-.
STRUCTURE
AND
FUNCTION
GENERAL STRUCTURE ................................................................ INTAKE AND EXHAUST
SYSTEM ......................................................
1 I-008
Turbocharger .....................................................................
II-016
After-cooler
II-018
......................................................................
ENGINE BODY ......................................................................... Cylinderhead .....................................................................
LUBRICATION
1 I-020 11-020
................................................................
11-022
SYSTEM ................................................................
1 I-032
Mainmovingparts
Lubricationsystemchart
...........................................................
II-032
Oil pump .........................................................................
1 I-034
Regulatorvalve..
II-036
.................................................................
Oil filter (Built-in safety valve) ......................................................
2 Fz w
1 I-004
1 I-036
Oil filter (with element clogging caution sensor) ......................................
1 I-037
By-passoilfilter
II-038
..................................................................
Oil cooler ........................................................................
1 I-040
FUEL SYSTEM ........................................................................
1 I-043
Fuelsystemchart
.................................................................
Fuelinjectionpump Governor
...............................................................
II-043 II-044
........................................................................
II-052
.......................................................................
II-058
Feedpump
Fuel injection nozzle ...............................................................
1 I-060
Fuelfilter .........................................................................
II-062
................................................................
Fuelcutsolenoid..
Engine stop motor ............................................................... COOLING SYSTEM ....................................................................
II-064 11-064-I
1 I-065
Cooling system chart ..............................................................
1 I-065
Waterpump
......................................................................
II-066
Thermostat
......................................................................
II-068
ELECTRICAL SYSTEM ................................................................. Wiringdiagram
...................................................................
11-070 II-070
Alternator ........................................................................
II-072
Startingmotor
II-074
....................................................................
Electrical intake air heater .......................................................... Oilpressureswitch Relayswitch
................................................................
.....................................................................
ACCESSORY .......................................................................... Aircompressor
..................................................................
II-076 II-078 II-078 II-080 11-OBO
11-003 0
GENERAL STRUCTURE SAGDllO-1
3i
3i
Engine No. 10001 - 49999
3b
2'9 2'8 i7
i6
i5
1.
Fan
11.
Cylinder head
21.
Thrust bearing
2.
Water pump
12.
Cylinder block
22.
Main bearing cap
3.
Cylinder liner
13.
Flywheel housing
23.
Main bearing
4.
Valve seat insert
14.
Ring gear
24.
Oil pan Connecting rod cap
5.
Valve guide
15.
Flywheel
25.
6.
Valve (exhaust)
16.
Tappet
26.
Connecting rod bearing
7.
Rocker arm shaft
17.
Cam bushing
27.
Front plate
8.
Valve (intake)
18.
Camshaft
28.
Crankshaft gear
Cylinder head cover
19.
Rear seal
29.
Oil pump drive gear
Breather
20.
Crankshaft
30.
Front seal
9. 10.
11-004 0
STRUCTURE
AND
FUNCTION
GENERAL
STRUCTURE
6138F102
31.
Crankshaft pulley
32.
Vibration
33.
idler gear
34.
Front cover
44.
35.
Cam gear
36.
Connecting rod
37.
Piston pin
damper
41.
Turbocharger
51.
Oil pump
42.
Piston
52.
Feed pump
43.
Exhaust manifold
53.
Fuel injection pump
Top ring
54.
Intake manifold
45.
Second ring
55.
Oil filter
46.
Oil ring
56.
Electrical intake air heater
47.
Oil filler
57.
Fuel filter
38.
Nozzle holder
48.
Oil level gauge
58.
Fuel injection pipe
39.
Oil filler
49.
Starting motor
59.
After cooler
40.
Rocker arm
50.
Oil strainer
110 SERIES
1 l-005
0
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
SAGD.llO-1
Engine
No. 50001
and up
11 12 13 14 15 16 17 16
6138F105
1.
Fan
11.
Cylinder head
21.
Thrust bearing
2.
Water pump
12.
Cylinder block
22.
Main bearing cap
3.
Cylinder liner
13.
Flywheel housing
23.
Main bearing
4.
Valve seat insert
14.
Ring gear
24.
Oil pan
5.
Valve guide
15.
Flywheel
25.
Connecting rod cap Connecting rod bearing
6.
Valve (exhaust)
16.
Tappet
26.
7.
Rocker arm shaft
17.
Cam bushing
27.
Front plate
8.
Valve (intake)
18.
Camshaft
28.
Crankshaft gear
9.
Cylinder head cover
19.
Reaseal
29.
Oil pump drive gear
Breather
20.
Crankshaft
30.
Front seal
10.
11-006
0
110
SERIES
STRUCTURE
AND
FUNCTION
GENERAL
STRUCTURE
6138F106
110
31.
Crankshaft pulley
41.
Turbocharger
51.
Oil pump
32.
Vibration
42.
Piston
52.
Feed pump
33.
Idler Qear
43.
Exhaust manifold
53.
Fuel injection pump
34.
Front cover
44.
Top ring
54.
Intake manifold
35.
Cam gear
45.
Second ring
55.
Oil filter
36.
Connecting rod
46.
Oil ring
56.
Electrical intake air heater
37.
Piston pin
47.
Oil filler
57.
Fuel filter
38.
Nozzle holder
48.
Oil level gauge
58.
Fuel injection pipe
39.
Oil filler
49.
Starting motor
59.
After cooler
40.
Rocker arm
50.
Oil strainer
SERIES
damper
1 l-007 0
INTAKE
AND
EXHAUST
SYSTEM
STRUCTURE
INTAKE AND EXHAUST S6DllO-1 INTAKE
AND
FUNCTION
SYSTEM
(For WA350-1) SYSTEM I.
Air cleaner
2.
Turbocharger
3.
Intake pipe
4.
Electrical intake air heater
5.
Intake rqanifold
6.
Inner element
7.
Outer element
A.
Intake
6138F109A
EXHAUST
SYSTEM 8.
Exhaust manifold
9.
Muffler
10. 8.
Exhaust pipe Exhaust
6138FllOA
11-008 0
110 SERIES
STRUCTURE
AND
SAGDllO-1
(For D66S-1)
INTAKE
INTAKE
FUNCTION
AND
EXHAUST
SYSTEM
SYSTEM 1. Precleaner 2.
Air cleaner
3.
Connector pipe
4.
Turbocharger
5.
Intake pipe
6.
After-cooler
7.
Intake manifold
A.
Intake
8.
Exhaust manifold
9.
Muffer
B.
Exhaust
6138F114-2A
EXHAUST
SYSTEM
v
110 SERIES
6138F1143A
11-009 0
INTAKE
SAGDllO-1 INTAKE
AND
EXHAUST
(For W120-2
SYSTEM
STRUCTURE
FUNCTION
and W120-3)
SYSTEM 1.
Ejector pipe
3.
Muffler
4.
Turbocharger
5.
Intake pipe
6.
After-cooler
7.
After-cooler
8.
Intake manifold
element
Electrical intake air heater
10.
Air cleaner
11.
Connector pipe
12.
Outer element
13.
Inner element
14.
Dust indicator
A. 6138Fll
Precleaner
2.
9.
EXHAUST
AND
Intake
1A
SYTEM 15. B.
Exhaust manifold Exhaust
8
6138F112A
110 SERIES
STRUCTURE
SAGDllO-1 INTAKE
AND
INTAKE
FUNCTION
AND
EXHAUST
SYSTEM
(For WA400-I) SYSTEM 1.
Air cleaner
2.
Turbocharger
3.
Intake pipe
4.
After-cooler
5.
Intake manifold
A.
Intake
6.
Exhaust manifold
7.
Muffer
8.
Exhaust pipe
B.
Exhaust
6138F1144A
EXHAUST
SYSTEM
6138F114-6A
110 SERIES
11-011 0
INTAKE
AND
SAGDllO-1 INTAKE
EXHAUST
SYSTEM
STRUCTURE
AND
FUNCTION
(For EG150-3)
SYSTEM 1.
Air cleaner
2.
Precleaner
3.
Turbocharger
4.
Intake pipe
5.
After-cooler
6.
Intake manifold
A.
Intake
6138Flll-1A
EXHAUST
SYSTEM 7.
Connector pipe
8.
Exhaust manifold
9.
Muffler
B.
Exhaust
1
6138F113-1A
11-012 0
110 SERIES
STRUCTURE
AND
FUNCTION
SAGDllO-1
(For
EG150S-3)
INTAKE
INTAKE
AND
EXHAUST
SYSTEM
SYSTEM 1.
Air cleaner
2.
Turbocharger
3.
Muffler
4.
Bellows
5.
Intake pipe
6.
After-cooler
7.
Intake manifold
A.
Intake
8.
Connector
9.
Exhaust manifold
8.
Exhaust
6138Flll-2B
EXHAUST
SYSTEM
by
110 SERIES
6138F113-2B
11-013 0
INTAKE
AND
SAGDllO-1 INTAKE
EXHAUST
SYSTEM
STRUCTURE
FUNCTION
(For EC21OZ-1)
SYSTEM
2
a
EXHAUST
AND
1.
Air cleaner
2.
Turbocharger
3.
Intake pipe
4.
After-cooler
5.
Intake manifold
A.
Intake
a.
TO air tank (for air compressor)
6.
Connector pipe
6138F1113A
SYSTEM
7.
Exhaust manifold
8.
Muffler
8.
Exhaust
6138F113-1A
11-014 0
110 SERIES
STRUCTURE
AND
FUNCTION
INTAKE
AND
EXHAUST
SYSTEM
Air cleaner
- Centrifugal
type + filter
paper type
with automatic
ejector Dust indicator
* Operating pressure (negative): 635 mmH,O
General description
1.
Structure of intake and echaust system
.
The intake
and exhaust system consists of the pre-
cleaner, air cleaner,
exhaust
manifold,
muffler
and
exhaust pipe. 2.
Circulation
.
of intake
The air intake is first filtered through the precleaner to remove large dust particles after which it is cleaned of fine dirt and dust by the air cleaner.
The air is
then charged into the engine.
.
In case of turbocharger through into
the air cleaner,
the
cylinders
type
engine,
the air intake
under
after
filter
is charged
pressure by the blower
impellers in the turbocharger.
3.
Function of dust indicator
.
After
filtered
intake
through
the air cleaner, the negative
air pressure is transmitted
dicator
on the operator’s
by, the clogged condition
to the dust in-
instrument
panel.
There-
of the air cleaner can be
sensed by the operator in his seat. Dust
indicator
mark) mmHs0 4.
.
is actuated
(gives a red warning
when the negative air pressure reaches 635 (water column).
Circulation
of exhaust
Gases produced by the combustion
in the cylinders
pass through the exhaust manifold,
silenced by muf-
fler, and expelled from the exhaust pipe.
.
In case of turbocharger
type engine, gases passed
through the exhaust manifold
are charged into muf-
fler after
impellers (the blower
driving the turbine
impellers).
110 SERIES
1 l-015
0
INTAKE
AND
EXHAUST
STRUCTURE
SYSTEM
AND
FUNCTION
TURBOCHARGER
14 ,15
1 I F059A
Specifications
of turbocharger
1.
Turbine impeller
12.
Thrust collar
2.
Piston ring
13.
Blower impeller
Type:
GARRET
3.
Turbine housing
14.
Blower housing
Overall length:
225 mm
4.
Shroud
15.
Lock nut
Overall width:
210 mm
5.
Journal bearing
Overall height:
180 mm
6.
Retaining ring
6.5 kg
A.
Intake
Weight:
CO. TO4B
7.
Center housing
B.
Air supply
Continuous speed:
125,000
8.
Seal ring
C.
Exhaust (inlet port)
Max. air supply:
22 kg/min.
9.
Thrust bearing
D.
Exhaust (outlet port)
Compression ratio:
3 (max.1
10.
Back plate
E.
Oil (inlet port)
Applicable exhaust temp.:
Max. 675°C
11.
Spring
F.
Oil (outlet port)
Direction of rotation:
Clockwise (as seen from belower side)
11-016 0
’
rpm (max.)
(at inlet)
110 SERIES
STRUCTURE
AND
INTAKE
FUNCTION
AND
EXHAUST
SYSTEM
Structure *
The
turbocharger
for S6DllO-1
and SA6DllO-1
en-
gines is the Type T04B.
* The
turbocharger
housing,
consists
blower
impeller,
shaft and the center
mainly
of
turbine
the
housing,
housing provided with
and seals and forming
the
lubrication
blower wheel bearings
and support
section.
* As the rotating
components
of
wheel shaft consists of turbine integrated fitted
together,
and blower
on the shaft portion
a turbocharger,
a
impellers and a shaft impellers
opposite
are force-
to the turbine
impellers and fixed positively with lock nuts.
- The
blower
housing
interconnected
with
and
the
center
ring type
center housing and the turbine
housing
V-clamps,
while
and the
housing are mutually
secured with 6 bolts. Function
-
In the turbocharger, by
the
energy
combustion
of
the turbine the
flowing
in the cylinders,
impeller
is rotated
gases produced
by
and the blower impeller
on the same shaft in turn charges the intake
air into
the cylinders under pressure.
-
For
lubrication,
a hole flows
the engine
in the top back
into
in the bottom
oil
of the center
the engine
is supplied housing.
oil pan through
through The oil a hole
of the center housing after lubricating
the bearings. Oil
in the
turbocharger
is prevented
from
leaking
out by means of the seals on both sides of the center housing.
110 SERIES
11-017 Co
INTAKE
AND
EXHAUST
AFTER-COOLER
STRUCTURE
SYSTEM
After-cooler
cover
2.
After-cooler
core
3.
Intake manifold
11-018 0
FUNCTION
(SAGDI 1 O-l)
1
1.
AND
2
110 SERIES
ENGINE
STRUCTURE
BODY
AND
FUNCTION
ENGINE BODY CYLINDER
1.
Cylinder head mounting bolt
11. Nozzle holder sleeve
2.
Nozzle holder
12.
Fuel injection nozzle
3.
Rocker arm shaft
13.
Oil filler cap
4.
Cylinder head
14.
Valve spring guide
5.
Cylinder head gasket
15.
Valve cotter
6.
Head cover
16.
Valve spring
7.
Valve guide
17.
Valve spring seat
8.
Exhaust valve
18.
Intake valve
9.
Valve seat insert
19.
Push rod
IO.
1 l-020 0
HEAD
Nozzle holder packing
110 SERIES
STRUCTURE
AND
ENGINE
FUNCTION
Cross section of exhaust val (No. 1 cylinder)
BODY
13 14 15
1
16
1
17 18
1
19
Crosssection of intake valve (No. 1 cylinder)
6138FOO88
Cylinder head Direct injection,
2 valve, injection nozzle assembled, one
piece Valve seat Valve seat insert press fitted for both intake and exhaust valves
1 l-021 0
110 SERIES
.
ENGINE
BODY
MAIN
MOVING
STRUCTURE
AND
FUNCTION
PARTS ‘(l/3)
Section A - A
Section B - B (no adapter)
11-022 0
Section B - B (with adapter)
1. Bearing cover
10.
2.
11. Thrust plate (for cam gear)
Crankshaft:
7 bearings
Camshaft:
4 bearings
Front cover
Cylinder block
3.
Rotation pick-up cap
12.
Main bearing cap
4.
Camshaft gear (52 teeth)
13.
Bolt of main bearing cap
5.
Idler gear (40 teeth)
6.
Idler gearshaft
7.
Bushing
8.
Thrust plate (for idler gear)
9.
Front elate
Cylinder block
110 SERIES
STRUCTURE
AND
FUNCTION
ENGINE
BODY
9 \
6138FOO82A
Valve timing Engine
No.
Engine
10001
No. 50001-
- 49999
Top dead center Top dead center
Bottom dead center
110 SERIES
6136FOlO
Bottom dead center
6136F116
1 l-023 0
ENGINE
MAIN
STRUCTURE
BODY
MOVING
PARTS
AND
FUNCTION
(2/3)
Engine No. 10001 - 49999
\
13
li
1 l-024 0’
\
\
14
15
:,
16
1.
Piston
14.
Oil pump drive gear
2.
Top ring
15.
Crankshaft gear
3.
Second ring
16.
Connecting rod bearing
4.
Oil ring
17.
Tappet
5.
Snap ring
18.
Camshaft
6.
Piston pin
19.
Crankshaft
7.
Connecting rod
20.
Main bearing (upper)
8.
Mounting bolt of crankshaft pulley
21.
Main bearing (lower)
9.
Spacer
22.
Thrust bearing
10.
Crankshaft pulley (0.0.144
23.
Rear seal
11.
Vibration
24.
Ring gear
12.
Taper collar
25. ‘Flywheel
13.
Front seal
26.
damper
mm)
Front P.T.O. pulley (0.D.
200 mm)
110 SERIES
STRUCTURE
AND
ENGINE
FUNCTION
BODY
/
23 Piston
6136FOO96
Piston ring
Elliptical taper profile, thermal flow type MTCC:
Micro Turbulence
Combustion
Chamber
Engine
Front seal Single lip with dust seal S8DllO SAGDI 10
Rear seal Double lip Single lip (generator) Connecting rod bolt
Top ring Both faces: keystone barrel face Hard chrome plating
Second ring One face: keystone taper face Hard chrome plating
Oil ring With coil expander
r--i--l 6138FOO9-1
Screw-in type Piston cooling:
Yes
110 SERIES
1 l-025 0
ENGINE
Engine
BODY
No. 50001
STRUCTURE
AND
FUNCTION
and up
11'
12
Ih
\
1‘5
16
1.
Piston
14.
Oil pump drive gear
2.
Top ring
15.
Crankshaft gear
3.
Second ring
16.
Connecting rod bearing
4.
Oil ring
17.
Tappet
5.
Snap ring
18.
Camshaft
6.
Piston pin
19.
Crankshaft
7.
Connecting rod
20.
Main bearing (upper)
8.
Mounting bolt of crankshaft pulley
21.
Main bearing (lower)
9.
Spacer
22.
Thrust bearing
23.
Rear seal
10.
11-026 0
13
Crankshaft pulley (0-D. damper
144 mm)
11.
Vibration
24.
Ring gear
12.
Taper collar
25.
Flywheel
13.
Front seal
26.
Front P.T.O. pulley (0.D.
200 mm)
110 SERIES
STRUCTURE
AND
FUNCTION
1c
2b
ENGINE
21
22
23
24
BODY
25 6138FO12
Piston
Piston ring
Elliptical taper profile, thermal flow type MTCC:
Micro Turbulence
Combustion
Engine
Chamber
Front seal Single lip with dust seal
S6DllO SAGDllO
Too rinq Both faces: keystone barrel face Hard chrome olatina
Second rirw One face: keystone taper face Hard chrome plating
Oil ring With coil expander
Rear seal Double lip Single lip (generator) Connecting rod bolt Screw-in type Piston cooling:
Yes
S6D110 (WA360-1 SAGDllO lWA400-1
Both faces: keystone barrel face Hard chrome plating
One face: keystone taper face Hard chrome plating
M-shape, steel ring, hard chrome plating with coil expander
6138F009.1A
110 SERIES
11-027 Co
ENGINE
MAIN Engine
STRUCTURE
BODY
MOVING
No. 10001
PARTS
FUNCTION
(3/3)
- 49999
1.
Flywheel housing
X-X’:
Center of crankshaft
2.
Flywheel mounting bolt
Y-Y’:
Center of cylinder
3.
Cylinder liner
4.
Oil pump regulator valve
5.
Tappet cover
6.
Camshaft bushing
1l-028 0
AND
110 SERIES
STRUCTURE
AND
FUNCTION
ENGINE
BODY
Y I
3 \
6136FOll
Cylinder liner Dry type
110 SERIES
11-029 0
ENGINE BODY
STRUCTURE AND FUNCTION
Engine No. 50001 and up
1 l-030 0
1.
Flywheel housing
X-X’:
Center of crankshaft
2.
Flywheel mounting bolt
Y-Y’:
Center of cylinder
3.
Cylinder liner
4.
Oil pump regulator valve
5.
Camshaft bushing
110 SERIES
STRUCTURE AND FUNCTION
ENGINE BODY
6136F116
Cylinder liner Dry type
1lOSERlES
11-031 0
LUBRICATION
SYSTEM
STRUCTURE
LUBRICATION LUBRICATION
AND
FUNCTION
SYSTEM
SYSTEM
CHART
Engine No. 10001 - 49
1. Oil strainer
u u
u
u
17
/
8
2.
Oil pump
3.
Oil cooler
4.
Oil filter
5.
Regulator valve
6.
Oil filter safety valve
7.
Oil cooler relief valve
8.
Crankshaft
9.
Camshaft
IO.
Piston
11.
Piston cooling
12.
Rocker arm
13.
Intake/exhaust
14.
Turbocharger
15.
Fuel injection pump
16.
Timing gear
17.
Oil pressure switch (Option)
18.
Oil pressure sensor (Option)
valve
6138f131
LUBRICATION 1. Structure The
SYSTEM
of Lubricating
lubricating
system
pump,
oil
system consists pump
mainly
strainer,
oil
oil filter
and safety valve to lubricate
regulator,
of the
The
oil
oil cooler
various engine
oil
discharged
from
the pump
is cleaned fully
through the oil filter (full-flow
type).
Thus,
to various
the
oil
is distributed
lubrication
points in the engine.
parts. Circulation The
of lubricating
lube oil flows from the oil pan to the oil pump
through
the oil strainer where
cles of
dust,
from
.
oil
the oil.
the crankshaft
dirt,
or,
foreign
relatively matter
large parti-
The
oil is cooled,
engine
cooling
through
water
heat exchanger
with the
at pipes in the oil bracket
in the oil cooler.
is removed
The oil pump is driven by the gear in cluster to such in and charge out the
oil under pressure.
1l-032 0
110 SERIES
or
STRUCTURE
AND
FUNCTION
LUBRICATION
SYSTEM
Engine No. 5000 1 and up
6136F014.5A
1. Oil strainer
Il.
Piston cooling nozzle
2.
Oil pump
12.
Rocker arm
3.
Oil cooler
13.
Intake/exhaust
4.
Oil filter
14.
Turbocharger
5.
Regulator valve
15.
Fuel injection pump
6.
Safety valve
16.
Timing gear
7.
Oil cooler therm0 valve
W.
Cooling water
8.
Crankshaft
9.
Camshaft
10.
valve
Piston
110 SERIES
11-033 0
LUBRICATION
SYTSTEM
STRUCTURE
AND
FUNCTION
OIL PUMP Engine
No. 10001
- 49999 6
Outer rotor
5.
inner rotor
2.
Pump cover
6.
Pump body
3.
Pump shaft
7.
Drive gear (38 teeth)
4.
Bushing
I.
6138FO13
Structure
Oil pump
* Oil pump a trochoid type and installed in the engine front cover. *
The
drive gear is attached
at the
Type:
Trochoid
Speed:
Engine speed x 1 .I 58
pump
rear end of the
rotor shaft of the oil pump and is in gear with the drive gear at the front side of the crankshaft.
Function
- The inner rotor together
with
teeth
in the
rotor
(2).
(1) of a trochoid
the inner
rotor rotor
pump is rotated
-
The
oil
is sucked
of
clearance
between
is one less than the outer
extended.
The
shaft (3).
Both rotors rotate
The number
in the same direction
oil
into the the
pump
inner
and
is discharged
when outer when
the tooth rotors
is
the tooth
clearance becomes smaller.
with their respective centers set off.
Intake
Exhaust I IF018
11-034
110 SERIES
STRUCTURE
AND
FUNCTION
LUBRICATION
SYSTEM
Engine No. 50001 and up
10/
110
Regulator valve
6136FO15-1
1.
Oil pump body (9 teeth)
2.
Drive gear
Type:
Gear pump
Speed:
Engine speed x 1 .I 58
Oil pump
3.
Pump cover
4.
Pump drive gear (38 teeth)
5.
Drive shaft
Regulator valve
6.
Driven gear (9 teeth)
* Cracking pressure: 6.5 f 0.5 kg/cm2
7.
Driven shaft
8.
Regulator valve
9.
Valve spring
10.
Valve retainer
A.
From oil strainer
B.
From oil pump
C.
To engine
D.
To oil pan
SERIES
11-035 0
LUBRICATION
REGULATOR Engine
No.
STRUCTURE
SYSTEM
10001
AND
FUNCTION
VALVE - 49999
1
1.
Nut
2.
Adjustment
shim
3.
Valve body
4.
Valve
5.
Valve spring
Regulator valve Cracking pressure:
7.4 f 0.8 kg/cm’
6136FO16
OIL FILTER
(Built-in safety valve) 1.
Filter bracket
2.
Cartridge
3.
Safety valve
AB-
A.
From oil pump
6.
To engine
a.
Oil pressure tap
Safety valve Actuating
pressure:
2 +_ 0.2
kg/cm2
Oil filter Filtration
area:
0.5 m2
6136FO17C
11-036 0
110 SERIES
STRUCTURE
AND
LUBRICATION
FUNCTION
SYSTEM
OIL FILTER (with element clogging caution sensor) 1 A
2 1.
Caution sensor
2.
Filter bracket
3.
Cartridge
4.
Safety valve
A.
From oil pump
B
3
B. To engine
Safety valve Cracking pressure: 2 f 0.2 kg/cm’
Oil filter Filtration
area: 0.5 m2
6136FO13-1
CLOGGING
CAUTION
SENSOR
1.
Spring
2.
Spring
3.
Contactor
4.
Contactor
Caution sensor Actuating
pressure:
1 .5+$4
kg/cm2
6136FO152
110 SERIES
1 l-037 Co
LUBRICATION
BY-PASS Engine
SYSTEM
STRUCTURE
FUNCTION
OIL FILTER
No. 10001
- 49999 1.
Filter cover
2.
Filter element
3.
Filter case
4.
Drain plug
5.
Center bolt
A.
Oil inlet port
B.
Oil outlet port
Filtration
14
1 l-038 0
AND
area:
2,450 cm2
6138FO14
110 SERIES
,-
LUBRICATION
STRUCTURE
SYSTEM
AND
FUNCTION
OIL COOLER Engine
No. 10001
- 49999
a
Section A - A
Section B - B Section C - C 6138FO15
1. Valve case 2.
Valve spring
3.
By-pass’valve
4.
Cooler cover
5.
Cooler element
D.
From oil pump
a.
Water drain port
Structure
Oil cooler by-pass valve Actuating
and function
* The oil cooler consists of element and cover. oil
flowing
through
cooling fin is cooled water flowing
11-040 0
pressure: 4 + 0.2 kg/cm2
the
cooler
properly
element
with
The the
by the engine cooling
outside the element.
110 SERIES
STRUCTURE
Engine
AND
No. 50001
FUNCTION
LUBRICATION
SYSTEM
and up
Section B - B
Section A - A
6136FO16.3
Section E - E
1.
Spring
Oil cooler therm0 valve
2.
Then-no valve
- Opening temperature:
104°C
3.
Valve spring
* Full opening temperature:
11 O’C
4.
Cooler cover
* Full opening
min.
5.
Cooler element
G.
From oil pump
(oil)
I.
From water pump
(cooling water)
J.
To oil filter
(oil)
110 SERIES
5 mm
(oil)
H. To engine
K. To engine
lift:
(cooling water)
11-041 0
STRUCTURE
AND
FUNCTION
FUEL
SYSTEM
FUEL SYSTEM FUEL SYSTEM
CHART
Engine No.50001 -
1.
Fuel tank
2.
Feed pump
3.
Fuel filter
4.
Fuel injection pump
5.
Fuel injection nozzle
GENERAL Structure The
‘2 6138FOl B-2A
DESCRIPTION of fuel system
fuel system consists mainly
feed
pump,
injection
fuel
filter,
nozzles
and
fuel
of the fuel tank,
injection
governor
pump,
(built
fuel
as one unit
2) Fuel entering the
pump
to
pump is pressurized
that
and injected into each cylinder nozzle
with the fuel injection pump).
the injection
plunger
in
the
quantity
required
for
by
injection
through the injection
required,
meeting
the
in-
jection timing for the cylinder. Circulation
of fuel
Fuel is delivered from the fuel tank to the injection pump
through
the
fuel
filter
driven by the fuel injection course fuel
from
the
is cleaned
tank of
by the
pump cam.
to the injection
rough
dirt
through
filter at the inlet to the feed pump. dust
removal
and
water
separation
feed
pump
During the pump, the
the
gauge
Then, complete from
the
oil
are accomplished through the filter.
110 SERIES
11-043 0
FUEL SYSTEM
FUEL INJECTION Without
STRUCTURE
AND
FUNCTION
PUMP
air compressor
i i
11-044 0
‘11
1.
Fuel injection pipe (No. 6)
IO.
Rotation pick-up shaft
a:
From fuel tank (fuel)
2.
Fuel injection pipe (No. 5)
11.
Drive shaft
b:
To fuel filter (fuel)
3.
Fuel injection pipe (No. 4)
12.
Automatic
c:
To fuel injection pump (fuel)
4.
Fuel injection pipe (No. 3)
13.
Injection pump bracket
d:
To injection nozzle (fuel) To fuel tank (fuel return)
timer
5.
Fuel injection pipe (No. 2)
14.
Fuel injection pump
e:
6.
Fuel injection pipe (No.
I)
15.
Boost compensation pipe
f:
From cylinder block (oil)
7.
Fuel hose
16.
Fuel filter
9:
To cylinder block (oil)
8.
Injection pump gear
17.
Oil pipe
9.
Ball bearing
18.
Oil pipe
110 SERIES
STRUCTURE
AND
FUNCTION
FUEL
El
View Z
SYSTEM
i 111
View Z
613SFO19
Fuel injection pump Type:
Diesel Kiki Bosch PE-AD with automatic
timer
(EC21 OZ-1) with boost compensator Lubrication:
Forced lubrication
(D66S-I)
with engine oil
Governor Type:
Diesel Kiki Bosch RSV (Centrifugal,
all-speed type)
Fuel injection timing: See, 12 TESTING
110 SERIES
AND ADJUSTING
DATA
1 l-045 0
STRUCTURE
FUEL SYSTEM
AND
FUNCTION
With air compressor
6138FO16
1.
Fuel injection pipe (No. 6)
12.
2.
Fuel injection pipe (No. 5)
13.
Rotation pick-up shaft
b:
To fuel filter (fuel)
3.
Fuel injection pipe (No. 4)
14.
Automatic
c:
To fuel injection pump (fuel)
4.
Fuel injection pipe (No. 3)
15.
Injection pump bracket
d:
To injection nozzle (fuel) To fuel tank (fuel return)
Drive shaft
a:
timer
From fuel tank (fuel)
5.
Fuel injection pipe (No. 2)
16.
Fuel injection pump
e:
6.
Fuel injection pipe (No. 1)
17.
Oil pipe
f:
From cylinder block (oil)
7.
Air hose
18.
Boost compensation pipe
9:
To air compressor (oil)
8.
Fuel hose
19.
Relay switch
h.
To cylinder block (oil)
9.
Air compressor
20.
Fuel filter bracket
10.
Injection pump gear
21.
Oil pipe
11.
Ball bearing
11-046 0
110 SERIES
STRUCTURE
AND
FUNCTION
FUEL SYSTEM
‘\M
Y
--A
\
::
i
I
I
+
+
6138FO17
Fuel injection pump Type:
Diesel Kiki
Bosch PE-AD
with automatic
timer (W120-2,3)
with boost compensator (W120-2,3, WA350-1, WA400-1) Lubrication:
Forced lubrication
with engine oil
Governor Type:
Diesel Kiki
Bosch RSV
(centrifugal,
all-speed type)
Injector Type:
Multiple hole
Injection pressure:
250 kg/cm2
Fuel injection timing: See, 12 TESTING
110 SERIES
AND
ADJUSTING
DATA
11-047 0
STRUCTURE
FUEL SYSTEM
FUEL
INJECTION
DESCRIPTION
.
injection
fuel
Its
pump
housing,
FUNCTION
PUMP
GENERAL
The
AND
pump
is a Bosch type
governor
housing
are
1.
Delivery valve holder
2.
Delivery valve spring
3.
Delivery valve
4.
Oil reservoir
5.
Plunger barrel
6.
Plunger
7.
Deflector
8.
Control rack
9.
Control sleeve
10.
Plunger spring
11.
Tappet
12.
Camshaft
PE-AD. forced
lubricated with the engine oil. *
The
fuel
injection
pump
drive gear in the timing tion of its rotation
is driven
by
the
pump
gear cluster and the direc-
is clockwise
as viewed from the
driving side.
13.
Oil inlet port
A.
From main gallery
14.
Oil outlet port
B.
To oil pan
15.
Drain plug
16.
Drain plug
1 l-048 0
I I F025
110 SERIES
STRUCTURE
AND
STRUCTURE
1. Structure .
FUEL
FUNCTION
AND
FUNCTION
5.
Plunger barrel
6.
Plunger
taPPets
9.
Control sleeve
rollers (18), each in the same quan-
10.
Plunger spring
11.
Tappet
12.
Camshaft
of injection
pump
The Bosch type fuel injection
pump contains; plunger
barrels (5). plunger (6), plunger springs (IO), (ll),
and tappet
tity as the engine cylinders, with the camshaft fuel injection
and these serve, together
(12), as the parts giving rise to the
pressure.
2. Pumping action 1) Each plunger deliver of
the
makes a vertical
piston movement
fuel under pressure by the combined cam
SYSTEM
on the
camshaft
and
plunger
17.
Fuel outlet and inlet port
18.
Tappet roller
to
action spring.
I I F026
2) If the plunger (6) is lowered so that the inlet and discharge
ports
(17)
in the
plunger
barrel
5. Plunger barrel
17
(5) are
6.
opened by the tip of plunger, fuel will begin to flow into the barrel and stop flowing
in when the plunger
17.
Plunger Fuel outlet
and inlet
comes into its lowest position.
5
Port (suction and discharge Port)
6
L.cJ 3) Then,
the plunger
(6) will
start to rise, and as soon
as the inlet and discharge ports (17) barrel
I I F027
in the plunger
(5) are closed, the fuel pressure in the barrel
will begin to rise. 4) If the
plunger
rises further
so that
a helical
Increase of pressure
relief
(19) in the plunger comes in line with the inlet and discharge ports, fuel will discharge center,
ports through
causing the
110 SERIES
fuel
flow
Under transfer
pressure
Withdrawal (no oil transfer)
I I F026
back to the inlet and
the helix
Completion of transfer
from the plunger to drop
rapidly. 5.
Plunger barrel
6.
Plunger
17.
Suction and discharge ports
19.
helical relief (Helix)
1 l-049 0
FUEL
STRUCTURE
SYSTEM
AND
FUNCTION
20 Effective
stroke
Distance
from
(6)
5 a position
closes the suction
the plunger barrel the helical with
the
relief inlet
fective stroke
where
(5) with (19)
rising plunger ports
6
of fuel to be injected
The
helical
in the
with
reference
to the
19
ports is called the ef-
Quantity
to this effective stroke.
plunger
in
where
in the plunger comes in line
varies in proportion relief
(17)
its tip to a point
and discharge (20).
the
and discharge
plunger
I I F029
is cut diagonally
upper surface.
causes the effective
Rotating
the
stroke or the quantity
5. 6.
of fuel to be injected to vary as desired.
17.
Adjustment
mechanism for fuel injection
In the
lower
shaped
flange
part
of plunger
(211,
which
Effective stroke is long
Effective stroke is short
19.
Helical relief
Plunger
20.
Effective stroke
Suction and discharge port
capacity
(6) is provided
is fitted
Plunger barrel
into
a T-
the helix
in the control sleeve (9). On the control
8
sleeve is mounted
(22)
which
The
control
rack is connected
fuel
control
lever.
The
the
plunger,
rack
is meshed
rotates
quantity
with
the
the control control
pinion
rack
(6).
to the governor
and
movement thereby
of the
22
control
adjusting
the
of fuel to be injected.
I I FO30
5. Switching
of fuel injection
On the top of plunger holder
(I)
in which
is installed the delivery
the dlivery
5.
Plunger barrel
9.
Control sleeve
6.
Plunger
21.
Plunger flange
8.
Control rack
22.
Control pinion
valve
valve (3) and spring
(2) are set.
.
Fuel highly
pressurized
delivery valve, overcoming
by the
plunger
openes the
1
1.
Delivery valve holder
2.
Delivery valve spring
3.
Delivery valve
the tension of the delivery
valve spring, and is discharged into the injection
pipe.
I IF031
11-050
0
110 SERIES
STRUCTURE
AND
FUEL
FUNCTION
SYSTEM
The piston section (23) is provided at the lower end If the fuel pressure drops after
of delivery valve (3).
fuel discharge by the plunger is completed,
the deli-
very valve will be pushed down by the delivery valve spring (2). causing the piston section in the valve to close the fuel port at first, which will, in turn, prevent
I I F032
the reverse flow of fuel. Retraction The
work
delivery
valve will
be pushed
causing fuel in’the
fuel injection
and the .valve will
be stopped
The above valve action WORK
of injection,
RETRACTION
assists in producing injection
further,
at its tapered
and such a working
WORK,
2.
Delivery valve spring
3.
Delivery valve
seat.
is called the RETRACTION
the valve is called the retraction The
down
pipe to flow back,
23.
Piston
24.
Retraction
stroke
stroke of
stroke (24). prevents
a satisfactory
dribbling
cut-off
of
or fuel
through the nozzle.
,. Special functions of the injection
pump
1) Damping valve *
A damping valve serves to slow down the drawingback action
of discharged
fuel for smaller pulsa-
tion of fuel being discharged.
- The necessity of using a damping valve depends on the amount
of fuel required
by an engine and the
engine speed. 2) Cancelling spring A cancelling spring is used at the injection trol
lever
and
serves to lessen the
pump con-
lever operating
effort.
110 SERIES
11-051 0
FUEL
STRUCTURE
SYSTEM
GOVERNOR
AND
FUNCTION
’
1.
Tension lever
2.
Start spring
3.
Floating lever
4.
Guide lever
5.
Idling sub-spring
6.
Shifter
7.
Sleeve
8.
Adapter spring
9.
Flyweight Full-load stopper
10. 11.
Control rack
12.
Swivel lever
13.
Governor spring
14.
Control lever
15.
Camshaft
16.
Torque spring
17.
Lever
I I F033
General description *
Functions of governor The
governor
type
is a Bosch RSV
and serves to control
by changing the position fuej
injection
pump
mechanical
ail-speed
the engine output of the control
(by adjusting
power
rack in the
the quantity
of
In addition the
rotational an
to the above, the angleich unit adjusting
maximum injection
change
fuel quantity
in load
during
sub-spring to maintain
fuel injected).
injection
speeds, the torque
corresponding
governor
actuated
serves to
by the centrifugal move
change in the rotational
the
force in the
sleeve depending
at to
engine operation,
various a
etc. are installed
governor.
on
speed and adjust the move-
ment of control rack through the guide lever. On the the
other
movement
hand, of
the fuel the
control
control rack
lever adjusts through
the
tension lever for the governor spring.
1 l-052 Co
sharp
an idling
an idling speed, a start spring
to ease the engine starting, A flyweight
quantity
spring unit to obtain
110 SERIES
in the
STRUCTURE
AND
FUNCTION
FUEL
SYSTEM
Function of the governor 1. *
Engine starting If the
fuel
position, swivel will into
control
lever (14) is pushed to START
the governor spring (13)
lever
(12)
integrated
with
connected the
to the
control
lever
be pushed until the tension lever (1) is brought contact
with
the
full-load
stopper
(IO)
at the
lower end.
- Then, the sleeve (7) will be shifted to the left, and the
control
spring
(2)
quantity,
rack in the
(11)
will
be pulled
direction
of
by the start
increasing
the
fuel
making ease the engine starting.
I I F034
2.
1.
Tension lever
2.
Start spring
14.
Control lever
7.
Sleeve
A.
Start position
10.
Full-load stopper
B.
Full-load position
11.
Control rack
C.
Idling position
12.
Swivel lever
0.
Stopping position
I 3. Governor spring
Engine idling
- If the control lever (14) is moved back to IDLING position will to
after engine start, the governor spring (13)
become weak open outward
(7) will
in tension,
causing the flyweight
at a low speed.
Then,
the sleeve
move to the right, pushing the tension
lever
(1) to a point where the idling sub-spring (5) applies Consequently,
tension.
move to the fulcrum,
right with
bringing
the
the
floating
the
lower end used as the
control
rack
lever (11)
(3) will into
the
idling position.
- When the revolution and move the tension idling
sub-spring
volution.
increases, the flyweight lever to the
operates
If the revolution
start spring (2) works
to
adjust
right, the
opens
then the idling
re-
decrease excessively, the
to keep the idling revolution. I F035
1.
Tension lever
2.
Start spring
3.
Floating lever
11.
Control rack
4.
Guide lever
13.
Governor spring
5.
Idling sub-spring
14.
Control lever
7. Sleeve 9.
Flyweight
C. Idling position
110 SERIES
1 l-053 0
STRUCTURE
FUEL SYSTEM
3. *
Max. speed control If the control position,
lever (14) is pushed into FULL-LOAD
the governor spring (13) will
all the way,
pulling
the tension
lever comes into contact (IO).
The flyweight
same time, direction
with
(9) will
the control
(1) unit the
the full-load
rack will
If the engine revolutions
be moved
(7) to move to the right, which fuel
in the
Thereby,
exceeds the specified range,
force of the flyweight
than the governor spring tension, the control
stopper
be closed and at the
speed will be obtained.
the centrifugal
the
be extended
lever
of increasing the fuel quantity.
the maximum
-
AND FUNCTION
rack (11)
be larger
will,
in turn, move
in the direction
of decreasing
Thereby,
quantity.
will
causing the sleeve
YO
i
the excessive increase
I I F036
in the revolutions will be prevented.
1.
Tension lever
11.
7.
Sleeve
13.
Governor spring
9.
Flyweight
14.
Control lever
Full-load stopper
B.
Full-load position
10.
4. 0
Angleich unit In the engine, if the revolution the
intake
air resistance will
the
air suction
fuel
is injected
revolutions
efficiency.
and therefore,
- The Angleich duction high
lever
aiming.
the complete
the
the
combustion
will be difficult.
IS FUEL
at COMPLETE
re-
at low
COMBUSTION
improving
the
above
un-
conditions. revolutions
(1) in contact
adapter
to the
unit serves to prevent the torque
and the centrifugal than
pump,
in proportion
range of revolution
speeds, thereby
satisfactory
- Where
In the injection
due to the trend of LOCK
speed, while at
increases excessively, increase, deteriorating
approximately
over the whole
tension
are
with
low
withe
the full-load
force of flyweight of
the
adapter
the
tension
stopper
(IO)
(9) is smaller
spring
(81, the
spring will
shift the sleeve (7) to the left,
causing the control
rack (11) to move in the direc-
tion
of increasing the
fuel quantity.
Thereby,
I I F037
the
torque at low speeds will be increased. -
Control rack
As the engine speed increases, the centrifugal of the flyweight the sleeve. the tension quantity
11-054 0
force
will push the adapter spring through
Flyweight
1.
Tension lever
7.
Sleeve
10.
Full-load stopper
8.
Adapter spring
11.
Control rack
9.
When the spring comes into contact with lever, the function
of increasing the fuel
will be terminated.
110 SERIES
STRUCTURE
5.
AND
FUEL
FUNCTION
SYSTEM
Engine stop
- The swivel lever (12) has a protrusion. lever (14) is pushed into STOP lever will
protrusion come
integrated
into
contact
with
with
If the control
position, the
the
the swivel
control
guide
lever
lever
(4).
- Then, the guide lever will move the control rack to the
NON-INJECTION
position
through
the floating
lever (3).
I IF038
6. *
Function The
1.
Tension lever
11.
Control rack
2.
Floating lever
12.
Swivel lever
4.
Guide lever
14.
Control lever
9.
Flyweight
D.
Stop position
of the torque spring
torque
reduction
spring
in the
serves to
engine
prevent
revolutions
the
or the
16
abrupt engine
stoppage due to a sharp increase in load.
- If the engine speed is about to decrease due to a * sharp increase in load during operation, the fly weight
(9) will
left, which
in the direction -
close to move the sleeve (7) to the
will cause the control
At
this time,
the torque
spring
the
tension
lever (1) will
apply
direction
of
increasing
down the control tion
rack (I
I) to move
to decrease the fuel quantity.
rack.
the
fuel
Thereby,
(16)
connected
its tension quantity, the abrupt
to
in the slowing reduc-
in the engine speed or the engine stoppage will
be prevented. I IF039
1lOSERlES
1.
Tension lever
11.
Control rack
7.
Sleeve
16.
Torque spring
9.
Flyweight
17.
Lever
11-055
0
FUEL
SYSTEM
WITH
STRUCTURE
BOOST
AND
FUNCTION
COMPENSATOR
2
1
3
4
5
6 1. Governor spring 2.
Floating lever
3.
Guide lever
4.
Tension lever
5.
Push rod
6.
Boost compensator spring
7. Adjustment
screw
8.
Diaphragm
9.
Boost compensator lever
10.
Idling subspring
11.
Adapter spring
12.
Full-load stopper
13.
Camshaft
14.
Flyweight
15. Swivel lever 16.
Control rack
17.
Start spring Boost pressure (From air CrOSSOVer)
A
B. Fuel injection quantity increasing direction
- The
Function of boost compensator *
The boost compensator of a turbocharger quantity
at high-speed,
conditions, -
is actuated by boost pressure
and serves to increase fuel injection
without
In a turbocharged
high-load
regard to
engine operation
governor
operation.
governor
largely
with
boost
compensator
exhaust gas as compare with
improve
governor with-
out boost compensator,
because fuel injection quan-
tity
an engine
is decreased when
is accelerated
or
running at low speed.
engine, inertia of the turbocharger
rotation accelerates increase of fuel injection quantity in advance of intake air when the fuel control lever is pulled
to accelerate
haust
smoky
- Accordingly,
engine speed, thus making
during
transitional
period
of
ex-
time.
any of three kinds of fuel injection sett‘-
ing must be selected: reducing fuel injection quantity to obtain clean exhaust with capacity; while
restricted turbocharger
keeping the maximum
smoky
intermediate
exhaust
being
fuel injection setting
left
unvaried;
and an
fuel injection setting which can partially
The boost compensator so that
the
. When boost pressure exceeds a set value, the diaphragm
(8)
phragm
is transmitted
improves the above problem,
turbocharger
can function
efficiently
with fine exhaust gas color when accelerating.
is pressed in.
boost compensator the control quantity
improve exhaust. -
Operation
. Working
movement the
of dia-
push rod
lever (9) and floating
(5),
lever (2) to
rack (16) to move it in the fuel injection
increasing direction. booster
pressure
and
movement
of
dia-
phragm depend on tension of the boost compensator spring (6) and setting
of spring tension can be ad-
justed with the adjustment
11-056
The
through
screw (7).
110 SERIES
FUEL
SYSTEM
STRUCTURE
AND
FUNCTION
FEED PUMP
1. Nut 2.
Oil seal
3.
Priming pump
4.
Camshaft
5.
Piston
A.
Suction port
6.
Dischargeport
. The fuel pump is driven by the cam on the fuel injection
pump camshaft and delivers fuel under pressure
of approx.
1.5 kg/cm’.
When removing the air, you
can feed the fuel by pushing the priming
pump by
hands. Function
1. .
Preparation The
piston
(5) in the
cam on the camshaft section
4.
Camshaft
5.
Piston
6.
Check valve
valve
7.
Check valve
into the upper
8.
Piston spring
A.
Suction port
6.
Discharge port
for fuel delivery
below
the
feed
pump
is pushed
in by the
(4) causing the fuel in the lower
piston
(6) on the discharge
to open the check
side and flow
section of the piston.
.
At this time, the check valve (7) on the suction side is closed under the pressure of fuel pushed in by the piston,
2.
.
preventing
the reverse flow
of fuel.
A
llF041A
A
11 FO42A
Suction and discharge If the camshaft
(4) is rotated,
bringing the cam out
of the piston, the piston
(5) will be pushed upward
by the piston spring (8).
The resultant fuel pressure
will while
.
thereby
close the check valve (6) on the discharge side, fuel
is delivered
to
the
discharge
port
(8).
In the section below the piston will be generated the negative pressure, causing the check valve (7) on the suction side to open so as to draw in fuel.
11-058 0
110 SERIES
STRUCTURE
AND
3. Control
fuel supply
.
FUNCTION
FUEL
SYSTEM
4.
Camshaft
Fuel in the section above the piston is through direct-
5.
Piston
ly to the passage on the discharge side.
6.
Check valve
pressure on the discharge come the
side increases, it will
impossible to push the piston piston spring (8).
If the fuel
Thus,
(5) upward
the suction
beby
and dis-
charge of fuel will be stopped until the fuel pressure on
the discharge side drops by controlling
quantity Function
.
The
A
of the priming pump
priming
pump
discharges
fuel
in the
below the piston when the piston (IO)
Check valve Piston spring
A.
Suction port
B.
Discharge port
the fuel
to be delivered.
4.
7. 8.
11 FO43A
section
is pushed in
by hand, and sucks in fuel when the piston is drawn up by spring (9). .
The
check valves on the suction and the discharge
sides (6) and in the
(7)
feed pump
are used in common body.
When
with
delivery
those
fuel,
the
valves on the suction side are closed and those on the discharge
side are opened.
When sucking
B
B
6
6
in fuel,
the valves on the suction sides are opened and those on the discharge side are closed.
n
Oil suction
Oil discharge
llFO44A
6.
110 SERIES
Check valve
10.
7.
Check valve
A.
Suction port
9.
Spring
B.
Discharge port
Piston
11-059 0
FUEL
STRUCTURE
SYSTEM
FUEL INJECTION
AND
FUNCTION’
NOZZLE
Engine No. 10001 -
6137FOlO.2
1.
Nozzle holder cap
2.
Adjustment screw
3.
Nozzle spring
4.
Nozzle holder
5.
Push rod
6.
Retaining cap
7.
Nozzle body
8.
Nozzle
A.
From fuel injection pump
FUEL
INJECTION
NOZZLE
*
Maker:
DIESEL
-
Type:
Multi-hole
*
Injection
*
Adjustment
pressure:
250
KIKI type
kg/cm2
of injection pressure: by adjustment
B. To cylinder (injection) C. To fuel tank
1 l-060
Co
110 SERIES
screw
STRUCTURE
Engine
AND
No. 50001
FUEL
FUNCTION
SYSTEM
and up
8
B
6138Fllg
1. Nozzle holder cap
FUEL
2.
-
Maker:
DIESEL
*
Type:
Multi-hole
-
Injection
*
Adjustment
Adjustment screw
3.
Nozzle spring
4.
Nozzle holder
5.
Push rod
6.
Retaining cap
7.
Nozzle body
8.
Nozzle
INJECTION
pressure:
NOZZLE KlKl type
250 kg/cm2
of injection
pressure: by adjustment
screw
A. From fuel injection nozzle 8. To cylinder (injection) C. To fuel tank
110 SERIES
11-061
0
FUEL
STRUCTURE
SYSTEM
AND
FUNCTION
FUEL FILTER S6DllO-1
6136F120
1.
Air bleed plug
FUEL
2.
Bracket
- Filtration area:
3.
Cartridge
A.
From feed pump
6.
To injection pump
1 l-062 Co
FILTER 0.5 m2
110 SERIES
STRUCTURE
AND
FUNCTION
FUEL
SYSTEM
SAGDllO-1
1
B
t
6138FOlSA 1.
Air bleed plug
FUEL
2.
Bracket
*
3.
Cartridge
A.
From feed pump
FILTER
Filtration
area:
0.5 m2
B. To injection pump
110 SERIES
1 1-063
0
FUEL
STRUCTURE
SYSTEM
AND
FUNCTION
FUEL CUT SOLENOID
Inner wiring
1. Shaft 2.
Boot
3.
EOdV
4.
Cover
C,:
O.BSX
c,:
1 l-064 0
6Oi-L
6138F122
SOLENOID
-
Maker:
NIKKO
Type:
Sealed
Rated voltage: Operating
DENKI
24V
current
Maximum:
Max. 35A
Continuity:
Max. 0.5A
* Stroke: - Weight:
12 f 0.3 mm 2.9 kg
110 SERIES
ENGINE
STOP MOTOR
I-A
i
/ Shape of cable tip -(non-threaded stopper type)-
..r---.‘r :_;._:.:,
35 Stroke
Shape of cable tip (threaded stopper type)
-
Stroke
Made by AMP Co., Econoseal connector, 8P male 2. Not used (filler plug added) /
\
!. Not used (filler plug added) 4.8(AV
0.85LR)
3. P, (AV 0.85LY) . Not
used
(filler plug added)
8. E(AV 0.858)
1. Motor assembly
Engine stop motor -
Maker:
Jidosha Denki Kogyo Co., Ltd.
2. Cover
-
Rated voltage:
DC24V
3. Cable assembly
- Operating force:
15 kg min.
*
.J5
4. Cable clamp 5. Coil spring 6. Cable 7. Screw 6. Breather 9. Bracket assembly 10. Cover assembly
Stroke:
+1.o, -0.4
*
Weight:
1.2 kg
mm
STRUCTURAL
DRAWING
1. Gear cover assembly 2. Slider assembly 3. Armature 4. Contactor
shaft assembly
5. Roller 6. Worm wheel assembly 7. Motor
assembly
8. Gear case assembly
’’-“;4-2
(1)
STRUCTURAL
DRAWING
(2)
1. Gear cover assembly 2. Motor
assembly
3. Cable clamp 4. Cable assembly 5. Gear case assembly
1 l-064-3 Gc
DESCRIPTION
OF OPERATION
1.
(O” or 360’)
Stop condition
AND
CIRCUITS
A,
The
above
drawing
shows the stopped
when a closed circuit has been formed. 2.
,
Battery
condition
assembly is stopped at the auto-stop position on the
The slider
PI side.
When switch is turned (when starting the motor) Batterv +1+-i
When the switch switch ON),
is moved to the P, side (starting
an electric current
side contactor
plate through.the
flows from the plus P, auto-stop
ter-
bly, thereby starting the motor.
The slider assembly
starts to move in the direction
of the arrow at the
same time as the roller starts to move.
minal and switch and into the armature shaft assem3.
Turning condition
(90’
in the drawing)
Electric current continues to pass through the arma-
slider assembly also continues to move in the direc-
ture
tion of the arrow.
turn.
11-064-4 @
shaft
assembly
and the
Because of the rotation
-:, ..
motor
continues
of the roller,
to the
4.
When stopped (180°) Battery 44 1
A closed circuit terminal 5.
is formed
when the P, auto-stop
rides on the minus-side
contactor
and the motor comes to a sudden stop.
plate,
The slider
assembly also stops.
When switch is turned (when starting the motor) Battery
A_ B:
,
! IW P, \
j$$@
6
When the switch switch OFF), contactor and switch 6.
-++I P,
I’ is moved to the PI side (starting
plate through
the PI auto-stop
and into the armature (270’
II
E,
thereby
an electric current flows from the plus
Turning condition
A0-J
-+ /-
1
starting
the motor.
terminal
same time as the roller starts to move.
in the drawing) Battery
PI
/El3 \.\
I
Electric current continues to pass through the arma-
the direction
ture
to stop condition
turn.
assembly
slider assembly
of the arrow at the
shaft assembly,
A_ B,
shaft
The
starts to move in the direction
and the motor
continues
to
of the arrow.
Then the circuit returns
1.
The slider assembly also continues to move in
1 l-064-5 0
STRUCTURE
AND
COOLING COOLING
COOLING
FUNCTION
SYSTEM
SYSTEM
SYSTEM
CHART
6138F151A 1.
Radiator
7.
Corrosion resistor
2.
Thermostat
8.
Cylinder head
3.
Water pump
9.
Cylinder liner
4.
Water temperature gauge
10.
Piston
5.
Water manifold (one unit with cylinder head)
11.
Cylinder block
6.
After-cooler
12.
Oil cooler
A.
From oil pump (oil)
’
General description 1. Structure -
The
of cooling system
cooling
thermostat,
system radiator,
to cool the cylinder ing the combustion
consists
3) The of
the
water
fan and water piping.
pump,
It serves
liners, and the areas surroundparts in the cylinder
heads.
the
cooling water
below
water pump,
approx.
over approx. ed fully,
in thermostat when
76°C.
the If the
will
flow
back to
water
temperature
is
water
temperature
is
90°C or so, the thermostat
will be open-
causing the water to flow into the radiator
for cooling.
.
In addition,
oil piping or oil cooler is equipped for
cooling oil by the engine cooling water. 2. Circulation
4) While the water prox.
of cooling water
temperature
ranges from 76’ to ap-
9O”C, some of the water
flows
back to the
water pump and the other to the raddiator. is distributed under pressure 1) The cooling water from the water pump driven together with the fan through the fan belt from the crank pulley. 2) The
cooling
the water various heads,
water
distributed
under
of water
flowing
pends on the degree of opening temperature)
The ratio
to the pump and the radiator (varying
de-
with the
of the thermostat.
pressure from
pump passes through the oil cooler, cools
parts in the engine, collects and
from
110 SERIES
there
flows
into
in the cylinder the thermostat.
11-065 0
COOLING
WATER Engine
STRUCTURE
SYSTEM
AND
FUNCTION
PUMP
No. 10001
-
10351
-A
6136FO21C
1.
Nut
6.
Pump body
2.
Fan pulley
7.
Impeller
3.
Pump shaft
8.
Snap ring
4.
Spacer
9.
Pump cover
5.
Water seal
A.
To engine
11-066
0
Fan pulley
Fan pulley O.D.
Applicable machine
215 mm
w 120-2
110 SERIES
STRUCTURE
Engine DOUBLE
AND
No. 10352 PULLEY
FUNCTION
COOLING
SYSTEM
and up TYPE 1.
Nut
2.
Fan pulley
3.
Pump shaft
4.
Spacer
5.
Water seal
6.
Pumpbody
7.
Impeller
8.
Snap ring
9.
Pump cover
A.
To engine
Fan pulley Fan pulley O.D.
1
215mm
1
Applicable machine W120-2,3,
192 mm
EG150M3
225 mm
WA350-1
235 mm
WA400-1
EC21 02-l
6138FO21.1
TRIPLE
PULLEY
TYPE 1.
Nut
2.
Fan pulley
3.
Pump shaft
4.
Spacer
5.
Water seal
6.
Pump body
7.
Impeller
8.
Snap ring
9.
Pump cover
A.
To engine
Fan pulley Fan pulley O.D.
Applicable machine
Air conditioner pulley O.D.
215mm
1
175 mm
I
D66S-1
215mm
I
215 mm
/
W120-3
(Option)
-A
6136FO21.2
110 SERIES
1 l-067 0
COOLING
STRUCTURE
SYSTEM
AND
FUNCTION’
THERMOSTAT 1.
Intake manifold
2.
Water pipe
3.
Thermostat
4.
Fan pulley
5.
Thermostat housing
6.
water pump
7.
Water hose
A.
From radiator To radiator From engine To aftercooler
E.
Water temperature sensor (generator)
Thermostat
(construction
equipment)
Cracking temperature:
76.5”C
Full open temperature:
90°C
Full open lift:
10 mm
Thermostat
(generator)
Cracking temperature:
82’C
Full open temperature:
95’C
Full open lift:
IOmm
6138F154 A
Structure The
and function thermostat
opens or closes depending
water
temperature
and serves to
water
temperature
within
automatically
adjusting
the
keep the
optimum
the flow
on the
range
with
the thermostat a high expansion
optimum
coefficient,
of
water ranges from 75” to 90°C.
containing movement
between
excessive
oil
the
excessive
BLOWBY
will
oil be
Function
of the thermostat
Aoolication
engine
cooling
not be warmed
up,
due to improper
pistons and liners.
lubrication,
of seals,
wax;
valve.
resulting in poor engine performance clearances
is too high,
deterioration
of the
If the water tempera-
ture is too low, the engine will
premature
O-rings, etc. and overheating will be caused. l
is a cylinder
temperature
deterioration,
rate of the engine
case opens and closes the termostat The
If the engine cooling water temperature oil
by
cooling water into the radiator. Within
*
cooling
Eventually,
contamination, encountered,
and
For construction
For generator
machine
set
Valve cracking tem-
I Valve’ full opening temperature
80-84
75-78
perature (OC)
I 90
95
IO
10
(‘Cl
during Valve full opening
engine operation.
lift (mm)
Where a thermostat ing temperature continuous frequent
11-068 0
is used for a generator,
is set at a high degree,
operation and the
under
engine
light
its operatbecause a
load is relatively
is difficult
to warm
up.
110 SERIES
ELECTRICAL
SYSTEM
ELECTRICAL WIRING Engine
STRUCTURE
AND
FUNCTION
SYSTEM
DIAGRAM
No. 10001
- 10348 Engine No. 10007 and up I
Starting switch key positions
6138F024B
Engine
No. 10349
and up Relay switch
I
Electrical intake air heater
I
-I
Heater signal
l!n,
Starting switch key POsitions Starting switch connections PREHEAT \
o;F
PN
6138FO24.1
11-070 0
110
SERIES
STRUCTURE
AND
FUNCTION
ELECTRICAL
SYSTEM
EG150W3
Relay switch
Electrical
intake air heater
I
I /I
x
Engine stop: switch
Starting
Emergency relay
switch
Starting stitch
key positions
Starting switch connections
I
I
I
6138FO24.2
110
SERIES
11-071 0
STRUCTURE
AND
FUNCTION
.:ELECTRICAL
SYSTEM
ALTERNATOR
Alternator
I
Regulator
internal wiring diagram
Engine
Machine
Type
6138Flg2
Specifications
D66.s1
Nikko Denki
24V. 35A
w120-2.3 EC21 OZ-1 EG 150, 15OS-3
Nikko Denki! Open type with built-in regulator
24V, 25A
Weight
Pulley O.D.
7.3 kg
95
SAGDllO-1
110 SERIES
11-073 0
ELECTRICAL
STRUCTURE
SYSTEM
STARTING
MOTOR
Engine
-
No. 10001
AND
10348
r
SW
B
C
6138F022B
Internal wiring diagram
Engine
SAGDI 1 O-l
11-074 0
FUNCTION
1.
Starting motor
2.
Starling motor pinion
B.
B,C,SW: Terminals
Machine
W120-2, W120-3 EGI 50,15OS-3
I
TYPO
Nikko Denki, sealed type
Specifications
24V. 7.5 kW
Weight
No. of pinion teeth
24.5 kg
13
110 SERIES
STRUCTURE
AND
Engine No. 10349
ELECTRICAL
FUNCTION
SYSTEM
and up
Bult-in safety relay
Internal wiring diagram
Starting motor
6138F194
1.
Starting motor
2.
Starting motor pinion
3.
Safety relay
B,C,E,S,R:
O-l
SAGDllO-1
Oil filler
Terminals
Applicable machine
Engine
S6Dll
a, b, c:
Type
WA350-1
Nikko Denki Water proof, oil proof type
D66S-1 WA400-1
Nikko Denki Water proof, oil proof type
W120-2.3 EG150(.9-3 EC21 02-l
Nikko Denki Sealed type
Specifications
1 24�,7.5KW
/
18 kg
110 SERIES
1
/
13
13
I
! / 24V,7.5KW
teeth
18 kg
24V. 7.5 KW
1
No. of pinion
Weight
24.5 kg
(
13
1 l-075 0
ELECTRICAL
ELECTRICAL Engine
STRUCTURE
SYTSTEM
No. 10001
INTAKE -
AND
FUNCTION
AIR HEATER
10006
2
1 \
/
P
=v
Section B - B
CA Section A -
Section B - B Section A -
Wiring diagram
r/7 6138F023A
1.
Heater coil
2.
Housing
Rated current:
164AI22V
Capacity:
3.6 KW [(6OOW x 3) x 21
11-076 0
110 SERIES
STRUCTURE
AND
ELECTRICAL
FUNCTION
Engine No. 10007 and up
Bi-
-IA
,,-1
Section A - A
Section B - B
SectionA-A
Section B - B
I__
Section A - A
A 1.
Heater coil
2.
Housing
Wiring diagram
Rated current:
173Al22V
Capacity:
3.8 KW [(63OW x 2) x 31
110 SERIES
Section B - B
6138F193
SYTSTEM
ELECTRICAL
SYSTEM
STRUCTURE
OIL PRESSURE
AND
FUNCTION
SWITCH
1.
Nipple
2.
Switch
3.
Connector
OIL
PRESSURE
* Operating
SWITCH
point
ON:
1.5fi.z
kg/cm2
OFF:
l.Ozi:,’
kg/cm2
t-l:, Return
Action
6136F125
RELAY SWITCH RELAY -
SWITCH
Rated voltage:
* Current:
DC24V 200A
(60 sec.)
To switch To battery To load
%k-Inner wiring 6136F126
11-078 0
110 SERIES
STRUCTURE
ACCESSORY
AND
FUNCTION
ACCESSORY AIR COMPRESSOR 14
15
5 4
1.
Crankshaft
11.
Unloader valve
A.
Air inlet
2.
Oil seal
12.
Unloader valve guide
B.
Air outlet
3.
Ball bearing
13.
Unloader valve spring
C.
Unloader
4.
Crankcase
14.
Outlet valve spring
5.
Cylinder block
15.
Outlet valve
6.
Connecting rod
16.
Outlet valve seat
7.
Piston pin
17.
Piston
8.
Cylinder head
18. .Top ring
Inlet valve spring
19.
Second ring
Inlet valve
20.
Oil ring
9. 10.
11-080 0
110 SERIES
STRUCTURE
AND
FUNCTION
ACCESSORY
I
Al R COMPRESSOR *
Maker:
UNLOADER DIESEL
KIKI
- Type: - Bore x stroke: - Discharge volume:
38O!Umin.
-
10 kg/cm2
Air pressure:
* Weight:
110 SERIES
6137FOll-2
Single-cylinder,
double
acting
VALVE
- Valve opening pressure: * Valve shutting pressure:
7.0 - 8.0 kg/cm2 6.2 - 7.3 kg/cm2
70mmx40mm
6.5 kg
(2,500
rpm)
.
11-081 0
12 TESTING AND ADJUSTING
ENGINE
110
SERIES
Engine Numbers: 10001 and up
12
110 SERIES
TESTING AND ADJUSTING
..
TESTING
ADJUSTING
......................................
.
12-004
Measuring
exhaust gas color
. . .
12-004
Adjusting
valve clearance
. . .
12-005
INTAKE
AND
EXHAUST
ENGINEBODY
SYSTEM
Measuring
compression
Measuring
blow-by
pressure
oil temperature
12-006 12-006
1 ....................................
. . .
12-007
..
12-008
.........................................
....................................................
Testing and adjusting Adjusting
timing.
.................................................
Testing and adjusting PERFORMANCETEST
Performance
fan belt tension
................................................ ..........................................
test criteria
ADJUSTING
Fuel injection
DATA
pump calibration
Testing and adjusting
tool
Testing and adjusting
data
TROUBLESHOOTING
...................................... data
..................................
....................................... .........................................
list
...............................................
of reading troubleshooting
Troubleshooting
..................................
...............................................
Run-in standard
AND
.............................. .........................................
fuel injection
fuel cut solenoid
COOLINGSYSTEM
Method
... ..
............................................
Measuring
table
.
.....................................
.............................................
oil pressure
FUELSYSTEM
...
pressure
Measuring
TESTING
........................................ ..........................................
....................................................
LUBRICATIONSYSTEM
z R CD
AND
table
................................
............................................
.
.
12-008
. .
12-008
. .
12-009
. . .
12-009 . 12-010-1
... ...
12-011 12-011
...
12-013
. . .
12-013
...
12-014
.
12-017
...
12-017
. . .
12-022
. . .
12-023
.
.
12-028
. . .
12-028
. . .
12-030
12-003 0
INTAKE AND EXHAUST MEASURING
A
When
EXHAUST
measuring
SYSTEM
GAS COLOR
the exhaust gas color,
be careful
not to touch the exhaust pipe.
* Measure the exhaust gas color while engine is warm (Oil temperature: 1.
Insert
Min. 6O’C)
probe @
in
outlet
of
exhaust
pipe
(I)
and
secure to exhaust pipe with clip. 2.
Connect
probe
hose,
connector
02
of
accelerator
switch and air hose to handy smoke checker A. * 3.
The pressure of air supply should be under 15 kg/cm2
Connect power cable to AClOOV *
Check
that
the
power
socket
switch
is OFF
before
con-
necting the cable. 4.
Loosen cap nut of suction pump and insert filter paper.
5.
Turn power siwtch ON.
6.
Accelerate
engine suddenly.
accelerator
pedal, operate relief valve and catch exhaust
At the same time, depress
gas color on filter paper. 7.
Lay filter unused
paper used to catch exhaust gas color on top
filter
papers
(IO
sheet or more)
inside filter
paper holder, and read indicated value. *
For the reference
values of the exhaust
see TESTING
ADJUSTING
12-004 0
AND
DATA.
gas color,
TESTING
AND
ADJUSTING
ADJUSTING 1.
INTAKE
AND
EXHAUST
SYSTEM
VALVE CLEARANCE
Remove cylinder head cover (1).
2.
Rotate
the crankshaft
watching cylinder “1.6 3.
direction.
While
of the valves, bring the No. 1
into the compression top dead center and align
TOP”
mark on crakshaft
When No. 1 cylinder adjust
in the normal
the movement
the
pulley
with pointer
(2).
is at compression top dead center,
valves marked
in the valve arrangement
l
chart. When
No. 6 cylinder
is at ompression top dead center,
adjust the valves marked 0. *
Valve arrangement
Cylinder
1
No.
To
4.
adjust,
2 a
Intake valve Exhaust valve
chart
3
0
l
insert feeler
a
0
l
5
4
l
gauge A
0
6 0
l
between
0 o
rocker
lever (3) and valve stem (4) and turn adjustment (5) until feeler gauge is slide fit. (6) to hold adjustment m
Locknut:
Next
5.
arm screw
Then tighten locknut
screw in position.
3.2 f 0.3 kgm
rotate the crankshaft
in the normal direction
and
adjust the valve clearance of the remaining valves marked, 0. *
It is also possible to adjust the valve clearance as follows: Adjust valve clearance of No. 1 cylinder
which is at com-
pression top dead center, then turn the crankshaft each time
and adjust
valve clearances following
120” firing
order. *
Firing order:
1-5-3-6-2-4
* After tightening the locknut, check the clearance again. *
For the reference valves of the valve clearance, see TESTING
AND
ADJUSTING
DATA. PIKFIOI
110 SERIES
12-005 0
ENGINE
TESTING
BODY
AND
ADJUSTING
ENGINE BODY MEASURING *
If performance
COMPRESSION
tests or troubleshooting
PRESSURE
shows that the
piston, piston ring or cylinder liner may be worn, measure the compression pressure.
Q
*
When
f
Measure
the
compression
pressure, be
careful
not to touch
the exhaust
manifold
muffler,
or to get caught in rotating parts.
the
measuring
compression
pressure while
or
the engine is
warm. (Oil temperature: 1.
40 -
60°C)
Adjust the valve clearance properly. *
For
detail
see 12 ADJUSTING
VALVE
CLEAR-
ANCE 2.
Remove nozzle holder assembly *
For detail see 13 DISASSEMBLY
+
Take care not to let any dirt or foreign
AND
ASSEMBLY matter
get
into cylinder. 3.
Install
adapter
of compression
gauge to nozzle ho!der
mounting section. 4.
Connect ompression gauge A to the adapter.
5.
Set engine tachometer
6.
Place fuel
control
the engine with
in position.
in NO starting
INJECTION motor
position,
crank
and measure compres-
sion pressure. *
Measure
the
compression
pressure at
point
where
the compression gauge indicate remains steady. *
When
measuring
the compression
pressure, measure
the engine speed to confirm that it is within specified range. *
For the reference values of the compression pressure, see 12 TESTING
*
After
AND
ADJUSTING
measuring the compression
DATA.
pressure, install nozzle
holder assembly.
12-006 0
110 SERIES
TESTING •t
AND
ADJUSTING
MEASURING *
ENGINE
BLOW-BY
PRESSURE
Measure blow-by pressure while engine is warm. (Oil temperature:
Min. 85’C)
1.
Install adapter of blow-by checker in breather hose (1).
2.
Connect adapter to blow-by checker A with tube.
3.
BODY
Run the engine at high idling, and measure the blow-by pressure. *
Blow-by
pressure
condition
of the engine.
Therefore, normal, tive
if the check
blow-by,
defective
greatly
blow-by
for
problem
such
exhaust
or deteriorated *
varies
according
value
110 SERIES
the
is considered
ab-
connected
as excessive oil
gas color,
with
defec-
consumption,
and prematurely
dirty
oil.
For the reference values of blow-by TESTING
to
AND ADJUSTING
pressure, see 12
DATA.
12-007 0
LUBRICATION
SYSTEM
TESTING
LUBRICATION MEASURING
ADJUSTING
SYSTEM
OIL PRESSURE
A
When measuring the oil pressure, be careful not to
Af
Always
.
AND
get caught in rotating parts. remove or install plugs or oil pressure gauges
with engine stopped.
Measure the oil pressure while engine is warm. (Oil temperature:
Min. 80°C)
Remove plug (1). Install oil pressure gauge A. Start the engine, and measure the oil pressure. *
For the reference values of oil pressure, see TESTING AND
ADJUSTING
DATA.
MEASURING 1. 2.
OIL TEMPERATURE
Remove dipstick (1). Insert sensor of thermistor
temperature
gauge in dipstick
guide. 3.
Connect sensor to therrnistor measure temperature *
For
the
TESTING
12-008 0
temperature
gauge A and
of oil in oil pan.
reference
values
AND ADJUSTING
of
oil temperature,
see
DATA.
110 SERIES
FUEL SYSTEM TESTING
AND
ADJUSTING
FUEL INJECTION
‘.
There
are two methods
injection The
timing “MATCH
MARK
is used when original
ALIGNMENT”
VALVE
or replaced
the fuel
method,
pump
and the pump
The “DELIVERY
adjusting
pump.
the injeciton
engine
a repaired
for checking
of an injection
which
is installed
is not being
method”,
which
injection
pump
to the
repaired.
is used when is installed
to
the engine. When
using
the
preparations
timing,
bring the No.1 cylinder
MARK
VALVE
AND
Align
crankshaft Confirm
that
If the stamp (3),
coupoing, m
align
timing
stamp
Disconnect
fuel
Remove
delivery
MATCH
lines the
rotating
the
injeciton
pump
line b on the coupling. are out of alignment, stamp
lines
injection
loosen
by shifting
the
the nut.
6.2 + 0.2
valve
rotate the
direction.
line on crankshaft
line a on the
stamp
kgm
BY THE DELIVERY
tube
cylinder. 2.
see 12
direction.
TESTING AND ADJUSTING VALVE METHOD 1.
THE
(2) by slowly
and tighten Nut:
BY
in the reverse
pointer
stamp
with
injection
For details,
piston at top position.
in the normal
is aligned
nut
stroke.
to 40°
the injection (1) with
fuel
METHOD
No.1 cylinder
pulley
the
copper
piston to the top dead
ADJUSTING
30°
make
valve
CLEARANCE.
ALIGNMENT
With
*
adjusting
of the compression
crankshaft
3.
parts.
inspecting
TESTING
2.
new
and O-rings
and
method,
delivery
Before center
with
VALVE
the
gasket
ADJUSTING
1.
DELIVERY
to replace
holder
(7).
(5)
for
the
No.1
TIMING
3. Remove
spring
delivery
(8)
and delivery
valve holder
(7),
valve
(9)
from
the
and reassemble the delivery
valve holder. 4. With
No. 1 cylinder
piston at TOP position, rotate the
crankshaft 30” to 40’ in the reverse direction. 5. Place the fuel rotate
the
operating when
control
crankshaft the priming
lever in FULL
position,
slowly
in the
direction
while
normal
pump, and observe the position
the fuel stops flowing
out of the delivery
valve
holder. 6. In the position where the outflow
of fuel stops, check
the injection timing stamp line on the crankshaft pulley to see if it is aligned with the pointer. *
If the injection timing stamp line passed through the The injection timing is late.
pointer: *
If the injection
timing
The injection timing is advanced.
pointer:
If the inspection of adjustment, following
stamp line did not reach the
shows that the injection timing
adjust the fuel
injection
timing
is out in the
manner.
1) Rotate the crankshaft direction,
starting
30’
from
to TOP
40”
in the
position
in
reverse No.
1
cylinder. 2) Align the injection with
pointer
(2)
timing stamp line on damper by slowly
rotating
(1)
the crankshaft
in the normal direction. 3) Loosen nut (3) on the injection pump mounting flange slot, and rotate the flange on the pump side little by little by operating
the priming
pump until
no fuel flows out of the delivery valve holder. 4) Tighten
the
nut
on the injection
pump
mounting
flange slot. *
Recheck
the injection
timing
to see if it is pro-
perly adjusted. 5) If match one. After
marks a and b are not aligned, stamp new
the checking and adjusting, be sure to reassemble
the spring and the delivery valve. Always
replace
the
delivery
O-rings with new parts.
valve copper
gasket and
ADJUSTING 1. Confirm
that
FUEL CUT SOLENOID
stop
lever
pump (1) is at the STOP (Usually,
the return
the STOP
position.)
2. Adjust
rod so that
(2) of the fuel
injection
(For WA380-1) 4. Start and stop the engine
position.
that
sp.ring holds the stop lever at
the solenoid
rod so clearance
tween
injection
pump
“b” is 0.4 stopper
has a maximum +
0.1
*
l
per (3).
Problems
current
stroke between
through
of the solinoid the stopper
the (12
solenoid,
l
stopper
is 0 when current 3. Pass
check (0.4
f
3 times,
smoothly
and check
and
that
the
IO seconds.)
adjustment
the
Solenoid
of
coil is’burned
(when solenoid
is half
engaged) l
is passed.
Breakage
or scuffing
of
injection pump governor
mm) and the clearance
lever and stopper
2 -
by improper
lever and stopper
12 mm
“a” =
caused
If clearance between
Stroke
moves
solenoid.
mm be-
lever (2) and stop-
solenoid
engine stops. (It must stop within
stroke. Adjust
the
(excessive
0.1
force brought
to bear on lever).
mm), then make final adjustments. l
If clearance between
stopper
lever and bolt at
l
Lack of engine output caused by drop in fuel injection amount.
FULL end is too large when free (linkage defective).
12-010-l 69
TESTING
AND
ADJUSTING
COOLING TESTING TESTING
BELT
Check the amount
ADJUSTING
*
For
the
/f--y
the fan belt deflects when pushed with
‘I I- 1Omm Approx.
6
kg
between the fan pulley
pulley.
reference
TESTING
FAN BELT TENSION
TENSION
a force of 6 kg at a point midway and the alternator
SYSTEM
SYSTEM
AND
FAN
COOLING
AND
values of
ADJUSTING
the
fan
belt tension,
see
DATA.
2lKFl02
ADJUSTING 1.
FAN
Loosen mounting adjustment
2.
BELT
TENSION
bolt (1) of alternator
and belt tension
bolt (2).
Using a bar or pipe, move alternator
and adjust tension
of
bolt,
beIt
(3).
Tighten
adjustment
then
tighten
mounting bolt.
110 SERIES
12-011 0
PERFORMANCE
TEST
RUN-IN STANDARD *
Load are give for the case of the dynamometer
arm length is 716 mm.
This list shows the standard on condition that the fan is removed.
Engine model
S6Dl IO-1
Applicable machine
WA35O-1
Item 1
2
3
4
5
6
5
10
10
15
15
5
1,000
1,300
1,600
1,900
2,200
Running time
min.
Engine speed
rpm
Load
kg
0
10
19
38
56
75
output
HP
0
9.9
24.2
60.1
105
163
Running time
min.
5
10
10
15
15
5
Engine speed
rpm
1,050
1,350
1,650
1,900
2,100
Load
kg
0
21
32
53
68
83
output
HP
0
21.3
41.7
84.4
126.1
168.3
Running time
min.
0
10
10
15
15
Engine speed
rpm
700 -
1,250
1,600
2,000
2,300
Load
kg
0
22
33
53
69
85
output
HP
0
27
53
105
159
212.5
Running time
min.
5
10
IO
15
15
5
Engine speed
rpm
‘30 - 780
1,000
1,300
1,600
1,900
2,200
Load
kg
0
12
23
46
68
86
output
HP
0
11.8
29.6
73
127.2
Running time
min.
5
10
10
15
15
5
Engine speed
rpm
‘00 - 750
1,000
1,300
1,600
1,900
2,200
Load
ks
0
12
23
46
68
92
output
HP
0
11.8
29.6
73
127.2
199.2
Running time
min.
5
10
10
15
15
Engine speed
rpm
750 - 80(
1,000
1,300
1,600
1,900
2,200
Load
kg
0
12
23
46
68
97
output
HP
0
11.8
29.6
73
‘I 27.2
210.4
700 -
75C
700 - 7E.f
D66.S1
WI 20-2 WI 20-3
SAGDllO-1
75(
5 2,500
WA38O-1
186.3
WA400-1
5
WA420-1
12-013 0
Order Engine mode I
Applicable machine
Item 1
2
3
4
5
6
5
10
10
15
15
5
1,250
1,600
2,000
2,300
2,500
Running time
min.
Engine speed
rpm
Load
kg
0
22
33
52
68
83
output
HP
0
26.2
51.4
100.9
151.3
201.3
Running time
min.
5
10
10
15
15
5
Engine speed
rpm
‘00 - 80C
1,000
1,200
1,400
1,700
1,800
Load
kg
0
22
39
68
84
105
output
HP
0
23.3
45.6
92.2
138.7
183.3
Running time
min.
Engine speed
rpm
Load
kg
output
HP
Running time
min.
Engine speed
rpm
Load
kg
output
HP
00-750
ECZIOZ-1
EG150-3 EG15O.S3
SA6Dl 1 O-l
Running time
min.
Engine speed
rpm
Load
kg
output
HP
Running time
min.
Engine speed
rpm
Load
kg
output
HP -
12-013-l @
PERFORMANCE
Engine model
S6DllO-1
Applicable machine
TEST CRITERIA
Test item
Specified value (fully equipped)
Engine speed
Dynamometer
(rpm)
(kg)
load
Flywheel horsepower
163 HP/2,200
rpm
2,195 - 2,205
74.8 - 79.4
Maximum torque
70 kgm/l,500
rpm
1,400 - 1,600
75.9 - 101.5
High idling speed
2,370 - 2.470 rpm
2,370 - 2,470
0
Low idling speed
700 - 750 rpm
700 - 750
0
WA350-1
Flywheel horsepower
160 HPl2.100
rpm
2,095 - 2,105
Maximum torque
70 kgmIl.450
rpm
1,350 - 1,550
High idling speed
2,250 - 2,350 rpm
2,250 - 2,350
0
Low idling speed
700 - 750 rpm
700 - 750
0
2,495 - 2,505
82.2 - 87.0
80.5 - 85.2 99.8 -
105.4
D66S1
Flywheel horsepower w 120-2 WI 20-3
SA6Dl IO-1
200 HPi2.500
rpm
Maximum torque
68 kgm/l,SOO rpm
1,700 -
High idling speed
2,700 - 2,800 rpm
2,700 - 2,800
0
Low idling speed
700 - 750 rpm
700 - 750
0
1,900
96.9 - 102.8
Flywheel horsepower
190 HP/2,200
rpm
2,195 - 2,205
Maximum torque
78 kgmil.500
rpm
1,400 -
High idling speed
2,480 - 2,580 rpm
2,400 - 2,500
0
Low idling speed
730 - 780 rpm
750 - 800
0
1,600
88.0 - 93.5 107.3 - 113.9
WA380-1
Flywheel horsepower
197 HP/2,200
rpm
2,195 - 2,205
Maximum torque
80 kgm/l,500
rpm
1,400 - 1,600
High idling speed
2,370 - 2,470 rpm
2,370 - 2,470
0
Low idling speed
700 - 750 rpm
700 - 750
0
90.3 - 95.7 109.2 - 115.9
WA400-1
Flywheel horsepower
204 HP/2,200
rpm
2,195 - 2,205
Maximum torque
82 kgm/l,500
rpm
1,400 - 1,600
High idling speed
2,400 - 2,500 rpm
2,400 - 2,500
0
Low idling speed
750 - 800 rpm
750 - 800
0
94.4 - 99.9 112.8-119.6
WA420-1
12-014 0
The values in the table are indicated at standard conditions
(atmospheric
temperature
25’C.
atmospheric
pressure
750 mmHg). The values given for the dynamometer
loads, output
and torque
are with
the fan removed,
so they differ from
those of the specification. Values are standardized
under the following
conditions:
Muffler
and air cleaner installed; alternator
idling; and air
compressor (if installed) open. Dynamometer
loads are given for the case of the arm length is 716 mm.
Fuel used:
ASTM
Lubrication
oil used: CLASS-CD
D975 No. 1 or No. 2 diesel fuel.
Exhaust temperature output (HP)
column t: Torque (kgm)
162.6 - 172.2
0 0
Coolant temperature
Lubrication oil. temperature
Lubrication oil pressure
(“C)
1°C)
PC)
Exhaust temperature (“C) (t: Intake temp. -25’C)
70-80
90-110
3.5 - 5.5
Max. 650 f 3t
68.7 - 72.7
24.3 - 25.8
70 - 80
90-
3.5 - 5.5
Max. 650 f 3t
0
-
70 - 80
90-110
3.5 - 5.5
-
0
-
70 - 80
Min. 1.5
-
20.7 - 22.0
70 - 80
go-
3.5 - 5.5
Max. 650 + 3t
23.7 - 25.2
70-80
90-110
3.5 - 5.5
Max. 650 + 3t
go-
3.5 - 5.5
-
Min. 1.5
-
-
71.5 - 75.5
0
0
70 - 80
0
0
70 - 80.
110
Min. 80
110
110
Min. 80
16.3 - 17.4
70 - 80
go-
110
3.5 - 5.5
Max. 660 + 3t
21 .O - 22.5
70 - 80
90-
110
3.5 - 5.5
Max. 650 + 3t
0
70 - 80
90-110
3.5 - 5.5
-
0
70 - 80
Min. 1.5
-
265.5 - 217.5 s
Fuel consumption (set/200 cc)
- 25°C.
19.9 - 21 .l
163.9 - 173.6
0
SAEBO. intake temperature
-
68.6 - 72.8
0 0
8 z
190.9 - 202.8 -
76.8 - 81.6
70 - 80
SO-
110
70 - 80
80-
110
80-
110
0
0
70 - 80
0
0
70 - 80
195.8 - 207.7 -
78.2 - 83.0
0
0
0
-
Min. 1.5
-
70 - 80
go-
110
3.5 -
Max. 650 + 3t
go-
110
3.5 - 5.5
70 - 89
0
-
Max. 660 + 3t
0
80.7 - 85.7
3.5 - 5.5
3.5 - 5.5
0
-
Max. 660 + 3t
110
70 - 86
Min. 16.3
Max. 650 + 3t
go-
0
-
Min. 80
3.5 - 5.5
70-80
0
204.5 - 216.8
Min. 80
Min. 80
70 - 80
80-
70 - 80 70 - 80 70 - 80
110
5.5
-
Min. 1.5
3.5 - 5.5
Max. 660 + 3t
80-110
-
Max. 700 + 3t
80-110
3.5 - 5.5
Min. 80
Min. 1.5
12-015 0
Engine model
Applicable machine
Test item
Specified value (fully equipped)
Engine speed (rpm)
Dynamometer (kg)
load
I , Flywheel horsepower
189 HP/2,500
rpm
2,495 - 2,505
Maximum torque
67 kgm/l,700
rpm
1,600 -
High idling speed
2,700 - 2,800 rpm
2,700 - 2,800
0
Low idling speed
700 - 750 rpm
700 - 750
0
1,800
80.2 - 85.0 92.9 - 101.3
EC2102-1
SAGD 11 o-1
EGI 50-3 EG 1505-3
Flywheel horsepower
High idling speed
(50 Hz)
148 HP/l,500
rpm
1,495 -
1,505
101.3 :
107.4
(60 Hz)
177 HP/l ,800 rpm
1,795 -
1,805
102.5 -
108.6
(50 Hz)
Max. 1,560 rpm
Max. 1,560
0
(60 Hz)
Max. 1,872 rpm
Max. 1,872
0
2 % a
12-016 0
The values in the table are indicated
at standard conditions
(atmospheric
temperature
25’C,
atmospheric
pressure
750 mmHg). The values given for the dynamometer
loads, output
and torque
are with
the fan removed,
so they differ
from
those of the specification. Values are standardized
under the following
conditions:
Muffler
and air cleaner installed; alternator
idling; and air
compressor (if installed) open. Dynamometer
loads are given for the case of the arm length is 716 mm.
Fuel used: ASTM Lubrication
D975 No. 1 or No. 2 diesel fuel.
oil used: CLASS-CD
Exhaust temperature
Output (HP)
194.5 - 206.1
-
column t:
Torque (kgm)
66.5 -
72.5
SAE30. Intake temperature
- 25’C.
Fuel
Coolant
consumption (set/200 cc)
temperature 1°C)
Lubrication oil temperature 1°C)
Lubrication oil pressure (kg/cm*)
Exhaust temperetu re (“Cd t=intake temp. -25’C
16.2 - 17.2
70 - 80
go-
I10
3.5 - 5.5
Max. 650 f 3t
21 .o - 22.0
70 - 80
go-
110
3.5 - 5.5
Max. 650 + 3t
70 - 80
90-110
0
0
-
0
0
-
70 - 80
Min. 80
3.5 - 5.5
-
Min. I.5
-
147.3 -
156.3
-
25.5 - 26.5
70 - 80
90-110
3.5 - 5.5
Max. 650 + 3t
179.0 -
189.6
-
19.5 - 20.5
70 - 80
go-
3.5 - 5.5
Max. 650 + 3t
70 - 80
90-110
3.5 - 5.5
-
70 - 80
90-110
3.5 - 5.5
-
0 0
0 0
0
110
12-016-l 0
TESTING
AND ADJUSTING
FUEL INJECTION Engine model
SAGDIIO-1
PUMP
Engine serial number
10001 and up
CALIBRATION Applicable
machine
DATA DATA Pump assembly number
Page
D66S-1
6138-72-l
600
12-018
WI 20-2 W120-3
6138-71-l
300
12-019
EG 150-3 EG 15OS-3
6138-71-1400
12-020
6138-72-I
320
12-019-I
6136-72-I
321
12-019-2
WA400-1
6138-72-l
111
12419-3
EG150-3 EG 15OS-3
6138-71-1400
12-020
EC210Z-1
,6138-7 l-1 510
12-021
WA360-1
12-017 @
Machine Model
Engine Model
Injection Pump Type
Pump Manufacturer
D66S-1
SAGDllO-1
PEGAD
DIESEL KlKl
Unit
Allowance
Injection
Pump Assembly
Number
6138-72-1600~101601-3100)...0
Timing Basis
I
Clockwise viewed from drive end
Rotating direction
Specification
Delivery valve retraction volume
80
mm3
for engine with fan
High idling:
rpm
2250
Low idling:
rpm
700 to 800
CCalibration Standard >onditions
Unit
Manufacturer standard (with nearly the same actual machine parts)
Nozzle Dart no.
(105780-0000) (105780-2080)
(105031-4480)
In echon rpe Id/D x lI#x length)
mm
6x2~730
Oil temperature
“C
43 to 47
43 to 47
Nozzle opening pressure
kg/cm*
250
175
ka/cm*
1.6
1.6
6x2~600
Test oil
ASTM D975
Transfer oumo oressure
to 2350
Service standard (with calibration test parts)
(105015-5680)
Nozzle holder part no.
(reference only)
No. 2 diesel fuel or equivalent
ipecifications Injection volumebz/l for service standard
Injection volume (cc/l OOOst) for manufacturer standard Rack osition Pmm) Calibration basic point ’
’
Rack cositions B to Bare the reference volume when adjusting the injection volume. Marks * are sverage volumes.
9.9
i%
Basis
1050
85.5
8
10.9
725
102.0
C
7.3
375
12.0
Allowance Each cyl. 84.5 to
86.5
Basis
Allowance
* 1.71
76.0
Each cyl. 75.0 to
77.0
tl.52
* 100.0
to 104.0
k4.08
85.0
*
83.0
to
87.0
-1-3.40
*
to
*I.20
13.0
*
11.8
to
14.2
kl.30
10.8
13.2
D
*
*
E
*
*
Pump speed (rpm) Numbers in parentheses are pump manufacturer
,-J
Maximum variance between cylinder
Maximum variance between cylinder
jovernor performance
12-018 0
OOOst)
part numbers.
Machine Model
Engine Model
Injection Pump Type
Pump Manufacturer
WlZO-2.3
SAGDllO-1
PEGAD
DIESEL KIKI
Unit
Allowance
Pump Assembly
Number
6138-71-1300~101601-3030)...1
Injection Timing Basis
I
Clockwise viewed from drive end
Rotating direction
Specification
Calibration
for engine with fan
(reference only)
Rated horsepower:
HP/rpm
200/2500
Maximum torque:
kgm/rpm
69
High idling:
rpm
2700
Low idling:
rpm
650 to 750
/I800 to 2800
Standard
Conditions
Unit
Manufacturer standard (with nearly the same actual machine parts)
Service standard (with calibration test parts)
Nozzle part no.
(I 05015-2860)
(
)
Nozzle holder part no.
(105031-3390)
(
1
In ection Ipe (d/D x l/ix length)
mm
6x2~600 ASTM D975
Test oil Oil temperature
OC
43 to 47
Nozzle opening pressure
kg/cm2
200
Transfer pump pressure
kg/cm*
1.6
No. 2 diesel fuel or equivalent
jpecifications Injection volume (cc/l OOOst) for manufacturer standard Rack Pump osition speed Pmm) (rpm) Calibration basic point
’
’
Rack Dositions B to iare the reference volume when adjusting the injection volume. Marks * are average volumes.
jovernor
Basis
Allowance
Injection volumeb/ for service standard
Maximum variance between cylinder
Basis
Allowance
10.8
1250
93.5
Each cyl. 92.5 to 94.5
21.87
B
11.0
900
96.0
*
94.0
to 98.0
+3.84
*
C
7.4
350
12.0
*
10.8
to13.2
k-c.20
*
St) Maximum variance between cylinder
Each cyl.
D E
performance
Y 8
a
Pump speed (rpm) Numbers in parentheses are pump manufacturer
part numbers.
12-019 0
I
Machine Model
Engine Model
Injection Pump Type
Pump Manufacturer
WA380-1
SAGDI 1 O-l
PE-AD
DIESEL KIKI
S/N 54352
Injection
Pump Assembly
I
6138-72-I
Basis
Allowance
Clockwise viewed from drive end
Injection order
l-5-3-6-2-4
Injection interval
60’
59”30’
3.95 to 4.05
Plunger pre-stroke
mm
4
Delivery valve retraction volume
mm3
80
Specification
for engine
Unit
730to
rpm
Manufacturer standard (with nearly the same actual machine parts)
780
Service standard (with calibration test parts)
Nozzle part no.
6138-12-3320(105015-5810)
(I 05780-0000)
Nozzle holder part no.
6136-12-3110(105031-4480)
(105780-2080)
I’ . r”d%t?l%?%angth)
mm
6x2~730
Oil temperature
“C
40 to 45
40 to 45
Nozzle opening pressure
kg/cm2
250
175
Transfer pump pressure
kg/cm2
1.6
6x2~600
Test oil
ASTM 0975
Specifications
No. 2 diesel fuel or equivalent
1.6 Injection volume (cc/l OOOst) for manufacturer standard
1 : Reference data
Calibration basic point
Rack Pump osition speed Pmm) (rpm)
Basis
10.0
L93.31
Injection volume (cc/l OOOst) for service standard
Maximum variance between cylinder
Allowance
1100
Governor performance
375
j21.41
*
Allowance
82.4
Each cyl. 81.4to83.4
~b1.64
15.5
*14.3to
k1.55
*
*
*
*
*
*
(375 - 1100 rpm)
Maximum variance between cylinder
Basis
Each cyl. A
8 approx. Rack positions 7.4 B to E are the referC ence volume when adjustingthe injection volume. D Marks t are averE age volumes.
l
fan (reference only)
y
Standard
Conditions
with
to 60”30
Low idling:
Calibration
l
. 0
1
Rotating direction
[
320 (I 01601-3370).
and up
Timing Unit
l
Number
Boost compensator performace (600 rpm)
16.7
Automatic timer performance
14 or more
12.8CO.l
-T
11.1*0.1 10.4 10.0
.k .-s .z
7.4
% Y 0 a:
5.3 Boost
Pump speed --
_--
_. Numbers in parentheses
_
12-019-l @
(rpm)
-.
pressure (mmHg)
Line @
:
Line @
:
Pump speed (rpm)
At boost pressure 300 mmHg or more At boost pressure 0 mmHg
are pump manufacturer
part numbers.
SEBH4548
I
Pump Assembly Number 6138-72-1321
Applicable
(101601-3430)
Machine
Model
( ): Manufacturer’s part No.
Applicable
Serial No.
Engine
Model
WA380-1
Serial No.
SAGDI IO-I
Injection Timing
Engine specification Clockwise viewed from drive end
Plunger pre-stroke
mm
4.0 + 0.05
Delivery valve retraction volume mm3/st
Pump tester capacity for Service standard
80
Motor
7.5
KW
Calibration Standard onditions iervice standard ndicates data Ising calibration est parts. danufacture tandard is data or factory test.
Service standard
Manufacturer
standard
Nozzle part no.
(105780-0000)
6138-12-3320
(105015-5810)
Nozzle holder part no.
(I 05780-2080)
6136-12-3110
(105031-4480)
Injection ipe (O/D x l/g x length)
6 x 2 x 600
mm
ASTM
Test oil Oil temperature
6x2~730
D975 No. 2 diesel fuel or equivalent 43
OC
to
47
Nozzle opening pressure kg/cm2
175
250
Transfer pump pressure
1.6
1.6
ljection volume Rack point
kg/cm*
Service standard
(cc/lOOOst)
Rack position
Pump speed
(mm)
(rpm)
Basis
1100
8l o .
Each cyl.
750
93.6
* 91.6
to95.6
375
15.5
*
to 16.7
Manufacturer
standard (cc/l OOOst
Maximum
Allowance
rerzE�,
Basis
Allowance
cylinder lack positions I to E are the refernce volume when djusting the injecion volume. larks l are averge volumes.
Basic point
wernor performance
B
C
10.0 1,l.l Approx. 7.4
80.0
14.3
to 82.0
g3 3 Each cyl.
.
*I.62 +I .55
113.7
*
21.4
t
D
*
*
E
*
*
Boost compensator
( 375 - 1100 rpm)
Maximurr variance between cylinder
performance
(600 rpm)
200 Boost pressure (mmHg)
Automatic
Pump speed (rpm)
Line @ Line @
: :
timer performance
At boost pressure 300 mmHg or more At boost pressure OmmHg
Pump speed (rpm) SE8 H4752
'.
12-019-2 0
Pump Assembly Number 6138-72-1111
Applicable
Machine
Applicable
Engine
(101601-3440) Model
( 1: Manufacturer’s
part No.
Serial No.
Model
WA400-1
Serial No.
SAGD 11 O-l
/I
injection Timing
I
Engine specification
Rotating direction
Clockwise viewed from drive end
1 Injection order
I
Injection
l-5-3-6-2-4
I
interval
1 Rated horsepower
I
Maximum
I
1
II
High idling
rpm
I LOW idling
rpm
mm
I
197.2/2200
kgm/rpm
I
80/l 500 2370 to 2470
60’ f 30’
I
Plunger pre-stroke
torque
HP/rpm
I
730 to 780
I
J
4.0 f. 0.05
Delivery valve retraction volume mm3/st
Pump tester capacity for Service standard
80
Motor
7.5
KW
Calibration Standard Conditions
- Service
standard indicates data using calibration test parts. * Manufacture standard is data for factory test.
Service standard
Manufacturer
Nozzle part no.
(105780-0000)
6138-12-3320
Nozzle holder part no.
(105780-2080)
6136-12-31
Injection ipe (O/D x I/! x length)
ASTM
Oil temperature
(105015-5810) IO (105031-4480)
6 x 2 x 730
6 x 2 x 600
mm
Test oil
D975 No. 2 diesel fuel or equivalent 43
“C
to
47
Nozzle opening pressure kg/cm’
175
250
Transfer pump pressure
1.6
1.6
Injection volume Rack point
Rack position (mm)
kg/cm2
Pump speed (rpm)
Service standard
Basis
standard
h/l
Allowance
OOOst)
Manufacturer
Maximum yergi?, Basis
standard (cc/l 000 st:
Allowance
cylinder
BRack
positions B to E are the reference volume when adjusting the injection volume. * Marks * are average volumes.
Basic
point B
Governor performance
10.5 APP;“J”.
1100
85 8 .
Each cyl. 84.8 to 86.8
*I.716
375
15.5
+14.3
fl.55
to 16.7
104.0
21.4 t
C
*
D
*
*
E
*
* Boost compensator
between cylinder
Each “1.
*
( 375 - 1100 rpm)
Maximum variance
performance
(600 rpm)
Boost pressure (mmHg) Automatic
1100::; Pump speed (rpm)
12-019-3 @
__: _-.
Line @ Line @
: At : At
timer performance
boost pressure 300mmHg boost pressure OmmHg
or more
1100 700 go0 Pump sped crpm)
SEBH4753
I
I
Machine Model
Engine Model
Injection Pump Type
Pump Manufacturer
EG15O(SI-3
SA6Dll
PEGAD
DIESEL KIKI
O-l
Pump Assembly
Number
6138-71-1400(101602-3231)...
1
Injection Timing Unit
Basis
Allowance
Rotating direction
Clockwise viewed from drive end
Injection order
l-5-3-6-2-4
Injection interval
60”
59”30’
3.95 to 4.05
Plunger pre-stroke
mm
4
Delivery valve retraction volume
mm3
80
Calibration
Specification to 60”30
for engine with fan 148/l 177/l
(reference only) 500 (50Hz) 800 (60Hz)
Rated horsepower:
HP/rpm
Maximum torque:
kgm/rpm
High idling:
rpm
Max. 1580 Max. 1872
Low idling:
rpm
700 to 800
(50Hz) (60Hz)
Standard
:onditions
Unit
Manufacturer standard (with nearly the same actual machine parts)
Service standard (with calibration test parts)
Nozzle part no.
(105015-4570)
(
)
Nozzle holder part no.
(10503
(
)
I. %t%?%ngth)
mm
6x2~730
Test oil
ASTM D975
Oil temperature
OC
43 to 47
Nozzle opening pressure
kg/cm*
250
Transfer pump pressure
kg/cm2
1.6
ipecifications
Calibration basic point ’
Rack positions B to E are the reference volume when adjusting the injection volume. * Marks * are average volumes.
B
Allowance Each c 1. 11. 3 to11.9
20.24
*
kO.12
900
11.8
7.7
325
1.2
*
C D
*
to :
0 szl3 Y)mwc
Pump speed (rpm)
1.08to
1.32
Injection volumeb2/ for service standard
Basis
Allowance Each cyl. * * *
:*
E
Maximum variance between cylinder
Basis
10.2
jovernor performance
0
No. 2 diesel fuel or equivalent
Injection volume (cc/l OOst) for manufacturer standard Rack Pump osition speed Pmm) (rpm)
12-020 0
l-4360)
*
St) Maximum variance between cylinder
Machine Model EC21
OZ-1
Engine Model
Injection Pump Type
Pump Manufacturer
SA6Dl 10
PEGAD
DIESEL KIKI
Unit
Allowance
Pump Assembly
Number
6138-71-1510(101601-309OL..
1
Injection Timing Basis
Rotating direction
Clockwise viewed from drive end
Injection order
l-5-3-6-2-4
I
Specification
for engine with fan
(reference only)
I
Calibration
Rated horsepower:
HP/rpm
19512500
Maximum torque:
kgm/rpm
68
High idling:
rpm
2650
Low idling:
rpm
700 to 800
I1700 to 2850
Standard
Conditions
Manufacturer standard (with nearly the same actual machine parts)
Unit
Service standard (with calibration test parts)
Nozzle part no.
(105015-4570)
(
Nozzle holder part no.
(105031-4360)
(
I’ %%%r?fength)
mm
‘) 1
6x2~730
Test oil
ASTM D975
Oil temperature
“C
43 to 47
Nozzle opening pressure
kg/cm2
250
Transfer pump pressure
kg/cm2
1.6
No. 2 diesel fuel or equivalent
Specifications Injection volume (cc/l OOOstj for manufacturer standard
’
Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.
Governor
Maximum variance between cylinder
Rack osition Pmm)
Pump speed (rpmj
Basis
Allowance
10.6
1250
85
Each cyl. 84
to 86
f1.7
B
10.8
1200
90
*
88
to 92
+-3.6
*
C
7.2
350
*
6.3
to8.7
50.75
*
Calibration basic point
’
Injection volume(cc/l for service standard
7.5
Basis
Allowance
OOOst) Maximum variance between cylinder
Each cyl.
D
*
*
E
*
*
’
performance
4
;s
;g --
Pump speed (rpm) Numbers in parentheses
110 SERIES
are pump manufacturer
part numbers.
12-021 0
TESTING
AND
TESTING
ADJUSTING
AND
TESTING
DATA
ADJUSTING
AND
ADJUSTING
TOOL LIST
rNo.
’
Testing and measuring item
1
IBngine speed
2
I
I I
Fault finding tool
Multi-tachometer
Part No.
799-203-8000
4
Digital reading: 60 - 20,000
000
I
-5
‘
\
- -50” c
o-2o0°c
i
790-500-I
300
5
I
o-1,000”c
6
ILubricating oil pressure
0 - 10 kg/cm’
7
IQel
8
rpm
1.100 - 1.300 795-500-I
3
Remarks
I
I
pressure
IIntake pressure, pressure
6exhaust
Engine pressure measuring kit
799-203-2002
0 - 20 kglcm’
0 - 1.500 mmHg
9
I3low-by pressure
0-l,000mmH,O
10
IIntake resistance
-1,000
11
tCompression pressure
Compression gauge
12
IBlow-by pressure
Blow-by checker
13
Valve clearance
Feeler gauge
14
Exhaust gas color
Handy smoke checker
15
1Water
Engine oil checker
799-201-6000
Provided with 0.1 and 0.2 water content standard sample
16
Fuel injection pressure Fuel injection nozzle spray condition
Nozzle tester
Commercially available
0 - 300 kg/cm’
17
Coolant quality
Water quality tester
799-202-7001
PH. nitrite ion concentration
18
Pressure valve function Leakage in cooling system
Radiator cap tester
799-202-9001
0 - 2 kg/cm’
19
Radiator blockage
Anemometer (Air speed gauge)
799-202-2001
1-40mls
- 0 mmH, 0
795-502-I
203
0 - 70 kglcm’
-
Dirtiness 0 - 70% with standard color (Dirtiness % x l/IO = Bosch
and fuel content in oil
-
-
-
-
79561
o-1 000
20 795-215-1600 21
Commercially available
Current, Voltage, Resistance
-
12-022 0
110 SERIES
TESTING
AND ADJUSTING
DATA
Engine model
S6DllO-1 WA350- 1 (50001 and up)
Applicable machine model
Item
Condition, etc.
Unit
Perr$s;ble
D66S-1 (50001 and up)
Standard value
Permissible value
High idling speed
rpm
,370-2,47(
!.370-2,47(
!,250-2.35C
!,250-2,350
Low idling speed
rpm
700 -
700 -
700 -
700 -
Necessary starting speed
OT
rpm
Min. 150
-
Min. 150
-
rpm
Min. 100
-
Min. 100
-
Intake resistance
At all speed
mmHz0
Max. 300
635
Intake pressure
At rated output
mmHg
Min. 450
Min. 400
Max. 380 -
635 -
Exhaust pressure (Turbine inlet press.)
At rated output
mmHg
-
-
-
-
Exhaust temperature (Turbine inlet temp.)
All speed (20°C)
OC
Max. 650
Max. 650
Max. 650
Max. 650
Max. 5.0
6.0
Max. 5.5
6.5
Engine speed
-20°C (with starting aid)
Quick acceleration Exhaust gas color
(Low idling-High
idling:
At rated output
Valve clearance (When engine is hot or cold.)
Compresion pressure (SAE30 oil)
Max. 1.0
Intake valve
Oil temperature: 40 -
60°C
Oil pressure [Oil temperature: Mln. 80°C)
At rated output
SAE30
At low idling
SAE30
oil
SAElOW
oil oil
SAEl OW oil
Max. 1.5
2.5
-
0.25
-
mm
0.45
0.45
-
kg/cm2
Min. 30
24
Min. 29
23
300 -
350)
mmHz0
Max. 150
kg/cm2
3.5 -
kg/cm2
5.5
Min. 1.5 -
kg/cm2 kg/cm2
300 -
350)
300 -
300
300 -
Max. 150
3.5 -
5.5
3.5 -
Min. 1.5 -
110
350)
5.5
3.5 -
Min. 1.5 -
OC
Oil consumption ratio
At continuous rated output [Ratio of fuel consumption)
%
Max. 0.5
1 .o
Max. 0.5
1.5
Fuel injection pressure
Nozzle tester
kg/cm2
250
200
250
200
Fuel injection timing
8.T.D.C
degree
16
~;ldisrtor pressure
Opening pressure :Differential pressure)
kg/cm2
0.5 It 0.1
Fan speed
At rated engine speed
rpm
Fan belt tension
Deflects when pushed with a force of 6 kg
mm
given
Do not use these
in the TESTING values
AND
as a guide
ADJUSTING
to change
375 -
161t
1,4X
7.5 DATA
the setting
120
go-
1
0.5 * 0.1
120
16zt
1
0.5 f 0.1
1,340 5-
10
7.5
are NOT for adjustment of the fuel
110
16
0.5 f 0.1
5.5
1.2 -
All speed (oil in oil pan)
90 -
350)
300
Oil temperature
The values
750
-
-
2.0
-
(rpm)
At rated output (Water temp.: Min. 70°C
750
0.25
mm
Exhaust valve
750
-
-
scale
(Engine speed) Blow-by pressure (SAE30 oil)
750
Bosch
At high idling
*
Standard value
I
SAGDI 10-l
injection
5 -
of the output.
pump.
10
Engine
model
SAGDllO-1 W120-2,
Applicable Classification
2 : E B 5 a
Item
Engine
speed
rpm (with
At all speed
mmH20
output
mmHg
At rated
Output
All speed
Quick Exhaust
(Low
gas color
mmHg
(200C)
OC
acceleration idling-High
idling)
At rated output
Bosch scale
At high idling
% -E Valve clearance (When engine is hot or cold.)
Compresion (SAEBO oil)
pressure
Intake
valve
Exhaust
mm
Oil temperature: 40 (Engine
Blow-by pressure (SAEBO oil)
mm
valve
60°C
speed)
At rated
Oil pressure (Oil temperature: Min. 80°C)
kg/cm2 (rpm)
output
(Water temp.: Min. 70°C) At rated
SAEBO oil
output
SAElOW
At low idling
SAE30
mmH20 kg/cm2
oil oil
SAEIOW
.-s
E
rpm
At rated
_c 3
’
aid)
pressure
temperature Inlet temp.)
5 5
starting
resistance
Exhaust (Turbine
k
rpm
Intake
2
5 5
rpm
Low idling speed
Intake
pressure inlet press.)
.-z P w
Unit
High idling speed
-2O’C
Exhaust (Turbine
2 2
etc.
ooc
Necessary starting speed
W120-3
model
Condition,
5 ;
g
machine
kg/cm2 kg/cm2
oil
kg/cm2
Oil temperature
All speed
(oil in oil pan)
OC
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
Fuel injection pressure
Nozzle tester
kg/cm2
B.T.D.C
degree
Opening pressure (Differential pressure)
kg/cm2
%
z$L= t 5 5 2 p .z s
+
Fuel injection Radiator valve
timing
pressure
Fan speed
At rated
speed
rpm
Fan belt tension
Deflects when pushed with a force of 6 kg
mm
The values
given
Do not use these
engine
in the TESTING values
AND
as a guide
ADJUSTING
to change
DATA
the setting
are
NOT
for adjustment
of the fuel
injection
of the output.
pump.
SAGDI
WA380Standard value 2,530
WA4001 (50001 and up)
I
Permissible value
Standard value
Permissible value
Standard value
1 Permissible value
Permissible value
+y
Min.
150
Min.
100 762
Max.
380
635
-
-
Min.
500
450
-
762 -
-
-
-
-
-
Max.
300
Max.
700
Max.
650
Max.
6.0
1.5
Max.
650
Max.
6.0
8.0
Max.
3.5
4.5
-
Max.
1.5
2.5
Max.
$
WA420-
I
k 50
730
z ;;,
1
IO-I
Max.
Max.
650
300
Max.
700
Max.
700
7.0
Max.
6.4
8.4
-
Max.
4.0
5.0
2.5
Max.
1.5
2.5
0.25
-
0.25
-
0.25
-
0.45
-
0.45
-
0.45
-
Min. (300
22
28
-
350)
Max.
(300
150
Min.
-
350)
(300
-
300
Max.
3.5 -
5.5
2.5
3.5 -
5.0
2.1
-
Min.
1.5
0.7
Min.
Min.
1.0
0.7
-
110
120
0.5
1 .o
Max. 250 16-t
1
16k
+ 40 7.5
Max.
I 1
-
1,342
go-
206
+f’;
1,342 5-
350)
10
(300
-
3.5 -
1.5
350)
(300
300 2.5
5.5 5.0
1.2
Min.
1.5
0.7
-
Min.
1.0
0.7
110
120
0.5
1 .o
Max.
200
250
16+
go-
16k
0.5 + 0.1
-
1,185
1,342 10
2.1
206
z’g
1
5-
150
350)
3.5 -
1 .o
1,220-1,280
-
3.0 -
0.5
16
(300
-
120
I
350)
Max. 5.5
22
28
-
110
250
7.5
Min.
300
5.5
0.5 + 0.1 + 40
22
150
3.0 -
go-
28
1
1
+ 40
7.5
161t
I
1,342 5-
+ 40 10
12-025 0
Engine model
SAGDI 1 O-l
! EC21 OZ-1 (10001 - 49999)
Applicable machine model Classificatior -
Item
Condition, etc.
I
Standard value
Unit
EC21 OZ-1 (50001 and up)
I
‘%duaerd
Permissible value
rpm rpm
2,700-2,800
wm wm
Min. 200
-
Min. 150
-
Min. 130
-
Min. 100
-
700 -
750
Intake resistance
At all speed
mmHz0
Intake pressure
At rated output
mmHg
Max. 380 Min. 1,000
635 -
Max. 380 -
635 -
Exhaust pressure (Turbine inlet press.)
At rated Output
mmHg
Max. 900
-
-
-
OC
Max. 650
Max. 650
Max. 650
Max. 650
Max. 5.0
6.0
Max. 5.0
6.0
( Quick acceleration (Low idling-
Exhaust gas color
High idling)
At rated output
Bosch -
-
scale
At high idling
-
-
Max. 1.5
2.5
Max. 1.5
2.5
0.35
-
0.25
-
0.65
-
0.45
-
Min. 27
21
Min. 29
23
I Valve clearance (When engine is hot or cold.)
Intake valve
mm
Exhaust valve
mm
kg/cm2
(300 -
(mm)
Oil pressure (Oil temperature: Min. BOOC)
Oil temperature
Radiator pressure valve
At rated output
SAE30
At low idling
SAE30
oil
SAElOW
oil oil
SAElOW
mmHz0
Max. 150
kg/cm2
3.5 -
kg/cm2 kg/cm2
oil
All speed (oil in oil pan)
Opening pressure (Differential pressure)
350)
5.5
go-
given
Do not use these
12-026 0
in the TESTING values
AND
(300 -
3.5 -
5.5
1.2 -
5.5
3.5 -
go-
120
110
1.0
Max. 0.5
1 .o
kg/cm2
250
200
250
200
degree
19
kg/cm2
0.75 + 0.1
DATA
the setting
19f
0.75 It 0.1
0.75 + 0.1 1,590 5-
10
7.5
injection
1,590 5-10
of the output.
pump.
1
0.75 f 0.1
1,635-1,715
are NOT for adjustment of the fuel
19f
19
1
5.5
1.2 -
Min. 1.5 -
120
350)
300
Max. 0.5
ADJUSTING
as a guide to change
350)
%
7.5 The values
(300 -
Max. 150
3.5 -
110
1,635-1,715
+
350)
300
Min. 1.5 -
kg/cm2 OC
(300 -
s % z
SAGDI
10-I
EG150-3, Engine
No.10001
Standard value Max.l,560 Max.l,872
Max.l,560 Max.l,872
Max.l,560 Max.l,872
(50 Hz) (60 Hz)
-
I
Permissible value Max.l,560 Max.l,872
(50 Hz) (60 Hz)
-
200
-
Min.
150
-
100
-
Min.
100
-
Max.
380
635 -
Max.
380 -
635 -
-
-
-
Max.
900
Max.
650
Max.
5.0
6.0
1.5
2.5
Max.
Max.
650
Max.
5.0
6.0
1.5
2.5
-
0.25
-
0.45
(300
-
21
350)
Max.
(300
150
3.5 -
120
0.5
1 .o
I
18k 0.75
,155(50 ,385(60
Hz) Hz)
1,070 1,280 5-
150
(50 (60 10
Hz) Hz)
I
0.5
1,095-l I,31 5-l
350)
5.5
1.2
I
Max.
0.75
-
3.5 -
1.5
110
I
120
1
I
1.0 200
18
181!z
+ 0.1
7.5
I
-
250
,I 55(50 ,385(60
I
300
5.5
90 -
1 i- 0.1
(300
-
200
I
23
350)
3.5 -
I
110
0.1
-
Min.
-
18
7.5
5.5
1.2
250
f
(300
29
Max.
3.5 -
Min. 1.5 -
Max.
350)
300
5.5
go-
Min.
-
650
-
0.65 27
Max.
Max.
0.35
Min.
0.75
650
-
-
1,095-l 1,315-l
(50 Hz) (60 Hz)
-
and UD
Min.
Max.
CD
50001 Standard value
Min.
Max. 1,000
$ R
EG150S-3
49999 Permissible value
(50 Hz) (60 Hz)
-
-
I
I Hz) Hz)
0.75 1,070 1,280 5 -
1
* 0.1
I
(50 Hz) (60 Hz) 10
12-027 0
TROUBLESHOOTING METHOD
OF READING
The following column
symbols
to indicate
TROUBLESHOOTING
are used in the “Remedy�
the
method
of eliminating
the
cause of a fault.
: Replace;
X A:
METHOD TABLE
Adjusting;
0:
Repair;
C:
Clean
OF READING
TROUBLESHOOTING
The symbol 0 in the table is inserted only for causes which
can be diagnosed.
If a cause cannot be diag-
nosed, the corresponding
box is left blank.
If the result of problem
1 using the troubleshooting
table
shown at right
trouble
is abnormal,
the cause of the
can be assumed to lie between a and d.
Be-
cause it is not possible to make a problems regarding e, it is necessary to perform the next problems (owing to the possibility of a multiple fault). If the result of problem
1 is normal, the cause of the
fault does not lie between a and d.
In such a case, be-
fore diagnosing the cause as e, however, carry out a check by means of problems 2 or 5. If now the result of problem result of problem or d.
1 is abnormal
and the
2 normal, the cause is one of a, b
In addition,
if the result of problem 3 is ab-
normal, the cause will be narrowed down to one of b or d.
To determine
which of b or d is the actual
cause, perform problem 4. If the result of problems is abnormal, corresponding
0
blacken out the
in the table and then perform
the
next problems on these causes in order to narrow the
Not necessary problems
likely causes.
Example 1: Problem 1 + Abnormal Problem 2 + Normal Problem 3 + Abnormal Problem 4 + Normal
From ample
the table
of ex-
1, the cause of
the fault is b.
Example 2: From
Problem 1 + Normal Problem 2 + Abnormal *
In example without
12-028 0
the table
of ex-
2, the cause of
the fault is e.
2, it is evident that the cause is e
carrying
out problem 2, however pro-
blem 2 is performed check.
ample
by way of an additional
Not necessary
problems
TABLE
TESTING
AND
ADJUSTING
TROUBLESHOOTING
Example 3: Problems 1 + Abnormal
From the table of ex-
Problems,2 + Normal
ample 3, the cause is I one of a, c and e.
Problems 3 7 Normal
kontinue
problems
i Problems 4 + Normal Problems 5 + Normal
From the table of example 3-1, the cause is c.
Example 4:
From the table of ex-
Problems 1 + Abnormal
ample 4, the cause is
Problems 2 T Normal
one of a, b or d.
Continue problems
Problems 3 i Abnormal
From the table of ex-
Problems ,4 + Abnormal
ample 4-1, the cause
Problems 5 + Normal
I is a or d. Example 4-1
As can be seen from the above examples, it is not necessary to perform all of the problems. Also, looking at a particular cause, no matter how many l
Rem&
x
c
A
A
x
X
marks there are in the column corresponding to that
cause, it will cease to be an actual cause if there is even one 0 mark in the same column.
110 SERIES
12-029 Co
TROUBLESHOOTING
TESTING
TROUBLESHOOTING
AND
ADJUSTING
TABLE
1. Starting defective or badness. 1) Engine does not turn. Questions to ask operator before starting troubleshooting 1. Did
machine
stop suddenly
during operation?
+
Damage or seizure of internal parts. 2. Did machine
make abnormal
noise during opera-
tion? + Damaged parts. *
Cause h:
battery charging rate
-_ _
-
I
1.26
1
1.24
1
0°C
1.28
1.27
1.25
1.24
-lODC
1.36
1.28
1.26
1.25
Specific
gravity
should
1
1.23
be at least figure
1.22
for
70% charging rate. -
In cold
weather,
specific
gravity
must be at
least figure for 75% charging rate.
When setting the starting switch to START; 1) No sound of pinion moving out.
4
Remove head cover. When checking valve cotter, it is out of place.
5
Remove oil pan. When checking internal parts, they are abnormal.
6
Remove cylinder head. When checking internal parts, foreign matter appears.
0 0 0
The following symbols are used to indicated the action to be taken when a cause of failure is located.
12-030 0
110 SERIES
TESTING
AND
TROUBLESHOOTING
ADJUSTING
2) Engine turns but no exhaust gas is emitted. Check before troubleshooting 1. Is there any fuel in fuel tank? 2. Is fuel feed valve open? 3. Is fuel
piping
leaking
or damaged
between
fuel
tank and injection pump? 4. Is there any leak from fuel filter? 5. Is there any water,
rust or sludge mixed with fuel
drained from fuel tank or fuel filter? (Injection
pump or nozzle are frequent
causes of
failure.)
No.
No fuel comes out even if injection pump bleed plug is loosened and priming pump operated. When cranking engine with starting motor; 1) Injection pump (coupling) does not rotate.
2
2) No fuel comes out even if injection pump bleed plug is loosened. 3) No fuel spurts out even if injection pump pipe sleeve nut is loosened.
3
When removing injection pump tappet cover, control rack does not move.
The following symbols are used to indicated the action to be taken when a cause of failure is located. A: Repair X: Replace C: Clean A: Adjust
110 SERIES
12-03 1 0
TROUBLESHOOTING
TESTING
AND
ADJUSTING
3) Exhaust gas is emitted but engine does not start. If there is always great difficulty output
power
in starting, lack of
is a possible cause, so perform
this
troubleshooting.
Check before troubleshooting 1. Is dust indicator
red? + Air cleaner element clogged.
2. Is SAEBO oil being used at temperatures (Oil
viscosity is too
O’C, use SAElOW 3. Is ASTM
D975
peratures
high)
below O’C?
temperature
below
oil. No. 2 diesel fuel being used at tem-
below
-
IO’C?
precipitated
parafin)
+
temperature
below -
IO’C.
4. Is fuel control
+At
(Clogging
Use ASTM
lever bent?
caused
D975
No.
Is there any play?
by 1 at
Is the
pin out of place?
Engine starts if air cleaner element is removed. 5
When removing injection pump tappet cover, control rack and plunger do not move.
6
When checking injection nozzle with nozzle tester, it does not inject.
7
Compression pressure is too low; blow-by is high.
8
Valve clearance is not proper value.
9
1 Injection timing is not proper position.
10
Air cleaner does not aspirate air. (After maintenance)
I
I
j
I
I
lol
I
I
I
I
0 0 0 I
loI
I
rII-I
0
The following symbols are used to indicated the action to be taken when a cause of failure is located. A: Repair x: Replace C: Clean A: Adjust
12-032 Co
110 SERIES
2. Engine stopped during operation. Questions
to ask operator
before troubleshooting.
1. Did engine stop slowly? + Fuel supply cut. 2. Did engine stop suddenly? + Internal parts damaged or seized. 3. Did engine make abnormal
noise? *
Parts damag-
ed. Check before troubleshooting 1.
Is there any fuel in fuel tank?
2. Is fuel
control
lever bent?
Is there
any play?
Is the pin out of place? 3. Is fuel
piping
leaking
or damaged
between
fuel
tank and injection pump. 4. Is beed hole of fuel tank cap clogged?
Starting mo!or does not crank engine. not turn when cranking engine with
out even if injection p
When cranking engine with starting motor; 1) Injection pump (coupling) does not rotate.
plug is loosened.
rack does not move.
The following symbols are used to indicated the action to be taken when a cause of failure is located. A: Repair x: Replace A:
Adjust
C:
Clean
12-033 0
3. Engine
4. Fuel consumption
runs abnormally.
1) Engine speed is too high.
l
too high.
Before starting the troubleshooting, tor why he noticed
ask the opera-
the fuel consumption
was too
high.
c Governor
adjustment
Cause
defective
2) Engine does not stop. Cause
Remedy
a
Fuel control lever linkage is bent; there is too much play; pin is out of position; something is catching.
b
Injection pump control tion defective
rack func-
C
Injection pump function (part other than rack)
defective
d
Governor
e
Defective adjustment solenoid link
of fuel
cut
f
Defective solenoid
of fuel
cut
function
XA XAA
Remedy
External leakage of fuel; Fuel tank, injection pump, fuel filter and piping. (Common cause when fuel consumption increases suddenly.)
XA
Excessive fuel injection, poor fuel consumption ratio (in this case exhaust gas is black).
Follow “6. Exhaust gas is black�
Internal leakage of fuel; Leakage from fuel tube inside cylinder head cover. (In this case, oil level rises and oil smells of kerosens.)
A Change oil
XAA
defective
adjustment
A
T
A
X
3) Hunting. Cause
*
a
Air sucking into system between fuel tank and feed pump
b
Governor
function
C
Governor
adjustment
d
Injection pump control tion defective
Set injection when
*
Remedy
XAA
defective
A
defective
xA
rack func-
and governor
on test
stand
adjusting.
Making than
pump
xA
up fuel
standard
pump
by injecting
may damaged
more
fuel
engine.
The following symbols are used to indicated the action to be taken when a cause of failure is located. A: Repair X: Replace C: Clean A: Adjust
12-034 0
TESTING
AND
ADJUSTING
TROUBLESHOOTING
5. Lack of power. *
5. Is there any water,
If lack of power is accompanied gas, follow problems
*
First troubleshoot
by black exhaust
(Injection
“6. Black exhaust smoke.”
whether
-
Judge
,Good
I
mainly
function,
pump
or
nozzle
are frequent
causes of
the cause is in the en-
(Check
strainer
clogged when
no fuel
comes out.)
At torque converter oil temperature approx. 76’C. and at Forwardhighest speed
stall speed. (tachometer)
1
with fuel
failure.)
gine or in the chassis as follows.
N.G.
rust or siudge mixed
drained from fuel tank?
checking
acceleration
for
track
tension,
brake
and engine high idling speed
when mounting DIRECT
transmission.
Check before troubleshooting 1.
Is fuel piping damaged or fuel leaking between fuel tank and injection pump?
2. Is bleed hole of fuel tank cap clogged? 3. IS tube
damaged
or
leaking
between
injection
pump and nozzle holder? 4. Is incorrect fuel being used?
1
Even with fuel control lever at FULL position, injection pump lever does not contact to the full-stopper.
0
When operating priming pump: 1) No reaction or slight reaction and quick return.
00
2) No reaction or slight reaction with normal return.
0
2
3
No fuel comes out even if injection pump bleed plug is loosened and priming pump operated.
0
4
Improper engine-running happens by hunting.
0
5
When checking with nozzle tester, injection spray is defective or injection pressure is low.
6
No fuel spurts out even if injection pump pipe sleeve nut is loosened.
0 I
lolol
I
I
I
I
Some cylinders little or no pulse when injection pipe is
When removing injection pump tappet cover and checking movement of control rack, does not move
The following symbols are used to indicated the action to be taken when a cause of failure is located. X: Replace A: Repair A: Adjust C: Clean
1lOSERlES
12-035 0
TROUBLESHOOTING
TESTING
AND
ADJUSTING
6. Exhaust gas is black. Check before troubleshooting Is dust indicator red? *<Air cleaner element clogged. Is injection
pump seal out of, position? +
out of adjustment
Pump
(excessive injection).
Is air leaking between
turbocharger
and cylinder
head? Is standard
spec. machine operating
at high alti-
tude?
method shows
7
8
I
0
Exhaust gas color improves when muffler is removed. Turbocharger
is sluggish when turned by hands.
(For engineswith turbocharger)
9
Exhaust gas color improves when injection pump is replaced. _____~ ~~
10
Exhaust gas color improves when auto-timer is replaced. (For engines with auto-timer)
0
I loi-I I T-I I / 0
The following symbols are used to indicated the action to be taken when a cause of failure is located. x: Replace A: Repair A: Adjust C: Clean
12-036 0
110 SERIES
TESTING
AND
TROUBLESHOOTING
ADJUSTING
7. Exhaust gas is blue. (Combustion of engine oil) Check before troubleshooting
1. Has engine continued
(For engine with turbocharger)
to run for over 20 mins at
low idling? -f Oil coming up into cylinder, from seal at turbocharger 2. Has engine
continued
at high idling? + cylinder,
oil leak
turbine side. to run for
Oil coming
over 20 mins
up or down
oil leak from seal at turbocharger
into
blower
side. 3. Is turbocharger
oil return pipe damaged? + oil leak
from turbocharger
seal.
ipe is coated with oil.
The following symbols are used to indicated the action to be taken when a cause of failure is located.
110 SERIES
12-037 0
TROUBLESHOOTING
TESTING
AND
ADJUSTING
8. Oil consumption too high. Before starting the problems, ask the operator why he noticed the fuel consumption *
If answer is:
was too high.
“Oil consumption
haust gas was blue”,
follow
was high and exproblems
“7.
Ex-
haust gas is blue”. Check before troubleshooting l
Is engine or engine lower part coated with oil. (Remove earth and sand and check.)
1
Oil leaking out of engine (check around engine).
2
Cooling water is mixed with engine oil.
3
Oil in main clutch or TORQFLOW or damper increases.
transmission
0 0 0
The following symbols are used to indicated the action to be taken when a cause of failure is located.
J 2-038 Cc
110 SERIES
TESTING
AND
TROUBLESHOOTING
ADJUSTING
9. Oil level rises. (Mixed water or fuel) Check before troubleshooting *
Is the cooler of engine oil dirt -
white?
+
Mixed
water.
4
Seal or seal contact face of hydraulic pump drive shaft is worn or damaged.
0
I
The following symbols are used to indicated the action to be taken when a cause of failure is located.
1 IO SERIES
12-039 0
TESTING
TROUBLESHOOTING
10. Oil quickly
AND
ADJUSTING
becomes dirty.
Before starting the troubleshooting, ask the operator the following questions. 1. Were oil and oil filter changed in accordance with the “Qperation
and Maintenance
Manual”?
2. Was improper oil used?
No.
1
Problems
I’/
Remedy
\
/X
I
I
I1
/X4X 'p,
7LLoaliohtload.
Exhaust gas is blue when engine is run at high speed
1~;;;y~~islack.
;
1 ~o~Cl~
After running at high idling for approx. 10 mins., oil can be seen leaking from turbocharger turbine outlet.
0
5
Turbocharger shaft play is excessive.
6
Oil cooler therm0 valve does not open (check directly).
t
If the above problems plete combustion
0
secondary cause of dirty oil is carbon from incomIn this case follow problems in “6. Exhaust gas is black”.
does not reveal the cause, a common
mixing with the oil.
The following symbols are used to indicated the action to be taken when a cause of failure is located. X: Replace A: Repair A: Adjust C: Clean
12-040 0
110 SERIES
TESTING
AND
TROUBLESHOOTING
ADJUSTING
11. Engine oil pressure gauge indicator fluctuates abnormally.
or valve guide is damage
The following symbols are used to indicated the action to be taken when a cause of failure is located. X: Replace A: Repair A: Adjust C: Clean
110 SERIES
12-041 0
TROUBLESHOOTING
TESTING
AND
ADJUSTING
12. Lack of oil pressure. (At
speed
engine
engine
oil
pressure
of
over
gauge
700
rpm,
is to
left
indicator
of
of “Operating
range”.) Question
to
be
asked
before
starting
trouble-
shooting. Is IOW oil being used at temperatures
2
I
I
above O’C?
Water or fuel mixed with fuel.
Oil in oil pan is lack (no sign of external oil leakage).
Engme or1 pressure IS normal If gauge IS replaced Oil hose, tube are clogged or damaged.
6
Oil filter is clogged and bypass valve function is defective. (Check directly)
7
Metal particles are caught in oil filter element. K.0.W.A (oil analysis) shows abnormality.
8
Remove oil pan. When checking oil, strainer is clogged or oil pipe is damaged.
9
Regulator valveb catching, spring is fatigued, valve or valve guide is damaged. (Check directly)
10
I
Oil pump does not rotate smoothly and oil pump shaft play is excessive.
e
I
I
I
I
II
I
II0
I
I
I
lol
I/II
0 0
lol
III
I/II
0
The following symbols are used to indicated the action to be taken when a cause of failure is located. x: Replace A: Repair A: Adjust C: Clean
12-042 0
110
SERIES
TESTING
AND
ADJUSTING
TROUBLESHOOTING
13. Oil in cooling system.
g
14. Water temperature does not rise. Water temperature â&#x20AC;&#x153;Operating *
gauge indicator
In cold weather and radiator
operation,
2
if reversible fan
shutters are not fitted,
gine may not warm up.
1
is to left of
rangeâ&#x20AC;?.
Water temperature
the en-
(If equipped.)
When thermostat is removed, it is found to stay open; or performance test shown cracking temperature is
toolow.
0
rises if gauge is replaced.
0
The following symbols are used to indicated the action to be taken when a cause of failure is located.
110 SERIES
12-043 0
.TROUBLESHOOTING
TESTING
AND
ADJUSTING
15. Water temperature rises excessively. (Water temperature “Operating Never
LI
gauge indicator
goes to right of
range”; engine overheats.)
remove
the
radiator
perature is still high.
cap when
the tem-
Boiling water may spurt out
and cause serious burns. *
When
the engine overheats, stopping the
immediately the water
engine
means water is no longer sent out by pump.
As a result the temperature
of
the parts being cooled rises sharply and this may cause cracking Before
starting
or other
the troubleshooting,
ator the following 1. Is anti-freeze
damage to the engine. ask the
oper-
questions. being used in summer?
2. Is water being supplied according to the “Operation and Maintenance
Manual”.
Check before troubleshooting 1. Is machine being operated
under excessive
load? 2. Is fan damaged or deformed? 3. Is belt groove of fan pulley or crank pulley worn? 4. Are
radiator
shutter
and
reversible
fan
being used properly?
Coolant level is too low.
Cooling water mixed with oil.
0
3
Fan belt loosens.
4
Radiator core is damaged or clogged with mud or dust.
5
Difference in temperature lower tanks is extreme.
6
Radiator is only slightly warm.
7
Valve opens when testing thermostat only.
8
If water temperature gauge is replaced, it returns to normal.
9
Torque converter oil temperature is too high. (with TORQFLOW transmission)
t
0
between upper and
If exhaust smoke is black, follow
0 I
problems “6.
I
lolol
I
I
I
I
0 0 0 Exhaust gas is black”. The following symbols are used to indicated the action to be taken when a cause of failure is located.
12-044 Co
110 SERIES
TESTING
AND
TROUBLESHOOTING
ADJUSTING
16. Too much vibration.
No.
Problems Ill
1
Engine mounting bolts are loose. (Check directly)
2
Vibration damper is not warm to touch after operation, during operation, gear noise is also excessive.
3
Air is mixed in fuel system.
4
Engine runs abnormally at low idling. line; exhaust gas color normal)
5
Exhaust gas is black.
6
Water temperature
7
8
I I
AX
lllllllll/
0 0 0
(No air in fuel
0 000
0
does not rise or rises slowly.
When checking injection nozzle with nozzle tester, injection spray is defective or injection pressure is low. Injection pump seal is out of position, injection pump is Out of adjustment. (Check directly with pliers)
9
When loosening injection pipe sleeve nuts in order at low idling, speed of some cylinders does not change.
10
oil pressure is low at low idling.
11
Remove cylinder head when checking it, the tappet or intake and exhaust valves are abnormal.
0
I
I
I I lo1I I I I l-1
I
00
0 0
0
The following symbols are used to indicated the action to be taken when a cause of failure is located.
110 SERIES
12-045 0
TROUBLESHOOTING
TESTING
AND
ADJUSTING
17. Abnormal noise emitted. * When noises indicating internal damaged are being emitted
continuing
to operate the machine
may make the damage worse. *
As far as possible, classify the abnormal noise to make location of the cause easier. Type of noisr - lnterferenl *
Abnormal
combustion
* Gears * Internal, external * Engine, power train
2
1 Exhaust gas is black.
3
Combustion noise is abnormal.
4
Seal is broken. (Check injection volume on test stand.)
5
Water temperature does not rise.
6
Vibration damper is not warm to touch after during operation, gear noise is also excessive.
7
When loosening injection pipe sleeve nut and setting engine to low idling, engine speed does not change.
8
Valve clearance is too large or too small.
9
Compression pressure is lack; blow-by is excessive.
10
When checking injector nozzle with nozzle tester, injection spray is defective or injection pressure is low.
11
Remove oil pan. When checking it, internal engine noise is excessive.
12
Remove gear cover.
13
When removing cylinder head, Internal engine noise is excessive.
00
00
00
0 0
1-1 I ! I I I I4 I I 1 0 0 0
I
IlolllllllllI
Gear noise is occured.
0 0
Other causes of abnormal noise (direct check)
The following symbols are used to indicated the action to be taken when a cause of failure is located. x: A: Repair Replace A: Adjust C: Clean
12-046 0
110 SERIES
18. Excessive wear of engine parts. Before starting the troubleshooting, tor the following
ask the opera-
questions.
1. Is the specified oil being used? 2. Is the specified fuel being used? 3. Is the air cleaner element according
to
the
cleaned and replaced
“Operation
and Maintenance
Manual”? 4. Is the fuel according
filter to
element
cleaned and replaced
the “Operation
and Maintenance
Manual”? 5. Are the engine oil and oil filter element replaced according
to
the
“Operation
and Mainten
Manual”? 6. Has there
been repeated
rapid
acceleration
rapid gear shifting? 7. Is the machine warmed and
left
cording
idling to
the
before
up before operation stopping
“Operation
and
engine
ac
Maintena
Manual”?
The following symbols are used to indicated the action to be taken when a cause of failure is located. x: A: Repair Replace C: Clean A: Adjust
12-047 0
19.
Engine does not start because of fault in electrical system. (Check starting circuit)
A
When checking, take care not to be caught in fan or other rotating parts if engine starts.
Check before troubleshooting
Is battery electrolyte
1.
level or specific gravity too
low? 2. Check starting circuit for broken or disconnected wires,
loose terminals
or short circuits
(Visual
check) Battery
-
Safety
relay
~--2 Battery relay switch 3. Immediately
after
repair,
-
Starting
switch
Battery mistaken
wiring
con-
nection is possible cause. 4. When gives
problems cause
i
l-1)
“Engine
“Electrical
does not
system
turn”
defective”,
use this problems.
No.
1
2
Problems
Remove the stop lever of injection pump then set the injection pump lever to the RUN side, engine will start.
If terminals (6) and (C) of starting motor are connected, pinion moves out. l Sparks are produced by this test.
A.
When pinion movement is confirmed, drsconnect-terminals immediately.
3
If terminals (6) and (Cl of starting switch are connected, engine will start.
If terminals (b) and (El of battery relay switch are connected, engine will start. If plug terminal of safety switch is connected to terminal (B) or (+) of starting motor, engine will start. If terminals (6) and (C) of safety relay are connected, engine will start.
7
Starting motor does not turn even if No. 1 starting motor terminals (6) and (C) are connected.
The following symbols are used to indicated the action to be taken when a cause of failure is located. x: Replace A: Repair A: Adjust C: Clean
12-048 0
TESTING
AND
ADJUSTING
TROUBLESHOOTING
20. Battery does not charge. (Check charging circuit) 7 Q
When checking, take care not to be caught in fan or other Take
rotating
parts if engine starts.
care also not to cause short circuits.
Before starting the troubleshooting,
ask the opera-
tor if the battery is old (in use for 2 or more years).
I
Ill
Check before troubleshooting 1. Is alternator
or dinamo drive belt loose?
2. Check starting circuit for broken or disconnected wires, loose terminals check, continuity Battery
cf
Regulator -
or short circuits.
Starting switch *
(Visual
check) *
Ammeter
*
Alternator
Battery relay switch
-
Battery
3. Do lamps or heater exceed specified limit?
Are
they left on? *
When lamp
engine
is stopped
stays on,
and
or ammeter
charged indicator
deflects to one side, lamps are still on, or there is a short circuit. 4. Following
repairs, mistaken wiring connec-
tion is possible cause.
During operation, deflection of ammeter and charging lamp are normal.
1
Continuity test using tester shows; 1) Little or no continuity when terminals (AC) and (6 of starting switch are connected. (with switch ON) 2) When the starting switch is ON, continuity between them above I) is proper, but when being OFF, no continuity.
2
I
3)
Little or no continuity between (+j terminal and (-) terminal of ammeter or charging lamp.
Run engine at medium speed (1,000 - 1,500 rpm) and measure charging voltage with tester. 1) Tester does not show charging voltage (26-3OV3 between terminal (E) of alternator and terminal (N) of regulator.
00
3
2) Tester shows charging voltage, or between terminal (B) and (E) of alternator, but does not show with above.
I
3) Tester shows charging voltage with 2) only.
0
0
The following symbols are used to indicated the action to be taken when a cause of failure is located. x: Replace A: Repair A: Adjust C: Clean
110
SERIES
12-049 0
13 DISASSEMBLY
ENGINE
AND ASSEMBLY
110
SERIES
Engine Numbers: 10001 and up
13
110 SERIES
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
Overalldisassembly..
AND
ASSEMBLY
..................................................................
Overallassembly...........................~ Disassembly and assembly of components
............................................
...............................................
13-004 13-102 13-201
*
The description of overall engine disassembly and assembly given in this section is based on the SAGDI 1 O-l engine, assuming the use of an overhaul stand. Sr The work procedure may differ slightly from that given here depending upon the machine in which the engine is mounted, engine accessories. and also the particular stand used, however it is fundamentally the same. * Use the correct service tools when performing disassembly and assembly.
110 SERIES
13-003 Co
OVERALL
DISASSEMBLY
OVERALL
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
Oil filler, dipstick guide
Engine SAGDI IO-1
13-004 0
1lOSERlES
DISASSEMBLY
AND ASSEMBLY
OVERALL
DISASSEMBLY
6138F301
110 SERIES
13-005
OVERALL
Special
DISASSEMBLY
tools
required
for overall
-
A
Engine stand
006
1 - Adapter
795-215-2000
) Remover
795-l 00-2800
1 Piston 1 Spring
795-102-2101
B
C
D
E
1
Engine overhaul stand
790-501-2000
AND ASSEMBLY
disassembly
Part Name
Part No.
790-901-l
DISASSEMBLY
1
plate
111
1
1
/
111
ring tool
1
/ 1
pusher
Preparatory work .
Clean
.
Drain cooling water and engine oil. b & Engine oil: Approx. 22 R
.
off all mud and dirt.
Prepare a stable engine stand A so that the engine will not overturn, and set the engine securely on the stand.
el kg
13-006
Engine assembly:
Approx.
650 kg
(Differs according to machine)
110 SERIES
DISASSEMBLY
1.
OVERALL
AND ASSEMBLY
DISASSEMBLY
Oil filler, dipstick guide 1) Remove oil filler (1). 2) Remove dipstick guide (2).
2.
Starting motor
.
Remove starting motor (3).
3.
Turbocharger,
exhaust manifold assembly
1) Remove muffler drain pipe (1). 2) Disconnect
turbocharger
intake
intermediate
hose
tube (2) at cylinder
block end. 3) Disconnect
(3)
between
turbo-
charger and aftercooler. 4) Remove
turbocharger
(4)
and
exhaust
manifold
assembly.
4.
Setting engine in engine overhaul stand
1)
Install adapter plate Bâ&#x20AC;&#x2122; (supplied with engine overhaul stand) on engine.
2) Raise engine assembly, align plate Bâ&#x20AC;&#x2122; with engine overhaul stand, and install engine. Engine assembly:
110
SERIES
Approx.
630 kg
13-007
OVERALL
DISASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
Fuel filter Disconnect
fuel filter
inlet hose (1) and outlet hose (2)
at fuel injection pump end, then remove fuel filter (3). Oil filter Disconnect
oil filter
inlet tube (4) and outlet tube (5),
then remove oil filter (6).
7.
Fuel injection pipe 1) Remove boost compensation
pipe (1).
2) Disconnect hose (2) at air compressor end. 3) Remove fuel injection pipe (3).
8.
Aftercooler
1) Disconnect wiring between relay switch and ribbon heater at switch end.
2) Disconnect
aftercooler
inlet
tube
(1)
at
cylinder
block end. 3) Disconnect end.
aftercooler
outlet tube (2) at thermostat
4) Using eye bolts @
(8 mm, P =. 1.25), sling aftercooler
(3). 5) Remove mounting ribbon heater (4).
bolts, then lift off .aftercooler
13-008
and
110
SERIES
DISASSEMBLY
AND
OVERALL
ASSEMBLY
9. Thermostat .
Remove thermostat
10.
Fuel injection pump
with case
(1).
1) Remove return tube (I) of fuel injection pump. 2) Disconnect feed tube (2) of fuel injection pump. 3) Remove bolts (3) connecting fuel injection pump air compressor. 4) Remove fuel injection pump (4). 5) Remove fuel injection pump bracket (5).
11. Oil cooler 1) Remove oil cooler inlet tube (1). 2) Remove oil cooler (2).
12. Air compressor 1) Remove oil feed tube (1) of air compressor. 2) Remove air compressor (2).
110
SERIES
DISASSEMBLY
OVERALL
13.
DISASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
Fan belt l
Loosen mounting
bolt of alternator,
move alternator
to inside, and remove fan belt (1).
14. Alternator 1) Remove
mounting
alternator
bolts (I)
and (2),
then
remove
number
before
(3).
2) Remove plate (4).
15. Water pump l
Remove water pump (1).
16. Spill pipe . 17.
Remove spill pipe (I).
Nozzle holder l
Remove nozzle holders (2).
*
Mark
each
removing.
nozzle
holder
with
a
Keep the nozzle holders in a safe place and
be careful not to damage them.
13-010
110 SERIES
DISASSEMBLY
18. Cylinder .
AND
OVERALL
ASSEMBLY
DISASSEMBLY
head cover
Remove cylinder head cover (1).
Rocker arm assembly 1) Loosen
lock nut of adjustment
screw, then loosen
each adjustment screw 2 to 3 turns. *
Loosen
the
adjustment
screws at this point
to
avoid excessive pressure being brought to bear on the
push
rods when
installing
the
rocker
arm
assembly. 2) Remove rocker arm assembly (1).
20.
Push rods .
Remove push rods (1).
110
SERIES
13-011
OVERALL
21.
DISASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
Cylinder head 1) Remove mounting bolts of cylinder head. 2) Remove cylinder head (1).
el kg
Cylinder head assembly:
57 kg
3) Remove cylinder head gasket.
. Disassemble cylinder head assembly as follows. i) Using spring pusher B, compress valve spring and remove valve cotter (I ).
ii)
Slowly
releaSe
spring
tension
and
remOve
spriâ&#x20AC;?g
guide (2), valve spring (3) and spring seat (4).
iii) Lift up cylinder head (5) and remove valves (6).
*
Valve spring
- Engine No. 10001 - 50000: 50001 and up:
13-012 0
Equal pitch Unequal pitch
110 SERIES
DISASSEMBLY
AND ASSEMBLY
OVERALL
22. Oil pan
. Turn over engine to put oil pan at top. . Remove oil pan (1). *
Be careful
not to deform
or damage the oil pan
when removing it, as this will cause oil leakage.
23.
Suction tube l
24.
Remove suction tube (1).
Vibration l
damper
Turn over engine to put cylinder head side at top.
1) Remove vibration damper (1). 2) Remove spacer (2).
25.
Crankshaft
pulley
1) Remove bolt (I), then remove plate (2). 2) Remove crankshaft
110
SERIES
pulley (3) and taper collar (4).
DISASSEMBLY
DISASSEMBLY AND ASSEMBLY
OVERALL DISASSEMBLY
26. Gear case cover 0
Remove gear case cover (I).
27. Drive gear for fuel injection pump l
28.
Remove drive gear (1) for fuel injection pump.
Oil pump 0
Remove oil pump (2).
Ir
When
disassembling the oil pump, see to Section
“DISASSEMBLY
AND ASSEMBLY”.
Engine No. 10001 - 50000: 50001 and up:
29.
pump
Gear pump
Drive gear for oil pump .
30.
Trochoid
Using puller 0,
remove drive gear (1) for oil pump.
Idler gear, shaft assembly 1) Remove thrust plate (I), then remove idler gear (2). 2) Remove idler shaft (3).
13-014 0
110
SERIES
DISASSEMBLY
31.
AND
OVERALL
ASSEMBLY
DISASSEMBLY
Flywheel l
Screw
in guide bolt @
(14 mm, P = 1.5),
mounting bolts (l), then remove flywheel Flywheel:
remove
(2).
22 kg
(Differs according to the machine)
32.
Flywheel
housing
1) Using eye bolts @
(12 mm, P = 1,75), sling flywheel
housing (1). 2) Remove mounting bolts and lift off flywheel Flywheel housing:
110 SERIES
housing.
26 kg
13-015
-. OVERALL
33.
DISASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
Piston, connecting rod assembly
. Turn over engine so that piston and connecting rod assembly is at side.
* To avoid damage when removing the piston, remove the top
inside surface of the liner with fine sand-
paper.
1) Rotate crankshaft so that piston to be removed is at bottom dead center.
2) Remove connecting rod cap (1). 3) Using wooden bar, push piston and connecting rod from oil pan side. Support piston (2) at cylinder head side and remove. *
When
removing,
be careful
not
to damage the
inside surface of the liner with the corners of the connecting rod. 4) Remove remaining pistons and connecting rods in the same way. * Keep the pistons and connecting rods in a safe place and be careful
not to damage the sliding surface of
the piston or the bearing.
*
Disassemble
piston
and
connecting
rod
assembly
as
follows i)
Using pliers (a), remove spring (4).
ii) Hold connecting
rod (5) by hand, and tap out piston
pin (6) from opposite side. iii) Disconnect piston assembly and connecting rod. iv) Remove snap ring on opposite side.
VI Using piston ring tool C, remove rings in turn, starting with top ring (5).
*
Keep piston, connecting rod, bearing, piston rings and piston pin in sets according to cylinder number.
13-016
110SERlES
DISASSEMBLY
AND ASSEMBLY
OVERALL
34. Crankshaft l
Turn over engine so that crankshaft side is at top.
1) Remove main bearing caps (1). *
The
lower
sides of
thrust
the
No.
bearing 7 main
is assembled on both bearing
cap, so after
removing, mark the position for assembly.
2) Using a nylon sling, remove crankshaft *
When raising the crankshaft,
(2).
be careful not to let
it hit or damage the cylinder block. *
Keep the crankshaft
in a safe place, and be careful
not to damage the sliding surface.
3) Remove upper thrust bearing (3) on crankshaft side.
4) Remove upper bearing (4). *
Mark
the positions for assembly of the main bearing
cap, main bearing and thrust bearing with a tag or felt pen. Keep in sets according to the cap number. them
in a safe place and be careful
them.
110 SERIES
Keep
not to damage
DISASSEMBLY
OVERALL
DISASSEMBLY
DISASSEMBLY
AND ASSEMBLY
35. Camshaft 1) Remove thrust plate (1). 2) Remove camshaft (2). 36.
Front plate 0
37.
Tappets 0
38.
Remove front plate (3).
Remove tappets (1).
Cylinder liner l l
Turn over engine so that cylinder head side is at top. Before
removing
the
cylinder
liner,
measure
the
protrusion of the liner. *
If there
is any
mounting
gasket, or any leakage of water into the
oil
always
pan,
without l
leakage from measure
the cylinder
the
liner
head
protrusion
fail.
The standard for the liner ID is determined it is assembled
in the cylinder
block.
for when
So to judge
wear of the liner ID, measure it before removing the liner. 1) Set tool C in position. 2) Rotate
tool
counterclockwise
and remove
cylinder
liner (1).
6136F302
13-018
110 SERIES
OVERALL
ASSEMBLY
OVERALL
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
4 Camshaft
L Cylinder block
Front plate
19
I
13-102 0
110 SERIES
DISASSEMBLY
OVERALL
AND ASSEMBLY
I
24 -II
\
ASSEMBLY
26
II
36
30
III
6138F311
110 SERIES
13-103
OVERALL
DISASSEMBLY
ASSEMBLY
AND ASSEMBLY
Special tools required for overall assembly Part Name
Part No.
-
BCDEFGH
1
790-501-2000
Engine overhaul stand
1
790-901-I
* Adapter plate
1
106
1
795-215-2000
Remover
795-l 00-2800
Piston ring tool
795-l 02-2101
Spring pusher
795-217-2800
1 Pistbn holder
795-215-I
1 Seal guide
800
795-l 16-l 330
Preparatory .
A
Engine stand
1 1
I
I
I
I
I
Ill
I II
Feeler gauge
1
11
work
Install tool Bâ&#x20AC;&#x2122; on cylinder
block, raise and set on engine
overhaul stand B.
13-104
110 SERIES
DISASSEMBLY
OVERALL -ASSEMBLY
AND ASSEMBLY
1.
Cylinder liner
*
For each cylinder,
check that the mark on the cylinder
Liner
m
1 or11 mark
liner and stamped mark (A or B) at the top and top left side of the cylinder block are correctly positioned. Mark Liner Part No.
Block mark
Bottom
*
Top
A
6138-21-2210
A
1
B
6138-21-2220
B
11
Clean the press-fitting cylinder
Liner mark Aor 8
6136FO25
surface of the cylinder
block thoroughly.
(Completely
liner and
remove the rust
preventive oil from the liner) *
Coat the press-fitting
surface of the cylinder
liner and
cylinder block thinly with engine oil (E030). 1) Bet cylinder liner (1) on cylinder block. *
Bet the cylinder
liner (1) with the top mark facing
the front of the engine.
2) Using tool C, press fit liner in block. *
Press fit slowly for the first 10 - 20 mm and make sure that the liner is not at an angle.
*
If the liner is not straight, there is a danger that it will
crack.
Use a pulling tool to remove it and
press fit from the beginning again. *
If there
is any dust or dirt
on the press-fitting
surface of the liner or the bottom flange, the liner will be deformed will not be even. putting
a wooden
surface of the
or the protrusion
Never try to install the liner by block on top of the liner and
hammering the liner into the block.
11_
110 SERIES
6138FO26
13-105
OVERALL
DISASSEMBLY
ASSEMBLY
AND ASSEMBLY
3) Measure protrusion of cylinder liner l
After
press-fitting
the cylinder
liner, measure the
amount that the cylinder liner protrudes. *
Protrusion of cylinder liner:
0.05 to 0.13 mm
4) Measure inside diameter of cylinder liner l After press-fitting the cylinder liner, measure the inside diameter
of the cylinder
liner and check
that it is within the standard value.
2.
Tappets l l
Turn over engine so that crankshaft side is at top. Assemble tappets (1). *
Check
that
the
tappets
move
up
and
down
smoothly.
3.
Front plate l
Fit gasket and install front plate (1). *
There
is a danger that the bolt cannot be aligned
when
the front
ear case is installed,
so coat the
gasket with gasket sealant before installing. *
13-106
Be sure to tighten all four mounting bolts.
110 SERIES
DISASSEMBLY
4.
AND
OVERALL
ASSEMBLY
ASSEMBLY
Camshaft 1) Assemble camshaft (2). *
Be careful
not to damage the cam bushing when
installing. *
Must not knock at the gear with hammer.
2) Install thrust plate (1).
5.
Idler gear shaft l
Align
position of roll pin, and install idler gear shaft
(1).
6.
Crankshaft 1) Align
protrusion
of
upper
main
bearing
(4)
with
notch in cylinder block, and install. *
After
installing the bearing, coat the sliding surface
with engine oil.
2) Install upper thrust bearing (3) on crankshaft side. *
Install the thrust
bearing with the groove on the
outside. *
Check that the protrusioti
of the roll pin is 1.5 to
1.9 mm. *
Coat the sliding surface of the thrust bearing with engine oil.
110 SERIES
13-107 0
OVERALL
DISASSEMBLY
DISASSEMBLY
3) Using a nylon sling, raise crankshaft
AND ASSEMBLY
(2) and set in
position on cylinder block. *
When
assembling,
align
the
A
mark
on
the
crankshaft gear with the A mark on the idler gear. *
When installing the crankshaft,
be careful
not to
let it hit or damage the cylinder block.
4) Align
protrusion
of
lower
main
bearing
(5)
with
notch in main bearing cap and install bearing on cap. 5) Assemble
lower thrust
bearing (6) on both sides of
No. 7 main cap bearing. *
Install the thrust
bearing with the groove on the
outside. *
Check that the protrusion
of the roll pin is 1.5 to
1.9 mm. 6) Assemble main bearing cap (I). *
Coat the sliding surface of the bearing with engine oil before installing.
*
Match
bearing no. and block no., and install the
main bearing cap with the â&#x20AC;&#x153;Fâ&#x20AC;? mark facing the front of the engine 7) Tighten bolts of main bearing cap as follows. *
Coat the threads
of the bolts and the seat face
with engine oil before tightening the bolts. *
Tighten both bolts uniformly m
in turn.
Main bearing cap Unit:
Order
Target
1st step
Range
7
2nd step
20
6-8 IQ-21 Loosen completely
3rd step
0
4th step
7
5th step
14
13-
6th step
20
19 - 21
*
After
tightening
kgm
6-8
the bolt,
shaft rotates smoothly.
15
check that the crank-
There must be no catching
or other abnormality.
13-108
110 SERIES
DISASSEMBLY
OVERALL
AND ASSEMBLY
ASSEMBLY
8) Measure end play of crankshaft l
After
tightening the main bearing cap, measure the
end play of the crankshaft. *
End play of the crankshaft:
0.14 to 0.315 mm
7.
Piston, connecting rod assembly
*
Assemble piston and connecting rod assembly as follows. i)
Install expander
(6) on piston (4).
ii) Using tool D, install oil ring (7). Install the piston ring with the stamped mark at the end gap facing up. When
fitting
the
oil
ring,
expander is fitted completely Position the expander
check
that
the
inside the oil ring.
and oil ring as shown in
the diagram.
*
,, ,, ,,
6136F304
a: Join of coil b: Teflon tube c: End gap
iii) Install compression ring (5). *
If the connecting install
the
rod bushing has been removed,
bushing
with
push tool @
(0.D.50
mm).
110 SERIES
13-109
OVERALL
DISASSEMBLY
ASSEMBLY
iv) Set “FRONT” number
on
direction.
AND ASSEMBLY
mark on piston head and cast part connecting
Insert
piston
rod pin
facing (3)
the
and
same
assemble
connecting rod (2) with piston pin. If the piston pin will
not go in easily, warm the
piston in hot water before installing. Match the numbers on the piston connecting rods with the cylinders. Use an electric pen to mark the cylinder
numbers
on the connecting rods. Install snap rings (1) on both sides. Turn
over engine to put cylinder
block facing
the side. Set the crankshaft cylinder
pin to top dead center in the
where the piston and connecting
rod
assembly is to be installed. Coat the inside surface of the cylinder, and the surface of the piston rings and connecting
rod
bearing with engine oil.
1) Align end gaps of piston rings as shown in diagram. 2) Insert piston and connecting
rod assembly (2) from
cylinder head side as far as piston ring. *
Assemble
the
piston
with
the “FRONT”
mark 6136FO31
facing the front of the engine. *
Assemble the piston and connecting
rod assembly
with the cylinder number facing the cam side.
3) Using piston holder F, compress piston rings and push piston head with a wooden bar. Then pull big end of connecting rod and fit on crankshaft
13-110
pin.
110 SERIES
DISASSEMBLY
OVERALL
AND ASSEMBLY
ASSEMBLY
4) Align notch in connecting rod cap with protrusion in lower bearing of connecting rod and install bearing.
5) Match cylinder cap cylinder Install
number
number
connecting
stamped on connecting stamped
rod
cap
on connecting (1)
so that
rod rod.
stamped
number is on cam side. *
Coat connecting rod cap bearing with engine oil.
6) Assemble connecting rod cap as follows. *
Coat the threads
of the
bolts and the seat face
with engine oil before tightening the bolts. *
Tighten the bolts uniformly m
in turn.
Connecting rod cap: Unit: kgm
Order
Target
Range
1ststep
6
5-7
2nd step
11
IO-2
3rd step
0
4th step
6
5th step
11.2
Loosencompletely 5-7 10.6 - 11.7
* After tightening the bolt, check that the crankshaft rotates
smoothly.
There
must
be no catching
or
other abnormality.
7) Measure side clearance of connecting rod cap l
After
installing
the
piston
and
connecting
rod
assembly, measure the side clearance between the cap and the side face of the crankshaft.
* Side clearance of cap:
110 SERIES
” ,,‘, ,‘,’
0.16 to 0.33 mm
13-111
_ . .. OVERALL
8.
DISASSEMBLY
ASSEMBLY
Flywheel
AND ASSEMBLY
housing
1) Using push tool @
(O.D.
135 mm), press fit rear seal
on housing. *
Press fit until the face of the seal plate is level with the face of the flywheel
*
If there
housing boss.
is any wear on the lip contact
surface
(over 0.1 mm, enough for fingernails to catch) or if it is worn as mirror surface, move the rear seal forward about 3 mm when assembling.
Flywheel housing Rear seal
Lip contact surface
6138FO27-1
2) Install tool G on end face of crankshaft. 3) Using eye bolts @ housing (1).
(12 mm, P = 1.75), raise flywheel
Fit gasket,
align dowel
pin hole and
Coat lip surface of rear seal iip space) with grease (G2-Ll).
(50 to 80% of
install. 4
*
Tighten mounting m
the flywheel
housing and cylinder
block
bolts in the order shown in the diagram. Flywheel
housing mounting bolt: 11 f 1.5kgm
6136F305
13-112
110 SERIES
DISASSEMBLY
4) Measure face runout housing.
OVERALL
AND ASSEMBLY
After
and radial runout
installing
the
ASSEMBLY
of flywheel
flywheel
housing,
measure the face runout and radial runout.
9.
*
Repair limit of face runout:
0.35 mm
*
Repair limit of radial runout:
0.3 mm
Flywheel 1) Screw guide bolt @
(14 mm, P = 1.5) into mounting
face of flywheel. 2) Set flywheel
(2) on crankshaft.
3) Tighten flywheel *
mounting bolts
(1) as follows.
Coat the threads of the bolts, the seat face, and the washers with
engine oil before tightening
6
the
bolts. l
Tighren the bolts in the order given in the diagram, and to the following tightening torques. B
Flywheel
Unit: kgm Target
1ststep 2nd steD
9 18
Range 6-12 16-20
1
T .â&#x20AC;? 4
mounting bolt:
Order
p_
7. 3
l .
2 .-
5
6136F306
4) Measure face runout and radial runout of flywheel. l
After
installing
the
flywheel,
measure the face
runout and radial runout. *
Repair limit of face runout:
*
Repair limit of radial runout:
110 SERIES
0.2 mm 0.15 mm
13-113
OVERALL
10.
DISASSEMBLY
ASSEMBLY
AND
ASSEMBLY
Oil pump l
Install oil pump (2).
*
When
assembling the oil pump,
-.“DISASSEMBLY
see the Section
AND ASSEMBLY”:Trochoid
Engine No. 10001 - 50000:
:
50001andup
pump
Gear pump
11. Drive gear for fuel injection pump Knock key (7) into shaft (6). press fit gear (8), then press fit bearings (9) and (10).
Assemble washer (11)
and tighten nut (12). w
Nut:
33 + 2 kgm
Install drive gear (1) for fuel injection pump.
12.
Drive gear of oil pump 1) Assemble idler gear (3), align position of roll pin and install thrust plate (4). m
11 f 1.5 kgm
Mounting bolt:
2) Install drive gear (5) of oil pump.
\9 6 6138F315
*
Check that
the
match marks of all drive gears and
idler gears are correctly
*
aligned.
Measure the backlash and end play of each gear. Align
l
assembling the drive gears and idler gears,
measure the backlash and end play of the following gears. i)
Backlash
Position
13-114 0
Gears
Range (mm)
110 SERIES
DISASSEMBLY
OVERALL
AND ASSEMBLY
*
End play of camshaft:
0.15 to 0.35 mm
*
End play of idler gear:
0.05 to 0.21 mm
ASSEMBLY
13. Gear case cover 1) Using push tool
press fit oil seal (2)
in case.
14. Crankshaft pulley 1) Align
key
of
crankshaft,
and assemble crankshaft
pulley (3). 2) Assemble taper collar (4). 3) Fit plate (2) and install bolt (1). Ir
Coat the bolt thread and seat surface with engine oil. m
110 SERIES
Mounting bolt:
38 + 3 kgm
13-115
OVERALL
15. Vibration l
DISASSEMBLY
ASSEMBLY
AND
ASSEMBLY
damper
Assemble spacer (2) and install vibration damper (1). *
Install the vibration
damper with the concave side
on the inside.
16. Suction tube .
Turn over engine to put crankshaft sie at top.
l
Fit O-ring and install suction tube (1).
17. Oil pan 1) Cut gasket so that it is level with cylinder block, front cover and flywheel 2) Check difference
housing lower face. in level with cylinder block. (Unit:
mm)
Difference in lower face
Measurement point
Within 0.04 (recess: within 0.22)
Block and front plate Block and front cover
I
Within 0.105
Block and flywheel housing
1
Within 0.13
3) Coat three Bond No. 45 on joining surface (stepped part) of oil pan, front cover, front plate and flywheel housing.
13-116
110 SERIES
DISASSEMBLY
OVERALL
AND ASSEMBLY
4) Fit gasket and install oil pan (1). t
Arrange the hot-rolled
face (polished face)
of the
gasket, and set it facing down on the surface of the oil pan. +
To
make
compound
assembly
easier,
use an
adhesive
(Three Bond No. 201) and stick the
gasket on the oil pan.
18. Cylinder head *
Assemble cylinder head as follows.
*
If the valve guide has been removed, use push tool I to install valve guide (7).
i)
Install valve (6). *
Coat
the
stem
of
the
valve with
engine oil
(EOSO-CD).
6136F308
ii)
Assemble
spring seat (4),
valve spring (3)
and
spring guide (2).
*
Valve spring Engine No. 10001 - 50000: 50001
Engine No. 50001
and up
Equal pitch
:
Unequal pitch
and up use an unequal pitch
valve spring, so be sure to install with the tight coils at the bottom
110 SERIES
(cylinder
head end).
ASSEMBLY
OVERALL
ASSEMBLY
DISASSEMBLY
AND ASSEMBLY
,ii) Using valve pusher B, compress valve spring and fit valve cotter (1) on valve stem. *
Remove tool B and tap the valve stem with a plastic hammer to check that the cotter is completely fitted.
*
The material of the cylinder head differs according to whether
a turbocharger
is mounted
or not, so
be careful when replacing or modifying. Ir The shape of the intake port swirl is different the construction
equipment
for
engine and the marine
engine, so be careful when procuring or repairing.
. Turn over engine to put cylinder head side on top. * Check that the mounting surfaces of the cylinder head and cylinder block are clean and that there is no dirt or foreign matter inside the cylinder.
1) Install cylinder head gasket (2).
2) Raise cylinder
head
assembly
(I),
use about
four
mounting bolts as guides and set on cylinder block.
3) Coat thread of mounting bolts with antifriction
com-
pound or engine oil. Tighten mounting bolts in order shown
in
diagram
and
to
following
tightening
torques. &
Mounting bolt: Antifriction
m
(LM-P)
Cylinder head:
-
Order
Antifriction
compound
Target 1St step
3rd step
13 18
Engine oil
Range
9
1
2ndstep
*
compound
Target
8 - 10
1
12-14
17.5 - 18.5
Range
9
1
13 20
S-10
1
12-14 19.5 - 20.5
Order for tightening cylinder head bolts Center
6136FO35
13-118
110 SERIES
DISASSEMBLY
AND
OVERALL
ASSEMBLY
ASSEMBLY
19. Push rods l
Assemble push rod (1). t
The push rods on the intake and exhaust sides are the same part.
*
Check that the push rod is properly
fitted
into the
tappet.
20.
Rocker arm assembly 1) Position rocker arm assembly (1). *
Check that the ball of the adjustment
screw is pro-
perly fitted into the socket of the push rod. *
If the spring is pushing the rocker arm, loosen the adjustement
screw.
2) Tighten mounting bolt (2). 3) Adjust valve clearance as follows. Adjust clearance between valve and rocker arm as follows (cold). Intake valve:
0.35 mm
Exhaust valve:
0.65 mm
Firing order: Rotate align
1- 5 - 3 - 6 - 2 - 4
the crankshaft pointer
crankshaft
(4)
in the normal direction
with
pulley
the
(3).
1.6
TOP
to
mark
When rotating,
on
check the
movement of the valves. *
When No. 1 cylinder is at compression top dead
*
When No. 6 cylinder
center, adjust the valves marked 0. is at compression top dead
center, adjust the valves marked 0.
Intake valve Exhaust valve
110 SERIES
2
1
Cylinder No.
0
0 l
3
0
4 0
0
0 0
6
5
0
0 0
0
13-119
OVERALL
DISASSEMBLY
ASSEMBLY
2) To adjust,
insert feeler gauge H between
AND
ASSEMBLY
rocker arm
(5) and valve stem (6) and turn adjustment screw (7) until clearance is a sliding fit.
3) Tighten
lock nut (8) to
hold adjustment
screw in
position. w +
Lock nut: After
tightening
3.2 f 0.3 kgm the lock nut, check the clearance
again.
21. .
Cylinder head cover Fit O-ring and install cylinder head cover (I). *
Apply
adhesive compound
head cover without w
22. *
and fit the O-ring of the
twisting.
Head cover mounting bolt:
0.9 z 1 kgm
Nozzle holder Check that there is no dirt or damage inside the holder sleeve or on the contact surface of the nozzle holder.
*
Coat the thread of the nozzle holder mounting bolt with engine oil.
.
Install nozzle holder (2) in cylinder head. *
Tighten
the nozzle holder mounting
bolts uniformly
to prevent them from being unevenly tightened. m
Mounting bolt:
1.7 f 0.2 kgm
23.
Spill pipe
.
Fit gasket and install spill pipe (1).
13-120
110 SERIES
DISASSEMBLY
AND
OVERALL
ASSEMBLY
ASSEMBLY
24. Water pump .
Fit gasket and install water pump (1).
25.
Alternator 1) Temporarily
install plate (4).
2) Assemble spacers, then set alternator *
Install
the thick
(3) in position.
spacer at the rear and the thin
spacer at the front. 3) Tighten
mounting
bolts
(2) and (I)
to temporarily
install alternator.
26.
Fan belt 1) Install fan belt (3). 2) Adjust fan belt tension as follows. i)
Raise alternator
to outside and tighten alternator
mounting bolt (2) and plate mounting bolt (1). ii) After adjusting tension, tighten bolts fully. iii) After
adjusting
tension,
check
amount
belt
deflects when pushed by a finger force of 6 kg at a point
midway
between
fan pulley
and alternator
pulley. *
Standard slack:
5to
10mm
6 kg.
6138F317
110 SERIES
13-121
OVERALL
DISASSEMBLY
ASSEMBLY
AND ASSEMBLY
27. Air compressor 1) Fit gasket, align match mark â&#x20AC;&#x153;0â&#x20AC;? of split-red part and install air compressor (2). *
Mounting bolt thread:
*
Align
the gasket with
Thread tightener the front
(LT-2)
plate hole when
installing. 2) Fit gasket and install oil feed tube (1) of air compressor.
28. Oil cooler 1) Fit gasket and install oil cooler (2). 2) Fit O-ring and install oil cooler inlet tube (1). *
For the parts where the tube is tightened with the cooler mounting
bolt,
insert a plate between the
cooler and the tube support, then tighten.
29. Fuel injection pump
1) Knock key into drive shaft of fuel injection pump. 2) Put fuel injection pump (4) and bracket (5) together, align key groove of pump coupling and fit pump drive shaft.
3) Secure bracket. 4) Install bolts (3) connecting fuel injection pump and air compressor. m
Connecting bolt:
5.2 f 0.2 kgm
5) Adjust fuel injection timing as follows. i)
Rotate
crankshaft
pointer
(7) with
in normal injection
direction
timing
and align
line on crank-
shaft pulley (6). *
When doing this, if the line on the timer side is not at the front, rotate one more turn.
13-122
110 SERIES
DISASSEMBLY
AND
OVERALL
ASSEMBLY
ASSEMBLY
ii) Align line A on injection pump side with line B on timer side. iii) In this position, tighten four pump mounting bolts (8) uniformly *
After
and in turn.
repairing
or replacing the fuel injection
pump, or if there is no line, adjust the injection timing by the delivery method.
Align A
30. .
6138FO26
Thermostat Fit gasket and install thermostat *
*
Align B
with case (1).
Engine hanger (2) is tightened with the same bolt.
If the
thermostat
has been
removed
from
the case,
assemble with the leak hole positioned as in the diagram. Leak hole
h
6136FO33
110
SERIES
13-123
OVERALL
31.
ASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
Aftercooler 1) Assemble
ribbon
heater
(4)
as shown
in diagram
below. *
Coat all of surface of area A with adhesive compound
(Three
Bond
No.
1215)
and
stick
in
position.
6138F318
2) Fit gasket and position ribbon heater (4) on cylinder head as shown in diagram below. +
Install the ribbon heater so that the terminals are positioned as shown in the diagram. Terminal
I Rear of engine a
Ii%
r
1~
w 3) Using eye bolts @ assembly
(3).
fit
6138F319
(8 mm, P = 1.25), raise aftercooler gasket
and
install
together
with
ribbon heater. m
Mounting bolt:
3.1 f 0.3 kgm
4) Fit gasket and connect aftercooler
outlet tube (2).
5) Fig gasket and connect aftercooler
inlet tube (1).
6) Connect
wire
(ground
connection)
and the wiring
between relay switch and ribbon heater at switch end.
32.
Fuel injection pipe 1) Install fuel injection pipe (3). 2) Connect hose (2). 3) Install boost compensation
13-124
pipe (1).
110 SERIES
DISASSEMBLY
33. .
AND
OVERALL
ASSEMBLY
ASSEMBLY
Oil filter Fit O-ring, and install oil filter
(6). oil filter
inlet tube
(4) and outlet tube (5). *
The clamp for the engine breather hose is tightened with the outlet tube mounting bolt.
34.
Fuel filter 1) Install fuel filter (3). 2) Connect fuel filter inlet hose (1). 3) Connect fuel filter outlet hose (2). *
The intermediate
bracket of the fuel hose is tightened
with the aftercooler
35.
mounting bolt.
Resetting engine in engine stand
1) Sling
engine
assembly,
remove
bolts
connecting
adapter plate and overhaul stand to disconnect engine assembly.
2) Set engine assembly (I) on engine stand A. 3) Remove adapter plate Bâ&#x20AC;&#x2122;.
110 SERIES
13-l 25
.â&#x20AC;&#x2122;
OVERALL
DISASSEMBLY
ASSEMBLY
36.
Turbocharger,
*
When
AND
ASSEMBLY
exhaust manifold assembly
connecting the inlet and outlet pipes, and oil feed and return tubes to the turbocharger, make sure
that
there
is no twisting
or any other
excessive force
on the pipes and tubes. 1) Fit gasket and install turbocharger
(4) and exhaust
manifold assembly. *
Assemble the gasket with the mark on the outside.
m
Mounting bolt:
2) Connect intermediate
6.5 + 1.0 kgm
hose (3) between turbocharger
and aftercooler. 3) Connect tube (2) between turbocharger
and cylinder
block. 4) Install muffler drain pipe (1).
1) Check that engine drain plug is tightened. 2) Add engine oil through oil filler. Q *
1
Engine oil pan:
Approx.
28 Q
Check the oil level after mounting
the engine on
the machine, and add oil to the specified level.
13-126
110 SERIES
DISASSEMBLY
AND
ASSEMBLY
Item
OF COMPONENTS
Page
Turbocharger Disassembly
13-201-l
Assembly
13-2014
Oil pump Disassembly
13-202
Assembly
13-203
Water pump
110 SERIES
Disassembly
13-204
Assembly
13-206
13-201 0
DISASSEMBLY
*
The
AND
subsequent
disassembling
should be performed
DISASSEMBLY
ASSEMBLY
and
reassembling
in a KOMATSU
authorized
AND
ASSEMBLY
OF
CdMPONENTS
operations maintenance
shop.
9 Center housing A&
7 Rotor
Wheel shaft AS’Y
Ass’y
15 Retaining
rina
Center housing
Thrust collar Ass’y
Acc’v
I .--I I -
’
I
1
Piston ring 1
1
13F015A
5. Locknut 1) Secure cartridge
holder with
a vice.
Put rotor ass’y (4) in the
holder and keep it so that the end of wheel shaft is set in socket. 2) Remove lock nut (6). using T wrench C. t
If the lock nut is removed, the wheel shaft ass’y will fall out of the rotor ass’y.
Therefore,
when carrying the rotor ass’y,
be sure to support the wheel and center housing sections by two hands.
6. Impeller 1) Remove
rotor
ass’y (4) from
the cartridge
holder and rest it
on blower housing (3). 2) Remove back plate (7) mounting bolts. 3)’ Remove impeller
(8) out of place.
7. Back plate
- Remove back plate (7) out of Place. 8. Wheel shaft ass’y
* Remove wheel shaft ass’y (9) from center housing (10). 9. Shroud
-
Remove shroud (11) from the center housing.
110
SERIES
l-3-201-2 0
DISASSEMBLY
AND
ASSEMBLY
OF
DISASSEMBLY
COMPONENTS
AND
ASSEMBLY
10. Piston ring *
Remove
piston ring (12) from wheel shaft ass’y by separat-
ing the mating parts wide by fingers.
11. Thrust collar ass’y -
Remove. thrust
collar ass’y (13)
from
center housing (IO).
12. Thrust bearing 13.
Remove
thrust
bearing
(14)
from
center
housing
(10).
Seal ring
* Remove seal ring (15) from center housing (10) 14.
Piston ring .
15.
Remove
piston
ring
(16)
from
thrust
collar
ass’y (13).
Retaining ring and bearing
1) Remove
outer
retaining
ring
(17)
from
the
blower
side of
center housing (IO), using a retaining ring remove D.
2) Remove
bearing (18) from
(IO). 3) Remove
inner
retaining
the blower
ring from
side of center housing
the center
housing
in the
same manner as described in 1) above. 4) Remove retaining
ring (17)
and bearing (18) from the turbine
side of center housing (10) in the same manner as described in l), 2) and 3) above.
13-201-3 0
110
SERIES
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY
ASSEMBLY
AND ASSEMBLY OF COMPONENTS
OF TURBOCHARGER
1
4
5
6
Center A
housing
8
9
10
7
8
11
12
A
13FOl6A
Tools to be prepared
Part Name
Japan Gallet P/N 801066
Lubriplate
801051
Deep socket
801090
Cartridge holder
801059
1T-wrench
801058
Retaining ring remover
801050
Piston ring guide
801052
I Pig
801056
1Radial
play measuring tool
IGTH
I-l~l6lClDlEl~ 1 1 1
I
I
I
III
I I I I 1 1
I I I I I I Ill I I I I I I I I Ill
601057
Radial play measuring probe
801083
End play measuring tool
1
801054
End play measuring probe
1
110
SERIES
1
13-201-4 0
DISASSEMBLY
AND
ASSEMBLY
OF
DISASSEMBLY
COMPONENTS
AND
ASSEMBLY
1. Retaining ring and bearing 1) Insert retaining ring (17) into center housing (lo), ing ring remover 0. *
using retain-
Make sure that the mating ends of ring are in a correct contact with each other with the oil outlet side up.
2) Coat the inner and outer surfaces of bearing with engine oil. 3) Set bearing (18) in the center housing. 4) Insert the outer retaining ring in the same manner as described in 1).
18
Oil outlet port
13FOl7
2. Piston ring +
Install piston ring (16) on thrust collar (19).
3. Thrust bearing 1) Coat thrust bearing (14) with engine oil. 2) Install the thrust bearing in groove in thrust collar (19). + At this time, oil groove (a) in the thrust collar should face outside.
4. Thrust collar assâ&#x20AC;&#x2122;y
- Install thrust collar assâ&#x20AC;&#x2122;y in center housing (10). 5. Seal ring
-
Install seal ring (15)
in the groove on the circumference
of
center housing (10).
13P219,
6. Back plate 11 Coat the ihside hole of back plate with engine oil. 2) Install back plate (7) with threaded hole in plate and drilled hole in center housing (IO) aligned with each other. *
Provide
a space for name plate away from
oil hole in the
housing.
13-201-5 0
110
SERIES
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
OF
COMPONENTS
3) Hold the center housing and back plate by hands, taking care not to allow the set parts to get out of place, and turn them with the back plate down. 4) Tighten the back plate (7) mounting bolts. Tightening
torque
of the back plate mounting
bolts:
0.95 f 0.1 kgm
7. Piston ring *
Install
piston
ring (12)
on wheel
shaft
(20).
using piston
ring guide E.
8. Wheel shaft ass’y I)
Rest center housing ass’y (21)
on blower
housing (3) used as
support.
2) Coat a bearing section in wheel shaft ass’y (9) with oil. 3) Contract piston ring in the wheel shaft ass’y, using pig F and insert wheel into the center housing, rotating the wheel gently. 9. Shroud * IO.
Install shroud (11) in center housing ass’y (21). Impeller
1) Remove the center housing wheel
shaft ass’y from the blower
housing and set it in cartridge holder B. 2) Coat
the
impeller
mounting
thread area with lubriplate
shaft and the lock nut installing
(to prevent seizure).
3) Install impeller (8).
11.
Locknut
1) Tighten lock nut (6). Lock nut tightening torque: 2) Retighten
110
the
SERIES
lock
nut
further
0.22 f 0.01 kgm
by 90°,
using T-wrench
C.
13-201-6 0
-. ’
DISASSEMBLY
AND
ASSEMBLY
OF
COMPONENTS
12
DISASSEMBLY
13
14
15
AND
ASSEMBLY
16
Turbine housing
13F019A
12.
Rotor ass’y
1) Install *
ass’y (4) in turbine housing (I).
rotor
Install the rotor ass’y gently, taking care not to impair parts.
*
Install
the turbine
housing in place as shown in schematic
drawing. *
drilled
Locate
2) Coat
turbine
hole in shroud so as to face an oil inlet side.
housing
mounting
bolt
holes with
antifriction
compound. +
Antifriction
compounds:
NICHIMOLI COAT
PG Paste or MOLI‘j,
AST Compount
* 1
3) Tighten the turbine housing mounting bolts. Tightening
torque
of turbine
housing mounting
t 3P.227
bolts:
1.7 f 0.1 kgm 4) Bend lock plates. Oil
as viewed from turbine side I3FO20
13.
Diffuser Install diffuser (5) on back plate (7). Bring
protrusion
protrusion
(c)
(b) of
the
of the diffuser back
to the right
plate to prevent
side of
the diffuser
from turning clockwise. If the diffuser has three protrusions,
bring these protrusions
in holes in the back plate.
I3P228
14.
Blower housing
1) Install blower
housing in place as shown in schematic drawing
below.
Oil oket (as viewed from dower
side)
I 3FO2
I
2) Tighten the blower housing mounting bolts. m
13-201-7 0
1.35 kO.15
kgm
110
SERIES
DISASSEMBLY
15.
AND
ASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
OF COMPONENTS
V band
- Attach
and tighten
V band
(2),
using deep socket A and
torque wrench (d). V band tightening torque: 0.8 f 0.1 kgm
16.
Checks after completion
of assembling
I) Make sure that the rotor assâ&#x20AC;&#x2122;y rotates smoothly push thereto. 2) Check play of rotor in the radial direction i)
Attach
a measuring
housing (10)
instrument
by giving light
(radial play).
G to oil outlet
of center
and set a dial gauge so that its probe comes
into contact with shaft. ii)
Hold
the rotor
by hands on both
parallel in the radial direction +
Rotor
radial
play
(allowable
ends and move it in
to measure play. 0.075
range:
31 Check play of rotor in the axial direction. i)
Set dial gauge in end play replace
the
mm
(End play)
measuring
gauge probe with
to 0.150
instrument
an exclusive
H and
one for
this
measurement. ii)
Attach
the measuring
instrument
to inlet port in blower
housing (3) and set the dial gauge so that a probe comes into contact with the shaft end, iii) t
Measure end play by moving the rotor in its axial direction. Play of rotor in axial direction Allowable
110
SERIES
(End play)
range: 0.025 to 0.075
mm
13-201-8 0
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY TROCHOID
AND
DISASSEMBLY
COMPONENTS
ASSEMBLY
AND
ASSEMBLY
OF OIL PUMP
PUMP (Engine No. 10001 - 49999)
DISASSEMBLY 1.
Remove cover (1).
2.
Remove
3.
Disconnect gear (3) and inner rotor (4).
4.
Remove bushing (5).
5.
Remove dowel pin (6).
outer rotor (2).
,,,
13-202 0
,,,
,,
110 SERIES
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
COMPONENTS
ASSEMBLY 1.
Install bushing (5).
2.
Knock in dowel pin (6).
3.
Press fit gear (3) on inner rotor (4).
4.
Install outer rotor (2).
5.
Align dowel pin and install cover (1).
110
SERIES
13-203
DISASSEMBLY
AND
DISASSEMBLY
ASSEMBLY
AND
DISASSEMBLY
COMPONENTS
ASSEMBLY
OF WATER
AND ASSEMBLY
PUMP
DISASSEMBLY 1.
Remove nut (1).
2.
Using puller 0,
3.
Remove snap ring (3). then remove cover (4).
4.
Using puller@,
13-204
remove fan pulley (2).
remove impeller (5).
110 SERIES
DISASSEMBLY
5.
6.
AND ASSEMBLY
DISASSEMBLY
AND
ASSEMBLY
COMPONENTS
Remove snap ring (6).
Remove shaft (7) from impeller side. *
Remove shaft and bearing as one unit.
7.
Remove water seal (8).
8.
Remove bearings (9) and (10) from shaft.
110 SERIES
-Wq&>, + “‘,,‘,
,j ,\\
,,
13-205
y/ DISASSEMBLY
AND
ASSEMBLY
COMPOhlENTS
DISASSEMBLY
AND
,:... ASSEMBLY
ASSEMBLY 1.
Install bearings (9) and (IO) on shaft. *
The side of the bearing where the ball can be seen faces the inside.
2.
Install shaft assembly (7) in water pump case (11) from pulley side. &
Space between bearings:
Grease (G2-Ll)
3.
Secure shaft assembly with snap ring (6).
4.
Press fit fan pulley (2).
5.
Tighten nut.
13-206
110 SERIES
DISASSEMBLY
AND ASSEMBLY
6.
Install water seal (8).
7.
Press fit impeller (5).
8.
Fit O-ring and install cover (4).
9.
Install snap ring (3).
110 SERIES
DISASSEMBLY
AND
ASSEMBLY
COMPONENTS
13-207
14 MAINTENANCE
STANDARD
110
Engine
14
110 SERIES
SERIES
Numbers:
10001
and up
MAINTENANCE STANDARD
MAINTENANCE
INTAKE AND EXHAUST Turbocharger
STANDARD
SYSTEM ......................................................
.....................................................................
ENGINE BODY .......
14-004
.: ...............................................................
Cylinder head ..................................................................... Valve and Valve guide ..............................
14-004
14-005 14-005
I ..............................
14-006
Rocker arm, Push rod and Tapet ....................................................
14-008
Cylinderliner
14-009
.....................................................................
Cylinderblock.. Crankshaft Camshaft
..................................................................
.......................................................................
14-010 14-012
........................................................................
14-013
Piston, Piston ring and Piston pin ...................................................
14-014
Connectingrod..
14-016
Timinggear
.................................................................
......................................................................
Flywheel and Flywheel housing LUBRICATION Oilpump
.....................................................
14-018
SYSTEM ................................................................
14-019
.........................................................................
14-019
Regulator valve and Safety valve
...................................................
COOLING SYSTEM .................................................................... Water pump and Thermostat
110 SERIES
14-017
.......................................................
14-02 1 14-023 14-023
14-003 0
INTAKE
AND
EXHAUST
INTAKE
SYSTEM
AND
MAINTENANCE
EXHAUST
STANDARD
SYSTEM
TURBOCHARGER
5 8
3 14F036-2B
14FO36-10
14FO366
Unit: NOI.
mm
Criteria
Check item
-
1
Standard size
Repair limit
0.075 - 0.150
0.18
0.025 - 0.075
0.10
Radial play of rotor
2
End play of rotor
3
Thickness of thrust bearing
â&#x20AC;&#x2122;
4.35
4.36
I
Outside diameter of wheel shaft
Repair or replace
I I
Measuring portion
Standard size
Repair limit
A
17.340
17.25
B
10.155
10.15
4
Repair limit:
Bend of wheel shaft
Inside diameter of back plate
5
6
Inside diameter of center housing
0.010
Repair limit
Standard size
I
12.70
I
Measuring portion
Standard size
Repair limit
C
15.80
15.81
D
18.03
18.08
Tightening torque blower housing boltof
1.3 + 0.15 kgm
8
Tightening torquebolt of turbine housing
2.0 + 0.2 kgm
0
12.73
I
7
14-004
Replace
(Total indicator reading)
110 SERIES
MAINTENANCE
ENGINE
STANDARD
BODY
ENGINE BODY CYLINDER
HEAD
Center
Front
Rear
6136FO35
6136FO34
Unit: No.
Check item
Criteria
mm
Remedy
Tolerance 1
Deformation of cylinder head mounting surface
Repair limit Grind or replace
0 - 0.09
0.12
Engine No.
Standard
10001 - 49999
0.79 - 1.71
50001andup
1.29 - 2.21
-
2
Protrusion of nozzle
Molybdenum sulphide
3
Tightening torque of cylinder head mounting bolt (Coat thread with molybdenum sulphide or engine oil)
4
Tightening torque of nozzle holder mounting bolt
Replace nozzle sleeve
Engine oil
Order
Target
1kgm)
Range (kgml Tighten
1.75
1.5 - 2.0
-
110 SERIES
14-005 0
ENGINE
BODY
VALVE AND
MAINTENANCE
STANDARD
VALVE GUIDE
6136F036
14-006 0
110 SERIES
MAINTENANCE
STANDARD
ENGINE
Unit: Nc
Check item
BODY
mm
Remedy
Criteria I
Engine No.
Valve
Standard size
I
I Intake valve
10001 1
Sinking of valve
-
2
Repair limit
to.24
2.6
1.5
Replace valve or valve seat
49999
50001 and up
Thickness of valve lip
Tolerance
I
Exhaust valve
1.5
Intake, exhaust valves
0
kO.28
to.1
I
2.6
1.1
I
Valve
Standard size
Repair limit
Intake valve
2.10
1.7
Exhaust valve
1.50
1.2
Intake valve
Exhaust valve
3oâ&#x20AC;?
45O
I
Replace valve
3
Angle of valve seat
Standard Engine No.
O.D. of valve stem
4
valve guide and stem
5
Free length of valve spring
10
-0.040 -0.060
Exhaust valve
IO
Intake, exhaust va Ives
9
50001 and up
Intake, exhaust valves
1
+0.025 -0.005
Clearance limit
0.035 - 0.085
0.22
Exhaust valve
0.060 - 0.110
0.24
Intake, exhaust valves
0.040 - 0.075
0.20
0.02 (total variation of indicator, per 100 mm) Standard
Replace valve guide
+0.030 +0.010
9 Standard clearance
Replace valve
-0.030 -0.045
Intake valve
Repair limit:
10001 - 49999
-0.065 -0.085
10
Valves
1000149999
Engine No. Height of valve guide when knocked in
Intake valve
Intake, exhaust valves
5001 and up Curvature of valve stem
Tolerance
10001 49999
Engine No.
Clearance between
Standard size
10001 49999
50001andup
I.D. of valve guide
Valve
Repair or replace valve or valve seat
Replace valve or valve guide
Replace
Tolerance
19
*0.2
50001 and up
25.9
r0.25
Engine No.
Standard size
Repair limit
10001 - 49999
59.4
58
50001 and up
63.8
62.4
Installed length
Standard load
Repair limit
50.1
29.0 * 1.3 kg
26.0 kg
Repair
6 Installed length of valve spring Out-of straight of valve spring
110 SERIES
Replace valve spring
Repair limit 2â&#x20AC;? (at both ends)
14-007 0
ENGINE
MAINTENANCE
BODY
ROCKER ARM,
PUSH
ROD AND
STANDARD
TAPPET
6136FO38
6136FO37
Unit:
No.
Check item
Criteria Tolerance
19
-0.010 -0.030 I
I
I
Engine No. I.D. of rocker arm shaft hole 1
Clearance between rocker arm shaft and rocker arm shaft hole
Remedy
Standard size O.D. of rocker arm shaft
mm
Replace rocker arm shaft I
I
Standard clearance
10001 - 49999
19
50001andup
19
Clearance limit Replace rocker arm
+0.030 +O.OlO iC.020 0
Standard clearance
Clearance limit
0.020 - 0.060
0.13
18
+0.020 0
Standard clearance
Clearance limit
0.015 - 0.055
0.20
Replace rocker arm or rocker arm shaft
Curvature of rocker
2
3
Valve clearance (when cold)
4
O.D. of tappet
I
I
I.D. of tappet hole
5
Clearance between tappet and tappet hole
14-008 0
Replace cylinder head Replace tappet or cylinder head
110 SERIES
MAINTENANCE
ENGINE
STANDARD
CYLINDER
BODY
LINER
6138F028A
Unit:
mm
0.
1
Criteria
Remedy
Permissible range: 0.05 - 0.13
%%Zkr cylinder block
Check item
IProtrusion of cylinder liner
Standard size
Tolerance
Repair limit
110
+0.035 0
110.20
Inside diameter of cylinder liner 2_
Repair limit:
Roundness of cylinder liner
0.15 Replace cylinder liner
Cylindricity
3
Repair limit:
of cylinder liner
Outside diameter of cylinder liner (Counter bore)
0.08
Standard size
Tolerance
120
0 -0.08 I
Clearance between cylinder block and cylinder liner (Counter bore)
Standard clearance:
0.10 - 0.28
Replace cylinder liner or cylinder block
Standard size
4
Interference between cylinder liner and cylinder block
Replace cylinder liner or cylinder block
115 B
+0.0425 +0.0300
+0.0250 +0.0125
1
110 SERIES
14-009 0
ENGINE
MAINTENANCE
BODY
CYLINDER
STANDARD
BLOCK
1
5 11
4 3 2 \
â&#x20AC;&#x2122; 8
9
10
6130F039A
14-010 0
110 SERIES
MAINTENANCE
ENGINE
STANDARD
Unit:
No.
1
Check item
Criteria
Repair limit
0 - 0.080
0.12
Standard size
Tolerance
91
+0.020 0
Inside diameter of main bearing mounting hole
3
Straightness of main bearing mounting hole
Repair limit:
0.010
Roundness of main bearing mounting hole
Repair limit:
0.005
Inside diameter of main bearing
Replace main bearing cap
Standard size
Tolerance
Repair limit
85
+0.060 +0.010
85.16
5
Standard size
Tolerance
57.5
+0.030 0
Inside diameter of camshaft bushing mounting hole
inside diameter of camshaft bushing
Tolerance
Repair limit
54.5
+0.070 0
54.78
6
Difference between cylinder block lower face and flywheel housing
Repair limit:
0.13
7
Difference between cylinder block lower face and front cover
Repair limit:
0.11
8
Difference between cylinder block lower face and front plate
I
Order
I
Plate protrusion:
0.04 0.22
Target (kgm)
2nd step
Range (kgm)
I
6-8
20
19-21 Loosen completely 6-8
4th step
7
5th step
14
13 - 15
6th step
20
19-21
10
Tightening torque of oil pan mounting bolt
2.5 * 1.0 kgm
11
Tightening torque of crankshaft pulley mounting bolt
38+3kgm
110 SERIES
I
7
3rd step
Replace camshaft bushing
Repair by reassembling
Plate inset:
1st step Tightening torque of main bearing cap mounting bolt (Coat bolt thread with engine oil)
Repair or replace
Standard size
Repair limit
Replace main bearing
I
I
4
Repair by grinding or replace
I
2
mm
Remedy
Standard size Distortion of cylinder head mounting surface
BODY
I
14-011 0
ENGINE
MAINTENANCE
BODY
STANDARD
CRANKSHAFT
6136FO42 Unit: NC
1
Check item
mm Remedy
Criteria
Standard size
Repair limit
0.140 - 0.315
0.40
Replace thrustâ&#x20AC;&#x2122; bearing or correct oversize
End play
Tolerance
Standard size
Repair limit
O.D. of main journal Correct undersize or replace 2 Out-of roundness of main journal
Repair limit:
0.020
Standard clearance
Clearance limit
Clearance at main journal 0.060 - 0.130
Tolerance
Standard size S.T.D.
0.30
I
Repair limit
66
65.91
0.25 U.S.
65.75
65.66
0.50 U.S.
65.50
O.D. of crank pin journal
3
0.75 U.S.
65.25
1 .oo U.S.
65.00
Out-of-roundness of crank Din iournal Clearance at crank pin journal
4
Bend of crankshaft
14-012 0
65.41
-0.050 -0.070
65.16
0.020
Standard
I
Clearance limit
0.040 - 0.105
I
0.30
Repair limit:
0.09
Correct undersize .or replace
64.91
Repair limit:
-
Replace main bearing
(total-variation
of indicator)
Replace connecting rod bearing Correct undersize or replace
110 SERIES
MAINTENANCE
ENGINE
STANDARD
BODY
CAMSHAFT
2
1
Section A-A
3
6136FO43
Unit: No
1
Remedy
Criteria
Check item
mm
Standard size
Repair limit
0.15 - 0.35
0.50
Standard size
Tolerance
Replace thrust plate
End play
O.D. of camshaft journal
Replace -0.080 -0.110
54.5 2
Clearance at camshaft journal
Standard clearance
Clearance limit
0.080 - 0.180
0.28
Replace bushing
3
Curvature of camshaft
I
Repair limit:
0.03 (total variation of indicator)
I
-
Replace 4
Cam height
Intake
45.82
f 0.10
45.32
Exhaust
46.24
* 0.10
45.74
50001 and up
110 SERIES
14-013 0
ENGINE
MAINTENANCE
BODY
STANDARD
PISTON, PISTON RING AND PISTON PIN S6DllO-1
No
Check item
Replace piston
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
Clearance between piston ring and piston ring groove
Replace piston Judge using groove wear gauge
Replace piston Piston ring gap
Outside diameter of piston pin
5
C!earance between piston pin and piston
14-014 0
110 SERIES
MAINTENANCE
STANDARD
SAGDI
10-l
Engine
No. 10001
ENGINE
Engine
- 49999
No. 50001
BODY
and up
34-
6136F6451 6136FO29 Unit: NC
Check item
Criteria
Standard size 1
mm
Remedy
Repair limit
Tolerance
Outside diameter of piston
Replace piston lg9.280
20.015
No. 2
Measuring point
Tolerance
Standard size
Top ring
3
Thickness of piston ring
Width of piston ring groove
3
Second ring
2.5
4
Oil ring
5
ll-+-EzA 4 No. 2
Clearance between piston ring and ring groove
Oil ring Measuring point
Replace piston ring
-0.01 -0.03
Measure with groove-wear gauge
Replace piston
+0.04 +0.02
5 Standard clearance
Clearance limit Replace piston or piston ring
Top ring Measure with groove-wear gauge
3
Second ring
4
Oil ring
0.03 - 0.07
0.15
2
Top ring
0.45 - 0.65
2.0
3
Second ring
0.40 - 0.60
1.5
4
Oil ring
0.30 - 0.50
1.0
. Piston ring gap
Standard size
Outside diameter of piston pin
40 5
Inside diameter of piston pin hole
Clearance between piston pin and piston
110 SERIES
I
.
Replace piston ring or cylinder liner
Tolerance Replace piston pin -Loo5
40
+0.015 0
Standard clearance
Clearance limit
0 - 0.020
0.05
Replace piston or piston pin
14-015 0
ENGINE
MAINTENANCE
BODY
CONNECTING
STANDARD
ROD
â&#x20AC;&#x2DC;6 6136FO46
Unit: Check item
Criteria
Remedy
Standard size
Tolerance
40
+0.040 +0.025
Standard clearance
Clearance limit
I.D. of bushing at small end of connecting rod
mm
Replace bushing
1
Clearance between bushing and piston pin at small end of connecting rod
0.025 -0.045
1
Reolace bushing or piston rod
0.10
I 2
3
Standard size
I.D. of bushing mounting hole at small end of connecting rod
Tolerance +0.035 +0.010
43
I.D. of bearing at big end of connecting rod (crank pin journal)
Replace connecting rod
Standard size
Tolerance
66
+0.035 +0.010
Repair limit Replace bearing 66.15
-
4
I.D. of bearing mounting hole at big end of connecting rod
70
I -
+0.025 0
70.04
I
Measure after tightening connecting rod cap to specified torque.
-
Replace connecting rod
Bend
5
Twist
Curvature and twist of connecting rod
Order
Tightening torque of connecting rod cap mounting bolts 6
7
Coat bolt threads and nut seats with engine oil)
14-016 Co
I
Target
(kgm)
1st
6
2nd
11
Loosen
Weight of connecting rod
-
Bend Twist
Repair limit: Repair limit:
Range (kgm)
5-7 10
0
0
3rd
6
5-7
11.2
10.6-l
2,087 i- 70 (g)
Tighten
-12
4th
Repair limit:
0.08 0.30
1.7 Replace
1 110 SERIES
MAINTENANCE
TIMING
STANDARD
ENGINE
GEAR
U No.
I
t: mm Remedy
Criteria
Check item
Measurement points
Standard
I
Repair limit
A ?
BODY
Replace bushing or gear
Gear backlash 11
Idler gear and injection pump gear
0.6
C
Standard size
I
44
I
O.D. of idler gear shaft
I.D. of idler gear bushing 1
Clearance between idler gear bushing and shaft
-0.025 -0.050
Clearance limit
Standard clearance
I
Standard
Repair limit
110 SERIES
I
Replace bushing
0.20
Idler gear end play 0.05 - 0.21
Reolace shaft
+0.075 +0.010
44
0.035 - 0.125
Tolerance
0.4
Replace thrust plate
14-017 0
ENGINE
MAINTENANCE
BODY
FLYWHEEL
AND
FLYWHEEL
6
HOUSING
6138FO31
6138FO30 Unit:
No
Face runout of flywheel housing
2
Radial runout of flywheel housing
3
Tightening torque of flywheel housing mounting bolts
Repair limit:
mm
Remedy
Criteria
Check item
1
STANDARD
0.35 Correct and reassemble
Repair limit:
0.30
Range (kgm)
Target (kern)
Tighten 11
9.5 - 12.5
4
Repair limit:
Face runout of flywheel
0.20 Correct and reassemble
5
Radial runout of flywheel
Tightening torque of flywheel mounting bolts 6
Coat thread, seat and washer with engine oil. >
14-018 @
Repair limit:
Order
I
0.15
Target (kgm)
I
Range (kgm)
9
6-12
18
16-20
Tighten
110 SERIES
MAINTENANCE
STANDARD
ENGINE
LUBRICATION
BODY
SYSTEM
OIL PUMP Engine
No. 10001
-
49999
6136FO49
Unit:
â&#x20AC;&#x2DC;if-r1
Axial clearance of rotor
2
Radial clearance of rotor
Criteria
pump and block
5
6
Interference between oil pump gear and shaft
Backlash between oil pump gear and oil pump drive gear
I
I.D. of rotor room
O.D. of rotor
+0.055 +0.010
-0.10 -0.13
Standard clearance
Clearance limit
0.110 -0.135
0.25
Standard clearance
Clearance limit
+0.060 +0.030
0.030 - 0.075
0.10
-0.010 -0.035
+0.025 0
0.010 - 0.060
0.10
Shaft O.D.
Gear I.D.
I
Shaft
22
I
0 -0.015
33
I
I
Hole
Standard interference
Interference limit
0.025 - 0.060
0.02
Replace bushing
Replace
c Replace
22
0 -0.015
-0.040 -0.060
Standard clearance
Clearance limit
Repair or replace
0.120-0.370
110 SERIES
Remedy
Reolace
78
Clearance between shaft and bushing
mm
I
0.60
14-019 Co
LUBRICATION
Engine
MAINTENANCE
SYSTEM
No. 50001
STANDARD
and up
6136FO49.1 Unit: No
Check item
Criteria
I Tolerance T;&.k.a;ss
Axial clearance of pump gear
1
32
Dt%tJyof +0.065 +0.040
-:.025
Remedy
I
Standard size
Standard clearance (End play)
Clearance limit (End play)
0.03 - 0.09
0.10
Standard clearance
Clearance limit
0.03 - 0.10
0.13
Standard clearance
Clearance limit
I nterference 0.030 - 0.060
-
mm
Reolace oear Tolerance Standard size
O.D. of gear
Radial clearance of pump gear
2
I.D. of body
-0.15 -0.21
51.4
+0.06 0
Tolerance Standard size
Interference between pump drive gear and drive shaft
3
Shaft
Hole
+0.105 +0.090
+0.060 +0.045
Replace 18
-4
Clearance between drive shaft and cover bushing
5
Interference between pump gear and drive shaft
18
+0.105 +0.090
+0.065 +0.045
6
Clearance between drive shaft and body bushing
18
-0.005 -0.025
+0.060 +0.035
Replace bushing
I
-
I
I
I nterference 0.025 - 0.060
-
-
0.040 - 0.085 I
I
Replace bushing I
7
Clearance between driven shaft and body
18
1 $$!g
1 ~~:~“,~ 1 0.020
-0.065
1
-
8
Clearance between body bushing driven shaft and
18
1 ;;:,“;;
1 z;:;;,”
-0.080
1
-
1 0.040
Replace
1
Replace
Replace bushing
Interference between driven shaft and cover
9 -
14-020 0
Replace
110
SERIES
LUBRICATION
MAINTENANCE STANDARD
REGULATOR Engine
No. 10001
VALVE -
SAFETY
VALVE
49999
6
4
5 14FO27
6136FO50
Unit:
No.
Check item
mm Remedy
Criteria
Standard size 1
-1
Standard clearance
Clearance between valve and body
Replace -0.020 -0.040
20
+0.050 +0.020
0.040 - 0.090
*
Free length Standard size: 66.6
2
Installed load
Regulator valve spring
Replace Installed length
Standard load (kg)
Repair limit (kg)
11.6
11.2
61.2 I Target (kgm) 3
Range (kgm)
Tightening torque of regulator valve plug
Tighten 13
12 - 14
I
-
4
Tightening torque of regulator valve assembly
I
Target (kern)
I
IO -
,
Range (kgm) Tighten 8-12
5
Operating pressure of regulator valve
7.4 f 0.8 (kg/cm21
Adjust
6
Operating pressure of relief valve
2
Replace cartridge
110
SERIES
* 0.2 (kg/cmâ&#x20AC;&#x2122;)
14-02 1 0
MAINTENANCE STANDARD
LUBRICATION SYSTEM
REGULATOR Engine
No. 50001
VALVE and up
6136FO501
Unit: NC
1
Remedy
Criteria
Check item
mm
Clearance between valve and body
Replace
. Free length Standard size: 49.1 . Installed load
2
Replace
Regulator valve spring Installed length
Standard load (kg)
Repair limit (kg)
34.8
10.8
9.8
3
Operating pressure of regulator valve
14-022 Co
Standard:
6.5 f
0.5 kg/cmâ&#x20AC;&#x2122;
Repair or replace spring
110 SERIES
MAINTENANCE STANDARD
COOLING WATER
PUMP
COOLING SYSTEM
SYSTEM AND
THERMOSTAT
I: 1
2
3
5
4
A
6136FO34
6138F033A
Unit:
NC
Check item
-
T
1
2
Clearance between body and impeller
3
Abrasion of seal ring in water seal
Remedy
Criteria
Standard size Clearance between impeller and shaft
1
Shaft O.D.
)
+0.020 +0.005
15.9
Standard clearance:
mm
Impeller I.D. -0.020 -0.059
1Standard
interfereno
0.025 - 0.070
Replace (usually replace impeller; shaft O.D. reraly changes)
0.2 - 0.6
A dimension repair limit:
0
Replace
14FO35
4
Curvature of shaft
Repair limit:
0.1 mm
Total variation of indicator; measure by face run-out at point 40 mm from center of fan pulley
Full open lift of thermostat
Construction equipment
Min. IO
Inspect after immersion for 4 - 5 minutes in water at goOc.
Generator
Min. 10
g5oc.
Construction equipment
Valve should be fully closed after immersion for 4 - 5 min in water from fully open (90°C) to fully closed (71’C).
Generator
Valve should be fully closed after immersion for 4 - 5 min in water from fully open (95’C) to fully closed (76OC).
Inspect after immersion for 4 - 5 minutes in water at
5 Opening and closing of thermostat
110 SERIES
14-023 0
15 REPAIR AND REPLACEMENT
ENGINE
OF PARTS
15 REPAIR AND REPLACEMENT OF PARTS
Replacing valve seat inserts ...................... 15-002 Replacing nozzle holder sleeve ................ .15-006 Pressure test ............................................... 15-008 Replacing valve guide ................................ 15-009 Grinding valve ............................................ 15-010 Replacing camshaft bushing ..................... 15-01 1 Replacing crankshaft gear.. ........................ 15-013 Replacing camshaft gear ........................... 15-013 Replacing flywheel ring gear.. ................... 15-014
15001 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
VALVE SEAT INSERTS
REPLACING VALVE SEAT INSERTS Special tools
. . Pulling out the valve seat insert A
Before using the grinder, run it for a minute to test it. After replacing the grindstone, run the grinder for three minutes to test it. l
4L
Confirm that the grindstone is not damaged, then install it to the shaft of the grinder without appling excessive force. Confirm that there is no play between the grindstone and shaft.
AL When using the grinder, wear safety goggles.
.
When using a valve seat puller to remove the valve seat 1) Install grindstone @ to grinder 0. 2) Align the groove of sleeve @ with holder 0, then insert.
15002 0
6162F504
REPAIR AND REPLACEMENT
3)
4) 5)
REPLACING
OF PARTS
VALVE SEAT INSERTS
Adjust the position of the grinder so that the center of grindstone @ will be at the center of seat insert (I),then tighten the set screw @ to secure the grinder. Rotate the grindstone and move slowly until it contacts insert (I). Press the grindstone against the inside of the insert, move it in a circular pattern, and make a groove about 1 mm deep. w 6162F505
6)
7)
8)
Push in the three claws (a) on puller head @ of tool A by hand to insert it into the groove of the insert (I). Tighten screw @ to press the three claws against the groove on the inside surface of the insert. Ir When the claws contact the groove completely, stop tightening. Place bridge @ over the puller head, then place plates @! and @I on the bridge. Tighten nut @I to pull out the insert.
6162F506A
.
When welding a bar to the insert to remove the seat insert. I) Weld bar (I) of radius approx. $110, that is 0.1 - 0.5 mm shorter than the inside diameter of insert (2). * Be careful not to let the welding metal stick to the cylinder head itself.
Eâ&#x20AC;&#x2122;
a 2)
When the temperature of the weld goes down to around room temperature, insert an old valve (3) in the reverse direction, and tap the head of the valve with a small hammer to knock out the insert. * If the valve is hitted too hard, the weld may break.
1
@IT
6127F205
15-003 0
REPAIR AND REPLACEMENT
2. l
OF PARTS
REPLACING
VALVE SEAT INSERTS
Press fitting the valve seat insert When not grinding and correcting the press fitting surface for the valve seat insert. 1) Using tool B or C guided by the inside diameter of the valve guide (4), press fit standard valve seat insert (2). + Do not use a hammer to press fit. * Press-fitting force for valve seat (intake and exhaust sides): Approx. 1 ton
Press
4 HEE00290
21
Check the depth of insert from the bottom surface of the cylinder head. * Depth of the insert (h) (intake and exhaust sides) : 2.05kO.15 mm (intake) : 1.55f0.15 mm (exhaust)
Bottom surface
of
cylinder
head
HEE00291
3.
.
Machining valve seat oversize 1) Using tools Dl and size larger. * Machine within size. If it is more than der head. Dimention
insert
mounting
D2, grind the hole to one a range
of insert and mounting
S.T.D.
Valve
15-004 0
-
1
O.D. (d)
1 Height (hl)
Intake
48.50::::
8.50_;.,0
Exhaust
44.00:;:;;
9.00_: _.,” ._
Intake
48.75:;:od:
8.50-i.,,
Exhaust
44.25:;:;;
9.00_;.,rJ
Intake
49.00:~:~~
8.62_&
Exhaust
44.50 ::::;
9.12_:.,rJ
0.25 OS.
1 .oo O.S.
hole Unit: mm
1
0.75 O.S.
of 1.0 mm over-
1.0 mm, replace the cylin-
Insert
0.50 O.S.
hole to
Intake
49.25::::;
8.75_&
Exhaust
44.75 ::II: _.-.
9.25-t _.I” ._
Intake
49.50$:$!
8.88-i.,,
Exhaust
45.00::::;
9.38_:.,0
“Y
622FO1037
HEE00292
REPAIR AND REPLACEMENT
Mounting
REPLACING
OF PARTS
hole for valve seat insert
VALVE SEAT INSERTS
Unit: mm Insert
mounting
dl
I
hole
--I
Bottom’surface of cylinder head HEE00293
Inside surface roughness: max. 6.3 S Mounting hole bottom roughness: max. 12.5 S Concentricity of valve guide hole and insert: max. 0.05 mm (T.1.R) 2)
Press fit the over size valve seat insert.
3)
Check the depth of inset-t from the bottom surface of the cylinder head.
Intake
valve
2.14
Exhaust
valve
1.67 W!dth of finishing i surface >
HEE00294
Finishing insert seat surface 1) Using tools Dl, D3 and D4, finish the insert seat surface to the dimensions shown in the diagram. * When inserting the pilot D5 into the valve guide, select a pilotthat will enter and leave no clearance. 2)
Fit the seat surface using the compound.
Final check Coat the seat surface thinly with minimum (red lead), and insert a new valve into the valve guide. Put it lightly in contact with the valve insert surface, and rotate IO”, then check the contact surface with the valve insert. Confirm that the contact is uniform with no breaks. . Another way is to mark the new valve with pencil marks as shown in the diagram, insert into the valve guide, bring into light contact with the valve insert surface, and rotate IO”. Check that the pencil marks are erased uniformly around the whole circumference. * If a vacuum tester is available, carry out an airtightness test to check. l
Pencil
marks
(about
20
places1
F6164701
15-005 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
NOZZLE HOLDER SLEEVE
REPLACING NOZZLE HOLDER SLEEVE Sr3ecial tools
I
1.
Part No.
1
Part Name
I Qâ&#x20AC;&#x2122;W
A
1 795-600-1191
1 Push bar
I
1
B
1 795-100-1540
1 Push tool
I
1
C
/ 795-600-1410
1 Rolling tool
I 1
D
795-901-1210
Sleeve holder
1
E
795-600-1420
Sleeve expander
1
F
795-600-l
460
Guide bushing
1
G
795-600-I
430
Sleeve cutter
1
Removing the sleeve 2) Using sleeve extraction tap 0, cut tap to about 25 mm depth from top face of sleeve. Add oil while cutting. * Extraction tap: M25, P=1.5 3)
Insert push bar A from the bottom of the head and tap with the hammer to remove the sleeve.
HEE00297
2.
Press-fitting the sleeve Insert sleeve (I) into the cylinder head, then using push tool B, tap lightly until the sleeve is completely in close contact with the seat surface. * Before installing the sleeve, clean the sleeve and seat. * Apply adhesive to outside taper part of the sleeve. 6 Adhesive: LT-2
6162F510A
15006 0
REPAIR AND REPLACEMENT
OF PARTS
3.
Roll-fitting the taper section of sleeve Using rolling tool C, roll-fit the taper section of the sleeve. f Set the roll-fitting amount with stopper @ of the rolling tool. * Install the rolling tool to a radial drilling machine or upright drilling machine to roll-fit with its own weight. -k Rotating speed: 200 to 300 rpm.
4.
Roll-fitting press-fitting portion at top of sleeve 1) Using sleeve holder D, tighten the sleeve from the bottom surface of the cylinder. w
2)
3) 4)
REPLACING
NOZZLE HOLDER SLEEVE
HEE00298
Sleeve holder: 19 Nm (2 kgm}
Using sleeve expander E, carry out rolling to caulk the press-fitting portion. Sr Rotating speed: 450 rpm Ir Inside diameter: 23.9fO.l mm * Amount of insertion of roller (h): 16 mm k Using stopper 0, fit inside diameter. After rolling, turn in the reverse direction and remove the sleeve expander. Remove the sleeve holder.
h 5.
Spot-facing the inside seat of the sleeve 1) Using guide bushing F as the guide, spot-face the seat with sleeve cutter G. * When grinding the seat surface, insert the nozzle holder, check that the protrusion is within the standard value, and cut a little more each time. * Rotating speed: 500 to 600 rpm * Protrusion of nozzle (S.T.D.): 1.29 - 2.21 mm
HEE00299
2) Remove all the metal chips and dust from the machined 6.
surface.
Checking the leakage from the seat Carry out a water pressure or air pressure test to check that there is no leakage from the sleeve seat surface or upper press-fitting portion. * When checking for leakage from the seat surface, install a used nozzle holder.
6162F514A
REPAIR AND REPLACEMENT
PRESSURE
OF PARTS
TEST
PRESSURE TEST .
If the area around test as follows.
the head has been corrected,
Special tools Part No.
Part Name
Qâ&#x20AC;&#x2122;ty
A
-
Coolant tester kit
1
B
79A-471-1050
Pump assâ&#x20AC;&#x2122;y
1
1.
Water pressure test 1) Tighten the nozzle holder assembly to the specified torque. 21 Assemble tool A and tool B, and connect a hose to flange (1). 3) Apply water pressure 0.35-0.4 MPa (3.5-4.0 kg/cm*) for approx. 10 minutes, and check for any leakage from around the head. * It is preferable to warm the whole cylinder head and carry out the test with hot water 82-93X.
2.
Air pressure test I) Tighten the nozzle holder assembly to the specified torque. 2) Connect the compressed air hose to flange (I). 3) Place the cylinder head in a water bath, apply air pressure 0.3-0.35 MPa (3.0-3.5 kg/cm*} for approx. 30 seconds, and checkfor any air leakage in the water. Ir If the above test shows that there are cracks around the nozzle holder and plugs, replace the cylinder head.
15-008 0
6202FO20
REPAIR AND REPLACEMENT
REPLACING
OF PARTS
VALVE GUIDE
REPLACING VALVE GUIDE Special tools Part No.
8 %
z
Part Name
CYty
A
795-100-1820
Valve guide remover
1
B
795-116-1410
Valve guide driver
1
1.
Removing the guide Remove the valve guide with valve guide remover A.
2.
Press-fitting the valve guide I) Press-fitting the valve guide until the tip of valve guide driver B contacts the cylinder head. * After press fitting, insert the valve. If the valve does not enter smoothly, modify with a reamer (#16+~.“‘8 ).
2) Confirm that the protrusion of the valve guide is within specification. * Protrusion of valve guide: 25.9f0.25
mm
622FOlO43
15-009 0
REPAIR AND REPLACEMENT
GRINDING
OF PARTS
GRINDING
VALVE
VALVE
Special tools Part No. A
Part Name
-
Valve refacer
Q’ty 1
(ourchase) 1. .
Grinding the seat surface Grinding the seat surface with valve refacer A. + Angle of valve seat (a): Intake valve: 30” Exhaust valve: 45”
2. .
Checking after grinding Confirm that the thickness of valve head, protrusion of the valve, and the contact surface of the valve seat are within specification. +
Allowable
thickness
Intake valve: Exhaust valve: *
Sinking distance
F6164107A
of valve head (h) Standard Repair limit 2.10 mm 1.7 mm 1.50 mm 1.2 mm
of valve: Standard OkO.1 mm
a HEE00300
Repair limit 1.1 mm
h HEE00301
Sinking When master
usino valve OT”.’
a
of
valve
When master Bottom
surface
Intake
side
usins valve OS”.’
a Bottom
surface
Exhaust
side
HEE00296
15010 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
CAMSHAFT
BUSHING
REPLACING CAMSHAFT BUSHING Special tc 01s Part No.
A
Part Name
Qâ&#x20AC;&#x2122;ty
795-216-1000
Push tool
1
1
k
795-215-1110
Push bar
1
2
795-216-1130
Push tool
1
3
795-216-l
140
Collar
1
I 4
795-2 16-l 150
Guide
1
I
792-103-0400
Grip
1
5
)
*
Before replacing the camshaft bushing, remove the blind plug from the rear side of the cylinder block.
1. .
Pulling out No. I,7 bushings Assemble push bar Al, push tool A2 and collar A3 of push tool A, then tap the push bar and remove bushing (2) from cylinder block (I).
8 %
A3
z
1 Y
l
I
1
l
Pulling out No. 2,6 bushing Assemble push bar Al, push tool A2, collar A3, and guide A4 of push tool A, then tap the push bar and remove bushing (3) from cylinder block
Pulling out No. 3,4,5 bushing Assemble push bar Al, push tool A2, collar A3, and guide A4 of push tool A, then tap the push bar and remove bushing (4) from cylinder block
6162F518
A2
3 1
c 6162F519
(I).
3.
Al
c
A3
2.
n2
2
4 1
(I). 6162F520
15-011 0
REPAIR AND REPLACEMENT
.
OF PARTS
REPLACING
CAMSHAFT
BUSHING
After pulling out bushing, removing all burrs and clean all dirt and dust from the bushing mounting hole.
1. Press fitting No. 3,4,5 bushing . Assemble bushing (4) to tool A, then press fit the bushing until the oil hole in cylinder block (I) is aligned with the oil hole in bushing.
4
+
1
6202FOl7
2.
.
Press fitting No. 2,6 bushings Assemble bushing (3) to tool A, then press fit the bushing until the oil hole in cylinder block (1) is aligned with the oil hole in bushing.
3 1
c 8 6162F522
tz t;
3. .
Press fitting No. I,7 bushings Assemble bushing (2) to tool A, then press fit the bushing until the oil hole in cylinder block (I) is aligned with the oil hole in bushing.
6202FO18
. .
* *
Using inside gauge 0, measure the inside diameter of the bushing. Check the clearance between the bushing and the shaft, and if the clearance is not within the standard range, or if the shaft does not pass through smoothly, correct the inside diameter of the bushing with a reamer. . After correcting the inside diameter of the bushing with a reamer, clean all chips from the oil hole and oil groove. Inside diameter of camshaft bushing: 4160â&#x20AC;&#x2122;~~â&#x20AC;&#x2122; mm Clearance at camshaft journal: 0.080-0.180 mm
15012 0
6202FO19
REPAIR AND REPLACEMENT
REPLACING CRANKSHAFT REPLACING CAMSHAFT
OF PARTS
GEAR GEAR
REPLACING CRANKSHAFT GEAR 1. .
Removing the crankshaft gear Make a groove on the tooth bottom surface of the gear with a grinder, then crack the gear with a chisel.
A Take care 2.
in handling
the grinder and chisel.
Press-fitting the crankshaft gear the ring gear. If 1) Check the fitting surfaceof any flaw is found, repair it with an oilstone. 2) Heat the ring at the specified temperature for the specified time for shrinkage fitting. * Heating temperature for crankshaft gear: 250°C Heating time: 30 minutes 3) With the timing mark side of crankshaft gear facing outside, fit it until its side contacts the crankshaft flange.
REPLACING CAMSHAFT 1.
GEAR
Removing of camshaft gear Set the camshaft assembly on a press stand, then push the camshaft out with press.
Press + I-J
2.
Press fitting camshaft gear 1) Heat the gear to the specified shrink-fitting temperature for the specified period of time. Ir Heating temperature for camshaft gear: 250°C Heating time: 30 minutes 2) Set the timing mark on the outside, then use a driving tool to press fit until the surface of the gear is in tight contact with the camshaft flange.
HE00302
15013 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING FLYWHEEL RING GEAR
a
Take care not to let the flywheel
fall.
1. .
Removing the ring gear Make a groove on the tooth bottom surface of the gear with a grinder, then crack the gear with a chisel.
A
Take care in handling
2.
Press-fitting the ring gear 1) Check the fitting surface of the ring gear. If any flaw is found, repair it with an oilstone. 2) Heat the ring at the specified temperature for the specified time for shrinkage fitting. * Heating temperature for ring gear: 315°C Heating time: 45 minutes 3) With the chamferred side of ring gear facing the front side of the engine, fit it until its side contacts the flywheel flange.
15-014 0
the grinder
and chisel.
REPLACING
FLYWHEEL
RING GEAR
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE: