12
CONTENTS
1.
General
..............................................................................................................................................................
15
1.1 Engine Nomenclature............................................................................................................................. 15
1.2 Specifications ......................................................................................................................................... 15
1.3 Fuel Oil, Lubricating Oil and Cooling Water ........................................................................................... 21
1.3.1 Fuel oil ............................................................................................................................................. 21
1.3.2 Lubricating oil .................................................................................................................................. 22
1.3.3 Cooling water................................................................................................................................... 22
1.4 Engine External Views ........................................................................................................................... 23
1.5 Structural Description ............................................................................................................................. 24
1.6 Exhaust gas emission regulation ........................................................................................................... 25
1.6.1 The Emission Standard in USA ....................................................................................................... 25
1.6.2 Engine identification ........................................................................................................................ 26
1.6.3 Guarantee Conditions for the EPA Emission Standard ................................................................... 27
2. Inspection and Adjustment
.......................................................................................................................
29
2.1 Periodic Maintenance Schedule............................................................................................................. 29
2.2 Periodic Inspection and Maintenance Procedure .................................................................................. 30
2.2.1 Check before Daily Operation ......................................................................................................... 30
2.2.2 inspection after initial 50 hours operation........................................................................................ 32
2.2.3 Inspection every 50 hours ............................................................................................................... 35
2.2.4 Inspection every 250 hours or 3 months ......................................................................................... 39
2.2.5 Inspection every 500 hours or 6 months ......................................................................................... 42
2.2.6 Inspection every 1,000 hours or one year....................................................................................... 44
2.2.7 Inspection every 2000 hours or 2 years .......................................................................................... 52
2.3 Adjusting the no-load maximum or minimum speed .............................................................................. 55
2.4 Sensor Inspection................................................................................................................................... 56
2.4.1 Oil pressure switch .......................................................................................................................... 56
2.4.2 Thermo switch ................................................................................................................................. 56
2.5 Water leak check in cooling water system ............................................................................................. 56
2.6 Radiator cap inspection.......................................................................................................................... 57
2.7 Thermostat Inspection............................................................................................................................ 57
2.8 Adjusting Operation................................................................................................................................ 58
2.9 Long storage .......................................................................................................................................... 58
3. TROUBLESHOOTING
..................................................................................................................................
59
3.1 Preparation before troubleshooting........................................................................................................ 59
3.2 Quick Reference Table for Troubleshooting........................................................................................... 61
3.3 Troubleshooting by measuring Compression Pressure ......................................................................... 64
4. Disassembly, Inspection and Reassembly of Engines
....................................................................
66
4.1 Complete disassembly and reassembly................................................................................................. 66
4.1.1 Introduction...................................................................................................................................... 66
4.1.2 Special service tools........................................................................................................................ 67
4.1.3 Complete disassembly .................................................................................................................... 73
4.1.4 Precautions before and during reassembly..................................................................................... 77
4.1.5 Adjusting operation.......................................................................................................................... 77
4.2 Cylinder Head: Disassembly, Inspection and Reassembly ...................................................78
4.2.1 Components (2-valve cylinder head)............................................................................................... 78
4.2.2 Disassembly procedure:.................................................................................................................. 78
4.2.3 Reassembly procedure: .................................................................................................................. 79
4.2.4 Servicing points ............................................................................................................................... 79
4.2.5 Parts Inspection and measurement................................................................................................. 83
4.2.6 Valve seat correction ....................................................................................................................... 87
4.2.7 Valve guide replacement ................................................................................................................. 88
4.2.8 Valve stem seal replacement .......................................................................................................... 89
4.3 Gear Train and Camshaft
.................................................................................................................. 90
4.3.1 Components .................................................................................................................................... 90
