KOMATSU 6BG1T-BE2_A4

6BG1T-BE2

SHOP MANUAL 6BG1, 6BG1T ENGINE

APPLICABLE MACHINE MODEL FD100/115/135/150E/160E-6 FD150/180/200Z-5 FD150/180/200Z-6 F4EC/5EC/6EC-1

SERIAL No. 5001 and up 2001 and up 2301 and up 1001 and up

No. 3-4, 2 Chome, Akasaka, Minato-ku, Tokyo, Japan

BE

2003 KOMATSU FORKLIFT All Right Reserved Printed in Japan 06-03(03)

00-1

CONTENTS No. of page

1

GENERAL INFORMATION ..................................................................1-1

2

ENGINE ASSEMBLY ...........................................................................2-1

3

LUBRICATING SYSTEM .....................................................................3-1

4

COOLING SYSTEM .............................................................................4-1

5

FUEL SYSTEM ....................................................................................5-1

6

AIR COMPRESSOR ............................................................................6-1

7

FLYWHEEL, P.T.O. ..............................................................................7-1

8

TROUBLESHOOTING .........................................................................8-1

9

SPECIAL TOOLS.................................................................................9-1

10

REPAIR SERVICE STANDARD ........................................................10-1

00-1

SAFETY FOREWORD

FOREWORD This workshop manual is designed to use for the repair and adjusting procedures on Model 6BG1 and 6BG1T industrial engines. This manual provides service men with a guide on maintaining the best conditions of the engines. Komatsu Forklift Co. LTD reserves the right to make changes concerning numerical values due to the design change at any time without prior notice.

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SAFETY

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

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SAFETY

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol 4

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: • Check for removal of all bolts fastening the part to the relative parts. • Check for existence of another part causing interference with the part to be removed. 2. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter (mm) 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60

Allowable load (tons) 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

a The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

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3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kg when hoisting is made with two ropes, each of which is allowed to sling up to 1,000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2,000 kg of total weight can be suspended. This weight becomes 1,000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4,000 kg if they sling a 2,000 kg load at a lifting angle of 150°.

GENERAL INFORMATION

1 GENERAL INFORMATION Page General precautions for repairing engine ...................................................................................................... 1- 2 How to read repair manual ............................................................................................................................ 1- 4 Sketch drawing .............................................................................................................................................. 1- 6 Main specifications ......................................................................................................................................... 1-11 Tightening torque specifications .................................................................................................................... 1-12 Angular tightening method ............................................................................................................................. 1-14 Tightening torque of main parts .................................................................................................................... 1-15 Parts which need packings ............................................................................................................................ 1-21 Inspection and maintenance .......................................................................................................................... 1-22 Recommended lubricants .............................................................................................................................. 1-26

1-1

GENERAL INFORMATION

GENERAL PRECAUTIONS FOR REPAIRING ENGINE When servicing an engine, take the following precautions to "prevent damage to the engine" and "secure the performance and reliability of the engine. 1. When servicing the engine "mounted on the machine", disconnect the cables from the battery terminals to protect the wiring harnesses from a burn caused by a short circuit. 2. When "lifting up" or "supporting" the engine, do not apply a jack, etc. to the oil pan. If the jack is applied so, the oil pan and oil pump may be damaged since the clearance between the oil pan and strainer is narrow. 3. If the air duct or air cleaner is removed, "cover the intake opening" to "prevent foreign matter from entering" the cylinders. If the foreign matter enters, it may damage the cylinders seriously. 4. Handle the oil and antifreeze carefully, since they can "stain the painted surfaces". 5. Use the specified "ISUZU special tools" effectively. 6. Use "ISUZU genuine parts". 7. Do not reuse the gaskets, oil seals, and lock washers as a rule. Remove all the used "gasket sealant" from the sealing faces. 8. Arrange the removed parts "by the groups" to perform the work securely. 9. Before inspecting and assembling the parts, clean them carefully. Check each oil hole for "clogging" with compressed air. Wipe the rubber parts lightly with cloths, taking care not to damage their sealing faces.

1-2

GENERAL INFORMATION 10. Arrange the valves, bearings, pistons, piston rings, connecting rods, bearing caps, etc. by putting "numbered tags" to them according to the "cylinder Nos." (The cylinders are number 1, 2, 3, and 4 from the crank pulley side.)

11. When installing the rotary parts and sliding parts, apply "engine oil" or "grease" to them. 12. Observe the "tightening torque" of the bolts and nuts. 13. After completing inspection and maintenance, perform the "final inspection" to make sure that the work has been performed correctly.

1-3

GENERAL INFORMATION

HOW TO READ REPAIR MANUAL 1. Find out each item in "General contents". 2. In each chapter, "Disassembly", "Inspection and maintenance", and "Assembly" sections are arranged in this order. 3. Work such as removal of each part from a unit, etc. is not explained, but important work such as "adjustment method", "tightening torque", etc. is mainly explained. 4. In the chapter of each inspection and maintenance work which starts with the disassembly drawing of the objective component, the component parts and the inspection procedure are shown. •

Main component parts A number in parenthesis ( ) shows the sequence of Disassembly, Inspection maintenance, Reassembly.

1-4

GENERAL INFORMATION 5. The following is the symbols identifying the type of the inspection maintenance operation.

6. Definition of terms "Nominal size" ....... A standard value for manufacture. "Standard" .............. A standard value for maintenance (inspection, adjustment, assembly, and installation). "Limit" ........ A maximum value or a minimum value which an inspected part must not exceed or fall below. If the inspected part exceeds the maximum value or falls below the minimum value, it must be replaced or repaired. 7. Explanation of abbreviations "IN" ...................... Intake (Intake air) "EX" .................... Exhaust (Exhaust gas) "STD" .................. Standard "O/S" ................... Oversize "Ø" ...................... Diameter

"rpm" ................... Revolutions per minute "A" ....................... Ampere (Current) "V" ....................... Volt (Voltage) "z" ...................... Ohm (Resistance)

8. Application of "SI (International System of Units)" The international system of units was applied to unify the "metric system" and various units used in many countries (Japanese conventional system, foot-pound system, etc.) and avoid "troubles with the units" (conversion with computers, etc.)

1-5

GENERAL INFORMATION

SKETCH DRAWING Model BB-6BG1T

1-6

GENERAL INFORMATION

1-7

GENERAL INFORMATION Model A-6BG1

1-8

GENERAL INFORMATION

1-9

GENERAL INFORMATION

MAIN SPECIFICATIONS Engine name Item

Unit

Type

BB-6BG1T (with turbocharger)

AA-6BG1

4-stroke, water-cooled, overhead valve, in-line

Type of combustion chamber

Direct injection

Number of cylinders - Bore x Stroke Displacement

mm

6 – 105 x 125

L

6.494

Compression ratio

18.0

Overall length x Overall width x Overall height * mm Weight of engine

*

Intake valve opening angle (before top dead center) Intake valve closing angle (before bottom dead center) Exhaust valve opening angle (before bottom dead center) Exhaust valve closing angle (before top dead center)

kg

1204 x 762 x 961

1143 x 672 x 797

484

458

°

19

°

47

°

57

°

15

Valve clearance (Intake)

mm

0.4 (When cold)

Valve clearance (Exhaust)

mm

0.4 (When cold)

Fuel injection timing (before top dead center)*

°

8 Clockwise when seen from fan side

Rotation direction

Centrifugal all-speed control

Governor

Forced-feed circulating water, pre-pressure cooling

Cooling method *

Quantity of cooling water (in only engine)

mm

Ø 600, 7 vanes, pull type Ø 500, 6 vanes, pull type

Made of plastics

L

12.0

Excluding water in radiator

Forced lubrication

Lubrication method Quantity of lubricating oil (in oil pan)

*

L

Max. 21.5 Min. 17.5

Max. 13 Min. 10

Generator output

*

Starting motor output

*

24V, 40A

24V, 25A

Model RHG6, IHI

—

Cartridge type

Oil filter

Cartridge type

Fuel oil

Diesel fuel

Oil cooler Recommended battery capacity

Generator and regulator are made in 1 unit.

24V, 4.5kW

Fuel filter

Lubricating oil

Prepared by manufacturer

Element type

Type of air cleaner

Turbocharger

Dry weight

1–5–3–6–2–4

Firing order

Cooling fan

Remarks

API classification, Class CD (ISUZU specified oil)

API classification, Class CD or CC

Installed —

Prepared by manufacturer

(Note) Items marked with *: Depend on the machine equipped with the engine.

1-11

GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS Standard bolts Apply the tightening torque in the following table, unless otherwise specified. (N·m {kgf·m}) Indication at boom head

Nominal thread size (Diameter x Pitch) M6 X 1.0

3.9 – 7.8 {0.4 – 0.8}

4.9 – 9.8 {0.5 – 1.0}

M8 X 1.25

7.8 – 17.7 {0.8 – 1.8}

11.8 – 22.6 {1.2 – 2.3}

16.7 – 30.4 {1.7 – 3.1}

M10 X 1.25

20.6 – 34.3 {2.1 – 3.5}

27.5 – 46.1 {2.8 – 4.7}

37.3 – 62.8 {3.8 – 6.4}

*M10 X 1.5

19.6 – 33.4 {2.0 – 3.4}

27.5 – 46.1 {2.8 – 4.7}

37.3 – 62.8 {3.8 – 6.4}

M12 X 1.25

49.1 – 73.6 {5.0 – 7.5}

60.8 – 91.2 {6.2 – 9.3}

75.5 – 114.0 {7.7 – 11.6}

*M12 X 1.75

45.1 – 68.7 {4.6 – 7.0}

56.9 – 84.4 {5.8 – 8.6}

71.6 – 107.0 {7.3 – 10.9}

M14 X 1.5

76.5 – 115.0 {7.8 – 11.7}

93.2 –139.0 {9.5 – 14.2}

114.0 – 171.0 {11.6 – 17.4}

*M14 X 2.0

71.6 – 107.0 {7.3 – 10.9}

88.3 – 131.0 {9.0 – 13.4}

107.0 – 160.0 {10.9 – 16.3}

M16 X 1.5

104.0 – 157.0 {10.6 –16.0}

135.0 – 204.0 {13.8 – 20.8}

160.0 – 240.0 {16.3 – 24.5}

*M16 X 2.0

100.0 – 149.0 {10.2 –15.2}

129.0 – 194.0 {13.2 – 19.8}

153.0 – 230.0 {15.6 – 23.4}

M18 X 1.5

151.0 – 226.0 {15.4 – 23.0}

195.0 – 293.0 {19.9 – 29.9}

230.0 – 345.0 {23.4 – 35.2}

*M18 X 2.5

151.0 – 226.0 {15.4 – 23.0}

196.0 – 294.0 {20.0 – 30.0}

231.0 – 346.0 {23.6 – 35.3}

M20 X 1.5

206.0 – 310.0 {21.0 – 31.6}

270.0 – 405.0 {27.5 – 41.3}

317.0 – 476.0 {32.3 – 48.5}

*M20 X 2.5

190.0 – 286.0 {19.4 – 29.2}

249.0 – 375.0 {25.4 – 38.2}

293.0 – 440.0 {29.9 – 44.9}

M22 X 1.5

251.0 – 414.0 {25.6 – 42.2}

363.0 – 544.0 {37.0 – 55.5}

425.0 – 637.0 {43.3 – 64.9}

*M22 X 2.5

218.0 – 328.0 {22.2 – 33.4}

338.0 – 507.0 {34.5 – 51.7}

394.0 – 592.0 {40.2 – 60.4}

M24 X 2.0

359.0 – 540.0 {36.6 – 55.0}

431.0 – 711.0 {43.9 – 72.5}

554.0 –831.0 {56.5 – 84.7}

*M24 X 3.0

338.0 – 507.0 {34.5 – 51.7}

406.0 – 608.0 {41.4 – 62.0}

521.0 – 782.0 {53.1 – 79.7}

Use the bolts marked with * for "female screws" of soft materials such as "cast iron".

1-12

GENERAL INFORMATION

Hexagon head bolts with flanges Apply the tightening torque in the following table, unless otherwise specified. (N·m {kgf·m}) Indication at boom head

Nominal thread size (Diameter x Pitch) M6 X 1.0

4.6 – 8.5 {0.5 – 0.9}

6.6 – 12.2 {0.6 – 1.2}

M8 X 1.25

10.5 – 19.6 {1.1 – 2.0}

15.3 – 28.4 {1.6 – 2.9}

18.1 – 33.6 {2.1 – 3.4}

M10 X 1.25

23.1 – 38.5 {2.4 – 3.9}

35.4 – 58.9 {3.6 – 6.1}

42.3 – 70.5 {4.3 – 7.2}

*M10 X 1.5

22.3 – 37.2 {2.3 – 3.8}

34.5 – 57.5 {3.5 – 5.8}

40.1 – 66.9 {4.1 – 6.8}

M12 X 1.25

54.9 – 82.3 {5.6 – 8.4}

77.7 – 117.0 {7.9 – 11.9}

85.0 – 128.0 {8.7 – 13.0}

*M12 X 1.75

51.0 – 76.5 {5.2 – 7.8}

71.4 – 107.0 {7.3 – 10.9}

79.5 – 119.0 {8.1 – 12.2}

M14 X 1.5

83.0 – 125.0 {8.5 – 12.7}

115.0 –172.0 {11.7 – 17.6}

123.0 – 185.0 {12.6 – 18.9}

*M14 X 2.0

77.2 – 116.0 {7.9 – 11.8}

108.0 – 162.0 {11.1 – 16.6}

116.0 – 173.0 {11.8 – 17.7}

M16 X 1.5

116.0 – 173.0 {11.8 –17.7}

171.0 – 257.0 {17.4 – 26.2}

177.0 – 265.0 {18.0 – 27.1}

*M16 X 2.0

109.0 – 164.0 {11.2 –16.7}

163.0 – 244.0 {16.6 – 24.9}

169.0 – 253.0 {17.2 – 25.8}

Use the bolts marked with * for "female screws" of soft materials such as "cast iron".

1-13

GENERAL INFORMATION

ANGULAR TIGHTENING METHOD A method to tighten bolts and nuts to specified torque is generally used, but the axial tension to the specified torque by this method dispereses widely. Therefore, the bolts may break at the upper limit value if the required minimum axial tension should e maintained. Conversely, less dispersed axial tension may be obtained by tightening bolts while measuring the elongation of the bolts. But this method is impractiocable in the actual work. The pitch of the screw thread is considered to be as corresponding to the elogation of the bolts, of which number of turns is controlled in the angular method. Accordingly, the dispersion of the axial tension can be diminished by tightening to the plastic limit. TIGHTENING METHOD (1) Apply molybdenum disulfide grease to the threaded portion and setting faces of the bolts. (2) Tighten all the bolts to the specified torque. (3) Mark the place corresponding to one end of the bolt as shown in the figure below, and tighten to the specified angle. Be sure to check by the marking that tightening has been made to the specified angle. Neglect of this checking may lead to another tightening by the angular method and may cause breakage of the bolts. (NOTE) Q Tighten bolts in the specified order. Q Do not overtighten when the angular method is used.

Draw a line across the center of the bolt (A – B ... bolt side) (C – D ... part side) and a line in the direction of the specified tightening angle from the center of the bolt (E – F) on the face of each part to be clamped.

1-14

Use a socket wrench to tighten the bolt to the point where the line on the bolt (A – B) is aligned with the point of the specified angle (line of the face of the part E – F).

GENERAL INFORMATION

TIGHTENING TORQUE OF MAIN PARTS Cylinder head, cylinder head cover, and manifold (N·m {kgf·m})

1-15

GENERAL INFORMATION Cylinder body, oil pan, and oil pump (N·m {kgf·m})

1-16

GENERAL INFORMATION Crankshaft, piston, flywheel, and flywheel housing (N·m {kgf·m})

1-17

GENERAL INFORMATION Camshaft and timing gear parts (N·m {kgf·m})

1-18

GENERAL INFORMATION Water pump, fan, generator, starting motor, etc (N·m {kgf·m})

1-19

GENERAL INFORMATION Injection pipe and turbocharger (N·m {kgf·m})

1-20

GENERAL INFORMATION

PARTS WHICH NEED PACKINGS (N·m {kgf·m})

1-21

GENERAL INFORMATION

INSPECTION AND MAINTENANCE Cylinder head bolts Tighten the cylinder head bolts in the order shown at left. (N·m {kgf·m}) Tightening torque

69 {7.0} o Loosen all o 88 {9.0} O 90° – 120°

Apply "molybdenum disulfide" to the "seat" and "thread portion" of each bolt. Use shorter bolts (6 pieces) on the nozzle side. Do not use the head bolts more than 2 times.

Bring the No. 1 or No. 6 cylinder piston to the compression top dead center. Rotate the crankshaft forward and match the "T.D.C line" of the pulley damper to the "pointer". At this time, check that there are "clearances" respectively between valves and rocker arms on both intake side and exhaust side of the No. 1 or No. 6 cylinder. (When a cylinder piston is at the compression top dead center, there are "clearances" respectively between valves and rocker arms on both intake side and exhaust side.) Adjusting the valve clearances Adjust the valve clearances of the cylinder, the piston of which is at the compression top dead center. Insert a feeler gauge in the clearance between the intake valve and rocker arm and adjust the clearance with the adjustment screw. Adjust the clearance of the exhaust valve similarly. Valve clearance

Both intake and exhaust valves: 0.4 mm (When cold)

When starting the adjustment with the No. 1 cylinder, adjust the valve clearances of the cylinders marked with "Q". When starting the adjustment with the No. 6 cylinder, adjust the valve clearances of the cylinders marked with "q". 1

Cylinder No.

2

Valve arrangement

IN

EX

IN

When No. 1 cylinder piston is at compression top dead center When No. 6 cylinder piston is at compression top dead center

Q

Q

Q

1-22

3 EX

q

IN

q

4 EX

IN

Q

Q

5 EX

IN

6 EX

IN

EX

q

q

Q q

q

GENERAL INFORMATION Fuel injection timing (1) Match the "T.D.C mark" (top dead center mark) of the crank pulley to the "pointer".

When the "pointer" is matched to the "T.D.C mark", if the plate stamp line of the injection pump is matched to the pointer of the timing gear case cover, the injection pump is installed normally.

Fuel injection timing (2) 1. Remove the No. 1 injection pipe and the No. 1 delivery holder of the injection pump. Pull out the delivery valve and spring and tighten only the holder to (39 - 44 N·m {4 - 4.5 kgf·m}). 2. Rotate the crank pulley counterclockwise about 30° from the "T.D.C" mark. 3. Operating the feed pump with the hand, rotate the crank pulley clockwise slowly, and the discharge rate of the fuel from the No. 1 delivery holder of the injection pump is reduced gradually to zero. 4. When discharge of the fuel stops (at the injecting timing), check the mark of the crank pulley indicated by the pointer tip. 5. Clean and reinstall the removed delivery valve and spring and tighten the delivery holder to the "specified torque". If you do not observe the tightening torque of (39 - 44 N·m {4.0 - 4.5 kgf·m}), the engine may hunt and have some troubles. 6. When removing and installing the delivery valve and spring, take extreme care that dirt will not enter. Injection timing

6BG1T

8° or 10°

6BG1

8°

If deviation is larger than ± 2°, adjust.

Note: The proper injection timing depends on the machine equipped with the engine.

1-23

GENERAL INFORMATION Adjusting the injection timing In the case of the flange mount type, loosen the mounting nuts (4 pieces) of the injection pump housing and pump bracket with the special tool and change the installed angle of the injection pump to adjust the injection timing. The injection timing adjusted when the engine was assembled is indicated by the stamped "match marks" at the joint of the injection pump housing and bracket. Special tool: Injection pump wrench 9-8511-3703-0

In the case of the center mount type, loosen the coupling bolt on the front face of the timer and match the timer stamp line to the pump body stamp line as shown in the figure.

Measuring the compression pressure Remove each glow plug and injection pipe from the cylinder head. Then, rotate the starting motor and measure the compression pressure in each cylinder with a "pressure gauge". Be sure to measure the compression pressure in all the cylinders. (Measure each cylinder at least twice.) (MPa {kgf/cm2}) Compression pressure (at 200 rpm)

Standard

Limit

3.0 {31}

2.5 {26}

Special tool: Compression gauge adapter 5-85317-001-0 1. Before measuring the compression pressure, warm up the engine (until the coolant temperature rises above 70°C). 2. Take care that foreign matter will not enter the cylinders. 3. The difference in the compression pressure between the cylinders must be less than 294 kPa {3 kgf/cm2}. If it exceeds this limit, inspect the engine. 4. The compression pressure varies with the altitude.

1-24

GENERAL INFORMATION Injection nozzle Check the condition and pressure of injection, and then adjust them if necessary. (MPa {kgf/cm2}) Fuel injection pressure

18.1 {185}

Note: When the nozzle holder is new, the injection pressure is set about 980 kPa {10kgf/cm2} higher than the above value, considering aging. When adjusting, however, observe the above value.

Using the nozzle tester, adjust the injection pressure with the adjustment screw.

Bleeding the air You can bleed the air from the fuel circuit by simply operating the feed pump with the hand, but that takes you much time. Accordingly, bleed the air according to the following procedure. Loosen the joint bolt of the fuel filter outlet and operate the feed pump, and the filter is filled with fuel. Then, operate the feed pump until the "air" is bled and "hissing sound" is heard.

Fan belt (mm) Belt deflection

Approx. 7 – 10

Loosen the generator mounting bolts and press the belt as shown in the figure at left, and then adjust the belt deflection to the specified value.

1-25

GENERAL INFORMATION

RECOMMENDED LUBRICANTS ENGINE TYPE AND GRADE Enging type

Recommended lubricants (API Service Cassification)

With turbocharger

CD Grade

Without turbocharger

CC or CD Grade

ENGINE OIL VISCOSITY CHART THE RELATIONSHIP BETWEEN ENGINE OIL VISCOSITY AND AMBIENT TEMPERATURE (Single grade) SAE 40, 50

SAE 20, 20W

SAE 10W

(Ambient –30°C Temperature) (–22°F)

–15°C (0°F)

SAE 30

–0°C (32°F)

15°C (60°F)

25°C (80°F)

30°C (90°F)

(Multi- grade) SAE 10W-30

SAE 15W-40, 20W-40, 20W-50

Start-up, operability, oil consumption, the wear of sliding portions and seizure of the engine may be affected by engine oil viscosity. Select the proper oil according to the temperature referring to the above table.

1-26

ENGINE ASSEMBLY

2 ENGINE ASSEMBLY Page General view of engine .................................................................................................................................. 2- 2 Disassembly ................................................................................................................................................... 2- 3 Main component parts ............................................................................................................................. 2- 3 Disassembly procedure (1) ..................................................................................................................... 2- 4 Disassembly procedure (2) ..................................................................................................................... 2- 5 Disassembly procedure (3) ..................................................................................................................... 2- 6 Engine oil and coolant ............................................................................................................................. 2- 7 Exterior parts ........................................................................................................................................... 2- 7 Rocker arm shaft assembly .................................................................................................................... 2-11 Cylinder head assembly .......................................................................................................................... 2-11 Cylinder body parts ................................................................................................................................. 2-13 Timing train parts, camshaft, and tappet ................................................................................................ 2-15 Piston and connecting rod assembly ...................................................................................................... 2-18 Crankshaft assembly ............................................................................................................................... 2-19 Inspection and replacement .......................................................................................................................... 2-20 Cylinder body ........................................................................................................................................... 2-20 Cylinder head .......................................................................................................................................... 2-22 Valve, valve guide, valve guide insert ..................................................................................................... 2-23 Rocker arm shaft assembly parts ........................................................................................................... 2-25 Camshaft, tappet, idle gear, and shaft ................................................................................................... 2-26 Piston, piston pin, piston ring .................................................................................................................. 2-30 Connecting rod, connecting rod bearing ................................................................................................. 2-32 Crankshaft, crankshaft bearing ............................................................................................................... 2-34 Reassembly ................................................................................................................................................... 2-37 Cylinder head assembly .......................................................................................................................... 2-37 Rocker arm shaft assembly .................................................................................................................... 2-39 Piston and connecting rod assembly ...................................................................................................... 2-40 Component parts ..................................................................................................................................... 2-42 Crank shaft assembly .............................................................................................................................. 2-43 Cylinder body parts ................................................................................................................................. 2-44 Piston and connecting rod ...................................................................................................................... 2-46 Timing gear, tappet, and oil pump .......................................................................................................... 2-47 Rear oil seal, housing, oil pan, and oil cooler ........................................................................................ 2-49 Fuel injection pump and gear case cover .............................................................................................. 2-50 Relationship between flywheel, crank pulley, and cylinder head ........................................................... 2-51 Exterior parts ........................................................................................................................................... 2-53

2-1

ENGINE ASSEMBLY

GENERAL VIEW OF ENGINE

2-2

ENGINE ASSEMBLY

DISASSEMBLY MAIN COMPONENT PARTS

2-3

ENGINE ASSEMBLY

DISASSEMBLY PROCEDURE (1)

2-4

ENGINE ASSEMBLY

DISASSEMBLY PROCEDURE (2)

2-5

ENGINE ASSEMBLY

DISASSEMBLY PROCEDURE (3)

2-6

ENGINE ASSEMBLY

ENGINE OIL AND COOLANT Engine oil Loosen the drain plug of the oil pan and drain the engine oil. Note: Be sure to collect the oil of first 0.1 L (100 cc) for inspection.

Coolant Loosen the drain valve of the cylinder body and drain the coolant remaining in the engine. Note: If water leaks through the water pump, collect first 0.1 L (100 cc) of it for inspection.

EXTERIOR PARTS Cooling fan Remove the cooling fan. Take care not to break or damage the removed fan.

Intake duct Remove the duct between the turbocharger and intake manifold. Note: Take care that foreign matter will not enter the turbocharger and intake manifold.

Fuel piping and nozzle holder Remove the leak-off pipe, fuel pipe, injection pipe, and nozzle holder. Note: Take measures to prevent foreign matter from entering the nozzle holder, injection pump, fuel filter, etc., since foreign matter can cause a trouble.

2-7

ENGINE ASSEMBLY Lubrication piping Remove the lubricating oil pipe of the injection pump, oil pipe of the oil filter, and oil feed pipe of the turbocharger (Remove the return pipe later). Note: Cover the oil feed opening of the turbocharger with an adhesive tape to prevent foreign matter from entering the turbocharger. When reassembling, remove the tape and clean.

Turbocharger 1. Remove the turbocharger and return oil pipe together. 2. Remove the return pipe from the turbocharger. Note: Take care that foreign matter will not enter the intake opening, exhaust opening, and return oil port of the turbocharger.

Generator Remove the adjustment plate of the generator, and then remove the generator and fan belt.

Starting motor Remove the starting motor mounting nuts, and then remove the starting motor and ground cable from the flywheel housing.

Glow plug Remove the glow plug connector, and then remove the glow plug from the cylinder head.

2-8

ENGINE ASSEMBLY Oil filter Loosen each cartridge, and then remove the oil filter assembly. (Replace the cartridges.) Note: Take care that foreign matter and dirt will not enter the oil filter fitting parts of the cylinder body.

Fuel injection pump Remove the fuel injection pump and bracket together from the timing gear case.

Oil cooler Remove the oil cooler from the cylinder body by lightly hitting around it with a wooden hammer, etc.

2-9

ENGINE ASSEMBLY Water pump and fan pulley Loosen the bypass hose band and remove the pump mounting bolts and water pump.

Cylinder head cover Remove the cylinder head cover mounting bolts and cylinder head cover. Air breather and tappet chamber cover Remove the air breather and tappet chamber cover. Oil pump pinion gear Remove the mounting bolts of the cylinder body hole cover (pinion gear), and then remove the cover and pinion gear shaft of the oil pump.

2-10

ENGINE ASSEMBLY

ROCKER ARM SHAFT ASSEMBLY

Rocker arm bracket Loosen the mounting bolts evenly from both ends and remove the rocker arm brackets.

CYLINDER HEAD ASSEMBLY Cylinder head Loosen the cylinder head bolts in the numerical order shown in the figure.

2-11

ENGINE ASSEMBLY

Before disassembling the valve mechanism, remove the nozzle holder assembly and glow plug. Remove the intake manifold and exhaust manifold together (including the gasket).

Valve Valve and valve spring Special tool: Valve spring replacer 1-85235-006-0 Compress the valve spring and remove the split collar, spring seat, valve spring, and valve.

2-12

ENGINE ASSEMBLY

CYLINDER BODY PARTS Crank pulley 1. Remove the claw nut and washer of the crank pulley with torque wrench (637 N·m and up {65 kgf·m and up}). Note: When loosening the claw nut, install a long bolt to the flywheel to stop the flywheel.

2. Using the taper bushing puller, pull out the taper bushing and remove the crank pulley. Special tool: Taper bushing puller 9-8521-0122-0

Oil pan Remove the mounting bolts and oil pan. Oil pump and oil pipe Remove the oil pump and oil pipe together from the cylinder body. At this time, remove the drive gear shaft coupling, too.

2-13

ENGINE ASSEMBLY Flywheel 1. Lock the crankshaft and remove the mounting bolts. 2. Remove the flywheel, hitting it lightly with a plastic hammer. Note: Do not damage the ring gear. Timing gear case cover 1. Loosen the bolts (7 pieces) of the timing gear case cover and remove the injection pump. Then, remove the other bolts and gear case cover. Note: Remove the rear bracket of the injection pump in advance. 2. Install the claw nut of the crank pulley temporarily to rotate the crankshaft.

Piston and connecting rod Rotate the crankshaft to bring the piston to the top dead center. Then, remove the bearing cap and push the connecting rod from the lower end with the grip of a hammer, etc. to push out the piston and connecting rod toward the top of the cylinder body. Note: Take care not to damage the oil jet.

2-14

ENGINE ASSEMBLY

TIMING TRAIN PARTS, CAMSHAFT, AND TAPPET

Backlash of gears Before removing each gear, measure its backlash. (mm) Standard

Limit

0.10 – 0.17

0.3

2-15

ENGINE ASSEMBLY Clearance of idle gear in axial direction (mm) Standard

Limit

0.128 – 0.185

0.2

Clearance of crankshaft in axial direction Before removing the crankshaft, measure its clearance. Measure the clearance at No. 4 bearing cap. (mm) Standard

Limit

0.15 – 0.33

0.4

Camshaft assembly Remove the thrust plate mounting bolts through the hole of the cam gear and pull out the camshaft slowly.

Gear case Remove the timing gear case from the cylinder body. Rear oil seal Remove the flywheel housing. Using the special tool, remove the oil seal. Special tool: Rear oil seal remover 5-8840-2360-0

2-16

ENGINE ASSEMBLY Flywheel housing Remove the flywheel housing from the cylinder body.

Idle gear shaft Utilize the seal plug concave of the oil gallery to remove the shaft with a screwdriver.

Crankshaft bearing and crankshaft Loosen the mounting bolts in the order shown in the figure. Remove the cap, hitting it lightly with a copper hammer. Then, remove the crankshaft.

Camshaft bearing Remove the flywheel and the flywheel housing, and pull out the plate plug, and then remove the bearings successively from the rear of the cylinder body using a puller. Special tool: Bearing puller 9-8523-1818-0

2-17

ENGINE ASSEMBLY

PISTON AND CONNECTING ROD ASSEMBLY

Piston ring Use a replacer to remove the piston ring. Special tool: Piston ring replacer 1-8522-1025-0

Piston pin Remove the snap ring. Put a holding-up rod to the piston pin and tap it out with a hammer.

2-18

ENGINE ASSEMBLY

CRANKSHAFT ASSEMBLY

Crankshaft gear Use a puller to remove the crankshaft gear. Special tools: Puller; Crankshaft gear 9-8521-0141-0

2-19

ENGINE ASSEMBLY

INSPECTION AND REPLACEMENT Make the necessary adjustments, and part replacement if excessive wear, damages or other defects are discovered during the inspection.

CYLINDER BODY Cylinder body Inspect the cylinder body for wear, breakage, water leakage, etc. Water leakage: Water pressure test 490kpa {5 kg/cm2} (for 3 min.) 2. Inspect the cylinder body for damage with defect detector material, etc.

Cylinder body top warpage Use a rule and a feeler gauge to measure the four sides and the two diagonals. (mm) Standard

Limit

0.05 or less

0.2

Repair procedure Grinding with surface grinder

The maximum grinding must not exceed 0.3 mm.

Cylinder liner bore (mm) Standard

Limit

Repair procedure

105.0

105.2

Replacement

Measure the maximum wear portion at 20 mm above the upper face of the liner Note: Since the inside of the liner is plated with special chromium, it cannot be finished by boring or honing. Accordingly, if the liner has a seizure mark or a flaw or the measured value exceeds the service limit, replace the liner.

2-20

ENGINE ASSEMBLY Setting of grade part Nos. of pistons, cylinder liners, and liner sets Part Nos. are set for each grade of the spare pistons, cylinder liners, and liner sets supplied in and after August 1997. Accordingly, when repairing these parts, observe the following points. 1. Repair standard Judge the repair standard of these parts by the repair standard values in this repair manual as before. 2. Grade part Nos. (Replacement of new and current part Nos.) 3. How to order parts Select a proper grade of each part in the new and current part Nos. table and place an order by the corresponding new part No. Selecting the liner The combinations of the liners and cylinder bores are as follows. The interference between each liner and cylinder must be 0.001 - 0.0019 mm. (mm) Liner inside Cylinder body diameter bore

Ø 105

Liner Liner outside grade No. diameter

107.001 – 107.010

1

107.001 – 107.010

107.011 – 107.020

2

107.011 – 107.020

107.021 – 107.030

3

107.021 – 107.030

The grade stamps are made on the outside and inside of each new liner, but they are defaced once the liner is used.

Cylinder liner projection Standard: 0.03 – 0.10 mm Check that the difference in the projection height between any two adjacent cylinders is not exceeding 0.03 mm.

Removing the cylinder liner Special tools: Remover; Cylinder liner 9 – 8523 – 1169 – 0 9 – 8523 – 1004 – 0 (Angle)

2-21

ENGINE ASSEMBLY Installing cylinder liner Carefully wipe away oil from the cylinder liner and body and install the liner with special tools. Use the bench press to apply initial pressure of 500 kg for press-fitting the liner and apply final pressure of 2500 kg for press-fitting and fully seating the liner. Special tools: Setting tool; Cylinder liner 5 – 85221 – 018 – 0

CYLINDER HEAD Cylinder head Remove carbon residues which are sticking on the bottom face of the head carfully not to damage the valve seat face and inspect wear, damage and the like. Water leakage: Water pressure test 490 kpa {5 kg/ cm2} (for 3 min) Perform a magnetic particle inspection and a red check, as necessary.

Lower face warpage Use a straight edge and a feeler gauge to measure the four sides and the two diagonals.

(mm) Standard

Limit

0.05 or less

0.20

Repair procedure Grinding with surface grinder

The maximum grinding must not exceed 0.3 mm.

2-22

ENGINE ASSEMBLY

VALVE, VALVE GUIDE, VALVE GUIDE INSERT Valve guide Check the wear of the inner face. If the measured values exceed the specified clearance, the valve and the valve guide must be replaced as a set. Measure at the position of 10mm above the upper face of the guide. (mm) Valve Stem Clearance

Standard

Limit

Inlet Valve Side

0.39 – 0.068

0.20

Inlet Valve Side

0.064 – 0.096

0.25

Removing the valve guide Special tools: Replace and Installer, Valve guide 1-85220-001-0

Valve contact width and valve depression (1) Contact width check (A) (2) Depression Check (B) (mm)

Depression (B)

Contact width (A)

Intake

Standard

Limit

1.0

2.5

Exhaust Intake

1.5

2.0

Repair procedure

Correct or replace the valve and insert

Exhaust

Valve seat insert Put a smooth patch on the insert surface not to damage the surface and use a bench press to apply pressure of [9,807 – 14,710N] 1,000 – 1,500kg for press-fitting. Notes on removing the valve seat insert. (1) Red-heat (700 – 800°) two diagonal points of the inside of the valve seat insert with a gas burner. (2) Allow the valve seat insert to cool for 3 – 5 minutes. Then tap the insert out. Take care not to damage the cylinder head.

2-23

ENGINE ASSEMBLY Valve stem diameter Correct slightly stepped wear with an oil stone. (mm) Standard

Limit

Repair Procedure

Ø 9.00

Ø 8.88

Replacement

Intake Exhaust

Valve thickness (mm) Standard

Limit

Repair Procedure

1.5

1.0

Replacement

Intake Exhaust

Valve spring force (Tension) Use a spring tester to measure the spring tension at specified setting. Without valve rotator: When compressed by 44.5 mm (N {kgf}) Distinction

Standard

Limit

Repair procedure

Blue

142 {14.5}

127 {13.0}

Replacement

With valve rotator: When compressed by 40 mm (N {kgf}) Distinction

Standard

Limit

Repair procedure

Pink

142 {14.5}

127 {13.0}

Replacement

Valve spring free length (A) Without valve rotator

(mm)

Distinction

Standard

Limit

Repair procedure

Blue

60.6

58.0

Replacement

With valve rotator

(mm)

Distinction

Standard

Limit

Repair procedure

Pink

55.0

53.0

Replacement

Valve spring squareness (B)

2-24

(mm)

Standard

Limit

Repair procedure

1.9 or less

2.7

Replacement

ENGINE ASSEMBLY

ROCKER ARM SHAFT ASSEMBLY PARTS Bracket Rocker arm Rocker arm shaft Check for wear, breakage and the like. Check for the clogged oil hole of the bracket (fron side).

Rocker arm shaft Use a micrometer to measure the shaft outer diameter at 6 places. Rocker arm shaft diameter. (mm) Normal Size

Limit

Repair procedure

Ø 19.00

Ø 18.85

Replacement

Measuring the bushing bore and inspecting the clearance limit. Clearance between the bushing and the rocker arm shaft. (mm) Standard

Limit

Repair procedure

0.01 – 0.05

0.2

Replacement

Check the rocker arm contact surface with the valve stem end, and replace the rocker arm if there is stepped or streaked surface. Measureing the rocker arm shaft warpage Support both ends of the shaft with V blocks and measure the run-out at the center with a dial gauge. (Warpage is 1/2 of the run-out.) Warpage of the rocker arm shaft. (mm) Standard

Limit

Repair procedure

0.2 or less

0.3

Replacement

If warpaage is slight, the shaft may be re-used after correcting by the press (to be corrected during cold processing).

2-25

ENGINE ASSEMBLY Push rod bend If the both ends of a push rod are worn or damaged remarkably, replace that push rod. (mm) Limit

0.3

CAMSHAFT, TAPPET, IDLE GEAR, AND SHAFT Inspecting the camshaft Inspect the journals, cams, and oil pump drive gear for wear and breakage, and replace the camshaft if there is any abnormality.

Axial clearance between thrust plate and camshaft journal end Before removing the camshaft gear, move the thrust plate to the gear side and measure the "clearance" between the thrust plate and camshaft journal end. If the measured value exceeds the limit, replace the thrust plate. Clearance between journal end and thrust plate (mm) Standard

Limit

0.050 – 0.114

0.2

Removing and installing the camshaft gear and thrust plate 1. Removal procedure (1) Grip the camshaft assembly in a vise and remove the gear clamping bolt. (2) Using the gear puller or a press, remove the camshaft gear and thrust plate together. 2. Installation procedure (1) Install the thrust plate and camshaft gear to the camshaft. When installing the gear, set the stamp of match mark "B" on this side. (2) Apply engine oil to the camshaft gear bolt. (N.m {kgf.m}) Tightening torque

2-26

142 – 172 {14.5 – 17.5}

ENGINE ASSEMBLY Camshaft runout Inspect the camshaft for bend. Measure the runout and divide it by 2 (to obtain the bend). (mm) Limit

Repair procedure

0.12

Replacement

Cam lobe height (Lift) Using a micrometer, measure the cam lobe height (lift). If the measured value is less than the limit, replace the camshaft. (mm) Standard

Limit

Repair procedure

7.71

7.21

Replacement

Clearance at camshaft journal 1. Using a micrometer, measure the outside diameter of the camshaft journal. If the measured value is less than the limit, replace the camshaft. Camshaft journal outside diameter

(mm)

Standard

Limit

Ø 55.94 – 55.97

Ø 55.6

Uneven camshaft journal wear Limit

(mm) 0.05

2. Using a bore gauge, measure the inside diameter of the camshaft bearing and calculate the difference between it and the outside diameter of the journal. If the measured value exceeds the limit, replace the bearing of camshaft. Clearance at camshaft journal

(mm)

Standard

Limit

0.03 – 0.09

0.15

2-27

ENGINE ASSEMBLY Replacing the camshaft bearing 1. Removal procedure (1) Remove the sealing cup of the cylinder body. (2) Using the camshaft bearing puller, remove the bearing. Special tool: Camshaft bearing puller 9-8523-1818-0

2. Installation procedure (1) Match the oil hole of the bearing to that of the cylinder body. (2) Using the bearing replacer, install the bearing. Special tool: Camshaft bearing installer 9-8523-1818-0

Inspecting the tappet contact face Inspect the tappets for wear, damage and any abnormality. Replace the pitted or cracked tappet.

Tappet outside diameter Measure the outside diameter of the tappet. (mm)

2-28

Nominal size

Limit

Repair procedure

Ø 28

Ø 27.92

Replacement

ENGINE ASSEMBLY Clearance between tappet and cylinder body Using a bore gauge, measure the inside diameter of the tappet inserting hole of the cylinder body and calculate the difference between it and outside diameter of the tappet. (mm) Standard

Limit

Repair procedure

0.020 – 0.054

0.1

Replacement

Inspecting the idle gear and shaft Visual inspection 1. If the sliding surfaces of the idle gear shaft and the inside wall of the idle gear bushing are worn or damaged remarkably, replace the shaft or gear. 2. If there is a stepped surface on the idle gear or thrust collar, replace the gear or thrust collar.

Idle gear shaft outside diameter Using a micrometer, measure the outside diameter of the shaft. If the measured value is less than the limit, replace the idle gear shaft. Shaft outside diameter

(mm)

Nominal size

Limit

Repair procedure

Ø 45

Ø 44.9

Replacement

Clearance between idle gear bushing and shaft Using a dial gauge, measure the inside diameter of the bushing and calculate the difference between it and outside diameter of the shaft. If the measured value exceeds the limit, replace the idle gear. (mm) Standard

Limit

Repair procedure

0.025 – 0.085

0.2

Replacement

2-29

ENGINE ASSEMBLY

PISTON, PISTON PIN, PISTON RING Selecting the grade The pistons and liners are classified into the grades of "A", "B", "C", and "D" when shipped. The service parts are classified into the grades of "AX" and "CX", however. 1. Use service pistons of grade AX for liners of grade A or B. 2. Use service pistons of grade CX for liners of grade C or D. Note: The grades of the liner and piston of each spare liner kit are selected properly. Cylinder liner and piston clearance (mm) Standard Cylinder liner inside diameter

Ø 105.021 – 105.060

Piston outside diameter

Ø 104.945 – 104.984

Clearance between cylinder liner and piston (for service)

0.051 – 0.085

Service piston outside diameter (mm) Grade Piston outside diameter

AX

CX

Ø 104.959 Ø 104.975 – 104.974 – 104.990

Liner and piston combination (for service)

2-30

Cylinder inside diameter grade

Piston grade

Combination

AX

AX

OK

CX

CX

OK

AX

CX

NG

CX

AX

NG

ENGINE ASSEMBLY Piston pin wear Piston pin outside diameter

(mm)

Nominal size

Limit

Repair procedure

Ø 35

Ø 34.95

Replacement

Piston pin hole and piston pin clearance Standard

(mm)

0.010 – 0.018

Piston ring gap Insert and push the piston ring horizontally in the cylinder bore using an inverted piston. (mm) Standard

Limit

Repair procedure

1.5

Replacement

1st pressure ring 0.35 – 0.50 2nd pressure ring 0.60 – 0.75 3rd pressure ring 0.60 – 0.75 Oil ring

0.30 – 0.50

Piston ring groove and piston ring clearance Measure at several points around the piston. (mm)

1st pressure ring

Standard

Limit

—

—

2nd pressure ring 0.07 – 0.11 0.15

Repair procedure

Replacement

3rd pressure ring 0.05 – 0.09 0.15 Oil ring

0.030 – 0.070 0.15

2-31

ENGINE ASSEMBLY Piston ring tension (N {kgf}) Standard 20.4 1st pressure ring {2.08 14.1 2nd pressure ring {1.44 14.1 3rd pressure ring {1.46 36.3 Oil ring {3.7

– – – – – – – –

30.6 3.12} 21.2 2.16} 21.2 2.16} 55.9 5.7}

Limit Repair procedure 9.8 {1.0} 4.9 {0.5} 4.9 {0.5} 31 {3.2}

Replacement

CONNECTING ROD, CONNECTING ROD BEARING Connecting rod torsion, parallelism (mm) Torsion (in 100 mm) Parallelism (in 100 mm)

Standard

Limit

0.05 or less

0.2

0.05 or less

0.2

Repair procedure Repair or replacement

Connecting rod small end bushing and piston pin clearance (mm)

2-32

Standard

Limit

Repair procedure

0.012 – 0.025

0.05

Replacement

ENGINE ASSEMBLY Replacing the bushing Use a proper rod and a bench press. Inside diameter finish after press fitting the bushing. (mm) Standard

(Ø 35) + 0.025 – 0.017

Bearing tension Check if the tension of the bearing is sufficient. The back face must be fit closely.

Wear of connecting rod bearing Bearing and crank pin clearance Measure the inside diameter of the bearing and calculate the clearance. (mm) Standard

Limit

Repair procedure

0.030 – 0.073

0.1

Replacement

Note: Tighten the bearing cap to 39 N.m {4.0 kgf.m} and further tighten by 60° - 90°, and then measure the inside diameter and calculate the clearance. Connecting rod axial cleranace Install the connecting rod to the crankshaft and measure the clearance with a feeler gauge. (mm) Standard

Limit

Repair procedure

0.17 – 0.30

0.35

Replacement

2-33

ENGINE ASSEMBLY

CRANKSHAFT, CRANKSHAFT BEARING Inspecting the crankshaft Check the whole crankshaft visually. If there are slight streaks on the sliding surfaces, remove them with an oilstone. If there are deep streaks, replace the crankshaft. Check the crankshaft for cracking by a red check or a magnetic particle inspection. In addition, check that the tufftride layers are left on the journals and pins. Note: Since the journals and pins are finished with TUFFTRIDE method, they cannot be polished. Accordingly, undersize bearings are not prepared. Tufftriding Inspection The crankshafts are finished with TUFFTRIDE method. Tufftrided areas: Journals, Pins 1. Judgment Apply a solution of ammonium cuprous chloride (5 – 10% solution dissolved in distilled water) on the test area excluding the periphery of the crankshaft pin and the journal oil port. If no discoloration appears (hte color of copper), the crankshaft may be re-used. If discoloration appears, the crankshaft must be replaced. 2. Inspection method (1) Clean the crankshaft carefully and degrease it perfectly. Do not check the range of about 10 mm around the oil hole. (2) Drop the inspection solution from a pipette or a glass rod onto the surface to be checked. At this time, keep the surface to be checked horizontally to prevent the solution from flowing down. * Inspection solution .... 5 - 10% distilled water solution of ammonium cuprous chloride (Judgment) (1) Re-usable No discoloration is recognized after 30 – 40 seconds. (2) Unusable (No tufftride layer remaining) After 30 – 40 seconds, the light blue color changes to clear and the solution dropped area becomes the color of copper. Note: 1) Since the inspection solution is very corrosive, wipe it off immediately after finishing the inspection, and then clean the inspected surface with water, steam, etc. 2) Never put the inspection solution to the eyes, hands, or clothes. If it enters the eyes, wash it away with much water, and then consult a doctor.

2-34

(mm)

ENGINE ASSEMBLY Journal, pin outside diameter (mm) Portion

Nominal size

Standard

Journal

Ø 80

Ø 79.919 – 79.939 No. 4 journal is Ø 79.905 – 79.925

Pin

Ø 64

Ø 63.924 – 63.944

Note: Regrinding is not allowed for the crankshaft as it is tufftrided. (mm) Uneven wear

Limit: 0.05

Runout of crankshaft Apply a dial gauge to No. 4 journal, turn the shaft slowly, and read the gauge. (mm) Standard

Limit

Repair procedure

0.05 or less

0.4

Replacement

Wear of crankshaft bearing Journal and bearing clearance Measure the inside diameter of the bearing and calculate the clearance. (mm) Standard

Limit

Repair procedure

0.025 – 0.084 No. 4 journal is 0.039 – 0.098.

0.11

Bearing replacement

Note: Tighten the bearing cap to 235 N.m {24 kgf.m}. Crankshaft bearing tension Check that the bearing has sufficient tension. If the tension is insufficient, replace the bearing.

2-35

ENGINE ASSEMBLY Removing the crankshaft gear Using the puller, remove the crankshaft gear. Special tool: crankshaft gear, puller 9-8521-0141-0

Gear case cover Using the special tool, press fit the oil seal. Special tool: Front oil seal setting tool 9-8522-0034-0

Removing and installing the ring gear 1. Strike with a hammer and chisel to remove.

2. Heat the ring gear with a gas burner to install.

2-36

ENGINE ASSEMBLY

REASSEMBLY CYLINDER HEAD ASSEMBLY

Valve seal When press fitting the valve seal, apply engine oil to the periphery of the valve guide. Special tool: Valve seal setting tool 1-85221-005-0 Note: Press fit the seal securely until it reaches the cylinder head top. When press fitting the seal, take care not to damage its lip. After press fitting, check that the spring has not come off.

2-37

ENGINE ASSEMBLY Valve Valve spring Lubricate valve stems with engine oil when inserting the valve. Install the valve spring with the shorter pitch side (painted side) down.

Spring seat, split collar Use a tool (replacer) to push the spring into position. Special tool: Valve spring; Replacer 1-85235-006-0

Intake manifold Tightening torque: 2.1 – 3.1 kg.m {20.6 – 30.4 N.m}

Exhaust manifold Tightening torque: 2.6 – 3.2 kg.m {25.5 – 31.4 N.m} Install the gasket with the “TOP” mark facing up to the engine and to you.

2-38

ENGINE ASSEMBLY

ROCKER ARM SHAFT ASSEMBLY

Brackets (Rear and inner) Warm the brackets in hot water and install them to the rocker arm shaft as shown in the figure.

Bracket (Front) Warm the bracket in hot water. Coat the O-ring with oil and fit it to the bracket. Install the bracket to the rocker arm shaft with the Oring side ahead.

2-39

ENGINE ASSEMBLY

PISTON AND CONNECTING ROD ASSEMBLY

Reassembling piston, connecting rod Install the connecting rod to the piston with the notch of the piston head and the direction of the connecting rod as illustrated. Then secure the piston pin with a snap ring. Finally, check that the piston moves smoothly.

Piston pin Insert the piston pin manually without heating the piston.

2-40

ENGINE ASSEMBLY Install the expander ring Engage the abutting faces of the expander ring closely and insert into the groove of the piston.

Piston ring Install the top ring with its marking facing up. Install the second ring with its undercut facing down. The oil ring has no facing mark. Then, lubricate the periphery of the rings with oil and rotate the rings. Check that the piston rings rotate smoothly without any catching. 1-8522-1025-0

2-41

ENGINE ASSEMBLY

COMPONENT PARTS

2-42

ENGINE ASSEMBLY

CRANK SHAFT ASSEMBLY

Crankshaft gear Install the crankshaft gear to the crankshaft with the chamfered side of the key facing the front. Use the setting tool to install the crankshaft gear with the gear timing set mark facing outside. Special tools: Crankshaft gear setting tool 9-8522-0033-0

2-43

ENGINE ASSEMBLY

CYLINDER BODY PARTS Installing the camshaft bearing 1. Match the oil holes of the bearing to those of the cylinder body. 2. Using the bearing installer, install the camshaft bearing. Special tool: Camshaft bearing installer 9-8523-1818-0

Piston oil jet Install oil jet , matching its dowel pin to the pin hole of the cylinder body, and tighten check valve . (N.m {kgf.m}) Tightening torque

16 – 25 {1.6 – 2.6}

Note: Take care not to deform or damage the oil jet nozzle.

Crankshaft bearings Since the lower bearing (on the bearing cap side) does not have an oil groove or an oil hole, take care not to mistake it for the upper bearing. Note: If the lower and upper bearings are installed reversely, the crankshaft bearing will be seized. Take care.

Thrust bearings Apply sufficient amount of engine oil to the inside of the crankshaft bearing and place the crankshaft slowly. Apply oil to both sides of the thrust bearings and push them into both sides of No. 4 journal with the hand, setting the oil groove sides out (on the crankshaft side).

2-44

ENGINE ASSEMBLY

Bearing caps (1) Apply engine oil to the journal of the crankshaft. Install the bearing caps in the numerical order with their "arrows" on the front side of the engine.

Bearing caps (2) Apply engine oil to the threads and seats of the bolts. Tighten each bolt in 2 - 3 times and tighten all the bolts from the central one (No. 4) to both ends in order. After tightening each bolt, check that you can turn the crankshaft lightly with the hand. (N.m {kgf.m}) Tightening torque

16 – 25 {1.6 – 2.6}

2-45

ENGINE ASSEMBLY

PISTON AND CONNECTING ROD Installing the piston ring Before inserting each piston in the cylinder, set the piston ring as shown in the figure at left. (The abutment joint must not be at a right angle to the piston pin.)

Installing the piston Apply engine oil to the inside of the cylinder and the side of the piston. Direct the cut (front mark) of the piston head toward the front side of the cylinder body. Using the setting tool, push in the piston with the grip of a hammer until it reaches the crank pin. Special tool: Piston setting tool 9-8522-1173-0

Note 1: When pushing in the piston, turn the crankshaft, as necessary, so that the large end of the connecting rod will not interfere with the crank pin. Note 2: Take care not to bend or damage the oil jet with the large end of the connecting rod.

Connecting rod and cap Apply engine oil to the bearing and crank pin and install the connecting rod cap, matching the stamp of connecting rod cap to that of the connecting rod. Apply molybdenum disulfide to the threads and seats of the bolts before tightening them. At this time, check that the stamps are on the camshaft side. (N.m {kgf.m}) Tightening torque

39 {4.0} o 60° – 90°

Note: After tightening the bolts, check that you can turn the crankshaft lightly.

2-46

ENGINE ASSEMBLY

TIMING GEAR, TAPPET, AND OIL PUMP Idle gear shaft 1. Direct the oil hole of the shaft toward the camshaft. 2. Match the bolt hole of the shaft to the screw hole of the cylinder body. 3. Using the thrust collar bolt as a guide, drive the shaft with a plastic hammer, etc.

Timing gear case Match the gear case to the dowel pin, install it and gasket together and tighten the bolts alternately and evenly. (N.m {kgf.m}) Tightening torque

21 – 30 {2.1 – 3.1}

Idle gear 1. Apply engine oil to the inside of the idle gear. 2. Match mark "A" of the idle gear to that of the crankshaft gear and install the idle gear to the idle gear shaft. 3. Install the idle gear with the chamfered side of the thrust collar out. (N.m {kgf.m}) Tightening torque

44 – 64 {4.5 – 6.5}

Camshaft assembly 1. Apply engine oil to the camshaft journals and install the camshaft to the cylinder body. Note: Install the camshaft carefully so that its lift will not damage the camshaft bearing.

2-47

ENGINE ASSEMBLY 2. When installing the camshaft, match mark "B" of the idle gear to that of the crankshaft gear. 3. Check that the camshaft is installed perfectly and tighten the thrust plate. (N.m {kgf.m}) Tightening torque

21 – 30 {2.1 – 3.1}

Tappet Coat each tappet with engine oil and install it to the cylinder body.

Oil pump assembly Fill the oil pump with engine oil and install it.

Oil pump assembly and coupling 1. Apply "engine oil containing molybdenum disulfide" to the serrated parts of the coupling and the tooth surfaces of the oil pump drive gear.

2. After installing the oil pump, install the oil pipe and tighten the bolts in the order shown in the figure. (N.m {kgf.m}) Tightening torque

2-48

Oil pump bolt

42 – 62 {4.3 – 6.3}

Oil pipe bolt

21 – 30 {2.1 – 3.1}

ENGINE ASSEMBLY

REAR OIL SEAL, HOUSING, OIL PAN, AND OIL COOLER Flywheel housing Apply gasket sealant and install the flywheel housing, taking care not to damage the oil seal, and then tighten the bolts in the numerical order shown in the figure. (N.m {kgf.m}) Tightening torque

Bolt (M8 x 1.25)

21 – 30 {2.1 – 3.1}

Bolt (M14 x 1.5) 147 – 167 {15.0 – 17.0}

Note: A part of the back side of the flywheel housing stops oil from oozing through the oil gallery plug of the cylinder body. Apply gasket sealant to that part, too.

Rear oil seal (Axial type) Install the adapter to the rear part of the crankshaft with the 2 bolts. Insert the oil seal around the adapter and press fit it with the sleeve and check the installed dimension. Standard dimension: 11.6 ± 0.3 mm Special tool: Rear oil seal setting tool 5-8840-9025-0

Oil pan Install the oil pan and gasket together to the cylinder body and tighten the bolts alternately and evenly. (N.m {kgf.m}) Tightening torque

21 – 30 {2.1 – 3.1}

Note: Wipe off oil and grease from the gasket fitting surface of the cylinder body, and then install the gasket to the correct position of the cylinder body.

Oil cooler Apply gasket sealant to the packing and stick it to the body case and tighten the bolts in the numerical order shown in the figure. (N.m {kgf.m}) Tightening torque

14 – 24 {1.4 – 2.4}

2-49

ENGINE ASSEMBLY Oil relief valve Apply engine oil to the threads of the oil relief valve and tighten it, check that the gasket is not shifted. (N.m {kgf.m}) Tightening torque

21 – 30 {2.1 – 3.1}

Oil pump pinion gear, collar, and hole cover 1. When installing the pinion gear, apply "engine oil containing molybdenum disulfide" to the part indicated with the arrow. 2. Fit the gasket to the hole cover groove securely and install them to the cylinder body. (N.m {kgf.m}) Tightening torque

21 – 30 {2.1 – 3.1}

FUEL INJECTION PUMP AND GEAR CASE COVER Installing the injection pump and gear case cover Match the "match marks" of the injection pump and install the gear case cover. Before installing the injection pump and case cover, fit the packing to the gear case. If a little Three bond is applied to the surface of the packing, the packing will not come off. Note: Match the "gear match marks" A, B, and C securely. (N.m {kgf.m}) Tightening torque

2-50

21 – 30 {2.1 – 3.1}

ENGINE ASSEMBLY

RELATIONSHIP BETWEEN FLYWHEEL, CRANK PULLEY, AND CYLINDER HEAD Flywheel Install the flywheel, matching it to the dowel pin of the crankshaft, and insert the bolts through the washers. Tighten the bolts in the diagonal order. (N.m {kgf.m}) Tightening torque

196 – 240 {20.0 – 24.5}

Apply engine oil.

Crank pulley (N.m {kgf.m}) Tightening torque

539 – 637 {55.0 – 65.0}

1. Match the crankshaft gear key to the key way at the crank pulley end. 2. Apply "molybdenum disulfide" to the washer contact surface of the taper bushing and install it. Then, apply "molybdenum disulfide" to all the threads and seat of the nut and tighten it with the chamfered side ahead. Cylinder head gasket Clean the top of the cylinder body. Fit the cylinder head basket to the cylinder body with the "stamp" (FRONT TOP) up and on the front side.

Cylinder head Clean the underside of the cylinder head and place it slowly on the gasket. Apply "molybdenum disulfide" to the seat and threads of the head bolts and tighten them spirally, starting with the central one, as shown in the figure. Use the 6 shorter bolts on the nozzle side. Do not use the head bolts more than 2 times. Tightening torque of head bolt (N.m {kgf.m}) Tightening Loosen 69 {7.0} o o 88 {9.0} o 90° – 120° torque all bolts

2-51

ENGINE ASSEMBLY Push rod Insert each push rod and hit it lightly with a plastic hammer to bring the tappet in contact with the cam surface of the camshaft.

Rocker arm shaft assembly Put the adjustment bolts of the rocker arms in the hollows of the push rods and tighten them evenly, starting with the central one. Note: Since the bolt of the front bracket is used as an oil passage, do not replace it with another one. (N.m {kgf.m) Tightening torque

25 – 35 {2.6 – 3.6}

Adjusting the valve clearance

Tappet chamber cover Apply "gasket sealant" (TB1207B) to the tappet chamber cover and install it to the tappet chamber of the cylinder block. (N.m {kgf.m}) Tightening torque

2-52

21 – 30 {2.1 – 3.1}

ENGINE ASSEMBLY

EXTERIOR PARTS

The Nos. in ( ) indicate the assembly order.

2-53

ENGINE ASSEMBLY Nozzle holder (N.m {kgf.m}) Tightening torque

17 – 21 {1.7 – 2.1}

Glow plug Connector (N.m {kgf.m}) Tightening torque (Glow plug)

20 – 25 {2.0 – 2.5}

Fuel piping 1. Install the injection pipe and secure it with the clip. (N.m {kgf.m}) Tightening torque

29 {3.0}

2. Install the fuel pipe and secure it with the clip. (N.m {kgf.m}) Tightening torque

20 – 25 {2.0 – 2.5}

3. Install the leak-off pipe. (N.m {kgf.m}) Tightening torque

10 – 15 {1.0 – 1.5}

Note: Be sure to use packing for each eyebolt. If dirt enters the pipes or injection pump, it can cause a trouble.

2-54

ENGINE ASSEMBLY Turbocharger Fit the gasket with the folded side up and install the turbocharger. At this time apply seizure prevention compound to the mounting nuts. Since heat-resistant nuts are used, do not replace them with other ones. (N.m {kgf.m}) Tightening torque

52 {5.3}

Oil pipe: Turbocharger Fit the O-ring to the oil feed pipe and install the oil pipe. (N.m {kgf.m}) Turbocharger Cylinder body side side Tightening torque

Oil feed pipe

25 {2.6}

21 {2.1}

Return pipe

37 {3.8}

21 {2.1}

Note: Before installing the pipe, supply engine oil through the oil inlet of the turbocharger.

Water pump (N.m {kgf.m}) Tightening torque

42 – 62 {4.3 – 6.3}

Fan pulley Fan belt Fan

2-55

ENGINE ASSEMBLY Generator For adjustment of the fan belt tension, see the section of the fan belt (page 1-25).

Starting motor (N.m {kgf.m}) Tightening torque

75 – 91 {7.6 – 9.3}

Note: Secure the ground cable and starting motor together.

2-56

LUBRICATING SYSTEM

3 LUBRICATING SYSTEM Page Lubricating oil circulation system diagram ...................................................................................................... 3-2 Oil pump .......................................................................................................................................................... 3-3 Disassembly .............................................................................................................................................. 3-3 Inspecting .................................................................................................................................................. 3-4 Assembly ................................................................................................................................................... 3-6 Oil relief valve .................................................................................................................................................. 3-8 Removing and installing the oil relief valve .............................................................................................. 3-8 Inspecting .................................................................................................................................................. 3-8

3-1

LUBRICATING SYSTEM

LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM

3-2

LUBRICATING SYSTEM

OIL PUMP DISASSEMBLY

Disassembly procedure 1. Oil pump body 2. Drive shaft and gear 3. Driven gear 4. Split pin and spring seat 5. Relief valve spring 6. Relief valve 7. Oil pump cover

3-3

LUBRICATING SYSTEM

INSPECTING Clearance between gear and inside wall Using a feeler gauge, measure the clearance between the gear and cover inside wall. If the clearance between the gear and cover inside wall exceeds the limit, replace the gear or cover assembly. Clearance between gear and cover inside wall (mm) Standard

Limit

0.075 – 0.150

0.2

Clearance between gear side and cover top Using a feeler gauge and a square, measure the clearance between the gear side and cover top. If the clearance between the gear side and cover top exceeds the limit, replace the gear or cover assembly. Clearance between gear side and cover top (mm) Standard

Limit

0.040 – 0.094

0.15

Clearance between drive shaft and pump body Measure the outside diameter of the drive shaft and the inside diameter of the pump body, and then calculate the clearance. 1. Using a micrometer, measure the outside diameter of the drive shaft. Outside diameter of drive shaft (mm) Nominal size

Limit

Ø 16

15.9

2. Using a dial gauge, measure the inside diameter of the pump body. If the clearance between the drive shaft and pump body exceeds the limit, replace the oil pump assembly. Clearance between drive shaft and pump body (mm)

3-4

Standard

Limit

0.032 – 0.070

0.15

LUBRICATING SYSTEM Clearance between driven gear shaft and gear 1. Using a micrometer, measure the outside diameter of the drive gear shaft. Outside diameter of driven gear shaft (mm) Standard

Limit

15.956 – 15.974

15.9

2. Using caliper calibrator, measure the inside diameter of the driven gear. If the clearance between the driven gear shaft and gear exceeds the limit, replace the gear or cover assembly. Clearance between driven gear shaft and gear (mm) Standard

Limit

0.045 – 0.078

0.15

Relief valve and spring Check the relief valve and spring visually. If they are damaged, replace them.

3-5

LUBRICATING SYSTEM

ASSEMBLY

Assembly procedure 1. Oil pump cover 2. Relief valve 3. Relief valve spring 4. Split in and spring seat 5. Driven gear 6. Drive shaft and gear 7. Oil pump body

3-6

LUBRICATING SYSTEM Driven gear Drive shaft and gear 1. Apply engine oil to the driven gear and shaft. 2. Apply engine oil to the drive shaft and gear and install them to the pump body. 3. Install the pump cover to the pump body and secure them with the bolts. (N.m {kgf.m}) Tightening torque

10 – 16 {1.0 – 1.6}

3-7

LUBRICATING SYSTEM

OIL RELIEF VALVE REMOVING AND INSTALLING THE OIL RELIEF VALVE Removal procedure 1. Remove the injection pump. 2. Remove the oil relief valve. Installation procedure 1. Install the oil relief valve. 2. Install the injection pump. (N.m {kgf.m}) Tightening torque

21 – 30 {2.1 – 3.1}

INSPECTING Relief valve and spring Press the relief valve with a screwdriver, etc. to check for fixing. If it is fixed, replace it. Breathe into the relief valve to check for air leakage. If air leaks through the relief valve, replace the relief valve.

3-8

COOLING SYSTEM

4 COOLING SYSTEM Page Cooling water circulating system ..................................................................................................................... 4-2 Water pump ..................................................................................................................................................... 4-3 Component parts ....................................................................................................................................... 4-3 Disassembly .............................................................................................................................................. 4-4 Assembly ................................................................................................................................................... 4-6 Inspecting .................................................................................................................................................. 4-8 Thermostat ....................................................................................................................................................... 4-9 Inspecting and replacing ........................................................................................................................... 4-9

4-1

COOLING SYSTEM

COOLING WATER CIRCULATING SYSTEM

4-2

COOLING SYSTEM

WATER PUMP COMPONENT PARTS

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cover Packing Screw Seal unit Impeller Shaft Ball bearing: Rear Ball bearing: Front Snap ring (Clip)

10. 11. 12. 13. 14. 15. 16.

Snap ring Fan center Spacer Dust cover Spacer (Washer) Seal: Secondary (Oil seal) Pump body

4-3

COOLING SYSTEM

DISASSEMBLY Rear cover Remove the rear cover and packing.

Fan center Remove the fan center.

Snap ring Remove the dust cover and the snap ring on the fan center side.

Impeller Using the special tool (remover), pull out the impeller. Special tool: Water pump impeller remover 9-8521-0097-0 Note: Never pull out the impeller by giving impacts with a hammer, etc.

4-4

COOLING SYSTEM Shaft and bearing Using a press, push out the shaft and bearing together from the impeller side.

Bearing and spacer Using a press, remove the bearing and spacer (including the washer) from the shaft.

Oil seal and seal unit Remove the oil seal from the impeller side and remove the seal unit from the center side.

4-5

COOLING SYSTEM

ASSEMBLY Note: Since the fan center and impeller are press fitted to the shaft, they are loosened if they are removed and installed repeatedly. Accordingly, if they have been removed 2 times or their press fitting load is less than 5.9 kN {600 kgf}, replace the water pump assembly. Oil seal Apply bearing grease (NIHON KOYU, HILEX NO. 3 GREASE) to the lip of the oil seal. Then, using a press, install the oil seal to the pump body. Note: Do not reuse the oil seal. Install the new oil seal by using the jig.

Rear bearing Install the washer to the shaft, and then press fit the rear bearing to the shaft with the seal side toward the impeller. Note: Hold the inner race or both inner race and outer race of the bearing.

Shaft Press fit the shaft to the pump body. At this time, press the outer race of the bearing with the special tool (setting tool). Special tool: Water pump bearing setting tool 9-8522-1140-0 Press fit the shaft until the bearing reaches the pump body. Before press fitting, fill the space between the inner race and outer race of the bearing with bearing grease (NIHON KOYU, HILEX NO. 3 GREASE). Note: The bearing may be reused only when it has little play and rotates smoothly.

4-6

COOLING SYSTEM Spacer Install the spacer to the shaft and supply sufficient bearing grease to the spaces between the bearing and body and shaft. (g) Quantity of grease

Approx. 28

Front bearing Press fit the front bearing. Direct the seal side toward the center. Hold both of the shaft and pump body so that the shaft will not go through down and the bearing will not be broken and press fit the bearing until it reaches the spacer. Use the jig to push the inner race and outer race simultaneously. Dust cover Install the slip ring and dust cover.

Fan center Press fit the fan center. Hold only the shaft so that it will not go through and the bearing will not be broken and press fit the fan center until it reaches the dust cover.

Seal unit Install the seal unit to the pump body. Note: Fix the pump body and press fit the seal unit with the jig. Do not reuse the seal unit.

4-7

COOLING SYSTEM Floating seat (Seal unit) Press fit the floating seal side of the seal unit to the impeller. Note: Limit leaning of the floating seal to 0.1 mm.

Impeller While press fitting the impeller, adjust the clearance between it and the pump body to the standard range. At this time, put a liner to the shaft on the fan center side so that the snap ring will not be broken. Clearance between impeller and body (mm) Standard

0.3 – 1.0

Cover Install the packing and cover with the screws.

INSPECTING Turn the pump with the hand and check that it rotates smoothly.

4-8

COOLING SYSTEM

THERMOSTAT INSPECTING AND REPLACING

Inspecting the outside Check the outside of the thermostat for wear, damage, deformation, etc. If there is any abnormality, replace the thermostat. Inspecting the function Opening temperature

82 ± 2 °C

Valve lift

Min. 10 mm (At 95°C)

If there is any abnormality, replace the thermostat.

4-9

FUEL SYSTEM

5 FUEL SYSTEM Page Fuel circulation system diagram ...................................................................................................................... 5-2 Nozzle holder assembly ................................................................................................................................... 5-3 Nozzle assembly .............................................................................................................................................. 5-3

5-1

FUEL SYSTEM

FUEL CIRCULATION SYSTEM DIAGRAM

5-2

FUEL SYSTEM

NOZZLE HOLDER ASSEMBLY

NOZZLE ASSEMBLY Inspection and replacement Put the removed nozzle into clean light oil and separate the needle valve from the nozzle body to clean them. Check to see if the valve moves lightly through the needle body. If the valve does not move smoothly, remedy or replace the defective part.

Adjustment Refer to “INSPECTION AND MAINTENANCE” for the injection pressure adjustments and spray conditions. (Page 1 - 25)

5-3

AIR COMPRESSOR

6 AIR COMPRESSOR Page Outline .............................................................................................................................................................. 6-2 Sectional view ............................................................................................................................................ 6-2 Disassembly ..................................................................................................................................................... 6-3 Inspecting and repairing .................................................................................................................................. 6-4 Assembly .......................................................................................................................................................... 6-6

6-1

AIR COMPRESSOR

OUTLINE SECTIONAL VIEW

Main specifications Piston ring Delivery Bore x Stroke Max. speed Revolution ratio (to crankshaft) Weight

6-2

mm rpm kg

3-piece unit 0.155 L/rev {155 cc/rev.} 70 X 40 1,650 0.5 7.0

AIR COMPRESSOR

DISASSEMBLY

Disassembly procedure 1. Cylinder head and gasket e2. Cylinder body 3. Piston 4. Bearing cover

5. Bearing 6. Connecting rod 7. Crankshaft

Important work 2. Cylinder body 1) Remove the cylinder mounting bolts. 2) Lightly hitting the cylinder, remove it from the crankcase.

6-3

AIR COMPRESSOR

INSPECTING AND REPAIRING If a damaged or abnormal part is found during inspection, repair or replace it. Cylinder Using a cylinder gauge, measure uneven wear of the inside of the cylinder at the piston skirt. Uneven wear of inside of cylinder (mm) Standard

Limit

0 – 0.03

0.2

Cylinder and piston 1. Measure the inside diameter of the cylinder and the outside diameter of the piston and calculate the clearance. Clearance between cylinder and piston (mm) Standard

Limit

0.10 – 0.30

1.0

Note: Measure the outside diameter of the piston at the skirt at a right angle to the piston pin.

2. Measure the clearance between the oil ring groove and oil ring and the closed gap of the piston. Clearance between ring groove and ring (mm) Standard

Limit

0.025 – 0.050

0.15

Closed gap of piston ring

6-4

(mm)

Standard

Limit

0.10 – 0.30

1.0

AIR COMPRESSOR Piston pin and connecting rod 1. Measure the clearance between the piston pin and piston pin hole. Clearance between piston pin and piston pin hole (mm) Standard

Limit

0.002 – 0.023

0.04

2. Measure the clearance between the piston pin and the small end of the connecting rod. Clearance between piston pin and small end of connecting rod (mm) Standard

Limit

0.002 – 0.026

0.1

Crankpin and connecting rod Measure the clearance between the crankpin and the large end of the connecting rod. Clearance between crankpin and large end connecting rod (mm) Standard

Limit

0.02 – 0.06

0.15

6-5

AIR COMPRESSOR

ASSEMBLY

Disassembly procedure e1. Crankshaft and bearing e2. Connecting rod 3. Bearing e4. Bearing cover

6-6

5. Piston e6. Cylinder body e7. Cylinder head and gasket

AIR COMPRESSOR Important work 1. Crankshaft, bearing, and spacer Using a copper hammer, install the bearing and spacer to the crankshaft.

2. Connecting rod (1) Apply engine oil to the bearing. (2) Install the connecting rod and bearing cap. (3) Tighten the connecting rod bearing cap bolts to the specified torque. Bearing cap bolt (N.m {kgf.m}) Tightening torque

23 – 26 {2.3 – 2.7}

4. Bearing cover Install the bearing cover to the crankcase and tighten the mounting bolts to the specified torque. Bearing cover mounting bolt (N.m {kgf.m}) Tightening torque

5.9 {0.6}

5. Piston pin snap ring Using the snap ring priers, install the snap ring.

6-7

AIR COMPRESSOR 5. Piston rings (1) Using the piston ring replacer, install the piston rings. (2) Direct the abutment joints of the piston rings as shown in the figure. Front mark No. 1 compression ring No. 2 compression ring Oil ring with expander (Upper) Oil ring with expander (Upper) Oil ring (Upper) rail (3) Apply engine oil to the surfaces.

7. Cylinder body (1) Apply engine oil to the O-ring and install it to the cylinder body. Take care not to twist the O-ring. (2) Install the cylinder body to the crankcase and tighten the mounting bolts to the specified torque. Cylinder body bolt (N.m {kgf.m}) Tightening torque

27 – 31 {2.8 – 3.2}

8. Cylinder head (1) Install cylinder head and tighten the mounting bolts to the specified torque. (2) Tighten unloader valve to the specified torque. Tightening torque of mounting bolt and valve (N.m {kgf.m})

6-8

Cylinder head bolt

27 – 31 {2.8 – 3.2}

Unloader valve

44 – 54 {4.5 – 5.5}

FLYWHEEL P.T.O.

7 FLYWHEEL, P.T.O. Page Component parts ............................................................................................................................................. 7-2 Disassembly ..................................................................................................................................................... 7-3 Inspection and measurement .......................................................................................................................... 7-6 Assembly .......................................................................................................................................................... 7-9

7-1

FLYWHEEL P.T.O.

COMPONENT PARTS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

7-2

Bearing case Packing Oil seal P.T.O. gear P.T.O. shaft Bearing Nut Lock washer P.T.O. flange Packing Oil thrower Washer Nut Split pin Spacer Shim Idle gear Bearing Outer spacer Inner spacer

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Cover Packing Spindle Bolt Nut Lock washer Bolt Spring washer Plain washer Bolt Spring washer Plain washer Clip; Oil pipe Bolt Nut Spring washer Spacer

FLYWHEEL P.T.O.

DISASSEMBLY The following disassembly and assembly drawings show Model DH100 engine. The shapes of some parts of other models are different from those in these drawings. Removing the P.T.O. gear assembly 1. Remove the P.T.O. gear assembly from the flywheel housing. Remove the oil pipe for lubrication of the P.T.O. gear in advance.

2. Removing the flywheel Remove the flywheel.

3. Removing the idle gear 1) Remove the idle gear cover.

2) Raise the lock washer claw and remove the fixing nut of the idle gear. (Width across flats: 65 mm)

7-3

FLYWHEEL P.T.O. Disassembling the P.T.O. gear assembly 1. Removing the flange mounting nut Grip the P.T.O. fixing nut in a vise and remove the split pin and flange mounting nut. Then, remove the flange, bearing (outer), bearing case, etc.

2. Removing the P.T.O. gear fixing nut Raise the lock washer claw and loosen the nut.

3. Removing the bearing (inner) Using a press, pull out the bearing.

Disassembly of idle gear The spindle, bearing, idle gear, etc. are removed by removing the idle gear in the above step.

3) Remove the spindle fixing bolt.

7-4

FLYWHEEL P.T.O. 4) Insert a proper rod in the Ø17 hole from which the bolt was removed and move it up, down, to the right, and to the left to remove the spindle. At this time, the tapered roller bearing (outer) is removed, too.

5) Put your hand in the hole from which the P.T.O. gear was removed and take out the idle gear and tapered roller bearing (inner).

4. Removing the crankshaft gear 1) Remove the oil seal retainer and oil thrower from the crankshaft.

2) Insert a proper rod in the hole of the crankshaft gear and move it up, down, to the right, and to the left to remove the gear.

7-5

FLYWHEEL P.T.O.

INSPECTION AND MEASUREMENT Measuring the backlash of each gear Insert and flatten fuses between the crankshaft gear and idle gear and between the idle gear and P.T.O. gear, and then measure their thickness, or measure the backlash between the gears with a dial gauge. If the backlash of each gear is exceeds the limit or the tooth surface of that gear is damaged extremely, replace that gear. (mm) Inspection item

Assembly standard

Limit

Backlash of each gear

0.10

0.2

Inspecting and replacing the bearing 1. Inspecting Visually inspect the bearings of the idle gear and P.T.O. gear. If there are pitting marks or bruises on their rollers or inside of their outer races, replace them. 2. Replacement procedure Use a press to remove and install the inner race of each bearing. The outer race can be removed and installed by hitting it lightly with a brass rod, however. For selection of the bearing shim inserted when the bearing is installed, see "SELECTING THE P.T.O. GEAR BEARING SHIM". Selecting the idle gear bearing spacer 1. Place the idler gear and bearing assembly, excluding the spacer, on a surface plate and measure (t1) of the bearing inner race top with a dial gauge.

2. Select and install a proper spacer and measure (t2) of the bearing inner race top similarly to step 1.

7-6

FLYWHEEL P.T.O. 3. Select one from 23 spacers prepared at intervals of 0.07 mm so that t1 - t2 will be 0 - 0.07 mm. Bearing spacer (mm) Part No. 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9

– – – – – – – – – – – – – – – – – – – – – – –

38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226 38226

– – – – – – – – – – – – – – – – – – – – – – –

022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044

Thickness – – – – – – – – – – – – – – – – – – – – – – –

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

9.28 9.21 9.14 9.07 9.00 8.93 8.86 8.79 8.72 8.65 8.58 8.51 8.44 8.37 8.30 8.23 8.16 8.09 8.02 7.95 7.88 7.81 7.74

Note: After the above adjustment, tighten the fixing nut of the idle gear to about 147 N.m {15 kgf.m} and check that you can turn the gear lightly with the hand.

7-7

FLYWHEEL P.T.O. Selecting P.T.O. gear bearing shim Similarly to "Selecting the idle gear bearing spacer" explained above, select the P.T.O. gear bearing shim. Select 3 shims, however, so that t2 - t2 will be 0.01 - 0.07 mm. Bearing shims

(mm) Part No.

9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9

7-8

– – – – – – – – – – – – – – – – – –

41229 41229 41229 41229 41229 41229 41229 41229 41229 41229 41229 38226 38226 38226 38226 38226 38226 38226

– – – – – – – – – – – – – – – – – –

324 325 326 327 328 329 330 331 332 333 334 045 046 047 048 049 050 051

Thickness – – – – – – – – – – – – – – – – – –

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3.50 3.51 3.52 3.53 3.54 3.55 3.56 3.57 3.58 3.59 3.60 17.95 18.20 18.45 18.70 18.95 19.20 19.45

FLYWHEEL P.T.O.

ASSEMBLY Assembling the P.T.O. gear 1. Install the P.T.O. gear and lock washer to the P.T.O. shaft and tighten the nut. (N.m {kgf.m}) Tightening torque

294 {30.0}

Install the gear with the more projected boss on the nut side. Do not lock at this time but lock after installing all the parts. Note: When tightening the nut, fit the flange to the spline for convenience.

2. Press fit the bearing to the shaft with a press. Apply engine oil to the inner and outer races of the bearing. Special tool: P.T.O. bearing setting tool 9-8524-1702-0

3. Install the bearing spacers and shims selected in the previous section to the shaft, and then install the O-ring and bearing case, bearing, and oil thrower. Next, apply engine oil between the lips of the oil seal and apply "SHINETSU KAGAKU, (KE42) SILICONE RUBBER" to the bearing case, and then press fit the oil seal.

4. Install the flange and washer to the shaft with the specified tightening torque, and then check that you can turn the bearing cage lightly with the hand. (N.m {kgf.m}) Tightening torque

294 – 392 {30.0 – 40.0}

7-9

FLYWHEEL P.T.O. Installing the flywheel to the P.T.O. 1. Assembling the crankshaft gear 1) Match the dowel pin at the rear end of the crankshaft to the dowel pin hole of the crankshaft gear and drive the crankshaft gear with a copper hammer.

2) Install the oil seal to the crankshaft gear.

2. Assembling the idle gear 1) Install the bearing outer race to the idle gear. Insert the idle gear and inner bearing together in the P.T.O. gear mounting hole and install the bearing and spindle assembly through the idle gear mounting hole (shown in the figure at right), and then tighten the spindle fixing bolt. (N.m {kgf.m}) Tightening torque

157 – 177 {16.0 – 18.0}

2) Tighten the nut to about 147 N.m {15 kgf.m} and bend the claw of the lock washer. 3) Fit the O-ring to the idle gear cover and install them to the flywheel housing.

7-10

FLYWHEEL P.T.O. 3. Installing the P.T.O. gear Install the P.T.O. gear assembly assembled in the previous section to the flywheel. 4. Installing the flywheel Apply engine oil to the flywheel and install it. (N.m {kgf.m}) Tightening torque

196 – 240 {20.0 – 24.5}

7-11

TROUBLESHOOTING

8 TROUBLESHOOTING Page Engine fails to start ........................................................................................................................................ 8- 2 Engine fails to run smoothly .......................................................................................................................... 8- 3 Engine lacks power ....................................................................................................................................... 8- 4 Engine knocks ............................................................................................................................................... 8- 6 Smoky exhaust .............................................................................................................................................. 8- 7 Excessive oil consumption ............................................................................................................................ 8- 8 Excessive fuel consumption .......................................................................................................................... 8- 9 Low oil pressure ............................................................................................................................................ 8-10 Run-down battery ........................................................................................................................................... 8-11 Engine does not start .................................................................................................................................... 8-12

8-1

TROUBLESHOOTING

ENGINE FAILS TO START

8-2

TROUBLESHOOTING

ENGINE FAILS TO RUN SMOOTHLY

8-3

TROUBLESHOOTING

ENGINE LACKS POWER

8-4

TROUBLESHOOTING

8-5

TROUBLESHOOTING

ENGINE KNOCKS

8-6

TROUBLESHOOTING

SMOKY EXHAUST

8-7

TROUBLESHOOTING

EXCESSIVE OIL CONSUMPTION

8-8

TROUBLESHOOTING

EXCESSIVE FUEL CONSUMPTION

8-9

TROUBLESHOOTING

LOW OIL PRESSURE

8-10

TROUBLESHOOTING

RUN-DOWN BATTERY

8-11

TROUBLESHOOTING

ENGINE DOES NOT START

Engine does not start

Crankshaft does not revolve

Crankshaft revolves

Check if starting motor revolves Revolving speed is low

Revolving speed is normal

Check battery charge level and check battery terminals for disconnection and corrosion

Check engine unit

OK Check battery charge level and check battery terminals for disconnection and corrosion

Check meshing condition of pinion and ring gear

OK Same as *1 • Charge or replace battery • Repair battery terminals

OK

Check operating sound of electromagnetic switch

• Check key switch • Check connecting condition • Check and repair wiring to electromagnetic switch of starting motor • Repair or replace electromagnetic switch

Check roller clutch of pinion, and replace if necessary

Engine oil viscosity is abnormal.

• Check meshing spring for fatigue and sliding condition of pinion. • If pinion ring gear end is worn, replace it. • Repair pinion cap.

Viscosity is improper (Replace engine oil)

OK

Replace starting motor

OK

Check revolution of starting motor unit (Connect to terminal M) Check inside of engine

OK

Replace starting motor (brush holder or armature)

8-12

OK

There is defective contact in electromagnetic switch of starting motor (Replace electromagnetic switch)

OK

Starting motor is defective (Repair starting motor)

SPECIAL TOOLS

9 SPECIAL TOOLS Page Special tool list ................................................................................................................................................. 9-2

9-1

SPECIAL TOOLS

SPECIAL TOOL LIST No.

Outside view

Part No.

Part name

Page

1

9 – 8511 – 3703 – 0

Injection pump wrench

1-24

2

5 – 85317 – 001 – 0

Compression gauge adapter

1-24

Valve spring replacer

2-12

3

1 – 85235 – 006 – 0 Removing and installing split collar

2-38

Tapered bushing puller 4

9 – 8521 – 0122 – 0

2-13 Removing tapered bushing of crank pulley Camshaft bearing puller and installer

5

6

7

Removing and installing camshaft bearing

2-17 2-28 2-44

Piston ring replacer

2-18

Removing and installing piston ring

2-41

Crankshaft gear puller

2-19

Removing crankshaft gear

2-36

9 – 8523 – 1818 – 0

1 – 8522 – 1025 – 0

9 – 8521 – 0141 – 0

9 – 8523 – 1169 – 0

Cylinder liner remover

5 – 8523 – 1004 – 0

Angle

8

Removing cylinder liner

2-22

Cylinder liner setting tool 9

5 – 8522 – 1018 – 0

2-22 Installing cylinder liner Valve guide replacer

11

1 – 85220 – 001 – 0

2-23 Removing and installing valve guide

9-2

SPECIAL TOOLS

No.

Outside view

Part No.

Part name

Page

Front oil seal setting tool 11

9 – 8522 – 0034 – 0

2-26 Installing oil seal to timing gear case cover Valve seal setting tool

12

1 – 85221 – 005 – 0

2-37 Installing valve seal Crankshaft gear setting tool

13

9 – 8522 – 0033 – 0

2-43 Installing camshaft bearing Piston setting tool

14

9 – 8522 – 1173 – 0

2-46 Installing piston to cylinder liner

15

5 – 8840 – 2360 – 0

Rear oil seal remover

2-17

16

5 – 8840 – 9025 – 0

Rear oil seal setting tool

2-49

9-3

REPAIR SERVICE STANDARD

10 REPAIR SERVICE STANDARD Page General .......................................................................................................................................................... 10-2 Repair service standard ................................................................................................................................. 10-4

10-1

REPAIR SERVICE STANDARD

GENERAL 1. This standard table is applicable to KOMATSU FORKLIFT diesel engine model 6BG1 and 6BG1T. 2. Repair Service Standard includes the Checking Item, Nominal Size, Assembly Standard, Limit, and Repair Method. 1) Nominal Size specifies the values to be referred to in manufacturing of new engines. 2) Assembly Standard specifies the target values that apply to reconditioned engines and may somewhat differ from those values of newly assembled engines. 3) Limit specifies the values beyond which any worn parts should not be used continually, but repaired or replaced. 4) Repair Method gives the points of repair work. 5) Unless otherwise specified, all dimensions are in mm. 3. Definition 1) “Wear” means a difference between the size of non-worn part (or nominal size if no part remains without wear) and the size of most worn down part. 2) “Uneven wear” means a difference between a maximum wear and a minimum wear. 4. When reconditioning an engine as a whole is entrusted to you, first check the engine by bench test or another suitable means to asscertain which part needs repairing, and proceed to an overhaul of the restricted, minimum necessary portion of the engine. When reconditioning a part of the engine is requested, carry out repair work of that part according to this repair service standard.

10-2

Part name

Cylinder block

Engine

10-4

Proper time for engine overhaul

Group

Hydraulic test (3 min)

Flatness of cylinder block top surface

Projection of liner from cylinder

0.05 or less

490 {5}

KPa {kgf/cm2}

0.2

Ø 105.2

200 %

100 %

Ø 105

140 %

2.5 {26}

Limit

100 %

0.03 – 0.10

3.0 {31}

Nominal size Assembly standard

mm

mm

mm

L/h

Oil consumption,

Wear of liner inside wall at position A – A

L/h

MPa {kg/cm2}

Cylinder compression pressure,

Fuel consumption,

Unit

Checking item

REPAIR SERVICE STANDARD

It water leak is found, repair or replace.

Use surface grinder for correction.

Adequate projection is indispensable

If uneven step-wear is found in upper portion, repair or replace with normal size of liner.

Overhaul the engine.

Repair method

Maximum allowable grinding depth 0.3.

Difference in projection between adjacent liners shall not exceed 0.03. (0.0012)

0.001 – 0.019

(Reference) Interface of liner to cylinder:

When measurement on new engine is assumed 100 %

Water temperature: 70 – 85°C Speed: Approx. 200 – 240 rpm (Varies with altitude)

Remarks

REPAIR SERVICE STANDARD

Engine

Main moving parts

Part name

Cylinder head

Piston

Group

• Clean bolt seat and threads and apply molybdenum disulfide. • After tightening by angular method, never retighten. • Do not use bolt more than 2 times.

69 (7.0) O (Loosen all) O 88 (9.0) O 90° – 120°

Wear of pin

Clearance between piston pin and pin hole

Piston and cylinder clearance measured at the position 82 mm below top surface

mm

mm

mm

N·m Cylinder head bolt tightening torque, (angular method) {kgf·m}

Ø 35

If water leak is found, repair or replace.

490 {5}

KPa {kgf/cm2}

Hydraulic test (3 min),

0.05 or less

0.005 – 0.018

Clearance at major axis 0.047 – 0.085

Ø 34.95

0.05

0.4

Replace piston.

It undue knock is mode, replace piston or piston pin.

Correct.

Correct with ginder.

mm

0.2

Flatness of manifold fitting surface

0.05 or less

mm

Warpage (flatness) of underside (mounting face) of cylinder head

Part Nos. of pistons have been set by grades since August 1997. For details, see page 56.

Tighten to 69 N·m {7.0 kgf·m}, then loosen. Next, tighten to 88 N·m {9.0 kgf·m}. Next tighten by 90° – 120°.

Maximum allowable grinding depth: 0.3 Never allow piston to strike valves.

After correction, lap contact surface satisfactorily.

Correct with valve seat cutter.

2.0

1.5

mm

Valve seat angle: 45°

Remarks

Replace valve seat insert.

Repair method

Width of contact to valve seat

Limit

2.5

Nominal size Assembly standard

1.0

Unit

mm

Checking item

REPAIR SERVICE STANDARD

10-5

Part name

Piston rings

Group

10-6

N {kgf}

mm 0.05 – 0.09

0.03 – 0.07

Oil ring

0.07 – 0.11

2nd pressure ring

3rd pressure ring

—

0.15

0.15

0.15

—

31 {3.2}

36.3 – 55.9 {3.7 – 5.7}

1st pressure ring

Oil ring

4.9 {0.5}

14.1 – 21.2 {1.44 – 2.16}

14.1 – 21.2 {1.44 – 2.16}

2nd pressure ring

3rd pressure ring

4.9 {0.5}

20.4 – 30.6 {2.08 – 3.12}

1st pressure ring

N {kgf}

9.8 {1.0}

0.30 – 0.50

Oil ring

1.5 0.60 – 0.75

mm

Limit

3rd pressure ring

Direction of abutment joint

Clearance between piston ring groove and ring

Tension

Closed gap of piston ring

0.60 – 0.75

No. 2 compression

Nominal size Assembly standard 0.35 – 0.50

Unit

No. 1 compression

Checking item

Remarks

Set rings at intervals of 120°.

Replace ring or piston.

Replace.

Replace.

Install rings to piston with ring marks up. If they are installed in reverse, oil consumption is increased. There is no difference between both sides of oil ring, however.

Measure with expander installed (including tension of coil expander of about 5.9 N {0.6 kgf}).

When measuring, compress ring to standard closed gap.

Standard inside diameter of Replace. In the case of engine overhaul, replace all gauge: Ø105 piston rings.

Repair method

REPAIR SERVICE STANDARD

Main moving parts

Part name

Connecting rod

Group

192

Repair method

39 o 60° – 90° {4.0}

mm

g

N·m {kgf·m}

Rod bore allgnment between big end and small end (for mm in distance)

Difference in weight between pistonand-rod assemblies,

Bearing cap bolt tightening torque (angular method,)

20 or less

mm

Connecting rod twist between big end and small end (for 100 mm in distance)

0.05 or less

0.05 or less

mm

Distance between large-end center and small-end center

0.17 – 0.30

mm

Play in axial direction between connecting rod and crank pin

Connecting rod brg under sizes

0.2

0.2

0.35

0.05

Coat bolts with molibuden disulphide grease.

Repair or replace.

Repair or replace.

Repair or replace.

Clearance between piston pin and pin hole

Replace bushing or pin.

0.012 – 0.025

Clearance between small-end bushin and piston pin mm

Replace if poorly contacted or scratched.

0.030 – 0.073

Contact of connecting rod brg to crank pin

mm Replace bearing.

0.1

Limit

Clearance between connecting rod brg and crank pin

1.5

Nominal size Assembly standard

Use bearing having projection and elasticity. Take care of fitness of back side.

mm

Unit

Elasticity of connecting rod bearing

Forward-backward play of small end against piston boss (on one side)

Checking item

For reference purpose

Do not polish crankshaft, regardless of installation of turbocharger (Undersize crankshaft is not prepared).

Clearance must be adequate enough to allow big end to be swung lightly.

Take care of accuracy of crankpin.

4.9kN {500kgf} Projection: 0.043 – 0.068

For reference purpose

Remarks

REPAIR SERVICE STANDARD

10-7

Main moving parts

Part name

Crankshaft

Group

10-8 mm

Journal and pin finish accuracy (Both taper and cylindroid)

mm

Crankshaft runout

N·m {kgf·m}

Journal brg cap bolt tightening tourque,

Wear of crankshaft rear oil seal

g-cm

Crankshaft balance

Ring gear

mm

Crankshaft play in axial direction

Journal bearing undersizes

Clearance between journal and bearing mm

Ø 64

mm

Wear of pins

Journal bearings

Ø 80

mm

Wear of journals

Ø 80 Ø 64

mm

Uneven wear of journals and pins

0.4

0.05 or less

226 – 245 {23.0 – 25.0}

36 or less

0.4

0.11

0.05

Limit

0.15 – 0.33

No.4 0.039 – 0.098 Other than # 4 0.025 – 0.084

Both taper and cylindroid 0.007

Ø 63.924 – 63.944

Ø 79.919 – 79.939 * No.4 journal Ø 79.905 – 79.925

Nominal size Assembly standard

Unit

Checking item

(Reference value) At both ends.

Measure on No.4 brg thrust surface.

If turbocharger is installed, do not polish.

Remarks

Replace if oil leaks.

Prevent oil seal from getting out of place. (Oil satisfactorily).

Brg cap joint surfaces shall be Apply engine oil to bolts before free from scratches and foreign tightening. particles.

Check for dynamic balance.

Chamfer to remove burrs if any. Replace if chipped excessively.

Replace.

Replace thrust bearing.

Do not undersize bearing.

Replace bearing.

Bearings must fit tightly into bearing cap and cylinder block.

Replace.

Repair method

REPAIR SERVICE STANDARD

Main moving parts

Main moving parts

Valve-train mechanism

Part name

Camshaft

Timing gear

Group

mm mm

Clearance between journal and bearing

Wear of journal

mm

mm

mm mm

Interference of crankshaft gear to crankshaft

Interference of camshaft gear to camshaft

Clearance between idle gear bushing and shaft

Uneven wear of idlegear shaft mm

mm

Timing gear backlash

Idle gear play in axial direction

mm

Camshaft play in axial direction

Oil pump drive gear

mm

mm

Uneven wear of journal

Cam lobe height A–B

Unit

Checking item

Ø 45

Ø 56

0.128 – 0.185

0.025 – 0.085

0.021 or less

0.021 or less

0.10 – 0.17

0.050 – 0.114

0.2

Ø 44.9

0.2

0.3

0.2

7.21

Ø 55.6

Ø 55.94 – 55.97

7.71

0.15

0.05

Limit

0.03 – 0.09

Nominal size Assembly standard

Replace thrust collar.

Replace gear shaft.

Replace bushing or shaft.

Replace gear.

Replace thrust plate.

If damaged excessively, replace camshaft.

Replace camshaft.

Replace camshaft.

Replace bearing.

Repair or replace camshaft.

Repair method

Clearance not exceeding 0.021 is also allowed.

Clearance not exceeding 0.016 is also allowed.

Correct slightly uneven stepwear on cam.

Remarks

REPAIR SERVICE STANDARD

10-9

10-10

Part name mm mm mm mm mm

mm

mm

mm

Wear of intake valve stem

Wear of exhaust valve stem

Clearance between intake valve stem and valve guide

Clearance between exhaust valve stem and valve guide

Interference of valve guide to cylinder head

Valve margin

Height of valve guide above cylinder head

Valve stem oil seal lip

Squareness

Free height Blue

Pink

mm

mm

Tension N {kgf} (When installed and compressed)

Unit

Checking item

Valve spring

Valves

Group

Ø 8.5

14.1

1.5

Ø9

Ø9

1.9 or less

2.7

58.0

53.0 55.0 60.6

127 {13.0}

Ø 8.8

1.0

0.25

0.20

Ø 8.88

Ø 8.88

Limit

142 {14.5}

0.024

0.064 – 0.096

0.039 – 0.068

Nominal size Assembly standard

Replace valve spring.

Replace oil seal.

Replace valve.

Replace valve or valve guide.

Replace valve.

Repair method

Take care not to scratch lip.

Reference value

Coat valve guide with oil.

Replace valve when valve seat has been worn down.

Remarks

REPAIR SERVICE STANDARD

Valve-train mechanism

Valve-train mechanism

Intake system

Part name

Valve

Tappet

Air creaner

Group

Air cleaner element

Tappet-to-cam contact surface

mm

Tappet-to-cam contact surface

Ø 28

mm

Clearance between tappet and cylinder block 0.020 – 0.054

mm

Ø 27.92

0.1

0.3

(Reference) Length of push rod: 301 mm

Remarks

This part is prepared by manufacturer.

If worn or deformed excessively, Remove slight scratches with replace. oil stone.

Replace tappet.

Replace tappet.

Replace.

Replace.

Bend of push rod

Ø 18.85

mm

Wear or rocker arm shaft

Ø 19

Replace bushing or shaft.

0.2

Adjust.

Repair method

mm 0.01 – 0.05

Limit

Clearance between rocker arm shaft and bushing

0.4

Nominal size Assembly standard

At arm tip and stem end.

mm

Unit

Contact of valve stem to rocker arm

Valve clearance; IN and Ex. (cold)

Checking item

REPAIR SERVICE STANDARD

10-11

Lubricating system

Oil pressure

Part name

mm

mm

mm

Clearance between drive shaft and pump body

Clearance between drive shaft and bushing

Diameter of drive shaft and bushing

Oil-cooler relief valve cracking pressure, KPa kPa{kg/cm2} {kgf/cm2}

Oil pump

KPa {kgf/cm2}

mm

Axial-direction clearance between pump cover and gear

Oil gallery

L/min

Delivery flow, (1650 rpm, SAE #30, delivery pressure 392 KPa {4 kg/cm2}, oil temp 50°C)

Relief valve cracking pressure,

mm

KPa {kgf/cm2}

Unit

Clearance between pump cover wall and gear tooth tip

Lubricating oil pressure

Checking item

Oil filter element clogging and damage

Oil pump and relief valve

Oil filter

10-12

Oil cooler

Group

Ø 16

196 {2.0}

785 {8}

441 {4.5}

0.045 – 0.078

0.032 – 0.070

0.040 – 0.094

53.3

0.075 – 0.150

Nominal size Assembly standard

Ø 15.9

0.15

0.15

0.15

0.2

Limit

Replace.

Replace shaft.

Replace bushing.

Replace gear or cover.

Replace bushing, gear or body.

Repair method

Replacement interval of cartridge: 500 hours

Reference value

Remarks

REPAIR SERVICE STANDARD

Part name

Water pump

Group

°C

mm

mm

Thermostat full-open temp. (Under atmospheric pressure)

Interference of fan center to bearing shaft

Interference of bearing shaft to impeller

mm

°C

Thermostat cracking temp. (Under atmospheric pressure)

Clearance between pulley and fan center

mm

mm

L/min

mm

Unit

Deflection of fan belt

Clearance between pump impeller and pump body

Delivery flow, (3720 rpm, normal water temp, total lift 13.5 mm)

Play of water pump ball brg. (Radial direction)

Checking item #6204 V

0.14 or less

Replace pump ASM.

Replace pump ASM. 0.020 – 0.060

A temperature at which thermostat lift is 10 mm or more.

Adjust.

If impeller contacts pump body, repair or replace.

Replace pump ASM.

Repair method

Replace pump ASM.

0.2

Limit

0.07 – 0.11

95

82 ± 2

Approx. 7 – 10

0.3 – 1.0

300

0.008 – 0.01

Nominal size Assembly standard

If malfunctioning, replace thermostat.

(Reference) 10 kg/belt (22 lb) [98 N]

Remarks

REPAIR SERVICE STANDARD

10-13

Cooling system

Fuel system

Part name

Piping, ets.

Fuel feed pump

Injection pump

10-14

Wear of delivery valve

Air tightness, [Air pressure: 196 kPa {2.0 kgf/cm2}]

Oil feed flow: pump speed 1,000 rpm 15 seconds Suction head 1 m Discharge head 0.3 m

Sucking capacity: Hand pumping speed 60 – 100 st./min; head 1 m; pipe ID 8 mm x length 2 m

cc

Air bubbles leaking from push rod shall be as small as a millet grain and shall not exceed 30 cc./min.

405 or more

Sucking to be completed by within 25 times of pumping.

Limit

Repair method

300 or less

Check valve piston and seat surface for damage. Replace valve assembly if lengthwise scroes are in piston, if seat surface is dented remarkably and lacking in luster, or if valve fails to return to original state when, after wetted with clean diesel fuel, it is compressed lightly, while valve seat bottom is plugged with a finger, and then the finger is released.

If leak exceeding specification is found, repair or replace.

Repair or replace.

120 times or more Repair or replace.

Replace.

Nominal size Assembly standard

Fuel filter element for clogging and damage.

Unit

Repair or replace.

Checking item

Fuel pipe, injection pipe, and nozzle holder for clogging, cracks, loose joint, and defective packings

Delivery valve

Group

Cartridge type

Remarks

REPAIR SERVICE STANDARD

Part name

Injection pump

Group

Nominal size Assembly standard

Limit

Repair method

Remarks

Adjustment condition

Adjustment of injection rate

Standard

Lever

Rack Lever

±2

± 14 —

89 ± 1.5

9 ± 1.3 150 ± 5

1,075

450 100

10.3

– 7.5 —

A

C

D

Rack limit

Remarks

Fixing method

Variance (%)

Average injection rate (mm3/stroke)

Pump speed (rpm)

Rack position (mm)

40 ± 5

°C

Fuel temperature

Adjustment point

JIS No. 2 diesel fuel

mm

Test fuel

Ø 6 x Ø 2.0 x 600

157 {1.6}

MPa {kgf/cm2}

Fuel feed pressure mm

17.2 {175}

MPa {kgf/cm2}

Cracking pressure of nozzle

Pipe Outside diameter x Inside diameter x Length

105780 – 8140

Clockwise when seen from drive side

115603 – 3280

Nozzle holder assembly No.

Unit

105780 – 0000

Part No. of pump

Nozzle No.

Turning direction

Adjustment item

The following are examples of adjustment values of the injection rate. For the adjustment values of each injection pump, see the data supplied by ZEXEL.

Checking item

REPAIR SERVICE STANDARD

10-15

Fuel equipment

Part name

Injection pump

Group

10-16 Nominal size Assembly standard

Examples of the governor performance curves are shown below.

Checking item

Limit

Remarks

Max. 13 Max. 16 Max. 20

1350 1230

Notch limit 1450

Speed at which governor starts working (min-1)

Target notch: 9

Remarks

Note) When changing the speed at which this governor starts working, observe the following. Interference limit of flyweight and swivel lever

Repair method

REPAIR SERVICE STANDARD

Fuel equipment

Fuel equipment

Electrical system

Part name

Injection nozzle

Charge indicator

[12 V, 50 A, MITSUBISHI 1-81200-530-1]

Wiring

AC generator

Limit

Repair method

0.06 or less

0.1

Rated output current: 27 V (5000min-1)

Loose bearing

A

50

Replace bearing.

Replace rotor.

Correct.

Loose connection, disconnection, and broken covering

Bent shaft

If abnormality is found at ordinary engine speeds, correct electrical system.

mm

(1) Relatively large drops must not be scattered, when checked with naked eyes. (2) Any drop must not be scattered sideway. Replace defective nozzle. (3) Spray must not be dispersed from each injection nozzle.

Lighting of warning lamp

Spray and injection (Adjust cracking pressure of needle valve to 19.1 MPa {195 kgf/cm2}.)

5.0 sec. or more

Replace.

Nominal size Assembly standard

Oiltightness of needle valve stem: sec (Apply initial pressure of 29 MPa {300 kgf/cm2} to nozzle and measure time spent to lower pressure from 24.5 MPa {250 kgf/ cm2} to 19.6 MPa {200 kgf/cm2}.)

Unit If fuel leaks through seat, repair or replace.

Checking item

Oiltightness of needle valve seat (at 7.8 MPa {80 kgf/cm2})

Rotor

Performance

Group

Rotor must be rotated smoothly by hand without causing abnormal sound or quiver.

Oil to be used: Diesel fuel Viscosity (Redwood): 37 – 40 sec at 120 °C

Remarks

REPAIR SERVICE STANDARD

10-17

Preheating system

Starting motor

Electrical system

Part name

[24 V, 4.5KW, HITACHI 1-81100-342-0]

10-18

Battery

Group

mm

mm

mm

mm

min-1

Hear side (Armature)

Front side (Armature)

Pinion shaft (Shaft)

No-load characteristics (Max. 24 V, 100 A)

mm

Outer diameter

Depth of undercut

z

Cloudy electrolyte

Battery plates, separators, cells

Battery terminal

z

mm

Unit

Resistance of series coil

Resistance of shaft coil

Control resistor and glow plug.

Performance

Ball bearing

Commulator

Magnetic switch

Brush length

Loose fitting

Checking item

Ø 16

3,500

Replace if disconnection or short-circuit is found.

6905D

Correct.

Replace armature.

Replace.

Ø 16 (Outside diameter of bearing)

0.2

Repair method Correct.

6001D

0.5 – 0.8

Ø 36.5

10

Limit

Ø 28 (Outside diameter of bearing)

Ø 37

0.187 (At 20°C)

1.31 (At 20°C)

18

Nominal size Assembly standard

This part is prepared by manufacturer. As per instructions of manufacturer.

Pinion must operate smoothly and must not make abnormal sound.

If bearing does not revolve smoothly or makes abnormal sound, replace it.

If deviation from standard resistance is remarkable, replace switch.

Remarks

REPAIR SERVICE STANDARD

Part name

Battery

Group

Electrical equipment

Completion inspection

290 (3) or less

290 – 590 {3 – 6} 85 or more

110 or less

KPa {kgf/cm2}

KPa {kgf/cm2} %

%

Difference in compression pressure between cylinders, (Water temp.: 70 – 85 °C, Approx. 200 min-1)

Lubricating oil pressure

Output inspection

Fuel consumption inspection

3.0 {31}

Nominal size Assembly standard

MPa {kgf/cm2}

Unit

Compression pressure of cylinder, (Water temperature: 70 – 85 °C, Approx. 200 min-1)

"Running-in" operation of engine

Electrolyte level

Terminal voltage

Capacity (20-hour rate)

Specific gravity of electrolyte (at 20°C after charged)

Checking item

Perform for at least 30 minutes.

Repair method

200 {2.0}

Adjust.

Correct.

2.5 {26} Correct.

Limit

Set value of new engine as 100.

Before engine warms up.

Before engine warms up.

This part is prepared by manufacturer.

Remarks

REPAIR SERVICE STANDARD

10-19

6BG1T-BE2

6BG1T-BE2

SHOP MANUAL 6BG1, 6BG1T ENGINE

APPLICABLE MACHINE MODEL FD100/115/135/150E/160E-6 FD150/180/200Z-5 FD150/180/200Z-6 F4EC/5EC/6EC-1

SERIAL No. 5001 and up 2001 and up 2301 and up 1001 and up

No. 3-4, 2 Chome, Akasaka, Minato-ku, Tokyo, Japan

BE

2003 KOMATSU FORKLIFT All Right Reserved Printed in Japan 06-03(03)

00-1