Kobelco 140SRLC-3 Hydraulic Excavator Engine Manual - PDF DOWNLOAD

51. ENGINE

51. ENGINE 51

PREFACE This service manual explains the single engine. Note that this manual is edited without modification by based on the service manual of MITSUBISHI HEAVY INDUSTRIES, Ltd.

Book Code No. S5YY5123E01 51-1

51. ENGINE a) Serial No. plate on the top of engine

 Serial No. plate on the top of engine



b) Serial No. plate on the top of engine ECU.

Serial No. plate on the top of engine ECU

ECU, CONTROLLER

51-2

SERVICE MANUAL

1COVER

for KOBELCO CONSTRUCTION MACHINERY CO. , LTD

February 2012 Pub. No. 99616-28100

Foreword 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 scheduled inspection and maintenance, and it may also be necessary to take appropriate measures which involve in disassembly, inspection, repair and assembly work 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 this manual are based on the engine model produced at the time of publication. Please note that the contents of this manual may change due to improvements made thereafter.

I

Foreword

HOW TO USE THIS MANUAL This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards, adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi diesel engines.

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

Regarding the procedures for operation and scheduled 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.

If you have an inquiry, please check the engine model and serial number, and contact our service department.

Description format (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 the Chapter 2.

(4) The tightening torque with engine oil applied on the thread is specified [Wet]. Unless otherwise specified, the tightening torque is of dry condition.

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

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, may result in property damage.

Note

II

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

Foreword

Terms used in this manual Nominal value means the basic nominal size of a part to be measured.

Standard value means the quantitative requirement for dimension of a part, clearance between parts and performance. The values are rounded off for the inspection job, and do not necessarily conform to the design values.

Limit value means the value, which the measured value reaches, the part needs repair or replacement with a new one.

Abbreviations and Standards BTDC : Before Top Dead Center ATDC : After Top Dead Center BBDC : Before Bottom Dead Center ABDC : After Bottom Dead Center TIR : Total Indicator Reading API : American Petroleum Institute ASTM : American Society for Testing and Materials JIS : 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

Unit of Measurement Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and U.S. customary values are in [ ]. For the 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 Output power :1 kW = 1.341 HP = 1.3596 PS Pressure (mercury column) :1 kPa = 0.7 cmHg Pressure (water column) :1 kPa = 10.197 cmH2O (cmAq) Rotation speed:1 min-1 = 1 rpm

III

Foreword

Safety Cautions Fire and Explosion Precautions Keep Flames Away

Pay Attention to Fuel, Oil and Exhaust Gas

Do not use flames near the engine (in

Leak

the engine room). The flame is dan-

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

gerous to ignite combustibles and

diately take corrective measures to stop it. Such leak-

cause a fire. Wipe off spilled fuel, oil

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

and LLC immediately and thoroughly.

reach hot engine surfaces or hot exhaust gas to con-

Spilled fuel, oil and LLC may ignite and cause a fire.

tact flammable material, may results in a fire, personal

Store the fuel and engine oil in a well ventilated area.

injury and damage to the equipment.

Make sure that the fuel and engine oil container caps

Use Explosion-Proof Light

are tightly fastened.

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

Keep Engine Surrounding Area Tidy and

trolyte, etc., use an explosion-proof light. If the lighting

Clean

is not an explosion-proof type, it may ignite and cause

Do not place combustible or explosive material, such

an explosion.

as fuel, engine oil, LLC or explosive powder near the

Prevent Electrical Wires from Short Circuit

engine. Such substances can cause a fire or explo-

Avoid inspecting or servicing the electrical system with

sion. Thoroughly remove dust, dirt and other foreign

the battery cable connected to the battery. Otherwise,

material collected on the engine and the area around

a fire could result from short circuit. Be sure to discon-

the engine. Such material can cause a fire or the

nect the battery cable from the negative (-) terminal

engine to overheat. In particular, clean the top surface

before starting work. A loose terminal and a damaged

of the battery thoroughly. Dust can cause a shortcir-

cable or wire may result in a short circuit and a fire.

cuit. Always place the engine at a position at least 1 m

Inspect, and if any defect is found, repair or replace it

[3.28 ft.] apart from buildings and other equipment to

before starting work.

prevent a possible fire caused by engine heat.

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 to be ready for use in an emergency. Make counteract procedures against a fire or an accident. Provide the contact person and means of communication in case of emergency.

IV

Foreword

Stay Away From Rotating and Moving Parts Install Protective Covers Over Rotating

Lockout and Tagout

Parts After Inspection and Maintenance

Be sure to lockout and tagout before starting inspec-

Work

tion and maintenance. Lockout and tagout are effec-

Check the covers over engine rotating parts for correct installation. Repair any damaged or loosed covers. Never remove the protective covers over rotating parts during operation. When the engine is coupled to a radiator or other equipment, install protective covers over the exposed connecting

tive methods of cutting off machines and equipment from energy sources. To accomplish the lockout/ tagout, remove the starter switch key, set the battery switch to OFF position and attach a DO NOT RUN or equivalent caution tag to the starter switch. The starter switch key must be kept by the person who performs inspection and maintenance work.

belt and coupling.

Be Sure to Stop the Engine Before Inspec-

Check Work Area for Safety Before Starting

tion and Maintenance

Before starting the engine, make sure that no one is

Be sure to stop the engine before proceeding to

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

inspection and maintenance work. Never try to make

the engine. Verbally notify persons within the immedi-

adjustments on the engine parts while the engine is

ate area when starting the engine. When the starter

running. Rotating parts such as belt can reel in your

device is tagged with the warning sign saying DO NOT

body and cause serious injuries.

RUN, never start the engine.

Always Put Back Engine Turning Tool After

Stay Away From Moving Parts While Engine

Use

Operates

Be sure to remove the turning tool used for inspection

Keep away from the rotating parts

and maintenance work. If the engine is started with a

during operation. Do not leave any

turning tool inserted, it can not only cause a damage

objects that may get caught in rotating

to the engine, but also lead to a personal injury.

parts. If clothes or a tool gets caught in rotating parts, serious injury will result.

V

Foreword

Be Careful of Exhaust Gas Poisoning

Be Careful of Falling Lift Engine Carefully

Be careful of Ventilation to Operate Engine

Use slings or wire ropes strong

If the engine is installed in an

enough to lift the load considering the

enclosed area, and the exhaust gas is

engine weight. To lift the engine, hitch

ducted outside, make sure that duct

the proper slings to the lifting hangers

joints are free from gas leak. Exhaust

prepared on the engine. To lift the

gas from the engine sometimes con-

engine, keep the engine in a well-bal-

tains harmful components. Operating the engine in an

anced position, thinking carefully of the engine center

ill-ventilated area can cause gas poisoning.

of gravity.

Be Careful of Hearing Loss

The hangers prepared on the engine are designed for lifting the weight of engine only. In the case where the

Wear Ear Plugs Always wear ear plugs when entering the machine room (engine room).

Combustion sound and mechanical noise of engine can cause hearing loss.

generator, marine gear, and others are installed to the engine, consideration that the additional weight will not affect the hangers of the engine.

Keep the angle formed by slings attached to hangers within 60°. If the angle exceeds this limit, excessive load may be applied to the hangers and damage the hangers. If the wire rope contacts the engine directly, place a cloth or other soft pad to avoid damage to the engine and wire rope. Remove the engine part if necessary.

Do not Climb Onto the Engine Do not climb onto the engine, nor step on any engine parts on the engine sides. To work on parts located high on the engine, use a ladder, footing, and others to prevent from slipping and falling. Climbing onto the engine may result in engine part damage and your injury by falling down.

Always Prepare a Stable Footing When working on the upper part of the engine and other hard-to-reach places, use a stable footing. Standing on an old footstool or parts box may result in personal injury. Do not put any unnecessary objects on a footing.

VI

Foreword

Be Careful When Handling Fuel, Engine Oil or Coolant

Be Careful of Burns Do Not Touch the Engine During or Immedi-

Use Specified Fuel, Engine Oil and Coolant

ately After Operation

Only

Do not touch any parts of the engine

Use the fuel, oil and coolant specified in this manual

during or immediately after operation.

only, and handle them carefully. Use of material other

You can get burned. Before starting

than specified one, or improper handling may cause

the maintenance and inspection work,

various engine defects and malfunctions. Get the

check the water temperature meter to make sure that

MSDS issued from the fuel, oil and coolant suppliers,

the engine is cooled down.

and follow the directions in the MSDS for proper han-

Be Careful to Open and Close the Radiator

dling.

Cap

Be Careful with Coolant

Never open the radiator cap while the engine is run-

When handling coolant, wear rubber gloves and a pro-

ning or immediately after the engine stops. Stop the

tective face mask. If the coolant contacts your skin, or

engine and give a sufficient time to allow the coolant to

get into your eyes or mouth, it may cause injury of skin

cool down before opening the cap. When opening the

or eyes, or poisoning. If coolant is accidentally swal-

radiator cap, slowly open the cap so as to release

lowed, induce vomiting immediately and seek medical

internal pressure. To prevent hot steam scalds, wear

attention. If coolant enters your eyes, flush them

thick rubber gloves or, cover the cap with a cloth.

immediately with plenty of water and seek medical

When closing the radiator cap, tightly close the cap.

attention. If coolant contacts your skin or clothing,

Do not open the radiator cap during engine running or

wash it away immediately with plenty of water. Keep

immediately after engine stop. Otherwise hot steam

flames away from coolant. Coolant can catch flames

and coolant gush out and can cause burns.

and cause a fire. Drained coolant is a hazardous mate-

Refill Coolant Only After the Coolant Tem-

rial. Do not discard it in an unauthorized procedure.

Practice the applicable law and regulations when discard drained coolant.

Proper procedure to discard waste oil and

perature Dropped Refill the coolant after the coolant temperature drops to a room temperature. Replacement job immediately after the engine stop may cause burns.

coolant Do not discard waste engine oil or coolant in an unauthorized procedure. Such a way of disposal is strictly prohibited by laws and regulations. Discard waste oil, coolant and other environmentally hazardous waste in accordance with the applicable laws and regulations.

VII

Foreword

Battery

When Abnormality Occurs

Be Careful with Battery

Stop overheated engine after cooling run

Never use flames or generate

Even if the engine is about to overheat, do not stop the

sparks near the battery. The bat-

engine immediately. Abrupt stopping of an overheated

tery gives off highly flammable

engine can cause the coolant temperature to rise,

hydrogen gas and oxygen gas.

resulting in seized engine parts. If the engine is about

Any flame or spark near a battery

to overheat, run the engine at low idling speed (cooling

may cause an explosion.

operation), and stop the engine after the coolant tem-

Do not use the battery if its fluid level is below the lower limit line. Wrong use of the battery may result in an explosion.

Do not short the battery terminals with a tool or other metal object.

perature lowers sufficiently.

Do Not Add Cooling Water Immediately After a Sudden Stop Due to Overheating If the engine stops suddenly due to overheating, or

When disconnecting battery cables, always remove

you suddenly stop the engine by any reason, do not

first from negative (-) terminal first. When reconnect-

add cooling water immediately. If water is added

ing the cables, always connect first to the positive

immediately, parts such as cylinder heads can be

(+) terminal.

damaged due to the sudden drop of temperature. Add

Charge the battery in a well-ventilated area, with all battery cables removed.

Make sure the cable clamps are securely fastened to

cooling water slowly after the engine becomes cool.

Be Careful to Restart After an Abnormal

the battery terminals. A loose terminal can cause

Stop

sparks that may result in an explosion.

If the engine stops abnormally, do not restart the

Before servicing electrical components or conducting

engine immediately after the stopping. If the engine

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

stops or is stopped, inspect the engine to clarify the

OFF] position or disconnect the cable from the nega-

cause of the defect and correct the cause before

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

restarting. If the engine is kept operating in such a

rent.

condition, it can result in serious engine failure.

Electrolyte (battery fluid) contains dilute sulfuric acid.

Careless handling of the battery may lead to the loss

Immediately Stop the Engine When Engine

of sight and/or skin burns. Also, do not swallow bat-

Oil Pressure Drops

tery fluid.

If the engine oil pressure drops significantly, stop the

Wear protective goggles and rubber gloves when

engine immediately, and inspect the lubrication sys-

working with the battery (such as adding water or

tem to find the cause. Continuous engine operation

charging).

with low oil pressure may cause bearings and other

If battery electrolyte is spilled onto the skin or clothing, immediately wash it away with lots of water. Use soap to clean thoroughly.

Battery fluid can make you blind if splash into your

parts to seize.

Stop the Engine Immediately When the Belt Break

eyes. Immediately flush it away with plenty of clean

If the belt breaks, stop the engine immediately. Contin-

water, and seek immediate medical attention.

uous engine operation with the broken belt can cause

If battery fluid is accidentally swallowed, gargle with

the engine to overheat. Steam of boiled cooling water

plenty of water, then drink lots of water, and seek

may gush out from the reserve tank or radiator, and

immediate medical attention.

results in burns.

VIII

Foreword

Other Cautions Do Not Tamper

Break-in the Engine

If tampered, the warranty is totally void even in the

To break-in a new engine or overhauled engine, oper-

warranty period. Tampering with the engine can not

ate the engine at a speed lower than the rated speed

only damage the engine but also may lead to personal

in a light load condition during the first 50 hours of

injury.

operation. Operating a new engine or overhauled

Perform All Specified Pre-operation Inspec-

engine in a severe condition during the break-in period

tions and Scheduled Inspections

shortens the service life of the engine.

Conduct the daily inspection and scheduled inspec-

Warm-up the Engine Before Use

tion/maintenance as described in this manual.

After starting the engine, run the engine at a low idling

Failure to conduct the specified inspections may cause

speed for warming-up, Start the work after this warm-

various engine problems, damage to parts, and a seri-

ing-up is completed. Warm-up operation circulates

ous accident.

lubricant in the engine, and works for the longer ser-

Wear Proper Work Clothing and Protective Gears Wear a hard hat, face shield, safety shoes, dust mask, gloves, ear plugs and other protective gears as

vice life and economical operation. Do not continue the warm-up operation for a longer time than necessary. Long warm-up operation causes carbon deposits in the cylinders, and may lead to incomplete combustion.

needed. When using compressed air, wear ear plugs, safety goggles, a hard hat, gloves and other neces-

Do Not Operate the Engine in an Over-

sary protective gears. Works without wearing proper

loaded Condition

protective gears may result in serious injury.

If the engine shows an overloaded condition such as

Never Break the Seals To ensure the proper engine operation, the high-pressure pump, governor, handle and fuel control link are provided with seals that protect the fuel injection volume and rotation speed settings against tampering. If the engine is operated with the seal tampered, no

black exhaust smoke, reduce the load immediately to an appropriate load condition. Overloading causes not only high fuel consumption but also excessive carbon deposits inside the engine. Carbon deposits cause various problems and will shorten the service life of the engine.

guarantee will be provided. The defects shown below

Cool Down the Engine Before Stop

may occur if the seal is tampered.

Cool down the engine at a low idling for five to six min-

Rapid wear of moving and rotating parts

utes before stopping it. Stopping the engine immedi-

Engine troubles such as seizure and damage of

ately after high-load operation will cause local heat up

engine parts Sudden increase of fuel and lubricating oil consumption

of engine parts and shorten the service life of the engine. During the cooling operation, check the engine for abnormalities.

Deterioration of engine performance due to improper balance between fuel injection volume and governor control, or a serious accident due to overrunning of the engine

IX

Foreword

Do Not Continue Low Load Operation

Use Proper Tools for Maintenance Work

Low load continuous operation (less than 30%) must

Always keep in mind to select most appropriate tools

be limited within one hour. Long warm-up operation

for the work and use them correctly. If a tool is dam-

causes carbon deposits in the cylinders, and may lead

aged, replace with new tool.

to incomplete combustion. Also, after low load opera-

Do Not Operate Starter for a Long Time

tion for approx one hour, run the engine at a 30% or higher load for five minutes or more.

Do not use the starter for more than 10 seconds at a time. If the engine does not start, wait for at least 1

Use Care to Protect Engine From Water

minute before starting again. Continuous operation of

Use care to protect engine from water such as rain

the starter to start a stubborn engine may lead to a flat

entering through the air inlet or exhaust openings. Do

battery or starter burning out.

not wash the engine while it is running. Cleaning fluid

Do Not Turn Off the Battery Switch During

or water can be sucked into the engine. Starting the engine with water inside the combustion chambers can cause the water hammering, and may result in engine inner parts damage and serious accident.

Operation Do not turn off the battery switch during operation. If the battery switch is turned OFF when the engine is running, not only various meters will stop working but

Properly maintain the air cleaner

also the diodes and transistors in the starter can be

The major cause of abnormal wear on engine parts is

damaged.

foreign materials from intake air. Worn parts produce many problems such as 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 during operation. For-

Cautions for Engine Transportation To road-transport the engine, consider the engine weight, width and height, and obey applicable laws and regulations such as road traffic laws, vehicle road acts and vehicle restriction ordinances.

eign material enters the engine and may result in a

Be Careful of Engine Room Ventilation

serious failure.

Always keep the engine room well-ventilated. Insuffi-

Remove the air cleaner slowly to prevent dust accu-

cient intake air amount of the engine can cause an

mulated on the element from falling off. After remov-

increase in the engine temperature, and could result in

ing the air cleaner, immediately cover the opening

a decrease in the output power and poor performance.

(inlet port of air cleaner) with plastic sheet or similar

It is highly recommended to calculate the required

means to prevent dust from entering the engine.

amount of air supply to the engine and install an ade-

An air cleaner with a dust indicator gives an alarm when it is clogged. Conduct maintenance when the alarm is given.

Observe Safety Rules at Work Site Observe the safety rules established at the workplace when operating and maintaining the engine. Do not operate the engine if you are in bad health. Consult your supervisor about your condition. Operation of the engine with decreased attention may cause improper operation and results in an accident. When working in a team of two or more people, use specified hand signals to communicate among workers.

X

quate ventilation system before installing the engine.

Do Not Touch High Pressure Fuel Jet. Do not touch fuel jet leaked or sprayed from the high pressure injection pipe. Fuel in the fuel injection pipe has a high pressure and if the fuel impinges your skin, it goes through the skin and can cause serious injury.

Foreword

Warning Labels Maintenance of Warning Labels Make sure all warning/caution labels are legible.

Clean or replace the warning or caution label when the description or illustration is not clear to read.

For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other chemicals to prevent the label from fading and peering.

Replace a damaged or missing label with a new one.

If any engine part stuck with a warning label is replaced with a new one, attach a new identical warning label to the new part.

To get new warning labels, contact our approved dealer.

Warning Labels

XI

Foreword

Points on Disassembling and Assembling This service manual contains the recommended practices to

Points on Assembling

service the engine. The manual also contains dedicated spe-

Wash all engine parts, except such parts as oil seals, O-

cial tools made for the work, and the basic safety cautions to

rings and rubber seats, in cleaning oil and dry them with

obey when working. Note that this manual does not cover

compressed air.

all potential hazards that could occur during maintenance,

Use correct tools and instruments.

inspection and service works of the engine.

Use only high-quality lubricating oil and grease of the

When working on the engine, follow the related instructions in this manual and also be careful of the following:

Points on Disassembling Use correct tools and instruments. Or serious damage or accident may result.

Do not use jack bolts having sharp edge, as they may cause damage to the surface.

Use a footing and workbench to place disassembled parts if necessary, and obey the disassembling procedures described in this manual. Do not place the parts on the floor directly. Place them on a workbench or the like.

Place the engine parts in the order of removal to prevent from missing. Place the parts in the serial order for reassembling.

When reusing the engine parts, unless there are special reasons, install them to their original positions.

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 found after disassembling or cleaning.

Pay attention to the safety, especially for the balancing of disassembled parts and carrying of heavy parts. (Get the help, and use jacks, chain blocks and guide bolts as necessary.)

Use protective gloves when you touch overheated or frozen parts. Touching the part with a bear hand can cause burns.

XII

appropriate type. Be sure to apply oil, grease or adhesive to specified surfaces.

Use a torque wrench to tighten parts correctly when their tightening torques are specified. Refer to "Tightening torque table."

Replace Gaskets, packings and O-rings with new ones.

Apply adhesive as required. Do not apply adhesive too much.

Use protective gloves when you touch overheated or frozen parts. Touching the part with a bear hand can cause burns.

GENERAL CONTENTS Chapter 1

GENERAL 1. External View 2. Outline of Systems 3. Engine serial number 4. 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 Mechanism - Disassemble and Inspect 3. Front Mechanism - 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 Mechanism - Inspect and Repair 3. Front Mechanism - 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 Mechanism - Assemble 3. Rear Mechanism - Assemble 4. Cylinder Head and Valve Mechanism - Assemble

Chapter 8

FUEL SYSTEM 1. Environmental Condition to Disassemble and Assemble the Fuel System 2. Fuel System - Remove 3. Common Rail Assembly - Disassemble and Inspect 4. Fuel System - Disassemble, Inspect and Assemble 5. High-Pressure Pump - Disassemble and Inspect 6. Fuel System - Install

Chapter 9

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

Chapter 10 COOLING SYSTEM 1. Cooling System - Remove 2. Cooling System - Inspect 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 4. Error Code Table

Chapter 1 GENERAL 1.

External View ........................................................................................................... 1-3

2.

Outline of Systems .................................................................................................. 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 .............................................................................................. 1-6

4.

Specifications .......................................................................................................... 1-7

1-1

Chapter 1 GENERAL Chapter 1 GENERAL

1. External View

Coolant outlet

Front hanger

Throttle valve Exhaust gas outlet

EGR valve

Thermostat case

Breather filter

High pressure pump Water drain Water pump Front

Rear Common rail

Coolant inlet Oil pressure switch Coolant drain plug

Flywheel

Relief valve

Engine oil drain cock

Left Side View

Oil level gauge Oil filler cap Air inlet Rear hanger

DPF system

Turbocharger

Rear

Front

Flywheel housing Fan Starter

Alternator

Right Side View

1-3

Chapter 1 GENERAL

2. Outline of Systems 2.1 Outline of Fuel System Injector

Common rail

To fuel tank High pressure pump From fuel tank

Fuel supply Fuel return

Fuel filter

Outline of Fuel System

2.2 Outline of Lubrication System Turbocharger

Push rod

Valve mechanism Tappet Piston Camshaft Main gallery

Oil jet Oil cooler

Idler gear Crankshaft Relief valve Oil filter

Fuel injection pump

Oil pan Oil pump Safety valve

Outline of Lubrication System

1-4

Oil strainer

Chapter 1 GENERAL 2.3 Outline of Cooling System

Cylinder head

Cooling outlet

Thermostat

Bypass pipe

Water jacket

Water pump

Cooling inlet

Oil cooler

Outline of Cooling System

2.4 Outline of Inlet and Exhaust System Charging air Exhaust air

Throttle valve DPF System Turbocharger

EGR Valve Air flow meter

EGR Cooler

Intercooler

Air cleaner

Outline of Inlet and Exhaust System

1-5

Chapter 1 GENERAL

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

Engine serial number

Engine serial number

1-6

Chapter 1 GENERAL

4. Specifications Specifications Table Engine model Type No. of cylinders - arrangement Combustion system

Overhead

Cylinder bore × stroke

94 × 120 mm [3.70 × 4.72 in.]

Total displacement

3.331 L [0.88005 US gal.]

Compression ratio

17 : 1

Fuel

Diesel fuel #2 (Equivalent of JIS K2204)

Firing order

1-3-4-2

Direction of rotation

Counterclockwise as viewed from flywheel side Length

Dimensions (with fan and DPF)

689 mm [27.13 in.]

Height

888 mm [34.96 in.]

360 kg [793.7 lb.]

Cylinder

Type

Piston ring

No. of units

Starting system

Compression ring:2 Oil ring (with expander) :1

Glow plug

Type

Common rail fuel injection system

Type

CP4.1

Manufacturer

Bosch Corporation

Lubrication method Engine oil

Forced circulation (pressure feed by oil pump) Standard

CJ-4, DH-2, viscosity SAE30 (API service classification) or equivalent

Capacity

Engine total: 10.5 L [2.774 US gal.]

Oil pan: 9.5 L [2.510 US gal.] (high level), oil filter: 1 L [0.26 US gal.]

Type Oil pump Oil system

Speed ratio to crankshaft Discharge rate

Relief valve Safety valve

Type

Trochoid 0.74 38.7 L [10.225 US gal.]/min (at pump rotation of 2230 min-1, 0.3 MPa {3.1 kgf/cm²} [43.5 psi]) Piston valve type

Valve opening pressure

0.35 ± 0.05 MPa {3.57 ± 0.50 kgf/cm²} [50.76 ± 7.25 psi]

Valve opening pressure

1.1 MPa {11.2 kgf/cm²} [159.5 psi]

Oil cooler

Type

Water-cooled, multi-plate type

Oil filter

Type

Cartridge type paper element

Cooling method

Water-cooled, forced circulation

Coolant capacity (engine water jacket) Type Cooling system

Dry (integral with cylinder block)

Starter

Starting aid system

Fuel system

1039 mm [40.91 in.]

Width

Dry weight

Engine body

4 cylinders, in-line Direct injection system

Valve mechanism

Main Specifications

D04EG-TAA Water cooled, 4 stroke cycle diesel engine

Water Pump

Speed ratio to crankshaft Discharge rate

Thermostat Inlet Turbocharger Exhaust system

Type Valve opening temperature Type

5.5 L [1.453 US gal.]

Centrifugal 0.84 (varies depending on the specification) 170 L [44.91 US gal.]/min (at pump rotation of 2500 min-1, 0.11 MPa {1.12 kgf/cm²} [15.95 psi]) Wax type 76.5 ± 1.5°C [169.7 ± 2.70°F] (90°C [194°F] when fully opened) TF035HL

1-7

Chapter 1 GENERAL Specifications Table Engine model Voltage - Polarity Pinion engagement type Starter

Output No. of pinion tooth/ring gear tooth Type Output

Electrical system Alternator

10/122 3-phase alternating current, with rectifier 24 V - 50 A 1000 to 8000 min-1

Rated speed

5000 min-1

Permissible speed

10000 min-1

Type

1-8

Pinion shift 24 V - 3.2 kW

Speed in use

Speed ratio to crankshaft Glow plug

D04EG-TAA 24V - negative (-) ground

Rated voltage - Armature current

2.0 (varies depending on the specification) Sheathed 24 V - 3 A (When applying rated voltage for 30 seconds.)

Chapter 2 SERVICE DATA 1.

Maintenance Service Data ...................................................................................... 2-3 1.1 1.2 1.3 1.4 1.5 1.6

2.

Maintenance Service Data of Engine General.......................................................................... 2-3 Maintenance Service Data of Basic Engine.............................................................................. 2-4 Maintenance Service Data of Lubrication System .................................................................... 2-7 Maintenance Service Data of Cooling System ......................................................................... 2-7 Maintenance Service Data of Inlet and Exhaust System.......................................................... 2-7 Maintenance Service Data of 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 2.9 2.10

Tightening Torque Spec for Basic Engine ................................................................................ 2-9 Tightening Torque Spec for Fuel System ................................................................................. 2-9 Tightening Torque Spec for Lubrication System....................................................................... 2-9 Tightening Torque Spec for Cooling System .......................................................................... 2-10 Tightening Torque Spec for Inlet and Exhaust System .......................................................... 2-10 Tightening Torque Spec for Electrical System........................................................................ 2-10 Main Tightening Torque of Sensors and ECM Related Components..................................... 2-10 Tightening Torque for Standard Bolts..................................................................................... 2-11 Tightening Torque for Standard Union Bolts .......................................................................... 2-12 Tightening Torque for Standard Union Nuts ........................................................................... 2-12

2-1

Chapter 2 SERVICE DATA Chapter 2 SERVICE DATA

1. Maintenance Service Data 1.1 Maintenance Service Data of Engine General

Unit: mm [in.]

Item

Nominal value

Compression pressure

at rated Engine oil pressure When idling:

Inlet Valve Timing Exhaust

Valve clearance (when cold)

Fan belt deflection

Limit value

Remarks

2.9 MPa {30 kgf/cm²} [420.6 psi] (300min-1)

2.6 MPa {27 kgf/cm²} [377.1 psi]

At the oil temperature and water temperature at 20 to 30 °C [68 to 86 °F].

0.2 to 0.4 MPa {2 to 4 kgf/cm²} [29.0 to 58.0 psi]

0.15 MPa {1.5 kgf/cm²} [21.76 psi]

0.1 MPa {1 kgf/cm²} [14.5 psi]

0.05 MPa {0.5 kgf/cm²} [7.25 psi]

Open

BTDC 18°

Close

ABDC 54°

Open

BBDC 66°

Close

ATDC 22°

Standard value

At the oil temperature is 70 to 110 °C [158 to 230 °F].

±2° (Crank angle)

Inlet

0.25 [0.0098]

Exhaust

0.25 [0.0098] 11 to 13 [0.43 to 0.51]

Deflection when pushed firmly with thumb New part standard 9 to 11 [0.35 to 0.43]

2-3

Chapter 2 SERVICE DATA 1.2 Maintenance Service Data of Basic Engine Unit: mm [in.]

Nominal value

Item

Crankcase

Distortion of top surface

ø 94 [3.70]

Inside diameter

Standard value

Limit value

Remarks

0.05 [0.0020] or less

0.20 [0.0079]

Reface slightly.

Do not grind the surfaces more than 0.2 mm [[0.008 in.] ] in total (cylinder head bottom surface plus crankcase top surface).

94.000 to 94.035 [3.7008 to 3.7022]

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

Cylinder Roundness

0.01 [0.0004] or less

Cylindricity

0.015 [0.0006] or below

Clearance between main bearing and crankshaft journal

0.03 to 0.09 [0.0012 to 0.0035]

0.200 [0.0079]

Use connecting rod with replacing bearing until reaching the limit.

When the repair limit is exceeded, grind the crank journal for the use of undersize bearings.

Thrust load bearing width (thrust clearance)

0.100 to 0.258 [0.0039 to 0.0102]

(0.300 [0.0118])

Replace thrust plate.

The limit value means the play in thrust direction.

14.000 to 14.018 [0.5512 to 0.5519]

14.100 [0.5551]

Reface slightly.

Clearance between tappet and tappet guide hole

0.016 to 0.052 [0.0006 to 0.0020]

0.018 [0.0007]

Replace a tappet when the clearance reaches the limit.

Clearance to the camshaft journal

0.070 to 0.110 [0.0028 to 0.0043]

0.15 [0.0059]

Replace bushing (Ream if needed.)

0.20 [0.0079]

Reface slightly.

Do not grind the surfaces more than 0.2 mm [0.008 in.] in total (cylinder head bottom surface plus crankcase top surface).

Main bearing

ø 14 [0.55]

Inside diameter Tappet guide hole

Camshaft Bushing

Distortion of bottom surface

0.05 [0.0020] or less

Cylinder head

Compressed thickness of gasket

Valve stem Outside diameter Valve and Bridge guide

Inlet Exhaust

1.2 [0.047] ø8 [0.32]

Clearance between Inlet valve stem and valve guide Exhaust Valve guide installed length

2-4

When the repair limit is exceeded, hone the cylinder to 0.25 [0.0098] or 0.50 [0.0197] oversize of nominal value for the use of oversize parts.

Use oversize piston and piston ring.

14 [0.55]

± 0.05 [0.0020] 7.940 to 7.955 [0.3126 to 0.3132]

7.900\ [0.3110]

7.920 to 7.940 [0.3118 to 0.3126]

7.850 [0.3091]

0.065 to 0.095 [0.0026 to 0.0037]

0.150 [0.0059]

0.080 to 0.115 [0.0032 to 0.0045]

0.200 [0.0079]

13.9 to 14.1 [0.547 to 0.555]

Chapter 2 SERVICE DATA Unit: mm [in.]

Nominal value

Item Valve seat angle

Inlet Exhaust

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]

2.13 [0.0839]

2.13 [0.0839]

1.83 [0.0720] or less after refacing

Free length

48.85 [1.9232]

47.60 [1.8740]

Squareness

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

Total length B = 1.5 [0.059]

43 mm [1.69 in.]/ 176 to 196 N {18 to 20 kgf} [39.57 to 44.06 lbf]

43 mm [1.69 in.]/147 N {15 kgf} [33.05 lbf]

Seat width

Inlet Exhaust

Valve margin

Valve spring

Set length / load

Rocker bushing inside diameter

ø 19 [0.75]

19.010 to 19.030 [0.7484 to 0.7492]

Rocker shaft outside diameter

ø 19 [0.75]

18.980 to 19.000 [0.7472 to 0.7480]

Clearance between rocker shaft and rocker bushing

0.010 to 0.050 [0.0004 to 0.0020]

Runout 0.04 or [0.0016] or less

Runout

Crankshaft

Sgtraightness ø 0.02 [0.0008] If the specified limit is exceeded when changing the standard size of main bearing, change it into the undersize main bearing.

Service limit: 79.10 [3.1142]

ø 60 [2.36]

59.955 to 59.970 [2.3604 to 2.3610]

59.800 [2.3543]

Distance between centers of journal and crankpin

60 [2.36]

60 [2.36]

Parallelism of journal and crankpin

Over entire pin length Max runout 0.01 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]

R4

± 0.2 [0.008]

0.100 to 0.258 [0.0039 to 0.0102]

Lf

0.10 [0.0039]

Crankpin outside diameter

Fillet radius of pin

B

TIR

79.850 [3.1437]

± 0.2 [0.008]

Valve margin

0.6 [0.024]

79.955 to 79.970 [3.1478 to 3.1484]

R4

Valve Valve seat angle sinkage

0.070 [0.0028]

ø 80 [3.15]

Fillet radius of journal

Seat width

A

Crankshaft main journal outside diameter

End play

Remarks

30° 0.4 [0.016]

Valve seat ring

Push rod

Limit value

Inlet Valve sinkage

Rocker arm

Standard value

0.300 [0.0118]

Use connecting rod with replacing thrust plate until reaching the limit.

When the limit is exceeded, replace it to the oversize thrust plate.

2-5

Chapter 2 SERVICE DATA Unit: mm [in.]

Nominal value

Item Standard Outside diameter (at piston skirt)

Over size

0.25 [0.0098]

ø 94 [3.70]

0.50 [0.0197]

Standard value

Limit value

93.915 to 93.945 [3.6974 to 3.6986]

93.730 [3.6902]

94.165 to 94.195 [3.7073 to 3.7085]

93.980 [3.7000]

94.415 to 94.445 [3.7171 to 3.7183]

94.230 [3.7098] Bearing Inspection of clearance Thickness when the gasket is installed 1.2 ± 0.05 [0.047 ± 0.0020]

0.7 [0.028]

Protrusion from crankcase Piston Clearance between piston pin bore and piston pin outside diameter

0 to 0.015 [0.00 to 0.0006]

Weight difference in one engine

Piston ring

5 g [0.176 oz.] or less 0.076 to 0.096 [0.0030 to 0.0038]

0.200 [0.0079]

Clearance between No.2 piston ring and compression ring groove

0.045 to 0.085 [0.0018 to 0.0033]

0.150 [0.0059]

Oil

0.020 to 0.060 [0.0008 to 0.0024]

0.150 [0.0059]

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]

ø 34 [1.34]

Outside diameter Piston pin

Clearance between connecting rod bushing Bushing inside diameter

33.995 to 34.000 [1.3384 to 1.3386] 0.02 to 0.06 [0.0008 to 0.0024]

ø 34 [1.34]

34.020 to 34.055 [1.3394 to 1.3407] 0.15 [0.0059]

Clearance between crankpin and connecting rod bearing

0.030 to 0.090 [0.0012 to 0.0035]

0.200 [0.0079]

End play

0.15 to 0.35 [0.0059 to 0.0138]

0.50 [0.0197]

Weight difference in one engine

10 g [0.353 oz.] or below

Flatness

0.15 [0.0059] or less

0.50 [0.0197]

Runout

0.15 [0.0059] or less

0.50 [0.0197]

Runout

0.04 or [0.0016] or less

0.10 [0.0039]

6.682 [0.2631]

6.382 to 6.782 [0.2513 to 0.2670]

6.182 [0.2434]

6.722 [0.2646]

6.422 to 6.822 [0.2528 to 0.2686]

6.222 [0.2450]

No. 1, 2

ø 54 [2.13]

53.94 to 53.96 [2.1236 to 2.1244]

53.90 [2.1220]

No. 3

ø 53 [2.09]

52.94 to 52.96 [2.0842 to 2.0850]

52.90 [2.0827]

0.10 to 0.25 [0.0039 to 0.0098]

0.30 [0.0118]

Flywheel

Camshaft

Inlet Cam lift (major axis - minor axis) Exhaust

journal Outside diameter

End play

2-6

0.080 [0.0032]

0.05/100 [0.0020/3.94] or less

Connecting rod bend and twist

Connecting rod

0.050 [0.0020]

No.1 compression

Piston ring end gap

Remarks

Replace connecting rod bearings

Sgtraightness ø 0.02 Repair with press or replace.

Replace thrust plate.

Chapter 2 SERVICE DATA Unit: mm [in.]

Item

Idler

Timing gear Bbacklash

Nominal value

Standard value

Limit value

Remarks

Clearance between idler bushing and shaft

0.009 to 0.050 [0.0004 to 0.0020]

0.100 [0.0039]

Replace bushing

Idler gear end play

0.05 to 0.20 [0.0020 to 0.0079]

0.35 [0.0138]

Replace thrust plate.

Shaft and Crankcase hole Interference

0.035 to 0.076 [0.0014 to 0.0030]

Between crankshaft gear and idler gear

0.042 to 0.150 [0.0017 to 0.0059]

0.25 [0.0098]

Camshaft gear to idler gear

0.037 to 0.190 [0.0015 to 0.0075]

0.25 [0.0098]

High-pressure pump idler gear to idler gear

0.051 to 0.163 [0.0020 to 0.0064]

0.25 [0.0098]

High-pressure pump idler gear to highpressure pump geart

0.049 to 0.190 [0.0019 to 0.0075]

0.25 [0.0098]

Oil pump gear to idler gear

0.047 to 0.180 [0.0019 to 0.0071]

0.25 [0.0098]

Replace gears

2-7

Chapter 2 SERVICE DATA 1.3 Maintenance Service Data of Lubrication System Unit: mm [in.]

Nominal value

Item Clearance between outer rotor and pump case

Standard value

Limit value

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 diameter (between oil pump bushing)

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 replace 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.

Relief valve

Valve opening pressure

0.35 ± 0.05 MPa {3.5 ± 0.5 kgf/cm²} [50.76 ± 7.25 psi]

Safety valve

Valve opening pressure

1.1 MPa {11 kgf/cm²} [159.5 psi]

Oil pump

1.4 Maintenance Service Data of Cooling System Nominal value

Item Temperature at which valve starts to open Thermostat

Standard value

76.5 ºC [169.7 ºF]

Temperature at which valve lift becomes 9 mm [0.35 in.] or more

Limit value

Remarks

76.5 ± 2ºC [169.7 ± 3.60 °F] 90 ºC [194 ºF]

1.5 Maintenance Service Data of Inlet and Exhaust System Unit: mm [in.]

Item Exhaust manifold distortion

2-8

Nominal value

Standard value Less than 0.2 [0.008]

Limit value

Remarks Repair by grinding or replace.

Chapter 2 SERVICE DATA 1.6 Maintenance Service Data of Electrical System Unit: mm [in.]

Nominal value

Item Outside diameter Commutator

Runout Undercut depth

Starter

Brush length Pressure of brush spring Voltage Non-load charCurrent acteristics Rotation speed

Alternator

Output current (when hot)

Rotational speed (min -1)

Regulator adjusting voltage

Standard value

Limit value

ø32 [1.26]

31.4 [1.236]

Replace.

0.05 [0.0020] or less

0.10 [0.0039]

Repair or replace.

0.5 [0.020]

0.2 [0.008]

Repair.

17.5 [0.689]

11.0 [0.433]

Replace.

26.7 to 36.1 N {2.7 to 3.7 kgf}

14.7 N {1.5 kgf}

Replace.

23 V

-

80 A or less

-

2960 min-1 or more

-

1500 or less

24 A or more

2500 or less

38 A or more

5000 or less

45 A or more 28.5±0.5 V

Remarks

Inspection

Inspection at 20ºC [68ºF]

2-9

Chapter 2 SERVICE DATA

2. Tightening Torque Table 2.1 Tightening Torque Spec for Basic Engine Description

Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

Cylinder head bolt

M 12 × 1.75

140 ± 5

14.3 ± 0.5

103.26 ± 3.68

Rocker cover bolt

M 8 × 1.25

11.5 ± 1.5

1.2 ± 0.2

8.48 ± 1.11

Rocker shaft bracket bolt

M 8 × 1.25

17.5 ± 2.5

1.8 ± 0.3

12.91 ± 1.84

Rocke adjusting nut

M 8 × 1.25

20 ± 2

2 ± 0.2

14.75 ± 1.47

Main bearing cap bolt

M 14 × 2

140 ± 5

14.3 ± 0.5

103.26 ± 3.68

Connecting rod cap nut

M 10 × 1.25

60 ± 5

6.1 ± 0.5

44.25 ± 3.68

Flywheel bolt

M 12 × 1.25

80 ± 5

8.2 ± 0.5

59.01 ± 3.68

Flywheel housing bolt

M 10 × 1.25

56 ± 6

5.7 ± 0.6

41.30 ± 4.42

Camshaft thrust plate bolt

M 8 × 1.25

18.5 ± 1.5

1.9 ± 0.2

13.64 ± 1.11

Front plate bolt

M 8 × 1.25

18.5 ± 1.5

1.9 ± 0.2

13.64 ± 1.11

Timing gear case bolt

M 8 × 1.25

18.5 ± 1.5

1.9 ± 0.2

13.64 ± 1.11

Crankshaft pulley nut

M 30 × 1.5

490 ± 10

50 ± 1

361.41 ± 7.37

Idler thrust plate bolt

M 10 × 1.25

34 ± 5

3.5 ± 0.5

25.08 ± 3.68

Piston cooling nozzle

M 12 × 1.25

34 ± 5

3.5 ± 0.5

25.08 ± 3.68

Oil pan bolt

M 8 × 1.25

11.5 ± 1.5

1.2 ± 0.2

8.482 ± 1.10

Oil pan drain cock

M 14 × 1.5

39 ± 5

4.0 ± 0.5

28.76 ± 3.68

Remarks

2.2 Tightening Torque Spec for Fuel System Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

M 14 × 1.5

25.0 ± 3.0

2.5 ± 0.3

18.44 ± 2.21

M 12 × 1.5

25.0 ± 3.0

2.5 ± 0.3

18.44 ± 2.21

M 14 × 1.5

25.0 ± 3.0

2.5 ± 0.3

18.44 ± 2.21

M 12 × 1.5

25.0 ± 3.0

2.5 ± 0.3

18.44 ± 2.21

Injection pipe nut on HPP

M 16 × 1.0

25.0 ± 3.0

2.5 ± 0.3

18.44 ± 2.21

Fuel inlet and outlet of HPP

M 12 × 1.5

17.5 ± 2.5

1.8 ± 0.3

12.91 ± 1.84

Nozzle gland

M 8 × 1.25

30.4 ± 2.9

3.1 ± 0.3

22.42 ± 2.14

Return pipe nut

M 10 × 1.25

19.7 ± 1.9

2.0 ± 0.2

14.53 ± 1.40

HPP idler oil supply pipe

M 10 × 1.25

16.5 ± 2.5

1.7 ± 0.3

12.17 ± 1.84

Eye bolt

HPP idler oil supply pipe

M 10 × 1.0

15.5 ± 2.5

1.6 ± 0.3

11.43 ± 1.84

Flare

Description Injection pipe nut on injector Injection pipe nut on raile

Remarks

2.3 Tightening Torque Spec for Lubrication System Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

M 22 × 1.5

49 ± 4.9

5 ± 0.5

36.14 ± 3.61

Safety valve

M 18 × 2.0

69 ± 5

7.0 ± 0.5

50.89 ± 3.68

Oil cooler element mounting nut

M 8 × 1.25

18 ±2

1.8 ± 0.2

13.28 ± 1.47

Description Relief valve

Shutoff valve

M 20 × 1.5

8.0± 1.0

0.8 ± 0.1

5.90 ± 0.74

Turbocharger oil supply union bolt

M 10 × 1.25

16.2 ± 2.4

1.7 ± 0.2

11.95 ± 1.77

Turbocharger oil supply pipe nipple

M 14 × 1.5

30 ± 3

3.1 ± 0.3

22.13 ± 2.21

2-10

Remarks

Chapter 2 SERVICE DATA 2.4 Tightening Torque Spec for Cooling System Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

Thermostat case

M 8 × 1.25

18.5 ± 1.5

1.9 ± 0.2

13.64 ± 1.11

Overheat warning unit (thermo switch)

M 16 × 1.5

22.6 ± 1.9

2.3 ± 0.2

16.67 ± 1.40

Description

Remarks

2.5 Tightening Torque Spec for Inlet and Exhaust System

Exhaust manifold

Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

Bolt only

M 8 × 1.25

30.4± 2.9

3.1 ± 0.3

22.42 ± 2.14

With spacer

Description

M 8 × 1.25

18.5± 3.5

1.9 ± 0.4

13.64 ± 2.58

EGR cooler stud

M 8 × 1.25

13 ± 1

1.3 ± 0.1

9.59 ± 0.73

EGR cooler in/out port nut

M 8 × 1.25

27.5 ± 2.5

2.8 ± 0.3

20.28 ± 1.84

Nut between EGR cooler/exhaust manifold and air cooler

M 8 × 1.25

27.5 ± 2.5

2.8 ± 0.3

20.28 ± 1.84

M6 × 1.0

9.0 ± 1.0

0.9 ± 0.1

6.64 ± 0.74

EGR cooler water pipe EGR pipe bolt

M 8 × 1.25

18.5± 1.5

1.9 ± 0.2

13.64 ± 1.11

EGR valve

M 8 × 1.25

18.5 ± 1.5

1.9 ± 0.2

13.64 ± 1.11

EGR cooler stay

M 8 × 1.25

18.5 ± 1.5

1.9 ± 0.2

13.64 ± 1.11

R 3/8

40 ± 5

4.1 ± 0.5

29.50 ± 3.68

M 10 × 1.25

34 ± 5

3.5 ± 0.5

25.08 ± 3.68

EGR cooler water outlet connector EGR cooler air bleed plug

Remarks

2.6 Tightening Torque Spec for Electrical System Description Starter terminal B Body (CRS)

Glow plug

Terminal

Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

M 8 × 1.25

10.8± 0.1

1.1 ± 0.01

7.966 ± 0.07

M 12 × 1.25

25 ± 5

2.5 ± 0.5

18.44 ± 3.68

M 4 × 0.7

1.25 ± 0.25

0.13 ± 0.03

0.92 ± 0.18

Remarks

2.7 Main Tightening Torque of Sensors and ECM Related Components Tightening torque

Thread size Dia × Pitch

N·m

kgf·m

lbf·ft

Crankshaft angle sensor

M6 × 1.0

8.0 ± 1.0

0.8 ± 0.1

5.90 ± 0.74

Cam sensor

M6 × 1.0

8.0 ± 1.0

0.8 ± 0.1

5.90 ± 0.74

Boost pressure sensor

M6 × 1.0

8.0 ± 1.0

0. 8 ± 0.1

5.90 ± 0.74

M 12 × 1.5

12.3 ± 2.5

1.3 ± 0.3

9.07 ± 1.84

Description

Water temperature sensor

Remarks

2-11

Chapter 2 SERVICE DATA 2.8 Tightening Torque for Standard Bolts Threads

Thread size Dia. × Pitch (M-thread)

Width across flats (mm) [in.]

Strength classification 7T

10.9

10

7 N·m

Metric automobile screw thread

Metric course screw thread

kgf·m

lbf·ft

N·m

kgf·m

8 × 1.25

12 [0.47]

17

1.7

12.3

30

3.1

22.4

10 × 1.25

14 [0.55]

33

3.4

24.6

60

6.1

44.1

12 × 1.25

17 [0.67]

60

6.1

44.1

108

11.0

79.6

14 × 1.5

22 [0.87]

97

9.9

71.6

176

17.9

129.5

16 × 1.5

24 [0.94]

145

14.8

107.1

262

26.7

193.1

18 × 1.5

27 [1.06]

210

21.4

154.8

378

38.5

278.5

20 × 1.5

30 [1.18]

291

29.7

214.8

524

53.4

386.2

22 × 1.5

32 [1.26]

385

39.3

284.3

694

70.8

512.1

24 × 1.5

36 [1.42]

487

49.7

359.5

878

89.5

647.4

27 × 1.5

41 [1.61]

738

75.3

544.7

1328

135.5

980.1

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

10 × 1.5

14 [0.55]

32

3.3

23.9

58

5.9

42.67

12 × 1.75

17 [0.67]

57

5.8

42.0

102

10.4

75.2

14 × 2

22 [0.87]

93

9.5

68.7

167

17.0

123.0

16 × 2

24 [0.94]

139

14.2

102.7

251

25.6

185.2

18 × 2.5

27 [1.06]

194

19.8

143.2

350

35.7

258.2

20 × 2.5

30 [1.18]

272

27.7

200.4

489

49.9

361.0

22 × 2.5

32 [1.26]

363

37.0

267.6

653

66.6

482.0

24 × 3

36 [1.42]

468

47.7

345.0

843

86.0

622.0

27 × 3

41 [1.61]

686

70.0

506.3

1236

126.0

911.4

Note:(a) The tightening torque listed in this table is for standard bolts and nuts. (b) The numerical values in the table are the values when spring washers are used. (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)

2-12

lbf·ft

Chapter 2 SERVICE DATA 2.9 Tightening Torque for Standard Union Bolts Thread size Dia. × Pitch (M-thread)

Strength classification Width across flats (mm) [in.]

4T N·m

kgf·m

lbf·ft

8 × 1.25

12 [0.47]

8±1

0.8 ± 0.1

5.90 ± 0.73

10 × 1.25

14 [0.55]

15 ± 2

1.5 ± 0.2

11.06 ± 1.47

12 × 1.25

17 [0.67]

25 ± 3

2.5 ± 0.3

18.44 ± 2.21

14 × 1.5

19 [0.75]

34 ± 4

3.5 ± 0.4

25.08 ± 2.95

16 × 1.5

22 [0.87]

44 ± 5

4.5 ± 0.5

32.45 ± 3.68

18 × 1.5

24 [0.94]

74 ± 5

7.5 ± 0.5

54.58 ± 3.68

20 × 1.5

27 [1.06]

98 ± 10

10.0 ± 1.0

72.28 ± 7.37

24 × 1.5

32 [1.26]

147 ± 15

15.0 ± 1.5

108.42 ± 11.06

27 × 1.5

41 [1.61]

226 ± 20

23.0 ± 2.0

166.69 ± 14.75

(Dry)

2.10 Tightening Torque for Standard Union Nuts Nominal

Cap nut thread size Dia. × Pitch (M-thread)

Width across flats (mm) [in.]

N·m

kgf·m

lbf·ft

63

14 × 1.5

19 [0.75]

39

4

28.76

80

16 × 1.5

22 [0.87]

49

5

36.14

100

20 × 1.5

27 [1.06]

78

8

57.53

120

22 × 1.5

30 [1.18]

98

10

72.28

150

27 × 1.5

32 [1.26]

157

16

115.80

180

30 × 1.5

36 [1.42]

196

20

144.56

200

30 × 1.5

36 [1.42]

196

20

144.56

220

33 × 1.5

41 [1.61]

245

25

180.70

254

36 × 1.5

41 [1.61]

294

30

216.84

(Maximum tolerance value: ±10%, dry condition)

2-13

Chapter 3 SERVICE TOOLS 1.

Special Tools............................................................................................................ 3-3

3-1

Chapter 3 SERVICE TOOLS Chapter 3 SERVICE TOOLS

1. Special Tools Tool name

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 psi]

Gauge adapter

32A91-01100

Compression Pressure - Measure

Socket for turning

58309-73100

Engine turning

Valve spring pusher

30691-04500

Valve spring installation/removal

Valve guide remover

32A91-00300

Valve guide removal

Valve seat ring caulking tool

Inlet: 36791-00200 Exhaust: 34491-03020

Valve seat ring installation

Stem seal installer

32A91-10200

Stem seal installation

Socket

34491-00300

Rocker bracket installation thrust plate of camshaft installation/ removal

3-3

Chapter 3 SERVICE TOOLS Tool name

Part No.

Illustration

Remarks

Valve guide installer

32A91-00100

Valve Guide - Install

Camshaft bushing installer set

30691-00010

Camshaft bushing installation/ removal

Idler bushing installer

30091-07300

Idler bushing installation/removal

Idler shaft puller

MH061077

Piston ring pliers

31391-12900

Piston ring installation/removal

Connecting rod bushing puller

32A91-00500

Connecting rod bushing install/remove

Oil seal sleeve installer set

30691-13010

Crankshaft rear side oil sleeve press in

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.

Illustration

Remarks

MH061326

Gear pull-out

Injector remover

32F91-03030

Injector remover

Connecting rod bushing installer

32K91-00010

Connecting rod bushing removal/ installation

30 25 20 15 10 5

Belt gauge

32591-09100

Belt tension - measure 2

1

Tension meter

32G91-01400

Belt tension - measure

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 decreases. An increase in engine oil consumption and blow-by gas should be considered when evaluating the engine condition.

Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and are not always effective to consider 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 symptoms: (1) Output power decrease (2) Fuel consumption increase (3) Engine oil consumption increase (4) Increased blow-by gas through the breather due to worn and piston rings(Visually check the blow-by amount.) ) (5) Gas leak increase due to poor seating of inlet and exhaust valves (6) Difficult starting (7) Noise increase from engine parts (8) Abnormal exhaust color after engine warm-up The engine shows these symptoms in various combinations.

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

Symptoms of items (2) and (6) are affected by improper fuel injection volume and timing of the high-pressure 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

Gauge adapter P/N:32A91-01100

for all the cylinders. It is not a good practice to measure the compression pressure for only one cylinder, and to assume the compression pressure is the same for all cylinders. (b) Also be sure to check the engine speed when measuring the compression pressure, as the compression pressure varies depending on the

Compression Pressure - Measure

engine speed. (c) It is important to measure the compression pressure at regular intervals, and know the change of the pressure. (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 starter. Read the engine speed and compression pressure while engine is running at a stable speed.

Note: Ensure the battery being fully charged when cranking the engine with the starter.

If the battery voltage is low, the proper compression pressure can not be measured because of a low cranking speed.

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

Standard value

Limit value

Basic Rotation speed

Compression pressure

2.9 MPa {30.0 kgf/cm2} [420.6 psi]

2.6 MPa {27 kgf/cm2} [377.1 psi]

300min-1

Oil and water temperatures

20 to 30ºC [68 to 86 °F]

-

-

Item

4-4

Compression gauge P/N:35A91-03100

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 1.7

2.

Rear Mechanism - Disassemble and Inspect ........................................................ 5-7 2.1 2.2 2.3

3.

Flywheel Face and Radial Runout - Measure........................................................................... 5-8 Flywheel - Remove ................................................................................................................... 5-8 Flywheel Housing - Remove..................................................................................................... 5-8

Front Mechanism - Disassemble and Inspect....................................................... 5-9 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

4.

Injector - Remove ..................................................................................................................... 5-4 Inspection of Valve Clearance .................................................................................................. 5-4 Rocker Shaft Assembly - Remove............................................................................................ 5-5 Cylinder Head Bolt - Remove ................................................................................................... 5-5 Cylinder Head Assembly - Remove.......................................................................................... 5-6 Measurement of Valve Sinkage................................................................................................ 5-6 Valve and Valve Spring - Remove............................................................................................ 5-6

Crankshaft Pulley - Remove ................................................................................................... 5-10 Timing Gear Case - Remove .................................................................................................. 5-10 Timing Gear Backlash - Measure ........................................................................................... 5-10 Idler Gear and Camshaft End Play - Measure........................................................................ 5-11 High-Pressure Pump - Remove.............................................................................................. 5-11 Oil Pan - Remove ................................................................................................................... 5-11 Oil Strainer - Remove ............................................................................................................. 5-11 Oil Pump Gear - Remove ....................................................................................................... 5-12 Idler Gear - Remove ............................................................................................................... 5-12 Camshaft - Remove................................................................................................................ 5-12 Camshaft gear - Replace........................................................................................................ 5-13 Front Plate - Remove.............................................................................................................. 5-14 Oil Pump - Remove ................................................................................................................ 5-14

Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect................................................................................... 5-15 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 ................................................................................................... 5-16 Carbon Deposits from the Upper Part of Cylinder - Remove.................................................. 5-16 Connecting Rod End Play - Measure ..................................................................................... 5-16 Connecting Rod Cap - Remove.............................................................................................. 5-16 Piston - Remove ..................................................................................................................... 5-17 Piston Ring - Remove............................................................................................................. 5-17 Piston Pin and Piston - Remove ............................................................................................. 5-17 Crankshaft End Play - Measure.............................................................................................. 5-17 Main Bearing Cap - Remove .................................................................................................. 5-18 Crankshaft - Remove.............................................................................................................. 5-18 Tappet - Remove .................................................................................................................... 5-18

5-1

Chapter 5 DISASSEMBLY OF BASIC ENGINE Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

Inspection of valve clearance Measurement of valve sinkage

4 Replace

11 Damaged threads, wear on rod contact surface Wear Wear, clogged oil holes

5 7

6

10

13 17 18

12 8

9 Wear at both ends, deflection

Wear on contact surface with valve cap, clogged oil holes

19 Replace

15

3

Fatigue, damage 21 2

Wear 14 16

Crack, damage, carbon deposits, water scale adhesion

1

22

Uneven wear on stems and faces, damage, fatigue

Replace 20 Uneven wear

Cylinder Heads and Valve Mechanisms - Disassemble and Inspect Disassembling sequence 1 2 3 4 5 6 7 8

leak-off hose Nozzle gland Injector Rocker cover Adjusting screw Rocker bracket bolt (short) Rocker bracket bolt (long) Rocker shaft bracket

9 10 11 12 13 14 15 16

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

17 18 19 20 21 22

Valve cotter Valve retainer Valve spring Valve Valve, valve stem seal Cylinder head gasket

5-3

Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.1 Injector - Remove (1) Fix the fuel inlet connector of injector with wrench, loosen the injection pipe nut and remove the injection

Leak off hose connector

pipe.

(2) Fully press the pin at the top injector and remove the

Leak off hose

Pin Injector

leak-off hose.

(3) Disconnect the harness connector of main harness and the injector connector.

Injection pipe

(4) Remove the injector together with the nozzle gland using the injector puller.

(5) Remove the gasket at injector inserting port in cylinder

Injection connector

Nozzle gland

Gasket

Injector - Remove

head.

Injector

Push Pin

Pin at the Top of Injector

Injector puller P/N:32G91-00100

Injector

Injector - Remove

For the inspection procedure, refer to "Valve Clearance Inspect and Adjust" of "ASSEMBLY OF BASIC ENGINE."

Adjusting screw Lock nut

0.25 mm [0.0098 in.]

1.2 Inspection of Valve Clearance Inspect the valve clearance, and know the current condition.

20 ± 0.2 N·m {2.0 ± 0.02 kgf·m} [15 ± 0.15 lbf·ft]

Inspection of Valve Clearance

5-4

Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.3 Rocker Shaft Assembly - Remove Adjusting screw

Always loosen shorter bolts first. Failing to do so may

Rocker bracket bolt

cause damage to the rocker shaft bracket.

(1) Loosen adjusting screw of rocker arm.

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

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

Rocker arm

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

Note: Keep the removed rocker shaft assembly and bolts as a set.

Rocker Shaft Assembly - Remove

(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

1.4 Cylinder Head Bolt - Remove Loosen cylinder head bolts in the numerical order as shown in the illustration.

14

6 2

10

13 17 9

5 1 4

Front 3

7

11 15 16 12

8

Number of bolt (17)

Cylinder Head Bolt - Remove

5-5

Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.5 Cylinder Head Assembly - Remove Cylinder head

When removing the cylinder head gasket, be careful not to damage the cylinder head or crankcase surface with a screwdriver or the like.

(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 crankcase by yourself. Use a crane or lift it up by 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.

1.6 Measurement of Valve Sinkage Measure the valve sinkage, and know the current condition.

For the measurement procedure, refer to "Valve Sinkage Measure" of "ASSEMBLY OF BASIC ENGINE."

1.7 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 the each valve seat and the mating valve to identify their original positions. Do not change the combination of the valve seat and the valve when reassembling.

Valve and Valve Spring - Remove

5-6

Chapter 5 DISASSEMBLY OF BASIC ENGINE

2. Rear Mechanism - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

Flywheel Face and Radial Runout - Measure

4

2

3 1

Replace

Crack, defect of knock hole

Lip wear, damage, aging

Crack, defect of knock hole, gear damage Damaged screw

Rear Mechanism - Disassemble and Inspect Disassembling sequence 1 Flywheel

2 Flywheel housing

3 Oil seal

4 Packing

5-7

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

For the measurement procedure, refer to "Flywheel Face and Radial Runout - Measure" of "ASSEMBLY OF BASIC ENGINE."

Radial runout measuring point Face runout measuring point

Flywheel Face and Radial Runout - Measure

2.2 Flywheel - Remove (Front)

(Rear)

(a) Be careful not to cut your hands with the ring gear when pulling-out the flywheel. (b) Be careful not to drop or hit the flywheel. Doing so may not only cause damage to the flywheel but also lead to personnel injuries. (c) The personnel who holds the pulley must pay due attention to safety. Also, personnel must closely communicate with each other during the work.

(1) One personnel must firmly hold the pulley with a

Guide bolt

Prevent the flywheel from rotating using a wrench.

Flywheel - Remove

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 Flywheel Housing - Remove

Be careful not to damage the oil seal.

(1) Remove bolts from the flywheel housing.

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

(3) Remove the flywheel housing.

(4) Remove the oil seal from the timing gear case.

Guide bolt

Flywheel Housing - Remove

5-8

Chapter 5 DISASSEMBLY OF BASIC ENGINE

3. Front Mechanism - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

Damper Face and Radial Runouts - Measure Timing Gear Backlash - Measure Idler Gear and Camshaft End Play - Measure

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

Wear, damage Clogging of oil hole, wear

12

Replace

5

Wear, damage 14

Replace

13

Clogged oil hole

11 10 Replace 7

15 16 Replace 9 Wear

6

8

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

Replace

3

4 Lip wear, damage or aging

Worn belt groove

1 Flaw

2

Crack, abnormality of knock hole

Front Mechanism - Disassemble and Inspect Disassembling sequence 1 2 3 4 5 6

Crankshaft pulley Insulator cover Insulator cover Timing gear case High-pressure pump Oil pan

7 8 9 10 11 12

Oil strainer Oil pump gear Thrust plate Idler gear Timing plate Camshaft

13 14 15 16

Camshaft gear Thrust plate Front plate Oil pump

5-9

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.1 Crankshaft Pulley - Remove (Front)

㧔Rear㧕 Prevent crankshaft from turning

The bar that stops the crankshaft from rotating may 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 nut, then remove the crankshaft pulley.

Crankshaft pulley

Guide bolt (M12 × 1.25 mm)

Crankshaft Pulley - Remove

3.2 Timing Gear Case - Remove Insulator 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 insulator cover from the timing gear case.

Insulator cover

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

(3) Remove the front oil seal from the timing gear case.

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

The lower bolts secure also the oil pan.

Timing gear case

Timing Gear Case - Remove

3.3 Timing Gear Backlash - Measure Measure the timing gear backlash, and know the current condition.

Dial gauge

For the measurement procedure, refer to "Timing Gear Backlash - Measure" of "ASSEMBLY OF BASIC ENGINE."

Timing Gear Backlash - Measure

5-10

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.4 Idler Gear and Camshaft End Play - Measure Measure the idler gear and camshaft end play, and recognize the current condition.

For the inspection procedure, refer to "Idler Gear and Camshaft End Play - Measure" of "ASSEMBLY OF BASIC ENGINE".

Dial gauge

Idler Gear and Camshaft End Play - Measure

3.5 High-Pressure Pump - Remove Remove the high-pressure pump from the front plate.

High pressure pump O-ring

High-Pressure Pump - Remove

3.6 Oil Pan - Remove

Oil pan

Do not remove the oil pan inserting chisel or drive between oil pan and crankcase. When inserting chisel or driver, oil pan flange will deform.

Bolt

(1) Turn over the engine.

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

Oil Pan - Remove

3.7 Oil Strainer - Remove Remove the oil strainer from the crankcase.

Oil strainer

Oil Strainer - Remove

5-11

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.8 Oil Pump Gear - Remove Remove the oil pump gear from the oil pump.

Oil pump gear

Oil Pump Gear - Remove

3.9 Idler Gear - Remove Remove the bolts and thrust plate, and remove the front idler gear from crankcase.

Idler gear

Thrust plate

Idler Gear - Remove

3.10 Camshaft - Remove

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

Camshaft gear Timing plate

(1) Remove the timing plate.

(2) Remove the thrust plate bolt.

(3) Remove the camshaft from the crankcase.

Camshaft - Remove

5-12

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.11 Camshaft gear - Replace 3.11.1 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

Camshaft

Thrust plate

from the camshaft.

Camshaft gear - Remove 3.11.2 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

5-13

Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.12 Front Plate - Remove Remove the bolts, and remove the front plate from crankPacking

case.

Note: If it is difficult to remove the front plate, lightly tap it with a plastic hammer paying attention not to bend.

Front plate

Front Plate - Remove

3.13 Oil Pump - Remove Remove the bolts, and remove the oil pump from crankcase.

Oil pump

O-ring

Oil Pump - Remove

5-14

Chapter 5 DISASSEMBLY OF BASIC ENGINE

4. Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

Piston Protrusion - Measure Connecting Rod End Play - Measure Crankshaft End Play - Measure Cylinder inside diameter - Measure Scratches on outside surface, cracks, damage, wear, carbon deposits

Wear, damage

4 5 6

19

Adhesion of water scale, corrosion, flaking

Fatigue

9 Wear

8

Cracks, clogged oil holes

7

Wear

Wear, clogged oil holes

14 10

Serration for cracks, wear

3

Scratches on inside and outside surfaces, adhesion, flaking, wear

17

18

2

16

1 Damaged threads

15

Scratches, cracks, dent, clogged oil holes, wear

14

Flaking, uneven contact Scratches on inside and outside surfaces, adhesion, flaking

14 12 13 Damaged threads

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

Cracks

11

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

Bolt 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

5-15

Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.1 Piston Protrusion - Measure Measure the piston protrusion, and know 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 Connecting Rod End Play - Measure Measure the connecting rod end play, and know the current condition.

For the measurement procedure, refer to "Connecting Rod End Play - Measure" of "ASSEMBLY OF BASIC ENGINE." Thickness gauge

Connecting Rod End Play - 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 numbers and upper/lower on connecting rod bearings to ensure correct assembling.

Connecting Rod Cap - Remove

5-16

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 remove 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) Place a piece of wood to piston pin end and lightly tap with hammer to remove the piston pin, and separate the piston from connecting rod.

Snap ring pliers

Note:(a) Do not tap the piston pin directly with hammer. (b) If the piston is stubborn, heat the piston with heater or in hot water.

Piston Pin and Piston - Remove

4.8 Crankshaft End Play - Measure Measure the crankshaft end play, and know the current condition.

For the measurement procedure, refer to "Crankshaft End Play - Measure" of "ASSEMBLY OF BASIC ENGINE."

Crankshaft End Play - Measure

5-17

Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.9 Main Bearing Cap - Remove

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

(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) Suspend the crankshaft in a horizontal position, and slowly lift the crankshaft upward.

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 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.

5-18

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

2.

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

3.

Flatness of Flywheel - Measure.............................................................................................. 6-10 Ring Gear - Inspect................................................................................................................. 6-10 Ring Gear - Replace ............................................................................................................... 6-10

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

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 Ring - Reface ......................................................................................................... 6-6 Valve Seat - Replace ................................................................................................................ 6-7 Valve and Valve Seat - Lap ...................................................................................................... 6-8 Squareness and Free Length of Valve Spring - Measure......................................................... 6-8 Push rod Runout - Measure...................................................................................................... 6-8 Distortion of Cylinder Head Bottom Surface - Measure............................................................ 6-9

Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure .......................... 6-11 Idler Shaft - Replace ............................................................................................................... 6-11 Cam Lift of Cam Shaft Lobe - Measure .................................................................................. 6-11 Camshaft Runout - Measure................................................................................................... 6-11 Camshaft Journal Outside Diameter - Measure ..................................................................... 6-12 Camshaft Hole (Bushing) Inside Diameter - Measure ............................................................ 6-12 Camshaft Bushing - Replace .................................................................................................. 6-12 Belt Groove Wear - Inspect .................................................................................................... 6-13

Piston and Connecting Rod - Inspect and Repair .............................................. 6-14 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14

Piston - Inspect Visually.......................................................................................................... 6-14 Piston Weight ......................................................................................................................... 6-14 Piston Outside Diameter - Measure........................................................................................ 6-14 Piston Ring Groove - Inspect.................................................................................................. 6-15 Piston Pin Bore Diameter and Piston Pin Outside Diameter - Measure ................................. 6-15 Standard for Piston Ring Replacement .................................................................................. 6-15 Clearance Between Connecting Rod Bearing and Crankpin - Measure................................. 6-16 Clearance Between Connecting Rod Bushing and Piston Pin - Measure .............................. 6-16 Connecting Rod Bushing - Replace........................................................................................ 6-17 Connecting Rod Bushing - Remove ....................................................................................... 6-17 Connecting Rod Bushing - Press-In ....................................................................................... 6-18 Connecting Rod Assembly Weight Rank................................................................................ 6-18 Connecting Rod Bearing - Inspect.......................................................................................... 6-19 Connecting Rod Bend and Twist - Inspect ............................................................................. 6-19

6-1

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

5.

Crankcase and Crankshaft - Inspect and Repair ................................................ 6-20 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14

6-2

Cylinder Inside Diameter - Measure ....................................................................................... 6-20 Crankcase Top Surface Distortion - Measure......................................................................... 6-21 Crankpin and Journal Outside Diameters - Measure.............................................................. 6-22 Width of Crankpin and Rearmost Crank Main Journal - Measure .......................................... 6-22 Crankshaft - Grind .................................................................................................................. 6-23 Crankshaft Runout - Measure................................................................................................. 6-23 Crankshaft Gear - Inspect....................................................................................................... 6-24 Crankshaft Gear - Replace ..................................................................................................... 6-24 Oil Seal Contact Surface - Inspect.......................................................................................... 6-24 Oil Seal Sleeve - Replace....................................................................................................... 6-25 Main Bearing - Inspect............................................................................................................ 6-26 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 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Inspect and Repair 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 value

Standard value

Limit value

Rocker bushing inside diameter

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.]

Item

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 valve stem and the inside diameter of valve guide at the top and bottom sliding ends in

Measuring directions

mutually right-angle directions as shown, as the sliding surfaces tend to wear at the top and bottom 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.

Measuring points

Note: Lap the valve and valve seat whenever a new valve is installed.

Nominal value

Standard value

Limit value

Inlet

ø8 mm [0.32 in.]

7.940 to 7.955 mm [0.3126 to 0.3132 in.]

7.900 mm [0.3110 in.]

Exhaust

ø8 mm [0.32 in.]

7.920 to 7.940 mm [0.3118 to 0.3126 in.]

7.850 mm [0.3091 in.]

-

0.065 to 0.095 mm [0.0026 to 0.0037 in.]

0.150 mm [0.0059 in.]

-

0.080 to 0.115 mm [0.0031 to 0.0045 in.]

0.200 mm [0.0079 in.]

14 mm [0.55 in.]

13.9 to 14.1 mm [0.547 to 0.555 in.]

-

Item

Valve stem outside diameter

Clearance between valve stem and valve guide

Inlet

Exhaust

Valve guide installed length

Valve Stem Outside Diameter - Measure

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 valve guide with 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-In

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 tap the valve face against valve seat with the valve lapper to check the contact condition. If the contact is not even, or any defects are found, or if the measurement exceeds the limit, reface or replace the valve.

Valve lapper

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

Lead-free coloring paste

seat.

Valve Face - Inspect

(c) Lap the valve and valve seat whenever the valve is refaced or replaced.

Item Valve seat ring

Valve seat angle Seat width

Valve margin

Nominal value

Standard value

Limit value

30°

-

-

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

-

2.13 mm [0.0839 in.]

1.8 mm [0.071 in.]

1.83 mm [0.0720 in.]

Bad

Good

Contact Condition Between Valve Seat and Valve

Valve seat angle

Seat width

Valve margin Valve sinkage

Valve-to-Valve Seat Contact Position

1.5 Valve Face - Reface When the valve is re-used by refacing, use the valve refacer.

Note:(a) Grind the valve face with valve refacer adjusted to

Valve refacer

the specified angle. (b) The valve margin is to be within the specified limit.

If the dimensions after refacing do not meet the specified values, replace the valve with a new one.

Grind valve face at the specified angle.

Valve Face - Reface

6-5

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.6 Valve Seat Ring - Reface If any damage or inclusions are found, grind the sheet face.

(1) When the valve seat ring is re-used by refacing, use the valve seat cutter or valve seat refacer. After refacing, insert sand paper of approx 400 grit between cutter and valve, and grind valve seat lightly.

Valve seat cutter

If the seat width exceeds the standard, grind the valve seat with the valve seat cutter having a different angle.

(2) Lap valve and valve seat ring.

Note:(a) The valve seat refacing depth is to be minimal. (b) If the seat width cannot be repaired to the standard value, or a line contact on valve seat outer periphery is shown, replace the valve seat with a new one. (c) If the valve sinkage exceeds the specified limit after refacing, replace the valve seat with a new one.

6-6

Valve Seat Ring - Reface

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.7 Valve Seat - Replace

Ensure the proper interference. Improper interference

Weld

Shaft

will cause the valve seat ring to fall off or the cylinder head to crack.

Valve seat

1.7.1 Valve Seat Ring - Remove by Welding To remove the valve seat, weld a stud to the valve seat as shown. Then, insert a shaft into the valve guide hole from the top of the cylinder head, and drive the valve seat out Stud

with the shaft.

Valve Seat - Remove

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

outside diameter of the valve seat to make sure that the interference is within the range of standard value.

+0.025

45°

ø46 0 [1.81 +0.0010 0.00 ] Inlet

2 ± 0.1 [0.08 ± 0.004]

diameter of the valve seat fit of cylinder head and the

2 ± 0.1 [0.08 ± 0.004]

8 ± 0.1 [0.31 ± 0.004]

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

8 ± 0.1 [0.31 ± 0.004]

1.7.2 Valve Seat Ring - Install

ø37 +0.025 0 [1.46 +0.0010 0.00 ] Exhaust

45° Unit: mm [in.]

Valve Seat Counterbore (2) Chill the valve seat ring at least for 4 minutes in liquid nitrogen and keep the cylinder head in a room tempera-

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

ture.

(3) Install the valve seat ring to the cylinder head with the valve seat caulking tool.

Valve Seat - Install

6-7

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Valve and Valve Seat - Lap Lap the valve and valve seat whenever the valve seat is refaced or the valve is replaced, or the contact surfaces fail to keep a pressure in the pressure test after assembling.

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

Note:(a) Do not allow the compound to adhere to the valve stem.

Compound

(b) The compound spreads more evenly when it is mixed with a small amount of engine oil. (c) Use a medium-grain compound (125 to 150 mesh)

Compound - Apply

for initial lapping, then use the fine-grain compound (200 mesh) for finishing.

(2) Use a valve lapper for lapping.

Tap the valve against the valve seat while rotating the

Valve lapper

valve little by little.

(3) Clean off the compound using diesel fuel.

(4) Apply engine oil to mating surfaces, and lap for finishing.

(5) Apply a thin coat of lead-free coloring paste on the valve face, and tap the valve face against the valve seat using a valve lapper to check the contact condition.

Valve and Valve Seat Ring - Lap

1.9 Squareness and Free Length of Valve Spring - Measure Measure the squareness and the free length of valve spring.

If the specified limit or standard value is exceeded, replace

Spring squareness

the valve spring with a new one.

Nominal value

Standard value

Limit value

Free length

48.85 mm [1.9232 in.]

47.60 mm [1.8740 in.]

A

Squareness

B Lf

set length / load

Free length

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 {17.9 to 20.0 kgf} [39.57 to 44.06 lbf]

At the whole length B=1.5 mm [0.059 in.]

43 mm [1.69 in.]/147 N {15.0 kgf} [33.05 lbf]

Squareness and Free Length of Spring - Measure

1.10 Push rod Runout - Measure Measure the runout of pushrod in the total indicator reading (TIR). If the run out exceeds the limit, replace the push rod with a new one.

Item Push rod runout

Limit value 0.6 mm [0.024 in.]

Remarks

V-block

Push rod

TIR

1/2

1/2 Surface plate

Push rod Runout - Measure

6-8

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.11 Distortion of Cylinder Head Bottom Surface - Measure

The refacing depth of cylinder head is to be minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and contact between piston and valve.

With a straight edge placed on the bottom face of cylinder head, measure the bottom face distortion with thickness gauges. If the distortion exceeds the limit, grind the cylinder head.

Distortion of Cylinder Head Bottom Surface - Measure Item Bottom face distortion of cylinder head

Standard value

Limit value

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).

6-9

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

2. Rear Mechanism - 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 value

Limit value

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 other appropriate heat source.

Flywheel

(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 Mechanism - Inspect and Repair 3.1 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 Clearance between idler bushing and idler shaft

Standard value

Limit value

0.009 to 0.050 mm [0.0004 to 0.0020 in.]

0.100 mm [0.0039 in.]

Bushing Inside Diameter and Shaft Outside Diameter of Idler - Measure

3.2 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 value

Interference between shaft and crankcase hole

0.035 to 0.076 mm [0.0014 to 0.0030 in.]

Idler Shaft - Replace

3.3 Cam Lift of Cam Shaft Lobe - Measure Measure the major axis and minor axis of cam to determine cam height. If the measured value is less than the limit,

Measuring points

replace the camshaft with a new one.

Nominal value

Standard value

Limit value

Inlet

6.682 mm [0.2631 in.]

6.382 to 6.782 mm [0.2513 to 0.2670 in.]

6.182 mm [0.2434 in.]

Exhaust

6.722 mm [0.2646 in.]

6.402 to 6.822 mm [0.2520 to 0.2686 in.]

6.222 mm [0.2450 in.]

Item

Camshaft cam lift (major axis minor axis)

Measuring directions

Cam Lift of Cam Shaft Lobe - Measure

6-11

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Camshaft Runout - Measure Measure the camshaft runout. If the value exceeds the limit, 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 value

Camshaft runout

0.04 mm [0.0016 in.] or less

Limit value

Remarks

0.10 mm TIR [0.0039 in.]

Camshaft Runout - Measure

3.5 Camshaft Journal Outside Diameter - Measure Measure the diameter of each camshaft journal in two directions at right angles to each other. If the value exceeds the Measuring points

limit, replace the camshaft with a new one.

Nominal value

Standard value

Limit value

No. 1, 2 journal

ø54 mm [2.13 in.]

53.94 to 53.96 mm [2.1236 to 2.1244 in.]

53.90 mm [2.1220 in.]

No. 3 Journal

ø53 mm [2.09 in.]

52.94 to 52.96 mm [2.0842 to 2.0850 in.]

52.90 mm [2.0827 in.]

Item

Camshaft journal outside diameter

Measuring directions

Camshaft Journal Outside Diameter - Measure

3.6 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: Be careful not to damage the inner surface of camshaft bushing when measuring the inside diameter.

Item Clearance between camshaft journal and camshaft bushing

6-12

Standard value

Limit value

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

Camshaft Hole (Bushing) Inside Diameter - Measure

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.7 Camshaft Bushing - Replace 3.7.1 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 3.7.2 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

3.8 Belt Groove Wear - Inspect Check the belt groove of pulley for wear. Attach a new belt around the pulley, apply high tension and measure the sinkage of belt.

If the wear appears excessive, and the belt top surface sinks 1.6 mm [0.063 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.

Belt Groove Wear - Inspect

6-13

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 defect is found, replace the piston with a new one.

Piston - Inspect Visually

4.2 Piston Weight When replacing pistons, be sure that the weight difference in one engine is within the permissible range.

Item

Standard value

Weight difference in one engine

±5 g [±0.176 oz.]

4.3 Piston Outside Diameter - Measure (1) Measure the piston outside diameter of piston skirt in Directions at right angles to piston pin

the right angle to the piston pin. If the value exceeds the limit, replace the piston with a new one. When replacing pistons, be sure that the weight difference in one

Measuring points

engine is within the permissible range.

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

Nominal value

Item

Standard

Piston outside diameter

+0.25 mm Size [0.0098 in.]

Over Size +0.50 mm [0.0197 in.]

Over Size

6-14

ø94 mm [3.70 in.]

Front mark

Standard value

Limit value

93.915 to 93.945 mm [3.6974 to 3.6986 in.]

93.770 mm [3.6917 in.]

94.165 to 94.195 mm [3.7073 to 3.7085 in.]

93.980 mm [3.7000 in.]

94.415 to 94.445 mm [3.7171 to 3.7183 in.]

94.230 mm [3.7098 in.]

Weight stamp

Identification mark

Piston weight punch mark location

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.4 Piston Ring Groove - Inspect

Remove carbon deposits from the piston and inspect No.1 compression ring groove

the entire circumference of piston.

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

No.2 compression ring groove

groove.

(2) Visually check each ring groove for wear or damage. If

Oil ring groove

faulty, replace the piston with a new one.

Piston Ring Groove - Inspect

4.5 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 value

Standard value

Limit value

Piston pin outside diameter

ø 34 mm [1.34 in.]

33.995 to 34.000 mm [1.3384 to 1.3386 in.]

-

Clearance between piston pin bore and piston pin outside diameter

-

0 to 0.015 mm [0.00 to 0.0006 in.]

0.050 mm [0.0020 in.]

᷹ቯ▎ᚲ

᷹ቯᣇะ

Piston Pin Bore Diameter and Piston Pin Outside Diameter - Measure

4.6 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.

4.6.1 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 value exceeds the limit, replace the piston rings with a new set of

Thickness gauge

rings.

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

Item

Piston ring end gap

Standard value

Limit value

No. 1 compression ring

0.30 to 0.50 mm [0.0118 to 0.0197 in.]

1.50 mm [0.0591 in.]

No. 2 compression ring

0.50 to 0.70 mm [0.0197 to 0.0276 in.]

1.50 mm [0.0591 in.]

Oil ring

0.30 to 0.50 mm [0.0118 to 0.0197 in.]

1.50 mm [0.0591 in.]

End gap

Piston ring end gap - Measure

6-15

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.7 Clearance Between Connecting Rod Bearing and Crankpin - Measure

When grinding crankpins, be sure to grind all the pins

Measuring directions

Measuring points

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

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 (oil clearance)

Crankpin Outside Diameter - Measure

Nominal value

Standard value

Limit value

ø60 mm [2.36 in.]

59.955 to 59.970 mm [2.3604 to 2.3610 in.]

59.800 mm [2.3543 in.]

-

0.030 to 0.071 mm [0.0012 to 0.0028 in.]

0.200 mm [0.0079 in.]

4.8 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

6-16

Measuring directions

Nominal value

Standard value

Limit value

ø34 mm [1.34 in.]

34.020 to 34.055 mm [1.3394 to 1.3407 in.]

-

-

0.02 to 0.06 mm [0.0008 to 0.0024 in.]

0.080 mm [0.0031 in.]

Measuring points

Connecting Rod Bushing Inside Diameter - Measure

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.9 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 Oil hole

Matching marks side

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

q

ing into the connecting rod.

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

q Oil hole

Bushing joint

Connecting Rod Bushing - Replace

4.10 Connecting Rod Bushing - Remove 4.10.1 Connecting Rod Bushing - Remove (1) Apply engine oil to the inner surface of connecting rod bushing.

Mandrel

Connecting rod bushing installer P/N:32K91-00010

Collar A Connecting rod bushing

(2) Install the collar A to the connecting rod bushing.

(3) Install the collar A and B to mandrel and fix them with a nut.

Connecting rod

(4) Align the matching mark (red scribed line) on the collar

Collar B

A with that on the adapter.

Align match mark.

Nut Base

Connecting Rod Bushing - Remove(1) (with connecting rod bush installer) (5) Install the connecting rod big end to the base B. (6) With a pressing machine, apply pressure slowly on the mandrel head to push-out the connecting rod bushing.

Base B

Connecting Rod Bushing - Remove(2) (7) Chamfer (C 0.5) the bore edge of connecting rod small end.

Chamfer 0.5

Connecting Rod Bushing, Chamfer the Small End Bore

6-17

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.11 Connecting Rod Bushing - Press-In (1) Install the new connecting rod bushing aligning with the matching mark on collar A and the bushing oil hole.

(2) Install the combination of collar A and collar B to the

Connecting rod bushing

Connecting rod bushing installer P/N:32K91-00010

Align match mark.

mandrel, and fix them with the nut.

Collar A

Connecting Rod Bushing - Press-In (1) (3) Install the connecting rod big end to the base B. (4) Apply engine oil to the outer periphery of the connecting rod bushing. Align the matching mark (red scribed line) on the collar A with the oil hole in the connecting rod, then install them to the press.

Base B

Connecting Rod Bushing - Press-In (2) (5) Press-in the collar B until it contacts with the connect-

Mandrel Collar B

Connecting rod bushing installer P/N:32K91-00010

ing rod with the press.

Connecting rod bushing

Connecting rod Collar A Align match mark.

Nut Base

Oil Hole Position of Connecting Rod and Bushing

4.12 Connecting Rod Assembly Weight Rank 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 Connecting rod Weight rank

Tolerance on weight 10 g [0.353 oz.] or less

#

Matching mark for assembly Weight rank mark

Connecting Rod Assembly Weight Rank

6-18

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.13 Connecting Rod Bearing - Inspect Inspect the sliding surface, back surface and end surfaces of the connecting rod bearing. If there is any defect such as local contact, sliding scratches, corrosion and foreign material inclusion, replace the bearing with a new one.

Scratches Flaking Seizure

End face

Connecting Rod Bearing - Inspect

4.14 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 machine so that the measured value meets the standard.

C L

C

Note: Before checking the bend and twist, tighten the con-

L Piston pin

necting rod cap to the specified torque.

C L

0.05 100

(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

Connecting rod twist

Connecting rod bend

Unit: mm [in.]

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

Connecting Rod Bend and Twist - Inspect

height of the bar with a dial gauge.

Item Connecting rod bend and twist

Standard value

Limit value

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

0.15/100 mm [0.0059/3.94 in.]

Unit: mm [in.]

D C

C D

0.05 100

[

0.0020 ] 3.94

A

B

Measuring with Dial Gauge

6-19

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

150 [5.91]

Measuring directions

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

Measuring points Unit: mm [in.]

Cylinder Inside Diameter - Measure

rebored cylinder.

(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.

Standard value

Limit value

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.]

Roundness

-

0.01 mm [0.0004 in.] or less

-

Cylindricity

-

0.015 mm [0.0006 in.] or less

-

Item

Cylinder inside diameter

6-20

Nominal value

Refacing Using a Ridge Reamer

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.2 Crankcase Top Surface Distortion - Measure

The refacing depth of the crankcase is to be 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 with thickness gauges. If the distortion exceeds the limit, grind the cylinder head using a surface grinder.

Note: Do not overgrind the crankcase, as the piston protru-

Crankcase Top Surface Distortion - Measure

sion deviates from the standard value.

Item Crankcase top surface distortion

Standard value

Limit value

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).

6-21

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.3 Crankpin and Journal Outside Diameters - Measure (1) Measure the outside diameter of 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 roundness, 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.

Nominal value

Standard value

Limit value

ø60 mm [2.36 in.]

59.555 to 59.770 mm [2.3447 to 2.3531 in.]

Service limit: 59.800 mm [2.3543 in.]

ø80 mm [3.15 in.]

79.955 to 79.970 mm [3.1478 to 3.1484 in.]

Repair limit: 79.850 mm [3.1437 in.]

Service limit: 79.100 mm [3.1142 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.

Max. 0.01 mm [0.0004 in.] or less

-

Item Crankpin outside diameter

Crank main journal Outside diameter

Pin and journal Parallelism

Crankpin Outside Diameter - Measure

Measuring directions

Measuring points

Crank Journal Outside Diameter - Measure

5.4 Width of Crankpin and Rearmost Crank Main Journal - Measure (1) Inspect the end of crankshaft for harmful scratch and wear.

(2) Measure the crankpin and rearmost crank journal

Crankpin width

Rearmost crank journal width

width.

Nominal value

Standard value

Crankpin width

29 mm [1.14 in.]

29 to 29.1 mm [1.14 to 1.146 in.]

Rearmost crank journal width

29 mm [1.14 in.]

29 to 29.033 mm [1.14 to 1.1430 in.]

Item

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

6-22

Crankshaft Bearing Width - Measure

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.5 Crankshaft - Grind The crankshaft should be grinded to the values of grinding dimension shown as the right table, and assemble it with same rank of undersize main bearing, undersize connecting

R4 mm

R4 mm

rod bearing or oversize thrust plate.

When grinding, be careful not to change the fillet radius and width. When grinding the outer surface of shaft, be careful

R4 mm

not to change the width.

If a remarkable decrease in hardness is found, quench the crankshaft again and inspect it with the magnetic particle inspection. If the surface hardness is considered to have been reduced, re-harden the crankshaft and check for flaws

Crankshaft - Grind

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 the grinding, measure the width of crankpins and rearmost crank main journal.

Item

Crank journal

Crankpin

Under size

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 main journals with V-blocks, and measure the crankshaft runout at the center journal with a dial gauge. If the runout deviates slightly outside the standard values, correct the crankshaft by grinding. If the value exceeds the standard value considerably, straighten the crankshaft with a pressing machine.

If the value exceeds the limit, replace the crankshaft with a new one.

If the crankshaft is repaired by grinding or pressing, inspect the crankshaft for cracks and other harmful damages with Crankshaft Runout - Measure

the magnetic particle inspection.

Item

Standard value

Crankshaft runout

0.04 mm [0.0016 in.] or less

Limit value Remarks 0.10 mm TIR [0.0039 in.]

6-23

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.7 Crankshaft Gear - Inspect If there is any defect on the crankshaft gear teeth, such as flaking, wear, or local contact, replace the crankshaft gear with a new one.

5.8 Crankshaft Gear - Replace

Use protective gloves when you touch hot parts.

Crankshaft gear

Handling with bear hands could result in burns.

5.8.1 Crankshaft gear - Remove Remove the gear from the crankshaft with a gear puller.

Note: When removing the crankshaft gear by heating, the

Gear puller P/N:MH061326

heating temperature is 180°C [356 °F] or less.

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

Shrink fit temperature: 260 to 300°C [500 to 572°F]

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

Key Aligning position

Crankshaft gear

Standard interference value: 0.025 to -0.025 mm [0.394 to -0.394 in.]

Crankshaft gear - Install

5.9 Oil Seal Contact Surface - Inspect (1) Check the oil seal contacting surfaces at the crankshaft pulley and crankshaft rear end.

(2) If the crankshaft pulley or crankshaft wears due to the

Front side

Rear side Oil seal

oil seal, replace the oil seal and the oil seal sleeve with new service parts.

Oil seal contact surface

Oil Seal Contact Surface - Inspect

6-24

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.10 Oil Seal Sleeve - Replace 5.10.1 Front 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.

Oil seal sleeve

If the sleeve can not be removed by the above procedure, hold the chisel against the sleeve in the axial direction and

Front oil seal sleeve - Remove

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.

5.10.2 Front oil seal sleeve - Install Crankshaft pulley

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

1.5 mm [0.059 in.] from the end face

Press-in to be flush

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

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

Oil seal sleeve

Front oil seal sleeve - Install

sleeve) with the new spare parts.

Crankshaft pulley

17.5 mm [0.69 in.]

13 mm [0.51 in.]

Oil seal

Oil seal sleeve 17 mm [0.67 in.]

Front oil seal assembly - Install

6-25

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.10.3 Rear 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

Rear oil seal sleeve - Remove

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.

5.10.4 Rear 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

Installer P/N:30691-13200

Rear oil seal sleeve - Install

sleeve) with the new spare parts.

7.5 mm [0.29 in.]

Oil seal

12 mm [0.47 in.]

5.5 mm [0.21 in.]

Oil seal sleeve

Rear oil seal assembly - Install

5.11 Main Bearing - Inspect Inspect the sliding surface, back surface and end surfaces of the main bearing. If any defect such as local contact, sliding scratches, corrosion and foreign material inclusion is found, replace the main bearing with a new one.

Flaw, corrosion, flaking

End face

Main Bearing - Inspect

6-26

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.12 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 undersize bearing is used, grind the crank journal to the undersized specification.

Item Clearance between main bearing and crank journal

Standard value

Limit value

0.069 to 0.110 mm [0.0027 to 0.0043 in.]

0.200 mm [0.0079 in.]

Measuring directions

Measuring points

Crank Journal Outside Diameter - Measure

5.13 Thrust Plate - Inspect Inspect the sliding surface, back surface and end surfaces of the thrust plate. If any defect such as local contact, sliding scratches, corrosion and foreign material inclusion is found, replace the thrust plate with a new one.

Scratch, corrosion flaking

Thrust Plate - Inspect

6-27

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.14 Tappet - Inspect 5.14.1 Contact surface of tappet and camshaft Inspect the cam contact surface of the tappet. If the tappet is

Flaw, local wear Flaw, local wear

worn unevenly, replace it with a new one.

Good

Bad

Bad

Contact surface of tappet and camshaft 5.14.2 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 5.14.3 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 value

Limit value

Tappet guide hole inside diameter

14.000 to 14.018 mm [0.5512 to 0.5519 in.]

14.100 mm [0.5551 in.]

Clearance between tappet and tappet guide hole

0.016 to 0.052 mm [0.0006 to 0.0020 in.]

0.08 mm [0.0031 in.]

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 Mechanism - Assemble............................................................................... 7-11 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.

Crankcase - Turn Over (Upend) ............................................................................................... 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 Shell and Lower Thrust Plate - Install ...................................................... 7-4 Main Bearing Cap - Install ........................................................................................................ 7-5 Crankshaft End Play - Measure................................................................................................ 7-6 Side Seal - Insert ...................................................................................................................... 7-6 Piston and Connecting Rod - Assemble ................................................................................... 7-7 Piston Ring - Install................................................................................................................... 7-7 Piston Installation - Prepare...................................................................................................... 7-8 Connecting Rod Bolt and Upper Connecting Rod Bearing - Install .......................................... 7-8 Piston - Install ........................................................................................................................... 7-8 Connecting Rod Cap - Install.................................................................................................... 7-9 Connecting Rod End Play - Measure ....................................................................................... 7-9 Piston Protrusion - Measure ................................................................................................... 7-10 Oil Pump - Install .................................................................................................................... 7-11 Front Plate - Install.................................................................................................................. 7-11 Camshaft - Install.................................................................................................................... 7-11 Idler Gear - Install ................................................................................................................... 7-12 Oil Pump Gear - Install ........................................................................................................... 7-12 High Pressure Pump - Install .................................................................................................. 7-12 Timing Gear Backlash - Measure ........................................................................................... 7-13 Idler Gear End Play - Measure ............................................................................................... 7-13 Camshaft End Play - Measure................................................................................................ 7-13 Front Oil Seal - Install ............................................................................................................. 7-13 Timing Gear Case - Install ...................................................................................................... 7-14 Oil Strainer - Install ................................................................................................................. 7-14 Oil Pan - Install ....................................................................................................................... 7-15 Crankcase - Turn Over ........................................................................................................... 7-15 Crankshaft Pulley - Install ....................................................................................................... 7-16

Rear Mechanism - Assemble ................................................................................ 7-17 3.1 3.2 3.3 3.4

Rear Oil Seal - Install.............................................................................................................. 7-17 Flywheel Housing - Install....................................................................................................... 7-17 Flywheel - Install ..................................................................................................................... 7-17 Flywheel Face and Radial Runout - Measure......................................................................... 7-18

7-1

Chapter 7 ASSEMBLY OF BASIC ENGINE

4.

Cylinder Head and Valve Mechanism - Assemble .............................................. 7-19 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

7-2

Cylinder Head - Assemble ...................................................................................................... 7-19 Measurement of Valve Sinkage.............................................................................................. 7-19 Cylinder Head Gasket - Install ................................................................................................ 7-20 Cylinder Head Assembly - Install............................................................................................ 7-20 Cylinder Head Bolt - Tighten................................................................................................... 7-20 Push rod - Insert ..................................................................................................................... 7-20 Rocker Shaft Assembly - Install.............................................................................................. 7-21 Valve Clearance - Check and Adjust ...................................................................................... 7-22 Injector - Install ....................................................................................................................... 7-23 Valve Clearance - Adjust ........................................................................................................ 7-23 Rocker Cover - Install ............................................................................................................. 7-23

Chapter 7 ASSEMBLY OF BASIC ENGINE Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Piston, Connecting rod, Crankshaft and Crankcase - Assemble 1.1 Crankcase - Turn Over (Upend) Using a turnover machine, turn over the crankcase. When the turnover machine is not available, hitch slings to the crankcase using wood pieces and cloth pads, and raise the crankcase with a hoist or crane. Then lay it on the wooden block with its side face downward. Then, change the positions of the slings, and turn over to upend the crankcase.

Crankcase - Turn Over (Upend)

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

1.3 Upper Main Bearing - Install

(a) Do not apply engine oil to the back face of the main bearing shell and the main bearing housing in the crankcase when installing the main bearing. Install the main bearing only after cleaning off foreign material, oil and grease from the surface using cleaning solvent. (b) When installing main bearings, be careful not to confuse the upper shell with the lower shell.

The upper main bearing shell is identified by machined oil hole. The lower main bearing shell has no oil hole nor groove. Be careful not to install the main bearing upside down. (c) Be careful not to damage the bearing when installing.

(1) Clean the main bearing housing and the main bearing

Upper main bearing

cap mating surfaces using cleaning solvent, and make sure that these surfaces are free from any foreign material.

(2) Make sure that the main bearing is free from damage or contamination.

(3) Fit the upper main bearing shell in the crankcase bore aligning the lug on the shell with the lug slot in the

Align with lug groove.

crankcase.

Note:(a) Make the main bearing crush heights even at both ends.

Upper Main Bearing - Install

(b) The oil hole in the upper main bearing shell is aligned with the oil hole in the crankcase by aligning the lug on the upper shell with the lug slot in the crankcase.

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

7-3

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.4 Rear Upper Thrust Plate - Install

Be careful not to damage the thrust plate when installing.

(1) With the oil grooves of the thrust plate facing the crankshaft web, install the rear upper thrust plate to the

Oil groove

dowel pins on the crankcase rearmost main journal.

(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 washing crankshaft, be sure to thoroughly wash oil holes so that they are free from foreign substances, Crankshaft - Install

dust and dirt. Make sure that oil holes are free from burrs.

(3) Lift the crankshaft horizontally and slowly install it to 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 Shell and Lower Thrust Plate - Install (1) Install the lower main bearing shell, aligning the lug with the lug slot in the main bearing cap.

Note: Make the crush heights even.

Lower main bearing

(2) Apply an even coat of clean engine oil to the sliding surfaces of lower main bearing shells.

(3) Install the lower thrust plates aligning with the dowel Lower thrust plate

pins on the rearmost main bearing cap.

Note: Install the lower thrust plates to place the oil grooves

Main bearing cap

facing outward.

Lower thrust plate

Lower Main Bearing and Lower Thrust Plates - Install

7-4

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.7 Main Bearing Cap - Install

Be sure to tighten the bolts in the specified sequence

Apply ThreeBond 1212 to corner of cap

when installing the main bearing cap bolts.

(1) Make sure that the main bearings and the thrust plates installed on the main bearing caps are evenly coated with clean 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 main bearing cap bolt and washer with engine oil, and install the bolts and washer temporarily.

(4) Tap the main bearing caps with a soft-head hammer evenly to install them in 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.

(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

140 ± 5 N·m {14.3 ± 0.5 kgf·m} [103.26 ± 3.68 lbf·ft] [Wet]

Main Bearing Cap Bolts - Install

surface contacts lightly with the main bearing cap.

Measure the crankshaft end play in this condition.

7-5

Chapter 7 ASSEMBLY OF BASIC ENGINE 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 value

Limit value

0.100 to 0.258 mm [0.0039 to 0.0102 in.]

0.300 mm [0.0118 in.]

Crankshaft thrust size after grinding Item

One side Over size

Both sides Over size

+0.15 mm [0.0059 in.]

Over size

31.15 mm [1.2264 in.]

31.30 mm [1.2323 in.]

+0.30 mm [0.0118 in.]

Over size

31.30 mm [1.2323 in.]

31.45 mm [1.2382 in.]

Tolerance +0.039 0 mm +0.0015 [ 0 in.]

1.9 Side Seal - Insert (1) Apply sealant (ThreeBond 1211) to the periphery of new side seal from the bottom to 2/3 height.

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

Crankcase

Side seal

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 Apply ThreeBond 1211 to side seal.

Side Seal - Insert

7-6

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.10 Piston and Connecting Rod - Assemble (1) Apply engine oil to the piston pin, and assemble the piston and the connecting rod. The orientation of the

A View A

Front mark

piston and the connecting rod is as shown in the illustration.

Note: The piston and the piston pin are made for a clearance fit. However, the piston pin is more easily inserted into

Matching mark with connecting rod cap

the piston if the piston is warmed up with a heater or with hot water.

Weight stamp

(2) Install the snap ring with ring pliers. Make sure that the snap ring is fully inserted into the ring groove.

Assembling Orientation of Piston and Connecting Rod

Snap ring pliers

Piston and Connecting Rod - Assemble

1.11 Piston Ring - Install

Every piston ring has an upper face mark near the end

Piston ring plier P/N:31391-12900

gap. Install the piston rings with the marks 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 gap

Oil Ring and Coil Spring Assembling

7-7

Chapter 7 ASSEMBLY OF BASIC ENGINE 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 face of the bear-

Lug groove

ings.

Install the upper connecting rod bearing on the connecting rod big end aligning the lug and the lug slot. Apply engine oil to the sliding surface.

Apply engine oil.

Connecting Rod Bolt Upper Connecting Rod Bearing - Install

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) Place the piston ring end gaps equally spaced 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 Anti-thrust direction

Oil ring ends 60°

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

7-8

Chapter 7 ASSEMBLY OF BASIC ENGINE 1.15 Connecting Rod Cap - Install

(a) Check that the matching mark of connecting rod is on the same side as cap's. (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.

55.0㨪65.0 N·m {5.6㨪6.6 kgf·m} [40.7㨪47.9 lbf·ft]

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

(2) Apply engine oil to the connecting rod bolt threads and

Connecting Rod Cap - Install

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.

1.16 Connecting Rod End Play - 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 value

Limit value

0.15 to 0.35 mm [0.0059 to 0.0138 in.]

0.50 mm [0.0197 in.]

Connecting Rod End Play - Measure

7-9

Chapter 7 ASSEMBLY OF BASIC ENGINE 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 value exceeds the limit, inspect the clearances between the concerned parts.

(1) Move piston to the top dead center.

(2) Apply a dial gauge plunger to the top face of crankcase, Piston Protrusion - Measure

and adjust the dial gauge to zero.

(3) Measure protrusions at four places on piston top face, 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 value

Piston protrusion

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

Compressed thickness of cylinder head gasket

1.15 to 1.25 mm [0.0453 to 0.0492 in.]

Top Clearance

7-10

1.0 to 1.5 mm [0.039 to 0.059 in.]

Chapter 7 ASSEMBLY OF BASIC ENGINE

2. Front Mechanism - 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 front plate packing mounting surface of the crankcase, and install the packing with the dowel pin.

(2) Install the front plate with the dowel pin on the packing.

Packing

Front plate

(3) Tighten the bolts to the specified torque.

(4) Make sure that the bottom face of the front plate is flush with the bottom face of the crankcase. Trim excess packing.

18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 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.

(2) Slowly insert the camshaft assembly.

11.5 ± 1.5 N·m {1.2 ± 0.2 kgf·m} [8.48 ± 1.11 lbf·ft]

(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

7-11

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

(2) Install the idler gear onto the shaft fitting the matching mark.

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

(4) Move the idler gear back and forth, and check the end

Idler gear

Thrust plate

play.

34 ± 5 N·m {3.5 ± 0.5 kgf·m} [25.08 ± 3.68 lbf·ft]

Idler Gear - Install Oil pump gear Fuel injection pump gear

Crankshaft gear

1

22

2

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.

33.0 ± 5.0 N·m {3.4 ± 0.5 kgf·m} [336.5 ± 51 lbf·ft]

Oil pump gear

Oil Pump Gear - Install

2.6 High Pressure Pump - Install (1) Install the high pressure pump by aligning the highpressure pump idler gear with the idler gear.

(2) Tighten the bolts to the specified torque.

Fuel injection pump idler gear

Idler gear

High Pressure Pump - Install

7-12

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.7 Timing Gear Backlash - Measure Measure the backlash of timing gears using either method: measure the gear backlash with a dial gauge applying its probe to a tooth flank on the pitch circle at a right angle to

Dial gauge

the tooth axis, or measure the clearance between gears by inserting thickness gauges between the engaging gear teeth.

If the value exceeds the limit, replace the gears with new ones.

Item Timing gear backlash

Standard value

Limit value

0.05 to 0.15 mm [0.0020 to 0.0059 in.]

0.25 mm [0.0098 in.]

Timing Gear Backlash - Measure

2.8 Idler Gear End Play - Measure Measure the end play of the idler gear. If the value exceeds the limit, replace the thrust plate with a new one.

Item Idler gear end play

Standard value

Limit value

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 value exceeds the limit, replace the thrust plate with a new one.

Item Camshaft end play

Standard value

Limit value

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

Front Oil Seal - Install

7-13

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.11 Timing Gear Case - Install (1) Install the timing plate to the cam shaft gear.

(2) Apply sealant to the packing to prevent it from displacing and install the packing on the front plate by aligning

Packing Timing gear case

with the dowel pin.

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

(4) Install the timing gear case and tighten the bolts to the specified torque.

18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 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

7-14

Timing plate

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 (32A91-05100: liquid gasket) in a 4 mm [0.16 in.] diameter bead all around the oil pan flange periphery, and spread it evenly.

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

(4) Tighten the bolts to 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

Bolt

11.5 ± 1.5 N·m {1.2 ± 0.2 kgf·m} [8.48 ± 1.11 lbf·ft]

Oil Pan - Install

Cut here

Cutting Point of the Liquid Gasket Tube Nozzle

2.14 Crankcase - Turn Over Using a turnover machine, turn over the crankcase. When the turnover machine is not available, hitch slings to the crankcase using wood pieces and cloth pads, and raise the crankcase with a hoist or crane. Then lay it on the wooden block with its side face downward. Then, change the sling positions. Turn over the crankcase on the wooden blocks to turn it to the normal position.

Crankcase - Turn Over

7-15

Chapter 7 ASSEMBLY OF BASIC ENGINE 2.15 Crankshaft Pulley - Install (Front)

㧔Rear㧕 Prevent crankshaft from turning

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.

(3) Install the damper to the crankshaft pulley.

(4) Tighten the nuts to the specified torque.

Crankshaft pulley 490 ± 10 N·m {50 ± 1 kgf·m} [361.41 ± 7.37 lbf·ft]

Guide bolt (M12 × 1.25 mm)

Crankshaft Pulley - Install

7-16

Chapter 7 ASSEMBLY OF BASIC ENGINE

3. Rear Mechanism - 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 flywheel housing.

Be careful of the oil seal installation direction.

Apply grease

Flywheel housing

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 Flywheel Housing - Install (1) Clean the mounting surface of the gasket.

(2) Apply sealant to the gasket using guide bolt to prevent

Apply engine oil

it from falling off.

(3) Install the gasket.

(4) Install the flywheel housing, aligning its dowel pin holes and dowel pins, and tighten the bolts.

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

Flywheel Housing - Install

3.3 Flywheel - Install (Front)

(Rear)

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 rotating.

(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.

(4) Temporarily tighten the bolts.

Guide Prevent the flywheel from rotating using a wrench.

83 ± 5 N·m bolt {8.5 ± 0.5 kgf·m} [61.22 ± 3.69 lbf·ft]

Flywheel - Install

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

(6) Tighten the bolts to the specified torque.

7-17

Chapter 7 ASSEMBLY OF BASIC ENGINE 3.4 Flywheel Face and Radial Runout - 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

Standard value

Limit value

Radial runout measuring point

0.15 mm [0.0059 in.] or less

0.50 mm [0.0197 in.]

Face runout measuring point

Flywheel Face and Radial Runout - Measure

7-18

Chapter 7 ASSEMBLY OF BASIC ENGINE

4. Cylinder Head and Valve Mechanism - Assemble 4.1 Cylinder Head - Assemble

(a) Be careful when inserting the valve through the

Stem seal installer P/N:32A91-20200

Valve

stem seal, as the edge of stem groove can cause damage to the stem seal lip.

Stem seal

(b) Do not apply oil or liquid sealant to the fitting faces between the stem seal and the valve guide.

15.2 ± 0.1 mm [0.598 ± 0.03 in.]

Valve guide

(c) Always replace the stem seal with a new one.

(1) Apply engine oil to the valve stem, and insert the valve into the valve guide.

Valve Stem Seal - Install

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

Valve spring pusher P/N:30691-04500

Note: Place the valve in the valve guide before installing the stem seal. The valve stem seal is centered with the valve stem.

(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 the valve spring and valve cotters are properly installed and seated firmly.

Valve Cotter - Install

4.2 Measurement of Valve Sinkage Measure the valve sinkage.

If the value exceeds the limit, replace the valve or valve seat

Seat width

with a new one. Lap the valve and valve seat whenever the

Nominal value

Standard value

Limit value

Inlet

0.4 mm [0.016 in.]

0.3 to 0.5 mm [0.012 to 0.020 in.]

1.0 mm [0.039 in.]

Exhaust

0.5 mm [0.020 in.]

0.4 to 0.6 mm [0.016 to 0.024 in.]

1.0 mm [0.039 in.]

Item

Valve seat angle

valve or the valve seat is refaced or replaced.

Valve margin Valve sinkage

Measurement of Valve Sinkage

7-19

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 contaminants from the cylinder head bottom surface and the crankcase top 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 crankcase by yourself. Use a crane or lift it 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} [87.03 ± 3.69 lbf·ft]

4

12 Front

5

15 11

13

1

8

16

7

3

9

17 14

2 6 10

Number of bolt:17

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

7-20

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.7 Rocker Shaft Assembly - Install

Always tighten the long bolt first. Failing to do so may

Bolt (short)

17.5 ± 2.45 N·m {1.78 ± 0.25 kgf·m} [12.9 ± 1.8 lbf·ft]

cause damage to the rocker shaft bracket.

(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

Rocker Shaft Assembly - Install

torque.

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

7-21

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

Standard value

Item Valve clearance (when cold)

Inlet Exhaust

0.25 mm [0.0098 in.]

(1) Inspect the valve clearance for all cylinders in the firing

Firing order 1-3-4-2 Turning angle: 180°

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

Marking line on crankshaft pulley

top dead center.

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

(2) When the No. 1 piston is at compression top dead cen-

Turning socket P/N:58309-73100

Crankshaft - Turn

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 between the rocker arm and valve cap, then adjust the 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.]

(4) Insert the thickness gauge of the specified thickness 20 ± 0.2 N·m {2.0 ± 0.02 kgf·m} [15 ± 0.15 lbf·ft]

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

Inspection of Valve Clearance

7-22

Chapter 7 ASSEMBLY OF BASIC ENGINE 4.9 Injector - Install (1) Install the gasket to the injector.

(2) Install the injector and nozzle gland to the cylinder

Leak off hose connector

head.

(3) Install the washer by facing its spherical side to the noz-

Leak off hose

Pin Injector

zle gland and tighten the hexagon socket bolt to the specified torque.

Note: Use the injector in the same cylinder before and after Injection pipe

the disassembling.

(4) Apply engine oil to the O-ring of leak-off hose.

Injection connector

Nozzle gland

Gasket

Injector - Install (5) Fully press the pin at the top injector and install the leak-off hose connector to the injector top.

(6) Install the injection pipe.

Injector

Push Pin

Pin at the Top of Injector

4.10 Valve Clearance - Adjust Adjust the valve clearance.

For adjusting procedures, refer to "Valve clearance - Inspect and Adjust of ADJUSTMENT AND OPERATION".

Injector

Push Pin

Valve Clearance - Adjust

4.11 Rocker Cover - Install (1) Make sure that the gasket is firmly installed into the rocker cover.

(2) Tighten the bolts evenly to the specified torque from the center position.

11.5 ± 1.5 N·m {1.2 ± 0.2 kgf·m} [8.48 ± 1.11 lbf·ft]

Rocker Cover - Install

7-23

Chapter 8 FUEL SYSTEM 1.

Environmental Condition to Disassemble and Assemble the Fuel System....... 8-3

2.

Fuel System - Remove ............................................................................................ 8-3 2.1 2.2

3.

Common Rail Assembly - Disassemble and Inspect ........................................... 8-6 3.1

4.

Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble ......................................... 8-7

High-Pressure Pump - Disassemble and Inspect ............................................... 8-10 5.1

6.

Common Rail Assembly - Inspect............................................................................................. 8-6

Fuel System - Disassemble, Inspect and Assemble ............................................ 8-7 4.1

5.

Fuel System - Remove and Inspect (1) .................................................................................... 8-4 Fuel System - Remove and Inspect (2) .................................................................................... 8-5

High-Pressure Pump - Inspect................................................................................................ 8-10

Fuel System - Install .............................................................................................. 8-11 6.1 6.2

Fuel System - Install (1).......................................................................................................... 8-11 Fuel System - Install (2).......................................................................................................... 8-12

8-1

Chapter 8 FUEL SYSTEM

1. Environmental Condition to Disassemble and Assemble the Fuel System To keep the cleanliness in installing, removing, inspection and repair works of the fuel system of this engine, obey the instructions below: Clean the engine before the work.

Cover the electronic components and connectors to protect the electric system and avoid the electrical leak and short circuit.

Drying and cleaning with compressed air must be applied before removing the fuel system to prevent the injection pipe from dust entering.

Seal the openings of fuel system parts with plugs

2. Fuel System - Remove

Chapter 8 FUEL SYSTEM

(a) Do not place flame or heat near the fuel system when removing. It may cause a fire. (b) Wipe off any spilled fuel. The spilt fuel may cause a fire. (c) Do not start the disassembling job immediately after the engine stop. Highly pressurized fuel may remain in the fuel system parts such as high-pressure pump, common rail and injection pipe. (d) Stop the fuel supply from the fuel tank then start the work.

or others immediately after the removal to avoid entering of foreign substances.

The assembling job must be done on a clean stainless-steel-top work table.

(a) Plug or cover the inlet and outlet of each part to prevent the fuel system from dust entering. (b) Ask the specialized service shop for the mainte-

Use clean tools, and clean the tools after the job.

nance job of high-pressure pump, common rail

Install a filter to the air inlet fan if installed on the

and injector if the procedure is not written in this

working room. Do not use fan in the working room.

The worker must not wear fuzzy clothes, must

manual. (c) Clean the fuel system inside with the clean fuel oil if foreign substances enter the fuel system.

wear clean dothes and must not use hand cream or others. Wear rubber gloves for presice-part work if needed.

8-3

Chapter 8 FUEL SYSTEM 2.1 Fuel System - Remove and Inspect (1)

13 2 E 1

5 4

B 3

D

Leak, crack, contact

A 6 C

7

B 1

E

9

8 D

11 G

C AF

10

12 F G

Replace: Sealing washer O-Ring Gasket Leak off hose

Fuel System - Remove and Inspect (1) Removing sequence 1 2 3 4 5

Fuel hose Leak-off hose Fuel return pipe Fuel hose Fuel pipe

8-4

6 Fuel pipe bracket 7 No.1 to No.4 fuel injection pipe 8 Nozzle gland 9 Injector

10 11 12 13 14

Fuel pipe High-pressure pump Common rail Main fuel filter Pre-fuel filter

14

Chapter 8 FUEL SYSTEM 2.2 Fuel System - Remove and Inspect (2)

8 Wear, flaw

6 4

Flaw 3 2

1

5 7

Flaking, wear

Fuel System - Remove and Inspect (2) Removing sequence 1 2 3 4

Thrust plate High-pressure pump idler bushing High-pressure pump idler gear High-pressure pump idler shaft

5 6 7 8

High-pressure pump gear High-pressure pump flange Connector High-pressure pump

8-5

Chapter 8 FUEL SYSTEM

3. Common Rail Assembly - Disassemble and Inspect 3.1 Common Rail Assembly - Inspect Remove the common rail from the engine. Then inspect items below: Replace the rail pressure sensor to a new one, if defective.

Replace the common rail assembly to a new one, if other part is defective.

Damage of mating surface and thread 4

1 2 Damage of mating surface

3 Damage of connector and terminal

Damage of mating surface and thread

Common Rail Assembly - Inspect 1 Fuel inlet connector 2 Fuel outlet connector

3 Fuel back flow connector 4 Rear pressure sensor

When a part of common rail system is replaced, run the engine for 10 minutes at low-idling after the replacement to check for the leak. Then run the engine for three minutes to check for the leak.

If a part in the common rail assembly is replaced, apply white or red marking (circle marking of 5 mm [0.20 in.] in dia.) to the replaced part.

8-6

Chapter 8 FUEL SYSTEM

4. Fuel System - Disassemble, Inspect and Assemble 4.1 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble

Pre-puel Filter Replace

Crack, damaged thread

3

Clogging, crack Replace Every 500 hrs Replace 1

2

Fuel Filter - Disassemble and Inspect Disassembling sequence 1 Case

2 Element

3 Head assembly

8-7

Chapter 8 FUEL SYSTEM

Main Fuel Filter

Replace

Crack, damaged thread

3

Clogging, crack Replace Every 500 hrs Replace 1 2

Fuel Filter - Disassemble and Inspect Disassembling sequence 1 Case

8-8

2 Element

3 Head assembly

Chapter 8 FUEL SYSTEM 4.1.1 Fuel Filter (Pre- and Main) - Assemble

(a) Make sure that there is no flame around the area before handling fuel. (b) Wipe off any spilled fuel. Spilled fuel can cause a fire.

(1) Wipe off any fuel on the head assembly and element

Air vent plug

mounting surface of case with waste cloth.

10 ± 2 N·m {1 ± 0.2 kgf·m} [7.38 ± 1.48 lbf·ft]

(2) Install the new element to the case.

Head

O-ring

Do not use the case that has a dent or flaw. It can

Case

20 ± 2 N·m {2 ± 0.2 kgf·m} [14.75 ± 1.48 lbf·ft]

cause damage to the filter, leading to fuel leaks during operation, and result in a fire.

Element

Drain plug

(3) Place a new O-ring, and install the case with element to the head assembly.

O-ring

2 ± 0.5 N·m {0.2 ± 0.05 kgf·m} [1.48 ± 0.37 lbf·ft]

Pre-fuel Filter - Assemble Be careful not to dent or scratch the surface of the ele-

Air vent plug

ment.

10 ± 2 N·m {1 ± 0.2 kgf·m} [7.38 ± 1.48 lbf·ft]

(4) Place a new O-ring and install the drain plug to the

Head

case.

20 ± 2 N·m {2 ± 0.2 kgf·m} [14.75 ± 1.48 lbf·ft]

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

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

(7) 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

O-ring Case

Element

O-ring Drain plug 2 ± 0.5 N·m {0.2 ± 0.05 kgf·m} [1.48 ± 0.37 lbf·ft]

Main Fuel Filter - Assemble

retighten the fuel filter.

8-9

Chapter 8 FUEL SYSTEM

5. High-Pressure Pump - Disassemble and Inspect 5.1 High-Pressure Pump - Inspect Remove the high-pressure pump from the engine. Then inspect items below: If a part is defective, replace it with a new one.

Damage of connector and terminal

Damage of mating surface and thread 2 Damage of mating surface and thread

1 4

3 Damage of connector and terminal

6

Damage of key groove and thread

5

High-Pressure Pump - Inspect 1 Fuel back flow connector 2 Fuel inlet connector 3 Fuel outlet connector

4 Fuel metering unit (MPROP) 5 Camshaft 6 Feed pump

When a part of high-pressure pump is replaced, run the engine for 10 minutes at low-idling after the replacement to check for the leak. Then run the engine for three minutes to check for the leak.

If a part in the high-pressure pump is replaced, apply white or red marking (circle marking of 5 mm [0.20 in.] in dia.) to the replaced part.

8-10

Chapter 8 FUEL SYSTEM

6. Fuel System - Install 6.1 Fuel System - Install (1)

Wear, flaw

Flaw

18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 lbf·ft]

18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 lbf·ft] Flaking, wear

70 ± 5 N·m {7.1 ± 0.5 kgf·m} [51.63 ± 3.69 lbf·ft]

Fuel System - Install (1)

8-11

Chapter 8 FUEL SYSTEM 6.2 Fuel System - Install (2)

E

B

D

A 6 C

B E D

G

C AF

F G

Replace: Sealing washer O-Ring Gasket Leak off hose

Fuel System - Install (2)

8-12

Leak, crack, contact

Chapter 9 LUBRICATION SYSTEM 1.

Lubrication System - Remove and Inspect ........................................................... 9-3 1.1 1.2

2.

Lubrication System - Disassemble, Inspect and Assemble ................................ 9-5 2.1 2.2 2.3 2.4

3.

Oil Pan and Bleezer - Remove and Inspect.............................................................................. 9-3 Oil Cooler, Relief Valve and Safety Valve - Remove and Inspect ............................................ 9-4 Oil pump - Disassemble and Inspect ........................................................................................ 9-5 Oil Pump - Inspect .................................................................................................................... 9-6 Relief Valve - Inspect................................................................................................................ 9-7 Safety Valve - Inspect............................................................................................................... 9-7

Lubrication System - Install.................................................................................... 9-8 3.1 3.2

Oil Pan and Breather Filter - Install........................................................................................... 9-8 Oil Cooler, Relief Valve and Safety Valve - Install.................................................................... 9-9

9-1

Chapter 9 LUBRICATION SYSTEM Chapter 9 LUBRICATION SYSTEM

1. Lubrication System - Remove and Inspect 1.1 Oil Pan and Breather - Remove and Inspect

10

1

11

4

7

6

5

Replace 3

9

8 2

Oil Pan and Breather - Remove and Inspect Removing sequence 1 2 3 4

Breather dust cover Oil drain pipe Oil drain hose Breather hose

5 6 7 8

Breather pipe Breather hose Breather assembly Oil pan

9 Oil strainer 10 Oil level gauge 11 Level gauge guide

9-3

Chapter 9 LUBRICATION SYSTEM 1.2 Oil Cooler, Relief Valve and Safety Valve - Remove and Inspect

Replace

Replace

Replace 6

2 Replace Replace 5

Replace

1

4

3

Replace

Oil Cooler, Relief Valve and Safety Valve - Remove and Inspect Removing sequence 1 Oil cooler case 2 Oil cooler element 3 Union bolt

9-4

4 Oil filter bracket 5 Relief valve 6 Safety valve

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

2 Shaft assembly

3 Outer rotor

4 Pump case

9-5

Chapter 9 LUBRICATION SYSTEM 2.2 Oil Pump - Inspect 2.2.1 Clearance between outer rotor and inner 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.

Thickness gauge

Item

Standard value

Limit value

Inner rotor and outer rotor clearance

0.13 to 0.15 mm [0.0051 to 0.0059 in.]

0.20 mm [0.0079 in.]

Clearance between outer rotor and inner 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 value

Limit value

0.04 to 0.09 mm [0.0016 to 0.0035 in.]

0.15 mm [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.

Thickness gauge

Item

Standard value

Limit value

Outer rotor and pump case clearance

0.20 to 0.30 mm [0.0079 to 0.0118 in.]

0.50 mm [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 Shaft diameter (Case side) Clearance between shaft and pump case

9-6

Nominal value

Standard value

Limit value

ø16 mm [0.63 in.]

15.985 to 16.000 mm [0.6293 to 0.6299 in.]

-

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

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

Nominal value

Standard value

Shaft diameter (oil pump bushing side)

ø14 mm [0.55 in.]

13.957 to 13.975 mm [0.5495 to 0.5502 in.]

-

0.025 to 0.111 mm [0.0010 to 0.0044 in.]

0.200 mm [0.0079 in.]

Shaft and oil pump bushing clearance

Limit value

Measuring points

Clearance between shaft and bushing - Measure

2.2.6 Oil pump bushing - Install

Crankcase Flush

Oil pump bushing

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

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

Flush

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

Oil pump bushing - Install

2.3 Relief Valve - Inspect (1) Check the relief valve and valve seat for contact. Check the spring for settling 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

Nominal value

Standard value

Valve opening pressure

0.35 MPa {3.57 kgf/cm2} [50.76 psi]

0.35 ± 0.05 MPa {3.57 ± 0.50 kgf/cm2} [50.76 ± 7.25 psi]

44 ± 4.9 N·m {4.5 ± 0.5 kgf·m} [32.45 ± 3.61 lbf·ft]

49 ± 4.9 N·m {5 ± 0.5 kgf·m} [36.14 ± 3.61 lbf·ft]

Relief Valve - Inspect

2.4 Safety Valve - Inspect (1) Check the safety valve and valve seat for contact.

Check the spring for fatigue and damage. If any defect is found, replace it with a new one.

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

Item

Standard value

Valve opening pressure

kgf/cm2}

1.1MPa {11

[159.54 psi]

69 ± 5 N·m {7 ± 0.5 kgf·m} {50.89 ± 3.68 lbf·ft}

Safety Valve - Inspect

9-7

Chapter 9 LUBRICATION SYSTEM

3. Lubrication System - Install 3.1 Oil Pan and Breather Filter - Install

Replace

11.5 ± 1.5 N·m {1.2 ± 0.2 kgf·m} [8.48 ± 1.11 lbf·ft]

Oil Pan and Breather Filter - Install Install the parts in the reverse order of the disassemble sequence.

(1) Replace packings and O-rings with new ones when assembling.

(2) Thoroughly clean oil passages of each part with cleaning oil, and dry the cleaned parts with compressed air before assembling.

(3) After installing the oil bracket, install the oil filter.

9-8

Chapter 9 LUBRICATION SYSTEM 3.2 Oil Cooler, Relief Valve and Safety Valve - Install

Replace

Replace

Replace 69 ± 5 N·m {7 ± 0.5 kgf·m} [50.89 ± 3.68 lbf·ft] Replace

Replace 49 ± 4.9 N·m {5 ± 0.5 kgf·m} [36.14 ± 3.61 lbf·ft]

Replace

Replace

Oil Cooler, Relief Valve and Safety Valve - Install

9-9

Chapter 10 COOLING SYSTEM 1.

Cooling System - Remove .................................................................................... 10-3

2.

Cooling System - Inspect...................................................................................... 10-4 2.1 2.2

3.

Water pump for smooth rotation - Inspect .............................................................................. 10-4 Thermostat - Inspect............................................................................................................... 10-4

Cooling System - Install ........................................................................................ 10-6

10-1

Chapter 10 COOLING SYSTEM Chapter 10 COOLING SYSTEM

1. Cooling System - Remove

Replace

5

Crack, water leakage, damage

Replace 4

2

Crack, wear 3

1

Cooling System - Remove Removing sequence 1 Fan 2 Spacer

3 Belt 4 Water pump assembly

5 Thermostat assembly

10-3

Chapter 10 COOLING SYSTEM

2. Cooling System - Inspect 2.1 Water pump for smooth rotation - Inspect Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities. If faulty, replace the water pump assembly.

2.2 Thermostat - Inspect

1 Replace

2

Replace 3

Thermostat - Disassemble and Inspect Disassembling sequence 1 Thermostat cover

10-4

2 Thermostat

3 Thermo case

Chapter 10 COOLING SYSTEM

Be careful of burns or fires when measuring temperature, especially if it involves a high-temperature and open flame.

To test thermostat operation, immerse the thermostat in a container filled with water. Heat the water while measuring water temperature. Measure the temperature at which the valve starts opening and valve lift becomes 8 mm [0.31 in.] or more. If the temperatures are not within the standard range, replace the thermostat with a new one.

Thermostat - Inspect

Note:(a) Stir the hot water to maintain even temperatures during the test. (b) At assembly, confirm the valve opening temperature stamped on its mounting flange.

Item

Standard value

Temperature at which valve starts to open

76.5 ± 2°C [169.7 ± 3.60 °F]

Temperature at which valve lift becomes 9 mm [0.35 in.] or more

90°C [194 °F]

Note: Install the thermostat to place its air vent hole upside.

10-5

Chapter 10 COOLING SYSTEM

3. Cooling System - Install

Replace

Crack, water leakage, damage

Crack, wear

Replace

Water pump mounting bolt M8 × 1.25 9.8 ± 0.98 N·m {1.0 ± 0.1 kgf·m} [7.23 ± 0.72 lbf·ft] Water pump mounting bolt (together with gear case) M8 × 1.25 18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 lbf·ft]

Fan and fan spacer mounting bolt M10 × 1.5: 35 ± 6 N·m {3.7 ± 0.6kgf·m} [26.55 ± 4.43 lbf·ft] Water pump pulley mounting bolt M8×1.25: 18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 lbf·ft]

Cooling System - Install

10-6

Chapter 11 INLET AND EXHAUST SYSTEMS 1.

Inlet and Exhaust Systems - Remove .................................................................. 11-3 1.1 1.2

2.

Inlet and Exhaust Systems - Disassemble, Inspect and Assemble .................. 11-5 2.1

3.

Inlet System - Remove ........................................................................................................... 11-3 Exhaust System - Remove ..................................................................................................... 11-4 Exhaust Manifold Distortion - Measure................................................................................... 11-5

Inlet and Exhaust Systems - Install...................................................................... 11-6 3.1 3.2

Inlet System - Install ............................................................................................................... 11-6 Exhaust System - Install ......................................................................................................... 11-7

11-1

Chapter 11 INLET AND EXHAUST SYSTEMS Chapter 11 INLET AND EXHAUST SYSTEMS

1. Inlet and Exhaust Systems - Remove 1.1 Inlet System - Remove

Cylinder head 3

Replace

2

1

Replace

Replace Air inlet

Inlet System - Remove Removing sequence 1 Throttle valve

2 Throttle adapter

3 Inlet manifold

11-3

Chapter 11 INLET AND EXHAUST SYSTEMS 1.2 Exhaust System - Remove

1

Replace

2 3 Replace

Cylinder head

Exhaust System - Remove Removing sequence 1 EGR cooler

11-4

2 EGR cooler pipe

3 Exhaust manifold

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.

Item Exhaust manifold distortion

Standard value 0.2 mm [0.008 in.] or less

Exhaust Manifold Distortion - Measure

11-5

Chapter 11 INLET AND EXHAUST SYSTEMS

3. Inlet and Exhaust Systems - Install 3.1 Inlet System - Install

Cylinder head 3

Replace

18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 lbf·ft]

2

18.5 ± 1.5 N·m {1.9 ± 0.2 kgf·m} [13.64 ± 1.11 lbf·ft]

1

Replace

Replace Air inlet

Inlet System - Install

11-6

Chapter 11 INLET AND EXHAUST SYSTEMS 3.2 Exhaust System - Install

Replace

30.4 ± 2.9 N·m {3.1 ± 0.3 kgf·m} [22.42 ± 2.14 lbf·ft]

Replace

Cylinder head

Exhaust System - Install

11-7

Chapter 12 ELECTRICAL SYSTEM 1.

Electrical System - Remove and Inspect............................................................. 12-3 1.1 1.2 1.3

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

3.

Starter - Remove and Inspect................................................................................................. 12-3 Alternator Before Removal - Inspect....................................................................................... 12-3 Alternator - Remove and Inspect ............................................................................................ 12-4 Starter Before Disassembling - Inspect .................................................................................. 12-5 Starter - Disassemble and inspect.......................................................................................... 12-7 Starter - Inspect and Repair.................................................................................................. 12-10 Starter - Assemble ................................................................................................................ 12-15 Alternator - Disassemble and inspect ................................................................................... 12-16 Alternator - Inspect and Repair............................................................................................. 12-19 Alternator - Assemble ........................................................................................................... 12-20 Air Heater - Inspect and Repair ............................................................................................ 12-22

Electrical System - Install ................................................................................... 12-23 3.1 3.2

Alternator - Install.................................................................................................................. 12-23 Starter - Install ...................................................................................................................... 12-23

12-1

Chapter 12 ELECTRICAL SYSTEM Chapter 12 ELECTRICAL SYSTEM

1. Electrical System - Remove and Inspect 1.1 Starter - Remove and Inspect (1) Disconnect the harness.

(2) Remove the starter.

Starter

Starter - Remove and Inspect

1.2 Alternator Before Removal - Inspect 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 Pay full attention when handling, as improper handling could result in damage or failure.

(1) Never connect the battery terminal reverse. 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.

(6) When using a steam cleaner, be careful not to 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.

Alternator

(2) Remove the adjusting plate.

Adjusting plate

Puller

Alternator - Remove and Inspect

12-4

Chapter 12 ELECTRICAL SYSTEM

2. Electrical System - Disassemble, Inspect and Assemble 2.1 Starter Before Disassembling - Inspect 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.

Battery 12V

Pull-in test (1) Disconnect the connector of M terminal.

Remove the connector

(2) Connect the starter to the circuit as shown in the illus-

Starter

Pull-in test

tration.

(3) The magnetic switch is normal if the pinion pops 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

Battery 24V

V

Voltmeter

of the pinion.

(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 value

Starter model number

32A66-11200

Nominal output

24 V - 3.2 kW Terminal voltage

Non-load characteristics

12-6

23 V

Current

80 A or less

Rotation speed

2960 min -1

Test at no-load

Chapter 12 ELECTRICAL SYSTEM 2.2 Starter - Disassemble and inspect

Open circuit, short circuit of magnetic switch

1

Replace 16

Contamination, seizure, wear 15

Open circuit, ground 11 12

6

5

Wear, damage

Replace

7

9

13

Replace

Replace

8

2

10

Wear of bearing hole

3

14 Function of overrunning clutch 4 Replace

Brush dust deposit, Replace uneven wear, brush movement inside the holder, rust, deterioration, Open circuit, insulated condition of short circuit holder of yoke

Starter - Disassemble and inspect Disassembling sequence 1 2 3 4

Magnetic switch Rear bracket Brush holder Yoke assembly

5 6 7 8

Armature Bearing Packing Cover set

9 10 11 12

Center bracket Gear Spring set Lever

13 14 15 16

Pinion set Overrunning clutch Bearing set Front bracket

12-7

Chapter 12 ELECTRICAL SYSTEM 2.2.1 Pinion set - Remove SW1

B

The starter will generate heat if the current is being applied. Remove the pinion within 10 seconds.

(1) Connect the starter to the circuit as shown in the illus-

S

SW2

M

Battery 24V

tration.

(2) Turn the switches SW1 and SW2 ON to move the pinion out, and turn the SW2 OFF to stop the rotation of

Disconnect lead wire with terminal, which connected to M terminal.

the armature and the pinion.

(3) Place an appropriate tube on the pinion stopper. Tap the

Connection to move the pinion forward

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

Overrunning clutch shaft

pinion.

Note: Do not reuse the stopper ring and pinion stopper when assembling.

Pinion stopper Stopper ring Pinion spring Pinion

Pinion - Remove 2.2.2 Magnetic switch - Remove Remove the magnetic switch screws and the M terminal nut,

Magnetic switch

and remove the magnetic switch.

Magnetic switch - Remove 2.2.3 Rear bracket - Remove (1) Remove the through bolts and brush holder screws.

Rear bracket

(2) Remove the rear bracket.

Rear bracket - Remove

12-8

Chapter 12 ELECTRICAL SYSTEM 2.2.4 Brush holder and brush assembly - Remove Brush holder

(1) Apply a socket (of the same diameter as the commutator) to the commutator of the armature.

(2) 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 and cover set.

Packing

Bearing

Cover set

Armature Bearing Yoke assembly

Armature and yoke assembly - Remove 2.2.6 Overrunning clutch - Remove Remove the center bracket, gear and overrunning clutch from the front bracket, and remove the spring set and lever.

Spring set

Gear

Lever

Bearing set Center bracket Overrunning clutch

Overrunning clutch - Remove

12-9

Chapter 12 ELECTRICAL SYSTEM 2.3 Starter - Inspect and Repair 2.3.1 Magnetic switch coil - Inspect B terminal

(1) Check for continuity between M terminal and the case.

If there is no continuity, replace the magnetic switch with a new one.

(2) Make sure there is no continuity between the M terminal and the B terminal. If there is continuity, replace the

S terminal

magnetic switch with a new one.

M terminal

Magnetic switch coil - Inspect 2.3.2 Brush - Inspect for wear Measure the length of the brushes.

If it is less than the limit, replace the brush holder assembly

Brush

and brush assembly with new ones.

Item Brush length

Standard value

Limit value

17.5 mm [0.689 in.]

11.0 mm [0.433 in.]

Brush - Inspect for wear 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 pressure

Standard value

Limit value

26.7 to 36.1 N {2.7 to 3.7 kgf} [6.002 to 8.116 lbf]

14.7 N {1.5 kgf} [3.305 lbf]

Brush spring load - Inspect 2.3.4 Brush holder for insulation - Inspect Check the isolation between the brush holder and the brush holder base. If there is continuity, replace the brush holder

Insulated brush holder

assembly with a new one.

Check the brush holders for looseness.

Brush holder for insulation - Inspect

12-10

Chapter 12 ELECTRICAL SYSTEM 2.3.5 Continuity of yoke assembly - Inspect (1) Check that there is continuity between the M terminal of the field coil and the lead wire for the brush. If there is no continuity, replace the yoke assembly with a new one.

Continuity of yoke assembly - Inspect (2) Check that there is no continuity between the yoke body and the brush. If there is continuity, replace the yoke assembly with a new one.

Yoke assembly for insulation - Inspect 2.3.6 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 value

Limit value

Commutator outside diameter

ø 32.0 mm [1.260 in.]

31.4 mm [1.236 in.]

Ou tsi de

dia m et er

Commutator outside diameter - Measure 2.3.7 Commutator - Check and 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

Standard value

Limit value

0.05 mm [0.0020 in.] or less

0.10 mm [0.0039 in.]

Commutator

Commutator runout - Measure

12-11

Chapter 12 ELECTRICAL SYSTEM 2.3.8 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.

Mica Item Undercut depth

Standard value

Limit value

0.5 mm [0.020 in.]

0.2 mm [0.008 in.]

Undercut depth - Measure 2.3.9 Front bracket - Inspect If ball bearing does not rotate smoothly or an abnormal noise is generated, replace the front bracket with a new one.

12-12

Chapter 12 ELECTRICAL SYSTEM 2.3.10 Armature coil - Inspect (1) Inspect the armature coil using a growler tester.

Iron plate

Place the armature on a growler tester, and attach a thin sheet of iron (e.g. teeth of a saw) to the core of armature. While holding the iron sheet, rotate armature slowly one revolution by hand. If the coil is shorted, the

Growler tester

iron plate is sucked on that position.

If the coil is shorted, replace the armature with a new one.

Armature coil - Check for short circuit (2) Check that the commutator and the shaft (core) are isolated. If there is continuity, replace the armature with a new one.

Commutator and shaft (core) isolation - Inspect (3) Check that there is continuity between each segment. If there is no continuity, replace the armature with a new one.

Continuity between segments - Inspect 2.3.11 Rear bracket - Inspect If the rear bearing box becomes worn, replace a rear bracket with a new one.

12-13

Chapter 12 ELECTRICAL SYSTEM 2.3.12 Overrunning clutch operation - Inspect

The overrunning clutch is coated with grease, thus, do not wash it in wash oil.

Make sure that, when attempting to turn the overrunning clutch, it locks in one direction and rotates smoothly in the opposite direction.

Overrunning clutch operation - Inspect 2.3.13 Starter gear - Inspect Inspect each starter gear. If it is worn or damaged, replace the gear with a new one.

12-14

Chapter 12 ELECTRICAL SYSTEM 2.4 Starter - Assemble To assemble the starter, follow the disassembly sequence in reverse.

(a) To avoid mixing of different greases, remove old grease before applying new grease. (b) Make sure that the starter mounting surface, brushes, commutator and other electric current conducting components are free from grease.

Magnetic switch lever thrust part (Apply Multemp #6129.)

9.8 +20 N·m {1 +0.20 kgf·m} [7.2 +1.40 lbf·ft]

Pinion shaft gear (Apply Multemp OA-171.)

Pinion shaft bearing (Apply Multemp #6129.)

Pinion shaft (Apply Multemp #6129.)

Armature shaft (Apply Multemp #6129.)

Starter - Assemble

12-15

Chapter 12 ELECTRICAL SYSTEM 2.5 Alternator - Disassemble and inspect

5 4 11

3 Rotation 8 2 1 10

Rotation 9 Crack, damage

7 Crack, damage

6 Short circuit and open circuit

Deformation, damage

Open circuit, ground of coil

Coil resistance

Alternator - Disassemble and inspect Disassembling sequence 1 2 3 4

Nut, washer Pulley (with fan) Screw Front bracket assembly

12-16

5 6 7 8

Rotor assembly Coil Stator coil Rear bracket

9 Regulator assembly 10 Rectifier assembly 11 Nut set

Chapter 12 ELECTRICAL SYSTEM 2.5.1 Stator and front bracket - Separate Stator

(a) Disassembly of alternator should be conducted only when repair is necessary. (b) Use care not to insert the screwdriver deeply. Otherwise its tip may damage the stator.

(1) Remove the through bolts.

(2) Insert the tip of a flat-blade screwdriver between the

Front bracket

stator and front bracket, and separate them each other.

Stator and front bracket - Separate 2.5.2 Field coil - Remove

(a) When removing the field coil, be sure to observe the removal order of screws. If removed in wrong

Screw B

order, the outgoing line of the field coil will be damaged. (b) If all the screws are removed, the coil will drop by its own weight. Be careful not to let the coil drop.

Screw A

(c) When removing the field coil, the exit of the coil

Field coil - Remove

may be caught with the stator. Do not pull the coil forcibly.

(1) Remove the screw A. (2) Remove the screw B. (3) Remove the field coil.

2.5.3 Pulley - Remove

Hold the base of claw with a vice.

When clamping the rotor in a vice, be sure to hold at the base of claw with a vice. Holding the tip of claw can cause damage.

(1) Wrap the rotor in cloth and clamp it in a vise.

(2) Remove the pulley nut, and then pull out the pulley.

Pulley - Remove 2.5.4 Rear bearing - Remove Rear bearing

Using the bearing puller, remove the rear bearing from the rotor.

Rotor

Rear bearing - Remove

12-17

Chapter 12 ELECTRICAL SYSTEM 2.5.5 Front bearing - Remove Remove the screw, and remove the bearing retainer and the

Front bracket

front bearing from the front bracket.

Front bearing

Front bearing - Remove 2.5.6 Stator - Remove Stator

Lead wire

The solder must be removed in a short time. If the

Rectifier

heat is applied for a long time, the diode will be damaged.

Melt the solder of stator and rectifier, and remove the stator from the rectifier.

Stator - Remove 2.5.7 Regulator assembly - Remove (1) Remove the screws from the regulator assembly.

Rear bracket

(2) Melt the solder at the regulator and rectifier connections, and remove the regulator assembly.

Regulator assembly

Regulator assembly - Remove 2.5.8 Rectifier assembly - Remove (1) Remove the screws, mold and nuts from the rectifier.

(2) Remove the rectifier assembly.

Rear bracket

Rectifier

Rectifier assembly - Remove

12-18

Chapter 12 ELECTRICAL SYSTEM 2.6 Alternator - Inspect and Repair 2.6.1 Stator - Inspect (1) Continuity between lead wires - Inspect Check that there is continuity between a pair of lead wires. If there is no continuity, replace the stator with a new one.

Continuity between lead wires - Inspect (2) Isolation between lead wire and core - Inspect Check that there is no continuity between stator lead wires and the stator core. If there is continuity, replace the stator with a new one.

Note: The core cannot be replaced as a single item.

Isolation between lead wire and core - Inspect 2.6.2 Rectifier - Inspect Check that the diodes in the rectifier function properly.

Inspection should be conducted at both positive and nega-

Trio-diodes Heat sink (-)

tive sides alternately, and if there is infinite resistance in both sides, it means open circuit, and if there is zero ohm indication, or close to zero ohm, it means short circuit. If defective, replace the rectifier with a new one.

Note: Use the largest measuring range. The current that flows during the test is much lower than the current that normally flows in the rectifier. Therefore, the tes-

Heat sink (+)

Diode terminal

Rectifier - Inspect

ter may not indicate resistance accurately in some cases. When the measuring range is small, this tendency becomes larger.

2.6.3 Field coil - Inspect Measure resistance between the terminals of the field coil. If

Field coil

the measurement is not within the tolerance, replace the field coil with a new one.

Item Field coil resistance (20 ºC [68 ºF])

Standard value 7.3 to 8.5 Ω

Field coil - Inspect

12-19

Chapter 12 ELECTRICAL SYSTEM 2.7 Alternator - Assemble

147 ± 15 N·m {15 ± 1.5 kgf·m} [108.4 ± 11.0 lbf·ft]

Alternator - Assemble Note: Be sure to use proper harness.

If the harness is modified, the alternator will not function properly.

12-20

Chapter 12 ELECTRICAL SYSTEM 2.7.1 Rectifier assembly and regulator assembly - Install

Rear bracket

Install the rectifier assembly and regulator assembly to the rear bracket.

Rectifier

Regulator assembly

Rectifier assembly and regulator assembly - Install 2.7.2 Stator - Install Lead wire

Solder must be applied in a short period of time. If the

Stator

Rectifier

heat is applied for a long time, the diode will be damaged.

(1) Install the stator.

(2) Solder the lead wire of stator to the rectifier.

Stator - Install 2.7.3 Front bearing - Install (1) Install the front bearing to the front bracket.

Front bracket

(2) Secure the bearing retainer with the screw.

Front bearing

Front bearing - Install 2.7.4 Rear bearing - Install Rear bearing

Install the rear bearing to the rotor.

Rotor

Rear bearing - Install

12-21

Chapter 12 ELECTRICAL SYSTEM 2.7.5 Pulley - Install (1) Insert the rotor to the front bracket.

Hold the base of claw with a vice.

(2) Wrap the rotor in cloth and clamp it in a vise.

(3) Install spacer and pulley, and fix them with nut.

Pulley - Install 2.7.6 Rear bracket assembly and front bracket assembly - Assemble Assemble the front bracket, stator, and rear bracket, and

Front bracket

Stator

secure them with the through bolt.

Rear bracket

Rear bracket assembly and front bracket assembly Assemble

2.8 Air Heater - Inspect and Repair 2.8.1 Air heater - Inspect Check that there are no looseness for each terminal, and contact or damages on the heater element.

12-22

Chapter 12 ELECTRICAL SYSTEM

3. Electrical System - Install 3.1 Alternator - Install (1) Install the adjusting plate.

Alternator

(2) Install the alternator.

Adjusting plate

Puller

Alternator - Install

3.2 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 9.8 9.80 +2N·m 0 N·m +0.2+0.2 {1{1 0 kgf·m} 0 kgf·m} [7.2 +1.40 lbf·ft] ࠬ࠲࡯࠲ Starter

45±± 15 15 N·m 45 N·m {4.6 ±± 1.5 1.5 kgf·m} {4.6 kgf·m} [33 ± 11 lbf·ft]

Starter - Install

12-23

Chapter 13 ADJUSTMENT AND OPERATION 1.

Engine - Adjust ...................................................................................................... 13-3 1.1 1.2 1.3 1.4

2.

Break-in Operation ................................................................................................ 13-8 2.1 2.2

3.

Engine Start-up....................................................................................................................... 13-8 Break-in Operation.................................................................................................................. 13-8

Performance Test .................................................................................................. 13-9 3.1 3.2 3.3 3.4

4.

Valve Clearance - Check ........................................................................................................ 13-3 Fuel System - Drain ................................................................................................................ 13-3 Fuel System - Bleed Air .......................................................................................................... 13-4 Belt and Belt Tension - Inspect and Adjust............................................................................. 13-5

Engine Equipment Condition .................................................................................................. 13-9 Test Items and Purposes........................................................................................................ 13-9 Other Lnspections .................................................................................................................. 13-9 Engine Output Adjustment...................................................................................................... 13-9

Error Code Table.................................................................................................. 13-11

13-1

Chapter 13 ADJUSTMENT AND OPERATION Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust 1.1 Valve Clearance - Check Check the valve clearance.

If it is not adjusted, adjust it to the standard value.

For the adjusting procedures, 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.

Spilled fuel can cause a 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 (Pre-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 (Pre-filter) - Bleed (1) Loosen the air vent plug of the fuel filter with a wrench.

(2) Repeatedly press the priming pump with a cloth applied to the air vent plug. When fuel with air bubbles no lon-

Air vent plug Tightening torque 10 ± 2 N·m {1 ± 0.2 kgf·m} [7.2 ± 1.5 lbf·ft]

ger comes out, tighten the air vent plug securely.

(3) Tighten the air vent plug to the specified torque after air bleeding.

Fuel Filter - Bleed (1)

Priming pump

Fuel Filter - Bleed (2)

13-4

Chapter 13 ADJUSTMENT AND OPERATION 1.3.2 Main Fuel Filter - Bleed air (1) Loosen the air bleed plug of fuel filter by approximately 1.5 turns.

(2) Bleed air.

(3) When fuel flowing from the vent holes no longer contains air bubbles, tighten the air vent plugs to the specified torque.

Air vent plug Tightening torque 10 ± 2 N·m {1 ± 0.2 kgf·m} [7.2 ± 1.5 lbf·ft]

Main Filter - Bleed Air

1.4 Belt and Belt Tension - Inspect and Adjust

If any defects such as separation or damage is found in the inspection, replace the belt with a new one.

Keep the belt free from oil and grease. Oil or grease causes 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 correct following the procedures below.

1.4.1 Belt - Inspect (1) Inspect the belt visually for separation or damage. If any defect is found, replace the belt with a new one.

(2) Inspect the deflection of belt.

Inspect the V-belt deflection by pressing it with approx 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 the standard, adjust the belt tension.

1.4.2 Belt tension (Alternator) - Adjust (1) Remove the belt cover.

(2) Loosen all retaining bolts (3 places) of the alternator

Adjusting plate

Fan pulley

Set bolt

and adjusting plate.

(3) Adjust the belt tension with the set bolt. Be sure to loosen the retaining bolt first, then adjust the tension with the set bolt.

Alternator

(4) Tighten all the retaining bolts of alternator and adjusting plate, after the tension adjustment.

(5) Install the belt cover.

Retaining bolts

Crankshaft pulley

Belt and belt tension - Inspect and Adjust

13-5

Chapter 13 ADJUSTMENT AND OPERATION 1.4.3 Belt deflection measurement (with tension gauge) (1) Prepare the tension gauge (P/N: 32591-09100).

(2) Set the O-ring of load scale to the value in the table Load scale

below.

Setting of tension gauge Item

O-ring

Set value 98 N {10 kgf} [22.03 lbf]

Load scale

Belt deflection scale

Tension gauge (3) Set the tip of tension gauge at the middle point between the alternator pulley and water pump pulley as shown in the illustration. Place the tip of tension gauge

Fan pulley

Alternator pulley

at the center point of belt width.

Belt deflection - Measure (1) (4) Push the tension gauge until its load scale comes to the Press

O-ring position and measure the deflection of belt in this condition. If the deflection amount is within the values shown below, the belt tension is normal.

Deflection amount of belt Item

Standard value

When the belt is new

9 to 11 mm [0.35 to 0.43 in.]

On scheduled inspection

11 to 13 mm [0.43 to 0.51 in.]

(5) Adjust the belt tension if the measured result is out of

O-ring position when pressed

Belt deflection - Measure (2)

the standard.

Tension gauge

Belt deflection

Belt deflection - Measure (3)

13-6

Chapter 13 ADJUSTMENT AND OPERATION 1.4.4 Belt tension measurement (with tension meter) (1) Prepare the tension meter (P/N: 32G91-01400).

(2) Push POWER button to turn on the meter.

(3) Set the items below in the setting display.

Liquid crystal screen Microphone

M 017.5 g/m W 012.0 mm/R

Setting of tension meter Item

S 0225 mm

Set value

MASS

Setting screen

141.1 g/m

WIDTH

1 mm [0.04 in.] /R

SPAN

246 mm [9.69 in.]

MEASURE

POWER

LED (Green)

Tension meter (4) Set the microphone tip of tension meter at the middle point between the alternator pulley and water pump pulley as shown in the illustration. Place the microphone tip of tension meter 10 mm far from the belt.

Place the microphone tip of tension meter at the center

Alternator pulley

mm .)

10 .39 in (0

Microphone Fan pulley

position of belt width.

Belt tension - Measure (1) (5) Push the MEASURE button to measure the belt tension. Check the LED (green) blinking and the liquid crystal screen showing as the illustration.

Waiting screen MEASURE

LED (Green)

Belt tension - Measure (2) (6) Flick the belt center with fingers to vibrate the belt.

Check the liquid crystal screen showing the measuring display.

(7) The measurement result is displayed when the measurement is completed. If the tension is within the values

TENTION

527.0 N

shown below, the belt tension is normal.

Belt tension Item

Standard value

When the belt is new

366 to 488 N {37.3 to 49.8 kgf} [82.28 to 109.71 lbf] / Belt

On scheduled inspection

256 to 341 N {26.1 to 34.8 kgf} [57.55 to 76.66 lbf] /Belt

Measuring screen

Measured result screen

Belt tension - Measure (3)

(8) Adjust the belt tension if the measured result is out of the standard.

Note: Refer to the operation manual of tension meter manufacturer for the detail of handling.

13-7

Chapter 13 ADJUSTMENT AND OPERATION

2. Break-in Operation 2.1 Engine Start-up (1) Before starting the engine, check the levels of fuel, engine oil and coolant, and then 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

Be prepared to activate the emergency stop for an unforseeable trouble of engine operation.

2.2.1 Break-in Operation Load and Time The load during break-in operation is to be increased progressively as shown in the table.

Note that the time shown in the table is the minimum time required to check the engine in a stable condition.

Break-in Operation Rotating speed (min-1) 1 Low rotating speed

600 to 900

Load (PS) Time (min) No-load

20

2 Medium rotating speed

1000 to 1200

No-load

10

3 High rotating speed

1400 to rated speed

No-load

10

4

25 %

20

5

50 %

20

75 %

30

100 %

20

6

Rated speed

7

2.2.2 Inspection While the Engine Is Running During the break-in operation, pay attention to followings and make sure that there is no abnormality.

Oil pressure and oil temperature

Exhaust temperature

Coolant temperature and level

Blow-by gas (amount and color)

Any leakage of oil, water, fuel, or gas (air)

Rotational fluctuation

Noise and vibration

Face and radial runouts of rotating parts

Intake air pressure and temperature

Indication and operation of meters and alarms

Exhaust color and odor 2.2.3 Inspection and adjustment after break-in operation Valve clearance (when cold) Fuel injection timing Bolts and nuts on the engine - retighten Belt tension Inspection and repair of defects such as oil leak

13-8

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 adjustments 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 Reference temperature 298 K (25ºC [77ºF]) Atmospheric total pressure: 100 kPa (750 mmHg) Reference atmospheric dry pressure: 99 kPa (743 mmHg)

13-9

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.

13-10

Chapter 13 ADJUSTMENT AND OPERATION

4. Error Code Table System

Detected failure item

Detail of detected failure item

Detecting condition

Fail safe action

P Code

KCM code (Reference)

J1939 DTC SPN

FMI

Battery short circuit

No reaction

P0380

1

677

3

GND short circuit

No reaction

P0380

2

677

4

Wire open circuit

No reaction

P0380

4

677

2

Over load

No reaction

P0380

8

677

12

High voltage

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure

P0563

1

168

3

Low voltage

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure

P0562

2

168

4

Engine boost low Intake pipe failure (open pipe)

The boost pressure does not rise to the specified value.

Output restriction

P2282

8

102

12

Engine over speed

The speed exceeds the upper limit.

Injection stop

P0219

1

1614

3

Battery short circuit

Engine can not be started.

P0617

1

2101

3

GND short circuit

Engine can not be started.

P0616

2

2101

4

Wire open circuit

Engine can not be started.

P0615

4

2101

2

Over load

Engine can not be started.

P0615

8

2101

12

Test pulse conversion failure

(Stop)

4

2008

2

Long converter processing time

(Stop)

8

2008

12

Read abnormal

Output restriction

P062F

2

1235

4

Write abnormal

Output restriction

P062F

4

1235

2

Delete impossible

Output restriction

P062F

8

1235

12

Failure of glow relay power stage

Battery voltage input (Note that this does not mean the battery voltage down.)

Engin body

Starter relay failure

AD converter abnormal

EEPROM abnormal ECU inside abnormal ECU inside SPI abnormal

No reaction

8

2080

12

Communication between CPU and IC inside failure

(Stop)

1

1231

3

Supply voltage abnormal

The final value before the failure is freeze before the failure decision.

(Intake pressure, analog accelerator) The substitutional value control after the failure decision (Intake pressure, analog accelerator) The CAN communication information is used for the value in failure Output restriction EGR fully closed AFM flow is used for some substitutes.

Accelerator opening degree - CAN discrepancy detection stop Accelerator sensor input voltage failure detection stop

1

3509

3

ECU

Sensor supply voltage (1) abnormal

P0642

13-11

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Sensor supply voltage (2) abnormal

Sensor supply voltage (3) abnormal

Fail safe action

P Code

KCM code (Reference)

Supply voltage abnormal

The final value before the failure is freeze before the failure decision. (POT accelerator, throttle valve) The substitutional value control after the failure decision (PTO accelerator, throttle valve) DPF regeneration prohibited Throttle valve stick detection prohibited Transfer to the single drive mode with crank sensor Cam - crank phase discrepancy detection prohibited

P0652

Supply voltage abnormal

The final value before the failure is freeze before the failure decision. (rail pressure, DPF differential pressure) The substitutional value control after the failure decision (rail pressure, DPF differential pressure) The CAN communication information is used for the value in failure Corrective differential pressure calculation invalid Soot collection stage decision reactivated Output restriction Injection stop EGR fully closed DPF regeneration prohibited * The possibility to continue the injection is in consideration.

Detail of detected failure item

Watch Dog timer

13-12

J1939 DTC SPN

FMI

1

3511

3

P0698

1

620

3

Supply voltage high

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Output restriction Soot regeneration amount estimated value invalid Soot collection stage decision reactivated EGR fully closed Intake temperature and pressure sensors are used for some substitutional processing.

P06A5

1

3597

3

Supply voltage low

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Output restriction Soot regeneration amount estimated value invalid Soot collection stage decision reactivated EGR fully closed Intake temperature and pressure sensors are used for some substitutional processing.

P06A4

2

3597

4

2

2010

4

ECU

Sensor supply voltage (12 V) abnormal

Detecting condition

ECU reset

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Sensor supply voltage (2) abnormal

Sensor supply voltage (3) abnormal

Fail safe action

P Code

KCM code (Reference)

Supply voltage abnormal

The final value before the failure is freeze before the failure decision. (POT accelerator, throttle valve) The substitutional value control after the failure decision (PTO accelerator, throttle valve) DPF regeneration prohibited Throttle valve stick detection prohibited Transfer to the single drive mode with crank sensor Cam - crank phase discrepancy detection prohibited

P0652

Supply voltage abnormal

The final value before the failure is freeze before the failure decision. (rail pressure, DPF differential pressure) The substitutional value control after the failure decision (rail pressure, DPF differential pressure) The CAN communication information is used for the value in failure Corrective differential pressure calculation invalid Soot collection stage decision reactivated Output restriction Injection stop EGR fully closed DPF regeneration prohibited * The possibility to continue the injection is in consideration.

Detail of detected failure item

Watch Dog timer

J1939 DTC SPN

FMI

1

3511

3

P0698

1

620

3

Supply voltage high

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Output restriction Soot regeneration amount estimated value invalid Soot collection stage decision reactivated EGR fully closed Intake temperature and pressure sensors are used for some substitutional processing.

P06A5

1

3597

3

Supply voltage low

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Output restriction Soot regeneration amount estimated value invalid Soot collection stage decision reactivated EGR fully closed Intake temperature and pressure sensors are used for some substitutional processing.

P06A4

2

3597

4

2

2010

4

ECU

Sensor supply voltage (12 V) abnormal

Detecting condition

ECU reset

13-13

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Detecting condition

KCM code (Reference)

J1939 DTC SPN

FMI

CAN accelerator inoperative The CAN communication information is used for the value in failure Accelerator opening degree - CAN discrepancy detection stop

4

91

2

CAN accelerator ID reception impossible

Accelerator opening signal can not be received. (ID nonexistent)

CAN accelerator inoperative The CAN communication information is used for the value in failure Accelerator opening degree - CAN discrepancy detection stop

4

1674

2

DPF regeneration require ID reception impossible

DPF regeneration require/load application signal can not be received. (ID nonexistent)

No reaction (Without the regeneration signal, the regeneration is impossible.)

4

2033

2

1

1671

3

Change to the rail pressure control open loop (MPROP steadily drive) EGR fully closed DPF regeneration prohibited Output restriction

2

2042

4

CAN accelerator opening out of the range

CAN

EGR fully closed CAN accelerator inoperative Output restriction Accelerator opening degree - CAN discrepancy detection stop

CAN bus off

CRS

Fail safe action

P Code

Engine speed >50rpm When a forced valve opening signal is generated

U0073

DBY kick off

Drive the MPROP steadily to close DBV forcibly.

DBV retention pressure high

Rail pressure exceeds the specified pressure when DBV is opened.

Injection stop EGR fully closed DPF regeneration prohibited

1

2019

3

DBV retention pressure deflection big

Deflection between rail pressure and specified pressure is big when DBV is opened.

Injection stop EGR fully closed DPF regeneration prohibited

2

2045

4

DBV opening rotation over

DBV opening rotation exceeds the BOSCH specification.

Injection stop EGR fully closed DPF regeneration prohibited

4

2042

2

DBV opening time over

DBV opening rotation exceeds the BOSCH specification.

Injection stop EGR fully closed DPF regeneration prohibited

4

2043

2

Input voltage high

Injection stop EGR fully closed DPF regeneration prohibited * The possibility to continue the injection is in consideration.

P0193

1

2011

3

Input voltage low

Injection stop EGR fully closed DPF regeneration prohibited * The possibility to continue the injection is in consideration.

P0192

2

2011

4

Rail pressure exceeds the max. allowable value.

Rail pressure exceeds the max. allowable value / change to rail pressure control open loop (MPROP steadily drive) EGR fully closed DPF regeneration prohibited Output restriction Rail pressure deflection error detection stop

Rail pressure sensor abnormal 1 (input signal out of the range)

Rail pressure too high

13-14

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Difference between rail pressure target and real pressure (real pressure high)

Detecting condition

J1939 DTC SPN

FMI

600rpm or higher

1

2013

3

600rpm or higher

Change to the rail pressure control open loop (MPROP steadily drive) Injection stop EGR fully closed DPF regeneration prohibited Rail pressure excessively high and deflection big error detection stop

1

2015

3

MPROP drive circuit excessive electrical flow (short circuit = fully closed)

Change to the rail pressure control open loop (MPROP steadily drive) EGR fully closed DPF regeneration prohibited Output restriction

P0251

4

2000

2

MPROP drive circuit energization impossible (open circuit = full open)

Change to the rail pressure control open loop (MPROP steadily drive) EGR fully closed DPF regeneration prohibited Output restriction

P0251

8

2000

12

MPROP LS line GND short circuit

MPROP stays closed in spite of the MPROP control is applied.

Injection stop EGR fully closed DPF regeneration prohibited

P0251

1

2001

3

MPROP LS line Battery short circuit / HS line GND short circuit

MPROP stays closed in spite of the MPROP control is applied.

Change to the rail pressure control open loop (MPROP steadily drive) EGR fully closed DPF regeneration prohibited Output restriction

P0251

2

2002

4

Fuel injector drive circuit bank 1 abnormal

Injector drive circuit bank 1 stop ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

8

651

12

Fuel injector drive circuit bank 2 abnormal

Injector drive circuit bank 1 stop ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

8

653

12

Injector drive IC abnormal

EGR fully closed DPF regeneration prohibited (Injection stop as a result of IC failure)

8

655

12

CRS MPROP open or short circuit

Injection

KCM code (Reference)

Change to the rail pressure control open loop (MPROP steadily drive) EGR fully closed DPF regeneration prohibited Output restriction Rail pressure excessively high and deflection big error detection stop

Rail pressure deflection big Difference between rail pressure target and real pressure (real pressure low)

Fail safe action

P Code

Injector 1 abnormal (short circuit)

Injector 1 abnormal (open circuit)

Short circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0201

8

657

12

Open circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0201

4

658

2

No reaction

P0201

4

2081

2

Injector 1 abnormal (injec- Injector correction tor correction information information not suplost) plied

13-15

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Fail safe action

P Code

KCM code (Reference)

J1939 DTC SPN

FMI

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0202

8

659

12

Open circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0202

4

660

2

Injector 2 abnormal (injec- Injector correction tor correction information information not suplost) plied

No reaction

P0202

4

2082

2

Injector 3 abnormal (short circuit)

Short circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0203

8

661

12

Open circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0203

4

662

2

Injector 3 abnormal (injec- Injector correction tor correction information information not suplost) plied

No reaction

P0203

4

2083

2

Injector 4 abnormal (short circuit)

Short circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0204

8

663

12

Open circuit

ECU inside failure system error partially stop EGR fully closed DPF regeneration prohibited

P0204

4

664

2

No reaction

P0204

4

2084

2

Input voltage high

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Accelerator opening degree - CAN discrepancy detection stop Accelerator sensor input voltage low failure detection stop

P0123

1

29

3

Input voltage low

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Accelerator opening degree - CAN discrepancy detection stop Accelerator sensor input voltage high failure detection stop

P0122

2

29

4

Lower opening degree of analog or CAN is used.

P0121

8

383

12

Injector 2 abnormal (open circuit)

Injector 3 abnormal (open circuit)

Injector 4 abnormal (open circuit)

Injector 4 abnormal (injec- Injector correction tor correction information information not supplied lost)

Sensor

Detecting condition

Short circuit

Injector 2 abnormal (short circuit)

Injection

Detail of detected failure item

Accelerator sensor 1 abnormal

Accelrator opening degree Deviation of 20 % or AD-CAN discrepancy more

13-16

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Input voltage high

Fail safe action

P Code

KCM code (Reference)

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Output restriction

P0108

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Output restriction

P0107

Detecting condition

SPN

FMI

1

108

3

2

108

4

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Output restriction EGR fully closed DPF regeneration prohibited AFM flow is used for some substitutes.

1

105

3

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Output restriction EGR fully closed DPF regeneration prohibited AFM flow is used for some substitutes.

2

102

4

Atmospheric pressure sensor abnormal

Input voltage low

Sensor Input voltage high

Intake air temperature abnormal

Input voltage low

J1939 DTC

13-17

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Input voltage high

Fail safe action

P Code

KCM code (Reference)

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Output restriction EGR fully closed DPF regeneration prohibited AFM flow is used for some substitutes.

P0238

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Output restriction EGR fully closed DPF regeneration prohibited AFM flow is used for some substitutes.

Detecting condition

SPN

FMI

1

102

3

P0237

2

102

4

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure

P0183

1

174

3

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure

P0182

2

174

4

Intake air pressure sensor abnormal

Input voltage low Sensor

Input voltage high

Fuel temperature sensor abnormal

Input voltage low

13-18

J1939 DTC

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Fail safe action

P Code

KCM code (Reference)

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision (The substitutional value for the glow plug is different from other substitutional temperatures.)

The CAN communication information is used for the value in failure Output restriction EGR fully closed DPF regeneration prohibited

P0118

Input voltage low

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision (The substitutional value for the glow plug is different from other substitutional temperatures.)

The CAN communication information is used for the value in failure Output restriction EGR fully closed DPF regeneration prohibited

Pulse input lost

Engine Engine in operation

Pulse number, position failure

Detail of detected failure item

Detecting condition

SPN

FMI

1

110

3

P0117

2

110

4

Transfer to the single drive mode with crank sensor Cam - crank phase discrepancy detection prohibited

P0336

1

636

3

Engine Engine in operation

Transfer to the single drive mode with crank sensor Cam - crank phase discrepancy detection prohibited

P0336

2

636

4

Pulse input lost

Engine Engine in operation

Transfer to the single drive mode with cam sensor Cam - crank phase discrepancy detection prohibited

P0340

1

637

3

Pulse number, position failure

Engine Engine in operation

Transfer to the single drive mode with cam sensor Cam - crank phase discrepancy detection prohibited

P0340

2

637

4

Phase abnormal

Engine Engine in operation

Cam sensor abnormal detection stop Shift to the offset drive mode.

P0016

1

228

3

Reference voltage high

P0113

1

172

3

Reference voltage low

P0112

2

172

4

Input voltage high

Water temperature sensor abnormal

Sensor

Cam sensor abnormal

Crank sensor abnormal

Cam-crank phase disagreement

AFM temperature sensor abnormal.

J1939 DTC

13-19

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Flow rate high

Fail safe action

P Code

KCM code (Reference)

Key switch ON

Key switch ON The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Output restriction Soot regeneration amount estimated value invalid Soot collection stage decision reactivated EGR fully closed Intake temperature and pressure sensors are used for some substitutional processing.

P0103

Key switch ON 600 rpm or higher

Key switch ON The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision Output restriction Soot regeneration amount estimated value invalid Soot collection stage decision reactivated EGR fully closed Intake temperature and pressure sensors are used for some substitutional processing.

Detecting condition

SPN

FMI

1

132

3

P0102

2

132

4

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure DPF regeneration prohibited Soot regeneration amount estimated value invalid

P0546

1

4753

3

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure DPF regeneration prohibited Soot regeneration amount estimated value invalid

P0545

2

4753

4

AFM flow rate abnormal

Flow rate low

DPF sensor

Reference voltage high

DOC intake temperature sensor abnormal

Reference voltage low

13-20

J1939 DTC

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Reference voltage high

Fail safe action

P Code

KCM code (Reference)

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure DPF regeneration prohibited Corrective differential pressure calculation invalid Soot regeneration amount estimated value invalid Soot collection stage decision reactivated

P2033

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure DPF regeneration prohibited Corrective differential pressure calculation invalid Soot regeneration amount estimated value invalid Soot collection stage decision reactivated

Detecting condition

SPN

FMI

1

3242

3

P2032

2

3242

4

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision DPF regeneration prohibited Corrective differential pressure calculation invalid Soot regeneration amount estimated value invalid Soot collection stage decision reactivated

P242D

1

3246

3

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision DPF regeneration prohibited Corrective differential pressure calculation invalid Soot regeneration amount estimated value invalid Soot collection stage decision reactivated

P242C

2

3246

4

DPF intake temperature sensor abnormal

Reference voltage low

DPF sensor

Reference voltage high

DPF exhaust temperature sensor abnormal

Reference voltage low

J1939 DTC

13-21

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

KCM code (Reference)

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Corrective differential pressure calculation invalid Soot collection stage decision reactivated Output restriction

P2455

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision The CAN communication information is used for the value in failure Corrective differential pressure calculation invalid Soot collection stage decision reactivated Output restriction

FMI

1

3251

3

P2454

2

3251

4

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision DPF regeneration prohibited Throttle valve stick detection prohibited

P0075

1

5374

3

Reference voltage low

Key switch ON

The final value before the failure is freeze before the failure decision.

The substitutional value control after the failure decision DPF regeneration prohibited Throttle valve stick detection prohibited

P0075

2

5374

4

Open side study value abnormal

Some range is judged from the studied value.

No reaction

P0075

1

2094

3

Close side study value abnormal

Some range is judged from the studied value.

No reaction

P0075

2

2094

4

DPF differential pressure sensor error

Reference voltage low

Reference voltage high

Throttle valve sensor abnormal

DPF

Throttle valve study value abnormal

13-22

J1939 DTC SPN

Reference voltage high

DPF sensor

Fail safe action

P Code

Detecting condition

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

DPF

KCM code (Reference)

J1939 DTC SPN

FMI

Open side stick abnormal

DPF regeneration prohibited

P0075

1

2093

3

Close side stick abnormal

After judging the sticking for 10000ms, five times of 6% open/close soot sweeping action are applied. The failure is judged if no change occurs.

DPF regeneration prohibited

P0075

2

2093

4

Throttle valve motor (Judgement not mounted. with inside IC)

DPF regeneration prohibited

P0075

4

2090

2

DPF regeneration prohibited

P0075

8

2095

12

Throttle valve over current Over current IC for throttle valve over current

Fail safe action

P Code

After judging the sticking for 10000ms, five times of 6% open/close soot sweeping action are applied. The failure is judged if no change occurs.

Throttle valve stick

Throttle valve motor abnormal

Detecting condition

IC inside over current

(Judgement with inside IC)

DPF regeneration prohibited

P0075

4

2091

2

Battery short circuit

(Judgement with inside IC)

DPF regeneration prohibited

P0075

1

2090

3

GND short circuit

(Judgement with inside IC)

DPF regeneration prohibited

P0075

2

2090

4

Battery short circuit

(Judgement with inside IC)

DPF regeneration prohibited

P0075

1

2091

3

GND short circuit

(Judgement with inside IC)

DPF regeneration prohibited

P0075

2

2091

4

DPF temperature rise error DPF stage duration 1 is long

During DPF control stage

DPF regeneration prohibited

8

3250

12

DPF temperature rise error DPF does not rise 2 the temperature.

During DPF control stage

DPF regeneration prohibited

8

3250

12

Engine exhaust abnormally high temperature 1

Engine speed 300rpm

DPF regeneration prohibited Output restriction

P200E

8

2071

12

DPF abnormally high temperature 1

DPF regeneration prohibited Output restriction

P200C

8

2072

12

DPF abnormally high temperature 2

Engine stop

P200C

8

2072

12

DPF clogging

DPF regeneration prohibited Output restriction

8

4795

12

DPF installing alarm

DPF regeneration prohibited Output restriction

8

3936

12

Soot accumulation too much

DPF regeneration prohibited Output restriction

8

3719

12

Throttle valve motor terminal 1 abnormal

Throttle valve motor terminal 2 abnormal

P2463

13-23

Chapter 13 ADJUSTMENT AND OPERATION

System

Detected failure item

Detail of detected failure item

Detecting condition

ERG inside IC EGR body driver EGR valve drive Duty too does not exejudges the too heavy heavy cute the return drive Duty. judgement.

EGR

P Code

KCM code (Reference)

EGR fully closed Output restriction

P0403

Fail safe action

J1939 DTC SPN

FMI

8

2062

12

EGR motor short circuit (short circuit to power line)

Motor short circuit to power line by EGR body driver judgement

ERG inside IC does not execute the return judgement.

EGR fully closed Output restriction

P0490

8

2061

12

EGR motor open circuit

Motor open circuit

by EGR body driver judgement

ERG inside IC does not execute the return judgement.

EGR fully closed Output restriction

P0489

4

2061

2

EGR position sensor abnormal

EGR position sensor abnormal by EGR body driver judgement

ERG inside IC does not execute the return judgement.

EGR fully closed Output restriction

P0409

4

2067

2

EGR valve stick

EGR valve sticking judgement

EGR target fluctuation continues 20 seconds within +/- 5%.

EGR fully closed Output restriction

P0403

4

2068

2

ECU to EGR signal lost

CAN signal transmitted from ECU to EGR valve can not be received.

Failure judging time is also in IC inside of EGR.

EGR fully closed Output restriction

P0403

4

2032

2

Valve opening range over

Opening degree transmitted from ECU to EGR valve is out of the range.

Failure judging time is also in IC inside of EGR.

EGR fully closed Output restriction

P049D

4

27

2

EGR signal lost

CAN signal transmitted from EGR valve to ECU can not be received.

EGR fully closed Output restriction

U010A

4

2031

2

EGR fully closed Output restriction

P0403

1

2063

3

P0403

2

2063

4

EGR supply voltage high

Failure judging time is also in IC inside of EGR.

EGR supply voltage low

Failure judging time is also No reaction in IC inside of EGR.

EGR supply voltage abnormal

Open sticking judgeEGR valve sticking on iniment on EGR valve tializing initializing

EGR fully closed Output restriction

P0403

4

2066

2

EGR valve initialize over time

EGR fully closed Output restriction

P0403

8

2066

12

EGR valve inside hightemperature thermistor abnormal

No reaction

P040A

2

2064

4

EGR valve inside lowtemperature thermistor abnormal

No reaction

P040A

2

2065

4

13-24

February 2012

SERVICE MANUAL

for KOBELCO CONSTRUCTION MACHINERY CO. , LTD

Pub. No. 99616-28100

Printed in Japan

Pub. No. 99616-28100