Ingersoll-Rand 3IRH2N Workshop Manual Download Page 2 | Manualshive

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PREFACE

This

manual describes the service procedures for the IR series engines of direct injection system that have

been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use.

Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in
this manual assumes the standard type engine, the specifications and components may partially be
different from the engine installed on individual work equipment (power generator, pump, compressor, etc.).
Please also refer to the service manual for each work equipment for details.

The specifications and components may be subject to change for improvement of the engine quality
without notice. If any modification of the contents described herein becomes necessary, it will be notified in
the form of correction information each time.

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Summary of Contents for 3IRH2N

Page 1: ...oosan purchased Bobcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliation between Ingersoll Rand Company and Doosan Company or the products of eithe...

Page 2: ...s manual assumes the standard type engine the specifications and components may partially be different from the engine installed on individual work equipment power generator pump compressor etc Please also refer to the service manual for each work equipment for details The specifications and components may be subject to change for improvement of the engine quality without notice If any modificatio...

Page 3: ...the manual Sufficient consideration for safety is required in addition to the matters marked Especially for safety precautions in a repair or maintenance job not described in this manual receive instructions from a knowledgeable leader Safety marks used in this manual and their meanings are as follows DANGER indicates an imminently hazardous situation which If not avoided WILL result in death or s...

Page 4: ...ous level and free from holes in the floor to prevent slip or trip and fall type accidents Bright Safely Illuminated Area The work area should be well lit or illuminated in a safe manner For work in enclosed or dark areas a drop cord should be utilized The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances Safety Equipment Fire extinguisher s fir...

Page 5: ...p as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do not overload this device serious injury may result Never run an engine without being properly secured to an engine support stand test bed or test cart serious injury may result Appropriate Tools Alwa...

Page 6: ...orm of ignition away Explosion may occur causing severe personal injury Battery Electrolyte Batteries contain sulfuric acid Do NOT allow it to come in contact with clothing skin and or eyes severe burns will result 7 WASTE MANAGEMENT Observe the following instructions with regard to hazardous waste disposal Negligence of these will have a serious impact on environmental pollution concerns Waste fl...

Page 7: ...lt Hot Surfaces Do NOT touch the engine or any of its components during running or shortly after shutting it down Scalding serious burns may result Allow the engine to cool down before attempting to approach the unit Rotating Parts Be careful around moving rotating parts Loose clothing jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury ...

Page 8: ...ed check the part installed state deformation damage roughening surface defect etc Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again Parts to be used again shall be washed and cleaned sufficiently Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump 5 Precautions for I...

Page 9: ...tallation removal replacement disassemble reassembly inspection adjustment and adjusting operation procedures for the IR series engines with direct injection system Refer to the manufacturer s manual for each of the fuel injection pump governor starting motor and alternator except for their installation ...

Page 10: ...In the explanation for each point detailed operation method information standard and precautions are described Description Example The job contents are described in the disassembly procedure for Nos not shown in the illustration Disassembly procedure 1 Follow steps 1 to 15 of the cylinder head disassembly procedure 2 Remove the cooling water pump 3 Remove the crankshaft pulley Point 1 Operation po...

Page 11: ...ause an accident Always observe it Standard Allowable range for inspection and adjustment Limit The maximum or minimum value that must be satisfied during inspection or adjustment Abbreviations Abbreviation Meaning Abbreviation Meaning Assy assembly T D C top dead center Sub Assy sub assembly B D C bottom dead center a T D C after top dead center OS oversize b T D C before top dead center US under...

Page 12: ...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 ...

Page 13: ...rse the procedure below for assembly 120 6 4 Servicing Points 120 7 FUEL INJECTION PUMP GOVERNOR 121 7 1 Introduction 121 7 2 Fuel Injection Pump 121 7 2 1 Fuel system diagram 121 7 2 2 External view and components 122 7 2 3 Disassembly procedure 122 7 2 4 Assembly procedure 123 7 2 5 Servicing points 123 8 TURBOCHAGER Disassembly inspection and reassembly 125 8 1 Structure and Functions 125 8 1 1...

Page 14: ... 6 Abnormal sound or vibration 146 9 SERVICE STANDARDS 147 9 1 Engine Tuning 147 9 2 Engine Body 148 9 2 1 Cylinder head 148 9 2 2 Gear train and camshaft 151 9 2 3 Cylinder block 152 9 3 Lubricating Oil System Trochoid Pump 157 9 3 1 Outside clearance of outer rotor 157 9 3 2 Side clearance of outer rotor 157 9 3 3 Inside clearance of inner rotor 157 9 3 4 Rotor shaft clearance 157 10 TIGHTENING ...

Page 15: ...ns table 1 2 Specifications NOTE 1 The information described in the engine specifications tables the next page and after is for standard engine To obtain the information for the engine installed in each machine unit refer to the manual provided by the equipment manufacturer 2 Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric condition Room temp 25 C Atmospheric press 100 kPa...

Page 16: ...Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 3 6 5 5 Lubricant capacity oil pan Effective L 1 2 2 2 Cooling water capacity engi...

Page 17: ... side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 4 7 7 2 Lubricant capacity oil pan Effective L 1 8 3 5 Cooling water capacit...

Page 18: ...ide Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 cetane No 45 min Applicable lubricant API grade class CD or CF Total L 5 8 8 6 Lubricant capacity oil pan Effective L 2 3 4 2 Cooling water capacity ...

Page 19: ...rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 10 2 Lubricant capacity oil pan Effective L 4 5 Cooling water capacity engine only L 4 2 Overall length mm 719 Overall ...

Page 20: ...ection of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 cetane No 45 min Applicable lubricant API grade class CD or CF Total L 10 2 Lubricant capacity oil pan Effective L 4 5 Cooling water capacity engine only L 4 2 Overall length mm 71...

Page 21: ...al Standard JIS No K2204 2 Fuel cetane number should be 45 or greater 2 Fuel handling Water and dust in the fuel oil can cause operation failure Use containers which are clean inside to store fuel oil Store the containers away from rainwater and dust Before supplying fuel let the fuel container rest for several hours so that water and dust in the fuel are deposited on the bottom Pump up only the c...

Page 22: ...th soap and water thoroughly 1 3 3 Cooling water Use clean soft water and be sure to add the Long Life Coolant Antifreeze LLC in order to prevent rust built up and freezing If there is any doubt over the water quality distilled water or pre mixed coolant should be used The coolants antifreezes which are good performance for example are shown below TEXACO LONG LIFE COOLANT ANTIFREEZE both standard ...

Page 23: ...23 1 4 Engine External Views ...

Page 24: ...24 1 5 Structural Description ...

Page 25: ... 2000 10 5 7 8 8 0 6 0 1 0 0 75 KW 8 hp 11 Tier 2 2005 7 5 5 6 8 0 6 0 0 80 0 60 Tier 1 2000 9 5 7 1 6 6 4 9 0 80 0 60 8 kW 19 11 hp 25 Tier 2 2005 7 5 5 6 6 6 4 9 0 80 0 60 Tier 1 1999 9 5 7 1 5 5 4 1 0 80 0 60 19 kW 37 25 hp 50 Tier 2 2004 7 5 5 6 5 5 4 1 0 60 0 45 Tier 1 1998 9 2 6 9 Tier 2 2004 7 5 5 6 5 0 3 7 0 40 0 30 37 kW 75 50 hp 100 Tier 3 2008 4 7 3 5 5 0 3 7 Tier 1 1997 9 2 6 9 Tier 2 ...

Page 26: ...26 1 6 2 Engine identification 1 Emission control labels of US EPA EPA label for constant speed engines EPA label for variable speed engines 2 Emission control label for both EPA and ARB ...

Page 27: ...es 1 Requirement on engine installation condition a Intake air depression kPa mmAq Initial Permissible 2 9 300 6 23 635 b Exhaust gas back pressure kPa mmAq Engine type Initial Permissible Naturally aspirated engines 12 7 1300 15 3 1560 4IRI8T 9 8 1000 11 7 1200 2 Fuel oil and lubricating oil a Fuel The diesel fuel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min b Lube oil API grade class CD or...

Page 28: ...years shown in the table come first in the condition that the maintenance inspection was carried out based on the List of Periodic Inspections Maintenance period Quality Guarantee Period Parts Power Rating Fuel nozzle cleaning Adjustment cleaning repairs for fuel nozzle fuel pump turbocharger electronic control unit etc For nozzle fuel pump turbocharger 37 kW 130 Every 1500 hours applied from Tier...

Page 29: ...t Lube oil level check Lube oil replacement Lubricating oil system Lube oil filter replacement 1st time 2nd time and thereafter Cooling water level check and replenish Radiator fin cleaning Cooling fan V belt tension check 1st time 2nd time and thereafter Cooling water replacement Cooling water system Cooling water path flushing and maintenance Rubber house Fuel pipe and cooling water pipe inspect...

Page 30: ...elt cracked loosened clamp 2 Checking and refueling Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary Refer to 1 3 1 3 Checking oil level and replenishing with engine oil a Checking oil level Check the engine oil level with the dipstick after adjusting the posture of the machine unit so that an engine may become horizontally Insert the dipstick fully ...

Page 31: ...eam and hot water will spurt out and seriously burn you Wait until the radiator is cooled down after the engine has stopped wrap the filler cap with a rag piece and turn the cap slowly to gently release the pressure inside the radiator Securely tighten the filler cap after checking the radiator Steam can spurt out during operation if the cap is tightened loosely a Checking cooling water volume Che...

Page 32: ...ting the engine If it feels heavy to manipulate lubricate the accelerator cable joints and pivots Adjust the accelerator cable if there is a dislocation or excessive play between the accelerator and the governor lever Refer to 3 2 3 6 Checking alarm operation Before and after starting the engine check to see that the alarm function normally Failure of alarm cannot warn the lack of the engine oil o...

Page 33: ...ean the mounting face of the oil filter Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface and tighten it further to 3 4 of a turn with the filter wrench Tightening torque 19 6 23 5N m 2 0 2 4kgf m Model Applicable oil filter Part No 3IRH2N 4IRI8T 22226351 c Filling oil and ...

Page 34: ... whichever you can easily carry out the check and adjustment on the machine unit New V belt refers to a V belt which has been used less than 5 minutes on a running engine Used V belt refers to a V belt which has been used on a running engine for 5 minutes or more The specified deflection to be measured at each position should be as follows Unit mm Direction A B C For used V belt 10 14 7 10 9 13 Fo...

Page 35: ...e from semi transparency material and in the cup the red colored float ring which rises on the surface of the drain is installed to visualize the amount of drain Also the oil water separator with sensor to detect the drain for warning device on a control panel is provided as the optional Drain off the oil water separator in the following manner 1 Prepare a waste oil container 2 Close the fuel cock...

Page 36: ...e fuel filter mounting Move the priming pump up and down to feed fuel until feel your hand slightly heavy 4 Battery Inspection Fire due to electric short circuit Make sure to turn off the battery switch or disconnect the negative cable before inspecting the electrical system Failure to do so could cause short circuiting and fires Always disconnect the Negative battery cable first before disconnect...

Page 37: ...ttery Remove the battery from the battery mounting of the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at 15 C or less And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature 2 Battery charge Use a battery tester or hydrometer and check the battery condition If the...

Page 38: ...creases by 0 0007 when the temperature varies by 1 C correct the value according to the equation below c Specific gravity and remaining battery charge Specific gravity 20 C Discharged quantity of electricity Remaining charge 1 28 0 100 1 26 10 90 1 24 20 80 1 23 25 75 d Terminals Clean if corroded or soiled e Mounting bracket Repair or replace it if corroded Retighten if loosened f Battery appeara...

Page 39: ... Refer to 2 2 1 1 2 Inspection and cleaning of radiator fin Beware of dirt from air blowing Wear protective equipment such as goggles to protect your eyes when blowing compressed air Dust or flying debris can hurt eyes Dirt and dust adhering on the radiator fins reduce the cooling performance causing overheating Make it a rule to check the radiator fins daily and clean as needed Blow off dirt and ...

Page 40: ...when the accelerating devices is in the high idling speed or low idling speed position 2 If either the high or the low idling speed side does not make contact with the limiting bolt adjust the accelerating wire Loosen the accelerating wire fixing nut and adjust the wire to contact with the limiting bolt Never release the limiting bolts It will impair the safety and performance of the product and f...

Page 41: ...ne running 4 Replace the element with new one If the element is damaged excessively dirty or oily 5 Remove the inside dust cover of the dustpan and clean inside of the dustpan 6 Reinstall the element with the wing bolt do not leave the gasket Reattach the inside dust cover to the dust pan and install the dust pan to the air cleaner case placing the TOP mark upward IMPORTANT When the engine is oper...

Page 42: ...re it is clogged with dust to adversely affect the fuel flow Also replace the fuel filter after the engine has fully been cooled 1 Close the fuel cock of the oil water separator 2 Remove the fuel filter using a filter wrench customer procured When removing the fuel filter hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping If you spill fuel wipe such spilla...

Page 43: ...e for drain sensor before removing the cup if it is with drain sensor 5 Wash the element and inside cup with clean fuel oil Replace the element with new one if any damaged Model Applicable element Part No 3IRH2N 4IRI8T 54468178 6 Insert the element to the bracket O ring and after putting the float ring in the cup install it to the bracket by tightening the retaining ring clockwise Tightening torqu...

Page 44: ...h rust or water scale reduces the cooling effect Even when antifreeze agent LLC is mixed the cooling water gets contaminated due to deteriorated ingredients Replace the cooling water at least once a year 1 Remove the radiator cap 2 Loosen the drain plug at the lower portion of the radiator and drain the cooling water 3 After draining the cooling water tighten the drain plug 4 Fill radiator and eng...

Page 45: ...k at no load after load running of the engine if it is difficult to pour the liquid into the blower at load running Specified quantity of washing liquid water Turbocharger model RHB31 RHB51 Injection amount one time 20 cc It causes an accident when large quantity of washing liquid is poured rapidly into a turbocharger 2 Pour the same amount of clear water as washing liquid water into the blower ab...

Page 46: ... about 5 hours because of the initial wear out of a spring etc Therefore adjust 0 5MPa 5kgf cm higher than the standard value of the above table when adjusting a new fuel nozzle of a spare part Remove carbon deposit at the nozzle hole thoroughly before measurement 1 Connect the fuel injection valve to the high pressure pipe of the nozzle tester 2 Operate the nozzle tester lever slowly and read the...

Page 47: ...htness check After injecting a few times increase the pressure gradually Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1 96 Mpa 20kgf cm2 and check to see that oil does not drip from the tip end of the nozzle If extreme oil leak from the overflow joint exists during injection by the nozzle tester check after retightening If much oil is leaking replace the n...

Page 48: ...liding test Wash the nozzle valve in clean fuel oil Place the nozzle body vertically and insert the nozzle into the body to about 1 3 of its length The valve is normal if it smoothly falls by its own weight into the body In case of a new nozzle remove the seal peel and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust preventive oil befo...

Page 49: ...means of the play when the arm head is held with a hand Also see that the crankshaft pulley top mark is positioned at zero on the timing scale If there is no valve clearance inspection in the disassembled state is necessary since the valve seat may be worn abnormally 3 Valve clearance measurement In case of 2 valve cylinder head insert a thickness gage between the rocker arm and valve cap and reco...

Page 50: ...t Suction Exhaust Suction Exhaust No 1 compression T D C The first time No 1 overlap T D C The second time For 4 cylinder engines Set No 1 cylinder to the compression T D C and adjust the clearance of the mark of the bottom table Next turn the flywheel once and adjust the clearance of the mark Ignition order of 3 cylinder engines 1 3 4 2 Cylinder No 1 2 3 4 Valve Suction Exhaust Suction Exhaust Su...

Page 51: ...en adjusting screw and push rod 4 Adjusting other cylinders In case of 4 cylinder engines turn the crankshaft 180 then and make adjustment for the No 3 cylinder Then adjust the No 4 and No 2 cylinders in this order The cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is the nearest to the top dead center after turning and make adju...

Page 52: ... the valves and seats 4 Fuel injection timing inspection and adjustment The fuel injection timing is adjusted so that engine performance may become the best condition As for the engine which adopts a MP type fuel injection pump the fuel injection angle Note1 is adjusted for the fuel injection timing adjustment because the adjusting method of fuel injection timing like an inline fuel pump can t be ...

Page 53: ...l pump number when the fuel injection angle on the fuel pump is hard to read Fuel injection angle difference cam angle the fuel injection angle of a reassembled fuel pump the fuel injection angle of a disassembled previous fuel pump When there is no difference in fuel injection angle install the pump precisely on the position where the mark off lines of the fuel pump and the gear case was met toge...

Page 54: ... Fuel injection timing is adjusted by changing the installation angle of the fuel pump When the fuel injection timing is advanced for example at 2 degree loosen the nuts which fasten a fuel pump on the gear case and turn a fuel pump body at 1 degree to the outside direction of the cylinder block Then tighten pump installation nuts And slant a pump to that reverse direction when the fuel injection ...

Page 55: ...miting bolt 3 Then set the no load minimum speed by adjusting the low idle limiting bolt Standards Unit min 1 Engine application class Rating speed No load maximum No load minimum 1500 1575 1625 CL 1800 1870 1920 1200 or more 2000 2180 2230 2200 2395 2445 2400 2590 2640 2500 2700 2750 2600 2785 2835 2800 2970 3020 VM 3000 3185 3235 800 or more Note The engine speed may differ from the above standa...

Page 56: ...temperature The switch is normal if the voltammeter shows continuity when the fluid temperature is 107 113 deg C 2 5 Water leak check in cooling water system Check cooling water leakage from the cooling water system visually If any problem is found Inspect as follows 1 Fill cooling water to the normal level in the radiator and install the cap tester on the radiator 2 Operate the manual pump to set...

Page 57: ...place the cap since it is abnormal 2 7 Thermostat Inspection Place the thermostat in a container filled with water Heat it while measuring the water temperature and see that the thermostat is actuated at temperature of following table Model Valve opening Temperature deg C Full open lift Temperature mm All models 69 5 72 5 8 or more 85deg C Valve opening temperature is carved on the flange ...

Page 58: ...ing water in a cold season or before a long storage This is unnecessary when antifreeze is used NOTICE Negligence of water draining will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts Water draining procedure a Remove the radiator cap b Loosen the water draining cock under the radiator to drain water from the inside c Loosen the drain cock ...

Page 59: ...ne number Mentioned in the engine label Examine the machine unit name and its number in the same way When was the engine maintained last time How much period and or time has it been used after it was maintained last time What kind of problem was there on the engine last time and what kind of maintenance was dane 3 Hear the occurrence phenomenon from the operator of the engine in detail 5W1H of the...

Page 60: ......

Page 61: ...ap the valve seat See 4 2 6 in Chapter4 Seizure of intake exhaust valve Correct or replace Blowout from cylinder head gasket Replace the gasket See 4 2 2 11 in Chapter4 Seized or broken piston ring Replace the piston ring See 4 2 2 5 10 in Chapter4 Worn piston ring piston or cylinder Perform honing and use oversize parts See 4 4 5 1 4 and 4 4 6 in Chapter4 Seized crankpin metal or bearing Repair o...

Page 62: ...erties of lubricating oil Use proper lubricating oil See 1 3 2 in Chapter1 Leakage from lubricating oil piping system Repair Insufficient delivery capacity of trochoid pump Check and repair See 5 5 in Chapter5 Clogged lubricating oil filter Clean or replace Defective pressure regulating valve Clean adjust or replace Insufficient lubricating oil level Add proper lubricating oil See 2 2 1 3 in Chapt...

Page 63: ... Excessive fuel consumption Excessive consumption Dilution by fuel oil Mixture with water Low L O pressure Much blow by gas Overheat Low water temperature Pressure drop Pressure rise Exhaust temperature rise Corrective action Clogged air filter Clean See 2 2 4 in Chapter2 Engine used at high temperatures or at high altitude Study output drop and load matching Clogged exhaust pipe Clean Air Exhaust...

Page 64: ...essure to diagnose presence of any abnormality in the engine 5 Compression pressure measurement method 1 After warming up the engine remove the fuel injection pipe and valves from the cylinder to be measured 2 Crank the engine before installing the compression gage adapter 1 Perform cranking with the stop handle at the stop position no injection state 2 See 12 2 18 in Chapter 12 for the compressio...

Page 65: ...Adjust the valve clearance See 3 5 in Chapter 3 3 valve timing Incorrect valve clearance Adjust the valve clearance See 3 5 in Chapter 3 4 Cylinder head gasket Gas leak from gasket Replace the gasket Retighten the cylinder head bolts to the specified torque See 4 2 2 12 in Chapter 4 5 Intake exhaust vale Valve seat Gas leak due to worn valve seat or foreign matter trapping Sticking valve Lap the v...

Page 66: ... lubricating oil and fuel 3 Clean soil oil dust etc from the engine by washing with solvent air steam etc Carefully operate so as to prevent any foreign matter from entering the engine Always wear glasses or other protectors when using compressed air or steam to prevent any foreign matter from getting in the eyes NOTICE Any part which is found defective as a result of inspection or any part whose ...

Page 67: ...de 3 4IRH8N 20 75 7 5 11 Model L1 L2 D1 D2 3IRH2N 12 60 13 19 3 4IRH8N 15 65 14 20 2 Valve guide tool for inserting valve guide 4IRI8T 7 60 13 16 Model L1 L2 D1 D2 3IRH2N 25 85 23 26 3 4IRH8N 20 100 26 29 3 Connecting rod bushing replacer for removal installation of connecting rod bushing 4IRI8N 20 100 30 33 4 Valve spring compressor for removal installation of valve spring Available on the market...

Page 68: ...tem seal 4IRH8N 16 2 22 13 5 18 8 65 4 6 Filter wrench for removal installation of L O filter Available on the market Model L1 L2 D1 D2 3 4IRH2N 8N 18 70 45 48 7 Camshaft bushing tool for extracting camshaft bushing 4IRI8N 18 70 50 53 Model Part No Cylinder Bore mm 3IRH2N 78 84 33 4IRH8N 83 95 8 Flex Hone For re honing of cylinder liner 4IRI8N 89 101 ...

Page 69: ...and tool size Illustration 9 Piston insertion tool for inserting piston The above piston insertion tool is applicable to 60 125 mm diameter pistons 10 Piston ring replacer for removal installation of piston ring Available on the market ...

Page 70: ...stand For holding the dial gage when measuring using a dial gage standing angles adjustable 4 Micrometer For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder gage For measuring the inside diameters of cylinder liners rod metal etc 6 Calipers For measuring outside diameters depth thickness and width 7 Depth micrometer For measuring of valve sink 8 Square For measurin...

Page 71: ...easuring gaps between ring and ring groove and shaft joints during assembly 12 Cap tester For checking water leakage 13 Battery coolant tester For checking concentration of antifreeze and the battery electrolyte charge status 14 Nozzle tester For measuring injection spray pattern of fuel injection nozzle and injection pressure 15 Digital thermometer For measuring temperatures ...

Page 72: ...se in the revolving shaft 16 Speedometer Photoelectric type For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft 17 Circuit tester For measuring resistance voltage and continuity of electrical circuits 18 Compression gage kit For measuring compression pressure ...

Page 73: ... 2 To prevent dust from entering fuel injection nozzle fuel injection pump and high pressure fuel pipe seal their respective threads with a tape or the like 3 Whenever extracting fuel injection nozzle replace nozzle protector with a new one 4 1 Remove bonnet assembly 5 1 Remove valve rocker arm shaft assembly 2 Remove push rod 1 Attach a tag to push rod for each cylinder No to put the push rod in ...

Page 74: ...tainer and valve spring c Remove intake valve and exhaust valve 11 1 Remove crankshaft V pulley clamping bolt 2 Using a puller extract crankshaft V pulley 1 Extract crankshaft V pulley by hitting the bolt of the puller using a plastic hammer or the like 12 1 Remove oil pan mounting bolt under gear case 2 Remove gear case mounting bolt 3 Remove gear case 1 Never fail to removes stiffner bolt at the...

Page 75: ...d upside down because the tappet is cylindrical in shape 19 1 Remove idle gear shaft and then remove idle gear 2 Remove mounting bolt of thrust bearing through the hole of the camshaft gear Remove camshaft assembly 1 Turn the cylinder block aside and carefully prevent tappet from jamming on the cam 2 Preheat camshaft gear and camshaft assembly to 180 200 which are shrink fitted before removing the...

Page 76: ...t gap All models 2 Notice on the removal of thrust metal a When removing thrust metal ascertain the position and direction where thrust metal is installed in relation to the cap b Make sure that the thrust metal groove is outward in relation to the cap 24 1 Remove piston and connecting rod assembly 1 To selectively remove a desired piston and connecting rod assembly without extracting crankshaft t...

Page 77: ...k cylinder head crankshaft and camshaft Ensure that they are free from chips dust sand and other foreign matter 12 Parts to be replaced during reassembly Be sure to replace the following parts with new ones during assembly Valve stem seal Head gasket packing Nozzle protector and nozzle seat of the fuel injection valve Various copper packing O rings and gasket packing 4 1 5 Adjusting operation Make...

Page 78: ... fuel oil piping Point3 5 Remove the oil level gage assy 6 Remove the oil filter Point4 7 Remove the fuel injection pipes Point5 8 Remove the intake manifold assy 9 Remove the exhaust manifold assy 10 Remove the bonnet Assy 11 Remove the rocker shaft assy push rods and valve caps Point6 12 Remove the cylinder head assy and head gasket Point7 13 Remove the fuel injection valves and fuel return pipe...

Page 79: ...orting the alternator Do not tilt the alternator toward the cylinder block in haste since it may damage the alternator or pinch a finger Reassemble The belt deflection shall be checked according to 2 2 2 in Chapter2 Reassemble Replace the belt with a new one if cracked worn or damaged Carefully prevent the belt from being smeared with oil or grease ...

Page 80: ...Disassemble Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of foreign matters Point 6 A point in case of 4 valve head is mentioned Disassemble Take off a bonnet in case of 4 valve head after removing fuel injection pipes and pipe seals NOTICE Attention is necessary because a fuel nozzle is caught in a pipe seal and the pipe seal is damaged when...

Page 81: ...gasket with a new one Uniformly install the head bolts manually after applying oil on the threaded and seat portions They shall be tightened in two steps in the reverse of the order for disassembly Tightening torque Nm kgf m 3IRH2N 3 4IRH8N First step 30 0 34 0 3 1 3 5 41 1 46 9 4 2 4 8 Second step 61 7 65 7 6 3 6 7 85 3 91 1 8 7 9 3 4IRI8N First step 49 0 58 8 5 0 6 0 Second step 103 1 112 9 10 5...

Page 82: ... remove it with an oilstone and extract the valve from the cylinder head Reassemble Replace the stem seal with a new one when an intake exhaust valve is disassembled Carefully install each valve after oil application so as not to damage the stem seal Different stem seals are provided for the intake and exhaust valves Do not confuse them since those for exhaust valves are marked with yellow paint A...

Page 83: ...d on four sides of the cylinder head and measure distortion with a thickness gage mm Standard Limit Distortion 0 05 or less 0 15 c Valve sink Measure with the valve inserted to the cylinder head mm Standard Limit Intake 0 35 0 55 0 8 3IRH2N 2 valve head Exhaust 0 30 0 50 0 8 3IRH8N 4IRH8N Intake 0 30 0 50 0 8 2 valve head Exhaust 0 30 0 50 0 8 Intake 0 36 0 56 0 8 4IRI8N 4IRI8T 4 valve head Exhaus...

Page 84: ... 6 945 6 960 6 90 Intake value Clearance 0 040 0 070 0 18 Guide I D 7 000 7 015 7 08 Stem O D 6 940 6 955 6 90 3IRH2N 2 valve head Exhaust value Clearance 0 045 0 075 0 18 Guide I D 8 010 8 025 8 10 Stem O D 7 955 7 975 7 90 Intake value Clearance 0 035 0 070 0 18 Guide I D 8 015 8 030 8 10 Stem O D 7 955 7 970 7 90 3 4IRH8N 2 valve head Exhaust value Clearance 0 045 0 075 0 18 Guide I D 7 000 7 0...

Page 85: ... thickness mm Model Part Standard Limit Intake 1 34 0 50 3 4IRH2N 8N Exhaust 1 45 0 50 d Valve stem bend mm Limit 0 01 e Overall length mm Standard Limit 3IRH2N Intake Exhaust 3 4IRH8N Intake Exhaust 4IRI8N Intake Exhaust 115 114 5 16 Valve spring Mainly inspect damage and corrosion mm Free length standard Inclination limit 3IRH2N 44 4 3 4IRH8N 42 0 1 2 4IRI8N 47 5 1 2 ...

Page 86: ...RI8T Clearance 0 01 0 05 0 13 18 Rocker arm shaft Mainly inspect seizure and wear at the surface in sliding contact with the arm The rocker shaft diameter shall be as specified in 5 5 above 19 Push rod Mainly inspect the surface in contact with the tappet and adjusting screw Slight defects shall be corrected with an oilstone Bend limit 0 03mm or less 20 Valve clearance adjusting screw Mainly inspe...

Page 87: ...valve and seat with a mixture of valve compound and engine oil B Lap with engine oil only 2 If the seat is heavily roughened but the width is almost normal correct with a seat grinder or seat cutter first Then perform lapping A and B intake Exhaust Seat cutter angle 120 90 3 If the seat is heavily roughened and the width is much enlarged grind the seat inner surface with a seat grinder whose cente...

Page 88: ...guide for replacement in it for cooling Then insert it in with a valve guide inserting tool Refer to No 2 of 4 1 2 in Chapter 4 Do not touch the cooled valve guide with bare hands to avoid skin damage 3 Check the inside diameter and finish to the standard inside diameter as required with a reamer 4 Check the projection from the cylinder head mm Model Number of valves Projection 3IRH2N 11 7 12 0 4I...

Page 89: ...nt do not confuse the intake and exhaust valves 1 Apply engine oil to the lip 2 Push with the inserting tool Refer to No 5 of 4 1 2 in Chapter 4 for installation Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem seal mm Model Number of valves Projection 3IRH2N 15 7 16 0 4IRH8N 18 7 19 0 4IRI8T 2 valves 11 7 12 0 ...

Page 90: ... 3 Remove the crankshaft pulley Point 1 4 Remove the gear case cover Point 2 5 Remove the fuel injection pump Point 3 6 Remove the idle gear assy Point 4 7 Remove the PTO drive gear Point 5 8 Remove the starting motor 9 Remove the flywheel Point 6 10 Remove the camshaft assy Point 7 11 Remove the gear case Point 8 12 Remove the oil seal from the gear case cover Point 9 4 3 3 Reassembly procedure R...

Page 91: ...oil seal lips See 4 3 6 Oil seal replacement When installing the crankshaft pulley apply lube oil to the set bolt to tighten and carefully assemble so as not to damage the oil seal N m kgf m Model Tightening torque 3IRH2N 8N 112 7 122 7 11 5 12 5 4IRI8N 8T 107 9 127 5 11 0 13 0 Point 2 Reassemble When installing the gear case cover do not forget to install the two reinforcing bolts at the center M...

Page 92: ...semble crankshaft gear A fuel injection pump drive gear B and camshaft gear C at the same time by aligning with idle gear A B and C marks Install the idle gear shaft with the oil hole facing upward Point 5 Reassemble Install the PTO drive gear with its inner spline side facing the flywheel Point 6 Disassemble Install a bolt as a handle in the hole at the end face of the flywheel and remove careful...

Page 93: ...ught by the cam After removing the camshaft set the engine horizontal and fix it on the base Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the horizontal position Proceed carefully so as not to lose balance Point 8 Gear case Reassemble Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case ...

Page 94: ...dial gage half of the runout is the bend mm Item Standard Limit Bend 0 0 02 0 05 b Intake exhaust cam height measurement mm Model Standard Limit 3IRH2N 8N 38 600 38 800 38 350 4IRI8N 43 400 43 600 43 150 c Camshaft outside diameter and bearing hole diameter measurement Measure the camshaft outside diameter with a micrometer The oil clearance shall be calculated by subtracting the measured camshaft...

Page 95: ...il clearance 0 040 0 130 0 240 Bushing I D 50 000 50 025 50 100 Camshaft O D 49 910 49 935 49 875 Intermediate position Oil clearance 0 065 0 115 0 225 Bushing I D 50 000 50 025 50 100 Camshaft O D 49 925 49 950 49 890 4IRI8N 8T Wheel side Oil clearance 0 05 0 100 0 210 23 Idle gear Mainly check the bushing seizure and wear and gear damage Shaft outside diameter and bushing inside diameter measure...

Page 96: ...as not to damage them when installing the pulley NOTICE Pay attention not to drop any oil on the taper surface of the crankshaft If dropped clean by wiping off using detergent 4 Carefully install the crankshaft pulley so as not to damage the oil seal lips Especially for the engine installed the oil seal with double lips dust seal be sure to use the crankshaft pulley installing tool 4 3 7 Camshaft ...

Page 97: ... in the gear train disassembly procedure Remove the oil pan Point 1 Remove the lubricating oil suction pipe Remove the piston w rod Point 2 Remove the mounting flange Point 3 Remove the bearing metal caps Point 4 Remove the crankshaft Point 5 Remove the tappets Remove the pistons and rings Point 6 Remove the oil seal from the mounting flange Point 7 4 4 3 Reassembly procedure Reverse of the disass...

Page 98: ...g rod big end with the wooden shaft of a hammer Proceed carefully so as not to cause the cylinder block catch the rod big end Set the rod caps and crankpin metals in their correct combinations Reassemble Apply oil especially carefully to the sliding contact surfaces of the pistons rods and rings Use the piston insertion tool see 12 1 9 in Chapter 12 to insert each piston w rod in the cylinder bloc...

Page 99: ...right figure 2 Put a thickness gauge in the clearance between thrust metal and crankshaft directly and measure it Side gap standard mm Model Standard Limit All models 0 13 0 23 0 28 Reassemble If the side gap exceeds the standard replace the thrust metal with an oversize one Machine the standard width of the crankshaft thrust part into the dimension of the below table at the same time Refer to a p...

Page 100: ...lock side has an oil hole and the lower one does not The wheel and arrow marks on the cap shall face the flywheel Main bearing cap bolt tightening torque apply lube oil Nm kgf m Model Standard 3IRH2N 76 4 80 4 7 8 8 2 3 4IRH8N 93 2 98 1 9 5 10 5 4IRI8N 108 1 117 9 11 0 12 0 Point 5 Crankshaft Disassemble Remove the crankshaft Remove each main bearing metal upper block side and pair it with the met...

Page 101: ...tical to the piston pin The coil expander joint shall be opposite to the oil ring joint Reassemble When installing the piston pin to the rod and piston the punched match mark on the big end of the connecting rod shal be opposite to the size mark on the piston top Reassemble Install the piston in the cylinder clock with the punched mark on the big end of the rod on the nozzle side The embossed mark...

Page 102: ... method Measure cylinder diameters of the A direction and the B direction on each section of a b and c Roundness is the maximum value among those difference values Cylindricity Cylindricity is found as follows though it is the simple method Measure cylinder diameters of a b and c sections in the A direction and calculate the difference in maximum value and minimum value of the measured diameters I...

Page 103: ... 22900 82 250 3 4IRH8N 129005 22900 88 250 4IRI8N 129902 22700 98 250 Piston ring assy for oversized 0 25mm Model Piston ring code No 3IRH2N 719802 22950 3 4IRH8N 129005 22950 4IRI8N 729907 22950 Cylinder dimension after boring and honing Model Cylinder dimension mm Honing angle deg Surface roughness Roundness Cylindricit y mm 3IRH2N 82 250 82 280 3 4IRH8N 88 250 88 280 4IRI8N 98 250 98 280 30 40 ...

Page 104: ...ly damaged Slight defects shall be corrected by grinding b Crankshaft bend Support the crankshaft journals at both ends with V blocks Use a dial gage and measure the runout at the center journal while rotating the shaft to inspect the bend Limit 0 02mm or less c Crankpin and journal measurement Measure the outside diameter roundness and taper at each crankpin and journal Correct by grinding if une...

Page 105: ...in outside diameter 57 952 57 962 57 902 Metal thickness 1 492 1 500 4IRI8N Oil clearance 0 038 0 074 0 150 If the oil clearance exceeds the limit use an undersized bearing Undersized crankpin bearing 0 25 mm Model Code No Standard thickness mm 3IRH2N 119810 23610 1 612 1 625 3 4IRH8N 129150 23610 1 617 1 625 4IRI8N 129900 23610 1 617 1 625 Pin machining dimension Model Pin machining dimension mm ...

Page 106: ...al O D 64 952 64 962 64 902 Metal thickness 1 995 2 010 4IRI8N Selective assembly Oil clearance 0 038 0 068 0 150 If the clearance limit is exceeded use an undersized bearing Undersized bearing 0 25mm Model Code No Standard thickness mm 3IRH2N 119810 02870 2 112 2 125 3 4IRH8N 129150 02870 2 112 2 125 4IRI8N 129900 02340 2 112 2 125 Crankshaft Journal machining dimension Model Journal machining di...

Page 107: ... of the metals coat it with blue or minimum Then assemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque to check the metal for contact lf the contact surface occupies 75 or more the metal is normal lf the contact surface is insufficient the metal interference is insufficient Replace the metal with a new one 27 Thrust metal inspection a Inspect any damage...

Page 108: ... 87 975 87 900 22 25 4IRI8T 97 940 97 950 97 895 22 If the clearance between piston and cylinder exceeds the limit use an oversized piston Refer to the tables of oversized pistons oversized piston rings and cylinder boring dimension on 4 4 5 1 c in chapter 4 b Piston pin hole measurement Measure the outside diameter of piston pin and the inside diameter of piston pin hole Calculate the clearance b...

Page 109: ...thickness gage in between the piston ring and groove to measure the gap between them Obtain the ring groove width by adding ring width to the measured side clearance To measure the end clearance push the piston ring into the sleeve using the piston head insert a thickness gage in end clearance to measure The ring shall be pushed in to approx 30 mm above the bottom end of the cylinder For the top r...

Page 110: ...70 0 105 Top ring End clearance 0 200 0 400 0 490 Ring groove width 2 025 2 040 2 140 Ring width 1 970 1 990 1 950 Side clearance 0 035 0 070 0 190 Second ring End clearance 0 200 0 400 0 490 Ring groove width 4 015 4 030 4 130 Ring width 3 970 3 990 3 950 Side clearance 0 025 0 060 0 180 3 4IRH8N Oil ring End clearance 0 200 0 400 0 490 Ring groove width 2 040 2 060 Ring width 1 940 1 960 1 920 S...

Page 111: ... or less per 100mm 0 08 c Rod small end measurement Measure the pin outside diameter according to 4 4 5 4 a described above mm Model Item Standard Limit Piston pin I D bushing 23 025 23 038 23 068 Pin O D 22 995 23 000 22 967 3IRH2N Clearance 0 025 0 043 0 101 Piston pin I D bushing 26 025 26 038 26 068 Pin O D 25 995 26 000 25 967 3 4IRH8N Clearance 0 025 0 043 0 101 Piston pin I D bushing 30 025...

Page 112: ...he crankpin metals in the rod big end not to mistake the top and bottom of the metals and tighten the rod bolts by the standard torque Tightening torque of rod bolt Model Tightening torque Nm kgf m Lubricating oil application threaded portion and bearing seat surface 3IRH2N 37 2 41 2 3 8 4 2 3 4IRH8N 44 1 49 0 4 5 5 0 4IRI8N 53 9 58 8 5 5 6 0 Lube oil applied Standard of rod big end mm Model Item ...

Page 113: ...flawed or otherwise damaged and cannot be repaired simply by honing rebore the cylinder first and then hone See 4 4 5 1 c for the boring dimension 2 Items to be prepared for honing Flex Hone see No 8 of 4 1 2 in Chapter 4 Electric drill Honing fluid 50 50 mixture of lube oil and diesel oil Model Item Standard Limit Tappet hole I D 12 000 12 025 12 04 5 Stem O D 11 975 11 990 11 95 5 3 4IRH8N Clear...

Page 114: ...ICE 1 Avoid faster revolution than 1200 rpm since it may cause breakdown 2 Do not insert or extract the Flex Hone in stopped state because the cylinder will be damaged 4 4 7 Piston pin bushing replacement Replace bushing by using the special service tool see 4 1 2 No 3 in Chapter 4 4 4 8 Oil seal replacement 1 Replace oil seal when mounting flange is removed Extract the used oil seal 2 Insert a ne...

Page 115: ...115 5 LUBRICATION SYSTEM 5 1 Lubrication System Diagram Note It varies in the specifications of each model whether Oil cooler and Piston cooling of the mark are attached ...

Page 116: ...vicing Points Point 1 Disassemble Check if the pump rotates smoothly and see that there is no play between the shaft and gear and inner rotor Reassemble Install the outer rotor in the gear case so that the punch mark on the end face is seen For installation on the gear case tighten four bolts uniformly in several steps NOTICE Always check if the pump rotates smoothly after installation on the gear...

Page 117: ...clearance put a right angle gage to the pump body insert a gap gage and measure the clearance Side clearance mm Model Standard Limit 3IRH2N 3 4IRH8N 0 02 0 07 0 12 4IRI8N 0 05 0 10 0 15 32 Inner rotor clearance 3IRH2N 4IRH8N Item Part Standard dimension mm Standard clearance mm Standard clearance limit mm Gear boss diameter 53 05 53 15 Inside clearance of inner rotor Rotor inner diameter 53 45 53 ...

Page 118: ...er of rotor shaft and the shaft hole diameter of gear case Calculate the clearance from that difference Model Inspection item Standard Limit Gear case bearing I D 13 0 13 02 13 05 Rotor shaft O D 12 955 12 965 12 955 4IRI8N Rotor clearance 0 035 0 065 0 105 ...

Page 119: ...119 6 COOLING SYSTEM 6 1 Cooling Water System 6 2 Cooling Water Pump Components ...

Page 120: ... the cooling water pump bearing is free from abnormal noise sticking or play and water leakage from the bearing If replacement is necessary replace the whole cooling water pump assy NOTICE Replace the O ring of the cooling water pump with new one when disassembling And be sure to use the special O ring for each engine model because the material is different although the dimension is the same as a ...

Page 121: ...ing but also finest assembling with top level The careful arrangement of keeping off the dust and the rust when disassemble adjustment and reassemble of the fuel injection pump is made in the market The YDP MP Pump is a distributor type pump which is unified of Mono plunger a distributing shaft a hydraulic head which equipped the delivery valve for each cylinder pump housing which has a cam shaft ...

Page 122: ...y and V belt See 4 2 2 2 in Chapter 4 2 Remove the fuel injection pipe fuel oil piping fuel return pipe and rear stay See point 1 of 7 2 5 3 Remove the fuel injection pump drive gear cover See 4 3 1 in Chapter 4 4 Remove the fuel injection pump drive gear See Point 2 of 7 2 5 5 Remove the fuel injection pump See Point 3 of 7 2 5 ...

Page 123: ...and the fuel injection pump Point 2 Disassemble Remove the fuel injection pump drive gear and idle gear after putting the I D marks NOTICE Don t remove four flange bolts Reassemble Assemble the gears after checking those I D marks Tightening torque of the gear installation nut Model N m kgf m Lubricating oil application thread portion and seat surface 3IRH2N 3 4IRH8N 78 88 8 9 Not applied ...

Page 124: ...fuel pump spacer between the fuel pump and the cylinder block Loosen fuel pump installation bolts with a closed wrench when disassembling a fuel pump Reassemble When installing a fuel pump on the gear case put a fuel pump spacer between the cylinder blocks and install it ...

Page 125: ...del RHB31 RHB51 RHF5 Turbocharger specification Standard w waste gate Turbine type Radial flow Blower compressor type Centrifugal Lubrication method External lubrication Max continuous allowable speed 250 000 180 000 Max continuous allowable gas inlet temperature 750 Dry weight N kgf 24 2 4 41 4 2 46 4 7 Note VM application is provided with the waste gate 8 1 2 Construction ...

Page 126: ...sor 36 Bearings Thrust bearing As the turbine shaft is constantly applied with a thrust force this bearing prevents the shaft from being moved by the thrust force Radial bearing A floating bearing is adopted Since the bearing moves with the turbine shaft as the oil films are formed both inside and outside the bearing the bearing sliding speed is slower than the turbine shaft speed resulting in hig...

Page 127: ...ng 5 Seal ring 21 Screw 6 Seal ring turbine side 22 Screw 7 Lock nut 23 Lock washer 8 Impeller 24 Heat protector 9 Seal plate 25 Liquid gasket 10 Journal bearing 26 Waste gate actuator 11 Thrust bearing 27 Hose 12 Compressor housing 28 Adapter 13 Flanged bolt 29 Clip 14 Spring washer 30 Retaining ring 15 Clamp 31 Waste gate valve 16 Turbine housing 32 Link plate ...

Page 128: ...haft Turbine shaft run out 0 002 0 011 Journal bearing inside diameter C 8 01 8 03 8 04 Journal bearing outside diameter D 12 32 12 33 12 31 Bearing Bearing housing inside diameter B 12 40 12 41 12 42 Thrust bearing width J 3 99 4 01 3 98 Thrust bearing Thrust bushing groove dimension K 4 04 4 05 4 07 Turbine side bearing housing F 15 00 15 02 15 05 Compressor side seal ring H1 12 40 12 42 12 45 S...

Page 129: ... 00 15 02 11 03 15 05 Compressor side seal ring H1 9 987 10 025 12 40 12 42 10 04 12 45 Seal ring fixing area Compressor side seal ring H2 7 968 8 00 10 00 10 02 8 01 10 05 Rotor play in axial direction 0 022 0 053 0 03 0 06 0 07 0 09 Rotor play in radial direction 0 061 0 093 0 08 0 13 0 12 0 17 8 2 2 Tightening torque 41 RHF5 type N m kgf cm Part Thread diameter Tightening torque Turbine housing...

Page 130: ... Every 6 months or 60 000km Every 12 months or 150 000km Every 24 months or 300 000km For construction machinery Every 6 months or 500hrs Every 12 months or 1 000hrs Every 24 months or 2 000hrs For faming machinery Every 6 months or 200hrs Every 12 months or 400hrs Every 24 months or 800hrs For marine use Every 6 months or 1 500hrs Every 12 months or 3 000hrs Every 24 months or 6 000hrs Rotor rota...

Page 131: ...ually If any high pitch sound is generated at intervals of 2 to 3 seconds the rotation is abnormal Since the bearing or rotor may be defective in this state either replace or overhaul the turbocharger 44 Rotor play inspection Remove the turbocharger from the engine and inspect the rotor play in the axial and radial directions according to the procedure below After removing the turbocharger from th...

Page 132: ...ift after its overhaul or inner parts replacement Negligence of this adjustment will adversely affect the engine performance NOTICE If the adjustment is impossible give up overhaul but replace the whole turbocharger assembly 45 Method for checking the waste gate valve opening pressure and lift a Equipment Prepare the equipment shown in the figure below ...

Page 133: ...t The gradually close the pressure regulating valve measure the pressure when the rod is moved to 2mm and obtain the difference from the pressure measured in b above 4 Precautions Set the dial gage on the extension line of the actuator rod The piping and joints shall completely be free from leak Fix the turbocharger and dial gage securely If an electric manometer is used it shall have sufficient p...

Page 134: ...liers For removing seal ring Torque driver for TORX bolt multifunctional type 0 5 to 4 9N m 5 to 50 kgf cm For thrust bearing installation for M3 1 3 N m 13 kgf cm For seal plate installation for M3 1 3 N m 13 kgf cm Item sold on market Type TORX TT20 or equivalent Box wrench For fixing turbine shaft mm dodecagonal Box only may be used Torque wrench single purpose For following bolts and nuts M8 m...

Page 135: ... Compressor impeller removal 1 Set a box spanner 10mm on the turbine side end of the turbine shaft and remove shaft end clamp 18 Note Pay attention to the loosening direction since the shaft end nut has left handed screw 2 Remove compressor impeller 18 49 Turbine housing removal 1 Remove hexagon nut 12 and turbine side keep plate 13 2 Remove turbine housing 11 50 Turbine shaft extraction 1 Hold he...

Page 136: ...remove circlip 16 from bearing housing 15 2 Remove floating bearing 5 from bearing housing 15 54 Seal ring removal 1 Remove turbine side seal ring 3 from turbine shaft 1 2 Remove compressor side seal ring small and compressor side seal ring large from oil thrower 2 ...

Page 137: ...hing the parts Part Tools and detergent Procedure a Turbine s haft Tools 1 Bucket 2 Heat source Steam or gas burner 3 Brush Detergent Standard carbon removing agent 1 Boil the turbine in the washing bucket Do not strike the blade to remove the carbon 2 Immerse in the detergent until the carbon and other deposits are softened 3 Use a plastic scraper or hand hair scrubber to remove the softened depo...

Page 138: ...ping thermal discoloration or deformation at the turbine wheel Check the shaft portion for bend the journal portion for thermal discoloration or abnormal wear and the seal ring groove for surface defect or wear Replace with a new one if defective 2 Measure the turbine shaft journal outside diameter A and seal ring groove width E Replace with a new turbine shaft if beyond the wear limit Wear limit ...

Page 139: ...ed Wear limits RHF5 G1 1 31mm G2 1 11mm RHB51 G1 1 31mm G2 1 11mm RHB31 G1 1 04mm G2 0 84mm c Thrust bearing 6 Measure the thrust bearing width J and replace with a new one if the wear limit is exceeded Wear limit RHF5 3 98mm RHB51 3 98mm RHB31 3 58mm 63 Floating bearing 5 1 Inspect the floating bearing for abnormal wear discoloration or surface defect Replace with a new one if defective 2 Measure...

Page 140: ...urbine side seal ring inserting portion F RHF5 15 05mm RHB51 15 05mm RHB31 11 03mm 65 Seal plate 4 1 Inspect the seal plate for any contact trace joint surface defect dent or crack Replace it if defective 2 Measure the seal ring inserting dimensions H1 and H2 on the compressor side and replace the seal ring with a new one if either wear limit is exceeded Wear limits RHF5 H1 12 45mm H2 10 05mm RHB5...

Page 141: ...15 3 Use the snap ring pliers and install outer circlip 16 on bearing housing 15 Note 1 The circlip joint shall be positioned as shown in the figure at right above The rounded side of the circlip shall face the bearing 2 Apply lubricating oil on the floating bearing before reassembly 69 Turbine shaft installation 1 Fit the seal ring onto turbine shaft 1 2 Install heat insulating plate 20 on the tu...

Page 142: ...m 71 Seal plate installation 1 Fit the seal ring on oil thrower 2 2 Insert oil thrower 2 into seal plate 4 Note The seal ring joint portion shall be positioned as illustrated at right 3 Apply liquid gasket Three Bond No 1207 on the seal plate mounting surface on the compressor side of bearing housing 15 Note See the illustration below for the applying position Applying thickness 0 1 0 2 mm 4 Insta...

Page 143: ...n 1 Apply liquid gasket Three Bond No 1207 on the compressor side flange of bearing housing 15 Note See section 4 3 for the portion to be applied Applying thickness 0 1 0 2 mm 2 Check the mark and install the compressor housing 7 on the bearing housing 15 Note When a part is replaced confirm a position of an oil entrance and a position of an air exit and assemble it 3 Install the keep plate 10 on ...

Page 144: ...il inlet pipe from the engine and outlet pipe and check no crushed pipe nor dirt or foreign matter remaining in the pipes 3 Connect the pipes securely so as to ensure no oil leak from joints Intake system 1 Check no foreign matter or dirt in the intake line 2 Connect securely to prevent any air leak from joints with the intake duct and air cleaner Exhaust system 1 Check no dirt or foreign matter i...

Page 145: ...xcessive revolution Excessive exhaust temperature rise Foreign matter invasion worn bearing Assembly defect Turbocharger overhaul disassembly and washing with lubricating oil replacement Turbocharger overhaul disassembly and repair Lubricating oil line inspection repair of defective portion and lubricating oil replacement Rotating part replacement or washing Strict observance of instructions in op...

Page 146: ...Engine combustion state inspection followed by improvement of combustion to normal state 8 8 6 Abnormal sound or vibration 79 Abnormal sound generation Cause Corrective action 1 Excessively narrowed gas path due to clogged nozzle in turbine wheel chamber or reverse flow of blower discharge in acceleration generally called surging 2 Contact rotating part Turbocharger disassembly and washing Turboch...

Page 147: ...H2N 3 16 31 0 1 1 2 45 25 0 1 1 5 Compression pressure at 250 min 1 MPa kgf cm 2 3 4IRH8N 3 43 35 0 1 1 2 75 28 0 1 1 3 3 3IRH2N 1 8 3IRH8N 2 0 4IRH8N 2 7 6 Cooling water Capacity Only engine body Liter 4IRI8T 4 2 2 2 1 4 Full Effective 3IRH2N 5 5 1 9 3IRH8N 6 7 2 8 4IRH8N 7 4 3 4 7 Lubricating oil capacity oil pan Liter 4IRI8T 10 2 4 5 2 2 1 3 at rated speed at low idle speed 3IRH2N 4IRI8N 0 29 3...

Page 148: ... mm 0 05 or less 0 15 Intake 0 350 55 0 9 3IRH2N 2 valve head Exhaust 0 300 50 0 8 Intake 0 300 50 0 8 3 4IRH8N 2 valve head Exhaust 0 300 50 0 8 Intake 0 360 56 0 9 Valve sink mm 4IRI8T 4 valve head Exhaust 0 350 55 0 9 4 2 5 1 Intake 120 Seat angle Deg Exhaust 90 Valve seat 2 valve 4 valve Seat correction angle deg 40 150 4 2 6 ...

Page 149: ... diameter 7 9557 975 7 90 Intake Clearance 0 0350 070 0 18 Guide inside diameter 8 0158 030 8 10 Valve stem outside diameter 7 9557 960 7 90 3 4IRH8N 2 valve head Exhaust Clearance 0 0450 075 0 18 Guide inside diameter 7 0007 015 7 08 Valve stem outside diameter 6 9456 960 6 90 Intake Clearance 0 0400 070 0 17 Guide inside diameter 7 0007 015 7 08 Valve stem outside diameter 6 9406 955 6 90 4IRI8T...

Page 150: ...e 1 4 4 2 5 4 82 Rocker arm and shaft mm Model Inspection item Standard Limit Reference page Arm shaft hole diameter 16 00016 020 16 07 Shaft outside diameter 15 96615 984 15 94 3 4IRH2N 8N Clearance 0 0160 054 0 13 Arm shaft hole diameter 18 50018 520 18 57 Shaft outside diameter 18 47018 490 18 44 4IRI8T Clearance 0 0100 050 0 13 4 2 5 5 83 Push rod mm Inspection item Standard Limit Reference pa...

Page 151: ...r 45 00045 025 45 100 Camshaft outside diameter 44 91044 935 44 875 Intermediate Clearance 0 0650 115 0 225 Bushing inside diameter 45 00045 025 45 100 Camshaft outside diameter 44 92544 950 44 890 3 4IRH2N 8N Wheel side Clearance 0 0500 100 0 210 Bushing inside diameter 49 99050 055 50 130 Camshaft outside diameter 49 92549 950 49 890 Gear side Clearance 0 0400 130 0 240 Bushing inside diameter 5...

Page 152: ... 3IRH2N 8N Crank gear cam gear idle gear fuel injection pump gear and PTO gear 0 070 15 0 17 Crank gear cam gear idle gear fuel injection pump gear and PTO gear 0 080 14 0 16 4IRI8T Lubricating oil pump gear 0 090 15 0 17 4 3 4 9 2 3 Cylinder block 1 Cylinder block mm Inspection item Standard Limit Reference page 3IRH2N 82 00082 030 82 130 3 4IRH8N 88 00088 030 88 130 Cylinder inside diameter 4IRI...

Page 153: ... 57 95257 962 57 902 Metal inside diameter 58 00058 026 Metal thickness 1 4921 500 Crank pin 4IRI8N Clearance 0 0380 074 Journal outside diameter 46 95246 962 46 902 Metal inside diameter 47 00047 032 Metal thickness 1 9872 000 3IRH2N Clearance 0 0380 080 0 150 Journal outside diameter 53 95253 962 53 902 Metal inside diameter 54 00054 020 Metal thickness 1 9951 990 3 4IRH8N Selective pairing Clea...

Page 154: ...he piston pin 4IRI8T 97 94097 950 97 895 3IRH2N 16 3 4IRH8N 24 Piston diameter measure position Upward from the bottom end of the piston 4IRI8T 22 Hole inside diameter 23 00023 009 23 039 Pin outside diameter 22 99523 000 22 965 3IRH2N Clearance 0 0000 014 0 074 Hole inside diameter 26 00026 009 26 039 Pin outside diameter 25 99526 000 25 965 3 4IRH8N Clearance 0 0000 014 0 074 Hole inside diamete...

Page 155: ...0700 105 Top ring End clearance 0 2000 400 0 490 Ring groove width 2 0252 040 2 140 Ring width 1 9701 990 1 950 Side clearance 0 0350 070 0 190 Second ring End clearance 0 2000 400 0 490 Ring groove width 4 0154 030 4 130 Ring width 3 9703 990 3 950 Side clearance 0 0250 060 0 180 3 4IRH8N Oil ring End clearance 0 2000 400 0 490 4 4 5 4 Ring groove width 2 0402 060 Ring width 1 9401 960 1 920 Side...

Page 156: ...iameter 25 99526 000 25 967 3 4IRH8N Clearance 0 0250 043 0 101 Bushing inside diameter 30 02530 038 30 068 Pin outside diameter 29 98730 000 29 959 4IRI8N Clearance 0 0250 051 0 109 4 4 5 5 84 Tappet mm Inspection item Standard Limit Reference page Tappet hole block inside diameter 12 00012 025 12 045 Tappet stem outside diameter 11 97511 990 11 955 3 4IRH2N 8N Clearance 0 0100 050 0 090 Tappet h...

Page 157: ...learance of inner rotor mm Item Parts Standard Standard Limit Reference page Gear boss diameter 53 0553 15 Inside clearance of inner rotor Rotor diameter 53 4553 55 0 30 5 0 6 Width across flat of Gear boss 49 4549 75 Width across flat clearance of inner rotor Width across flat of rotor 49 9550 05 0 20 6 0 7 5 5 1 2 9 3 4 Rotor shaft clearance mm Model Inspection item Standard Limit Reference page...

Page 158: ...4 4 3 4IRH8N M10 1 25 83 3 88 2 8 5 9 0 Flywheel set bolt 4IRI8T M14 1 5 2 205 8 19 21 Applied 4 3 4 3IRH2N M10 1 25 76 4 80 4 7 8 8 2 Bearing cap set bolt 4IRI8N M11 1 25 108 1 117 9 11 0 12 0 Applied 4 4 4 3 4IRH8N M14 1 5 112 7 122 7 11 5 12 5 Crankshaft pulley set bolt 4IRI8T M14 1 5 107 9 127 5 11 0 13 0 Applied 4 3 4 3 4IRH8N M8 1 25 24 4 28 4 2 5 2 9 Fuel nozzle set bolt 4IRI8T M8 1 25 22 6...

Page 159: ...5 147 1 13 15 Hexagon bolt 7T and nut M16 1 5 215 7 235 4 22 24 Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts 1 8 9 8 1 0 1 4 19 6 2 0 3 8 29 4 3 0 PT plug 1 2 58 8 6 0 M8 12 7 16 7 1 3 1 7 M10 19 6 25 4 2 0 2 6 M12 24 5 34 3 2 5 3 5 M14 39 2 49 0 4 0 5 0 Pipe joint bolt M16 49 0 58 8 5 0 6 0 Note Lubricating oil is not appl...

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