Caterpillar Cat DP20 MC Lift Truck Service Manual - Complete Set - PDF DOWNLOAD

Service Manual S4S Diesel Engine 1001-up

For use with DP20/20K, DP25/25K,DP30/30K and DP35/35K

Chassis Service Manual.

99729-96100

FOREWORD

This service manual covers S4S Diesel Engine of Cat ® Lift Trucks and gives detailed maintenance and repair information. The instructions are grouped by systems to serve the convenience of your ready reference.

Long productive life of your lift trucks depends to a great extent on correct servicing – the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting any work.

All descriptions, illustration, specifications, and serial numbers in this manual are effective as of the date printing of this manual. Cat Lift Trucks reserves the right to change specifications or design without notice and without incurring obligation.

Pub. No. 99729-96100

How to Use This Manual In this service manual, the S4S Diesel Engine specifications, maintenance standards and adjustment procedure as well as service procedures such as disassembly, inspection, repair and reassembly are arranged in groups for quick reference.

There are separate manuals for the fuel injection pump and governor.

A short summary of each Group is given in the General Contents, and there is also a table of contents at the beginning of each Group.

Regarding engine operation and periodical maintenance, refer to the Operation & Maintenance Manual. For component parts and ordering of service parts, refer to the Parts Catalogue. Structure and function of the engine are described in various training manuals.

1.

Methods of Indication

(1) Parts shown in illustrations and described in text are numbered to correspond with the sequence of disassembly.

(2) Inspections to be conducted during disassembly are indicated in a box

in disassembled views.

(3) Maintenance standards for inspection and repair are described in text where they are relevant, are also listed in Group 2 in the General Contents.

(4) The sequence in which parts are to be assembled is summarized below each assembled view.

4

←

←

2

3

←

←

Such as: 5

1 .

(5) The following marks are used in this manual to emphasize important safety cautions.

WARNING

…Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

…Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTE

…Indicates important information or information which is useful for engine operation or maintenance.

(6) Tightening torque under wet conditions is indicated by “[Wet].” When so indicated, apply engine oil to the threaded portion of the fastener. Unless indicated as such, the tightening torque is to be assumed in the dry condition.

2.

Terms Used in This Manual

Nominal value: Indicates the standard dimension of a part to be measured.

Standard: Indicates the dimension of a part, the clearance between parts, or the standard performance. Since the value is indicated in a range needed for inspection, it is different from the design value.

Limit: A part must be repaired or replaced with a new part when it reaches the limit value.

3.

Abbreviations, Standards, Etc.

• BTDC = Before Top Dead Center • ATDC = After Top Dead Center • BBDC = Before Bottom Dead Center • ABDC = After Bottom Dead Center • TIR = Total Indicated Reading • API = American Petroleum Institute • ASTM = American Society for Testing and Materials • JIS = Japanese Industrial Standards • LLC = Long Life Coolant • MIL = Military Specifications and Standards (U.S.) • MSDS = Material Safety Data Sheet • SAE = Society of Automotive Engineers (U.S.)

4.

Units of Measurement

Measurements are based on the International System of Units (SI), and their converted metric values are indicated in parentheses ( ). For metric conversion, the following rates are used.

• Pressure: 1 MPa = 10.197 kgf/cm2 • Torque: 1 N·m = 0.10197 kgf·m • Force: 1 N = 0.10197 kgf • Horsepower: 1 kW = 1.341 HP = 1.3596 PS • Meter of mercury: 1 kPa = 0.7 cmHg • Meter of water: 1 kPa = 10.197 cmH2O (cmAq) • Rotational speed: 1 min−1 = 1 rpm

GROUP INDEX GROUP INDEX

Items

GENERAL

Outline (external view, engine serial number location, engine model and application codes), Specifications

1

MAINTENANCE STANDARD

Maintenance Standards Table, Tightening Torques, Sealants and Lubricants Table, Maintenance Schedule

2

SPECIAL TOOL

Special Tool List

3

GENERAL INSTRUCTIONS

Determination of Overhaul Timing, Testing Compression Pressure, Tips on Disassembly and Reassembly, Precautions for Disassembly and Reassembly

4

DISASSEMBLY, ENGINE MAIN PARTS

Preparation before Disassembly, Electrical System, Fuel System, Oil System, Cooling System, Inlet and Exhaust System, Engine Main Parts

5

INSPECTION AND REPAIR, ENGINE MAIN PARTS

Cylinder Head and Valve Mechanism, Flywheel, Timing Gears, Piston, Connecting Rod, Crankshaft, Crankcase and Tappet

6

REASSEMBLY, ENGINE MAIN PARTS

Piston, Connecting Rod, Crankshaft, Crankcase and Tappet, Timing Gears, Flywheel, Cylinder Head and Valve Mechanism

7

FUEL SYSTEM

Fuel System, Fuel Filter, Injection Nozzle, Fuel System Bleeding

8

LUBRICATION SYSTEM

Lubrication System, Oil Pump, Oil Filter, Oil Pressure Relief Valve

9

COOLING SYSTEM

Cooling System, Water Pump and Fan, Thermostat

10

INLET AND EXHAUST SYSTEM

Description, Exhaust Manifold

11

ELECTRICAL SYSTEM

Starter, Alternator, Glow Plugs, Stop Solenoid

12

ADJUSTMENT, BENCH TEST, PERFORMANCE TEST

Adjustments, Bench Test, Performance Tests

13

TROUBLESHOOTING

Cause of Engine Problems and Remedies

14

GENERAL 1 1. Outline ................................................................................................. 1 – 1 1.1 External View ................................................................................. 1 – 1 1.2 Engine Serial Number Location ...................................................... 1 – 3 1.3 Engine Model and Application Codes ............................................. 1 – 3

2. Specifications .................................................................................... 1 – 4

1.

GENERAL

Outline

1.1 External View; with Distributor Type Fuel Injection Pump Inlet manifold

Injection nozzle

Oil level gauge

Water pump (Water inlet)

Fuel filter

Water drain plug

Rear

Front

Fuel injection pump

Crankshaft pulley Oil filter

Flywheel Oil drain plug

Left view Left view

Oil filler cap

Water outlet Exhaust outlet

Exhaust manifold

Thermostat case

Alternator Fuel outlet Fuel inlet Rear

Front

V-belt Starter

Oil pan

Rightview view Right

1-1

GENERAL

1.1

External View (Cont’d)

With In-line Type Fuel Injection Pump Injection nozzle

Inlet manifold Oil level gauge

Fuel filter Governor

Water pump (Water inlet)

Fuel injection pump

Water drain plug

Rear

Rear

Feed pump

Oil filter

Crankshaft pulley

Flywheel Oil drain plug

Left view

Left view

Oil filler cap

Water outlet Exhaust outlet

Exhaust manifold

Thermostat case

Alternator Fuel outlet Fuel inlet Rear

Front

V-belt Starter

Oil pan

Right view Right view

1-2

GENERAL

1.2 Engine Serial Number Location The engine serial number is located on the side of the crankcase.

Engine serial number

Name plate

1.3 Engine Model and Application Codes S Series code Number of cylinders Initial of “Sagamihara Plant”

1-3

GENERAL

2.

Specifications Model designation

S4S

Type

Water-cooled, 4-stroke cycle

No. of cylinders–arrangement

4–in line

Combustion chamber type

Swirl chamber

Valve mechanism

Overhead

Cylinder bore × stroke

mm (in.)

Piston displacement

liter (cu in.)

Compression ratio General

1–3–4–2

Fuel

Diesel fuel (JIS K2204 or equivalent)

Direction of rotation

Counterclockwise as viewed from flywheel side Overall length Overall width Overall height

mm (in.)

647 (25.5)

mm (in.)

578 (22.8)

mm (in.)

710 (28.0)

kg (lb)

245 (540)

Weight (dry) Type of cylinder sleeve No. of piston ring

Engine main parts

Dry (Integral with cylinder block)

Compression ring

2

Oil ring

1 (w/spring expander)

Inlet valve Valve timing Exhaust valve

Open

BTDC 30°

Close

ABDC 50°

Open

BBDC 74°

Close

ATDC 30°

Starting system

Electric–starter

Starting aid

Glow plugs Type

Fuel injection pump

Diameter of plunger mm (in.)

Type Cam lift

mm (in.)

Mechanism

Delphi Diesel System, all speed type DENSO, RSV DENSO, throttle type

Type of nozzle No. of spray orifice Fuel injection nozzle

Diameter of spray mm (in.) orifice Spray angle Valve opening pressure MPa (kgf/cm2) [psi]

Fuel filter

8.0 (0.315), DENSO, piston type Centrifugal

Type

Fuel system

Distributor type (Delphi Diesel System, VE) In-line type (DENSO) 7.0 (0.276) for distributor type 6.5 (0.256) for in-line type Delphi Diesel System, vane type DENSO, piston type

Fuel feed pump

Governor

3.331 (203) 22 : 1

Firing order

Dimension (with fan)

94 × 120 (3.70 × 4.72)

Type

1 1.0 (0.039) 15° 14.22 (145) [2062] Cartridge of paper element

1-4

GENERAL

Model designation

S4S

Type

Force feed by oil pump Specification

Engine oil

Class CF oil (API Service Classification)

Capacity (engine) liter (U.S. gal.)

Type

Lubrication system

Oil pump

Trochoid

Speed ratio to crankshaft

0.73

Capacity liter (U.S. gal.)/min

28.6 (7.6) at 0.3 MPa (3 kgf/cm2) [44 psi] discharge pressure of pump running at 2230 min-1

Type

Piston valve

Relief valve

Opening pressure MPa (kgf/cm2) [psi]

0.35±0.05 (3.6±0.5) [50±7]

Oil filter

Type

Cartridge of paper element

Refill capacity (engine water jacket) liter (U.S. gal.)

Type Cooling system

Approx. 9 (2.4) [Oil pan: 8 (2.1), Filter: 1 (0.3)]

Water pump

V-belt Thermostat

Speed ratio to crankshaft

1.3

Capacity liter (U.S. gal.)/min

160 (42.3) at 0.75 MPa (7.5 kgf/cm2) [109 psi] discharge pressure of pump running at 3600 min-1

Type

Low-edge cogged A type V-belt × 1

Type

Wax pellet

Valve opening temperature °C (°F)

76.5±1.5 (170±2.7) 12V–ground

Model (Output)

Mitsubishi Electric Corp.

M8T75171(12V-2.2kW) M2TS0071A (12V-2.2kW) M3T67671 (12V-3.0kW)

Type

Pinion shift

No. of pinion teeth/ flywheel ring gear teeth Alternator

8.75 (2.3) 8.75 (2.3) 9.05 (2.4)

Centrifugal

Voltage–polarity Starter

DP20, 25 DP30, 35 (Manual) DP30, 35 (Powershift)

Model (Output)

Mitsubishi Electric Corp.

A7T02077C (12V-50A) A2TN0878 (12V-50A) A2TA7877 (12V-25A)

Electrical system Working speed

10/122

min-1

1000 to 18000; 1000 to 10000; 1000 to 8000

Rated output generating speed min-1

5000

Maximum permissible speed min-1

22000; 12000; 10000

Speed ratio to crankshaft

1-5

2.0

GENERAL

Model

S4S Type

Glow plug Electrical system

Sheathed

Rated voltage-current Operating voltage

10.5V–9.7A (30 sec. rating) 8 to 14V

Stop Solenoid

Operating temperature

(In-line fuel injection pump)

Rated time

-30 to 90°C (-86 to 194°F) 10 seconds or less

Rated current

22.6A or less

1-6

MAINTENANCE STANDARDS 1. Maintenance Standards Table ...................................................... 2 – 1 2. Tightening Torques .......................................................................... 2 – 6 2.1 Important Bolts and Nuts ................................................................ 2 – 6 2.2 Standard Bolts ................................................................................ 2 – 7 2.3 Standard Studs ............................................................................... 2 – 7 2.4 Standard Plugs ............................................................................... 2 – 7

3. Sealants and Lubricants Table ..................................................... 2 – 8 4. Maintenance Schedule ................................................................... 2 – 9

2

MAINTENANCE STANDARDS

1.

Maintenance Standards Table Unit: mm (in.)

Group

Inspection Point

Maximum min−1 (no-load)

Minimum min−1 (no-load)

Nominal Value

Distributor type pump

2350

0 -50

In-line type pump

2405

+10 -20

Distributor type pump

690

+30 0

In-lin type pump

805

+10 -15

Compression pressure MPa (kgf/cm2) [psi]

General

Engine oil pressure MPa (kgf/cm2) [psi] Valve timing ±3° (crank angle)

0.15 (1.5) [21.8]

0.1 (1) [14.5] or more at idling

0.05 (0.5) [7.3]

Inlet open: BTDC 30° Exhaust open: BBDC 74°

Warpage of gasket contact surface

Crankcase

94 (3.70)

Camshaft bore

Oil temperature 70 to 90°C (158 to 194°F)

Inlet close: ABDC 50° Exhaust close: ATDC 30° Both inlet and exhaust valves

BTDC 20° (Distributor type pump) BTDC 22° (In-line type pump)

Differs depending on the specifications. See the spec.

10 to 12 (0.4 to 0.5)

Push belt in ward with thumb pressure {98 N (10 kgf) [22 lbf]} and measure deflection.

0.05 (0.0020) or less

0.20 (0.0079)

94.000 to 94.035 (3.7008 to 3.7022)

94.200 (3.7087)

94.700 (3.7283)

0.200 (0.0079)

–0.09 (–0.035) as journal diameter which is 78 (3.07)

Circularity

0.01 (0.0004) or less

Cylindricality

0.015 (0.0006) or less

Regrind if warpage is minor.

Refinish cylinder to 0.25 (0.0098) or 0.50 (0.0197) oversize of normal value by honing and use the same oversize pistons and piston rings.

If repair limit is reached, replace bearings. If is exceeded, regrind journals and use undersize bearings.

Bearing undersizes: 0.25 (0.0098) 0.50 (0.0197) 0.75 (0.0295)

Clearance between bearing and journal

0.050 to 0.110 (0.0020 to 0.0043)

Width of thrust journals (Clearance between thrust and journal)

0.100 to 0.264 (0.0039 to 0.0104)

0.300 (0.0118)

Inside diameter

14.000 to 14.018 (0.5512 to 0.5519)

14.100 (0.5551)

Clearance between tappet and bore

0.016 to 0.052 (0.0006 to 0.0021)

0.080 (0.0031)

If it exceeds the repair limit, replace tappets.

Clearance between camshaft journal and bore

0.070 to 0.110 (0.0028 to 0.0043)

0.15 (0.0059)

If it exceeds the repair limit, refinish bores and install bushings, or replace camshaft.

Main bearing

Tappet bore

Remark

Oil and water temp.

20 to 30°C (68 to 86°F)

0.25 (0.0098)

V-belt deflection

Cylinder

2.84 (29) [412]

0.29 to 0.49 (3 to 5) [42 to 71] at 1500 min−1

Fuel injection timing

Inside diameter

Repair Service Limit Limit (Clearance) (Clearance)

Adjust governor setting

3.24 (33) [469] at 300 min−1

Valve clearance (cold)

Crankcase

Assembly Standard (Standard Clearance)

2-1

Replace thrust plate.

MAINTENANCE STANDARDS

Unit: mm (in.)

Group

Inspection Point

Cylinder head

Warpage of gasket contact surface Compressed thickness of gasket Diameter of valve stem

Valve and Clearance valve guide between guide and stem

Inlet valve

Valve seat

0.05 (0.0020) or less 1.2 (0.05)

0.065 to 0.095 (0.0026 to 0.0037)

0.150 (0.0059)

Exhaust valve

0.080 to 0.115 (0.0032 to 0.0045)

0.200 (0.0079)

Inlet valve

0.4 (0.016)

Exhaust valve

0.5 (0.020) 1.4 (0.055)

±0.14 (±0.0055)

1.8 (0.071)

2.13 (0.0839)

Up to 1.83 (0.0720) by refacing

Squareness of ends with respect to center line

19 (0.75)

147 (15) [33]

19.010 to 19.030 (0.7484 to 0.7492) 18.980 to 19.000 (0.7472 to 0.7480) 0.010 to 0.050 (0.0004 to 0.0020)

0.070 (0.0028)

Deflection

0.3 (0.012) or less

Deflection

0.02 (0.0008) or less

0.05 (0.0020)

1/2 of dial indicator reading

Journal diameter

78 (3.07)

77.955 to 77.970 (3.0691 to 3.0697)

77.850 (3.0650)

Crankpin diameter

58 (2.28)

57.955 to 57.970 (2.2817 to 2.2823)

57.800 (2.2756)

Center to center distance between journal and crankpin

60 (2.36)

±0.04 (±0.0016)

Parallelism between journal and crankpin

Valve Valve Valve margin seat angle sinkage

43 (1.69)

Clearance between bushing and shaft

Crankshaft

Seat width

47.60 (1.87)

177 to 196 (1.8 to 20) [40 to 44]

Set force N (kgf) [lbf]

Diameter of rocker shaft

1.0 (0.039)

1.5° or less

Set length

Inside diameter of rocker bushing

±0.1 (±0.004)

48.85 (1.92)

Squareness

Main moving parts

13.9 to 14.1 (0.5472 to 0.5551)

30°

Free length

Valve pushrod

±0.05 (±0.002)

Inlet valve

14 (0.55)

Remark Regrind if warpage is minor.

7.850 (0.3091)

8 (0.31)

Valve margin

Rocker arm

0.20 (0.0079)

7.920 to 7.940 (0.3118 to 0.3126)

Exhaust valve

Width

Valve spring

Repair Service Limit Limit (Clearance) (Clearance)

7.900 (0.3110)

Angle Valve sinkage

Assembly Standard (Standard Clearance)

7.940 to 7.955 (0.3126 to 0.3132)

Height to top of valve guide

Cylinder head

Nominal Value

Runout : 0.01 (0.0004) or less (over crankpin length)

2-2

77.100 (3.0354)

MAINTENANCE STANDARDS

Unit: mm (in.)

Group

Inspection Point

Nominal Value

Circularity of journal and crankpin

0.01 (0.0004) or less

Cylindricality of journal and crankpin

Crankshaft

Fillet radius of journal and crankpin

Piston

Outside diameter (at skirt)

End play (Width of shaft thrust journal)

3 (0.12)

3.1 (1.22)

Standard 0.25 (0.0098) oversize

94 (3.70)

0.50 (0.0197) oversize

Connecting rod

Clearance Clearance between between ends groove and ring

Main moving parts

0.100 to 0.264 (0.0039 to 0.0104)

If thrust plate clearance exceeds the repair limit, replace thrust plates.

If it is exceeded, use oversize thrust plates.

Thrust plate oversizes: 0.15 (0.0059) 0.30 (0.0118)

0.300 (0.0118)

93.955 to 93.985 (3.6990 to 3.7002)

93.770 (3.6917)

94.205 to 94.235 (3.7089 to 3.7100)

94.020 (3.7016)

94.455 to 94.485 (3.7187 to 3.7199)

94.270 (3.7114) Check bearing clearance.

0.200 (0.0079)

No.2 ring

0.045 to 0.085 (0.0018 to 0.0034)

0.150 (0.0059)

Oil ring

0.025 to 0.065 (0.0010 to 0.0026)

0.150 (0.0059)

No.1 ring No.2 ring Oil ring

0.30 to 0.50 (0.0118 to 0.0197)

1.50 (0.0019)

29.994 to 30.000 (1.1809 to 1.1811)

Clearance between pin and piston

0.000 to 0.016 (0.000 to 0.0006)

0.050 (0.0019)

Clearance between pin and bushing

0.020 to 0.051 (0.0008 to 0.0020)

0.080 (0.0032)

Inside diameter of bushing

30 (1.18)

Clearance between crankpin and connecting rod bearing

Flatness Face runout

30.020 to 30.045 (1.1819 to 1.1829) 0.05/100 (0.0019/3.94) or less

Bend and twist

End play Flywheel

±0.2 (±0.008)

0.07 to 0.11 (0.0028 to 0.0043)

30 (1.18)

Remark

0.03 (0.0012)

No.1 ring

Diameter Piston pin

Repair Service Limit Limit (Clearance) (Clearance)

-0.25 to 0.15 (-0.0098 to 0.0059)

Protrusion

Piston ring

Assembly Standard (Standard Clearance)

33 (1.30)

0.030 to 0.090 (0.0012 to 0.0035)

0.200 (0.0079)

If service limit is exceeded, replace bearing or regrind pin and use undersize bearing.

0.15 to 0.35 (0.0059 to 0.0138)

0.50 (0.020)

Replace connecting rod.

0.15 (0.0059) or less

2-3

0.50 (0.020)

MAINTENANCE STANDARDS

Unit: mm (in.)

Group

Inspection Point

Nominal Value

0.02 (0.0008) or less

Exhaust valve

6.720 (0.2646)

6.420 to 6.820 (0.2528 to 0.2685)

6.220 (0.2450)

No.1, 2

54 (2.13)

53.94 to 53.96 (2.1236 to 2.1244)

53.90 (2.1220)

No.3

53 (2.09)

52.94 to 52.96 (2.0842 to 2.0850)

52.90 (2.0827)

5 (0.20)

0.10 to 0.25 (0.0039 to 0.0098)

0.30 (0.0118)

Replace thrust plates.

0.009 to 0.050 (0.0004 to 0.0020)

0.100 (0.0040)

Replace bushing.

0.35 (0.0138)

Replace thrust plates.

0.25 (0.0098)

Replace gears.

Idler gear

End play

4.5 (0.18)

0.05 to 0.20 (0.0020 to 0.0079)

Fit (interference) of bushing in crankcase bore

35 (1.38)

0.035T to 0.076T (0.0014T to 0.0030T) 0.05 to 0.15 (0.0020 to 0.0059)

Injection nozzle

Valve opening pressure MPa (kgf/cm2) [psi]

Spray cone angle

Starter (12 V–2.2 kW) (M8T75171/M2TS0071A)

Oil tightness of need valve seat

Starter (12 V–3.0 kW) (M3T767671)

&

6.184 (0.2435)

Backlash

Fuel system

Straighten by cold working or replace.

6.384 to 6.784 (0.2513 to 0.2671)

Clearance between shaft and bushing

Diameter of commutator Length

14.22 (145) [2062]

15°

32 (1.26)

Diameter of commutator Length

Test by means of hand tester using diesel fuel at the temperature of about 20°C (68°F). If discharge pattern is bad even after nozzle is washed in clean diesel fuel, replace nozzle tip.

31.8 to 32.2 (1.25 to 1.27)

18 (0.71)

Wash or replace nozzle tip.

31.4 (1.24) 11 (0.43)

26 to 36 (2.7 to 3.7) [5.8 to 8.1]

Spring force, N (kgf) [lbf]

&

Make shim adjustment.

Pressure varies by 1 (10) [142] per 0.1 mm (0.004 in.) thickness of shim.

14.22 to 15.00 (145 to 153) [2062 to 2176]

Seat shall hold a test presser 1.96 MPa (20 kgf/cm2) [284 psi] lower than valve opening pressure for 10 seconds.

Pinion clearance

Brush

0.05 (0.0020)

Remark

6.684 (0.2632)

End play

Brush

Repair Service Limit Limit (Clearance) (Clearance)

Inlet valve

Camprofile (D1 - D2)

Journal diameter

Timing gear

Camshaft

Deflection

Electrical system

Assembly Standard (Standard Clearance)

15 (1.5) [3.4]

0.5 to 2.0 (0.020 to 0.079) 38.7 (1.52)

38.5 to 38.9 (1.52 to 1.53)

17 (0.67)

Spring force, N (kgf) [lbf]

Pinion clearance

No-load characteristics (M8T75171) Voltage, V Current, A Speed, min−1 11 130 or less 3800 or more

38.1 (1.50) 11 (0.43)

33 to 45 (3.4 to 4.6) [7.4 to 10.1]

18 (1.5) [4.1]

0.5 to 2.0 (0.020 to 0.079) No-load characteristics (M2TS0071A) Voltage, V Current, A Speed, min−1 11 130 or less 3750 or more

2-4

No-load characteristics (M3T67671) Voltage, V Current, A Speed, min−1 11 180 or less 3800 or more

MAINTENANCE STANDARDS

Unit: mm (in.)

Inspection Point Alternator Alternator Alternator (12 V–25 A) (12 V–50 A) (12 V–50 A) (A2TA7877) (A2TN0878) (A7T02077C)

Electrical system

Group

Nominal Value

18.5 (0.73)

Brush height Resistance in slip rings

Oil pump

Repair Service Limit Limit (Clearance) (Clearance)

21.5 (0.85)

Brush height Resistance in slip rings

at 20°C (68°F) 8.0 (0.32)

9.0 to 10.4 ohm 20.0 (0.79)

Brush height Resistance in slip rings

at 20°C (68°F) 5.0 (0.20)

14 to 16 ohm 0.20 to 0.30 (0.0079 to 0.0118)

Diameter of main shaft (case side)

16 (0.63)

15.985 to 16.000 (0.6293 to 0.6299)

Diameter of main shaft (oil pump bushing side)

14 (0.55)

13.957 to 13.975 (0.5495 to 0.5502)

Remark

5.0 (0.20)

12.4 ohm

Clearance between outer rotor and case

Lubrication system

Assembly Standard (Standard Clearance)

at 20°C (68°F) 0.50 (0.0197)

Replace oil pump assembly.

Clearance between main shaft and case

0.032 to 0.074 (0.0013 to 0.0029)

0.150 (0.0059)

Replace pump assembly.

Clearance between main shaft and oil pump bushing

0.025 to 0.111 (0.0010 to 0.0044)

0.200 (0.0079)

Replace bushing or pump assembly.

Clearance between outer and inner rotors

0.13 to 0.15 (0.0051 to 0.0059)

0.20 (0.0079)

Replace outer rotor and shaft assembly.

Clearance between rotors and cover

0.04 to 0.09 (0.0016 to 0.0035)

0.15 (0.0059)

Replace pump assembly.

Inner rotor bore Valve opening Relief valve pressure, MPa (kgf/cm2) [psi]

16 (0.63)

15.951 to 15.968 (0.6280 to 0.6287)

0.35 (3.6) [50.8]

0.30 to 0.40 (3.1 to 4.1) [43.5 to 58.0]

2-5

(Main shaft and shrinkage fit)

MAINTENANCE STANDARDS

2.

Tightening Torques

2.1 Important Bolts and Nuts Thread Dia. × Pitch (M-thread)

Width across flats mm (in.)

N·m

kgf·m

lbf·ft

Cylinder head bolt

M12 × 1.75

19

113 to 123

11.5 to 12.5

83 to 91

Cylinder head plug

M16 × 1.5

14

39.2 to 49.0

4.0 to 5.0

28.9 to 36.2

Rocker cover

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.38 to 9.59

Rocker shaft brackets (long)

M8 × 1.25

12

10.0 to 20.0

1.0 to 2.0

7.38 to 14.8

M14 × 2

19

98 to 108

10.0 to 11.0

72.3 to 79.7

Connecting rod caps nut

M10 × 1.0

14

49.0 to 59.0

5.0 to 6.0

36.2 to 43.5

Flywheel

M12 × 1.25

17

78.5 to 88.3

8.0 to 9.0

57.9 to 65.2

Camshaft thrust plate

M8 × l.25

12

10.0 to 13.0

1.0 to 1.3

7.38 to 9.59

Front plate

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.38 to 9.59

Timing gear case cover

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.38 to 9.59

Crankshaft pulley

M30 × 1.5

46

480 to 500

49 to 51

354 to 369

Idler gear thrust plate

M10 × 1.25

14

29.0 to 39.0

3.0 to 4.0

21.4 to 28.8

Oil pan

M8 × 1.25

12

10.0 to 13.0

1.0 to 1.3

7.38 to 9.59

Rear plate

M10 × 1.25

14

54.0 to 65.7

5.5 to 6.7

39.9 to 48.5

Fuel injection pump delivery valve holders (In-line type pump)

M20 × 1.5

22

34.4 to 39.2

3.5 to 4.0

25.4 to 28.9

Fuel injection pump gear nut (Distributor type pump)

M14 × 1.5

22

76.5 to 86.3

7.8 to 8.8

56.5 to 63.7

Fuel injection pump gear nut (In-line type pump)

M12 × 1.75

19

58.9 to 68.6

6.0 to 7.0

43.5 to 50.6

Fuel return pipe nuts

M12 × 1.5

17

20.6 to 24.5

2.1 to 2.5

15.2 to 18.1

Fuel return pipe flare nut

M10 × 1.25

14

17.7 to 21.6

1.8 to 0.22

13.1 to 15.9

Fuel injection pipe nuts

M12 × 1.5

17

26.5 to 32.4

2.7 to 3.3

19.6 to 23.9

Oil pump gear

M10 × 1.25

14

28.0 to 38.0

2.9 to 3.9

20.7 to 28.0

Oil pan drain plug

M14 × 1.5

17

34.0 to 44.0

3.5 to 4.5

25.1 to 32.5

Oil pressure relief valve

M22 × 1.5

27

44.1 to 53.9

4.5 to 5.5

32.5 to 39.8

l/4–18 NPTF

14

35.3 to 43.1

3.6 to 4.4

26.1 to 31.8

Thermostat

M16 × 1.5

19

20.6 to 24.5

2.1 to 2.5

15.2 to 18.1

Exhaust manifold

M8 × 1.25

12

27.5 to 33.3

2.8 to 3.4

20.3 to 24.6

Starter terminal B

M8 × 1.25

12

9.8 to 11.8

1.0 to 1.2

7.23 to 8.71

Glow plug (body)

M10 × 1.25

12

15.0 to 20.0

1.5 to 2.0

11.7 to 14.8

Glow plug (terminal)

M4 × 0.7

7

1.0 to 1.5

0.10 to 0.15

0.74 to 1.11

Nozzles tip retaining nut (to engine)

M20 × 1.5

21

49.0 to 68.6

5.0 to 7.0

36.2 to 50.6

Thermostat case

M8 × 1.25

12

16.0 to 20.0

1.6 to 2.0

11.8 to 14.8

Description

Main bearing caps

Water drain plug

2-6

Tightening Torque

MAINTENANCE STANDARDS

2.2 Standard Bolts Torque Thread Diameter (mm)

4T

7T

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

M6

2.94 to 4.90

0.3 to 0.5

2.17 to 3.62

7.85 to 9.80

0.8 to 1.0

5.79 to 7.23

M8

9.80 to 12.7

1.0 to 1.3

7.23 to 9.40

14.7 to 21.6

1.5 to 2.2

10.8 to 15.9

M10

17.7 to 24.5

1.8 to 2.5

13.0 to 18.1

29.4 to 41.2

3.0 to 4.2

21.7 to 30.4

M12

29.4 to 41.2

3.0 to 4.2

21.7 to 30.4

53.9 to 73.5

5.5 to 7.5

39.8 to 54.2

2.3 Standard Studs Torque (tap end) Thread Diameter (mm)

For driving in aluminum materials

For driving in ferrous materials

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

M8

4.90 to 5.90

0.50 to 0.60

3.62 to 4.35

11.8 to 13.7

1.2 to 1.4

8.71 to 10.1

M10

12.7 to 14.7

1.3 to 1.5

9.37 to 10.8

21.6 to 25.5

2.2 to 2.6

15.9 to 18.8

2.4 Standard Plugs Torque Thread Diameter

For aluminum materials

For ferrous materials

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

NPTF 1/16

4.90 to 7.85

0.5 to 0.8

3.62 to 5.79

7.85 to 11.8

0.8 to 1.2

5.79 to 8.71

PT 1/8

7.85 to 11.8

0.8 to 1.2

5.79 to 8.71

14.7 to 21.6

1.5 to 2.2

10.8 to 15.9

PT 1/4, NPTF 1/4

19.6 to 29.4

2.0 to 3.0

14.5 to 21.7

34.3 to 44.1

3.5 to 4.5

25.3 to 32.5

––

––

––

53.9 to 73.5

5.5 to 7.5

39.8 to 54.2

PT 3/8

Remarks: a. The tightening torques of above tables are for the standard bolts and nuts. b. The torque values shown above are for the bolts with spring washers. c. The tolerance of above values is ±10%. d. Use the above torque unless otherwise specified. e. Do not apply any oil to the bolt threads. (dry condition)

2-7

MAINTENANCE STANDARDS

3.

Sealants and Lubricants Table Apply to

Mating Parts

Sealant or Lubricant

How to Use

Oil pan

Crankcase

ThreeBond 1207C

Apply to seal.

Rear bearing cap seat on crankcase

Rear bearing cap

ThreeBond 1212

Apply to corners before installing cap.

Side seals

Crankcase rear bearing cap

ThreeBond 1211

Apply to side seals.

Cylinder head coolant hole plug

Cylinder head

ThreeBond 1386D

Apply to plug hole.

Crankcase coolant hole plug

Crankcase

ThreeBond 1386D

Apply to plug hole.

Crankcase oil hole plug

Crankcase

ThreeBond 1386D

Apply to plug hole.

Return oil hole plug hole

Crankcase

ThreeBond 1386D

Apply to plug hole.

Crankshaft threads

Crankshaft pulley nut

ThreeBond 1212

Apply to crankshaft thread before tightening nut.

Mating face of crankcase rear end and bearing cap rear end

Rear gasket

ThreeBond 1212

Apply to mating face of crank case and bearing cap rear ends.

Note: 1207C:

Nonsolvent type silicone-based liquid gasket, Deacetone, High viscosity

1211:

Nonsolvent type silicone-based liquid gasket, Deoxime, Low viscosity

1212:

Nonsolvent type silicone-based liquid gasket, Deoxime, High viscosity

1386D:

Anaerobic high-strength sealant

2-8

MAINTENANCE STANDARDS

4.

Maintenance Schedule (3) Perform service on items at multiples of the original requirement. For example, at Every 200 service hours, also service those items listed under Every 50 service hours and Every 10 service hours.

(1) Use the service meter to determine servicing intervals.

(2) The servicing intervals in the schedule are for an average operating conditions. Service the engine earlier than the scheduled intervals if necessary.

(The intervals depends on application, operating conditions and fuel oil and lube oil used in the engine. Adjust the intervals to meet the actual operating conditions.)

Check, clean, wash or adjust.

Change.

S Rely on Cat lift truck dealer if necessary.

* Items to be serviced after initial 50 hours of operation of a new, reconditioned or long-stored engine.

Lubrication system

Fuel system

Cooling system

Engine oil

Electrical system

V belt

Every 1000 service hours

Every 3 months or every 500 service hours

Remarks

Check oil level Change oil

S

Oil filter (cartridge)

Change

S

Fuel tank

Check oil level

Fuel filter

Change

Every 6 months or every 1200 service hours S

Injection nozzles

Check

Every 12 months or every 2400 service hours S

Check coolant level Radiator Radiator fins

Air inlet system

Every month or every 200 service hours

Item

Every week or every 50 service hours

Group

Every day or every 10 service hours

Interval

Air cleaner (paper-element type)

Every 24 months or every 4800 service hours

Change coolant Clean Clean element Change element

Every 6 months or every 1200 service hours

Battery

Check electrolyte level

Add distilled water if necessary

Alternator

Check

S

Starter

Check

S

Check tension

2-9

SPECIAL TOOLS Special Tool List ...................................................................................... 3 – 1

3

SPECIAL TOOLS

Special Tool List Tool name

Part No.

Shape

Valve spring pusher

30691-04500

Valve spring removal/ installation

Valve guide remover

32A91-00300

Valve guide removal

Valve guide installer

32A91-00100

Valve guide installation

Stem seal installer

32A91-00200

Stem seal installation

Valve seat insert caulking tool

Intake: 36791-00200 Exhaust: 34491-03020

Valve seat installation

Piston ring pliers

31391-12900

Piston ring removal/ installation

Piston guide (installer)

34491-00200

Piston installation

3-1

Use

SPECIAL TOOLS

Tool name Idler gear bushing installer

Idler gear shaft puller

Part No.

Shape

30091-07300

Use Idler gear bushing removal/ installation

MH061077

Idler gear shaft removal

Crankshaft oil seal sleeve installer set

30691-13010

Crankshaft rear oil seal sleeve installation

Adapter

30691-21100

Compression pressure testing

Compression gauge

33391-02100

Compression pressure testing

Turning socket

58309-73100

Engine turning

Socket

34491-00300

Camshaft thrust plate and rocker shaft bracket installation

3-2

SPECIAL TOOLS

Tool name Connecting rod bushing puller

Part No.

Shape

MH061236

Use Connecting rod bushing removal and installation

Camshaft bushing installer set

30691-00010

Camshaft bushing removal and installation

Oil pump bushing installer

32A91-00400

Oil pump bushing installation

3-3

GENERAL INSTRUCTIONS 1. Determination of Overhaul Timing ............................................... 4 – 1 2. Testing Compression Pressure ..................................................... 4 – 2 3. Tips on Disassembly and Reassembly ....................................... 4 – 3 3.1 Disassembly ................................................................................... 4 – 3 3.2 Reassembly ................................................................................... 4 – 3

4. Precautions for Disassembly and Reassembly ........................ 4 – 4 4.1 Oil Seals ......................................................................................... 4 – 4 4.2 O-rings ........................................................................................... 4 – 4 4.3 Bearings ......................................................................................... 4 – 5 4.4 Lock Plates ..................................................................................... 4 – 5 4.5 Split Pins and Spring Pins .............................................................. 4 – 5

4

GENERAL INSTRUCTIONS

1.

Determination of Overhaul Timing

In most cases the engine should be overhauled when the engine’s compression pressure is low. Other factors that indicated the necessity of engine overhaul are as follows: (a) Decreased power. (b) Increased fuel consumption. (c) Increased engine oil consumption. (d) Increased blow-by gas volume through the breather due to abrasion at the cylinder liner and the piston ring. (e) Gas leakage due to poor seating of the inlet and the exhaust valves. (f) Starting problems. (g) Increased noise from engine parts.

Any one or a combination of these symptoms may indicate that engine overhaul is required. Of the items listed above some are not directly related to the necessity of engine overhaul. Items (b) and (f) are more likely to be affected substantially by • Injection volume of the fuel injection pump • Fuel injection timing • Wear of injection-pump plunger • Fitting of the injection nozzle • Condition of electrical equipment: battery, starter, or alternator Item (d) above, however, requires special consideration because decreased pressure due to wear at the cylinder liner and the piston ring is one of the most obvious signs that the engine requires overhauling.

The most effective way to make a decision is by testing the compression pressure; other factors are to be considered secondarily.

4-1

GENERAL INSTRUCTIONS

2.

Testing Compression Pressure

2.1

Preparation

(1) Make sure the engine oil, air cleaner, starter and battery are normal.

(2) Start the engine and allow it to warm up to operating temperature.

2.2

Testing

(1) Move the stop lever to the stop position (fuel cut).

(2) Remove all glow plugs from the cylinder head.

Connect compression gauge (33911-02100) to the cylinder on which the compression is to be measured with compression gauge adapter (30691-21100).

Compression gauge adapter

(3) Crank the engine with the starter, then read the compression gauge indication when the engine begins running at 300 rpms.

(4) If the compression pressure is lower than the repair limit, overhaul the engine.

Measuring compression pressure

CAUTION (1) Measure the compression pressure on all cylinders.

(2) Compression pressure varies with the engine speed. Check the engine speed when measuring the compression pressure.

Unit: MPa (kgf/cm2) [psi] Item Compression pressure

Assembly Standard

Service Limit

3.24 (33) [470] 2.84 (29) [412]

NOTE Measure the compression pressure, with the engine running at 300 rpms and the oil and water temperatures at 20 to 30°C (68 to 86°F).

CAUTION (1) Measure the compression pressure at regular intervals to obtain correct data.

(2) The compression pressure will be slightly higher in a new or overhauled engine due to new piston rings, valve seats, etc. Pressure will drop gradually by the wear of parts.

4-2

GENERAL INSTRUCTIONS

3.

Tips on Disassembly and Reassembly 3.2 Reassembly

This service manual covers recommended procedures to be followed when servicing diesel engines. It also contains information on special tools required and basic safety precautions.

(1) Wash all parts, except for oil seals, O-rings, rubber seals, etc., in cleaning solvent and dry them with compressed air.

It is the responsibility of service personnel to be familiar with these requirements, precautions and potential hazards and to discuss these points with their foreman or supervisor.

(2) Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

Study this manual carefully and observe the following general precautions to prevent serious personal injury and to avoid damage to the engine, equipment and parts.

(3) Use only good quality lubricating oils and greases.

Be sure to apply a coat of oil, grease or sealant to parts as specified.

3.1 Disassembly

(5) Replace all gaskets and packing.

(4) Use a torque wrench to tighten parts when specified tightening torques are required.

(1) Use the correct tools and instruments. Serious injury or damage to the engine can result from using the wrong tools and instruments.

(2) Use an overhaul stand or a work bench if necessary.

Also, use assembly bins to keep the engine parts in order of removal.

(3) Lay down the disassembled or cleaned parts in the order in which they were removed. This will save you time at reassembly.

(4) Pay attention to the marks on assemblies, components and parts for positions or directions.

Put on your own marks, if necessary, to aid reassembly.

(5) Carefully check each part for faults during removal or cleaning. Signs of abnormal wear will tell if parts or assemblies are functioning improperly.

(6) When lifting or carrying heavy parts, get someone to help you if the part is too awkward for one person to handle. Use jacks and chain blocks when necessary.

4-3

GENERAL INSTRUCTIONS

4.

Precautions for Disassembly and Reassembly

4.1 Oil Seals When installing oil seals, carefully observe the following points:

Driving oil seals into housings (1) Check the seal lip for damage, and be sure to position it correctly in the housing.

(2) Apply a smear of grease to the surface of the oil seal (contact side with housing).

(3) Use an oil seal driver as shown to guide the seal lip and drive the outer diameter squarely. To avoid leaking or damage to the oil seal, never hammer on it directly.

Oil seal installer

Driving oil seals onto shafts (1) Apply a smear of grease to the oil seal lip.

(2) Use an oil seal guide like the one shown to the right when driving the oil seal over the stepped portion, splines, threads, or key way to prevent damage to the oil seal lip.

Oil seal guide

4.2 O-rings Use an O-ring guide to install an O-ring over stepped parts, splines, threads, or key way to prevent damage to the ring.

Apply a smear of grease to the O-ring before installation.

O-ring guide

4-4

GENERAL INSTRUCTIONS

4.3 Bearings (1) When installing a rolling bearing, be sure to push the inner or outer race by which the bearing is fitted. Be sure to use a bearing driver like the one shown.

Bearing driver

(2) Whenever possible, use a press to minimize shock to the bearing and to assure proper installation.

Installing a bearing with a press

4.4 Lock Plates Bend lock plates against the flats of the nuts or bolt heads as shown.

Good

Good

Bad

Bad

Good

Bad

Bending lock plates

4.5 Split Pins and Spring Pins Generally, split pins are to be replaced once disturbed.

Insert the pin fully and spread it properly. Drive each spring pin into position to hold it in place after later installation of parts is completed.

4-5

Good

DISASSEMBLY, ENGINE MAIN PARTS 1. Preparation before Disassembly ........ 5 – 1

9. Flywheel, Disassembly ......................... 5 – 11

1.1 Draining Engine Oil ........................... 5 – 1

9.1 Removing Flywheel ........................... 5 – 12

1.2 Draining Coolant................................. 5 – 1

9.2 Removing Oil Seal Case ................... 5 – 12

2. Electrical System ................................... 5 – 2

9.3 Removing Rear Plate ........................ 5 – 12

2.1 Removing Starter .............................. 5 – 2

10. Timing Gears, Disassembly ..................5 – 13

2.2 Removing Alternator ........................... 5 – 2

10.1 Removing Crankshaft Pulley .............5 – 14

2.3 Removing Glow plugs ........................ 5 – 2

10.2 Removing Oil Pan .............................5 – 14

3. Fuel System (Distributor type pump) .. 5 – 3

10.3 Removing Timing Gear Case Assembly..5 – 14

3.1 Removing Fuel Filter ......................... 5 – 3

10.4 Measuring Timing Gear Backlash .....5 – 14

3.2 Removing Fuel Injection Pipes .......... 5 – 3

10.5 Removing Oil Pump Gear .................5 – 15

3.3 Removing Fuel Injection Nozzles ...... 5 – 3

10.6 Removing Idler Gear .........................5 – 15

3.4 Removing Fuel Injection Pump .......... 5 – 4

10.7 Removing Camshaft .........................5 – 16

4. Fuel System (In-line type pump) .......... 5 – 5

10.8 Removing Camshaft Gear .................5 – 16

4.1 Removing Fuel Filter ......................... 5 – 5

10.9 Removing Front Plate .......................5 – 16

4.2 Removing Fuel Injection Pipes .......... 5 – 5

11. Pistons, Connecting Rods, Crankshaft, Crankcase and Tapet, Disassembly .....5 – 17

4.3 Removing Fuel Injection Nozzles ...... 5 – 5 4.4 Removing Fuel Injection Pump .......... 5 – 6

5. Oil System ............................................... 5 – 7 5.1 Removing Oil Filter ............................ 5 – 7 5.2 Removing Side Cover ........................ 5 – 7

6. Cooling System ...................................... 5 – 7 6.1 Removing Water Pump ...................... 5 – 7 6.2 Removing Thermostat ....................... 5 – 7

7. Inlet and Exhaust System .................... 5 – 8 7.1 Removing Exhaust Manifold .............. 5 – 8 7.2 Removing Inlet Manifold .................... 5 – 8

8. Cylinder Heads and Valve Mechanism, Disassembly .......... 5 – 9 8.1 Removing Rocker Shaft Assembly ..... 5 – 10 8.2 Disassembling Rocker Shaft Assembly ... 5 – 10 8.3 Removing Cylinder Head ................... 5 – 10 8.4 Removing Valves and Valve Springs ... 5 – 10

11.1 Removing Connecting Rod Cap .......5 – 18 11.2 Preparation before Removing Pistons...5 – 18 11.3 Removing Piston ..............................5 – 18 11.4 Removing Piston Rings ....................5 – 18 11.5 Removing Piston Pin ........................5 – 19 11.6 Removing Main Bearing Caps ..........5 – 19 11.7 Removing Crankshaft .......................5 – 19 11.8 Removing Tappets ............................5 – 19

5

DISASSEMBLY, ENGINE MAIN PARTS

1.

Preparation before Disassembly

1.1 Draining Engine Oil (1) Shut off the fuel supply and disconnect the starting system from the engine.

(2) Remove engine oil drain plug at the bottom of oil pan and drain the engine oil.

Engine oil Oil pan: Approx. 9 litter (2.4 U.S. gal.) capacity [Engine overall: Approx. 10 liter (2.6 U.S. gal.)]

Engine oil drain plug

Draining engine oil

WARNING Hot engine oil could cause personal injury if it contacts the skin. Use caution when draining the oil.

1.2 Draining Coolant Loosen the drain plugs on the left side of crankcase and drain coolant.

Coolant drain plug

Coolant capacity DP20, 25

8.75 litter (2.3 U.S. gal.)

DP28, 30, 35 (Manual transmission)

8.75 litter (2.3 U.S. gal.)

DP28, 30, 35 (Powershift)

9.05 litter (2.4 U.S. gal.)

Draining coolant (Distributor type pump)

Coolant drain plug

Draining coolant (In-line type pump)

5-1

REASSEMBLY, ENGINE MAIN PARTS

2.

Electrical System ԙ

2.1 Removing Starter Disconnect harness from starter. Remove nut 1 and remove the starter 2.

Ԙ

Removing starter

2.2 Removing Alternator

Ԙ

ԛ

(1) Disconnect harness from alternator. Remove adjusting bolt 1.

Ԛ ԙ

(2) Remove bolts 2 and remove the alternator 3.

(3) Remove V-belt 4. ԙ

Removing alternator

(Alternator with Vacuum Pump)

ԛ

(1) Disconnect harness, flexible hose and rubber hose from the alternator and remove adjusting plate mounting bolt 1.

Ԙ Ԛ ԙ

(2) Remove bolts 2 and remove the alternator 3.

(3) Remove V-belt 4. ԙ

Removing alternator w/vacuum pump

Ԙ

2.3 Removing Glow Plugs

ԙ

Loosen nuts 1, then remove connection plate 2 and glow plug 3.

Ԛ

Removing glow plugs

5-2

DISASSEMBLY, ENGINE MAIN PARTS

3.

Fuel System (Distributor type Pump) ԛ

3.1 Removing Fuel Filter

Ԙ

(1) Disconnect fuel hoses 1 and 2.

(2) Remove fuel filter 3 complete with bracket 4 from the inlet manifold.

Ԛ ԙ

Removing fuel filter (Distributor type pump)

3.2 Removing Fuel Injection Pipes (1) Remove pipe clamps 1 and disconnect injection pipes 2 from the injection pump and nozzle holders.

ԛ Ԝ

(3) Disconnect leak-off pipe 5.

Ԙ

Ԛ

(2) Disconnect return pipe 3 and fuel pipe 4. ԙ

CAUTION Be sure to put rubber caps over the openings of the injection pump and nozzle holders to prevent dust from getting inside the fuel system.

Removing fuel injection pipes (Distributor type pump)

3.3 Removing Fuel Injection Nozzles Remove nozzle 1 and gasket 2.

Ԙ ԙ

Removing fuel injection nozzles

5-3

REASSEMBLY, ENGINE MAIN PARTS

3.4 Removing Fuel Injection Pump (1) Check the stamped marks on the fuel injection pump flange and the pump mounting flange. The marks are used for alignment on reassembly.

CAUTION Be sure to check the stamped marks before removing the pump.

Checking stamped marks (Distributor type pump)

(2) Remove the gear case mounting bolt 1 and the gear case cover.

(3) Remove the flange mounting bolt 2 and remove the fuel injection pump with gear attached to it.

Ԙ

ԙ

Removing fuel injection pump (Distributor type pump)

5-4

REASSEMBLY, ENGINE MAIN PARTS

4.

Fuel System (In-line type pump) ԛ

4.1 Removing Fuel Filter (1) Disconnect fuel hoses 1 and 2.

Ԛ

(2) Remove fuel filter 3 complete with bracket 4 from the inlet manifold. Ԙ ԙ

Removing fuel filter (In-line type pump)

4.2 Removing Fuel Injection Pipes (1) Remove pipe clamps 1 and disconnect injection pipes 2 from the injection pump and nozzle holders.

(2) Disconnect leak-off pipe 3.

Ԝ Ԛ

ԙ

ԛ Ԝ

Ԙ

(3) Remove return pipe 4 and fuel pipe 5.

CAUTION Be sure to put rubber caps over the openings of the injection pump and nozzle holders to prevent dust from getting inside the fuel system.

Removing fuel injection pipes (In-line type pump)

4.3 Removing Fuel Injection Nozzles Remove nozzle 1 and gasket 2.

Ԙ ԙ

Removing fuel injection nozzles

5-5

REASSEMBLY, ENGINE MAIN PARTS

4.4 Removing Fuel Injection Pump (1) Check the stamped marks on the fuel injection pump flange and the pump mounting flange. The marks are used for alignment on reassembly.

CAUTION Be sure to check the stamped marks before removing the pump.

Checking stamped marks (In-line type pump)

(2) Remove the oil pipe 1 and bracket 2.

(3) Remove the gear case mounting bolt 3 and remove the gear case cover.

(4) Remove the flange mounting bolt 4 and remove the fuel injection pump with gear attached to it.

Ԛ ԙ

ԛ Ԙ

Removing fuel injection pump (In-line type pump)

5-6

DISASSEMBLY, ENGINE MAIN PARTS

5.

Oil System

5.1 Removing Oil Filter

Ԙ

Using a filter wrench, remove oil filter 1.

Removing oil filter

5.2 Removing Side Cover Ԛ

(1) Remove side cover mounting bolt 1.

ԙ

(2) Remove side cover 2 and gasket 3.

Ԙ

Removing side cover

6.

Cooling System

6.1 Removing Water Pump Ԛ

(1) Remove pulley mounting bolt 1 and remove the pulley 2.

(2) Remove thermostat bypass pipe 3 connected to water pump.

ԙ Ԙ

ԟ Ԟ

(3) Remove water pump mounting bolt 4 and dismount water pump 5, gasket 6, cover 7 and gasket 8.

ԝ Ԝ ԛ

Removing water pump

6.2 Removing Thermostat (1) Remove thermostat case mounting bolt 1 and dismount thermostat case 2 and thermostat attached to it.

Ԛ

(2) Remove gasket 3.

Ԙ

ԙ

Removing thermostat

5-7

DISASSEMBLY, ENGINE MAIN PARTS

7.

Inlet and Exhaust System

Ԙ

ԙ

ԛ

7.1 Removing Exhaust Manifold

Ԝ

(1) Remove insulator mounting bolt 1 and remove the insulator 2.

(2) Remove the exhaust manifold mounting bolt 3 and remove the exhaust manifold 4 and gasket 5 from the head.

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Removing exhaust manifold

Ԙ

7.2 Removing Inlet Manifold ԛ

(1) Remove breezer hose 1.

(2) Remove inlet manifold mounting bolt 2 and remove the inlet manifold 3 and gasket 4 from the cylinder head.

Ԛ ԙ

Removing inlet manifold

5-8

DISASSEMBLY, ENGINE MAIN PARTS

8.

Cylinder Heads and Valve Mechanism, Disassembly

1

Check threads for stripping.

Check surface that makes contact with valve push rod for wear.

Replace.

9

3 4 5 Check for wear. Check oil hole for clogging.

Check for wear.

2 8

Check surface that makes contact with valve cap for wear. Check oil hole for clogging. Check bushing for wear.

10 7 Check for pitted or fracture coils. Test force and length.

17 18

11 15 16

12

Replace.

Check for wear.

13

6 Check end faces for wear.

Check for bend.

19 Check for cracks, or carbon or scale deposits.

Replace.

Check for cracks.

Check for uneven wear.

Check face for pitting or ridging (exhaust valve).

Check stem for scratches or scuff marks.

14

Disassembly sequence 1 2 3 4 5 6 7 8 9 10

11 Valve cap 12 Cylinder head bolt (Remove 13 and 14 in assembly.)

13 Cylinder head 14 Valve 15 Valve cotters 16 Valve retainer 17 Valve stem seal 18 Valve spring 19 Cylinder head gasket

Rocker cover Adjusting screw Bolt (short) Bolt (long) Rocker shaft bracket Pushrod Snap ring Rocker arm Rocker shaft spring Rocker shaft

5-9

DISASSEMBLY, ENGINE MAIN PARTS

8.1 Removing Rocker Shaft Assembly (1) Loosen the adjusting screw one turn.

(2) Loosen the bolts, short and then long, that hold the rocker shaft bracket to the cylinder head. Be sure to loosen the short bolt first. Remove the rocker shaft assembly from the cylinder head.

CAUTION If the long bolt is loosened first, the rocker shaft bracket might suffer damage.

Removing rocker shaft assembly

8.2 Disassembling Rocker Shaft Assembly Arrange the disassembled rockers in the order removed so that you can install them in that order at reassembly. This will ensure the same rockershaft clearance as it was.

Disassembling rocker shaft assembly

8.3 Removing Cylinder Head Remove the cylinder head bolts. Lift the head off the crankcase.

NOTE Use care when removing gaskets from cylinder heads.

Do not damage contact surfaces of cylinder and crankcase. If any parts of the cylinder head are faulty, check the cylinder head bolts for torque with a torque wrench before removing them.

Removing cylinder head

8.4 Removing Valves and Valve Springs

Valve spring pusher

Use valve spring pusher (30691-04500) to compress the valve spring squarely, then remove the valve cotters.

NOTE If the existing valves are to be reused, put a mark on each valve for its location.

Removing valves and valve springs

5-10

DISASSEMBLY, ENGINE MAIN PARTS

9.

Flywheel, Disassembly

6 5

Replace O-ring.

4 2 3

Check for stripped threads.

Replace gasket.

Check lip for wear, damage or deterioration.

Check for cracks or defective dowel hole.

Check ring gear for worn or defective teeth.

Disassembly sequence 1 2 3

Flywheel Oil seal case Oil seal

4 5 6

5-11

O-ring Rear plate Gasket

1

DISASSEMBLY, ENGINE MAIN PARTS

9.1 Removing Flywheel (1) Remove one of the flywheel mounting bolts.

(2) Screw safety bar [M12 × 1.25 mm (0.47 × 0.049 in.)] in the bolt hole and remove the remaining bolts.

Remove lock washers.

(3) Hold the flywheel firmly with both hands and pull it straight while rocking it back and forth.

CAUTION When removing the flywheel, wear heavy gloves to protect your hands.

Removing flywheel

9.2 Removing Oil Seal Case Remove the bolts holding the oil seal case, then remove the oil seal in one piece with the case.

CAUTION Use care when removing the oil seal. Do not damage the surface.

Removing oil seal case

9.3 Removing Rear Plate Remove the bolts that hold the rear plate, then remove the rear plate.

Removing rear plate

5-12

DISASSEMBLY, ENGINE MAIN PARTS

10. Timing Gears, Disassembly Replace gasket.

11 Check for wear or damage.

15 14

13 3 12

10 4 9 Replace O-ring.

Check for clogged oil hole or wear.

6

5 Check for wear.

Replace gasket.

8

Check teeth for wear, nicks, burrs or chips.

Check keyway and bushing for damage or wear.

Check for cracks or defective dowel hole.

7 1

Check for worn belt grooves.

Replace O-ring.

Check lip for wear, damage or deterioration.

2

Disassembly sequence 1 2 3 4 5 6

Crankshaft pulley Cover Fuel injection pump Oil pan Timing gear case Gasket

7 Oil seal assembly 8 Oil pump gear 9 Thrust plate 10 Idler gear (Remove 11 through 13 in assembly.)

11 Camshaft 12 Camshaft gear

5-13

13 14 15

Thrust plate Front plate Gasket

DISASSEMBLY, ENGINE MAIN PARTS

10.1 Removing Crankshaft Pulley (1) Screw two bolts (M12x1.25mm) into the threaded holes on the back-end of the crankshaft, and put a bar between the bolts to prevent the crankshaft from rotating.

(2) Remove the nut and remove the crankshaft pulley.

CAUTION Pay attention to safety. The bar could slip off the bolts.

Removing crankshaft pulley

10.2 Removing Oil Pan Remove the mounting bolts and remove oil pan.

Removing oil pan

10.3 Removing Timing Gear Case Assembly Remove the timing gear case assembly as shown.

CAUTION Use care not to cause damage to the oil seal.

Removing timing gear case assembly

10.4 Measuring Timing Gear Backlash (1) Measure the backlash between gears and make a record of the measurements for reassembly. If the backlash exceeds the service limit, replace the gears.

Item Backlash between gears

Unit: mm (in.)

Assembly Service Standard Limit 0.05 to 0.15 (0.0020 to 0.0059)

0.25 (0.0098)

5-14

Measuring timing gear backlash

DISASSEMBLY, ENGINE MAIN PARTS

(2) Measuring idler gear end play Measure the end play with feeler gauges or a dial gauge. If the end play exceeds the repair limit, replace the thrust plate.

Unit: mm (in.)

Item End play of idler gear

Assembly Standard

Service Limit

0.05 to 0.20 (0.0020 to 0.0079)

0.35 (0.0138)

Measuring idler gear end play

(3) Measuring camshaft end play Use a dial gauge to measure the end play of the camshaft to which the camshaft gear is installed. If the end play exceeds the service limit, replace the thrust plate.

Unit: mm (in.)

Item End play of camshaft

Assembly Standard

Service Limit

0.10 to 0.25 (0.0039 to 0.0098)

0.30 (0.0118)

Measuring camshaft end play

10.5 Removing Oil Pump Gear Remove the gear mounting nuts and remove the oil pump gear.

Removing oil pump gear

10.6 Removing Idler Gear Remove thrust plate mounting bolt and remove the idler gear.

Removing idler gear

5-15

DISASSEMBLY, ENGINE MAIN PARTS

10.7 Removing Camshaft (1) Turn the crankcase upside down.

(2) Position the camshaft gear so that its lightening holes come to top and bottom. Remove the bolts that hold the thrust plate. Remove the camshaft from the crankcase.

CAUTION Use care not to cause damage to the lobe faces of the camshaft and crankcase bore.

Removing camshaft

10.8 Removing Camshaft Gear Remove the gear from the camshaft with a puller. Now the thrust plate can be removed.

NOTE Do not separate the thrust plate from the camshaft gear unless they are defective.

Removing camshaft gear

10.9 Removing Front Plate Remove the bolts that hold the front plate to the crankcase.

Remove the front plate.

Removing front plate

5-16

DISASSEMBLY, ENGINE MAIN PARTS

11. Pistons, Connecting Rods, Crankshaft, Crankcase and Tapet, Disassembly Check for wear or damage.

4 5

Check for wear, scoring, cracking, damaged or widened ring grooves, clogged oil drain holes or carbon deposits.

Check for fatigue.

6

19 Check for wear.

Check for wear.

9

8

Check for clogged oil hole, and cracks.

7

Check for wear or clogged oil hole.

10

14 3

Check for stripped thread.

Check for wear or cracks.

17

2 18

Check for pitting, flaking, chipping, cracking, loss of overlay or signs of overheating.

1

16

15

Check for scale deposits, corrosion or flaking.

Check for scratches, cracks, dents, clogged oil hole or wear.

14 13

Check for nicking, chipping, or abnormal tooth contact.

Note:

12 Check for scratching, pitting, flaking, chipping or loss of overlay.

When replacing the crankcase, carefully remove the parts (such as relief valve) attached to the the crankcase so that they can be reused.

14

11 Check for cracks.

Check for stripped thread.

Disassembly sequence 1 2 3 4

5

Nut Connecting rod cap Connecting rod bearing No.1 ring (Remove 4 through 10 in assembly.)

No.2 ring

6 7 8 9 10 11 12

Oil ring Snap ring Piston pin Piston Connecting rod Bearing cap bolt Main bearing cap

5-17

13 14 15 16 17 18 19

Side seal Thrust plate Main bearing (lower half) Crankshaft Main bearing (upper half) Tappet Crankcase

DISASSEMBLY, ENGINE MAIN PARTS

11.1 Removing Connecting Rod Cap (1) Remove the nuts that hold the cap to the connecting rod. Tap the bolts squarely and evenly with a hammer and, after the cap comes off the reamer bolts, remove the cap.

(2) Mark the bearings for cylinder number and location.

Removing connecting rod cap

11.2 Preparation before Removing Pistons (1) Lay the crankcase on its side.

(2) If any carbon deposits are present on the upper areas of the cylinder liner, remove them with a cloth or oil paper as they will make it difficult to pull a piston upward.

Removing carbon from cylinders

11.3 Removing Piston (1) Turn the crankshaft to bring the piston (from which the connecting rod cap has been removed) to top dead center.

(2) Put the handle of a hammer on the big-end of the connecting rod and push the piston assembly out the cylinder.

Removing piston

11.4 Removing Piston Rings Piston ring pliers

Using piston ring pliers (31391-12900), remove the piston rings.

Removing piston rings

5-18

DISASSEMBLY, ENGINE MAIN PARTS

11.5 Removing Piston Pin (1) Using snap ring pliers, remove the snap rings from the piston.

Snap ring pliers

(2) Remove the piston pin to separate the piston from the connecting rod.

(3) If it is difficult to pull out the pin, heat the piston with a piston heater or in hot water to expand the pin bore.

Removing piston pin

11.6 Removing Main Bearing Caps Remove the bolts that hold the cap to the crankcase.

Remove the cap with lower main bearing attached to it.

Remove the rearmost bearing cap using a puller.

NOTE When removing the caps, use care not to cause damage to the bearings. After removing the caps and bearings, mark each combination of the cap and bearing for its location to ensure correct reassembly.

Removing main bearing cap

11.7 Removing Crankshaft Attach a hoist to the crankshaft. Remove the crankshaft by lifting it in horizontal position.

Removing crankshaft

10.8 Removing Tappets Remove the tappets.

NOTE Put a mark on each tappet so that it can be installed in the same position.

5-19

INSPECTION AND REPAIR, ENGINE MAIN PARTS 1. Inspection and Repair of Cylinder Head and Valve Mechanism ............................ 6 – 1

2.8 Measuring Clearance between Idler Gear Bushing and Shaft ..................... 6 – 11

1.1 Measuring Rocker Arm Bushing and Rocker Shaft................................ 6 – 1

2.9 Removing Idler Gear Shaft ................ 6 – 11

1.2 Measuring Valve Stem ....................... 6 – 1 1.3 Checking Clearance between Valve Stem and Guide ........................ 6 – 2 1.4 Replacing Valve Guides ..................... 6 – 2 1.5 Inspecting Valve Face ....................... 6 – 3 1.6 Refacing Valve Face .......................... 6 – 4 1.7 Refacing Valve Seat .......................... 6 – 4 1.8 Replacing Valve Seat ........................ 6 – 4

2.10 Checking V-belt Groove of Crankshaft Pulley .............................. 6 – 11

3. Inspection and Repair, Piston, Connecting Rod, Crankshaft, Crankcase and Tappet ........................... 6 – 12 3.1 Checking Crankcase Top Face Distortion ............................................ 6 – 12 3.2 Inside Diameter of Cylinders ............. 6 – 12 3.3 Measuring Piston Diameter ............... 6 – 13

1.9 Lapping Valve in Valve Seat .............. 6 – 5

3.4 Measuring Cut Clearance between Ends of Piston Ring ............................ 6 – 13

1.10 Measuring Valve Spring Perpendicularity and Free Length....... 6 – 6

3.5 Measuring Clearance between Groove and Piston Ring .................................. 6 – 14

1.11 Measuring Cylinder Head Distortion ............................................ 6 – 6

3.6 Measuring Clearance between Piston Pin and Bore....................................... 6 – 14

1.12 Measuring Valve Pushrods Runout .... 6 – 6

3.7 Measuring Piston Protrusion .............. 6 – 15

1.13 Replacing Combustion Jets ............... 6 – 7

3.8 Measuring Clearance between Connecting Rod Bearing and Crankpin ............................................. 6 – 16

2. Inspection and Repair, Flywheel and Timing Gear ..................................... 6 – 8 2.1 Measuring Flatness of Flywheel ........ 6 – 8 2.2 Checking Ring Gear .......................... 6 – 8 2.3 Replacing Ring Gear ......................... 6 – 8 2.4 Measuring Cam Lift ........................... 6 – 9 2.5 Measuring Camshaft Deflection ......... 6 – 9 2.6 Checking Clearance between Camshaft Journal and Bore in Crankcase (or Bushing)........................................ 6 – 10 2.7 Replacing Camshaft Bushings ........... 6 – 10

3.9 Measuring Clearance between Connecting Rod Bushing and Piston Pin ........................................... 6 – 16 3.10 Installing Connecting Rod Bushing .... 6 – 17 3.11 Inspecting Connecting Rods for Bend and Twist ................................... 6 – 17 3.12 Inspecting Connecting Rod Bearings.............................................. 6 – 18 3.13 Measuring Connecting Rod End Play ... 6 – 19 3.14 Measuring Journal Diameter .............. 6 – 19 3.15 Measuring Crankpin Diameter ........... 6 – 19

6

3.16 Grinding Crankshaft ........................... 6 – 20 3.17 Measuring Crankshaft End Play ........ 6 – 20 3.18 Measuring Crankshaft Deflection ....... 6 – 21 3.19 Replacing Crankshaft Gear ............... 6 – 21 3.20 Checking Oil Seal Running Surface ... 6 – 22 3.21 Inspecting Main Bearing Surface ......... 6 – 23 3.22 Clearance between Bearing and Journal......................................... 6 – 23 3.23 Checking Tappets for Wear ................ 6 – 24 3.24 Checking Clearance between Tappet and Bore ................................. 6 – 24

INSPECTION AND REPAIR, ENGINE MAIN PARTS

1.

Inspection and Repair of Cylinder Head and Valve Mechanism

1.1 Measuring Rocker Arm Bushing and Rocker Shaft Measure the inside diameter of the rocker arm (bushing bore) and the diameter of the rocker shaft as shown in the illustration to check the clearance between the rocker arm and shaft. If the clearance is out of the assembly standard and within the repair limit, replace the rocker arm. If it exceeds the repair limit, replace both rocker arm and bushing.

Unit: mm (in.)

Item

Nominal Value

Assembly Standard

Repair Limit

Inside diameter of rocker arm bushing

19 (0.75)

19.010 to 19.030 (0.7484 to 0.7492)

—

Diameter of rocker shaft

19 (0.75)

18.980 to 19.000 (0.7472 to 0.7480)

—

Clearance between rocker bushing and shaft

—

Measuring rocker arm bushing and rocker shaft

0.010 to 0.050 0.070 (0.0004 to 0.0020) (0.0028)

1.2 Measuring Valve Stem Measuring directions

Measure the diameter of the valve stem as shown in the figure. If the service limit is exceeded, replace the valve.

Also replace the valve if localized wear is significant.

Unit: mm (in.)

Item Inlet valves

Nominal Value

Assembly Standard

Service Limit

8 7.940 to 7.955 7.900 (0.315) (0.3126 to 0.3132) (0.3110)

Valve stem diameter Exhaust 8 7.920 to 7.940 7.850 valves (0.315) (0.3118 to 0.3126) (0.3091)

6-1

Measuring locations

Measuring valve stem

INSPECTION AND REPAIR, ENGINE MAIN PARTS

1.3 Checking Clearance between Valve Stem and Guide

Measuring directions

Inside micrometer caliper

The valve guide wears more rapidly at its both ends than at any other portions. Measure the inside diameter of the valve guide at its ends, as shown in the illustration, to check the clearance. If the clearance exceeds the service limit, replace the guide or valve whichever is badly worn.

Unit: mm (in.)

Item Clearance between valve stem and guide

Nominal Value

Assembly Standard

—

0.150 0.065 to 0.095 (0.0026 to 0.0037) (0.0059)

Exhaust valves

—

0.080 to 0.115 0.200 (0.0032 to 0.0045) (0.0079)

14 (0.55)

13.9 to 14.1 (0.5472 to 0.5551)

Measuring valve guide

Service Limit

Inlet valves

Height to top of valve guide

Measuring locations

—

1.4 Replacing Valve Guides Valve guide remover

(1) To remove the valve guide for replacement, use valve guide remover (32A91-00300).

Replacing valve guide

(2) To install a replacement valve guide, use valve guide installer (32A91-00100) and a press.

Press Valve guide installer

CAUTION The height to top of valve guide is specified; be sure to use the valve guide installer to insure the correct height.

r OO (0.55 r0.004 in.)

Installing valve guide

6-2

INSPECTION AND REPAIR, ENGINE MAIN PARTS

1.5 Inspecting Valve Face Coat the valve face lightly with gear marking compound.

Use the valve lapper to inspect the valve contacts with its seat. If the contact is not uniform, or if the valve is defective or if the service limit is exceeded, repair or replace the valve and valve seat.

Valve lapper

Gear marking compound

Inspecting valve face

NOTE (1) Check the valve contact after checking/replacing the valve guides.

(2) Do not rotate the valve being coated with gear marking compound when holding it against the seat for checking the contact surface.

(3) After refacing or replacing the valve or valve seat, be sure to lap the valve in the seat. (See “1.9 Lapping Valve in Valve Seat.”)

Good

Bad

Valve contact pattern

Unit: mm (in.)

Item

Valve seat

Angle Inlet Valve Valve sinkage Exhaust Valve

Assembly Standard

Repair Limit

30°

—

0.4±0.1 (0.016±0.004) 0.5±0.1 (0.020±0.004)

Valve seat width

1.0 (0.039)

Valve seat angle

Width

1.4±0.14 (0.055±0.0055)

1.8 (0.071)

Valve margin

2.13 (0.0839)

Up to 1.83 (0.0720) by refacing

Valve margin Valve sinkage

Valve contact with valve seat

6-3

INSPECTION AND REPAIR, ENGINE MAIN PARTS

1.6 Refacing Valve Face If the valve face is badly worn, reface it with a valve refacer.

NOTE

Grind valve faces at a 30qangle with a valve refacer.

(1) Set a valve refacer at an angle of 30°.

(2) Secure the valve margin above the limit.

Refacing valve face

If maintaining the repair limit seems difficult after a griding, replace the valve.

1.7 Refacing Valve Seat Use the Valve seat cutter or valve seat grinder to reface the valve seat. After refacing, grind the seat lightly with #400 grade sandpaper inserted between the cutter and valve seat.

Valve seat cutter

NOTE (1) Refacing of the valve seat shall be kept to the minimum.

Refacing vale seat

(2) Replace the valve seat if the seat width is more than the repair limit as a result of wear or refacing.

Weld

1.8 Replacing Valve Seat (1) Driving valve seat out

Shaft Valve seat

Weld a stud to the valve seat. Insert a shaft through the valve guide from the upper side of the cylinder head to put its end on the stud as shown in the illustration.

Then, drive the seat off from the cylinder head.

Stud

Replacing valve seat

NOTE When welding the stud to the valve seat, avoid contact of any spatter with the machined surface of the cylinder head.

6-4

INSPECTION AND REPAIR, ENGINE MAIN PARTS

Chill the valve seat in liquid nitrogen [about -170°C (-338°F)] for more than 4 minutes with the cylinder head kept at normal temperature, or heat the cylinder head to 80 to 100°C (176 to 212°F) with the valve seat chilled in ether or alcohol containing dry ice.

+0.025 0 +0.0010 q Ǿ1.810 Ǿ46

8r0.1

(0.31r0.004)

2r0.1

(0.08r0.004)

2r0.1

(0.08r0.004)

(3) Cool down the valve seat by either way of the following:

8r0.1

Before inserting a new valve seat, measure the bores in the cylinder head for the valve seats to make sure they are correct in dimension.

(0.31r0.004)

(2) Installing valve seat

+0.025 Ǿ37 0 +0.0010 Ǿ1.46 0 q

Inlet valve Exhaust valve seat bore seat bore

Unit: mm (in.)

Valve seat bore dimensions

(4) Insert the above cooled valve seat into the cylinder head using the caulking tool.

Caulking tool

Tools needed Tool Name

Part Number

Caulking tool (for inlet valve seat)

36791-00200

Caulking tool (for exhaust valve seat)

34491-03020 Installing valve seat

1.9 Lapping Valve in Valve Seat (1) Be sure to lap the valve in the valve seat whenever the seat is replaced.

(2) Apply a lapping compound to the valve face lightly and evenly.

NOTE (a) Do not permit the compound to come in contact with the valve stem. (b) Use a compound of 120 to 150 mesh for initial lapping and the compound finer than 200 mesh for finish lapping.

Compound

Applying a lapping compound

(c) Mixing the compound with a small amount of engine oil will facilitate coating.

(3) Use the Valve lapper to lap the valve in the seat. To lap, raise the valve off the seat, then rotate the valve only a partial turn and strike it against the seat.

Valve lapper

(4) Wash off the compound with diesel fuel.

(5) Coat the valve face with engine oil, and again lap the valve.

(6) Check the valve face for contact.

Lapping valve in valve seat

6-5

INSPECTION AND REPAIR, ENGINE MAIN PARTS

1.10 Measuring Valve Spring Perpendicularity and Free Length Measure the free length and perpendicularity of each valve spring. If the free length or perpendicularity exceeds the service limit, replace the spring.

Assembly Standard

Service Limit

Free length

48.85 mm (1.92 in.)

47.60 mm (1.87 in.)

Perpendicularity

1.5° or less

—

43 mm (1.69 in.)

—

177 to 196 N (18 to 20 kgf) [40 to 44 lbf]

147 N (15 kgf) [33 lbf]

Item

Set length

Set force

Perpendicularity

Free length

Measuring valve spring perpendicularity and free length

1.11 Measuring Cylinder Head Distortion Using a heavy accurate straight edge and a feeler gauge, check for distortion in three positions lengthwise, two crosswise and two widthwise as shown in the illustration. If distortion exceeds the repair limit, reface the head with a surface grinder.

Unit: mm (in.)

Item Distortion of bottom face

Assembly Standard

Repair Limit

0.05 (0.0020) or less

0.20 (0.0079)

Checking cylinder head for distortion

1.12 Measuring Valve Pushrods Runout With a dial indicator, check for runout as shown in the illustration. If runout exceeds the assembly standard, replace the pushrod.

Push rod

Unit: mm (in.)

Item Pushrod deflection

Assembly Standard

0.3 (0.012) or less

Measuring valve pushrod runout

6-6

INSPECTION AND REPAIR, ENGINE MAIN PARTS

1.13 Replacing Combustion Jets Round bar

The combustion jets should be replaced only when they are cracked or defective.

(1) To remove the combustion jet, tap the jet off the cylinder head with a 6 mm (0.24 in.) diameter round bar inserted through the glow plug hole as shown in the illustration.

Combustion jet

Removing combustion jet

(2) To install a replacement jet, position the jet so that the orifice faces toward the center of the cylinder and drive it into position with a plastic hammer.

Combustion jet Orifice

Installing combustion jet

6-7

INSPECTION AND REPAIR, ENGINE MAIN PARTS

2.

Inspection and Repair, Flywheel and Timing Gear

2.1 Measuring Flatness of Flywheel Put the flywheel on the surface plate. Set a dial indicator at one side of the friction surface and move it over to the opposite side of the surface as shown in the illustration. If the friction surface is not flat within the repair limit, regrind it.

Unit: mm (in.)

Item Flatness of flywheel

Assembly Standard

Repair Limit

0.15 (0.0059) or less

0.50 (0.0197)

Checking flywheel

2.2 Checking Ring Gear Check the ring gear and if it has missing teeth or shows evidence of abnormal abrasion on the tooth surface, replace it according to the following procedure.

2.3 Replacing Ring Gear (1) Removing ring gear Heat the ring gear evenly with an acetylene torch.

Tap the ring gear all the way around with a bar and a hammer to remove it from the flywheel (2) Installing ring gear Heat a replacement ring gear up to about 100°C (212°F) with a piston heater and install it to the flywheel with unchamfered side of the gear teeth foremost.

NOTE Do not heat the ring gear excessively.

6-8

Removing ring gear

INSPECTION AND REPAIR, ENGINE MAIN PARTS

2.4 Measuring Cam Lift Measure the lobe height and base circle of inlet and exhaust cam with micrometer. If the lobe lift is less than the service limit, replace the cam shaft.

&

Measuring locations

&

Unit: mm (in.)

Item

Nominal Value

Assembly Standard

Service Limit

Inlet 6.684 6.684 to 6.784 6.184 Lobe valve (0.2631) (0.2631 to 0.2671) (0.2435) lift 6.420 to 6.820 6.220 (D1-D2) Exhaust 6.720 valve (0.2646) (0.2528 to 0.2685) (0.2449)

Measuring directions

Measuring cam lift

2.5 Measuring Camshaft Deflection If the deflection exceeds the repair limit, straighten the camshaft with a press, or replace it with a new one.

NOTE Set up a dial gauge on the camshaft, then turn the camshaft. Take one half (1/2) of the gauge indication as the deflection.

Unit: mm (in.)

Item Camshaft deflection

Assembly Standard

Repair Limit

0.02 (0.0008) or less

0.05 (0.0020)

6-9

Measuring camshaft deflection

INSPECTION AND REPAIR, ENGINE MAIN PARTS

2.6 Checking Clearance between Camshaft Journal and Bore in Crankcase (or Bushing) Measure the diameter of the camshaft journal and the inside diameter of the bore in the crankcase (or bushing) for camshaft as shown in the illustration to check the clearance. If the clearance exceeds the service limit, replace the camshaft.

Measuring locations

Measuring directions

Measuring camshaft journal

Unit: mm (in.)

Item

Nominal Value

No. 1 54 Diameter of and (2.13) No. 2 camshaft journal 53 No. 3 (2.09) Clearance between camshaft journal and bore in crankcase (or bushing) for camshaft

—

Assembly Standard

Service Limit

53.94 to 53.96 53.90 (2.1236 to 2.1244) (2.1220) 52.94 to 52.96 52.90 (2.0843 to 2.0850) (2.0827)

0.07 to 0.11 0.15 (0.0028 to 0.0043) (0.0059)

Measuring bore in crankcase (bushing) for camshaft

2.7 Replacing Camshaft Bushings Adaptor

(1) If the clearance between the camshaft journal and bore in the crankcase exceeds the service limit, refinish the bore to 57H6 ( + 00.019 ) 3.125 Ra. and install bushings.

Bushing

Piece

Bushing Adaptor

(2) To replace or install bushings, use camshaft bushings installer set (30691-00010).

(3) Install bushings with their oil holes aligned with the holes leading to the oil gallery.

Rod Rod Removal

Oil holes Installation

Replacing camshaft bushings

6-10

INSPECTION AND REPAIR, ENGINE MAIN PARTS

2.8 Measuring Clearance between Idler Gear Bushing and Shaft

Measuring directions

Measure the inside diameter of the bushing and the diameter of the shaft to determine the clearance between the two. If the clearance exceeds the service limit, replace the idler gear or shaft.

Measuring locations

Unit: mm (in.)

Item Clearance between idler gear bushing and shaft

Assembly Standard

Repair Limit

0.009 to 0.050 (0.0004 to 0.0020)

0.100 (0.0039)

Measuring clearance between idler gear bushing and shaft

2.9 Removing Idler Gear Shaft To remove the idler gear shaft for replacement, use idler shaft puller (MH061077).

Idler shaft puller

Removing idler gear shaft

2.10 Checking V-belt Groove of Crankshaft Pulley Check the V-belt groove for wear. Wrap a new belt around the pulley, pressing it in the groove as far as it goes, and see if the top surface of the belt is above the top of the pulley.

If the top surface of the new belt is uniformly above the top of the pulley all the way around, it is not necessary to replace the pulley.

1.6mm (0.06 in.) or more

If the top surface of the new belt sinks into the groove more than 1.6 mm (0.06 in.), replace the pulley.

Checking V-belt groove for wear

6-11

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.

Inspection and Repair: Piston, Connecting Rod, Crankshaft, Crankcase and Tappet

3.1 Checking Crankcase Top Face Distortion Check the top face for distortion using an accurate straight edge and a feeler gauge in three positions lengthwise, two crosswise and two widthwise, as shown in the illustration.

If distortion exceeds the assembly standard, grind the crankcase using surface grinder. When grinding, do not overdo and keep it to the minimum.

Unit: mm (in.)

Item Distortion of crankcase top face

Assembly Standard

Repair Limit

0.05 (0.0020) or less

0.20 (0.0079)

Checking crankcase top face

3.2 Inside Diameter of Cylinders Measuring directions 11(0.433) 80(3.150)

(1) Measure the inside diameter of the cylinder at the top (step wear portion), middle and bottom, each in two directions parallel and transverse to the crankshaft, as shown in the illustration.

Item

Assembly Standard

Repair Limit

150(5.91)

Unit: mm (in.)

Service Limit

Inside diameter of cylinder

94.000 to 94.035 94.200 (3.7008 (3.7087) to 3.7022)

94.700 (3.7283)

Circularity

0.01 (0.0004) or less

––

––

Cylindricality

0.015 (0.0006) or less

––

––

Measuring locations Unit: mm(in.)

Measuring cylinder

(2) If the cylinder has reached the repair limit, with the wear less than the service limit, bore it to 0.25 mm (0.0098 in.) or 0.5 mm (0.0197 in.) oversize.

(3) Hone the cylinder within an accuracy of 0.035 mm (0.00138 in.), and use the piston and piston rings of the same oversize.

(4) If any cylinder is unevenly worn, determine the oversize on the basis of the maximum wear noted to ensure perfect roundness in the oversized bore.

6-12

INSPECTION AND REPAIR, ENGINE MAIN PARTS

NOTE (1) Refinish all cylinders to the same oversize.

(2) If the cylinder is found in good condition, with the wear far less than the repair limit, replace the piston ring and ream off “ridge” at the top of the cylinder. Hone the bore if necessary.

Ridge-reaming cylinder

3.3 Measuring Piston Diameter (1) Measure the diameter of the piston at skirt in the direction transverse to the piston pin with a micrometer as shown in the illustration. If the piston is worn beyond the service limit, replace it.

Unit: mm (in.)

Assembly Standard

Service Limit

Standard

93.955 to 93.985 (3.6990 to 3.7002)

93.770 (3.6917)

0.25 (0.0098) oversize

94.205 to 94.235 (3.7089 to 3.7100)

94.020 (3.7016)

0.50 (0.0197) oversize

94.455 to 94.485 (3.7187 to 3.7199)

94.270 (3.7114)

Outside diameters of pistons

Item

Measuring piston diameter

3.4 Measuring Cut Clearance between Ends of Piston Ring Place the piston ring in the gauge or a new cylinder sleeve and measure the cut clearance with feeler gauges as shown in the illustration. If the clearance exceeds the service limit, replace all piston rings.

Thickness gage

Inside diameter of gauge: 94 + 00.035 (3.70 + 00.00138 )

NOTE Cut clearance

Use the piston to place the ring in the gauge or in the cylinder sleeve squarely.

Unit: mm (in.)

Item Cut No.1 ring, clearance No.2 ring, Oil ring

Assembly Standard

Service Limit

0.30 to 0.50 (0.0118 to 0.0197)

1.50 (0.0591)

6-13

Measuring cut clearance between ends of piston ring

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.5 Measuring Clearance between Groove and Piston Ring Put a new piston ring in the groove. Measure the clearance between the groove and piston ring with a straight edge and feeler gauges as shown in the illustration. If the clearance exceeds the service limit, replace the piston.

Unit: mm (in.)

Assembly Standard

Repair Limit

No.1 ring

0.07 to 0.11 (0.0028 to 0.0043)

0.200 (0.0079)

No.2 ring

0.045 to 0.085 (0.0018 to 0.0034)

0.150 (0.0059)

Oil ring

0.025 to 0.065 (0.0010 to 0.0026)

0.150 (0.0059)

Item

Clearance between groove and piston ring

Measuring clearance between groove and piston ring

3.6 Measuring Clearance between Piston Pin and Bore Measure the inside diameter of the piston pin bore and the diameter of the pin as shown in the illustration to check the clearance between the piston and pin. If the clearance exceeds the service limit, replace the pin or piston whichever is excessively worn.

Measuring locations

Measuring directions

Unit: mm (in.)

Item

Diameter of piston pin Clearance between piston pin and bore

Nominal Value

Assembly Standard

Service Limit

30 (1.18)

29.994 to 30.000 (1.1809 to 1.1811)

––

––

0.000 to 0.016 (0.0000 to 0.0006)

0.050 (0.0020)

Measuring clearance between piston pin and bore

6-14

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.7 Measuring Piston Protrusion Measure the piston protrusion as described below and if the piston protrusion is not correct, check the various parts for clearance.

(1) Measure the top dead center of the pistons with a dial gauge.

(2) Install the dial indicator on the top of the crankcase.

Set the indicator to read 0.0 mm (0.000 in.).

(3) Measure the piston protrusion at least three locations on the top of the piston and average the three measurements to check the protrusion. Subtract the projection from the compressed thickness of the cylinder head gasket to check the clearance between the piston top and the cylinder head.

Unit: mm (in.)

Item

Assembly Standard

Piston protrusion

-0.25 to 0.15 (-0.0098 to 0.0059)

Compressed thickness of cylinder head gasket

1.2±0.05 (0.05±0.002)

CAUTION Incorrect piston protrusion affects engine performance and causes valve interference with the piston.

6-15

Measuring piston protrusion

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.8 Measuring Clearance between Connecting Rod Bearing and Crankpin Measure the diameter of the crankpin and the inside diameter of the connecting rod bearing as shown in the illustration to check the clearance between the two. If the clearance exceeds the service limit, replace the bearing. If the crankpin is badly or unevenly worn, grind the crankpin and use an undersize bearing.

Measuring directions

Measuring locations

54r5 N㨯m {5.5r0.5 kgf㨯m} (40r4 lbf㨯ft)

0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.) and 0.75 mm (0.0295 in.) undersize connecting rod bearings are available for service.

Measuring connecting rod bearing

NOTE To measure the inside diameter of the connecting rod bearing, install the upper and lower halves in the connecting rod and tighten the cap bolts to the specified torque.

Unit: mm (in.)

Item

Diameter of crank pin Clearance between connecting rod bearing and crankpin

Nominal Value

Assembly Standard

Service Limit

58 (2.28)

57.955 to 57.970 (2.2817 to 2.2823)

57.800 (2.2756) (Repair limit)

––

0.030 to 0.090 (0.0012 to 0.0035)

0.200 (0.0079)

3.9 Measuring Clearance between Connecting Rod Bushing and Piston Pin

Measuring directions

Measure the inside diameter of the connecting rod bushing and the diameter of the piston pin as shown in the illustration to check the clearance between the two. If the clearance exceeds the service limit, replace the pin or bushing whichever is badly worn.

Measuring locations

Measuring connecting rod bushing

6-16

INSPECTION AND REPAIR, ENGINE MAIN PARTS

Unit: mm (in.)

Item

Nominal Value

Assembly Standard

Service Limit

30 (1.18)

30.020 to 30.045 (1.1819 to 1.1829)

––

––

0.020 to 0.051 (0.0008 to 0.0020)

0.080 (0.0032)

Inside diameter of connecting rod bushing Clearance between pin and bushing

3.10 Installing Connecting Rod Bushing Weight mark side

(1) Use connecting rod bushing puller (MH061236) to install the connecting rod bushing.

(2) When installing a new bushing, align the oil holes in the bushing and connecting rod. Position the ends of the bushing as shown in the illustration.

Oil hole

(3) After installing the bushing, place the piston pin in position and make sure the pin rotates freely without play.

Joint of bushing

Installing connecting rod bushing

3.11 Inspecting Connecting Rods for Bend and Twist (1) Measure C and L. If the measurement at C is more than 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) of L, straighten the rod with a press.

C l

C l Piston pin

l

C l

0.05 100 (

Unit: mm (in.)

Item Bend or twisting of connecting rod

Assembly Standard

Repair Limit

0.05/100 (0.0020/3.94) or less

0.15/100 (0.0059/3.94)

Bend

6-17

0.05 100 (

0.0020 ) 3.94

C

0.0020 ) 3.94

Twist Unit: mm (in.)

Inspecting connecting rod

INSPECTION AND REPAIR, ENGINE MAIN PARTS

(2) A connecting rod aligner is generally used for checking the connecting rod for twist and bend.

NOTE To check the connecting rod for bend, install the cap to the rod and tighten the cap nuts to the specified torque.

Tightening torque

54±5 N·m (5.5±0.5 kgf·m) [40±4 lbf·ft] Checking connecting rod with a connecting rod aligner

(3) When the measurement is taken with the piston installed to the connecting rod, place the piston upside down on a surface plate, insert a round bar having the same diameter as the crank pin, and measure the height of the round bar using a dial gauge.

㧰 㧯

㧭

㧮

Checking connecting rod with a dial indicator

3.12 Inspecting Connecting Rod Bearings Check each bearing for flaking of overlay, scratches, seizure, dents or other damages. Replace damaged bearings if any.

Scratching Flaking

Seizing

Checking connecting rod bearing

6-18

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.13 Measuring Connecting Rod End Play Install the connecting rod to the mating crankpin by tightening the cap nuts to the specified torque. Measure the end play (clearance between the rod and crank arm) with feeler gauges as shown in the illustration. If the end play exceeds the service limit, replace the connecting rod.

Unit: mm (in.)

Assembly Standard

Repair Limit

0.15 to 0.35 (0.0059 to 0.0138)

0.50 (0.020)

Item End play of connecting rod

Measuring connecting rod end play

3.14 Measuring Journal Diameter Measure the journal with a micrometer as shown in the illustration to check wear, circularity, cylindricality and clearance between the bearing and journal. If any measurement exceeds the repair limit, grind the crankshaft to an undersize. If it exceeds the service limit, replace the crankshaft.

Unit: mm (in.)

Item

Journal diameter

Nominal Assembly Value Standard

Service Limit

78 (3.07)

77.955 to 77.970 (3.0691 to 3.0697)

77.850 (3.0650)

77.100 (3.0354)

––

0.01 (0.0004) or less

0.03 (0.0012)

––

Circularity Cylindricality

Repair Limit

Measuring directions

Measuring locations

Measuring journals

3.15 Measuring Crankpin Diameter Measure the crankpin with a micrometer as shown in the illustration to check wear, circularity, cylindricality and clearance between the bearing and crankpin. If any measurement exceeds the repair limit, grind the crankshaft to an undersize, or replace the crankshaft.

Unit: mm (in.)

Nominal Assembly Service Item Value Standard Limit Crankpin diameter

58 (2.28)

57.955 to 57.970 (2.2817 to 2.2823)

57.800 (2.2756)

––

0.01 (0.0004) or less

0.03 (0.0012)

Circularity Cylindricality

Measuring directions

Measuring locations

Measuring crankpins

6-19

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.16 Grinding Crankshaft

Crankshaft grinding dimensions Unit : mm (in.)

When grinding the crankpins and journals, be sure to produce the same fillet radius as the original one. They should have a hardness of 620 or more in terms of Vickers Hardness Number. If necessary, re-harden the crankpins and journals, and inspect them for cracks by conducting a magnalux (magnetic particle) test.

Journal

Crankpin

NOTE

Undersize

Grinding dimension

0.25 (0.0098)

77.705 to 77.720 (3.0593 to 3.0598)

0.50 (0.0197)

77.455 to 77.470 (3.0494 to 3.0500)

0.75 (0.0295)

77.205 to 77.220 (3.0396 to 3.0402)

0.25 (0.0098)

57.705 to 57.720 (2.2719 to 2.2724)

0.50 (0.0197)

57.455 to 57.470 (2.2620 to 2.2626)

0.75 (0.0295)

57.205 to 57.220 (2.2522 to 2.2528)

R3 mm (0.12 in.)

R3 mm (0.12 in.)

(1) Grind all journals or pins to the same undersize.

(2) Finish the fillet radius to 3 mm (0.12 in.).

R3 mm (0.12 in.)

Fillet radius

3.17 Measuring Crankshaft End Play (1) With the thrust plates installed in the front and rear of a journal and all bearing caps tightened to the specified torque, measure the end play (the difference in width between the journal and thrust plate). If the end play exceeds the repair limit, replace the thrust plates.

(2) If the end play still exceeds the repair limit even after the new thrust plates have been installed, replace the thrust plates with the oversize ones. 0.15 mm (0.0059 in.) and 0.30 mm (0.0118 in.) oversize thrust plates are available for service. Generally the rear journal is likely to wear more rapidly than the front journal. This means that replacement of the rear thrust plates will generally be sufficient.

6-20

mm 31 +0.039 0

(1.22 +0.00154 in. ) 0

Crankshaft journal width

INSPECTION AND REPAIR, ENGINE MAIN PARTS

Unit: mm (in.)

Assembly Standard

Repair Limit

0.100 to 0.264 (0.0039 to 0.0104)

0.300 (0.0118)

Item Crankshaft end play

Crankshaft grinding dimensions for oversize thrust plates Unit: mm (in.)

Oversize

Oversize for Oversize for front or rear front and rear

0.15 (0.0059)

31.15 (1.2264)

31.30 (1.2323)

0.30 (0.0118)

31.30 (1.2323)

31.45 (1.2382)

Tolerance

(

+0.039 0 +0.00154 0

Measuring crankshaft end play

)

31.60 (1.2441)

3.18 Measuring Crankshaft Deflection Support the crankshaft on its journals in V-blocks, then measure the deflection at the center journal with a dial gauge. Depending on the amount of deflection, repair the crankshaft by grinding or straightening with a press. If the deflection exceeds the repair limit, replace the crankshaft.

Unit: mm (in.)

Item Crankshaft deflection

Assembly Standard

Repair Limit

0.02 (0.0008) or less

0.05 (0.0020

Measuring crankshaft deflection

3.19 Replacing Crankshaft Gear (1) Use gear puller to remove the gear from the crankshaft.

CAUTION Do not tap the gear with a hammer to remove it.

Replacing crankshaft gear

6-21

INSPECTION AND REPAIR, ENGINE MAIN PARTS

(2) Heat a replacement gear up to 100°C (212°F) with a gear heater. Put the gear on the crankshaft with its keyway aligned with the key and tap the end face of the gear with a copper hammer.

To be aligned

Installing crankshaft gear

3.20 Checking Oil Seal Running Surface Check the oil seal sleeve running surface of the crankshaft rear-end. If the sleeve is badly worn by the oil seal, replace the oil seal sleeve.

Oil seal

Oil seal running surface

Checking oil seal running surface

(1) Installing oil seal sleeve Apply oil to the inside of an oil seal sleeve and, using crankshaft sleeve installer set (30691-13010), install the sleeve in position as shown in the illustration.

Sleeve installer

Guide (30691-13100)

CAUTION Use care when installing the sleeve. Do not damage the sleeve.

Installer (30691-13200)

Installing oil seal sleeve

When the oil seal sleeve is worn, remove oil seal sleeve as described below and replace oil seal and oil seal sleeve with new ones.

Oil seal

Oil seal sleeve

Checking oil seal running surface

6-22

INSPECTION AND REPAIR, ENGINE MAIN PARTS

(2) Removing oil seal sleeve Hold a flat cold chisel at right angles to the sleeve and cut the sleeve at three places to loosen it as shown in the illustration. If it is impossible to remove the sleeve in this method, hold the chisel in the axial direction and lightly tap the sleeve to loosen it.

CAUTION Be extra careful not to cause damage the crankshaft when removing the sleeve with a chisel.

Removing oil seal sleeve

3.21 Inspecting Main Bearing Surface Inspect each bearing shell for abnormal contact such as scratching, corrosion, flaking, etc. Also check for signs of poor seating in the bore of the crankcase or bearing cap.

Scratches, corrosion or flaking

Inspecting main bearing surface

3.22 Clearance between Bearing and Journal (1) Install the bearings to the crankcase and bearing cap.

Tighten the cap to the specified torque. Measure the inside diameter of the bearing in two positions lengthwise and three crosswise as shown in the illustration to take an average. Check the clearance between the bearing and journal on the basis of this measurement.

98 VQ 108 N㨯m (10.0 VQ 11.0 kgf㨯m) [72 to 80 lbf㨯m]

Measuring directions

Unit: mm (in.)

Item

Assembly Standard

Repair Limit

Clearance between bearing and journal

0.050 to 0.110 (0.0020 to 0.0043)

0.200 (0.0079)

Measuring main bearing

(2) When the clearance is bigger than the standard and smaller than the limit, replace main bearings with new ones. If the clearance exceeds the limit, grind the crankshaft to assemble with undersize (-0.25, -0.50, -0.75) bearings.

(3) Finish the journal diameter according to the bearing inner diameter to ensure correct fitting.

6-23

Measuring locations

INSPECTION AND REPAIR, ENGINE MAIN PARTS

3.23 Checking Tappets for Wear Check the cam contact face of each tappet for wear.

Replace badly worn tappets if any.

Good

Bad

Bad

Cam contact face of tappet

3.24 Checking Clearance between Tappet and Bore

Measuring directions

Measuring directions

Measure the diameter of the tappet and the inside diameter of the bore in the crankcase for the tappet as shown in the illustration to check the clearance. If the clearance exceeds the service limit, replace the tappets.

Unit: mm (in.)

Item

Nominal Value

Inside diameter of bore for tappet

14 (0.55)

14.000 to 14.018 14.100 (0.5512 to 0.5519) (0.5551)

—

0.016 to 0.052 0.080 (0.0006 to 0.0021) (0.0032)

Clearance between tappet and bore

Assembly Standard

Service Limit

6-24

Measuring locations

Checking clearance between tappet and bore

REASSEMBLY, ENGINE MAIN PARTS 1. Reassembly; Piston, Connecting Rod, Crankshaft, Crankcase and Tappets.................................................................................

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12

Installing Main Bearings, Thrust Plate and Tappets .............................................

Installing Crankshaft ............................................................................................

Installing Main Bearing Caps ...............................................................................

Installing Main Bearing Cap Bolts ........................................................................

Measuring Crankshaft End Play ..........................................................................

Assembling Piston and Connecting Rod .............................................................

Installing Piston Rings .........................................................................................

Preparation before Installing Pistons ...................................................................

Assembling Connecting Rod Tightening Bolts and Bearing .................................

Inserting Pistons ..................................................................................................

Assembling Pistons .............................................................................................

Installing Connecting Rod Cap ............................................................................

2. Reassembly, Timing Gear

...........................................................................

2.1 Installing Front Plate ...........................................................................................

2.2 Installing Camshaft Gear and Thrust Plate ..........................................................

2.3 Installing Camshaft ..............................................................................................

2.4 Installing Idler Gear .............................................................................................

2.5 Installing Oil Pump Gear .....................................................................................

2.6 Inspecting and Adjusting after Reassembly .........................................................

2.7 Installing Oil Seal ................................................................................................

2.8 Installing Timing Gear Case ................................................................................

2.9 Installing Oil Pan .................................................................................................

2.10 Installing Crankshaft Pulley .................................................................................

3. Reassembly, Flywheel 3.1 3.2 3.3 3.4

...................................................................................

Installing Rear Plate ............................................................................................

Installing Oil Seal ................................................................................................

Installing Flywheel ...............................................................................................

Measuring Flywheel Runout ................................................................................

4. Reassembly, Cylinder Head and Valve Mechanism 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

...................

Installing Valve Stem Seal ...................................................................................

Installing Valve and Valve Spring ........................................................................

Installing Cylinder Head .......................................................................................

Assembling Rocker Arms and Rocker Shaft ........................................................

Installing Valve Pushrod ......................................................................................

Installing Rocker Shaft Assembly .........................................................................

Checking No.1 Piston Compression Top Dead Center ........................................

Adjusting Valve Clearance ...................................................................................

7– 7– 7– 7– 7– 7– 7– 7– 7– 7– 7– 7– 7–

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

7– 7– 7– 7– 7– 7– 7– 7– 7– 7– 7–

5 5 5 6 6 7 7 7 7 8 8

7– 7– 7– 7– 7–

9 9 9 9 9

7 – 10 7 – 10 7 – 10 7 – 11 7 – 11 7 – 12 7 – 12 7 – 12 7 – 13

7

REASSEMBLY, ENGINE MAIN PARTS

1.

Reassembly; Piston, Connecting Rod, Crankshaft, Crankcase and Tappets

1.1 Installing Main Bearings, Thrust Plate and Tappets (1) Install each upper shell of the main bearing to the crankcase so that the bearing lug fits into the notch in the crankcase. The oil hole in the bearing and crankcase will be aligned when the bearing lug is installed into the notch.

Oil grooves

(2) Apply a small amount of engine oil to the bearings.

(3) Install the thrust plate to the rear face of the crankcase with oil grooves toward the outside as shown in the illustration.

Installing main bearings

(4) Apply engine oil to tappets and insert them to the crankshaft.

1.2 Installing Crankshaft (1) Wash the crankshaft with cleaning solvent, and dry it by air blow.

(2) Hold the crankshaft in a horizontal position by using a hoist, and carefully place it in the crankcase.

(3) Lightly coat the journals with engine oil.

Installing crankshaft

1.3 Installing Main Bearing Caps (1) Apply engine oil to the bearings and install the bearings to the caps.

Apply ThreeBond 1212

(2) Apply ThreeBond 1212 to the corners of the rear bearing cap and install the cap to the crankcase so that the rear face of the cap is even with the the rear face of the crankcase.

Apply ThreeBond 1211

Installing main bearing caps

7-1

REASSEMBLY, ENGINE MAIN PARTS

(3) Apply ThreeBond 1211 to the side seals and install the seals in the groove in each bearing cap with rounded side toward outside. Push them into position to some level by hands and then completely fit in with the blade of a screwdriver or the like, taking care not to bend or twist them.

Crankcase

Bearing cap

Side seal

(4) Apply ThreeBond 1211 to and around the side seals.

Rounded side

NOTE Install the main bearing caps in number sequence.

Installing side seals

1.4 Installing Main Bearing Cap Bolts (1) Apply engine oil to the bolts and tighten them to the specified torque.

Tightening torque for main bearing cap bolts

98 to 108 N·m (10.0 to 11.0 kgf·m) [72 to 80 lbf·ft]

98㨪108 N㨯m (10.0㨪11.0 kgf㨯m) [72 to 80 lbf㨯ft] Wet

(2) Make sure crankshaft rotates smoothly.

Installing main bearing cap bolts

1.5 Measuring Crankshaft End Play After installing the bearing caps, check the end play of the crankshaft.

Unit: mm(in.)

Item Crankshaft end play

Assembly Standard

Repair Limit

0.100 to 0.264 (0.0039 to 0.0104)

0.300 (0.0118) Measuring crankshaft end play

1.6 Assembling Piston and Connecting Rod (1) Assemble the piston and the connecting rod with the WEIGHT mark of the piston and the MATCHING mark of the rod on the same side.

(2) Apply engine oil to the piston pin and insert the pin into position.

㧭

A view Front mark

WEIGHT mark MATCHING mark

Assembling piston and connecting rod

7-2

REASSEMBLY, ENGINE MAIN PARTS

(3) Install each snap ring in the snap ring groove of the piston with snap ring pliers. Make sure the snap ring fits in the groove properly.

Snap ring pliers

NOTE Install the snap ring with its ends toward the bottom of the piston.

Installing snap rings

1.7 Installing Piston Rings

Top mark

(1) Put the compression rings and oil ring in the ring grooves of the piston with piston ring pliers (3139112900).

㪩

No. 1 compression ring No. 2 compression ring

NOTE Install the compression rings on the piston with “R” mark of the rings toward the top of the piston.

Oil ring

Oil ring has no mark and can be installed in any direction.

Installing piston rings

(2) Install the oil ring with the joint of the coil spring 180° apart from those of the ring gap.

Joint of coil spring

q

Ends of oil ring

Ends of oil ring and coil spring

1.8 Preparation before Installing Pistons (1) Lay the crankcase on its side.

(2) Clean the cylinder bores with a clean rag and apply engine oil to the bore surfaces.

Preparation before for piston installation

7-3

REASSEMBLY, ENGINE MAIN PARTS

1.9 Assembling Connecting Rod Tightening Bolts and Bearing

Tab and groove

(1) Place the connecting rod cap bolts in the big end of the connecting rod so that the flats of their heads fit to the rod properly.

(2) Install the upper half of the connecting rod bearing to the big end of the connecting rod, making sure the locating lug fits into the notch in the rod. Apply engine oil to the bearing.

Connecting rod and bearing

1.10 Inserting Pistons

Camshaft side Thrust

(1) Apply engine oil to the piston rings. Install the rings on the piston with the ring ends positioned as shown in the illustration to avoid pin and thrust/anti-thrust directions.

q

End gap of No. 1 compression ring

End gap of No. 2 compression ring q

End gap of

qoil ring

Anti thrust Inlet valve side

Configuration of piston ring ends

1.11 Assembling Pistons (1) Turn the crankshaft to bring a crankpin top dead center to install the piston and connecting rod assembly.

Using piston installer (34491-00200), insert the assembly in the cylinder, with FRONT mark ( ) on the piston toward the front of the engine.

(2) After resting the big-end of the connecting rod on the crankpin, turn the crankshaft 180° while pushing the piston head to bring the big-end to a position where the cap can be installed easily.

Front mark

Piston installer

Installing piston and connecting rod assembly

7-4

REASSEMBLY, ENGINE MAIN PARTS

1.12 Installing Connecting Rod Cap (1) Install the lower half of the connecting rod bearing to the cap, making sure the locating lug fits into the notch in the cap. Apply engine oil to the bearing.

(2) Install the cap to the rod and tighten the cap nuts to the specified torque.

Tightening torque for cap nuts

49.0 to 59.0 N·m (5.0 to 6.0 kgf·m) [36.2 to 43.5 lbf·ft]

Apply engine oil

Installing connecting rod cap

CAUTION Make sure the matching mark on the cap is on the same side as the mark on the connecting rod.

2.

Reassembly, Timing Gear

2.1 Installing Front Plate (1) Put the gasket on the crankcase, making sure the dowels enter the holes in the gasket.

(2) Install the front plate and tighten the bolts that hold the front plate to the crankcase to the specified torque.

Tightening torque for front plate bolts

10.0 to 13.0 N·m (1.0 to 1.3 kgf·m) [7.38 to 9.59 lbf·ft] Installing front plate

(3) Cut off the excess of the gasket with a cutter.

2.2 Installing Camshaft Gear and Thrust Plate (1) Heat the camshaft gear for installation.

(2) Install the thrust plate in advance.

Thrust plate Camshaft gear

Installing camshaft gear and thrust plate

7-5

REASSEMBLY, ENGINE MAIN PARTS

2.3 Installing Camshaft (1) Apply engine oil to the lobes and journals of the camshaft.

(2) Carefully insert the camshaft into the bore in the crankcase.

(3) Tighten the bolts that hold the thrust plate to the specified torque.

10.0 to 13.0 N·m (1.0 to 1.3 kgf·m) [7.38 to 9.59 lbf·ft]

Tightening torque for front plate bolts

Installing camshaft

CAUTION Do not cause damage to the lobes and bushings.

2.4 Installing Idler Gear (1) Install the idler gear by aligning its matching mark with those on the crankshaft gear, injection pump gear and camshaft gear and install the thrust plate.

(2) Tighten the thrust plate mounting bolts to the specified torque.

Tightening torque for thrust plate bolts

29.0 to 39.0 N·m (3.0 to 4.0 kgf·m) [21.4 to 28.8 lbf·ft] Installing idler gear

Camshaft gear

Idler gear

(3) The marks on the gears will be aligned as shown when the No.1 piston is at top dead center of compression stroke.

Injection pump gear Crankshaft gear

Oil pump gear

Marks on timing gears

7-6

REASSEMBLY, ENGINE MAIN PARTS

2.5 Installing Oil Pump Gear (1) Install the gear to the oil pump shaft.

(2) Tighten the jam nut to the specified torque.

28.0 to 38.0 N·m (2.9 to 3.9 kgf·m) [21.0 to 28.0 lbf·ft]

Tightening torque for jam nut

Installing oil pump gear

2.6 Inspecting and Adjusting after Reassembly Timing gear backlash and end play.

After reassembling the timing gears, check the backlash and end play and, if necessary, adjust them.

Unit: mm(in.)

Assembly Standard

Repair Limit

Backlash between gears

0.05 to 0.15 (0.0020 to 0.0059)

0.25 (0.0098)

End play of idler gear

0.05 to 0.20 (0.0020 to 0.0079)

0.35 (0.0138)

End play of camshaft

0.10 to 0.25 (0.0039 to 0.0098)

0.30 (0.0118)

Item

Inspecting backlash and end play

2.7 Installing Oil Seal Apply a small amount of grease to the oil seal and install it to the timing gear case with an installer.

Installing oil seal

2.8 Installing Timing Gear Case (1) Put the gasket on the front plate, making sure the dowels enter their holes in the gasket.

(2) Apply oil to the lip of the oil seal.

(3) Tighten the bolts that hold the timing gear case to the specified torque.

Tightening torque for timing gear case bolts

10.0 to 13.0 N·m (1.0 to 1.3 kgf·m) [7.38 to 9.59 lbf·ft]

Installing timing gear case

7-7

REASSEMBLY, ENGINE MAIN PARTS

2.9 Installing Oil Pan (1) Clean the mounting surfaces of the crankcase, timing gear case and oil pan.

(2) Squeeze out a 4 mm (0.2 in.) thickness of ThreeBond 1207C (32A91-05100) from the tube and apply it on the oil pan flange.

(3) Install the oil pan to the crankcase within 5 minutes after applying ThreeBond 1207C. (4) Tighten the bolts to the specified torque.

Application of ThreeBond 1207C on oil pan flange

10.0 to 13.0 N·m (1.0 to 1.3 kgf·m) [7.38 to 9.59 lbf·ft]

Tightening torque for oil pan bolts

NOTE (1) To squeeze out a 4 mm (0.2 in.) thickness of ThreeBond, cut the first node of the nozzle.

Cut nozzle here

(2) When the above ThreeBond (liquid type) is not available, general use gaskets (32A13-03200) can be substituted.

Nozzle for ThreeBond 1207C tube

2.10 Installing Crankshaft Pulley Install two safety bars (M12 x 1.25) to the rear end of the crankshaft. Put a bar between the safety bars to hold the crankshaft. Under this condition, install the crankshaft pulley and tighten the nut to the specified torque.

Tightening torque for crankshaft pulley nut

480 to 500 N·m (49 to 51 kgf·m) [354 to 369 lbf·ft]

WARNING

Installing crankshaft pulley

Be alert just in case the safety bar should come off accidentally.

7-8

REASSEMBLY, ENGINE MAIN PARTS

3.

Reassembly, Flywheel

3.1 Installing Rear Plate (1) Apply ThreeBond 1212 to the mating surfaces of crankcase rear end and bearing cap rear end.

(2) Aligning holes to the dowel pins on the crankcase, install the rear plate and gasket together to the crankcase.

(3) Tighten the rear plate mounting bolts to the specified torque.

Installing rear plate

54.0 to 65.7 N·m (5.5 to 6.7 kgf·m) [39.9 to 48.5 lbf·ft]

Tightening torque

3.2 Installing Oil Seal (1) Fit the oil seal in the oil seal case.

(2) Apply engine oil to the oil seal lip.

(3) Fit O-ring to the oil seal case, then install the oil seal case to the rear plate.

(4) Tighten bolts firmly to secure the oil seal case in place.

Installing oil seal

3.3 Installing Flywheel (1) Install the flywheel in place by using the dowel pins on the crankshaft for alignment.

(2) Install the lock washers and bolts, and tighten the bolts to the specified torque.

(3) After tightening bolts, bend the corners of lock washers to prevent bolts from loosening.

Tightening torque

78.5 to 88.3 N·m (8.0 to 9.0 kgf·m) [57.9 to 65.2 lbf·ft]

Installing flywheel

3.4 Measuring Flywheel Runout Measure the amount of runout of the installed flywheel. If the measured value exceeds the standard value, check the torque of the bolts and the mounting face for foreign particles.

Unit: mm (in.)

Item Flywheel runout

Assembly Standard

Repair Limit

0.15 (0.0059) or less

0.50 (0.0197) 7-9

Measuring of flywheel runout

REASSEMBLY, ENGINE MAIN PARTS

4.

Reassembly, Cylinder Head and Valve Mechanism

4.1 Installing Valve Stem Seal (1) After the installation of the valve, install a new stem seal on the valve guide using the stem seal installer (32A91-10200).

CAUTION

Stem seal installer

Valve

Stem seal

Do not apply a liquid seal to the contact area between the stem seal and valve guide.

To ensure the initial lubrication of stem seal lip, apply engine oil to the valve stem before installation of the stem seal.

Valve guide

Installing valve stem seal

Do not pull out the valve to avoid scraping of the seal lip once that the stem seal is installed.

4.2 Installing Valve and Valve Spring

Valve spring pusher

(1) Set the valve spring and retainer on the valve guide.

Using valve spring pusher (30691-04500), compress the valve spring and install the valve cotters to the valve.

Installing valve and valve spring

(2) Tap the top of the valve with a soft faced hammer several times to make sure the valve spring and valve cotters are properly installed.

Testing valve cotter installation

7-10

REASSEMBLY, ENGINE MAIN PARTS

4.3 Installing Cylinder Head (1) Secure the cylinder head gasket in the position by using the two locating dowels on the surface of crankcase.

(2) Place the cylinder head on the crankcase by inserting the locating dowels into the hole of cylinder head and tighten the cylinder head bolts.

Dowel pin

CAUTION Do not use any liquid packing.

Installing cylinder head

Make sure the surface of crankcase is free from damage such as dent.

(3) Tighten the cylinder head bolts to the specified torque in the sequence shown in the illustration.

Front

Tightening torque

113 to 123 N·m (11.5 to 12.5 kgf·m) [83.4 to 90.8 lbf·ft]

Number of bolts: 17

Cylinder head bolt tightening sequence

4.4 Assembling Rocker Arms and Rocker Shaft

Assembly mark

When installing the rocker arms to the rocker shaft, position the arms with their assembly marks pointing forward. After installing the arms, make sure they move smoothly.

Assembling rocker arms and rocker shaft

7-11

REASSEMBLY, ENGINE MAIN PARTS

4.5 Installing Valve Pushrod (1) Insert the pushrod into position through the pushrod hole in the cylinder head.

(2) Make sure the ball end of each pushrod rests securely on the curved surface (R section) of the tappet.

4.6 Installing Rocker Shaft Assembly (1) Install valve caps.

(2) When installing rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (in reverse of removal sequence).

Tightening torque

10.0 to 20.0 N·m (1.0 to 2.0 kgf·m) 7.38 to 14.8 lbf·ft] Installing rocker shaft assembly

4.7 Checking No.1 Piston Compression Top Dead Center (1) Find the top dead center on the compression stroke for No.1 piston as specified below:

(b) Stop turning when the stamped “0” line on the periphery of the crankshaft pulley aligns with the pointer on the turning gear case.

(a) Using the turning socket wrench (58309-73100), turn the nut on the crankshaft pulley in the engine’s forward rotating direction (clockwise when viewed from the front of the engine).

Finding top dead center on compression stroke for No.1 piston-1

(c) Try to move up and down the inlet and exhaust valve rocker arms of the No.1 cylinder to make sure they are not being pushed up by the pushrods.

The No.1 piston is at the top dead center on the compression stroke when the rocker arms are not being pushed up by the pushrods. If the rocker arms are being pushed up, turn the crankshaft one turn.

Finding top dead center on compression stroke for No.1 piston-2

7-12

REASSEMBLY, ENGINE MAIN PARTS

4.8 Adjusting Valve Clearance

Unit: mm (in.)

Item Valve clearance (cold setting)

Assembly Standard Inlet valves

Adjusting screw Rock nut

0.25 mm (0.0098 in.)

(1) Insert a 0.25 mm (0.0098 in.) feeler gauge between the rocker arm and valve cap.

0.25 (0.0098)

Exhaust valves Adjusting valve clearance

(2) Loosen the lock nut for the adjusting screw and turn the adjusting screw in either direction until the feeler gauge is slightly gripped between the rocker arm and valve cap.

(3) After adjusting, tighten the lock nut and recheck the clearance.

(4) Adjust the valve clearance on the remaining cylinders by turning the crankshaft 180° at a time in the firing order.

Sequence (cylinder No.)

Turning angle

1–3–4–2

180°

CAUTION After adjusting the valve clearance on all cylinders, rotate the crankshaft two or three turns and recheck the clearance.

7-13

FUEL SYSTEM 1. Fuel System ....................................................................................... 8 – 1 2. Fuel Filter ............................................................................................ 8 – 2 Disassembly and Inspection ................................................................... 8 – 2

3. Injection Nozzle ................................................................................ 8 – 4 3.1 Disassembly .................................................................................... 8 – 4 3.2 Testing and Adjusting ...................................................................... 8 – 5 3.3 Reassembly .................................................................................... 8 – 7

4. Fuel System Bleeding ..................................................................... 8 – 8 4.1 Fuel filter ......................................................................................... 8 – 8 4.2 Fuel injection pump ......................................................................... 8 – 9

8

FUEL SYSTEM

1.

Fuel System

Distributor type fuel injection pump Leak off pipe

Injection nozzle

Fuel filter Fuel inlet

Return pipe

Fuel outlet

Fuel injection pump

In-line type fuel injection pump Injection nozzle Leak off pipe

Fuel filter

Return pipe Fuel outlet Fuel inlet

Fuel injection pump

Fuel feed pump

8-1

FUEL SYSTEM

2.

Fuel Filter

Disassembly and Inspection Distributor type fuel injection pump

Check for cracks, stripped threads.

3

Air bleeding plug

2

Check for clogging or cracks.

Replace filter every 1200 hrs or 6 months.

1 Replace O-ring.

Sequence 1

Level sensor assembly

2

Filter element

8-2

3

Bracket

FUEL SYSTEM

2.

Fuel Filter (Continued)

Disassembly and Inspection In-line type fuel injection pump Air bleeding plug Check for cracks, stripped threads.

2

Apply engine oil to the packing when installing.

1

Check for clogging or cracks.

Replace filter every 500 hours.

Sequence 1

Filter element

2

Bracket

8-3

FUEL SYSTEM

3.

Injection Nozzle

3.1 Disassembly

7 Check for wear.

6 Check for fatigue or squareness.

5 4

Check for wear, damage

3 2

Check for carbon on tip or in orifice.

1

Disassembly sequence 1 2 3

Retaining nut Nozzle tip Piece

4 5

Pressure pin Pressure spring

8-4

6 7

Washer Nozzle body

FUEL SYSTEM

3.2 Testing and Adjusting (1) Injection pressure (valve opening pressure) (a) Install the injection nozzle on the tester. Slowly operate the tester handle full strokes to bleed (remove) air from the pipe and nozzle. (b) Make a slow increase in pressure by operating the tester handle at a speed of more than one stroke per second while observing the pressure gauge. (c) The pressure gauge reading will slowly increase and, when the nozzle starts discharging fuel, it will go down fast. Take the gauge reading right then as the injection pressure.

Unit: MPa (kgf/cm ) [psi] 2

Injection pressure Nominal

Assembly Standard

14.22 (145) [2062.4]

14.22 to 15.00 (145 to 153) [2062.4 to 2175.6]

Testing fuel injection nozzle

CAUTION When testing the injection nozzle, keep its tip pointed away from the operator and never touch the discharged fuel. The fuel from the orifices in the tip of the nozzle is under high pressure and may cause injury.

Value is based on the new nozzle. (d) If the injection pressure is not correct, make an adjustment of the nozzle by adding or removing the shims inside the nozzle holder. Shims come in 10 different thicknesses from 1.25 mm (0.049 in.) to 1.7 mm (0.067 in.) at intervals of 0.05 mm (0.002 in.). The thickness is not indicated on the shim, so any shim should be measured with a vernier caliper before being used.

NOTE A change of 0.1 mm (0.004 in.) in the shim thickness yields a change of approximately 1° in the injection timing.

(2) Spray pattern (a) When checking pressure with nozzle tester, also check for clogged holes, spray condition and fuel dripping from the hole. b) Operate the tester handle at a speed of one stroke per second and check that the spray pattern is good with a spray angle of 15° as shown in the illustration.

Good Bad (Diffused)

Bad Bad Bad (Dribbling) (Deflected) (Feathering)

Possible spray pattern

8-5

FUEL SYSTEM

(3) Cleaning/Replacing (a) If the nozzle is bad, loosen the retaining nut and remove the tip from the nozzle. Wash the tip — needle valve and body — in clean diesel fuel.

After washing, put the needle valve in the body while submerged in clean light oil.

Nozzle tip end

CAUTION Use care not to damage the nozzle tip when removing it from the nozzle body. (b) After cleaning the nozzle tip, install it to the nozzle body and tighten the retaining nut to the specified torque.

Removing retaining nut

34.3 to 39.2N·m (3.5 to 4.0 kgf·m) [25.3 to 28.9 lbf·ft]

Tightening torque

NOTE Needle valve and body are finished to high precision.

Use care in handling and never change the combination.

Needle valve Body

Washing nozzle tip

(c) If the discharge pattern (nozzle) is still bad after the nozzle tip has been washed, replace the tip.

NOTE (1) Do not touch the sliding surface of the needle valve.

(2) When installing a new nozzle tip, remove resin film from the tip and slide the needle valve in the body in clean diesel fuel to wash off inhibitor completely. After cleaning, assemble the needle valve in the body while submerged in clean light oil.

8-6

FUEL SYSTEM

3.3 Reassembly

7

6

5

Retaining nut Tightening torque: 34.3 to 39.2 N･m (3.5 to 4.0 kgf･m) [25.3 to 28.9 lbf･ft]

4 Tightening torque for fuel injection nozzle to the engine: 49.0 to 68.6 N･m (5.0 to 7.0 kgf･m) [36.2 to 50.6 lbf･ft]

3 2 1

Reassembly sequence 4

←

←

5

3

←

←

6

2

←

←

7

1

8-7

FUEL SYSTEM

4.

Fuel System Bleeding

4.1 Fuel filter Distributor type fuel injection pump

Priming button

(1) Loosen air bleed plug on the fuel filter (about 1.5 turns).

(2) Pump the priming button on the fuel feed pump.

(3) When the flow of fuel becomes free of bubbles, tighten the air bleed plug

Air bleed plug

Bleeding fuel system (Distributor type fuel injection pump)

In-line type fuel injection pump (1) Loosen air bleed plug on the fuel filter (about 1.5 turns).

Air bleed plug

(2) Loosen the priming button on the fuel pump by turning it to counterclockwise and pump the button.

(3) When the flow of fuel becomes free of bubbles, tighten the air bleed plug.

Priming button

Bleeding fuel system (In-line type fuel injection pump)

8-8

FUEL SYSTEM

4.2 Fuel injection pump In-line type fuel injection pump (1) Loosen air bleed plug on the fuel injection pump (about 1.5 turns).

Air bleed plug

(2) Pump the priming button on the fuel feed pump.

(3) When the fuel flow from the air bleed plug becomes free of bubbles, push the priming button and turn it clockwise (while pushing) to lock the button in the original position.

Priming Button

(4) Tighten the air bleed plug on the fuel injection pump.

Bleeding fuel injection pump (In-line type fuel injection pump)

CAUTION If the air bleed plug on the injection pump is tightened before locking the priming button, the priming button will not return in the original lock position due to the pressure of fuel feed pump.

Be sure to tighten the air bleed plug with the priming button locked.

Wipe off the spilled fuel from the air bleed plug with a cloth.

8-9

LUBRICATION SYSTEM 1. Lubrication System .......................................................................... 9 – 1 2. Oil Pump ............................................................................................. 9 – 1 2.1 Disassembly ................................................................................... 9 – 1 2.2 Inspection ....................................................................................... 9 – 2 2.3 Reassembly ................................................................................... 9 – 4

3. Oil Filter ............................................................................................... 9 – 5 Disassembly and Inspection .................................................................. 9 – 5

4. Oil Pressure Relief Valve ................................................................. 9 – 6 Inspection .............................................................................................. 9 – 6

9

LUBRICATION SYSTEM

1.

Lubrication System Valve mechanism

Push rod

Piston Tappet Camshaft

Relief valve

Idler gear

Oil filter Oil pump

Oil pan

Oil strainer

2.

Oil Pump

2.1 Disassembly Replace O-ring

1 3 2

4 5

Disassembly sequence 1 O-ring (Remove 2 and 3 in assembly.)

2 Main shaft

3 4 5

9-1

Inner rotor Outer rotor Pump case

LUBRICATION SYSTEM

2.2 Inspection (1) Checking clearance between outer rotor and inner rotor Check the clearance with a feeler gauge as shown in the illustration. If the clearance exceeds the service limit, replace the pump assembly.

Unit: mm (in.)

Item Clearance between outer rotor and inner rotor

Assembly Standard

Service Limit

0.13 to 0.15 (0.0051 to 0.0059)

0.20 (0.0079)

Checking clearance between outer rotor and inner rotor

(2) Checking clearance between rotors and cover Check the clearance with a feeler gauge and straight edge as shown in the illustration. If the clearance exceeds the service limit, replace the oil pump.

Unit: mm (in.)

Item Clearance between rotors and cover

Assembly Standard

Service Limit

0.04 to 0.09 (0.0016 to 0.0035)

0.15 (0.0059) Checking clearance between rotors and cover

(3) Checking clearance between outer rotor and case Check the clearance with a feeler gauge as shown in the illustration. If the clearance exceeds the service limit, replace the oil pump.

Unit: mm (in.)

Item Clearance between outer rotor and case

Assembly Standard

Service Limit

0.200 to 0.300 (0.0079 to 0.0118)

0.500 (0.0197) Checking clearance outer rotor and case

9-2

LUBRICATION SYSTEM

(4) Checking clearance between main shaft and pump case Measure the diameter of the shaft and the inside diameter of the bore in the case to find the clearance between the two. If the clearance exceeds the service limit, replace the pump case or the pump assembly.

Unit: mm (in.)

Assembly Standard

Service Limit

Diameter of main shaft (case side)

15.985 to 16.000 (0.6293 to 0.6299)

—

Clearance between main shaft and case

0.032 to 0.074 (0.0013 to 0.0029)

0.15 (0.0059)

Item

Checking clearance between main shaft and pump case

(5) Checking clearance between main shaft and bushing Measure the diameter of the shaft and the inside diameter of the oil pump bushing in the crankcase to find the clearance between the two. If the clearance exceeds the service limit, replace the bushing or the pump assembly.

Unit: mm (in.)

Assembly Standard

Service Limit

Diameter of main shaft (bushing side)

13.957 to 13.975 (0.5495 to 0.5502)

—

Clearance between main shaft and bushing

0.025 to 0.111 (0.0010 to 0.0044)

0.200 (0.0079)

Item

(6) Installing oil pump bushing To install the oil pump bushing, use oil pump bushing installer (32A91-00400)

NOTE Install the oil pump bushing in the crankcase so that it is flush with the front face of the crankcase.

9-3

Checking clearance between main shaft and bushing

LUBRICATION SYSTEM

2.3 Reassembly

5 1 3 Flush

Flush 4 2

Reassembly sequence 3

←

←

4

2

←

←

5

1

9-4

LUBRICATION SYSTEM

3.

Oil Filter

Disassembly and Inspection

When installing new filter element apply engine oil to gasket.

1

Check for clogging or rips.

Replace filter every 500 hours or 3 months.

Disassembly sequence 1

Filter element

9-5

LUBRICATION SYSTEM

4.

Oil Pressure Relief Valve

Inspection

Tightening torque: 44.1 to 53.9 N㨯m (4.5 to 5.5 kgf㨯m) =32.5 to 39.8 lbf㨯ft]

(1) Check the valve and valve seat for contact. Check the spring for damage.

(2) Measure the opening pressure. If the opening pressure is not correct, make a shim adjustment.

Unit: MPa (kgf/cm2) [psi] Item Opening pressure

Assembly Standard

Shims

Cap bolt

Checking pressure relief valve

0.35 to 0.40 (3.1 to 4.1) [50.8 to 58.0]

9-6

COOLING SYSTEM 1. Cooling System .................................................................................10 – 1 2. Water Pump.........................................................................................10 – 2 Inspection ...............................................................................................10 – 2

3. Thermostat .........................................................................................10 – 3 Inspection ...............................................................................................10 – 3

10

COOLING SYSTEM

1.

Cooling System

Cylinder head

Coolant outlet Bypass hose

Water jacket

Water pump

Coolant inlet

10-1

COOLING SYSTEM

2.

Water Pump

Inspection

4

3

Check groove for wear or damage.

Replace.

Check for corrosion, crack, or damage.

1 2

Check for wear, fraying or separated piles.

Disassembly sequence 1 2

V-belt Pulley

3 4

Check the water pump visually and replace it as an assembly if any defect is found.

Check for water leakage, rough rotation, cracks, etc. and replace the water pump as an assembly if necessary.

10-2

Water pump assembly Cover

COOLING SYSTEM

3.

Thermostat

Put the thermostat in a glass jar filled with water, and test it for thermostatic action by heating the jar to raise the water temperature. In the test, measure the temperature at which the valve starts opening and that at which the valve lift is more than 8 mm (0.3 in.). If these measurement are out of the assembly standard, replace the thermostat.

Item

Valve lift, mm (in.)

Inspection 8 (0.3)

0 76.5r1.5 (170r2.7)

( F) Temperature,͠ ࠑ

Assembly Standard

Temperature at which valve starts opening

76.5±1.5°C (170±2.7°F)

Temperature at which valve lift exceeds 8 mm (0.3 in.)

90°C (l94°F)

Testing thermostat

NOTE (1) Stir up the water with a stick to keep the temperature uniform.

(2) Install the thermostat with its air vent hole up.

10-3

90

INLET AND EXHAUST SYSTEM 1. Description ......................................................................................... 11 – 1 2. Exhaust Manifold .............................................................................. 11 – 1 Inspection .............................................................................................. 11 – 1

11

INLET AND EXHAUST SYSTEM

1.

Description

Exhaust manifold Inlet manifold

2.

Exhaust Manifold

Inspection (a) Check the flanges for cracking. (b) Check the flanges for distortion as shown in the illustration. If the distortion exceeds the assembly standard, repair the flanges.

Unit: mm (in.)

Item Distortion of exhaust manifold flange

Assembly Standard 0.2 (0.008), maximum

Checking exhaust manifold flange for distortion

11-1

ELECTRICAL SYSTEM 1. Starter ..................................................................................................12 – 1 1.1 Inspection before Disassembly (inspection of assembly) ...............12 – 1 1.2 Disassembly ...................................................................................12 – 3 1.3 Inspection .......................................................................................12 – 6 1.4 Reassembly ................................................................................... 12 – 10 1.5 Inspection and Adjustment after Assembly ...................................... 12 – 14

2. Alternator ............................................................................................ 12 – 15 2.1 On-vehicle Inspection ..................................................................... 12 – 15 2.2 Disassembly ................................................................................... 12 – 17 2.3 Inspection ....................................................................................... 12 – 21 2.4 Reassembly ................................................................................... 12 – 23 2.5 Installation ...................................................................................... 12 – 23

3. Glow Plugs ........................................................................................ 12 – 24 3.1 Inspection ....................................................................................... 12 – 24 3.2 Installation ...................................................................................... 12 – 24

4. Stop Solenoid (In-line type injection pump) .............................. 12 – 25 4.1 Inspection ....................................................................................... 12 – 25

12

ELECTRICAL SYSTEM

1. Starter Lightly press the tip

1.1 Inspection before Disassembly (inspection of assembly)

S

If an abnormality is found, disassemble and repair. + − Battery 12 V

(1) Pinion gap (a) Connect the positive (+) cable of the battery to terminal S of the starter and the negative (-) cable to the starter body to extend the pinion.

Starter

0.5 to 2.0 mm (0.0197 to 0.0787 in.)

Inspection of pinion gap

CAUTION Do not supply electricity for more than 10 continuous seconds.

(b) Lightly press the tip of the extended pinion shaft with a finger, and measure the distance of the shaft movement.

Switch Ammeter A

Revolution indicator

Stater

V

−

+

Battery 12 V

(c) If the measured value is not within a range of 0.5 to 2.0 mm (0.0196 to 0.0787 in.), increase or decrease the number of packings at the magnetic switch section for adjustment. An increase of packings results in a decrease of the pinion gap.

No-load test

(2) No-load test (a) As shown in the illustration, connect an ammeter, voltmeter, revolution indicator and battery. (b) Turning on the switch should extend the pinion and operate the starter at the specified speed or faster.

If the current or rotating speed does not conform to the standard value, disassemble the starter for inspection and repair.

CAUTION (1) Use thick wires, and tighten the connections at the terminals.

(2) Note that the rotation sound is louder than the sound produced by a starter without a reduction gear mechanism.

(3) When measuring the rotation speed at the tip of the pinion, be careful of the pinion extension at the start of operation.

12-1

No load characteristics Model

Voltage V

Current Rotation Speed A min-1

M8T75171 (12V-2.2kW)

11

130 or lower

3800 or higher

M2TS0071A (12V-2.2kW)

11

130 or lower

3750 or higher

M3T67671 (12V-3.0kW)

11

180 or lower

3800 or higher

ELECTRICAL SYSTEM

(3) Inspection of magnetic switch Conduct the following inspection. If the magnetic switch is faulty, replace.

S M

(a) Disconnect the wire from terminal M. _

(b) Suction test Connect the battery to terminals S and M of the magnetic switch. The pinion should extend when the switch is turned on.

+

Battery 12 V Disconnect connector

Suction test

CAUTION Do not supply electricity for more than 10 continuous seconds. (c) Holding test With the battery connected to terminals S and the body of the magnetic switch, pull out the pinion fully with fingers. The pinion should not return to the original position when it is released.

Disconnect connector

S M

+

_

Battery 12 V

CAUTION Do not supply electricity for more than 10 continuous seconds.

Holding test

(d) Return test With the battery connected to terminals M and the body of the magnetic switch, pull out the pinion fully with fingers. The pinion should return immediately to the original position when it is released.

Disconnect connector M

+

_

Battery 12 V

CAUTION Do not supply electricity for more than 10 continuous seconds.

12-2

Return test

ELECTRICAL SYSTEM

1.2 Disassembly M8T75171 (12V-2.2kW) 1

16 17 Replace snap ring.

Seizure, wear or surface cleanliness of commutator, worn or damaged gear, and disconnection.

18

Check for wear or damage.

6 Check for rotation.

5

Check for rotation.

8

7 14

13 Accumulation of brush dust, uneven wear or sticking in holder.

Check for slippage or seizure.

12 11

2

9 10

Replace washer.

Check gear for worn or damaged teeth.

15

3

4

Pole and field coil installation conditions.

Disassembly sequence 1 2 3 4 5 6

Magnetic switch assembly Rear bracket Brush holder assembly Yoke assembly Armature Bearing

7 8 9 10 11 12

Ball Packing set Washer set Internal gear Gear shaft Gear

12-3

13 14 15 16 17 18

Lever assembly Pinion set Overrunning clutch Bearing Oil seal Front bracket

ELECTRICAL SYSTEM

M2TS0071A (12V-2.2kW)

1

Seizure, wear or surface cleanliness of commutator, worn or damaged gear, and disconnection.

16 15

5

Check for rotation.

Replace snap ring.

7

12

Check for wear or damage.

6 Check for rotation.

11

8

13

2 9

3 Accumulation of brush dust, uneven wear or sticking in holder.

10 14 Check for slippage or seizure.

Check gear for worn or damaged teeth.

4

Pole and field coil installation conditions.

Disassembly sequence 1 2 3 4 5 6

Magnetic switch assembly Rear bracket Brush holder assembly Yoke assembly Armature Bearing

7 8 9 10 11 12

Bearing Cover set Center bracket assembly Gear Lever assembly Spring set

12-4

13 14 15 16

Pinion set Pinion shaft assembly Bearing set Front bracket assembly

ELECTRICAL SYSTEM

M3T67671 (12V-3.0kW)

Seizure, wear or surface cleanliness of commutator, worn or damaged gear, and disconnection.

1

16 Replace snap ring.

15

5

6 Check for rotation.

Check for rotation.

7

Check gear for wear or damage.

11

12

8

2 3 Accumulation of brush dust, uneven wear or sticking in holder.

13 10 14

Check for slippage or seizure.

9 Check gear for wear or damage.

4

Pole and field coil installation conditions.

Disassembly sequence 1 2 3 4 5 6

Magnetic switch assembly Rear bracket Brush holder assembly Yoke assembly Armature Bearing

7 8 9 10 11 12

Bearing Cover set Center bracket assembly Gear Lever assembly Spring set

12-5

13 14 15 16

Pinion set Pinion shaft assembly Bearing set Front bracket assembly

ELECTRICAL SYSTEM

1.3 Inspection

Iron stick Growler tester

(1) Armature (a) Testing for short circuits Place the armature on a growler, and slowly revolve it with a hacksaw blade held above the armature core.

The hacksaw blade vibrates against the core when it is above a slot containing a shorted winding. Replace the armature if shorted.

Testing short circuits

(b) Testing for grounded circuits If there is any continuity between the commutator and shaft (or core), the armature is grounded and should be replaced.

Testing grounded circuits

(c) Inspecting commutator 1) Support the armature in V-blocks and measure the runout of the commutator with a dial indicator. If the runout is near the service limit, recondition the commutator, making sure the commutator diameter does not exceed the service limit.

Unit: mm (in.)

Item

Assembly Standard

Service Limit

Runout of commutator

0.05 (0.002)

0.10 (0.004)

Measuring the runout

2) Measure the diameter of commutator. If it is less than the service limit, replace the armature.

Di am et er

Unit: mm (in.)

Assembly Standard

Service Limit

12V-2.2kW

31.8 to 32.2 (1.25 to 1.27)

31.4 (1.24)

12V-3.0kW

38.5 to 38.9 (1.52 to 1.53)

38.1 (1.50)

Item

Diameter of Commutator

Measuring the diameter

12-6

ELECTRICAL SYSTEM

3) Measure the depth of each mold between segments with a depth gauge. If the depth is less than the repair limit, recondition the mold.

Mold depth Segment Mica

Unit: mm (in) Item Depth of commutator mold

Assembly Standard

Repair Limit

0.4 to 0.6 (0.016 to 0.024)

0.2 (0.008) or less Measuring the mold depth

4) Inspecting armature gear Check the armature gear for abnormal wear and missing teeth, and replace it if necessary.

(2) Field coil (a) Testing for open circuits If there is no continuity between the lead wire and positive (+) brush, the field coil is open and the yoke assembly should be replaced.

Testing yoke coil for open circuit failure

(b) Testing for grounded circuits If there is any continuity between the yoke and positive (+) brush, the field coil is grounded. Check the insulation and repair or replace the yoke assembly if reconditioning is impossible.

Testing yoke coil for grounding failure

12-7

ELECTRICAL SYSTEM

(3) Magnetic switch S terminal

(a) Testing coil for open circuits If there is no continuity between S and M terminals and between S terminal and body (ground) , replace the switch.

M terminal B terminal

(b) Checking contactors for fusion If there is continuity between B and M terminals, replace the switch. (c) Checking contactors for poor contact action

Testing magnetic switch

Check for voltage drop. If voltage drop is excessive, the contactors are defective.

(4) Brushed and holders Brush

(a) Wear of brushes Measure the brush length and, if it is less than the service limit, replace the brushes. If the brushes are unevenly worn or rough, recondition them with a sandpaper of #300 to #500.

Unit: mm (in) Assembly Standard

Service Limit

12V-2.2kW

18 (0.71)

11 (0.43)

12V-3.0kW

17 (0.67)

11 (0.43)

Item Length of brush

Measuring brush length

(b) Brush spring force Test the spring force using a new brush. In the test, read the load at the instant the spring moves off the brush. If the force is less than the service limit, replace the spring.

Unit: N (kgf) [lbf] Item

12V-2.2kW Force of Brush Spring 12V-3.0kW

Assembly Standard

Service Limit

26 to 36 (2.7 to 3.7) [5.8 to 8.1]

15 (1.5) [3.4]

33 to 45 (3.4 to 4.6) [7.4 to 10.1]

18 (1.8) [4.0]

Measuring brush spring force

12-8

ELECTRICAL SYSTEM

(c) Testing brush holders insulation If there is any continuity between the positive (+) brush holder and negative (-) holder plate, replace the brush holder assembly.

Brush holder

Testing brush holders insulation

(5) Inspecting bearings Check the bearings and replace any that fails to turn smoothly or emits noise.

(6) Inspecting overrunning clutch (a) Make sure that the pinion shaft turns freely when turned in the direction of driving (clockwise) and it is locked when turned in the opposite direction. (b) Check the overrunning clutch for worn-out or damaged pinion, and replace it if necessary.

CAUTION Never wash overrunning clutch in wash oil.

Inspecting overrunning clutch

(7) Front bracket If the ball bearing fails to turn smoothly or emits noise, replace it together with the front bracket.

NOTE Replace the oil seal at every disassembly.

(8) Reduction gear Replace the reduction gear if it is worn out or damaged.

12-9

ELECTRICAL SYSTEM

1.4 Reassembly To reassemble, follow the disassembly sequence in reverse.

(1) Applying grease When overhauling the starter, apply grease to sliding parts, gears, and bearings as shown below: M8T75171 (12V-2.2kW)

G

H B C

A

E

D

F

Greasing points on reassembly E F G H

A Armature shaft gear B Armature rear bearing (Slightly. Be careful not to let the grease enter the commutator.)

C Reduction gear D Pinion shaft gear

12-10

Lever sliding section of magnetic switch Pinion shaft bearing Pinion Oil seal

ELECTRICAL SYSTEM

M2TS0071A (12V-2.2kW)

G

H B F C

A

D

E

Greasing points on reassembly A Armature shaft gear B Armature rear bearing (Slightly. Be careful not to let the grease enter the commutator.)

C Armature front bearing D Reduction gear

E F G H

12-11

Lever sliding section of magnetic switch Pinion shaft bearing Pinion Oil seal

ELECTRICAL SYSTEM

M3T67671 (12V-3.0kW)

G

*

B

F C

A

D

E

Greasing points on reassembly E F G H

A Armature shaft gear B Armature rear bearing (Slightly. Be careful not to let the grease enter the commutator.)

C Armature front bearing D Reduction gear

12-12

Lever sliding section of magnetic switch Pinion shaft bearing Pinion Oil seal

ELECTRICAL SYSTEM

(2) Installing stopper ring Pinion stopper

Fit the stopper ring into the ring groove on the pinion shaft.

Then, using a puller, pull the pinion stopper over the stopper ring to fit the stopper ring into the ring groove inside the pinion stooper.

Pinion stopper

Stopper ring

Installing stopper ring

(3) Adjusting pinion shaft end play Using an appropriate number of adjusting washers in between the center bracket and reduction gear, adjust the end plate (thrust gap) to 0.5 mm (0.020 in.) or less. (a) Assemble the pinion shaft, reduction gear, washer and snap ring to the center bracket. (b) Moving the pinion shaft in the axial direction, measure its end play. If the end play exceeds 0.5 mm (0.020 in.), increase the number of adjusting washer as required to reduce it to 0.5 mm (0.020 in.) or less.

Adjusting washer

Reduction gear

Washer Snap ring

End play

0.5 mm (0.02 in.)

Max

Adjusting pinion shaft end play

(4) Installing lever Front bracket

Install the lever facing in the correct direction.

Lever Lever spring

Installing lever

12-13

ELECTRICAL SYSTEM

1.5 Inspection and Adjustment after Assembly Following inspections and tests shall be performed after starter assembling.

Lightly press the tip

S

(1) Checking pinion gap

With the pinion fully protruded, lightly press the pinion shaft end back with a finger. Measure the extent of shaft return to determine if the pinion gap is larger or smaller than 0.5 to 2.0 mm (0.0196 to 0.0984 in.). Make adjustment, if necessary, with the packing provided where the magnetic switch is fitted; increase the number of pieces of packing if the gap is larger and decrease otherwise.

Starter

Battery 12V 0.5 to 2.0 mm (0.0196 to 0.0984 in.)

Adjusting pinion gap

CAUTION Do not supply electricity for more than 10 continuous seconds.

(2) No-load test After adjusting the pinion clearance, hook up the starter as shown, and test it for no-load characteristics.

A Ammeter Switch S

CAUTION

Battery

V

Use wires as thick as possible and tighten each terminal securely.

Voltmeter

B M

Switch

Starter

No-load test

No load characteristics

12-14

Model

Voltage V

Current Rotation Speed A min-1

M8T75171 (12V-2.2kW)

11

130 or lower

3800 or higher

M2TS0071A (12V-2.2kW)

11

130 or lower

3750 or higher

M3T67671 (12V-3.0kW)

11

180 or lower

3800 or higher

ELECTRICAL SYSTEM

2.

Alternator

If a problem occurs in the charge system, check the following abnormal conditions to locate the cause of the problem. Only when inspection cannot be conducted on the alternator installed on the engine, dismount the alternator from the engine for inspection and repair.

Overcharging

Voltage regulator adjustment value is high.

Undercharging

Voltage relay adjustment value is low.

Faulty battery.

Faulty alternator output.

Alternator

Power consumption is extremely high.

Special load is used.

Faulty wiring.

2.1 On-vehicle Inspection (1) Cautions in handling Handle the alternator carefully. Incorrect handling can result in alternator damage and malfunctions. (a) Do not connect the battery cables in reverse. Note that the negative cable is a grounding wire. (b) Do not use a high-voltage tester such as a megger. (c) When charging the battery, disconnect the cables from the battery terminals. (d) Do not disconnect the lead wire from terminal B of the alternator while the engine is operating. (e) Do not ground terminal B of the alternator since it is constantly applied with battery voltage. (f) Do not short or ground terminal L (unit with integrated IC regulator). (g) When using a steam cleaner, do not allow steam to directly contact the alternator.

12-15

ELECTRICAL SYSTEM

(2) Inspection of adjustment voltage (unit with integrated IC regulator) (a) Disconnect the cable from the positive (+) terminal of the battery, and connect an ammeter between the terminal and cable. (b) Connect a voltmeter between terminal L and ground. (c) Make sure that the voltmeter indicates “0” when the starter switch is turned off.

Make sure that the voltmeter indicates a voltage level sufficiently lower than the battery voltage when the starter switch is turned on (without starting the engine).

Clamp ammeter

Ammeter

A

Switch

L

Battery

R

V Voltmeter

12V

Inspection of adjustment voltage and wiring diagram for output test unit with integrated IC regulator

(d) Short-circuit the terminal of the ammeter, and start the engine. (e) Read the indication (adjustment voltage) on the voltmeter with the ammeter indicating 5 A or lower, the engine operating at 1800 to 2500 min-1, and the lamp switches turned off.

(3) Inspection of output (unit with integrated IC regulator) (a) Disconnect the grounding cable from the battery.

Adjustment voltage at 20°C (68°F) Model

Standard Value

V-A

A7T02077C

14.7±0.3V

12-50

A2TN0878

14.7±0.3V

12-50

A2TA7877

14.7±0.3V

12-25

(b) Disconnect the wire from terminal B of the alternator, and connect an ammeter. Connect a voltmeter between terminal B and ground. (c) Connect the grounding cable to the battery. (d) Start the engine. (e) Immediately after the engine starts, turn on all load devices such as lamps. (f) Increase the engine speed. When the voltmeter indicates 13.5 V, read the maximum current at the specified alternator rotation speed.

If the measured value conforms to the standard value, the alternator is normal.

Output characteristics (when warm) Standard value Terminal voltage/ Rotation Model current Speed A7T02077C A2TN0878 A2TA7877

12-16

-1

13.5V/33A or higher

2500 min

13.5V/47A or higher

5000 min

13.5V/48A or higher

5000 min

13.5V/16A or higher

2500 min

13.5V/21A or higher

5000 min

-1 -1

-1 -1

ELECTRICAL SYSTEM

2.2 Disassembly A7T02077C (12V-50A) 5 Check slip rings for cleanliness, damage, and seizure. Check for coil resistance.

4 3 Check for rotation.

10 2

Check for rotation.

1

Check for sliding condition and wear of brush.

7 9

Check for short or open circuit.

8

6

Check coil for disconnection or grounding.

Disassembly sequence 1 2 3 4

Nut Pulley, Spacer Screw Front bracket assembly

5 6 7 8

Rotor assembly Stator Rear bracket Regulator assembly

12-17

9 10

Rectifier assembly Nut set

ELECTRICAL SYSTEM

A2TN0878 (12V-50A) 10

Check for rotation.

Check slip rings for cleanliness, damage and seizure. Check for coil resistance.

9

16

8

7

Check for rotation.

6 Check for sliding condition and wear of brush.

13 15

Check for short or open circuit.

14

11

3

Check for coil for disconnection or grounding.

12

2

1

4 5

Disassembly sequence 1 2 3 4 5

Connector set Housing assembly Valve set Rotor, vane Bracket

6 7 8 9 10

Nut Pulley, Spacer Screw Front bracket assembly Rotor assembly

12-18

11 12 13 14 15 16

Seal set Stator Rear bracket Regulator assembly Rectifier assembly Nut set

ELECTRICAL SYSTEM

A2TA7877 (12V-25A)

Check slip rings for cleanliness, damage and seizure. Check for coil resistance.

5 Check for rotation.

4 3

10

2 Check for rotation.

1 Check for sliding condition and wear of brush.

7 Check for short or open circuit.

9

8 6

Check coil for disconnection or grounding.

Disassembly sequence 1 2 3 4 5

Nut Pulley, Spacer Screw Front bracket assembly Rotor assembly

6 7 8 9 10

Stator Rear bracket Regulator assembly Rectifier assembly Nut set

12-19

ELECTRICAL SYSTEM Key points in disassembly

(1) Separation of front bracket from stator core (a) Insert the tip of a slotted screwdriver into the gap between the stator core and front bracket, and pry open.

CAUTION Never insert the screwdriver too deep into the assembly as it can damage to the stator core.

Disassembly of alternator

(2) Removal of pulley (a) Wrap the rotor with a cloth for protection, and hold it with a vice. Unscrew the pulley nut, then remove the pulley and spacer. (b) Remove the rotor from the front bracket.

Removal of pulley

(3) Removal of stator core and rectifier (a) Disconnect the lead wires from the stator core to the rectifier at the soldered sections. Then, remove the stator core.

Soldered sections

Rectifier

CAUTION Melt the soldered sections as quickly as possible. If heat is applied too long, the diode can be damaged. (b) Unscrew the rectifier mounting screws, and dismount the rectifier.

12-20

Soldered section

Removal of stator core

ELECTRICAL SYSTEM

2.3 Inspection Key points in inspection Trio diodes

(1) Inspecting rectifier

Heat sink (-)

For inspection of individual diode, check the resistance between each diode lead and heat sink. Take resistance measurements by connecting the positive (+) wire of a tester to the diode and also by connecting the negative (-) wire to the diode. If the resistance shows “infinite” in both measurements, there is an open circuit. If the resistance is close to 0 in both measurements, there is a short circuit.

If there is an open or short circuit, the diode is faulty and the rectifier must be replaced.

Heat sink (+)

Diode lead

Inspecting diode

(2) Inspecting field coil (a) Check the resistance between slip rings and if the measurement does satisfy the standard value, replace with a new rotor.

Resistance between slip rings Model

Standard Value

A7T02077C (12V-50A)

12.4 ohm

A2TN0878 (12V-50A)

9.0 to 10.4 ohm

A2TA7877 (12V-25A)

14 to 16 ohm

Field coil continuity

(b) Check the continuity between the slip ring and shaft (or core).

If there is electric conduction, the field coil is grounded: replace the rotor with new one.

Field coil grounding test

12-21

ELECTRICAL SYSTEM

(3) Inspecting stator core (a) Check the continuity between the stator core and each lead wire.

If there is no electric conduction, there is an open circuit: replace the stator core with new one.

Stator core continuity test

(b) Check to make sure that there is no continuity between the lead wires and core.

If there is continuity, the circuit is grounded: replace the stator with new one.

Stator core grounding test

(4) Inspecting brushes (a) If the brushes are worn close to the wear limit line (service limit), replace the brushes.

Unit: mm (in.)

Brush length Assembly Standard

Service Limit

A7T02077C (12V-50A)

18.5 (0.728)

5.0 (0.197)

A2TN0878 (12V-50A)

21.5 (0.846)

8.0 (0.315)

A2TA7877 (12V-25A)

20.0 (0.787)

5.0 (0.197)

Model

18.5mm (A7T02077C,12V-50A) 20.0mm (A2TA7877,12V-25A) 21.5mm (A2TN0878,12V-50A)

5.0mm(A7T02077C, A2TA7877) 8.0mm(A2TN0878) Wear limit line

Inspecting brush

Soldered sections

(b) Disconnect the brush lead wires at the soldered sections to remove the brushes and springs.

Replacement of brushes

12-22

ELECTRICAL SYSTEM

(c) To install new brushes, press them into the brush holders as shown in the illustration, then solder the lead wires.

Replacement of brushes

2.4 Reassembly To reassemble, follow the disassembly sequence in reverse.

Be sure to observe the following during assembly.

Key points in reassembly

Wire

(1) When press-fitting the rear bearing into the rear bracket, heat the rear bracket to 50 to 60°C (122 to 140°F).

(2) The brushes must be raised before the rotor is installed to the rear bracket. To do so, put a wire through the small hole located on the rear bracket, then remove the wire after completing the reassembly.

Rear bracket Brush

Wire

Reassembly of alternator

2.5 Installation (1) Install the fan belt on the alternator, and mount the alternator on the engine.

Temporarily tighten all the bolts.

(2) Insert a bar between the alternator and crankcase.

Using the bar as leverage, move the alternator and adjust the belt tension.

While keeping the alternator at that position, tighten the bolt that secures the alternator to the adjusting plate.

Installation of alternator

12-23

ELECTRICAL SYSTEM

(3) Check the belt tension. If the belt tension does not conform to the standard value, loosen the belt and repeat the above step (2).

Unit: mm (in.)

Item Belt tension (crankshaft pulley – alternator pulley)

Standard Value 10 to 12 (0.39 to 0.47) (when pressed with force of 98 N (10 kgf) [22 lbf])

(4) When the belt tension is properly adjusted, tighten all the bolts that secure the alternator in place.

Bolt

Adjusting plate

98N f) [22 lbf] g (10 k 2 mm 10 to 1 to 0 .3 (0 .)

0.47 in

Alternator pulley Bolt

Inspection of belt tension

3. Glow Plugs 3.1 Inspection As shown in the illustration, check the conductivity between the terminal and body. If there is no conductivity or if the resistance is high, replace the glow plug.

Item Resistance

Assembly Standard 0.2 ohm

Inspecting glow plug

3.2 Installation (1) Install the glow plug in the cylinder head by tightening to the specified torque.

Tightening torque

15.0 to 20.0 N·m (1.5 to 2.0 kgf·m) [11.1 to 14.8 lbf·ft]

(2) Install the connection plate to the glow plug, and tighten the retaining nut to the specified torque.

Tightening torque

1.0 to 1.5 N·m (0.10 to 0.15 kgf·m) [0.74 to 1.1 lbf·ft]

12-24

Water pump pulley

Crankshaft pulley

ELECTRICAL SYSTEM

4. Stop Solenoid (In-line type injection pump) 4.1 Inspection Turn on electricity to the stop solenoid and make sure the stop lever is at stop position.

Turn off electricity and make sure the stop lever returns the run position.

Operating voltage

8 to 14 V

Operating temperature

-30 to 90°C

Rated time

10 seconds or below

Rated current

22.6 A or below

12-25

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1. Adjustments .......................................................................................13 – 1 1.1 Valve Clearance .............................................................................13 – 1 1.2 Draining Water from Fuel Filter (Distributor type fuel injection pump) ...............................................13 – 2 1.3 Fuel Injection Timing Adjustment (In-line type fuel injection pump)..13 – 3 1.4 Fuel Injection Timing Correction ......................................................13 – 4 1.5 V-belt Inspection and Adjustment ....................................................13 – 4 1.6 Governor Adjustment (Distributor type fuel injection pump) .............13 – 5 1.7 Governor Adjustment (In-line type fuel injection pump) ...................13 – 6

2. Bench Test ...........................................................................................13 – 11 2.1 Starting Up ......................................................................................13 – 11 2.2 Inspection after Starting Up .............................................................13 – 11 2.3 Bench Testing (Dynamometer) Conditions ......................................13 – 11 2.4 Inspection and Adjustment after Bench Testing ...............................13 – 11

3. Performance Tests ............................................................................13 – 12 3.1 Engine Equipment Condition ...........................................................13 – 12 3.2 Tests and Their Purposes ................................................................13 – 12 3.3 Other Inspections ............................................................................13 – 12 3.4 Engine Output Adjustment...............................................................13 – 12

13

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.

Adjustments

1.1 Valve Clearance Valve clearance should be inspected and adjusted when the engine is cold.

Unit: mm (in.)

Item Valve clearance (cold setting)

Assembly Standard Inlet Exhaust

0.25 (0.0098)

(1) Inspection (a) Inspect the valve clearance in the injection sequence. To check, turn the crankshaft by the specified crank angle in the normal direction to bring the piston to the top dead center of the compression stroke.

Crank angle

1–3–4–2

180°

Injection sequence

Checking top dead center (1)

(b) Put socket (58309-73100) and ratchet handle on the crankshaft pulley nut and turn the crankshaft in the normal direction (clockwise as seen from the front end).

Unit: mm (in.)

Width across flats of crankshaft pulley nut

46 (1.81)

Checking top dead center (2)

(c) The top dead center on compression stroke of No. 1 piston is identified by the timing mark “0” (on the crankshaft pulley) being aligned with the pointer on the gear case. With the piston at top, both the inlet and exhaust valve rocker arms are not being pushed up by their pushrods.

(d) Insert a feeler gauge between the rocker arm and valve cap, and check the clearance.

13-1

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(2) Adjusting

Rock nut

0.25 mm (0.0098 in.)

Adjusting screw

(a) Loosen the lock nut of the adjusting screw. Adjust the clearance by turning the screw in either direction to the extent that the gauge is slightly gripped between the rocker arm and valve cap. (b) After adjusting the clearance, tighten the lock nut.

Inspect the clearance again and make sure that it is correct.

Adjusting valve clearance

1.2 Draining Water from Fuel Filter (Distributor type fuel injection pump) When water accumulates in the bottom of fuel filter more than specified level, water is likely to get mixed into the fuel system.

Drain water as follows: (a) Loosen the drain plug at the bottom of fuel filter.

Drain plug

Draining water from fuel filter(1)

(b) For quick draining, push the hand pump several times (about 7 times) to fuel. (c) Tighten the drain plug after draining. (d) Make sure to bleed air from fuel system after draining.

Hand pump

CAUTION When draining water, fuel also comes out. Be sure to clean up adhesion of oil from the fuel filter.

13-2

Draining water from fuel filter(2)

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.3 Fuel Injection Timing Adjustment (In-line type fuel injection pump) The injection timing varies depending on the output, speed and specifications of the engine. Be sure to verify the timing by referring to the specifications.

(1) Bringing the No. 1 cylinder piston to the top dead center on compression stroke. (a) Put socket (58309-73100) on the crankshaft pulley nut and turn the crankshaft in the normal direction (clockwise viewing from the front end).

Finding top dead center on compression stoke

(b) Stop turning the crankshaft when the mark “0” on the crankshaft pulley is aligned with the pointer of timing gear case. (c) Move the rocker arms of inlet/exhaust valves for No. 1 cylinder up and down to make sure both rockers are not being pushed by the pushrods (the inlet and exhaust valves have some clearance).

(2) Checking injection timing (a) Remove delivery valve holder from No. 1 cylinder of injection pump. Remove delivery valve, spring and stopper from the holder and reinstall the holder alone to the pump. (b) Connect a injection pipe to No. 1 plunger with its free end held downward so that the fuel flow can be observed. (c) Turn the crankshaft to bring No.1 piston to 60 degrees position before the top dead center of compression stoke. (d) While operating the priming pump to allow the fuel to flow from the injection pipe, slowly turn the crankshaft in the normal direction.

Delivery valve holder Spring Delivery valve

Checking injection timing -1 (Removing delivery valve)

(e) When the fuel from injection pipe is less and less, just about stopping, turn the engine more slowly and stop turning when the flow of fuel is stopped completely. (f) Make sure the timing mark on the crankshaft pulley is aligned with the pointer.

Checking injection timing -2

13-3

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.4 Fuel Injection Timing Correction If the injection timing is retarded, move the injection pump toward the crankcase. If the timing is advanced, move the pump away from the crankcase.

To advance injection timing To retard injection timing

Adjusting injection timing

1.5 V-belt Inspection and Adjustment Push the belt inward with thumb pressure exerted midway between the pulleys, as shown, to check the belt tension (deflection). If the tension is incorrect, loosen the adjusting bracket bolt and mounting bolt, and move the alternator in or out.

Unit: mm (in.)

Item V-belt deflection

Bolt

Adjusting plate

] 98N f) [22 lbf g (10 k

12 mm 10 to .47 in.)

0 (0.39 to

Alternator pulley Crankshaft pulley

Bolt

Assembly Standard 10 to 12 (0.39 to 0.47)

Checking V-belt

13-4

Water pump pulley

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.6 Governor Adjustment (Distributor Type Fuel Injection Pump) Idling Speed and Maximum Speed Setting Inspection and Adjustment

CAUTION (1) The idling speed (no-load) and maximum speed are set for each engine at factory bench testing, then the set bolts are sealed.

These settings are to be inspected and adjusted at Cat lift truck service shops only.

(2) After adjusting the governor be sure to seal the stopper.

(3) The stoppers are to be sealed. It is very important to set and to seal the injection pump correctly in order to validate the warranty.

(4) When inspecting and adjusting these settings, be ready to operate the engine stop lever manually against the engine overrunning.

NOTE Prior to inspection and adjustment, warm up the engine until coolant and oil temperature rise to 70°C (158°F) or higher (operating temperature).

(1) Starting the engine (a) Pull the speed control lever toward the HIGH SPEED side, and operate the starter switch.

Idle adjusting screw

Maximum speed adjusting screw

(b) The engine ignites when the rotation speed reaches approximately 150 rpms. When the engine speed starts to increase, operate the speed control lever and maintain the engine speed between 800 and 1000 rpms. (c) After the engine speed stabilizes, return the speed control lever to the low idling position.

(2) Low idling setting (no-load minimum rotation speed setting) (a) Set the speed control lever at the position of noload minimum rotation speed, then secure the lever in that position using the idling adjust screw.

13-5

Control lever

Starting the engine

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

CAUTION If there is a speed range which causes dangerous torsional vibration, avoid setting the engine speed in that range.

(3) Governor setting (maximum rotation speed setting) (a) Keep the speed control lever at the position of the specified maximum rotation speed. (b) With the speed control lever held in that position, adjust and set the maximum speed adjusting screw (maximum rotation speed set screw) to the specified rotation speed.

1.7 Governor Adjustment (In-line Type Fuel Injection Pump) Idling Speed and Maximum Speed Setting Inspection and Adjustment

CAUTION (1) The idling speed (no-load) and maximum speed are set for each engine at factory bench testing, then the set bolts are sealed.

These settings are to be inspected and adjusted at Cat lift truck service shops only.

(2) After adjusting the governor be sure to seal the stopper.

(3) The stoppers are to be sealed. It is very important to set and to seal the injection pump correctly in order to validate the warranty.

(4) When inspecting and adjusting these settings, be ready to operate the engine stop lever manually against the engine overrunning.

NOTE Prior to inspection and adjustment, warm up the engine until coolant and oil temperature rise to 70°C (158°F) or higher (operating temperature).

13-6

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(1) Starting the engine (a) Pull the speed control lever toward the HIGH SPEED side, and operate the starter switch. (b) The engine ignites when the rotation speed reaches approximately 150 rpms. When the engine speed starts to increase, operate the speed control lever and maintain the engine speed between 800 and 1000 rpms.

Speed control lever Governor set bolt

Low idle set bolt Idle sub-spring adjusting screw

(c) After the engine speed stabilizes, return the speed control lever to the low idling position.

(2) Low idling setting (no-load minimum rotation speed setting)

Starting the engine

(a) Set the speed control lever at the position of noload minimum rotation speed, then secure the lever in that position using the idling adjust screw.

Low idle set bolt

CAUTION If there is a speed range which causes dangerous torsional vibration, avoid setting the engine speed in that range. (b) The engine speed will increase when the low idle speed set screw is turned clockwise. (c) If the engine speed tends to fluctuate, turn idle sub-spring adjusting screw clockwise to bring this spring into slight contact with the tension lever to stabilize the engine.

Setting no-load minimum (idle) speed

Idle sub-spring adjusting screw

CAUTION Do not tighten the idle sub-spring adjusting screw clockwise excessively as it could cause the engine to overrun to during noload operation.

Setting idle sub-spring adjusting screw

13-7

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(3) Setting rack (maximum output) (a) Set the torque spring free. Hold the speed control lever at the position for the specified output and speed. (b) Under this condition, check to be sure that the engine is running in a steady state. (c) Keeping the engine steady, adjust the full-load stopper bolt as below. (d) By tightening or loosening the full-load stopper bolt, find out the position where the engine delivers the rated output .

Setting rack (maximum output)

(e) After adjusting stopper bolt for rated output, back it off slowly while observing the speed. Stop backing off the stopper bolt just when the engine speed begins to decrease from the rated speed and secure it in that position with its lock nut. (f) At this time, the speed control lever should be in the maximum speed position. (g) Turning the full-load stopper bolt clockwise will increase the injection quantity (engine output), and vice versa.

(4) Setting governor (maximum speed) (a) Apply full load to the engine and hold the speed control lever at the position for the specified maximum speed. (b) Set governor set bolt (maximum speed set bolt) at the position for the specified speed.

Governor set bolt

Setting governor (maximum speed)

(5) Setting torque spring (a) Set the speed control lever at maximum speed and apply load. (b) Turn the torque spring adjusting screw to gain the rated output by rated speed. After the adjustment, secure the spring screw with lock nut and then put the cap on it.

Torque spring adjusting screw

Setting torque spring

13-8

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(6) Measuring speed variation Speed variation upon removing load

Speed variation upon removing load

N2

(a) Run the engine with the speed control lever set at the position for the rated load and speed.

N3 N1

(b) Under this condition, remove the load in a moment to bring the engine into no-load condition. Keep the speed control lever at the position set above (a). (c) The engine speed will increase instantaneously and then decrease and settle at a new steady speed as shown. Read the highest speed (N2) occurring in this transition and the speed (N3) after settlement, and the time (t1) from the moment of removing the load at the initial speed (N1) to the settling at the new level (N3).

t1

Instantaneous speed variation (%)

Steady-state speed variation (%) N3 - N1 x 100 N1

N2 - N1 x 100 N1

N1 = Initial speed, min-1, before load is removed.

N2= Highest speed, min-1, during transitional period.

Speed variation upon applying load With the engine running under no-load condition and with the speed control lever held in the same position as described above (b), apply the specified load in a moment to the engine: the engine speed will decrease instantaneusly and then increase, as shown, and settle at a new steady speed. Read the lowest speed (N5) occurring in this transition and the speed (N6) after settling, and the time (T2) from N4 to N6.

N3= Speed, min-1, at which the engine settles after load is removed. t1 = Recovery time.

Speed variation upon applying load t2 N4

Calculating the speed variation

N6

From the values obtained above, calculate the speed variation for each load change.

If the calculated values do not meet the specified values, adjust the governor notch.

N5

Instantaneous speed variation (%) N4 _ N5

x 100

N4

Steady-state speed variation (%) N4 _ N6

x 100

N4

N4 = Initial speed, min-1, before load is applied.

N5= Lowest speed, min-1, during transitional period.

N6= Speed, min-1, at which the engine settles after load is applied. t2 = Recovery time.

13-9

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(7) Setting no-load maximum speed (Governor notch adjustment) (a) This adjustment is to be made to increase or decrease the preload of the governor spring by turning the adjusting screw of the swivel lever . (b) To gain access to the adjusting screw, remove the plug at the top of the governor housing. Turn the speed control lever all the way to the low idle position: this will turn up the swivel lever , pointing the head of the adjusting screw toward the plug hole. Insert a flat-tip screwdriver through the hole to catch the screw head. (c) Tightening the adjusting screw will increase the preload of the governor spring to narrow the speed variation; loosening it will decrease the preload to widen the variation. One notch corresponds to 1/4 turn of the adjusting screw and to 3 to 5 speed change of the engine speed. (d) Changing the setting of this adjusting screw changes the governor setting (for limiting the maximum speed). After making a governor notch adjustment, be sure to readjust the governor setting as described above (4). (e) Tightening the adjusting screw will increase the maximum speed, and vice versa.

CAUTION Never loosen the adjusting screw by more than 20 notches (5 turns) from the fully tightened position as it can be hazardous for the control action of the governor.

(8) Sealing Seal the set bolts.

13-10

Adjusting speed variation

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

2.

Bench Test

2.3 Bench Testing (Dynamometer) Conditions

An overhauled engine should be tested for performance on a dynamometer. This test is also for breaking in the major running parts of the engine, follow the procedures described below:

Here is a summary table of bench testing conditions.

2.1 Starting Up

Step

Speed (rpm)

Load (PS)

Time (min.)

1

1000

No-load

30

2

1500

25%

30

25%

10

50%

10

75%

30

100%

20

3 (1) Inspect the levels in the radiator, oil pan and fuel tank. Prime the fuel and cooling systems to bleed air out.

(2) Crank the engine with the starter for 15 seconds to permit lubricating oil to circulate through the engine. For this cranking, do not supply fuel to the engine.

(3) Move the speed control lever slightly in the direction of increasing the injection, and turn the starter switch to START to start the engine. Do not move the control lever to the “full fuel injection” position.

(4) After the engine starts, let it idle under no load by operating the speed control lever.

4 5 6

Rated speed (2300)

2.4 Inspection and Adjustment after Bench Testing (1) Checking external bolts and nuts for looseness and retightening (2) Adjusting valve clearance (3) Checking and adjusting injection timing

2.2 Inspection after Starting Up After starting up the engine, check the following points.

If you find anything wrong, immediately stop the engine, then investigate for the cause.

(1) Lubricating oil pressure should be 0.29 to 0.49 MPa (3 to 5 kgf/cm2) [29 to 58 psi] at 1500 min–1 or over 0.1 MPa (1 kgf/cm2) [15 psi] at 750 min–1.

(2) Coolant temperature should be 75 to 85°C (167 to 185°F).

(3) Lube oil temperature should be 70 to 90°C (158 to 194°F).

(4) Check for leakage of oil, coolant, fuel.

(5) Knocking should die away as the coolant temperature increases. No other defective noise should be heard.

(6) Check for exhaust color and abnormal odors.

13-11

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

3.

Performance Tests

3.4 Engine Output Adjustment

There are various performance test procedures, and the procedures for “Earth moving machinery Engines, Part 1: Test code of net power (JIS D 0006-1)” and “Earth moving machinery Engines, Part 2: standard format of specifications and tests methods of diesel engines (JIS D 0006-2)” are described. Other test items may be required per application. Engine performance is judged with integrated test results.

Diesel engine output is affected by atmospheric pressure, temperature, and humidity. Therefore, correction calculations must be performed to obtain the value of engine output under the standard atmospheric conditions.

(1) Standard atmospheric conditions: Base temperature: 298 K (25 °C) [77 °F] Atmospheric pressure: 100 kPa (750 mmHg) Dry atmospheric pressure: 99 kPa (743 mmHg)

3.1 Engine Equipment Condition

(2) Calculation of corrected power:

Engine must be equipped with such standard auxiliaries as cooling fan, air cleaner and alternator.

Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value.

Corrected output=Correction factor (αc) × Measured brake power

3.2 Tests and Their Purposes

• Atmospheric conditions during test (1) Operation load test

Temperature(T): 283 K (10°C) [50°F]%T%313 K (40 °C) [104 °F]

Conduct this test to evaluate engine output, torque, fuel consumption rate and governor performance under various load conditions.

Dry atmospheric pressure(P): 80 kPa (600 mmHg)%P%110 kPa (825 mmHg)

(3) Calculation of correction factor (αc):

(2) Continuous load test Operate the engine continuously for 10 hours at 90% load (continuous load application) of nominal net brake power while engine speed is maintained at revolutions corresponding to the nominal brake power. In this test, evaluate fuel consumption rate and operating condition and confirm continuous engine operation.

(3) No-load minimum idle speed test Conduct this test to confirm that the engine can operate stably at the specified no-load minimum idle speeds.

αc = (fa)fm fa: Atmospheric factor fm: Engine factor (a) Calculation of atmospheric factor (fa) 1) Natural aspiration engine and engine with mechanically driven air charger 99 T 0.7 )•( ) Pd 298 2) Turbocharged engine without air cooler or with air-to-air cooler fa = (

3.3 Other Inspections

99 0.7 T 1.2 ) •( ) Pd 298 3) Turbocharged engine with air-to-liquid cooler

During performance testing, inspect for leakage of gases, coolant, lubricating oil, or fuel, and for noise or hunting. Make adjustment as needed.

99 0.7 T 0.7 ) •( ) Pd 298 (b) Calculation of engine factor (fm)

fa = (

fa = (

fm = 0.036 qc − 1.14 qc: Corrected fuel supply volume

13-12

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1) qc =

q r

(z) × (Fuel flow rate g/s) q = (Stroke volume liter) × (Engine speed min-1) z = 120000 (4-cycle engine) r: Ratio between pressure at turbocharger or air cooler outlet and atmospheric pressure (r = 1 for natural aspiration engine)

2) Applicable range of engine factor (fm) 37.2 % qc % 65 mg/(liter-cycle)

[

• qc % 37.2 mg/(liter-cycle): fm = 0.2 (constant) • 65 mg/(liter-cycle) % qc: fm = 1.2 (constant)

]

(c) Range of correction equation use The range of correction factor ( α c ) is as follows: 0.9 % αc % 1.1 If this range is exceeded, indicate the corrected valued and record the test conditions on the test record.

13-13

TROUBLESHOOTING Causes of Engine Problems and Remedies .................................... 14 – 1

14

TROUBLESHOOTING

Causes of Engine Problems and Remedies

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Fuel System

Insufficient fuel injection volume Excessive fuel injection volume

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—

Injection nozzle defective

— —

Excessive fuel return from injection nozzles

—

Injection timing is too advanced

— —

Lubrication System

White

Black

Engine produces loud knocking sound

Engine produces abnormal noise

Engine produces irregular combustion sound

Large amount of black exhaust smoke

At idling

Large amount of white exhaust smoke

Glow plugs produce red heat too fast

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Cranking speed low

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Injection timing is too retarded

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Engine speed is too low

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Failure to stop

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Improper fuel

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Fuel viscosity is too high

Air Intake System

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In operation

Injection pump oil seals defective

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Engine hunts

At idling

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Engine cannot be cranked manually

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Exhaust smoke abnormal In operation

Engine can be cranked manually

Greater variance of fuel injection quantity

Large amount of exhaust smoke

Small amount of exhaust smoke

No exhaust smoke

No fuel to injection pump

Glow plugs do not produce red heat

Engine does not turn

Engine turns

Possible causes

Not enough power

Hard starting

Small amount of exhaust smoke

Problems/Symptoms

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Improper oil quality

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Oil viscosity is too high

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Oil viscosity is too low

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Oil pressure does not rise

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Oil leaks

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Excessive pumping up of oil

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Clogged oil filter

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Oil pressure switch or lamp defective

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Insufficient intake air

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Insufficient compression pressure

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Ambient temperature is too high, or ambient pressure is too low (high altitude)

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14-1

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TROUBLESHOOTING

( Refer to the separate troubleshooting chart.)

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Engine does not pick up speeds

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Poor response for deceleration

Indicator lights when engine operates at high speed

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Indicator does not light when engine is not operating

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Low

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Overheating

— — — —

Indicator lights when engine operates at high speed

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Indicator lights when engine operates at low speed

— — —

—

Indicator does not light when engine is not operating

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Excessive blowby

— — — —

Water mixes with oil

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Fuel mixes with oil

—

Oil consumption is high

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Abnormal Alternator coolant temperature defective

Fuel consumption is high

Engine rotates in reverse direction —

Engine stalls

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Engine vibrates excessively

Engine operates at high speeds and does not stop

Abnormality in lubrication system

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Remedies

Disassemble, replace if necessary.

Replace nozzle tip(s).

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Use fuel designed for cold areas.

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Use high quality oil.

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Use oil of proper viscosity.

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Use oil of proper viscosity.

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Replace filter element and oil.

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Replace filter element and oil.

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14-2

Tighten bolts and nuts. Replace packing(s) if necessary.

(Adjust full-load setting of governor.)

TROUBLESHOOTING

Black

Engine produces abnormal noise

Engine produces irregular combustion sound

At idling

In operation

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Starter magnetic switch defective

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Starter defective

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Starter free wheel defective

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Flywheel ring gear and pinion defective

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Battery voltage is too low

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Open circuit in glow plug or pilot lamp

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Short circuit in glow plug

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Alternator malfunction

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Relay defective

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Wiring defective

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Seizing of moving parts

— — —

Worn cylinder(s), piston(s) or piston ring(s)

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Worn piston ring(s)

— —

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Excessive oil clearance

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Loose connecting rod cap bolts

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Interference between valve(s) and — piston(s)

—

Excessive cooling by radiator

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Insufficient coolant

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Insufficient cooling by radiator

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Water leakage from cylinder head gasket

—

Cracks in crankcase water jacket Starter switch defective

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At idling

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— —

Cranking speed low

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Large amount of exhaust smoke

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Small amount of exhaust smoke

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No exhaust smoke

Large amount of black exhaust smoke

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Large amount of white exhaust smoke

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Small amount of exhaust smoke

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Glow plugs produce red heat too fast

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Glow plugs do not produce red heat

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Engine cannot be cranked manually

—

Engine can be cranked manually

Cooling System

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—

Engine is too cold

Engine hunts

—

—

Possible causes

Electrical System

Exhaust smoke abnormal In operation

White

Engine does not turn

Engine turns

Mechanical problems

Not enough power

Hard starting

—

—

Engine produces loud knocking sound

Problems/Symptoms

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Damaged valve spring(s)

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Excessive valve clearance

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Foreign particles in cylinder(s)

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Excessive gear backlash

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14-3

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TROUBLESHOOTING

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Indicator lights when engine operates at high speed

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Indicator does not light when engine is not operating

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Low

Indicator lights when engine operates at low speed

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Abnormal Alternator coolant temperature defective

Overheating

Indicator does not light when engine is not operating

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Indicator lights when engine operates at high speed

Excessive blowby

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Water mixes with oil

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Fuel mixes with oil

Engine rotates in reverse direction

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Oil consumption is high

Engine operates at high speeds and does not stop

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Fuel consumption is high

Engine does not pick up speeds

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Abnormality in lubrication system

Poor response for deceleration

Engine stalls

Engine vibrates excessively

( Refer to the separate troubleshooting chart.)

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Tighten, replace gasket if necessary.

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Disassemble and replace crankcase.

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Disassemble and repair.

Replace part(s) if necessary.

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Repair or replace.

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Repair or replace.

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Repair or replace starter if necessary.

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Repair or replace ring gear.

Replace pinion gear.

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Charge or replace battery.

Heat it if necessary.

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Replace part(s).

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Replace copper packing(s).

Replace glow plug(s), if necessary.

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Heat oil pan at starting. After starting warm up engine thoroughly.

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Remedies

Replace alternator if necessary.

Adjust or replace.

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Connect wires properly.

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Check and replace bearings with undersize ones if necessary.

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Tighten.

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Reinstall timing gears or adjust valve sinkage.

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Replace part(s).

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Adjust valve clearance to 0.25 mm (0.0098 in.)

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Repair.

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Replace gear(s) or idler gear bushing.

14-4

TROUBLESHOOTING Causes Fuel is not supplied to injection pump properly

Irregular injection pump operation

Insufficient fuel injection volume (by injection pump)

Excessive fuel injection volume

Fuel injection nozzle(s) defective

Fuel injection timing is too advanced

Details of Causes

Remedies

Fuel tank supply valve is closed

Open the valve.

No fuel in tank

Add fuel.

Fuel lines restricted

Repair or clean fuel pipes with compressed air.

Air in fuel system

Tighten mounting sections or replace fuel pipes.

Fuel leakage

Retighten connections.

Fuel filter is clogged

Clean or replace filter element.

Inadequate air bleeding

Conduct air bleeding.

Sticking of plunger(s)

Disassemble and replace parts.

Worn plunger(s)

Disassemble and replace parts.

Worn bearing(s)

Disassemble and replace parts.

Damaged plunger spring(s)

Disassemble and replace parts.

Loose plunger pinion(s)

Reinstall by matching marks.

Delivery valve(s) defective

Replace parts.

Damaged delivery valve spring(s)

Replace parts.

Catching of governor stop lever link

Repair link properly and set lever to neutral position.

Control rack does not move

Supply lubricant, or disassemble and repair.

Seizing of plunger(s)

Disassemble and replace parts.

Worn plunger(s)

Disassemble and replace parts.

Worn bearing(s)

Disassemble and replace parts.

Loose plunger pinion(s)

Reinstall by matching marks.

Full-load setting of governor does not work

Readjust governor setting on bench.

Stop lever sticking in “increase” position

Repair link properly and set lever to neutral position.

Full-load setting of governor improper

Adjust governor setting on bench.

Loose plunger pinion(s)

Reinstall by matching marks.

Seizing of nozzle tip needle

Repair or replace.

Nozzle tip seat(s) defective

Repair or replace.

Damaged nozzle spring(s)

Replace parts.

Fuel injection pressure is too low

Change adjusting shim and set standard injection start pressure using nozzle tester.

Carbon deposits on packing at nozzle tip(s)

Remove carbon deposits.

Faulty mounting angle of injection pump

Match stamped lines on injection pump and flange correctly.

Timing gears incorrectly installed

Correct timing gear engagement.

14-5

TROUBLESHOOTING Causes Fuel injection timing is too retarded

Improper fuel

Low oil pressure

Pumping up of oil

Insufficient intake air

Insufficient compression pressure

Insufficient coolant

Details of Causes

Remedies

Faulty mounting angle of injection pump

Match stamped lines on injection pump and flange correctly.

Timing gears incorrectly installed

Correct timing gear engagement.

Worn fuel injection pump bearing

Replace parts.

Poor fuel quality

Drain fuel, and add high-quality fuel.

Water is mixed with fuel

Drain fuel, and add high-quality fuel.

Insufficient amount of oil in oil pan

Add oil to specified level.

Air in oil strainer

Correct damaged pipe and loose flange by replacing parts and tightening.

Oil pump defective

Disassemble and repair.

Oil lines restricted

Disassemble and clean.

Relief valve defective

Disassemble and inspect for damaged spring, foreign particles on valve, and other abnormalities.

Clogged oil filter

Replace filter element and oil.

Leak in oil lines

Disassemble and repair.

Too much oil in oil pan

Drain oil to specified level.

Worn cylinder(s), piston(s) or piston ring(s)

Disassemble and repair. Replace parts.

Seizing of piston ring(s)

Disassemble and repair. Replace parts.

Worn valve guide(s)

Disassemble and repair. Replace parts.

Engine operated too long under no load

Disassemble and repair if engine continues to produce smoke for a while or if large amount of oil is discharged from exhaust pipe.

Clogged air cleaner

Clean or replace filter element.

Clogged intake manifold

Inspect and clean.

Valve seat(s) defective

Disassemble and correct.

Seizing of valve stem(s)

Disassemble and correct.

Valve is pressed down by rocker

Adjust valve clearance to 0.25 mm (0.0098 in.).

Worn cylinder(s), piston(s) or piston ring(s)

Disassemble and repair. Replace parts.

Seizing of piston ring(s)

Disassemble and repair. Replace parts.

Gas leakage from cylinder head gasket

Tighten. Replace gasket if necessary.

Damaged valve spring(s)

Disassemble and replace parts.

Insufficient starter speed (at startup)

Disassemble and replace parts.

Insufficient amount of coolant.

Add coolant to specified level.

Overheating

Add coolant to specified level.

Water leakage from unit seal of water pump

Disassemble and replace parts.

Cracks in crankcase water jacket

Disassemble and replace parts.

Water leakage from other part(s)

Disassemble and replace parts.

14-6

TROUBLESHOOTING Causes

Insufficient cooling by radiator

Excessive cooling by radiator

Seizing of moving parts

Details of Causes

Remedies

Inadequate air bleeding of cooling system Loosen air vent plug, drainage plug or hose clamp, and bleed air.

Rust or water scale accumulation inside radiator

Clean.

Dust accumulation on radiator

Clean.

Fan belt slipping

Adjust belt tension.

Thermostat defective (stuck closed)

Replace parts.

Ambient temperature is low Radiator is not covered

Cover radiator.

Thermostat defective (stuck open)

Replace parts.

Seizing of cylinder(s), piston(s) or piston ring(s)

Disassemble and repair. Replace parts.

Seizing of main or connecting rod bearing(s)

Disassemble and repair. Replace parts.

Seizing of idler gear bushing

Disassemble and repair. Replace parts.

14-7