Service Manual
99709-56120
For use with FD40K, FD40KL, FD45K, FD50K,FD60, FD70, Chassis Service Manual.
S6S Diesel Engine
28620-up
Page 1: ...Service Manual 99709 56120 For use with FD40K FD40KL FD45K FD50K FD60 FD70 Chassis Service Manual S6S Diesel Engine 28620 up...
Page 2: ...on correct servicing the servicing consistent with what you will learn from this service manual We hope you read the respective sections of this manual carefully and know all the components you will w...
Page 3: ...d with the sequence of disassembly 2 Inspections to be conducted during disassembly are indicated in a box in disassembled views 3 Maintenance standards for inspection and repair are described in text...
Page 4: ...ottom Dead Center TIR Total Indicated Reading API American Petroleum Institute ASTM American Society for Testing and Materials JIS Japanese Industrial Standards LLC Long Life Coolant MIL Military Spec...
Page 5: ...Performance Tests ENGINE AUXILIARIES REMOVAL AND INSTALLATION Preparation Engine Auxiliaries Removal Engine Auxiliaries Installation ENGINE MAIN PARTS Cylinder Head and Valve Mechanism Flywheel Damper...
Page 6: ...1 Outline 1 1 1 1 External View 1 1 1 2 Engine Serial Number Location 1 2 2 Specifications 1 3 3 Tips on Disassembly and Reassembly 1 5 3 1 Disassembly 1 5 3 2 Reassembly 1 5 1 GENERAL...
Page 7: ...flywheel side Fuel feed pump Water pump Fuel filter Stop solenoid Relief valve Fuel injection pump Oil level gauge Fuel injection nozzle Inlet manifold Water drain plug Flywheel Oil filter Oil pan Oil...
Page 8: ...1 2 GENERAL 1 2 Engine Serial Number Location The engine serial number is located on the side of the crankcase Engine serial number Engine serial number location...
Page 9: ...th cylinder block No of piston ring Compression ring 2 Oil ring 1 w spring expander Inlet valve Open BTDC 30 Close ABDC 50 Valve timing Exhaust valve Open BBDC 74 Close ATDC 30 Starting system Electri...
Page 10: ...fugal Type of nozzle Bosch hole No of discharge orifice 1 Diameter of discharge 1 0 0 039 Injection nozzle orifice mm in Spray cone angle 0 Valve opening pressure 11 77 120 1707 MPa kgf cm2 psi Fuel f...
Page 11: ...ed This will save you time at reassembly 4 Pay attention to the marks on assemblies components and parts for positions or directions Put on your own marks if necessary to aid reassembly 5 Carefully ch...
Page 12: ...ng Torques 2 6 2 1 Important Bolts and Nuts 2 6 2 2 Standard Bolts 2 7 2 3 Standard Studs 2 7 2 4 Standard Plugs 2 7 3 Sealants and Lubricants Table 2 8 4 Regarding Submission of Parts for EPA Exhaust...
Page 13: ...t inward with thumb V belt deflection pressure and measure 0 394 to 0 472 deflection Crankcase Warpage of gasket contact 0 05 0 0020 0 20 Regrind if warpage is minor surface or less 0 0079 Inside diam...
Page 14: ...by refacing Free length 48 85 47 60 1 92 1 87 Valve spring Perpendicularity 1 5 or less Set length 43 1 69 Set force N kgf lbf 176 to 196 18 to 20 147 15 40 to 44 33 Inside diameter of rocker 19 010 t...
Page 15: ...ne or less No 1 ring 2 5 0 135 to 0 157 0 200 Clearance 0 098 0 0053 to 0 0062 0 0079 between No 2 ring 2 0 0 045 to 0 085 0 150 groove and 0 079 0 0018 to 0 0034 0 0059 Piston ring ring Oil ring 4 5...
Page 16: ...0 25 Replace gears 0 0012 to 0 0071 0 0098 Clearance between outer 0 20 to 0 30 0 50 Replace pump assembly rotor and case 0 0079 to 0 0118 0 0197 Diameter of main shaft 16 0 63 15 985 to 16 000 case s...
Page 17: ...4 to 39 2 3 to 4 13 7 1 4 N kgf lbf 7 7 6 6 to 8 8 3 1 0 5 to 2 0 Pinion clearance 0 020 to Starter 0 079 Output Rotating 1500 min 1 20 A or higher When cold current speed 2500 min 1 29 A or higher W...
Page 18: ...2 3 5 to 4 0 25 3 to 28 9 retaining nut Fuel injection nozzle M20 1 5 21 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 install to engine Fuel injection pump 22 34 5 to 39 2 3 5 to 4 0 25 3 to 28 9 delivery va...
Page 19: ...o 30 4 53 9 to 73 5 5 5 to 7 5 39 8 to 54 2 Thread Diameter Torque tap end mm For driving in aluminum materials For driving in ferrous materials N m kgf m lbf ft N m kgf m lbf ft M8 4 90 to 5 90 0 50...
Page 20: ...y to side seals bearing cap Cylinder head coolant hole plug Cylinder head ThreeBond 1386D Apply to plug hole Crankcase coolant hole plug Crankcase ThreeBond 1386D Apply to plug hole Crankcase oil hole...
Page 21: ...Special Tool List 3 1 3 SPECIAL TOOLS...
Page 22: ...00300 Valve guide removal Stem seal installer 32A91 10200 Valve stem installation Valve seat insert Inlet valve Valve seat installation caulking tool 36791 00200 Exhaust valve 34491 03020 Piston ring...
Page 23: ...Oil seal sleeve 30691 13010 Crankshaft rear oil seal sleeve installer set installation Gauge adapter 30691 21100 Compression pressure measurement Compression gauge 32A91 03100 Compression pressure me...
Page 24: ...Use Connecting rod 32A91 00500 Connecting rod bushing bushing puller removal installation Camshaft bushing 30691 00010 Camshaft bushing removal installer set installation Oil pump bushing 32A91 00400...
Page 25: ...1 Determination of Overhaul Timing 4 1 2 Testing the Compression Pressure 4 2 4 OVERHAUL INSTRUCTIONS...
Page 26: ...ction volume of the fuel injection pump Fuel injection timing Wear of injection pump plunger Fitting of the injection nozzle Condition of electrical equipment battery starter or alternator Item d abov...
Page 27: ...sure varies with engine speed Check engine speed when measuring the compression pressure Item Assembly Repair Standard Limit Compression pressure 3 2 33 469 2 8 29 413 NOTE Measure the compression pre...
Page 28: ...eed Setting 5 4 1 5 V belt Inspection and Adjustment 5 8 2 Bench Testing 5 9 2 1 Starting Up 5 9 2 2 Inspection After Starting Up 5 9 2 3 Bench Testing Dynamometer Conditions 5 9 2 4 Inspection and Ad...
Page 29: ...pulley and aligned with the pointer on the gear case With the piston so positioned both the inlet and exhaust valve rocker arms are not being pushed up by their pushrods d Insert a feeler gauge in bet...
Page 30: ...injection pump by 1 5 full turns b Move the priming pump cap up and down c When fuel flowing from the plug hole contains no air bubbles depress the priming pump cap and turn clockwise to lock in plac...
Page 31: ...st valves have some clearance 2 Checking injection timing a Remove delivery valve holder from the No 1 plunger of the injection pump Remove delivery valve and spring from the holder Restore the holder...
Page 32: ...njection timing To retard injection timing Adjusting injection timing Adjusting injection timing scale CAUTION 1 The no load minimum idle speed and maxi mum speed are set for each engine on the test b...
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