · CYLINDER HEAD DISSASSEMBLY : ..........

3-3 .......·....·'. ........... · ° CYLINDER HEAD B6lT REMOVAL ..... .... · : ...... ................ 3-4 ROCKER ARM AND SHAFT ASSEMBLY REMOVAL ............ ; .... 3-4 VALVE RETAINERf?EMOVAL.: ...·.·: ................... : .......... 3-4 VALVE SEAL REMOVAL .: .............·.: ........................ 3-4 VALVE GUIDE REMOVAL ......... .......... ................. .... 3-4 CYLINDER BLOCK DiSSASSEMBLY-ACCESSORY COMPONENTS ... . . 3-5 FLYWHEEL REMOVAL ........................................... 3-6 CRANKSHAFT PULLEY REMOVAL ............... ............ ..... 3-6 CYLINDER BLOCK DISSASSEMBLY-EXTERNAL COMPONENTS .. . . ... 3-7 CAM GEAR AND FRICTION GEAR REMOVAL ...................... 3-7 CYLINDER BLOCK DISSASSEMBLY-INTERNAL COMPONENTS ........ 3-8 REAR OIL SEAL REMOVAL .................................. ... . 3-9 CAMSHAFT REMOVAL ..... ; ................................ .... 3-9 CONNECTING ROD AND PISTON ASSEMBLY REMOVAL ........... 3-9 PISTON RING REMOVAL ; . .';' .'.. ·:.;. :"............................ 3-10 SNAP RING AND PISTON PIN REMOVAL : ·............. : ........... 3·1 O MAIN BEARING CAP REMOVAL .... '..; '· ........................... 3-11 CYLINpER_LIN_ER REMOVAL ..................................... 3-11 ENGINE INSPECTION AND REPAIR ................................. · 3-12 SPECIAL TOOLS AND SUPPLIES REQUIRED ......... ;: ........... 3-12 CYLINDER HEAD INSPECTION ... : ...... ; ........................ 3-13 CYLINDER HEAD BOLT INSPECTION ........ : ...-................. 3-13 VALVE AND VALVE GUIDE INSPECTION, ............ : ............. 3-13 VALVE SEAT INSPECTION ......................... : ............. 3-14 VALVE SPRING INSPECTION ................ : ................... 3-16 ROCKER ARM AND ROCKER SHAFT INSPECTION ....... · .· : ....... 3-16 PUSH ROD INSPECTION ........... ·:'.. ::: .. ; .................... 3-16 CYLINDER BLOCK INSPECTION ................................. 3-17 CYLINDER BLOCK AND LINER DIMENSIONS ..................... , 3-17 CYLINDER'LINER iNSPECTION ............................'...... 3-18 PISTON AND PISTON PIN INSPECTION ........................... 3-18 CYLINDER BLOCK AND LINER IDENTIFICATION ................... 3-19 CONNECTING ROD INSPECTION ................................ 3-20 CRANKSHAFT INSPECTION ..................................... 3-20 MAIN BEARING AND CONNECTING ROD BEARING INSPECTION ... 3-21 CAMSHAFT INSPECTION ........................................ 3-21 TAPPET INSPECTION ........................................... 3-23 '

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(Continued on following page)

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Yale

Industrial Trucks

SECTION 3 - CONTENTS (Continued) ENGINE DISASSEMBLY/ ASSEMBLY DESCRIPTION

PAGE NUMBER

CYLINDER HEAD REASSEMBLY .................................... 3-41 ASSEMBLY AND TORQUE VALUE ILLUSTRATION ................. 3-41 VALVE GUIDE INSTALLATION .................................... 3-41 VALVE SEAL/NSTALLATION ..................................... 3-42 VALVE-VALVESPRING�VALVE SPRING SEAT INSTALLATION ....... · 3-42 VALVE RETAINER INSTALLATION ................................ 3-42 ROCKER ARM INSTALLATION .................................... 3-43 THERMOSTAT HOUSING INSTALLATION .......................... 3-43 CYLINDER.HEAD GASKET INSTALLATION ........................ 3-43 CYLINDER HEAD INSTALLATION .................. : .............. 3-43 INTAKE MANIFOLD INSTALLATION ............................... 3-44 INJECTION NOZZLE INSTALLATION .............................. 3-44 FUEL INJECTOR LINE INSTALLATION ............................ 3-45 INJECTOR LINE CLIP INSTALLATION ............................. 3-45 OIL LEVEL GAUGE (DIPSTICK) AND GUIDE PIPE INSTALLATION .... 3-45 CYLINDER HEAD COVER INSTALLATION ......................... 3-46 SEAL COVER INSTALLATION .................................... 3-46 EXHAUST MANIFOLD INSTALLATION ............................. 3-46 ENGINE O VERHAUL WEAR LIMITS ................................. 3-47 TORQUE SPECIFICATIONS ......................................... 3-50 TROUBLESHOOT/NG GUIDE ....................................... 3-51

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Yale Industrial Tru_cks

ENGINE DISASSEMBLY/ REASSEMBLY

ENGINE DISASSEMBLY

SPECIAL TOOLS REQUIRED (ENGINE STAND) SPECIAL TOOLS REQUIRED

9225423-01 Engine stand hanger

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For attaching engine to engine stand

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9225423-03 Bolt (component of 9225423-01)

PROCEDURE

SPECIAL TOOLS REQUIRED

9225423-02 Body (component of 9225423-01) •I • •

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PROCEDURE

For attaching engine to engine stand

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For attaching engine to engine stand

9125483-05 Engine stand

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Engine stand for engine overhaul

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MOUNTING THE ENGINE TO ENGINE STAND 1.

Remove the exhaust manifold and gasket.

2. Remove the oil hoses between the alternator and the engine block.

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3.

Remove the engine·mounts.

4.

Install the engine stand hanger as shown in the illustration.· .

.

WARNING: The engine is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the engine. The engine can weigh approximately 340 kg (750 lb).

5.

Install the engine assembly on the engine stand.

3-1

Yale

Industrial Trucks

·'

ENGINE DISASSEMBLY NOTE: When disassembling the engine, remove the parts in the order given in the disassembly illustration. Parts that must be handled with care after disassembly are noted.

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NOTE: When there are multiple parts with the same ·shape _. (pistons, piston rings, connecting rods, etc.), tag or mark each part before removing. Always install the same parts in their orig­ i�al position.

NOTE: Thoroughly clean or wash each part that has been re­ moved. Completely dry the parts after cleaning, using low pres­ sure compressed air. Check each part for deformation, damage and wear.

ORDER OF DISASSEMBLY a. b. c. d.

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ENGINE DISASSEMBLY i REASSEMBLY

Cylinder head Cylinder block (accessory components) Cylinder block {external components) CylindE;ir block (internal components)

SPECIAL TOOLS REQUIRED (ENGINE DISASSEMBLY) SPECIAL TOOLS REQUIRED

9225423-04 Pivot

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PROCEDURE

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PROCEDURE

For valve replacement

9125483-59 Valve spring lifter arm

For valve replacement

For removal of the cylinder liner

9225423-09 Attachment

For cylinder liner removal

9225423-10 Coupling flange holder

For preventing cam gear from rotating

9225423-11 Valve seal remover

For valve seal removal

9225423-12 Valve guide installer

For valve guide removal

9225423-13 Clutch disk centering tool

For clutch disk removal

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SPECIAL TOOLS REQUIRED

9225423-08 Cylinder liner remover set

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9225423-14 Ring gear brake

For preventing the crankshaft from ro-. tating

9225423-18 Pulley puller

For crankshaft pulley removal

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3-2

9225423-15 Oil seal installer

For oil seal installation

9225423-17 Oil seal installer (component of 9225423-15)

For oil seal installation

9224473-00 Wrench oil filter

For oil bypass filter replacement

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

»lie

Industrial Trucks

ENGINE DISASSEMBLY/ REASSE�BLY .

CYLINDER BLOCK DISSASSEMBLY-ACCESS. ORY COMPONENT S 1.

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Refec to the NOTES dudng disassembly. . the illustration Disassemble in the order shown tn

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1 . Engine block 2. Water pipe 3. Alternator strap 4. Crankshaft pulley jock nut 5. Lock washer

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6. Crankshaft pulley assembly 7. Alternator bracket 8- Oil line 9- Flywheel

10- Y'Jasher 11 · Fuel line 12· Oil line 13· Fuel line 14. 0·I 1 f'titer assembly

3-5

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

FLYWHEEL REMOVAL 1. Bolt the ring gear brake to the block a:s shown in the illustration to lock the flywheel in place.

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2. Remove the flywheel retaining bolts and washers. Remove· the flywheel.

1.

Loosen and remove the pulley lock nut.

2. Remove the spacer. Attach the removal tools to the pulley.

Tighten the bolts.

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3. When the pulley starts to come off, tap it lightly with a plastic hammer to remove it.

4.

Remove the special tools.

1.

Refer to the N!JTES during disassembly.

Disassemble in the order shown in the illustration.

I 3-6

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

.Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

REAR OIL SEAL REMOVAL 1.

Remove the rear oil seal as illustrated.

NOTE: Do not scratch the crankshaft during seal removal.

3. Gradually pull out the camshaft while turning it by hand

NOTE: Remove the camshaft carefully. Support the camshaft as illustrated to prevent scratches during removal.

NOTE: The following rear seals are used:

NT (Automatic Transmission) vehicle: Single lip seal Mfr (Manual Transmission) vehicle: Double lip seal

NOTE: All trucks manufactured for the North American market are only available with automatic transmissions.

Specilication

Engine rear seal

End plate classification

Single lip seal

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CONNECTING ROD AND PISTON ASSEMBLY REMOVAL 1. Check the following points before removing the connecting rods and pistons.

Double lip seal

a.

Inspection of connecting rod large end's end play: Standard value: 0.200-0.400 mm/ {.0079-.0157 in) Limit value: 0.50 mm/ (.0197 in)

b.

Inspection of connecting rod bearing's oil clearance: Standard value: 0.040-0.062 mm/ (.0016-.0024 in) Limit value: 0.1o mm/ (.0039 in)

M � side

See: "PISTON AND CONNECTING ROD INSTALLATION". .

CAMSHAFT REMOVAL 1.

Remove the woodruff key.

2.

Remove _the thru�//1�te.

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NOTE: Cover the threads of the connecting rod bolts with vinyl

hose so that the inner wall of the cylinder liner and crankshaft do not get scratched. Arrange the removed connecting rods and pistons so the original position is clear.

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3-9

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

Cover the thread with vinyl hose.

2.

Remove the snap ring with snap ring pliers.

Remove the conn�cting r�d cap and bearing.

2.

3. Tap the connecting rod bolts lightly with a hammer handle.

Remove the connecting rod and piston from the cylinder block.

PISTON RING REMOVAL 1. Use a piston ring tool (commercial product) to remove the piston. rings.

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NOTE: If a piston ring is expanded too far, the ring may break.

Wear eye protection and use caution when handling the rings.

3. Place the piston in water, and warm the water with a heater ° ° until the piston reaches 50�70 C / (120-160 F).

4. Remove the piston pins. Push out the piston pins using a drift pin or driver. T he drift pin or driver should have an O.D. (outside diameter) slightly smaller than the O.D. of the piston pin to prevent damage to the piston pin or piston during · removal.

SNAP RING AND PISTON PIN REMOVAL Inspect the foliowing befo/e rem�ving the piston pin:

1.

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With the piston statiQnary, verify that the connecting rod moves freely and smoothly throughout its range.

5. Arrange the removed pistons, piston pins, piston rings and connecting rods for each cylinder.

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Yale Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

MAIN BEARING CAP REMOVAL

C YLINDER LINER REMOVAL

1. cap:

Inspect the following before removing the main bearing

1. Place a front I rear positioning mark on the cylinder block and on each cylinder liner. Pull out the cylinder liners by hand.

Inspection of crankshaft end play: Standard value: 0.14-0.39 mm/ (.0055-.0154 in) Limit value: 0.40 mm/ (.0157 in)

Use the cylinder liner puller as shown if the cylinder liner cannot be pulled out by hand.

a.

See: "CRANKSHAFT AND BEARING INSTALLATION".

2. Loosen and remove the main bearing cap retaining bolts in the order shown in the illustration.

3. Remove the bearing cap and lower main be<;1ring metal as · �- i •·, . an assembly. :, '•

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· ., : Inspect the main journal oil clearance: Standar.d.value:.

Number 1,2A5 0.058-0.092 mm/ (.0023-0036 in) 0.084-0.118 mm/ (.0033�.,0046 in) Number 3 Limit value: Number 1,2,4,5 0.12 mm I (.0047 in) 0.15 mm r(.0059 in) Number 3 See: "CRANKSHAFT AND BEARING INSTALLAT ION".

4.

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NOTE: Do not drive out the liner. The liner edge can be dam­ aged. Arrange the removed cylinder.liners for each cylinder.

·, WARNING: The crankshaft is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the crankshaft. The crankshaft can weigh approximately 38 kg (84 lb).

3-11

Yale Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

ENGINE INSPECTION AND REPAIR NOTE: Replace all worn or damaged seals and gaskets. Re­ move all traces of dirt, oil, grease, carbon, etc. thoroughly clean all parts.

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NOTE: Use caution to prevent scratching aluminum parts such as the pistons.

NOTE: Carry out the inspection and repai� in th� '�pecified or­

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SPECIAL TOOLS AND SUPPLIES REQUIRED .;"£· .

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Red check

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SPECIAL TOOLS AND SUPPLIES REQUIRED

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lnspe§tion of cylinde'r head cracks . .

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Straightedge · '

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PROCEDURE

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Distortion inspec:;on

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T hickness Gauge

Distortion inspection, clearance measurement

Calipers·

Dimensional inspection of valves

Micrometer

Various dimensional measurements

Caliper gauge

Various inner diameter measurements

Table

Vibration inspection

Square

Inspection of valve spring right angle

V block

Vibration inspection

Dial gauge

End plate measurement ....

Plasti-gauge

Oil clearance measurement

Cylinder gauge

Measurement of cylinder inner diameter

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Connecting rod aligner

Inspection of connecting rod curve

Prussian Blue

Inspection of valve seat contact

Valve seat cutter

Correction of valve seat

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.. .

Industrial Trucks

ENGINE DISASSEMBLY/ REASSl;MBLY

CYLINDER HEAD INSPECTION

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Manifold mating surface distortion limit:

1. Thorou ghly clean the mating surfaces of the cylinder head, cylinder block, and manifolds with a scraper.

.10 mmi (.0039 in)

WARNING: The cylinder head is heavy. Be sure

that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the cylinder head. The cylinder head can weigh approximately 33 kg (73 lb).

NOTE: Take care not to scratch the machined surfaces. Wipe off any oil on the mating surfaces with a clean rag.

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7. If the distortion exceeds the limit, remove the stud bolts, and polish with a surface grinder; or replace the cylinder head.

CYLINDER HEAD BOLT INSPECTION 1. Measure the length of the shaft 6n the cylinder head bolts.

Reuse the bolt if it is within the limit, and replace it if the limit is exceeded.

Cylinder head bolt shaft length: Standard value: 130.2-130.8 mm I (5.126-5.150 in) Limit value: 131.5 mm/ (5.1772 in) Standard value: 158.2-158.8 mm/ (6.2283-6.252 in) Limit value 159.5 mm/ (6.2795 in)

2. Remove the carbon in the combustion chamber with a wire brush. Wash with a light oil.

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3. Check for cracks and scratches with the red check (color penetration method). Replace the cylinder head if there are any defects. · · 4. -check the distortion ih the locations shown in the illustration using a straightedge and thickness gauge.

Cylinder block mating surface distortion limit: 0.10 mm J (.0039 in) Left to right: Front to rear: (longitudinal direction) 0.25 mm/ (.0098 in)

VALVE AND VALVE GUIDE INSPECTION 1. Visually inspect the following points for each valve.

Replace the valve if there are any defects.

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a. · Damage or eccentric wear of the valve stem at the retainer notch. b. Damage or bends in valve stem. c. Da_mage of valve face.

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If the distortion exceeds the limit, replac·e the cylinder head.

6- Check the distortion in the locations shown in the illustration using a straightedge and thickness gauge.

2.

Carefully remove any carbon from the valve.

3-13

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY 5. Measure the inner diameter of the valve guide with the caliper gauge. If the diameter is not within the standard value, replace the guide.

Standard value for inner diameter of valve guide: 9.018-9.033 mm/ (.3550-.3556 in)

3. Measure the thickness of the valve head with calipers. If the measurement is less than the minimum value, replace the v�ve. · · ·- · Minimum thickness value: • ' -..j, I l' · intake 1.0 m1,11 / (.0394 in). exhaust 1.0 inm I (.0394 in) 6. Measure the maximum value of the valve guide's inner diameter, and the minimum value of the valve stem diameter to obtain the clearance. If the limit value is exceeded, replace the valve or valve guide.

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Intake

Exhaust

4. Measure the six locations of the valve stem shown in the illustration using a micrometer. If the measurement is less than the limit value, replace the valve.

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3-14

Standard value

8.965�8.980 mm (.3530-.3535 in)

Limit value,

8.884 m m (.3498 in)

Standard value

8.945-8.960 mm . (:3522-.3528 in)

Limit value

8.864 m m (.3490 in)

0.038-0.068 mm (.0015-.0027 in)

Limit value

0.127 mm (.005 in)

Standard value

0.058-0.088 (.0023-.0035 in)

Limit value

0.127 (.005 in)

VALVE SEAT INSPECTION 1. Check the contact surface of the valve seat and valve face for wear and damage.

2.

Intake

Standard value

If there are any defects, correct with a valve seat cutter. ° Intake: 45 ° Exhaust: 30

r Yale

w

Industrial Trucks

3_

ENGINE DISASSEMBLY/ REASSEMBLY

Apply a thin coat of prussian blue to the valve face.

4_ Press the valve lightly so that the valve seat does not rotate, and check the contact position. a. Replace the valve if the prussian blue is not found on the entire circumference of the valve face as illustrated.

.6. Check that the valve seat contact surface is in the center of the valve face. a. If the contact surface is over the center of the valve face, ° correct with a 75 valve seat cutter. b. If the contact surface is under the center of the valve ° face, correct with a 0 valve seat cutter.

7. Using compound and valve lapper, match the valve and valve seat.

Prussian Blue

8. Check the valve stem's protruding length.

L dimension

b. If a contact area is not found on the entire circumference of the valve seat's contact surface, correct the valve seat with a valve seat cutter.

Valve angle: ° Intake: 45 , ° Exhaust: 30

a. Measure the protruding length ("L" dimension) of the valve stem.

Standard "L" dimension: Intake

48.40 mm I (1.906 in)

Exhaust

48.40 mm I (1.906 in)

NOTE: Install the lower valve spring seat when measuring. b. If the "L" dimension is within the range given below, re­ use the valve seat.

EXfiAUST 5.

IN1AKE

Check the contact width of the valve face and v·alve seat.

Standard value of contact width: 1.7 mm/ (.067 in)

Intake

48.40-48.90 mm (1.906-1.925 in)

Exhaust

48.40-48.90 mm . (1.906-1.925 in)

c. If the "L" dimension is within the range given below, place a suitable spacer between the lower spring seat and cylinder head, and adjust so that the standard "L" dimension is ob­ tained.

Contact width

Contact position

Intake

48.90-49.90 mm (1.925-1.965 in)

Exhaust

48.90-49.90 mm (1.925-1.965 in)

3-15

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

d. If the "L" dimension exceeds the following value, replace the cylinder head.

Intake

49.90 mm/(1.965 in)

Exhaust

49.90 mm I (1_.965 in)

VALVE SPRING INSPECTION 1.

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ROCKER ARM AND ROCKER SHAFT INSPECTION 1. Check for wear and damage on the rocker arm and rocker shaft. Replace if defective.

2. Measure the rocker arm and shaft clearance with the following procedure: a. Measure the inner diameter of the rocker arm.

Standard value: 21.000-21.021 mm I (.8268-.8276 in)

Inspect for cracks. ?,n_d damage on tt,e ya Ive spring.

of the valve spring. Replace the 2. Inspect the natural length I spring if the measurement is less than the limit value.

Spring natural length.: 1 · •. •• Inner

Outer

Standa.rd value

53.84 mm/ (2.120 in)

Limit value

52.84 mm/(2.080 in)

Standard value

59.47 mm/(2,341 in)

Limit value

58.47 mm/ (2.302 in)

EB b.

Measure the outer diameter of the rocker shaft.

Standard value: 20.959-20.980 mm I (.8252-.8260 in)

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3. Inspect the valve spring squareness (right angle of the valve spring). Replace the spring if the limit value is exceeded.

Spring squareness limit value:

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Inner

1.88 mm/(.0740 in)

Outer

2.08 mm/(.0819 in)

C. Obtain the clearance between the outer diameter of the rocker shaft and inner diameter of the rocker arm.

Replace the rocker shaft and/or rocker arm if the limit value is exceeded.

Standard value: 0.020-0.062 mm I (.0008-.0024 in) Limit value: 0.07 mm I (.0028 in)

PUSH ROD INSPECTION

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1. Check for wear and damage on the push rod.

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3-16

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

I

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

CYLINDER LINER INSPECTION 1. Measure the outer diameter of the cylinder liner. A total of six points A, Band C in both the X-X and Y-Y directions are measured as shown in the illustration.

Outer diameter standard value: 112.474-112.50 mm/ (4.4281-4.4291 in) Inner diameter standard value: 109.005-109.031 m�/ (4.2915-4.2926 in)

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a. · Remove the carbon from the piston with a scraper. b. Clean the piston ring grooves with an old piston ring.

2.

Verify that there is a Y or Z mark on the top of the piston.

Y or Z Mark

See: "CYLINDER BLOCK AND LINER DIMENSIONS" for specific cylinder liner dimensions.

See: "CYLINDER BLOCK AND LINER IDENTIFICATION" for identification mark l,ocations.

2. Obtain the clearance between. the .cylinder bore and cylinder liner fro� the dat_a of the ·cylinder bore and the cylinder · .. liner outer diameter. ·· Standard value: 0.013-0.039 mm I (.0005-.0015 in) If the value is not within the standard value, replace the cylinder liner. Be sure that the replacement cylinder liner has the

sarrie marking as the cylinder block.

See: "NOTE: Pistons and liners for service parts" (this page).

X

3. Measure the piston outer diameter at the X thrust · direction position from the piston lower end.

Measurement position X: 22 mm/ (.8661 in) Standard value Mark Y: 108.945-108.958 mm/ (4.2892-4.2897 in) Standard value Mark Z: 108.932-108.945 mm I (4.2887-4.2892 in) 4. Calculate the difference between the minimum diameter of the cylinder liner in the thrust direction, and the outer diameter of the piston ("X" measurement position) to obtain the piston clearance.

Standard value: 0.060-0.086 mm I (.0024-.0034 in) If the standard value is exceeded, replace the piston and/ or the cylinder liner. Remeasure the clearance if orily one of these is replaced.·

NOTE: Pistons and liners for service parts

PISTON AND PISTON PIN INSPECTION NOTE: Do not use a wire brush to clean the piston.

1.

Clean the piston.

1) Pistons and liners for seNice are manufactured with smaller tolerances. Only one size piston is available for seNice. The pistons for seNice parts do not have marks.

2) The cylinder block requires two selections of liners. The block and each liner are identified by an "A" or "B" stamp for · each cylinder.

3) It is possible to have "A" and "B" liners in the same block.

Check the marking for each cylinder.

4) Service parts are identified with "RED" or "GREEN" markings.

5) See:

"CYLINDER BLOCK AND LINER IDENTIFICATION"

for identification mark locations.

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3-18

I

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

Industrial Trucks

8. Using a micrometer, measure the four positions shown in ·the illustration of the A, B, C and D piston outer diameters for both the X-X and Y-Y directions.

Standard value: 34.993-35.000 mm I (1.3777-1.3780 in)

9. Obtain the difference between. the pist�n pin hole diameters and piston pin o·uter diameters. ·1f the press-in amount (matching) is not within the stand::vd value, replace the piston and/ or piston pin. Replace the pistcn or piston pins if not within the standard value.

Standard value: ci.004-0.015 mm I (0.00016-0.0006 in)

CONNECTING ROD INSPECTION 1. Measure the inside diameter of the bushing in the small end of the connecting rod with a caliper gauge.

Standard value: 35.012-35.033 I (1 .3784-.1.3792 in) 2. Obtain the difference between the inside diameter of the connecting rod bushing and the outer diameter of the piston pin.

Replace the connecting rod bushing or piston pin if the limit is exceeded. · · · ,· Standard value: 0.012-0.040 mm I (.0005-.0016 in) · · Limit: 0.05 mm/ (.0020 in)

ENGINE DISASSEMBLY/ REASSEMBLY 4.

Distortion inspection.

To check distortion, place the gauge on the piston pin as shown in the illustration. The three pins of this gauge should contact the flat surface of the aligner evenly.

If the pin section is separated from the flat surface, a bent rod is indicated. Use a thickness gauge to measure this clearance.

If the bend exceeds the limit value, replace the connecting rod.

Bending limit value: 0.1 mm or less for each 100 mm (.0039 in or less for each 3.937 in) Distance between center lines: 187.000-187.050 mm I (7.3622-7.3642 in)

NOTE: The connecting rod and connecting cap have been

machined as an assembly. When replacing the connecting rod, also replace the connecting rod cap, connectin.g rod bolts and nuts. Always replace the connecting rod baits and nuts even when only disassembling the connecting rod.

&.

CRANK$HAFT INSP_ECT!Ot{.

EB 3. Install the the piston pin into the cohriecting rod. Install the large end of the connecting rod on the shaft of the aligner.

3-20

' '

WARNING: Th·e cra�ksh�ft is heavy. Be sure that

all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the crankshaft. Tlie crankshaft can weigh approximately 38 kg (84 lb).

1. 1/isually check th·e crankshaft's journal section, pin section and sliding section of oil seal for damage. Repair or replace if necessary.

'

WI---------------------

Yale

µstrial Trucks ,, Jnd ,,., .... ..

of the crankshaft with a V . 2: ·Check the deflection (run-out) _ 1 and number 5 Journal of number the Use . block and dial gauge points, and measure the the crankshaft as supporting nal.

3 jour ber num the with defl�ction Deflection limit value: 0.050 mm/(.002 in) If the limit value is exceeded, replace the crankshaft.

ENGINE DISASSEMBLY/ REASSEMBLY 4. If the diameter measurement is less than the limit value, grind the journal and use an undersize bearing.

Undersize bearings: 0.254, 0.508, 0.762 mm/(0.010, 0.020 0.030 in) Journal finish dimensions: Undersize Bearing mm/(in) 0.254 (0.010)

I ...

:;.

�'. M�· ;sure the main journal dia�eter and crank pin diameter -at the four points shown in the illustrations.

Main journal diameter: Standard value number 1, 2, 4, 5: 78.980-79.000 mm I (3.1094-3.1102 in) Standard value number 3: 78.954-78.974 mm/ (3.1084-3.1092 in) number 1, 2, 4, 5: Limit value 78.306 mm I (3.0829 in) Limit value number 3: 78.280 mm I (3.0819 in)

0.508 (0.020)

0.762 (0.030)

Main Journal mm/(in) Number 1, 2, 4, 5

78.726-78.746 (3.0994-3.1002)

Number 3

78. 700-78.720 (3.0984-3.0992)

Number 1, 2, 4, 5

78.472-78.492 (3.0894-3.0902)

Number 3

78.446-78.466 (3.0884�3.0892)

Number 1, 2 , 4, 5

78.218-78.238 (3.0794-3.0802)

Number 3

78.192-78.212 (3.0784-3.0792)

Crank pin mm/(in) 63. 733-63. 746 (2.5092-2.5097)

63.479-63.492 (2.4992-2.4997)

63.225-63.238 (2.4892-2.4897)

NOTE: Do not grind the filet (chamfered) section.

MAlN BEARING AND CONNECTING ROD BEARli\lG INSPECTION 1. Visually check the surface of the main bearings and the connecting rod bearings for separation and scratches. Replace if defective.

Crank pin diameter: Standard value: 63.987-64.00 mm I (2.5192-2.5197 in) Limit value: 63.75 mm/(2.5098 in)

])]1 (ill) (fil fil

DD(D)OQ CAMSHAFT INSPECTION 1. Position the number camshaft in the V block.

and number 4 journals of the

3-21

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

2. Check the camshaft deflection (run-out). Replace if the limit value is exceeded.

Deflection limit value: 0.08 mm/ (.0031 in)_

,· I

Journal diameter mm/ (in): Number 1 3. Check for wear and dam_ · -age on the cam surface. Replace if defective.

4.

Measure the cam height.

Camshaft: Standard intake value: 48.415 mm/ (1.9061 in) Limit intake value: 47.886 mm I (1.8853 in) Standard exhaust value: 48.547 mm/ (1.9113 in) Limit exhaust value: 47.996 mm/ (1.8896 in)

Replace the camshaft if the cam height is less than the limit value.

Number 2

Number 3

Number 4

Standard value

58.41 0-58.440 (2.2996-2.3008}

Wear Limit value

0.08 I (.0031)

Standard value

58.160-58:190 (2.2898-2.2909}

Wear Limit value

0.08 I (.0031)

Standard value

57.910-57.940 (2.2799-2.2811}

Wear Limit value

0.08 I (.0031)

Standard value

57.660-57.690 (2.2701-2.2713)

Wear limit value

0.08 I (.0031)

6. Measure the oil clearance of the camshaft's journal section with the following p"rocedure: a. Thoroughly clean the journal section. b. Measure the inner diameter of the bearing.

5. Measure each journal diameter. Measure.the diameters of the "A" a.nd "B" points in the illustration for both the X-X and Y-Y directions. Replace if the wear.limit value is exceeded.

Y a le

(,

cks . str ,, .. ''Jndu , .. i;;JI Tru

ENGINE DISASSEMBLY/ REASSEMBLY

Bearing standard inner diameter: rNumber 1

58.500-58.530 mm I (2.3031-2.3043 in)

Number 2

58.250-58.280 mm I (2.2933-2.2945 in)

Number 3

58.000-58.030 mm I (2.2835-2.2846 in)

N�mber 4

57.750-57.780 mm I (2.2736-2.2748 in)

2. Measure the outer diameter of the tappet follower with a micrometer.

Standard value: 15.518- 1 5.533 mm/ (.6109-.6115 in) ,

c. Obtain the maximum oil clearance from the maximum . value of the bearing inner diameter and minimum value of the rt- c�m,snaft journal outer diam�.ter. If the limit js ex�eeded, re­ block. · · · i ., ' · ' �¾��J��-��e camshaft or cylinder

!

I_:-

EB

Oi_l ,cle.arance: mm I (in) , ,yNurnber. 1 -

.,. '

r

,•1.

Number 2

Number 3

Number 4

_.

1 I I l

·Standard value

..

.'

Limit value

·,

0.06-0.12, (.0024-.0047) .

1·

.. ,

0 .145/ (.0057)

Standard value

0.06-0.12 (.0024-.0047)

Limit value

0 .145 I (.0057)

Standard value

0.06-0.12 (. 0024-.0 047)

Limit v·alue

0.145/ (.0057)

Standard value

0. 06-0.12 (.0024-.0047)

Limit value

0.145 I (.0057)

7. Measure the end play of the camshaft. If the limit value is exceeded, replace the thrust plate or camshaft. ,j · ·.·,r.1, .. End play: 0.02-0.18 mm/ (.0008-.0071 in) ,vi ,,• ,·· · Limit value: o.�o rfim/ (.0118 in)

...

..

,:: ,

3. Measure. the inner diameter of the tappet ·cavity in the cylinder block with a caliper gauge, Standard value: 15.588-15.619 mm/ (.6137-.6149 in)

�

,,,-------------

.

0 �

4. ·. Calculate the difference between the cylinder block tappet cavity inner diameter and tappet's outer diameter. If the value exceeds the limit value, replace the tappet or cylinder block.

Standard value: 0.055-0.101 mm/ (.0022-.0040 in) Limit value: 0.15 mm/ (.0059 in)

--• ..�,.______________________ J

·TAPPET INSPECTION

j,

. . /.

1. Visually check the t9j:Jpet follower for unusual wear' or damage. Replace if defer;tive.

•

•I��'•\ :

•

3-23

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

ENGINE REASSEMBLY NOTE: Do not reuse the gaskets, O-rings or oil seals.

Thoroughly clean all surfaces before installing the new gas­ kets, O- rings, oil seals or sealant.

NOTE: Apply new engine oil on all friction points of the engine (bearings, gears etc.) during assembly.

.

NOTE: Thoroughly clean all parts before assembling. Pay par­ �cular attention to the sliding parts of the bearings and other friction points of the engine.

NOTE: �ighten the bolts and nuts to the specified tightening

torque.

I

SPECIAL TOOLS REQUIRED. SPECIAL TOOLS REQUIRED

·,1, .,

PROCEDURE

SPECIAL TOOLS REQUIRED

9125483-59 Valve spring lifer arm

for replacement of valves

9125483-56 Valve s:�·al 9nd v,,,ve guide installer set

9125483-81 Installer (valve seal) (component of 9125483-56}

For replacement of valve seals and valve guide

9125483-82 Body (component of 9125483-56)

9125483-83 Installer (valve guide) (component of 9125483-56}

For replac_�rnent of valve seals and valve guide

9125483-84 ', Nut (component of 912548.3-56)

For replacement of valve seals and valve guide

9225423-04 Pivot

For· replacement of valves, etc.

For disassembly of valves, etc.

9225423-06 Foot (component of 9225423-04)

For disassembly of valves, etc.

.

r/1

·?

PROCEDURE

For replacement of valve seal and valve guide

(I_-:i) · •

I

For replacement of valve seal and valve · guide

For replacement of valve seal and valve guide

I

!

,··11· I,

t'-1

9125483-87 Spacer (component of 9125483-56}

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9225423-05 Body (component of 9225423-0{1

3-24

Yale J,:idustrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

SPECIAL TOOLS REQUIRED

PROCEDURE

SPECIAL TOOLS REQUIRED

PROCEDURE

9225423-07 Lock nut (co mponent of 9225423-04)

For disassembly of valves, etc.

9225423-13 Clutch disc centering tool

For installation of clutch disc

9225423-14 Ring gear brake

To prevent crank­ shaft from rotating

9125483-34 Piston pin installer·

For installation of pis­ ton pins

9225423-15 Oil seal installer

For installation of oil seal

9225423-16 Handle (component of 9225423-15)

For installation of oil seal

9225423-07 Oil seal installer (component of 9225423-15)

For installation of oil seal

9224473-00 Wrench oil filter bypass

For replacement of oil bypass filter

COMMERCIAL PRODUCT TOOLS (NOT AVAILABLE THROUGH YALE) SPECIAL TOOLS REQUIRED Piston ring tool

PROCEDURE

For replacement of piston ring

SPECIAL TOOLS REQUIRED Piston ring compressor

PROCEDURE

For installing the piston as· sembly into the cylinder block

3-25

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

.Yale

, J· ,.Jndustrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

.. 1 _ Apply engine oil to the outer circumference of the cylinder liner.

NOT E: Do not drive the liner into the block with a hammer or other similar object,_ whe n 1nsert1ng.

2. Insert the cylinder liner into the cylinder block with an even_ force. Be sure to position the liner properly. Align the front I rear marks which were made during disassembly.

l.

�'.r

:?

NOTE: The surface of the thrust bearings with grooves should face the side that contacts the crankshaft.

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3.

r--..c=-------c::, =---- -----,

. � <B

------- ' :

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Install the thrust bearings.

',,J.

CAMSHAFT INSTALLATION 1. Apply oil to the camshaft and insert into the cylinder block using a slow turning motion.

2. Apply oil to the surfaces (flat surface) where the trust plate contacts the camshaft, and where it contacts the cylinder block.

Tightening torque: 1.9-2.6 kgm / (165-225 lb/ in)

&

' 4. Thoroughly clean the journal and pin sections of the crankshaft.

WARNING: The crankshaft is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the crankshaft. The crankshaft can weigh approximately 38 kg (84 lb).

5.

Install the crankshaft into the cylinder block.

CRANKSHAFT AND BEARING INSTALLATION 1. Thoroughly clean the surface of the upper main bearing metal (with grooves) and the bearing installation surface of the ' cylinder block.

2. �atch the convex and concave sections of the bearing, and install the bearing.

3-27

'

Yale

Industrial Trucks

6.

ENGINE DISASSEMBLY/ REASSEMBLY

Measure the oil clearance with the following procedure: a. Cut the plasti-gauge to the same length as ihe width of the crankshaft journal, and lay it parallel to the crankshaft.

NOTE: Do not turn the crankshaft when mea·suring the oil clearance. b. Thoroughly clean the lower main bearing (no grooves in the center), and the installation surface of the bearing cap.

Install the bearings in the cap. •. -•·. c. Face the "Cap number" and"<>" marks on the bearing cap toward the engine· front (fan side) and inst�II.

g.

Measure the oil clearance using the plasti-gauge scale.

Standard value Number 1,2,4,5: 0.058-0.092 mm/ (.0023-.0036 in) Number 3: 0.084-0.118 mm/ (.0033-.0046 in) Limit value Number 1,2,4,5: 0.12 mm I (.0047 in) Number 3: 0.15 mm/ (.0059 in)

If the limit value is exceeded, replace the bearing or grind the journal section and use undersize bearings. d. Use new bolts for the bearing cap. Apply a light coat of engine oil on the bolt threads and the washer, and install. e. Tighten the bearing cap bolts as follows:

O

G) Tighten the bolts in the order of the numbers in the illustration '. Tighten in two or three stages to a tightening torque of 12 kgm/ (87 !bf ft). Loosen in the order of the numbers.

D

® Tighten again in the order· of the O numbers

alternately in two or three stages to a tightening torque of 4.5 kgm / (33 lbf ft)..

® Tighten another 90 from that position. °

f. After tightening to the specified torque, remove the bearing caps. ,.:1• !'·

I .' ' I

1I:,qi .

It·

.,

3-28

I

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

8. Inspect the end play of the crankshaft with the following procedure:

Standard value: Limit value:

0.14-0.39 mm/(.0055-.0154 in) 0.40 mm/(.0157 in)

If the limit value is exceeded, replace the thrust bearing, or grind the thrust surface of the crankshaft and use an oversize thrust bearing.

a. Position the dial gauge as shown· In the illustration. b. Pull the flyweight section of the crankshaft in the direc­ tion of the shaft with a screwdriver, and mepsure the end play.

CRANKSHAFT THRUST BEARING FINISH DIMENSIONS Thrust Bearing mm/(in)

Thickness mm/(in)

(A) section dimensions mm I (in)

Standard

2.275-2.325 I (.0896-.0915)

35.365-35.465 /(1.3923-1.3963)

0.35 / (.0138) Oversize

2.453-2.503 /(.0966-.0985)

35.543-35.643 /(1.3993-1.4033}

PISTON AND CONNECTING ROD INSTALLATION 1. Place the piston in hot water and warm to approximately ° ° 50·60 C/( 122·140 F) 2.

Install a snap ring in one end of the piston. .

- ..

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·,

; .

.�

.

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.

3. Apply e·ngine oil to the piston.pin and to the bushing in the connecting rod's small end. When reusing the original piston, assemble the piston so that connecting rod's matching mark faces the grade symbol on the top of the piston as shown in the illustration. Insert the piston pin." If the piston is new, assemble so that the center of the combustion chamber on the top of the piston is near the connecting rod's matching mark.

4.

Install the second snap ring in the other end of the piston.

Piston grade symbol

·· )

5. After pressing in the piston pin, inspect the connecting rod's swaying torque. With the piston held stationary, verify that the connecting rod moves freely and smoothly throughout its range. Holding the piston in one hand, lift the large end of the connecting rod upward as shown. Release the large end of the connecting rod. The weight of the connecting rod must cause it to swing downward freely. Replace the piston, piston pin and/ or the connecting rod if there is any binding or any defects.

-· .. ,; � ,,.:-:: _--:_

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1;

3-30

\IJ)

r

Connecting rod matching mark

6. Install each piston ring as shown in the illustration, assemble in the following order: oil ring expander_.. oil ring_.. second ring and top ring. Install the rings so that the gaps are spaced as shown in the illustration.

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

a. Cut the plasti-gauge to the same length as the connect­ ing rod bearing width, and place it parallel to the cranKshaft.

Avoid the oil hole.

e. After tightening to the specified torque, remove the con­ necting rod cap. b. Thoroughly clean the lower connecting bearing and the installation surface of the connecting r6-d bearing cap. Install the bearings in the cap. ·.· c. Align the matching marks on the connecting rod and cap.

Install the connecting rod cap. d. Tighten the connecting rod cap.

f. Measure the oil clearance using the plasti-gauge scale.

Standard value: 0.040-0.062 mm/ (.0016-.0024 in) Limit value: 0.1 o mm/ (.0039 in)

(1) Apply a small amount of engine oil to the connecting rod bolt threads and the washer. Tighten to a torque of 9 kgm / (65 lbf ft) and then loosen.

NOTE: Never reuse the connecting cap bolts and nuts. Al­ ways replace the connecting cap bolts and nuts with new at reassembly.

(2) Tightening to a:;torque of 3.5 kgm/ (25 lbf ft). Tighten the bolt another 90 ° .'

If the limit value is exceeded, replace the bearings or grind the crank pin and use undersize bearings.

CRANKSHAFT CRANK PIN FINISH DIMENSIONS Bearing size mm/ (in)

Center thickness mm/ (in)

crankshaft finish dimensions mm/ (in)

Standard

2.025-2.030 I (.0797-.0799)

63.987-64.000 I (2.5192-2.5197)

Undersize 0.254/ (0.010)

2.152-2.157/.(.0847-.0849)

63.733-63.746 I (2.5092-2.5097)

. 2.279-2.284 I (.6897-.0899)

· 63.479-63.492 I (2.4992-2.4997)

2.406-2.411/ (.0947-.0949)

63.225-63.238 2.4892-2.48967

Uhdersize 0.508/ (0.020) Undersize . 0.7q? I (�.030) .

!:

,,

17. After measuring and / or correcting the oil cle�rance, install the connecting rod caps wjth the following procedure: a. Remove the plasti�gauge, b. Apply engine oil to the sliding parts of the crank pin and connecting rod bearings. c. Align the matching marks on the connecting rod and cap.

Install the connecting rod cap.

· 1;

li,.

,i

3-32

d.

Tighten the connecting rod cap.

(1) Apply a small amount of engine oil to the connecting ro9 bolt threads and the washer. Tighten to a torque of 9 kgm/ (65 lbf ft) and thel") loosen.

(2) Tightening to a torque of 3.5 kgm / (25 lbf ft).. Tighten the bolts another 90 °.

Yale

', . -Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY 4. Install the oil seal using the special seal installation tool. Be sure to seat the oil seal against the rib on the engine plate.

f�

lI

Transmission type

Engine rear seal

End plate Identification mark

Single lip seal

I

AfT

�,;de

A

. i

Double lip seal

. '

e_nd of the connecting rod 18. Check th� .�nd pliy of the larQe · · '· re: edu proc wing ollo f · with the a. Position the dial gauge as shown in the illustration . b. Move the large en� back and forth, and measure the end play.

Standard value: Limit value:

Mrf

.. ,.

·�,;a, 1

M

0.200-0.400 mm/ {.0079-.0157 in) 0.50 mm i {.0197 in)

II the limit value is exceeded, replace the connecting rod, connecting rod cap and connecting rod bolts and nuts.

&

5. Apply SH780 liquid gasket P/N 9010858-20 to the machined mating surfaces of the end plate shown in the illustration. Install _the end plate on the cylinder block.

END PLATE AND REAR OIL SEAL INSTALLATION .

WARNING: The end plate is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the end plate. The end plate can weigh . . approximately 16 kg {36 lb). · 1 .. Different engine rear 6il �eals are used for the automatic tran�rT;)iss_ion (Nr) truck and th_e manual transmission (MIT) truck. Be' sure to install . the correct seal. Identification illustrations· are shown in !h·e following table.

. NOT E: All trucks manufactLJred for the North American market

I are only available with automatic transmissio ns. .

L____

2. Always install a new oil seal.

3. Apply engine oil to the press-in surface of the oil seal, to the end plate and to the lip of the oil seal.

Use new seal washers (MB, M14), and tighten to the following torque.

Tightening torque: MS: 1.6-2.3 kgm/ {139-200 lbf in) M14: 7.7-10.5 kgm/ {56-76 lbf ft) 3-33

"l

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

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M

Yale

I

.,,.., . _ Industrial Trucks

ENGINE DISASSEMBLY/ REAS SEMBLY

OIL PRES SURE SWITCH INSTALLATION 1_

I:

Install the oil pressure switch.

Tightening torque: 1.0-1.5 kgm / (87-130 lbf in)

NOTE: Apply SH780 liquid gasket P/N 9010858-20 to the mating surfaces of the timing gear case and the cylinder block. -

(

I

I. TIMING GEAR INSTALLATION OIL COOLER ASSEMBL'( INSTALLATlON. 1.

.· t

.

Install the oil cooler assembly, using a new gasket.

Tightening torque: 1.9-2.6 kgm / (165-226 lbf in)

J

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I

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... , - � -,0

1. Align Hie cam ge·ar with the woodruff key in the camshaft.

Install the gear.

·-

TIMING GEAR CASE INSTALL.ATION'

2. Install the idler gear spindle. Be sure that the oil hole in the idler--gear spindle and the oil hole in the cylinder block are aligned.

I·-

.• 1---:a;;, ...i-,_�.fl'· "''

)

\ "_ .

1.

Install the timing gear case, using a new gasket.

Tightening torque: 1.9-2.6 kgm / (165-226 lbf in)

�

3. Align the idler gear with the other gears so the timing marks are as shown in the illustration.

3-35

Yale Indus.trial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY 6. .Install the friction gear, gear spring and oil deflector on the crankshaft.

;.·.

1

. I

4. Install the friction gear·�� d plain washer on the cam �ear.

Hold the cam gear statiQnc\ry with.the special .holder (wrench).

Install and tighten the retaining bolt.

Tightening torque:':I� 9-7.::1.3.7 kgm / (7.7-99 lbf ft) • '

• �-

/

' I

FUEL INJECTION PUMP INSTALLATION 1 .. Install the fuel injection pump. Be sure to align the mark on the fuel injection pLtmp gear to the mark on the idler gear.

Tightening torq'ue: 1.9-2.6 kgm / (165-226 lbf in)

WARNIN.G: The fuel injection pump is heavy. Be

I !

sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the fuel injection pump. The fuel injection pump can weigh approximately 17 kg (38 lb).

i

See: "INJECTION PUMP INSTALLATION" for the complete installatio,n and adjustment procedure.

<1 :l.1

5. Install the thrust plate ori- the idler ��ar. Install and tighten the retaining oolts. .. �· ..

Tightening torque: 1.9-2.6 kgm / (165-226 lbf in)

i..I,

T IMING GEAR COVER 'INS,TALLATION .

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3-36

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,

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Install the ti�inb �ear cover:using a new gasket. ·' .

Tightening torque:J .9-2.6 kgm / (165-226 lbf in) :';f ...

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

CYLINDER BLOCK REASSEMBLY-ACCESSORY COMPONENTS ASSEMBLY AND TORQUE VALUE ILLUSTRATION New Part

· Apply Lock-Tight

. <... \

1.9-2.6 kgm (165-226 lbf in)'-+--'UZll,,,,,3.8-5.3 kgm (330-460 lbf in).

f

1.9-2.6 kgm {165-226 lbf in) ..

• .

39-44 kgm �

b��

(282-318 lbf ft) �� \

I'

®

®

Special Tool

Pump drive plate

3.2-4.7 kgm (278-408 lbf in)

A·

N ... __ ew part 1.0-1.3 kgm (87-113 lbf ® ti<

0 1.0-1.3 kgm

(87-113 lbf in)

[§J 2.0-2.5 kgm

(174-217 lbf in)

.. r I I

� � . � New part

1.9-2.6 kgm {165-226 lbf in)

ENGINE MOUNT INSTALLATION 1.

Install the engine mount.

Tightening torque: 4 _ .2-5.0 kgm / (33-36 lbf ft)

3-38

21-23 kgm � (152-166 lbfft)

A

B

@

{165-226 lbf in)

I

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----------------�•·.,

.Yale

· _. ':

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

OIL FILTER ASSEMBLY INSTALLATION 1 _ Install the oil filter assembly on the block, using a new gasket. . Tightening torque: 1.9-2.6 kgm / (165-226 lbf in) See: "MAIN AND B YPASS OIL FILTER REPLACEMENT" (LUBRICATION SECTION) for the oil filter replacement procedure.

FUEL LINE INSTALLATION 1.

•:.

lnst"all the fuel 1iri�s, using new sealing washers.

Tighte17ing torque: 2.0-2.5 kgm/ (174-217 lbf in)

FLYWHEEL INSTALLATION 1.

2.

Install the oil by-pass pipe, using new O-rings.

Tightening torque: 1.9-2.6 kgm / (165-226 lbf in)

2. Install the flywheel on the crankshaft. Install the flywheel retaining bolts and washers and hand tighten them.

\ --n----no 7pa

3. Install the flywheel brake to stop the flywheel from rotating.

Tighten the flywheel bolts in several steps. Tighten the bolts in the order shown in the illustration.

Tightening torque: 21.0-23.0 kgm / (152-166 lbf ft)

-�-OJ

�,

J

OIL PIPE INSTALLATION 1.

Apply "Lock-Tight" to the flywheel retaining bolt threads.

I

Pfff·4tfM :,.r..,;,,;;;=�',#r">---<'./

Install the oil pipe, using new sealing washers.

Tightening torque: G) 1.0-1.3kgm/(87-113lbf in) @ 1.9-2.6 kgm/ {165-226 lbf in)

3-39

c.

Yale

Industrial Trucks

CRANKSHAFT PULLE YINSTALLATION 1.

Install the flywheel brake to prevent flywheel rotation.

2. Install the pulley, tapered ring, and spacer in that order, on the crankshaft. · 3.

Tighten the pulley lock nut.

Tightening torqu�: 39-44 kgm / (282-318 lbf ft)

4.

Remove the flywheel ?r�ke from the flywheel.

WAT ER PIPE INSTALLATION 1. Bolt the water pipe and the alternator bracket to the block as an assembly. Use a new gasket when installing the water pipe.

Tightening torque: @ 3.2-4.7 kgm / (23-34 lbf ft) @ 1.9-2.6 kgm / (165-226,lbf in)

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3-40

ENGINE DISASSEMBLY/ REASSEMBLY

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Yale

Industrial Trucks

VALVE SEAL INSTALL ATION 1. Adjust the valve seal installation .tool so that the "L" dimension in the illustration is the standard value.

Sta,ndard value: 15.5-15.9 mm/ (.610-.626 in)

ENGINE DISASSEMBLY/ REASSEMBLY VALVE-VALVE SPRING-VALVE SPRING SEAT INSTALL ATION 1.

Apply a small amount of engine oil to the valve stern.

2. Insert the valve into the valve guide, from the combustion chamber side.

3. Install the following parts over the valve stern and onto the cylinder head in the following order: lower valve spring seat, '.Jnner valve spring, outer valve spring, and upper valve spring seat.-

NOTE: Install the inner and outer valve springs so that the coil dir�·ctions are opposite as illustrated.

2.

Install a new valve seal on the valve guide by hand.

3. Install the the valve seal installation tool on top of the valve seal.

VALVE RETAINER INSTALLATION 1. Compress the spring with the valve spring compressor so that the valve retainer notch on the valve stern is visible.

2. Install the valve retainer, and release· the spring compression.

4. Install the valve seal into the cylinder head with the valve seal installation tool.

3-42

3. Remove the valve spring compressor, and lightly tap the top of the valve stem with a plastic hammer to ensure that the valve retainer is seated properly in the notch.

Yale

..

Industrial Trucks

ENGINE DISASSEMBLY/ REASS�MBLY

RO CKE R ARM INSTALLATION

CYLINDER HEAD INSTALLATION

1_ Apply oil on each sliding surface. Install the rocker arms, the rocker shaft. Install the rocker shaft brackets and springs on rings. snap

1.

&-

Install the cylinder head assembly on the head gasket.

WARNING: The cylinder head is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the cylinder head. The cylinder head can weigh approximately 33 kg (73 lb).

2. · · Apply"engine oil on the ends of the push rods, and insert them into the tappet followers.

NOTE: Verjfy that the lower end of the push rod fits properly into the center of the tappet follower as illustrated.

INCORRECT

CORRECT

THERMOSTAT HOUSING INSTALLATION 1.

Install the thermostat housing, using a new gasket.

Tightening torque: @ 1.9-2.6 kgm / (165-226 lbf in) (MS) @ 0.8-1.1 kgm / (69-95 lbf in) (M6)

3. Install the rocker arm and shaft assembly on the cylinder head.

Tightening torque: _1.9-2.6 kgm / (165-226 lbf in)

\.

CYLINDER HEAD GASKET INSTALLATION · 1.

Install a new cylinder head gasket on the cylinder block.

3-43

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

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" Y a le

trial Trucks . Jn'.dµs .1.1.JJ11 -· 2_

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holders. lnsti:!11 the injection nozzle kgm / {34-40 lbf ft) 4.7-5.5 torque: g ghtenin Ti

ENGINE DI SA SSEMBLY/ REASSEMBLY INJECTOR LINE CLIP INSTALLATION . 1.

Install the injector line clips.

Tightening torque: 0.8-1.1 kgm / {69-95 lbf in)

FUEL INJECTOR LINE INSTALLATION 1.

Install the injector lines.

Tightening torque: 2.5-3.0 kgm / {217-260 lbf in)

OIL L EVEL GAUGE (DIP ST ICK) AND GUIDE PIPE INSTALLATION 1. Install a new O-ring on the oil level gauge guide pipe (dipstick tube). Insert the dipstick tube into the cylinder block and install the retaining bolt.

Tightening torque: 1.9-2.6 kgm / {165-2_26 lbf in)

NOT E: Coat the newO-Ring with engine oil before installation.

2. ·Insert the oil level gauge (dipstick).

3-45

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

CYLINDER HEAD COVER INSTALLATION 1.

Install the cylinder head cover, using a new gasket.

Tightening torque: 0.35-0.55 kgm / (30-48 lbf in)

-··

-

�-: Q) � ,=-�·-•

I

1

SEAL COVER INSTALLATION 1.

Install the seal cover.

Tightening torque: 0.35-0.55 kgm / {30-48 lbf in)

2.

Install the oil filler cap.

EXHAUST MANIFOLD INSTALLATION 1. Install the exhaust manifold, using a new gasket.

Tightening torque: 4.5-4.9 kgm / (33-35 lbf ft)

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY Timing gear

Camshaft Camshaft deflection limit Camshaft end play mm/ (in)

mm/(in)

0.08 I {.0031)

Standard

0.020-0.180 {.0008-.0071)

Limit

0.30 I (.0118)

No. 1

"

.

'

No. 2.

Journal diameter standa.rd diameter·.· mm I (in)

58.160-58.190 {2.2898-2.2909)

•-·•·•·

t,Jo. 3

57.910-57.940 (2.2799-2.2?,11)

)

No. 4

...

'.

;

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•·11,

Journal diameter limit diameter ._ ,

. ,,:

No. 1

.,

No. 2

.

-· - -·-· ···· ·

· Camshaft bore standard diameter mm/ (in)

'•,:1.

Journal oil clearance mm/(in) Cam height mm/(in)

58.410-58.440 {2.2996-2.3008)

'

Intake Exhaust '•

a • _,

. - . . '

57.660-5'7:690 (2.2701-2.2713) 0.08 I {.0031) 58.500-58.530 {2.3031-2:3043) 58.250-58.280 . (2.2933-2.2945)

No. 3

58.000-58.030 {2.2835-2.2846)

No. 4

57.750-57.780 (2.2736-2.2748)

Standard

0.06-0.12 (.0024-.0047)

Limit

0.145 /(.0057)

Standard

48.415 I (1.9061)

Limit

47.886/(1.8853)

Standard

48.547 /(1.9113)

Limit.

47.996 I {1.8896)

·-·

Gear backlash ·mm/(in)

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3-48

0.06-0.18 {.0024-.0071)

Limit

0.30 I {.0118)

Idle gear end play mm/(in)

0.05-0.22 {.0020-.0087)

Idle gear bushing inner diameter mm I (in)

44. 009-44.034 (1. 7326-1. 7336)

Idle g'ear spindle diameter mm/(in)

43.950-43.975 {1.7303-1.7313)

Clearance bushing to spindle

Standard

0.034-0.084 {.0013-.0033)

Limit

0.15/ {.0059)

· mm/(in)

Connecting rod and bearings Length (between hole centers) mm/(in)

187.000-187.050 (7.3622-7.3642)

Bending limit

0.1 per 100 mm {.0039 per 3.937 in)

mm/(in)

Inner diameter of small end mm I (in)

38.000-38.039 {1.4961-1.4976)

Clearance small end bushing to piston pin

Standard

0.012-0.040 (.0005-.0016)

Limit

0.05 I {.0020)

Standard

0.200-0.400 {.0079-.0157)

Limit

0,50 I (.0197)

Standard

0.040-0.062 {.0016-.0024)

Limit

0.10/(.0039)

mm/(in) End play Large end mm/(in) Oil clearance Large end mm/(in) Bearings Undersize available mm/(in)

I·

Standard

0.254 I (.0100) 0.508 I (.0200) 0.762 (.0300)

!

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

,.. ' !.....

, .'. , 'tndustrial Trucks

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ENGINE DISASSEMBLY/ REASSEMBLY .

DE r ··rnoUBLESHOOTING GUI

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Possible causes

Problems

I

Low compression pressure * The valve clearance is incorrect * The compression pressure is leaking past the valve seat. * Seizure of the valve stem * Fatigue or damage of the valve spring * Failure of the cylinder head gasket * Cracks or strain in the cylinder head * Stuck, damaged or worn piston rings * Worn or cracked. piston

Low output, Improper, sluggi sh acceleration ..

,

l-

'

I

..

Improper fuel system· operation

* Worn or stuck piston ring or worn piston ring grooves ,. * Worn piston or cylinder . * Valve seal defective *. Worn valve �tern and/ or guide

Excessive engin e oil consumption

.•

..

Oil leakage

Remedy Adjust Repair (fit the valve) Replace Replace Replace Replace Replace Replace Refer to fuel system section Replace Replace or repair Replace Replace Refer to lubrication system section.

Defect in engine main body

Hard starting

* Burnt valves * Worn piston, piston ring and/ or cylinder * Damaged or ·cracked cylinder head

Irregular engine operation (Engine missing)

-

Defect in fuel system

Refer to fuel system section

Defect in electrical system

Refer to electrical part section

Defect in engine main body

* Incorrect valve clearance * Sticking or burning of valves * Fatigued or broken valve springs * Carbon accumulation in combustion chamber Defect in fuel system

Rough idling, stalling

Replace Replace or repair Replace

Adjust Replace Replace Remove Refer to fuel system section

Defect in engine main body

* Incorrect valve clearance • Sticking or leaking valves * .Leaking cylinder head gasket Defect in fuel system

Engine noise

Adjust Repair or replace Replace Refer.to fuel system section

Crankshaft and bearing system

'

* Excessive main bearing oil clearance * Seized or spun main bearings * Excessive crankshaft end play * Excessive oil clearance for connecting rod bearings * Seized or spun connecting rod bearings * Wear or seizure of connecting rod bushing

Replace or repair Replace Replace or repair Replace Replace Replace

,.

3-51

Industrial Trucks

ENGINE DISASSEMBLY/ REASSEMBLY

Problems

Possible causes Piston system • Cylinder wear • Wear of piston or piston pin • Seized piston * Stuck or broken piston ring * Bent connecting rod

Engine noise

.

•· · ,.

-·

I ;1 I

I

i

3-52

..

. ,._

Replace Replace Replace Replace Replace

Valve and timing system • Excessive valve clearance • Broken valve spring \< .

• - * Excessive gap between valve stem arid guid�

"

'

I, ,I

Remedy

�

'

Others . . --_, ..... * Defective water p1,1mp bearings_ * Incorrect alternator belt tension or worn· belt * Defective alternator bearings * Exhaust gas leakage '.

• Compression leak past fuel injection nozzle

Adjust Replace Replace

.,

. ..

Replace Adjust Replace Repair Repair

,

Ya Indus 1!'!cks

NOTES.

_-_-_-_-�-_ -___ -_ -_ -_ -_ -__ _ -

______ _

---

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SECTION 4 industrial Trucks

.l

LUBR�CATION SYSTEM

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Yale Industrial Trucks SECTION 4 - CONTENTS LUBRICATION SYSTEM DESCRIPTION

PAGE NUMBER

LUBRICATION SYSTEM DIAGRAM ..................................

LUBRICATION SYSTEM SPECIFICATIONS ........................'...

ENGINE OIL ................ , . . . ............. . . . ...................

ENGINE OIL INSPECTION .... . ...... . ....................... . ...

ENGINE OIL REPLACEMENT INTERVAL ..................... .....

ENGINE OIL FILTEF/ REPLACEMENT INTERVAL ....... : ...........

ENGINE OIL REPLACEMENT. .. . .............. ...................

ENGINE OIL CAPACITY ....'......................................

MAIN AND BYPASS OIL FILTER REPLACEMENT......................

OIL FILTER HOUSING REPLACEMENT ..............................

TESTING ENGINE OIL PRESSURE ........................... : . .....

SPECIAL TOOLS REQUIRED . ........ ................... . ......... .

OIL PRESSURE SWITCH INSTALLATION.................. ...........

OIL PUMP. ...... . .... ................ .................. . ..........

OIL PUMP INSPECTION ............... ................ . .........

OIL PUMP INSTALLATION........................................

OIL COOLER INSTALLATION ILLUSTRATION .........................

OIL LINE AND OIL PIPE INSTALLATION ..................... . ... . . ....

TROUBLESHOOTING GUIDE ................... . ..... . .............

4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-4 4-4 4-4 4-4 4-5 4-5 4-6

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Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

lndust;ia/ Trucks

LUBRICATION SYSTEM

LUBRICATION SYSTEM SPECIFICATIONS Lubricating oil capacity

ENGINE OIL REPLACEMENT INTERVAL 1. Replace the engine oil initially after the first 50 hours of op­ eration on a new or overhauled engine.

Oil pan capacity

7.0 litres/ (7.4 qts)

Delivery pressure (Minimum)

1.5 kg/cm2 @ 680 rpm . 21.3 psi @ 680 rpm

2. R!=)place the engine oil every *200 hours or every *month, whichever comes first. * Normal operating conditions.

Oil pump type

Pressure feed gear pump Full flow filter . (paper filter element)·:

Oil filter type -

.

.

t

.

•

•

,} 1·,

NOTE:·· Use ro�tjrie �ngine oil analysis to determine mainte­ _narice ·intervals during operation under other than normal · conditions. '\. . __.1- -·

'._, , .

.

,- .{ -r·r:- ·.,,

: ..r i; f\•)FNGINE OIL FILTER REPLACEMENT INTERVAL

Water-cooled, built-in type

Oil cooler type

. .

9.3 litre:;s i {9.83 qts) SAE 10W-30 SG /CD SAE 5W-30 SG ICD* *Not for use in temperatures above +60° F

Oil type (See Recommended Fluids Oils and Grease in the truck Maintenance Manual for complete specifications)

I,!

* The amount between F (Full) and L (Low) is approximately 2.0 liters / (2.1 qts)

. -. ,•:�

I

,·"��•.

.

-

' 1' ·1 .. ; : · Replace both the main and bypass filters initially after the .\ . ·· · 'ffrst 5 0 hours of operation . . on a new or overhauled engine. .

i '

ENGINE OIL ENGINE OIL INSPECTION 1. Park the lift truck on a flat surface. Place the gear selector in neutral and apply the parking brake.

2. Allow the engine to run until it reaches normal operating temperature.

NOTE: Use routine engine oil analysis to determine mainte­ nance intervals during operation under other than normal conditions.

ENGINE OIL REPLACEMENT

3. Stop the engine, and wait five minutes.

4. Pull out ,he oil level gauge (dipstick), and verify that the oil level is between "F" (Full) and "L" (low) on the gauge.Check. the condition of the oi\ and,s. �_ rvice if-necessary.

: .....� .;; . ! � i:::<i ..,;·

··;,. Replace both th� i:nain and bypass filters every* 400 hours or every *2 mon\hs, whichever comes first. * No.rmal operating conditions.

"'..

NOTE: Do not operate:th�_'.engine if the oil level is below the

"L" level.

1. Park the lift truck on a flat surface. Place the gear selector in neutral and apply the parking brake. .

:. :�,-'' ,:· _> .

2. Rem�ve the oil filler cap and oil drain plug. Drain the oil into a suitable container.

3. Clean the oil drain plug and the mating surface on the oil pan.

4.

Install the drain plug, using a new gasket.

Tightening torque: 3.0-4.2 kgm / (260-365 lbf in)

5. Install the correct amou�t of the recommended oil.

ENGINE OIL CAPACITY

5. If the oil level is below L, refill with the specified oil.

4-2

Oil pan capacity (At full level)

7.0 litres 7.4 qts

Total engine oil capacity (Including filters, after engine overhaul)

9.3 litres 9.8 qts

Yale

''"i \". -:-:

..... .. .::.

. Industrial Trucks

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LUBRICATION SYSTEM

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6 .. Install the oil filler cap.

TESTING ENGINE OIL PRESSURE

7.

Start the engine, and verify that there ar.e no oil leaks.

SPECIAL TOOLS REQUIRED

a.

Check the oil level.

MAIN AND BYPASS OIL FILTER REPLACEMENT 1. Remove the main oil filter and bypass oil filter using an oil filter wrench.

For main oil filter: commercial wrench For bypass oil filter: special tool 9224473-00 2. Apply a light coat of engine oil on the 0-ring of the new filters.

9125483-40 Oil pres9ure gauge

.

�

For oil pressure inspection

1. Remove the oil pressure switch.

3. Install the filters by hand until the 0-ring contacts the filter housing body. Then, tighten each filter an additional quarter of a turn with the oil filter wrench.

Reference tightening t orque: Main oil filter: 1.8-2.3 kgm . (156�200 lbf in) Bypass oil filter: 2.0-2.5 kgm (174-217 lbf in)

NOTE: Do not over tighten the filters.

(The filters can be damaged.)

OIL FILTER HOUSING REPLACEMENT 1.

2.

Install the oil pressure gauge (special tool 9125483-40).

Install the oil filter housing, using a new gasket.

Tightening torque: 1.9-2.6 kgm / (165-226 lbf in)

4-3

»J/e

Industrial Trucks

·,·:..•.:1 .

'

LUBRICATION SYSTEM

_. -

'

. -:, ',,·:. .

., . ,

3. Run the engine until it reaches normal operating'temperature. Adjust the idle to 680 rpn;i, <;t�d r13ad the,valu� indicated on · · - ··• ., · · · the oil pressure gauge.

3.

Measure the side clearance using a thickness gauge.

Standard value: 0.04-0.09 mm/ {.0016 in) Limit value: 0.15 mm/ (.0059 in)

Delivery.pressure: 1 .5kg/cm2 or more @ 68_().JP.m . .

• .. . . . f ··---0··--'-'-·, -· (21.3 psi or more-@ J>sf -1'irmh-.:..-,-- �-'�_:.�--:_· __ -�<

•.

OIL PRESSURE sWIT�H 1.

'. ?!ff�{t; � iNsriZtA�idf ·-- . . \>�· . �'.'---:...• , .. --=---\...:.

Install the oil pressure switch and reconnec t the wire.

Tightening torque: 1.0-1.5 kgm/(87-130 lbfin)

. <'."\ �=-----\

OIL PUMP INSTALL ATION 1. Apply engine oil to the bearing and rotor gear, and install the assembly into the cylinder block.

Tightening torque: 1.9-2.6 kgm/ {165-226 lbf in)

OIL PUMP OIL PUMP INSPECTION Check the following items, and replace the part if defective.

oil pump components.

1.

Visually check for damage on all

2.

Measure the tip clearance using a thickness gauge.

Standard value: 0.10-0.19 mm/ {.0039 in) Limit value: 0.20 mm/ (.0079 in)

4-4

I_

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

Industrial Trucks

LUBRICATION SYSTEM

TROUBLESHOOTING GUIDE Problems

I'

* Deterioration of oil ., . * Insufficient oil

Replace Refill

Excessive oil consumption

* Wear or sticking of piston ring or piston ring grooves * Wear of piston or cylinder * Defective valve seal * Wear in valve stem or guide

Replace Replace Replace Replace

Oil leakage

Repair

* Insufficient oil * Oil leak • Wear or clamage of oil pump rotor * Wear of plunger (in oil pump body) or fatigue of plunger spring ' . * Clogged oil strainer • Excessive clearance in rriain bearing and connecting rod bearing

Refill Repair Replace Replace

!11i:

Decrease in oil pressure

i

!I I

,1

!

Remedy

Hard starting Engine spins slowly

I ,I

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Possible causes

Oil warning lamp lights during engine operation

I1,

4-6

• Drop in oil_ pressure * Insufficient oil * Defective oil pressure switch * Defective oil level sensor (if equipped) * Defect in electrical system

Clean Repair Same as above Refill Replace Replace Repair

�l�cks Jndustn

NOTES

i

i.1

/

SECTION 5 Industrial Trucks

COOLING SYSTEM

..,... .

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

,

..

I J

I

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Yale

. Industrial Trucks

SECTION 5 - CONTENTS COOLING SYSTEM DESCRIPTION

PAGE NUMBER

COOLING SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE BLOCK COOLING SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . .

THERMOSTAT INSPECTiON ........................................ ..................

WATER PUMP ...................... .............. · WATER PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOT/NG GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-2 5-2 5-2 5-3 5-3 5-3 5-4

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Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

,,- • l

Industrial Trucks

COOLING SYSTEM THERMOSTAT INSPECTION

COOLING SYSTEM SPECIFICATIONS

Cooling system capacity (Complete system)

17 litres (17.97 qt)

Cooling system capacity (Engine only)

9.8 litres (10.36 qt)

T hermostat

,,

82 C ° 180 F

Temperature at which the valve is c9mpletely ,., ope11ed ,.'·

94�·c ° 201 F

Water pump type

'·

I

/

'·g'.fmm · '".- ·-p�5-83 in)

460 mm/(18.1 in)

Fan belt tension (After belt break in) Deflection: @ 10 kg/ {22 lb) pressure.

11-12 mm (.433-.472 in)

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New part

Gasket

I

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7

ENGINE BLOCK COOLING SYSTEM COMPONENTS

I'

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.. ·ce�tfLfugal type

Cobling fan diameter

/r *.

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(1) Remove the mounting bolts, and then remove the ther­ mostat cover.

(2) Remove the thermostat gasket. Remove the thermo­ stat from the thermostat casing.

'<

'

Cooling fan number of blades

Spacer

Removal

°

Temperature at '!Jhich thermostat begins opening valve

Minimum lifting amount of fully open.ed valve

'.J :ii

1.

Water-cooled, V belt driven pump

Cooling method

�-;,;__• ,-

Pulley

-�

-

.

.

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2.

Inspection (1) Visually inspect the thermostat. Check that the valve is closed at room temperature. Replace the thermostat if the valve is not closed prope,rly.

(2) Put the thermostat into water, and gradually heat it.

(3) Check the temperature at which the valve starts to open.

(4) Check the temperature at which the valve is completely open.

(5) Check the amount thermostat valve opens.

(6) Replace the thermostE!t · if it does not meet specifications.

See "COOLING SYSTEM SPECIFICATIONS"

.

Water pump ass'y

.

5-2

'

I

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

Industrial Trucks

COOLING SYSTEM

TROUBLESHOOTING GUIDE Problems

Possible causes

Remedy

Coolant leakage

• Damage to the radiator • Coolant leaking from radiator hose or heater hose • Coolant leaking at the water temperature switch • Defective water pump seal • Lo.ose or darnaged thermostat cover or gasket • Loose cylinder head bolt t Damaged cylinder head gasket � Cracks in _cylind�r block * Cracks in cylinder head

Corrosion

* Foreign matter in the coolant I

Clean

Overheating

* Clogg�d c�oJ�nt passage * Improper th�rr:nostat operation * Clogged radiator fins * Improper water'pump operation * L,oose or qrdken fan belt * Insufficient coolant * Defective radiator cap

Clean Replace Clean Repair or replace Adjust or replace Replenish Replace

Engine not reaching normal operating temperature

* Improper thermostat operation

Replace

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5-4

......

Repair or Replace Repair or replace Repair or replace Replace water pump Repair or replace Tighten Replace Replace Replace

Y al,tcks Jndustr,a

NOTES

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SECTION 6

Industrial Trucks

6

FUEL SYSTEM

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Yale

lndustrial Trucks

SECTION 6 - CONTENTS FUEL SYSTEM DESCRIPTION

PAGE NUMBER

FUEL SYSTEM DIAGRAM .......................................... 6-1 INJECTION PUMP .................... ...................... ....... 6-1 .INJECTION PUMP COMPONENT ILLUSTRATION ................ 6-1 INJECTION PUMP DESCRIPTION .............................. 6-2 GOVERNOR DESCRIPTION ... . ............ ................... 6-2 INJECTION PUMP LUBRICATION DESCRIPTION ................ 6-2 INJECTION PUMP LUBRICATION DIAGRAM ......... ......... . . 6-2 FUEL FEED PUMP DESCRIPTION ............ ................. 6-3 INJECTION PUMP TIMER COMPONENT ILLUSTRATION ......... 6-3 TIMER DESCRIPTION ...................... ........... ....... 6-3 INJECTION PUMP SPECIFICATIONS ........ . ......... ... ..... . 6-4 ENGINE IDLE . . ................... . ............. ......... .. ..... 6-4 INSPECTION OF THE ENGINE IDLE. . ............. ...... .. . .... 6-4 ADJUSTMENT OF THE ENGINE IDLE ....... . . ........... .... .. 6-4 INJECTION TIMING . ................... . .................. .... . . 6-4 INSPECTION OF THE INJECTION TIMING .. ...... ............. . 6-4 ADJUSTMENT OF THE INJECTION TIMING . . ................ . .. 6-5 INJECTION PUMP REMOVAL, REPLACEMENT AND INSTALLATION . 6-8 FUEL INJECTION PUMP ASSEMBLY REMOVAL ................. 6-8 INJECTION PUMP ASSEMBLY AND TORQUE VALUE ILLUSTRATION .......................... 6-10 INJECTION PUMP REPLACEMENT ............................... 6-11 INJECTION PUMP INSTALLATION AND SETUP .................. 6-11 BLEEDING AIR FROM THE FUEL SYSTEM ........................... 6-13 FUEL FILTER ELEMENT,REPLACEMENT ............................ 6-14 FUEL FEED PUMP STRAINER INSPECTION ......................... 6-14 INJECTORS-FUEL ... , ....... , ..................................... 6-15 INJECTOR REMOVAL ........................................... 6-15 INSPECTION OF THE, INJECTORS ...·............................. 6-15 CHECKING INJECTOR STARTING PRESSURE..................... 6-16 CHECKING VALVE SEAT INTEGRITY ............................. 6-16 CHECKING INJECTOR SPRAY PATTERti .......................... 6-16 DISASSEMBLY OF THE INJECTOR ........ : ...................... 6-17 CLEANING OF THE INJf=CTOF{ .... · .''. ............................. 6-17 REASSEMBLY OF THE INJECTOR . ; .... : ......................... 6-17 INSTALLATION OF THE INjECTOR ..... ; ......................... 6-18 · FUEL STOP MECHANISM .. )... : ..'................................. 6-19 FUEL STOP CABLE INSPECT/ON AND ADJUSTMENT .............. 6-20 OPERATION Oi= THE FUEL STOP CONTROL ...................... 6-21 FUEL STOP REiAY CIRCUIT INSPECTION ........................ 6-23 'FUEL STOP RELAY BENCH TEST ................................ 6-24 FUEL STOP MOTOR CIRCUIT INSPECTION ....................... 6-24 FUEL STOP MOTOR BENCH TEST ............................... 6-25 TROUBLESHOOT/NG GUIDE ....................................·... 6-26

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FUEL SYSTEM

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IAGRAM

, : 1 fUEL SYSTEM D t..i � '> 1 rr "

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CAUTION:

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Fuel lines are pressurized

INJECTION PUMP ASSEMBLY

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Feed Pump

INJECTION PUMP INJECTION PUMP COMPONENT ILLUSTRATION Pinion Control rack

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Control lever Full speed adjustment bolt

Idle adjustment bolt

Delivery valve stopper Delivery valve holder

Return spring Cancei spring

Delivery valve spring Delivery valye Plunger_barrel" Fuel inlet Plunger

Supporting lever Supporting lever Floating lever Cancel spring

•ir:�i�����;,'l���:&�=t...--- Torque cam

Control sleeve Plunger spring Pump gear Tappet

Governor spring Guide lever

Tension lever Full load adjustment bolt

Flywheel Camshaft Ttmer spring ___.__,,,�

Governor bolt Full load set lever ldling_spring

Timer housing Flange

· U shaped lever Shifter

Small cam Large cam • Tappet

Flywheel Sleeve Piston spring

·,_'i.·p_rfrning _p�m�

,·}.

6-1

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

Yale

: .� .. i-'. ::-·:-1

.,,.·, . J�dustrial Trucks .

FUEL SYSTEM FUEL FEED PUMP DESCRIPTION The fuel feed pump is a piston type pump installed directly on the injection pump. An addltional cam lobe on the camshaft drives the fuel feed pump piston through a tappet and rod. A manual priming pump is provided to prime the system and to bleed air from the system when required.

Priming pump

n, ,1

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1,.-L-----�---------------J INJECTION PUMP TIMER COMPONENT ILLUSTRATION

Shim Shim

I.

Largecam Smallc

Spring s

·

Pil

[j·

Bolt

Snap ring Shim

Fl

Timer housing

Snap ring Spring washer Nut

.. '

T,IMER DESCRIPTION �

.

.

·: :A.n· eccentric cam type (centrifugal advance)ai.Jtoma tic timer,· i' SCDM type, is used on the injection pump. The injection timing

�omponents are located on the front of the injection pump.

6-3

Yale

Industrial Trucks

FUEL SYSTEM

INJECTION PUMP SPECIFICATIONS Model

Cam lift

I ,

Plunger diameter

Governor type

Injection timing adjustment method

Nozzle 11 11,I

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Starting injection pressure

In-line Bosch type, A type 9.0 mm I (.3543 in)

q> 9.5 mm/ (.37 4 in) Centrifugal type

Centrifugal type

Injection order Idle speed

Injection timing

200 kg/cm2 (2845 psi) 850±25

BTDC 9

°

INSPECTION OF THE ENGINE IDLE

(1) Apply a piece of reflective tape on the crankshaft pulley or flywheel. (Follow the tachometer manufacturers instructions for surface preparation and installation of the tape.)

(2) Warm up the engine.

(3) Check the accelerator cable adjustment at the fuel injec­ tion pump. T he throttle arm on the fuel injecti?n pur,p must be allowed to completely return to the idle position.with the'-accel­ erator pedal in the full up position. The throttle ·a rm 6n the, fuel _ injection pump must move to the full speed position with the accelerator pedal in the full down position.

,,

I,:

INJECTION TIMING

1-3-4-2

ENGINE IDLE

(4)

.-� .. .-·, '

Multiple hole type

Idle the engine.

(5) Point the photoelectric tachometer at the tape and check the idle speed.

(6) Another method that can be used is to set the tacho-dwell tester (P/N 9125483-58), or equivalent on the fuel injection pipe, to check the idle speed.

Idle speed: 825-875 rpm

,

NOTE: The inje�tion timir,g is very critic�:! in a direct injection engine. Incorrect. adjustment can cause in�reased engine noise (knock) anc:i'/ or power loss: Always check the injection timing after installing the pump, and verify that it is correct.

The actual injection timing is 9 • BTDC, but the inspection and adjustment mUst carried out with the following method.

NOTE: Before inspecting the injection timing, verify that the

timing marks on the timing gear case and injection pump flange align.

INSPECTION OF THE INJECTION TIMING 1.

Remove the floor plate.

2. Rotate the flywheel forward (CCW), and set the indicator ° pin to 30 BTDC.

NOTE: Northai engine direction of rotation (forward rotation) is counterclockwise viewed from rear of engine/ flywheel.

. NOTE: The number 1 cylinder must be on the compression . , ·stroke, during this procedure. This can be verified with the use ·• of a compression gauge or by ensuring that both the intake and _the exhaust valves are closed with the number 1 piston at Top Dead Center.

-'., . ,)

ADJUSTMENT OF THE ENGINE IDLE

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(1) If the idle speed is not within the specified range, loosen the idle adjustment bolt lock nut ori the top of the injection pump. Turn the bolt to adjust the speed.

(2) Tighten the lock nut after adjustment.

(3) Accelerate the engine, S!3Veral times, and verify that the idle speed is within the standard value.

Tightening torque: 1.0-1.4 kgm/ (87-122 lbf in)

6-4

'----

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·. , , Yale Industrial Trucks

FUEL SYSTEM 3. Loosen the number 2,3 and 4 injector fuel lines at the pump side

.... j

:l Transmission Housing , I: ,3. Remove the cover froni the timing' gear case on the pump �ide. Verify that th.e marks on the case and timer circumference _ .'are aligned.

I'.

· ·: 4. Remove the number 1 injector fuel line, and remove the de­ livery valve holder.

Timing gear case

'

If they match, the number 1 _ cylinder is set at 30 ° BTDC, and the ° injection timing is correct. (Injection pump timing is ·s et at 9 l -�TDC.) ° : , ,_,, '1 �Maximum allowable variation: ±2 : ·'

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' !:w, 'ADJUSTMENT OF THE INJECTION TIMING 1. Remove the fuel stop cable from the fuel stop bracket and _ .. from the fuel stop arm at the fuel injection pump.

2.

Remove the fuel stop bracket from the injection pump.

5.

. .

Remove the delivery valve stopper and spring.

J;\_

CAUTION: Do not move the delivery valve body � when removing the above parts.

Delivery valve body

Barrel

6. Position the delivery valve body at an angle to one side in order to break the surface tension between the delivery valve body and the plunger barrel.

6-5

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

'

·ya/e

· · . _ 1ndi.Jstrial Trucks

FUEL�YSTEM

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manu_ally (by �a�d) rotate the fly".'lheel forward · .. _,12 . Sl_owly, : I,'.: )ccW) while p�mping the priming pump, and verify that the fuel 9 BTDC. :',,,,'' ..>.flow stops at 'i•

11

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3. To adjust the injection ti�ing, loosen the four injection .pump mountin g nuts and the governor bracket. Turn the pump position where the fuel flow stops. ' · -,-:I , I, iunit to the ,·

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right (looking from fan) · ,:i '��••whe •· . . n. early -Turn ·'

i h�n late, - Tum left (loo.king f�om fan) � _ _

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18. ln�tall the number 1 injector fuel line.

Tightening torque: 2.5-3.0 kgm / (19-22 lbf ft)

19. Tighten the number 2, 3 and 4 injector fuel lines (pump side).

Tightening torque: 2.5-3.0 kgm / (19-22 lbf ft)

\ •

' 14. Tighten the nuts after adjustment.

Tightening torque: 3.5-4.0 kgm / (35-25 lbf ft)

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15. Mark the pump flange and pump body.

16.

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Reassemble the delivery valve, spring and stopper.

�� Stopper �

t

Spring

fit-

Delivery valve

· 17. Tighten the delivery valve holder to the specified torque.

Tightening torque: 4.0-4.5 kgm / (29-33 lbf ft)

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20.

21.

Install the fuel stop bracket.

\

Install the fuel stop cable to the fuel stop arm.

22. Turn the ignition switch on to energize the fuel stop motor.

Pull the fuel stop cable housing to extend the fuel stop cable completely. Install the cable housing on the fuel stop bracket.

Check ,t_he adjustment of the fuel stop cable. See: " FUEL

STOP CABLE INSPECTION AND ADJUSTMENT".

23.

Install the cover on the timing gear case.

:?4.. Bl,eed the �-ir fro�'thE! fuel system. See: "BLEEDING AIR FROM.THE FUEL SYSTEM" for the complete procedure.

1

6-7

.

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

·.Yale 1 , ; Industrial

·-�

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Trucks

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FUEL SYSTEM

Transmission Housing

7. Remove the access cover on the timing gear case (located bn the pump side). Verify that the markings on the timer circum­ ° ference and the peep hole notch match. (30 BTDC) ° Maximum allowable variation: ±2 .

··,:NOTE: If the markings do not match, the number 4 cylinder ° instead of the number 1 cylinder, may be set at 30 BTDC. Re­ peat the procedure starting from step number 6.

&

8. Remove the fuel injection pump with the procedure'J�own on the following page.

WARNING: The fuel injeqtion pump is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capai;:ity to litt the fuel injection pump. The fuel injection pump can weigh approximately 17 kg (38 lb). .

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Remove the injection pipe, fuel pipe and oil pipe, etc. Remove the injection pump and timiog gear case installation bolts and nuts, and then, remove the injection pump assembly.

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NOTE: Cover the intake manifold and injector fuel lines so that · • foreign matter cannot enter.

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NOTE: . Do not crank the engine after removing the pump.

l 6-9

!ii

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 269 673 1638

. iYale

�-

·-·

us..trial Trucks �1., (Ind ,.,

;&·J :

FUEL SYSTEM

·•;. INJECTION PUMP REPLACEMENT .,,: � .

•1-

WARNING: The fuel injection pump is heavy. Be sure that all lifting devices (hoists, cables, chains, ( -�"' '• · slings etc.) are suitable and of adequate capacity , . 'to ptt th� fuel injection pump. The fuel injection pump can weigh ,ii lb). ,approximately 17 kg (38

._ ...,; :,':" .i," '

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NO :

,!rr TE Always use a protector over the jaws of ·the vice as . . n in the illustration. r.show

1. Clamp the injection pump timer in the vice, and remove the · • ·•timer·fastening bolt. l .

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6... Insert the woodruff key \nto the pump shaft. Install the timer and gear assembly on the pump shaft.. . ' ..

2. Remove the timer and gear assembly from the pump as­ sembly 3. ·Remove the woodruff key from the pump shaft.

7. Temporarily tighten the timer retaining bolt. Clamp the tim­ er in the vice, and tighten the bolt to the specified torque.

Tightening torque: 6.0-7.0 kgm / (43-51 lbf ft)

INJECTION PUMP INSTALLATION AND SETUP 1. Installation is.the reverse of removal. Install the fuel injec­ tion pump by using the removal procedures in reverse. The fol­ lowing NOTES, and PROCEDURES must be followed during install?1tion.

NOTE: The injection pump timing must be adjusted after the

.. Remove the flarige plate.

5. Clamp the replacement injection pump in the vice. Install the flange plate. Aligri the marks on the punip and flange plate.

Tighten the four nuts to the ,specified torque.

Tightening torque: 3.5-4.0 kgm / (35-25 lbf ft)

injection pump is installed. The 'injection timing is very critical •in a direct injection engine. Incorrect adjustment can cause in­ creased _engine noise (knock) .and / or power loss. Always check the injection timing _after installing the pump, and verify . that it is correct: See: "INSPECTION AND ADJUSTMENT OF

TIMING;' ... .THE . INJECTION . .

·,

NOTE: The air must be bled frorn the fuel system after the in­ jection pump is installed. See: "BLEEDING AIR FROM THE FUEL SYSTEM".

6-11

Yale

(

Industrial Trucks

FUEL SYSTEM

NOTE: The engine idle speed must be adjusted after the injec­ tion pump is installed. See: "IN.SPECTION AND ADJUST­ MENT OF THE ENGINE IDLE" ..

- . ��

NOTE: Before installing the injection pump or inspecting the ;�.

injection timing, verify that the 'timing marks on the injection pump case and injectior, pump flahg� are aligned.

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NOTE: Helical gears are used. Take care to prevent misalign­

ment during installation into the timing gear case. The pump timer 30' BTDC mark must align with the timing gear case 8ointer, when the pump is installed in the timing gear case.

4. Install the timing gear case bolts and hand tighten to draw ' the pump flange against the timing gear case. Verify that the r mark on the pump timer circumference aligns with the timing gear case pointer. Check 'alignment through the timing gear case access hole.

Maximum allowable variation: ±2 ° .

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2. Using the flywheel indicator pin, verify that number 1 cylin­ ° der is at the 30 BTDC position on the flywheel side before as­ sembling the injection pump.

5. Tighten the timing gear case bolts.

Tightening torque: 1.9-2.6 kgm / (165-225 lbf in)

'I

6. Install the injector fuel lines. Install the remaining fuel lines.

Complete installation by referring to the "INJECTION PUMP REMOVAL PROCEDURE" and reinstalling the remaining parts in the reverse order of removal.

7.

Adjust the injection timing. See: "INSPECTION ANO AD-.· JUSTMENT OF THE INJ.ECTION TIMING" . .

3. Install a new O-ring on the injection pump housing plate.

Align the notches on th.e flange plate and gears. Install the injec­ tion pump into the timing gear case.· ' ;. t

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6-12

'

8. Install the accelerator cable and fuel stop cable. Check the accelerator cable adjustment at the fuel injection pump. The throttle arm on the fuel injection pump must be allowed to com· pletely return to the idle position with the accelerator pedal in the full up position. The throttle arm on the fuel injection pum� must move to the full speed position with the accelerator pedal in the full down position.

9. Install the air cleaner bracket and stop motor bracket. Ad­ just the fuel stop cable. See: "I=UEL STOP CABLE INSPEC .TION AND ADJUSTMENT" for adjustment procedures on th fuel stop cable.

10.

h:1�tali'the fuel filter �nd air cleaner.

Yale

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strial Truc . 'iJndu .

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,

FUEL SYSTEM

BLEEDING AIR FROM THE FUEL SYSTEM NOTE; For correct engine operation, always bleed the fuel

Overflow valve

system after the following procedures: d a. When th� fuel filter cartridge is replace . is �trainer _ cleaned. pump feed b. When the fuel is emptied during truck fuel tank operation. the •c. When ·· (Truck runs out of fuel) d. When the sedimentor (optional) is cleaned or drained.

•..

, 1. Loosen the air vent plug on the top of the fuel filter body.

I )--------------:----------,

Air vent plug

5. After bleeding the air �ut of ihe fuel filter and injection plug, press down the top of the prirning pump plunger, and tighten it securely. fuel tilter

2. Loosen the top of the priming pump (unscrew the pump plunger). The priming pump is located on the side of the fuel injection pump.

CAUTION: If you forget to tighten the priming pump plunger after completing the air bleeding process, fuel leaks can occur and / or the fuel injec­ tion pump can receive an insufficient fuel supply. A loose prim­ ing pump plunger can cause a hazardous situation (fuel leaks, fire hazard) or result in improper engine operation (low output, stalling, rough idling). Always push down the priming pump plunger and tighten it securely after completing the bleeding process.

6. After completing air bleeding, verify that no fuel is leaking from the air vent plug or the overflow valve.

7. Lo6seh the four flare nuts·on the injection nozzle side of the injector fuel lin.es.

'•

.

---------

3 .. Pump the priming pump plunger until f\Jel without air bubbles is discharged froin�he air V�IJ� P.Lug on t'�� fuel filter body. Close the air vent plug ori th'e fuel filter body.

Tightening torque: 0.6-0.9 kgm / (52-78 lbf in) Next, loosen the injectioh pump's o��rflow valve, and pump . the priming pump plunger until fuel without air bubbles is discharged from the overflow valve. Close the overflow valve.

Tightening torque: 1.2-1.5 kgm/ (104-130 lbf in)

-

.

.

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)

8. Crank the engine until fuel without air bubbles is discharged from the injector fuel lines.

NOTE: Do not crank the engine for extended periods without allowing the starter to cool.

9. Install the injection fuel lines.

Tightening torque:2.5-3.0 kgm / (217-260 lbf in) 6-13

»lie

Industrial Trucks

FUEL SYSTEM

&

1 O. Start the engine and verify that there are no fuel leaks.

,·

WARNING: bo· ·not use your hand to check for high pressure leaks. High pressure fluid can pene­ trate the skin and may cause toxic symptoms if it enters the blood system. Use a piece of cardboard or paper next to high pressure lines ai,9 fittings to check for leaks.

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.

.

FUEL FILTER ELEMENT REPLACEMENT ·. ..

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WARNING: Diesel fuel is flammable. Make cer­

tain therfare_ no ignition sources (sparks, open flames, etc:) in the area during this procedure. .

.

.

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righten t /3 of a turn

.

Remove the filter element with an oil filter wrench.

4. ,. Bleed the air from the filter. See: "BLEEDING AIR FROM

THE FUEL SYSTEM",

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Fuel strainer (in eyebolt)

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2. Apply a thin coat of light oil on the 0-ring of the replacement filter.

Replacement period: Replace the elernent cartridge approximately once every six months or every ,1200 hours . . ,. �

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.

FUEL FEED PUMP STRAINER INSPECTION 1. Remove the strainetfrom the inlet of the fuel feed pump (lo­ cated on the side of irijedion pump). Clean it with solvent and compressed air. Rerriove all traces of the cleaning solvent and dry completely i;>efore reinstallation.

2. Replace the t�o g�skets with-�ew ones when reinstalling the strainer. ligh�!:ming torque: 2.0-2.5 kgm / (174-217 lbf in) •

3. Install the filter element on the filter body. lighten it by hand until the 0-ring contacts the filter body. Tighten the filter another 1/3 of a turn with the oil filter wrench.

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3. · Bleed the airjn the fuel after installing the strainer.

See: ;'BLEEDfN<fAIRF=ROM THE FUEL SYSTEM".

4.

Start the engiri�, and verify that there are no fuel leaks.

Fuel Feed. Pump Strainer Periodic cleaning and inspection: Once a month or every 20C hours.

6-14

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 2696731638

»lie

FUEL SYSTEM

Industrial Trucks

CHECKING INJECTOR STARTING PRESSURE 1.

Install the nozzle on the nozzle tester.

2.. If there �re fu�l-leak�, disassemble and clean the nozzle. .:Then, reinspe�,t_the·valve seat integrity (oil tightness). Replace -· t�e injector if necessary.

2. Pump the nozzle tester's Ii andle several times to bleed the '.\,: ·:. :· 'CHiCKING INJECTOR SPRAY PATTERN air from the injector and the tester. . 1. Remove or·. disable the pressure gauge on the injector 3. Gradually lower the nozzle tester handle and verify that the tester. (The procedure varies between nozzle testers.) Install injector opens at the proper pressure. the nozzle on the nozzle tester.

Injection starting pressure: New injector: 21 0 kg/cm2 / {2987 psi) Used injector: 200 kg/cm2 / (2845 psi) 4. If the injector starting pressure is not the specified value, adjust the pressure by shimming, and then retest the injector as previously described.

NOTE: 21 sizes of shims from 0.5 to 1.5 mm / {.0197 to .0591

in) are available in 0.05 I (.00197 in) increments. The injection · pressure will change approximately 5 kg/cm2 / (71.1 psi) with each 0.05 mm I (.00197 iri) size change.

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I

NOTE: The pressure gauge must be disabled or removed from the nozzle tester for this test to be accurate. If the gauge is removed, be sure to install a plug in its place.

2. Pump the handle on the nozzle tester several times to bleed the air from the injector and the tester.

3. Rapidly pump the handle on the nozzle tester. (Pump the handle quickly so that a whistle like sound is heard.)

4. Repeat this procedure several times and check the spray pattern. * Is the mist equally vaporized? * Is the mist sprayed in the proper direction?

.

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Correct

Wrong

Wrong

CHECKING VALVE SEAT INT�GRITY 1. While applying a pressure 20 kg/cm2 / (284 psi) lower than the specified fuel injection pressure, make sure that no fuel leaks from the nozzle injection port.

6-16

5. If the spray pattern is improper, disassemble and clean thf nozzle. Reinspect the spray pattern after cleaning. Replace the injector if necessary.

'1 .

\tJ/e

Industrial Trucks

FUEL SYSTEM

DISASSEMBLY OF THE INJECTOR hol er in the vice as shown in the illustra­ 1. Clamp the nozzle � _ ing nut. retain the ve remo and tion,

NOTE: Alway s use a protector over the jaws of the vice as

1 shown in the

illustra tion.

3.

• l

Inspect all parts for wear and damage.

4. Carefully inspect the- nozzle body valve seat and the needle valve for damage. Place the needle valve in the nozzle ° body, tilt the body up 60 and check for binding (verify that the weight of the' needle valve will cause it to slide to the seat).

Disassemble as shown in the illustration.

2.

3

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I

7

______________________

,··, ,.__ 1.

;

Retaining nut 2. Nozzle body (seat) 3. _ Guide pin 4. Needle valve 5. Spacer 6. Spring seat 7. Pressure spring 8. Shim 9. Nozzle holder

REASSEMBLY OF THE INJECTOR 1.

Assemble the parts in reverse order of disassembly.

Tightening torque: 3.0-4.0 kgm / (260-347,lbf in)

i I

:1

l

CLEANING OF THE INJECTOR 1,

;! j 2. )

'

L,

.

Clean the parts with fresh diesel fuel. Start with the nozzle.

I

Clean any carbon off the nozzle with carburetor cleaner.

Use a piece of hardwood to polish the nozzle if necessary.

2. Always check the starting injection pressure, valve seat integrity (oil tightness) and spray pattern after assembly.

6-17

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·1 I

Yale Industrial Trucks

FUEL SYSTEM

INSTALLATION OF THE INJECTOR NOTE: Always replace the gaskets and O-rings with new parts when reassembling the injector.

1.

Install the parts using the removal procedure in reverse.

Tightening torque: 4.7-5.5 kgm / {34-40 lbf ft)

�-

.

I'

2.

\

.

c! ct)

. . :..

.

--=•..____,,..,

Start the engine and check for compression and f uel leaks.

WARNING: Do not use your hand to check for

high pressure leaks. High pressure fluid can pene­ trate the skin and may cause toxic symptoms if it enters the blood system. Use a piece of cardboard or paper next to high pressure lines and fittings to check for leaks.

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6-18

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Ya l e

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_ Industrial Trucks I

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FUEL SYSTEM

•

FUEL $TOP MECHANISM An electric fuel stop mechanism is used for the in-line injection · _ pump on the TM engine.

When the ignition switch is turned from "ON" to "OFP', the fuel stop motor operates. The fuel stop lever on the injection pump is moved, and the fuel supply is stopped.

Stop lever

,('

; ,

✓-

Fuel stop Governor unit

Fuel stop motor

:

..

Stop device lever

Cover set

Bolt set

Holder set Fuel stop motor -

Bracket

Spring set

Hose

6-19

Yale

Industrial Trucks

FUEL SYSTEM

FUEL STOP CABLE INSPECTION AND ADJUSTMENT 1. Check that the fuel stop cable is not rusted, frayed, kinked or damaged in any way. Check that the fuel stop cable moves freely inside the cable housing. Replace the fuel stop cable assembly if any binding or defects are found.

2.

Check the fuel stop cable's tension. See: Step (3).

NOTE: Inspect the tension with the ignition switch "ON".

(Fuel stop lever in the "FUEL ON" position)

3. Use the following procedure to replace or adjust the fuel stop cable.

(1) Install the cable at th� switch "ON".

fu'ei stcit motor and tu��·t,ti� · \gn�ion · •:· ·

· · -: -�-.-

.

1

(2) Install the cable end on the _fuel stop lever. Install the snap . . ,:. , pin (retaining clip).

;J:· .- � .· · _

.

NOTE: It may be necessary to manually extend the fuel stop cable in order to attach the end of the cable to the fuel stop lever on the injection pump. The ignition switch must be "ON" in order to extend the fuel stop cable.

( 4) Manually move the fuel stop lever and verify that the lever travel is not limited or restricted by the fuel stop cable. The fuel stop lever must be allowed to return fully to the "FU EL ON" posi. .. tion with the cable extended (ignition key "ON"). ·,; n:.• .

(5) Check that the fuel stop cable moves smoothly by cycling the ignition switch "ON" and "OFF'. Recheck that the fuel stop arm is allowed to return completely to the "FUEL ON" position with the ignition switch ON. Check that the fuel stop arm is moved to the "FUEL OFF" position and that the engine stops when the ignition switch is moved to the "OFF" position .

,

.

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(3) Install the cable housing in the stationary bracket. Adjust the cable to allow approximately 3 mm/ (.12 in) deflection with light pressure applied to the cable as shown in the illustration.

Tighten the cable adjustment �ut

"N.

NOTE: Do not over tighten the stop cable. 3 mm / (.12 in)

deflection with the ignition switch "ON" is necessary for proper . . · · · . , operation. .. . /,.

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FUEL SYSTEM

ON OF •.THE FUEL STOP CONT 'bPERATi . ]ir

ROL

�•

·· .

ENGINE OFF F _OF H ITC SW N IGNITIO FUEL STOP RELAY COIL DEENERGIZED .· •..

FUEL STOP MOTOR OFF SED CLO ER �EV ,FUEL STOP -,FU.EL OFF ON OFF ·. '- I

(§)

Battery

ENGINE OFF IGNITION SWITCH TURNED FROM OFF TO ON FUEL STOP RELAY COIL ENERGIZED FUEL STOP MOTOR OPERATING FUEL STOP LEVER CLOSED, MOVING TO OPEN FUEL BEING TURNED ON

,.,..-• N

.

OFF

1Gs�itch

Battery

:

9

([) IGswitch

',-----------.,'

1 2

.

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0--1 I

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___ J_

-j�

----------- I

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6

_______ _i

==--

White White/Red 3. Blue/White 4. Black

5.

6.

1.

2.

,

. . ) 1Jq:-i, ,,. . '. . . ' ,

7.

.

i\iVhen tlie ignition switch is OFF:

Red Motor Latch Switch Relay Contacts

. 0.:: .

·r·i u,l1, •· The fuel= stop lever is stationary in the 1 cilosed position

· :, .,, ..

(FUEL OFF).

The fuel stop cable is stationary and fully retracted.

(FUEL OFF position.)

3. The fuel stop relay coil is deenergized. .\ !, · ;• 4. The fuel stop motor is not operating (stationary). ) li;; n · 5. The fuel stop motor is now connected to the "A" terminal (battery-) and the "B" terminal (battery-). The "D" terminal is not connected to the fuel stop motor circuit,

). · ••' · · 1 2.

J' ,,,: ' ·,

..:i-:�

Fuel stop relay

Fuel stop motor

4

Fuel stop motor

1.

White

2. White/Red 3. Blue/White 4.

\4'�-�

Black

3

>C.-

_,

COM. _ ____ j

5

Fuel stop relay 5.

6.

7.

Red Motor Latch Switch Relay Contacts

· · Wh.en ttie ignition switch is turned from OFF to ON:

1. · The fuel stop lever is initially in the closed position (FUEL OFF) {IGNITION SWITCH OFF).

2. The ignition switch.is turned on and the fuel stop relay coil is energized.

3. The relay's normally open contacts switch from open to closed and supply battery (+) to the fuel stop motor "A" ter• • ·• minal. i· · '· · · 4. The fuel stop motor is now connected to the "A" terminal (battery+) and the "8" terminal (battery-). The "D" terminal is not connected. The circuit is complete and the fuel stop motor operates to extend the fuel stop cable.

5. The fuel stop lever begins moving from the closed (FUEL OFF) to the open (FUEL ON) position.

6. The fuel stop cable extends completely. The latch switch in the fuel stop motor moves and changes the motor connec­ tion points.

7. Battery(+) is now supplied to both sides of the fuel stop mo­ tor and it is stops operating. The fuel stop motor circuit is now connected to the "A" terminal (battery+) and the "D" terminal (battery +). The "B" terminal is no longer con­ nected to the fuel stop motor circuit.

6-21

»lie

Industrial Trucks

FUEL SYSTEM ENGINE ON IGNITION SWITCHED TURNED FROM ON TO OFF FUEL STOP RELAY COIL DEENERGIZED FUEL STOP MOTOR OPERATING FUEL STOP LEVER <;:>PEN, MOVING TO CLOSED FUEL BEING TURNED OFF

ENGINE ON IGNITION SWITCH ON FUEL STOP RELAY COIL ENERGIZED FUEL STOP MOTOR OFF FUEL STOP LEVER OPE� FUEL ON

OFF

. . - (]) IG switch

Battery

1

2

�-----------,

r+--01 1- ! -� ---·-.

-

! -�

:

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oOFF

·

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ON l----'

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,---------"'I

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1_,-___,:.! _____ 3

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________ i \ : ___________ j '

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3

Fuel stop motor 1.

2.

3.

4.

�

2

I

White White/Red Blue/White Black

5

Fuel stop relay 5.

6.

7.

Red Motor Latch Switch Relay Contacts

! i ----;���-!

l______

, .

IG switch

I

1

I

---------,

. (§)

Battery

''I ---------- - I 1

L ______ J

6

ON OFF ,�1

9N

ON

-1 '

l _____ ______ J

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3

------7

-·-;..----, I I I

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6

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--------� \ L __________ �

..::'i=�==--4

Fuel stop motor 1. White 2. White/Red 3. · Blue/White 4. Black

3

5

Fuel stop relay 5.

6.

7.

· When the ignitio[l �wit�h is 9N:

When ignition switch is turned from ON to OFF:

The fuel stop lever is stationary in the open position (FUEL ON). '. .. ·,.' ,, .· 2. The fuel stop cable is stationary and fully extended.

(FUEL ON position.) ...

3. The fuel stop relay coil is energized.

4. The fuel stop motor is not operating (s1ationary).

5. The fuel stop motor is now cqnnected to the "A" terminal (battery+) and the "D" terminal (battery+). The "B" termi­ nal is not connected to the fuel stop motor circuit.

1. The fuel stop lever is initially in the open position (FUEL ON) (IGNITION SWITCH ON).

2. The igriition switch is turned off and the fuel stop relay coil is deenergized.

3. The.relay's norma.lly open contacts switch from closed to open and supply battery(-) to th_e fuel stop motor"A" termi­ nal.

4. The .fuel stop motor is now connected to the "A" terminal (battery-) and the"D"terminal(battery+). The"B" terminal is not connected. l;he circuit is complete and the fuel stop moto_r operates t9 retract the fuel stop cable..

5. The fuel stop lever begins moving from the open (FUEL ON) to the closed (FUEL OFF) position.

6. The fuel stop cable retracts completely. The latch switch in the fuel stop motor moves and changes the motor connec­ tion points.

7. Battery(-) is now supplied to both sides of the fuel stop motor and it is stops operating. The fuel stop motor circuit is now connected to the "A" terminal (battery-) and the "B" terminal (battery -). The "D" terminal is no longer con­ nected to the fuel stop motor circuit.

1.

6-22

· 1

Red Motor Latch Switch Relay Contacts

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'. J.i..,,Industrial Trucks I

J

•-

FUEL STOP RELAY CIRCU

IT INSPECTION

Verify that battery volts is present at the relay normally wire). If the correct voltage is not present, op· en terminal (White .. . . d wiring and associate link fusible check the 1

NOTE: It is necessary to isolate the fuel stop relay from the fuel stop motor to properly perform test four (4) and test five (5).

Isolate the relay from the motor by disconnecting the three wire connector at the fuel stop motor OR by removing the red wire from the common terminal on the fuel stop relay connector as illustrated. Insulate the red wire to prevent a short during the test procedure.

4. · With the ignition switch "OFP', verify that there is a continu­ ity between the relay common terminal (where red wire was connected to the relay) and battery (-) (ground). If continuity is not present the relay may be defective.

Relay Corr1mon Terminal (Test here)

..,.

!

�'.ii Turn the ignition switch "ON" and verify that battery volts is

;f� �=�nwire

present at the relay coil(+) terminal (Blue/White wire). If the cor­ rect voltage is not present, check the main fuse, ignition switch and associated wiring.

disconnected from relay

..,.

5. With the ignition switch "ON", verify that battery volts is present at the relay common terminal (where red wire was con­ nected to the relay). If the correct voltage is not present, the relay may be defective.

Blue/White

Relay Common Terminal (Test here)

..,.

;, r

Voltmeter

3. Verify that there is a continuity between the relay coil (-) terminal (Black wire) and battery(-) (ground). Verify that there is continuity between the relay normally closed terminal (Black wire) and battery(-) (ground). If continuity is not present check · the associated wiring.

Black

;f� �=�nwire

disconnected from relay

..,.

6.

Turn the ignition switch off and reconnect the red wire.

Whit

Red ��

Black

---4W#�

7

Blue/White Black

6-23

I

Yale

Industrial Trucks

FUEL SYSTEM 3.

FUEL STOP RELAY BENCH TEST

Verify that the voltmeter indicates battery voltage.

1. Remove the fuel stop relay and unplug it from the wire har­ ness connector.

2. Check the continuity between the c�mmon and normally closed terminals. If there is no continuity, replace the relay.

· h :.

Corii�bn Coil (+) Nor�a·11�' open

I"

i ::

Fuel-'stop relay ;-;-

Normally closed ' No· t used

,, ! '· 'i

Coil(-)

4. If the correct voltage is r,ot present, check the associated wiring and the fusible link.

5. Check the continuity at the truck wire harness connector between the black wire and batte''iy (-) (ground). If there is no continuity, check the associated wiring.

3. Check the continuity between the coil (+) and the coil (-) terminals. If there is no continuity, replace the relay.

4. Connect a fully charged 12 volt battery to the relay coil.

Connect the battery positive(+) terminal to the coil(+) terminal, and the battery negative (-) terminal to the coil (-) terminal.

5. With the relay coii energized, check the continuity between the common and the normally open terminals. If there is no con­ tinuity, replace the relay.

Common . ·::.., Coil(+) ·� �-formally open :

6. Connect the voltmeter at the truck wire harness connector between the red w\re and ground (battery-).

Fuel stop relay -

: Battery

+

l.i

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,.I. I ,,.' .

FUEL STOP MOTOR CIRCUIT tINSPECTION �

.

1. Unplug the fuel stop motor wire harness connector(located at the fuel stop motor).

2. Connect the voltm·eter at the truck wire harness connector between the white wire and battef"/ (-)(ground).

6-24

} 7. Verify that the voltmeter indicates battery voltage with the ignition switch "ON" and zero (0) volts with the ignition switc�.

"OFF".

. .. ------ ----==,=--=......., ----!!!!!!!!!!!!!�=

·Yale

- Industrial Trucks t,.., l; •• ! - .

FUE:L SYSTEM

a. If the correct voltage is not present, check the fusible link, fueJstop motor relay, ignition switch and the associated wiring.

1FUEL �TOP MOTOR BENCH TEST 'NOTE: Used a fully charged battery to test the fuel stop motor.

Make allthe connections at the fuel stop motor connector as il•lustrated.

11. Verify tha_� the key switch is "OFF". Remove the k�y from ithe key s_'Nitqh to_ prevent accidental starting. Unplug the fuel _ l�to_p motor w.ir� harness connector.

I

.

,. -

i2:'· conn�ct-the battery positive(+) terminal to the blue/white 1 \wire, and tb_e,,battery negative (-) terminal to the black wire. -'

e 3. Verify that the motor extends the cable completely. If the motor does not operate, repair or replace the motor. , 4. Connect the battery positive {+) terminal to the white/red - i,, wire, and the battery negative (-) terminal to the blue/white - ·5. · Verify that the motor retracts the cable completely. If the motor does not operate, repair or replace the motor.

e

6-25

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I

Yale

Industrial Trucks

FUEL SYSTEM

TROUBLESHOOTING GUIDE Problems Engine Difficult to Start

Incorrect Engine Idle

I.

Excessive Engine Noise (Engine Knocks)

-

Possible Cause of Problem

Correction

Causes related to fuel filter * Clogging or water in the fuel * Air in the fuel Causes related to the fuel injection pump * Defective fuel stop lever position * Defective fuel stop cable * Air in the fuel * Incorrect injection timing * Defect in the pump Causes related to injection nozzle * Seizure of the needle valve * Fuel drips fro111 the ngzzle * Incorrect valve opening pressure * Incorrect the air heater operation Causes related to fuel filter * Clogging or water in the fuel * Air in the fuel Causes related to the fuel injection pump * Defective fuel stop lever position * Defective fuel stop cable * Air in the fuel * Incorrect injection timing * Defect in the pump Causes related to injection nozzle * Seizure of the needle valve * Fuel drips from the nozzle * Incorrect valve opening pressure * Incorrect nozzle holder tightening Causes related to the fuel injector-'lines * Fuel leakage from the lines * Fuel leakage from the connections Incorrect adjustment of idle adjusting bolt Causes related to injection pump * Incorrect injection timing Causes related to injection nozzle * Incorrect valve openi,ng pressure (too low) * Seizure of the needl� valve * Fuel drips from the nozzle * Use of incorrect fuel

Replace.

Repair and bleed Adjust Replace Repair and bleed Adjust Replace Replace Replace Adjust Repair or replace Replace Repair and bleed Adjust Replace Repair and bleed Adjust Inspect and repair or Replace Replace Replace Adjust Re-tighten Replace Repair or replace Adjust Adjust

..

•

Adjust Replace Replace Replace

\ \

6-26

I

FUEL SYSTEM Problems Excessive fuel consumption

'. Poor acceleration

Possible Cause of Problem Causes related to injection pump * The full-load adjusting screw seal is removed * Incorrect injection timing * Incorrect idling speed (too high) Causes related to injection nozzle * Incorrect valve opening pressure (too low) * Fuel drips from the nozzle * Fuel leaks from the connections * Clogged air cleaner Causes related to injection nozzle * Incorrect valve opening pressure (too low) * Seizure of the needle valve * Fuel drips from the nozzle * Defect in the pump Causes related to injection pump * Defective fuel stop lever position * Defective fuel stop cable * Air in the fuel * Incorrect injection timing Causes related to fuel injector lines * Fuel leakage from the lines * Fuel leakage from the connections Causes related to fuel filter * Clogging or water in the fuel * Air in the fuel

Correction Repair Adjust Adjust Adjust Replace Replace Replace Adjust Replace Replace Inspect and repair or Replace Adjust Replace Repair Adjust Replace Repair or replace Replace Repair

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6-27

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· ,Yale

SECTION 7

· 1Jndustrial Trucks

ELECTRICAL SYSTEM � ..__._________ IfI: 7

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..

,Industrial Trucks

SECTION 7 -· CONTENTS ELECTRICAL SYSTEM DESCRIPTION

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· PAGE NUMBER

ALTERNATOR ..................................... ; ............... 7-1 ALTERNATOR SPECIFICATIONS ...... ; .......................... · - 7-1 ALTERNATOR CONNECTION ILLUSTRATION ....... ;.............. 7-1 ALTERNATOR CJRCUIT SCHEMATIC .. '. ........................... 7-1 ALTERNATOR NO-�OAD-,PUTP_UT TEST .......................... 7-1 ALTERNATOR CIRCUIT DIAGRAM-........... ,:,................... 7-2 ALTERNATOR LOADED OUTPUT TEST·...-........................ 7-2 ALTERNATOR REMOVAL AND INSTALL ATION ..-: ................. . 7-2 ALTERNATOR DlSASSEMBLY ....... : ............................ 7-3 ALTERNATOR EXPLODED VIEW .............. ; .. . ...... . ..... . .. 7-3 STATOR REMOVAL. ... .................... ............. .. . . ..... 7-3 STATOR INSPECTION .............. · ............................. 7-3 ROTOR INSPECTION. ... . ........ . ..................... .... . . .. . 7-4 RECTIFIER REMOVAL .. ......... .... . ........... . . ............ . . 7-4 BRUSH INSPECTION AND REPLACEMENT. ......... ......... . .... 7-4 RECTIFIER INSPECTION .. ....... .... . . ....... . . . . . . . ... .. . . .. .. 7-5 FRONT BEARING INSPECTION .. . .. . ... ........ .. .. . .. .. ..... ... 7-5 REAR BEARING INSPECTION..................................... 7-5 ALTERNATOR REASSEMBLY..................................... 7-5 STARTER ................... . .... ........... ....... . . . . . . ..... . ... 7-6 STARTER ASSEMBLY ILLUSTRATION......................... ;... 7-6 STARTER COMPONENTS LIST. ............ ...................... 7-6 · STARTER CIRCUIT DIAGRAM ... ........................ ......... 7-7 STARTER SPECIFICATIONS ..................................... 7-7 STARTER INSPECTION (ON VEHICLE)............................ 7-7 STARTER CURRENT DRAW SPECIFICATIONS .................... 7-7 STARTER CIRCUIT INSPECTION ................................. 7-8 STARTER REMOVAL AND INSTALLATION ....... , ................. 7-8 STARTER DISASSEMBLY ..... .. . . ......................... ...... 7-9 STARTER EXPLODED VIEW ................................ ..... 7-9 STARTER ASSEMBLY WIRING LAYOUT ........................... 7-10 STARTER RELAY BENCH TEST .................................. 7-10 STARTER SOLENOID CONTINUITY TEST . . . ...................... 7-11 STARTER SOLENOID COIL TEST ................................. 7-11 ARMATURE INSPE�TION ........................................ 7-12 FIELD COIL INSPECTION ........................................ 7-13 BRUSH AND BRUSH HOLDER INSPECTION ....................... 7-13 BRUSH REPLACEMENT ......................................... 7-14 STARTER NO-LOAD BENCH TEST ............................... 7-14 STARTER INSTALLATION ........................................ 7-14 ' (Continued on following page)

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Yale

Industrial Trucks

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SECTION 7 - CONTENTS (Continued) ELECTRICAL DESCRIPTION

\I ;,

AIR HEATER SYSTEM .............................................. 7-15 AIR HEATER PRINCIPAL OF OPERATION ............. , ........... 7-15 AIR HEATER SYSTEM DIAGRAM ....... ; ......................... 7-15 · AIR HEATER TIMER OPERATION GRAPH .............. ; .......... 7-16 AIR HEATER DESCRIPTION OF OPERATION ...................... 7-16 AIR HEATER CONTR OL UNIT INSPECTION ............... : ....... 7-16 CONT ROL UNIT TEST P OINTS AND VALUES ...................... 7-17 AIR HEATER ELEMENT'INSPECTION ............. ; ............... 7-18 AIR HEATER RELAY INSPECTION ................................ 7-18 INPUT/OUTPUT V OLTAGE INSPECTION .......................... 7-18 AIR HEATER RELAY BENCH TEST ................................ 7-19 COOLANT TEM PERATURE SENSOR INSPECTION .................. 7-19 COLO START INDICATOR LAM P INSPECTION ..... , ..... , ......... 7-20 HEATER ELEMENT A ND INTAKE ELBOW INSTALLATION ........... 7-20 TROUBLESHOOTING GUIDE ....................................... 7-21

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PAGE NUMBER

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I

/ndusfrial Trucks

ELECTRICAL SYSTEM

••

I .

ALTERNATOR CIRCUIT SCHEMATIC

R , , , ALTERf'JAJ9 ,

A�TERNATOR SPECIFICATIONS

Mitsubish_i !=lectric

Manufacturer

12 volt 50 amp

Nominal output

Ground polarity 1 n tion. dirE; 'pulley rota ' . --;JIctio �. i .,l1J(', I

Negative ground (-) ••

•

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Voltage

j I l"1 i> L

I

:output 1, 'cwreot I I 1' ,_ ;;:, I '

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Hot .. .

Cold

'

Revolution

Regulator type

Unloaded regulated voltage Quantity

Brush

------:-,

A002T19384

Model name

Standard size new Wear limit

-�Y/ (, G.,!o,f:�ise).

.( _ tram P.�l!�V:�ide)

.-t-t---l-�-·i

-I---� L____

r-"1ITTT'--r-_;=-==---

vo-�

·' ,··.:13.5'volts·· ..

16 amps

41 amps

.1300 rpm - '

:250_0 rpm

..

22 amps. '4s·arnps .,

·-

IC regulator

14.4 ± 0.3 volt 2 23 mm I (.9055 in)

. gAUTIQN: Do not reverse the battery conneclliaaic,a.iJ tions. (The rectifier will be damaged.)

1 . ,r • . :,rCAUTiON:. ·���ery voltage is supplied to the alter­ nator's B and S terminals at all times. Avoid short circuits. (Disconnect the negative(-) battery termi­ nal prior to removing the alternator.)

8 mm/ (.3150 in)

CAUTION: Do not ground the L or 8 terminals during engine operation.

ALTERNATOR CONNECTION ILLUSTRATION

CAUTION: Do not start engine with the wiring to the IC regulator and the LS connector discon­ nected.

L terminal B terminal

ALTERNATOR NO-LOAD OUTPUT TEST 1.

. Engine oil supply port

Verify that the battery is completely charged.

•: ,''·

' .

2. Disconnect the negative (-) battery cable.

7-1

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Industrial Trucks '

..

ELECTRICAL SYSTEM

3. Connect.the volt-ohmmeter arid ammeter as shown in the circuit diagram.

NOTE: The ammeter reading may be higher than the standard value if the battery is not completely charged.

ALTERNATOR CIRCUIT DIAGRAM

ALTERNATOR LOADED OUTPUT TEST 1. Connect the volt-ohmmeter and ammeter as shown in the circuit diagram. St.art the engine.

Ammeter

2. Raise the engine speed to 2000-2400 rpm with all electrical accessories "ON�.

Engine switi,h_

.

.

-. .

3 .- Read°the ·ar:rimeter. Alternator output current should be greater tha·n th�value recorded on the ammeter during the no­ load test. Maximum alternator output current should be greater that 90% of the rated output current.

;[

1 ·. i �'. �,l i_:

•·. ,,._

1. • ��

NOTE: Connect the voltmeter (+1 terminal to the alternator L · " :r ·

terminal.

T_, · • ,:

4. Reconnect the negative H battery terminal, and turn the key switch "ON". Verify that the voltmeter's reading is less than battery voltage.

Standard value: 0.5-4.0 volts.

If battery voltage is present, the alternator may be defective.

5. Remove the voltmeter (+)terminal from the alternator L ter­ minal. . 6. Connect the voltmeter.(+)terminal to the alternator S termi.·_ ·· ·, '· · 1· · nal.

�OTE: It may be necessary to apply an artificial load (Carbon pile load tester, etc.)to the electrical system to obtain maximurr, ·alternator. o�tput. Follow manufacturer's instructions.

ALTERNATOR REMOVAL AND INSTALLATION 1.

Disconnect the negative (-) battery terminal.

2.

Remove the alternator wiring (B terminal, L,S connector).

3.

Remove bolt A.

4.

Remove the drive belt.

5.

Remove the oil lines.

6.

Remove bolt B, and remove the alternator.

7.

Follow the above procedure in reverse to install.

8.

Adjust the drive belt tension.

9.

I

Tighten bolts A and B. Tightening . torque: Bo!t A: 1.9-2.6 kgm / (165-226 lbf in) Bolt El: 3.8-5.3 kgm / (330-460 lbf in)

terminal . .. . '�··

:·..

:

�:: .:�: .

7. Start the engine and raise the alternator speed to 5000 rpm (engine speed 2000-2400 rpm) in the no-load state (lights and all electrical accessories "OFP')i 8.

I

\. I

Read the ammeter and voltmeter readings.

Standard value with fully charged battery: Ammeter 5 amps or less Voltmeter 14.4 ± 0.3 volts @ 20 ° C / (68 ° F)

7-2

,·

I

(

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 2696731638

i,

'·'

Yale

Industrial Trucks

ELECTRICAL SYSTEM RECTIFIER REMOVAL

.1 ...

&

I.

1. Un-solder the rectifier from the brush assembly and sepa­ rate.

CAUTION: The semiconductors for the regulator

and rectifier may be damaged if the parts are over­ heated during the soldering operations. Use low! heat and a heat sink (pliers, etc.) when performing any solder, ing operation ori the alternator. Standard safety practices s�ould be observed to prev'enF damage to the rectifier.

The parts are normal if there is continuity.

ROTOR INSPECTION 1. Check the continuity between the core and each slip ring · -··. · with an ohm meter.

BRUSH INSPECTION AND REPLACEMENT •

1. Measure the brush length. If the length is below the lim1, value, replace the brush. Un-soldering the old brush to replacr Limit value: 8 mm I (.3150 ip)

,· :1 I

The parts are normal_if t_here is no continuity. .

' ...

-.

'

2. Check the resistance between both slip rings with a voltohmmeter. ° Standard value: 4-5 .0. @ 20 C / {68 ° F)

Wear limit

0 - ·.3150 . in .

- .9055 in· ___

1�::1 ._:?� -� o

-�-.

, .

I

_. ·. ':';' ;: ..

2. When installing a new brush, pull the lead wire and sole so that approximately '5 mm/ (.1969 in) of the brush fits into the holder.

NOTE: Replace both brushes at the same time.

7-4

I

·Yale

"Industrial Trucks

ELECTRICAL SYSTEM FRONT BEARING INSPECTION 1. If the front bearing is loose or makes an abnormal sound when turned with a finger, replace the bearing.

�

:

1

:._

.

'/

R INSPEfTION f! ECTIFIE

�.

� �. Set the oh�- meter in_ the t��ist�_ nc'e range, and 9heck-the ' continuity of each rectifier at the test points listed bel�w_:: Ohm meter (-) terminal

_.Ohm meter (+)_terminal

Continuity

E

•

B

I

, l

P1

P2

P3

L P2

B

P3

REAR BEARING INSPECTION

No continuity

1. If the rear bearing is loose or makes an abnormal sound when turned with a finger, replace the rear bearing.

No continuity

Use a commercial bearing puller for bearing removal.

No continuity

E P1

Standard value

Continuity Continuity

L

If the measured values differ from the standard test values, re­ place the rectifier.

Rear bearing

Bearing puller

E (rear side)

ALTERNATOR REASSEMBLY Reverse_ the disassembly procedures to reassemble.

NOTE: Before installing the rotor in the rear housing, retract the brushes into the brush holder. Hold the brushes in this posi­ tion using a piece of wire inserted through the hole in the rear of the housing. Remove the wire and verify that the brushes are contacting the slip ring after installing the rotor.

P,

L

7-5

Yale

Industrial Trucks

,.

ELECTRICAL SYSTEM

STARTER STARTER ASSEMBLY ILLUSTRATION

(

®

(

1 i

·'

M{f vehicles only (for wet clutch)

STARTER COMPONENTS. LIST #

1 2 3 4 5 6 7 8

;;,

1:1 · I!: ·11· I

:i I·

I

I,.• 11: ••

,i I \,

I

Component

-

Front bracket assembly

-

Shift lever assembly Packing

.__

Cente'r bracket assembly

'---

Swhch a��embly

'---

Bolt set

-

-

.__

,' ,,

� !.

'·

Shaft assembly clutch set Gear set

.__ Pinion shaft assembly

I

:

.

Armatu're set'

Bfjlarii:ig ,__ � ·' BearinQ·

10 11

7-6

�--- O_escription

Starter assembly

'---

.g

12 13

·.

�

..

'•

..

Qty.

#

Component

1 1 1 1 1 1

14 15 16 17

L.-

1 1 1 1 1 1 1

18

19 20 21 22 23

24 25 26

II.II. ,7

-

L

..

7

L_

n[_.

--·-

Description Gear Pinion set Stopper set Cover set Field coil and frame assembly Brush l3rush holder assembly Spring brush Rear bracket

Qty.

1 1 1 1 1 2 1 4 I

Packing

2

Rubber ring

2 1 1

Switch assembly Screw set

I

I

I

I

Yale

.- '

Industrial Trucks

-...·

ELECTRICAL SYSTEM

GRAM STARTER CIRCUIT DIA

-STARTER INSPECTION (ON VEHICLE) Special tools required

Engage switch

Starter relay

'

.1

.

T

K.

S.

, ' ,' i

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...I-· . • .

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J

,�

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-

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•

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M003T 67771

Manufacturer

Mttsubishi Electric

Applicable engine

TM

Nominal output

12 volt, 2.2 kw 30 sec.

CW (Clockwise) (from pinion side)

Rotation direction

-co

2. Turn the key switch to engage the starter (start the engine).

Measure current draw, battery voltage and engine rpm. Make note of any abnormal noise. Verify that there are no external condnions causing the starter malfunction. Check that the en­ gine, transmission and hydraulic pump are free to rotate nor­ mally.

Cur'rent

180 'amp ·or iess

Speed

3,800 rpm

Ambient Temperature_

Current ;(cimps)

Volts (approx.)

Minimum Speed (engine rpm)

··2 volt

o c 1 (32 °F)

650-?'00

8

200

Current

1050 amp

-15 °c 1 (5 °F)

900-950

8

100

Torque

3.0 kgm / {260 lbf in) or more

Quantity '

QJ

:i::: CO

11 volt

: :

Standard size (new)

· ,STARTER CURRENT DRAW SPECIFICATIONS Standard (oh vehicle):·:

0

. ;

8 volt or less

Magnet switch operation voltage Brush

,

I

Voltage

Voltage . Lock test

I

V

Model name

},fo�ioad test

- �

+

•

Rated time

-,

To measure current draw

Ammeter

I !srARTER SPECIFICATIONS

.

Ammeter

-

___ ,

.

.: I

.

t··.:-:==

t

,: ';

I

For starter inspection

1. Verify that the battery is completely charged. Connect the voltmeter and ammeter as shown in the illustration. Connect a tachometer to measure engine rpm. Follow the manufacturer's recommendations when installing the tachometer.

�--::i:::-,

"SM

_

Volt-ohmmeter

--

4

..-···-

18mm (,71.in)_ , ..

,,. ·.

TEST RESULTS

Current draw

· Battery voltage

Engine speed

High

Low

Low/ none

A,B,C

Low

High

Low

D,E

High

Low/ nornial

High

F

Possible cause

Wear limn

11 mm/(.43 in)

A.

Commutator groove depth•

0.5-0.8 mm (.0197-.0315 in)

B. Starter overload.

Tight or binding engine, transmission or hydraulic pump.

1:

i

Discharged or defective battery.

7-7

I Ii II

Yale

,

Industrial Trucks

ELECTRICAL SYSTEM

C.

Malfunctioning starter.

Armature or field coil shorted to ground.

Armature coil internal short.

Worn, damaged or seized bearings.

External short (solenoid to starter wiring).

Solenoid shorted to ground.

D.

Excessive voltage drop in the starter circuit.

High resistance or open in power wiring, battery con­ nections, st�rter relay, starter solenoid, etc.

E. Malfunctioning st?rter. , ,: .

Armature or field coil open, brushes worn or sticking, commutator worn or dirty.

F.

Malfunctioning starter: Shorted field coil. ' ! .

NOTE: Proceed with the following steps to check the truck wir­ ing if the starter will not operate.

I . .,i

STARTER CIRCUIT INSPECTION 1. Check for battery voltage at the starter solenoid input con­ tact. Measure the voltage be1·,•.1een the solenoid terminal (large red wire) and ground (starter body). Use a volt-ohmmeter.

Standard value: Battery voltage If the correct voltage is not present, check the power cables (+) and(-) from the battery and the ground cable from the starter to the frame.

2. Check for battery voltage at the starter relay input contact.

Measure the voltage between the terminal (black/white wire) and battery (-) (ground).

Standard value: Battery voltage If the correct voltage is not present, check the power wire (black/white) from the starter solenoid !o tre relay. _

y

4. Check for battery voltage at the starter solenoid coil. Mea­ sure the voltage at the coil terminal on the starter solenoid (black wire) with the key switch in the "START" position. ·.. _Standard value: Battery_voltage (approximately 8 volts during cranking) If the correct voltage is not present, check the connections and the wire(black) between the starter relay output contact and the starter solenoid coil. Check the solenoid ground. If voltage is still not present,: th� starter relay may be defective.

5. If the correct voltage is present and the starter does not op­ erate properly,· remove the starter assembly, and inspect it.

STARTER REMOVAL AND INSTALLATION 1.

Remove the negative battery (-) terminal.

2. Label the wiring to the starter, relays and solenoid. Remove the wiring from the starter assembly.

3. Check for battery �'oltage at-th·e:��arter relay coil. Measure the voltage between the coil(+) terminal(black/yellow wire) and ground (starter body). Measure the voltage with the key switch · ·· · in the "START" position. · Standard value: Battery voltage (approximately 8 volts during cranking) If voltage is not present, check the fusible link, key switch, direc­ tion switches, neutral relay number 1, the associated wiring and the relay ground. ·,'._1

3 .. Remove the mounting bolts, and remove the starter from the engine. , .

. i

: I' ,'.I

I

4. Follow the above procedure in reverse to install.

Tightening torque: 7.3-8.8 kgm / (53-64 lbf ft) See: "STARTER ASSEMBLY WIRING LAYOUT" for wire connections.

. ,

(· 7-8

Yale

1 (nt;IL!strial Trucks

ELECTRICAL•SYSTEM

STARTER DISASSEMBLY-

1_ Disassemble the starter with the procedure shown in the exploded view.

2.

Reverse the disassembly procedure _to reassemble. '

,.

STARTER EXPLODED VIEW

1.0-1.2 kgm/ (87-104 lbf in)

'

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J.

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-

., ·

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13

® 9

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1.

Inspection of auxiliary relay

3.

4.

5,

Lever Center bracket Driving gear \ Over running clutch

2. Inspection of magnetic switch

6.

7.

Bearing Front bracket Pinion gear 10. Bearing 11. Inspection of armature 12. . Bearing

8.

9.

13. lnspe�tion of field coil and frame Replacement (brush) 14.' Inspection of brush, brush holder Replacement (brush) 15. Rear bracket

7-9

Yale

(

Industrial Trucks

(

ELECTRICAL S YSTEM

STARTER ASSEMBLY WIRING LAYOUT

( II White Relay Coil(+) Input from After Heat Relay Cold Start Circuit)

(

AIR HEATER RELAY White to truck harness

STARTER --- SOLENOID ·

Buss Bar

Black/Yellow Relay Coil(+) Input from Neutral Relay (Key Switch Start Circuit) Battery Positive(+) Cable

,. ;:,;)

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\; ;:::::: ·.

..

·

STARTER MOTOR

STARTER REL AY BENCH TEST !: .

I. ..

1 1•

.i: ·,

1

,.··

•I;,

NOTE: Disconnect all wires from the relay before performing the following test.

1. Check the continuity between the coil (+) terminal and ground (solenoid body) with the volt-ohmmeter. Standard coil ° ° resistan.ce value: 2.96 .Q@ 20 C I(68 F). Replace the relay if there is no continuity. Chec]<the continuity between each of the two (2) contact terminals and ground (relay metal body). Re­ place the relay if ther13 is co_ntinuity. Check the continuity be­ tween the two(2) contact terminals. Replace the relay if there is continuity (relay coil deenergized).

I (

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...___________________'"'ll..__

7-10

)

.·Yale

. · ·.. , Industrial .Trucks

ELECTRICAL. SYSTEM

2. Check that the relay is activated when the relay coil is ener­ gized. Listen for a clicking sound. Connect battery positive(+} to the coil terminal and battery negative(-) to ground (metal body of the solenoid). Verify continuity between the two(2) con­ tact terminals with the relay coil energized. Replace the relay if there is no continuity.

� .n

0

3. Check the continuity between the two(2) contact terminals.

Replace the relay if there is continuity (relay coil deenergized).

.)

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'

'

.

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l !ITARTER SOLENOID CONTINUITY TEST .(i:

�,. ,v1

·.1 ;-, -

•

Disconnect all wires from the solenoid before perform. , ! NOTE: .

• ing the following test.

'

1. Check the continuity between the coil terminal and lower output contact terminal(terminal which connects to starter mo­ tor and has buss bar to solenoid coil ground) with the volt-ohm­ . meter. Replace the solenoid if there is no continuity. Check the continuity between the coil terminal and upper output contact terminal. Replace the solenoid if there is continuity.

STARTER SOLENOID COIL TEST NOTE: Disconnect all wires from the solenoid before perform­ ing the following test.

1.

Coil pull in test.

(1) Remove the starter solenoid from the starter.

(2) Apply battery voltage to the starter solenoid between the coil terminal and the output contact terminal which was connected to the starter motor. The solenoid plunger should extend. If the plunger does not extend, replace the solenoid.

•

.. , 2. · Check the continuity between the coil termfnal and the met­ al solenoid body (ground) with the volt-ohmmeter. Replace if there is no continuity.

NOTE: ·oo not energi.z e the coil for more than 1 O seconds. Al­ low \tie.•••sol�rioid to cool before repeating the ·test.

• I

7-11

Yale

Industrial Trucks

ELECTRICAL SYSTEM

f

2.

Coil holding test.·

(1) Remove the start�r solenoid from the starter.

(2) Apply battery voltage to the starter solenoid between the coil terminal ·and the solenoid, body. Connect battery positive(+) to the coil terminal and battery negative(-) to the solenoid metal body (ground)'. Manually pull the soleqoid plunger out.

(3) Release the plunger. The plunger should remain ex­ tended once released. If the plunger returns with battery volts applied, replace the solenoid.

3.

4.

I

;

lnspectio'n of pinion stroke. . .

',',,

. '

( 1) lristall• the starter solenoid on the starter. The wire be­ tween �he st9-rter solenoid output contact terminal and starter motor must remain disconnected for this test.

(2)' When the battery is connected between the coil termi­ nal and ground, the pinion sh.ould extend 17 mm/(.6693 in).

Measure and verify this distance. Connect battery positive (+) to the coil terminal and battery negative(-) to the metal body of the starter(ground).

NOTE: Do not energize the coil for more than 20 seconds. Al­ low the solenoid to cool before repeating the test.

.A - B = Pinion distance

Plunger return test.

(1) Remove the starter solenoid from the starter.

(2) Connect the battery to the starter solenoid between the output contact terminai ·on the starter solenoid and the sole­ noid body. Conne•cf battery positive(+) to the output contact terminal(terminal which was connected to the starter motor) and battery negative (-) to the metal body of the solenoid (ground).

(3) Verify that the plunger extends with battery volts applied and that is retracts immediately after disconnecting the bat­ tery. Replace the solenoid if the plunger does not extend and retract as stated.

7-12

ARMATURE INSPECTION 1. Check the continuity betweeh each segment of the com'� mutator and the shaft. If there is no continuity, the armature i:, · n3rmal. If there is continuity, replace the armature.

• ,.

•

•·.

•

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,I

Yale

:· , ,. Industrial Trucks

ELECTRICAL SYSTEM 0.5-0.8 mm I (.0197-.0315 in)

Correct

� Wrong

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L•

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. FIELD COIL INSPECTION

Checkthe continuity between each.of the.commutator bars and the two (2) segments adjacl?nt to it: Replace the armature if .there'i� continuity between �ny '&(the adjacint segments..

1. Checkthe continuity between the external lead on the mo­ tor frame and each of the brushes with the volt-ohmmeter. Re­ pair or replace the field coil if there is no continuity.

. . y.;·.,.......-

. t

3. Checkthe runout of the commutator surface with a dial indi­ cator. If the runout is 0.1 mm/ (.0039,Jn) or great�r. replace the ;armature or machine the·sutface so'that it is Within the standard

_V9-I_Ue..

I;

.

... .

• . _ ..

.'

. .

.

.·

Commutator standard runout : 0.05 mm/ (.0020 in) or less.

Commutator standard O.D.: 38.7 mm/ (1.52 in) • Commutator minimum 0.0.: 38.1 mr:n/ (1.50 in)

.. :. 2 .... Checkthe continuity b�tween the external lead on the mo­ tor frame and the motor frame with a volt-ohmmeter. Replace if there is continuity.

BRUSH AND BRUSH HOLDER INSPECTION H,·· f ,..

.· ,- .._.,

�- Inspect the depth of the mica. Repair (underc�t) or replace the armature if the depth is 0.2 mm/ (.0079 in) or less.

Standard value: 0.5-0.8 mm/ (.0197-.0315 in)

~

1. . Pheck_the_ continuity between the insulated brush holder and brush holder frame (mounting plate) with the volt-ohmme­ ter. Replace the brush holder assembly if there is continuity .

7-13

Yale

Industrial Trucks

ELECTRICAL SYSTEM NOTE: u·se high tempe.rature solder. The melting temperature

of the solder should be 285-296 •c / {545-564• F). Use a solder­ ing iron with a heat rating of 1 00W o.r higher.

. '·

(

STARTER NO-LOAD BENCH TEST

0

1. Connect the starter, ammeter, voltmeter and battery as shown in the illustratio�.

Ammeter

Voltmeter

2. Check the condition of the brushes. If the brushes are worn to the limit or is unevenly worn, replace them.

Wear limit value: 11 mm/"(:4331 in)'.'. ' ' ...�. ·i

' •�' ..

• u

.

'

Ammeter .

-I i':'

+

())

t:: (I) -aJ I I

V

· BRUSH REPLACEMENT NOTE: Al0ays replace th'e. brush hol.der when replacing the brushes.

1.

Cut the br_ush wire off at the field coil.

2. Solder a new brush onto the field coil near where the old brush was cut off.

2.

Activate the starter. Verify that the starter rotates smoothly and that t_he voltage, current· and speed are at specified val­ ues.

Standard values (off vehicle):

Type (kw)

2.2

Terminal voltage (volts)

11 180 or less

Current (amps)-�. 'Speed (rpm)

- ...

!. .

STARTER INSTA LLATION

I

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'

I I

3800 or higher\

{

Perform the removal procedures in reverse to install the starte., Tightening torque: 7.3-8.8 kgm / {53-64 lbf ft) See: "STARTER ASSEMBLY WIRING LAYOUT" for wire con:: nections. .· ·

7-14

,'

I

Yale

..Jnd.ustrial Trucks

ELECTRICAL SYSTEM

,4 -

AIR HEA , ... ,I\

TER SYSTEM 0

,· �:�i"R.HEATER PRINCIPAL OF OPERATION ..

' l

th e installation of an air heater in the intake manifold allows the intake air to be warmed prior to entering the combustion chamber.

Warmed air aids in igniting the fuel in a cold engine, and cold start characteristics are improved . Air heater operation after engine startup. reduces the noise and the white smoke evident immediately after starting a cold engine.

lJ

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,1 • ••

'

,AIR HEATER SYSTEM DIAGRAM

'.-1

-- . ·1'

Battery

Fusible link

·e;/

Starter relay -

s Starter switch ..- .M

I

SW

L.�_1____

.. •

=

!

Starter motor

I\.

Alternator Water temperature sensor

Air heater

7-15

Yale Industrial Trucks

ELECTRICAL SYSTEM 3) "Start bypass" to shut off the air heater element during starter operation. Operation of the air heater is will be termi­ nated tem·porarily to protect the battery and increase cold start engine cranking speed.

AIR HEATER TIMER OPERATION GRAPH

(Sec.) 20

10

(

AIR HEATER CONTROL UNIT INSPECTION

(

1. Remove the control unit cover and unbolt the control unit.

The air heater control unit is located in the engine compartment on the front plate near the starter.

Q)

E i=

[

Tl

(

T2

(1 sec. or less)

T3

0 L----r----.----.----.�--1---'"'T--�

0 10 20 30 40 · 20 - 1 0 Engine cooling water :temperature <-CJ

T1: T2: T3:

Col� start indicator lamp Preheat timer · 1, After heat timer

E

C

*

F

D

*

* : Free terminals

AIR HEATER DESCRIPTION OF OPERATION When starting the engine, the control unit regulates the opera­ tion time of the air heater according to the engine coolant tem­ perature. Operation of the air heater system is indicated by the illumination of the cold start lamp on the instrument panel. The cold star t lamp will extinguish after a short period to indicate that the engine is prepared to start.

The air heater will not operate if the coolant temperature is ° ° 20 C/(68 F) or higher. ..· .. · .

I I

The following funciions are al;o incorpor�ted:

• 1,i·

1) "Safety circuit" to automatically turn off the air heater ele­ ment and protect the battery from excessive discharge if the key switch is left in the "ON" position and the engine has not been started.

2. Inspect the•voltage of each terminal on the unit with a volt meter.

NOTE: Connect the negative (-) probe of the volt meter to battery(-) (ground). Connect the positive(+) probe of the volt meter to the points listed. Tests are to be performed with the control unit connected. Insert the probe from behind the connecto� 3. Inspect the suspect, component, associated wirina and connectors if an incorrect voltage is present. If all inpu: · ·i the control unit are correct and a malfunction is present in a;·, :;utput component, check the output component and associated wir­ ing:.!f a �alfunction is still present replace the control unit .

. _,

2) "After heat" to r·educe noise and smoke levels immedi­ ately after starting. At temperatures below 20 • C/(68 • F) the air heater will operate for a short period after the engine has started.

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7-16

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-_- \tile

· ; Andustrial Trucks

ELECTRICAL SYSTEM CONTROL UNIT TEST POINTS AND VALUES

'1 ··,, . ·.- -.,,·

;: ·] : n.-.;

E

C

*

F

D

*

. *: Free terminals

1...----r---r------,--------------------- -------r-------, I

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D

. Wi �e.. color

, ,. •;, -" : •. _ · � ,: , - _Component . ,

Standard values (volts)

Measurement conditi ons Engine coolant temperature approx. 20 ·c / (68 • F).

Green/ Coolant red temperature sensor

Key switch "ON"

Green/ Alternator yellow

When key switch is in the "ON" posit i on (igniti on) and the engine is no'! running.

Less than battery volts

When key switch is in the "ON" position (ign i tion) and the engine is run­ ning.

NOTE: Alternator light must be off. Charging sys1em must be func­ tional. Accelerate engine slightly if necessary.

Battery volts

When key switch is in the "ON" (ignit ion) and start positions.

Battery volts

When key switch is in the "OFF" position.

Zero (0) volts

°

°

Engine coolant temperature approx. 80 C / (176 F).

Approx. 3-4 volts Approx. 2-3 volts

E

Blue/ white

Key switch (IGNITION c ircuit)

F

Black/ yellow

Key switch (START circuit)

When key switch is in the "START" position.

Battery volts

When key switch is in the "ON" ( i gnition) and "OFF" positions.

Zero (0) volts

At all times

Zero (0) volts

H

Black

Ground (battery-)

K

White/

Cold start indicator lamp

L

red

Blue

Air heater relay

When engine

coolant temperature is 20�C ?r less.• 1 When eng i ne

coolant ___ .. temperature is ° 20 C or less.• 1

'ij 11

:i

When key switch is turned "ON".

Initially, for a period of. approx. 2 seconds. * 2 _

battery volts

Approx.. 2 sec. after kE;lY swi tch is turned "ON".• 2

Battery volts

When key switch is turned "ON".

Initially, for a period of approx. 7 seconds. * 2

Battery volts

When the-kiy switch is "START' position.* 2

Battery volts

Approx. 60 sec. after engine switch is turned from "START' to "ON". (Engine not running) * 2

Zero (0) volts

Other than the above.

I'I

: I

Less than

Zero (0) volts

•· Footnotes: .' '' · '.·'(,;. · '· • 1. T he coolant temperature sensor for the ai r heater control uni t must be bypassed.,o pert��� this fest when the engine coolant tem­ ° perature is approximately 20 "C / (68 F) or higher. To bypass the coolant temperature�se : '�s'or, disconnect the green/red wire from the water temperature sensor and install a 800 res istor between the green/red wireJand battery (-) (ground).

• 2. Voltage and ti me value·s listed are for an engine with a coolant temperature of 20 • C / (68 • F). For other temperature ranges see

.o:

TIMER OPERATION GRAPH.

7-17

Yale

Industrial Trucks

AIR HEATER ELEMENT INSPECTION

AIR HEATER RELAY INSPECTION

1. Disconnect the wiring to the air heater. Remove the air heater. Isolate the two (2) elements from each other for testing by unbolting one end of one {1) element and insulating it from the connection.

INPUT/OUTPUT VOLTAGE INSPECTION

NOTE: The two {2) elements are wired in parallel and must be

isolated from each other for proper testing. It is not necessary to remove the elements from the housjng for testing. Insulate or position the unbolted end of the element away from the other element and away from the connection point on the housing. · 2. Check the continuity of each element. Replace the air heat­ er assembly if either of the two {2) elements tests open (no con­ tinuity). Measure 'the resistance between each terminal using a volt-ohmmeter. , Standard resistance value: ...

Approximately 0.053-0.1 ohm {.Q) (each element) ''

·1 t'

ELECTRICAL SYSTEM

3. Check the continuity between each of the elements and the metal housing. Repair the insulators or replace the air heater if there is continuity.

4.

Visually check the air heater for soot and dust.

5.

Clean the air heater with water if it is contaminated.

NOTE: T he air heater must be allowed to dry completely prior to reinstallation.

i.

°

°

Verify that the coolant temperature is 20 C / (68 F) or less.

NOTE;: "Air heater on time" (the amount of time the air heater relay is energized) will vary with coolant temperature. The coolant temperature sensor for the air heater control unit must be bypassed to perform the following tests when the engine coolant temperature is approximately 20 ° C / {68° F) or higher.

To bypass the coolant temperature sensor, disconnect the green/red wire from the water temperature sensor and install a 800 .Q resistor between the green/red wire and battery (-) (ground).

2. Check for battery voltage at the relay input contact. Mea­ sure the voltage at the B terminal on the air heater re.lay with a volt-ohmmeter.

Standard value: Battery voltage If the correct voltage is not present, check the fusible link and associated wiring.

3. Check for battery voltage at the relay coil. Measure the volt­ age between Jhe C terminal (white/blue) and the D termina, (black). Measure the voitage with the key switch on.

Standard value: Battery voltage for approximately 7 seconds after the key switch is turned "ON".

If the correct voltage is not present, check the air heater control the after heat relay and the associated wiring.

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Coil Terminal 7-18

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.Yale

, , Industrial Trucks

ELECTRICAL SYSTEM

., I

4_ Check for battery voltage at the relay output contact. Mea­ sure the voltage at the.A terminal on the air heater relay with the key switch "ON".

Standard value: Battery voltage for approximately 7 seconds after the key switch is turned "ON".

If the correc t voltage is not present, the relay may be defective.

Output Terminal

COOLANT TEMPERATURE SENSOR INSPECTION

&

1.

Remove the water temperature sensor.

CAUTION: T he engine coolant can be under pressure. Allow the engine to cool completely and relieve the cooling system pressure before removing the water temperature sensor 2. Test the water temperature sensor as shown in the illustra­ tion. Use ice to lower the water temperature. Gradually raise the water temperature by heating the water, and measure the resistance.

5. Remove the bypass resistor and reconnect the water tem­ perature sensor connector. (If bypass resistor had been installed for testing purposes).

AIR HEATER RELAY BENCH TEST NOTE: Disconnect all wires from the relay before performing the following test.

1.

Disconnect the battery's (-) terminal.

2. Remove the air heater relay.

3. · Check the coil continuity. Verify continuity between the relay coil terminals (wire color: white/blue and black). _

Standard Vc).lue: Wate�· temperature

Resistance (.Q)

O �C/(32 �F)

1,860

40 "C/(104 °F)

207-255

80 °C/ (176 °F)

46.8-55.2

100 °C/(212 °F)

-·

25.2-30.8

Contact Terminal

Contact Terminal

2000 1000 � 500 § 300 � 200 w 100 .. a:' (Q) 50 30 20 0

"----,....

I !.

'

..

80 40 60 Water temperature (°C)

20

·.,

� '-... �

i i

.....______,.

,:

100

1:

I:

4. Verify that there is a continuity between the relay contact ter minals, when battery voltage is applied between to relay coil terminals. Verify that there is no continuity between the relay contact terminals, when battery voltage is removed from the relay coil terminal s.

5.

Replace the relay if it fails any of the above tests. . 7-19

I.··:·:i1

Industrial Trucks

ELECTRICAL SYSTEM

COLD START INDICATOR LAMP INSPECTION 1. Verify that the cold start indicator lamp on the instrument· panel lights for several seconds when · · the · -·engine switch is turned "ON".

,..,. .... ...,,,,.. .

See "TIMER OPERATION GRAPH" for ·specific operation temperatures and times.

HEATER ELEMENT AND INTAKE ELBOW INSTALLATION 1. Assemble the air heater using two (2) new gaskets (inner and outer). !

' ' I

I

NOTE: Always use new gaskets when installing'the air heater.

Be sure to install the gaskets properly as shown in the illustra­ tion.

. _Gasket

Tightening torque: 1.9-2.6 kgm / (165-225 lbf in) _

) I

'

Yale

Industrial Trucks

ELECTRICAL SYSTEM

TROUBLESHOOTING GUIDE .. Problems

Possible causes

The starter motor does not rotate, or the rotation speed is not sufficient to start the engine.

·,;.

Remedy

Causes related to battery and 1:i"ower wiring * Battery connections loose or dirty * Bad ground (-) to frame. * Bad battery positive (+) cable. * Discharged (low) battery * Low voltage due to defective battery

Clean and tighten Clean and repair Clean and repair Charge Replace

Causes related to control wiring * Key switch defective * Voltage drop in key switch wiring or connectors * Starter relay defective. * Starter solenoid coil defective.

Replace Repair or replace Replace Replace

Causes related to starter solenoid * Broken wire in pull-in coil in starter solenoid * Defective contact of contact plate in starter solenoid * Broken wire in holding coil in starter solenoid Causes related to starter motor '* Defective brushes * Weak brush springs * Defective field coil * Defective field coil connections • Defective commutator * Defective armature The starter motor rotates but * Discharged (low) battery the engine does not start Causes related to air heater system(when cold) * Defective air heater control unit * Defective air heater relay * Defective air heater * Defective water temperature sensor * Defective wiring for air heater system : ....1.._�.---·--

Replace Replace Replace Replace Replace Replace Repair Repair or replace Replace Charge Replace Replace Replace Replace Repair or replace

The starter motor turns but the * Worn over-running clutch pinion end pinion does not engage·prop- • Fatigued over-running clutch drive spring erly with the ring gear.

• Slipping over-running clutch * Binding spline * Worn bushing • Worn ring gear

Replace Replace Replace Repair or replace Replace Replace

The starter motor does not * Starter solenoid contacts welded closed stop running * Solenoid coil shorted to battery positive(+) * Defective key switch (stuck or shorted in the start position)

Replace Repair or replace Replace

Discharging of the battery

.

Overcharged battery

* Loose alternator drive belt * Short circuit or broken wire in the stator coil * Defective brush and slip ring contact * Defective rectifier * Defective IC regulator • Insufficient or improper battery fluid • Faulty battery electrode (internally short circuited) * Battery connections loose or dirty * Excessive electrical load Defective IC regulator

Adjustment Replace Clean or replace Replace Replace Adjustment Replace Clean and tighten Inspect each electrical part Replace

7-21

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Yale

SECTION 8

Industrial Trucks

:1 I: ,I

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8

USER SUPPORT INFORMATION

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Jn�ustrial Trucks

SECTION 8 - CONTENTS USER SUPPORT INFORMATION DESCRIPTION

PAGE NUMBER

SPECIAL TOOL LIST ............................................... . 8-1

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IIi .i

Yale

Industrial Trucks

USER SUPPORT INFORMATION

SPECIAL TOOL LIST Tool Part Number/ Description

Illustration

Tool Part Number/ Description

9225423-01 Engine stard hanger

9225423-02 Body (component of 9225423-01)

9225423-03 Boil ";· r (component of 9225423-01)

9125483�05 Engine stand

9225423-04 Pivot

9225423-05 Body (component of 9225423-04}

9225423-06 Foot (component of 9225423-04}

9225423-05 Lock nut (component of 9225423-04)

9125483-59 Valve spring lifter arm

9225423-08 Cylinder liner remover set

Illustration

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9225423-09 Attachment

�

9225423�10 Coupl[ng flange holder

9225423-11 · Valve seal remover

9225423-11 Valve guide installer

9225423-13 Clutch disk centering tool

9225423-14 Ring gear brake

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8-1

Yale

Industrial Trucks

Ii

USER SUPPORT INFORMATION

SPECIAL TOOL LIST Tool Part Number/ Description

Illustration

Tool Part Number/ Description

9225423-15 Oil seal installer

9225423-16 Handle (component of 9225423-15)

9225423-17 Oil seal installer (component of 9225423-1p)

9225423-18 PLilleiy puller

Illustration

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9224473-00 Wrench oil filter bypass

9125483-56 ...

Valve seal and valve guide installer set

9125483-81 Installer (component of 9125483-56)

9125483-82 Body . (component cif 9125483-56)

9125483-83 Installer (valve guide) (component of 9125483-56)

9125483-84 Nut. (component_ ?f 9125483-56)

9125483-87 Spacer (component of 9125483-56)

9125483-40 Piston pin installer

9225423-19 Compression gauge adapter

9125483-40 Oil pres��re gauge

9125483-58 Tacho dwell tester

8-2

a=---; Ji)

.\ile

/n:!;ial Trucks

NOTES

---

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 2696731638

I I I J ij ·11

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'·!-. !1

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.

Industrial Trucks

ALPHABETICAL INDEX A

Air Cleaner Replacement ............ ....................... 2-4 Service ...... ......................... ...... ... 2- 4 Air Heater System Air Heater Relay ............................... 7-18 Bench Test ................................. 7-19 Input/Output Voltage Inspection ... ........ .... 7-18 Cold Start Indicator Lamp Inspection ............. 7-20 Control Unit Inspection ................ .. ....... 7-16 Coolant Temperature Sensor Inspection .... , ..... 7-19 Description of Operatirrn .. . ..................... 7-16 Diagram-System ...... : ....................... 7-15 Heater Element and Intake Elbow Installation ...... 7-20 Heater Element Inspection ................. ..... 7-18 Principal of Operation .......................... 7-15 Test Points and Values ......................... 7-17 Timer Operation Graph ......................... 7-16 Alternator Circuit Diagram ................................. 7-2 Circuit Schematic ........... : ................... 7-1 Connection Illustration ........................... 7-1 Disassembly ................................... 7-3 Brush Inspection and Replacement ............. 7-4 Exploded View ........ ............ . .. ..... ... 7-3 Front Bearing Inspection ...................... 7-5 Rear Bearing Inspection ................. .. ... 7-5 Rectifier Inspection .... ... .......... .......... 7-5 Rectifier Removal ..... . ........... . ....... ... 7-4 Rotor Inspection ............................. 7-4 Stator Inspection ............................. 7-3 Stator Removal ................... '. ........ .. 7-3 Loaded Output Test ...............•; ............. · 7-2 No-Load Output Test ............................ 7-1 Reassembly ._.................................. 7-5 Removal and Installation ......................... 7-2 Specifications .................................. 7-1 Alternator Belt Adjustment ............................ ........ 2-3 Inspection ..... ................................ 2-3 Replacement ... ....................... ......... 2-3

B

Bleeding Air from the Fuel System .............. 2-8, 6-13

·c· . Compression Test-Engine .......................... 2-7 · Cooling System . Components-Engine .. : ............... : .. ....... 5-2 Diagram ... .... ....... .............. ..... ...... 5-1 Specifications ............ ............ ......... . 5-2 T hermostat Inspection ..... ...................... 5-2 Water Pump ................................... 5-3 Description .................................. 5-3 Specifications ........... .................... 5-3

D

Diagrams Air Heater System ............................. 7-15 Alternator Circuit ................................ 7-2 Alternator Rectifier .............................. 7-5 Alternator Schematic ............................ 7-1 Cooling System ....... ....................... .. 5-1 Fuel Stop Motor Circuit ......................... 6-21 Fuel System . . ......... . ................... 1-8, 6-1 Injection Pump Lubrication ....................... 6-2 Lubrication System ......... ...... .............. 1-7 Starter ....... ............. ..... ............... 7-7 Starter Bench Test ................. ........... . 7-14 Starter/Relay Assembly . .............. .......... 7-10

E

Engine Disassembly Cylinder Block Disassembly-Accessory Components 3-5 Crankshaft Pulley Removal .................... 3-6 Flywheel Removal ... ......................... 3-6 Cylinder Block Disassembly-External Components .. 3-7 Cam Gear and Friction Gear Removal .......... 3-7 Cylinder Block Disassembly-Internal Components .. 3-8 Camshaft Removal ... ........................ 3-9 Connecting Rod and Piston Assembly Removal .. 3-9 Cylinder Liner Removal ....... .............. . 3-11 Main Bearing Cap Removal .................. 3-11 Piston Ring Removal ........................ 3-1O Rear Oil Seal Removal ...................... .. 3-9 Snap Ring and Piston Pin Removal ............ 3- 10 Cylinder Head Disassembly ...................... 3-3 Cylinder Head Bolt Removal ................... 3-4 Rocker Arm and Shaft Removal ................ 3-4 Valve Guide Removal . ......... ............... 3-4 Valve Retainer Removal ...................... 3-4 Valve Seal Removal .. ........................ 3-4 Mounting the Engine to the Engine Stand .......... 3-1 Special Tools Required ....................... 3-1 Order of Disassembly .. ......................... 3-2 Special Tools Required .......................... 3-2 Engine Identification Illustration ...................... 1-3 · ' , .

Engine Inspection and Repair ............ .......... 3-12 Camshaft Inspection ........................... 3-21 Connecting Rod Inspection ...................... 3-20 Crankshaft Inspection .......... : ............... 3-20 Cylinder Block an_d Liner Dimensions ............. 3-17 Cylinder Block and Liner Identification ............ 3-19 Cylinder Block Inspection ....................... 3-17 Cylinder Head Bolt Inspection ................... 3-13 Cylinder Head Inspection ....................... 3-13 Cylinder Liner Inspection ........................ 3-18 Main and Connecting Rod Bearing Inspection ..... 3-21 Piston and Piston Pin Inspection ................. 3-18 Push Rod Inspection ........................... 3-16 Rocker Arm and Rocker Shaft Inspection ......... 3-16 Special Tools and Supplies Required ............. 3-12 Tappet Inspection .............................. 3-23 Valve and Valve Guide Inspection ................ 3-13 Valve Seat Inspection ........................... 3-14 9-1

Yale

'

Industrial Trucks

ALPHABETICAL INDEX E

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I

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II , :I :''' i' I � I,

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I ;I l ',1111 i' 11 i\l, 1·.,

Ir:'rI_'.

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Valve Spring Inspection ......................... 3-16 Engine Introduction Cooling System ............................... : 1-6 Cylinder Block ........ .. ........ ... ............. 1-4 Cylinder Head .......... ........ .. .............. 1-5 Cylinder Head Cover .. .......... ........ ........ 1-4 Electrical System ............... ................ 1-8 Fuel System ........................... ........ 1-8 Diagram-Fuel System ................ ....... . 1-8 Intake and Exhaust Systems ................ ..... 1-6 Lubrication System .. ... ......................... 1-7 Diagram .................................... 1-7 Pistons and Crankshaft ....·...................... 1-4 Timing Gear and Timing Gear Case ............... 1-4 Valve System ....................... ... ........ 1-5 Engine Oil. See Oil Engine Reassembly ............._.................. 3-24 Cylinder Block Reassembly-Accessory Components 3-38 Assembly ana Torque Value Illustration ......... 3-38 Crankshaft Pulley Installation ................. 3-40 Engine Mount Installation .................... 3-38 Flywheel Installation ......................... 3-39 Fuel Line Installation ......................... 3-39 Oil Filter Assembly Installation ................ 3-39 Oil Pipe Installation .......................... 3-39 Water Pipe Installation .......... ............. 3-40 Cylinder Block Reassembly-External Components . 3-34 Assembly and Torque Value Illustration ......... 3-34 Fuel Injection Pump Installation ............... 3-36 Oil Cooler Assembly Installation ............... 3-35 Oil Pan Installation .... . ..................... 3-37 Oil Pressure Switch Installation ............... 3-35 Oil Pump Installation ......................... 3-34 Oil Strainer Installation ....................... 3-37 Stiffener Plate lnstallatidn .................... 3-37 Timing Gear Case Installation . ... . ............ 3-35 Timing Gear Cover Installation ................ 3-36 T iming Gear Installation ...................... 3-35 Cylinder Block Reassembly-Internal Components .. 3-26 Assembly and Torque Value Illustration ......... 3-26 Camshaft Installation : ...... ; ................ 3-27 Crankshaft and Bearing Installation ............ 3-27 Crankshaft Crank Pin Finish Dimensions ....... 3-32 Crankshaft Main Journal Finish Dimensions .... 3-29 Crankshaft Thrust Bearing Finish Dimensions ... 3-30 End Plate and Rear Oil Seal Installation ........ 3-33 Piston and Connecting Rod Installation ......-:·.. 3-30 Piston Cooling Jet Installation ... : ............. 3-26 Cylinder Head Reassembly ....... .............. 3-41 Assembly and Torque Value Illustration ......... 3-41 Cylinder Head Cover Installation .............: · 3-46 Cylinder Head Gasket Installation ,. ............ 3-43 Cylinder Head Installation .................... 3-43 Dipstick and Guide Pipe ·installation ............ 3-45 Exhaust Manifold Installation .................. 3-46 Fuel Injector Line Installation .................. 3-45 Injection Nozzle Installation ................... 3-44 Injector Line Clip Installation .................. 3-45 9-2

E

Intake Manifold Installation ................... 3-44 Rocker Arm Installation ...................... 3-43 Seal Cover Installation ....................... 3-46 T hermostat Housing Installation ......... : ..... 3-43 Valve Guide Installation ...................... 3-41 Valve Retainer Installation .................... 3-42 Valve Seal Installation ....................... 3-42 Valve-Valve Spring-Valve Spring Seat Installation 3 -42 Special Tools Required ......................... 3-24 Engine Specification Table .......................... 1-1 Engine Specifications Overhaul Specifications and Wear Limits .......... 3-47 Torque Specifications ........................... 3-50 F Fuel Feed Pump Strainer Inspection ................ 6- 14 Fuel Filter . ...................................... 6- 14 Bleeding Air From the Fuel System ......... ....... 2-8 Element Replacement ....................·...... 6-14 Fuel Filter Replacement ...... . .................. 2-4 Straine: ':·,spection ............................. 6-14 Fuel Injector. See Injectors Fuel Pump. See ln)ection Pump Fuel Stop Mechanism ............................. 6-19 Description ................................... 6-19 Fuel Stop Cable Inspection and Adjustment ....... 6-20 Fuel Stop Motor ............................... 6-24 Bench Test .......................... ....... 6-25 Circuit Inspection ............................ 6-24 Fuel Stop Relay ............... ................ 6-23 Bench Test ................................. 6-24 Circuit Inspection ............................ 6-23 Operation of the Fuel Stop Control ............... 6-21 Fuel System Diagram .............................. 6-1

Idle-Engine Adjustment ................................ 2-5, 6-4 Inspection ...... . .......................... 2-5, 6-4 Injection Pump Component Illustration ........................... 6-1 Description .......... .......................... 6-2 Fuel Feed Pump Description ..................... 6-3 Governor Description ... ; ........................ 6-2 Lubrication Description' ..... : .................... 6-2 Lubrication Diagram .............................. 6-2 Removal/Replacement/Installation Pump Assembly and Torque Value Illustration ... 6-10 Pump Assembly Removal ..................... 6-8 Pump Installation and Setup .................. 6-11 Pump Replacement ......................... 6-11 Specifications .................................. 6-4 Timer Component Illustration ..................... 6-3 Timer Description ............................... 6-3 Injection Timing Adjustment .................................... 6-5 Inspection ..................................... 6-4

·Yale

Industrial Trucks

ALPHABETICAL INDEX

Injectors-Fuel Cleaning .. .................................... 6-17 Disassembly .................................. 6-17 Inspection .. ............................ .... .. 6-15 Spray Pattern ............................... 6-16 Starting Pressure ........................... 6-16 Valve Seat Integrity .......................... 6-16 Instal lation .................................... 6-18 Reassembly .................................. 6-17 Removal ...................................... 6-15 L Lubrication System Diagram ....................................... 4-1 Specifications .. ........................ ...... .. 4-2

0

Oil and Filter-Engine Engine Oil Capacity ............................. 2-1 Oil Change and Refill ........ . ........ ....... .. . . 2-1 Oil Filter Replacement ........................... 2-1 Oil Level Inspection ............................. 2-1 Oil-Engine Capacity .................... . ........ ..... .. ... 4-2 Cooler Installation Illustration ..................... 4-5 Filter Housing Replacement ...... ...... .. ... .. ... 4-3 Filter Replacement Interval ....................... 4-2 Filter Replacement-Main and Bypass ... .. ... .. . . . 4-3 Inspection ........................... .. ..... .. . 4-2 Line and Pipe Installation ................ ... .... . 4-5 Lubrication System Diagram ..................... 4-1 Lubrication System Specifications ........... .... .. 4-2 Pressure Switch Installation ...................... 4-4 Pressure Test .. ............................... . 4-3 Special Tools Required ....................... 4-3 Pump-Oil Inspection ................................... 4-4 Installation .............. .......... .. ..... ... 4-4 Replacement .............................. .. ... 4- 2 Replacement Interval ............................ 4-2 Pump-oil. See Oil-Engine

p

R Recommended Schedule of Preventive Maintenance ... 2-9

s

Special Tool List .. .. ............................... 8-1 Starter Armature Inspection ....... ......... ............ 7 -12 Assembly Illustration ............................ 7-6 Brush and Brush Holder Inspection ............... 7-13 Brush Replacement ............................ 7-14 Circuit Diagram ................................. 7-7 Components List ............................... 7-6 Disassembly ................................... 7-9 Exploded View ... .. . ... ...... ................ 7-9 Field Coil Inspection ............................ 7-13 Inspection-On Vehicle ........................... 7-7 Starter Circuit Inspection ................... ... 7-8 Starter Current Draw Specifications ............. 7-7 Installation .................................... 7-14 No-load Test ................................. 7-14 Relay Bench Test .............................. 7-10 Removal and Installation .................. ....... 7-8 Solenoid ...... .. ...... .. ...................... 7-11 Coil Test ................................... 7-11 Continuity Test .............................. 7-11 Specifications .................................. 7-7 Wiring Layout ................................. 7-10 Strainer Inspection-Fuel Feed Pump ................ 6-14 T T hermostat. See Cooling System Timing-Engine. See Injection Timing Timing-Injection Pump Adjustment. See Inspection and Adjustment of the Injec­ tion Timing Inspection ..................................... 2-6 Tool List - Special .................·....... .. ....... 8-1 Torque Specifications ............................. 3-50 Troubleshooting Guides Cooling System Troubleshooting Guide . ........... 5- 4 Electrical System Troubleshooting Guide .......... 7-21 Engine Troubleshooting Guide ................... 3-51 Fuel System Troubleshooting Guide .............. 6-26 Lubrication System Troubleshooting Guide .. ....... 4-6 V Valve Clearance-Engine Adjustment ..... ..... .. ... .............. ....... 2-2 Inspection ..................................... 2- 2

9-3

Mazda TM Engine Parts contact: EngineParts@HeavyEquipmentRestorationParts.com

Phone: 2696731638