S 4 S

 

SERVICE M

NU

M IT S U ISHI   IE S E L E N G I N E S

 

March  

I D

S ~ ~ ~ .

 

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 oreword

This This se serv rvic icee manu manual al is writ writte ten n to fa fami mili liar ariz izee yo you u with with the the ma main inte tenan nance ce of your S4S S4S and and S6S S6S Di Dies esel el En Engi gine ne.. If th thee engi engine ne is ca care refu full lly y main mainta tain ined ed it wi will ll del deliv iver er a long long produ product ctive ive li life fe and and effi efficie cient nt pe perf rfor orma manc ncee ma mark rked ed by powerr and powe and econ econom omy. y. Be Befo fore re yo you u at atte temp mptt to insp inspec ect, t, disa disass ssem embl ble, e, or re repa pair ir the the engi engine ne,, re read ad th this is ma manu nual al ca care refu full lly y to le leam am mo more re abou aboutt th the e engi en gine nealand an deho how w toive care ca for iteprop prda oper ly.inti . ting AHde AHdesc ptio ions ns, , al. illu il stra rati tion ons, s, speci specifi ficat catio ions ns an and d seri serial al nu numb mber erss in th this is manu ma nual ar are ef effe fect ctiv e re as fo ofr the th date teerly prin pr ng ofscri this thript is manu ma nual .lust The The in info form rmat atio ion n co cont ntai aine ned d in th this is manu manual al appl applie iess to the the engi engine ne mo mode dell pro produc duced ed at th thee ti time me of pu publ blic icat atio ion. n. It sh shou ould ld be no note ted d th that at sp spec ecif ific icat atio ions ns and and de desi sign gn may may cha change nge du duee to im impro provem vement entss ma made de th ther erea eaft fter er..

item emss other other tha than n thos thosee in this his publ public icat atio ion, n, refer refer to the the oper operat atio ion n engi engine ne is mou mounted nted,,

 o r

m nu l

for a unit on which the

Ho How w to Us Usee Thi This Manu Manual al 1. Part Partss in il illu lust stra rati tion onss ar aree numb number ered ed to corre correspo spond nd wi with th re refe fere renc nces es to th thes esee numbe numbers rs in te text xt.. 2. Item emss or co con ndi dittions ons to be insp inspec ecte ted d dur during ing disa disass ssem embl bly y are are en encl clos osed ed in a box box in th thee di disa sass ssem embI bIed ed vi view ews: s:

 

Cl Clog ogge ged d oil oil hole hole

 

3. Ma Main inte tena nanc ncee stan standa darrds for inspe nspeet etio ion n an and d repa epaiir are are desc descri ribe bed d in te text xt wher wheree they they are are rel elev evan antt. Fo Forr a qui quick summ summar ary y of main mainte tena nanc ncee st stan anda dard rdss re refe ferr to grou group p 2 of this this manu manual al.. 4. The The seq sequenc uencee in whic which h par parts are are to be reas reasse semb mble led d is summ summar ariz ized ed belo below w ea eaeh eh asse assem mbIed bIed vi view ew.. Su Sueh eh as: as:

@ 

@  @ 

5. Ti Tigh ghte teni ningtor ngtorqu quee un unde derr w con condit dition ionss is indiea indieated ted as wet) in text, text, drawin drawings, gs, and tables tables.. When When so ind indiea ieated ted as wet et)), ap appl ply y en engi gine ne oil oil to the thre thread aded ed por portion of the fas astten ener er.. Unl nles esss in indi diea eate ted d as such such,, the tig ight hten eniing to torrque que is to be assu assume med d in the dry dry co cond ndit itio ion. n. 6. Pa Pay y at atte tent ntiion to the spec specia iall not notes es,, ca caut utio ions ns an and d wami waming ngs. s.

Pub. Pub. No No.. 99616-1 99616-10170 0170

 

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No Note tes, s, Caut Cautions ions,, Warnin Warnings, gs, Dangers No Note tes, s, ca caut utio ions ns,, wam waming ings, s, dang danger erss are are use used in th this is man anu ual to em emph phas asiz izee im imp porta ortan nt or crit critic ical al ins instr tru uct ctio ion ns or advice.   OANGER)

Indicates Indica tes th thee most most se seri riou ouss spec specif ific ic pote potent ntia iall ha haza zard rd result resulting ing in se seri riou ouss bodi bodily ly in inju jury ry or de deat ath. h.

RNING

In Indi dica cate tess a spec specif ific ic pote potent ntia iall haza hazard rd resu result ltin ing g in bodily bod ily inj injury ury..

( CAUTION)

Indicates opera operating ting proce procedure dure,, pract practice, ice, etc., resulting resulting in pe pers rson onal al injury or damage to or dest destru ruct ctio ion n of engine.

  OTE)

An operatingproc operatingproced edur ure, e, cond conditi ition on,, et etc. c. that that wi will ll help help yo you u wo work rk more more effi effici cien ently tly..

 W

 e rms Used in This erms This Manual Before Befo re you you re read ad this this man manual ual,, no note te th that at the the follo followi wing ng sp spec ecia iall te term rmss are are used used in dime dimens nsio iona nall an and d ot othe herr spec specif ific icat atio ions ns.. Asse mb ly S ta n d a rd

Itime dicaotfereas s asse thesemb dmbly imly enor sioth n eost f anda a pdard arrd t, p therfo e form dirman meance nsce. io.n Ttohebvalu e alue tteaiis neroun d unde at ded thd e tinme re the stan er va ro to the the nea neares restt whol wholee num number ber ne need eded ed for for in insp spee eeti tion on and and isdif isdiffe fere rent nt from from th thee de desig sign n va valu lue. e.

N omi n a l Va Value

Indic ate s tth he standa rd di d imensio n of of a p paart.

Re p a i r Li Limit. .

Ap paart which has r e a ch e d th this limit must b bee rreepaired.

Se rv ic e Li L i mi t

Ap paart which has re r e a c he d th this limit m mu ust be b e rreeplaced.

St an d a r d C l e a r an ce

Indicates the c lleeara nc e to t o be o b bttained between m maating pa p arts aatt rreeassembly.

 

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Summary o f M a n ua ua l C o n te te n t s

Contents

Group

1. General

External view, engine serial number location, engine model an d

application applic ation code codes, s, spec specifica ification tions, s, tips tips on dis disasse assembl mbly y an and d reasse reassembl mbly. y. 2. Maintenance Standards

Maintenance stand standards, ards, tig tighte htening ning torq torque ues, s, seal sealant antss an and d lub lubric ricant ants. s.

3.

specia ciall too tools ls requi required red.. A l is is t o f spe

Special Tools

4. Overhaul Instructions

Determinin Determ ining g when when to ove overha rhaul ul the the engi engine ne,, testi testing ng com compre pressi ssion on pressu pressure re

5. A d djj ust ustme men n ts, ts,   enchTest, Performance Tests

Adjustment of val Adjustment valve ve cle cleara arance nce,, fuel fuel sy syst stem em ble bleed edin ing, g, fuel fuel inje injecti ction on timing tim ing,, no-lo no-load ad minimum and maxi maximu mum m sp speeed sett settin ing, g, V-be -belt, lt, benc bench h testi testing ng,, perfor performance mance tes tests. ts.

6. Engine Auxiliaries Removal

Removal an and d inst install allati ation on of turb turboc ocha harg rger er,, fu fuel el inj inject ection ion pu pump mp,, alte altern rnat ator or,, water pump starte starter, r, etc etc..

an d Installation

7. Engine Mai Main n Par Parts ts

Disas Disasse sembl mbly, y, insp inspee eeti tion on and reas reasse semb mbly ly of the the main main part parts, s, to incl includ udee cylinder head and cylinder and valv valvee mec mecha hani nism, sm, flyw flywhe heel el,, dampe damper, r, tim timin ing g gea gears rs and and camshaft cams haft,, pis piston tons, s, conn connecti ecting ng rods rods,, cran cranks ksha haft ft,, crank crankcas casee and and tapp tappet ets. s.

8. I n l e t an d Exhaust System

D iisa sass ssee mb mb ly ly , i nsp nspee et et io io n and re reaass ssee mb mb ly ly of i nl nl et et and e xh xh au au sstt sy syst stee m  exhaust manifo manifold ld .

9. Lub Lub ri ricc at at io io n System

Disassembly, Disassemb ly, inspe inspeetio etion n an and d reasse reassembl mbly y oflu oflubrica brication tion sy syst stem em,, to inl inlcud cudee oil pump oil oil filt filter er,, oil oil coo cooler ler,, oil oil pres pressu sure re relief relief valv valvee and and sa safe fety ty valv valve. e.

lO.Cooling System

Disas Disasse sembl mbly, y, insp inspeet eetio ion n and reas reasse semb mbly ly of cool coolin ing g sy syst stem em,, to incl includ udee water pump an and d thermo thermostat. stat.

11.Fuel System

Disasse Dis assembl mbly, y, ins inspee peetio tion n and and reas reasse semb mbly ly offuel sy syst ster ern, n, to includ includee fuel fuel filter an d injec injection tion nozzl nozzles. es.

12.Electrical System

Disassemb Disass embly, ly, insp inspeet eetion ion and and reas reasse semb mbly ly of elec electri trica call sy syste stem, m, to inc includ ludee star starte ter, r, alt altern ernato ator, r, glow plu plugs gs and and st stop op so sole leno noid id optio option n .

13.Workshop Ti Tips ps

Basic recommended asse assembl mbly y proc proced edur ures es:: oil oil seal seals, s, O-r O-rin ings gs,, beari bearing ngs, s, sp spli litt pin pinss an and d sp sprin ring g pins pins..

 

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G N R L 1 Outline

1 2

1 1 External View

1 2

1 2 Engine Serial Number Location

1 6

13 E En ngine Model and Application Codes 2 Specifications

1 6 1 7

3 Tips on Disassembly and Reassemb1y

1 13

3 1 Disassembly

1 13

3 2 Reassembly

1 13

 

 

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GENERAL

1. Out Outl iin ne 1.1 Ex Exte tern rnal al Vie View [84 848 8 Standard] Fu Fueel fi filt lteer

Fan

Fuel in inje ject ctio ion n pu pum mp

Inlet man manifo ifold ld

Fuell injec Fue injectio tion n nozzl nozzlee

 T

stop sole solenoid noid

Governor Coolan Coo lantt drain drain plug plug

IFront I

Dipstick

n

Fu Fuel el feed feed pu pump mp

C -I Oil Oil dr drai ain n pl plug ug

tt

I Rear I

Flywheel

on filter

I Left eft view Oil fil filler ler Thermostat

Exhaust Exhau st man manifol ifold d Alternator

I Rear I

IFront I

Starter

V belt

n

I I:

I  ight v

üi l pan

wl

Re Rema mark rk:: Dire Direct ction ion of rota rotati tion on of this this en engi gine ne is co coun unte terc rclo lock ckwi wise se as seen seen from from fl flyw ywhe heel el side side..   2

 

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GENERAL

[S4S-DT -

S ttaa nd nd ar ar d d]] Fu Fuel el inj injec ectio tion n pu pump mp n Fuel fi filter Fan

Water p u

~

p ~

\

r

~

~

F

~

~ ? n

p

~ 13

0 :/

V

Fu Fuel el feed feed pu pump mp

0

: : L -

~

I  , -

  1. ra

 Q

~

 

ol--

F ;;

 

,~

K

y

b

:

~

 

0

:

• 1 r U i ; = ~ ~ o ? J ; » - ~ ~ - . - i ~ 0 Ë = Q : ~ ~ :j l ~ ~

h>

 

f'\f

 0

/1,

 

[l.l.AF::J 1 -

v E TRs t o p s o l e n o i d

I

r

 :

I

 

\ ~

I p , ~

;:

Fuell inject Fue injection ion nozzle nozzle fT i T i:

-\.lIJ   I

IFront

1JI

tJ UI

rr

I / I n let man manifol ifold d

<

h .rT

 

~

o v

Coolan Coo lantt drain drain plug plug

/

 

_

Q.r-

 

r n o r

~

~

  Dipstick

I Rear I

,- -

::n

\

 

ol

\ ~ ~ r - ~ - d n

1111 ~ f - - I j

- - - H - - F I

ywheel

.'

 

~

\

on drain P I L

ILeft view I

on filter

Turbocharger

on filler

Thermostat

Exhaust manifo manifold ld

------.11ll-

 

Altemator

I Rear I

IFront

Starter

I

V-belt (1-1\

Oil Oil pan pan

IRignt viewl Remark Rem ark:: Dir Direct ection ion of rotat rotation ion of thi thiss en engi gine ne is cou counte ntercl rclock ockwis wisee as se seen en from rom flywh lywhee eell side side..

1-3

 

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GENERAL

[868

Standard Standard]]

uel fi fillter

Fuel injection pump   ~

Fan

1

lnlet manifold

l e : : : : : ~ I

~ e : : : : : ~ ~

: v :

ETR ETR stop stop sole soleno noid id

1NI bb l;a

Water Wat er pump pump

Fuell inject Fue injection ion noz nozzle zle

t

~ ~ ~

h ~ ~

~ ~ r

Governor Cool Coolan antt dra drain in plug plug

I ront I

I Rear I

Flywheel

Oil dr drai ain n pl plug ug

Oil filter filter Dipstick

I   ef t view

Oil Oil fi fill ller er Thermostat Exhaus Exh austt manifold

Alternator

I ront I

I Rear I Starter

V belt

Oilpan

IRight viewl Remark: Rema rk: Direct Direction ion of rota rotati tion on of this this en engi gine ne is cou count nter ercl cloc ockw kwise ise as seen seen from rom fl flyw ywhe heel el side side

4

 

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G N R L

[S6S [S6 S DT

Standard]

Fuel inje injectio ction n noz nozzle zle Fan

ETR stop stop soleno solenoid id  

Water Wat er pump

IFront

F ~ ~ ~ ~ ~ ~

Governor

I

I Rear

I

Flywheel

Gil d drrain p pllug

I Lef

view

Dipstick

I

Turbocharger Gil filler filler Thermostat Exhaust Exha ust mani manifold fold Alternator

I Rea.. I

IFront I

Starter V belt Gil Gil pan pan

IRight viewl viewl

  emark

Direct Dir ection ion of rota rotati tion on of this this en engi gine ne is cou count nterc erclo lock ckwi wise se as seen from from flywh flywhee eell si side de..

15

 

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GENERAL

1 2 En Engi gine ne Serlal Number Number Loca Locati tion on The engine serial number is located on the side of the crankc crankcase ase

1 3 En Eng g iin n e Model  n App Applic licati ation on Codes Codes

s

D

s

[ ][ï T : Eq Equi uipp pped ed with with turb turboc ocha harg rger er D : Di Dire rect ct inje inject ctio ion n type type Series Ser ies cod codee Numb Number er of cylind cylinders ers Manufa Man ufactu ctured red by Sag Sagami amihar haraa ma mach chin iner ery y wo work rkss

6

 

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G N R L

2. Sp Spec ecif ifie ieat atio ions ns Model Mod el desig designatio nation n

S4S-DT

S4S

Type

Water-cool Water -cooled, ed, 4-stroke 4-stroke cyc cycle le

No. No. of cy cyli lind nder erss - arra arrang ngem emen entt

4

Combustio Comb ustion n chamber type type

Overhead

Cylinder Cylin der bor boree x stroke

liter [[ccu iin n.]

Compressi Comp ression on ratio ratio

 

Ll

94 x 120 120 [3 [3.7 .70 0 x 4.72]

mm [ i n . ]

Piston d isplacement

3.3 3.331 31 [203] [203]

Ll

0

 

Dir Direct ection ion of rotati rotation on

Dimension

No. No. of pist piston on ri ring ng

0..

e;

Overal Ove ralll wid width th mm[in.]

593 593 [2 [23. 3.3] 3]

Overal Ove ralll hei height ght mm[in.]

710 710 [2 [28. 8.0] 0]

821 821 [3 [32. 2.3] 3]

kg [I [Ib] b]

245 [540]

25 0 [ 55 1 ]

In Inte tegr gral al with with cyli cylinder nder bl bloc ock k Compression Compressio n ring Oilring InIett val InIe valve ve

Valve timin timing g

  Ll

I:

·So I:

 xhaust valve

p:l

2 1 (w (w/s /spr prin ing g expander expander))

Open

BTDC 30°

BTDC 18°

Close

ABDC ABDC 50 50°°

ABDC ABDC 54 54°°

Open

BBDC 74°

BBDC BBDC 66 66°°

Close

ATDC 30°

AT ATDC DC 22° 22°

Starti Starting ng system system  

t .2

 

>

l U t I

: l

Electric-starter

Starti Starting ng aid

G10wplugs

Air cleaner

Type

Turbocharger

Model

Paper-element T D 0 4 HL

Type

For orce ce fe feed ed by oil oil pum ump p Specification

Engi Engine ne oi oill

a

2

781 781 [3 [30. 0.7] 7]

I:

a

4

Overall1ength mm[in.]

Type Type of cylind cylinder er sl slee eeve ve Ol>

3

Counterc Coun terclock lockwise wise as vi view ewed ed fr from om fl flyw ywhe heel el si side de

Weight Wei ght (dry) (dry)

 0 _

17 : 1

22 : 1

Firing Firing order order

I:

Direct inject injection ion

Swir Swirll chamber chamber

Valve mechanism mechanism

 ;J

in li line ne

Clas Classs CD oi oill (AP (APII Serv Service ice Cla Classi ssifica ficatio tion) n)

Capacity (engine) Type

Approx. 10 10 [2.6]

liter [[U U.S. ga g al]

(Oil p paan: 9 [[2 2.4], Filter: 1 [0 [0.3]) Trochoid

Speedratioto crankshaft

0.74

0

Capacity liter [[U U.S g gaal]

28 28.6 .6 [7 [7.6 .6]] at 0.3M 0.3MPa Pa (3 kg kgf/ f/cm cm ) disc dischar harge ge pres pressu sure re of p pu ump rru un nin g aatt 2 23 230 min:

u

Type

Ol>

>,

Oi Oill pump pump

Ol>

I:

·C .0

::l

Re1ieff va1ve Re1ie

Opening pressure Opening pressure MPa (kgf/c (kgf/cm m ) [ps [psi] i]

Oil Cooler Cooler

Type

Oi Oill fi filt lter er

Type

Saf Safety ety val valve ve

Opening pressure Opening pressure MP MPaa (kgf/c (kgf/cm m ) [ps [psi] i]

  l

Piston Piston val valve ve 0.35 0.35 ± 0.05 0.05 (3 (3.5 .5±0 ±0.5 .5)) [5 [50± 0±7] 7]  

I

Water-cooled multi-plate

Cartridge of p ap er elem ent -

I

1.1

 1 1

[156]

1-7

 

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G N R L

Model designatio designation n

S4S

S4S-DT

Re Refi fill ll cap capaci acity ty (engine (engine wate waterr jack jacket) et) lite literr [U.S [U.S.. gal. gal.]]

5.5 [1.5]

5 [1.3]

Type Water pump  

2 Jl

;>,

 Jl

o .S 0

Fan Fan belt belt Thermostat

Ce n t r i f u g a l

Speedrationto crankshaft C a pa c it y liter liter [U. [U.S S galj/min/mirr

1.3

160 [42.3] at 0.075 MPa [0.75 kgf/cm ] discharge pressure of pu pump mp ru runn nnin ing g at 36 3600 00 min

Type

Low- e dge B type V-belt x 1

Type

Wax pellet

temperature ture Valve opening tempera °C [ ]

76.5±1.5 [170±2.7 [170±2.7]]

Type Fan

P u s h e r ( PP) 6

No.ofblade

Diameter

mm [i [in. n.]]

440 440 [1 [17. 7.3] 3]

Type Injection pump

Bosch A

Diameter Diam eter of plung plunger er mm [i [in. n.]]

7 [0.276]

9 [0.354]

Type Feedpump

Bosch, piston

Ca m lobe lift lift

mm [i [in. n.]]   co

;>,

Governor

Jl

Q)

No. of spray spray ori orific ficee

:l

 

Type Type of nozz1e

Injection noz nozz1e z1e

Diameterof Diamet erof sprayorifice mm [i [in. n.]] Sprayangle

Valve Valve open opening ing pres pressure sure (kgf/cm f/cm ) [psi [psi]] MP a (kg Fuel f ilter  

;>, Cl

 

S t a r te r

1

4

1.0 [0. [0.039] 039]

0. 0.28 28 [0 [0.0 .011] 11] (f (for or D/G) D/G) 0. 0.24 24 [0 [0.0 .009 09]] (f (for or Powe Powerr Unit Unit))

0°

155°

11.77   I20) [1707]

\7.65 (I 80) [2 [ 2561]

O ut p ut

e ground

M008T75171 Pin Pinion ion shi shift ft

Type

 Jl

B o sc h RSV, centrifugal Bosch tth h r o tt l e Bosch h ho ole

12V M o de l

 Jl

9 [0.354]

Ca r tr idg e of paper element

Voltage - p ola ri ty

2 ë

Type

8 [0.315]

V-kW

12 - 2.2

Cl Cl)

 

1 8

of pini No. pinion onge teeth/ tee fl flywh ywhee eel l ri ring ng gear arth/ teeth teeth

lO/l22

 

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G N R L

Model designation designation

S4S

Type Output

s

Altemator

S4S-DT

3-phase, with rectifier 12 5

V

Working speed min:  

I

10 1000 00 to 18 1800 000 0

Rated Rated outpu outputt ge genera nerati ting ng min: speed

5000

Maximum perrnissib1e

22000

Speed ratio to crankshaft

2.0



 

Service L im i t Clearance

1.2 [0.05]

Exhaust va1ve

Ang1e

 

Repair As Asse semb mbly ly Sta Standa ndard rd Limit St Stan anda dard rd Clear learan ance ce Clearance

Insid Insidee diame diameter ter

Il

 

No Nomi mina nall Va Valu luee

±0. ±0.1 1 [±0.004] [±0.004]

1.0 [0.039]

±0.14 [±0.0055 [±0.0055]]

1.8 [0.071]

2.13 2.13 [0 [0.0 .0839 839]]

Up to 1. 1.83 83 [o on ] by refacing

48.85 [ 1.92]

 :l :lè

Valve Valve seat seat angle

Valve margin sin age

47. 60 [ 1.87]

S q ua r e n e ss

1.50 or less

Set le ngth

43 [1.69]

Se Sett for force ce N kgf [l [lbf bf]]

176 176 to 196  1 8 to 20 [40 to 44] 44]

Squareness Squaren ess of ends ends with respect to center line 147 15 [33]

2-3

 

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MAINTENAN MAIN TENANCE CE 8TANDARD8

Un Unit it:: mm [i [in. n.]] Group

Nominal Value

I n spe e t ion P o i nt Inside diam Inside diamete eterr of rocker rock er bus bushing hing

S

a 

 0

0::1

Q.}  :

à:

 

 0

.S

Diameter of roc Diameter rocker ker shaft

Q.}

 

u 0

0 ....

;.-

. :

'::s

 

Deflection

0.02 0.02 [0. [0.0008 0008]] or lleess

0.05 [0.0020]

Journal di a m e t e r

78 [3.07]

77.9 77.955 55 to 77.9 77.970 70 [3. [3.069 0691 1 to 3.0697 3.0697]]

77.850 [3.0650]

Crankpin d ia m e t e r

58 [2.28]

57.9 57.955 55 to 57.9 57.970 70 [2.2817 to 2 2..2823]

57.800 [2.2756]

Center to cent Center center er di sta n c e be betwee n journal an and d crankp crankpin in

60 [2.36]

±0.04 [±0.0016]

 

Circular Circ ularity ity of journal an and d crankp crankpin in

U 

Taper of jour journal nal an and d crankpin

~'

Fillet radius radius of journal and cr c r a nk p in

.' i ....

1/2 of di dial al indicat indicator or reading

0.3 0.3 [0 [0.01 .012] 2] or less less

77.100 [3.0354]

Runout: 0.01 [0.004] or less less over crankpi crankpinn

Parallelism betwe Parallelism between en journal an and d crankp crankpin in

 

length

0.01 0.01 [0. [0.0004 0004]] or lleess 3 [0.12]

0.03 [0.0012]

±0.2 [±0.008] [±0.008] If th thrus rustt pl plate ate cl clea eara ranc ncee exce exceed edss the repair lim limit, it, re repla place ce thr thrust ust pl plate ates. s. exceed eded ed,, use Ifit is exce oversize t hr us t plates. Thrust Thrust pla plate te oversize oversizes: s:

0::1

..

eo

I:

.;; 0

S

33 [1.30]

End play

:::

ca  ca

::E

Re m a r k

0.070 [0. [0.0028 0028

Deflection

0..

t - - - - - - - j - - - . . .[0.079] . . . . . . . : :. :  .[0.0018 - -18 - -to-0.0034]) - - - - .]). . . . . . . . . : :. : .   [0.0059]) ---- ----U

Q)

g

~

5i:J

U

4.5 [0.177]

Gi Gill rin ring g No.   2rings

-

Gil ring

 

30 [U8]

Diameter Clearance Clear ance between pin pin and and bus bushin hing g

o

  0.150)   [0.0059])

0.30 0.30 to 0.50 0.50 [0. [0.0118 0118 to 0.0197 0.0197]]

1.50 [0.0591]

30 [U8]

 

Cl)

.S I:: I::

o

U

33 [1.30]

Endplay Ra d weight difference difference

  0.200)   [0.0079])

  0.15 0.15 to 0.35 0.35))   [0.0059 [0.0059 to 0.0138]) 0.0138])

  0.50)   [0.020])

Face runou runoutt Deflection

DI

A =46.918: 2 [

Inlet valve SC

8 4 7 : t i ~

46.916: 2) [ 1

 

DI Exhaust valve

1 1

 

SC No.l 2 S 4S 4S )

g [0.35 oz]

[ 1

8 4 7 1 :

2 ~ 1

46.878::;N 8 4 5 6 :

2 ~ 1

46.880: 2) 8 4 5 7 :

2 ~ 1

0.15 0.15 [0. [0.005 0059] 9] or less less

0.50 [0.020]

0.02 0.02 [0. [0.0008 0008]] or less less

0.05 [0.0020]

Str Straig aighte hten n by cold working workin g or replac replace. e.

6.682 [0.2631]

6.182 [0.2434]

6.684 [0.2632]

6.184 [0.2435]

6.722 [0.2647]

6.222 [0.2450]

6.720 [0.2646]

6.220 [0.2450]

No.l 2 3   S6S)

54 [2.13]

53.9 53.94 4 to 53.9 53.96 6 [2 [2.1 .123 236 6 to 2.124 2.1244] 4]

53.90 [2.1220]

No No..3 S4 S4S) S) No.4   S6S)

53 [2.09]

52.9 52.94 4 to 52.9 52.96 6 [2 [2.0 .084 842 2 to 2.085 2.0850] 0]

52.90 [2.0827]

5 [0.20]

  0.  to 0.25 0.25))   [0. [0.003 0039 9 to 0.0098] 0.0098]))

End play

Replacee conne Replac connecting cting rad.

orless

Flatness

E o:l

  0.03 0.030 0 to 0.09 0.090) 0)   [0. [0.0012to 0012to 0.0035 0.0035]) ])

 

pe r engine

U

0.15 [0.0059]

or less less

Clearance between Clearance crankpin and conneet ing ing ra rad d bearin bearing g

U

  0.080)   [0.0032])

30 30.0 .020 20 to 30 30.0 .045 45 [l.l819 [l.l819 to l.l8 l.l829 29]] 0.10/100 [0 0039 3 94]

Bend and and twi twist st

-----------i

29. 29.99 994 4 to 30.0 30.000 00 [l.l809 [l.l8 09 to l.l8 I I]   0.02 0.020 0 to 0.05 0.051) 1)   [0.0008 [0.0008 to 0.0020]) 0.0020])

Inside diameter of bushing

 0

  0.025 0.025 to 0.06 0.065) 5)   [0. [0.0010to 0010to 0.0026 0.0026]) ])

Tcr

  0.30) Replacee th Replac thru rust st pla plate tes. s.   [0.0118])

  5

 

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MAINTENANCE STAN STANDARD DARDS S

Unit:mm [in.]

Inspeetion Point Point

Group

No om m in in al al Valu Valuee

Clearance between Clearance between shaft aan nd bu bus hi ng  

 l

 ll

 l

 co

I

Runout Runo ut of commuta tor

0.03 [ 0. 00 12 ]

[0.004]

0. \

0. 4 t o 0.6

0.2 0.2 [0.0 [0.008 08]] or less less

[0.016 [0.016 to 0.024]

11

Length

18 [0.71]

Spring force, N kg k gf) [Ibf]

30.4 to 3 8. 8. 2 3.1 to 3.9) [6.8to [6.8to 8.6] 8.6]

T h r u s t c l e ar a n c e o off p i ni o n ssh haft

en

Pinion Pinio n clea clearan rance ce

 

Wa Wash sh or re repl plac acee n o z zl e tip. 31.4 [ 1.24]

N  

l

Test Test by me mean anss of hand te test ster er,, us usin ing g dies diesel el fuel, uel, at 20° 20°C [68° [68°P] P].. If dis dischar charge ge pat patter tern n is bad even even af afte terr nozz nozzle le is wa wash shed ed in cl clea ean n die diesel sel fu fuel el,, rep replac lacee nozzle tip. tip.

32 [1.26]

Brush

 

 l

-. fJ

[0.004 [0.00 4 in.] in.] thickness thickness

130)  l 20 to 130)

Spra Spray y cone cone

üi l tigh tightne tness ss of

 fJ

P rree ssss ur ur e varies by I  l 0 [142] per 0.1 mrn

angle

ï

[0.43] 19.6   2.0) [4.4]

0. 5 [ 0. 0 20 ]

o or mo more re

0.5 to 2.0 [0.020 [0.0 20 to 0.079]

No-load Noload characteristics characteristics Voltage V

11

DI - Direct injection

Re m a r k Make shirn adjustrnent adjustrnent..

Cl)

a

a

Re pa i r Se r v i ce Assembly Standard Assembly L i mi t Limit St Stan anda darrd Cl Clea earrance ance))   Clearance)   Clearance)

Nominal

Inspeeti on Point

Current

A 130 or lleess

Speed min: 3800

or more

Locked c ha r a c t e r i s t i c s

Torque

Voltage V

C urren t A

Nrn   kgf-m)

3

1120 or le less ss

31 31.3 .36 6 3.2) 3.2) [23.1] or mo more re

[lbfft]

M a g n e t i c sw it c h Switch-in vol voltag tagee V

8 or Iess

SC - Swirl ch cham ambe berr

2-7

 

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MAINTEN MAI NTENANC ANCE E 8TANDARD8

Unit Unit:: mm [i [in. n.]] Service Repair Assembly Stand Standard ard Nominal Assembly Limit Limit Va Valu luee St Stan anda dard rd Cle Cleara aranc ncee)   Clearance)   Clearance)

Inspeet Insp eetion ion Point Point

Group

Diameter of commutator

38.7 [1.S2]

38.1 [I.SO]

Runout of commutator

0.03 [0.0012]

0.1 [0.004]

to 0.6 0.6 [0 [0.0 .016 16 to 0.024]

 

Depth of commutator mold

  ..

;: c<

I

>

 

 

C1

n -. on

 -

Brush

17 [0.67]

Spring force, N k g f) [Ibf]

33.3 to 4S 3.4 to 4. 4.6) [7.5to 1 1]

11

[0.43] 17.7   1.8) [4.0]

  S

o or more more

[0.020]

 

a

o

  ZJ

 

to 2.0 2.0 [ 0.020 to to 0.079]

OS

P i n i o n c l ea r a n c e

ll

  No laad

 

0

r

I

> N   

E

 

28

0.2 0.2 [0 [0.0 .008 08]] or Iess Iess

Length

Thrust cleara clearance nce of pinion pini on shaf shaftt

Remark

B

c ha r a c t e r i s t i c s

Loc ke d ch c h ar a ct e r i s t i cs

Voltage V

Current A

Speed min:

11

180 or le less ss

3800

Voltage V

2

or more more

Torque Current Nr n   kgf.m) A [lbf.ft] lOS0 or le less ss

Switch-in vo volt ltag agee V

2S.0 2.S5 [18 4]

8 or le lesss

or mo more re

B r u s h s p ri n g force, N gf) [Ibf]

3.0 to 4.2 310 to 430) [0.7 to 0.9]

2.1   210) [0.5]

Brush height height

18.S [0.73]

7 [0.28]

Resistance Resista nce in slip slip rin rings gs

 

Q

Magnetic switch

at 20°C 20°C [6 [68° 8°F] F]

 

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M INTEN INTEN NCE

T ND RD

2. Tig Tight hten enin ing g Torq Torque uess 2.1 Impo Import rtan antt Bolts and Nuts Th r e a d Dia. x P itc itch h  M-thread

Wi d t h across fl across flat ats, s, mm

N· m

kgf-rn

IbHt

Cylinder head head

M12 x 1.75

19

113 to 12 123

11 11.5ta .5ta 12 12.5 .5

83 ta 90

Rockerr cove Rocke coverr

M8 x 1.25

12

10.0 to 13.0

9.40 40 1.0 ta 1.3 7.23 to 9.

Rocker sh s haft br b r a c ke t s

M8 x 1.25

12

10.0 ro 20.0

1.0 to 2.0 7.23 ta 14.5

M14x2

22

98 to 108

10.0 to 11.0

x 1.25 1.25

14

4 9 . 0 ta 59.0

5.0 to 6.0

Description

Main Main be bear arin ing g caps caps

Tightening Torque Torque

Remark

72 ta 80

Connecti Conn ecting ng rod rod caps caps

Ml O

Flywheel

M12x

1.25

17

78.5 ttaa 88 88.3

8.0 ta 9.0 57.9 to 65.1

Camshaft Cams haft thrust thrust pla plate te

M8 x 1.25

12

10.0 tto o 13.0

1.0 ttaa 1.3 7.23 ttaa

9 4

Frontt plat Fron platee

M8 x 1.25

12

10.0 ta 13 1 3.0

1.0 to 1.3 7.23 to

9 4

Timing gear case

M8 x 1 1..25

12

10.0 ta 13 1 3.0

1.0 to 1.3 7.23 to 9 ..4 40

Crankshaft Cranksha ft pull pulley ey

M3

x 1.5

46

480 to 500

49 ro 5 51 1

354 to 369

Idle Idlerr ge gear ar thru thrust st pla plate te

MlO x 1.25

14

29.0 tto o 39 39.0

3.0 to 4.0

21.7 ta 28.9

Oil Oil pan pan

M8 x 1.25

12

10.0 tto o 13.0

1.0 ttaa 1.3 7.23 rro o9

M8 x 1.25

Oil Oil pan pan

12

27.5 ta 33.4

36.2 ta

43 4

4

2.8 tto o 3.4 20.3 to 2 24 4.6

Pre Press ss pro produc ductt Cast Cast oi oill pan pan for aag gricultur tural al tra tracto ctorr

Rear Rear plat platee

x 1. 1 .25

14

54.0 ttaa 6 65 5.7

5.5 ta ta 6 6..7

x 1.5 x 1.5

22 24

3 4 . 0 ta 4 44 4.0 73.0 tto o8 83 3.0

3. 3.5 5 to 4. 4.5 5 25 25..3 to 32 32.5 .5 54.2 .2 to 61 61..5 7.5 tto o8 8..5 54

Fu Fuel el injecti injection on no nozz zzle le glan glands ds dire direct ct inj inject ection ion ty type pe

M8 x 1.25

12

21.0 ttaa 23 23.0

2.0 ta 2.4

14.5 to 17.4

Fu Fuel el injecti injection on no nozz zzle less  swir  swirll cham chamber ber typ typee

M2

1.5

21

5 3 . 0 to 6 64 4.7

5.4 ta 6.6

39.1 ta 47.7

22

34.0 tto o 3 39 9.0

3.5 to 4.0

25.3 ta 28.9 15.2 ta 18.1

Ml O

Oi Oill pa pan n drai drain n plug plug

M1 4

M2

x

Fu Fuel el injecti injection on pu pump mp deliver delivery y va valv lvee ho hold lder erss

39.8 to to 48.5

Fuel Fuel leak-o leak-off ff pipe pipe nut nut

M1 2

x 1.5

17

20.6 tto o 24 24.5

2.1 ta 2.5

Fuel Fuel inje inject ctio ion n pump pump gear gear  distribution  distrib ution typ typee

M1 4

x 1.5

22

76.5 tto o 8 86 6.3

7.8 ta 8.8 56 56.4 .4 to 63. 63.7 7

x 1. 1 .75 x 1.5

19 22

58.8 ta ta 6 68 8.6 83.4 to 98 9 8. 0

6.0 ta ta 7 7..0 43.4 ttaa 5 50 0.6 8.5 tto o 10.0 61.5 ta 72.3

x 1.25 M12 x 1.25 M 4xO 7

12 12 8

15.0 to 20.0 1.5 t o 2.0 10.8 ta 14.5 20.0 to 30.0 2.0 ta 3.0 14.5 tto o 21.7 1.0 ta 1.5 0.10 ta 0.15 0.72 ta 1.08

Exhaust manifol Exhaust manifold d  balt only  wi with th spac spaceer

M8 x 1.2 1.25 M8 x 1.25 1.25

12 12

27.5 tto o 3 33 3.3 15.0 tto o 22 22.0

2.8 ta 3.4 20.3 to 2 4 . 6 1. 1.5 5 ta 2. 2.2 2 10 10.8 .8 to 15 15.9 .9

Oi Oill pre pressur ssuree relief va valv lvee

M2 2

x 1.5

27

44.1 ta 53.9

4.5 to 5.5

24

64.0 to 7 74 4.0

6.5 tto o7 7..5 47.0 tto o

14

35.3 tto o 43.1

3. 3.6 6 to 4.4

26.0 ta 31. 31. 8

x 1.5

19

26.5 to 3 32 2.4

2.7 tto o 3.3

19.5 ttaa 2 3 . 9

x 1.25 x 1.25

14 14

17.7 ta 21 21.6 28.0 ta ta 3 38 8.0

1.8 to 2.2 13.0 ta 15.9 2.9 ta ta 3 3..9 21.0 to to 28 28.2

Fuel Fuel inje inject ctio ion n pump pump gear gear  in-l  in-lin ine, e, swir swirll chamb chamber er typ typee  i  in-l n-line ine,, dir direct ect injecti injection on type Gl Glow ow plug plug  swir  swirll cham chamber ber typ typee  direct injection ty t ype  terminal

Safety Safety valve valve

ar

blind pl plug

Coolant drain pl plug Fuel Fuel injec injectio tion n pipe pipe nuts nuts Fuel Fuel re retu turn rn pipe pipe nuts nuts Oil Oil pump pump gear gear

M1 2

M1 4

Ml O

M18

 

1/4 - 1 8NP TF M1 2

Ml O Ml O

Agricultural tra tracto ctorr use

32.5 to 39.8 54 2

2-9

 

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M INTEN NCE ST ND ROS ROS

Th r e a d Dia. x Pi P i t ch  M-thread

Width a cr oss ffllats, mm

N·m

kgf-m

lbf-ft

Overhe Ove rheat at warning warning unit unit  thermostat

M16 x 1.5

19

20.6 to 24.5

2.1 to 2.5

15.2 to 18.1

S t a r t er t e rmi n al B

M8 x 1 1..25

12

9.81 to 1 11 1.8

7.23 23 to 8. 8.68 68 1.0 to 1.2 7.

Plug

M16 x 1.5

24

39.2 to 49.0

4.0 to 5.0 28.9 to 36.2 Cy llii n nd d eerr head

Balancer

M8 x 1.25

12

27.5 27.5 to 33.4 33.4

2.8 to 3.4 20.3 to 24.6

Fuel injection injection pump fe feed ed pipe pipe fla flare re

M12 x 1.0

17

16.0 to 23.0

1.6 to 2.3

11.6 to 16.6

Fu Fuel el injection injection pump ey eyee bolt bolt

M14x 1.5

22

15.0 to 20.0

1.5 t o 2.0

10.8 to 14.5

17

15.0to 15.0to 20.0 20.0

1.5 to 2.0

10.8 to 14.5

24

49.0 to to 58.8

5.0 to 6.0 36.2 to 43.4

De sc r i pti on

Fuel injection injection pump overflow overf low valve Oil le leve vell sens sensor or

1 1/16 12

Tightening Tighte ning Torque

Remark

2.2 Standard BoUs Torque

Thread Diameter  m m

7T

4T N·m

kgf-rn

lbf-ft

N·m

kgf-rn

Ibf-ft

M6

2.94 to 4.90

0.3 to 0.5

2 17t03 62

7.89 to 9.80

0.8 to 1.0

5. 5.79 79 to 7. 7.23 23

M8

9.80 to 12.7

1.0 to 1.3

7.23 to 9. 9 .40

14.7 t o 21.6

1.5 to 2.2

10 10.8 .8 to 15 15..9

MlO

17 7t024 5

1.8 1.8 to 2.5 2.5

13.0 to 18.1

29.4 to 41.2

3. 3.0 0 to 4. 4.2 2

21 21..7 to 30 30.4 .4

M12

29.4 to 41.2

3.0 to 4.2

21.7 to 30.4

53.9 to 73.5

5.5 to 7.5

39.8 to 54.2

2.3 Standard Studs Thread Diameter mm

Torq Torque ue ta tap p end end For drivin driving g in aluminummat aluminummater eria ials ls

For drivin drivingin gin ferrousmaterials ferrousmaterials

M8

N-m 4.90 to 5 . 90

kgf-m 0. 50 to 0. 6 0

lbf-ft 3.62 to 4.34

N·m 11.8 tto o 13.7

kgf-rn 1.2 tto o 1.4

lbf-ft 8.68 to 10.1

MlO

12.7 to 14.7

1.3 to t o 1.5

9. 40 to 10.8

21.6 to 25.5

2.2 to 2.6

15.9 tto o 18.8

2.4 Standard Plugs Torque Fo Forr fe ferr rrou ouss materi materials als

For For alum aluminum inum mate materi rial alss

Thread Diameter N·m

kgfm

lbf-ft

N·m

kgf-rn

lbf-ft

NPTF 1/l6

4.90 4.90 to 7.85 7.85

0.5 to 0.8

3.62 to 5.79

7.85 to 11.8

0.8 to 1.2

5.79 to 8.68

PT 1/8

7.85 to 11.8

0.8 to 1.2

5.79 to 8.68

14.7 tto o 21.6

1.5 tto o 2.2

10.8 to 15.9

PT 1/4, NPTF 1/4

19.6 to 29.4

2.0 to 3.0

14.5 to 21.7

34.3 to 4 44 4.1

3.5 to 4. 4 .5

25.3 to 32.5

53.9 53.9 to 73.5 73.5

5.5 to 7.5

39.8 to 54.2

PT3/8

Remarks:

2-10

 

-

-

1. Th e to torq rque ue valu values es show shown n ab abov ovee are are fo forr the balt baltss wit ith h spr sprin ing g wa wash sher ers. s. 2. Do not appl pply any oil to the bolt olt thr thr ead eads. s.

 

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MAINTENANCE MAINT ENANCE STANDA STANDARDS RDS

3 Sealants  n Lubricants Tabl Tablee Apply to

Sealant or Lubricant

How to Use

Crankcase

Three Bond   Ü?C

Appl Apply y to se seal al

Rear bea bearing ring ca cap p seat on cran kcas e

Rear b beearing ccaap

Three Bo Bond 2 2

Appl Apply y to co corn rner erss be befa fare re installing cap

Si Side de seal sealss

Crankc Cra nkcase ase re rear ar bea bearin ring g ca cap p

Three Bo Bond 2 2

Apply to to ssiide se seals

Cylinder head head coolant hole coolant hole pl plug ug

Cylinder head

Three B Bo ond 386D

Apply to plug h ho ole

Crankcase coolant hole hole pl plug ug

Crankcase

Three Bond l3 l3 8 6D

Apply to plug ho hole

Crankcasee oi Crankcas oill hole hole plug

Crankcase

Three B Bo ond 386D

Apply to to p pllug hole

Re Retu turn rn oi oill ho hole le b l in d plug or o r pi pipe of crankcas crankcasee

Crankcase

Three Bo Bond 344

Apply to to bl blind pl plug or or pi pipe

C r a n k s h a ft t h re a d s

Crankshaft pulley nut

Three Bond 2 2

Appl Apply y to cra cranks nkshaf haftt thre thread ad be befo fore re tightenin tigh tening g nut

üi l

pan

Mating part

2

 

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SPECIAL r Special   oo List

l 3

 

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SPE I

L TOOLS TOOLS

  peci l To Tooi oi List Taal na name me

Pa Part rt No

Shape

Use

Valv Valvee spring spring pus pusher her

3 691

Va Valv lvee gu guid idee remave remave

32A91 o 3

Val Valve ve gui guide de remov removal al

Valv Valvee guid guidee ins instal taller ler

32A91

Valvee guide Valv guide inst installa allation tion

Stem se seal al in inst stal alle lerr

32A91 10200

Valve stem installat installation ion

Va Valv lvee seat seat in inse sert rt caulking t l

In Inle lett valve: valve:

Valvee seat inst Valv installat allation ion

Valvee spring Valv spring remov removal/ al/ installation

45

100

o

36791 00200 Exhaust Exha ust valv valve: e:

34491 03020

Piston Piston ri ring ng pl plie iers rs

31391 12900

Pis Piston ton ring ring removal/ removal/ installation

Piston Pist on inst installe allerr

34491

Piston Pisto n inst installat allation ion

Idlerr shaft Idle shaft pu puller ller

3

2

MH061077

®

Id Idle lerr ge gear ar sh shaf aftt re remo mova vall

 

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SPECIAL SPECI AL TOOLS

Tooi Tooi name Oil Oil se seal al sleeve sleeve install installer er set

Gage ad a p t o r

Gage adapto adaptorr

Shape

Pa Part rt No. No.

Use Cran Cranks ksha haft ft rear rear oi oill seal seal sleeve sleeve installation

3 691 13 1

32A91-01100   direct injectio injection) n)

3 691 211

swirl chamber) chamber)

Compression Compressio n press pressure ure measurement

 

Compression pressu Compression pressure re measurement

 

Compression press Compression pressure ure measurement

Compression Compress ion ga gage ge

33391

Turning Turni ng socket

583 9 731

En Engi gine ne tuming tuming

Socket

34491

Cams Camsha haft ft thrust thrust pl plat atee an and d roc rocker ker bracket installa bracket installation tion

Connecting ra d

21

3

Connec Con necting ting rad rad bush bushing ing

MH061236

bushing bush ing pull puller er

Camshaftt bushing Camshaf bushing ins instal tal1e 1err set

rernoval/installation

3 691

Camshaft bushing Camshaft bushing remova removall installation

1 j. /

Oil pump bushing instal1er

32A9]

4

.-

Oi Oill pu pump mp bus bushing hing installa installation tion

3-3

 

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OVERH OVE RH UL INSTRU TIONS  

2

etermination of Overhaul Timing Testing the  ompression Pressure

4 4 3

 

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OVERHAUL OVERHA UL INSTRU INSTRUCTION CTIONS S

Dete term rmln lnat atio ion n of Ove Overha rhaul ul Timi Timing ng 1. De In most most ca case sess the the en engi gine ne shou should ld be overh overhau aule led d when when th e e n ng g in in e s c o omp mpre ress ssio ion n p re re sssu sure re is low. Other fa fact ctor orss that that ind indica icate te the the ne nece cess ssit ity y of engi engine ne ov over erha haul ul ar aree as fo foll llow ows: s:   aa)) Dec Decre reas ased ed pow power er  b b)) Increa Increased sed fu fuel el con consum sumpti ption on   c) In Incr crea ease sed d en engi gine ne oil oil co cons nsum umpt ptio ion n   d) Incr Increase eased d blow-by blow-by gas v ol ol um um e through the br brea eath ther er due due to ab abra rasi sion on at the the cy cylin linder der line linerr an and d the the pist piston on ring ring   e) Gas lea lea ka ka g gee due to poor seating of the inlet and the the exh exhaus austt va valv lves es Sta Starti rting ng problem problemss

 f

  g) In Incr crea ease sed d nois noisee fr from om en engi gine ne part partss   h) Ab Abno norm rmal al col color or of ex exha haus ustt ga gass fr from om en engi gine ne af afte terr warm-up Any one or a co mb mbina ina ttio ion n of these symp sympto toms ms may may indi indica cate te that that engi engine ne ov over erha haul ul is re requ quir ired ed.. Of the the item itemss listed ab ov ov e some are not dir eecctly r eell aatt eed d to the ne nece cess ssiity of engi engine ne over overha haul ul.. It Item emss b) and  f are mo more re like likely ly to be af affe fect cted ed subs substa tant ntia iall lly y by •

Inje Injecc tio tion n v olu olume me of the fuel in inje jecc ttio ion n pump

•

Fuel inje injecctio tio n timi timin ng

•

Wear o f injec injection-p tion-pump ump plunger

•

Fitting of the inj inje ccti tio on nozzle

•

Co on n di di ti ti on on of e le le cctt ri ri ccaa l e q qu u iip pm mee n ntt : ba tt tt eerry , star starte ter, r, or altem altemator ator

Item

d

above, however, requires special

considera consid eratio tion n becau because se dec decrea reased sed pre pressu ssure re due to wea wearr atthee cyli atth cylind nder er lin liner an and d the the pist pisto on ri rin ng is one ofthe most o bv bv io io us us s ig ig ns ns t ha ha t th e e n gi gi n e r eq eq u uii r es es

overhauling. The most e ff ec ti ve way to make a de cis io n is by te test stin ing g the the co compr mpress ession ion pres pressu sure re;; oth other er fa fact ctor orss ar aree to be con consid sidere ered d se secon conda daril rily. y.

4

 

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OVERHAUL INSTRUCT INSTRUCTIONS IONS

2. Test Testla lag g the the Comp Compre ress ssio ion n Pres Pressu sure re  1) Rem Remove ove the the inje inject ctio ion n no nozz zzle le from from the the cyli cylind nder er

head where the co comp mpre ress ssio ion n pressure is to be measured.  2) On the the di dire rect ctio ion n inje inject ctio ion n type type engi engine ne,, atta attach ched ed gage gage ad adap apto torr 32A9l-0 32A9l-01100) 1100) to th thee cy cyli lind nder er,, an and d conneet conn eet th thee co comp mpre ress ssio ion n gage gage 333 3339191-021 02100) 00) to the ada adapto ptor. r. On th thee swir swirll ch cham ambe berr ty typeengi peengine ne,, atta attachthegage chthegage adaptor  3 0 69 69 11- 2 21 1 10 10 0) 0) to the cy li li nd nd er er , and conneet conn eet th thee co comp mpre ress ssio ion n gage gage 333 3339191-021 02100) 00) to the ada adapto ptor. r.

Measuring com compre pressi ssion on pressu pressure re direc directt inject injection ion type) type)

 3) Crank the engine by means of the starter, with th thee go gove vern rnor or sto stop leve leverr pull pulled ed th thee fuel fuel su supp pply ly an d read th e compression gage sh hu u t o ffff indication w he he n the engine r un un n nii ng ng at the specified specifi ed spe speed. ed.  4)

 

the co comp mpre ress ssio ion n pres pressu sure re is lower than the

re repair pair limi limit, t, over overha haul ul th thee engi engine ne.. C

 

UTION

 

a) M ea ea su su re re the c om om p prre ss ss io ion pressure on all cylinders. I t is no t a good prac practi tice ce to measur mea suree the the comp compre ress ssio ion n pres pressu sure re on on only ly few cylind cylinders ers,, and pre presur surne ne the com compre pressi ssion on on th thee re rema main inin ing g cy cyli lind nder ers. s.

Measuring com compre pressi ssion on pressu pressure re swi swirl rl chambe chamberr type) type)

 b) Co Comp mpre ress ssio ion n pr pres essu sure re varies with engine spee speed. d. Ch Chec eck k en engi gine ne sp spee eed d when when me meas asur urin ing g the com compre pressi ssion on pre pressu ssure. re.

Unit: MP a  kg  kgf/c f/cm m ) [psi] [psi] Item

Compression pressure

Direct injection Swirl chamber

 

4

l

A ss e mb l y S t a n d a rd

Repair Limit

2.9  3  30 0) [427]

2.6 27) [384]

3

 3  33 3) [469]

2.8 29) [413]

NOTE J r

M ea ea su su re re the c om om p prr es es ssii on on p re re ss ss u urr e with the engi engine ne ru runn nnin ing g at 30 300 0 minmin-I. I.

4-3

 

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OVERHAUL OVERHAU L INSTRU INSTRUCTION CTIONS S

......

i[

C A U TI ON J I

 a

Mea Measure sure the compression compression pressu pressure re at reg regula ularr in inte terv rval alss to obta obtain in corr correc ectt da data ta..

 b

Th Thee co comp mpre ress ssio ion n pres pressu sure re will will be slig slight htly ly higher   a new new or over overha haul uled ed engin nginee due due to ne new w pi pist ston on rings, rings, va valv lvee seat seats, s, et etc. c. Pres Pressu sure re wi will ll drop drop grad gradua uall lly y by th thee we wear ar of parts arts..

 

.

 

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  DJUSTMENTS BEN BENCH CH TE TEST ST PERFO PERFORM RM NCE TESTS 1. A d j u s t m e n t s

5- 2

1.1 Valve Clearance

5- 2

1.2 Fuel Syst em Bleeding

5- 3

1.3 Fuel Injection Timing 1.4 No-load M Miinimu m Idling Speed an a nd M Maaximum Sp e e d S Seetting

5- 4 5- 5

1.5 V V--belt Inspeetion and Adjustment

5-10

2. Be n c h Testing ..

5-11

2.1 Starting Up

5-11

2.2 IIn nspeetion After Starting Up

5-11

2.3 Be nch Testing Dynamometer Conditions

5-11

2.4 Inspeetion and Adjustment After Bench Testing

5-11

3. Per fo rma nc e Tests

5-12

3.1 E En ng ine Equipment Condition

5-12

3.2 Tests and Th ei r Purposes

5-12

3.3 Oth er Inspections

5-12

3.4 Ad justment Engine Output

5-12

 

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ADJUSTME ADJU STMENTS NTS BENC BENCH H TEST TEST PERFORMANCE TESTS

1. Adju Adjust stme ment ntss 1. 1.1 1 Valv Valvee Clearan Clearance ce Valv Valvee cl clea eara ranc ncee shou should ld be insp inspec ecte ted d and and adju adjust sted ed when when th thee engi engine ne is cold cold.. Unit Unit:: mm [i [in. n.]] Item

Assembl y Standard

Valve clearance InIet  cold  col d setti setting) ng) Exhaust

0.25 0.25 [0 [0.00 .0098 98]]

Inspeetion

 l

 a)  a)

Inspeet the valve cl clea earran ance ce in the injection sequen seq uence.To ce.To che check, ck, turn turn the crankshaf crankshaftt by the sp spec ecif ifie ied d cr cran ank k an angl glee in the the norm normal al dire direct ctio ion n to bring the piston to the top dead center of the compre compressi ssion on str stroke oke.. Injection sequ sequence ence S4S S6S

 

 

3

4

2

5

3

6

2

Crank an angle gle 1800 4

1200

 b) Pu Putt sock socket et 58 5830 309-7 9-7310 3100) 0) and and ra ratc tche hett ha hand ndle le on the c ra n k s ha ha f t pull ey nut and turn the cranks crankshaf haftt in the nor normal mal direct direction ion clockw clockwise ise as seen seen from from th thee fron frontt end) end).. Unit: mm [in] Widt Width h acro across ss flat flatss of cranks cranksha haft ft pull pulley ey nut nut

 c)

 d)

46

[1.81]

The top dead ce nt nt eerr on compression stroke ofNo.1pisto ofNo.1pis ton n is iden identi tifi fied ed by the the ti timi ming ng mark mark  0 on th thee cran cranksha kshaft ft pull pulley ey)) bein being g al alig igne ned d with the po poin inte terr on the gear case. With the pistonso pistonso positi positione oned, d, bot both h the inl inlet et andexha andexhaust ust va valv lvee ro rock cker er anns ar aree no nott be bein ing g pu push shed ed up by their push pushrods rods..

ol

 

I I I I

In Inse serta rta fee eeIe Ierr gag agee in bet etw ween the the rock rocker er ar arm m and and va valv lvee cap, cap, and and chec check k the the cl clea eara ranc nce. e. Checkin Chec king g va1vecleara va1veclearance nce turn turning) ing)

52

 4

 

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ADJUSTMENTS BE NCH TEST PER PERFOR FORMAN MANCE CE TEST TESTS S

 2 Adjusting  a

Lo Loos oseen th thee lo loek ek nut of the the ad adju just stin ing g scr creew. Adj djus ustt th thee clea cleara ranc ncee by tumi tuming ng the the sc scre rew w in eith eitheer di dire rect ctio ion n to the the ext exten entt that that the the ga gage ge is sl slig ight htly ly gr grip ippe ped d be betw twee een n the the ro rock cker er ar arm m and and valve valve cap cap..

 b

After After adju adjusting sting the cle cleara arance nce,, tig tighte hten n the loek loek nut nut.. Ins Inspee peett the cle cleara arance nce aga again in and make make sur suree th that at it is co corr rrec ect. t. Adjusting valve valve cleara clearance nce

1.2 Fuel Fuel Syst System em Bl Blee eedi ding ng Ai Airr ve vent nt pl plug ug

Fuell filter Fue filter

ll)  )

 a

Loosen air v e n t plug on the fuel f i lt e r by tu tumi ming ng it abou aboutt 1.5 1.5 rota rotati tion ons. s.

 b

Unlo Unlock ck ble bleed edin ing g pu pump mp plu plunge ngerr by tum tuming ing it counterc counte rcloc lockw kwise ise,, an and d oper operat atee the the pump pump..

 c

Tigh Tighte ten n th thee ai airr ve vent nt plug plug when when the the fuel fuel flow flowss withou withoutt bubbl bubbles. es.

 2 Fue Fuell inject injection ion pump pump  a

Lo Loos osen en air air ven vent plug lug on the the in inje ject ctio ion n pump pump by tu tumi ming ng it 1. 1.5 5 rota rotati tion onss

 b

Unlock bl blee eedi ding ng pump plun plunge gerr by tumi tuming ng countercl counte rclock ockwis wise, e, an and d oper operat atee the the pump pump..

 c

Tigh Tighte ten n th thee ai airr ve vent nt plug plug wh when en the the fuel fuel flow flowss without witho ut bubb bubbles. les.

 - - - - - - - - - i

DANGER  

When fu When fuel el over overfl flow owss fr from om the the ai airr vent vent plug plug,, wipe wipe thoroughly with a cloth. Spi ll ll eed d fuel is a fire hazard.

 - - - - - - - - - - 1

NOTE

f----------

If th thee ven entt pl plu ug is ti tigh ghte ten ned bef efo ore the blee bleedi ding ng pu pump mp pl plun unge gerr is lo lock cked ed,, fuel fuel pressu pressure re ac acts ts on the the feed pump, m ak ak in in g it di ff ff ic ic ul ult to r eess tto o re re the plunger.

53

 

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ADJUSTMENTS, ADJUST MENTS, BENC BENCH H TEST TEST,, PERFORMA PERFORMANCE NCE TE TEST STS S

1.3 Fuel Fuel In Inje ject ctio ion n Timi Timing ng Th Thee in inje ject ctio ion n ti timi ming ng va vari ries es acco accord rdin ing g to the the ou outp tput ut,, sp spee eed d and and speci pecifi fica cati tion onss of the the en engi gine ne.. Be sure ure to veri verify fy th thee ti timi ming ng by re refe ferr rrin ing g to the the spec specif ific icat atio ions ns..

 

II

II

I   Ql

Bringi nging ng th thee No.l cy cyli lind nder er pist piston on to the the top top dead dead  1 Bri center on co comp mpre ress ssio ion n st stro roke ke  a

Put Put so sock cket et 5830 58309-73 9-73100 100 on the the cr cran anks ksha haft ft pu ll e y nut and turn the c r an k s h af t in the no norm rmal al di dire rect ctio ion n clockw clockwise ise as se seenfrom enfrom the the front front end .

 b

Stop Stop tu turn rnin ing g the the cr cran anks ksha haft ft when when the the ti timi ming ng the mark  0 on the c rraa n nk k sh sh af af t pulley is al alig igne ned d wi with th the the poin pointe ter. r.

 c

Push down on the inlet and exhaust valve ro rock ckerarmsfor erarmsfor the the No.l cy cyli lind nderto erto ma makesur kesuree th they ey ar aree no nott be bein ing g pu pushe shed d up by the the pu push shro rods ds  th  th e i nl e t and e x xh h aau u st st v a l ve ve s have some clearance .

Fi Find ndin ing g top top dead dead center center on compres compressio sion n st stro roke ke

 2 Checking inj inject ection ion timing timing  a

 b

Re Remo move ve deli delive very ry valv valvee hold holder er fr from om the the No.l No.l plunger of th e injection pump pump.. Re Remo move ve deliv eliver ery y va valv lvee an and d sp spri ring ng fr from om the the hol holde der. r. Re Rest stor oree th thee ho hold lder er to the the pu pump mp.. Conneet a spare injec njecti tion on pipe to the No.1 pl plun unge ger, r, with with it itss free free end end he held ld do down wnwa ward rd so th that at you you can ob obse serv rvee the the fuel uel fl flow ow fr from om tha that end.

 c

Turn Turn th thee cr cran anks ksha haft ft to brin bring g the the No.1 No.1 pist piston on to 60° po si ti on b e ffo o r e top dead center on compressio compr ession n stroke stroke..

 d

Wh Whil ilee op oper erat atin ing g the the prim primin ing g pump pump to al allo low w th thee fu fuelto elto fl flow ow fr from om the the inje inject ctio ion n pipe pipe,, sl slow owly ly tu turrn th thee cran cranks ksha haft ft in the the norm normal al dir directi ection on.. Stop Sto p tur turnin ning g the cranks crankshaf haftt whe when n the fuel fuel flow flow stops.

 e

Ma Make ke sure sure th thee ti timi ming ng mark mark on the the cran cranks ksha haft ft pu pull lley ey is al alig igne ned d with with the the poin pointe ter. r.

Delivery Deliv ery valve h O l d e

t

 

Spring Del Delive ivery ry val valve ve _

Checking in jec jectt io io n timing - I  Removi Removing ng delivery val valve ve

Check ecking inject ection timing -

5-4

2

 

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ADJUSTMENTS BENCH BENCH TES TEST T PERFORMANC PERFORMANCE E TESTS

 3 Adjus Adjustin ting g injec injecting ting tim timing ing  a

If th thee in inje ject ctio ion n ti tim ming ing is reta retard rded ed,, move ove the the in inje ject ctio ion n pum ump p tow towar ard d the the cr cran ankc kcaase. se. If the the t iim mi n ng g is adva dvance nce d, d, move the pump away from from th thee crankc crankcase ase..

 

To ret retard ard injection

timing

Adju Adjust stin ing g inj njec ecti tion on ti timi ming ng - I

 b

One gr graaduat duatio ion n of the the sca scale on the the inje injeccti tion on pump coup coupli ling ng changes the timing by 6° in term termss of cran crank k angl angle. e.

Adju Adjust stin ing g in inje ject ctio ion n ti timi ming ng - 2

1.4 No-l No-lea ead d  inimum  Idlin Idling g Speed an d  aximum Spee Speed d Settin Setting g .-----------I

CAUTION   f - - - - - - - - - .

a

he no no-I -Ioa oad d mini minimu mum m

idle idle spee speed d and maxi maximu mum m spee speed d ar aree se sett for for each each engi engine ne on the test bench at the factory. The set bolts are are se seal aled ed.. Th Thes esee se sett ttin ings gs ar aree to be insp inspec ecte ted d and and adju adjust sted ed at our our auth author oriz ized ed serv servic icee shop shop only.

b

Afte Afterr ad adju just stin ing g the the govemo govemorr by brea breaki king ng the the seal seals, s, be sure sure to re re-s -sea eall al alll vi visi sibl blee stop stoppe pers rs,, mak akin ing g th them em appea ppearr as if they they were seal sealed ed at th thee fact factor ory. y.

c

When inspecting an d adjusting these

se sett ttin ings gs,, be on st stan andb dby y to oper operat atee the the en engi gine ne st stop op leve leverr manu anually ally in the the even eventt of eng engine ine overrun. For For in insp spee eeti tion on and and adju adjust stme ment nt,, wa warm rm up the the engi engine ne thor thorou ough ghly ly unti untill th thee coola coolant nt and and oi oill te temp mper erat atur uree ar aree abov abovee 70°C 70°C [l58 [l58°F]. °F].

5-5

 

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ADJUSTMENTS BENCH TES TEST T PER PERFORMAN FORMANCE CE TES TESTS TS

 1 Starting Starting engine  a

Pu Pull ll speedcontrolle speedcontrolleverto verto the the high high sp spee eed d si side de.. Operat Ope ratee th thee star starter ter swit switch ch to cran crank k the the en engi gine ne..

 b

Th e e n ng g in in e w iill l fi re up at 150 min lof

cr cran anki king ng spee speed. d. Whe hen n the the engi engine ne fi fire res, s, ho hold ld th thee en engi gine ne spee speed d betw betwee een n 80 800 0 and and 1000 1000 c

min I

Speed Spe ed co contro ntroll lever lever Govemor set b bo olt -

Low Low id idle le spee speed d se sett sc scre rew w Idle sub-spring sub-spring adjustingscrew

When the engi engine ne runs with a steady speed, move ove the spe speed ed contr controll olleve everr back back to the idle dle speed speed positi position. on.

 2 Settin Setting g no-Ioa no-Ioad d minimu minimum m id idle le spe speed ed  a

...

Hol old d the speed speed co cont ntrrol lev ever er at the the posi posittion ion fo forr no no-I -Ioa oad d mini minimum mum idl idlee sp spee eed d and and se sett low low idle id le sp spee eed d se sett sc scre rew. w.

JLt CAUTION

Low Low id idle le spee speed d se sett sc scre rew w

 

f

a cr crit itic ical al sp eed d es thedue spee atrsio whic wh ich the thsona e nanc engi ennce gine ne exce excessive ssively lyspee vibrat vib rates dusp e eed todtors to iona nal lh reso re e might mig ht exis exist, t, sh shif iftt th thee se sett ttin ing g to a low lower er or high higher er idle spee speed d leve level. l.  b

Th Thee eng engine ine spee speed d will will incr increa ease se wh when en the the low low idle id le speed speed set set sc scre rew w is turn turned ed cloc clockw kwis ise. e.

 c

If th thee engin enginee speedten speedtends ds to fl fluc uctu tuat ate, e, turn turn idle idle sub-sp sub -spri ring ng adjust adjusting ing scr screw ew clock clockwise wise to bri bring ng th this is spr spring ing in into to sl slig ight ht con contac tactt wi with th the the tens tensio ion n leve leverr fo forr elim eliminat inating ing fluctu fluctuati ation. on.

...

JLt CAUTION

Id Idle le sub-s sub-spring pring adjusting sc adjusting scre rew w

 

Ti Tight ghten enin ing g th thee idle su subb-sp spri ring ng ad adju just stin ing g sc scre rew w is likely to ca caus usee the engine to over oversp spee eed d when th thee lo load ad is remo removed ved dur during ing op oper erat atio ion. n. Be su sure re to tighten this adjusting screw just enough to eliminat elim inatee th thee unstabl unstablee cond condit itio ion. n.

5 6

Setting Sett ing no-Ioad no-Ioad minimu minimum m idle spee speed d

Setti Setting ng id idle le sub-sp sub-sprin ring g adjust adjusting ing scr screw ew

 

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ADJUSTMENTS ADJUSTMENT S BENCH TES TEST T PERFORMANC PERFORMANCE E TES TESTS TS

 3 Setting Setting ra rack ck max maximu imum m ou outp tput ut a

Hold th thee sp spee eed d con contro trollev llever er at th thee posi positi tion on fo forr th thee ind indica icated ted ou outp tput ut and and spee speed. d.

 b

Unde Underr this this cond condit itio ion, n, check to be sure tha that th thee en engi gine ne is ru runn nnin ing g in a stea steady dy stat state. e.

 c

W it it h the e n ng g in in e r un unn in ing in a steady state, adj adjust ust the the fu ful1 l1-l -loa oad d stop stoppe perr bo bolt lt.. Tigh Tighte ten n or loos loosen en th this is bo bolt lt to find find ou outt th thee po posi siti tion on wher wheree th thee engi engine ne de deliv livers ers the the rate rated d outp output ut..

 d

Settingrack  m ximum output

fte terr ad adju just stin ing g th thee stop stoppe perr bolt bolt,, ba back ck it off s lo lo wl wl y w h hii le le o serving the s pe pe e d . S t o op p

b aacc k kii ng ng off the st op oppe r bolt j u uss t when the en engi gine ne sp spee eed d be begin ginss to decr decrea ease se fromthe fromthe rated rated leve levell and and se secu cure re itin that that po posi siti tion on withits withits loek loek nut.  e

At thi this tim imee, the speed contro trol lev lever should be in th thee maximum maximum spee speed d po posi siti tion on..

 f

Tuming the Tuming the fu fuIl Il-l -loa oad d stop stoppe perr bo bolt lt cloc clockw kwis isee wi will ll in incr crea ease se th thee in inje ject ctio ion n qu quan anti tity ty en engi gine ne outpu outputt , and and vi vice ce ve vers rsa. a.

4 Setting Setting gove govemor mor max maximu imum m spee speed d a

 b

Ap pp p ly ly fuIl load to the engine and hold the sp pee eed d co on n tr tr ol ol l ev ev eerr at the pos it it io ion for the indicated indic ated maximum sp spee eed. d. S et g o ov v em em or or set bolt maximum speed set bo bolt lt at th thee po posit sition ion for for th thee in indi dica cate ted d spee speed. d.

Governor

set set bolt bolt

Settinggovernor m ximum speed

57

 

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ADJUST ADJ USTMEN MENTS, TS, BENCH TEST TEST,, PERFORMANCE PERFORMANCE TESTS TESTS

 5) Dete Deterr rrni nini ning ng spee speed d reg regula ulatio tion n spe speed ed dro droop) op) [I]

Speed regu regula lati tion on upon re remo movi ving ng load

 a)

Run the e ng ng in in e with the s p peee d c on ont rro ol lever se sett at the the po posit sitionfor ionfor the the ra rate ted d load load and and sp spee eed. d.

 b)

Vn Vnde this cond ion, remo lo tobrin theder erng nth g in iis n eco indit nt oitio nt n n, oo- lo lre oamovethe d cvethe on d on dii ti tload i on oad n . tobr Do ing nogt mo move ve the the speed speed con contra trall leve lever. r.

 c)

Th he e e ng ng in in e s p pe e ed ed will i n nc c r ea ea s e o n nc c e and

decr decrea ease se an and d sett settle le at a new ste stead ady y stat statee lev level as shown. Read th e highest speed  N2  N2)) oc occu curri rring ng in this this tr tran ansi sitio tion n and and the the spe speed ed  N3 af t eerr s e tttt li li n ng g , a nd nd t h he e t im im e tr   ) from the moment of r em em ov ov in in g the load at the initial spee speedt dtbli bli)) to th thee sett settlin ling g at th thee ne new w leve levell  N3 . [2]

Sp Spee eed d reg regula ulatio tion n upo upon n app applyi lying ng load load

With With th thee engin enginee runn running ing underno-load con conditi dition on subseque subs equentto ntto th thee con conditi dition on ment mentione ioned d in b), b), [1], above, and with the spee speed d co cont ntro roll leve leverr held in th thee sa same me pos positi ition on as abov above, e, appl apply y the the prescr prescribe ibed d load in inst stan anta tane neou ousl sly y to the the en engi gine ne:: the the en engi gine ne sp spee eed d will will dec decrea rease se onc oncee and and increa increase, se, as sh show own, n, and settle at a new steady state level . Read the lowest low est speed speed  N  Ns) s) occ occurrin urring g in this this tran transitio sition n an and d the speed speed  N6 after ter se sett ttlin ling, g, an and d the the tim timee  ts) from N4 to N6. [3]

5-8

Sp Spee eed d regula regulatio tion n up upon on re remo movi ving ng load load N,

Insta stanta tan neous spee speed d regulation   ) NI NI

  z

NI

X

Steady-sta tatte spee speed d regulation   ) N3-NI

100

NI

X

100

= init initia iall

spee speed, d, mi minn-I, I, be befo fore re load load is removed N, = highest spe speed, ed, min min-I,duri -I,during ng tra transi nsitio tional nal period N3 = spee speed, d, mi minn-I,at I,at wh whic ich h the the en engi gine ne sett settle less af afte terr load load is re remo move ved d ti = stabiliz stabilization ation tim timee

Speed r e g N.

pqn,applying loa load d l a t pqn i ,applying ~ n

N,

In Inssta tan ntaneous spee speed d regulation   ) N4 - Ns N4

Calcu Calculat latee the the spe speed ed re regu gulat latio ion n

X

100

Steady-state spee speed d regulation   ) N4-N6  

X

100

initia iall spee speed, d, mi minn-I, I, be befo fore re lo load ad is N4 = init

From rom th thee valu values es obta obtain ined ed in [1] an d [2], above, compute th e speed regulation fo r each load chan change ge.. A tota totall of four pe perc rcen entt va valu lues es of spee speed d re gu latio n are to be d et et er er m mii ne ne d by u s in in g the

applied Ns = lowest spe speed, ed, min min-I,durin -I,during g tra transi nsitio tional nal period

indicated indica ted forr forrnula nulas. s.

N6

speed, d, mi minn-I,at I,at wh whic ich h the the en engi gine ne sett settle less = spee af afte terr load load is appl applie ied d

If the comp comput uter er values are at va vari rian anee ee with the prescr prescribe ibed d valu values, es, govern governor or notch adju adjustmen stmentt sh sho ould uld be mad madee to elim elimin inat atee the the vari varian anee ee..

 

= stabiliz stabilization ation tim timee

 

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ADJUSTMENTS BENCH TEST PERFOR PERFORMANCE MANCE TEST TESTS S

 6 Set Settin ting g no-loa no-load d maximum maximum spe speed ed make gov govern ernor or notch notc h adju adjustmen stmentt a

Thi hiss ad adju just stme ment nt is to be ma made de by turn turnin ing g the the adjust adjustingscr ingscrew ew for the swivel swivelleverto leverto inc increa rease se ordecreasethe ordecre asethe pre preloa load d of the gov govemo emorr spr spring ing..

 b

Togain Togain ac acce cess ss to the the ad adju just stin ing g sc scre rew,rem w,remov ovee the plug at the top of the gove govern rnor or housing. Turn the speed control lever all the way to the low idle position: this will turn up the swivel swi vellev lever, er, poi pointi nting ng the hea head d of theadju theadjusti sting ng sc scrrew to towa ward rd th thee plug plug hole hole.. Inse Insert rt a fl flaatt-ti tip p s ccrr ew ewdr iv iv er er t hr hr o ou u gh gh the h ol ol e to ca ttcc h the scr screw ew hea head. d.

 c

Ti Tigh ghte teni ning ng th thee ad adju just stin ing g scre screw w will will increa increase se th thee pr prel eloa oad d of th thee go gove vern rnor or spri spring ng to na narr rrow ow t he he s pe pe e ed d regul tion loosening it w i l l decr decrea ease se th thee pre preloa load d to wide widen n the the re regu gula lati tion on.. One notch c or or re re sp sp on on ds ds to 1/4 turn o f the adju adjust stin ing g scre screw w and and to 3 to 5 spee speed d chan change ge of th thee en engi gine ne sp spee eed. d.

 d

Ch Chan angi ging ng th thee sett settin ing g of this this adju adjust stin ing g sc scre rew w ch chan ange gess th thee governor governor se sett ttin ing g for for li limi miti ting ng the the ma maxi xim mum speed peed . Aft fteer ma maki kin ng a gove govern rnor or no tc tch a dj dj us us ttm m en en t, t, be sure to r eeaa dj dj us us t the go gove vern rnor or sett settin ing, g, as expl explai aine ned d in 4 , abov above. e.

 e

Tigh Tighte teni ning ng th thee adju adjust stin ing g sc scre rew, w, menti mentione oned d abov above, e, wi will ll increa increase se the the maxi maximum mum sp spee eed, d, an and d vic vicee versa. versa.

  - - - - - - - - - i h CAUTION

Adjusting speed speed reguJa reguJatio tion n

1

Neve Ne loos the e rns adju adsjust stin scre ore or etene tha th and 20 ver nortclo hose esen5th tu turn fring orgn sc threw ew fub llyy m ti tigh ghte ned position, or the con ontr trol ol action of the gove govern rnor or will will becom becomee hazardous hazardous..

Seal th thee set set bo bolt lts. s.  7 Seal

59

 

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ADJUSTMENTS BENCH BENCH TEST TEST PERFO PERFORMANCE RMANCE TES TESTS TS

1. 1.5 5 VV-be belt lt Ins Inspee peetio tion n  n Adjustment Pus Push the be bellt inwar ard d with thumb press essur uree exerted midway mid way be betw twee een n th thee pu pull lleys eys,, as sh show own, n, to chec check k the the bel beltt tensi tension on def deflec lectio tion n .   the the tens tensio ion n is inco incorr rrec ect, t, lo loos osen en th thee adju adjust stin ing g bra bracke ckett bo bolt lt and and moun mounti ting ng bolt bolt,, and move the alte altema mato torr in or out. Unit Unit:: mm [i [in. n.]] Item VV-be belt lt deflection deflection

5 10

Assembly Assem bly Stan Standard dard 12 [0 [0.5 .5]]

Checking V-b V-belt elt

 

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ADJUSTMENTS BENCH TES TEST T

2. B e n c h Testing er h ha au ull ed ed e n ng g iin n e should be t e ess te te d f o orr An o v er perfor performan mance ce on a dy dynam namom omete eter. r. Th This is test test is also also fo forr br brea eaki king ng in the ma majo jorr ru runn nnin ing g parts of the engine. To test test the the engi engine ne,, follow follow the the pr proc oced edur ures es de desc scri ribe bed d below:

2.1 Starting Up  l

Inspee Inspeett th thee lev levels els in the the ra radi diat ator or,, oil oil pa pan, n, and and fu fuel el tank tank.. Pr Prim imee the the fu fuel el and and cool coolin ing g syst system emss to blee bleed d air air ou out. t.

(2 (2)) Cra Crank nk the the en engin ginee with with the the star starte terr for for 15 sec secon onds ds to permit permit lub lubric ricati ating ng oil oil to circ circul ulate ate thro throug ugh h the the engi engine ne.. Por this cran cranki king ng,, do not supply fuel to th thee en engi gine ne,, placi placing ng the the st stop op leve leverr in stop stop posi positio tion. n. (3) Move the speed c on on tr tr ol ol l ev ev er er sl ig ight ly ly in the dire direct ctio ion n of incr increa easi sing ng fuel fuel in inje ject ctio ion n, an and d turn turn the the st star arte terr sw switc itch h to ST STAR ART T to sta start the the en engi gine ne.. Do not move the con tr trol l ev ev er er to the full fuel injection position.

PERFORM

N

E TESTS

2.3 Ben ch Testlng (Dynamometer) Conditions Step

Spe Speed ed (mi (min-I) n-I)

Load (PS)

Time (min.)

1

1000

No-load

30

2

1500

3

-4 -

5 6

2.4

(According (Accordi ng to engine engi ne spec specifiification)

25

30

25

10

50

10

75

30

100

20

I n spe etio n an d Adjustments Afte r Bench Test Testing ing

(a (a))

Ad Adju just stin ing g val alve ve cl clea eara ranc ncee

(b) (b)

Ad Adju just stin ing g inje inject ctio ion n timi timing ng

(c (c))

Re Re-t -tig ight hten enin ing g ex exte tern rnal al bolt boltss an and d nuts uts

(4) A fter the engi engine ne star tarts, let it idle un unde derr no load by operat operating ing the the spe speed ed contr control ol leve lever. r.

2.2 Insp Inspee eeti tion on After Starti Starting ng Up Af ter s ta tar ti ti n ng g up th e en engi gine ne,, ch chec eck k the the foIl foIlo owing wing

points. Ifyou find find anyth anything ing wr wron ong, g, imm immedi ediate ately ly stop stop th thee engin engine, e, th then en invest investiga igate te th thee caus cause. e. (1 (1)) Lub Lubric ricati ating ng oi oill pressu pressure re sh shou ould ld be 0.3 0.3 to 0.5 0.5 MP MPaa (3 to 5 kgf/cm ) [43 to 71 psi] at rated speed or 0.1 MP a  l kg kgf/ f/cm cm ) [1 [14. 4.2 2 ps psi] i] at idli idling ng sp spee eed. d. (2) Cool Coolan antt temp temper erat atur uree shou should ld be 75 to 85°C [167 to 18 185° 5°P] P].. (3) Lube oil t em em pe pe ra ra tu tu rree should be 60°C to 95°C [l40oP to 203  F] (V (Var arie iess acco accord rdin ing g to engi engine ne specifications.) (4 (4)) Checkfor lea leakag kagee of oil, oil, cool coolan ant, t, fu fuel el,, espe especi ciaI aIly ly o i l le a k a ag g e fro m oil pip e con n ne e cti o n s fo r

turbocharger lubrication lubrication.. (5 (5)) Kno Knocki cking ng shou should ld di diee aw away ay ascoo ascoola lant nt temp temper erat atur uree rise rises. s. No oth other er defe defect ctiv ivee nois noisee sh shou ould ld be hea eard rd.. (6) Check fo forr exh exhaust aust color color and and abno abnorm rmal al od odor ors. s.

5-11

 

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ADJUSTMEN ADJUS TMENTS TS BENC BENCH H TEST TEST PERFORMANCE TESTS

3. Pe Perfo rform rman ance ce Test Testss The There are are vario ariou us perf perfor orma manc ncee test test proc proced edur ures es,, an and d here here the the proc proced edur ures es for for Ear Earth th movi moving ng mach machin iner ery y Engi Engine nes, s, Pa Part rt 1 : Test Test co code de of net net pow power er (J (JIS IS D 0006 0006-1 -1)) aand nd Ea Eart rth h movi moving ng ma mach chin iner ery y Engi Engine nes, s, Pa Part rt 2 : st stan anda dard rd fo form rmat at of sp spec ecif ific icat atio ions ns and and test testss me metho thods ds of diesel diesel engin engines es (JIS (JIS D 000 0006-2 6-2)) ar aree de desc scri ribe bed. d. Othe Otherr test test item itemss ma may y be re requ quir ired ed on appl applic icati ation on.. Eng Engine ine perfor performan mance ce is judg judged ed with with integr integrate ated d te test st re resu sult lts. s.

3.1 3.1 Engi Engine ne Equipm Equipment ent Cond Condit itio ion n Engine Eng ine mu must st be equi equipp pped ed with with such such stand standard ard auxi auxili liar arie iess as cooli cooling ng fa fan, n, ai airr cle cleane anerr and and al alte tema mato tor. r.

3.2 Tests  nd Their Purpos Purposes es Oper erat atio ion n lo load ad test test (1) Op Conductt th Conduc this is test test to eval evalua uate te eng engine ine outpu output, t, torq torque ue,, fu fuel el con consum sumpti ption on ra rate te and and gov govern ernor or pe perfo rforma rmanc ncee un unde derr var variou iouss loa load d con conditi ditions ons.. (2 (2)) Cont Contin inuo uous us lo load ad test test Op Oper erat atee the the en engi gin ne co cont ntin inuo uous usly ly for for 10 hour hourss at 90 load load (c (con onti tinu nuou ouss load load ap appl plic icat atio ion) n) of nomin ominal al net net br brak akee po powe werr whil whilee engi engine ne sp spee eed d is mai mainta ntained ined at rev revolu olutio tions ns corre corresp spon ondin ding g to the the no nomin minal al brak brakee po powe wer. r. In this this test test,, evalu evaluat atee fu fuel el consu consump mptio tion n ra rate te and and opera operatin ting g con condit dition ion and and confi confinn nn conti continuo nuous us eng engine ine op oper erat atio ion. n. (3 (3)) No-l No-loa oad d min minimu imum m idle idle sp spee eed d test test Co on nduct this test to c on on ffii nn nn that the e ng ng in in e can o p peer at at e stably at the spe ci cif ie ied n oo- lo lo ad ad minimum idle speeds.

3.3 Other Other In Insp spee eeti tien enss Du Duri ring ng perf perfor orma manc ncee test testin ing g, insp inspee eett for for leak leakag agee of gase gases, s, co cool olan ant, t, lubr lubric icat atin ing g oil, oil, or fuel fuel,, an and d for for nois noisee or hunt huntin ing. g. Ma Make ke ad adju just stme ment nt,, as needed. needed.

3.4 3.4 Adjust Adjustme ment nt Engi Engine ne  utput Diese Die sell en engi gine ne ou outp tput ut is af affe fecte cted d by atmo atmosphe spheric ric pres pressure sure,, temp temperat erature ure,, an and d humid humidit ity. y. There Therefore fore,, the the en engi gine ne ou outp tput ut sh shou ould ld be set set fo forr stand standar ard d atm atmosp ospher heric ic cond conditi ition ons. s. Standard rd atmospheri atmosphericc condi conditions tions (1) Standa Basee temper Bas temperature ature

29 298 8 K (2 (25° 5°C) C) n  p]

Atmospheric Atmosp heric pressu pressure re

 

kPa kPa [7 [750 50 mm mmHg Hg]]

kPa [743 [743 mm mmHg Hg]] Atmosph Atmo spheri ericc vap vapor or pre pressu ssure re 99 kPa

5 12

 

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ADJUSTME ADJU STMENTS, NTS, BENC BENCH H TE TEST ST,, PERF PERFOR ORMA MANC NCE E TEST TESTS S

 2 Calcul Calculat ation ion of cor correc rected ted power Multip Mult iply ly th thee me meas asur ured ed bra brake ke pow power er or torq torque ue by the the calcu calculat lated ed di dies esel el eng engin inee co corr rrec ecti tion on fact factor or see see be belo low w to obta obtain ined ed a cor correc rected ted valu value. e. Corrected Corr ected outpu outputt

=Cor Correct rection ion fact factor or  a c

x Me Meas asur ured ed brak brakee powe powerr

• At Atmo mosp sphe heri ricc con condit dition ionss for for test test Te Temp mper erat atur uree T : 283 283 K  l0°C [SOap]

T

313 K  40°C [104°P]

Dry Dry at atmo mosp sphe heri ricc pre pressu ssure re Pd : 80 kP kPaa 600 600 mm mmHg Hg

Pd

110 110 kPa kPa 825 825 mmHg

3 Cal Calcul culati ation on of cor correc rectio tion n factor factor  oe cc

 a

= fa fm

fa: At Atmo mosp sphe herric facto actorr

fm: En Engi gine ne f act actor or

Calcu Calcula latio tion n of atm atmosph ospheri ericc fact factor or fa Na Natu tura rall as aspi pira rati tion on eng engine ine and and eng engine ine with with me mech chani anica call lly y driv driven en ai airr cha charg rger er fa = @

0.7

298

Turboc Tur bochar harged ged engine wit withou houtt air air cool cooler er afte afterr cool cooler er or wi with th air air-to -to-ai -airr cool cooler er

fa = @

• l

Pd

99 Pd

T 298

0.7 •

1.2

Turboc Tur bochar harged ged engi engine ne wi with th air air-to -to-li -liqui quid d coole coolerr

fa =  _990 . 7 . Pd

T 298

  _ 07

 b Calcul Calculati ation on of en engi gine ne factor factor fm fm = 0.036 qc - 1.14  

q

qc Co Corr rrec ecte ted d fu fuel el su supp pply ly vol volum umee

q

=r

 z x Fuel uel flow rate ate g s x Engi Engine ne idle dle spee speed d minin-I

= Stro  Stroke ke volume volume  

z = 1200 120000 00 44-cy cycl clee engine engine r: Ra Rati tio o of pr pres essur suree at turboc turbochar harger ger or air air coo cooler ler to atmo atmosph spher eric ic press pressur uree  r = 1 fo forr na natu tura rall asp aspir irat atio ion n eng engine ine @

Appl Applic icab able le ra rang ngee of eng engine ine fac factor tor fm 37.2

qc

65 mg/ f-cycle

• qc 37.2 mg/ f-cycle • 65 mgl f-cycle qc

: fm : fm

=0.2 0.2 = 1.2

Con Consta stant nt Constant Constant

c Rang Rangee of cor correc rectio tion n equation equation us usee Th Thee ra rang ngee of corre correct ctio ion n fac factor tor  o e use use is as foll ollows: ows: 0.9 0.9

ac

l.I.

If th this is ra rang ngee is exc exceed eeded, ed, ind indica icate te the the correc correcte ted d va valu luee and and re recor cord d th thee te test st con condi diti tion onss on th thee te test st reco record rd sh shee eet. t.

5-13

 

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ENGINE

AUXlllARIES

REMOV

l  N

INSTAllATION

1 Preparation

6

2

2 Engine Auxiliaries Removal

6

2

3 Engine Auxiliaries Installation

6

7

 

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ENGINE ENGIN E AUXILIA AUXILIARIE8 RIE8 REMO REMOVA VAL L AND AND IN8T IN8TALLAT ALLATION ION

This This sectio ction n explai plain ns the pr proc oced edur ures es and tip tips for re remo mov v al al and inst instaa lla llati tio o n of the a u ux x ili iliaa rrie iess - the pr pre1 e1im imin inar ary y pr proc oces esss to go thro throug ugh h for for ove overha rhauli uling ng the engin engine. e.

1. Pr Prep epar arat atio ion n  a

Shut Shut of offf the the fu supp supply ly,, and and dis discon connee neett the the sta starti rting ng sys system tem from from the eng engine ine..

 b

Loos Looseen th thee dra rain in plu plugs on the the le left ft-r -rea earr side ide of cr crank ankcas case, e, and drain drain coola coolant. nt.

 c

Loo Loose sen n theoil pa pan n dra drain in plug plug anddrai anddrain n en engin ginee oil.

Hot engine oil can cause personal injury if it co conta ntacts cts the ski skin. n. Use cau cautio tion n whe when n drain draining ing the oil. .-------....

NOTE   1 - - - - - - - -

Chec Check k the the dr drai aine ned d oil oil for for cont contam amina inatio tion. n.

2. Engine Engine Auxil Auxilia iari ries es Remo Remova vall  1 Tur Turboc bochar harger ger eng engine iness wit with h turb turbocha ocharger rger

a

Disc Di scon onne neet et pipe pipe fr from om the the turb turboc ocha harg rger er and and inlet mani manifold fold..

 b

Disc Discon onne neet et oil oil pipe pipe an and d drai drain n pipe pipe fr from om the the turbocharger.

 c

oc h r g e err f rro o m th e exh ust Remove t u r oc manifold.

üi l pipe

Turbocharger

Removi Rem oving ng turboc turbocharge hargerr

6-2

 

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ENGINE AUXIL AUXILlARIE lARIES S RE REMO MOVA VAL L AN AND D INST INSTAL ALLA LATI TION ON

 2 Exh Exhaus austt manif manifold old Re Remo move ve th thee bolt boltss that that ho hold ld exh exhaus austt ma mani nifo fold ld to the cyli cylind nder er head. Remove the ma mani niffold old and ga gask sket et fr from om th thee he head ad..

Exhaust manifold

Removing Remo ving exhau exhaust st manifold manifold

 3 Fue Fuell filter filter  a  b

Di Disc scon onne neet et fu fuel el pipe pipess an and d from from the the fuel fuel fi filt lter er.. Re Remo move ve fuel f ilt ilter er comp comple lete te with br brac acke kett fr from om th thee in inle lett mani manifo fold ld..

Removing Remo ving fu fuel el fi filte lterr

 4 Fuel Fuel inj inject ection ion pip pipes es  a

 b  c

 

Rem Remove ove pipe pipe cla clamps mps and disco disconneet nneet inj inject ection ion pipes from the injection p um um p and n oz oz zzll e holders. Disc Disconnee onneett lea leak-of k-offf pipe. pipe. Disc Disconnee onneett return return pip pipe. e.

llLtCAUTION f

Return pipe

.

Be su surre to put r u ubb bber er caps over the op open enin ings gs of th thee in inje ject ctio ion n pump pump and and nozz nozzle le hol holder derss to prev prevent ent du dust st fr from om ge gett ttin ing g in insi side de the the fu fuel el sy syst stem em..

Removing Rem oving fu fuel el injectio injection n pip pipes es

 5 Inle Inlett mani manifold fold Re Remo move ve th thee bo bolt ltss th that at ho hold ld inle inlett manif manifold old to the the cy cyli lind nder er he head ad.. Re Remo move ve the the ma mani nifo fold ld and and ga gaske skett fr from om th thee cyli cylinder nder head head..

Removing Remo ving inl inlet et manifold manifold

6

 

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ENGINE AUXILIARIE8 REMOVALAND IN8 IN8TAL TALLAT LATION ION

 6) Fu Fuel el inje inject ctio ion n no nozz zzle less di dire rect ct inje inject ctio ion n type type)) Remo Remove ve gl glan and, d, th then en remo remove ve noz nozzle zle an and d ga gask sket et from from the the cyl cylind inder er he head ad..

Remov Removing ing fuel fuel inject injection ion noz nozzle zless direct direct injec injectio tion n type) type)

 7) Fuel Fuel in inje ject ctio ion n nozz nozzle less swir swirll ch cham ambe berr ty type pe))

Re Remo move ve nozz nozzle le an and d gask gasket et..

~

 

Nozzle Gasket

Remov Removing ing fuel fuel injec injectio tion n noz nozzle zless swi swirr ehamber ehamber type) type)

 8  8)) Glow Glow pl plug ugss di dire rect ct inje inject ctio ion n type type)) Re Remo move ve nu nuts ts,, th then en remo remove ve co conn nnee eeti tion on plat platee an and d glow glow plug plug..

Remo Removi ving ng glow glow plug plug dire direct ct inje inject ctio ion n type type))

 9) Gl Glow ow pl plug ugss sw swir irll ch cham ambe berr type type)) Loosen nu Loosen nuts ts,, then then remo remove ve conn connee eeti tion on pl plat atee and and glow glow plug plug..

1liIIP

;

Nut

Conneetion

plate  

low plug

Remo Removi ving ng glow glow plug plug sw swir irll eh eham ambe berr type type))

6

 

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EN ENGI GINE NE AUX AUXILIA ILIARIE RIE8 8 RE REMO MOVA VAL L AN AND D IN8 IN8TALL TALLATI ATION ON

 10  10 Fuel Fuel inje inject ctio ion n pu pump mp  a

Re Remo move ve oil oil pipe pipe..

 b

Remo Remove ve bo bolt ltss that that ho hold ld the the gear gear ca case se cove cover. r.

 c

R em em o ov v e b ol ol ts ts t h aatt hold the f l a nge pl at e.

Fuell inj Fue inject ection ion pump pump

Re Remo move ve pu pump mp with with gear gear and and flan flange ge from from the the fron frontt plat plate. e. So Some me en engi gine ness are are no nott equi equipp pped ed wi with th pu pump mp br brac acke ket. t. Removi Rem oving ng fue fuell inj inject ection ion pump pump

11 Oil Oil cool cooler er eeng ngin ines es with with oil oil co cool oler er Remove bolts that hold oil cooler cover to the cr cran ankc kcaase se.. Remo Remove ve the the co coo oler, ler, co comp mpllete ete with with the the cove cover, r, fr from om the the cran crankc kcas ase. e. Remo Remove ve gask gaskeet and O-r O-ring ing..

Removi Rem oving ng oil coo cooler ler

 12 Oil filter filter  a

Remo Remove ve oil oil fi filt lter er with with a filt filter er wren wrench ch.. ü

filter

Removi Rem oving ng oil filter filter

C13 Alt Altema emator tor  a

Disconnee Discon neett hame hamess ss from from alte altern rnat ator or.. Remo Remove ve adjust adjusting ing bolt. bolt.

 b

Re Remo move ve bolt boltss to remo remove ve the the alte altema mato tor. r.

 c

Remove Rem ove V-belt V-belt..

Removing Remov ing alternator

6

 

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ENGINEAUXILIARIE8 REM REMOV OVALA ALAND ND IN8 IN8TAL TALLAT LATION ION

 14 Water Water pump pump  a

Rem Remove ove th thee bolts bolts that that holdfan holdfan andpull andpulley ey and remove rem ove the them. m.

 b

Re Remo move ve the bolt boltss that hat hol hold wate waterr pump pump an and d re remo move ve th thee pu pump mp and and ga gask sket ets. s.

Removing Rem oving wate waterr pump pump

 15 Starter Disconneet Disconn eet harne harness ss fr from om st star arte ter. r. Remo Remove ve nuts nuts to re remo move ve th thee star starte ter. r.

 

~ r t

r ~

Removing starter starter

 16 Thermostat  a

Remo Remove ve wa wate terr by-p by-pass ass hos hose. e.

 b

Re Remo move ve the bo bolt ltss that that hold hold th ther ermo most stat at ca case se to re remo move ve th thee term termos osta tatt ca case se..

Removing therm thermostat ostat

 17

û

pan

Re Remo move ve bo bolt ltss to re remo move ve oil oil pa pan. n.

L

~ Removi Rem oving ng oi oill pa pan n

 

o t on pan

 

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ENGINE ENG INE AUXILlAR AUXILlARIES IES REMOVALAND INSTAL INSTALLAT LATION ION

3. Engine Engine Auxi Auxili liar arie iess Instal Installat lation ion To i n nss ttaa ll ll the engi ngi n nee a uxi uxill iiaa rrii eess , follow the remova rem ovall pro proced cedure uress in rev revers erse. e. Aft After er ins instal tallat lation ion,, service service th them em as fo foll llow ows: s:  a)  a)

Refill the engine with the recommended oil up to th thee spec specif ifie ied d le leve vel. l.

 b) Refil efilll th thee cool coolin ing g syst system em wit ith h cool coolan ant. t.  c) Ch Chec eck k each each pi pipeco peconn nnee eeti tion on for for oil oil orcool orcoolan antt leaks.  d) Pri Pri me me the fuel system.  e)

To in inst stal alllat atiion of the fuel injection pump is de desc scri ribe bed d below. Aft fteer ins nsttalling the fuel injecti inje ction on pump pumps, s, be sure sure to insp inspee eett and and adju adjust st th thee in inje ject ctio ion n ti tim ming. ing. Re Refe ferr to Sect Sectio ion n 1.3 1.3 of Gro roup up 5, Adj djus ustm tmen ent, t, Bench ench Te Test stin ing, g, and and Performance Perform ance Tes Tests. ts.

  7

 

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ENGINE M IN P RTS RTS 1. Cy Cyli lind nder er He Head adss and and Valv ValveMechan eMechanism ism 1. 1.1 1 Di Disa sass ssem embl bly y

 

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4. Piston Pistonss Conn Connect ecting ing Rods Rods Crank Crankshaf shaftt Cra Crankc nkcase ase and Tappets 4. 4.1 1 Di Disa sass ssem embl bly y .. .... .... .... ..

 

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ENGINE ENGIN E MAIN MAIN PAR PARTS TS

1. Cyli Cylin nd dee r Head

an d

Valv Va lvee Mechanism Mechanism

1. 1.1 1 Di Disa sass ssem embl bly y

Check Check valv valvee ca cap p contac contactt face face   heckoil hole for clogging.

for wea wear. r.

Ch Chec eck k for for cra cracks. cks. or carbon or scale scale depo deposits, sits,

Check for for uneven

WeM

  heckface face

for for pitring pitring or ridging   exhaust valve), valve),   heckstem for serarc serarches hes or scuff marks.

IDisa Disassem ssembly bly sequence sequence I   D Rocke Rockerr cove coverr ® Adjus Adjusting ting screw ® Bolt Bolt sho short) rt) @ Bolt long long)) Remove @ through  @ as an assembly. @ Ro ock cker er sh shaf aftt br brac acke kett @ Snap Snap ri ring ng  j In Inle lett val alve ve roc rocker ker arm arm

@ Exha Exhaus ustt va valv lvee ro rock cker er arm ® Roc Rocker ker shaft shaft sprin spring g  @ Roc Rocker ker shaft shaft  jJ Val Valve ve cap © Va Valv lvee pushrod  j] Cylinder head bolt Remove ® through @ as an assembly. ® Cyl Cylind inder er head

@ Val Valve ve cot cotter ter @ Valve retain retainer er

® Val Valve ve spring spring

@ Valve

® ®

Va Valv lvee st stem em se seal al Cylinder head Cylinder head gaske gaskett

7

 

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ENGI ENGINE NE MA MAIN IN PART PARTS S

 1 Rem Removin oving g rocke rockerr sha shaft ft asse assemb mbly ly

 a

Loosen Loosen th thee ad adjus justin ting g scre screw w on onee rot rotat ation ion..

 b

Loo Loosen sen the the bolts, bolts, shor shortt and and long long,, that that hold th thee rocker roc ker sha shaft ft brack bracket et to th thee cy cylin linde derr hea ead d. Be su sure re to loose loosen n th thee sh shor ortt bol oltt firs first. t. Rem Removeth ovethee rocker shaft assem assembly bly from from the the cylind cylinder er he head ad..

-  - - - - ---- l

CA UT ION

1

If th thee lo long ng bol oltt is lo loos osen ened ed firs first, t, th thee rocke rockerr sh shaf aftt bracke brackett might might suff suffer er da damag mage. e.

Removing Remov ing roc rocker ker sh shaft aft assembly assembly

 2 Disassembling rocker shaf shaftt asse assembl mbly y Put a ma r k on the ro c k e r arm and shaft so that the the ar arm m can can be instal installedon ledon th thee same same shaf shaftt po posi sitio tion n fro from m wh whic ich h it wa wass remo remove ved. d.

Disassem Disa ssemblin bling g ro rocke ckerr shaft shaft assembly assembly

 3 Rem Removin oving g cylin cylinder der he head ad  a

Remove the the cyli cylinder nder he head ad bo bolt lts. s.

 b

Lift the the head of f the the cra crankc nkcase ase..

 

1

a

NOTE }

h en removing t he he g as as ke ke t f r o m t h e crankcase be c a r e f u l not to damage th e

gaske gaskett con contact tact su surf rfac acee of th thee crankc crankcase ase  b

I f an any y cylind cylinder er head head parts arts are are faul faulty ty,, che check ck th e cylinder head b olts for t o r q u e w i t h a

torque torq ue wren wrench ch before before remo removi ving ng th them em..

7-3

 

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ENGINE ENGIN E MA MAIN IN PARTS PARTS

 4 Remove Remove va valv lvee and and va valv lvee sp spri ring ng  a

Us e va valv lvee spri spring ng pus pusher her 30 3069 6911-04 0450 500 0 to

co comp mpre ress ss th thee valv valvee spri spring ng,, then hen rem emov ovee the the valve cot cotter ters. s.  b

Rem Remove ove th thee valv valves es an and d valv valvee sp spri ring ngs. s.

  .....

I [ NOTE

ÎI

If th thee or orig igin inal al valv valves es are are to be re reus used ed,, markthe markthem m fo forr their lo loca cati tion onss to en ensu sure re the the ori origin ginall allocat ocation ion and com combi bina nati tion onss of the valve, valve seat and valve gu guid ide. e.

1.2

Remo Removi ving ng va valv lvee and and va valv lvee sp spri ring ng

I nspe e tion

Rockerr arms, rocker Rocke rocker bu bush shin ings gs an d rocker sha shafts fts  1 Me Measu asurin ring g roc rocker ker ar arm m bush bushin ing g and and rock rocker er sh shaf aftt

Measure theinsid theinsidee dia diamet meter er of the rockerbush rockerbushing ing an and d the di diam amet eter er of the the rocke ockerr sh shaaft as show shown n in the illus illustr trati ation. on. Det Determ ermine ine theclear theclearanc ancee bet betwee ween n us h iin ng an nd d s h af af t on th e basis o f the th e b us measurements. If the the cle cleara arance nce do does es not not exce exceed ed th e r e ep p ai ai r limit , rep la la ce ce the r oc oc k kee r arm. If it exce exceed edss the repa paiir limit, replace the shaft and rocker ar arm. m. Unit Unit:: mm [i [in. n.]] Item Inside diameter diameter of ro rock cker er bushings Di a met er of rocker shaft rocker shaft Cl e a r a n c e between rocker bushing and shaft

Nominal Value

Assembly Standard

Service Limit

19.010 to 19 19.0 .030 30 [0.7484 19 [0.75]

to 0.74 0.7492] 92] 18.980 to 19.000 [0.7472 to 0.748 0.7480] 0] 0.010 to 0.050 [0.0004 to 0.0020]

 

7

[0.0028]

Measur Mea suring ing rock rocker er arm arm bush bushing ing and and rock rocker er sh shaf aftt

7

 

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EN ENGI GINE NE MA MAIN IN PART PARTS S

Valves Val ves,, valve valve gul guldes des an d valve valve sea seats ts

Measuring Measur ing dia diagra gram m

 

 1 Measuring valve stem Measure the diameter of th thee valv valvee ste tem m as shown

in th e illustration. If the s tem tem is wo m beyon beyond d the service limit or u n ne e ve ve nl nl y w o m e xc xc e ss ss i ve ve l y replace the the valve. valve.

Item

Nominal Value

lniet Diameter valve ofvalve   Exhaust stem valve

8 [0.31]

Un Unit it:: mm [i [in. n.]] Assembly Standard

Service Limit

7.9 7.940 40 to 7.9 7.955 55 [0.3126 to 0.31 0.3132] 32]

7.900 [ 311 ]

7.9 7.920 20 to 7.9 7.940 40 [ 3118 to 0.3 0.3126 126]]

7.850 [0.3091]

Measur Mea suring ing valve valve stem stem

ec k iin n g c le le a ra ra nc nc e b e ett w ee ee n valve stem an d  2 C h ec valvee guide valv guide

Measuring diagram

e

Th e v a all ve ve g u uii de de w eeaa rs rs m o orr e r ap ap id id ly ly at its both ends than than at any other parts. parts. Measure Measure th thee inside

diameter of the guide at its e n nd d s as s ho ho w wn n in th e

illustr illu stratio ation n to determine th thee clea clearan rance ce between t he he g u uii de de an d stem If clearance e xc xc e ed ed s t h e whichever is e x xcc eess si si v vee lly y wo om m.

Item InIet Clearance valve

between valve stem Exhaust and guide valve

Heig Height ht to top top of valve gu guide

Nominal Value

Unit: mm [in.]

Assembly Standard

Service Limit

-

0.0 0.065 65 to 0.0 0.095 95 [0.0026 to 0.0 0.0037 037]]

[

 

0.0 0.080 80 to 0.1 0.115 15 [0.0032 to 0.0 0.0045 045]]

0.200 [0.0079]

11.5 [0.45]

Measur Mea suring ing valve valve guide guide

0.150 59]

±O.I [±0.004]

 3 Repl Replacin acing g valve valve guide guide  a

 

replace t h e v a lv lv e o r g u i d e

service limit

Valve guide remover

Us e the the va valv lvee guide remover remover 32A9132A91-OO3 OO300 00 , to remove the val valve ve guide guide fo forr replac replaceme ement. nt.

 

~

Removi Rem oving ng valve valve guide guide

7-5

 

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ENGINE ENG INE MA MAIN IN PART PARTS S

 b

To ins instal talll are arepla placem cement ent gui guide, de, use val valve ve guide guide installerr 32A9 installe 32A91-o010 1-o0100 0.

 

Press

Valve Valve guide instalIer instalIer

iLLCAUTION 1

The in st stal llaat iio on depth for the val ve ve guide is spec specif ifie ied; d; be su sure re to use use the the valv valvee guid guidee inst instal alIe Ierr to ins insure ure th thee corr correc ectt de dept pth. h.

Ins Instal tallin ling g val valve ve gui guide de

4 Inspectin Inspecting g valv valvee fa face ce Coat th Coat thee valv valvee face face li ligh ghtl tly y wi with th re red d le lead ad.. Us Usee the the Val alve ve lapp lapper er to insp inspee eett the the va valv lvee co cont ntaact ctss wit ith h its seat. If the contact is not unif niform, or if the valv valvee is defe defect ctiv ivee orif the the re repa pair ir li limi mitt is exce exceed eded ed,, repa repair ir or repl replac acee the the va valv lvee and and valv valvee se seat at..  ..

a b c

1

NOTE

1

Inspeet Ins peet th thee valv valvee fa face ce afte terr the the insp inspee eeti tion on or replacem repl acement ent of the the va valv lvee guid guide. e. Do not rotate the valve when ch chec ecki king ng its contact. fter refa refaci cing ng or re repl plaaci cing ng the the va valv lvee or the the valve seat, be sure to lap the valve in the seat seat.. See See 8 Va Valv lvee la lapp ppin ing. g.

Ins Inspec pectin ting g val valve ve face

Unit Unit:: mm [i [in. n.]] Assembly Standard

Item Angle

 

Q

 

>

30° Inlet Valve

Valve sinkage

  Width Va Valv lvee margin margin

Exhaust Valve

Repair Limit -

Bad

 o od

0.4±0.1 [0 [0.0 .016 16 ± 0.0 0.004 04]]  inlet 0.5±0.1 [0.020±0.004]  exhaust

1.0 [0.039]

1.4±O.14 [0.O55±0.OO55]

1.8 [0.071]

2.13 [0.0839]

Up to 1.83 [o on ] by refacin refacing g

Val Valve ve con contac tactt pat patter tern n

Valve Valve mar margin gin Valve Valve sinkage

7-6

 

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EN ENGI GINE NE MA MAIN IN PA PART RTS S

 5) Re Refa faci cing ng va vallve fa face ce the valve face is badly wo wom, m, reface it with a valve ref reface acer. r.

 

NOTE

1

a)

Set a valve r e fa c er to an angle of 30°

b)

val valve has a st stel ella late te fac acin ing. g. Thi This fac aciing will will be gone gone if the the va valv lvee mar margin gin ex exce ceed edss the the ser servic vicee lim limit. it.  f the ma marg rgin in seem seemss to be less less th than an th thee servi service ce lim limit it when when grou ground nd,, re repl plac acee th thee va valv lve. e. Th e

Refa Refaci cing ng va valve lve fa face ce

 6)) Refa  6 Refaci cing ng valv valvee sea seatt the Va the Valv lvee se seat at cutt cutter er or va valv lvee se seat at grin grinde derr to re refa face ce th thee val valve seat seat..  f ter ter refa refaci cing ng,, grin grind d the the seat li ligh ghtl tly y us usin ing g 400 gra grade de san sandpa dpaperinse perinsert rted ed betwe between en th thee cu cutt tter er an and d val valve seat seat.. Use

a)

b)

NOTE 1 C u t or grind the valve seat only as needed for ref refaci acing. ng. Replace the va l ve seat if the seat width is mor oree th thaan the rep repairli airlim mit as a resu resullt of wear ear or cut cuttin ting. g.

Refa Refaci cing ng va valve lve se seat at

 7) Rep Replac lacing ing va valv lvee seat

 a )

Weld a stud to the valve seat. Insert a shaft into the v aallv e g ui ui de de h ol ol de de r from the u pp pp er er side of the cyli cylind nder er head. Dr Driv ivee the seat off from rom the cyl cylind inder er head head as show shown. n.

.

I

NOTE

 

yo you u weld weld th thee stud stud,, do no nott to pe perm rmit it sp spla latt tter er to come come in cont contac actt with the mach machin ined ed surfaces of cylind cylinder er he head ad..

When

Stud

Removin Rem oving g va valve lve se seat at

77

 

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ENGIN ENG INE E MA MAIN IN PA PARTS RTS

 b

Before Before insta install llin ing g repl replac acem emen entt va valv lvee se seat atss in the cyli cylind nder er head ead, measure the bores in the cyl cylind inder er he head ad fo forr the the va valv lvee se seat ats. s.

4 6 ~ ~ · O O 2 5

[1.8II -

; ;

~

Inlet valve seat bo b ore

]

Ex xh haust valve seat bore

Valvee sea Valv seatt dimensions dimensions

 c

Chill the v al alv e seat in liquid nitrogen of  l7 [ 274 for for more more than than 4 mi minu nute tess wi with th th thee cylinder cylinder head head kep keptt atnorm atnormal al temp temper erat atur ure, e, or heat heat th thee cyl cyliinder nder headup headup to 80 to 100 100 [176 to 212 with with the the va valv lvee se seat at ch chil ille led d in eth ether er or alc alcoho oholl cont contai aini ning ng dry dry ice. ice.  F ]

 

 F

 d

D

 F]

Usin Using g ins insert ert caul caulki king ng taal taal,, driv drivee the the se seat at into into position.

To Tool olss needed Ins Inser ertt caulking caulking tooI tooI  for inle inlett va valve lve seat seat

36791-00200

In Inse sert rt caul caulking king tooI tooI  fo forr exhaus exhaustt va valv lvee se seat at

34491-03020

Ins Instal tallin ling g valv valvee se seat at

8 Lappin Lapping g valv valvee in va va1v 1vesea eseatt Be sure sure to lap th thee val valve in the the val valve seat seat aft afterthe va vallve or th thee seat seat have have been been rep epllac aced ed..  a

Co oaa t the v aall v vee face lightly with a lapping compound.

 - - - - - - - - - j

a

NOTE

If

Do not p er er mi mi t the compound to come in contac con tactt with with th thee va valv lvee st stem em..

 b

Use a c o m p o u n d of 120 to 150 mesh for initialla init iallapping pping and and the the comp compou ound nd fi fine nerr than than 20 200 0 me mesh sh fo forr fi fini nish sh lapp lappin ing. g.

 c

Mixing Mixing th thee com compou pound nd with with a sm smal alll am amou ount nt of engine oi oill wi will ll faci facili lita tate te co coat atin ing. g.

Coat Coatin ing g val valve ve with with lapp lapping ing compound compound

7-8

 

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ENGiNE ENGi NE MA MAiN iN PA PART RTS S

 b

Usin Using g lapp lappin ing g tool tool,, hold hold the the valve valve ag agai ains nstt the the seat seat an and d ro rota tate te it only a part of a turn, then raise th thee va valv lvee of offf the the se seat at,, rota rotati ting ng it toa new new positio pos ition. n. Th Then en pr pres esss the the valv valvee ag agai ains nstt the the seat seat fo forr an anot othe herr pa part rt of a turn turn.. Re Repe peat at this this oper operat atio ion n until th thee comp compound ound we wear arss an and d lose losess it cu cutti tting ng particle.

 c

Wa Wash sh of offf th thee comp compou ound nd with with diese diesell fu fuel el..

 d

Apply the valve face to the e ng ngi ne ne oil, and agai again n lap lap the the va valv lve. e.

 e

Check th thee va valv lvee fa face ce fo forr cont contac act. t.

Valve lapping lapping

t

La Lapp ppin ing g va valv lvee in va valv lvee se sett

 9 Measuring val valve ve spring spring per perpen pendicu diculari larity ty and fre freee length Measuree the Measur the free free leng length th and and pe perp rpen endi dicu cular larity ity of each valve spring the free length or perpendicularity exceeds th e service limit, replace repl ace the the spri spring ng..

Perpendicularity

Unit Unit:: mm [i [in. n.]]

Item F r e e le l e ngt h Perpendicularity

Assembly Standard

Service Limit

48.85 [1 [1.92]

47.60 [1 [ 1.87]

1.5°or 1.5°or less less

-

  etl e n g t h

43 [1.69]

-

Se Sett force force N kgf [l [lbf bf]]

176 to 196  18 to 20 [40 to 44]

147 15 [33]

Measuring Measur ing valv valvee sp spri ring ng perpendi perpendicula cularity rity an and d fr free ee le leng ngth th

  9

 

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ENGI ENGINE NE MAIN MAIN PART PARTS S

 10 Meas Measuri uring ng cylind cylinder er hea head d wa warpa rpage ge Usin Using g a he heav avy y accu accura rate te st stra raig ight ht edge edge and and fe feel eler er gage gages, s, che check ck th e gasket cont ct su surfa rface ce for warp warpag agee in tw o posi position tionss leng lengthwis thwise e two crosswise and two widthwise as shown in the illustration.   th thee war arp page age ex exce ceed edss the rep epaair li limi mit, t, refa reface ce th thee he head ad with with a surf surfac acee grin grinde der. r. Unit Unit:: mm [i [in. n.]]

Item

A s s e mb l y St a n d a r d

Repair Li m i t

Warpagee of gas Warpag gasket ket contact su surface

0.05 [0.0020] or less

0.20 [0.0079]

Measuring Measu ring cyl cylind inder er head head wa warp rpag agee

 11 Me Measu asurin ring g val valve ve pushro pushrod d deflec deflectio tion n

Measu easure re th thee pu push shrod rod de defl flec ecti tion on wi with th a V-bl V-bloc ock k and and a di dial al in indi dica cato torr as show shown n in the the il illu lust stra rati tion on.. If thedial indicato indicatorr readin reading g exc exceed eedss the ass assem embly bly standa standard, rd, replac replacee the pus pushro hrod. d. Unit Unit:: mm [i [in. n.]]

Item

Assembly Standard Standard

Deflectio Deflec tion n dial dial indicator readin reading g of val valve ve pushrod

0.3 0.3 [0 [0.0 .012 12]] or less less Measuring val valve ve pus pushro hrod d def deflec lectio tion n

1.3

R eeaa s se se mbl y

 1 In Inst stal alli ling ng va valv lvee stem stem se seal al

Afte Afterr in inst stal alli ling ng th thee va valv lvee in po posi siti tion on,, inst instal alll the the seal to the valve guide with stem seal inst instaall ller er  32A91-10200 . ..

a

b

l

LÏ: CAUTION11

Do not put any oil or sealant on the face of th thee st steem sea eall th that at come omes in co cont ntac actt wit ith h the valv lvee guid idee. When When inst instal alli lin ng the the sea eal, l, put put engi engine ne oi oill on th thee se seal al cont contac actt surf surfac acee of the the stemto stemto en ensu sure re init initiall iallubri ubricati cation on of the the st stem em seallip. Do not re rem mov ovee the valve aft fteer the seal has beeninsta beeninstalle lled d in posi positi tion on to preven preventt dama damage ge to th thee se seall allip. ip.

Ste Stem m seal instal instalIer Ier

  lve

  lve

stem stem seal seal

  lve

guide

Ins Install talling ing valv valvee st stem em se seal al

7 1

 

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ENGINE ENGI NE MAIN MAIN PART PARTS S

 2) In Inst stal alli ling ng valve valve an and d va valv lvee sp spri ring ng  a)

Put the va valv lvee sp sprring and r eta etain iner er on the valve gu guid ide. e. Usin Using g valve spring pus pusher her  3069104500), 0450 0), compress compress the the valv valvee spri spring ng and and inst instal alll the the valve valve co cott tter ers. s.

 b  b))

the e v al Tap th al ve ve stem top wi t h a s o off t - f ae eed d hammer several time timess to ma make ke su sure re the the va valv lvee spr spring ing and and cott cotter erss are are prope properl rly y inst instal alle led. d.

 3) Ins Instal tallin ling g cylinder he head ad

Installing Insta lling valve valve cotter cotterss

 a  a))

Put the gas ket on the top of the crankcase, maki making ng sure the two dow oweel pins pins en ente terr their ho hole less in th thee gask gasket et..

 b  b))

Pu t th e cylinder head on th e crankcase

maki making ng sure the two do dowe well pins pins ente enterr their ho hole less in the head. Tighten the head bolts. . ..

I

CA UT ION

 

-

Do not use any sealant. Ma ke ke sure the gasket contactt surface ofthe cra contac crankc nkcase ase is fr free ee fr from om any any defects.

 c)

Installing Instal ling cylinde cylinderr head head

T ig ig ht ht en en t he he c yl yl in in de de r h ea ea d b ol ol ts ts to th e

specifiedtorq specif iedtorque ue inthe seq sequen uence ce sho shown wn in the the illustration. Tightening torque Tightening torque for for cylinder cyli nder head bolt boltss

113 to 123 Nrn  11.5 to 12.5 kgf-m [83 [83 to90 lbHt lbHt]]

15

4

0

16

0

0

0

12

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