Generac 0D5451 Engine Shop Manual by engineparts2

MITSUBISHI MOTORS

Shop Manual diesel engine

OC8222

602. SDC (for industrial use)

sEngine Parts for Mitsubishi Industrial Engines

eContactemail: iEngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

Website: www.HeavyEquipmentRestorationParts.com

SKE SERN

602.BDC diesel engine

Shop Manual

GROUP INDEX GENERAL ····································D

ENGINE <602> .............................. -

FOREWORD This shop manual contains the specification, construction, operation, adjustment and service pro cedures of the Model 6D2. 8DC diesel engine for ser vice mechanics engaged in servicing of the Mitsubishi diesel engines. Please make the most of this shop manual to perform correct servicing and wasteless operations. Note that some of the contents of this shop manual are subject to change owing to improvements, etc. that may be introduced after publication of this shop manual. JULY 1995

m m m m

ENGINE <8DC> .............................. -

LUBRICATION ...............................

FUEL AND ENGINE CONTROL ............

COOLING ····································m INTAKE AND EXHAUST .................... ENGINE ELECTRICAL .......................

CLUTCH ······································PJI

Applicable Engine Models SPECIAL EQUIPMENT ...................... 6D22 6D22-T Generac 12.0 Liter 0A5399 MMC Mitsubishi 6D24-DT041 6D24DT041 6D22-TC Generac 12.0 Liter 0D5451 MMC Mitsubishi 6D24-DT051 6D24DT051 6D24-T Generac 12.0 Liter 12.0DTA 0A5399 MMC Mitsubishi 6D24-DT041 6D24DT041 6D24-TC Generac 12.0 Liter 12.0DTA 0D5451 MMC Mitsubishi 6D24-DT051 6D24DT051 8DC9 Generac 16.0 Liter 0A8829 MMC Mitsubishi 8DC9-DT051 8DC9DT051 8DC9-T Generac 16.0 Liter 1600TA 0A8829 MMC Mitsubishi 8DC9-DT051 8DC9DT051 Generac 16.0 Liter 16.0DTA 0A8829 MMC Mitsubishi 8DC9-DT051 8DC9DT051 8DC9-TC 8DC9-TL

COMPILATION OF THIS MANUAL CONTENTS 1. GROUP CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . 2. TERMS AND UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. CONVERSION TABLE FOR SI UNITS INTO FOOT-POUND UNITS . . . . . . . . . . . . . . . . . . . . . 4. READING THE ILLUSTRATION . . . . . . . . . . . . . . . . .

4 5 6 7

COMPILATION OF THIS MANUAL - GROUP CLASSIFICATION 1. GROUP CLASSIFICATION This manual is organized into several groups classified according to the engine basic elements. Description

Group name

No.

Genera!

External view, major specifications, engine outputs classified by application, engine numbers, caution plate, genera! precautions for servicing, general bolts and nuts tightening torque table

11A

Engine <602>

Engine proper (cylinder head, valve mechanism, camshaft, piston, crankshaft, timing gear, flywheel), specifications, service standards, special tools, troubleshooting

118

Engine <80C>

Lubrication

Lubrication system (oil pump, oil filter, oil cooler), specifications, service standards, special tools, troubleshooting

Fuel and engine control

Fuel system (injection pump, injection nozzle, fuel filter, pump drive case, water separator), specifications, service standards, special tools, troubleshooting

Cooling

Cooling system (water pump, thermostat, radiator, cooling system cleaning procedures, fan), specifications, service standards, special tools, troubleshooting

Intake and exhaust

Air cleaner, turbocharger, aftercooler, specifications, service standards, special tools, troubleshooting

Engine electrical

Starter, alternator, preheating system, relays, automatic stop-device, specifications, service standards, special tools, troubleshooting

Clutch

Clutch proper, bearing case, specifications, service standards, special tools, troubleshooting

Special equipment

Air compressor, pressure governor, specifications, service standards, special tools

NOTE: Page number begins with 1 for each guoup.

COMPILATION OF THIS MANUAL - TERMS AND UNITS 2. TERMS AND UNITS The following terms and units are used throughout the entire texts of this manual. (1) Front and rear The terms "front" is the fan side and "rear" the fly wheel side of the engine. (2) Right and left The terms "right" and "left" shall be used to indi cate the side as viewed from the flywheel side of the engine. (3) Service standard terms • Nominal value Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an assembly, or the standard performance of an assembly. • Limit Shows the value of a part at which the part is no longer serviceable from the performance as well as strength viewpoints, requiring replacement or repair.

(4) Tightening torque

Over- or undertightening of bolts and nuts has criti cal effects on performance and functions. Tighten ing torque is therefore specified for some tighten ing points. All tightening torque specifications may be consid ered as "dry" unless "wet" is specified. Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts Tightening Torque Table. (5) Units Length, weight, surface area and capacity are given in International Systems of Units with metric units indicated in ( ). Temperatures are given in degrees Celsius. For the conversion into the foot-pound system, refer to the following conversion table.

COMPILATION OF THIS MANUAL - CONVERSION TABLE FOR SI UNITS INTO FOOT-POUND UNITS 3. CONVERSION TABLE FOR SI UNITS INTO FOOT-POUND UNITS A system of units used in this manual is SI (International System of Units). When the units are converted to those used in the foot-pound system, use the following conversion table. Unit

Sign of SI unit

Sign of foot-pound unit

Conversion rate

Mass quantity of matter

kg g

lb oz

1 kg = 2.2046 lb 1 g = 0.03527 4 oz

Dimension

m mm

ft. in.

1 m = 3.2808 ft. 1 mm :: 0.03937 in,

Capacity

gal.

cu.in.

1 L = 0.2642 gal. (U.S.) 1 L = 0.220 gal. limp.) 1 cm3 = 0.033814 oz (U.S.) 1 cm3 = 0.035195 oz (Imp.) 1 cm3 = 0.061023 cu.in.

Force

N (Newton)

lb!

1 N = 0.2248 lbf

Pressure

kPa (kilopascal}

lbf/in z

1 kPa = 0.145 lbf/in 2 1 kPa = 0.2953 in.Hg

Stress

N/cm2

lbf/in 2

1 N/cm2 = 1 .45 lbf[ln 2

Moment of force

N-m

!bf.ft

1 N-m = 0.7375 lbf.ft

Output

kW (kilowatt)

1 kW= 1.34HP

Temperature

t°C = {1.8t°C + 32)°F

COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION 4. READING THE ILLUSTRATION (Ex. 1: Disassembly and Inspection)

�: l / \b� *Protrusion from crankcase to surface NV 0.10 to 0.50

Damage, ,,.--, discoloration

Indicates the service standards.

Breakage, damage

t:)

1----3 Carbon deposits, scratches on outer surfaces, cracks, discoloration

*Connecting rod end play NV 0.15 to 0.45

L 0.6

Indicates visual checks.

* Indicates inspection to be made before disassembly. Damage on outer and inner surfaces, corrosion, flaking •

Damageon outer and inner 2

surfaces, corrosion, flaking

Numbers assigned indicate a typical disassembly sequence.

Disassembly sequence 1 Connecting rod cap 2 Connecting rod bearing 3 Piston

@ 1st compression ring @ 2nd compression ring

If,

@ Oil ring 7 Snap ring

NV .. Nominal Value L. .... Limit

8 Piston pin 9 Connecting rod

Indicates that the disassembly procedures is explained in the text. A0014A

COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION (Ex. 2: Reassembly)

Gives instruction for jobs to ·, be done at reassembly.

""-.

' Apply engine oil.

I Piston projection I NV 0.48 to 0.74 I ,

98N-m {10 kgf-m} (Wet)

Specifies the tightening torque; (Wet) means the part must be tightened in wet st Indicates a typical assembly sequence.

Face the oil groove toward the crankshaft , End play NV 0.10 to 0.25 j, L 0.4

Indicates the service standards.

NV . Nominal Value L.. Limit

Assembly sequence

3➔@➔@➔7➔@➔@➔@➔2➔1

Indicates that the assembly procedure is explained in the text.

Illustrations (exploded views and assembly drawings) shows a typical service procedures if it is identical 8

A0013A

among various types of available systems and units.

GENERAL

CONTENTS 1. EXTERNAL VIEW . . . . . . . . . . .. . . ... . . . . . . . . . . . 2 2. MAJOR SPECIFICATIONS ... . .. . . . . . . . . . . . . . 4 2.1 Major Specifications . . ...... . . . . . . . . . . . . . . 4 2.2 Engine Outputs Classified by Application . . . . . .. . . . . . . .. . .. . . . . .. . . . . . . . . 4 3. ENGINE NUMBER AND CAUTION PLATE ........................................ 5

4. GENERAL PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . 7 5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE . . . . . . .. . . . . . . 8

00-1

GENERAL - EXTERNAL VIEW

1. EXTERNAL VIEW <6D2>

Natural-aspirated engine

Turbocharged engine

A0243A

A0244A

00-2

GENERAL - EXTERNAL VIEW

<8DC>

Natural-aspirated engine

Turbocharged engine

A024SA

A02468

00-3

GENERAL - MAJOR SPECIFICATIONS

2. MAJOR SPECIFICATIONS

2.1 Major Specifications Item

Engine model I

Type

6D22

6D22-T

Cylinder bore x stroke

Overall length Overall width

Overall height Empty weight

I 6D24-TC

8DC9

8DC9-T 12-turbo)

cm 3

i 8DC9-TC I 8DC9-TL

Direct injection

6, in-line

No. and arrangement of cylinder

Engine dimension (with fan)

6D24-T

Diesel, 4-cycle, water-cooled

Combustion method

Total displacement

6D22-TC

8-90°V

130 X 140

130 X 150

135 X 140

11149

11945

16031

1473

1238

1518

1525

1598

866

881

1028

1140

1160

1058

1169

1209

1169

1209

1126

1165

1232

1177

895

920

950

930

960

1120

1300

1350

1255

mm kg•

• Empty weight as measured according to Mitsubishi Motors Corporation standard.

2.2 Engine Outputs Classified by Application I

6D22

� gine Ap

6D22-T Turbocharged

6D22-TC Turbocharged with Aftercooler

8DC9-T Twin Turbocharged

speed rpm

Intermittent rated output kWIHP)

Continuous rated kWIHP) output

charged with Aftercooler

1500

1091146)

1611216)

1791240)

212 (284)

247 1331)

1800

129 (173)

186 (249)

2071277)

242 (325)

2911390)

2000

141 (189)

195(261)

2191294)

257 (345)

3061410)

2200

149 (200)

201 (2691

2271304)

265 (355)

3141421)

1500

99 (132)

146 (196)

1631218)

193 (259)

2251302)

1800

117 (157)

169 1226)

188 (252)

220 (295)

265 (355)

2000

128 (171)

178 (238)

1991267)

234 (314)

2781373)

2200

135 (181)

183 (245)

2061276)

241 (323)

2851382)

NOTE: 1. The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349. 2. The continuous rated output allows 10% (one hour) overload operation.

00-4

8DC9-TC

Twin Turbo-

GENERAL - ENGINE NUMBER AND CAUTION PLATE 3. ENGINE NUMBER AND CAUTION PLATE (1) Engine number

(2) Caution plate <6D2>

<6D2>

<8DC9>

E0175

E0143

<8DC> <8DC9-T>

8DCS -012345

<8DC9-TC>

A02488

A024BC

E0186

The engine number is stamped on the following posi tions. 6D2: Left front of the crankcase 8DC: Right center of the crankcase

Example: 6D22 -012345 �---Engine number �------- Engine model

<8DC9-TL>

A0248D

The engine number is important in knowing the history of the engine.

A0247A

00-5

GENERAL - ENGINE NUMBER AND CAUTION PLATE

The caution plate is attached to the portion shown in the illustration. The caution plate indicates the follow ing items.

VALVE CLE AR AN CE (CO l D) INLET 0.4mm(0.016in)tt1 EXHAUST 0.6mm(0.024in)y-1 FIRING ORDER 1-5-3-6-2-4�2 FUEL INJECTION TIMING O O BTDC� 3

1 Valve clearance 2 Firing order 1-5-3-6-2-4 <6D2> 1-2-7-3-4-5-6-8 <BDC> 3 Fuel injection timing

A0166B

00-6

GENERAL - GENERAL PRECAUTIONS FOR SERVICING 4. GENERAL PRECAUTIONS FOR SERVIC ING Before starting the service procedures, check the vehi cle for total time driven, use conditions, and user's complaints and requests to know exactly the engine conditions. Record information where necessary. To ensure you are doing correct and efficient service jobs, observe the following precautions:

MITSUBISHI MOlORS

GENUINE PARTS A0006A

(7) The oil seals, packings, O-rings, and other rubber parts, gaskets, and split pins must be replaced with a new one whenever they are removed. For replacement, use Mitsubishi Genuine parts.

A0012A

(1) Before performing the service procedures given in this manual, know the trouble spots and isolate the possible cause to determine whether the removal or disassembly procedure is required. (2) Select a flat surface for the service job. (3) When servicing the electrical system, be sure to disconnect the negative cable from the battery. (4) Carefully check parts for oil leaks before cleaning. After cleaning, it may become difficult to spot defective areas. (5) Ready and make the most of the special tools required for servicing. Use the right tools (speci fied special tools) in the right place to prevent dam ages to parts and personal injury. (6) Make alignment marks and keep disassembled parts neatly arranged to ensure that they are reas sembled into the right positions. • Special care must be taken for assemblies involv ing a number of parts, similar parts, or parts identi cal at right- and left-hand sides to ensure correct reassembly. • For alignment and punching markings, select a position that would not mar the appearance and function. • Clearly distinguish parts to be replaced from those reused.

A0007A

Apply the specified grease to U-packings, oil seals, dust seals, and bearings before installation. (9) When work requires an assistant or two, always make sure of the safety each other. Never play with switches and levers. (10) Make sure that your shoes are free from grease and oil especially when working on a heavy item. (11)When checking or changing lubricants, wipe off grease and oil from parts immediately with a waste. (12)Special care must be taken in handling sensors and relays which are suspectible to shocks and heat. (13)Use care so that hands and fingers are not injured by sharp edges or corners of the parts. (14)Wear safety goggles whenever handling a grinder or welding machine. Wear gloves as required to ensure utmost safety.

(8)

00-7

GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABL E

5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE •

Use specified bolts and nuts and tighten them with the applicable torques according to the following table, unless otherwise specified. Threads and contact seats shall be dry. Where there is difference in strength classification between nut and bolt (or stud bolt), the torque specified for bolt shall apply.

• •

Hex-head Bolt and Stud Bolt Unit: N-m {kgfm} Strength classification n

. I

� MS

@o © ©0 0 @ @ ® !Stud)

2to 3 {0.2to0.3)

!Stud)

4to6 {0.4 to0.6)

7to11{0.7to1.1}

!Stud}

5to 7 {0.5 to0.7)

8to 12 {0.8to 1.2)

4 to6 {0.4 to0.6)

9to 14 {0.9to 1.4}

M10

19 to28 {1.9to2.8)

18to26 (1.8 to2.7)

36to52 {3.5 to 5.5)

33to49 {3.5 to 5.0)

45 to 60 {4.5to6.0}

41to 59 {4.3to 6.9)

M12

35 to 50 {3.4to 5.0J

31 to 46 {3.1 to 4.7)

70to95 {7 .0 to 9.5)

65 to85 {6.5 to8.5)

85to110{8.Sto11)

75to 100 {7.5 to 10)

M14

60to85 {6.0 to8.5)

55 to 75 {5.5to 7.SJ

120to160 {12to16)

11010140 {11to14J

130to 180 {13 to 18)

120 to 160 {12to 17)

M16

90to130 {9.5to13)

90to120 {9.0 to 12)

180to240 (18 to24)

160 to220 (16 to22)

200 to270 {20to27)

190 to 260 (19to26)

M18

140 to 190 (14 to19)

120to 160 {12to 16)

260to340 {25to 35)

220to 290 (22 to 30)

290to390 {30to 40)

260to 340 {26 to35)

M20

190to 260 (19to26)

170 to 230 {17to23)

350 to470 (36 to 48)

320to420 (32 to43)

410to 550 {41 to 56)

370to 490 (37 to50)

M22

260to340 {26to35)

230to 300 (23to31)

470 to640 (48to65)

430to570 (43to58)

550 to 740 {56to 75)

490to 670 (50to 68)

M24

340to 450 (34to 46)

290to390 (29to 40)

630to 840 (63 to 86)

540to730 (55 to74)

730to 980 {74 to100)

630to 840 {64to86)

17to26 {1.7to2.6)

20to29 (2.0to3.0)

Hex-head Flange Bolt Unit: N-m {kgf-m)

Strenfith classi 1cation n

. �

<0 -

0 0 Sto12 (O.Sto 1.2)

� 9to 14(0.9to1.4)

0 -

4to6 {0.4to 0.6)

10to 15 (1.0 to1.5)

M10

21to30 (2.1to3.1)

20to 28 {1.9 to 2.9)

39to 58 {3.9to 6.0}

37to 53 {3.6 to 5.4}

50to65 {5.0to 6.5)

45 to65 {4.5to6.5)

M12

38 to 54 (3.8to 5.5)

35to51 {3.4 to 5.2)

80to110 {8.0to11}

70 to95 {7.0 to9.5)

90to120 (9.0to12)

85to110 {8.5to11)

00-8

19to28 {1.9to2.8)

22to32 {2.2 to 3.3)

GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

Hex-head Nut Unit: N•m {kgf.m}

Strength classification \ Repre\ sentation

o;; �

Standard screw

MS M6

CED

[I:J)

Coarse screw

Standard screw

2to 3 (0.2to0.3}

4to6 (0.4to 0.6)

4 to6 (0.4to0.6)

7to 11 (0.7 to 1.1)

9 to 14 {0.9 to 1.4)

17to26 (1.7 to 2.6)

M10

19 to 28 (1.9 to 2.8}

18to26{1.8to2.7}

36 to52 (3.5 to5.5)

33to49 {3.5to5.0)

M12

35 to50 (3.4to 5.0)

31 to46 (3.1 to4.7}

70to95 (7 .0 to9.5}

65 to85 (6.5 to8.5)

M14

60 to 85 (6.0 to8.5)

55 to 75 (5.5 to 7 .5)

120 to160 {12 to16)

110to140{11to14)

M16

90 to130 (9.5to13}

90to 120 (9.0 to12)

180 to240 (18 to24)

160to220 {16 to22)

M18

140to190 {14to19)

120to 160 (12 to16)

260 to340 (25 to 35)

220 to290 (22 to30)

M20

190 to260 (19 to26)

170 to230 (17 to23)

350to 470 {36to48)

320to 420 (32 to43}

M22

260 to340 (26to35)

230to300 (23to31}

470to 640 (48to65)

430 to570 (43to 58)

M24

340to450 (34 to 46)

290to 390 (29 to 40)

630 to840 {63 to86)

540to730 (55to 74)

symbol

Hex-head Flange Nut Unit: N-m {kgf-m) 4T

Stren th classifiication

Repre-

sentato i n

Diameter

(@)

symbol

Standard screw

Coarse screw

4to 6 (0.4 to0.6}

10 to15 (1.0 to 1.5)

M10

21 to30{2.1to3.1}

20 to28 (1.9 to2.9)

M12

38to54 (3.8 to5.5)

35to51 {3.4to5.2}

00-9

ENGINE <6D2> CONTENTS 1. GENERAL .. .. . .. . ... ....... .. ... ........ .. ... 2 2. SPECIFICAT IONS .. .. ........ .. .. .. .. .. .... .. 8 3. SERVICE STANDARDS ........ .. .... .. .. .... 9 3.1 Service Standa ds Table .................. 9 r 3.2 lightening Torque Table .... .. ...... .. .. . 11 4. SPECIAL TOOLS .. .... .............. ........ 12 5. SERVICE PROCEDURES .................... 16 Measuring Compression Pressure ...... 16 5.1 Cylinder Head and Valve Mechanism ... 17 5.2 Disassembly . . .. .... . ... .. .. ....... .. .. 17 5.2.1 Inspection .... .. .. .. .. .. .. . . ........... 20 5.2.2 5.2.3 Reassembly ........................... 26

5.3

r �•:;:::� ��'.��- ��- ��-��-� .............. 31 5.3.1 Disassembly ... . ..... . .. . . . .... . . .. . ... 31 5.3.2 Inspection . ... . ... ... . . .. . . ... ......... 35 Reassembly .. ........... .. . ...... .. ... 41 5.3.3 5.4 Crankcase and Main Moving Parts ... ... 46 Disassembly ..... ... .. .. . . ......... .. .. 46 5.4.1 Inspection ....... ..... .. .. .. ..... .. .. .. 50 5.4.2 Reassembly . . .. ... . .. . .... . . . ..... . ... 60 5.4.3 5.5 Inspecting and Adjusting Valve Clearances . . ....... .. . ... . .... ........ . .. 66 6. T ROUBLESHOOTING .. .......... ...... ..... 68

11A-1

ENGINE <6D2> - GENERAL

1. GENERAL

(1) Combustion chamber

Injection nozzle Cylinder head

—- O-ring _—~ Nozzle tube

Cylinder head gasket Combustion chamber

Water director

80376A

Water directors pressed into the bottom of the cylinder head optimize cooling of the combustion chambers by directing the flow of coolant.

B0375C

The combustion chambers are formed by the cylinder head and pistons. The injection nozzles, sheathed by the nozzle tubes, are mounted on the cylinder head. The nozzle tubes hold the nozzles and protect them from cooling water. Since the nozzles are exposed to the water in the water jacket, they are sealed by 0-rings at the top and by staking at the bottom. Combustion is effected by compression of fuel injected directly into the combustion chambers.

11A-2

ENGINE <6D2> - GENERAL (2) Valve mechanism Rocker cover Adjusting screw

Rocker shaft bracket

----fl:-=-i-fll--,-.J�·�

Rocker ,Valve cap / Valve cotter / ·___Upper retainer __________. Valve spring outer inn r ��; 1U�-1t-Valve spring e /

-- Lower retainer

Valve stem seal Valve guide

Oil passage

Rocker

Push rod 65040A Tappet

B03750

The valve mechanism is of an overhead-valve (OHV) type and is constructed as shown in the diagram. (a) Valve stem seals are fitted to the inlet and exhaust valve stems to control the amount of lubricant flowing onto the sliding surfaces of the valves and valve guides. (b) The inlet and exhaust valve springs are unevenly pitched. Two springs are mounted for each valve, and the inner and outer springs are wound in oppo site directions. (c) The rocker and rocker shaft are supported by the rocker shaft bracket and are installed indepen dently for each cylinder. The same type of rocker is used for both inlet and exhaust valves, and the cen ter of each rocker forms an oil passage. The rocker shaft is a hollow rod sealed by a thrust plate at each end. The inside of the rocker shaft forms an oil passage.

(d) A steel ball is welded to the bottom end of each push rod, and a spherical concave piece is welded to the top end. (e) The tappets are cylindrical. To help prevent local ized wear, the areas that make contact with the camshaft are curved. The overall design enables the tappets to be removed via the side of the crank case. (f) The camshaft is held by camshaft bushings that are pressed into the crankcase. The cam profiles are specially curved to achieve smooth acceleration.

11A-3

ENGINE <602> - GENERAL (3) Crankcase and cylinder liner

(4) Piston and piston rings (a) Pistons <6D22, 22-TC>

| §<6022-T,

24-T, 24-TC>_

mark

Size mark

(A, B, C}

Mar

JFonly) |

Weight mark

pani art

No.

Pistonring

Insert

| (A, B, C}

No.

Front indicated by “F” and arrow

Cooling cavity <6D22-TC, 24-T, 24-TC>

Camshaft bushing

(a) Seven camshaft bushings are fitted in the camshaft bearing section of the crankcase. To facilitate removal and reinstallation of the camshaft, the diameter of each bearing is smaller toward the front. (b) Coolant is fed in from the water pump (located at the front left of the crankcase). After cooling the oil cooler, it flows through the water jacket holes and around the cylinders, then reaches the cylinder head.

Coolant

thrattling

BO319K

The piston is an aluminum casting, and a combustion space is recessed into its crown. A piston ring insert is cast into the 1st piston ring groove to improve durabil ity. Stamped on top of the piston are a size mark, a piston weight mark, the piston's part number, an identifica tion mark, plus an "F" and arrow, which indicate the piston installation direction. The size mark is provided to enable selection of the correct cylinder liner size. In the case of an oversize piston, the size mark shows the degree of oversize. The piston pin is fully floating and is held in position by a snap ring at either end. (b) Piston rings

shelf

O-ring Cylinder liner

1st compression ring (full keystone type)

Crankcase

2nd compression ring (typer faced inner cut type)

Rubber ring 0-ring

80378A

(c) The cylinder liner is a removable wet type. It is press-fitted into the crankcase, with its top held by the top of the crankcase and its bottom held by the water jacket. Rubber rings and 0-rings are provided at the top and bottom of the cylinder liner to prevent the ingress of coolant. The water jacket has a water throttling shelf to opti mize cooling performance.

11A-4

==ca=-= Oil ring (oV (dual type with an ==\�'.J'l..,� expander spring)

<Ex�T>

<6D22-T only>

B0374C

Two compression rings and one oil ring are fitted to each piston. They are shaped as shown in the illustra tion.

ENGINE <6D2> - GENERAL (5) Connecting rod and connecting rod bearing

{6) Crankshaft and crankshaft main bearings

<6D22-TC, 24-T, 24-TC,

_ij

Oil hole Journal

1 Connectingrod bushing

Balance weight 84206A

Connecting rod ___... Oil passage Connecting rod bearing (upper)

--Connecting rod

bolt

,);;,__Jlt- �"" Cylinder number, :::

�

Nut

ing rod

bearing “~ Oil hole

weight mark Mating mark

(a) The crankshaft is highly rigid and is cast in one piece with its balance. Between each journal and pin is an oil hole. Some of the main bearing oil is fed through this hole to lubricate the connecting rod bearing.

;

<Axial lip type> 80379K

The connecting rod is a highly rigid I-section forging. A bushing is pressed into the small end, and a split-type plain bearing is used at the big end. Since it is a split-type bearing, the connecting rod bear ing has an upper half and a lower half. The upper half has an oil hole. This oil hole is in line with the oil pas sage inside the connecting rod. Engine oil for lubrica tion of the small end bushing is supplied via the oil hole and oil passage. In the 6D22-TC, 24-T, 24-TC, an oil hole is provided at the top of the connecting rod to help cool the piston. The connecting rod and connecting rod cap are held together by four connecting rod bolts.

Flywheel housing

0-ring

Crankshaft gear Crankshaft

Rear oil seal slinger

80351A

Flywheel housing

Crankshaft gear Crankshaft

0-ring

Rear oil seal Retainer

B0351B

(b) The crankshaft gear that drives the timing gears is press-fitted onto the rear of the crankshaft. Note that a radial- or axial-lip-type oil seal is fitted to the front and rear ends of the crankshaft.

11A-5

<Rubber type> • Single mass

ENGINE <6D2> - GENERAL (d) Main bearings

Torsional damper

/ Crankshaft pulley

• Double mass

Torsional damper ,...----Crankshaft pulley

Thrust plate

Crankshaft Torsional damper

�Crankshaft

B4489A

(c) The front end of the crankshaft is flanged, and the crankshaft pulley is bolted to the flange. A torsional damper is mounted on the crankshaft pulley to absorb the crankshaft's torsional vibration.

11A-6

Upper main bearing

lower main bearing

Thrust plate

B0382A

Each main bearing is a split-type plain bearing made of special alloy-plated kelmet metal with backing mate rial. Since they are split-type bearings, the main bearings have upper halves and lower halves. Each upper half has an oil groove on its inside surface, plus an oil hole. The oil hole lines up with an oil hole in the crankcase. There are 7 main bearing pairs. A split-type thrust plate is fitted to the rearmost bearing.

ENGINE <6D2> - GENERAL (7) Timing gears

Idler gear B

2=66

Camshaft gear A

2=63

Each idler gear is mounted onto the crankcase with an idler shaft bolt and is supported at the other end by the flywheel housing. The idler gears turn on the idler shafts by means of pressed-in bushings. The bushings are lubricated by oil that flows through the inside of the idler shafts via the crankcase oil holes. (8) Flywheel

injection pump gear }

Z=63

Angle scale, cylinder number

i }

Idler gear A 2233

111

111 I 11] (1 I l I l i ffi11in1111i11fli111l11111fi11

mJr

Crankshaft gear

2=63

inc

Flywheel

idler gear C z=68

Cylinder No.

Ring gear

Idler gear

1111 I JI ! ! I 'I

2=47 Oil p�mp gear

2=53

B0383L

The timing gears are located in the flywheel housing at the rear of the engine. The geartrain is as shown in the illustration. The timing gears are helical, and each is stamped with a timing mark. The timing marks ensure that the gears mesh correctly when reassembled.

Oil hole||

Cylinder No.

! I I 210 I! Ill I I /

)IT[

Valve timing \.._ "'-. check mark

IQJHI j I 11

I I

10355

The flywheel is made of cast iron, and at its center is a pilot bearing for the clutch shaft. The outer ring gear that meshes with the starter pinion is shrink-fitted. The ring gear teeth are chamfered on one side to ensure that the starter pinion fits easily. Cylinder numbers, an angle scale, and valve timing check marks are stamped on the outside of the fly wheel, as shown in the illustration.

Re Rae

YY| Boit| idler shaft . 4/1

Thrust plate

80384A

The crankshaft gear is press-fitted onto the crankshaft and held in place by a dowel pin. The crankshaft gear drives the other gears.

11A-7

ENGINE <6D2> - SPECIFICATIONS 2. SPECIFICATIONS Item

Specification 6D22

6D22-T

6D22-TC

6-cylinder, in-line, water-cooled, 4-cycle diesel

Combustion chamber type

Direct injection

Valve mechanism

Overhead valve

... ... ...

Engine model Type

Cylinder bore x stroke (mm) Total displacement (cm ) 3

Compression ratio Fuel injection sequence Cylinder liner type

...

130 X 140

11149

15.5

1-5-3-6-2-4

.... .... ....

Wet

Piston type

Trunk-type slipper skirt

No. of piston rings

Compression ring: 2 Oil ring: 1

Item Engine model

Fuel injection sequence Cylinder liner type Piston type

16.5 1-5 -3-6-2- 4 Wet Trunk-type slipper skirt (with cooling cavity}

No. of piston rings

6D24-TC

11945

Overhead valve

Compression ratio

(with cooling cavity)

130 X 150

Direct injection

Valve mechanism Total displacement (cm3)

....

.... .... .... ....

6-cylinder, in-line, water-cooled, 4-cycle diesel

Combustion chamber type Cylinder bore x stroke (mm)

Specification 6D24-T

Type

Compression ring: 2 Oil ring: 1

.... .... .... .... 4

Engine Parts for Mitsubishi Industrial Engines Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com Located in USA, Engine Parts Delivery in USA, Canada and worldwide

11A-8

ENGINE <6D2> - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table

Unit: mm Maintenance item Compression pressure (at 200 rpm}

Rocker bushing-to-rocker shaft clearance

Outer valve spring

Free length Installed load/installed length

Inner valve spring

Free length Installed load/installed length Squareness

TappeMo-crankcase clearance

Push rod runout Cylinder head bottom surface distortion Height of cylinder head fromtop to bottom surface

Nominal value (Basic diameter in [ l)

limit

Remedy and remarks

2.75 MPa {28 kgf/cm 2}

1.96 MPa {20 kgf/cm 2}

Difference between cylinders: 390 KPa {4 kgf/cm'J or less

128) 0.03 to0.08

0.2

Replace bushing

89.38

Replace

450N {46. 1 kgf} / 58.35

380N {39 kgf} / 58.35

65.04

115N {12 kgf} / 50.35

100N {10.2 kgf} / 50.35

135) 0.06 to0.10

0.2

Replace

0.5

Replace

0.07 or less

0.08

Correct or replace

130

129.8

Replace

11.85

Replace

0.2

Replace valve guide

Reface or replace

Replace

2.5

Valve stem outside diameter

Inlet

11.95to11.96

Exhaust

11.91 to11.93

Valve stem-to• valve guide clearance

Inlet

112J0.05 to0.09

Exhaust

112) 0.09 to0.12

Valve margin

Inlet

2.2

1.7

Exhaust

2.5

2.0

45 °

Inlet

0.25to 0.75

1.0

Exhaust

--0.05 to0.45

0.7

2.69 to2.96

3.5

Correct or replace

Between crankshaft gear and idler gear B

0.08to 0.20

0.4

Inspect

Between idler gear A and camshaft gear

0.07 to0.18

0.4

Inspect

Between idler gear A and idler gear C

0.07to0.18

0.4

Inspect

Between injection pump gear and idler gear C

0.08to0.20

0.4

Inspect

Idler gear end play

0.05 to0.15

0.4

Replace thrust plate

Camshaft gear end play

0.05 to0.22

0.4

Valve seat angle Valve sinkage from cylinder head bottom surface

Valve seat insert seat width liming gear backlash

Replace valve seat insert (- shows projection)

0.2

Correct or replace

49.5

Replace

0.2

Correct or replace

Idler gear A-to-idler shaft A clearance

14010.03 to0.06

0.2

Replace bushing

Idler gear C-to-idler shaft C clearance

146) 0.03 to0.06

0.2

Replace bushing

eT Friction surface distortion

Flywheel

Distance from clutch cover mounting surface to friction surface Friction surface runout (when

fitted)

0.1 or less 47.8to 48.2

11A-9

ENGINE <6D2> - SERVICE STANDARDS Unit mm Maintenance item Cam profile (difference between lobe height and base circle diameter)

Camshaft journal-to-camshaft bushing clearance

Nominal value (Basic diameter in [ l)

Limit

Inlet

8.83

8.3

Replace

Lobe height: 56.167 Base circle diameter: 47.334

Exhaust

8.82

8.3

Replace

Lobe height: 56.036 Base circle diameter: 47.216

No. 1

[65.001 0.03 to 0.08

0.25

Replace bushing

No. 2

[65.251 0.03 to 0.08

0.08

Replace

i No. 3, 4

[65.501 0.03 to 0.08

i No.5,6

[65.751 0.03 to 0.08

j No. 7

[66.001 0.03 to 0.08

0.05 or less

Camshaft bend

Remedy and remarks

[4010.02 to 0.05

0.2

Correct

Connecting rod end play

0.2 to 0.5

1.0

Projection of piston from top surface of crankcase

0.87 to 1.33

Replace

Crankshaft end play

0.09 to 0.23

Camshaft gear-to-camshaft interference Flywheel housing eccentricity

Flatness of cylinder liner supporting flange Crankcase top surface distortion Cylinder liner

Piston-to-cylinder liner clearance

Piston ring groove-topiston ring clearance

1st compression ring

2nd compression ring

11A-10

0.4

Replace thrust plate

0.1

Replace crankcase Correct

0.07 or less

0.2

130.014 to 130.054

130.25

Flange projection

0.0, to0.08

Cylindricity

0.02 or less

Replace or grind to oversize

6D22

[13010.178 to 0.204

6D22-T

[130J0.173to0.199

6D22-TC

[13010.188 to 0.214

6D24-T, 24-TC

[130] 0.193 to 0.219

0.25

Replace piston ring or piston

0.25

Replace piston ring or piston

6D22

0.05 to 0.12

6D22-T

0.03 to 0.10

6D22-TC

0.01 to 0.09

6D24-T, 24-TC

0.02 to 0.10

6D22

0.05 to 0.08

6D22-T, 22-TC, 24-T, 24-TC

0.07 to0.10 0.03 to 0.06

0.15 1.5

1st compression ring

6D22, 22-T, 22-TC

0.4 to 0.6

6D24-T, 24-TC

0.4 to 0.55

2nd compression ring

6D22, 22-T, 22-TC

0.4 to 0.6

6D24-T, 24-TC

0.5 to 0.65

Oil ring

Inspect

Inside diameter

Oil ring Piston ring end gap

Can be reassembled up to 3 times

0.4 to 0.6

1.5 1.5

Correct or replace cylinder liner, or replace piston

Replace

ENGINE <6D2> - SERVICE STANDARDS

Maintenance item

Nominal value (Basic diameter in [ l)

Piston pin-to-piston pin hole clearance

1501 0.01 to 0.02

Piston pin-to-connecting rod small end bushing clearance

150] 0.02 to 0.05

Connecting rod bend and torsion

I '

Unit: mm Limit

Remedy and remarks

0.1

Replace piston or piston pin

0.1

Replace bushing

0.05 or less

Correct or replace

Less than 90.5

Connecting rod bearing-to-crankshaft pin clearance

]841 0.07 to 0.13

0.25

Replace bearing

Main bearing-to-crankshaft journal clearance

1100] 0.08 to 0.15

0.25

Replace bearing

Less than 106.5

Replace

0.01 or less

0.08

Correct

0.006 or less

0.04 or less

0.1

Correct or replace

0.4

Adjust

Connecting rod bearing span when free

Main bearing span when free Crankshaft pin and journal

[ Roundness

I Cylindricity Crankshaft bend Valve clearance (when cold)

1 tnlet I Exhaust

Replace

0.6

3.2 lightening Torque Table Location tightened

Screw size 0. D. x pitch Imm)

Remarks

lightening torque N-m {kgf-m)

Cylinder head bolt

M14x2

Rocker shaft bracket mounting bolt

M10x 1.5

34 {3.5}

Rocker cover bolt

MS x 1.25

4.9 {0.5}

Rocker adjusting screw lock nut

M10x1.25

59 {6}

Flywheel mounting bolt

M16 X 1.5

315 {32}

Idler shaft bolt A

M16x2

155 {16)

Idler shaft bolt C

M16x2

155 {16}

Idler shaft nut (for mounting collar)

M16x1.5

98 {10]

Flywheel housing bolt

M12 x 1.75

69 {7}

Oil jet check valve

M12 X 1.75

34 {3.5)

Cannot be reused

Connecting rod cap nut

M13x1.25

115{12}

Main bearing cap bolt

Wet

M18x2.5

Crankshaft pulley mounting bolt

M14x1.5

175 {18}

Front cover mounting bolt

M12 x 1.75

33 {3.4}

Wet. See item (6) of section 5.23 . for tightening procedure.

Wet

Wet. See item (7) of section 5.4.3for tightening procedure.

ENGINE <6D2> - SPECIAL TOOLS 4. SPECIAL TOOLS Unit: mm

Unit: mm Tool name Compression Gauge Adapter MH061461 Measuring compression pres� sure

Tool name

Shape

Caulking Tool Body MH061360 Installing and caulking valve seat inserts

16W x 18 threads

Caulking Ring (Inlet) MH061650 Installing and caulking valve

Caulking Tool Body r::;:]1:llj--Caulking Ring

seat inserts Center distance 46 Valve lifter MH061668 Removing and installing valve

01942

For inlet: (jl 59 For exhaust: q> 54

Caulking Ring (Exhaust) MH061651 Installing and caulking valve seat inserts

-'-'--$12

Valve Lifter

B5202A

cotters

Valve Lapper 30091-07500 Valve lapping

Vatve Lifter Hook MH061679 Removing and installing valve cotters 1.0. 42

Hook 01956 Nozzle Tube Stamp MH061229 Installing nozzle tubes

Nozzle Tube Remover MH061232 Removing nozzle tubes $12.5 $8.7

13597

Nozzle Tube installer Boi

Nozzle Tube Installer Flange MH061416 Installing noule tubes Nozzle Tube Installer Bolt MH061231 Installing noule tubes

to-center

eetances 46

Rocker Bushing Puller MH061236 Replacing rocker bushings

Nozzle Tube Installer Flange

NouleTube Stamp <1>8

B5181A Valve Stem Seal Installer ME067431 Installing valve stem seals 10593 Valve Guide Puller 30091-08100 Replacing valve guides

$24

B5111A

11A-12

B5191A

ENGINE <6D2> - SPECIAL TOOLS Unit: mm Idler Gear Bushing Puller MH061228 Replacing idler gear bushing (for idler gear A)

Unit: mm

Camshaft Bushing Extractor Bar MH062118 Removing camshaft bushings Nos. 1 to 6

$39.5

03532

Idler Gear Bushing Puller MH062046 Replacing idler gear bushing (for idler gear C)

84867A Camshaft Bushing Extractor Guide MH062119 Removing camshaft bushings Nos. 1 to 6 $45.5

84384A

Gear Puller MH061061 Removing gears and pulleys 84868A

Maximum pulling outside dia. 200 85071A Socket Wrench MH061540 Tightening cylinder head bolts

Camshaft Bushing Extractor Adapter MH062120 MH062121 MH062122 MH062123 Removing camshaft bushings Nos. 1 to 6

Part No.

Applicable bushing

MH062120

89.75

MH062121

MH062122

70.25

65.5

No.3,4

MH062123

70.75

65.7

No.5,6

65.25

No.1 No.2

84869A

80598A Socket Wrench MH063365

•• •• "

Camshaft Bushing Extractor MH062124 Removing camshaft bushing No. 7

lightening main bearing cap bolts

13204

84870A

11A-13

ENGINE <6D2> - SPECIAL TOOLS Unit: mm

Unit mm

Camshaft Bushing Installer Bar MH062125

Camshaft Bushing Installer MH062131 MH062143

Installing camshaft bushings Nos. 2 to 6

Installing camshaft bushings Nos. 1 and 7

M24 x 1.5 84871A Camshaft Bushing Installer Guide MH062127 Installing camshaft bushings Nos. 2 to 6

Part No.

•A

MH062131 i 70.75 1

MH062143 I 72.25

••

' Applicable bushing No.1 No.7

84875A Oil Seal Slinger Installer MH061652 Installing rear oil seal slinger

84872A Camshaft Bushing Installer Adapter MH062133 MH062134 MH062135 MH062136 MH062137 Installing camshaft bushings Nos. 2 to 6

B51618

Part No MH062133 MH062t3' MH06213S MH062136 MH062137

. , " " ••

65.25

71.25 i 65.5 71.S

71.75

65.S 65.75 I 65.75

" ., " "

Piston Ring Tool 31191-02900 Removing piston rings Applicable buthiog i No.2 No.3 No., I No.S No.6

84873A Camshaft Bushing Installer

Nut

MH062130 Installing camshaft bushings Nos. 2 to 6

For<!>102to 178

02013 Crankcase Table MH061889 Measuring flatness of cylin• der-liner-supporting flanges on crankcase

M24 x 1.5

84874A

11A-14

81480A

ENGINE <6D2> - SPECIAL TOOLS $120

Unit mm

Unit: mm

Oil Seal Sleeve Installer 31191-07100 Installing rear oil seal sleeve

Cylinder Liner Extractor MH061490 Removing cylinder liners

/If,

PE7264 85131A

Cylinder Liner Installer MH061759 Installing cylinder liners

Oil Seal Slinger Installer MH061817 Installing front oil seal slinger

95.065 te 95.165

85141A Guide Plate Assembly MH063368 Removing connecting bushings

80585A Piston Guide Clamp MH061666 Installing pistons

rod

Mandrel 31291-75200

Removing

bushings

Piston Guide Lever connecting

rod

Guide Plate

LD_:130

Collar A

MH063370 Removing connecting bushings Collar B MH062189 Removing connecting bushings Nut 31291-75500 Removing connecting bushings

Piston Guide Clamp

MH061658 Installing pistons

rod

Piston Guide Lever

B5171B

rod 85151A

Oil Seal Installer 31191-04300 Installing rear oil seal (radial lip type)

PE7263

Thickness Gauge MH061359 Measuring valve clearances

11605

11A-15

ENGINE <6D2> - SERVICE PROCEDURES 5. SERVICE PROCEDURES Compression pressure

5.1 Measuring Compression Pressure

(at 200 rpm)

NV 2.75 MPa {28 kgf/cm2 ) L 1.96 MPa {20 kgf/cm 2)

Compression pressure should be measured prior to disassembly of the engine. Take measurements regu larly and keep track of changes. During the engine's running-in period or after parts have been replaced, the compression pressure will increase slightly as the piston rings and valve seats fit snugly in position. T he pressure will come down as parts wear.

Difference between cylinders 390 kPa {4 kgf/cm 2l maximum NV .. Nominal Value L .... Limit

Measurement procedure Compression gauge

Compression Gauge Adapter MH061461

85561A 85554A

( 1) Warm up the engine until the coolant temperature reaches 75 to 85°C, then turn off the ignition.

(3) Mount the Compression Gauge Adapter (special tool) onto an injection nozzle hole together with a gasket. Connect the compression gauge. (4) To prevent fuel from being pumped into the cylin der by the injection pump, pull the injection pump governor's stop lever fully in the "stop" direction. (5) Turn the engine over with the starter and measure the compression pressure at 200 rpm.

85560A

(2) Remove all injection nozzles from the cylinder head.

NOTE: Covar all mounting holes and injection pipes to pre vent the entry of dust and dirt.

11A-16

NOTE: 1. Be sure to measure at the correct engine speed since changes in engine speed cause changes in compression pressure. 2. Since wear and other factors vary from one cylin der to another, measure the compression pressure in every cylinder.

ENGINE <602> - SERVICE PROCEDURES 5.2 Cylinder Head and Valve Mechanism 5.2.1 Disassembly <6D22, 22-T, 22-TC> S

Oil hole clogging

,,,,

�

a -,,

ar Wear, damaged threads

8-10 Wear e

e--,2

�dr; wear

Wear, damage 9

�

I�

I_, 16wear<SI>� 1--,:\dge

®'

��

Carbon deposition, cracks, scale deposition, damage 22 ----

�

�!

19 Water leaks, gas leaks J

Wear, cracks

Corrosion

Carbon deposition, burn, cracks, damage, ridge wear / Water leaks, oil leaks, gas leaks Disassembly sequence 9 Push rod

1 Rocker cover 2 Rocker

shaft

bracket

mounting bolt 3 Cylinder head bolt 4 Thrust plate 5 Rocker 6 Set screw 7 Rocker shaft

10 Valve cap Valve cotter 12 Upper retainer

13 Outer valve spring 14 Inner valve spring 15 Lower retainer

*116 Valve stem seal

17 Inlet valve

Exhaust valve

*2® Nozzle tube

*220 Water director

* 221 Sealing cap

@ Cylinder head

23 Crankcase side cover 24 Tappet

@ Rocker shaft bracket For parts wit circled numbers, refer to the following section, "Disassembly Procedure". Parts marked with "*1" should be replaced and not reused, even if only the valve is removed. Parts marked with "*2" should not be removed unless defects are evident.

C1542A

11A-17

ENGINE <6D2> - SERVICE PROCEDURES

<6D24-T, 24-TC>

Oil hole

threads Wear, damaged clogging

47 Water leaks, gas leaks

Wear, damage 7

Wear, cracks

Carbon deposition, cracks, scale deposition, --damage 20 ---- -

Deterio-

ration,

Corrosion 18 -

Carbon deposition, cracks, damage, ridge wear Water leaks, oif leaks, gas leaks

Disassembly sequence 1 Rocker cover 2 Rocker shaft bracket mounting bolt 3 Cylinder head bolt 4 Thrust plate 5 Rocker @ Rocker shaft bracket 7 Push rod

8 Valve cap

® Valve cotter

10 Upper retainer 11 Outer valve spring 12 Inner valve spring 13 Lower retainer * 1 14 Valve stem seal 15 Inlet valve

16 Exhaust valve * 2 @ Nozzle tube * 2 18 Water director * 219 Sealing cap ® Cylinder head 21 Crankcase side cover 22 Tappet

For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with u*1" should be replaced and not reused, even if only the valve is removed. Parts marked with "*2 n should not be removed unless defects are evident.

11A-18

13208

ENGINE <6D2> - SERVICE PROCEDURES Disassembly Procedure

The cylinder head is located on the top surface of the crankcase by dowel pins. To remove the cylinder head, lift it straight upward. Rocker cover Rocker shaft bracket mounting bolt

Cylinder head . bolt

Adjusting screw

C15436

(1) Before removing the bolts, loosen the adjusting screw on every rocker that is being pushed up by its push rod.

NOTE: 1. Remove the injection nozzles before taking off the cylinder head. (Refer to Group 13, Fuel and Engine Control.) If the cylinder head is placed on a work bench with the nozzles still mounted, the ends of the nozzles projecting from the bottom of the cyl inder head will be damaged. 2. When removing the cylinder head gasket, take care not to scratch or dent the cylinder head and crankcase mounting surfaces. (4) Removing valve cotters

(2) Removing rocker shaft bracket assembly

f �

] MH061668

Rocker shaft bracket assembly

in Ss

Valve Lifter Hook MH061679

Va OLY a

F ;•cotter

Spring pin 652826

C15446

The rocker shaft bracket assembly is held in place in the cylinder head by a spring pin. To remove the assembly, lift it straight upward. (3) Removing cylinder head assembly

injection nozzie

To remove the valve cotters, use the Valve Lifter and Valve Lifter Hook (special tools) to evenly compress the valve springs. (5) Removing nozzle tubes

Nozzle Tube Remover MH061232

Nozzle tube

Cylinder head

C1527A

Cylinder head gasket Knock pin

690146

NOTE: Whenever a nozzle tube is removed, it must be replaced with a new one. 11A-19

ENGINE <602> - SERVICE PROCEDURES 5.2.2 Inspection Item Free length Rocker bushing to-rocker shaft clearance 8D 28 NV 0.03 to 0.08 L 0.2

Runout L 0.5

Installed load/installed length

Outer valve spring

89.38

Inner valve spring

65.04

Outer valve spring

450 N {46.1 kgll/58.35

380 N {39 kgfl/58.35

Inner valve spring

115 N {12 kgll/50.35

100 N {10.2 kgf}/50.35

2.5

Inner valve spring squareness

e " e

--��·

8D . Basic Diameter NV . Nominal Value L.. Limit

y � '\'

� If

I I

Tappet-to-crankcase clearance 8D 35 NV 0.06 to 0.10 L 0.2

Cylinder head bottom surface distortion NV 0.07 or less L 0.08 Height of cylinder head from top to bottom surface NV 130 L 129.8

Item Valve stem 0. D.

8D Inlet valve Exhaust valve

11.951011.96

11.85

11.91 to 11.93

Valve stem-to-valve guide clearance

Inlet valve

0.05 to 0.09

Exhaust valve

0.09 to 0.12

Valve seat insert seat width

Inlet valve

0.2

2.69 to 2.96

3.5

Inlet valve

0.25 to 0.75

1.0

Exhaust valve

-0.05 to 0.45

0.7

Inlet valve

2.2

1.7

Exhaust valve

2.5

2.0

Exhaust valve Valve sinkage from cylinder head bottom surface Valve margin

Valve seat angle

11A-20

C27578

ENGINE <602> - SERVICE PROCEDURES Inspection Procedure

Measure the free length and installed load of each valve spring. Replace any spring that is not up to speci fication. With inner springs, check also for squareness.

(1) Rocker bushing-to-rocker shaft clearance Measuring position

(4) Tappet-to-crankcase tappet hole clearance <Tappet measurement>

Measuring position

Measuring position 2734A

If the clearance exceeds the specified limit, replace the rocker bushing.

C2745A

(2) Replacing rocker bushing To install

To remove Rocker Bushing Puller MH061236

C2763A

BushNS

If the clearance exceeds the specified limit, replace the tappet.

Oil hole

0 Adjusting screw side

Rocker oil hole

C2762B

(5) Push rod runout

When installing a bushing, face the bushing's seam toward the rocker adjusting screw and align the bush ing and rocker oil holes. (3) Inspecting valve springs Squareness (inner spring only)

01948

Check for runout and replace the push rod if the dial reading exceeds the specified limit.

11A-21

ENGINE c6D2>

SERVICE PROCEDURES (8) Valve stem-to-valve guide clearance

(6) Cylinder head bottom surface distortion

Valve

Valve guide

C3125A

C3126B

If distortion exceeds the specified limit, correct it using a surface grinder.

Insert the valve in the valve guide and measure the play at the specified distance from the valve guide's top (as illustrated). If the amount of play exceeds the specified limit, replace the valve guide.

NOTE: Replace the cylinder head if grinding causes the height from its top surface to bottom surface to fall below 129.8mm.

(9) Replacing valve guide

(7) Valve stem outside diameter Valve Guide Puller 30091-08100

Measuring position

JI+

Valve guide , Seat the collar-" of valve guide -c"l--1----. securely on cylinder head

To remove

C3102A

Replace the valve if its stem's outside diameter is below specification or if it is severely worn.

To install

To install a valve guide, insert it with the Valve Guide Puller (special tool) until its flange sits securely on the cylinder head.

11A-22

C3113A

ENGINE <6D2>

SERVICE PROCEDURES

(10)Contact between valve and valve seat insert

(11 )Rectifying valve face

Valve margin I

Valve seat angle

Valve Lapper 30091-07500

Valve B2024B

(al Apply an even coat of minium to the valve seat insert surface that comes into contact with the valve. (bl Using the Valve Lapper (special tool), strike the valve against the valve seat insert once.

NOTE: 1. Do not turn the valve when striking it against the valve seat insert. 2. The contact pattern should be checked whenever a valve guide is inspected or replaced.

C2708A

Seat width

C2710B

With a valve refacer, grind the valve face to achieve the specified valve seat angle.

NOTE: 1. Keep grinding to a minimum. 2. If the valve margin is below specification after grinding, replace the valve. 3. After grinding, be sure to lap the valve and valve seat insert. [See item (14) for details]. (12)Rectifying valve seat insert

000 Good

Bad

C3127A C2707A

Valve sinkage

Valve

margin

Valve seat angle

If the minium indicates a poor contact pattern, rectify it as follows: Minor defect: Lapping Serious defect: Rectify valve and valve seat

Valve seat Valve

C2710A

11A-23

ENGINE <6D2> - SERVICE PROCEDURES

(a) Using a valve seat cutter, cut the insert to achieve the specified valve seat angle and seat width. Use a 15° or 75° cutter first, followed by a 45° cutter.

NOTE: 1. Keep cutting to a minimum. 2. If the valve sinkage exceeds the specified limit after cutting, replace the valve seat insert. (b) After cutting, put some sandpaper of around #400 grade between the cutter and valve seat insert and grind the valve seat insert lightly.

Cylinder head I.D. 57 +0.03

NOTE: After rectification, be sure to lap the valve and valve seat insert. [Refer to item (14} for details.]

Install

(13)Replacing valve seat insert Valve seats are installed by expansion fitting and should therefore be replaced according to the follow ing procedure.

<Inlet>

Cylinder head 1.D. 52 +0.03 0 <Exhaust>

C31288

Caulking

Caulking Tool Body MH061360

Caulking Ring I--"�/ Inlet MH061650 Exhaust MH061651

81111 B

01973

(b) Check that there is sufficient interference between the cylinder head and valve seat insert. (c) Cool the valve seat insert by immersing it in liquid nitrogen. Heat the cylinder head. (d) Install the valve seat insert using the Caulking Tool Body and Caulking Ring (special tools), and caulk the periphery of the valve seat insert.

(a) Grind the inside surface of the valve seat insert to reduce its thickness. Remove the valve seat insert at room temperature.

NOTE: When installing the valve seat insert, ensure that the chamfered side of the Caulking Ring faces the valve seat insert.

Cut off.

0.5 to 1.0

(e) Reface the valve seat insert to achieve the specified seat width and valve sinkage. [See item (12) for details.]

11A-24

ENGINE <602>

SERVICE PROCEDURES

(14)Lapping valve and valve seat insert Contact between the valve and valve seat insert must be even over the entire contact area. Lapping should be carried out whenever the valve or valve seat insert has been rectified or replaced.

Valve

Valve stem

(b) Using the Valve Lapper (special tool), lightly strike the valve against the valve seat insert while turning it little by little. (c) Wash away the compound with gas oil or a similar fluid. (d) Apply engine oil to the contact surfaces and rub it in so that the contact surfaces are lubricated and mate together snugly. (e) Check that the valve is properly seated. [Refer to item (10) for details.]

Compound

01970

(a) Apply a thin, even coat of lapping compound to the seating surface of the valve. NOTE: 1. Ensure that no compound adheres to the valve stem. 2. Start with intermediate-mesh compound (120 to 150 mesh), and finish with fine-mesh compound (200 mesh or more). 3. The addition of a small amount of engine oil makes lapping compound easier to apply.

C3130A

ENGINE <6D2> - SERVICE PROCEDURES 5.2.3 Reassembly <6D22, 22-T, 22-TC> Close-coiled end on the cylinder head side

14 10

59N-m {6 kgf-m}

13 Close-coiled end on the cylinder head side

—,

Leak test:

No leaks are alowed with |

| 195kPa{2kgf/cm?} hydraulic pressure

I Apply sealant

i IHERMESEALS-2 or equivalent)

Apply sealant to nozzle tube. (THREEBOND 1211 or equivalent)

6 2

4.9 N-m (0.5 kgf-m}

34N-m

Cylinder head bolt tightening sequence {refer to item (6).J

Assembly sequence @--,@--,@➔@➔

@1➔ 18➔17

15➔14➔13➔12➔®➔10

-f' 24➔23--�

9➔@➔7 ➔6➔5➔4'""*®➔2➔1 For parts with circled numbers, refer to the following section, "Reassembly Procedure." C6641E

11A-26

ENGINE <6D2> - SERVICE PROCEDURES

<6024-T, 24-TC> Tightly wound end toward

cylinder head

Tightly wound end toward cylinder head

Leak test: No leaks are allowed

| with 195 kPa{2 kgf/cm}

| hydraulic pressure

; Apply sealant to nozzle tube. I (THREEBOND 1211 or equivalent) j

19 2

I Apply sealant I (HERMESEAL S-2 or equivalent)

4.9N-m (3.5 kgf.m)

34N-m

{3.5 kgf-m}

Cylinder head bolt tightening sequence [refer to item (6).1

Assembly sequence

®➔@➔@➔®➔@➔ 13➔ 12-4ID➔B➔ 7➔6➔5➔4➔3➔2➔ 1 '1' 16➔1SJ

'1'

22➔21 _J

For parts with circled numbers, refer to the following section, "Reassembly Procedure."

10369

11A-27

ENGINE c6D2> - SERVICE PROCEDURES (3) Valve stem seal installation

Reassembly Procedure ( 1) Water director and sealing cap installation Water director ealing cap

Align notch with this line. Cylinder head

�

0 O

� 0 :o

Valve Stern Seal Installer ME067431

Apply sealant (HERMESEAL 5-2 or equivalent) 10363 Valve Stem Seal

Align each water director with the notch provided, as shown in the illustration. (2) Nozzle tube installation

Cylinder head

Nozzle Tube Installer Bolt MH061231 Nozzle Tube Flange MH061416

15 to 20 N·m (1.5 to 2.0 kgf-m}

09179

To install a valve stem seal, first apply engine oil to the seal lip. Then, push in the seal using the Valve Stem Seal Installer (special tool), striking the tool until it touches the cylinder head.

MB x 1.25 0-ring Nozzle tube ---

Apply engine oil. Apply sealant

(THREEBONO 1211

or equivalent).

09178

(a) Clean the cylinder head nozzle tube holes. Take care to remove dirt, oil, water and carbon deposits from the seating surfaces. (b) Apply sealant to the new nozzle tube, and insert the nozzle tube into the cylinder head. (c) Using the Nozzle Tube Installer Flange (special tool), press the nozzle tube into the cylinder head. (d) Apply engine oil to the Nozzle Tube Stamp (special tool) and insert it into the nozzle tube. (e) Screw in the Nozzle Tube Installer Bolt (special tool) until the Nozzle Tube Stamp can be pulled out of the bottom of the cylinder head. (fl After installing the nozzle tube, carry out a leak test to verify air-tightness.

11A-28

NOTE: 1. When installing a valve, apply a small amount of engine oil to its stem. 2. After installing a valve stem seal, check that its spring has not been deformed or damaged.

ENGINE <6D2> - SERVICE PROCEDURES (4) Valve cotter installation

Install the rocker shaft bracket by positioning it on the spring pin in the cylinder head. Mount the cylinder head by positioning it on the dowel pins in the crank case. (6) Tightening cylinder head bolts Valve Lifter Hook MH061679

Valve MH061668 Lifter

'✓

•cotter

, I

852828

Install the valve cotter while evenly compressing the spring using the Valve Lifter and Valve Lifter Hook (spe cial tools).

C6649A

NOTE: Valve springs must be installed with their tightly wound portions toward the cylinder head.

(5) Mounting rocker shaft bracket and cylinder head Rocker shaft Rocker shaft bracket bolt � bracket 34 N m {3.5 kgf m} ..._,�

Spring pin

� €) o

�

Tighten the cylinder head bolts to 175 N-m {18 kgf.m} (wet) in the order shown. After confirming that the bolts are tightened to 175 N-m {18 kgf-m}, give each one an extra turn in accordance with the following procedure.

Socket

Cylinder head bolt

Socket Wrench MH061540

Rod

Cylinder --�§i'i�

head

Rod (for extension}

Cylinder gasket

' n. \

80654A

(a) Before fitting the Socket Wrench (special tool) over a cylinder head bolt, turn the holder counter-clock wise to tension the built-in socket spring. Knock

89014C

11A-29

ENGINE <6D2> - SERVICE PROCEDURES

Socket Wrench

MH061540

09182

(bl Fit the socket over the cylinder head bolt and set it such that the built-in spring forces the rod against the rocker shaft bracket, an injection pipe, or another nearby part.

Scale inscribed on socket

Lines inscribed on holder

B0656A

(c) Observing the inscribed lines on the holder and socket, turn the socket clockwise by 90 to 110° (1 pitch= 10° ) to fully tighten the bolt.

11A-30

ENGINE <6D2> - SERVICE PROCEDURES 5.3 Flywheel, liming Gears, and Camshaft 5.3.1 Disassembly

<With mechanical

tachometer drive>

.z-,

1�

<With electric I speed sensor> 1

10�-i

\ <"' -''- � \\\\_ . '-

""� �.t"l:i�

¾?! 'ii,"/7' c:=,c;. .

/�

Damage/abnormally worn gear teeth

7 Oil leaks deterioration 3 Streaks/cracks/stepped wear on friction surface 4

8 swear/

C1926F

Damage/abnormally

worn gear teeth

�

\ Disassembly sequence 1 Flywheel mounting bolt *2 Pilot bearing @ Flywheel @ Oil seal retainer 5 Oil seal @ Collar

5 Wear/deterioration

Streaks/cracks/stepped wear

on friction surface

7 Flywheel housing *8 Rear oil seal slinger <models with axial-lip type oil seal only> Sleeve <models with wet type clutch only>

•® Ring gear 10 Tachometer drive *10A Speed sensor 108 Cover

For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with"*" should not be removed unless defects are evident.

C1926L

11A-31

ENGINE <602> - SERVICE PROCEDURES

Timing gear backlash

Between crankshaft gear and idler gear B

0.08 to 0.20

0.4

Between idler gear A and camshaft gear

0.07to 0.18

0.4

Between idler gear A and idler gear C

0.07to 0.18

0.4

0.08 to 0.20

0.4

Item

i Between injection pump gear and idler gear C Injection pump gear

(Refer to Group 61, Special Equipment) NV .. Nominal Value Limit L.. 21 Oil leaks

Oil hole clogging 20

* NV

Idler gear end play 0.05 to 0.15 L 0.4

Wear

Disassembly sequence (jj) Camshaft assembly *® Camshaft *@ Camshaft gear 14 Thrust plate

15 Idler shaft bolt 16 Thrust plate 17 Idler gear C 18 Idler gear A

i * Camshaft gear end play i

NV 0.05 to 0.22

0.4

19 Idler gear B

20 Idler shaft A 20A Idler shaft C *21 Rear plate

For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with should be inspected prior to disassembly. Parts marked with ..... should not be removed unless defects are evident.

"*"

C1927D

11A-32

ENGINE <602> - SERVICE PROCEDURES (3) Removing ring gear

Disassembly Procedure

(1) Removing flywheel Threaded hole for removal

Ring gear B2356C C1928B

To remove the flywheel, screw its mounting bolts into the threaded removal hole.

To remove the ring gear, heat it evenly with an acety lene torch, then tap around its entire periphery with a hammer and rod.

(2) Removing collar and oil seal retainer

(4) Measuring gear backlash

Threaded hole for removal (M4 x 0.7) Collar

Threaded hole L---'cW,!IU

for removal

• •

\ Oil seal retainer

C1929O

C1930A

To remove the collar, screw M4 x 0.7 bolts into the threaded removal holes. To remove the oil seal retainer, screw its mounting bolts into the threaded removal holes. Remove the oil seal retainer with the oil seal attached.

If backlash exceeds the specified limit, inspect the idler gear bushings and gears, and replace parts as required.

Oil seal

NOTE: For any pair of gears, measure backlash at more than 3 points to determine whether it is acceptable.

11A-33

ENGINE <6D2> - SERVICE PROCEDURES

(5) Measuring idler gear and camshaft gear end play

(7) Removing camshaft gear

♦

oe) oO e w=oO£ om®ri]—

11824

10992

If the end play exceeds the specified limit, replace the thrust plate.

To remove the camshaft gear, push out the camshaft using a press.

(6) Removing camshaft

NOTE: Do not attempt to remove the gear by striking it with a hammer. Be sure to use a press. Thrust plate

Camshaft gear

Camshaft

Remove bolts through these holes

Thrust plate mounting bolt

10991

Remove the thrust plate mounting bolts via the holes in the camshaft gear. Remove the camshaft together with the camshaft gear and thrust plate.

11A-34

ENGINE <6D2> - SERVICE PROCEDURES 5.3.2 Inspection

ltem

Friction surface distortion

0.1 or less

0.2

Distance from clutch cover

47.8 to 48.2

49.5

mounting surface to fric

tion surface

I !

C2758F

Clearance BO 40 NV 0.03 to 0.06 L 0.2 Clearance BO 46 NV 0.D3to0.06 L 0.2

BO .. Basic Diameter Nominal Value NV L .. .. Limit NV

Inlet

8.83

8.3

Exhaust

8.82

8.3

0.05 or less

0.08

0.03 to 0.08

0.25

0.02 to 0.05

Can be reassembled up to 3 times

Item Cam profile (difference between base circle diameter and lobe height) Camshaft bend Camshaft journal-to-camshaft bushing clearance

No.1

65.00

No. 2

65.25

No. 3, 4

65.50

No.5,6

65.75

No. 7

66.00

Camshaft gear-to-camshaft interference

C2759O

11A-35

ENGINE <6D2> - SERVICE PROCEDURES Inspection Procedure

(3) Idler gear-to-idler shaft clearance

( 1) Friction surface distortion Measuring position

Measuring position

EB Surface plate

Flywheel

C3807B C3506A Place the flywheel on a surface plate. To measure dis tortion, pass a dial indicator over the flywheel from its periphery toward its center. If distortion exceeds the specified limit, grind the fric tion surface as necessary. NOTE: If the ring gear appears abnormal in any way, replace it before measuring distortion. [For details, refer to item (3) of section 5.3.1.)

If the clearance exceeds the specified limit, replace the bushing in the idler gear. (4) Replacing idler gear bushing

Press

(2) Rectifying flywheel friction surface Idler Gear

Bushing Puller MH061228 (for idler gear "A" MH062046 (for idler gear "C") Bushing

Clutch cover mounting surface Friction surface

Idler gear Dimension B

Removal

Installation

C35098 Grind the friction surface such that dimension B (the distance from the clutch cover mounting surface to the friction surface) is below the specified limit. The fric tion surface must be parallel with surface A to within 0.1 mm. If dimension B exceeds the specified limit, replace the flywheel.

11A-36

C3808A Install the bushing from the side of the idler gear whose internal diameter is chamfered. After installation, confirm that the bushing-to-idler shaft clearance is within the nominal value. If the clear ance is smaller than the nominal value, ream the bush ing.

ENGINE <6D2> - SERVICE PROCEDURES (5) Cam profile (difference between base circle diame ter and lobe height)

Measuring position

(7) Replacing camshaft bushings (a) Removal Remove the camshaft bushings in the following order: No.6 ➔ No.5 ➔ No.4 ➔ No.3 ➔ No.2 ➔ No.1 ➔ No.7. Remove them in accordance with the fol lowing instructions. 1) Removing camshaft bushings Nos. 6 to 1

IIA_J'"--'<-..1-'g��"' Forward nf. Ht. Base 9.5

9.5

circle diameter

No. 6 camshaft bushing Crankcase

C4101A

Measure the lobe heights and base circle diameters. Replace the camshaft if the difference between them is below the limit.

NOTE: Since the cams are tapered, they must be measured at the points shown in the illustration.

Camshaft Bushing

No. 7 camshaft bushing Camshaft Bushing Extractor Bar MH062118

( Camshaft Bushing Extractor Guide MH062119

Extractor Adapter

84859A

MH062123

Engine front

(6) Camshaft journal-to-crankcase camshaft bushing clearance

Camshaft bushing

09166

If the clearance exceeds the specified limit, replace the camshaft bushing. [Refer to item (7) for details.]

Camshaft Bushing Extractor Adapter

No.1

MH062120

No.2

MH062121

No.3,4

MH062122

No.5,6

MH062123 84860A

a) Mount the Camshaft Bushing Extractor Adapter and Camshaft Bushing Extractor Guide (special tools) onto the Camshaft Bushing Extractor Bar (special tool). Insert this assembly into the crank case. When doing this, fit the Guide onto the No. 7 camshaft bushing to support the Bar. b) Hold the Camshaft Bushing Extractor Adapter against the No. 6 camshaft bushing. As shown in the illustration, remove the No. 6 bushing by strik ing the Bar with a hammer. 11A-37

ENGINE <6D2> - SERVICE PROCEDURES cl

After removing the No. 6 bushing, remove bush ings Nos. 5 to 1 in that order using the appropriate Camshaft Bushing Extractor Adapter for each one.

Removing camshaft bushing No. 7

Mount the Camshaft Bushing Installer Adapters (special tool) and bushings Nos. 2 to 4 on the Cam shaft Bushing Installer Bar (special tool). When doing this, align the inscribed lines on the Adapters with the clinches (seams) on the bushings and position the oil holes as shown in the illustration.

No. 7 camshaft bushing

Camshaft Bushing Extractor MH062124

Camshaft Bushing \. installer Guide

MH062127 Instailer CamshaftBar MH062125 Bushing

(';;\

09171

(bl Installation In accordance with the following instructions, install camshaft bushings Nos. 2, 3, and 4 simultaneously, then bushings Nos. 5 and 6 simultaneously, then bush ings Nos. 1 and 7 in that order. 1)

Arrow

/'1:;r__.- mark

84861A

Simultaneous installation of bushings Nos. 2, 3, and 4

No. 3 camshaft bushing tingpin �

No. 2 camshaft bushing

�'"'

b) Fit the Camshaft Bushing Installer Guide (special tool) in the place where the No. 1 camshaft bushing is to be installed so that the Camshaft Bushing Installer Bar (special tool) may be supported by it. Then, insert the Camshaft Bushing Installer Bar into the crankcase, making sure that the arrow on it points toward the top of the crankcase.

—

Installer Nut

MHO062130

Camshaft Bushing Installer Adapter MH062134

Camshaft Bushing Installer Adapter MH062133

Camshaft Bushing

\ Ka

No. 2 camshaft

bushing

��

Camshaft Bushing Installer Bar MH062125

View A

�

Camshaft Bushing Installer Adapter MH062135

7 hae Tighten to

� Clinch Oi!hole�

View A

� , re

Clinch Engraved line (on camshaft bushing installer adaptor) 848620

11A-38

contact

Camshaft Bushing Installer Bar MH062125

09172

Confirm that the clinches (seams) on the bushings are aligned with the inscribed lines on the Cam shaft Bushing Installer Adapters [refer to item (a) for details]. Then, screw the Camshaft Bushing Installer Nut (special tool) onto the end of the Cam shaft Bushing Installer Bar, and tighten the Nut to press-fit the bushings. Continue turning the Nut until the Bar's flange touches the crankcase.

ENGINE <6D2> - SERVICE PROCEDURES d) After installing the bushings, remove the Camshaft Bushing Installer Nut and gently withdraw the Camshaft Bushing Installer Bar.

3) Installation of bushings Nos. 1 and 7 No. 1 camshaft bushing

NOTE: When removing the Camshaft Bushing Installer Bar, take care not to damage the inside surfaces of the bushings.

2) Simultaneous installation of bushings Nos. 5 and 6

~~Clinch

Inscribed Drive in until seated

Inscribed line lin€

Camshaft Bushing Installer MH062143

Camshaft Bushing

installer Guide X

MH062127

“oH

Drive in until seated

No. 5 camshaft bushing Camshaft Bushing

No. 6 camshaft

installer Bar MH062125

bushing

Camshaft Bushing

Arrow

mark

instalier Adaptor MH062136

Camshaft Bushing Installer Adaptor MH062137

B4865A

B4866D

Install bushings Nos. 1 and 7 as follows: Align the inscribed lines on the Camshaft Bushing Installer (spe cial tool) with the clinches {seams) on the bushing and position the oil holes as shown in the illustration. Face the arrow on the Installer toward the top of the crank case. Drive in the Installer until its flange touches the crankcase.

Follow the procedure in section 1) using the appropri ate Camshaft Bushing Installer Adapters (special tool) for bushings Nos. 5 and 6.

11A-39

ENGINE <6D2> - SERVICE PROCEDURES (8) Camshaft bend

(9) Camshaft-to-camshaft gear interference

10995

Measure the extent of bending in the crankshaft. If it exceeds the specified limit, replace the crankshaft.

If the interference is below the specified nominal value, replace the camshaft or camshaft gear.

NOTE: Apply a dial indicator to the camshaft and turn the camshaft through one revolution. One-half of the dial indicator reading represents the amount of bending.

NOTE: Even if the interference is up to specification, reas sembly should be carried out no more than 3 times.

11A-40

ENGINE <602> - SERVICE PROCEDURES 5.3.3 Reassembly

21 7

8D. Basic Diameter NV. Nominal Value L.. Limit

j Flywheel housing ' eccentricity / I L 0.2 Bend lock washer

Camshaft gear-to-camshaft interference 8D 40 NV 0.02 to0.05 L Reassemble max. 3 t imes

Idler gear end play NV0.05to0.15 L 0.4

12 I Camshaft gear end play j 13 111 NV 0.05 to0.22 L 0.4 t j 141

<Radial-lip-type oil seab

20A

16 15 155 N-m {16 kgf.m) 98 N-m {10 kgf.m)

8 9

*10A

Assembly sequence

10B

18 98 N-m {10 kgf.m} 15 155 N-m {16 kgf-m}

Apply engine oil or lithium-base grease ! to oil seal lip

3�-----� Flywheel friction surtacerunout L 0.2

86013A

6 19

/ Backlash , NV0.08 to0.20 � I L 0.4 .

69 N-m {7 kgf-m}

I Backlash NV0. 7to0.18 L 0.4 ,

' Backlash NV0.07 to0.18 L 0.4

w M �

Backlash NV 0.08 to 0.20

For parts with circled numbers, refer to the following section, .. Reassembly Procedure." For parts marked with .. * .. refer to Group 61, Special Equipment.

B1902E

11A-41

ENGINE <6D2> - SERVICE PROCEDURES (3) Fitting camshaft gear

Reassembly Procedure

(1) Mounting rear plate

feRt_ i-

l__

Camshaft gear

Thrust plate

Cut here.

Camshaft � 10980 C6230C

Mount the rear plate and gasket, ensuring that they are aligned with the locating pins on the crankcase. After the gasket is fitted, its bottom (oil pan mounting surface) will protrude. Cut off the protruding part of the gasket after fitting the flywheel housing. (2) Installing idler gears Crankshaft gear

OL)

NOTE: 1. When fitting the camshaft gear, press down on its central section using a tube. Do not press down on the gear's periphery. 2. Reassembly should be carried out no more than 3 times. (4)

Idler gear B

Fit the camshaft gear using a press, ensuring that the side stamped with "4" marks is facing away from the thrust plate.

Installing camshaft

\ee

2 6

155 N-m (16 kgf-m}

155 N-m {16 kgf-m}

C6231D

Fit idler gear B and the crankshaft gear such that their "1" alignment marks are aligned with each other. Then, fit idler gears A and C such that their "2" align ment marks are aligned with each other. Tighten the idler shaft bolts to the specified torques. NOTE: 1. Align the "1" marks with pistons Nos. 1 and 6 at top dead center. 2. Ensure that the "1" marks are aligned before align ing the "2" marks.

11A-42

Camshaft gear C6231C

Install the camshaft such that the "4" alignment marks on the camshaft gear and idler gear A are aligned with each other. NOTE: 1. When inserting the camshaft, take care not to damage the camshaft bushings. 2. Ensure that the "1" marks on the crankshaft gear and idler gear Bare aligned before aligning the" 4" marks.

ENGINE <6D2> - SERVICE PROCEDURES (5) Check the end play in the camshaft gear and idler gears. [Refer to item (5) of section 5.3.1 for details.] (6) Check the backlash in the gears. [Refer to item (4) of section 5.3.1 for details.]

the Oil Seal Sleeve Installer. The sleeve is in the correct position when the Installer can be driven in no further. (9)

Fitting ring gear

(7) Installing rear oil seal slinger <With axial-lip-type oil seal> Rear oil sea! slinger Oil Seal Installer MH061652

Ring gear

Chamfered

Flywheel

Seat this surface

B2357C

tightly all around Threaded groove

C5529B

Face the threaded groove toward the flywheel. Using the Oil Seal Slinger Installer (special tool), evenly press the oil seal slinger until it is seated tightly on the crank shaft gear.

Using a piston heater, heat the ring gear to approxi mately 100°c for 3 minutes. Fit the ring gear with the non-chamfered side of its teeth toward the flywheel. (10)Fitting flywheel housing

18) Fitting oil seal sleeve <With radial-lip-type oil seal> Correct sleeve position

-f'==><j��:=:;;J;......-

Oi! seal sleeve

Applyo 2 mm sealant bead (THREEBOND 1207C)

Dowe! pin

Strike 848570 Oil Seal Sleeve Installer 31191-07100 Crankshaft

85774A

Apply engine oil to the crankshaft and to the inside diameter of the sleeve. Using the Oil Seal Sleeve Installer (special tool), press the sleeve into position on the crankshaft. NOTE: 1. The sleeve's inside diameter is chamfered on one side. When fitting the sleeve, face the chamfered side toward the crankshaft. 2. Since the sleeve must be pushed into the correct position (shown in the illustration), you must use

(a) Apply a bead of sealant to the flywheel housing as shown in the illustration. Fit the flywheel housing within 3 minutes of applying the sealant. NOTE: 1. Apply a new bead of sealant whenever the fly wheel housing mounting bolts have been loos ened. 2. Keep the flywheel housing sealing surface free of dirt and oil. 3. Apply the sealant evenly and without breaks.

4. When fitting the flywheel housing, hold it firmly in position to prevent spreading the sealant. 5. After fitting the flywheel housing, wait at least 1 hour before starting the engine. 11A-43

ENGINE <6D2> - SERVICE PROCEDURES (12)1nstalling oil seal <Axial-lip-type oil seal>

Locating pin

Oil seal

Flywheel housing

/ Seat oil seal end on

the retainer positively all around.

Oil seal retainer

C6230E

(b) Fit the flywheel housing such that it is aligned with the locating pins in the crankcase.

10362

To fit the oil seal onto its retainer, apply pressure evenly to its entire periphery until it is seated tightly in the retainer.

( 11 )Checking flywheel housing eccentricity

<Radial-lip-type oil seal>

69N-m {7 kgf-ml

Oil Seal Installer 31191-04300 Oil seal retainer

C6233B

Tighten the flywheel housing mounting bolts to the specified torque. Then, rotate the flywheel and check for eccentricity at the flywheel housing joint. If eccen tricity exceeds the specified limit, remove the flywheel housing, refit it according to the instructions in item (10), and measure the eccentricity again. If the eccentricity exceeds the specified limit even after remedial measures have been taken, replace the fly wheel housing.

11A-44

C6209C

(a) To install the oil seal, apply pressure evenly to its entire periphery using the Oil Seal Installer (special tool) until it reaches the step in the oil seal retainer.

ENGINE <6D2> - SERVICE PROCEDURES (14)Checking valve timing If you need to recheck the valve timing after reassem bling the engine, do so according to the following pro cedure.

Oil Seal Installer 31191-04300

Rocker arm Oil seal retainer Oil seal

C6209D

(b) Turn the oil seal retainer over, then apply the Oil Seal Installer (special tool) to the oil seal from the opposite direction until the oil seal reaches the retainer's outer surface. NOTE: Different oil seals have different installation direc tions. Be sure to install the oil seal in the correct direc tion.

(13)Checking flywheel runout

Valve cap B5714C

(a) Bring cylinder No.1 to its compression-stroke top dead center position. (b) Insert a 3 mm shim between cylinder No.1 's exhaust valve rocker arm and valve cap. Make any adjustments necessary using the adjusting screw, then tighten the lock nut.

) C6236B

After tightening the flywheel mounting bolts to the specified torque, rotate the flywheel and check for run out. If runout exceeds the specified limit, check the bolts' tightness and/or check the mounting surface.

Confirmation marks 10408

(c) Crank the engine in its normal direction of rotation (clockwise when viewed from the front). When cyl inder No.1's exhaust valve begins to lift, confirm that the pointer on the flywheel housing is between the valve timing confirmation marks on the fly wheel's outer periphery. If the timing marks are in the wrong position, refer to items (2) and (4), and check the timing marks again.

11A-45

ENGINE <6D2> - SERVICE PROCEDURES 5.4 Crankcase and Main Moving Parts 5.4.1 Disassembly

8== 0---- } 4

Damage/discoloration 7

8 discoloration/melting

! * Projection of piston fro

rod end play * Connecting NV 0.2 to 0.5

Damage/ abnormal wear

Scratches on outer periphery/ cracks on top/

� C) -C) Cracks 9

NV . Nominal Value L.. Limit

)

top surface of crankcase NV 0.87 to 1.33

jJ-10

1.0

3 Scratches/corrosion/ peeling on inner and outer peripheries

Repair kit: Liner and Piston Kit I

Scratches/corrosion/ 2 peeling on inner and (\ _.,,...,....... outer peripheries � 1

�

Disassembly sequence 1 Connecting rod cap 2 Lower connecting rod bearing 3 Upper connecting rod bearing @ 1st compression ring 2nd compression ring

@ Oil ring

7 Piston pin

Piston

® Connecting rod

*10 Connecting rod bolt

For parts with circled numbers, refer to the following section, "Disassembly Procedure." should be inspected prior to disassembly. Parts marked with Parts marked with "*" should not be removed unless defects are evident.

"*"

11A-46

C2337G

ENGINE <6D2> - SERVICE PROCEDURES

NV . Nominal Value L.. Limit

Clogged oil hole

Rear oil seal slinger (Refer to 5.3.)

ail hole

24 .

Scratches/corrosion/ peeling on inner and uter peripheries

�

15 19

��" peripheries

Scratches, cracks, dents, seisure, clogged oil hole, corrosion

1 i j

* End play NV 0.09 to 0.23 L

0.4

Disassembly sequence 11 Torsional damper 12 Crankshaft pulley *113 Front oil seal 14 Front cover 1 • 15 Front oil seal slinger 16 Main bearing cap

17 Thrust plate 18 Lower main bearing 19 Crankshaft 20 Upper main bearing •1@ Crankshaft gear

•1 22

Cylinder liner •223 Check valve 24 Oil jet 25 Oil spray plug 26 Crankcase

For parts with circled numbers, refer to the following section, urnsassemb!y Procedure." Parts marked with should be inspected prior to disassembly. Parts marked with "*1" should not be removed unless defects are evident. Parts marked with "*2" must not be reused since they are held in place by thread-lock cement and may be deformed during disassembly. 80599G

"*"

11A-47

ENGINE <602> - SERVICE PROCEDURES (3) Removing pistons

Disassembly Procedure ( 1) Piston projection The piston projection measurements must conform with specifications, partly since they affect engine per formance, and partly since the pistons must not inter fere with the valves.

.. . .

Fr.o

•

Measuring point

Withdraw the piston from the crankcase together with its connecting rod, working from the top surface of the crankcase. C23398

la) Attach a dial indicator to the top surface of the crankcase and adjust it to zero. lb) Using the dial indicator, find the piston's top dead center position. (c) Take measurements at 4 points on the piston's top surface and determine their average. (d) If the piston projection does not conform with specifications, check the clearances between pis ton/connecting rod and neighboring parts.

NOTE: When removing a piston, take care not to damage the cylinder liner. (4) Separating piston from connecting rod Snap ring Piston

(2) Connecting rod end play

Connecting rod

B2428C

Remove the snap rings, then use a rod and hammer to tap the piston pin out. If the piston pin is hard to remove, heat the piston in hot water or with a piston heater.

C2340A

Measure each connecting rod's end play. If any mea surement exceeds the specified limit, replace the con necting rod.

11A-48

ENGINE <6D2> - SERVICE PROCEDURES 15) Removing piston rings

17) Removing main bearing caps

Slide hammer

Piston Ring Tool 31191-02900

M10 X 1.5

C2321A

16) Crankshaft end play

B0183B

The rearmost main bearing cap is located on dowel pins and must therefore be removed with a slide ham mer. (8) Removing crankshaft gear Rear oil seal slinger

Crankshaft gear

B0181C

Before removing the main bearing caps, measure the end play in the crankshaft. If it exceeds the specified limit, replace the thrust plate with an oversized one. [Refer to item (3) of section 5.4.3 for details.]

(a) Split the rear oil seal slinger with a chisel and remove it from the crankshaft. (b) Remove the crankshaft gear from the crankshaft using the Gear Puller (special tool).

NOTE: Do not attempt to remove the crankshaft gear by strik ing it.

11A-49

ENGINE <6D2> - SERVICE PROCEDURES 5.4.2 Inspection End gap Item

Clearance 8D 50 NV 0.01 to0.02 L 0.1

C) C)

L 1.5

1st compression ring

6D22, 22-T, 22-TC

0.4 to 0,6

6D24-T, 24-TC

0.4 to 0.55

'2nd compression ring

6D22, 22-T, 22-TC

0.4 to0.6

6D24-T, 24-TC

0.5 to0.65 0.4 to0.6

Oil ring

1.5

Piston ring groove-to-piston ring clearance Item NV 1st com- , 6022

0.05 to 0.12

pression f-------1------, 6D22-T 0.03to0.10 ring Clearance 8D 50 NV 0.02 to0.05 L 0,1 ! Bend and torsion I L 0.05 or less

2nd com pression ring

6D22-TC

0.01 to0.09

6D24-T, 24-TC

0.02 to0.10

6D22

0.05 to0.08

6D22-T, 22-TC, : 24-T, 24-TC

0,07 to0.10

I Oil ring Crankcase top surface distortion NV 0.07 or less L 0.2 Flatness of cylinder liner supporting flange L 0.1

, Projection of cylinder liner from ' top surface of crankcase NV 0.01 to0,08 Inside diameter NV 130.014to 130.054 L 130.25 Cylindricity NV 0.02 or less

0,03 to 0.06

L 0.25

0.25

0.15

Clearance

Item 6D22

130

0, 178 to0.204

6D22-T

0, 173 to0.199

6D22-TC

0.188 to0.214

6D24-T, 24-TC

0.193 to0.219

BD . Basic Diameter NV . Nominal Value L.. Limit

Connecting rod bearing-to-crankshaft pin clearance 8D 84 NV 0.07to 0.13 L 0.25 Connecting rod bearing span when free L Less than 90.5

C2760C

11A-50

ENGINE <6D2> - SERVICE PROCEDURES

8D .. Basic Diameter NV . Nominal Value L.. . Limit

Bend NV 0.04 or less L 0.1 Roundness NV 0.01 or less L 0.08 Cylindricity NV 0.006 or less

Main bearing-to-crankshaft journal clearance BD 100 NV 0.08 to 0.15 L 0.25 Main bearing span when free L Less than 106.5 B0599H

Inspection Procedure (1) Flatness of cylinder-liner-supporting flange on crankcase

Bi479A

If the measured value is out of specification, replace the crankcase. 11A-51

ENGINE <6D2>

SERVICE PROCEDURES (4) Cylinder liner flange projection

(2) Distortion of crankcase top surface

Measurement points

If distortion of the crankcase top surface exceeds the specified limit, correct it with a surface grinder. NOTE: When grinding the crankcase, take care that the piston projection does not exceed the specified nominal value. [Refer to item (1) of section 5.4.1 for details.)

If any cylinder liner projection does not conform with its specified nominal value, replace the cylinder liner or crankcase. [Refer to item (5) for details of cylinder liner replacement.] (5) Replacing cylinder liner (a) Removal

(3) Cylinder liner inside diameter Cylinder Liner Extractor MH061490 Size mark

30 or more -,,;,<,,f-, t----j II'!'.

70 or more

A: Direction of crankshaft axis B: Direction of right angle to crank� shaft axis C4424A

Measure each cylinder liner's inside diameter at 6 points, as shown in the illustration. If the inside diame ter exceeds the specified limit, replace the cylinder liner or bore it to oversize. [Refer to item (5) for details of cylinder liner replacement.]

11A-52

C4414B

ENGINE <602> - SERVICE PROCEDURES (b) Installation Strike in . Size mark {A, B, C)

Piston

Cylinder Liner Installer MH061759

..,..J�::_..j::::::�l,.,e' Cylinder liner Cylinder liner

C4427B

C4813C

1) Make sure the new cylinder liner bears the same size mark as that of the piston. Piston size mark Cylinder liner size mark A--------A

B C 0-ring---"'=!i

Rubber packing 0-ring

B C

Soap suds to be applied

3) Using the Cylinder Liner Installer (special tool), gently tap the cylinder liner down until its flange is securely seated on the crankcase. NOTE: 1. Do not stretch 0-rings more than is necessary, and be careful not to damage them. 2. Contact with gas oil, kerosene, anti-corrosion oil, and similar fluids causes 0-rings to swell. Immedi ately wipe off any such fluids that come into con tact with the 0-rings. A 3. fter installing a cylinder liner, carry out a leak test to check for air-tightness.Apply thrust force to the cylinder liner flange.

Soap suds to be applied

C4426B

2) Fit new 0-rings and rubber packing to the cylinder liner, and apply soap suds to the crankcase and cyl inder liner at the points where they will touch each other.

11A-53

ENGINE <6D2>

SERVICE PROCEDURES

(6) Selection of pistons and cylinder liners A piston may be either standard or oversized. Cylinder liners are selected accordingly. (a) Standard piston

(b) Oversized piston In accordance with the following instructions, bore the cylinder liner to suit the oversized piston to be used (+0.5, +0.75, or +1.00 mm). Cylinder liner 1.0.

<6D22, 22-TC, Size mark IA, B, C )

<6D22-T, 24-T, 24-TC> Weight "T" mark D'[!;_T only> l /<6 � Part number � Size mark (A, B, C)

or more -J4�L---.J

,-J;.

Size mark stamped

Weight Part number

(

70 or more

-· -· •

A:Axial direction of crank shaft B: Direction at right angles to crankshaft

C4424A

Oversize piston O.D. 102 <6D22, 22-T, 22-TC>

<6D24-T, 24-TC> Cylinder liner

0.0. measuring position 4428A

B4221D

1) The piston must bear the same size mark as that stamped on the cylinder liner. 2) The weight of all 6 of an engine's pistons must be within 10 g of the weight that is stamped on each piston's crown. NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.

11A-54

Determine the amount of metal to bore out. To do this, measure the inside diameter of every cylinder liner and find the most worn point. 2) Bore and hone-finish the cylinder liner to achieve the specified nominal clearance between the over sized piston and cylinder liner. NOTE: 1. Even if only one cylinder requires boring, bore every cylinder to the same oversized inside diame ter. 2. Replace the piston rings with oversized piston rings that correspond to the increased cylinder liner dimension.

ENGINE <6D2>

SERVICE PROCEDURES

(7) Piston-to-cylinder liner clearance

(9) Piston ring gap

If the clearance is out of specification, replace the pis ton or cylinder liner. [Refer to item (6) for details.] (8) Piston-to-piston ring clearance Piston

Piston ring

Cylinder liner C48078

C48068

If the clearance exceeds the specified limit, replace the piston or piston rings.

NOTE: 1. After removing any carbon deposits, measure the clearance around the piston's entire periphery. 2. Always replace piston rings as a set, never individ ually.

Measure the piston ring gaps with the piston rings hor izontally pushed into a standard cylinder liner, either in or out of the crankcase. Replace the rings if any gap exceeds the specified limit. Standard cylinder liner inside diameter: 130 ± 0 mm

NOTE: Use a piston to push the piston rings into the cylinder liner for measurement. (10)Piston pin-to-piston pin hole clearance Piston

Thickness gauge

1st

Piston

••·� Straight edge

�,,,

+ C4810D

Measure the 1st compression ring clearance while pressing the ring against the piston with a straight edge.

If the clearance exceeds the specified limit replace the piston pin or piston.

NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.

11A-55

ENGINE <6D2> - SERVICE PROCEDURES

( 11 )Piston pin-to-connecting rod small end bushing clearance Connecting rod bushing

(a) Removing bushing Mandrel 31291-75200

n ® +...,

Collar A MH063370 Bushing Fixing bracket

ffi

Guide Plate Assembly MH063366 Larger dimension facing downward

Piston pin

If the clearance exceeds the specified limit, replace the connecting rod bushing. (12)Replacing connecting rod bushing

Press bench

C5203A

1) Remove the bearing from the connecting rod's big end, then mount the connecting rod on the Base (special tool). 2) Fit the Mandrel and Collar A (special tools) onto the connecting rod's small end as shown in the illustra tion. Slowly apply pressure with a press that has a capacity of at least 49 kN {5,000 kgf). (b) Press-fitting bushing kN{5, 000 kgf]

Approx. 49 �

Guide Plate Assembly Collar B MH063366 MH062189--i.�_.;., Oil hole Bushing Nut Collar A 31291- Larger dimension facing downward 75500 MH063370

10976

Replace the bushing using the Connecting Rod Bush ing Puller (special tool).

Press bench

10977

Set up the Mandrel, Collar B, Collar A, and the Nut (special tools) on the bushing as shown in the illustration. 2) Apply engine oil to the connecting rod's small end and to the bushing. 3) Using the press, apply pressure of approximately 49 kN {5,000 kgf) such that the bushing is pressed into the connecting rod's small end. 4 ) After press-fitting the bushing, remove the special tools. Then, ream the bushing to achieve the speci fied nominal clearance between the bushing and piston pin. 1)

11A-56

ENGINE <602> - SERVICE PROCEDURES NOTE: 1. When press-fitting the bushing, align the oil hole in the bushing with the oil hole in the connecting rod. 2. When the piston pin is inserted, ensure that it turns easily and without play. (13)Connecting rod bend and twist Bend I= 100

C5209A

Connecting rod aligner

If the span is less than the specified requirement, replace the upper and lower bearings as a set.

NOTE: Do not attempt to manually expand a bearing if its span is insufficient.

Piston pin C5205A

C5206A

(15)Connecting rod bearing-to-crankshaft pin clear ance Connecting rod bearing inside diameter Measuring position Measuring direction

Piston pin

Connecting rod aligner C5207 A

---=-=--��

C5208A

Measure the amount of bend and twist in the connect ing rod using a special connecting rod aligner. If the measurements exceed the specified limits, replace the connecting rod or rectify it using a press.

NOTE: 1. Measurements must be made with the connecting rod bushing and upper and lower connecting rod bearings fitted in their respective positions. 2. Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. (14)Span of connecting rod bearings and main bear ings when free

01996 Crankshaft pin outside diameter

Measuring position Measuring direction

C5223A

If the clearance exceeds the specified limit, replace the upper and lower bearings as a set.

NOTE: Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. 11A-57

(16)Main bearing-to-crankshaft journal clearance

(18)Crankshaft bend

Main bearing inside diameter

Measuring direction

C5526A

C5524A

Crankshaft journal outside diameter

Measuring position

Measure the extend of bending in the crankshaft at the middle journal. If the measurement exceeds the speci fied limit, grind to undersize or replace the crankshaft. NOTE: With the dial indicator applied to the middle journal, turn the crankshaft through one revolution. One-half of the dial indicator reading represents the extent of bending in the crankshaft. {19)Grinding crankshaft to undersize

If the clearance exceeds the specified limit, replace the upper and lower bearings as a set. ( 17) Roundness and cylindricity of crankshaft pin and journal Roundness

Cylindricity

Measuring direction

Measuring position

70± 0.1 <6D22, 22-T, 22-TC> 75±0.07 <6D24-T, 24-TC>

RS R C5527A

C5523A

If roundness and cylindricity do not conform with the specified limits, grind to undersize. [Refer to item (19) for details.]

11A-58

Any damaged or scorched journal or pin must be ground in accordance with the following instructions. If grinding is carried out, the main bearing must be replaced with an undersized one. {a) Grind such that the center distance between the journal and pin does not change. (b) Grind such that the width of the journal and pin does not change. (c) Finish the corner fillet smoothly and to the speci fied radius.

ENGINE <6D2> - SERVICE PROCEDURES (d) Use magnetic flaw detection to check for ground cracks. Also, check that the Shore hardness of the surface has not dropped below Hs 75.

Finishing

Grinding

(e) When grinding, turn the crankshaft counter-clock wise as viewed from its front end. The grinder should also rotate counter-clockwise as viewed from the crankshaft's front end. (f) When finishing the crankshaft with sandpaper or a whetstone, turn the crankshaft clockwise.

'. Whetstone or sand paper

Grinder Crankshaft

C5509A

I I

Journal 0. D.

Pin 0. D. finished dimension

Roundness

Cylindricity

finished dimension

--0.25

--0.08 99.75 --0.10

--0.06 83.75 --0.09

0.01 or less

0.006 or less

--0.50

--0.08 99.50 --0.10

83.50

--0.06 --0.09

--0.75

--0.08 99.25 --0.10

83.25

--0.06 --0.09

-1.00

--0.08 99.00 --0.10

--0.06 83.00 --0.09

Amount of

undersize

11A-59

ENGINE <602> - SERVICE PROCEDURES 5.4.3 Reassembly NV . Nominal Value Limit L..

Assembly sequence

26322

+H+B

Cylinder liner flange projection NV 0.01 to 0.08

0 =D00

®39 47 © © @ @

| 26

➔@➔14➔@➔12➔11 For parts with circled numbers, refer to the following section, "Reassembly Procedure."

10 Locating pin 34N-m {3.5 kgf-mJ 23

1st compression ring gap

Expander sprmg ends

Lug direction -�lit--

' i Piston projection ; NV 0.87 to 1.33

2nd

com �re nng gap

g gap

115 N-m {12 kgf ml+ 60 ° {wet)

115N-m {12 kgf-m) (wet)

33N-m {3.4 kgf-ml

Align lug directions

Locating pin

Rear oil seal slinger [ Refer to item (7) of section 5.3.3) Oil seal sleeve (Refer to item (8) of section 5.3.3)

175 N-m

{18 kgf-m}

11 12

Apply lithium-base grease to lip

Connecting rod end play NV 0.2 to 0.5 L 1.0

17 Side with oil groove faces sliding surface Crankshaft end play NV 0.09 to 0.23 L 0.4

C5835F

11A-60

ENGINE <6D2> - SERVICE PROCEDURES

(3) Installing upper main bearing and thrust plate

Reassembly Procedure ( 1) Installing oil spray plug

Upper mam bearmg

ffl'!,."J'.J!vThrust plate

mounting pin

) C5837A

C2335B

Install the oil spray plug such that the arrow stamped on it points toward the top of the engine. (2) Installing oil jet and check valve

�

Check valve 34N-m {3.5 kgf-m)

Install the upper main bearing such that the bearing lug is aligned with the lug groove on the crankcase. Install the rearmost thrust plate with its grooveless side facing the crankcase. NOTE: 1. The main bearing's upper part has an oil groove. The lower part does not have a groove. Take care not to confuse the upper and lower parts. 2. Oversized thrust plates are available for adjust ment of crankshaft end play [refer to item (6) of section 5.4.1 for details]. The oversized thrust plates available are +0.15, +0.30, and +0.45 mm. If any of these is used, ensure that the correct size thrust plate is fitted to the bearing cap [refer to item (7) for details].

C5836C

(4) Installing cranksj,aft gear

Insert the oil jet's locating pin into the hole on the crank case, and tighten the check valve to the specified torque. NOTE: Check valves cannot be reused. Be sure to use a new one.

Dowel pin

-;�

Crankshaft

Crankshaft gear 84202A

(a) Heat the gear to approximately 100° C using a pis ton heater.

11A-61

ENGINE <6D2> - SERVICE PROCEDURES

(bl Locate the gear such that the dowel pin on the crankshaft will fit into the notch in the gear. Fit the gear by lightly striking it with a soft hammer. (c) Fit the rear oil seal slinger (refer to item (7) of sec tion 5.3.31 or oil seal sleeve (referto item (8) of sec tion 5.3.3). (5) Fitting front oil seal slinger <Axial-lip-type oil seal>

(7) Installing lower main bearings and main bearing caps Install the lower main bearings and main bearing caps in accordance with the following procedure.

�O.I 7\ O� i Front

Front oil seal slinger Oil Seal Slinger Installer MH061817

Crankshaft

�

�;r;kshaft

�o

direc1ion

Dowel pin 13192

B0596A

Fit the front oil seal slinger using the Oil Seal Slinger Installer (special tool).

(a) Drive the locating dowel pins into the rearmost main bearing cap in the direction shown in the illustration. Thrust plate

(6) Installing crankshaft

Main bearing cap

Thrustplatein eemountin ingp ~

Oil groove Thrust

Lower main bearing -

ENS

—~,one

otal 8s,

C5833A

Lift the crankshaft with a hoist. Keeping it horizontal, gently lower it into the crankcase.

Embossed main bearing

cap nu� Fro�t of..,A,-, engine�

(�

o � o/�oo� C

�

•

'¾ B4222E

(b) Mate each main bearing with its main bearing cap, ensuring that the lugs on the bearings are aligned with the lug grooves in the caps.

11A-62

ENGINE <6D2> - SERVICE PROCEDURES (c) Only to the rearmost main bearing cap, install a thrust plate on each side, with the thrust plates' grooveless sides facing the main bearing cap.

counter-clockwise to tension the built-in socket spring.

NOTE: Thrust plate for front side of the bearing cap Thrust plate for rear side of the bearing cap

Should be the same size. 10505

Thrust plate for rear side of the crankcase

C5838H

If an oversized thrust plate is used, ensure that the bearing cap rear thrust plate and the rearmost thrust plate in the crankcase [refer to item (311 are the same size. Note, however, that the bearing cap front and rear thrust plates may be of different sizes.

(d) Fit the main bearing caps in the order of the num bers that are embossed on them, working from the front of the engine. Fit them such that the sides with lug gr.coves are toward the right of the engine. (e) Press down the main bearing caps until they touch the crankcase. Tighten the main bearing cap mounting bolts to 115 N-m {12 kgf-m} (wet). After confirming that the bolts are tightened to the specified torque, give each one an extra turn in accordance with the following procedure.

Socket Wrench MH063365

Fit the socket over the main bearing cap mounting head bolt. Set it such that the built-in spring forces the rod against the side of the crankcase.

Scale inscribed on socket

Lines inscribed on holder

09183

3) Observing the inscribed lines on the holder and socket, turn the socket 60 ° clockwise (1 pitch= 10 °) to fully tighten the bolt. After assembly, check that the crankshaft can be turned easily by hand. Also, check that the crankshaft's end play conforms with the specified nominal value. [Refer to item (6) of section 5.4.1 for details.]

Rod

13205

1) Before fitting the Socket Wrench (special tool) over a main bearing cap mounting bolt, turn the holder 11A-63

ENGINE <602>

SERVICE PROCEDURES NOTE: All the connecting rods in an engine must have the same weight mark. Weight marks are as follows:

(8) Installing connecting rod bolts Flattened side toward connecting rod

Ii \

Heavy ,________________,. Light B C D E F G H J K

Press fir with max. 5.9 kN {600 kgf}

(10)Fitting piston rings

rApplyengineoil

��

�/r-==

Piston Ring Tool

Ends

31191-02900

Check for damage/burrs 890078

Checkthat there are no burrs or damage in the connect ing rod's bolt holes. Apply engine oil to the connecting rod bolts, then press fit the bolts such that the flattened side of their heads face inward.

\ Manufacturer mark stamped (Compression ring only)

C5841B

(9) Reassembling piston and connecting rod

Expander spring ends

---+----

Piston

Arrow indicating front

�--=2nd compression ring ends Connecting rod

Piston pin

Weight mark lug groove mark

_J_--Alignment mark

C5840C

Connect the piston to the connecting rod with the pis ton pin such that the piston's front mark is on the same side as the connecting rod's lug groove mark. If the piston pin is difficult to insert, heat the piston in hot water or with a piston heater. 11A-64

Oil ring ends

C5843A

Using the Piston Ring Tool (special tool), fit the piston rings in the positions shown in the illustration. Ensure that the manufacturer's marks on the compression rings face upward. Fit the rings in the following order: 1. 2. 3.

Oil ring 2nd compression ring 1st compression ring

ENGINE <6D2> - SERVICE PROCEDURES ( 11) Installing upper and lower connecting rod bear ings Lower connecting rod bearing

Align these.

Upper connecting g jp. SS rod bearing :

Oil hole

NOTE: 1. Check that the size mark on the piston matches the size mark on the cylinder liner. 2. Ensure that the piston ring ends stay in their cor rect positions. 3. Slip some plastic tube over the connecting rod bolts to prevent them from damaging the cylinder liner and crankshaft pin. <Using the Piston Guide Clamp and Piston Guide Lever (special tools)>

Piston Guide Clamp

Connecting rodcap = Connecting rod

84223A

Install the upper connecting rod bearing such that its lug is aligned with the connecting rod's lug groove. Install the lower connecting rod bearing such that its lug is aligned with the connecting rod cap's lug groove. NOTE: The upper connecting rod bearing has an oil hole. The lower bearing does not have an oil hole. Take care not to confuse the upper and lower parts.

B5291C

Align the Piston Guide with the piston skirt and set the Piston Guide Lever in position. Turn the adjusting bolt such that the Clamp's inside diameter matches the pis ton's outside diameter. Next, remove the Clamp from the piston and apply engine oil to the outside of the pis ton, to the inside of the Clamp, and to the inside of the cylinder liner. Fit the Clamp over the piston such that it is flush with the piston's crown. Using a wooden mallet or block, tap the piston into the cylinder, taking care not to damage it.

(12)Installing piston and connecting rod

Piston Guide Lever MH061658

Adjusting bolt

Piston Guide

Clamp MH061666

C5834B

Using the Piston Guide Clamp and Piston Guide Lever (special tools), install the piston and connecting rod such that the front mark on the piston's crown faces the front of the engine.

11A-65

ENGINE <6D2>

SERVICE PROCEDURES

I 13) Fitting connecting rod caps

5.5 Inspecting and Adjusting Valve Clearances

Connecting rod cap

wo I i ek! Pat ie | tis ed iy ~4 ]os

Aj vo

Valve clearances should be checked and adjusted when the engine is cold.

)

Front of engine

mm wey % Vv

Lug groove mark

C58448

Ensure that the alignment marks and lug groove marks on the connecting rod caps and connecting rods are aligned with each other. I 14)Check the connecting rod's end play. [Refer to item (2) of section 5.4.1 for details.] (15)Check that the piston projections conform with specifications. [Refer to item ( 1) of section 5.4.1 for details.]

( 1) Crank the engine until the inscribed "1-6" mark on the flywheel is aligned with the pointer in the fly wheel housing inspection window. When this hap pens, the pistons whose push rods are not pushing up their rockers are at the top-dead-center (TDC) position of their compression stroke.

(16)Fitting front oil seal

Front oil seal

Press.fit Oil seal flange Front cover

84187A

Press evenly around the oil seal's entire periphery until its flange is seated securely on the front cover.

10404

ENGINE <6D2> - SERVICE PROCEDURES 12) When piston No. 1 is at the TDC position of its com pression stroke, check and adjust the clearances of the valves marked "O" in the following table. When piston No. 6 is at the TDC position of its comCylinder No. Valve arrangement No. 1 at TDC of compression stroke No. 6 at TDC of compression stroke

I I 0 i 0

Ex.

In.

i !

In.

Valve clearance (when cold)

i Inlet

NV 0.4

I Exhaust NV0.6 �-

,��Thickness

Gauge MH061359

NV .. Nominal Value

85714B

press ion stroke, check and adjust the clearances of the valves marked "x" in the table. Be sure to check and adjust every valve. 2

4 3 i 5 6 I Ex. I In. Ex. I In. Ex. i In. Ex. In. Ex. 0 I I I 0 !I 0 I I

I !

I X I

(3) Using the Thickness Gauge (special tool), check that the rocker arm-to-valve cap clearance con forms to specifications. To measure the clearance, insert a gauge of the same thickness as the speci fied nominal clearance between the rocker arm and valve cap. The gauge should be able to move in the gap, but not loosely. If the clearance is incorrect, loosen the lock nut and turn the adjusting screw as required. When the clearance is correct, tighten the lock nut to the spe cified torque to secure the adjusting screw. NOTE: After tightening the lock nut, confirm that the clear ance is still correct.

Engine Maintenance Kits Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts. Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets, Replace filters, Replace V-belts. Engine Maintenance Kit part numbers: # ME051727 Generac 12.0 Liter 0A5399 MMC Mitsubishi 6D24-DT041 6D24DT041 # ME051730 Generac 12.0 Liter 0D5451 MMC Mitsubishi 6D24-DT051 6D24DT051 # ME051727 Generac 12.0 Liter 12.0DTA 0A5399 MMC Mitsubishi 6D24-DT041 6D24DT041 # ME051730 Generac 12.0 Liter 12.0DTA 0D5451 MMC Mitsubishi 6D24-DT051 6D24DT051 # ME051731 Generac 16.0 Liter 0A8829 MMC Mitsubishi 8DC9-DT051 8DC9DT051 # ME051731 Generac 16.0 Liter 1600TA 0A8829 MMC Mitsubishi 8DC9-DT051 8DC9DT051 # ME051731 Generac 16.0 Liter 16.0DTA 0A8829 MMC Mitsubishi 8DC9-DT051 8DC9DT051

11A-67

ENGINE <602> - TROUBLESHOOTING

6. TROUBLESHOOTING Symptom Engine will not

start

Probable cause

Incorrect oil viscosity

Remedy Replace

• Defective cylinder head gasket

Group 12 Group 13

Incorrect/defective fuel Low compression pressure • Incorrect valve clearance(s)

Reference

Adjust Replace

• Worn valve and valve seat/carbon deposits • Weakened valve spring • Worn/damaged piston ring(s) • Worn/damaged piston ring groove(s) • Worn piston(s)/cylinder liner(s) Defective preheater • Defective starter switch

Change to oversize Repair or replace

Group 16

Adjust

Group 13

Repair or replace

Group 13

Repair or replace

Group 14

Replace

Group 12

• Defective heater relay Incorrect injection timing Insufficient fuel injection volume • Defective injection pump • Incorrect fuel injection volume Defective cooling system Rough idling

Incorrect oil viscosity Incorrect/defective fuel Defective cooling system

Group 13 Repair or replace

Group 14

Adjust

Group 13

Repair or replace

Group 13

Replace

Group 13

Cooling system malfunctioning

Repair or replace

Group 14

Intake/exhaust system malfunctioning • Clogged air cleaner

Repair or replace

Group 15

Repair or replace

Group 13

Low compression pressure {see "Engine will not start") Incorrect injection timing Defective fuel system • Defective injection pump • Defective injection nozzle • Air trapped in fuel system Abnormal exhaust gas color

Incorrect/defective fuel

• Clogged muffler • Oil leaking into intake/exhaust pipes Low compression pressure (see "Engine will not start") Defective fuel system • Malfunctioning injection pump • Defective injection nozzle Incorrect injection timing Excessive engine oil Seizure of major moving parts

11A-68

Adjust Adjust Repair or replace

Group 12

ENGINE <6D2> - TROUBLESHOOTING

Probable cause

Symptom Low power output

Incorrect oil viscosity

Remedy Replace

Incorrect/defective fuel

Reference Group 12 Group 13

Cooling system malfunctioning

Repair or replace

Group 14

Intake/exhaust system malfunctioning • Clogged air cleaner

Repair or replace

Group 15

Repair or replace

Group 13

• Clogged muffler Low compression pressure (see "Engine will not start n ) Fuel system malfunctioning • Malfunctioning injection pump • Defective injection nozzle • Air trapped in fuel system Incorrect injection timing Excessive oil consumption

Oil leaking from lubrication system Oil leaking from engine and related parts • Defective gasket/oil seal

Adjust Inspect and/or repair Replace

Oil entering combustion chamber past piston • Worn cylinder liner(s)/piston(s)

Rectify or replace

• Piston ring(s) worn, damaged, or seized

Replace whole set

• Clogged piston/oil ring oil hole(s) Oil entering combustion chamber via valves • Worn valve stem(s)/valve guide(s)

Group 12

Clean Replace

• Worn valve stem seal(s) Abnormal engine noise

Noise emanating from outside parts of engine • Loose piping/hose connection(s) • Injection pump, alternator, other auxiliary unit(s) incorrectly mounted • Loose/damaged V•belt • Incorrectly mounted crankshaft pulley

Inspect Inspect and/or adjust Replace

Repair or replace

Noise emanating from vicinity of rocker cover • Incorrect valve clearance(s)

Adjust

• Defective rocker shaft/bracket • Improper lubrication of rocker shaft

Group 14

Inspect and/or adjust

• Malfunctioning air cleaner and/or muffler

• Defective valve spring(s)

Groups 13 and 16

Group 15

Replace Inspect and/or repair Inspect

11A-69

ENGINE <6D2> - TROUBLESHOOTING Remedy

Probable cause

Symptom

Reference

Noise emanating from vicinity of flywheel housing

Abnormal engine noise

Rep ace

• I ncorrect tImmg gear bac �as h

• Incorrect lubrication of timing gears and idler shaft

I Noise emanating from cylinder head/crankcase

! !

Inspect

• Low compression pressure (see "Engine will not start")

• Incorrect injection timing

Adjust

• Incorrect spray of injection nozzles

Repair or replace

• Worn connecting rod small end bushing(s) and piston pin(s) Ii • Worn/damaged crankshaft pin(s) and connecting rod big end

Group 13

Replace

bearing(s)

• Worn/damaged crankshaft journat(s) and main bearing(s) • Excessive crankshaft/camshaft end play • Worn tappet(s)/camshaft Turbocharger malfunctioning

11A-70

Replace thrust p!ate(s)

Replace worn part(s)

Inspect and/or rectify

Group 15

ENGINE <8DC> CONTENTS 1. GENERAL .. . .. . . .... .... . . . . .. . . . . .. . . .. .. ... 2 2. SPECIFICATIONS ...... . ... . . .... . . . ... . .. . .. 7 3. SERVICE STANDARDS . . .... . .. .. . . .... . .. .. 8 3.1 Service Standards Table .................. 8 3.2 lightening Torque Table . . . . . . .. . . .... . . . 11 4. SPECIAL T OOLS ............................ 12 5. SERVICE PROCEDURES ... . . ..... ....... ... 16 5.1 Measuring Compression Pressure . . .. . . 16 5.2 Cylinder Head and Valve Mechanism ... 17 5.2.1 Disassembly ........................... 17 5.2.2 Inspection .. . .... . ....... . . . . . ......... 19 5.2.3 Reassembly . ... . . .... . ... ...... . . . ... . 25

5.3

Flywheel, liming Gear, and Camshaft ............................... . 28 Disassembly ......................... . 28 5.3.1 Inspection ............................ 31 5.3.2 5.3.3 Reassembly .......................... 36 5.4 Crankcase and Main Moving Parts ..... . 41 Disassembly .......................... . 41 5.4.1 Inspection ............................ . 46 5.4.2 Reassembly .......................... . 56 5.4.3 5.5 Inspecting and A djusting Valve Clearances ... . . . . . ........ . .. . .... . ... . . . 62 6. TROUBLESHOOTING .......... . . . . .. ..... .. 6 4

11B-1

■

ENGINE <8DC> - GENERAL (2) Valve mechanism

1. GENERAL

(1) Combustion chamber

Rocker Rocker shaft bracket Rocker shaft

Cylinder head

Push rod

Tappet

Injection nozzle O•ring Combustion chamber

B0344E

The combustion chambers are formed by the cylinder head and piston. The injection nozzles, sheathed by the nozzle tubes, are mounted on the cylinder head. The nozzle tubes hold the nozzles and protect them from cooling water. Since the nozzle tubes are exposed to the water in the water jacket, they are sealed by 0-rings at the top and by staking at the bottom. Combustion is effected by compression of fuel injected directly into the combustion chamber.

Camshaft

niet vaive

Exhaust valve

Outer valve spring ..._...,--.., Inner valve spring Valve stem seal Valve guide

Oil passage

B0345C Rocker

B5007A

The valve mechanism is of an overhead-valve (OHV) type and is constructed as shown in the diagram.

C1511C

Water directors pressed into the bottom of the cylinder head optimize cooling of the combustion chamber by directing the flow of coolant.

118-2

(a) Valve stem seals are fitted to the inlet and exhaust valve stems to control the amount of lubricant flowing onto the sliding surfaces of the valves and valve guides. (b) The inlet and exhaust valve springs are unevenly pitched. There are inner and outer springs, and these are wound in opposite directions. (c) The rocker and rocker shaft are supported by the rocker shaft bracket. The rocker shaft is a hollow cylinder sealed with an expansion plug at each end. The inside of the shaft forms an engine oil pas sage. (d) A steel ball is welded to the bottom end of each push rod, and a spherical concave piece is welded to the top end.

ENGINE <8DC> - GENERAL le) The tappets are cylindrical. To help prevent local ized wear, the areas that make contact with the camshaft are large-diameter spherical surfaces. If the side cover is removed, the tappets can be re moved and reinstalled easily without removing the camshaft. If) The camshaft is held by camshaft bushings which, in turn, are located in the "V" of the crankcase. The camshaft actuates the valves in both the left bank and right bank. The cam profiles are specially curved to achieve smooth acceleration. 13) Crankcase and cylinder liner

seal off oil and coolant. They also minimize the clear ance between the cylinder and crankcase, thus pre venting cavitation which would otherwise be caused by vibration of the wall surface. The rubber is particu larly effective in preventing the ingress of coolant through the cylinder liner's fitting points. If coolant en tered, it would cause pitting of the crankcase. 14) Piston and piston rings

“UP” mark and arrow

(A, B, C)

Part number

Piston ring insert

B0319C

Camshaft bushing

B4205B

(a) Five camshaft bushings are inserted in the cam shaft journal sections (i.e., bearing sections) of the crankcase. To facilitate removal and reinstallation of the camshaft from the rear end of the case, the diameter of each bushing is smaller toward the front. (b) Cylinder liner Crankcase

(a) The piston is an aluminum alloy casting, and its crown is shaped to form a combustion chamber. A piston ring insert is cast into the 1st piston ring groove to improve durability. To ensure the best possible fit between the piston and cylinder liner, a size mark is stamped on the piston head. An "UP" mark and arrow are also stamped to indicate the piston installation direc tion. The piston pin is fully floating and held in position with a snap ring at each end. (b) Piston rings

Size classification mark (A, B, Cl

1st compression ring � Barre! face full � keystone type 2nd compression ring Taper face inner

0-ring Rubber packing Cylinder liner

3rd compression ring � Taperface d.____r undercut type Oil ring Dual type with coil expander <8DC9, 9-T>

Water throttling

shelf

] cut type

B0346A

The cylinder liner is fitted into the crankcase and held by it at the top and bottom. At the bottom of the cylin der liner, 0-rings and rubber packing are provided to

<8DC9-TL, 9-TC>

64261C

Three compression rings and one oil ring are fitted to each piston. They are shaped as shown in the diagram. 118-3

ENGINE <8DC> - GENERAL (5) Connecting rod and connecting rod bearings

(6) Crankshaft and main bearings

rodbushing Connecting SpiSs Connecting rod

Left/right side

identitication

Balance weight Upper ---IJ,,r connecting rod bearing �

B4206B

Connectin�� redcap /

Connectin rod bolt

(a) The crankshaft is a highly rigid forging. Between each journal and pin is an oil hole via which oil passes to lubricate the journal and pin. To keep the crankshaft well balanced during opera tion, it has six balance weights on its webs plus a front balance weight at the front.

Lower connecting rod bearing

�"'"'

B0362C

The connecting rod is a highly rigid I-section forging. A bushing is pressed into the small end, and a split-type plain bearing is used at the big end. Since it is a split type bearing, the connecting rod bearing has an upper half and lower half. The upper half has an oil hole. This oil hole is in line with the oil passage inside the connecting rod. Engine oil for lubrication of the small end bushing is supplied via the hole. The connecting rod and connecting rod cap are held to gether by two connecting rod bolts.

118-4

Flywheel housing Crankshaft gear Crankshaft

Rear oil seal slinger

80351A

(b) The crankshaft gear that drives the timing gears is fitted on the rear of the crankshaft. Also, a rear oil seal on the rear of the crankshaft prevents oil leaks.

ENGINE <8DC> - GENERAL

The rearmost bearing cap is fitted with a split-type thrust plate to support the thrust of the crankshaft.

Balance weight Crankshaft

Front cover

Front balance weight

Main bearing cap 81881C

Torsional dam er

(c) The crankshaft pulley is mounted on the front of the crankshaft. In certain 8DC engines, a torsional damper is mounted on the crankshaft pulley to ab sorb the crankshaft's torsional vibration. An oil seal is fitted to the front cover to prevent oil leaks.

Main bearing cap bolt Main bearing cap side bolt

80347A

The main bearing is secured to the crankcase with side bolts. {7) Timing gears Injection pump gear Z=63

Camshaft----i

gear Z=63

bearing, upper

Main

Main bearing,

"'(

Idler gear B Z=66 Oil pump drive gear Z=56

,-( c·

Main bearing,

st lat

Crankshaft gear Z=63

Oil pump idler gear Z=39

80383K

80352A

(d) Main bearings The main bearings are split-type plain bearings with upper and lower halves. The inside surface of each up per half has an oil groove plus an oil hole that lines up with the oil hole of the crankcase.

The timing gears are located in the flywheel housing at the rear of the engine. The geartrain is as shown in the diagram. The timing gears are helical, and each is stamped with a timing mark. The timing marks ensure that the gears mesh correctly when reassembled. 11B-5

ENGINE <8DC> - GENERAL (8) Flywheel Bushing Idler shaft Collar

Oil hole Idler gear A

Idler shaft bolt

Idler gear 8 Crankshaft gear

B03848

The crankshaft gear is pressed onto the crankshaft and held in place with dowel pins. The crankshaft gear drives the other gears. The idler gears turn on the idler shaft which is sup ported at one end by the crankcase at the other end by the flywheel housing by means of the idler shaft bolt. The idler gears A, B have bushings press-fitted in their center holes and turn on the idler shaft. The bushings are lubricated by oil that flows through the inside of the idler shaft from the crankcase oil hole.

Pilot bearing

Cylinder No.

Flywheel Ring gear

08979

The flywheel has a pilot bearing at its center as a sup port for the clutch shaft. The outer ring gear that meshes with the starter pinion is shrink-fitted on the flywheel. The ring gear teeth are chamfered on one side to en sure that the starter pinion engages easily. Cylinder numbers, an angle scale, and valve timing marks (check marks) are stamped on the outside edge of the flywheel.

11B-6

ENGINE <8DC> - SPECIFICATIONS 2. SPECIFICATIONS Item Engine model Type

Specification

BDC9-TL, 9-TC

VB (90") water-cooled, 4-cycle diesel

VS (90") water-cooled, 4-cycle diesel

Direct injection

Overhead valve

135x140

135 X 140

16031

15.5

1➔2➔7 ➔3➔4➔5➔6➔8

1 ➔ 2 ➔7 ➔3 ➔4➔5➔ 6--+8

1 ➔2➔7 ➔3 ➔ 4➔ 5 ➔6➔ 8

Wet

VS (90 ) water-cooled, 4-cycle diesel

Combustion chamber type

Direct injection

Valve mechanism

Overhead valve

Cylinder bore x stroke mm Total displacement cm 3 Compression ratio Fuel injection sequence Cylinder liner type Piston type No. of piston rings

BDC9-T

BDC9 °

135x140

Trunk-type slipper skirt Compression ring: 3, OH ring: 1

' i

I I

Trunk-type slipper skirt

Compression ring: 3, Oil ring: 1

11B-7

ENGINE <8DC> - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item

Nominal value (Basic diameter in { 1)

Umit

2.75 MPa {28 kgf/cm2J

1.96 MPa {20 kgf/cm 2J

Adjust until difference between cylinders is 390 kPa {4 kgf/cm2} or less

128) 0.03 to 0.08

0.2

Replace bushing. Clearance in engine not to exceed 0.08.

89.38

Replace

470 {48.0}

400 {41.0)

65.04

190 {19.5)

160 {16.6)

Squareness

2.5

Tappet-to-crankcase tappet hole clearance

135) 0.06 to 0.10

0.2

Replace

0.5

Replace

Compression pressure (at 200 rpm)

Rocker-to-rocker shaft clearance

Outer valve spring

Inner valve spring

Free length Installed load N {kgf} (installed length: 58.35) Free length Installed load N {kgf} (installed length: 50.35}

Runout of push rod

Remedy and remarks

Replace

Cylinder head bottom surface distortion

0.07 or less

0.2

Correct or replace

Cylinder head height (from top to bottom surface)

114.910115.1

114.6

Replace

Valve stem outside diameter

Inlet valve

11.95to 11.96

11.85

Replace

Exhaust valve

11.91 to 11.93 0.2

Replace valve guide

2.2

1.7

Reface or replace

2.5

2.0

Valve guideto-valve stem clearance

Inlet valve

112) 0.05 to 0.09

Exhaust valve

112) 0.09 to 0.12

Valve margin

Inlet valve Exhaust valve

45°

Inlet valve

0.25 to 0.75

1.0

Exhaust valve

-0.05 to 0.45

0.7

Inlet valve

2.59 to 2.97

3.5

Correct or replace

Between crankshaft gear and idler gear

0.08to 0.20

0.4

Inspect

Between idler gear and camshaft gear

0.07 to 0.18

Between injection pump gear and camshaft gear

0.08 to 0.20

Valve seat angle Valve sinkage from cylinder head bottom surface Valve seat insert seat width Timing gear backlash

11B-8

Replace valve seat insert (- shows projection)

Exhaust valve

ENGINE <8DC> - SERVICE STANDARDS Unit: mm Nominal value (Basic diameter in [])

Limit

Idler gear end play

0.05 to0.15

0.4

Camshaft gear end play

0.11 to0.2

0.4

0.1 or less

0.2

Correct or replace

49.5

Replace

0.2

Correct or replace

(4010.03 to0.06

0.2

Replace bushing

Inlet

8.86

8.36

Replace

Lobe height: 56.138 Base circle diameter: 47.282

Exhaust

8.78

8.36

Replace

Lobe height: 56.017 Base circle diameter: 47.23 9

No.1

165.251 0.07 to0.10

0.25

Replace bushing

No.2

(65.25]0.07 to0.10

No.3

165.50] 0.07 to0.10

No.4

(65.7510.07 to0.10

No.5

166.00] 0.07 to0.10 0.08

Replace

Maintenance item

Flywheel

Friction surface distortion Depth from clutch cover mounting surface to friction surface Friction surface runout {when fined)

Clearance between idler gear and idler shaft Carn profile (difference between lobe height and base circle diameter)

Camshaft journal-to-camshaft bushing clearance

0.05 or less

Camshaft bend Interference between camshaft and camshaft gear Flywheel housing eccentricity Connecting rod end play

Remedy and remarks Replace thrust plate

1401 0.02 to0.05

0.2

Correct

0.4 to0.8

1.0

Replace

Reassembly must be limited to three times

socs

0.75 to 1.25

8DC9-T, 9-TL, 9-TC

0.65 to1.15

Crankshaft end play

0.15100.29

0.4

Replace thrust plate

Crankcase top surface distortion

0.07 or less

0.2

Correct or replace

Bore

135 to 135.04

135.25

Flange projection

0.08 to0.17

Cylindricity

0.02 or less

1135] 0.163 to0.18 9

8DC9-T

I 1351 0.1 93 to0.21 9

8DC9-TL, 9-TC

(135] 0.183 to0.20 9

Projection of piston from top surface of crankcase

Cylinder liner

Clearance between piston and cylinder liner

8DC9

Inspect

Repla�e or regrind to an oversize

Correct or replace cylinder, or replace piston

11B-9

ENGINE <8DC> - SERVICE STANDARDS Unit: mm

Maintenance item Clearance between piston ring grooves and piston rings

Nominal value (Basic diameter in [ J)

Limit

Remedy and remarks

0.02 to 0.10

0.25

Replace piston ring or piston

8DC9

0.05 to 0.08

0.25

8DC9-T, 9-TL, 9-TC

0.07 to 0.10

8DC9

0.05 to 0.08

1st compression ring 2nd compression ring

3rd compression ring

8DC9-T, 9-TL, 9-TC Oil ring

Piston ring end gap

0.15

0.07to 0.10

! I

0.03 to 0.06

0.15

1st ring, Oil

0.4 to 0.6

1.5

Replace

! 2nd ring

0.4 to 0.55

ring, 3rd ring

Clearance between piston pin and piston pin hole

[50] 0.01 to 0.02

0.1

Replace piston or piston pin

Clearance between piston pin and connecting rod small end bushing

[50] 0.01 to 0.05

o.1

Replace bushing

Connecting rod bend and torsion

0.05 or less

Correct or replace

Connecting rod bearing span when free

Less than 95.5

Replace

Connecting rod bearing-to-crankshaft pin clearance

1901 0.05 to 0.11

0.25

Replace bearing

Main bearing-to•crankshaft journal clearance

110010.06 to 0.12

0.25

Replace bearing

Less than 106.5

Roundness

0.01 or less

0.08

: Grind to undersize

Cylindricity

0.006 or less

0.03 or less

0. 1

Correct or replace

Main bearing span when free Crankshaft pin and journal Crankshaft bend Valve clearance {when cold)

, Inlet

I Exhaust

11B-10

0.4 0.6

Replace

Adjust

ENGINE <8DC> - SERVICE STANDARDS 3.2 lightening Torque Table Screw size 0. D. x pitch mm

Location tightened

M14 X 2

Cylinder head bolt

M16 x 2

I '

'' I

175 {18)

Wet

285 {29)

Wet

Rocker shaft bracket mounting bolt

M12 x 1.75

Crankcase side cover bolt

M10 x 1.5

2.9 {0.3)

Rocker cover bolt

M8 x 1.25

3.9 {0.4)

Rocker adjusting screw lock nut

M10 x 1.25

Remarks

Tightening torque N·m {kgfm}

49 {5) !

59 {6} Wet

315 {32)

Flywheel mounting bolt

M16 x 1.5

Idler shaft bolt

M16x 2

155 {16)

Idler shaft nut

M16 x 1,5

98 {10)

Flywheel housing bolt

M12 x 1.75

69 {7)

Connecting rod cap bolt

M16 x 1.5

225 {23)

Main bearing cap bolt

M18 X 2.5

Main bearing cap side bolt

M14x 2

175 {18)

Crankshaft pulley bolt

M14 x 1.5

175 {18)

Front cover bolt

M10 X 1.5

29 {3}

Balance weight mounting bolt

M16 x 1.5

i Wet Wet. See item {6) in section 5.4.3 for tightening method. Wet

Wet. See item (18) in section 5.4.2 for

tightening method.

Torsional damper mounting bolt

M12 X 1.75

98 {10)

118-11

ENGINE <8DC> - SPECIAL TOOLS 4. SPECIAL TOOLS Unit: mm

Unit: mm Tool name Compression Pressure Gauge Adapter MH061461 Measuring compression pres sure

09 16W x 18 threads

Center distance 46 Socket Wrench ME067973 Removing and installing con necting rod cap, flywheel, and cylinder head bolts

01942

Width across flats 22

019

D===u)

85081A Valve Lifter MH061668 Removing and installing valve cotters Valve Lifter Stud MH061678 Removing and installing valve cotters

Valve Lifter

Valve Lifter Seat

Valve Lapper 30091-07500 Valve lapping

Caulking Tool Body MH061360 Installing and caulking valve seat inserts Caulking Tool Body Caulking Ring

Caulking Ring (Inlet) MH061680 Installing and caulking valve seat inserts

For inlet: 63 For exhaust: 57

Caulking Ring (Exhaust) MH061681 Installing and caulking valve seat inserts

12 B5202A

� 4>42

Nozzle Tube Remover MH061232 Removing nozzle tubes

Shape

Tool name

Shape

Valve Lifter Stud 85041A

4>125

tr:Dr::t

Nozzle Tube Installer Flange MH061416 Nozzle tube installation Nozzle Tube Stamp MH061229 Nozzle tube installation

Nozzle Tube Installer Bot

N. Org

Nozzle Tube Installer Bolt MH061231 Nozzle tube installation

4>8.7

center: 46

Nozzle Tube Installer Flange

85051A Rocker Bushing Puller MH061236 Replacing rocker bushings

Nozzle Tube Stamp 4>8 B5181A

Valve Stem Seal Installer ME067431 Valve stem seal installation

4> 12

10593 Valve Guide Puller 30091-08100 Replacing valve guides

4>24 B5111A

11B-12

B5191A

ENGINE <8DC> - SPECIAL TOOLS Unit: mm Too! name

Unit: mm Tool name

Shape

Piston Ring Tool 31191-02900 Removing and fitting piston rings

Socket Wrench MH063365 Attaching main bearing caps

13204

Socket Wrench 31191-13500 Removing and installing main bearing cap bolts

Shape For $102 to 6178

Width across flats 24

Gear Puller MH061061 Removing gears

B5061A Cylinder Liner Extractor MH061490 Plate MH061494 (MH061490 component part) Removing cylinder liners Maximum pulling outside

dia. 200

1 w, 2; Lao

B5071A

Idler Gear Bushing Puller MH061228 Replacing idler gear bushings

B5131A

Camshaft Bushing Extractor Bar MH062118 Removing camshaft bushings Nos. 1 to 4 03532

1240

Oil Seal Slinger Installer MH061652

84867A

Installing rear oil seal slinger

Camshaft Bushing Extractor Guide MH062119 Removing camshaft bushings Nos. 1 to 4 $123

11B-13

ENGINE <8DC> - SPECIAL TOOLS Unit mm Tool name

Unit: mm Tool name

Shape

Camshaft Bushing Installer Adapter MH062314 MH062315 MH062137 Installing camshaft bushings Nos. 2 to 4

Camshaft Bushing Extractor Adapter MH062121 MH062122 MH062123 Removing camshaft bushings Nos.1to4

••

Applicable bushing

65.25

No.1,2

MH062122

70.25

65.5

No.3

MH062l23

70.75

65.7

No.4

Part No .

•A

MH06212l

I PartNo

d,A

MH062314 I 71.5

QlB

MH062.:m I 71.75 ! 65.5 MH062137

i 72

diC

, 65.25 · 27

! .43

! 65.75 i 59

B4869A Camshaft Bushing Extractor MH062124 Removing camshaft bushing No.5

Ari!�.��" No 2

No,3

No•

B4873A Camshaft Bushing Installer Nut MH062130 Installing camshaft bushings Nos. 2 to 4

M24 x 1.5

\ $ 71.25

B4874A B4870A

Camshaft Bushing Installer MH062313 MH062316

Installing camshaft bushings Nos.1 and 5

Camshaft Bushing Installer Bar MH062312

Installing camshaft bushings Nos.2to4

M24x 1.5 B4871B

Camshaft Bushing Installer Guide

,;A

MH062313

I 71.25

MH062316

72.25

•• I

65.25

App!i�b!e I bushmg No.1 No.5

B4875B

Cylinder Liner Installer MH061759

MH062311 Installing camshaft bushings

Installing cylinder liners

Nos. 2 to 4

B4872A

118-14

Part No.

B5141A

ENGINE <BOC> - SPECIAL TOOLS

Unit mm

Unit: mm Tool name

Shape

Too! name

Shape

Piston Guide Clamp MH061667 Installing pistons

Connecting Rod Bushing Pull er Kit MH061370 Replacing connecting rod bushings

Piston Guide Lever MH061658 Installing pistons

85151A Oil Seal Slinger Installer MH061818 Installing front oil seal slinger

Piston Guide Clamp

I. D.: 135

Piston Guide Lever

85171B

Thickness Gauge MH061359 Measuring valve clearances

80585A

85011A

11B-15

ENGINE <8DC> - SERVICE PROCEDURES 5. SERVICE PROCEDURES NV .. Nominal Value L .... Limit

5.1 Measuring Compression Pressure Compression pressure should be measured prior to disassembly of the engine. Take measurements regu larly and keep track of changes. During the engine's run-in period or after parts have been replaced, the compression pressure will increase slightly as the pis ton rings and valve seats fit snugly in position. T he pressure will then come down as parts wear. Measurement Procedure

Compression

gauge

Compression pressure (at 200 rpm) NV 2.75 MPa {28 kgf/cm 2} L 1 .96 MPa {20 kgf/cm 2) Difference between cylinders : 390 kPa {4 kgf/cm2} maxiI mum MHO061461 Pressure Gauge Adapter 85558A

) -=---:: )I � ��

(3) Mount the Compression Pressure Gauge Adapter (special tool) onto an injection nozzle hole together with a gasket. Connect the compression pressure gauge.

�

�� - -l..'::,,---

(4) To prevent fuel from being pumped into the cylin der by the injection pump, pull the injection pump's stop lever fully in the "stop" direction.

JI B5554B

(1) Warm up the engine until the coolant temperature reaches 75 to 85'C, then turn off the engine.

B5552A

(2) Remove all injection nozzles from the cylinder head. NOTE: Cover the mounting holes and injection pipes to pre vent the entry of dust and dirt.

11 B-16

(5) Turn the engine over with the starter and measure the compression pressure at 200 rpm. NOTE: 1. Be sure to measure the engine speed while taking compression pressure measurements since changes in engine speed cause changes in com pression pressure. 2. Since wear and other factors vary from one cylin der to another, measure the compression pressure in every cylinder.

ENGINE <8DC> - SERVICE PROCEDURES 22 Water gas leaks leaks,

Im.I

5.2 Cylinder Head and Valve Mechanism 5.2.1 Disassembly

Cracks, damage

Clogging oil hole, contact surface worn, thread damaged

II� . . ,J

Ridge wear 5 Carbon deposits, cracks, 15 �\ 10 24 scale deposits, damage Cracks/'16 11 S 4 � 13 17� Cracked contact surface, ridge Damage 18 � . Wear wear 14 Ridge wear 1� Wear Wear, damage

Water leaks, oil leaks, gas leaks Carbon deposits, burns, cracks, damage, ridge wear � 26 Wear, damage

Disassembly sequence Rocker cover 2 Rocker case ® Cylinder head bolt © Rocker shaft bracket bolt 5 Snap ring 6 Washer 7 Rocker 8 Set screw 9 Rocker shaft bracket 1

10 Rocker shaft spring 11

Rocker shaft

12 Push rod

13 Valve cap

® Valve cotter

19 Lower retainer 20 Inlet valve 21 Exhaust valve

*2@ Nozzle tube *223 Water director

15 Upper retainer

16 Outer valve spring

17 Inner valve spring 1 * 18 Valve stem seal

For parts with an encircled number, refer to Disassembly Procedure that follows. Parts marked with *1 should not be reused, but replaced. It must be replaced when the valve only is removed. Parts marked with *2 should not be removed unless defects are evident.

24 Cylinder head 25 Crankcase side cover 26 Tappet

C1529B

11 B-17

ENGINE <8DC> - SERVICE PROCEDURES (3) Removing valve cotters

Disassembly Procedure

Valve Lifter MH061668 \

Rocker shaft bracket

mounting boit

Cylinder head bolt

| Vaive Lifter Stud MHO61678

C15358

85281C

(1) Before removing the bolts, loosen the adjusting screw on every rocker that is being pushed up by its push rod.

To remove the valve cotters, use the Valve Lifter and Valve Lifter Stud (special tools) to evenly compress each spring.

(2) Removing cylinder head assembly

(4) Removing nozzle tubes

Nozzle Tube Remover MH061232

Socket Wrench ME067973

Nozzle tube

C1530A

C1527A

Loosen the cylinder head bolts in the opposite order to their tightening sequence, beginning with the M14 bolts. Use Socket Wrench (special tool) to remove the M16 cylinder head bolts and rocker bracket bolts.

NOTE: Whenever a nozzle tube is removed, it must be re placed with a new one.

NOTE: 1. Remove the injection nozzles before taking off the cylinder head (refer to Group 13, Fuel and Engine Control). If the cylinder head is placed on a work surface with the nozzles still mounted, the ends of the nozzles projecting from the bottom of the cyl inder head will be damaged. 2. Wilen removing the cylinder head gasket, take care not to scratch or dent the cylinder head and crankcase gasket surfaces.

118-18

ENGINE <BDC> - SERVICE PROCEDURES 5.2.2 Inspection

Item

Free length

Installed load/length

BD . Basic Diameter NV. Nominal Value L. Limit

Outer valve spring i

89.38

Inner valve spring ]

65.04

Outer valve spring 1 470 N {48.0 kgf)/58.35

400 N {41.0 kgf}/58.35

Inner valve spring

160 N {16.6 kgfl/50.35

190 N {19.5 kgf)/50.35

i Inner valve spring squareness

2.5

Item

2.69 to 2.97

3.5

! Cylinder head bottom surface distortion

0.07 or less

0.2

i Cylinder head height (from top to bottom I surface)

114.9 to 115.1

114.6

· Valve seat insert seat width Inlet valve

Rocker-to-rocker shaft clearance

Exhaust valve

BD 28

NV 0.D3to 0.08

0.2

, Runout L 0.5

Tappet-to-crankcase tappet hole clearance BD 35 NV0.06to0.10 L 0.2

Inlet valve

11.95to 11.96

11.85

Exhaust valve

11.91 to 11.93

Inlet valve

0.05 to 0.09

Exhaust valve

0.09 to 0.12

Valve sinkage from cylinder head bottom surface

Inlet valve

0.25 to 0.75

1.0

--0.05 to 0.45

0.7

Valve margin

Inlet valve

2.2

1.7

2.5

2.0

Item Valve stem O.D.

Valve guide-to-valve stem clearance

i / Valve seat angle

Exhaust valve

I I

45°

0.2

C1529E

11B-19

ENGINE <BDC> - SERVICE PROCEDURES (3) Valve spring inspection

Inspection Procedure ( 1) Rocker bushing-to-rocker shaft clearance

Squareness (inner spring only)

Measuring

pffi

Free length

Rf.

C2734A

position

If the clearance exceeds the prescribed limit, replace the rocker bushing. (2) Replacing rocker bushing To remove

Measure the free length and installed load of each spring and replace the spring if these are below the specified limits. With inner springs, check also for squareness. (4) Tappet-to-crankcase tappet hole clearance

To install

Measuring position

Rocker Bushing Puller MH061236

Bushing note Bushing oil hole Bushing

Rocker oil passage

Clinch Rocker chamfer Rocker

oil hole

C2753B

<Crankcase tappet hole diameter> Measuring position

C2745A

To install a bushing, proceed as follows: Face the chamfered side of the rocker up and position the notch in the bushing on the same side as the oil pas sage in the rocker. Using the Rocker Bushing Puller (special tool), press-fit the bushing into the rocker, making sure that bushing oil hole, rocker oil hole, and rocker oil passage are aligned correctly.

C27468

If the clearance exceeds the specified limit, replace the tappet.

11B-20

ENGINE <8DC> - SERVICE PROCEDURES (7) Valve stem outside diameter

(5) Push rod runout

Measuring position

01948

01965

Check for runout and replace the push rod if the read ing on the dial indicator exceeds the specified limit.

Replace the valve if its outside diameter is below the specified diameter or if it is severely worn.

(6) Distortion of cylinder head bottom surface

(8) Valve stem-to-valve guide clearance

Measuring position

[;x:]

C2739A

C2749C

If distortion exceeds the specified limit, correct it using a surface grinder.

Insert the valve into the valve guide and measure the play atthe specified distance from the valve guide's top (as illustrated). If the measured amount exceeds the specified limit, replace the valve guide.

NOTE: Replace the cylinder head if grinding causes the height from its top surface to bottom surface to fall below the specified nominal value.

11 B-21

ENGINE <BOC> - SERVICE PROCEDURES (9) Valve guide replacement

000

� Valve Guide Pull er 30091-08100 � I Valve guide" . Seat the collar of valve guide securely -"l:oha on cylinder head.

Replacement

Press fit

Good

Bad

C2707A C3113A

To install a valve guide, insert it with the Valve Guide Puller (special tool) until its collar sits securely on the cylinder head. (10)Contact between valve and valve seat insert

(--

Bad

If the minion indicates a poor contact pattern, rectify it as follows: Minor defect: Lapping Serious defect: Rectify valve and valve seat (11 )Valve face rectification

Valve margin '

Valve seat angle

Valve Lapper 30091-07500 Valve

Valve C2708A

(a) Apply an even coat of minium to the valve seat in sert surface that comes into contact with the valve. (b) Using the Valve Lapper (special tool), hit the valve against the valve seat insert once.

NOTE: 1. 2.

Do not turn the valve when hitting it against the valve seat insert. The contact pattern should be checked whenever a valve guide is inspected or replaced.

11B-22

C2710B

With a valve refacer, grind the valve face to achieve the specified valve seat angle.

NOTE:

1. 2.

Keep grinding to a minimum. If the valve margin is below the prescribed level af ter grinding, replace the valve. After grinding, be sure to lap the valve and valve seat insert. See item (14) for details.

ENGINE <8DC>

SERVICE PROCEDURES

l12)Valve seat insert rectification

(13)Replacing valve seat insert Valve seat inserts are installed by expansion fitting and should therefore be replaced as follows:

< C3116A Valve sinkage

Valve

Valve seat angle

Cut off

0.5 to 1.0 01973

(a) Grind the inside surface of the valve seat insert to reduce its thickness, and remove the valve seat in sert at room temperature.

Seat width Valve seat insert Valve

C2710A

la) With a valve seat cutter, cut the insert to achieve the specified valve seat angle and seat width. Use a 15 ° or 75 ° cutter first, followed by a 45° cutter. NOTE: 1. Keep cutting to a minimum. 2. If the valve sinkage exceeds the prescribed limit af ter cutting, replace the valve seat insert.

(b) After cutting, put some sandpaper of around #400 between the cutter and valve seat insert and grind the valve seat insert lightly. NOTE: After rectification, be sure to lap the valve and valve seat insert. Refer to item (14) for details.

Cylinder head l.D. (exhaust}

Cylinder head 1.0. (inlet)

55 + g.o3

61 + g.o3

Driving in

Caulking

C3119A Caulking Tool Body MH061360 Caulking Ring Inlet MH061680 Exhaust MH061681

C3120A

(b) Check that there is sufficient interference between the cylinder head and valve seat insert. le) Cool the valve seat insert in liquid nitrogen and heat the cylinder head.

118-23

ENGINE <8DC> - SERVICE PROCEDURES (d) Install the valve seat insert using the Caulking Tool Body and Caulking Ring (special tools), and caulk the periphery of the valve seat insert. NOTE: When installing the valve seat insert, ensure that the chamfered side of the Caulking Ring faces the valve seat insert.

Valve Lapper 30091-07500

(el Reface the valve seat insert to achieve the pre scribed seat width and valve sinkage. See item (12) for details. ( 14) Lapping valves and valve seat inserts Contact between the valve and valve seat insert must be even over the entire contact area. T he valve and valve seat insert must be lapped whenever the valve or valve seat insert has been rectified or replaced.

Valve stem

01970

(a) Apply a thin, even coat of lapping compound to the seating surface of the valve. NOTE: 1. Ensure that no compound adheres to the valve stem. 2. Start with intermediate size compound (120 to 150 mesh), and finish with fine compound (200 mesh or more). 3. The addition of a small amount of engine oil makes lapping compound easier to apply.

11B-24

C3122B

(b) Using the Valve Lapper (special tool), lightly strike the valve against the valve seat insert while turning it little by little. (c) Wash away the compound with gas oil or a similar fluid. (d) Apply engine oil to the contact surfaces and rub it in. (e) Check that the valve is properly seated. Refer to item (10) for details.

ENGINE <8DC> - SERVICE PROCEDURES 5.2.3 Reassembly

59 N-m {6 kgf-m) 3.9 N-m 49 N-m {5 kgf-m) {0.4 kgf-m) 7 4

locating pin

14 15 �.,;;-,;.,i¥-----·1s 19

Leak test (water passage): Apply 145 kPa {1.5 kgf/cm 2) air pressure. Leak should be less than 10 cm 3/min.

Apply sealant to nozzle tube (THREEBOND 1211 or equivalent).

�24 C linder head asket Face coated side of engine model identification mark

285 N-m {29 kgf-ml (wet)

toward cylinder head.

Ensure water director notch is correctly aligned.

2 3

M14: 175 N-m {18 kgf-m) {wet) M16: 285 N-m {29 kgf-m) {wet)

Install with closely wound portion of spring at bottom,

[16 17

Assembly sequence ®➔@-,@➔21➔20➔19➔®➔17➔16➔ 15➔®➔ ) 12 —_—} §9-2-1 � 26➔25 I 11➔10➔@➔8➔ ➔6➔5 _J

1Ll

For parts with an encircled number, refer to Reassembly Procedure that follows. 818348

11B-25

ENGINE <BDC> - SERVICE PROCEDURES

Reassembly Procedure

(1) Water director installation

□

Portion A {8 places)

(c) Apply engine oil to the Nozzle Tube Stamp (special tool) and insert it into the nozzle tube. (d) Screw in the Nozzle Tube Installer Bolt (special tool) until the Nozzle Tube Stamp can be pulled out of the bottom of the cylinder head. (e) After installing the nozzle tube, carry out a leak test to verify water-tightness. (3)

Valve stem seal installation

Water hole

"ig

direction _ “ection hoje direction direction “ee o

Water {i

|. direction

direction

Drive in water direction 1 mm from cylinder

head bottom surface

Valve

□

Valve Stem Seal Installer ME067431

Portion C (4 places}

Portion 8 (4 places)

Valve Cylinder stemhead seai

C15118

Push the water directors into the cylinder head so that they point in the directions shown in the diagram and are sunk 1 mm below the cylinder head's bottom sur face. 09179

(2) Nozzle tube installation

To install a valve stem seal, first apply engine oil to the lip. Then, push in the valve stem seal using the Valve Stem Seal Installer (special tool), striking the tool until it touches the cylinder head.

Nozzle Tube Installer Bolt MH061231 Nozzle Tube Flange MH061416 Nozzle Tube

Stamp

MH061229

15 to 20 N-m {1.5 to 2 kgf-m} MB X 1.25

--LLL! I

0-ring Nozzle tube---\;1-11

I Apply engine oil. I

Apply sealant (THREEBONO 1211 I or equivalent). i 1 09178

(a) Apply sealant to the nozzle tube and insert it into the cylinder head. (bl Using the Nozzle Tube Installer Flange (special tool), press the nozzle tube against the cylinder. 11 B-26

NOTE: 1. When installing a valve, apply a small amount of engine oil to its stem. 2. After installing a valve stem seal, check that the valve stem seal's spring has not been deformed or damaged.

ENGINE <8DC> - SERVICE PROCEDURES (61 Mounting cylinder head

{41 Valve cotter installation Valve Lifter MH061668

zod ion ==a ©== &ie©baw ~

Cylinder

Valve cotter

MH061678 Cylinder head

C6633B

Install the valve cotter while evenly depressing the spring with the Valve Lifter and Valve Lifter Stud (spe cial tools).

NOTE: Valve springs must be installed with their tightly wound portions toward the cylinder head.

151 Rocker and rocker shaft installation

When mounting the cylinder head, align it with the dowel pins in the crankcase. Fit the cylinder head gasket such that the side with the identification mark is facing upward. 171 Tightening cylinder head bolts Bolts marked with • also tighten rocker brackets. 1 to 18 Bolt {M16) 285 N-m {29 kgf-m} {wet) 19 to 23 Bolt {M14) 175 N-m {18 kgf-m} {wet)

Adjusting screw

Oil hoje

{o 5} $

0 @

Rocker shaft

0 0 0

e "

C6607B

Set screw Rocker

C6616B

Socket Wrench ME067973

(a) Install the rocker such that the adjusting screws lean toward the rocker shaft bracket. lb) Align the rocker shaft oil holes at the front and rear shaft bracket ends, then lock the rocker shaft into position with the set screw (front only).

Tighten the cylinder head bolts in the order shown. Tighten the bolts little by little before tightening them to the specified torque. Use the Socket Wrench (special tool) to tighten the M 16 bolts to their specified torque. 11B-27

ENGINE <8DC> - SERVICE PROCEDURES 5.3 Flywheel, Timing Gear, and Camshaft 5.3.1 Disassembly Tliming gear backlash I Between crankshaft gear and idler gear ' NV 0.08 to 0.20 L 0.4 Between idler gear and camshaft gear NV 0.07 to 0.18 L 0.4

:• 1 ��=- �[

I Between camshaft gear and injection pump gear I NV 0.08 to 0.20 I L 0.4

<With mechanical tachometer ,,c. drive> ,, •' 1 l � 9A

<With electric spe senso �

-·

� � �

I ¼Camshaft end play . NV 0.11 to 0.2 I L 0.4 12

�1

11%'.7 \

Tooth 14 surface wear, damage

Streaks, ridge wear, cracks, damaged or abnormally 5 worn gear teeth

Oil hole clogging

I !Mdler gear end play I Oil leaks

NV0.05to0.15 L 0.4

Disassembly sequence Flywheel mounting bolt *2 Pilot bearing ® Flywheel •@ Ring gear @ Oil seal retainer 6 Oil seal (j) Collar 1

8 Flywheel housing *9 Speed sensor (models with electric speed sensor) *9A Tachometer drive (models with mechanical tachometer drive)

10 Cover (models

with electric speed sensor) *11 Rear oil seal slinger @ Camshaft assembly 13 Camshaft

For J:!Brt� with an encircl�d number, refer to Disassembly Procedure that follows. Service ,terns �arked with ¼ should be checked before disassembly. Parts marked with • should not be removed unless defects are evident.

11B-28

1 i

NV . Nominal Value L ..... Limit

Camshaft gear Thrust plate Idler shaft bolt Thrust plate 18 Idler gear 19 Idler shaft *20 Rear plate 14 15 16 17

B1832J

ENGINE <SDC> - SERVICE PROCEDURES (3) Removing collar and oil seal retainer

Disassembly Procedure

(1) Removing flywheel Threaded hole for removal (M4 x 0.7}

Threaded hole for removal

Oil sea! retainer

Socket Wrench ME067973

Threaded holes for removal

Oil seal

Collar C1914B

To remove the flywheel, screw the mounting bolts into the removal holes.

•

(2) Removing ring gear

C1915B

To remove the collar, screw M4 x 0.7 bolts into the threaded removal holes. To remove the oil seal retainer, screw the mounting bolts into the threaded removal holes. Remove the oil seal retainer with the oil seal attached.

(4) Measuring gear backlash

FJ=r--= =Co) ~~ (3Ll=.tEo =+.EY cA F={ re4 s cas =t= raE7 ca i 9 - Te

Ring gear 82356C

To remove the ring gear, heat it evenly with an acety lene torch or the like, then tap around its entire periph ery with a hammer and bar.

C1916C

If backlash exceeds the specified limit, inspect the idler gear bushing and gears, and replace parts as required.

NOTE: 1.

Secure the air compressor to the rear plate before measuring the injection pump gear's backlash. For any gear pair, measure backlash at more than three points to determine whether it is acceptable.

11B-29

ENGINE <8DC> - SERVICE PROCEDURES 15) Measuring idler gear and camshaft gear end play Camshaft gear

17) Removing camshaft gear Camshaft gear

Idler gear

Camshaft

C1919C

�97

If end play exceeds the specified limit, replace the thrust plate.

Remove the camshaft first with a press, and then re move the camshaft gear from the shaft.

(6) Removing camshaft

NOTE: Never strike the gear with a hammer. Always use a press for removed.

Remove bolts through these holes

Camshaft

C1917C

Loosen the thrust plate mounting bolts via the holes in the camshaft gear. Remove the camshaft together with the camshaft gear and thrust plate.

11 B-30

ENGINE <8DC> - SERVICE PROCEDURES 5.3.2 Inspection

Friction surface distortion NV 0.1 or less L

0.2

Depth from clutch cover mounting surface to friction surface NV 48 L 49.5

�: -��

.-{ �' '.)

�

C3504A

Item

Cam profile (difference l Inlet between lobe height and base circle diameter) Exhaust

8.86

8.36

8.78

8.36

0.05 or less

0.08

0.07 to 0.10

0.25

f------+------+-----

Camshaft bend Camshaft journal-to camshaft bushing clearance

BD .. Basic Diameter NV . Nominal Value L .... Limit

No.1, 2

65.25

No.3

65.50

No.4

65,75

No.5

66.00

Clearance BO 40 NV 0.03 to 0.06

0.2

C3804E

11 B-31

ENGINE <8DC> - SERVICE PROCEDURES (3) Idler gear-to-idler shaft clearance

Inspection Procedure

( 1) Distortion of friction surface Measuring position

Dial gauge

Measuring position

Flywheel

C3807B Dimension B

C3506A

Place the flywheel on a surface plate. To measure dis tortion, pass a dial indicator over the flywheel from its periphery toward its center. If distortion exceeds the specified limit, grind the fric tion surface as necessary.

If the clearance exceeds the prescribed limit, replace the bushing in the idler gear. (4) Replacing idler gear bushing

NOTE: If the ring gear appears abnormal in any way, replace it before measuring distortion. For details, refer to item (21 of section 5.3.1 and item (81 of section 5.3.3.

Idler Gear Bushing Puller MH061228 Bushing Idler gear

(2) Rectifying flywheel friction surface

A Press

Press

Clutch cover

mounting surface

Friction surface

Installation

C3808A

Install the bushing from the side of the idler gear whose internal diameter is chamfered. After installation, confirm that the bushing-to-idler shaft clearance is within the nominal value range. If it is below the acceptable value, ream the bushing. C3509B

Grind the friction surface so that dimension B (the height from the clutch cover mounting surface to the friction surface) is below the prescribed limit. The fric tion surface must also be parallel with surface A with a tolerance of 0.1 mm. If dimension B exceeds the prescribed limit, replace the flywheel.

11 B-32

Removal

ENGINE <8DC> - SERVICE PROCEDURES (7) Replacing camshaft bushings

(5) Cam profiles

Measuring position

(a) Removal Remove the camshaft bushings in the following or der: No. 4--,No. 3➔No. 2➔No. 1 ➔No. 5. Remove them in accordance with the following instruc tions.

Base circle diameter

rnLobe height

Removing camshaft bushings Nos. 4 to 1

No. 4 camshaft bushing \ Crankcase

No. 5 camshaft bushing

C4113C

Measure the lobe heights and base circle diameters, and replace the camshaft if the difference between them is below the specified amount. NOTE: Since the cams are tapered, they must be measured at the points shown in the diagram. (6) Camshaft journal-to-camshaft bushing clearance

C4108B

If the clearance exceeds the prescribed limit, replace the camshaft bushing. Refer to item (7) for details.

Camshaft Bushing Extractor Adaptor MH062123

Camshaft Bushing Extractor bar MH062118

Camshaft Bushing Extractor Guide MH062119 B4859C

Front of engine

Camshaft bushing

No.1,2 No.3

No.4

No.5

Camshaft Bushing Extractor Adaptor MH062121

MH062122 MH062123 B4860C

a) Mount the Camshaft Bushing Extractor Adapter and Camshaft Bushing Extractor Guide (special tools) on the Camshaft Bushing Extractor Bar (spe cial tool). Insert the Bar into the crankcase. When doing this, mount the Guide onto the No. 5 crank case bushing and support the Bar while inserting it. b) Hold the Camshaft Bushing Extractor Adapter (special tool) against the No. 4 camshaft bushing. As shown in the diagram remove the No. 4 bushing by striking the Extractor Bar with a hammer. 11B-33

ENGINE <8DC> - SERVICE PROCEDURES c)

After removing the No. 4 bushing, remove bush ings Nos. 3 to 1 using the appropriate Camshaft Bushing Extractor Adapter (special tool) for each one.

Removing camshaft bushing No. 5

No.5 camshaft bushing I

Camshaft Bushing Extractor MH062124

@W, ..iii I I

Mount the Camshaft Bushing Installer Adapters (special tools) and camshaft bushings Nos. 2 to 4 on the Camshaft Bushing Installer Bar (special tool). When doing this, align the scribed lines on the Camshaft Bushing Installer Adapter (special tool) with the clinch joints on the bushings so that the oil holes will also be aligned.

Camshaft

CRY

MHO62311

inctallee «=<osONS

/°@

oP pg

GPE j

Camshaft Bushing Installer Bar MH062312

84861C

84863C

(b) Installation In accordance with the following instructions, install camshaft bushings Nos. 2, 3, and 4 simultaneously, fol lowed by bushings Nos. 1 and 5, in that order. 1)

Simultaneous installation of bushings Nos. 2, 3, and 4 No. 2 camshaft bushing

�""

Camshaft Bushing Installer Adapter MH062314

No. 4 camshaft bushing pin � Camshaft Bushing Installer Adapter MH062317

No. 3 camshaft bushing

b) Mount the Camshaft Bushing Installer Guide (spe cial tool) on where the No. 1 camshaft bushing is to be installed such that the Camshaft Bushing Install er Bar (special tool) can be supported by the Guide. Then, insert the Installer Bar into the crankcase. When doing this, ensure that the arrow on the In staller Bar points toward the "V" of the crankcase.

�"'"

Camshaft Bushing Installer Nut MH062130

Camshaft Bushing Installer Adapter MH062315

Camshaft Bushing Installer Bar MH062312 Oil hole View A

Oil hole

�inch

Camshaft Bushing Installer Bar MH062312 Thread the installer nut in until it touches this surface.

Clinch (joint) Scribed line (on camshaft bushing installer adapter)

11B-34

c) B4862E

B4864C

Confirm that the clinch joints on the bushings and the scribed lines on the Camshaft Bushing Installer Adapters (special tools) are aligned with each oth er [refer to item (a) for details]. Screw the Camshaft

ENGINE <8DC> - SERVICE PROCEDURES Bushing Installer Nut (special tool) onto the end of the Installer Bar, and tighten the Nut to press-fit all the bushings. Continue turning the Nut until the In staller Bar's flange touches the crankcase. d) After installing the bushings, remove the Camshaft Bushing Installer Nut and gently withdraw the In staller Bar.

(8) Camshaft bend

NOTE: When withdrawing the Installer Bar, take care not to damage the inside surfaces of the bushings. 2)

Installing camshaft bushings Nos. 1 and 5 Camshaft bushing installer MHO62313

CA11TA'

No. 1 camshaft bushing

Oil hole

Measure the extent of bend in the crankshaft. If it ex ceeds the specified limit, replace the crankshaft.

e~ Oil hole

AMTOW —strike theinstaller until these surfaces come in contact.

NOTE: Apply a dial indicator to the camshaft and turn the camshaft through one revolution. One-half of the dial indicator reading represents the camshaft's bend. (9) Camshaft-to-camshaft gear fit

Camshaft gear

No. 5 camshaft bushing --y,b,,.,LflM a ....

amsha

>I 062316

Strike the installer until these surfaces come in contact.

B4866F

Install the bushings as follows: Align the nick line on the Camshaft Bushing Installer (special tool) with the clinch joints on the bushings so that the oil holes will also be aligned. Face the arrow on the Camshaft Bush ing Installer toward the "V" of the crankcase. Strike the Installer until its flange touches the crankcase.

11834

If the amount of interference between the camshaft and its gear is below the nominal value, replace the camshaft or camshaft gear whichever appropriate. NOTE: Even if the interference is up to specification, reas sembly should be carried out no more than 3 times.

11B-35

ENGINE <8DC> - SERVICE PROCEDURES 5.3.3 Reassembly

: Camshaft gear end play NV 0.11 to 0.2 I LoL 0.4

I EndNVplay 0.05to0.15

, 12

0.4

Locking key

1315

Interference BD 40 NV 0.02 to0.05 L May be reassembled up to 3 times.

Section A-A

Locating pin 155 N-m {16 kgf-m} 98 N-m {10 kgf-m} 7

16 19 18

315 N-m {32 kgf-m} (Wet)

2 : Apply engine oil or � 6 I lithium grease to lip

|Flywheel housing |

ora - ta

3 SA

La Q y

Friction surface runout L 0.2

weih _

L 0.4

Backlash NV 0.07 to 0.18 L 0.4

1 ij

pen’

0 0

na Backlash NV 0.08 to 0.2 L 0.4

Assembly sequence

� r J J

@-,19....@-,17-,15-,® 7 �

.,J�®

®113-,15-,14)

9Aor10

➔7➔5➔3➔2➔1 @ @0

For parts with an encircled number, refer to Reassembly Procedure that foll ows.

118-36

I I

BO .. Basic Diameter NV .. Nominal Value L .... Limit C6201P

ENGINE <BDC> - SERVICE PROCEDURES 13) Installing camshaft gear

Reassembly Procedure 11) Mounting rear plate

O©

a esa < a ®©we

c;±==l:::;::::i--.-- Thrust plate Locating pin

Camshaft 11798

C6203B

Mount the rear plate and gasket, ensuring that they are aligned with the locating pin on the crankcase. After the gasket is fitted, its bottom (in front of the oil pan mounting surface) will protrude. Cut off the pro truding part of the gasket after fitting the flywheel housing. 12) Installing idler gear

Press the camshaft gear onto the camshaft with the side having maks "2" faced toward the side opposite to the thrust plate side.

NOTE: Use a cylinder to press the camshaft gear at its central portion. Never press a gear teeth area. 2. The camshaft gear and camshaft may be reas sembled at a maximum of 3 times. 1.

Idler gear Thrust plate

Idler shaft bolt

155 N-m \ {16 kgf-m} � .

G 2.

‘

mbbe Y Fo Bf U

Locating

;::--__

i� I

C6204C

Install the idler shaft, ensuring that it is aligned with the locating pin on the crankcase. Then fit the idler gear, ensuring that the "1" alignment marks on the idler gear and crankshaft gear are aligned with each other. Final ly, tighten the idler shaft bolt to the specified torque.

11B-37

ENGINE <BDC> - SERVICE PROCEDURES Face the threaded groove toward the flywheel. Using the Oil Seal Slinger Installer (special tool), evenly press the oil seal slinger until it is seated tightly in position.

141 Installing camshaft

(8) Fitting rear gear Camshaft Ring gear

Chamfered

Flywheel

)) I

B2357C|

Using a piston heater, heat the ring gear to approxi mately 100 °C for 3 minutes. Fit the ring gear with the non-chamfered side of its teeth toward the flywheel. (9) C6206C

Install the camshaft such that the "2" alignment marks on the camshaft gear and idler gear are aligned with each other. NOTE: When installing the camshaft, take care not to damage the camshaft bushings.

Fitting flywheel housing

69 N-m

Flywheel housing {7kgf-m} fitfoF SN way Q

(51 Check the end play in the camshaft gear and idler gear. Refer to item (4) of section 5.3.1 for details. (6)

Check each gear's backlash. Refer to item (31 of sec tion 5.3.1 for details.

Locating pin C6207C

(71 Installing rear oil slinger Mount the flywheel housing and gasket such that they are aligned with the locating pin on the crankcase. After the gasket is fitted, its bottom part (in front of the oil pan mounting surface) will protrude. Cut off the ex cess portion. Also cut off the protruding portion of the gasket be tween the rear plate and crankcase.

Rear oil sea! slinger Oil Seal Slinger Installer MH061652

Threaded groove

118-38

C5529B

ENGINE <8DC> - SERVICE PROCEDURES <Using sealant> Apply© 2 mm sealant bead (sealant: THREEBOND 1207C or equivalent)

85689A

(a) Apply a bead of sealant as shown in the diagram. Fit the flywheel housing within 3 minutes of apply ing the sealant. NOTE: 1. Apply a new bead of sealant whenever the fly wheel housing mounting bolts have been loos ened. 2. Keep the flywheel's sealing surface free of dirt and oil. 3. Apply the sealant evenly and without breaks. 4. When fitting the flywheel housing, hold it firmly in its correct position to prevent spreading the seal ant. 5. After fitting the flywheel housing, wait at least 1 hour before moving the engine.

69 N-m fl kgf-m} Locating pin

C6207D

(b) Fit the flywheel housing, ensuring that it is aligned with the locating pin on the crankcase. (10)Checking flywheel housing eccentricity

lighten the flywheel housing mounting bolts to the specified torque. Then check for eccentricity at the fly wheel housing I.D. (joint section). If eccentricity ex ceeds the specified limit, loosen the mounting bolts and lightly strike the housing to rectify its position.

11B-39

ENGINE <8DC> - SERVICE PROCEDURES (13)Valve timing check

( 11) Installing oil seal

After the engine has been reassembled, the valve tim ing must be rechecked. A simple valve timing check method is shown below.

Oil seal Seat oil seal end on the retainer positively all around. Oil seal retainer

10362

When fitting an oil seal onto its retainer, apply pressure evenly to its entire periphery until it is seated tightly in position.

Shim

85705E

(a) Bring the No.1 cylinder piston to the TDC on its compression stroke. (b) Insert a 3 mm thick shim between the No.2 cylinder exhaust valve's rocker arm and the valve cap. Turn the adjusting screw until the shim is held firmly and then lock the screw with the lock nut.

(12)Checking flywheel runout Socket Wrench ME067373

)

315 N-m {32 kgf-m) (Wet)

Flywheel

C6210C

After tightening the flywheel mounting bolts to the specified torque, turn the flywheel and check for run out. If runout exceeds the specified limit, check the bolts' tightness and/or inspect the mounting surface.

Valve timing reference marks

85713D

(c) Crank the engine in the normal direction (crock wise as viewed from the front), and make sure that just at the moment the No.1 cylinder exhaust valve starts lifting, the pointer on the flywheel housing is between the valve timing reference marks on the flywheel. If otherwise, recheck the timing mark alignment of each gear pair according to items (2) to (4).

11B-40

ENGINE <8DC> - SERVICE PROCEDURES 5.4 Crankcase and Main Moving Parts 5.4.1 Disassembly

*Projection of piston from top surface of crankcase 8DC9 NV 0.75 to 1.25

{4 j

Damage, wear Scratches of

BDC9-T, 9-TL, 9-TC NV0.65to 1.15

outer surface, cracks, fusion and discoloration of head

Damage, discoloration

11 Cracks

3 Scratches, corrosion, peeling of inner and outer surfaces

¼Connecting rod end play ·1 NV 0.4 to 0.8 1 L 1.0 I

Scratches, corrosion, peeling of inner and outer surfaces

I Repair kit: I j Cylinder liner and piston kit I

NV .. Nominal Value L... Limit

Disassembly sequence CD Connecting rod cap 2 Lower connecting rod bearing 3 Upper connecting rod bearing @ 1st compression ring @ 2nd compression ring @ 3rd compression ring

([J Oil ring 8 Snap ring 9 Piston pin @) Piston

® Connecting rod

*12 Connecting rod bolt

For parts with an encircled number, refer to Disassembly Procedure that follows. Service items marked with should be checked before disassembly. Part marked with * should not be removed unless defects are evident.

C2315A

11 B-41

ENGINE <8DC> - SERVICE PROCEDURES

Oil hole clogging

23 � 18

Scratches, corrosion, cracks, dents, scorching, oil hole clogging

�

� Inner and outer penphenes

"-¾�� Disassembly sequence 13 Crankshaft pulley 14 Torsional damper 15 Front balance weight 16 Front cover *17 Front oil seal *18 Front oil seal slinger ® Main bearing cap 20 Thrust plate

*Crankshaft end play NV 0.15 to 0.29

0.4

21 Lower main bearing 22 Crankshaft 23 Upper main bearing *® Crankshaft gear *25 Cylinder liner 26 Oil spray plug 27 Crankcase

For parts witn an encircled number, refer to Disassembly Procedure that follows. Service items rl"!arked with + should be checked before disassembly. Parts marked with * should not be removed unless defects are evident.

11 B-42

84488A

ENGINE <8DC> - SERVICE PROCEDURES (3) Removing connecting rod cap

Disassembly Procedure

( 1) Piston projection The piston projection measurements must conform with specifications, partly since they affect engine per formance, and partly since the pistons must not inter fere with the valves.

-. .

Fr.o

•

Socket Wrench ME067973

C2319B

(4) Removing piston

C23188

(a) Attach a dial indicator to the top surface of the crankcase and adjust it to zero. (b) Using the dial indicator, find the piston's top dead center position. (c) Take measurements at 4 points on the piston's top surface and determine their average. (d) If the piston projection does not conform with specifications, inspect the connecting rod and check the clearances between neighboring com ponents. (2) Connecting rod end play

C2320A

Withdraw the piston from above the crankcase togeth er with its connecting rod. NOTE: When withdrawing the piston, take care not to scratch the cylinder liner.

Replace a connecting rod if its end play exceeds the specified limit.

11B-43

ENGINE <8DC>

SERVICE PROCEDURES (7) Crankshaft end play

(5) Separating piston from connecting rod

Piston pin

Connecting rod

B2428B

Remove the snap ring, then use a rod and hammer to tap the piston pin out. If the piston pin is hard to remove, heatthe piston in hot water or with a piston heater.

Before removing the main bearing caps, measure the end play in the crankshaft. If end play exceeds the spe cified limit, replace the thrust plate with an oversize one. Refer to item {6) of section 5.4.3 for details.

(6) Removing piston rings

(8) Removing crankshaft gear Rear oil seal slinger

Piston Ring Tool

31191-02900

Gear MHO061061 Pullera, £

C5510B

{a) Split the rear oil seal slinger with a chisel and re move it from the crankshaft. {b) Remove the crankshaft gear from the crankshaft using the Gear Puller (special tool).

NOTE: Do not attempt to remove the crankshaft by striking it.

118-44

ENGINE <8DC> - SERVICE PROCEDURES 191 Removing main bearing cap Slide hammer Main bearing cap side bolt Main bearing cap bolt

®; Main bearing

Socket Wrench 31194-73500

C2325A

(a) Remove the main bearing cap side bolts, then re rnove the main bearing cap bolts. For the main bearing cap bolts, use the Socket Wrench (special tool).

C2326A

(bl Remove the main bearing cap using a slide ham mer. NOTE: 1. Do not attempt to pry off main bearing caps with a screwdriver. 2. The main bearing caps are positioned on the crankcase with dowel pins and should therefore be pulled straight upward.

11B-45

ENGINE <BDC> - SERVICE PROCEDURES 5.4.2 Inspection 8D

Item !

Clearance

1st ring

piston ring grooves and piston rings

i 2nd ring

between

8DC9

I 8DC9-T, 9-TL, 9-TC

0.02 to0.10

0.25

0.05 to0.08

0.25

0.07 to0.10

0.25

0.05 o t 0.08

0.15

3rd ring I 8DC9-T, ! 9-TL, 9-TC

End gap

O.G7to0.10

0.15

Oil ring

0.03 t o0.06

0.15

8DC9

Clearance

8DC9

135

0.163 to0.189

piston and cylinder · liner

8DC9-T

135

0.193 t o0.219

8DC9-TL, 9-TC

135

0.183 t o0.209

0.01 t o0.02

between

BO . BasicDiameter NV . Nominal Value L. Limit

i Clearance between piston pin and piston ! pin hole

! L

Remarks

1.5

3rd ring Oil ring

0.4 to0.6

0.4 to0.55

1st ring

2 nd ring

0.1

Top surface distortion I

NV 0.07 or less L

0.2

Clearance 8D 50 NV 0.01 to0.05 L 0.1 i Bend and torsion L 0.05 or less Connecting rod b earing-to crankshaft pin clearance 8D 90 NV 0.05to0.11 L 0.25 I Spanwhen free ! L Less than95.5

Flange projection from crankcase top surface NV 0.08 to0.17 Cylinder liner bore NV 135 to135.04 L 135.25 Cylindricity NV 0.02 or less

C4804A

11B-46

ENGINE <8DC> - SERVICE PROCEDURES

Bend NV 0.03 or less L 0.1 Roundness NV 0.01 or less L 0.08 Cylindricity NV 0.006 or less

I .

Main bearing-to-crankshaft journal clearance 8D 100 NV 0.06to0.12 L 0.25

8D .. Basic Diameter NV .. Nominal Value L .... Limit

Span when free L

Less than 106.5

B0591H

Inspection Procedure

NOTE:

(11 Distortion of crankcase top surface

2. Measurement points

When grinding the crankcase, take care that the piston projection does not exceed its nominal lev el. Refer to item (1 l of section 5.4.1 for details. Remove the cylinder liners before measuring dis· tortion. Refer to item (4) for cylinder liner replace• ment.

117�

C4417A

If distortion of the crankcase top surface exceeds the specified limit, correct it with a surface grinder. 11 B-47

ENGINE <8DC> - SERVICE PROCEDURES 12) Cylinder liner bore

14) Replacing cylinder liner la) Removal Size mark Cylinder Liner Extractor MH061490

or more

A: Direction of crankshaft axis. 8: Direction of right angle to crankshaft axis. C4424A

Measure the cylinder liner's bore diameter at 6 points, as shown in the diagram. If the diameter exceeds the prescribed limit, replace the cylinder liner or bore it to an oversize. Refer to item (4) for details of cylinder liner replacement.

Plate MH061494

{MHO61490 component part}

C4414B

(b) Installation

Size mark

13) Cylinder liner flange projection

Jc !IiIII I

a�"

(AB, C)

0 0 06

Cylinder liner

Piston C48058

1) Make sure the new cylinder liner bears the same size mark as that of the piston.

Ooe)OJ

�\

C4413A

If any cylinder linerflange projection does not conform with its specified nominal value, replace the cylinder liner or crankcase. Refer to item (4) for details of cylin der liner replacement.

118-48

Size mark IA. B,CJ

Piston size mark

Cylinder liner size mark

A--------A B B C C

ENGINE <8DC> - SERVICE PROCEDURES (51 Selection of pistons and cylinder liners A piston may be either standard or oversize. Cylinder liners are selected accordingly. (a) Standard piston Rubber packing

Apply soapsuds.

0-ring

Size mark (A, B, C ) �

C4415A

2) Fit new rubber packing and a new O-ring onto the cylinder liner. Apply soap suds to the crankcase and cylinder liner at the points where they will touch each other. Drive in

Cylinder Liner Installer MH061759 Cylinder liner

Size mark (A, B,C) Cylinder liner

Piston C4805B

The piston must bear the same size mark as that stamped on the cylinder liner. NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.

(b) Oversize piston In accordance with the following instructions, bore the cylinder liner to suit the type of oversize piston to be used (+0.5, +0.75, or+ 1.00 mm). C

4416A

3) Using the Cylinder Liner Installer (special tool), gently tap the cylinder liner down until its flange is securely seated on the crankcase. NOTE: 1. Do not stretch O-rings more than necessary, and be careful not to damage them. 2. Contact with gas oil, kerosene, anti-corrosion oil, and similar fluids causes O-rings to swell. Immedi ately wipe off any such fluids that come into con tact with the O-rings. 3. After installing a cylinder liner, carry out a leak test to check for air-tightness. Apply thrust force to the cylinder liner flange during the leak test.

118-49

ENGINE <8DC> - SERVICE PROCEDURES (6) Piston-to-cylinder liner clearance If the clearance is out of specification, replace the pis ton or cylinder liner. Refer to item (5) for details.

Size mark 25 or more

(7) Piston-to-piston ring clearance

or more

Oversize piston 0.0.

A: Direction of crankshaft axis. B: Direction of right angle to crankshaft axis. C4424A

100

C4B06B

Measuring point (Direction at right angles with pin} C4418A

Determine the amount of metal to bore out. To do this, measure the bore diameter of every cylinder liner and find the most worn point. Bore and hone-finish the cylinder liner such that the clearance between the oversize piston and cyl inder liner is up to specification.

NOTE: 1. Even if only one cylinder requires boring, bore ev ery cylinder to the same oversize diameter. 2. Replace the piston rings with rings corresponding to the degree of oversize.

If the clearance exceeds the specified limit, replace the piston or piston rings. NOTE: 1. After removing any carbon deposits, measure the clearance around the piston's entire circumfer ence. 2. Always replace piston rings as a set, never individ ually. Thickness gauge

Straight edge

C4810C

Measure the 1st compression ring clearance while pressing the ring against the piston with a straight edge.

11 B-50

ENGINE <8DC> - SERVICE PROCEDURES (8) Piston ring end gaps

(10)Piston pin-to-connecting rod bushing clearance Connecting rod bushing

Piston

0 Piston pin

Piston ring

Cylinder liner C4807B

Piston ring end gaps can be measured with the piston rings either horizontally pushed into a standard cylin der liner or actually fitted to a piston in the crankcase. Replace the rings if any gap exceeds the specified limit. Standard cylinder liner bore diameter: 135±0 mm NOTE:

♦

C5201A

If the clearance exceeds the specified limit, replace the connecting rod bushing. ( 11 )Replacing connecting rod bushing Connecting Rod Bushing Puller Kit MH061370

Use a piston to push the piston rings into the cylinder liner for measurement.

(91 Piston-to-piston pin clearance Piston

C52028

To replace the bushing, use the Connecting Rod Bush ing Puller Kit (special tool) in accordance with the fol lowing instructions. C4811A

If the clearance exceeds the specified limit, replace the piston pin or piston. NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.

118-51

ENGINE <8DC> - SERVICE PROCEDURES NOTE: 1. When press-fitting the bushing, align the oil hole in the bushing with the oil hole in the connecting rod. 2. When the piston pin is inserted, ensure that it turns easily and without play.

(al Removing bushing Mandrel Collar A Bushing Fixing bracket Face the larger

Base dimension downward

----

(12)Connecting rod bend and torsion Bend C

Press bench

C5203A

L = 100 Connecting rod aligner

Remove the bearing from the connecting rod's big end and mount the connecting rod on the Base (special tool). 2) Set the Mandrel and Collar A (special tools) on the connecting rod's small end, as shown in the dia gram. Slowly apply pressure with a press that has a capacity of at least 49 kN {5000 kgf}.

Piston pin

Twist

C5205A

C5206A

(b) Press-fitting bushing L

Approx. 49 kN {5000 kgfJ

Oil hole

Bushing Base Face the larger dimension downward

Press bench

C5204A

Place the bushing in the position shown in the dia gram relative to the Mandrel, Collar B, Collar A, and Nut (special tools). 2) Apply engine oil to the connecting rod's small end. 3) Apply pressure from above such that the bushing is pressed into the connecting rod's small end. After press-fitting the bushing, remove the special 4) tools. Then, ream the bushing such that the clear ance between the bushing and piston pin is up to the specified nominal value.

118-52

Piston pin Connecting rod aligner C5207A Measure the connecting rod's bend and torsion using a special connecting rod aligner. If the measurements exceed the specified limits, replace the connecting rod or correct it using a press.

ENGINE <8DC> - SERVICE PROCEDURES l13)Tension in connecting rod bearing and main bear ing when free

NOTE: The connecting rod cap nuts must be tightened to the specified torque when measurements are made.

( 15) Main bearing-to-crankshaft journal clearance Main bearing internal diameter Measuring

direction

If the tension is less than the specified requirement, re place the upper and lower bearings as a set.

NOTE:

Crankshaft journal diameter Measuring direction

Measuring position

C5503B

Measuring position

Do not attempt to manually expand the bearing if the tension is insufficient.

l14)Connecting rod bearing-to-crankshaft pin clear ance Connecting rod internal diameter

Measuring direction

Measuring

position

C5502A

If the clearance exceeds the specified limits, replace the upper and lower bearings as a set.

or more

(16)Roundness and cylindricity of crankshaft pin and journal

or more

Roundness

Crankshaft pin diameter Measuring direction

Measuring position

Cylindricity

C5210A

C5211A C5211A

If the clearance exceeds the specified limits, replace the upper and lower bearings as a set.

If roundness and cylindricity exceed the specified lim its, grind to undersize. Refer to item (18) for details. 118-53

ENGINE <8DC> - SERVICE PROCEDURES NOTE:

(17)Crankshaft bend

Before removing any balance weight, scribe a mating mark on it so that you can refit it in the original posi tion. Pin +0.2 0

Journal 42

C5506A

Measure the extent of bending in the crankshaft at the center journal. If the measurement exceeds the speci fied limit, grind to undersize or replace the crankshaft.

NOTE: With the dial indicator applied to the center journal, turn the crankshaft through one revolution. One-half of the dial indicator reading represents the extent of bending.

(18)Grinding crankshaft to undersize Any damaged or scorched journal or pin must be ground in accordance with the following instructions. If grinding is carried out, the main bearing must be re placed with an undersized one.

Shore hardness Hs 75 or more

C5508A

(b) Grind such that the center-to-center distance be tween the journal and pin does not change. (c) Grind such that the width of the journal and pin does not change. (d) Finish the corner fillet to the specified radius. (e) Use a magnetic partick method to check for cracks caused by grinding. Also, check that the Shore hardness of the surface has not dropped below Hs 75.

Grinding

Finishing

Wet stone or sand paper Crankshaft C5509A

Balance weight mounting bolt 08991

(a) Remove the balance weight(s) from the crankshaft as necessary. Take care not to damage the dowel pins when reinstalling them. Tighten the balance weight bolts to a torque of 98 N-m {10 kgf.m}, then ° '. turn them by a further 120

•h0

118-54

(f) When grinding, turn the crankshaft counter-clock wise as viewed from its front end. The grinder should rotate in the same direction. (g) When finishing the crankshaft with sandpaper or a whetstone, turn the crankshaft clockwise.

ENGINE <8DC> - SERVICE PROCEDURES

Undersize

Finished journal diameter

-0.25

-0.08 99.75 -0.10

-0.50 -0.75

I •

-1.00

•

Finished pin diameter -0.07 89.75 -0.09

-0.08 99.50 -0.10

89.50

-0.07 -0.09

-0.08 99.25 -0.10

89.25

-0.07 -0.09

-0.08 99.00 -0.10

Roundness

Cylindricity

0.01 or less

0.006 or less

-0.07 89.00 -0.09

11 B-55

ENGINE <8DC> - SERVICE PROCEDURES

5.4.3 Reassembly Projection of piston from top surface of crankcase 8DC9 NV 0.75 to 1.25 8DC9-T. 9-TL. 9-TC NV0.65 to 1.15

10 4

I Flange projection I NV 0.08to0.17 j

Fr 1D}

175Nem

et Ror

18 kgf-m}(Wet) Serer

115 N-m{12 kgf-m)+60' (Wet)

Assembly sequence 27➔25➔®➔@➔@➔®➔@➔@ ----i ilJ)....5 ➔ @➔®➔9➔8➔(£)➔@➔@➔@➔@-J®--' @-t ➔®➔16➔®➔15➔14➔13

L--4D

Piston ring end gap directions

3rd ring gap

2nd ring 9 Connecting rod end play NV0.4to 0.8 L 1.0

�

1st ring gap

�

For parts with an encircled number, refer to Reassembly Procedure that follows.

1 ring gap

Install with arrow pointing upward

26 With rubber damper

Apply engine oil to lips 29 N-m 17 {3 kgf.m)

Rear oil seal slinger See 5.3. 3 181.

14 15

98 N-m {10 kgf-m} 175 N-m {18 kgf-m}

1 98 N-m {10 kgf-m}

11 B-56

Install with oil

I End play ' NV 0.15 to0.29 L 0.4

groove facing crankshaft

80594G

ENGINE <BDC> - SERVICE PROCEDURES (3) Installing crankshaft gear

Reassembly Procedure

(1) Installing oil spray plug Dowel pin Notch

Crankshaft gear

Crankshaft

84202A C58028

Install the oil spray plug such that the arrow stamped on it points toward the top of the engine. (2) Installing upper main bearing and thrust plate

nrr--

Lug Upper main ............_ bearing � Oil hole Thrust plate Lug groove

�::'";)

(a) Heat the gear to approximately 100° C using a pis ton heater. (b) Locate the gear such that the dowel pin in the crankshaft fits into the notch in the gear. Fit the gear by lightly striking it with a soft hammer. (c) Fit the rear oil seal slinger. {4) Fitting front oil seal slinger

Front oil seal slinger Oil Seal Slinger Installer MH061818

Crankshaft

�

Install the upper main bearing such thatthe bearing lug fits in the lug groove on the crankcase. Install the rear most thrust plate with its grooveless side facing the crankcase. NOTE: 1. The main bearing's upper haH has an oil groove. The lower half does not have a groove. Take care not to confuse the upper and lower halves. 2. Oversize thrust plates are available in 3 sizes to ad just crankshaft end play [refer to item (7) of section 5.4.1 for details]. The oversize thrust plates avail able are +0.15 mm, +0.30 mm, and +0.45 mm. H any of these is used, ensure that the correct size thrust plates are fitted to the bearing caps. Refer to item (6) for details.

80596A

Press the front oil seal slinger into place using the Oil Seal Slinger Installer {special tool). Refer to item (7) of section 5.3.3 for details.

11B-57

ENGINE <BDC> - SERVICE PROCEDURES lb) Fit each lower main bearing into the relevant main bearing cap, ensuring that the lugs on the bearings are aligned with the lug grooves in the caps. le) Install a thrust plate on each side of the rearmost main bearing cap, ensuring that the grooveless sides of the thrust plates face toward the cap.

15) Installing crankshaft

Crankshaft

NOTE:

Main bearing cap Bearing cap rear thrust plate C5804A

lift the crankshaft with a hoist. Keeping it horizontal, gently lower it into the crankcase.

Use the same size.

(6) Installing lower main bearings and main bearing caps

Crankcase rearend thrust plate

Install the parts as follows.

C5838C

If oversize thrust plates are used, ensure that the bear ing cap rear thrust plate and the rearmost thrust plate in the crankcase are the same size [refer to item (2) for details). Note, however, that the bearing cap front and rear thrust plates may be of different sizes.

Front

Crankshaft axial direction

B1897B

la) Drive dowel locating pins into the rearmost main bearing cap in the direction shown in the diagram. Front of engine

'� �

(J -

Front of engine

• a

•" a

•• a

B4222B � �,/;i; um �,:�:::::,:: :::.

tf �fl

/)o.

Lug groove

locating pm Thrust � beanng VJ"-._ -

Oil groove � Lower mam

Lug

118-58

Number embossed on main bearing cap

Dowel pin

bearmg

C5805B

(d) Fit the main bearing caps in the order of the num bers that are embossed on them and such that the sides with lug grooves are toward the right of the engine.

ENGINE <8DC> - SERVICE PROCEDURES

Lug (as viewed from front)

Installing direction of washer

<l>

Crankcase side

Main bearing cap bolt 115 N-m {12 kgf-m} + 60° (Wet)

Main bearing cap side bolt 175 N-m {18 kgf-m} IWetJ C5806C

13306

(el Strike the bearing cap until it comes in contact with the crankcase and tighten its bolts to 115 N-m {12 kgf-m} (wet). After checking the tightening torque of each bolt, additionally tighten it as follows:

2) Fit the Socket Wrench on the main bearing cap bolt such that the tool's rod is held pressed against the crankcase flank by the inside spring force.

Angle scale on socket

Holder section

Rod

Reference line on holder 13205

1) Turn the holder section of the Socket Wrench (spe cial tool) counter-clockwise to give the inside spring a tension before fitting the tool on a main bearing cap bolt.

09183

3) Using a line on the holder as reference, turn the socket clockwise through 60° (one graduation of the scale on the socket represent 10 ° ) to additional ly tighten the main bearing cap bolt. 4) After tightening both the main bearing cap bolts, tighten the main bearing side bolts to the specified torque. After tightening the bolts, confirm that the crank shaft can still be rotated freely by hand. Also, check that the crankshaft's end play is up to the indicated nominal value. Refer to item (7) of section 5.4.1 for details.

11 B-59

ENGINE <BDC>

SERVICE PROCEDURES Connect the piston to the connecting rod with the pis ton pin such that the "UP" mark on the piston and the lug groove on the connecting rod are on the same side. If it is difficult to insert the piston pin, heat the piston in hot water or with a piston heater.

(7) Installing connecting rod bolts Install with flat side toward connecting rod center. Press�fit with a press. Max. 9.8 kN {1000 kgfJ

(9) Fitting piston rings

111----] Apply engine oil. I Damage, peeling

Check that there are no burrs or damage in the connect ing rod's bolt holes. Apply engine oil to the connecting rod bolts, then press-fit the bolts such that the flat sides on their heads face inward.

Expander spring ends

(8) Reassembling piston and connecting rod

3rd compression ring ends

Piston

Piston pin

--+--

2nd compression ring ends

C58418 1st compression ring ends

C58438

Using the Piston Ring Tool (special tool), fit the rings in the positions shown in the diagram. Ensure that the manufacturer's marks on the compression rings face upward. Fit the rings in the following order:

(

1. 2. 3. 4. Lug groove C5840C

11B-60

Rini Manufacturer ends mark stamped (Compression ring only)

��

Piston Ring Tool 31191-02900

Connecting rod C5808A

Oil ring 3rd compression ring 2nd compression ring 1st compression ring

ENGINE <BDC> - SERVICE PROCEDURES (10)Installing upper and lower connecting rod bear ings Lower connecting arin rod be g �

Conn�cting

rod cap

Upperc�nnecting b ga rod1ne \

Allgn.

Connecting rod

Align.

Align oil �\ /:11/ \ hole s. \

B4223B

NOTE: 1. Different connecting rods are used in the left and right banks of the engine. Identification markings ("LH" and "RH") are embossed on the connecting rods to prevent erroneous installation. 2. Ensure that the size mark on the piston matches the size mark on the cylinder liner. 3. Ensure that the piston ring end gaps stay in their correct positions. 4. Slip some vinyl hose over the connecting rod bolts to prevent them from damaging the cylinder liner and crankshaft pin.

<Using Piston Guide Clamp and Piston Guide Lever (special tools)> Piston GuideClamp

Install the upper connecting rod bearing such that its lug is aligned with the connecting rod's lug groove and such that the oil holes in the bearing and connecting hole are aligned with each other. Install the lower connecting rod bearing such that its lug is aligned with the lug groove on the connecting rod cap. NOTE: The connecting rod bearing's upper half has an oil hole, and the lower half does not have a hole. Be aware also that different parts are used in the left and right banks of the engine.

( 11 )Installing piston and connecting rod Piston Guide Lever MH061658

•UP" mark

Piston Guide Clamp MH061667

Adjusting bolt

B5291C

Align the Piston Guide with the piston skirt and set the lever in position. Turn the adjusting bolt such that the Clamp's internal diameter matches the piston's outside diameter. Next, remove the Guide from the piston and apply engine oil to the outside of the piston, to the in side of the Guide, and to the inside of the cylinder liner. Fit the Guide back onto the piston such that it is flush with the piston's crown. Using a wooden mallet or block, tap the piston into position, taking care not to damage it.

B5301B

Using the Piston Guide Clamp and Piston Guide Lever (special tools), install the piston such that the "UP" mark on its crown faces toward the "V" of the engine.

11 B-61

ENGINE <8DC>

SERVICE PROCEDURES 5.5 Inspecting and Adjusting Valve Clearances

(12)Fitting connecting rod caps

Valve clearances should be checked and adjusted when the engine is cold.

225 N-m {23 kgf-m)

{Wetl

.f Connecting rod cap

Connecting rod bearing

Alignment mark

ME067973 Socket Wrench

Connecting rod

C5810D

Fit the connecting rod cap such that its alignment mark meets the alignment mark on the connecting rod. Us ing the Socket Wrench (special tool), tighten the nuts to the specified torque. (13)Check the connecting rod's end play. Refer to item (2) of section 5.4.1 for details. (14)Check that the pistons project by the specified amount. Refer to item (1) of section 5.4.1 for de tails. (15)Fitting front oil seal

.....

0000

- 0000 -

85704A

Front oil seal Press-fit

Oil seal flange J Front cover

84187A

Press the oil seal evenly around its entire periphery un til its flange fits tightly against the front cover.

118-62

�

85703A

(1) Crank the engine until the No. 1 or No. 4 piston is at top dead center on compression stroke. (2) Confirm that the pointer in the flywheel housing in spection window is aligned with the "1,4" mark on the flywheel.

jules

ENGINE <8DC> - SERVICE PROCEDURES

check and adjust the clearances of the valves marked x. Be sure to check and adjust every valve.

(3) If the No. 1 piston is at top dead center, check and adjust the clearances of the valves marked O in the table below. If the No. 4 piston is at top dead center, Cylinder No.

Valve

In. ) Ex.

No. 1 piston at TDC

No. 4 piston at TDC

Ex. ' In.

OjOj 0

NV0.6

In. j Ex. I I 0

i I

4 Ex. I In. .

' I

In. I Ex. I Ex.

In.

i X

In.

I X

Ex.

' 0 i j

Ex.

i In.

I 0

(4) Using the Thickness Gauge (special tool), check that the clearance between the rocker arm and valve cap is in line with specifications. To check the clearance, insert a gauge of the same thickness as the nominally acceptable clearance between the rocker arm and valve cap. The gauge should be able to move in the gap, albeit not loosely. If the clearance is incorrect, loosen the lock nut and turn the adjusting screw as required. When the clearance is correct, tighten the lock nut to secure the adjusting screw.

Valve clearance (when cold, both inlet and exhaust) Inlet Exhaust

NV .. Nominal Value

NV 0.4

Thickness Gauge MH061359

B5705C

NOTE: After tightening the lock nut, confirm that the clear ance is still correct.

11B-63

ENGINE <8DC> - TROUBLESHOOTING

6. TROUBLESHOOTING Probable cause

Symptom Engine will not start

Incorrect oil viscosity

Remedy Replace

Reference Group 12 Group 13

Incorrect/defective fuel Low compression pressure • Incorrect valve clearance

Adjust

• Defective head gasket

Replace

Change to oversize Repair or replace

Group 16

Adjust

I Group 13

Repair or replace

Group 13

Repair or replace

Group 14

Replace

Group 12

• Defective heater relay Incorrect injection timing

Insufficient fuel injection volume • Defective injection pump

• Incorrect fuel injection volume Defective cooling system Rough idling

Incorrect oil viscosity

Group 13

Incorrect/defective fuel Repair or replace

Group 14

Adjust

Group 13

Repair or replace

Group 13

Replace

Group 13

Cooling system malfunctioning

Repair or replace

Group 14

Intake/exhaust system malfunctioning • Clogged air cleaner

Repair or replace

Group 15

Repair or replace

Group 13

Defective cooling system low compression pressure (see "Engine will not start"} Incorrect injection timing Defective fuel system • Defective injection pump • Defective injection nozzle • Air trapped in fuel system Abnormal exhaust gas color

Incorrect/defective fuel

Adjust

Excessive engine oil

Adjust

Seizure of major moving parts

11B-64

Repair or replace

Group 12

ENGINE <8DC> - TROUBLESHOOTING

Probable cause

Symptom Low power out-

Incorrect oil viscosity

put

Remedy Replace

Incorrect/defective fuel

Reference Group 12 Group 13

Cooling system malfunctioning

Repair or replace

Group 14

Intake/exhaust system malfunctioning • Clogged air cleaner

Repair or replace

Group 15

Repair or replace

Group 13

• Clogged muffler 1 Low compression pressure (see "Engine will not start") Fuel system malfunctioning • Malfunctioning injection pump • Defective injection nozzle i

• Air trapped in fuel system Incorrect injection timing

Excessive oil consumption

Oil leaking from lubrication system Oil leaking from engine and related parts • Defective gasket/oil seal

Adjust Inspect and/or repair Replace

Oil entering combustion chamber past piston • Worn cylinder liner(s)/piston(s)

Rectify or replace

• Piston ring(s) worn, damaged, or seized

Replace whole set

• Clogged piston/oil ring oil hole(s) Oil entering combustion chamber via valves • Worn valve stem(s)/valve guide(s)

Group 12

Clean Replace

• Worn valve stem seal(s) Abnormal engine noise

Noise emanating from outside parts of engine • Loose piping/hose connection(s) • Injection pump, alternator, other auxiliary unit(s) incorrectly mounted • Loose/damaged V-belt

Inspect Inspect and/or adjust Replace

• Incorrectly mounted crankshaft pulley

Inspect and/or adjust

• Malfunctioning air cleaner and/or muffler

Repair or replace

• Turbocharger malfunctioning

Inspect/rectify

Noise emanating from vicinity of rocker cover • Incorrect valve clearance(s) • Defective valve spring(s) • Defective rocker shaft/bracket

Groups 13 and 16 Group 14 Group 15

Adjust Replace Inspect and/or repair

• Improper lubrication of rocker shaft

Inspect

• Worn, damaged, or carbon-deposited valve/valve seat

Replace

11B-65

ENGINE <8DC> - TROUBLESHOOTING Symptom Abnormal engine noise

Remedy

Probable cause

Noise emanating from vicinity of flywheel housing • Incorrect timing gear backlash • Incorrect lubrication oftiming gears and idler shaft

Replace

Inspect

• Incorrect spray of injection nozzles • Worn connecting rod small end bushing(s) and piston pin(s)

Repair or replace Replace

ing(s)

• Worn/damaged crankshaft journal(s) and main bearing(s) • Excessive crankshaftJcamshaft end play

Replace thrust plate(s)

• Worn tappet(s)/camshaft

Replace worn part(s)

• Worn/damaged piston ring groove(s)

118-66

I I

Adjust

• Worn crankshaft pin(s) and connecting rod big end bear-

• Worn/damaged piston ring(s)

Reference

Noise emanating from cylinder head/crankcase • Low compression pressure (see "Engine will not start") • Incorrect injection timing

Replace

Group 13

LUBRICATION CONTENTS 1. GENERAL .. .. .. .... .. ..... ... . . .. .... .. .. . .. 2 2. SPECIFICATIONS ........................... 15 3. SERVICE STANDARDS .... ... .. .. .. . ... .... 16 3.1 Service Standards Table ................. 16 3.2 lightening Torque Table ................. 17 4. SERVICE PROCEDURE ..................... 18 4.1 Oil Pump .. .. .. .... . ...... .. . .... .... .... . 19 4.1.1 Removal and installation ......... .... 19

4.1.2 Disassembly and inspection .......... 21 4.1.3 Reassembly ........................... 26 4.2 Oil Filter and Oil Cooler ...... .. ..... .. ... 28 Removal and installation .. . . . . . . . . ... 28 4.2.1 4.2.2 Oil filter .. . .. .. . . ... . .... . ... . .... . .. . .. 29 4.2.3 Oil cooler .. .. . ... .. ..... .. .. .... .. . .. .. 31 4.3 Regulator Valve .. .... . .. ...... .... .. .. .. . 32 5. TROUBLESHOOTING .. .. .. ..... .. .... .. . .. . 33

12-1

LUBRICATION - GENERAL 1. GENERAL <6D2> Oil pressure gauge

0f-----�

Warning lamp

Otl pressure Oil pressure -------'s'-'-w,itc:C"h'--dl:rl gauge unit Main oil gallery Regulator valve -�-�• Turbo charger

Air Crankshat main

Water pump

Fuf-

Cooling of

flaw

Piston

oil filter

Timing gur idler bustun11

Oil spray plug

Oil pan

<8DC>

81539H Oil pressure gauge

Warning lamp

:------<S) Oil pressure gauge unit Qi! pressure switch

Main oil gallery Crankshatt

imain basring

Water

pump

| Connecting

Connecting rod bushing

: Oil bypass alarm

Camshaft bushing

—

� Injection pump

Fult-flow olf filter

Timing gear oil spray plug

Air

compresso

Turbo· charger

•

oil filter

Regulator valve

Oil pan

* Models with turbocharger Engine lubrication is accomplished by forced lubrica tion system using gear pump. The engine oil in the oil pan is drawn up through the oil strainer by the oil pump 12-2

--- Oil strainer

81551K

and force-fed to the oil filter and oil cooler to lubricate all parts.

LUBRICATION - GENERAL (11 Oil pump

<602>

<8DC> Crankshaft gear

Crankshaft gear

Oil pump idler gear Oil pump gear $ 2 =Oo io Soom See bod & ® om Ms o is oe 2 >

‘D am a

a > &

To oil filter a

Oil pump (with built-in relief valve)

Oil pipe

Oil strainer

81540A

The oil pump, of a gear pump type, is mounted in the rear bottom portion of the crankcase, driven by the crankshaft gear. The oil strainer atthe suction port prevents entry offor eign matter in the oil pan and air. The engine oil is routed to the crankcase by the oil pipe connected to the delivery port.

81504A

Oo“ie

Delivery_ side

_ Suction side (oil strainer side) "il==+-Driven gear

Oil pump case

B1505A

S_uction 2;::' :;BJ / side t. Deliveiy I Drive gear side I To oil filter, D '. �I nvengear

V /I

From oil strainer

B1541A

The crankshaft gear drives the oil pump idler gear and oil pump gear to transmit rotation to the oil pump drive gear.

Inside the oil pump case, there are oil pump drive gear and driven gear which are in mesh with each other. When the drive gear is driven, the driven gear is caused to turn in an opposite direction. As the gears rotate with the gear teeth sliding on the inner surfaces of pump case, the resultant negative pressure causes the engine oil to enter the oil pump and the oil trapped in the space formed by the teeth and gear case inner wall is forced outthrough the deliv ery port.

12-3

LUBRICATION - GENERAL (2) Oil filter (a) 6D2

<6D22, 22-T, 22-TC>

Oil filter head

H3 ao} ro

Steel bail

en Element

Relief valve 81542A

Center bolt {Bypass filter) Center bolt (Full-flow filter)

<6D24-T, 24-TC>

Relief valve

+ From oil pump Split pin Valve spring

<8DC>

To oil pan

Ball valve

85693A

Relief valve Split pin Valve spring

To oil filter

Oil pump 81506A

The oil pump is driven at a speed proportionate to the engine speed. Therefore, it is provided with a relief valve that prevents excessive pressure from being applied to the lubrication system when the engine is started in cold weather involving a surge in oil pump delivery pressure.

12-4

Drain plug

81543A

The oil filter assembly consists of a full-flow filter and a bypass filter. Paper elements are used. Engine oil fed under pressure from the oil pump passes through the oil hole in the crankcase and enters thefull flow and bypass filters via the oil filter head. Engine oil that passes through the full-flow filter is routed from the oil filter head to the oil cooler via the crankcase oil hole. Engine oil that passes through the bypass filter returns to the oil pan.

LUBRICATION - GENERAL (bl BOC Oil hole B Cooling water outlet

Cooling water inlet

Bypass valve Oil cooler

'ti'

Bypass alarm Oil hole A

Regulator valve

Water drain cock

Oil pipe Full-flow oil filter

Bypass oil filter----t Drain plug

Drain plug 815078

The oil cooler and full-flow oil filter are constructed as an integral unit and the bypass oil filter is connected by an oil pipe to oil cooler to keep oil in good condition. Oil hole A ..... From crankcase oil passage to inside full-flow oil filter Oil hole B ..... From full-flow oil filter to oil cooler cover oil passage Oil hole C ..... From oil cooler cover oil passage to oil cooler element Oil hole D ..... From oil cooler element to oil cooler cover oil passage Oil hole E ..... From oil cooler cover oil passage to crankcase main gallery

Full-flow oil filter

To oil cooler -cover oil passage From crankcase oil passage

81508A

The oil filter element is filter paper element. Oil sup plied by the oil pump is fed into the oil filter through the crankcase oil passage. Then, oil filtered by element is fed into the oil passage of the oil cooler cover.

12-5

LUBRICATION - GENERAL 2)

Bypass oil filter

From oil cooler cover oil passage

Crankcase+

The oil filter element is a filter paper . This unit serves to keep oil in good condition through circulation of a part of the oil from the oil pan to the full-flow oil filter, oil cooler, bypass oil filter and then to oil pan.

To oil pan

81510A

(cl Oil bypass alarm <6D2>

<BDC>

—,

oo 5

aie a

From crankcase

Oil bypass alarm

815448

When the oil filter element is plugged resulting in the difference in pressures between before and after the element exceeding a predetermined level, the valve overcomes the spring tension to move. As a result, unfiltered oil flows directly to the oil cooler. The oil bypass alarm has electric contacts that are closed to turn on the pilot lamp, warning the driver of clogged element when the valve is opened.

12-6

B1509C

LUBRICATION - GENERAL (31 Oil cooler (al 6D2 OFcooler element

Bypass valve

To main

oil gallery

81545C

The oil cooler is of the shell-and-plate (multi-plate) type. It is mounted in the coolant path on the left of the crankcase. Engine oil that has been forced through the oil filter flows through the inside of the oil cooler element. At

the same time, coolant from the water pump flows around the outside of the element. The engine oil in the element is thus cooled or heated before flowing to the main oil gallery.

Bypass valve

Regulator valve

Mainoil¢

Regulator vaive

Bypass valve

To main oil gallery 815308

81529A

When the oil's viscosity is high at low temperatures or when the element is clogged and resists the oil's flow, the oil cooler's bypass valve opens, thus allowing oil to flow to the main gallery without passing through the cooler.

The regulator valve is fitted to the main oil gallery in the crankcase. If the oil pressure in the main gallery exceeds a specified level, the regulator valve allows the oil to escape to the oil pan, thereby protecting the lubrication system from excessive pressure.

12-7

LUBRICATION - GENERAL (b) SDC Cooling water outlet

Bypass valve

Cooling water inlet

Regulator valve

The oil cooler is of the shell and plate type (multi-plate type) and introduces coolant from the crankcase water jacket by means of a water pipe. Engine oil that has been forced through the oil filter flows through the inside of the oil cooler element. At the same time, coolant from the water pump flows around the outside of the element. The engine oil in the element is thus cooled or heated before flowing to the main oil gallery. A bypass valve and a regulator valve are fitted in the oil cooler cover's oil passage.

81511A

Bypass valve Bypass valve Valve spring Valve

81512A

When the oil viscosity is high because of a low oil tem perature or when the flow resistance is high because of a clogged element, the bypass valve opens, allowing the oil to flow into the crankcase main gallery without heat exchange. For details of the regulator valve, refer to the corre sponding section in item (a) 6D2.

12-8

LUBRICATION - GENERAL 2) Camshaft

14) Lubrication of components la) 6D2 Engine oil routed to the main oil gallery lubricates the engine's various components as follows: 1)

Main bearings, connecting rod bearings, and con necting rod bushings

Camshaft bushing

Piston 6D22-TC, 24-T, 24-TC only

Connecting rod bushing

Connecting

rod

Crankshaft main bearing

81547A

The camshaft bushings are lubricated via the crank case oil holes that extend to them from the periphery of the crankshaft main bearings. 3) Valve mechanism RockeAgt: � bracket e

Connecting rod

Crankshaft main bearing

Rocker bushin9

Rocker shaft

Crankshaft

. From cylinder head

/ �

G/ � To cylinder head

Mamo1I':--__/ � / ,,,---�

gallery

11920

An oil passage extends from the main oil gallery to the crankshaft main bearing and lubricates the main bear ing. Part of the oil that has lubricated the main bearing passes through the hole in the crankshaft and lubri cates the connecting rod bearing. It then goes through an oilway inside the connecting rod and lubricates the connecting rod small end bushing. In the 6D22-TC, 24-T and 24-TC, there is also an oil hole in the top of the connecting rod. Oil spurts out of this hole onto the inside of the piston.

"f I

J �••ii,

"J/, I

81548A

Engine oil that has lubricated the No. 7 camshaft bush ing flows to the cylinder heads via an oilway and holes in the top of the crankcase. Engine oil that is bound for the cylinder heads flows through oil holes in the rocker shafts and lubricates the rocker bushings. lt then spurts out of a hole in the top of each rocker to lubricate the sliding surfaces of the valve caps, the valve stems, and the contact points of the valve stems, push rods, and adjusting screws. The oil then flows through the push rod holes in the cylinder head and crankcase to lubri cate the tappets and camshaft cams. Finally, the oil returns to the oil pan.

12-9

LUBRICATION - GENERAL 4)

5) Cooling of pistons (oil jet)

Timing gears

Idler shaft installation section

6D22-TC, 24-T, 24-TC only

Oil spray plug

Mam OIi gallery

Main oil gallery

81549A

As shown in the illustration, the timing gear idler shaft bushings are lubricated via oil holes that extend from the main oil gallery and from the rearmost crankshaft main bearing. The gears are lubricated by the oil spray plug.

Oil jet

11921

An oil jet is fitted under the main oil gallery for each cyl inder. These oil jets spray engine oil onto the inside sur faces of the pistons to help cool the pistons. Each oil jet has a check valve that opens and closes at specified oil pressures, thus preventing decreases in oil volume and the loss of oil pressure when the pres sure is already low. In the 6D22-TC, 24-T and 24-TC, each piston has a cool ing cavity. Oil sprayed out of the oil jets enters these cavities to further cool the pistons.

12-10

LUBRICATION - GENERAL lb) BDC Oil supplied to the crankcase main gallery returns to the oil pan after lubricating each part. 1) Main bearing, connecting rod bearing and piston

Connecting rod bearing

Main oil gallery

815140

Oil fed from the oil main gallery through the oil pas sage in crankcase lubricates the main bearing. Then, it lubricates connecting rod bearing through the oil pas sage in the crankshaft and, finally, it lubricates the con necting rod bushing through the oil passage in the con necting rod.

2) Camshaft Set screw

Camshaft bushing

Camshaft

Crankcase

Main bearing 81515A

Oil fed through the crankcase oil passage from the oil main gallery lubricates camshaft bushing.

12-11

LUBRICATION - GENERAL coming out of the oil hole in the side of the rocker lubri cates the adjusting screws and the surfaces in contact with the push rod.

3) Valve mechanism Cylinder head bolt Rocker shaft Oil pipe

Rockerbracket—

Oilpas�-

i=ll'---Camshaft bushi y / Camshaft

Side cover

Oil main gallery

Camshaft

81518A

Oil flows into the tappet along the push rod. Oil coming out of the oil hole of the tappet lubricates the sliding portion of tappet and the contact area of camshaft and returns to the oil pan. 4) Timing gear

B1516A

Oil, which has lubricated the camshaft bushing No. 1, flows through an oil pipe into the oil passage at the top of the crankcase. The oil passage is connected to the hole for the cylinder head bolt and oil flows into the rocker shaft through the cylinder head bolt from the rocker bracket.

Oil spray

�

Oil hole

----�- 'J;f

� '{()='::.=-,:- ·::.:::.:::.

Oil main gallery Rocker shaft Rocker bracket Cylinder head bolt B1517A

Oil fed into the rocker shaft lubricates the rocker bush ing through the oil hole and then flows into an oil groove in the rocker bushing. Furthermore, oil spurts out from the top of the rocker to lubricate the surfaces in contact with the valve cap and the valve stem. Oil 12-12

B1519B

Oil flows from the oil main gallery through the crank case oil passage to the oil spray plug area and then to the oil hole. Oil that has splashed from the oil hole lubricates the meshing surfaces of each gear.

LUBRICATION - GENERAL (6) Injection pump and air compressor <6D2>

Sromo;,:�e\

Idler shaft

\ J

\ •

\� \ '-11\To timin_g

gear tram

843648 815378

<BDC>

Oil, which has reached the oil hole through the crank case oil passage, lubricates the bushing through the gap between the bolt and idler shaft. (5) Lubrication of turbocharger

Bearing housing

Bearing

Piston ring

To oil pan 84365A Air in=>

The injection pump and air compressor are lubricated as follows: <6D2> Main oil gallery

Piston ring

l l

84363A

Injection pump

Oil cooler

Crankcase

Air compressor

Part of the engine oil is directed through the oil pipe from the crankcase into the turbocharger. The engine oil passes through the oil hole in the turbocharger bearing housing to lubricate the bearings. It is then returned through the oil outlet at the bottom of the bearing housing back to the crankcase and to the oil pan. A piston ring is installed on the outside of each bearing, serving as an oil seal.

1 1

Gear train

Oil pan

<BDC> Camshaft bushing

Injection pump

Air compressor

Crankcase

Gear train

Oil pan

12-13

LUBRICATION - GENERAL

(7) Lubrication of water pump <6D2>

Section B-B To oil pan

Section A-A

<BDC>

From oil main gallery

00052A

To oil pan

Section A-A

,'»--11.._ From oil main gallery 00051A

The engine oil drawn by the pump is routed through the crankcase oil passage to the water pump. The engine oil delivered to the water pump flows through 12-14

the oil hole of the water pump and lubricates the bear ings. The engine oil is then forced back from the drain port to the crankcase and returns to the oil pan.

LUBRICATION - SPECIFICATIONS 2. SPECIFICATIONS Item

Specification 6D2

Engine oil

Quality Capacity

Oil pan

j Oil filter

8DC

API classification class CC or better (without turbocharger) AP! classlfication class CD or better {with turbocharger) Approx. 27 L (for general use) Approx. 25 L (for construction machinery)

Approx. 30 L

Approx. 4 to 4.5 L

Forced lubrication by oil pump

Lubrication method Oil pump

Type

Forced lubrication by gear pump (integral relief valve)

Relief valve

Type

Ball valve

Type

Filter paper type

Oil filter

I Full-flow filter element

I Bypass filter element

Type

Filter paper type

Oil bypass alarm

Type

Piston valve type {integral electric contact)

Oil cooler

Type

Shell and plate type (multi-plate type)

Oil bypass valve

Type

Piston valve type

Regulator valve

Type

Piston valve type

Oil jet check valve

Type

Piston valve type

12-15

LUBRICATION - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item

Nominal value {Basic diameter in [ ])

Limit

Remedy and remarks Inspection

Oil pressure (Oil

At idle

145 kPa {1.5 kgf/cm2} or more

49 kPa {0.5 kgf/cm2}

ture 70° C to 90°CI

At maximum speed

295 to490 kPa {3 to 5 kgf/cm 2}

195 kPa {2 kgf/cm2}

Oil pump

Backlash between crankshaft gear and oil pump idler gear

6022, 22-T, 22-TC

0.15 to0.27

0.4

Replace

6024-T, 24-TC

0.08 to0.2

0.4

Replace

0.15

Replace

tempera-

BOC

0.08 to0.19

6022, 22-T, 22-TC

0.15 to0.27

6024-T, 24-TC

0.08 to0.2

BOC

0.08 to0.19

6022, 22-T, 22-TC, BOC

0.05to0.11

6024-T, 24-TC

0.05 to0.12

6022, 22-T, 22-TC, BOC

0.11 to0.18

0.2

6024-T, 24-TC

0.20 to0.29

0.35

Drive gear shaft to cover clearance

1201 0.04 to0.07

0.15

Replace

Driven gear shaft to driven gear bushing clearance

1201 0.04 to0.07

0.15

Replace

Idler gear shaft to idler gear bushing clearance

602

1221 0.03 to0.05

0.15

Replace bushing

BOC

1201 0.03 to0.05

6022, 22-T, 22-TC, 24-T, 24-TC

1080 to 1270 kPa {11 to 13 kgf/cm2)

Replace spring

BOC

1570 to 1860 kPa {16 to19 kgf/cm 2}

Installed length: 46.3

6022, 22-T, 22-TC

150 to160 N {15.3 to 16.9 kgf}

Installed length: 47.7

6024-T, 24-TC

180 to200 N {18.3 to 20.5 kgf}

Installed length: 56.6

BOC

255 to270 N {26 to27.6 kgf}

340 to 390 kPa {3.5 to 4 kgf/cm 2}

Backlash between oil pump idler gear and oil pump gear

Difference between pump case

depth and gear height

Gear tooth tip to pump case clearance

Relief valve opening pressure

Relief valve spring load

Oil bypass alarm valve opening pressure (on start pressure) Oil cooler bypass valve

Valve opening pressure

Regulator valve

Valve opening pressure Spring load (Installed length: 48.3)

12-16

602

175 to215 kPa {1.8 to2.2 kgf/cm2}

BOC

390 to490 kPa {4 to5 kgf/cm2} 360 to420 kPa {3. 7 to4.3 kgf/cm 2} 76 to 80 N {7 .8 to 8.2 kgf}

Replace Replace

Replace

LUBRICATION - SERVICE STANDARDS 3.2 lightening Torque Table Tightening torque N·m {kgf.m)

Remarks

M12x 1.25

59 to 78 {6to 8)

Apply LOCTITE No. 262

16024

M10x 1.25

39 to 49 {4to 5)

Wet

8DC

M10 x 1.5

Oil pump idler shaft nut Oil pump cover mounting bolt

Screw size 0. D. x pitch mm

Location tightened

M20 X 1.5

44to 54 (4.5to 5.51

Oil filter center bolt

M16x 1.5

59to 6916to7)

Oil filter drain plug

M10x 1.25

20 ± 4.9 {2 ± 0.5)

M20x 1.5

15 to 2011.5to 2.01

Oil bypassalarm

Oil cooler

Bypassvalve plug (602)

I Bypassvalve

M27 x 1.5

Regulator valve

M27 x 1.5

98to 115{10to 12)

Oil pan drain plug

M18x 1.5

69 {7)

12-17

LUBRICATION - SERVICE PROCEDURE 4. SERVICE PROCEDURE Oil Pressure Measurement

89016A At idle NV 145 kPa {1.5 kgf/cm2} or more L 49 kPa {0.5 kgf/crn 2J At maximum speed NV 295 to 490 kPa {3 to 5 kgf/crn 2J L 195 kPa {2 kgf/crn2J

NV .. Nominal Value L.... Limit 890168

{1) With the oil pressure switch removed and pressure gauge installed, warm up the engine until the oil temperature reaches 70°C to 90° C. {2) Measure the oil pressure at idle and maximum speeds. If the measurement is below the limit, overhaul the lubricating system.

12-18

LUBRICATION - SERVICE PROCEDURE 4.1 Oil Pump 4.1.1 Removal and installation <6D2>

NV .. Nominal Value L .... Limit

69 N-m {7 kgf-m}

1 Oil pan *2 Oil strainer *3 Oil pipe 4 Oil pump 5 Drain plug

*Backlash from crankshaft gear <6D22, 22-T. 22-TC, NV 0.15 to 0.27 L 0.4 <6D24-T, 24-TC> NV 0.08 to 0.2 L 0.4

Bolt tightening sequence (j)➔�➔@

After installation, check that the oil pump gear can be turned smoothly by hand. Pour engine oil into pump I

C1160C

<8DC>

69 N-m {7 kgf-m}

7�

.. 1 Oil pan

*#Backlash from crankshaft gear NV 0.08 to 0.19

*2 Oil strainer *3 Oil pipe 4 Flange 5 Relief valve 6 Oil pump 7 Drain plug

| L 0.4 Bolt tightening sequence

cz➔@

CD➔

After installation, check that the oil pump gear can be turned smoothly by hand.

| Pourengine | 6

| oil intopump|

Icey ok ddlnes rime aaa

Service items marked with should be checked before and after the removaL Part marked with * should not be removed unless defects are evident. (Remove it with the oil pump as an assembly.) C1155E

12-19

LUBRICATION - SERVICE PROCEDURE

( 1) Inspection of relief valve <BDC>

Installation load/instal lation length (56.6)

Yield

-2

NV 255 to 270 N {26 to 27.6 kgfl

Valve opening pressure NV 1570 to 1860 kPa {16 to 19 kgf/cm 2J

1 Spring seat 2 Valve spring 3 Ball valve 4 Relief valve case

12-20

NV .. Nominal Value C98518

LUBRICATION - SERVICE PROCEDURE 4.1.2 Disassembly and inspection

<6D22, 22-T, 22-TC> BD . Basic Diameter NV .. Nominal Value Limit L..

Relief valve opening pressure NV 1080 to 1270 kPa {11 to 13 kgf/cm2} Spring installed load (installed length: 46.3) ! NV 150 to 165 N {15. 3 to 16.9 kgf} i

*Backlash I NV 0.15to0.27 ! L 0.4

Idler shaft to idler gear clearance 8D 22 NV 0.03 to 0.05 L 0.15

---�=

Wear on teeth/damage ________.c c..; Shaft to cover clearance 10 8D 20 NV 0.04 to0.07 L 0.15

5 Clogged Oil hole

6 Wear on bushing, wear and damage on teeth

��,

3 Wear and damage on teeth, wear on bushing Wear on bushing

Clearance BD 20 NV0.04 to 0.07 L 0.15 *Gear tooth tip to oil pump case clearance NV 0.11 to0.18 L 0.2 *Difference between oil pump case depth and gear height NV0 .05to0.11 L 0.15

Disassembly sequence

6 Idler gear 7 Seat 8 Spring 9 Ball 10 Case and gear assembly

1 Oil strainer ® Oil pump cover 3 Driven gear * 4 Driven gear shaft 5 Idler gear shaft

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow. Parts marked with * should not be removed unless defects are evident. Service items marked with should be checked before disassembly.

C9518D

12-21

LUBRICATION - SERVICE PROCEDURE

<6D24-T, 24-TC>

Wear on bushing *Backlash NV 0.08 to 0.2 L 0.4

3 Clogged oil hole

valve opening pressure I!. Relief NV 1080 to 1270 kPa { 11 to 13 kgf/cm } 2

Spring installed load (installed length: 47.7) NV 180 to 200 N {18.3 to 20.5 kgf} ,

Clearance

8D22

NV 0.03 to 0.05 L 0.15

Clearance 8D 20 NV 0.04 to 0.07 L 0.15

Wear on bushing 1

Wear and damage on teeth, wear on bushing

Clearance 8D 20 NV 0.04 to 0.07 L 0.15

*Difference between oil pump case depth and gear height NV 0.05 to 0.12 L 0.15 *Gear tooth tip to oil pump case clearance NV 0.2 to 0.29 L 0.35

BO . Basic Diameter NV . Nominal Value Limit L..

Disassembly sequence G) Oil pump cover 2 Driven gear assembly 3 Idler shaft 4 Idler gear

5 Spring seat 6 Valve spring 7 Ball valve 8 Case and gear assembly

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow. Service items marked with * should be checked before disassembly,

12-22

10374

LUBRICATION - SERVICE PROCEDURE

<BDC>

I *Bacldash NV 0.08 to0.19 L 0.4

Wear on bushing, wear and damage on tooth surface 6 5 Clogged oil hole

Clearance BD 20 NV 0.04to0.07 L 0.15

Clearance BD 20 NV 0.03to0.05 L 0.15

damage on tooth surface,

x \%

wear on

~* A) ; if

7 Wear on bushing, wear and damage on tooth surface

bushing

NEA

Wear on bushing

Clearance BD 20 NV 0.04to0.Q7 L 0.15

*Difference between pump case depth and gear height NV0.05 to0.11 L 0.15 ¼Clearance between gear tip and pump

case

NV 0.11 to0.18 L 0.2

1 Clogging, cracks

BO . Basic Diameter NV . Nominal Value

L..

Limit

Disassembly sequence

1 Oil strainer ® Oil pump cover 3 Driven gear *4 Driven gear shaft

5 Idler gear shaft 6 Idler gear 7 Case and gear assembly

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow. Parts marked with* should not be removed unless defects are evident. Service items marked with¼ should be checked before disassembly.

C9501C

12-23

LUBRICATION

SERVICE PROCEDURE (2) Difference between oil pump case depth and gear height

Disassembly and Inspection Procedures (1) Removal of oil pump cover <6022, 22-T, 22-TC>

Oil pump cover

C9520A C9519A

If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced with a case and gear assembly.

<6024-T, 24-TC>

(3) Gear tooth end to oil pump case clearance

Oil pump cover

Dowel pin 10375

<8DC> C9521A

If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced with a case and gear assembly.

Dowel pin

C9502A

The oil pump cover is positioned with the dowel pin of the oil pump case. To remove the oil pump cover, tap on it with a plastic hammer or the like.

12-24

LUBRICATION - SERVICE PROCEDURE (4) Gear shaft to case, cover, and driven gear clear ance

C9506A

If the measurement exceeds the limit, replace the part to which bushing is installed.

12-25

LUBRICATION - SERVICE PROCEDURE 4.1.3 Reassembly <6D22, 22-T, 22-TC> Apply thread-lock cement (LOCTITE 262) to threads I after degreasing

Backlash NV 0.15 to 0.27 L 0.4

59 to 78 N-m {6to 8 kgfm}

Shaft oil hole must be in this range

@ Relief valve

! Apply MOLYKOTE ! to portion that will : fit in bushing

Arrow and "UP" mark must face upward and align oil holes

Shaft end surface

must be flush with case

9 Assembly sequence 10➔9➔8➔7 ➔6➔5➔4➔3➔2➔ 1

C9525C

<6D24-T, 24-TC>

I Apply thread-lock cement j I {LOCTITE 262) to threads I after degreasing I

39 to 49 N-m {4 to 5 kgf-m} Backlash NV 0.08 to 0.2 L 0.4

I-A Sectmn 8-8

59 to 78 N-m (6 to 8 kgf-m}

4 ow and "UP• mark must e upward and align oil holes

�

'v0

r==

Section A-A

Shaft end surface must be flush with case

5 67 Section C-C

Section D-D

Assembly sequence 8➔7➔6➔5➔4➔3➔2➔1

NOTE:

Hold the oil strainer 1 in position temporarily for subsequent attachment to the crankcase.

12-26

11924

LUBRICATION - SERVICE PROCEDURE <8DC> [ Backlash NV 0.08 to 0.19 I L 0.4

Apply thread-lock cement I LOCTITE 262) to threads I after degreasing 39 to 49 N•m {4 to 5 kgf m} (Wet)

59 to 78 N•m {6 to 8 kgf•mJ

6 5

Assemble so that oil holes may be upward. I Apply MOLYKOTE to portion that will , fit in bushing ·

Install so that oil hole in shaft may be located within this range. Assembly sequence 7 ➔6➔5➔4➔3➔2➔ 1

Shaft end surface should be flush with case end surface.

1 2

NOTE: Hold the oil strainer 1 in position temporarily for subsequent attachment to the crankcase.

4 C9517B

12-27

LUBRICATION - SERVICE PROCEDURE 4.2 Oil Filter and Oil Cooler 4.2.1 Removal and installation

<6D2>

1 Oil filter 2 Oil cooler 3 Gasket

C1158E

<BDC>

1 Oil pipe 2 Bypass oil filter 3 Oil cooler and oil filter

NOTE: 1. Do not apply oil or grease to tha O.,.ings at the oil cooler's water inlet and outlet. 2. After installation, run the engine and check for possible oil and water leak. C1151B

12-28

LUBRICATION - SERVICE PROCEDURE 4.2.2 Oil filter NOTE: The elements in the bypass and full-flow oil filters should be replaced every other time the engine oil is

replaced. For specific replacement intervals, refer to the Owner's Handbook.

11) Disassembly and reassembly . <6D2>

Cracks 7

Clogging, deformation

Ct_ -8 44 to 54 N-m {4.5 to 5.5 kgfm}

'1'

1 Drain plug

6 Clogging, deformation

6 5

Hardening splitting

Hardening splitting 5

Cracks, deformation

2 Center bolt 3 Washer 4 Oil filter case 5 Element retainer 6 Oil filter element 7 Oil filter head 8 Oil bypass alarm

20 + 4.9 N-m {2 + 0.5 kgf-m} 1——-@ 3

59to 69 N-m {6 to 7 kgf-m}

59to 69 N-m

{6 to 7 kgf-m} C9705C

<8DC>

Full-flow oil filter

Bypass oil filter 7

Cracks

8 44to 54 N-m {4.5 to 5.5 kgf-m}

Clogging, deformation

Hardening, cracks

Hardenin,sg�,

Crack,

deformation f----4

cracks

--=��:_-

Hardening, cracks

Crack, 4 20 ± 4.9 N-m 1 __,,__, (2 ± 0.5 kgf-mJ

deformation

Ci!::!,,---3 2

59 to 69 N-m {6 to 7 kgf-m}

3---<i::\,1:i) 2 -----i!ll 59to 69 N-m {6 to 7 kgf-m}

1 Drain plug 2 Center bolt 3 Washer 4 Oil filter case 5 Element retainer 6 Oil filter element 7 Oil filter head 8 Oil bypass alarm

1 20 ± 4.9 N-m {2 ± 0.5 kgf-m}

C9701D

12-29

LUBRICATION - SERVICE PROCEDURE

Inspection of oil bypass alarm Pressure gauge

�-------, Valve opening pressure !

I i

NV 340 to 390 kPa I {3.5 to 4 kgf/cm 2} I

U0700C

With no air pressure applied, check for continuity across the terminals as shown and replace the oil bypass alarm if there is continuity. Next, with the air pressure applied and gradually increasing, measure the air pressure when there is continuity. If the measurement is out of specification, replace the oil bypass alarm.

12-30

LUBRICATION - SERVICE PROCEDURE 4.2.3 Oil cooler (1I

Disassembl Y and reassembly

<6D2> 1 Scale, damage, cracks, oil leaks

Scale, cracks (o} �

-- � ;-n ;,;;;;-1-:::: ressure i VV.a;rlvwe;-;o)!Cp;;,e; �i 175 ton Pa V k N I {1.8t o 2.2 kgf/cm2 } ' 2 15to20N {1.5to 2 o'f't g m}

. � f,j -s'l<--- -- j.

.. '

��

10 @""'

�

1 Oil cooler element 2 Bypass valve 3 Oil cooler cover

<BDC>

C9804E

Scale

o�---'> 0 \

•

Scale, dama cracks, oil 1e2k;

2 I Valve openinjJ{��:ure NV 390 to {4 to 5 kgf/cm'J · gf-ml 15to20N -m{1.5to20k .

98to115N 5 {10 to 12 kgf'm} <8DC9-TC o n I y>

1 Oil cooler cover 2 Bypass valve Oil cooler element Regulator valve 5 Inlet pipe 6 Outlet pipe 7 Oil cooler case

0 0 0

Scale, cracks C9803E

12-31

LUBRICATION - SERVICE PROCEDURE

(2) Cleaning (a) Check for carbon or sludge deposited in the oil pas sage of the oil cooler element and bypass valve. If contamination is evident, wash in a cleaning oil. (b) If there is a lot of scale on the element and cover, wash it away with tap water (preferably hot). (3) Pressure resistance test

NOTE: Never attempt to apply pressure exceeding the speci fied test pressure. Check for possible leak by applying a 1470 kPa {15 kgf/ cm2J air pressure to the element. Replace the element if air or oil leak or any other faulty condition is evident as a resu It of the test.

Conduct the pressure resistance test to check for oil leak caused by damaged or cracked element.

4.3 Regulator Valve 98to 115 N-m {10 to 12 kgf-m}

Set load (set length: 48.3) NV 76to 80 N {7 .8 to 8.2 kgf}

Lost tension 3

Valve opening pressure NV 360 to 420 kPa {3.7 to 4.3 kgf/cm 2}

1 Snap ring 2 Valve 3 Spring 4 Body Regulator valve installation position: 6D2: Left side of crankcase BDC: Oil cooler case

12-32

C9902A

LUBRICATION - TROUBLESHOOTING 5. TROUBLESHOOTING Probable cause

Symptom Overheating

Abnormal oil level • Oil leaks into coolant • Oil leaks Incorrect oil viscosity • Oil out of life • Fuel in oil

Oil pressure does not increase

Remedy

Oil pressure switch not functioning properly

I I

Ref. group

Correct and fill to specified level

Replace Change oil after repair of faulty parts

Replace

Loaded oil filter element

Replace element

Loaded oil strainer, loose oil pump joint, cracked pipe

Correct or replace

Relief valve, bypass valve not functioning properly Worn or damaged oil pump proper Excessive oil consumption

Replace

Oil leaks from engine

Correct or replace

Oil leaks from crankshaft front or rear oil seal

Correct or replace

Leaks to cooling system • Defective oil cooler water jacket

Correct or replace

Abnormal compression pressure

Check

Group 11 A and 8

Group 11 A and B

12-33

m FUEL AND ENGINE CONTROL CONTENTS 1. GENERAL ... .... ....... ..... ...... ....... .... 2 2. SPECIFICATIONS ...... .. ... . . .. ...... ...... 28 3. SERVICE STANDARDS ..................... 30 3.1 Service Standards Table .. . ...... .. .. . ... 30 3.2 lightening Torque Table .......... .. ... .. 32 4. SPECIAL TOOL ..... .... .. .. ........ ....... . 34 5. SERVICE PROCEDURE .. .. ... .. . .... ..... .. 35 5.1 Injection Pump Assembly . . . . ........... 35 5.1.1 Removal and installation ... . . . .. . .... 35 5.2 AD Type Injection Pump ................. 40 5.2.1 Disassembly, inspection and reassembly .. ..... .. .... ... ........ .. . . 41 5.2.2 Testing and adjustment ... . .. . .. . . ... 42 5.3 P Type Injection Pump .. .... .... ... ...... 46 5.3.1 Disassembly, inspection and reassembly . ....... .. . . .... .. ... .... . . . 47 5.3.2 Testing and adjustment . .. . . . ... . .. .. 48 5.4 RSV Type Governor .. . .... ............... 52 5.4.1 Disassembly, inspection and reassembly . ... .. . .. .. . ... ... ... . .. . ... 53 5.4.2 Testing and adjustment ............. . 55 5.5 RFD Type Governor . ..... ..... ......... .. 61 Disassembly, inspection and 5.5.1 reassembly .. ...... .. .. . . .. . ..... .. .. .. 62 5.5.2 Testing and adjustment ........... ... 64 5.6 Feed Pump .... .... .... .... ............ ... 73 Disassembly, inspection and 5.6.1 reassembly . .. . ..... ...... ..... . ... .. .. 73 Tests ................................... 75 5.6.2 5. 7 SA Type Automatic limer ....... .. .. . .. . 75 Removal and inspection ... . . ..... . .. . 76 5.7.1 Installation and adjustment ... .. . . .. . 77 5.7.2 5.8 SP Type Automatic limer . . .. .... . ...... 78

5.8.1 Removal and inspection . ........... .. 78 Installation and adjustment . .. . . ... .. 79 5.8.2 5.9 SPG Type Automatic limer ....... ....... 80 5.9.1 Removal and inspection .............. 80 Installation and adjustment . ........ . 81 5.9.2 5.10 Bleeding of Fuel System .... . ........... . 82 5.11 Inspection and Adjustment after Installing the Injection Pump ...... ... ...... ....... 83 5.11. 1 Inspection and adjustment of 1 fuel injection start timing ...... ..... . . 83 5.11.2 Inspection and adjustment of minimum and maximum no-load speeds ....... 84 5.12 Pump Drive Case .. .. .... . . .. .. .... ...... . 86 5.12.1 Removal and installation .... . . . . ..... 86 5.12.2 Disassembly and inspection .......... 86 5.12.3 Reassembly ........ .. .. ..... .... .... .. 87 5.13 Injection Nozzle . ..... .. . ..... ............ 89 5.13.1 Removal and installation ..... ........ 89 5.13.2 Disassembly ........................... 89 5.13.3 Cleaning and inspection . ... . . . ... . . . . 91 5.13.4 Reassembly and adjustment <1-spring nozzle> ..................... 92 5.13.5 Reassembly and adjustment <2-spring nozzle: except identification mark "2D"> ........................... 93 5.13.6 Reassembly and adjustment <2-spring nozzle: identification mark u2D"> .................................. 99 5.14 Hydraulic Governor (RHOS-type for 8DC9) Inspection and Adjustment .... . .. . . . .. 104 5.15 Fuel Filter ............................... 107 5.16 Water Separator ........................ 108 6. TROUBLESHOOTING ...... ................ 109

13-1

FUEL AND ENGINE CONTROL - GENERAL

1. GENERAL

Injection pipe

Injection nozzle Fuel feed pipe Governor

Fuel , ___ filter

Fuel leak-off'-- -1 pipe

Fuel feed pipe

Overflow pipe

Feed pump

Water L-- -- separator (option)

Fuel return pipe

Fuel tank

B2115A

The fuel system consists of the injection pump general assembly (injection pump proper, governor, automatic timer, feed pump and coupling), fuel filter, water sepa rator, injection nozzle, fuel leak-off pipe, etc.

13-2

The injection pump is connected with the air compres sor or pump drive case by a coupling and driven at one half the engine speed.

FUEL AND ENGINE CONTROL - GENERAL (11 Injection pump proper (a) Injection pump <AD type injection pump>

Delivery valve holder

Delivery valve spring Delivery valve

Stopper

Delivery valve seat

Delivery valve holder

Delivery vaive spring

Plunger barrel

Deflector

Delivery valve seat

Plunger barre!

:,;--;---Delivery valve ===•''"'

Control sleeve --4/,,-\--4 Plunger spring

-t-+-iilL

Lower spring seat

Plunger

Control rod

Leak hole

Control rack

Pinion

Oil sump

Upper spring seat

"&+----- Control

�

sleeve

�JJIA'lfr-r--- spring Upper seat r-

Plunger spring Lower spring seat Tappet

Housing

Cam chamber Camshaft Screw plug

89082A

The camshaft driven at half the engine speed is sup ported by taper roller bearings at both ends. The cam shaft has a cam for operating the plunger and a cam for operating the feed pump. A tappet operating with the pump housing as the guide is in contact with the camshaft. The tappet changes the rotary motion of the cam to up-and-down motion which is transmitted to the plunger. The P type injection pump offers the following fea tures.

B9083C

1) The pump housing is a totally enclosed type. 2) The plunger barrel has an oblique hole made to return the fuel that has leaked to the oil sump to minimize the leakage of the fuel into the cam cham ber. 3) To prevent the fuel in the oil sump from leaking into the cam chamber, an 0-ring is provided on the outer circumference of the plunger barrel, thereby maintaining its tightness. 4) A deflector is provided on the outer circumference of the plunger barrel to prevent erosion of the pump housing that may be caused by counter flow of fuel at the end of an injection.

13-3

FUEL AND ENGINE CONTROL - GENERAL When the plunger moves down from the top dead cen ter and opens the suction/discharge ports in the plunger barrel, fuel is not only drawn into the barrel by a vacuum created during the plunger's downward stroke but also sent into the barrel under pressure by the feed pump. On the upward stroke, the plunger begins to compress fuel as it completely closes the suctional discharge ports in the plunger barrel. With the plunger further going up and with the fuel pressure increasing, the plunger overcomes the force of delivery valve spring, pushing up the delivery valve. This causes fuel to be sent under pressure through the injection pipe to the injection nozzle.

(b) Plunger and plunger barrel The plunger has an obliquely cut groove (lead) and a vertical groove as illustrated. The plunger barrel has two fuel suction/discharge ports. Fuel fed into the injection pump is sent under pressure by the camshaft rotation, or the reciprocating motion of the plunger as follows.

Fuel drawn in

Beginning of pressure feed

Pressure feed

End of pressure feed 82204A

Control rod

Plunger barrel

Control rack

Plunger

Control sleeve

Driving face

Control sieeve

Driving face

B2224A

The amount of fuel injected will be changed according to the engine operating loads by turning the plunger a given angle to increase or decrease the effective stroke. To be more precise, operation of the control lever or governor moves the control rack (or control rod) to the right or left, which results in the control sleeve being turned. The bottom end of the control 13-4

82206A

sleeve meshes with the driving face of the plunger; thus, as the control sleeve rotates, the plunger also rotates to vary the effective stroke, thereby increasing or decreasing the amount of fuel injected.

FUEL AND ENGINE CONTROL - GENERAL

Effective stroke

B2205A

As the plunger rises and its oblique groove (the reed) meets the inlet/outlet hole, fuel flows into the plunger's vertical groove and is expelled from the inlet/outlet hole. No pressure feed takes place thereafter, regard less of how much the plunger rises. The stroke length during which pressure feed takes place (from when the plunger closes the plunger bar rel's inlet/outlet hole until the plunger's oblique groove opens them) is known as the effective stroke. (c) Delivery valve

The delivery valve is further brought down until it is held against the seat surface tightly. The amount of fuel corresponding to the stroke during the period is drawn back from above to instantly lower the residual pressure in the line between the delivery valve and nozzle. The draw-back effect improves the cutting of fuel from the nozzle and prevents after-injection drip ping. A delivery valve stopper, provided on the top of the delivery valve spring, limits the lift of the delivery valve to prevent the surging of the valve during high speed operation. It also reduces the dead volume between the delivery valve and nozzle and stabilizes the injec tion rate. (d) Overflow valve

Spring 2 Oo >a2

pipe

Spring seat

Steel ball

Suction stroke B2208A

Beginning of Injection injection

End of End of injection injection {beginning of suction) 01827

When the fuel pressure in the injection pump exceeds a predetermined pressure, the steel ball in the overflow valve is pushed up to let the fuel flow out from the injec tion pump and return to the fuel tank, thereby stabiliz ing the fuel temperature and temperature distribution in the injection pump and maintaining the injection rate into each cylinder constant.

The fuel highly pressurized by the plunger pushes the delivery valve up and gushes out. When delivery of the fuel under pressure by the plunger is completed, the delivery valve is pushed back by the delivery valve spring and closes the fuel passage to prevent counter flow of the fuel.

13-5

FUEL AND ENGINE CONTROL - GENERAL

(2) Governor The construction and operation of the governor are the same regardless of the applicable model of the injec tion pump. This section describes the governor based on the AD type injection pump. (a) RSV type governor

Supporting lever shaft Guide lever

Governor housing

Tension lever

Start spring

Control rack

Shackle

Control lever

Governor spring

Camshaft

Flyweight

Ungleich spring or idling spring

Stop lever Full-load stopper bolt

82657B

The RSV type governor is a centrifugal type all-speed governor coupled to the camshaft of the injection pump. The governor not only controls the maximum and minimum speeds but also automatically controls the engine speed at any intermediate speed position.

13-6

FUEL AND ENGINE CONTROL - GENERAL

whereas the top of the lever is coupled through the shackle to the control rack. The start spring, attached to the top end of the control lever, always pulls the control rack in the direction that fuel is increased.

Slider

Ball bearing

Guide !ever

Camshaft

Governor sleeve

Flyweight supporting shaft B2658C

Flyweight

The governor, as shown, consists of flyweights mounted to the injection pump camshaft. When the flyweights turning on the flyweight supporting shaft open outward, the slider mounted to the end of fly weight arm pushes the end of the sleeve in the axial direction. The governor sleeve, being made integral with the shifter through a bearing, moves only in the axial direction. The shifter is fixed to the end of the guide lever with a pin to prevent its rotation. Supporting lever

djusting lever

/ /

, Adjusting screw

Tension lever

Governor spring

Swivel lever

n....---Ungleich spring or idling spring

Full-load stopper bolt

B3970A

Start spring

Control rack

Control lever

Pressure spring Governor shaft

Return spring

Stop lever 82659A

The control lever is mounted to the middle of the guide lever by the shaft with the bottom end as the fulcrum,

The turning shaft of the swivel lever is fitted into the bushing of the governor cover and its center is eccen tric with respect to the mounting position of the gover nor spring installed to the tension lever. The governor spring is installed to the end of the swivel lever. When the governor spring receives tension, the bot tom end of the tension lever touches the adjustable full-load stopper bolt. When the angle of the adjusting lever is changed, the angle of the swivel lever is also changed and the ten sion of the governor spring changed. This is because the turning center of the swivel lever and the mounting position of the governor spring installed to the tension lever are eccentric to each other as mentioned above. An adjusting screw is also mounted to the swivel lever. Adjustment of the screw changes the tension of the governor spring, thereby making it possible to adjust the speed regulation. An Ungleich spring (or idling spring) is provided in the bottom portion of the tension lever. Adjust the tension of the spring by adding or removing shims. An idling sub spring adjustable from outside is pro vided in the middle of the governor cover. During 13-7

FUEL AND ENGINE CONTROL - GENERAL

idling, the spring always keeps in contact with the ten sion lever to maintain a constant idling speed. The stop lever, mounted through the supporting lever to the bottom end of the control lever, returns the con trol rack to the stop position with a slight pressure irre spective of the adjusting lever position. 1) Start of engine

Idling control

Start spring

II I Adjusting lever

Adjusting lever

Control rack

Tension lever

Starting

s=:, 1111111 Control rack

Governor spring Tension lever

Shifter

Guide lever B2661A

Governor sieeve Flyweight

Full-load stopper bolt

B2660A

When the adjusting lever is moved to the start position (until it touches the maximum speed stopper), the swivel lever which moves with the adjusting lever pulls the governor spring and moves the tension lever until it touches the full-load stopper bolt. At that time, the flyweights are stationary, and the start spring with weak tension pulls the control lever in the direction that fuel is increased. At the same time, the shifter and governor sleeve push the flyweight slider to the left. As the result, the tension lever and shifter are spaced that much apart, and the corresponding amount offuel is supercharged to facilitate starting.

13-8

Once the engine is started and the adjusting lever returned to the idling position, the tension of the gover nor spring is drastically reduced. Now the flyweights can move outward even at a low speed, so the tension lever is pushed back until it touches the idling sub spring and places the control rack at the idling position. In this state, the centrifugal force of the flyweights and the weak-state governor spring and idling sub spring achieve balance and main tain smooth idling. When the speed falls, the centrifugal force decreases, the flyweights move inward, and the idling sub spring pushes the tension lever to the left and moves the con trol rack in the direction that fuel is increased. If the speed falls radically, the start spring with weak tension acts and moves the control rack in the direction that fuel is increased to maintain the idling speed.

FUEL AND ENGINE CONTROL - GENERAL 3)

position, thereby preventing over-speed operation of the engine. The RSV type governor controls the entire speed range from idling to maximum speed. If load increases or decreases at a certain speed determined by the posi tion of the adjusting lever, the governor automatically functions and maintains the engine speed constant at all times.

Maximum speed control

1111

No-load

(Idling)

Adjusting lever

Ungleich operation

Tension lever

When max. injection is set at low-speed operation

Control rack Governor spring

Injection matched \ :�: i �k�'.:_ _

Idling sub spring A Injection/ stroke

A'1,__-,

--- ---

B B'

When max. injection is set at high-speed operation Shifter

Full-load stopper bolt Engine speed

82662A

When the adjusting lever is moved to the full-load posi tion, the tension of the governor spring is increased and pulls the tension lever until it touches the full-load stopper bolt. When the engine exceeds the specified speed, the cen trifugal force of flyweights becomes larger than the force of the governor spring pulling the tension lever. So the tension lever is moved to the right and moves the control rack in the direction that fuel is reduced, thereby preventing the engine from exceeding the spe cified speed. If the speed further increases, the centrifugal force of flyweight increases and pushes the tension lever to the right and also compresses the idling sub spring to pull the control rack back to the no-load maximum speed

B2663A

The air intake rate of the engine falls as the engine speed increases. The injection pump, on the other hand, increases the per-stroke injection as the speed increases, even with the control rack at the same posi tion. Therefore, if full-load is set at point A to derive enough output at low speeds, the injection will reach B as the speed increases, and the engine will produce black smoke. If full-load is set at point B' to prevent black smoke, the low speed injection will come down to A:, allowing combustion of more fuel. So the Ungleich device accomplishes the function of setting full-load at point A to derive the largest possible torque in the low speed range, and changing it to adjust the injection to point B' in the high speed range.

13-9

FUEL AND ENGINE CONTROL - GENERAL As the engine speed increases, the centrifugal force of flyweight increases. If it becomes larger than the pres sure of the Ungleich spring, the Ungleich spring is slowly compressed before the start of high speed con trol, and the control rack moves in the direction that fuel is reduced. The Ungleich stroke is completed at the position where the shifter directly touches the ten sion lever.

t ·� 0 0.

�u � a:

5) Stopping of engine N2 N1 Pump speed (rpm) __,.

Ungteich effect

Stop position

Adjusting lever

Without Ungleich effect Control rack

N2 N1 Engine speed (rpm) _..,

82664A

When the engine speed is low and the centrifugal force of flyweight smaller than the pressure of the Ungleich spring, the shifter is moved as much as the Ungleich stroke to the left, so the control rack moves in the direc tion that fuel is increased to increase the torque of the engine at low speeds. Full-load

Tension lever

Control rack

Ungleich spring

Flyweight Shifter

13-10

82665A

Stop Stop lever

82666A

When the stop lever is moved to the stop position, the control rack is moved to the stop position to stop the engine regardless of the position of the adjusting lever.

FUEL AND ENGINE CONTROL - GENERAL

6) Operation of torque spring

E E

D \B

(/) Q_

-�0

� A

�u

"' 0:

Governor operating range

---

Engine speed (rpm) ...,.l-..,__P2

P2 Pump speed (rpm)-.-.

B2667A

Construction machinery engines are often subjected to a large load during operation, and reduced speeds often lead to stalls. To prevent this, a torque spring is provided. When the adjusting lever is fixed in the lever set posi tion, a sudden increase of load, if no torque spring is provided, will move the control rack along the B-D curve as the speed falls. The rotational displacement at the time may be expressed as P1. Torque spring

ree

~5 oe

Torquecontrol ee

If a torque spring is provided, the control rack moves along B-C, and the rotational displacement at the time may be expressed as P2 . Therefore, large changes occur in P2 and engine speed, and because of increased fuel injection, the engine torque increases, and large combustion noise warns the operator of the increased load, enabling him to take proper action to prevent stopping the engine. In an abrupt increase of load occurs when the engine is running at continuous rating, the engine speed falls. So the flyweights are moved inward and the tension lever pulled to left by the control spring, causing the control rack to move in the direction that fuel is increased. At the time, the tension lever pin pushes the bottom of the torque control lever, and the lever moves with the pin "A" as the fulcrum, whereas the portion "B" is pushed to right. As the result, the torque spring per forms the function of reducing movement of the ten sion lever.

lever

Ree]

Full-load stopper

B2668A

13-11

FUEL AND ENGINE CONTROL - GENERAL

(b) RFD type governor

Governor cover

Stop lever Governor housing

Guide !ever

Governor spring Tension lever Control rack

Floating� " lever lin� � Start spring

Swivel lever

Damper spring Camshaft

Speed control tever %

a ‘,S

%\ BL

;

ce r) a

Sts

bel

;

rth

HANS weet m

oy,

Gh iusFY am

Load control

fever

Torque spring

Idling spring Sleeve Stroke adjusting bolt Floating lever

Flyweight Sliding lever

B2682B

The RFD type governor is a minimum-maximum gov· ernor which controls only the minimum and maximum speeds. The RFD type governor make it possible to increase or reduce fuel by the load control lever which operates the control rod. Any desired speed can be set as a dis placement of the speed control lever changes the ten sion of the governor spring. Because of the construction described above, the RFD governor can be operated as an all-speed governor by holding the load control lever in the full position and operating the speed control lever. Flyweights are mounted on the injection pump cam shaft. Each of the flyweights pivots about a pin press· fitted in the flyweight holder. When the flyweights move out, the slider fitted to the end of the flyweight arms pushes the sleeve end face axially. The sleeve which contacts the flyweight slider is coupled to the shifter by a snap ring. The guide lever suspended from 13-12

the tension lever shaft holds the shifter, preventing it from turning. The guide lever has an intermediate shaft, on each side of which there is a floating lever mounted. A block is press-fitted in the bottom end of one floating lever and this block is fitted in the bottom of the sliding lever. The load control lever is fitted to this sliding lever through an eccentric shaft. The floating lever can be moved by operating the load control lever. At the upper end of the floating lever placed on the other side via a shaft, there is an injection pump control rack fitted via a floating lever link. A start spring is hooked at the lower end of the floating lever and the other end of the start spring is hooked at the spring eye on the governor housing side. The tension lever is suspended from the tension lever shaft from which the guide lever is suspended. A gov ernor spring is fitted across this tension lever and the swivel lever. Its tension is determined by the speed control lever mounted on the swivel lever shaft. Within

FUEL AND ENGINE CONTROL - GENERAL normal speed ranges, therefore, the lower end of the tension lever is always in contact with the stroke adjusting bolt A pin is press-fitted in the side of the lower end of the tension lever. It fits into the groove in the upper part of the sliding lever. During high speed control, therefore, a greater lever ratio is obtained from the linkage formed by the pin, sliding lever, and floating lever. Built into the lower end of the tension lever is the idling spring that provides low speed control. 1)

The engine stop lever is fitted to the top of the gover nor, that moves the control rack to the non-injection position to stop the engine. The cancel spring is installed to prevent excessive force from being applied to the control rack at this time. Mounted on top of the governor cover is the smoke set assembly. It functions to ensure good starting by increasing the amount of fuel injected at starting and improve smoke condition in the practical full-load low speed range.

Control of engine start and idling Speed control lever Maximum speed position Stan spring

Control rack

�

Guide lever Tension lever Floating lever

Swivel lever Governor spring

Load control lever Full position

Sliding idling pesition lever

Shifter

When the engine is not running, the flyweights are in the closed position, pushed by the governor spring, idling spring, and start spring. If, in this condition, the load control lever is moved all the way to the full posi tion (in the direction of greater fuel delivery), the start spring and idling spring cause the control rack to move to a point which is beyond the full-load position and provides the maximum amount of fuel injected, thus making it easier to start the engine. When the load control lever is returned to the idling position after the engine has started, the flyweights increase or decrease their centrifugal force as the engine speed changes. In the idle speed range, the cen trifugal force is such that it just compresses the idling spring. The centrifugal force of the flyweights balances the combined force of the idling spring and start

Idling spring

82670A

spring, which keeps the control rack at a given position. This results in the engine running at smooth idle speed. If the engine speed increases at this time, the centrifu gal force of the flyweights increases causing the fly weights to move out to push the shifter to the right. As a result, the guide lever and floating lever are moved, which in turn moves the control rack in the direction of smaller fuel delivery (to the right). If the engine speed decreases, on the other hand, the control rack is moved in the direction of greater fuel delivery. The governor controls the amount of fuel injected in this way to stabi lize the engine at idle speed.

13-13

DI 2)

FUEL AND ENGINE CONTROL - GENERAL 3)

Normal speed operation

Control of maximum speed

Speed control lever Maximum speed position Tension lever Floating lever ll'l·ltl

Load control lever

“>

Eccentric shaft

Sliding lever 82671A

If the load control lever is moved in the full direction (for greater fuel delivery), the eccentric shaft coupled to the load control lever causes the sliding lever to pivot about pin D fitted in the bottom of the tension lever. At the same time, the floating lever pivots about point B to push the control rack in the direction of greater fuel delivery, which results in the engine speed increasing. When the engine speed reaches a point over the idling control range, the idling spring is completely com pressed in the tension lever, causing the shifter to be in direct contact with the tension lever. The tension lever, however, is in contact with the stroke adjusting bolt by the tension of the governor spring which is tightened by the speed control lever. Since the centrifugal force of the flyweights is small in the normal speed range, the tension lever is unable to move. This means that point B can not move either, and the operation of the load control lever is directly transmitted through the eccentric shaft, sliding lever, and floating lever to the control rack, thereby increasing and decreasing the amount of fuel injected.

13-14

82672A

As the engine load varies and engine speed reaches a predetermined maximum speed, the centrifugal force of the flyweights overcomes the governor spring ten sion, causing the flyweights to start moving out. This motion results in the shifter and tension lever being moved to the right. Then, point B is moved to B' and point D in tension lever to D', which prevents the engine speed from exceeding the predetermined max imum level. If this governor is used as an all-speed governor, the engine speed is varied by operating the speed control lever with the load control lever fixed at the full posi tion. That is, a given engine speed is maintained as the speed control lever is tilted; if load changes, however, the governor automatically controls to keep the given speed. For example, suppose the speed control lever is tilted to a position which provides the maximum out put (where it contacts the maximum speed stopper bolt). When the engine speed increases in this condi tion, the centrifugal force of the flyweights becomes greater.

FUEL AND ENGINE CONTROL - GENERAL As the force becomes greater than the force of the gov ernor spring which pulls the tension lever, the fly weights start moving out. This motion of the fly weights causes the shifter and tension lever to be moved to the right. At the same time, point Bis moved to B', point D to D', and point C to C'. This results in the control rack being pulled in the direction of smalier fuel delivery, thus reducing the engine speed. If load increases to cause the speed to decrease, the centrifugal force of the flyweights becomes smaller than the governor spring tension. Then, point B' is moved to B, point D' to D, and point C' to C. This results in the control rack being moved in the direction of greater fuel delivery. The governor automatically activates as load changes to maintain a given speed at all times. 4)

With smoke set assembly Without smoke set embly

,..._/ '

Rs>---"-

Rack position {mml

Start booster (smoke set assembly) N2

"Stroke

Pump speed (rpm) ...

adjusting }.:

'lilllil

B2674B

9 Spring

Floating lever

Sliding lever

82673A

The smoke set assembly installed to the rear of the governor has a spring with setting force and a stopper as functional parts. It also has sleeve, stroke adjusting nut, spring adjusting nut and cap.

As indicated by the governor characteristics shown above, when without the smoke set assembly, the shifter and floating lever are pushed back by the idling spring force, moving the control rack toward fuel increasing direction when pump speed reaches N1. Namely, N1 is the smoke limit in this case. When with the smoke set assembly, the spring force of the smoke set assembly overcomes that of the idling spring so that the floating lever motion is inhibited until the speed reaches N 2. Thus, the smoke limit decreases from N1 to N2. It is also possible to secure rack position Rs needed at time of start.

13-15

FUEL AND ENGINE CONTROL - GENERAL

5) Engine stop lever

(3) Feed pump <6D2> Priming pump Normal position

Spring Outlet check valve

Inlet check valve

Stop lever assembly Internal lever

Gauze filter From fuel tank

To fuel filter

83006A <8DC> Priming pump Floating lever link

Control rack

82675A

To stop the engine, the stop lever on top of the gover nor must be operated to cut off the fuel. The stop lever is cable-connected to the engine stop button on the driver's seat. The stop lever is operated by pulling the button. When the stop lever is rotated, the internal lever pushes the tab on the floating lever link, forcing the control rack to the non-injection posi tion to stop the engine. The stop lever returns to the normal position by the reaction of a built-in spring.

13-16

Outlet check valv

Inlet check valve

spring

Gauze filter From fuel tank

12186

Supply of fuel to the injection pump proper is accom plished by the feed pump mounted to the side of the injection pump proper and driven by the cam of the injection pump camshaft provided for the purpose. The priming pump mounted to the feed pump makes it possible to lift fuel manually when the engine is sta tionary.

FUEL AND ENGINE CONTROL - GENERAL (c) Stop

(a) Suction stroke

Boss:

Suction chamber

Outlet check

Pressure

vaive

chamber Camshaft’ Push rod

01835

01837

When the camshaft of the injection pump forces the push rod up, the fuel in the suction chamber is com pressed and opens the outlet check valve. Most of the fuel forced out is drawn into the pressure chamber above the position.

When the pressure in the pressure chamber exceeds specification, the piston cannot be brought back by the pressure of the piston spring and stops the pump func tion. So the pressure in the fuel filter is adjusted not to rise more than necessary.

(b) Pressure feed stroke Suction chamber

Inlet check valve

Piston spring Outlet check valve Camsha

Pressure chamber

01836

When the cam, moved away by rotation of the cam shaft, ceases to push up, the piston is pushed back by the pressure of the piston spring and forces out the fuel from the pressure chamber and forces it into the fuel filter. At the time, the· outlet check valve closes, and the inlet check valve opens, so the fuel is drawn into the suction chamber.

13-17

FUEL AND ENGINE CONTROL - GENERAL

(4) Automatic timer The interval between fuel injection into the cylinder and its ignition is called the ignition delay interval. The ignition delay interval is constant regardless of the engine speed. If the ignition timing is always constant, changes in the engine speed will vary the relation between the piston position and ignition timing, mak ing it impossible to obtain the best engine perfor-

mance. To maintain the relation between the piston position and ignition timing constant at all times, the injection timing must be changed to match the engine speed. The automatic timer is a device which automatically changes the injection timing according to the engine speed.

(a) SA-type automatic timer <6D22>

Flyweight

Flange

Timer case

Flyweight holder

83210A

Each of the two flyweights has a hole in one side. The flyweight holder pins fit into these holes. The flange legs touch the flyweights' curved surfaces. Timer springs are fitted to the flyweight pins and flange legs.

13-18

Engine rotation is transmitted by the flange to the flange legs, flyweights, flyweight holder, and injection pump camshaft.

FUEL AND ENGINE CONTROL - GENERAL

Flange leg

F!ywelght Advance angle

Flyweight holder pin

At !ow speeds

63211A

At low engine speeds, no centrifuga I force acts on the flyweights, so the timer springs have their maximum installed length.

At high speeds

83212A

At high engine speeds, centrifugal force acts on the fly weights. The flyweights thus open outward, pivoting on the flyweight holder pins. When this happens, the flange legs are pushed by the curved surfaces of the flyweights in the timer springs' compression direction but cannot move since they are coupled to the drive side. While compressing the timer springs, the flyweight holder pins are thus drawn in the direction of rotation, which moves the pump camshaft in the direction of rotation and advances the injection timing. If the engine slows from a high speed to a low speed, the flyweights' centrifugal force diminishes. The fly weights thus return to their original positions and the flyweight holder pins are pushed back by the timer springs.

13-19

FUEL AND ENGINE CONTROL - GENERAL

(bl SP type automatic timer <6D22-T, TC, 24-T, 24-TC, 8DC8, 9, 9-T, 9-TC>

Injection pump side

Oil seal

0-ring

�

jr(L ---, �-

Flange

Cover

� Spring seat Flyweight Timer housing

83201A

Two flyweights are fitted on the pins of the timer hous ing and are held in the timer housing. On the other hand, the injection pump connection side flange has a curved surface, and the roller fitted on the pin installed in the flyweight touches the curved surface. Timer Timer spring

When the engine is running at a low speed, the timer spring pressure is stronger than the centrifugal force of flyweight, so the roller of flyweight is held down by the flange, creating no advance state. When the engine reaches a high speed, the centrifugal force of flyweight becomes stronger, the roller of fly weight pushes the curved surface of flange with the timer housing pin as the fulcrum, and the flyweight opens outward, while compressing the timer springs. In this manner, the roller installed on the flyweight moves the flange in the turning direction and advances the injection timing.

Flange

Timer h0using pin \

Advance angle

83202A

13-20

springs are held between the spring seats fitted on the timer housing pins which extend through the flange and flyweight. These parts are housed in the timer housing and are totally enclosed with a cover, 0-ring and oil seal.

FUEL AND ENGINE CONTROL - GENERAL (c) SPG type automatic timer <BDC9-TL>

Cover Pilot pin

Timer holder

Timer housing

Eccentric cam {larger} Eccentric carn (smaiier}

B0023A

Flyweight pin

-�

�

Timer holder

Flyweight

Eccentric cam (larger) ��Eccentric cam (smaller) (� � Timer housing

Timer holder �

Housing pin

�

Pilot pin

Timer spring

B0024A

B0025A

The timer housing receives rotating motion of the engine through a coupling. The timer holder is directly connected to the injection pump camshaft. Two oppos ing pins are press-fitted in the timer housing. A small eccentric cam is mounted on each of the pins and a large eccentric cam is slid over the periphery of the small cam. The two holes in the timer holder fit over the large eccentric cams. Pins are pressed into the undersides of the flyweights. These flyweight pins fit into holes in the larger eccen tric cams. When the timer housing is rotated, the timer holder is rotated at the same time driving the injection pump.

The two flyweights have the timer holder in between and are provided with timer springs having the same set tension to keep the flyweights evenly in position. When the engine is not running or running at low speeds, the flyweights are pressed against the timer holder by the set tension of the springs.

13-21

FUEL AND ENGINE CONTROL - GENERAL 15) Boost compensator Timer housing pin {Point C) Eccentric cam (smaller)

Boost pressure Timer housing

Turbocharger

Ss Exhaust

Eccentric cam {larger}

Inlet manifold v

Seepe

Flyweight

Timer spring

Flyweight pin Advance angle Rotating direction

Flyweight in maximum lifted state 80026A

When the engine is not running, the flyweights are pressed against the timer holder by the timer spring set tension. When the engine is started, a centrifugal force is pro duced by the flyweights; however, it is less than the timer spring set tension keeping the flyweights remaining the original positions, without lifting. As the engine speed increases, the centrifugal force of the flyweights also increases and will be balanced with the spring tension. When the engine speed further increases, the centrifugal force overcomes the timer spring set tension, causing the flyweights to lift out ward. This causes the center (point B) of the large eccentric cam pivot about the center (point A) of the timer, moved in the rotating direction, by the small eccentric cam pivoting about the timer housing pin (point C). Since the large eccentric cam is fitted to the timer holder, that motion of the large eccentric cam is imparted to the timer holder. The maximum advance is obtained when the backs of the flyweights are against the inner wall of the timer housing.

13-22

Turbine

86012A

The boost compensators increase the engine's power output by increasing the rate of fuel injection to match increases in air intake caused by the turbocharger. To increase the amount of fuel injected, the boost com pensators utilize the boost pressure in the inlet man ifold. There are two boost compensators. One is fitted to the governor, and the other is fitted to the drive side of the injection pump.

FUEL AND ENGINE CONTROL - GENERAL (b) Drive-side boost compensator

(a) Governor-side boost compensator

Boost compensator set spring

�ly

Connection pipe Boost pressure Boost compensator i Boost compensator spring

Increase� Control rod

Floating lever

Diaphragm

eyA i re Pressurization Boost

Inlet manifold

Diaphragm Push rod

es 3 BS

Compensator lever

Start fuel increase stroke

82693C

Control rod.

82691A

As the boost pressure overcomes the compensator spring, the diaphragm and push rod are pushed to the left. Movement of the diaphragm is pivoted on point "A" of the compensator lever and moves the compen sator lever in the direction shown by the dotted lines. As the diaphragm and compensator lever move, the floating lever pivots counter-clockwise about point "B," thereby pushing the control rod in the fuel-in crease direction. The system is thus able to increase the fuel quantity irrespective of the governor.

Load control lever idling position

Control rod

lOo

�t;f :h �ting lever Cancel spring

Floating lever link

[Ff: :Jft4{)J

Load control lever full position (turbocharger off)

�

Load control lever full position (turbocharger on)

• F[F: =t:'§f� �

82693A

When the boost pressure rises above the boost com pensator spring set pressure by the action of the turbo charger, the diaphragm forces out the push rod. The cancel spring installed between the control rod and floating lever on the governor side is set so that it pushes, at all times, the control rod in the direction of greater fuel supply. This means that, when the push rod moves in the direction shown by the arrow, the control rod moves in the direction of greater fuel sup ply. This boost compensator also has a spring that increases fuel supply at engine start.

13-23

FUEL AND ENGINE CONTROL - GENERAL P) Injection nozzle (a) Hole type (1-spring nozzle)

Adjusting screw

4b Fee Hf :1%tiae heres H 2

From injection pump

srs 23

�

� Nozzle hold

Smoke set spring

__,I:-'-.,I�

Nozzle spring _ Control rod

B2692A

Before the engine is started, the idling spring in the governor, forcing the control rod in the direction of more fuel supply overcomes the force of the smoke set spring and therefore the control rod moves to the start fuel increase position while forcing the arm. When the engine is started, the idling spring is compressed by the shifter and as a result, it loses the force to push out the control rod. Then, the smoke set spring forces the control rod back to the normal position. (6) Pump drive case

Pump drive shaft

Pump drive gear

Injection pump side

Flywheel housing side 84191A

The pump drive case, installed at the left of the fly wheel housing, is driven by the timing gear of the engine at half the engine speed. The pump drive shaft, with its end connected to the coupling of the injection pump, drives the injection pump.

13-24

04538

The fuel delivered from the injection pump enters the nozzle holder and has a pressure higher than the speci fied pressure. So the fuel overcomes the nozzle spring and pushes the needle valve up. The high pressure fuel which has forced the needle valve up is injected from the orifice at the end of the nozzle into the engine combustion chamber. Some of the high pressure fuel lubricates the needle valve, etc. and is returned through the fuel leak-off pipe to the fuel tank. The injection pressure of the injection nozzle is adjusted by changing the tension of the nozzle spring with the adjusting screw.

FUEL AND ENGINE CONTROL - GENERAL (b) Hole type (2-spring nozzle) Two models of hole type injection pumps are used. Their constructions are as follows.

C)J

From injection pump <Other than nozzle identification mark "2D">

To leak-off pipe

Cap nut Adjusting screw

To leak-off pipe

No. 1 valve opening pressure--t--t--fi adjusting shim

From injection pump

Locknut-__ Set screw----1-,

No, 2 spring

Gasket

No. 1 spring

es 2 cfom mE xosSo 9 ¥

o&3 £

No. 1 spring seat

Spacer ---- No. 2 push rod :----Nozzle holder > 0

hee @

a=-2©a)

No. 1 spring

No. 2 valve opening pressure adjusting shim No. 2 spring seat

No. 2 spring

Needle valve

No. 1 push rod Needle valve

Nozzle Retaining nut

83406A

The nozzle has two springs and push rods, and a clear ance (prelift) is provided between two rods. When the high pressure fuel fed from the injection pump overcomes the 1st spring which determines the valve opening pressure, the needle valve opens to start the pre-injection and simultaneously moves the 1st push rod upward. When the 1st push rod moves through the prelift and contacts the 2nd push rod, the needle valve stops mov ing momentarily. As the fuel pressure further increases and overcomes the resultant force of the 1st and 2nd springs, the needle valve restarts moving upward for the main injection. Some of the high-pressure fuel is used to lubricate the needle valve and other components and is returned to the fuel tank via the leak-off pipe. Fuel injection pressure adjustments are made using the shim.

11933

With this nozzle, a prelift clearance is provided between the lift-piece and No. 2 spring seat, and the nozzle's injection starting pressure is determined by the force of the No. 1 spring.

13-25

FUEL AND ENGINE CONTROL - GENERAL (8) Fuel filter

No. 1 spring if 7Yy we d

aYE :

“Y

Push rod

----I

és on =

ry oN eee eh ee +

';:!...-L--No. 1 spring seat

Se oe

No. 2spring a o LiftN “uy Qa‘czc a a @®aut

B3501B piece

Needle valve

Fuelfilter head

01846

As the pressure of the fuel fed from the injection pump (i.e., the pressure in the nozzle tube) overcomes the No. 1 spring, the needle valve rises by the prelift distance. When the lift-piece rises by the pre lift distance, it meets the No. 2 spring seat. Since the lift-piece and No. 1 spring seat are pressing together, the spring force at this time is that of the No. 1 and No. 2 springs com bined, and the needle valve momentarily stops rising. As the fuel pressure rises and the pressure in the nozzle tube overcomes the two springs, the needle valve rises further and the nozzle injects the remaining larger quantity of fuel. Fuel injection pressure adjustments are made using the shim.

13-26

Element

B3501C

The fuel filter may be either the element replace type or the spin-on type which facilitates replacement of ele ment. It separates water content in the fuel fed under pres sure from the fuel feed pump of injection pump and eliminates dirt in the fuel by the element.

FUEL AND ENGINE CONTROL - GENERAL (9) Water separator

Water level ring

B3551A

The sedimenter type water separator separates gas oil and water centrifugally by taking advantage of their difference in specific gravity. The fuel that has flowed in from the inlet connector is squeezed by the fuel path of the head to increase the flow velocity and spins. The separated water is sedi mented in the case, whereas the water-separated fuel is drawn through the fuel path in the center of the head into the feed pump. The water separator sediments not only water but also mud components. A red float goes up and down with the water level in the semi-transparent case, making it possible to visually check the water quantity.

13-27

FUEL AND ENGINE CONTROL - SPECIFICATIONS

2. SPECIFICATIONS ( 1) Injection pump and injection nozzles <6D2> Specification

ltem

Manufacturer ZEXEL Corp. <6022-T>

Applicable engine model <6D22> Injection pump proper Type Model

Turning direction

(viewed from drive side) Plunger diameter

(Standard)

(Optional)

(Standard)

(Optional)

Bosch in-line type

Clockwise

10.5

RSV-type all-speed mechanical

governor

RFD-type minimum/ maximum mechanical

RSV-type all-speed mechanical governor

RFD-type minimum/ maximum mechanical governor

RSV-type all-speed mechanical governor

SA-type mechanical automatic timer

SP-type mechanical automatic timer

Governor Model, Type

Fuel feed pump Model Automatic timer Model, Type

governor

(Standard)

(Optional)

Type

Hole type (1-spring)

Hole type (2-spring)

Hole type ( 1-spring)

Hole type (1-spring)

Model

OLLA

0.37

0.38

154°

157 °

Injection nozzles

No. of holes Hole diameter

Spray angle

Specification

Item

Manufacturer ZEXEL Corp. <6D24-TC>

<6024-T>

<6D22-TC> Injection pump proper

(Standard)

(Optional) Bosch in-line type

Type

Bosch in-line type

Model

Clockwise

RSV-type all-speed mechanical governor

RFD-type minimum/ maximum mechanical governor

RSV-type all-speed mechanical governor

SP-type mechanical automatic timer

Turning direction (viewed from drive side) Plunger diameter

Governor Model, Type Fuel feed pump Model Automatic timer Model, Type

(Standard)

(Optional)

Type

Hole type (1-spring)

Hole type (2-spring)

Hole type (2-spring}

Hole type I2-spring)

Model

OLLA

0.36

150°

157°

150°

Injection nozzles

No. of holes Hole diameter Spray angle

13-28

FUEL AND ENGINE CONTROL - SPECIFICATIONS (2) Injection pump and injection nozzles <BDC> Specification

Item

Injection pump proper Type Model Turning direction (viewed from drive side) Plunger diameter Governor

Model, Type

Fuel feed pump Mode! Automatic timer Model, Type

Manufacturer ZEXEL Corp. (Standard)

Bosch

in-line type

(Standard) I

(Optional)

Bosch in-line type

Clockwise

10-5

10.5

12_0

11.0

12.0

RSV-type all-speed mechanical governor

RFD-type minimum/ mechanical governor

maximum

RFD-type minimum/ maximum mechanical governor

RSV-type all-speed mechanical governor

RFD-type minimum/ maximum mechanical governor

RSV-type all-speed mechanical governor

SP-type mechanical automatic timer

SPG-type mechanical automatic timer

SP-type mechanical automatic timer

Hole type (1-spring)

Hole type {2-spring)

Hole type (2-spring)

Hole type ( 1-spring)

OLLA

Hole type (1-spring)

Model

OLLA

0.32 158°

Spray angle

Bosch

in-line type

<8DC9-TC>

Clockwise

Type

I <8DC9-TL>

Clockwise

(Standard)

No. of holes

(Optional)

Injection nozzles

Hole diameter

<BDC9-T>

<8DC9>

(Optional)

Hole type Hole type 12-spring) (1-spring)

DLLA

OLLA

0.32

0.36

0.34

0.36

158°

160°

157°

155°

157 °

155°

(2) Others Item

Specification

Fuel filter Type

Spin-on type

Water separator Type

Sediment trap type

13-29

FUEL AND ENGINE CONTROL - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table I 1) Injection pump

Unit: mm Maintenance item

Fuel injection start timing {BTDC)

Remedy and remarks Adjust

afar

Adjust shims

155 kPa {1.6 kgf/cm2 }

6D22: For construetion machinery, 6D22-T, 22-TC, 8DC9-T, 9-TL, 9-TC

255 kPa {2.6 kgf/cm2 }

Sliding resistance of control rack {when stationary)

AD type

i 6D2

1.5 N {150 gf} or less

i BDC

2.0 N {200 gf} or less

1.3 N {130 gf} or less

I 6D2

! End play of camshaft

1.5 N {150 gf} or less

0.02 to 0.06

0.1

Overalltappet (roller) clearance

Injection start interval

Check

Adjust shims

0.2

Replace

0.3

Replace

21 or more

Check

AD type

4.5 ± 0.05

Adjust

Ptype

4.8 ± 0.05

6D2

60 ± 30'

BDC

45 ± 30'

AD type

0.3 or more

Full stroke of control rack (or control rod) Prestroke

Replace

0.15

AD type

Backlash between control rack and pinion

Adjust

I RFD type

33 to 33.4

· Tightness [when 195 kPa {2 kgf/cm 2} of air pressure is applied]

Ocm3/min.

Replace

25 strokes or less

Replace

60 cc

Replace

Tappet clearance Dimension from governor housing to shifter

I RSV type

Delivery (min.) for 15 seconds

100 rpm

KE type K type

I 602

! BDC KD type 500 rpm

KD type

Adjust Adjust shims

60 cc

70 cc

•

I 6D2

130 cc

i BDC

145 cc

KE type K type

19 to 19.2

Priming pump lift capacity {No. of strokes required before lifting when operated at 60 to 100 strokes/min.)

13-30

8DC9

! soc

Feed pump

Dependent on specification

Overflow valve opening pressure

P type

Limit

0.2 or less

Eccentricity with respect to air compressor crankshaft (or pump drive shaft) Injection pump proper

Nominal value {Basic diameter in ! II

340 cc 6D2

260 cc

SDC

300 cc

6D2

700 cc

BDC

710 cc

•

FUEL AND ENGINE CONTROL - SERVICE STANDARDS Nominal value I {Basic diameter in { II

Maintenance item Feed pump

1000 rpm

Delivery (min.) for 15

KE type K type

seconds

KO type

! 602

i I

K type

I KO type

600 cc

i 602

soc

1170 cc I

1170 cc

Limit

! '

Remedy and remarks

Replace

430 cc

[ 602

520 cc

BOC

580 cc

602

1000 cc

BOC

1035 cc

KE type

1500 rpm

530 cc

I BOC 1

405 cc

Unit: mm

(2) Injection nozzle Unit: mm Maintenance item Valve opening pressure 2-spring nozzle

I Prelift

11-spring nozzle

21.6 MPa {220 kgf/crn2}

2-spring nozzle

17.7 MPa {180 kgf/crn 2l

I Except nozzle identification mark "20"

I Nozzle identification mark "20"

2-spring regulated pressure (open pressure) <Except nozzle identification mark "20"> 2-spring regulated pressure (cover pressure) with a 0.05 needle valve lift

Limit

Nominal value (Basic diameter in [ I)

0.10 ± 0.02 0.07 ± 0.02

Standard

24.8 to 25.4 MPa {253 to 259 kgf/crn2}

Option

26.2 to 26.9 MPa {267 to 274 kgf/crn2}

Except nozzle identi� fication mark "2D n

23.0 to 23.5 MPa {235 to 240 kgf/crn 2}

Nozzle identification mark "2D"

25.5 to 26.5 MPa {260 to 270 kgf/crn 2l

Remedy and remarks

Adjust

13-31

FUEL AND ENGINE CONTROL - SERVICE STANDARDS

3.2 Tightening Torque Table Location tightened Injection pump bracket mounting bolt

6D2

Screw size 0.0. x pitch (mm)

Tightening torque

M10 x 1.5

35 to 53 {3.6 to 5.4)

On pump side

ADtype

M12 X 1.5

29 {3)

P type

M14 x 1.5

29 {3)

On nozzle side Injection pump

.I Overflow valve

Injection pump fuel inlet side eyebolt

AD type 16D2 only), p type ADtype (BOC only)

Lubricant (inlet) side eyebolt

AD type

lubricant (outlet) side eyebolt

ADtype

Ptype

?type

29 {3} 20 to 29 {2 to 3) 20 to 29 {2 to 3)

25 to 29 {2,5 to 3) 9,Bto 13{1 to 1.3) 12 to 15 {1.2 to 1.5) 15to 18{1.5to 1.8) 20 to 29 {2 to 3)

Boost compensator eyebolt

12 to 15 {1.2 to 1.5)

Delivery valve holder

64 to 69 {6.5to 7}

P type Lock plate

ADtype

Flange sleeve nut

P type

Governor flyweight mounting round nut Fuel feed pump

Fuel inlet side eyebolt Fuel outlet side eyebolt

KE,K,KD type 16D2 only) K, KOtype (8OConly)

Automatic timer round nut

4.4 to 5,9 {0.45to 0.6) 39 to 44 {4 to 4.5} 49 to 59 {5 to 6) 20to 25 {2to 2.5) 20to 25 {2 to 2,5)

20 to 29{2 to 3)

SP type

125to 145{13to 15)

SPG type

145 to 165 {15to 17}

Cover mounting bolt

SPtype

Cover

SPG type

SPtype SPGtype

Oil filler port bolt

105to 115{11 to 12)

SA type

Cap screw

83 to 98 {8.5to 10)

29to 39 {3 to 4) 64to 83 {6.5 to 8,5) 22 to 24 {2.2 to 2.4) 295to 345{30 to 35) 9.8to 15{1.0to 1.5)

A bolt

�IOO��c

B bolt

29 to 34 {3to 3.5)

A �

C bolt

29 to 34 {3to 3.5)

<6D2: AD type>

�

49 to 54 {5 to 5.5}

- � -'] B

13-32

M12 x 1.5

AD type

B3408A

Remarks

42 to 59 {4.3 to 6.0)

BOC Injection pipe union nut

N-m {kgf-m)

Tighten three times to the specified torque

FUEL AND ENGINE CONTROL - SERVICE STANDARDS Screw size

lightening torque

A bolt

74to 83 {7.5 to 8.5)

B bolt

59 to 64 (6 to 6.5)

C bolt

59 to 64{6 to 6.5)

Injection pump gear mounting nut of pump drive case

M24 x 1.5

215{22)

Injection nozzle

Leak-off pipe eyebolt

M8x1

9.8to 15{1to 1.5)

Injection nozzle bolt (for attaching to cylinder head)

Max1.25

15 {1.5}

Retaining nut

M19 X 1

59 to 78 (6 to 8)

Cap nut

M14 X 1

39 to 49 {4 to 5)

Inlet connector

M14 X 1.5

69 to 78 {7to 8)

Retaining nut

M19 x1

59 to 78 {6to 8)

Cap nut

M22x 1.5

39 to 49 {4to 5}

Inlet connector

M14x1.5

69 to 78{7 to 8)

Set screw

M22 x 1.5

49 to 59 {5 to 6}

Lock nut

M14 X 1

Leak-off connector

M14 x1

Retaining nut

M19 x0.75

Location tightened

�✓B

<6D2: Ptype, 8DC,

�.,i� �('� J/

a ~

1-spring nozzle

2-spring nozzle

N·rn {kgf.rn)

Remarks

83401A

Fuel filter connector bolt Water separator

0.0. x pitch (mm)

J Eye bolt

Air plug

Except nozzle identification mark "2D"

20 to 25 {2 to 2.5) 29 to 39 {3 to 4) 59 to 78 {6 to 8)

M14 x 1.5

25 {2.5)

M14x1.5

25 {2.5)

MS x1.25

7.8to 12 {0.8 to 1.2)

Nozzle identification mark "2Dn

13-33

FUEL AND ENGINE CONTROL - SPECIAL TOOL

4. SPECIAL TOOL Unit: mm

Unit: mm Tool name

Tool name

Shape

Injection Pump Centering Tool MH061270 <AD type> Centering of bracket of injection pump

Filter Wrench MH061572 Removal of fuel filter element

B5222A Injection Pump Centering Tool MH061340 <P type, Centering of bracket of injection pump

B5031A

13-34

Shape

12221

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5. SERVICE PROCEDURE

NOTE:

5.1 Injection Pump Assembly 5.1.1 Removal and installation ( 1) Removal procedure (a) Ready a fluid receiver and waste cloth to ensure that the engine is not contaminated by fuel or engine oil. (b) Remove all pipes and harness connectors that make the removal job difficult or impossible. C0557A

<602>

Keep the injection pump removed on wooden blocks so as to protect the automatic timer area from impact. (e) Do not remove the injection pump bracket unless defects, such as cracks, are evident. (2) Installation procedure NOTE: The following procedures assume that the injection pump is equipped with an air compressor. The same procedures apply to one with a pump drive case. 86120C

<BDC>

86120D

13-35

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(a) Adjustment of injection pump bracket <602>

Dial gauge Injection Pump Centering Tool MH061270' Measuring point

Air compressor

C0603A

C0597A

<8DC>

Dial gauge Injection Pump Centering Tool MH061340 Air compressor $ 25 Position <Except 6D24•T, 24•TC> q, 30 position <6D24-T, 24-TC> Injection pump bracket 11929

Make zero-point adjustment with Injection Pump Centering Tool {special tool) placed on the injec tion pump bracket and a dial gauge set on the man drel of the special tool.

13-36

Crankcase C0582B

2) Slide the dial gauge toward the air compressor and measure the misalignment between the mandrel of the special tool and the air compressor crank shaft at points shown in the figure.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Shim inserting requirements <6D2>

•

I Eccentricity , NV 0.2 or less i

• • 4)

The number of shims used in a single location must not exceed three. Top and bottom shims both at front and rear must be equal in thickness. The difference in number between right and left shims must not exceed one.

After adjustment, tighten injection pump bracket to the specified torque before confirmation.

(b) Installation of injection pump Dowel pin

1) 35 to 53 N-m

{3.6 to 5.4 kgf-m)}

C0598A

<8DC> 1

Crank the engine to bring the No. 1 cylinder piston to the fuel injection timing position. (Refer to Section 5.11. 1 .) Keyway

Eccentricity NV 0.2 or less

..---7

�T� , ' - �-----------1

42 to 59 N-m {4.3 to 6.0 kgf m}

NV .. Nominal Value

cossgc

2) At that time, verify that the keyway of air compres sor crankshaft faces upward. If not, rotate the crankshaft one complete turn.

If the eccentricity between the mandrel and air compressor crankshaft is in excess of the nominal value, adjust by adding or removing injection pump bracket shims. <When the measured value at point B is positive (+)>

Insert shims evenly to four places. <When the measured value at point A is positive (+)>

Insert shims to the lower side of point C. <When the measured value at point C is positive (+)>

Insert shims to the upper side of point A.

C0562A

3) Align the pointer of the injection pump and the inscribed mark on the automatic timer.

13-37

DI 4)

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Installation of injection pump <AD type injection pump> Cross coupling

Driving coupling Timing adjustment bolt <6D2> 29 to 34N-m

{3 to 3.5 kgf-m}

Air compressor crankshaft

<8DC> 59 to 64N-m

{6 to 6.5 kgf-rm}

�

Coupling plate mounting boit <6D2>

;

29 to 34 N-m {3 to 3.5 kgf-m}

Coupling plate

<8DC> 59 to 64 N-m

{6 to 6.5 kgf-m}

Cotter bolt <602> 49 to 54 N·m {5 to 5.5 kgfm) <8DC> 74 to 83 N·m {7.5 to 8.5 kgf m}

83405D

Crosscoupling Coupling plate mounting bolt

Timing adjustment bolt 59 to 64 N•m (6 to 6.5 kgfm} Driving coupling

59 to 64 N-m

{6 to 6.5 kgf-m}

Coupling plate

Air compressor crankshaft

Cotter bolt 74 to 83 N·m (7.5 to 8.5 kgfm} 83402C

liming adjustment bolt

Clearance

13-38

85893A

<6D2;. • Loosen the cotter bolt and remove the timing adjustment bolt. Remove the driving coupling from the coupling plate. • Fit the driving coupling onto the air compressor crankshaft and push it toward the air compressor. • Fit the injection pump onto the injection pump bracket. • Temporarily fit the timing adjustment bolt onto the driving coupling. Slide the driving coupling until there is clearance of 0.5 mm or less between it and the coupling plate. Then, tighten the cotter bolt to the specified torque. • Confirm that the injection starting timing is cor rectly adjusted as per items (b) 1) to 3), then tighten the timing adjustment bolt to the specified torque. <8DC> • Loosen the cotter bolt and adjusting bolt, then remove the coupling plate mounting bolts. Remove the driving coupling and coupling plate. • Fit the driving coupling and coupling plate onto the air compressor crankshaft and push them toward the air compressor. • Fit the injection pump onto the injection pump bracket. • Fit the driving coupling and coupling plate using the coupling plate mounting bolts, tightening the bolts to the specified torque. • Tighten the cotter bolt to the specified torque, ensuring that there is clearance of 0.5 mm or less between the driving coupling and coupling plate. • Confirm that the injection starting timing is cor rectly adjusted as per items (b) 1) to 3), then tighten the timing adjustment bolt to the specified torque.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

29 Nm {3kgf·m)

20 to29N-m

{2 to3 kgf.m) \ 1

\ \ 1

_,-r��J\fJ7v0[L�=d

r :_ l

20 to29 N•m {2to3kgfm)

I /

t'l�

�

29 N-m (3kgf.m)

9.8 to 13 N-m

{1 to 1.3kgf.m)

9.8 to 13 N-m

{1 to 1.3 kgf,m)

20 to 29 N-m

{2 to 3 kgf.m)

25 to29N-m

{2.5 to 3kgf.m)

_J 'i qD�-

C'.____,'-----"l -'-..-,I.--\ 20 to25N-m

,,,[ s '---'

(2 to 2.5kgf-m)

15 to 18 N-m

20 to 25N-m

15to 18 N-m

{1.5 to 1.8 kgf·m)

(1.5 to 1.8kgf m)

{2to2.5 kgf ml

B43908

84390A

<602>

<BDC> 20to29 N•m (2 to3kgf.m)

20to29Nm {2to3kgfm)

r r

�

29N·m {3 kgf.m)

vv<:

,r, n n r 7S LT _

I \

__J

20to29 N·m {2 to3kgf.m)

{2 to2.5kgf.m)

12to15N-m

\ �. n n n ( VV 1

20 to 29N-m

{2to 3kgf.m)

<8DC9-T, TL>

L\....__/\

{1 ·2 to1· 5k9f·m )

�

12to15N-m

{1.2 to 1.5kgf.m)

29Nm {3kgfm)

o'f

20to29Nm 3kgfm)

, l) l � LJ J

��-�I 20to25N-m

20to29N-m

{2 to 3kgf·m)

20to25Nm

{2 to2.5 kgf.m) 84308C

20 to25N-m

20 to29 N-m

{2 to2.5 kgf.m) {2 to3 kgf.m)

}c, n v

12 to 15 N-m

{1.2to1.5kgf.m)

with boost compensator

�{ ___JJ(J \

84310E

(c) Tighten each pipe to specification. (d) After the injection pump has been installed, be - sure to check and adjust, if necessary, the fuel injection start timing. (Refer to Section 5.11.1.) 13-39

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.2 AD Type Injection Pump NOTE: 1. When disassembling the injection pump, clean the workbench and keep all disassembled parts neatly arranged by the cylinder. Never change the com bination of the plunger and plunger barrel, and that of delivery valve and delivery valve seat.

2. 3.

Special care should be used when disassembling and reassembling major parts. For disassembly and reassembly, use the follow ing special tools (Zexel products) and never apply excessive force or handle them carelessly.

The following Zexel special tools should be used for injection pump maintenance: Special tool name

Part No.

Application

(Zexel product No.)

Injection Pump Special Too! Set (includes items marked with "*n)

105790-1060

Injection pump disassembly and reassembly

Universal vice

105794-0090

Securing of bracket

Tappet pin

157931-3120

Supporting of tappet

Measuring device

*105782-4130

Measurement of camshaft end play

Wrench

*157910-1120

Removal and installation of screw

Guide

• 157920-5400

Protection of oil seal

Roller pincers

• 157921-3020

Removal and installation of tappet

Tappet pincers

157931-7120

Plunger pincers

157921-6120

Removal and installation of plunger

Wrench

*157914-0500

Removal and installation of delivery valve holder

Extractor

*157925-6520

Removal of inner race

*157925-0520

Removal of outer race (timer side)

• 157925-0120

Removal of outer race (governor side)

Reamer

157930-4620

Correction of pump housing

Fixing stand

105781-0430

Test and adjustment of injection pump

Measuring device

105782-6180 105782-4020

Holder

157931-4400

Nozzle holder wrench

157916-8220

13-40

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.2.1 Disassembly, inspection and reassembly

64 to 69 N-m{6.5to 7 kgf-m} 21

20 5.9N-m{0.45 pressure NV 155vaive kPa {1.6 opening kgf/cm} 4.4to to 0.6Overfiow kgf-m}

<8DC9>

Wear, damage24

<6D22 for construction

6 Deterioration

Wear, scratch,

28 Bend Sliding resistance of control rack ! {when stationary) NV 1.5 N {150 gl} or less <6D2> 2.0 N {200 gl} or less <8DC> I

Backlash between control rack and pinion NV 0.15 L 0.3

Rotating

condition

7 Wear and damage of cam surface

ond @

8 Rotating condition

| Camshaft end NV0.02 to0.play 6. 13�15

Wear, damage 12

Wear, damage, seisure

-1--

;.a J--sfii

----,·1

Wear

,=-� Overall tappet (roller) clearance _L_0_.2___�

�'

' Tappet clearance L 0.3 or more NV .. Nominal Value L .... Limit

Disassembly sequence 1 Overflow valve

2 Housing cover 3 Screw

4 Screw 5 Bearing cover 6 Oil seal 7 Camshaft 8 Taper roller bearing 9 Shim 10 Ring

11 Center bearing 12 Tappet 13 Shim 14 Plunger 15 Lower spring seat 16 Plunger spring 17 Upper spring seat 18 Control sleeve 19 Pinion 20 Lock plate

21 Delivery valve holder 22 Stopper 23 Delivery valve spring 24 Delivery valve 25 Delivery valve seat 26 Plunger barrel 27 Screw 28 Control rack 29 Pump housing D1566D

13-41

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.2.2 Testing and adjustment Since injection volume adjustment values and mea surement conditions vary according to configuration, please refer to a Zexel service station.

NOTE: Make sure that the center of coupling is aligned with that of injection pump so that the coupling and injec tion pump turn smoothly. (2) Setting position "0" of control rack

| injection start interval! > i

i Full stroke of control rack NV 21 or more

NV 60° + 30’ <6D2> 45° + 30’ <8DC>

80822C

Prestroke P-> esin H Oo oSrs)

NV .. Nominal Value

Measuring Device 105782-6180

Tappet clearance NV 0.3 or more 89143A

Injection sequence

1 - 2 - 3 - 6 - 2 - 4 <6D2> 1-2-7-3-4-5-6-B<BDC>

NOTE:

1. Supply oil to the injection pump cam chamber. 2. Adjust the injection amount after adjusting the governor.

<With RSV governor> (a) Keep the pump running at 750 rpm. (b) Loosen the stopper bolt and pull the adjusting lever toward the non-injecting direction. (c) Press the end of the Measuring Device all the way toward the governor and adjust the position of point "0" on the scale of the Measuring Device. <With RFD governor> (a) Fix the load control lever at the idling position. (b) Let the pump run at 500 to 600 rpm and temporarily fix the speed control lever so that the governor will begin to provide control at the speed. (c) Press the end of the Measuring Device all the way toward the governor and adjust the position of point "0" on the scale of the Measuring Device.

NOTE: If the injection pump is not running at the speed men tioned above, position "O" won't be obtained even if the control rack is pressed with a strong pressure, and there will be danger of damage to the link mechanism of the pump. 1-----.L:..__:::., Fixing stand 105781-0430 819118

( 1) Mount two Fixing Stands (special tools) onto the injection pump tester, then secure the injection pump onto the Fitting Stands.

13-42

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (31 Checking stroke of control rack Measuring Device 105782-6180

Nozzle Haler Wrench 157916-8220

Pressure feed stroke {bottom dead center)

D34268

80822C

Move the control rack to confirm that the total stroke is over the specified value. (4) Adjusting prestroke (a) Pull the control rack out to the total injection posi tion and secure it there. Remove the overflow valve and plug the hole.

Measuring Device 105782 - 4020 or 105782 - 4330

(d) Send a high pressure fuel into the injection pump to let the fuel flow out from the overflow pipe of the nozzle holder. NOTE: The pressure of the fuel forced into the injection pump must be higher than the delivery valve opening pres sure.

Static injection beginning

D3425C

( bl Place the plunger of the No. 1 cylinder in the bot tom dead center position and mount Measuring Device (special tool). Set the contactor on the tap pet. (c) Couple the injection pump and tester nozzle.

D3427A

(el Slowly turn the camshaft until the fuel ceases to flow from the overflow pipe of the nozzle holder (until static injection begins). NOTE: Make measurement by turning the camshaft clock wise.

13-43

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Prestroke

Timer inscribed

89144A

B1912A

(f) Read the prestroke from the bottom dead center to the point where the fuel ceases to flow (static injec tion begins), using a dial gauge.

(h) After adjustment of the prestroke, check to see that, at the static injection beginning, the inscribed lines of the pointer and timer are in alignment. If they are out of alignment, restamp a line on the automatic timer. Perform the same procedure when the automatic timer has been replaced with a new one. (5) Adjustment of injection start interval

Angie scale

Holder 157931-4400

D3471B

(g) If the prestroke is out of specification, adjust by shims. Position the tappet at the top dead center and insert Holder (special tool) between the lower spring seat and the tappet. Turning the camshaft will provide a clearance between the lower spring seat and tappet. Using this clearance, change the number of shims used as necessary to adjust the prestroke. Add shims to make prestroke smaller. Remove shims to make prestroke greater.

Using an angle scale, measure the injection start inter vals between cylinders according to the injection sequence with the static injection start of No. 1 cylinder used as reference. If the specified angle is not obtained, perform the same procedure as the prestroke adjustment. NOTE: Injection sequence 1-5-3-6-2-4 <6D2> 1-2-7-3-4-5-6-8 cSDC>

13-44

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (a) Loosen the screw of the pinion. (b) While blocking movement of the control rack, turn the control sleeve with an adjusting rod. (c) Tighten the screw of the pinion.

(6) Adjustment of tappet clearance

1-.-----

Control sleeve

NOTE: 1. A maladjusted injection amount will produce marked effects on engine performance. Make sure the injection amount is carefully adjusted. 2. The injection amount varies on different nozzles and pipes. Make sure that the measuring condi• tions are observed. 3. Injection amount uneven ratio

Tappet clearance Plunger touches

Shim

Tappet

D3522A

Maximum injecAverage injec tion amount in _ tion amount of each cylinder each cylinder

(a) Place the tappet in the top dead center position. (b) Raise the tappet with a screwdriver, etc. until the driving face of the plunger touches the bottom end of the plunger barrel. (c) Measure the stroke of the tappet from the top dead center to the point where the plunger barrel is touched. (d) If the tappet clearance is less than the nominal value, adjust within the extent permitted by the injection start interval. If correction within the permitted extent is impossi· ble, set the prestroke of the No. 1 cylinder to the maximum of the set value and readjust.

Uneven ratio(+)=

(7) Adjustment offuel injection amount

•

If the injection amount is out of specification, adjust by the following procedures.

(10)lnspection of parts

Decrease -- Increase

J-½ © 0

Uneven ratio (-) =

Average injection amount of each cylinder Maximum injecAverage injec tion amount in _ tion amount of each cylinder each cylinder Average injection amount of each cylinder

X 100 (o/o)

(8) Adaptation to engine After the governor has been adjusted, measure the fuel injection rate adaptable to the engine. (9) Inspection of fuel and oil leaks •

Fuel leaks from delivery valve attaching position and other parts Oil leaks from oil seals and other parts

Check parts for unusual noise and bearings for exces• sive heat

•

D3472B

13-45

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.3 P Type Injection Pump NOTE: 1. When disassembling the injection pump, clean the workbench and keep all disassembled parts neatly arranged by the cylinder. Never change the com• bination of the plunger and plunger barrel, and that of delivery valve and delivery valve seat.

2. 3.

Special care should be used when disassembling and reassembling major parts. For disassembly and reassembly, use the follow• ing special tools and never apply excessive force or handle them carelessly.

The following Zexel special tools should be used for injection pump maintenance: Special tool name

Application

Part No. (Zexel product No.)

Injection pump special tool set {includes items marked with "l"'')

105790-7050

Injection pump disassembly and reassembly

Universal vice

157944-8520

Securing bracket

Bracket

157944-8620

Securing injection pump

Special wrench

157924-2520

Preventing timer from turning

Tappet holder

*157931-4700

Supporting tappets

Box wrench

157914-0300

Removal and installation of round timer nuts (width of 2 faces: 19)

Extractor

*157926-7020

Extracting timer (M32 x 1.5)

157926-7220

Extracting timer (M26 x 1.5, M32 x 1.5)

Wrench

157915-0100

Removal and installation of round governor nuts Extracting flyweights

Extractor

* 157926-5320

Oil seal guide

*157920-5500

Protecting bearing cover oil sea!

Extractor

*157920-7720

Removal of bearing cover

Tappet insert

* 157921-8020

Removal and installation of tappets

Shaft

*157921-8900

Removal and installation of tappets

Plunger insert

157921-4820

Removal and installation of plungers

Extractor

157921-5620

Removal and installation of control sleeves and upper spring seats

*105792-0030

Removal of plunger block assembly

Special wrench

*157915-6500

Removal and installation of screw bushings

Bearing extractor

* 157925-7120

Removal of inner bearing race

*157925-2020

Removal of outer bearing race

Plate

• 157944-3520

Disassembling plunger block assembly

Socket wrench

*157914-0500

Insert Q+ring

*105792-0000

Inserting O+rings into pump housing

Plate

*157828-7200

: Assembling camshaft

Measuring device

*105782-4140

· Measuring camshaft end play

Removal and installation of delivery valve holders (width across

flats: 22)

Nozzle and nozzle holder assembly

105780-8140

Testing and adjustment

Nozzle

105780-0000

Testing and adjustment

Nozzle holder

105780-2080

Testing and adjustment

Fixing stand

105781-0170

Securing injection pump on injection pump tester

Measuring device

105782-4210

: Measuring control rod positions

105782-4270

I Measuring prestroke amounts

13-46

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.3.1 Disassembly, inspection and reassembly

Sliding resistance of control rod (when stationary) i NV 1.3 N {130 gf} or less <6D2> I 1.5 N {150 gf} or less <BOC>

39 to 44 N-m {4 to 4.5 kgf-m} 28

20 a--

11--C

105to 115N-m {11to12kgfm}

Check air-tightness

V 21 Deterioration 1--22 23

Scratches ) and wear on seat surface 24

Checksliding

wear,

condition

discoloration, rust

eo? 32

Rotating

condition

damage

33 Cracks,

damage

Overflow valve opening pressure NV 255 kPa {2.6 kgf/cm2 } <6D22-T, 22-TC, 8DC9-T, 9-TL, 9-TC> 155 kPa {1.6 kgf/cm 2} <8DC9'>

8�

Seisure, wear, peeling

Wear

Deterio ration

12 Wear

Rotating

10 condition

11 Damage, wear

Overalltappet (roller) clearance ! L 0.2

Camshaft end play NV 0.02 to 0.06 L 0.1

NV .. Nominal Value L ..... Limit

Disassembly sequence 1 Pipe joint bolt (or Overflow valve) 2 Overflow valve (or Pipe joint bolt) 3 Bottom cover 4 Screw plug 5 Shim 6 Bearing cover 7 Oil seal 8 Center bearing 9 Camshaft 10 Roller bearing

11 Tappet assembly 12 Lower spring seat 13 Plunger 14 Plunger spring 15 Upper spring seat 16 Control sleeve 17 Nut 18 Plunger block assembly 19 Deflector 20 Delivery valve holder 21 Stopper 22 Delivery valve spring

23 Delivery valve 24 Delivery valve seat 25 Plunger barrel 26 Distance ring 27 Flange sleeve 28 Screw bushing 29 Pin 30 Bushing 31 Control rod 32 Bushing 33 Pump housing

D1568B

13-47

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Precautions when removing and fitting delivery valve holder Before removing or fitting only a delivery valve holder, first confirm that the two nuts that hold the flange sleeve down are completely tight. If a delivery valve holder is removed or fitted with the nuts loose, the flange sleeve can move and thus alter the fuel injection volume. 5.3.2 Testing and adjustment Since injection volume adjustment values and mea surement conditions vary according to configuration, please refer to a Zexel service station.

i Prestroke I NV 4.8 ± 0.05 I i

Injection start interval NV 60 ° ± 30• <602> 45° ± 30· <BDC>

Full stroke of control rack NV 21 or more

( 1) Install and secure two injection pump tester Fixing Stands (special tool) to the injection pump.

NOTE: Make sure that the center of coupling is aligned with that of injection pump so that the coupling and injec tion pump turn smoothly. (2) Control rod "0" position setting

Measuring Device 105782-4210

NV "' Nominal Value D34018

Injection sequence 1-5-3-6-2-4<6D2> 1-2-7-3-4-5-6-B<BDC>

NOTE: 1. Fill the injection pump cam chamber with oil. 2. Adjust the injection rate after adjusting the gover nor.

O3409A

<With RSV governor> (a) Maintain a pump speed of 750 rpm. (b) loosen the stopper bolt and pull the adjusting lever in the "injection stop" direction. (c) Push the end of the measuring device fully against the side of the governor and zero the Measuring Device's scale. <With RFD governor> (a) Set the load control lever in the idling position. (b) Run the pump at a speed of 500 to 600 rpm and set the speed control lever such that the governor just starts to exert control.

13-48

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (c) Push the end of the Measuring Device fully against the side of the governor and zero the Measuring Device's scale.

NOTE: 1.

2. 3.

Unless the injection pump is run at the speed given above, the scale cannot be zeroed regard less of how hard the control rod is pushed. Also, the governor's link mechanism may be damaged. The damper springs must be removed. If a boost compensator is fitted, it must be removed before the measuring device is fitted.

(b) Install Measuring Device (special tool)to the flange sleeve. (c) Turn the pump tester flywheel to determine the bottom dead center of the plunger with the dial indicator.

(3) Control rod stroke check

I Full stroke ' NV 21 or more I,

NV .. Nominal Value

D3412A

(d) With the control rod set in the full position, send fuel under high pressure to the injection pump and let it flow out from the overflow pipe.

03410A

Move the control rod to ensure that its entire stroke is more than as specified. Also confirm that the start spring and idling spring move the control rod smoothly in the maximum injec tion volume direction. (4) Adjustment of prestroke Remove the overflow valve and install the blind plug. (a) Remove the delivery valve holder, spring, delivery valve, and gasket from the No. 1 cylinder on the governor end.

D3413A

(e) Slowly turn the pump tester flywheel clockwise until no more fuel flows out from the overflow pipe (static injection start).

Measuring Device

105782 - 4270--\C.

D3411A

13-49

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Prestroke

—, Pointer inscribe “dine

D3414A

if) Measure the plunger prestroke from BDC to the point where fuel stops flowing (static injection start).

D3416A

(h) After making prestroke adjustments, confirm that the inscribed lines on the timer and pointer are aligned with each other. If they are not aligned, inscribe a new line on the timer. The same instruc tions apply if the automatic timer is replaced with a new one. (5) Adjustment of injection start interval

D3415A

(g) If the prestroke is out of specification, adjust by varying shims between flange sleeve and pump housing. Shim thickness: 0.5 to 1.975, 59 types in 0.025 steps Use thicker shim to increase the stroke; thinner one to decrease the stroke. NOTE: When installing the plunger block, apply grease to each 0-ring. First, install the 0-ring under the plunger barrel into the pump housing; then, apply grease to plunger barrel skirt.

13-50

D3426A

(a) Set the static injection start position of No. 1 cylin der with the pump tester dial. (b) Feed high-pressure fuel into the injection pump to let the fuel flow out from the overflow pipe of the tester nozzle. NOTE: The fuel pressure must be higher than the delivery valve opening pressure.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(a) Loosen two nuts that secure the flange sleeve. (b) Tap the flange sleeve to give it a turn. (c) Tighten nuts to specification to secure the flange sleeve (39 to 44 N-m {4 to 4.5 kgf-m}). Repeat these steps.

Static injection beginning

D3427A

le) Slowly turn the pump tester flywheel clockwise until the fuel stops flowing out from the tester nozzle. Read the interval between static injection starts according to the injection sequence. (d) If the injection start intervals are not up to specifi cation, adjust by using the same procedure as the prestroke adjustment. 16) Adjustment of fuel injection rate

NOTE: 1. Use special care to make the adjustment. Improper or failure of adjustment greatly influences engine performance. 2. The fuel injection rate varies with nozzle and pipe used. Strictly observe the measuring require ments. 3. Injection rate uneven ratio

Uneven ratio (+) =

Uneven ratio (-) =

Maximum injecAverage injec tion amount in _ tion amount of each cylinder each cylinder Average injection amount of each cylinder Maximum injecAverage injec tion amount in _ tion amount of each cylinder each cylinder Average injection amount of each cylinder

X 100 (o/,)

(7) Adjustment of smoke limiter

Install the overflow valve and hose to the pump. Use a measuring cylinder to measure the fuel injection rate and uneven ratio to see if they are up to specifica tion with the specified rack position and speed. Adjust as follows if the measured values are out of specification.

Control rod Stopper

Spring capsule

Lock nut

Cap D4515A

D3463A

Place the load control lever in the full-load position. Run the pump at the specified speed to place the con trol rod in the specified position. Remove Measuring Device (special tool) and install the smoke set assembly (without cap). Tighten the spring capsule until the stopper comes in contact with the control rod.

13-51

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Run the pump at 700 rpm and ensure that the fuel injec tion rate is up to specification. Secure the spring cap sule with lock nut, then mount the cap. (8) Adaptation to engine After the governor has been adjusted, measure the fuel injection rate adaptable to the engine. (9) Diesel fuel and oil leak check • Diesel fuel leak from delivery valve mounting area and other parts. • Oil leak from oil seals and other parts. 04516A

With the pump run at 100 rpm, measure the fuel injec tion rate. If the rate is out of specification, retighten or back off the spring capsule.

( 10) Miscellaneous check Check for unusual noise and overheated bearings.

5.4 RSV Type Governor The following Zexel special tools should be used for governor maintenance: Special tool name

Part No. (Zexel product No.)

Application

Handle

157910-1120

Socket wrench

157914-0500

Special wrench

157915-0100

Removal and installation of round nut

Wrench

157916-2620

Adjustment of Ungleich

AD type injection pump

157926-5110

Removal and installation of flyweight

P type injection pump

157926-5320

Extractor

13-52

Removal and installation of lock nut

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.4.1 Disassembly, inspection and reassembly 15

�

Cracks, deformation-------------

Disassembly sequence ,

2 3

Cracks, damage 9

Cracks,

deformation

Cracks, damage

6i)�' J ' '\

49 to 59 N-m , , {5 to 6 kgf-mJ

Damage, unevenly wear of contacting surface

17 Wear, separation of chrorneplated surface of shifter

\ �

-�

1 Cover 2 Ungleich spring or

idling spring 3 Idling sub spring 4 Torque spring 5 Governor cover 6 Start spring 7 Round nut 8 Flyweight 9 Governor housing 10 Plug 11 Tension lever shaft

12 Adjusting lever 13 Collar 14 Shim 15 Governor spring 16 Tension lever

® Guide lever assembly @ Sleeve

19 Shackle 20 Snap ring 21 Bushing 22 Oil seal 23 Swivel lever

For parts with an encircled number, refer to Disassembly Procedure that follows. For reassembly, reverse the order of disassembly. NOTE: Do not remove the shackle and sleeve from the guide 1. lever unless replacement is necessary. 2. Do not remove the swivel lever from the governor cover unless parts replacement is necessary or when its motion is not smooth.

24 Stop lever 25 Shim 26 Spring cap 27 Return spring 28 Bushing 29 Sliding lever 30 Bolt 31 Snap ring 32 Spring 33 Torque control lever 34 Adaptor

Do not remove the governor housing unless oil leak is evident or parts replacement is necessary. H it needs to be removed, use Tappet Insert (special tool) to make sure that the camshaft will not contact with the tappet. 89150A

13-53

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

49 to 59 N-m

{5 to 6 kgf-m}

Disassembly sequence

1 Idling sub spring 2 Lock nut

3 Cover 4 Governor cover 5 Pin 6 Connector 7 Start spring 8 Round nut 9 Flyweight 10 Bracket 11 Cover 12 Stop lever 13 Collar 14 Return spring 15 Washer

16 Bolt 17 Shaft 18 Lever

19 Washer 20 Oil seal 21 Oil seal 22 Governor housing 23 Adjusting lever 24 Plug 25 Tension lever shaft 26 Tension lever 27 Governor spring 28 Snap ring 29 Snap ring 30 Bushing

31 Bushing 32 Swivel lever 33 Bolt 34 Link

® Guide lever assembly

36 Link ® Sleeve 38 Pin 39 Lever 40 Cover 41 Diaphragm 42 Push rod 43 Boost compensator spring 44 Adjusting shim

For parts with an encircled number, refer to Disassembly Procedu�e that follows. For reassembly, reverse the order of disassembly. NOTE: 1.

13-54

Do not remove the shackle and sleeve from the guide lever unless replacement is necessary. Do not remove the swivel lever from the governor cover unless parts replacement is necessary or when its motion is not smooth.

Do not remove the governor housing unless oil leak is evident or parts replacement is necessary, If it needs to be removed, use Tappet Insert (special tool} to make sure that the camshaft will not contact

with the tappet.

86011A

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Shifter assembly dimensions

When the shifter and sleeve are assembled, the shift er's assembly dimensions are adjusted using the shims. Therefore, do not rearrange the shims. If the shim needs to be replaced, install the associated parts into position. Select the shim of a correct thick ness to obtain the specified dimension between the housing end face and shifter.

Shim

Shim thickness (6 types): 0.2, 0.3, 0.4, 0.5, 1.0, 1.5

NOTE: Measure the dimension as assembled without lifting the flyweights. 5.4.2 Testing and adjustment The performance curves used when making governor adjustments vary according to the governor configura tion. Please refer to a Zexel service station for details.

19 to 19.2

D2054A

Adjustment of

speed fluctuation rate

(2) Sa

rot

Adjustment of torque spring Adjustment of high speed control

Adjustment of idling sub spring Adjustment of idling spring or Ungleich spring

Adjustment of stopper bolt

NOTE: 1.

Adjustment of mid speed control

2. 3. 4.

Supply engine oil to the injection pump cam chamber.

Loosen the adjusting lever stopper bolt. Remove the idling sub spring. Do not allow the Ungleich spring or idling sub spring and torque spring to work.

B9163A

13-55

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (4) Adjustment of intermediate speed control Ung!eich spring

Ra Re Rg

j d

High speed control

Low speed control

,·;;;g

Re Ri

rod po

Rack

89164A Ng

Pump speed {rpm}----;.

D34748

Adjust the relationship between pump speed and the rack or rod position to specified governor performance curve by the following procedure. ( 1) "O" position setting of control rack <AD type pump> [Refer to Section 5.2.2 (2).1 "O" position setting of control rod [Refer to Section 5.3.2 (2).] 12) Install the angle scale plate for fixing the adjusting lever.

Adjust the full-load stopper bolt so that the pump speed becomes "Ne" which is slightly lower than uNd". (5) Adjustment of Ungleich spring (governor with Ungleich spring only)

Special Wrench 157916-2620

(3) Temporary adjustment of high speed control 89166A

Maximum speed stopper bolt

89169A

With the adjusting lever in full position, adjust the max imum speed stopper bolt so that high speed control starts to work when the pump speed is "Nd".

13-56

(a) Keep the pump running at a speed which is slightly lower than "Na" (speed at which Ungleich spring starts to work). (b) Fix the adjusting lever at the full position. (c) Using Wrench (special tool), tighten the Ungleich spring so thatthe rack will move from "Re" to "Ra". Fix the spring with lock nut. (d) Check that the pump speed is "Na" and "Nb" when the rack position is "Ra" and "Re", respectively.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (b) Adjustment of idling sub spring

(6) Adjustment of idling spring (governor with idling spring only)

.S Re .___._k _____ .g ·;;;

0 C. "C

e 0

Rack Pump speed (rpm)

89168A B4070A

Adjust the idling spring so that the rack or rod starts to move from "Re" to direction to increase fuel rate at point k.

Adjust the idling sub spring so that the rack or rod is positioned at "Ri" when the pump speed is "Ni". Check that the rack is positioned at "Rh" when the pump speed is further increased.

(7) Adjustment of low speed control

(8) Adjustment of high speed control

(a) Adjustment of stopper bolt

Adjust as in Item (3) and fix the maximum speed stop per bolt in position.

Idling position

(91 Adjustment of speed regulation

B9167A

Adjust the stopper bolt so that the rack or rod is posi tioned at "Rg" when the adjusting lever is set at idling position with the pump stationary.

B9170A

Check that the rack or rod is pulled back to position "Re" when the pump speed is increased from "Nd" to "Ne".

13-57

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE With the adjusting lever fixed at the full position, pull the stop lever all the way to the stop side and check that the rack is positioned at O mm.

Governor spring

(11)Adjustment of full-load

Adjusting screw

Swivel lever D3482A

If the pump fails to do so, adjust tightening amount of the swivel lever adjusting screw. Tightening gives better speed regulation. Loosening gives poorer speed regulation. Speed regulation=

Ne-Nd Nd

X 100 (%)

NOTE: 1. If the speed regulation is poor, the engine will exceed the specified maximum speed at no load and will enter a hazardous condition. 2. The maximum extent to which the adjusting screw can be loosened is 20 notches (5 turns) from the fully tightened position. Loosening it any fur ther can be dangerous, 3. If the adjusting screw is adjusted, the tension of the governor spring will change and the high speed control start point will change. Be sure to readjust the high speed control in accordance with Item (8).

(10)Stop lever operation check Stop Normal position positio�//

\'/5Jlt

'C1� 1-� . 1r1 r . / � l · · �frw; • '\ /, 1(��1.';,i{_j

©.�]%1�:f;, t·Jr: ,r� �--- L..--\

'.Ji

Stop uposition

Norma! position

13-58

Gl-.s.'1 ct:;.\

...,"\

<>.. \"". 1 ,_ �-

bt711i LVo",� B9171A

-�

�

B9171F

(a) Install the lever to the governor cover. (b) With the adjusting lever at the full position, adjust the full-load stopper bolt so that the rack or rod is positioned at "Re". (12)Adjustment of torque spring

0 'll

fi.

{

Ni� Nk

Pump speed (rpm) -

I B9172B

(a) Fix the adjusting lever at the full position and set the pump speed at "Nk". (b) Screw in until the torque spring contacts the lever and fix temporarily. (c) Adjust the torque spring so that the rack or rod is positioned at "Rf" when the pump speed is low ered to "NC". (d) Check that the pump speed is "Nj" when the pump speed is lowered to position the rack or rod at "Re". (e) After the adjustment, check that the rack position is as specified at each pump speed. If the rack position is out of specification, readjust the torque spring and full-load stopper bolt.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE ( 13) Boost compensator adjustment (a) Adjusting boost compensator stroke 11

Remove the cap nut and loosen the lock nut.

E E

Ra ___ ..l,.._ -- ', ' ... _ I I

.·;;;g

0. � u � a:

---,

I I I

Na Pump speed (rpm) ___._ 86005A

Fully tighten the adjusting screw and secure it with the lock nut. 3) Attach the air pipe. 4) Set the control lever in its FULL position.

Maintaining the pump speed indicated by "Na," turn the adjusting screw such that the control rack moves from the "Rb" position to the "Ra" position. Secure the adjusting screw with the lock nut.

NOTE: Do not apply pressure during this adjustment.

13-59

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

lb) Adjusting boost pressure Adjustment shim Pump speed : Na r.p.m

Boost compens tor spnng �

l (uuu) U -·��

Gasket

yoey od 0

Boost pressure kPa {mm Hg} --... 86007A

86009A

5) Remove the components labeled in the above illustration, then change the adjustment shim. If boost pressure P1 is too low, fit a thicker shim. If boost pressure P1 is too high, fit a thinner shim.

1) Maintaining the pump speed indicated by "Na," move the control lever to its FULL position. 21 Gradually raise the boost pressure. When it reaches the pressure indicated by "P1 ", check that the control rack begins to move in the direction of increase relative to the position indicated by "Ra." If measurements are out of specification, change the adjustment shim in accordance with the follow ing procedure. 3) Loosen the three bolts that retain the cover, then remove the cover.

Pump speed : Na r.p.m

tc ae to ~

Boost pressure kPa {mm Hg} � 86010A

6) After adjusting the boost pressure, raise it further. When it reaches the pressure indicated by "P2," check that the control rack is in its "Rb" position. If measurements are out of specification, fit a new boost compensator spring.

NOTE:

The boost compensator stroke may change when the cover is removed. Be sure to recheck the boost com pensator stroke.

4) Using a screwdriver and spanner [ADDED], remove the nut that prevents the push rod from turning. 13-60

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

l14)Adjustment of adaptation to engine

After adjustments, lock the governor with wires.

After the governor has been adjusted, measure overall injection amount at the same lever angle as in the high speed control and in accordance with the adjustment standard and readjust as necessary.

NOTE: Locking of the sections marked with * must be done after adjustment of no-load minimum and maximum speeds.

l15)Locking with wire

Lock with wire.

Lock with wire

B1370D

5.5 RFD Type Governor The following Zexel special tools should be used for governor maintenance: Special tool name

Application

Part No. (Zexel product No.)

Handle

157910-1120

Socket wrench

157914-0500

Wrench

157915-0100

Removal and installation of round nut

Extractor

157926·5110

Removal of flyweight

Special wrench

157916-2620

Adjustment of idle speed

157976-3100

Adjustment of rack limit

Guide screw

Removal and installation of lock nut

13-61

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.5.1 Disassembly, inspection and reassembly

NOTE: 1. Do not remove the floating lever link and sleeve from the guide lever unless replacement is neces sary. 2. Do not remove the swivel lever from the governor cover unless parts must be replaced or operation is not smooth.

Do not remove the governor housing unless there are oil leaks or parts must be replaced. If the gover nor housing must be removed, use the Tappet Insert (special tool) to sever the camshaft-to-tap pet contact. Do not remove the stop lever assembly from the top of the governor housing. Cracks, deformation

Cracks, deformation

\ Oil leaks

Cracks, damage

26 Cracks, damage � ,--,

Wear, separation of chromeplated surface of shifter

49 to 59 N-m {5 to 6 kgf-ml 18

Damage, unevenly wear of contacting surface

Wear

1 Cover 2 Lock nut 3 Idling spring assembly or

9 Tension lever plug 10 Tension lever shaft

13 Floating lever link 14 Tension lever 15 Governor spring 16 Load control lever

6 7

Ungleich spring capsule Cap nut Lock nut Damper spring capsule Governor cover Start spring

® Guide lever assembly ® Sleeve

17 Bushing

For parts with an encircled number, refer to Disassembly Procedure that follows. For reassembly, reverse the order of disassembly.

13-62

89155A

Disassembly sequence

18 Lever shaft 19 Sliding lever 20 Speed control lever 21 Snap ring 22 Bushing 23 Swivel lever 24 Round nut 25 Flyweight 26 Governor housing

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

ti�

<8DC> <With boost compensator>

28 Deformation

Deformation

0 �\1 �3 ,

. '�

Le..,. 29 Damage

Cracks, deformation

Cracks,

deformatio

Cracks, damage

Oi! leaks

\ 24

25 26 Cracks,

49to 59 N-m

{5 to 6 kgf-m}

damage

Damage, unevenly wear of contacting surface

Wear, separation of chrome plated surface of shifter

6 21

Oil leaks

Disassembly sequence

1 Cover 2 Lock nut 3 Idling spring assembly or 4 5 6 7 8 9 10

Ungleich spring capsule Cap nut Lock nut Damper spring capsule Governor cover Start spring Tension lever plug Tension lever shaft Guide lever assembly

lg Sleeve

13 Floating lever link 14 Tension lever 15 Governor spring 16 Load control lever 17 Bushing 18 Lever shaft 19 Sliding lever 20 Speed control lever 21 Snap ring 22 Bushing 23 Swivel lever

For parts with an encircled number, refer to Disassembly Procedure that follows. For reassembly, reverse the order of disassembly.

24 Round nut 25 Flyweight 26 Governor housing 27 Smoke limiter 28 Boost compensator cover 29 Diaphragm 30 Boost compensator spring 31 Start spring 32 Push rod 33 Boost compensator housing 34 Spacer

D20418

13-63

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.5.2 Test and adjustment

Assembly dimension of shifter

For governor performance curve, see Service Informa tion published separately.

Shim

<602::>

Smoke limiter

Stopper bolt Damper spring

',.

Stopper bolt

ldling spring',�

33.0 to 33.4

: *.Stopper boit

D2025A

Speed contro} lever

Full-load Loadcontrollever When the shifter and sleeve are assembled, be sure not to change the adjusting shim, as the assembly dimen sion of the shifter has been adjusted by the shim. If readjustment is necessary, assemble all related parts correctly and select the right shim thickness to make sure that the dimension from the housing end to the shifter complies with the specified value. Shim thickness (4 types): 0.2, 0.3, 0.4, 1.0 NOTE:

Measure the assembly dimension with all flyweight lifted.

stopper bolt

Stroke adjusting bolt D44038

<8DC>

Ful!•load stopper bolt Idling spring Stopper boit

Speed control lever Stopper bolt

0 0

Stroke adjusting bolt D4428B <With boost compensator>

Boost compensator

load control lever Stopper bolt

Full-load stopper bolt Idling spring Stopper bolt

Stroke adjusting bolt

13-64

Stopper bolt Speed control lever

D4428C

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Adjustment of rack limiter or smoke set

Adjustment of high speed control start point

Adjustment of damper spring

Adjustment of idling

Adjustment of idling spring or Ungleich spring

Adjustment of stopper bolt Adjustment of full-load position

89174A NOTE: Remove the damper spring. 1. 2. Remove the idling spring or Ungleich spring. 3. Remove the smoke set assembly. 4. Keep the stopper bolt of the speed control lever loos� ened. 5. Keep the stopper bolt of the load control lever loosened.

Adjustment of flyweight lift

Adjust the relationship between pump speed and the rack or rod position to specified governor performance curve by the following procedure.

Set by start booster

Ra' E Ru 1---1-------''-'.

� Ra 1--+---+-=>,.;;.;...._____;,_, a '

:� Rf ,--,.--, 0 C,

High speed

Low speed control

0 Re 1--t---"-

"'u

Adjustment of Load contrl lever angle

control

(1) "O" position setting of control rack <AD type pump> [Refer to Section 5.2.2 (2).] "O" position setting of control rod [Refer to Section 5.3.2 (2).] (2) Install the angle scale plate for fixing the control lever.

� Rbl---1----+-+..-+--------+--t Rc1---+---+-�--,... Rtl--+--1-+--++------,r-+-'-r Nv

Ne Nu

Nd Ne

Pump speed (rpm)

Na Nb

03486C

13-65

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(3) Adjustment of flyweight lift and full-load position Ra

;1--------,--"t-----,

E E

(c) Lower the pump speed to "Nu" and adjust the high speed lift "L" with the stroke adjusting screw. 14) Adjustment of high speed control (a) Adjustment of high speed control start point

)49eYH p ,g410 ·a; 0 0.

2 Rt f------------4----4---1--,.--L 0

Nu 700 to 800 NI Pump speed {rpm}

84061A

Divide the flyweight full lift into the lift necessary for high speed control and the lift necessary for idling con trol. (a) With the load control lever fixed at the full-load position, temporarily set the speed control lever so that high speed control works when the pump speed is 700 to 800 rpm.

81917A

Set the control lever atthe full-load position and setthe speed control lever at the maximum speed position. Increase the pump speed slowly and adjust the speed control lever stopper bolt so that the rack starts to move from "Ra" toward fuel decreasing direction when the pump speed reaches "Na". (b) Check of speed regulation

E E

.g 8.

·a;

81916A

(b) Increase the pump speed slowly and adjust the full load stopper bolt so that the rack is positioned at "Rt" when the pump speed reaches "Nt".

X u ro 0:

Pump speed (rpm)

Na Nb

D44348

Increase the pump speed slowly until the control rack or rod is pulled back to "Rb" position. Upon reaching "Rb" position, check that the pump speed is "Nb". Further increase the pump speed and check that the rack or rod pull back amount "L" is as specified.

13-66

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE NOTE: 1.

If the speed regulation check point (point b) is where the damper spring acts, check the speed regulation after idling and damper spring adjust• ment. If the value is out of specification, replace the gov· ernor spring.

(5) Adjustment of idling spring (governor with idling spring only)

(6) Adjustment of Ungleich spring (Vehicles with Ungleich spring only)

Ungleich stroke

Ra ;

.-�g 5

�

Nf Na Pump speed (rpm)� 84580A

O4506A

(a) Set the pump speed at "Ne" and adjust the stopper bolt so that the rack or rod is positioned at "Re".

Special Wrench 157916-2620

. )1/ �

Special Wrench 157916-2620

B1919A

B4317A

(a) Set the pump speed at "Nf" and place the load con trol lever in the full-load position. (bl Using Special Wrench (special tool). adjust the Ungleich spring position so that the Ungleich stroke e in the state of Step (a) will have the speci fied value. After the adjustment, firmly tighten it with the lock nut.

(bl Lower the pump speed to "Ne" and adjust the idling spring using Special Wrench (special tool) so that the rack is positioned at "Re". (cl When the pump is stopped the rack should be at "Rf" or higher position. Also check that the rack is positioned at "Re" when the pump speed is increased to "Nd".

13-67

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE If the lever angle is out of specification, replace the shim installed between the shifter and sleeve.

NOTE: If the shim was replaced, repeat adjustment of the governor from the beginning. (8) Adjustment of damper spring

Ra + I I---------'---,-� -' Raf-------t------l ,-��

Nf Ng Nh Na Pump speed {rpm) � 84581A

Damper spring set point

Rg � Rg-0.1 Rg-0.2

·�

C. 'C

Rack ro or 0

--,

Ne Nh Pump speed (rpm)

___..,.

84062A

84582A

(c) Slowly increase the pump speed from "Nf" to "Ng" and adjust the screw position so that the Ungleich spring will start working. (d) Increase the pump speed to check that the Ungleich spring stops working at "Nh". (e) Change the pump speed between "Nf" and "Na" to check that the Ungleich stroke has the specified values.

NOTE: 1. If the Ungleich stroke is out of specification, read just the Ungleich spring position. 2. If the speed at which the Ungleich spring stops working is out of specification, replace the Ungleich spring. (7) Measurement of load control lever angle Check that when the load control lever is held at the idling position and the full-load position, the lever angle at the respective positions is up to specification.

13-68

(a) Holding the load control lever at the idle position (point e) and slowly increase the pump speed from "Ne" until the rack or rod is positioned at "Rg -0.2 mm". Hold the pump speed "Nh" when the rack or rod is so positioned.

84318A

(b) Adjust the damper spring tightening amount so that the rack or rod is positioned at "Rg -0.1 mm".

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

n �-

D4506A

(cl After adjustment, stop the pump and loosen and adjust the stopper bolt so that the rack or rod is positioned at "Ri". (9) Adjustment of rack limit (a) Rack cap type

B3769A

3) Adjust the adjusting nut mounted to the tip of the rack for the same depth as the rack cap depth mea sured above. Fix the nut in position with the lock nut. After adjustment, install the cap nut securely. (bl Screw type

��

Guide Screw 157976-3100

�

� 84583A

1) Remove the guide screw from the back of the pump housing and install Guide Screw (special tool).

Place the load control lever in the full-load position and keep the pump speed at "Nv". 2) Adjust the screw of the rack limiter so that the rod position and fuel injection (point E) will be up to specification, and secure it with the lock nut.

B3768A

Using a depth gauge, measure the rack cap depth. 13-69

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(10)Adjustment of start booster (smoke set assembly)

<8DC>

<6D2>

84579A D3496A

(a) Move the load control lever to the full-load position and set the smoke set assembly's adjusting nut Oto 4 mm from the end of the stopper. (b) When adjusting the pump speed to "Nd," adjust it such that the rack and rod positions are from "Ra" to "Ra.' "

(a) Place the load control lever in the full-load position. (b) Turn down the screw on the smoke set assembly so that the specified fuel injection rate is obtained when the pump speed is at "Nu". Then, secure the screw with the lock nut. ( 11 )Adjustment of boost compensator <8DC9-T, TL>

(a) Install the boost compensator and connect air pipe to the boost pressure test port.

Boost compensator stroke

-�.g0

0. ,:, 0 a:

D3497A

Pump speed (rpm)

84319A

.sE

C 0

. -�0

Boost compensator stroke

� R 1 t---r------!--'-P2 P1 Boost pressure (mmHg} �

D4498A

(b) Drive the pump at the specified adjustment speed "N" and place the load control lever into the full load position. 13-70

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

E R,

c 0 ·.c

�----------,-_,,....,.--+

·a0

a: R, 1---+-"--.I'--' A 0

(c) Turn the stopper bolt as required so that the control rod is positioned at "R1" with a 2ero boost pressure (adjustment A). (d) Gradually increase the boost pressure. Select shim so that the control rod movement starts at pressure "P1" (adjustment B). (e) Further increase the boost pressure. Adjust the full-load position of the load control lever so that the movement of control rod stops at "R2" even when the boost pressure exceeds "P2" (adjust ment C). Shim thickness: 0.2, 0.5

P, Boost pressure (mmHg)

NOTE: D4525A

Adjusting shim Boost compensator spring

Adjustments A and C, when made, cause the set tension of the boost compensator spring to change, meaning that up," also changes. This performance should not be deviated even after the final adjustment for fuel injection rate.

(12)Adaptation to engine After the governor has been adjusted, measure and adjust the total fuel injection rate with the same lever angle as in high speed control according to the adjust ment specifications.

D4522A

13-71

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(13)After the injection pump governor has been adjusted, seal the pump. <6D2>

Seal with wire

*Seal with cap Seal with cap

843208

<8DC>

Seal with wire

Seal with wire <With boost compensator> Boost

compensator

• *Seal with cap Seal with wire

NOTE:

Sealing of the part marked with • should be made after the no•load maximum speed has been adjusted, 81862C

13-72

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.6 Feed Pump 5.6.1 Disassembly, inspection and reassembly

11 Wear

bene

a Dirt,plugging

20 to 25 N-m 12 to 2.5 kgf-m}

20 to 25 N-m

Deterioration

Cracks, damaged thread

7 D2805D

<Model K: BOC> 2

20 to 29 N-m

{2 to 3 kgf-m} 4

1 Eyebolt (suction side : with gauze filter) 2 Eyebolt (discharge side) 3 Priming pump 4 Check valve plug <model KE, K: 6D2> Adaptor <model K: BDC> 5 Check valve spring 6 Check valve 7 Plug 8 Piston spring 9 Piston 10 Snap ring 11 Tappet 12 Push rod 13 Feed pump housing NOTE: Before starting the disassembly pro cedure, isolate and know the faulty spots.

20 to 25 N-m 1 12 to 2.5 kgf-m} Dirt, clogging

13 Cracks,

damaged thread

12 D2801 B

13-73

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5 Deterioration § Wear

Eyebolt (suction side with gauze filter) 2 Eyebolt (discharge side) 3 Priming pump 4 Check valve plug <6D2> Adaptor <8DC> 5 Check valve spring 6 Check valve 7 Plug 8 Piston spring 9 Piston 10 Snap ring 11 Tappet 12 Push rod 13 Feed pump housing 1

20 to 25 N-m

{2 to 2.5 kgf-m}

1 Sire Deen damaged thread 12

{2 to 2.5 kgf-m}

Scratches 8

Deterioration 7

D28078

<BDC> 20 to 29 N-m

{2 to 3 kgf-m}

NOTE: Before starting the disassembly pro cedure, isolate and know the faulty spots.

3 Settling 5

7 20to 25N-m

{2 to 2.5 kgf-m} Dirt, clogging

Cracks, damaged 13 thread D2807C

13-74

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.6.2 Tests The feed pump must be tested on the following items. Unit: mm Nominal value

Test item

Remarks

0 cm 3/min.

Air•tightness test

Refer to Section 3.1 Service Standards Table.

Delivery test (minimum)

Lift capacity test

25 strokes or less

When a 195kPa {2kgf/cm2} air pressure is applied. Delivery for 15 seconds Test conditions Fuel pipe: O.D. 10, LO. 8, length 2000 Cam lift: 4 (double cam): Models Kand KO 6 (eccentric cam): Model KE

No. of strokes required before pulling up fuel when priming pump is operated at 60 to 100 strokes/min. (!jft 1 meter) : Test conditions [ Same as the delivery test.

Delivery (min., for 15 seconds) Nominal value 100 rpm

60cc

KE type Ktype

BOC

70 cc

602

130 cc

BOC

145 cc

KE type

500 rpm

340cc

Ktype KO type I

Nominal value

! 1000 rpm

60 cc

602

KO type

602

260 cc

BOC

300 cc

602

700cc

BOC

710 cc

1500 rpm

KE type

405 cc

Ktype

602

BOC

600cc

KO type

602

1170 cc

I soc

KO type

1170cc 430cc

KE type Ktype

530cc

i 602

520cc

BOC

580cc

602

1000 cc

I BOC

1035cc

5.7 SA Type Automatic 1imer The following Zexel special tools should be used for SA type automatic timer maintenance: Application

Special tool name

Part No. (Zexel product No.}

SA type automatic timer special tool set {includes items marked with ""'")

105790-5010

Disassembly and reassembly

Special spanner

157916-5320

!' Removal and installation of round nut

Extractor

157926-6210

Flange insert Hand spanner Thrust bushing Guide bushing

Removal oftimer

'157924-0120 '157916-6120

Removal and installation of timer case

157924-1500

Installation of oil seal

I '

Removal and installation

157924-1200

Block

157924-0800

Guide bushing

157924-1300

Guide

157924-0900

Support

*157932-0100

'Installation of flyweight

Guide

157924-0400

Thrust bushing

157924-0500

Oil seal guide

*157924-0600

----------------+-------�

1 Installation of flange

I Insert of timer case

13-75

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.7.1 Removal and inspection

Damage on curved surface

Wear of pin 10

Wear, 6

damage

Wear, damage

Deformation 5 Wear of pin

D3152A

Disassembly sequence 1

13-76

Round nut Timer plug Timer case Oil seal Flange

6 Oil seal 7 Timer spring 8 Shim 9 Flyweight 10 Flyweight holder

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.7.2 Installation and adjustment

/ After reassembly, pack ' 150 g of Automatic I I Timer Grease (Zexel)

83 to 88 N-m

{8.5to 10 kgf-m} | if

10 Assembly sequence

6➔57 10➔9➔8➔7 �-f------;,) 2➔1

0-ring 03153A

4➔3__J

Automatic timer advance characteristics To adjust the automatic timer's advance characteris tics, increase or decrease the number of shims, or replace the springs. Thicker shims reduce the advance angle; thinner shims increase it. Shim thickness (6 types): 0.1, 0.15, 0.2, 0.5, 1.0,1.5 Advance adjusting

shim

Advance adjusting

shim

06711A

13-77

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.8 SP Type Automatic Timer The following Zexel special tools should be used for SP type automatic timer maintenance: Part No. (Zexel product No.)

Special tool name

Application I

SP type automatic timer special too! set (includes items marked with"•")

105790-5050

Disassembly and reassembly

Box spanner

*157915-2320

Removal and installation of round nut

Box wrench

*157916-2800

Special spanner

157916-5320

Extractor

157926-6420

Base

*157924-2520

Special spanner

157916-8320

Removal and installation oftimer

! Disassembly and reassembly

5.8.1 Removal and inspection

\ il

Wear 7 6 5

Rust, scratches, deformation

� 3 Deformation 4 Deterioration, 8 wear Damage on

curved surface

� 11 9

D3103A

Disassembly sequence 1 Cap screw

2 Round nut 3 Cover 4 Oil seal 5 Washer 6 Roller 7 Bushing

13-78

8 Flange 9 Retainer 10 Timer spring 11 Spring seat 12 Shim 13 Flyweight 14 Timer housing

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.8.2 Installation and adjustment

1�� 7

Roller end

6 5/

�

Cover end

�

I After reassembly I 3 I fill 2.50 ta: 270 cm \ engine 011 i

22 to 24 N-m {2.2 to 2.4 kgf-m}

2 125 to 145 N,m

{13 to 15 kgf-m}

1 29 to 39 N-m {3 to 4 kgf-m}

I Apply engine 1 oil to lip

Gasket

O-ring

D3112A

Assembly sequence 3-94

44313-12-11-3109-837 -»6 95-9251

Adjustment of automatic timer timing advance charac teristics To adjust the automatic timer advance characteristics, increase or decrease the number of adjusting shims, or replace the spring. Using a thicker shim makes the advance smaller.

Advance adjusting shim

Shim thickness (12 types): 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2.0

Advance adjusting shim

D6703A

13-79

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.9 SPG Type Automatic Timer The following Zexel special tools should be used for SPG type automatic timer maintenance: Part No.

Special tool name

Application

(Zexel product No.)

Removal and installation of timer spring

157921-9820

Spring insert

5.9.1 Removal and inspection

Bend, wear

Deterioration, bend 8

Deterioration, bend

9 10

Wear of taper 12

Scratches,

wear

Scratches, wear B0023B

Disassembly sequence 1 Cap

2 Round nut

Cover O-ring 5 Flyweight Spring seat 7 Shim Timer spring

13-80

9 Timer spring

10 Spring support 11 Pilot pin

12 Timer holder

13 Eccentric cam (large)

14 Eccentric cam (small) 15 Timer housing 16 Bolt

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.9.2 Installation and adjustment

295 to 345 N-m {30 to 35 kgf-m}

I After reassembly, I fill 180 to 200 cm .;1 engime oil

$.8to 15 N-m

{1.0 to 1.5 kgf-m}

64to 83 N-m {6.5 to 8.5 kgf-m}

145 to 165 N-m

{15 to 17 kgf-m}

B0023C

For parts with an encircled number, refer to Reassembly Procedure that follows.

Assembly sequence 11➔10➔9➔@➔7➔6 7

16➔®➔®➔®➔®➔5➔4➔3➔2➔ 1

Reassembly Procedure (1) If the timer spring is of the uneven pitch type, place the wider pitch coiled end outside. Timer housing pin

Looking from the cover end

(2) Install the eccentric cams (large and small) in the correct directions using alignment marks on the periphery of the timer housing as reference. The timer housing and large eccentric cam should rotate in the same direction as the timer holder as flyweights lift, as viewed from the drive end. With the two timing housing pins aligned vertically, the flyweight shoulder should be lower on the right end.

Flyweight shoulder (right end down) B0027A

13-81

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.10 Bleeding of Fuel System Perform fuel system air bleeding as follows. Pin

Timer housing

Timer holder 85909A

(1) Loosen air plug of fuel filter. 80028A

(3) With the keyway in timer holder facing down, turn the small eccentric cam as necessary so that the distance between the centerline of the small eccen tric cam and that of the timer holder is the same on the right and left, and that it measures 1/2 of the center-to-center distance of the timer housing pins. (4) After reassembly, feed lubricating oil into the timer up to a point about 1 mm below the flyweight top end surface.

84324A

Adjustment of automatic timer advance characteristics To adjust the advance characteristics of the automatic timer, add or remove shims or replace the spring. Adding shims makes advance smaller. Shim thickness (4 types): 0.1, 0.3, 0.5, 1.0

(2) Turn counterclockwise the priming pump knob of injection pump so that it comes loose. (3) Move priming pump knob up and down to feed fuel until air bubble does not come out from air plug. (4) With no air bubble coming out in fuel, tighten air plug. (5) Move priming pump knob up and down several times, then screw in knob. NOTE: Sop up fuel spilt around. (6) Actuate starter to discharge air in injection pump and pipe. NOTE: Do not actuate starter for more than 15 seconds.

13-82

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.11 Inspection and Adjustment after Installing the Injection Pump

5.11. 1 Inspection and adjustment of fuel injection start timing

Adjusting bolt

<6D2> 29 to 34 N•m {3 to 3.5 kgf-m} <8DC> 59 to 64 N•m {6 to 6.5 kgf-mJ

)

B6120A

Adjusting bolt 59 to 64 Nm

{6 to 6.5 kgf-m}

86118A

(1) Crank the crankshaft more than 180° in forward direction to line up the pointer with the fuel injec tion start timing angle scale inscribed on the out side periphery of the flywheel.

NOTE: If the engine is turned in reverse direction (either when the engine is stopped or by cranking), the automatic timer will stay advanced and may not return to normal even if the engine is slightly cranked in the normal direction. Make sure that the engine is cranked manu ally more than 180" in the normal direction.

B6117C

(3) If they are out of alignment, loosen the timing adjusting bolt of the coupling and adjust by turning the automatic timer. After adjustment, recheck by the procedures of steps (1) and (2), and tighten the timing adjusting bolt to the specified torque.

NOTE: Do not loosen the bolts of the coupling except the tim ing adjusting bolt.

Inscribed line

C0562A

(2) If the inscribed mark of the injection pump and the inscribed mark of the automatic timer are in align ment in the above condition (1), the fuel injection start timing is correct.

13-83

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.11.2 Inspection and adjustment of minimum and maximum no-load speeds Start and idle the engine until it reaches normal operat ing temperature. Then, make the following checks. ( 1) RSV type governor

Idling

NOTE:

Quickly move the adjusting lever from the full-speed position to the idling position to make sure that the engine does not stall or develop hunting. If defects are evident, adjust within the specification. (2) RFD type governor <602>

Fu!l•speed

position ,.--�position

Stopper bolt

Adjusting lever

Stopperbolt JF

:.___,<

stopper Maximum bolt speed

Stopper bolt

Idling stopper bolt Full-load stopper bolt '-'� arl

�_J

Load control lever

<8DC>

r . /fl.. .�

Stopper bolt

Stop lever

B6310B <With Boost compensator>

Idling position

Speed control lever

�

�.

B6306B

Speed control lever Stopper bolt

,:�::·�,:,.: c:�·:;,'�dling stopper 0 '-, bolt • . :/�

Full-speed position Adjusting lever

Stopper bolt Full-load stopper bolt

Load control lever

Stopper bolt

B6310D

(a) Minimum speed Make sure that the adjusting lever is in contact with the stopper bolt. In this condition, check that the minimum speed is within the specification. If the specification is not met, adjust with the stopper bolt. (b) Maximum speed Place the adjusting lever to the full-speed position. If the maximum speed is outside the specification in this condition, adjust with the maximum speed stopper bolt.

13-84

86306A

(a) Minimum speed Check to see that the load control lever is in contact with the idling stopper bolt. In this state, check that the minimum speed is within specified limits. If not, adjust with the idling stopper bolt. (b) Maximum speed Set the load control lever at the full-load position (where it contacts the full-load stopper bolt). If the max imum speed is outside specified limits in this state, adjust with the maximum speed stopper bolt and stop per bolt. NOTE: 1. Never attempt to change the locked position of the full-load stopper bolt. 2. Quickly move the load control lever from the full load position to the idling position to make sure that the engine does not stall or develop hunting. If defects are evident, adjust within the specifica tion.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (3) RFD type governor with control cylinder <8DC> Load contro} Jever

Control cylinder

Compressed air [air pressure: 390 to 490 kPa {4 to 5 kgf/cm 2}]

�

Control cylinder

�

___r--� Speed control J .....--�ever

L Stopper bolt B

Stopper bolt A

Full-load

stopper bolt 80587A

To check and adjust the no-load maximum speed, pro ceed as follows. Inspection and adjustment proce dures of no-load minimum speed are as described above. (a) Operate the control cylinder with the specified air pressure and check that the speed control lever is in contact with stopper bolt A. (b) Move the load control lever to the full-load position in this condition (where it contacts the full-load stopper bolt) and measure the maximum speed to see if it is within specification. (c) If the specification is not met, adjust with stopper bolt A.

�I

Load control lever

Ful!-'load stopper bolt 80588A

(d) Next, with no air pressure applied to the control cylinder, make sure that the speed control lever is in contact with stopper bolt B. (e) Place the load control lever into the full position and measure the maximum speed to see if it is within specification. (fl If the specification is not met, adjust with stopper bolt B.

13-85

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.12 Pump Drive Case 5.12.1 Removal and installation <8DC>

<602>

Pump drive case

�&l

� Bracket

B4194A

B4565A

( 1) For removal and installation of the pump drive case, refer to Section 5.1.T in Group 61 Special Equipment. 5.12.2 Disassembly and inspection <602>

Deterioration, damage

1 Cracks, wear 84196A

Disassembly sequence 1 Sensor plate 2 Injection pump gear 3 Collar 4 Bearing holder 13-86

5 Oil seal 6 Shaft 7 Bearing

8 Bearing 9 Cover 10 Crank case

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Deterioration, damage

<8DC>

4 ., ....."'"

7 Rotating condition

8 Rotating condition 215 N-m {22 kgf.m} Cracks, wear

Disassembly sequence 1 Sensor plate (guide plate: BDCB only) 2 Injection pump gear 3 Spacer

B4578A

4 Bearing case

8 Front bearing 9 Cover 10 Crank case

5 Oil seal

6 Shaft

7 Rear bearing

5.12.3 Reassembly <6D2> 7

215 N•m {22 kgf-m}

FD \ Assembly sequence

,o ➔B➔6➔3➔ ' ® ➔CD➔s

4➔7➔5_....J

For parts with an encircled number, refer to Reassembly Procedure that follows.

‘

1 B4197A

13-87

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

<8DC>

215 N-m {22 kgf-m}

5 4 Assembly sequence 10➔8➔6➔3....®-,(j)➔g 4➔7➔5_j'

7 For parts with an encircled number, refer to Disassembly Procedure that follows.

84566A

( 1) Installation of injection pump gear Install the injection pump gear, sensor plate (or guide plate) and nut as shown.

Align ·o· and ·u· marks (6D21 or •o• and •o• marks (SDC)

Align the notch of sensor plate with mark “O* of

this To beside tightened toward with gear

Align notch . the of sensor claw injection with plate . pump gear

D9274B

13-88

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.13 Injection Nozzle

5.13.2 Disassembly

5.13.1 Removal and installation

<1-spring nozzle>

v.:

•• 0-1

9.8to 15 N-m

{1 to 1.5 kgf-m}

15 Nm 11.5 kg! m)

Wear4

Cracks, deformation

5 �

,,/

Wear

8 Carbon deposited

o---s 1 Cap nut

2 Adjusting 1 Injection pipe 2 Leak-off pipe 3 Injection nozzle

4 Dust seal 5 Nozzle tip gasket C0577B

screw

3 Spring

4 Push rod

5 Inlet connector 6 Retaining nut 7 Needle valve 8 Nozzle 9 Nozzle holder 07027A

13-89

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

<2-spring nozzle: except identification mark "2D">

,-{j ---0

f-14

Gasket

3�

2--l@is,l

Cracks, deterioration 4

!II 19

5 Wear

Nozzle

W �

•r �

� Carbon deposits

l®l_,o

---U

Shim (for valve opening --® pressure) ---11 Cracks, detenorat,on

1 Cap nut 2 Adjusting screw 3 Lock nut 4 2nd spring 5 Set screw 6 2nd push rod 7 Spacer

-----®L)'

14�

es rr ea ee em

13� 12

a-&

9�

1dentif1cat1on

Shim (forprelift)�

Identification mark position

�

17-u

/ mark stamped position

<2-spring nozzle: identification mark "2D">

8 1st spring 9 1st push rod 10 Retaining nut 11 Nozzle 12 Needle valve 13 Nozzle holder 14 Inlet connector D7015A

15449

(D Retaining nut 2 Needle valve 3 Nozzle 4 Pin (q,3) 5 Spacer 6 Lift piece 7 Pin (<j,2.5) 8 Spring seat 9 Shim (For adjust ment of second ary valve opening pressure)

10 2nd spring

11 Push rod 12 Callar 13 Spring seat 14 1st spring 15 Shim (For adjust ment of primary opening valve pressure) 16 Nozzle holder 17 Leak-off connector

NOTE: 1. Clean off any carbon deposits before disassem bling, reassembling, or adjusting any nozzle assembly, Note, however, that the spray pressure and shape should be inspected and the assembly checked for oil leaks first. If no abnormalities are apparent, do not commence disassembly. 2. Under no circumstances change the combination of needle valves and nozzles used.

13-90

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Disassembly Procedure The following special tools should be used in disas sembly: Tool name

Part No. (Zexel product No.)

Plate

157944•9520

Special Wrench

157914·2800

Removing retaining nut

D7003A

------ Special Wrench

Retaining nut-----

1157914·2800)

“PER

(a) Remove the needle valve from the nozzle and clean the needle valve with the needle valve cleaning wood piece.

(157944-9520)

01888

Secure the Plate (special tool) in a vise and fit the injec tion nozzle onto it. Loosen and remove the retaining nut using the Special Wrench (special tool). 5.13.3 Cleaning and inspection

(1) Cleaning D7004A

Nozzle Cleaning Tool 105789-0010

(b) Insert, while turning, a cleaning needle into the injection orifice of the nozzle to remove carbon.

01891

After washing the nozzle in gas oil, remove deposited carbon using Nozzle Cleaning Tool (special tool) by the following procedures. NOTE:

Never change the combination of the nozzle and needle valve.

D7029A

(c) Clean the nozzle seat using the cleaning needle. (di To remove burnt and hardened carbon, use FUSO Carbon Remover or equivalent. 13-91

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE ( 1) Injection pressure

(2) Inspection

Injection pressure 0ever operating at 60 to 100 strokes/minute) 1 Injection pressure I NV 21.6 MPa {220 kgf/cm2} NV .. Nominal Value Nozzle tester

D7005B

D7007A

Clean and immerse the nozzle in gas oil, slide the needle valve and check that it moves smoothly. Next, pull up the needle valve vertically about 1/3 of its entire stroke and check that it falls under its own weight. If it does not fall, replace the nozzle.

(a) Remove the cap nut and install to the nozzle tester. (b) Loosen the adjusting screw and operate the nozzle tester two or three times for bleeding. (c) Operate the nozzle tester at specified speed, adjusting the adjusting screw for specified injec tion pressure.

5.13.4 Reassembly and adjustment

NOTE:

<1-spring nozzle>

Never let yourself exposed directly to the atomized fuel injected from the nozzle. 39to 49N-m 1 {4 to 5 kgf-m} 2

69to78N-m {7 to 8 kgf-m}

9 3

4 7 59 to 78 N-m {6 to 8 kgf-ml 6 Assembly sequence 9➔5➔4➔3➔2➔ 1 S-.8➔7 -1' NOTE:

13-92

Locating pin 8

D7008A

D7028A

Never touch the sliding surface of the needle valve by hand. Install the cap nut after injection pressure adjustment.

(d) After adjustment, tighten the cap nut to specified torque. Fix the adjusting screw with a screwdriver inserted through the cap nut hole to prevent turn ing of the adjusting screw. (e) After tightening the cap nut, check again the injec tion pressure.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.13.5 Reassembly and adjustment <2-spring nozzle: except identification mark "2D">

(2) Spray condition 1 Good

Good

Poor

;

�

Good 1 2

Evenly sprayed from five injection orifices Even and symmetrical

Poor

Adjust while assembling the parts by the following procedures. As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt before adjustment. The following special tools should be used when mak ing adjustments: Tool name Adjusting Device

Zexel product No. 105789-0500

Poor 3 4 5 6

Asymmetrical Branched Thin Irregular

Adjusting Device (105789�0500) components

07009A

When adjusting the pressure with a nozzle tester, check also for clogged injection orifices, spray condition, and fuel leaks from the orifices. Replace the nozzle if defec tive. (3) Fuel tightness test

Test pressure 19.6 MPa {200 kgf/cm2J

83942A 07010A

Install a nozzle that has been adjusted to specified injection start pressure to the nozzle tester. Slowly increase the pressure to the test pressure and keeping this condition, check for fuel leaks from the bottom of the nozzle. The nozzle is functioning normally if there is no leak.

Adjusting device assembly

157892-0220

Dial gauge

157954-3800

Pin .f = 50 mm

157892-1200

Pin e = 60.5 mm

157892-1100

Connector assembly

157892-1320

Base

157892-1800

Gasket <for Retaining nut>

157892-1500

Retaining nut for adjustment

157892-1420

Gasket <for bolt of retaining nut>

026508-1140

13-93

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE ( 1) Adjustment of nozzle valve opening pressure 1 39to 49 N-m {4 to 5 kgf-m) 2

{l"PF;tL-3 20 to 25 N-m {2 to 2.5 kgf-m) 5 49to 59 N-m {5 to 6 kgf-m)

Nozzle holder

4 !lrmiH-r14

Shim (for prelift)

7 IIJU..-+-6

u.-+-Shim (for valve opening pressure)

Needle valve Retaining Nut for Adjustment 157892-1420 59to 78 N-m {6 to 8 kgf-m) Locating pin Nozzle

8 9 12

j__--

Locating pin

11 10

Gasket A 157892-1500

59to 78N-m {6 to 8 kgf-m)

Assembly sequence 13➔9➔8➔7 ➔5➔6➔4➔2➔3 7 11➔12

D7016C

_r 10--> 14--> 1

NOTE: Never touch the sliding surface of the needle valve by hand.

07017A

{a) Using the Retaining Nut for Adjustment {special tool), install the nozzle and needle valve to the nozzle holder. NOTE:

Adjusting Steps G) Adjustment of nozzle opening pressure ® Selection of prelift adjusting shims ® Adjustment of 2-spring adjusting pressure •@ Check of needle valve full lift '.§: Installation of prelift shims *'§: Checking of prelift *0 Checking of 2-spring adjusting pressure -� Inspection Inspection make operations marked with * as neces sary for inspection or confirmation.

13-94

Make sure that the knock pin has seated com pletely in the nozzle before tightening the Retain ing Nut for Adjustment. lighten the retaining nut finger tight and then tighten to specified torque using a torque wrench. 2. Remove the bolt from the tip of the retaining nut.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE NOTE:

1. When using a shim, be sure to check its thickness by a micrometer. 2. Use same shim for prelift adjustment. 3. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa {2.4 kgf/cm2}.

Set screw 49 to 59 N•m {5 to 6 kgf-m}

(2) Selection of prelift adjusting shim (a) "0" point adjustment of adjusting device

Spacer Shim {for valve opening pressure) 1st spring

Dial Gauge 157954-3800

1st push rod

Adjusting Device 157892-0220

Pin 157892-1100 2nd push rod Base 157892-1800

O7018A

(b) Insert 1st push rod, 1st spring, valve opening pres sure adjusting shim (first use about 1 mm thick one) and spacer to the nozzle holder. Then tighten the set screw to specified torque. Operate lever at 60 to 100 strokes/minute ! Injection pressure \ I NV 17.7 MPa j (180 kgf/cm 2} I NV .. Nominal Value Nozzle tester

Keep bah removed

D7019D

(c) Install the nozzle holder to nozzle tester and adjust the shim thickness for nominal injection pressure. 0.50 to 1.54 mm (in 0.02 mm steps)

O7030A

Install Dial Gauge (special tool) to Adjusting Device (special tool). Install the 2nd push rod to Base (special tool) and install the assembly to a vice. Set the pin and Adjusting Device as indicated in the above illustration and adjust "O" point of the Dial Gauge. Use a 60.5 mm long pin. (b) Install the 2nd push rod to the nozzle holder. NOTE:

Do not install the 2nd spring and prelift adjusting shim.

13-95

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (3) Adjustment of 2-spring adjusting pressure (open pressure) 20to 25 N-m {2 to 2.5 kgf-mJ--- Lock nut Adjusting screw----tiail 2nd spring ----i!!l

Dia! Gauge holder

Set screw

Intermediate screw of Adjusting Device

Set screw

D7032A

2nd push rod

Nozzle holder

Install the 2nd spring, adjusting screw and lock nut to the nozzle holder. NOTE: Do not install the prelift adjusting shim. Operate lever at 60 to 100 strokes/minute

D7031A

Injection pressure NV 24.8 to 25.4 MPa {253 to 259 kgf/cm 2) <Standard> 26.2 to 26.9 MPa {267 to 274 kgf/cm 2) <Option>

(c) Install the adjusting device to the set screw using its intermediate screw. After installation, holding the Dial Gauge at its holder, move it up and down to check that the gauge operates smoothly. Push down the gauge, holding its holder and read its lift h.

NV .. Nominal Value Nozzle tester

NOTE: Read to 1/100 mm. (d) Selection of prelift adjusting shim t=f+h where t: Shim thickness (measured) Prelift (0.10 ± 0.02 mm) h: Dimension selected in step (c)

T=t ± 0.015mm T: Thickness of shim to be used Shim thickness: 0.75 to 1.50 mm (in 0.01 mm steps) (e) Remove the Adjusting Device from the nozzle holder.

13-96

Keep bolt removed D7019D

Using nozzle tester, adjust the adjusting screw for nominal injection pressure (open pressure). After adjustment, tighten the lock nut to specified torque.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

t t-

14) Checking full lift of needle valve

(a) Remove the set screw, lock nut and adjusting screw as an assembly from the nozzle holder.

DialGauge 157954-3800 39 to 49 N-m {4 to 5 kgf-m)

Connector

157892-1320 Pin -t-= 50 mm 157892-1200

Retaining Nut for Adjustment 157892-1420

Gasket 8 026508-1140---<ll> �Bolt

07033A

la) Install the special tools indicated in above illustra tion and set "O" point of the Dial Gauge. lb) Install the nozzle to the nozzle tester and operate the tester lever to bleed the inside of the retaining nut. Also check for fuel leaks. (c) Operate the tester lever to increase the pressure to about 34.3 to 44.1 MPa {350 to 450 kgf/cm2} so that the needle valve of the nozzle is fully lifted. Read this lift dimension "L" off the Dial Gauge. Id) Remove the Dial Gauge, Connector and Pin (spe cial tools). 15) Installation of prelift shim Adjusting screw

NOTE: Never loosen the lock nut as loosening it changes the 2-spring adjusting pressure. (b) Install the prelift shim selected in Item (2) between the spacer and 2nd push rod. (c) Install the 2nd push rod and 2nd spring and tighten the set screw, lock nut and adjusting screw as an assembly to specified torque. (d) Check again that the needle valve full lift dimen sion "S" with the Dial Gauge by the procedures described in Item (4). (6) Checking prelift

Check the prelift based on dimension "L" measured in Item (4) and dimension "S" measured in Item (5). L-S=t.f where C - 0.02 mm ;as t. C ;a, C + 0.02 mm t. f: Prelift (measured) C: Prelift (0. 1 mm) L: Needle valve full lift dimension (measured) S: Needle valve lift dimension (measured) with prelift subtracted If t. C is outside of specified dimension f ± 0.02 mm, replace the prelift adjusting shim as described in (5) and repeat steps (4) and (5) so that t. twill fall within f ± 0.02 mm. Select thfokness t' of shim to be used as follows. t' = t + (f - t.f)

Lock nut

T=t' ± 0.015 mm

Set screw

49to 59 N-m

where t: Thickness of existing shim t': Shim thickness T: Thickness of shim to actually replace exist ing shim f: Prelift (0.1 mm)

{5 to 6 kgf-m)

07034A

13-97

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(7) Checking allowance of2-spring regulated pressure (cover pressure)

(b) Spray condition 1

2-spring regulated pressure {lift 0.05} I NV 23 to 23.5 MPa {235 to 240 kgf/cm 2}

Good

2 Good

3 Poor

NV .. Nominal Value

Nozzle tester

Bolt installed

Good D7035A

(a) After checking the prelift in Item (6), increase the pressure again to about 34.3 to 44.1 MPa {350 to 450 kgf/cm 2} so that the needle valve of the nozzle is fully lifted.

NOTE: Retaining Nut for Adjustment (special tool) must have a bolt fitted at its tip. (b) When the nozzle tester lever operation is stopped with the nozzle needle valve fully lifted, the pres sure will start to drop and the needle valve will go down. le) At the moment the nozzle lift has dropped to 0.05 mm, read the pressure gauge indication. Id) If the 2-spring regulated pressure (open.pressure) is out of specification, adjust the 2-spring regu lated pressure in accordance with Item (3).

4 Poor

5 Poor

�

Evenly sprayed from five injection orifices Even and symmetrical

Poor

)

t Poor 3 4

5 6

Asymmetrical Branched Thin Irregular

D7009A

! Test pressure I

15.7 MPa {160 kgf/cm 2}

NOTE: Adjust without installing prelift shim. le) Remove special tools. (8) Inspection (a) Tighten the retaining nut and cap nut to specified torque.

NOTE: 1. Make sure that the knock pin has seated com pletely before tightening the retaining nut. 2. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench.

13-98

D7010A

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.13.6 Reassembly and adjustment <2-spring nozzle: identification mark "2D">

The adjustment should be performed during reas sembly as described below. The prelift should be adjusted in 1/100 mm unit. Therefore the parts must be Tool name and shape Adjusting Device

cleaned with the clear cleaning fluid to remove dust and foreign materials completely. For the adjustment, following special tools are required.

Part No. (Zexe! product No.)

Application

157892-4920

*1 Adjusting Device

157892-4420

*2 Holder

157892-4400

*2 Nut

157892-1000

*1 Dial Gauge

157954-3800

*1 Pin

157892-4700

*1 Retaining Nut for Adjustment

157892-4020

*3 Retaining Nut for Adjustment

157892-4000

I, Securing Dial Gauge

*3 Gasket

026508-1140

*3 Plug

157892-1600

*1 Gasket

157892-1500

Plate

157944-9520

Securing nozzle holder

Special Wrench {SW19)

157914-2800

Removal and installation of retaining nut

Special Wrench (SW22)

157914-0500

I Removal and installation of Retaining Nut for Adjustment

Items marked "*1" are parts of Adjusting Device 157892�4920. Items marked "*2" are parts of Adjusting Device 157892�4420. Items marked "*3" are parts of Retaining Nut for Adjustment 157892-4020.

13-99

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Reassembly and Adjustment Procedure 29to39Nm {3 to 4 kgf•m}

(1) Reassembly

18 70 to 78 N•m {7 to 8 kgf.m}

Nozzle

Nozzle holder ......______

Plate 157944·9520

(/ 9

'l--�--13 \.-+---12

l'l-,/----10

�)

01895

(a) Secure the Plate (special tool) in a vise, then mount the nozzle holder on the Plate. Carry out reas sembly in the opposite of the disassembly sequence.

2 3

34 ± 4.9N•m {3.5 ± 0.5 kgf.m}

Gasket 157892·1500

59 to 78 N·m {6 to 8 kgf.m}

Nozzle For reassembly, reverse the order of disassembly. NOTE: Do not touch the needle valve's sliding surfaces.

11937

During reassembly, make adjustments and checks in the following sequence: ( 1) Adjust the No. 1 valve's opening pressure (2) Check the needle valve's total lift (3) Check the prelift amount (4) Check the No. 2 valve's opening pressure (5) Adjust the No. 2 valve's opening pressure (6) Replace the retaining nut

(7) Make an overall inspection

13-100

Retaining Nut for Adjustment 157892-4000

1--- Special Wrench 157914-0500

Nozzle holder 01896

(b) Fit the Gasket (special tool) onto the nozzle. Then, secure the nozzle on the nozzle holder using the Retaining Nut for Adjustment (special tool). Turn the Retaining Nut for Adjustment as far as possible by hand, then tighten it to the specified torque using the Special Wrench (special tool).

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (2) Adjusting No. 1 valve opening pressure Spray pressure NV 17.7 MPa {180 kgf/cm 2} /

ve So j-—— Nut Holder 157892-1000 157892-4400 Plate 157944-9520

NV .. Nominal Value

Injection nozzle--J-. assembly

15263

15262

(a) Fit the injection nozzle assembly onto the tester and measure the valve opening pressure.

(b) Mount the injection nozzle assembly upside-down on the Plate (special tool). Then, fit the Holder and Nut (special tools).

NOTE:

Do not touch the spray that comes out of the nozzle. (b) lfthe spray pressure is out of specification, adjust it using No. 1 valve opening pressure adjustment shim. (This shim has an outside diameter of 8.9 mm.) A 0.02 mm change in shim thickness causes a 235 kPa {2.4 kgf/cm2} change in valve opening pres sure. Dial Gauge 1579543800

Shim thickness: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70 (3) Checking needle valve total lift

Plug 151092-1eoo

_/ � Gasket� I ' 026508·1140 / / _,/

.Retaining Nut for Adjustment 157892-4000

Pin 1578924700

Nut 157892-1000 Holder 157892-4400

Spring seat

Plate 157944-9520 .-:/� ...

"�J

15264

01898

(a) Fit the Gasket and Plug (special tools) onto the Retaining Nut for Adjustment (special tool).

(c) Fit the Pin (special tool) into the Dial Gauge (special tool). (d) Fit the Dial Gauge (special tool) onto the injection nozzle assembly and secure it with the Nut (special tool) such that the Pin (special tool) is touching the top surface of the No. 1 spring seat.

13-101

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

NOTE: 1. Secure the Dial Gauge such that a stroke of approximately 1.2 mm can be measured. 2. Do not overtighten the Nut. If the Nut is too tight, the Dial Gauge shaft will stick in one position.

14) Checking prelift

�

Pressure gauge

Retaining Nut

for Adjustment 157892-4000

Pipe pressure (MPa {kgf/cm 2}) 01903

••:s;;:

��

Plug 157892-1600

15265

le) Fit the injection nozzle assembly onto the Nozzle Tester, then zero the Dial Gauge. Loosen the Plug (special tool) and operate the Nozzle Tester. Bleed the Retaining Nut for Adjust ment, and check for fuel leaks at the same time. After fully bleeding the Retaining Nut for Adjust ment, securely tighten the Plug.

(a) Once the needle valve is in its fully lifted position, the pipe pressure will start to drop if the Nozzle Tes ter handle is not moved. The needle valve lift mea surement (as shown by the Dial Gauge) will drop concomitantly. In the graph, A: Needle valve total lift amount

a° NSnoupny pos Oo

NV 0.07 ± 0.02

�=!,,,,:!1...-1!:===11

NV .. Nominal Value

E 5

�

34.3 to 44.1 {350 to 450}

Pipe pressure (MPa {kgf/cm 2})

01902

(f) Operate the Nozzle Tester. When the pipe pressure is raised to 34.3 to 44.1 MPa {350 to 450 kgf/cm2 }, the needle valve should lift completely. When this happens, make a note of the total lift measure ment. In the graph, A: Needle valve total lift amount C: No. 1 valve opening pressure NOTE: This check is necessary to check for abnormal wear on the nozzle seat. 13-102

Needle valve

C Pipe pressure (MPa {kgf/cm 2})

01904

(b) Read the Dial Gauge indication when the No. 2 spring stops acting and the needle valve stops dropping. This point is labeled "F" in the above graph. Confirm that the reading conforms with the specified nominal value.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE The prelift measurement point (labeled "G" in the graph) corresponds to C + approx. 980 kPa {10 kgf/ cm 2 J, where "C" is the No. 1 valve opening pres sure.

In the graph, A: Needle valve total lift amount C: No. 1 spring opening pressure F: Prelift G: Prelift measurement point

E � �>

Af---------��-

'">

F+0.05

F f------�-'

34.3 to 44.1 {350 to 450)

Pipe pressure (MPa {kgf/cm2}) F+0.05

Needle valve

Nozzle

,___ Capsule

01905

(c) If the prelift measurement is out of specification, replace the pin, lift-piece, spacer, nozzle, and needle valve with the Nozzle Service Kit. (5) Checking No. 2 valve opening pressure

Dial Gauge

Pressure gauge 01907

(b) Read the pressure gauge indication at the instant when the Dial Gauge indicates the specified nomi nal needle valve lift (normally prelift F + 0.05 mm). In the graph, A: Needle valve total lift amount C: No. 1 valve opening pressure F: Prelift J: No. 2 valve opening pressure (6) Adjusting No. 2 valve opening pressure

No. 2 valve opening pressure I NV 25.5 to 26.5 MPa {260 to 270 kgf/cm2} i NV .. Nominal Value

15266

(al After checking the prelift, operate the Nozzle Tester and raise the pipe pressure to 34.3 to 44.1 MPa {350 to 450 kgf/cm2} such that the needle valve lifts fully. If the Nozzle Tester handle is not moved, the pipe pressure will drop. The needle valve lift measure_ment (shown by the Dial Gauge) will drop concom itantly.

01908

If the No. 2 valve opening pressure is out of specifica tion, disassemble the nozzle mounting side of the injection nozzle assembly and change the No. 2 valve 13-103

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

opening pressure adjustment shim. (This shim has an outside diameter of 9.9 mm.) Shims are available in the following thicknesses: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, and 0.70 mm. A 0.02 mm change in shim thickness causes a change in valve opening pressure of 196 kPa {2 kgf/cm2J.

(8) Inspection

NOTE: 1. 2.

Do not touch the spray that comes out of the nozzle. Changing the No. 1 valve opening pressure causes the No. 2 valve opening pressure to also change.

(7) Replacing retaining nut

15268 34 ± 4.9 N·m {3.5 ± 0.5 kgf•ml

Retaining Nut for Adjusting

Fit the injection nozzle assembly onto the Nozzle Tes ter. Check the No. 1 valve opening pressure, the spray shape, and the oil-tightness of the seat. Check also that there are no leaks.

NOTE: 1. If the No. 1 valve opening pressure does not con

form to its specified nominal value, go through the adjustment procedure again from step (1 J. Do not touch the spray that comes out of the nozzle.

5.14 Hydraulic Governor (RHD6-type for 8DC9) Inspection and Adjustment 15267

(1) Bleeding hydraulic governor Oil plug

Remove the Dial Gauge, Pin, Nut, and Holder. Then, take off the Plug, the Gasket, and the Retaining Nut for Adjustment and its Gasket. Fit the regular retaining nut and tighten it to the specified torque using the Special Wrench (special tool). Special tools: 1. Special Wrench 2. Gasket 3. Retaining Nut for Adjustment 4. Gasket 5. Plug 6. Holder 7. Nut 8. Pin 9. Dial Gauge

13-104

Inspection window

(157914-0500) ( 157892-1500) ( 157892-4000) (026508-1140) (157892-1600) (157892-4400) (157892-1000) ( 157892-4700) (157954-3800)

84567A

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (a) Before starting the engine, remove the oil plug from the governor's top cover and pour in ATF up to the inspection window's middle mark.

Speed control !ever

Plug Plug

Plug

NOTE: 1. Bleed the hydraulic governor with the engine cool ant at a temperature of approximately 75 °C. 2. After bleeding the hydraulic governor, top up the ATF until it reaches the middle of the inspection window. 3. After starting the engine, the needle valve must be tightened until hunting stops. Set the needle valve as loosely as possible without hunting taking place. 4. All air in the hydraulic governor must be bled out. If any air remains inside, hunting will not stop after the engine is started. (2) Adjusting speed alteration rate

N�edle valve B4568A

(b) Loosen the three plugs, then turn the needle valve three turns back from its fully closed position.

_....__,LOW

Speed alteration rate adjusting screw

Speed control lever 84570A

Remove the governor's top cover and set the speed alteration rate scale to 9 or 10. (3) Rod adjustment

Moves forward and backward 84569A

(c) Push the speed control lever to "FULL" side or "LOW" side. Then, move the fuel control lever on the power piston side. Repeat this procedure sev eral times with the speed control lever in both the "FULL" and "LOW" positions to fully bleed the hydraulic governor.

B4571A

(a) With the hydraulic governor standing alone, check the stroke of the fuel control lever (the lever's maxi mum movable distance). Confirm that there is no discrepancy between the scale and needle. 13-105

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Fuel control needle (adjust to 6 on scale}

Injection-pumpside governor's governor lever position

Hydraulic governor's speed control lever position

Torque converter speed

Ball Jotnt

LOW

600 ± 50 rpm

\,,

HIGH

LOW

600 ± 50 rpm

LOW

HIGH

700 ± 50 rpm

(5) Adjusting HIGH idle Control lever 84572A

(b) Set the injection-pump-side governor's fuel con trol lever to its full-load position. Connect the con trol rod to the hydraulic governor's fuel control lever such that hydraulic governor's fuel needle points to 6 on the scale. To make adjustments, remove the ball joint from the control lever, loosen its lock nut, then rotate the ball joint to alter the control rod's effective length.

Maximum speed set screw

Lock nut

(4) Adjusting LOW idle

LOW idle stopper set screw

84574A

Set the injection-pump-side governor's governor lever to its HIGH idle position. Turn the maximum speed set screw such that the torque converter runs at a speed of 2,000 to 2,050 rpm.

Lock nut

84573A

Turn the LOW idle stopper set screw (on top of the hydraulic governor) such that the following conditions are satisfied: 13-106

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (61 Checking for hunting <6D2, 8DC9, 9-T, 9-TC>

25 N-m {2.5 kgf-m} 2 Cracks, threaded

Speed control lever HIGH idle {full-speed) position

portion

Apply thin coat � of engine oil · when mounting.

1 Stopper bolt

D7301E

<8DC9-TL> <6D2, BOC: Option> Cracks, threaded portion 2

Injection-pump-side governor 84575A

(a) Set the injection-pump-side governor's governor lever to its HIGH idle position. Gradually raise the hydraulic governor's speed control lever and check that no hunting occurs over the entire range. lb) Set the hydraulic governor's speed control lever to itsHIGH idle position. Gradually raise the injection pump-side governor's governor lever and check that no hunting occurs over the entire range.

Apply thin coat of

engine oil when

mounting.

5.15 Fuel Filter 1 Fuel filter element 2 Fuel filter head

25 N-m (2.5 kgf-m}

Filter Wrench MH061572

89181C

The element can be removed easily using the Filter Wrench (special tool).

D7309D

NOTE: 1. When removing the element, check for the gasket left behind on the head side. 2. To mount, apply a thin coat of engine oil to the gas ket, and then secure the element by tightening 3/ 4 to 1 turn after the gasket comes in contact with the fuel filter head. 3. After installation, bleed the fuel system. 4. After bleeding the air, start the engine and check for fuel leaks. 13-107

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.16 Water Separator <BOC: Twin type>

<:6D2, BOC> 25N-m g {2.5 kg t-m}

{2.5 kgf-m}

7.8t0 12 N-m {0.8 to 1.2 kgf-m}

7.8to12N•m -,--- 9 {0.8 to 1 .2 kgl-m} @

@ 10�!

25N-m {2.5 kgl-m}

@ 78to12N-m

{0.8 to 1.2 kgf-m}

@w� 4

7 5

25 N-m 12.5 kgf.m)

9 25N-m {2.5 kgl-m}

m=:: @-, �:

1�

D7405C

D7401E

1 Drain plug 2 Drain cup (twin type only)

tr----1

D7406B

7 Screen assembly

8 Water level ring 9 Eyebolt 10 Air plug 11 Cover

3 Ring nut 4 Case 5 Baffle plate 6 Isolation plate

If the red water level ring in the translucent case rises to the level of the red line marked on the outer circumfer ence of the case, immediately loosen the drain plug to discharge water. It is not necessary to completely remove the drain plug, as water is discharged gradually through the groove of the loosened plug.

Red line

Drain Water plug level ring

NOTE:

After draining, tighten firmly the drain plug before bleeding the fuel system. 09278

13-108

FUEL AND ENGINE CONTROL - TROUBLESHOOTING 6. TROUBLESHOOTING Probable cause

Symptom Engine will not

start

Remedy

Defective feed pump • Loaded gauze filter

Ref. group

Clean

• Check valve inoperative

Replace

• Seized or worn piston

Replace

• Seized push rod

Replace

• Worn tappet

Replace

Defective injection pump • Seized or worn plunger

Replace

• Seized control rack or control rod

Replace

• Seized delivery valve

Replace

• Worn tappet

Replace

• Worn camshaft

Replace

Defective injection nozzle • Seized needle valve

Replace

• Valve opening pressure too low

Adjust

• Clogged injection orifice • Nozzle not air-tight Fuel tank empty

Engine starts but soon stops

Engine knocks

Supply fuel

Clogged fuel pipe or fuel leaks from connection

Correct or replace

Air or water trapped in fuel system

Bleed or replace

Loaded fuel filter

Replace

Clogged fuel filter

Correct or replace

Air or water trapped in fuel system

Bleed or replace

Defective feed pump

Check

Injection timing too advanced

Adjust

Defective injection nozzle • Valve opening pressure too high

• Clogged injection orifice

Smoky engine exhaust and knocking

Clean Correct or replace

Adjust Clean

• Nozzle not air-tight

Correct or replace

Low quality fuel in use

Replace

Defective injection pump • Incorrect injection timing

Adjust

• Worn plunger

Replace

• Defective valve seat

Replace

Low quality fuel in use

Replace

Defective injection nozzle • Valve opening pressure too low

Adjust

• Broken spring

Replace

• Clogged injection orifice

Clean

13-109

FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause

Symptom

Unstable engine I Defective injection pump output • Insufficient plunger sliding stroke

i !

• Broken plunger spring

Remedy I

• Poor control rod or control rack sliding • Broken delivery valve spring

• Poor tightness due to loose delivery valve holder

• Delivery valve not functioning properly

Replace Correct Replace Replace

• Incorrect valve opening pressure

Adjust

Defective feed pump • Check valve not functioning properly

Replace Replace Bleed or replace

Loaded fuel filter

Replace

Incorrect injection timing

Adjust

Control lever not in contact with full�speed set bolt

Adjust

Defective injection nozzle • Nozzle not air�tight

Correct or replace

• Broken spring

Replace

• Clogged injection orifice

Clean

Defective injection pump • Worn plunger

Replace

• Broken delivery valve

Replace

• Defective delivery valve seat

Replace

• Poor tightness due to loose delivery valve holder

Correct

Defective governor • Timing control is performed at low speed due to weak governor spring

Adjust

• Faulty full•load stopper position

Adjust

• Adjusting lever (or load control lever) incorrectly adjusted

Adjust

Poorly adjusted injection timing

Adjust

Insufficient advance angle of automatic timer

Adjust

Poor quality fuel in use

Replace

Defective governor • Governor spring tension too weak

Adjust

• Incorrect adjusting lever (or load control lever) position Defective injection nozzle • Clogged injection orifice • Nozzle not air·tight • Valve opening pressure too low

13-110

Replace

Air or water trapped in fuel system

Engine not reaching max. speed

Replace

• Broken spring

• Worn piston

Insufficient engine output

Replace Correct

• Worn tappet, poor sliding

Defective injection nozzle • Poor sliding of needle valve

Ref group

Adjust Clean Correct or replace Adjust

FUEL AND ENGINE CONTROL - TROUBLESHOOTING Symptom Engine max. speed too high

Defective governor • Poorly adjusted speed control lever

idling

Defective injection pump • Seized, binding or worn plunger • Loose control pinion

| I I

Correct

• Delivery valve holder too tight

Correct

• Uneven injection amount to cylinders

Adjust

• Broken plunger spring

Replace Bleed or replace

Defective governor • Idling spring tension too weak

• Large friction or play of link

Adjust

Correct Replace

• Loose round nut

Correct

• Incorrectly adjusted idling stopper bolt

Adjust

Defective feed pump • Defective check valve

Replace

• Worn piston

Replace

• Loaded gauze filter

Clean

Loaded fuel filter

Fuel supply failure

Replace

• Air or water trapped in fuel system

Engine cannot be stopped

Adjust Correct

• Plunger spring not seating correctly

• Bent link

Replace

Incorrect injection timing

Adjust

Defective automatic timer

Correct

Defective injection nozzle • Clogged injection orifice

Clean

• Deteriorated spring

Replace

• Nozzle not air-tight

Correct or replace

Broken or stretched engine stop cable

Ref. group

Correct

Poor sliding of injection pump control rod or control rack

• Flyweight not functioning effectively

Unstable engine

Remedy

Probable cause

Replace

Poorly adjusted engine stop cable

Adjust

Damaged governor stop mechanism

Replace

Cracked fuel hose, pipe

Replace

Leaky fuel tank

Replace

13-111

COOLING CONTENTS 1. GENERAL . . . . ... ........ . .... . ..... . . .. . .... 2 2. SPECIFICATIONS .. . . .. .... . .... . . . . . . .. . . . . 7 3. SERVICE STANDARDS ... . . . .. . .... . ... .. .. 8 3.1 Service Standards Table . ... . . . .. .. ... .. . 8 3.2 lightening Torque Table . . . . . . . . .. ... . ... 8 4. SPECIAL TOOL .. . ... .. ... ... . .. . . . . .... . . . . 9 5. SERVICE PROCEDURE . . . . . .. . . . .. . .. . ..... 10 5.1 Removal and Installation of Fan Shroud ... .................. .............. 10 5.2 Removal and Installation of Cooling Fan ........ . ...... ........... .. . . .......... 10 5.3 Water Pump <602> . . ... .... ... . .... . ... . 11 Removal and installation . . . . . . . . . . .. . 11 5.3.1 Disassembly and inspection .. . . . .. ... 11 5.3.2 5.3.3 Reassembly ..... . . ... . . . ... . . ..... . . .. 14 5.4 Water Pump <BOC> . . . . .. . . . . . . . . . .. . . ... 15 5.4.1 Removal and installation ... . . ... . . . .. 15 Disassembly and inspection ...... .... 16 5.4.2 Reassembly ... . .... . . . ... ... ... . . . . . . . 19 5.4.3

5.5 Thermostat . . .... . ..... . . . . . . ........... . 21 Removal and installation . . . . ... ..... . 21 5.5.1 Inspection .. . .... . . ... . . .... .. ... . . . . . . 22 5.5.2 Fan Drive .... .... . . . .. . ... . . . . . . ..... . . . .. 23 5.6 Disassembly and inspection .. . ..... . . 23 5.6.1 Reassembly ... . . . . . . .. .. . . . . ........ . . 24 5.6.2 5.7 Tension Pulley .. .. . ... . .. .. . . .. ... . . .. .. . 25 Disassembly and inspection . . .. . . . . . . 25 5.7.1 Reassembly ... . .. .. ............. . . . ... 26 5.7.2 5.8 Inspection of Auto Cool Fan Coupling ...... .......................... . 26 5.9 Inspection of Radiator .................. . 27 5.10 V-beltTension . ................ .. ........ . 291 5.10.1 Inspection .... .................. ....... 29 5.10.2 Adjustment ............. ...... ........ 30 5.11 Cleaning of Cooling System ............. 32 5.12 Gas Leak Test ... ... ... . .......... ....... . 34 5.13 Bleeding the Cooling System ...... .... . 34 6 . TROUBLESHOOTING ...................... . 35

14-1

COOLING - GENERAL

1. GENERAL

( 1) Water pump

The cooling system is of the water-cooling forced cir culation type consisting of a radiator, water pump, thermostat, and related parts.

<6D2> re From thermo ay

<602>

Impeller Radiator

Thermostat

From radiator

<BDC>

81746C

From thermostat impeller

Water pump

Thermostat

81745D

“To engine

� �

From radiator

To engine 81734D

The water pump, of the centrifugal type, is driven by V-belt from the crankshaft pulley. Mounted at one end of the water pump shaft is an impeller with blades and the coolant is sealed up by unit seal. For lubrication of the water pump, see Group 12 Lubrication.

14-2

COOLING - GENERAL

Ill

(2) Thermostat Jiggle valve <6D2>

When coolant temperature is high (bottom bypass , valve is closed)

Water pressure To water pump When coolant temperature is low (bottom bypass valve is open)

81747A <8DC> From cylinder head

To radiator (High temperature)

81703A

A jiggle valve is installed in the thermostat for 8DC. The jiggle valve is normally in the lower position. Air in the engine is led to radiator through the clearance between the jiggle valve and the breather hole, which permits easy supply of coolant. When the engine is started and coolant flows, the jiggle valve is pushed up to close the breather hole. There fore, coolant cannot flow into the radiator until the tem perature rises enough to open the thermostat valve. This contributes to a shorter engine worm up time.

From cylinder head To water pump {Low temperature)

81735A

The thermostat is of bottom bypass type with a valve controlled by special wax enclosed in a pellet. When the wax is heated, it passes from a solid to a liquid state with its volume changing. This change in volume regu lates the amount of coolant flowing into the radiator and water pump (bypass side), thereby controlling coolant temperature.

14-3

COOLING - GENERAL

13) Radiator

14) Pressure cap

<With pressure release lever> Radiator

Pressure release lever

Pressure cap

Pressure spring,

��. =cW".·•·•71

Reserve tank

Ventv�lve ' operation condition

Vent valve spring

__..'Ti:l

�IP B17168

61740A

<Without pressure release lever> Pressure spring

The radiator, with a tube-and-corrugated-fin type core (and with a reserve tank on some models), not only cools the engine coolant but also separates vapor from liquid water and regulates pressure in the cooling sys tem.

Pressure valve

From reserve tank

Vent valve When vent valve is opened

B02958

The pressure cap regulates the pressure in the cooling system. When the pressure builds up in the system that exceeds a predetermined level, the pressure valve compresses the pressure spring, releasing the exces sive pressure through the overflow pipe into the atmo sphere. 14-4

COOLING - GENERAL If equipped with a reserve tank, the coolant that has overflowed is channeled into it. When the coolant temperature drops and negative pressure builds up in the system, the vent valve opens to take in air to prevent the radiator from becoming deformed. If equipped with a reserve tank, coolant is taken from the reserve tank to prevent the radiator from becoming deformed and to keep the quantity of coolant in the system constant. If equipped with a pressure release lever on the cap, raising the lever upright opens the pressure valve and releases the pressure in the cooling system. (5) Auto cool fan coupling

is controlled by a bimetallic strip that moves in response to temperature changes. <When the temperature of the air passing through the radiator is low>

Storage chamber

Operating chamber

Control hole

Divider plate

)< Le::]

�

Valve� B1metal 80243A

Rotor

Storage

chamber

Cover

,�""'1'ffl�:;,,,\ Case

Ball bearing

The valve fully closes the control hole of the divider plate. As a result, the silicone oil forced back from the pump hole is stored in the storage chamber and is not sent into the operating chamber. In the meantime, the silicone oil in the operating chamber decreases, and consequent slippage between the case and cover and the rotor causes the fan to rotate at a lower speed. <When the temperature of the air passing through the radiator rises>

Divider plate

n o r t hole lo �

'.:

Divider plate

Valve B0574C

Depending on the temperature of the air passing through the radiator, the auto cool fan coupling auto matically controls the rotating speed of the fan. The autocool fan coupling is constructed as follows: The rotor is mounted on the shaft and rotates between the case and cover. Viscous coupling material (silicone oil) enters the gap and turns the fan. A control hole in the divider plate allows silicone oil to pass from the storage chamber to the operating chamber. The hole is controlled by a valve. Opening and closing of the valve

80244A

As the temperature rises, the valve slowly opens the control hole of the divider plate, allowing silicone oil to flow into the operating chamber. Therefore, the sili cone oil contacting area between the case and cover and the rotor slowly increases. So more torque is trans mitted to the fan, causing it to rotate at a higher speed .

14-5

11111

COOLING - GENERAL

Autocoaol {at medium fantemperature} coupling

Direct�couple fan

Autocool fan coupling (at high temperature)

}

Autocool fan coupling (at low temperature)

Crankshaft speed {rpm) B0245A B1728B

The valve fully opens the control hole of the divider plate, and more silicone oil flows into the operating chamber. As a result, a maximum torque is transmitted from the shaft to the fan, causing the fan to rotate at a given maximum speed.

Temperature passing through the radiator (°C) B0575A

14-6

COOLING - SPECIFICATIONS 2. SPECIFICATIONS <6D2> Item

Specification .i Water-cooling forced circulation type

Cooling system Coolant quantity (Engine-proper only)

i 6D22, 22-T, 24-T -

. 6D22- TC 24 TC

1 Approx. 22 L pprox. 24 L

Type

Centrifugal type

Drive method

V-belt

Radiator

Type

Tube-and-corrugated-fin type or Tube-and-plate-fin type

Thermostat

Type

Wax pellet/bottom bypass type

! Valve opening \ temperature x O'ty

Without jiggle valve: 76.5 °C x 2

Water pump

Suction type or blower type

Cooling fan Type x Number of belts

V-belt

Without fan drive

Low edge cog B type x 1 or B type x 2

With fan drive

Low-edge cogged type Bx 1 (for water pump) Low-edge cogged type C x 2 (for alternator) Low-edge cogged type 8 x 1 (for water pump) Low-edge cogged type Bx 2 (for alternator)

<8DC>

Specification

Item Cooling system

Water-cooling forced circulation type

Coolant quantity (Engine-proper only)

8DC9, 9-T, 9-TL

Approx. 25 L

8DC9-TC

Approx. 28 L

Type

Centrifugal type

Drive method

V-belt

Radiator

Type

Tube-and-corrugated-fin type or Tube-and-plate-fin type

Thermostat

: Type

Wax pellet/bottom bypass type

Valve opening temperature x Q'ty

8DC9, 9-T, 9-TC

With jiggle valve: 82°C x 2

Option: 8DC9-T, 9-TL

With jiggle valve: 82°C x 2 Without jiggle valve: 82°C x 1

Option: 8DC9

Without jiggle valve: 76.5 °C x 2

8DC9-TL

With jiggle valve: 82°C x 1 Without jiggle valve: 88°C x 1

Water pump

Cooling fan

Suction type or blower type

Autocool fan coupling <8DC9-TL>

Type

Viscous type

Hydraulic fluid

Silicone oil

V-belt

Type x Number of belts

Without fan drive

Low edge cog C type x 1 or C type x 2

With fan drive

Low-edge cogged type C x 1 {for water pump) Low-edge cogged type C x 2 (for alternator) Low-edge cogged type C x 2 (for water pump) Low-edge cogged type Bx 2 (for alternator)

14-7

COOLING - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item

Nominal value (Basic diameter in [ II

Limit

4.5 to 8.5

Adjust

6D2

[251 0.05 to 0.08

8DC9. 9-T, 9-TC

1351 0.05 to 0.08

: Up to second : reassembly !

8DC9-TL

1281 0.03 to 0.06

6D2

I 11.81 0.03 to 0.06

8DC9, 9-T, 9-TC

1 1 5.510.04to 0.06

8DC9-TL

115.510.03to 0.05

Clearance between fan and fan shroud (Only I BDC

for type with a fan shroud secured to engine) Interference between pump shaft and flange

Interference between pump shaft and impeller

Thermostat

6D2 8DC9: Option

8DC9, 9-T, 9-TC, 9-TL:

8DC9-TL: LH

Valve opening

7 4.5 to 78.5 C

Valve lift/ temperature

10or more/90° C

Valve opening temperature

80 to 84 ° C

Valve lift/ temperature

10 or more/95 °C

Valve opening temperature

86to 90 ° C

Valve lift/ temperature

1 O or more/100°C

temperature

Up to second reassembly

Replace

Pressure cap, replace

10to15

Adjust

8DC

10to 15

8DC9: Option (for alternator only)

15 to 18

BDC9-T (For tension pulley only), 9-TC (For fan drive only), 8DC9: Option (For water pump only),

7to10

Radiator inspection pressure (air pressure)

98 kPa 1 { kgf/cm 2)

Pressure valve opening pressure

39 to 59 kPa (0.4 to 0.6 kgf/cm2}

V-belt deflection [with a push force of about 98 N (10 kgf)]

Remedy and remarks

6D2

Correct or replace

3.2 Tightening Torque Table location tightened

Screw size O.D. x pitch (mm)

Tightening torque N-m {kgf-m}

Spacer mounting bolt

8DC9-TL

M10x1,5

49 {5}

Water pump pulley mounting bolt

8DC9-TL

M10x1.5

44 {4,5 )

Water pump cover mounting bolt

8DC

M8x1.25

9.8 {1}

Fan drive flange mounting nut

Tension pulley mounting nut

14-8

6D2

M20 x 1.5

145 1 { 5)

8DC

M 27 x 1.5

245 2 { 5)

6D2

M16 x1.5

98 1 { 0)

COOLING - SPECIAL TOOL 4. SPECIAL TOOL Unit: mm Tool name

Unit: mm Too! name

Shape

Tip Clearance Spacer MC019470 Adjustment of clearance between fan and shroud (Only for type with a fan shroud secured to engine}

Shape

Water Pump Pulley Puller MH062411 <6D2> Removing water pump flange

Tr 18 X 4

85211A

PCD60

Impeller Puller MH062192 Removal of water pump impeller

85258A

85252C

Belt Tension Gauge MH062345 Measuring V-belt tension

Unit Seal Installer MH062195 <6D2> MH062199 <BDC> Water pump unit seal instal� lation

6D2

9.6±0.03

12.5

BDC

11.3±0.03

16.5

85094A

03612

14-9

COOLING - SERVICE PROCEDURE

5. SERVICE PROCEDURE 5.1 Removal and Installation of Fan Shroud

<8DC> (Only for type with a fan shroud secured to engine)

When the fan shroud is installed, adjust the clearance between the shroud and cooling fan. Hold the fan shroud in the Tip Clearance Spacer (spe cial tool), and move the fan shroud to make sure that the clearance between the shroud and cleaning fan is constant. After the adjustment, secure the fan shroud. 5.2 Removal and Installation of Cooling Fan <6D2>

00914A

<8DC9, 9-T, 9-TC>

1 Deformation

G) Fan shroud

2 Upper shroud stay Lower shroud stay RH Lower shroud bracket RH 5 Lower shroud stay LH Lower shroud bracket LH

For parts with an encircled number, refer to Installation Procedure that follows. 84599A

Installation Procedure NV .. Nominal Value Fan shroud

Fan . Clearance NV 4.5 to 8.5

C1011A

14-10

COOLING - SERVICE PROCEDURE <8DC9-TL>

5.3 Water Pump <602> 5.3.1 Removal and installation

D0915C B9019B

5.3.2 Disassembly and inspection

<6022. 22-T, 24-T>

Bend,rust, wearin

Damage,

surface over which

wear

bearing fits Rotation

Damage, wear 3

interference BD 11.8 NV 0.03 to 0.06

Reassembly no more than 2 times

interference

BD 25 NV 0.05 to 0.08

Reassembly no more

than 2 times Repair kit: Water pump repair kit

7 Corrosion, damage

13 Damage, wear

Cracks, wear in surface over which bearing fits,

BD .. Basic Diameter NV .. Nominal Value

water leak, rust

Disassembly sequence 1 Water pump pulley

® Flange

3 Oil seal 4 Snap ring

5 Snap ring 6 Water pump cover 7 Impeller

8 Water pump shaft 9 Bearing 10 Spacer 11 Bearing 12 Oil seal 13 Unit seal 14 Water pump case

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow.

D0044G

14-11

COOLING - SERVICE PROCEDURE

BO . Basic Diameter NV .. Nominal Value

<6D22-TC, 24-TC> Bend, rust, wear in surface over which bearing fits

Damage, wear

---------------

Rotation

Rotation9

·"·

Damage, wear 4. 3

��/: ttii:'\

�:..J!

| Interference 8D 11.8 / '" NV 0.03 to 0.06 / , I Reassembly no more than 2 times

Interference 8D 25 NV 0.05 to 0.08

Reassembly no more than 2 times

7 Corrosion, damage Cracks, wear in surface over which bearing fits, water leak, rust

Disassembly sequence 1 Water pump pulley

® Flange

3 Oil seal 4 Snap ring

5 Snap ring

6 Water pump cover 7 Impeller

8 Water pump shaft 9 Bearing 10 Spacer 11 Bearing 12 Oil seal 13 Unit seal 14 Water pump case

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow.

00044H

14-12

COOLING

Ill

SERVICE PROCEDURE

(3) Flange to water pump shaft tightening margin

Disassembly and Inspection Procedures

(1) Removal of flange

Water pump flange M10x1.5

Water Pump �---tt,==,:','\ Flange

Water Pump Pulley Puller MH062411 Water pump shaft

D00318 13480

Remove the water pump flange using the Water Pump Pulley Puller and Bolt (special tools). Slip an iron pipe or similar item over the handle to gain the necessary leverage. (2) Removal of impeller

If the tightening margin exceeds specification, replace the flange or water pump shaft. NOTE: Do not reassemble more than three times even when the specification is met.

(4) Impeller to water pump shaft tightening margin

impeller Puller MH062192

Water pump shaft 09192

D0031C

Using two threaded holes (MB x 1.25) in the impeller and the Water Pump Impeller Puller (special tool), pull off the impeller.

If the tightening margin exceeds specification, replace the impeller or water pump shaft. NOTE: Do not reassemble more than three times even when the specification is met.

14-13

COOLING - SERVICE PROCEDURE

5.3.3 Reassembly

• Apply �ngine I. 011 to lips. ii 12

______ I Apply engine oil to external cylinder.

i Installation load I 39.2 kN {4000 kgf}

\ é;

7installation ioad|

o \ C\

._—¢-—

Make sure that the impeller and water pump shaft are flush with each other where installed.

raveKe

Assembly sequence

'', �·�'

I Apply engine I oil to lips.

� -- - ----1

\'::'. -<'-1-1------>-__,,

1..1.._____Jj

After reassembly, rotate the water pump pulley by hand to confirm that the impeller does not interfere with the water pump cover and water pump case. When the impeller and flange are installed, confirm that they are not installed with a load of 4900 N {500 kgf}.

Reassembly Procedure <Installation of unit seal>

Unit Seal Installer MH062195

♦

irn

For parts with an encircled number, refer to Reassembly Procedure that follows. D0047D

To install the unit seal, use the Unit Seal Installer (spe cial tool) as shown and press-fit the unit seal until the installed dimensions shown are obtained.

Unit seal

9.6, .3

14-14

8➔11➔10➔9➔14➔7 t (jj)--'

~9§9594-93-21

NOTE:

127

Installation load 31 to 44 N {3.2 to 4.5 kgf} Installation speed 14 to 28 mm/sec.

09194

COOLING - SERVICE PROCEDURE

Ill

5.4 Water Pump <8DC> 5.4.1 Removal and installation <BDC9, 9-T, 9-TC>

(\ \ \ \ \

D0053A

<BDC9-TL>

\\ \

D0053C

14-15

COOLING - SERVICE PROCEDURE

5.4.2 Disassembly and inspection <8DC9, 9-T, 9-TC>

BO . Basic Diameter NV . Nominal Value

Cracks, wear in surface over which bearing fits, water leak, rust, plugged oil hole 13 Bend, rust, wear in surface over which bearing fits

Wear, damage

Rotation

'll�bt

Rotation

Corrosion, damage

Damage

Damage,

wear

Interference

BO 15.5

NV 0.04 to 0.06 Reassembly no more than 2 times

Interference

BO 35

NV a.as to a.as

Reassembly no more than 2 times

Disassembly sequence Water pump pulley ® Flange 3 Oil seal 4 Snap ring 5 Water pump cover ® Impeller (J) Water pump shaft

8 Bearing 9 Bearing 10 Spacer 11 Oil seal 12 Unit seal 13 Water pump case *14 Nozzle

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow. Do not remove the parts marked with * unless defects are evident.

00022F

14-16

COOLING - SERVICE PROCEDURE

<BDC9-TL>

Bend, rust, wear in surface over which bearing fits

Rotation Damage, wear

Basic Diameter BD NV . Nominal Value

I Interference 8D 15.5 "'NV 0.03 to 0.05

I Reassei:nbly no more , than 2 times

Interference 8D 28 NV 0.03 to 0.06

Reassembly no more than 2 times I Repair kit: i Water pump repair kit

Corrosion, damage

Damage, wear

Cracks, wear in surface over which bearing fits, water leak, rust

Disassembly sequence 1 Water pump pulley B <models with air conditioner only> 2 Water pump pulley A ® Flange 4 Oil seal 5 Snap ring 6 Hanger 7 Water pump cover @ Impeller

® Water pump shaft 10 Bearing 11 Bearing 12 Spacer 13 Oil seal 14 Unit seal 15 Water pump case *16 Nozzle

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow. Do not remove the parts marked with * unless defects are evident.

D0022D

14-17

SERVICE PROCEDURE

COOLING

(3) Impeller to water pump shaft tightening margin

Disassembly and Inspection Procedures

( 1) Removal of impeller Impeller

~ impeller Puller MH062192

Water pump shaft

D0031C B5098C

Using two threaded holes (MB x 1.25) in the impeller and the Water Pump Impeller Puller (special tool), pull off the impeller. (2) Flange to water pump shaft tightening margin Water pump flange

Water pump shaft

D0031K

If the tightening margin exceeds specification, replace the flange or water pump shaft. NOTE: Do not reassemble more than three times even when the specification is met.

14-18

If the tightening margin exceeds specification, replace the impeller or water pump shaft. NOTE: Do not reassemble more than three times even when the specification is met.

COOLING - SERVICE PROCEDURE 5.4.3 Reassembly <8DC9, 9-T, 9-TC>

[ Apply engine I i' oil to lips.

11 [ Apply engine

1 oil to lips.

I Installation load I 73.6 kN {7500 kgfl /2'

13 9.8 N-m {1 kgf-m} 73.6 KN {7500 ee|| [instaliationload load

ae 1=e Biot . Or

“plo SE rHoH 1

ys SI

Apply engine oil to external cylinder.

NOTE: 1. After reassembly, rotate the water pump pulley by hand to confirm that the impeller does not interfere with the water pu�p cover and water pump case. 2. When the impeller and flange are installed, confirm that they are not installed with a load of 8.82 kN {900 kgf}.

r Make sure that the impeller and| water pump shaft are flush with each other where installed.

5 Assembly sequence

14 14

11--,

7➔9➔ 10➔8➔ 13➔6➔5➔ (jj)____i 49332-3414

For parts with an encircled number, refer to Reassembly Procedure that follows.

B1022E

14-19

COOLING - SERVICE PROCEDURE

<8DC9-TL> I Apply engine oil to lips. ! 1

i Apply engine oil to : external cylinder. i Apply engine i oil to lips. I

——<—— |3

; Installation load ! 49.0 kN {5000 kgf)

Installation load 8 1i 49.0 kN {5000 kgf)

la | a EH

y—F ik

9.8N-m (1kgf-m}

/ , each other where installed.

44 N·rn {4.5 kgf.rn}

,�

16 I Apply engine oil to 1 external cylinder.

0-ring

Assembly sequence 137 9-+11-+12-+10➔15➔8➔7

®---' NOTE: 1. After reassembly, rotate the water pump pulley by hand to confirm that the impeller does not interfere with the water pump cover and water pump case. 2. When the impeller and flange are installed, confirm that they are not installed with a load of 5.88 kN {600 kgf}.

Reassembly Procedure

For parts with an encircled number,

refer to Reassembly Procedure that follows.

B1022C

To install the unit seal, use the Unit Seal Installer (spe cial tool) as shown and press-fit the unit seal until the installed dimensions shown are obtained.

Unit Seal Installer

MH062199

Installation load 40.0 to 57.0 N {4.05 to 5.85 kgf)

♦ >-------=� Installation speed 14 to 28 mm/sec.

84153B

14-20

365 433-92-1 18

COOLING - SERVICE PROCEDURE 5.5 Thermostat 5.5.1 Removal and installation

<6D2>

<8DC9-T, 9-TL: Option>

Thermostat

890218

<8DC9, 9-T, 9-TL>

D0308A

<8DC9-TC, 9-T: Option>

Thermostat

For thermostat installation instructions, refer to Installation Procedure that follows. D0306A

D0309A

14-21

Ill

COOLING - SERVICE PROCEDURE Install the thermostat with a jiggle valve at the location shown.

Installation Procedure

<8DC9, 9-T, 9-TL>

5.5.2 Inspection Thermostat

82°C: 8DC9, 9-T, 976.5°C: BDC: Option)

taal valve i ~'99!e

Thermostat marking For 76.5°C

For 82°C i For 88°C

Valve opening

80 to 84

86 to 90

10 or more/95

10 or more/100

74.5 to 78.5 10 or more/90

temperature ( ° C) Valve lift/

temperature °

lmml C)

Thermostat / (Valve opening temperature 88°C: 8DC9-TL 82 °C: 8DC9, 9-T 76.5°C: 8DC9: Option)

Valve lift Stirring rod

10229

Valve opening

Thermometer

temperature stamped

Thermostat holder

<8DC9-TC, 9-T: Option>

Thermostat (Valve opening temperature 82°C)

Thermostat

Jiggle valve

�-;--<-' Heat source

841518

Install the thermostat so that the jiggle valve is located at the top. <8DC9-T, 9-TL : Option> Jiggle valve

Thermostat (Valve opening temperature 82°C) 84584A

Install the thermostat so that the jiggle valve is located at the top. 14-22

---{7

D03018

Agitate water in the container with the stirrer to obtain uniform temperature. For the inspection, use the fol lowing procedures. (1) Slowly heal water to the thermostat valve opening temperature. The valve opening temperature is stamped on the thermostat. Its nominal value is the stamped tem perature ± 2 ° C. (2) Keep this condition for about five minutes and make sure that the valve is open. (3) Raise the temperature further to heat the water to the valve lift measuring temperature correspond ing to the valve opening temperature. (See the table above.) Keep this state for five minutes and measure the bypass valve lift. (4) Lower temperature down to 65° C or below and ensure that the valve is fully closed. If the thermostat is found defective in any of the above items, replace it with a new one.

Ill

COOLING - SERVICE PROCEDURE 5.6 Fan Drive 5.6.1 Disassembly and inspection

<6D2, 8DC9-TC>

Rotation

4 8

Rotation

6 2

1 Disassembly sequence 1 2 3 4

5 6 7 8

Fan pulley Flange Snap ring Fan drive shaft

Bearing Spacer Bearing Bearing case

B9023D

<8DC> 5 2

Rotation

7 Rotation

Disassembly sequence 1 2 3 4

Fan pulley Flange Snap ring Snap ring

5 Fan drive shaft 6 Bearing 7 Bearing 8 Bearing case D0917A

14-23

COOLING - SERVICE PROCEDURE

5.6.2 Reassembly

<8DC>

<602, 8DC9-TC>

To be packed with approx. 170 g of grease (multipurpose grease)

Sealing side to be faced outward. To be packed with grease I {multipurpose grease}

145 N {15 kgf-m}

245 N {25 kgf-m}

6 To be packed with approx. 86 g of grease (6D2) approx. 148 g of grease (8DC9-TC) (multipurpose grease)

Assembly sequence

8➔5➔3➔2➔ 1

8➔7➔3 2➔, z

5➔6➔4 J

4-..+7➔

89024D

14-24

Sealing side to be faced outward. To be packed with grease (multipurpose grease)

D0916A

COOLING - SERVICE PROCEDURE 5.7 Tension Pulley 5.7.1 Disassembly and inspection

<6D2>

<8DC9, 9-T>

%))@

il ��'to�

Rotation

Rotation B9023E

D0917B

<8DC9-T: Option, 9-TC >

2 I

'�

Rotation

Disassembly sequence

D0917C

1 Adjusting bolt

2 Tension pulley bracket 3 Snap ring 4 Tension pulley shaft 5 Tension pulley 6 Bearing

14-25

COOLING - SERVICE PROCEDURE 5.8 Inspection of Auto Cool Fan Coupling

5.7.2 Reassembly <6D2> Sealing side to be faced outward. To be packed with grease (multipurpose grease)

RC dana casera Ey

LL Large amount of silicone oil deposited Bearing rotating condition

= =G&toC CG =Cg ~~

Silicone oil

I To be packed with approx. 6 g of grease I (multipurpose grease) 89024E

deposited

<8DC9, 9-T>

Sealing side to be faced outward. To be packed with grease (multipurpose grease)

Fan axial runout or play, continuous high noise or unusually high noise of fan

NOTE: 1.

To be packed with approx. 15 g of grease (multipurpose grease)

2. 809168

<8DC9-T: Option, 9-TC> Sealing side to be faced outward. To be packed with grease (multipurpose grease)

6 3

1 Assembly sequence

$3321

14-26

To be packed with approx. 15 g of grease (multipurpose grease) D0916C

Since the autocool fan coupling is constructed as a single unit, the silicone oil does not require main tenance. The autocool fan coupling cannot be dismantled. tf defects become evident, the whole autocool fan coupling assembly must be replaced. B18558

COOLING - SERVICE PROCEDURE (1) Play in axial direction

5.9 Inspection of Radiator

( 1) Cleaning

01213A

When engine is cold, pinch the fan fitting portion and move it in axial direction. If the fan blade tip has exces sive runout or play is observed, replace the auto cool fan coupling, because the ball bearing is defective. (2) Cleaning bimetal

00402A

Remove mud, bugs, etc., if present on the radiator core front surface, with a copper wire. During the removal work, use care to prevent damage to the tubes. j Radiator inspection pressure I i (air pressure} [ 2 I NV 98 kPa {1 kgf/cm ) NV .. Nominal Value

00409A D1214C

If dirt or dust is adhering to the bimetal, remove it care fully with a wire brush or the like. NOTE: Use care not to apply excessive force to the bimetal.

(2) Attach hose to the inlet of the radiator and cap the outlet. Then, immerse the radiator in a waterfilled tank. Using a radiator cap tester, send compressed air at the specified inspection pressure through the hose to check for leaks. If leaks are evident, re-solder or replace the radia tor.

14-27

COOLING - SERVICE PROCEDURE

(31 Inspection of radiator cap

Pressure valve opening pressure NV 39 to 59 kPa {0.4 to 0.6 kgf/cm 2J

Radiator cap tester

Radiator cap NV .. Nominal Value

00420A

Check the spring tension and sealing condition of the pressure valve and vent valve. If defective, replace. Check the pressure valve opening pressure, using a radiator cap tester.

14-28

COOLING - SERVICE PROCEDURE

5.10 V-belt Tension

Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed with a force of approximately 98 N (10 kgf).

5.10.1 Inspection

<8DC9, 9-T, 9-TL>

10 to 158mm

Water pump

Water pump pulley

10to15mm

Alternator Alternator pulley

Crankshaft pulley Crankshaft

865258

E0198

Alternator

<BDC9: Option>

Tension pulley

Crankshaft

86525C <BDC9>

10 to 15 mm

<6D2>

Fan pulley

Tension pulley

10 to 15 mm

Alternator

Water pump Tension pulley £

<BDC9-T, 9-TC>

Crankshaft

865278

Alternator pulley

7 to 10 mm

Crankshaft pulley

E0198

Water pump pulley Alternator

pulley

NOTE: Crankshaft pulley E0198

A slack belt can be a cause of overheating and

An excessively tight belt may result in damaged bearings and belts.

undercharge.

14-29

Ill

COOLING - SERVICE PROCEDURE <BDC>

5.10.2 Adjustment

( 1) Alternator

<6D2>

( 1) Alternator Mounting bolt

Mounting bolt � Mounting bolt

E0165

Loosen the upper and lower mounting bolts of the alternator. Then, fit a wrench handle and move the alternator as necessary. NOTE: When moving the alternator, use care not to damage the stator coil between the front and rear brackets, and the through bolt.

E0199

(2) Turnbuckle type

(2) Tension pulley Adjusting bolt

Mounting nut Turnbackle

E0166

Loosen the idler puller mounting nut, then turn the adjusting bolt to adjust the belt tension. (Turning the adjusting bolt moves the idler pulley.)

14-30

E0200

Ill

COOLING - SERVICE PROCEDURE •

<8DC9: Option>

,n,r,..,v

Using Belt Tension Gauge (special tool) 0-ring A

. Mounting nut /

Belt Tension Gauge MH062345

Turnbackle

Lock nut

Depression load scale

0-ring B Deflection gauge 03613

B5880A

(a) Slightly loosen the alternator mounting bolt. (b) Loosen the lock nut, then turn the turnbuckle as necessary. A more tension is given if the rod is longer. (c) After the adjustment, hold the turnbuckle in posi tion with a spanner to prevent it from turning while tightening the lock nut. (3) Tension pulley

Set 0-ring A at the 98 N {10 kg) mark on the depres sion load scale. (2) Set 0-ring B at the V-belt's specified nominal deflection value (max.) on the lower scale.

( 1)

Top of gauge

Tension pulley mounting boits

03614

Adjusting bolt

E0202

(3) Apply the Belt Tension Gauge (special tool) to the V-belt's tension measurement point. Depress the top of the gauge until 0-ring A reaches the flange.

Loosen the tension pulley mounting bolts, then turn the adjusting bolt to move the tension pulley as required.

14-31

Ill

COOLING - SERVICE PROCEDURE 3. If much rust is found, water may leak from the ra diator after cleaning. Check carefully each section of the radiator after cleaning. 4. If the coolant temperature is still very high, never attempt to remove the pressure cap.

) Deflection /

V-belt

Coolant in use

03615

(4) Measure the amount of deflection in the V-belt. Adjust the V-belt's tension if the amount of deflec tion is out of specification. 5.11 Cleaning of Cooling System

Cleaning interval

FUSO Diesel Long Life Coolant

Every 2 years

Anti-rust, anti-freeze

At time of coolant replacement of every 6 months or before and after use of anti-freeze

(1) Washing with water

JOmin. phatFe

Prta, 80426A

80429A

If the radiator is used for a long time, rust, scale, mud, etc. are deposited inside, resulting in overheat. Clean the cooling system with city water by using the follow ing procedures.

NOTE: 1. 2.

Use a cleaning solution if the radiator is seriously obstructed or coolant is seriously contaminated. When the cooling system is cleaned or washed with water, make sure that the coolant tempera ture is maintained at 90°C; the coolant tempera ture below the valve opening temperature closes the thermostat, resulting in poor coolant circula tion.

14-32

(a) Discharge coolant from the radiator, crankcase, and reserve tank. After draining the system, fill it with tap water (pre (b) ferably hot water) and, with the water temperature kept at around 90° C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until the drained water runs clear. (2) Washing with cleaning solution (When radiator clogging or coolant contamination are serious) (a) Discharge coolant from the radiator, crankcase, and reserve tank.

COOLING - SERVICE PROCEDURE

Ill

(d) After discharging the solution, fill the system with

tap water (preferably hot water) and with the water temperature kept at around 90 ° C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until drained water runs clear.

oCJ D1319A

(b) Ready a mixture of FUSO Radiator Cleaner (Radi pet-7 or equivalent: 5 to 10%) and cooling water. Pour the specified amount of mixture into the radiator.

NOTE: 1. If the inside is heavily stained, washing with tap water before charging radiator detergent will be effective. 2. Running the engine at idle for longer than an hour with detergent left in engine could cause damage to the cooling system. Be sure to observe specified cleaning time. 3. After cleaning with detergent, fill with coolant as soon as possible. (3) Cooling water (a) When Long Life Coolant is used:

80428A

D1322B

(c) Run the engine to raise the solution temperature to around 90°C. Let the engine run at idle for another 30 minutes, then remove the solution.

In order to prevent freezing of cooling water and corro sion of the cooling system, add FUSO Diesel Long Life Coolant at a ratio of 30 to 60% of quantity of water. Replace the coolant once every two years to retain its anti-freeze and anti-rust effects. For usage of Long Life Coolant, refer to its instruction manual. NOTE: 1. Be sure to use FUSO Diesel Long Life Coolant. 2. Never mix it with DIAOUEEN Long Life Coolant or other commercial long life coolants, anti-freezes or anti-rusts.

80426A

14-33

COOLING

SERVICE PROCEDURE

(b) When anti-rust and anti-freeze are used:

5.12 Gas Leak Test

Air or exhaust gas leaked into the coolant promotes corrosion and rust formation. Perform the following check and, if defects are found, take remedial action. (1) Inspection

01310A

1) After cleaning, add Fuso Radiator Anti-rust (Radi pet-98 or equivalent) at a ratio of 5% to the coolant quantity to prevent corrosion in summer. (a) Remove the pressure cap from the radiator. (b) Run the engine to raise the coolant temperature up to around 90'C. (c) If bubbles continue forming in the coolant under the condition, it indicates that air or exhaust gas has leaked into the coolant. (2) Causes

D1322A

2) In winter, add the Fuso Anti-freeze or equivalent at a ratio of 30 to 60% to prevent freezing. For usage of anti-rust and anti-freeze, see respec tive instruction manuals. NOTE: When the anti-rust or anti-freeze is used, never use with other long life coolants.

14-34

(a) If air is trapped in coolant, check cylinder head bolts, water pump mounting bolts, and hose and its connections for looseness. Check also hoses for damage. (b) If the exhaust gas has leaked into coolant, check the cylinder head gasket or nozzle tube end stake for damage. Check also cylinder head for cracks. 5.13 Bleeding the Cooling System

( 1) With the pressure cap removed from the radiator, let the engine run at idle with coolant temperature of about 90'C to bleed the system completely. (2) After the system has been bled of air, add coolant to radiator and reserve tank as required.

COOLING - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Overheat

Probable cause

Defective V-belt • Incorrect tension • Broken belt

Remedy

Adjust Replace

Clogged cooling system

Clean

Defective thermostat

Replace

Defective water pump • Loose shaft to impeller engagement

Replace

• Loose shaft to flange engagement

Replace

• Improper clearance between impeller and water pump case

Correct

• Damaged impeller

Replace

Clogged radiator fins

Clean

Defective autocool fan coupling .::8DC9-TL> • Damaged bimetal

Clean

• Defective autocool fan coupling proper

Replace

Damaged cooling fan

Replace

Low coolant level

Replenish

Overcool

Defective thermostat

Quick loss

Defective radiator hose • Loose hose connection

Correct

• Worn or damaged hose

Replace

Defective radiator • Radiator proper not tight

Correct or replace

• Pressure cap not tight

Replace

of coolant

Replace

• Clogged birnetal

Ref. group

Replace

: Defective water pump • Defective unit seal

Replace

• Defective oil sea!

Replace

• Pump mounted improperly

Correct

Defective oil cooler

Replace

Thermostat case or cover mounted improperly

Correct

Defective heater hose ' • Loose hose connection

Correct

• Worn or damaged hose

Replace

Defective cylinder head gasket

Replace

Group 12

Group 11

14-35

INTAKE AND EXHAUST CONTENTS 1. GENERAL . ... . .. . . . . . . . .. . . .... . . . .. . .. .. . . . 2 2. SPECIFICATIONS . . . . ... .... . . . . . . . . ........ 7 3. SERVICE STANDARDS ... . . . . . . .... ... . . . .. 8 Service Standards Table . . . ...... ........ 8 3.1 3.2 lightening Torque Table . .. .. . .. . ... . ... . 9 4. SPECIAL TOOLS . . .. . . . . .. . .. . ..... . ... . . .. . 10 5. SERVICE PROCEDURE . . . . . .. ... . . . ... . . ... 11 5.1 Removal and Installation of Intake System ................................... 11 5.2 Removal and Installation of Exhaust System ................................... 19 Air Cleaner ..... ..... . . . .. . .. . . . . .. . . . . .. . 24 5.3

5.3.1 Disassembly and reassembly ... .. . . . . 24 5.3.2 Inspection and cleaning .. . . .. . . . .... . 25 Turbocharger . ... . . . .. . . . . . .. . . .. .. ...... . 26 5.4 5.4.1 TD0S type turbocharger . . . . ... . ... . .. 26 4LF type turbocharger . .. .. .. .. .. .. ... 36 5.4.2 3LM type turbocharger ...... . .. .. .... 42 5.4.3 lntercooler . . . .. . . . . . .. . ... . . . .... . .. . . .. . 47 5.5 Disassembly and reassembly . . . .. .. . . 47 5.5.1 A ir pressure test .. .. . . . . . . . . . .... . . .. . 48 5.5.2 5.6 Bleeding of Aftercooler Coolant Circuit .................................... 49 6. TRO UBLESHOOTING .. .. .. . . .. .. . .. .. ...... 50

15-1

INTAKE AND EXHAUST - GENERAL

1. GENERAL ( 1) Air cleaner <Single element type>

80618A

Outside air

The cyclone type air cleaner uses a filter paper type ele ment. Because of plastic coating and heat treatment, the ele ment is highly resistant to water and oil. Even if it is contaminated, its functions can be regained by clean ing. The intake air is given a spin by the vanes for centrifu gal separation of large particles of dust and dirt. Small particles of dust and dirt are filtered out by the filter paper element so that a clean air is drawn into the engine. The standard air cleaner is a single element type, and the double element type can be effective for operation safety under unusual conditions with a lot of dust and dirt. (2)

Precleaner

To engine

Guide vane 80619A

Outside air Inner element

To engine B0608C

Outside air

To engine

Guide vane

Vacuator valve 80620A

15-2

Outside air To air cleaner

80610A

The precleaner, coupled with the air cleaner, collects relatively large particles of dust contained in the air drawn in by engine. The air entering the precleaner is made to spin by the guide vanes of the precleaner to centrifugally separate large particles of dust before the air is drawn into the air cleaner. These dusts are collected in the precleaner.

INTAKE AND EXHAUST - GENERAL

body, indicating that it is time to clean or replace the element. After the element has been cleaned or replaced, depress the reset button on the top, and the signal will return to its original position.

13) Vacuator valve

Dust and din

Warning lamp

Starter switch Electrical .-----�,-..,__, dust indicator Battery

..L -=-

Valve to be opened by repulsion of rubber B0604B

Centrifuged dust collects at the bottom of the air cleaner. A vacuator valve made of rubber is mounted to the bottom, which pulsates to automatically dis charges dust and water when the engine speed is below about 800 rpm. Namely when the engine is run ning at a speed higher than 800 rpm, the negative pres sure in the air cleaner keeps this valve closed but when the negative pressure drops as the engine speed decreases, the valve is made to open by rubber action, thereby discharging dust and water.

B1824A

With the electric dust indicator, its electric contact points close when the vacuum reaches 6.2 kPa {635 mmH20}. This turns on the warning lamp, warning the driver that it is time to clean or replace the element.

(4) Dust indicator

Reset button Indicator body

Transparent section

•

Negative pressure

Spring

B0605B

The dust indicator is mounted near the outlet of the air cleaner. The dust indicator operates on the negative pressure of the air drawn into the engine performing the function of indicating the time to clean or replace the element. When the element is plugged with dust and dirt, the suction resistance increases. When this vacuum reaches 6.2 kPa {635 mmH20}, the signal (red) is pulled down against the spring tension. The signal (red) is then visible through the transparent section in the 15-3

INTAKE AND EXHAUST - GENERAL (5) Turbocharger <TD08 type> Compressor wheel

Turbine wheel

Bearing housing

Compressor cover

Exhaust outlet

Shaft-andturbine-wheel

Air inlet Back plate

Exhaust manifold

Inlet manifold

Turbine housing

Compressor wheel

<3LM type>

B1213A Bearing housing Compressor cover Compressor wheel

Back plate

Cylinder

B1215A

The turbocharger utilizes the energy of the engine exhaust gas to feed more air into the engine, thereby offering advantages such as boosted engine power output, thrifter fuel consumption, and reduced engine noise.

The exhaust gases discharged from the cylinder of the engine are led through the exhaust manifold into the turbocharger and are accelerated in the turbine hous ing and are blown against the turbine wheel. Accordingly, the turbine is made to rotate at a speed of scores of thousands of revolutions a minute, and turns the compressor wheel mounted on the same shaft as the turbine wheel. By rotation of the compressor wheel, a larger amount of air than without supercharg ing is forced into the cylinder of the engine, so a corre spondingly larger amount of fuel can be burnt. This increases the effective pressure during combustion (the pressure forcing the piston down) and thus increases the output.

I Shaft-and turbine-wheel B9026B Turbine housing

Compressor 1wheel

Bearing housing

Thrust bearing

81202A

15-4

INTAKE AND EXHAUST - GENERAL The turbocharger can be divided into three basic sec tions: the turbine wheel that is driven by the exhaust gases, the compressor wheel which forces intake air into cylinders and the bearing housing which supports the shaft of these wheels. The shaft connecting the turbine wheel with the com pressor wheel is supported in floating type bearings,

which absorb vibrations during high speed operation that are caused by slight imbalance of the shaft. The shaft axial load is borne by the thrust bearing. The bearing housing has its inside cooled and lubri cated by engine oil to prevent seizure and other troubles of the sliding parts. (Refer to Group 12 Lubrication.)

16) Aftercooler <8DC9-TC>

<6D22-TC, 24-TC>

Turbocharger From air

Plate-and-corrugated-fin type water-cooling heat exchanger

To outlet water pipe

Plate-and-corrugated-fin type water-cooling heat exchanger \ To muffler (exhaust)

From air cleaner (intake)

To thermostat

{coolant

From oii cooler

{coolant}

From water pump radiator

80627A

The intake air cooling system, incorporating a plate and-corrugated-fin type heat exchanger, transfers heat from the intake air to the engine coolant. It has the same function as the intercooler on automobile engines. The system cools off the intake air, whose temperature has gone high due to compression by the turbochar-

B0627B

ger, through heat exchanging with the engine coolant. This allows the density of intake air to be increased, admitting more air into the engine, which in turn increases the fuel injection rate and improves the com bustion efficiency. Thus the fuel economy and output are improved and the exhaust gases are reduced to a minimum.

15-5

INTAKE AND EXHAUST - GENERAL

<8DC9-TL>

From left air cleaner (intake)

Turbocharger lntercooi0r To muffler {exhaust) 841278

The intercooler is an air-to-air tube-and-corrugated-fin type heat exchanger installed at the front of the radia tor. The temperature of the intake air becomes very high when it is compressed by the turbocharger. This air cooled at the intercoolerthrough heat exchanging with

15-6

the outside air to increase its density before it is sent to the cylinders. This improves combustion efficiency, which in turn results in a greater fuel economy and power output with a reduced amount of harmfu I exhaust gases.

INTAKE AND EXHAUST - SPECIFICATIONS 2. SPECIFICATIONS -----__ Model I 6D22, I Item � BDCB, 8DC9 i j I Type i Air cleaner element I Supercharger

Type Model

i I

Aftercooler

Type

6D22-T

6D22-TC

6D24-T

Model

8DC9-T

8DC9-TC

8DC9-TL

Cyclone type paper element (Nippon Donaldoson Ltd. products) Turbocharger

Mitsubishi TDOB <Option> Mitsubishi i Schwitzer I 3LM or 4LF

Mitsubishi TDOB <Standard> Mitsubishi TDOBH <Option>

Mitsubishi TDOBH

Plate and corrugated fin type,

ing (built in the inlet manifold, cooled by the engine coolant)

Mitsubishi TD08

Plate and corrugated fin type,

water-cool-

6D24-TC

water-coo!-

ing (built in the inlet manifold, cooled by the engine coolant)

Plate and 1, Tube-andcorrugated i corrugatedfin type, fin type, air-cooling water-cooling (built in the inlet manifold, cooled by the engine coolant) C70

15-7

INTAKE AND EXHAUST - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item Dust indicator operating resistance

Shaft runout O.D. I.D. Length

Turbocharger 13LMI

Piston ring end gap in insert

0.05 to 0.25

Shaft-and-turbine-wheel to turbine housing clearance

0.39 to 1.0

Compressor wheel to compressor cover clearance

0.08 to 0.28

Shaft-and-turbine-wheel axial play

0.075 to 0.155

Shaft-and-turbine-wheel to turbine back plate clearance

0.48 to 0.92

! Shaft runout

Piston ring end gap in insert

Turbocharger l4LFI

0.05 to 0.13 0.74 to 1.55

Bearing housing

Shaft-and- turbine-wheel

Bearing inserting partion I.D.

Replace

20.382

Replace

Replace Replace Replace

11.18

Replace

i I

22.268

Piston ring groove width

1.68

Bearing journal O.D.

14.254

Replace

22.5

Replace

19.06

Piston ring groove width in flinger sleeve

Replace Replace Replace Replace Replace

Replace

0.015 3.3

Replace

Shaft-and-turbine-wheel to turbine back plate clearance

0.43 to 1.05

Compressor cover to compressor wheel diametric clearance

0.15

Shaft-and-turbine-wheel to turbine housing diametric clearance

0.15

Replace

0.026 to 0.102

Replace

Shaft-and-turbine-wheel to turbine housing clearance Shaft-and-turbine-wheel axial play

Piston ring end gap in insert

15-8

Replace

0.015

Piston ring inserting portion LD.

Shaft runout

Aftercooler

11.996

0.015

0.53 to 1.04

Shaft-and-turbine-wheel to turbine back plate clearance

Replace Replace

Shaft-and-turbine-wheel axial play

Remedy and remarks

20.506

0.015 to 0.18

Shaft-and-turbine-wheel to turbine housing clearance

11.94

i Bearing journal O.D.

12.042

Bearing inserting portion 1.0. Shaft-and-turbine-wheel

6.2 ± 0.6 kPa (635 ± 58 mmH2O}

Turbocharger I LD. of section in bearing housing receiving bearing ITD08, TD08Hl Bearing journal O.D. f Shaft-and-turbine-wheel

Bearing

Limit

Nominal value (Basic diameter in { l)

Core assembly air-tightness

6D22-TC, 24-TC

Element assembly air-tightness

8DC9-TC

lntercooler air-tightness

8DC9-TL

I I

0.84 to 1.75 0.08 to 0.152

No leak is allowed with a 195 kPa {2 kgf/cm2} air pressure

No leak is allowed with a 390 | kPa {4 kgf/cm } air pressure 2

No leak is allowed with a 145 kPa {1.5 kgf/cm2} air pressure

Replace Replace Replace Replace

Replace

INTAKE AND EXHAUST - SERVICE STANDARDS

3.2 Tightening Torque Table Location tightened

Inlet manifold mounting bolt <except 6022-TC, 24-TC> Exhaust manifold mounting bolt Turbocharger mounting nut Turbocharger ITDOB. TD08H}

Mounting nut Lock nut Coupling mounting nut Shaft-and-turbine-wheel mounting lock nut

Turbocharger l4LFI

V-clamp mounting nut

Turbocharger l3LMI

Shaft-and-turbine-wheel mounting lock nut

Compressor cover mounting cap screw Turbine housing mounting cap screw

I I

I i

Screw size

Tightening torque N-m {kgf.m}

M10x 1.5

35 (3.6)

M10x1.25

41 (4.2)

M10x 1.25

26 (2.7)

M10x 1.25

35 {3.6)

5.9 (0.6)

O.D. x pitch (mm)

20 (2) 11 {1.1)

27 (2.8)

17 to 20 {1.73 to 2.07)

6.9 {0.7)

17{1.7}

Remarks

Apply MOLYKOTE grease to threads. Apply MOLYKOTE grease to threads.

15-9

INTAKE AND EXHAUST - SPECIAL TOOLS

4. SPECIAL TOOLS Unit: mm Tool name

Shape

Socket <602> MH061242 For exhaust manifold attach ing nut

Width across flats 14 85341A

15-10

INTAKE AND EXHAUST - SERVICE PROCEDURE 5. SERVICE PROCEDURE 5.1 Removal and Installation of Intake System . <6D22>

� � - Install with the arrow mark facing toward the inlet manifold.

4 35N-m {3.6 kgf-m}

2 1 Ground plate 2 Inlet pipe 3 Air heater 4 Inlet manifold NOTE:

1. 2. 3.

Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.

84556A

15-11

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D22-T, 24-T> 3

4 5

5 35N-m {3.6 kgf-m)

" ,..

��-� gdown.

�

1 Ground plate 2 Inlet pipe 3 Rubber hose 4 Air heater 5 Inlet manifold NOTE:

1. 2. 3.

Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16. 84557A

15-12

INTAKE AND EXHAUST - SERVICE PROCEDURE <6D22-TC, 24-TC: Standard>

Install with the arrow mark facing toward the cylinder head.

5 I

�/ 1 Inlet pipe 2 Air escape pipe 3 Water inlet pipe 4 Water return pipe

6 Ground plate 7 Heater harness 8 Air heater 9 Rubber hose

5 Air cooler assembly NOTE: 1. Remove harnesses before disassembly. 2. Ensure that the arrow points in the correct direction when installing the air heater. 3. For details of air heater inspections, refer to Group 16. B4558C

15-13

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D22-TC, 24-TC: Low profile type>

Install with the arrow mark facing toward the cylinder head.

1 Inlet pipe 2 Rubber hose 3 Water inlet pipe 4 Water return pipe

5 Air cooler assembly 6 Ground plate 7 Heater harness 8 Air heater

NOTE: Remove harnesses before disassembly. 1. Ensure that the arrow points in the correct direction when installing the air heater. 2. For details of air heater inspections, refer to Group 16. 3.

B4558D

15-14

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9> 5

2 1 6

8 35 N-rn {3.6 kgf-rn)

Up mark

·��

----

� Arrow facing down.

� 1 2 3 4

Inlet cover Upper manifold LH Rubber hose Inlet coupler

5 Upper manifold RH 6 Air heater 7 Inlet manifold cover 8 Inlet manifold

NOTE: 1. Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater 2. and inlet manifold gasket. For details of air heater inspections, refer to Group 16. 3. 84559A

15-15

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9-T>

& Damage, cracks

7 ---5 Damage, deterioration

Damage, cracks 1

ee we% 10

~\m

Damage,

deterioration cracks

10 MEF

11 Damage, cracks

35 N.m

{3.6 kgf-m}

p-<

1 Upper manifold 2 Rubber hose

3 Air heater 4 Rubber hose 5 Rubber hose 6 Inlet coupler

�--

�

Arrow facing down.

7 Oil pipe 8 Inlet coupler 9 Coupler bracket 10 Inlet manifold cover 11 Inlet manifold

NOTE: 1. Remove harnesses before disassembly. 2. Ensure that the arrow points in the correct direction when installing the air heater and inlet manifold gasket. 3. For details of air heater inspections, refer to Group 16.

84884D

15-16

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9-TC> Damage, deterioration

Damage, cracks

Damage, cracks&---

7 13 Damage, cracks14

ND UP mark facing up.

�

1 Air pipe

Rubber hose Bracket Water inlet pipe 4 5 Water outlet pipe

6 Aftercooler assembly 7 Air heater 8 Air inlet coupler 9 Rubber hose 10 Oil pipe

Arrow facing down.

11 Inlet coupler 12 Coupler bracket 13 Inlet manifold cover 14 Inlet manifold

NOTE: Remove harnesses before disassembly. 1. 2. Ensure that the arrow points in the correct direction when installing the air heater and inlet manifold gasket. For details of air heater inspections, refer to Group 16. 3.

B4885B

15-17

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9-TL>

Damage,

Damage, cracks

deterioration

4 Damage, deterioration

Damage, deterioration 5

2 Damage, —

deterioration

UP mark facing up.

Arrow facing down.

1 Manifold assembly

Rubber hose 3 Upper manifold RH 4 Rubber hose 5 Air inlet hose

6 Upper manifold LH 7 Air outlet hose 8 Air heater 9 Inlet manifold 10 lntercooler

NOTE: Remove harnesses before disassembly. 1. Ensure that the arrow points in the correct direction when installing the air heater 2. and inlet manifold gasket. 3. For details of air heater inspections, refer to Group 16. B5674G

15-18

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.2 Removal and Installation of Exhaust System <6D22>

2 41 N-m {4.2 kgf,m}

Exhaust Seal rings manifold

"TOP" mark Install with stamped "TOP" mark facing manifold

Expansion rings

Seal ring Install the seal rings such that their gaps are staggered by 1so·. Install the expansion rings such that their gaps are opposite the seal ring gaps.

1 Heat insulator 2 Exhaust manifold 3 Seal ring

4 Expansion ring 5 Center exhaust manifold

84560A

Socket, MH061242 (special tool) is available to facili tate fitting of the exhaust manifold mounting nuts. Use

of this tool is recommended. 15-19

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D22-T, 22-TC, 24-T, 24-TC>

4 35 N-m {3.6 kgf-m}

� --e

26 N-m {2.7 kgf-m)

L 5 8

7 5

oc -

"TOP" mark

Install with stamped

"TOP" mark facing

manifold

"''

(��

---

ring

Seal rings mam.1o Id

Cl I

Expansion rings

Gap

Seal ring

Install the seal rings such that their gaps are staggered by 1 so·. Install the expansion rings such that their gaps are opposite the seal ring gaps.

1 2 3 4

Heat insulator Oil pipe Oil return pipe Turbocharger

5 Exhaust manifold 6 Seal ring 7 Expansion ring 8 Center exhaust manifold B4561A

Socket, MH061242 {special tool) is available to facili tate fitting of the exhaust manifold mounting nuts. Use of this tool is recommended.

15-20

NOTE: Some types of turbocharger fit onto the top of the exhaust manifold, while other types fit onto the bot• tom of the exhaust manifold. Maintenance procedures for both types are the same.

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9>

Seal rings Manifold joint/

Expansion ring

Exhaust manifold side

Seal ring

Expansion ring

Install the seal rings such that their gaps are staggered by 1so·. Install the expansion rings such that their angles are away from the seal ring gaps.

1 Exhaust manifold 2 Manifold joint 3 Seal ring

4 Expansion ring 5 Exhaust manifold cover

84562A

15-21

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9-T, 9-TC>

Damage, cracks

Deformation

Damage, cracks

3 35N-m

✓ {3.6 kgf-ml

'�;? -26N-m

41 N-m {4.2 kgf-m)

S�5 Deformation

7 Damage, cracks

Cylinder head side

Expansion

Exhaust manifold

side

Damage,

cracks

11 6I

o"o

Deformation

Seal rings ��nifold A JOln! /I

��

Gap

I I

Seal ring

Expansion ring

Install the seal rings such that their gaps are staggered by 180". Install the expansion rings such that their angles are away from the seal ring gaps.

1 Oil pipe 2 Oil return pipe 3 Turbocharger cover 4 Turbocharger

5 Insulator 6 Exhaust manifold cover 7 Exhaust manifold, rear

8 Exhaust manifold adapter 9 Manifold joint 10 Center exhaust manifold 11 Seal ring 12 Expansion ring 13 Exhaust manifold, front 14 Exhaust manifold cover

84131F

15-22

INTAKE AND EXHAUST - SERVICE PROCEDURE

<8DC9-Tl>

35 N-m {3.6 kgf-m} 26 N-m {2.7 kgf-m}

Deformation oD

Cylinder head side

Damage,

�cks

Exhaust manifold side

Seal rings

Manifold joint

Expansion ring

Damage, cracks

Deformation

Gap

Seal ring

Expansion ring

• Install the seal rings such that their gaps are staggered by 1so·. • Install the expansion rings such that their angles are away from the seal ring gaps.

1 Oil pipe 2 Oil return pipe 3 Turbocharger cover 4 Turbocharger

5 Insulator

6 Exhaust manifold cover

7 Exhaust manifold, rear

8 Exhaust manifold adapter 9 Manifold joint 10 Center exhaust manifold 11 Seal ring 12 Expansion ring 13 Exhaust manifold, front 14 Exhaust manifold cover B4131D

15-23

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.3 Air Cleaner 5.3.1 Disassembly and reassembly <Single element type>

Dust cup

Air cleaner body

:;-,...

'Installation direction mark installation direction mark

� Dust indicator

O-ring

Dust indicator

Air cleaner body Element Air cleaner body

84563A

9ust cup

Dust indicator

Aircleaner body

Installation y i ~ direction mark

inner

Qiement

Dustcup Wing nut

Vacuator vaive Outer element1

cleaner

Dust indicator

body:

Wing nut

Installation

direction mark

Clamp element

Gasket

Outer element Inner . Air cleaner body Dust md1cato

,� \

ele ment

�t:t

i ' ' i1· 1 \ �

.:::!!::,;; � Wing nut

� ]!::_:::.;-: 0

.\ nut Wmg .�

.;,:., ·:-

i Cover

Wing nut

e-Vacuator valve NOTE:

Remove the inner element only for replacement.

15-24

84564A

INTAKE AND EXHAUST 5.3.2 Inspection and cleaning

SERVICE PROCEDURE

(4) Clean the inside of the air cleaner body and dust cup, and discharge the deposited dust.

(1) When there is dry dust on the element

(5) Dust indicator Reset button

I :

1 Operating resistance , NV 6.2 ± 0.6 kPa {635 ± 58 mmH,O} \

Window {red signal) C7207A

NV .. Nominal Value

C7210B

If there is dry dust on the element, clean the dust by blowing 685 kPa {7 kgf/cm2J or lower compressed air against the element. Blow the compressed air from inside the element up and down along the frills of the filter paper and clean the whole element evenly.

Start the engine and close the inlet port of air cleaner gradually to increase negative pressure. If the red sig nal is displayed at the dust indicator, or warning lamp lights for the electric type dust indicator, the dust indi cator is normal.

NOTE: 1. Do not strike the element or strike it against a hard object to loosen the dust. 2. Do not clean, but replace, the inner element.

NOTE: Perform this inspection after cleaning or replacement of the air cleaner element if the element is heavily clogged.

(2) When there is moist dust on the element If the element is contaminated with moist soot, replace it regardless of the specified replacement frequency. (3) Inspection of element

C7209A

After the element has been cleaned, put an electric lamp inside the element to check for damage and pin hoills. If there are thin portions in the filter paper, replace the element. If the packing on the top surface of the element is broken, replace the element.

15-25

INTAKE AND EXHAUST - SERVICE PROCEDURE

5.4 Turbocharger 5.4.1 TD08, TDOSH type turbocharger

11) Disassembly

Wear in surface receiving thrust

Wear

16 17

Blade bend and damage, corrosion, marks of Interference on back surface 4 Interference with compressor wheel, cracks, damege

y--..._

Interference with turbine wheel, cracks due to overheat, pitching, deformation

Blade bend and damage, corrosion, marks of interference on back sur face, damage on piston ring groove, damage on bearing journal

Interference with turbine wheel, damage

Bearing hole surface roughness, damage, gas corrosion, clogged oil hole, turbine side flange deformation

Disassembly sequence 1

Coupling assembly ® Turbine housing 3 Snap ring @ Compressor cover @ Compressor wheel 6 Snap ring (J) Insert 8 Piston ring 9 Oil deflector

10 11

Thrust sleeve Thrust bearing 12 Thrust ring 13 Shaft-and-turbine-wheel 14 Piston ring 15 Turbine back plate 16 Bearing 17 Snap ring 18 Bearing housing

For parts with an encircled number, refer to Disassembly Procedure that follows.

C89658

15-26

INTAKE AND EXHAUST - SERVICE PROCEDURE (cl Removal of compressor cover

Disassembly Procedure Alignment mark

Snap ring

Compressor cover

Turbine housing Compressor cover

Bearing housing

B2819D

C8982C

(al Before disassembling the turbocharger, make alignment marks on the compressor cover, bearing housing, and turbine housing so that they can be properly reassembled.

Remove the compressor cover by tapping it with a plastic hammer or similar tool which will not damage the cover, with the snap ring loosened.

(bl Removal of turbine housing

NOTE: Use care not to damage the compressor wheel during the removal procedure.

(d) Removal of compressor wheel Coupling assembly

Bearing housing

Turbine housing

Turbine housing 839468

To remove the turbine housing, remove the coupling assembly and tap the housing with a plastic hammer or similar tool to prevent damage to it. NOTE: The turbine wheel blades are easy to bend. Use care not to damage them.

82820C

1) Clamp the turbine housing in a vise and fit the bear ing housing into the turbine housing with the tur bine wheel side of the bearing housing facing the turbine housing.

15-27

INTAKE AND EXHAUST - SERVICE PROCEDURE (e) Removal of insert

Snap ring

Shaft-and-turbine-wheel boss C8983C

C8978B

2) While holding the shaft-and-turbine-wheel boss, remove the lock nut that secures the compressor wheel.

Snap off the snap ring that secures the insert onto the bearing housing.

NOTE: Retain the snap ring by hand to prevent it from spring ing out when slipping off the snap ring pliers.

C8984C

3) Slowly slide off the compressor wheel upward. C89858

15-28

Fit the tip of a screwdriver into the portion of the insert shown and carefully remove it from the bear ing housing.

INTAKE AND EXHAUST - SERVICE PROCEDURE (2) Cleaning and inspection

I Piston ring end gap ) NV 0.05 to 0.25

Clean

Bearing

0.0. L

20.382

Clean

Bearing journal 0.0. L 11.996

Shaft runout (total indi cator reading) L 0.015

Clean

I Bearing inserting \ ,. I portion LO. L 20.506 I

NV .. Nominal Value L.. . Limit

NOTE: Before cleaning, visually inspect each component to find any scorching or rubbing that will not be apparent after cleaning. For details, refer to item (1) of section 5.4.1.

C8988B

(a) Cleaning

Immerse all parts in a non-flammable solvent

(Daido Kagaku Kogyo's Dai Cleaner T-30 or equiva lent) to clean oily contamination.

13628

15-29

INTAKE AND EXHAUST - SERVICE PROCEDURE (b) Inspection of bearing housing

C8990A C8993A

Blow clean compressed air against the entire inter nal and external surfaces.

Measure I.D. of the area receiving the bearing. Replace the bearing housing if the measurement exceeds the limit. (c) Inspection of bearing

Measuring direction

Measuring position

EB C8991A

3) Clean deposits, using a plastic scraper or bristle brush. After deposits have been removed, soak parts in a non-flammable solvent again; then, blow com pressed air against them.

NOTE: Use care to prevent damage to parts.

15-30

C8971A

Measure I.D., O.D., and length of the bearing. If the measured values exceed the limit, replace.

INTAKE AND EXHAUST - SERVICE PROCEDURE (di Inspection of shaft

(e) Inspection of insert

1) Journal O.D. Insert Ends

Piston ring

80467A 80465A

Measure the shaft-and-turbine-wheel journal diame ter. If the measured value is less than the limit, replace the shaft-and-turbine-wheel.

Fit a new piston ring in the insert bore and measure the end gap of the piston ring using a feeler gauge. If the end gap is out of the nominal value, replace the insert.

21 Shaft runout

80466A

Set a dial indicator to the shaft as shown and turn the turbine wheel slowly to measure shaft runout. If the measurement exceeds the limit, replace the shaft-and-turbine-wheel. If the shaft journal is rough, clamp both centers on a lathe and lightly grind the journal surface with a sand paper #400 and engine oil with a spindle speed at 300 to 600 rpm. NOTE: After polishing the journal, measure its outside diame ter (the part that rotates in the bearing). If the outside diameter is beyond the service limit, replace the shaft and turbine wheel. 15-31

INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Reassembly

12 ! Apply engine oil i

5.9 N-m {0.6 kgf-m} • Molykote grease or equivalent to be applied to screw and seating surface in lock nut. • Hammer entire periphery.

14 I Apply engine oil

20 N-m {2 kgf-m}

i Molykote grease or equiva• i lent to be applied to screw

Shaft-and-turbine-wheel to

1 turbine back plate clearance i NV 0.48 to 0.92

! Apply engine oil I 8

Compressor wheel to com: presser cover clearance NV 0.08 to 0.28

I I

Shaft-and-turbine-wheel to turbine housing clearance NV 0.39 to 1.0

Assembly sequence

18➔17➔16➔157 12➔11 � ➔@➔@ ➔ ® 14 ➔13__r 3 ➔ ➔m 9➔10➔@➔1---I

·~

, Shaft-and-turbine-wheel i 1 axial play i NV 0.075 to 0.155

For parts with an encircled number, refer to Reassembly Procedure that follows.

(a) Installation of piston ring

C89748

NOTE: When mounting piston ring to the thrust sleeve, ensure that the ring is not expanded and ring ends are not twisted.

Thrust sleeve Oil deflector

15-32

NV . Nominal Value

Set the thrust sleeve into the oil deflector, and install the piston ring.

Reassembly Procedure

Piston ring

B0472C

INTAKE AND EXHAUST (b) Installation of snap ring

SERVICE PROCEDURE

Taper surface

Snap ring

Shaft-andtu rbine-wheel

Bearing housing

C8978C C90018

Bearing housing Snap ring

Set a dial indicator to the end of the shaft and move the shaft in the axial direction to measure the clearance. If the measurement is out of specification, disassemble and isolate the cause. (d) Installation of compressor wheel

C8979A

Bearing housing

Install the snap ring to the bearing housing with its taper up. After installation, using a screwdriver, drive the snap ring into the groove in the bearing housing by hum mering.

Turbine housing

NOTE: 1.

Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring pli ers. Special care must be exercised, when tapping the snap ring into position, to prevent damage to the bearing housing by the screwdriver.

82820C Lock nut � Compressor wheel---e Shaft-and-turbine� wheel

C9002C

Holding the turbine housing in a vice, set the tur bine wheel side of the bearing housing into the tur bine housing.

15-33

INTAKE AND EXHAUST 2) Coat threads in the shaft-and-turbine-wheel with molybdenum disulfide base grease Li soap and mount the compressor wheel onto the shaft. 3) Holding the boss on the turbine wheel side, tighten the compressor wheel lock nut to the specified torque.

SERVICE PROCEDURE (f)

Measurement of clearance between the turbine back plate and shaft-and-turbine-wheel back sur face

NOTE: Set the bearing housing carefully to prevent damage on the turbine wheel blades.

Bearing housing

(e) Measurement of axial play in shaft-and-turbine wheel Compressor cover B2830C

Shaft-and turbine-wheel

Shaft-and turbine wheel

Compressor wheel

C9003B

Set a dial gauge on the shaft-and-turbine-wheel end. With compressor wheel moved in the axial direction, measure the end play. If the play is out of specification, disassemble and check to locate the cause.

Compressor cover C9004A

Temporarily mount the bearing housing to the com pressor cover from the compressor wheel side. Mea sure the clearance between the turbine back plate and shaft-and-turbine-wheel back surface. If the clearance is out of specification, disassemble and isolate the cause. NOTE: Be sure to use two thickness gauges and take mea surement at the tip of the blades.

15-34

INTAKE AND EXHAUST (g) Compressor wheel to compressor cover clearance

SERVICE PROCEDURE

(h) Installation of turbine housing and compressor cover

Compressor whee!

�Jl I

84468A

Check by the following procedures. 1)

Move up and down the compressor wheel to measure runout (R),

NOTE: Do not measure runout by turning the compressor wheel.

2) Measure compressor cover inside diameter (D) and compressor wheel outside diameter (d) at places indicated in the illustration. 31 Calculate the clearance by the equation given below. If it is out of specification, disassemble and check again. Clearance = 1/2 (D - d - R)

Coupling

| assembly

Compressor� cover Alignment mark

Coupling assembly 5.9 N-m 10.6 kgf ml

82819E

Make sure that the alignment marks are aligned and secure the parts with the coupling assembly and snap ring. Install the coupling assembly by the following proce dures. 1) Tighten the coupling assembly to specified torque. 2) Hammer the coupling assembly all around. 3) Tighten again the coupling assembly to specified torque. (i) After reassembly, turn the turbine wheel and com pressor wheel by hand and check for smooth rota tion. If the wheels turn heavily, or bind, disassemble, and locate the cause of trouble.

15-35

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.2 4LF type turbocharger For disassembly, inspection, cleaning, and reassembly procedures, refer to section 5.4.1 unless where they are described here. (1) Disassembly

Blade bend and damage, corrosion, marks of inter ference on back surface

Dented outside circumference,

18 Worn beyond covering

layer, deep scratch

worn inside

circumference Interference with compressor wheel

17 14 Deep scratch, clogged oij hole, worn beyond

covering layer

Unevenly worn piston ring inserting area

Interference with turbine wheel, damage

Interference with turbine wheel, cracks due to overheat, corrosion, damage

Worn beyond covering layer, deep scratch

Blade bend and damage, corrosion, marks of interference on back surface, stepped wear of piston ring fitting por tion, damage on bearing journal

Crack, bearing hole surface roughness, damage on piston ring fitting portion 84265A

15-36

INTAKE AND EXHAUST - SERVICE PROCEDURE

Disassembly sequence

1 V-clamp 2 Turbine housing 3 V-clamp 4 Compressor cover 5 Compressor wheel 6 Shaft-and-turbine-wheel 7 Piston ring 8 Snap ring

10 Piston ring 11 Flinger sleeve 12 Oil deflector 13 Thrust ring 14 Thrust bearing 15 Sleeve 16 Thrust ring @ Snap ring

9 Insert

18 Bearing

® Snap ring

@ Snap ring 21 Oil control sleeve 22 Bearing ®l Snap ring 24 Back plate 25 Bearing housing

For parts with an encircled number, refer to Disassembly Procedure that follows. NOTE: 1. Before disassembly, draw alignment marks on the compressor cover, bearing housing, and turbine housing to facilitate later reassembly. The blades of the compressor wheel and turbine wheel bend easily. Be careful not to drop or crush 2. these items. Do not remove the bearing housing pins (2 places). 3.

Disassembly Procedure

When the snap ring holding the bearing in position is to be removed, use pliers (tip diameter 1 mm) to prevent damage to the inside of the bearing housing.

Removing snap ring

84266A

15-37

INTAKE AND EXHAUST - SERVICE PROCEDURE

12) Cleaning and inspection

Piston ring end gap (new piston ring to be used for measurement) NV 0.026 to 0.102 Clean

i Piston ring groove width ! L 3.3

Clean Bearing journal 0.D. L 14.254 Piston ring groove width (clearance when new piston ring is mounted) 1.68

Clean Bearing inserting portion I.D. L 22.268

Shaft runout (total indicator reading) L 0.015

Piston ring inserting portion 1.0. L 22.5

NOTE: Before cleaning, visually inspect each component to find any scorching or rubbing that will not be apparent after cleaning. For details, refer to item 11) of section 5.4.2.

15-38

NV . Nominal Value L. Limit

84267A

INTAKE AND EXHAUST la) Measurement of piston ring groove width

SERVICE PROCEDURE

lb) Measurement of flinger sleeve groove width

Clearance

New piston ring

Thickness

C8914A

C8916A

Install a new piston ring in the piston ring groove and measure the clearance. If the reading is more than the limit, replace the shaft and-turbine-wheel.

Measure the piston ring groove width of the flinger sleeve. If the reading is more than the limit, replace the flinger sleeve.

15-39

INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Reassembly

Flat side to be directed toward insert �

Molykote grease or equivalent to be applied to screw and seating surface 11 N-m {1.1 kgf-m}

Engine oil to be applied to thrust side 14

I Shaft-and-turbine-wheel to I turbine housing clearance NV 0.84 to 1.75

Grease to be applied to flange surface 7

———_—_—____——

to compressor wheel diametric clearance

i Compressor cover

Engine oil to

beapplied , EE eM

Engine oil to be applied

NV 0.15

11__i.;----

1'----!-�-�:f

Shaft-and-turbine-

s wheel axial play

NV 0.08 to 0.152

Shaft-and-turbine

Molykote grease or equivalent to be applied to screw and seating surface 27 N-m {2.8 kgf-m)

wheel to turbine back plate clearance NV 0.43 to 1.05

Shaft-and-turbine wheel to turbine housing diametric clearance NV 0.15

Engine oil to be 10 applied To rotate smoothly when turned by hand Ke

™

Round side

to be faced

toward bearing

4 Grease to be applied to flange area NV . Nominal Value

Assembly sequence 25-,24-,@-,22-,21-,@)-,@ ➔ 18➔®7 5-,,7

h1s-,15-,@

.......J

➔13➔127

H9➔8➔5 ➔4➔3➔2➔ 1 11 ➔ 10 ........J

For parts with an encircled number, refer to Reassembly Procedure that follows. NOTE: 1.

2. 3.

Piston rings cannot be reused; be sure to use a new one. Also, do not expand piston rings more than is necessary since they break easily. Apply engine oil to all moving parts before installation. When fitting the compressor cover and turbine housing, use the alignment marks on them and the bearing housing. 84268A

15-40

INTAKE AND EXHAUST - SERVICE PROCEDURE

(c) Measurement of clearances between shaft-and turbine-wheel and turbine housing, and compres sor wheel and compressor cover in diametrical direction

Reassembly Procedure

(a) Installation of snap rings

Compressor cover

Ciearancein dia-

metricaldirection

Compressor

wheel

Turbine housing

Clearancein dia-

metrical direction

Turbine whee!

C8925A

Measure each clearance with a thickness gauge to check that it is within the nominal value. NOTE: When a clearance is to be measured, press the shaft in the axial direction to minimize the clearance. B4266A

Use pliers (tip diameter 1 mm) in installing snap rings. NOTE: Install each snap ring with its round side toward the bearing.

ib) Installation of thrust bearing Locating pin

Locating hole

CB919A

To install the thrust bearing, apply engine oil to the thrust receiving side. Press it in with its locating hole in alignment with the locating pin of the bearing housing until it is in flat contact with the bearing housing. 15-41

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.3 3LM type turbocharger

For instructions on disassembly, inspection, cleaning, and reassembly other than those shown here, refer to section 5.4.1. (1) Disassembly

Wear, cracks

Knocks from compressor wheel

Bending and scratches on blades, corrosion, knock marks on back

Knocks from turbine wheel, damage

Knocks from turbine wheel, splitting, pitting, or deformation from overheating

Bending and scratches on blades, corrosion, knock marks on back, damage in seal ring grooves

11 Roughness on bearing hole surface,

damage, gas corrosion, deformation of turbine�side flange

B9029A

15-42

INTAKE AND EXHAUST - SERVICE PROCEDURE

Disassembly sequence

<:D Turbine housing �\

Compressor cover

3 Compressor wheel 4 Snap ring

5 Insert

Flinger sleeve Piston ring Oil deflector Thrust ring 10 Thrust bearing 6 7 8 9

11 Bearing housing 12 Shaft-and-turbine-wheel 13 Piston ring 14 Turbine backplate 15 Bearing

For parts with an encircled number, refer to Disassembly Procedure that follows. NOTE: 1.

2. 3.

Before disassembly, draw alignment marks on the compressor cover, bearing housing, and turbine housing to facilitate later reassembly. The blades of the compressor wheel and turbine wheel bend easily. Be careful not to drop or crush these items. Do not remove the bearing housing pins (2 places).

Disassembly Procedure

(b) Removing compressor cover

(a) Removing turbine housing

? :.: . .>..._____

-- \

. :.2�:-�:;_ -. 89048A

15-43

INTAKE AND EXHAUST - SERVICE PROCEDURE

(21 Cleaning and inspection

Clean

Piston ring end gap {new piston ring to be used for measurement) NV 0.015 to 0.18

Clean

Clean Bearing journal 0.0. L 11.18 Shaft runout (total indicator reading) L 0.015

Clean

Bearing inserting portion I.D. L 19.06

NV .. Nominal Value

L ... Limit

NOTE:

Before cleaning, visually inspect each component to find any scorching or rubbing that will not be apparent after cleaning. For details, refer to item ( 1) of section 5.4.3. 890348

15-44

INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Reassembly

Face flat surface toward insert 6.9 N-rn {0.7 kgf-rn}

lock washer bend 17 N-rn {1.7 kgf-rn}

Shaft-and-turbine-wheel to turbine housing clearance NV 0.53 to 1.04

Apply engine oil

1 I Shaft-and-turbine-wheel i i axial play NV 0.05 to 0.13

13 Apply engine oil

17 to 20 N-m {1.73 to 2.07 kgf-rn}

Shaft-and-turbine-wheel to turbine back plate clearance NV 0.74to 1.55

Apply engine oil

Apply grease or oil to stepped joint

Apply engine oil

Gasket

Face bronze surface toward compressor wheel NV . Nominal Value

Assembly sequence 11➔ 14➔13➔12➔15➔®➔9➔87 _r-+4➔3....®...CD 5➔7➔6 For parts with an encircled number, refer to Reassembly Procedure that follows. NOTE: Piston rings cannot be reused; be sure to use a new one. Also, do not expand 1. piston rings more than is necessary since they break easily. 2. Apply engine oil to all moving parts before installation. 3. When fitting the compressor cover and turbine housing, use the alignment marks on them and the bearing housing. B9037A

15-45

INTAKE AND EXHAUST - SERVICE PROCEDURE (c) Fitting turbine housing

Reassembly Procedure

(a) Fitting thrust bearing

17N·m (1.7 kgf.m}

Locating hole Locating pin

89031A

Fit the turbine housing with its cap screws, tightening the cap screws to the specified torque. NOTE: Apply antiseize compound to the cap screws.

89041A

Apply engine oil to both faces of the thrust bearing. Align the thrust bearing with the locating pin on the bearing housing, then push the thrust bearing onto the bearing housing until it sits flat. (b) Fitting compressor cover

6.9 N-m {0.7 kgf-m}

.89048A

Fit the compressor cover and bearing housing with its cap screws, tightening the cap screws to the specified torque.

15-46

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.5 lntercooler 5.5.1 Disassembly and reassembly ( 1) Water-cooled type I <6D22-TC, 24-TC>

5 dirt on fins, water scaie

\ 4 Damage, water leaks, dirt on fins, water scale and rust inside core

and rust inside core

C9305C

C9305B

<8DC9-TC>

Damage, water leaks,

dirt on fins, water scale and rust inside core 4

,-----0@

(e)�>ll'K�

1 Connector

2 3 4 5

Cover Plate Core assembly Inlet manifold

2 5

84886A

15-47

INTAKE AND EXHAUST - SERVICE PROCEDURE (2) Air-cooled type <BDC9-TL>

1 Air intake hose 2 lntercooler

84157A

5.5.2 Air pressure test

(2) Inspection of intercooler <8DC9-TL>

(1) Inspection of core assembly <6D22-TC, 24-TC,

8DC9-TC> Conduct the air pressure test to check for water leaks due to damaged element. To check, apply an air pres sure of 390 kPa {4 kgf/cm2 } to the core assembly. Replace the core assembly if it is leaking air or other wise defective.

NOTE: Never apply pressure over specification. C90078

(a) Remove the drain plug from the intercooler lower tank to discharge collected condensate.

15-48

INTAKE AND EXHAUST - SERVICE PROCEDURE

5.6 Bleeding of Aftercooler Coolant Circuit <6D22-TC, 24-TC (Low profile type)>

eu" Airvent plug Water return pipe

C9303A

<8DC9-TC> (b) Remove the intercooler and use copper wire or the like to remove mud, insects, etc. from the front side of intercooler core, using care not to damage the tube.

848878

�Air vent plug I

e I

I Pressure for inspection of I 1 1 intercoo!er (compressed air) / I NV 145 kPa {1.5 kgf/cm 2} I

84887A

NV .. Nominal Value C9009A

Immerse the intercooler in a water tank with one open ing for air dosed and with the other opening connected to a hose. Send compressed air at specified test pres sure through the hose and make sure thatthere is no air leak.

(a) Remove the air vent plug from the water outlet pipe. (b) Pour coolant into the radiator until coolant flows out from the air vent. Install the air vent plug. (c) With the pressure cap left removed from the radia tor, run the engine at idle, keeping coolant temper ature of about 90°C, to thoroughly bleed the sys tem. (d) After the air in the coolant circuit has been thor oughly bled, add coolant as necessary to the radia tor and reservoir tank.

15-49

INTAKE AND EXHAUST - TROUBLESHOOTING

6. TROUBLESHOOTING Remedy

Probable cause

Symptom

Insufficient intake air • Loaded air cleaner element

Low output

Ref. group

Clean Correct

• Air suction {with dust and other foreign matter) from intake system • Defective turbocharger • Turbocharger rotation failure • Seized bearing

Replace

• Carbon deposit on turbine wheel

Clean

• Turb'mew h ee and turb'me bac k pa I emterfermg • Turbine wheel and turbine housing interfering

Ch eck Check

Replace

• Bent shaft-and-turbine-wheel 8

• Compressor wheel and compressor housing interfering

Check

• Seized thrust sleeve and/or thrust bearing

Replace Clean, check

• Incorrect sliding between inside parts due to clogged lubrieating oil pipe • Damaged compressor wheel

Replace

• Damaged turbine wheel

Replace Clean

• Foreign matter on front surface of intercooler core <8DC9·Tl> Low exhaust efficiency • Deformed front pipe, muffler and/or tail pipe (large exhaust resistance)

Replace

• Defective turbocharger • Turbocharger rotation failure (See above.)

Check Replace

• Damaged turbine wheel Whitish and much exhaust

gas

Dark and much exhaust gas

Abnormal noise and/or vibration from intake and exhaust system

15-50

Incorrect injection timing

Adjust

Group 13

Low compression pressure

Check

Group 11

Poor quality fuel

Replace

Group 13

Defective turbocharger • Oil leaks due to worn piston ring, and/or insert

Replace

• Damaged oil seal due to clogged oil return pipe

Replace

Loaded air cleaner element

Clean

Trouble in engine proper

Check

Group 11

Nonuniform fuel injection amount to cylinders

Adjust

Group 13

Incorrect injection timing

Adjust

Group 13

Poor connection of intake and exhaust systems Deformed front pipe, muffler or tail pipe (large exhaust resistance) Defective turbocharger (See above.)

I !

Correct Replace Check

ENGINE ELECTRICAL CONTENTS 1. GENERAL ..... ........... .... .... .......... .. 2 1.1 Starter ..................................... 4 Alternator ............ .... ................. 6 1.2 1.3 Safety Relay ...............................11 1. 4 Regulator ................................. 13 1.5 Intake Air Heater . ........................ 17 1.6 Automatic Stop System ................. 18 1.6.1 Shutdown type ........................ 19 Run-on type ............ ..... ..... ..... 21 1.6.2 2. SPECIFICATIO NS .. ........ .. .. .............. 24 3. SERVICE STANDARDS .... ........ .. .. ...... 27 3.1 Service Standards Table .. . .. .. . .. .. .. .. . 27 3.2 lightening Torque Table ............ ..... 3 4 4. SPECIAL TOOL ............. ............ ..... 34 5. SERVICE PROCEDURE . .... . . .. .... .... ..... 35 5.1 Starter .............. .... ...... ............ 35 5.1.1 Removal and installation .... . . ....... . 35 5.1.2 Disassembly ...... .... .... .. . .. .... .... 36 5.1.3 Inspection .......... ... .... ... .... .. .... 43 5.1. 4 Reassembly ............................ 49 5.1.5 Inspection and adjustment after reassembly . . .......................... 58 5.2 Starter Relay .......... ............. ...... 60 5.3 30 A, 35 A, 40 A <except A4T57471>, 80 A Alternators (with brush type) ...... 61 Removal and installation . . .. . . .. .... . . 61 5.3.1 Disassembly . ..... ... . ... ... ...... ..... 63 5.3.2 Inspection ...... . . ............. . ... ..... 67 5.3.3 Reassembly .. ........ ....... .. ........ . 7 4 5.3.4 Inspection and adjustment after 5.3.5 installation ......... .. . ..... ... . . ....... 76 40 A Alternator <A4T57471> 5.4 (with brush type) .... . . .. ....... ......... . 81 Removal and installation . .. . .......... 81 5.4.1 Disassembly and inspection .... ..... . . 81 5.4.2

5.4.3 Reassembly ............... .. ......... .. 82 5.4.4 Testing ........ .. .................. .... 82 5.5 40 A, 50 A Alternators (brushless type) ... . .. . ... . . ..... . ........ 83 5.5.1 Removal and installation ..... . ..... ... 83 5.5.2 Disassembly .. .. ... .. . ... .......... .... 83 5.5.3 Inspection ...................... ........ 86 5.5.4 Reassembly .. ... .. . ........... .... .. ... 89 5.5.5 Inspection and adjustment after installation ................ .... ......... 90 5.6 90 A Alternator (brushless type) . ........................ . 91 5.6.1 Removal and installation .... .. ..... ... 91 5.6.2 Disassembly .. . .... ............ .. ...... 91 5.6.3 Inspection .......... ....... .... . ........ 93 5.6.4 Reassembly ...... .......... .... ..... ... 97 5.6.5 o an d e t er �::�:�! b�y � � !��- � -�� .. . .... 98 5.7 60 A, 110 A, 150 A Alternators ........... 100 5.7.1 Removal and installation ... . . . . . . . . . . 100 5.7.2 Disassembly .......................... 100 5.7.3 Inspection ............................. 102 5.7. 4 Reassembly ........................... 104 5.7.5 Inspection and adjustment after reassembly ...... ..................... 105 5.8 Regulator Inspection and Adjustment .............................. 105 5.9 Safety Relay Inspection .. ..... . ......... 107 5.10 Preheater ................................ 109 5.10.1 Intake air heater . ..................... 109 5.10.2 Heater relay ....................... .... 109 5.11 Automatic Stop System ... .. .. .. .... . .. 110 5.11.1 Shut down type .............. ........ 110 5.11.2 Run-on type ...................... .... 115 6. TROUBLESHO OTING .. .................... 121

16-1

ENGINE ELECTRICAL - GENERAL 1. GENERAL <6D2>

,----------Alternator

Starter

�-�==�:11 ! I �ko Starter relay

Iii)....

r;>-j-{!SW

.•. --... 1

IC regula, tor

·r::•·

r-i

�

5 0.85

Oil bypass alarm lamp

er J

�

"'-!-

0.85 0.85

0.85

Air heater indicator

Heater relay

�--;,- n-4'"4f!\ r--

0.85

L' __J...I:J [!¼-·· ---+

0.85

-�

¢ �. _cy © I

'--= -- . Air heater

�

Safety relay

Oil bypass \ alarm

•� 7 �

L�

1�r

•. I '------1'"'!"-t-""'

�

<6022-TC only> - I Air heater

-:=

Ir-- ! :P,ti

rl-<lf,1 ' N>,--, ;--.,

L�J

Ammeter

�u_�1l e r-n7 �-r��-➔-+---;

-o'------"--+ �� 0.85

--- 0- 85 J i �0.85 � -t,.,,,...._ �

L:-.. :J

1�1

5 I � I

r---� , � - -=�••: 'B� ; Thermometer

��lu�': ssure

�

I�:--� i ·-7

��lressure :

mometer unit 47I: r--�o· r:Ther ,

�

u:�ss -- urel

'Li j

__J

-7

--4 Battery switch

>--

-=- Battery :;iJ_

"'"'

00 00

00 Starter switch

OFF

l�H�E-:;A:,T ON

-=: --J

::..+ 7

tc->:t:o=_ l==l=o=l==l=�oi

-:--

START

R "s::'.�+� (R�,)• +I ( 0 +�t �• ti �..::: ®-=u i :: :: O ':

o:'...rm 11��0�• � .:i:::,'' na'.:c'. I

Code size 0.85 0.85 mm2 or more 5 5 mm2 or more 15 15 mm2 or more 60 60 mm2 or more

� -1-0-f-<::J-f-()-f-C>-t--<-)i-O_

81646F

16-2

ENGINE ELECTRICAL - GENERAL

1,=;:::::::::::=��J-j

<8DC> Alternator

�

R 0.85 0.85

0.85 5

Oil bypass alarm lamp

0.85

Cy©

_.,---,

->-....

: '

L ..ii:J

0.85

Air heater indicator

heat• Air ��--, •• -1-.. I -:I '[td] 1 • L:: __ r A irheate l_ _7 ' ti ., ,;, i__::__::::....i

-· __J

��::7 1ii7 L----'!..-+<>"-" 5

!�--� U : -� '

-+,o'"'-J

j ..:..J

<8DC9>

<8DC9-T, 9-TC, 20 9-TL>

I '

: 01 I �{�s� i

L:-...£1

'--�.::::JH--+---li { Battery switch

-=- Battery

Thermometer

·-7

=�_J

j � ' 1

15 60

1 _ 1 5 l ¢:lJ=oM-i

�� l Lre:� I � �

(s)--

Heater relay

mmeter A

0.8 5 .-------, ,-, ::,0.85

Oil pressure unit

,,,..._I : T : LJ

L____j L-..� -

Oil pressure gauge

cp,"'L l

Safety refay

rr·-

:Pi! L�J

0.85

! '-----------

Oil bypass alarm ..-+-<Y,,...__T'I>�

,-=-- . -M �

�--� l_J__ Jj

IC regula-I tor J

7 ...-".

___ Starter

! ��o-©1 �

�rf@r. �

:·

lAJ .........,,'-"'..-.. -

Starter relay 60

Thermometer unit

Starter switch

Ke.y Terminal ,.-::-,, B pcsition

OFF

-+---;-o;; o o-

HEAT

START

'--

Code size 0.85 0.85 mm 2 or more 5 5 mm2 or more 15 15 mm2 or more 20 20 mm 2 or more 60 60 mm 2 or more

81646G

16-3

ENGINE ELECTRICAL - GENERAL (2) Overrunning clutch section

1.1 Starter Magnet switch

Outer race Roller

Spring

' Motor

Reduction gear

Pinion Overrunning clutch

837118

The starter is a reduction starter with a built-in reduc tion gear. Its motor has been downsized with even higher speed capability. Major components of the starter are: motor section generating power; the overrunning clutch section transmitting armature torque and preventing the engine from overrunning after startup; the magnetic switch section which puts the pinion in mesh with the ring gear and feeds load current into the motor·' and ' the reduction gear and transmitting torque to the pinion. (1) Reduction gear section Overrunning clutch Pinion Internal gear Armature

83702A

The end of the armature shaft is shaped as a gear and is in mesh with the internal gear.

16-4

Pinion

83703A

The overrunning clutch is of roller type. Each roller is set in the wedge-shaped groove provided by the outer and inner races (pinion) and is pressed by a spring. The roller is pressed against the narrower side of the groove by the spring transmitting outer race rotation to the pinion by its wedge action. On the other hand, no torque is transmitted from the pinion as the roller moves to the wider side releasing the wedge action.

ENGINE ELECTRICAL - GENERAL

13) Operation Starter switch Starter switch SW

8��

...,._...,

S'--:----c--...JL Starter relay

Field coil

Reduction

Field coil

Ring gear

Battery Ring gear

83708A

While the starter switch is ON, current flows from the terminal "SW" of the starter relay to the terminal "L" and closes the contact "P2". When the contact "P2" closes, current from the battery flows from the terminal "$" of the magnetic switch to the pull-in coil "P" and holding coil "H". Furthermore, the current that has decreased flows from the terminal "M" to the motor section. The plunger, attracted by the magnetic flux of the pull-in coil and holding coil, pushes out the pinion through a lever.

83709A

When the pinion comes into complete mesh with the ring gear, the contact "P1 " closes and the large current of the battery directly flows to the motor section to turn the pinion powerfully. In this condition, no current flows to the pull-in coil. The plunger is retained by the holding coil alone.

16-5

ENGINE ELECTRICAL - GENERAL

1.2 Alternator (1) 30 A, 35 A, 40 A, 80 A alternator (with brush type)

Starter switch 0 SW

:��,, Starter relay

<30A,40A,80A Alternator>

Rectifier R.'otor '

s�-------s1

M' IC regulator

<35 A Alternator> Rectifi , Rotor

86003A

Ring gear

83710A

Setting the starter switch to OFF position causes the contact "P2" to open. At the moment the starter switch is opened, the "P1" still remains closed and the battery current flows from the terminal "B" to the pull-in coil "P" and holding coil "H". Since the coil are wound in opposite direction to each other, the magnetic fluxes cancel each other so that the return spring can move the plunger back to its original position. At the same time, the contact "P1" opens to shut down the current flow to the motor.

16-6

IC regulator 860028

The alternator is a brush type in which a current flows from the brushes through the slip ring to the field coil in the rotor. Major components include: the rotor (field coil) that generates magnetic field; the stator that generates electromotive force; the rectifier that rectifies electro motive force so generated; the regulator that keeps generated voltage constant.

ENGINE ELECTRICAL - GENERAL

(a) Rotor <30 A, 40 A, 80 A Alternator>

<30 A, 40 A, 80 A Alternator>

Slip ring

Field coil

Rotor core

<35 A Alternator>

B27020

B2704A

<35 A Alternator>

Field coil Slip ring

Rotor core

B4392B

84393A

When the rotor is driven by the pulley rotation, a cur rent flows from the brushes, through the slip ring, to the field coil. The rotor core tabs then become mag netic poles.

The rectifier mainly consists of 3 diode trios, 6 diodes and 2 heat sinks. It rectifies the AC stator output to DC power. Each heat sink has the (+) or H leads from 3 diodes attached to it, performing full wave rectification for 3-phase AC. Two rectifiers are used in the 80 A alternator.

lb) Stator

(d) Regulator Regulator

Stator coil

Stator core 82703A

Together with the rotor core, the stator core forms the magnetic flux path. The magnetic flux lines in the sta tor core are affected by the passage of the rotor core field and generate electricity.

Brush spring

Brush

B2708A

The regulator alters the strength of the field coil field to stabilize output power which varies with engine speed fluctuations. 16-7

ENGINE ELECTRICAL - GENERAL The regulator is integral with the brush holder. The assembly combines the IC regulator, the brushes and the brush springs.

2) Starting the engine

Alternator

(e) Charging circuit 1) Turning ON the starter switch

r0-

�

L: :

--c;l!J I

I t -

ill

Safety relay o, -' --charge lamp

' OFF

OFF

t t B

HEAT ON

�·-�·· START

HEAT ON

82542G

Starter switch

Alternator ("A" terminal)

Ground

16-8

I t /

R AC

Safety celay,\ o, - Charge lamp

- - - -

0 0

J J

82542H

When the engine is started and the alternator starts generation so thatthe voltage at the alternator "B" terminal becomes higher than the battery voltage, the current flows as shown below. Alternator ( .. B" terminal)

Batter; i

-------

I!.

!:_

Battery

I t

i Safety relay or charge � lamp(ON)

c___________;

Starter switch Battery

Alternator ("L" terminal)

]---------------�

Ground

In this way, battery charge is started and at the same time, the charge lamp goes out.

ENGINE ELECTRICAL - GENERAL (2) 50A, 90A alternator (brushless type)

(bl Neutral point diode operation •

Diode

.I Stator coil Neutral point

When the neutral point's peak electric potential is 28V or below, only the six normal rectification diodes function. Neutral point diode

' .. , _JI�

��---<@

7 Regulator

85887A

This brushless alternator has neutral point diodes. That is, two diodes are added to the neutral point where three stator coils are connected. This configuration provides higher DC voltage at high speeds of alternator rotation when compared with the alternator without neutral point diode. (a) Changes in neutral point electric potential

B5889A

•

When the neutral point's peak electric potential exceeds 28V, the neutral point diode arrangement supplements the regular DC output to the vehicle's on-board electrical systems.

(3) 40A alternator (brushless type) IV)

At high speed1. Neutral point At low speed J voltage waveform

_________ .. ____ _ Output voltage

Stator Rotor

Rectifier --------- --·Neutral point average voltage

oL----\-,,.,/-----1-,,,+-Ground potential

� �e of rotation

85888A

As illustrated, the neutral point's electric potential rises and falls on either side of the neutral point's average DC voltage. (The neutral point's DC voltage is one-half of the alternator's DC output voltage.) At high speeds of rotation, the peak emf generated greatly exceeds the alternator's output voltage. A neutral point diode arrangement eliminates the excess emf.

Regulator Field coil

B2976F

As its name implies, the 40A brushless alternator allows current to flow directly to the field coil without the use of brushes. The alternator's key components are as follows: the field coil (which generates the required magnetic field); the stator (which generates electromotive force), the rectifier (which converts the generated AC waveform into direct current); and the regulator (which maintains the generated emf at a constant level).

16-9

ENGINE ELECTRICAL - GENERAL (a) Field coil

Together with the rotor coil, the stator core forms the magnetic flux path. The magnetic flux lines in the sta tor core are affected by the passage of the rotor core field and generate electricity. (d) Rectifier

83862A

The field coil, secured onto the rear bracket, receives current from the terminal and generates magnetic field.

827048

(b) Rotor The rectifier mainly consists of 3 diode trios, 6 diodes and 2 heat sinks. It rectifies the AC stator output to DC power. Each heat sink has the (+) or H leads from 3 diodes attached to it, performing full wave rectification for 3-phase AC. (e) Regulator

83863A

The rotor is rotated by the pulley to surround the field coil. By the magnetic field generated by the field coil, the rotor core tabs become magnetic poles. (c) Stator 827088

The regulator alters the strength of the field coil field to stabilize output power which varies with engine speed fluctuations. (f) Charging circuit Refer to Item ( 1) (e) Alternator with brush.

Stator coil

16-10

Stator core

82703A

ENGINE ELECTRICAL - GENERAL (4) 60A, 110A, 150A alternator (with brush type)

1.3 Safety Relay <R8T30171,R8T30172,R8T30174,R8T30274>

r-7 I

! I

I I I

I I I I I I I

Field coil CAARAG

OOCOOKX)

}

B1453C

The alternator rpm is detected and when it exceeds the reference level, the safety relay prevents the starter from operating even if its switch is accidentally turned on during engine revolution.

B4007C

The alternator is an open type three-phase alternator. The three-phase AC generated in the stator coil is con verted into DC by the silicon diodes. A total of 12 diodes (6 on the positive side and 6 on the negative side) are housed in 6 heat sinks, two in each heat sink. The alternator generated voltage is controlled by the regulator.

16-11

ENGINE ELECTRICAL - GENERAL

Operation

Alternator

Ir-�

I L

I)+---------, Charge lamp

Foul)

Starter switch

R;--� Safety relay

�-""'E>---' -=-- ---=-

Battery switch

J_ Battery

-------t ---<JE:r-To starter

81454A

(1) When the starter switch is set to ON, current flow from the starter relay to terminal "S" and to termi nal "E" of the safety relay, closing contact "P1". The charge lamp also illuminates if provided. (2) As the starter runs and the engine starts running, pulses of frequency 1/10 of the alternator speed appear at terminal "P" of the alternator. The charge lamp goes out.

16-12

(3) When the pulse frequency at terminal "P" exceeds the specified value, continuity between terminals "S" and "E" is lost. Then, the starter does not oper ate even if the starter switch is set to ON while the engine is running.

ENGINE ELECTRICAL - GENERAL 1.4 Regulator (Model R7T01071, R7T01072, RMS4227B, R8T10183) <RMS4227B>

<R7T01071, R7T01072>

ffl

F IG

B44018

Its functions include:

DD N □D A

B4401C

output voltage would otherwise vary with changes in engine speed.

(1) Voltage regulator Maintains constant.

□□

L; E

IG FL

voltage generated

by the

generator

(3) Field relay Minimizes discharge current to the alternator field coil even when the battery switch is left closed.

(2) Safety relay Keeps the starter circuit in OFF state even with the starter switch turned on during operation of engine. <R8T10183>

e e

85891A

The regulator is an electronic unit. By varying the mag netic field generated by the field coil, the regulator keeps the alternator's output voltage constant. The 16-13

ENGINE ELECTRICAL - GENERAL Connections of the alternator to the regulator are shown below. <R7T01071, R7T01072> Starter relay Transistor

-----

Alternator

-, Field coil

L__

----Regulator

1 :�

I�

I Battery L_

Voltage regulator

I _ .J

Battery switch Starter switch

-'-

Pilot lamp

__J

81891A

The battery switch in ON position causes field current to flow in the circuit as follows: Battery➔ Battery switch➔ Regulator "IG" termi nal➔Resistor R 1 ➔ Voltage regulator "K" terminal ➔Voltage regulator "F" terminal ➔Alternator "F" terminal➔ Field coil➔ Ground When the starter switch is set to ON, the starter relay coil is energized with its contact closed. When the starter cranks the engine, the alternator generates power, causing a current to flow in the coil "VC 1 " in the following sequence: Alternator "N" terminal➔ Regulator "N" terminal ➔ Coil VC1 ➔ Ground - As the coil "VC 1 " is energized, the contact "P 1" is opened. In this state, setting the starter switch to ON 16-14

with the engine in operation leaves the starter inopera tive. While the engine is in operation, field current flows in the following circuits, with alternator output voltage controlled by the voltage regulator. Alternator" A" terminal---> Regulator" A" terminal ---> Contact P2---> Voltage regulator "K" terminal➔ Transistor➔ Regulator "F" terminal➔ Alternator "F" terminal---> Field coil➔ Ground If the transistor remains off too long, the alternator "N" terminal output is decreased and the coil "VC 1" loses its magnetic force to such an extent that the contact "P2 " may be opened or "P 1 " closed. The circuit of coil "VC2 " and resistor "R 2 " keeps "P 2 " closed and "P,'' open in such a case.

ENGINE ELECTRICAL - GENERAL

<RMS4227B> Alternator

Regulator Safety relay

Field

coil --+-,h.;-

,1 R3

Start,er relay coil

vc,

To starter

--7

\1 '---I---+-_ Pilot lamp

-0-,

! Starter

relay

Starter switch

'---------------c{Ai:>---1>--'

I •

Battery

818918

When the starter switch is turned to the "1" position, field current flows as follows: Battery➔ Starter switch Pilot lamp➔ Regulator L terminal➔ Contact P2➔ Ground 4 Regulator IG terminal➔ Resistor R4 ➔ Contact P 1➔ Regulator F terminal ➔ ➔ Alternator field coil➔ Ground When the starter switch is turned to the "2" position, current flows as shown below, the starter turns, and the engine starts. Battery➔ Starter switch➔ Starter relay coil➔ Regulator L terminal➔ Contact P2 ➔ Ground When the engine starts and the starter switch is returned to the "1" position, the starter stops turning. At this time, the voltage at the alternator's N terminal is applied to coil VC2, so contact P2 is open. As a result, the starter cannot function if the starter switch is accidentally turned again. When the engine reaches a certain speed (driven by the starter), the voltage across coil VC2 causes contact P3to close. The field current is thereafter supplied by the alternator itself. As the alternator's output voltage increases, the voltage applied to coil VC 1 rises concomitantly. When the coil VC 1 voltage reaches a specified level, contact P 1 opens, thus cutting off the field current and reducing the gener ated voltage. When the voltage drops, contact P1 closes again, causing field current to flow and allowing the generated voltage to rise again. This mechanism maintains the alternator's output at a constant voltage. When the engine stops, the field current flows into resistor R4. Since very little current can flow through this resistor, the battery is not significantly drained even if the user forgets to cut the starter switch.

•

• •

•

16-15

ENGINE ELECTRICAL - GENERAL The regulator incorporates the following auxiliary cir cuits: ( 1) Capacitor C and resistor R 2 When contact P1 opens, capacitor C and resistor R2 increase the speed at which the circuit becomes open and minimize arcing across the contact points. When the contact closes, capacitor C and resistor R 2 increase the contact pressure and minimize contact resistance, thus lengthening the contact points' service life.

(2) Choke coil CC1 This component minimizes ripple in the alternator's output. (3) Choke coil CC2 and resistor Rs When contact P1 opens, the voltage at terminal N momentarily drops. Choke coil CC2 and resistor Rs pre vent contact P3 from opening at this time.

<R8T10183> Alternator

.----=--------- ===il Regulator

-----'BJ------

.___--1A,>----fA}--------1 ' ' Tr 1

Dz Tr 3 Field coil

,�7-=E�-\.-L

--,---;;c-�- d

To safety relay K terminal

l 1

Battery

B5886A

•

When the alternator's output voltage is low, the voltage between terminals A and E is concom itantly low. The voltage across resistor R thus becomes lower than the voltage of zener diode Dz, and no current flows through zener diode Dz. As a result, no current flows through transistorsTr 1 and Tr 2, and current starts flowing through power tran sistor Tr 3. Current thus flows into the field coil, and the alternator generates a higher output voltage.

16-16

•

When the alternator's output voltage is high, the voltage between terminals A and E is concom itantly high. When the voltage between terminals A and E reaches a specified level, zener diode Dz allows current to pass. As a result, transistors Tr 1 andTr2 allow currentto pass,and power transistor Tr 3 does not allow current to pass. Current is thus prevented from flowing into the field coil, and the alternator's output voltage decreases. The action of power transistor Tr 3 on the flow of field current thus controls the alternator's output voltage.

ENGINE ELECTRICAL - GENERAL

The intake air heater is an electric heater which heats the intake air to facilitate engine starting. Place the starter switch to HEAT position to operate the heater. If current is supplied for about 40 to 60 seconds by keeping the starter switch at HEAT position, the tem perature of the intake air heater will exceed 800° C. The intake air heater circuit has an indicator to let the driver recognize the heat condition.

1.5 Intake Air Heater <6D2>

Air heater

Starter switch

<6022, 22-T, 24-T>

START

Battery switch

-- --L

Air heater indicator

Battery

<BDC> Starter switch . 0

iOfF HEAT

0---,{)

o-;-------1,,

D8803C

SlAIIT 9

111

"CC

C '

Air heater indicator <8DC9>

Battery B4508F

16-17

ENGINE ELECTRICAL - GENERAL

1.6 Automatic Stop System

Battery switch Solenoid relay

•

Stop switch

�

T'.....J"

�-;;;

IS gg

Thermostatic switch

Solenoid drive signal

Solenoid operation <Shutdown type> When the solenoid status changes from OFF to ON, the stop lever is pulled to the STOP side. Stop !ever {returned to RUN side by return spring when solenoid status changes from ON to OFF)

Solenoid

�===:j_l=="' ====i:0:�

Injection pump governor

"' ·;;; "' C

·;;;

�

-ri

RUN OP �

�

Return spring return direction

Solenoid

B5883A

Stop lever

Oil pressure switch B5882A

<Run-on type> When the solenoid status changes from ON to OFF, a stop lever pulls the stop lever back to the STOP side. <6D2>

Stop lever {pulled to RUN side by solenoid when solenoid status changes from OFF to ON)

-----i.+ir:��....��==€@J /

Solenoid

RUN

STOP

85883B Stop lever (pulled to RUN side by solenoid when solenoid status changes from OFF to ON)

Solenoid Return spring return direction

16-18

STOry-RUN B5883C

ENGINE ELECTRICAL - GENERAL The automatic stop system automatically stops the engine if the oil pressure drops to an abnormally low level or the coolant temperature reaches an abnor mally high level. The system's key components include an oil pressure switch, a thermostatic switch, a sole noid relay, and a solenoid. Any abnormal drop in oil pressure is sensed by the oil pressure switch, which then activates the solenoid. Similarly, any abnormal increase in coolant tempera ture is sensed by the thermostatic switch, which then activates the solenoid. When actuated, the solenoid moves the injection pump governor's stop lever in the STOP direction and thereby stops the engine. There are two types of automatic stop system: shut down type and run-on type. The solenoid operation with each type is as illustrated. 1.6, 1 Shutdown type

Battery

Battery switch i I Starter B terminal

Solenoid relay 8 terminal

At this time, the oil pressure switch contacts are closed since the engine has not been started. Current thus flows as follows: Solenoid relay B terminal

Oil pressure switch

Solenoid relay W terminal

I 1) Before engine is started

Ground Solenoid relay

1B](Wi

Since there is no alternator voltage at the solenoid relay's A terminal, however, the solenoid relay is not actuated and does not supply current to the solenoid. With the solenoid not actuated, the governor's stop lever is positioned to allow the engine to be started.

starts}

To alternator L terminal

(2) When engine is started Thermostatic switch

Oil pressure switch

Starter

Stop switch

OFF

Heater relay

Battery

B5470A

When the battery switch is turned ON, current flows as follows:

When the engine is started, alternator voltage is applied to the solenoid relay's A terminal. At this time, the oil pressure is still low, so the oil pressure switch contacts are closed, current is flowing to the solenoid relay's W terminal, and the solenoid relay is actuated. However, the capacitor inside the solenoid relay charges up using the voltage at terminal A, so current does not immediately flow to the solenoid relay's actuation circuit. Charging of the capacitor thus delays actuation of the solenoid relay. During this time delay, the engine's oil pressure increases and the oil pressure switch contacts open. This cuts the supply of current to the solenoid relay's W terminal, rendering the solenoid relay totally inactive.

16-19

ENGINE ELECTRICAL - GENERAL (3) Automatic engine stop

Alternator 8 terminal

Ammeter

Starter switch B terminal

Heater relay

Solenoid�

Battery switch

Thermostatic switch

Oil pressure switch --1

Starter swi�h B terminal

Starter

fj=-----4"ui=:.J

Solenoid relay B terminal Banery switch Thermostatic switch

Oil pressure switch

OFF

HEAT

ON START

Solenoid relay W terminal Starter switch

854708

If the oil pressure drops abnormally or the coolant tem perature increases abnormally while the engine is run ning, the output current from the alternator flows as shown below and the engine is stopped.

At this time, output voltage from the alternator is pres ent at the solenoid relay's A terminal and current is flowing to the solenoid relay's internal circuit. The sole noid relay is thus actuated, causing further current to flow, as follows: Solenoid relay C terminal

1 1

Solenoid

Ground

With the solenoid thus actuated, the injection pump governor's stop lever is pulled in the STOP direction. Until the engine stops completely, the solenoid is kept activated by current from the solenoid relay's internal capacitor.

16-20

ENGINE ELECTRICAL - GENERAL 1.6.2 Run-on type

(4) Manual engine stop

(1) Before engine is started Solenoid retay

H Battery switch i)

. Solenoid"'-

Thermostatic switch Thermostatic switch

Oil pressure switch .-J-' -4\..0-

fr----

Solenoid ,,,

Starter

l!:::--t<c:<'::1-=i

Oil pressure

Stop switch!

switch

Battery switch

OFF

HEAT

IOFO+—-4-04 4

ON START iO+t04-0+0-404 IOtO0+0-40} Starter switch

OFF

HEAT

Heater relay Battery B5470C

If the stop switch is turned ON while the engine is run ning, battery current flows as follows and the engine is stopped. Alternator B terminal Ammeter Stop switch

Solenoid relay ST terminal

When current flows to the solenoid relay's ST terminal, the solenoid relay is actuated and the engine is stopped in the way described in item (3).

ON Starter switch

Heater relay

Battery B5472A

When the battery switch is turned ON, current flows as follows: Battery Battery switch

Heater relay

t t t

Starter switch B terminal Ammeter *Stop switch

Solenoid relay B terminal (* : Contacts are open with stop switch ON and closed with stop switch OFF)

Although there is a voltage at the solenoid relay's B ter minal, there is no input at any other terminal so the 16-21

ENGINE ELECTRICAL - GENERAL

solenoid relay does not actuate. The governor's stop lever is therefore in the STOP position.

Solenoid relay C terminal

(2) When engine is started

Solenoid

Ground

Solenoid relay

is}

By LC

The solenoid is thus actuated and positions the gover nor's stop lever such that the engine can be started. The engine then starts. (3) If starter switch is turned ON after engine is started

Thermostatic switch

|-::;:, !1:-+c,----c>jStop switch I

Oil pressure switch Ammeter

Solenoid relay

irBattery foe} =] switch

rr--�

Thermostatic swit� OFF

HEAT

•I

Oil pressure switch Heater relay

Starter switch

Battery 854728

Ammeter

Solenoid�

!1-1-o---4>+-� Stop switch -i ...J

Alternator

When the starter switch is turned to the START posi tion, current flows as follows: Battery

Battery switch

Heater relay

Starter switch B terminal

Starter switch C terminal

Solenoid relay S terminal

When current flows to the solenoid relay's S terminal, the solenoid relay is actuated and further current flows, as follows:

16-22

Starter switch

Heater relay Battery

85472C

When the starter switch is turned to the ON position, the connection between the starter switch C terminal and the solenoid relay's S terminal is broken. However, the solenoid relay is kept actuated by its internal capac itor. During this period, the engine's oil pressure increases and the oil pressure switch contacts close. Current generated by the alternator flows as follows:

ENGINE ELECTRICAL - GENERAL Alternator 8 terminal

Ammeter

Starter switch 8 terminal

Starter switch BR terminal ·-j

Oil pressure switch Thermostatic switch

Solenoid relay H terminal

When current flows to the solenoid relay's H terminal, the solenoid relay actuates, thereby keeping the sole noid actuated. (4) Automatic stop If the oil pressure drops abnormally and/or the coolant temperature increases abnormally while the engine is running, the oil pressure switch and/or thermostatic switch contacts open, cutting the supply of current to the solenoid relay. The solenoid relay thus stops oper ating, causing the solenoid to also stop operating. When it stops operating, the solenoid moves the gov ernor's stop lever in the STOP direction, thus stopping the engine. (5) Manual engine stop If the engine stop switch* is turned ON while the engine is running, the supply of current to the solenoid relay's B terminal is cut, thus stopping the solenoid relay from operating. The engine is thus stopped in the way described in item (4). ( * : Contacts are open with stop switch ON and closed with stop switch OFF)

16-23

ENGINE ELECTRICAL - SPECIFICATIONS 2. SPECIFICATIONS (1) Starter 6D2 Item

Specification

Voltage - Polarity

24 V -0 ground

Starter (Manufacturer Mitsubishi Electric Corp.)

Type

Electromagnetic push-in type reduction starter

Model

M3T95082

Output

24 V-5.5kW

M5T50275

Reduction gears

M5T50276

M-00095-75

24 V-6kW

M5T50279

Single reduction internal teeth spur gear

8DC Item

Specification

Voltage - Polarity

24 V -0 ground

Starter (Manufacturer Mitsubishi Electric Corp.)

Type Model Output

Electromagnetic push-in type reduction starter

M4T95082

M5T50076 I M5T50085 I 24V-6kW

Reduction

M-00180-24

M5T55171

M5T55172

24 V-7 kW

Single reduction internal teeth spur gear

gears

(2) Starter relay 6D2 Item Starter relay

(Manufacturer

Model

Specification

U1T06072

U1T06074

U1T07076

Mitsubishi

Electric Corp.)

soc Item

Starter relay (Manufacturer Mitsubishi Electric Corp.}

16-24

Model

Specification

U1T06376

U1T06372

ENGINE ELECTRICAL - SPECIFICATIONS 13) Alternator

6D2 Specification

Item 'Type

Al ternator

(Manufacturer

Mitsubishi Electric Corp.)

A2T 73387

Model

. h b UI·1t-ln IC regu ator Al ternator wit A2T 72987

I 24 V-30A

j Output

With brushes

I 35A

24V

24V-40A

24 V-80A

24 V- 40 A

24 V-90A

Specification

Item Alternator (Manufacturer Mitsubishi Electric Corp.)

Brush less

A4T A6T ! A6T I A6T · A4T [ A4T . A4T i 72986 A2T A3TN A4T i A4T 5387 57987 • 57986 76087 ! 75386 75387 40287 1 58987 70187 I 75687

Y-connection alternator with silicon diode rectifier

Type

A4T65773

Model

24 V-60A

Output

A4T86387

A4T86287

24 V-150A

24 V - 110A

BDC Item

Specification

Type

Alternator (Manufacturer Mitsubishi Electric Corp.)

With brushes Model Output

Alternator with built-in IC regulator

I I

A2T 72987

A4T 57471

24 V30A

i 57987 A4T I A6T 75387

I I

24 V-40A

Brushless A4T 58989

24 V80A

A4T

I 58289

24 V-40A

A4T 66487

A4T 75589

24V50A

24 V90A

Y-connection alternator with silicon diode rectifier A4T 85774

A4T 85777

24V-110A

14) Safety relay

6D2 Item , Model

Safety relay

Specification R8T30174

R8T30172

R8T30171

R8T30274

0-25000-5341

BDC Specification

Item Safety relay

0-25000-5341

R8T30171

:' Model

15) Regulator

Specification

Item Regulator

Model

R7T01071

6D2 R8T10183

RMS42278

8DC

R7T01072

16-25

ENGINE ELECTRICAL - SPECIFICATIONS 16) Intake air heater 602 Item !

Specification

Type

Electric heating type

' Capacity x ' q'ty

Heater relay

0.3kWx 6 U1T06671

! Mode!

! :

0.476kW x 6

2 kW x 1

U1T06672

U1T06671

127A

91 A

2.86 kW x 1

U1T06672

f-------,---------+--------�-- - - - -�-------: Fuse capacity

91 A

127 A

soc Item

Specification

I Type

I Capacity x i q'ty

Heater relay

1.4kWx2

I Model

1 Fuse capacity

1.43kWx 1

Electric heating type 1.45 kWx 1

U1T06672

U1T06675

127A

200A

1.9kWx2

1.8kWx2 U1T06673 164 A

17) Automatic stop system (option) Item

Specification For shutdown

Stop solenoid (Nippon Denso Products)

Type

Electromagnetic

Stop solenoid (Kimura Yoko Products)

Type

Solenoid relay (Nikko Denki Produkts)

Type

0-25000-5592

Oil pressure switch Thermo switch

16-26

For run-on

Electromagnetic

<except 80C9-T, 9-TC> Electromagnetic <8DC9-T, 9-TC, 0-25000-6720

Diaphragm-type with built-in electric contacts Wax-type with built-in electric contacts

ENGINE ELECTRICAL - SERVICE STANDARDS 3. SERVICE STANDARDS 3. 1 Service Standards Table 11) Starter <6D2> Maintenance item M3T95082

M5T50275, M5T50276, M5T50279, M-00095-75

i Commutator O.D.

Unit: mm Nominal value (Basic diameter in [ ])

---

38.7

43.2

M3T95082

M5T50275, M5T50276, M5T50279, M-00095-75

Brush length

I Replace

0.1

42.6

I Correct or replaces

25 to 34 N {2.5 to 3.5 kgf)

18 N {1.8 kgf)

Replace

Check

No-load characteristics

M3T95082, M5T50275, M5T50276, M5T50279, M-00095-75 (Voltage 23.5

110 A or less 3300 rpm or more

Magnetic switch operating voltage

M3T95082, M5T50279

M5T50275, M5T50276, M-00095-75

Correct or replaces

0.2 or less

Depth of groove between segment

B rush spring pressure

38.1

- -----'--------�'

Commutator outside circumference runout M3T95082, M5T50275, M5T50276, M5T50279, M-00095-75

Remedy and remarks

Limit

' Pinion gap

Gear shaft thrust gap

16 V or less 1 to 3

4to 6

0.1 to 0.5

Replace

Adjust washers

16-27

ENGINE ELECTRICAL - SERVICE STANDARDS (2) Starter <8DC> Unit mm

Maintenance item Commutator O.D.

M4T95082 M5T50076, M5T50085, M5T55171, M5T55172, M-00180-24

Commutator outside circumference runout M4T95082, M5T50085, M5T55171, M5T55172, M5T50076, M-00180-24

Depth of groove between segment

M4T95082

Brush spring pressure

M5T50076, M5T50085, M5T55171, M5T55172, M-00180-24

M5T50076, M5T50085, M5T55171, M5T55172, M-00180-24 M4T95082, ; No-load characteristics M5T50085, M5T50076, (Voltage 23.5

38.7

38.1

43,2

42.6

Remedy and remarks Replace

0.1

Correct or replaces

0.2 or less

Correct or replaces

33to 45N {3.4 to 4.6 kgf}

20 N {2 kgf}

' Replace

25to34N {2.5 to 3.5 kgf}

18N {1.8 kgfl

110 A or less 3300 rpm or more

j Replace

Check

110 A or less 3400 rpm or more

Magnetic switch operating voltage Pinion gap

M5T50076 Gear shaft thrust gap

16-28

Limit

M5T55171, M5T55172, M-00180-24, (Voltage 23.5 I V)

M4T95082, M5T50085, M5T55171, M5T55172, M-00180-24

Nominal value

I (Basic diameter in I ])

Brush length

M4T95082

16 V or less 1 to 3

4 to 6 0.1 to 0.5

Adjust washers

Replace

ENGINE ELECTRICAL - SERVICE STANDARDS (3) Alternator <6D2>

Unit: mm Maintenance item Alternator 30A IA2T72987 A2T72986 A2T73387)

Field coil resistance {at 20 °C) Brush spring tension

Load characteristics (When cold)

3.1 to 4.3 N {0.32 to0.44 kgf)

2 N {0.2 kgf) 8

17A or more

1500 rpm, Terminal voltage 27V

26A or more

i Check I I

28to29V

Replace

Field coil resistance (at 20°C)

9to 10.40

Replace

32.4

Replace

18.5

Replace

Slip ring O.D. Brush length

20A or more

29A or more

28to29V

Replace

[ Field coil resistance {at 20 °C)

Approx. 8. 7 n

40.Bto41.2

Brush spring tension

40.4

Replace

3.1 to4.3 N {0.32 to0.44 kgf)

2 N {0.2 kgf)

1 1600 rpm, Terminal voltage 27V 2500 rpm, Terminal voltage 27V

IC regulator regulated voltage range (5000 rpm, 5 A or less)

! Slip ring O.D.

Brush length

Load characteristics (When cold)

f 1600 rpm, : Terminal j voltage 27V

IC regulator regulated voltage range (5000 rpm, 5 A or less) Field coil resistance (at 20°C)

Slip ring O.D.

Brush spring tension Brush length

Load characteristics (When cold)

I 2500 rpm, Terminal j voltage 27V

Alternator 60A IA4T65773)

40.4

Replace

; IC regulator regulated voltage range (5000 rpm, 5A or less)

Load characteristics (When hot)

Alternator 40A IA4T57986 A4T57987)

40.8 to 41.2

Remedy and remarks

2500 rpm, Terminal voltage 27V

Alternator 35A IA3TN5387)

Limit

Approx. 8.7 Q

I Slip ring 0.0. Brush length

Nominal value (Basic diameter in I ])

2200 rpm, Terminal voltage 28V

26A or more

37 A or more

28to29V

Approx. 13 0

45.4

3.8 N {0.38 kgf)

2 N {0,2 kgf)

60 A or more

i Check

Check

Replace Replace

Check

16-29

ENGINE ELECTRICAL - SERVICE STANDARDS

Field coil resistance (at 20 c c)

Alternator 80 A iA6T75386 A6T75387 A6T76087)

Slip ring O.D.

! A6T75386, i A6T75387

; Brush spring tension Brush length

2 N {0.2kgf} 8

2Bto29V

Approx. 8 Q

Replace

26 A or more

Check

37 A or more

28to29V

Replace

Field coil resistance (at20°C)

Approx. 6.2Q

Replace

Load characteristics (When cold)

30A or more

41 A or more

28to29V

Replace

2500 rpm, Terminal voltage27V

: IC regulator regulated voltage range , (5000rpm, 5 A or less)

i '

Field coil resistance (at20"C) 1500 rpm, Terminal voltage27V

Load characteristics (When cold)

2500 rpm, Terminal i voltage 27V I IC regulator regulated voltage range · (5000 rpm, 5 A or less)

I Terminal 1500rpm,

voltage 27V

2500 rpm, Terminal voltage27V IC regulator regulated voltage range (5000rpm, 5 A or less)

Check

Replace

Check

I A4T 70187

Approx. 7 Q

! A4T75687

Approx. 8.2Q

1500rpm, Terminal voltage27V

53 A or more

2500rpm, Terminal voltage27V

8 2A or more

IC regulator regulated voltage range (5000rpm, 5 A or less)

28to 29V

Replace

Field coil resistance (at20°C)

9.6to 11.6

Replace

i Field coil resistance (at Alternator ° 90 A (brush- 20 CI less) (A4T 70187 Load characteristics A 4T75687) (When cold) I

I !

Slip ring 0.D. Brush spring tension Brush length Load characteristics (When cold)

16-30

40.4

71 A or more

Alternator 110 A IA4T863871

3.1 to 4.3N {0.3 2 to 0.44 kgfl

Replace

39A or more

1500 rpm, Terminal voltage 27V

Alternator 40 A (brushless) (A4T402 871

40.8 to 41.2

Remedy and remarks

: Load characteristics 1 (When cold)

Alternator 40 A (brushless) IA4T58987)

Approx. 7 .2 Q

A6T 76087

Limit

Nominal value {Basic diameter in { ])

Maintenance item

2500 rpm, Terminal voltage28V

40.4

3.1 to 4.3 N {0.32 to 0.44kgfl

2 N {0.2kgf}

100Aor more

Check

ENGINE ELECTRICAL - SERVICE STANDARDS

Alternator 150A IA4TB6287I

Maintenance item

Nominal value (Basic diameter in [ ]}

Field coil resistance (at 20 ° C)

3.0 to 3.Hl

, Slip ring 0.D. I

[

Brush spring tension Brush length I

2500 rpm, .' Terminal I voltage28V

Load characteristics (When cold)

Limit

Remedy and remarks Replace

45.4

3.1 to4.3 N {0.32 to 0.44 kgf)

2 N {0.2 kgf)

140 A or more

Check

14) Alternator <8DC> Unit: mm Maintenance item Alternator 30A A I 2T729871

i Field coil resistance (at 20 C) °

Slip ring O.D.

Brush spring tension

I Brush length Load characteristics (When cold)

I 1500 rpm, Terminal voltage27V 2500 rpm, Terminal

voltage 27V

I 1c regulator regulated voltage range I

A lternator 40A (A4T57987)

(5000 rpm, 5A or less)

Field coil resistance (at 20 °C)

! Slip ring O.D.

I 1

Brush spring tension Brush length

/ Load characteristics , (When cold)

I !

2 N {0 2 . kgf) 8 Check

Replace

2Bto29V

Replace

40.B to41.2

40.4

Replace

3.1 N to 4.3 N {0.32 to 0.44 kgfJ

2 N {0.2 kgfJ

Replace

About8.7

2500 rpm, Terminal voltage27V

37A or more

Brush spring tension Brush length

i !

40.4 2 N {0.2 kgfJ

26A or more

2500 rpm, Terminal I voltage27V

37A or more

IC regulator regulated voltage range (5000 rpm, 5A or less)

3.1 to4.3 N {0.32 to0.44 kgf) ! 1500 rpm, Terminal voltage27V

28to29V

Check

28to29V

40.Bto41.2

, Slip ring O.D.

Load characteristics (When cold)

40.4

26A or more

Field coil resistance (at 20 °C)

3.1 to 4.3 N {0.32 to0.44 kgf)

26A or more

Replace

40.Bto41.2

17A or more

Remedy and remarks

A pprox. 8.7 n

Limit

1600 rpm, Terminal voltage27V

IC regulator regulated voltage range (5000 rpm, 5A or less) A lternator 40A A ( 4T57471)

Nominal value (Basic diameter in [ 1) I

! I

! Replace

i Replace

I Check

Replace

16-31

ENGINE ELECTRICAL - SERVICE STANDARDS Limit

Remedy and remarks

Maintenance item

Nominal value (Basic diameter in [ J)

'. Field coil resistance (at 20 ° C) Alternator 40 A ibrush1500 rpm, Load characteristics less) Terminal (When cold) (A4T58289, voltage27V A4T58989)

Approx. 8 Q

Replace

26 A or more

Check

2500 rpm, Terminal voltage27V : 1C regulator regulated voltage range : (5000 rpm, 5 A or less) Alternator 50 A (brushless) IA4T66487)

28to29 V

1500 rpm,

Terminal

Replace

26 A or more

46A or more

28to29V

Replace Replace

Approx. 8 Q

Field coil resistance (at 20°C) Load characteristics (When cold)

37 A or more

Replace Check

voltage27 V 2500 rpm,

Terminal

voltage27V IC regulator regulated voltage range (5000 rpm, 5 A or less) Alternator BOA IA6T753 87)

Field coil resistance (at20 °C)

Approx. 7 2 .

Slip ring O.D.

40. 8 to 41.2

40.4

3 .1 to 4.3 N {0.32 to 0.44 kgf)

2 N {0.2 kgf)

Brush spring tension

1500 rpm, Terminal voltage27V

39 A or more

2500 rpm, Terminal voltage27V

71 A or more

28to29 V

Replace

1500 rpm, Terminal voltage27V

53 A or more

2500 rpm, Terminal voltage27V

82 A or more

IC regulator regulated voltage range (5000 rpm, 5 A or less)

28to29V

Field coil resistance (at20°C)

9.6 to 11.6 Q

45.4

3.1 to 4.3 N {0.32 to 0.44 kgf)

2 N {0.2 kgf)

Brush length Load characteristics (When cold)

IC regulator regulated voltage range (5000 rpm, 5 A or less) Alternator 90 A (brushless) (A4TI5589Al

Alternator 110 A IA4T85774, A4T8 5777)

Field coil resistance (at 20 °C) Load characteristics (When cold)

Slip ring 0.0. Brush spring tension Brush length Load characteristics (When cold)

16-32

2500 rpm, Terminal voltage28V

100 A or more

Check

Replace

Check

ENGINE ELECTRICAL - SERVICE STANDARDS (5) Regulator

Unit: mm Nominal value (Basic diameter in { l)

Maintenance item

Remedy and remarks

28to29 V

Replace

R8T10183

28to 29V

Replace

RMS4227B

28to30V

Voltage regulator regulated voltage(at 4,000 rpm) <R7T01071,R 7T01072> Voltage regulator regulated voltage \at 3,000 rpm)

Limit

(6) Safety relay Unit: mm Maintenance item Resistance between "L" and "R" terminals

Nominal value (Basic diameter in ( 1)

Remedy and remarks

Limit

Approx. 200Q

I Replace

(7) Intake air heater Unit mm Maintenance item Time required for indicator to become red-hot

Nominal value (Basic diameter in I ])

Limit

40 to 60 sec.

Remedy and remarks ! Check

(8) Automatic stop system (a) Shutdown type <6D2> Unit: mm Maintenance item Solenoid

Solenoid relay

Pointer gap

Nominal value (Basic diameter in [ l)

Limit

1,5 to 2.0

Stop lever to external stopper clearance

1.2±0,2

Holding coil current

SA or less

Delay time at starting (after 28.5 V applied to terminals "8" and "W" and 28.5 V to terminal "A")

13 to 23 sec.

Delay time at stopping (after 24 V applied to terminals "8" and "W" and no voltage to terminal "A")

25 to 35 sec.

Thermo switch actuating temperature Oil pressure switch actuating pressure

Oil pressure switch relay (24 V}

Coil resistance Min. operating voltage

93to 97 ° C 69 to 98 KPa {0.7 to 1.0 kgf/cm 2) or less

190to 2800

16 V or less

Replace

Remedy and remarks

Replace 1

Replace

16-33

ENGINE ELECTRICAL - SERVICE STANDARDS / SPECIAL TOOL

(bl Run-on type

Solenoid

Unit mm Maintenance item

Nominal value (Basic diameter in [ l) i

· Pointer gap <8DC9, 9-T, 9-TL>

0.8 to 1.2

Stop !ever to external stopper clearance

0.7 ± 0.2

Remedy and remarks

------------' --------------�------ ----' !

' Holding coil current Solenoid relay delay time Thermo switch

Limit

I Actuating temperature

1A or less

I. cooling Tap water type

26 to 34 sec. 93 to 97°C

Replace

i Replace

99to 103°c

Radiator cooling type

Within 7°C

ON-OFF difference

79to 115 KPa {0.8 to 1.2 kgf/cm2l or less

Oil pressure switch actuating pressure

Replace

3.2 lightening Torque Table Screw size 0.0. x pitch (mm)

Location tightened

Alternator pulley tightening nut

4. SPECIAL TOOL Unit: mm Tool name

Shape

Socket 31191-06100 Removal and installation of starter Width across flats 17

16-34

85021A

Tightening torque N-m {kgfm}

M17 x 1.5

83 to 105 {8.5 to 11}

M20 x 1.5

130 to 160 (13.5 to 16.5)

Alternator shaft nut

345 to 360 {35 to 37)

Remark

ENGINE ELECTRICAL - SERVICE PROCEDURE 5. SERVICE PROCEDURE

NOTE:

Whenever removing electrical parts from the vehicle, be sure to place the starter switch in OFF position, dis connect the negative battery cable, and wind the cable end with vinyl insulation tape. 5.1 Starter 5.1.1 Removal and installation <8DC>

<6D2>

Starter

C0118A

B4553A

To remove the starter mounting nut inside (on the crankcase end), use Socket (special tool: 31191-06100).

16-35

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.1.2 Disassembly

<6D2 : M3T95082> NV . Nominal Value

17 16

15 14

Gear shaft thrust gap NV 0.1 to 0.5

�,�,. Rotating condition

Worn and

20 21 damaged gear

m.��i)---'

Rota�r�g

cond1t1on

Roughened commutator surface, seizure, ridge wear, worn damaged gear

19 12

Rotating condition

\ 6

0 5

3 4

Deposited brush powder, uneven wear, movement of brush in holder 1 Mounted condition of ball and field coil 811048

Disassembly sequence

CD Yoke assembly

2 Rear bracket 3 Brush holder @ Brush spring @ Brush 6 Armature *7 Front bearing *8 Rear bearing

® Magnetic switch

10 Center bracket

@ Gear bracket @ Gear shaft @ Overrunning clutch 14 Packing 15 Plate 16 Spacer

Parts marked with * should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-36

17 Lever 18 Collar *19 Gear shaft bearing @) Ring ® Pinion stopper 22 Front bracket *23 Sleeve bearing

ENGINE ELECTRICAL - SERVICE PROCEDURE

<6D2 : M5T50275, M5T50276, M5T50279, M-00095-75> <BDC : M5T50076, M-00180-24>

Gear shaft thrust gap NV 0.1 to 0.5

NV .. Nominal Value Commutator surface roughness, seizure, stepped wear, worn or damaged gear 6 Rotating condition

Rotating condition

Worn or damaged gear

19 3

Brush power deposits, uneven wear, brush motion in holder 1 Pole and field coil installation condition

B9071C

Disassembly sequence G) Yoke assembly 2 Rear bracket 3 Brush holder @ Brush spring @ Brush 6 Armature *7 Front bearing

*8 Rear bearing ® Magnetic switch 10 Center bracket ® Gear bracket @ Gear shaft @ Overrunning clutch 14 Packing

15 *16 @ @ 19 *20

Lever Gear shaft bearing Ring Pinion stopper Front bracket Sleeve bearing

Parts marked with* should not be removed unless defects are evident, For parts with an encircled number, refer to Disassembly Procedure that follows,

16-37

ENGINE ELECTRICAL - SERVICE PROCEDURE

<BDC : M5T50085> NV .

Gear shaft thrust gap NV 0.1 to 0.5

1 1817 6

14 12

Rotating condition 7

Nominal Value

Commutator surface roughness, seizure, stepped wear, worn or damaged gear

8 Rotating condition

23 11

Rotating

condition

Worn or damaged gear Brush powder deposits, 3 uneven wear, brush motion in holder

Pole and field coil installation condition

Disassembly sequence G) 2 3 @

Yoke assembly Rear bracket Brush holder Brush spring @ Brush 6 Armature *7 Front bearing *8 Rear bearing

® Magnetic switch 10 Center bracket ® Gear bracket @ Gear shaft @ Overrunning clutch 14 Packing 15 Plate 16 Spacer

17 Lever 18 Collar *19 Gear shaft bearing @ Ring @ Pinion stopper 22 Front bracket *23 Sleeve bearing

Parts marked with* should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows. 07564B

16-38

ENGINE ELECTRICAL - SERVICE PROCEDURE

<8DC : M4T95082> Roughened commutator surface, seizure, ridge wear, Rotating condition 12 10 . worn damaged gear

condition

NV .. Nominal Value Gear shaft thrust gap NV 0.1 to 0.5 I

2 I 22 Mounted condition of pole and field coil

Disassembly sequence (D Yoke assembly 2 Rear bracket 3 Brush holder @ Brush spring @ Brush 6 Armature *7 Front bearing *8 Rear bearing

Deposited brush powder, uneven wear, movement of brush in holder

® Magnetic switch 10 Center bracket @ Gear bracket ® Gear shaft @ Overrunning clutch 14 Packing 15 Plate 16 Spacer

B1104C

17 Lever

18 *19 @) @ 22 *23

Collar Gear shaft bearing Ring Pinion stopper Front bracket Sleeve bearing

Parts marked with * should not be removed un Jess defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-39

ENGINE ELECTRICAL - SERVICE PROCEDURE

<8DC: M5T55171, M5T55172>

Commutator surface roughness, seizure, stepped wear, worn or damaged gear

Gear shaft thrust gap NV 0.1 to 0.5

Rotating

Rotating condition

condition

NV .. Nominal Value

Worn or 13 11

damaged

gear

2 1

Pole and field coil installation condition

Brush power deposits, uneven wear, brush motion in holder

4 2 5 Brush 3 power deposits,

1 uneven wear, Pole and field coil brush motion in holder installation condition

Disassembly sequence

CD Yoke assembly 2 Rear bracket

B1104L

® Magnetic switch

10 Center bracket @ Gear bracket ® Gear shaft @ Overrunning clutch 14 Packing 15 Plate 16 Spacer

Parts marked with * should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-40

17 Lever 18 Collar *19 Gear shaft bearing ® Ring @ Pinion stopper 22 Front bracket *23 Sleeve bearing

ENGINE ELECTRICAL - SERVICE PROCEDURE Disassembly Procedure The disassembly procedure is common to all models. The following description is based on the model M3T95082 starter. I 1) Removal of yoke assembly

Magnetic switch

13) Removal of overrunning clutch

Gear bracket

Front bracket assembly Gear bracket mounting bolt

Yoke assembly

829546

Gear shaft Overrunning clutch B2951B

Front bracket

Gear bracket

Remove the magnetic switch and separate the front bracket assembly and yoke assembly. NOTE: Do not drop the armature. Especially when disassembling with the armature staying in the yoke, do not tilt the yoke assembly. 12) Inspection of gear shaft thrust gap

B2955D

(a) Remove the gear bracket mounting bolt and remove the overrunning clutch, to which the gear shaft and gear bracket remain installed, from the front bracket.

Tool pipe

Ring groove

Pinion stopper

B2963B

Before disassembly, set the dial indicator as shown to measure the thrust gap in the gear shaft. If the mea surement is out of specification, use adjusting washers to obtain correct gap. [For adjustment procedure, refer to Item (8), Section 5.1.3.]

82957A

(b) Apply a tubular tool to the pinion stopper and ham mer the pinion stopper out toward the pinion side. Then remove the ring.

16-41

ENGINE ELECTRICAL - SERVICE PROCEDURE �

(4) Removal of brush spring

Ring

11 I' ijil

�---- Pinion stopper the Ringgear groove shaftof

Brush spring

82958A

Overrunning clutch Gear bracket Gear shaft

82959A

(d) Remove the overrunning clutch and gear bracket from the gear shaft.

16-42

02464

To remove the brush spring, first release the brush spring and remove the brush.

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.1.3 Inspection

Item

Commutator O.D.

M3T M4T

38.7

38. 1

MST, M-00095-75, M-00180-24

43.2

42.6

Commutator outside circumference runout

0.1

Depth of groove between segment

0.2 or less I

Short circuit test, coil ground test, open circuit test

Coil open circuit test, fused con1 tact, bad contact I 1

•

NV . Nominal Value L. Limit

Coil ground test, ) \ open circuit test I Item 1

Brush spring pressure

Brush length

M3T M5T, M-00095-75, M-00180-24

25to 34N {2.5 to 3.5 kgfl

18N {1.8 kg!)

M4T

33to45N {3.4 to 4.6 kgfl

20 N {2 kgfl

M3T

M4T

MST, M-00095-75, M-00180-24

Insulation test

B1104E

16-43

ENGINE ELECTRICAL - SERVICE PROCEDURE Inspection Procedure

The inspection procedure given in the following is based on the model M3T95082 starter. For any other starter models, those points which are different from M3T95082 are described together.

( 1) Armature inspection (a) Coil short circuit test

02473

02471

Place the armature on a growler tester. Hold a piece of iron in parallel with the armature and slowly turn arma ture by hand. If the iron piece is attracted or vibrates, it means there is a short circuit. Replace the armature.

Measure the runout of commutator using a dial gauge and turning the armature by hand. If the runout exceeds the limit, correct, ensuring that the 0.0. limit is not exceeded. If the commutator surface is rough developing ridge wear, correct with sandpaper (No. 300 to 500). After correction, make sure to check the runout again. (d) Commutator 0.0.

(b) Coil ground test

, / 02474

02472

Check for continuity across the commutator and shaft (or core). If there is a continuity, indicating that the coil is grounded, replace the armature.

16-44

Measure the commutator 0.0. If the measurement exceeds the limit, replace the armature.

ENGINE ELECTRICAL (e) Mica depth groove between segments

SERVICE PROCEDURE

If there is no continuity, indicating an open circuit, replace the yoke assembly. (b) Coil ground test

�Mica depth

�

Measure the Mica depth of groove between segments. If it does not reach the limit, correct the armature.

Check that there is no continuity between the yoke and brush(+). If there is continuity, indicating that the coil is grounded, check for poor insulation. If repair is impossible, replace the yoke assembly.

Mica

Good

D75118

�

(3) Inspection of brush

Bad

D75098

If the segment indicates the faulty condition as shown in the illustration, replace the armature. (2) Inspection of field coil (a) Coil open circuit test D7512C

(a) Measure the brush length and, if the measurement is less than the limit, replace the brush as an assembly[(+) side: yoke assembly; H side: brush holder assembly]. (b) If the brush is unevenly worn or develops rough surfaces, correct with sandpaper (No. 300 to 500).

NOTE:

Correct the brush contact surface to a curve of the commutator. D75108

Check that there is continuity between the terminal lead and brush (+).

16-45

ENGINE ELECTRICAL

1u1

SERVICE PROCEDURE (61 Inspection of magnetic switch

141 Inspection of brush spring

(al Coil open circuit test

�

/ "B" t�? "•:•"

3:,�:::::,,

"M" terminal

02466

�✓ terminal

Measure the installed load of the brush spring. Using a new brush read the load at the moment the spring leaves the brush.

M4T95082 MSTS00BS MST55171 MST55172

(5) Brush holder insulation test

MST50275 M5T50276 MST50279 M5T50076 M-00180-24 M-00095-75

M3T95082

B2586H

•

Check that there is a continuity across "S" and "M" terminals. If there isn't, replace the magnetic switch.

02467

Check to ensure that there is no continuity between the (+) brush holder and (-) holder plate. If there is continuity, replace the brush holder.

B2586J

•

16-46

Check to ensure that there is a continuity across "S" and ground terminals. If there isn't, replace the magnetic switch.

ENGINE ELECTRICAL - SERVICE PROCEDURE •

lb) Fused contact check "B" terminal

(or "M" terminal)

"M" terminal

(or "B" termi n

In this condition, check that there is a continuity across "B" and "M" terminals. If there isn't, replace the magnetic switch.

(7) Inspection of overrunning clutch

J,�-"&,4

:_:: •�I ) '.__

B2586B

•

Check that there is no continuity across "B" and "M" terminals. If there is, replace the magnetic switch.

Install the gear shaft to the overrunning clutch and check to see if the gear shaft turns smoothly when turned clockwise (in the drive direction) and locks when turned counterclockwise. If any unusual condition is noted, replace the overrun ning clutch. With the overrunning clutch fitted into the gear shaft, check also that the overrunning clutch moves smoothly along the splines.

le) Contact test

B2587B

•

B2960B

Close the contacts of the magnetic switch as shown in the illustration.

NOTE: Do not clean the overrunning clutch with cleaning oil. If the overrunning clutch is cleaned with cleaning oil, the grease inside it will come out.

(8) Adjustment of gear shaft thrust gap

"B" terminal (or "M" terminal)

"M" terminal (or "B" termina:'.l)'..____.J,j:;-=""6

Adjusting washer

B2964B B2586B

If the thrust gap is out of specification, insert the adjust ing washer into the position shown. [For adjusting procedures, refer to Item (2), Section 5.1.2.]

16-47

ENGINE ELECTRICAL

SERVICE PROCEDURE (b) Replacement of front and rear bearings (Removal)

(Adjusting washer: 0.25, 0.5 mm) (9) Replacement of bearings (a) Replacement of gear bearing (Removal) Press down with a press.

Bearing puller

Internal gear

Rear bearing

Armature Cylindrical block

Front bearing

B25768

D7503A

(Installation)

If the bearing of the gear shaft is defective, put a pin or bolt in each of the four holes (6 mm in diameter) in the internal gear and press down the bearing out of posi tion with a press. (Installation)

Inner race

Tubular toot 82577D

•

Install the rear bearing by striking its inner race uni formly with a soft hammer.

B2962B

Apply a tubular tool to the bearing inner race and ham mer it into position.

Inner race

B25788

•

16-48

Install the front bearing applying a tubular tool diameter as its inner race and striking it into posi tion.

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.1.4 Reassembly <6D2 : M3T95082>

NV .. Nominal Value

; Apply grease *3.

14 16 18

Apply grease *1.

i Apply grease *1.

i Apply a thin coat 1· of grease *2 to outer periphery.

Pinion gap NV1to3

I I

Apply grease *4.

10 12

I Apply grease *3.

Apply grease *1.

Gear shaft thrust gap \ NV 0.1 to 0.5

D7548C

<Recommended greases> *1 MULTEMP MS-2 {Kyodo Yushi) or equivalent *2 MULTEMP HD-2 (Kyodo Yushi) or equivalent *3 MYSTIK JT-6 (Kyodo Yushi) or equivalent *4 MOLYKOTE AS-19 {Dow Corning) or equivalent Assembly sequence

®➔23--, I➔16➔ 15➔14➔ 10---iID ®➔ 19 ➔®➔@➔@➔@ -, , �2 s➔1 ➔B -----i r---' @➔®---' 3➔5➔4--lD ___,

1-I· ,

For parts with an encircled number, refer to Reassembly Procedure that follows.

16-49

ENGINE ELECTRICAL - SERVICE PROCEDURE

<6D2 : M5T50275, M5T50276, M5T50279, M-00095-75> <8DC: M5T50076, M-00180-24>

I Apply grease *3.

9 NV .. Nominal Value

Apply grease * 1. !

Apply a thin coat of grease

•2 to

outer periphery.

I Apply grease *1. i

13 Pinion gap

MST50279 Apply grease *3. Gear shaft thrust gap I NV 0.1 to 0.5 i

M-00180-24

NV 1 to 3

MST50076 MST50276 M-00095-75

4 to 6

MST50275

@➔ 16➔®➔@....® ....®....®

--,!-> 14➔10➔®

19➔20--:

6➔7---+8

::J

�

I i➔2 3---+5---+4➔CD ___J

For parts with an encircled number, refer to Reassembly Procedure that follows.

16-50

890738

ENGINE ELECTRICAL - SERVICE PROCEDURE

14 \

Apply grease *1.

NV .. Nominal Value

I Apply grease *2.

�o

;

|of grease*3to

| Outer periphery.

| |

\ \

! Apply grease *2. Apply grease *1. ,

Apply grease *4.

Gear shaft thrust gap

NV 0.1 to 0.5

Pinion gap NV 1 to 3

<Recommended greases> *1 MYSTIK JT-6 {Kyodo Yushi) or equivalent *2 MULTEMP MS-2 {Kyodo Yushi) or equivalent *3 MULTEMP HD-2 (Kyodo Yushi) or equivalent *4 MOLYKOTE AS-19 {Dow Corning) or equivalent Assembly sequence

®➔23--� ➔16➔15➔14➔10--lID @➔19➔® ➔®➔@➔@ @➔@___J

2 _f 6➔7➔8 � 3➔5➔4-iD

For parts with an encircled number, refer to Reassembly Procedure that follows.

D75668

16-51

ENGINE ELECTRICAL - SERVICE PROCEDURE

<BDC : M4T95082> 9

! Apply grease ..3.

NV .. Nominal Value

Vay

20 4

“4 4

OS ie

i BR

y uri|e

Lol Se

Apply a thin coat of grease *2 to outer periphery.

23 I Apply grease *1.

Pinion gap NV 1 to 3 2

6 7

i Apply grease *3.

I Apply grease *4. I Apply grease *1. j i

Gear shaft thrust gap NV O. 1 to 0.5

I <Recommended greases> *1 MULTEMP MS-2 (Kyodo Yushi) or equivalent *2 MULTEMP HD-2 (Kyodo Yushi) or equivalent *3 MYSTIK JT-6 (Kyodo Yushi) or equivalent *4 MOLYKOTE AS-19 (Dow Corning) or equivalent Assembly sequence

®➔23

➔16➔15➔14➔10➔®-®➔19➔®➔@➔®➔@;:-l 1. ➔2 LJ . 6➔ 7 ➔8 I ®➔® 3➔5➔4➔CD

�

_J-·

For parts with an encircled number, refer to Reassembly Procedure that follows.

16-52

D7548D

ENGINE ELECTRICAL - SERVICE PROCEDURE

<BDC : M5T55171> 9

Apply grease *3. NV .. Nominal Value

14 I Apply a thin coat of grease *2 to

'\E!:ilt:lf'\U�!....JI

i outer periphery.

I Apply grease *1.

i Apply grease *3. !

8 21

I Apply grease • 4. I I

12 19

Pm1on gap NV 1 to 3

Apply grease * 1.

Gear shaft thrust gap NV 0.1 to 0.5 i

D7548E

<Recommended greases> *1 MULTEMP MS-2 (Kyodo Yushi) or equivalent *2 MULTEMP HD-2 (Kyodo Yushi) or equivalent *3 MYSTIK JT-6 (Kyodo Yushi) or equivalent *4 MOLYKOTE AS-19 (Dow Corning) or equivalent Assembly sequence ®-,23--� 1➔1s-,1s-,14-,10-,@

®-,, 9-,®➔@-,®-,®-w ® "" . 1 -➔\& ___J

�2

s-,7 -,a----,

\.------'

3➔5--+4-,,CD __J

For parts with an encircled number, refer to Reassembly Procedure that follows.

16-53

ENGINE ELECTRICAL - SERVICE PROCEDURE

<BDC: M5T55172>

ree i] qi ce ran)Bin Mira eatenlod y LE ‘4

ae Fa

Nominal Value

}

1 Apply grease *3. ! NV .

Apply a thin coat i of grease *2 to outer periphery. !

Apply grease •1.

Apply grease *3. I

✓--� ‘ae.

Apply grease *4

10 Apply grease * 1. I

Gear shaft thrust gap NV 0.1 to 0.5 I

13 12

i Apply grease *1. i

Pinion gap NV 1 to 3

D7548H <Recommended greases> *1 MULTEMP MS-2 (Kyodo Yushi) or equivalent *2 MULTEMP HD-2 (Kyodo Yushi) or equivalent *3 MYSTIK JT-6 (Kyodo Yushi) or equivalent *4 MOLYKOTE AS-19 (Dow Corning) or equivalent Assembly sequence

3➔4➔5➔CD➔2 6➔7➔8J

For parts with an encircled number, refer to Reassembly Procedure that follows.

16-54

ENGINE ELECTRICAL - SERVICE PROCEDURE Reassembly Procedure The reassembly procedure given in the following is based on the model M3T95082 starter. For any other starter models, those points which are different from M3T95082 are described together.

m �Ring 1----Gearshaft Ring groove

(1) Reassemble the gear shaft, overrunning clutch, and gear bracket in the following way. Overrunning clutch

B2968A

Gear bracket Gear shaft

, Grease (MULTEMP MS-2 or equivalent)

Grearse (MOLYKOAT AS-19 or equivalent)

B2959B

la) Coat the portions in gear shaft shown with the spe cified greases and install the gear bracket and over running clutch over the gear shaft. B2969A

Pinion stopper

►.....-�►�

(d) Pull hard the pinion gear toward the ring and secure it by fitting the ring into the ring groove in pinion stopper.

!Ejj--

(2) Installation of lever (a) Collar fixed type <M3T95082, M4T95082, M5T50085, M5T55172> 82967A

Front bracket

(b) Install the pinion stopper to the gear shaft in the direction shown.

B2956C

16-55

ENGINE ELECTRICAL - SERVICE PROCEDURE

Install the lever in the direction shown, together with the collar, into the front bracket.

Upon installation, make sure that the lever is wedged into the overrunning clutch.

(b) Pin fixed type (Model M5T50076 only)

(4) Installation of magnetic switch

<M5T50275, M5T50276, M-00095-75, M-00180-24>

M5T50279,

M5T50076, "B" terminal

"S" terminal

Magnetic switch Grease

Screw

(MYSTIKJIT-6

or equivalent)

82956D

"M" terminal " S" "B" terminal "8" terminal

82952C "S" terminal "B" terminal

Insert the lever in the direction shown and mount it with the pin from outside the front bracket. (3) Installation of overrunning clutch and gear shaft Overrunning clutch

Front bracket

Gear shaft

<M5T50275, M5T50276, M5T50279, M5T50076, M-00095-75, M-00180-24>

<M4T95082, M5T50085, M5T55171, M5T55172> 84538A

Apply grease to the part of the magnetic switch shown in the illustration, then fit the magnetic switch onto the lever. Type M3T magnetic switches should be fitted with the B terminal on top. Types M4T and MST should be fitted with the S terminal on top. Grease IMYSTIKJT-6 or equivalent)

Grease IMULTEMPMS-2 or equivalent)

(5) Installation of yoke assembly 82955E

Grease IMOLYKOAT MS-2 or equivalent)

Overrunning clutch

82970B

Before installing the overrunning clutch and gear shaft to the front bracket, be sure to apply the specified greases to the portions indicated. 16-56

82697A

Apply the specified grease to the armature splines, then install the yoke assembly to the center bracket.

ENGINE ELECTRICAL - SERVICE PROCEDURE

<M3T>

Center bracket notch

829738

<M-00095-75, M-00180-24, M4T, M5T>

Center bracket notch Yoke terminal

82973C

Fit the yoke assembly such that the yoke terminal fits into the center bracket notch.

16-57

ENGINE ELECTRICAL 5.1.5 inspection and adjustment after reassembly

( 1) Inspection of pinion gap

SERVICE PROCEDURE (a) Wire the reassembled starter as shown above. (b) Turn ON switches K 1 and K2 to project the pinion. (c) Turn OFF switch K2 to stop pinion from rotating.

<M3T95082> Switch K,

Pinion

"S"

"M" terminal

Connector to be removed

<M4T95082, M5T50085> sw· K2 Pinion gap

"S" terminal

Model

' M3T95082, M4T95082, M5T50085, M5T50279, M5T55171, M5T55172, M--00180-24 , M--00095--75, M5T50076, i M5T50276, M5T50275

<M5T50275, M5T50276, M5T50279, M5T50076, Switch K2 M--00095--75, ,.___ M--00180--24> Switch K1

/7:

"M" terminal

;�.'\

,Is�, a} ,:;. \$f) ��

1-----

,I--

t____,_ _,, _ -w_,.::I L� :

80054D1

,.,

iJ1

Connector to be removed

<M5T55171, M5T55172> Switch K2

4 to 6

Magnetic switch

:]�� ! 0 11

1 to 3

(d) Measure the axial movement (pinion gap) when the pinion is pushed lightly toward the armature side.

Battery

"S" terminal

NV .. Nominal Value

82909E

Connector to be removed

82909G

Battery 829758

82909F

16--58

(e) If the measurement is out of specification, increase or decrease the number of washers used at the por tion to which magnetic switch is mounted. Washers: 0.25, 0.5, 1.0 mm

ENGINE ELECTRICAL - SERVICE PROCEDURE (2) Inspection of no-load characteristics and magnetic switch operating voltage <M3T95082>

Trans Ammeter Voltmeter former

M-00180-24>

Use a wire as thick as possible and secure each connection firmly. Apply voltage gradually from O V up to 24 V.

(b) With the specified voltage applied, measure the current and speed of rotation. If the measurements are out of specification, inspect the starter again and replace any faulty components. Measure the rotating speed by illuminating the pinion with strobe light. Trans former

B36218

<M5T50275, M5T50276, M5T50279, M5T50076, M-00095-?S,

NOTE: 2.

8 t_ermina

<M4T95082, M5T50085>

(a) Set up a circuit as shown including the ammeter, voltmeter and transformer.

Ammeter Voltmeter i��:r

Nominal values (no-load characteristics) Type

Voltage

M3T. M4T, M5T {except M5T55171, M5T55172, M-00180-24I M-00095-75 M5T55171, M5T55172, M-00180-24

23.5 V

Nominal values Current I Speed of rotation 110A or less I 3,300 rpm or above I

110A or less

(C) When a potential of 15 to 16V is applied, the pinion should spring out and turn. If the pinion does not spring out and turn unless the voltage is above the specified nominal level, inspect the starter again and replace any faulty components. Nominal values {magnetic switch operating voltage)

<M5T55171, M5T55172> Trans AmmeterVoltmeter former

3,400 rpm

ceor above

16V or less

B3621E

S terminal

B3621O 16-59

ENGINE ELECTRICAL - SERVICE PROCEDURE

5.2 Starter Relay <U1T06372>

"SW" terminal

"SW" terminal

"L" terminal

aoe

"S" terminal "8" terminal

"L" terminal

"S" terminal

080030

<U1T06376> '"SW'" term

©!3;

"B" terminal 08003J

<U1T06074,U1T07076> terminal

"B" terminal

�

t�rminal

"L" terminal "SW"

"L"

"S" terminal "SW" terminal

080030

(a) Check for continuity between the "SW" and "L"

�--17

terminals and check to ensure that the coil resis tance is up to specification. (b) Check to ensure that when the battery voltage (24 V) is applied across the "SW" and "L" terminals, there is continuity between the "B" and "S" termi nals.

L_ 16-60

08003A

08002A

ENGINE ELECTRICAL - SERVICE PROCEDURE

5.3 30 A, 35 A, 40 A <except A4T57471>, 80 A Alternators (with brush type) 5.3.1 Removal and installation <6D2>

Alternator

V-belt V-belt

80104H

85884A

<8DC9>

Alternator

C0113E

85885A

16-61

ENGINE ELECTRICAL - SERVICE PROCEDURE <8DC9-TL, 9-TC>

<8DC9-T>

Alternator

C0113D

After installation, adjust the V-belt tension by referring to Section 5.10 of Group 14 Cooling.

16-62

80104J

ENGINE ELECTRICAL - SERVICE PROCEDURE

5.3.2 Disassembly

I <30 A, 40 A, 80 A Alternators>

83907E

Disassembly sequence G) Rear bracket assembly ® Stator 3 Rectifier ®A Rectifier <BOA> 4 Regulator 5 Brush 6 Brush spring

7 8 ® (@ 11 12 13

Rear bracket Pulley and fan Pulley Fan Spacer Rotor assembly Spring

*14 Rear bearing @ Rotor @ Front bracket assembly 17 Cover 18 Cover *19 Front bearing @) Front bracket

Parts marked with * should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-63

ENGINE ELECTRICAL - SERVICE PROCEDURE

<35 A Alternator> 1� 11

�12

\ 14

13' \ \ \

, , '\ 17g\ ,,

\�

2 B6000A

Disassembly sequence

CD Rear bracket assembly ® Stator 3 Plate

Brush 5 Brush spring 6 Regulator and holder 4

brush

7 Sringa

8 Rectifier ® Rear bracket @) Pulley 11 Front bracket assembly 12 Cover *13 Front bearing

Parts marked with * should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-64

® Front bracket

15 Rotor assembly *16 Rear bearing

@ Rotor

ENGINE ELECTRICAL - SERVICE PROCEDURE Disassembly Procedure

The inspection procedure is almost the same for all alternators. For clarity, the instructions in this section are written for 30A alternators, and extra notes are pro vided for other models where necessary.

<Except 35 A Alternator> Spring

I 1) Separation of front bracket assembly from rear bracket assembly

88107H

At time of separation, use care not to lose the spring fitted to the outside of the rear bearing.

(2) Removal of pulley Pulley

Fan

B1949O

(except 35 A Alternator)

Remove the through bolt and, using a screwdriver, pry off the front bracket assembly from the rear bracket assembly. NOTE:

Bearing

box

B1029T

Hold the rotor in a vice, etc. and remove the pulley, fan and front bracket. NOTE:

Do not hold these areas.

B1949P

The rear bearing is tightly fitted. Before separa tion, therefore, preheat the bearing box of the rear bracket by an air dryer to facilitate separation.

When holding the rotor in a vice, be sure to hold at illustrated portion. 16-65

ENGINE ELECTRICAL - SERVICE PROCEDURE

131 Removal of stator coil

(4) Separation of rectifier

<30 A, 40 A Alternator>

<35 A Alternator>

en = _

Ali

RectifierYW A <80 A Alternator>

Rectifier

04787

B1031C

<35 A Alternator> Rectifier diode area

83909A

Stator coil leads

Separate the rectifier by unsoldering the area shown. Stator 04760

<80 A Alternator>

ifi

Stator coil leads

81950A

To remove the stator coil, unsolder the stator coil leads soldered to the rectifier. NOTE: When unsoldering, finish it in a short time (less than 5 seconds) with a soldering iron.

16-66

NOTE: When unsoldering, finish it in a short time {less than 5 seconds) with a soldering iron.

lie

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.3.3 Inspection

-=====��:_---+__+•;

<30A,40A' 8 0A Alternator>

I L = =� 8 ·_8 Q ' A pp r�ox: -}_7 Field co1·; resistance 30A, 40A . � :� � � ; -=[, '. �BOAOA�:__:_:-+ Approx. 7.2 Q � ��! r : Slip ring O.D;-. _'_4�0-_E.B�t�o�4�1 ·�2= i 40.4.:_ ! i i Ground test _ ltem

.. �·,�o<I:2�1\ &"

�

�-;;-A

@ �� )

. .·

Brush length ! NV 23 , I L 8 '

Open circuit test I ! Ground test

'®

��

:y �," . � . Brush spnng / tension N V 3.1 to 4 3 N {0.32 to· 0.44 kg · L 2 N {0.2 kgf} f) j

I 1

<35 A Alternator>

LNV.. : . N �'f:inal Value u

Short circuit test I

test Qpen circuit .

83907F

Item

Field coll resistance

I Slip spring o.D. . Ground test

Brush length NV 18.5 I L 5 - i- tt� - est:: _n_c�,,. cu 'O"pe � j

l : Ground test

9to 10.4 33

L 32.4

3'�

]

Short circuit test l i

Iopen cir. cuit test I 860008

16-67

ENGINE ELECTRICAL - SERVICE PROCEDURE

Inspection Procedure The inspection procedure is almost the same for all alternators. For clarity, the instructions in this section are written for 30A alternators, and extra notes are pro vided for other models where necessary.

12) Inspection of rotor la) Continuity between slip ring and core

I 1) Inspection of stator (a) Continuity across leads

Meee D8130D

Check that there is no continuity between the slip ring and core. If there is, replace the rotor as it is grounded. D8058A

(b) Field coil resistance

Check that there is continuity across stator leads. If there is no continuity, indicating a broken wire, replace the stator. lb) Continuity across stator leads and core

D8131D

Measure the resistance across slip rings. Replace the rotor if the resistance is not within the specification. D80588

Check that there is continuity across the stator leads and core. If there is, replace the stator as it is grounded.

16-68

ENGINE ELECTRICAL - SERVICE PROCEDURE (bl Inspection of brush spring

<30 A, 40 A Alternators> Brush spring

D8132C

Measure the slip ring O.D. lfthe slip ring has rough sur face or is unevenly worn, correct with sandpaper or lathe. Correction must be made within the limit of slip ring O.D. (3) Inspection of brush and brush spring (a) Inspection of brush 82718A

, <30 A, 40 A Alternators>

If the spring pressure is lower than the limit, replace, � ne én

]

"' 15,"' "'� _, C

Wear limit line

D8062A

<35 A Alternator> Brush fength when new ength

limi

— /

02353

• wear limit line

Unsolder the position shown in the illustration and remove the brush and brush spring.

04786

Replace the brush if it is worn beyond the limit.

16-69

ENGINE ELECTRICAL - SERVICE PROCEDURE • Pin

Brush

Insert the brush into the regulator and brush holder, making sure it faces in the direction shown. Then, resolder the unsoldered points.

NOTE: Be sure to use a soldering iron to remove and replace the solder. Apply the soldering iron for as short a time as possible (within 5 seconds). (41 Inspection of rectifier

827378

•

When soldering the brush, insert a pin into the brush hole and fix to the regulator assembly.

NOTE: When soldering or unsoldering, work quickly (within about 5 seconds) with a soldering iron. <35 A Alternator>

B6001A

•

Unsolder the parts of the regulator and brush assembly shown in the illustration. Then, with draw the brush and brush spring.

Regulator and brush holder

Brush 04785

16-70

Measure resistance of each diode. Measure both when with the circuit tester(+) probe applied to the diode and when with the H probe applied to the diode. • If resistance is infinite in both cases, the diode is open. • If resistance is close to zero in both cases, the diode is shorted. In the case of open or shorted diode, replace the recti fier. Measure according to the following procedures.

ENGINE ELECTRICAL la) Measurement of diode mounted to heat sink

SERVICE PROCEDURE

Measure between the heat sink and stator coil lead connections.

<30 A, 40 A, 80 A Alternator>

(b) Measurement of diode trio (3 places)

Stator coil lead wire connections (3 places)

<30 A, 40 A, 80 A Alternator>

Heat sink 82720A

82722A

<35 A Alternator>

82721A 04789

<35 A Alternator>

Measure between the plate connecting to the regulator and the stator coil lead connections. (5) Inspection of bearings Replace the bearing if defect is evident. (a) Replacement of front bearing (Removal)

Cover

Front bracket

B2724A

04788

1) Remove the bearing cover. 16-71

ENGINE ELECTRICAL - SERVICE PROCEDURE

•

Rod

Rod Spacer

l!i' ''

� j\ Spacer Front bracket

Front bearing

Front bracket

Front bearing

82730A

82725A

2) Apply a rod to the spacer on the front side of the front bracket and strike out the bearing. (Installation)

Install the cover and strike the spacer with a soft hammer, etc. to make sure that the bearing and cover are in contact with each other. If not, strike the spacer to bring them into contact.

(b) Replacement of rear bearings (Removal)

Rear bearing

82728A Front bearing

Cover

Front bracket

------,=,:;�=r-.l-

B3109A

1) Apply a light coat of engine oil to the outside of the bearing and install to the inside of the front bracket using a press. Install flush with the cover mounting portion.

16-72

B2731D

NOTE: Use care not to cause damage to the slip ring by the bearing puller.

ENGINE ELECTRICAL - SERVICE PROCEDURE

(Installation)

Apply grease.

Spring fitting groove

827320

Apply a light coat of engine oil to the inside of the bear ing and using a press, install with the spring fitting groove of the bearing facing the rotor field coil side.

16-73

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.3.4 Reassembly <30 A, 40 A Alternators>

8 I

10 11

9 130 to 160 N,m {13.5 to 16.5 kgf,m}

5 Apply engine oil to rotor shaft I outer periphery

B2990L

<80 A Alternator>

13 15

130 to 160 N-m

{13.5 to 16.5 kgf-m}

I Apply engine oil . to rotor shaft I outer periphery

82990M

Components

Reassembly sequence

1: 3, 3A <BOA only>, 4, 5, 6, 7 12: 13, 14, 15 16: 17, 18, 19, 20

16 (20� 19➔ 18➔ 17)➔ 12 (15➔ 14➔@)➔8 (10-+9)➔2➔CD(7➔@➔6➔5➔(3)-/�)A<80Aonly>)

16-74

For parts with an encircled number, refer to Reassembly Procedure that follows.

ENGINE ELECTRICAL - SERVICE PROCEDURE

<35 A>

130to 160 N·m (13.5 to 16.5 kgf.ml

6 4

9 5

Components 1: 3, 4, 5, 6, 7, 8, 9 11: 12, 13, 14 15: 16, 17

Apply engine oil to rotor shaft outer periphery

Reassembly sequence

11 (14-913-312)-915 (17-316}310-2-91(9-47-654-983) For parts with an encircled number, refer to Reassembly Procedure that follows.

86002A

16-75

ENGINE ELECTRICAL - SERVICE PROCEDURE (3) Installation of front bracket and rear bracket assembly

Reassembly Procedure

(1) Installation of rectifier <80 A alternator> Rear bracket

Rectifier

819518

82745A

When the rectifiers are to be connected together by sol dering, do the soldering with the regulator as well as the rectifiers mounted to the rear bracket.

(a) Push in the brush by hand and insert the pin into the brush hole from the rear of the rear bracket to fix the brush. (b) Keeping this condition, install the rear bracket assembly to the front bracket assembly.

NOTE: When soldering, finish it in a short time (less than 5 seconds).

(2) Installation of spring (30 A, 40 A, 80 A Alternators)

., ,0

NOTE: After completion of reassembly, be sure to remove the pin and close the hole. 5.3.5 Inspection and adjustment after installation

(1) Handling precautions When servicing the alternator, observe the following precautions.

Spring

Keep spring protrusion minimum.

D8099E

Install the spring with its highest point seated in the deepest of the spring fitting groove of the bearing. 02369

(a) Never connect the battery reversely. If the polarity of the battery is reversed when con nections are made, a large current flows from the battery to alternator, damaging the diode and IC regulator.

16-76

ENGINE ELECTRICAL - SERVICE PROCEDURE

02370

02373

(b) Do not disconnect the battery terminal connec tions while the engine is running, or a surge volt age develops deteriorating the diode and regula tor.

(e) Operating the alternator with its "B" and "l" termi nals shorted results in the damaged diode trio.

I /

,,,.

02374 02371

(f)

When quick-charging the battery with a quick char ger, be sure to disconnect terminal connections in advance. Otherwise, a damaged diode and regula tor will result.

02372

(d) Do not expose the alternator to the water. If the alternator is exposed to water, short circuit may result, causing damaged alternator. 16-77

ENGINE ELECTRICAL - SERVICE PROCEDURE •

(2) Performance test (a) Test bench inspection

[SJ

<30 A, 40 A, Ammeter S0AAlternators>

'+--+-' '-'f--9>-'

While gradually increasing the alternator speed and reducing the load resistance, measure the cur rent value with the specified terminal voltage and speed. If the measurement is below the specification, check alternator parts. Output current 30A alternator (when cold) 35A alternator (when cold)

"B" Alter terminal nator

-; o\�

<35 A Alternator>

40A alternator (when cold) BOA alternator {when cold)

Variable resistor

"R" termi�-�I

"R" terminal

Switch K1

Alternator drive motor

Ammeter Voltmeter

B3622C Battery

�--+---, Switch K1 Switch K2 Alternator

Variable resistor Alternator drive motor "B" terminal ' "L" terminal

"R" terminal

B36220

Perform the test using the circuit shown above. • With the load resistance set at maximum (meaning that there is almost no load current flowing), close switches K1 and K2.

16-78

1.500 rpm. 27V

17A or more

2,500 rpm, 27V

26A or more

1,500 rpm. 27V

20A or more

2.500 rpm. 27V

29A or more

1,600 rpm, 27V

26A or more

2,500 rpm, 27V

37A or more

1.500 rpm, 27V

39A or more

2.500 rpm. 27V

71A or more

ENGINE ELECTRICAL - SERVICE PROCEDURE 13) Inspection of regulator

I b) On-vehicle inspection

(a) Test bench inspection Voltmeter

<30 A, 40 A, 80 A Alternator>

Ammeter Voltmeter

Switch

"B" terminal

•

• •

•

B3623B

Provide a switch between the battery and alterna tor "B" terminal. With the switch turned off, con nect an ammeter (with 60 A full-scale to the 30 A or 40 A alternator and 100 A full-scale to the 35 A, 80 A alternator) and voltmeter. Turn on the switch and make sure that the voltme ter indicates the battery voltage. Start up the engine and immediately turn on all lamp switches. Then, increase the engine speed and read the maximum current value when the alternator speed reaches 5000 rpm. fthe current reading is 70% or more of the nominal output, the alternator may be regarded as in good condition.

"R" terminal

"B" terminal Alternator

Alternator drive motor

.,..M . "' " • · QJ aJ “L” terminal

<35 A

Ammeter

Vol

83624C

eter

Alternator>

Switch

NOTE: The on-vehicle test is an easier way of inspection; the test bench inspection is necessary for more accurate results.

Alternator

"B" terminal,

Alternator drive motor

"L" terminal

"R" terminal

63624P

Inspect the regulator regulated voltage as follows using the circuit shown above. • Use a fully-charged battery. Turn on the switch. • Gradually increase the alternator speed up to 5000 rpm. Check that the current value at this speed is 5 A or less. 16-79

•

ENGINE ELECTRICAL - SERVICE PROCEDURE

The regulator is in good condition if the regulated voltage under this condition is within specification. If not, replace the regulator assembly.

• •

28 to 29V

Nominal value

(bl On-vehicle inspection

•

<30 A, 40 A, 80 A Alternator>

•

Voitmeter

Ammeter

•

“L*

<35 A Alternator>

terminal B3625E

"L" terminal

Switch

16-80

"B" terminal

83625R

Connect a voltmeter and ammeter and provide a switch as shown. The regulator is in good condition if the voltmeter registers O when the switch turns ON. lfthe voltme ter pointer deflects, the alternator or wiring is defective. With the ammeter terminal shorted to prevent flow of the starter current through it, start the engine. Increase the engine speed to around 2000 rpm and read the regulated voltage value if the charge cur rent is 5 A or less. If the charge current is 5 A or more, continue charging for a while or replace the battery with a fully-charged one. Or 1/4 n (25 W) resistor may be connected in series to the battery to limit the charge current. If the measurement is out of specification, replace the regulator assembly.

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.4 40 A Alternator <A4T57471> (with brush type) 5.4.1 Removal and installation [Refer to Section 5.3.1.] 5.4.2 Disassembly and inspection For disassembly procedure, refer to Section 5.3.2. For inspection procedure, refer to Section 5.3.3.

Item

Brush length

i Brush spring pressure

NV .. Nominal Value L .... Limit Item i Slip ring O.D Field coil resistance

40.8 to 41.2

40.4

3.1 to 4.3 N (0.32 to 0.44 kgf)

{0.2 kgfl i

�

100

Ground test

Bearing rotating condition

Rotating

condition

11 Short circuit test

Contamination, damage or seizure of slip ring

Disassembly sequence 1 Cover 2 Regulator assembly

3 Through bolt 4 Front bracket

5 Pulley 6 Fan 7 Spacer 8 Rotor

Open circuit test

1 Short circuit test

Open circuit test j D8118A

9 Rear bracket 10 Stator 11 Rectifier assembly

NOTE: Do not pull out the rotor without removing the regulator assembly as this will damage the brushes in the regulator assembly.

16-81

ENGINE ELECTRICAL - SERVICE PROCEDURE (2) Regulator inspection

5.4.3 Reassembly

(a) Test bench inspection Ammeter

HIHlllllljllliw:t=1

�-+---< A )---------------,

Switch

+ Alternator

Voltmeter

T Battery 1 ..l.

83 to 105 N·m {8.5to 11 kgf.m}

O8128A

Regulated voltage Nominal value

28 to 29V

(b) On-vehicle inspection Reassembly sequence

8➔4➔7➔6➔5�3➔2➔1 9➔11➔10 _J D81268

5.4.4 Testing Refer to section 5.3.5 for information other than the cir cuit diagrams and nominal values given here.

Alternator

�

Switch Ammeter

r Battery

( 1) Performance test (bench inspection)

O8071A

+ V

Switch K1 Voltmeter

Switch K2

Battery T

Load resistor (variable resistor)

O8127A

Nominal values Output current 1500 rmp, 27 V

26A or more

2500 rmp, 27 V

37A or more

16-82

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.5 40 A, 50 A Alternators (brushless type} 5.5.1 Removal and installation 5.5.2 Disassembly

8 17 19 1

�9

5 3

2 D8117L

Disassembly sequence G) Rear bracket assembly ® Stator @ Rectifier @ Regulator 5 Rear bracket 6 Field coil 7 Pulley and fan

@ Pulley ® Fan 10 Rotor assembly 11 Spring *12 Rear bearing 13 Cover ® Rotor

@ Front bracket assembly 16 Spacer 17 Cover *18 Front bearing 19 Oil seal ® Front bracket

Parts marked with* should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-83

ENGINE ELECTRICAL - SERVICE PROCEDURE 2.

Disassembly Procedure

( 1) Separation of front bracket assembly from rear bracket assembly

At time of separation, use care not to lose the spring fitted to the outside of the rear bearing.

(2) Removal of pulley

Front bracket assembly

Rear bracket assembly

Pulley

Through bo!t

810278

Remove the through bolt. Using a screwdriver, pry off the front bracket assembly from the rear bracket assembly. NOTE:

82712N

Hold the rotor in a vice, etc. and remove the pulley, fan and front bracket. NOTE: Do not hold these areas.

Bearing box

B1029Y 81027D

The rear bearing is tightly fitted. Before separa tion, therefore, preheat the bearing box of the rear bracket by an air dryer to facilitate separation. Spring

�-'"""""

88107G

16-84

When holding the rotor in a vice, be sure to hold at illustrated portion.

ENGINE ELECTRICAL - SERVICE PROCEDURE

(4) Separation of rectifier from regulator

13) Removal of stator coil

Rectifier

Regulator

Rectifier Stator

02335

83866A

To remove the stator coil, unsolder the stator coil lead wires from the rectifier at three places.

To separate the rectifier from the regulator, unsolder ing the connection shown.

NOTE:

Unsolder within as short a time as possible (within 5 seconds) using a soldering iron.

16-85

ENGINE ELECTRICAL - SERVICE PROCEDURE

5.5.3 Inspection NV

Item Field coil resistance ; 40A <A4T40287> i 40A <Except A4T40287>, 50A

Approx. 6.2 Q Approx. 8 Q

; Ground test

NV .. Nominal Value

Short circuit test i

Open circuit test !

Short circuit test Open circuit test B1174E

16-86

ENGINE ELECTRICAL - SERVICE PROCEDURE

In the case of open or shorted diode, replace the rectifier. Measure according to the following procedures.

Inspection Procedure

I 1) Inspection of stator

la) Continuity across leads

(a) Measurement of diode mounted to heat sink (40 A: 6 places, 50 A: 8 places)

Stator coil lead wire connections

02336

Heat sink

827208

Check that there is continuity across stator leads. If there is no continuity, indicating a broken wire, replace the stator.

lb) Continuity across stator leads and core

827218

Measure between the heat sink and stator coil lead connections. (b) Measurement of diode trio (3 places) 02337

Check that there is no continuity across the stator leads and core. If there is, replace the stator as it is grounded. (2) Inspection of rectifier Measure resistance of each diode. Measure both when with the circuit tester(+) probe applied to the diode and when with the (-) probe applied to the diode. • If resistance is infinite in both cases, the diode is open. • If resistance is close to zero in both cases, the diode is shorted.

'•-�

� �-

\ 827228

Measure between the plate connecting to the regulator and the stator coil lead connections.

16-87

ENGINE ELECTRICAL - SERVICE PROCEDURE 21

131 Inspection of field coil

Apply a rod to the spacer on the front side of the front bracket and strike out the bearing.

(Installation)

Apply engine oil

02325

Measure the resistance across field coil terminals and, if the measurement is out of specification, replace the field coil.

02322

Front bearing

(4) Inspection of bearing Replace the bearing if defect is evident. (al Replacement of front bearing (Removal)

83109A

11 Apply a light coat of engine oil to the outside of the bearing and install to the inside of the front bracket using a press. Install flush with the cover mounting portion.

Cover

02320

Remove the bearing cover. Spacer "---�-�Front bracket

Front bearing

� B2730B

Rod 2)

Spacer

Bearing

16-88

02321

Install the cover and strike the spacer with a soft hammer, etc. to make sure that the bearing and cover are in contact with each other. If not, strike the spacer to bring them into contact.

ENGINE ELECTRICAL (b) Replacement of rear bearing

SERVICE PROCEDURE (Installation)

(Removal) Apply engine oil. Rear bearing

B2732C 02330

Apply a light coat of engine oil to the inside of the bear ing and using a press, install with the spring fitting groove of the bearing facing the rotor side.

5.5.4 Reassembly

8 12

130 to 160 N-m

{13.5 to 16.5 kgf-m}

16 I Apply engine oil to rotor I shaft outer periphery

Components

Reassembly sequence

1: 3, 4, 5

15 (20316319-318-317)@

10: 11, 12, 13, 14

15: 16, 17, 18, 19,20

··

(1451339123D)37 (89)31 (53@-@) 62

For parts with an encircled number, refer to Reassembly Procedure that follows.

B2990N

16-89

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.5.5 Inspection and adjustment after installation

Reassembly Procedure ( 1 I Installation of regulator and rectifier

The inspection and adjustment procedures for the 30 A, 40 A, 80 A alternator are applicable. Refer to Section 5.3.5 and use the following specifications.

Rectifier

<Alternator output current> Output current 40A alternator <except A4T40287> {when cold) 40A alternator <A4T40287> (when cold)

Rear bracket

Regulator

83904A

Solder the regulator to the rectifier with the two parts installed to the rear bracket.

NOTE: Solder within as short a time as possible (within 5 seconds) using a soldering iron. (2) To install the stator coil, reverse the order of disas sembly. [Refer to Item (3), Section 5.5.2.J (3) Installation of spring

Spring

High point

Minimize spring projection.

D8099D

Install the spring with its highest point seated in the deepest of the spring fitting groove of the bearing.

16-90

50A alternator (when cold)

1,500 rpm, 27V

26A or more

2,500 rpm. 27V

37A or more

1,500 rpm, 27V

30A or more

2,500 rpm, 27V

41A or more

1,500 rpm, 27V

26A or more

2,500 rpm. 27V

46A or more

<IC regulator regulated voltage> Nominal value

28 to 29V (5000 rpm. 5 A or less)

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.6 90 A Alternator (brushless type) 5.6.1 Removal and installation 5.6.2 Disassembly

858888

Disassembly sequence @) Pulley and fan Cg) Front bracket

Rotor *4 Rear bearing

5 Cover *6 Front bearing 7 Oil seal 8 Field coil

® Stator ®) Regulator ® Rectifier ® Rear bracket

Parts marked with* should not be removed unless defects are evident. For parts with an encircled number, refer to Disassembly Procedure that follows.

16-91

ENGINE ELECTRICAL - SERVICE PROCEDURE Disassembly Procedure

(1) Separation of front bracket and rear bracket

Be sure the vise grips the rotor only at the points illus• trated.

(3) Removal of rotor Front bracket assembly Rear bracket assembly Through bolt

Rotor

B1027B

Remove the through bolt. Then, pry apart the front bracket and rear bracket using a screwdriver. (2) Removal of pulley and fan

Front bracket

Nut

85145A

The rotor and front bracket are held together by a nut. Take off the nut before removing the rotor. (4) Removing stator

Pully and fan

82712K

Secure the rotor in a vise, then remove the pulley and fan. NOTE:

Rectifier B1031C

Unsolder the stator coil leads from the rectifier (3 places) before removing the stator. NOTE: Be sure to use a soldering iron to remove and replace the solder. Apply the soldering iron for as short a time as possible (within 5 seconds).

( ( 16-92

\ Rotor

81029N

ENGINE ELECTRICAL 15) Separation of rectifier and regulator

SERVICE PROCEDURE

Separate the rectifier and regulator by unsoldering the joint shown in the illustration. NOTE: Rectifier

Be sure to use a soldering iron to remove and replace the solder. Apply the soldering iron for as short a time as possible {within 5 seconds).

Regulator

838668

5.6.3 Inspection Item Field coil resistance I A4TT0187,A4D5589A A4TT5687

NV Approx. 7 n. Approx. 8.2 O

Short circuit test Open circuit test j

NV .. Nominal Value Open circuit test Ground test

858898

16-93

ENGINE ELECTRICAL - SERVICE PROCEDURE If any diode is either open-circuited or short-cir cuited, the rectifier must be replaced. Take mea surements in accordance with the following instructions.

Inspection Procedure (11 Stator inspection (a) Continuity of leads

(a) Measurement across heat sink and diodes (8 places)

Stator coil lead wire connections (at 4 places)

II '

02336

Check for continuity between each pair of stator coil leads. If any test shows a lack of continuity, a lead is broken and the stator must be replaced

B2720B

(b) Continuity between stator leads and core

B2721B

Measure the resistance between the heat sink and sta tor coil lead connection points. (b) Diode trio measurements (3 places) 02337

Confirm that there is no continuity between the stator leads and core. If continuity exists between any lead and the core, the stator is grounded and must be replaced. (2) Inspection of rectifier Measure the resistance of each diode. Take measure ments first with the tester's (+) probe applied to the diode, then with the tester's H probe applied to the diode. • If both measurements show infinite resistance, the relevant diode is open-circuited • If both measurements show resistance of close to zero, the relevant diode is short-circuited. 16-94

B2722B

Measure the resistance between the stator coil lead connection points and the plate that leads to the regu lator connections.

ENGINE ELECTRICAL - SERVICE PROCEDURE 1)

(3) Field coil inspection

Remove the bearing cover.

Rod Spacer

02325

Measure the resistance between the field coil termi nals. If the measurements are out of specification, replace the field coil.

Bearing

02321

2) Apply a rod to the spacer on the front surface of the front bracket. Tap out the bearing with a hammer. <Installation>

(4) Bearing inspection Replace any bearing that appears defective.

Apply engine oil

NOTE: If the front bearing is replaced, the oil seal must also be replaced.

Front bracket

la) Front bearing replacement <Removal>

Front bearing

82728D

Cover Front bracket

02320 Oil seal

831098

Insert the oil seal in the position shown and pack its lip with grease. Next, apply a thin film of engine oil to the bearing's outer periphery. Finally, press-fit the bearing until it is flush with the cover mounting surface.

16-95

ENGINE ELECTRICAL - SERVICE PROCEDURE <Installation> Apply engine oil

B2730C

2) Fit the cover.

82732H

(b) Rear bearing replacement <Removal>

Rear bearing

02330

16-96

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.6.4 Reassembly

130 to 160 N-m

{13.5 to 16.5 kgf-m}

85127C

Reassembly sequence

For parts with an encircled number, refer to Reassembly Procedure that follows.

Fit the regulator and rectifier into the rear bracket before soldering them.

Reassembly Procedure (1) Regulator and rectifier installation

NOTE: Be sure to use a soldering iron and apply it for as short a time as possible (within 5 seconds).

Rectifier

(2) Install the stator. The stator installation sequence is the opposite of the disassembly sequence (refer to item (4) of section 5.6.2). (3) Install the pulley and fan. The pulley and fan instal lation sequence is the opposite of the disassembly sequence (refer to item (2) of section 5.6.2). Regulator

Rear bracket 839048

16-97

ENGINE ELECTRICAL 5.6.5 Inspection and adjustment after reassembly I 11 Read and adhere to the precautions given in item ( 1) of section 5.3.5. (21 Performance test

SERVICE PROCEDURE •

•

(a) Bench test <A4D0187, A4T75687>

Set the load resistor for maximum resistance (such that almost no current flows), then close switches K 1 and K2. Gradually increase the alternator speed and reduce the load resistance. Measure the current flowing when the alternator's terminal voltage and speed reach the specified nominal values . If the measurement is out of specification, inspect the alternator. Output current

90A alternator (when cold)

1,500 rpm, 27V

53A or more

2,500 rpm, 27V

82A or more

(bl On-vehicle test Switch K1 Voltmeter Switch K2

Variable resistor

Switch

L terminal

• • • Switch K1

•

Alternator Variable resistor B termmal

L terminal

B3622R

Carry out testing with the circuit connected as shown above. 16-98

' 8 terminal B3623S

Alternator drive motor

Connect a switch between the battery and terminal B of the alternator. With the switch open, connect an ammeter (with a capacity of at least 90A) and voltmeter. Close the switch and confirm that the voltmeter indicates the battery voltage. Start the engine and immediately switch on all the vehicle's lamps to increase the engine speed. Observe the maximum ammeter reading when the alternator speed reaches 5,000 rpm. If the ammeter reading is at least 70% of the alter nator's rated output current, the alternator may be considered usable.

NOTE: On-vehicle tests provide only a rough indication of alternator performance. More precise tests on a bench must also be carried out.

ENGINE ELECTRICAL - SERVICE PROCEDURE •

(31 Regulator tests (al Bench test <A4D0187, A4T75687>

0p�-"--9 -'-'

Ammeter Voltmeter

M; �-

Baner-'v _ __

If the voltage (regulated voltage) at this time con forms with the specified nominal value, the regula tor is usable. If the voltage does not conform with the nominal value, replace the regulator assembly.

(bl On-vehicle test

Switch

�.

w� µ, �

Voltmeter <A4TT55

894>

�

Alternator

• ��,o,m,,a,

�

--L terminal L terminal

<A4T70187,C) A4T75687>

Alternator drive motor

28 to 29V

Nominal value

�

Ammeter

��-----------' �:::'.�\B terminal :-_ Switch \,

R terminal

•

L terminal

83624N

Ammeter

�

• •

Switch

•

Alternator

•

B terminal Alternator drive motor

LJ / R terminal

L terminal

B3625S

Connect an ammeter, voltmeter, and switch between the harness and alternator, as illustrated. Close the switch and confirm that the voltmeter reading is zero. If the voltmeter needle moves, the alternator or wiring is defective. So that no current flows through the ammeter when the engine is started, short-circuit the ammeter terminals. Then, start the engine. If the charging current is 5A or less when the engine speed reaches 2,000 rpm, observe the regu lated voltage reading. If the charging current exceeds 5A, either wait for the battery to charge or replace the battery with a fully charged one. Alter natively, connect a 0.25 Q (25 W) resistor in series with the battery to suppress the charging current. If the regulated voltage does not conform with the specified nominal value, replace the regulator assembly.

B36240

Check the regulated voltage with the circuit connected as shown above. • Using a fully charged battery, close the switch. Gradually increase the alternator speed. Confirm that the current flowing is 5A or less when the alter nator speed reaches 5,000 rpm.

16-99

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.7 60A, 110A, 150A Alternators 5.7 .1 Removal and installation (Refer to the instructions in section 5.3.1) 5.7.2 Disassembly

<60A Alternator>

I� 14

�

Disassembly sequence Cover 2 Brush holder assembly 3 Brush holder 4 Brush 5 Brush spring 6 End cover 7 Cover 8 Bolt set 9 Rear bracket assembly 1

10 Stator 11 Plate 12 Lead wire assembly 13 Terminal set 14 Connector 15 Condenser 16 Heat sink set 17 Rear bracket @ Pulley assembly

*19 Pulley *20 Fan 21 Rotor assembly @ Rotor *23 Rear bearing @ Front bracket assembly 25 Cover *26 Front bearing @ Front bracket

Parts marked with u*" should not be removed unless damage is evident. For parts with circled numbers, refer to section 5.3.2, "Disassembly Procedure." 84539A

16-100

ENGINE ELECTRICAL - SERVICE PROCEDURE

' <110A, 150A alternators>

10 24 26

,5 14

Disassembly sequence 1 2 3 4 5 6

Cover Brush holder assembly Brush holder Brush Brush spring End cover 7 Cover 8 Bolt set 9 Rear bracket assembly

10 Stator 11 Plate 12 Lead wire assembly 13 Terminal set 14 Connector 15 Condenser 16 Heat sink set 17 Rear bracket (@ Pulley and fan

*19 Pulley *20 Fan 21 Rotor assembly ® Rotor *2 3 Rear bearing ® Front bracket assembly 25 Cover *26 Front bearing ® Front bracket

Parts marked with "*" should not be removed unless damage is evident. For parts with circled numbers, refer to section 5.3.2, "Disassembly Procedure." B4541A

16-101

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.7.3 Inspection <60A, 110A, 150A alternators> Field coil resistance

· Slip ring 0. 0. , Ground test

1tem

60A 110A 150A 60A. 110A I8DCI, 150A 110A I6D2I

n n

Approx. 13 9.6 to 11.6 Approx. 3.0 to 3.7 Q 46 41

16-102

I Open circuit test 45.4 40.4

· Ground test

Item Brush 60A spring tension 110A, 150A

I Short circuit test Refer to section 5.3.3 for inspection procedure.

3.8 N {0.38 kgf} 3.1 to 4.3 N {0.32 to 0.44 kgf}

2N {0.2 kgf} 2N {0.2 kgf}

NV .. Nominal Value L .... Limit

Open circuit test 845398

ENGINE ELECTRICAL - SERVICE PROCEDURE

To check for a diode short or field coil open-circuit, it is not necessary to disassemble the alternator. Measure the continuity between the connector terminals using a tester to determine whether the diodes and field coil are usable.

<A4T65773,A4T85774,A4T85777>

<A4T86287,A4T86387> N

A B

t;B p E E

�:

�---<OF

A co nector � �

Connector A�F

N�E D8078A

Measuring points

F-E N-A

I f

Good

Tester shows continuity.

i ,• Tester shows continuity when 1 (black) is connected to N and i (red) connected to A. '

N-E

I Tester shows continuity when I (black) is connected to E and (red) connected to N. j

�

-C�

N�

J:: E

85890A

Defective

No continuity (Brush in poor contact or field coil open circuited) Resistance O (Field coil short circuited) If tester shows no continuity when (black) is connected to N and (red) connected to A, all three ffi: diodes are open circuited or stator coil open circuited. If tester shows continuity when {black) is con nected to A and (red) connected to N, ffi diodes are short circuited. If tester shows no continuity when (black) is connected to E and {red) connected to N, a!I three diodes are open circuited. !f tester shows continuity when (black) is connected to N and (red) con nected to E, EB diodes are short circuited.

NOTE: The colors in parentheses show the colors of tester lead rods. All three diodes are rarely open circuited. Each diode should be tested to determine whether it is good or defective.

16-103

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.7.4 Reassembly <60A alternator>

3 4

83 to 105 N·m {8.5 to 11 kgf-m)

26 15

84543A

<11 0A, 150A alternators>

83 to 105 N-m

{8.5 to 11 kgi-m}

7 23

345 to 360 N-m |

{35 to 37 kgf-m}

27 17 Component parts 2: 3, 4, 5, 9: 11, 12, 13, 15, 16, 17 18: 19,20 21: 22,23 24: 25,26,27

16-104

Assembly sequence 24 (27->26->25H21 (23->22H 18 (20-> 19)->10->9 (17➔ 16➔ 15➔ 13➔ 12➔ 11 )➔ 14➔8➔7➔6➔2 (5➔4➔3)➔ 1

84544A

ENGINE ELECTRICAL 5.7.5 Inspection and adjustment after reassembly

SERVICE PROCEDURE 5.8 Regulator Inspection and Adjustment (R7T01071,R7T01072)

+ ,---,-----,--{ A ;--,-----, Ammeter

(center zerol/S witch

Voltmeter

T I

Switch K, Zi oad resistor

-' Battery 24V

'�-ci Ul I '!'-\

D8080A

I '

AN E

Carry out tests with the circuit connected as shown above. Load Test Increase the load resistance R to a maximum and close the switches K1 and K 2. Measure the current value when the alternator reaches the specified speed. Nominal values Output current 60A alternator (when cold)

2,200 rpm 128V

60A or more

110A alternator (when cold)

2,500 rpm 128V

100A or more

150A alternator (when cold)

2,500 rpm/ 28V

140A or more

844018

(1) Voltage regulator regulated voltage Nominal value (between A and E terminals) at 4,000 rpm = 28 to 29 V Battery overcharged ... Voltage too high Battery discharged ... Voltage too low NOTE:

This regulator uses a transistor type voltage regulator, so the regulated voltage cannot be changed. Hthe reg ulated voltage is out of the nominal value, replace the regulator. (2) Voltage regulator regulated voltage measuring procedure (a) Increase the engine speed until the alternator reaches the specified speed. (b) Continue charging until the charging current to the battery falls to less than 10 A (the battery fully charged). (c) Measure the voltage across the "A" and "E" termi nals. (d) Measure the voltage across the "A" terminal and the negative terminal of the battery and check to ensure that there is no difference between the value and the value measured under Item (c).

16-105

ENGINE ELECTRICAL - SERVICE PROCEDURE (3) Adjusting voltage regulator regulated voltage

(RMS4227B)

Leaf spring

Spring support

Higher voltage

L�00 E F

DD N DD A

� Cowoc '""'"'

84401C

85881A

(1) Voltage regulator regulated voltage Nominal value (between A and E terminals) at 3,000 rpm = 28 to 30 V

The regulated voltage is adjusted by reducing the force of the leaf spring. Bend up the spring support to increase the regulated voltage. Bend the spring support down to decrease it.

(2) Measure the regulated voltage in accordance with the following procedure. (a) Start the engine and run the alternator under no load. (b) Increase the engine speed to approximately 1,500 rpm and confirm that the battery charging current is 10A or less. (If the charging current is over 10A, allow the battery to charge until the current drops below 1 0A or replace the battery with a fully charged one.) (c) Measure the voltage between terminals A and E when the alternator speed reaches 3,000 rpm. NOTE: If the battery is prone to overcharging, carry out a con tinuity test first to check whether the regulator is bro ken. Should the regulator not be working, the gener ated voltage will increase dangerously if the battery switch is opened during engine operation.

16-106

NOTE: • Make sure the battery switch is open before mak ing adjustments. • After making adjustments, fit the cover and check the regulated voltage again. • If the regulator is removed for adjustment, be sure to refit it facing the same direction and at the same angle as before.

Continuity tests Without opening the cover, use a continuity tester to measure the continuity between the regulator termi nals. (4)

Measurement I Acceptable point i condition

Unacceptable condition (fault)

N-E

i Continuity

No continuity (open circuit in coil VC2)

L-E

: Zero resistance

IG-F

34to420

High resistance {contact P 1 defective) No continuity (open circuit in ! resistor R4)

F-E

Continuity

: No continuity (open circuit in i coil VC1 or resistor R3)

IG-A

No continuity

Continuity (contact P3 fused together)

Resistor R 1

57to67n

Resistor R3

93 to 101 n

Resistor R4

! 34 to 42 Q

Resistance (contact P2 defec tive)

ENGINE ELECTRICAL - SERVICE PROCEDURE NOTE: When measuring between terminals F and E, apply the negative probe of the tester to terminal F and positive probe to terminal E.

5.9 Safety Relay Inspection

<R8T30171,R8T30172,R8T30174,RBT30274>

(R8T10178)

Ter�inal L-to-R

1·

resistance I NV Approx. 200 Q [ 1

E terminal

�

S terminal

e/,

/"' e

P terminal KJJOCA

<RBT30174,RBT30274>

R terminal R terminal

L terminal S terminal

B5891B

Since the regulator is transistorized, its regulated volt age cannot be changed. If the regulated voltage does not conform with the specified nominal value, replace the regulator. Measure the regulated voltage in accordance with the following procedure. 11 I Increase the engine speed until the alternator turns at the specified speed (3,000 rpm). 12) Allow the battery to charge until the charging cur rent is 10A or less. (When the charging current reaches this level, the battery is fully charged.) (31 Measure the voltage between terminals A and E. (4) Measure the voltage between terminal A and the battery's H terminal. Confirm that this voltage is the same as the voltage across terminals A and E. The regulated voltage should be 28 to 29V.

P terminal

E terminal

B1453D

Measure voltage at each terminal in the sequence shown below to identify faulty parts.

NOTE: While taking measurements, do not turn the battery switch OFF, disconnect the battery, or make connec tions to any terminals.

16-107

ENGINE ELECTRICAL - SERVICE PROCEDURE (a) On-vehicle test Sequence

Engine operation i Starter switch ON

Voltage at terminal "P"

Voltage at terminal "$"

Terminal "R"

• 1 V or less

! • Approx. 24 V

• (+) diode shorted if close to

: • If O V, wiring is faulty Terminal "L" (with charge lamp) • Approx. 24 V Terminal "L" {with charge lamp) • Approx. 3 V or less • If close to battery voltage, wiring alternator is faulty

battery voltage

During cranking

Idling (600 rpm or higher)

• Approx. 1 V or less • If close to battery voltage, safety relay is faulty (crank ing impossible) • Approx. 13 to 16 V (Be sure to use analog type tester)

(b) Component test The resistance value between terminals "R" and "L" shall be within specified range.

16-108

i Voltage at terminal "R" or "L"

• A bulb connected between battery and terminal "$" does not come on

• If bulb comes on despite normal terminal "P" voltage (shown to left), replace safety relay and test again

ENGINE ELECTRICAL - SERVICE PROCEDURE

(a) Time required before indicator becomes red-hot: Standard time: 40 to 60 seconds (b) Check each terminal of the air heater for looseness and the heater element for damage and contact with other parts.

5.10 Preheater 5.10.1 Intake air heater

( 1) Removal and installation (Refer to Group 15 Intake and Exhaust.) (2) Inspection

5.10.2 Heater relay

Inspection

<6D2> Air heater Starter switch OFF HEAT

“S” terminal

0 N

START

--� --� L

ACC R2

Battery switch

Heater relay

Air heater indicator

Capacity stamped here

Battery

o--,---------<)

DBB03C

<BDC>

Starter switch Off

"SW" terminal

O8901A

(1) Check to ensure that there is continuity between the terminals "B" and "S" when 2.3 A (24 V) excit ing current is applied between terminal "SW" in the figure and body ground. (2) Check also the heater relay fuse and replace with new one if it has been burnt out. When replacing fuses, be sure to use a fuse of spe cified capacity.

START

Battery switch

,Cl ACC IIJ:

C '

Fuse Airheater(6) indicator �

<8DC9-TL only>

B450BF

Perform the following inspection and check the func tion of each part or the wiring if necessary. 16-109

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.11 Automatic Stop System 5.11.1 Shutdown type

( 1) Adjustment and inspection of stop solenoid <6D2 only>

__ r '_

Stop side

Stop lever

-1

1-----�---

Operation side Outer stopper

Lock nut

Rod

Solenoid : 1

Pointer Clearance NV 1.5 A to 2.0

"B" terminal

L__

Clearance NV 1.2 ± 0.2

Before attraction

After attraction

Stroke 27 to 29 mm

P.C

�11,

NV .. Nominal Value

H.C

(a) Adjustment of stroke 1) Connect the rod between the stop lever and the solenoid. 2) Remove the solenoid cover. 3) Turn the battery switch ON to actuate the solenoid. Then, make the following adjustments: • Make sure that the solenoid pointer gap does not exceed the nominal value. • Adjust the length of the rod until a clearance not exceeding the nominal value is maintained between the stop lever and the outer stopper. 4) Turn the battery switch OFF. (b) Operational check 1) After the adjustment described in 1) above, repeat the ON-OFF operation of the solenoid 2 to 3 times (at approx. 10-second intervals) and perform the following.

16-110

Cover

•

841218

Make sure that the stop lever, rod and solenoid operate smoothly from the operation side to the stop side and also from the stop side to the opera tion side. • Make sure that the clearance between the stop lever and the outer stopper and the solenoid pointer gap do not exceed the respective nominal values. 2) Tighten the lock nut on each end of the rod securely. 3) Install the solenoid cover. 4) As to the check of amperage when the solenoid is ON, be sure that an amperage of nominal value is indicated by the ammeter.

ENGINE ELECTRICAL - SERVICE PROCEDURE (2) Solenoid relay

la) Unit test

Solenoid relay Terminal voltage Checking oil pressure timer:

DC28.5V

SW@

Checking stop timer:

---(I""o�,:.__Jf>-_.J

DC24V

SW©

SW@

{ Terminal voltage

Manual stop timer When the push switch C (stop switch) is set to ON, the solenoid will be operated. Operate a stop watch as soon as the stop switch C is set to OFF, and measure the time required before the solenoid is reset. After the tests of the above items 1) and 2), allow 5 minutes before making retests. It takes 5 minutes before the capacitor C1 which is an element of the time constant of the oil pressure timer finishes dis charging.

Solenoid or coil load: 30 A± 3 A

SW@ ON

Oil pressure timer

18±5"

SW@

30±5"

Stop timer

Test schedule Legend SW@: Snap switch A SW®: Snap switch B SW@: Snap switch C

D9558A

Make connections as shown above and perform the following checks. 1) Oil pressure timer Set the snap switch A to ON. Operate a stop watch as soon as the snap switch Bis set to ON, and mea sure the time required before the solenoid is oper ated. 2) Stop timer Set the snap switch B to OFF 5 seconds after the solenoid has been operated. At the same time, using a stop watch, measure the time required before the solenoid is reset. The snap switch B is set to OFF 5 seconds after operation of the solenoid because if the solenoid is operated, it takes 5 seconds before the alternator voltage disappears.

16-111

ENGINE ELECTRICAL - SERVICE PROCEDURE (b) On-vehicle inspection Check the solenoid relay according to the following flowcharts and determine whether it is good or not on the basis of the terminal voltage, etc. measured in the individual states. • The terminal symbols denote those of the solenoid relay. • The voltage 24 V means the battery voltage.

Turning the battery switch from OFF to ,--"' ON actuates the solenoid

Engine cannot be·L-�� stopped by stop switch

Is voltage 24 V avail able at "A" terminal?

Measure voltage at "ST" terminal

Yes Alternator defective

I Stop switch defective

J 24 V

Measure voltage at 'ST" terminal

J OV 1 Stop switch defective

Solenoid

0V >--------=-'----------s,, relay defective

24 V

Measure voltage at "C" terminal

Solenoid 0y >------.:C.:'----------a>i relay defective

24 V

I Solenoid relay defective j

Perform measurements with engine running Engine does not stop with watertem perature high and oil pressure low

Is voltage 28to29V available at terminal

Measure voltage at"W" terminal

Measure voltage at "C" terminal

I ov

/ Solenoid defective )

16-112

at “C" terminal

No Alternator defective

Thermo switch or oil pressure switch defective

Solenoid is not forced to OFF state after engine has stopped

Yes

24 V

Measure voltage at ·sr terminal 24 V Stop switch defective

Solenoid ,_ :::,._,o v'-1 relay

I defective

1 Solenoid defective

Is voltage 24 V available at "A" terminal? Yes

I Alternator defective /

Solenoid relay defective

ENGINE ELECTRICAL - SERVICE PROCEDURE

Perform measurements with engine running

' Solenoid operates 1 } while en, gine is running

Measure voltage at "C" terminal

�/

Measure voltage at "ST" terminal

24 V

Measure voltage at "W" terminal

o V I Solenoid relay � defective

J 24 V

w OV

I Solenoid defective

[ Stop switch defective

(3) Thermo switch The thermo switch won't operate if the tempera ture-sensing portion is not in contact with coolant. If the coolant level is low or if there is only steam, the thermo switch won't operate completely.

0 0

Thermo switch or I oil pressure switch defective

No - ' In normal operation, ma� [ responding to ab normal water tem perature or oil pres sure

(b) Confirm that there is no continuity between the terminals, then begin heating the test fluid. NOTE: Stir the liquid to ensure that it heats up uniformly.

(c) Measure the fluid temperature when the thermostatic switch operates and continuity appears between its terminals. NOTE: Increase the fluid temperature very slowly as it approaches the operating temperature of the thermo static switch. (When the fluid temperature is 5°C below the operating temperature, maintain this tem perature for 5 minutes. Then, increase the tempera ture by 1 °C every 2 to 3 minutes.)

(§)

Item

!NV

Operating temperature

93 to 97 C

Tap water cooling type

Remarks

99 to 103 °c

Radiator cooling type

ON-OFF difference

Within 7 °C

,J, 24 V

(di Briefly continue increasing the fluid temperature, then allow the fluid to cool. Measure the fluid tem perature when the thermostatic switch operates and continuity between its terminals disappears. Calculate the difference between the upper and lower operating temperatures, and check that it is correct.

NV .. Nominal Value 85329A

Inspection (a) Set a circuit tester to measure resistance, then apply its probes to the thermostatic switch termi nals. Put the thermostatic switch into glycerin up to the end of its threaded section. 16-113

ENGINE ELECTRICAL - SERVICE PROCEDURE

(4) Oil pressure switch

Test oil pressure gauge

� 0

o ®

Engine oil pressure gauge

Operating pressure NV 69 to 98 kPa {0.7 tot .0 kgf/cm2 } or less 85330A

Inspection (a) Connect the pipes as shown in the above illustra tion. Then, set a tester to measure resistance and apply its probes to the oil pressure switch termi nals. (b) With cocks A and B closed, start the engine. When the oil pressure increases, fully open cock A to apply pressure to the oil pressure switch. (c) Close cock A to cut the oil passage from the engine and maintain the accumulated pressure in the oil sump. (d) Confirm that there is no continuity between the oil pressure switch terminals. (e) Gradually open cock B to reduce the oil pressure. Observe the test oil pressure gauge indication when the oil pressure switch operates and continu ity appears between its terminals.

16-114

ENGINE ELECTRICAL - SERVICE PROCEDURE 5.11.2 Run-on type ( 1) Stop solenoid <6D2>

,-----,-- _-_-_-_=1/-7 I

: Clearance NV 0.7 ± 0.2

Pointer gap NV 0.8 to 1.2

Solenoid i

Stop lever

Lock nut

Rod

Lock nut

8 terminal

0 0

I 0 0

STOP side Outer stopper

Before attraction P.C

_J_ T Battery 124V)

After attraction

Stroke 27 to 29 mm

Cover

NV . Nominal Value

H.C

I <Except 8DC9-TC>

Ammeter NV 1A or less

B4121C

Before attraction

After attraction

! Clearance

NV 0.7 ± 0.2 Stop lever

I Ammeter NV 1A or less

Solenoid

Lock nut STOP side RUN side

gap I Pointer NV 0.8 to 1.2 1

NV .. Nominal Value

D9576C

16-115

ENGINE ELECTRICAL - SERVICE PROCEDURE

(a) Adjustment of stroke 1) Connect the rod between the stop lever and the solenoid. 21 Remove the solenoid cover. 3) Turn the battery switch ON to actuate the solenoid, then make the following adjustments: • Confirm that the solenoid pointer clearance con forms with the specified nominal value. • Adjust the rod length such that the stop lever-to outer stopper clearance conforms with the speci fied nominal value. Temporarily tighten the lock nut at either end of the rod. 4) Turn the battery switch OFF. (b) Operational check

1) After the adjustment described in 1) above, repeat the ON-OFF operation of the solenoid 2 to 3 times

(at approx. 10-second intervals) and perform the following. • Make sure that the stop lever, rod and solenoid operate smoothly from the operation side to the stop side and also from the stop side to the opera tion side. • Make sure that the clearance between the stop lever and the outer stopper and the solenoid pointer gap do not exceed the respective nominal values. 2) Tighten the lock nut on each end of the rod securely. 3) Install the solenoid cover. 4) As to the check of amperage when the solenoid is ON, be sure that an amperage of nominal value is indicated by the ammeter.

<8DC9-TC only> Clearance

NV 0.7 ± 0.2

Solenoid

Ammeter

NV 5A or less I

Stroke

25mm

Rod

Switch

f--'----lf--j Battery

__j

124V)

Solenoid

NV .. Nominal Value

(a) Adjustment of stroke Connect the stop lever and solenoid with the rod. 2) Turn the switch ON to actuate the solenoid. Then, adjust the rod length such that the stop lever-to outer stopper clearance conforms with the speci fied nominal value. Temporarily tighten the lock nut at either end of the rod. 3) Turn the switch OFF. 1)

(b) Adjustment of operation After adjusting the stroke, turn the solenoid ON and OFF 2 or 3 times. T hen, check the following points: 16-116

Lock nut RUN side Outer stopper STOP side D9576F

•

Check that the stop lever, rod, and solenoid move smoothly between the RUN side and STOP side. • Check that the stop lever-to-outer stopper clear ance conforms with the specified nominal value. 2) Confirm that the check lamp illuminates or that the solenoid current conforms with the specified nom inal value. NOTE: When repeatedly turning the solenoid ON and OFF, wait a moment between each switch operation.

ENGINE ELECTRICAL - SERVICE PROCEDURE 12) Solenoid relay la) Unit test

E 8

SW, ''I

SW,

�

Terminal voltage 24V i Delay time NV 26 to 34 sec.

.. I

1 'SW2

NV .. Nominal Value Solenoid or coil load 30A:l:3A

7'7

D9564A

Wire as shown and check the following. Relay operation and delay time a) Check if the solenoid is energized when switches SW 1 and SW2 are turned ON. b) Using a stop watch, measure the time required for the solenoid to return after switch SW 2 is turned OFF.

2) Relay holding a) Turn ON switches SW 1 and SW2 and, after the sole noid is activated, turn ON the switch SW3. b) Turn OFF the switch SW2 and make sure that the solenoid remains activated for more than 34 seconds. c) After verifying b) above, turn OFF the switch SW3 to ensure that the solenoid returns.

16-117

ENGINE ELECTRICAL - SERVICE PROCEDURE •

(b) On-vehicle inspection Check the solenoid relay according to the following flowchart and determine whether it is good or not on the basis of the terminal voltage, etc. measured in the individual states.

' Turning the battery switch (or key I-�;<' i switch) from OFF to ON actuates sole noid

Measure voltage at "S" terminal

•

Terminal symbols denote those of the solenoid relay. Voltage 24 V means the battery voltage.

Solenoid >--=---ov_:___________________________,, relay I defective

24 V

Battery switch (or key ! switch) defective or miswired I

Solenoid does not operate when key switch is set from ON to START

Check battery

Measure voltage at "8" terminal

24 V

ls voltage 18 or more avail able at terminal with key switch t START?

No i Battery defective

Yes

Measure voltage at "C" terminal

!s there con tinuity be tween emer gency switch terminals?

No I Solenoid � relay I defective

Yes

I Solenoid defective nor miswired

Emer-

No gency ;>--------------"'1

switch defective

Yes Solenoid defective

Solenoid operates when key switch is ,-�xc._ changed back from START to ON

s voltage 18 or more avail able at terminal with key switch t START?

v No Battery defective

16-118

Solenoid Yes --;,i relay >---'-'"'-----------------------defective

ENGINE ELECTRICAL - SERVICE PROCEDURE

Perform measurements with engine running Measure voltage at "H" terminal

Engine does not stop with water tem perature high and oil pressure low

J 24 V

Thermo switch or oil pressure switch defective

, Engine does not stop with emer gency switch at OFF

Measure voltage at "8" terminal

Measure voltage at "S" terminal

Measure voltage at "C" terminal

J 24 V

Key switch defective

> ------

24 V

Solenoid relay I defective

J, OV

Solenoid defective

i Solenoid 24 v -------'"'---'-------------->! relay defective

,f O V

Solenoid defective

Perform measurements with engine running

While engine is ' running, sole- 1----s><� noid is forced to , OFF state and i engine stops

Measure voltage at "C" terminal

24 V

Solenoid defective

Measure voltage at "B" terminal

lov

Emergency switch defective

Measure voltage at "H" terminal

24 V

I-

I Thermo switch or oil pressure switch , defective I

24 V : Solenoid relay defective

Nor mal

In normal operation, responding to abnormal water tem perature or oi! pressure

16-119

ENGINE ELECTRICAL - SERVICE PROCEDURE 13) Thermo switch The thermo switch won't operate if the temperature sensing portion is not in contact with coolant. If the coolant level is low or if there is only steam, the thermo switch won't operate completely.

(d) Briefly continue increasing the fluid temperature, then allow the fluid to cool. Measure the fluid tem perature when the thermostatic switch operates and continuity appears between its terminals. Cal culate the difference between the upper and lower operating temperatures, and check that it is cor rect. (4) Oil pressure switch

Thermometer |

0 0

o to 5 Operating pressure NV 79 to 115 kPa {0.8 to 1.2 kgf/cm 2} or less

NV .. Nominal Value

NV .. Nominal Value Item

Remarks

Operating temperature

93 to 97 °C

Tap water cooling type

99 to 103 °C

Radiator cooling type

ON-OFF difference

Within 7°C

85329A

Inspection la) Set a circuit tester to measure resistance, then apply its probes to the thermostatic switch termi nals. Put the thermostatic switch into glycerin up to the end of its threaded section. (bl Confirm thatthere is no continuity between the terminals, then begin heating the test fluid.

NOTE: Stir the liquid to ensure that it heats up uniformly.

le) Measure the fluid temperature when the thermo static switch operates and the continuity between its terminals disappears

NOTE: Increase the fluid temperature very slowly as it approaches the operating temperature of the thermo static switch. (When the fluid temperature is 5 °C below the operating temperature, maintain this tem perature for 5 minutes. Then, increase the tempera ture by 1 °C every 2 to 3 minutes.) 16-120

Test oil pressure gauge

Cock A

Engine oil pressure gauge

Crankcase oil pressure

gauge

Cock B 85332A

Inspection (a) Connect the pipes as shown in the above illustra tion. Then, set a tester to measure resistance and apply its probes to the oil pressure switch termi nals. (b) With cocks A and B closed, start the engine. When the oil pressure increases, fully open cock A to apply pressure to the oil pressure switch. (c) Close cock A to cut the oil passage from the engine and maintain the accumulated pressure in the oil sump. (d) Confirm that there is continuity between the oil pressure switch terminals. (e) Gradually open cock B to reduce the oil pressure. Observe the test oil pressure gauge indication when the oil pressure switch operates and the con tinuity between its terminals disappears.

ENGINE ELECTRICAL - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom

Starter will not start

I Probable cause

i Remedy

Defective battery or low capacity

Replace or charge

: Defective wiring

Correct

• Defective starter wiring • Defective starter relay wiring • Defective magnetic switch wiring

: Ref. group

I I

• Defective heater relay wiring • Defective starter switch wiring • Defective battery or battery switch wiring Defective magnetic switch

Replace

Defective starter relay Worn or damaged binding brush Defective motor

Replace armature or yoke

Defective overrunning clutch

Replace

Defective heater relay Defective starter switch Starter starts but engine does

not

Pinion not meshing with ring gear • Incorrect voltage at magnetic switch "S" terminal

Replace starter relay or

starter switch

• Incorrect voltage at starter relay "SW" terminal • Worn or damaged pinion

Replace

• Worn or damaged ring gear

Replace

Pinion meshes with ring gear but does not turn

Group 11

Charge or replace battery

• Defective battery or insufficient battery voltage

Alternator is functioning normally but battery is overdischarged

• Insufficient brush contact

Replace brush and/or brush spring

• Defective overrunning clutch

Replace

Low V-belt tension

Adjust

Damaged V-belt

Replace

Defective wiring

Correct

Group 14

• Defective alternator wiring Defective battery

Replace

16-121

ENGINE ELECTRICAL - TROUBLESHOOTING Symptom25

Probable cause

I Remedy

Battery is normal but is overdischarged

Defective alternator

Replace

• Open circuit in stator coil • Stator coil and core grounded • Slip ring and rotor core grounded (excluding brush!ess alter nators) • Defective field coil • Worn slip ring \excluding brush less alternators) • Worn brush (excluding brush less alternators) • Defective brush spring (excluding brushless alternators) • Defective rectifier • Defective regulator

Charge !amp does not come on when engine is stopped (starter switch

Defective regulator

Replace

Premature loss of battery elec-

Defective alternator (See "Battery is normal but is overdischarged".)

Replace

High battery electrolyte ternperature

Defective regulator

ONI

trolyte

Engine is hard to start

Defective wiring

Correct

• Defective air heater wiring • Defective heater relay wiring • Defective water temperature sensor wiring Defective heater relay or blown fuse

16-122

Replace

Ref. group

CLUTCH CONTENTS 1. GENERAL . . . . . . . . . . . . . . . . . . . . . ... . . ... . . . . . . . 2 2. SPECIFICATIONS . . . . . . . . . . . .. . . . . .. . . . .. ... . 3 3. SERVICE STANDARDS . . . . . . .. . . . . . .. . .. . . .. 4 3.1 Service Standards Table .. . . .... . . . . .. . ... 4 Tightening Torque Table . .. .. . . . ... . . . .. . . 4 3.2 4. SPECIAL TOOL .. . . ... . . . . . . . . . . .. . . . .. . . . . . . 5 5. SERVICE PROCEDURE . . . . . . . . . . . . . ... ... . .. 6 5.1 Removal and Installation .. . . . . . . . . . . . . . . . 6

5.2 Clutch Proper . . . . . ...... . . .. . . . ... . ... . . . Disassembly and inspection . . ...... . . 5.2.1 5.2.2 Reassembly ........................... 5.3 Bearing Case ............................. 5.3.1 Disassembly and inspection .......... 5.3.2 Reassembly . . . . . . . . . . . . ... . .... ..... . . 6. TROUBLESHOOTING . .... . . . . . .. . . . . ...... .

9 9 13 15 15 16 17

21-1

Ell

CLUTCH - GENERAL

1. GENERAL i+a cor H 14 GR rta by10 —a Clutch eje isf es NFF} Ps A i]& =cover ¥ a} s iy,5 Pressure epee spring

Release bearing

Clutch++�+-� shaft

fI1·

Rejease fork

i ·1'

Flywheel

i �

Clutch disc Release lever support

Flywheel

Clutch disc E0423C

The clutch consists of a clutch disc to transmit engine power to the bearing case and a pressure plate to press the clutch disc against the engine flywheel. When the clutch lever is in the released state, the force of the pressure springs act on the pressure plate. The clutch disc is pressed against the flywheel by the pres sure plate. The clutch disc pressed against the flywheel turns with the flywheel and transmits power to the clutch shaft in the bearing case.

21-2

Release lever support

Release lever Pressure plate

: (Qillat

Pressure plate

EOSBSC

When the clutch lever is operated, the release fork will push forward the release bearing. The release bearing will then push the inner end of the release lever which pivots on the release lever support pin. The outer end of the release lever is connected to and will pull the pressure plate away from the flywheel. At this time, there will be a clearance between the clutch disc and flywheel. The engine power will not be sent to the bearing case.

CLUTCH - SPECIFICATIONS 2. SPECIFICATIONS ( 1) Clutch �del Item

6D22

6D22, 6D22-T, 6D22-TC, 8DC9, 8DC9-T

C10W41

Model

C12W43

Clutch drive

Strap drive Dry single disc coil spring type

Type

Facing

I Material

Woven 410x250

i O.D. x I.D. Imm)

430 X 250

[ Coil spring

Pressure plate type

(2) Bearing case Item

Engine model I

6D22, 6D22-T, 6D22-TC, 8DC9, 8DC9-T

Type

Direct-coupled type

Model

PC12

21-3

CLUTCH - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item

Nominal value (Basic diameter in { l)

Limit

Depth from facing surface to rivet head

2.2 to 2.8

0.2

Remedy and remarks

Clutch proper Clutch disc

I Flatness

0.6 or less

! Lateral runout

1.2 or less

1.0 or less

1.5

! Vertical runout

C10W41 C12W43

; Replace Correct or replace

1.2 or less

Clearance of hub spline turning direction

0.06 to0.195

0.42

Replace

Thickness

59.7to59.9

56.8

Replace

Flatness

0.05 or less

0.2

Correct or replace

' Strap bolt fitting hole

12.21 to 12.22

12.5

Replace

112.210.01 to0.11

0.3

Replace

Pressure plate

Clearance between strap plate and strap bolt Pressure spring

Free length

99.5

C12W43

92.1

C10W41

1200to 1330 N {122.6 to 135.4 kgf)

1070 N {109 kgf)

C12W43

1420 to 1570 N {145 to 160.2 kgf)

1270 N 1129 kg!)

C10W41

3.5 or less

5.2

C12W43

3.2 or less

4.8

36.5 to 37.5

[12.7J0.06to0.15

0.3

1301 0.03 to0.08

0.2

C10W41

Installed load {Installed length: 63)

! Spring squareness (In free length state)

Release lever height (Dimension from clutch cover top surface) Clearance between release lever pin and bushing

{Difference among four levers: 0.7 or less)

Replace

Adjust

Replace

Bearing case Clearance between release fork shaft and needle roller bearing

Replace

3.2 Tightening Torque Table Location tightened

Screw size 0.0. X pitch {mm)

lightening torque

Strap bolt

M12 x 1.5

39 to 49 {4 to5}

Lock plate mounting bolt

MB x 1.25

9.8to15 {1 to1.5}

Pressure plate and lever assembly mounting bolt

M10 x 1.5

32 to49 {3.3 to5.0}

Bearing case mounting bolt

M16 x 2.0

140 {14.2}

21-4

N·m {kgf.m}

CLUTCH - SPECIAL TOOL 4. SPECIAL TOOL Unit: mm

Unit: mm Tool name

Shape

Tool name

Shape

Clutch lever Aligner

Clutch Alignment Arbor

MH061330

03726-21000 <C10W41, C12W43>

Adjustment of release lever

height

43490-00100

<C12W43: for disc with 12 splines> Alignment of clutch disc at

installation

Part No.

Dimension A

03726-21000

<1>42

43490-00100

<1,36

E0013A 08903

Clutch Installer

Needle Roller Bearing Installer 44590-12600

Installation of needle roller

MH061331

bearing of bearing case

Removal and installation of c lute h cover

01306

09326

21-5

CLUTCH - SERVICE PROCEDURE

5. SERVICE PROCEDURE

NOTE: 1. Before removing the clutch, be sure to install the stopper bolt and plain washer to prevent the strap plate from being damaged. 2. Use the stopper bolt (M 10 x 1.25-85 with effective length 30 mm or more) and plain washer (for M12 threads) commercially available.

5.1 Removal and Installation 11) Removal

12) Installation Part number

stamped here

Pilot

�\

bearing

Clutch Alignment Arbor 03726-21000 <C10W41, C12W 43> 43490-00100 <C12W 43: for disc with 12 splines> EO 187A

(a) Install the clutch disc using Clutch Alignment Arbor (special tool).

1 Bearing case assembly 2 Pressure plate & lever assembly 3 Clutch disc assembly E0755A

Clutch Alignment Arbor ;/‘ 03726-21600

<C1QOW41,CI2W43>

~ ,

‘

43490-00100

<C12W43: for disc with

Stopper bolt,

Plain washer (4 places)

E0119B

When removing the pressure plate and lever assembly, secure the pressure plate with Stopper Bolt and Plain Washer (special tools). Before removing the pressure plate and lever assem bly, install Clutch Alignment Arbor (special tool) to pre vent the clutch disc from dropping.

21-6

Clutch disc

NOTE: When installing the clutch disc, make sure that it is installed in the correct direction: install it so that its side with the part number stamped is visible.

CLUTCH - SERVICE PROCEDURE (c) Inspection of release lever height Clutch Lever Aligner MH061330

Release lever

Stopper bolt (4 places: M10 x 1.25)

08910

(b) Secure the pressure plate of the pressure plate and lever assembly with the stopper bolts, then install the clutch, aligning it with the knock pins in the fly wheel.

Clutch cover

E0421A

Using Clutch Lever Aligner (special tool), check the heights of the clutch cover and release lever. Use the support nut for adjustment.

NOTE: 1. Before installing the clutch, check and clean the flywheel and repair or replace as necessary. 2. lighten bolts evenly, in the diagonal order. 3. After installation, be sure to remove the set bolt.

21-7

CLUTCH - SERVICE PROCEDURE

(d) Adjustment after installation of clutch and bearing case

�_f I

, ngaged j

i Most worn position 19°25'

9° 10'

I ,�.,..,

E0756A

The clutch should be set in the most worn position as wear of the clutch disc during service causes the clutch to slip. 1) Move the lever in the direction that the clutch en gages. At a position where a click is heard in the clutch, turn the adjusting bolt A until it is blocked by the stopper, and lock it by turning down the bolt another two or three threads. 2) From the position where the release bearing has touched the release lever, turn the adjusting bolt B in the direction that the clutch disengages, check to see that the clutch is in disengaged position, and then lock the bolt.

21-8

CLUTCH - SERVICE PROCEDURE 5.2 Clutch Proper 5.2.1 Disassembly and inspection Depth to clutch disc rivet head NV 2.2to 2.8 L 0.2

I C!ear�nce of hub spline turning direction NV 0.06 to 0.195 I I L 0.42

I I

<C10W4b Free length , NV 99.5

Clutch disc runout Flatness NV 0.6or less

Installed load (Installed length: 63) NV 1200 to 1330 N {122.6to 135.4 kgf} L 1070 N {109 kgf}

Lateral runout NV 1.2or less Vertical runout NV 1.0or less <C10W41> 1.2or less <C12W43> L 1.5

1 15

Strap bolt fitting hole NV 12.21to 12.22 L 12.5

Squareness NV3.5 or less L 5.2

Thickness NV 59.7 to 59.9 L 56.8

<C12W43> Free length NV92.1

.i Flatness NV 0.05 or less L 0.2

Installed load (Installed length: 63) NV 1420to 1570 N {145to 160.2 kgfl L 1270 N {129kgf} Squareness NV 3.2or less L 4.8

Clearance between release lever pin and bushing BD 12.7 NV0.06to0.15 L 0.3

1 o/• re

13 6

Clearance between strap plate and strap bolt BD 12.2 NV 0.01to 0.11 0.3 L �_ __, _ -c___ _ _ _ _ v \

rr\

5 4 3

BO .. Basic Diameter NV . Nominal Value L.. . Limit

Disassembly sequence

G) Clutch disc assembly ® Strap bolt @ Lock bolt @ Lock plate @ Support nut @ Clutch cover (with strap plate) (J) Pressure spring 8 Spring seat

9 Release lever pin

10 Return spring 11 Release lever support 12 Release lever pin 13 Release lever subassembly 14 Bushing

® Pressure plate

For parts with an encircled number, refer to Disassembly and Inspection Proce dures that follow . NOTE: 1. Since the clutch cover and pressure plate are balanced, make alignment marks before disassembly. 2. Do not remove the strap plate.

E0757B

21-9

CLUTCH

SERVICE PROCEDURE

Disassembly and Inspection Procedures

(2) Inspection of clutch disc

( 1) Removal of clutch cover

(a) Facing wear

Strap� <l;l) Support nut

Depth to rivet head or cup head I

1: ts P-,11

Assembled thickness

E0694A

Measure the assembly thickness of facing and the depth from facing surface to rivet head or cup head. If the measurement is below the limit, replace the clutch disc assembly.

Stopper boit {4 places}

(bl Flatness of clutch disc Dial indicator Clutch disc

08913

(a) Compress the pressure spring with the stopper bolts and, atthe same time, remove the strap bolts, support nut, and other parts. Clutch Installer

Surface plate

MH061331

Portable

screw fack

E0695A

Measure the flatness of facing surface. If it is beyond the limit, correct or replace.

Alig stopper bolts with plate holes. 08914

(b) Put alignment marks on the clutch cover and pres sure plate. Compress the pressure spring using Clutch Installer (special tool), and the same time, remove the stopper bolt. (c) Gradually loosen the handle of Clutch Installer to remove the clutch cover. 21-10

CLUTCH - SERVICE PROCEDURE (3) Inspection of pressure plate

(a) Measurement of thickness

Pressure piate!

thickness >

E0696A

Using the runout tester, measure the clutch disc run out. If the measurement exceeds specification, correct or replace the clutch disc. (d) Spline play in turning direction

/i�

Pressure plate 08919

Measure the pressure plate thickness and, if it is below the limit, replace. (b) Measurement of flatness

Pressure plate

E0697D

Using a piano wire, measure the play in the turning direction of the clutch disc hub splines and bearing case clutch shaft. If the limit is exceeded, replace the clutch disc.

08920

Measure the flatness of the pressure plate friction sur face. Regrind or replace if the limit is exceeded.

21-11

CLUTCH - SERVICE PROCEDURE (5) Inspection of pressure spring

Squareness

Strap bolt hole

length Free Pressure spring

08921

Measure I.D. of strap bolt fitting hole in the pressure plate and, if the limit is exceeded, replace. (4) Inspection of release lever Release lever

Release lever pin

Release lever pinBushing

08922

Measure the release lever pin O.D. and bushing I.D. Re place if clearance exceeds specification.

21-12

E0487A

Measure the free length, squareness, and installed load of the pressure spring. If the measurement is be low the limit, replace the spring.

CLUTCH - SERVICE PROCEDURE 5.2.2 Reassembly

32 to 49 N,m

{3.3 to 5.0 kgf-m)

9.Bto 15 N.m {1 to 1.5 kgf.m)

2 39to 49 N-m

{4 to 5 kgf-m)

�Strap support washer Strap plate

Apply Molybdenum disulfide grease.

Assembly sequence 7-,12-

14 -

__J-t1,➔9➔10➔8➔7�➔5➔4➔3➔2➔1

For parts with an encircled number, refer to Reassembly Procedure that follows.

E0754B

(1) Whenever the pressure plate friction surface is cor rected, insert adjusting washers of thickness equivalent to correction amount.

Reassembly Procedure

Friction surface correction amount Adjusting washer thick� (mm) (mm) ness Adjusting washer

Less than 1

None required

1 or more to less than 2

One 1.2

2 or more to less than 3

Two 1.2 or one 2.3

t = thickness

08925

21-13

CLUTCH - SERVICE PROCEDURE

Clutch Installer MH061331

Clutch Lever Aligner MH061330

Alig’ stopper bolts with plate holes. 08914

(21 To install the clutch cover, align the alignment marks and, using Clutch Installer (special tool), temporarily tighten the stopper bolts.

Strap� &

�

Stopper bolt {4 places}

08913

(31 With the pressure spring compressed by the stop per bolts, install the strap bolt, support nut, and other parts.

21-14

(4) After installing the clutch, check the clutch cover and release lever for height using Clutch Lever Aligner (special tool).

CLUTCH - SERVICE PROCEDURE 5.3 Bearing Case 5.3.1 Disassembly and inspection Cracks, damage

Rotating condition

t}�

13 6

Clearance BD 30 NV 0.03 to 0.08 ! L 0.2

8D .. Basic Diameter NV .. Nominal Value L .... Limit

Rotating condition, wear, damage, seizure

Disassembly sequence 1 *2 3 4 5 6

Clutch shifter Clutch release bearing Return spring Stopper plate Stopper Clutch release fork shaft

7 Clutch release fork 8 Drive shaft front cover 9 Oil seal 10 Clutch shaft 11 Snap ring

12 13 14 *15 16

Ball bearing Bearing case Oil seal Needle roller bearing Clutch housing

NOTE:

Parts marked* should not be removed unless they are to be replaced.

E0760A

21-15

CLUTCH - SERVICE PROCEDURE

5.3.2 Reassembly

; Pack grease

Pack grease Mitsubishi wheel bearing grease

i Templex N-3 grease

grease I! Apply Molykote BR2 Plus

Oil groove to be placed in uppermost position

5 6

140 N,m {14.2 kgf-m) Apply sealant THREEBOND 1102C

Templex Pack grease N-3 grease |

Assembly sequence 13➔14--10➔12➔11 __j➔S➔S � 3➔4 16--ii§:.➔6➔7➔5 1➔2 For parts with an encircled number, refer to Installation of Needle Roller Bearing that follows. E0761A

Reassembly Procedure Installation of Needle Roller Bearing Using Needle Roller Bearing Installer (special tool), install the needle roller bearing in the housing. The needle roller bearing should be pressed in up to the specified dimension with the oil seal side inward and the inscribed side outward.

if/

ll! I� I ')I!,'

NOTE: When installing the needle roller bearing, direct the lip in the correct direction.

inscribed side

{dust seal side)

E0123A

Installing direction __,...

Dust seal

3to5 mm

21-16

E0762A

CLUTCH - TROUBLESHOOTING 6. TROUBLESHOOTING Probable cause

Symptom Clutch drags when d'1sengaged

i Defective clutch proper I Disassem bl e and ch eek elute h assem bly.) • Damaged or poorly lubricated pilot bearing • Damaged release bearing • Uneven height of release lever or its damage • Defective clutch disc

Remedy

Ref. group

Replace or lubricate Replace Adjust height or replace Replace

• Damaged or deformed clutch disc • Worn or rusty splines and clutch disc hub • Distored or damaged pressure plate

Replace or correct defective parts Grind or replace

Distored or damaged flywheel Clutch slips

Group 11

Defective clutch proper (Disassemble and check clutch assembly.) • Uneven height of release lever

Adjust

• Pressure spring losing proper tension

Replace

• Defective clutch disc • Worn facing • Deformed clutch disc • Hardened facing • Oil on facing • Distored or damaged pressure plate

Remove hardened surface or replace Remove oil or replace Grind or replace

Distored or damaged flywheel Clutch is not smoothly engaged

Group 11

Defective clutch proper (Disassemble and check clutch assembly.) • Defective clutch disc

Replace

• Distored facing • Hardened facing

Remove hardened surface or replace

• Loose rivet

Replace

• Oil on facing

Remove oil or replace

• Binding clutch disc splines

Correct or lubricate splines

• Clutch disc torsion spring losing proper tension or broken

Replace

• Uneven height of release lever

Adjust

• Pressure spring losing proper tension

Replace

• Distored or damaged pressure plate

Grind or replace

i Distored or damaged flywheel

Group 11

21-17

CLUTCH - TROUBLESHOOTING

Probable cause

Symptom Clutch is noisy when disen gaged

Worn, damaged, or poorly lubricated pilot bearing

Remedy

Ref. group

Replace or lubricate

Worn damaged, or poorly lubricated release bearing Defective clutch disc • Worn clutch disc splines

Replace

• Clutch disc torsion spring losing proper tension or broken Bent strap plate Clutch is noisy when engaging

Defective clutch disc • Clutch disc torsion spring losing proper tension or broken

Replace clutch cover Replace

• Worn clutch disc hub splines Worn splines of clutch shaft Pressure spring losing proper tension Low idle speed

21-18

Adjust

Group 13

SPECIAL EQUIPMENT CONTENTS 1. GENERAL .. .... .. ...... ...... .. .... ........ . 2 1.1 Air Compressor .......... .. ........ .... .. 2 Air Pressure Governor .... .. .. .. .... .. ... 4 1.2 2. SPECIFICATIONS .. .. .. .. ...... .. .. .. .. .. ... 5 3. SERVICE STANDARDS .. .... .. .. ........ .. . 6 3.1 Service Standards Table .. .... ...... .. .. . 6 3.2 lightening Torque Table .. .. .. .. .. .. ..... 8 4. SPECIAL TOOL ...... .. .. .. .... .. .. .... ..... 9 5. SERVICE PROCEDURE ..................... 10

5.1 Air Compressor . .... . . . .. .. . . ... .. . . . ... . 10 Removal and installation .. ..... . .. . . . 10 5.1.1 Disassembly .. .. .. ... .. ..... .. .... ... .. 15 5.1.2 Inspection .... .. .. .... .. . .. .. .. ........ 20 5.1.3 Reassembly ... .. .. .... .. ........ .. .. .. 27 5.1.4 Air Pressure Governor ... . . . .. ... ... ..... 32 5.2 Disassembly and inspection . . ... . .. . . 32 5.2.1 Reassembly and adjustment . . ... ... . 33 5.2.2

61-1

SPECIAL EQUIPMENT - GENERAL 1. GENERAL 1.1 Air Compressor <602> (1-cylinder type)

(2-cylinder type)

To air tank From air pressure governor Unloader valve-�,

-........./'·· !

,·

From air pressure governor

Delivery valve

Suction valve

Delivery valve

09601

B48098

<8DC> (1-cylinder type)

(2-cylinder type) From air pressure governor

From air pressure

governor

To air tank

)J Unloader valve

84808B

The air compressor is driven by the injection pump gear in mesh with the timing gear of the engine at a speed one half of the engine speed. On the cylinder head of the air compressor, a suction valve, delivery valve and unloader valve are provided which respec tively accomplishes the suction, delivery and exhaust functions. The air compressor comes in two types; the 1- and 2-cylinder types. 61-2

�

Unloader valve

N2880C

SPECIAL EQUIPMENT - GENERAL When the piston enters the up stroke, the suction valve is forced back by the valve spring to close the air suc tion port of the valve seat. (2) How air is routed under pressure

To air tank

Sensor plate

N2919A

A sensor plate for the tachometer is provided on the in jection pump gear side of the air compressor. The sen sor plate has sensor bars.

spring Delivery vaive

( 1) How air is drawn in

84814A

Valve spring Suction valve

The air, compressed in the cylinder as the piston moves down, gets over the action of the valve spring on the delivery side and forces up the delivery valve stopping up the delivery port of the valve seat. So the air is routed under pressure to the air tank. When the piston enters the down stroke, the delivery valve is forced back by the valve spring to close the air delivery port of the valve seat.

Piston

N2725A

The air is drawn in by the negative pressure which is produced in the cylinder as the piston moves down. When the negative pressure is produced in the cylin der, the suction valve that has been stopping up the suction port of the valve seat compresses the valve ·spring to open the suction port. So the air is drawn into the cylinder. 61-3

SPECIAL EQUIPMENT - GENERAL 1.2 Air Pressure Governor

(3) How unloader valve operates

Unloader valve

Compressed air (from air pressure governor)

Exhaust port

Adjust spring

3 &Q.aUG ®ben >c=o

air compressor To unloader of

Low

pressure valve

Suction vaive

Diaphragm Filter

High pressure valve

From air tank

N2727A

B4080A

When the air pressure in the air tank exceeds the speci fied pressure (pressure governor operating pressure), the pressure governor opens to send the compressed air to the unloader valve. The compressed air not only depresses the unloader valve, but keeps the suction valve open, causing the air compressor to operate un der no load. When the air pressure in the air tank falls below specifi cation, the pressure governor resumes operation, dis charging compressed air present at top of the unload er. Then the unloader valve spring puts the unloader valve back to its original position, causing the suction valve to begin operation.

The pressure governor controls compressor operation to keep the air tank pressure within specified limits. To the high pressure valve of the diaphragm, the same air pressure as in the air tank acts always through the filter, thereby balancing with the adjusting spring force. When the pressure in the air tank increases to ex ceed that opening pressure of the high pressure valve, the air forces up the high pressure valve seat of the dia phragm. This causes increase of acting area so that the diaphragm moves up quickly to close the seat of the low pressure valve. When the low pressure valve is closed, air now flows through the valve body to force down the unloader valve of the air compressor, thereby stopping air sup ply to the air tank. As the air pressure in the air tank gradually drops, the diaphragm is forced down by the adjusting spring and the low pressure valve opens and the high pressure one closes. As a result, the air on the unloader side is exhausted through the exhaust hole and air supply to the air tank is resumed.

61·4

SPECIAL EQUIPMENT - SPECIFICATIONS 2. SPECIFICATIONS Unit: mm Item

Air compressor

Type

Water-cooled 2-cylinder type

Cylinder diameter x stroke

85 X 50

80 x50

Cylinder capacity

284 cm 3

502 cm 3

Turning direction {as viewed from drive side) Pressure governor

Specification Water�cooled 1-cylinder type

Type

Clockwise Diaphragm type

61-5

SPECIAL EQUIPMENT - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table

(1) Air compressor Maintenance item 6D2 Engine 1-cylinder type

Installed load/ installed length

I Suction valve spring , deterioration

I deterioration Delivery valve spring

i Piston ring open end clearance (measured inside cylinder liner)

· Clearance between piston ring and ring groove of piston

j Compression ring only

Piston pin to piston clearance

Piston pin to connecting rod small end clearance Piston to cylinder liner clearance

! I

Top portion

I Skirt portion

4.4 N {0.45 kgfJ/5

3.5 N {0.36 kgf)/5

: Replace

4.5 N {0.46 kgf)/9.5

3.6 N {0.37 kgf)/9.5

1.0

0.08

[181 [181

[85)

Crankshaft to connecting rod bearing clearance

[341

Connecting rod bearing

Crankshaft end play

Connecting rod end play Installed load/ installed length

! Piston ring open end clearance (measured ! inside cylinder liner)

Clearance between piston ring and ring groove of piston

Compression ring only

Piston pin to piston clearance

Piston pin to connecting rod small end clearance iner

I �t!��i/ylinder l

I Top portion

! Skirt portion

Crankshaft to connecting rod bearing clearance

0.07

When copper color is exposed because of worn internal plated layer 1.0

4.4 N {0.45 kgf)/5

3.5 N {0.36 kgfJ/5

4.5 N {0.46 kgf)/9.5

3.6 N {0.37 kgf}/9.5

1.0

0.08

1161

0.08

[801

0.29

0.07

[161

[801

[34)

Crankshaft end play

0.17

Replace piston pin or con-

necting rod

Replace bearing Replace bearing

Replace crankshaft

Replace crankshaft or connecting rod Replace

Replace all piston rings as a set

Replace all piston rings as a · set Replace

Replace piston pin or connecting rod Replace piston or cylinder liner Replace bearing

When copper color is exposed because of worn interna! plated layer

Replace bearing

0.5

! Replace

0.1

1.0

Replace crankshaft or crank� case

0.5

Replace all piston rings as a set

0.1

I !

Replace all piston rings as a set

Replace piston or cylinder liner

0.18

Remedy and remarks

0.27

Connecting rod bearing

. Connecting rod end play

0.08

[851

142)

I Delivery valve spring I deterioration

61-6

Limit

Bearing to crankshaft clearance

2-cylinder i Suction valve spring type I deterioration

Unit: mm

Nominal value (Basic diameter inf])

! Replace crankshaft

! Replace crankshaft or con1 necting rod

SPECIAL EQUIPMENT - SERVICE STANDARDS

Unit: mm

Maintenance item 80C Engine Suction valve spring deterioration

1-cylinder type

Delivery valve spring deterioration

Installed load/ installed length

Piston ring open end clearance (measured inside cylinder liner) Clearance between piston ring and ring groove of piston

Nominal value (Basic diameter in [ ])

Limit

4.4 N {0.45 kgf)/5

3.5 N {0.36 kgfJ/5

Compression ring ! only I

Piston pin to connecting rod small end clear-

0.08

Replace all piston rings as a set

0.08

Replace

1181

O.Q7

Replace piston pin or connecting rod

I Top portion

l851

0.27

1851

0.18

Replace piston or cylinder liner

1341

0.1

Replace bearing

When copper color is exposed because of worn internal plated layer

Replace bearing

Skirt portion

Crankshaft to connecting rod bearing clearance Connecting rod bearing

2-cylinder type

I I

1181

Piston to cylinder liner clearance

Replace

i 4.5 N {0.46 kgf)/9.5 I 3.6 N {0.37 kgfJ/9.5 I i T 1.0 Replace al! piston rings as a set

Piston pin to piston clearance

ance

Remedy and remarks

Crankshaft end play

1.0

! Replace crankshaft

Connecting rod end play

0.5

Replace crankshaft or connecting rod

4.4 N {0.45 kgfJ/5

3.5 N {0.36 kgfJ/5

4.5 N {0.46kgf}/9.5

3.6 N {0.37 kgf)/9.5 i

1.0

Replace all piston rings as a set

0.08

Replace all piston rings as a set

1161

0.08

Piston pin to connecting rod small end clearance

1161

0.07

I Replace piston pin or connecting rod

Piston to cylinder liner clearance

l801

0.29

180]

0.17

Replace piston or cylinder liner

134]

0.1

Replace bearing

When copper color is exposed because of worn internal plated layer

Replace bearing

Crankshaft end play

1.0

Replace crankshaft

Connecting rod end play {with two paired)

1 .0

Replace crankshaft or con necting rod

Suction valve spring deterioration Delivery valve spring deterioration

! Installed load/ installed length

Piston ring open end clearance (measured inside cylinder liner) Clearance between piston ring and ring groove of piston

Compression ring ; only

Piston pin to piston clearance

l Top portion I Skirt portion

Crankshaft to connecting rod bearing clearance Connecting rod bearing

I !

Replace !

Replace

61-7

SPECIAL EQUIPMENT - SERVICE STANDARDS

(2) Air pressure governor Maintenance item High pressure valve opening pressure

MC802148

MC802150

Low pressure valve opening pressure

MC802148 MC802150

Un it: kPa {kg/cm 2 } Nominal value

Limit

34 { 715 -+ 4.9 73 j:J�l

34 784 -+4

{8.0 j:J�)

. 9 49 625 + . {64j:g �) -34 +4 .9 595 -34 {7.1

::gs�}

Remedy and remarks Adjust or replace

3.2 lightening Torque Table ( 1) Air compressor Location tightened

0.0. x pitch

Tightening torque N-m {kgf-m)

M10 x 1.25

23 to27 {2.3 to2.8)

M10 x 1.5

25 to 29 {2.5 to 3.0}

MS x 1.25

14to 18 {1.4to1.8)

Screw size {mm)

Cylinder head nut

602 <1-cylinder type>, SOC

Cylinder head bolt

602 <2-cy!inder type>

Cylinder liner nut

602 <2-cylinder type>

Injection pump gear mounting nut 6D2, BOC <1-cylinder type>

Bearing holder bolt

BOC <2-cylinder type> 602 <2-cylinder type>

Bearing holder nut Connecting rod cap nut Joint

6D2

Unloader valve guide Delivery valve holder

M10 x 1.5

M24 x 1.5

MB X 1.25

215 {22)

19to25 {1.9to 2.6}

14to 18{1.4to 1.8}

MB X 1.25

23 to25 {2.3to2.6)

M28 x 1.5

98to 115 {10to 12)

PT1/8

15to20 {1.5to 2.0)

M36 x 1.5

98to115(10to12)

Screw size 0.0. X pitch

Tightening torque N-m {kgf-m}

15 to 20 {1.5 to2)

M45 x 1.5

Suction valve holder

39 to49 {4to 5)

98to 115(10to12)

(2) Air pressure governor Location tightened

(mm)

Sleeve lock nut Adjusting screw lock nut

61-8

9.8 to15 {1to1.5)

SPECIAL EQUIPMENT - SPECIAL TOOL 4. SPECIAL TOOL Air compressor Unit: mm Tool name

Shape

Unit: mm Tool name

Air Compressor Suction Valve Tool

Shape

Piston Ring Tool MH060014

MH061263

Removal and installation of piston ring

Installation and removal of suction valve holder

01730

01732

61-9

SPECIAL EQUIPMENT - SERVICE PROCEDURE

5. SERVICE PROCEDURE 5.1 Air Compressor 5.1.1 Removal and installation NOTE: 1. To remove the air compressor, remove the injec tion pump beforehand. 2. At installation, the injection pump gear installed on the air compressor should be in mesh as speci fied. <6D2> (1-cylinder type air compressor)

(2-cylinder type air compressor)

1 Water outlet pipe 2 Air outlet pipe 3 Unloader pipe A 4 Unloader pipe B (2-cylinder type only) 5 Water inlet pipe

6 Air suction hose (1-cylinder type) Air suction pipe (2-cylinder type) 7 Oil pipe 8 Air compressor B9050B

61-10

B9051B

SPECIAL EQUIPMENT - SERVICE PROCEDURE

<8DC>

(2-cylinder type air compressor)

{1-cylinder type air compressor)

4 \

1 Unloader pipe A 2 Unloader pipe B (2-cylinder type only) 3 Air suction pipe 4 Air suction hose 5 Air outlet pipe 6 Water outlet pipe

7 Water inlet pipe A (2-cylinder type only) 8 Water inlet pipe B 9 Oil inlet pipe 10 Air compressor bracket 11 Air compressor 84490A

89057A

Removal Procedure

With the piston at any other position, the injection pump gear guide plate cannot be removed as it is caught by the idler gear.

61-11

SPECIAL EQUIPMENT - SERVICE PROCEDURE Installation Procedure (1) 6D2

)

!I I Engraved line of injection pump gear

Injection pump gear Idler gear C ,;,-:::,,/

Air 5oO€ a 2 a% aooe

of rear plate

09637

(a) Crank the engine until the "16" marked on the out er periphery of the flywheel is aligned with the pointer of the inspection window of the flywheel housing to place the piston in the No. 1 cylinder of the engine at the top dead center on the compres sion stroke. If the piston in the No. 1 cylinder is at the top dead center on the compression stroke, the valve clearance should exist in the No. 1 cylinder. If there is no valve clearance, the piston in the No. 6 cylinder is at the top dead center on the compres sion stroke. Therefore, rotate the engine 360 ° .

NOTE:

When the engine is to be cranked, crank it by hand 180° or more in the direction of normal rotation.

61-12

f\,

B�lt (M10 x 1.5) ,� Length ..,. (about 100 mm)

Injection pump gear

C0768A

(b) Insert bolts (M10 x 1.5 about 100 mm long) from the rear end plane of the flywheel housing to sup port the air compressor. Insert the air compressor in the hole provide in flywheel housing until its gear end makes contact with the end surfaces of both injection pump gear and camshaft gear. Align the inscribed lines on rear plate and injection pump gear and push the air compressor inward.

SPECIAL EQUIPMENT - SERVICE PROCEDURE (d) Installation of tachometer sensor

1) Adjustment-free type Plug or tachometer sensor mounting position

Apply a sealant (THREEBOND 1211 or 1212) to the threaded portion

Hexagonal portion 29 • 5.9 N,m {3 • 0.6 kgf,m}

Flywheel housfng

09640

To install the tachometer sensor, apply sealant to the threaded portion of the sensor and screw the sensor in until the hexagonal portion of the sensor seats. 2) Adjustment type

Mounting threaded hole

09639

(c) Remove the tachometer sensor or plug. Look through the threaded hole to confirm that the pro jection on the sensor plate is positioned at the cen ter of the threaded hole, and then secure the air compressor. If the projection on the sensor plate is not positioned at the center of the threaded hole, remove the air compressor and perform Item (b) again.

NOTE: If the meshing teeth of the injection pump gear and idler gear C are one tooth different, about one haH of the sensor plate bar will be hidden from the threaded hole.

Flywheel housing

Sensor plate Tachometer sensor

Lock nut Apply a sealant (THREEBOND 1211 or 1212) to the threaded portion

29 • 5.9 N•m {3 • 0.6 kgf-m}

N2825A

To mount the tachometer sensor, apply a sealant to the threaded portion of the sensor and turn down the sen sor until it comes in contact with the sensor plate. Then back it off 2/3 of a turn (240°) (Clearance 1.0 mm). Secure it by tightening the lock nut to specification. 61-13

SPECIAL EQUIPMENT - SERVICE PROCEDURE (2)

soc

extending from the engraved line of the rear plate). Then push the air compressor into position.

NOTE: On the sensor plate equipped version, perform the fol lowing procedures to check that the gears are in mesh.

i� 85703A

a = o 5 6 > c= c D \.ce

position

(a) Crank the engine until the piston of the No. 1 cylin der is placed at the top dead center on the com pression stroke. When the engraved line 1,4 of the flywheel housing is in alignment with the pointer of the inspection window of the flywheel housing, the piston of the No. 1 or No. 4 cylinder is at the top dead center on the compression stroke. In this case, the piston of the cylinder where the push rod is not pushing the rocker up is at the top dead cen ter on the compression stroke.

Sensor plate bar

NOTE: When you crank the engine, be sure to manually crank the engine more than 180 ° in the forward direction. Line up the engraved lines with each other.

�1��

Flywheel housing

Rearplate

�(1__

C0761B

(b) Insert the air compressor into the mounting hole of the flywheel housing. With both end planes of the injection pump gear and camshaft gear in contact, line up the engraved line of the rear plate with the engraved line on the tooth surface of the injection pump gear (make sure that the engraved line on the gear tooth surface is in alignment with the line 61-14

(c) Remove the plug, look through the threaded hole to verify that the sensor plate bar is positioned at the center of the hole, and then secure the air com pressor. (d) When the sensor plate bar is not positioned at the center of the threaded hole, withdraw the air com pressor, and re-perform Step (b).

NOTE:

N2826A

If the meshing teeth of the injection pump gear and camshaftgear are one tooth different, about one half of the sensor plate bar will be hidden from the threaded hole.

SPECIAL EQUIPMENT - SERVICE PROCEDURE 5.1.2 Disassembly <6D2> I1-cylinder type)

12 Sagging spring

13 Wear, damage 14 Wear, damage

Crack, scratch

�Fillll-----24 1"

� 2

Crack, worn bushing, 27� l!ll clogged oil hole �

-v

Circumference damaged 29 � or worn

Crack, wear

31 Crack

Wear, damage 6 2

c�!�

33 30 Scratch, clogged oil hole

play ! � ference � ---28 I· End �� L 1.0 : � damaged� ., or worn � � 2 25 3 Disassembly sequence 10 Delivery valve holder 19 Cylinder liner 1 Sensor plate @ Compression ring 11 Spring holder 2 Injection pump gear @ Oil ring 12 Delivery valve spring 3 Collar Snap ring 22 13 Delivery valve 4 Cylinder head 23 Piston pin 14 Delivery valve seat 5 Stud bolt Piston 24 @ Suction valve holder 6 Snap ring 25 Bearing holder 16 Suction valve spring 7 Unloader valve 26 Oil seal 17 Suction valve 8 Valve spring

9 Valve guide

L ... Limit

27 Connecting rod 28 Connecting rod cap 29 Connecting rod bearing 30 Crankshaft 31 Crankcase *32 Bearing *33 Bearing

18 Suction valve seat

For parts with an encircled number, refer to Disassembly Procedure that follows. Parts marked with* should not be removed unless defects are evident.

09252A

61-15

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(2-cylinder type) 10

11 Sagging spring 12 Wear, damage

13 Wear, damage

17 Wear, damage 16 Wear, damage —15 Sagging spring

Crack, worn bushing, 26 clogged oil hole

Circumference damaged 28 or worn

Crack, wear

30 �

� 25

Wear, damage

Circumference damaged or worn

29 Scratch, clogged oil hole End play

L ... Limit

1.0

Disassembly sequence 1 Sensor plate 2 Injection pump gear 3 Collar 4 Cylinder head 5 Snap ring 6 Unloader valve 7 Valve spring 8 Valve guide

9 Delivery valve holder 10 Spring holder 11 Delivery valve spring 12 Delivery valve 13 Delivery valve seat Suction valve holder 15 Suction valve spring

16 17 18 @) @ 21 22 23 24

Suction valve Suction valve seat Cylinder liner Compression ring Oil ring Snap ring Piston pin Piston Bearing holder

For pans with an encircled number, refer to Disassembly Procedure that follows.

61-16

25 Oil seal 26 Connecting rod 27 Connecting rod cap 28 Connecting rod bearing 29 Crankshaft 30 Crankcase 31 Bearing 32 Bearing 09641

SPECIAL EQUIPMENT - SERVICE PROCEDURE

<BDC> {1-cylinder type)

Sagging spring 11——___¢ Wear,damage12

Crack,

worn ‘pushing, clogged oil hole

Circumference

damaged or worn

2 7 Wear, w damage o—16 Wear damage Ra

e—15Sagging spring E 19

@-i4)

Rotating condition

2 Crack, wear Rotating condition

25 39 Scratch, clogged oit hole

End play

Crack, damage --~@) Disassembly sequence

1 Sensor plate 2 Injection pump gear 3 Spacer 4 Cylinder head 5 Snap ring 6 Unloader valve 7 Valve spring 8 Valve guide 9 Delivery valve holder 10 $piing holder 11 Delivery valve spring

1.0

12 Delivery valve 13 Delivery valve seat

® Suction valve holder

15 Suction valve spring 16 Suction valve 17 Suction valve seat 18 Cylinder liner 19 Stud

® Compression ring @ Oil ring

22 Snap ring

For parts with an encircled number, refer to Disassembly Procedure that follows.

L ... Limit

23 Piston pin 24 Piston 25 Bearing holder 26 Oil seal 27 Connecting rod 28 Connecting rod cap 29 Connecting rod bearing 30 Crankshaft 31 Bearing 32 Bearing 33 Crankcase N2750A

61-17

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(2-cylinder type)

Sagging spring 11

Crack, damage

1 Crack, wear

30 Scratch, clogged oi! hole

(?9J 26 Crack, damage

Endplay | L

1.0;

23 -————_ Circumference damaged or worn 28

Disassembly sequence 1 Sensor plate 2 Injection pump gear 3 Spacer 4 Cylinder head 5 Snap ring 6 Unloader valve 7 Valve spring 8 Valve guide 9 Delivery valve holder 10 Spring holder 11 Delivery valve spring

12 Delivery valve 13 Delivery valve seat ® Suction valve holder 15 Suction valve spring 16 Suction valve 17 Suction valve seat 18 Cylinder liner 19 Stud @) Compression ring @ Oil ring 22 Snap ring

L. .. Limit

23 Piston pin 24 Piston 25 Bearing holder 26 Oil seal 27 Connecting rod 28 Connecting rod cap 29 Connecting rod bearing 30 Crankshaft 31 Rear Bearing 32 Front Bearing 33 Crankcase

For parts with an encircled number, refer to Disassembly Procedure that follows. N2877A

61-18

SPECIAL EQUIPMENT - SERVICE PROCEDURE Disassembly Procedure

(2) Disassembly of piston ring

I 1) Disassembly of suction valve holder

Suction Valve Tool MH061263

N3166A

NOTE: Since the suction valve holder is staked by punching, do not attempt disassembly unless trouble is evident.

NOTE: When a piston ring is removed, do not widen the open ends of the piston ring more than 28 mm for 1-cylinder type and more than 26 mm for 2-cylinder type.

61-19

SPECIAL EQUIPMENT - SERVICE PROCEDURE

5.1.3 Inspection <6D2> (1-cylinder type)

Sagging spring Installed load/installed length NV 4.5 N {0.46 kgf}/9.5 L 3.6 N {0.37 kgf}/9.5

Clearance between piston ring and ring groove of piston I Compression ring only i , L 0.08

Sagging spring Installed load/installed length NV 4.4 N {0.45 kgfJ/5 L 3.5 N {0.36 kgfJ/5

! Piston ring open end clearance L 1.0

Top portion BO 85 L 0.27 Skirt portion BO 85 L 0.18

, Clearance BO 18 i L 0.08

I End play I

0.5 !

Clearance BO 34 L 0.1

Clearance BO 42 L 0.1 End play L 1.0 i

BD .. Basic Diameter NV .. Nominal Value L .... Limit 092528

61-20

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(2-cylinder type)

' I Clearance Top portion BO 80 L 0.29

,I: 1

Skirt portion BO 80

0.17

1·

I Saggmg spnng Installed load/mstaHed I length / NV 4.5 N (0.46 kgfJ/9.5 L 3.6 N (0.37 kgf}/9.5 '

Sagging spring Installed load/installed length NV 4.4 N (0.45 kgf)/5 L 3.5 N (0.36 kgf}/5

Clearance BO 16 [ . L 0.08

Clearance BO 16 L 0.07 j

Clearance between piston ring and ring groove of piston ) Compression ring only L 0.08

I Piston ring open end 1 clearance L 1.0 I

BD .. Basic Diameter NV .. Nominal Value Limit L..

09646

61-21

SPECIAL EQUIPMENT - SERVICE PROCEDURE

<BDC>

( 1-cylinder type)

Clearance Top portion 8D 85 L 0.27

Clearance between piston ring and ring groove of piston I Compression ring only ' L 0.08

Skirt portion BD 85 L 0.18

Sagging spring Installed load/installed length NV 4.5 N {0.46 kgf)/9.5 L 3.6 N {0.37 kgf)/9.5

,·

Piston ring open

1.0

I Clearance 1 8D 18

i Sagging spring : Installed load/installed ! length NV 4.4 N {0.45 kgf)/5 L 3.5 N {0.36 kgfl/5 i

0.07

' Clearance II LBD 34 0.1

End play L 1.0

i BO .. Basic Diameter NV .. Nominal Value L. ... Limit N2752A

61-22

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(2-cylinder type)

Clearance Top portion 8D 80 L 0.29 Skirt portion 8D 80 L 0.17

Sagging spring Installed load/installed length NV 4.5 N {0.46 kgf)/9.5 L 3.6 N {0.37 kgfl/9.5

�'@ ';) · Sagging spring Installed load/ installed length NV 4.4 N {0.45 kgfl/5 L 3.5 N {0.36 kgf)/5

©i0 tfj)

I Clearance between piston ring and ring groove of piston Compression I ring only L 0.08 i

Piston ring open end clearance L 1.0

Clearance 8D 16 I L 0.08 1.

® �,

Jg�-�-, \

'7'-1\, <.,

�,.,,.,.

I 1

End play ! L 10 I

' End play L 1.0

BO . Basic Diameter NV .. Nominal Value L .... Limit D92268

61-23

SPECIAL EQUIPMENT - SERVICE PROCEDURE (3) Piston ring open end clearance

Inspection Procedures (1) Piston to cylinder clearance

Measuring direction

D9266A

Measuring position

Fit the piston ring over a standard gauge or new cylin der liner and measure the open end clearance. If the clearance is over the limit, replace the piston ring.

NOTE: Push the piston in and measure the clearance with the piston ring in horizontal position.

i'!-------11

(4) Piston to piston pin clearance

D9264A

If the clearance is over the limit, replace the piston or cylinder liner.

Measuring position

Measuring direction

(2) Piston ring and piston ring groove clearance

D9271A

Calculate the clearance. If it is in excess of the limit, re place the piston or piston pin.

D9265A

If the clearance is over the limit, replace the compres sion ring or piston.

NOTE: Measure the clearance all around the piston.

61-24

SPECIAL EQUIPMENT (51 Piston pin and connecting rod clearance

Measuring position

SERVICE PROCEDURE

(6) Crankshaft and connecting rod bearing clearance [Crankshaft: 6D2, BOC <1-cylinder type>]

Measuring direction

Measuring position

Measuring direction

09267A

If the clearance is over the limit, replace the piston pin or connecting rod.

09268A {Crankshaft: SOC <2-cylinder type>] Measuring direction

Measuring position

09218A [Connecting rod bearing} Measuring direction

Measuring position

B4134A

Calculate the clearance. If it is in excess of the limit, re place the bearing or crankshaft.

61-25

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(7) Clearance between crankshaft journal and bearing <602 only>

(9) Unloader valve assembly Snap ring�

Measuring position Unloader valve 1

1 ( 1 1-----II

Measuring direction

Valve spring -------§�31

>©=wa=a @

09272A

* 1-cylinder type shown

09269A

Calculate the clearance. If it is in excess of the limit, re place the parts. (8) Connecting rod end play End play

"1-cylinder type shown

09270A

If the play exceeds the limit, replace the connecting rod.

NOTE: On a 2-cylinder type compressor, measure the end play with both connecting rods pushed to one side.

61-26

If the unloader valve in unloader valve assembly is badly worn, replace the unloader valve assembly.

SPECIAL EQUIPMENT - SERVICE PROCEDURE 5.1.4 Reassembly

<602> (1-cylinder type)

98to 115 N-m {10 to 12 kgf-m} 9

98to 115 N,m {10 to 12 kgf,m}

98to 115 N•m {10 to 12 kgf-ml 10 11

Apply THREEBONO NEJILOCK i T813238tothreethreadsofthe I | threaded portion 0.2 to 0.3 cm 3

23to 27 N•m {2.3 to 2.8 kgf-m)

15to 20 N.m

{1.5 to 2.0 kgf-m} 27

215 N-m {22 kgf-ml

Apply engine26 :|oil to lips

23to 25 N-m {2.3 to 2.6 kgf-m}

Bend lock washer.

14to 18 N-m {1.4to 1.8 kgf-m)

Reassembly sequence 31 ➔32➔33➔30➔29➔®➔®➔25➔26➔24➔23➔22➔®➔®➔ 19➔5➔4➔3➔®➔® t 14➔ 13➔ 12➔ 11➔ 10➔ 18➔ 17 ➔ 16➔®

—

8---+7➔6➔9 ...........J

For parts with an encircled number, refer to Reassembly Procedure that follows. 83256B

61-27

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(2-cylinder type)

98to 115 N-m {10 to 12 kgf-m) 9

39to 49 N-m {4to 5 kgf.m}

Apply THREEBOND NEJILOCK 1323B to three threads of the threaded portion 0.2 to 0.3 cm 3 98to 115 N-m {10 to 12 kgf.m} 8 5

12 13

15 to 20 N-m {1.5 to 2.0 kgf-ml

25to 29 N-m {2.5 to 3.0 kgf-m}

31 Apply engine I oilto : lips

17 �

---c.....

m, �.,

215 N-m {22 kgf.m}

1 ___:c

14 98to 115 N-m 15 {1010 12 kgf-ml

'� I

Positioning pin

25 24

Bend lock washer.

I 2

Reassembly sequence 30➔32➔31➔29➔24➔25➔28➔®➔®➔23➔22➔21 ➔®➔@➔ 18➔4➔3➔@➔(j) 13➔12➔11➔10➔9➔ 17➔ 16➔ 15➔®� 8--+7--+6--+5 __J

For parts with an encircled number, refer to Reassembly Procedure that follows.

61-28

09644

SPECIAL EQUIPMENT - SERVICE PROCEDURE

<8DC> (1-cylinder type)

Apply THREE BOND NEJILOCK 10 TB13238 to three 98to115N-m threads of the threaded portion (10 to 12 kgf-m) 9 0.2 to 0.3 cm3

6 8 98to115N-m (10 to 12 kgf-m)

20 23

�--n_ll=;:;:::=:;:;:::=ll;J

14 98to 115 N-m

(10 to 12 kgf-m)

23 to 25 N-m {2.3 to 2.6 kgf-m)

23 to 27 N-m {2.3 to 2.8 kgf-m) 215 N-m -1----(22 kgf-m)

Apply engine 26 i oil to lips

�--- Bend lock washer.

Reassembly sequence 30--,32--,31 --,33--,2s--,26.....®--,29--,®--,24--,@.....@--,23--,22--, 19--, 1s--,4--,3--,®.....G) 13--, 12--, 11--> 10--,9--, 17--> 16--> 15� 8➔7➔6➔5 For parts with an encircled number, refer to Reassembly Procedure that follows. N2754A

61-29

SPECIAL EQUIPMENT - SERVICE PROCEDURE

(2-cylinder type)

98to 11S N-m

~———= {10 to 12 kgf-m} om

I Apply THREEBOND NEJILOCK I ' TB 1323B to three threads of the i threaded portion 0.2 to 0.3 cm3 I

98 to 115 N-m

{10 to 12 kgf-rm}

23 to 27 N-m {2.3 to 2.8 kgf-m}

14 98to 115N-m

21-...--J�i,=�1

22 18---===i:i�Sc=Si::�W------24

{10to 12 kgf-m}

2 1

Apply engine

oil to lips

23 to 25 N-m {2.3 to 2.6 kgf-m}

i 26

215 N-m {22 kgf-m}

Bend lock washer.

19 to 25 N-m {1.9 to 2.6 kgf-m}

Reassembly sequence 30---+32➔31➔33➔25➔26➔®---+29➔®➔@➔®➔24➔23➔22➔19➔18➔4➔3➔@➔CD 13➔ 12➔ 11➔ 10➔9➔ 17 ➔ 16-t15----,,®� s--,,7 ➔6➔5 ___: For parts with an encircled number, refer to Reassembly Procedure that follows. D92220

61-30

SPECIAL EQUIPMENT - SERVICE PROCEDURE Reassembly Procedure 111 Assembly of connecting rod

Face stamped character side up. 1st compressio ]§= ---\ ring \ 2nd and 3rd � compression rings

-·;:I====

rside rail� Oil ring i Spacer� LSiderai!

�

23to25Nm {2.3 to 2.6 kgf ml

2nd compression ring open ends ---t-../

Bend lock washer

-�:

Alignment marks Connecting rod cap

Face notch in bolt head toward the connecting rod cap end

Approx. 120 °

Approx. 120"

':f!"" 1fP"' ,,�\

3rd compression ring open ends

::Jc Spacer open

\ ends

1st compression ring open ends

Side rail open ends

09645

Make sure that the alignment mark on the connecting rod is aligned with that on the connecting rod cap. 121 Installation of piston rings

09647

Install each piston ring in place and locate their ends as shown in the illustration. 131 Installation of suction valve holder Punch to stake (three places). (Do not punch head gasket surface.)

Cylinder head =_

Piston Ring Too!

MH0600 14

83261A --..:' ' --�643 ...

Stake the cylinder head atthree places shown over the suction valve holder.

61-31

SPECIAL EQUIPMENT

(4) Installation of injection pump gear

SERVICE PROCEDURE 5.2 Air Pressure Governor 5.2.1 Disassembly and inspection

Make sure that "O" and "U" marks are the sensor plate. in alignment when they areofmounted.

1 Damage, corrosion

r.1---2 '-3 Sagging, damage

i-4

bearing surface on this side toward the

Injection pump gear Align the notch with the “OQ” mark on the gear.

215 N-m {22 kgf-m}

Align the bar with the notch

... �-�-"�··" 9 Damage, deterioration

8 83262A

Install the injection pump gear, sensor plate (guide plate), and nut as instructed in the illustration.

7--o

:�

Pressure governor kit

Disassembly sequence 1 Cover

2 Adjusting screw 3 Spring 4 Sleeve

5 Snap ring

61-32

�-------Repair kit:

6 Filter

7 Screen 8 Cap 9 Diaphragm 10 Body 84081A

SPECIAL EQUIPMENT

SERVICE PROCEDURE Testing

5.2.2 Reassembly and adjustment

Air pressure governor

Air gauge

9.8to 15 N-m {1.0 to 1.5 kgf-m)

15 to 20 N-m {1.5 to 2.0 kgf-m)

0 Air compressor

Low

pressure valve

High pressure valve

7 5

6 Reassembly sequence 10➔9➔8➔7--+6➔5➔4➔3➔2➔1

8 40808

High and low pressure valve opening pressure Part No.

MC802148

MC802150

Nominal value High pressure valve opening pressure

Low pressure valve opening pressure

7 15 +34 kPa -4.9

625 +4 -9kPa -34

{7 .3

:'.&3�

kg/cm2J

784 +34 k Pa -4.9 {8.0

j:3�

kg/cm2}

+0.05 I6. 4 --0.35 kg/cm 'l 4 9 695 +-3.4 kPa

{7 .1

j:��

Air tank 84082A

( 1) Connect an air gauge between the air pressure governor and air tank. (2) Start the engine and increase air pressure slowly while observing the air gauge. Check that the read ing of the gauge when it has stabilized is as speci fied (high pressure valve opening pressure). If not, adjust by adjusting tightening amount of the sleeve. After adjustment, tighten firmly with the lock nut. (3) Slowly decrease the air tank pressure and check that the air gauge reading starts to increase when the nominal pressure (low pressure valve opening pressure) is reached. For adjustment, use the adjusting screw. After ad justment, tighten firmly with the lock nut. (4) After tightening the lock nut, check again the high and low pressure valve opening pressures. If they are out of specification, adjust again. (5) Install and seal the cover.

kg/cm2}

61-33

602.BOC diesel engine

Shop Manual � MITSUBISHI MOTORS CORPORATION JULY 1995 315IH)

ehh 8 a

Pub. No. 97841-02010 <2.

“et

“

J.. MITSUBISHI MOTORS CORPORATION JULY '95H Printed in Japan