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Mitsubishi Heavy Industries S3L, Service Manual

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Summary of Contents for S3L

Page 1: ...Printed in Japan Pub No Pub No SERVICE MANUAL SERVICE MANUAL July 2016 July 2016 99619 12150 99619 12150 ...

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Page 3: ...ntenance and also to take necessary measures which involves the disassembly inspection repair and reassembly of the engine and engine parts Read this manual carefully and understand the work procedures fully before disassembling inspecting repairing or reassembling the engine The contents of the manual are based on the engine models that are being produced at the time of publication Due to improve...

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Page 5: ...isassembly 2 Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views 3 Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text They are also collectively indicated in Group 2 the General Contents group 4 Fasteners to be tightened in wet condition or with engine oil applied are identif...

Page 6: ... ABDC After Bottom Dead Center TIR Total Indicated Runout API American Petroleum Institute ASTM American Society for Testing and Materials JIS Japanese Industrial Standards LLC Long Life Coolant MIL Military Specifications and Standards U S A MSDS Material Safety Data Sheet SAE Society of Automotive Engineers U S A Units of measurement Measurements are based on the International System of Units SI...

Page 7: ...e crankcase which can cause oil mist to ignite and explode Care about fuel oil and exhaust gas leakage If any fuel oil or exhaust gas leakage is found immedi ately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equip...

Page 8: ... rotating part se rious bodily injuries could result Lockout and Tagout Be sure to lockout and tagout before starting inspection and maintenance Lockout and tagout are effective 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 and attach a Do Not Run or similar caution tag to the starter s...

Page 9: ...ter the coolant tempera ture dropped Do not add coolant immediately after the engine stops Wait until the coolant temperature lowers sufficiently to avoid a risk of burns Never remove heat shields The exhaust system which becomes extremely hot while the engine is operating is provided with various heat shields Do not remove these heat shields If any of these heat shields have been removed owing to...

Page 10: ...cified in this manual and handle them carefully Use of any other fuel oil or LLC or improper handling may cause various engine problems and malfunctions Obtain the Material Safety Data Sheets MSDS issued by the fuel oil and LLC suppliers and follow the direc tions in the MSDSs for proper handling Handle LLC long life coolant carefully When handling LLC always wear rubber gloves and protective face...

Page 11: ...t away with plenty of clean fresh water and seek immediate medical attention If the battery fluid is accidentally swallowed gargle with plenty of water then drink lots of water and seek immediate medical attention When abnormality occurs Stop overheated engine after cooling run Even if the engine comes to overheat do not stop the engine immediately Abrupt stopping of an overheated engine can cause...

Page 12: ...ling speeds for 5 to 10 minutes for warming up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lu bricated before they are subjected to heavy loads This is very important for longer service life high perfor mance and economical operation Do not conduct warm up operation for a longer time than ...

Page 13: ... of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace with new tools Avoidance of prolonged time of starter oper ation Do not operate the starter for more than 10 seconds at a time even if the engine does not start Wait for at least 30 seconds before next engine cranking Continuous opera...

Page 14: ...o read For cleaning the warning caution labels use a cloth water and soap Do not use cleaning solvents gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened Replace damaged or fractured labels with new ones If any engine part on which a warning label is attached is replaced with a new one attach a new identical warning label to the new part War...

Page 15: ...ton 6 Reassembly of basic engine Reassembling cylinder block crankshaft piston and oil pan Reassembling flywheel timing gear and camshaft Reassembling cylinder head and valve mechanism 7 Fuel system Removing fuel system Disassembling inspecting and reassembling fuel system Installing fuel system 8 Lubrication system Removing lubrication system Disassembling inspecting and reassembling lubrication ...

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Page 17: ...low diagrams 1 4 2 1 Fuel system flow diagram 1 4 2 2 Lubrication system flow diagram 1 4 2 3 Cooling system flow diagram 1 5 2 4 Inlet and exhaust system flow diagram 1 5 3 Engine serial number location 1 6 4 Specifications 1 7 5 Tips on disassembling and reassembling 1 10 5 1 Disassembling 1 10 5 2 Reassembling 1 10 ...

Page 18: ...nlet Hanger Thermostat Alternator Fan V belt Oil pan Left side Front Flywheel Rear Starter Exhaust manifold Fuel injection nozzle Water pump Fuel injection pump Front Crankshaft pulley Right side Oil drain plug Flywheel housing Oil filter Oil level gauge Rear Coolant drain plug Stop solenoid Inlet cover ...

Page 19: ...ger Thermostat Alternator Fan Front V belt Oil pan Left side Flywheel Rear Starter Exhaust manifold Fuel injection nozzle Water pump Fuel injection pump Front Crankshaft pulley Right side Oil drain plug Flywheel housing Oil filter Oil level gauge Rear Coolant drain plug Stop solenoid Inlet cover ...

Page 20: ... Lubrication system flow diagram Lubrication system flow diagram To fuel tank Fuel leak off pipe Fuel injection nozzle Fuel pump From fuel tank Fuel filter Fuel injection pump Fuel injection pipe Oil pressure switch Oil main gallery Oil filter Relief valve Oil pump Oil drain plug Oil strainer ...

Page 21: ...4 Inlet and exhaust system flow diagram Inlet and exhaust system flow diagram Water pump Water bypass hose Thermostat Radiator Cooling fan Exhaust Inlet Air breather pipe blow by gas reduction From air cleaner Inlet Exhaust To muffler Blow by gas Inlet cover Exhaust manifold ...

Page 22: ...erial number location The engine serial number is stamped on the upper side of the fuel injection pump installation part located in the right side of cylinder block Stamp location of engine serial number Engine serial number ...

Page 23: ...U S gal 1 500 L 0 396 U S gal 1 758 L 0 464 U S gal Compression ratio 22 1 Fuel used JIS K2204 Diesel oil or its equivalent ASTM D975 etc Order of ignition 1 3 2 1 3 4 2 Direction of rotation Counterclockwise as viewed from flywheel side Dimenshon Length 536 mm 21 10 in 620 mm 24 41in 620 mm 24 41in Width 433 mm 17 05 in 433 mm 17 05 in 452 mm 17 80 in Height 572 mm 22 52 in 572 mm 22 52 in 640 mm...

Page 24: ...Oil pan high low approx 5 5 3 7 L 1 45 0 98 U S gal Deep oil pan Including filter approx 6 2 L 1 64 U S gal Oil pan high low approx 5 7 3 1 L 1 51 0 82 U S gal Including filter approx 8 2 L 2 17 U S gal Oil pan high low approx 7 7 4 2 L 2 03 1 11 U S gal Oil pump Type Gear pump Discharge rate 18 L 4 76 U S gal min Relief valve Type Piston valve type Valve opening pressure 0 3 to 0 4 MPa 3 to 4 kgf...

Page 25: ... A Rated voltage generating speed 5000 min 1 at 13 5 V 47 A 5000 min 1 at 27 0 V 22 A Regulator adjust ing voltage 14 7 0 3 V 12 V 50 A 26 5 0 5 V 24 V 25 A Glow plug Type Sheathed Rated voltage current 12 V 10 5 V 9 7 A 30 second duration 24 V 22 5 V 5 A 25 second duration Stop solenoid Working voltage Run off type ETS Energized to stop 12 V 10 to 15 V or less 24 V 20 to 30 V or less Run off type...

Page 26: ... losing them 4 Pay attention to assembling marks Put your marks on the parts if necessary to ensure correct reassembling 5 Carefully check each part for defects during disassembling or cleaning Do not miss symptoms which can not be detected after disassembling or cleaning 6 When lifting or carrying heavy parts exercise utmost caution to ensure safety Pay attention to balance of heavy parts when ha...

Page 27: ...7 Electrical system 2 6 2 Tightening torque table 2 7 2 1 Major bolt tightening torque 2 7 2 1 1 Basic engines 2 7 2 1 2 Fuel system 2 7 2 1 3 Lubrication system 2 8 2 1 4 Cooling system 2 8 2 1 5 Inlet and exhaust systems 2 8 2 1 6 Electrical system 2 8 2 2 Standard bolt and nut tightening torque 2 9 2 3 Standard eyebolt tightening torque 2 10 2 4 Standard union nut tightening torque 2 10 ...

Page 28: ...DC 41 Exhaust open BBDC 54 closes ATDC 10 Valve clearance Inlet 0 25 0 0098 When engine is cold Exhaust 0 25 0 0098 Fuel injection timing before TDC 17 Table 2 2 Maintenance service data table Basic engine 1 3 Unit mm in Inspection point Nominal Standard Limit Remark Rocker arm Rocker arm inside diameter ø 18 9 0 744 18 910 to 18 930 0 7445 to 0 7453 Rocker shaft outside diameter ø 18 9 0 744 18 8...

Page 29: ...ock top surface 0 05 0 0020 or less 0 10 0 0039 Repair Inside diameter ø 78 3 073 ø 78 0 030 0 060 3 07 0 0012 0 0024 78 2 3 079 Repair to oversize or replace Cylindericity 0 01 0 0004 or less Piston Outside diameter STD 78 00 3 0709 77 93 to 77 95 3 0681 to 3 0689 77 80 3 0630 0 25 OS 78 25 3 0807 78 18 to 78 20 3 0779 to 3 0787 78 05 3 0728 0 50 OS 78 50 3 0905 78 43 to 78 45 3 0878 to 3 0886 78...

Page 30: ...e main bearing Connecting rod bearings oil clearance 0 025 to 0 072 0 0010 to 0 0028 0 150 0 0059 Replace connecting rod bearings End play 0 050 to 0 175 0 0020 to 0 0069 0 500 0 0197 Replace flanged No 3 main bearings Timing gear back lash Between crankshaft gear and idler gear 0 04 to 0 12 0 0016 to 0 0047 0 30 0 0118 Replace Between idler gear and valve camshaft gear Between idler gear and pump...

Page 31: ...essure switch illuminates 0 04 to 0 06 MPa 0 4 to 0 6 kgf cm 5 6 to 8 4 psi Replace Table 2 5 Maintenance service data table Cooling system Unit mm in Inspection point Nominal Standard Limit Remark Thermostat Temperature at which valve starts opening 82 1 5 C 179 6 2 7 F Replace Temperature at which valve lift becomes 8 0 32 or more 95 C 203 F Thermoswitch At 111 3 5 C 231 8 6 3 F 30 mΩ in oil of ...

Page 32: ...5 34 lbf 26 7 to 36 1 N 2 7 to 3 7 kgf 6 00 to 8 12 lbf 6 86 N 0 70 kgf 1 54 lbf 14 7 N 1 5 kgf 3 31 lbf Replace Commutator radial runout 0 05 0 0020 0 03 0 0012 0 10 0 0039 Repair or replace Commutator outside diameter 29 4 1 158 32 0 1 260 28 8 1 134 31 4 1 236 Replace Depth of undercuts between segments 0 5 0 020 0 2 0 008 Repair Alternator IC regulator adjusting voltage at 20 C 68 F A007T02071...

Page 33: ...o 14 0 94 0 to 101 3 Crankshaft pulley nut M18 1 5 147 to 196 15 0 to 20 0 108 5 to 144 6 Rear plate mounting bolt For gen eral use M12 1 25 53 9 to 73 5 5 5 to 7 5 39 8 to 54 2 Equivalent to 7T For tractor M12 1 25 83 4 to 103 8 5 to 10 5 61 5 to 75 9 Table 2 9 Tightening torque list Fuel system Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Hollow screw fuel injection pump M12 1...

Page 34: ...orque Remark N m kgf m lbf ft Thermoswitch M16 1 5 18 6 to 26 5 1 9 to 2 7 13 7 to 19 6 Thermostat cover bolt M8 1 25 16 to 20 1 6 to 2 0 11 8 to 14 8 Thermo case bolt M16 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 1 Table 2 12 Tightening torque list Inlet and exhaust systems Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Inlet cover bolt M8 1 25 14 7 to 21 6 1 5 to 2 2 10 8 to 15 9 E...

Page 35: ...47 17 1 7 13 30 3 1 22 M10 1 25 14 0 55 33 3 4 24 60 6 1 44 M12 1 25 17 0 67 60 6 1 44 108 11 0 80 M14 1 5 22 0 87 97 9 9 72 176 17 9 130 M16 1 5 24 0 94 145 14 8 107 262 26 7 193 M18 1 5 27 1 06 210 21 4 155 378 38 5 279 M20 1 5 30 1 18 291 29 7 215 524 53 4 386 M22 1 5 32 1 26 385 39 3 284 694 70 8 512 M24 1 5 36 1 42 487 49 7 359 878 89 5 648 M27 1 5 41 1 61 738 75 3 544 1328 135 5 979 Metric c...

Page 36: ... 0 5 32 3 7 M18 1 5 24 0 94 74 5 7 5 0 5 55 3 7 M20 1 5 27 1 06 98 10 10 0 1 0 72 7 4 M24 1 5 32 1 26 147 15 15 0 1 5 108 11 1 M27 1 5 41 1 61 226 20 23 0 2 0 167 14 8 Dry Table 2 16 Standard union nut tightening torque Nominal diameter Cap nut size M mm Width across flats mm in N m kgf m lbf ft 63 M14 1 5 19 0 75 39 4 29 80 M16 1 5 22 0 87 49 5 36 100 M20 1 5 27 1 06 78 8 58 120 M22 1 5 30 1 18 9...

Page 37: ...3 1 SERVICE TOOLS 1 Basic tools 3 2 2 Special tools 3 3 ...

Page 38: ... Part No Use Tool set MM413900 Includes 1 to 5 1 Spanner MK96008010 Width across flats 8 mm 10 mm 0 32 0 39 in 2 Spanner MK96012014 Width across flats 12 mm 14 mm 0 47 0 55 in 3 Spanner MK96017019 Width across flats 17 mm 19 mm 0 69 0 75 in 4 Screwdriver MM300110 5 Tool bag MM300783 ...

Page 39: ...in removal installation Camshaft bushing installer ST332340 Punching press fitting of front camshaft bushing Compression gauge adapter ST332270 Compression measuring Oil pressure switch socket wrench 26 MD998054 Oil pressure switch removal installation Piston ring plier 31391 12900 Piston ring removal installation ...

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Page 41: ...4 1 DETERMINATION OF OVERHAUL 1 Determining overhaul timing 4 2 2 Testing compression pressure 4 3 ...

Page 42: ...ressure 1 Decreased output power 2 Increased fuel consumption 3 Increased engine oil consumption 4 Increased blow by gas through the breather due to worn cylinder liners and piston rings Visually check the blow by amount 5 Increased gas leakage due to poor seating of inlet and exhaust valves 6 Difficulty in starting 7 Increased noise from engine parts 8 Abnormal exhaust color after warm up operati...

Page 43: ...on nozzles from their positions except for the one being measured 1 Remove the injection nozzle from the cylinder head where the compression pressure is to be measured 2 Remove the glow plugs from all cylinders 3 Attach the compression gauge adapter to the injection nozzle mount and connect compression gauge 4 Stop the fuel supply 5 Crank the engine with the starter then read the compression gauge...

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Page 45: ...3 Disassembling and inspecting gear case timing gear and camshaft 5 8 3 1 Removing tappet 5 9 3 2 Removing crankshaft pulley 5 9 3 3 Removing timing gear case 5 9 3 4 Measuring timing gear backlash 5 10 3 5 Removing idler gear 5 10 3 6 Removing camshaft 5 10 3 7 Removing fuel injection pump camshaft 5 11 3 8 Removing oil pump 5 11 3 9 Removing front plate 5 11 4 Disassembling and inspecting cylind...

Page 46: ...0 Valve 3 Push rod 7 Valve cap 11 Valve spring 4 Cylinder head bolt 8 Valve lock 12 Valve stem seal 6 10 5 4 3 7 8 9 12 11 1 2 Worn rocker shaft Clogged oil hole Spring fatigue Bottom face distortion Valve guide wear damage Valve seat contact damage wear Dent Wear Stepped wear Damage End face wear damage Cracks Damage Coolant leakage Oil leakage Scale formation Gasket Carbon deposit Damaged thread...

Page 47: ... assembly Disassemble the rocker shaft assembly Note Be sure to arrange the parts in order during disassembly Keep the original combination of rocker arm and shaft assembly and when reassembling make sure to install them in their original positions to restore the same clearance between the rocker shaft and arms Disassembling rocker shaft assembly 1 3 Removing cylinder head bolt Loosen cylinder hea...

Page 48: ...Note If there is a cylinder head problem check the bolts for tightness with a torque wrench before removing the cylinder head bolts Removing cylinder head assembly 1 5 Removing valves and valve spring 1 Use a valve lifter to compress the valve spring and remove the valve lock 2 Remove the retainer valve spring and valve Note Put match marks for easy identification of the installing position if the...

Page 49: ...l Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel 3 Rear plate 2 Flywheel housing 4 Oil seal case oil seal 1 2 3 4 Frictional surface streak stepped wear cracks Ring gear damage abnormal wear Oil seal wear damage deterioration Cracks Damage Replace ...

Page 50: ... 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 Locking the flywheel Removing flywheel 2 2 Removing flywheel housing 87 21 Be careful not to damage the oil seal 1 Remove bolts from the flywheel housing 2 Remove the flywheel housin...

Page 51: ...C ENGINE 5 7 2 4 Removing oil seal case 87 21 Be very careful not to damage the oil seal 1 Remove bolts from the oil seal case 2 Pry out the oil seal case from the cylinder block using a screwdriver Removing oil seal case ...

Page 52: ...ge Ball bearing wear noise Wear damage of each gear Speedometer driven gear damage Cam lobe wear Bent shaft Cracks Damage Distortion Crankshaft pulley groove wear damage Replace Replace 1 Tappet 7 Thrust plate 11 Fuel injection pump camshaft Remove parts 9 to 11 as a unit 2 PTO gear 8 Camshaft Remove parts 6 to 8 as a unit 3 Crankshaft pulley 12 Oil pump 4 Timing gear case 9 Fuel injection pump ca...

Page 53: ...haft Stick a bar across the guide bolts to prevent the crankshaft from turning 2 Remove the crankshaft pulley 3 Take out the woodruff key of the crankshaft Removing crankshaft pulley 3 3 Removing timing gear case 87 21 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 bolts from the timing g...

Page 54: ... turning the gear Removing idler gear 3 6 Removing camshaft 87 21 Be careful not to damage the camshaft cam the cam shaft journal and the cam hole of the cylinder block 1 Rotate the camshaft to see the thrust plate bolt through the camshaft gear hole 2 By using the socket remove the thrust plate bolt 3 Remove the camshaft from the cylinder block Removing camshaft Item Standard Limit Timing gear ba...

Page 55: ...ection pump camshaft to the front side Note Use hydraulic press to separate the camshaft gear and fuel injection pump camshaft gear from the shaft Perform separating the gears as necessary Removing pump camshaft stopper bolt Removing pump shaft 3 8 Removing oil pump Remove the oil pump mounting bolt and remove the oil pump from the cylinder block Removing oil pump 3 9 Removing front plate 1 Remove...

Page 56: ...connecting rod bearing 10 Piston Remove parts 5 to 10 as a unit 15 Upper main bearing 16 Cylinder block 5 Connecting rod 11 Upper connecting rod bearing 6 Piston pin Seizing Scoring Pealing 7 8 9 10 5 6 11 16 15 14 13 12 4 1 3 2 Piston ring wear damage Ring gap clearance Piston wear seizure streak ring groove wear Cylinder damage stepped wear Connecting rod bend twist Big end thrust clearance Cran...

Page 57: ... strainer 4 3 Removing connecting rod cap 1 Lay the engine by its side 2 Mark the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when reassembling 3 Remove the connecting rod caps Note Mark the cylinder No and upper lower on connecting rod bearings to ensure correct reassembling Removing connecting rod cap 4 4 Pulling out piston 1 Turn the cra...

Page 58: ...reful not to damage main bearings b Mark each main bearing for its cylinder number Removing main bearing cap 4 7 Removing crankshaft 87 21 Be careful not to damage bearings when removing the crankshaft 1 Slowly lift the crankshaft straight up 2 Arrange the bearings in the order of disassembly so that their original positions are restored when reassembling Note a When raising the crankshaft do not ...

Page 59: ...inated and requires a great force to remove replace piston pin and or con necting rod with a new one after removing Removing the piston pin using a piston pin setting tool Removing piston pin 1 Removing piston pin 2 Push rod Connecting rod Identification mark Tool body Piston pin Piston arrow mark Piston Piston pin setting tool P N 31A91 00100 ...

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Page 61: ... idler shaft 6 8 3 3 Replacing idler shaft 6 8 3 4 Measuring clearance between camshaft journal and bushing 6 9 3 5 Replacing camshaft bushing 6 9 3 5 1 Removing camshaft bushing 6 9 3 5 2 Driving in camshaft bushing 6 9 3 6 Measuring cam lift 6 10 3 7 Measuring cam height of fuel injection pump camshaft 6 10 3 8 Inspecting tappet 6 10 3 9 Measuring clearance between tappet and tappet guide hole 6...

Page 62: ...arm and rocker shaft 1 3 Measuring perpendicularity and free length of valve spring Measure the perpendicularity and free length of the valve spring If the limit is exceeded replace the valve spring with a new one Measuring perpendicularity and free length of valve spring Item Standard Limit Bottom surface distortion 0 05 mm 0 0020 in or less 0 10 mm 0 0039 in Measuring points and directions Item ...

Page 63: ... press fit the valve guide with a press from the cylinder head top surface 3 After press fitting the valve guide insert the valve and check the movement 4 When replacing the valve with new one check the contact between the valve and the valve seat Replacing valve guide Item Standard Remark Push rod runout 0 3 mm 0 012 in or less Total indicated reading TIR 1 2 1 2 Push rod Item Nominal Standard Li...

Page 64: ... between valve seat and valve Valve sinkage 1 8 Refacing valve face If the valve face is significantly worn out reface the valve face using a valve refacer Note a Grind the valve face using the valve refacer at the specified angle b Secure the valve margin width equal to or greater than the limit If the dimensions after refacing does not meet the specified values replace the valve with a new one R...

Page 65: ...valve and valve seat Always lap the valve against the valve seat after refacing the valve seat or after replacing the valve 1 Apply a thin coat of lapping compound evenly to the valve face Note a Do not allow the compound to adhere on the valve stem b Compound spreads more evenly if it is mixed with a small amount of engine oil c Use medium grain compound 120 to 150 mesh for initial lapping then u...

Page 66: ...mm 0 24 in into glow plug hole and tap the combustion jet inner face perimeter lightly to pull out the combustion jet 2 When installing the combustion jet align the positioning hole and jet nozzle with the center of cylinder press fit with tapping by plastic hammer Removing combustion jet Press fitting combustion jet Round rod Combustion jet Combustion jet 14 30 ...

Page 67: ...ace the ring gear 2 3 Replacing ring gear 2 3 1 Removing ring gear 1 Heat the ring gear evenly using an acetylene torch or other appropriate heat source 2 With a rod placed on the periphery of ring gear tap the rod with a hammer evenly around the ring gear and remove the ring gear 2 3 2 Installing ring gear 1 Heat the ring gear evenly up to approx 150 C 176 F with an appropriate heater 2 Install t...

Page 68: ...ar and outside diameter of the idler shaft Replace the idler gear or idler shaft if the clearance exceeds the limit Measuring clearance between idler gear and idler shaft 3 3 Replacing idler shaft Press fit the idler shaft into the cylinder block to the dimension in the illustration Replacing idler shaft Item Standard Limit Timing gear backlash Between crankshaft gear and idler gear 0 04 to 0 12 m...

Page 69: ...mshaft bushing 3 5 1 Removing camshaft bushing Remove the camshaft bushing with a camshaft bushing installer 3 5 2 Driving in camshaft bushing When driving in a bushing match the oil pressure of the oil gallery and the bushing Removing camshaft bushing Driving in camshaft bushing Item Standard Limit Clearance between camshaft journal and camshaft bushing 0 050 to 0 125 mm 0 0020 to 0 0049 in 0 150...

Page 70: ... damaged Contact surface of tappet and cam 3 9 Measuring clearance between tappet and tappet guide hole Measure clearance between the tappet and tappet hole Replace the tappet with a new one if the limit is exceeded Measuring clearance between tappet and tappet guide hole Item Standard Limit Cam height of camshaft major axis 35 62 to 35 82 mm 1 4024 to 1 4102 in 34 72 mm 1 3669 in Measuring points...

Page 71: ...tration Measuring piston outside diameter Piston and piston ring size Cylinder inside diameter Size Size mark Standard Limit S T D STD ø 78 0 030 0 060 mm 3 0709 0 012 0 024 in Standard 0 2 mm 0 008 in 0 25 mm O S 0 0098 in 25 ø 78 25 0 030 0 060 mm 3 0807 0 012 0 024 in 0 50 mm O S 0 0197 in 50 ø 78 50 0 030 0 060 mm 3 0905 0 012 0 024 in Cylindericity of cylinder 0 01 mm 0 0004 in or less A B Me...

Page 72: ...om of the cylinder where the wear is minimum b When replacing the ring use the ring of the same size as the piston Insert the piston ring into the cylinder bore and push it with the piston to achieve squareness Then measure the end gap with feeler gauges Replace the piston ring if the limit is exceeded Measuring piston ring end gap Item Standard Limit Clearance between piston ring and ring groove ...

Page 73: ...ten the connecting rod cap to the specified torque Measurement with connecting rod aligner 3 To inspect the connecting rod with the piston installed turn the piston upside down and place it on a surface plate Insert a round bar having the same diameter as the crankpin into the big end bore and measure the height of the bar using a dial gauge Measuring bend of connecting rod Item Nominal Standard L...

Page 74: ...o the specified torque 2 Measure the clearance to the crank arm end play at two positions above and below the crankpin 3 If the limit is exceeded replace the connecting rod with a new one Measuring connecting rod end play Item Standard Limit Connecting rod end play 0 10 to 0 35 mm 0 0039 to 0 0138 in 0 50 mm 0 0197 in Thickness gauge 32 4 to 37 3 N m 3 3 to 3 8 kgf m 24 to 27 lbf ft ...

Page 75: ...sure the clearance between the connecting rod bearing and the crank pin again Use the undersize bearing if the limit is exceeded 8 If an undersize bearing is used grind the crank pin to the specified undersize Measuring connecting rod bearing inside diameter Measuring crankpin outside diameter Finish dimension of fillet radius Item Nominal Standard Limit Pin outside diameter STD ø 48 mm 1 89 in 47...

Page 76: ...earing cap and the crank journal again Use the undersize bearing if the limit is exceeded 8 If an undersize bearing is used grind the crank journal to the specified undersize Measuring main bearing fitting bore Measuring crank journal outside diameter Width of crankshaft thrust bearing surface Item Nomi nal Standard Limit Outside diameter of journal S T D ø 52 mm 2 05 in 51 985 to 52 000 mm 2 0466...

Page 77: ...the crankshaft If the crankshaft has been repaired by grinding or pressing inspect the crankshaft for cracks and other harmful damage using a magnetic particle method Measuring crankshaft runout 4 11 Replacing crankshaft gear 4 11 1 Removing crankshaft gear Using a gear puller remove the gear from the crankshaft Note Do not strike the gear with a hammer Removing crankshaft gear 4 11 2 Installing c...

Page 78: ...ch as defective combustion and stamping contact between piston and valve Measure the distortion of the crankcase top surface with a straight edge and feeler gauge If the measurement exceeds the limit grind the top surface with a surface grinder Measuring distortion cylinder block top surface Item Standard Limit Distortion of cylinder block top serface 0 05 mm 0 0020 in or less 0 10 mm 0 0039 in Me...

Page 79: ...ling fuel injection pump camshaft 7 9 2 5 Installing camshaft 7 10 2 6 Installing idler gear 7 10 2 7 Installing timing gear case 7 10 2 8 Installing crankshaft pulley 7 11 2 9 Installing PTO gear 7 11 2 10 Installing tappet 7 11 2 11 Installing oil seal case 7 11 2 12 Installing rear plate 7 12 2 13 Installing flywheel housing 7 12 2 14 Installing flywheel 7 12 3 Reassembling cylinder head and va...

Page 80: ...er without groove to the main bearing cap 2 Install the flange main bearing to the rearmost crankcase mating surface 3 Apply a small amount of engine oil to each bearing Installing main bearing 1 2 Installing crankshaft 1 Wash the crankshaft thoroughly with cleaning oil and dry it completely by compressed air Note When washing the crankshaft clean the inside of the oil holes completely and make su...

Page 81: ... front of the engine 3 Temporarily tighten bolts Reassembled position of main bearing cap Installing main bearing cap 1 4 Inserting side seal 1 Apply a sealant to the outer periphery of new side seals 2 With the round section of the side seals facing outward press them partway into the front and rear caps using hands 3 When the side seals are installed partway into caps use a tool with flat surfac...

Page 82: ...kshaft for rotation 1 6 Measuring crankshaft end play Attach a dial gauge to the end of the crankshaft to measure the end play If the end play deviates from the standard value loosen the main bearing cap bolts and retighten Make sure that the camshaft turns freely Measuring crankshaft end play 49 0 to 53 9 N m 5 0 to 5 5 kgf m 36 2 to 39 8 lbf ft Item Standard Limit Measuring crankshaft end play 0...

Page 83: ...ston pin guide 4 Press in the piston pin with the push rod using hydraulic press pin press in load 9807 4903 N 1000 500 kgf 2205 1102 lbf until the guide contacts the piston setting tool 5 After reassembling make sure that the piston and the connecting rod move lightly on the piston pin Reassembling piston and connecting rod 1 Reassembling piston and connecting rod 2 Reassembling piston and connec...

Page 84: ...he circumference of the piston and piston rings 2 Place the ring end gaps in diagonal positions avoiding the piston pin direction and its right angle direction 3 Fit the connecting rod bearing upper to the connecting rod aligning the lug and lug groove 4 Turn the crankshaft to place the crank pin of the assembling cylinder to the top dead center 5 Face the front mark arrow stamped on the piston to...

Page 85: ...ion 4 Tighten the connecting rod cap nuts evenly and progressively to the specified torque 5 Inspect end play of the connecting rod If end play is small loosen and retighten the cap nuts Installing connecting rod caps Tightening connecting rod cap nuts 1 11 Installing oil strainer 1 Invert the cylinder block to face up the oil pan mounting surface 2 Make sure that the end of the strainer does not ...

Page 86: ... the oil pan mounting bolts diagonally in several steps and finally to the specified torque Applying sealant to oil pan mounting face of cylinder block Sealant application pattern Cutting end of sealant tube Installing oil pan R17 4 front and rear locations in total Apply sealant as lined 9 5 0 37 R7 from hole center same for all 17 holes 36 1 42 R40 corresponding to hole centers same for all 4 co...

Page 87: ... Install the oil pump to the crankcase and secure it with the bolt 3 Ensure that the oil pump gear rotates smoothly Installing oil pump 2 3 Rotating crankshaft 1 Install two bolts in the flywheel mounting holes of the crankshaft 2 Rotate the crankshaft with a bar using the bolts to bring the No 1 cylinder at the top dead center Rotating crankshaft 2 4 Installing fuel injection pump camshaft 1 Inse...

Page 88: ...d make sure there is end play Installing camshaft Installing thrust plate 2 6 Installing idler gear 1 Apply engine oil to the idler gear shaft 2 With aligning the timing mark install the idler gear 3 Check the backlash between the gears Align the timing marks 2 7 Installing timing gear case 1 Apply sealant to the gasket to prevent it from displacing and install the gasket on the front plate 2 Appl...

Page 89: ... gear Drive the PTO gear into the timing gear case Ensure that the side of the gear with no oil hole face the rear of the engine Installing PTO gear 2 10 Installing tappet Coat the periphery of tappets with engine oil insert them into the tappet holes and place them gently on the camshafts Inserting tappet 2 11 Installing oil seal case 87 21 Be careful not to damage the oil seal 1 Install the new ...

Page 90: ...ywheel 87 21 The person who holds the pulley must be very careful to assure safety by communicating with the person who is installing the flywheel 1 One person must firmly hold the pulley with a wrench to prevent the crankshaft from turning 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 T...

Page 91: ...eal that comes in contact with the valve guide 1 Apply engine oil to the lip of the valve stem seal 2 Push the shoulder of the valve stem seal and fit the valve stem steal into the valve guide 3 Make sure the valve stem steal is fully inserted into the valve guide Installing valve stem seal 3 3 Installing valve spring Install the valve spring with its white or yellow enamel painted side facing upw...

Page 92: ...t 3 6 Installing cylinder head assembly Align the cylinder head to the locating guide bolts and install the cylinder head Installing cylinder head 3 7 Tightening cylinder head bolts In the numerical order as shown in the illustration tighten cylinder head bolts progressively to the specified torque Tightening cylinder head bolts 3 8 Inserting push rod 1 Insert each push rod into its hole in the cy...

Page 93: ...head Tighten the mounting bolts to the specified torque Installing rocker shaft assembly 3 11 Adjusting valve clearance Adjust the valve clearance For adjusting procedures refer to Adjustment and Operation Adjusting valve clearance 3 12 Installing rocker cover 1 Make sure that the gasket is firmly installed into the rocker cover 2 Tighten the rocker cover mounting nuts to the specified torque Inst...

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Page 95: ...uel injection nozzle 8 7 2 2 Fuel injection pump 8 8 2 2 1 Inspecting fuel injection pump on engine 8 8 2 2 2 Disassembling and inspecting fuel injection pump 8 8 2 3 Governor 8 14 2 3 1 Disassembling and inspecting governor 8 14 2 4 Inspecting fuel pump 8 16 2 5 Fuel filter 8 17 2 5 1 Disassembling inspecting and reassembling fuel filter 8 17 3 Installing fuel system 8 18 3 1 Installing fuel inje...

Page 96: ...njection pipe to prevent dust from entering the fuel system Removing fuel system Removing sequence 1 No 1 fuel injection pipe 5 Fuel leak off pipe 2 No 2 fuel injection pipe 6 Fuel injection nozzle 3 No 3 fuel injection pipe 7 Governor 4 No 4 fuel injection pipe 8 Fuel injection pump 8 5 4 3 2 1 6 7 Replace Replace ...

Page 97: ...e Using a wire or screwdriver remove the holder gasket Removing fuel injection nozzle 1 3 Removing governor assembly 1 Remove the tie rod cover 2 Using a pair of cutting pliers remove the tie rod spring Disconnect the tie rod from the fuel injection pump 3 Remove the governor assembly Removing governor assembly 1 4 Removing governor weights 1 Remove the sliding sleeve 2 Remove the sliding sleeve s...

Page 98: ...g a pair of cutting pliers remove the tie rod spring Disconnect the tie rod from the fuel injection pump 3 Remove the fuel injection pump Note Note the thickness of shim pack for the adjustment of the fuel injection timing Removing tie rod Removing fuel injection pump Adjusting shim ...

Page 99: ...ing and inspecting fuel injection nozzle Disassembling and inspecting fuel injection nozzle Disassembling sequence 1 Nozzle retaining nut 4 Pin 7 Nozzle holder 2 Nozzle tip assembly 5 Spring 3 Piece 6 Washer 7 6 5 4 3 2 1 Wear Fatigue and perpendicularity Wear and damage Carbon deposit clogged injection nozzle tip ...

Page 100: ...jection valve opening pressure Replacing fuel injection nozzle tips 2 1 3 Inspecting fuel spray pattern of fuel injec tion nozzle 1 When adjusting the nozzle opening pressure using the nozzle tester check for nozzle hole condition and fuel spray pattern 2 Checking points of fuel spray are as follows Fuel is injected from all spray holes simultaneously Fuel is injected conically at the specified sp...

Page 101: ...do not change the combination of the valve and body 3 Tighten the nozzle tip retaining nut to the specified torque 4 If the spray pattern is still faulty after cleaning and adjusting replace the nozzle tip Note When using a new nozzle tip remove the anti corrosive agent from the nozzle tip and clean the nozzle tip in wash oil Then clean the tip again in the fuel before assembly Cleaning nozzle tip...

Page 102: ...rve exhaust color during sudden acceleration under no load Observe exhaust color under load No remarkable black smooke is emitted Nozzle injection condition Remove the nozzle and reassemble them so that spray holes face outward Rotate the starter to carefully observe the spray pattern The spray pattem must be good 1 Tappet guide pin 7 Plunger spring 13 Delivery valve spring 2 Lock plate 8 Spring u...

Page 103: ...de pin s flat edge with the counterpart in the housing 3 While pushing in the tappet pull out the tappet guide pin with long nose pliers Removing tappet guide pin Removing tappet 2 2 4 Removing plunger 1 Remove the tappet adjusting shim 2 Using tweezers remove the plunger together with the spring lower seat 3 Remove the plunger spring 4 Remove the control sleeve together with the spring upper seat...

Page 104: ... Removing delivery valve 2 2 6 Removing plunger barrels 87 21 a Plungers and plunger barrels are precision machined parts Do not smear or scratch them b Keep the combination of the plunger barrel and plunger for each cylinder when removing Do not mix the plunger barrel with the plunger of a differ ent cylinder Remove the plunger barrels Note a When replacing plunger barrels or delivery valves do n...

Page 105: ...rel groove the plunger barrel will not be installed correctly Make sure that O ring is not protruded from the pump housing when the delivery valve holder is snugly tightened Installing plunger barrel Tightening torque M12 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 8 to 14 5 lbf ft M14 19 6 to 24 5 N m 2 0 to 2 5 kgf m 14 5 to 18 1 lbf ft Air bleed plug Tightening torque 9 81 to 13 7 N m 1 0 to 1 4 kgf m...

Page 106: ...ol sleeves and the control rack so that the central tooth of each sleeve is aligned with the corresponding notch on the rack 2 Insert the plunger into the hole in the sleeve Assembling control sleeve Installing plunger 2 2 11 Assembling tappet 87 21 Always use new lock plate Never reuse the lock plate that has been removed With the tappet pushed in move the control rack When the tappet s groove an...

Page 107: ...trol rack for smooth opera tion 1 Remove the pump housing from the vise and check the control rack for smooth movement If the movement is not smooth the following defects are suspected Sliding of the element is poor A foreign substance is present in the teeth of rack or sleeve The valve holder is overtightened 2 Check the injection timing Inspecting control rack for smooth operation 39 2 to 49 0 N...

Page 108: ... 9 Grooved pin 15 Governor spring lever Remove 11 to 15 as an as sembly 4 Sliding sleeve 10 Governor shaft 5 Sliding sleeve shaft 11 Governor lever 16 Stop solenoid 6 Governor weight 12 Start spring 17 Rack set screw 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Levers should operate smoothly Worn or damaged weight Sliding sleeve wear damage smooth sliding Shaft scoring Worn or damaged lever contact w...

Page 109: ...he direction of the arrow until a slight resistance is felt Note This is the initial resistance by the governor spring Do not pull the tie rod further to try to overcome the resistance 4 While holding the tie rod in this position screw in the torque spring set until the notched line on the control rack is aligned with that on the pump body 5 With the both notched lines aligned lock the torque spri...

Page 110: ...apply the specified voltage and check for operation and fuel leakage For the type with filter element remove the cover and clean or replace the filter element 2 Electromagnetic diaphragm type fuel pump Do not disassemble this pump Apply the specified voltage and check for operation and fuel leakage Plunger fuel pump standard version Plunger fuel pump compact size version Electromagnetic diaphragm ...

Page 111: ... the case bottom or in the element replace the filter as an assembly Replace the fuel filter every 400 hours Check the filter every 100 hours If defective replace the filter regardless of the replacement interval Inspecting fuel filter cartridge type 3 4 5 1 2 10 8 7 9 6 Air bleed plug Do not remove Wash in light oil every 100 hours Replace every 500 hours Check for accumulation of water or sedime...

Page 112: ...g fuel system Fuel leak off pipe nut 20 6 to 24 5 N m 2 1 to 2 5 kgf m 15 2 to 18 1 lbf ft Fuel injection pipe nut 24 5 to 34 3 N m 2 5 to 3 5 kgf m 18 1 to 25 3 lbf ft Nozzle holder 49 0 to 58 8 N m 5 0 to 6 0 kfg m 36 2 to 43 4 lbf ft Replace Replace ...

Page 113: ...injection pump housing Installing fuel injection pump Removing tie rod 3 2 Installing governor weights Install the governor weights onto the rear end of the pump camshaft and tighten the sliding sleeve shaft to the specified torque Installing governor weights 3 3 Installing sliding sleeve Install the sliding sleeve onto the sliding sleeve shaft Ensure that the sleeve slides smoothly Installing sli...

Page 114: ...ion nozzle Installing fuel injection nozzle 3 6 Installing fuel pipes 1 Install the fuel leak off pipe onto the fuel injection nozzles 2 Install the fuel injection pipes and hold them in place with clamps 3 Tighten the fuel leak off and fuel injection pipe nuts to the specified torques Installing fuel pipe 49 0 to 58 8 N m 5 0 to 6 0 kgf m 36 2 to 43 4 lbf ft Replace Tightening torque for fuel inj...

Page 115: ...oil pressure switch 9 3 2 Disassembling inspecting and reassembling lubrication system 9 4 2 1 Inspecting the oil pump 9 4 2 2 Inspecting relief valve 9 4 2 3 Inspecting oil pressure switch 9 5 3 Installing lubrication system 9 6 3 1 Installing oil pressure switch 9 7 3 2 Installing relief valve 9 7 3 3 Installing oil filter 9 7 ...

Page 116: ...RICATION SYSTEM 9 2 1 Removing lubrication system Removing lubrication system Removing sequence 1 Oil filter 3 Oil pressure switch 5 Oil strainer 2 Relief valve 4 Oil pan 5 4 3 2 1 Replace Replace Replace ...

Page 117: ...il filter using a filter wrench Removing oil filter 1 2 Removing relief valve Remove the relief valve Removing relief valve 1 3 Removing oil pressure switch Using an oil pressure switch socket wrench remove oil presssure switch Removing oil pressure switch Oil pressure switch socket wrench P N MD998054 ...

Page 118: ...pressure oil pressure when the engine is running at rated speed of the relief valve If the measured value is out of the standard remove the plug and make an adjustment by increasing and decreasing the shim thickness Engine oil pressure take out port Next to the oil filter Rp 1 8 thread PS 1 8 Inspecting relief valve Engine oil pressure measuring port Inspect for damage and smooth rotation Item Sta...

Page 119: ...il hole and lightly push it The switch is normal if there is no continuity between them If there is continuity when the rod is pushed in replace the switch 3 When air pressure of 0 05 MPa 0 5 kgf cm 7 1 psi is applied from the oil hole and there is no continuity the switch is normal Also check for air leaks If there are air leaks the diaphragm is damaged Replace the switch Inspecting oil pressure ...

Page 120: ...4 1 to 53 9 N m 4 5 to 5 5 kgf m 32 5 to 39 8 lbf ft 7 85 to 11 8 N m 0 8 to 1 2 kgf m 5 8 to 8 7 lbf ft Replace Replace Replace Press oil pan mounting bolt 9 8 to 12 7 N m 1 0 to 1 3 kgf m 7 2 to 9 4 lbf ft Cast oil pan mounting bolt 24 5 to 30 4 N m 2 5 to 3 1 kgf m 18 1 to 22 4 lbf ft ...

Page 121: ...ling relief valve Install the relief valve to the cylinder head side face and tighten it to the specified torque Installing relief valve 3 3 Installing oil filter 1 Apply a light coating of engine oil to the filter gasket 2 Screw the filter in by hand When the filter gasket contacts the mounting surface screw the filter in another turn Installing oil filter Oil pressure switch socket wrench P N MD...

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Page 123: ...mbling cooling system 10 3 2 1 Disassembling and inspecting thermostat10 3 2 2 Inspecting thermostat 10 3 2 3 Inspecting thermoswitch 10 4 2 4 Inspecting thermostat 10 4 2 4 1 Inspecting water pump for smooth rotation10 4 3 Installing cooling system 10 5 3 1 Installing cooling system 10 5 ...

Page 124: ...stem Disassembling sequence 1 Fan 4 Thermostat case 7 Water pump 2 Fan pulley 5 Thermo switch 3 V belt 6 Pipe 5 4 6 7 1 2 3 Crack water leak damage Replace Crack deterioration damage Crack water leak damage Replace Crack extension wear damage Crack deformation damage ...

Page 125: ...suring the water temperature Record the temperature at the conditions shown in the table below If the temperatures are not within the standard range replace the thermostat Note a Stir the water in the container with a stick to ensure uniform temperature distribution b Before installing the thermostat be sure to check the valve opening temperature stamped on the thermostat valve side face Inspectin...

Page 126: ...mperature If the resistance extremely deviates from the standard replace the thermoswitch Reassembling thermostat 2 4 Inspecting thermostat 2 4 1 Inspecting water pump for smooth rotation 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 Checking impeller and shaft for smooth rotation Temperatuve ...

Page 127: ...talling cooling system Installing cooling system Apply TreeBond 1104 to the thread Replace Replace 16 to 20 N㨯m 1 6 to 2 0 kgf㨯m 11 8 to 14 8 lbf㨯ft 18 6 to 26 5 N㨯m 1 9 to 2 7 kgf㨯m 13 7 to 19 6 lbf㨯ft 39 2 to 49 0 N㨯m 4 0 to 5 0 kgf㨯m 28 9 to 36 1 lbf㨯ft ...

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Page 129: ...haust manifold 11 2 2 Disassembling inspecting and reassembling inlet and exhaust systems 11 3 2 1 Inspecting intake cover and exhaust manifold 11 3 2 2 Measuring distortion of inlet and exhaust manifold 11 3 3 Installing inlet and exhaust systems 11 4 3 1 Installing intake cover and exhaust manifold 11 4 ...

Page 130: ...EMS 11 2 1 Removing inlet and exhaust systems 1 1 Removing intake cover and exhaust manifold Removing intake cover and exhaust manifold Removing sequence 1 Intake pipe 2 Intake cover 3 Exhaust manifold 3 1 2 Replace Replace ...

Page 131: ...aight edge and thickness gauges measure distortion across the cylinder head mounting surfaces of the inlet cover and exhaust manifold If the measured distortion exceeds the limit correct by grinding or replace the part Measuring distortion on exhaust manifold Crack damage contaminant adhension of dirt corrosion Crack Crack corrosion Item Limit Distortion on mounting surfaces of intake cover and ex...

Page 132: ... inlet and exhaust systems 3 1 Installing intake cover and exhaust manifold Installing intake cover and exhaust manifold Replace Replace 14 7 to 21 6 N㨯m 1 5 to 2 2 kgf㨯m 10 8 to 15 9 lbf㨯ft 14 7 to 21 6 N㨯m 1 5 to 2 2 kgf㨯m 10 8 to 15 9 lbf㨯ft ...

Page 133: ... 12 17 2 4 10 Inspecting continuity of yoke assembly 12 17 2 4 11 Inspecting insulation between yoke body and brush 12 17 2 4 12 Inspecting pinion 12 18 2 4 13 Inspecting front bracket 12 18 2 4 14 Inspecting gears of starter 12 18 2 4 15 Inspecting continuity of magnetic switch between M terminal and case 12 18 2 4 16 Inspecting insulation of magnetic switch between M terminal and B terminal 12 1...

Page 134: ...ELECTRICAL SYSTEM 12 2 1 Removing electrical system 1 1 Removing starter Removing starter Removing sequence 1 2 1 Harness 2 Starter ...

Page 135: ...d E terminal is negative 2 Do not use any high voltage tester such as megger 3 Do not disconnect lead wire from B terminal of the alternator while the engine is running 4 Battery voltage is constantly applied to B terminal of the alternator Do not ground at this terminal 5 Do not short circuit or ground at L terminal For a built in IC regulator type 6 When a steam cleaner is used do not allow the ...

Page 136: ...he battery ground cable 2 Connect B terminal of the alternator to the ammeter then connect the voltmeter between B terminal and ground 3 Connect the battery ground cable 4 Start the engine 5 Immediately apply all loads such as lamps 6 Increase the engine speed and measure the maximum output current at the specified alternator rotation speed with the voltmeter indicated the specified value 7 If the...

Page 137: ...ELECTRICAL SYSTEM 12 5 1 3 Removing alternator Removing alternator Removing sequence 5 1 4 3 2 1 Harness 3 Generator brace 5 Alternator 2 Flange bolt 4 Bolt ...

Page 138: ...ELECTRICAL SYSTEM 12 6 1 4 Removing stop solenoid Removing stop solenoid Removing sequence 1 2 1 2 ETR type ETS type 3 1 Nut 2 Stop solenoid 3 Rubber cap ETS type ...

Page 139: ...ELECTRICAL SYSTEM 12 7 1 5 Removing glow plug Removing glow plug Removing sequence 1 2 e t a l p g u l p w o l G 2 g u l p w o l G 1 ...

Page 140: ... In normal condition the pinion pops out when the switch is turned ON and the starter rotates at or more the specified rotation speed If the terminal voltage current or rotation speed does not meet the standard disassemble inspect and repair the starter Test at no load A V B S M Ammeter Battery 12V Voltmeter Switch Starter Item Standard Starter model name M001T68281 M008T70471A M008T81071A Nominal...

Page 141: ...acking 14 Front bracket 3 Rear bracket 9 Packing 15 Overrunning clutch 4 Brush holder 10 Plate 16 Internal gear 5 Armature 11 Ball 17 Gear shaft 6 Bearing 12 Planetary gear 1 14 10 2 17 12 11 8 3 4 16 15 9 13 5 6 7 Worn pinion gear Bearing loose noisy binding Overrunning clutch operation Gear worn damaged Yoke circuit open or shorted Brush wear insulation Magnet switch circuit open or shorted Arma...

Page 142: ... Ball 18 Internal gear 5 Brush assembly 12 Planetary gear 19 Gear shaft 6 Armature 13 Lever 7 Yoke 14 Front bracket 1 14 2 13 10 9 12 11 8 6 15 16 17 18 19 5 7 4 3 Coil open Coil shorted Coil continuity Rough surface of commutator Commutator worn Gear damaged Gear worn Worn pinion gear Coil open Bearing loose noisy binding Overrunning clutch operation Gear worn damaged Worn brush Worn brush Spring...

Page 143: ...op the rotation of the armature and the pinion 3 Place an appropriate tube on the pinion stopper Tap the tube with a hammer to drop the pinion stopper to the clutch side This will expose the stopper ring 4 Remove the stopper ring with pliers and remove the pinion Note Do not reuse the stopper ring for reassembly Connection to move the pinion forward Removing pinion 2 3 2 Removing magnetic switch D...

Page 144: ...the brush holder and brush assembly by sliding on the socket Removing brush holder and brush assembly 2 3 5 Removing armature and yoke 1 Remove the armature and the yoke 2 Remove the packing from the internal gear 3 Remove the packing and plate on the lever support 4 Remove the ball from the internal gear 5 Remove the planetary gears Removing armature and yoke Rear bracket Through bolt Brush holde...

Page 145: ...e front bracket and remove the lever Removing overrunning clutch 2 3 7 Removing gear shaft 1 Remove the stopper ring and then the stopper 2 Separate the overrunning clutch internal gear and gear shaft Removing gear shaft Lever Front bracket Gear shaft Overrunning clutch Internal gear Stopper ring Stopper Overrunning clutch Internal gear Gear shaft ...

Page 146: ...lder for insulation Check that there is no continuity between each brush holder and the brush holder base If continuity is observed replace the whole brush holder assembly Check the brush holders for looseness Checking brush holder for grounding Item Standard Limit Brush length M001T68281 16 5 mm 0 650 in 10 0 mm 0 394 in M008T70471A M008T81071A 17 5 mm 0 689 in 11 0 mm 0 433 in Measure the length...

Page 147: ... armature with a new one Measuring commutator outside diameter 2 4 6 Measuring undercut depth Measure the depth of undercutting between the commutator segments If the measured value is less than the limit repair or replace with a new part Measuring commutator mica depth Item Standard Limit Commutator radial runout M001T68281 0 05 mm 0 0020 in 0 10 mm 0 0039 in M008T70471A M008T81071A 0 03 mm 0 001...

Page 148: ...there is no continuity between the commutator and the shaft core If any continuity is observed replace the armature with a new one Inspecting insulation between commutator and shaft 3 Check that there is continuity between segments in various combinations If poor or no continuity is observed replace the armature with a new one Inspecting continuity between segment 2 4 8 Inspecting rear bracket Rep...

Page 149: ... Inspecting overrunning clutch 2 4 10 Inspecting continuity of yoke assembly Check that there is continuity between M terminal of field coil and the lead wire for the brush If no continuity is observed replace the yoke assembly with a new one 2 4 11 Inspecting insulation between yoke body and brush Check that there is no continuity between yoke body and brush If continuity is observed replace the ...

Page 150: ...for wear or damage If faulty replace the starter 2 4 15 Inspecting continuity of magnetic switch between M terminal and case Check that there is continuity between M terminal and case If no continuity is observed replace the magnetic switch with a new one 2 4 16 Inspecting insulation of magnetic switch between M terminal and B terminal Check that there is no continuity between M terminal and B ter...

Page 151: ...f ft Magnet switch 4 1 to 7 6 N m 0 4 to 0 8 kgf m 3 0 to 5 6 Ibf ft Apply Multemp 6129 Kyodo Yushi made Apply Molykote RAG650 Dow Corning Toray made Terminal B nut 9 8 to 11 8 N m 1 0 to 1 2 kgf m 7 2 to 8 7 lbf ft Terminal B nut 9 8 to 11 8 N m 1 0 to 1 2 kgf m 7 2 to 8 7 lbf ft Apply Multemp OA 171 Kyodo Yushi made Apply Multemp 6129 Kyodo Yushi made Apply Molykote RAG650 Dow Corning Toray made...

Page 152: ...g apply grease to the inner race groove of the front bracket bearing Be sure to use a new stopper ring Do not reuse the stopper ring that has been removed 1 Put the overrunning clutch through the front bracket 2 Fit the internal gear into the gear shaft 3 Put the gear shaft through the overrunning clutch and install the stopper on it 4 Install the stopper ring firmly to the shaft groove of overrun...

Page 153: ...tment of play in the axial direction of the gear shaft is not necessary because its required amount is automatically secured Installing gear shaft 2 5 4 Installing yoke and armature 1 Install the planetary gears on the gear shaft 2 Install the packing on the internal gear 3 Install the plate and packing 4 Install the yoke on the front bracket 5 Apply grease to the armature shaft end and install a ...

Page 154: ...mbly 2 5 6 Installing rear bracket Install the rear bracket to the yoke and tighten the through bolt and the brush holder screws Installing rear bracket 2 5 7 Installing magnetic switch 1 Install the magnetic switch and tighten the screws 2 Connect the lead to the terminal M and secure it with the fixing nut Installing magnetic switch Socket Brush holder Brush assembly Rear bracket Through bolt Br...

Page 155: ...sure the distance over which the pinion has returned movement amount 5 If the measured value is out of the standard increase or decrease the number of packings between the magnetic switch and the front bracket for adjustment or replace the lever with a new one Note When the number of packings is increased the pinion clearance becomes small Wiring during inspection of pinion clearance Inspecting pi...

Page 156: ... Nut 5 Rotor bearing 9 Rectifier 2 Pulley spacer 6 Stator 10 Nut set 3 Through bolt 7 Rear bracket 4 Front bracket bearing 8 Regulator 1 2 3 4 6 9 7 8 10 5 Crack damage Rotation Deformation and damage Broken wire and ground of coil Rotation Crack damage Sliding state and wear of brushes Dirt damage and seizure of slip ring and coil resistance Short cincuit and open circuit ...

Page 157: ...ing the rotor in a vise be sure to hold the base of the rotor claw Do not hold the rotor claw as it causes damage to the claw 1 Apply a cloth to the rotor and set it in a vise 2 Remove the pulley nut and then pull out the pulley and spacer 3 Remove the rotor from the front bracket Removing pulley 2 6 3 Removing stator 87 21 Unsoldering must be finished as quickly as possible Extended heating will ...

Page 158: ...uch as possible The current flow during test is significantly lower than the current that normally flows in the rectifier by which the accurate resistance may not be measured using a tester and this tendency is noticeable if the measuring range is small Inspecting rectifier 2 6 5 Inspecting rotor 1 Check that there is continuity between slip rings If no continuity is observed replace the rotor wit...

Page 159: ...ere is no continuity between each lead wire and the stator core If continuity is observed replace the stator Note The core cannot be replaced as a single item Checking for continuity between leads Checking for grounding between the leads and the core 2 6 7 Inspecting brushes for wear Measure the length of the brushes If the measured value is less than the limit replace both the brush holder assemb...

Page 160: ...r bearing Insert the rotation retaining snap ring so that the highest protruded section of the ring is positioned at the deepest section of the groove 2 When replacing the rear bearing press fit the rear bearing so that the groove on the periphery of the bearing faces the snap ring side 3 When press fitting the rear bearing into the rear bracket heat the rear bracket to 50 to 60 C 122 to 140 F fir...

Page 161: ...low plug Check continuity between the terminal and the body as shown in the illustration If no continuity is indicated or the resistance is large replace the glow plug with a new one Inspecting glow plug Item Standard Resistance value 0 55 Ω ...

Page 162: ...ELECTRICAL SYSTEM 12 30 3 Installing electrical system 3 1 Installing glow plug Installing glow plug 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 8 to 14 5 Ibf ...

Page 163: ...ELECTRICAL SYSTEM 12 31 3 2 Installing stop solenoid Installing stop solenoid ETR type ETS type 39 2 to 49 N m 4 0 to 5 0 kgf m 28 9 to 36 2 Ibf ft 39 2 to 49 N m 4 0 to 5 0 kgf m 28 9 to 36 2 Ibf ft ...

Page 164: ...to 45 from the above condition and temporarily tighten the nut 6 Move the control rack side to side and make sure that there is play of approx 0 15 to 0 20 mm 0 0059 to 0 0079 in 7 Tighten the nut to the specified torque 3 3 2 Verification after reassembling ETR type 1 After starting the engine turn the starter switch key to the OFF position and make sure that the stop solenoid activates and the e...

Page 165: ... tie rod At this time the clearance of A should be 0 mm 0 in position where the plunger is also turned by screwing in the stop solenoid 5 Turn the stop solenoid in the reverse direction by 30 to 45 from the above condition at this time the clearance between the control rack and shaft is 0 15 to 0 20 mm 0 0059 to 0 0079 in and tighten the nut to the specified torque 6 Finally reassemble the rubber ...

Page 166: ...the engine stops 2 During engine start turn the starter switch key to the ON position and make sure that the solenoid activates and the engine enters a stopped state 3 Turn the starter switch key from the OFF position to ON and then to START position Make sure that the solenoid activates with the key turned to ON and that the solenoid instantly stops to activate with the key turned to START ...

Page 167: ...ELECTRICAL SYSTEM 12 35 3 5 Installing alternator Installing alternator ...

Page 168: ...ELECTRICAL SYSTEM 12 36 3 6 Installing starter Installing starter 9 81 to 11 8 N m 1 0 to 1 2 kgf m 7 2 to 8 7 Ibf ft ...

Page 169: ...fuel system 13 6 1 5 1 Bleeding air from fuel filter 13 6 1 5 2 Bleeding air from fuel injection pump 13 6 1 6 Adjusting V belt tension 13 7 2 Break in operation 13 8 2 1 Starting up 13 8 2 2 Inspecting engine condition after starting up 13 8 2 3 Break in operation time 13 8 2 4 Inspection and adjustment after break in operation 13 8 3 Performance test JIS standard 13 9 3 1 Engine equipment condit...

Page 170: ...g the valve clearance from the No 1 cylinder and adjust the valve clearance of other cylinders according to the ignition order Note To set the next cylinder to the compression top after adjustment of No 1 cylinder rotate the crankshaft in the forward direction clockwise toward the timing gear case by the angle corresponding to the number of cylinders 3 Insert a thickness gauge between the rocker a...

Page 171: ...et the control rack to the medium position of the operating range 8 Feed fuel from the fuel hose and check that the fuel flows out from the delivery holder 9 Rotate the crankshaft forward clockwise The fuel injection timing is the moment when the fuel stops flowing from the delivery valve holder outlet Note When the fuel stops flowing rotate the crankshaft backward counterclockwise to allow the fu...

Page 172: ...ve installed check the fuel injection timing as follows Note If the fuel injection pump and the engine are dirty removing the delivery valve allows dirt and dust to enter the fuel injection pump 5 Remove the tie rod cover and disconnect the tie rod from the control rack 6 Set the control rack to the medium position in the operating range and then remove the No 1 fuel injection pipe on the nozzle s...

Page 173: ...ll of the specified locations c When inspecting and adjusting the governor be prepared to operate the engine stop lever manually in anticipa tion of engine overrevving running at an extremely high speed 1 4 1 Preparation 1 Operate the engine to warm up until coolant temperature reaches 60 C or higher 2 Make sure that valve clearance fuel injection timing nozzle opening pressure spray condition and...

Page 174: ...vity type fuel will flow into the filter by itself 2 Cock type paper element Place the fuel filter cock lever in the OPEN position and push the button several times to bleed the filter Note When the fuel supply is gravity type fuel will drop by itself and when the fuel supply is the pump type fuel and air in the filter will flow out with the starter key positioned ON Bleeding air from fuel filter ...

Page 175: ... within the specified value Note When replace the belt with a new one the deflection should be 8 to 13mm 0 31 to 0 51mm because of the new belt is extensible After replacing operate the engine at idling speed for 5 to 10 minutes and adjust the belt tension to set the deflection 10 to 15 mm 0 39 to 0 6mm Adjusting deflection of V belt Belt tension with pushing force of approx 98 N 10 kgf 22 lbf App...

Page 176: ...d take appropriate measures 1 The oil pressure must be within the specified value 2 The coolant temperature must be within the specified value 3 The engine must be free from any leakages such as oil coolant and fuel Pay special attention to oil leakage from the fitting face of turbocharger lube oil pipe 4 Check for an abnormal noise Note Knocking noise will disappear as the coolant temperature ris...

Page 177: ... 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 Low idle test Co...

Page 178: ...rrection equation use ޓ 6JG TCPIG QH EQTTGEVKQP HCEVQT ǩ c KU CU HQNNQYU 0 9 ǩ c 1 1 Natural aspiration engine and engine with mechanically driven air charger Turbocharged engine without air cooler or with air to air cooler Turbocharged engine with air to liquid cooler f a 㨯 99 Pd T 298 f a 㨯 99 Pd T 298 f a 㨯 99 Pd T 298 Calculation of correction factor fa Calculation of engine factor fm fm 0 036...

Page 179: ... 1 3 2 Problem Knocking 14 4 1 4 Overheating 14 5 1 4 1 Check items before troubleshooting 14 5 1 4 2 Problem Overheating 14 5 1 5 Excessive black smoke 14 6 1 5 1 Check items before troubleshooting 14 6 1 5 2 Problem Excessive black smoke 14 6 1 6 Idling malfunction 14 7 1 6 1 Check items before troubleshooting 14 7 1 6 2 Problem Unstable idling 14 7 1 7 Low output 14 8 1 7 1 Check items before t...

Page 180: ...enon Especially a similar phenomenon occurs in troubles of the fuel injection pump fuel injection nozzles and compression pressure It is therefore necessary to conduct a careful study to determine the cause From the reason above troubleshooting described in this section is summarized as the inspecting order from items which are more likely to cause problems or items easy to inspect in sequence 2 T...

Page 181: ...ow plug Is the electrical wiring normal If the preheating device is equipped with a fuel pump does the pump operate when the key switch is turned ON Inspect wiring of fuel pump Does fuel flow in the fuel line Adjust engine Inspect fuel injection nozzles Inspect fuel injection pump Is fuel drained when the air bleeding screw of the fuel injection pump is loosened Inspect fuel filter fuel pipe and f...

Page 182: ...sene 1 3 2 Problem Knocking Problem Knocking NO NO NO YES YES YES YES Adjust fuel injection timing Examine fuel injection nozzles Is the compression pressure in cylinders normal Is the fuel injection timing normal fuel injection timing is early Are fuel injection nozzles normal drop in injection valve opening pressure and faulty Inspecting valves pistons piston rings and cylinder head gasket Is th...

Page 183: ...p If the engine itself is normal and overheat occurs measure the ambient and coolant temperatures in the loaded condition thermostat full open If the temperature difference is greater than 60 C 140 F the investigation into other components as well as the engine is suggested Problem Overheating Does the engine run continuously under overload Examine the cause of load Repair cooling system Adjust fu...

Page 184: ...set Adjust engine Is the compression pressure normal Inspect fuel injection nozzles Inspect valves cylinder head gasket pistons and piston rings Inspect fuel injection pump NO YES YES YES YES NO NO NO Is the smoke set amount of the fuel injection pump normal Is the engine correctly adjusted valve clearance excessive fuel injection timing out of order Are fuel injection nozzles normal spray state i...

Page 185: ...ble idling Problem Unstable idling YES YES YES NO NO NO Adjust engine Inspect fuel injection nozzles Inspect valves pistons and piston rings Inspect fuel injection pump and governor system Is the engine correctly adjusted engine idle speed valve clearance and fuel injection timing Are fuel injection nozzles normal spray state injection valve opening pressure too high Is the compression pressure no...

Page 186: ...ufficient Adjust engine YES Fuel pump Inspect fuel injection nozzles Inspect valves cylinder head gasket pistons and piston rings Inspect fuel injection pump Does fuel including the fuel amount in the fuel tank flow sufficiently in the drop type Does fuel flow with the switch turned ON in the electromagnetic type Inspect fuel filter fuel pipe and fuel tank Is the engine correctly adjusted valve cl...

Page 187: ...and width 4 Cylinder head bottom face distortion 5 Connecting rod bearings oil clearance 6 Rocker arm inner diameter and rocker shaft diameter 7 Piston pin boss inner diameter and piston pin diameter 8 Valve clearance 9 Fuel injection nozzle opening pressure 10 Camshaft journal diameter and camshaft bushing inner diameter 11 Crankshaft end play ...

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Page 189: ...rks Approved by Confirmed by Measured by Measuring location Standard value ࡇࡦᣇะ ࡇࡦ ⷺᣇะ Square with piston pin Parallel with piston pin Nominal value Standard value Limit Cylinder bore φ78 3 07 78 030 to 78 060 3 0720 to 3 0732 Standard value 0 2 0 0080 Measurement Name Cylinder bore No Location A B C X 1 Y X 2 Y X 3 Y X 4 Y ...

Page 190: ...No Location X Y X Y X Y X Y Max Min Max Min Inlet 1 Exhaust Inlet 2 Exhaust Inlet 3 Exhaust Inlet 4 Exhaust Nominal value Standard value Limit Inlet φ6 6 0 260 6 600 to 6 615 0 2600 to 0 2606 Valve guide inner diameter Exhaust φ6 6 0 260 6 600 to 6 615 0 2600 to 0 2606 Inlet φ6 6 0 260 6 565 to 6 580 0 2586 to 0 2592 6 500 0 256 Valve stem diameter Exhaust φ6 6 0 260 6 530 to 6 550 0 2572 to 0 258...

Page 191: ...rks Approved by Confirmed by Measured by Measuring location Standard value Standard value Limit Valve seat angle 45 Valve seat width 1 30 to 1 80 0 0512 to 0 0709 2 50 0 0985 Measurement Name No Valve Valve seat angle Valve seat width Inlet 1 Exhaust Inlet 2 Exhaust Inlet 3 Exhaust Inlet 4 Exhaust ࡃ ࡉࠪ ࠑ Ԙ ԙ Ԙ ԙ Ԙ ԙ Ԙ ԙ Valve seat width ...

Page 192: ...ylinder head bottom face distortion Unit mm in Remarks Approved by Confirmed by Measured by Measuring location Standard value Standard value Limit Cylinder head bottom face distortion 0 05 0 0020 or less 0 10 0 0039 Measurement Name Cylinder head bottom face distortion No A B C D E F G H 1 2 3 4 ...

Page 193: ...cation Standard value Nominal value Standard value Limit Connecting rod bearings inner diameter φ48 1 89 47 990 to 48 022 1 8894 to 1 8906 Crank pin diameter φ48 1 89 47 950 to 47 965 1 8878 to 1 8884 Connecting rod bearings oil clearance 0 025 to 0 072 0 0010 to 0 0028 0 150 0 0059 Measurement Name Connecting rod bearings inner diameter Crank pin diameter Oil clearance No Location X Y Z X Y 1 2 3...

Page 194: ... Measurement Name Rocker arm inner diameter Rocker shaft diameter Rocker arm to shaft clearance No Location X Y X Y Max Min Inlet 1 Exhaust Inlet 2 Exhaust Inlet 3 Exhaust Inlet 4 Exhaust Nominal value Standard value Limit Rocker arm inner diameter φ18 9 0 744 18 910 to 18 930 0 7450 to 0 7458 Rocker shaft diameter φ18 9 0 744 18 880 to 18 898 0 7438 to 0 7445 Rocker arm to shaft clearance 0 012 t...

Page 195: ...ing location Standard value Measurement Name Piston pin inner diameter Piston pin diameter Piston pin to boss clearance No Location X Y X Y Max Min A 1 B A 2 B A 3 B A 4 B Nominal value Standard value Limit Piston pin inner diameter φ23 0 91 23 006 to 23 012 0 9057 to 0 9060 Piston pin diameter φ23 0 9062 22 994 to 23 000 0 9053 to 0 9055 Piston pin to boss clearance 0 006 to 0 018 0 0002 to 0 000...

Page 196: ... Approved by Confirmed by Measured by Measuring location Standard value Measurement Valve clearance No Inlet Exhaust Before adjustment 1 After adjustment Before adjustment 2 After adjustment Before adjustment 3 After adjustment Before adjustment 4 After adjustment Standard value Inlet 0 25 0 01 Valve clearance Exhaust 0 25 0 01 ...

Page 197: ...kgf cm 2 psi Remarks Approved by Confirmed by Measured by Measuring location Standard value Measurement Valve opening pressure Valve opening pressure No Before adjustment Hours used h After adjustment 1 2 3 4 Nominal value Standard value Valve opening pressure 13 73 140 1991 14 22 to 15 00 145 to 153 2062 to 2176 New parts value Nozzle tester ...

Page 198: ...Standard value Measurement Name Camshaft bushing inner diameter Camshaft journal diameter Camshaft journal to bushing clearance No Location X Y X Y Max Min 1 Nominal value Standard value Limit Camshaft bushing inner diameter No 1 φ45 1 77 45 000 to 45 055 107730 to 1 7751 Camshaft journal diameter No 1 φ45 1 77 44 930 to 44 950 1 7702 to 1 7710 Camshaft journal to bushing clearance No 1 0 050 to 0...

Page 199: ...umber Date Item to be measured Crankshaft end play Unit mm in Remarks Approved by Confirmed by Measured by Measuring location Standard value Measurement On disassembly On reassembly Standardvalue Limit Crankshaft end play 0 050 to 0 175 0 0020 to 0 0069 0 500 0 0197 ...

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