Ingersoll-Rand 3IRL2N Workshop Manual Download | Manualshive

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Ingersoll-Rand

3IRL2N, 3IRL4N & 4IRL5N

Diesel Engines

WORKSHOP MANUAL

© Ingersoll-Rand Co. 2001

54579925 March.2001

Revised (

10

-12)

Doosan 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

either.

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2
3
...
»

Summary of Contents for 3IRL2N

Page 1: ...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 either ...

Page 2: ...ry maintenance service and repair procedures on applicable Ingersoll Rand industrial engines Information contained in this Workshop Manual is the latest available at the time of publication Ingersoll Rand reserves the right to make changes at any time without prior notice ...

Page 3: ...OF CONTENTS SECTION 1 GENERALINFORMATION 4 SECTION 2 ENGINE 31 SECTION 3 LUBRICATING SYSTEM 94 SECTION 4 COOLING SYSTEM 97 SECTION 5 FUEL SYSTEM 102 SECTION 6 TROUBLESHOOTING 115 SECTION 7 CONVERSION TABLE 120 ...

Page 4: ...IONS 5 NOTES ON THE FORMAT OF THIS MANUAL 5 APPEARANCE 8 MAIN DATAAND SPECIFICATIONS 9 TIGHTENINGTORQUE SPECIFICATIONS 10 ANGULAR NUTAND BOLTTIGHTENING METHOD 12 TIGHTENING TORQUE ON MAJOR COMPONENTS 14 GASKET LOCATION 21 MAINTENANCE 25 RECOMMENDED LUBRICATING OIL 30 GENERAL INFORMATION ...

Page 5: ...re from any machine mounted air tank s before dismounting the engine or disconnecting pipes and hoses To not do so is extremely dangerous 11 Always check and recheck your work No service operation is complete until you have done this NOTES ON THE FORMAT OF THIS MANUAL This workshop manual is applicable to the Ingersoll Rand L series 3 and 4 cylinder industrial engines namely the 3IRL2N 3IRL4N 4IRL...

Page 6: ...iteria are defined by the terms standard and limit A measurement falling within the standard range indicates that the applicable part or parts are serviceable Limit should be thought of as an absolute value A measurement which is outside the limit indicates that the applicable part or parts must be either repaired or replaced 8 Components and parts are listed in the singular form throughout the Ma...

Page 7: ...s Front The cooling fan side of the engine viewed from the flywheel Right The injection pump side of the engine Left The exhaust manifold side of the engine Rear The flywheel side of the engine Cylinder numbers are counted from the front of the engine The front most cylinder is No 1 and rear most cylinder is No 4 The engine s direction of rotation is counterclockwise viewed from the flywheel ...

Page 8: ...8 APPEARANCE 1 MODEL 4IRL5N 1 Left side view GENERAL INFORMATION 2 Right side view ...

Page 9: ...5 1 1 0 9 2 2 3 1 2 4 3 5 5 1 p o t s t a n e h w C D T B g n i m i t n o i t c e j n i l e u F 9 1 4 1 r e d r o g n i r i F 2 4 3 1 l e u F 2 o N E A S l e u f l e s e i d d e e p s h g i H d e e p s g n i l d I n i m 1 0 5 8 m c g k a P M e r u s s e r p n o i s s e r p m o C 2 i s p n i m 0 5 2 e r o m r o 0 4 4 1 3 3 1 d l o c e c n e r a e l c e v l a V n i m m e k a t n I 8 0 0 0 2 0 7 5 1 ...

Page 10: ...10 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified ...

Page 11: ...11 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified ...

Page 12: ...he nuts and bolts to remove all oil and grease 2 Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts 3 Tighten the nuts and bolts to the specified torque snug torque with a torque wrench 4 Draw a line A B across the center of each bolt ...

Page 13: ...be an exten sion of the line A B 6 Draw another line F G on the face of each of the parts to be clamped This line will be in the direction of the specified angle Q across the center E of the nut or bolt 7 Use a socket wrench to tighten each nut or bolt to the point where the line A B is aligned with the line F G ...

Page 14: ...14 GENERAL INFORMATION TIGHTENING TORQUE ON MAJOR COMPONENTS 1 COOLING FAN AND WATER PUMP ...

Page 15: ...15 GENERAL INFORMATION 2 CYLINDER HEAD AND CYLINDER HEAD COVER ...

Page 16: ...16 GENERAL INFORMATION 3 CYLINDER BLOCK AND OTHER COMPONENTS 1 N m kgf m ft lb ...

Page 17: ...17 GENERAL INFORMATION 4 CYLINDER BLOCK AND OTHER COMPONENTS 2 Kg m ft lbs 3IRL2N ...

Page 18: ...18 GENERAL INFORMATION 4 CYLINDER BLOCK AND OTHER COMPONENTS 2 3IRL4N 4IRL5N ...

Page 19: ...19 GENERAL INFORMATION 5 CYLINDER BLOCK AND OTHER COMPONENTS 3 ...

Page 20: ...20 GENERAL INFORMATION 6 EXHAUST MANIFOLDAND GASKET ...

Page 21: ...21 GENERAL INFORMATION GASKET LOCATION 1 LOCATIONS WHERE GASKETS ARE USED 3IRL2N ...

Page 22: ...22 GENERAL INFORMATION GASKET LOCATION 1 LOCATIONS WHERE GASKETS ARE USED 3IRL4N 4IRL5N ...

Page 23: ...ket was used previously thoroughly clean the reside sealant using a scraper and wipe the surface by waste cloth to remove oil moisture dust etc from the surface 2 When using the gasket remover Bundo 391D made by Three Bond to facilitate the cleaning work apply the remover and leave it as is for about 10 minutes before starting the removal work 3 Be careful not to apply too much or too little 4 How...

Page 24: ...24 GENERAL INFORMATION Caution When the application method is being designated in the repair manual follow the designation 3 Locktite ...

Page 25: ... on the compression stroke If the No 1 cylinder intake and exhaust valve rocker arms are depressed the No 4 piston is at TDC on the compression stroke Adjust the circle or double circle marked valves as shown in Fig 1 while the No 1 or the No 4 cylinder is at TDC on compression stroke 3 Loosen each valve clearance adjusting screw as shown in the illustration 4 Insert a 0 40 mm 0 015 in feeler gaug...

Page 26: ...g 4 Use the filter wrench to turn in the oil filter an addi tional 3 4 of a turn or one turn 5 Check the engine oil level and replenish to the specified level if required 6 Start the engine and check for oil leakage from the oil filter Cooling Fan Drive Belt Adjustment 1 Check the cooling fan drive belt for cracking and other damage 2 Check the drive belt tension by exerting a force of 98 N 10 kg ...

Page 27: ...at when seen by the timing mark provided in the timing gear case When the value is out of the range of the normal injection timing adjust it accordingly 4 INJECTION TIMING Note The injection timing varies according to the specifica tions of the machine 6 Adjust the injection timing with a shim between the injection pump and the cylinder block Shim is available in the following 9 types and iden tif...

Page 28: ...rature reachs to 75 degree C 167 F 2 Remove all of the glow plugs and the injection pipes 3 Attach a compression gauge to the No 1 cylinder glow plug installation threads Note Compression pressure may be measured starting at any cylinder and in no particular cylinder order However it is very important that the compression pressure be measured in each cylinder Therefore start at the No 1 cylinder a...

Page 29: ...Supply fuel to the new filter This will facilitate air bleeding 3 Turn in the new fuel filter until the filter O ring is fit ted against the sealing face 4 Use the filter wrench to turn in the fuel filter an additional 2 3 of a turn Injection nozzle Check to see if the spray condition and the injection pressure are normal Adjust them to the specified value respectively when they don t meet the sta...

Page 30: ...ORMATION RECOMMENDED LUBRICATING OIL Protect your investment Use IR PRO TECH Engine Fluid and Filters Package sizes available 1 Gallon 3 78 Litres 54480918 5 Gallon 18 9 Litres 36875938 55 Gallon 208 Litres 36866903 ...

Page 31: ...31 ENGINE SECTION 2 ENGINE TABLE OF CONTENTS CONTENTS PAGE DISASSEMBLY 32 INSPECTION AND REPAIR 48 REASSEMBLY 69 ...

Page 32: ...32 1 EXTERNAL PARTS Right hand side 3IRL2N ENGINE DISASSEMBLY ...

Page 33: ...33 ENGINE 1 EXTERNAL PARTS Right hand side 3IRL4N ...

Page 34: ...34 ENGINE 1 EXTERNAL PARTS Left hand side 4IRL5N ...

Page 35: ...NAL PARTS Right hand side 4IRL5N 10 Oil filter 11 Dipstick 12 Injection pipe 4 pcs 13 fuel hose 14 F l leak off pipe 15 Fuel pipe 16 Engine stop solenoid 17 Injection pump housing cover 18 Injection pump and shim 4 set ...

Page 36: ... ASM Remove the solenoid ASM Injection pump housing cover 1 Remove the bolts and nut 2 Install the bolts M8 x 1 25 to the replacer hole 3 Tighten the bolts and then remove housing cover Injection pump 1 Align the hole of the fuel cut lever with the hole of the governor cover and then insert a pin 6o into this hole to hold the fuel cut lever 2 Check to see if the pin groove of the control link is a...

Page 37: ...37 ENGINE NOTE 1 Mark each injection pump as to which cylinder it was removed from 2 Do not reuse the shim replace it with the same thickness that was removed ...

Page 38: ...Hanger 5 Cylinder Head Assembly 6 Cylinder Head Gasket 7 Tappets 8 Oil Pan 9 Oil Strainer IO Oil Pipe 11 Crank Pulley 12 Flywheel 13 Flywheel Housing 14 Timing Gear Case without PTO 15 Oil Pump Assembly 16 Idler Gear and Shaft 17 Cam Gear 18 Camshaft 19 Rear Seal Retainer 20 Piston Assemblies 21 Crankshaft ...

Page 39: ...39 ENGINE Internal Parts 1 3 ...

Page 40: ...40 ENGINE Internal Parts 2 3 ...

Page 41: ...41 ENGINE Internal Parts 3 3 ...

Page 42: ... x 1 25 for replacer of rocker bracket assembly Cylinder head assembly I Remove the rear and front hangers 2 When removing the cylinder head bolts loosen them slowly a little at a time starting with the outside working in a circular pattern inward 3 Remove the cylinder head assembly and the head gasket 4 Pull out the tappet from the cylinder body ...

Page 43: ...Head Assembly Valve mechanism 1 Before disassembling the valve mechanism remove the connector glow plug and nozzle holder assembly 2 Compressing the valve spring remove the split collar spring seat valve spring and valve ...

Page 44: ...44 ENGINE Timing Gear ...

Page 45: ...he cam shaft 3 Remove the lock nut of the cam shaft gear and then remove the flyweight assembly and the cam gear Camshaft 1 Remove the snap ring which holds down the front bearing of the cam shaft from the ring groove of the cylinder block 2 Pull out the cam shaft from the cylinder block together with the bearing ...

Page 46: ...aft to position the piston at the top dead center 4 With the handle of a hammer placed at the bottom of the connecting rod push the piston assembly upward out of the cylinder block Notes 1 Before removing the piston scrape the carbon deposit off the cylinder wall 2 When pushing out the piston assembly care should be taken not to damage the cylinder wall 3 Attach a tag with a cylinder number to the...

Page 47: ...h a ring pliers Piston pin 1 Remove the snap rings with a commercially avail able tool 2 With a brass bar attached to the piston pin push it out by hammering it lightly Note Keep the pistons piston pins and connecting rods in order for each cylinder ...

Page 48: ...ection Cylinder block Check the cylinder block for wear damage or any other defects Use the hydraulic gauge to check the water jacket water pressure Apply water pressure to the water jacket at 5 kg cm2 71 1 psi for three minutes Cylinder bore Measurement position 13mm below the top Measure in X X and Y Y directions Near the No 1 compression ring ...

Page 49: ...ues are greater than the specified limit but less than the maximum grinding allowance If the measured values exceed the maximum grinding allowance the cylinder body must be replaced Cylinder bore diameter and grade mark The grade mark is stamped on the top surface of the cylinder block on the mating face with the cylinder head If the measured value is less than the limit the cylinder body may be r...

Page 50: ...50 ENGINE 1 CYLINDER BLOCK ...

Page 51: ...ht edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face 2 Regrind the cylinder head lower face if the mea sured values are greater than the specified limit but less than the maximum grinding allowance If the measured values exceed the maximum grinding allowance the cylinder head must be replaced Note If the cylinder head lower face is reground val...

Page 52: ...ed faces for cracking and other damage If cracking or damage is present the cylinder head must be replaced Note Be absolutely certain that there are no scratches or protuberances on the combustion chamber surfaces which will be in contact with the hot plug after it is installed These flaws will prevent the hot plug from seating correctly Hot Plug Replacement Hot Plug Removal 1 Insert a 3 0 5 0 mm ...

Page 53: ...edure Steps 1 4 for the remaining hot plugs Note Do not apply pressure greater than that specified Damage to the cylinder head will result 6 Use a surface grinder to grind off any hot plug surface protuberances The hot plug surfaces must be perfectly flush with the cylinder head lower face 7 After grinding make sure that the hot plug surfaces are completely free of protuberances The hot plug surfa...

Page 54: ...der head from the nozzle holder installation hole side Lightly tap the heat shield flange into place with a hammer and a brass bar The heat shield flange side must be facing up Note Always install a new heat shield Never reuse the old heat shield ENGINE 3IRL2N only ...

Page 55: ... AND VALVE SEAL Inspection of valve seat 1 A Contact width 2 B Valve depression Valve Stem Outside Diameter Measure the valve stem diameter at three points If the measured value is less than the specified limit the valve must be replaced ...

Page 56: ...ert 2 Note The smooth side of the attachment must contact the valve seat insert 2 Use a bench press 3 to gradually apply pressure to the attachment and press the valve seat insert into place 4 000 kg 8 819 Ibs Note Do not apply an excessive amount of pressure with the bench press Damage to the valve seat insert will result Valve Seat Insert Correction I Remove the carbon from the valve seat insert...

Page 57: ...remove the abrasive compound and metal particles Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination If the measured value exceeds the specified limit the valve spring must be replaced Valve Spring Tension Use a spring tester to measure the valve spring tension If the measured value is less than the specified limit the valve spring must be replaced Val...

Page 58: ...damage and any abnormalities Use a micrometer to measure the tappet diameter Use a dial indicator to measure the clearance be tween the tappet and cylinder body tappet travelling bore PUSH ROD Use a filler gauge to measure the valve push rod runout Roll the push rod along a smooth flat surface illustra tion ...

Page 59: ... or any other defect Note With the front and rear parts of camshaft pressed in with ball bearings and with the cylinder block pressed in with roller bearings as the center bearing check to see if the camshaft rotates smoothly with no play at each bearing I Measurement of journal and cam 1 Cam height A B ...

Page 60: ...han the specified limit the shaft must be replaced Rocker Arm Shaft and Rocker Arm Clearance 1 Use a vernier caliper to measure the rocker arm bushing inside diameter 2 Measure the rocker arm shaft outside diameter Replace either the rocker arm or the rocker arm shaft if the clearance exceeds the specified limit 3 Check that the rocker arm oil port is free of obstructions If necessary use compress...

Page 61: ...angle to the piston pin in the unit of l 1 000 mm 2 Calculate the clearance based on the measure ments of the cylinder bore and the outside diameter of the piston Outside diameter of piston and grade mark The grade mark is stamped on the top surface of the piston installed at the factory The piston for service part doesn t have the grade Wear of piston pin outside diameter ...

Page 62: ...ston ring gap With the ring inserted into the cylinder bore push it in with the piston head so that it becomes a right angle to the cylinder and then measure the gap of the piston ring If worn beyond the limit replace the rings 8 PISTON PISTON PIN AND PISTON RING ...

Page 63: ...63 Clearance between piston ring groove and ring Measure clearance at several places on the circum ference If worn beyond the limit replace the rings or piston ENGINE 8 PISTON PISTON PIN AND PISTON RING ...

Page 64: ...in hole of connect ing rod and piston pin inside diameter of bushing Connecting Rod Bearing Inspection 1 Fit the connecting rod bearing lower half into the connecting rod bearing cap 2 Check the connecting rod bearing lower half tension If the tension is insufficient the bearing must be replaced 3 Tighten the connecting rod and the bearing cap to the specified torque ...

Page 65: ...65 Clearance between bearing and crank pin Inside diameter with bearing installed and without ENGINE 9 CONNECTING ROD AND CONNECTING ROD BEARING ...

Page 66: ...eters of journal and pin If worn beyond the limits replace Note When there occurs an uneven wear to the crank shaft replace it with a new one without grinding it for reuse Clearance between journal and bearing inside diameter with bearing installed and without ...

Page 67: ...67 Runout of crankshaft Replace if beyond limit Crankshaft gear Check the crankshaft gear visually for damage and any other defects ENGINE lO CRANKSHAFT AND CRANKSHAFT BEARING ...

Page 68: ...the ring gear If the ring gear teeth are broken or excessively worn the ring gear must be replaced Ring Gear Removal Strike around the edges of the ring gear with a hammer and chisel to remove it Ring Gear Installation 1 Heat the ring gear evenly with a gas burner to invite thermal expansion Do not allow the temperature of the gas burner to exceed 200 C 390 F 2 Use a hammer to install the ring gea...

Page 69: ...ne oil Use a valve stem oil seal installer to install the oil seal Valve Stem Oil Seal Installer 54419403 Intake and Exhaust Valves I Place the cylinder head on a flat wooden surface 2 Lubricate valve stems with engine oil 3 Install the valves to the intake or exhaust guides Install the valves to their original lapped valve seats ...

Page 70: ... Refer to INSPECTION AND SERVICE Assemble to the cylinder head the gasket Install the nozzle holder assembly and then tighten it to the specified torque Glow plug and connector Assemble the glow plug to the cylinder head and then tighten it to the specified torque Install the connector to the glow plug and then tighten until snug Nozzle holder assembly 3IRL2N only Before assembling the nozzle hold...

Page 71: ...rations Piston Use a piston heater to heat the pistons to approxi mately 100 C 212 F Connecting Rod 1 Install the connecting rod to the piston with setting the marks as illustrated 2 Install the piston pin into the piston and the connecting rod bushing ...

Page 72: ...ller 5 8840 9018 0 Install the piston rings in the following order 1 Oil ring 2 2nd compression ring 3 1st compression ring The marked side of the two compression rings must be facing up The undercut side of the second compression ring will be facing down As the oil ring has no any facing mark it may face in either direction 2 Lubricate the piston ring surfaces with engine oil 3 Check that the pis...

Page 73: ... Camshaft 5 Cam Gear 6 Idler gear and Shaft 7 Oil Pump Assembly 8 Timing Gear Case Without PTO 9 Flywheel Housing 10 Flywheel 11 Crank Pulley 12 Oil Pipe 13 Oil Strainer 14 Oil Pan 15 Tappets 16 Cylinder Head Gasket 17 Cylinder Head Assembly 18 Push Rods 19 Rocker Bracket Assembly 20 Engine Hangers ...

Page 74: ...74 ENGINE Internal Parts l 3 ...

Page 75: ...75 Internal Parts 2 3 ENGINE ...

Page 76: ...76 ENGINE Internal Parts 3 3 ...

Page 77: ...rings with engine oil install the crankshaft install the thrust bearings with the groove facing the crankshaft Crankshaft Bearing Cap 1 Lubricate the bearing cap bolts with engine oil 2 Install the bearing caps to the crankshaft The arrow mark must be pointing to the front of the engine 3 Tighten the bearing cap bolts to the specified torque a little at a time in the numerical order shown in the i...

Page 78: ... front of the engine Use the piston ring compressor to compress the piston rings Use a hammer grip to push the piston in until it makes contact with the crank pin At the same time rotate the crankshaft until the crankpin reaches its highest point Set the bearing cap cylinder number marks and the connecting rod cylinder number marks The marks must be facing the injection pump side Note After instal...

Page 79: ...ter applying engine oil to the lip of the oil seal install the retainer Apply sealant TB1207B to the retainer Tighten bolts on the retainer to the specified torque in the order as shown in the figure left 3IRL4N 4IRL5N 3IRL2N ENGINE ...

Page 80: ...g point a dot mark a comes to the front side 2 With the flyweight installed tighten the cam gear with a lock nut 3 Apply engine oil to the shaft of the sleeve and the slide of the flyweight 4 With the lip of the sleeve placed in the cavity of the flyweight insert the shaft of the sleeve into the tip end of the camshaft Note Check to see if the sleeve moves smoothly Idle Gear Install the idler gear...

Page 81: ...d install the oil pump to the front plate Front plate only for those provided with PTO Apply sealant to the front plate incorporated with the oil pump before installing it to the cylinder block Front oil seal Install the front oil seal to the timing gear case Installation is made according to the L dimension shown in the figure ...

Page 82: ...advance 2 Apply engine oil to the bushes provided on both ends of the main spring lever of the governor 3 Apply sealant to the gear case and then install it to the cylinder block or the front plate 4 Assemble the gasket and the governor cover to the top of the gear case and then tighten them to the specified torque Flywheel housing Install the flywheel housing to the cylinder body Flywheel Lubrica...

Page 83: ...ing cap Oil pan 1 Apply sealant to the oil pan 2 Install the oil pan to the cylinder block and tighten fixing bolts evenly Tappet and head gasket 4IRL5N 3IRL4N only 1 Install the tappet to the cylinder block 2 When installing the head gasket face up the UP mark Install the head gasket over the cylinder head locaing dowels 4IRL5N 3IRL4N 3IRL2N Tappet and head gasket 3IRL2N only 1 Install the tappet...

Page 84: ...ll the push rods Rocker arm bracket assembly Apply liquid gasket to the the bottom of the rocker arm bracket assembly being careful not to get any in the groove around the oil galley as shown in the illustration Install the rocker arm bracket assembly making sure the push rods align with the rocker arms and tighten to the specified torque 4IRL5N 3IRL4N 3IRL2N ...

Page 85: ...85 ENGINE Adjustment of valve clearance Front hanger and rear hanger Tighten them to the specified torque shown below ...

Page 86: ...86 ENGINE 4 EXTERNAL PARTS Right hand Side 3IRL2N ...

Page 87: ...87 ENGINE 5 EXTERNAL PARTS Left hand Side 3IRL2N ...

Page 88: ... pump Align the two 2 holes in the fuel cut lever and the governor and lock into place with a pin This will center and hold the control link for the installation of the injection pumps Install a new shim with the same thickness as the one that was removed Refer to the maintenance section on shim selection Install the injection pump making sure the rack pin is in the groove of the control rack befo...

Page 89: ...iquid gasket is applied are about 4 mm in width from the cover edge and about 2 mm around the bolts Solenoid assembly 1 Apply sealant TB1207C to the surface bite groove in which the solenoid is installed Note Avoid the application of sealant to the screw thread 2 Screw in the solenoid from the rear of the cylinder block the rear of the No 3 injection pump rack and then tighten it to the specified ...

Page 90: ...orque Injection pipe Install the injection pipe to the injection pump and the nozzle holder and tighten them up with sleeve nuts Note Set the thread of the sleeve nut securely before tightening it up Note When tightening it hold the pipe securely by hand so that it will not rotate 3 Connect the fuel pipe and the leak off pipe with the fuel hose and fix them with clips 3IRL2N 4IRL5N 3IRL4N 3IRL2N 4...

Page 91: ...mble the thermostat install the gasket and the water outlet pipe and then tighten it to the specified torque Water pump assembly 1 Put sealant on the water pump where it contacts the block and head 2 Tighten to the specified torque ENGINE ...

Page 92: ... 3 Install the cylinder head cover to the rocker arm bracket and tighten it to the specified torque Air inlet pipe 1 Apply sealant TB1207C to the surface in which the air inlet pipe is installed 2 Install the air inlet pipe to the cylinder head cover and tighten it to the specified torque Exhaust manifold Assemble the gasket to the cylinder head install the exhaust manifold along the stud bolts an...

Page 93: ...the fixing bolts onto the top of the alternator through the adjusting plate Temporary tightening Fan pulley and fan belt 1 Install the fan pulley to the water pump and then tighten it up 2 locations 2 Set the fan belt to each pulley Fan belt tension Adjust the alternator as specified and tighten to the specified torque Cooling fan 1 Assemble the spacer before tightening the cooling fan 2 Tighten i...

Page 94: ...94 LUBRICATING SYSTEM SECTION 3 LUBRICATING SYSTEM TABLE OF CONTENTS CONTENTS PAGE LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM 95 OlLPUMP 96 ...

Page 95: ...95 LUBRICATING SYSTEM LUBRICATING OIL CIRCULATION DIAGRAM ...

Page 96: ...here is wear damages or any other defects found repair or replace the rotor Clearance between the outer rotor or inner rotor and the pump cover Clearance between the periphery of the outer rotor and the pump body Clearance between the inner rotor and the outer rotor ...

Page 97: ...97 COOLING SYSTEM SECTION 4 COOLING SYSTEM TABLE OF CONTENTS CONTENTS PAGE COOLING WATER CIRCULATION SYSTEM DIAGRAM 98 WATERPUMP 99 THERMOSTAT 101 ...

Page 98: ...98 COOLING SYSTEM COOLING WATER CIRCULATION SYSTEM DIAGRAM ...

Page 99: ... Fan center Cover 1 Loosen the set screw 2 Remove the cover Note The cover is applied with sealant TB1207B When removing the cover much care should be taken not to deform it by applying an excessive force to it Impeller Seal unit Bearing unit ...

Page 100: ... in the impeller with a press until the clear ance between the pump impeller and the body gets to the specified value Cover 1 Apply sealant to the surface to which the cover is installed and then install the cover 2 Apply Screw lock to the cover installation screws and then tighten them Clearance play and tightening allowance between parts 1 Clearance between the pump impeller and the body 2 Play ...

Page 101: ...101 COOLING SYSTEM THERMOSTAT Inspection and replacement Replace the thermostat when there is wear damages or any other defects found ...

Page 102: ...102 FUEL SYSTEM SECTION 5 FUEL SYSTEM TABLE OF CONTENTS CONTENTS PAGE FUEL CIRCULATION SYSTEM DIAGRAM 103 GOVERNOR 105 NOZZLE HOLDER ASSEMBLY 113 ...

Page 103: ...103 FUEL SYSTEM FUEL CIRCULATION SYSTEM DIAGRAM 3IRL2N ...

Page 104: ...104 FUEL SYSTEM FUEL CIRCULATION SYSTEM DIAGRAM 3IRL4N 4IRL5N ...

Page 105: ... performance test 2 Before disassembling the governor measure the dimensions A and B given in the structural drawing to ensure the same dimensions in reassembly 3 Do not disassemble the governor when the performance test cannot be conducted after reassembly 1 STRUCTURAL DRAWING OF GOVERNOR 1 ...

Page 106: ...106 FUEL SYSTEM 2 STRUCTURAL DRAWING OF GOVERNOR 2 ...

Page 107: ...g gear case lever respectively 2 Put the return spring of the control lever through the shalt of the lever main spring 3 Assemble the bushes Assemble the bush of the lever main spring first and then the control lever bush Note When assembling the bushes apply Loctite 601 to the periphery of the bushes 4 Hook both ends of the return spring control lever securely to the protrusion and the pin of the...

Page 108: ...rst and then assemble the washers and the control lever before tightening up the control lever with a nut Notes 1 Tighten the control lever after locking the control lever firmly Do not tighten the control lever after locking the main spring lever 2 After assembly confirm that the control lever moves smoothly ...

Page 109: ...assembly of shifter I Assemble the shifter to the guide lever put the shaft through it and then assemble the snap ring 2 After assembly confirm that the shaft moves smoothly 3 Also confirm that the shifter shakes smoothly ...

Page 110: ... 2 Set both ends of the return spring securely to the notched groove at the bottom of the cover and the bent up arm of the lever respectively 3 After reassembling the governor cover confirm that the governor moves smoothly 4 When assembling the timing gear case to the governor cover tighten the A dimension shown in the illustration to 2 3 mm temporarily The parts given in the square indicated by a...

Page 111: ...111 FUEL SYSTEM 6 Reassembly of full load stopper Install the full load stopper to the timing gear case and then tighten it with a nut temporarily ...

Page 112: ...each slide such as the end face of the lever the hole in the shaft and the periphery of the shaft 2 Install the set spring securely to the groove of the pin connecting the floating lever with much care to its assembling direction 3 Confirm that each lever moves by its dead weight before installing the start spring 4 After assembly confirm that each lever moves smoothly and also confirm that each s...

Page 113: ...113 FUEL SYSTEM NOZZLE HOLDERASSEMBLY 3IRL2N ...

Page 114: ...an light oil disassemble it into the nozzle body and the needle valve and clean them thoroughly Then check to see if the valve moves smoothly in the body When it does not move smoothly repair or replace the nozzle Adjustment For the adjustment of the injection pressure and the spray condition of fuel refer to Section 1 INSPEC TION AND SERVICE ...

Page 115: ...115 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING ...

Page 116: ...116 TROUBLESHOOTING ...

Page 117: ...117 TROUBLESHOOTING ...

Page 118: ...118 TROUBLESHOOTING ...

Page 119: ...119 TROUBLESHOOTING ...

Page 120: ...120 SECTION 7 CONVERSION TABLE TABLE OF CONTENTS CONVERSION TABLE LENGTH 121 AREA 122 VOLUME 122 MASS 124 PRESSURE 125 TORQUE 126 TEMPERATURE 127 MILLIMETERS TO INCHES INCHES TO MILLIMETERS ...

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