Caterpillar S6S Diesel Engine Lift Trucks Service Manual - PDF DOWNLOAD

Service Manual S6S Diesel Engine

For use with DP40N/NF - DP55N/NF Chassis Service Manuals.

99739-32110

INTRODUCTION This service manual describes the maintenance and adjustment procedures, and specifications for Mitsubishi diesel engines.

To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and it may also be necessary to take measures which involve disassembly, inspection, repair and assembly of the engine and engine parts.

Read through this manual carefully and understand the work procedures fully before disassembling, inspecting, repairing or assembling the engine.

The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may differ partially from the one described in this manual.

I

INTRODUCTION

How to use this manual This service manual consists of several chapters, which are arranged so as to allow you to make reference quickly to specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection, repair and assembly of the Mitsubishi Diesel Engine (standard model for land use).

A short summary describing the content of each chapter is given in the General Contents page, and there is also a detailed table of contents at the beginning of each chapter.

Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and function of the engine are described in the relevant training manuals.

Methods of presentation (1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indication of the sequence of disassembly.

(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.

(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They are also collectively indicated in Group 2, the General Contents group.

(4) Fasteners to be tightened in “wet” condition, or with engine oil applied, are identified by [Wet] placed after tightening torque values. If no such indication is suffixed, the fastener should be tightened in “dry” condition, or without lubricating with engine oil.

(5) In this manual, important safety or other cautionary instructions are emphasized with the following marks headed.

Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.

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

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

Indicates a potentially hazardous situation which, if not avoided, can result in property damage.

Note

II

Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.

INTRODUCTION

Terms used in this manual Nominal means the rated (design) size or magnitude of a part to be measured.

Standard means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of tolerance. Therefore, the values shown are not in agreement with the design values.

Limit means that, if this value is reached, the part must be repaired or replaced with a new part.

Abbreviations BTDC: Before Top Dead Center ATDC: After Top Dead Center BBDC: Before Bottom Dead Center ABDC: After Bottom Dead Center TIR: Total Indicated Runout 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.A.) MSDS: Material Safety Data Sheet SAE: Society of Automotive Engineers (U.S.A.) P/N: Part Number

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

III

INTRODUCTION

Safety Cautions Fire and explosion Keep flames away

Care for fuel, oil and exhaust gas leakage

Do not use flames near the engine

If any fuel, oil or exhaust gas leakage is found, imme-

and in the engine compartment. Fuel

diately take corrective measures to stop it. Such leak-

vapor or other gases can catch fire

ages, if left uncorrected, can cause fuel or engine oil to

and produce dangerous situations.

reach hot engine surfaces or hot exhaust gas to con-

Thoroughly, wipe off spilled fuel, oil

tact flammable materials, possibly leading to personal

and LLC immediately. Spilled fuel, oil and LLC may

injury and/or damage to equipment.

ignite and cause a fire. Store fuel and engine oil in a

Use explosion-proof lighting apparatus

well ventilated designated area. Make sure that the

When inspecting fuel, engine oil, coolant, battery elec-

fuel and engine oil container caps are tightly closed.

trolyte, etc., use a flameproof light. An ordinary lighting

Keep engine surrounding area tidy and

apparatus may ignite a gas and cause an explosion.

clean

Prevent electrical wires from short-circuit-

Do not leave combustible or explosive materials, such

ing

as fuel, engine oil and LLC, near the engine. Such

Avoid inspecting or servicing the electrical system with

substances can cause fire or explosion. In particular,

the ground cable connected to the battery. Otherwise,

clean the top surface of the battery thoroughly. Dust

a fire could result from short-circuiting. Be sure to dis-

can cause a short-circuit. Always operate the engine

connect the battery cable from the negative (-) termi-

at a position at least 1 m [3.28 ft.] away from buildings

nal before beginning with the work procedure. Short-

and other equipment to prevent possible fire caused

circuits, possibly resulting in fire, may be caused by a

by engine heat.

loose terminal or damaged cable/wire. Inspect the terminals, cables and wires, and repair or replace the faulty parts before beginning with the service procedure.

Keep fire extinguishers and first-aid kit handy Keep fire extinguishers handy, and become familiar with their usage.

Keep a first-aid kit at the designated place where it is easily accessible by anyone

at

any

time.

Establish

response procedures to follow in the event of fire or accident. Provide an emergency evacuation route, contact points, and means of communication in case of emergency.

IV

INTRODUCTION

Stay clear of all rotating and moving parts Install protective covers on rotating parts

Lockout and tagout

Make sure the protective covers of

Be sure to lockout and tagout before starting inspec-

the engine are correctly installed.

tion and maintenance. Lockout and tagout are effec-

Repair any damaged or loose covers.

tive methods of cutting off machines and equipment

Never remove the protective covers of

from energy sources. To accomplish the lockout/

rotating parts during operation. When

tagout, remove the starter switch key, set the battery

the engine is coupled to the radiator or other equip-

switch to OFF and attach a “Do Not Run” or similar

ment, install protective covers around the exposed

caution tag to the starter switch. The starter switch key

connecting belt and coupling.

must be kept by the person who performs inspection

Check work area for safety

and maintenance during the work.

Before starting the engine, make sure no one is near

Keep engine stopped during servicing

the engine and tools are not left on or near the engine.

Be sure to stop the engine before proceeding to

Verbally notify persons within the immediate area

inspection and service procedure. Never attempt to

when starting the engine. When the starter device is

make adjustments on the engine parts while the

posted with a sign that prohibits startup operation, do

engine is running. Rotating parts such as belt can

not operate the engine.

entangle your body and cause serious injuries.

Stay clear of moving parts during engine

Always restore engine turning tools after

running

use

Do not approach rotating or sliding

Be sure to remove all turning tools used during mainte-

parts of the engine when the engine is

nance and inspection work. Starting the engine with

in operation. Keep objects likely to be

the turning tools inserted or with the turning gear in

caught by rotating parts away from

engagement can lead to not only engine damage but

such parts. If any part of the clothing

also personal injuries.

or outfitting is caught by a rotating part, serious bodily injuries could result.

V

INTRODUCTION

Be careful of burns

Protect ears from noise

Do not touch the engine during or immedi-

Wear ear plugs

ately after operation

Always wear ear plugs when entering

To avoid burns, do not touch the

the machine room (engine room).

engine during or immediately after

Combustion sound and mechanical

operation. A hot engine can cause

noise generated by the engine can

burns. To conduct maintenance and

cause hearing problems.

inspection work, wait until the engine has cooled suffi-

Be careful of falling down

ciently by checking the temperature gauge.

Do not open the radiator filler cap when the

Lift engine carefully

engine is hot

To lift the engine, always use a cor-

Never open the radiator filler cap while the engine is running or immediately after the engine stops. Give a sufficient cooling time to the engine coolant before opening the cap. When opening the radiator filler cap, slowly turn the cap to release internal pressure. To prevent scalds with steam gushing out, wear thick rubber gloves or cover the cap with a cloth. Close the radiator cap tightly without fail. The coolant is very hot and under pressure during engine running or just after the engine stops. If the radiator cap is not closed tightly, scalding steam and hot coolant may gush out that can cause burns.

Add coolant only after the coolant temperature dropped Do not add coolant immediately after the engine stops.

Wait until the coolant temperature lowers sufficiently to avoid a risk of burns.

Be careful of exhaust fume poisoning

rect wire rope capable of withstanding the engine weight. Attach the wire rope to the lifting hangers provided on the engine using a correct sling. During lifting process, keep the engine in a well-balanced position by taking the center of gravity of the engine into consideration. Keep the angle formed by slings attached to hangers within 60°. If the angle exceeds this limit, excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident. If the wire rope contacts the engine directly, place a cloth or other soft padding to avoid damage to the engine and wire rope.

Do not climb onto the engine Do not climb onto the engine, nor step on any engine parts located on the lateral sides. To work on parts located on the upper section of engine, use a ladder, stool, etc., that is firmly secured. Climbing on the engine may not only damage engine parts but also cause falling down from the engine and result in per-

Operate engine in well-ventilated area If the engine is installed in an enclosed area, and the exhaust gas is ducted outside, ensure that there is no exhaust gas leak from duct joints.

Exhaust gas from the engine contains carbon monoxide and other harmful substances.

Operating the engine in an ill-ventilated area can produce gas poisoning.

VI

sonal injuries.

Always prepare stable scaffold When working on the upper part of the engine and other hard-to-reach places, use a stable work platform.

Standing on a decrepit stool or parts box may result in personal injury. Do not place any unnecessary objects on a work platform.

INTRODUCTION

Be careful of handling fuel, engine oil and LLC

Service battery Handle the battery correctly

Use only specified fuel, engine oil and longlife coolant (LLC) Use only the fuel, oil and LLC specified in this manual, and handle them carefully. Use of any other fuel, oil or LLC, or improper handling may cause various engine problems and malfunctions. Obtain the Material Safety Data Sheets (MSDS) issued by the fuel, oil and LLC suppliers, and follow the directions in the MSDSs for proper handling.

Handle LLC (long life coolant) carefully When handling LLC, always wear rubber gloves and a protective face mask. If LLC or cooling water containing LLC comes into contact with your skin or eyes, or if it is swallowed, you would suffer from inflammation, irritation or poisoning. Should LLC be accidentally swallowed, induce vomiting immediately and seek medical attention. Should LLC enter your eyes, flush them immediately with plenty of water and seek medi-

Never use flames or allow sparks to generate near the battery. The battery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity could cause an explosion. Do not use a battery with a fluid level below the lower limit line. Sustained use of the battery could result in an explosion. Do not short the battery terminals with a tool or other metal object. When disconnecting battery cables, always remove the cable from the negative (-) terminal first. When reconnecting the cables, attach the cable to the positive (+) terminal first. Charge the battery in a well-ventilated area, with all filling hole plugs removed. Make sure the cable clamps are securely installed on the battery terminals. A loose cable clamp can cause sparks that may result in an explosion.

cal attention. If LLC splashes onto your skin or cloth-

Before servicing electrical components or conducting

ing, wash it away immediately with plenty of water.

electric welding, set the battery switch to the [Open/

Keep flames away from LLC. The LLC can catch

OFF] position or disconnect the cable from the nega-

flames, causing a fire. Coolant containing LLC is a

tive (-) battery terminal to cut off the electrical cur-

hazardous material. Do not dispose of it in unauthor-

rent.

ized manner. Abide by the applicable law and regulations when discarding drained coolant.

Proper disposal of waste oil, LLC and coolant

Electrolyte (battery fluid) contains dilute sulfuric acid.

Careless handling of the battery can lead to the loss of sight and/or skin burns. Also, keep the battery fluid off the mouth. Wear protective goggles and rubber gloves when

Do not discharge waste engine oil, LLC and coolant

working with the battery (when adding water, charg-

into sewerage, river, lake or other similar places. Such

ing, etc.).

a way of disposal is strictly prohibited by laws and reg-

If electrolyte is spilled onto the skin or clothing, imme-

ulations. Dispose of waste oil, LLC, coolant and other

diately wash it away with lots of water. Use soap to

environmentally hazardous waste in accordance with

thoroughly clean.

the applicable law and regulations.

The battery fluid can cause blindness if splashing into eyes. If it gets into eyes, immediately flush it away with plenty of clean fresh water, and seek immediate medical attention. If the battery fluid is accidentally swallowed, gargle with plenty of water, then drink lots of water, and seek immediate medical attention.

VII

INTRODUCTION

When abnormality occurs Stop overheated engine after cooling run If the engine starts to overheat, do not immediately stop the engine. Abrupt stopping of an overheated engine can cause the coolant temperature to rise, resulting in seized engine parts. If the engine starts to overheat, run the engine at low idling speed (cooling operation), and stop the engine after the coolant temperature lowers sufficiently.

Do not add coolant immediately after sudden stop due to over heating If the engine stops suddenly or if you have no choice but to stop the engine suddenly due to overheating, do not add coolant immediately. Adding water while the engine is hot can damage parts such as cylinder heads due to a sudden drop of temperature. Add coolant gradually after the engine has completely cooled.

Avoid immediate restart after abnormal stop If the engine stops abnormally, do not restart the engine immediately. If the engine stops with an alarm, check and remedy the cause of the problem before restarting. Sustained use of the engine without any remedy could result in serious engine problems.

Avoid continuous engine operation with low oil pressure If an abnormal engine oil pressure drop is indicated, stop the engine immediately, and inspect the lubrication system to locate the cause. Continuous engine operation with low oil pressure may cause bearings and other parts to seize.

Stop the engine immediately if fan belt is broken If the fan belt breaks, stop the engine immediately.

Continuous engine operation with the broken fan belt could cause the engine to overheat and thereby the coolant to boil into steam, which may gush out from the reserve tank or radiator, and cause personal injuries.

VIII

INTRODUCTION

Other cautions Never modify engine

Never operate the engine in an overloaded

Unauthorized modification of the engine will void the

condition

manufacturer’s warranty. Modification of the engine

If the engine shows an overloaded condition such as

may not only cause engine damage but also produce

black smoke, reduce the load immediately to operate

personal injuries.

the engine at an appropriate output and load. Over-

Never break the seals

loading causes not only high fuel consumption but also

To ensure proper engine operation, the fuel control

excessive carbon deposits inside the engine. Carbon

link is provided with seals that protect the fuel injection

deposits cause various problems and will shorten the

volume and rotation speed settings against tampering.

service life of the engine.

If these seals are broken and the settings are

Conduct cooling operation before stopping

changed, proper operation of the engine will no longer

the engine

be guaranteed, and the following problems will be

Before stopping the engine, let it idle at low speed for 5

expected to occur.

to 6 minutes to cool down. Stopping the engine imme-

Rapid wear of moving and rotating parts

diately after high-load operation will cause engine

Engine troubles such as damage and seizure of

parts to heat up and shorten the service life of the

engine parts Increased consumption of fuel and lubricating oil Degradation of engine performance due to improper

engine. During cooling operation, check the engine for abnormalities.

balance between fuel injection volume and governor

Protection of engine against water entry

operation or overrunning of the engine which could

Do not allow rainwater, etc. to enter the engine

result in a serious accident

through the air inlet or exhaust openings. Do not wash

Break-in the engine To break in new engines or overhauled engines, operate the engine at a speed lower than the rated speed in a light load condition during the first 50 hours of operation. Operating a new engines or overhauled

the engine while it is operating. Cleaning fluid (water) can be sucked into the engine. Starting the engine with water inside the combustion chambers can cause the water hammer action which may result in internal engine damage and serious accidents.

engines in a severe condition during the break-in

Properly maintain the air cleaner

period shortens the service life of the engine.

The major cause of abnormal wear on engine parts is

Warming up engine before use

dust from intake air. Worn parts produce many prob-

After starting the engine, run the engine at low idling speeds for 5 to 10 minutes for warming-up. Start the work after this operation is completed. Warm-up operation circulates the lubricant through the engine.

Therefore, individual engine parts are well lubricated before they are subjected to heavy loads. This is very important for longer service life, high-performance and economical operation. Do not conduct warm-up operation for a longer time than necessary. Prolonged warm-up operation causes carbon build-up in the cylinders that leads to incomplete combustion.

lems such as an increase of oil consumption, decrease of output and starting difficulties. For effective removal of dust from intake air, maintain the air cleaner according to the following instructions. Do not maintain the air cleaner while the engine is operating. Operating the engine without the air cleaner can suck particles of foreign matter into the engine and could result in serious accidents. Remove the air cleaner slowly to prevent dust accumulated on the element from falling off. After removing the air cleaner, immediately cover the opening (inlet port of air cleaner) with plastic sheet or similar means to prevent dust from entering the engine.

IX

INTRODUCTION If the engine is equipped with a dust indicator, conduct maintenance only when the clog warning sign appears.

Cautionary instructions for transporting engine When transporting the engine on a truck, consider the

Observe safety rules at work site

engine weight, width and height to ensure safety.

Observe the safety rules established at your work-

Abide by road traffic laws, vehicle road acts, vehicle

place when operating and maintaining the engine. Do

restriction ordinances and other pertinent laws.

not operate the engine if you are feeling ill, inform your

Do not operate engine continuously under

supervisor of your condition. Operation of the engine with reduced awareness may cause improper operation that could result in accidents. When working in a team of two or more people, use specified hand signals to communicate among workers.

Work clothing and protective gear Wear a hard hat, face shield, safety shoes, dust mask, gloves and other protective gear as needed. When handling compressed air, wear safety goggles, hard hat, gloves and other necessary protective gear.

Works without wearing proper protective gear could result in serious injuries.

low load When operating the engine with a 30% of rated load or lower, limit each operation to 10 minutes. Operating the engine at low load tends to result in unburned fuel, which can adhere on internal engine parts, and cause malfunctions and shorten the engine service life.

Ventilation of engine room Always keep the engine room well-ventilated. Insufficient amount of intake air cause the operating temperature to rise, resulting in poor output and lowered performance. It is highly recommended to calculate the required amount of air supply to the engine and

Use of tools optimum for each work

install an adequate ventilation system before installing

Always keep in mind to select most appropriate tools

the engine.

for the work to be performed and use them correctly. If tools are damaged, replace with new tools.

Do not touch high-pressure injection fuel If fuel leaks or sprays out from the high pressure injec-

Do not operate the starter for a prolonged

tion pipe, do not touch the fuel. Fuel in the fuel injec-

time

tion pipes is under high pressure and if the fuel comes

Do not use the starter for more than 10 seconds at a

into contact with your skin, it goes into the deep tis-

time. If the engine does not start, wait for at least 30

sues and may result in gangrene.

seconds before cranking again. Continuous operation of the starter will drain the battery power and cause seizing of the starter.

Do not turn off battery switch during operation Do not turn off battery switch during operation. If the battery switch is turned OFF when the engine is running, not only various meters will stop working but also the alternator may have its diode and transistor deteriorated.

X

INTRODUCTION

About warning labels Maintenance of warning labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened. Replace damaged or fractured labels with new ones. If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning label to the new part. To obtain new warning labels, contact your authorized Cat® lift truck dealer.

Warning labels

XI

INTRODUCTION

Tips on disassembling and assembling This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines. The manual also specifies the special tools that are required for the work, and the basic safety precautions to follow when working. Note that this manual does not exhaustively cover potential hazards that could occur during maintenance, inspection and service work of engine.

When working on an engine, follow the relevant directions given in this manual and observe the following instructions:

Tips on disassembling  Use correct tools and instruments. Serious damage to the engine can result from using the wrong tools and instruments. Do not use jack bolts with sharp edges, as they may cause damage to the surface. Use an overhaul stand or work bench if necessary, and follow the disassembling procedures described in this manual. Do not place the engine parts on the floor directly. Place them on the work bench. Keep the engine parts in their order of removal to prevent losing them. If the engine parts are reused, install them to the original position unless there are any specific purpose.

Pay attention to assembling marks. Put your marks on the parts, if necessary, to ensure correct assembling. Carefully check each part for defects during disassembling or cleaning. Do not miss symptoms which can not be detected after disassembling or cleaning. When lifting or carrying heavy parts, exercise utmost caution to ensure safety. Pay attention to the balancing of heavy parts when handling. (Get help, and use jacks, chain blocks and guide bolts as necessary.)

Tips on assembling  Wash all engine parts, except such parts as oil seals, O-rings and rubber seats, in cleaning oil and dry them with compressed air. Use correct tools and instruments. Use only high-quality lubricating oils and greases of appropriate types. Be sure to apply oil, grease or adhesive to the part wherever specified. Use a torque wrench to tighten parts correctly when their tightening torques are specified. Refer to “Tightening torque table.” Replace all gaskets, packings and O-rings with new ones unless specified otherwise. Apply adhesive if necessary. Use only the proper amount of adhesive.

XII

GENERAL CONTENTS Chapter 1

GENERAL 1. External View 2. System flow diagrams 3. Engine serial number location 4. Main specifications

Chapter 2

SERVICE DATA 1. Maintenance service data 2. Tightening torque table

Chapter 3

SERVICE TOOLS 1. Special tools

Chapter 4

OVERHAUL INSTRUCTIONS 1. Determining overhaul timing 2. Compression pressure - Measure

Chapter 5

DISASSEMBLY OF BASIC ENGINE 1. Cylinder heads and Valve mechanisms - Disassemble and Inspect 2. Rear equipment - Disassemble and Inspect 3. Front equipment - Disassemble and Inspect 4. Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect

Chapter 6

INSPECTION AND REPAIR OF BASIC ENGINE 1. Cylinder head and Valve mechanism - Inspect and Repair 2. Rear equipment - Inspect and Repair 3. Front equipment - Inspect and Repair 4. Piston and Connecting rod - Inspect and Repair 5. Crankcase and Crankshaft - Inspect and Repair

Chapter 7

ASSEMBLY OF BASIC ENGINE 1. Piston, Connecting rod, Crankshaft and Crankcase - Assemble 2. Front equipment - Assemble 3. Rear equipment - Assemble 4. Cylinder head and Valve mechanism - Assemble

Chapter 8

FUEL SYSTEM 1. Fuel system - Remove 2. Fuel system - Disassemble, Inspect and Assemble 3. Fuel system - Install

Chapter 9

LUBRICATION SYSTEM 1. Lubrication system - Remove 2. Lubrication system - Disassemble, Inspect and Assemble 3. Lubrication system - Install

Chapter 10 COOLING SYSTEM 1. Cooling system - Remove 2. Cooling system - Disassemble, Inspect and Assemble 3. Cooling system - Install

Chapter 11 INLET AND EXHAUST SYSTEMS 1. Inlet and exhaust systems - Remove 2. Inlet and exhaust systems - Disassemble, Inspect and Assemble 3. Inlet and exhaust systems - Install

Chapter 12 ELECTRICAL SYSTEM 1. Electrical system - Remove and Inspect 2. Electrical system - Disassemble, Inspect and Assemble 3. Electrical system - Install

Chapter 13 ADJUSTMENT AND OPERATION 1. Engine - Adjust 2. Break-in operation 3. Performance test

Chapter 1 GENERAL 1.

2.

External View ........................................................................................................... 1-3 System flow diagrams............................................................................................. 1-4 2.1 2.2 2.3 2.4

Outline of fuel system ............................................................................................................... 1-4 Outline of lubrication system..................................................................................................... 1-4 Outline of cooling system.......................................................................................................... 1-5 Outline of inlet and exhaust system.......................................................................................... 1-5

3.

Engine serial number location ............................................................................... 1-6

4.

Main specifications.................................................................................................. 1-7

1-1

Chapter 1 GENERAL

1. External View

Chapter 1 GENERAL

Oil level gauge Fan Fuel filter Water pump Coolant drain plug Flywheel Front

Rear

Oil filter

Magnetic valve (Stop solenoid) Fuel injection pump Oil drain plug

Relief valve

Engine left view

Oil filler

Oil filler

Coolant outlet Hanger

Hanger Thermostat case Alternator

Rear

Front

Rear plate V-belt Starter Damper Oil pan

Engine right view

1-3

Chapter 1 GENERAL

2. System flow diagrams 2.1 Outline of fuel system Fuel filter Fuel inlet Leak-off pipe Fuel injection nozzle Return pipe

Fuel outlet

Fuel injection pump

Outline of fuel system

2.2 Outline of lubrication system Piston Crankshaft

Push rod Tappet

Valve mechanism

Camshaft Main gallery

Relief valve Oil filter Idler gear

Oil pump Oil pan Oil strainer

Outline of lubrication system

1-4

Chapter 1 GENERAL 2.3 Outline of cooling system Thermostat Coolant outlet

Cylinder head

Bypass hose

Water jacket

Coolant inlet Water pump

Outline of cooling system

2.4 Outline of inlet and exhaust system

Breather hose Exhaust manifold

Inlet manifold

Exhaust

Inlet

Outline of inlet and exhaust system

1-5

Chapter 1 GENERAL

3. Engine serial number location The engine serial number is stamped on the right of the crankcase.

Engine serial number

Engine serial number location

1-6

Chapter 1 GENERAL

4. Main specifications Main specifications Engine model

S6S-E35AFL

Type No. of cylinders - arrangement

Swirl chamber

Valve mechanism

Overhead

Cylinder bore × stroke

94 × 120 mm [3.70 × 4.72 in.]

Displacement

4.996 L [305 cu. in.]

Compression ratio

22.0 : 1

Fuel

ASTM diesel fuel oil No.2-D (JIS K2204 diesel fuel)

Firing order

1-5-3-6-2-4

Direction of rotation

Counterclockwise as viewed from flywheel side Length

Dimensions

1004 mm [39.52 in.]

Width

587 mm [23.11 in.]

Height

801 mm [31.53 in.]

Dry weight

Basic engine

350 kg [772 lb]

Cylinder

Type

Piston ring

No. of rings

Dry (integral with cylinder block) Compression ring: 2 Oil ring (with expander) : 1

Inlet valve

Open

BTDC 30°

Close

ABDC 50°

Exhaust valve

Open

BBDC 74°

Close

ATDC 30°

Valve timing

Starting system

Starter

Starting aid system

Glow plug Type

Fuel injection pump Fuel feed pump Fuel system

Plunger outside diameter Cam lift

Vane type

No. of spray holes Spray diameter Spray angle Type

Capacity Type

Oil pump

Speed ratio to crankshaft Discharge rate

Relief valve

Throttle type 1 ø1.0 mm [0.039 in.]

0° 11.8 MPa {120 kgf/cm²} [1707 psi] Cartridge type paper element Forced circulation (pressure feed by oil pump)

Specification

Lubrication system

1.741 mm [0.068 in.]

Type

Lubrication method

Engine oil

ø 11 mm [0.43 in.]

All speed

Valve opening pressure Fuel filter

Distribution (VE type)

Governor type

Nozzle type Fuel injection nozzle

S6S-E35CFL

6 cylinder in-line

Combustion system

Main specifications

S6S-E35BFL

Water cooled, 4 stroke cycle diesel engine

Type Valve opening pressure

Class CF (API service category) Engine total: 15 L [3.96 U.S. gal.], Oil pan: 11.5 L [3.03 U.S. gal.] (high level), oil filter: 1 L [0.26 U.S. gal.]

Trochoid 0.74 38.7 L [10.22 U.S. gal.]/min (at pump rotation of 2230 min-1, 0.3 MPa {3 kgf/cm²} [42.67 psi]) Piston valve type 0.35 ± 0.05 MPa {3.6 ± 0.5 kgf/cm2} [51 ± 7 psi]

Oil cooler

Type

Plate type

Oil filter

Type

Cartridge type paper element

1-7

Chapter 1 GENERAL Main specifications Engine model

S6S-E35AFL

Cooling method Coolant capacity (engine water jacket)

Centrifugal

Speed ratio to crankshaft Water pump Discharge rate

Cooling fan Thermostat

1.2 160 L [42.27 U.S. gal.]/min (at pump rotation of 3600 min-1, 0.075 MPa {0.75 kgf/cm²} [11 psi])

Type

Push type (PP fan)

Outside diameter

ø400 mm [15.7 in.]

Type

Wax type

Valve opening temperature

76.5 ± 2°C [169.7 ± 35.6°F] (90°C [194.0°F] when fully opened)

Voltage

12 V

Polarity

Negative (-) ground Model number

Starter

M008T55472

Pinion meshing type

Pinion shift

Output

12 V, 3.0 kW

No. of pinion tooth/ring gear tooth Model number Type

Electrical system

A007TA0483A 12 V, 50 A

Speed in use Rated speed

Type

12 V, 75 A

12 V, 25 A to 8000 min-1

22000 min-1

22000 min-1

10000 min-1

1.85 Sheathed

Rated voltage Current

10.5 V 9.7 A (When applying rated voltage for 30 sec.) x 6

Rated voltage Magnetic valve (Stop solenoid)

A002TA7871

5000 min-1

Speed ratio to crankshaft Glow plug

A005TA5083A

1000 to 18000 min-1 1000 to 18000 min-1

Permissible speed

Power consumption ETR type Starting voltage (RUN-ON) Return voltage Coil resistance

1-8

10/122 3-phase alternating current, with rectifier

Output Alternator

S6S-E35CFL

8 L [2.1 U.S.gal.]

Type

Cooling system

S6S-E35BFL

Water-cooled, forced circulation

12 V 14 W 6.3 V or below 2.5 V or more 8Ω

Chapter 2 SERVICE DATA 1.

Maintenance service data ....................................................................................... 2-3 1.1 1.2 1.3 1.4 1.5 1.6 1.7

2.

Engine general ......................................................................................................................... 2-3 Basic engine ............................................................................................................................. 2-4 Fuel system .............................................................................................................................. 2-7 Lubrication system.................................................................................................................... 2-7 Cooling system ......................................................................................................................... 2-7 Inlet and exhaust system .......................................................................................................... 2-7 Electrical system....................................................................................................................... 2-8

Tightening torque table........................................................................................... 2-9 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Basic engine ............................................................................................................................. 2-9 Fuel system .............................................................................................................................. 2-9 Lubrication system.................................................................................................................. 2-10 Cooling system ....................................................................................................................... 2-10 Inlet and exhaust system ........................................................................................................ 2-10 Electrical system..................................................................................................................... 2-10 Standard bolt and nut tightening torque ................................................................................. 2-11 Standard stud tightening torque ............................................................................................. 2-11

2-1

Chapter 2 SERVICE DATA

1. Maintenance service data

Chapter 2 SERVICE DATA

1.1 Engine general Unit: mm [in.]

Nominal

Standard

Maximum rotation speed (No-load)

Item

2550 min-1

2500 to 2550 min-1

Limit

Remarks

Minimum rotation speed (No-load)

820 min-1

720 to 820 min-1 3.2 MPa {33 kgf/cm2} [469 psi] or more

Faulty if lower or 2.8 MPa {29 kgf/cm2} [412 psi] or less

When oil and water temperatures at 20 to 30 °C [68 to 86 °F]

Rotated speed at 1500 min-1

0.3 to 0.5 MPa {3 to 5 kgf/cm2} [43 to 71 psi]

Faulty if lower or 0.15 MPa {1.5 kgf/cm2} [21 psi] or less

Idling speed

0.10 MPa {1.0 kgf/cm2} [14 psi] or more

0.05 MPa {0.5 kgf/cm2} [7 psi]

Compression pressure (at 300 min-1)

Engine oil pressure

Valve timing

Valve clearance Fuel injection timing

Inlet opens

BTDC 30°

Inlet closes

ABDC 50°

Exhaust opens

BBDC 74°

Exhaust closes

ATDC 30°

Inlet

0.25 [0.0098]

Exhaust

0.25 [0.0098]

When oil temperatures at 60 to 70°C [140 to 158°F]

Values are only for checking valve timing and are different from the actual ones.

When cold

BTDC 5°

2-3

Chapter 2 SERVICE DATA 1.2 Basic engine Unit: mm [in.]

Item

Rockers

Nominal

Standard

Rocker bushing inside diameter

ø19 [0.75]

19.010 to 19.030 [0.7484 to 0.7492]

Rocker shaft outside diameter

ø19 [0.75]

18.980 to 19.000 [0.7472 to 0.7480]

Clearance between rocker bushing and shaft

Valve stem Outside diameter Valve and valve guide

Clearance between valve stem and guide

0.070 [0.0028]

ø8 [0.31]

7.940 to 7.955 [0.3126 to 0.3132]

7.900 [0.3110]

Exhaust

ø8 [0.31]

7.920 to 7.940 [0.3118 to 0.3126]

7.850 [0.3091]

Inlet

0.065 to 0.095 [0.0026 to 0.0037]

0.150 [0.0059]

Exhaust

0.080 to 0.115 [0.0031 to 0.0045]

0.200 [0.0079]

Valve seat angle

14 [0.55]

13.9 to 14.1 [0.547 to 0.555]

Inlet

0.4 [0.016]

0.3 to 0.5 [0.012 to 0.020]

1.0 [0.039]

Exhaust

0.5 [0.020]

0.4 to 0.6 [0.016 to 0.024]

1.0 [0.039]

1.4 [0.055]

1.26 to 1.54 [0.0496 to 0.0606]

1.8 [0.071]

Valve margin

2.13 [0.0839]

Refacing permissible up to 1.83 [0.0720]

Free length

48.85 [1.9232]

47.60 [1.8740]

Squareness

A=1.5°or less B=1.3 [0.051] or less Lf = 48.85 [1.9232]

B = 1.5 [0.059] at the end

43 mm [1.69 in.]/ 176 to 196 N {18 to 20 kgf} [39 to 40 lbf]

43 mm [1.69 in.]/ 147 N {15 kgf} [33 lbf]

Valve seat and valve Seat width

Valve spring

Set length/load

Runout 0.05 [0.0020] or less

Distortion of bottom surface Cylinder head Compressed thickness of gasket

1.2 [0.047]

1.15 to 1.25 [0.0453 to 0.0492]

Inside diameter

ø94 [3.70]

94.000 to 94.035 [3.7008 to 3.7022]

Cylinder

Remarks

30°

Valve sinkage

2-4

0.010 to 0.050 [0.0004 to 0.0020]

Inlet

Valve guide mounting length

Push rod

Limit

Roundness

0.01 [0.0004] or less

Cylindricity

0.015 [0.0006] or less

Seat width

Valve Valve sinkage seat angle

Valve margin

A B Lf

0.6 [0.024]

TIR (dial gauge reading) when pushrod is supported along center line of spherical surface at either end.

0.20 [0.0079]

Reface slightly.

Repair limit: 94.200 [3.7087] Service limit: 94.700 [3.7283]

Refinish cylinder to 0.25 [0.0098] or 0.50 [0.0197] oversize of nominal value by honing.

Use oversize piston and piston ring.

Chapter 2 SERVICE DATA Unit: mm [in.]

Item

Nominal Standard

Outside diameter (at piston skirt)

+0.25 [0.0098] Oversize

ø 94 [3.70]

+0.50 [0.0197] Oversize

Piston

94.020 [3.7016]

94.455 to 94.485 [3.7187 to 3.7199]

94.270 [3.7114]

No.1 compression

0.30 to 0.50 [0.0118 to 0.0197]

1.50 [0.0591]

No.2 compression

0.50 to 0.70 [0.0197 to 0.0276]

1.50 [0.0591]

Oil

0.30 to 0.50 [0.0118 to 0.0197]

1.50 [0.0591]

ø30 [1.18]

Outside diameter Piston pin

94.205 to 94.235 [3.7089 to 3.7100]

29.994 to 30.000 [1.1809 to 1.1811]

Clearance between piston

0.000 to 0.016 [0.0000 to 0.0006]

0.050 [0.0020]

Clearance between connecting rod bushing

0.020 to 0.091 [0.0008 to 0.0036]

0.120 [0.0047]

Bushing inside diameter

ø30 [1.18]

Connecting rod bend and twist

Connecting rod Clearance between crankpin and connecting rod bearing (oil clearance) End play

30.020 to 30.045 [1.1819 to 1.1829] 0.05/100 [0.0020/3.94] or less

0.15/100 [0.0059/3.94]

0.030 to 0.090 [0.0012 to 0.0035]

0.200 [0.0079]

Use undersize connecting rod bearing when the limit is exceeded replacing with standard size bearing.

0.15 to 0.35 [0.0059 to 0.0138]

0.50 [0.0197]

Replace connecting rod.

Weight difference of connecting rod assembly in one engine

10 g [0.35 oz.] or less

Flatness

0.15 [0.0059] or less

0.50 [0.0197]

Runout

0.15 [0.0059] or less

0.50 [0.0197]

Outer circumference face runout

0.5 [0.020] or less

1.5 [0.0591]

Outer circumference radial runout

0.5 [0.020] or less

1.5 [0.0591]

Runout

0.04 [0.0016] or less

0.10 [0.0039]

Flywheel

Damper

Inlet

6.684 [0.2631]

6.384 to 6.784 [0.2513 to 0.2671]

6.184 [0.2435]

Exhaust

6.720 [0.2646]

6.420 to 6.820 [0.2528 to 0.2685]

6.220 [0.2449]

No.1, 2, 3

ø54 [2.13]

53.94 to 53.96 [2.1236 to 2.1244]

53.90 [2.1220]

No.4

ø53 [2.09]

52.94 to 52.96 [2.0842 to 2.0850]

52.90 [2.0827]

Clearance between camshaft journal and camshaft bushing

0.040 to 0.090 [0.0016 to 0.0035]

0.15 [0.0059]

Camshaft end play

0.10 to 0.25 [0.0039 to 0.0098]

0.30 [0.0118]

Cam lift

Camshaft Journal diameter

Remarks

5g [0.2 oz.] or less

Weight difference in one engine

Piston ring end gap

Limit 93.770 [3.6917]

-0.25 to 0.15 [-0.0098 to 0.0059]

Protrusion from crankcase

Piston ring

Standard 93.955 to 93.985 [3.6990 to 3.7002]

Replace with new one when engine is operated for 8000 hours TIR

Replace thrust plate.

2-5

Chapter 2 SERVICE DATA Unit: mm [in.]

Item

Idler

Nominal

Standard

Limit

Clearance between bushing and shaft

0.009 to 0.050 [0.0004 to 0.0020]

0.100 [0.0039]

Idler gear end play

0.05 to 0.20 [0.0020 to 0.0079]

0.35 [0.0138]

Replace thrust plate.

Interference between shaft and crankcase hole

0.035 to 0.076 [0.0014 to 0.0030] 0.05 to 0.15 [0.0020 to 0.0059]

0.25 [0.0098]

Replace gears

Timing gear backlash

Crankshaft

Crankshaft journal outside diameter

ø78 [3.07]

77.955 to 77.970 [3.0691 to 3.0697]

77.850 [3.0650] (Repair) 77.100 [3.0354] (Replace)

Crankpin outside diameter

ø58 [2.28]

57.955 to 57.970 [2.2817 to 2.2823]

57.800 [2.2756]

Parallelism of journal and crankpin

Pin maximum defection: 0.01 [0.0004] or less.

Circularity of journal and crankpin

0.01 [0.0004] or less

0.03 [0.0012]

Cylindricity of journal and crankpin

0.01 [0.0004] or less

0.03 [0.0012]

Fillet radius of pin and journal

0.10 [0.0039]

TIR

End play

0.100 to 0.264 [0.0039 to 0.0104]

0.300 [0.0118]

Use oversize thrust plate when the limit is exceeded replacing with standard size thrust plate.

Clearance between crank journal

0.050 to 0.110 [0.0020 to 0.0043]

0.200 [0.0079]

Use undersize main bearing when limit is exceeded replacing with standard size bearing.

0.05 [0.0020] or less

0.20 [0.0079]

Reface slightly.

Tappet guide hole inside diameter

14.000 to 14.018 [0.5512 to 0.5519]

14.100 [0.5551]

Clearance between tappet and tappet guide hole

0.016 to 0.052 [0.0006 to 0.0020]

0.08 [0.0031]

Distortion of top surface Crankcase

2-6

2.8 to 3.2 [0.110 to 0.126] 0.04 [0.0016] or less

Runout

Main bearing

R3 [0.12]

Remarks

Replace a tappet until the clearance reaches the limit.

Chapter 2 SERVICE DATA 1.3 Fuel system Item Injection start pressure

Nominal

Standard

11.77 MPa {120 kgf/cm²} [1707 psi]

11.77 to 12.75 MPa {120 to 130 kgf/cm²} [1707 to 1849 psi]

Limit

Make shim adjustment.

Pressure varies by 1 MPa {10 kgf/cm²} [144 psi] per 0.1 [0.004] thickness of shim.

Fuel injection nozzle Spray angle

Remarks

Check nozzle with a hand tester (at fuel oil temperature 20°C [68°F]).

Replace the nozzle tip if the spray pattern is still bad after washing in clean fuel oil.

0°

1.4 Lubrication system Unit: mm [in.]

Item

Nominal

Clearance between outer rotor and pump case

Oil pump

Relief valve

Standard

Limit

0.20 to 0.30 [0.0079 to 0.0118]

0.50 [0.0197]

Replace pump assembly.

Shaft outside diameter (between case)

ø16 [0.63]

15.985 to 16.000 [0.6293 to 0.6299]

Shaft outside diameter (oil pump bushing side)

ø14 [0.55]

13.957 to 13.975 [0.5495 to 0.5502]

Remarks

Clearance between shaft and pump case

0.032 to 0.074 [0.0013 to 0.0029]

0.150 [0.0059]

Replace pump case or pump assembly.

Clearance between shaft and oil pump bushing

0.025 to 0.111 [0.0010 to 0.0044]

0.200 [0.0079]

Replace pump bushing or pump assembly.

Clearance between inner rotor and outer rotor

0.13 to 0.15 [0.0051 to 0.0059]

0.20 [0.0079]

Replace outer rotor and shaft assembly.

End play of rotor and pump case

0.04 to 0.09 [0.0016 to 0.0035]

0.15 [0.0059]

Replace pump assembly.

Valve opening pressure

0.35 MPa {3.5 kgf/cm²} [50 psi]

0.35 ± 0.05 MPa {3.5 ± 0.5 kgf/cm²} [50 ± 7.1 psi]

Nominal

Standard

1.5 Cooling system Item Temperature for opening Thermostat

76.5°C [169.7°F]

Temperature at which valve lift becomes 9 mm [0.31 in.] or more

Limit

Remarks

76.5 ± 2°C [169.7 ± 3.6°F] 90°C [194°F]

1.6 Inlet and exhaust system Item Exhaust manifold distortion

Nominal

Standard 0.2 mm [0.008 in.] or less

Limit

Remarks Repair by grinding or replace.

2-7

Chapter 2 SERVICE DATA 1.7 Electrical system Unit: mm [in.]

Item

Nominal

Standard

Limit

ø32 [1.2598]

31.4 [1.2362]

Replace

Runout

-

0.10 [0.0039]

Repair or replace.

Undercut depth

-

0.2 [0.0079]

Repair

18 [0.7087]

11 [0.4331]

Replace

29.2 to 39.4 N {3.0 to 4.0 kgf} [21.53 to 29.06 lbf]

13.7 N {1.4 kgf} [10 lbf]

Replace

11 V

-

180 A or less

-

3800 min-1 or more

-

Outside diameter Commutator

Brush length

Starter

34 N {3.5 kgf} [25 lbf]

Pressure of brush springs Voltage Nonload characteristics

Current Rotational speed

Output current (When heated) A007TA 0483A

Rotational speed (min-1)

1500 or less

-

2500 or less

33 A or more

5000 or less

47 A or more

Regulator adjusting voltage

18.5 [0.7283]

Resistance between slip rings Output current (When heated) Alternator

A002TA 7871

Rotational speed (min-1)

-

2500 or less

16 A or more

5000 or less

21 A or more

Brush length Resistance between slip rings

A005TA 5083A

Regulator adjusting voltage

Resistance between slip rings Glow plug Magnetic valve

V-belt tension

2-8

Replace

Inspection at 20°C [68°F] 5.0 [0.1969]

Replace

13.6 to 15.9 Ω 1500 or less

24A or more

2500 or less

53 A or more

5000 or less

71 A or more

Inspection

14.7 ± 0.3 V 18.5 [0.7283]

Brush length

5.0 [0.1969]

14.7 ± 0.3 V 18.5 [0.7283]

Rotational speed (min-1)

at 20°C [68°F]

2.7 to 3.2 Ω 1500 or less

Regulator adjusting voltage

Output current (When heated)

Inspection

Inspection

14.7 ± 0.3 V

Brush length

Remarks

at 20°C [68°F] 5.0 [0.1969]

Replace

2.4 to 2.9 Ω

Rated voltage

DC 10.5 V

Current

9.7 ± 1.0 A Rated voltage

12 V

Resistance

8Ω

Deflection

12 [0.4724]

When center of belt pressed at approx. 98 N {10 kgf} [22 lbf]

Chapter 2 SERVICE DATA

2. Tightening torque table 2.1 Basic engine Description

Thread Dia. × Pitch (M-thread)

Torque N·m

kgf·m

lbf·ft

Cylinder head

12 × 1.75

118 ± 5

12 ± 0.5

87 ± 3.6

Cylinder head plug

16 × 1.5

44.1 ± 5

4.5 ± 0.5

33 ± 3.6

Rocker cover

8 × 1.25

11.5 ± 1.5

1.15 ± 0.15

8.5 ± 1.1

Rocker shaft bracket bolt (long)

8 × 1.25

17.2 ± 2.45

1.75 ± 0.2

12.9 ± 1.8

Main bearing cap

14 × 2.0

103 ± 5

10.5 ± 0.5

76 ± 3.6

Connecting rod cap

10 × 1.25

54 ± 5

5.5 ± 0.5

40 ± 3.6

Flywheel

12 × 1.25

83 ± 5

8.5 ± 0.5

61 ± 3.6

Camshaft thrust plate

8 × 1.25

11.5 ± 1.5

1.15 ± 0.15

8.3 ± 1.1

Front plate

8 × 1.25

11.5 ± 1.5

1.15 ± 0.15

8.3 ± 1.1

Timing gear case

8 × 1.25

18.5 ± 1.5

1.9 ± 0.1

13.4 ± 1.1

Crankshaft pulley

30 × 1.5

490 ± 10

50 ± 1

361 ± 7.3

Idler thrust plate

10 × 1.25

34 ± 5

3.5 ± 0.5

25 ± 3.6

Rear plate

10 × 1.25

55.9 ± 5.8

5.7 ± 0.5

41.2 ± 3.6

Rocker adjusting nut

8 × 1.25

20 ± 2

2 ± 0.2

15 ± 1.4

Remarks

2.2 Fuel system Description Fuel injection nozzle (engine)

Thread Dia. × Pitch (M-thread)

Torque N·m

kgf·m

lbf·ft

20 × 1.5

58.9 ± 5.8

6 ± 0.5

43 ± 4.3

Fuel injection nozzle retaining nut

16 × 0.75

36.8 ± 2.4

3.8 ± 0.2

27.1 ± 1.8

Fuel injection pump gear

12 × 1.75

59.5 ± 0.5

6.1 ± 0.05

43.9 ± 0.37

Fuel injection pump overflow valve

-

24.5 ± 4.5

2.5 ± 0.46

18 ± 3.3

Fuel injection pipe nut

12 × 1.5

29.5 ± 2.9

3 ± 0.3

21.8 ± 2.14

Fuel return pipe nut

10 × 1.25

19.7 ± 1.9

2 ± 0.1

14.5 ± 1.4

Fuel filter drain plug

14 × 1.0

1.1 ± 0.3

0.1 ± 0.03

0.8 ± 0.22

Fuel filter cartridge

20 × 1.5

13.5 ± 1.5

1.4 ± 0.1

10 ± 1.1

Fuel filter water level sensor assembly

36 × 1.5

13.5 ± 1.5

1.4 ± 0.1

10 ± 1.1

Fuel leak-off pipe mounting nut

12 × 1.5

22.6 ± 1.9

2.3 ± 0.1

16.7 ± 1.4

Remarks

2-9

Chapter 2 SERVICE DATA 2.3 Lubrication system Thread Dia. × Pitch (M-thread)

N·m

kgf·m

lbf·ft

Oil pan

8 × 1.25

11.5 ± 1.5

1.2 ± 0.1

8.3 ± 1.1

Oil pan drain plug

20 × 1.5

78 ± 5

8 ± 0.5

57 ± 3.7

Oil pump gear

10 × 1.25

33 ± 5

3.4 ± 0.5

24 ± 3.7

Relief valve

22 × 1.5

49 ± 4.9

5 ± 0.5

36 ± 3.7

Relief valve plug

18 × 1.5

44 ± 4.9

4.5 ± 0.5

32.5 ± 3.6

Description

Torque Remarks

2.4 Cooling system Thread Dia. × Pitch (M-thread)

N·m

kgf·m

lbf·ft

Thermostat case

8 × 1.25

18.5 ± 1.5

1.9 ± 0.1

13.6 ± 1.1

Water drain plug

Description

Torque

1/4-18NPSF

39.2 ± 3.9

4 ± 0.3

28.9 ± 2.8

Water pump mounting bolt (tightening with water pump case cover)

8 × 1.25

9.8 ± 1

1 ± 0.1

7.2 ± 0.7

Water pump mounting bolt (tightening with crankcase)

8 × 1.25

18.2 ± 3.4

1.9 ± 0.3

13.4 ± 2.5

R3/8

31.9 ± 2.4

3.3 ± 0.2

23.5 ± 1.8

Water pump plug

Remarks

2.5 Inlet and exhaust system Description Exhaust manifold (bolt only)

Thread Dia. × Pitch (M-thread)

Torque N·m

kgf·m

lbf·ft

8 × 1.25

18.5 ± 3.5

1.9 ± 0.3

13.6 ± 2.5

Remarks

2.6 Electrical system Description

Thread Dia. × Pitch (M-thread)

Torque N·m +2 0

kgf·m +0.2 0

lbf·ft +1.5 0

Starter terminal B

8 × 1.25

9.8

Starter mounting nut

10 × 1.25

45 ±15

Glow plug (main)

10 × 1.25

25 ± 5

2.5 ± 0.5

18 ± 3.6

4 × 0.7

1.3 ± 0.2

0.13 ± 0.02

0.96 ± 0.22

Glow plug (terminal)

2-10

1

4.6 ± 1.5

7

33.2 ± 11

Remarks

Chapter 2 SERVICE DATA 2.7 Standard bolt and nut tightening torque 2.7.1 Metric automobile screw thread Thread Dia. × Pitch (M-thread)

Strength classification

Width across flats (mm) [in.]

4T

7T

4 6 × 1.0

10

10.9

10

7

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

4

0.4

2.9

9

0.9

6.5

13

1.3

9.4

8 × 1.25

12

12

1.2

8.7

18

1.9

13

30

3.1

22

10 × 1.25

14

21

2.15

16

35

3.6

26

60

6.1

44

12 × 1.25

17

35

3.6

26

64

6.5

47

108

11.0

80

2.7.2 Metric course screw thread Thread Dia. × Pitch (M-thread)

Width across flats (mm) [in.]

Strength classification

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

10 × 1.5

14

32

3.3

24

58

5.9

43

12 × 1.75

17

57

5.8

42

102

10.4

75

7T

10.9

Note:(a) This table lists the tightening torque for standard bolts and nuts. (b) The numerical values in the table are for fasteners with spring washers. (c) The table shows the standard values with a maximum tolerance value of ±10%. (d) Use the tightening torque in this table unless otherwise specified. (e) Do not apply oil to threaded portions. (Dry)

2.8 Standard stud tightening torque Thread Dia. × Pitch (M-thread)

For driving in aluminum materials

For driving in ferrous materials

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

8 × 1.25

5.4 ± 0.5

0.55 ± 0.05

4.0 ± 0.4

12.8 ± 0.9

1.3 ± 0.1

10.1 ± 0.7

10 × 1.25

13.7 ± 1.0

1.4 ± 0.1

9.4 ± 0.7

23.5 ± 1.9

2.4 ± 0.2

17.4 ± 1.4

2-11

Chapter 3 SERVICE TOOLS 1.

Special tools............................................................................................................. 3-3

3-1

Chapter 3 SERVICE TOOLS

1. Special tools Tool name

Chapter 3 SERVICE TOOLS

Part No.

Illustration

Remarks

Compression gauge

35A91-03100

Engine compression pressure measuring 0 to 7 MPa {0 to 71.4 kgf/cm²} [0 to 1015.54 psi]

Gauge adapter (swirl chamber)

30691-21100

Engine compression pressure measuring

Socket

58309-73100

Turning an engine

Valve spring pusher

30691-04500

Valve spring removal/installation

Valve guide remover

32A91-00300

Valve guide removal

Valve seat insert caulking tool

Inlet: 36791-00200 Exhaust: 34491-03020

Valve seat installation

Stem seal installer

32A91-10200

Stem seal installation

Socket

34491-00300

Rocker bracket installation Thrust plate of camshaft removal/ installation

3-3

Chapter 3 SERVICE TOOLS Tool name

Part No.

Illustration

Remarks

Valve guide installer

32A91-00100

Valve guide installation

Camshaft bushing installer set

30691-00010

Camshaft bushing removal/installation

Idler bushing installer

30091-07300

Idler bushing removal/installation

Idler shaft puller

MH061077

Piston ring pliers

31391-12900

Piston ring removal/installation

Connecting rod bushing puller

32A91-00500

Connecting rod bushing removal/installation

Oil seal sleeve installer set

30691-13010

Oil seal sleeve installation of crankshaft rear side

Piston installer

34491-00200

Piston installation

Oil pump bushing installer

32A91-00400

Oil pump bushing installation

3-4

Idler shaft removal

Chapter 3 SERVICE TOOLS Tool name

Gear puller

Part No.

MH061326

Illustration

Remarks

Gear removal

3-5

Chapter 4 OVERHAUL INSTRUCTIONS 1.

Determining overhaul timing .................................................................................. 4-3

2.

Compression pressure - Measure.......................................................................... 4-4

4-1

Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining overhaul timing

Chapter 4 OVERHAUL INSTRUCTIONS

In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in engine oil consumption and blow-by gas should be considered when evaluating engine condition.

Symptoms like a decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and increase in noise should be considered when evaluating overhaul timing, although those symptoms are often affected by other causes, and are not always effective to evaluate overhaul timing.

Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately determine when the engine needs an overhaul.

The following shows typical problems caused by reduced compression pressure.

(1) Decreased output power (2) Increased fuel consumption (3) Increased engine oil consumption (4) Increased blow-by gas through the breather due to worn cylinder and piston rings (Visually check the blow-by amount) (5) Increased gas leakage due to poor seating of inlet and exhaust valves (6) Difficulty in starting (7) Increased noise from engine parts (8) Abnormal exhaust color after warm-up operation The engine can exhibit these conditions in various combinations.

Some of these problems are directly caused by worn engine parts, while others are not.

Phenomena described in items (2) and (6) can result from improper fuel injection volume and timing of the fuel injection pump, worn plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter.

The most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder and pistons, as described in item (4), and once this is determined, it is reasonable to take other problems into consideration for making a final evaluation.

4-3

Chapter 4 OVERHAUL INSTRUCTIONS

2. Compression pressure - Measure (a) Be sure to measure the compression pressure for all the cylinders. It is not a good practice to measure the compression pressure for only one cylinder, and to assume the compression pres-

Adapter P/N:30691-21100

Compression gauge P/N:35A91-03100

sure is the same for all cylinders. (b) Also be sure to check engine speed when measuring the compression pressure, as compression pressure varies with engine speed. (c) Measuring the compression pressure at regular intervals is important to obtain correct data. (d) 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 these parts. (e) Turn off the solenoid valve to stop fuel injection.

(1) Remove the glow plug from the cylinder head where the compression pressure is to be measured.

(2) Attach the compression gauge adapter to the glow plug mount and connect compression gauge.

(3) Crank the engine with the starter, then read the compression gauge indication while the engine is running at the specified speed.

(4) If the measured value is lower than the limit, overhaul the engine.

Item Compression pressure

Standard

Limit

3.2 MPa {33 kgf/cm2} [469 psi]

2.8 MPa {29 kgf/cm2} [412 psi]

Note: Engine speed should be 300 min-1, oil and water temperature should be at 20 to 30°C when measuring the compression pressure.

4-4

Compression pressure - Measure

Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.

Cylinder heads and Valve mechanisms - Disassemble and Inspect .................. 5-3 1.1 1.2 1.3 1.4 1.5 1.6

2.

Rear equipment - Disassemble and Inspect ......................................................... 5-6 2.1 2.2 2.3

3.

Flywheel face and radial runouts - Measure............................................................................. 5-7 Flywheel - Remove ................................................................................................................... 5-7 Rear plate - Remove................................................................................................................. 5-7

Front equipment - Disassemble and Inspect ........................................................ 5-8 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14

4.

Valve clearance - Inspect ......................................................................................................... 5-4 Rocker shaft assembly - Remove............................................................................................. 5-4 Cylinder head bolt - Remove .................................................................................................... 5-4 Cylinder head assembly - Remove........................................................................................... 5-5 Valve sinkage - Measure .......................................................................................................... 5-5 Valve and Valve spring - Remove ............................................................................................ 5-5

Damper face and radial runouts - Measure .............................................................................. 5-9 Damper and Crankshaft pulley - Remove................................................................................. 5-9 Timing gear case - Remove...................................................................................................... 5-9 Timing gear backlash - Measure .............................................................................................. 5-9 Idler gear and camshaft end play - Measure .......................................................................... 5-10 Fuel injection pump - Remove ................................................................................................ 5-10 Oil pan - Remove.................................................................................................................... 5-10 Oil strainer - Remove.............................................................................................................. 5-10 Oil pump gear - Remove......................................................................................................... 5-11 Idler gear - Remove ................................................................................................................ 5-11 Camshaft - Remove................................................................................................................ 5-11 Camshaft gear - Replace........................................................................................................ 5-12 Front plate - Remove .............................................................................................................. 5-12 Oil pump - Remove................................................................................................................. 5-12

Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect 513 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

Piston protrusion - Measure.................................................................................................... 5-14 Carbon deposits from the upper part of cylinder - Remove .................................................... 5-14 End play of connecting rod big end - Measure ....................................................................... 5-14 Connecting rod cap - Remove ................................................................................................ 5-14 Piston - Remove ..................................................................................................................... 5-15 Piston ring - Remove .............................................................................................................. 5-15 Piston pin and Piston - Remove ............................................................................................. 5-15 Crankshaft end play - Measure............................................................................................... 5-16 Main bearing cap - Remove.................................................................................................... 5-16 Crankshaft - Remove.............................................................................................................. 5-16 Tappet - Remove .................................................................................................................... 5-16

5-1

Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and Valve mechanisms - Disassemble and Inspect

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part of the engine and to maintain the engine efficiently.

Depending on the maintenance purpose, inspect the following items before disassembling the engine. Valve clearance - Inspect Valve sinkage - Measure

1 Replace 9 4

10

8 Wear

3 Damaged threads, wear on rod contact surface

5

Wear on contact surface with valve cap, clogged oil holes

2 7

Wear, clogged oil holes

12

6

Wear at both ends, deflection

11 15 16

Fatigue, damage

17 20

Replace

Crack, damage, carbon deposits, water scale adhesion 14

Wear

21 Replace

13

Uneven wear Uneven wear on stems and faces, damage, fatigue 19 18

Cylinder heads and Valve mechanisms - Disassemble and Inspect Disassembling sequence 1 2 3 4 5 6 7

Rocker cover Adjusting screw Rocker shaft bracket bolt (short) Rocker shaft bracket bolt (long) Rocker shaft bracket Snap ring Rocker arm

8 9 10 11 12 13 14

Rocker arm Rocker shaft spring Rocker shaft Valve cap Push rod Cylinder head bolt Cylinder head

15 16 17 18 19 20 21

Valve cotter Valve retainer Valve spring Inlet valve Exhaust valve Valve stem seal Cylinder head gasket

5-3

Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.1 Valve clearance - Inspect Inspect the valve clearance, and recognize the current condition.

Inspect and Adjust” of “ASSEMBLY OF BASIC

Adjusting screw Lock nut

ENGINE”.

20 ± 2 N·m {2.0 ± 0.2 kgf·m} [15 ± 1.4 lbf·ft]

0.25 mm [0.0098 in.]

For the inspection procedure, refer to “Valve clearance -

Valve clearance - Inspect

1.2 Rocker shaft assembly - Remove Adjusting screw

Always loosen shorter bolts first. Failing to do so

Rocker bracket bolt

may cause the damage to the rocker shaft bracket.

(1) Loosen the adjusting screw on each rocker arm.

(2) Remove the rocker shaft bracket bolt (short).

(3) Remove the rocker shaft bracket bolt (long).

Rocker arm

(4) Remove the rocker shaft assembly from the cylinder head.

Note: Keep the removed rocker shaft assembly together with Rocker shaft assembly - Remove

the bolts.

(5) Remove push rods.

(6) Disassemble the rocker shaft assembly.

Rocker shaft spring

Note: Do not remove the rocker bushing unless it is defective or its inside diameter exceeds the limit.

Rocker shaft Rocker arm

Bracket Snap ring

Rocker shaft assembly - Disassemble

1.3 Cylinder head bolt - Remove Loosen cylinder head bolts in the numerical order as shown in the illustration.

2

6

10

14

18

22

21 25

17

13 9

Front

4 3

7 11 15 19 23 24 20 16 12 8 Number of bolts: 25

Cylinder head bolt - Remove

5-4

5

1

Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.4 Cylinder head assembly - Remove

When removing the cylinder head gasket, be careful

Cylinder head

not to damage the cylinder head or crankcase surface with the screwdriver or other tool.

(1) Lift up the cylinder head assembly, and remove the cylinder head assembly from the crankcase.

Note: If the cylinder head assembly cannot be removed due to crimping of the cylinder head gasket, tap the thick area on the side of the cylinder head using a plastic hammer to give a shock.

Cylinder head assembly - Remove

Do not lift up the cylinder head by yourself. Use a crane or lift it up with two persons.

(2) Remove the cylinder head gasket.

Note: If there is a cylinder head problem, check the bolts for tightness with a torque wrench before removing the cylinder head bolts.

1.5 Valve sinkage - Measure Measure the valve sinkage, and recognize the current condition.

Seat width

For the measurement procedure, refer to “Valve sinkage Measure” of “ASSEMBLY OF BASIC ENGINE”.

Valve seat angle

Valve margin Valve sinkage

Valve sinkage - Measure

1.6 Valve and Valve spring - Remove Using a valve spring pusher, compress the valve spring evenly and remove the valve cotters.

Valve spring pusher P/N:30691-04500

Note: If valves are reusable, mark each valve seat and the mating valve guide for identifying their original positions. Do not mix valve seats with other valves.

Valve and Valve spring - Remove

5-5

Chapter 5 DISASSEMBLY OF BASIC ENGINE

2. Rear equipment - Disassemble and Inspect Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part of the engine and to maintain the engine efficiently.

Depending on the maintenance purpose, inspect the following item before disassembling the engine. Flywheel face and radial runouts - Measure

4 2

3

1

Damaged threads

Replace

Crack, knock hole defect Lip wear, damage, aging

Crack, knock hole defect, gear damage Rotational state

Rear equipment - Disassemble and Inspect Disassembling sequence 1 Flywheel

5-6

2 Rear plate

3 Rear oil seal

4 Rear packing

Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.1 Flywheel face and radial runouts - Measure Measure the face and radial runouts of the flywheel, and recognize the current condition.

For the measurement procedure, refer to “Flywheel face and radial runouts - Measure” of “ASSEMBLY OF BASIC

Face runout measuring point

ENGINE”.

Radial runout measuring point

Flywheel face and radial runouts - Measure

2.2 Flywheel - Remove (Front)

(Rear)

(a) Be careful not to cut yourself with the ring gear when pulling out the flywheel. (b) Be careful not to drop or hit the flywheel. This may not only cause damage to the flywheel but also personal injury. (c) The personnel who holds the pulley must pay due attention to safety. Also, personnel must stay in close contact with each other during work.

Guide bolt

Prevent flywheel from rotating using wrench

Flywheel - Remove

(1) One personnel must firmly hold the pulley with a wrench to prevent the flywheel from rotating.

(2) Remove one bolt from the flywheel.

(3) Screw a guide bolt into the threaded hole of the bolt that has been removed.

(4) Remove remaining bolts from the flywheel.

(5) Hold the flywheel firmly with both hands, and by moving it back and forth, pull it out straight.

Note: The ring gear is shrink fitted to the flywheel. Do not remove the ring gear unless it is defective.

2.3 Rear plate - Remove

Be careful not to damage the oil seal.

Oil seal

Using a guide bolt, remove the rear plate from the crankcase.

Rear plate - Remove

5-7

Chapter 5 DISASSEMBLY OF BASIC ENGINE

3. Front equipment - Disassemble and Inspect Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part of the engine and to maintain the engine efficiently.

Depending on the maintenance purpose, inspect the following items before disassembling the engine. Damper face and radial runouts - Measure Timing gear backlash - Measure Idler gear and camshaft end play - Measure

Wear, damage

Flaking, uneven contact, damage, key groove defect, abnormal wear bushings

Clogged of oil hole, wear Wear, damage

11

Replace

5 13

12 Clogged oil hole

10 Replace Replace

15

Wear

7

14

9 4

Flaking, uneven contact, damage, key groove defect, abnormal wear bushings

Replace

8 Replace 6 Lip wear, damage, aging

Replace

Wear on belt groove Crack, knock hole defect Damaged threads 3

1 Crack, knock hole defect

2

Front equipment - Disassemble and Inspect Disassembling sequence 1 2 3 4 5

Damper Crankshaft pulley Cover Timing gear case Fuel injection pump

5-8

6 7 8 9 10

Oil pan Oil strainer Oil pump gear Thrust plate Idler gear

11 12 13 14 15

Camshaft Camshaft gear Thrust plate Front plate Oil pump

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.1 Damper face and radial runouts - Measure Measure the face and radial runouts of the damper, and recognize the current condition.

For the measurement procedure, refer to “Damper face and radial runouts - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Face runout Radial runout

Damper face and radial runouts - Measure

3.2 Damper and Crankshaft pulley - Remove (Front)

The bar that stops the crankshaft from rotating may

(Rear) Prevent crankshaft from rotating

come off. Pay due attention to safety.

(1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft. Stick a bar across the guide bolts to prevent the crankshaft from rotating.

(2) Remove the crankshaft pulley and the damper.

Guide bolt (M12 × 1.25 mm)

Damper and Crankshaft pulley - Remove

3.3 Timing gear case - Remove Cover

The front plate is bolted to the crankcase from inside the gear case. Do not attempt to remove the front plate together with the gear case by tapping.

(1) Remove the cover from the timing gear case.

(2) Remove the timing gear case from the front plate.

Note: Bolts have different lengths. Pay attention to the positions of bolts to ensure correct assembling.

Packing

Timing gear case

Timing gear case - Remove

3.4 Timing gear backlash - Measure Measure the timing gear backlash, and recognize the current condition.

Dial gauge

For the measurement procedure, refer to “Timing gear backlash - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Timing gear backlash - Measure

5-9

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.5 Idler gear and camshaft end play - Measure Measure the idler gear and camshaft end play, and recognize the current condition.

For the measurement procedure, refer to “Idler gear and camshaft end play - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Idler gear and camshaft end play - Measure

3.6 Fuel injection pump - Remove Remove the fuel injection pump from the front plate.

Fuel Injection pump

O-ring

Fuel injection pump - Remove

3.7 Oil pan - Remove Oil pan

Do not insert a chisel or screwdriver between the oil pan and crankcase to remove the oil pan, as it could deform the oil pan flange.

(1) Invert the engine.

(2) To remove oil pan from the crankcase, tap bottom corners of the oil pan with a plastic hammer.

Bolt

Oil pan - Remove

3.8 Oil strainer - Remove Remove the oil strainer from the crankcase.

Oil strainer

Oil strainer - Remove

5-10

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.9 Oil pump gear - Remove Remove the oil pump gear from the oil pump.

Oil pump gear

Oil pump gear - Remove

3.10 Idler gear - Remove Remove the idler gear from the crankcase.

Idler gear

Idler gear - Remove

3.11 Camshaft - Remove

Be careful not to damage the cams of camshaft and the bushings.

(1) Remove the thrust plate bolt.

Camshaft gear

(2) Remove the camshaft from the crankcase.

Camshaft - Remove

5-11

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.12 Camshaft gear - Replace 3.12.1 Camshaft gear - Remove Remove with press

Do not remove the camshaft gear from the camshaft unless the camshaft gear or the thrust plate is defec-

Camshaft gear

tive.

Using a press, remove the camshaft gear and thrust plate from the camshaft.

Thrust plate

Camshaft

Camshaft gear - Remove 3.12.2 Camshaft gear and Thrust plate - Install Press fit with press

(1) Install the woodruff key and the thrust plate on the camshaft.

Note: Be sure to install the thrust plate before installing the camshaft gear.

Camshaft gear

(2) Heat the camshaft gear with a gear heater to a tempera-

Thrust plate

ture of about 150°C [302°F].

(3) Press fit the camshaft gear with press.

Camshaft

Camshaft gear and Thrust plate - Install

3.13 Front plate - Remove Remove the front plate from the crankcase.

Note: If it is difficult to remove the front plate, lightly tap it with a plastic hammer.

Packing Front plate

Front plate - Remove

3.14 Oil pump - Remove Remove the oil pump from the crankcase.

Oil pump

O-ring

Oil pump - Remove

5-12

Chapter 5 DISASSEMBLY OF BASIC ENGINE

4. Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect Understanding current condition of the engine before disassembling is very important to investigate the faulty part of engine and to maintain the engine efficiently.

Depending on the maintenance purpose, inspect the following item before disassembling the engine. Piston protrusion - Measure End play of connecting rod big end - Measure Cylinder inside diameter - Measure Wear, damage

4 5 6

Fatigue

Scratches on outside surface, cracks, damage, wear, carbon deposits 19

Wear 7

9 Cracks, clogged oil holes

8

Wear, clogged oil holes

Wear

10 14

Damaged threads 3 Serration for cracks, wear Scratches on inside and outside surfaces, adhesion, flaking, wear

2

18

17

1

16 Adhesion of water scale, corrosion, flaking 15

Scratches, cracks, dent, clogged oil holes, wear

14

Flaking, uneven contact 14

Note: When replacing the crankcase, remove the parts installed in the crankcase (relief valve,etc.) carefully for reuse.

Scratches on inside and outside surfaces, adhesion, flaking Cracks

12

13

11 Damaged threads

Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect Disassembling sequence 1 2 3 4 5 6 7

Nut Connecting rod cap Connecting rod bearing No. 1 compression ring No. 2 compression ring Oil ring Snap ring

8 9 10 11 12 13 14

Piston pin Piston Connecting rod Main bearing cap bolt Main bearing cap Side seal Thrust plate

15 16 17 18 19

Lower main bearing Crankshaft Upper main bearing Tappet Crankcase

5-13

Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.1 Piston protrusion - Measure Measure the piston protrusion, and recognize the current condition.

For the measurement procedure, refer to “Piston protrusion - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Piston protrusion - Measure

4.2 Carbon deposits from the upper part of cylinder - Remove

Be sure to remove hard carbon deposits from the upper part of the cylinder before removing the piston.

They could cause damage to the piston and piston ring.

(1) Lay the engine on its side.

(2) Remove hard carbon deposits from the upper part of cylinder using a carbon remover.

Note: Be careful not to damage the inner surface of the cylinder.

Hard carbon

Carbon deposits from the upper part of cylinder Remove

4.3 End play of connecting rod big end - Measure Measure the end play of connecting rod big end, and recognize the current condition.

For the measurement procedure, refer to “End play of connecting rod big end - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Thickness gauge

End play of connecting rod big end - Measure

4.4 Connecting rod cap - Remove (1) Mark the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when assembling.

(2) Remove the connecting rod caps.

Note: Mark the cylinder No. and upper/lower on connecting rod bearings to ensure correct assembling.

Connecting rod cap - Remove

5-14

Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.5 Piston - Remove (1) Rotate the crankshaft to bring the piston to top dead center.

(2) Using a piece of wood such a hammer handle, push the mating surface of the connecting rod cap, and pull the piston and connecting rod upward from the cylinder.

Piston - Remove

4.6 Piston ring - Remove Remove the piston rings using piston ring pliers.

Piston ring pliers P/N:31391-12900

Piston ring - Remove

4.7 Piston pin and Piston - Remove (1) Remove the snap ring with snap ring pliers.

(2) Using a wooden block and mallet, remove the piston pin, and separate the piston from the connecting rod.

Note:(a) Do not tap the piston pin directly with a mallet.

Snap ring pliers

(b) If the piston is stubborn, heat the piston with a heater or in hot water.

Piston pin and Piston - Remove

5-15

Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.8 Crankshaft end play - Measure Measure the crankshaft end play, and recognize the current condition.

For the measurement procedure, refer to “Crankshaft end play - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Crankshaft end play - Measure

4.9 Main bearing cap - Remove

When removing the main bearing cap from the crankcase, be careful not to damage the lower main bearing or the lower thrust plate that are attached to the cap. Also be careful not to drop those parts, which may damage the crankshaft.

(1) Remove the main bearing cap bolt.

(2) Remove the main bearing cap.

(3) Remove the lower thrust plate from the rearmost main bearing cap.

Main bearing cap - Remove

4.10 Crankshaft - Remove

When placing the crankshaft onto a pallet or other stands, be careful not to damage the crankshaft.

Once placed on a pallet, the crankshaft should be locked in place to prevent it from rotating.

(1) Keeping the crankshaft in a horizontal position, slowly raise the crankshaft.

Note: Do not attach a metal chain or other hoisting devices directly onto the crankshaft, as they could damage the crankshaft. Place cloth belts or pads in position where a chain or other hoists are hooked before raising crankshaft.

(2) Remove the upper main bearing from the crankcase, paying attention to the lug position, and remove the upper thrust plate on the rear side.

4.11 Tappet - Remove Remove the tappets using a magnet.

Note: Be sure to arrange the removed tappets for assembling to the same tappet hole.

5-16

Crankshaft - Remove

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.

Cylinder head and Valve mechanism - Inspect and Repair ................................. 6-3 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12

2.

Rear equipment - Inspect and Repair .................................................................. 6-10 2.1 2.2 2.3

3.

Damper - Inspect visually ....................................................................................................... 6-11 Idler bushing inside diameter and Idler shaft outside diameter - Measure ............................. 6-11 Idler shaft - Replace................................................................................................................ 6-11 Cam lift of camshaft - Measure............................................................................................... 6-12 Camshaft runout - Measure .................................................................................................... 6-12 Camshaft journal outside diameter - Measure........................................................................ 6-12 Camshaft hole (bushing) inside diameter - Measure .............................................................. 6-13 Camshaft bushing - Replace .................................................................................................. 6-13 V-belt groove wear - Inspect................................................................................................... 6-14

Piston and Connecting rod - Inspect and Repair ............................................... 6-15 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

5.

Flatness of flywheel - Measure ............................................................................................... 6-10 Ring gear - Inspect ................................................................................................................. 6-10 Ring gear - Replace................................................................................................................ 6-10

Front equipment - Inspect and Repair ................................................................. 6-11 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

4.

Clearance between rocker bushing and rocker shaft - Measure .............................................. 6-3 Valve stem outside diameter and Valve guide inside diameter - Measure ............................... 6-3 Valve guide - Replace............................................................................................................... 6-4 Valve face - Inspect .................................................................................................................. 6-5 Valve face - Reface .................................................................................................................. 6-5 Valve seat - Reface .................................................................................................................. 6-6 Valve seat - Replace................................................................................................................. 6-6 Valve and Valve seat - Lap....................................................................................................... 6-8 Squareness and free length of valve spring - Measure ............................................................ 6-8 Pushrod runout - Measure ........................................................................................................ 6-8 Distortion of cylinder head bottom surface - Measure .............................................................. 6-9 Combustion jet - Replace ......................................................................................................... 6-9

Piston - Inspect visually .......................................................................................................... 6-15 Piston outside diameter - Measure ......................................................................................... 6-15 Piston ring groove - Inspect .................................................................................................... 6-16 Piston pin bore diameter and Piston pin outside diameter - Measure .................................... 6-16 Standard for piston ring replacement...................................................................................... 6-17 Clearance between connecting rod bearing and crankpin - Measure .................................... 6-18 Clearance between connecting rod bushing and piston pin - Measure .................................. 6-18 Connecting rod bushing - Replace ......................................................................................... 6-19 Weight difference of connecting rod assembly in one engine ................................................ 6-19 Connecting rod bearing - Inspect............................................................................................ 6-19 Connecting rod bend and twist - Inspect ................................................................................ 6-20

Crankcase and Crankshaft - Inspect and Repair ................................................ 6-21 5.1 5.2 5.3 5.4 5.5 5.6 5.7

Cylinder inside diameter - Measure ........................................................................................ 6-21 Crankcase top surface distortion - Measure ........................................................................... 6-22 Crankpin and Crank journal outside diameters - Measure ..................................................... 6-23 Crankpin and journal width - Measure .................................................................................... 6-23 Crankshaft - Grind .................................................................................................................. 6-24 Crankshaft runout - Measure .................................................................................................. 6-24 Crankshaft gear - Inspect ....................................................................................................... 6-25

6-1

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15

6-2

Crankshaft gear - Replace...................................................................................................... 6-25 Oil seal contact surface - Inspect............................................................................................ 6-25 Oil seal sleeve - Install............................................................................................................ 6-26 Oil seal sleeve - Remove........................................................................................................ 6-26 Main bearing - Inspect ............................................................................................................ 6-27 Clearance between main bearing and crank journal - Measure ............................................. 6-27 Thrust plate - Inspect .............................................................................................................. 6-27 Tappet - Inspect...................................................................................................................... 6-28

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder head and Valve mechanism - Inspect and Repair

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1.1 Clearance between rocker bushing and rocker shaft - Measure Measure the inside diameter of the rocker bushing and the outside diameter of the rocker shaft. If the clearance

Measuring direction

exceeds the limit, replace either rocker assembly or rocker

Measuring direction

shaft with a new one.

Nominal

Standard

Limit

Rocker bushing inside diameter

Item

ø19 mm [0.75 in.]

19.010 to 19.030 mm [0.7484 to 0.7492 in.]

-

Rocker shaft outside diameter

ø19 mm [0.75 in.]

18.980 to 19.000 mm [0.7472 to 0.7480 in.]

-

Clearance between rocker bushing and shaft

-

0.010 to 0.050 mm [0.0004 to 0.0020 in.]

0.070 mm [0.0028 in.]

Clearance between rocker bushing and rocker shaft Measure

1.2 Valve stem outside diameter and Valve guide inside diameter - Measure Measure the outside diameter of the valve stem and the inside diameter of the valve guide at the respective top and

Measuring directions

bottom ends in two crossing directions, since they are likely to wear more rapidly at both ends. If the outside diameter is less than the limit, or the clearance exceeds the limit, replace either the valve or the valve guide with a new one.

Item Valve stem outside diameter Clearance between valve stem and valve guide

Nominal

Standard

Inlet

ø8 mm 7.940 to 7.955 mm 7.900 mm [0.32 in.] [0.3126 to 0.3132 in.] [0.3110 in.]

Exhaust

ø8 mm 7.920 to 7.940 mm 7.850 mm [0.32 in.] [0.3118 to 0.3126 in.] [0.3091 in.]

Inlet

Exhaust

Valve guide mounting length

-

Measuring points

Limit

Valve stem outside diameter - Measure

0.065 to 0.095 mm 0.150 mm [0.0026 to 0.0037 in.] [0.0059 in.]

-

0.080 to 0.115 mm [0.0031 to 0.0045 in.]

14 mm [0.55 in.]

13.9 to 14.1 mm [0.547 to 0.555 in.]

0.200 mm [0.0079 in.]

Inside micrometer

Measuring directions

-

Measuring points

Valve guide inside diameter - Measure

6-3

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Valve guide - Replace

The valve guide must be inserted to the specified

Valve guide remover P/N:32A91-00300

depth. Be sure to use the valve guide installer when press-fitting the valve guide.

(1) Remove the valve guide using the valve guide remover.

(2) Use the valve guide installer to press-fit a new valve guide.

(3) Check contacts between valves and valve seats after replacing valve guides.

Valve guide - Remove Press Valve guide installer P/N:32A91-00100

13.9 to 14.1 mm [0.547 to 0.555 in.]

Valve guide - Press fit

6-4

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.4 Valve face - Inspect Apply a thin lead-free coloring paste on the valve face, and strike the valve face against the valve seat using a valve lapper to check for contact condition. If the contact is not even, or any defects are found, or if the limit is exceeded, reface or replace the valve.

Valve lapper

Note:(a) Inspect the valve face after the valve guide is repaired or replaced. (b) Do not rotate the valve when pressing the valve face coated with lead-free coloring paste against the

Lead-free coloring paste

valve seat.

Valve face - Inspect

(c) Always lap the valve and valve seat after the valve has been refaced or replaced.

Item Valve seat Valve angle seat Seat width

Nominal

Standard

Limit

30°

-

-

1.4 mm 1.26 to 1.54 mm [0.055 in.] [0.0496 to 0.0606 in.]

Valve margin

-

2.13 mm [0.0839 in.]

1.8 mm [0.071 in.]

Refacing permissible up to 1.83 mm [0.0720 in.]

Good

Bad

Contact condition between valve seat and valve

Seat width

Valve seat angle

Valve margin Valve sinkage

Valve-to-valve seat contact position

1.5 Valve face - Reface If the valve face is significantly worn out, reface the valve face using a valve refacer.

Valve refacer

Note:(a) Grind the valve face using the valve refacer at the specified angle. (b) Secure the valve margin width equal to or greater than the limit. If the dimensions after refacing does not meet the specified values, replace the valve with a new one.

Grind the valve face using the valve refacer at the specified angle.

Valve face - Reface

6-5

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.6 Valve seat - Reface (1) Use the valve seat cutter or valve seat grinder to reface the valve seat. After refacing, sand the valve seat lightly using 400 grit sandpaper, inserting it between the cutter and valve seat.

If the seat width exceeds the standard, grind the valve

Valve seat cutter

seat with the 60 degree valve seat cutter.

(2) Lap the valve in the valve seat.

Note:(a) Valve seat refacing should be kept to an absolute minimum. (b) If the seat width cannot be repaired to the standard

Valve seat - Reface

value, or valve contact surface moves to outside periphery of valve seat, replace the valve seat with a new one. (c) If the valve sinkage exceeds the limit after refacing, replace the valve seat with a new one.

1.7 Valve seat - Replace 1.7.1 Valve seat - Remove (by welding) To remove the valve seat, weld a stud to the valve seat as illustrated. Then, insert a shaft into the valve guide hole

Weld

Shaft

from the top of the cylinder head, and press out the valve seat with the shaft.

Valve seat

Note: Be careful not to allow spatters to adhere to the machined surface of the cylinder head during welding.

Stud

Valve seat - Remove

6-6

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

the valve seat, and confirm that the specified amount of interference is assured.

45°

ø46 +0.025 0 [1.81 +0.0010 0.00 ] Inlet

2 ± 0.1 [0.08 ± 0.004]

fitting bore of cylinder head and the outside diameter of

2 ± 0.1 [0.08 ± 0.004]

8 ± 0.1 [0.31 ± 0.004]

(1) Before installing the valve seat, measure the valve seat

8 ± 0.1 [0.31 ± 0.004]

1.7.2 Valve seat - Install

ø37 +0.025 0 [1.46 +0.0010 0.00 ] Exhaust

45° Unit: mm [in.]

Valve seat fitting bore (2) Cool the valve seat at least for four minutes in liquid nitrogen before fitting it into the cylinder head that is

Valve seat caulking tool P/N:36791-00200 (Inlet), 34491-03020 (Exhaust)

kept at room temperature.

(3) Install the valve seat into the cylinder head using a valve seat caulking tool.

Valve seat - Install

6-7

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Valve and Valve seat - Lap Always lap the valve against the valve seat after refacing the valve seat or after replacing the valve.

(1) Apply a thin coat of lapping compound evenly to the valve face.

Note:(a) Do not allow the compound to adhere on the valve stem. (b) Compound spreads more evenly if it is mixed with

Compound

a small amount of engine oil. (c) Use medium-grain compound (125 to 150 mesh) for initial lapping, then use fine-grain compound

Compound to valve face - Apply

(200 mesh) for finishing.

(2) Use a valve lapper for lapping.

Strike the valve against the valve seat while rotating the valve little by little.

Valve lapper

(3) Wash off the compound using diesel oil.

(4) Coat the contact surface of the valve with engine oil, then lap the valve again.

(5) Check valve face contact condition.

Valve and Valve seat - Lap

1.9 Squareness and free length of valve spring - Measure Measure the squareness and free length of valve spring. If the limit and standard are exceeded, replace the valve spring with a new one.

Spring squareness Nominal Free length

Standard

Limit

48.85 mm [1.9232 in.]

47.60 mm [1.8740 in.]

A B

Squareness

Lf

A = 1.5° or less B = 1.3 mm [0.051 in.] or less Lf = 48.85 mm [1.9232 in.]

43 mm [1.69 in.]/ 176 to 196 N {18 to 20 kgf} [39 to 44 lbf]

Set length/ load

B = 1.5 mm [0.059 in.] over entire length 43 mm [1.69 in.]/ 147 N {15 kgf} [33 lbf]

Free length

Squareness and free length of spring - Measure

1.10 Pushrod runout - Measure Measure the runout of push rod by TIR. If the run out exceeds the limit, replace the push rod with a new one.

Item Pushrod runout

Limit 0.6 mm [0.024 in.]

Remarks TIR

Push rod

1/2

1/2

Pushrod runout - Measure

6-8

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.11 Distortion of cylinder head bottom surface - Measure

Refacing of cylinder head should be kept to an absolute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve).

With a straight edge placed on the bottom face of the cylinder head, measure the bottom face distortion using a thickness gauge. If the distortion exceeds the limit, grind the Distortion of cylinder head bottom surface - Measure

cylinder head.

Item Distortion of cylinder head bottom surface

Standard

Limit

0.05 mm [0.0020 in.] or less

0.20 mm [0.0079 in.]

Note: Do not grind the surfaces more than 0.2 mm [0.0079 in.] in total (cylinder head bottom surface plus crankcase top surface).

1.12 Combustion jet - Replace Replace the combustion jet only when it has a defect such as Round rod

a crack.

(1) Insert a round bar (approx. ø6 mm [0.24 in.]) into glow plug hole, and tap the combustion jet inner face perimeter lightly to pull out the combustion jet.

Combustion jet

Combustion jet - Replace (2) When installing the combustion jet, align the positioning hole and jet nozzle with the center of the cylinder, press fit by tapping with a plastic hammer.

Combustion jet

Jet nozzle

Combustion jet - Press-fit

6-9

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

2. Rear equipment - Inspect and Repair 2.1 Flatness of flywheel - Measure Place the flywheel on a surface plate and move a dial gauge onto the friction surface of the flywheel to measure the flatness. Grind the friction surface of the flywheel if the limit is exceeded.

Item Flatness of flywheel

Standard

Limit

0.15 mm [0.0059 in.] or less

0.50 mm [0.0197 in.]

Flatness of flywheel - Measure

2.2 Ring gear - Inspect Inspect the ring gear for a missing tooth or wear on teeth, and if defects are found, replace the ring gear.

2.3 Ring gear - Replace 2.3.1 Ring gear - Remove (1) Heat the ring gear evenly using an acetylene torch or Flywheel

other appropriate heat source.

(2) With a rod placed on the periphery of ring gear, tap the rod with a hammer evenly around the ring gear, and remove the ring gear.

Ring gear

Ring gear - Remove 2.3.2 Ring gear - Install (1) Heat the ring gear evenly up to approx. 150°C [176°F] with an appropriate heater.

(2) Install the ring gear onto the flywheel with the no-gear chamfering side faced to the flywheel.

Note: Do not heat the ring gear excessively.

6-10

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

3. Front equipment - Inspect and Repair 3.1 Damper - Inspect visually Inspect the rubber on the damper. When it has a crack, replace it with a new one.

Rubber

Damper - Inspect visually

3.2 Idler bushing inside diameter and Idler shaft outside diameter - Measure Measure the idler bushing inside diameter and the idler shaft outside diameter. If the measurement exceeds the limit,

Measuring direction

replace the idler bushing with a new one. If the outside

Measuring points

diameter is less than the limit, replace the idler shaft with a new one.

Item

Standard

Limit

Clearance between idler bushing 0.009 to 0.050 mm 0.100 mm and idler shaft [0.0004 to 0.0020 in.] [0.0039 in.]

Idler bushing inside diameter and Idler shaft outside diameter - Measure

3.3 Idler shaft - Replace Remove the idler shaft with the idler shaft puller.

Note: When installing the idler shaft into the crankcase, ori-

Idler shaft puller P/N:MH061077

ent the idler shaft so that its oil hole faces the upper crankcase.

Item

Standard

Interference between shaft and crankcase hole

0.035 to 0.076 mm [0.0014 to 0.0030 in.]

Idler shaft - Replace

6-11

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Cam lift of camshaft - Measure Measure the major axis and minor axis of cam to determine cam lift. If the measured value is less than the limit, replace

Measuring points

the camshaft with a new one.

Item

Cam lift of camshaft (major axis minor axis)

Nominal

Standard

Limit

Inlet

6.684 mm [0.2631 in.]

6.384 to 6.784 mm 6.184 mm [0.2513 to [0.2435 in.]

0.2671 in.]

Exhaust

6.720 mm [0.2646 in.]

6.420 to 6.820 mm 6.220 mm [0.2528 to [0.2449 in.]

0.2685 in.]

Measuring directions

Cam lift of camshaft - Measure

3.5 Camshaft runout - Measure Measure the camshaft runout. If the limit is exceeded, correct the camshaft using a press, or replace the camshaft with a new one.

Note: With a dial gauge set on the camshaft, rotate the camshaft one turn and read the gauge indication.

Item

Standard

Camshaft runout

0.04 mm [0.0016 in.] or less

Limit

Remarks

0.10 mm TIR [0.0039 in.]

Camshaft runout - Measure

3.6 Camshaft journal outside diameter - Measure Measure the diameter of each camshaft journal in two direction at right angles to each other. If the limit is exceeded, Measuring points

replace the camshaft with a new one.

Item

Camshaft journal outside diameter

6-12

No.1, 2, 3 journal

No.4 journal

Nominal

Standard

Limit

φ 54

53.94 to 53.96 mm 2.1236 to 2.1244 in.]

53.90 mm [2.1220 in.]

φ 53

52.94 to 52.96 mm [2.0842 to 2.0850 in.]

52.90 mm [2.0827 in.]

Measuring directions

Camshaft journal outside diameter - Measure

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.7 Camshaft hole (bushing) inside diameter - Measure (1) Check the inside surface of each bushing for damage, corrosion, flaking and other abnormalities. If any defect is found, replace the camshaft bushing with a new one.

(2) Measure the camshaft bushing inside diameter with the bushing installed in the crankcase.

If the measurement exceeds the limit, replace the bush-

Measuring directions

ing with a new one.

Note: Do not damage the inside of camshaft bushing when measuring the inside diameter.

Item Clearance between camshaft journal and camshaft bushing

Standard

Limit

Camshaft hole (bushing) inside diameter - Measure

0.040 to 0.090 mm 0.15 mm [0.0016 to 0.0035 in.] [0.0059 in.]

3.8 Camshaft bushing - Replace 3.8.1 Camshaft bushing - Remove (1) Install a camshaft bushing installer set to the camshaft bushing.

Bushing

Adapter

(2) Remove the camshaft bushing by tapping the end of the rod of camshaft bushing installer set.

Camshaft bushing installer set P/N:30691-00010

Rod

Camshaft bushing - Remove 3.8.2 Camshaft bushing - Install (1) Install the camshaft bushing to a camshaft bushing

Piece

Bushing Adapter

installer set.

(2) When driving in a bushing, tap the end of rod of camshaft bushing installer set so that the oil hole in the bushing aligns with the oil hole to the oil gallery.

Camshaft bushing installer set P/N:30691-00010

Rod Oil hole

Camshaft bushing - Install

6-13

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.9 V-belt groove wear - Inspect Check the V-belt groove of the pulley for wear. Attach a new V-belt around the pulley, apply high tension and measure the sinkage of V-belt.

If the wear appears excessive, and the belt top surface sinks 1.6 mm [0.06 in.] or more down from the top edge of groove, replace the pulley with a new one. If the pulley has

1.6 mm [0.063 in.] or less

two or more grooves for belt, and the difference of the wear amount between grooves is significant, replace the pulley with a new one.

V-belt groove wear - Inspect

6-14

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

4. Piston and Connecting rod - Inspect and Repair 4.1 Piston - Inspect visually Check the combustion surface, piston pin bore, ring groove, sliding surface and bottom surface of the piston. If any defects are found, replace the piston with a new one.

Piston - Inspect visually

4.2 Piston outside diameter - Measure (1) Measure the piston outside diameter of the piston skirt Directions at right angles to piston pin

at right angles to the piston pin. If the measured value is less than the limit, replace the piston with a new one.

When replacing a piston in an engine, be sure to select a

Measuring points

replacement piston with a weight difference in the permissible range for that engine.

Piston outside diameter - Measure (2) The piston weight is stamped on the top of piston head.

Item

Nominal Standard

Piston outside diameter

+0.25 Size Over Size

ø94 mm [3.7 in.]

+0.50 Over Size Weight difference in one engine

Standard

Limit

93.955 to 93.985 mm [3.6990 to 3.7002 in.]

93.770 mm [3.6917 in.]

94.205 to 94.235 mm [3.7089 to 3.7100 in.]

94.020 mm [3.7016 in.]

94.455 to 94.485 mm [3.7187 to 3.7199 in.]

94.270 mm [3.7114 in.]

5 g [0.2 oz.] or less

-

Identification mark

Weight stamp

Number stamp Front mark

Piston weight stamping position

6-15

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.3 Piston ring groove - Inspect

Remove carbon from pistons and check the entire circumference of the piston.

(1) Remove all deposits such as carbon from each ring

No.1 compression ring groove

groove.

No.2 compression ring groove

(2) Check each ring groove for wear or damage. If faulty, replace the piston with a new one.

Oil ring groove

Piston ring groove - Inspect

4.4 Piston pin bore diameter and Piston pin outside diameter - Measure Measure the piston pin bore diameter and piston pin outside diameter. If the limit is exceeded, replace it with a new one.

Item

Nominal

Standard

Limit

Piston pin outside diameter

ø 30 mm [1.18 in.]

29.994 to 30.000 mm [1.1809 to 1.1811 in.]

-

Clearance between piston pin bore and piston pin outside diameter

-

0.000 to 0.016 mm [0.0006 in.]

0.050 mm [0.0020 in.]

Measuring points

Measuring directions

Piston pin bore diameter and piston pin outside diameter - Measure

6-16

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.5 Standard for piston ring replacement

Replace the piston rings with new ones during periodical overhauls. Sustained use of old piston rings can lead to abnormal engine operation.

If engine disassembly is necessary for some reason before the next periodical overhaul, piston ring replacement is not required provided that no abnormalities are found when making the following inspections.

Check the sliding surface and the top and bottom surfaces for seizing, sticking, abnormal wear, foreign substance biting and plating delamination. If any such traces are found, replace the piston rings with new ones.

4.5.1 Piston ring end gap - Measure Place the piston rings in a gauge or a new cylinder, and measure the gap of each ring with thickness gauges. If the limit is exceeded, replace all the rings as a set.

Thickness gauge

Note: Using a piston, push the piston ring squarely into the gauge or the cylinder.

Item

Standard

Limit

No. 1 compression ring

0.30 to 0.50 mm [0.012 to 0.020 in.]

1.50 mm [0.0591 in.]

Piston ring No. 2 compression ring end gap

0.50 to 0.70 mm [0.020 to 0.028 in.]

1.50 mm [0.0591 in.]

0.30 to 0.50 mm [0.012 to 0.020 in.]

1.50 mm [0.0591 in.]

Oil ring

End gap

Piston ring end gap - Measure

6-17

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.6 Clearance between connecting rod bearing and crankpin - Measure

When grinding crankpins, be sure to grind all the

Measuring directions

Measuring points

54 ± 5 N·m {5.5 ± 0.5 kgf·m} [40 ± 3.6 lbf·ft]

pins to the same size.

Finish the fillet radius to the specified dimension.

(1) Assemble the bearing into the big end of the connecting rod.

(2) Tighten the connecting rod cap to the specified torque.

(3) Measure the inside diameter of the connecting rod bearing.

Connecting rod bearing inside diameter - Measure

(4) Measure the crankpin outside diameter.

(5) Calculate the clearance from the difference between the inside diameter of the connecting rod bearing and outside diameter of the crankpin.

(6) If the clearance exceeds the limit, replace the connecting rod bearing with a new one.

(7) Measure the clearance between the connecting rod

Measuring directions

Measuring points

bearing and the crankpin again. Use the undersize bearing if the limit is exceeded.

(8) If an undersize bearing is used, grind the crankpin to the specified undersize.

Item Crankpin outside diameter

Clearance between crankpin and connecting rod bearing (oil clearance)

Crankpin outside diameter - Measure

Nominal

Standard

ø58 mm [2.28 in.]

57.955 to 57.970 mm 57.800 mm [2.2817 to [2.2756 in.]

2.2823 in.]

-

0.030 to 0.090 mm [0.0012 to 0.0035 in.]

Limit

0.200 mm [0.0079 in.]

4.7 Clearance between connecting rod bushing and piston pin - Measure Measure the inside diameter of the connecting rod bushing and the outside diameter of the piston pin. Replace if the limit is exceeded.

Item Bushing inside diameter Clearance between connecting rod bushing and piston pin

Nominal

Standard

ø30 mm 30.020 to 30.045 mm [1.18 in.] [1.1819 to 1.1829 in.]

-

0.020 to 0.091 mm [0.0008 to 0.0036 in.]

Limit

Measuring directions

0.120 mm [0.0047 in.]

Measuring points

Connecting rod bushing inside diameter - Measure

6-18

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Connecting rod bushing - Replace (1) Use the connecting rod bushing puller to replace the connecting rod bushings.

(2) With the bushing joints oriented as shown in the illus-

Connecting rod bushing puller P/N:32A91-00500 Matching marks side

tration, align the oil hole of bushing with the oil hole of connecting rod, and press-fit the connecting rod bushing into the connecting rod.

Oil hole

(3) After press-fitting, insert the piston pin, and make sure the smooth movement of the connecting rod and piston without looseness.

Bushing joint

Connecting rod bushing - Replace

4.9 Weight difference of connecting rod assembly in one engine When replacing a connecting rod, be sure to check the weight rank of the connecting rod. In one engine, all the connecting rods must be of the same weight rank.

Item

Tolerance on weight 10 g [0.35 oz.] or less

A

Weight difference of connecting rod assembly in one engine

Matching mark for assembly Weight rank mark

Weight difference of connecting rod assembly in one engine

4.10 Connecting rod bearing - Inspect Inspect the sliding surface, back surface and end surface of connecting rod bearing. If there is a damage such as poor contact, sliding scratches, corrosion and foreign substance biting, replace it with a new one.

Flaking

Scratches Adhesion

End face

Connecting rod bearing - Inspect

6-19

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.11 Connecting rod bend and twist - Inspect (1) Measure the dimensions of C and L as shown in the illustration to check the bend and twist of the connect-

Connecting rod cap tightening torque 54 ± 5 N·m {5.5 ± 0.5 kgf·m} [40 ± 3.6 lbf·ft]

ing rod. Straighten the connecting rod with a press to

C L

C

meet the standard.

Note: Before checking bend, tighten the connecting rod cap

L Piston pin

to the specified torque.

0.05 100

C L

[

(2) To inspect the connecting rod with the piston installed,

0.0020 ] 3.94

0.05 100

[

0.0020 ] 3.94

L

C

turn the piston upside down and place it on a surface plate. Insert a round bar having the same diameter as

Unit: mm [in.]

the crankpin into the big-end bore, and measure the

Connecting rod bend and twist - Inspect

height of the bar using a dial gauge.

Item

Standard

Limit

Connecting rod bend and twist

0.05/100 mm [0.0020/3.94 in.] or less

0.15/100 mm [0.0020/3.94 in.]

Connecting rod twist

Connecting rod bend

Unit: mm [in.]

D C

C D

0.05 100

[

0.0020 ] 3.94

A

Measuring with dial gauge

6-20

B

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

5. Crankcase and Crankshaft - Inspect and Repair 5.1 Cylinder inside diameter - Measure (1) Measure the inside diameter of the cylinder at three levels, i.e., upper (position of No.1 compression ring when

11 [0.43] 80 [3.15]

in both directions parallel to and perpendicular to the crankshaft direction.

(2) If the measurement is between the repair limit and replacement limit, re-bore the cylinder to +0.25 mm [0.0098 in.] or +0.5 mm [0.0197 in.] oversize. Hone the re-bored cylinder to the accuracy of the standard.

(3) Use an oversize piston and piston rings to fit the rebored cylinder.

150 [5.91]

Measuring directions

piston is at top dead center), middle, and lower levels,

Measuring points Unit: mm [in.]

Cylinder inside diameter - Measure

(4) If the cylinder is worn unevenly, select an oversize that ensures complete cylindricity when the cylinder is rebored to the maximum. All cylinders must be rebored to the same oversize if one cylinder is re-bored.

(5) If the cylinder has a slight wear and is reused after replacing only the piston rings, remove the steps in worn portion in the upper part of the cylinder using a ridge reamer. Hone it as necessary.

Item Cylinder inside diameter

Roundness Cylindricity

Nominal

Standard

Limit

ø 94 mm [3.70 in.]

94.000 to 94.035 mm [3.7008 to 3.7022 in.]

Repair limit: 94.200 mm [3.7087 in.]

Replace limit: 94.700 mm [3.7283 in.]

-

0.01 mm [0.0004 in.] or less

-

-

0.015 mm [0.0006 in.] or less

-

Refacing using a ridge reamer

6-21

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.2 Crankcase top surface distortion - Measure

Refacing of crankcase should be kept to an absolute minimum.

Excessive grinding of the crankcase may result in defects such as defective combustion and stamping (contact between piston and valve).

Apply a straight edge to the top surface of the crankcase and measure its distortion using a thickness gauge. If the distortion exceeds the limit, grind the cylinder head using a surCrankcase top surface distortion - Measure

face grinder.

Note: Do not overgrind the crankcase, as the piston protrusion deviates from the standard value.

Item

Standard

Limit

Crankcase top surface distortion

0.05 mm [0.0020 in.] or less

0.20 mm [0.0079 in.]

Note: Do not grind the surfaces more than 0.2 mm [0.0079 in.] in total (cylinder head bottom surface plus crankcase top surface).

6-22

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.3 Crankpin and Crank journal outside diameters - Measure (1) Measure the outside diameter of the crankpins and crank journals. If the limit is exceeded, grind the pin or journal to fit the diameter of the next undersize bearing.

(2) Determine the out-of-roundness, the out-of-cylindricity (taper) and clearance between bearing based on the outside diameters that have been measured.

Measuring directions

Measuring points

(3) If the measured value is less than the repair limit, grind it to the specified undersize. If the measured value is less than the service limit, replace it with a new one.

Item

Nominal

Standard

Limit

ø58 mm [2.28 in.]

57.955 to 57.970 mm [2.2817 to 2.2823 in.]

Service limit: 57.800 mm [2.2756 in.]

ø78 mm [3.07 in.]

77.955 to 77.970 mm [3.0691 to 3.0697 in.]

Repair limit: 77.850 mm [3.0650 in.]

Service limit: 77.100 mm [3.0354 in.]

Roundness

-

0.01 mm [0.0004 in.] or less

0.03 mm [0.0012 in.]

Cylindricity

-

0.01 mm [0.0004 in.] or less

0.03 mm [0.0012 in.]

-

Pin maximum defection: 0.01 mm [0.0004 in.] or less.

-

Crankpin outside diameter

Crank journal outside diameter

Pin and journal

Parallelism

Crankpin outside diameter - Measure

Measuring Measuring directions points

Crank journal outside diameter - Measure

5.4 Crankpin and journal width - Measure (1) Inspect the either end of crankpin and crank journal width for harmful scratch and wear.

(2) Measure the crankpin and crank journal width.

Item

Nominal

Standard

Crankpin width

33 mm [1.299 in.]

33 to 33.1 mm [1.299 to 1.303 in.]

Rearmost crank journal width

31 mm [1.2205 in.]

31 to 31.039 mm [1.2205 to 1.2220 in.]

Crankpin width

Rearmost crank journal width

Note:(a) The purpose of measuring the crankpin and crank journal width is to make sure the end play of the big end of the connecting rod and crankshaft are appro-

Crankpin and crank journal width - Measure

priate. (b) Width of rearmost crank journal is important to select the thickness of thrust plate. (c) Always inspect the width of the crankpin and crank journal when regrinding the shaft.

6-23

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.5 Crankshaft - Grind

(a) When grinding crank journals, be sure to grind all

R3mm [0.12in.]

R3mm [0.12in.]

the journals to the same size. (b) Finish the fillet radius to the specified dimension.

Grind the crank journal (or pin) to the diameter that fits the inside diameter of the next undersized main (or connecting)

R3mm [0.12in.]

bearing. By doing so, checking the fit with an actual bearing can be omitted. When grinding, be careful not to change the fillet radius and width.

If the surface hardness is considered to have been reduced,

Crankshaft - Grind

re-harden the crankshaft and check for flaws by means of magnetic particle inspection. Ensure that the surface finish accuracy of the crankpins and crank journals is kept within the standard even after the correction by grinding. After grinding the crankshaft, measure the width of crankpin and crank journal.

Item

Crank journal

Crankpin

Undersize

Finishing dimension

0.25 mm [0.0098 in.]

77.705 to 77.720 mm [3.0592 to 3.0598 in.]

0.50 mm [0.0197 in.]

77.455 to 77.470 mm [3.0494 to 3.0500 in.]

0.75 mm [0.0295 in.]

77.205 to 77.220 mm [3.0396 to 3.0402 in.]

0.25 mm [0.0098 in.]

57.705 to 57.720 mm [2.2718 to 2.2724 in.]

0.50 mm [0.0197 in.]

57.455 to 57.470 mm [2.2620 to 2.2626 in.]

0.75 mm [0.0295 in.]

57.205 to 57.220 mm [2.2522 to 2.2528 in.]

5.6 Crankshaft runout - Measure Support the crankshaft at the front and rear journals with Vblocks, and measure the crankshaft runout at the center journal using a dial gauge. If the runout deviates from the standard only slightly, grind the crankshaft to repair. If the runout exceeds the standard considerably, straighten the crankshaft using a press.

If the limit is exceeded, replace the crankshaft.

If the crankshaft has been repaired by grinding or pressing, inspect the crankshaft for cracks and other harmful damage using a magnetic particle method.

Item Crankshaft runout

6-24

Standard 0.04 mm [0.0016 in.] or less

Crankshaft runout - Measure Limit

Remarks

0.10 mm TIR [0.0039 in.]

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.7 Crankshaft gear - Inspect If there are faults on the crankshaft gear tooth, such as flaking, wear, tooth contact, replace the crankshaft gear with a new one.

5.8 Crankshaft gear - Replace 5.8.1 Crankshaft gear - Remove Using a gear puller, remove the gear from the crankshaft.

Note: Do not strike the gear with a hammer.

Crankshaft gear

Gear puller P/N:MH061326

Crankshaft gear - Remove 5.8.2 Crankshaft gear - Install (1) Install the key on the crankshaft.

(2) Press-fit the gear fully in alignment with the key.

Key Aligning position

Crankshaft gear

Crankshaft gear - Install

5.9 Oil seal contact surface - Inspect Inspect the oil seal contact surface located on the crankshaft rear part. If the crankshaft wears due to the oil seal, replace the oil seal and the oil seal sleeve with new spare parts.

Oil seal

Oil seal sleeve

Oil seal contact surface

Oil seal contact surface - Inspect

6-25

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.10 Oil seal sleeve - Install Oil seal sleeve installer set P/N:30691-13010

Be careful not to hit or damage the outside surface of sleeve.

When installing the oil seal sleeve, apply the oil to the inside of the oil seal sleeve, and drive it into the crankshaft

Guide P/N:30691-13100

by using oil seal sleeve installer set.

When the engine is operated again and the oil seal sleeve wears, remove the oil seal sleeve by using following method and replace the oil seal assembly (oil seal and oil seal sleeve) with the new spare parts.

Installer P/N:30691-13200

Oil seal sleeve - Install

Oil seal

Oil seal sleeve

Oil seal contact surface

Oil seal contact surface - Inspect

5.11 Oil seal sleeve - Remove

When making a cut in the sleeve, be very careful not to damage the crankshaft with the chisel.

Make a cut at three locations on the periphery of the oil seal sleeve to reduce its tension. To do so, hold a chisel against the sleeve periphery in the radial direction and strike it with a hammer. When the sleeve is loosened, remove the sleeve.

If the sleeve can not be removed by the above procedure, hold the chisel against the sleeve in the axial direction and tap on it lightly to make the sleeve expand. Once the interference between the crankshaft and sleeve is eliminated, the sleeve will be removed easily.

6-26

Oil seal sleeve - Remove

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.12 Main bearing - Inspect Inspect the sliding surface, back surface and end surface of main bearings. If there is a damage such as poor contact, sliding scratches, corrosion and foreign substance biting,

Scratch, corrosion, flaking

replace it with a new one.

End

Main bearing - Inspect

5.13 Clearance between main bearing and crank journal - Measure (1) Install the main bearings.

(2) Secure the main bearing cap to the specified torque.

Measuring directions

(3) Measure the inside diameter of the main bearings.

(4) Measure the outside diameter of the crank journal.

(5) Calculate the clearance between the inside diameter of the main bearing and outside diameter of the crank

Measuring points

journal.

(6) If the clearance exceeds the limit, replace the main bearing.

(7) Measure the clearance between the main bearing cap and the crank journal again. Use the undersize bearing

103 ± 5 N·m {10.5 ± 0.5 kgf·m} [76 ± 3.6 lbf·ft]

Main bearing inside diameter - Measure

if the limit is exceeded.

(8) If an undersized bearing is used, grind the crank journal to the undersized specification.

Item Clearance between main bearing and crank journal

Standard

Limit

0.050 to 0.110 mm 0.200 mm [0.0020 to 0.0043 in.] [0.0079 in.]

Measuring Measuring directions points

Crank journal outside diameter - Measure

5.14 Thrust plate - Inspect Inspect the sliding surface of the thrust plates. If there is a damage such as poor contact, sliding scratches, corrosion and foreign substance biting, replace the thrust plate with a new one.

Scratch, corrosion flaking

Thrust plate - Inspect

6-27

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.15 Tappet - Inspect 5.15.1 Contact surface of tappet and camshaft Inspect the cam contact surface of the tappets. Fit new tappets if the surface is excessively worn or damaged.

Good

Bad

Bad

Contact surface of tappet and camshaft 5.15.2 Contact surface of tappet and push rod (1) Apply lead-free coloring paste on the push rod, and check the contacts.

Good

Bad Section A - A

(2) Check that the push rod contacts the tappet concentrically. If it does, replace the tappet and push rod with a new one.

A Push rod should not contact tappet concentrically.

A

It should be round.

Dent should not be exist.

Contact surface of tappet and push rod 5.15.3 Clearance between tappet and tappet guide hole - Measure

Measuring points

Measuring directions

Measure clearance between the tappet and tappet hole. If the limit is exceeded, replace the tappet with a new one.

Item

Standard

Limit

14.000 to 14.018 mm [0.5512 to 0.5519 in.]

14.100 mm [0.5551 in.]

Clearance between tappet and 0.016 to 0.052 mm tappet guide hole [0.0006 to 0.0020 in.]

0.08 mm [0.0031 in.]

Tappet guide hole inside diameter

Clearance between tappet and tappet guide hole Measure

6-28

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.

Piston, Connecting rod, Crankshaft and Crankcase - Assemble........................ 7-3 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17

2.

Front equipment - Assemble ................................................................................ 7-10 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17

3.

Oil pump - Install..................................................................................................................... 7-10 Front plate - Install .................................................................................................................. 7-10 Camshaft - Install.................................................................................................................... 7-10 Idler gear - Install .................................................................................................................... 7-11 Oil pump gear - Install............................................................................................................. 7-11 Fuel injection pump - Install .................................................................................................... 7-11 Timing gear backlash - Measure ............................................................................................ 7-12 Idler gear end play - Measure................................................................................................. 7-12 Camshaft end play - Measure................................................................................................. 7-12 Front oil seal - Install............................................................................................................... 7-12 Timing gear case - Install........................................................................................................ 7-13 Oil strainer - Install.................................................................................................................. 7-13 Oil pan - Install........................................................................................................................ 7-14 Crankcase - Invert .................................................................................................................. 7-14 Cover - Install.......................................................................................................................... 7-15 Damper and Crankshaft pulley - Install................................................................................... 7-15 Damper face and radial runouts - Measure ............................................................................ 7-15

Rear equipment - Assemble ................................................................................. 7-16 3.1 3.2 3.3 3.4

4.

Crankcase - Invert .................................................................................................................... 7-3 Tappet - Install .......................................................................................................................... 7-3 Upper main bearing - Install...................................................................................................... 7-3 Rear upper thrust plate - Install ................................................................................................ 7-4 Crankshaft - Install.................................................................................................................... 7-4 Lower main bearing and Lower thrust plate - Install ................................................................. 7-4 Main bearing cap - Install.......................................................................................................... 7-5 Crankshaft end play - Measure................................................................................................. 7-5 Side seal - Insert....................................................................................................................... 7-6 Piston and Connecting rod - Assemble .................................................................................... 7-6 Piston ring - Install .................................................................................................................... 7-7 Piston installation - Prepare...................................................................................................... 7-7 Connecting rod bolt and Upper connecting rod bearing - Install............................................... 7-7 Piston - Install ........................................................................................................................... 7-8 Connecting rod cap - Install ...................................................................................................... 7-8 End play of connecting rod big end - Measure ......................................................................... 7-9 Piston protrusion - Measure...................................................................................................... 7-9

Rear oil seal - Install ............................................................................................................... 7-16 Rear plate - Install................................................................................................................... 7-16 Flywheel - Install ..................................................................................................................... 7-16 Flywheel face and radial runouts - Measure........................................................................... 7-17

Cylinder head and Valve mechanism - Assemble .............................................. 7-18 4.1 4.2 4.3 4.4 4.5 4.6 4.7

Cylinder head - Assemble....................................................................................................... 7-18 Valve sinkage - Measure ........................................................................................................ 7-18 Cylinder head gasket - Install ................................................................................................. 7-19 Cylinder head assembly - Install............................................................................................. 7-19 Cylinder head bolt - Tighten.................................................................................................... 7-19 Push rod - Insert ..................................................................................................................... 7-19 Rocker shaft assembly - Install............................................................................................... 7-20

7-1

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.8 4.9

7-2

Valve clearance - Inspect and Adjust ..................................................................................... 7-21 Rocker cover - Install .............................................................................................................. 7-22

Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Piston, Connecting rod, Crankshaft and Crankcase - Assemble

Chapter 7 ASSEMBLY OF BASIC ENGINE

1.1 Crankcase - Invert Using a chain block and tackle or similar tool, turn the crankcase to lay it on its side. Then, fasten wire ropes to the crankcase and turn it over.

Crankcase - Invert

1.2 Tappet - Install Apply engine oil onto the periphery of tappets, insert them into the tappet holes.

1.3 Upper main bearing - Install

(a) Do not apply engine oil to the back of the shells and main bearing fitting bores in the crankcase when installing the main bearing shells. Install the main bearings after cleaning off foreign matters as well as oil and grease from these surfaces using cleaning solvent. (b) Install the main bearings correctly. Do not confuse upper shells with lower shells.

The upper shells are identified by a machined oil groove. The lower shells have no oil groove and are finished flat. It is possible to install the main bearing to wrong side, but it damages the crankshaft. (c) Do not damage the bearings when installing.

(1) Clean the main bearing fitting bores and main bearing Upper main bearing

cap seating surface, and make sure that these surfaces are free from any foreign matter.

(2) Make sure that the main bearings are neither damaged nor contaminated.

(3) Fit the upper main bearing shells in the crankcase bores while aligning their lugs with the corresponding notches in the crankcase.

Note:(a) Make the main bearing end protrusion from the crankcase bore even at both ends. (b) The oil hole in the upper main bearing will be

Align with lug groove.

Upper main bearing - Install

aligned with the oil hole in the crankcase by fitting the lug of the upper shell into the notch in the crankcase.

(4) Apply an even coat of engine oil to the sliding surface of each upper main bearing.

7-3

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.4 Rear upper thrust plate - Install

Do not damage the thrust plate when installing.

(1) Install the thrust plate to the dowel pin on the rearmost end of crankcase with facing the oil groove to the engine rear side.

Oil groove

(2) Apply engine oil evenly to the sliding surface.

Align with lug groove.

Rear upper thrust plate - Install

1.5 Crankshaft - Install (1) Make sure that the upper main bearing shells that are installed in the crankcase bores have their inner periphery (the surface comes into contact with the journal) lubricated with an even coat of fresh engine oil.

(2) Wash the crankshaft thoroughly with cleaning oil and clean it completely by blowing compressed air. Then, apply an even coat of fresh engine oil to the crankshaft journals.

Note: When cleaning the crankshaft, pay special attention to the oil holes in the crank journals and crankpins. Make

Crankshaft - Install

sure that oil holes are free from any burrs.

(3) Keeping the crankshaft in a horizontal position, slowly install into the crankcase.

Note: Do not attach a metal chain or other hoisting devices directly onto the crankshaft, as they could damage the crankshaft. Place cloth belts or pads in position where a chain or other hoists are hooked before raising crankshaft.

1.6 Lower main bearing and Lower thrust plate - Install (1) Install the lower main bearing, aligning with the lug groove of the main bearing cap.

Lower main bearing

Note: Make a protrusion amount of bearings even.

(2) Apply an even coat of engine oil to the sliding surface of each lower main bearing.

(3) Install the lower thrust plate to the dowel pin on the

Lower thrust plate

rearmost main bearing cap.

Note: Install the lower thrust plate so that its oil groove faces

Main bearing cap

outward.

Lower thrust plate

Lower main bearing and Lower thrust plate - Install

7-4

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.7 Main bearing cap - Install

Be

sure

to

observe

the

specified

tightening

Apply ThreeBond 1212 to corner of cap

sequence when installing the main bearing cap bolts.

(1) Make sure the main bearing and thrust plate that were installed to the main bearing cap are lubricated with an even coat of fresh engine oil.

(2) Install the main bearing cap from the front side to the rear side of the engine with the arrow on the bottom of the main bearing cap facing the front side of the engine.

All of the lug grooves on the main bearing cap should

Main bearing cap - Install

be in the same position.

(3) Coat the threads of the main bearing cap and washer with engine oil, and tighten the bolts temporarily.

(4) Tap on each main bearing cap with a soft-head hammer to drive it into position.

Note: The foremost and rearmost main bearing caps should be flat with the end face of the crankcase.

(5) Apply engine oil to the threads and bolt seat surface.

103 ± 5 N·m {10.5 ± 0.5 kgf·m} [76 ± 3.6 lbf·ft] [Wet]

(6) Tighten the main bearing cap bolts alternately and progressively to the specified torque.

(7) Tighten the rearmost main bearing cap bolt until its seat

Main bearing cap bolt - Install

surface contacts lightly with the main bearing cap.

Measure the crankshaft end play in this condition.

1.8 Crankshaft end play - Measure (1) Measure the crankshaft end play (clearance between the crank arm at the thrust force receiving journal and the bearing cap with thrust plate attached). If the limit is exceeded, replace the thrust plate with a new one.

(2) If the limit is still exceeded after a new thrust plate has been installed, use an oversize thrust plate.

Note: In general, the rear thrust plate wears faster than the front thrust plate. Therefore, in most cases, the correction is achieved by replacing the rear thrust plate with a next oversize one.

Crankshaft end play - Measure

Item Crankshaft end play

Standard

Limit

0.100 to 0.264 mm [0.0039 to 0.0104 in.]

0.300 mm [0.0118 in.]

Crankshaft thrust size after grinding One side Oversize

Both sides Oversize

+0.15 mm [0.0059 in.]

Oversize

31.15 mm [1.2264 in.]

31.30 mm [1.2323 in.]

+0.30 mm [0.0118 in.]

Oversize

31.30 mm [1.2323 in.]

31.45 mm [1.2382 in.]

Item

Tolerance

+0.039 0 mm +0.0015 [ 0.00 in.]

7-5

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.9 Side seal - Insert (1) Apply a sealant (ThreeBond 1212) to the outer periphery of new side seals.

(2) With the round section of the side seals facing outward, press them partway into the front and rear caps using

Side seal

Crankcase Bearing cap

hands.

(3) When the side seals are installed partway into caps, use a tool with flat surface such as flat-head screwdriver to install completely, taking care not to bend them.

R section

Note: Make sure that the rear bearing cap rear face is flushed with the engine rear face.

Apply Threebond 1212 to side seal.

Side seal - Insert

1.10 Piston and Connecting rod - Assemble (1) Apply engine oil to the piston pin, and assemble the

A

piston and the connecting rod, observing the orientation

View A

of piston and connecting rod shown in the illustration.

Note: The piston and piston pins are assembled to each other

Front mark

with a clearance fit. However, the piston pins are more easily inserted into the pistons if the pistons are warmed up with a heater or with hot water.

(2) Install the snap ring with ring pliers. Make sure the

Weight stamp

Matching mark with connecting rod cap

snap ring is fully inserted into the ring groove.

Assembling direction of piston and connecting rod

Snap ring pliers

Piston and Connecting rod - Assemble

7-6

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.11 Piston ring - Install

Every piston ring has a top mark such as an “R” near

Piston ring plier P/N:31391-12900

the end gap. Install all piston rings with this mark facing upward.

No.1 compression ring

Top mark

No.2 compression ring

If the rings are installed upside down, it could cause malfunctions such as excessive oil consumption or engine seizing.

Oil ring

(1) Install the piston rings to the piston with a ring expander.

(2) Install the oil ring with its end gap 180° away from the

Combination of piston and piston ring

joint of the coil spring, as shown in the illustration.

Coil spring joint

180°

Oil ring ends

Oil ring end gap and coil spring joint orientation

1.12 Piston installation - Prepare (1) Lay the engine along its side.

(2) Clean the cylinder inner surface and the crankpin, and apply engine oil to the cylinder.

Cleaning cylinder inner surface and applying engine oil

1.13 Connecting rod bolt and Upper connecting rod bearing - Install

Do not apply engine oil to the back of the bearings.

Lug groove

Install the upper connecting rod bearing into the connecting rod big end while aligning its lug with the lug groove, and apply engine oil to the sliding surface.

Note: When press fitting the bolt, make sure that the bolt ful-

Apply engine oil.

ly contacts its seating position without any interference with the shoulder of mounting surface.

Connecting rod bolt and Upper connecting rod bearing - Install

7-7

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.14 Piston - Install Camshaft side

Do not forcefully insert the piston, as it may cause

No.1 compression ring ends

Thrust direction

damage to the piston rings and crankpin.

180°

(1) Apply engine oil to the circumference of the piston and piston rings.

(2) The piston rings end gaps should be equally spaced from each other, avoiding thrust and anti-thrust direction and pin direction.

(3) Rotate the crankshaft to bring the crankpin of the cylinder to bottom dead center.

(4) Orientate the front mark on the top of piston toward engine front.

No.2 compression ring ends

Oil ring ends 60°

Anti-thrust direction

60°

Combustion chamber side

Orientation of piston ring end gaps Piston installer P/N:34491-00200

(5) Insert the piston from the top face of crankcase using a piston installer.

Front mark

Piston - Install

1.15 Connecting rod cap - Install

(a) Make sure that the matching marks of the rod and connecting rod cap positions are on the same side. (b) When fitting the connecting rod caps, make sure that dust, metal particles, etc. are not caught between bolt seating surfaces and in the bolt threads.

54 ± 5 N·m {5.5 ± 0.5 kgf·m} [40 ± 3.6 lbf·ft]

(1) Install the lower connecting rod bearing, aligning with the lug groove of the connecting rod bearing cap.

(2) Apply engine oil to the connecting rod bolt threads and seating surface, and the sliding surface of the connecting rod bearing shell.

(3) Install the connecting rod cap with its matching mark facing on the same side as the matching mark on the connecting rod.

(4) Tighten the connecting rod cap nuts evenly and alternately to the specified torque.

(5) Inspect end play of the connecting rod. If end play is small, loosen and retighten the cap nuts.

7-8

Connecting rod cap - Install

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.16 End play of connecting rod big end - Measure (1) Install the connecting rods onto the respective crankpins and tighten the connecting rod cap bolts to the specified torque.

(2) Measure the clearance to the crank arm (end play) at two positions (above and below the crankpin) with a thickness gauge.

(3) If the limit is exceeded, replace the connecting rod with

Thickness gauge

a new one.

Item Connecting rod end play

Standard

Limit

0.15 to 0.35 mm 0.50 mm [0.0059 to 0.0138 in.] [0.0197 in.]

End play of connecting rod big end - Measure

1.17 Piston protrusion - Measure

Piston protrusion must always meet the standard, as the amount of protrusion not only influences engine performance, but it also prevents valve interference.

Measure the protrusion of each piston following the instructions below. If the measured value does not meet the standard, inspect the clearances between various parts involved.

(1) Bring the piston to top dead center.

(2) Apply the dial gauge to the top surface of the crankPiston protrusion - Measure

case, and zero the dial gauge.

(3) Measure the protrusion at four points on the piston head, and calculate the mean value.

Note: The top clearance (clearance between the piston top surface and the cylinder head bottom surface) can be determined by the measured piston protrusion and thickness of the cylinder head gasket.

Top clearance = Thickness of cylinder head gasket Piston protrusion Item

Standard

Piston protrusion

-0.25 to 0.15 mm [-0.0098 to 0.0059 in.]

Thickness of cylinder head gasket

1.15 to 1.25 mm [0.0453 to 0.0492 in.]

Top clearance

1.0 to 1.0 to 1.5 mm [0.039 to 0.059 in.]

7-9

Chapter 7 ASSEMBLY OF BASIC ENGINE

2. Front equipment - Assemble 2.1 Oil pump - Install Install the new O-ring to the oil pump case, then, install the oil pump to the crankcase.

Oil pump

O-ring

Oil pump - Install

2.2 Front plate - Install (1) Apply sealant (ThreeBond 1211) to the crankcase mating surface to the front plate.

Packing

(2) Apply the same sealant (ThreeBond 1211) to the packing, and then install the front plate packing, and attach

Front plate

the packing.

(3) Tighten the bolt with the specified torque.

(4) Check that the lower end of the front plate is flush with the bottom surface of the crankcase. Cut off any excess packing neatly.

11.5 ± 1.5 N·m {1.15 ± 0.15 kgf·m} [8.3 ± 1.1 lbf·ft]

Front plate - Install

2.3 Camshaft - Install

Be careful not to damage camshaft journals, cams and camshaft holes during insertion.

(1) Apply engine oil to the camshaft journals and cams.

11.5 ± 1.5 N·m {1.15 ± 0.15 kgf·m} [8.3 ± 1.1 lbf·ft]

(2) Slowly insert the camshaft assembly.

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

(4) Make sure that the camshaft rotates lightly. Move the camshaft gear back and forth, and check the end play.

Camshaft - Install

7-10

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.4 Idler gear - Install (1) Apply engine oil evenly to the idler shaft.

(2) Install the idler gear with its matching marks aligned with the marks on the crankshaft gear and camshaft

Idler gear

gear.

(3) Install the thrust plate and tighten bolts to the specified torque.

34 ± 5 N·m {3.5 ± 0.5 kgf·m} [25 ± 3.6 lbf·ft]

Idler gear - Install Oil pump gear

Crankshaft gear

Fuel injection pump gear

1

2

22

33

3

11

Idler gear

Camshaft gear

Timing gear train

2.5 Oil pump gear - Install (1) Install the oil pump gear to the oil pump shaft.

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

Oil pump gear

33 ± 5 N·m {3.4 ± 0.5 kgf·m} [24.6 ± 3.6 lbf·ft]

Oil pump gear - Install

2.6 Fuel injection pump - Install Install the fuel injection pump gear with its matching marks aligned with the marks on the idler gear, then, tighten the bolt.

Fuel injection pump gear

Fuel injection pump - Install

7-11

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.7 Timing gear backlash - Measure Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge applied to a tooth flank on the pitch circle at a

Dial gauge

right angle to the tooth axis, or measure the clearance between gears by inserting a thickness gauge between the gears at the tooth-to-tooth contacting area. If the limit is exceeded, replace the gears with new ones.

Item Timing gear backlash

Standard

Limit

0.05 to 0.15 mm [0.0020 to 0.0059 in.]

0.05 to 0.15 mm [0.0020 to 0.0059 in.]

Timing gear backlash - Measure

2.8 Idler gear end play - Measure Measure the end play of the idler gear. If the limit is exceeded, replace the thrust plate with a new one.

Item Idler gear end play

Standard

Limit

0.05 to 0.20 mm [0.0020 to 0.0079 in.]

0.35 mm [0.0138 in.]

Dial gauge

Idler gear end play - Measure

2.9 Camshaft end play - Measure Measure the camshaft end play. If the limit is exceeded, replace the thrust plate with a new one.

Item Camshaft end play

Standard

Limit

0.10 to 0.25 mm [0.0039 to 0.0098 in.]

0.30 mm [0.0118 in.]

Dial gauge

Camshaft end play - Measure

2.10 Front oil seal - Install Using an installer, install new oil seal to the timing gear case. Make sure the oil seal is flush with the gear case.

Installer

7-12

Front oil seal - Install

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.11 Timing gear case - Install (1) Apply sealant to the packing to prevent it from displacing and install the packing on the front plate.

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

Packing Timing gear case

(3) Install the timing gear case and tighten the bolts with specified torque.

18.5 ± 1.5 N·m {1.9 ± 0.1 kgf·m} [13.4 ± 1.1 lbf·ft]

Timing gear case - Install

2.12 Oil strainer - Install Set a new O-ring to the oil strainer, and install the oil strainer to the crankcase.

Oil strainer

Oil strainer - Install

7-13

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.13 Oil pan - Install (1) Clean the mount surfaces of the crankcase, timing gear case, and oil pan.

(2) Squeeze ThreeBond 1207C (32A91-051100: liquid gasket) in a 4 mm [0.16 in.] diameter bead all around the oil pan periphery, and spread it evenly.

(3) Install the oil pan to the crankcase within five minutes of applying the liquid gasket.

(4) Tighten the bolt with the specified torque.

Note: Cutting the top of the sealant tube at the point shown in the illustration will provide a 4 mm [0.16 in.] bead.

Apply ThreeBond 1207C all around the oil pan flange.

Liquid gasket application position Oil pan

11.5 ± 1.5 N·m {1.2 ± 0.1 kgf·m} [8.3 ± 1.1 lbf·ft]

Bolt

Oil pan - Install

Cut here

Cutting point of the liquid gasket tube nozzle

2.14 Crankcase - Invert Using a chain block and tackle or similar tool, turn the crankcase to lay it on its side. Then, fasten wire ropes to the crankcase and turn to the original position.

Crankcase - Invert

7-14

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.15 Cover - Install Install the cover to the timing gear case.

Cover

Cover - Install

2.16 Damper and Crankshaft pulley - Install (Front)

(Rear) Prevent crankshaft from rotating

The bar could come off. Be very careful.

(1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft. Place a bar across the two guide bolts so that the crankshaft does not rotate.

(2) Install the woodruff key on the crankshaft.

Crankshaft pulley 490 ± 10 N·m {50 ± 1 kgf·m} [361 ± 7 lbf·ft]

(3) Install the damper to the crankshaft pulley.

(4) Tighten the nut with the specified torque.

Guide bolt (M12 × 1.25 mm)

Damper and Crankshaft pulley - Install

2.17 Damper face and radial runouts - Measure Measure the face and radial runouts of the damper. Attach the dial gauge plunger on the outer circumference of the damper to measure the radial runout, or on the end face near the perimeter to measure the face runout, and slowly turn the crankshaft. If the limit is exceeded, replace the damper with a new one.

Item

Standard

Limit

Face runout

0.5 mm [0.020 in.] or less

1.5 mm [0.059 in.]

Radial runout

0.5 mm [0.020 in.] or less

1.5 mm [0.059 in.]

Face runout Radial runout

Damper face and radial runouts - Measure

7-15

Chapter 7 ASSEMBLY OF BASIC ENGINE

3. Rear equipment - Assemble 3.1 Rear oil seal - Install Apply a small quantity of grease to the new oil seal, and install the oil seal to the rear plate.

Be careful of the oil seal installation direction.

Apply grease

Rear plate

Engine side

Flywheel side

Note: Use an oil seal with a sleeve if the oil seal contacting surface of the crankshaft is worn.

Oil seal

Rear oil seal - Install

3.2 Rear plate - Install (1) Clean the mounting surface of the packing.

Apply engine oil

(2) Apply sealant to the packing to prevent it from falling.

(3) Install the packing.

(4) Install the rear plate aligning with the dowel pin by using the guide bolt, and tighten the bolts to the specified torque.

Note: When the dowel pins are worn or when the rear plate is replaced, replace the dowel pins with new ones.

55.9 ± 5.8 N·m {5.7 ± 0.5 kgf·m} [41.2 ± 3.6 lbf·ft]

Packing

Rear plate - Install

3.3 Flywheel - Install Guide bolt

(a) Be careful not to drop or hit the flywheel. This

Flywheel

may not only cause damage to the flywheel but also personal injury. (b) The person holding the pulley must be very careful to assure safety by communicating with the person who is installing the flywheel.

(1) One person must firmly hold the pulley with a wrench to prevent the crankshaft from turning.

Flywheel - Install

(2) Screw the guide bolt into the rear end of the crankshaft.

(3) Align the bolt hole of flywheel with the guide bolt and install the flywheel to the crankshaft.

(Front)

(Rear) Guide bolt

(4) Temporarily tighten the bolts.

(5) Remove the guide bolt and temporarily tighten the last bolt.

(6) Tighten the flywheel bolts to the specified torque.

Crankshaft pulley

83 ± 5 N·m {8.5 ± 0.5 kgf·m} [61 ± 3.6 lbf·ft]

Flywheel bolts - Tighten

7-16

Chapter 7 ASSEMBLY OF BASIC ENGINE 3.4 Flywheel face and radial runouts - Measure Measure the runouts of the flywheel in the installed condition. If the measured value exceeds the standard, check the bolt for looseness as well as the accumulation of foreign matter on the mounting face.

Item Face and radial runouts

Face runout measuring point Standard

Limit

0.15 mm [0.0059 in.] or less

0.50 mm [0.0197 in.]

Radial runout measuring point

Flywheel face and radial runouts - Measure

7-17

Chapter 7 ASSEMBLY OF BASIC ENGINE

4. Cylinder head and Valve mechanism - Assemble 4.1 Cylinder head - Assemble

(a) Be careful when inserting the stem seal through the valve, as the edge of the valve can cause damage to the lip of stem seal. (b) Do not apply oil or liquid sealant to the stem seal inside that comes in contact with the valve guide.

Stem seal installer P/N:32A91-10200

Valve

Stem seal

15.2 ± 0.1 mm [0.598 ± 0.03 in.]

Valve guide

(c) Always replace the stem seal with a new one once it has been removed.

(1) Apply engine oil to the valve stem, then insert the valve

Valve stem seal - Install

onto the valve guide.

(2) Insert the stem seal through the valve guide using a

Valve spring pusher P/N:30691-04500

stem seal installer.

Note: Press fit the valve stem seal with centering by the valve stem that is installed to the cylinder head.

(3) Apply engine oil to the lip of stem seal.

(4) Install the valve spring and retainer to the valve guide, and then install the valve cotter with a valve spring pusher.

Valve and Valve spring - Install (5) Tap the top of valve stem lightly several times with a Valve cotter

soft-head hammer to ensure that the valve spring and valve cotters are properly installed and seated firmly.

Valve cotter - Install

4.2 Valve sinkage - Measure Measure the valve sinkage.

If the measurement exceeds the limit, replace the valve or

Seat width

valve seat with a new one. Always lap the valve and valve seat after the valve or valve seat has been refaced or replaced.

Item

Standard

Limit

Inlet

0.3 to 0.5 mm [0.012 to 0.020 in.]

1.0 mm [0.04 in.]

Exhaust

0.4 to 0.6 [0.016 to 0.024 in.]

1.0 mm [0.04 in.]

Valve seat angle

Valve margin Valve sinkage

Valve sinkage - Measure

7-18

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.3 Cylinder head gasket - Install

Do not use the liquid gasket to the cylinder head.

(1) Wipe off oil, grease and other stains from the cylinder head bottom surface and the crankcase upper surface.

(2) Place new gasket on the crankcase by aligning it with dowel pins on the crankcase.

4.4 Cylinder head assembly - Install Install the cylinder head to fit the dowel pins on the crankcase top surface with guide.

Cylinder head

Note:(a) Install the cylinder head gasket with paying attention not to displace the cylinder head gasket. (b) Do not lift up the cylinder head by one person. Use crane or lift up by two persons.

Cylinder head assembly - Install

4.5 Cylinder head bolt - Tighten Progressively tighten the cylinder head bolts in the numerical order and to the specified torque as shown in the illustration.

118 ± 5 N·m {12 ± 0.5 kgf·m} [87 ± 3.6 lbf·ft]

Front

24

12

20 16

8

23 19 15 11 7

4

3

5

13

1 2

9

21 17 25 22

6 10 14 18

Number of bolt (25)

Tightening sequence of cylinder head bolts

4.6 Push rod - Insert (1) Insert each push rod into its hole in the cylinder head.

(2) Make sure that the ball end of each push rod is placed correctly on the tappet cup.

Push rod

Tappet

Push rod - Insert

7-19

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.7 Rocker shaft assembly - Install

Always tighten the long bolt first. Failing to do so may cause damage to the rocker shaft bracket.

Bolt (short)

17.2 ± 2.45 N·m {1.75 ± 0.2 kgf·m} [12.9 ± 1.8 lbf·ft]

(1) Apply engine oil to the rocker shaft.

(2) Assemble the rocker shaft assembly.

(3) After assembling, make sure the rocker arm move

Bolt (long)

freely.

(4) Install the valve caps to the valve heads.

(5) Install the rocker shaft assembly.

(6) Tighten the rocker bracket bolt (long) to the specified torque.

(7) Tighten the rocker bracket bolt (short).

7-20

Rocker shaft assembly - Install

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.8 Valve clearance - Inspect and Adjust The valve clearance should be inspected and adjusted when the engine is cold.

Item Valve clearance (when cold)

Standard Inlet Exhaust

0.25 mm [0.0098 in.]

(1) Inspect the valve clearance for all cylinders in the firing order by turning the crankshaft to the specified degrees in the normal direction (clockwise when viewed from engine front side) to bring each piston to compression top dead center.

Injection timing 1-5-3-6-2-4 Turning angle: 120°

Note: To rotate the crankshaft, fit a socket and ratchet handle on the crankshaft pulley nut.

(2) When the No. 1 piston is at compression top dead center, the scribed line on the periphery of the damper is aligned with the “0” graduation mark on the pointer.

Neither the inlet valve nor the exhaust valve should be

Socket for turning P/N:58309-73100

Rotating crankshaft

lifted off its seat by the push rod.

(3) Insert a thickness gauge between the rocker arm and valve cap to inspect the clearance.

No. 1 cylinder compression top dead center - Check (4) Insert the thickness gauge of the specified thickness clearance by turning the screw in either direction so that the gauge is gripped softly between the rocker arm and bridge cap.

Adjusting screw Lock nut

0.25 mm [0.0098 in.]

between the rocker arm and valve cap, then adjust the

20 ± 2 N·m {2.0 ± 0.2 kgf·m} [15 ± 1.4 lbf·ft]

(5) After adjustment, tighten the lock nut firmly. Then, check the clearance again.

Valve clearance - Adjust

7-21

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.9 Rocker cover - Install (1) Make sure that the gasket is firmly installed into the rocker cover.

(2) Tighten the bolt to the specified torque.

11.5 ± 1.5 N·m {1.15 ± 0.15 kgf·m} [8.5 ± 1.1 lbf·ft]

Rocker cover - Install

7-22

Chapter 8 FUEL SYSTEM 1.

2.

Fuel system - Remove............................................................................................. 8-3 Fuel system - Disassemble, Inspect and Assemble............................................. 8-4 2.1 2.2 2.3 2.4 2.5 2.6

3.

Fuel filter - Disassemble, Inspect and Assemble...................................................................... 8-4 Fuel filter - Assemble ................................................................................................................ 8-5 Fuel injection nozzle - Disassemble and Inspect...................................................................... 8-6 Fuel injection nozzle - Inspect and Adjust ................................................................................ 8-7 Fuel injection nozzle - Assemble .............................................................................................. 8-9 Gauze filter of distribute type fuel injection pump - Inspect and Clean................................... 8-10

Fuel system - Install .............................................................................................. 8-11

8-1

Chapter 8 FUEL SYSTEM

1. Fuel system - Remove

Chapter 8 FUEL SYSTEM

Replace

2 6 5 3

7 4

1

9

8

Replace

Fuel system - Remove Removing sequence 1 Fuel hose 2 Fuel filter 3 Fuel filter bracket

4 Fuel return pipe 5 No. 1 to No. 6 fuel injection pipe 6 Fuel leak-off pipe

7 Fuel injection nozzle 8 Bracket 9 Fuel injection pump

Cover the openings on the injection pump, injection nozzle and injection pipe to prevent dust from entering the fuel system.

8-3

Chapter 8 FUEL SYSTEM

2. Fuel system - Disassemble, Inspect and Assemble 2.1 Fuel filter - Disassemble, Inspect and Assemble

Crack, damaged threads

3

Replace

2 Clogged, cracks.

Replace: Every 500 hrs.

Replace 1

Fuel filter - Disassemble and Inspect Disassembling sequence 1 Level sensor

8-4

2 Filter element

3 Body

Chapter 8 FUEL SYSTEM 2.2 Fuel filter - Assemble

(a) Check that there is no flame when handling fuel. (b) Wipe off any spilled fuel. This can cause a fire.

(1) Clear the fuel filter and its surroundings.

5 ± 1 N·m {0.51 ± 0.10 kgf·m} [3.69 ± 0.74 lbf·ft]

(2) Disconnect the fuel filter level sensor from its connector.

(3) Prepare the fuel plate and place it under the fuel filter.

(4) Loosen the drain plug and drain fuel from the fuel filter.

(5) Remove the level sensor from the fuel filter.

(6) Remove the fuel filter element.

(7) Wipe off any fuel on the fuel filter element mounting surface of fuel filter body with a waste cloth.

(8) Prepare the new fuel filter element and make sure that the gasket is properly seated on the groove.

13.5 ± 1.5 N·m {1.4 ± 0.1 kgf·m} [10 ± 1.1 lbf·ft]

1.1 ± 0.3 N·m {0.1 ± 0.03 kgf·m} [0.8 ± 0.22 lbf·ft]

Fuel filter - Assemble

Do not use a filter that has dents in the casing, it may be internally damaged and cause fuel leakage during operation, which results in a fire hazard.

(9) Install the fuel filter element to the filter body.

Be careful not to dent or scratch the surface of the fuel filter.

(10)Install the level sensor to the fuel filter element through new O-ring.

(11)After completion of the fuel filter change, bleed the fuel system.

(12)Start the engine and idle for a few minutes.

(13)Check the fuel filter element mounting surface for fuel leakages. If leakages are found, loosen the fuel filter and check the gasket for seating or damage. Then retighten the fuel filter.

8-5

Chapter 8 FUEL SYSTEM 2.3 Fuel injection nozzle - Disassemble and Inspect Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part of the engine and to maintain the engine efficiently.

Depending on the maintenance purpose, inspect the following items before disassembling the engine. Fuel injection start pressure - Inspect Fuel injection nozzle spray - Inspect

Replace 8

Wear

7

Fatigue, breakage 6 5 4 Wear, damage

3 2

Carbon deposit, nozzle hole clogging

1

Fuel injection nozzle - Disassemble and Inspect Disassembling sequence 1 Nozzle retaining nut 2 Nozzle tip assembly 3 Distance piece

8-6

4 Pressure pin 5 Pressure spring 6 Shim

7 Nozzle holder 8 Gasket

Chapter 8 FUEL SYSTEM 2.4 Fuel injection nozzle - Inspect and Adjust 2.4.1 Fuel injection start pressure - Inspect and Nozzle tester

Adjust Never touch the fuel injection nozzle tip during nozzle injection test.

(1) Mount the nozzle on the nozzle tester.

(2) Push down the handle at a speed of once a second and measure the pressure when injection starts. If it is out of the standard, adjust it to the standard.

(3) To adjust the injection start pressure, remove the retain-

Fuel injection nozzle with nozzle tester - Inspect

ing nut, and change the shim. Changing the shim with a thicker one increases the pressure, and changing the shim with a thinner one decreases the pressure.

(4) After adjustment, tighten the retaining nut with the specified torque.

(5) After tightening the retaining nut, check if the injection start pressure is within the standard again.

Item Injection start pressure

Nominal

Standard

11.77 MPa {120 kgf/cm2} [1707 psi]

11.77 to 12.75 MPa {120 to 130 kgf/cm2} [1707 to 1849 psi]

Note:(a) Standard is new parts value. (b) A change in thickness of the shim by 0.1 mm [0.004 in.] results in a change in the fuel injection pressure by 1.0 MPa {10 kgf/cm2} [142 psi]. There are ten kinds of shim from 1.25 to 1.70 mm [0.0492 to 0.0669 in.].

2.4.2 Fuel injection nozzle spray - Inspect When adjusting for nozzle opening pressure using the noz-

Defective spray pattern

zle tester, inspect for nozzle hole condition and fuel spray pattern. If spray condition is faulty, clean or replace the nozzle tip.

Checking points of fuel spray are as follows: Fuel is injected from all spray holes simultaneously. Fuel is injected conically at the specified spray angle.

Good

Large spray angle

After Deflected Branched spray dribble spray

Fuel is injected in a spray of fine droplets. Fuel is injected without after-dribbling.

Fuel injection nozzle spray - Inspect

8-7

Chapter 8 FUEL SYSTEM 2.4.3 Nozzle tip - Clean and Replace Be careful not to hit the nozzle tip.

Nozzle tip end

(1) Remove the retaining nut.

(2) Remove the nozzle tip.

Fuel injection nozzle tip - Remove (3) Clean the needle valve and body of the nozzle tip.

When cleaning the needle valve and nozzle tip body, use clean wash oil. Assemble the needle valve and body in clean diesel fuel after cleaning.

Note: The needle valve and body are precision parts. Handle them carefully, and do not change the combination of the valve and body.

(4) Tighten the nozzle tip tightening retainer nut to the

Needle valve

specified torque.

Body

(5) If the spray pattern is still faulty after cleaning and Nozzle tip - Clean

adjusting, change the nozzle tip with a new one.

New nozzle tips are coated with anti-corrosive agent to prevent from rusting. At first, wash it off in wash oil.

Then wash it again with clean diesel fuel before installation.

2.4.4 Pressure pin - Inspect Inspect the pressure pin visually. If its spring seat wears

Spring seating surface wear (Uneven wear)

unevenly, or its needle valve contact surface wears remarkably, or the cavitation occurs on its tapper part, replace the pressure pin with new one.

Cavitation Needle valve contact surface wear

Pressure pin - Inspect 2.4.5 Distance piece - Inspect Inspect the distance piece visually. If its needle valve contact surface and high pressure seal surface wear remarkably,

High-pressure seal face

replace the distance piece with a new one.

High-pressure seal face Needle valve width ø4 mm [0.16 in.]

Distance piece - Inspect

8-8

Chapter 8 FUEL SYSTEM 2.5 Fuel injection nozzle - Assemble

36.8 ± 2.4 N·m {3.8 ± 0.2 kgf·m} [27.1 ± 1.8 lbf·m]

58.9 ± 5.8 N·m {6 ± 0.5 kgf·m} [43 ± 4.3 lbf·m]

Fuel injection nozzle - Assemble

8-9

Chapter 8 FUEL SYSTEM 2.6 Gauze filter of distribute type fuel injection pump - Inspect and Clean

Keep away from flame when handling diesel oil. Wipe off any spilled fuel. This can cause fire.

Cover the injection pump openings to prevent the injection pump from contamination of dust, water and etc. If foreign material, water and etc. enter the inside of injection pump, faulty sliding, seizure and rusting of inner parts could occur.

When output shortage and/or hunting of the engine Fuel hose

occurred, the gauze filter may be dirty. Clean the gauze filter accordingly.

(1) Clean around the injection pump.

Fuel pipe

(2) Drain the fuel in the injection pump, and remove the

Gasket

fuel hose and fuel pipe.

(3) Remove the spring with a tweezer.

(4) Remove the gauze filter with a tweezer.

Note: Do not damage the metal mesh when removing the gauze filter.

(5) Remove the dirt and dust from the gauze filter cleaning

Fuel hose and Fuel pipe - Remove

with compressed air or diesel fuel. When damage is found, or when the gauze filter is still dirty after clean-

Spring

ing, replace the gauze filter with a new one.

(6) Install the cleaned gauze filter and new gasket, and in reverse order of disassembly, install the fuel pipe and fuel hose.

Spring - Remove Gauze filter

Gauze filter - Remove

8-10

Chapter 8 FUEL SYSTEM

3. Fuel system - Install 29.5 ± 2.9 N·m {3 ± 0.3 kgf·m} [21.8 ± 2.14 lbf·ft]

19.7 ± 1.9 N·m {2 ± 0.1 kgf·m} [14.5 ± 1.4 lbf·ft]

Replace 22.6± 1.9 N·m {2.3 ± 0.1 kgf·m} [16.7 ± 1.4 lbf·ft] 58.9 ± 5.8 N·m {6 ± 0.5 kgf·m} [43.4 ± 4.3 lbf·ft]

Replace

Fuel system - Install

8-11

Chapter 9 LUBRICATION SYSTEM 1.

2.

Lubrication system - Remove................................................................................. 9-3 Lubrication system - Disassemble, Inspect and Assemble................................. 9-4 2.1 2.2 2.3 2.4 2.5

3.

Oil pump - Disassemble and Inspect ........................................................................................ 9-4 Oil pump - Inspect..................................................................................................................... 9-5 Oil pump - Assemble ................................................................................................................ 9-7 Oil filter - Inspect....................................................................................................................... 9-8 Relief valve - Inspect ................................................................................................................ 9-9

Lubrication system - Install .................................................................................. 9-10

9-1

Chapter 9 LUBRICATION SYSTEM

1. Lubrication system - Remove

Chapter 9 LUBRICATION SYSTEM

Replace

1 Replace When removing oil pump, refer to “DISASSEMBLY OF BASIC ENGINE”.

2

3 Replace

5

When removing oil strainer, refer to “DISASSEMBLY OF BASIC ENGINE”.

6

4 When removing oil pan, refer to “DISASSEMBLY OF BASIC ENGINE”.

Lubrication system - Remove Removing sequence 1 Oil filter 2 Relief valve

3 Oil pump 4 Oil pan

5 Oil strainer 6 Oil level gauge

9-3

Chapter 9 LUBRICATION SYSTEM

2. Lubrication system - Disassemble, Inspect and Assemble 2.1 Oil pump - Disassemble and Inspect

1

Replace

2

3

4

Oil pump - Disassemble and Inspect Disassembling sequence 1 O-ring

9-4

2 Shaft assembly

3 Outer rotor

4 Pump case

Chapter 9 LUBRICATION SYSTEM 2.2 Oil pump - Inspect 2.2.1 Clearance between inner rotor and outer rotor Measure Measure the clearance between the inner rotor and outer rotor. If the measured value exceeds the limit, replace the oil pump with a new one.

Item Clearance between inner rotor and outer rotor

Thickness gauge Standard

Limit

0.13 to 0.15 mm 0.20 mm [0.0051 to 0.0059 in.] [0.0079 in.]

Clearance between inner rotor and outer rotor Measure 2.2.2 End play of rotor and pump case - Measure Measure the end play of the rotor and the pump case. If

Straight edge

measured value exceeds the limit, replace the oil pump with new one.

Item End play of rotor and pump case

Standard

Limit

0.04 to 0.09 mm 0.15 mm [0.0016 to 0.0035 in.] [0.0059 in.]

Thickness gauge

End play of rotor and pump case - Measure 2.2.3 Clearance between outer rotor and pump case Measure Measure the clearance between the outer rotor and the pump case. If measured value exceeds the limit, replace the oil pump with a new one.

Item Clearance between outer rotor and pump case

Thickness gauge Standard

Limit

0.20 to 0.30 mm 0.50 mm [0.0079 to 0.0118 in.] [0.0197 in.]

Clearance between outer rotor and pump case Measure 2.2.4 Clearance between shaft and pump case Measure Measure the diameter of the shaft and the inside diameter of

Measuring directions

Measuring directions

the bore in the pump case for the shaft to find the clearance between the two. If the clearance exceeds the limit, replace the oil pump assembly with a new one.

Item

Standard

Limit

Shaft outside diameter (between case)

15.985 to 16.000 mm [0.6293 to 0.6299 in.]

-

Clearance between shaft and pump case

0.032 to 0.074 mm [0.0013 to 0.0029 in.]

0.150 mm [0.0059 in.]

Measuring points

Measuring points

Clearance between shaft and pump case - Measure

9-5

Chapter 9 LUBRICATION SYSTEM 2.2.5 Clearance between shaft and bushing - Measure Measure the diameter of the shaft and the inside diameter of

Measuring directions

Measuring directions

the oil pump bushing in the crankcase. If the clearance exceeds the limit, replace the bushing or the oil pump

Measuring points

assembly with a new one.

Item Shaft outside diameter (oil pump bushing side)

Standard

Limit

13.957 to 13.975 mm [0.5495 to 0.5502 in.]

-

Clearance between shaft and oil 0.025 to 0.111 mm 0.200 mm pump bushing [0.0010 to 0.0044 in.] [0.0079 in.]

2.2.6 Oil pump bushing - Install Install the oil pump bushing in the crankcase so that

Measuring points

Clearance between shaft and bushing - Measure

Crankcase Oil pump bushing

Flush

it is even with the front face of the crankcase.

Install the oil pump bushing by using the oil pump bushing installer.

Oil pump bushing installer P/N:32A91-00400

Oil pump bushing - Install

9-6

Flush

Chapter 9 LUBRICATION SYSTEM 2.3 Oil pump - Assemble

Flush

Flush

Oil pump - Assemble

9-7

Chapter 9 LUBRICATION SYSTEM 2.4 Oil filter - Inspect

When attaching, apply engine oil to the gasket.

Clogged, cracks.

Replace: Every 500 hrs.

Oil filter - Inspect

9-8

Chapter 9 LUBRICATION SYSTEM 2.5 Relief valve - Inspect (1) Check the relief valve and valve seat for contact. Check the spring for fatigue and damage. If any defects are found, replace the relief valve with a new one.

(2) Measure the relief valve opening pressure. If the measured value does not meet the standard, replace the relief valve with a new one.

Item

Standard

Valve opening pressure

0.35 ± 0.05 MPa {3.5 ± 0.5 kgf/cm2} [50 ± 7.1 psi]

44 ± 4.9 N·m {4.5 ± 0.5 kgf·m} [32.5 ± 3.6 lbf·ft]

49 ± 4.9 N·m {5 ± 0.5 kgf·m} [36 ± 3.7 lbf·ft]

Relief valve - Inspect

9-9

Chapter 9 LUBRICATION SYSTEM

3. Lubrication system - Install

When installing oil pump, refer to “ASSEMBLY OF BASIC ENGINE”.

49 ± 4.9 N·m {5 ± 0.5 kgf·m} [36 ± 3.7 lbf·ft]

When installing oil strainer, refer to “ASSEMBLY OF BASIC ENGINE”.

11.5 ± 1.5 N·m {1.2 ± 0.1 kgf·m} [8.5 ± 1.1 lbf·ft]

When installing oil pan, refer to “ASSEMBLY OF BASIC ENGINE”.

Lubrication system - Install

9-10

78 ± 5 N·m {8 ± 0.5 kgf·m} [57 ± 3.7 lbf·ft]

Chapter 10 COOLING SYSTEM 1.

Cooling system - Remove..................................................................................... 10-3

2.

Cooling system - Disassemble, Inspect and Assemble..................................... 10-4 2.1 2.2 2.3

3.

Thermostat - Disassemble and Inspect .................................................................................. 10-4 Thermostat - Inspect............................................................................................................... 10-5 Water pump - Disassemble and Inspect................................................................................. 10-6

Cooling system - Install ........................................................................................ 10-7

10-1

Chapter 10 COOLING SYSTEM

1. Cooling system - Remove

Chapter 10 COOLING SYSTEM

11

12 Replace

Crack, deterioration, damage 10 Crack, water leakage, damage 8

9

Crack, deformation, damage 6

Replace 4 7

Crack, extension, wear, damage

2 3

Replace

5

1

Cooling system - Remove Removing sequence 1 2 3 4

Plate Cooling fan Fan spacer V-belt

5 6 7 8

Water pump pulley Water pump assembly Packing Water pump spacer

9 10 11 12

Packing Hose Thermostat assembly Packing

10-3

Chapter 10 COOLING SYSTEM

2. Cooling system - Disassemble, Inspect and Assemble 2.1 Thermostat - Disassemble and Inspect

1

2 Replace 3

4

5

Thermostat - Disassemble and Inspect Disassembling sequence 1 Cover assembly 2 Gasket

10-4

3 Packing 4 Thermostat

5 Thermostat case

Chapter 10 COOLING SYSTEM

Be very careful of hot water and flames.

It may cause burns and fire.

(1) Immerse the thermostat in a container filled with water.

(2) Heat the water while measuring the water temperature.

Valve lift (mm [in.])

2.2 Thermostat - Inspect 9 [0.35] 0

76.5 [170]

90 [194]

Temperature (°C [°F])

Record the temperature when the valve starts to open, and when the valve lift is about equal to the standard value in the table below. Replace the thermostat if temperatures are not within standard.

Note:(a) Stir the hot water to maintain even temperatures

Thermostat - Inspect

during the test. (b) At assembly, confirm the valve opening temperature stamped on its mounting flange.

Item Temperature for opening Temperature at which valve lift becomes 9 mm [0.31 in.] or more

Standard 76.5 ± 2°C [169.7 ± 35.6°F] 90°C [194°F]

10-5

Chapter 10 COOLING SYSTEM 2.3 Water pump - Disassemble and Inspect

Crack, water leakage, deformation Replace Crack, water leakage, damage, impeller and shaft rotation 3

1 2

Water pump - Disassemble and Inspect Disassembling sequence 1 Water pump cover

10-6

2 Packing

3 Water pump

Chapter 10 COOLING SYSTEM

3. Cooling system - Install 18.5 ± 5 N·m {1.9 ± 0.1 kgf·m} [13.6 ± 3.7 lbf·ft]

Mounting bolt for water pump and cover (x3) 9.8 ± 1 N·m {1 ± 0.1 kgf·m} [7.2 ± 0.7 lbf·ft]

Replace

Crack, deterioration, damage Crack, water leakage, damage

Crack, deformation, damage

Replace

Crack, extension, wear, damage Replace 31.9 ± 2.4 N·m {3.3 ± 0.2 kgf·m} [23.5 ± 1.8 lbf·ft] Mounting bolt for water pump and crankcase (x5) 18.2 ± 3.4 N·m {1.9 ± 0.3 kgf·m} [13.4 ± 2.5 lbf·ft]

Cooling system - Install

10-7

Chapter 11 INLET AND EXHAUST SYSTEMS 1.

2.

Inlet and exhaust systems - Remove................................................................... 11-3 Inlet and exhaust systems - Disassemble, Inspect and Assemble................... 11-4 2.1

3.

Exhaust manifold distortion - Measure ................................................................................... 11-4

Inlet and exhaust systems - Install ...................................................................... 11-5

11-1

Chapter 11 INLET AND EXHAUST SYSTEMS

1. Inlet and exhaust systems - Remove

Chapter 11 INLET AND EXHAUST SYSTEMS

4 Replace

1 Replace 3

2

Replace

Inlet and exhaust systems - Remove Removing sequence 1 Breather hose

2 Air inlet elbow

3 Inlet manifold

4 Exhaust manifold

11-3

Chapter 11 INLET AND EXHAUST SYSTEMS

2. Inlet and exhaust systems - Disassemble, Inspect and Assemble 2.1 Exhaust manifold distortion - Measure (1) Check the flange for crack.

(2) Check the flange surface for distortion. If the distortion exceeds the standard, reface the surface or replace it

Straight edge

with a new one.

Item Exhaust manifold distortion

Standard 0.2 mm [0.008 in.] or less

Thickness gauge

Exhaust manifold distortion - Measure

11-4

Chapter 11 INLET AND EXHAUST SYSTEMS

3. Inlet and exhaust systems - Install

Replace 18.5 ± 3.5 N·m {1.9 ± 0.3 kgf·m} [13.6 ± 2.5 lbf·ft]

Replace

Replace

Inlet and exhaust systems - Install

11-5

Chapter 12 ELECTRICAL SYSTEM 1.

Electrical system - Remove and Inspect ............................................................. 12-3 1.1 1.2 1.3 1.4 1.5

2.

Electrical system - Disassemble, Inspect and Assemble .................................. 12-5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15

3.

Starter - Remove and Inspect................................................................................................. 12-3 Inspection before removal of alternator .................................................................................. 12-3 Alternator - Remove and Inspect ............................................................................................ 12-4 Magnetic valve (stop solenoid) - Remove and Inspect ........................................................... 12-4 Glow plug - Remove and Inspect............................................................................................ 12-4 Inspection before disassembling starter ................................................................................. 12-5 Starter - Disassemble and Inspect.......................................................................................... 12-7 Starter - Inspect and Repair.................................................................................................. 12-10 Starter - Assemble ................................................................................................................ 12-14 Alternator - Disassemble and Inspect (A007TA0483A) ........................................................ 12-17 Alternator - Inspect and Repair (A007TA0483A) .................................................................. 12-20 Alternator - Assemble (A007TA0483A) ................................................................................ 12-23 Alternator - Disassemble and Inspect (A005TA5083A) ........................................................ 12-26 Alternator - Inspect and Repair (A005TA5083A) .................................................................. 12-29 Alternator - Assemble (A005TA5083A) ................................................................................ 12-32 Alternator - Disassemble and Inspect (A002TA7871) .......................................................... 12-35 Alternator - Inspect and Repair (A002TA7871) .................................................................... 12-38 Alternator - Assemble (A002TA7871)................................................................................... 12-41 Glow plug - Inspect and Repair ............................................................................................ 12-44 Magnetic valve (stop solenoid) - Inspect and Repair............................................................ 12-44

Electrical system - Install.................................................................................... 12-45 3.1 3.2 3.3 3.4

Glow plug - Install ................................................................................................................. 12-45 Magnetic valve (stop solenoid) - Install................................................................................. 12-45 Alternator - Install.................................................................................................................. 12-45 Starter - Install ...................................................................................................................... 12-45

12-1

Chapter 12 ELECTRICAL SYSTEM

1. Electrical system - Remove and Inspect

Chapter 12 ELECTRICAL SYSTEM

1.1 Starter - Remove and Inspect (1) Disconnect the harness.

(2) Remove the starter.

Starter

Starter - Remove and Inspect

1.2 Inspection before removal of alternator 1.2.1 Alternator operation - Inspect Locate the cause of faulty charging from the malfunctions described below. Do not remove the alternator for inspection and repair unless inspection cannot be performed with the alternator installed on the engine.

Overcharge

Adjusted value of voltage regulator is high.

Faulty battery.

Adjusted value of voltage relay is low.

Faulty alternator output.

Over discharge

Electric power consumption is extremely high.

Special load is used.

Faulty wiring.

1.2.2 Handling precaution Improper handling could cause damage or failure to the alternator.

(1) Connect battery cables correctly. The B terminal is (+) and the E terminal is (-).

(2) Do not use any high voltage tester such as a megger.

(3) Do not disconnect lead wire from B terminal of the alternator while the engine is running.

(4) Battery voltage is constantly applied to B terminal of the alternator. Do not ground at this terminal.

(5) Do not short circuit or ground at L terminal. (For a built-in IC regulator type) (6) When a steam cleaner is used, do not allow the steam to come into contact with the alternator.

12-3

Chapter 12 ELECTRICAL SYSTEM 1.3 Alternator - Remove and Inspect (1) Remove the alternator.

(2) Remove the adjusting plate.

Adjusting plate

Alternator

Alternator bracket

Alternator - Remove and Inspect

1.4 Magnetic valve (stop solenoid) - Remove and Inspect (1) Remove the wire assembly.

Wire assembly

(2) Remove the magnetic valve.

Fuel Injection pump

Magnetic valve assembly

Magnetic valve (stop solenoid) - Remove and Inspect

1.5 Glow plug - Remove and Inspect (1) Loosen the fixing nut and remove the connection plate.

Connection plate

(2) Remove the glow plug.

Nut

Glow plug

Glow plug - Remove and Inspect

12-4

Chapter 12 ELECTRICAL SYSTEM

2. Electrical system - Disassemble, Inspect and Assemble 2.1 Inspection before disassembling starter 2.1.1 Magnetic switch - Inspect Inspect the magnetic switch as described below. If faulty, replace the magnetic switch with a new one.

Switch

Do not apply current continuously for longer than 10 seconds.

Pull-in test (1) Disconnect the connector of M terminal.

(2) Connect the starter to the circuit as shown in the illus-

Battery 12V Remove the connector

Starter

Pull-in test

tration.

(3) The magnetic switch is normal if the pinion springs out when the switch is turned ON. Holding test (1) Disconnect the connector of M terminal.

(2) Connect the starter to the circuit as shown in the illus-

Switch

tration.

(3) Turn ON the switch and pull out the pinion fully by hand.

The magnetic switch is normal if the pinion does not return when it is released.

Battery 12V Starter

Holding test Return test (1) Disconnect the connector of M terminal.

(2) Connect the starter to the circuit as shown in the illus-

Switch

tration.

(3) Turn OFF the switch and pull out the pinion fully by hand. The magnetic switch is normal if the pinion returns immediately when it is released.

Battery 12V Starter

Return test

12-5

Chapter 12 ELECTRICAL SYSTEM 2.1.2 Test at no load

Switch

(a) Use a thick wire as possible and firmly tighten A Ammeter

each terminal. (b) Be careful that the pinion pops out during operation when measuring the rotation speed at the tip of the pinion.

Battery 12V

V Voltmeter

(1) Connect the starter to the circuit as shown in the illustration.

(2) In normal condition, the pinion pops out when the switch is turned ON, and the starter rotates at more than the specified rotation speed. If the terminal voltage, current or rotation speed does not meet the standard, disassemble, inspect and repair the starter.

Item

Standard

Starter model number

M008T55472

Nominal output

12 V, 3.0 kW Terminal voltage

Nonload characteristics

Current Rotational speed

12-6

11 V 180 A or less 3800 min-1 or more

Test at no load

Chapter 12 ELECTRICAL SYSTEM 2.2 Starter - Disassemble and Inspect 3

1

Open circuit, short circuit of magnetic switch 18

Contamination, seizing, wear

Replace

Replace Open circuit, ground

16 17

Replace 8

Wear, damage

2

Wear, damage

13

7

Replace

Wear of bearing hole

9 13

14 12

11

10

15

Replace

4 5

Replace

Replace

Function of overrunning clutch 6

Open circuit, short circuit of yoke

Brush dust deposit, uneven wear, brush movement inside the holder, rust, deterioration, insulated condition of holder

Starter - Disassemble and Inspect Disassembling sequence 1 2 3 4 5 6

Safety switch Pinion set Magnetic switch assembly Rear bracket Brush holder Yoke assembly

7 8 9 10 11 12

Armature Ball bearing Packing set Washer set Internal gear Gear shaft

13 14 15 16 17 18

Planetary gear Lever assembly Overrunning clutch Bearing Oil seal Front bracket

12-7

Chapter 12 ELECTRICAL SYSTEM 2.2.1 Pinion set - Remove SW1

B

The starter generates heat with current being applied

S

over a period of time. Remove the pinion within 10

M

seconds.

(1) Connect the starter to the circuit as shown in the illustration.

(2) Turn the switches SW1 and SW2 ON to move the pin-

Battery 12V

SW2

Disconnect lead wire with terminal, which connected to M terminal.

ion out and then turn the SW2 OFF to stop the rotation of the armature and the pinion.

Connection to move the pinion forward

(3) Place an appropriate tube on the pinion stopper. Tap the tube with a hammer to drop the pinion stopper to the clutch side. This will expose the stopper ring.

(4) Remove the stopper ring with pliers and remove the pinion.

Overrunning clutch shaft

Note: Do not reuse the stopper ring and pinion stopper for assembly.

Pinion stopper Stopper ring Pinion spring Pinion

Pinion - Remove 2.2.2 Magnetic switch - Remove (1) Remove the safety switch and the lead wire.

Magnetic switch

(2) Remove the magnetic switch.

Magnetic switch - Remove 2.2.3 Rear bracket - Remove (1) Remove through bolts and screws of brush holder.

(2) Remove the rear bracket.

Rear Bracket

Rear bracket - Remove

12-8

Chapter 12 ELECTRICAL SYSTEM 2.2.4 Brush holder and Brush assembly - Remove Apply a socket (of the same diameter as the commutator) to

Brush holder

the commutator of the armature. Remove the brush holder and brush assembly by sliding on the socket.

Brush holder and Brush assembly - Remove 2.2.5 Armature and Yoke assembly - Remove (1) Remove the armature and yoke assembly.

(2) Remove the packing from the internal gear.

Yoke assembly Lever

(3) Remove the packing and plate on the lever support.

(4) Remove the ball from the internal gear.

(5) Remove the planetary gears.

Planetary gear Armature Packing set Ball

Armature and Yoke assembly - Remove 2.2.6 Overrunning clutch - Remove (1) Remove the E-ring.

Note: Remove the gear shaft from the overrunning clutch as

Gear shaft

following procedure because the spline part of gear shaft is hooking into overrunning clutch.

(2) Shift the spline of gear shaft by a tooth with pressing the gear shaft to the overrunning clutch.

(3) Remove the gear shaft from the overrunning clutch.

E-ring Overrunning clutch

Overrunning clutch - Remove Overrunning clutch Gear shaft

Spline part

Spline of gear shaft

12-9

Chapter 12 ELECTRICAL SYSTEM 2.3 Starter - Inspect and Repair 2.3.1 Magnetic switch coil - Inspect (1) Check the conduction between M terminal and the case.

B terminal

S terminal

If isolated, replace the magnetic switch with a new one.

(2) Check that the M terminal and the B terminal are isolated. If electricity is conducted, replace the magnetic switch with a new one.

M terminal

Magnetic switch coil - Inspect 2.3.2 Brush for wear - Inspect Measure the length of the brushes.

If it is less than the limit, replace the brush holder assembly and brush assembly with new ones.

Item

Standard

Limit

Brush length

18 mm [0.71 in.]

11 mm [0.43 in.]

Measure the height, and replace parts if it is less than the limit.

Brush for wear - Inspect 2.3.3 Brush spring load - Inspect Using a new brush, measure the spring load at which the spring lifts from the brush. If it is less than the limit, replace the spring with a new one.

Item Brush spring load

Standard

Limit

29.2 to 39.4 N {2.98 to 4.02 kgf} [21.54 to 29.06 lbf]

13.7 N {1.4 kgf} [10 lbf]

Brush spring load - Inspect 2.3.4 Brush holder for insulation - Inspect Check that each brush holder and the brush holder base are

Insulated brush holder

isolated. If electricity is conducted, replace the whole brush holder assembly with a new one.

Check the brush holders for looseness.

Brush holder base

Brush holder for insulation - Inspect

12-10

Chapter 12 ELECTRICAL SYSTEM 2.3.5 Commutator outside diameter - Measure Measure the commutator outside diameter. If the measured value is less than the limit, replace the armature with a new one.

Item

Nominal

Limit

Commutator outside diameter

ø 32 mm [1.26 in.]

31.4 mm [1.236 in.]

O dia utsid m e et er

Commutator outside diameter - Measure 2.3.6 Commutator runout - Measure (1) Inspect the commutator surface. If the surface is rough, polish it using a 400 to 600 grit sandpaper.

(2) Measure the commutator runout with a dial gauge.

If the measured value exceeds the limit, replace the armature with a new one.

Item Commutator runout

Limit 0.10 mm [0.0039 in.]

Commutator

Commutator surface - Polish

12-11

Chapter 12 ELECTRICAL SYSTEM 2.3.7 Undercut depth - Measure Measure the depth of undercutting between the commutator Undercut

segments. If the measured value is less than the limit, repair Segment

or replace the commutator.

Item Undercut depth

Mica

Limit 0.2 mm [0.008 in.]

Undercut depth - Measure 2.3.8 Front bracket - Inspect If ball bearing does not turn smoothly or the abnormal noise is generated, replace the front bracket with a new one.

2.3.9 Armature coil - Inspect (1) Inspect the armature coil using a growler tester.

Put the armature on the growler tester, attach the iron

Growler tester

Iron plate

plate (e.g. teeth of a saw) at the core of armature. Hold the iron plate, and rotate the armature with hands. If the coil is shorted, the iron plate is sucked on that position.

If the coil is shorted, replace the armature with a new one.

Armature coil for short circuit - Inspect (2) Check that the commutator and the shaft (core) are isolated. If electricity is conducted, replace the armature with a new one.

Commutator and shaft (core) for insulation - Inspect (3) Check for conduction between segments in various combinations. If isolated, replace the armature with a new one.

Conduction between segments - Inspect

12-12

Chapter 12 ELECTRICAL SYSTEM 2.3.10 Rear bracket - Inspect If the rear bearing box becomes worn, replace a rear bracket with a new one.

2.3.11 Overrunning clutch - Inspect Do not clean the overrunning clutch in an oil wash since grease is applied inside.

Make sure that, when attempting to turn the overrunning clutch, it locks in one direction and rotates smoothly in the opposite direction.

Overrunning clutch - Inspect 2.3.12 Starter gear - Inspect Inspect each starter gear. If it worn or damaged, replace the gear with a new one.

12-13

Chapter 12 ELECTRICAL SYSTEM 2.4 Starter - Assemble

3.38 ± 1.03 N·m {0.35 ± 0.1 kgf·m} [2.49 ± 0.76 lbf·ft] Apply Multemp #6129 +2 9.8 0 N·m +0.2 {1 0 kgf·m} [7.2 +1.4 0 lbf·ft]

Apply Multemp OA-171

Apply Molykote AG650

Starter - Assemble

12-14

Apply Multemp #6129

Chapter 12 ELECTRICAL SYSTEM 2.4.1 Gear shaft - Install Gear shaft

(1) Put the washer, internal gear and overrunning clutch Washer

through the gear shaft.

(2) Shift the spline of gear shaft by a tooth.

Internal gear

(3) Pull the overrunning clutch.

(4) Make sure the overrunning clutch does not come off from the gear shaft.

(5) Install the E-ring.

E-ring Overrunning clutch

Gear shaft - Install Overrunning clutch Gear shaft

Spline part

Spline of gear shaft 2.4.2 Pinion - Install (a) Before assembling, apply grease to the inner race groove of the front bracket bearing. (b) Be sure to use a new stopper ring and pinion

Overrunning clutch shaft

stopper. Do not reuse the stopper ring and pinion stopper that has been removed.

(1) Put the overrunning clutch through the front bracket.

(2) Install the pinion spring, pinion and pinion stopper in this order onto the shaft of the overrunning clutch.

Pinion stopper Stopper ring Pinion spring Pinion

Pinion - Install

(3) Install the stopper ring firmly to the shaft groove of overrunning clutch.

(4) Using a gear puller, firmly pull the pinion stopper closer to the stopper ring to fix.

12-15

Chapter 12 ELECTRICAL SYSTEM 2.4.3 Yoke and Armature - Install (1) Install the planetary gears on the gear shaft.

(2) Install the plate and packing.

Yoke assembly Lever

(3) Install the yoke on the front bracket.

(4) Apply grease to the armature shaft end and install a ball on it.

Planetary gear

(5) Install the armature.

Armature Packing set Ball

Yoke and Armature - Install 2.4.4 Brush holder and Brush assembly - Install (1) Attach the socket to the commutator of the armature.

Brush holder

(2) While sliding the brushes on the socket, install the brush holder and brush assembly on the armature.

Brush holder and Brush assembly - Install

12-16

Chapter 12 ELECTRICAL SYSTEM 2.5 Alternator - Disassemble and Inspect (A007TA0483A)

[12 V, 50 A] 4 Dirt, damage and seizing of slip ring, and coil resistance

Rotation

5

1

Crack, damage

Crack, damage

3 8 Rotation 2

6

10 9

Deformation, damage

Short circuit and open circuit

Sliding state and wear of brushes 7 Open circuit, ground of coil

Alternator - Disassemble and Inspect (A007TA0483A) Disassembling sequence 1 2 3 4

Screw Nut Pulley assembly Rotor assembly

5 6 7 8

Front bracket assembly Stator Regulator assembly Nut set

9 Rectifier assembly 10 Rear bracket

12-17

Chapter 12 ELECTRICAL SYSTEM 2.5.1 Stator and Front bracket - Remove Rear bracket

(a) Disassemble the alternator only when repair becomes necessary. (b) Use care not to insert the screwdriver too deep, or its tip may damage the stator.

(1) Remove through bolts.

(2) Insert the tip of a flat-blade screwdriver between the stator and front bracket, and wrench them.

Stator core

Front bracket

Stator and Front bracket - Remove 2.5.2 Pulley - Remove

Pulley assembly Front bracket

When holding a rotor with a vice, be sure to hold at the base of claw with a vice. Holding the tip of the claw can cause malfunctions.

(1) Attach the cloth to the rotor and fix it to the vise.

(2) Remove the pulley nut, and then pull out the pulley assembly.

(3) Remove the rotor from the front bracket.

Rotor

Pulley - Remove 2.5.3 Rear bearing - Remove Rotor

Remove the rear bearing from the rotor with the bearing puller.

Rear bearing

Rear bearing - Remove 2.5.4 Front bearing - Remove Remove screws, and then remove the bearing retainer and front bearing from front bracket.

Screw

Front bracket

Front bearing

Bearing retainer

Front bearing - Remove

12-18

Chapter 12 ELECTRICAL SYSTEM 2.5.5 Stator - Remove The solder must be removed in a short time. If the heat is applied for a long time, the diode will be damaged.

Melt the solder of stator and rectifier, and remove the stator Stator core

from the rectifier.

Rectifier Soldering

Stator - Remove 2.5.6 Regulator assembly - Remove Screws

(1) Remove the screws from the regulator assembly.

(2) Remove the solder that is connecting the regulator and rectifier.

Regulator assembly

(3) Remove the regulator assembly.

Rectifier assembly Soldering

Regulator assembly - Remove 2.5.7 Rectifier assembly - Remove (1) Remove the screws, molds and nuts from the rectifier.

(2) Remove the rectifier assembly.

Nut Rectifier assembly

Mold Screw

Rear bracket

Rectifier assembly - Remove

12-19

Chapter 12 ELECTRICAL SYSTEM 2.6 Alternator - Inspect and Repair (A007TA0483A) 2.6.1 Stator - Inspect Terminal 2

(1) Conduction of stator terminals - Inspect

Terminal 3

Make sure the terminals shown in the illustration are conducted. If isolated, replace the stator with a new

Terminal 1

one.

Inspection items Terminal 1 and Terminal 2 Terminal 2 and Terminal 3 Terminal 1 and Terminal 3

Conduction of stator terminals - Inspect (2) Insulation between terminal of stator coil and core Terminal 2

Inspect

Terminal 3

Make sure the each terminal of stator coil and the stator core are isolated. If electricity is conducted, replace the

Terminal 1

stator with a new one.

Insulation between terminal of stator coil and core Inspect 2.6.2 Rectifier - Inspect Inspect the conduction and insulation of each diodes with analog tester.

D

If inspected result does not match the below table, replace

F

the rectifier with a new one.

Polarity of tester Negative (-) E D

Positive (+) A,B,C

Condition Conducted Isolated

D

Conducted

F

A,B,C

Isolated

A,B,C

F

Conducted

Note: A,B,C:Stator coil lead wire connection part D,E:Heatsink F:Regulator connection part

12-20

B

C

Isolated

E

A,B,C

A

Rectifier - Inspect

E

Chapter 12 ELECTRICAL SYSTEM 2.6.3 Rotor - Inspect (1) Measure the resistance between the slip rings (rotor coil). If the measured value does not meet the standard, replace the rotor with a new one.

Item Resistance between slip rings

Standard 2.7 to 3.2 Ω

Resistance between slip rings (rotor coil) - Measure (2) Check that the slip ring and the shaft (or core) are isolated. If conducted, replace the rotor with a new one.

Insulation between slip rings and shaft - Inspect

12-21

Chapter 12 ELECTRICAL SYSTEM 2.6.4 Brush for wear - Inspect Measure the length of the brushes. If the limit is exceeded, replace the brush with a new one.

Item

Standard

Limit

Brush length

18.5 mm [0.728 in.]

5.0 mm [0.197 in.]

Wear limit line

Brush for wear - Inspect 2.6.5 Brushes - Replace (1) To remove the brush and the spring, unsolder the brush

Soldering

lead.

Brushes - Replace (2) To install a new brush, push the brush into the brush holder as shown in the illustration, and then solder the

Brush

lead to the brush.

Note: Install the brush to the correct direction.

Brush - Install

12-22

Chapter 12 ELECTRICAL SYSTEM 2.7 Alternator - Assemble (A007TA0483A)

[12 V, 50 A]

4.4 ± 1 N·m {0.45 ± 0.1 kgf·m} [3.2 ± 0.7 lbf·ft] 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

117.5 ± 19.5 N·m {12 ± 1.9 kgf·m} [87 ± 14 lbf·ft]

Alternator - Assemble (A007TA0483A)

12-23

Chapter 12 ELECTRICAL SYSTEM 2.7.1 Rectifier assemble and

6.9 ± 1.9 N·m {0.7 ± 0.19 kgf·m} [5.1 ± 1.4 lbf·ft] Nut

regulator assembly - Install (1) Install the rectifier assembly and regulator assembly to the rear bracket.

(2) Solder the connecting part of regulator and rectifier.

Rectifier assembly

Mold Screw 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

Rear bracket

Rectifier assembly - Install Screws 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

Regulator assembly

Rectifier assembly Soldering

Regulator assembly - Install 2.7.2 Stator - Install Solder must be applied for a short period of time. If heat from the soldering iron is applied for a long time period, the diode will be damaged.

(1) Install the stator.

Stator core

(2) Solder the lead wire of stator to the rectifier.

Rectifier Soldering

Stator - Install 2.7.3 Front bearing - Install (1) Install the front bearing to the front bracket.

(2) Secure the bearing retainer with the screw.

Screw

Front bracket

Front bearing

Bearing retainer

Front bearing - Install

12-24

Chapter 12 ELECTRICAL SYSTEM 2.7.4 Rear bearing - Install Rotor

Install the rear bearing to the rotor.

Rear bearing

Rear bearing - Install 2.7.5 Pulley - Install

Pulley assembly

(1) Insert the rotor to the front bracket.

(2) Attach the cloth to the rotor and fix it to the vise.

Front bracket

(3) Install the pulley assembly and secure it with the nut.

Rotor

Pulley - Install 2.7.6 Rear bracket assembly and Front bracket assembly - Assemble

Rear bracket

(1) Lift up the brushes with a piece of wire inserted through the small hole in the bracket to the brush hole.

Brush Wire

Brush - Fix (2) Assemble the rear bracket assembly and front bracket Front bracket

assembly, and secure them with the through bolt.

Through bolt

Stator core

Rear bracket assembly and Front bracket assembly Assemble

12-25

Chapter 12 ELECTRICAL SYSTEM 2.8 Alternator - Disassemble and Inspect (A005TA5083A)

[12 V, 75 A] 4 Dirt, damage and seizing of slip ring, and coil resistance

Rotation

5

1

Crack, damage

Crack, damage

3 8 Rotation 2

6

10 9

Deformation, damage

Short circuit and open circuit

Sliding state and wear of brushes 7

Open circuit, ground of coil

Alternator - Disassemble and Inspect (A005TA5083A) Disassembling sequence 1 2 3 4

Screw Nut Pulley assembly Rotor assembly

12-26

5 6 7 8

Front bracket assembly Stator Regulator assembly Nut set

9 Rectifier assembly 10 Rear bracket

Chapter 12 ELECTRICAL SYSTEM 2.8.1 Stator and Front bracket - Remove Rear bracket

(a) Disassemble the alternator only when repair becomes necessary. (b) Use care not to insert the screwdriver too deep, or its tip may damage the stator.

(1) Remove through bolts.

(2) Insert the tip of a flat-blade screwdriver between the stator and front bracket, and wrench them.

Stator core

Front bracket

Stator and Front bracket - Remove 2.8.2 Pulley - Remove

Pulley assembly Front bracket

When holding a rotor with a vice, be sure to hold at the base of claw with a vice. Holding the tip of the claw can cause malfunctions.

(1) Attach the cloth to the rotor and fix it to the vise.

(2) Remove pulley nut, and then pull out the pulley.

(3) Remove the rotor from the front bracket.

Rotor

Pulley - Remove 2.8.3 Rear bearing - Remove Rotor

Remove the rear bearing from the rotor with the bearing puller.

Rear bearing

Rear bearing - Remove 2.8.4 Front bearing - Remove Remove screws, and then remove the bearing retainer and front bearing from front bracket.

Screw

Front bracket

Front bearing

Bearing retainer

Front bearing - Remove

12-27

Chapter 12 ELECTRICAL SYSTEM 2.8.5 Stator - Remove Solder must be applied for a short period of time. If heat from the soldering iron is applied for a long time period, the diode will be damaged.

Melt the solder of stator and rectifier, and remove the stator Stator core

from the rectifier.

Rectifier Soldering

Stator - Remove 2.8.6 Regulator assembly - Remove Screws

(1) Remove the screws from the regulator assembly.

(2) Remove the solder that is connecting the regulator and rectifier.

Regulator assembly

(3) Remove the regulator assembly.

Rectifier assembly Soldering

Regulator assembly - Remove 2.8.7 Rectifier assembly - Remove (1) Remove the screws, molds and nuts from the rectifier.

(2) Remove the rectifier assembly.

Nut Rectifier assembly

Mold

Screw

Rear bracket

Rectifier assembly - Remove

12-28

Chapter 12 ELECTRICAL SYSTEM 2.9 Alternator - Inspect and Repair (A005TA5083A) 2.9.1 Stator - Inspect Terminal 2

(1) Conduction of stator terminals - Inspect

Terminal 3 Terminal 4

Make sure the terminals shown in the illustration are conducted. If isolated, replace the stator with a new

Terminal 1

one.

Inspection items Terminal 1 and Terminal 2 Terminal 2 and Terminal 3 Terminal 2 and Terminal 4

Conduction of stator terminals - Inspect (2) Insulation between terminal of stator coil and core Terminal 2

Inspect

Terminal 3 Terminal 4

Make sure the terminal 2 of stator coil and the stator core are isolated. If electricity is conducted, replace the stator with a new one.

Terminal 1

Insulation between terminal of stator coil and core Inspect 2.9.2 Rectifier - Inspect Test the resistance and insulation of each of the diodes with an analog tester.

E

If inspected result does not match the below table, replace

F

the rectifier with a new one.

Polarity of tester Negative (-) G E

Positive (+) A,B,C,D

Condition

A Conducted

B

D

G

Isolated

G

Isolated

E

Conducted

F

A,C,D

Isolated

A,C,D

F

Conducted

A,B,C,D

C

Rectifier - Inspect

Note: A,B,C,D:Stator coil lead wire connection part E,G:Heatsink F:Regulator connection part

12-29

Chapter 12 ELECTRICAL SYSTEM 2.9.3 Rotor - Inspect (1) Measure the resistance between the slip rings (rotor coil). If the measured value does not meet the standard, replace the rotor with a new one.

Item Resistance between slip rings

Standard 2.4 to 2.9 Ω

Resistance between slip rings (rotor coil) - Measure (2) Check that the slip ring and the shaft (or core) are isolated. If resistance is not present, replace the rotor with a new one.

Insulation between slip rings and shaft - Inspect

12-30

Chapter 12 ELECTRICAL SYSTEM 2.9.4 Brush for wear - Inspect Measure the length of the brushes. If the limit is exceeded, replace the brush with a new one.

Item

Standard

Limit

Brush length

18.5 mm [0.728 in.]

5.0 mm [0.197 in.]

Wear limit line

Brush for wear - Inspect 2.9.5 Brushes - Replace (1) To remove the brush and the spring, unsolder the brush

Soldering

lead.

Brushes - Replace (2) To install a new brush, push the brush into the brush holder as shown in the illustration, and then solder the

Brush

lead to the brush.

Note: Install the brush to the correct direction.

Brush - Install

12-31

Chapter 12 ELECTRICAL SYSTEM 2.10 Alternator - Assemble (A005TA5083A)

[12 V, 75 A]

4.4 ± 1 N·m {0.45 ± 0.1 kgf·m} [3.2 ± 0.7 lbf·ft] 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

117.5 ± 19.5 N·m {12 ± 1.9 kgf·m} [87 ± 14 lbf·ft]

Alternator - Assemble (A005TA5083A)

12-32

Chapter 12 ELECTRICAL SYSTEM 2.10.1 Rectifier assemble and

15.7 ± 2.9 N·m {1.6 ± 0.3 kgf·m} [11.5 ± 2.1 lbf·ft] Nut

regulator assembly - Install (1) Install the rectifier assembly and regulator assembly to the rear bracket.

(2) Solder the connecting parts of the regulator and recti-

Rectifier assembly

fier.

Mold

Screw 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

Rear bracket

Rectifier assembly - Install Screws 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

Regulator assembly

Rectifier assembly Soldering

Regulator assembly - Install 2.10.2 Stator - Install Solder must be applied for a short period of time. If heat from the soldering iron is applied for a long time period, the diode will be damaged.

(1) Install the stator.

Stator core

(2) Solder the lead wire of stator to the rectifier.

Rectifier Soldering

Stator - Install 2.10.3 Front bearing - Install (1) Install the front bearing to the front bracket.

(2) Secure the bearing retainer with the screw.

Screw

Front bracket

Front bearing

Bearing retainer

Front bearing - Install

12-33

Chapter 12 ELECTRICAL SYSTEM 2.10.4 Rear bearing - Install Rotor

Install the rear bearing to the rotor.

Rear bearing

Rear bearing - Install 2.10.5 Pulley - Install

Pulley assembly

(1) Insert the rotor to the front bracket.

(2) Attach the cloth to the rotor and fix it to the vise.

Front bracket

(3) Install the pulley assembly and secure it with the nut.

Rotor

Pulley - Install 2.10.6 Rear bracket assembly and front bracket assembly - Assemble

Rear bracket

(1) Lift up the brushes with a piece of wire inserted through the small hole in the bracket to the brush hole.

Brush Wire

Brush - Fix (2) Assemble the rear bracket assembly and front bracket Front bracket

assembly, and secure them with the through bolt.

Through bolt

Stator core

Rear bracket assembly and front bracket assembly Assemble

12-34

Chapter 12 ELECTRICAL SYSTEM 2.11 Alternator - Disassemble and Inspect (A002TA7871) 4

[12 V, 25 A] Dirt, damage and seizing of slip ring, and coil resistance

Rotation

5

1

Crack, damage Crack, damage

3

Rotation

8

2

6 10

Deformation, damage 9

Short circuit and open circuit

Sliding state and wear of brushes 7 Open circuit, ground of coil

Alternator - Disassemble and Inspect (A002TA7871) Disassembling sequence 1 2 3 4

Screw Nut Pulley assembly Rotor assembly

5 6 7 8

Front bracket assembly Stator Regulator assembly Nut set

9 Rectifier assembly 10 Rear bracket

12-35

Chapter 12 ELECTRICAL SYSTEM 2.11.1 Stator and Front bracket - Remove Rear bracket

(a) Disassemble the alternator only when repair becomes necessary. (b) Use care not to insert the screwdriver too deep, or its tip may damage the stator.

(1) Remove through bolts.

(2) Insert the tip of a flat-blade screwdriver between the stator and front bracket, and wrench them.

Stator core

Front bracket

Stator and Front bracket - Remove 2.11.2 Pulley - Remove Pulley assembly

When holding a rotor with a vice, be sure to hold at Front bracket

the base of claw with a vice. Holding the tip of the claw can cause malfunctions.

(1) Attach the cloth to the rotor and fix it to the vise.

(2) Remove pulley nut, and then pull out the pulley.

(3) Remove the rotor from the front bracket.

Rotor

Pulley - Remove 2.11.3 Rear bearing - Remove Rotor

Remove the rear bearing from the rotor with the bearing puller.

Rear bearing

Rear bearing - Remove 2.11.4 Front bearing - Remove Remove screws, and then remove the bearing retainer and front bearing from front bracket.

Screw

Front bracket

Front bearing

Bearing retainer

Front bearing - Remove

12-36

Chapter 12 ELECTRICAL SYSTEM 2.11.5 Stator - Remove Solder must be applied for a short period of time. If heat from the soldering iron is applied for a long time period, the diode will be damaged.

Melt the solder of stator and rectifier, and remove the stator Stator core

from the rectifier.

Rectifier Soldering

Stator - Remove 2.11.6 Regulator assembly - Remove Screws

(1) Remove the screws from the regulator assembly.

(2) Remove the solder that is connecting the regulator and rectifier.

(3) Remove the regulator assembly.

Regulator assembly

Rectifier assembly Soldering

Regulator assembly - Remove 2.11.7 Rectifier assembly - Remove (1) Remove the screws, molds and nuts from the rectifier.

(2) Remove the rectifier assembly.

Nut Rectifier assembly

Mold Screw Rear bracket

Rectifier assembly - Remove

12-37

Chapter 12 ELECTRICAL SYSTEM 2.12 Alternator - Inspect and Repair (A002TA7871) 2.12.1 Stator - Inspect Terminal 2

(1) Conduction of stator terminals - Inspect

Terminal 3

Make sure the terminals shown in the illustration are conducted. If isolated, replace the stator with a new

Terminal 1

one.

Inspection items Terminal 1 and Terminal 2 Terminal 2 and Terminal 3 Terminal 1 and Terminal 3

Conduction of stator terminals - Inspect (2) Insulation between terminal of stator coil and core Terminal 2

Inspect

Terminal 3

Make sure the each terminal of stator coil and the stator core are isolated. If electricity is conducted, replace the

Terminal 1

stator with a new one.

Insulation between terminal of stator coil and core Inspect 2.12.2 Rectifier - Inspect Inspect the conduction and insulation of each diodes with F

D

analog tester.

If inspected result does not match the below table, replace the rectifier with a new one.

Polarity of tester Negative (-) E D

Positive (+) A,B,C

Condition Conducted Isolated

E

Isolated

D

Conducted

F

A,B,C

Isolated

A,B,C

F

Conducted

A,B,C

Note: A,B,C:Stator coil lead wire connection part D,E:Heatsink F:Regulator connection part

12-38

A

C B

E

Rectifier - Inspect

Chapter 12 ELECTRICAL SYSTEM 2.12.3 Rotor - Inspect (1) Measure the resistance between the slip rings (rotor coil). If the measured value does not meet the standard, replace the rotor with a new one.

Item Resistance between slip rings

Standard 13.6 to 15.9 Ω

Conduction between slip rings (rotor coil) - Measure (2) Check that the slip ring and the shaft (or core) are isolated. If electricity is conducted, replace the rotor with a new one.

Insulation between slip rings and shaft - Inspect

12-39

Chapter 12 ELECTRICAL SYSTEM 2.12.4 Brush for wear - Inspect Measure the length of the brushes. If the limit is exceeded, replace the brush with a new one.

Item

Standard

Limit

Brush length

18.5 mm [0.728 in.]

5.0 mm [0.197 in.]

Wear limit line

Brush for wear - Inspect 2.12.5 Brushes - Replace (1) To remove the brush and the spring, unsolder the brush

Soldering

lead.

Brushes - Replace (2) To install a new brush, push the brush into the brush holder as shown in the illustration, and then solder the

Brush

lead to the brush.

Note: Install the brush to the correct direction.

Brush - Install

12-40

Chapter 12 ELECTRICAL SYSTEM 2.13 Alternator - Assemble (A002TA7871)

[12 V, 25 A]

4.4 ± 1 N·m {0.45 ± 0.1 kgf·m} [3.2 ± 0.7 lbf·ft]

3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

117.5 ± 19.5 N·m {12 ± 1.9 kgf·m} [87 ± 14 lbf·ft]

Alternator - Assemble (A002TA7871)

12-41

Chapter 12 ELECTRICAL SYSTEM 2.13.1 Rectifier assemble and

7.9 ± 1.9 N·m {0.8 ± 0.19 kgf·m} [5.8 ± 1.4 lbf·ft] Nut

regulator assembly - Install (1) Install the rectifier assembly and regulator assembly to the rear bracket.

(2) Solder the connecting part of regulator and rectifier.

Rectifier assembly

Mold Screw 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

Rear bracket

Rectifier assembly - Install Screws 3.9 ± 1 N·m {0.4 ± 0.1 kgf·m} [2.9 ± 0.7 lbf·ft]

Regulator assembly

Rectifier assembly Soldering

Regulator assembly - Install 2.13.2 Stator - Install Solder must be applied for a short period of time. If heat from the soldering iron is applied for a long time period, the diode will be damaged.

(1) Install the stator.

Stator core

(2) Solder the lead wire of stator to the rectifier.

Rectifier Soldering

Stator - Install 2.13.3 Front bearing - Install (1) Install the front bearing to the front bracket.

(2) Secure the bearing retainer with the screw.

Screw

Front bracket

Front bearing

Bearing retainer

Front bearing - Install

12-42

Chapter 12 ELECTRICAL SYSTEM 2.13.4 Rear bearing - Install Rotor

Install the rear bearing to the rotor.

Rear bearing

Rear bearing - Install 2.13.5 Pulley - Install Pulley assembly

(1) Insert the rotor to the front bracket.

(2) Attach the cloth to the rotor and fix it to the vise.

(3) Install the pulley assembly and secure it with the nut.

Front bracket

Rotor

Pulley - Install 2.13.6 Rear bracket assembly and front bracket assembly - Assemble

Rear bracket

(1) Lift up the brushes with a piece of wire inserted through the small hole in the bracket to the brush hole.

Brush Wire

Brush - Fix (2) Assemble the rear bracket assembly and front bracket

Front bracket

assembly, and secure them with the through bolt.

Through bolt Stator core

Rear bracket assembly and front bracket assembly Assemble

12-43

Chapter 12 ELECTRICAL SYSTEM 2.14 Glow plug - Inspect and Repair 2.14.1 Heating test of glow plug Connect the wiring to the terminal and ground the body as shown in the illustration. If the glow plug heats red, it is normal.

Item

Standard

Remarks

Rated voltage Armature current

9.7 ± 1.0A

When applying DC10.5 ± 0.1V for 30 sec.

Heating test of glow plug

2.15 Magnetic valve (stop solenoid) - Inspect and Repair 2.15.1 Conduction test of magnetic valve (stop solenoid) - Inspect Test the resistance between the terminal and body as shown in the illustration. If isolated or if the resistance is lower than the standard value, replace the magnetic valve assembly with a new one.

Item Resistance

Standard 8Ω

Conduction test of magnetic valve 2.15.2 Magnetic valve (stop solenoid) operation Inspect Check visually for rubber strips of the tip of the armature and damages. Also, check the armature moves smoothly by rotating with a hand.

Armature

Magnetic valve operation - Inspect

12-44

Chapter 12 ELECTRICAL SYSTEM

3. Electrical system - Install 3.1 Glow plug - Install (1) Install the glow plug, and tighten it to the specified Connection plate

torque.

(2) Install the connection plate and tighten the fixing nuts to the specified torque.

Nut 1.2 ± 0.2 N·m {0.12 ± 0.02 kgf·m} [0.9 ± 0.18 lbf·ft] 17.2 ± 0.2 N·m {1.7 ± 0.24 kgf·m} [12.6 ± 1.8 lbf·ft]

Glow plug

Glow plug - Install

3.2 Magnetic valve (stop solenoid) - Install Install the magnetic valve assembly to the injection pump distributor head with the specified torque.

Magnetic valve assembly 20 ± 5 N·m {2 ± 0.5 kgf·m} [15 ± 3.6 lbf·ft]

Injection pump distributor head

Magnetic valve (stop solenoid) - Install

3.3 Alternator - Install (1) Install the adjusting plate.

(2) Install the alternator.

Alternator

Adjusting plate

Alternator bracket

Alternator - Install

3.4 Starter - Install (1) Install the starter.

(2) Connect the harness, and tighten the fixing nut to the specified torque.

Starter terminal B ࠬ࠲࡯࠲B┵ሶ +2 +2 9.8 N·m 0 9.8 0 N·m +0.2 {1 00 kgf·m} {1 +0.2 kgf·m} [7.2 +1.4 lbf·ft] 0 Starter

45 ± 15 N·m {4.6 ± 1.5 kgf·m} [33 ± 11 lbf·ft]

Starter - Install

12-45

Chapter 13 ADJUSTMENT AND OPERATION 1.

Engine - Adjust ...................................................................................................... 13-3 1.1 1.2 1.3 1.4

2.

Break-in operation ................................................................................................. 13-6 2.1 2.2

3.

Valve clearance - Inspect ....................................................................................................... 13-3 Fuel system - Drain................................................................................................................. 13-3 Fuel system - Bleed air ........................................................................................................... 13-4 V-belt tension - Inspect and Adjust ......................................................................................... 13-5 Starting up .............................................................................................................................. 13-6 Break-in operation .................................................................................................................. 13-6

Performance test ................................................................................................... 13-7 3.1 3.2 3.3 3.4

Engine equipment condition ................................................................................................... 13-7 Test items and purposes ........................................................................................................ 13-7 Other inspections.................................................................................................................... 13-7 Engine output adjustment ....................................................................................................... 13-7

13-1

Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust

Chapter 13 ADJUSTMENT AND OPERATION

1.1 Valve clearance - Inspect Inspect the valve clearance.

If the valve clearance is out of standard, adjust it to the standard value.

For the adjusting procedure, refer to “Valve clearance Inspect and Adjust” of “ASSEMBLY OF BASIC ENGINE”.

1.2 Fuel system - Drain

(a) When draining the fuel filter, fuel flows out together with the water. Wipe off any spilled fuel.

This can cause fire. (b) Tighten the drain plug securely after draining the water. Failure to do so could cause a fire.

If water trapped in the bottom of the fuel filter exceeds the specified level, the water may enter into the fuel system.

1.2.1 Fuel filter - Drain (1) Loosen the drain plug on the bottom of the fuel filter.

(2) Water is easily drained by pressing the priming pump repeatedly (approx. 7 times) to feed the fuel.

(3) Tighten the drain plug securely after draining the water.

(4) Always bleed the air in the fuel system after draining the water.

Drain plug

Fuel filter - Drain (1)

Priming pump

Fuel filter - Drain (2)

13-3

Chapter 13 ADJUSTMENT AND OPERATION 1.3 Fuel system - Bleed air

Wipe off fuel spilled from the air vent plug thoroughly with a cloth. Be sure to tighten the air vent plug after air bleeding. Failure to do so could cause a fire.

1.3.1 Fuel filter - Bleed air (1) Loosen the air vent plug of the fuel filter with a wrench.

(2) Repeatedly press the priming pump with the cloth applied to the air vent plug. When fuel with air bubbles no longer comes out, tighten the air vent plug securely.

(3) Be sure to tighten the air vent plug after air bleeding.

Air vent plug

Fuel filter - Bleed (1)

Priming pump

Air vent plug

Fuel filter - Bleed (2)

13-4

Chapter 13 ADJUSTMENT AND OPERATION 1.4 V-belt tension - Inspect and Adjust

If the damages such as cuts or surface separations are found during inspection, replace the V-belt with a new one.

Keep oil and grease away from the V-belt. They may cause the belt to slip and shorten the service life.

Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.

Adjust the belt tension accurately by following the procedures.

1.4.1 V-belt - Inspect (1) Inspect the belt visually for separation or damage. If any abnormality is found, replace the V-belt with a new one.

(2) Inspect the deflection of V-belt.

Inspect the V-belt deflection by pressing it with 98 N {10 kgf} [72 lbf] force at the center of its span. The belt deflection should be 12 mm [0.47 in.].

If the deflection is out of standard, adjust the belt tension.

1.4.2 V-belt tension - Adjust (1) Loosen all retaining bolts of the alternator and adjusting plate.

Adjusting bolt

98 N rox. f} p p A kg {10 lbf] [72

Water pump pulley

(2) Adjust V-belt tension properly.

(3) Tighten all retaining bolts of the alternator and adjusting plate.

mm 12 in.]

7 4 [0.

Adjusting plate

Crankshaft pulley

Alternator pulley Fixing bolt

V-belt tension - Adjust

13-5

Chapter 13 ADJUSTMENT AND OPERATION

2. Break-in operation 2.1 Starting up (1) Before starting the engine, check the levels of fuel, engine oil, and coolant, and also bleed the fuel system and cooling system.

(2) Stop the fuel supply, and crank the engine with the starter for 10 seconds to lubricate the engine.

(3) Move the control lever slightly in the fuel increase direction (but not to the “full injection” position), and then turn the starter switch key to the [START] position to start the engine.

(4) After the engine has started, adjust the control lever to let the engine operate at a minimum no-load speed (low idle speed).

(5) Turn the starter switch key to the [OFF] position and make sure that the engine is stopped.

2.2 Break-in operation

If an abnormal condition occurs during engine operation, make sure an emergency stop can be activated.

2.2.1 Load in the break-in operation and operation time Progressively, increase the load during break-in operation.

The following times indicated in the chart below show the minimum times required for the engine to operate reliably.

Break-in operation Load (PS)

Time (min)

600 to 900

No-load

20

1000 to 1200

No-load

10

1400 to rated speed

No-load

10

4

25%

20

5

50%

20

Engine speed (min-1) 1 Low rotation speed 2

Medium rotation speed

3 High rotation speed

6

Rated speed

7

75%

30

100%

20

2.2.2 Inspecting engine condition after starting up During the break-in operation, take care the followings and make sure no abnormalities are found. Oil pressure, oil temperature

Exhaust temperature

Coolant level, water level

Blow-by gas (level and color)

Any leakage of oil, coolant fuel, and gas (air)

Rotational fluctuation

Noise, vibration

Face and radial runouts of rotating parts

Intake air pressure, intake air temperature

Indication and operation of meter and alarm

Exhaust color, odor 2.2.3 Inspection and adjustment after break-in operation Valve clearance

Belt tension

Fuel injection timing

Inspect and repair for defects such as oil leakage

Additional tightening of exterior bolt and nut

13-6

Chapter 13 ADJUSTMENT AND OPERATION

3. Performance test The following describes the procedures specified in “Earth moving machinery - Engines - Part 1: Test code of net power (JIS D0006-1)” and “Earth moving machinery Engines - Part 2: Standard format of specifications and testing methods of diesel engines (JIS D0006-2).” Other test items may be required in some applications. All test results should be evaluated comprehensively in order to determine the engine performance.

3.1 Engine equipment condition The engine must be equipped with standard auxiliary devices such as cooling fan, air cleaner and alternator.

3.2 Test items and purposes 3.2.1 Operation load test Conduct this test to evaluate the engine output, torque, fuel consumption rate and governor performance under various load conditions.

3.2.2 Continuous load test Operate the engine continuously for 10 hours at 90% load (continuous load application) of nominal net brake power while the engine speed is maintained at revolutions corresponding to the nominal brake power. In this test, evaluate the fuel consumption rate and operating condition, and confirm that the engine is capable of continuous operation.

3.2.3 No-load minimum engine speed test Conduct this test to confirm that the engine can operate stably at the specified No-load minimum engine speed.

3.3 Other inspections Check for gas, coolant and oil leaks; abnormal odors; and hunting. Make adjustment as needed.

3.4 Engine output adjustment 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.

3.4.1 Standard atmospheric conditions Base temperature: 298 K (25°C) [77°F] Total pressure: 100 kPa (750 mmHg) Dry pressure: 99 kPa (743 mmHg)

13-7

Chapter 13 ADJUSTMENT AND OPERATION 3.4.2 Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value. If the applicable range of the correction formula is exceeded, indicate the corrected values and record the test conditions on the test record.

Calculation output = Correction factor (

) × Measured brake power

Atmospheric conditions during test Temperature( ):283 K(10 °C)[50 °F] T 313 K(40 °C )[104 °F] Dry atmospheric pressure( ):80 kPa(600 mmHg) 110 kPa(825 mmHg) =(

)

:Atmospheric factor

:Engine factor

Range of correction equation use The range of correction factor ( ) is as follows: 0.9 1.1.

Calculation of correction factor (

)

Natural aspiration engine and engine with mechanically driven air charger 0.7 99 =( )·( ) 298 Turbocharged engine without air cooler or with air-to-air cooler 1.2 99 0.7 =( ) ·( ) 298 Turbocharged engine with air-to-liquid cooler 0.7 99 0.7 =( ) ·( ) 298

13-8

Calculation of engine factor (

)

=0.036 -1.14 :Corrected fuel supply volume = ( ) × (Fuel flow rate g/s) (Stroke volume ) × (Engine speed min-1) = 120000 (4-cycle engine) :Ratio between pressure at turbocharger or air cooler outlet and atmospheric pressure ( =1 for natural aspiration engine) · Applicable range of engine factor ( ) 37.2 65mg/( -cycle) · 37.2mg/(l -cycle): =0.2 (constant) · 65mg/( -cycle) : =1.2 (constant) =

TECHNICAL PUBLICATIONS FEEDBACK (Please print)

Dealer name: __________________________

Submitted by: _________________________

Address: _____________________________

P. O. Box: ____________________________

City: ________________________________

State: ________________________________

Zip code: _____________________________

Country: _____________________________

The following discrepancy or omission has been discovered in: Operation & Maintenance Manual

Option Bulletin

Part List/Manual

Special Instruction

Service Manual

Service Data Manual

Electronic Manual

Other: ___________________________

Publication # ________________________

Engine model # ________________________

Truck model # _______________________

Issue date # ___________________________

Truck serial # _______________________

Page # _______________________________

(Please print)

Explanation of discrepancy or omission: _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________

Please fax or mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2121 W. Sam Houston Parkway N. Houston, Texas 77043-2305 Fax: 713-365-1616

Mitsubishi Caterpillar Forklift Europe B.V. Attn: Product Support Hefbrugweg 77 1332 AM, Almere, The Netherlands Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Warranty & Service Engineering No.1 Tuas West Street Singapore 637444 Republic of Singapore Fax: 65-6897-7562 RCB No.: 199203169H

MCF Forklift (Shanghai) Co., Ltd. A/23F, Meixin Mansions 728 Xizang Rd (M.) Shanghai, 200001 China Fax: +86-21-6360-7107

Cat Lift Trucks Service Manual

S6S Diesel Engine

99739-32110

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. RCB No.: 199203169H No.1, Tuas West Street Singapore 637444 Copyright © 2013. All rights reserved. CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow," the "Power Edge" trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. All registered trademarks are the property of their respective owners. Some products may be shown with optional equipment.

Printed in China 99739-32110

03/13