Documente Academic
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MITSUBISHI
MOTORS
Shop Manual
diesel engine
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F @ i i W i ENGOME ............................................... 1 1
1. G R O U P C L A S S IF IC A T IO N
This m anual is organized into several g ro up s classified a ccording to the e ng in e basic elements.
11 Engine Engine p ro p e r (c y lin d e r head, va lve m e cha n ism , ca m sha ft, p is to n , crankshaft, tim in g gear, fly w h e e l),
sp ecifica tio ns, service sta n d ard s, special to o l, tro u b le s h o o tin g
12 Lubrication L u b rica tio n system (oil p um p , o il filte r, o il coole r), s p e cifica tio ns, service standards, special to o l,
tro u b le s h o o tin g
13 Fuel and engine Fuel system (in je ctio n p u m p , in je c tio n nozzle, fuel filte r, p u m p d riv e case, w a te r sepa ra to r), specifica tio ns,
co ntro l service standards, special to o l, tro u b le s h o o tin g
14 C ooling C oo lin g system (w a te r p u m p , th e rm o s ta t, ra d ia to r, c o o lin g system clea n ing p rocedures, fan), specifica tio ns,
service standards, special to o l, tro u b le s h o o tin g
15 Intake and exhaust A ir cleaner, tu rb o c h a rg e r, a fte r co ole r, s p e cifica tio n s, service s ta n d ard s, special to o l, tro u b le s h o o tin g
16 Engine e lectrical S tarter, a lte rn a to r, p re h e a ting syste m , relays, a u to m a tic stop device, s p e cifica tio n s, se rvice standards,
special to o l, tro u b le s h o o tin g
21 Clutch C lutch prop e r, bea rin g case, s p e cifica tio n s, service sta n d ard s, special to o l, tro u b le s h o o tin g
61 Special e q u ip m e n t A ir co m pre sso r, a ir p ressure g o v e rn o r, sp e c ific a tio n , service sta n d ard s, special to o l
MOTE:
Each group starts w ith page i .
2
ORGANIZATION - TERMS AND UNITS, TABLE OF
CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS
The term s " f r o n t " is the fan side and "r e a r " th e fly w h e e l side o f the engine.
The te rm s " r i g h t " and " le ft" shall be used to indicate the side as vie w e d fr o m the fly w h e e l side o f the engine.
N om ina l value
Show s the n om in a l d im en sion s, d im e n sio n o f an ind ivid u a l part, standard clearance betw een parts in an
assembly, or the standard perform an ce o f an assembly.
Lim it
Sh ow s the value of a part at w h ic h the part is no lo n g e r serviceable fr o m the p erform an ce as w ell as strength
vie w p o in ts, req uirin g replacem ent or repair.
Over- or u n d e rtig h te n in g of bolts and nuts has critical effects on p erfo rm a n ce and functions.
T igh ten ing to rq u e is therefore specified fo r som e tig h te n in g points.
All tig h te n in g to rq u e specifications m ay be considered as " d r y " unless " w e t " is specified.
W here no tig h te n in g to rq u e is specified, use a to rq ue value specified in the General Bolts and Nuts T ig h te n in g
T orq ue Table.
(5) Units
For length, w e ig h t, area, and v o lu m e , the SI unit (International System o f Units) is used w ith the m e tric n ota tion
jo in tly s h o w n in parentheses.
Tem p eratu re is sh ow n in centigrade (C).
3
ORGANIZATION - READING THE ILLUSTRATION
4. R EAPIN G TH E OLLUSTRATO^
(Ex. 1: D isassem bly and Inspection)
NV ... N o m in a l Value
L ... L im it
D am age, a bn o rm a l w e a r
Indicates the
service standards.
l
Indicates th a t th e disa sse m b ly
p roce d u re is e xpla ine d in th e text.
C2337C
4
O R G A N IZ A T IO N R E A D IN G THE IL L U S T R A T IO N
(Ex. 2: Reassembly)
(1) Illustrations (exploded view s and a ssem bly d ra w - identical a m o n g v a riou s typ es of available systems
ings) show a typical service procedures if it is and units.
5
00
CONTENTS
00-1
00 GENERAL E X T E R N A L V IE W
i . E XTER N A L VBEW
N atural-aspirated e n g in e >
A0243A
A0244A
00-2
GENERAL - MAJOR SPECIFICATIONS 00
2 M A J O R S P E C IF IC A T IO N S
2.1 M AJO R SPEC0F1CAT1OMS
E ngine d im e n sio n
(w ith o u t fan)
O verall length mm 1 390 1 390 1 401
O verall w id th mm 898 872 882
O verall heig h t mm 1 023 1 162 1 209
2.2 E N G IN E O U T P U T S C L A S S IF IE D BY A P P L IC A T IO N
E ngine m o de l 6D22-TC
6D22-T
6D22 (Tu rb och a rg ed , w ith
(Tu rb och a rg ed )
A p p lica tio n a fte r co ole r)
In te rm itte n t rated o u tp u t kW (H P )/rp m 109 (1461/1 500 161 (2161/1 500 179 (2401/1 500
129 (1731/1 800 186 (2491/1 800 207 (2771/1 800
141 (1891/2 000 195 (2611/2 000 219 (2341/2 000
149 (200I/2 200 201 (269I/2 200 227 (3041/2 200
C on tin u ou s rated o u tp u t kW (H P )/rp m 99 (1321/1 500 146 (1961/1 500 163 (2181/1 500
117 (1571/1 800 169 (2261/1 800 188 (2521/1 800
128 (1711/2 000 178 (2381/2 000 199 (2671/2 000
135 (1811/2 200 183 (2451/2 200 206 (2761/2 200
MOTE:
1. Tine o u tp u t {SAE, gross) Is c o rre c te d to
s tan d a rd a m b ie n t c o n d itio n s based on
SAE J 1 3 4 9 .
2. T h e con tinuous ra te d o u tp u t a llo w s
10% tone hour) o ve rlo ad o p e ra tio n .
00-3
00 GENERAL - ENGINE NUMBERS AND CAUTION PLATE
3. E N G IN E N U M B ER S AND CAUYOON
PLATE
(1) Engine N u m b er
V A L V E C L E A R A N C E (COLD)
______ 1
IN L E T 0.4m m (0 .0 l 6 i n U
E X H A U S T 0.6m m ( 0 . 0 2 4 in )
F IR IN G O R D E R 1 - 5 - 3 - 6 2 4 -
------ 2
FUELINJECTION TIMINGEZTBTDC-
3
1 Valve clearance
2 Firing order
3 Fuel injection timing
B9012A
Ex: 6 D 2 2 - 0 1 2 3 4 5
------------------------- Engine n u m b e r
----------------Engine m od el
(2 ) C a u tio n P la te
E0175
00-4
GENERAL - GROUP P R E C A U T IO N S FO R S E R V IC IN G
A0006A
required fo r servicing. Use the rig h t tools (specified make sure o f the safety each other. Never play w ith
parts and personal injury. (10) Make sure th a t y o u r shoes are free f r o m grease
(6) Make a lig n m e n t marks and keep disassem bled and oil especially w h e n w o r k in g on a heavy item.
parts neatly arranged to ensure th a t th ey are reas (11) W hen checking o r ch a n g in g lubricants, w ip e off
sem bled into the rig ht positions. grease and oil fro m parts im m e d ia te ly w ith a waste.
Special care m u s t be taken fo r assem blies in v o lv (12) Special care m u s t be taken in h a n dling sensors
ing a n u m b e r o f parts, s im ila r parts, or parts and relays w h ich are suspectible to shocks and heat.
identical at right- and left-hand sides to ensure (13) Use care so that hands and fin g e rs are not injured
For a lig n m e n t and p u n ch in g m arkings, select a (14) W e a r safety g og gles w h e n e v e r h a n dling a g rin d e r
00-5
G ENERAL - G ENERAL BOLTS A N D N U TS
00 T IG H T E N IN G T O R Q U E T A B L E
5 0.8 2.0 to 2.9 (0.2 to 0.3) 3.9 to 5.9 (0.4 to 0.6) 4.9 to 6.9 (0.5 to 0.7)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 6.9 to 10.8 (0.7 to 1.1) 7.8 to 11.8 (0.8 to 1.2)
8 1.25 8.8 to 13.7 (0.9 to 1.4) 16.7 to 25.5 (1.7 to 2.6) 19.6 to 29.4 (2.0 to 3.0)
10 1.25 18.6 to 27.5 (1.9 to 2.8) 34.3 to 53.9 (3.5 to 5.5) 44.1 to 58.8 (4.5 to 6.0)
1.5 17.7 to 26.5 (1.8 to 2.7) 32.4 to 49.0 (3.3 to 5.0) 42.1 to 58.8 (4.3 to 6.0)
12 1.25 33.3 to 49.0 (3.4 to 5.0) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
1.75 30.4 to 46.1 (3.1 to 4.7) 63.7 to 83.4 (6.5 to 8.5) 73.5 to 98.1 (7.5 to 10)
14 1.5 58.8 to 83.4 (6.0 to 8.5) 118 to 157 (12 to 16) 127 to 177 (13 to 18)
2.0 53.9 to 73.5 (5.5 to 7.5) 108 to 137 (11 to 14) 118 to 167 (12 to 17)
16 1.5 93.2 to 127 (9.5 to 13) 177 to 235 (18 to 24) 196 to 265 (20 to 27)
2.0 88.3 to 118 (9.0 to 12) 157 to 216 (16 to 22) 186 to 255 (19 to 26)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 7.8 to 11.8 (0.8 to 1.2) 8.8 to 13.7 (0.9 to 1.4)
8 1.25 9.8 to 14.7 (1.0 to 1.5) 18.6 to 27.5 (1.9 to 2.8) 21.6 to 32.4 (2.2 to 3.3)
10 1.25 20.6 to 30.4 (2.1 to 3.1) 38.2 to 58.8 (3.9 to 6.0) 49.0 to 63.7 (5.0 to 6.5)
1.5 18.6 to 28.4 (1.9 to 2.9) 35.3 to 53.0 (3.6 to 5.4) 44.1 to 63.7 (4.5 to 6.5)
12 1.25 37.3 to 53.9 (3.8 to 5.5) 78.5 to 108 (8.0 to 11) 88.3 to 118 (9.0 to 12)
1.75 33.3 to 51.0 (3.4 to 5.2) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
00-6
11
ENGINE
CONTENTS
11-1
11 E N G IN E - GENERAL
1. Q E I^ E fm iL
(1 ) C o m b u s tio n C h am b er
(2 ) V a lv e M e c h a n is m
11-2
E N G IN E - GENERAL 11
(a) Both inlet and exhaust valves are m ade of
surface-treated heat-resistant steel. The valve seat
angle is 45 .
A valve stem seal is p ro vid e d on the stem of valve to
control the q u a n tity o f lub rica nt of the valve and valve
g uide sliding portions.
(b) The valve springs are u ne ven ly-p itche d springs.
Two inn er and o u te r sp ring s d ifferen t in coiled
direction are installed.
(c) The rocker and rocker shaft are s u pp orte d on the
rocker shaft bracket and are in d e p e n d e n tly installed
fo r each cylinder. S o m e rockers are used fo r both inlet B0378A
(a) Seven ca m sh a ft b ush in gs are installed to the The piston, m ade of a lu m in u m alloy casting, has a
ca m shaft bearing p o rtio n of th e crankcase. To facili to ro id a l type c o m b u s tio n ch a m b e r at its top.
tate insertion and rem oval o f the ca m sh a ft fr o m the
rear end of the case, the bearing I.D. is n a rro w e r
to w a rd th e front.
11-3
11 ENGINE - GENERAL
A N iresist piston ring insert is cast into the 1st piston (5 ) C o n n e c tin g Rod a n d C o n n e c tin g Rod
ring g ro o v e to increase d u ra b ility. B e a rin g
S tam pe d on the top surface o f the piston are a size
m ark (or oversize d im e n s io n on oversize pistons) for
selection fit w ith the c y lin d e r liner, a piston w e ig h t
mark, part n um be r, id e n tifica tion mark, and the "F "
w ith an a rr o w fo r the fro n t m ark s h o w in g the piston
installing direction.
Piston pin fo r co nn ectin g piston to co nnecting rod is
of fu ll-flo a tin g type and is pre ven te d fr o m m o v in g out
by means of a snap ring installed on each end of the
pin ends.
On the piston fo r the 6D22-TC, a co o lin g ca vity is
provided.
(b ) P is to n rin g
11-4
E N G IN E - GENERAL m
(6) C ra n k s h a ft and M ain B earing
11-5
11 E N G IN E - GENERAL
la} Maim bearin g The m ain bearing is a split type plain bearing m ade o f
special alloy plated kelm et metal w ith backing metal.
The u p p e r main bearing has an internal oil g ro o ve
and oil hole w h ic h coincides w ith the oil hole in the
crankshaft.
Seven pairs o f m ain bearings are provided. Split type
th ru s t plates are m o u n te d to the rear-m ost bearing to
bear the th ru st o f the crankshaft.
B0382A
11-6
ENGINE - GENERAL 11
Each gear is a carbon steel helical gear having a (8) F lyw h eel
high-prescision to o th surface m ach in e d by the sh a v
ing m achine and given surface tre a tm e n t to im p ro v e
d urability.
A tim in g m ark is sta m p ed on each tim in g gear.
Correct m eshing can be achieved by a lig ning the
tim in g marks at reassem bly.
The crankshaft gear, press-fitted o n to the crankshaft
and held in position by a d o w e l pin, drives all gears.
11-7
11 ENGINE - SPECIFICATIONS
2. S P E C IF IC A T IO N S
11-8
ENGINE - SERVICE STANDARDS 11
3. 3EFVDCE S T A N D A R D S
3.1 S E R V IC E S T A N D A R D T A B L E
U nit: m m
C om p re ssio n pressure 2.75 MPa 1.96 MPa D ifference betw een c y lin d e r w ith in
(at 200 rpm ) (28 kg f/c m 2) 20 kg f/c m 2 0.39 MPa (4 kg f/c m 2)
Squareness - 2.5
C ylin de r head b o tto m surface d is to rtio n 0.07 o r less 0.08 C orrect o r replace.
Valve stem to valve Inlet [12| 0.05 to 0.09 0.2 Replace valve guide.
guid e clearance
E xhaust 112[ 0.09 to 0.12
D epth o f va lve fro m c y lin d e r head Inlet 0.25 to 0.75 1.0 Replace valve seat insert.
b o tto m surface S ervice lim it: va lu e w he n a
n ew valve is installe d.
E xhaust -0 .0 5 to 0.45 0.7 ( - indica te s p ro je c tio n am ount.)
11-9
n ENGINE - SERVICE STANDARDS
U n it: m m
Backlash Betw een cra nksh a ft gear and 0.12 to 0.26 0.4 Replace.
o f tim in g id le r gear "B "
gears
Betw een id le r gear " A " and 0.13 to 0.26 0.4
ca m sha ft gear
Betw een idle r gear "A " and 0.13 to 0.26 0.4
id le r gear "C "
Id le r sh aft " A " to idle r gear " A " b u sh in g clearance I40] 0.2 Replace bush in g.
0.03 to 0.06
Id ler sh aft "C " to id le r gear "C " b u sh in g clearance (46] 0.2 Replace bush in g.
0.03 to 0.06
No. 4 jo u rn a l (65.50]
0.03 to 0.08
No. 5 jo u rn a l (65.75]
0.03 to 0.08
No. 7 jo u rn a l (66]
0.03 to 0.08
11-10
E N G IN E - S E R V IC E S T A N D A R D S m
U n it: m m
6D22-TC [130] -
0.188 to 0.214
Piston 1st ring 0.06 to 0.11 0.25 Replace p iston ring o r piston.
ring
g ro o ve 2nd ring 6D22 0.05 to 0.08 0.15
to ring
clearance 6D22-T, 6D22-TC 0.07 to 0.10
P rojection o f p isto n fro m to p surface o f crankcase 0.87 to 1.33 - Check each part.
Piston p in hole to p isto n p in clearance [50] 0.1 Replace p iston or p istn pin.
0.01 to 0.02
Flatness o f c ylin d e r lin e r fla ng e s u p p o rtin g surface - M ore than Replace crankcase.
on crankcase 0.1
O u t-o f-ro u n dn e ss o f jo u rn a l and pin 0.01 o r less 0.08 G rin d and correct to undersize.
11-11
11 ENGINE - SERVICE STANDARDS
3 .2 TBGIHITEMiMG TO RQ UE TABLE
11-12
E N G IN E - S P E C IA L T O O L II
SPECIAL T@OIL
11-13
11 ENGINE - SPECIAL TOOL
B5311A
3 5 1 11a
V alve seat inse rt C aulking to o l b od y In s ta lla tio n and caulkin g o f valve seat
caulking to o l MH061360 inse rt
C aulking tool
1 b od y
C aulking ring in le t
MH061650 {Ip - C aulking
[ i ring
D ia m e te r 12 B5202A
B5261A
Id ler gear bush in g p u lle r MH061228 R em oval and in s ta lla tio n o f id le r gear
b u sh in g (Idler gear " A " )
' B5121A
^ J -' B4384A
B1480A
11-14
E N G IN E - S P E C IA L T O O L II
Tool nam e Part No. Shape Use
1 2 9 .5 ^ ^ C
B5131A
\ O.D. 129.5
\\
w j
B5141A
C onnecting rod b ush in g p u lle r MH061238 Rem oval and in s ta lla tio n o f co nn e ctin g
rod bushing
B5321A
Rear oil seal slin g e r installe r MH061652 P ress-fitting o f rear o il seal slin g e r
D ia m e te r '.
123 \
B5161B
y
D ia m e te r \
95 V "
B0585A
P is to n g u id e le v e B5171B
11-15
11 ENGINE - SPECIAL TOOL
11-16
E N G IN E - S E R V IC E PROCEDURES m
5. S E R V IC E P R O C E B U R E S NOTE:
5.1 M E A S U R E M E N T <DP CO M PRESSIO N C over th e m ounting holes and in je c tio n
PRESSURE pipes to p reve n t e n try of dust and dirt.
M e a s u re m e n t P ro c ed u re
B5561A
NOTE:
1. M a k e sure th a t th e eng ine speed is also
m easu red as co m pressio n pressu re
va rie s w ith th e en g in e speed.
2. M a k e m e a s u re m e n t fo r all c y lin d ers, as
w e a r and o th e r co n d itio n s vary from
one c y lin d er to a n o th e r.
<Disassembly sequence>
1 Rocker cover 13 Outer valve spring
2 Rocker bracket mounting bolt 14 Inner valve spring
3 Cylinder head bolt 0 Valve stem seal
4 Thrust plate 16 Lower retainer
5 Rocker 17 Inlet valve
'6 Set screw 18 Exhaust valve
7 Rocker shaft (T?) Nozzle tube
(D Rocker shaft bracket 20 Water director
9 Push rod 21 Sealing cap
10 Valve cap (22) Cylinder head
0 Valve cotter 23 Crankcase side cover
12 Upper retainer 24 Tappet
For d is a s s e m b ly o f parts w ith an e n circle d n um b e r, see fo llo w in g item s.
C1542A
11-18
E N G IN E - S E R V IC E PROCEDURES m
D isassem bly P ro c ed u re (2} R em o val off C ylin d er H e ad A ssem bly
{11} [Removal off She R o cker S h aft B ra c k e t
A ssem bly
C ylinder head
C ylinder head
gasket
Knock pin
B9014B
(a) W here the push rod is fo rcin g the rocker up, the the cylin d e r head, lift it d ire c tly u pw ard .
11-19
11 ENGINE - SERVICE PROCEDURES
C1527A
MOTE:
The nozzle tube need not be removed
unless w a fe r leaks, gas leaks, e tc . are
evident.
11-20
E N G IN E - S E R V IC E PROCEDURES
5 .2 .2 Otispecora
11-21
11 ENGINE - SERVICE PROCEDURES
If the lim it is exceeded, replace the b u sh in g in the and replace if the m e a s u re m e n t exceeds the lim it. For
IMOTE:
1. Align the bushing and rocker oil holes.
2. Face the bushing jo int tow ard the ad*
justing screw .
11-22
E N G IN E - S E R V IC E PROCEDURES 11
(5) Runout of Push Rod (7) V a lv e S tem 0 , 0 .
C2747A C3102A
Check fo r ru n o u t and replace if the reading on the dial Replace the valve if the m e a s u re m e n t is b e lo w the
in d ic a to r exceeds the lim it. lim it.
M OTE;
Grind th e eylieiider head only to th e e x te n t
th a t th e heig h t fromm th e top to bo tto m
su rface s is w ith in th e lim it.
11-23
ENGINE - SERVICE PROCEDURES
(9) R e p la c e m e n t of V a lv e G uide
M@TE;
(a) A p p ly an even coat o f m in iu m to the valve seat 1. K e e p grinding m arg in to a m in im um .
inse rt surface in co n ta ct w ith the valve. 2. if th e v a lv e m arg in is b e lo w th e lim it
(b) U sing Valve Lapper (special to o l), let the va lve h it a fte r th e grindin g c o rre c tio n , re p la c e
a gainst the va lve seat in se rt once. th e v alve.
M TE;
3. A fte r th e grinding c o rre c tio n , fee sure to
1. W hen le ttin g th e v a lv e h it a g a in s t th e lap th e v a lv e and v a lv e s e a t in sert.
v a lv e s e a t in sert, do not tu rn th e v alve. [Fieffer to Ite m (1 4 ) th a t fo llo w s .]
2. C o n ta c t p a tte rn should be c h e c k e d
w h en th e valve guide is in s p e c te d or
re p la c e d .
11-24
E N G IN E - S E R V IC E PROCEDURES II
(12) C o rrec tio n of V alu e S e at In s e rt (13) R e p la c e m e n t o V alu e S e a t In s e rt
Since the valve seat in s e rt is in sta lle d by expa nsion
fit, replace it by th e fo llo w in g procedures.
C 3127A
MOTE;
1. K eep th e am o u n t of c u t to a m in im um .
2. If th e value sin k a g e a fte r c u ttin g ex-
, see d s th e lim it, re p la c e th e ualue s e a t
in sert.
(b) A fte r co rre ctio n , lig h tly g rin d by h o ld in g a bo ut
#40 0 sandpaper betw een th e cu tte r and va lve seat
insert.
MOTE;
A fte r th e c o rre c tio n p ro ce d u re, he sure to
lap th e ualue and ualue s e a t in sert. [R e fe r
to Ite m (14) th a t fo llo w s .]
11-25
11 ENGINE - SERVICE PROCEDURES
C3130A
11-26
E N G IN E - S E R V IC E PROCEDURES 11
5 .2 .3 R e assem b ly
11-27
11 ENGINE - SERVICE PROCEDURES
Install th e w a te r d ire c to r w ith its notch d ire cte d as e n g in e o il to the lip and s trikin g d o w n V alve Stem
A p p ly sealant
(THREEBOND 1211
o r equivalent).
C6620B
11-28
E N G IN E - S E R V IC E PROCEDURES 11
{5} In s ta lla tio n of R o c k e t S h aft B ra c k e t (8) T ig h te n in g of th e C ylin d er H e ad Bolts
and C ylinder H ead
11-29
11 ENGINE - SERVICE PROCEDURES
< W ith m echanical tachom eter d rve > < W ith electrical speed se n so r>
Dam age,
unusual w ear
in gear
Streaks on w o rn surface,
cracks, taper w ear
< D is a s s e m b ly se q u e n c e >
For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
items.
C1926F
11-30
ENGINE - SERVICE PROCEDURES 11
NV ... N o m in a l Value
<Disassembly sequence>
fii) Camshaft
*(2) Camshaft gear
13 Thrust plate
14 Idler shaft bolt
15 Thrust plate
16 Idler gear "C"
17 Idler gear "A"
18 Idler gear "B"
19 Idler shaft "A"
19A Idler shaft "C"
20 Rear plate
For d isa sse m b ly o f parts w ith an e ncircled n u m b e r, see fo llo w in g item s.
The part m arked -x- m u st be inspected before disassem bly.
Part m arked w ith * sh o u ld n ot be re m ove d unless defects are e vident.
C1927C
11-31
11 ENGINE - SERVICE PROCEDURES
Thread the m o u n tin g b o lt in to the re m o v in g th re ad e d b u sh in g and gears and replace parts as necessary.
11-32
E N G IN E - S E R V IC E PROCEDURES II
(5) R em o val of C a m s h a ft Seat* MOTE;
Do not s trik e th e g ears w ith a h am m er.
T hrust plate M a k e sure th a t th e g ea rs a re rem o ved by
use of a g ea r p u ller.
(7) R em o val off Ring G ear
C1932B
11-33
ENGINE - SERVICE PROCEDURES
5.3.2 Dtispection
NV ... N o m in a l Value
D epth fro m clutch cover L ... L im it
m o u n tin g surface to
fric tio n surface
NV 48
L 49.5
C2758C
11-34
ENGINE - SERVICE PROCEDURES 11
BD Basic D ia m e te r
NV ... N o m in a l Value
C2759C
11-35
11 ENGINE - SERVICE PROCEDURES
Use o f a p o rta b le jack w ill m ake it p o ssib le to take a lim it, replace.
MTEs
Off Site ring g e a r sh o w s and ab n o rm a l c o n d i
tion , re p la c e th e ring g e a r b efo re m e a s u re
m en t. [R e fe r to 5.3.1 (7)1
11-36
ENGINE - SERVICE PROCEDURES 11
(4) R e p la c e m e n t of Id le r G ear Bushing (6) C a m s h a ft Jou rn al to C ra n k c a s e C a m
sh aft Bushing C le a ra n c e
MOTE:
H. (Install th e hushing w ith c h a m fe re d side
of g e a r LO. in w a rd .
2. A fte r in s ta lla tio n , c h e c k to en s u re th a t
th e hushing to id le r s h a ft c le a ra n c e is
w ith in th e nom inal dim en sio n . Iff it is
b e lo w th e n o m in al dim en sio n , ream th e
bushing.
If the lim its are exceeded, the b ush in g In the cranio
(5) Gam P rofile case s h o u ld be replaced.
(7) Bend of C a m s h a ft
C4118A
M easure the lobe h e ig h t and base circle d ia m e te r and
replace the ca m sh a ft if the d iffe re n ce b etw een the
M easure the bend o f the ca m sh aft. If the lim it is
tw o is b e lo w the lim it.
exceeded, replace.
NOTE:
NOTE:
T h e cam m ust he m e a s u re d a t lo c a tio n s
Turn th e c a m s h a ft a turn and read th e
sho w n as it is ta p e re d .
d e fle c tio n of th e p o in te r, using a dial in
d ic a to r.
One h a lf off th e read in g is th e bend.
11-37
11 ENGINE - SERVICE PROCEDURES
11-38
E N G IN E - S E R V IC E PROCEDURES 11
R e asse m b ly P ro c ed u re (3) In s ta lla tio n of C a m s h aft G ear
(1) In s ta lla tio n of R ear P la te
C6230C
Install the c a m sh a ft gear so th a t th e side having
The b o tto m o f gasket in sta lle d betw een the rear plate sta m p ed n u m b e rs " 4 " faces fro n t.
and crankcase w ill p ro tru d e . A fte r the fly w h e e l h o u s (4) In s ta lla tio n of C a m s h aft
ing has been installed , cu t aw ay the p ro tru d in g
p o rtio n .
11-39
11 ENGINE - SERVICE PROCEDURES
(7) In stallation of Reas1 @51 Seal Sliwger (9) In stallation of Flyw heel Housing
(8) In stallation of Ring Geai? Install the fly w h e e l hou sin g and gasket so th a t th ey
are a lig n e d w ith the loca ting p in s in the crankcase.
Cut the b o tto m p o rtio n s o f th e gasket after in s ta lla tio n
as th e y are excess.
Cut at the same tim e the excess p o rtio n s o f the gasket
betw een the rear plate and crankcase.
11-40
E N G IN E - S E R V IC E PROCEDURES 11
{111} installation off SI Seal (1 2 ) F ly w h e e l R u n o u t C h e c h
W hen p re ss-fittin g an o il seal to the reta ine r, a p p ly Install the fly w h e e l to the crankshaft by tig h te n in g to
force u n ifo rm ly to the e ntire p erip h e ry. the sp ecified to rq u e .
M easure the fly w h e e l m o u n tin g c o n d itio n (ru no ut). If
the p o in te r o f the dial in d ic a to r deflects beyond the
lim it, check the b o lt tig h tn e s s or m o u n tin g surface.
11-41
11 ENGINE - SERVICE PROCEDURES
D isasse m b ly sequence
For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
item s.
Part m arked w ith * should not be rem oved unless defects are
evident.
Service ite m s m arked w ith -X- should be inspected before disassem
bly.
C2337D
11-42
E N G IN E - S E R V IC E PROCEDURES
For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
items.
The part m arked x- m ust be inspected before disassem bly.
Parts m arked w ith 1 should not be rem oved unless defects are
evident.
For inspection o f the part m arked w ith *2, refer to G roup 12
Lubrication. B0599G
11-43
11 ENGINE - SERVICE PROCEDURES
M C Tis
W hen rem oving th e pistons, use c a re to
(a) H old the dial in d ic a to r to the to p surface o f the
p re v e n t d a m a g e to th e c y lin d er liner
crankcase and m ake zero a d ju stm e n t. (4) S e p a ra tin g P iston from C o n n ectin g Rod
(b) Find the to p dead ce nte r o f p iston w ith a dial
ind icato r.
(c) M easure th re e p o in ts on the to p surface o f p iston
to fin d the average value.
(d) If the p ro je ctio n is o u t o f sp e cifica tio n , check the
co nn ectin g rod, b u sh in g , p iston pin, co n n e c tin g rod
b earing, etc. and replace d efe ctive parts.
Rem ove the snap rin g and, using a rod, tap p iston pin
off.
If, h ow eve r, the p iston pin is hard to rem ove , heat the
p iston w ith a p is to n heater o r in h o t w ater.
11-44
E N G IN E - S E R V IC E PROCEDURES 11
(5) R em oval o Piston Ring (7) R em oval of M ain B earing Cap
MOTE;
Bo not a tte m p t rem oving th e c ra n k s h a ft
g ea r by s trikin g w ith a h a m m e r or prying
w ith a lever.
11-45
11 ENGINE - SERVICE PROCEDURES
5.4.2 Inspection
Clearance
BD 50 Piston ring g ro o ve to piston ring
NV 0.01 to 0.02 clearance
L 0.1 1st ring
NV 0.06 to 0.11
L 0.25
2nd ring
NV 0.05 to 0.08 < 6 D 2 2 >
0.07 to 0.10 <6D22-T, 6D22-TC:;
L 0.15
Oil ring
NV 0.03 to 0.06
L 0.15
Clearance
BD 50
NV 0.02 to 0.05
L 0.1
Clearance
BD 130
NV 0.178 to 0.204 < 6 D 2 2 >
0.173 to 0.199 < 6 D 22-T >
Bend or to rsio n 0.188 to 0.214 < 6D 22-TC :
L 0.05 o r less
D istortion o f to p surface
NV 0.07 o r less
L 0.2
Oil clearance
BD 84
NV 0.07 to 0. 13
L 0.25
C2760C
11-46
E N G IN E - S E R V IC E PROCEDURES RH
exceeded.
11-47
11 ENGINE - SERVICE PROCEDURES
M OJ E: (4 ) C y lin d e r L in e r F la n g e P ro je c tio n
W h e n She c r a n k c a s e is g ro u n d , m a k e s u re
th a t th e p is to n p ro je c tio n d o e s n o t e x c e e d
th e n o m in a l v a lu e .
[R e fe r to Ite m (1 ), S e c tio n 5 .4 .1 .]
(3 ) C y lin d e r L in e r I.D .
(5 ) R e p la c e m e n t o f C y lin d e r L in e r
(a ) Rem oval
M easure the c y lin d e r lin e r I.D. at six p o s itio n s as
sh ow n in the rig h t fig u re . If the I.D. is m o re th an the
lim its , replace the c y lin d e r lin e r o r bore it to oversize.
[For re p la ce m e nt o f the c y lin d e r line r, refe r to Item
(5).]
11-48
E N G IN E - S E R V IC E PROCEDURES U
(b) Installation
S iz e m a rk P is to n
1) W hen rep la cing the c y lin d e r line r, use a c y lin d e r by lig h tly s trik in g the fla ng e p o rtio n , using C ylin d e r
lin e r w ith the sam e size m ark as th a t o f the piston to Liner In sta lle r (special tool).
be selected. MOTEs
1. Apply soap suds to the crankcase and
Size m ark o f p iston A B C cylinder loner fitting portions and make
Size m ark o f cylin d e r lin e r A B C sore that the rubber packing and -ring
are not twisted when inserted.
2. After installation, conduct the leak test
to verify air-tightness. Apply thrust
force to cylinder liner flange.
11-49
ENGINE - SERVICE PROCEDURES
(a ) S ta n d a rd p is to n
C ylin d e r lin e r I.D.
C4424A
Oversize piston O.D.
11-50
E N G IN E - S E R V IC E PROCEDURES m
{8} Piston to Piston Ring Clearance (9) Piston Ring Gap
M easure the p iston to p isto n ring clearance. If the M easure the p iston rin g gap w ith the p isto n ring
lim it is exceeded, replace the p iston rin gs or piston. h o riz o n ta lly pushed in to a sta nd ard c y lin d e r lin e r or
11. After carbon has been removed, m ea Replace the p is to n rin g if the gap exceeds the lim it.
sure the clearance all around the pis S tan da rd c y lin d e r lin e r I.D.: 130 0
ton. MOTE;
2. Replace the piston rings as a set. Use the piston to push the piston rings
horizontally into a standard gauge.
Thickness gauge (HO) Piston to Piston Pin Clearance
Piston pin
C4815A
M TEs
Whenever the piston is replaced, be sure
to replace the piston rings.
11-51
11 ENGINE - SERVICE PROCEDURES
(1 3 ) C o n n e c tin g Rod B e n d a n d T w is t
(1 2 ) R e p la c e m e n t of C o n n e c tin g Rod
B u s h in g
Replace the b u sh in g by p ro ced ures sh o w n in illu s tra
tio n , u sing C on ne cting Rod B ushing P uller (special
tool).
I
P
Connecting Rod
Bushing Puller
____ MH061238
NOTE:
1. In s ta ll th e b u s h in g a n d c o n n e c tin g rod
b e a rin g to th e c o n n e c tin g ro d b e fo re
m e a s u r e m e n t.
2 . T ig h te n th e c o n n e c tin g ro d a n d c o n
C5221B n e c tin g rod c a p to th e s p e c ifie d to rq u e
b e fo re m e a s u r e m e n t.
11-52
E N G IN E - S E R V IC E PROCEDURES M
{114} Ten sio n of C o n n ectin g Rod B earing (1) Main Bearing to Crankshaft Journal
and M ain B earing w h en Free Clearance
C5523A
MOTE;
Bo not use the bearing by artificially ex
panding it. M ain b e a rin g I D.
C5524A
11-53
11 ENGINE - SERVICE PROCEDURES
NOTE:
Ulead th e c r a n k s h a ft c e n t e r jo u rn a l ru n o u t
w ith a d ia l in d ic a to r. O n e h a lf o f th e r e a d
in g is th e b e n d .
11-54
E N G IN E - S E R V IC E PROCEDURES m
G rinding Finishing
' ft
V A/v.' *' - J \ r
\ \ G rinder
W hestone or
sand paper
Crankshaft
C5509A
U n it: m m
-0 .5 0 - 0.06
99 50 ~
aa.ou _~ 8
0 '^1Q
8
83,50 - 0.09
-0.75
99 25 0 08
80,25 - 0.10 83,25 1 o'o9
-1 .0 0
99 00 ~
sa.uu _ 8
Q'^1Q
8
83,00 ' 0*09
11-55
ENGINE - SERVICE PROCEDURES
5 .4 .3 R e a s s e m b ly
11-56
E N G IN E - S E R V IC E PROCEDURES 11
(Reassembly Procedure (3) Installation of Upper Main (Bearing and
(15 Installation of Oil Spray Plug Thrust Plate
Install the oil spray plug w ith the a rro w sta m p ed on MOTEs
the plug to w a rd th e to p o f th e engine. 1. Install the thrust plate with the oil
grooveless side toward the crankcase.
(2) Installation off Oil Jet and Check Valve
2. Line up the lug off the main bearing and
the groove off the crankcase.
The upper main bearing is one with oil
holes. Take care not to confuse it with
the lower ene.
3. Oversize (0.115, 0.30, 0.45 mm) thrust
plates are available for adjusting the
end play in crankshaft [refer to Item (6),
Section 5.4.1]. Iff any orne of these is
used, ensure the correct off the thrust
plate to be installed to the main bearing
cap [refer to Item (7)].
(4) Installation off Crankshaft dear
(a) Install the oil jet, w h ile m aking sure th a t Its
loca ting pin fits In the crankcase.
(b) M o u n t the lock w a sh e r in such a w a y th a t its
b ending p o rtio n w ill fit the end o f the o il jet.
(c) A fte r the check valve has been tig h te n e d to the
specified to rq u e , bend the lock w a sh e r to fit the
hexagonal p o rtio n o f the check valve.
11-57
11 ENGINE - SERVICE PROCEDURES
Install the fro n t oil seal slin g e r, using Oil Seal S lin g e r
In sta lle r (special to o l).
(6 ) In s ta lla tio n o f C r a n k s h a ft
11-58
E N G IN E - S E R V IC E PROCEDURES Hi
(c) O nly to both sides o f th e re a rm o st m ain bearing (f) Check to see if the end p la y o f the cra n ksh a ft is
cap, install the th ru s t plates fa cing th e ir oil g ro ove less w ith in n o m in a l value.
side to w a rd the cap. [R efer to Item (6), S ection 5.4.1.]
M OTE? (0) flrsstalfiaffioM) off Connecting Rod Bolt
Iff an oversize ffinrast piaffe is used, use the A fte r checking the co n n e ctin g rod fo r d am age and
bearing cap rear ffhrusff piaffe off the same b u rr in the b o lt hole, a p p ly eng in e o il to the co n n e c t
size as that off the thrust plate in the ing rod b o lt and p re s s -fit it in to the co n n e c tin g rod.
crankcase rear end [liefer to Item (3)].
Mote, however, that the bearing cap ffront
and rear thrust plates may be off difffferent
sizes.
(d) Install the m ain bea rin g caps, m aking sure th a t
the side w ith the lug g ro o ve placed on the rig h t-h a n d
side o f the eng in e and th ey are in sta lle d in the o rd e r
o f em bossed n u m b e rs fro m the fro n t o f engine.
(e) T igh ten m ain bea rin g cap b o lts to specified
to rq u e . Then, tig h te n m ain bearing cap side b olts to
sp ecified to rq u e .
A fte r the b o lts are tig h te n e d , m ake sure th a t the
cran ksha ft is free to rotate by hand.
11-59
11 ENGINE - SERVICE PROCEDURES
M TE :
T h e p a rts fo r an e n g in e m u s t b e of th e
s a m e w e ig h t m a rk .
W e ig h t m arks
11-60
E N G IN E - S E R V IC E PROCEDURES 11
(11) Dnsfallafiou of Upper amd Lowes' Con MOTE:
necting Rod Bearings 11. Make sure that the size symbol of the
piston is the same as that off the cylin
der liner.
2. Make sure that the piston ring open end
directions do not change.
3. Put a vinyl hose or something else on
the bolt of connecting rod for protec
tion of the crankshaft pin against dam
age by the bolt.
Using the Piston Guide d a m p and Piston
Guide Lever (special tools).
MOTE:
Mole that the only the upper connecting
rod bearing has an oil hole.
(12) Installation of Piston and Connecting
Line up the Piston G uide w ith the p iston skirt and set
Bod
the leve r in to p o s itio n . Then, tu rn th e a d ju s tin g b o lt
so th a t th e clam p I.D. e quals p iston O.D. A fte r th e
a d ju s tm e n t, a p p ly eng in e o il to p isto n o u te r surfaces,
Piston G uide in n e r surfaces, and c y lin d e r lin e r in n e r
surfaces.
A fte r these p ro ced ures have been c o m p le te d , fit
Piston G uide o n to the p isto n so th a t it is flu s h w ith th e
p iston he ad . U sing a m a lle t o r w o o d block, tap p iston
Into p o s itio n w ith care n ot to dam age it.
11-61
11 ENGINE - SERVICE PROCEDURES
C y lin d e r No. 1 2 3 4 5 6
V alve In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
a rra n g e m e n t
sion stroke
11-62
ENGINE - SERVICE PROCEDURES 11
(3) M easure the rocker arm to va lv e cap clearance
w ith a thickness gauge to d e te rm in e w h e th e r the
clearance is up to sp ecificatio n.
If the thickness gauge o f the sp ecified thickness is
s o m e w h a t hard to m ove, the clearance is good.
If the clearance is o u t o f s p e c ifica tio n , loosen the lock
n ut and a d ju s t w ith the a d ju s tin g screw . A fte r a d ju s t
m ent, tu rn d o w n the lock n ut to lock th e a d ju stin g
screw s.
M O TE:
A fte r th e lo c k n u t h a s b e e n fu m e d d o w n ,
r e c h e c k th e c le a r a n c e .
11-63
11 ENGINE - TROUBLESHOOTING
. TR O U B L E S H O O T IN G
L ow c o m p re ssio n pressure
o In co rrect valve clearance A d ju s t
D efective preheater
o D efective sta rte r sw itch C orre ct o r replace G ro u p 16
In s u ffic ie n t in je c tio n a m o u n t
D efective in je c tio n p um p C orrect o r replace G ro u p 13
In co rrect in je ctio n a m ou n t
C logged m u ffle r
11-64
E N G IN E - T R O U B L E S H O O T IN G
S ym p to m Probable cause R em edy Ref. g ro u p
C logged m u ffle r
Large oil Oil leaks fro m lu b ric a tio n system Check and correct G ro u p 12
co n su m p tio n
O il leaks fro m e n g in e and related parts
D efective gasket and o il seal Replace
11-65
11 ENGINE - TROUBLESHOOTING
11-66
12
l_UBRICATION
COM TENTS
12-1
12 LUBRICATION - GENERAL
1. G E N E R A L
E ngine lu b ric a tio n is a cco m p lish e d by fo rce d lu b ric a
tio n syste m u sin g gear p u m p . The e n g in e o il in th e oil
pan is d ra w n up th ro u g h the oil stra in e r by the oil
p u m p and fo rce -fe d to the o il filte r and o il c o o le r to
lu b rica te all parts.
Oil pressure
gauge
B1539F
12-2
L U B R IC A T IO N - GENERAL 12
fH J 050 P u m p
Oil p um p gear
12-3
12 LUBRICATION - GENERAL
(2 ) O il F ilte r
B1543A
W hen the oil filte r e le m e n t is c log ge d and the
d iffe re n ce in pressure betw een the filte re d and u n fil
The o il filte r is a d o u b le oil filte r co n sistin g o f a
te re d oil exceeds the lim it sp ecified, the va lve in the
fu ll-flo w filte r m ade in te g ra l w ith bypass filte r. Ele
oil bypass alarm m oves a ga in st th e s p rin g force,
m e n t is a filte r paper e lem ent.
a llo w in g the u n filte re d o il to flo w to the filte re d o il
Engine o il fed u n d e r pressure fro m the oil p um p
path.
passes th ro u g h the o il hole in the crankcase and flo w s
The o il bypass alarm has e le ctric contacts th a t are
fro m the oil filte r head into the fu ll- flo w filte r and
closed to tu rn on the p ilo t lam p, w a rn in g the d riv e r o f
, bypass filte r. The e n g in e o il filte re d th ro u g h the
clog ge d e le m e n t w h e n the va lve is opened.
fu ll-flo w filte r is rou ted fro m the oil filte r head th ro u g h
th e crankcase oil hole to th e o il co oler. The eng in e oil
filte re d th ro u g h the bypass filte r re tu rn s to the oil pan.
12-4
L U B R IC A T IO N - GENERAL 12
(3) I C ooler
Oil cooler e le m e n t
B1545A
12-5
12 LUBRICATION - GENERAL
(5 ) R e g u la to r V a lv e (b) C a m s h a ft
B1529A
The re g u la to r va lve is m o u n te d in the m ain o il g a lle ry L u b rica tio n o f the ca m sh aft b u sh in g s is a ccom plishe d
in the crankcase to m ake sure th a t no excessive by the oil flo w in g th ro u g h the o il holes fro m the
pressure acts on the lu b ric a tio n system . o u tsid e p e rip h e ry o f the cran ksha ft m ain bearing to
the in d iv id u a l ca m sh aft b ush in g.
(6 ) L u b ric a tio n o f AID F a rts
The e n g in e o il rou ted to th e m ain oil g a lle ry lubricates (c ) V a lv e m e c h a n is m
all parts as described in the fo llo w in g .
12-6
L U B R IC A T IO N GENERAL 12
E ngine o il fed to the c y lin d e r head flo w s th ro u g h the (e) Cooiirag th e piston (oiO je t)
o il holes in the rocker sh aft bracket and rocker sh aft to
lu b rica te each rocker b ush in g. The eng in e oil is also
sprayed o u t o f the rocker arm o il holes fo r lu b ric a tio n
o f the slid in g surfaces o f va lve cap and valve stem as
w e ll as the slid in g surfaces o f push rod and a d ju stin g
screw . The oil th en flo w s th ro u g h the push rod holes
in the c y lin d e r head and crankcase to lu b ric a te the
ta p p e t and cam o f the ca m sh a ft and retu rns to the oil
pan.
(d) Tmrag g e a r s
B1535B
12-7
12 LUBRICATION - GENERAL
(8 ) In je c tio n P u m p a n d A ir C o m p re s s o r
12-8
LUBRICATION - GENERAL 12
(9) L u b ricatio n of W a te r Pump
The eng in e o il d ra w n by the oil p u m p is routed The engine oil is th en fo rce d back fro m the drain p ort
th ro u g h the crankcase oil passage to the w a te r pum p. to the crankcase and retu rn s to the oil pan.
The engine o il d elivered to th e w a te r p u m p flo w s
th ro u g h the o il hole o f the w a te r p u m p and lub rica te s
the bearings.
12-9
12 LUBRICATION - SPECIFICATIONS, SERVICE STANDARDS
2n S P E C IF IC A T IO N S
Oil filte r
F u ll-flo w filte r elem ent Type F ilte r p ap e r type
Oil bypass alarm Type Piston v a lve typ e w ith b u ilt-in e le ctric contacts
O il jet
Check valve Type Piston v a lv e type
O il pum p Backlash betw een cra nksh a ft 0.13 to 0.25 0.4 Replace.
gear and o il p u m p id le r gear
12-10
L U B R IC A T IO N - S E R V IC E S T A N D A R D S 12
D escription N om in al value L im it C orre ctio n and rem arks
IBasic dia m e te r)
S p rin g load 76 to 80 N
(Installed le n g th : 48.3) (7.8 to 8.2 kgf)
3 .2 T IG H T E N IN G TO R Q U E TABLE
12-11
12 LUBRICATION - SERVICE PROCEDURES
B9016A
M OTE:
1. M e a s u re th e b a c k la s h in a d v a n c e of
rem o va l of oil pum p.
2. T h e oil s tra in e r and oil p ipe should be
rem o ve d to g e th e r w ith th e oil pum p
unless an yth in g w rong is e v id e n t.
3. A fte r th e oil pum p has b een in s ta lle d ,
ve rify th a t th e b a c k la s h is w ith in th e
s p e c ifie d range.
12-12
L U B R IIC A T IO N - S E R V IC E PROCEDURES 12
4 .2 D ISA SS EM B LY , IM SPECYIOM AMD REASSEMBLY
4.2.1 Oil Pump
(1) D isassem bly and In s p e c tio n
NOTE:
1. Do n o t re m o v e th e d riv e n g e a r s h a ft u n le s s it is fa u lty .
R e m o v a l o f th e s h a ft m a y re s u lt in lo s s o f a llo w a n c e
fo r tig h te n in g th e o il p um p c a s e .
2. T h e c a s e and g e a r a s s e m b ly is a n o n -d is a s s e m b le d
ty p e . R e p la c e th e a s s e m b ly if it is d e fe c tiv e .
C9518D
12-13
12 LUBRICATION - SERVICE PROCEDURES
INIOTE;
The oil pum p co v er is lo c a te d by th e d ow el
pins in s ta lle d to th e oil pum p case.
(c) Before the d rive n gears are rem o ve d , m easure
and record the fo llo w in g item s.
12-14
L U B R IC A T IO N - S E R V IC E PROCEDURES 12
(2) R eassem b ly
N O TE:
1. B e fo re re a s s e m b ly , a p p ly e n g in e o il to all p a rts u n le s s
o th e rw is e s p e c ifie d .
2. T e m p o ra rily tig h te n th e o il s tr a in e r , ta k in g in to c o n s id
e ra tio n its in s ta lla tio n to th e c ra n k c a s e .
C9525C
12-15
12 LUBRICATION - SERVICE PROCEDURES
4 .2 .2 O il F ilte r
<Disassembly sequence>
1 Drain plug
2 Center bolt
3 Washer
4 Oil filter case
5 Oil filter element
6 Element retainer
7 Oil filter head
8 Oil bypass alarm
C9705C
In s p e c tio n o f O il B y p a s s A la rm
12-16
L U B R IC A T IO N - S E R V IC E PROCEDURES 12
4 .2 .3 51 C ooler
Damage, cracks,
scale, o il leaks
1 Oil c o o le r e le m e n t
2 Bypass valve
3 Oil c o o le r cover
NV ... N o m in al Value
C9804C
{1 ) G le a m in g |2 ) Air P ressu re T e s t
(a) Check fo r carbon or slud ge d ep osite d in the oil To check fo r oil leaks due to a broken o r cracked
passage o f the oil co oler e le m e n t and bypass valve. If e le m e n t, air pressure te st s h o u ld be p e rfo rm e d .
c o n ta m in a tio n is e vid en t, w ash in a clea nin g oil. A p p ly 1470 kPa (15 k g f/c m 2) air pressure to the
(b) If th ere is m uch scale on the e le m e n t and cover, e le m e n t to check fo r leaks. If air leaks o r o th e r defects
w ash w ith tap w a te r (p re fe ra b ly h o t w ater). are e vid en t, replace the e le m e n t.
MTEs
M a k e sure th a t tine s p e c ifie d a ir p ressure
Is not e x c e e d e d .
12-17
12 LUBRICATION - SERVICE PROCEDURES
4 .2 .4 R e g u la to r V a lu e
4 .2 .5 C h e c k V a lv e
For the check va lve m o u n tin g p o s itio n , re fe r to (e) in (6) in 1 G eneral and (2) in 5.4.3 in G rou p 11 Engine.
12-18
L U B R IC A T IO N S - T R O U B L E S H O O T IN G 12
5 TPUBLESHOTDIMG
12-19
13-1
13 FUEL AND ENGINE CONTROL - GENERAL
1. G E N E R A L
NOTE:
The fig u re s h o w s th e AD im p ro v e d
ve rsio n in je c tio n p um p .
B2115A
13-2
FUEL A N D E N G IN E CONTROL - GENERAL 13
(1) In je c tio n Pum p Ps-opes1
(a) In je c tio n pum p
13-3
13 FUEL AND ENGINE CONTROL - GENERAL
B2204A
AD ty p e in je c tio n p u m p P ty p e in je c tio n p u m p
C on tro l rod
B2224A B2206A
A d e fle c to r is in sta lle d on the p e rip h e ry o f th e p lu n g e r w h ic h engages w ith th e c o n tro l rod (or the c o n tro l
barrel so th a t hig h pre ssure fu el o il d isch arg ed fro m rack and p in io n ). Since the d riv in g face o f p lu n g e r
in le t and o u tle t p o rts w ill n o t erode the p um p m eshes w ith the c o n tro l sleeve at the lo w e r p art
h o u sin g . Fuel in je c tio n v o lu m e is c o n tro lle d by the th e re o f, th e p lu n g e r tu rn s w ith th e ro ta tio n o f c o n tro l
g o v e rn o r w h ich m ove s th e c o n tro l rod (or the c o n tro l sleeve and in je c tio n v o lu m e is c o n tro lle d th ro u g h th e
rack) le ft and rig h t and ro ta te s th e c o n tro l sleeve c h a n g in g o f the e ffe ctive stroke.
13-4
FUEL A N D E N G IN E CONTROL - GENERAL 13
A d e liv e ry va lve sto p p e r, p ro v id e d on th e to p o f the
d e liv e ry valve s p rin g , lim its the lift o f the d e liv e ry
Effective stroke va lve to p re v e n t the s u rg in g o f the va lve d u rin g high
speed o p e ra tio n . It also reduces the dead v o lu m e
b etw een the d e liv e ry va lve and nozzle and stabilizes
the in je c tio n rate.
(d) O v e rflo w v a lv e
B2205A
(c ) D e liv e ry v a lv e
W hen th e fu el pressure in th e in je c tio n p u m p exceeds
a p re d e te rm in e d pressure, the steel ball in the
o v e rflo w va lve is pushed up to let th e fuel flo w o u t
fro m the in je c tio n p u m p and retu rn to the fu e l tank,
th e re b y s ta b iliz in g th e fu e l te m p e ra tu re and te m p e ra
tu re d is trib u tio n in the in je c tio n p u m p and m a in ta in
ing th e in je c tio n rate in to each c y lin d e r constant.
13-5
13 FUEL AND ENGINE CONTROL - GENERAL
(2) Governor
(aj KSW ftype governor
S u p p o rtin g lever
B2657B
13-6
FUEL A N D E N G IN E CONTROL - GENERAL 13
W hen the g o v e rn o r s p rin g receives te nsio n, the
b o tto m end o f the te n s io n lever touches the a d ju s t
able fu ll-lo a d s to p p e r bolt.
W hen the angle o f the a d ju s tin g lever is changed, the
angle o f the s w ive l lever is also changed and the
te n s io n o f the g o v e rn o r spring changed. T his is
because th e tu rn in g ce nte r o f the sw ivel lever and the
m o u n tin g p o s itio n o f the g o v e rn o r spring installed to
the te n s io n lever are eccentric to each o th e r as
m e n tio n e d above.
An a d ju s tin g screw is also m o u n te d to the sw ivel
lever. A d ju s tm e n t o f the screw changes th e te nsio n o f
the g o v e rn o r s p rin g , th e re b y m aking it p ossible to
a d ju s t th e speed re g u la tio n .
An U n g le ich s p ring is p ro v id e d in the b o tto m p o rtio n
o f the te n sio n lever. A d ju s t the tension o f the sp ring
by a d d in g or re m o v in g shim s.
An id lin g sub s p rin g a d ju sta b le fro m o u tsid e is
p ro v id e d in the m id d le o f the g o v e rn o r cover. D uring
id lin g , th e s p rin g a lw a ys keeps in co nta ct w ith the
te n s io n lever to m a in ta in a co nsta nt id lin g speed.
The sto p lever, m o u n te d th ro u g h the s u p p o rtin g lever
to the b o tto m end o f the c o n tro l lever, returns th e
The c o n tro l lever is m o u n te d to th e m id d le o f the c o n tro l rack to the sto p p o s itio n w ith a s lig h t pressure
g u id e lever by the s h a ft w ith th e b o tto m end as the irre s p e c tiv e o f the a d ju s tin g lever p o sitio n .
fu lc ru m , w he re a s the to p o f th e lever is coup le d
th ro u g h the shackle to th e c o n tro l rack. H| S ta rt of eng ine
The sta rt sp rin g , attached to th e to p end o f the c o n tro l
lever, a lw a ys p ulls th e c o n tro l rack in th e d ire c tio n
th a t fu e l is increased.
13-7
13 FUEL A N D E N G IN E CONTROL - GENERAL
2 ) Ddling c o n tro l
13-8
FUEL A N D E N G IN E CONTROL - GENERAL 13
4) UsugleSch o p e ra tio n The a ir intake rate o f the eng in e fa lls as the engine
speed increases. The in je c tio n p um p, on the o th e r
hand, increases the per-stroke in je c tio n as the speed
W hen m ax. in je ctio n is set increases, even w ith the c o n tro l rack at the sam e
at low -speed operation
\ Injection m atched p o s itio n .
\ w ith a ir intake rate T he refo re , if fu ll load is set at p o in t A to derive
A 1 - 4- - - 1 e n o ug h o u tp u t at lo w speeds, the in je c tio n w ill reach
Injection/stroke B
A' B as the speed increases, and the e n g in e w ill produce
1
W h e n m a x. in je c tio n is set
at h ig h -s p e e d o p e ra tio n |
black sm oke.
If fu ll load is set at p o in t B' to pre ven t black sm oke, the
Engine speed lo w speed in je c tio n w ill com e d o w n to A ', a llo w in g
c o m b u s tio n o f m ore fuel.
B2663A
So the U ng leich device a ccom plishe s the fu n c tio n o f
se ttin g fu ll load at p o in t A to d erive the largest
The U ng leich device c o n tro ls fu e l in je ctio n in such a possible to rq u e in the lo w speed range, and c h an ging
B2664A
13-9
13 FUEL AND ENGINE CONTROL - GENERAL
5) S to p p in g of e n g in e
B2667A
C o n stru ctio n m a ch in e ry eng in es are o fte n su bjected o fte n lead to stalls. To p re ve n t th is , a to rq u e sp ring is
to a large load d u rin g o p e ra tio n , and reduced speeds p ro v id e d .
13-10
FUEL AM D E N G IN E CONTROL - GENERAL 13
W hen the a d ju stin g lever is fixe d in the lever set A t the tim e , the te nsio n lever pin pushes the b o tto m
p o sitio n , a sudden increase o f load, if no to rq u e o f the to rq u e c o n tro l lever, and the leve r m oves w ith
sp rin g is p ro vid e d , w ill m ove th e c o n tro l rack along the pin " A " as the fu lc ru m , w hereas th e p o rtio n "B " is
the B-D curve as the speed falls. The ro ta tio n a l pushed to rig ht. As the result, th e to rq u e spring
d isp la ce m e n t at the tim e m ay be expressed as P,. p e rfo rm s the fu n c tio n o f reducing m o v e m e n t o f the
If a to rq u e sp rin g is p ro vid e d , th e c o n tro l rack m oves te n sio n lever.
along B-C, and the ro ta tio n a l d is p la c e m e n t at the tim e
m ay be expressed as P2. T he refo re , large changes (b) RFD (type governor [O ption]
o ccur in P2 and eng in e speed, and because of
increased fu el in je ctio n , the e n g in e to rq u e increases,
and large c o m b u s tio n noise w a rn s th e o p e ra to r o f th e
increased load, e na b lin g h im to take p ro p e r action to
p re ven t sto p p in g the engine.
13-11
13 FUEL AND ENGINE CONTROL - GENERAL
1) S ta r t o f e n g in e a n d c o n tro l of id lin g
B2605A
W hen the e ng in e is sta tio n a ry, the fly w e ig h t is in after the eng in e has started, the flo a tin g lever w ill
closed p o s itio n , pushed by the g o v e rn o r s p rin g , id lin g m ove the c o n tro l rod back to a p o s itio n w h e re a fuel
sp rin g and sta rt sp ring . in je c tio n rate su ita b le fo r the id lin g speed is available,
If, in th is c o n d itio n , the load c o n tro l lever is m ove d all w ith the p o in t B as th e fu lc ru m .
the w a y to th e FULL p o s itio n (in th e d ire c tio n o f As the eng in e speed increases, the fly w e ig h ts w ill
g re a te r fu e l d e live ry), the sta rt sp rin g and id lin g m ove o u tw a rd by the c e n trifu g a l fo rce and w ill s h ift
sp ring w ill cause the c o n tro l rod to m ove to the fuel the s h ifte r by the p o in t A u n til the s h ifte r com presses
13-12
FUEL A N D E N G IN E CONTROL - GENERAL 13
A t th e sam e tim e , the fu lc ru m B w ill also s lig h tly As the eng in e speed increases, the ce n trifu g a l fo rce o f
m ove to w a rd the p u m p h o u sin g to push the co n tro l the fly w e ig h t w ill increase, and the fly w e ig h t w ill
rod back in the d ire c tio n fo r decreasing the fuel push the sh ifter. In the n o rm a l speed range, h ow eve r,
in je ctio n rate. the s h ifte r w ill have o n ly a th ru s t eno ug h fo r c o m
In th is m anner, the id lin g speed is m a in ta in e d stable pressing th e id lin g s p rin g and w ill n o t be able to push
by s lig h t a d ju s tm e n t o f the in je c tio n rate. the te nsio n lever o ut by o v e rc o m in g the te n sio n o f the
g o v e rn o r sp ring .
2 } N o r m a l s p e e d o p e r a t io n In th is m anner, the fu el in je c tio n rate is increased or
reduced s im p ly by o p e ra tio n o f the load c o n tro l lever
w h ic h m oves the c o n tro l rod.
3 ) G o r jir a l o f m a x im u m speed
13 -13
13 FUEL AND ENGINE CONTROL - GENERAL
B2674B
13-14
FUEL A N D E N G IN E CONTROL - GENERAL 13
5} E n g in e s to p The flo a tin g lever A p ushed by the flo a tin g lever link
tu rn s in such a w a y as to m ake the cancel spring bend
o ver the sh aft B. So no load is placed on the flo a tin g
lever C blocked by the idle s to p p e r b o lt o u tsid e the
g o v e rn o r.
O p eratio n o f the u ng le ich device is the sam e as the
RSV typ e g o v e rn o r.
{3} F e e d P u m p
B1631A
13-15
13 FUEL AND ENGINE CONTROL - GENERAL
(4 ) A u to m a tic T im e r
The in te rv a l b etw e en fu e l in je c tio n in to th e c y lin d e r
and its ig n itio n is called th e ig n itio n delay inte rva l.
The ig n itio n d elay in te rv a l is c o n s ta n t regardless o f
the e n g in e speed. If the ig n itio n tim in g is alw ays
co nsta nt, changes in the e n g in e speed w ill v a ry the
The feed p u m p feeds fu el u n d e r pressure as fo llo w s . re la tio n b etw een the p is to n p o s itio n and ig n itio n
W hen the p iston is p ushed up by th e cam o f the tim in g , m aking it im p o s s ib le to o b ta in the best eng in e
ca m sh aft, the fuel in the su ctio n c h a m b e r opens the p e rfo rm a n ce . To m a in ta in the re la tio n b etw een the
o u tle t check valve, so m o st o f th e fu el is fo rce d o ut p isto n p o s itio n and ig n itio n tim in g c o n s ta n t at all
and d ra w n in to the pressure ch am be r. W hen the cam tim e s , the in je c tio n tim in g m u s t be chan ge d to m atch
is m ove d aw ay by ro ta tio n o f th e ca m sh aft, th e p iston the e n g in e speed.
is p ushed back by the pre ssure o f th e p isto n s p rin g . At The a u to m a tic tim e r is a device w h ic h a u to m a tic a lly
the tim e , the o u tle t check va lve closes and th e in le t changes the in je c tio n tim in g accordin g to the eng in e
check va lve opens. So fu e l is d ra w n in to the su ction speed.
ch am be r, w hereas the fu el in the pressure c h a m b e r is
fo rce d out.
F ly w e ig h t
B3210A
13-16
FUEL A N D E N G IN E CONTROL - GENERAL 13
The tw o fly w e ig h ts have a hole at one end. The pins
o f the fly w e ig h t h o ld e r fit in the holes. The fla n g e legs e At m a x im u m
Spnng , .
advance anqle
touch the curve d surfaces o f the fly w e ig h ts . T im e r e xte n sio n J
B3212A
D uring lo w speed o p e ra tio n o f th e e ngine, no c e n tri in th e tu rn in g d ire c tio n , w h ile co m p re s s in g the tim e r
fu g a l fo rce acts on the fly w e ig h ts , so the tim e r s p rin g s sp ring s, and m ove the c a m sh a ft o f the p u m p in the
have th e lo n g e st in sta lle d len gth. tu rn in g d ire c tio n to advance the in je c tio n tim in g .
If the eng in e speed changes fro m a high to lo w speed,
the c e n trifu g a l fo rc e o f the fly w e ig h ts w ill decrease
and the fly w e ig h ts w ill retu rn to th e ir o rig in a l p o s i
tio ns. A t the sam e tim e , the pins o f the fly w e ig h t
h o ld e r w ill be pushed back by the tim e r sp ring s.
13-17
13 FUEL A N D E N G IN E C O N T R O L - GENERAL
Oil seal
B3201A
T w o fly w e ig h ts are fitte d on th e p in s o f th e tim e r T im e r s p rin g s are held b e tw e e n th e s p rin g seats fitte d
h o u sin g and are held in th e tim e r h o u s in g . On the on the tim e r h ou sin g p in s w h ic h exten d th ro u g h the
o th e r hand, th e in je c tio n p u m p co n n e c tio n side fla n g e fla n g e and fly w e ig h t. These parts are housed in the
has a curve d surface, and the ro lle r fitte d on the pin tim e r h o u sin g and are to ta lly enclosed w ith a cover,
in sta lle d in the fly w e ig h t to u ch e s the cu rve d surface. O -ring and oil seal.
13-18
FUEL AND ENGINE CONTROL - GENERAL 13
(5 ) C o u p lin g
[For AD type]
T im e r sp rin g Flange
B3405A
[For P typ e]
B3202A
13-19
13 FUEL AND ENGINE CONTROL - GENERAL
{6} Pump five C ase The high pressure fuel w h ic h has fo rce d the needle
va lve up is inje cted fro m the o rific e at the end o f the
nozzle in to the eng in e c o m b u s tio n cham ber.
S om e o f the hig h pressure fu el lu b rica te s th e needle
valve, etc. and is re tu rn e d th ro u g h the fuel leak-off
pipe to the fu e l tank.
The in je c tio n pressure o f the in je c tio n nozzle is
a djusted by c h a n g in g the te n sio n o f th e nozzle s p rin g
w ith the a d ju s tin g screw .
p um p. 2 sp rin g
Spacer
(a) Hole type (1-spring nozzle)
No. 2 p ush ro d
Nozzle hold e r
V alve o p e n in g pressure
a d ju s tin g shim
No. 1 spring
No. 1 push rod
Nozzle
N eedle valve
R etaining nut
B3406A
The fu e l d e live re d fro m th e in je c tio n p u m p e nte rs the The in je c tio n pressure o f the in je c tio n nozzle is
sp ecified pressure. So the fu e l o ve rco m e s the nozzle w ith the sh im and a d ju s tin g screw .
B3551A
13-21
13 FUEL AND ENGINE CONTROL - SPECIFICATIONS
2. SPECIF0CAT0ONS
13-22
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E S T A N D A R D S 13
3c SEPVDGE STAE\3DA13I0)S
3H S E R V IC E S T A N D A R D T A B L E
(1 ) In je c tio n P u m p
U n it: m m
13-23
FUEL AND ENGINE CONTROL -
SERVICE STANDARDS
U n it: m m
Feed T ig htn ess (w hen 195 kPa (2 kg f/cm z) o f air pressure 0 cc/m in. - Replace.
pum p is applied)
K typ e 260
K type 530
K type 520
{ 2 ) Qnjectsora quoszO
U n it: m m
In je ctio n nozzle in je ctio n O ne-sp rin g nozzle 21.6 MPa (220 kg f/c m 2) A d ju s t o r replace
pressure nozzle.
T w o -sp rin g nozzle 17.7 MPa (180 k g f/c m 2)
13-24
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E S T A N D A R D S 13
3 .2 T IG H T E N IN G TO R Q U E TABLE
G o ve rn o r fly w e ig h t nut 49 to 59 (5 to 6)
Cap screw 29 to 39 (3 to 4)
B B b o lt 29 to 34 (3 to 3.5)
wf \ C b olt 29 to 34 (3 to 3.5)
Q C
-
E g "* A
/
* \
B
B3408A
B b o lt 59 to 64 (6 to 6.5)
C b o lt 59 to 64 (6 to 6.5)
B
Xji
c[ / r A B
B3401A
Cap n ut M14 x 1 39 to 49 (4 to 5)
Set screw 49 to 59 (5 to 6)
Lock n ut 20 to 25 (2 to 2.5)
13-25
13 F U E L A M D E N G IN E C O N T R O L -
S E R V IC E S T A N D A R D S
Fuel o v e rflo w - 20 to 29 (2 to 3)
P type - 20 to 29 (2 to 3)
13-26
FUEL A N D E N G IN E CONTROL - S P E C IA L T O O L 13
SPECDAL TOOL
U n it: m m
B5032A
B5031A
94 2 1
B5222A
T a p p e t pincers 157931-6120
13-27
13 FUEL AM D E N G IN E CONTROL - S P E C IA L T O O L
105782-4020
H older 157931-4400
Nozzle h o ld e r w re n ch 157916-8220
(2 ) P T y p e O bjection P u m p P ro p e r
The p art n um b e rs are the DIESEL KIKI part num bers.
P type in je ctio n p u m p special 105790-7050 D isa sse m bly and reassem bly
to o l
Plate 157944-3820
Fittin g plate 157944-3520 D isa sse m bly and re asse m b ly o f p lu n g e r b lock a ssem b ly
105782-4270
13-28
FUEL A N D E N G IN E CONTROL - S P E C IA L T O O L 13
{3) R8W T y p e G o v e rn o r
The part n u m b e rs are the DIESEL KIKI part num bers.
(41 T y p e G o v e rn o r
The part n u m b e rs are the DIESEL KIKI p art num bers.
SA type a u to m a tic tim e r special to o l set 105790-5010 D isassem bly and re asse m b ly
Base 157924-0110
Block 157924-0800
G uide b u sh in g 157924-1300
G uide 157924-0900
G uide 157924-0400
13-29
13 FUEL A N D E N G IN E C O N T R O L - S P E C IA L T O O L ,
S E R V IC E P R O C E D U R E S
SP typ e a u to m a tic tim e r special to o l set 105790-5050 D isassem bly and reassem bly
E xtractor 157926-7220
{7 } in je c tio n M o b ile
The p art n u m b e rs are th e DIESEL KIKI part num b e rs.
Pin ( = 50 *157892-1200
C onnector *157892-1320
Base *157892-1800
Gasket *157892-1500
Gasket *026508-1140
d isa sse m b ly to p re cise ly kn o w th e ir c o n d itio n s . Use the sp ecified special to o ls fo r d isa sse m b ly and
Select a clean site fo r d isa sse m b ly and reassem bly rea ssem bly; never a p p ly excessive force or handle
w o rk, as even sm all d u st p article s on th e fu e l system parts carelessly.
parts can a dve rse ly a ffe ct e n g in e p erfo rm a n ce . W hen Before d isa ssem b ly, te st the system to kn o w e xactly
d isa sse m b lin g the in je c tio n p u m p , keep w o rk bench the tro u b le spots.
clean and d isa ssem b le d parts n e a tly arran ge d fo r
each cylin d e r. Use special care to ensure co rrect
c o m b in a tio n o f p lu n g e r and p lu n g e r barrel and o f
d e live ry valve and d e liv e ry va lve seat.
13-30
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
5.1 IMJECTOOM PU M P
5.1.1 IRemoval
2 1 AD ty p e -
< P ty p e >
(1) A t rem ova l, firs t loosen b o lts ind icate d by a rro w s (2) Use a w o o d block to store in je c tio n p u m p lest
in fig u re fro m co u p lin g . excess fo rce m ig h t be a pp lie d to tim e r.
13-31
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
5 .1 .2 AD T y p e In je c tio n P u m p
(1 ) D is a s s e m b ly
Damage, w o rn seat 22
< D is a s s e m b ly se q u e n ce >
1 H ousing co ver
i2) S crew
3 Screw
(4) Bearing cover
5 Oil seal
6 C am shaft
7 Taper ro lle r bea rin g
8 C enter bearing
(9) T appet
10 Shim 20 D elivery valve s p rin g
@ Plunger 21 D elivery valve
@ L ow er sp rin g seat 22 D elivery valve seat
13 P lunger sp rin g 23 P lunger barrel
14 U pp er sp rin g seat 24 Screw
15 C on trol sleeve 25 C on trol rack
16 Pinion 26 Pum p housing
17 Lock plate
@ D elivery va lve h o ld e r For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
items.
19 S top pe r The part marked * m ust be inspected before disassem bly.
D1566B
13-32
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
(a) Install the in je c tio n p u m p in U nive rsa l Vice (spe (f) Rem ove the hou sin g cover.
cial to ol). Insert T appet Pins (special to ols) into the ta pp et holes
(b) Rem ove the feed pum p. o f all the c y lin d e rs to space th e tappets aw ay fro m the
(c) Rem ove the c o u p lin g and a u to m a tic tim e r. [Refer cam shaft.
to 5.4.1.]
(d) Rem ove the g o ve rn o r. (Refer to 5.2.1 o r 5.2.2.)
13-33
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
B9093A
(h) R em ove the screw s at the b o tto m o f th e in je ctio n (j) Push the ta pp ets up fro m th e b o tto m o f the
p u m p w ith W rench (special to ol). in je ctio n p u m p w ith R oller Pincers (special to o l) and
rem ove the T appet Pins (special tools).
MOTE: rem ove the R oller Pincers (special to o l), and th en take
m o v e She w o o d ru ff k e y fro m th e c a m
s h a ft a n d p u t Mode (s p e c ia l to o l} on th e
th r e a d e d p o rtio n .
2 . T o re m o v e th e c a m s h a ft, d ir e c t th e firs t
c a m lo b e on th e re m o v a l s id e of c a m
s h a ft to w a r d th e to p o f th e p u m p to
p re v e n t th e c a m s h a ft lo b e fro m
to u c h in g th e ta p p e ts , a n d th e n lig h tly
s tr ik e .
(a) Plunger and plunger barrel A fte r cleaning in gas o il, check to see th a t the p lu n g e r
fa lls s m o o th ly in th e p lu n g e r barrel u nd er its ow n
w e ig h t.
Check by the fo llo w in g procedure.
13-35
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
(c) Tapped
13-36
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
(3} Reassembly
-i - i 4.5 to 5.8 Nm
O C f$i (0.45 to 0.6 kgfm )
o 18 64 to 68 Nm
(a) M o u n t the p u m p h ou sin g in U niversal Vice (spe (b) Insert the p lu n g e r barrel into th e h ou sin g.
cial to o l). A fte r th e co n tro l rack has been inserted, M @ TEs
th re a d the screw in to th e back o f the p u m p h ou sin g. H. Align She notch of the plunger barrel
Check to see if the c o n tro l rack lig h tly operates. with the dowel pon of the housing.
2. Do not lightly strike the plunger barrel
but securely push in by finger.
13-37
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
M anufacturer mark
B9109A B9111A
(c) Place the p u m p h o u sin g on its side and set the NOTE:
co n tro l rack so th a t the pun che d m arks o f the c o n tro l In s ta ll th e p lu n g e r w ith th e s ta m p e d m o d e l
rack w ill be p o sitio n e d the sam e d im e n s io n aw ay n u m b e r to w a r d you (th e h o u s in g c o v e r}.
fro m the ends o f the h o u sin g . A fte r th e p in io n and
co n tro l sleeve have been c o m b in e d , p u t the p in io n in
m esh w ith th e teeth o f the co n tro l rod.
M OTE;
H. In s ta ll th e p in io n a n d c o n tro l s le e v e so
th a t th e jo in t of th e p in io n a n d n o tc h of
th e c o n tro l s le e v e w ill b e fa c e d to w a rd
you.
2 . A fte r e a c h p in io n h a s b e e n in s ta lle d ,
m o v e th e c o n tro l r a c k to c o n firm th a t it
c a n b e m o v e d th e s a m e a m o u n t to rig h t
an d le ft.
13-38
F U E L A N D E N G IN E C O N T R O L ---
S E R V IC E P R O C E D U R E S 13
13-39
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
5 .1 .3 P T y p e O njection P om p
(1 ) D is a s s e m b ly
^ W e a r , dam age,
1 2 'd is c o lo r a t io n
6 W o rn or dam aged
Rotating
co n d itio n
< D is a s s e m b ly se q u e n ce :
P lunger 29 Pin
13 P lunger sp ring 30 Bushing
14 U pper sp rin g seat 31 C on trol rod
13-40
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
(a) Rem ove the feed pum p.
MOTE;
1. W hen th e b ea rin g coves is rem o ved , use
c a re not So lose th e end play ad ju stin g
shim s.
2. C h eck th e oil seal and do not rem o ve it
unless d e fe c tiv e .
13-41
13 F U E L A M D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S
SVIOTEs
Put th e rem o ve d plungers ord erly in a tra y
c o n ta in in g c le a n gas oil.
NO TE:
T h e c o n tro l s le e v e cannot he rem oved
unless th e ball m o u n ted ora th e fla n g e of
th e c o n tro l s le e v e and th e ta p p e t guide
groove in th e pum p housing a re in a lig n
m en t.
Extractor
13-42
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
1
Fitting Plate
157944-3520
(o) D isassem ble the p lu n g e r block a ssem bly by the (q) Rem ove the g o v e rn o r side screw b u sh in g w ith
fo llo w in g procedure. special W rench (special to o l) and rem ove the pin and
a) M o u n t F itting Plate (special to ol) in the vice. b ush in g.
Then rem ove the c o n tro l rod and b u sh in g fro m the
tim e r side.
NOTE:
1. Arrange all removed parts orderly by
cylinders.
2. Be sure not to change the combination
of the paired plunger barrel and plunger
and that of delivery valve and delivery
valve seat.
13-43
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
Rem ove in n e r race by use o f Inner Race E xtractor O uter Race E xtra cto r (special to o l).
To in s ta ll, in sta ll a n ew o il seal and then install the
(special tool).
To install, use press. o u te r race.
13-44
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S
(3} R eassem b ly
Control rod
sliding resistance
(when stationary) 110 to 115 Nm
MV 1.3 N (11 to 12 kgfm )
(0.13 kgf) or less (Tighten three tim es)
13-45
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
(a) M o u n t the p u m p h o u sin g in U nive rsa l Vice (spe (c) U sing Socket W re nch (special to o l), tig h te n the
cial tool). d e liv e ry va lve h o ld e r to the sp ecified to rq u e (tigh ten
Then install b u sh in g s and c o n tro l rod, pin and screw in th re e stages).
b ush in g w ith Special W rench (special to o l). Check to NO TE:
see th a t the c o n tro l rod lig h tly operates. Df th e tig h te n in g to rq u e is s m a lle r th an th e
s p e c ifie d to rq u e , oil le a k a g e or d a m a g e to
th e re la te d p a rts cou ld re s u lt.
If th e tig h te n in g to rq u e is e x c e s s iv e , un
sm ooth p lu n g er m o v e m e n t r d a m a g e to
th e re la te d p a rts cou ld re s u lt.
NOTE:
M a k e sure th a t th e lo w e r sid e O-ring is not
s e t on th e p lu n g er b a rrel and slid ed along (d) M o u n t the p lu n g e r to P lunger In sert (special to o l)
th e w a ll su rfa c e of pum p housing. and in se rt it in to the p lu n g e r barrel.
13-46
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
(e) M o u n t T appet M o u n tin g Device (special to o l) to (g) Install the g o v e rn o r h o u sin g . A t th is tim e , p e rfo rm
the p u m p housing. th e fo llo w in g o p e ra tio n . M o u n t M ea suring Plate (spe
Then install the ta p p e t by o p e ra tin g the T appet cial to o l) to the tim e r side ta p e r p o rtio n o f the
M o u n tin g Device. ca m sh aft, and install and p o s itio n the g o v e rn o r side
A t th is tim e , co m p re ss the p lu n g e r sp rin g and inse rt ta p e r ro lle r bearing o u te r race in the ring so th a t the
the m itt p o rtio n o f the p lu n g e r in to th e g u id e g ro ove d im e n s io n fro m the end o f the p um p h ou sin g to the
in the co n tro l sleeve, and in se rt T appet H older end o f th e M e a suring Plate w ill be 13.85 0.5 m m .
(special to o l) into the screw plu g hole. The o p e ra tio n
o f in se rtin g the m itt p o rtio n o f the p lu n g e r into the
guide g ro o ve o f the co n tro l sleeve can be easily
p e rfo rm e d by in se rtin g the m itt p o rtio n , w h ile m o v in g
the c o n tro l rod to rig h t and left.
13-47
13 F U E L A M D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S
S him th ickne ss: 0.10, 0.12, 0.14, 0.16, 0.18, 0.30, 0.50
mm
13-48
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
5 .1 .4 A d ju s tm e n t a fte r R e assem b ly
For fuel in je ctio n rate a d ju stin g sta nd ard , see Service
In fo rm a tio n p u b lish e d separately.
MOTE:
M a k e sure th a t She c e n te r of coupling 5s
a lig n e d w ith th a t of in je c tio n pum p so th a t
She co u p lin g and in je c tio n pum p turn
sm o o th ly.
MOTE:
1. Supply ool So She in je c tio n pum p cam
ch a m b er.
2 . ' A djust She in je c tio n a m o u n t a fte r a d
ju stin g She governor.
In je c tio n s eq u en ce
1 5 3 6 2 4
13-49
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
NTEs
Off th e in je c tio n pum p is not running a t th e
speed m e n tio n e d a b o ve, po sitio n 6 w o n t
be o b ta in e d eve n iff th e c o n tro l racEt is
pressed w ith a strong p ress u re, and th e re
w ill be d an g er off d a m a g e to th e link
m e ch a n is m off th e pum p.
13-50
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
MOTE:
The pressure of the fuel forced into the
injection pump must be higher than the
delivery valve opening pressure.
MOTE:
Make measurement by turning the cam
shaft clockwise.
(e) A d ju s tm e n t o f in je c tio n s ta rt in te rv a l
6) Read the prestroke fro m the b o tto m dead center flo w o u t fro m the te s te r nozzle.
to the p o in t w h e re th e fu e l ceases to flo w (static 3) On the basis o f th e sta tic in je c tio n b e g in n in g o f
in je ctio n begins), using a dia l gauge. the No. 1 c y lin d e r, m easure the in te rv a l w h e n the fuel
MOTE:
Injection sequence
1 5 3 6 2 4
13-51
FUEL AND ENGINE CONTROL -
13 SERVICE PROCEDURES
(g) A d ju s tm e n t o f fu el in je c tio n a m o u n t
To check w h e th e r th e in je c tio n a m o u n t is up to
s p e c ific a tio n at th e sp ecified rack p o s itio n and speed,
m easure w ith a m e a su rin g cylin d e r.
If th e in je c tio n a m o u n t is o u t o f s p e c ific a tio n , a d ju s t
by the fo llo w in g procedures.
1) Loosen th e screw o f th e p in io n .
2) W h ile b lo cking m o v e m e n t o f the c o n tro l rack, tu rn
D3522A
the c o n tro l sleeve w ith an a d ju s tin g rod.
3) T ig h te n the screw o f the p in io n .
(f) A d ju s tm e n t o f ta p p e t clearance
M O TE:
1) Place th e ta p p e t in the to p dead ce n te r p o s itio n . 1. A m a la d ju s te d in je c tio n a m o u n t w ill
2) Raise the ta p p e t w ith a sc re w d riv e r, etc. u n til the p ro d u c e m a rk e d e ffe c ts on e n g in e per
d riv in g face o f the p lu n g e r to u ch e s the b o tto m end o f fo r m a n c e . M a k e s u re tlhe in je c tio n
the p lu n g e r barrel. a m o u n t is c a r e fu lly a d ju s te d .
13-52
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
2. T h e in je c t io n a m o u n t v a r ie s o n d if f e (h) A d a p ta tio n to eng in e
r e n t n o z z le s a n d p ip e s . M a k e s u r e t h a t
A fte r the g o v e rn o r has been adjusted, m easure the
th e m e a s u r in g c o n d it io n s a r e o b s e r v e d .
fu el in je c tio n rate a da pta b le to the engine.
3. I n je c t io n a m o u n t u n e v e n r a t io
(i) In spe ction o f fu el and oil leaks
M a x im u m in je c - A v e ra g e in je c
tio n a m o u n t in tio n a m o u n t of a Fuel leaks fro m d e liv e ry va lve a tta ch in g p o s itio n
e a c h c y lin d e r e a c h c y lin d e r and o th e r parts
U n e v e n ra tio (+ ) -----------------------------------------------------------x 1 0 0 (% j
Oil leaks fro m o il seals and o th e r parts
A v e ra g e in je c tio n a m o u n t of
e a c h c y lin d e r (j) In spe ction o f parts
(2 ) P T y p e I n je c t io n P u m p
A d ju s tm e n t o f in je c tio n
sta rt interval
NV 60 30'
A d ju s tm e n t o f prestroke
NV 4.8 0.05 m m C hecking stroke o f c o n tro l rod
NV 21 o r m ore
NV ... N om in al Value
N O TE :
1. S u pp ly o il to th e in je c tio n p um p c a m c h a m b e r.
2. A d ju s t th e in je c tio n a m o u n t a ft e r a d ju s tm e n t o f th e
g o v e rn o r.
B9146A
13-53
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
13-54
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
5) S lo w ly tu rn the fly w h e e l of the p u m p te ste r
clockw ise u n til the fuel ceases to flo w o u t fro m the
o v e rflo w pipe (un til static in je c tio n begins).
Prestroke
(d) A d ju s tm e n t o f prestroke
MOTEs
To in s ta ll th e p lu n g er b lo ck, ap p ly g reas e
to e a c h -ring. A fte r insertiong th e O-ring in
th e lo w e r p a rt of th e p lu n g er b a rre l onto the
pum p housing ion a d v a n c e , ap p ly g reas e to
th e s k irt portio n of th e p lunger b arrel and
th en in s ta ll th e p lu n g er b arrel.
13-55
FUEL AND ENGINE CONTROL -
13 SERVICE PROCEDURES
D3416A D3427A
13-56
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
1) Loosen the tw o nuts tig h te n in g the fla ng e sleeve. M in im u m in je c - A v e ra g e in je c
2) T urn th e fla n g e sleeve by lig h tly strikin g . tio n a m o u n t in tio n a m o u n t of
e a c h c y lin d e r e a c h c y lin d e r
3) T ig h te n the nuts to the sp e cifie d to rq u e to secure
U n e v e n ra tio ( - ) -----------------------------------------------------------x 1 0 0 (% )
the fla ng e sleeve. (39 to 44 Nm (4 to 4.5 kgfm )] A v e ra g e in je c tio n a m o u n t of
P e rform the o p e ra tio n s repeatedly. e a c h c y lin d e r
MOTE:
(g) A d a p ta tio n to engine
1. m a la d ju s t e d in je c t io n a m o u n t w il l
p r o d u c e c o n s id e r a b le e f f e c t s o n e n g in e A fte r the g o v e rn o r has been a djusted , m easure the
p e r fo r m a n c e . M a lte s u r e t h a t th e in je c fu e l in je c tio n rate a da pta b le to the engine.
t io n a m o u n t is c a r e f u lly a d ju s t e d . (h) In spe ction o f fu el and oil leaks
2 . S in c e t h e in je c t io n a m o u n t v a r ie s o n Fuel leaks fro m d e liv e ry va lve a tta ch in g p osition
d if f e r e n t n o z z le s a n d p ip e s , m a k e s u r e and o th e r parts.
t h a t th e m e a s u r in g c o n d it io n s a re Oil leaks fro m o il seals and o th e r parts
o b s e rv e d .
(i) In spe ction o f parts
3 . I n je c t io n a m o u n t u n e v e n r a t io
Check parts fo r unu sua l noise and bearings fo r
M a x im u m in je c - A v e ra g e in je c
tio n a m o u n t in tio n a m o u n t of excessive heat.
e a c h c y lin d e r e a c h c y lin d e r
U n e v e n ra tio ( ! ) -------------------------------------------------------------x 1 0 0 (% )
A v e ra g e in je c tio n a m o u n t of
e a c h c y lin d e r
5 .1 .5 I n s t a lla t io n
< A D ty p e >
5 6
13-57
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
(1 ) A d ju s tm e n t o f In je c tio n P u m p B r a c k e t
C0603A 89148A
(a) Place In je ctio n Pum p C en te rin g T oo l (special to o l) (b) Slide the dial in d ic a to r o f the ce n te rin g to o l
on the in je c tio n p u m p bracket, h o ld a dia l in d ic a to r to to w a rd the a ir c o m p re s s o r (or in je c tio n p u m p drive)
the m a n d re l o f the ce n te rin g to o l, and p e rfo rm and m easure the p o s itio n s o f the co m p re s s o r crank
O -p o in t a d ju stm e n t. sh aft (or in je c tio n p u m p d riv e shaft) sh ow n in the
illu s tra tio n w ith the dial in d ica to r.
13-58
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
K eyw ay
(c) If the e cce n tricity betw een the m a n d re l and air (b) A t th is p o in t, check to ensure th a t th e keyw ay of
co m p re s s o r cran ksha ft is in excess o f the n o m in a l the cran ksha ft o f the a ir co m p re sso r (or in je ctio n
d im e n s io n , a djust by a d d in g o r re m o vin g in je c tio n p u m p drive) is in the u p p e rm o s t p o s itio n .
p u m p bracket shim s. If the keyw ay is n o t in the u p p e rm o s t p o s itio n , tu rn
S him In serting C o n d itio n the eng in e crankshaft.
The n u m b e r o f sh im s inse rted in to a sing le p o in t
m u st n ot exceed three.
The fro n t and rear sh im s m u s t be equal in
n um b e r.
e The d ifferen ce in n u m b e r betw een the to p and
b o tto m sh im s m u st n ot exceed one.
(2 ) DnisiaSlaiSoiiti of InJecSorii P u m p
13-59
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
IM 0TE:
A fte r th e in je c tio n pum p has b een in s ta l
led, be sure to c h e c k and a d ju s t th e fuel
in je c tio n s ta rt tim in g . (R e fe r to 5.11.7.)
13-60
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 33
5 .1 .7 In s p e c tio n and A d ju s tm en t off Fuel
In je c tio n S ta rt Tim ing
B5908A
13-61
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
[P typ e in je c tio n p u m p ]
13-62
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
(2) RFD T yp e G overnor (e) In the above c o n d itio n (d), m easure the m a x im u m
speed to d e te rm in e w h e th e r it is w ith in the specified
lim its.
(f) If it is not w ith in the specified lim its , adjust the
fixe d p o s itio n o f the speed c o n tro l leve r w ith the
s to p p e r bolt.
M OTE;
1. Df th e fix e d position of th e full load
sto p p er bolt is chan g ed , th e am o u n t of
fuel in je c tio n w ill change. Be ca re fu l
not to ch a n g e th e fixed position .
2. C h eck to ensure th a t even if th e load
co n tro l lever is q u ickly re tu rn ed from
th e full load position to th e idling posi
(a) Check to ensure th a t the load c o n tro l lever is tion, th e en g in e does not stop and is
to u c h in g the idle s to p p e r bolt. fre e from hunting.
(b) In the above c o n d itio n (a), m easure the id lin g
speed to d e te rm in e w h e th e r it is w ith in the specified
lim its.
(c) If it is n ot w ith in the sp e cifie d lim its , a d ju s t w ith
the idle sto p p e r bolt.
(d) O perate the load co n tro l lever to the fu ll load
p o s itio n (u n til it to uch es th e fu ll load s to p p e r bolt).
13-63
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
5.2 GOVERNOR
5 .2 .1 R S V T y p e G o v e rn o r
(1 ) D is a s s e m b ly , In s p e c tio n an d R e a s s e m b ly
24
< D is a s s e m b ly se q u e n ce >
13-64
FU E L A N D ENGSNE C O N T R O L -
S E R V IC E P R O C E D U R E S 13
MOTE: (b) R em oval o f fly w e ig h t
1. 0 not d is a s s e m b le She s h a c k le and U sing Special W rench (special to ol), rem ove the
governor s le e v e from She guide lever,
rou nd n ut tig h te n in g the fly w e ig h t. A t th is tim e , hold
unless re p la c e m e n t is n e c essa ry .
the d rive side to pre ven t it fro m tu rn in g .
2. D not rem o ve th e governor housing
unless rem o va l is n e c e s s ita te d for c o r
re c tio n of oil le a k s , p a rts re p la c e m e n t,
e tc .
B efore rem oving th e housing, use T a p
p e t In s e rt (s p e c ia l tool} to s e p a ra te the
c a m s h a ft from th e ta p p e t.
M O TE ;
Do not a tte m p t d isassem b ly to rem ove the
s w iv el le v e r e x c e p t when re p la c e m e n t of
(a) R em oval o f u ng le ich s p rin g a ssem bly
parts is n e c e s s a ry or when unsm ooth op
U sing Socket W rench (special to o l), loosen the nut era tio n is violent. In ad d itio n , d is a s s e m
tig h te n in g the u ng le ich s p rin g a ssem bly to th e te n bly of p arts for th e stop d e v ic e and torque
sion lever, and rem ove the u n g le ich sp ring capsule.
spring m ech a n is m of th e governor is not
g e n e ra lly required.
13-65
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
(c) R eplacem ent o f sleeve o r guide lever a ssem bly 6) W hen the s h im has to be replaced, assem ble all
related parts c o rre c tly and select th e rig h t sh im
1) Rem ove the bearing fro m insid e th e sh ifte r, using
thickness to m ake sure th a t the d im e n s io n fro m the
a press.
end o f the h o u sin g to the s h ifte r c o m p lie s w ith th e
2) U sing a press, rem ove the s h ifte r o f the guide
specified value.
lever assem bly fro m the bearing.
Shim thickness (6 typ es):
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 m m
M OTE:
M easu re th e a s s e m b ly dim en sio n w ith o u t
liftin g th e fly w e ig h ts .
MTE:
1. Do not re p la c e th e shim , as it has a
th ic k n e s s d e te rm in e d by a d ju s tm e n t of
Ite m 6).
2. During th e rem o va l and in s ta lla tio n op
e ra tio n s , use c a re not to d am ag e th e
c h ro m e p la te d s u rfa c e of th e s h ifte r.
13-66
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
5 .2 .2 RIFO T yp e G overnor
(H ) D isassem bly, In s p e c tio n arad R eassem b ly
16
< D is a s s e m b ly s e q u e n ce >
1 G o ve rn o r co ve r 15 G o verno r sp ring
Lock nut 16 Load c o n tro l lever
Id lin g sp rin g a ssem bly 17 Bushing
4 Cap n ut 18 Lever sh aft
5 Lock nut 19 S lidin g lever
6 D am per sp rin g 20 Speed c o n tro l lever
7 G o ve rn o r co ver 21 Snap ring
8 S tart sp ring 22 Bushing
9 T ension lever plug 23 S w ivel lever
10 T ension lever sh a ft @ Round nut
G uide lever a ssem bly @ F lyw e ig h t
Sleeve (26) G o ve rn o r housing
13 Floating leve r link
For disassem bly and reassem bly o f
14 T ension lever see fo llo w in g items.
For reassem bly, reverse the ord e r o f disassem bly.
B9155A
13-67
13 F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S
NO TE:
B@ not rem o ve th e stop le v e r ass em b ly on
th e top off th e govern o r housing from tin
governor housing.
13-68
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
Sleeve
(d) R eplacem ent o f sleeve o r g u id e lever a ssem bly (e) A sse m b ly d im e n s io n o f sh ifte r
To d isassem ble the s h ifte r and sleeve, rem ove the W hen the s h ifte r and sleeve are assem bled, be sure
snap ring in the sleeve, and th e s h ifte r and sleeve can n ot to change the a d ju s tin g sh im , as the a ssem bly
be separated. d im e n s io n o f the s h ifte r has been a djusted by the
shim .
If re a d ju s tm e n t is necessary, assem ble all related
parts c o rre c tly and select the rig h t sh im thickness to
make sure th a t the d im e n s io n fro m the hou sin g end
to the s h ifte r c o m p lie s w ith the sp ecified value.
IM0TE:
M e a s u re th e a s s e m b ly d im e n s io n w ith a ll
fly w e ig h t lifte d .
D2024A
M O TE:
W h e n th e s h ifte r a n d b u s h in g a re in s ta lle d ,
u s e c a r e n o t to d a m a g e th e c h ro m e p la te d
s u r fa c e o f th e s h ifte r.
13-69
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
A d ju stm e nt o f speed
regulation
A d ju stm e n t o f torque
spring
A d ju stm e nt of id lin g
spring o r ungleich
spring
A d ju stm e nt o f sto p pe r
bolt
NO TE:
1. S u p p ly e n g in e o il to th e in je c tio n p u m p c a m c h a m b e r.
2. L o o se n th e a d ju s tin g le v e r s to p p e r b o lt.
3. R e m o v e th e id lin g sub s p rin g .
A d ju stm e nt o f in te rm e d ia te 4. Do n o t a llo w th e U n g le ic h s p rin g o r id lin g sub spring
speed control and to rq u e s p rin g to w o rk .
B9163A
13-70
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
Full p o sitio n
13-71
13 FUEL AND ENGINE C O N T R O L -
SERVICE P R O C E D U R E S
B9170A
D3482A
13-73
13 FUEL AND ENGINE CONTROL -
SERVICE PRCEDURES
B9174A
13-74
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S 13
(c) A d ju s tm e n t o f fly w e ig h t lift and fu ll load p o s itio n 3) L ow er th e p u m p speed to "N u " and a d ju s t the
D ivide the fly w e ig h t fu ll lift in to the lift necessary fo r high speed lift " L " w ith the stroke a d ju s tin g screw .
high speed 'control and the lift necessary fo r id lin g (d) A d ju s tm e n t o f high speed c o n tro l
co n tro l.
1) W ith the load co n tro l lever fixe d at the fu ll load
p o sitio n , te m p o ra rily set the speed c o n tro l lever so
th a t high speed co n tro l w o rks w he n the p u m p speed
is 700 to 800 rpm .
13-75
13 FUEL AND ENGINE CONTROL -
SERVICE PRCEDURES
Increase the p u m p speed s lo w ly u n til the c o n tro l rack Id lin g s p rin g using the special to o l, W rench so th a t
is pulled back to "R b " p o s itio n . the rack is p o s itio n e d at "R e ".
3) W hen th e p u m p is sto p p e d th e rack sh o u ld be at
U pon reaching "R b " p o s itio n , check th a t the p um p
speed is "N b ". "R f" o r h ig h e r p o s itio n . A lso check th a t th e rack Is
p o s itio n e d at "R c " w h e n the p u m p speed is increased
F urther increase the p u m p speed and check th a t the
rack pull back a m o u n t " L " is as sp ecified. to " N d " .
IMOTE:
1. Df fthe speed regulation check point
(point b) is where the damper spring
acts, check the speed regulation a fte r
idling and damper spring adjustment.
2. Of the value is out of specification,
replace the governor spring.
(e) A d ju s tm e n t o f id lin g s p rin g (g o v e rn o r w ith id lin g
sp ring only)
D4506A
13-76
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S 13
(f) A d ju s tm e n t o f U ng leich sp ring
(Vehicles w ith U ngleich s p rin g only)
B4317A
3) S lo w ly increase the p u m p speed fro m " N f" to
"N g " and a d ju s t th e screw p o s itio n so th a t the
1) Set the p u m p speed at " N f" and place the load U ng leich s p rin g w ill sta rt w o rk in g .
c o n tro l lever in the fu ll load p o sitio n . 4) Increase the pum p speed to check th a t the
2) Using th e special to o l. Special W re nch , a djust the U ng leich s p rin g sto ps w o rk in g at " N h " .
U ngleich sp rin g capsule p o s itio n so th a t th e U ngleich 5) Change the p u m p speed betw een " N f" and "N a "
stroke C in the state o f Step 1 w ill have the specified to check th a t the U n g le ich stroke has th e specified
13-77
FUEL AND ENGINE CONTROL -
SERVICE PRCEDURES
SMOTE:
If She s h im w a s r e p la c e d , r e p e a t a d ju s t
m e n t o f th e g o v e rn o r fro m th e b e g in n in g .
(h) A d ju s tm e n t o f d a m p e r sp rin g
13-78
F U E L A M D E N G IN E C O N T R O L
S E R V IC E P R C E D U R E S
-
13
(i) A d ju s tm e n t o f rack lim it A fte r a d ju s tm e n t, in sta ll the cap n u t securely.
a) R em ove the g u id e screw fro m the back o f the a) Place the load c o n tro l lever in the fu ll load
p um p hou sin g and install th e special to o l, G uide p o s itio n and keep th e p u m p speed at " N v " .
Screw. b) A d ju s t the screw o f the rack lim ite r so th a t the rod
p o s itio n and fuel in je c tio n (p o in t E) w ill be up to
s p e c ific a tio n , and secure it w ith th e lock nut.
B3768A
1) W ith the load c o n tro l lever set at th e fu ll load (I) Locking w ith w ire
p o s itio n , set the sm oke set a sse m b ly a d ju stin g n ut at
0 to 4 m m fro m the sto p p e r tip.
2) A d ju s t to m ake sure th a t w h e n the p u m p speed is
chan ge d to " N d " , the rack p o s itio n w ill change fro m
T o be lo c k e d w ith w ire fe v P P r
"R a " to "R a "'.
N^ l t \ r S S
""
SP'
\
v -x- T o be lo cke d
/ w ith cap
T o be ca p lo cke d
B4320C
A fte r a d ju s tm e n ts , lock th e g o v e rn o r.
MOTE;
L o c k p a rts m a r k e d w ith * a f t e r a d ju s tm e n t
o f no Hoad m a x im u m s p e e d .
13-80
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S 13
5 .3 FE E D P U M P
5 .3 .1 D is a s s e m b ly , In s p e c to ra a n d R e a s s e m b ly
< D is a s s e m b ly s e q u e n ce >
NOTE:
B e fo re d is a s s e m b ly , k n o w th e tro u b le s p o ts th ro u g h ly by
m a k in g te s ts .
B9175A
13-81
FUEL AND ENGINE CONTROL -
SERVICE PRCEDURES
5 .3 .2 T e s t a n d A d ju s tm e n t
The feed p u m p tests are as fo llo w s .
Test co n d itio n s
Fuel pipe
I.D. 8
Length 2 000
Cam lift
6 (eccentric cam ) [KE type)
4 (double cam ) [K type] 1 m
Height fro m o il level 1 000
Test bench FPT-1
Test oil
SAE Standard Test Oil (SAE J967c)
NV... N om inal Value
D6401A
13-82
FUEL AND ENGINE CONTROL -
SERVICE PRCEDURES 13
5 .4 A U T O M A T IC TAMER
5 .4 .1 SA T y p e A u to m a tic T im e r
(1 ) D is a s s e m b ly a n d D nspection
For d isa sse m b ly and re a ssem bly o f the a u to m a tic
tim e r, use SA Type A u to m a tic T im e r Special T ool
(105790-5010).
W ear of
pin section
< D is a s s e m b ly s e q u e n ce >
Round nut
2 T im e r plug
@ T im e r case
4 O il seal
5 Flange
6 Oil seal
7 S pring
8 S him
9 F lyw e igh t
10 Flolder
W ear,
dam age
For disassem bly o f parts w ith an encircled num ber, see fo llo w in g
item s.
D3152A
13-83
13 F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S
(b) M o u n t Special S p an n er (special to o l) in the c o u (e) R em ove the tim e r plu g and place the a u to m a tic
p lin g m o u n tin g th re ad e d hole to p re ve n t tu rn in g , and tim e r on Base (special to ol).
rem ove the ro u n d nut. MOTH;
Lone up fidie hole in tine tim er plug with the
pin f the base.
13-84
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S 13
(2) Reassembly
9 3
D3153A
(a) M o u n t Base and G uide B o lt (special to o ls) in a (b) Install th e o il seal in th e flange.
vice. 1) M o u n t Block (special to o l) to th e base.
2) Put th e fla n g e so th a t its pins w ill fit in th e holes in
the block.
3) A p p ly NEJI LOCK to the o il seal in s ta llin g hole in
the flange.
4) Put the oil seal in the hole in the fla n g e . Install the
o il seal by tu rn in g d o w n T h ru s t B ushing (special to o l)
w ith G uide B ushing (special to o l) in betw een.
13-85
13 F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S
M O TE :
Select the proper shim thickness so it a hie
for the advance angle of the automatic
timer.
13-86
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R C E D U R E S 33
(i) Inject app ro x. 150 g o f a u to m a tic tim e r grease
fro m the tim e r plu g hole.
Hand Spanner A fte r grease has been Injected, tig h te n the tim e r plug.
13-87
13 FUEL AND ENGINE CONTROL -
SERVICE PRCEDURES
5 .4 .2 SP T y p e A u to m a tic T im e r
(1 ) D is a s s e m b ly amid In s p e c tio n
For d isa sse m b ly and rea sse m b ly o f the a u to m a tic
tim e r, use th e special to o l, SP Type A u to m a tic T im e r
Special T ool (105790-5050).
<Disassembly sequence>
1 Cap screw
@ Round nut
3 Cover
4 Oil seal
Washer
Roller
Bushing
8 Flange
9 Retainer
10 Timer spring
11 Spring seat
12 Shim
13 Flyweight
14 Timer housing
For d isa sse m b ly o f parts w ith an encircled n um b e r, see fo llo w in g item s.
D3103A
13-88
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
(d) M o u n t Base (special to o l) in a vice. (f) M ount Special S panner (special to o l) to the
flange. W ith th e tim e r sp ring com pressed, rem ove the
w asher, ro lle r and b ushing.
13-89
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
(2 ) R e a s s e m b ly
(a) M o u n t Base (special to o l) in a vice and secure the (b) M o u n t Special S panner (special to o l) to the
tim e r h o u sin g to th e base. flange. W ith the tim e r sp ring co m p re ssed , install the
b ush in g, ro lle r and w asher.
13-90
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
Cover side
R oller side
D3113A
SMOTE: (d) R em ove the plu g at the rear end o f the tim e r and
W h e n th e w a s h e r is in s ta lle d , d ir e c t it as s u p p ly 250 to 270 cc o f e ng in e oil.
show n.
13-91
13-92
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
5 .5 P U M P 1 D R IV E C A S E For rem ova l and in s ta lla tio n o f the p u m p d riv e case,
5 .5 .1 R em oval and I n s ta lla tio n refer t0 5-1-1 in G ro u P 61 Special E q uip m e nt.
5 .5 .2 D i s a s s e m b l y a ra d I n s p e c t i o n
13-93
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
13-94
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
5 .6 IM JECTIO M WOZZLE 5 .6 .2 D isassem bly
5.6.1 R em oval and In s ta lla tio n ____________________
(1-spring nozzle)
1
of t '
2
. 3 Settling
W ear 4 .....
TJ
9
7 W ear
f g Carbon
deposited
0 ' 6
>
D isasse m b ly sequence
(2-spring nozzle)
D isasse m b ly sequence
1 Cap nut
2 A d ju s tin g screw
3 Lock nut
Cracks,
d e te rio ra tio n 4 4 No. 2 spring
5 Set screw
6 No. 2 push rod
7 Spacer
8 No. 1 spring
9 No. 1 push rod
10 R etaining nut
11 Nozzle
12 Needle valve
13 Nozzle h o ld e r
14 C onnector
D7015A
13-95
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
MOTE;
M ever ch a n g e th e co m b in a tio n of th e n o z
zle and n ee d le valve.
(2) Inspection
13-96
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
Next, pull up the needle va lve v e rtic a lly a bo ut 1/3 o f (1) In je c tio n P ressure
its e ntire stroke and check th a t it fa lls u nd er its ow n
w e ig h t. If it does n o t fa ll, replace the nozzle.
5 .6 .4 R e asse m b ly and A d ju s tm e n t in
spiring nozzle)
M OTE;
Met/er Bet you rself exp o sed d ire c tly to th e
a to m ize d fuel in je c te d from th e nozzle.
D7008A
13-97
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
(2) Spray Condition 5.6.5 Reassem bly and A djustm ent (2-
spring nozzle)
A d ju s t w h ile a s s e m b lin g th e p arts b y the fo llo w in g
procedures.
As the p re lift is adjusted in 1/100 m m in cre m e n ts, use
clean d e te rg e n t to th o ro u g h ly re m o ve d u s t and d irt
befo re a d ju stm e n t.
For a d ju s tm e n t, th e fo llo w in g special to o ls are re-
q uire d .
3 Pin, ( - 50 m m 157892-1200
13-98
FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES 13
(1) A d ju s tm en t of M ozzle Waive pening
P ressure
0 A d ju s tm e n t o f nozzle o p e n in g pressure
(2) S election o f p re lift a d ju stin g shim s (a) U sing the R etaining N ut fo r A d ju s tm e n t (special
(3) A d ju s tm e n t o f 2-spring a d ju stin g pressure to o l) in sta ll the nozzle and needle va lve to the nozzle
* 0 Check o f needle va lve fu ll lift holder.
(5) In sta lla tio n o f p re lift sh im s MOTE:
*(6) Checking o f p re lift H. M a k e sure th a t th e kn o c k pin has s e a
* 0 C hecking o f 2-spring a d ju stin g pressure te d c o m p le te ly in th e no zzle b efo re
0 ' Inspection tig h te n in g th e re ta in in g nut fo r adjust-
In spe ction m ake o p e ra tio n s m arked w ith * as neces orient. T ig h ten th e re ta in in g nut fin g er
sary fo r insp ectio n o r c o n firm a tio n . tig h t and th en tig h te n to s p e c ifie d to r
que using a to rq u e w re n ch .
2. IRemove th e bolt fro m th e tip of th e
re ta in in g nut.
13-99
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
NOTE:
1= W hen using a shim , be sure So c h e e k its
th ic k n e s s by a m ic ro m e te r.
2. U se s am e shim for p re lift a d ju s tm e n t.
3. U se of a 0 .0 2 m m th ic k shim ch a n g es
th e v a lv e opening p ress u re by ab o u t
2 3 5 kP a (2 .4 k g f/e m 2}
Dial Gauge
(c) Install the nozzle h o ld e r to the Nozzle Tester (b) Install the 2nd push rod to the nozzle holder.
(special to o l) and a d ju st the sh im th ickne ss fo r NOTE;
n o m in a l in je ctio n pressure. O not in s ta ll th e 2nd spring and p re lift
Shim types: ad ju stin g shim .
0.50 to 1.54 m m (by 0.02 m m )
13-100
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
(e) Rem ove th e a d ju s tin g device fro m the nozzle
holder.
MOTE?
R ead t 1 / 1 0 0 m m .
(d) S election o f p re lift a d ju stin g sh im
t = ( + h
Type o f sh im s
0.75 to 1.50 m m (by 0.01 m m )
13-101
13 F U E L A M D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S
() C h eckin g P re lift
Check th e p re lift based on d im e n s io n " L " m easured
in (4) and d im e n s io n "S " m ea sured in (5).
(a) Install the special to o ls ind icate d in above illu s tra
tio n and set 0 p o in t o f the Dial Gauge. L - S = A('
(b) Install the nozzle to th e nozzle te ste r and operate w h e re ( 0.02 < AC < (' + 0.02 m m
the tester le v e rto bleed the insid e o f th e re ta in in g nut.
At : P re lift (m easured)
A lso check fo r fu el leaks.
( : P re lift (0.1 m m )
(c) O perate the te ste r lever to increase th e pressure
L: N eedle valve fu ll lift d im e n s io n (m ea
to a b o u t 34.5 to 44 MPa (350 to 450 kg f/c m 2) so th a t
sured)
the needle valve o f th e nozzle is fu lly lifte d . Read th is
S: N eedle valve lift d im e n s io n (m easured)
lift d im e n sio n " L " o ff the dial gauge.
w ith p re lift su btracted
(d) R em ove the Dial G auge, C on ne cto r and Pin
If A ( is o u tsid e o f sp e cifie d d im e n s io n C 0.02
(special to ol).
m m , replace the p re lift a d ju s tin g s h im as d e
{) In s ta lla tio n f P re liff Shim scrib ed in (5) and repeat steps (4) and (5) so th a t
A ( w ill fa ll w ith in C 0.02 m m .
S elect th ickne ss t' o f sh im to be used as fo llo w s .
t' s= t + [C - AC)
T = t ' 0.015 m m
w h e re t: T hickness o f e x is tin g s h im
t': S him thickness
T: Thickness o f sh im to a ctu a lly replace
e x is tin g s h im
C: P re lift (0.1 m m )
13-102
F U E L A M D E M G IM E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
1?) C h e c k in g A d ju s tin g A llo w a n c e o 2- (b) S pray co n d itio n
s p rin g
NOTE:
T h e R e ta in in g N u t fo r A d ju s tm e n t {s p e c ia l
to o l} m u s t h a v e a h o lt fit t e d a t its tip .
(b) W hen the nozzle tester lever o p e ra tio n is stopped
w ith the nozzle needle valve fu lly lifte d, the pressure
W hen a d ju s tin g th e pressure w ith a nozzle tester,
w ill sta rt to d ro p and the needle va lve w ill go dow n.
check also fo r clo g g e d In je c tio n o rifice s, sp ra y c o n d i
(c) A t the m o m e n t the nozzle lift has d ro pp ed to 0.05
tio n , and fuel leaks fro m the o rifices. Replace the
m m , read the pressure gauge in d ica tio n .
nozzle If defective.
(d) If the 2-spring a d ju stin g pressure (cover pressure)
(c) Fuel tig h tn e s s test
is o u t o f sp e cifica tio n , a djust th e 2-spring adjustin g
pressure as described in (3).
M O TE:
A d ju s t w ith o u t in s ta llin g p r e lift s h im .
(e) Rem ove special tools.
{8} In s p e c tio n
(a) T igh ten the reta inin g n ut and cap n u t to specified
torque.
M O TE:
1. M a k e s u re th a t th e k n o c k pin h as s e a -
te d c o m p le te ly b e fo re tig h te n in g th e
r e ta in in g n u t.
2 . T ig h te n th e re ta in in g n u t fin g e r fig h t
Install a nozzle th a t has been a d ju ste d to specified
an d th e n tig h te n to s p e c ifie d to rq u e
Injection sta rt pressure to the nozzle tester. S lo w ly
u sin g a to rq u e w re n c h .
increase the pressure to the te st pressure and keeping
th is c o n d itio n , check fo r fuel leaks fro m th e b o tto m o f
the nozzle. The nozzle is fu n c tio n in g n o rm a lly if there
is no leak.
13-103
13 FUEL AND ENGINE CONTROL -
SERVICE PROCEDURES
5 .7 F U E L F IL T E R
MOTE:
1. W h e n re m o v in g th e e le m e n t, c h e c k fo r
th e g a s k e t le f t b e h in d on th e h e a d s id e .
2 . T o m o u n t, a p p ly a th in c o a t o f e n g in e oil
to th e g a s k e t, a n d th e n s e c u re th e
e le m e n t by tig h te n in g % to 1 tu rn a fte r
th e g a s k e t c o m e s in c o n ta c t w ith th e
fu e l f ilt e r h e a d .
3 . A fte r in s ta lla tio n , b le e d th e fu e l sys-
te rn .
4 . A fte r b le e d in g th e a ir, s ta r t th e e n g in e
a n d c h e c k fo r fu e l le a k s .
13-104
F U E L A N D E N G IN E C O N T R O L -
S E R V IC E P R O C E D U R E S 13
5 .8 W ATER SEPAR ATO R
1 Drain plug
2 Ring nut
3 Case
4 Baffle plate
5 Isolation plate
6 Screen assem bly
7 W ater level ring
8 Cover
1 ------- )
D7405C
MOTE:;
A fte r d ra in in g , tig h te n firm ly th e d ra in p lu g
b e fo re b le e d in g th e fu e l s y s te m .
13-105
13 FUEL A N D E N G IN E C O N T R O L - T R O U B L E S H O O T IN G
TR O U B LES H O O TIN G
W o rn ta p p e t Replace
D efective in je c tio n p um p
B ind in g o r w o n p lu n g e r Replace
W o rn ta p p et Replace
W o rn ca m sha ft Replace
V alve o p e n in g p ressure to o lo w A d ju s t
13-106
FUEL AND ENGINE CONTROL - TROUBLESHOOTING 13
S ym p to m Probable cause R em edy Ref. g ro u p
V alve o p e n in g pressure to o lo w A d ju s t
D efective feed p u m p
Check va lve n ot fu n c tio n in g n o rm a lly Replace
Defective in je ctio n p u m p
W o rn p lu n g e r Replace
Loss o f D efective g o ve rn o r
e ngine o u tp u t
Too e arly ro ta tio n c o n tro l due to w eak g o v e rn o r sp rin g A d ju s t
13-107
13 FUEL A N D E N G IN E CONTROL - T R O U B L E S H O O T IN G
Engine ca nn o t D efective g o v e rn o r
deve lo p m a xim u m A d ju s t
G o ve rn o r sp rin g to o w eak
speed
A d ju s tin g leve r (o r load c o n tro l lever) p o o rly adjusted A d ju s t
Valve o p e n in g p ressu re to o lo w A d ju s t
D efective g o v e rn o r
Id lin g sp rin g to o w eak A d ju s t
Loose ro un d n ut C orrect
W o rn p iston Replace
13-108
14
CO O LIN G
CONTENTS
14-1
14 C O O L IN G - GENERAL
1. G E N E R A L (2) T h e rm o s ta t
The e n g in e is co o le d by fo rce d c irc u la tio n o f c o o la n t
by the w a te r p um p. The illu s tra tio n b e lo w sh o w s the
co o la n t flo w .
i l } W a te r P o m p
(3) R a d ia to r
The w a te r p u m p is a c e n trifu g a l p u m p . M o u n te d on
the le ft side o f th e crankcase, the p u m p is d riv e n by
the cran ksha ft p u lle y via a V -belt.
An im p e lle r having a blade is m o u n te d at one end o f
the w a te r p u m p sh a ft and c o o la n t is sealed o ff by a
u n it seal.
For lu b ric a tio n o f th e w a te r p u m p , refe r to "G ro u p 12
L u b ric a tio n ".
14-2
COOLING - GENERAL, SPECIFICATIONS 14
C o n side ra tion s are, th e re fo re , paid to the fan d ia The pressure cap regulates th e pressure in the
m eter, ra d ia to r ca pacity and o th e r factors. Som e u nits c o o lin g system . W hen the pressure b u ild s up in the
fo r co n stru ctio n p lants are e q u ip p e d w ith an oil co oler system th a t exceeds a p re d e te rm in e d level, the
to cool h y d ra u lic oil. pressure va lve co m p re sses the pressure s p rin g , re
(4) Pressure Cap leasing the excessive pressure th ro u g h the o v e rflo w
pipe in to the a tm o sph e re .
If e q u ip p e d w ith a reserve tank, the c o o la n t th a t has
o v e rflo w e d is ch anneled in to it.
W hen the c o o la n t te m p e ra tu re d ro p s and negative
pressure b u ild s up in the syste m , the v e n t valve
opens to take in a ir to p re ve n t the ra d ia to r fro m
b e co m in g d e fo rm e d .
If e q u ip p e d w ith a reserve tank, c o o la n t is taken fro m
the reserve tank to p re v e n t the ra d ia to r fro m b e c o m
ing d e fo rm e d and to keep the q u a n tity o f c o o la n t in
the syste m co nsta nt.
If e q u ip p e d w ith a pressure release leve r on the cap,
raising the lever u p rig h t o pe ns the pressure va lve and
releases the pressure in th e c o o lin g system .
2. S P E C IFIC A TIO N S
14-3
14 C O O L IN G - S E R V IC E S T A N D A R D S , S P E C IA L T O O L
3. S i r a C E SYAMDAKOS
3.1 SE R V IC E STAM DARB TABLE
U n it: m m
3 .2 TIGKITEKIOMQ TO R Q U E TA BLE
4. SPECIAL TOOL
U n it: m m
14-4
C O O L IN G - S E R V IC E PROCEDURES 14
5. SERVQGE PROCEDURES 5.2 W ATER PU M P
5.1 REM O VAL ANB IN S T A L L A T IO N OF 5 .2 .1 Removal! arnci OiiDStaSlatiiorTi
CO O LIN G FAN
< D is a s s e m b ly s e q u e n c e >
1 W a te r p u m p p u lle y W a te r p u m p sh a ft
Flange 9 Bearing
3 Oil seal 10 Spacer
4 Snap ring 11 Bearing
5 Snap ring 12 Oil seal
6 W a te r p u m p co ver 13 U n it seal
Im p e lle r 14 W a te r p u m p case
For parts w ith an encircled num ber, refer to Disassem bly and
Inspection Procedures that fo llo w . D0044C
14-5
14 COOLING - SERVICE PROCEDURES
D is a s s e m b ly a n d In s p e c tio n P ro c e d u re s
(3 ) Im p e lle r to W a te r P u m p S h a ft T ig h te n
ing M a rg in
(1 ) R e m o v a l o f D m peller
If the tig h te n in g m a rg in exceeds sp e c ific a tio n , replace
U sing tw o th re ad e d holes (M 8 x 1.25) in the im p e lle r
th e im p e lle r o r w a te r p u m p shaft.
and the W a te r Pum p Im p e lle r P uller (special to o l), pull
o ff the im p e lle r. NOTE:
Do n o t re a s s e m b le m o re th a n th r e e tim e s
e v e n w h e n th e s p e c ific a tio n is m e t.
(2 ) F la n g e to W a te r P u m p S h a ft T ig h te n in g
M a rg in
If the tig h te n in g m a rg in exceeds sp e c ific a tio n , replace
the fla ng e or w a te r p u m p shaft.
NOTE:
Do n o t re a s s e m b le m o re th a n th r e e tim e s
e v e n w h e n th e s p e c ific a tio n is m e t.
14-6
C O O L IN G - S E R V IC E P R O C E D U R E S 14
5 .2 .3 R e a s s e m b ly
A p p ly e n g in e
o il to lip s .
12
1. A fte r re a s s e m b ly , tu rn th e w a te r p u m p p u lle y by h an d
to m a k e s u re th a t th e im p e lle r is n o t in c o n ta c t w ith
th e c a s e a n d c o v e r.
2. W h en p re s s -fittin g th e im p e lle r a n d fla n g e , m a k e s u re
t h a t th e y c a n n o t b e in s ta lle d w ith a lo a d of 4 .9 kM (5 0 0
D0047D
14-7
14 COOLING - SERVICE PROCEDURES
T herm ostat _
Heat source
D0301B
14-8
C O O L IN G - S E R V IC E P R O C E D U R E S m
6 Spacer
7 Ball bearing
8 Bearing case
B9023D
6 Rotating co n d itio n
< D is a s s e m b ly se q u e n c e >
14-9
14 COOLING - SERVICE PROCEDURES
5 .5 .2 R e a s s e m b ly
5 .6 R A 0 B A T 0R
5 .6 .1 In s p e c tio n
14-10
COOLING - SERVICE PROCEDURES 14
5.7 IN S P E C T IO N AMD A D J U S T M E N T OF (a) A lte rn a to r section
V-BELT T E N S IO N S lig h tly loosen the a lte rn a to r m o u n tin g b o lt and
(1) In s p e c tio n a d ju s tin g b olt, then m ove the a lte rn a to r to rig h t or left
by in s e rtin g a to o l such as w re nch handle.
NOTE:
W hen m oving th e a lte rn a to r, try not to
d am ag e th e s ta to r co il s e c tio n b e tw e e n
th e fro n t and rear b ra c k e ts . The sam e
a p p lies to th e bolts.
A d ju s tin g b olt
I f } W ashing w ith W a te r
14-12
C O O L IN G - S E R V IC E PROCEDURES m
Replace the c o o la n t once e very tw o years to retain its
anti-freeze and a n ti-ru s t effects.
For usage o f Long Life C oolant, refer to Its in s tru c tio n
m anual.
NOTE:
1. Be sure to use FUS B iesel Long Life
C o o lan t.
2. INIever m ix it w ith DIAQUEEM Long Life
C o o la n t or o th e r c o m m e rc ia l long life
c o o la n ts , a n ti-fre e z e s or a n ti-ru s ts .
B0426A
E\ITE:
1. Iff Slue inside is h e a v ily sta in e d , w ashing
w ith ta p w a te r b efo re ch arg in g ra d ia to r
d e te rg e n t w ill be e ffe c tiv e . B13IU A
2. Running th e en g in e a t id le for longer
th an an hour w ith d e te rg e n t le ft in (b) W hen A n ti-ru s t and A n ti-fre e ze are
en g in e could c a u s e d a m a g e to th e c o o l used:
ing sys te m . Be sure to o b serve s p e c i
1) A fte r clea nin g, add Fuso R adiator A n ti-ru s t
fied c le a n in g tim e .
(Radipet-9B or e q u iva le n t) at a ra tio o f 5% to the
3. A fte r c le an in g w ith d e te rg e n t, fill w ith
co o la n t q u a n tity to p re ve n t c o rro sio n in su m m er.
c o o la n t as soon as possible.
(3) C ooling W ater
o .
B1322A
14-13
14 COOLING - SERVICE PROCEDURES
(1 ) Onspectioin)
Rem ove the pressure cap fro m the ra d ia to r, and run
the e ng in e to raise th e c o o la n t te m p e ra tu re up to
a ro un d 90C.
If b ub bles co n tin u e fo rm in g in th e co o la n t u n d e r the
c o n d itio n , it ind icate s th a t a ir or e xh a u st gas has
leaked into the co olan t.
(2 ) C a u s e s
(a) If air is tra p p e d in co o la n t, check c y lin d e r head
b olts, w a te r p u m p m o u n tin g b olts, and hose and its
co n n e ctio n s fo r looseness. Check also hoses fo r
dam age.
'(b ) If the e xha ust gas has leaked in to co olan t, check
the c y lin d e r head gasket o r nozzle tu b e end stake fo r
dam age. Check also c y lin d e r head fo r cracks.
14-14
C O O L IN G - T R O U B L E S H O O T IN G 14
6. TR O U B LE S H O O T IN G
D efective w a te r p u m p
o Loose shaft to fla ng e e ng a g em e n t Replace
D am aged im p e lle r
L ow co o la n t level Replenish
D efective ra d ia to r
R adiator p ro p e r n ot a ir tig h t Replace
D efective w a te r p u m p
o D efective u n it seal Replace
D efective o il seal
14-15
15
INTAKE i B EX3MUST
CONTENTS
15-1
15 IN T A K E A N D EXHAUST - GENERAL
1. GENERAL
{US Air leaner
(2) P re c le a n e r
15-2
INTAKE AND EXHAUST - GENERAL 15
(3 ) V a c u a to r V a lv e A fte r the e le m e n t has been cleaned o r replaced,
depress the reset b u tto n on the top, and the signal
w ill return to its o rig in a l p osition .
\ \
A |
^ : n.
B0624A
(4 ) D u s t (In d ic ato r
15-4
IN T A K E A N D EXHAUST - G E N E R A L , S P E C 1 F S C A T IO N S 15
(6) After Oooller The intake air c o o le r system , in c o rp o ra tin g a plate-
a nd -c o rru g a te d -fin typ e heat e xcha ng er w ith a b u ilt-in
in le t m a n ifo ld , tran sfe rs heat fro m the intake a ir to the
engine coolant.
The system cools o ff the intake air, w h o s e te m p e ra
T u rb o ch a rg e r tu re has gone high due to co m p re ssio n by the
tu rb o c h a rg e r, th ro u g h heat e xch a n g in g w ith the
eng in e co olan t. This a llo w s the d e n sity o f intake air to
be increased, a d m ittin g m ore air in to the e ngine,
w h ic h in tu rn increases the fuel in je c tio n rate and
im p ro v e s the c o m b u s tio n efficien cy. Thus the fuel
e c o n o m y and o u tp u t are im p ro v e d and the e xhaust
gases are reduced to a m in im u m .
B0627A
2 . SPECDFflCATDOMS
T u rb o ch a rg e r (6D22-T1 (6D22-TC)
(S tandard) (O ption)
15-5
15 INTAKE AND EXHAUST - SERVICE STANDARDS
3 SERFAGE S T A N D A R D S
3.1 SERVICE STASMOAKD TABLE
U n it: m m
I.D. 12.042
Length 11.94
Bearing jo u rn a l - 14.254
O.D.
15-6
INTAKE AND EXHAUST - SERVICE STANDARDS
SPECIAL TOOL 15
U n it: m m
3 .2 TOKIT EM I MG TO R Q U E TABLE
4= SPEeOAL TOOL
15-7
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
< 6 D 2 2>
1 Earth plate
2 In let pipe
3 A ir heater
4 In let m a n ifo ld
NOTE:
1. R e m o v e a ll h a rn e s s e s b e fo re d is a s s e m b ly .
2. P a y a tte n tio n to th e a ir h e a t e r m o u n tin g d ir e c tio n .
3. F o r in s p e c tio n o f a ir h e a te r , s e e G ro u p 1 6 .
B4556A
15-8
INTAKE AND EXHAUST - SERVICE PROCEDURES 15
< 6 D 2 2 -T >
1 Earth plate
2 Inlet pipe
3 R ubber hose
4 A ir heater
5 Inlet m a n ifo ld
N O TE :
1. R e m o v e a ll h a rn e s s e s b e fo re d is a s s e m b ly .
2. P a y a tte n tio n to a ir h e a te r m o u n tin g d ire c tio n .
3. F o r in s p e c tio n o f a ir h e a te r, s e e G ro u p e 1 6 .
B4557A
15-9
15 IN T A K E A N D EXHAUST - SERVSCE P R O C E D U R E S
< 6 D 2 2 -T C >
1 In let pipe
2 A ir escape pipe
3 W a te r in le t pipe
4 W a te r retu rn pipe
5 A fte r c o o le r assem bly
6 Earth plate
7 A ir heater
8 R ubber hose
MOTE:
1. R e m o v e a ll h a rn e s s e s b e fo re d is a s s e m b ly .
2. P a y a tte n tio n to a ir h e a te r m o u n tin g d ir e c tio n .
3. F o r in s p e c tio n of a ir h e a te r, s e e C ro u p e 1 6 .
B4558A
15-10
IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES 15
5.2 REMOVAL AND OMSTALLATOON OF E X H A U S T S Y STE M
<6D22>
1 Heat in s u la to r
2 Exhaust m a n ifo ld
3 Seal ring
4 E xpansion ring
5 C enter e xha ust m a n ifo ld
B4560A
<6D22-T, TC>
35 Nm
(3.6 kgfm )
26 Nm
(2.7 kgfm)
41 Nm
(4.2 kgfm )
Install the seal ring so th a t the ends o f each ring are positioned
180 apart fro m those o f the other.
Install the expansion ring so th a t any one o f its crests is not
p o sitio n ed at the seal ring ends.
1 Heat in s u la to r
2 Oil pipe
3 Oil retu rn pipe
4 T u rb o c h a rg e r
5 E xhaust m a n ifo ld
6 Seal ring
7 E xpansion rin g
8 C enter e xha ust m a n ifo ld
B4561A
15-12
IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES 15
5 .3 A m CLEANER
5 .3 .1 D is a s s e m b ly a n d R e a s s e m b ly
'S in g le e le m e n t ty p e >
A s s e m b lin g d ire c tio n m ark
Do n o t re m o v e th e in n e r e le m e n t w h e n c le a n in g th e o u te r
V acuator va lve e le m e n t. E0158
15-13
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
5 .3 .2 In s p e c tio n a n d C le a n in g (3 ) In s p e c tio n o f E le m e n t
(1 )W h e n th e r e os D ry O u s t on th e E le m e n t
C7209A
b lo w in g 685 kPa (7 kg f/cm 2) o r lo w e r co m p re sse d air holes. If th ere are th in p o rtio n s in the filte r paper,
M@TE;
Perform th is in s p e c tio n a f t e r c le a n in g or
r e p la c e m e n t o f th e a ir c le a n e r e le m e n t if
th e e le m e n t is h e a v ily c lo g g e d .
15-14
INTAKE AND EXHAUST - SERVICE PROCEDURES 15
5 .4 TURBOCHARGER
5 .4 .1 T D 0 8 T y p e T u rb o c h a rg e r
11) D is a s s e m b ly
Interference w ith
tu rb in e w heel, cracks
due to overheat, pitch in g ,
d e form a tion
C8965B
15-15
INTAKE AND EXHAUST - SERVICE PROCEDURES
15-16
IN TA K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S 15
{e} R em o ve ftline in s e rt.
15-17
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
(2 ) C le a n in g a n d In s p e c tio n
C8988B
15-18
INTAKE AND EXHAUST - SERVICE PROCEDURES 15
(a ) C le a n in g
T u rb o c h a rg e r m a n u fa ctu re rs use a b la s tin g e q u ip
m e n t fo r cleaning parts at th e ir w o rk s h o p s . As an
a lte rn a tive e ffective m e th o d fo r o v e rh a u l at the
d ealer's w o rksh o p , use the fo llo w in g procedures.
W hen a c o m m e rc ia lly a va ila b le neutral d e te rg e n t is
used fo r cleaning, m ake sure th a t it does n o t co nta in
co rro sive co m p o n e n t.
M OTE;
(Use c a re So p re v e n t d a m a g e t p arts.
MOTE:
T h e b ea rin g housing and tu rb in e w h e e l
s h a ft should be re -im m e rs e d in a non-
in fla m m a b le d e te rg e n t a fte r S tep 4). A fter
d ep o sits have b een re m o ve d , blow co m
p ressed air.
15-19
15 IN T A K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S
C9034A
NOTE:
Do not c o rre c t b u t re p la c e a b en t sh a ft.
15-20
INTAKE AND EXHAUST - SERVICE PROCEDURES 15
5) Insert
(3 ) R e a s s e m b ly
15-21
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
^ T E s
1. W hen m ounting pisto n ring to th e th ru s t
s le e v e , en s u re th a t th e ring is not e x
panded and ring ends a re not tw is te d .
2. Df th e piston ring is to be re p la c e d w ith a
n e w one, be sure to re p la c e also th e
th ru s t s le e v e and s h a ft a n il tu rb in e Install th e snap ring to the bearing hou sin g w ith its
w h e e l w ith n e w ones. ta p e r up.
A fte r in s ta lla tio n , using a s c re w d riv e r d rive the snap
ring in to the g ro o v e in the bea rin g hou sin g by
h u m m e rin g .
M OTE:
1. R e ta in th e snap ring fey hand to p reve n t
it fro m springing out w h en slipping off
th e snap ring p liers.
2. S p e c ia l c a re m ust be e x e rc is e d , w hen
ta p p in g th e snap ring in to position, to
p re v e n t d a m a g e to th e bearin g housing
fey th e s c re w d riv e r.
15-22
IN TA K E A N D EXHAUST - S E R V IC E P R O C E D U R E S 05
(c) M e a s u re m e n t off c le a ra n c e b e tw e e n 2) Coat th re ad s in the sh a ft and tu rb in e w h e e l w ith
sh aft and tu rb in e w h e e l and tu rb in e m o ly b d e n u m d is u lfid e base grease (NLGI N o .2) Li
housing s o a p a n d m o u n tth e c o m p re s s o r w he el o n to th e shaft.
3) H old in g th e boss on the tu rb in e w he el side,
tig h te n the c o m p re s s o r w he el lock n u t to the specified
to rq ue .
M OTE;
S e t th e bearing housing c a re fu lly to p re
ven t d a m a g e on th e tu rb in e wSneel blades-
(d) In s ta lla tio n off c o m p res so r w h e e l (e) Set a dia l gauge on the sh aft and tu rb in e w heel
end.
W ith c o m p re s s o r w h e e l m o ve d in th e axial d ire ctio n ,
m easure the end play. If the p lay is o u t o f sp ecifica
tio n , d isassem ble and check to locate the cause.
U sing tw o thickness gauges, m easure the clearance (h) In s ta lla tio n of tu rb in e housing and co m
b etw een the tu rb in e back p late and tu rb in e w he el pressor cotter
back surface. If th e clearance is o u t o f sp e cifica tio n ,
d isa ssem b le and check to locate the cause.
NO TE:
lie sure to use tw o th ic k n e s s g au ges and
ta k e m e a s u re m e n t a t th e tip of th e blad es.
(g) S h aft and tu rb in e w h e e l to co m p res so r
cotter c le a ra n c e
Check by the fo llo w in g pro ced ures. 2) H am m er the c o u p lin g assem bly all around.
3) T ig h te n again the c o u p lin g assem bly to specified
1) M ove up and d o w n the co m p re s s o r w he el to
to rq ue .
m easure ru n o u t (R)
4) A fte r reassem bly, tu rn the tu rb in e w heel and
MOTE: co m p re sso r w he el by hand and check fo r sm o o th
0@ not m e a s u re runou t by turnin g th e ro ta tion .
co m p res so r w h e e l. If the w heels tu rn h ea vily, o r b in d , d isassem ble, and
2) M easure c o m p re sso r co ve r insid e d ia m e te r (D) locate the cause o f tro u b le .
and co m p re sso r w he el o u tsid e d ia m e te r (d) at places
ind icate d in the illu s tra tio n .
3) C alculate the clearance by th e e q u a tio n given
b elow .
If it is o u t o f sp e cifica tio n , d isa ssem b le and check
again.
Clearance = 1/2(D - d - R)
15-24
IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES 15
5 .4 .2 4LF Typ e T u rb o c h a rg e r
See pages d e scrib in g the TD08 tu rb o c h a rg e r fo r
disa ssem b ly, in sp e ctio n , clea nin g and rea ssem bly
procedures.
NOTE:
1 . M a k e a lig n m e n t m a rk s to c la rify th e p o s itio n a l r e la 2. T h e c o m p re s s o r w h e e l a n d tu rb in e w h e e l b la d e s a re
tio n s h ip s a m o n g th e c o m p re s s o r c o v e r, b e a rin g h o u s e a s ily b e n t. U s e c a re n o t to a llo w th e m to fa ll a n d n ot
ing a n d tu rb in e h o u sin g b e fo re d is a s s e m b ly . to s tr ik e th e m .
3. Do n o t re m o v e th e tw o p in s of th e b e a rin g h ou sin g.
B4265A
15-25
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
(2 ) C le a n in g a n d (In s p e ctio n
15-26
IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES 15
flai M e a s u re m e n t of piston ring groove (b) M e a s u re m e n t off flin g e r s le e v e groove
w id th w id th
Install a n ew p iston rin g in th e p isto n ring g ro o ve and M easure the p iston rin g g ro o v e w id th o f the flin g e r
m easure th e clearance. sleeve.
If the reading is m o re th an the lim it, replace th e sh aft If th e rea din g is m ore th an the lim it, replace the
and tu rb in e w heel. flin g e r sleeve.
15-27
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
(3 ) Reassreiis8y
B4268A
15-28
IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES 15
A ssem bly P ro c ed u re (e]| M easuring c le a ra n c e s b e tw e e n sh aft
(a) In s ta llin g snap rings and tu rb in e w h e e l and tu rb in e housing,
and co m p resso r w h e e l and com pressor
cower in d ia m e tric a l d ire c tio n
MOTls
M easure each clearance w ith a thickness gauge to
QnstaDII e a c h snap ring w ith its round side
check th a t it is w ith in the n o m in a l value.
to w a rd th e b earin g .
MOTEs
(b) In s ta llin g th ru s t bearin g
W hen a c le a ra n c e is to be m eas u red , press
th e s h a ft in th e a x ia l d ire c tio n to m in im ize
th e c le a ra n c e .
15-29
15 INTAKE AND EXHAUST - SERVICE PROCEDURES
5 .4 .3 3 L M T y p e T urbocharges-
See pages d e scrib in g th e TD08 tu rb o c h a rg e r fo r
d isa ssem b ly, insp e ctio n , clea nin g and reassem bly
procedures.
(1 ) D is a s s e m b ly
Interference w ith
co m pre sso r w heel
2
>
Blade bends,
dam age, c o rrosio n ,
m arks o f interference
on back surface &
Interference w ith
tu rb in e w he e l, dam age
Interference w ith
tu rb in e w he e l, cracks
due to overheat,
12 p itc h in g , d e fo rm a tio n
Blade bends, dam age
c o rrosio n , m arks of
interfe re n ce on back surface,
dam aged seal rin g g ro o ve
N O TE :
1. B e fo re d is a s s e m b ly , m a k e a lig n m e n t m a rk s to in d i
c a te th e p o s itio n a l re la tio n s h ip s a m o n g th e c o m p re s s
o r c o v e r, b e a rin g h ou sin g and tu rb in e h o u sin g .
2. T h e c o m p re s s o r w h e e l a n d tu rb in e w h e e l b la d e s a re
e a s ily b e n t. U s e c a re n o t to a llo w th e m to fa ll a n d n o t
to s tr ik e th e m .
3. Do n o t re m o v e th e tw o p in s o f th e b e a rin g h o u s in g .
B9029A
15-30
IN TA K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S 15
D isassem b ly P ro c ed u re
MOTE:
0 not drop and s trik e th e compresses'
w h e e l and tu rb in e w h e e l, as th e ir blades
a re re a d ily b en t.
15-31
15 IN TA K E A N D E X H A U S T - S E R V IC E P R O C E D U R E S
(2 ) C le a n in g a n d (In s p e ctio n
N O TE :
The p a rts m ay be c le a n e d by use of a b la s t
e q u ip m e n t o r a n y o th e r e ffe c tiv e m e th o d s , b u t a non-
c o rro s iv e n e u tra l d e te rg e n t sho uld b e u se d .
B9034B
15-32
IN T A K E A N D EXHAUST - SERVJCE P R O C E D U R E S 15
(3) Reassembly
13 A p p ly e ngine o il.
17 to 20 Nm
(1.73 to 2.07 k g fm ) '
T u rb in e backing p late to
sh aft and tu rb in e w he e l clearance
NV 0.74 to 1.55
< A s s e m b ly se quence>
Gasket
11 14 13 12 15 do:
15 5 - ,1
A p p ly engine o il.
B ronze side to w ard
A p p ly grease or o il co m pre sso r w heel For parts w ith an e ncircled num ber,
to socket p o rtio n . re fe r to R eassem bly Procedure th a t fo llo w s .
NOTE:
1. T h e p is to n rin g sh o u ld a lw a y s b e re p la c e d w ith a n e w
o n e . S in c e it is e a s ily b ro k e n , do n o t o p e n it m o re th a n
n e c e s s a ry .
2. A p p ly e n g in e oil to a ll s lid in g s u rfa c e s b e fo re in s ta lla
tio n .
3. W h en th e c o m p re s s o r c o v e r and tu rb in e h o u s in g a re
in s ta lle d , m a k e sure th a t th e ir a lig n m e n t m a rk s a re in
a lig n m e n t w ith th e m a rk s on th e b e a rin g h o u sin g .
B9037A
15-33
15 IN T A K E A N D EXHAUST - S E R V IC E PROCEDURES
R e assem b ly P ro c ed u re
15-34
INTAKE AND EXHAUST - SERVICE PROCEDURES 15
S .5 A F T E R C O O LE R
5 .5 . H D is a s s e m b ly , In s p e c tio n a n d R e a s s e m b ly
5 .5 .2 A ir-p re s s u re T e s t
C on du ct th e a ir-pressu re te st to check fo r w a te r leaks
due to d am aged core. To check, a p p ly an a ir pressure
o f 195 kPa (2 kg f/cm 2) to the core. Replace the core if it
is leaking a ir or o th e rw is e defective.
M OTE?
M e y e r a p p ly p re s s u re o y e r s p e c ific a tio n .
15-35
15 INTAKE AND EXHAUST - TROUBLESHOOTING
6. TR O U B LES H O O TIN G
L ow o u tp u t In su fficie n t intake a ir
Loaded a ir clea n e r e le m e n t Clean
o D efective tu rb o ch a rg e r
T u rb o ch a rg e r ro ta tio n failu re
L ow exhaust e fficie n cy
D eform e d fro n t pipe, m u ffle r a n d /or tail pipe Replace
(large exha u st resistance)
Q D efective tu rb o ch a rg e r
D efective tu rb o c h a rg e r
Oil leaks due to w o rn p iston rin g , a n d /or in s e rt Replace
15-36
16
ENGINE ELECTRICAL.
CQ W TE1TS
16-1
16 ENGINE ELECTRICAL - GENERAL
1. GENERAL
16-2
E N G IN E E L E C T R IC A L - GENERAL 16
1.1 S ta rte r (2) O verrunning C lu tch
16-3
16 ENGINE ELECTRICAL - GENERAL
(3 ) O p e ra tio n
B3708B
W hen the p in io n com es in to c o m p le te m esh w ith th e
W h ile th e sta rte r sw itch is ON, cu rre n t flo w s fro m the rin g gear, th e c o n ta c t " P i" closes and the large
c u rre n t o f the b a tte ry d ire c tly flo w s to the m o to r
te rm in a l "S W " o f the sta rte r relay to the te rm in a l "L "
and closes the co n ta ct "P 2". se ction to tu rn th e p in io n p o w e rfu lly .
W hen the co n ta ct "P 2 " closes, cu rre n t fro m the In th is c o n d itio n , no c u rre n t flo w s to the p u ll-in co il.
b a tte ry flo w s fro m th e te rm in a l " S " o f the m a g n e tic The p lu n g e r is reta ine d by the h o ld in g coil alone.
16-4
E N G IN E E L E C T R IC A L - GENERAL 16
1 .2 ALTERNATOR
(1 )3 0 A , 40A , 8 0 A A lte rn a to r
16-5
16 ENGINE ELECTRICAL - GENERAL
16-6
E N G IN E E L E C T R IC A L - GENERAL 16
2) S tartin g th e engine (2 )6 0 A A lte rn a to r
A lte rn a to r
Starter sw itch
W hen the engine is started and the a lte rn a to r starts The 60A a lte rn a to r is an open typ e thre e-p ha se
g en eratio n so th a t the vo lta g e at the a lte rn a to r "B " a lte rn a to r. The th re e-p ha se AC g enerated in the sta to r
te rm in a l becom es h ig h e r than the b a tte ry vo lta g e , the coll is co n ve rte d into DC by the s ilic o n diodes.
cu rre n t flo w s as sh o w n below . A to ta l o f 12 dio de s (6 on the p o s itiv e side and 6 on
the n eg ative side) are housed in 6 heat sinks, tw o in
each heat sink.
The a lte rn a to r g enerated vo lta g e is c o n tro lle d by th e
re g u la to r.
16-7
16 ENGINE ELECTRICAL - GENERAL
O p e ra tio n
B1454A
(1) W hen the sta rte r sw itch is set to ON, c u rre n t flo w (3) W hen th e pulse fre q u e n c y at te rm in a l "P " e x
fro m the sta rte r relay to te rm in a l " S " and to te rm in a l ceeds th e sp e cifie d va lu e, c o n tin u ity betw een te rm in
"E " o f the safety relay, c lo sin g c o n ta ct Pi. The charge als " S " and "E " is lost. Then, the sta rter does n ot
lam p also illu m in a te s if p ro vid e d . o perate even if th e sta rte r s w itc h is set to ON w h ile
(2) As the sta rter runs and the e n g in e sta rts ru n n in g , the e n g in e is ru n n in g .
pulses o f fre q u e n cy 1/1 Oth o f the a lte rn a to r speed
appear at te rm in a l "P " o f the a lte rn a to r. The charge
lam p goes out.
16-8
E N G IN E E L E C T R IC A L - GENERAL 16
1 .4 R E G U L A T O R {M o d e l R 7 T 0 1 0 7 1 ) Its fu n c tio n s in c lu d e :
(1) V oltage re g u la to r
M a in ta in s vo lta g e g enerated by the g e n e ra to r c o n
stant
peraftiora o R e g u la to r
S afety relay T ra n s is to r
B1891A
(1) The b a tte ry sw itch in ON p o s itio n causes fie ld p o w e r, causing a c u rre n t to flo w in the c o il VC i in the
cu rre n t to flo w in the c irc u it as fo llo w s : fo llo w in g sequence:
B attery * B a tte ry sw itch * R eg u lator IG te rm in a l * R esistor Ri * V oltage A lte rn a to r N te rm in a l R eg u lator N te rm in a l * Coil VC i > G round
re g u la to r K te rm in a l V o lta ge re g u la to r F te rm in a l A lte rn a to r F te rm in a l
> Field c o il G ro u n d
As the coil VC i is energized, th e c o n ta ct Pi is opened.
(2) W hen the sta rte r sw itch is set to ON, th e sta rter In th is state, se ttin g the sta rte r s w itc h to ON w ith the
relay coil is energized w ith its co n ta ct closed. W hen e n g in e in o p e ra tio n leaves th e s ta rte r ino pe rative .
th e sta rter cranks the e ngine, the a lte rn a to r generates
16-9
16 ENGINE ELECTRICAL - GENERAL
1 .6 A P T O M A T ie S T O P BEWSCE
If th e c o o la n t te m p e ra tu re rises o r the o il pressure
fa lls w h ile the e n g in e is ru n n in g , th is device operates
the sto p leve r o f the in je c tio n p u m p g o v e rn o r to cut
fu el s u p p ly and a u to m a tic a lly stops the engine.
16-10
ENGINE ELECTRICAL - GENERAL
So le n oid relay
VRi
S)<@
A lte rn a to r
Solenoid
T herm o sw itch
i---------------- Stop 'j -
^switch H
Pressure sw itch l"'"'
r e la y H ^
Battery sw itch
1
Oil pressure
B4926C
1) W hen the b a tte ry sw itch is placed at "O N ", pressure rises as the e n g in e speed increases, and the
cu rre n t flo w s fro m the so le n o id relay (B) to the RY coil co nta ct o f the oil pre ssure sw itch is opened and no
and applies the vo lta g e to the co lle c to rs o f TR4 and vo lta g e a pp lie d fro m R4 to T R i. In th is c o n d itio n , the
TR5 but RY does n ot operate, as th ere is no in p u t to a lte rn a to r vo lta g e is a pp lie d up to th e base o f TRi
a pp lie d fro m the te rm in a l "L " o f the a lte rn a to r R4 -r> C and E o f TRi Base o f TR 2 G round
th ro u g h VRi to ZD i (Zener vo lta g e 24V), and charge
b egins w ith the tim e co n sta n t (Oil pressure tim e r)
L ---- * C and E o f TR 2 -------- ^
d e te rm in e d by VRi and C l. (At th is p o in t the eng in e 2) S o le n o id re la y () * RY c o il * C and E o f TR 4 and TRs Rs > G round
16-11
16 ENGINE ELECTRICAL - GENERAL
(2 ) E n e rg iz e -to -ru n T y p e
S o lenoid relay
B4927B
16-12
E N G IN E E L E C T R IC A L - G E N E R A L , S P E C IF IC A T IO N S 16
3) W hen the RY contacts tu rn ON: This causes the c u rre n t to flo w fro m the s ta rte r (AC)
C urren t flo w s fro m so le n o id relay to RY, so le no id s w itc h to o il pressure sw itc h , th e rm o s w itch , so le n o id
relay , and the so le n o id , a ctiva tin g the so le n o id and r e la y , R Y h o ld in g co I H , and to g ro u n d , keeping the
s ta rtin g the engine. RY co nta cts in ON state.
4) As the engine starts and sta rte r sw itch is placed in (to) A u to m a tic s to p c ir c u it
the ON p o sitio n , vo lta g e to the so le n o id relay is cut
W hen th e th e rm o s w itc h and oil pressure sw itch
o ff; h ow eve r, TR i and TR2 stay ON fo r a p p ro x im a te ly
detect an a b n o rm a l c o n d itio n , each sw itch tu rn s OFF
a n o th e r 30 seconds by th e d isch arg e c u rre n t o f the
and the RY contacts open, d e a c tiv a tin g the so le n o id
ca pa citor C. D uring ca p a cito r C's d isch a rg in g , the oil
and s to p p in g the engine.
pressure b u ild s up as the eng in e speed increases,
causing the o il pressure sw itch to tu rn ON. (c ) P u s h b u tto n s to p
To s to p the eng in e d u rin g o p e ra tio n , o perate the stop
s w itch , and the stop o p e ra tio n is p e rfo rm e d ju s t as
w he n the a u to m a tic sto p is p e rfo rm e d .
2 SPECSF1CTDOWS
S tarter Type Front nose e le c tro m a g n e tic push-in ty p e re d u c tio n sta rte r
(M itsu b ish i Electric
Corp. products) M o de l M3T95082 M 5T50276 M 5T50277 M5T50279
O u tp u t 24V-5kW 24V-6kW
M odel A2T A2T A2T A4T A4T A4T A4T A6T A6T
72987 72986 73387 57986 57987 65772 65773 75386 75387
Fuse ca pa city 91 A
16-13
16 ENGINE ELECTRICAL - SPECIFICATIONS
SERVICE STANDARDS
A u to m a tic S to p S y s te m [O p tio n ]
Item S p ecification
M5T50276 4 to 6
M5T50277
16-14
E N G IN E E L E C T R IC A L - S E R V IC E S T A N D A R D S 16
U n it: m m
16-15
16 E N G IN E E L E C T R IC A L - S E R V IC E S T A N D A R D S
U n it: m m
H o ld in g co il c u rre n t 5A o r less -
H o ld in g c o il current 1A o r less -
3 .2 T IG H T E N IN G T O R Q U E T A B L E
16-16
E N G IN E E L E C T R IC A L - S P E C IA L T O O L ,
S E R V IC E P R O C E D U R E S m
4 . S P E C IA L T O O L
U n it: m m
16-17
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
5 .1 .2 D is a s s e m b ly
<M 3T>
< D is a s s e m b ly se q u e n c e >
Part m arked w ith * should not be rem oved unless defects are
evident.
For parts w ith an encircled num ber, refer to D isassem bly Procedure
that fo llo w s.
B1104B
16-18
E N G IN E E L E C T R IC A L - S E R V IC E P R O C E D U R E S 16
<M 5T>
Roughened co m m u ta to r surface,
Gear shaft thrust seizure, ridge wear,
gap w o rn dam aged gear
NV 0.1 to 0.5 Rotating
------------------------------ co n d itio n 6
M ounted c o n d itio n of
ball and fie ld coil
< D is a s s e m b ly se q u e n c e >
16-19
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
w ash ers to o b ta in co rrect gap. [For a d ju s tm e n t p ro ce side. Then rem ove the ring and rem ove the o v e rru n
16-20
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
M OTE:
O verrunning clutch
B2959A
(c) Rem ove the ring fro m the rin g g ro o ve o f the gear To rem ove the brush s p rin g , firs t release the brush
sh ^ft. Rem ove the p in io n s to p p e r fro m the gear shaft. sp ring and rem ove the brush.
16-21
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
5 .1 .3 In s p e c tio n
Item NV L
Item NV L
NV ... N om inal Value
L ... L im it Brush spring 25 to 34 N 18 N
tension (2.5 to 3.5 kgf) (1.8 kgf)
M5T 23 14
Insulation test - -
B1104E
16-22
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
In sp ec tio n P rocedure (c) In s p e c tio n of co m m u ta to r
The insp ectio n p rocedure fo r the M3T95082 s ta rte r is
described. On the o the r sta rters, o n ly the differen ce s
are jo in tly described.
{I ) A rm a tu re In s p e c tio n
(a) oil short c irc u it te s t
D7507A
M easure the ru n o u t o f c o m m u ta to r u s in g a d ia lg a u g e
and tu rn in g the a rm a tu re by hand.
If the ru n o u t exceeds the lim it, correct, ensu rin g th a t
the O.D. lim it is n o t exceeded.
D7505A If the c o m m u ta to r surface is rough d e v e lo p in g ridge
w ear, c o rre ct w ith sandpaper (No. 300 to 500).
Place th e a rm a tu re on a g ro w le r tester. H old a piece o f A fte r co rre c tio n , m ake sure to check the ru n o u t again.
iro n in parallel w ith the a rm a tu re and s lo w ly tu rn
{d} C o m m u ta to r O.D.
a rm a tu re by hand. If the iro n piece is attracte d or
vib ra te s, it m eans th ere is a s h o rt circu it. Replace the
arm ature.
16-23
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
(b )C o il g ro u n d te s t
(3 ) in s p e c tio n of B ru sh
(2 ) In s p e c tio n o f F ie ld C o il
(a ) C o il o p e n c ir c u it te s t
N O TE :
C o rre c t th e b ru s h c o n ta c t s u rfa c e t a
D7510B c u rv e o f th e c o m m u ta to r.
16-24
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
(4) In s p e c tio n off Brush Spring (6) In sp ec tio n off M a g n e tic S w itc h
(a) Cool open c irc u it te s t
16-25
ENGINE ELECTRICAL - SERVICE PROCEDURES
Check th a t th ere is no c o n tin u ity across "B " and " M " Install the gear sh a ft to the o v e rru n n in g clutch and
te rm in a ls. If there is, replace the m ag ne tic sw itch. check to see if th e gear sh aft tu rn s s m o o th ly w hen
tu rn e d clockw ise (in the d rive d ire c tio n ) and locks
(c ) L o o s e c o n ta c t te s t
w he n tu rn e d co u n te rclo ckw ise .
If any unusual c o n d itio n is noted, replace the o v e rru n
ning clutch.
(8) A d ju s tm en t f G e a r S h a ft T h ru s t G ap
(Rem oval)
If the bearing o f the gear sh aft Is defe ctive, p u t a pin the a rm ature.
(Installatio n)
5 .1 .4 R e a s s e m b ly
<M 3T>
o r equivalent
*4 : MOLYCOAT AS-19 (D ow Coning) 6>7>8-------
o r equivalent
3 >5>4>(i V
D7548C
16-28
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES m
<M 5T>
B9073B
16-29
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
R e a s s e m b ly P ro c e d u re
The reassem bly pro ced ure fo r the M 3T95082 s ta rte r is
described. On the o th e r starters, o n ly the differen ce s
are described.
(1 ) R e a s s e m b ly th e G e a r S h a ft, O v e rru n
nin g C lu tc h , a n d G e a r B r a c k e t in th e
F o llo w in g W a y
(2 ) In s ta lla tio n f L e v e r
(a ) C o lla r fix e d ty p e < M 3 T >
16-30
ENGINE ELECTRICAL - SERVICE PROCEDURES 16
(b) Pin fin e d ty p e < M 5 T > (4) Installation of M agnetic S w itch
16-31
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
(5) In s ta lla tio n of Y o k e A ssem bly (a) W ire the reassem bled sta rte r as s h o w n above.
(b) T urn ON sw itche s and K2 to p ro je c t the p in io n .
(c) T urn OFF s w itc h K2 to s to p p in io n fro m ro ta tin g .
M@YEs
W hen th e yo ke ass em b ly and c e n te r brack
M odel N om inal Value
e t are m o unted, th e lo c a tin g notch should
M3T95082 1 to 3
be alig n ed w ith th e p ro je c tio n . M5T50279
M5T50276 4 to 6
5 .1 .5 In s p e c tio n and A d ju s tm e n t a fte r M5T50277
R e assem b ly
(1) In s p e c tio n of Pinion Gap B0054D
16-32
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
MOTE:
1. Use a w ire as th ic k as possible and
sec u re eac h co n n e c tio n firm ly.
2. Apply v o lta g e g rad u ally from QV up to
24V .
(b) M easure the c u rre n t and ro ta tin g speed w h e n the
specified vo lta g e is app lie d. If the m e a su re m e n t is o u t
o f sp e c ific a tio n , replace the starter.
M easure the ro ta tin g speed by illu m in a tin g the p in io n
w ith strob e light.
W ashers
0.25, 0.5, 1.0 m m (c) G ra d u a lly increase the vo lta g e fro m 0V and
m easure the vo lta g e w h e n the p in io n sp rin g s o u t and
{2) In sp ec tio n of Mo-load C h a ra c te ris tic s
turns.
and M a g n e tic S w itc h O p eratin g V o l
If the v o lta g e exceeds the s p e c ific a tio n , replace the
ta g e
starter.
16-33
16 E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES
5 .2 STARTER RELAY
In s p e c tio n P ro c e d u re
16-34
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 96
5 .3 .2 D isassem bly
< D is a s s e m b ly se q u e n c e >
16-35
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
D isassem bly P ro c ed u re
(1 9 S e p a ra tio n of Front B ra c k e t A ssem bly
from P e a r B ra c k e t A ssem bly
MOTE:
MOTE:
1. The re a r bearin g is tig h tly fitte d . B efore
se p a ra tio n , th e re fo re , p re h e a t th e b e a r
ing box of th e re a r b ra c k e t by an air
dryer to fa c ilita te s e p a ra tio n .
16-36
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
{3} R em oval of Station* Coil (4) S e p a ra tio n of R e c tifie r < 8 0 A >
B3909A
MOTES
W hen unso ld erin g , finish 54 in a sh o rt tim e
(less th an 5 seco n d s) w ith a so ldering iron.
MOTEs
W hen unsoldering, finish iti in a short tim e
(less than 5 seconds) w ith a soldering iron.
16-37
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
5 .3 .3 In s p e c tio n
D escription NV L
G round test - -
B3907F
16-38
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
In sp ec tio n (Procedure (2) In s p e c tio n of IRotor
f 11) In s p e c tio n of S ta to r (a) C o n tin u ity b e tw e e n slip ring and c o re
(a) C o n tin u ity across leads
there is no c o n tin u ity in d ic a tin g a broken w ire , If th ere is, replace the ro to r as it is g ro u n d e d .
Check th a t th ere is c o n tin u ity across the s ta to r leads ro to r If the resistance is n o t w ith in the sp ecificatio n.
and core.
If there is, replace the sta to r as it is g ro u n d e d .
16-39
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
M easure the slip rin g O.D. If the slip rin g has rou gh
surface o r is u n e v e n ly w o rn , c o rre c t w ith sand pa pe r
o r lathe.
C orrectio n m u st be m ade w ith in the lim it o f slip ring
O.D.
D8062A
16-40
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
(a) Measurement of diode mounted to heat
sink (6 places)
M OTE:
When soldering or unsoldering, work
quickly (within about 5 seconds} with a
soldering iron.
(4) Inspection of Rectifier
M easure resistance o f each d iode. M easure both
w h e n w ith the c irc u it te ste r (+) p ro be a pp lie d to
the d io d e and w he n w ith the (-) probe a p p lie d to
th e diode.
a If resistance is in fin ite in b oth cases, the d io de M easure b etw een the heat sink and s ta to r coil lead
is open. co nn ectio ns.
e If resistance is close to zero in b oth cases, the (b) Measurement of diode trio (3 places)
d io d e is shorted.
16-41
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
16-42
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
|b) ^placement of rear bearings (Insta lla tio n )
(Rem oval)
Rear bearing
Use care not to cause damage to the slip fittin g g ro o v e o f th e bea rin g fa cing th e ro to r fie ld coil
16-43
16 ENQBiXJE E L E C T R IC A L - S E R V IC E PROCEDURES
5.3=4 R e asse m b ly
<80A alternator>
Components
1: 3, 3A <80A only>, 4, 5, 6, 7
12: 13, 14, 15
16: 17, 18, 19, 20
<Assem bly sequence>
16 (20 -> 19 18 -> 17) -> @ (15 -> 14 -> @) -> 8
(11 -> 10 -> 9) -> 2 -> 1 ( 7 > 6 > 5 > (3)A<80A only>)
On components marked o, refer to the follow ing reassembly
procedure.
B2990M
16-44
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
Reassembly Procedure Installation of Front Bracket Assembly and
(1) Installation off Rectifier {SQA Alterna Rear Bracket Assembly
tor)
W hen the re ctifie rs are to be co nn ecte d to g e th e r by the bru sh hole fro m the rear o f the rear bracket to fix
as the re ctifie rs m o u n te d to the rear bracket. (b) N o tin g the s p rin g p o s itio n o f the ro to r bearing
m o u n te d to the fr o n t bracket side, install the rear
MOTE:
bracket assem bly.
When soldering, finish it in a short time
{ess than 5 seconds). M OTE;
After completion of reassembly, be sure to
(2) Installation of Spring
remove the pin and close the hole.
16-45
E N G IN E E L E C T R iC A L - S E R V IC E PROCEDURES
D8074A
D8075B
(e) O p e ra tin g th e a lte rn a to r w ith its " B " and " L "
te rm in a ls sh o rte d results in the d am aged d io d e trio .
ENGINE ELECTRICAL - SERVICE PROCEDURES 16
2) W h ile g ra d u a lly increa sing the a lte rn a to r speed
and red ucin g the load resistance, m easure the c u rre n t
value w ith the specified te rm in a l vo lta g e and speed.
If the m ea su re m e n t is b e lo w the sp e c ific a tio n , check
a lte rn a to r parts.
Voltmeter
83623B
Kl@T:
The omvehicie test: is an easier way of
inspection; the test bench inspection is
necessary for more accurate results.
{3} Inspection of Regulator
(a) Test bench inspection
N o m in a l value 28 to 29V
16-48
ENGINE ELECTRICAL - SERVICE PROCEDURES 16
5.4 6QA ALTERNATOR
5.4.1 Removal and Installation
[R efer to 5.3.1.]
5.4.2 Disassembly
< D is a s s e m b ly se q u e n ce >
B4539A
16-49
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
5.4.3 finspectioira
B4539B
16-50
E N G IN E E L E C T R IC A L - S E R V IC E P R O C E D U R E S 16
5 -4 .4 R e a s s e m b ly
18
C o m p o n e n ts
2: 3, 4, 5
9: 11, 12, 13, 15, 16, 17
21: 22, 23
24: 25, 26, 27
< A s s e m b ly s e q u e n c e >
24 (27 > 26 > 25) >21 (23 22) 18 (20 19) 10 9 (17 16
> 1 5 > 1 3 1 2 1 1 ) 1 4 > 8 > 7 6 2 ( 5 > 4 * 3) > 1
B4543A
16-51
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
5 = 4 .5 In s p e c tio n a ra d A d ju s tm e n t a fte r
R e a s s e m b ly
(1 ) S im p le P r o c e d u r e s f o r C h e c k in g A lt e r
n a to r fro m O u ts id e I n s p e c tio n b y C o n
tin u ity T e s te r
NOTE: L o a d te s t
T h e c o l o r s in p a r e n t h e s e s s h o w t h e c o l o r s Increase the load resistance R to a m a x im u m and
o f t e s t e r le a d r o d s . A ll th r e e d io d e s a re close the sw itche s K i and 2 . M easure the c u rre n t
r a r e ly o p e n - c ir c u it e d . value w h e n the a lte rn a to r reaches the specified
E a c h d io d e s h o u ld b e t e s t e d t o d e t e r m in e speed.
w h e t h e r i t is g o o d o r d e fe c tiv e .
N o m in a l value
(w hen a lte rn a to r is cold)
T e rm ina l vo ltag e 28 V
C urrent 60 A o r m ore
(2 ) P e r fo r m a n c e T e s t
16-52
E N G IN E E L E C T R IC A L - S E R V IC E P R O C E D U R E S 16
5 .5 SAFETY R E L A Y [M o d e l R 8 T 3 Q 1 7 1 ]
In s p e c tio n
( t ) O im - v e liic le T e s t
( 2 ) O f f f - v e h ic le T e s t
The resistance valve b etw een te rm in a ls "R " and " L "
shall be w ith in sp ecified range.
16-53
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
In s p e c tio n 5 .7 .1 In ta k e A ir H e a te r
(1 ) R e m o v a l a n d In s t a lla t io n
(2 ) In s p e c tio n
A ir heater
f t ) R e g u la te d V o lt a g e o f V o lt a g e R e g u la to r
M OTE:
T h is r e g u la t o r u s e s a t r a n s is t o r t y p e v o lt
age r e g u la to r , so th e r e g u la te d v o lt a g e
c a n n o t b e c h a n g e d . Df t h e r e g u l a t e d v o l t
Battery
a g e is o u t o f t h e n o m in a l v a lu e , r e p la c e t h e
r e g u la to r .
D8803C
(2 ) V o lta g e R e g u la to r R e g u la te d V o lta g e
M e a s u r in g P ro c e d u re P erform the fo llo w in g in sp e ctio n and check the
fu n c tio n o f each part o r the w irin g if necessary.
(a) Increase the e n g in e speed u n til the a lte rn a to r
(a) T im e req uired before in d ic a to r becom es red -h o t:
reaches the sp ecified speed.
(b) C on tinu e ch a rg in g u n til the ch a rg in g c u rre n t to S tandard tim e
th e b a tte ry fa lls to less th an 10 A (the b a tte ry fu lly 40 to 60 seconds
charged). (b) Check each te rm in a l o f the air heater fo r lo o se
(c) M easure th e vo lta g e across th e A and E te rm in a ls. ness and the heater e le m e n t fo r d am age and c o n ta ct
(d) M easure th e vo lta g e across the A te rm in a l and the w ith o th e r parts.
n eg ative te rm in a l o f the b a tte ry and check to ensure
th a t th ere is no d iffe re n ce b etw een the va lu e and the
va lu e m easured u n d e r Item (c).
16-54
E N G IN E E L E C T R IC A L - S E R V IC E P R O C E D U R E S 16
5 .7 .2 IH IeaeF R e la y 5 .8 A U T O M A T IC S T O P DEVDC1
In s p e c tio n 5 .8 .1 E n e r g iz e - to - s to p T y p e
(1 ) S to p S o le n o id
16-55
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
(2) Solenoid Relay A fte r the tests o f the above ite m s 1) and 2), a llo w 5
m in u te s before m aking retests. It takes 5 m in u te s
(a) Unit test
befo re the ca p a c ito r Ci w h ic h is an e le m e n t o f the
tim e co n sta n t o f the o il pressure tim e r fin ish e s
d isch arg in g.
2) Stop timer
Set the snap sw itch B to OFF 5 seconds a fte r the
s o le n o id has been operated. A t th e sam e tim e, using
a sto p w atch, m easure the tim e req uired befo re the
so le n o id is reset.
The snap sw itch B is set to OFF 5 seconds after
o p e ra tio n o f the so le n o id because if the so le n o id is
ope ra te d, it takes 5 seconds before th e a lte rn a to r
vo lta g e disappears.
3 ) M anuaS s to p tim e r
16-56
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
(b) O n -v e h ic le smspecSiora
Check th e so le n o id relay accordin g to the fo llo w in g
flo w c h a rts and d e te rm in e w h e th e r it is good or n ot on
the basis o f the te rm in a l vo lta g e , etc, m easured in the
in d iv id u a l states.
16-57
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
D9559A
H I @51 P re s s u re S w itc h
D9562A
16-58
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
5 .8 .2 E n e rg iz e -to -ru n T y p e (2 ) S o le n o id K e la y
(1 ) S to p S o le n o id {a) UraiS to s t
E
B C H s
; r
SW1 SW3 ^ ^SW 2
I Delay tim e
NV 26 to 34 sec. 7 t NV... N om inal Value
D9564A
2) Relay h o ld in g
16-59
16 E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES
(Ib) O n -v e h ie le in s p e c tio n
Check th e so le n o id relay a ccordin g to the fo llo w in g
flo w c h a rt and d e te rm in e w h e th e r it is g oo d o r n o t on
the basis o f the te rm in a l vo lta g e , etc. m easured in the
in d iv id u a l states.
T e rm in a l s ym b o ls d enote th ose o f the so le n o id
relay.
a V oltage 24V m eans th e b a tte ry vo lta g e .
16-60
E N G IN E E L E C T R IC A L - S E R V IC E PROCEDURES 16
P erform m e asu re m e nts w ith e ngine runn in g.
I
16-61
16 ENGINE ELECTRICAL - SERVICE PROCEDURES
Item NV
O perating 93 to 97C
te m p e ra tu re
ON-OFF 7C
difference
D9559B
16-62
ENGINE ELECTRICAL - TROUBLESHOOTING 16
6 . T R O U B L E S H O O T IN G
W o rn , d am aged, b in d in g brush
0 D efective fie ld co il
0 W o rn s lip ring
0 W o rn brush
0 D efective re c tifie r
0 Defective re g u la to r
16-63
16 ENGINE ELECTRICAL - TROUBLESHOOTING
16-64
21
etT H
CONTENTS
C A U T IO N ;
W h e n s e r v ic in g c lu t c h a s s e m b lie s o r c o m p o n e n t s , d o N O T c r e a t e d u s t b y
s a n d in g o r b y c le a n in g c lu t c h p a r ts w it h a d r y b r u s h o r w it h c o m p r e s s e d
a ir . (A w a t e r d a m p e n e d c lo t h s h o u ld b e u s e d ).
T h e c lu t c h d is c c o n t a in s A s b e s to s F ib e r s w h ic h c a n b e c o m e a ir b o r n e if
d u s t is c r e a te d d u r in g s e r v ic e o p e r a t io n s . B r e a t h in g d u s t c o n t a in in g
A s b e s to s F ib e r s m a y c a u s e s e r io u s b o d ily harn.
21-1
21 CLUTCH - GENERAL
1. GEiMEKiAL
E0754A
The clutch is a d ry sin g le disc typ e w h ic h tra n s m its is p e rfo rm e d , th e pressure s p rin g fo rc e causes th e
and disco nn ects e n g in e p o w e r th ro u g h th e clutch pre ssure plate to press th e clutch d isc a g a in st th e
s h ift shaft. e n g in e fly w h e e l to tra n s m it pow er.
W hen the o p e ra tio n fo r clutch d ise n g a g e m e n t is The clutch co nsists o f a clu tch disc, pressure plate and
p e rfo rm e d , the clutch release leve r is pushed. Since release lever assem bly. The clu tch d isc has a w o v e n
th e clutch release leve r p ivo ts ro u n d th e release lever fa cing .
pin in the release lever s u p p o rt p ro v id e d in th e clutch The d riv e system is th e strap d riv e typ e w h ic h uses a
.cover, the pressure sp rin g is co m p re sse d , ca using the s tra p plate b etw e en the clu tch c o v e r and pressure
clutch disc clam pe d betw een the e n g in e fly w h e e l and plate to co u p le th e m . T his system insures sm o o th
pressure plate to becom e free and cuts tra n s m is s io n e n g a g e m e n t and d is e n g a g e m e n t o f the clutch.
o f pow er. W hen the o p e ra tio n fo r clutch e n g a g e m e n t
21-2
CLUTCH - SPECIFICATIONS, SERVICE STANDARDS 21
2. S P E C O F IC A T IO M S
C lutch (O ption]
Item S pecifica tio n
3. SEKVDCE S T A N D A R D S
3.1 SERVBCE STANDARD TABLE
D escription N o m in a l value L im it C orre ctio n and
(Basic d ia m e te r] rem arks
Clutch D epth fro m facing surface to rive t head 2.2 to 2.8 0.2 Replace.
disc
Flatness 0.6 o r less - Replace.
Pressure Flatness o f fric tio n surface 0.05 or less 0.2 C orre ct o r replace.
piafe
Thickness 59.7 to 59.9 56.8 Replace.
C learance betw een strap plate and stra p b o lt |12.2| 0.3 Replace.
0.01 to 0.11
S trap b o lt M 12 x 1.5 39 to 49 (4 to 5)
Pressure p late and lever assem bly m o u n tin g b o lt M 10 x 1.5 32 to 49 (3.3 to 5.0)
21-3
m CLUTCH - S P E C IA L T O O L
4. SPECDAL @[L
U n it: m m
21-4
CLUTCH - SERVICE PROCEDURES 21
5. SERVBCE P R O C E D U R E S NOTE:
5.1 R E M O V A L AMD HIMS T A LL A YOON 1. B e fo re re m o v in g th e c lu tc h , b e s u re to
in s ta ll th e s to p p e r b o lt a n d p la in
(1 ) R e m o v a l
w a s h e r to p re v e n t th e s tra p p la te fro m
b e in g d a m a g e d .
2. U s e th e s to p p e r b o lt (MHO x 1 .2 5 8 5
w ith e ffe c tiv e le n g th 3 0 m m o r m o re )
a n d p la in w a s h e r (fo r M 1 2 th re a d s )
c o m m e r c ia lly a v a ila b le .
(2 ) In s ta lla tio n
NOTE:
W h e n in s ta llin g th e c lu tc h d is c , m a k e sure
th a t it is in s ta lle d in th e c o r r e c t d ire c tio n :
in s ta ll it so th a t its s id e w ith th e p a rt
n u m b e r s ta m p e d is v is ib le .
215
21 CLUTCH - S E R V IC E P R O C E D U R E S
21-6
CLUTCH - S E R V IC E P R O C E D U R E S 21
5.2 CLU TC H PROPER
5.2.1 D isassem bly and In s p e c tio n
V ertical ru no u t
NV 1.0 o r less (C10W41) S tia p b o lt fittin g hole Flatness
1.2 o r less (C12W43) NV 12.21 to 12.22 NV 0.05 o r less
L 1.5 L 12 5 L 0.2
Thickness
NV 59.7 to 59.9
L 56.8 (C10W41) (C12W43)
Installed load Installed load
(Installed le n g th 63) (Installed len g th 63)
NV 1 205 to 1 325 N NV 1 425 to 1 570 N
(122.6 to 135.4 kgf) (145 to 160.2 kgf)
L 1 070 N (109 kgf) L 1 270 N (129 kgf)
S quareness Squareness
NV 3.5 o r less NV 3.2 o r less
L 5.2 L 4.8
<Disassembly sequence>
(ij Clutch disc assembly 9 Release lever pin
(2 ) Strap bolt 10 Return spring
3) Lock bolt 11 Release lever support
(4) Lock plate 12 Release lever pin
( 5) Support nut 13 Release lever subassembly
(6) Clutch cover (with strap plate) 14 Bushing
(7) Pressure spring (15) Pressure plate
8 Spring seat
For parts w ith an e ncircled n u m b e r, refer to D isassem bly and Insp e ction
Procedure th a t fo llo w s .
MOTE:
1. S in c e th e c lu tc h c o v e r a n d p re s s u re p la te a re b a
la n c e d , m a k e a lig n m e n t m a rk s b e fo re d is a s s e m b ly .
2. Do n o t re m o v e th e s tra p p la te .
E0757A
21-7
21 CLUTCH - S E R V IC E P R O C E D U R E S
(a) C om press the pressure s p rin g w ith the s to p p e r M easure the a sse m b ly th ickne ss o f fa cing and the
b olts and, at the sam e tim e , re m o ve th e strap bolts, d epth fro m fa cing surface to riv e t head o r cup head. If
s u p p o rt nuts, and o th e r parts. th e m e a s u re m e n t is b e lo w th e lim it, replace th e clutch
disc assem bly.
{lb} F la tn e s s of c lu tc h disc
21-8
CLUTCH - S E R V IC E P R O C E D U R E S 21
(c) C lu tch disc runout (3) In s p e c tio n of P ressure P la te
(a) M e a s u re m e n t of th ic k n e s s
E0697B
U sing a piano w ire , m easure th e play in the tu rn in g M easure the fla tn e ss o f the pressure plate fric tio n
d ire c tio n o f the clutch disc h ub sp lin es and bearing surface. R egrind o r replace if th e lim it is exceeded.
case clutch shaft. If th e lim it is exceeded, replace the
clutch disc.
21-9
21 CLUTCH - S E R V IC E P R O C E D U R E S
M easure the I.D. o r stra p b o lt fittin g h ole in the M easure the free le n g th , squareness, and installed
pressure plate and, if th e lim it is exceeded, replace. load o f the pressure s p rin g . If th e m ea su re m e n t is
b e lo w the lim it, replace the sp ring .
In s p e c tio n f IReOease Lewes'
21-10
CLUTCH - SERVICE PROCEDURES 21
5 .2 .2 [R eassem b ly a n d A d ju s tm e n t
32 to 49 Nm
(3.3 to 5.0 kgfm)
2
it CiT Tfc.
; .Sv ' 7
' =f.3. 8
9.8 to 15 Nm
icq ||i 2
ja -j (1 to 1.5 kgfm)
'> 13
^ m \ 7 10
5
-is ii ]fy& /y fc y " Strap plate
11
39 to 49 Nm
9 2 (4 to 5 kgfm)
IIIC -fJ p \ .. Strap support washer
12 Strap -S S T
Apply Molybdenum plate Strap plate
disulfide grease.
1 15 6 washer 1 1
<Assembly sequence;
- 12-,
~ 1 19 10 b 765 4 3 2 1
R e a s s e m b ly P ro c e d u re
(1) W h e n e ve r the pressure plate fric tio n surface is m arks and, using th e special to o l, C lutch Installer,
21-11
21 CLUTCH - SERVICE PROCEDURES
(3) W ith th e pressure s p rin g co m p re ssed by the (4) A fte r in s ta llin g the clutch, check th e clutch cover
s to p p e r b olts, in sta ll th e strap b o lt, s u p p o rt n ut, and and release leve r fo r h e ig h t using the special to o l,
o th e r parts. C lutch Lever A lig n e r.
5 .3 B E A R IN G A S E
5 .3 .1 D is a s s e m b ly a n d In s p e c tio n
<Disassembly sequence>
1 Clutch shifter
*2 Clutch release
bearing 7 Clutch release 11 Snap ring bearing
3 Return spring fork 12 Ball bearing 16 Clutch housing
4 Stopper plate 8 Drive shaft front 13 Bearing case
5 Stopper cover
NOTE:
P a rts m a rk e d * s h o u ld n o t b e re m o v e d u n le s s th e y a re to
b e re p la c e d .
E0760A
21-12
CLUTCH - S E R V IC E PROCEDURES 21
5 .3 .2 R easse m b ly
In s ta lla tio n of M eedle R o ller B earing U sing special to o l, the N eedle R oller Bearing Installer,
install the needle ro lle r b e a rin g in the housing.
The needle ro lle r bea rin g sh o u ld be pressed in up to
the sp ecified d im e n s io n w ith the o il seal side in w a rd
and the inscribe d side o u tw a rd .
MOTE:
W hen in s ta llin g th e n e e d le ro lle r b earing,
d ire c t th e lip in th e c o rre c t d irectio n .
21-13
21 CLUTCH - TROUBLESHOOTING
6a TROUBLESHOOTINGS
W o rn facing
21-14
CLUTCH - T R O U B L E S H O O T IN G 21
S ym p to m P robable cause R em edy Ref. g rou p
Clutch is W orn, d am a g e d, o r p o o rly lub ricate d p ilo t bearing Replace or lub ricate
n oisy w hen
disengaged W orn, d am a g e d, o r p o o rly lub ricate d release bea rin g
L ow idle speed A d ju s t G ro u p 11
21-15
61
SPECIAL EQUIPMENT
COW TENTS
61-1
61 S P E C IA L E Q U IP M E N T - GENERAL
1. G E N E R A L
B4809A B4810A
61-2
S P E C IA L E Q U IP M E N T - GENERAL 61
Snap ring
U nlo a de r valve
C ylin de r head nlo a d er valve
uide
D elivery valve U nlo a de r valve To a ir tank
h old e r sp rin g
0 -n n g
S u ctio n valve
S p rin g holde seat
D e livery valve Suction valve
sp rin g S uctio n valve
D e livery valve sp rin g
D elivery valve
seat
B4812A
B4814A
61-3
61 S P E C IA L E Q U IP M E N T - G E N E R A L , S P E C IF IC A T IO N S
(2 ) P re s s u re G o v e rn o r
2a SPiCIFieATIO M S
A ir C om pressor
Type W a ter-cooled 1-c y lin d e r typ e W ater-cooled 2 -cylin d e r type
C ylin d e r d ia m e te r x stroke mm 85 x 50 80 x 50
Pressure g o v e rn o r
Type D iaphragm typ e
61-4
S P E C IA L E Q U IP M E N T - S E R V IC E S T A N D A R S 61
3. S E R V IC E STAWOAKOS
3U SERVflGE STAMDAIRD TABLE
(1) 1 -cylin d er Aar C o m p ressor
U n it: m m
S u ctio n valve sp rin g Installed loa d / 4.4 N (0.45 kgf 1/5 3.5 N (0.36 kgfl/5 Replace.
in sta lle d len g th
D e livery valve sp rin g 4.5 N (0.46 kg 0/9.5 3.6 N (0.37 kgfl/9.5
Fit betw een p isto n p in hole and p iston pin [181 0.08 Replace.
Piston p in to co rin e ctin g rod sm all end clearance 118] 0.07 Replace p iston pin or
co nn e ctin g rod.
C rankshaft to co nn e ctin g rod bearing clearance 1341 0.1 Replace. (Replace bearing
fo r w o rn p la tin g .)
S u ctio n valve sp rin g Installed load/ 4.4 N (0.45 kgf)/5 3.5 N (0.36 kgf)/ Replace.
in stalle d le n g th
D e livery valve sp rin g 4.5 N (0.46 kgf)/9.5 3.6 N (0.37 kgfl/9.5
Piston rin g g roo ve to p iston ring clearance - 0.08 Replace. (Replace p iston
rin g s as a set.)
Fit betw e e n p isto n p in hole and p iston pin 1161 0.08 Replace.
Piston p in to co nn e ctin g rod sm all end clearance [16| 0.07 Replace p iston pin or
c o nn e ctin g rod.
C rankshaft to co nn e ctin g rod bea rin g clearance 1341 0.1 Replace. (Replace bearing
fo r w o rn plating.)
61-5
61 SPECIAL EQUIPMENT - SERVICE STANDARDS
(3 ) P re s s u re G o v e rn o r
U n it: kPa (kg f/cm 2)
MC802150 78 (8 0) + 3 4 ( + 0 35) -
78 ,8 '0) - 0 .5 (-0.05)
M C802150 -
70 (7 1) + - 5 ( + ' 51
70 l7 -1' -3 .4 (-0.35)
3 .2 T IG H T E N IN G T O R Q U E T A B L E
( I j A i r C o m p re s s o r
J o in t PT 1/8 15 to 20
(1.5 to 2.0)
(2 ) P re s s u re G o v e rn o r
61-6
SPECIAL EQUIPMENT - SPECIAL TOOL 61
4. SPEC0AL TOOL
A ir C o m p re s s o r
U nit: m rn
61-7
61 SPECIAL EQUIPMENT - SERVICE PROCEDURES
5 . S E R V IC E P R O C E D U R E S
5.1 A IR C O M P R E S S O R
5 .1 .1 R e m o v a l arid In s ta lla tio n
NOTE:
1. T o re m o v e th e a ir c o m p re s s o r, re m o v e
th e in je c tio n p u m p b e fo re h a n d .
2 . A t in s ta lla tio n , th e in je c tio n p u m p g e a r
in s ta lle d on th e a ir c o m p re s s o r s h o u ld
b e in m e s lt a s s p e c ifie d .
61-8
S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES 61
In s ta lla tio n of Air C om pressor (2) Insert the b o lt (M10 x 1.5 a bo ut 100 m m long)
fro m the rear end o f the fly w h e e l h ou sin g to s u p p o rt
the air co m p re ssor. U sing the b o lt as a g uide , in se rt
the air co m p re s s o r into the m o u n tin g hole o f the
fly w h e e l h ou sin g. A t the p o s itio n w h e re b o th ends o f
the In jectio n p um p gear and Id ler gear C have
to u ch e d each o the r, alig n th e inscribed line on the
rear plate w ith th a t on the in je c tio n p u m p gear to o th
surface, and then push the air co m p re s s o r in.
(1) Crank the eng in e to a lign the sta m p ed m ark " 1 , 6 "
on th e p e rip h e ry o f the fly w h e e l w ith the p o in te r o f
the in sp e ctio n w in d o w in the fly w h e e l h ou sin g and
p u t the p isto n in the No. 1 c y lin d e r o f the eng in e a tto p
dead center on the co m p re ssio n stroke.
If the p iston in the No. 1 c y lin d e r is at to p dead center
on the co m p re ssio n stroke, the No. 1 c y lin d e r w ill
have a va lve clearance. If both in le t and e xhaust
valves have no va lve clearance, the p iston in the No. 6
c y lin d e r w ill be at to p dead center on the co m p re ssio n
stroke. So let the eng in e rotate 360.
M OTE;
W hen th e en g in e is to be c ra n k e d , m ake
sure th a t it is c ra n k e d m an u a lly m ore than
1180 in th e norm al d ire c tio n .
M O TE;
Of th e in je c tio n pum p g e a r arad id le r g e a r
a re m isalig n ed a to o th , ab o u t h a lf of th e
p ro je c tio n on th e sen sor p la te w ill be
hidden from th e plug hole.
61-9
61 SPECIAL EQUIPMENT - SERVICE PROCEDURES
Sealant to be applied
to threaded portion
(THREEBOND 1211) Hexagonal po rtio n
--------------------------------------24 to 35 Nm
61-10
SPECIAL EQUIPMENT - SERVICE PROCEDURES 61
5 .1 .2 D is a s s e m b ly
[ 1 -cylin d e r Type)
<Disassembly sequence>
1 Sensor plate 11 Spring holder .211 Oil ring
2 Injection pump gear 12 Delivery valve spring 22 Snap ring
3 Collar 13 Delivery valve 23 Piston pin
4 Cylinder head 14 Delivery valve seat 24 Piston
5 Stud bolt '15 Suction valve holder 25 Bearing holder
6 Snap ring 16 Suction valve spring 26 Oil seal
7 Unloader valve 17 Suction valve 27 Connecting rod
8 Valve spring 18 Suction valve seat 28 Connecting rod cap
9 Valve guide 19 Cylinder liner 29 Connecting rod bearing
10 Delivery valve holder 20 Compression ring 30 Crankshaft
31 Crankcase
D9252A
M OTE:
O n o t re m o v e th e s tu d b o lt u n le s s tro u b le is e v id e n t.
61-11
61 SPECIAL EQUIPMENT - SERVICE PROCEDURES
[2 -cylin d e r Type]
<Disassembly sequence>
1 Sensor plate 11 Delivery valve spring 21 Snap ring
2 Injection pump gear 12 Delivery valve 22 Piston pin
3 Collar 13 Delivery valve seat 23 Piston
4 Cylinder head (14) Suction valve holder 24 Bearing holder
5 Snap ring 15 Suction valve spring 25 Oil seal
6 Unloader valve 16 Suction valve 26 Connecting rod
7 Valve spring 17 Suction valve seat 27 Connecting rod cap
8 Valve guide 18 Cylinder liner 28 Connection rod bearing
9 Valve holder (19) Compression ring 29 Crankshaft
10 Spring holder o; Oil ring 30 Crankcase
For parts w ith an encircled n um b e r, refer to D isa sse m bly P rocedure that
fo llo w s.
D9253A
The p rocedures fo r d isa sse m b ly o f the 1- and 2- p ro ced ures fo r d is a s s e m b ly o f th e 1 -c y lin d e r typ e are
c y lin d e r typ es are m uch the sam e. So o n ly the d escrib e d b elow .
61-12
SPECIAL EQUIPMENT - SERVICE PROCEDURES 61
D is a s s e m b ly P ro c e d u re
(2) U sing Piston Ring T ool (special to o l), rem ove the
(1) U sing S u ction Valve T ool (special to ol), rem ove co m p re s s io n ring and oil ring fro m the piston.
61-13
61 S PEC 8A L E Q U IP M E N T - S E R V IC E P R O C E D U R E S
Tension
Loa d /in sta lle d len g th
NV 4.5 N (0.46 kgf)/9.5
L 3.6 N (0.37 kgf)/9.5
Piston rin g g ro o v e to i
co m p re ssio n ring clearance =
L 0.08
D9252B
61-14
S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S 61
[2 -cylind e r Type]
L ... L im it
D9253B
61-15
61 S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S
fH} Poston and Cylinder Liner (a) M easure the clearance betw een th e p iston ring
g ro o v e and co m p re s s io n ring. If the clearance is over
the lim it, replace the co m p re s s io n rin g o r p iston.
NOTE:
Measure the clearance a00 around the pis
ton-
IMOYEs
Push the piston in and measure the clear
M easure the c y lin d e r lin e r in sid e d ia m e te r and p iston
ance with the piston ring in horizontal
to p and skirt o u tsid e d ia m e te r and calculate the
position.
clearance.
If the clearance is o ve r the lim it, replace the p iston o r
(3) Connecting Rod and Crankshaft
c ylin d e r liner.
61-16
S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S 61
(c) M easure th e cra n ksh a ft jo u rn a l o u ts id e d ia m e te r
[Crankshaft]
M e asu rin g
and bearing insid e d ia m e te r and calculate the clea r
M e asu rin g p o s itio n d ire c tio n
ance. If the clearance is o ve r th e lim it, replace parts.
l~
~T\ V End play
C JV
D9271A
61-17
61 SPECIAL EQUIPMENT - SERVICE PROCEDURES
61-18
SPECIAL EQUIPMENT - SERVICE PROCEDURES 61
5 .1 .4 R eassem b ly
[ 1 -cylin d e r Type]
98 to 115 Nm
(10 to 12 kgfm )
98 to 115 Nm
23 to 25 Nm
For reassem bly o f parts w ith an encircled num ber, see procedure
give n in the fo llo w in g .
B3256C
61-19
61 S P E C IA L E Q U IP M E N T - S E R V IC E P R O C E D U R E S
[2 -cylin d e r Type]
For reassem bly o f parts w ith an e ncircled n u m b e r, see p roce d u re g iven In the
fo llo w in g .
N2753B
61-20
S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES 61
R e a s s e m b ly P ro c e d u re
(1 ) A s s e m b ly of C o n n e c tin g Rod
(2 ) In s ta lla tio n of P is to n R in g s
61-21
61 S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES
B3251A
61-22
S P E C IA L E Q U IP M E N T - S E R V IC E PROCEDURES m
5 .2 .2 R e a s s e m b ly a n d A d ju s t m e n t
M C 802150 7 H
7 la n))
8 (8 .0 f 30 .45 (( + Q
0 .3
0 55)) ~in l i t \ * 0-5 (4 0 .0 5 )
70 {7A ) - 3 . 4 ( - 0 .3 5 )
B4080B
B4082A
61-23
A MITSUBISHI
MOTORS CORPORATION
ENGINE
Shop Manual
364 MAR. 1989
2 0 0 (H)